2013 IM Solutions Training Forum Emission Testing Readiness Issues Presented By Scot Manna Top Tech Training Inc

The Repair Industry and Monitor Readiness Problems Readiness monitor issues are some of the most challenging diagnoses a repair shop may encounter These problems are usually seen on vehicles that operate fine, leading technicians to believe that nothing is wrong with the vehicle If monitors do not run, the vehicle is BROKEN! The following 2 case studies will illustrate the problem and the challenges technicians face

2008 Ford E350 Bus OBD Emission Reject 01/14/13

Issue This Ford E350 Super Duty chassis with a bus conversion will not pass the State of Illinois OBD II test due to a readiness reject This is the 1 st test cycle for this vehicle, the GVWR is lbs. and none of the 4 supported monitors are showing complete A call to the EPA offices confirms the vehicle is OBD II compliant and should pass the test Almost 200 similar vehicles have passed the test

1 st Look The bus will be scanned with an IDS factory scan tool A close look at sensor inputs is performed A drive cycle will also be attempted The monitors are reading incomplete

Identifying the Ford with the IDS for an initial scan test

Non-Continuous Monitors read in-complete, Sensor values appear normal

There are no codes stored!

Drive Cycle will be selected

Intake Air Temperature is Too Cold to Run the EVAP Monitor

Mode 6 Data After Highway Test Drive, Catalyst Monitor Data shows Zero’s

Drive Cycle Results No monitors show complete after the drive cycle attempt Data appears normal during the drive cycle Mode 6 test results show the catalyst monitor did not run during the drive cycle A check of the PCM calibration shows an update is available, a flash is performed

Mode 6 after test drive with new flash, Cat monitor displays numbers!

After short test drive, Mode 6 confirms tests are running

Post Flash Two different test drives were performed after the PCM flash, in each case the Catalyst test data has updated so it appears the PCM is running monitor tests It was noticed on both the Snap-on scanner in Global Mode and the IDS generic data list selection mode a strange PID that was available, (PTO)

The Generic Data List PID Selection List Includes a PTO Status PID Which Will Be Viewed on the Next Screen

Research It was unknown what impact the PTO state had on the PCM running readiness monitors so some research is necessary There are Ford OBDII guides available on the Motorcraft website for free download The 2008 guide will be reviewed to see if there is mention of the PTO

This switch increases idle RPM and changes PTO status

Fix The PTO activation does not prevent monitors from running, it prevents the monitor status data bit from being transmitted in the data stream The IDS is used to take a recording while looking at readiness status while the fast idle switch is pressed and released

Holding down PTO Switch

Fix? The wire seen in the previous picture is left disconnected while the bus is returned to the test lane As expected, the vehicle passes with no issue

2008 Mazda CX DISI Turbo Readiness Not Completing After Battery Replacement 08/09/12

Catalyst Monitor has not completed!

Oxygen Sensor Monitor Has Not Completed!

Initial Scan Results Catalyst, Oxygen Sensor and EVAP monitors have not ran A drive cycle will be attempted

There Are No Codes Set Prior To Performing the Drive Cycle

Fully Warmed Up, At Idle, Post O2 is 910mv and Front O2 is 6.72ma. Front O2 is Air\Fuel Sens.

Air\Fuel Sensor Current is Not Changing During Heavy Throttle Applications

Analysis A recording was taken while driving on the highway The previous 3 slides show the recording with 2 hard accelerations The engine will go rich, then lean during these transitions The air\fuel sensor output can be seen stuck at 6.72 milliamps the entire recording There was no MIL or stored codes after the drive cycle, But the A\F sensor is BAD

After driving to and back from COD

Fuel Status constantly shows OL, Air/Fuel sensor is stuck at 6.73 milliamps

Scan Tests The IDS allows the fuel injectors to be turned on and off while running This will be done while watching scan data An interesting issue happens while the injectors are being controlled

While injector #1 was turned off, the Air\Fuel sensor began to respond

Analysis The Air/Fuel sensor has failed and will be replaced Codes are cleared prior to a re-start to clear monitor readiness

Fuel Control switches to Closed Loop

O2 heater monitor runs first

EGR monitor runs 2nd

O2 monitor runs 3rd

Catalyst monitor runs 4th

Repair Industry Challenge Technicians performing emission repairs in states with testing programs will require continued technical training to help programs reach the desired goal of clean air Readiness monitor problems will be one of the major topics to be addressed, with training on how to deal with these problem vehicles a necessity

Thank You For Your Time