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OBJECTIVES

OBJECTIVES. After studying Chapter 1, the reader will be able to: Prepare for ASE computerized engine controls diagnosis (A8) certification test content area “E.” List the steps of the diagnostic process.

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OBJECTIVES

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  1. OBJECTIVES After studying Chapter 1, the reader will be able to: • Prepare for ASE computerized engine controls diagnosis (A8) certification test content area “E.” • List the steps of the diagnostic process. • Describe the simple preliminary tests that should be performed at the start of the diagnostic process. • List six items to check as part of a thorough visual inspection. • Explain the troubleshooting procedures to follow if a diagnostic trouble code has been set. • Explain the troubleshooting procedures to follow if no diagnostic trouble code has been set. • Discuss the type of scan tools that are used to assess vehicle components. • Describe the methods that can be used to reprogram (reflash) a vehicle computer.

  2. THE EIGHT-STEP DIAGNOSTIC PROCEDURE • It is important that all automotive service technicians know how to diagnose and troubleshoot engine computer systems. • All vehicle manufacturers recommend a diagnostic procedure, and the plan suggested in this chapter combines most of the features of these plans plus additional steps developed over years of real-world problem solving. FIGURE 1-1 A funnel is one way to visualize the diagnostic process. The purpose is to narrow the possible causes of a concern until the root cause is determined and corrected.

  3. THE EIGHT-STEP DIAGNOSTIC PROCEDURE • Step 1 Verify the Problem • Step 2 Perform a Thorough Visual Inspection and Basic Tests • Step 3 Retrieve the Diagnostic Trouble Codes (DTCs) • Step 4 Check for Technical Service Bulletins (TSBs) • Step 5 Look Carefully at Scan Tool Data • Step 6 Narrow the Problem to a System or Cylinder • Step 7 Repair the Problem and Determine the Root Cause • Step 8 Verify the Repair and Clear Any Stored DTCs

  4. THE EIGHT-STEP DIAGNOSTIC PROCEDURE FIGURE 1-2 Step #1 is to verify the customer concern or problem. If the problem cannot be verified, then the repair cannot be verified.

  5. THE EIGHT-STEP DIAGNOSTIC PROCEDURE FIGURE 1-3 A form that the customer should fill out if there is a driveablilty concern to help the service technician more quickly find the root cause.

  6. THE EIGHT-STEP DIAGNOSTIC PROCEDURE FIGURE 1-4 This is what was found when removing an air filter from a vehicle that had a lack-of power concern. Obviously the nuts were deposited by squirrels or some other animal, blocking a lot of the airflow into the engine.

  7. THE EIGHT-STEP DIAGNOSTIC PROCEDURE FIGURE 1-5 Using a bright light makes seeing where the smoke is coming from easier. In this case, smoke was added to the intake manifold with the inlet blocked with a yellow plastic cap and smoke was seen escaping past a gasket at the idle air control.

  8. THE EIGHT-STEP DIAGNOSTIC PROCEDURE FIGURE 1-6 A spark tester connected to a spark plug wire or coil output. A typical spark tester will only fire if at least 25,000 volts is available from the coil, making a spark tester a very useful tool. Do not use one that just lights when a spark is present, because they do not require more than about 2,000 volts to light.

  9. THE EIGHT-STEP DIAGNOSTIC PROCEDURE FIGURE 1-7 Step #3 in the diagnostic process is to retrieve any stored diagnostic trouble codes.

  10. THE EIGHT-STEP DIAGNOSTIC PROCEDURE FIGURE 1-8 After checking for stored diagnostic trouble codes (DTCs), the wise technician checks service information for any technical service bulletins that may relate to the vehicle being serviced.

  11. THE EIGHT-STEP DIAGNOSTIC PROCEDURE FIGURE 1-9 Looking carefully at the scan tool data is very helpful in locating the source of a problem.

  12. THE EIGHT-STEP DIAGNOSTIC PROCEDURE FIGURE 1-10 Step #8 is very important. Be sure that the customer’s concern has been corrected.

  13. SCAN TOOLS • Scan tools are the workhorse for any diagnostic work on all vehicles. Scan tools can be divided into two basic groups: • Factory scan tools. • Aftermarket scan tools. FIGURE 1-11 A TECH 2 scan tool is the factory scan tool used on General Motors vehicles.

  14. SCAN TOOLS FIGURE 1-12 Some scan tools use pocket PCs which make it very convenient to use.

  15. RETRIEVAL OF DIAGNOSTIC INFORMATION • To retrieve diagnostic information from the powertrain control module (PCM), a scan tool is needed. • If the factory scan tool is used, then all of the data can be retrieved. • If a generic OBD-II scan tool is used, only the emissions-related data can be retrieved.

  16. TROUBLESHOOTING USING DIAGNOSTIC TROUBLE CODES • Pinning down causes of the actual problem can be accomplished by trying to set the opposite code. • For example, if a code indicates an open throttle position (TP) sensor (high resistance), clear the code and create a shorted (low-resistance) condition. • This can be accomplished by using a jumper wire and connecting the signal terminal to the 5-volt reference terminal.

  17. TROUBLESHOOTING USING DIAGNOSTIC TROUBLE CODES • This should set a diagnostic trouble code. • If the opposite code sets, this indicates that the wiring and connector for the sensor is okay and the sensor itself is defective (open). • If the same code sets, this indicates that the wiring or electrical connection is open (has high resistance) and is the cause of the setting of the DTC.

  18. TROUBLESHOOTING USING DIAGNOSTIC TROUBLE CODES • Methods for Clearing Diagnostic Trouble Codes • Clearing diagnostic trouble codes from a vehicle computer sometimes needs to be performed. • Clearing codes—Method 1. The preferred method of clearing codes is by using a scan tool. • Clearing codes—Method 2. If a scan tool is not available or a scan tool cannot be used on the vehicle being serviced, the power to the computer can be disconnected. • 1. Disconnect the fusible link (if so equipped) that feeds the computer. • 2. Disconnect the fuse or fuses that feed the computer. • Clearing codes—Method 3. If the other two methods cannot be used, the negative () battery cable can be disconnected to clear stored diagnostic trouble codes.

  19. FLASH CODE RETRIEVAL ON OBD-I GENERAL MOTORS VEHICLES • The GM system uses a “check engine” or “check engine soon” MIL to notify the driver of possible system failure. Under the dash (on most GM vehicles) is a data link connector (DLC) previously called an assembly line communications link (ALCL) or assembly line diagnostic link (ALDL). FIGURE 1-13 To retrieve flash codes from an OBD-I General Motors vehicle, connect terminals A and B with the ignition on–engine off. The M terminal is used to retrieve data from the sensors to a scan tool.

  20. RETRIEVING FORD DIAGNOSTIC CODES • The best tool to use during troubleshooting of a Ford vehicle is a self-test automatic readout (STAR) tester, new generation STAR (NGS), WDS (Worldwide Diagnostic System), or another scan tool with Ford capabilities. FIGURE 1-14 A Ford OBD-I self-test connector. The location of this connector can vary with model and year of vehicle.

  21. RETRIEVING FORD DIAGNOSTIC CODES FIGURE 1-15 To retrieve Ford DTCs using a test light and a jumper wire, turn the ignition switch on (engine off) and make the connections shown. The test light will blink out the diagnostic trouble codes.

  22. FLASH CODE RETRIEVAL ON CHRYSLER VEHICLES • To put the computer into the self-diagnostic mode, the ignition switch must be turned on and off twice within a 5-second period (on-off-on-off-on). • The computer will flash a series of fault codes. • Older Chrysler brand products flash the “check engine” lamp on the dash.

  23. OBD-II DIAGNOSIS • Starting with the 1996 model year, all vehicles sold in the United States must use the same type of 16-pin data link connector (DLC) and must monitor emission-related components. FIGURE 1-16 A typical OBD-II data link connector (DLC). The location varies with make and model and may even be covered, but a tool is not needed to gain access. Check service information for the exact location if needed.

  24. OBD-II ACTIVE TESTS • The vehicle computer must run tests on the various emission related components and turn on the malfunction indicator lamp (MIL) if faults are detected. • OBD II is an active computer analysis system because it actually tests the operation of the oxygen sensors, exhaust gas recirculation system, and so forth whenever conditions permit. • It is the purpose and function of the powertrain control module (PCM) to monitor these components and perform these active tests.

  25. OBD-II ACTIVE TESTSOBD-II Drive Cycle • The vehicle must be driven under a variety of operating conditions for all active tests to be performed. • A trip is defined as an engine-operating drive cycle that contains the necessary conditions for a particular test to be performed.

  26. OBD-II ACTIVE TESTSTypes of OBD-II Codes • Not all OBD-II diagnostic trouble codes are of the same importance for exhaust emissions. • Each type of DTC has different requirements for it to set, and the computer will only turn on the MIL for emissions-related DTCs. • Type A Codes. • Type B Codes. • Type C and D Codes.

  27. OBD-II ACTIVE TESTSOBD-II Freeze-Frame • To assist the service technician, OBD II requires the computer to take a “snapshot” or freeze-frame of all data at the instant an emission-related DTC is set. • A scan tool is required to retrieve this data. • CARB and EPA regulations require that the controller store specific freeze-frame (engine-related) data when the first emission related fault is detected.

  28. OBD-II ACTIVE TESTSDiagnosing Intermittent Malfunctions • When dealing with an intermittent concern, you should determine the conditions when the malfunction occurs, and then try to duplicate those conditions. • If a cause is not readily apparent to you, ask the customer when the symptom occurs. • Ask if there are any conditions that seem to be related to, or cause the concern.

  29. SERVICE/FLASH PROGRAMMING • The following are three industry-standard methods used to reprogram the EEPROM: • Remote programming • Direct programming • Off-board programming FIGURE 1-17 The first step in the reprogramming procedure is to determine the current software installed using a scan tool. Not all scan tools can be used. In most cases using the factory scan tool is needed for reprogramming unless the scan tool is equipped to handle reprogramming.

  30. SERVICE/FLASH PROGRAMMING FIGURE 1-18 Follow the on-screen instructions.

  31. SERVICE/FLASH PROGRAMMING FIGURE 1-19 An Internet connection is usually needed to perform updates although some vehicle manufacturers use CDs which are updated regularly at a cost to the shop.

  32. SERVICE/FLASH PROGRAMMING FIGURE 1-20 Connecting cables and a computer to perform offboard programming.

  33. J2534 REPROGRAMMING • Legislation has mandated that vehicle manufacturers meet the SAE J2534 standards for all emissions-related systems on all new vehicles starting with model year 2004. • This standard enables independent service repair operators to program or reprogram emissions-related ECMs from a wide variety of vehicle manufacturers with a single tool.

  34. J2534 REPROGRAMMING FIGURE 1-21 The J2534 pass through reprogramming system does not need a scan tool to reflash the PCM on most 2004 and newer vehicles.

  35. J2534 REPROGRAMMING FIGURE 1-22 A typical J2534 universal reprogrammer that uses the J2534 standards.

  36. MANUFACTURER’S DIAGNOSTIC ROUTINES • Each vehicle manufacturer has established their own diagnostic routines and they should be followed. Most include the following steps: • Retrieve diagnostic trouble codes. • Check for all technical service bulletins that could be related to the stored DTC. • If there are multiple DTCs, the diagnostic routine may include checking different components or systems instead of when only one DTC was stored. • Perform system checks. • Perform a road test matching the parameters recorded in the freeze-frame to check that the repair has corrected the malfunction. • Repeat the road test to cause the MIL to be extinguished.

  37. COMPLETING SYSTEM REPAIRS • After the repair has been successfully completed, the vehicle should be driven under similar conditions that caused the original concern. • Verify that the problem has been corrected.

  38. PROCEDURES FOR RESETTING THE PCM • The PCM can be reset or cleared of previously set DTCs and freeze-frame data in the following ways: • Driving the Vehicle. • Clear DTCs Using a Scan Tool. • Battery Disconnect.

  39. ROAD TEST (DRIVE TRACE) • Use the freeze-frame data and test-drive the vehicle so that the vehicle is driven to match the conditions displayed on the freeze-frame. • If the battery has been disconnected, then the vehicle may have to be driven under conditions that allow the PCM to conduct monitor tests. • This drive pattern is called a drive cycle.

  40. EUROPEAN BOSCH DIAGNOSIS • Diagnosing a European brand vehicle, such as a Volkswagen, Audi, Mercedes, or BMW, can be a challenge. • One of the challenges is that global (generic) scan tools, while capable of supplying the specified data, do not allow access to many diagnostic trouble codes that might be set and stored.

  41. SUMMARY • Funnel diagnostics—Visual approach to a diagnostic procedure: • Verify the problem (concern) • Perform a thorough visual inspection and basic tests • Retrieve the diagnostic trouble codes (DTCs) • Check for technical service bulletins (TSBs) • Look carefully at scan tool data • Narrow the problem to a system or cylinder • Repair the problem and determine the root cause • Verify the repair and check for any stored DTCs • Care should be taken to not induce high voltage or current around any computer or computer-controlled circuit or sensor. • A thorough visual inspection is important during the diagnosis and troubleshooting of any engine performance problem or electrical malfunction. • If the MIL is on, retrieve the DTC and follow the manufacturer’s recommended procedure to find the root cause of the problem. • OBD-II vehicles use a 16-pin DLC and common DTCs.

  42. REVIEW QUETSIONS • Explain the procedure to follow when diagnosing a vehicle without any stored DTCs using a scan tool. • Discuss what the PCM does during a drive cycle to test emissionrelated components. • Explain the difference between a type A and type B OBD-II diagnostic trouble code. • List three things that should be checked as part of a thorough visual inspection. • List the eight-step funnel diagnostic procedure. • Explain why a bulletin search should be performed after stored DTCs are retrieved. • List the three methods that can be used to reprogram a PCM.

  43. CHAPTER QUIZ • Technician A says that the first step in the diagnostic process is to verify the problem (concern). Technician B says the second step is to perform a thorough visual inspection. Which technician is correct? • Technician A only • Technician B only • Both Technicians A and B • Neither Technician A nor B

  44. CHAPTER QUIZ • Technician A says that the first step in the diagnostic process is to verify the problem (concern). Technician B says the second step is to perform a thorough visual inspection. Which technician is correct? • Technician A only • Technician B only • Both Technicians A and B • Neither Technician A nor B

  45. CHAPTER QUIZ 2. Which item is not important to know before starting the diagnosis of an engine performance problem? • List of previous repairs • The brand of engine oil used • The type of gasoline used • The temperature of the engine when the problem occurs

  46. CHAPTER QUIZ 2. Which item is not important to know before starting the diagnosis of an engine performance problem? • List of previous repairs • The brand of engine oil used • The type of gasoline used • The temperature of the engine when the problem occurs

  47. CHAPTER QUIZ 3. A paper test can be used to check for a possible problem with _____. • The ignition system (bad spark plug wire) • A faulty injector on a multiport engine • A burned valve • All of the above

  48. CHAPTER QUIZ 3. A paper test can be used to check for a possible problem with _____. • The ignition system (bad spark plug wire) • A faulty injector on a multiport engine • A burned valve • All of the above

  49. CHAPTER QUIZ • Which step should be performed last when diagnosing an engine performance problem? • Checking for any stored diagnostic trouble codes • Checking for any technical service bulletins (TSBs) • Performing a thorough visual inspection • Verify the repair

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