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Actron CP9087 Automobile Accessories User Manual

1. the sensor Black FORD Yellow Red HONDA 1 HONDA 2 Honda uses two sensor types Try hook up 1 first If good test results are not obtained retest Red Yellow Red using hook up 2 Yellow Black before judging sensor Refer to vehicle service manual for connectors not shown Hook up as follows Red test lead to sensor power pin Yellow test lead to sensor signal pin Black test lead to sensor ground pin 2 17 Section 2 MECS Eu Typical Oxygen Sensor What is It oxygen sensor is a zirconium dioxide ceramic mounted in the tip of a threaded metal housing The tip is perforated to protect the sensing element but still allow exhaust gases to pass through The sensor produces a voltage signal based on the amount of oxygen it contacts A low voltage indicates a lean exhaust too much oxygen A higher voltage signals a rich exhaust not enough oxygen The sensor must be very hot to operate 349 C 660 F Many have 2 wire heating elements built in to quicken the warm up time How itis The computer uses this sensor to calculate used optimum air fuel mixture for low emissions and good fuel economy If the sensor indicates a rich exhaust not enough oxygen because of too much fuel the computer will compensate by reducing fuel delivery If the computer receives a lean signal too much oxygen because of too little fuel it
2. a az Section 2 Ii Eae 5 5 yx Yellow E N Black Black What is It The knock sensor is piece of piezoelectric material mounted in a metal housing The sensor acts like a microphone it changes vibrations into a small AC voltage signal The sensor usually has a one wire or two wire connector How itis computer or other spark timing controller is used designed to recognize sensor signals caused by engine knock vibrations Then spark timing is retarded to eliminate the damaging knock condition Location Usually threaded into or bolted on the engine block intake manifold or exhaust manifold Often near the cylinder heads When to Test Related trouble codes sent by computer Knocking during cruise or hard acceleration not enough spark retard hesitation poor perfor mance and fuel economy excess spark retard What to sensor operation see test on page 2 27 Poor In t connections at sensor or computer Faulty sensor SPEC wiring open or short circuits Spark timing Bad fuel quality Engine KNOCK Knock Sensor Test Procedure Sensor may be tested on or off vehicle Warning Observe all safety precautions see page ii if testing sensor on vehicle 1 Verify ignition key is OFF 2 Check Tester battery refer to page 1 4 3 Disconnect wiring harness from sensor Inspect for damage 4 Connect test leads to sen
3. You must follow vehicle service manual cautions when working around the air bag system If the cautions are not followed the air bag may open unexpect edly resulting in personal injury Note that the air bag can still open up several minutes after the ignition key is turned OFF or even if the battery is discon nected because of a special energy reserve module Always follow vehicle manufacturer s warnings cautions and service procedures Section Tester Basics Description of Controls and Accessories Installing and Checking the 9 Volt Battery Note Detailed procedures for testing sensors and ignition modules are located in Section 2 sensors and Section 3 ignition modules 1 Controls power to the Tester and selects measure ment range sensitivity as required by various RANGE sensor tests Switch POWER OFF No power supplied to either the tester or RED test lead LOW Tester powered up for use Voltage from 9 volt battery supplied to RED test lead Selects range for measuring low levels of voltage resistance or frequency HIGH Tester powered up for use Voltage from 9 volt battery supplied to RED test lead Selects range for measuring higher levels of voltage resistance or frequency 2 Selects the type of signal being measured for conducting sensor and ignition module tests Different FUNCTION kinds of signals are used by various sensors Switch VOLTS Measures vol
4. CP9087 SENSOR TESTER C Vehicle Service Info The following publishers have manuals containing diagnostic information for electronic engine control and ignition systems Contact the publishers for availability and pricing specifying the make model and year of your vehicle Some manuals may be available at auto parts stores or your local public library Vehicle Service Manuals from General Motors Corporation Buick Cadillac Chevrolet GEO GMC Oldsmobile amp Pontiac Helm Incorporated Post Office Box 07130 Detroit MI 48207 Saturn Adistra Corporation c o Saturn Publications 101 Union Street Post Office Box 1000 Plymouth MI 48170 Vehicle Service Manuals Chilton Book Company Chilton Way Radnor PA 19089 Cordura Publications Mitchell Manuals Inc Post Office Box 26260 San Diego CA 92126 Haynes Publications 861 Lawrence Drive Newbury Park CA 91320 Motor s Auto Repair Manual Hearst Company 250 W 55th Street New York NY 10019 Suitable manuals have titles such as Electronic Engine Controls Fuel Injection and Feedback Carburetors Fuel Injection and Electronic Engine Controls Emissions Control Manual or similar titles Vehicle Service Manuals from Ford Motor Company Ford Lincoln Mercury Ford Publication Dept Helm Incorporated Post Office Box 07150 Detroit MI 48207 Vehicle Service Manuals from Chrysler Corporation Chrysler Corporation Dyment
5. Set RANGE switch to LOW 8 Set FUNCTION switch to FREQUENCY 9 Operate sensor Watch PULSE light for results Note Ignore any TEST light action Section 2 Bii inn Esa On Car test Crank engine STAY AWAY from moving engine parts Observe all safety precautions see page ii engine may start or backfire _ Good sensor PULSE light flashes or stays ON during cranking varies with sensor type Bad sensor PULSE light OFF during cranking Note Some computer systems will store a trouble code in memory and turn on the Check Engine light if engine is cranked with sensor disconnected Ignore or erase the code after testing Refer to vehicle service manual Off Car test Slide a flat piece of iron or steel in and out of the sensor slot Use a scrap piece of sheet metal knife blade steel ruler or similar Good sensor Single flash on PULSE light whenever metal is moved in and out of slot The flash will occur either when the metal enters the slot or when it is removed depends upon sensor Bad sensor PULSE light OFF during testing 10 Testing is complete Set RANGE switch to POWER OFF and remove all test leads Yellow Black QU Chrysler Distributor Hall Effect Ford Distributor Hall Effect PIP Sensor TFI IV Ignition Section Testing Ignition Modules Save yourself time Always begin with a thorough visual and hands on inspection You can often find the cause of m
6. for testing GM 1988 2 8L Mass Airflow Sensor 5 pin only also has a built in air tempera ture sensor Use same test procedure as for vane airflow temperature sensor Refer to page 2 34 for testing Sensor may be tested on or off vehicle Warning On car testing involves running engine Observe all safety precautions see page ii Work in well ventilated area 1 Verify ignition key is OFF Allow engine to cool to outside temperature before testing 2 Check Tester battery Refer to page 1 4 Set RANGE switch to POWER OFF when done 3 Disconnect wiring harness from sensor Inspect for damage Some vehicles use a metal snap ring to secure wiring harness to sensor Remove this snap ring before discon necting wiring harness 4 Off Car testing only Remove sensor Be careful of coolant spillage from mounting hole if removing engine temperature sensor 5 Connect test leads YELLOW to either sensor pin BLACK to remaining sensor pin E Yellow Black Engine Air TEMPERATURE HIGH LOW RANGE VOLTS OHMS FREQUENCY FUNCTION 6 Verify test clips make good contact and do not touch each other Make sure red and green test clips are not touching anything 7 Set RANGE switch to HIGH 8 Set FUNCTION switch to OHMS 9 Note TEST light position on tester If the sensor is good the light will move downwards as the sensor heats up 10 On Car test only Disconnect test leads and reconnect sensor to vehic
7. 1 first If good test results are not obtained retest using hook up 2 before judging sensor Nissan uses two sensor types Try hook up 1 first If good test results are not obtained retest using hook up 2 before judging sensor MN m py Black Yellow Refer to vehicle service manual Hook up as follows Red lead to sensor power pin for connectors not shown Yellow lead to sensor signal pin Black lead to sensor ground pin Section 2 iE Eu TEST PREPARATION All Air Flow Meter Sensor Tests IMPORTANT Test all hook ups shown for the sensor The letter next to the hook up refers to the test procedure for that hook up Each hook up should test O K Exception If two hook ups are marked with an asterisk only one of the two hook ups has to test O K This is neces sary because some sensors look alike but have different internal connec tions Sensor may be tested on or off vehicle Warning Observe all safety precautions see page ii if testing sensor on vehicle 1 Verify ignition key is OFF 2 Check Tester battery Refer to page 1 4 Set RANGE switch to POWER OFF when done 3 Disconnect wiring harness from sensor Inspect for damage Some vehicles use a metal snap ring to secure wiring harness to sensor Remove this snap ring before disconnecting wiring harness 4 Disconnec
8. GROUND MAF SIGNAL 1989 Newer FUNCTION on FREQUENCY MAT SIGNAL MAT RTN POWER GROUND MAF SIGNAL 1988 2 8L only RANGE on LOW FUNCTION on FREQUENCY GROUND MAF RETURN MAF SIGNAL BURN OFF SIGNAL POWER All 5 Pin except 1988 2 8L RANGE on HIGH FUNCTION on VOLTS MAF SIGNAL Fo rd a MAF RETURN RETURN is not connected to vehicle GROUND tt GROUND POWER RANGE on HIGH FUNCTION on VOLTS Refer to vehicle service manual for connectors not shown Section 2 2772217 Vehicle Harness Connectors for MAF Sensor Mating side of connector shown MAF MAF Signal Ground Power Power Ground Signal Signal Ground Power Pulsar NX SE All except 1987 88 1987 88 Pulsar NX SE only E 1 ekkel 615151 EI MAF Signal Ground Power Ground Power Return Signal 1987 Pulsar NX 1985 86 Maxima 1987 Sentra E161 1985 86 300ZX 1988 Pulsar NX XE 1985 86 300ZX Turbo 1988 Sentra Erkko gt t a MAF MAF L E Power Ground Signal Signal Ground Power 1987 88 Maxima 1987 88 200SX SE 1989 90 Sentra 1987 89 300ZX 1990 Pulsar NX Ll Ei EERE C MAF MAF MAF Signal Ground Return Power Power Ground Signal 1989 and Up Maxima All Nissan xL 1 1 DX FUNCTIO
9. Hall Effect These are described below along with Optical types which are in limited use e Magnetic basic reluctance sensor consists of a permanent Reluctance magnet with a coil of wire wrapped around it Nearby the sensor is a toothed ring made of iron or steel sometimes called a reluctor The ring is attached to a rotating component such as the crankshaft or camshaft Whenever a tooth from the ring passes by the sensor it attracts the magnetic field lines surrounding the magnet As the field lines move they pass through the wire coil and generate a small voltage pulse magnetic induction principle Thus a voltage pulse is generated every time a tooth passes by the sensor coil Crankshaft Camshaft Position HIGH SHUTTER SIGNAL ut SWITCH VOLTAGE GROUND MAGNET SIGNAL LOW ROTATION Typical Hall Effect Sensor Typical Sensor Signal Voltage Hall Effect Optical The computer determines rotational speed or position by measuring how fast or when pulses appear Note The voltage pulses get larger when the teeth pass by more quickly Values can range from a fraction of a volt crank RPM to over a hundred volts high RPM The basic Hall effect sensor consists of a permanent magnet and a small module containing a transistorized Hall effect switch Power and ground connections are required for operation A small air gap separates the sensor and the magnet The magnet
10. Set RANGE switch to HIGH 7 Set FUNCTION switch to OHMS 8 Observe TEST light for test results Good Heater TEST light OFF low resistance Bad Heater TEST light ON in any position resistance too high or open circuit 9 Heating Element test is complete Set RANGE switch to POWER OFF and remove all test leads Go to On Car Test Section 2 317775 On Car Test Important Reliable testing of the oxygen sensor while on vehicle is very difficult because test conditions cannot be well controlled If the sensor responds during on car testing then it is probably good and no other tresting is necessary If the sensor does not seem to respond when tested on car remove it and perform the off car test before deciding whether or not the sensor is bad Warning This test involves running the engine Observe all safety precautions see page ii Work in well ventilated area 1 Verify ignition key is OFF 2 Check Tester battery Refer to page 1 4 Set RANGE switch to POWER OFF when done 3 Connect test leads YELLOW to sensor SIGNAL circuit BLACK to good vehicle GROUND Keep sensor connected to vehicle wiring and use backprobe adapter to contact sensor SIGNAL circuit if possible If you cannot use backprobe disconnect sensor connector and connect YELLOW test lead directly to sensor SIGNAL pin Note Most computer systems will store a trouble code in memory and turn on the Check Engine light if
11. This sensor sends a dc voltage signal to the computer is It indicating the amount of air entering the engine The voltage signal increases as the air flow increases The sensor assembly has a pivoting door vane which is opened by incoming air The vane is connected to a potentiometer a variable resistor like a dashboard dimmer control which generates the voltage signal Some sensor assemblies also contain an air temperature sensor or a vane position switch or both How itis computer needs to know incoming air flow to properly used adjust air fuel mixture and ignition timing for varying E engine load and operating conditions Location sensor is mounted in the engine incoming air duct between the air cleaner and the throttle body When tO Related trouble codes sent by computer Test Driveability problems such as hard starting rough idle stalling hesitation stumble surging knocking ping ing poor fuel economy black exhaust smoke backfir ing catalytic converter overheating or no torque converter lock up Sensor operation see tests on pages 2 43 through 2 44 What to Poor connections at sensor or computer Faulty sensor Inspect wiring open or short circuits Airflow obstructions in ductwork or clogged air filter Binding pivot on vane door Air leaks around sensor or throttle body Vane Air Flow VAF Sensor Connectors Toyota Toyota uses two sensor types Try hook up
12. down as sensor is operated The TEST light may go off if it moves to the bottom of the column this is O K Range of TEST light movement varies with sensor type Bad Sensor TEST light position does not change during test OR light movement is erratic showing a sudden jump or dip during smooth sensor operation 7 Test A is complete Set RANGE switch to POWER OFF and remove all test leads Reconnect sensor to vehicle if all testing is done Section 2 WCS Eae TEST B Air Temperature Sensor Warning Observe all safety precautions see page ii if testing sensor on vehicle 1 Do all Test Preparation steps Refer to page 2 42 2 Connect test leads Connect TEST leads according to diagram B in the component drawing T 3 Verify test clips make good contact and do not touch each other LOW Make sure unused clips are not touching anything RANGE 4 Set RANGE switch to HIGH vos 5 Set FUNCTION switch to OHMS FREQUENCY FUNCTION 6 Note TEST light position on tester If the sensor is good the light will move downwards as the sensor heats up 7 Heat temperature sensor thoroughly The air temperature sensor is located either n a small tube extending into the air intake passage in front of the closed vane door OR In its own housing threaded into the side of the air flow meter assembly Heat sensor using a hair dryer or similar device DO NOT use a match or open flame 8 Observe TEST light
13. engine operating condition idle closed throttle cruise part throttle or hard acceleration wide open throttle The computer can then properly control air fuel mixtures spark advance idle speed and lock up torque converters Fuel injected engines Rotary type sensor usually mounted to outside of throttle body and linked to throttle shaft Computer controlled carburetor engines Linear sliding type usually mounted inside carburetor GM or outside carburetor Ford Related trouble codes sent by computer Driveability problems such as hard starting rough idle stalling hesitation stumble surging knocking pinging poor fuel economy backfiring no torque converter lock up Sensor operation see test on page 2 10 or switch operation see test on page 2 12 Poor connections at sensor or computer Sensor position adjustment Faulty sensor wiring open or short circuits Binding throttle shaft or linkage If used Cruise Control linkage problems idle speed control motor vacuum hose connected to throttle positioner choke or cam systems affecting throttle position 2 7 Section 2 Throttle Position Sensor Connectors A Test A page 2 10 Some sensors require more than one test Test B page 2 12 Note If the Red and Black test lead hook ups are reversed the TEST light will move in the opposite direction during Test A This does not affect the accuracy of the test or harm the sen
14. engine is run with sensor disconnected Ignore or erase the code after testing Refer to Vehicle Service Manual T 4 Verify test clips make good contact Low Make sure unused clips are not touching anything RANGE 5 Set RANGE switch to LOW VOLTS OHMS 6 Set FUNCTION switch to VOLTS FREQUENCY FUNCTION 7 Start engine Idle until hot Run engine until upper radiator hose is hot and pressurized OXYGEN 8 Observe RICH LEAN lights during fast idle The TEST light column also indicates sensor voltage but it is easier to check operation by watching the RICH LEAN lights Maintain throttle partially open 2000 RPM idle IF the RICH LEAN lights flash back and forth every 3 seconds or less THEN the sensor is good and no further testing is necessary Go to step 10 IF it takes longer than 3 seconds for the RICH LEAN lights to switch back and forth THEN the sensor may be degraded Go to step 10 then do the Off Car test on page 2 24 IF the RICH LEAN lights do not flash back and forth THEN go to step 9 9 Observe RICH LEAN lights during throttle changes Quickly move throttle from idle to partially open 2000 RPM position then back to idle This attempts to create a momentary rich or lean engine operating condition Repeat this throttle action several times while observing the RICH LEAN lights IF the RICH LEAN lights switch within 3 seconds of the throttle action THEN
15. hook up tests O K Green Yellow Not present on some modules Section 3 Toyota Yellow Use a paper clip to connect test lead 0 Red Green Connect BLACK test lead to igniter mounting hole or good vehicle ground IMPORTANT For Toyota modules not pictured refer to vehicle service manual and connect as follows Red lead to battery pin Yellow lead to coil pin Black lead to module ground Green lead to IGT pin Red Green Yellow Black Connect BLACK test lead to igniter mounting hole or good vehicle ground Green Yellow Section 3 ls BIETET Yellow Use a paper clip to connect test lead or good vehicle Black Connect BLACK test lead to igniter mounting hole L or good vehicle ground Yellow Use a paper clip to connect test lead Section 3 Toyota Black Connect BLACK test lead to igniter mounting hole or good vehicle ground Yellow Use a paper clip to E connect test leads Toyota Yellow Ec L Connect BLACK test lead to igniter mounting hole or good vehicle ground Section 3 Toyota Green Connect BLACK test lead to igniter mounting hole or good
16. is complete Set RANGE switch to POWER OFF and remove all test leads Reconnect sensor to vehicle if all testing is done Section 2 2772217 Wire Coi Tooth Reluctor Ring p Magnet S P Positive S N VOLTAGE Zero r ii oe d UU Computer 4 Rotation Negative ROTATION Air Gap Reluctance Sensor Operation Typical Sensor Signal Voltage Crankshaft Camshaft Position sensors Whatis It The computer needs to know rotational speed or position of the engine crankshaft camshaft for controlling and ignition and fuel injector systems If the computer is How is It handling a Distributorless or Direct ignition system or controlling the operation of individual fuel injectors it also Used needs to know when cylinder 1 is active The sensors have various names such as Crankshaft Position Crank Angle Flywheel Distributor Pick Up Camshaft Position Cylinder TDC and RPM Similar sensors are used in anti lock brake and electroni cally shifted transmission systems These sensors have names such as Wheel Speed Vehicle Speed and Driveshaft The sensors come many styles using different connectors Sometimes an assembly contains more than one sensor Other versions combine two functions into a single sensor usually camshaft position and cylinder 1 identification The most common sensor types are Magnetic Reluc tance and
17. resistance becomes The thermistor is mounted inside the tip of a threaded metal housing This is a 2 wire sensor The computer needs to know air temperature to calculate the amount of air entering the engine Then the computer can provide the proper air fuel mixture for the desired operating condition The sensor is threaded into the intake manifold throttle body rear of air cleaner assembly or elsewhere along the path of air entering the engine Sometimes this sensor is built into a vane airflow meter or mass airflow sensor assembly One connector handles both the air flow and temperature sensor circuits Related trouble codes sent by computer Driveability problems such as hard starting rough idle stalling hesitation stumble surging poor fuel economy or black exhaust smoke Sensor operation see test on page 2 4 Poor connections at sensor or computer Faulty sensor wiring open or short circuits Heavy deposits on sensor tip which can cause poor response Restricted or blocked air passageways Engine running too hot problems with antifreeze thermostat water pump fan belts low engine oil Section 2 iiz dir ees Temperature Sensor Test Procedure Use this procedure for testing all engine coolant or inlet air temperature sensors Exceptions Certain Toyota Nissan and Ford engines using vane airflow sensors have the air temperature sensor built into the vane airflow assembly Refer to page 2 40
18. signal increase higher voltage or fre quency The computer supplies power and ground to the sensor How itis The computer needs to know air pressure both used outside and inside the manifold to properly adjust the air fuel mixture and ignition timing for varying engine load and altitude conditions On turbo charged engines the computer also uses the sensor to monitor boost pressure and operate the wastegate accordingly Manifold Absolute Pressure MAP BARO Location When to Test The sensor is mounted either on the bulkhead air cleaner throttle body or elsewhere in the engine compartment A vacuum hose connects the sensor to a strong source of manifold vacuum Some new MAP sensor types may be directly mounted to the manifold eliminating the vacuum hose connection The BARO sensors are vented to the atmosphere there is no vacuum hose attached Some Honda engines locate the MAP sensor inside a control box containing several vacuum hoses and solenoids Related trouble codes sent by computer No start hard starting stalling rough idle hesitation stumble surging poor fuel economy black exhaust smoke knocking backfiring catalytic converter overheating or no torque converter lock up Vehicle GM CHRYSLER FORD Harness Connectors for MAP Sensor Mating side of connector shown HONDA Ground Power Signal Refer to vehicle service manual for connectors not shown Power MAP Signa
19. the sensor is good and no further testing is necessary Go to step 10 IF it takes longer than 3 seconds for the RICH LEAN lights to switch THEN the sensor may be degraded Go to step 10 Do the Off Car test on page 2 24 IF the RICH LEAN lights do not flash back and forth THEN go to step 10 Do the Off Car test on page 2 24 10 On Car test is complete Turn ignition key OFF Set RANGE switch to POWER OFF and remove all test leads If the RICH LEAN lights did not flash or flashed too slowly in steps 8 or 9 then do the Off Car test on page 2 24 Section 2 iE Eu Off Car Test Warning This test involves use of an open flame from a propane torch Observe all safety precautions for torch operation Do not use near flammable material or gases 1 Verify ignition key is OFF 2 Check Tester battery Refer to page 1 4 Set RANGE switch to POWER OFF when done 3 Disconnect wiring harness from sensor Inspect for damage Some vehicles use a metal snap ring to secure wiring harness to sensor Remove this snap ring before disconnecting wiring harness 4 Remove sensor 5 Firmly grasp sensor with a pair of locking pliers 6 Connect test leads YELLOW to sensor SIGNAL pin BLACK to sensor GROUND 7 Verify test clips make good contact and do not touch each other HIGH LOW Make sure unused clips are not touching anything RANGE 8 Set RANGE switch to LOW pe 9 Set FUNCTION switch to V
20. vehicle ground Yellow Red Yellow Connect BLACK test lead i 2 Black to igniter mounting holes Section 4l More Uses for the Ignition Module amp ngine Sensor Tester Circuit Voltage Checks This function is useful for checking the presence or absence of voltages throughout the vehicle electrical system such as wiring switches relays and connectors It is safe for probing computer and sensor circuits Warning Observe all safety precautions when working on vehicles see page ii HIGH LOW RANGE VOLTS OHMS FREQUENCY FUNCTION VOLTS over5 gt 45 20 4 20 3 5 3 _ 25 2 1 5 1 0 5 ko 1 Set FUNCTION switch to VOLTS 2 Set RANGE switch to HIGH 3 Connect BLACK test lead to circuit ground 4 Probe with YELLOW test lead Warning Do not connect to secondary ignition circuits dangerous voltages present 5 TEST light position indicates measured voltage Each light represents a 0 5 volt step along a span of 0 5 to 5 volts Top TEST light ON voltage is 5 volts or higher Other TEST lights ON see illustration for voltage level All TEST lights OFF voltage is less than 0 5 volts not present or negative polarity Important Always make sure all connections are good at the contact points Negative voltages no matter how large will NOT turn on TEST lights More than one TEST light on or ju
21. 4 Off Car testing only Remove sensor Note Some sensors are permanently attached to the EGR valve and cannot be removed 5 Connect test leads according to diagram 6 Verify test clips make good contact and do not touch each other Make sure unused clips are not touching anything 7 Set RANGE switch to HIGH 8 Set FUNCTION switch to VOLTS 9 Operate sensor Watch TEST light for results Note TEST light may be on or off before sensor is operated On Car test Remove vacuum control hose from EGR valve Connect hand vacuum pump to EGR valve Gradually apply vacuum to slowly open valve Section 2 iE Eu Off Car test Slowly push sensor element back and forth from end to end Good Sensor TEST light smoothly moves up or down as sensor is operated The TEST light may go off if it moves to the bottom of the column this is O K Range of TEST light movement varies with sensor type and vehicle mounting Bad Sensor TEST light position does not change during test OR light movement is erratic showing a sudden jump or dip during smooth sensor operation 10 Testing is complete Set RANGE switch to POWER OFF and remove all test leads Black EGR Valve Position Lift S Sensor Connectors Note If the Red and Black test lead hook ups are reversed the TEST light will move in the opposite direction during the test This does not affect the accuracy of the test or harm
22. Distribution Service Post Office Box 360450 Strongsville OH 44136 Vehicle Service Manuals from Toyota Honda Nissan Toyota Motor Corporation Toyota Service Publications 750 W Victoria Street Compton CA 90220 5538 Honda Motor Co Ltd Helm Incorporated Post Office Box 07280 Detroit MI 48207 Nissan North America Inc Dyment Distribution Service c o Nissan 20770 Westwood Drive Strongsville OH 44136 Index Section Vehicle Service Information Inside front cover Safety Precautions ii 1 Tester Basics 1 1 2 Testing Sensors etn 2 1 e Troubleshooting Tips 2 1 e Engine Coolant Temperature 2 2 e Inlet Air Temperature 2 3 e Throttle Position TP 2 6 e EGR Valve Position 2 14 SOXY OEM cete teet eie eshte Engine Knock Manifold Absolute Pressure MAP BARO 2 28 e Mass Air Flow MAF 2 34 Vane AIPFEIOW irte oett tire 2 40 e Crankshaft Camshaft Position 2 46 Magnetic Reluctance Type 2 49 Hall Effect or Optical Type 2 51 Testing Ignition 3 1 4 More Uses for the S
23. N on VOLTS 27 Power Ground z not be used not be used Refer to vehicle service manual for connectors not shown Mass Air Flow MAF Mass Air Flow MAF Sensor Test Procedure Testing is done on vehicle Warning This test involves running the engine Observe all safety precautions see page ii Work in well ventilated area 1 Verify ignition key is OFF 2 Check Tester battery Refer to page 1 4 Set RANGE switch to POWER OFF when done 3 Connect test leads refer to hook up diagram Keep sensor connected to vehicle wiring YELLOW to sensor SIGNAL circuit Use backprobe adapter BLACK to good vehicle GROUND 4 Verify test clips make good contact Make sure unused clips are not touching any thing 5 Set switches refer to hook up diagram 6 Turn ignition key ON but DO NOT START ENGINE 7 Note TEST light position on tester Typically the TEST light will be off at the bottom of the column or blinking Ignore any PULSE light action If the sensor is good the light will move upwards during engine run 8 Start engine and let idle Watch TEST light for results Good Sensor TEST light moves upward after engine starts TEST light moves up even further if engine RPM is momentarily increased Move throttle to check Range of TEST light movement varies with sensor type and engine speed 2 37 Sect
24. OLTS FREQUENCY FUNCTION 10 Light torch Heat sensor tip Observe RICH LEAN lights Thoroughly heat sensor tip until tip is as hot as possible but not glowing See Fig 1 The sensor tip must be very hot to operate 349 C 660 F The LEAN or RICH light should be ON If both lights are off the sensor is defective OXYGEN 11 Observe RICH LEAN lights while operating sensor After sensor tip is hot move the flame until the sensor tip is completely surrounded by the flame This keeps oxygen away from the tip See Fig 2 Good Sensor RICH light turns ON within 3 seconds indicating a rich low oxygen condition Bad Sensor RICH light takes longer than 3 seconds to turn on or does not turn on at all Move flame so oxygen can reach sensor tip Keep sensor tip hot with flame See Fig 1 Good Sensor LEAN light turns ON within 3 seconds indicating a lean high oxygen condition Bad Sensor LEAN light takes longer than 3 seconds to turn on or does not turn on at all 12 Repeat step 11 a few times to verify results 13 Testing is complete Extinguish flame set RANGE switch to POWER OFF let sensor cool and remove test leads IMPORTANT Special anti seize compound must be applied to sensor housing threads before reinstallation Refer to vehicle service manual for proper type
25. any problems by just looking Has the vehicle been serviced recently Some times things get reconnected to the wrong place or not at all Poor grounding can cause no starts Some modules make ground connections to vehicle chassis Check mounting hardware module flanges and chassis for clean contact surfaces and snug attachment Inspect wiring for Contact with sharp edges Contact with hot surfaces such as exhaust manifolds Pinched burned or chafed insulation Proper routing and connections Check electrical connectors for Corrosion on pins Bent or damaged pins Contacts not properly seated in housing Bad wire crimps to terminals Check crankshaft camshaft sensors connected to ignition module Refer to page 2 46 Many ignition modules require heat transfer grease applied between module and mounting surface Modules can overheat and fail if grease is missing or incorrectly applied Section 3 Ignition Module Test Procedure GM Ford Chrysler Toyota Honda Nissan Important This test checks for dead modules causing a no start This test will not detect intermittent failures due to heat or engine vibration Refer to vehicle service manual for module location removal and installa tion procedures Module access may require distributor removal Follow service manual procedures Check ignition timing with a timing light when the
26. cle 1 Verify ignition key is OFF 2 Check Tester battery Refer to page 1 4 Set RANGE switch to POWER OFF when done 3 Disconnect wiring harness from sensor Inspect for damage Some vehicles use a metal snap ring to secure wiring harness to sensor Remove this snap ring before disconnecting wiring harness 4 Off Car testing only Remove sensor IMPORTANT Many throttle position sensors require special adjustment when reinstalled Refer to vehicle service manual for adjustment procedure A good sensor will not perform properly if incorrectly adjusted 5 Connect test leads Connect TEST leads according to diagram A in the compo nent drawing 6 Verify test clips make good contact and do not touch each other Make sure unused clips are not touching anything THROTTLE POSITION Sensor Switch HIGH LOW RANGE VOLTS OHMS FREQUENCY FUNCTION 7 Honda only 1988 92 Civic and CRX Remove vacuum hose from dashpot diaphragm Apply 20 in Hg to the dashpot diaphragm using a hand vacuum pump The dashpot diaphragm is part of the throttle body assembly It is used to control cold engine fast idle and throttle closure speed so engine will not stall 8 Set RANGE switch to HIGH 9 Set FUNCTION switch to VOLTS 10 Operate sensor Watch TEST light for results Note TEST light may be on or off before sensor is operated On Car test Slowly move throttle linkage back and forth from idle
27. distributor is reinstalled Always check the 9 volt battery in the tester refer to page 1 4 1 Locate module diagram on proceding pages 2 Connect test leads as shown Begin with the Test 1 hook up if more than one test is shown den Always make sure metal clips make good contact Low and do not touch each other RANGE 3 Set RANGE switch to LOW Hah 4 Set FUNCTION switch to FREQUENCY FREQUENCY FUNCTION 5 Observe PULSE light for test results Flashing light means good module There may EE be a short delay before flashing starts No flashing means bad module Note The bottom TEST lights may also flash This is normal and may be ignored Exception When testing ring type modules lower half page 3 11 spin the distributor shaft to activate the PULSE light Light on or flashing during spin means good module IGNITION MODULES GM 7 amp 8 pin modules only Reconnect test leads as shown in Test 2 diagram Observe PULSE light It should NOT be flashing If PULSE light flashes module is bad Short pins E and R together using paper clip or other metal jumper Observe PULSE light for test results Flashing light means good module There may be a short delay before flashing starts No flashing means bad module Ford modules with two test hook ups Reconnect test leads as shown for Test 2 Only the Green test lead is moved Observe PULSE lig
28. e Sensor Tester Continuity Checks cont Yellow Black Yellow Black e o e o Switch Switch Closed Open Yellow Black Yellow Black No Ground Connection Ground Connection Diode Checks Tests diodes and rectifiers for proper operation HIGH 1 Set RANGE switch to HIGH 2 Set FUNCTION switch to OHMS OHMS n 3 Connect TEST leads as shown in Figure 1 FUNCTION YELLOW to anode BLACK to cathode 4 The bottom TEST light should be ON If a different TEST light is on or all lights are off the diode is defective 5 Reverse test lead connections as shown in Figure 2 YELLOW to cathode BLACK to anode 6 The top TEST light should be ON If a different TEST light is on or all lights are off the diode is defective Note Always make sure all connections are good If necessary scrape away corrosion paint etc at the contact points Yellow Black Black Yellow Fig 1 Fig 2 Warranty Garantia FULL ONE 1 YEAR WARRANTY Actron Manufacturing Company 9999 Walford Avenue Cleveland Ohio 44102 4621 USA warrants to the user that this unit will be free of defects in materials and workmanship for a period of one 1 year from the date of original purchase Any unit that fails within this period will be repaired without charge when returned to an authorized factory repair center Actron requests that a c
29. e replaced Section 2 775217 Sensor S Mass Air Flow Sensors What is It This sensor is an electronic module which sends a signal to the computer indicating the amount of air entering the engine Depending upon sensor type the signal may be a dc voltage or a frequency The signal level increases higher voltage or frequency as the air flow increases Within the sensor is a heated wire located in the path of incoming air The module determines air flow by measuring the temperature drop of the heated wire as air passes around it How it iS computer needs to know incoming air flow to used properly adjust air fuel mixture and ignition timing for varying engine load and operating conditions Location sensor is mounted in the engine incoming air ducts typically just behind the air cleaner assem bly or near the throttle body When to Test Related trouble codes sent by computer Driveability problems such as hard starting rough idle stalling hesitation stumble surging knocking pinging poor fuel economy black exhaust smoke backfiring catalytic converter overheating or no torque converter lock up Mass Air Flow MAF Vehicle Harness Connectors for MAF Sensor Mating side of connector shown GM POWER MAF SIGNAL GROUND 1988 and Older RANGE on LOW FUNCTION on FREQUENCY an POWER H
30. eck MAP sensor ground circuit Same set up as previous step but move YELLOW test lead to sensor GROUND circuit Use backprobe adapter Good ground circuit TEST light OFF Go to next step Bad ground circuit Any TEST light ON Repair open in ground circuit wiring then retest 13 Check for connector problems gnition key OFF Disconnect wiring harness from MAP sensor Some vehicles use metal snap ring to secure wiring harness to sensor Remove this snap ring before disconnecting wiring harness Soe Check terminals for damage corrosion bad wire crimps or improper seating in connector Repair as necessary then retest If no trouble found go to next step Manifold Absolute Pressure MAP BARO HIGH LOW RANGE VOLTS OHMS FREQUENCY FUNCTION 14 Check MAP signal wire for short to ground Verify ignition key OFF and MAP sensor wiring harness disconnected RANGE on LOW FUNCTION on OHMS YELLOW test lead to MAP signal pin on vehicle harness connector BLACK test lead to good vehicle GROUND Good circuit no short TEST light ON in any position Go to next step Bad circuit shorted TEST light OFF Repair short in signal circuit wiring then retest 15 Testing is complete Verify ignition key OFF Set RANGE switch to POWER OFF and remove all test leads If steps 10 through 14 are all good but step 8 showed a problem then the sensor is bad and needs to b
31. ed linear type When the sensor is mounted on the engine the element is linked to the throttle so they move together The sensor sends a voltage signal back to the computer indicating element and thus throttle position The voltage signal increases when the throttle opens and operates the sensor element Throttle position sensors on Asian vehicles may also include one or two throttle position switches Throttle Position Switch This is one or two switches usually built into a single housing often resembling a throttle position sensor Movement of the throttle linkage operates the throttle switches The switches are wired to the computer The computer usually supplies an ground connection to one side of each switch MIN ROTATION MAX The idle position switch is closed or open depends upon vehicle when the throttle is resting The switch operates when the throttle is opened by any amount and no longer in the idle position THROTTLE POSITION Sensor Switch How it is used Location When to Test What to Inspect Sometimes a second switch is used to signal a wide open throttle condition This switch is normally open or closed depends upon vehicle when the throttle is at idle or just partially open The switch operates when the throttle is opened beyond a certain point The amount of throttle opening required to operate the switch varies with vehicle The computer uses throttle position to determine
32. ed in various places around the engine where it can be mechanically linked to the crankshaft or camshaft Driveshaft Sensor located in transmission housing or near driveshaft Wheel Speed Vehicle Speed Sensors on individual wheels drive shaft or transmission shaft When tO Related trouble codes sent by computer Test Problems with Ignition No start stalling rough running Electronic Transmission No torque converter lock up faulty shifting or slipping ABS system Faulty or not working What to Ali Sensor Types Sensor operation see tests on page 2 49 through 2 52 Poor connections at sensor or computer Inspect Faulty sensor wiring open or short circuits Magnetic Reluctance Too much gap between sensor coil and reluctor ring Cracked broken or missing teeth on reluctor ring Note Some rings may normally have a gap or irregular tooth space This gives the computer cylinder identification information Hall Effect Foreign objects in gap between Hall sensor and shutter assembly Cracked broken or missing blades on shutter Note Some shutter assemblies may normally have irregular blade spacing This gives the computer cylinder identification information Optical Dirt in the rotor blade slots or light source detector assembly Broken or worn teeth on the distributor shaft if used or sensor shaft Crankshaft Camshaft Position Test A Magnetic Reluctance Type Se
33. ensor Probe 4 1 e Circuit Tester Voltage Check 4 1 e Continuity Checks 4 2 Diode Gheck 2 eee ER 4 4 Safety First General Safety Guidelines to Follow When Working on Vehicles Always wear approved eye protection Always operate the vehicle in a well ventilated area Do not inhale exhaust gases they are very poisonous Always keep yourself tools and test equipment away from all moving or hot engine parts Always make sure the vehicle is in Park automatic transmission or Neutral manual transmission and that the parking brake is firmly set Block the drive wheels Never lay tools on vehicle battery You may short the terminals together causing harm to yourself the tools or the battery Never smoke or have open flames near vehicle Vapors from fuel or charging batteries are highly flammable and explosive Never leave vehicle unattended while running tests Always keep a fire extinguisher suitable for all types of fires handy Always turn ignition key OFF when connecting or disconnecting electrical components unless otherwise instructed Use shop rags to cover fuel line fittings when connecting or disconnecting fuel lines Avoid contact with fuel Dispose of all rags properly Clean up all fuel spills immediately Keep away from engine cooling fan On some vehicles the fan may start up unexpectedly
34. f the adapter will break if you bend it To Computer Section 1 Tester Basics Used when checking some ignition modules Makes extra connections as required for testing J umper Lead 9 Used for easier attachment of test leads to certain sensor or wiring connector pins Connector Push end of the adapter onto the desired Pin Adapters connector pin Grasp the other end with the test lead clip Sensor A4929 volt transistor radio battery must be installed to power the unit Use an alkaline battery conventional Tester batteries are too weak for ignition module testing Power Installing the Battery 1 Hold the tester face down with both hands 2 Using both thumbs firmly press downwards and outwards on the battery compartment door at the bottom of the tester 3 Slide the battery compartment door away from the tester to remove 4 Attach battery to connector and install inside compartment 5 Replace battery door Slide door inwards until it snaps closed Checking the Battery 1 Make sure none of the test leads are connected together or touching anything HIGH LOW RANGE 2 Set RANGE switch to HIGH en 3 Set FUNCTION switch to OHMS FREQUENCY 4 Battery is good if the top TEST light is ON If any light FUNCTION below the top TEST light is ON the battery is too weak for reliable testing and should be replaced TIP To extend battery life always switch to POWER OFF when not making a
35. for adjustment procedure A good switch will not perform properly if incorrectly adjusted 5 Connect test leads Connect TEST leads according to diagram B in the compo nent drawing 6 Verify test clips make good contact and do not touch each other Make sure unused clips are not touching anything THROTTLE POSITION Sensor Switch HIGH LOW 7 Set RANGE switch to HIGH RANGE 8 Set FUNCTION switch to OHMS VOLTS PERDU 9 Operate sensor Watch TEST light for results FUNCTION On Car test Slowly move throttle linkage back and forth from idle to wide open position Off Car test Slowly rotate sensor element back and forth from end to end Good Switch TEST light switches between being ON at top of column and OFF Bad Switch TEST light always ON at top of column or always OFF 10 Testing is complete Set RANGE switch to POWER OFF and remove all test leads What is it HIGH SENSOR VOLTAGE LOW MIN MAX VALVE OPENING How it is used Location When to Test What to Inspect Section 2 MECS Run FORD HONDA EGR Valve This sensor is a potentiometer a type of variable resistor similar to a dashboard light dimmer control The computer supplies power and ground to the sensor the sensor has a shaft which is pushed When the sensor is mounted on the EGR valve the shaft gets pushed as the valve opens The sensor sends out a voltage sig
36. ht for test results Flashing light means good module There may be a short delay before flashing starts No flashing means bad module 6 Testing is complete Set RANGE switch to POWER OFF and remove all test leads Section 3 GM 4 and 5 pin Test clip must touch both base plate and bushing BUSHING BASE gt 4 Yellow Test clip must touch both base plate and bushing BUSHING BASE f 2 Section 3 GM 8 pin Green Test 1 VIEW END VIEW Test 2 WES VIEW Yellow Blue Jumper Ford Dura Spark Blue Jumper Note Dura Spark ignition modules come in several Black versions with different Black or Black Green connector types Make connections based on ignition Yellow Green 7_ module wire colors Green nmm Orange Other module wires not used for testing oo Ford TFI Blue Jumper Red Yellow VIEW END VIEW Section 3 Ford TFI IV Test 1 Connect leads as shown Test 2 M in 5 Black est ove Green lead to pin 5 Other leads remain in original position Green Yellow SIDE VIEW Ford Test 1 Connect
37. ic field causes the Hall switch to turn on and send out a low voltage signal If a metal strip iron or steel is placed in the gap it blocks the magnetic field from reaching the Hall device This causes the Hall switch to turn off and send a high voltage signal out on the signal wire The metal strips blades are part of a disk or cup attached to a rotating component such as the crankshaft or camshaft As the blades pass through the sensor gap the voltage signal switches high and low creating a series of pulses The computer determines rotational speed or position by measuring how fast or when pulses appear The optical crank angle sensor consists of a light Source a light detector photo electric cell and a rotor plate which is a slotted disk Since the distributor shaft and or camshaft are linked to the rotor plate they move together As the rotor plate rotates the slits on the disk interrupt a beam or light sent by the light source to the light detector This interrupting action creates two pulse waveforms that are monitored by the engine computer The engine computer uses these waveforms and other engine sensors to optimally control ignition timing Section 2 iE Eu Where iS Crankshaft Position Crank Angle Flywheel Distributor It Pick Up Camshaft Position Cylinder TDC and RPM The sensor is usually located inside the distributor if the engine has one Vehicles without a distributor have the sensor locat
38. ion 2 Ii Eu Note If test results are O K but a computer trouble code indicates a bad sensor signal the wire between the sensor signal pin and the computer may be open Testing is complete Problem exists Bad sensor or wiring TEST light position does not change during test Go to step 9 and continue testing to find cause Do all steps to avoid replacing a good sensor Note Sensor is defective if TEST light jumps erratically when sensor GENTLY tapped with lightweight tool 9 Ignition key OFF 10 Check for air intake problems Air leaks around MAF sensor ductwork or throttle body Obstructions in air duct Clogged air filter Repair as necessary then retest If no trouble found go to next step 11 Check MAF sensor power circuit Keep sensor connected to vehicle wiring Ba YELLOW test lead to sensor POWER circuit Use backprobe adapter RANGE BLACK test lead to good vehicle GROUND Mo RANGE on HIGH FREQUENCY FUNCTION on VOLTS Ignition key ON Good power circuit Top or next to top TEST light ON Go to next step FUNCTION Bad power circuit TEST light OFF or not in top or next to top position Repair open or short in power circuit wiring then retest 7 HIGH LOW RANGE VOLTS OHMS FREQUENCY FUNCTION Mass Air Flow MAF 12 Check MAF sensor ground circuit Same set up as previous step but move YELLOW test
39. l MAP Signal round Ground TOYOTA SE Ground Power Ground Signal Signal Section 2 iE Eu Manifold Absolute Pressure MAP Sensor Test Procedure Testing is done on vehicle Warning This test involves running the engine Observe all safety precautions see page ii Work in well ventilated area 1 Verify ignition key is OFF 2 Check Tester battery Refer to page 1 4 Set RANGE switch to POWER OFF when done 3 Connect test leads Keep sensor connected to vehicle wiring YELLOW to sensor SIGNAL circuit Use backprobe adapter BLACK to good vehicle GROUND 4 Verify test clips make good contact Make sure unused clips are not touching any thing Backprobe 9 5 Set switches RANGE on HIGH FUNCTION on VOLTS Exception Ford vehicles with frequency type sensor see diagram RANGE on LOW FUNCTION on FREQUENCY 6 Turn ignition key ON but DO NOT START ENGINE 7 Note TEST light position on tester If the sensor is good the light will move downwards when vacuum is applied Manifold Absolute Pressure MAP BARO Note If the TEST light is OFF a problem exists Go to step 9 and continue testing to find cause 8 Operate sensor Watch TEST light for results Note Ignore any PULSE light action Non Turbo Engines only Start engine and let idle Turbo Engines only Attach hand vacuum pump to sensor vacuum port Apply 18 in vac
40. le wiring harness 11 Heat sensor tip thoroughly On Car test Start engine and idle at 2000 RPM until upper radiator hose is hot Off Car test Dip sensor tip into boiling water OR metal sensor housing Heat tip with flame from candle or cigarette lighter OR plastic sensor housing Heat tip with hair dryer 12 On Car test only Turn ignition key OFF Disconnect vehicle wiring harness from sensor and reconnect test leads as before 13 Observe TEST light position for test results Good Sensor TEST light moved downwards below original position TEST light may go off if sensor is very hot this is OK The TEST light will move upwards as the sensor cools off Range of TEST light movement varies with sensor type and temperature change Bad Sensor TEST light position did not change during test 14 Testing is complete Set RANGE switch to POWER OFF and remove all test leads Section 2 WES Eu TYPICAL THROTTLE POSITION SENSORS HIGH What Throttle Position Sensor SIGNAL is It throttle position sensor is VOLTAGE potentiometer a type of variable resistor similar to a dashboard dimmer control These sensors come in a wide variety of styles some with Low connectors at the end of a short wire pigtail The computer supplies power and ground to the sensor The sensor has an element which is turned rotary type or push
41. lead to sensor GROUND circuit Do not probe MAF RETURN pin Use backprobe adapter Good ground circuit TEST light OFF Go to next step Bad ground circuit Any TEST light ON Repair open in ground circuit wiring then retest 13 Check for connector problems Ignition key OFF Disconnect wiring harness from MAF sensor Some vehicles use a metal snap ring to secure wiring harness to sensor Remove this snap ring before disconnecting wiring harness Check terminals for damage corrosion bad wire crimps or improper seating in connector Repair as necessary then retest If no trouble found go to next step 14 Check MAF signal wire for short to ground Verify ignition key OFF and MAF sensor wiring harness disconnected RANGE on LOW FUNCTION on OHMS YELLOW test lead to MAF signal pin on vehicle harness connector BLACK test lead to good vehicle GROUND Good circuit no short TEST light ON in any position Go to next step Bad circuit shorted TEST light OFF Repair short in signal circuit wiring then retest 15 Testing is complete Verify ignition key OFF Set RANGE switch to POWER OFF and remove all test leads If steps 10 through 14 are all good but step 8 showed a problem then the sensor is bad and needs to be replaced Section 2 77 al Vane Air Flow Sensors Typical VAF Sensor AIRFLOW Referred to as Vane Air Flow gt VAF sensor or Air Flow Meter What
42. leads as shown Test 2 Move Green lead to pin 5 Other leads remain in original position Green eu SIDE VIEW Chrysler 5 pin type shown 4 and 5 pin 4 pin uses same hook up Black Hall Effect Pick up Section 3 ties Honda Yellow Connect BLACK test lead to igniter mounting holes or a metal ground inside distributor Honda Nissan Yellow Bushing Base plate Black Not present on Test clip must touch both some modules base plate and bushing IMPORTANT 1 Remove distributor from engine before testing 2 Module remains inside distributor during test Connect BLACK test lead Yellow to a good ground inside distributor Black Connect BLACK test lead to a good ground inside distributor Connect BLACK test lead to a good ground inside distributor Section 3 ls BIETET Nissan Test clip must touch both base plate and bushing Bushing Base plate Nissan One Coil System 1987 1989 300ZX only Photo pick up Nissan uses two types of connector wiring Module is good if either Yellow Green Black hook up tests O K Green Black Yellow Yellow Black Green Nissan Two Coil System Photo pick up Yellow Green Black Nissan uses two types of connector wiring Module is good if either
43. measurement This is safe to do even if the tester is connected to a circuit Section 2 Testing Sensors Troubleshooting Save yourself time Always begin with a thorough visual and hands on inspection You can often find the cause of many problems by just looking Tips Has the vehicle been serviced recently Sometimes things get reconnected in the wrong place or not at all Don ttake shortcuts Inspect hoses and wiring which may be difficult to see due to location Inspect the air cleaner and ductwork for defects Check sensors and actuators for damage Inspect all vacuum hoses for Correct routing Refer to vehicle service manual or Vehicle Emission Control Information VECI decal located in the engine compartment Pinches and kinks Splits cuts or breaks Inspect wiring for Contact with sharp edges this happens often Contact with hot surfaces such as exhaust manifolds Pinched burned or chafed insulation Proper routing and connections Check electrical connectors for Corrosion on pins Bent or damaged pins Contacts not properly seated in housing Bad wire crimps to terminals Section 2 HIGH SENSOR RESISTANCE LOW Cold Hot Typical Engine Coolant TEMPERATURE Temperature Sensor What is It The engine temperature sensor is a thermistor a resister whose resistance changes with tempera tu
44. mping around means the measured voltage is erratic or rapidly changing Continuity Checks Test wiring ground connections switch operation relay contacts or similar Important Docontinuity tests on unpowered circuits only Always make sure all connections are good If necessary scrape away corrosion paint etc at the contact points Warning If working on car turn ignition key OFF and observe all safety precautions see page ii HIGH LOW 1 Set RANGE switch to HIGH RANGE 2 Set FUNCTION switch to OHMS 42 3 Connect YELLOW test lead to one end of circuit such as FREQUENCY wire switch or relay contact 4 Connect BLACK test lead to other end of wire switch or relay 5 TEST light position indicates Yell Black Yell Black amount of continuity 2 a ac All TEST lights OFF Short Circuit measured resistance is 200 ohms or less Top TEST light ON Open Circuit measured resistance is 7 Kohms or higher Short EE circuit cio Other TEST lights ON mean circuit has resistance between 200 ohms and 7 K ohms Low Resistance Checks RANGE switch on LOW RANGE FUNCTION switch on OHMS Enid Use YELLOW and BLACK test leads FREQUENCY All TEST lights OFF resistance is 30 ohms or less FUNCTION Top TEST light ON resistance is 300 ohms or higher Other TEST lights ON mean resistance is between 30 ohms and 300 ohms More Uses for the Ignition Modul
45. nal indicating the amount of valve opening lift The voltage signal gets larger the more the valve is opened The computer is programmed to provide optimum EGR flow during idle cruise and hard acceleration operating conditions The computer uses the sensor signal to calculate actual EGR flow Then the computer can modify the EGR valve opening as required Attached to the top of the EGR valve Related trouble codes sent by computer Driveability problems such as hesitation stumble surging poor fuel economy erratic acceleration knocking pinging no torque converter lock up Sensor operation see page 2 15 Poor connec tions at the sensor or computer Damaged or sticking EGR valve Worn or broken vacuum hoses vacuum connectors Damaged vacuum reservoir canister Problems with control solenoids supplying operating vacuum to open EGR valve EGR Valve Position Lift Sensors EGR Valve Position Sensor Test Procedure Sensor may be tested on or off vehicle Warning Observe all safety precautions see page ii if testing sensor on vehicle HIGH LOW RANGE VOLTS OHMS FREQUENCY FUNCTION 1 Verify ignition key is OFF 2 Check Tester battery Refer to page 1 4 Set RANGE switch to POWER OFF when done 3 Disconnect wiring harness from sensor Inspect for damage Some vehicles use a metal snap ring to secure wiring harness to sensor Remove this snap ring before disconnecting wiring harness
46. nsor Testing is done on vehicle DO NOT test vehicle speed or driveshaft type sensors since they require vehicle motion Warning Observe all safety precautions see page ii when testing sensor on vehicle 1 Verify ignition key is OFF 2 Check Tester battery Refer to page 1 4 Set RANGE switch to POWER OFF when done 3 Disconnect wiring harness from sensor Inspect for damage Some vehicles use a metal snap ring to secure wiring harness to sensor Remove this snap ring before disconnecting wiring harness 4 Connect test leads Refer to vehicle service manual for sensor pin identification Some connectors handle more than one sensor Test all sensors YELLOW to one end of sensor coil pin BLACK to other end of sensor coil pin 5 Verify test clips make good contact and do not touch each other s Make sure unused clips are not touching anything oe 6 Set RANGE switch to LOW F vous 7 Set FUNCTION switch to VOLTS Sh 8 Operate sensor Watch TEST light for results Note Ignore any RICH LEAN light flashes Crankshaft Camshaft sensor Crank engine STAY AWAY from moving engine parts Section 2 iE Eu Observe all safety precautions see page ii engine may start or backfire Note Some computer systems will store a trouble code in memory and turn on the Check Engine light if engine is cranked with sensor disconnected Ignore or erase the code after testing Refer to vehicle
47. nsors using the LOW VOLTS range Two or more of these are used for the various tests and checks Yellow The SIGNAL lead Signals probed by this lead cause the TEST lights to react Usually connected to a sensor or ignition module output circuit during testing Black The COMMON lead Used as a circuit ground or signal reference point for all tests and checks This lead is always used Green The TRIGGER lead Used when testing ignition modules Sends a signal to fire the module Usually connected to the module crankshaft camshaft input circuit Red The 9V power lead This lead is connected to the 9 volt battery inside the tester whenever the RANGE switch is in the LOW or HIGH positions Ignition modules and some sensors require this power for testing KOSTON MODULE amp ENGINE 93019813 1 HIGH LOW 1 RANGE voLTS OHMS FREQUENCY FUNCTION m DISCONNECT ALL LEADS WEAK IF ANOTHER LIGHT IS 7 Allows test lead to probe sensor circuits when the sensor is connected to vehicle wiring harness Backprobe Slide the scooped end of adapter next to circuit wire Ada pter entering rear of connector Continue pushing adapter until it touches terminal inside To Sensor connector Slightly twisting adapter while pushing may ease entry Grasp open end of adapter with test lead clip Keep Q pushing on adapter to maintain circuit contact Caution The end o
48. o sensor SIGNAL Second wire goes to sensor GROUND Refer to vehicle service manual for wire identification Sensor wire is often black 3 Wire Two wires often the same color go to the sensor heating element Third wire different color from the others goes to sensor SIGNAL Sensor housing is connected to sensor GROUND 4 Wire Two wires often the same color go to the sensor heating element Third wire goes to sensor SIGNAL Fourth wire goes to sensor GROUND Refer to vehicle service manual for wire identifica tion Signal wire is often black OXYGEN Heating Element Test Do this test if sensor has a heating element 3 or 4 wire connector f sensor has 1 or 2 wire connector do not do this test Go directly to On Car Test page 2 22 Warning Observe all safety precautions see page ii if testing sensor on vehicle HIGH LOW RANGE VOLTS OHMS FREQUENCY FUNCTION 1 Verify ignition key is OFF 2 Check Tester battery Refer to page 1 4 Set RANGE switch to POWER OFF when done 3 Disconnect wiring harness from sensor Inspect for damage Some vehicles use a metal snap ring to secure wiring harness to sensor Remove this snap ring before disconnecting wiring harness 4 Connect test leads YELLOW to either sensor HEATER pin BLACK to remaining sensor HEATER pin 5 Verify test clips make good contact and do not touch each other Make sure unused clips are not touching anything 6
49. opy of the original dated sales receipt be returned with the unit to determine if the warranty period is still in effect This warranty does not apply to damages caused by accident alterations or improper or unreasonable use Expendable items such as batteries fuses lamp bulbs and flash tubes are also excluded from the scope of this warranty Actron Manufacturing Company disclaims any liability for incidental or consequential dam ages for breach of any written warranty on the unit Some states do not allow the disclaimer of liability for incidental or consequential damages so the above dis claimer may not apply to you This warranty gives you specific legal rights and you may also have rights which vary from state to state All information illustrations and specifications contained in this manual are based on the latest information available from industry sources at the time of publication No warranty expressed or implied can be made for its accuracy or completeness nor is any responsibility assumed by Actron Manufacturing Company or anyone con nected with it for loss or damages suffered through reliance on any information contained in this manual or misuse of the accompanying product Actron Manufac turing Company reserves the right to make changes at any time to this manual or accompanying product without obligation to notify any person or organization of such changes Customer Service Centers Actron Manufacturing Actron Euro
50. pe Actron Europe Company Coppen Road Dagenham 60 Rte de St Gemme 9999 Walford Avenue Essex RM8 1NU 78860 St NOM LA BRETECHE Cleveland Ohio 44102 4621 UNITED KINGDOM FRANCE USA Tel 44 0 181 984 8855 Tel 33 1 30802205 Tel 1 261 651 9200 Fax 44 0 181 984 8866 Fax 33 1 30802182 Fax 1 216 651 2853 Product Information amp Repair Product Information Only Product Information amp Repair aGcirons Actron Manufacturing Company 9999 Walford Avenue Cleveland Ohio 44102 4696 1997 Actron Manufacturing Company Made in the U S A Part No 2 221301
51. position for test results Good Sensor TEST light moved downwards below original position TEST light may go off if sensor is very hot this is OK The TEST light will move upwards as the sensor cools off Range of TEST light movement varies with sensor type and temperature change Bad Sensor TEST light position did not change during test 9 Test B is complete Set RANGE switch to POWER OFF and remove all test leads Reconnect sensor to vehicle if all testing is done Mass Air Flow MAF Test C Air Flow Meter Position Switch Warning Observe all safety precautions see page ii if testing sensor on vehicle HIGH LOW RANGE VOLTS OHMS FREQUENCY FUNCTION 1 Do all Test Preparation steps Refer to page 2 42 2 Connect test leads Connect TEST leads according to diagram C in the compo nent drawing 3 Verify test clips make good contact and do not touch each other Make sure unused clips are not touching anything 4 Set RANGE switch to HIGH 5 Set FUNCTION switch to OHMS 6 Operate sensor Watch TEST light for results Slowly move the sensor element pivoting door or sliding cone back and forth from fully closed to fully open position Use a pencil or similar object to push on the This will not harm the sensor Good Switch TEST light switches between being ON at top of column and OFF Bad Switch TEST light always ON at top of column or always OFF 7 Test C
52. re The hotter the sensor gets the lower the resistance becomes The thermistor is mounted inside the tip of a threaded metal housing This is a 2 wire sensor Exception some Chrysler engines have a dual sensor with three wires How is It computer needs to know engine temperature Used so it can modify air fuel ratios spark advance idle speed and emission device operation such as an EGR valve Location sensor is usually threaded into the engine block lower intake manifold or cylinder head to provide direct contact with coolant When to Test Related trouble codes sent by computer Driveability problems such as hard starting rough idle stalling hesitation stumble surging knocking pinging poor fuel economy or black exhaust smoke What to Sensor operation see test on page 2 4 Poor Inspect connections at sensor or computer Faulty sensor wiring open or short circuits Heavy deposits on sensor tip which can cause poor response Leakage into sensor housing Engine running too hot problems with antifreeze thermostat water pump fan belts low engine oil Air TEMPERATURE HIGH SENSOR RESISTANCE LOW Cold Hot Typical Air Temperature Sensor TEMPERATURE What is It How is It Used Location When to Test What to Inspect The air temperature sensor is a thermistor a resister whose resistance changes with temperature The hotter the sensor gets the lower the
53. service manual Wheel Speed sensor Raise wheel off ground Use jack stands and observe all safety precautions see page ii Give the wheel a quick spin in either direction to test Good sensor TEST lights flicker or stay ON during testing Position and range of TEST light activity varies with sensor type Bad sensor TEST lights OFF during testing 9 Testing is complete Ee e Set RANGE switch to POWER OFF and remove all test leads Crankshaft Camshaft Position Test B Hall Effect Type or Optical Type Sensor Sensor may be tested on or off vehicle Warning Observe all safety precautions see page ii if testing sensor on vehicle HIGH LOW RANGE VOLTS OHMS FREQUENCY FUNCTION 1 Verify ignition key is OFF 2 Check Tester battery Refer to page 1 4 Set RANGE switch to POWER OFF when done 3 Disconnect wiring harness from sensor Inspect for damage Some vehicles use a metal snap ring to secure wiring harness to sensor Remove this snap ring before disconnecting wiring harness 4 Off Car testing only Remove sensor 5 Connect test leads Refer to vehicle service manual for sensor pin identification Some connectors handle more than one sensor Test all sensors RED to sensor power pin YELLOW to sensor signal pin BLACK to sensor ground pin 6 Verify test clips make good contact and do not touch each other Make sure unused clips are not touching anything 7
54. sor GM FORD Red Black Yellow A Yellow ANS GM FORD CHRYSLER HONDA FORD Black Yellow Yellow A Red A Red Black HONDA HONDA HONDA Yellow Black Red Black Red Black Red i Yellow Yellow Refer to vehicle service manual for connectors not shown Hook up as follows Red test lead to sensor power pin Yellow test lead to sensor signal pin Black test lead to sensor ground pin THROTTLE POSITION Sensor Switch TOYOTA TOYOTA NISSAN Red Yellow Black Yellow Black Me Tx Not used on some vehicles Perform this test only if vehicle Yellow Black Black Yellow mating connector has 3 wires Red Yellow Black vehicles Perform this test only if vehicle mating 5 connector ome sensors nave has 3 wires cable attached here Testing is identical Yellow 1 Black Not used on some Section 2 iE Eu TEST A Throttle Position Sensor Important If more than one hook up is shown it means more than one test is required to check all parts of the sensor Do all tests shown for your sensor The letter next to the hook up refers to the test procedure Sensor may be tested on or off vehicle Exception On car test only for most Honda sensor permanently attached to throttle body Warning Observe all safety precautions see page ii if testing sensor on vehi
55. sor One wire connector e YELLOW test lead to signal pin top of sensor BLACK test lead to body of sensor off car or nearby ground on car Two wire connector uk YELLOW test lead to either sensor pin eem BLACK test lead to remaining sensor pin 5 Set RANGE switch to LOW VOLTS OHMS Frequency 6 Set FUNCTION switch to VOLTS FUNCTION 7 Operate sensor Watch TEST light for results Note Ignore any RICH LEAN light flashes On car test Lightly tap surface near sensor using a socket extension or similar tool and a light hammer Do not tap directly on sensor Off car test Grasp sensor firmly Gently tap sensor tip with a light hammer Good sensor TEST lights flash upward from the bottom of the TEST light column during a tap Only a few lights may flash This is O K Range of TEST light movement varies with sensor type and tapping force Bad sensor TEST lights do not flash during a tap 8 Testing is complete 2 2 Section 2 MECS Eau GM CHRYSLER MANIFOLD VENT TOYOTA HONDA Manifold Absolute Pressure MAP Sensor Barometric Pressure BARO Sens What is It uis sensor is an electronic module which sends signal to the computer indicating atmospheric pressure and or engine vacuum Depending upon sensor type the signal may be a dc voltage or a frequency More pressure less vacuum makes the sensor
56. t ductwork from sensor air intake This is so you can operate the sensor element for testing Refer to vehicle service manual for disassembly procedure 5 Off Car testing only Remove sensor 6 Test Preparation is complete Do tests referenced in hook up diagrams Test A Air Flow Meter Sensor page 2 43 Test B Air Temperature Sensor page 2 44 Test C Air Flow Meter Position Switch page 2 45 Mass Air Flow MAF TEST A Air Flow Meter Sensor Warning Observe all safety precautions see page ii if testing sensor on vehicle HIGH LOW RANGE VOLTS OHMS FREQUENCY FUNCTION 1 Do all Test Preparation steps Refer to page 2 42 2 Connect test leads Connect TEST leads according to diagram A in the component drawing Important If two hook ups are marked with an asterisk only one of the two hook ups has to test O K This is necessary because some sensors look alike but have different internal connections 3 Verify test clips make good contact and do not touch each other Make sure unused clips are not touching anything 4 Set RANGE switch to HIGH 5 Set FUNCTION switch to VOLTS 6 Operate sensor Watch TEST light for results Slowly move the sensor element pivoting door or sliding cone back and forth from fully closed to fully open position Use a pencil or similar object to push on the door This will not harm the sensor Good Sensor TEST light smoothly moves up or
57. tages This function is used to test most sensors OHMS Measures resistance Also used for checking continuity and testing diodes see section 4 Mostly used for testing temperature sensors FREQUENCY Measures frequency signals Peak signal voltage must be at least 3 volts to register Some MAP and MAF sensors send a frequency signal This function is also used to test ignition modules 3 TEST Lights PULSE Light RICH LEAN Lights Test Leads A single TEST light turns on to show the level of a measured signal voltage resistance or frequency When signal values are low the TEST light is off or near the bottom of the column The TEST light moves higher up the column as the signal level increases Sensor tests involve working the sensor and watching the TEST light move up down or flash Note that the motion of the light is more important than its actual position Used when testing ignition modules The PULSE light will flash if the module is good Note that the PULSE light will also be on or flash whenever frequency signals are being measured this is normal These lights are active when the tester switches are set to LOW VOLTS only LEAN green ON for voltages between 0 1 and 0 59 volts RICH red ON for voltages above 0 6 volts The RICH LEAN lights work along with the TEST lights and are helpful when testing oxygen sensors The RICH LEAN lights may be ignored when testing other se
58. to wide open position Off Car test Slowly rotate sensor element back and forth from end to end Good Sensor TEST light smoothly moves up or down as sensor is operated The TEST light may go off if it moves to the bottom of the column this is O K Range of TEST light movement varies with sensor type and vehicle mounting Bad Sensor TEST light position does not change during test OR light movement is erratic showing a sudden jump or dip during smooth sensor operation 11 Testing is complete Set RANGE switch to POWER OFF and remove all test leads Section 2 iE Eu TEST Throttle Position Switch Important If more than one hook up is shown it means more than one test is required to check all parts of the switch Do all tests shown for your switch The letter next to the hook up refers to the test procedure Switch may be tested on or off vehicle Warning Observe all safety precautions see page ii if testing sensor on vehicle 1 Verify ignition key is OFF 2 Check Tester battery Refer to page 1 4 Set RANGE switch to POWER OFF when done 3 Disconnect wiring harness from switch Inspect for damage Some vehicles use a metal snap ring to secure wiring harness to switch Remove this snap ring before disconnect ing wiring harness 4 Off Car testing only Remove switch IMPORTANT Many throttle position switches require special adjustment when reinstalled Refer to vehicle service manual
59. uum More than 25 in vacuum may damage sensor Good Sensor TEST light moves downward during engine idle or when vacuum applied The TEST light may go off if it moves to the bottom of the column this is O K Range of TEST light movement varies with sensor type and applied vacuum Note if test results are O K but a computer trouble code indicates a bad sensor signal the wire between the sensor signal pin and the computer may be open Testing is complete Problem exists Bad sensor or wiring TEST light position does not change during test Go to step 9 and continue testing to find cause Do all steps to avoid replacing a good sensor 9 Ignition key OFF 10 Check MAP sensor vacuum hose for Correct hook up Pinches kinks or collapsed sides Splits cuts breaks or clogs Repair as necessary then retest If no trouble found go to next step Section 2 iE Eu 11 Check MAP sensor power circuit Keep sensor connected to vehicle wiring YELLOW test lead to sensor POWER circuit Use backprobe adapter HIGH LOW BLACK test lead to good vehicle GROUND didus RANGE on HIGH VOLTS OHMS FUNCTION on VOLTS FREQUENCY FUNCTION Ignition key ON Good power circuit Top or next to top TEST light ON Go to next step Bad power circuit TEST light OFF or not in top or next to top position Repair open or short in power circuit wiring then retest 12 Ch
60. will increase fuel delivery NOTE Some vehicles use more than one oxygen sensor Location sensor is threaded into the exhaust manifold to give it direct contact with the exhaust gases HIGH SENSOR VOLTAGE LOW Lean OPTIMUM Rich AIR FUEL MIXTURE When to Test Inspection IMPORTANT Related trouble codes sent by computer Driveability problems such as rough running hesitation stumble poor fuel economy poor performance black exhaust smoke Sensor operation see page 2 21 Poor connec tions at the sensor or computer This sensor often fails because of contamination from fuel oil additives gasket sealer or an overly rich running engine Factors which can make a rich running engine include ignition system problems coil distributor cap rotor spark plugs wires fuel contaminated by engine oil emission devices carbon canister EGR valve PCV valve air injection system manifold leaks air filter fuel pressure and engine not at normal operating temperature Some engines usually off road applications use a titania type oxygen sensor This sensor resembles the common zirconium type but has an open ended tip The titania sensor changes resistance when it operates This tester is not designed to test the titania type sensor Section 2 iE Eu Sensor Types 1 Wire Single wire goes to sensor SIGNAL Sensor housing is connected to sensor GROUND 2 Wire One wire goes t

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