Fuel pressure sensors in a 2006 DB9

Disclaimer: This instruction worked for me, there's no guarantee it will work in your car the same way. If you follow this instruction of modifying your car, you will do it at YOUR OWN RISK.


Note: Up to 11/2005 AM used two pressure sensors plus one standalone fuel rail temperature sensor. From 2006 on they used two sensors each of which reads pressure and temperature. However, only the temperature data (the one of the rear sensor) is read, while the front one isn't even connected. Therefore, you see 4 wires going to the rear connector and just 3 wires on the front connector.

Introduction

The fuel pressure sensors are one key element in engine control. If they do not work properly, the PCM misinterprets the data and the amount of fuel delivered to the injectors might be way too high or way too low (i.e. too rich or too lean) and can cause engine stalls and MIL lamp going on.

Unfortunately there is not that much information on these sensors that you can find easily, and what you find (from Bosch regarding a similar absolute pressure sensor) is a quick and dirty data sheet that comprises lots of obvious errors (Bosch, i know you definitely CAN do better!).

So let's see what i found out:

Functionality

The pressure sensor reads the pressure difference between the fuel line (main flange) and the engine vacuum (attached via vacuum line at the side). It is a piezoresistive Eeement with amplifier electronics and temperature compensation on a single silicon chip.
The temperature sensor is a passive NTC resistor.

Wiring

Sensor descriptionSensor PinWire colorComment
OUT1GR green redOutput voltage between 0.3 and 4.8V. Typical output voltage of sensor with no pressure difference between both sides is 0.5V
VCC2U Bluepositive voltage supply; should be 5.0V
NTC3G GreenTemperature sensor; just used at front sensor. Measure resistance between NTC and GND
GND4BP black purpleGround

Testing

Testing the temperature sensor is easy: Simply measure resistance between pins 3 and 4. Typical reading is about 30 kOhm at ambient temperature. Use a hair dryer pointing at the tip that reaches into the fuel rail and you should see the resistance dropping fast to about 10k Ohm when "hot".


The pressure sensor is more difficult to test, since it requires the built in amplifier to work. You neet to connect a +5V supply to VCC and GND and then measure the voltage between GND and OUT. No pressure exerted you should read 0.5V. If you use a disposable 5 or 10ml syringe, fill it half with air and attach it to the vacuum connector (it nicely fits in there), then you should see the Voltage drop and rise as you move the plunger within the syringe.




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