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Ford NEW GENERATION STAR TESTER, Introduction Manual

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   INTRODUCTION TO

NEW GENERATION STAR TESTER

APRIL 1997

Course Code: 30S02T0

Course Code: 30F03T0

Order Number: FCS-12854-97-REF

Diagnostic Link Module 

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Summary of Contents for NEW GENERATION STAR TESTER

Page 1: ...AR TESTER APRIL 1997 Course Code 30S02T0 Course Code 30F03T0 Order Number FCS 12854 97 REF D i a g n o s t i c L i n k M o d u l e V E H IC L E IN T E R F A C E M O D U L E N o 1 C O M S IG 1 8 9 0 2...

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Page 3: ...APRIL 1997 D i a g n o s t i c L i n k M o d u l e V E H IC L E IN T E R F A C E M O D U L E N o 1 M A X 2 0 0 C O M S IG A U X 1 8 9 0 2 3 4 5 6 7 TRIGGER CANCEL O B D II Course Code 30S02T0 Course...

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Page 5: ...vehicle Tie long hair securely behind your head Keep hands and other objects clear of the radiator fan blades Electric cooling fans can start to operate any time by an increase in underhood temperatu...

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Page 7: ...bles 2 4 Program Card 2 9 Control Unit Set Up 2 9 Vehicle Hook Up 2 11 NGS Start Up Screen 2 12 NGS Main Menu 2 13 Vehicle And Engine Selection 2 15 LESSON 3 Menu Tree 3 2 Set Up Menus 3 2 Vehicle Spe...

Page 8: ...and Self Test 4 6 Wiggle Test 4 7 PID DATA Monitor And Recorder 4 9 LESSON 5 Diagnostic Links 5 2 Diagnostic Data Link MCN Diagnostics 5 2 Diagnostic Modules 5 3 EEC IV System 5 4 Diagnostic Test Mode...

Page 9: ...nd MIL Operation 6 12 Diagnostic Trouble Codes 6 12 Clear Diagnostic Codes 6 12 Oxygen Sensor Test Results 6 13 Diagnostic Monitoring Test Results 6 14 Pending Trouble Codes 6 14 On Board System Readi...

Page 10: ...TOC 4 TABLE OF CONTENTS TABLE OF CONTENTS NOTES...

Page 11: ...s in which the NGS can aid in diagnosis n list the primary functions of the NGS n identify the various NGS diagnostic link capabilities n Primary NGS Functions n Diagnostic Links n Digital Measurement...

Page 12: ...S Depending on the vehicle selected NGS can establish diagnostic links within the following areas l Powertrain Control Module PCM l Anti Lock Brake System 4WAL l Anti Lock Brake System ABS l Governor...

Page 13: ...example of what may be provided l Stored Codes l Self Tests l PID Data and Monitor l Function Tests l Active Command Modes DIGITAL MEASUREMENT The NGS can be used as a conventional tester NGS provides...

Page 14: ...II lesson of this manual VIEW RECORDER AREAS Many of the NGS functions allow you to record the parameter identification numbers PlDs or DTCs for review at a later time In the case of PlDs the data can...

Page 15: ...JECTIVES CONTENT Technicians will n identify the various components of the NGS n connect the NGS for vehicle testing n select a vehicle and the appropriate engine n System Components n Control Unit Se...

Page 16: ...unit houses the 48 hour memory a 16 bit and an 8 bit micro processor The main control unit also provides an area designed for interfacing with the vehicle interface module VIM and the program card The...

Page 17: ...ction to printers and modems 6630 2 2 D i a g n o s t i c L i n k M o d u l e V E H IC L E IN T E R F A C E M O D U L E N o 1 M A X 2 0 0 V C O M S IG A U X DIAG LINK RS 232 VPWR OUT MCL 3 A 3 A G DIA...

Page 18: ...fuse replacement refer to the troubleshooting section of your instruction manual Diagnostic Link Jack provides a connection with the communication link through various vehicles connectors RS 232 Print...

Page 19: ...hicle to connect theVIM to the vehicle being diagnosed The battery hook up adapter cable is used to connect the NGS power cable directly to the vehicle battery The EEC V OBD II adapter cable is used t...

Page 20: ...the vehicle s data link connector Ford calls this connector a vehicle information plug VIP The DDL adapter cable connects to the VIM at the diagnostic link jack and is used as a connection to the dia...

Page 21: ...SON 2 NOTES The Anti Lock Brake adapter cable attaches to the harness in the engine compartment The Flash cable connects the NGS to the PCM via the vehicle s data link connector A Data transfer card i...

Page 22: ...TO SML Connector To STI Connector To Battery Negative All other MECS Self Test PC M AB S AU X 1 AU X 2 AU X 3 SM L SU PER M E C S SE LF T ES T AD AP TE R 0 0 7 0 0 0 5 2 TC M 6630 2 7 Large male round...

Page 23: ...12 use with Diagnostic Link Module Vehicle Interface Module No 1 Version 10 0 DC volts AC volts Ohms Frequency Duty Cycle Pulse Width Digital Measurement System Sensor Simulation CONTAINS MONITOR RECO...

Page 24: ...o r S im u la ti o n D ia g n o s ti c D a ta L in k s IN SE RT CA RD TH IS SI DE O UT F O R D 1 9 8 4 9 2 v e h ic le s 1 9 9 3 V il la g e r P ro b e E s c o rt T ra c e r C a p ri F e s ti v a V e...

Page 25: ...Connect one end to the diagnostic link jack on the VIM and the other end to the data link connector l Plug the power cable into the vehicle s cigarette lighter or into the battery hook up adapter and...

Page 26: ...e module l software version update label l error message if necessary see System Messages Results of the system check l M Indicates that there is information stored in the system s 48 hour memory l B...

Page 27: ...NE SELECTION l DIAGNOSTIC DATA LINK l VIEW RECORDER AREAS l DIGITAL MEASUREMENT SYSTEM l GENERIC OBD II FUNCTIONS l NEW GENERATION STAR TESTER SET UP l INTERNAL SYSTEM TESTS 6630 2 13 1 2 3 4 5 6 7 8...

Page 28: ...rn to the previous screen turn the scroll dial counter clockwise Pressing the numbers two or nine on the numeric keyboard also acts as a back up function Scroll dial rotation moves the selection curso...

Page 29: ...ine selection from the main menu This is not necessary however when using the digital measurement system without link or when using Generic OBD II VEHICLE AND ENGINE SELECTION MENU The vehicle and eng...

Page 30: ...current vehicle that has been selected If a vehicle had been selected and is still in memory it is listed by year engine and model If no vehicle is selected the words NO VEHICLE SELECTED appear on thi...

Page 31: ...you can scroll to the correct year and vehicle identification number VIN that is applicable Select the Vehicle Year To select the vehicle year use the scroll dial to highlight the vehicle year and the...

Page 32: ...nt Model Deselect current model allows you to clear the selected vehicle Certain functions of the NGS such as digital measurement and NGS set up do not require a vehicle selection Use the scroll dial...

Page 33: ...ck selection n capture save and view data n access the diagnostic test modes n access the active command mode n access module identification n access the DTC library n Menu Tree n Basic Navigation n A...

Page 34: ...to adjust certain NGS parameters e g LCD contrast VEHICLE SPECIFIC MENUS These menus run tests on specified vehicles They require that a vehicle and an engine be selected before proceeding TOOL FUNCT...

Page 35: ...n 7 Section 4 Section 4 PCM 4WAL ABS GOVN SUSP TCM GEM Voltmeter Ohmmeter Frequency meter Duty Cycle meter Signal simulation PID Data monitor Freeze frame diagnostic trouble codes Oxygen sensor test O...

Page 36: ...quired actions Here is how they work MAIN MENU SCREEN The main menu screen displays the menus from which you can choose as you navigate through the NGS capabilities 6630 3 2 1 2 3 4 5 6 7 8 9 0 DIAGNO...

Page 37: ...d such as SELECT ITEM AND PRESS TRIGGER TO START In other situations the action statement may direct you to a problem that needs correction such as IAT CIRCUIT ABOVE MAX VALUE 6630 3 3 1 2 3 4 5 6 7 8...

Page 38: ...ew screen s menu is highlighted A menu screen can display up to five items Rotating the scroll dial clockwise moves the highlighting down Rotating the dial counter clockwise moves the highlighting up...

Page 39: ...s shown on the screen Rotate the scroll dial counter clockwise to return to those menu items NOTE in many menus it is possible to switch to the additional pages by pushing the 1 or 0 buttons at either...

Page 40: ...ing the red dot at either end results in a single beep tone if the selected function activates If the cancel trigger command is valid the NGS will beep once If not valid there is a double beep tone Pr...

Page 41: ...ration Either dot may be used If the cancel command is valid the NGS beeps once If not valid there is a double beep tone Pressing the cancel button is the same as saying NO or LET S GET OUT OF HERE NO...

Page 42: ...ions change they appear on the screen above the corresponding numeric key A single beep tone sounds if a numeric keypad command is accepted and a double beep tone if the command is not valid 6630 3 9...

Page 43: ...e capability to run one or more tests at a time Tests may be selected individually or in blocks Once the data is captured it can be viewed and or stored for later review To get to the desired test men...

Page 44: ...s test by pressing CANCEL If you press cancel this brings up a screen that shows systems available for testing PCM ABS etc Figure B if you take this route it takes you to Step 2 BASED ON LEVEL 10 0 SO...

Page 45: ...gure C appears After a moment a third screen appears similar to the one shown in Figure D The actual content of this screen varies from vehicle to vehicle 6630 3 10 C 1 2 3 4 5 6 7 8 9 0 PERFORMANCE D...

Page 46: ...ON This brings up the systems available for testing on the selected vehicle Figure B ANYTIME YOU RETURN TO THE MAIN MENU YOU HAVE TO REPEAT THE ABOVE SEQUENCE 2 Select PCM from the systems available 6...

Page 47: ...Pressing button 3 DEFN allows you to see the definition for each PID on screen as you scroll through the displayed PlDs using the scroll dial Press 3 again to deselect the DEFN function Pressing butto...

Page 48: ...s as necessary allowing the fastest possible processing and display of information Number of PIDs selected One through four One sampling of all selected PIDs every 0 1 seconds 10 x per second Number o...

Page 49: ...l dial to move the cursor to the desired PID then press the TRIGGER button The NGS places an asterisk in front of the PID The asterisk designates that a PID has been selected for viewing and recording...

Page 50: ...is initiates the DCL and starts the NGS recording session SELECTING DESELECTING BLOCKS OF PIDS It is often desirable to select several PlDs to run at the same time They can be selected individually as...

Page 51: ...n be left on and additions to the block can be made by scrolling to them To add a second block to the first block 1 Scroll to the start of the second block 2 Press the TRIGGER 3 Scroll to the end of t...

Page 52: ...escribed above 1 Scroll to the individual test 2 Push the TRIGGER 3 Push the TRIGGER again and an asterisk will appear 4 Scroll to the next desired individual test or block of tests When you have comp...

Page 53: ...onal button is provided labeled HELP Pressing the help button summarizes the block instructions as shown 6630 3 18 1 2 3 4 5 6 7 8 9 0 SCROLL TO START OF BLOCK THEN PRESS TRIGGER SCROLL TO END OF BLOC...

Page 54: ...MODULE NOT RESPONDING appears on the screen If this message appears make sure the vehicle ignition key is in RUN or ON position and the connections to NGS are secure At any point the data being monit...

Page 55: ...t a storage recording area 1 2 or 3 from the menu If an area already has data in it a warning message is displayed If an area is empty this is also indicated 6630 5 12 1 2 3 4 5 6 7 8 9 0 STORE RECORD...

Page 56: ...VIEW RECORDED DTCs After selecting the recorder area to be viewed a screen appears indicating all of the recorded PlDs during that session Select the PlDs that you wish to view by scrolling through t...

Page 57: ...ou need to select which of the test results you wish to view Single Selection To make a single selection scroll to that selection and press the TRIGGER An asterisk will appear before that selected PID...

Page 58: ...splayed across the top of the screen with their respective values underneath them Review of the captured data is controlled by the specific functions displayed above the corresponding numeric keypad b...

Page 59: ...an two PlDs have been selected for viewing you can change what is displayed on screen by using the numeric keypad To change the left hand PID push number 2 on the numeric keypad To change the right ha...

Page 60: ...of the recording Each time either button is pressed the screen moves in the appropriate direction in approximately five second intervals The middle number shows the value of the PID at the point where...

Page 61: ...either table or graph form 1 Attach the printer to the VIM 2 If you are viewing either a table or a graph push the cancel button and return to the PID selection screen 3 Select the PlDs you want to pr...

Page 62: ...3 30 NGS Navigation LESSON 3 NOTES 6630 5 16...

Page 63: ...NGS Navigation 3 31 LESSON 3 NOTES...

Page 64: ...N l HIGHFAN Additional commands are available for vehicles equipped with a 5R55E transmission To use this function highlight the desired mode and press the START button This causes the output to cycle...

Page 65: ...system PCM ABS etc 2 Select DIAGNOSTIC TROUBLE CODE LIBRARY 3 The screen that appears shows the following 4 The selected vehicle 94 3 8L AUTO MUSTANG in the example 5 The selected diagnostic trouble c...

Page 66: ...3 34 NGS Navigation LESSON 3 NOTES NOTES...

Page 67: ...will n set up NGS for Body Chassis module diagnosis n navigate the various Body Chassis modules n retrieve Body Chassis DTCs n perform the various tests available through Body Chassis modules n Select...

Page 68: ...ately diagnose concerns Answer the option questions on the screen it is important to anwer the questions correctly Answering yes to a question allows the NGS to display all codes that the module sends...

Page 69: ...MODULE IDENTIFICATION DIAGNOSTIC TROUBLE CODE LIBRARY DIAGNOSTIC TEST MODES SELECT ITEM AND PRESS TRIGGER TO START This brings up the GEM function options We have already covered the Active Command mo...

Page 70: ...IAGNOSTIC TEST MODES Selecting diagnostic test modes brings up three options l RETRIEVE CLEAR CONTINUOUS DTCs l ON DEMAND SELF TEST l WIGGLE TEST 6630 8 3 1 2 3 4 5 6 7 8 9 0 RETRIEVE CLEAR CONTINUOUS...

Page 71: ...M PASSED message is displayed Pressing CANCEL returns you to the diagnostic test modes If DTCs are present they are displayed You can run the test again by pressing START or you can PRINT SAVE CLEAR A...

Page 72: ...ressing START brings up the instructions shown Press TRIGGER to begin the tests The systems you selected and saved at the beginning of the session are now tested 1 2 3 4 5 6 7 8 9 0 ON DEMAND SELF TES...

Page 73: ...rings up the instructions shown Press TRIGGER to begin the tests The systems you selected and saved at the beginning of the session are available for wiggle testing 6630 8 4 1 2 3 4 5 6 7 8 9 0 WIGGLE...

Page 74: ...the wiggle test the number of I O transitions will be tracked Pressing TRIGGER brings up SYSTEM PASSED or list of DTCs 1 2 3 4 5 6 7 8 9 0 WIGGLE TEST PRESS TRIGGER TO EXIT NUMBER OF I O TRANSITIONS N...

Page 75: ...BS share screen toggle between them in the upper left corner to highlight the GEM PlDs Select PlDs individually or in blocks start capture and save as covered in Lesson 3 1 2 3 4 5 6 7 8 9 0 SELECT IT...

Page 76: ...are routines that the NGS performs on the module The function test may involve several diagnostic functions e g ABS service bleed or I O circuit check Since function tests are unique for each type of...

Page 77: ...ians will n navigate through diagnostic link menus n activate tests n record test results n Diagnostic Links n EEC IV System n EEC V System n MCN Diagnostics n Retrieve Clear Continuous DTCs n KOEO An...

Page 78: ...rmation as it processes There are different types of diagnostic links available when servicing a vehicle NGS currently supports the following links l DCL l SCP l ISO9l41 l STI STO l DDL DIAGNOSTIC DAT...

Page 79: ...for the vehicle you have selected The options available with the vehicle and the type of powertrain system used determine the diagnostic modules that are displayed 6630 5 1 1 2 3 4 5 6 7 8 9 0 ABS AN...

Page 80: ...SYSTEM Upon selecting the PCM POWERTRAIN CTRL MODULE from the diagnostic module menu screen and pushing the TRIGGER a screen with the following options will be displayed l DIAGNOSTIC TEST MODES l PID...

Page 81: ...OTE Available tests depend on application l KOEO OUTPUT CYCLE SELF TEST l KOEO WIGGLE TEST l KOER TIMING SELF TEST l KOER CYL BAL SELF TEST l KOER IDLE SPEED SELF TEST 6630 5 3 1 2 3 4 5 6 7 8 9 0 KOE...

Page 82: ...inks l DCL l SCP l ISO9141 l STI STO l DDL DIAGNOSTIC DATA LINK MCN DIAGNOSTICS In version 10 0 of the NGS software the first thing that appears when you select Diagnostic Data Link is a test of the M...

Page 83: ...for the vehicle you have selected The options available with the vehicle and the type of powertrain system used determine the diagnostic modules that are displayed 6630 5 1 1 2 3 4 5 6 7 8 9 0 ABS AN...

Page 84: ...ROL MODULE from the diagnostic module menu screen and pushing the TRIGGER a screen with the following options is displayed l DIAGNOSTIC TEST MODES l PID DATA MONITOR AND RECORDER IF APPLICABLE l ACTIV...

Page 85: ...ON BOARD SYSTEM READINESS TEST If you scroll down to KOER ON DEMAND for example and press TRIGGER an action window appears This action window displays the name of the test you selected 6630 5 21 1 2 3...

Page 86: ...inuous diagnostic trouble code screen you have the following options to choose from l START Pressing START repeats the code retrieving process l PRINT Pressing PRINT prints all of the DTCs check print...

Page 87: ...ou with all of the necessary steps to be completed prior to performing the actual self test The following figure shows a typical vehicle preparation screen that is displayed prior to performing the KO...

Page 88: ...begins the self test process If a fault is detected by the PCM during the test it is displayed on the screen When any code listed on the screen is highlighted a description of that code is displayed...

Page 89: ...urn to the Main Menu 2 Select VIEW RECORDER AREAS 3 Select VIEW RECORDED DTCs 4 Review data 5 Print data if required The procedures outlined above apply to all tests under diagnostic test modes 6630 5...

Page 90: ...re continuous or complete PID DATA MONITOR AND RECORDER EEC V VEHICLE When the PID DATA MONITOR AND RECORDER function is chosen you can select from the PlDs that are available for the vehicle and engi...

Page 91: ...nicians will n set up NGS for generic OBD II usage n navigate the Generic OBD II Module n retrieve and clear DTCs n perform the tests available through the Generic OBD II Module n Generic OBD II On Bo...

Page 92: ...facturers In general use the generic OBD II functions only if you need freeze frame data or if you are diagnosing emissions concerns on a non Ford vehicle SELECTING AN OBD II EEC V VEHICLE The generic...

Page 93: ...the PCM automatically reports if all on board system readiness tests have not been completed MIL status is also reported at this time MIL status is indicated on the screen as either ON or OFF 6630 7 3...

Page 94: ...dicated so on the screen If the MIL status is ON while at the supported tests screen there is a message on the screen reading MIL STATUS ON and the MIL function also appears above a numeric key 6630 7...

Page 95: ...function key provides you with a screen that displays the number of the module related to the code that triggered the MIL Pressing the cancel button exits this screen 6630 7 4 1 2 3 4 5 6 7 8 9 0 PRE...

Page 96: ...s l PID DATA MONITOR l FREEZE FRAME PID DATA l DIAGNOSTIC TROUBLE CODES l CLEAR DIAGNOSTIC CODES l OXYGEN SENSOR TEST RESULTS l DIAGNOSTIC MONITORING TEST RESULTS l PENDING TROUBLE CODES l ON BOARD SY...

Page 97: ...screen is similar to diagnostic data link PID selection screen Selecting and deselecting PlDs is performed in the same manner by pressing the TRIGGER button while the cursor is on the desired PID Pres...

Page 98: ...s the data monitoring process A screen that displays PlD data monitor results such as the selected PlDs data monitoring results and the NODE module of the related PID will appear after START is presse...

Page 99: ...tes the MIL PID 0005 0003 0003 0007 0009 0004 000C 0006 0008 000D ACRONYM ECT FUELB1 FUELB2 LFT1 LFT2 LOAD RPM SFT1 SFT2 VSS DESCRIPTION Engine Coolant Open Closed Loop 1 Open Closed Loop 2 Long Term...

Page 100: ...the first detected emission related concern That means that if more than one emission related concern is encountered the first one detected will have freeze frame data available The exceptions to this...

Page 101: ...right box displays the freeze frame stored information The area below the boxes shows the definition of the stored TRIGGER DTC If more than one TRIGGER DTC is ever stored the UP and DOWN screen button...

Page 102: ...ystem failure has been seen under identical operating conditions In other words the component or circuit malfunctioning and the failure is not because of an operating condition that occurred only once...

Page 103: ...IGGER displays a screen that provides oxygen sensor test results The test results are from the most recent monitoring of the oxygen sensors during an OBD II drive cycle Test results will be updated ea...

Page 104: ...n the PCM that compares certain PlDs to stored parameters and provides data to the NGS so that the tool can determine pass or fail information PENDING TROUBLE CODES The Pending Trouble Codes function...

Page 105: ...hese tests are continuously run and the results are displayed on the screen as CONT Other tests within this function are not continuously run and can be completed In order to complete these tests cert...

Page 106: ...n be installed in the vehicle before the drive cycle to observe DTC output An NGS can be used anytime through the course of the drive cycle to observe monitor completion status on board readiness menu...

Page 107: ...s Any drive mode is acceptable However a vehicle at idle for the entire six minutes duration of time cannot bring the engine to proper operating temperature 3 Continue driving the vehicle until the en...

Page 108: ...Check monitor completion status on board readiness menu and repeat drive cycle 5 Accelerate to 45 mph at 1 4 throttle elapsed time is about 10 seconds 6 Drive to accumulate at least four minutes in th...

Page 109: ...onverter Adaptive Fuel Monitor OBDII required monitor to flag adaptive fuel adjustments that may cause emissions to exceed California ARB limits Adaptive Strategy The ability of the PCM to adapt to ha...

Page 110: ...s air Breakout Box A service tool that tees between the PCM and the 104 pin harness connector The breakout box contains test pins that can be probed for EEC system testing BTDC Before Top Dead Center...

Page 111: ...evice which uses mechanical magnetic or friction type connections to facilitate engaging or disengaging of two shafts or rotating members CMP Camshaft Position sensor indicates camshaft position CMS C...

Page 112: ...des reprogrammability of PCM without removal from the vehicle EGO Exhaust Gas Oxygen sensor Replaced by HO2S EGR Exhaust Gas Recirculation reduces NOx emissions levels by adding exhaust gas to incomin...

Page 113: ...M Fuel Pump Monitor checks the fuel pump operation Freeze Frame Data The information supplied as Freeze Frame Data is stored for every DTC that illuminates the MIL Freeze Frame Data is reached from th...

Page 114: ...ream of the catalytic converter HO2S UPSTREAM Heated Oxygen Sensor formerly HEGO is an Oxygen Sensor 02S that is electrically heated and located upstream of the catalytic converter HSC High Swirl Comb...

Page 115: ...unning Self Test A test of the EEC system conducted by the PCM with the engine running and vehicle at rest Knock The sharp metallic sound produced when two pressure fronts collide in the combustion ch...

Page 116: ...tandard Corporate Protocol Module communication system NAAO North American Automotive Operations NC Normally Closed NGS New Generation Star tester is used to communicate with OBDII system called EEC V...

Page 117: ...e DTC Fault must occur again as required by an EEC V monitor to light the MlL or flash the TCIL PFE Pressure Feedback EGR is an EGR system that monitors EGR pressure across a remote orifice to control...

Page 118: ...ate Protocol is the multiplexing communication language used by Ford Motor Company for communications between stand alone modules and devices Secondary Air Air provided to the exhaust system to improv...

Page 119: ...Throttle Controller STI Self Test Input STO Self Test Output Switch A device for making breaking or changing the connections in an electrical circuit SUSP Suspension System Control Module System A gr...

Page 120: ...nd vehicle travel during which the OBD l components and five of the system monitors are tested at least once TSB Technical Service Bulletin TSS Transmission Speed Sensor indicates rotational speed of...

Page 121: ...n other operating conditions Warm Up Cycle Warm Up cycle is vehicle operation after an engine off period with engine coolant temperature rising at least 40 degrees Fahrenheit and reaching at least l60...

Page 122: ...GLOSSARY 14 GLOSSARY GLOSSARY NOTES...

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