(Đồ án hcmute) using techstream software to diagnose toyota engine operation

MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION PROJECT AUTOMOTIVE ENGINEERING USING TECHSTREAM SOFTWARE TO DIAGNOSE TOYOTA ENGINE OPERATION LECTURER: PH.D DO QUOC AM STUDENT: VU BINH CHANH LE HONG HIEU SKL010464 Ho Chi Minh City, December 2022 HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION PROJECT USING TECHSTREAM SOFTWARE TO DIAGNOSE TOYOTA ENGINE OPERATION Vu Binh Chanh Student ID: 18145004 Le Hong Hieu Student ID: 18145017 Major: AUTOMOTIVE ENGINEERING Advisor: ĐỖ QUỐC ẤM, PhD Ho Chi Minh City, December 2022 HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION PROJECT USING TECHSTREAM SOFTWARE TO DIAGNOSE TOYOTA ENGINE OPERATION Vu Binh Chanh Student ID: 18145004 Le Hong Hieu Student ID: 18145017 Major: AUTOMOTIVE ENGINEERING Advisor: ĐỖ QUỐC ẤM, PhD Ho Chi Minh City, December 2022 THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -Ho Chi Minh City, December 24, 2022 GRADUATION PROJECT ASSIGNMENT Students: Vu Binh Chanh Le Hong Hieu Major: Automotive Engineering Student ID: 18145004 Student ID: 18145017 Class: 18145CLA Advisor: Ph.D Do Quoc Am Faculty: Faculty high quality Project title: Using Techstream software to diagnose Toyota engine operation Content: Using Techstream software to diagnose Toyota engine operation Products of project: Final product: CHAIR OF THE PROGRAM (Sign with full name) ADVISOR (Sign with full name) THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -Ho Chi Minh City, December 24, 2022 ADVISOR’S EVALUATION SHEET Students: Vu Binh Chanh Le Hong Hieu MSSV: 18145004 MSSV: 18145017 Major: Automotive Engineering Project title: Using Techstream software to diagnose Toyota engine operation Advisor: Ph.D Do Quoc Am EVALUATION Content of the project: Strengths: Weaknesses: Approval for oral defense? (Approved or denied) Overall evaluation: (Excellent, Good, Fair, Poor) Mark:……………….(in words:…………………………………………………………….) Ho Chi Minh City, December 24, 2022 ADVISOR (Sign with full name) THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -Ho Chi Minh City, December 24, 2022 PRE-DEFENSE EVALUATION SHEET Students: Vu Binh Chanh Le Hong Hieu MSSV: 18145004 MSSV: 18145017 Major: Automotive Engineering Project title: Using Techstream software to diagnose Toyota engine operation Name of Reviewer: EVALUATION Content and workload of the project Strengths: Weaknesses: Approval for oral defense? (Approved or denied) Overall evaluation: (Excellent, Good, Fair, Poor) Mark:……………….(in words: ) Ho Chi Minh City, December 24, 2022 REVIEWER (Sign with full name) THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -Ho Chi Minh City, December 24, 2022 EVALUATION SHEET OF DEFENSE COMMITTEE MEMBER Students: Vu Binh Chanh Le Hong Hieu MSSV: 18145004 MSSV: 18145017 Major: Automotive Engineering Project title: Using Techstream software to diagnose Toyota engine operation Name of Defense Committee……………………………………………………………………: EVALUATION Content and workload of the project Strengths: Weaknesses: Overall evaluation: (Excellent, Good, Fair, Poor) Mark:……………….(in words: ) Ho Chi Minh City, December 24, 2022 COMMITTEE MEMBER (Sign with full name) Disclaimer I hereby declare that this graduation project with the title " Using TECHSTREAM Software to Diagnose Toyota Engine Operation" is my own independent research At the same time, the data provided from the report is all from the school, which is a completely honest research result, not copied from any other research work All sources cited have been cited I would like to take full responsibility before the school if any errors or copying problems are discovered in this topic Acknowledgements During the process of implementing the project, although the team of the topic met many difficulties but with the enthusiastic and sincere help from our teachers, friends and family the project has been completed well Sincerely thank Mr.Do Quoc Am for his enthusiasm guide and help us in the process of doing the project Thank you to the Department of Automotive Engine create conditions for us to have the workshop and necessary equipment and machines to be able to complete the design of the project on schedule, as well as help and care about us a lot Thank you to the teachers in the Faculty of Vehicle and Energy Engineering, for your interest help and contribute ideas in the implementation of the topic Thank you to friends for helping the group throughout the process implementation of the topic Table of Contents CHAPTER 1: INTRODUCTION 1.1 The Reason to Choose a Project 1.2 Objective of Project CHAPTER 2: LITERATURE REVIEW & TECHSTREAM SOFTWARE 2.1 Theoretical Basis of On-Board Diagnostics 2.1.1 Introduction 2.1.2 OBD Generations 2.1.2.1 OBD 2.1.2.2 OBD II 2.2 Diagnostic Steps and Procedures 2.2.1 The 6-Step Diagnostic 2.2.2 DTC Check Operation Flow 2.2.3 DTC Information 2.3 What is TECHSTREAM Software? 2.3.1 What Car Models Are Supported by TECHSTREAM Software? 2.3.2 The Advantages Of TECHSTREAM Software 2.4 The Functions of TECHSTREAM Software 2.4.1 Trouble Codes 2.4.1.1 Trouble Codes Type 2.4.1.2 Trouble Codes Type and Type 2.4.2 Freeze Frame Data Display 12 2.4.2.1 Single Freeze Frame Data 12 2.4.2.2 Multi Freeze Frame Data 13 2.4.3 Data List 14 2.4.4 Active Test 17 4.3.4 Checking The Operation of the Mass Air Flow Sensor 4.3.4.1 Mass Air Flow Sensor When Normal Operating Condition By measuring the volume (flow) of the intake air entering the engine, the MAF (Mass Air Flow Sensor) sensor produces a voltage signal that is communicated to the engine ECU The fundamental fuel injection amount and ignition advance angle are calculated by the ECU using the signal from the MAF sensor When the intake air flow sensor is malfunctioning, the engine will run erratically or not at all, with inadequate engine power and increased fuel consumption The operating principle: The air passing through cools the heating wire, so the resistance of the heating wire decreases, causing the current to flow through the heating wire to increase to maintain a constant temperature By testing the current through the heating wire, the mass of the air will be determined First, let's take a look at the main parameters of MAF in normal operation, with stats like throttle require (it receives a signal from the accelerator pedal, displays the intake air flow based on throttle opening through information from the accelerator pedal) Figure 4.34 Mass Air Flow Sensor When Normal Operating Condition 95 4.3.4.2 Mass Air Flow Sensor When Is Disconnected Then, we proceed remove the MAF sensor, trouble codes are displayed immediately as below This is the intake air sensor cluster, as well as the gas pressure in the pipeline (including IAT and MAF), so when we disconnect the assembly wire, we will lose the signal of both, the engine will stop working and cannot be started The diagnostic code table has fully demonstrated the above problems Figure 4.35 Diagnostic Codes and Output Signals When Is Disconnected Finally, with the diagram above, it shows the process of simulating the loss of the MAF sensor With the first item being the signal showing the value of the intake air when 96 the car is in idle mode (about 2.5 gm/s) (with forced intake air intake, the engine's suction power), when we withdraw the sensor variable, the vehicle will stop immediately, and the value of MAF is zero, when the sensor is plugged back in, it measures about 0.5 gm/s because the vehicle is not running at this time, there is no forced intake of air If, when reconnecting the sensor, the sensor does not measure the amount of air as shown above, the sensor may be flickering or already dead Results and Solutions With trouble code P0102, Mass Air Flow circuit low, Mass air flow sensor (MAF) voltage less than 0.2 V for seconds (Single stroke detection algorithm) suspect fault location: ·Open or short mass air flow sensor circuit When we disconnect the MAF sensor, the MAF returns to approximately zero from which we can limit it to possibility Open circuit of mass air flow sensor, VG circuit is open or short circuited Check the pole voltage (Main voltage of the MAF sensor), measure the voltage between pin B+ (at the connector connecting the wire to the sensor) and the body mass at this time, the electric lock is in the ON position, if the voltage reaching the value of the battery voltage, then continue to measure the resistance of the wire and the connector (MAF sensor - ECM) respectively, the wire VG (under 1ohm), E2G (under 1ohm) and VG with body mass vehicle (greater than 10k ohm), if OK, check the intake air flow sensor using TECHSTREAM software if the MAF value changes when increasing the engine speed, then the MAF is still working fine, so finally the PCM has a problem We will repair or replace the PCM 97 Figure 4.36 Mass Air Flow Sensor Wiring Diagram 98 Figure 4.37 Mass Air Flow Sensor Circuit With trouble code P0113, High input voltage signal of the intake air temperature sensor circuit suspect the fault location: The intake air temperature sensor circuit is open circuit, the intake air temperature sensor (mass air flow cluster) or ECM, From the graph below we can see that the temperature that ECM is always at -40 degrees Celsius from which it can be deduced that the circuit is open 99 Figure 4.39 IAT Output Signal When Is Disconnected Figure 4.38 IAT Circuit Conduct an open circuit test on the wire side, remove the connector from the sensor, connect the THA and E2 terminals of the sensor on the wire side, if TECHSTREAM shows a temperature value of 140 degrees Celsius, the connection to the sensor is good, the sensor is damaged, and it is outside the range of 140 degrees Celsius, then we continue to check the wires and connectors (MAF and PCM sensors) by measuring the continuity of the THA pin (in front of the connector with the sensor with THA pin (in front of the connector to PCM) and pin E2 (in front of the connector to the sensor) with the ETHA pin (in front of the connector to PCM) if both are connected then PCM has a problem, we proceed PCM replacement or repair 100 4.3.5 The Simulation Misfire Operation 4.3.5.1 Data List of the Engine When It Has Misfire Firstly, with this simulation, we have a fourth position misfire, at the top of the list though you can see ignition trigger count (Ignition trigger is counting ignition events and it is using that to help with misfire) This is the time when the engine runs in idle mode, the check light is on or flashing, the vehicle jerks or hesitates during acceleration, performance is reduced as shown by rough idling, stalling, reduced fuel economy and loss of power TECHSTREAM now displays error code P0304 which stands for “Cylinder Misfire Detected.” The code indicates that the powertrain control module (PCM), has counted enough stalls on cylinder to store the code for that cylinder Code P0304 belongs to a series of diagnostic trouble codes beginning with P0300 that refer to engine stalling, misfire, or incomplete combustion in one of the engine's cylinders Figure 4.40 Data List When the Engine Has Misfire (The Condition Without Load) 101 If I bring RPM up, we easy to see that ignition trigger count goes away and you notice now that our misfire counter is not necessarily accurately counting misfire if that ignition trigger counter is not ticking away then you are not accurately counting misfire This is a problem with misfire because you rarely have misfire at idle, you almost misfire under load and if we try to duplicate the condition with load, we are not going to get any misfire showing on the data list Figure 4.41 Data List When RPM Goes Up (The Condition with Load) 102 4.3.5.2 Monitor Screen of Misfire Figure 4.42 Monitor Screen Secondly, instead of using data list option, we go over monitor screen, this is gives us more accurate misfire count however it is a snapshot when I enters the monitor screen it takes a snapshot those numbers are recording constantly but we just see them once in time when I enter the screen You see misfire at the top, then we will hit the detail button in order to see the information misfire box Now, we see the great detail but is just as history EWMA is what is happened over ten trips, the last ten strips prioritize the history Misfire rate is the current counter and you can see the misfire rate is very high right now, EWMA tell me we have some problems in the past, rate tells we have problems right now 103 Figure 4.43 Monitor Misfire Test Table The following pages shows us the EWMA misfire and rate for each cylinder, Cylinder good, cylinder has a little bit of history but nothing happening right now, cylinder has tiny problem now, now let look number 4, it has a small history but the number of current rate is 1389, we are actively missing on cylinder right now and that is continuing to count those misfires while we are looking at the screen 104 Figure 4.44 Monitor Misfire Test Table and Now, I had actually unplugged the number two ignition coil at the beginning simulation, you can see EWMA shows that sometime in the past about ten strips ag, we had some misfires on cylinder 2, we had a fairly significant misfire count on there but it is missing right now because the rate is zero Cylinder that is our issue right now Results and Conclusion Based on counting the number of ignitions on the TECHSTREAM program to determine whether the engine is burning locally or randomly igniting 105 If the engine fires locally at one cylinder then we conduct the on-plug ignition coil test by swapping their positions and check if the dropout moves with the coil, if not We continue to check engine compression and fuel pressure If accidental ignition occurs, then typically a poor air mass flow sensor will cause the engine carburetor to pale causing accidental dropout Short-term fuel compensation (STFT) and long-term fuel compensation (LTFT) should be checked with a scan tool (diagnostic machine) to see if the air/fuel mixture is too thin If igniting occurs only at no-load, the EGR valve and the EVAP purge valve should be checked, as either may be stuck open In addition to checking the PCV valve for vacuum leaks as well as the crankshaft cover for leaks, it is likely to cause the nearest engine to ignite Crankshaft or camshaft sensors are also the cause of false ignition 106 CHAPTER 5: CONCLUSION After a period of research, studying documents, finding feasible design directions, planning and conducting design and manufacturing Finally, the topic "Using TECHSTEAM Software to Diagnose Toyota Engine Operation" has been completed on time The results of the Project have been achieved: With the automotive engineering technology, the graduation thesis project is the last big exercise for students to show their professional competence, confirm their graduation conditions, and participate in the labor market In the graduation project, students put themselves in the position of real "employees", investors and teachers in the judging council play the role of "customers" Therefore, the graduation project shows high applicability, all projects come from real projects that you have been participating in the workplace The process of implementing the project helps you become more aware of the importance of teamwork and time management skills These are the skills you are guided in the learning process, but you have not realized that it is the "vital" key for a career The common problem of those who work in a group project is not able to arrange time to work together, so the system's integrity is not good Graduation project is where you identify professional issues, and also the values to cultivate and develop on the sidelines (such as business, law, soft skills, the spirit of lifelong learning, etc.) From today's lessons, you will enter the labor market; When you return to school, you will be the one who teaches new lessons for juniors, more realistic and convincing 107 REFERENCE Engine Control System I, “Course 852 Technician Handbook” Toyota Technical Training 2010 Engine Control System II, “Course 874 Technician Handbook” Toyota Technical Training 2010 Misfire Monitor Using TECHSTREAM, Toyota Technical, Scott Webster Toyota Workshop Repair Manual, https://www.onlymanuals.com/ https://www.youtube.com/@CaoNguyen86 108