DRAPER) THE TOOL COMPANY IGNITION MODULE & SENSOR TESTER * INSTRUCTIONS + IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY TO ENSURE THE SAFE AND EFFECTIVE USE OF THIS TOOL. [a 08/2003 GENERAL INFORMATION This manual has been compiled by Draper Tools and is an integrated part of the product with which itis enclosed and should be kept with it for future references. This manual describes the purpose for which the product has been designed and contains all the necessary information to ensure its correct and safe use. We recommend that this manual is read before any operation or, before performing any kind of adjustment to the product and prior to any maintenance tasks. By following all the general safety instructions contained in this manual, it will ensure both product and operator safety, together with longer life of the product itself Allphotographs and drawings in this manual are supplied by Draper Tools to help illustrate the operation of the product ‘Whilst every effort has been made to ensure accuracy of information contained in this manual, the Draper Tools policy of continuous improvement determines the right to make modifications without prior warning.IGNITION MODULE & SENSOR TESTER THE TOOLCOMPANY "STOCK No.68268 PART NoMST1 CONTENTS: Guarantee Safety Precautions Getting to Know Your Tester Assembly Operation and Use (Sensor Testing) Operation and Use (Module Testing) 15-22 Operating and Use (Misc) ------- ve 23 1 2 3 GUARANTEE THETOOLCOMPANY Draper Tools have been carefully tested and inspected before shipment and are guaranteed to be free from defective materials and workmanship for a period of 12 months from the date of purchase except where tools are hired out when the guarantee period is ninety days from the date of purchase. Should the machine develop any fault, please return the complete tool to your nearest authorized warranty repair agent or contact Draper Tools Limited, Chandler's Ford, Eastleigh, Hampshire, SO53 1YF. England. Telephone: (023) 8026 6385. If upon inspection it is found that the fault occurring is due to defective materials or workmanship, repairs will be carried out free of charge. This guarantee does not apply to normal wear and tear, nor does it cover any damage caused by misuse, careless or unsafe handling, alterations, accident, or repairs attempted or made by any personnel other than the authorised Draper warranty repair agent. This guarantee applies in lieu of any other guarantee expressed or implied and variations of its terms are not authorised. Your Draper guarantee is not effective unless you can produce upon request a dated receipt or invoice to verify your proof of purchase within the 12 month period. Please note that this guarantee is an additional benefit and does not affect your statutory rights. Draper Tools Limited.PT ATAD SAFETY PRECAUTIONS THE TOOL COMPANY Follow the safety precautions below to avoid injury and prevent damage to this product and any vehicles connected to it When working on a vehicle ensure the wheels are securely chocked and if raised up, is supported with appropriate axle stands. Avoid electric shock. Always turn ignition key OFF when connecting or disconnecting electrical components. Wear eye protection, Always wear approved eye protection. Keep the vehicle in PARK or NEUTRAL. Always make sure the vehicle is in Park or Neutral and that the parking brake is firmly set. Keep away from all moving or hot engine parts. To avoid injury ensure yourself and the product are away from all moving or hot engine parts, Do not leave vehicle unattended, To avoid injury or fire hazard, do not leave vehicle unattended while running tests. Do not operate in badly ventilated areas. To avoid breathing dangerous exhaust gases (carbon monoxide), always operate the vehicle in a well ventilated area. Do not operate in an explosive atmosphere. To avoid injury or fire hazard, do not operate this product in an explosive atmosphere. Smoking is prohibited during testing, Keep a fire extinguisher suitable for all types of fires to hand. Do not lay the product on a vehicle battery. To avoid short circuiting the terminals, do not lay the product on a vehicle battery. Clean up all fuel spills immediately. To avoid contact with fuel, use suitable materials to cover fuel line fittings when connecting or disconnecting fuel lines. Keep away from engine cooling fan. On some vehicles, the fan may start up unexpectedly. Always follow vehicle manufacturer's warnings, cautions, and service procedures, especially when working around the air bag system. The air bag can still open up several minutes after the ignition key has been turned OFF even if the battery is disconnected because of a special energy reserve module. An air bag deploying can result in personal injury.GETTING TO KNOW YOUR TESTER ‘THE TOOL COMPANY GREW) Expert PL Red Pree @ Range Switch @ Backprobe Adapter @ Function Switch Connector Pin Adapters @ Test Lights @® Jump Lead @ Pulse Light © Rich/lean Lights ® Test Leads UNPACKING: After removing the packing material, make sure the product is in perfect condition and that there are no visible damaged parts. If in doubt, do not use the tester and contact the dealer from whom it was purchased The packaging materials (plastic bags, polystyrene etc.,) must be disposed of in an appropriate refuse collection container. These materials must not be left within the reach of children as they are potential sources of danger. -3-DRAPER ASSEMBLY THETOOL COMPANY Loosen and remove the three screws from the rear of the unit. Power supplied by a 9-volt PP3 type battery (Draper Stock No.61837). Ensure the battery is installed observing the correct polarity. Resecure the housing but do not overtighten the screws. Battery Condition Test 1. Make sure the test leads are not connected together or touching anything. 2. Set the range switch to high 3, Set the function switch to ohms 4, Ifthe top test light is illuminated it indicates the battery is good. If the top light does not illuminate, but one further down the strip does the battery is too weak for reliable testing and should be replaced. NOTE: Always keep the range switch in the OFF position when not in use to prolong the battery life. The tester can even be switched off while it is connected to a circuit without causing a problem.OPERATION AND USE ‘THETOOL COMPANY Test Procedure SENSOR TESTING This testing procedure is suitable for all = engine coolant or inlet air temperature $1 vn sensors, They can be tested both on and off A the vehicle, Typical Engine Coolant & ‘Temperature Sensor wg oH Pa 9° 88 aa og Low _ cola Hot TEMPERATURE TEMPERATURE SENSORS: Brief Outline The engine and air temperature sensors are thermistors (a resistor where resistance change is caused by temperature). The thermistor is a 2-wire sensor located inside the tip of threaded metal housing. Note: Some engines have a dual sensor with three wires. The engine temperature reading is used to control the air/fuel ratios, spark advance, idle speed, and emission device operation by the engine management. The air temperature reading is used to control the amount of air entering the engine, for the correct air/fuel ratios. Location The engine temperature sensor is usually threaded into the engine block, lower intake manifold or cylinder head to provide direct contact with coolant. The air temperature sensor is threaded into the intake manifold, throttle body, air cleaner body or any where else along the path of air entering the engine. Refer to the vehicle manufacturer's handbook or Haynes manual. Checks Check connections at sensor and ECU (open or short circuits) Poor response is caused by: Heavy deposits on sensor tip (e.g, rust) Blocked or restricted air passageway Leakage into sensor housing (coolant), Problems with antifreeze, thermostat, water pump, fan belts and low engine oil will make the engine run too hot Allow the engine to cool to outside temperature before testing Disconnect wiring harness from sensor. Some vehicles use a metal snap ring to secure the wiring harness to the sensor, Connect the test leads. Connect the yellow test lead clip to one terminal and the black test lead clip to the other terminal NOTE: Ensure red and green test clips are not touching each other or anything else. Position the range switch to high position and position the function switch to ohms. Heat the tip of the sensor and observe the test lights. The lights move downwards as the sensor heats up which indicates the sensor is working (as the sensor cools the lights will begin to move upwards) Disconnect test leads and reconnect sensor to vehicle wiring harness. oo gS, cas THROTTLE POSITION SENSOR Brief Outline Thuottle position sensor is a potentiometer (a type of variable resistor). These sensors come in a wide variety of styles, some with connectors at the end of a short wire. Power and ground to the sensor are supplied by computer. The sensor has an element which is turned (rotary type) or pushed (linear type). When the sensor is mounted on the engine, the sensor is linked to the throttle so they move together. The sensor sends a voltage signal back to the computer indicating the throttle position. The voltage signal increases when the throttle opens.‘THE TOOL COMPANY OPERATION AND USE The engine management system uses the throttle position to determine engine operating conditions: idle - closed throttle, cruise - part throttle, or hard acceleration - wide open throttle and controls air/fuel mixtures, spark advance, idle speed accordingly. Location For the specific location please refer to the vehicle manufacturer's handbook or Haynes manual. Checks Check connections at sensor and ECU (open or short circuits) Sensor position adjustment Binding throttle shaft or linkage. If applicable "Cruise Control” linkage problems, idle control motor, vacuum hoses, choke, etc. Test Procedures NOTE: If the red and black test lead clips are attached with reversed polarity, the test light will move in the opposite direction during testing This does not affect the accuracy of the test or harm the sensor. Some sensors require more than one test. Test A Please refer to the vehicle manufacturers handbook or Haynes manual. They can be tested both on and off the vehicle. Disconnect wiring harness from sensor, some vehicles use a metal snap ring to secure wiring harness to sensor. Connect the red test lead clip to the sensors power terminal, the yellow test lead clip to the sensors signal terminal and the black test lead to the sensors ground terminal. Position the range switch to high. Position the function switch to volts. Operate the sensor and observe the results Working Sensor: Test lights smoothly move up or down as sensor is operated. Failed Sensor: Test lights position does not, change during test or light movement is erratic, showing a sudden jump or dip during smooth sensor operation. Disconnect test leads and reconnect sensor to vehicle wiring harness. Test B Disconnect wiring harness from sensor some vehicles use a metal snap ring to secure wiring harness to sensor. Connect the test leads. Connect the yellow lead clip to the sensors signal terminal and the black lead clip to the sensors ground terminal. Position the range switch to high. Position the function switch to ohms Operate the sensor and observe the results. Working Sensor: Test light switches between being on and off. Fail Sensor: Test light remains on at top of column or remains off completely. Disconnect test leads and reconnect sensor to vehicle wiring harness. ah (EGR) EXHAUST GAS RECIRCULATION VALVE POSITION SENSOR Brief Outline EGR valve position sensor is a potentiometer (a type of variable resistor). Power and ground to the sensor are supplied by computer. The sensor is mounted on the EGR valve and the shaft built into the sensor is pushed as the valve opens. The sensor sends out a voltage signal indicating the amount of valve opening. The voltage increases the more the valve is opened. The engine management uses the sensor signal to calculate actual exhaust gas recirculation flow and can then modify the EGR valve opening as required. The computer is programmed to provide optimum EGR flow during idle, cruise, and hard acceleration operating conditions. Location Attached to the top of the EGR valve. Refer to the vehicle manufacturer's handbook or Haynes manual. Checks ‘Check connections at sensor and ECU (open or short circuits)THETOOLCOMPANY OPERATION AND USE Damaged or sticking EGR valve. Test Procedure Worn or broken vacuum hoses, vacuum, connectors. Damaged vacuum reservoir. Disconnect wiring harness from sensor, some vehicles use a metal snap ring to secure wiring harness to sensor. Connect the test leads. Connect the yellow test lead clip to the sensors signal terminal, the black test lead clip to the sensors ground terminal and the red test lead clip to the sensors power terminal, Position the range switch to high. Position the function switch to volts. Operate the sensor and observe the test lights. Working Sensor: Test light smoothly moves up or down as sensor is operated. Failed Sensor: Test light position does not change during test or light movement is erratic, showing a sudden jump or dip during smooth sensor operation Testing is complete. Disconnect test leads and reconnect sensor owe ‘ TIGH SENSOR. VOLTAGE Low HIGH | SENSOR | VOLTAGE | Low Lean OPTIMUM) Rich AIR FUEL MIXTURE LAMBDA/OXYGEN SENSOR Brief Outline The oxygen sensor is a zirconium dioxide ceramic, mounted in the tip of threaded metal housing. The tip is perforated to protect the sensing element but still allow exhaust gases to pass through. The sensor produces a voltage signal based -7- on the amount of oxygen it contacts. A low voltage indicates a lean exhaust, a higher voltage indicates a rich exhaust. The sensor must be operated in very hot temperature. The ECU uses the sensor signals to calculate the optimum air/fuel mixture for low ‘emissions and good fuel economy. If the sensor indicates a rich exhaust mixture, the computer will compensate by reducing fuel delivery. If the computer receives a lean mixture signal, it will increase fuel delivery. NOTE: Some vehicles use more than one oxygen sensor. Location They are usually threaded into the exhaust manifold/downpipe to give it direct contact with the exhaust gases. Refer to the vehicle manufacturer's handbook or Haynes manual. Checks Check connections at sensor and ECU. This sensor often fails because of contamination from fuel, oil additives, gasket sealer or an overly rich running engine and short journeys. Factors which can make a rich running engine include: ignition system problems, manifold leaks, blocked air filter and fuel pressure. NOTE: Some engines use a titania-type oxygen sensor. This sensor resembles the common zirconium type, but has an open-ended tip. The titania sensor changes resistance when it operates. This tester is not designed to test the titania type sensor. Test Procedure Sensor Types Single wire: Connect the yellow clip to the sensor wire and the black clip to the sensor housing. Connect the yellow clip to the sensor wire and the black clip to the sensor ground (Note: the sensor wire is usually black). Three wire: Connect the yellow clip to the sensor wire and the black clip to the sensor housing. (Note: There are usually two wires the same colour which go to the heating element, the remaining different colour wire is the sensor cable). Connect the yellow clip to the sensor wire and the black clip to the sensor ground (Note: There are usually two wires the same colour which go to the heating element, the black wire is the sensor cable) ‘Two wire: Four wire:‘THE TOOL COMPANY OPERATION AND USE Heating Element Test NOTE: Only applicable if sensor has a heating element (3 or 4 wire connection). Disconnect wiring harness from sensor, some vehicles use a metal snap ring to secure the wiring harness to the sensor. Connect the test leads Connect the yellow test lead clip to one of the heating element terminals and the black lead clip to the other terminal. Position the range switch to high. Position the function switch to ohms, Observe the test lights. Working Sensor: Test light off (low resistance). Failed Sensor: Test light on (resistance too high, or open circuit) Testing is complete, move onto next test, Oxygen Test IMPORTANT: Reliable testing of the oxygen sensor while on the vehicle is very difficult because test conditions cannot be fully controlled. If the sensor responds during the on-car testing, then it is probably good and no other testing is necessary. If the sensor does not seem to respond when tested, remove it and perform the off-car test before deciding whether or not the sensor has failed. Keep the sensor connected to the vehicle wiring and use the backprobe adapter to contact sensor signal circuit if possible. Connect the test leads. Connect the yellow test lead clip to the sensor signal wire ant the black clip to a good vehicle ground. If you cannot use backprobe, disconnect sensor connector and connect the yellow test lead clip directly to the signal pin. Position the range switch to low and position the function switch to volts. Start the engine and idle until hot Run engine until upper radiator hose is hot and pressurised. Pay attention to rich/lean lights during fast idle. The test light column also indicates sensor voltage, but it is easier to check operation by the rich/lean lights. Maintain throttle (2000 RPM idle). If the rich/lean lights flash back and forth every 3 seconds or less then the sensor is good and no further testing is necessary. Ifit takes longer than 3 seconds for the rich/lean lights to switch back and forth then _g the sensor may require replacement. Try the off car test to verify. If the rich/lean lights do not flash back and forth then quickly move the throttle from idle to partially open and back to idle. Repeat this throttle action several times while observing the rich/lean lights. If the rich/lean lights switch within 3 seconds of the throttle action then the sensor is working and no further testing is necessary. Ifit takes longer than 3 seconds for the rich/lean lights to switch then the sensor may require replacement. If the rich/lean lights do not flash back and forth then proceed to the off car test. Off-Car Test WARNING: This test involves use of an open flame from a propane torch, Observe all safety precautions for torch operation. Do no use near flammable material or gases. Remove sensor as per the vehicle manufacturers handbook or Haynes manual. Firmly hold the sensor, taking care not to. cause damage, with a pair of self grip pliers. sy AS Fig.l. Connect the test leads Connect the yellow test lead clip to the sensor signal pin and the black test lead clip to a good vehicle ground. Position the range switch to low. Position the function switch to volts. Ignite torch and heat sensor tip. Observe rich/lean lights (heat sensor tip until the tip is as hot as possible, but not glowing) The sensor tip must be very hot to operate (349C - 660C) The lean or rich light should be on. If both lights are off, the sensor is defective. After the sensor tip is hot, move the flame. until the sensor tip is completely surrounded by the flame. This keeps oxygen away from the tip (see fig.2 Working Senso: Rich light turns on within 3 seconds indicating a “rich” (low oxygen) condition.THETOOLCOMPANY OPERATION AND USE Failed Sensor: Rich light takes longer than 3 seconds to turn on, or does not turn on at all. Move flame so oxygen can reach sensor tip but keep sensor tip hot with flame (see fig. 1.) Working Sensor: Lean light turns ON within 3 seconds indicating a “lean” (high oxygen) condition. Connect the test leads. Single wire: The yellow clip to the signal pin and the black test lead clip to the body of the sensor or nearby earth point. Double wire:The yellow clip to either sensor pin and the black test lead clip to the remaining sensor pin. Position the range switch to low. Position the function switch to volts. Operate The Sensor: Lightly tap surface near sensor using a socket extension (or similar tool) and a light hammer. Do not tap directly on sensor! Working Sensor: Test lights illuminate upward from the bottom of the column during a tap. (Only a few lights may flash. This is normal). Failed Sensor: Test lights do not illuminate during a tap. NOTE: Excessive force during testing may cause damage te engine components. Failed Sensor: Lean light takes longer than 3 seconds to turn Repeat these test a few times to verify the accuracy of the results. Allow sensor to cool. Refit sensor correctly, disconnect test leads and reconnect sensor to IMPORTANT: Special anti-seize compound should be applied to sensor housing threads manual for information. E z oR Brief Outline ‘The Knock Sensor is a piezoelectric material like a microphone it converts vibrations into a small voltage signal. The sensor usually has The ECU or other spark timing controller is designed to recognise sensor signals caused ‘The spark timing is adjusted to eliminate the damaging knock condition. Threaded into or bolted onto the engine block or intake manifold, Refer to the vehicle Check Check connections at sensor and ECU (open Spark timing. Bad fuel quality. Disconnect wiring harness from sensor, some vehicles use a metal snap ring to secure the on, or does not turn on at all. Testing is complete vehicle wiring harness. before reinstallation. Refer to vehicle service KNOCK SENSORS mounted in a metal housing, The sensor acts a single or double wire connector. by engine knock vibrations (misfiring etc). Location manufacturers handbook or Haynes manual. or short circuits) Test Procedure wiring harness to the sensor, -9- Intake # LL manifold vent MANIFOLD ABSOLUTE PRESSURE MAP/BARO SENSOR Brief Outline This sensor is an electronic module which sends a signal to the ECU indicating atmospheric pressure and/or engine vacuum. Depending upon sensor type, the signal may be a DC voltage or a frequency. More pressure (less vacuum) makes the sensor signal increase (higher voltage or frequency). The computer supplies power and ground to the sensor. The ECU needs to know air pressure both outside and inside the manifold to properly adjust the air/fuel mixture and ignition timing for varying engine load and altitude conditions. On turbo-charged engines, the ECU also uses the sensor to monitor boost pressure and operate the wastegate accordingly. Location The sensor is mounted either on the bulkhead, air cleaner or throttle body. A vacuum hose connects the sensor to a strong source of manifold vacuum, Refer to the vehicle manufacturers handbook or Haynes manual.OPERATION AND USE THE TOOL COMPANY Note: Some new MAP sensor types may be Workin directly mounted to the manifold, eliminating Top or adjacent test light on. the vacuum hose connection. Checks Check MAP sensor vacuum hose for, correct connection, pinches, kinks or collapsed and check MAP sensor power circuit. Test Procedure Signal Test: Connect test leads but keep sensor connected to the vehicle wiring use backprobe adapter. Connect the yellow test lead clip to the sensor single circuit and the black test lead clip to a good vehicle ground. Position the range switch to high. Position the function switch to volts. Non-Turbo Engines only: Start engine and let idle. Turbo Engines only: Attach hand vacuum pump to sensor vacuum port and apply 18"Hg. vacuum. (More than 25"Hg. vacuum may cause damage to the sensors) Working Sensor: Test light moves downward during engine idle or when vacuum applied. (The test light may extinguish if it moves to the bottom of, the column, this is normal) ‘Movement range of test light varies with sensor type and applied vacuum. NOTE: Ignore any pulse light action. Failed Sensor: Test light position does not change during test. Vehicles with frequency type sensor. Position the range switch to low. Position the function to frequency. Turn ignition key on but do not start the engine, Working sensor: The test light will move downwards when vacuum is applied. NOTE: If the test light is not illuminated a problem exists. Power Test Connect test leads but keep sensor connected to the vehicle (use back probe adapter). Connect the yellow test lead clip to the sensor power circuit end the black test lead clip to a good vehicle ground. Position the range switch to high. Position the function switch to volts. Switch the ignition key on. -10- Failed: Test light off or not in top few position. Repair open or short in wiring, then retest. Earth Test: Connect with the same set-up as previous test, but move the yellow test lead clip to ground circuit Working: No test lights illuminated. Failed: Any test light on. Repair open circuit in ground wiring, then retest. Disconnect wiring harness from MAP sensor. Some vehicles use a metal snap ring to secure wiring harness to sensor. Position the range switch to low. Position he function switch to ohms. Connect the yellow test lead clip to the MAP. signal pin on the vehicle harness connector and connect the black test lead clip to a good vehicle ground. Working: Test light on in any position. Failed: No test lights illuminated. Testing is complete. Disconnect test leads and reconnect sensor to vehicle wiring harness. ‘Typical Sensor Janniow Referred to.sVane Ais Fw ae” Sensor or AirFlow iotor AIR MASS METER Brief Outline This sensor is an electronic module which sends a signal to the ECU indicating the density of air entering the engine. Depending upon sensor type, the signal will be a DC voltage. The signal level increases or a frequency as the air mass increases.‘THETOOLCOMPANY OPERATION AND USE Within the sensor is a heated wire located in the path of incoming air. The ECU determines air mass by measuring the temperature drop of the heated wire as air passes around it (colder air is more dense). The ECU needs to know incoming air mass to properly adjust air/fuel mixture for varying engine load and operating conditions. Location The sensor is mounted in the incoming air ducts typically around the air cleaner assembly. Checks Check for air intake problems. Air leaks — around sensor, ductwork or throttle body, Obstructions in air duct, Clogged air filter Test Procedure Signal Test Connect the test leads. Keep sensor connected to vehicle wiring, use backprobe adapter. Connect the yellow test lead clip to the sensor signal circuit and the black test lead clip to a good vehicle ground. Depending on the connection configuration the switch settings will be: Range on low Function on frequency or Range on high Function on frequency Turn the ignition key on but do not start the engine. NOTE: The test light position. Typically, the test light will be off, at the bottom of the column or flashing. Ignore any pulse light action. Start engine and idle. Observe test lights for results. Working Sensor: Test light moves upward after engine starts Test light moves up even further if engine RPM is momentarily increased. (Move throttle to check) Range of test light movement varies with sensor type and engine speed. Failed Sensor: Test light position does not change during test. Carry out all steps to avoid replacing a working sensor, POWER TEST: Keep sensor connected to vehicle wiring, use backprobe adapter. Attach the yellow test lead clip to the sensor power circuit and the black test lead clip toa good vehicle ground. Position the range switch to high. Position the function to volts, Switch Ignition key on. Working: Top or adjacent test light illuminated. Failed: No test lights illuminated or test light illuminated in lower part of range. Repair open or short in power circuit wiring, then retest. EARTH TEST: Connect with the same set-up as previous but move the yellow test lead clip to the sensor ground circuit. Working: Test light off. Failed: Any test lights illuminated. Repair ground circuit wiring, then retest. With ignition key switched OFF disconnect wiring harness from MAF sensor, Some vehicles use a metal snap ring to secure wiring harness to sensor. Position the range switch to low. Position the function switch to ohms Connect the yellow test lead clip to the signal pin on the vehicle wiring connector. Connect the black test lead clip to a good vehicle ground. Working (no short): Test light on in any position. Failed (shorted): Test lights illuminated. Repair short in signal circuit wiring, then retest.‘THE TOOL COMPANY OPERATION AND USE Typical Sensor VANE AIR FLOW SENSORS Brief Outline This sensor sends a DC voltage signal to the ECU indicating the amount of air entering the engine. The voltage signal increases as the air flow increases. The sensor assembly has a pivoting door (vane) which is opened by incoming air. The vane is connected to a potentiometer which generates the voltage signal. Some Air Flow Meters contain a vane position switch or both The ECU needs to know the amount of incoming air flow to properly adjust the air/fuel mixture and ignition timing for varying engine load and operating conditions. Location The sensor is mounted in the incoming air ducts between the air cleaner and the throttle body. Checks Check for sensor operation, poor connections at sensor or ECU, Faulty sensor wiring (open or short circuits) Airflow obstructions in ductwork or clogged air filter. Binding pivot on vane “door” Air leaks around sensor or throttle body. IMPORTANT: Carry out all three tests for the sensor. ‘You can test the sensor both on and off the vehicle. Air Flow Meter Sensor Connect Test leads to sensor. Note: Refer to the vehicle manufacturers handbook or Haynes manual. Connect the red test lead clip to the sensor power terminal, Connect the yellow test lead clip to the sensor signal terminal and connect the black test lead clip to a good vehicle ground. Position the range switch to high. Position the function switch to volts. Operate sensor and observe test light. Slowly move the sensor (pivoting door) back and forth from fully closed to fully open position. -12- Use a pencil, or similar object, to push on the door. (This will not harm the sensor). Working Sensor: Test light smoothly moves up or down as sensor is operated, (The test light may go off if it moves to the bottom of the column = this is normal) Range of TEST light movement varies with sensor type. Failed Sensor: Test light position does not change during test or light movement is erratic, showing a sudden jump or dip during smooth sensor operation. Testing is complete Air Temperature Sensor Position the range switch to high. Position the function switch to ohms. Heat sensor using a hair dryer or similar device. DO NOT use a match or open flame. Heat temperature sensor thoroughly. Observe test lights. Working Sensor: Test light moves downwards below original position. (Test light may go off if sensor is very hot - this is normal) The test light will move upwards as the sensor cools off. Range of test light movement varies with sensor type and temperature change. Failed Sensor: Test light position did not change during test. Testing is complete Air Flow Meter Position Switch Position the range switch to high. Position the function switch to ohms. Operate sensor and observe test light. Slowly move the sensor element (pivoting door) back and forth from fully closed to fully open position. Use a pencil, or similar object, to push on the door.( This will not harm the sensor). Working Switch: Test light switches between being on at top of column and off. Failed Switch: Test light always on at top of column or always off. Testing is complete.OPERATION AND USE CS wget Tooth yen Ring ps ay: on “ fu { "t esto = sor Negate| ROTATION ——> ‘Typical Sensor Signal Voltage CRANKSHAFT/CAMSHAFT POSITION SENSOR, Brief Outline The ECU needs to know rotational speed (or position) of the engine crankshaft/camshaft for controlling ignition and fuel systems. If the ECU is handling a Distributorless (Direct) ignition system or controlling the operation of individual fuel injectors, it also needs to know when cylinder #1 is active. The sensors have various names such as: Crankshaft Position, Crank Angle, Flywheel, Distributor Pick-Up, Camshaft Position, Cylinder, TDC and RPM ete. Similar sensors are used in ABS and automatic transmission systems. These sensors have names such as : Wheel Speed, Vehicle Speed and Drive shaft etc. These sensors come in many styles using different connectors. Other versions combine two functions into a single sensor (usually camshaft position and cylinder #1 identification.) The most common sensor types are Magnetic inductance and Hall Effect. These are described below. Magnetic Inductance The basic inductance sensor consists of a permanent magnet with a coil of wire wound around it, Near the sensor is a toothed ring made of iron or steel (sometimes called a “reluctor”). The ring is attached to a rotating component such as the crankshaft or camshaft. Whenever a tooth from the ring passes by the sensor, it attracts the magnetic field lines surrounding the magnet. This generates a small voltage pulse (magnetic induction principle). A pulse is generated every time a tooth passes the sensor. The ECU determines rotational speed (or position) by measuring how fast (or when) pulses appear. Note: The voltage pulses get larger when the teeth pass by more quickly. - ill ULL risen Sensor Signal Voltage Hall Effect The basic Hall effect sensor consists of a permanent magnet and a small module containing a transistorized Hall effect switch. (Power and ground connections are required for operation ) A small air gap separates the sensor and the magnet. The magnetic field causes the Hall switch to turn on and send out a low voltage signal. If a metal strip (iron or steel) is placed in the gap, it blocks the magnetic field from reaching the Hall device. This causes the Hall switch to turn off and send a high voltage signal out on the signal wire. ‘The metal strips (blades) are part of a disk or cup attached to a rotating component such as the crankshaft or camshaft. As the blades pass through the sensor gap, the voltage signal switches high and low creating a series of pulses. Location The sensor is usually located inside the distributor. Vehicles without a distributor have the sensor located in various places around the engine where it can be mechanically linked to the crankshaft or camshaft Drive shaft sensors are located in transmission housing or near drive shaft. Wheel speeds sensors are located usually on individual wheels, drive shaft, or transmission shaft Checks Problems with Ignition: No start, stalling, rough running. Automatic Transmission: No torque converter lock-up, faulty shifting or slipping. ABS system: Faulty or not working.THE TOOL COMPANY OPERATION AND USE Inspect: Sensor operation, Poor connections at sensor or ECU. Faulty sensor wiring (open or short circuits) Magnetic Inductance: Too much gap between sensor coil and reluctor ring. Cracked, broken, or missing teeth on reluctor ring, (Note: Some rings may normally have a gap or irregular tooth space. This gives the ECU location/identification information). Hall Effect: Foreign objects in gap between Hall sensor and shutter assembly. Cracked, broken, ‘or missing blades on shutter. (Note: Some shutter assemblies may have irregular blade spacing. This gives the ECU location/identification information). Test Procedure Magnetic Inductance Sensor NOTE: It is not possible to safely test drive shaft type sensors since they require the vehicle to be in motion. Disconnect wiring harness from sensor, some vehicles use a metal snap ring to secure wiring harness to sensor. Connect test leads. Connect the yellow test lead clip to one end of the sensor coil pin and the black test lead clip to the other end of the sensor coil pin, Position the range switch to low. Position the function switch to volts. Operate the sensor and observe the test lights. (Note: Ignore any rich/lean light flashes.) For the Crankshaft/Camshaft sensor, crank the engine. STAY AWAY from moving engine parts. NOTE: Some manufacturers ECU's will store a trouble code if the engine is cranked with the sensor disconnected. For the wheel speed sensor, raise the wheel off, the ground and support with axle stands. Give the wheel a spin in either direction to test. Working sensor- test lights flicker or stay illuminated during testing. Position and range of test lights activity varies with sensor type. Failed sensor-test lights remain off during testing. Disconnect wiring halleffect sensor harness from sensor, some vehicles use a metal snap ring to secure wiring harness to sensor. Connect test leads. Connect the red test lead clip to the sensor power pin, Connect the yellow test lead clip to the sensor signal pin and the black test lead clip to the sensor ground pin. -14- Position the range switch to low. Position the function switch to frequency. Operate the sensor and observe the pulse light. (Note: Ignore any test light illumination.) Crank the engine, Stay away from moving engine parts. ‘Working sensor — pulse light flashes or stays illuminated during cranking (varies with sensor type). Failed sensor — pulse light remains off during cranking. NOTE: Some ECU's will store a fault code, if the engine is cranked with the sensor disconnected.OPERATION AND USE =a IGNITION MODULES NOTE Tue acon ont ge ray ale ash MOD-01 ‘You can save yourself time, always begin with a thorough visual and “hands-on” inspection. ‘You can often find the cause of many problems by just looking. Has the vehicle been serviced recently. Has something been reconnected to the wrong place, or not at all. Poor earthing can cause a vehicle not to start. Some modules, the casing makes the ground connection to the vehicle chassis. Check mountings, module flanges and casing for clean contact surfaces and correct attachment, + Inspect wiring for: - Contact with sharp edges. - Contact with hot surfaces, such as exhaust manifolds, etc. - Pinched, burned or chafed insulation. - Correct routing and connections. + Check electrical connectors for: = Corrosion on pins - Bent or damaged pins. - Contacts not properly seated in housing. - Bad wire crimps to terminals. - Some ignition modules require heat transfer grease applied between the module and the mounting surface. Modules can overheat and fail if the grease is missing or sufficiently applied. IMPORTANT: + This test checks for faulty modules causing a non-start. This test will not detect modules with intermittent failures due to heat or engine vibration. + Refer to the vehicle manufacturers handbook or haynes service manual for module location, removal and installation procedures + Prior to testing, always check the charge condition of the 9 volt battery in the tester (refer to page 4). L Identify the make/module from the diagrams on the following pages 2, Connect test leads as shown. Begin with the Test 1, if more than one test is shown. 3.Set range switch to low, 4,Set function switch to frequency. 5. Observe pulse light for test results, + Flashing light indicates working module. (There may be a short delay before flashing starts). + No flashing indicates a failed module. L Black Red, Yellow -15- Green‘THE TOOLCOMPANY MOD-04 MOD-05 Black OPERATION AND USE MOD-07 Blue Jumper MOD-08 Magnetic Inductance Pick-up Hall Effect Pick-up -16-OPERATION AND USE MOD-10 Mop-14 MOD-15 agen a fp ni pecepeeseanionse = : q tiew of ai 4 cues wl LI Rod il Simm a MOD-16 ————— MOD-12 o oO) Ei # wu) \ om) Cater MOD-17 MOD-13 Black Red yenowOPERATION AND USE ‘THE TOOL COMPANY MOD-18 MOD-24 I Bushing s ao a Al RN tkeup Yollow hoa Nene MOD-25 ———— Yotew AS Ss oo ‘Blue jumper ; 1 Yelow feos +—| Red on Oo even Since MOD-26 MOD-20 MOD-23 MOD-27 «4 SO IMPORTANT ‘Yellow ‘Raenees = ] * cat ma * Ustribuior dering test Connect Black test load fore good ground inside aistrbutor Connect Black test lead Mack to mounting holes -18-‘THE TOOL COMPANY MOD-28 MOD-29 MOD-30 OPERATION AND USE MOD-32 Blue module Tead MOD-33OPERATION AND USE MOD-37 ‘Yellow Use a paper clip to connect text lead. (c- TL af= Use a paper clip to connoct test load Connect Black test Yead to ignitor mounting hole or good vehicle around MOD-38 MOD-36 o]|—=| 8 Use a papor clip to Gan connect test leads fellow, Green Yeu -20- Red’OPERATION AND USE MoD-39 MOD-42 VEHICLE Alfa Romeo Audi BMW Citroen Chrysler Fiat Ford Honda Jaguar Lancia Land Rover Mazda Mitsubishi MOD-41 Nissan/Datsun How Peugeot Porsche Rover Saab Seat Talbot Toyota Use a paper clip to connect test lead Vauxhall/Opel UU Volkswagon Volvo Re GreenN -21- ‘Yugo Green EUROPEAN APPLICATION LisT The ignition modules references shown here are not part numbers, they only identify the diagrams in the preceding pages: MODULE No. 07/18 01/08/29/32 02/18/30 2/12 08/09/14/25 02/06/07/19 04/06/07/10/12/18 1/7 01/07 01/02/04/07 08, 14/28/28 14/24 01/13/24 02/06/07/12 ol 02/04/08/11/17 ol ol 02/08/08 20/21/22/23/33/34/35/ 36/37/38/39/40/41/42 01/038/16/26/27 01/27/29/32 01/31 01/02OPERATION AND USE ‘THE TOOL COMPANY MORE USES FOR THE Low Resistance Checks TESTER + Position range switch to low. Circuit Voltage Checks This function is useful for checking the presence (or absence) of voltages throughout the vehicle electrical system (such as wiring, switches, relays, and connectors). It is safe for probing computer and sensor circuits 1, Position function switch to volts. 2, Position range switch to high. 3, Connect black test lead clip to circuit ground. 4, Probe with yellow test lead. Warning: Do not connect to secondary ignition circuits - dangerous voltages present! 5, Test light position indicates measured voltage. Each light represents a 0.5 volt step along a Span of 0.5 to 8 volts. NOTE: Top test lights on - voltage is 5 volts, or higher. + Alltest lights off = voltage is less than 0.5, volts, not present or negative polarity. Important: + Always make sure all connections are good at the contact points. + Negative voltages, no matter how large, will not illuminate on test lights. + More than one test light on, or jumping around, means the measured voltage is, erratic or rapidly charging. Continuity Checks This function is useful to test wiring, ground connections, switch operation, relay contacts and similar. Important: + Carry out continuity tests on unpowered circuits only. + Always make sure all connections are good. Ifnecessary, scrape away corrosion, paint, etc, at the contact points. 1, Position range switch to high. 2, Position function switch to ohms. 3, Connect yellow test lead clip to one end of circuit, switch or relay contact. Connect black test lead to other end of wire, switch or relay. 5, Test light position indicates level of continuity. + All test lights off - short circuit (measured resistance is 200 ohms, or less). + Top test light on - open circuit (measured resistance is 7K ohms, or higher). Other test lights on mean circuit has resistance between 200 ohms and 7K ohms. + Position function switch to ohms. + Connect yellow and black test lead clips All test lights off - resistance is 80 ohms, or less. Top Test light on - resistance is 300 ohms, or higher. Other Test lights on mean resistance is between 30 and 300 ohms. Diode Checks Tests diodes and rectifiers for correct operation. 1. Position range switch to high. 2. Position function switch to ohms. 3. Connect test lead clips as shown in Fig.3. (yellow to anode - black to cathode). 4, The bottom test light should be on. Ifa different test light is on or all lights are off, the diode has failed. 5. Reverse test lead connections as shown in Fig.4. (yellow to cathode - black to anode). 6. To top test light should be on. Ifa different test light is on or alll lights are off, the diode has failed. Note: Always make sure all connections are good. If necessary, scrape away corrosion Paint, etc. at the contact points. Fig.3. Yellow Black Fig. 4. Black Yellow® THE TOOL COMPANY DRAPER TOOLS LIMITED, Hursley Road, Chandler's Ford, Eastleigh, Hants. SO53 1YF. UK Helpline: (023) 8049 4344. Sales Desk: (023) 8049 4333. General Enquiries: (023) 8026 6355. Fax: (023) 8026 0784. &y http://www.draper.co.uk ©“ e-mail: sales @ draper.co.uk ‘YOUR DRAPER STOCKIST ©Published by Draper Tools Ltd. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical photocopying, recording or otherwise without prior permission in writing from Draper Tools Ltd.