Audi Cars 1999-05

Components & Systems


This section describes the operating principles of sending units, warning lights and gauges. For additional information on Sensors that provide information to the Engine Control Module (ECM), please refer to the following topic(s): Driveability and Emission Controls, Electronic Engine Controls, Emission Controls, Engine Control Module.

Instrument panels contain a number of indicating devices (gauges and warning lights). These devices are composed of two separate components. One is the sending unit, mounted on the engine or other remote part of the vehicle, and the other is the actual gauge or light in the instrument panel.

Several types of sending units exist, however most can be characterized as being either a pressure sensitive or a heat sensitive sensor. Sensors used for warning lights, such as a low oil pressure warning light are essentially on/off sensors. These sensors function similar to an electrical switch. The switch is operated by pressure and is either on (closed) or off (open). In the case of an oil pressure switch, it is designed to warn of low oil pressure. If the engine's oil pressure is within the manufacturer's recommendations, a properly working oil pressure switch will be in the open (off) position. If the oil pressure drops below a safe operating pressure, the oil pressure switch is closed (on) and completes the electrical circuit for the low oil pressure warning light, and the warning light should be turned on in the instrument cluster.

The other type of sensor used to monitor engine-operating parameters is the variable resistance sensor. This sensor can be either pressure or temperature sensitive. For these sensors, as the pressure or temperature changes, the resistance in the sensor changes. This type of sensor is ideal for gauges and the Engine Control Module (ECM) because it can be used to monitor changes in pressure as in an oil pressure gauge, or temperatures, as in an engine temperature gauge. The sensors used by A4 and Passat models to monitor changes in temperature are the Negative Temperature Coefficient (NTC) type.

A temperature sensor changes its resistance based on the temperature of the sensor's probe. As the temperature of the probe increases, the resistance of the sensor decreases. If a sensor's probe is installed in an engine's coolant passage, it can be used to by the coolant temperature gauge to transmit the engine's coolant temperature.

Pressure type sending units convert liquid pressure into an electrical signal that is sent to the gauge or warning light. Resistance type sending units are most often used to measure temperature and use variable resistance to control the current flow back to the indicating device. Both types of sending units are connected in a series circuit to the gauge or warning light by an electrical wire.

When the ignition is turned ON , current flows from the battery to the gauge or warning light and onward to the sending unit. If the sending unit is a single wire terminal sending unit, then the component to which the sending unit is attached supplies the electrical ground for the circuit and the circuit is grounded through the sensor. Examples of a single wire terminal sensor include:

On/Off pressure sensors: Oil pressure light sensor
Variable resistor temperature sensors: Coolant temperature gauge sensor
Variable resistor pressure sensors: Oil pressure gauge sensor.

If the sending unit is a multiple wire terminal sending unit, then at least one of the sensor's terminals are used as a source of a ground or a positive electrical current. The sensor does not use the component it is mounted on to complete the electrical circuit, therefore it needs a source of ground or positive electrical current to complete the series circuit between the sensor and the other wire(s) used to operate the component or gauge controlled by the sensor. Examples of multiple wire terminal sensors include:

On/Off thermal sensors: Electric Cooling fan thermal sensor
Variable resistor temperature sensors: Coolant temperature gauge sensor

The basic operation of a sending unit can be summarized as follows:

If it operates a light, a relay, or a cooling fan it is most likely an on/off type sensor
If it operates a gauge it is most likely a variable resistor type sensor

The basic wiring circuit for a gauge or warning light consists of:

Switched (ignition switch) battery positive ( + ) power to the gauge or warning light
A wire from the gauge or warning light wire to the sensor
On single wire terminal sensors: The ground is supplied by the component though the sensor
On multiple wire terminal sensors: A wire from the sensor to ground (either chassis or supplied from instrument cluster)

All single wire terminal sensors receive their ground from the component they mounted on.

Sometimes a variable and an on/off sensor are combined, such as the case with an oil pressure gauge with a warning light. The variable resistor portion of the sensor operates the gauge; the on/off portion of the sensor is used to operate the warning light to warn of low oil pressure should it fall below a safe level.