175_大众基础车载诊断系统OBDII（翻译）

On-Board Diagnosis System II in the New Beetle (USA) Design and Function Self-Study Program 175 Service. 2 175_001 NEW Important Note The Self-Study Program is not a Workshop Manual! Please always refer to the relevant Service Literature for all inspection, adjustment and repair instructions. Service literature. Far-reaching man-made atmospheric changes are looming on the horizon. They will have grave consequences for the earths biosphere unless we dramatically reduce and control the pollutant emissions of motor vehicles, among other things. The On-Board Diagnosis System (or OBD) was introduced for this purpose. OBD is a diagnosis system integrated in the vehicles engine management system which continuously monitors the components affecting exhaust emissions. If a fault occurs, OBD recognizes it, stores it and indicates it via the self-diagnosis fault warning lamp (MIL). OBD II is the second generation of engine management systems with diagnosis capability. OBD II offers the following advantages over periodic vehicle checks: G It checks pollutant emissions continuously, G indicates malfunctions early, and G provides full-fledged diagnosis functions which simplify troubleshooting and fault correction for workshop personnel. In the long term, we will expand the capabilities of the diagnosis system to make it possible to detect faults in the exhaust system that are detrimental to emission behavior by means of a simple OBD reader, even during spot checks. Self-Study Program No. 175 was developed and published specially for the U.S. market at that time. On account of recent developments (launch of US Beetle model onto European market), we have updated this SSP and included it in our Program under No. 175. 目前人为因素对大气环境产生了很大的影响。为保证对 环境的影响不断降低， 对车辆的尾气控制提出更高要 求。车载诊断系统（ O BD ） 就是为此开发的。它是集成 在发动机电脑中的一个子系统， 它持续的监控与尾气排 放有关的部件。如果出现故障， 并被O BD 识别到， 故障 将被存储并通过自诊断警告灯（ M I L） 显示。 O BD II 是第二代带有诊断能力的发动机控制系统， 相比 以前的技术， 它有以下好处： 它可以持续的监控尾气、 更早的指示故障、提供详细的诊断功能以便更好发现 故障。在以后我们还要发展诊断能力， 这样可以更好的 识别到尾气排放中的问题。 3 Contents OBD Variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Overview of OBD-II (Gasoline Engine) . . . . . . . . . . . 6 System Overview (Gasoline Engine) . . . . . . . . . . . . 20 System Components (Gasoline Engine) . . . . . . . . . . 22 Overview of OBD-II (Diesel) . . . . . . . . . . . . . . . . . . . 60 System Overview (Diesel) . . . . . . . . . . . . . . . . . . . . . 64 System Components (Diesel) . . . . . . . . . . . . . . . . . . . 66 Self-Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 OBD-II (Gasoline Engine) . . . . . . . . . . . . . . . . . . . . . . 78 OBD-II (Diesel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Function Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 2.0-liter Gasoline Engine . . . . . . . . . . . . . . . . . . . . . . 84 1.9-liter TDI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Test Your Knowledge . . . . . . . . . . . . . . . . . . . . . . . . . 88 O BD 差异 汽油发动机的O BD II外观 汽油发动机系统图 汽油发动机系统部件 柴油发动机的O BD II 柴油发动机系统图 柴油发动机系统部件 自诊断 汽油发动机O BD II 柴油发动机O BD II 功能图 2 . 0 L汽油发动机 1. 9L柴油发动机 测试 4 OBD Variants 175_025 Engine variants used in the New Beetle (U.S. model) The U.S. models of the New Beetle have been delivered with two engine variants: G Gasoline engine: 2.0-liter four-cylinder (AEG) with OBD-II for the gasoline engine G Diesel engine: 1.9-liter four-cylinder TDI (ALH/90 bhp) with OBD-II for the diesel The components of the New Beetle (USA) which affect exhaust emissions are monitored on both the gas- oline engine and the diesel engine. On account of the different system requirements relating to combustion and exhaust gas treatment, we had to adapt and separate the diagnosis of these systems. The results of this work are the OBD-II for the gasoline engine and the OBD-II for the diesel engine. Both variants are described separately in this SSP. O BD I I 用于甲克虫汽油发动机和柴油发动机。因为发动机形式的不同， 对于燃烧形式和排放要求都不一样， 我们将 分开讲述两种发动机。 采用的发动机： 装备了两种发动机 2 . 0 L 4缸 O BD II 汽油发动机、1. 9L 4缸 O BD II柴油发动机 5 02J01M 175_022 175_023 1,9 l TDI (90 bhp) 175_021 Gasoline engine monitoring functions -Exhaust gas recirculation -Misfiring -Injection commencement control -Charge pressure control -Automatic transmission -CAN bus -Diesel direct injection system control unit -All sensors and actuators affecting exhaust emissions connected to the control unit Gasoline engine monitoring functions -Catalytic converter function monitor -Lambda probe aging diagnosis -Lamdba probe voltage test -Secondary air system -Fuel vapor retention system -Leak diagnosis -Fuel supply system -Misfiring -CAN bus -Motronic control unit -All sensors and actuators affecting exhaust emissions connected to the control unit 2.0-liter four-cylinder 02J01M 175_021 175_020 175_022汽油发动机的控制功能： 催化转化功能控制、 氧传感器衰老诊断 氧传感器电压测试、二次空气系统 汽油蒸汽利用系统、渗漏诊断 燃油供应系统、失火诊断 CA N数据、发动机控制单元 所有影响排放的传感器和做动气连接到控制单元上。 柴油发动机控制 未翻译 6 Year Emission limits 175_002 175_003 HC CO NOx Basic Concept of OBD-II History of pollutant emissions in California: Overview of OBD-II (Gasoline Engine) Malfunctions and faulty components in the engine management system can lead to a drastic increase in pollutant emission. In view of the technical complexity involved, the concentrations of CO carbon dioxide HC hydrocarbons, and NOx nitrogen oxides cannot be measured directly. Instead, they are determined by testing the components of the engine management system which affect exhaust emissions. This also has the advantage that faults can be traced directly by using a Scan Tool. Since 1970 the California Air Resources Board (CARB) has tried everything within its power to curb atmospheric pollution by imposing statutory requirements. The concepts which these efforts have spawned, such as OBD-I (1985) for example, have already contributed to a welcome reduction in the emis- sion values of motor vehicles. 100% 80% 60% 40% 20% 0% 197519801985199019952000 O BD I I 的基础概念： 从197 0 年开始“ 加利福尼亚大气资 源中心“ 开始倡导” 通过立法的方式降低对大气的污 染。由此发展了很多技术， 例如198 5年的O BD I 就用于减 少发动机的尾气排放控制。 加利福尼亚的污染历史 有故障的部件会造成尾气排放的升高。 排放有害物质包括： CO H C NO X 这些数据是不能直接测量的， 然而 通过检测与尾气排放的相关部件是 可以监控尾气系统的， 并且错误可 以直接通过检测仪器诊断出来。 7 As the function of the transmission also affects exhaust emission quality, data from the trans- mission control unit must also be exported during a diagnosis. Requirements: G Standardized diagnosis plug connection in the driver area G Standardized fault codes for all manufacturers G Fault indicated by commercial diagnosis and testing systems G Indicate the operating conditions in which a fault occurred G Determine when and how a fault affecting exhaust emissions is indicated G Standardized names/abbreviations of components and systems Objective: G Monitor all parts which are important to emission quality G Protect the catalytic converter from damage G Indicate visual alarms when parts affecting exhaust emissions malfunction G Fault storage G Diagnosis capability To reach this objective, the Motronic control unit monitors the following components and systems: G Catalytic converter G Lambda probe G Misfire detection system G Secondary air system G Exhaust gas recirculation system G Fuel tank purging system and leak testing system G Fuel distribution system G All sensors and actuators affecting exhaust emissions and connected to the control unit G Automatic transmission 目的： 控制所有与排放有关的部件的状况 避免催化转换器的损坏 当发生影响排放的故障时， 及时发出警告 错误记录 诊断能力 为达到此目的， 发动机控制单元控制以下部件和系统： 催化转换器、氧传感器、失火识别功能、二次空气系统、 废气再循环、油箱净化系统和泄漏检测系统、燃油分配系 统、影响排放的所有传感器和做动器连接到控制单元、自 动信息传递 8 Overview of OBD-II (Gasoline Engine) 175_004 OBD-I monitors: the functional capability of sensors and actuators by measuring the voltage drops across components. OBD-II monitors: -all functions of the input and output components such as OBD I, e.g.: short-circuit to positive, short-circuit to ground, open circuit -signals and components of functions affecting exhaust emissions for plausibility (e.g. catalytic converter, lambda probe) -system functions (e.g. secondary air system) -the entire drivetrain (e.g. emergency operation of automatic transmission) The OBD II is an improved version of the OBD-I. OBD II HC CO NOx O BD II比O BD I 的改进： O BD I 监控： 通过测量传感器和做动器的电压变 化来实现监控。 O BD I I 的监控： 所有输入输出的元件功能， 例如O BD I 的对地短路、 对正极短路、开路等 影响排放的信号和元件信号更加真实， 例如 催化转 换、氧传感器 系统功能 例如 二次空气系统 全部的驱动模式 例如 应急情况下的自动信息传递 9 CARB (California Air Resources Board) SAE (Society of Automotive Engineers) This society drafts proposals/guidelines for implementing statutory requirements (e.g. standards). NLEV (Non-Low Emission Vehicles) Approval level for vehicles which comply with the currently valid requirements (0.25 g/mi HC). TLEV (Transitional Low Emission Vehicles) Approval level for vehicles with low exhaust emission figures (0.125 g/mi HC). LEV (Low Emission Vehicles) Approval level for vehicles which must comply with the new, more stringent requirements (0.075 g/mi HC). ULEV (Ultra Low Emission Vehicles) Approval level for vehicles with a further reduction in emission values (0.04 g/mi HC). SULEV (Supra Ultra Low Emission Vehicles) A further improvement on approval level ULEV. EZEV (Equivalent Zero Emission Vehicles) Approval level for vehicles which emit practically no pollutants. ZEV (Zero Emission Vehicles) Approval level for vehicles which emit no pollutants. Generic Scan Tool The universal tester to fetch fault messages from fault memory. ISO 9141-CARB Standard for data transfer to the reader Comprehensive Components Monitoring (also: Comprehensive Components Diagnosis) Diagnosis system which checks all electrical com- ponents and output stages for correct functioning by determining the voltage drop across the com- ponent in question. Driving Cycle Driving cycle comprising starting the engine, exe- cuting the diagnosis function in question and turning off the engine. Glossary: 术语 CA RB 加利福尼亚大气资源中心 SA E 汽车发动机法规 NLEV 无铅低排放车辆 以满足当前的标准 0 . 2 5G / M I H C T LEV过渡型低排放车辆 标准0 . 12 5G / M I H C EZEV等价零排放车辆 基本没有污染 ZEV零排放车辆 没有污染 通用测试仪器 用于调取错误记录 ISO 9141-CA RB 信息读取标准 LEV 低排放汽车 标准0 . 0 7 5G / M I H C U LEV更低排放车辆 标准0 。0 4G / M I H C SU LEV超低排放车辆 远远低于标准 广泛元件控制 / 诊断 通过识别元件的电压变化来检测 电子元件和输出状况来实现诊断功能 驱动周期： 从启动发动机、故障诊断、关闭发动机 10 Overview of OBD-II (Gasoline Engine) MIL (Malfunction Indicator Light) U.S. designation for self-diagnosis fault warning lamp K83. The MIL indicates that the Motronic control unit has detected a fault in components affecting exhaust emissions. A fault is indicated in the form of a steady or a flashing light after it is detected by the control unit either -immediately or -after 2 driving cycles depending on the nature of the fault and what display conditions apply. There are also faults which are stored to memory but which do not activate the self-diagnosis fault warning lamp (MIL). NOx (nitrogen oxides) Nitrogen oxide compounds. The NOx component in motor vehicle exhaust emissions is based on the presence of atmospheric nitrogen during fuel combustion under high pressure and at high tem- peratures in the engine. CO (carbon dioxide) occurs during the combustion of carbon in an oxygen-deficient atmosphere. HC (hydrocarbons) Within the context of the exhaust system, the HC component is the concentration of unburnt fuel in the exhaust gas. Stoichiometric In vehicle production, a stoichiometric fuel-air mixture is the ideal intake air to fuel mass ratio at which the fuel is burnt completely without pro- ducing any incompletely burnt subproducts (e.g. carbon dioxide). Readiness Code 8-digit binary code which indicates whether all diagnoses affecting exhaust emissions have been conducted by the engine management system. The Readiness Code is generated when: -all diagnoses have been conducted without fault and the self-diagnosis fault warning lamp (MIL) is not lit, -all diagnoses have been conducted, detected faults have been stored to fault memory and indicated by the self-diagnosis fault warning lamp (MIL). v kph 175_005 t s FTP72 100 80 60 40 20 0 200400600800100012001372 FTP72 (Federal Test Procedure) A driving cycle over a distance of 7.5 miles for a time of 1372 s defined for the U.S.A. Max. speed is 91.2 kph. FT P7 2 美国联邦测试程序： 137 2 秒 行驶7 . 5K M 最大 车速91. 2 K M / H NO X 氮氧化物： 汽油在高温、高压燃烧过程中所产生的 CO 碳化物在氧气不足时所产生的 H C 在尾气中， 他们是由未完全燃烧的燃油所产生的 混合浓度： 在车辆生产中， 它是指怠速情况下， 空气与 燃油混合后， 完全燃烧的混合浓度。 M I L故障指示灯： 美国规定的自诊断错误警告灯K 8 3 ，此灯用 于 指示发动机控制单元是否识别到影响尾气的错误发生。 故障指示灯持续亮或闪烁的条件： 发现故障立即产生或2 个 驱动程序。依据故障的性质， 由不同的单元显示。同样有很 多故障是存储在控制单元中的， 但他们不会激活警告指示 灯。只有影响尾气的故障才会激活警告灯。 就绪码： 8 位的二进制代码， 用于指示是否所有有关 尾气排放因素都被发动机控制单元所控制。 当出现 以下情况产生二进制代码： 所有的诊断都无故障的被控制并且指示灯没亮 所有的诊断都被控制， 识别到的故障都被存储并且 指示灯亮（ M IL) 11 175_006 175_007 Diagnosis Stored malfunctions can be exported by means of a Scan Tool connected to the diagnosis inter- face which can be accessed from the drivers seat. In the new program version, the diagnosis with VAG 1551 offers the following possibilities: G Read out/erase fault memory G Display data relevant to assemblies to support troubleshooting G Read Readiness Codes G Execute a short trip (to generate the Readiness Codes) G Print diagnosis data Lawmakers have stipulated that diagnosis systems must be designed by auto makers in such a way that OBD data can be interrogated with any OBD reader (Generic Scan Tool). This Generic Scan Tool mode can be invoked by diagnosis systems V.A.G 1551 (software version 5.0 or higher), V.A.G 1552 (software version 2.0 or higher) and VAS 5051 via address word “33“. However, the units can also provide - via address word “01“ - functions which go far beyond this mode and are required for troubleshooting and repair work as well as reading and generating Readiness Codes. OBD-II 175_010 O BD I I 诊断 存储的故障可以通过检测仪器调出 VA S50 5X可以显示以下信息： 读取/ 删除错误 记录、故障信息、故障编码、生成就绪码、 打印数据 根据法规要求， O BD 系统可以使用通用检测仪器进行检测。 通用的检测仪器需要专用设备支持 VA G 1551/ 1552 或VA S50 5X都可以进行诊断。使用通道 0 1可以生成就绪码。 12 Overview of OBD-II (Gasoline Engine) 175_009 Self-diagnosis fault warning lamp (MIL) in the New Beetle (U.S.A.) Self-diagnosis fault warning lamp (MIL) in dash panel insert Diagnosis interface175_008 Fault indication If the system detects a malfunction affecting exhaust emissions, it indicates this fault to the driver by means of a warning lamp which is integrated in the instrument panel at an easily noticed location. Diagnosis interface This interface is integrated in the passenger cabin and is within easy access of the drivers seat. 175_912 175_902 The driver or mechanic must check that the MIL functions correctly during the starting cycle. The MIL must come on approx. 2 seconds after starting the engine. 故障指示： 如果系统识别到一个影响尾气排放的故 障， 通过仪表的警告指示灯提示驾驶员。 诊断接口 仪表的警告指示灯 诊断接口 O BD 报警灯 启动发动机后警告指示灯必须亮两秒 13 Flashing rate 1/sec 175_014 175_016 175_015 Steady light If misfiring, which can damage the catalytic con- verter, occurs, the self-diagnosis fault warning lamp (MIL) must indicate this immediately by flashing. The vehicle can then only be operated at a reduced power output. The self-diagnosis fault warning lamp (MIL) switches to steady light. If the fault causes a deterioration in emission quality, the self-diagnosis fault warning lamp (MIL) must indicate the fault by a steady light after fulfilling the relevant storage and switch-on conditions (immediately, after 2 driving cycles). Example: Misfiring Under all driving conditions the system checkswhether: 1. The number of misfires is high enough to damage the catalytic converter, 2. the number of misfires causes the emission values to deteriorate by a factor of 1.5. If the 2nd condition is met, then a fault is stored at the end of the first driving cycle but the self- diagnosis fault warning lamp (MIL) does not come on. If the fault continues to exist until the end of the second driving cycle, the fault warning lamp must be steady on. If the 1st condition is met, the self-diagnosis fault warning lamp (MIL) must flash once a second. Fault indication by self-diagnosis fault warning lamp K83 (MIL) 自诊断错误警告灯K 8 3 M I L 如果出现失火， 将危害催化转换器， 自诊断警告灯立即通过 闪烁方式发出报警。车辆动力输出降低。如果错误影响到尾 气质量， 警告指示灯转为持续亮起（ 两次驱动程序后） 例如： 失火 满足以下条件 失火次数足够高到影响尾气状况 失火导致排气变化超过厂家要求1. 5倍 出现第一阶段情况， 警告指示灯每秒闪一次 闪烁频率1次/ 秒 如果达到第二阶段， 警告指示灯在首轮循环后， 持 续亮 如果警告指示灯直到第二循环结束仍存在， 警告 灯持续高亮。 14 Overview of OBD-II (Gasoline Engine) The diagnosis fault codes are standardized to SAE and must be used in a harmonized fashion by all manufacturers. The fault code always consists of a five-character alphanumeric value, e.g. P0112. The first character is a letter. It identifies the system type: Pxxxx for drive Bxxxx for body Cxxxx for suspension and Uxxxx for future systems Only P-codes are required for OBD II. The second character identifies the standard code. P0xxx Freely selectable fault codes defined in accordance with SAE which can be used by the diagnosis system and contain specified fault texts (from model year 2000: P0xxx and P2xxx). P1xxx Additional freely selectable fault codes affecting exhaust emissions which are offered by the manufacturer and contain no specified fault texts but must be registered with lawmakers (from model year 2000: P1xxx and P3xxx) The third character indicates the module in which the fault occurs: Px1xx Fuel and air metering Px2xxFuel and air metering Px3xxIgnition system Px4xxAdditional emission control Px5xxCruise and idle speed control Px6xxComputer and output signals Px7xxTransmission The fourth and fifth characters contain the component/system IDs. When carrying out a diagnosis, you can initiate different diagnosis functions by entering different address words. The Scan Tool Mode is started by entering the key “33“. It includes all functions stipulated for a generic Scan Tool by lawmakers within the framework of the OBD. In this context, individual physical data (e.g. Lambda probe data) can be exported. Workshops with universal diagnosis units such as the VAG 1551/1552 can optimize troubleshooting by accessing all key engine data by entering the key “01“. In the Bosch Motronic, the Readiness Code can also be generated by taking the vehicle out on a short trip