February 2011 1 www.mastertechmag.com
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1. DEtEPREmT ae UPPER LETT STL ara T la PLAN Dia Epes uis w THAFU EW iur FR HE FRINAG BaP m PAMLELABEE nr dealt y LI T FACT Wei FREE T pu d DE TE Phi 81 inal kar LEFT Row ew ne F Fr CS Sr face paces ss Ga me E sati Un aan qm T Bakan E r ann ad m L deed FACT Pri t hats uwa foam pt WI ARAS CH MAREE LEFI WIR iad TS DE D Ts oe PAN CLAI bab CL ag gt k rnm atif E ma me lt usu mmm s 2 He OLASS T CONTROL MODULE s pam CLAMARE BARE pone s L E F rape OCA F HK Figure 3 Data communication wiring diagram showing all the onboard controllers on the serial data network linked to the ALDL connector 10 Master Technician Online WWW mastertechmag COM the scan tool I pulled some U codes of interest Figure 4 The c2. MultiTaal EScope Dual Scope stacked Scope Measure amp Deep Rec Meter Timing Function Gen Patent Persino Pot A Data Start Deep Record ave Deep hec Mark 4 Data Reo Time 2 E Load Deep No Hold Next Pointer Tad Zoom Window Hold Mext Fa Zoom In Foor Cul Znam Reset Hold A amp B F5 Save Custom Setup Fe Load Setup Waveform 7 Save Data 8 BENE Smooth or FFT Save Data B Load Data F10 Save Screen F11 Print Screen F12 I i I I j0124m im 240m 2 300m xim 3m Node that Testis actually freq if EE T Tir EScope www AutormatveTestBolutipns com Figure 8 Secondary KV spikes present a spark plug for performance purposes without any regard to its effects in a coil over plug environment The problem it created mimicked a failed PCM that any tech would have automatically changed in the field There were no codes no sensor failures or wiring issues A multi trace scope would have to be used to find a cascading effect of events that would point you in the right direction I own many one two and four trace scopes but with so many circuits involved with onboard control modules today it sometimes makes more sense to use a bigger net to throw at a problem rather than fishing around with only a few h
3. Resistant Areiniiclalsers 121021112 515 Ceniecnaas We MCiaaciaeciiace e EPDM Rubber For Extended Life r F n F r IN DAY CUE www dayco com www daycoW com www accessdayco com A Sprinter at the Start Dodge has a test for the high pressure pump assuming there are no leaks in the system You start by unplugging the solenoid and checking fuel pressure while cranking The engine will not start but you should see about 800psi on your scan tool or 8 volts on the high pressure sensor signal wire Your display rate may be too slow to give you an accurate reading so you might want to use a graphing multi meter or a lab oscilloscope to watch the voltage You should see a steady signal above 9V You may see it spike over 1 0V but then drop down The drop indicates that the pump cannot maintain pressure or has a weak piston This pressure drop will keep the engine from starting and you ll have to replace the high pressure pump We ve noticed that they may start to become questionable at between 90 000 and 100 000 miles Of course the glow plug system can cause a starting issue On 2004 models the glow plug controller is under the battery tray It has three connections a battery power cable six pin connector with five wires one for each glow plug and a two wire con
4. 1 04 T 1 b EScope www AutamaleTestBolutinns com Figure 7 Checking for loss of crank signal COLOR META METALLIC U No matter what kind of car you ve got your paint shop a perfect color match is always the goal And that s where BASF Refinish breaks from the field Only BASF offers the COLOR MAX 3 system which covers every color category in the Spectrum and only uses chips sprayed with authentic BASF Refinish paint not printed with ink So you are assured a precise match the first time every time reducing comebacks and increasing productivity And remember BASF Refinish coatings are already approved for use by most major OEMs in North America For the kind of color matches that also match your customers expectations call The Chemical Company your local BASF distributor at 1 800 825 3000 or visit www basfrefinish com sa n i Foose Chip Foose Foose Design and the Chip Foose signature are pe registered trademarks of Foose Design Inc and used with permission ri 2009 BASF Corporation Cascading Diagnostics I went back to my primary pattern and this time lifted it off the zero line to expose any activity below Figure 9 and I was surprised to see multiple cylinders getting hit with secondary kickback voltage Cars using PCMs that directly control coil primary may have a little secondary kick that may n
5. have attended the VISION event many times The from the windy city to the sunshine state Dollar for dollar training is the best of the best Everyone in the auto ASA MoKan puts on the best training show the country motive business should be there I Gary Walsh Technician Terry Steenholdt AAM Th fo Hughes Motor Corp Yonkers NY 7 D S Auto Repair Sioux Falls SD Automotive Service professionals 8 hen you first noticed one on the road you probably thought What an unusual looking vehicle And the first service problem you ran into was likely when your customer needed brakes What you want me to bring them down so you can match them up Who ever heard of such a thing was a common customer response to your likely request Eventually parts suppliers learned the difference between Ate and Bosch so that problem smoothed out When it comes to diesel diagnosis and repair issues however things are not so easy Given this winters cold weather you ve probably run into more than your fair share of no starts hard starts and extended cranks You probably have some experience with American by Kerry Jonsson ri The PLM wont open the injectors unless it sees a signal from the crankshaft position sensor which is mounted in the block on the drivers side by the bell housing You can check resistance AL voltage
6. Einen nol Bead Bos A SED 55 Ponder Tool Hold B F3 j Pan Hand Hold Next B F4 i i Zoom Window Znam in Zoom Cul boom Hasal Hohi A a 8 20 Save Setup F6 Recall Setup F7 Save Data FS save Data B 29 Load Data F10 Save Screen F11 Print Screen F12 Tips a Ee g B 002 J 52 EStapi Ww corn Figure 5 Above ELM releasing ASU relay coil Figure b Below Checking for loss of cam signal Controls Setup Muitoa 2 _ Dual Scope Stacked Scope Measure amp Deep Rec Meter Timing Function Gen 2012 Plot A Data star Deep Record Flol B Data Rec Tuna a DEB Load Deep Hold Next A F2 DMMZARERSANSEHERHENHMNSDXSI A unns Pointer Toa Hold F3 Pan Hand Hold Next B Fa i Zoom In Oui zoom Reset Hold 8 B F5 Curgor Meggurrgnig Save Custom Setup Fo Load Setii Waveform 27 Save Data save Data B 29 Load Data F10 save Screen F11 Print Screen F12 2088 5 rh io 3 08 iar bebe that Ti is artuq iby Frag Hz if FFT EStape www Auhomoive com Cascading Diagnostics stick around and give mea joy ride When I captured another event Figure 8 I was surprised to see that I was losing all eight coil drivers at the same time The PCM was letting
7. Freeze Frame Storage a0 Nore Read Freeze Frame Data 1J8HR582X70524915 weeAutomotveTestSolulions com com OTC Codes Present Select Pending Codes Present Figure 2 shows no codes in memory www mastertechmag com February 201 31 Cascading Diagnostics had to find the problem or this PCM was going to be this evening s meal I knew my timeframe was short for finding the culprit because I had no idea how long the problem was going to stick around I quickly placed my Escan tool on the vehicle and graphed some PCM parameters to see if anything looked unusual or out of range Figure 3 I was monitoring the rpm MAP and TPS sensors and could see the engine rpm going into an idle roll But then something unusual happened I lost communication with the PCM as the problem got worse Figure 4 then the Controls MultiTool Info 7 Clear Data F1 Save Text Report F2 Load Text Report F3 Print Text Report F4 Save Graphed Data F8 Save Selected PIDs Continuously F8 Mark Continuous Data Page Load Data F10 1 00 L 0 Save Screen F11 Print Screen 212 D 00 l 08 www Ahomas TestROluiams caorn Figure 3 Graphing data parameters Stacked Dual Combo Measure 1 I 1 1 I 28 88 15 1 3 14 SEE i aca c 3 Ll La _
8. ee engine cut out This had to be a loss of power or ground to the PCM or possibly a reference voltage feed momentarily shorting to ground because the PCM was shutting down operations at the same time as it decided to no longer communicate with my scan tool The only way I was going to nail this problem would be with a multi trace scope to watch as many signals as I could before this problem decided to go away I used my eight trace Escope and quickly selected six main items that would help me pinpoint the problem using my different colored leads as EScan DTCs Monitors PIDs Digital Graphs Mode6 02 Sharp SHOOTER wwwATsnmcom Cleat Data Number ofFoints dleptayed on Graph 1 B a FET Ho Au 58 56 20 00 24 ore 00 59 NU LOK PISTON CUSHION NEW TECHNOLOGY FROM THE INDUSTRY LEADER IT S QUICK QUIET AND COOL NUCAP SNAPS IN PLACE AND HOLDS TIGHT REDUCE NOISE REDUCE HEAT REDUCE COMEBACKS NOISE PREVENTION The hi temp rubber coated No brake job is truly complete without the NU LOK Piston Cushion NUCAP the Brake Technology Company has developed this revolutionary new product to create a barrier between the piston surface and brake pad The NU LOK Piston Cushion is a snap to use It improves noise control while extending caliper life Keep quiet keep cool with the NU LOK Piston Cushion improve performa
9. SSEI of no power window operation on a 2003 Pontiac Bonneville SSEI Figure 1 They had already checked the power and ground feeds at the driver door master switch and everything seemed okay The odd thing was that the other door windows would not operate from their individual switches It was just hard to believe that this vehicle could have four bad window switches The window motors all worked okay when power and ground were applied to each motor individually The garage was uncertain where to turn so rather than throwing parts at this car they decided to call me in for a second opinion was called in to ashop for a complaint by John Anello The Auto Tech on Wheels Figure 1 2003 Pontiac Bonneville SSEI When I arrived at the shop I verified the complaint by trying each power window switch and nothing responded I next decided to print out a wiring diagram to familiarize myself with the system layout and see if I could find something in common that would affect power window operation at all four doors such as a main power or ground feed As I viewed the diagram I found out that these were not your everyday how you doin window switches Instead they were all separate door control modules Each module in turn controlled window motor operation through an internal window motor driver Operating the window switch only created a high low signal to command the window up or down The switch no longer h
10. a k a Airbag Control Module and an OCM Occupancy Classification Module a k a Occupant Sensor In earlier years the ORC controlled both driver s and passengers side airbags solely on the basis of the seat belt buckle switch status In 2005 the OCM got input from additional sensors that monitor the passenger s side front seat Since we had a warning light our first step was to pull codes We looked in the ORC and found two codes Driver s Seat Belt Tensioner Circuit Open and OCM Active DTCs On this particular model the seat belt tensioner is on the buckle side of the belt assembly not on the adjustable belt side We then checked for codes in the OCM Occupant Classification Undetermined Status No ORC Messages and OCM Data Transfer Error came up The ORC code for the driver s side seat belt tensioner circuit was a straightforward diagnosis Chrysler has a one ohm resistor tool that you substitute for the tensioner or airbag circuit You then clear the codes and see if they come back If they do you have a wiring or control unit problem If they don t replace the seat belt tensioner Of course before doing any diagnostic or repair work you must disconnect the battery for at least two minutes to be safe You can then unplug the airbags and tensioners and replace them with the one ohm load simulator to test for codes If you don t have this special tool you can also check resistance on individual wires between
11. and scope the signal to verify that its working properly diesels such as Ford Powerstroke Chevy DuraMax and Dodge Cummins and may feel pretty comfortable with them While the same basic principles apply you can reduce your diagnostic time if you know the particulars of the systems found on the Dodge Sprinter Scan tool diagnostics used to be readily available to us but now not so much When dealing with no starts hard starts and extended cranks on pre 2004 Sprinters you often have to go on a road call and or tow them in Or some incautious person may have tried the dangerous practice of spraying starting fluid or carburetor cleaner into the intake to get the engine started You ve probably heard the appropriate cautions Leave the key on to time out the glow plugs and spray while cranking You may do this every day but it s our duty to inform you that it s foolhardy Suppose for example that somebody else accidentally cycles the key kaboom While we wont go on record as recommending it silicone spray is a much safer alternative Actually nobody should have to add an explosive fuel source to get the engine started regardless of the weather What engineer would allow a non starter to be produced You just have to figure out what the problem is Glow plugs Fuel delivery Injection These 2 7L vehicles direct injection common rail diesel www mastertechn corri fuel system developed
12. for all the wires to share I removed all of the wires and repaired the splice Suddenly all the windows were working fine So now the recap on this whole scenario I discovered that the door modules were on a private network with Figure 5 Lifting the rug noticing lot of rust build up on the floor from a prior water leak each other and even though they had their own power and ground feeds and switch signals they all refused to operate when they were unable to communicate with one another It was a default built into the system What was amazing to me was why any manufacturer would use a Scotch Lock to connect these wires inside a harness running along a floorboard Wouldn t it have been better to use a solder joint located in a higher area not so susceptible to water damage But then again who am I to second guess the engineers There s always the Figure 6 ccs a eae EIE possibility that this was a field repair held the splice internally wrapped done by another shop with black electrical tape _ hope this story has enlightened you to better understand how a network whether large or small needs to be in proper order or things may not work the way they were intended to Just doing a simple power or ground check Figure 7 Removing the tape a Scotch Lock connector joined all four at a component does not always validate UART lines going to the door modules system integrity Parts replacers bewa
13. ran it again for quite a while and could not reproduce the problem It was as if the crank or cam sensor was giving an erratic signal or the PCM had an internal board issue I could no longer reproduce the problem so I offered the garage a free opinion Try a new crank sensor due to their high failure rate It would be a cheap fix if it worked The shop called back the next day and told me that the crank sensor did not fix the problem and that they had rechecked all the PCM power and ground feeds The shop was willing to try a new PCM since the problem was so intermittent and everything seemed to lead to an erratic computer I agreed to program the new PCM for them in hopes that the problem would go away I could not think of anything else that could cause such an erratic problem I went there the next day after the new PCM was delivered to program it with new software and configure it to match the vehicle I started the Jeep and it ran fine for the first 15 minutes but then it went back into its dance At this point I got that feeling we all get when we realize that there is an expensive unneeded part installed that someone has to take the blame for At this point the shop I were both now married to the vehicle and we Controls MuliiTool info EScan DTCs Monitors PIDs Digital Graphs Modes 02 Sharp SHOOTER 151 B2S1 Reading idi Read DTC amp DTC that Caused _
14. the ORC and in our case the driver s side seat belt lt N The module is located under the front passenger seat cushion It gets voltage from the Front Control Module and relies on both a weight sensor and a seat belt tension sensor to determine how the passengers side airbags Should be fired This Seat is Occupied tensioner squib Keep in mind that there are shorting bars in the ORC computer connector When it s unplugged the two wires for each squib are shorted together to prevent accidental firing measure resistance between these wiring pairs you should see continuity which is normal This vehicle ended up needing the driver s side seat belt buckle but we had other fish to fry If you The three codes found in the OCM still turned on the light These codes all dealt with the passenger s side airbag system the heart of which is the OCM module This module doesn t fire the airbags or control the airbag warning light What it does is monitor if someone is sitting in the passenger side seat and reports this information back to the ORC which is in charge of deployment These modules communicate through a single wire PCI bus We wanted to verify that this wire was not shorted to power or ground or open We checked resistance from pin 15 of the ORC and pin 8 of the OCM and measured just under of an ohm By putting a lab scope on the communication wire we could see if there was
15. weak battery will yield a lower cranking speed and AC voltage output so check the battery first The engine will start without the cam position sensor signal but you ll have a MIL Malfunction Indicator Lamp and a code will set If you have extended crank time you still need to be concerned with fuel pressure and the glow plug system There are two halves to fuel pressure the low pressure delivery system that draws fuel from the tank and supplies it to the next phase and the high pressure pump that is driven off of the camshaft The high pressure goes to the fuel rail and distribution pipes that supply each injector Excess fuel is collected in a 1b Master Technician Online The high pressure sensor is mounted on the front of the fuel rail Measure the signal voltage on the center pin you should see 5V During cranking it Should go to about 1 UV before the engine starts manifold at the rear of the cylinder head and returned through the fuel filter and finally a cooling coil The low pressure system comprises a mechanically driven pump that draws fuel from the tank through a filter That is unless there s a blockage somewhere A clogged fuel filter from additives and contaminants is a common problem Additives intended to improve lubricity www mastertechn lad corri 20 tip Sprinter injectors are of the direct Variety You can
16. Volume 5 issue February 2011 Solutions for Professional Automotive Repair Technicians A mastertechmag com inline Publication 0 0 0 92 S OY X THERE HAS NEVER BEENA BUY THE WORLD S BEST E Availability Access to 80 000 Original BMW replacement parts and 200 million of inventory is available to your BMW center no other supplier can make that claim Commitment Six Parts Distribution Centers provide daily service to all BMW centers Obtaining non stocked items is no longer a headache Expertise BMW Parts Professionals know BMW vehicles better than anyone else They will ask you the right questions to get you the right parts the first time Warranty BMW replacement parts carry a 2 year limited warranty Your customers will travel with confidence knowing that Original BMW parts were tested by BMW for BMWs For Original BMW Parts Please contact your authorized BMW center Or log on to www bmwusa com standard content dealer default aspx Details available at your authorized BMW center BETTER WAY TO C NGINEERED PARTS m Original BMW Parts The Ultimate www bmwusa com Driving Machine _ DOG Switching It Up k by John No power window switches on a 2003 Pontiac Bonneville SSEI A Sprinter at the Start by Kerry Jonsson While a tall fuel efficient delivery truck answers
17. ad to transmit a power or ground feed to the window motor directly which made for less wear and tear on the switch contacts I used my Paintbrush function in Mitchell to diagram I chose green for the grounds purple for the high current circuit breaker feed orange and red for low current battery feed Figure 2 The color code the wiring ground feeds for each door module were at different locations so it was hard to believe that the system had four open grounds The rear door modules shared the same low current battery feeds but the front door modules had two other separate low current battery feeds so here too nothing seemed common to all four door modules Looking a little closer at the diagram I could see that all four modules did share the same high current feed from a 30 Amp circuit breaker so this was the first place I wanted to look I used my test light and checked each door module for high current battery feed and they all seemed to be okay The tech said that all the wiring checked okay and it did but I still had to see for myself because you just never know There have been many times when techs have used a logic probe to do a power and ground check without finding anything yet a bad ground or power feed turned out to be the culprit They relied on the logic probe s ability to light a green or red LED as a valid check which only required about 20 mA to light up but when the ground or power had to step u
18. an Magazine 486 Pinecrest Rd Springfield 19064 FE A 484 472 844 484 472 7460 Master Technician is published by Master Technician LLC The publisher and editors of this magazine accept no responsibility for statements made herein by advertisers or for the opinions expressed by authors of bylined articles or contributed text The current Issue of the Master Technician Emag is free to qualified automotive repair shop owners managers amp technicians Contact ayersc3 mastertechmag com for more information All other content is available on a subscription basis Visit www mastertechmag com for subscription information If you have a letter to the editor a Tech Tip or a story idea Contact Us for Email bfreud mastertechmag com or Personal Bootcamp Training and Visit www mastertechmag com other contact_us Seminar Presentations Follow our Real World Tech Tips and Story of the Month f Find John at the 2011 VISION AIRSEPT 25 Henry Rifles 9 Training Expo AutoTechOnWheels 5 40 BMW 2 Mercedes Benz 21 37 33 19 VISION 11 Garage Operator 29 Hi Tech Training amp Expo Switching It Up No power window switches on a 2003 Pontiac Bonneville
19. ance down And while small businesses are not required to offer insurance for un their employees the keeping your current pif T P y technician workforce gr pM Act provides strong productive and happy It all begins with the 3R s Recruitment Retention and Recognition incentives for them to do so Until the Small Business Health Options Programs or SHOP insurance The who what where NM o when and hows you need to know
20. by Mercedes Benz Instead of the traditional pump timing high pressure pulses to the injectors this works more like gasoline EFI albeit at much much higher psi The common rail is continuously supplied with ultra high pressure and the injectors are electrically triggered by means of electronic logic So there s a computer in control of timing and pulse width Obviously that control unit needs to know when to fire the injectors partially on the basis of signals from crankshaft and camshaft position sensors This is the low pressure fuel sensor 5 mounted under the 1 and 2 intake runner Since it s a typical three wire sensor you can monitor the signal line Key on engine off you should see 5V cranking running it should be just over one volt A Sprinter at the Start The fuel injection control unit is mounted under the driver s side of the dash to the left of the brake pedal The crank sensor resides on the driver s side of the engine block toward the back by the transmission bell housing The engine will not start at all without the crank sensor signal This sensor is an AC pulse generator Like most AC pickups it uses a two wire design A good sensor will ohm out at about 900 ohms between pins 1 and 2 on the sensor If you crank the engine at normal speed you should see about one volt AC If youre scoping the signal expect over 4 VAC peak to peak A normal cranking rpm would be about 200 to 220 A
21. communication or if there was interference from other voltage By watching the oscilloscope pattern of the PLI bus we could easily determine that there was communication among control units he bus links many modules so it was possible that some other unit was interfering with communications That should have flagged some other communication code however ea Master Technician Online www mastertechn 9 NEW 159 AIRSEPT INCREASE YOUR REPAIR REVENUE amp CUSTOMER SATISFACTION PROBLEM SOLUTIO il LINE SPLICE NEW METRIC SIZES COMPRESSOR GUARD FIX LEAKS IN 5 MINUTES STOP COMPRESSOR COMEBACKS KITS AVAILABLE FOR Honda CRV TRS090 amp HS110 10S20F Crown Victoria 10PA 17 import M R4 amp H Series Ford FS 10 amp FX 15 Chrysler A590 amp C171 D440A R134A LEAK DETECTOR FIND SMALL REFRIGERANT LEAKS FAST J2791 CERTIFIED FASTER RECYCLE GUARD PROTECT A C SERVICE MACHINES FROM SEALANT amp DEBRIS CALL 1 800 999 1051 OR 678 987 0500 TO ORDER gt gt WWW AIRSEPT COM This Seat is Occupied or ground sources We did see a 7 1 to 7 5V square wave with the ignition key on This meant the wires were not shorted and the control units could communicate with each other If there was acommunication problem between these two units it could be because one of the units was malfunctioning or some other control unit was putting out erroneous data and confusing the oth
22. e voltage rise to about 1 0V as the engine starts If you do not reach about 875 psi the engine may not start That s about 875V at the signal wire If you don t see at least that much look for external leaks in the high pressure lines There may also be internal leaks For example a leaky injector may keep the pressure from building up sufficiently There s also a solenoid at the back of the high pressure fuel rail that controls psi according to load It s called logically enough the Fuel Rail Pressure Control Solenoid which the fuel injection control unit can close or open to raise or lower fuel pressure according to need It has an O ring at its end If that should break it will create an internal leak that will not allow enough pressure to build to allow starting You may have to physically remove the solenoid to make sure this is intact If you suspect that an injector is leaking you can unscrew each injector line one at a time and install a ball bearing to block flow When you get to the leaking injector high side fuel pressure will rise and the engine should start the other four cylinders If you can t find any internal or external leaks you may just have a high pressure pump that is not up to its task WWW rnastertechrr aj COM 4 NEXT GENERATION OF BELTS Visit www daycoW com To Receive Your FREE Dayco AWEAR ness Belt Gauge g Features 5 1 _
23. ead for the cam signal Figure 6 and my yellow lead for the crank signal Figure 7 Neither waveform pattern showed loss of cam or crank signal when the ASD relay was being released but the tachometer was definitely following the cutting in and out of the engine I had an eight trace scope so it was to my advantage to monitor all eight ignition coil primary circuits to see if any coil trigger was dropping out I moved all my leads to the coil drivers and continued to monitor the engine s operation Today was my lucky day because this problem was only getting worse and it decided to Digital Graphs Modes 02 Sharp SHOOTER weiteren Communications Detected Comm Type CaN Loop Read Speed ms 1354 Speed Per PID 902 BARO at Shop Location kPa 101 33 wwe Automotive TestSolutions com Dema Kove PONE 4 Loss oF Scanner communication 34 Master Technician Online www mastertechn aj COM Controls Setup MulliTool EScope Duel Scope Stacked Scope Measure amp Deep Rec Meter Timing Function Gen T I ted Pane Z ce Se j data from Ao B Ere base scope Hold A Pilot Pata start Deep Record save Deep Rec Deap Record ures A ramping speed bul records Pilot Data xd Desp for 250k teenies and to Eis graph oniy Et D Udo nra end ono LAGER veg Deep Record fist
24. ers We decided to check codes in the other control units on the PCI bus but didn t find any that dealt with a loss of communication So we concluded that the communication problem was isolated between the ORC and the OCM units We suspected the OCM module because the first code Occupant Classification Undetermined Status suggested that it may not be functioning properly The second code No ORC Messages meant that the OCM could not communicate with the ORC even though we could see the communication on the PCI bus The final nail in the OCM coffin was the last code OCM Data Transfer Error We knew the communication wire was okay so the OCM itself must have been causing the problem We wanted to be sure that there were no other outside influences causing the OCM to not work properly You should always check powers and grounds before replacing any control L ooking at this weight sensor signal we see about 4V volts with the ignition key on The voltage dropped to about IV with 165lbs in the seat You can watch this signal voltage with a UMM as well 26 Master Technician Online www mastertechn iac corri unit but with newer CAN systems that can be tricky This OCM is directly grounded through pin 5 The power supply is another matter theres no conventional fuse supplying ignition on power to the unit A Front Control Module incorporated into the Integrated Power Module supplies almost 11V to pin 9 o
25. f the OCM when the ignition key is turned on Without this power up signal the OCM may not communicate with the other control units on the PCI bus In our case both the power up signal and ground passed our tests To further see if outside influences were causing the OCM to fail we decided to check the two other sensors that provide inputs to the OCM The first is a weight sensor in the bottom of the passenger seat It is a bladder type sensor with three wires for reference voltage signal and ground The reference is 5V and comes from pin 7 The signal comes in on pin 6 and changes with the weight applied to the seat With no weight you should see about 4V and with a 185 Ib man in the seat the signal drops to just about 1V In other words the greater the weight the lower the signal voltage If you have codes for this sensor refer to TSB 08 Phone The seat belt tension sensor is mounted in the lower mount of the belt so moving the reel will not change the signal voltage You can Check the voltage and pull up on the belt You should see the signal voltage Change from about IV to 4 3V while pulling www mastertechn corri February 2011 27 This Seat is Occupied 001 04 on passenger side airbag safety issues and aftermarket parts such as an add on cushion that can interfere with proper sensor operation The second is the Belt Tension Sensor This compone
26. g com m uan Cascading Diagnosis by John Anello The Auto Tech on Wheels The Jeep s erratic running pointed to the PCM but what other work had been done recently was called in to a shop for a complaint of erratic engine operation on a 2007 Jeep Grand Cherokee with a 5 7L engine Figure 1 The engine would run fine with no problems for a while but at any given moment it would begin to abruptly surge up and down and cut out The engine could be immediately restarted and would run perfectly again until the next episode The shop had installed high performance spark plugs and ignition coils a few weeks earlier but there were no drivability complaints at the time The shop even put the old ignition coils back into the engine but the problem still remained There were no codes stored in the PCM memory and the shop did not want to start playing Russian roulette with auto parts so they called me in for tech assistance When I arrived I attached my Escan generic OBD II scan tool to the vehicle to check for codes none were recorded in memory Figure 2 I started the vehicle and it seemed to run okay but then it suddenly started to run erratically with a bouncing tachometer The engine seemed to dip in and out with a near stall condition After a few seconds of this the engine just cut out as if the ignition key had been turned off I immediately restarted the engine and the problem was gone
27. go of the ASD relay coil and it did not start to trigger the ignition coils again until about 300ms later There was something making this PCM halt all operations momentarily or I possibly had a bad new PCM on hand It would not be the first time I have come across a defective new part I decided to call Bernie Thompson from Automotive Test Solutions just get his opinion on things because everything Controle Setup MultiTao all g Flot A Data Hold Save Custom Setup F5 Load Setup VWaveform EScope Dual Scope Stacked Scope Measure amp Deep Rec Meter Timing Function Gen Any Patent Per Start Deep Record I have done so far has lead me to erratic PCM operation and I just could not pinpoint the cause I could see what the PCM was doing but what was its reasoning Bernie basically wanted me to go back to my scope and look below the zero line for any secondary voltage kickback that could cause a PCM reset condition That s when outside noises penetrate the PCM through electromagnetic and disrupt its normal algorithms making it momentarily skip a beat The engine in interference no way or fashion had an engine misfire due to a bad ignition coil or spark plug but it still seemed like a logical possibility Patent Mending Cam 13 4 Get Cursors Puer tool Cursor Hand Zoom In Zoom Qui Rese
28. l elderly people sometimes can t survive the full force of a deploying airbag For years the only defense was to relegate such passengers to the back seat Now airbag technology has advanced to the point that ee Master Technician Online This Seat Is Occupied Kerry Jonsson In the quest for ever increasing safety seat occupancy detection systems help by giving the electronics the info needed to determine how to fire the airbags That system is malfunctioning in this 2005 Chrysler Town amp Country It s our job to diagnose and repair what s wrong occupant detection systems measure the rapidly advancing weight of the passenger and determine if and how the airbags should be fired The primary code led us to diagnose a bad seat belt tensioner but the second directed us to a relatively new item added 2005 the Occupancy Classification Module VVVVW mastertechmag But what if something goes wrong In the past we ve had to diagnose bad airbag squibs crash sensors and clock springs but a problem in the detection system was new to us A 2005 Chrysler Town amp Country came in with the airbag light on While pulling codes we realized that there are two different systems we can communicate with On this Town amp Country Chrysler used an ORC Occupant Restraint Controller
29. many commercial needs it also presents some new challenges for us in diesel diagnostics and repair Cascading Diagnostics by John Anello The Jeep s erratic running pointed to the PCM but what other work had been done recently Cover Story __ _ ee This Seat is Occupied by Kerry Jonsson In the quest for ever increasing safety seat occupancy detection systems help by giving the electronics the info needed to determine Lontent MI Hi NS QL ES COAG HE XE ZIEHT AZ TE E WEEE NN AW UN NS T3 pe Wir w EUR Christopher M Ayers Jr SS President Publisher cayers mastertechmag com Jos Bob Freudenberger Editor bfreud mastertechmag com A u O D C John Anello Steve Campbell Paul Cortes zS Kerry Jonsson Phil Fournier Chip Keen E Greg McGoniga Tony Molla Tom Nash 6 ee AS Henry Olsen Matt Ragsdale Dave Russ Contributing Editors bfreud mastertechmag com Chri VIEW OUR NEW SITE ristopher Michael Ayers Art Director Project Mgr ayersc3 mastertechmag com WWW AUTOTEGHONWHEELS COM Joann Turner Circulation Manager jturner mastertechmag com Editorial Circulation Advertising Sales and Business Office i Master Technici
30. nce in everyday braking conditions and during extreme braking maneuvers FOR A QUICK AND COST EFFECTIVE SOLUTION TO NOISY BRAKES ORDER NOW AT WWW PISTONCUSHION COM NU LOK Piston Cushion based on floating design principles is designed to absorb movement and minimize piston wear It integrates with the existing brake pad shim to further reduce noise on any braking system HEAT DISSIPATION The NU LOK Piston Cushion also acts as a heat shield between the pad rotor and the caliper This reduces brake fluid temperature for better pedal feel more controlled stops and longer fluid life The cushion also prevents caliper boots from overheating and possibly melting Cascading Diagnostics follows white for PCM battery feed blue for PCM ignition feed red for PCM Auto Shutdown Down relay feed purple for ASD relay coil driver yellow for 5V reference and green for PCM ground As the engine started to run erratically I captured my first event Figure 5 I could see that the ASD relay driver momentarily was released by the PCM under 50ms but I never lost my 5V reference or my powers and grounds It was as if something was telling the PCM to let go of the ASD relay coil so I now had to dig a little deeper I wanted to see if I was losing a cam or crank signal so I captured two more events using my Controls MultiTool Info 7 DTCs Monitors PIDs green l
31. nd to none and we ll IR P jv do whatever it takes to guarantee your complete t4 x Henry Acu Bolt 22 LR 22 Mag 17 HMR satisfaction We invite you to become part of the Henry family Please order our free catalog which includes information about our rifles a list of dealers in your area and a free Henry decal For a FREE color catalog visit www henryrepeating com or call Toll Free 866 200 2354 Made in America and Priced Right Henry U S Survival 22 LR LT saper umap um samcuwRI 42 L Ia Da eT EF atya iisas LADEN Era Ba gt gt gt gt I a em CLARI Z gt EE G Pee Bs F en LB i ee The i A HAREE HARCER Lt FP mamcumag i a m ET j 5 eee Patek eus Cc E Bi m mum m i TERT ope o M mi Pelo K BARC LAE j aus h PFL a a E Cy eet p Xm ERE ACE REODUSE CUT TA ef eimi T FPE wo ETAF az eel Fm HN Damar 2 2 er THEFT eT pipi i o _
32. nector one wire is ground and the other is the signal from the fuel injection control unit for how long to energize the plugs If you want to measure the resistance of the glow plugs simply unplug the six pin 20 Master Technician Online connector and check ohms between each pin on the connector and an engine or battery ground You should see about 1 ohm These are pencil type glow plugs which heat up very quickly The draw for each is about 20 amps If you measure the current on all of them you will normally see 75 to 100 amps depending on how cold the temperature is The signal from the fuel injection control unit to the glow plug controller starts off at 10 to 11 volts with the key on and the engine off wait to start light will come on in the instrument cluster The CTS Coolant Temperature Sensor signal is used to determine how long the glow plugs are energized The signal will then change to an inconsistent square wave This is normal as the glow plugs are still pulsed on the first few seconds the engine is running to help with combustion on a cold engine You can unplug the CTS to get maximum glow plug time from the controller be aware that the electric cooling fan will come on as a fail safe when you do this Starting problems can be tricky but the more you know about the systems involved the more efficient you ll be at troubleshooting Sprinters are typically fleet vehicles so any downtime i
33. nt also uses a three wire design The 5V reference comes from pin 16 of the OCM and isnt shared with that of the weight sensor The ground is also separate and comes through pin 14 The belt tension signal comes in on pin 4 With no tension on the belt you should see just under 1V on the signal line Pulling the belt out of the B pillar mount will not cause the signal to change The sensor reads the tension on the mount side at the base of the B pillar Grab the belt near the base and pull up You should see the signal rise to about 4 3V Since the sensors were functioning properly our repair was going to be the installation of a new OCM Its mounted on the underside of the passenger seat cushion and is fairly easy to get to Even though its a control unit it doesnt need to be programmed or coded when installed However it is not just plug and play either You will have to calibrate the weight sensor after installing a new OCM With your DRB III Star Scan or equivalent you can calibrate the weight sensor but you are going to have to throw some weight around It is a three stage process You start with an empty seat You then put 37 5 lbs on the seat In the next step you add an additional 10 6 Ibs and finally 52 5 Ibs With a total of five codes in this Chrysler airbag system we needed to make the customer aware of the hours of diagnostic time that would be needed to be accurate and precise with our conclusi
34. odes 171161 U1162 and 171163 all pertained to the drivers door modules inability to talk to the other three door modules There was no access for my scan tool to talk to the other three modules because it was only able to access the mainstream controllers all on one network as seen in the communication link diagram The door modules had their own private UART network that was shared among them as can be seen by the blue colored coded lines in the Power Window Circuit diagram Figure2 This seemed like a 0 of LEDM Loss of u1163 31583 _ B 1 Left Hirror H sor Circuit Highs Figure 4 U codes www mastertechi corri possible culprit if there was damage to this private network According to the diagram there was a splice for this private UART network located under the rug about 14cm from the left power seat breakout I had the shop remove the front drivers seat and as I lifted the rug I noticed a lot of rust build up on the floor from a prior water leak Figure 5 I next located a conduit that held the splice internally wrapped with black electrical tape Figure 6 I slowly removed the tape and was surprised to see a Scotch Lock llata F 7129 IL February 2011 11 Switching It Up connector joining all four UART lines going to the door modules Figure 7 This connector was badly corroded and was barely making a connection
35. ons We must be bold enough to ask for an honest amount of diagnostic time so we don t paint ourselves in a corner During that time we need to perform all of the testing we can so we can make come to an educated conclusion We know With all the new systems springing up these days that s easier said than done W Share MasterTechnician with a friend Get an extra 45 days FREE Access when you Tell a Friend New registration subscribers must have valid Email Tell your Friend to enter friend your user ID into the promocode section at sign up Promotion valid through June 2011 Garege Operator A NEW INDUSTRY STANDARD IN SHOP MANAGEMENT SOFTWARE EIMIPOWIERIMIEINg Control your business Own the software and your data Connect amp communicate with your based shop equipment Order parts electronically from vendors of YOUR choice 214 answers you need from 5 unique reports 630828 iz Regular updates amp basic support for one low monthly fee Continuous review and refinement from GO Users Forum Selected as the exclusive shop management software for AAIA Shop Of Tomorrow amp See Empowerment above free demo Visit www garageoperator com for more information Operator Clann www mastertechma
36. ooks Figure 10 Comparing performance spark plug Repair and Business Solutions for Professional Automotive Technicians amp Shop Owners COM Digital Magazines Hybrids amp Everything Green Tool Equipment Review Weekend Warrior Fun Stuff Check out what s coming in 2010 Register For sixty days free access im mido a 215110655 E NS IDE R Questions Comments _ E Contact Us via Website or Call Chris Ayers Jr 484 472 8441 Small Businesses May Health Care ABG See Some Relief in the will affect nearly every New Health Care Act small business The main by Mary Louisa LHommedieu Esq provisions of the Act roll out over the next four years page 1 The new Health Care Act will affect nearly every small business The main provisions of the Act roll out over the next four years with the major changes occurring in 2014 Most notably beginning in 2014 businesses with more than 50 employees or full time equivalents strategies WEB E must provide affordable health insurance for their a business may take in employees or face penalties Businesses with fewer advance to maximaize the than 100 employees will be permitted to participate in _ protection of its interests is risks insurance exchanges to be set up in each state where a page 1 pooling of resources should drive the costs of insur
37. ot have any effect on PCM operation but if the kick does get great enough it could give the PCM a momentary heart attack and make it skip a beat or worse do permanent damage to the PCM or an internal coil driver I knew the original coils were put back Controls Setup gt aa Plot A Data Save Custom Setup FS Load Setup Waveform Fi Save Data A FB Save Data B 29 Load Data Save Screen F11 Print Screen F12 EIL Figure 8 Scoping all 8 coil drivers Start Deep Record Se in but I was not so sure about the spark plugs I had the shop pull a spark plug to get a look at what was currently installed in the engine I then compared that spark plug to the original Figure 10 and there was something funky about it It had a triangle shaped electrode for a special performance feature it offered I had the shop remove all the spark plugs and put factory spec spark plugs back in Once this was done the problem was completely resolved I can only tell you that I was taken aback by this turn of events It is just so hard to believethata company could manufacture EScopa Dual Scope Stacked Scope Measure amp Deep Rec Lu Meter Timing d 23 Rerum Gam Shaft 013 Cylinders Cursor Pan Hani Window zoom In Qul Zoom Reszel MERE i
38. p to the plate to handle a a high current circuit it would lose it s connection This is where a standard test light which can load a circuit up to 300 mA would be a better choice Keep in mind though that this type of test light cannot be used on computer circuits because it can harm them I discovered that the driver door module had the ability to communicate with a scan tool by looking at a data communication wiring diagram Figure 3 which showed all the onboard controllers on the II scan tool to see 1 there were any trouble serial data network linked to the ALDL codes stored in memory that could lead connector So I hooked up my GM Tech me in the right direction Looking at Figure 2 Wiring diagram color coded Green a m m s a m CMS UND iN m SSS lt s 7 see m D Tai Tra 1 ames _ muet reo a TS S Com eee Pid 8 doe era PRONTI SER RODA LEFT TGBT He H map Cr poem r i barme Des Ear METT kia stat CSS mamas ma sm Lie mam mam
39. re 12 Master Technician Online www mastertechmag com 7 2 Hi Tech Training amp Expo Y a 5 how NV motive essiona TRAINING NETWORKING EXPO Expanded in 2011 March 3 6 2011 Over 85 technical and Collision Industry Day amp Expo March 3 management courses Conference March 4 6 Expo March 4 5 during the 4 day event presen ted by overland park convention center Two new features Collision Industry Day and Collision Expo Thursday March 3 2011 Friday March 4 2011 Don t miss out on this unique and energizing day Designed for shop owners and managers this designed for collision professionals premier training day is dedicated to bringing Networking breakfast together some of the industry s most knowl Select from multiple breakout sessions edgeable most influential and most thoughtful on a variety of hot topics and industry issues people to delve into many Important topics Lunch with keynote speaker issues and trends that are impacting the inde Collision specific expo featuring vendors pendent service marketplace d M SUCCESS LEADERSHI Check the website for the latest POWER PANEL ENERGI schedule and course offerings NETWORKING have gone from the east coast to the west the coast
40. s Ground ym High current Circuit Breaker Feed Orange amp Red Low current Battery Feed 8 Master Technician Online WWW mastertechmag COM LI I Henry rifles will only b made in America or the won t be made at aii Antho President of Henry Rep Henry 22 Lever Frontier Model with Octagonal Barrel An affordable beautiful rifle FS with superior tack driving accuracy Crafted by American workers for American shooting enthusiasts It s not a prideful boast It s a solemn oath from all of us at Henry Repeating Arms Every Henry rifle is and always will be made in America by American workers Decent hard working folks like you who take great pride in their work We won t follow the path of other manufacturers who have their products made overseas and slap their name on them When you read the rollmark on the barrel of a Henry it s going to read Made in the USA We start with only the finest ingredients gun barrel quality steel from Ohio genuine American walnut from Missouri and Iowa steel castings from Wisconsin and brass components from Pennsylvania We manufacture a rifle that you will be proud to own with the smoothest action flawless reliability and pinpoint accuracy Made in America with the same integrity as the Henry rifle President Lincoln owned We are a family owned business and we stand behind every rifle that leaves our plant You will find our customer service seco
41. s costing your customers money A fast and accurate diagnosis will keep them happy with you What more could you want WWW rnastertechrr iac corri on all eight with www startekinfo com Mercedes Benz USA Dealer Workshop Services is the source for all the technical information needed to support service and maintain Mercedes Benz vehicles Mercedes Benz workshops rely on DWS products and services for getting jobs done quickly and more efficiently Our products include STAR TekInfo with WIS net Workshop Information System Electrical Troubleshooting Manuals Installation Instructions M Technical Bulletins Campaigns Mercedes Benz Special Tools 9 STAR Dealer Workshop Services Engineering Services Mercedes Benz USA LLC Maintenance Manuals and Sheets STAR Service Manual Library CDs WIS and DAS software updates star Diagnosis System SDS Operator s Manuals and COMAND Manuals Mercedes Benz Equipment Inventory of technical publications Mercedes Benz eve all had to keep pace with technology perhaps especially so with new developments in automotive safety It seems that every year or so a new airbag gets added driver s side passenger s side dual stage side curtain airbag knee bolster etc These measures have reduced fatalities and serious injuries and their resultant medical costs But they ve also been known to kill Small children and frai
42. shaft Like those of all other modern clean diesels it generates tremendous pressure which is injected directly into the combustion chamber Full pressure is needed to get the engine started and volume is relatively low so even small leaks will bleed off enough pressure to cause a no start Be very careful when inspecting the high pressure side for leaks wear safety glasses and gloves as there s plenty of psi to penetrate your skin and give you a diesel tattoo We re not aware of any February 2011 17 A Sprinter at the Start gauge outside of engineering circles that can be tapped into the rail to measure this pressure but it can be monitored by means of the high pressure sensor mounted on the front of the fuel rail This is a three wire sensor with a 5V reference signal line and ground You can see these voltages on your DRB III scan tool but youll need the Sprinter Card a MUX box adapter and a special red plug cable The signal line will have 5V with no significant pressure in the 200ms D1V Tria Al PROBE PICTURE xui CAL The upper trace is the low pressure sensor signal and the lower trace is that of the high pressure sensor The first step up in both patterns is the ignition key turned on The next step is cranking and running The end of the lower pattern Shows an increase in high pressure from acceleration GRID 18 Master Technician Online system While cranking you should see th
43. use a noid light to see if theyre getting a pulsing Signal while cranking Another test is to remove the return line and crank fuel should pulse out of the top Be careful of the pressure and fire hazard can over time settle in the filter and restrict flow Dodge recommends changing the filter every 30 000 miles or once a year The water in fuel sensor is mounted in the bottom of the filter up to the 2004 model year It s a three wire sensor with a 12V reference 12V signal line and ground The signal line gets pulled towards ground when there s water in the fuel www mastertechn corri The purpose of the low pressure system 15 to assure that the high pressure system doesn t run out of fuel when the engine is under heavy loads Injection pressure may be as high as 30 000 psi you read that right 2 000 BAR so a constant supply of fuel is definitely needed A transparent nylon line feeds the high pressure pump so you should be able to see bubbles if there s air in the system You can check the low pressure side by splicing a gauge into this feed line You should see about 17 psi at idle but it can go as high as 35 to 45 psi while driving There s also a three wire low pressure sensor On the signal line you should see 5V with no pressure and about 2 5V at idle It can go over 3 0V during acceleration The high pressure side uses a three piston pump that runs at 1 1 3 the speed of the cam
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