Chap 63

start
Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

By James D. Halderman
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OBJECTIVES:
After studying Chapter 63, the reader should
be able to:
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.
Continued

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OBJECTIVES:
After studying Chapter 63, the reader should
be able to:
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.

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KEY TERMS:
data link connector (DLC) drive cycle
flash code retrieval
keyonengine off test (KOEO) keyonengine running
test (KOER)
pending code paper test
self-test automatic readout (STAR) smoke machine
technical service bulletin (TSB) trip

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THE EIGHT-STEP DIAGNOSTIC PROCEDURE

Itisimportantthatallautomotiveservicetechsknowhowto
diagnoseandtroubleshootenginecomputersystems.
Thediagnosticprocesseliminatesknowngoodcomponentsor
systemsinordertofindtherootcauseofautomotiveengine
performanceproblems.
Allmanufacturersrecommendadiagnosticprocedure,andthe
plansuggestedinthischaptercombinesmostofthefeaturesof
theseplansplusstepsdevelopedinrealworldproblemsolving.
Manydifferentthingscancauseanengineperformanceproblem
orconcern.Theservicetechnicianhastonarrowthepossibilities
tofindthecauseoftheproblemandcorrectit.
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Afunnelisawayofvisualizing
adiagnosticprocedure.Atthe
widetoparethesymptomsofthe
problem;thefunnelnarrowsas
possiblecausesareeliminated
untiltherootcauseisfoundand
correctedatthebottom.
Figure 631 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.
Thewiderangeofpossible
solutionsmustbenarrowedto
themostlikelyandthesemust
eventuallybefurthernarrowed
totheactualcause.
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Figure 632 Step #1 is to verify the customer concern or problem. If the problem cannot be
verified, then the repair cannot be verified.
Step#1VerifytheProblem
(Concern)Becertainaproblem
exists.Iftheproblemcannotbe
verified,itcannotbesolvedor
testedtoverifythattherepairwas
complete.
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Thedriverofthevehicleknowsmuchaboutthevehicleandhowit
isdriven.Beforediagnosis,alwaysaskthefollowingquestions:
Isthemalfunctionindicatorlight(checkengine)on?
Whatwasthetemperatureoutside?
Wastheenginewarmorcold?
Wastheproblemduringstarting,acceleration,cruise,or
someothercondition?
Howfarhadthevehiclebeendriven?
Wereanydashwarninglightson?Ifso,whichone(s)?
Hastherebeenanyserviceorrepairworkperformedonthe
vehiclelately?
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NOTE: Manyengineperformancefaultsareoftentheresultofsomething
beingknockedlooseorahosefallingoffduringrepairwork.Knowingthat
thevehiclewasjustservicedbeforetheproblembeganmaybeanindicator
astowheretolookforthesolutiontoaproblem.
NOTE: Becausedriversdiffer,itissometimesthebestpolicytotakethe
customeronthetestdrivetoverifytheconcern.
Afterthenatureandscopeoftheproblemaredetermined,the
complaintshouldbeverifiedbeforefurtherdiagnostictestsare
performed.
Asampleformthatcustomerscouldfilloutwithdetailsofthe
problemisshowninFigure633
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Figure 633 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.
SeethecompleteformonPage764ofyourtextbook.
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Original Equipment is not a Four-Letter

Word
To many service technicians, an original-equipment part is considered to
be only marginal and to get the really good stuff an aftermarket (renewal
market) part has to be purchased. However, many problems can be traced
to the use of an aftermarket part that has failed early in its service life.
Technicians who work at dealerships usually go immediately to an aftermarket part
that is observed during a visual inspection. It has been their experience that simply
replacing the aftermarket part with the factory original-equipment (OE) part often
solves theproblem.
Original equipment parts are required to pass quality and durability standards and
tests at a level not required of aftermarket parts. The tech should be aware that the
presence of a new part does not necessarily mean that the part is good.
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Step#2PerformaThoroughVisualInspectionandBasicTests
Themostimportantaspectofdiagnosis!Mostexpertsagreethat
between10%and30%ofallengineperformanceproblemscanbe
foundsimplybyperformingathoroughvisualinspection.
Checkforobviousproblems(basics,basics,basics).
Vacuumhosesdisconnectedorsplit
Fuelleaks
Corrodedconnectors
Unusualnoises,smoke,orsmell
Checktheaircleanerandairduct
(smallanimalscanbuildnestsor
storedogfoodinthem)
Figure 634 This is what was found when removing an air filter from a vehicle that had a lack-ofpower concern. Obviously the nuts were deposited by squirrels or some other animal, blocking a
lot of the airflow into the engine.
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Checkeverythingthatdoesanddoesnotwork.Thisstep
involvesturningthingsonandobservingthateverythingis
workingproperly.
Lookforevidenceofpreviousrepairs.Anytimeworkis
performedonavehicle,thereisalwaysariskthatsomething
willbedisturbed,knockedoff,orleftdisconnected.
Ensureadequatefuellevel.Makecertainthatthefueltankis
atleastonefourthtoonehalffull;ifthefuellevelislowitis
possiblethatanywateroralcoholatthebottomofthefueltank
ismoreconcentratedandcanbedrawnintothefuelsystem.
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CheckcoolantlevelandconditionManymechanicalengine
problemsarecausedbyoverheating.Theproperoperationof
thecoolingsystemiscriticaltothelifeofanyengine.
NOTE: Checkthecoolantlevelintheradiatoronlyiftheradiatoriscool.
Iftheradiatorishotandtheradiatorcapisremoved,thedropinpressure
abovethecoolantwillcausethecoolanttoboilimmediately,whichcan
causesevereburnsbecausethecoolantexpandsexplosivelyupwardand
outwardfromtheradiatoropening.
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CheckoillevelandconditionAnotherareaforvisual
inspectionisoillevelandcondition.
OillevelOilshouldbetotheproperlevel.
OilconditionUsingamatchorlighter,trytolighttheoil
onthedipstick;iftheoilflamesup,gasolineispresentin
theengineoil.Dripsomeengineoilfromthedipstickonto
thehotexhaustmanifold.Iftheoilbubblesorboils,coolant
(water)ispresentintheoil.Checkforgrittinessbyrubbing
theoilbetweenyourfingers.
NOTE: Gasolineintheoilwillcausetheenginetorunrichbydrawing
fuelthroughthepositivecrankcaseventilation(PCV)system.
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UsethepapertestAsoundlyrunningengineshouldproduce
evenandsteadyexhaustatthetailpipe.
Forthepapertest,holdapieceofpaper(evenadollarbill
works)ora3by5inchcardwithin1inch(2.5centimeters)
ofthetailpipewiththeenginerunningatidle.
Thepapershouldblowevenlyawayfromtheendofthe
tailpipewithoutpuffingorbeingdrawninwardtowardthe
endofthetailpipe.
Ifthepaperisattimesdrawntowardthetailpipe,thevalvesin
oneormorecylinderscouldbeburned.
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Otherreasonswhythepapermightbedrawntowardthetailpipe
includethefollowing:
1. Theenginecouldbemisfiringbecauseofaleancondition
thatcouldoccurnormallywhentheengineiscold.
2. Pulsingofthepapertowardthetailpipecouldalsobecaused
byaholeintheexhaustsystem.Ifexhaustescapesthrougha
holeintheexhaustsystem,aircouldbedrawninthe
intervalsbetweentheexhaustpuffsfromthetailpipetothe
holeintheexhaust,causingthepapertobedrawntoward
thetailpipe.
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Smoke Machine Testing

Vacuum (air) leaks cause a variety of driveability problems and are often
difficult to locate. One good method is to use a machine that generates a
stream of smoke. Connecting the outlet of the smoke machine to the hose
that was removed from the vacuum brake booster allows smoke to enter
the intake manifold. Vacuum leaks will be spotted by observing smoke
coming out of the leak.
Figure 635 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.

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CheckthebatteryvoltageThevoltageofthebatteryshouldbe
atleast12.4voltsandthechargingvoltage(enginerunning)
shouldbe13.5to15.0voltsat2,000RPM.
Lowbatteryvoltagecancauseavarietyofproblemsincluding
reducedfueleconomyandincorrect(usuallytoohigh)idle
speed.Higherthannormalbatteryvoltagecanalsocausethe
PCMproblemsandcouldcausedamagetoelectronicmodules.
CheckthefuelpumppressureRelativelyeasyonmanyport
fuelinjectedengines.Oftenintermittentengineperformanceis
duetoaweakfuelpumporcloggedfuelfilter.Checkingfuel
pumppressureearlyinthediagnosticprocesseliminateslow
fuelpressureasapossibility.
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CheckthesparkusingasparktesterRemoveonespark
plugwireandattachtheremovedplugwiretothesparktester.
Attachthegroundingclipofthesparktestertoagoodclean
engineground,startorcranktheengine,andobservethetester.
Thesparkatthesparktester
shouldbesteadyandconsistent.
Anintermittentsparkshouldbe
treatedasanosparkcondition.
Carefullyinspectandtestall
componentsoftheprimaryand
secondaryignitionsystems.
Continued
Figure 636 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.

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NOTE: Donotuseastandardsparkplugtocheckforproperignition
systemvoltage.Anelectronicignitionsparktesterisdesignedtoforcethe
sparktojumpabout0.75inch(19mm).Thisamountofgaprequires
between25,000and30,000volts(25to30kV)atatmosphericpressure,
whichisenoughvoltagetoensurethatasparkcanoccurunder
compressioninsideanengine.

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Figure 637 Step #3 in the diagnostic process is to retrieve any stored diagnostic trouble
codes.
Step#3RetrievetheDiagnostic
TroubleCodes(DTCs)
Ifatroublecode(DTC)ispresent
inthecomputermemory,itmay
besignaledbyilluminatinga
malfunctionindicatorlamp
(MIL),commonlylabeledcheck
engineorserviceenginesoon.
Anycode(s)displayedwhenthe
MILisnotoniscalledapending
code.BecausetheMILisnoton,
thisindicatesthefaulthasnot
repeatedtocausethePCMtoturn
ontheMIL.
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Step#4CheckforTechnicalServiceBulletins(TSBs)Checkfor
correctionsintechnicalservicebulletins(TSBs)thatmatchthe
symptoms.Accordingtostudies,asmanyas30%ofvehiclescanbe
repairedfollowingtheinformation,suggestions,orreplacementparts
foundinaservicebulletin.
Figure 638 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.
DTCsmustbeknownbefore
searchingforservicebulletins,
becausebulletinsofteninclude
informationonsolvingproblems
thatinvolveastoreddiagnostic
troublecode.
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Figure 639 Looking carefully at the scan tool data is very helpful in locating the source of a
problem.
Step#5LookCarefullyatScan
ToolDataManufacturershavebeen
givingthetechmoreandmoredataon
ascantoolconnectedtothedatalink
connector(DLC).
Thebestwaytolookatscandata
isinadefinitesequenceandwith
specific,selectedbitsofdatathat
cantellthemostaboutthe
operationoftheengine.
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Step#6NarrowtheProblemtoaSystemorCylinder
Narrowingthefocustoasystemorindividualcylinderisthehardest
partoftheentirediagnosticprocess.
Performacylinderpowerbalancetest.
Ifaweakcylinderisdetected,performacompression
andacylinderleakagetesttodetermineprobablecause.
Step#7RepairtheProblemandDeterminetheRootCause
Therepairorpartreplacementmustbeperformedfollowing
vehiclemanufacturersrecommendationsandbecertainthatthe
rootcauseoftheproblemhasbeenfound.Alsofollowthe
manufacturersrecommendedrepairproceduresandmethods.
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Figure 6310 Step #8 is very important. Be sure that the customers concern has been
corrected.
Step#8VerifytheRepairand
ClearAnyStoredDTCs
Testdrivetoverifytheoriginal
problem(concern)isfixed.
Verifynoadditionalproblems
haveoccurredduringtherepair
process.
Checkforandthenclearall
diagnostictroublecodes.

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One Test is Worth 1,000 Expert Opinions

Whenever any vehicle has an engine performance or driveability concern,
certain people always say:
Sounds like its a bad injector.
Ill bet you its a bad computer.
I had a problem just like yours yesterday and it was a bad EGR
valve.
Regardless of the skills and talents of those people, it is still more accurate
to perform tests on the vehicle than to rely on feelings or opinions of others
who have not even seen the vehicle. Even your own opinion should not
sway your thinking. Follow a plan, perform tests, and the test results will
lead to the root cause.

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SCAN TOOLS
Scantoolsaretheworkhorsefordiagnosticworkonallvehicles
andcanbedividedintotwobasicgroups:
1. FactoryscantoolsThesearethescantoolsrequiredbyall
dealersthatsellandservicethebrandofvehicle.Examplesof
factoryscantoolsinclude:
FordNewGenerationStar(NGS)
ChryslerDRBIIIorStarScan
GeneralMotorsTech2
HondaHDSorMasterTech
ToyotaMasterTech
Figure 6311 A TECH 2 scan tool is the factory

scan tool used on General Motors vehicles.
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2. AftermarketscantoolsThesescantoolsaredesignedtofunction
onmorethanonebrandofvehicle:
Snapon(variousmodelsincludingtheMT2500andModis)
OTC(variousmodelsincludingGenisysandTaskMaster)
AutoEnginuityandotherprogramsthatusealaptoporhandheld
computerforthedisplay
Whilemanyaftermarketscantools
candisplaymostifnotallofthe
parametersofthefactoryscantool,
therecanbeadifferencewhen
tryingtotroubleshootsomefaults.
Figure 6312 Some scan tools use pocket PCs which
make it very convenient to use.

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RETRIEVAL OF DIAGNOSTIC INFORMATION

Toretrievediagnosticinformationfromthepowertraincontrol
module(PCM),ascantoolisneeded.Ifthefactoryscantoolis
used,thenallofthedatacanberetrieved.IfagenericOBDIIscan
toolisused,onlytheemissionsrelateddatacanberetrieved.
ToretrievediagnosticinformationfromthePCM:
Step#1Locateandgainaccesstothedatalinkconnector(DLC).
Step#2ConnectthescantooltotheDLCandestablish
communication.
Step#3Followtheonscreeninstructionsofthescantoolto
correctlyidentifythevehicle.
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Step#4Observescandata,aswellasanydiagnostictrouble
codes.
Step#5FollowmanufacturersinstructionsifanyDTCsare
stored.IfnoDTCsarestored,compareallsensorvalueswitha
factoryrangecharttoseeifanysensorvaluesareoutofrange.
NOTE: Ifnocommunicationisestablished,followthevehicle
manufacturersspecifiedinstructions.
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SeethechartonPage768ofyourtextbook.
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TROUBLESHOOTING USING DIAGNOSTIC

TROUBLE CODES
Causesofactualproblemscanbedeterminedbytryingtosettheopposite
code.
Ifacodeindicatesanopenthrottleposition(TP)sensor(high
resistance),clearthecodeandcreateashorted(lowresistance)
condition.Dothisbyusingajumperandconnectingthesignal
terminaltothe5voltreferenceterminal.
Iftheoppositecodesets,thisindicatesthatthewiringand
connectorforthesensorisokayandthesensoritselfis
defective(open).
Ifthesamecodesets,thisindicatesthatthewiringor
electricalconnectionisopen(hashighresistance)andisthe
causeofthesettingoftheDTC.
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MethodsforClearingDiagnosticTroubleCodesClearing
diagnostictroublecodesfromavehiclecomputersometimesneeds
tobeperformed.
CAUTION: Clearingdiagnostictroublecodes(DTCs)alsowillclearall
ofthenoncontinuousmonitors.
Threemethodscanbeusedtoclearstoreddiagnostictroublecodes:
ClearingcodesMethod1Thepreferredmethodof
clearingcodesisbyusingascantool.Thisisthemethod
recommendedbymostvehiclemanufacturersiftheprocedure
canbeperformedonthevehicle.Thecomputerofsome
vehiclescannotbeclearedwithascantool.
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ClearingcodesMethod2Ifascantoolisnotavailableor
ascantoolcannotbeusedonthevehiclebeingserviced,the
powertothecomputercanbedisconnected.
1. Disconnectthefusiblelink(ifsoequipped)that
feedsthecomputer.
2. Disconnectthefuseorfusesthatfeedthe
computer.
NOTE: Thefusemaynotbelabeledasacomputerfuse.Forexample,
manyToyotascanbeclearedbydisconnectingthefuelinjectionfuse.
Somevehiclesrequiretwofusesbedisconnectedtoclearstoredcodes.

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ClearingcodesMethod3Iftheothertwomethodscannot
beused,thenegative()batterycablecanbedisconnectedto
clearstoreddiagnostictroublecodes.
NOTE: Becauseoftheadaptivelearningcapacityofthecomputer,a
vehiclemayfailanexhaustemissionstestifthevehicleisnotdriven
enoughtoallowthecomputertorunallofthemonitors.
CAUTION: Bydisconnectingthebattery,theradiopresetsandclock
informationwillbelost.Theyshouldberesetbeforereturningthevehicle
tothecustomer.Iftheradiohasasecuritycode,thecodemustbeentered
beforetheradiowillfunction.Beforedisconnectingthebattery,always
checkwiththevehicleownertobesurethatthecodeisavailable.

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FLASH CODE RETRIEVAL ON OBD-I

GENERAL MOTORS VEHICLES
TheGMsystemusesacheckengineMILtonotifyofpossible
systemfailure.Underthedashisadatalinkconnector(DLC)
previouslycalledanassemblylinecommunicationslink(ALCL)
ordiagnosticlink(ALDL).
Mosttroublecodescanbe
retrievedbyusingametaltool
andcontactingterminalsAand
Bofthe12pinDLC.
Figure 6313 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.
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ThismethodiscalledflashcoderetrievalbecausetheMILwill
flashtoindicatediagnostictroublecodes.Thestepsareasfollows:
1. Turntheignitionswitchtoon(engineoff).Thecheck
enginelightorserviceenginesoonlightshouldbeon.If
theambermalfunctionindicatorlight(MIL)isnoton,a
problemexistswithinthelightcircuit.
2. ConnectterminalsAandBattheDLC.
NOTE: RefertoservicemanualdiagnosticproceduresiftheMILison
anddoesnotflashacode12whenterminalsAandBareconnected.
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3. ObservetheMIL.Acode12(oneflash,thenapause,then
twoflashes)revealsthatthereisnoenginespeedindication
tothecomputer.Becausetheengineisnotrunning,this
simplyindicatesthatthecomputerdiagnosticsystemis
workingcorrectly.
NOTE: Troublecodescanvaryaccordingtoyear,make,model,and
engine.Alwaysconsulttheserviceliteratureorservicemanualforthe
exactvehiclebeingserviced.Checkserviceinformationforthemeaning
andrecommendedstepstofollowifadiagnostictroublecodeisretrieved.
4. Aftercode12isdisplayedthreetimes,theMILwillflashany
otherstoredDTCsinnumericorderstartingwiththelowest
numbercode.Ifonlycode12isdisplayedanotherthree
times,thecomputerhasnotdetectedanyotherfaults.
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Do Not Lie To a Scan Tool!

Because computer calibration may vary from year to year, using the
incorrect year for the vehicle while using a scan tool can cause the data
retrieved to be incorrect or inaccurate.

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RETRIEVING FORD DIAGNOSTIC CODES

Thebesttoolisaselftest
automaticreadout(STAR)
tester,newgenerationSTAR
(NGS),WDS(Worldwide
DiagnosticSystem),or
anotherscantoolwithFord
capabilities.
Figure 6314 A Ford OBD-I selftest connector. The location of
this connector can vary with
model and year of vehicle.
Thetestconnectorisusually
locatedunderthehoodon
thedriversside.
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KeyOnEngineOffTest(OnDemandCodesorHardFaults)
Withtheignitionkeyon(engineoff),watchthevoltmeterpulses,
whichshouldappearwithin5to30seconds.(Ignoreanyinitial
surgeofvoltagewhentheignitionisturnedon.)
Thecomputerwillsendatwodigitcodethatwillcausethe
voltmetertopulseormovefromlefttoright.
Ifthevoltmeterneedlepulsestwotimes,thenpausesfor2
seconds,andthenpulsesthreetimes,thecodeis23.
Thereisnormallya4secondpausebetweencodes.
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SeparatorpulseAfterallthecodeshavebeenreported,the
computerwillpauseforabout6to9seconds,thencausethe
voltmeterneedletopulseonce,andthenpauseforanother6to9
seconds.Thisisthenormalseparationbetweencurrenttrouble
codesandcontinuousmemorycodes(forintermittentproblems).
Code11isthenormalpasscode,whichmeansthatnofaulthas
beenstoredinmemory.Normaloperationofthediagnostic
procedureusingavoltmetershouldindicatethefollowingifno
codesareset:1pulse(2secondpause),1pulse(6to9second
pause),1pulse(6to9secondpause),1pulse(2secondpause),
andfinally,1pulse.
Theselasttwopulsesthatareseparatedbya2secondinterval
representacode11,whichisthecodeusedbetweencurrentand
intermittenttroublecodes.
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ContinuousMemoryCodes(SoftCodes)Continuousmemory
codesaresetbasedoninformationstoredwhilethevehiclewasin
normaloperation.
Thesecodesrepresentanintermittentproblemandshouldonlybe
usedfordiagnosisiftheKOEOtestresultsincode11(nofaults
detected).Anycodesdisplayedaftertheseparationpulserepresent
failuresthathavebeendetectedbutmaynolongerbepresent.
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Put a Wire in the Attic and a Light in the

Basement! - Part 1
Retrieving DTCs from a Ford using low-cost test equipment is easier when
you remember the following: Put a wire in the attic and a light in the
basement. After warming the engine to operating temperature, perform
these simple steps:
1. Locate the data link connector (DLC) under the hood. Connect a
jumper wire from the single-wire pigtail called the self-test input to
terminal #2 at the top (attic) of the connector.
2. To read DTCs, connect a standard 12-volt test light (not a selfpowered continuity light) to the positive battery terminal and the
lower (basement) terminal (#4) of the DLC. See Figure 6315. Turn
the ignition to on (engine off). The DTCs will be displayed by means
of the flashes of the test light.
To clear stored Ford DTCs, simply disconnect the jumper wire from the
self-test input while the codes are being flashed. This interruption is the
signal to the computer to clear any stored DTCs.
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Put a Wire in the Attic and a Light in the

Basement! - Part 2
Put a wire in the attic and a light in the basement.
Figure 6315 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.

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KeyOnEngineRunning(KOER)TestDuringtheKOERself
test,thesensorsarecheckedbythecomputerunderactual
operatingconditionsandtheoutputdevices(actuators)are
operatedandcheckedforexpectedresults.
Starttheengineandraisethespeedto2,500to3,000RPMto
warmtheoxygensensorwithin20secondsofstarting.Holda
steadyhighenginespeeduntiltheinitialpulsesappear(2pulses
forafourcylinderengine,3pulsesforasixcylinder,and4pulses
foraneightcylinder).
Thesecodesareusedtoverifytheproperprocessor(computer)is
inthevehicleandthattheselftesthasbeenentered.Continueto
holdahighenginespeeduntilthecodepulsesbegin(10to14
seconds).
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Steering,Brake,andOverdriveSwitchTestTotestthepower
steeringpressureswitch,thetechnicianmustturnthesteering
wheelonehalfturnaftertheIDcodehasbeendisplayed.The
brakepedalandoverdrivecancelmustbecycledaftertheIDcode
toallowthesystemtodetectastatechangeoftheseswitches.
DynamicResponseCheckThedynamicresponsetestchecksthe
throttleposition(TP)massairflow(MAF)andmanifoldabsolute
pressure(MAP)sensorsduringabriefwideopenthrottle(WOT)
testperformedbythetechnician.Thesignaltodepressthethrottle
brieflytowideopenisasinglepulseoraSTARcode10.
Ifanyhard(ondemand)faultsappear,theseshouldberepaired
firstandthenanysoft(continuous)codesnext.Usethefactory
pinpointteststotracetheproblem.Refertoserviceinformation
foradescriptionofFordspecificalphanumericDTCs.
Continued

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FLASH CODE RETRIEVAL ON CHRYSLER

VEHICLES
Toputthecomputerintotheselfdiagnosticmode,theignition
switchmustbeturnedonandofftwicewithina5secondperiod
(onoffonoffon).Thecomputerwillflashaseriesoffaultcodes.
OlderChryslerproductsflashthecheckenginedashlamp.
NOTE: Unlikeothermanufacturers,mostChryslerbrandvehicles
equippedwithOBDIIwilldisplaythePcodesontheodometerdisplayby
cyclingtheignitionkeyaspreviouslyperformedonoldervehicles.

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OBDII DIAGNOSIS
Startingwiththe1996modelyear,allvehiclessoldintheUSmust
usethesame16pindatalinkconnector(DLC)andmustmonitor
emissionrelatedcomponents.
RetrievingOBDIICodes
Ascantoolisrequiredto
retrievediagnostictrouble
codesfrommostOBDII
vehicles.
EveryOBDIItoolwillbeable
toreadallgenericSocietyof
AutomotiveEngineers(SAE)
DTCsfromanyvehicle.
Continued
Figure 6316 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.
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OBDII DIAGNOSTIC CODES
SeethecompletechartsonPage771773ofyourtextbook.
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OBDII ACTIVE TESTS

Thevehiclecomputermustruntestsonthevariousemission
relatedcomponentsandturnonthemalfunctionindicatorlamp
(MIL)iffaultsaredetected.
OBDIIisanactivecomputeranalysissystembecauseitactually
teststheoperationoftheoxygensensors,exhaustgasrecirculation
system,etc.,wheneverconditionspermit.
Becausethesetestsareactiveandcertainconditionsmustbe
presentbeforethesetestscanberun,thecomputerusesitsinternal
diagnosticprogramtokeeptrackofthevariousconditionsandto
scheduleactivetestssothattheywillnotinterferewitheachother.
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OBDIIDriveCycleThevehiclemustbedrivenunderavariety
ofoperatingconditionsforallactiveteststobeperformed.
Atripisdefinedasanengineoperatingdrivecyclethatcontains
thenecessaryconditionsforaparticulartesttobeperformed.
FortheEGRtest,theenginehastobeatnormaloperating
temperatureanddeceleratingforaminimumamountoftime.
Sometestsareperformedwhentheengineiscold,whereothers
requirethatthevehiclebecruisingatasteadyhighwayspeed.
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TypesofOBDIICodesNotallOBDIIdiagnostictroublecodes
areofthesameimportanceforexhaustemissions.Eachtypeof
DTChasdifferentrequirementsforittoset,andthecomputerwill
onlyturnontheMILforemissionsrelatedDTCs.
NOTE: TypeAandTypeBcodesareemissionrelatedandwillcausethe
lightingofthemalfunctionindicatorlamp,usuallylabeledcheckengine
orserviceenginesoon.
TypeACodesEmissionrelated;willcausetheMILtobeturned
onatthefirsttripifthecomputerhasdetectedaproblem.Engine
misfireoraveryrichorleanairfuelratiowouldcauseatypeA
diagnostictroublecode.Thesealertthedrivertoanemissions
problemthatmaydamagethecatalyticconverter.
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TypeBCodesAtypeBcodewillbestoredandtheMILwillbe
turnedonduringthesecondconsecutivetrip,alertingthedriverto
thefactthatadiagnostictestwasperformedandfailed.
TypeCandDCodesTypeCandtypeDcodesareforusewith
nonemissionrelateddiagnostictests.Theywillcausethelighting
ofaservicelamp(ifthevehicleissoequipped).
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OBDIIFreezeFrameToassistthetech,OBDIIrequiresthe
computertotakeasnapshotorfreezeframeofalldataatthe
instantanemissionrelatedDTCisset.Ascantoolisrequiredto
retrievethisdata.
CARBandEPAregulationsrequirethatthecontrollerstore
specificfreezeframe(enginerelated)datawhenthefirstemission
relatedfaultisdetected.
Thedatastoredinfreezeframecanonlybereplacedbydatafrom
atroublecodewithahigherprioritysuchasatroublerelatedtoa
fuelsystemormisfiremonitorfault.
NOTE: AlthoughOBDIIrequiresonefreezeframeofdatabestored,the
instantanemissionrelatedDTCisset,manufacturersusuallyprovide
expandeddataabouttheDTCbeyondthatrequired.Retrievingenhanced
datausuallyrequiresuseofavehiclespecificscantool.
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Thefreezeframehastocontaindatavaluesthatoccurredatthe
timethecodewasset(thesevaluesareprovidedinstandardunits
ofmeasurement).
Freezeframedataisrecordedduringthefirsttriponatwotrip
fault.Asaresult,OBDIIsystemsrecordthedatapresentatthe
timeanemissionrelatedcodeisrecordedandtheMILactivated.
Thisdatacanbeaccessedanddisplayedonascantool.Freeze
framedataisoneframeoroneinstantintime.
Freezeframedataisnotupdated(refreshed)ifthesamemonitor
testfailsasecondtime.
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RequiredFreezeFrameDataItems
Codethattriggeredthefreezeframe
A/Fratio,airflowrateandcalculatedengineload
Basefuelinjectorpulsewidth
ECT,IAT,MAF,MAP,TP,andVSsensordata
Enginespeedandamountofignitionsparkadvance
Openorclosedloopstatus
Shorttermandlongtermfueltrimvalues
Formisfirecodesidentifythecylinderthatmisfired
NOTE: Allfreezeframedatawillbelostifthebatteryisdisconnected,
powertothePCMremoved,orthescantoolusedtocleartroublecodes.
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DiagnosingIntermittentMalfunctionsOfallthedifferenttypes
ofconditionsthatyouwillsee,thehardesttoaccuratelydiagnose
andrepairareintermittentmalfunctions.
Theseconditionsmaybetemperaturerelated(onlyoccurwhenthe
vehicleishotorcold),orhumidityrelated(onlyoccurwhenitis
raining).Regardlessofconditionsyoumustdiagnoseandcorrect
thecondition.
Whendealingwithanintermittentconcern,youshoulddetermine
conditionswhenthemalfunctionoccurs,andtrytoduplicatethem.
Ifacauseisnotreadilyapparenttoyou,askthecustomerwhenthe
symptomoccurs.Askifthereareanyconditionsthatseemtobe
relatedto,orcausetheconcern
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WhenworkingonanOBDIIequippedvehicleiswhethera
concernonlyoccurswhenaspecifictestisperformedbythePCM.
SinceOBDIIsystemsconductdiagnostictestsonlyunderprecise
conditions,sometestsmayonlyrunonceduringanignitioncycle.
Ifrequirementsneededtoperformthetestarenotmet,thetestwill
notrunduringanignitioncycle.Thistypeofonboarddiagnostics
couldbemistakenasintermittent
ExamplesofthisareHO2Sheaters,evaporativecanisterpurge,
catalystefficiency,andEGRflow.Whendiagnosingintermittent
concernsonanOBDIIequippedvehicle,alogicaldiagnostic
strategyisessential.
Theuseofstoredinformationcanalsobeveryusefulwhen
diagnosinganintermittentmalfunctionifacodehasbeenstored.
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SERVICE/FLASH PROGRAMMING
Reprogrammingconsistsofdownloadingnewcalibrationfiles
fromascantool,personalcomputer,ormodemintothePCMs
electronicallyerasableprogrammablereadonlymemory
(EEPROM).Thiscanbedoneonoroffthevehicle.
SincereprogrammingisnotanOBDIIrequirementhowever,
manyvehicleswillneedanewPCMintheeventsoftware
changesbecomenecessary.Physicallyremovingandreplacing
thePROMchipisnolongerpossible.
Thefollowingarethreeindustrystandardmethodsusedto
reprogramtheEEPROM:
Remoteprogramming
Directprogramming
Offboardprogramming
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RemoteProgramming
ConnectthescantooltothevehiclesDLC.
Figure 6317 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.
Figure 6318 Follow the on-screen instructions.
Entervehicleinformationintothescantoolusingprogramming
applicationsoftwareincorporatedinthescantool.
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RemoteProgramming
DownloadVINandcurrentEEPROMcalibrationusingascan
tool.
DisconnectthescantoolfromtheDLCandconnectthetoolto
theshopPC.
DownloadthenewcalibrationfromthePCtothescantool.
Figure 6319 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.
Reconnectthescantoolto
thevehiclesDLCand
downloadthenewcalibration
intothePCM.
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CAUTION: Beforeprogramming,thevehiclesbatterymustbebetween
11and14volts.Donotattempttoprogramwhilechargingthebattery
unlessusingaspecialbatterychargerwhichdoesnotproduceexcessive
ripplevoltagesuchastheMidtronicsPSC300(30amp)orPSC550(55
amp)orsimilarasspecifiedbythevehiclemanufacturer.
Figure 6320
Connecting cables and a computer
to perform off-board programming.
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DirectProgrammingDirectprogrammingdoesutilizea
connectionbetweentheshopPCandthevehicleDLC.
OffBoardProgrammingOffboardprogrammingisusedifthe
PCMmustbeprogrammedawayfromthevehicle.Thisis
preformedusingtheoffboardprogrammingadapter.

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J2534 REPROGRAMMING
LegislationhasmandatedthatvehiclemanufacturersmeettheSAE
J2534standardsforallemissionsrelatedsystemsonallnew
vehiclesstartingwithmodelyear2004.
Thisstandardenablesindependentservicerepairoperatorsto
programorreprogramemissionsrelatedECMsfromawidevariety
ofvehiclemanufacturerswithasingletool.
Thissystemallowsprogrammingofallvehiclemanufacturer
ECMsusingasinglesetofprogramminghardware.
Programmingsoftwaremadeavailablebythevehiclemanufacturer
mustbefunctionalwithaJ2534compliantpassthroughsystem.
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Figure 6321 The J2534 pass-through reprogramming

system does not need a scan tool to reflash the PCM
on most 2004 and newer vehicles.
AJ2534passthrough
systemisastandardized
programminganddiagnostic
system.
Itusesapersonalcomputer
(PC),astandardinterface
toasoftwaredevicedriver,
andahardwarevehicle
communicationinterface.
Theinterfaceconnectstoa
PC,andtoaprogrammable
ECMonavehiclethrough
theJ1962datalink
connector(DLC).
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Thesoftwareforatypicalpassthroughapplicationconsistsoftwo
majorcomponentsincluding:
Thepartdeliveredbythecompanythatfurnishesthehardware
forJ2534enablesthepassthroughvehiclecommunication
interfacetocommunicatewiththePCandprovidesforall
VehicleCommunicationProtocolsasrequiredbySAEJ2534.It
alsoprovidesforthesoftwareinterfacetoworkwiththesoftware
applicationsasprovidedforbythevehiclemanufacturers.
Figure 6322 A typical J2534 universal

reprogrammer that uses the J2534 standards.
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Thesecondpartofthepassthroughenablingsoftwareis
providedforbythevehiclemanufacturers.
Thisisnormallyasubsetofthesoftwareusedwiththeir
originalequipmentmanufacturer(OEM)toolsandtheir
websitewillindicatehowtoobtainthissoftwareandunder
whatconditionsitcanbeused.
RefertotheNationalAutomotiveServiceTaskForce(NASTF)
websitefortheaddressesforallvehiclemanufacturersservice
informationandcost.
VisittheNationalAutomotiveServiceTaskForceonthe
Internetatwww.nastf.org
Sincethemajorityofvehiclemanufacturersmakethissoftware
availableindownloadableform,havinganInternetbrowser
(Explorer/Netscape/Firefox)andconnectionisamust.
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MANUFACTURERS DIAGNOSTIC ROUTINES

Eachvehiclemanufacturerhasestablishedtheirowndiagnostic
routinesandtheyshouldbefollowed.Mostinclude:
Step#1Retrievediagnostictroublecodes.
Step#2Checkforalltechnicalservicebulletinsthatcouldbe
relatedtothestoredDTC.
Step#3IftherearemultipleDTCs,thediagnosticroutinemay
includecheckingdifferentcomponentsorsystemsinsteadofwhen
onlyoneDTCwasstored.
Step#4Performsystemchecks.
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Step#5Performaroadtestmatchingtheparametersrecordedin
thefreezeframetocheckthattherepairhascorrectedthe
malfunction.
Step#6RepeattheroadtesttocausetheMILtobeextinguished.
NOTE: Dontclearcodes(DTCs)unlessinstructedbyserviceinfo.
Followingthevehiclemanufacturersspecificdiagnosticroutines
willensurethattherootcauseisfoundandtherepairverified.
Thisisimportantforcustomersatisfaction.

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COMPLETING SYSTEM REPAIRS

Aftertherepairhasbeensuccessfullycompleted,thevehicle
shouldbedrivenundersimilarconditionsthatcausedtheoriginal
concern.Verifythattheproblemhasbeencorrected.
Toperformthistestdrive,itishelpfultohaveacopyofthe
freezeframeparametersthatwerepresentwhentheDTCwasset.
Bydrivingundersimilarconditions,thePCMmayperformatest
ofthesystemandautomaticallyextinguishtheMIL.Thisisthe
methodpreferredbymostvehiclemanufacturers.
TheDTCcanbeclearedusingascantool,butthenthatmeans
thatmonitorswillhavetoberunandthevehiclemayfailan
emissioninspectionifdrivendirectlytothetestingstation.
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PROCEDURE FOR RESETTING THE PCM

ThePCMcanberesetorclearedofpreviouslysetDTCsandfreeze
framedatainthefollowingways:
1. DrivingthevehicleDrivethevehicleundersimilar
conditionspresentwhenthefaultoccurred.IfthePCM
performedthenoncontinuousmonitortestandpassedthree
times,thePCMwillextinguishtheMIL.Thisisthemethod
preferredbymostmanufacturers,however,thismethod
couldbetimeconsuming.
Ifthreepassescannotbeachieved,theownerofthevehicle
willhavetobetoldthateventhoughthecheckenginelight
(MIL)ison,theproblemhasbeencorrectedandtheMIL
shouldgooutinafewdaysofnormaldriving.
Continued
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2. ClearDTCsUsingaScanToolAscantoolcanbeusedto
clearthediagnostictroublecode(DTC),whichwillalsodelete
allofthefreezeframedata.
Theadvantageofusingascantoolisthatthecheckengine
(MIL)willbeoutandthecustomerwillbehappythatthe
problem(MILon)hasbeencorrected.
DonotuseascantooltoclearaDTCifthevehicleisgoingto
becheckedsoonatateststationforstatemandatedemission
tests.
Continued
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3. BatteryDisconnectDisconnectingthenegativebatterycable
willclearDTCsandfreezeframe,eraseradiostationpresets
andothermemoryitemsonmanyvehicles.
Mostvehiclemanufacturersdonotrecommendthatthebattery
bedisconnectedtoclearDTCsanditmaynot
workonsomevehicles.
The Brake Pedal Trick

If the vehicle manufacturer recommends the battery be disconnected, first
disconnect the negative battery cable and then depress the brake pedal.
Because the brake lights are connected to battery power, depressing the
brake pedal causes all of the capacitors in the electrical system and
computer(s) to discharge through the brake lights.

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ROAD TEST (DRIVE TRACE)

Usethefreezeframedataandtestdrivethevehiclesothevehicleis
driventomatchtheconditionsdisplayedonthefreezeframe.
Ifthebatteryhasbeendisconnected,thenthevehiclemayhaveto
bedrivenunderconditionsthatallowthePCMtoconductmonitor
tests.Thisdrivepatterniscalledadrivecycle.
Thedrivecycleisdifferentforeachvehiclemanufacturerbuta
universaldrivecyclemayworkinmanycases.Inmanycases
performingauniversaldrivecyclewillresetmostmonitorsinmost
vehicles.
Continued
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UniversalDriveCyclePreconditioning:Phase1
MILmustbeoff.NoDTCs.Fuelfillbetween15%and85%.
ColdstartPreferred=8hoursoakat68Fto86F.
Alternative=ECTbelow86F.
1. Withtheignitionoff,connectscantool.
2. Startengineanddrivebetween20and30mphfor22
minutes,allowingspeedtovary.
3. Stopandidlefor40seconds,graduallyaccelerateto55mph.
4. Maintain55mphfor4minutesusingasteadythrottleinput.
5. Stopandidlefor30seconds,thenaccelerateto30mph.
6. Maintain30mphfor12minutes.
7. Repeatsteps4and5fourtimes.
Continued
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Usingscantool,checkreadiness.Ifinsufficientreadinessset,
continuetouniversaldrivetracephaseII.
Important:(Donotshutoffenginebetweenphases).PhaseII:
1. Vehicleatastopandidlefor45seconds,thenaccelerate
to30mph.
3. Repeatsteps1and2threetimes.
5. Maintainspeedbetween30and35mphfor4minutes.
8. Repeatsteps6and7fivetimes.
9. Usingscantool,checkreadiness.
Continued
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SUMMARY
1. FunneldiagnosticsVisualapproachtoadiagnosticprocedure:
Step1
Step2
Step3
Step4
Step5
Step6
Step7
Step8
Verifytheproblem(concern)
Performathoroughvisualinspectionandbasictests
Retrievethediagnostictroublecodes(DTCs)
Checkfortechnicalservicebulletins(TSBs)
Lookcarefullyatscantooldata
Narrowtheproblemtoasystemorcylinder
Repairtheproblemanddeterminetherootcause
VerifytherepairandcheckforanystoredDTCs
Continued
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SUMMARY
(cont.)
2. Careshouldbetakentonotinducehighvoltageorcurrentaroundany
computerorcomputercontrolledcircuitorsensor.
3. Athoroughvisualinspectionisimportantduringthediagnosisand
troubleshootingofanyengineperformanceproblemorelectrical
malfunction.
4. IftheMILison,retrievetheDTCandfollowthemanufacturers
recommendedproceduretofindtherootcauseoftheproblem.
5. OBDIIvehiclesusea16pinDLCandcommonDTCs.

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end
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start

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

List the steps of the diagnostic process.

should be performed at the start of the

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

Explain the troubleshooting procedures to

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

THE EIGHT-STEP DIAGNOSTIC PROCEDURE

Original Equipment is not a Four-Letter

Smoke Machine Testing

Figure 635 Using a bright light makes seeing

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

Figure 636 A spark tester connected to a spark plug wire or coil

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

One Test is Worth 1,000 Expert Opinions

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

Figure 6311 A TECH 2 scan tool is the factory

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

RETRIEVAL OF DIAGNOSTIC INFORMATION

TROUBLESHOOTING USING DIAGNOSTIC

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

FLASH CODE RETRIEVAL ON OBD-I

Do Not Lie To a Scan Tool!

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

RETRIEVING FORD DIAGNOSTIC CODES

Put a Wire in the Attic and a Light in the

Put a Wire in the Attic and a Light in the

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

FLASH CODE RETRIEVAL ON CHRYSLER

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

Figure 6316 A typical OBD-II data link connector

OBDII DIAGNOSTIC CODES

OBDII ACTIVE TESTS

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

Figure 6318 Follow the on-screen instructions.

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

Figure 6321 The J2534 pass-through reprogramming

Figure 6322 A typical J2534 universal

MANUFACTURERS DIAGNOSTIC ROUTINES

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

COMPLETING SYSTEM REPAIRS

PROCEDURE FOR RESETTING THE PCM

The Brake Pedal Trick

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

ROAD TEST (DRIVE TRACE)

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

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