AVL DiTEST – On-Board Diagnostic Training

AVL DiTEST – On-Board Diagnostic Training
FUTURE SOLUTIONS FOR
TODAY
www.avlditest.com
1
Contents
AVL DiTEST
(E)OBD vs. Vehicle diagnostics
ECU Communication
Legislation
(E)OBD Details
2
AVL DiTEST – MISSION
AVL DiTEST offers products and services for statuary tests and efficient
diagnosis of in service vehicles and supplies them to vehicle manufacturers,
workshops and test centers.
3
AVL DiTEST – BUSINESS FIELDS
AVL DiTEST offers products and services for statuary tests and efficient diagnosis
of in service vehicles.
OEM
Vehicle Manufacturers
Emissions
Test Organizations
Speed Measurement
Free Garages
ECU Diagnostics
Chains
Engine&
Component Test
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(E)OBD vs. Vehicle Diagnostic
5
Vehicle Diagnostics
6
Example – network in modern vehicles
Engine-CAN
Motor
Panel
Gear
Driver
Co-driver
Back left
Back right
Driver
Loud
Speaker
Co-driver
Heater
Ventilator
Steering
Park
Control
Steering
Column
Wireless
Phone
Inclination
Back
Luxus
Speech
Recognition
Source: Audi
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Example – network in modern vehicles
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OBD, OEM, Multibrand Diagnostics
(E)OBD Diagnostics
Standardized services to execute emission system related
diagnostics for periodical technical inspection.
OEM Diagnostics
Diagnostic devices and software tailored, branded and sold to
OEM workshop to carry out required servicing and repair.
Multi-branded Diagnostics
Diagnostic devices and software designed
to be applicable to many vehicle brands.
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ECU
Bus & Communication
Protocols
10
ECU - Bus Protocols
(E)OBD Connector (ISO 15031-3 / SAE J1962)
K/L-Line (ISO9141)

Slow serial bus connected to a gateway, no inter ECU communication, up to 10.4 kbit/s
CAN - Controller Area Network (ISO 11898-1/2/3 or ISO 11519 / SAE J2284 / SAE J2411,
ISO11992 / SAE J1939 for Trucks, ISO11783 for Agriculture)

Fast seriell data exchange between ECU‘s

High Speed - 500/250 kbit/s (ISO 11898-2 / SAE J2284),

Mid Speed - 125/95,8 kbit/s, Low Speed/Single wire – 50kbit/s (ISO 11898-3 = ISO 11519-2 / SAE J1939
Truck & Bus / SAE J2411 single wire)
LIN - Local Interconnect Network (OEM Consortium, US: SAE J2602)

Less costly communication between intelligent sensors and actuators, i.e. within a seat
MOST - Media Oriented Systems Transport (OEM Consortium)

to transfer multimedia applications (infotainment),

optical bus system with high transfer rate up to 25 Mbit/s
FlexRay (OEM Consortium)

For safety relevant applications with high data rate up to 10 Mbit/s, i.e. steering, braking

PWM (SAE-J1850, Ford SCP), up to 41.6 kbit/s

VPW (SAE-J1850, GM Class 2, Crysler PCI), up to 41.6 kbit/s

TTCAN - Time Triggered CAN (ISO 11898-4, Bosch), up to 1Mbit/s
Other
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Example: Communication via K/L-Line
Originally single wire K-Line
L-Line used for initialization
Full Duplex, Two Lines (K- und L-line)
Asynchronous und UART-based
Little implementation effort
L- Line (unidirectional)
K- Line (bidirectional)
ECU 1
ECU 2
ECU 3
Motor
Airbag
ABS
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Example: Communication via CAN
Controller Area Network (especially designed for usage in automotive vehicles)
Supports Complex Network Systems and increasing number of ECU‘s
Safe data transfer by sophisticated error handling
Fast reaction times
Prioritization of information
Central Diagnostic Gateway
Inter ECU Communication
16 Pin OBD connector
ABS ECU
Motor ECU
Airbag ECU
Gateway 1
Gateway 2
Gateway 3
Gateway xxx
...
Diagnostic Gateway
Gateway 4
CAN Bus
Gateway ...
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ECU - Communication Protocols
(E)OBD (ISO 15031-5 / SAE J1979)
 On K-Line (ISO 9141-2 or ISO 14230-4), Info: mostly EU manufacturer
 On CAN (ISO 15765-4)
 On J1850 (SAE J1850 VPW or PWM), Info: mostly US manufacturer
 On Truck, Bus CAN (SAE J1939)
KWP2000 (ISO 14230-3 / SAE J2190)
 Slow and fast
 On K-Line (ISO 14230-2)
 On CAN (ISO 15765-2)
UDS (ISO 14229)
 On CAN (ISO 15765-2), Info: Implementation in ISO 15765-3
 On K-Line (ISO 14230-5), Info: DoK
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ECU - Communication Protocols, others
Blink Code
KWP





KWP71, Bosch, Info: mainly BMW, Opel, Peugeot/Citroen, Volkswagen
KWP81/82, Opel/Vauxhall/GM
KWP1271, 2026 Hyundai, 2027 ?
KWP1281, VAG, over K-Line, Info: Extension to KWP71
KW-FB (Franz Becker), MB propriatary
TP2.0 on CAN – VAG (SAE J2819)
BMW


BMW DS1, DS2: propriatary
BMW Fast
GM, Crysler




Crysler SCI (SAE J2610)
GMW3110 over CAN – GMLAN, Info: GMW 3104 (GMLAN Comm), GMW 3110 (enhanced DIAG), GMW 3089 (sw GMLAN), GMW 3122 (dw
GMLAN)
GM, Crysler Class 2 (SAE J 1850 VPW)
Multec2: GM propriatary
MB ISO (which is a variation of ISO-9141-2)
Ford


Ford ISO (Ford CAN, ISO15765 11-bit)
Ford SCP (SAE J 1850 PWM)

Ford UBP (UART Based Protocol)


Renault ISO
Renault FreeRunning XR25, Info: sends a continuous telegram based on the RS232C protocol with the only change in voltage levels of 0 to
12 Volt
Renault
PSA2000
Peugeot ISO
Volvo D2 over CAN: propriatary
Truck & Bus on UART (SAE J1587 + SAE J1708)
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AVL DiX - DiOBD 880 ECU Diagnostics Hardware (VCI)
Multi-functional ECU diagnostics module
Includes all vehicle communication protocol
standards (OBD, ISO 9141-2, KWP 2000,
SAE J1850 PWM and VPW, …)
Includes all CAN bus protocol standards
Manufacturer specific protocols
Manufacturer specific diagnostic cables
Petrol and diesel engine emission tests
USB, RS232, Bluetooth enabled
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Future Outlook: WWH-OBD (ISO 27145)
WWH-OBD - Worldwide harmonized OBD
Driven by UN ECE
Establish world-wide harmonized set of requirements for
OBD
Implementation approx. For EURO 6 (2014)
Communication requirements
 OBD on CAN (ISO 15031 and ISO 15765)
 UDS (ISO 14229)
 DoIP – Diagnostic over IP (ISO 13400)
…
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AVL DiTEST – Multibrand ECU Diagnostics
Multi-functional, vehicle specific ECU diagnostic software for car, bike
and truck
Wide vehicle coverage
ECU Communication (OBD + OEM Specific)
Support Standard Protocols
Error Code Reading: Blink code / EOBD / OBD II / CAN-Bus
Error Code Translation (Text)
Error Code Deleting
Measurement Values and Live Data
Actuator Tests
Learning, Coding, Adaptation
Service Resets
(Programming/Flashing)
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EU Frame Legislation
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Overview EU Frame Legislation
Homologation
(Type Approval)
Periodical Technical Inspection
(PTI, I&M)
manufacturer/vehicle view
workshop/test centers view
technical, emission, OBD,
service, maintenance,
diagnostic, … relevant
requirements
safety, emission, inspection, …
relevant requirements
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EU HOMOLOGATION (Emissions)
Political Part
1991 – EURO 1
Council Directive 70/220/EWG
(+ 91/441/EG)
1994 – EURO 2
Council Directive 70/220/EWG
(+ 94/12/EG)
1998 – EURO 3 & 4
Council Directive 70/220/EWG
(+ 98/69/EG)
2007 – EURO 5 & 6
Regulation 715/2007/EC
•
Commitology Part
Regulation 692/2008/EC
(Euro 5: Sept. 2009 for new type approved cars, Jan. 2011 for
all cars; Euro 6: Sept. 2014 for new type approved cars, Sept.
2015 for all cars)
Decreasing Homologation limits for mass emissions (mg/km)
• Car: Driving cycle (Japan, Europe, USA, …) on roller test bench
•
Increasing requirements & additional functions for On-Board OBD (since 2000)
•
Note:
• OEM also determines nominal value of exchaust gas in Vol% or ppm as well as
opacity for diesel cars
• in addition since Euro 5 & 6: RMI, ECU flashing, diagnostic tool data
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EU HOMOLOGATION - Light Duty Emission Limits
Petrol - EU Limits
10000
mg/km
1000
CO
HC
100
NOx
NMHC
10
PM
1
EU-1
1992
EU-2
1996
EU-3
2000
EU-4
2005
EU-5
2009
EU-5+
2011
EU-6
2014
Diesel - EU Limits
10000
mg/km
1000
CO
100
HC + NOx
NOx
10
PM
1
EU-1
1992
EU-2
1996
EU-3
2000
EU-4
2005
EU-5
2009
EU-5+
2011
EU-6
2014
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EU HOMOLOGATION - OBD Tests
Engine family tests: Miss firing, combustion system, CAT & DPF, EGR
Test against Thresholds (much higher than homologation limit)
OBD test separate to emission measurement: OBD is model based system and
homologation test checks plausibility's
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The “Inspection” Directive 96/96/EC
Periodic roadworthiness tests for
vehicles registered on the European
territory to make sure that vehicles
on the road meet regulations during
their lifetime in the given limit
values.
Entered into force on 9 March 1997
Has been amended Six Times
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Directive 96/96/EC Content
Coverage
Buses
Coaches
Roadworthiness test focuses
Braking systems
Steering and Steering wheel
Heavy goods vehicles
Visibility
Trailers (> 3.5 tones)
Lamps, reflectors, electr. equip.
Taxis
Axles, wheels, tires, suspension
Ambulances
LCV (< 3.5 tones)
Private cars (<= 8 seats)
Chassis and chassis attachments
Nuisance
Exhaust emissions
Vehicle identification
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Directive 96/96/EC Amendments
Directive1999/52/EC:
Adaptation emission limits and test procedures for new engine
technologies
Directive 2001/9/EC:
Introduction of OBD reading and proper OBD System functioning
Directive 2001/11/EC:
Functional testing of commercial vehicles' speed limitation device
Directive 2003/27/EC:
Adaptation emission limits and test procedures for new engine
technologies
Directive 2009/40/EC: + Amendment Directive 2010/48/EU:
Editorial changes, Additional safety checks
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Directive 96/96/EG
2001/9/EG Core Message
Alternative to the CO measurement at engine idling
speed, the correct functioning of the emission system
through the appropriate reading of the OBD device and
the simultaneous checking of the proper functioning of
the OBD system could be performed
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Directive 96/96/EC Future Revision
>2011: Directive 96/96/EC needs to be adapted to the technology of the
vehicle.

Brake + ABS + EBS

Suspension + ESP/ESC + EDC

Head Light + Electronic Head Light (Xenon)

Steering + Electronic Controlled Steering

Emission + OBD + DPF

Speed Limiter/Trip Recorder + Digital Tacograph

Safety Belt + SRS
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Status European wide introduction - Obligatory OBD inspection
Germany
since 2002 EOBD gasoline, complex procedure, check of lambda
probe; since 10/2005 Diesel; since 2009 emission guideline 4 
elimination tailpipe measurement if no fault codes
Finland
EOBD for gasoline, Trouble codes (DTC) readout, lambda control
loop testing
Hungary
Gasoline, similar to Germany, no check of lambda probe; Diesel
since 2008, similar to Germany
Switzerland
EOBD for gasoline, DTC readout
Greece
Gasoline since 2006, DTC readout
Slovakia
Since 1.1.2009 EOBD gasoline; DTC readout
France
Since 2008: EOBD Gasoline and Diesel separate to emission test
procedure; DTC readout
Austria
No EOBD testing  Visual check of MIL lamp
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(E)OBD Details
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What is OBD ?
„On Board Diagnostics“ means that all emission relevant components and
systems will continuously be checked during driving. Malfunctions will
be recorded, stored and displayed by the standardized malfunction
indicating lamp (MIL).
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OBD History
1984 First Draft CARB (OBD I)
1988 First Draft CARB (OBD II)
1990 the standard was incorporated into the federal clean
air act (for all 49 US states)
since 1996 all vehicles have to be equipped with OBD II
1996 (E)OBD Proposal introduced to EU Parliament
1998 change of directive 70/220/EWG with 98/69/EC
came into force
2000 graduated scheme starts
2007 regulation 715/2007 (Euro5/6)
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Which vehicles have OBD?
1. Jan. 2000 OBD all new vehicle models (petrol)
99 1. Jan.
00 200101OBD 02
03 (petrol)
04
05
06
all vehicles
1. Jan. 2003 OBD vehicles (diesel) + LCV (all new models)
1. Jan. 2004 OBD vehicles (diesel) + LCV (all vehicles)
1. Jan. 2005 OBD HDV (diesel)
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Overview OBD System
Sensors and actuators
Sensor 2
Sensor 1
Actuator 3
(Engine) ECU
MIL (Malfunction indication
Engine ECU
lamp)
Diagnostic- Interface
Generic Scantool
Generic Scantool
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Standard OBD Connectors (SAE J 1962, ISO 15031-3)
Standard OBD II / EOBD Diagnosis socket
Standard Diagnosis connector
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What is OBD ECU doing?
Monitoring of all emission relevant systems and
components, e.g. operation and function of
sensors and actuators
Protection of the catalytic converter, e.g.
plausibility check of signals and components
Visual warning, if emission relevant parts
showing operational malfunctions
Storage diagnostic trouble codes and other
useful information for repair
Diagnostic ability of the monitoring system
Emission quality not only for new vehicles 
ensure ever lasting low emissions
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What is OBD ECU doing?
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What is monitored by OBD ECU?
Petrol
Diesel
Catalyst monitoring
Catalyst monitoring
Combustion drop outs
Particle filter
Engine Missfiring
Injection begin control
Lambda probe aging
Tank ventilation system and
tank density monitoring
Tank ventilation system and
tank density monitoring
Boost pressure regulation
Secondary air system
Exhaust gas recycling
Exhaust gas recycling
NOx After treatment
-
All sensors and actuators connected to the control unit.
Electronically controlled power train systems (automatic – transmission)
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Generic OBD Scantool
Read/ erase fault codes
Display of relevant live data data for components
to support troubleshooting and repair
Readout readiness codes
Execute actuator tests
…
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Standardized OBD Modes - (SAE J 2190, ISO 15031-5)
Mode 1:
Current engine data / Power train diagnostic data
Mode 2:
Read DTC environment data (Freeze Frame)
Mode 3:
Read of emission-relevant DTC’s
Mode 4:
Clear all stored DTC’s
Mode 5:
Read test results from Lambda probe monitoring
Mode 6:
Read test results of monitored
system components (Readiness codes)
Mode 7:
Read of emission-relevant DTC’s (intermittend)
Mode 8:
Activation of single tests or triggering of actuators
Mode 9:
Request vehicle information (e.g. VIN)
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Standardized OBD Faultcodes (SAE J 2012, ISO 15031-6)
Decoding of faultcodes according to
SAE J2012
The first digit of the faultcode is
indicated with a letter. It
indicates the startup of the
system:
 Pxxxx for powertrain
 Bxxxx for car body
 Cxxxx for chassi and
 Uxxxx for extensions (future
systems)
For OBD II are only P-Codes
required.
Faultcode
1-Fuel-air measurement
2-Injection nozzles
3-Ignition dropouts
4-Aggregate emissions
5-Idling and speed control
6-Vehicle computer
7-Gear
8-Gear
9-Hybrid-electric powertrain
0- SAE J2012 defined
1- manufacturer defined
P- Powertrain
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What happen on OBD Failure?
• First sign of a potential OBD failure:
• Freeze Frame Data stored
• amount of data is up to OEM
• Fault must be detected in less than 10 driving cycles
• Fault stored into memory
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OBD Readiness codes
The control unit executes
single diagnosis from exhaust
gas relevant components
(e.g. Lambda probe, heating etc.)
The Result of these single diagnosis are the so called
Readiness codes (=readiness test).
The Readiness code indicates, if all required diagnoses
could have been executed by the system.
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OBD Readiness codes
If single diagnosis is successful and ok, the Readiness
code will be activated (e.g. after driven through a specific
driving cycle).
Specific RC is only set if specific diagnoses have been
finished.
IMPORTANT!
If all fault codes are erased from the control unit, also the
RC will be erased from specific control units  All single
diagnosis have to be executed again.
The Readiness code gives no information if a system error
exists.
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OBD Driving Cycle (VW/Audi)
Stage 1: Cold Start (<50°C)
O2S heater, misfire, AIR, fuel system, and
EVAP monitors run.
Stage 2: Idle 2½ Minutes (A/C and headlights
on to help the misfire monitor)
O2S heater, AIR, EVAP, misfire, and possibly
fuel system monitors run
Stage 3: Accelerate (A/C and headlights off, Throttle halfway open until 89km/h)
Misfire, fuel system, and EVAP monitors run
Stage 4: Steady State Cruise
O2S, AIR, EGR, EVAP, misfire, and fuel system monitors run
Stage 5: Decelerate (w/o brakes, remain high gear & no clutch)
EGR, EVAP, and fuel system monitors run.
Stage 6: Accelerate (¾ throttle until reaching 60 MPH (97 KPH)
misfire, fuel system, and EVAP monitors run
Stage 7: Steady State Cruise
CAT, O2S, AIR, EGR, EVAP, misfire, and fuel system monitors run.
Stage 8: Decelerate (w/o brakes, remain high gear & not clutch)
EGR, EVAP, and fuel system monitors run.
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Many Thanks!
Questions?
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BACKUP
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EU Law Making Process
“Split Level” Approach
POLICY PROPOSAL
POLITICAL PART
TECHNICAL PART
Co-decision procedure
(EP + Council)
Commitology/Scrutiny procedure
(MS experts + Commission)
Umbrella
Regulation
Technical
Regulation
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DE Legislation
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PTI in Germany - History
1985
Emission test for vehicles without controlled catalyst (CO only)
1993
GL1: Emission test for all petrol & diesel vehicles
(CO, Lambda, Opacity)
2002
GL2: emission test with OBD reading for petrol vehicles
2006
GL3: emission test with OBD reading for diesel vehicles
2008
GL4 (Regulation 41 from 2006): Two stage emission test
>2012
GL5: particle mass and NO/Nox for diesel vehicles ?
52
Guideline 4 (Regulation 41)
Summary
Passenger cars. LCV and motor bikes, (truck)
Combination of technical inspection and emission
test
Examination of safety relevant systems during
technical inspection
Two stage approach
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Guideline 4 (Regulation 41) - Two Stage Approach
Visual Technical Inspection
Vehicle Identification Data
Visual MIL Check
OBD Test Procedure
OEM Emission Limit Values
Emission Measurement
Inspection Report
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Guideline 4 (Regulation 41) OBD Test Procedure
Visual MIL Check
Communication VCI - Vehicle
Function Test OBD: MIL, DTC?, RC?
NO
> 01.01.2006 ?
YES
NO
RC OK?
YES
OEM Emission Limit Values
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