The AuTo. Emissions Bible. How to Pass the Vehicle Emissions Test. Sam Bell Ralph Birnbaum

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1 The AuTo Emissions Bible How to Pass the Vehicle Emissions Test Sam Bell Ralph Birnbaum

2 The Auto Emissions Bible Copyright 2012 by Sam Bell and Ralph Birnbaum Cover Design, Typeset, Illustrations, and Layout: Ralph Birnbaum NOTICE OF RIGHTS All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the authors. DISCLAIMER The information in this book is distributed on an as is basis, without warranty. While every precaution has been taken in the preparation of this book, the authors make no warranty, expressed or implied, and will not be liable for any errors or for incidental or consequential damages resulting from the use of information, herein. Users encouraged by this book to engage in repair and diagnosis of real vehicles, do so entirely at their own volition and risk. ISBN-13: ISBN-10:

3 About the Authors Sam Bell has owned and operated The Lusty Wrench, a premium auto repair facility in Cleveland Heights, Ohio for 32 years. In addition to the normal ebb and flow of common maintenance and repair tickets, Sam is often called upon to diagnose and repair driveability issues that stump other local repair shops. Awards and Experience: Sam was named the 2010 Delmar/Cengage ASE Technician of the Year for earning the highest composite score on the ASE certification exams. Sam had another perfect score on the L1 (Advanced Engine Performance Specialist) test, and his overall scores were the highest of more than 350,000 professionals who took the tests. Publishing Credentials: Sam is a frequent contributor to Motor magazine, and has garnered five International Automotive Media Awards, including a Gold Medallion. He has also won three ASBPE Awards (American Association of Business Publications Editors), including a Gold Medal. He teaches Ohio One training courses on driveability and emissions. Ralph Birnbaum has 40 years of automotive experience, and that includes real experience fixing cars as a master automotive technician, specializing in auto electric and vehicle performance issues. His is a former tech editor and editor of a national trade publication, and has been researching and preparing books and training materials for two decades. He is currently Automotive Editor at ECS Tuning, where he prepares ad copy and training materials. He also contributes technical illustrations used in Standard Motor Products automotive training classes. Ralph still has all his tools, and regularly gets his hands dirty fixing real car problems. Publishing Credentials: Writing credits include numerous automotive articles and over 20 training programs for professional technicians. His training materials have been used in both corporate and state emissions training programs.

4 Table of Contents Introduction 1 - Combustion 2 - The MIL 3 - DTCs 4- The DLC 5- Datastream 6- Monitors 7- Emission Controls 8- Testing Emissions 9 - Analyzing Test Results 10 - Troubleshooting Tips 11- Passing the Emissions Test 12 - Mode NOx 14- Diesel Emissions 15 - Information Glossary OBD II Modes Index 5

5 Combustion Combustion Triangle Oxygen and Fuel Ignition Suck-Squeeze-Bang-Blow Intake Stroke - Suck Compression Stroke - Squeeze Power Stroke - Bang Exhaust Stroke - Blow A Chemical Reaction A Balanced Mixture Combustion By-products - Carbon Dioxide Combustion By-products - Carbon Monoxide Combustion By-products - Oxygen Combustion By-products - NOx Combustion By-products - HC Review 11

6 Combustion Exhaust Stroke As the piston moves downward, the explosion burns out and its force weakens. Burned remains of the combustible charge are similar to the soot and ash left over after a wood fire goes out. Any leftover pressure and waste gas material must be exhausted from the cylinder before a fresh charge of filtered air and fuel enters on the next intake stroke. During the exhaust stroke, the exhaust valve opens and the next upward motion of the piston blows the waste gas out of the cylinder to the exhaust system. This completes one entire four stroke combustion cycle. The process repeats itself as long as the elements needed for combustion continue to show up in the cylinders in the right proportions, at the right times. The Auto Emissions Bible 19

7 The MIL The MIL OBD Sensors MIL Illumination The MIL Matters OBD II Scan Tool Emissions Tests Scan Tool Tests and the MIL MIL Tampering MIL Fun Facts 29

8 DTCs Diagnostic trouble Codes Sign Posts The First Diagnostic Step DTC Numbers Code Number Classes Where Do DTC Numbers Come From? What s In a DTC? What Descriptors Tell Us SAE vs. OEM DTCs DTC Descriptor v. DTC Definition DTC Definitions DTC Definition Examples One Trip-Two Trip Freeze Frame Putting DTCs to Work Cautions and Pitfalls Keep Things Simple Exceptions to the Rule Professional Grade Diagnostics Review 39

9 The DLC Say AHHHHHH Generic vs. Enhanced Data Connect the Scan Tool DLC Quick Tips DLC Hiding Places DLC BOB Scan Tool Power Connection Cautions Careful There, Sparky Texting the Vehicle Data Protocols Data Delivery Speed Controller Area Network DLC Review 61

10 DLC Generic Versus Enhanced Data The Generic OBD II interface provides emissions-related data to a generic scan tool interface. Generic data include DTCs and Freeze Frame, datastream, and information about monitors and their status. An Enhanced interface provides additional data, including information about non-emissions components. Scan tools from equipment makers who make dedicated scan tools for professional repair technicians normally include both generic and enhanced interfaces. Both are accessed through the DLC after the scan tool user selects the correct interface from a menu. Scan Master Please scroll to select scan interface: Generic (Global) OBD II Ford Enhanced Chrysler Enhanced GM Enhanced Toyota Enhanced Honda Enanced Dedicated scan tools are purpose-built to communicate with vehicles through multiple interfaces. Many professional grade scan tools can download and install software updates to keep them current. Our image shows a scan tool capable of communicating with several vehicle brands plus OBD II generic. The scan tool interfaces at new car dealerships are a different story. OEM interfaces commonly have additional, proprietary capabilities that exceed features found in aftermarket scan tools. The Auto Emissions Bible 63

11 Datastream Spies Everywhere! What s a PID? Data Display Samples Original OBD II Generic Datastream Generic Data Interface CAN Data Pids - Honda Fit CAN Generic PIDs The Value of Generic Datastream Data Traps Substituted Values Start With Generic Dynamic Substitution 77

12 Datastream Data Traps In general, scan tool interfaces connected through the OBD data link connector (DLC) allow us to sample two general classes of data: OBD II generic data, dedicated to emissions, and a separate, manufacturer-specific data class that we ll call enhanced data. Enhanced datastream commonly displays additional PIDs including non-emissions items. Scan Master Engine rpm TPS V Throttle Angle % Engine Coolant Temp V Engine Coolant Temp Intake Air Temp V Intake Air Temp O2 Sensor 1/1 V Vehicle Speed Sensor rpm V % V DegF V DegF V mph Core generic PIDs commonly number between 20 and 40. Manufacturerspecific PIDs displayed in the enhanced interface may number in the hundreds. While there is some overlap in the PID lists of the two data classes, there is a big difference in the way the data are represented. Let s begin with the enhanced scan data display shown above. This display is typical of what you see with the factory interface selected on your scan tool. (There are many more PIDs than will fit on the screen.) Concentrate on the Engine Coolant Temp sensor (ECT) PIDs; there are two, and we highlighted them on a black background. One displays ECT voltage, and the other, an interpretation of that voltage, indicating coolant temperature, in degrees. Since the normal operating range for the ECT is between zero and 5 volts, the 2.59 volt sensor value and the interpreted temperature of 189 F look logical. These readings are normal. They should be, because this car has no DTCs. It is good to go. Now let s see what the scan tool displays in both generic and enhanced data when there is an open in the ECT circuit. This is where we have to pay special attention to both the interface and the data, or get sidetracked. The Auto Emissions Bible 87

13 Monitors Monitors May Be Murky What Is A Monitor? Enabling Criteria Monitors Come In Two Flavors When Do Monitors Run? Scheduling OBD II Tasks Running Monitors It s Fixed Now. Right? Added Thoughts 93

14 Emission Controls Powertrain Management Closed Loop Oxygen Sensors The AF Sensor or Wide Range Sensor (WRAF) Catalytic Converter Chemistry Catalyst Killers Secondary AIR Injection Positive Crankcase Ventilation Evaporative Emissions Leak Detection Simplified Leak Detection Pumps Natural Vacuum Leak Detection Ford EONV EVAP Leak Testers Sample EVAP System Leak Test EGR DPFE Linear EGR VVT and EGR Ignition System Designs Common Misfire Causes 103

15 Emission Controls VVT and EGR In VVT, a fluid-operated control valve rotates a cam timing mechanism built into the camshaft sprocket(s). Cam timing is adjusted in degrees to regulate the amount of exhaust gas that gets trapped inside the cylinder. Retarding the exhaust cam timing holds the exhaust valves open longer, to increase valve overlap. This mixes the incoming air/fuel charge and trapped exhaust more completely during the intake stroke. Trapped exhaust is precisely metered, and injector pulse-width and ignition timing are modified to reduce NOx, without affecting engine performance. Common problems include sticking cam phasers, often due to oil sludge caused by lack of basic maintenance. Other problems include the wrong oil viscosity, low oil pressure, and electrical or hydraulic phaser solenoid failures. Even the wrong oil filter can cause the system to malfunction. exhaust cam sprocket camshaft cam rotation Cases of improper reassembly during a timing belt job have also resulted in numerous driveability symptoms. Cam Phaser hydraulic control valve Some VVT systems change intake valve timing for better performance, and a few also control valve lift. The newest engines continually control both intake and exhaust valve timing to improve engine breathing over a wide rpm range. The Auto Emissions Bible 131

16 Testing Emissions Sniff, Fix, Test Prepare the Vehicle Catalyst Efficiency Lambda Lambda and Air/Fuel Ratio Conversion Lambda Notes Mixture Testing Without Lambda Catalyst Efficiency - Oxygen Efficiency Test Catalyst Reduction Test Catalyst Efficiency Cranking Test Scan Tool Emissions Tests Pass/Fail Test Standards How Does a Vehicle Fail the Scan Tool Test? Review 135

17 Analyzing Test Results Analyzing Test Results Rich-Lean Analysis Using CO and O2 Interpreting Gases Using Lambda 151

18 Troubleshooting 10 Tips Fixing Cars Baseline the VehicleBaseline the Vehicle Emissions Checklist Standard Test Procedures Check Basic Settings Basic Electrical System Tests Identify the Fuel System - Air Flow MAF Sensor Tips and Hints Identify the Fuel System - MAP Style MAP Sensor AS Diagnostic Tool Backpressure Tests The i Vac The Importance of Oxygen Sensors Oxygen Sensor Tips Oxygen Sensors and Catalyst Efficiency Using Fuel Trim for Diagnosis Fuel Supply Tips OBD II Vehicle Reapir Sheet Common Repair Steps 157

19 Troubleshooting Tips Identify the Fuel System - MAP Style air intake throttle psi inhg Engine Vacuum MAP intake manifold The term Speed Density refers to PCM fuel calculations based primarily on engine speed and air density. These two factors are the primary variables, although throttle position and intake air and coolant temperatures are also monitored. Oxygen sensor feedback fine tunes these calculations in closed loop. These are also referred to as Manifold Absolute Pressure systems since they measure manifold pressure as (a big) part of their fuel delivery calculations. Manifold pressure normally increases as the throttle is opened. MAP systems measure manifold pressure below the throttle plate. Compare this to MAF and VAF systems that measure air mass before the throttle. 170 The Auto Emissions Bible

20 Passing the Emissions Test Post-Repair Vehicle Prep Running Monitors Drive Cycle Special Notes Using an OEM Drive Cycle Practice Exercise Monitor Exercise Common Emissions Failures Top Ten Emissions Failures - Oregon Pass the Test the First Time 197

21 Section Two Advanced Troubleshooting 12 - Mode NOx 14 - Diesel Emissions 217

22 Mode What Is Mode 6? What Does Mode 6 Look Like? Uninterpreted - Interpreted Data What s Real, What Isn t Mode 6 Operational Overview Mode 6 Translated TIDs and CIDs Interpreting a Mode 6 Minimum Test Interpreting a Mode 6 Maximum Test Not Too High, Not Too Low: Just Right Mode 6 Limitations Mode 6 - Use With Caution Crazy Data Crazier Data Mode 6 Case Study 219

23 Mode 6 Crazy Data Lets look at sample Mode 6 data from a 1997 Lincoln Continental. This vehicle has no DTCs, the MIL is commanded OFF, and the screen capture shown below tells us that all monitors are complete. This vehicle would pass an emissions test. Let s erase DTCs and see what happens to Mode 6 data. All Monitors are complete before we erase DTCs These data are bogus. This screen is a real example of why it is important to use Mode 6 frequently, if you plan to use it at all. Experience is the best teacher. Even though this vehicle would pass a scan tool emissions test, several Mode 6 data lines have been highlighted by the scan tool and labeled as undocumented. But there is nothing to fix. These parameters are not used in this vehicle. The correct response is to ignore the phantom parameters. 232 The Auto Emissions Bible

24 NOX NOx As Nemesis Preventing NOx Radiator Caps Cooling Fan Codes Cooling Systems and NOx Testing EGR Operation Common NOx Problem Areas Miscellaneous NOx Tips Where NOx Originates Older Cars General Tips Tips from the Injector Guru PCV Valves Knock Sensors If You Hit the Wall 237

25 Diesel Emissions st Century Diesels Diesels-Old Smog, New Tricks More Parts - More Systems - More DTCs Diesel Monitors - Monitored Components Diesel Fuel and Emissions Diesel Exhaust Cleaning Components Sample DTCs 261

26 Diesel Emissions 21st Century Diesels When your dad was a kid, diesels were pretty simple engines, loved for their long life, low-end torque, and great fuel economy. Most diesel problems were caused by mechanical problems or poor fuel quality. Most diesel electrical system problems could be diagnosed with a test light. No more. Diesels are 21st Century high-tech. Mechanical/hydraulic diesel injection pumps are museum pieces. The current generation of car and light truck diesels uses computer-controlled Common Rail injection. The good news: If you already understand gas engine emissions, you ll make the jump to diesels quickly. Common Rail injection is patterned after gas port injection, with one computer-controlled injector per cylinder. The big difference? Big pressures. Diesel high pressure fuel pumps ram fuel to the injectors though a common fuel rail. Maximum pressures now hover near 30,000 psi, in the latest generation of common rail systems. (Workers remove paint from bridge overpasses with less pressure than that!) The injectors are different, too. Solenoid injectors are out; piezo-electric injectors are in. Piezos demand lots of watts, with some injectors operating at volts, at amp levels that can level you if you aren t careful. This is serious business: Wear professional safety gear, use approved voltmeters, and read the manufacturer s safety warnings. Make sure you wear high voltage protective gloves, and put the old test light away before you hurt yourself. Our purpose here will be to give you an overview of modern diesel components and emission strategies. OEM-specific engine and emissions strategies each demand a (long) book to cover exact features and specifications. But they re out there, and the numbers are growing. Look for clean diesels in both light and medium duty trucks, and in passenger cars with German accents. 262 The Auto Emissions Bible

27 Information Repair Information NASTF iatn Identifix Repair Databases 275

28 Index actual position 128 air flow style fuel system 166 AIR 24, 112, 143, 176 AllData 279 backpressure 173 BARO (barometric pressure sensor) 166 baseline vehicle 159, 192 biofuel 262 bulb check 35, 147 cam phaser 131 canister (EVAP) 114, 117, , 125 catalytic converter 110, 111, , 176, , 208, 234, 235 check engine light (see MIL) CID 224, 225, 226,227, 228, 229 closed loop 105, 106 common rail 261 controller area network (CAN) 75, 81, 83, CO2 (carbon dioxide) 20, 22, 27 CO (carbon monoxide) 22, 27, 142, 143, 153, 154, 161, 238 combustion 12, 20 combustion triangle 12 commanded equivalence 84, 86 commanded position 128 comprehensive component monitor (CCM) 97 compression 14 compression stroke 17 continuous monitors 97, 98 cooling fans 241 cooling systems data protocol 73, 74 datastream 74, 78-91, 191 descriptors (DTC) 45, 47 diagnostic executive 99 diesel emissions diesel exhaust fluid 271 diesel oxidation catalyst 270 diesel particulate filter 263, 267, 269, 271 DLC (Data Link Connector) 62-76, 64, 293

29 Index 87, 146 DLC BOB 68 DPFE (differential pressure EGR) 128 drive cycle 100, 101, , 202, 203 DTC (Diagnostic Trouble Code 30, 31, 37, 40-59, 87, 88, 89, 99, 101, 102, 121, 124, 146, 160, 190, 198, 199, 203, , 264 DTC definitions 48, 49, 94, 95 dynamic substitution 90 ECT (Engine Coolant Temperature sensor) 23, 45, 46, 50, 57, 79, 87, 88, 161 EGR (Exhaust Gas Recirculation) 26, 56, 126, 127, 128, 129, 161, 176, 185, 209, 244, 245, 248, 266 electrical system tests emissions tests emissions checklist 162 enabling criteria 97, 199, 200, 203 enhanced interface 63 EONV EVAP (evaporative emissions) 26, 51, 56, 114, 115, 116, 119, 120, 121, 176, 211, 258 exhaust stroke 19 exhaust system leaks 24 EVAP test port 124, 125 false air 179 flow gauge 124 four stroke 14 freeze frame 52, 91, 190 FTP (fuel tank pressure sensor) 115, 116, 117 fuel supply fuel trim gas cap 124 GDI (gas direct injection) 187 generic interface 62, 63, 81, 82, 86, 87, 89 glow plugs 264 HC (hydrocarbons) 13, 27, 142, 143, 145, 154, 161 hybrid vehicle 55 IAC (idle air control) 115, 171 IAT (intake air temperature) 203 iatn 277 Identifix 278 ignition 14, , 162 ignition timing 160, 161, 250 inches of water 118, 119, 121 injector 16, 265 injector cleaning intake stroke 16 internal combustion 14 interpreting gas readings The Auto Emissions Bible

30 Index J keep alive memory 199, 201 knock sensor 208, 257 KOEO 35 KOER 35, 116, 164 lambda 21, 106, 108, , 143, leak detection leak detection pump 118 leak testers lean mixture 24 limp home 161, 164 linear EGR 128 LTFT (long term fuel trim) 169, MAF (mass air flow) sensor 23, , 264 manifold absolute pressure 170 MAP sensor 90, 91, 172, 264 MAP system MIL (Malfunction Indicator Light) 30, 31, 32, 33, 34, 35, 40, 41, 51, 53, 78, 81, 101, 121, 146, 147, 152 MIL command 36, MIL tampering 36 misfire 14, 18, 24, 176, 210 Mitchell OnDemand 279 Mode monitor(s) , 98, 99, 100, 146, 198, 199, 200, , 215, 268, 269 NASTF 192, 276 natural vacuum leak detection 119 networks 55 nitrogen 13 non-continuous monitors 98 NOx 25, 27, 126, 144, 154, OBD II 32, 33, 52, 53, 54, 64, 65, 78, 81, 82, 87, 89, 95, 152 oil viscosity 251 one-trip DTC 51 oxidation 110 oxygen (O2) 12, 13, 27, 142, 143, 153, 154 oxygen sensor (O2 sensor) 23, 56, 57, 105, 106, 107, 158, , 209, 212 oxidation 20 oxides of nitrogen (see NOx) P P P P0100-P P0105-P P0106-P , 272 P The Auto Emissions Bible 295

31 Index P0110-P P P , 45, 46 P , 46 P , 46, 50 P , 45, 46, 57, 88 P , 46 P0125-P , 56, 161, 272 P P0130-P P , 57, 113, 115, 142, 187 P P , 113, 115, 142, 161, 187 P , 113, 115, 142 P , 142 P P , 272 P0191-P P0234-P P03xx 142, 256 P , 42, 210 P0325-P P0350-P P0400-P P , 57, 256, 272 P P P P P , 112 P P , 144 P P , 144 P , 117 P P P , 117 P , 117 P P0450 -P P P045x 115 P046C 272 P0480-P P P0505-P P P P P07xx, P08xx, P09xx 161 P The Auto Emissions Bible

32 Index P2004-P P0324-P particulate emissions 262 PCM (Powertrain Control Module) 30, 31, 37, 41, 45, 53, 54, 78, 90, 98, 120, 121, 162, 199 PCV (Positive Crankcase Ventilation)113, 162, 168, 256 pending DTC 51 permanent code (permanent DTC) 32, 37, 51 PID (Parameter IDentification) 79, 83, 86, 87 piezo 265 pilot injection 265 plug-in value 88 power stroke 18 purge valve 114, 115, 116, 117, 118, 120 radiator cap 240 readiness status 147 reduction 110, 144 repair database 193, 201 repair grade analyzers 136, 137 repair sheet reprogramming 194 SAE 44 scan tool 63, 64, 69, 70, 71, 74, 80, 87, 88, 89, 160, 220, 221 scan tool emissions test 34, 35, 36, 95, 146, 152 Schrader valve 124 secondary air injection (see AIR) selective catalyst reduction 271 sensors 31 STFT (short term fuel trim) 184, 185 spark 14 spark-ignition 14, 17 spark plug heat range 247 speed density (see MAP system) stoichiometry 21, 105, 106 tailpipe cooler 271 targeted gases 20 task manager 99 temperature sensors 267, 271 throttle valve 267 TID (Test ID) 224, 225, 226,227, 228, 229 two trip DTC 51 trip 98, 100 TSB (technical service bulletin) 194 trouble trees 58 U-codes 55 ULSD (ultra low sulfur diesel) 269 The Auto Emissions Bible 297

33 Index vacuum (engine) 161 vacuum gauge VAF (vane air flow sensor) 166 VECI (Vehicle Emissions Certification Information 160 vent valve (canister vent) 115, 116, 117, , 121 VIN (Vehicle Identification Number) 34, 36 VIR 158, 159 VSV (vacuum switching valve) 128 VVT (variable valve timing) wide range air fuel sensor 108, The Auto Emissions Bible

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