25

Computers and Sensors—

Operation, Diagnosis,
and Service
represent a variety of information—temperature,
OBJECTIVES: After studying Chapter 25, you should speed, or even words and letters. A computer
be able to: processes the input voltage signals it receives by com-
puting what they represent, and then delivering the
1. Prepare for the interprovincial Red Seal certification
data in computed or processed form.
examination in Appendix VIII (Engine Performance)
on the topics covered in this chapter.
2. Explain the purpose, function and operation of on- NOTE: Standardized Emissions Terminology
board computers. In the early 1990s, the Society of Automotive Engineers
3. Discuss programming differences between a PROM developed a common list of terms (SAE J1930) for emis-
and an EEPROM. sion related parts, i.e., ignition, fuel delivery and emis-
4. Discuss the operation and testing procedures for sion control components. These terms, by law, have
been used in all Canadian and U.S. automotive service
throttle position, manifold absolute pressure and
and training publications since January 1, 1995. Many
coolant temperature sensors.
automobile manufacturers began using the new terms
5. Explain the operation of heated and non-heated in 1993 when California adopted J1930.
exhaust gas oxygen sensors. As an example, the on-board computer had been
6. Explain adaptive strategy. known as a Micro-computer, a Processor, an Engine
Control Assembly (ECA), or an Engine Control Unit
(ECU) depending on the manufacturer. The new term,
standard in the industry, is Powertrain Control Mod-
ule (PCM).
COMPUTER CONTROL It is important to note that older publications be-
fore the mid-1990s may use different terms than cur-
Modern automotive control systems consist of a net- rent texts.
work of electronic sensors, actuators, and computer
modules designed to regulate the powertrain and ve-
hicle support systems. The powertrain control
module (PCM) is the heart of this system. It coordi- THE FOUR BASIC
nates engine and transmission operation, processes COMPUTER FUNCTIONS
data, maintains communications, and makes the con-
trol decisions needed to keep the vehicle operating. The operation of every computer can be divided into
Automotive computers use voltage to send and re- four basic functions. See Figure 25–1.
ceive information. Voltage is electrical pressure and
does not flow through circuits, but voltage can be used ■ Input
as a signal. A computer converts input information or ■ Processing
data into voltage signal combinations that represent ■ Storage
number combinations. The number combinations can ■ Output
591
592 CHAPTER 25

Processing
Input voltage signals received by a computer are
processed through a series of electronic logic circuits
maintained in its programmed instructions. These
logic circuits change the input voltage signals, or
data, into output voltage signals or commands.

Storage
Figure 25–1 All computer systems perform four basic
functions: input, processing, storage, and output. The program instructions for a computer are stored
in electronic memory. Some programs may require
that certain input data be stored for later reference
or future processing. In others, output commands
may be delayed or stored before they are transmitted
to devices elsewhere in the system.

Output
After the computer has processed the input signals,
it sends voltage signals or commands to other de-
vices in the system, such as system actuators. An ac-
tuator is an electrical or mechanical device that
converts electrical energy into a mechanical action,
such as adjusting engine idle speed, altering suspen-
sion height, or regulating fuel metering.
Computers also can communicate with, and con-
trol, each other through their output and input func-
Figure 25–2 A potentiometer uses a movable contact to tions. This means that the output signal from one
vary resistance and send an analog signal. computer system can be the input signal for another
computer system.

These basic functions are not unique to comput-

ers; they can be found in many noncomputer sys- DIGITAL COMPUTERS
tems. However, we need to know how the computer
handles these functions. In a digital computer, the voltage signal or process-
ing function is a simple high/low, yes/no, on/off sig-
nal. The digital signal voltage is limited to two
Input voltage levels: high voltage and low voltage. Since
First, the computer receives a voltage signal (input) there is no stepped range of voltage or current in be-
from an input device. The device can be as simple as tween, a digital binary signal is a square wave.
a button or a switch on an instrument panel, or a The signal is called digital because the on and off
sensor on an automotive engine. See Figure 25–2 for signals are processed by the computer as the digits
a typical type of automotive sensor. or numbers 0 and 1. The number system containing
Vehicles use various mechanical, electrical, and only these two digits is called the binary system.
magnetic sensors to measure factors such as vehicle Any number or letter from any number system or
speed, engine RPM, air pressure, oxygen content of language alphabet can be translated into a combina-
exhaust gas, airflow, and engine coolant tempera- tion of binary 0s and 1s for the digital computer.
ture. Each sensor transmits its information in the A digital computer changes the analog input sig-
form of voltage signals. The computer receives these nals (voltage) to digital bits (binary digits) of informa-
voltage signals, but before it can use them, the sig- tion through an analog-to-digital (AD) converter
nals must undergo a process called input condi- circuit. The binary digital number is used by the com-
tioning. This process includes amplifying voltage puter in its calculations or logic networks. Output sig-
signals that are too small for the computer circuitry nals usually are digital signals that turn system
to handle. Input conditioners generally are located actuators on and off.
inside the computer, but a few sensors have their The digital computer can process thousands of
own input-conditioning circuitry. digital signals per second because its circuits are
 Computers and Sensors—Operation, Diagnosis, and Service 593

 

   






Figure 25–4 Typical ignition timing map developed from

testing and used by the vehicle computer to provide the
optimum ignition timing for all engine speeds and load
Figure 25–3 Many electronic components are used to combinations.
construct a typical vehicle computer. Notice all of the
chips, resistors, and capacitors that are used in this
computer.

able to switch voltage signals on and off in billionths PROM

of a second. See Figure 25–3.

Parts of a Computer
The software consists of the programs and logic func-
tions stored in the computer’s circuitry. The hard-
ware is the mechanical and electronic parts of a
computer.

Central Processing Unit (CPU) The micro-

processor is the central processing unit (CPU) of
a computer. Since it performs the essential mathe-
matical operations and logic decisions that make up
its processing function, the CPU can be considered
the heart of a computer. Some computers use more
than one microprocessor, called a coprocessor.
Figure 25–5 A replaceable PROM used in a General
Computer Memory Other integrated-circuit Motors computer. Notice that the sealed access panel has
(IC) devices store the computer operating pro- been removed to gain access.
gram, system sensor input data, and system actu-
ator output data, information necessary for CPU
operation. and powertrain combination. Each combination is
permanently mapped digitally onto an IC chip called
a programmable read-only memory (PROM).
Computer Programs
This allows an automaker to use one basic computer
By operating a vehicle on a dynamometer and man- for all models; a unique PROM individualizes the
ually adjusting the variable factors such as speed, computer for a particular model. Also, if a driveabil-
load, and spark timing, it is possible to determine the ity problem can be resolved by a change in the pro-
optimum output settings for the best driveability, gram, the manufacturers can release a revised
economy, and emission control. This is called engine PROM to supersede the earlier part.
mapping. See Figure 25–4. Some manufacturers use a single PROM that
Engine mapping creates a three-dimensional plugs into the computer. See Figure 25–5. Other com-
performance graph that applies to a given vehicle puters use a non-replaceable calibration module that
594 CHAPTER 25

contains the system PROM. If the on-board computer

needs to be changed, the replaceable type of PROM or
calibration module must be removed from the defec-
tive unit and installed in the replacement computer.
The original PROM was programmed to re-
duce emissions, improve fuel economy and provide
acceptable power. Replacing the factory PROM
with an aftermarket “hot” PROM to increase en- CRYSTAL OSCILLATOR
gine performance often increases engine emis- (CLOCK GENERATOR)
sions as well.
In order to reduce tampering and the use of af-
termarket PROMs, the Environmental Protection
Agency (EPA) mandated that the on-board com-
puter be tamper resistant. As a result, beginning in
1994, PROMs are soldered into place and are not
replaceable.
Some PROMs are made in a way that they can be
erased by exposure to ultraviolet light and repro- Figure 25–6 The clock generator produces a series of
grammed. These are called EEPROMs (electroni- pulses that are used by the microprocessor and other
cally erasable), or EPROMs (erasable PROMs). components to stay in step with each other at a steady rate.
The new EEPROM chips allow technicians to re-
program them with special electronic service tools.
Replacement computers must be programmed (ei-
ther in the car or on the bench) before the vehicle will
run; further updating can be done any time. This
Baud Rate
type of service is usually done by dealership techni- The computer transmits bits of a serial data stream
cians, although aftermarket reprogramming tools at precise intervals. The computer’s speed is called
are becoming common. the baud rate, or bits per second. (It is named for
J. M. E. Baudot [1845–1903], a French inventor and
telegraphy expert.) Just as km/h helps in estimating
Clock Rates and Timing
the length of time required to travel a certain dis-
The microprocessor receives sensor input voltage tance, the baud rate is useful in estimating how long
signals, processes them by using information from a given computer will need to transmit a specified
other memory units, and then sends voltage signals amount of data to another computer. Storage of a sin-
to the appropriate actuators. The microprocessor gle character requires eight bits per byte, plus an ad-
communicates by transmitting long strings of 0s and ditional two bits to indicate stop and start. This
1s in a language called binary code. But the micro- means that transmission of one character, or “word,”
processor must have some way of knowing when one requires 10 bits. Dividing the baud rate by 10 tells us
signal ends and another begins. That is the job of a the maximum number of words per second that can
crystal oscillator called a clock generator. See Fig- be transmitted. For example, if the computer has a
ure 25–6. The computer’s crystal oscillator generates baud rate of 600, approximately 60 words can be re-
a steady stream of one-bit-long voltage pulses. Both ceived or sent per minute.
the microprocessor and the memories monitor the Automotive computers have evolved from a baud
clock pulses while they are communicating. Because rate of 160 used in the early 1980s to a baud rate as
they know how long each voltage pulse should be, high as 60 500. The speed of data transmission is an
they can distinguish between a 01 and a 0011. To important factor both in system operation and in
complete the process, the input and output circuits system troubleshooting.
also watch the clock pulses.
Control Module Locations
Computer Speeds
The on-board automotive computer has many
Not all computers operate at the same speed; some names. It may be called an electronic control unit,
are faster than others. The speed at which a com- module, controller, or assembly, depending on the
puter operates is specified by the cycle time, or clock manufacturer and the computer application. The
speed, required to perform certain measurements. Society of Automotive Engineers (SAE) bulletin
Cycle time or clock speed is measured in megahertz J1930 standardizes the name as a powertrain
(4.7 MHz, 8.0 MHz, 15 MHz, 18 MHz, etc.). control module (PCM). The computer hardware is
 Computers and Sensors—Operation, Diagnosis, and Service 595

PCM

Figure 25–7 This powertrain control module (PCM) is

located under the hood on this pickup truck.

Figure 25–8 This PCM on a Chrysler vehicle can only be

seen by hoisting the vehicle because it is located next to
all mounted on one or more circuit boards and in- the radiator in the airflow to help keep it cool.
stalled in a metal case to help shield it from electro-
magnetic interference (EMI). The wiring harnesses
that link the computer to sensors and actuators con- it may ignore sensor input. Or, it may respond in dif-
nect to multipin connectors or edge connectors on ferent ways to the same input signal, based on inputs
the circuit boards. from other sensors. Most current control systems
On-board computers range from single-function have two operating modes: open and closed loop. The
units that control a single operation to multifunction most common application of these modes is in fuel-
units that manage all of the separate (but linked) metering feedback control where the computer re-
electronic systems in the vehicle. They vary in size sponds to a signal from the oxygen sensor and, if
from a small module to a notebook-sized box. Most needed, changes the amount of fuel delivered; this is
early engine computers were installed in the pas- closed loop mode.
senger compartment either under the instrument During periods of prolonged idle, cold engine op-
panel or in a side kick panel where they can be eration, wide open throttle or no oxygen sensor sig-
shielded from physical damage caused by tempera- nal, the computer only looks at ROM (read-only
ture extremes, dirt, and vibration, or interference by memory), permanent memory stored in the com-
the high currents and voltages of various underhood puter. This is open loop mode.
systems. See Figures 25–7 and 25–8. Later model The latest PCMs have increased memory and op-
PCMs are larger, have increased memory and are erate in closed loop mode under many conditions
usually located in the engine compartment where that were not monitored on older systems.
they are cooled by air from the radiator fan. Shorter
wiring harnesses with fewer connections are another
advantage. BASIC COMPUTER OPERATION
Input
FUEL CONTROL SYSTEM Battery power is supplied to the computer when the
OPERATING MODES ignition switch is closed. Because (most) input sen-
sors must operate with a fixed voltage in order to
A computer-controlled fuel metering system can be generate a reliable signal, battery voltage is reduced
selective. Depending on the computer program, it to 5 volts by an internal regulator before being sent
may have different operating modes. The on-board to the major input sensors. See Figure 25–9. In our
computer does not have to respond to data from all of example, these are the throttle position, manifold
its sensors, nor does it have to respond to the data in absolute pressure, and the engine coolant tempera-
the same way each time. Under specified conditions, ture sensors.
596 CHAPTER 25

Figure 25–9 Basic computer inputs. (Courtesy General Motors)

THROTTLE POSITION SENSOR

Most computer-equipped engines use a throttle po-

sition (TP) sensor to signal the position of the throt-
tle. See Figure 25–10 and 25–11. The TP sensor THROTTLE
consists of a potentiometer variable resistor. A typ- POSITION
ical sensor uses three wires: THROTTLE SENSOR
BODY
■ A 5 volt reference feed wire from the computer
■ A ground wire
■ A voltage signal wire back to the computer; as
the throttle is opened, the voltage to the
computer changes Figure 25–10 A typical throttle position (TP) sensor
mounted on the throttle plate of this port-injected engine.
Normal throttle position voltage on most vehicles is
about 0.5 volts at idle (closed throttle) and 4.5 volts
at wide-open throttle (WOT). The TP sensor voltage
at idle is usually about 10% of the TP sensor voltage the engine coolant temperature, and oxygen sen-
when the throttle is wide open. The computer sor(s). Some throttle position sensors are adjustable
senses this change in throttle position and changes and should be set according to the engine manufac-
the fuel mixture and ignition timing. The actual turer’s exact specifications. A defective or misad-
change in fuel mixture and ignition timing is also justed throttle position sensor can cause hesitation
partly determined by other sensors, such as the on acceleration and other driveability problems. On
manifold pressure (engine vacuum), engine RPM, some vehicles equipped with an automatic trans-
 Computers and Sensors—Operation, Diagnosis, and Service 597

Figure 25–11 Schematic of a typical throttle position (TP) sensor circuit. Movement of the wiper on the potentiometer
sends a voltage signal (0.5 to 4.5 volts) to the computer. (Courtesy General Motors)

mission, the throttle position sensor also affects the

application of the torque converter clutch (TCC).
The throttle position (TP) sensor used on fuel-
injected vehicles acts as an electronic accelerator
pump. If the TP sensor is unplugged or defective, the
engine may still operate satisfactorily, but hesitate
upon acceleration as though the carburetor were in
need of a new accelerator pump. Holding the throttle
to the floor while cranking usually causes fuel injec-
tion to stop or reduce. This is called “clear flood”
mode and is used to clear a flooded engine.

Manifold Absolute Pressure

Sensor
The manifold absolute pressure (MAP) sensor Figure 25–12 This MAP sensor is installed on the
is used by the engine computer to sense engine bulkhead with a vacuum hose attached that runs to the
load. The typical MAP sensor consists of a ceramic intake manifold. Some MAP sensors are attached directly
or silicon wafer sealed on one side with a perfect to the intake manifold.
vacuum, and exposed to intake manifold vacuum
on the other side. See Figure 25–12. As the engine
vacuum changes, the pressure difference on the The PCM uses information from the MAP sen-
wafer changes the output voltage (or frequency) of sor to control ignition advance, timing, and fuel de-
the MAP sensor. livery. A typical MAP sensor uses three wires (see
Figure 25–13), similar to a TPS.

■ A 5 volt reference feed wire from the computer

■ A ground wire
Engine Manifold Manifold MAP Sensor ■ A voltage (or frequency) wire back to the
Load Vacuum Pressure Voltage Signal computer; as manifold vacuum changes, the
voltage signal back to the computer also changes
Heavy Low High High
(WOT) (almost 0 mm Hg) (almost
atmospheric) (4.6–4.8 V)
Barometric Pressure Sensor
Light High Low Low
(idle) (430–530 mm Hg) (lower than (0.8–1.6 V) The barometric pressure (BP or BARO) sensor
(17-21 in. Hg) atmospheric) is used by the engine computer to sense the baro-
metric pressure. This input not only allows the com-
598 CHAPTER 25

(a)

(b)

Figure 25–13 (a) Schematic of a typical manifold absolute pressure (MAP) sensor circuit. (b) As manifold pressure
(vacuum) changes, the voltage signal to the computer also changes. (Courtesy General Motors)

puter to adjust for changes in atmospheric pressure Engine Coolant Temperature

due to weather, but also is the primary sensor used
to determine altitude.
Sensor
A MAP sensor and a BARO sensor are usually When the engine is cold, the fuel mixture must be
the same sensor. The MAP sensor is capable of read- richer to prevent stalling and engine stumble. When
ing barometric pressure just as the ignition switch is the engine is warm, the fuel mixture can be leaner
turned to the “on” position before the engine starts. to provide maximum fuel economy with the lowest
Therefore, altitude and weather changes are avail- possible exhaust emissions. Because the computer
able to the computer. During mountainous driving, it controls spark timing and fuel mixture, it will need
may be an advantage to stop and then restart the en- to know the engine temperature. An engine coolant
gine so that the engine computer can take another temperature sensor (ECT) threaded into the engine
barometric pressure reading and recalibrate fuel de- coolant passage will provide the computer with this
livery based on the new altitude. The computer on information. See Figure 25–14. This will be the most
some vehicles will monitor the TP sensor and use the important sensor while the engine is cold. The igni-
MAP sensor reading at wide-open throttle (WOT) to tion timing can also be tailored to engine (coolant)
update the BARO sensor if it has changed during temperature. A hot engine cannot have the spark
driving. timing as far advanced as a cold engine. Most
 Computers and Sensors—Operation, Diagnosis, and Service 599

coolant sensors have very high resistance when the If the coolant temperature sensor has a poor connec-
coolant is cold and low resistance when the coolant tion (high resistance at the wiring connector), the com-
is hot. This is referred to as having a negative tem- puter will supply a richer than normal fuel mixture
perature coefficient (NTC), which is opposite to based on the resistance of the coolant sensor. There-
the situation with most other electrical components. fore, poor fuel economy and a possible-rich trouble
See Figure 25–15. code can be caused by a defective sensor or high re-
A typical CTS uses only two wires (see sistance in the sensor wiring. If the sensor was shorted
Figure 25–16): or defective and has too low a resistance, a leaner-
than-normal fuel mixture would be supplied to the en-
■ The computer sends a 5 volt signal through an gine. A too-lean fuel mixture can cause driveability
internal resistor to the coolant temperature problems and a possible lean diagnostic trouble code.
sensor and measures the voltage between the
two resistors. The changing resistance in the
Oxygen Sensors
sensor causes the voltage to be high with a cold
engine and low with a warm engine. Most automotive computer systems use oxygen sen-
■ A ground wire. sors (02S) in the exhaust system to measure the oxy-
gen content of the exhaust. See Figure 25–17. If the

Coolant Sensor
Temperature to Resistance Values (Approximate)
THERMOSTAT
HOUSING °C °F Ohms
ENGINE COOLANT 100 210 185
TEMPERATURE
70 160 450
SENSOR
38 100 1800
20 70 3400

UPPER RADIATOR HOSE 4 40 7500

–7 20 13 500
–18 0 25 000
–40 –40 100 700

Figure 25–14 A typical engine coolant temperature Figure 25–15 Engine coolant temperature resistance
(ECT) sensor. ECT sensors are located near the values. Note the resistance decreases as the temperature
thermostat housing on most engines. rises. These are typical values only; always refer to the
vehicle specifications. (Courtesy General Motors)

Figure 25–16 Schematic of a typical

engine coolant temperature sensor
circuit. The computer measures the
voltage signal between the PCM
resistor and the ECT resistance.
(Courtesy General Motors)
600 CHAPTER 25

EXHAUST OXYGEN
MANIFOLD SENSOR

Figure 25–18 Typical zirconia oxygen sensor.

Figure 25–17 Many fuel control oxygen sensors are

located in the exhaust manifold near its outlet so that the
sensor can detect the presence or absence of oxygen in
the exhaust stream for all cylinders that feed into the
manifold.

exhaust contains very little oxygen (O2), the com-

puter assumes that the intake charge is rich (too
much fuel) and reduces fuel delivery. On the other
hand, when the oxygen level is high, the computer
assumes that the intake charge is lean (not enough
fuel) and increases fuel delivery. There are several
different designs of oxygen sensors, including:
Figure 25–19 A cross-sectional view of a typical zirconia
■ One-wire oxygen sensor. This one wire of the oxygen sensor.
one-wire oxygen sensor is the O2S signal wire.
The ground for the O2S is through the shell and
threads of the sensor and through the exhaust mV) by comparing the oxygen content of the exhaust
manifold. to the oxygen content of the outside air (21%).
■ Two-wire oxygen sensor. The two-wire sensor Zirconia oxygen sensors (O2S) are constructed so
has a signal wire and a ground wire for the O2S. that oxygen ions flow through the sensor when there
■ Three-wire oxygen sensor. The three-wire sensor is a difference between the oxygen content inside
design uses an electric resistance heater to help get and outside the sensor. An ion is an electrically
the O2S up to temperature more quickly and to charged particle. The greater the differences in the
help keep the sensor at operating temperature even oxygen content between the inside and outside of the
at idle speeds. The three wires include the O2S sensor, the higher the voltage.
signal, the power, and ground for the heater.
■ Four-wire oxygen sensor. The four-wire ■ Rich mixture. A rich mixture results in little
sensor is heated O2S (HO2S) that uses an O2S oxygen in the exhaust stream. Compared to the
signal wire and signal ground. The other two outside air, this represents a large difference and
wires are the power and ground for the heater. the sensors create a relatively high voltage of
about 1.0 volt (1000 mV).
■ Lean mixture. A lean mixture leaves some
Zirconia Oxygen Sensors oxygen in the exhaust stream that did not
The most common type of oxygen sensor is made combine with the fuel. This leftover oxygen
from zirconia (zirconium dioxide). It is usually con- reduces the difference between the oxygen
structed using powder that is pressed into a thimble content of the exhaust compared to the oxygen
shape and coated with porous platinum material content of the outside air. As a result, the sensor
that acts as electrodes. See Figure 25–18 and 25–19. voltage is low or almost zero volts.
The oxygen sensor reacts with the exhaust gases to ■ O2S voltage above 450 mV is produced by the
produce a voltage from 0 volts to 1 volt (0 mV to 1 000 sensor when the oxygen content in the exhaust is
 Computers and Sensors—Operation, Diagnosis, and Service 601

Figure 25–20 Microprocessor schematic showing input, processing, and output. Note that input sensors operate from a
5 volt reference signal and the output devices operate from battery voltage. (Courtesy Ford Motor Co.)

low. This is interpreted by the engine computer Computers have two types of memory: permanent
(PCM) as being a rich exhaust. and temporary. Permanent memory is called read-
■ O2S voltage below 450 mV is produced by the only memory (ROM) because the computer can only
sensor when the oxygen content is high. This is read the contents; it cannot change the data stored in
interpreted by the engine computer (PCM) as it. This data is retained even when power to the com-
being a lean exhaust. puter is shut off. Part of the ROM is built into the com-
puter, and the rest is located in an IC chip called a
programmable read-only memory (PROM) or
Titania Oxygen Sensor
calibration assembly.
The titania (titanium dioxide) oxygen sensor does Temporary memory is called random-access
not produce a voltage but rather modifies one as it memory (RAM) because the microprocessor can
samples the presence of oxygen in the exhaust. All ti- write or store new data into it as directed by the
tania oxygen sensors use a four-terminal variable re- computer program, as well as read the data already
sistance unit with a heating element. A titania in it. Automotive computers use two types of RAM
sensor samples exhaust air only and uses a reference memory: volatile and nonvolatile. Volatile RAM
voltage from the PCM. Titania oxide oxygen sensors memory is lost whenever the ignition is turned off.
use a 14-mm thread and are not interchangeable However, a type of volatile RAM called keep-alive
with zirconia oxygen sensors. One volt is applied to memory (KAM) can be wired directly to battery
the sensor and the changing resistance of the titania power. This prevents its data from being erased
oxygen sensor changes the voltage of the sensor cir- when the ignition is turned off. Both RAM and KAM
cuit. As with a zirconia oxygen sensor, the voltage have the disadvantage of losing their memory when
signal is about 450 mV when the exhaust is rich, and disconnected from their power source. One example
low (below 450 mV) when the exhaust is lean. of RAM and KAM is the loss of station settings in a
programmable radio when the battery is discon-
nected. Since all the settings are stored in RAM,
PROCESSING AND MEMORY they have to be reset when the battery is recon-
nected. System diagnostic trouble codes (DTC) are
The microprocessor is the decision making part of commonly stored in RAM and can be erased by dis-
the computer. It takes data from the various input connecting the battery.
sensors and compares it with information stored in Adaptive strategies that compensate for wear
memory. See Figure 25–20. and aging are another function of KAM. The original
602 CHAPTER 25

computer program in ROM is written for the average hicle. When speedometer replacement is necessary,
engine operating under average conditions, but this the odometer chip is removed and installed in the
is often not the case. new speedometer unit.
Fuel delivery calculations are based on informa- The computer processes the input voltage sig-
tion from the engine sensors; throttle position, air and nals through a series of logic circuits maintained in
coolant temperatures, engine speed and load are a few its programmed instructions. The logic circuits
of these inputs. Based on these data, the computer change the input data into output voltage signals or
refers to a look-up table stored in ROM and injects a commands that control output transistors.
given amount of fuel into the engine. The resulting
air–fuel mixture is monitored by an exhaust-mounted
oxygen sensor, which sends data back to the computer. OUTPUT
When the oxygen sensor detects a lean or rich
condition, the computer increases or decreases fuel Actuators are electrical or mechanical devices that
volume as a correction. When a major shift is deter- convert electrical energy into mechanical action. The
mined over a period of time, the computer changes computer sends a voltage signal to the base circuit of
the original program to reflect different fuel require- an output driver transistor which activates the de-
ments. This is called adaptive strategy and is stored vice, usually a relay or solenoid. See Figure 25–21.
in KAM. Many vehicles run well, even with low fuel When the ignition switch is closed, battery voltage
pressure or restricted fuel injectors. is supplied to the actuators; no current flows until
If the battery is disconnected, all adaptive infor- ground is supplied by turning the transistor on. This is
mation stored in KAM is lost; the computer now de- known as ground side control and is the most common
faults to the original program and begins the circuit. Technicians often check output circuits by
relearning process. grounding the wire between the actuator and the mi-
Nonvolatile RAM memory can retain its infor- croprocessor. Any actuator that runs at 100% duty cy-
mation even when the battery is disconnected. One cle can be tested by grounding. Actuators such as fuel
use for this type of RAM is the storage of odometer injector solenoids never run at 100% duty cycle and can
information in an electronic speedometer. The mem- be damaged by grounding. Follow the service instruc-
ory chip retains the distance accumulated by the ve- tions exactly when working with computer circuits.

Figure 25–21 Basic computer outputs. (Courtesy General Motors)

 Computers and Sensors—Operation, Diagnosis, and Service 603

Our basic computer shows only a single driver

transistor for each device; most computers bank the
transistors into a group of four called quad-drivers,
but the function is the same.
Output devices are usually tested for resistance
with an ohmmeter, or checked for current flow; a
shorted solenoid coil, as an example, will allow ex-
cessive current to flow which could damage the
driver transistor in the computer.

SENSOR TESTING

The correct operation of computerized engines de-

pends on accurate and dependable sensors. Proper
testing of sensors is an important part of computer
problem diagnosis and troubleshooting.

Testing the Engine

Coolant Temperature by
Visual Inspection
The correct functioning of the engine coolant tem- Figure 25–22 Measuring the resistance of the ECT
perature (ECT) sensor depends on the following sensor. The resistance measurement can then be
items that should be checked or inspected: compared with specifications. (Courtesy of Fluke
Corporation)
■ Properly filled cooling system. Check that
the radiator reservoir bottle is full and that the
radiator itself is filled to the top.
with specifications. See Figure 25–22. See the fol-
CAUTION: Be sure that the radiator is cool before re- lowing chart showing examples of typical engine
moving the radiator cap to avoid being scalded by hot coolant temperature sensor specifications. Some ve-
coolant. hicles use a second resistor in the ECT circuit to pro-
vide a more accurate measure of the engine
temperature. See Figure 25–23.
The ECT sensor must be submerged in coolant to
be able to indicate the proper coolant temperature.
■ Proper pressure maintained by the
radiator cap. If the radiator cap is defective General Motors ECT Sensor without Pull-Up Resistor
and cannot allow the cooling system to become Voltage Drop Across
pressurized, air pockets could develop. These air °C °F Ohms Sensor
pockets could cause the engine to operate at a

40
40 100 000 4.95
hotter than normal temperature and prevent
proper temperature measurement, especially if
8 18 14 628 4.68
the air pockets occur around the sensor. 0 32 9420 4.52
■ Proper antifreeze–water mixture. Most
10 50 5670 4.25
vehicle manufacturers recommend a 50/50
mixture of antifreeze and water as the best 20 68 3520 3.89
compromise between freezing protection and 30 86 2238 3.46
heat transfer ability.
40 104 1459 2.97
■ Proper operation of the cooling fan. If the
cooling fan does not operate correctly, the engine 50 122 973 2.47
may overheat. 60 140 667 2.00
70 158 467 1.59
Testing the ECT 80 176 332 1.25
Using a Multimeter
90 194 241 0.97
Both the resistance (in ohms) and the voltage drop 100 212 177 0.75
across the sensor can be measured and compared
604 CHAPTER 25

Figure 25–23 When the voltage drop reaches 10k Ω

approximately 1.20 volts, the PCM turns on a transistor. 1k Ω
ECT Sensor
The transistor connects a 1 k resistor in parallel with the
ECT Signal circuit
10 k resistor. Total circuit resistance now drops to
around 909 ohms. This function allows the PCM to have 5V VREF
ECT Ground circuit over 50°C
full binary control at cold temperatures up to
Signal
approximately 50°C (122°F), and a second full binary Engine 5V VREF
IN
Block under 50°C
control at temperatures greater than 50°C (122°F).
A/D Converter
Ground Connection

Figure 25–24 A typical ECT sensor

being tested using a digital storage
oscilloscope. The illustration shows the
voltage of the sensor after the engine
was stopped. As the resistance of the
sensor increased, the voltage decreased.
(Courtesy of Fluke Corporation)

If resistance values match the approximate Testing the ECT Sensor

coolant temperature and there is still a coolant sen- Using a Scan Tool
sor trouble code, the problem is generally in the Comparing the temperature of the engine coolant as
wiring between the sensor and the computer. Always displayed on a scan tool with the actual temperature
consult the manufacturer’s recommended procedures of the engine is an excellent method to test an engine
for checking this wiring. If the resistance values do coolant temperature sensor.
not match, the sensor may need to be replaced.
Normal operating temperature varies with vehi- 1. Record the scan tool temperature of the coolant
cle make and model. Some vehicles are equipped (ECT).
with a thermostat with an opening temperature of 2. Measure the actual temperature of the coolant
82°C (176°F), whereas other vehicles use a thermo- using an infrared pyrometer or contact-type
stat that is 90°C (195°F) or higher. Before replacing temperature probe.
the ECT sensor, be sure that the engine is operating
at the temperature specified by the manufacturer.
Most manufacturers recommend checking the ECT HINT: Often the coolant temperature gauge in the
sensor after the cooling fan has cycled twice, indicat- dash of the vehicle can be used to compare with the
ing a fully warmed engine. See Figure 25–24. scan tool temperature. Although not necessarily ac-
curate, it may help to diagnose a faulty sensor, espe-
cially if the temperature shown on the scan tool
NOTE: Many manufacturers install a pull-up resistor varies greatly from the temperature indicated on the
inside the computer to change the voltage drop across dash.
the ECT sensor. This is done to expand the scale of the
ECT sensor and to make the sensor more sensitive.
The maximum difference between the two
Therefore, if measuring voltage at the ECT sensor,
check with the service manual for the proper voltage at readings should be 5°C (10°F). If the actual tem-
each temperature. perature varies by more than 5°C (10°F) from the
temperature indicated on the scan tool, check the
 Computers and Sensors—Operation, Diagnosis, and Service 605

ECT sensor wiring and connector for damage or cor- ■ Threaded into the intake manifold where it
rosion. If the connector and wiring are okay, replace senses the temperature of the air entering the
the ECT sensor. If the connector and wiring are cylinders
okay, check the sensor with a DVOM for resistance
and compare to the actual engine temperature NOTE: An IAT installed in the intake manifold is the
chart. If that checks out okay, check the computer. most likely to suffer damage due to an engine backfire,
which can often destroy the sensor.
NOTE: Many manufacturers use two coolant sen-
sors, one for the dash gauge and another one for the The purpose and function of the intake air tem-
computer. perature sensor is to provide the engine computer
(PCM) the temperature of the air entering the engine.

■ Cold air—is more dense and contains more

INTAKE AIR oxygen and therefore requires a richer mixture
TEMPERATURE SENSOR to achieve the proper air–fuel mixture. Air at 0°C
(32°F) is 14% denser than air at 40°C (104°F).
The intake air temperature (IAT) sensor is a nega- ■ Hot air—is less dense and contains less oxygen
tive temperature coefficient (NTC) thermistor that and therefore requires a leaner mixture to
decreases in resistance as the temperature of the achieve the proper air–fuel mixture.
sensor increases. The IAT sensor can be located in
one of the following locations: The IAT sensor is a low-authority sensor and is
used by the computer to modify the amount of fuel
■ In the air cleaner housing and ignition timing as determined by the engine
■ In the air duct between the air filler and the coolant temperature sensor.
throttle body as shown in Figure 25–25 Engine temperature is most accurately deter-
■ Built into the mass air flow (MAF) or air flow mined by looking at the engine coolant temperature
sensor (ECT) sensor. In certain conditions, the IAT has an
effect on performance and driveability. One such con-
dition is a warm engine being stopped in very cold
weather. In this case, when the engine is restarted,
the ECT may be near normal operating temperature
such as 93°C (200°F) yet the air temperature could
be
30°C (
20°F). In this case, the engine requires
a richer mixture due to the cold air than the ECT
would seem to indicate.

Testing the Intake Air

Temperature Sensor
If the intake air temperature sensor circuit is dam-
aged or faulty, a diagnostic trouble code (DTC) is set
IAT
and the malfunction indicator lamp (MIL) may or
SENSOR may not be on depending on the condition and the
type and model of the vehicle. To diagnose the IAT
sensor follow these steps:

Step 1 After the vehicle has been allowed to cool for

several hours, use a scan tool and observe the
IAT and compare it to the engine coolant tem-
perature (ECT). The two temperatures should be
within 3°C (5°F) of each other.
Step 2 Perform a thorough visual inspection of the
sensor and the wiring. If the IAT is threaded into
the intake manifold, remove the sensor and
Figure 25–25 The IAT sensor on this General Motors check for damage.
3800 V-6 engine is in the air passage duct between the air Step 3 Check the voltage and compare to the follow-
cleaner housing and the throttle plate. ing chart.
606 CHAPTER 25

Manifold/Intake Air Temperature Sensor Temperature vs.

Resistance and Voltage Drop (Approximate)
T E C H T I P ✔
Voltage Drop Across Check the Hose
°C °F Ohms Sensor (V)
A defective vacuum hose to a MAP sensor can cause a va-
–40 –40 100 000 4.95
riety of driveability problems including poor fuel econ-
–8 18 15 000 4.68 omy, hesitation, stalling, and rough idle. A small air leak
0 32 9400 4.52 (vacuum leak) around the hose can cause these symp-
toms and often set a trouble code in the vehicle com-
10 50 5700 4.25
puter. When working on a vehicle that uses a MAP
20 68 3500 3.89 sensor, make certain that the vacuum hose travels con-
30 86 2200 3.46 sistently downward on its route from the sensor to the
source of manifold vacuum. Inspect the hose, especially if
40 104 1500 2.97
another technician has previously replaced the factory-
50 122 1000 2.47 original hose. It should not be so long that it sags down
60 140 700 2.00 at any point. Condensed fuel and/or moisture can be-
come trapped in this low spot in the hose and cause all
70 158 500 1.59
types of driveability problems and MAP sensor codes.
80 176 300 1.25
90 194 250 0.97
Four different types of test instruments can be
100 212 200 0.75
used to test a pressure sensor:

1. A digital voltmeter with three test leads

connected in series between the sensor and the
T E C H T I P ✔ wiring harness connector (see Figure 25–26)
2. A scope connected to the sensor output, power,
Poor Fuel Economy? Black Exhaust and ground
Smoke? Look at the IAT. 3. A scan tool or a specific tool recommended by the
vehicle manufacturer
If the intake air temperature sensor is defective, it may be 4. A breakout box connected in series between the
signaling the computer that the intake air temperature is computer and the wiring harness connection(s).
extremely cold when in fact it is warm. In such a case the A typical breakout box includes test points at
computer will supply a mixture that is much richer than which pressure sensor values can be measured
normal. with a digital voltmeter (or frequency counter, if
If a sensor is physically damaged or electrically open, a frequency-type MAP sensor is being tested)
the computer will often set a diagnostic trouble code
(DTC). This DTC is based on the fact that the sensor
temperature did not change for a certain amount of time, NOTE: Always check service literature for the exact
testing procedures and specifications for the vehicle be-
usually about 8 minutes. If, however, the wiring or the sen-
ing tested.
sor itself has excessive resistance, a DTC will not be set
and the result will be lower than normal fuel economy,
Use jumper wires, T-pins, or a breakout box to
and in serious cases, black exhaust smoke from the
gain electrical access to the wiring to the pressure
tailpipe during acceleration.
sensor. Most pressure sensors use three wires:

1. A 5 volt wire from the computer

2. A variable-signal wire back to the computer
Testing the Manifold Absolute 3. A ground or reference low wire
Pressure Sensor
The procedure for testing the sensor is as follows:
Most pressure sensors operate on 5 volts from the
computer and return a signal (voltage or frequency) 1. Turn the ignition on (engine off)
based on the pressure (vacuum) applied to the sen- 2. Measure the voltage (or frequency) of the sensor
sor. If a MAP sensor is being tested, make certain output
that the vacuum hose and hose fittings are sound 3. Using a hand-operated vacuum pump (or other
and making a good, tight connection to a manifold variable vacuum source), apply vacuum to the
vacuum source on the engine. sensor
 Computers and Sensors—Operation, Diagnosis, and Service 607

Figure 25–26 A digital multimeter set to test a MAP sensor. (1) Connect the red meter lead to the
V meter terminal and the black meter lead to the COM meter terminal. (2) Select DC volts. (3) Connect
the test leads to the sensor signal wire and the ground wire. (4) Select hertz (Hz) if testing a MAP sensor
whose output is a varying frequency—otherwise keep it on DC volts. (5) Read the change of frequency
as the vacuum is applied to the sensor. Compare the vacuum reading and the frequency (or voltage) reading
to the specifications.

A good pressure sensor should change voltage (or points at which TP voltages can be measured
frequency) in relation to the applied vacuum. If the with a digital voltmeter.
signal does not change or the values are out of range ■ An oscilloscope.
according to the manufacturers’ specifications, the
sensor must be replaced. Use jumper wires, T-pins, or a breakout box to
gain electrical access to the wiring to the TP sensor.
See Figure 25–27.
Testing the Throttle
Position Sensor
NOTE: The procedure that follows is the usual
A TP sensor can be tested using one or more of the method used by many manufacturers. Always refer to
following tools: service literature for the exact recommended procedure
and specifications for the vehicle being tested.
■ A digital voltmeter with three test leads connected
in series between the sensor and the wiring The procedure for testing the sensor using a dig-
harness connector or backprobing using T-pins. ital multimeter is as follows:
■ A scan tool or a specific tool recommended by the
vehicle manufacturer. 1. Turn the ignition switch on (engine off).
■ A breakout box that is connected in series 2. Measure the voltage between the signal wire
between the computer and the wiring harness and ground (reference low) wire. The voltage
connector(s). A typical breakout box includes test should be about 0.5 volt.
608 CHAPTER 25

Figure 25–27 A meter lead connected to a T-pin that

was gently pushed along the signal wire of the TP sensor
until the point of the pin touched the metal terminal inside
the plastic connector.

NOTE: Consult the service literature for exact wire Figure 25–28 A typical waveform of a TP sensor signal as
colours or locations. recorded on a DSO when the accelerator pedal was
depressed with the ignition switch on (engine off). Clean
3. With the engine still not running (but with transitions and the lack of any glitches in this waveform
the ignition still on), slowly increase the indicate a good sensor. (Courtesy of Fluke Corporation)
throttle opening. The voltage signal from the
TP sensor should also increase. Look for any
“dead spots” or open circuit readings as the
throttle is increased to the wide-open position.
T E C H T I P ✔
See Figure 25–28 for an example of how a good
TP sensor would look when tested with a digital Check Power and Ground Before
storage oscilloscope (DSO). Condemning a Bad Sensor
Most engine sensors use a 5 volt reference and a ground.
HINT: If TP sensor specifications are not available, re- If the 5 volt to the sensor is too high (shorted to voltage)
member that the TP sensor voltage at idle should be or too low (high resistance), then the sensor output will
about 10% of the voltage at the wide-open throttle be skewed or out of range. Before replacing the sensor
(WOT) position. Therefore, if the WOT voltage is 4.5 that did not read correctly, unplug the sensor and meas-
volts, then TP sensor voltage at idle should be about ure both the 5 volt reference and ground. To measure the
0.45 volts.
ground, simply turn the ignition on (engine off) and touch
one test lead of a DMM set to read DC volts to the sen-
4. With the voltmeter (or scan tool) still connected, sor ground and the other to the negative terminal of the
slowly return the throttle down to the idle battery. Any reading higher than 0.6 volt (600 mV) repre-
position. The voltage from the TP sensor should sents a poor ground. See Figures 25–29 and 25–30.
also decrease evenly on the return to idle.

The TP sensor voltage at idle should be within

readings are obtained or if the correct setting at idle
the acceptable range as specified by the manufac-
cannot be obtained.
turer. Some TP sensors can be adjusted by loosening
their retaining screws and moving the sensor in re-
lation to the throttle opening. This movement Testing the Oxygen Sensor
changes the output voltage of the sensor.
All TP sensors should also provide a smooth Zirconia oxygen sensors produce a voltage (like a
transition voltage reading from idle to WOT and small battery) when in the absence of oxygen, when
back to idle. Replace the TP sensor if erratic voltage the sensor is hot (over 315°C or 600°F). The output
 Computers and Sensors—Operation, Diagnosis, and Service 609

Figure 25–30 Checking the voltage drop between the TP

sensor ground and a good engine ground with the ignition
on (engine off). A reading of greater than 0.6 V (600 mV)
represents a bad computer ground.

b. The oxygen sensor(s) must be producing a

usable, variable voltage signal.
c. A certain amount of time must elapse after
engine start for closed loop to be achieved.
Figure 25–29 Checking the 5 volt reference from the This time could vary from a few seconds to
computer being applied to the TP sensor with the ignition several minutes depending on the vehicle
switch on (engine off). and the temperature.
3. In closed-loop operation, the oxygen sensor
voltage of a typical oxygen sensor varies depending voltage should be constantly changing as the
on the oxygen content of the exhaust gases passing fuel mixture is being controlled.
the sensor.
Typical oxygen sensor values are as follows: The results should be interpreted as follows:

■ Rich exhaust. Oxygen sensor voltage above ■ If the oxygen sensor fails to respond, and its
800 mV voltage remains at about 450 millivolts, the
■ Lean exhaust. Oxygen sensor voltage below sensor may be defective and require replacement.
200 mV Before replacing the oxygen sensor, check the
manufacturers’ recommended procedures.
■ If the oxygen sensor reads high all the time
Testing an Oxygen Sensor Using (above 550 millivolts), the fuel system could be
a Digital Voltmeter supplying too rich a fuel mixture or the oxygen
The oxygen sensor can be checked for proper opera- sensor may be contaminated.
tion using a digital high-impedance voltmeter. ■ If the oxygen sensor voltage remains low (below
350 millivolts), the fuel system could be
1. With the engine off, connect the red lead of the supplying too lean a fuel mixture. Check for a
meter to the oxygen sensor signal wire. See vacuum leak or partially clogged fuel injector(s).
Figure 25–31. Before replacing the oxygen sensor, check the
2. Start the engine and allow it to reach closed-loop manufacturer’s recommended procedures.
operation. To achieve closed-loop operation, the
engine computer must have achieved three Testing the Oxygen Sensor Using
criteria including:
the Min-Max Method
a. The engine coolant temperature must be
above a certain temperature, usually above A digital meter set on DC volts can be used to
40°C (104°F). record the minimum and maximum voltage with
610 CHAPTER 25

Figure 25–31 Testing an oxygen sensor using a digital multimeter set

on DC volts. With the engine operating in closed loop, the oxygen
voltage should read over 800 millivolts and lower than 200 millivolts and
be constantly fluctuating. (Courtesy of Fluke Corporation)

the engine running. A good oxygen sensor should Post–Catalytic Converter

be able to produce a value of less than 300 milli- Oxygen Sensor Testing
volts and a maximum voltage above 800 millivolts.
The oxygen sensor located behind the catalytic con-
Replace any oxygen sensor that fails to go above
verter is used on OBD II (On-Board Diagnostics—
700 millivolts or lower than 300 millivolts.
Generation II) vehicles to monitor converter efficiency.

Min/Max Oxygen Sensor Test Chart

Minimum Voltage Maximum Voltage Average Voltage Test Results

Below 200 mV Above 800 mV 400 to 500 mV Oxygen sensor is okay.
Above 200 mV Any reading 400 to 500 mV Oxygen sensor is defective.
Any reading Below 800 mV 400 to 500 mV Oxygen sensor is defective.
Below 200 mV Above 800 mV Below 400 mV System is operating lean.*
Below 200 mV Below 800 mV Below 400 mV System is operating lean. (Add propane to
the intake air to see if the oxygen sensor reacts.
If not, the sensor is defective.)
Below 200 mV Above 800 mV Above 500 mV System is operating rich.
Above 200 mV Above 800 mV Above 500 mV System is operating rich. (Remove a vacuum
hose to see if the oxygen sensor reacts. If not,
the sensor is defective.)
*Check for an exhaust leak upstream from the O2S or ignition misfire that can cause a false lean indication before further diagnosis.
Frequently Asked Question ??? DIAGNOSTIC STORY

What Is the Difference Between The O2 Sensor Is Lying to You

a “False Lean” and a
A technician was trying to solve a driveability problem
“Real Lean” Oxygen Sensor Reading?
with a V-6 passenger car. The car idled roughly, hesitated,
A false lean signal is a result of oxygen flowing past the and accelerated poorly. A thorough visual inspection did
oxygen sensor that did not result from combustion inside not indicate any possible problems, and there were no di-
the engine. Two examples of a false lean oxygen sensor agnostic trouble codes stored.
indication include: A check was made on the oxygen sensor activity
using a DMM. The voltage stayed above 600 millivolts
1. A cracked exhaust manifold or an exhaust leak
most of the time. If a large vacuum hose was removed,
upstream from the oxygen sensor (between the
the oxygen sensor voltage would temporarily drop to
exhaust valve and the oxygen sensor) can cause a
below 450 millivolts and then return to a reading of
false lean. As an exhaust pulse occurs, an area of
over 600 millivolts. Remember:
lower pressure develops behind the pulse of
exhaust. This lower pressure area draws outside air • High O2S readings  rich exhaust (low O2 content
into the exhaust stream and flows past the oxygen in the exhaust)
sensor. The oxygen sensor voltage drops as a result • Low O2S readings  lean exhaust (high O2 content
of this extra oxygen brought into the exhaust at in the exhaust)
the leak. The drop in oxygen sensor voltage is
As part of a thorough visual inspection, the tech-
interpreted by the engine computer as a message
nician removed and inspected the spark plugs. All the
that the mixture supplied to the engine is too lean,
spark plugs were white, indicating a lean mixture, not
and it increases the amount of fuel supplied. As a
the rich mixture the oxygen sensor was indicating. The
result, the mixture now being supplied to the
high O2S reading signalled the computer to reduce
cylinder is too rich because the oxygen sensor was
the amount of fuel resulting in an excessively lean
fooled and provided a false lean signal to the
operation.
computer.
After replacing the oxygen sensor, the engine ran
2. An ignition misfire as a result of a defective spark
great. But what killed the oxygen sensor? The techni-
plug wire or fouled spark plug can cause a false
cian finally learned from the owner that the head gas-
lean. When a spark plug does not fire, the
ket had been replaced over a year ago. The
unburned gas and air inside the cylinder are pushed
silicone-silicate additives in the antifreeze coolant had
into the exhaust manifold by the piston(s) on the
coated the oxygen sensor. Because the oxygen sensor
exhaust stroke. The unburned gas and air contain
was coated, the oxygen content of the exhaust could
oxygen that is detected by the oxygen sensor as
not be detected—the result, a false rich signal from the
too lean a mixture.
oxygen sensor.

NOTE: Remember, the oxygen sensor is a sensor

to detect oxygen, not unburned fuel (hydrocarbons
or HC)! DIAGNOSTIC STORY

As a result of this oxygen being detected, the voltage The Pickup Truck Story
produced by the oxygen sensor is lower. This lower-
voltage signal is interpreted by the computer as a sign The owner of a pickup truck complained that the engine
that the mixture being supplied is too lean. The computer ran terribly. It would hesitate and surge, yet there were
then increases the amount of fuel delivered. This extra no diagnostic trouble codes (DTCs). After hours of
fuel can often cause more spark plug fouling and even troubleshooting, the technician discovered while talking
more unburned oxygen passing the oxygen sensor. to the owner that the problem started after the trans-
Because a lean condition can be false, the wise ser- mission had been repaired. Before the transmission was
vice technician checks the exhaust system and the igni- repaired, the problem started, yet the transmission shop
tion system before trying to correct a lean indication. said that the problem was an engine problem and not
related to the transmission.
A thorough visual inspection revealed that the front
and rear oxygen sensor connectors had been switched.
The computer was trying to compensate for an air–fuel
mixture condition that did not exist. Reversing the OSS
connectors restored proper operation of the truck.

611
612 CHAPTER 25

A changing air–fuel mixture is required for the most

CATALYTIC POST-CATALYST
efficient operation of the converter. If the converter is CONVERTER OXYGEN SENSOR
working correctly, the oxygen content after the con-
verter should be fairly constant. See Figures 25–32
and 25–33.

SPEED DENSITY

Fuel-injection computer systems require a method

for measuring the amount of air the engine is taking
in, to be able to match the correct fuel delivery. There
are two basic methods used:
1. Speed density method
2. Airflow method

The speed density method does not require an Figure 25–32 Most 1996 and newer vehicles use an
air quantity sensor, but rather calculates the amount oxygen sensor behind the catalytic converter. The
of fuel required by the engine. The computer uses in- purpose of the oxygen sensor is to sense the
formation from sensors such as the MAP and TP to percentage of oxygen in the exhaust to check the
calculate the needed amount of fuel. efficiency of the catalytic converter.
■ MAP sensor. The value of the intake (inlet)
manifold pressure (vacuum) is a direct indication
of engine load.
■ TP sensor. The position of the throttle plate and
its rate of change are used as part of the equation (IAT) are used to calculate the density of the air
to calculate the proper amount of fuel to inject. and the need of the engine for fuel. A cold engine
■ Temperature sensors. Both engine coolant (low coolant temperature) requires a richer
temperature (ECT) and intake air temperature air–fuel mixture than a warm engine.

1.25
OXYGEN
SENSOR
BEFORE THE
CONVERTER
0.00
VOLT 5.00 SEC/DIV

1.25
OXYGEN
SENSOR
AFTER THE
CONVERTER
0.00
VOLT 5.00 SEC/DIV

GOOD (EFFICIENT) CONVERTER

1.25
OXYGEN
SENSOR
AFTER THE
CONVERTER
0.00
VOLT 5.00 SEC/DIV

BAD (INEFFICIENT) CONVERTER

Figure 25–33 The post–catalytic converter oxygen sensor should display very little
activity if the catalytic converter is efficient.
 Computers and Sensors—Operation, Diagnosis, and Service 613

DAMPER
AIR VANE
FLAP

AIRFLOW TO INTAKE
INTAKE MANIFOLD

BYPASS AIR
(a) SCREW

AIRFLOW TO INTAKE
INTAKE MANIFOLD

BYPASS AIR Figure 25–35 A typical air vane sensor with the cover
(b) SCREW
removed. The movable arm contacts a carbon resistance
path as the vane opens. Many air vane sensors also have
Figure 25–34 A typical air vane sensor. (a) At idle the air contacts that close to supply voltage to the electric fuel
flows through a bypass passage. The bypass air screw is pump as the air vane starts to open when the engine is
adjusted at the factory and should not require adjustment. being cranked and air is being drawn into the engine.
(b) As the throttle is opened, the airflow moves the vane.
The vane is attached to a potentiometer similar to a
throttle position (TP) sensor. passes through the sensor, this type of sensor can ac-
tually produce an output based on the mass of the
airflow. The output of this type of sensor is usually a
AIRFLOW METHOD frequency based on the amount of air entering the
sensor. The more air that enters the sensor, the more
The airflow method measures the amount of air as the hot film is cooled. The electronics inside the sen-
part of the computer input information necessary for sor, therefore, increase the current flow through the
accurate fuel delivery control. There are three basic hot film to maintain the 75°C (165°F) temperature
types of airflow sensors used on port-injected en- differential between the air temperature and the
gines: the air vane sensor, the hot film sensor, and temperature of the hot film. This change in current
the hot wire sensor. flow is converted to a frequency output that the com-
puter can use as a measurement of airflow. Most of
these types of sensors are referred to as mass air-
AIR VANE SENSOR flow (MAF) sensors because unlike the air vane
sensor, the MAF sensor takes into account relative
This air vane sensor uses a movable vane that humidity, altitude, and temperature of the air. The
translates the amount of movement of the vane into denser the air, the greater the cooling effect on the
the amount of air being drawn into the engine. An hot film sensor and the greater the amount of fuel re-
air vane sensor can be tested using a digital meter quired for proper combustion.
or an oscilloscope. See Figures 25–34 and 25–35.

HOT WIRE SENSOR

HOT FILM SENSOR
The hot wire sensor is similar to the hot film type,
The hot film sensor uses a temperature-sensing re- but uses a hot wire to sense the mass airflow instead
sistor (thermistor) to measure the temperature of of the hot film. Like the hot film sensor, the hot wire
the incoming air. Through the electronics within the sensor uses a temperature-sensing resistor (ther-
sensor, a conductive film is kept at a temperature mistor) to measure the temperature of the air enter-
75°C (165°F) above the temperature of the incoming ing the sensor. See Figure 25–37. The electronic
air. See Figure 25–36. circuitry within the sensor keeps the temperature of
Because the amount and density of the air both the wire at 75°C (165°F) above the temperature of
tend to contribute to the cooling effect as the air the incoming air.
614 CHAPTER 25

Figure 25–36 A GM hot film mass air flow (MAF) sensor that has been taken apart.
The electronic circuit measures the cooling effect of the air entering the engine and
generates a frequency output signal that is proportional to the amount of air passing
through the sensor.

DIAGNOSTIC STORY

The Dirty MAF Sensor Story

The owner of a Buick Park Avenue complained that the
engine would hesitate during acceleration, showed lack of
power, and seemed to surge or miss at times. A visual in-
spection found everything to be like new, including a new
air filter. There were no stored diagnostic trouble codes
(DTCs). A look at the scan data showed airflow to be
within the recommended 3 to 7 grams per second. A
check of the frequency output showed the problem.
Idle frequency  2.177 kHz (2177 Hz)
Normal frequency at idle speed should be 2.37 to
Figure 25–37 A typical hot wire MAF sensor located 2.52 kHz. Cleaning the hot wire of the MAF sensor re-
between the air filter and the throttle plate. stored proper operation. The sensor wire was covered
with what looked like fine fibres, possibly from the re-
placement air filter.

Testing Mass Airflow Sensors NOTE: Older AC MAF sensors operated at a lower
Start the testing of a MAF sensor by performing a frequency of 32 to 150 Hz, with 32 Hz being the aver-
thorough visual inspection. Look at all the hoses that age reading at idle and 150 Hz for wide-open throttle.
direct and send air, especially between the MAF sen-
sor and the throttle body. Also check the electrical
connector for:

■ Corrosion False Air

■ Terminals that are bent or pushed out of the Airflow sensors and mass airflow (MAF) sensors are
plastic connector designed to measure all the air entering the engine.
■ Frayed wiring If an air inlet hose was loose or had a hole, extra air
 Computers and Sensors—Operation, Diagnosis, and Service 615

Figure 25–38 Carefully check the hose between the MAF sensor and the throttle plate
for cracks or splits that could create extra (false) air in the engine that is not
measured by the MAF sensor.

Frequently Asked Question ??? could enter the engine without being measured.
This extra air is often called false air. See Figure
25–38. Because this extra air is unmeasured, the
What Is Meant by computer does not provide enough fuel delivery and
a “High-Authority Sensor”? the engine operates too lean, especially at idle. A
A high-authority sensor is a sensor that has a major influ- small hole in the air inlet hose would represent a
ence over the amount of fuel being delivered to the engine. fairly large percentage of false air at idle, but would
For example, at engine start-up, the engine coolant temper- represent a very small percentage of extra air at
ature (ECT) sensor is a high-authority sensor and the oxy- highway speeds.
gen sensor (O2S) is a low-authority sensor. However, as the To diagnose for false air, hook up a scan tool and
engine reaches operating temperature, the oxygen sensor look at long-term fuel trim numbers at idle and at
becomes a high-authority sensor and can greatly affect the 3000 rpm.
amount of fuel being supplied to the engine. See the chart.
Tap Test
High-Authority Low-Authority
Sensors Sensors With the engine running at idle speed, gently tap the
MAF sensor with the fingers of an open hand. If the
ECT (especially when IAT (intake air temperature) engine stumbles or stalls, the MAF sensor is defec-
the engine starts and sensors modify and back tive. This test is commonly called the tap test.
is warming up) up the ECT
O2S (after the engine TFT (transmission fluid Digital Meter Test
reaches closed-loop temperature)
operation)
of a MAF Sensor
MAP PRNDL (shift position A digital multimeter can be used to measure the fre-
sensor) quency (Hz) output of the sensor and compare the
reading with specifications.
MAF KS (knock sensor)
The frequency output and engine speed in RPM
TP can also be plotted on a graph to check to see if the
616 CHAPTER 25

frequency and RPM are proportional, resulting in a

straight line on the graph. T E C H T I P ✔
The Unplug It Test
SENSOR TESTING USING
DIAGNOSTIC TROUBLE CODES If a sensor is defective yet still produces a signal to the
computer, the computer will often accept the reading and
Many vehicles display diagnostic trouble codes make the required changes in fuel delivery and spark ad-
(DTCs), yet do not display scan data. To check if the vance. If, however, the sensor is not reading correctly, the
problem is the sensor itself or the electrical sensor computer will process this wrong information and per-
circuit that is at fault, follow these steps. form an action assuming that the information being sup-
plied is accurate. For example, if a mass airflow (MAF)
1. Clear the DTC. sensor is telling the computer that 12 grams of air per sec-
2. Create the opposite sensor condition. For ond is going into the engine, the computer will then pulse
example, if the DTC indicates an open engine the injector for 6.4 ms or whatever figure it is programmed
coolant temperature (ECT) circuit, unplug the to provide. However, if the air going into the engine is ac-
sensor and, using a jumper wire, short the two tually 14 grams per second, the amount of fuel supplied by
terminals of the harness (not the sensor) the injectors will not be enough to provide proper engine
together. operation. If the MAF sensor is unplugged, the computer
knows that the sensor is not capable of supplying airflow
information, so it defaults to a fixed amount of fuel based
NOTE: If the ECT sensor wires are shorted together, on the values of other sensors such as the TP and MAP
the scan tool will display about 150°C (300°F) and sensors.
about
40°C (
40°F) if the sensor wires are open
If the engine operates better with a sensor un-
(disconnected).
plugged, then suspect that the sensor is defective. A sen-
sor that is not supplying the correct information is said
When checking three-wire sensors, such as the to be skewed. The computer will not see a diagnostic
throttle position (TP) sensor, MAP, or MAF, use a trouble code for this condition because the computer
jumper wire to jump the 5 volt reference back into can often not detect that the sensor is supplying wrong
the signal return after disconnecting the connector information.
from the sensor.
Shorting the 5 volt reference to the signal should
cause the vehicle computer to set a shorted sensor
DTC. If a shorted sensor DTC is stored, simply clear
the DTC and unplug the sensor. If the wiring is okay,
the opposite (open) sensor DTC should be set.
PHOTO SEQUENCE 19 Throttle Position Sensor Diagnosis

P19–1 Besides a scan tool, other equipment that can P19–2 Consult the factory service manual for the
be used to check a throttle position (TP) sensor specifications and wire colors used for the TP sensor as
includes a scope or graphing multimeter, a digital well as the recommended testing procedure.
multimeter equipped with MIN/MAX function, and
T-pins to safely backprobe the sensor wires.

P19–3 A scan tool display showing no diagnostic P19–4 A scan tool can be used to observe the output
trouble codes (DTCs). A fault could still exist even voltage and the calculated percentage (%) of throttle
though a diagnostic trouble code is not set—it depends opening.
on what type of fault and when it occurs.

P19–5 Most throttle position sensors use a 5 volt P19–6 Connect the red lead from the digital
reference voltage from the computer. To test that this multimeter to the T-pin and attach the black meter lead
signal is available at the sensor, carefully backprobe the to a good, clean engine ground.
5 volt reference (grey on this General Motors vehicle)
wire at the connector on the TP sensor. Simply push
the T-pin alongside the wire until it touches the metal
terminal inside the connector.

617
 Throttle Position Sensor Diagnosis—continued

P19–7 Select DC volts and turn the ignition key on P19–8 Another important step when testing a TP
(engine off). The meter reads slightly over 5 volts, sensor is to verify that the ground circuit is okay. To
confirming the computer is supplying the reference check the ground of the TP sensor, carefully backprobe
voltage to the TP sensor. the ground wire at the TP sensor connector (black on
this General Motors vehicle) and connect the red meter
lead to the T-pin.

P19–9 Attach the black meter lead to a good, clean P19–10 With the ignition on (engine off) and the
engine ground. digital meter still set to read DC volts, read the voltage
drop of the TP sensor ground. The voltage drop is the
difference in voltage between the leads of the meter.
General Motors specifies that this voltage drop should
not exceed 35 mV (0.035 V). This TP sensor ground
shows 31.1 mV (0.0311 V).

P19–11 To measure the signal voltage, backprobe the P19–12 Select DC volts and manually range the meter.
signal wire (dark blue on this General Motors vehicle). This Fluke meter changes from the 4 volt scale to the
40 volt scale as the sensor voltage goes slightly higher
than 4 volt. For an instant,“OL” appears on the display
as it switches ranges. This OL could also indicate a fault.

618
Throttle Position Sensor Diagnosis—continued

P19–13 Slowly move the throttle from idle speed to P19–14 The high reading for this sensor was
wide open and back to idle speed position. For best 4.063 volts.
results, this test should be performed by depressing the
accelerator pedal. This puts the same forces on the
sensor as occurs during normal driving.

P19–15 Pushing the MIN/MAX button shows the P19–16 A Snap-On Vantage graphing multimeter or
minimum voltage the meter recorded during the test digital storage oscilloscope can also be used to test a
(0.399 volts). TP sensor. To test the sensor using the Snap-On
Vantage, select TP sensor from the menu.

P19–17 The Vantage has a built-in database that can be P19–18 After attaching the meter leads to the signal
accessed to show connector position and wire colour wire and ground (ignition key on, engine off), the graphing
information. multimeter shows the waveform of the voltage signal as
the throttle is depressed, released, and depressed again.
These are normal for a TP sensor. A fault would show as
a vertical line or dip in the waveform.

619
620 CHAPTER 25

SUMMARY 4. The voltage output of a zirconia oxygen sensor when

the exhaust stream is lean (excess oxygen) is ________.
1. The vehicle computer is called the powertrain control a. Relatively high (close to 1 volt)
module (PCM) because it controls the engine and the b. About in the middle of the voltage range
transmission on most vehicles. c. Relatively low (close to 0 volt)
d. Dependent on atmospheric pressure
2. The four basic computer functions include: input, pro-
cessing, storage, and output. 5. The sensor that most determines fuel delivery when a
fuel-injected engine is first started is the ________.
3. Permanent memory is called ROM, PROM, EPROM, a. Oxygen sensor (O2S)
or EEPROM. b. Engine coolant temperature (ECT) sensor
4. Temporary memory is called RAM or KAM. c. Engine MAP sensor
5. The central processing unit (CPU) is the “brains” of d. BARO sensor
the computer and does all the calculations. 6. The standardized name for the sensor that measures
6. As the temperature of the engine coolant increases, the temperature of the air being drawn into the engine
the resistance of the ECT sensor decreases. is called a(n) ________.
a. Intake air temperature sensor (IAT)
7. A throttle position sensor can best be checked with a
b. Air temperature sensor (ATS)
voltmeter set on MIN/MAX or with a scope.
c. Air charge temperature (ACT)
8. An oxygen sensor should switch rapidly from high to d. Manifold air temperature (MAT) sensor
low on a fuel-injected engine operating in closed loop.
7. Which sensor is generally considered to be the elec-
tronic accelerator pump of a fuel-injected engine?
a. Oxygen sensor
REVIEW QUESTIONS b. Coolant temperature sensor
c. Throttle position sensor
d. Engine manifold absolute pressure sensor
1. List the four functions of a computer.
8. The sensor that must be warmed up and functioning
2. What is meant by the term Baud rate?
before the engine management computer will go to the
3. Explain how to test an engine coolant temperature closed loop is the ________.
sensor. a. Oxygen sensor (O2S)
4. Describe the best method to test a MAP sensor. b. Engine coolant temperature (ECT) sensor
5. Describe how a zirconia oxygen sensor works and how c. Engine MAP sensor
best to determine if it is operating correctly. d. BARO sensor
9. Which of the following describes an acceptable oxygen
sensor voltage range?
RED SEAL CERTIFICATION- a. 0.5 to 0.7 volt
b. 200 mV to 800 mV
TYPE QUESTIONS c. 300 mV to 500 mV
d. 400 mV to 800 mV
1. Which of the following is an input sensor to the vehicle 10. A pull-up resistor inside the computer (ECT circuit) is
computer? used to
a. Fuel injector a. Expand the scale of the ECT sensor
b. Idle-speed control motor b. Dampen voltage fluctuation
c. Combustion chamber temperature sensor c. Prevent amperage from back-feeding into
d. Engine coolant sensor other circuits
2. Which part of the computer does the actual calculations? d. Compare resistance with the intake air
a. PROM temperature (IAT) sensor
b. RAM
c. CPU
d. KAM
3. Typical TP sensor voltage at idle is about ________.
a. 2.50 to 2.80 volts
b. 0.5 volts or 10% of WOT TP sensor voltage
c. 1.5 to 2.8 volts
d. 13.5 to 15.0 volts