Part 3

Design (Continued)

Preheating of the heated oxygen sensors (HO2S)
The heated oxygen sensor (HO2S) only functions above a certain temperature, approximately 300 °C. The normal operating temperature is between 300-900 °C. The heated oxygen sensors (HO2S) are electrically pre-heated so that operating temperature is rapidly reached. This also ensures that the heated oxygen sensors (HO2S) maintain a normal operating temperature and to prevent condensation which could damage the heated oxygen sensor (HO2S).
The heater element in the probe consists of a positive temperature coefficient (PTC) resistor. The system relay supplies the heater element with voltage. The element is grounded in the engine control module (ECM). When the control module grounds the connection a current flows through the PTC resistor. When the heated oxygen sensor (HO2S) is cold, the resistance in the PTC resistor is low and a large current will flow through the circuit. The current from the Engine Control Module (ECM) is pulsed at first to prevent condensation damage to the heated oxygen sensor (HO2S). Depending on the temperature, allowances are made for factors such as the dew point. As the temperature in the PTC resistor rises, the resistance rises, the current falls and switches in stages to a constant current. The pre-heating time for the front heated oxygen sensor (HO2S) is short, approximately 20 seconds. The rear short-term fuel trim takes longer to warm up. This is to prevent damage to the probe. The pre-heating time for the front heated oxygen sensor (HO2S) is short, approximately 20 seconds.
Probe preheating begins as soon as the engine is started. The heater element heats the heated oxygen sensors (HO2S) to approximately 350 °C. The probes maintain this as a minimum temperature.
The engine control module (ECM) can diagnose the heater element.

Engine coolant temperature (ECT) sensor




The engine coolant temperature (ECT) sensor checks the temperature of the engine coolant. The temperature of the engine coolant is required so that the engine control module (ECM) can regulate:
- the injection period
- the idle speed
- the engine cooling fan (FC)
- the ignition advance
- engagement and disengagement of the A/C compressor
- diagnostic functions.
The sensor is a negative temperature coefficient (NTC) type which is supplied with power from the control module (signal) and is grounded in the control module.
The resistance in the sensor changes according to the temperature of the engine coolant. This provides the control module with a signal of between 0.1-4.9 V. The lower the temperature the higher the voltage (high resistance). A high temperature results in low voltage (low resistance).
The engine coolant temperature (ECT) sensor is located beside the thermostat.
The engine control module (ECM) can diagnose the engine coolant temperature sensor. The sensor value can be read off using VIDA.

Engine cooling fan (FC) / engine cooling fan (FC) control module




The engine cooling fan (FC) has two functions. One is to cool the engine compartment, the other is to cool the condenser when the air conditioning (A/C) compressor is working.
The engine control module (ECM) transmits a pulse width modulated (PWM) signal to the engine cooling fan (FC) control module. The control module then activates the fan at one of three different speeds. The speed of the engine cooling fan (FC) is determined by the engine control module (ECM), depending on the coolant temperature (based on the signal from the engine coolant temperature (ECT) sensor) and the vehicle speed.
When the vehicle is stationary, the engine cooling fan (FC) is activated as follows:
- the first stage is activated at approximately 105 °C and shut of at approximately 100 °C
- the second stage is activated at approximately 110 °C and shut of at approximately 105 °C
- the third stage is activated at approximately 115 °C and shut of at approximately 110 °C.

Note! The engine cooling fan may have a post-run of up to approx. 6 minutes after the engine has been turned off. The time for the fan's post-run depends on engine temperature, temperature in the engine compartment and pressure level in the AC-system.

Warning! Be careful since the engine cooling fan may have a post-run after the engine has been turned off.

The engine cooling fan (FC) and its control module are behind the radiator.
The engine control module (ECM) can diagnose the engine cooling fan. The fan can be activated using VIDA.

Mass air flow (MAF) sensor




The mass air flow (MAF) sensor gauges the air mass sucked into the engine. It continuously transmits signals to the engine control module (ECM) about the mass of the intake air. This data is used by the engine control module (ECM) to calculate:
- the injection period
- the ignition timing
- the engine load.
The gearbox control module (TCM) also uses this data for its gear shift calculations. This data is transmitted to the gearbox control module (TCM) from the engine control module (ECM) via the high speed side of the Controller area network (CAN).
The mass air flow (MAF) sensor is a hot wire type. Unlike other hot wire types, the mass air flow sensor in the Denso system uses a hot wire which has a ceramic casing. This eliminates the need for a clean burn function.
The mass air flow (MAF) sensor is supplied with battery voltage by the system relay and is grounded in the engine control module (ECM). The signal from the sensor is analogue and varies between 0.5 - 4.5 V depending on the air mass. Low air flow (low mass) results in low voltage, high air flow (high mass) gives high voltage.
The mass air flow (MAF) sensor is positioned between the air cleaner (ACL) housing and the intake manifold.
The mass air flow (MAF) sensor also contains an intake air temperature (IAT) sensor.
The engine control module (ECM) can diagnose the mass air flow (MAF) sensor. The signal can be read using VIDA.

Outside temperature sensor




The outside temperature sensor detects the temperature in the surrounding air. The signal is used by the engine control module (ECM) as a substitute value in the event of a fault in certain components or functions and to control certain diagnostic functions.
The sensor is a negative temperature coefficient (NTC) type which is supplied with power from the control module (signal) and is grounded in the control module.
The resistance in the sensor, which provides a signal between 0.1-4.7 V, changes depending on the outside temperature. Low temperatures produce high voltage (high resistance), high temperatures produce low voltage (low resistance).
The outside temperature sensor is positioned in the left door mirror.
The engine control module (ECM) can diagnose the outside temperature sensor. The sensor value can be read off using VIDA.

Engine speed (RPM) sensor




The engine speed (RPM) sensor provides the Engine Control Module (ECM) with information about the speed and position of the crankshaft. The Engine Control Module (ECM) is able to use the signal from the engine speed (RPM) sensor to determine when a piston is approaching top dead center (TDC). However it is unable to use the signal from the engine speed (RPM) sensor to determine whether the piston is in the combustion stroke or whether the exhaust valve is open (exhaust stroke). The signal from the camshaft position (CMP) sensor is also required to determine the operating cycle of the engine.
The signal from the engine speed (RPM) sensor is also used to check the engine for misfires (misfire diagnostics).
Cars with manual transmissions have a series of holes drilled in the periphery of the flywheel. Cars with automatic transmissions have a steel ring with punched holes. This steel ring is welded to the edge of the carrier plate. In both cases, there is 6° between each hole. This arrangement creates a hole for each tooth. There are 360° in one revolution. 6° between each hole means that there are 60 holes. However one hole is not drilled/punched, to create a reference position (tooth) for the crankshaft. This reference position is 72° before the top dead center (TDC) of cylinder 1 on a 5 cylinder engine.
The engine speed (RPM) sensor is at the rear of the engine above the flywheel.
The sensor is inductive with a permanent magnet. An alternating current is induced in the sensor when the flywheel/carrier plate passes the engine speed (RPM) sensor. The generated voltage and frequency increases with the engine speed (rpm).
The signal varies between 0.1 - 100 V (AC) depending on the engine speed (RPM).
The Engine Control Module (ECM) is able to determine the engine speed (RPM) by counting the number of holes per time unit. When the reference tooth passes the engine speed (RPM) sensor, the voltage and frequency drop momentarily to zero, even though the engine is still running. This allows the Engine Control Module (ECM) to determine the position of the crankshaft.
If the signal from the engine speed (RPM) sensor is incorrect or missing, the control module will use the signals from the camshaft position (CMP) sensor, on the condition that the position of the camshaft has been adapted and the car can be driven if there is no signal.
The engine control module (ECM) can diagnose the engine speed (RPM) sensor. The sensor value (engine speed (rpm)) can be read off using VIDA.

Camshaft position (CMP) sensor




The Engine Control Module (ECM) uses the signals from the camshaft position (CMP) sensor and the engine speed (RPM) sensor to establish the operating cycle of the engine. This enables the engine control module (ECM) to:
- start the engine more quickly
- control the correct ignition coil and injector
- function as a substitute for the engine speed (RPM) sensor
- check the camshaft continuous variable valve timing (CVVT).
The pulse wheel on the camshaft has five teeth with different gaps which correspond to a specific cylinder.
For further information, also see Knock sensor (KS), Engine speed (RPM) sensor.
The sensor, which is a magnetic resistor with a permanent magnet, is grounded in the control module and supplied with current from the control module. When one of the teeth on the camshaft pulse wheel passes the camshaft position (CMP) sensor, a signal is transmitted to the control module from the camshaft position (CMP) sensor. The signal varies between 0-1 V and is low when a flank passes the camshaft position (CMP) sensor.
The camshaft position (CMP) sensor is positioned at the rear of the engine on the camshaft with continuous variable valve timing (CVVT).
The engine control module (ECM) can diagnose the camshaft position (CMP) sensor.

Knock sensor (KS)




Cars of model year 1999-2000 have a knock sensor. Cars from model year 2001 are equipped with two knock sensors (KS).
The function of the knock sensor (KS) is to monitor combustion knocking from the engine. Knocking may damage the engine and reduces the efficiency of engine combustion.
If the engine control module (ECM) registers knocking from any of the cylinders, the ignition will be retarded for that cylinder at the next combustion stage. If repeated ignition retardation does not prevent knocking, the injection period will be increased. This has a cooling effect.
The sensor is made up of a piezo electrical crystal. If there is engine knock, vibrations (sound waves) spread through the cylinder block to the knock sensor (KS). The resultant mechanical stress in the piezo electrical material in the knock sensors generates a voltage. This signal is transmitted to the Engine Control Module (ECM). The signal corresponds to the frequency and amplitude of the sound waves. This allows the Engine Control Module (ECM) to determine if the engine is knocking. The camshaft position (CMP) sensor and engine speed (RPM) sensor are used to determine the operating cycle of the engine (which cylinder is igniting) and thereby which cylinder is knocking.
The knock sensors (KS) are positioned on the cylinder block below the intake manifold.
The engine control module (ECM) can diagnose the knock sensors (KS).