: (Contents) : CHAPTER 1 (SENSORS) CHAPTER 5 (SENSOR CHECKING) 5 2. Cam Sensor 2 3, Mass Air Flow 1 4. Boost Pressure Sensor £5, Speedo Meter Sensor + 6, ABS SensorfWheel Speed Sensor £7. Accelerator Pedal Position Sensor + 8, Rail Pressure Sensor 2 9, ORV Valve + 10, Knock Sensor 11. Engine Coolant Temperature Sensor Sime Soe : 1. Pins Deseripions CHAPTER 8 (CAN) : CHAPTER 2 (SWITCHES) (28 to 31) 1. cAN High GH to 64) : 5 4, Break Pedal Switch 2.CANLow : + 2. Clutch Pedal Switch Chapter 9 (Relay) t CHAPTER 3 (VALVES) (32 to 38) 2. Five Pi Raley b 4.EGR VaNe 3. Maio Rely + 2, Solenoid Valve CHAPTER 10 (SCANNER) 4. Functions of Scanner 2. Code Descrgtion 3, Fuel Metering Unit Valve | CHAPTER 4 (MULTIMETER) (39 to 44) 1 1.0€ Voltage + 2. Continuity Check CHAPTER {1 (DIAGNOSE PHILOSOPHY) 4. Fault Diagnose with Scanner 2 Reed Fault(Contents) : > CHAPTER 12 In _.. CHAPTER 22 (SENSOR VOLTAGE ABOVE UPPER LIMIT) = {GRDI Engne Stating Problems (80 to 82) 4. Fault Language Deserition (107 to 110) : ; CHAPTER 13 (VALVE & SENSORS) CHAPTER 23 (BELOW LOWER LIMIT) 5 |. Diflerence Between Valve & Sensors (83 to 84) Fauit Language Description (111 to 114) : s CHAPTER 4 + (OPEN }CIRCUT) CHAPTER 25 (CIRCUTT | RANGE E PERFORMANCE) 5 7) Fault Language Description (116 to 119) : ; eee eee ua. CHAPTER 26 (SENSOR HIGH OR LOW FREQUENCY) —: (88 to 92) Fault Language Description (120 to 121) : CHAPTER 17 (CIRCUIT LOW) CHAPTER SENSOR CONTROLCIRCUT) Fault Language Descipion (93 to 96) Fut Language Description (122 to 124) : : CHAPTER 18 (REFERENCE VOLTAGE) _ CHAPTER 28 (FAULT CODE) _ : {1 Fault Language Description (97 to 98) Faun code Grout specton (125 to 169) : CHAPTER 19 (INPUT SIGNAL) 1 Fault Language Description (99 to 101) + CHAPTER 20 (OUTPUT SIGNAL) : 4. Fault Language Description (102 to 103) HAPTER 21 (BANK{ & BANK2) |, Fault Language Description (104 to 106)SENSORS These (Sensor) are the parts attached to the engine. Which senses the movement of the engine and send to the ECM, which we called a signal. These sensors giving signal to the ECM. Like:- how many RPMs of the engine, which speed the vehicle is running etc. The job of the sensors is to give signal to ECM as our sense organs gives signal to our Brain and our brain gives command to our hands-feet and other organs of the body. Vehicles has the following types of sensors. Full details of the sensors. gives in the next chapters:- SENSORS Crank Shaft Sensor Cam Shaft Sensor Rail Pressure Sensor Boost Pressure Sensor Coolant Temperature Sensor Mass Air Flow Sensor Oil Pressure Sensor Knock Sensor Accelerator Pedal Sensor V. Sensor The sensors has commonly 2 wires and 3 wires. In two wires sensor one wire has a (+ve) voltage and second has (-ve) voltage. In three wires sensor, (+ve) voltage, which is called the reference voltage and second wire is (-ve) voltage. when sensor received (+ve) and (-ve) voltage then the third wire become ON gives signal to ECM or any other electronic modules. For this reason , to work on any vehicle, we should write the voltage coming on the sensor:- How many sensors are there in all the vehicle that come to us and how much voltage comes onthe sensors.Intwo wires sensors the voltage has the followings:- This is two wires sensor’s the voltage come’s in the both wires has 2.5v and 2.5v. circuit inthe ECM. Inthe three wires sensor's, the voltage as the following :- HD Reference Signal ead Body Vehicle’s Voltage wire Ground +12v +12v +5v +5v +2.5v +2.5v In above, we the see the base of the sensor’s has 2 wires and 3 wires Similarly when the number of wires the sensor (mounted on the engine) increase, there can be more than one sensor ina sensor due to having 4 wires, Swires. Like In mass air flow sensor:- It has 2 sensors. Accelerator pedal sensor has also two sensors.(CHAPTER 1) Location):- Crank Sensor is fitted in petrol and diese! vehicles. This sensor is located close 0 the crank. Such as near the crank sproket (pully) and near the flywheel. (Working):- 4. The crank shaft sensor measures the position of the crank and the degree at which the crank shaftis rotating. Sensor provides its information to ECM. 2. Crank sensor is also called RPM sensor. This sensor gives a signal to the ECM about how fast the crank is rotating. 3. The ECM gives pulse over the injectors only after the signal from the crank sensor. ET (Problems):- 1. Ifthe crank sensor is faulty then the engine will not start. GiCeun eso2. Pulse will not come on injectors. 3. The RPM needle in the meter will not go up either. 4. RPM will not be displayed in the live data of the scanner while scanning any vehicle. 5. The engine can emit black smoke. 6. Misfire can happen. The vehicle may tremor while on road. 7. It has been observed in trucks that the performance of the truck decreases due to the presence of garbage in front of the crank sensor. (Things to keep in mind while opening and fitting the sensor /Precautions):- 41. Never pull the connector from the wires attached to the sensor. 2. The ‘O’ring’ inside the crank sensor should be taken care of. It should never be left inside the block. Re-inserting the ‘O’ring in it can increase the air gap of the sensor. 3. Never keep the sensor near high temperature. 4. Do not place the sensor near the magnet. 5. Torque should be 8 + 2 Nm to tighten this sensor. 6. The sensor wires should be protected from twisting. 7. Prevent the sensor from falling down. 8. Do not hit with any tool while opening and fitting on the sensor. (CODES) P0336:-Crank Shaft Wrong Signal. P0335:- Crank Shaft Sensor No Signal. P0337:- Crank Shaft Position Sensor Circuit Low. P0338:- Crank Shaft Position Sensor Circuit High. { i i t t i { t 4(CAM SHAFT SENSOR). cI (Location):- Itis clear from the name of the sensor that sensor is located close to the cam shaft and measures the position of the cam shaft. The cam sensor is located near the cam shaft, either on the front side of the Sprocket (Pully) or on the top ofthe tapet cover. (Working):- This sensor indicates the position of the cam shaft as it measures piston number 4 and sends the signal to ECM. The ECM gives the firing order to the injectors after receiving the signal from the cam sensor. The pulse on the injector in the diesel engine and the spark on the plug in the petrol engine start after the signal of this sensor. In the engines of many companies, if the cam sensor signal does not give correct signal to the ECM then it does not start. Where as the engines of many companies start but the starting is late and the code of the sensor also appear. Logan, Ford- Quadrajet Engines can start without signal from cam but starting is delayed. (Wiring):- This sensor is usually 2-wires and 3-wires. ‘2WIRES| cence eect‘SIGNAL 5V 2.5V = 1. The resistance of this sensor can be 850 # 10%. But the resistance of the sensors of many petrol and diesel engines may be different. 2. The air gap between cam sensor and teeth can be 0.1mm to 2.8mm (Problems/Faults):- 1. The engine will not start. 2. Many engines will start late. 3. Misfire in the Engines. (Precautions):- 1.Prevent the sensor from falling down. 2. Do not hit the sensor with any tool while opening or fitting it. 3. Do not twist the sensor wires. 4. Tightening torque should be 8t1NM 5. The air gap should be 0.1mm-2.8mm. 6. Never clean the sensor with sandpaper from the front side. PRCon ne emery(CODES) :-Cam Shaft Sensor Wrong Signal. :-Cam Shaft Sensor No Signal. :-Cam Shaft Position Sensor ‘A’ Circuit Low. :-Cam Shaft Position Sensor'‘A' Circuit High. :-Cam Shaft Position Sensor‘A’ Circuit Intermittent.(Mass AIR FLOW SENSOR):- Co (Location):- This sensor is attached to the air filter. (Working):- Ithas two sensors. The first is the mass air flow sensor. Its function is to report to the ECM how many kilograms of air is entering into the engine in a per/sec. The function of the second sensor is to determine the temperature of the air entering the engine and to give the signal of this air to the ECM. ECM decides fuel and air mixture ratio after the signal of this sensor. (Types):- This sensor consists of:- 4wires sensor has two signals, Oneis (+ ve) Voltage and Second is (-ve) Voltage. 5 wires sensor can have 2 signals, 2 positive and1 negative wire. 6 wires sensor can have 2 signals, 2 positive and 2 negative wires. 4 Wires 5 Wires 6 Wires 2 (22 22]] [Gees] (| PaCS eineProblems/Fault): 4. If there is (Fault) in this sensor then some engines do not start like Quadrajet engine. 2. Engine will not take more than 3000 RPM. 3. The engine starts emitting black smoke. 4. Misfire in the engine. (Precautions):- 4. This sensor should be protected from oil and water from inside where the sensor Senses. 2. The sensor should be protected from falling. } 3.ltshould not be hit with any tool while opening or fitting. 4. Pipes that are attached to it should not be tightened too much. 5. Air should not be blown directly to clean it. 6. It can be washed with light petro! but the company does notallowit.. (CODES) P0101:- Mass Or Volume Air Flow Circuit Range/performance. P0102:- Mass Or Volume Air Flow Circuit Low Input. P0103:- Mass Or Volume Air Flow Circuit High. P0104:- Mass Or Volume Air Flow Circuit Intermittent. P0110:- Intake Air Temperature Sensor 1 Circuit. Pee eratetekeek scl acca4. (Boost PRESSURE SENSOR):- ———<—_ od (Location):- This sensor is attached after turbo charged. This sensor can be of 3 wires or 4 wires. There are 2 sensors in this one sensor. (Working):- The function of this sensor is to measure the pressure of air after turbo charger. Measure it and give its signal to ECM. Then, it informs the ECM about temperature of the compressed air that the turbo has pushed into the inlet manifold. If the pressure is low or the pressure is high then ECM increases or decreases the pulse on the injectors. The ratio of fuel and air also depends on this sensor. 3 WIRES} 4 WIRES| CUM ine(Wires):- 1. Boost pressure sensor consists of 3 wires it measures the air pressure. 2. If it has 4 wires then it gives the signal to the ECM about the temperature of the boostair. (Fault):- 41. The engine will not exceed 3000 RPM. 2. The engine will emit black smoke. 3. The scanner may not show any code. 4. The vehicle will tremors while running. (Precautions):- 1.Don’'t hit with tool when opening and fitting this sensor. 2. This sensor should not fall. 3. Do not insert the wire into the front hole while cleaning this sensor. 4. It can be cleaned with petrol but companies recommended only change the sensor. 5. Be careful not to cut the ‘O’ring init. 6. Air should not be blown directly into the hole in the sensor. 7. |gnition should be turned off while opening the sensor. Pac eee(CODES) P0105:-Manifold Absolute Pressure/barometric Pressure Circuit. P0106:-Manifold Absolute Pressure/barometric Pressure Circuit Range/performance. P0107:-Manifold Absolute Pressure/barometric Pressure Circuit Low Input. P0108:-Manifold Absolute Pressure/barometric Pressure Circuit High. P0109:-Manifold Absolute Pressure/barometric Pressure Circuit intermittent. Pes cence RSI SU) -1 Co) SUAS5. (SPEEDO METER SENSOR) : — (Location & Working):- This sensor is mounted on gears in cars and trucks. It measures the speed of the vehicle. It gives a signal to the ECM. Sometimes the speed signal can go directly to the meter or to the BCM. The speedometer sensor sets the ratio of ECM fuel and Air after the sensor signal. With the help of this sensor we know the speed of the vehicle. (Wires):- This sensor has three wires. 12V +12v. SIGNAL GROUND Pcrb cnet reenact udi (Fault): 1. If there is a fault in the vehicle speed sensor then the RPM in Ford, VW and Skoda cars does not exceed 2000. 2. The engine will misfire or jerk. 3. The speedometer needle does not rise in the odometer. 4. The engine is misfire when truck is loaded. 5. If speedometer sensor code is appearing then the vehicle will not accelerate athigh speed. 6. The center lock system stops working. In many vehicles, at the speed of 20 Kr, all four doors are auto locked. But if fault occurs in this sensor, then this system will also stop. 7. The warming light will On in the ODOMETER and the steering wheel becomes hard. (CODES) P0500:-Vehicle Speed Sensor‘A'. P0501:-Vehicle Speed Sensor 'A' Range Performance. P0502:-Vehicle Speed Sensor ‘A’ Circuit Low input. P0503Vehicle Speed Sensor ‘A' Circuit High.3 6. (ABS SENSOR/ WHEEL SPEED SENSOR):- co (New Generation):- In Cars, the speed signal of the vehicle is taken from the ABS sensor. ABS sensors give signal to ABS module and ABS module gives signal to ECM. ABS sensors are mounted on all four wheels. (Types):- ABS Sensor are usually 2 wires. 2WIRES (ag 4. Vehicles of many companies do not go above 2000 RPM if there is a fault in (Fault):- this sensor. 2. Misfire. 3. The speedometer needle does not rise in the odometer. 4.. In many vehicles the main fuse blows out when the sensor is short or faulty. ier cue seca uae(Things to keep in mind):- 1. The sensor must not touch with any metal from the front while fitting. 2. Left and right side should be taken care of while fitting the sensor. 3. Do not place the sensor near any magnet. 4. The wire attached to the sensor should not touch with the body. 5. Many sensor receive signals from wheel bearings. Only one side of the wheel bearing is fitted with metal to give the signal. If this bearing is reversed, then the ABS light starts showing/blinking into the meter and the speedometer will not work. (CODES) C1227:- Speed Wheel Sensor LR input Short Circuit to Battery. C1228:-Speed Wheel Sensor LR input Short Circuit to Ground. C1230:-Speed Wheel Sensor Rear Center input Circuit Failure. C1231:- Speed Wheel Sensor Rear Center Circuit Open. 1234:-Speed Wheel RF Input Signal Missing. Panes7. (ACCELERATOR PEDAL POSITION SENSOR):- — (Location):- This sensor is located near the brake pedal. (Working):- Accelerator pedal position sensor's function is to send signals to the ECM what the driver wants, how many RPM to increase or decrease, It increases or decrease the pulse of the Injectors. The ratio of fuel and air depends on the signal of the accelerator pedal. This accelerator pedal sensor has 2 types of sensors:- Name of the Sensor 4. Sensor Track 1, Bank 1, Accelerator Pedal Sensor 1 2. Sensor Track 2, Bank 2, Accelerator Pedal Sensor 2 Both these sensors are of resistance type. In the signal wires that signal to ECM, as we press the pedal, they increase the voltage. (Types):- This sensor has 3 wires and 6 wires. Pipers coe saecoReference Voltage Signal to ECM Ground 6 Wires Ve i= 5V 01 Signal Ground | 5V Signal Ground | (1Track) (2Track) 1) 2 wires of the accelerator pedal have reference voltage in the accelerator pedal. 2) There are 2 wires of signals in accelerator pedal which signal to the ECM from the pedal. 3) 2wires have body ground. {Fault):- 1. If there is a fault in this sensor then ideal RPM is increases from 800 RPM to 1100 RPM. 2. In case of fault in this sensor, pressing the accelerator pedal does not increase the RPM of the engine. 3. If there is a fault in this sensor, the engine will jerk while driving the vehicle. 4.The pedal's position will be at 0% when the accelerator pedal is pressed in Race cue eee aedscanner's live data. 5. Both sensors of accelerator pedal’s Sensor show the different voltage in scanner's live data. (CODES) P0220 :-Throttle/ Pedal Position Sensor Switch “B” Circuit. P0221:-Throttle/ Pedal Position Sensor! Switch Circuit Range/ Performance. P0222 :-Throttle/ Pedal Position Sensor Switch “B” Circuit Low. P0223:-Throttle/ Pedal Position Sensor Circuit High. P0226:-Throttle/Pedal Position Sensor Circuit intermittent. Sue en eee eenoS 8. (RAIL PRESSURE SENSOR) :- | (Location):- This sensor is mounted on the rail above the engine. (Working):- The function of Rail pressure sensor is to measure the bar pressure of diesel in the common rail on the engine and give signal to ECM about pressure of diesel. This sensor is a piezo resistive type sensor. This sensor increases the voltage to the ECM as the pressure of diesel in the common rail increases. We can check this signal with a multimeter. The ECM detects from this sensor whether the pressure of diesel in the common rail is low or high. . 3 WIRES 1 2 5V 5V 1. Reference Voltage 2. Signal to ECM 3. Body Ground aK CUL Au ceca eet cane(Wires):- This sensor has 3 wires. if the diesel pressure increase in the rail and RPM increase in the engine. Similarly the voltage in the signal wire of the rail pressure sensor is also increases. (Fault):- 1. Incase of fault in this sensor, the engine will knock. 2. In case of fault in this sensor, the engine will not go above 3000 RPM. 3. If there is a fault in this sensor, the actual value of the rail will be wrong in the ive data of the scanner. (CODES) P0087:- Fuel Rail/System Pressure Too Low. P0088:- Fuel Rail/System Pressure Too High. P0190:-Fuel Rail Pressure Circuit. P0191:-Fuel Rail Pressure Circuit Range/Performance. P0194:-Fuel Rail Pressure Circuit Intermittent. Pecos eee9. (DRV VALVE "4 (Location):- Diesel Rail valve is attached to the diesel common rail on the engine. (Working):- Rail pressure sensor sends signals to the ECM by measuring the pressure of diesel in common rail. ECM maintains diesel pressure in common rail through DRV at how many RPM and how many bar pressure common rail to keep. This valve leaks diesel in the fuel tank if the pressure of diesel in the rail is high but does not leak diesel in the rail if the pressure is low. DRV does this only after taking the command from ECM. It is a valve not a sensor so it works to maintain diesel in the rail. +H2v (Wires):- (Wires):- DRV is operated with 2 wires. One wire has +12V. It comes from 12Vdirect fuse box, meter or ECM. The other wire coming to DRV is-ve from ECM. When we check the voltage in this wire, it is found to be 2.5v or 3.5v. But in thi wire only (-ve) voltage comes from ECM. The multimeter reading comes with 2.5V to 3.5V because it is connected to an integrated circuit in the ECM. The ECM controls the DRV by increasing or decreasing (-ve) voltage. PES(2) 2.5 3.5v (Fault):- 1.The engine will not start. 3 2.The start engine will tremor. 3. RPM will go upto 5000 on tressing accelerator and RPM. will drop mediately after that. 4. The engine will stop after taking RPM. 5. When the DRV is short, the diesel pump in the fuel tank will shut down or shut down as soon as itis ON. 6. If there is a fault in the DRV then the vehicle will stop after half a minute start. 7. If the incoming wires to the DRV are shorted by any other wire then ECM will turn off the incoming (-ve) on the main relay. 8. The low pressure code appears in the scanner, if the faultis in the DRV. (CODES) P0089:- Fuel Pressure Regulator 1 Performance. P0090:- Fuel Pressure Regulator 1 Control Circuit. P0091:- Fuel Pressure Regulator 1 Circuit Low. P0092:- Fuel Pressure Regulator 1 Circuit High. cree eee suc eae Kscu10. (KNOCK SENSOR) (Location) :- This sensor is located on to the engine block. This sensor is usually of 2 wires. (Working):- The function of this sensor is to measure the vibrations in the engine and gives the signal to ECM. If the engine is vibrating after receiving the signal from the Knock sensor, then the engine vibration be eliminated by ECM with following methods:- 1. ECM eliminates vibration by increasing or decreasing fuel. 2. ECM tries to eliminate the vibration coming from the engine by retire or advance the time of injection of fuel into the engine. 3. Knock sensor is installed to enhance the performance of the engine. 4. Piezoelectric ceramics material is used in this sensor. (Wires):- This sensor is usually of 2 wires. Its voltage can be as per the figure shown below. ACCUM ee ane(2 wires) (Fault):- 4. In case of fault in this sensor, the engine check light in the meter will turn On. 2. Ifthere is a fault in this sensor, the scanner will give the code. 3. If there is a fault in this sensor, there will be a knocking sound in the engine. 4. Ifthere is a fault in this sensor, the engine will emit black smoke. 5. If there is a fault in this sensor, the engine may misfire. (CODES) P0325:-Knock Sensor 4 Circuit. P0327:-Knock Sensor 4 Circuit Low. P0328:-Knock Sensor 1 Circuit High. P0331:-Knock Sensor 1 Circuit Range/Performance. P0325:-Knock Sensor 4 Circuit. P0329:-Knock Sensor 4 Circuit Input Intermittent. beeen ees eae sua cred11. (Engine Coolant Temperature Sensor): | ATS (Location):- The engine coolant temperature sensor is usually located near the engine head or above the elbow. (Working):- The name of this sensor indicates that this sensor measures the coolant temperature of the engine and gives signal to ECM. ECM gives the command to turn On the radiator fan with the help of this sensor the engine avoids overheating. The ECM sets the ratio of AiR and fuel after the signal from the coolant temperature sensor. As the engine heats up, the resistance of this sensor decreases and as the sensor cools, its resistance increases. This sensor is an NTC type sensor. (Types):- Coolant temperature sensor can be 2 or 3 wires. 1 ra 1 i T | Voltage Signal Ground Signal Ground 1> 10 ReorenceVotoge 1-2 Signal to ECM 2-55 Signal to EOM 2. Body Ground 3-9 Body Ground Pam eee ee cued(Fault): 1. Starting may be delayed in case of fault in this sensor. 2. In case of fault in this sensor, Misfire/Start engine will jerk. 3. If there is fault in this sensor, the temperature needle in the odometer will notwork. 4. In case of fault in this sensor, the mixture of AIR and fuel ratio decreases more and more. Due to which the mileage of the vehicle is affected. 5. If there is a fault in this sensor, the sound of knocking will come from the Engine. 6. If there is a fault in this sensor, AC compressor will turn Off automatically. 7. Ifthere is a fault in this sensor, the radiator fan will turn On automatically. (CODES) P0115:-Engine Coolant Temperature Circuit. P0116:- Engine Coolant Temperature Circuit Range/Performance P0117:-Engine Coolant Temperature Circuit Low. P0118:- Engine Coolant Temperature Circuit High. P0119:- Engine Coolant Temperature Circuit Intermittent. Pic eerie meuece cua(Location):- This sensor is attached to the exhaust manifold and in some vehicles have one or more sensor attached. Such as in many vehicles one before the Catalytic converter and the other after the catalytic convertor . (Working):- The function of the oxygen sensor is to check the amount of oxygen emission in the exhaust gas and send signal to the ECM after diagnosing it so that the ECM can set the correct amount of fuel and air ratio. If the amount of air and fuel is correct then the mileage of the vehicle will increase and the amount of hazardous gases emitted from other exhausts will decrease. If the amount of oxygen in the exhaust is leaking, the blast in the combustion chamber of the engine may not be correct. So after receiving the signal from the sensor, ECM sets the ratio of air and fuel. In some vehicles this sensor can be one or more than in one vehicle. if there is more than one, they are lentified by the following names. Sensors located before the catalytic converter and near the exhaust manifold: 1.UP Stream Sensor 2. Bank 1 Sensor 3.Sensor1 GaKcUn uae ree aaetSensors fitted after Catalytic Converter:- 41. Down Stream Sensor 2. Bank 2 Sensor 3.Sensor2 The function of the oxygen sensor before the catalytic converter is to check the amount of oxygen in the exhaust and send signal tothe ECM. The function of the sensor that is attached after the catalytic converter is to check the efficiency of the catalytic converter and give the signal to ECM. UP Stream Down Stream Bank 1 Bank 2 Sensor 1 Sensor 2 Wm Mt Catalytic Converter (Fault):- Loe 4. If there is a fault in this sensor, the engine check light will appear in the cluster meter. 2. 1n case of fault in this sensor the mileage of the vehicle will reduce 3. If there is a fault in this sensor, the engine can emit black smoke. 4. If there is a fault in this sensor, the engine may misfire. (CODES) P0131:- 02 Sensor Circuit Low Voltage. P0132:- 02 Sensor Circuit High Voltage. P0135:- O02 Sensor Heater Circuit. P0136:- 02 Sensor Circuit. P0146:- O2 Sensor Circuit No Activity Detected. Perec(CHAPTER 2) SWITCHES (Break Pedal Switch):- =I (Location):- This switch is attached to the brake pedal. It can be two wires or four wires 2 WIRES 4 WIRES [sz] (Working):- 1. Turn On the tail bulbs. 2. Its function is that when the driver presses the brake pedal, it signals the position of the brake pedal to the ECM. The ECM reduces the amount of pulse and fuel going to the injector after the signal of the brake pedal switch so that the RPM of the engine decreases and braking is applied automatically. The mileage and speed of the vehicle has increased since the ECM's came into the vehicles. This increased speed is controlled by ECM in many ways. That is why the Break Switch plays a very important role in the vehicle. PR eee1. The moving vehicle will immediately drop the RPM at a speed of 70-80 Km/hr and will pick up the RPM again when the accelerator is given again. In is way, when the problem occur, the Malfunction Indicator Lamp (MIL) will turn Onin odometer. 2. The vehicle will start jerking at a speed of 40-50 Km/hr. 3. In case of a fault in the brake switch, Tail Lights will remain On. 4. The break switch and accelerator code will appear. (Note):- Therefore the code of the switch break pedal should never be ignored. (CODES) P0703:- Break Switch Circuit. P0724:- Break Switch 'B' Circuit.(Clutch Pedal Switch):- rd (Location):- This switch is attached to the clutch pedal. It can be 2 wires and 4 wires. 2WIRES 4WIRES PeEN (Working):- It functions is when we press the clutch pedal in the moving car then it sends signal to ECM and ECM will reduce the pulse going up to the injector and the RPM of the engine will decrease automatically. The clutch switch plays an important role in controlling the RPM of the engine. (Fault):- 1. If there is a fault in the clutch pedal switch then the code will appear in the scanner. 2. Misfire. 3. If fault occur even after changing the clutch pedal switch and checking the wiring, then ECM may also have a fault. UU Leena eae4, In some vehicle the starter motors will not rotate if fault in the clutch pedal switch (CODES) P0704:- Clutch Switch Input Circuit Malfunction. Preemie eremeaeacec cin(CHAPTER 3) VALVES 1. (EGR Valve):- ___ (Exhaust Gas Recirculating Valve):- (Location):- Its name indicates that it acts as a valve. This valve is attached to the engine and it is of the following two types:- 1.(Mechanical EGR Valve/Mechanic! EGR):- 2.(Electrically EGR Valve / Electrically EGR) GCE Cue Meche tue eee candIt is operated with vacuum. The ECM commands the solenoid valve and the solenoid valve operates the EGR through a vacuum. (Mechanical Fault):~ 1. Mechanical valve clogged with carbon. 2. Vacuum pipes become hard and burst. 3. Damage to solenoid valve. 4. The wires of solenoid valve faulty. 5. The RPM will not increase above 3000 if their is fault in the EGR valve and black smoke emits form the vehicle. 2. (Electrical EGR Valve):- This valve is operated directly by ECM. This valve has a motor and PCB (printed circuit board). (Electrical Fault):- 1. Fault in wiring & ECM 2. RPM will not go above the 3000, engine can emit black smoke. (Working):- EGR valve re-circulates the gases entering the exhaust and sends them to the combustion chamber. The amount of gases entering the intake manifold can be only around 20%. This is done because when the temperature in the combustion chamber rises too high, Nox (Nitrogen, Oxide) and other toxic crue ees cere auaneaccr cudgases are produced in the exhaust gases. An EGR valve is fitted to reduce the amount of these toxic gases. When 2000-2500 degree fahrenheit heat occurs in the combustion chamber, NOx is formed by the chemical reaction of nitrogen and oxygen. When these gases come out through the exhaust, they become dangerous to us and the environment with the reaction of other gases. To reduce their risk and reduce the temperature of the combustion chamber, 20% exhaust gas is re-circulated and added to the intake manifold. By this NOxis controlled with the help of EGR Valve. (Fault):- 1. The engine will emit black smoke. 2. Vehicle speed will decrease. 3. The vehicle willtremor while moving. 4. The engine check light will appear 5. The engine does not rise more than 3000 RPM. 6. The mileage of the vehicle will also decrease. (CODES) P0400:- Exhaust Gas Re-circulation (EGR) System Flow Mal Function. P0403:- Exhaust Gas Re-circulation Control Circuit. P0402:-Exhaust Gas Re-circulation Flow Excessive Detective. P0401:-Exhaust Gas Re-circulation Flow Insufficient Detected. P0404:- Exhaust Gas Re-circulation Control Circuit Range/Perrformance. PIS unas sua eai (Location):- This valve is attached to the engine. (Working):- This solenoid valve is fitted for working of EGR valve and turbo booster and is controlled by ECM. This valve controls. mechanical EGR valve and turbo booster through air vacuum pressure. One ofits wire's has +12V and the other wire has (-ve) voltage from ECM. But when checked with a multimeter, it comes with only 2.3V. This is because the wire in the ECM is connected to the integrated circuit. In many vehicles, with the check of multimeter, the voltage become ‘0’voltage .The ECM control this valve through the -ve voltage. (Fault):- 1. In case of fault in this solenoid valve, the code of mechanical EGR valve and turbo booster will come. 2. Vehicle will not take full RPM. 3. The engine will emit black smoke. 4.The RPM suddenly drop down on the road and the solenoid valve code wi Pcecen erence ce(CODES) P0085:- Exhaust Valve Control Solenoid Circuit Low. P0084:-Exhaust Valve Control Solenoid Circuit . P0086:-Exhaust Valve Control Solenoid Circuit High. P0045:-Turbo/Super Charger Boost Control Solenoid Circuit Open. P0046:-Turbo/Super Charger Boost Control Solenoid Circuit Range/Performance.| Perec mene ere3. (FUEL METERING UNIT VALVE):- | | (Location):- is attached to a high pressure pump. (Working):- This valve is attached on the high pressure pump. The working of this valve is to monitor the fuel from high pressure pump to Rail so that the fuel does not overflow in the common Rail. Secondly, to that the pressure of fuel does not decrease in the Rail. The valve works maintain the fuel pressure in the Rail. This valve is controlled by two wires. The first wire can get 12V from ECM, fuse box and cluster meter. The ECM control this valve through the (-ve) voltage. If in this valve the (-ve) voltage is increased or decreases, then diesel pressure will fluctuate. The voltage of these wires comes to be 2.5v and 3.5v, if we check with the multi meter This is because these wires are connected with the integrated circuit in the ECM. It's job is to send the right amount of fuel from the pump so that the fuel does not overflow into the common rail and the pipes are not damaged in any way. It is controlled by 2 wires viaECM. 12v 3.5v1. It can be delivered 12V from ECM or even from the fusebox and odometer in some vehicles. 2. The ECM command to the second wire (3.5V) (Fault):- 1. Engine No start. 2. Decreased RPM in the moving vehicle. 3. The engine does not rise above 3000 RPM. 4. The high pressure pump does not give diesel to the Rail. (CODES) P0251:- Injection Pump Fuel Metering Control ‘A’ (Cam/Rotor/injector). P0252:- Injection Pump Fuel Metering Control 'A' Range/Performanc(Cam/Rotor/Injector). P0253:- Injection Pump Fuel Metering Control ‘A’ Low (Cam/Rotor/Injector). P0254:- Injection Pump Fuel Metering Control'A' High (Cam/Rotor/Injector). P0255:- Injection Pump Fuel Metering Control'A' Intermittent (Cam/Rotor/Injector). Pacer ad(CHAPTER 4) MULTIMETER (MULTIMETER) | Sane (Working):- With a digital multimeter we can check the following 1DC Voltage 4Continuity Check 5 Resistance Check Voltage Voltage [Econ1. The black wire should be attached to the (-) 2. The red wire should be attached tothe V2. mA Red Probe Black Probe 1 (DC Voltage):- The Symbol of DC Voltage = To check DC Voltage & DC Circuit. Turn the multi meter Rotary switch to DC range and sett 20 Voltage. We can be checking the12v in following figure :- ReGen ane(Voltage Checking):- In cars the voltages is 12v so take the rotary Switch on the Multimeter and set the range of DC20V Be sure to always place the black wire on the negative terminal of the battery and check the voltage by connect the red wire on any wire or sensor. 2 WIRES Red Wire Pree aaeatace caeNote:- If we invert the wires of Multimete: e red wire on the negative terminal of the battery and with black wire we check the voltage anywhere, then the voltage on the multimeter will always show in Negative voltage (-ve). Red Probe to (-ve) Terminal 2 WIRES) [42] Black Probe to (+ve) Terminal ¥ Fl Battery So don’t change these wires (In trucks):- Trucks have 24v. So by rotating the Rotary Switch on the multimeter set the rauge of DC to 200v. Set to the range of Black Probe to (-ve) Terminal Red Probe 2 WIRES [44] Scene cee cansElectricians and mechanics need know of these options on the mu 1. DC Voltage Check. 2. Resistance of wires / sensors Check. 3. To check continuity of wires. (Voltage Checking):- To check the voltage we can connect the black wire to the -ve terminal of the battery and the red wire to those point which we want to check voltage. Turn the rotary switch tothe 20v and 2000 DC in the multi meter. 2 WIRES (Resistance):- To check the wiring harness, one has to check the resistance of the wire from the sensor to the ECM with a multimeter. If the resistance of the checking wire increases then we can take the decision that there is Fault in the Wiring. Pc menecce1. Note: Corrosion in the male and female connectors of the wire wil the resistance of the wire. By checking this way we can estimate the fault. 2. The multimeter will not show any value, if the wire from the ECM to the sensoris cut. 3. With multimeter we can check the resistance of the sensor to find out if the sensor is faulty or not faulty. Continuity Range (CONTINUITY RANGE):- rotats the rotary switch point at continuity range On this range we can detect the ing fault by checking the continuity of any wire from ECM to sensor. If we want to check up to dashboard then we can check the color of that wire on continuity range. Pee eee eee ane(CHAPTER 5) SENSOR CHECKING TE (Checking the sensor with a multimeter):- In this chapter it is stated that by checking the resistance of any sensor we can guess whether this sensor is faulty or ok. Let’s check the resistance of the correct sensor and keep a note so that we can make a correct judgement combining the resistance of the vehicle of the same model or the same sensor. It is the only way to check the resistance. (Note):-By writing the engine model 1 and noting that which two pins out of three pins showing the resistance. Make a note on your copy. Sensor Ok Value's 8609 0hm Sensor Faulty Value's " 1502.0hm Pace een ccca(For Example) Mahindra, Scorpio is not starting and was not giving the scanner code. But when the resistance of the crank sensor was checked, the resistance was 15029. But the Resistance of Ok Sensor should have been 860. This way we can quickly diagnose the fault. Before fitting a sensor, the resistance of the sensor should be checked. How to check Sensor’s Resistance 1. (Crank Sensor TATA) The resistance of this sensor is 2.3 KQ. Ohm. We will check it by keeping rotary switch at20KQ. Resistance 2.38kQ ok Value Tolerance 210% (Faulty):- 4) NoResistance. 2) Wrong Value. 3) It Gives Beep. Pec es3. The sensor will show resistance on any 2 pins in three pin sensor. Resistance = 4899.0hm Ok Value Tolerance=210% (Fault):- 1.No Resistance 2. Wrong Value 3.ItGives Beep Faulty Value = 2002. OR =20002 4, (Delco Point):- Pon eemeaeacccunResistance = 240 Ok VALUE:- To check this, we should set the rotary switch to 2000: Range on the multi meter. Tolerance =410% (Faulty):- 1.No Resistance. 2.Wrong Value. 3. It Gives Beep. 4. (Ignition Coil) (Maruti):- In this example, we have checked the resistance of k - series engine ignition coil. This resistance may vary from company to company. Resistance = 510 Ok VALUE:- To check this, we should set the rotary switch to 540Q range in the multi meter. Tolerance =410% (Faulty): 1.No Resistance. 2. Wrong Value. 3.It Gives Beep. Pace eee ea5. (ABS Sensor):- Resistance = 892 Ok VALUE Tolerance =£10% (Faulty):- 1.No Resistance. 2. Wrong Value. 3.It Gives Beep. 6. (DRV VALVE):- Putting it at 200 range will give the above resistance. If the resistance of DRV is more than 05.52 Ohm, then DRV will be faulty. If either of the two Pee euen eeuDRV pins are beeping when connected with the body of the DRV, then DRV is short. This way we can check the DRV Valve. (Note): If there is an mechanical fault in the DRV valve, Diesel pump has to be checked by the Diesel pump technician. } Resistance Check of Injector 7. (Injector): Body Short Injector Coil Resistance = 1.89 Ohm OkVALUE Tolerance =£10% The above resistance is a Bosch’s injector's resistance. If it does not show resistance or resistance increases after checking with multimeter:-3.5k Q Ohm comes then there is fault in the coil of injector. Some-times the body of the injector starts beeping with the coil, then it will still be short. The Technician check through this method, they find fault of injector Sagnoss Pc eee nee caevery easi Ford- Fiesta Injector (SIEMENS) Resistance = 199k? ok Value. Tolerance =+5% When checked in this way, the actuator should not be short with the body of the injector. As shown above tolerance can be +5% Ifthe resistance increases or decreases then the injector will be faulty. In ford esta or VW if 199M resistance comes, but show 1502 or 2502 resistance then injector become faulty. If the code is related with injector comes then by this method we can diagnose fault very shortly.(CHAPTER 6) WIRING (Check voltage with multimeter:-) 1. Voltage checking +ve 2. Ground (-ve) Voltage check 3. Check the Signal wire 4. Checking the voltage in a three wire sensor: 3 WIRES| 1. (Voltage Checking):- 1. Positive (+ve) : To check the voltage, we will first place the black prob of the multimeter on the negative (-ve) terminal of the battery and attach the red prob to the connector of the sensor. Then rotate rotary switch to DC range 200v and 20v range of the multimeter will then display a value which can be 12v, 5v and 2.5v. 2. (Ground Checking):- Checking Negative:- Pico eremnee asBattery 4. This way we will check the ground with a multimeter. Displays in (Valve)-12v onthe multimeter. 2. We can also check the ground on continuity range. We should move the rotary switch the continuity range and the black wire is connected with the negative pole of the battery and the red wire with the pin of the sensor connecter with the multmeter, then the beep sound comes. By this method the ground wire is checked. Mostly sensors give the body ground. We can check the body ground through the above two methots 2 WiRES| Onchecking the range of continuity the wire which will beep will be connected to the ground of the battery. This way we can find the ground wire. 3. (Signal Check): [aveneq Poe amenwe see that there is one wire left in the connector. In this we see the voltage given below while checking the signal. (Figure No. 2.1) Ground In figure 2.1 the first wire is of 12v and the second wire is of ground and the third wire of 5v and this wire will be of signal. (Figure No. 2.2) Sv SV Ground In Figure 2.2 we see that the first wire has 5v and the third wire also has 5v. Here we will further check the signal wire in 2 ways. When we look at the sensors on the engine, we find two types of sensors. 1, Resistance Type / Piezo Resistive type Sensors 2. Hall Effect Type / Inductive type Sensors (Resistance Type/ Piezo Resistive Type Sensors):- In the above given sensors, to check the signal wire, close the wire connector to the sensor. As seen in Fig 2.2, there is 5v in wire No1 and wire No 3. To find out which wire is signal wire because both wires come from ECM, we check after closing the wire connector on the sensor. PRCo eee csClosed Connector (Figure No. 2.3) nv Ground It can be seen Fig 2.3 the voltage in wire No.3 decreases from 5v to 2.5v in signal wires closed connecter voltage decrease. By doing so, we can check the signal wire in resistance type sensor. As the RPM increases the voltage will fluctuate in this signal wire. we check the signal with multimeler in close connector. (Piezo Resistive /Resistance Type Sensors):- 1)Mass Air Flow Sensor i 2)Rail Pressure Sensor 3) Boost Pressure Sensor 4) Coolant Temperature Sensor 2. (Inductive Type Sensor/ Hall Effect Type Sensor):- We have to take the help of DSO (digital oscilloscope) to detect the incoming signal wire to these sensors as we cannot measure frequency with a multimeter nor does fitting a wiring connector in these sensors reduce the voltage in the signal wire. So by checking the frequency with DSO we can find the signal wire. be. acer eeewv 5v (Hall Effect Type Sensors/ Inductive Type Sensor):- 1. Crank Sensor 2.Cam Sensor 3. Speedo Meter Sensor 4, Wheel Sensor/ABS Sensor In the above sensor’s, we can’t check the signal wire through the multimeter on close connector because the voltage does not decrease in the signal wire like in fig. 2.2. We can not guess which wire of the sensor gives signal to the ECM. For this, in Hall effect type or inductive type sensor’s we can take the help of DSO to check the frequency in the wire and guess which wire is signal wire. Because sensors gives signal to the micro processor of the ECM. The sensor give frequency through the signal wire to the ECM. This frequency can’t found through the simple multimeter. For this, we can check with the help of DSO and in which wire we found the frequency that is signal wire. In the above way we can check + ve,-ve and signal wires in wiring and sometimes if any of these 3 wires is broken then we check with multimeter and find voltage is'0". This way we can quickly guess on the wire coming from the ECM or the other side that there is fault in the wiring. 1. First, we put the red probe of multimeter on sensor connector and black wire on -ve terminal of the battery. Then the multimeter shows the value'0". 2.Again we put the red probe of multimeter on the same pin of the sensor CUR nee eaeconnector and black wire o +ve terminal of battery in this way, we can diagnoses the fault easily. If the wire is broken from some where then the value is '0' show in the multimeter. Make a note of these numbers and also note down the COLOR CODE of these wires the copy so that when you need to check the Voltage, you see in your copy. 3. (Mass Air Flow Sensor):- OPEN CONNECTOR CLOSE CONNECTOR iv This sensor has 2 signals, so in close connecter, the voltage of 2 wires have decreased. 1. Mass Airflow Sensor 2. Intake Air temperature Sensor In this way, we can recognize the +ve,-ve and signal of the sensors with multimeter. In this step, we can find the voltage of any sensor and write the number (that gives on connector), in our notebook and also noted the colors of the wires. if we will write clearly in our notebook which wires has which color code. Sometimes sensor’s female connector is broken and connector also changed, it is difficult to find the wire color properly, If technician write proper data then it will be easy to diagnose problem.(CHAPTER 7) OBD CONNECTOR a (Location):- 16 pin OBD connector is attached on the driver side in 70% of the vehicles. Itis used for scanning a vehicle. With this OBD connector we can read every module (electronic) in the vehicle. Around year 2000, this connector was of 2 pins or 3 pins. (Example.):- It used to come in Palio diesel and Honda City but now most of the vehicles have only 16 pins connector. The technician does not need to fit separate connectors for scanning. (Type of use):- This connector has 16 wires and what is their function and how much voltage it contains:~ eee(Special Note) The scanner should be connected only after checking the voltage of the OBD| connector as the 4 numbered and 5 numbered pins attached to it are grounded. Sometimes due to short wiring a (+ve) positive voltage comes In| these wires and connecting a scanner without checking the voltage can| damage the scanner. So special care needs to be taken to avoid damage. (Pins,4 and 5):- Gin 3):-This is chassis ground Pin. €in5):-This is sensor ground Pin. Sometimes there is a communication error then the ground should be checked on 4and 5 number pins. Some times the wire of the 5 number pin gets lost in the wiring is broken in then wire of the scanner is connected to OBD connector and engine starts when the connector is removed then engine will shut down again, If this happens then the wiring may break somewhere. - Can High Control Area Network: We can check all data through this wire and it will have voltage from 2.5v to 3.5v. :- K-Line:Many companies check fault through k-line. It may have 12v_ when checked. -Not Use intd- CAN Low Control Area Network : Through this wire we can check the fault of the modules attached to the vehicle and it has voltage from 1.5 to 2.5V. :-NotUse :+ Battery Power : In this wire we have given (+12) voltage from direct fuse and if (+12) is not in it then scanner will not be ON then ii they are intertwined. i 6NoPin : CANHigh 1 44NoPin : — CANLow CLUSTER METER (resnnenuscccseevescureneen: These two wires go from the OBD connector to each module and transfer data to another module. The distinguishing feature of these wires in wiring is that CANLow (OBD Connector) ABS AIR BAG 1. (Checking of CAN High Or Low:)- (Checking of CAN on the OBD Connector): Touch the black wire of the multimeter with the body Ignition On and attach the red wire to pin number 6 and see the voltage coming in the following range in CAN high. eost { { ! t i i : 1. No. Pin 2.5v to 3.5v Tolerance=+ 5% Can Low: 14No. Pin 1.5v to 2.5v Tolerance=+ 5% Total Voltage of Both Wires---—-5v Touch the black wire of the multimeter with the body on ignition On and attach the red wire to pin number 14 and see the voltage coming in the range mentioned above in low CAN. The total voltage of these two wires should not exceed 5v. Tolerance 5V+ 10% Ignition On 2. (Second way to check):-(Ignition Off):- (Ignition Off):-The above figure (as per 1.1) set the rotany switch of the multimeter to rotation (200 Ohm) and check the resistance on pin number 6 and pin number 14, Their resistance should be 60 ohm Tolerance +5% This resistance of CAN High and CAN Lowresistance is(120 Ohm) on ECM pin. (Note):- The wire numbers of different companies on the ECM may also be different (Fault):- lf the scanner is not connected to the vehicle and the code of No communication is received then the voltage and resistance of the CAN wire should be checked. (Code. U0100): If U0100 starts the code from U in the scan then itis related to CAN. If there is code related to any module then check CAN High or CAN Low going to that module. FOREXAMPLE:- Some times it has been observed that the vehicle does not start when the ABS module is faulty in vehicle. The engine starts when the connector is removed rom the faulty module. In this type of fault, it has been observed that there was a big difference in the actual voltage of the CAN wire in the faulty module and thus ECM was getting wrong signal from ABS. In this condition the processor in the ECM stops giving pulse on the injectors. ‘So we can estimate the fault in the faulty module by looking at the voltage of the CAN wires and checking the resistance of the CAN wires. (CODES) U2101 :-Missing Data for Seat Motion/ Control. aE en eee(CHAPTER 9) Relay We are dealing with the related components of the ECM in this Chapter. | (Definition):- Relay is applied to give full power to any actuator. ECM mostly gives negative and turns on ECM relay on (-ve) Voltage. Relay then takes the whole ampere from the direct battery through the fuse box and gives (+ve) Voltage to the fan, AC compressor, fuel pump. Relay is attached between these components. Even if these components become short, the ECM is saved from being short. Vehicles have 4 pins or 5 pins relay. cece ene1. (4 Pin Relay):- This is a basic common relay. This relay has 4 points. How much voltage should come to these 4 points for the relay to turn On is shown inthe fig. 0 87 30. At this point +12 voltage Is given from direct fuse box this point can also have (-v) voltage depending on the company. 86. At this point +12 is given from ignition. 85. It comes negative from ECM and when checked with multimeter will show 3.5 voltage multimeter at this point. 87. At this point the voltage is out to turn On any actuator. (Note): This describes the basic voltage of a 4 pin relay. Sometimes companies even change these points. But basically +12 voltage will come in 2 pins and relay voltage will come outin 1 pin.2. (Main Relay):- Main Relay plays a very big role In the vehicle. In this chapter we are discussing how itturns ON and how Itworks. (Types):- Main Relay has 4 pins or 5 pins. 1.30 comes from the +12v direct fuse box this point. 2.86 comes from +12v Ignitions at this point. 3.85 at this point comes from-12v ground ECM. When checking the voltage with a multimeter at this point, the multimeter will show 2.5v. If the point Is not written on the relay then we can guess from which pin Is the ground coming from ECM. Due to this Integrated circult, 2.5v will be visible on the pin of the relay. This point should always be checked with a multimerter as follows:- Wiring | _—Eonnector ]85 ECM Ground Red Prob Black Prob If checking with multimeter at this point does not show 2.5 voltage then:- 1. Check the wire by placing it on the range of continuity from ECM ifthe wire is giving continuity. I wii ing |—Co nnector i { i { { ; i i t { ' ' i } i i t i ; 4This wire is OK then this fault may occur in ECM. 87. After giving +ve and -ve voltage on the remaining three points of the relay, the relay turns On. The main relay turns out the voltage from 87 points which turns On the ECM by its thick wires. So if the scanner is giving us the code of the main relay then it should work by checking the voltage on the points of the main relay. If the voltage between all the points is correct then try to change the main relay. Therefore ECMis half On before main relay is On and full ECM is On only after main relay is On. Therefore main relay plays an important role in trucks/ cars. Main Relay Circuit:- How is main relay On in those vehicles which has ECM. The direct voltage on Pin No.30 of the main Relay comes from fuse box. When we ignition On, then in 86 pin of main relay comes (+12v) and the current reaches to ECM. The ECM become 50% On at the time of ignition On. After the main IC of the ECM become On then ECM gives (-ve) voltage to the 85th pin of Main Relay. By this, the full circuit of main relay is complete and its become On. By this way 30th pin meet with 87th pin points of Main Relay & ECM become 100% On and check light comes in the cluster meter. If the engine check light does not come in Truck & car then we should check the main relay and see whether the 87th pin of main relay gives out put to ECM or not. Note:- It depends on the manufacturer to which pins gives (+ve) and (- voltage in the main relay.(CHAPTER 10) SCANNER (PS 70 Pro) (AUTEL) (G-SCAN) (LAUNCH) (SCAN PLUS) bas (Scanner Introduction):- Ascanner is a device that has brought a revolution in fault diagnosis. At first we used to find faults in the cars of some companies manually and after that:: For example how many times the light was blinked in the cluster meter by shortening any 2 pins of OBD connector and then the code was checked in manual. After this, as the progress continues, to find fault in the vehicle quickly, then it was necessary to have a machine that could find fault perfect and quickly. This was done by machine, which is called car fault diagnose (scanner). At the time of starting, the OBD connectors of many companies were different. Such as 2 pins, 3 pins etc. and later 16 pins connectors were used by most car companies and most of the heavy duty trucks companies. 4. The scanner has enhanced the technician’s ability to diagnose the fault. Ascanner is a machine that guides what is wrong with our vehicle and on which faulty part we should be working. PRme eee neces(Working) The function of the scanner is to read the processor of electronic module in the vehicle. The scanner reads the processor of these modules through the CAN wires. If there is any fault in the vehicle and one (MIL) light is On in the cluster meter. When this MIL light is On, we have to diagnose the vehicle with a ‘scanner. We can find by scanning different modules that to which module this MIL light belongs. New Generation:- There are more than one module in the vehicles. There are many parts in them which have to. be changed and adapted so that the part starts working Properly. (For Example):- 1. Any module needs to be changed. 2. Injector coding 3. Immobilizer matching ete. Why itis Compulsory to buy a scanner:- At first we worked with guess. It used to take a long time to diagnose a fault. Fifteen years ago, most technicians did not have scanners, which forced them to repair a car in a week or 10 days, and very few people outside the company did that. But now no one has enough time to waste and the scanners which were around priced two lakhs, now have started from Rs. 40000 only. The technicians who took the scanner 12-15 years ago are doing a great job today ACURA CUS ee eaand new generation cars are coming to them and updating. Whenever a new technique comes along the customer gives you time and money to work. First the mechanics who were asked to buy the scanner then they said there is no need to purchase any tool, When new technology comes in the vehicle, then it is become difficult to find the fault and their performance comes down, so later they also purchased the scanner . The technicians who took the first scanner have taken many other types of scanners today. Suchas:- 1) OEM Scanner Tool 2) Meter Repair Tool 3) Key Programmer So we need a scanner. Today no one has the time. If we (install) ascanner on a vehicle, then we start working by giving it a charge (fees) but once (installing) a scanner, working on the same fault code does not solve the problem. So we have to install scanners many time. In addition to the code with the scanner, the actual reading of the sensor has to be checked The problem is not solved until the code is cleared with the scanner after the work is done. Therefore, technicians who do not have scanners have a reduced performance. (PS 70 Pro) (LAUNCH) (G-SCAN) Le a (Scanner Functions):- After turning On the scanner, first we select the area in Europe, Chinese, Asi: etc. After selecting the company, the model of the vehicle is selected.i 1. (Health Report):- After checking this option, all the modules in the vehicle are automatically scanned. In this option, the codes of all the modules appear onthe screen. 2. System Scan:-In this option all the modules are scanned. This option takes more time. If we want to check the code in one module then we can check after scanning all the modules. 3. System selection:- In this option we can see the fault by selecting one module atatime. It saves a lots of time. After selecting the system selection version information it contains information about all the modules we scan:- 4) VIN No... 2) Software No. 3) Hardware No & etc (Read Fault):- Fault is read in this option. In this option, when we read and see the fault, we see two faults:- 1) Current Fault/ Active 2) History Fault 1 (Current Fault/ Active):- This code come with the name of read fault code. For example, current & active. It's meaning those fault which are present in our vehicle & for this nc oe ee ae ceareason MIL light appears in cluster meter. 2 History Fault It is written under the name of Fault (read fault code). Sometimes the ! technicians remove the connector of the sensors while repairing the car and { fit it back then these faults are saved in the module. After clearing these ! codes, these codes do not reappear. It has been observed many times that if it + is in Code Current then it shows the same in code ECM processor history. (Read Data Stream):- Actual Reading:- In this option we.can find out the performance of any sensor and actuator that how many percent it is working. With the help of this data we can quickly diagnose fault by looking at the working of any actuator. (Actuation Test):- By going to this option, we can see ACTUATORS by ON-OFF. It depends on the vehicle company how many options it gives. Fuel Pump: DRV-----—---On———-— OFF Fan ------. ene) onnmnnnnnennne- OFF Injector mee) -nnmnnmmnnnnn=- OFF(Special Function) :- In this option some companies give extra work like when we change the injector, then the injector number also changed. By this special function we canchange the injector number. Some companies gives extra functions. Like 1) ECM Change 2) Steering Calibration 3) Throttle Learning 4) Injector Id Change/write (Program):- By this option we can change any module that's given by the different companies in the vehicles. Be careful if we do not know the function of coding (Immobilizer) never give any command on this option. Otherwise vehicle's engine may stop. CODE DESCRIPTION How to find the Code description P--------_ power train B------- body C------- chassis U-------- CANn network Like:- 1. (P):-The fault code started with Alphabetic 'P' are related to Engine & transmission gear.P0101:-Mass Air Flow Circuit Range/performance. P0701:-transmission Control System Range/performance. 2. (B):- The fault code started with Alphabetic 'B' are related to body control module. Like :- (BCM, Wipers Lights, Center Lock, Roof Glass) and there are many more functions which are controlled by BCM. EXAMPLE:- B1240:-Wiper Washer Rear Pump Relay Circuit Failure. B1301:-Power Door Lock Circuit Open. 3. (C):-The fault code started with Alphabetic ''C’ are related to chassis. Example :- ABS, EPS 1095:-Abs Hydraulic Pump Motor Circuit Failure. 1445:- Speed Vehicle Signal Circuit Failure 4, (U):- The fault code started with Alphabetic 'U' are related to CAN Network. Example:- U1051:- Scp Invalid Or Missing Data For Brakes. U1200:- Missing Data For Seat Motion. PicoOBD Il FAULT CODES:. P0Oxx:- Fuel And Air Metering P03xx:-ignition System And Misfire Detection P05xx:-Vehicle Speed P0600:- Control Module In Software Problem P0700:-transmission DTC (P106E85) PO to P3 powertrain 0150/SAE FTB BO to B3 body 1)MANUFACTURE Failure CO to C3 chassis 2)ISO/SAE Type U to U3 network 3)ISO/SAE Bytei (CHAPTER 11) DIAGNOSE PHILOSOPHY Ccsccnacccan (How to diagnose first time:- How to find Fault for the first time? 1. Customer Complaint 2. Fault diagnose with scanner 3.Read Fault 4. Actual Reading Check (CUSTOMER COMPLAINT) 1. First of all, we will ask the customer about the problem occurring in the vehicle how and how many times it has come before. If any kind of work on vehicle has been done or not as sometimes some kind of fault can be related to the work done. Before from history we can quickly reach fault. 2. Fault Diagnose with scanner:- Before working, we will diagnose the fault with the scanner and click the screen shot/image of these fault codes. More codes may come on the first time scanning. After clearing these codes, the engine will start and if the code does not come again, we can take the try of vehicle. Take a screen shot of the codes that have been scanned again or copy and note them down then work on these codes. 3. Actual reading:-The codes that are coming after clearing with scanner. We will also take a screen shot of the actual reading of those sensors and guess from the actual reading whether the reading is wrong or right. PRC iaeae er cueFor Example P0087:-Fuel Rail Pressure Sensor Control Circuit. P0117:- Engine Coolant Temperature Circuit High. P0504:-Brake Switch Control Circuit Low. P0380:- Glow Plug/short Circuit We can estimate for their actual reading how much value they are giving. lf these codes are appearing in any vehicle and if there is starting problem then most of the technicians start working with related fault codes with diesel. Sowauocccaucanaacccnccesaacsaz=cneaccoaeeeaeey Suchas:- 1. Check by replacing sensor. 2. Wiring Checking. 3. ECM Change. Too much time is wasted on these tasks. So how do we work on this philosophy? First of all, out of all the fault codes that are coming, the ones that we can fix by working quickly For Example:- 1. Break Switch 2. Glow Plug 3. Coolant Temperature 4. Rail Pressure Sensor Before these four codes, we should start working as above. This takes less e and works faster. Sometimes the problem is solved with a code that is not even thought of in mind. RCo uence cisSTARTING PROBLEM:- 1. QUADRAJET ENGINE may also have starting problem when glow plug is short. Sometimes we ignore the code of glow plug while working. 2. FAULTY COOLANT TEMPERATURE SENSOR may cause starting problem. This is not necessarily the case with the code associated with the starting problem in diesel engine. If more than one sensor comes on the same pin in (+ve) voltage from ECM then with one sensor short, more than one fault starts coming and by correcting one fault all code are deleted. So as long as a single code is coming and the vehicle is giving problem to run, the work should be done in another direction only after fixing the incoming fault. 1. First ask the Customer about the problem in the vehicle. 2. Connect the scanner. 3. Write Code. 1 4.ClearCode. i 5. Take try & then write the Code 'that appeared. Work on codes that will be Solved first and soon are easy to rectify. 6. Check and note the Actual, correct Reading in Scanner of the Code that has come. 7. Check the wiring of fault code one by one to the Solve and check the Voltage as well. 8. Explain the language of the Code that Scanner is giving. The Code belongs toan Actuator or belongs to Sensor. for Example:- P0091:- Rail Pressure (Regulator valve) Circuit P0087:- Rail Pressure (Sensor) Circuit Note:- Here’s how to do it. Sensor’s Shape may vary from company to company and Voltage may vary from wire to wire. The Color Code of the wire can also be different. We must record the data of each vehicle in order to operate. fipceun un(CHAPTER 12) STARTING PROBLEM What check to start any CRD! Truck/Car. If we have a Starting Problem. For Example:- First ask the customer about complaint. Whether the engine Late Start or Whether the engine no Start? After asking Complaint we will first check the Scanner to see if the Code is appearing the Scanner. If Code is appearing in Scanner then we will check Actual Reading with Scanner. If scanner is not displaying any code, then check the following 1. Rail Pressure (How much Rail Pressure is coming) 2.R.P.M. of Engine 3. Voltage on Battery 1. (Rail):- First we will check the Rail Pressure. With the scanner in the common Rail. There should be at least 150 Bar Pressure between 250 Bar Pressure. At and at the time of Cranking the engine there should be at least 150 Bar Pressure in common Rail. If there is not enough pressure then find the reason:- 1. Injector Back Leakage Check. 2, DRV Mechanical Fault Check. 3. Diesel high presser pump and fuel metering unit check. 4, Low Pressure Pump & Fuel Filter check. There may be other reasons besides these. See them in the Circuit Inspection of Rail Sensor fuel Metering Unit. eee eee eaeRail’s Pressure can be in the following Unit. MPA BAR 25 250 This is how different companies may have given Rail Pressure in different Units. If Diesel’s Pressure in Rail is getting above 150 Bar then go to Next Step. 2. (RPM):- We will check this by going to Actual Reading with Scanner. Check Engine Speed in Actual Reading, Engine Speed must be at least 180 RPM or more. The engines of many companies start even at 160-180 RPM. So keep a note of the data of the vehicles coming to us. But if the RPM of Quadrajet Engine is less than 200 then Starting is delayed and Code does not appear in Scanner. (Faulty Area):- If RPM is not being formed then it has to be seen that whether the Self Motor on the engine is fine or there is Fault in it. Sometimes even with self Repair, the Self does not produce the full RPM. ‘Starting is only corrected by changing Self. Be aware that we have to keep the Data of the vehicles coming to us so that we know that at how many RPMs engine starts. 3) Voltage Check:- If both the above steps are correct then we should check the Voltage of Battery. We can check it with Scanner and also with a multimeter. In this Step we will cranking the engine and Battery Voltage will remain till 9v. Even if the engine crank revolves but the engine will not start in this Condition. The Fault Code will not appear in the Scanner. So try to change the battery. In thisqranseaaneusassnssaesacsaassecsaceeoneeneeeaeen condition, the battery voltage should be at least 10v. 1. Sometimes it has been observed that if the vehicle suddenly stops while moving then it can also be a Battery Fault. 2. Crank Sensor also gets hot and quits giving signal to ECM and thus the i staring is late. RailPressure - 200BAR Okcondition R.P.M. - 210 Ok condition Voltage - 10V Ok condition Sometimes it has been observed that all the above parameters are correct How to find Electrical Fault, Mechanical Fault, or ECM Fault. But Problem is still coming in Vehicle and no Code is appearing in Scannerso how do we find that fault is Electrical, mechanical or inECM In this Situation we will take out an injector from the engine. After cracking the engine to check if the Injector is spraying or not. We will cracking continuously and see spray should be give at least 20-25 times. If the injector is turned off by spraying 2-3 times, there will be a fault related to diesel or a -faultrelated to Crank Sensor and CAN Sensor. But if the Injector is spraying 20-25 times then we can Say that there isno electrical fault in the Vehicle, no fault in the wiring and no fault in its ECM. (Mechanical Fault) :- 1. Piston ring worn out. 2. Head valve seats are at fault. 3. Turbo is spraying on pistons. 4. Check the Time of cam and crank in the engine.(CHAPTER 13) DIFFERENCE BETWEEN VALVE OR ee In this Chapter, we are writing about what is the Language in Scanner so that we don’t have to read about Code every time and get advice from any one. Most technicians do not read the Code care fully and start working. Such as :- P0193 : Rail Pressure Sensor Circuit Malfunction P0001 : Rail Pressure Regulator Valve Circuit Mal Function When such codes come, many technicians do not read the Codes carefully and start working only after watching the Rail Pressure. One of these Codes has Rail Pressure Sensor written in one Code and Rail Pressure Regulator Valve in the other. By this we can trying to change the Rail Presser sensor and sometime regulator valve change. For this lots of time is wasted. (Sensor):- These are the Parts attached to the engine which sense movement of the engine and send to the ECM which we called a signal. These sensors gives signal to the ECM as to how much air is going into the engine, how many