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失效模式分析 Failure mode analysis



氧传感器常见故障
- 氧传感器中毒
- 积碳
- 氧传感器陶瓷碎裂
- 加热器电阻丝烧断
- 氧传感器内部线路断脱

故障的检查方法
- 氧传感器加热器电阻的检查
拔下氧传感器线束插头,用万用表电阻档测量氧传感器接线端中加热器接柱与搭铁接柱之间的电阻,其阻值为4-40Ω。
如不符合标准,应更换氧传感器。

- 氧传感器反馈电压的测量
测量氧传感器的反馈电压时,应拔下氧传感器的线束插头,对照车型的电路图,从氧传感器的反馈电压输出接线柱上引出一条细导线,然后插好线束插头,在发动机运转中,从引出线上测出反馈电压。对氧传感器的反馈电压进行检测时,最好使用具有低量程(通常为2V)和高阻抗(内阻大于10MΩ)的指针型万用表。具体的检测方法如下:

1) 将发动机热车至正常工作温度(或起动后以2500r/min的转速运转2min);

2) 将万用表电压档的负表笔接故障检测插座内的E1或蓄电池负极,正表笔接故障检测插座内的OX1或OX2插孔,或接氧传感器线束插头上的信号输出线;

3) 让发动机以2500r/min左右的转速保持运转,同时检查电压表指针能否在0-1V之间来回摆动,记下10s内电压表指针摆动的次数。在正常情况下,随着反馈控制的进行,氧传感器的反馈电压将在0.45V上下不断变化,10s内反馈电压的变化次数应不少于8次。如果少于8次,则说明氧传感器或反馈控制系统工作不正常,其原因可能是氧传感器表面有积碳,使灵敏度降低所致。对此,应让发动机以2500r/min的转速运转约2min,以清除氧传感器表面的积碳,然后再检查反馈电压。如果在清除积碳可后电压表指针变化依旧缓慢,则说明氧传感器损坏,或电脑反馈控制电路有故障。

4)检查氧传感器有无损坏
拔下氧传感器的线束插头,使氧传感器不再与电脑连接,反馈控制系统处于开环控制状态。将万用表电压档的正表笔直接与氧传感器反馈电压输出接线柱连接,负表笔良好搭铁。在发动机运转过程中测量反馈电压,先脱开接在进气管上的曲轴箱强制通风管或其他真空软管,人为地形成稀混合气,同时观看电压表,其指针读数应下降。然后接上脱开的管路,再拔下水温传感器接头,用一个4-8KΩ的电阻代替水温传感器,人为地形成浓混合气,同时观看电压表,其指针读数应上升。也可以用突然踩下或松开加速踏板的方法来改变混合气的浓度,在突然踩下加速踏板时,混合气变浓,反馈电压应上升;突然松开加速踏板时,混合气变稀,反馈电压应下降。如果氧传感器的反馈电压无上述变化,表明氧传感器已损坏。

5) 氧传感器外观颜色的检查
从排气管上拆下氧传感器,检查传感器外壳上的通气孔有无堵塞,陶瓷芯有无破损。如有破损,则应更换氧传感器。
通过观察氧传感器顶尖部位的颜色也可以判断故障:
① 淡灰色顶尖:这是氧传感器的正常颜色;
② 白色顶尖:由硅污染造成的,此时必须更换氧传感器;
③ 棕色顶尖:由铅污染造成的,如果严重,也必须更换氧传感器;

黑色顶尖:由积碳造成的,在排除发动机积碳故障后,一般可以自动清除氧传感器上的积碳。


Faults of the Oxygen Sensor
●  Oxygen sensor poisoning
●  Carbon deposit
●  Oxygen Sensor Ceramics cracked
●  Heater resistance wires burnt out
●  Oxygen Sensor internal circuits broken off Inspection methods of faults
●  Checking of the oxygen sensor heater resistance
Unplug the oxygen sensor wiring harness plug, and measure the resistance with a multimeter between the oxygen sensor heater terminals connected column and bond strap connected column, its standard resistance is 4-40Ω. If not meet standards, you should replace the oxygen sensor.

●  Measurement of the oxygen sensor feedback voltage
When measuring oxygen sensor feedback voltage, you should unplug the oxygen sensor wiring harness plug. First, collate electric circuit chart, and extract a thin wire from output terminal of the oxygen sensor feedback voltage. Then plug the wiring harness plug, and measure the feedback voltage from the outgoing line in the engine running. When detecting the oxygen sensor feedback voltage, you would best to use low-range (typically 2V) and high-impedance (R>10MΩ) pointer-type multimeters. Specific detection methods are as follows:

1) Heat the car's engine to a normal operating temperature (or start running for 2min at a speed of 2500r/min)

2) Put the negative pen-shape metre of voltage profile multimeters to contact the E1 within failure detection socket or the battery negative, and the positive pen-shape metre to contact the OX1 or OX2 jack within failure detection socket, or receive the signal output line of oxygen sensor wiring harness plug.

3) Allow the engine to remain running at a speed of around 2500 r/min, and at the same time check whether the voltmeter pointer could swing back and forth between 0-1V, and note the swing number of voltmeter pointer within 10s. Under normal circumstances, with the ongoing of feedback control, oxygen sensor feedback voltage will be 0.45V changing up and down, the change number of feedback voltage should not less than 8 times. If less than 8 times, it shows that the oxygen sensor or feedback control system is not working properly. The reason may be the oxygen sensor surface carbon deposition, making lower sensitivity. This should allow the engine to run at a speed of 2500 r/min for 2min, to clear the carbon deposition of oxygen sensor, and then check the feedback voltage. If after clearing the carbon deposition, the change of voltmeter pointer is still slow, it shows that the oxygen sensor is broken or the computer feedback control circuit is defective.

4) Check the oxygen sensor whether damage
Unplug the oxygen sensor wiring harness plug, so that the oxygen sensor is no longer connected to the computer, and the feedback control system is in a state of open-loop control. Put the positive pen-shape metre of voltage profile multimeter to directly connect with the feedback voltage output terminal of oxygen sensor, and the negative pen-shape metre have a good put up iron. Measure the feedback voltage in the course of engine running. First disengage the crankcase forced ventilation tube which connected to the intake manifold or other vacuum hose, to artificially form dilute mixture gas, and also notice the voltmeter, its pointer readings should decline. Then connect the disengaged pipe up, and disconnect the water temperature sensor connector, and substitute with a 4-8 KΩ resistance to a water temperature sensor, to artificially form rich mixture gas, and also notice the voltmeter, its pointer readings should be increase. It also can use a method of suddenly trample or loose accelerator pedal to change the concentration of the mixture. When you suddenly trample the accelerator pedal, the mixture gas become thicken, and the feedback voltage should be increased; when you suddenly loose the accelerator pedal, the mixture gas become thinning, and the feedback voltage should decline. If the oxygen sensor feedback voltage has no above changes, shows that the oxygen sensor is damaged.

5) Check the color appearance of oxygen sensor
Remove the oxygen sensor from the exhaust pipe, Check the venthole of sensor enclosure whether be plug and the ceramic core whether be damaged. If damaged, you should to replace the oxygen sensor.
We can also judge faults by observing the top color of oxygen sensor, such as:
① Light gray top: This is the normal color of oxygen sensor.
② White top: It caused by the silicon contamination, this moment you must replace the oxygen sensor.
③ Brown top: It caused by the lead contamination, if serious, must also replace the oxygen sensor.
Black top: It due to the carbon deposit, after excluding the fault of engine carbon deposit, general it can automatically clear the carbon deposit of oxygen sensor.


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