Advanced Automotive Fault Diagnosis



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Advanced Automotive Fault Diagnosis
LÔØI NOÙI ÑAÀU, ledklok
2.5.9 Flight recorder tests
It is said that the best place to sit in an aeroplane is
on the black box flight recorder! Well, apart from
the black box usually being painted bright orange
so it can be found after a crash, my reason for men-
tioning it is to illustrate how the flight recorder
principle can be applied to automotive diagnostics.
Most hand-held scopes now have flight record
facilities. This means that they will save the signal
from any probe connection in memory for later
play back. The time duration will vary depending
on the available memory and the sample speed but
this is a very useful feature.
As an example, consider an engine with an
intermittent misfire that occurs only under load.
If a connection is made to the suspected compon-
ent (coil HT output for example), and the vehicle
is road tested, the waveforms produced can be
examined afterwards.
Many engine (and other system) ECUs have
built in flight recorders in the form of self-
diagnostic circuits. If a wire breaks loose causing
a misfire but then reconnects the faulty circuit
will be ‘remembered’ by the ECU.
2.5.10 Faultfinding by luck!
Or is it logic? If four electric windows stopped
working at the same time, it would be very unlikely
that all four motors had burned out. On the other
hand if just one electric window stopped working,
Input 1
Output 1
2
2
ECU
3
3
4
5
Figure 2.3 System block diagram

1

2
Component
such as a
sensor
With wires
disconnected
Wires disconnected
from ECU
ECU
Figure 2.4 Ohmmeter tests


Diagnostic techniques
15
then it may be reasonable to suspect the motor. It
is this type of reasoning that is necessary when
faultfinding. However, be warned it is theoretic-
ally possible for four motors to apparently burn
out all at the same time!
Using this ‘playing the odds’ technique can save
time when tracing a fault in a vehicle system. For
example, if both stop lights do not work and every-
thing else on the vehicle is OK, I would suspect the
switch (stages 1 to 3 of the normal process). At this
stage though, the fault could be anywhere – even
two or three blown bulbs. None-the-less a quick
test at the switch with a voltmeter would prove the
point. Now, let’s assume the switch is OK and it
produces an output when the brake pedal is pushed
down. Testing the length of wire from the front to
the back of the vehicle further illustrates how ‘luck’
comes into play.
Figure 2.5 represents the main supply wire
from the brake switch to the point where the wire
‘divides’ to each individual stop light (the odds
say the fault must be in this wire). For the purpose
of this illustration we will assume the open circuit
is just before point ‘I’. The procedure continues
in one of the two following ways. Either:

guess that the fault is in the first half and test
at point F;

we were wrong! Guess that the fault is in the
first half of the second half and test at point I;

we were right! Check at H and we have the
fault … on test number THREE;
or:

test from A to K in a logical sequence of tests;

we would find the fault … On test number
NINE!
You may choose which method you prefer!

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