Emission control and OBD

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1 Emission control and OBD Our knowledge for your work SERVICE TIPS & INFOS POSTER INSIDE

OBD = On-Board Diagnostic System The European on-board diagnostic system (EOBD) is still

The Emission control and OBD from the PIERBURG series Service Tips & Infos provides easily

For us, it is of particular importance to impart system skills because the component

fault. And this is where an expert with system skills is needed.

relationships between diagnostic trouble code and the cause of the fault are also dealt with.

2 OBD = On-Board Diagnostic System The European on-board diagnostic system (EOBD) is still virgin territory to many independent garages. The Emission control and OBD from the PIERBURG series Service Tips & Infos provides easily understandable information on the complex subject self-diagnostics in motor vehicles. For us, it is of particular importance to impart system skills because the component indicated as a faulty component by the OBD system is not the actual cause of the failure or fault. And this is where an expert with system skills is needed. In addition to information on the structure and function of the systems, potential faults and relationships between diagnostic trouble code and the cause of the fault are also dealt with. The brochure also includes practical instructions on error diagnostics and fault clearance on emission-relevant components. The contents of this brochure are mainly based on practical cases experienced by the PIERBURG technical after-sales service department. It is intended as an everyday help, in particular for error diagnostics work on vehicles equipped with OBD systems.

Systems and diagnosis 4 with PIERBURG products Diagnostic instructions A malfunction of a component in the secondary air system will often cause damage to several components.

During the repair the actual cause of the damage is often not detected and the secondary air pump is just replaced.

For example, stuck non-return valves are classified by OBD as malfunctions of the secondary air pump even if they are working properly.

3 Systems and diagnosis 4 with PIERBURG products Diagnostic instructions A malfunction of a component in the secondary air system will often cause damage to several components. A frequently occurring error is a malfunctioning secondary air pump. Almost always damage is caused by exhaust gas condensates in the pump. During the repair the actual cause of the damage is often not detected and the secondary air pump is just replaced. The cause of the damage remains in the vehicle and can cause the secondary air pump to malfunction again. For this reason, when there is damage, all associated components must be checked. For example, stuck non-return valves are classified by OBD as malfunctions of the secondary air pump even if they are working properly. Moreover, damage to the secondary air system can cause errors that are attributed to other components by the error detection. Fig. 28: condensate in the secondary air pump Fig. 29: secondary air pump corroded electric connections Fig. 30: cut-off secondary air valve damage to the diaphragm and valve plate due to condensates Fig. 31: deposits in the non-return valve Malfunction Possible causes/errors Possible solutions/actions loud whistle ( howling ) after cold start SLP generates noises SLP fails repeatedly exhaust pipe noises or smell of exhaust gas in the engine compartment Bearing corroded with condensates. Lines and insulation destroyed by conden sates. EUV incorrectly connected (to wrong cables). Leaks in the exhaust gas tract or in the se condary air system, between the exhaust gas manifold and the cut-off secondary air valve or non-return valve. If the SLP causes noises, replace it and determine the cause of the damage as described under fault codes P0410 and P0411. Check the ARV and the EUV. If there are several EUVs in the vehicle, ensure that the connections are not mixed up. Let the secondary air pump run still installed (externally powered). Determine the leaky places (e.g. using leak detection spray). Replace faulty line or gasket. Attention: When the line between the SLP and the exhaust manifold is scorched, proceed as for fault codes P0410 and P0411. Extract from the brochure Emission control and OBD 37 Details on this subject can be found in our brochure Emission control and OBD. Order-No.: (English) or via

KEEPING THE WORLD MOVING! Motor Service Group. Quality and Service from a single source.

It is one of the leading suppliers of engine components for the independent aftermarket including the premium brands KOLBENSCHMIDT, PIERBURG and TRW Engine Components.

As a problem solver for dealers and repair shops, Motor Service offers extensive services and the technical expertise that you would expect from the subsidiary of one of the largest

As long-standing partners to the automotive industry, the companies in the KSPG Group develop innovative components and system solutions with acknowledged competence for air supply and

4 KEEPING THE WORLD MOVING! Motor Service Group. Quality and Service from a single source. The Motor Service Group is the sales organisation for the worldwide aftermarket activities of Kolbenschmidt Pierburg. It is one of the leading suppliers of engine components for the independent aftermarket including the premium brands KOLBENSCHMIDT, PIERBURG and TRW Engine Components. Our comprehensive product range allows our customers to procure engine components from a single source. As a problem solver for dealers and repair shops, Motor Service offers extensive services and the technical expertise that you would expect from the subsidiary of one of the largest automotive suppliers. KSPG (Kolbenschmidt Pierburg). Renowned supplier to the international automotive industry. As long-standing partners to the automotive industry, the companies in the KSPG Group develop innovative components and system solutions with acknowledged competence for air supply and emission control, for oil and water pumps, for pistons, engine blocks and engine bearings. The products comply with the high demands and quality standards of the automotive industry. Low emission, reduced fuel consumption, reliability, quality and safety these are the forces that drive innovation at Kolbenschmidt Pierburg. Motor Service Partner: Headquarters: MS Motor Service International GmbH Wilhelm-Maybach-Straße Neuenstadt, Germany MS Motor Service International GmbH /10 EN

OBD On-Board-Diagnosis and PIERBURG Products Fault codes often caused by the system.

control unit after an emissions-relevant fault, when permissible emission values are exceeded.

PIERBURG PRODUCTS Fuel supply 1 Fuel feed unit 2 In-tank pump/pre-delivery pump 3 In-line pump 4 Fuel filter 5 Fuel tank pressure valve 6 Active carbon filter valve/purge valve 7 Fuel check valve 8

D A - Which system set the fault code? P = Powertrain B = Body C = Chassis U = Network B - Which fault group is displayed?

1/2 = Fuel and air delivery 3 = Ignition system/misfiring 4 = Systems for exhaust gas purification 5 = Cruise control and idle speed control 6 = Control unit and its output signals 7/8 = Transmission

(here: exhaust gas recirculation malfunction) Secondary air system 10 Non-return valve 11 Electronic switchover valve 12 Combination valve 13 Electronic secondary air pump 14 Switchable non-return

Mass air flow sensor 20 Throttle neck (incl. ancilliaries such as the throttle valve switch, idle air control valve, idle air charge controller etc.) 21 Suction pipe (incl.

5 OBD On-Board-Diagnosis and PIERBURG Products Fault codes often caused by the system. Fault indicator/malfunction indicator light MIL The fault indicator lights up continuously, when the ignition is switched on (lamp function check) when a fault is detected during the self test of the control unit after an emissions-relevant fault, when permissible emission values are exceeded. The fault indicator flashes when faults occur that lead to cylinder shut-off or to damage/failure of the catalytic converter (e. g. misfiring). PIERBURG PRODUCTS Fuel supply 1 Fuel feed unit 2 In-tank pump/pre-delivery pump 3 In-line pump 4 Fuel filter 5 Fuel tank pressure valve 6 Active carbon filter valve/purge valve 7 Fuel check valve 8 Active carbon filter shut-off valve 9 Pressure regulator The P0-Code A C B The fault indicator is also referred to as the malfunction indicator or MIL (Malfunction Indicator Light). D A - Which system set the fault code? P = Powertrain B = Body C = Chassis U = Network B - Which fault group is displayed? 0 = Manufacturer independent code 1 = Manufacturer specific code (not required) C - Which assembly does the fault refer to? 1/2 = Fuel and air delivery 3 = Ignition system/misfiring 4 = Systems for exhaust gas purification 5 = Cruise control and idle speed control 6 = Control unit and its output signals 7/8 = Transmission D - Which component is affected by which fault? Refer to table of fault codes! (here: exhaust gas recirculation malfunction) Secondary air system 10 Non-return valve 11 Electronic switchover valve 12 Combination valve 13 Electronic secondary air pump 14 Switchable non-return valve 15 EGR valve/exhaust gas recirculation valve 16 Electro-pneumatic pressure transducer for actuation of EGR valve 17 Electronic switchover valve 18 Electric pressure transducer Air supply 19 Mass air flow sensor 20 Throttle neck (incl. ancilliaries such as the throttle valve switch, idle air control valve, idle air charge controller etc.) 21 Suction pipe (incl. ancilliaries such as the electronic drive module EAM-i) 22 Electro-pneumatic pressure transducer for actuation of the turbocharger (VTG charger) The nine operating modes of the scan tool Mode 1: Read out the diagnostic values (actual values) of the system Mode 2: Read out the operating conditions when the fault occurred (freeze frame) Mode 3: Read out the emissions-relevant faults which caused the fault indicator to come on Mode 4: Delete the emissions-relevant fault codes and reset the freeze frames Mode 5: Display the test values and signal curves of the oxygen sensors Mode 6: Display the measured values of intermittently monitored systems Mode 7: Read out the stored faults which have not yet caused the fault indicator to light up Mode 8: Status display of OBD test functions (readiness code, component testing) Mode 9: Display vehicle information data (engine code, vehicle identification number etc.) Components which are not yet monitored by the OBD 23 Vacuum pump 24 Exhaust flap Products of other manufacturers 25 Active carbon filter 26 Catalytic converter 27 Oxygen sensor (before catalytic converter sensor) Details on the subject of OBD and emission control are provided in the brochure Service Tips & Infos Emission control and OBD. Fuel system Exhaust gas Fuel supply Secondary air system Example Example Example Example P0170 P0179 P0410 P0419 P0400 P0409 P0170 Fuel mixture, cylinder Leakage on intake side P0410 Secondary air Engine control unit P0400 (EGR) flow mal- malfunction Engine control unit P0505 Idle speed control Engine control unit P0190 P0194 bank 1 malfunction Fuel pressure malfunction P0200 P0212 function Fuel injectors P0263 P0296 Relays Injection system Sticking or coking Injector nozzles Heated oxygen sensor Activated carbon filter solenoid valve Secondary air injection system Fuel pump P0301 P0314 P0440 P0469 Leaking vacuum lines Condensation/splash water Secondary air valve Secondary air system solenoid valve Sticking or coking Basic setting not performed Hoses leaking or blocked EGR valve EGR control valve Idle controller Idle air control valve Throttle valve Throttle valve positioner 15 Pneumatic system Vacuum system Air supply KSPG Automotive Group P0033 P0035 P0105 P0109 P0120 P0124 P0220 P0229 P0234 P0235 P0243 P0250 P0505 P0510 P0638, P0639 MS Motor Service International GmbH /10 EN

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