REFERENCES

[1] TS. Le minh duc, lecture Sensor and Measurement Techniques

[2] Technical service manua Toyota
[3] Automotive Sensor, (Sensors Technology)
[4] English specialized in -automotive sensors, University of New South Wales
(UNSW)
[5] https://oto-hui.com/

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Preface
The automobile is one of the crucial means of transportation for the current economic
and social development. Its history and development have spanned many years,
experiencing ups and downs to move towards improvement and convenience, such as
increasing engine capacity, enhancing fuel economy, ensuring safety features, increasing
comfort, and security. With the rapid development of modern technologies, cars now have
witnessed an explosion in the number of various types of sensors. These sensors are the
"senses" of the automobile. They are a fundamental part of the electronic control system,
recording changes in physics as well as chemistry and converting them into electrical
signals provided to the central control unit.. In Vietnam, with the automotive industry still
in its infancy, most of the automotive technologies come from countries around the world.
We need to access these advanced technologies not only to lay the foundation for the
automotive industry but also to serve maintenance and repair Over the course of studying
and researching in the field of "Sensors and Measurement Techniques" at the University of
Science and Technology in Da Nang, I was entrusted with the research topic "Study on the
fuel pressure sensor of automobile engines" by my professor. This is a very practical topic
but comes with many challenges. With my efforts and under the dedicated guidance of TS.
Le Minh Duc, along with the help of my classmates in the 21C4CLC1 class, I have
completed the topic to meet the set requirements. However, during the research process,
due to my limited abilities and experience, some shortcomings were unavoidable.
Therefore, I am looking forward to the contribution and guidance of my professors to
further improve my research, which will serve as valuable professional experience for us
after graduation.
We would like to sincerely thank all the professors, especially TS. Le Minh Duc, for their
dedicated guidance and instruction, which has enabled us to successfully complete our
research topic.
A great thanks to you! You are our teachers who give us recommendations and intellect

STUDENTS PERFORM:

Nguyễn Thành Tâm

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 Table of Contents
PART I: Introduction..........................................................................................................3
1. REASON FOR CHOOSING THE TOPIC......................................................................3
2. THE GOAL OF THE TOPIC.........................................................................................4
3. PURPOSE OF THE TOPIC...........................................................................................4
4. RESEARCH METHODS……………………………………………………………....4
5. LIMITATION OF THE TOPIC......................................................................................4
PART II:
CONTENT…………………………………………………………………....51.1.
GENERAL OVERVIEW OF THE SENSOR SYSTEM
1.1.1.1. Function of the sensor system……………………………………………………..6
1.1.1.2. Tasks of the sensor system………………………………………………………...6
1.1.1.3. Requirements of the sensor system………………………………………………..6
1.1.1.4. Classification of sensor systems…………………………………………………………..6
1.2 The Fuel Rail Pressure Sensor (RPS)
1.2.1 Structure of The fuel pressure sensor.........................................................................7
1.2.2 Where is the fuel rail pressure sensor located ?..........................................................8
1.2.3 What are the symptoms that the sensor is faulty?.......................................................9
Check Light Engine on...............................................................................................9
Engine Starting Issues.................................................................................................9
Sluggish acceleration...................................................................................................9
Stalling.........................................................................................................................9
Low fuel efficiency......................................................................................................9
PART III. REPAIRING FUEL PRESSURE SENSORS IN AUTOMOBILE ENGINES10
2.1. GENERAL KNOWLEDGE OF DIAGNOSIS
2.1.2. Basic theory of diagnosis………………………………………………………….11
2.1.3. Concept of self-diagnosis……………………………………………………………….11
2.1.4. Principle of forming a self-diagnostic system…………………………………..….…11
2.1.5. Types of parameters used in diagnostics. ………………………………..…….….11
2.1.6. How to read electrical circuit diagrams...................................................................12
2.1.7 How to check fuel pressure sensor...........................................................................14
PART IV: CONCLUSION OF RECOMMENDATIONS……………………………….17

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 PART I: Introduction
Introduction to the Topic
1. REASON FOR CHOOSING THE TOPIC
With the rapid and robust development of the Vietnamese automotive market, a demand
is being placed on how to maximize the efficiency of automotive engines, especially in
terms of control, in order to be able to evaluate and fully utilize its features, bringing the
highest technical and economic indicators (low fuel consumption, pollution, engine
power) ... This is a task set for a country like Vietnam that is integrating with the world.
That is also the reason why I chose the research topic of my academic research as
"Research on fuel pressure sensor". Within the limited scope of the topic, it is difficult to
describe all the work that needs to be done to fully exploit the features of the fuel pressure
sensor control. However, this will be the foundation for taking the basis to exploit similar
engines in the future, how to use them in the most effective and economical way in the
longest period of time.

Automotive Sensors

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2. THE GOAL OF THE TOPIC
As presented in the previous section, the objective of this topic is to provide a general
overview of the work that can be done to effectively exploit the fuel pressure sensor on a
car engine. Through research, we can have an overview of the structure of the fuel pressure
sensor components, understand the detailed structure and operation of each component in
the fuel pressure sensor on the engine. From there, we can draw out the causes of damage
and how to repair when the system encounters problems.
Thanks to this understanding, automotive engineers can provide advice to users on how
to use and exploit the engine in the most effective way, for the longest time to help the
engine operate with the highest economic and productivity. Finally, mastering and
effectively exploiting the engine crankshaft position sensor system, on the basis of that
foundation, we will be able to exploit well the new types of fuel pressure sensors that are
born later and have more advanced systems.
3. PURPOSE OF THE TOPIC
In the process of researching and implementing this topic, the student himself/herself
realizes that this is a great opportunity to consolidate the knowledge they have learned. In
addition, students can also learn more practical knowledge that is difficult to transmit in
school. These are really the knowledge that each student needs when working in the future.
4. RESEARCH METHODS
During the research process, I used some of the following research methods:
 Search in technical documents, textbooks, books, especially the manuals of
exploitation, maintenance and repair of automobile companies.
 Search for information on the Internet, websites in and outside the country.
Compare and select to use the necessary and reliable information.
 Refer to the opinions of lecturers in the field of mechanical engineering -
specializing in mechanical engineering. This includes lecturers in the Department
of Transportation Engineering of the University of Engineering and Technology of
da Nang, engineers, technical experts in automobiles at maintenance centers, repair
shops, and even those with many years of experience in using and maintaining
vehicles.
 Synthesize and analyze the collected data sources, and then provide your own
assessments and comments.
5. LIMITATION OF THE TOPIC
Due to the limited time to write the research report, only the structure and operating
principle in the system were studied, from which the general operating principle and how
to repair damage to the fuel pressure sensor were given.

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 PART II: CONTENT
Automotive Engine Sensor System
1.1. GENERAL OVERVIEW OF THE SENSOR SYSTEM
1.1.1. Functions, Tasks, Requirements, and Classification
1.1.1.1. Function of the sensor system
The automotive sensor system plays an important role in controlling the fuel supply to
the engine to ensure that the vehicle runs smoothly and efficiently.
1.1.1.2. Tasks of the sensor system
To control the operation of the engine and assist in the control of the vehicle to improve
operational efficiency, save fuel, reduce harmful emissions, and increase safety and driving
experience.
1.1.1.3. Requirements of the sensor system
The automotive sensor system is an important component that helps to collect
information about the state of the vehicle and the surrounding environment and transmit it
to the central control unit (ECU). The ECU will process this information and issue the
necessary control commands to ensure the safety and efficiency of the vehicle.
Therefore, the automotive sensor system must meet the following requirements:
 Accuracy: The sensors must be accurate to provide accurate information to the ECU. This
is necessary to ensure that the systems on the vehicle operate efficiently and safely.
 Reliability: The sensors must be reliable to ensure the stable operation of the vehicle.
 Noise immunity: The sensors must have high noise immunity to ensure that the collected
information is not affected by external factors.
 Long life: The sensors must have a long life to ensure low maintenance and repair costs for
the vehicle.
Additional requirements:
 Integration: The sensors must have high integration to ensure the efficient operation of the
systems on the vehicle.
 Connectivity: The sensors must have high connectivity to ensure the rapid and accurate
transmission of information.
 Self-diagnosis: The sensors must have self-diagnosis capabilities to detect and report errors
during operation.
1.1.1.4. Classification of sensor systems
Today, there are many different types of sensors equipped on automotive engines.
Based on the structure, operation, and control method, the system is classified into the
following categories: providing engine control signals, controlling vehicles, and sensors on
vehicles.
 Throttle position sensor (TPS): Measures the angle of the throttle valve to determine the
amount of air intake into the engine.
 Engine speed sensor (RPM): Measures the rotational speed of the engine.
 Wheel speed sensor (ABS): Measures the rotational speed of each wheel.
 Engine temperature sensor (ECT): Measures the temperature of the engine.
 Fuel pressure sensor (FP): Measures the fuel pressure in the fuel supply system.
 Oxygen sensor (O2): Measures the amount of oxygen in the exhaust gas to determine the
amount of fuel needed for complete combustion.
 Light sensor (ALS): Measures the ambient light intensity to turn on/off the headlights
automatically.

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 Rain sensor (SRR): Measures the amount of rain to turn on/off the windshield wipers
automatically.
 Tire pressure sensor (TPMS): Measures the tire pressure of each wheel.
 Fuel rail pressure sensor (FRP): Measures the fuel pressure in the engine.
Today, with the development of science and technology, the technology of engine
production in particular and automobile production in general has achieved many high
achievements in all fields, from the technology of manufacturing mechanical parts to the
breakthrough in the technology of manufacturing new materials. With the strong support of
the field of electronics and automatic control, the sensor system today has become more
perfect and accurate. Today's engines are all controlled entirely by computers based on
signals from various sensors. This allows for accurate identification of the engine condition
and the output of the most accurate control signals.
1.2 The Fuel Rail Pressure Sensor (FRP)

PICTURE 1. The position of the fuel rail pressure temperature sensor on the Toyota Camry
engine
The Fuel Rail Pressure Sensor (FRP) is an essential component used in Common Rail
Diesel and Direct Injection Petrol applications. Its main function is to provide accurate
pressure readings in the fuel rail to the Powertrain Control Module (PCM) of the vehicle.
The fuel pressure sensor is responsible for converting fuel pressure into an electrical signal
through a piezoresistive sensor and sending it to the ECM. When there is a change in fuel
pressure, the diaphragm of the piezoresistive sensor will be deformed. Therefore, the
electrical signals are generated by this deformation. The computer will then examine the
data and make the required adjustments to the timing and volume of the fuel injections.
If the fuel pressure in the delivery pipe is high, the diaphragm will be deformed to a
greater extent, thus generating a high voltage signal.
Conversely, low pressure will generate a low voltage signal.
This enables the engine to run at its best under the current driving circumstances.
The precise amount of gasoline the engine requires will be determined by the engine
control unit. Your fuel economy declines if more fuel than necessary is pumped into the
combustion chamber.

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 (a) (b)

PICTURE 1.2 (a) Fuel pressure sensor loop, (b) Fuel pressure sensor circuit diagram
Additionally, extra carbon emissions are released into the environment and the lifespan of
emissions-related parts shortens. The fuel rail pressure sensor is a crucial component that
must always be operational because the majority of vehicles on the road today are designed
to be as ecologically friendly as possible.
1.2.1 Structure of The fuel pressure sensor

The fuel pressure sensor consists of three main components:

 Sensor element: This is the component that actually measures the pressure of the
fuel. It is typically a piezoresistive element, which means that its resistance changes
in response to changes in pressure.
 Signal conditioner: This component converts the resistance change from the sensor
element into a voltage signal that can be sent to the ECU.
 Connector: This component provides a connection between the sensor and the ECU.
Sensor element
The sensor element is typically a piezoresistive element. This type of element is made up of
a material that changes its resistance in response to changes in pressure. The most common
type of piezoresistive element used in fuel pressure sensors is a strain gauge. A strain gauge
is a thin strip of material with a resistor embedded in it. When the strip is stretched or
compressed, the resistor changes its resistance.
In a fuel pressure sensor, the sensor element is typically located in a chamber that is
exposed to the fuel pressure. As the fuel pressure changes, the sensor element changes its

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resistance. This change in resistance is then converted into a voltage signal by the signal
conditioner.
Signal conditioner
The signal conditioner is a circuit that converts the resistance change from the sensor
element into a voltage signal. The voltage signal is then sent to the ECU.
The signal conditioner typically consists of a Wheatstone bridge circuit. A Wheatstone
bridge is a circuit that is used to measure the resistance of a component. In the case of a
fuel pressure sensor, the sensor element is one of the resistors in the Wheatstone bridge
circuit.
Connector
The connector is a component that provides a connection between the sensor and the ECU.
The connector typically has two wires, one for the signal from the sensor element and one
for the power supply.
1.2.2 Where is the fuel rail pressure sensor located ?
On the fuel rail, which is frequently found next to or below the intake manifold, is where
the fuel rail pressure sensor is located. The fuel rail pressure sensor can also be mounted on
the fuel line in some car models; however, this is quite uncommon. The injectors, fuel rail,
and fuel rail pressure sensor should all be located someplace underneath the intake
manifold

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1.2.3 What are the symptoms that the sensor is faulty?
Check Light Engine on

On your dashboard, the “Check Engine” warning light can come on if your fuel rail
pressure sensor malfunctions. When the vehicle’s engine control unit notices a problem that
somehow impacts the engine, this light turns on. It’s possible that something else in the car
is preventing the engine from performing its function properly rather than the engine itself
being defective.
At first, you probably won’t realize the problem is with the fuel rail pressure sensor, but
a diagnostic scan tool may frequently identify the problem. The most frequent DTC codes
indicating a problem with the fuel rail sensor are P0190, P0191, P0192, P0193, and P0194.
Engine Starting Issues
The ECU won’t supply the engine with the appropriate amount of fuel if the fuel rail
pressure sensor is defective. Your car will be challenging to start as a result. It may usually
take a few attempts to crank the engine before it starts when this issue first arises.
However, it will require more and more effort to start as the issue worsens. It frequently
starts and stops right away. The engine will eventually cease to start at all.
Sluggish acceleration
You may have a damaged fuel pressure sensor if you press the gas pedal and the car
doesn’t accelerate as it should. Because the sensor provides erroneous data, the engine
control unit is unable to deliver the signal to the fuel system correctly. Because of this, it
won’t be able to meet the engine’s fuel requirements.
Stalling
As the fuel rail pressure sensor gets worse, engine stalling could arise. Your engine will
abruptly stall while you are driving. While idling, it might also stall. This will make driving
very challenging (and dangerous), and it should inspire you to take action. If it turns out
that your sensor is to blame, drive your car as soon as possible to the closest auto shop to
have it changed.
Low fuel efficiency
You’ll notice a significant decrease in fuel economy and mileage when your fuel
pressure sensor isn’t functioning properly. Your engine control unit will either feed too
much fuel or not enough fuel into the combustion chamber via the fuel rail.

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PART III. REPAIRING FUEL PRESSURE SENSORS IN AUTOMOBILE
ENGINES
2.1. GENERAL KNOWLEDGE OF DIAGNOSIS
2.1.2. Basic theory of diagnosis
Diagnosis is a logical process of receiving and analyzing information transmitted to the
diagnostician from diagnostic devices to find out the faults of the object (vehicle, engine
assembly, transmission, chassis, etc.).
The technical status of the vehicle, as well as the symptoms of their damage, are quite
complex, while the amount of information is not very complete.
2.1.3. Concept of self-diagnosis
Self-diagnosis is an advanced technology in the field of manufacturing and
manufacturing of vehicles. When the systems and structures of the vehicle operate with the
participation of specialized computers (ECUs), the ability for self-diagnosis is conveniently
opened up. People and vehicles can communicate with diagnostic information (the amount
of this information depends on the capabilities of the specialized computer) through
notification systems, so that failures or symptoms of damage are reported promptly,
without having to wait for the scheduled diagnosis.
2.1.4. Principle of forming a self-diagnostic system
The principle of forming a self-diagnostic system is based on the basis of automatic
adjustment systems. On automatic adjustment systems, there are basic components: signal
sensors, central control unit (ECU), actuators. These components work according to the
principle of closed-loop control (continuous).
The basic requirements of the self-diagnostic device include: sensors to measure diagnostic
parameters in real time, information processing and storage, notification signals.
Therefore, the combination of two general diagrams is: The sensors are used in
common, the information processing and storage unit is connected to the ECU. The
notification signal is placed separately. The two diagrams of the automatic adjustment
system with self-diagnosis are described in the figure.
Due to the limitations of cost, space on the vehicle, therefore the self-diagnostic
components are not a complete system compared to specialized diagnostic devices, but
their presence is a positive factor in use.
2.1.5. Types of parameters used in diagnostics.
A system consists of many components, and a component consists of many parts. The
quality of the system's operation is determined by the quality of the components and parts.
Structural parameters are a set of technical parameters that reflect the structural features of
a component or part. The quality of the components and parts is determined by the
structural parameters:
 Shape and size (of spark plugs, coils, and sensors)
 Relative position (between spark plugs and the engine block)
 Surface finish
 Assembly quality
Output parameters are characteristics that reflect the operating state of a component.
These characteristics are determined by measurement. For example:
 Power
 Exhaust gas composition
 Water, oil temperatures
 Oil pressure
 Amount of metal particles in oil

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  Noise, knocking, vibration.
 Braking distance
 Resistance values of sensors and coils
Each system has output limits, which are values that, if exceeded, will not ensure
technical or economic efficiency or will not be allowed. By comparing the test results with
the limit values, it is possible to determine and predict the state of the system. The output
limits are specified by the manufacturer or determined by statistical experience on that type
of system.
If only one output parameter reaches the limit value, the system must be stopped to
identify the cause and find a solution.
Conditions for an output parameter to be used as a diagnostic parameter.
 Homomorphism condition: An output parameter is used as a diagnostic parameter
when it is proportional to a certain structural parameter.
 Extended variation range condition: An output parameter is used as a diagnostic
parameter when its change is much greater than the change in the structural
parameter it represents.
 Easy to measure and convenient to measure condition: An output parameter is used
as a diagnostic parameter when it meets all three conditions simultaneously.

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2.1.6. How to read electrical circuit diagrams
Example : Map of electric diagrams stop light

PICTURE 3. DIAGRAM ELECTRIC

[A]: System Title

[B]: Indicates a Relay is blocked. Cover is not used and the Relay block index is displayed
to distinguish it from J/B. Example: Indicates Relay Block No. 1
[C]: It is used to refer to different wires and connections etc. when vehicle models, engine
types, or specifications are different.
[D]: Indicates system related.

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[E]: Indicates the connection code (male connector and female connector) used to join two
wires together. The connection code consists of two alphabetical characters and one
numeric character.
- The first character of the connection code is represented alphabetically.
PICTURE First
Pins connector
character only the connecting wires for the female connector, and the second
character refers to the connecting wires for the male connector
- The symbol indicating which end of the device to connect is male connector and
end female connector.Ngoài mã số kết nối cho biết các số lượng các chân giắc kết
nối của male connector and female connector
[F]: Part description (all parts are shown in blue frames). This code is the same as the
number used to indicate part locations.
[G]: Connection block (The number in the circle is
the J/B Code and the connection is displayed
next to it). The connection block is clearly 3C indicates that it is inside Co
marked separately from other parts (Figure
2.3).

PICTURE
[H]: Indicates the wire color: It is indicated by a code made up of letters. The first
characters indicate the basic wire colors and the second characters indicate the colors of the
stripes.
Example L - Y L = Blue (background color)
Y = Y = Yellow (stripe color)

Hình 2.4.
Wire color code table:
B = Black W = White Y = Yellow
L = Blue V = Violet GR = Gray
R = Red G = Green O = Orange
P = Pink BR = Brown
SB = Sky Blue LG = Light Green

[I]: Indicates a wire is protected (PICTURE 3)

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 PICTURE 3

[J]: Indicates the number of pins of the jack. The system

of connection numbers on the male and female jacks
is arranged differently. For example: The numbers on
the female jacks are numbered from top left to bottom
right. The numbers on the male jack are numbered female
from upper right to lower left (picture 4) connector
[K]: Indicates contact points. This code consists of two
characters: A letter and a number. The first characters
of this code indicate the alphabetic code order used
for the wires. The second character is an ordinal male
number used to distinguish between ground points in connector
cases where there is more than one ground point on the same wire..picture 4
[L]: Page
[M]: Indicates the positions of the ignition switch when
power is supplied to the fuses.
[N]: Indicates the connection point of a wire (picture 5)

picture 5

2.1.7 How to check fuel pressure sensor

To check with a multimeter:
 Check voltage:
 Start the engine and warm it up to normal operating temperature.
 Allow the engine to idle.
 Use a voltmeter to measure the voltage between pins 1 and 2 of the FRP sensor.
 If the displayed voltage is different from the standard voltage, proceed to the sensor
circuit test. If the circuit is not faulty, replace the sensor. If it matches the standard
voltage, then:
Turn off the engine and wait 3 minutes.
Turn the ignition switch ON (do not start the engine).
Use a voltmeter to measure the voltage between pins 1 and 2 of the FRP sensor.
The displayed voltage should be 1.3-1.8 V.
Check pressure:
 When idling, the pressure should be in the range of 25-35 MPa. If you press the gas
pedal, the pressure should then increase to 100 MPa.

15
 Characteristics of Fuel Pressure Sensor

If the displayed voltage is different from the standard voltage, move on to checking the
sensor circuit:
– Unplug the FRP sensor connector and the ECM connector.
– Use an Ohm meter to measure the continuity between the sensor pin (unplug)
corresponding to the sensor pin in the ECU circuit:
Pin 1 (Mass) with Mass FRP-ECM: R ~ 0: good; R ~ ∞: broken ground wire.
Pin 2 (signal) with FRP-ECM signal pin: R ~ 0: good; R ~ ∞: broken signal wire.
Pin 3 (Vcc) with FRP-ECM Vcc pin: R ~ 0: good; R ~ ∞: positive wire broken.
Things to note: The output voltage at the signal pin is 0.5V - 4.5V for sensors
manufactured by Bosch, Delphi, Siemens or 1V - 4.2V for Denso sensors.
2.1.8 Some common errors with fuel pressure sensors:
Common fuel pressure sensor faults
 P1064/65: Open or short circuit in the fuel pressure sensor circuit
Symptoms:
 Engine stalls when fuel pressure sensor is disconnected.
 The engine will not start when fuel pressure sensor is disconnected.
Cause:
 The ECU is unable to control the fuel pressure in the fuel rail when the sensor is
disconnected.
 P0192: Fuel rail pressure too low
Symptoms:
 The engine will not start.
Cause:
 A leak in the fuel rail pressure line.
 P0193: Fuel rail pressure too high
Symptoms:
 Engine stalls, stalls, or stops running.
Cause:

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 The signal from the fuel pressure sensor to the ECU is outside of the normal range,
indicating a condition of high fuel pressure or a fuel leak.

17
 PART IV: CONCLUSION OF RECOMMENDATIONS
I. CONCLUSION
After a long process of research with the efforts of the group and the enthusiasm of the
lecturers. The research topic of my "Research on fuel pressure sensor" has been completed.
The results of the topic:
 Presented the structural characteristics of the fuel pressure sensor
 Analyzed and built a method for testing and diagnosing fuel pressure sensors
II. RECOMMENDATIONS
The topic "Research on fuel pressure sensor installed on automotive engine" is a topic with
high practical application, so it needs to be further developed.

Although I have tried my best to complete the research process, but due to limited time,
knowledge and experience, my topic cannot avoid shortcomings. I would like to ask
teachers and friends to contribute constructive opinions to make the topic better.

Finally, we would like to express our sincere gratitude to the enthusiastic guidance and
assistance of the teachers and lecturers in the Department of Mechanical Engineering,
especially the advisor, TS. Le Minh Duc, who helped us complete this research topic.

18