Engine Retrofitting Group Work

Mechanical Engineering (AUTO) Level 400

Group 13

50. Transmission Fluid Temperature (TFT) Sensor

This sensor is a vital part of the transmission's internal electronics, often integrated
into the internal wiring harness or the valve body. It is submerged in Automatic
Transmission Fluid (ATF). Because ATF serves as both a lubricant and a hydraulic fluid,
this sensor monitors the fluid’s heat, which directly correlates to its viscosity and its
ability to hold pressure within the transmission’s clutch packs.

Purpose: Monitors the operating temperature of the automatic transmission fluid (ATF).
Function: Aids the Transmission Control Module (TCM) in adjusting shift patterns (e.g.,
delaying shifts when cold), controlling torque converter clutch lockup, and activating
"limp mode" to prevent damage if the fluid overheats.

51. Cylinder Head Temperature (CHT) Sensor

The CHT is unique because it is a dry sensor. It does not come into contact with any
liquid. It is threaded into a blind hole in the aluminum casting of the cylinder head. It
measures the thermal energy of the metal itself. This allows it to provide a reading even
if the engine has suffered a total loss of coolant, a scenario where a standard "wet"
sensor would become useless.

Purpose: Directly measures the temperature of the metal in the cylinder head.
Function: Often used in engines that lack a traditional ECT sensor or as a backup; it
detects overheating faster than coolant sensors and can trigger failsafe modes to
prevent engine destruction.

52. Radiator Coolant Level Sensor

Usually a magnetic reed switch or a conductivity probe. In the reed switch version, a
small float with a magnet inside sits in a chamber in the radiator’s upper tank. As the
fluid level moves the float, the magnet opens or closes a circuit. In conductivity
versions, it uses the coolant itself to complete a small electrical path between two
probes; if air replaces the coolant, the circuit breaks.
Purpose: Detects if the coolant level inside the radiator is too low.
Function: Triggers a low-coolant dashboard warning light to prevent engine damage due
to overheating caused by loss of fluid.

53. Expansion Tank Coolant Level Sensor

Located in the pressurized plastic reservoir (the degas bottle). Like the radiator level
sensor, it uses a float-and-switch mechanism. It is designed to detect the volume of the
"reserve" fluid. It sits at a specific "minimum" line to account for the natural expansion
and contraction of the fluid as it heats and cools.
Purpose: Monitors the fluid level in the pressurized expansion tank/coolant reservoir.
Function: Alerts the driver of low coolant levels before the fluid level drops dangerously
low within the main radiator.

54. Engine Block Heater Temperature Sensor

This sensor is specifically associated with the cold-climate heating element plugged
into a 110V/220V outlet. It is often a clip-on or threaded thermistor located near the
heating element or in a nearby water jacket. It measures the localized rise in
temperature provided by the external heating source rather than the heat generated by
combustion.
Purpose: Detects the temperature of the coolant when a block heater is in use.
Function: Regulates the operation of the electric heater to ensure the engine is at a
sufficient starting temperature in cold climates, preventing energy waste.
Temperature & Fluid Sensors

55. Turbocharger Coolant Temperature Sensor

This is a high-temp thermistor located on the coolant return line exiting the
turbocharger center housing. Because turbochargers are exhaust-driven and can glow
red-hot, the coolant passing through them gains heat rapidly. This sensor monitors the
specific thermal "load" the turbo is adding to the overall cooling system.
Purpose: Measures the temperature of the coolant specifically cooling the
turbocharger.
Function: Monitors turbo heat soak to prevent damage, often triggering electric pumps
to circulate coolant through the turbocharger after the engine is turned off (turbo timer
function).

56. Intercooler Temperature Sensor

Also known as a Charge Air Temperature (CAT) sensor. It is located in the intake piping,
specifically after the intercooler but before the throttle body. It measures the
temperature of the compressed air. Unlike fluid sensors, this sensor is designed with an
exposed "cage" or element to respond very quickly to rapid changes in airflow
temperature.
Purpose: Measures the temperature of the air leaving the intercooler (charge air) before
it enters the intake manifold.
Function: Helps the ECU calculate air density to optimize fuel delivery and ignition
timing, and monitors the efficiency of the turbocharger intercooler.

57. Automatic Transmission Oil Cooler Temperature Sensor

Located on the external cooling lines that run from the transmission to the front of the
car. It is usually found at the junction where the fluid enters the dedicated transmission
heat exchanger. It monitors the fluid's state as it interfaces with the ambient air cooling.
Purpose
The primary purpose of this sensor is to monitor the thermal efficiency of the
transmission's external cooling circuit. While the internal Transmission Fluid
Temperature (TFT) sensor tells the computer how hot the transmission is,

Function* Cooling Fan Control: If the sensor detects that the fluid exiting or entering the
cooler is above a specific threshold, it triggers the electric cooling fans to pull more air
through the transmission cooler fins.
* Active Grille Shutter Adjustment: In modern vehicles, the ECU may open active
aerodynamic shutters to increase airflow to the transmission cooler based on this
sensor's data.
* Overheat Protection: If the temperature at the cooler remains too high, the system
may trigger a "Limp Mode" or "Reduced Power Mode" to protect the transmission
clutches from burning.

Pressure and Lubrication sensors

[Link] Sensors
● Definition: Devices that measure the force exerted by gases or liquids on a surface,
 ●
converting this physical pressure into an electrical signal (voltage or current).
● Working Principle: A diaphragm inside the sensor bends under pressure, altering a
resistive (piezoresistive) or capacitive element. This change in electrical properties is
proportional to the pressure applied.
● Types:
○ Gauge Pressure: Measures pressure relative to atmospheric pressure (e.g., tire
pressure).
○ Absolute Pressure: Measures pressure relative to a vacuum.
○ Differential Pressure: Measures the difference between two points (e.g., to
detect clogged filters).
● Applications: Industrial machinery, hydraulics, pneumatic systems, engines, and HVAC
systems.

2. Lubrication (Oil Pressure) Sensors

● Definition: A specific type of pressure sensor designed to monitor the pressure and,
sometimes, the quality of lubricating oil within an engine or machinery.
● Working Principle: Similar to general pressure sensors, they typically use a diaphragm.
As oil pressure drops (due to low oil) or increases, the diaphragm moves, changing
electrical resistance and sending a signal to the engine control unit (ECU) or a
dashboard gauge.
● Types:
○ Switch-type: Triggers a warning light if pressure drops below a set threshold.
○ Analog/Resistive: Provides continuous, real-time pressure readings to a gauge.
○ Oil Property/Quality Sensors: Advanced sensors that monitor viscosity, density,
and contamination in real-time.
● Purpose: Ensures proper lubrication to prevent overheating and premature engine/
machine failure

58. Engine Coolant Temperature (ECT) Sensor 2 (Radiator Outlet)

This is typically a Negative Temperature Coefficient (NTC) thermistor. Physically, it is
encased in a plastic or brass housing and is submerged directly into the coolant flow.
While the primary ECT sensor sits near the thermostat (engine side), Sensor 2 is located
at the "cold" side of the system, usually in the bottom tank of the radiator or the lower
radiator hose. It tracks the temperature of the liquid after it has completed its pass
through the radiator fins.
Purpose: Monitors the temperature of the coolant after it has passed through the
radiator.
Function: It compares the radiator outlet temperature with the engine-inlet temperature
(ECT 1) to determine the efficiency of the radiator and manage fan speed/thermostat
operation to ensure optimal cooling.

59. Engine Oil Temperature Sensor

Constructed similarly to a coolant sensor but designed to withstand higher thermal
ranges and the chemical properties of synthetic lubricants. It is often integrated into
the oil level sensor assembly at the bottom of the oil pan or threaded into the oil filter
housing where the oil flow is most concentrated. Unlike coolant, which stays relatively
stable, this sensor monitors a fluid that can exceed 120°C (250°F) during high-
performance driving.

Purpose: Monitors the temperature of the engine oil.

Function: Provides data to the ECU to manage engine longevity, adjust for oil viscosity,
and warn of high engine load or overheating that may not be immediately apparent
through coolant temperature alone.