EOBD - Diesel

Exhaust-gas composition - diesel engine

Air In case of a complete combustion, the hydrocarbon compounds react completely with the oxygen and
78% Nitrogen (N2) produce carbon dioxide and water. Nitrogen and inert gases do not react.
21% Oxygen (O2)
Oxygen, carbon dioxide(CO2), nitrogen, water (H2O), inert gases
1 % inert gases (Ar, Xe)
Water (H2O), dust
However, in reality, a 'complete' combustion does not take place. Moreover, nitrogen and sulphur
form harmful compounds:
Fuel
Emissions
Hydrocarbons (HC)
carbon monoxide (CO), nitrogen oxides (NOx), unburnt hydrocarbons (HC), particulate matter (C+
Sulphur (50ppm)
residues), hydrogen sulphide (H2S)

others
Engine oil (HC, S,
additives)
Phosphorous (Biodiesel) in total 0.09% of emissions, of
Exhaust gases which
75% N2 0.043% CO
Substances in the 15% O2 0.034% NOx
combustion chamber 0.005% HC
7,1% CO2
2,6% H20 0.008% PM
0.001% others

Pollutant emission in diesel engine under partial load without exhaust-gas recirculation (in
weight-%)
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 EOBD - Diesel

Emission limits of Euro standards for diesel cars

E5 E6
Euro 4
Euro 3

Euro 2
Euro 1: from 1992
Euro 2: from 1996
Euro 3: from 2000
Euro 4. from 2005
Euro 5: from 2009
Euro 6: from 2014
Euro 1
Specifications for emission
limits in g/km

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 EOBD - Diesel

System overview 01 Control unit

11 15
02 MIL
08 BOSCH 03 Glow-plug indicator
04 Diagnosis connection
05 CAN bus
10 13
06 HFM 5
07
06 18 07 Turbocharger
08 Boost pressure control
09 Intake manifold pressure sensor with
09 17 14
NTC I
10 EGR valve
11 EGR solenoid valve
12
BOSCH

01 12 Speed sensor
13 Nozzle holder with NBF
14 NTC II
05
15 Distributor-type injection pump
04 16
16 Accelerator pedal sensor
02
17 Glow-plug relay
03
18 Pencil-type glow plug
1. In the course of (E)OBD(II), what is monitored in diesel systems?
Combustion failure, EGR, start-of-injection control, boost pressure control, CAN bus, all
sensors and actuators, automatic transmission , glow system, particle filter, control unit
function
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 EOBD - Diesel

Monitoring
7
2 1 1. Are the type and scope of the monitoring always
6 identical?
No, the type and scope of monitoring greatly
5 varies depending on which system it deals with
and how the system is equipped!

3
4
EOBD does not specify that a certain component or
function has to be available.
EOBD specifies that, if an exhaust-gas related
component/function is present, then it should be
1 = Start-of-injection monitored for compliance with (like always) emissions.
2 = Injector
3 = Exhaust-gas recirculation
4 = Lambda sensor
5 = Boost pressure Examples for
6 = Lambda controller monitoring functions
7 = Control unit

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 EOBD - Diesel

Comprehensive Components Monitoring

1. How does the monitoring of the actuators take
place?
xxx
The control unit monitors the components,
e.g., based on the output stage diagnosis.
2. Which criteria are checked in case of sensors?
Monitoring of the signals
Short circuit to ground or plus
Line interruption
Plausibility
Stuck value
Signal value out of range
3. Which fault codes are generated?
For every case, a specific fault code is written.

Comprehensive Components Monitoring

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 EOBD - Diesel

Air mass meter

1 From the speed, boost pressure and air temperature values, a setpoint air mass
will be calculated. This is constantly compared with the actual air mass.

1. Which errors can be detected?

- Charge-air cooler defect
- EGR valve is open or jammed
1 = Sensor ready-to-fit 2
2 = Sensor element / Section - HFM is contaminated (value does not suit the operating
state)
- Leakage in intake manifold

For every case, a specific fault code is written.

which, however, specifies only one test path.

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 EOBD - Diesel

Combustion failure detection

Cyl. Cyl.
3&2 1&4

1. When is the system active in diesel (vehicles)?

In principle, in diesel vehicles the system is active only in idle.

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 EOBD - Diesel

Start-of-injection monitoring
Example UIS(PDE) / UPS(PLD)
1. What is the function of the BIP signal that
1 = Start of actuation arises during valve closing time in UIS?
2 = Valve closing time (BIP) For monitoring the unit injector and for the
3 = End of actuation
4 = Control range
feedback of the actual start of delivery.
A = Current strength
ms = Duration of actuation
2. How is the start-of-injection control monitored
BIP = Beginning of Injection Period
(Start of injection) in engines with VE-EDC?
The map calculated from the operating point,
Example EDC with NBF
speed, temperature, fuel mass is constantly
compared with the signal of the NBF (needle
motion sensor). Small differences will be
tolerated, but not big deviations!

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 EOBD - Diesel

Quantity adjustment
1. What are the different types of quantity
adjustments?
Injector quantity adjustment
Zero-fuel quantity adaptation
Fuel mean value adaptation

2. In principle, which components cause the maximum

dispersion over the operating time which results in
the necessity of an adjustment?
Injectors
Air mass meter
Injector CRS Rail pressure sensor
1 = Identification of the injector
2 = Pins, two-piece armature 3. Can these adjustments be carried out with the help
3 = Stop, two-piece armature of OBD diagnosis?
4 = ferromagnetic core
5 = Valve ball No, because OBD basically means to detect faults, to
6 = Piston store faults, to display faults and to give out faults.
7 = Nozzle seat

Picture: BMW M47TU

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 EOBD - Diesel

Injector fuel quantity adjustment

1. What does injector fuel quantity adjustment mean?
Determination of correction values for pre and main
injection by the input of codes into the control unit
2. When is this adjustment necessary?
When the injector or the control unit is replaced

Injector CRS
If this is not observed, then the control unit works with the old or incorrect
1 = Electrical control element
values.
2 = manufacturing data
3 = 7 digit code for service Although there is a correction through the concentricity evaluation, the frame
of adjustment is limited (10-25%, depending on the manufacturer).
Attention:
7 digit code for exhaust emission standard EURO4 Where applicable, this may result in early or unjustified fault entry.
6 digit code for exhaust emission standard EURO3

Figure: BMW M47TU

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 EOBD - Diesel

Zero-fuel quantity adaptation

1. What does zero-fuel quantity adaptation mean?
It ensures the availability of a definite amount of
pre-injection after a run-in period of 1500km.
2. When is this adaptation required?
The control unit is not always ready after 1500km
and performs this adaptation continuously.

Injector CRS

1 = Electrical connection
In the overrun phases between 2500 and 1500 rpm, a small fuel
2 = manufacturing data
3 = 7 digit code for service quantity (approx. 1mm2) is injected. But the injected quantity is
only so much that the control unit detects a non-uniformity via
Attention:
7 digit code for exhaust emission standard the speed sensor. Using this, the actuating time of the cylinder
EURO4 at which the control unit starts functioning is determined.
6 digit code for exhaust emission standard
EURO3

Figure: BMW M47TU

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 EOBD - Diesel

Fuel mean value adaptation

1. What does fuel mean value adaptation mean?

It is a process in which the fuel-air ratio in the
partial load range is corrected. It is a slow
learning process.
2. What should be taken into account while
servicing?
On replacing the air mass meter, injector/s and
rail pressure sensor, if possible, the adaptation
1 = LSU close to engine values have to be reset.
2 = Pre-catalytic converter

Picture: Exhaust system BMW M47TU

Based on the engine speed, temperature and load, the control unit determines a fuel mass. Using the signals of the lambda
sensor and the air mass meter, the control unit calculates a new average fuel mass across all the cylinders. If any deviations
arise, the air mass - and not the fuel mass - will be corrected through the EGR. Increased EGR with excess air and reduced
EGR with less air.

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 EOBD - Diesel

Lambda sensor diagnosis

1 In diesel engines, monitoring strategies cannot be implemented in the same form as
in gasoline engines. A somewhat different path will be chosen.

2
1. Which functions are monitored?
Lambda Sensor Heating
Plausibility check of the measured O2 concentration

3 2. What should be taken into account while servicing?

4 When the lambda sensor is replaced, resetting of the adaptation
value may be necessary.
5

Balancing 1 in the overrun phase – expected result atmospheric oxygen,

1 = Formed hose Balancing 2 in the partial load range - from the air mass and
2 = Contact holder the fuel mass measured, a definite lambda arises which should also be reported
3 = Sealing pack by the sensor, heating - via internal resistance and/or temperature comparison
4 = Housing
5 = Sensor element

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 EOBD - Diesel

Particulate filter
1. What is monitored?
The delta pressure or the exhaust gas back-pressure
and if required, the delta temperature before/after the
filter will be monitored by the particulate filter.
2. What happens if the delta pressure is very large?
A regeneration takes place.

In order to disintegrate the particles, the temperature in the filter

should increase.
There are different possibilities for that.
- Increasing the temperature by additives in the fuel
- Increasing the temperature by injecting additives or fuel in
front of the filter
- Post-injection and throttling of the engine using a throttle
valve and coating of the particle filter with noble metal
Particulate filter with noble metal

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 EOBD - Diesel

Oxidation catalytic converter The oxidation catalytic converter converts CO, HC and soot particles
into carbon dioxide (CO2) and water vapours (H2O). The oxidation
catalytic converter consists of a coated (e.g. with platinum),
honeycomb ceramic substrate (1).
Platinum serves as the catalytic converter during oxidation.
The exhaust-gases flow through the honeycombs, heat these up and
initiate the conversion of pollutants into harmless substances.
The chemical reaction for the oxidation of CO,
HC and particles takes place between 200 and 350°C.
1 Above 350°C, sulphur present in diesel oil is oxidised to sulphur
dioxide and sulphur trioxide.

2
In a few US vehicles, parallel to the OXI catalytic converter, another
system for reducing the Nitrogen oxides was implemented, parallel to
the EGR system.
Here, if needed, fuel was sprayed in front of the catalytic converter
and with it, the nitrogen oxide emission was once again reduced
through an oxidation process.
1 = Oxidation catalytic converter
Monitoring is carried out by two temperature sensors, before and after
2 = Temperature sensor for catalytic
the catalytic converter.
converter

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 EOBD - Diesel

DENOXTRONIC

8 1 = Control unit 8 = Reservoir

1 2 = Additive reservoir 9 = valve
9
3 = Additive pump 10 = Pressure regulator Air
10
7 4 = Pressure regulator 11 = OXI-catalytic converter*
5 = Dosing valve 12 = Exhaust gas sensor
6 = SCR catalytic 13 = Cleaned exhaust gas
converter 14 = Exhaust Gas Temperature
7 = Compressor Sensor

2 4 3 5 6
12 * Optional, results in high efficiency
13
14
5

1. What will be monitored?

6 In the SCR systems, compliance with the
NOx values will be monitored.
11

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 EOBD - Diesel

Boost pressure control

For an optimum performance increase, under the consideration of exhaust-gas
emissions, the boost pressure should also be permanently regulated. Boost pressure
is adjusted to different driving situations so that the air mass calculated is always
A
available for combustion. For regulating (the boost pressure), previously, the
control unit actuated an electro-pneumatic pressure converter. In the new variants,
this is replaced by an electrical boost pressure actuator.

A 1 = EDC-control unit B 1 = Boost pressure actuator with

2 = Pressure converter electrical drive
3 = Vacuum reservoir 2 = Control motor
B
4 = Actuator 3 = Electronics
5 = Turbocharger 4 = Turbocharger
5 = Adjusting lever
1. What will be tested?
Depending on the system:
– Function of the solenoid valve
– Function of the actuator
– Plausibility of sensors

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 EOBD - Diesel
Exhaust gas recirculation
By introducing a certain quantity of exhaust gas, the combustion
temperature can be reduced and with it, the NOx emissions.
There are two different ways for the monitoring of EGR. Variant 1
Position control and variant 2 Control deviation. In the first variant,
an electrical actuator with position sensor is used, in the second
variant, the EGR rate is plausibilised via the HFM5.

1. What will be monitored?

Function of the actuator and valves, sensors, air
mass meter and altitude sensor

1 = EGR valve 2. What are the technical possibilities available?

2 =EDC control unit
3 = EGR cooler Evaluation of the valve sensor (variant 1)
4 = Exhaust manifold
5 = Intake housing Evaluation of HFM signal (variant 2)

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 EOBD - Diesel

Glow time monitoring

The driveability will be improved and pollutant emissions will
be reduced through pre-glow during engine start and post-glow
up to 2500 rpm.

1. What is monitored?
- Electrical function of the glow relay
1= EDC control unit Glow control unit
2= Control unit for glow time monitoring - Function of the glow plugs e.g. through
3= Glow plugs
4= Main relay paired comparison

2. Which faults should be detected?

Short circuit or interruption

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 EOBD - Diesel

Emission warning lamp MIL

Faults that have a strong influence on emission will be displayed through the emission warning
lamp (MIL).
On switching the engine on, the MIL should light up as function check.
After 'start', the MIL switches off if no fault has been stored. If exhaust-gas related faults are
detected in three consecutive driving cycles, the MIL lights up with steady light.

1. Which colours are allowed?

The only colour allowed is yellow and not red! In USA, at times, still
an acoustic warning is given.

2. What leads to the switching off of MIL?

• Deleting of the fault memory in the OBD menu
• Deleting of the fault memory in the manufacturer's menu
• 3 driving cycles, without the occurrence of the fault stored

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 EOBD - Diesel

Fault entry

The path to fault entry

Immediate fault entry Catalyst damaging

But, if it is catalyst damaging
with MIL blinks off, MIL on

Fault 1x Faults Fault 40x (WUC) not Fault deleted

Mode 7 detected (environment, do)

Fault 80x (DCY) not

detected (environment
different)

Fault 3x Fault Mode 3 MIL on Fault 3x not MIL off/

detected Fault
Entry in Freeze Frame remains

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 EOBD - Diesel

OBD – Fault handling in case of NOx faults

Faults Tank empty Torque reduction
yes after standstill detection
no
Tank display on
3 driving cycles
without faults 2 driving cycles
Outside temperature >-7°C<35°C
Altitude <1600m After 50h
Engine temperature >70°C
Entry in Freeze
MIL off/
MIL on Frame and
Fault
blocking for 400
remains
no injection days

400 days without No NOx detection

fault

Very little injection

Fault deleted

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 EOBD - Diesel

Service Training Center

We offer seminars on the following topics:
- Vehicle electrical system/electronics
- Gasoline injection
- Diesel injection
- Brake systems
- Mechanical system

Multimedia training:

- Web-based training
Diesel technology •
• Electrical/electronics
• Gasoline direct injection
• Active brake safety systems
- eLearning  Multimedia lectures on motor vehicle technology

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 EOBD - Diesel

Service Training Center

Training courses:
- Bosch diesel engineer
- Bosch diesel aggregate engineer
- Bosch gasoline injection engineer
- Bosch breaking systems engineer
- Vehicle electrical system/electronics engineer

Further information can be found in the internet under:

http://rb-aa.bosch.com/diagnostics/de/start/index_flash.htm

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 EOBD - Diesel Titles/ISBN can differ – here a simple translation from German was done

Further Information Technical publications ISBN Order no.

Motor vehicle handbook (25th edition) 978-38348-01388 1 XXX XXX XXX
Motor vehicle electrical system/electronics (4th edition) 978-35282-38728 1 XXX XXX XXX
Gasoline engine management 978-38348-00376 1 XXX XXX XXX
Safety and convenience systems (3rd edition) 978-35282-38735 1 XXX XXX XXX
Diesel engine management 978-35281-38752 1 XXX XXX XXX
Gasoline engine management
Gasoline engine exhaust systems 978-3-86522-000-4 1 XXX XXX XXX
K-Jetronic gasoline injection system 978-3-86522-001-1 1 XXX XXX XXX
KE-Jetronic gasoline injection system 978-3-86522-002-8 1 XXX XXX XXX
L-Jetronic gasoline injection system 978-3-86522-003-5 1 XXX XXX XXX
Mono-Jetronic gasoline injection system 978-3-86522-028-8 1 XXX XXX XXX
Gasoline engine ignition 978-3-86522-006-6 1 XXX XXX XXX
Gasoline engine management - basic principles and components 978-3-86522-004-2 1 XXX XXX XXX
Gasoline engine management - Motronic systems 978-3-86522-005-9 1 XXX XXX XXX
Diesel engine management
Diesel in-line injection pumps 978-3-86522-013-4 1 XXX XXX XXX
Overview of diesel engine management 978-3-86522-007-3 1 XXX XXX XXX
Diesel distributor injection pumps with helix control 978-3-86522-012-7 1 XXX XXX XXX
Diesel distributor injection pumps with solenoid control 978-3-86522-008-0 1 XXX XXX XXX
Diesel injection syst. Unit Injector / Unit Pump System 978-3-86522-009-7 1 XXX XXX XXX
Electronic diesel control EDC 978-3-86522-011-0 1 XXX XXX XXX
Diesel Storage injection Common Rail CR 978-3-86522-010-3 1 XXX XXX XXX
Diesel engine exhaust systems 978-3-86522-082-0 1 XXX XXX XXX
Safety and convenience systems
Conventional and electronic brake systems 978-3-86522-014-1 1 XXX XXX XXX
Cruise stabilizing systems 978-3-86522-015-8 1 XXX XXX XXX
Safety and convenience systems 978-3-86522-019-6 1 XXX XXX XXX
Audio, navigation and telematics 978-3-86522-020-2 1 XXX XXX XXX
Adaptive cruise control ACC 978-3-86522-018-9 1 XXX XXX XXX Further information on the
Electronic transmission control EGS 978-3-86522-026-4 1 XXX XXX XXX
Comm. veh. pneumatic systems (1): Basics, topics covered by this training
systems and diagrams 978-3-86522-016-5 1 XXX XXX XXX course as well as other
Comm. veh. pneumatic systems (2): Equipment 978-3-86522-017-2 1 XXX XXX XXX
Motor vehicle electrical system / electronics
interesting items can be found
Batteries and electrical systems 978-3-86522-024-0 1 XXX XXX XXX in the following Robert Bosch
Alternators and starting systems 978-3-86522-025-7 1 XXX XXX XXX GmbH publications. The
Lighting and washer systems 978-3-86522-023-3 1 XXX XXX XXX
Motor vehicle microelectronics 978-3-86522-022-6 1 XXX XXX XXX "yellow booklets" can be
Motor vehicle sensors 978-3-86522-021-9 1 XXX XXX XXX obtained from the Service
Networkig in motor vehicles 978-3-86522-276-3 1 XXX XXX XXX Training Center.
Hybrid drive, fuel cells and alternative fuels 978-3-86522-277-0 1 XXX XXX XXX

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 EOBD - Diesel

Additional information
Attention:
This is a training document, which shall not be used for maintenance of vehicles.
Instructions for error diagnosis and system testing and repairs are always to be referred
from the applicable
ESI[tronic]-SIS instructions.

More information on the topics handled in this training program can be found in the
following publications by Robert Bosch GmbH.

1 987 723 001 1 987 723 501 1 987 723 504 1 987 723 502
ISBN 3-528-03876-4 ISBN 3-528-13872-6 ISBN 3-528-13877-7 ISBN 3-528-13873-4

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 EOBD - Diesel

European On-Board-Diagnostics

Thank you very much for your attention

Further information can be found in the
Bosch publication:
Steuergerätediagnose
„Steuergerätediagnose über die Carb-Schnittstelle“
(Control unit diagnosis via the Carb interface)
Type no.: 1 689 980 282
Price: approx. € 11,25 EUR
Carb-Schnittstelle
EOBD / OBDII

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