Administration

Fire procedure
Toilets
Breaks
Mobile telephones please turn off
 Agenda
Technology development
ECM logic
Terminology
Ignition system analysis
Engine management systems
Sensor identification and testing
Closed loop fuelling
 Todays Petrol Engines
Inputs Outputs
Cam sensor (CKP) Ignition coil(s)
Crank sensor (CMP) Idle speed control valve (ISCV)
Air flow sensors (AMM/MAF) Throttle motor
Engine coolant sensor (ECT) Injectors (petrol or diesel)
Throttle position switch (TPS) Fuel pump
Heated oxygen sensors (HEGO) Exhaust gas recirculation valve
Accelerator position (APP) (egr)
Map sensor (MAP) Turbocharger control
Knock sensor (KS) Swirl flaps
Exhaust gas temperature VVT control
Fuel temperature sensor Variable induction control
EGR position sensor

A BIG INCREASE IN ELECTRONICS!

 Todays Diesel Engines
Inputs Outputs
Cam sensor Electronic injectors
Crank sensor EGR valves
Air mass meter Additive systems
Map sensor Inlet metering valves
Rail pressure sensor Pressure regulator
Throttle position Swirl flaps
Fuel temperature Glow plugs
EGT
EGR position
DPFE sensor
 Petrols and Diesels

All controlled by a computer!

 Communications

01000110110111001100011
 ECM Logic

No codes

Codes, no descriptions

Codes and descriptions

 P 0 1 0 0
System Code Type Sub System Setting Conditions
P = Powertrain 0 = Generic 1 = Fuel or air = Variable
B = Body 1 = Enhanced 2 = Fuel or air
C = Chassis 2 = Generic 3 = Misfire
U = Network 3 = Either 4 = Emission control
5 = Vehicle or Idle speed
6 = ECU or output
circuit
7 = Transmission
8 = Transmission
9 = SAE Reserved
0 = SAE Reserved
 Electrical
Fundamentals,
Sensors and Testing
 What Testing Can We Do?

ELECTRONIC MECHANICAL
Resistance Compression
Voltage (DC & AC) Fuel pressure
Duty cycle/pulse width Vacuum/pressure
Current Back pressure
Frequency Timing

Scanner gives direction: Fault codes & live data

 Electrical Fundamentals

The physical
pathway for current
flow is called an
electrical circuit
 Electrical Fundamentals

Voltage

Voltage is
an electrical force or pressure, which
causes current to flow through an electrical
conductor:
Measured in units of volts (V)
 Electrical Fundamentals

Current

Current is the flow of electrons through a

conductor
Measured in units of amperes or "amps" (A)
 Electrical Fundamentals

Resistance

Resistance is the opposition offered to the

flow of an electrical current by a substance
through which it is passing
Measured in units of ohms ()
Symbol for calculations is (R)
 Resistance Is Futile!

Resistance testing requires the component to

be taken out of circuit
Resistance varies with temperature
Resistance testing is not live testing in a
normal operating environment
 How Do We Test Circuits?
Resistance has limited use
Use volt drop
V
Use current
A
 Ohms Law

A relationship exists between the

voltage, current and resistance within V
the circuit, and this relationship is
called Ohms Law
Ohms law states:
That one Volt is required to pass
A X R
one Amp through a one Ohm
resistance, providing that the
temperature remains constant
An easy way to calculate Ohms law,
Current with a constant voltage =
within a circuit, is to use the diagram
Higher resistance - lower amps
to the side Lower resistance - higher amps
 Example
A heated rear screen
has a resistance of 0.5
Ohms
Using Ohms Law, ?
calculate the total
current flow within
the circuit, assuming a
V
battery voltage of 12V
12 Volts 0.5 Ohms = 24 Amps A R
 Watts Law

W
When electricity flows in a
circuit, the electrical energy is
V
converted into thermal energy
(heat), radiant energy (light) or A X V
mechanical energy
(movement) A R
The amount of work done by
electricity in a time unit (i.e.
one second) is called electrical
power
This is measured in Watts (W)
Voltage

12v

12v BATTERY
Voltage

<0.5v

12v BATTERY
 Voltage

12v

12v BATTERY
Bad Earth
 Volt Drop Testing
(Path of least
resistance) 3.4v
0.5v
RESISTANCE

LOW RESISTANCE
More voltage gets
through the circuit
HIGH RESISTANCE
More voltage gets
through the meter
 Volt Drop Positive

0.5v

ECU
BATTERY
 Volt Drop Negative

0.5v

ECU
BATTERY
Voltage ECM Output

SENSOR ECU
BATTERY

0.25 TO 4.75V
Note: If 5v NO circuit exists
Typical sensor cicuit

SENSOR ECU
BATTERY

Measuring Point
Inside ECU

+ve
 Typical Sensor Circuit
ECU measures

0.2 v voltage here

0.2 v
0.2 v

SENSOR ECU
BATTERY

+ve
 05 volts
1.5 volts FAULT CODE
CTS VOLTAGE
HIGH

PCM

SIGNAL

TEMP SENSOR

1- 4 v
+ve
 Current Testing
Current can tell us:
There is a circuitcurrent can only flow if there is a
circuit
How much current is flowing
What work is being done by the component
Current ramping is an advanced technique used with
oscilloscopes
 Jargon Busting

Analogue (AC wave form output)

Digital (square wave form output)
Frequency
Pulse width (Modulated)
Duty cycle (Modulated)

The ECM uses all of these signals to control and monitor

sensors and actuators
Analogue Waveform
Digital Waveform
 Digital Square Waveform

Frequency
1 sec
period

Voltage does not change due to frequency increase

Voltage must peak to input voltage and switch to 0v for ECU to acknowledge an
on/ off signal
Variable Pulse Width (PWM)

Off time Total time, one cycle = 100%

On time Duty Cycle 30%

 PWM & Duty Cycle
Pulse width alters the current being used.
Pulse widths can be measured with duty cycle.

Current

Pulse
 Basic System Layout

Inputs Outputs
 Fuel Pump

What tests can I do Failure effects Different What is it used for

types
Current Non start No Proving sufficient flow and
Volt drop Incorrect pressure to the fuel rail
Pressure fuelling
Actuator tests Surging
(Scanner) Misleading
DTCs
 Fuel Pump Analysis

Any motor can be tested for current flow. The waveform can tell us a
great deal about the circuit.
Fuel Pump Analysis

Find a convenient point in

the circuit and simply
clamp one of the wires.
Inbuilt Tuition
Fuel Pump Testing

Fuel pump speed analysis

Fuel Pump Testing

Dead segments in pump

 Basic System Layout

Inputs Outputs
 Ignition Coil
What tests?

What tests can I do Failure effects Different types What is it used for
Primary voltage Non start Wasted spark To send sufficient
Secondary voltage Misfire Direct voltage to the
(kv) MIL Distributor less spark plug to ignite
Resistance the fuel air mixture
at the right time
Primary current
 Coil Principles
+ 12v HT

The ignition coil is a step-up

transformer that converts supply
voltage to the high voltage required
to jump across a spark plug gap.

Switched Earth
 Conventional System
Direct
connection to
plug COP
System

Terminal 15 Primary
Ignition Supply
Secondary
Terminal 1
Coil Control
ECU/ Ignition AMP
Removing the points and
condenser
 Double Ended Coil
Common
Supply System

1342
Firing
Order

TDC TDC
Power Exhaust
 Double Ended Coil
System

1342
Firing
Order

TDC TDC
Exhaust Power
Ignition Coils
There are a few combinations of coil but all
operate in exactly the same way as each
other.
Coil Pack, Cartridge and Coil On Plug.
 Ionization Theoretical diagram only
Detection of an engine misfire can take between 20 and 12v
90 seconds for the ECM to detect and respond
Possible damage to the catalyst if a prolonged misfire
occurs
The misfire may also be caused by an injector or an air
leak on a manifold
By using an ionization trace a misfire can be detected
immediately
This is done by an additional amplifier built into the coil
pack which puts a small voltage to the spark plug which
in normal circumstances would not earth out to the
electrode. High tension voltage creates the ionization
field which is plasma, when combustion has taken place
then the voltage will track across the ion particles in the Low volt
plasma field and discharges to earth, the ECM now Ion circuit
knows that combustion has taken place.
This very accurate control and the ECM can use this
trace for cylinder recognition so the ECM does not
require a cam sensor signal
Also because the ionization can accurately detect the Voltage stored in the low volt ion circuit
combustion gas quality, it can detect pre detonation as discharges when ion particles are
well present (combustion)
Coil On Plug Adapter
Built-in Tuition Guidance
Ignition Coil Signal
 Basic System Layout
Inputs Outputs
 Fuel Injectors

What tests can I do Failure effects Different types What is it used for

Duty cycle Non start Mechanical Injects the right

Pulse width Black smoke - Ve switch amount of fuel Into
Current Misfire + Ve switch the engine
Fuel pressure drop Poor performance
Actuator test
(scanner)
Fuel Injector
Why do we need it?
The fuel injector supplies fuel to the
engine when switched by the ECU.
Can be located in the inlet manifold
(MPI) or in the cylinder head (DI)

What happens if it fails?

Misfire/hesitation
Lean/rich mixture
No start/cutting out
 Testing Injectors

Noid lights do not tell if injector has

fired

Current
Pressure drop (with scanner)
ASNU
Exhaust gas analysis
Built-in Tuition Guidance
 Fuel Injector Current Ramp

Battery voltage due to no ground being supplied by ECU

Current ramping is still present as injector needs it

to remain open against spring & fuel pressure The ECU removes the ground supply, this
causes the magnetic field which has built
up in the windings to be released. This is
The windings reached their saturation
known as
point. Enough energy is stored to
Electro-Motive Force
overcome pintle spring & fuel pressure
(EMF)

No ground means no current is

flowing as injector is not energised
This deflection in the voltage on the falling edge
is where a diode in the ecu is regulating the rate
The injector is now energised, meaning current diminishes from the circuit. Preventing
current flows into the injector windings pintle bounce and seat damage.

ECU Provides
ground to injector
Injector Voltage (Request)
Injector (Amps)
Good waveform Bad waveform
Piezo Injector Driver Signal
Piezo Injector Amps Trace
 Basic System Layout
Inputs Outputs
 Crankshaft Sensor
What is it used for?

What tests can I do Failure effects Different types What is it used for?

AC voltage Non start Hall effect Engine speed

Resistance Misfire Ac generator TDC reverence
Oscilloscope Magnetic Misfire detection
Scanner
(engine speed)
 CKP Crank Position Sensor

Crankshaft position sensor (what's it

for)
Engine position (ref cylinder 1 TDC)
Engine speed
Used for misfire detection
Accurate engine timing in conjunction
with cam sensor
Live Data, CKP
Built-in Tuition Guidance
 CKP Crank Position Sensor
Crankshaft position sensor

Permanent magnet sensor (generator)

 Onboard Misfire Detection

Crank sensor output (Waveform)

0v

The speed of crankshaft rotation affects the

size and shape of the waveform
 Onboard Misfire Detection

the crank slows for compression

Slow Fast

and accelerates on power

 Onboard Misfire Detection

so when a misfire occurs

Misfire Event

Slow Fast Slow Fast Slow Slow Fast

the crank does not accelerate as expected

Case Study
 Basic System Layout
Inputs Outputs
 Cam Position Sensor

What tests can I do Failure effects Different types What is it used for?

AC volts Non start Hall effect Cylinder reference

Resistance Misfire Frequency Misfire detection
(inductive only) Inductive (AC) Engine position
DC volts
Oscilloscope
 Hall Effect Sensor

Magnet

Plate
Digital Cam Sensor Testing
Analogue CMP Sensor Testing
Built-in Tuition Guidance
 Basic System Layout
Inputs Outputs
 Manifold Pressure Sensor

What tests can I do Failure effects Different types What is it used for
Volts No idle Analogue Sense engine load
Frequency Erratic Idle Digital Turbo control
Vacuum Poor performance
Black smoke
Built-in Tuition Guidance
Map Sensor Signal
 Basic System Layout
Inputs Outputs
 Coolant Temp Sensor
Coolant temp sensor (why is it needed?)
Identifies cold and hot engines
Cold start enrichment
Hot soak starting
Emissions control
Faulty component will cause:
Possible not start
Poor running
High fuel consumption
High emissions
Misleading fault codes
 Basic System Layout
Inputs Outputs
 Throttle Position Sensor

What tests can I do Failure effects Different types What is it used for
Voltage MIL on? Analogue Acceleration enrichment
Frequency Digital Over-run fuel cut off
Scanner Auto box kick-down
TPS Sensor Signal Return
0.25V
TPS
0v - 4.5V

5v +
TPS
TPS Signals
 Basic System Layout
Inputs Outputs
 Mass Air Flow Meter
(MASS, MAF, AMM)

What tests can I do Failure effects Different types What is it used for

Output Volts Loss of power Analogue EGR control

Volt drop Digital Fuel quantity control
Frequency Turbo control
Live Data, AMM
Whats The Difference?

Diesel Petrol
Built-in Tuition Guidance
Digital AMM
 MAF Sensor Testing
Digital sensors give a square waveform which can be checked with an oscilloscope

This is a variable frequency signal that can be measured with a graphing meter
 Basic System Layout
Inputs Outputs
 Closed Loop Control
To keep the catalytic converter happy the ECU
controls fuelling (air fuel ratio)
Fuelling can be altered to compensate for
wear/ageing and other fuelling problems
Correct fuelling is achieved by the ECU altering the
injector on time
 Heater Oxygen Sensor

B1S1, Pre catalytic converter

B1S2, Post catalytic converter

What tests can Failure Different types What is it used for

I do effects
Voltage Incorrect Zirconia Fuel control
Current fuelling Titania Catalytic converter testing
Frequency Surging at Wideband
cruise
Built-in Tuition Guidance
 O2 Sensor Closed Loop

By increasing and reducing the

Injector Pulse Width, the PCM can
satisfy two important functions:

1. Send measurements to the PCM so

that it can maintain the A/F at a
desired 14.7:1 ratio (stoichiometric)

2. Maintain an efficient Catalytic

Converter.
Zirconia Sensor

1 Hertz
 Basic System Layout
Inputs Outputs
 Post Cat Oxygen Sensor

Pre Cat Sensor Post Cat Sensor

Upstream Downstream
 Knock Sensor

What tests can I do Failure effects Different types What is it used for

Oscilloscope Loss of power Analogue Combustion cylinder

Volt drop knock
 Knock Sensor Construction

1) Retaining bolt
2) Engine cylinder block
3) Electrical connections
4) Seismic mass
5) Piezoelectric element
 Knock Sensor

Piezoelectric Crystal

Body

Seismic Mass
Knock Sensor
Built-in Tuition Guidance
QUICK BREAK
Live VERUS Pro Demo
MODERN DAY DIAGNOSTICS

What is the key to profitable

vehicle diagnostics?
MODERN DAY DIAGNOSTICS

What is the key to profitable vehicle

diagnostics?

Can we still apply the same tried and

true diagnostics methods from before?
 ITS ALL ABOUT SPEED AND
EFFICIENCY!

Average diagnostic charge is 20 per hook up

Average charge per healthcheck is 10

The more you do the more money you

make
ITS ALL ABOUT SPEED AND
EFFICIENCY!
%

Diagnostic Time
RETURN ON INVESTMENT
Diagnostic Tool Return on Investment
Input in blue coloured cells:

How long will you, or have you had your tool? 24 Mth

How many times do you hook up per week? 5

What is your diagnostic charge? 25

How many Health Checks per week? 5

What is your Health Check charge? 25

Total you have spent on subscription? 1889.76

How much did you pay for your tool ? 2911.92

Income generated since you bought the tool 26,000

Total Profit for the 24 Months 21,198

RETURN ON INVESTMENT
 VERUS PRO BENEFITS

1. JOB CARD: A permanent time, dated recorded history of the vehicle (with
DTCs and additional notes or attachments)

2. KNOWN GOOD VALUES: History of scope comparisons

3. COMPONENT TEST METER: Shows you where and how to connect, tells
you what the results should be and the possible causes

4. INFORMATION: Component locations and wiring diagrams

5. INTERNET ENABLED: For diagnostic forums and information

RETURN ON INVESTMENT
 Thank You
We hope tonights presentation has been of interest to you, and
that we have been able to answer some of those questions you
always wanted to ask.