KNOCK SENSORS

KNOCK SENSORS

Gone are the days when you could fix your own car with simply logic. Today you require digital logic, a scan tool  and a tech savvy mechanic to make sense of the latest cars because they are all very precisely controlled by electronic circuits. The Engine Control Module is just one such circuit and largely depends on several of its sub-circuits and associated automotive control modules to achieve the precision needed to propel the latest engines using high octane fuel, and burn it stoichiometrically in order to deliver the performance expected from these modern cars. But this is easier said than done because these sub-circuits and associated control modules rely on a number of inputs sensors and actuators distributed all over the engine and the car in general, to successfully control of the crank synchronous path.

In order for the ignition sub-system to function optimally for example, it requires feedback information about what is presently happening in the engine so that it can take corrective action if needs be, in real time. Likewise the fuel mixture sub-circuit can only determine if the mixture is rich or lean from the feedback information, then take corrective action to increase or decrease the quantity of fuel based on the amount of oxygen present. Like wise the crankshaft timing sub-circuit depends on feedback information and maintain a constant torque. Yet all three these ECM sub-circuits works very closely in conjunction with one another and other sub-circuits to achieve optimal performance. 

Restated, the ECM is in control of the torque and torque reduction circuits, which just happens to annoy the arse-mousse out of Volkswagen, Audi, SEAT and Skoda owners. It is commonly referred to as the EPC -Electronic Power Control. Essentially EPC is limp mode's best friend and vehicle owners worst enemy.  ECM torque reduction is handled via the crank synchronous path, and involve the  ignition system sensors, the knock sensors, and fuel mixture both short trim and long trim. 

Input signals are needed for calculating precise ignition timing:

1) Engine Coolant Temperature Sensor (ECT)  

2) Engine Speed Sensor (RPM)  

3) Throttle Control Valve Sensor  

4) Camshaft Position Sensors

5) Knock Sensors  

6) Accelerator pedal Position sensors


By monitoring the Engine Coolant Temperature Sensor (ECT), the ECM varies the parameters of the engine as it heats up and maintains it when it has reached the correct operating temperature. 

By monitoring Engine Speed Sensor (RPM) the ECM can determine how many times the coils misfires per 1000 revolutions and how many times the injectors fail to deliver fuel. 

By monitoring the Throttle Control Valve Sensor the ECM can calculate the torque compared to how wide the throttle opens. 

By monitoring the Camshaft Position Sensors the ECM can better determine the exact time when the valves close and the exact point of ignition. 

By monitoring the  Knock sensors the ECM decides whether detonation is bad enough to take action, either  to retard / advance the engine or reduced the torque and consequently prevent engine damage. 

By monitoring the Accelerator Pedal Position sensors it can determine synchronicity between the position of the accelerator pedal when depressed and the throttle control valve and and discrepancy outside of its normal parameters will reduce the torque. 

KNOCK SENSORS

Knock sensors are very important to the overall engine torque because they detect combustion knocks in the individual cylinders. This is common when high octane fuel self ignites  which is generally known as knocking (detonation) or pinging (pre-ignition).
Knock sensors are piezo-electric components acts something like microphones do, but instead of picking up sound,  they detect vibrations in an engine which are needed by the ECM to correct the combustion process in the event of detonation or pinging.  This allows the ECM  to "retard" the engine so that it would work with different quality fuel. This implies that lower octane fuels are more prone to knock than higher octane fuels. It is therefore imperative to use the correct octane fuel prescribed for your vehicle since failure to do so can cause the EPC light to turn on and cause the vehicle to enter into limp mode.

TESTING KNOCK SENSORS

Four and six cylinder engines have 2 knock sensors each. Knock sensor 1 monitors the even bank of cylinders while Knock sensor 2 monitors  the odd bank of cylinders. W8 and W12 engine have 4 knock sensors each.  Knock sensor 1 monitors  cylinders  1 & 2, Knock sensor 2 monitors  cylinders 3 & 4, Knock sensor 3 monitors cylinder 5 & 6, and  Knock Sensor 4 monitors cylinder  7 & 8. Knock sensors are mounted directly on the crankcase and must be torqued. Failure to torque a knock sensor may cause it to malfunction and pickup engine vibrations as well as detonations.

The plug for Knock sensor (KS) 1 is normally green and it monitors cylinders  1 & 2, whereas the plug for Knock sensor (KS) 2 is normally grey and it monitors cylinders 3 & 4. Knock sensors are three pin devices with  Pin 1 = Signal, Pin 2 = Ground and Pin 3 = Shielding. Using a multimeter measure the resistance for "short circuit" between pins 1 and 2, then 1 and 3, then 2 and 3 at the Knock sensor connector. This measurements should always read infinity (open circuit).  If short circuit, replace knock sensor and make sure that it is correctly torqued to the crankcase.  Also check the wires for short circuit. If short circuit, replace. If a oscilloscope is available, connect it between pins 1 & 2 of the knock sensor. Tap the knock sensor lightly with a wrench, this should produce a fairly high frequency irregular sinusoidal waveform with a higher amplitude towards its middle. If there is no waveform coming out of the knock sensor its best to replace it because it will lead to a rise in fuel consumption and the engine management system may reverts to emergency knock control and reduce overall engine performance.

A CALL FOR EMISSIONS TESTING OF ALL MAKES OF MOTOR VEHICLES

A CALL FOR EMISSIONS TESTING OF ALL MAKES OF MOTOR VEHICLES  

By now, virtually everyone who owns a VW, Audi, Skoda or a Seat or those who don't, must  have heard about the Volkswagen AG emissions scandal. A scandal of global proportions  that rocked the entire automotive  industry and affects 11 million diesel powered vehicles as well as some 430 000 petrol powered vehicles, all of which were fitted with the now notorious "cheat device". Initially the Volkswagen management pleaded ignorance about said "cheat device" but later stepped up to the plate, admitting their liability and offering restitution to all VAG vehicle owners directly affected  by the "cheat device". 

This excludes you and me and all our fellow VW group vehicle owners who have also been compromised by Volkswagen's exploits, whether it was intentional or not. I'm specifically referring to all VAG vehicle owners loosing value on the vehicles since the scandal  broke, which is still dropping steadily.  According to Volkswagen we would just have to bite the bullet, but is offering to make a once off financial cash/voucher disbursement to all VAG vehicle owners directly affected by the "cheat device". Meanwhile, Governments from several countries are up in arms about their carbon credits, and instituting litigation against Volkswagen for the shortfall on taxation paid by consumers, because of the "doctored emission values.  Scandal mongers have been heckling and spreading rumours that the emissions problem, more than likely affect all of the 127 models of cars produced by Volkswagen. 

However, in my opinion, Volkswagen cannot be the only auto manufacturer that got their emissions figures to wrong, especially considering its global market share and its clout within the automotive industry. It gives the impression that someone out there is not too happy with Volkswagen for whatever reason and decided to set the wheels of blame, revenge, envy in motion. Having said that, there are rumours and allegations that other motor manufacturers used similar software  devices to cheat at emissions. However, none of them have come forward or owned up like Volkswagen did. Is it possible that the Kyoto protocol emission reduction agreements that were discussed over several years then ratified are unattainable, too presumptuous or just impossible to meet? If there is even the slightest truth in that, then all automotive manufactures would fall short of the target. Or is it that out of a class of x, Volkswagen is the only kid that failed. 

Evidently his cannot be true especially considering that German engineering impress and in many cases even exceeds their own expectations.  Based on this assumption, I call for emissions testing across the entire spectrum of motor vehicles, especially American cars because they were renown as gas guzzlers and where there is fire, is obviously a lot of smoke. With COP21 just a month away, it would be in the interest of all vehicle owners to demand that their preferred manufacture submit their cars for emission testing. It would be a great injustice to Volkswagen and VAG vehicle owners if all the manufacturers are guilty and only Volkswagen gets burnt in the process. Add you opinion below if you think that all motor manufacturers emissions figures needs to be scrutenized.

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TRAPPED INSIDE VW POLO

TRAPPED INSIDE VW POLO

Believe it or not, I got locked inside my VW Polo and couldn't get out. The self lock was activated, and me pulling at the door release lever just had no effect. The locking indicator pin surfaced from hiding put retracted when I released the door lever. For the sake of clarity, let me start at the beginning.  In a previous blog, I mentioned that when my VW Polo 2.0 Highline sedan was returned from its 90 000 Km service, it came back with a stripped nut  that tightens the earth terminal of the battery. I suspected that it was the cause of intermittent loss of power steering and I was going to get round to replacing it, but I just didn't have the time. Yep, procrastination is an evil that does get the better of all of us at one time or the other. 

VW Polo 9N Fuse card

Anyway, getting locked inside my VW Polo on Saturday morning gave me a scare that I immediately went and replaced the entire terminal and not just the stripped nut. The previous evening, whilst driving home from movies, the dashboard lights on my VW Polo stopped working, it kinda just went dark. So when I arrived home, I started fiddling to determine why, and I discovered that the wipers and the indicators weren't working either. Must be a fuse I thought. So I went straight to the fuse box and whipped out  the scorecard. Seconds later I identified the fuse responsible for supplying the dashboard with power (marked with yellow arrow and see the powdery substance in fuse holder, it's most probably oxidation from condensation). I got out my multimeter and checked the 5A fuse (fuse 30) and as I suspected, it was open circuit, fused, blown. Oh crap, I didn't have a spare so the following morning, off I went to the auto spare to get a replacement.  It was rather hot so I opened my window about 10 cm before I took off. As I pulled away,  the  self  lock  engaged at the very moment I realized that I didn't  take my wallet. So I stopped, reversed back about the 100 meters I drove, switched off the engine pulled out the key, pulled the door handle and it wouldn’t  open. Pulling at the door release lever just raised the locking indicator pin put retracted when I released the door lever. I then reinserted the key, turned on the ignition, pressed the unlock button on the door, heard the door unlock, opened the door, jumped out, ran inside grabbed my wallet, got back into the Polo and off I went once again.  

VW Polo 9N Fuse holder

This time, I noticed that the auto lock engaged at about 40km ph. Thinking nothing of it, I arrived at the auto spares, switched off the engine, pulled out the key, pulled the door release lever and like before it wouldn't open.  And as before I reinserted the key turned on the ignition, pressed the door release yet nothing happened. I then realized that the ignition wasn’t on. So I attempted to start the engine and nothing happened. The battery terminal wasn't making contact, I came loose once again and the engine wouldn't start. By extension, there was also no power to the door electronics that operated the door. In desperation to get out, I even tried the fob remote unlock button even though I knew that without a battery connection the door electronics cannot open and neither power the motor that rolls down the electric windows. I was stuck inside. I figured if I could get my arm through the 10 cm opening, I could possibly open the door manually with the key. But the opening was too small or my arm too thick.  Now it was starting to get hot inside the Polo. My only other option was to ask a passer-by to unlock the door for me. So a few minutes later an elderly gentleman walked by, whom I alerted, and speaking through the window opening, and handing him the key   through the window opening, I asked him to unlock the door which he obligingly did.  

VW Polo 9N Fuse card

With the door open, my mind was racing, what if the window wasn't slightly open, meaning I wouldn't have been able to pass the key to anyone to open the door. I would have been trapped inside and helpless. The escalating heat would have got the better of me. I probably would have had to kick-in the driver-door window since it's the only door that actually has a key receptacle, so that I could unlock it from the outside. This made me wonder what would happen if the battery gets damaged or destroyed in a collision and I was injured inside and not able to break the window. I know that in the event of a crash when the airbags pop, the on-board software is configured to automatically unlock the doors, but what if the supply voltage to the indicators gets shorted in a crash causing that fuse in question  also to blow. Clearly this is a hazard, and I would think a small sealed backup battery like those used for alarm systems fitted inside the cockpit under the dash or the consol would be a good idea. I think the brave among you should try to replicate this problem on your vehicles by removing the 5A fuse in question and disconnect the battery then assess whether or not this is acceptable design or a reason to get into Volkswagen's face about it. They are already going through the pressures of their emissions scandal, and it really isn't nice to kick a dog when it's down.

AUDI OIL USAGE

EXCESSIVE OIL USAGE ON AUDI A4

In a previous blog Audi Oil Pump Problem - Audi A4 Engine Noise, I mentioned the benefits of using VW 503.00 Long Life Engine Oil, but it seems that I was also mislead by the VW propriety oil specification the expanse of which I was unaware. This is probably the reason why my sister's A4 2.0L 2007 engine gave up the ghost. But as they say in the legal circles, "Ignorance of the Law is no excuse". Apparently as long ago as the year 2000 increased requirements compelled vehicle manufacturers globally to reduce exhaust emissions, minimize their carbon footprint, and improve overall fuel economy. Since motor oil plays a crucial  role in meeting these requirements,  the API's (American Petroleum Institute) old petroleum-based motor oils standards was abandoned by VW in favour of advanced cutting-edge synthetic motor oil formulations. As a result, the technologically advanced Audi engine designs required a very specific motor oil that met with Audi quality specification. 

Its newer models fitted with advanced fuel injection systems needs to  be lubricated  by this very specific motor oil formulations in order to guarantee optimal system reliability and fuel economy. These oil specifications started with VW 500.00 for models prior to year 2000 which has been superceded by VW 502.00. Then there is  also  VW 503.00, VW 503.01, VW 504.00, VW 505.00, VW 505.01, VW 506.00, VW 506.01, VW 507.00, etc, each applicable to either or both gasoline and diesel Euro standard engines. But certain oil specs are not suitable for certain vehicles. For example RAVENOL WIV III SAE 5W-30 is not suitable for specification VW 506 01. Meaning Audi engines with LongLife Service (QG1): Diesel-Engines (R5-, V10 TDI Pumpe-Düse) with or without Diesel Particulate Filter.  As well as  Audi engines without LongLife Service: R5-, V10 TDI Pumpe-Düse with or without Diesel Particulate Filter.

Topping up with conventional motor oil that does not meet Audi oil quality standards is therefore risky because the wrong motor oils could cause damage to internal engine components, somewhat increase emissions, reduce fuel mileage, and very likely void applicable vehicle warranties. The vehicle is also bound to use excessive oil and tend to smoke a lot more.

Ravenol HPS 5W-30 oil meets the Audi oil quality standard 502 00 and is  recommended for Audi A4 2005/2006 and on Audi A3 models equipped with the 2.0 Liter Turbo engine with FSI. Their fuel pumps are driven directly off the engine camshaft and lubricated with engine motor oil.  By not using the approved Audi motor oil  these models are subject to premature engine wear which will result in a loud ticking valve noise  after the engine has warmed up to its  operating temperature.  

Ravenol VMP Audi Oil 2010 - meets the Audi 507 00 Oil Spec and is recommended for use on Audi A3 TDI and 2009 - on Audi Q7 TDI models equipped with a Diesel Particulate Filter (DPF). Using non-approved Audi motor oil will results in increased oil consumption oil since it will be burning oil. Any non-approved TDI motor oils will clog the DPF  prematurely which is also  quite costly to replace. 

Since the VW oil specification and oil usage cannot be generalized across the Audi and Porsche ranges and old petroleum-based motor oils are no longer usable, it is no wonder that Audi owners are complaining about excessive oil use. Some Audi owners have driven as little as 600 miles or about 950 kilometers before the engine oil low light goes on and the buzzer drives  the m crazy. This is probably because they topped-up with non synthetic oil. Funny enough, Audi stresses the  point of not adding petroleum-based motor oil to its synthetic brands.

FOOL ME ONCE SHAME ON YOU; FOOL ME TWICE SHAME ON ME

VW SHAMED  TWICE SHAME FOR EMISSION CHEATING

Thus far Volkswagen AG, Audi AG and Volkswagen Group of America, Inc. and Volkswagen (VW) as a whole has gone through the mill for the EPA emissions scandal that broke on the 18 September 2015. They have suffered massive third-quarter financial losses. Legal injunctions have compelled them to recall 11 million vehicles fitted with the now notorious 2.0L TDI engine. They are obliged to repair them entirely at their own cost which could take at least two years. They had to set aside some 7 billion Euros as restitution and compensation to VAG vehicles owners whose vehicles will, as a result of the "cheat device", have  diminished performance and poorer fuel economy. They fired their heads of Research and Development and launched an internal investigation into the “rogue software engineers” responsible for fitment of "cheat device". They have even instated a new CEO, Matthias Mueller, the former  boss of Porsche to the helm, to steer them out of the arse mousse  that Volkswagen find themselves sinking into deeper day by day.

The largest Automobile manufacturer in the World.

As if this isn't enough,  US’s Environmental Protection Agency (EPA) just notified Volkswagen Aktiengesellschaft of a second breach of clean air legislation. On the 2nd  November 2015, the EPA issued them with a second notice of violation (NOV) of the Clean Air Act. This NOV alleges that VW developed and installed defeat mechanisms in model years 2014 through 2016 VW, Audi and Porsche light duty diesel vehicles equipped with 3.0 liter V6 TDI engines. The harmful nitrogen oxide (NOx) emissions produced by diesel engines fitted in the 2014 VW Touareg, the 2015 Porsche Cayenne, and the 2016 Audi A6 Quattro, A7 Quattro, A8, A8L, and Q5, appear to exceed the EPA’s standard by at least nine times. 

3.0 Liter V6 TDI Engine

In their own defence VW emphatically denied the charges of fitting the “cheat device” into its luxury brand of vehicles. However the following day  VW admitted that certain “unexplained inconsistencies” had been found during the testing process for CO2 emissions. VW added that approximately 800,000 vehicles are currently thought to be involved, most of them sold in Europe.  But some of the vehicles now involved have petrol engines, implying that the scale of the second  installment of the emission scandal could be much greater than initially assumed. 

Suddenly the “credibility” of the “rogue software engineers” argument just fades into obscurity. It is just to outlandish, flimsy and too incredulous now that Porsche and other luxury brand of vehicles are also involved. This boils down to down-right systematic manipulation and rigging of emissions test data by VW in order to gain themselves and unfair and an illegal  competitive advantage over its competitors. These latest developments just tarnished Volkswagen’s reputation and future sales even further, perhaps irreparably.  But to regain any sort of confidence and trust from both customers and investors, Volkswagen would have to make some radical changes to its management  and come clean. 

Considering that for the first time Toyota sales has overtaken that of VW.  And that Volkswagen  will forfeit all its CAFE (Corporate Average Fuel Economy)  carbon credits, and have to pay the taxation difference between the lower vehicle tax that  VW’s customers have unwittingly paid and what was actually due. Besides  getting grilled at COP 21 on the 7- 8 December 2015 for fooling the rest of the world twice.  And to add insult to injury, VW sales across all models, including petrol engines sales dropped by almost 10% since October 2015. Credit ratings agencies Moody’s and S&P have downgraded VW and three other major ratings agencies have VW on negative watch considering further downgrades. What a  deal breaker!