General Sir John Kotelawala Defence University, Ratmalana

Department of Mechanical Engineering

Automobile Laboratory

ECU Scanning and Fault Diagnosis

Instructor : Mr. PRA Dissanayake Group: MC 01

Group Members:
Name : LLD Perera OBH Thanthreege
Index : D/ENG/21/0025/MC DV Lokuranamuka
Intake : 38 IRG Wijeratne
Stream : Mechatronics WLS Wickramaarachchi
AIM
To study the operation of the failure diagnosis tool.

OBJECTIVES
• Learning how to use the scanner.
• Learning how to read fault codes and clear the faults.
• Identifying real-time monitoring.
• Identifying the positions of the main sensors in an EFI system.

APPARATUS

Nissan Sunny FB15

THINKTOOL ECU Scanner

THEORY

ECU Scanning – This is a diagnostic procedure where a specialized device is connected to a

vehicle's Electronic Control Unit (ECU) to access and interpret diagnostic trouble codes
(DTCs). These codes provide information about specific problems in the vehicle's systems,
including the engine, transmission, or emissions control.

Fault Diagnosis – This refers to a structured approach to pinpointing the underlying cause of a
system or component malfunction. It combines technical expertise, the use of diagnostic tools,
and problem-solving abilities.

PROCEDURE

1. Detailed information was gathered from the customer about the issue, including
vehicle model, manufacturing year, mileage, recent repairs, and modifications.
2. Customer’s details were noted as “engine issue indicator” was turned on.
3. An external inspection of the vehicle was conducted to identify any visible damage or
leaks.
4. An under-hood inspection was performed to check for loose connections or damaged
wiring.
5. A test drive was taken with the customer to better understand the issue.
6. After the test drive the vehicle was powered down.
7. Once the vehicle was powered down, the Scanner was connected to the vehicle’s
OBD-II port which was under the steering wheel.
8. For a proper connection we made sure the Scanner device made a “ding” noise.
9. Vehicle was powered on to establish connections with the ECU and Scanner.
10. From the “THINKTOOL” Scanning tool, the correct car model selected for proper
diagnosis.
11. A system scan was made once the scanner was connected to the vehicles ECU.
12. Error code “P0120” was showed once the scanning was completed.
13. The repair manual was referenced to identify the fault mentioned by the code.
14. It was identified that the fault is at the “throttle sensor”.
15. The hood was opened and checked the throttle sensors position and wiring.
16. It was identified that the sensors connecting wires were unplugged.
17. Before plugging the wires into the connection socket, a voltage and connectivity test
was done to sensor wires to ensure that there were no errors in the wiring.
 18. As there were no faults in the connecting wires the sensor wires were plugged in back.
19. Hood was closed, along with the customer another test drive was driven.
20. Through the test drive, the fault indicator was not anymore after the repair.
21. The scanner was used to clear any stored DTCs.
22. While the test drive another smart scan was done, to identify any other errors that
have not been identified.
23. There were no errors been shown and the “P0120” error code was not there anymore.
24. For perfect service a real-time monitoring of the systems was done while the test
drive.
25. No wave anomalies were found through the graphs of internal systems.
26. After the test drive, once the vehicle was powered off the Scanner module
disconnected from the OBD-II port.
27. Repairs made were clearly explained to customer.

DISCUSSION

1. Write the procedure of conducting ECU diagnose.

Procedure of conducting ECU diagnose is mentioned above.

2. Identify four main sensors that recognize when handling the practical and state their
functions.

Here are four main sensors commonly recognized during practical vehicle diagnostics, along
with their functions[1]:

• Throttle Position Sensor (TPS)

Function - Monitors the position of the throttle valve in the intake manifold. It sends data to
the ECU to regulate fuel injection and ignition timing for optimal engine performance.

• Oxygen Sensor (O2 Sensor)

Function - This measures the oxygen levels in the exhaust gases. This information helps the
ECU to adjust the air-fuel mixture for efficient combustion and reduced emissions.
 • Mass Air Flow Sensor (MAF)

Function - Measures the amount of air entering the engine. This data is used by the ECU to
determine the proper amount of fuel to inject for optimal engine performance.

• Crankshaft Position Sensor

Tracks the rotational position and speed of the crankshaft. The ECU uses this data to control
ignition timing and fuel injection, ensuring proper engine synchronization and operation.

3. Identify the error code and fault of the system and then give reasonings for that error.

Error Code – P0120

This diagnostic trouble code (DTC) indicates a problem with the throttle position sensor (TPS)
or its circuit. The TPS monitors the throttle plate’s position and sends that information to the
Engine Control Module (ECM). This helps the ECU determine the proper fuel injection and
ignition timing for optimal engine performance.

Causes for P0120

• Faulty Throttle Position Sensor: A damaged or malfunctioning TPS can provide

incorrect readings, affecting the engine's performance and control.
• Damaged Wiring: Worn or damaged wiring between the TPS and ECM can result in
poor or lost signal transmission.
• ECU Malfunction: Though rare, a malfunctioning ECU might misinterpret the TPS
signal.

4. Explain the remedy for the fault by stating which sensor, what are the solutions for it.

The issue is related to the Throttle Position Sensor (TPS). This sensor monitors the position of
the throttle plate and sends signals to the ECU for controlling fuel injection and ignition timing.

Solutions are as follows[3].

• Inspect wiring

Examine the wiring harness connected to the Throttle Position sensor for signs of damage,
corrosion, or loose connections. Repair or replace any compromised wires to restore proper
communication between the sensor and the ECU.
 • Replace throttle position sensor

Test the TPS using a multimeter to check its voltage output at various throttle positions. If the
sensor is faulty or provides inconsistent readings, replace it and calibrate as per vehicle
requirements.

• Clean throttle body

Check the throttle body for carbon buildup or debris that could interfere with the throttle plate’s
movement. Clean it using a throttle body cleaner to ensure accurate sensor readings and smooth
operation.

• Check ECU

If the sensor and wiring are functioning correctly, test the ECU to ensure it processes TPS
signals accurately. Repair, reprogram, or replace the ECU if diagnostics confirm it as the source
of the fault (rare).

• Clear Code

After repairs, use a diagnostic scanner to erase the P0120 code from the ECU memory. Conduct
a test drive and monitor the system to confirm the fault is resolved.

CONCLUSION

This report outlines the steps taken to diagnose and repair a vehicle fault using an ECU scanner.
The identified issue, indicated by error code P0120, pointed to a malfunction in the throttle
position sensor or its circuitry. The diagnosis was performed systematically through data
collection, visual inspections, diagnostic tools, and error code analysis. The issue was resolved
by repairing a faulty wiring connection, restoring the vehicle to proper working condition.

The practical session underscored the importance of ECU scanners for precise fault diagnosis
and efficient repairs. Decoding error codes, combined with real-time data monitoring using
diagnostic tools, forms the foundation of effective vehicle troubleshooting. Examples of fault
codes include:

• Engine Misfire (P0300 to P0305)

Causes include worn or incorrectly gapped spark plugs, damaged or loose spark plug wires,
poor fuel quality, clogged fuel injectors, incorrect valve timing, or low cylinder compression.
 • Emissions Issues (P0400 to P0499)

Potential causes are faulty EGR valve solenoids or wiring issues in the sensor system.

• Failed Oxygen Sensor (P0150 to P0175)

Common causes include sensor wear due to heat or mechanical stress, damaged wiring, or
vacuum leaks affecting the air-fuel mixture.

• Catalytic Converter Problems (P0420 to P0434):

Issues may arise from physical damage, catalyst poisoning by lead or sulfur, or incomplete
combustion causing unburned fuel to pass through the converter.

During the session, several challenges impacted the diagnostic process:

Environmental Conditions - Heavy rain posed risks while working with electrical equipment,
and the workspace was constrained.

Vehicle Limitations - The vehicle, from the 1990s, had slow feedback and response times.
Smart scans took longer to complete, and faults were detected only after a test drive.

In conclusion, proper use of diagnostic tools and adherence to safety protocols are critical when
working on vehicles. Combining technical expertise with hands-on experience enables
technicians to accurately diagnose and effectively repair vehicle issues.

REFERENCES

[1] “Types and Functions of Sensors in Automotive Systems,” Monolithicpower.com, 2024.

https://www.monolithicpower.com/en/learning/mpscholar/automotive-
electronics/automotive-sensing-and-actuators/types-and-functions-
ofsensors?srsltid=AfmBOooVNRH1EWTBLHMIz_Ae10fzOmXi73vBUUeACIKqnCxzsL6
Ug9Xy (accessed Dec. 25, 2024).

[2] “How to Diagnose Your Engine Control Unit - Symptoms of Bad/Faulty

ECUs,” Specialized ECU Repair. https://www.ecudoctors.com/pages/ecu-faults.