11

ONBOARD DIAGNOSTICS
FOR DIESELS
 ORIGINS AND DEVELOPMENT OF OBD
• Early Onboard Diagnostics
• Electronic control systems operate almost invisibly
• Emissions System and Onboard Diagnostics
• OBD-II Introduction
• The technical standards for OBD-II emissions legislation
was developed by the:
• Society of Automotive Engineers (SAE)
• Federal Test Protocol and OBD-II
• How much emissions a vehicle produces is measured
using the Federal Test Protocol (FTP)
• Federal Versus Green State Emission Standards
• Two emissions standards used to regulate emissions from
on-highway vehicles sold in North America are:
FIGURE 11–1 The malfunction indicator lamp (MIL) and the glow plug lamp (in some
models only) illuminate when a condition exists that could potentially cause excessive
emissions from a vehicle. MIL light operation is a key to OBD-II requirements to alert
the driver for any potential emissions related malfunctions.
FIGURE 11–2 A 16-pin connector located beneath and slightly to the left of the
steering column is standardized in its location and shape. This permits the use of a
single connector cable for all makes and models of vehicles under 14,000 lb GVW.
 OBD-II REQUIREMENTS
• The EPA or SAE does not specifically explain to a:
• Manufacturer how to maintain emissions
compliance of a vehicle but instead what the
outcome should be
• Other OBD-II Requirements
• Heavy-duty diesels are legislated to begin using an
onboard diagnostic system beginning in 2010
FIGURE 11–3 Older OBD-I systems used OEM specific data link connectors. This
GM truck with a 6.5L diesel used a 12-pin DLC connector to establish communication
between the scanner and the ECM.
FIGURE 11–4 Late model GM vehicles use a CAN-II network communication
protocol. Accessing OBD-II related information from the GM Duramax 6.6L requires a
communication adapter between the scanner and the DLC to translate the high
speed of serial data, which is up to 500 kb/sec, into a form usable by this scanner.
FIGURE 11–5 All the modules that have any input or output related to engine
operation or emission control are connected together by a single pair of twisted wires
which forms an onboard network. Communication takes place between the modules
in a digital equivalent of Morse code. Each module takes turn sending and receiving
information. Communicating with any module connected to the network is through the
16-pin J-1962 DLC connector.
FIGURE 11–6 Some transmission problems will cause the MIL light to illuminate.
Since light-duty emission are measured in grams per mile (or kilometer), higher
engine speeds caused by transmission related problems increase emissions.
FIGURE 11–7 OBD-II fault codes for diesels are standardized. Failure of a similar
components or system on any make of vehicle will generate the same code.
 OBD-II DIAGNOSTIC CODES
• DTC Code Nomenclature
• OBD-II requires standardization of emission related fault
codes
• First Character
• P = Powertrain
• B = Body
• C = Chassis
• U = Undefined or onboard network related codes
• Second Character
• Currently, the numbers 0 through 3 are used
• Third Character
• 1 = Fuel or Air Metering
• 2 = Fuel or Air Metering
• 3 = Ignition or Engine Misfire
• 4 = Auxiliary Emission Controls
 • 5 = Vehicle or Idle Speed Controls
• 6 = Computer or Output Circuit
• Fourth and Fifth Characters
• DTC P0192 indicates:
• P = Powertrain
• 0 = Generic
• 1 = Fuel or Air Metering Fault
• 90s block indicates a fuel rail pressure sensor.
• 92 = Fuel rail pressure sensor circuit low input
• 93 = Fuel rail pressure sensor high input
• 00 = General circuit malfunction
• P0344 = Camshaft Position Sensor Circuit Intermittent
• P0380 = Glow Plug/Heater Circuit “A” Malfunction
• Network Codes
FIGURE 11–8 Example of OBD-II code nomenclature.
 OBD-II DIAGNOSTIC CODES
• U0003 High Speed CAN Communication Bus (1) Open
• N U0005 High Speed CAN Communication Bus (1) High
• N U0006 High Speed CAN Communication Bus (2) Open
• N U0105 Lost Communication with Fuel Injector Control
• Module
• N U0306 Software Incompatibility with Fuel Injector Control
• Module
• N U0407 Invalid Data Received from Glow Plug Control
Module
• DTC Codes
• Three types of codes are set by OBD: type A, B, and C
• Readiness Code
FIGURE 11–9 A variety of code types assist a technician to identify what type of fault
has occurred, and where and when it happened.
FIGURE 11–10 A readiness code or message is displayed after an emission monitor
has performed a check of a particular emission system.
 DIESEL OBD MONITORS

• What Is a Monitor?
• Monitoring of individual components and
major engine emission control systems:
performed by OBD system
• Threshold monitoring
• Functionality monitoring
• Rationality or plausibility monitoring
FIGURE 11–11 The engine ECM contains software which not only controls engine
operation but identifies emission system related faults. The executive or supervisory
function determines when a monitor should run and whether a fault exists.
FIGURE 11–12 The NOx sensor which measures output of NOx in the exhaust
system is an example of a component used for threshold monitoring.
 MAJOR SYSTEM MONITORS
• Misfire Detection Monitor
• Description
• Misfire Monitor Operation
• EGR System Monitor
• Description
• EGR Monitor Operation
• Fuel System Monitors
• Description
• Boost Pressure Control Monitoring
• Description
• Cooling System Monitor
• Tech Tip
• Auxiliary Heaters and OBD
• Closed Crankcase Ventilation System
• Glow Plug Monitor
FIGURE 11–13 Waveforms generated from a variable reluctance type sensor (VRS)
type crank and cam position sensor. The crank and cam sensor are typical inputs for
the misfire detection monitor. The distance between each wave generated by the
teeth of the crankshaft sensor will change depending on whether the cylinder is on
compression stroke (farther apart) and power stroke (closer together).
FIGURE 11–14 The introduction of EGR gas into the intake manifold will decrease
the quantity of fresh air intake. The difference between measured intake airflow and
flow predicted without EGR gas is calculated to be the quantity of EGR recirculated
into the engine.
FIGURE 11–15 Typical EGR system configuration with a mass airflow sensor used
to provide closed-loop feedback data for EGR gas flow. Other sensors monitor cooler
efficiency and EGR valve movement. Temperature and pressure sensors can provide
data for calculating air and exhaust flow using a speed density calculation.
FIGURE 11–16 The fuel rail pressure sensor combined with the fuel pressure control
regulator is used on this common rail engine to detect fuel pressure leaks and
excessive fuel flow through the injectors. If the duty cycle of the electrical signal
applied to the actuator needs to increase beyond an expected value, then a fault with
the fuel system is logged.
FIGURE 11–17 The PCV system monitor used on this Cummins 6.7L diesel uses a
pressure sensor connected to the valve cover. A plugged PCV filter or a disconnected
PCV system will cause pressure readings to be out of range of expected values
producing a fault code. Note the coalescing crankcase filter is removed.
FIGURE 11–18 The glow plugs on this Duramax engine are operated by a module
which measures voltage drop to each plug. Variations in current flow caused by open
or excessively resistive plugs are identified by the module which sends a fault signal
through the twisted pair of wires connected to the vehicle network.
COMPREHENSIVE COMPONENT MONITOR
• An onboard diagnostic strategy designed to monitor
a fault in any electronic component or circuit that:
• Can cause an increase to emissions or affect
any other OBD monitors
• The CCM evaluates many components and their
circuits
• Typical components monitored by the CCM
FIGURE 11–19 The throttle position sensor is critical for vehicle and occupant safety.
As many as three different potentiometers are used in a diesel TPS to confirm the
rationality of data from the other TPS potentiometers. Inconsistent data from any one
of the potentiometers will illuminate the MIL and the vehicle will operate normally. If
two signals from the TPS are missing or incorrect, the ECM will only allow the engine
to idle illuminate the MIL.
 RATIONALITY MONITOR
• Evaluating the data produced by a sensor to
determine whether it makes sense when compared
to:
• Other sensor inputs and operating conditions
• Electrical tests of the circuit may not indicate an
open or short
 ONBOARD DIAGNOSTIC SOFTWARE
• OBD Executive
• OBD system configuration software is referred
to as the diagnostic executive or supervisor
• Freeze Frame
• Information captured by the OBD-II software
at the point the first fault is detected
 DIESEL ENGINE AFTERTREATMENT
MONITORS
• Ensuring the functionality of the exhaust
aftertreatment systems is the priority of the OBD-II
system
• Diesel Oxidation Catalyst Monitors
• Diesel Particulate Filter Monitor
• Selective Catalyst Reduction Monitor
• Lean NOx Traps and NOx Adsorbing Catalysts
FIGURE 11–20 Location of exhaust gas temperature sensors used with an oxidation
converter combined with a diesel particulate filter. Three temperature sensors provide
input to the ECM which can be used to distinguish normal and abnormal functioning
of the oxidation converter used with the DPF. Exhaust temperatures should rise as
exhaust gases laden with hydrocarbons pass though the oxidation converter. Burning
the soot in the DPF will cause exhaust temperature to rise even farther at the outlet of
the DPF.
FIGURE 11–21 A pressure differential sensor measures the pressure drop across
the diesel particulate filter. DPF regeneration is based on a model of expected soot
accumulations but an excessive drop in pressure will trigger a regeneration event.
Excessive pressure after a DPF regeneration will produce a fault code. A
disconnected, plugged, or restricted filter will trigger the appropriate code or action
from the onboard diagnostic system.
 Electronic Service Tools—Scanners
• SAE Requirements for OBD Scan Tools
• OBD standards for handheld scan tools
• Tech Tip
• Erasing SCR Codes
• Additional Scan Tool Functions
• Bidirectional control
• Graphical display
• Heavy-duty applications
• Help menu/trouble code library
• Printer/computer output
• Record/playback or snapshot mode
• Reprogramming of vehicle ECM
• Scopes and meters
• Troubleshooting/diagnostic aid
• Code Readers
• Tech Tip
• Using Diagnostic Codes
FIGURE 11–22 A partial menu of output devices that this scanner can actuate during
diagnostic procedures.
FIGURE 11–23 This aftermarket DLC cable contains a built-in communication
adapter enabling it to communicate with an off-the-shelf laptop or PC using
aftermarket or OE software.
FIGURE 11-24
FIGURE 11–24 An OBD-II code reader.