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VEHICLETROUBLESHOOTER

DIAGNOSTIC TECHNIQUES

For the sixth instalment in thisseries of Bosch ESI 2.0 technicalarticles we want to go into a bitmore detail by covering some of

the advanced functions that can be performedon the vehicle with Bosch KTS duringmaintenance or repair.

Once connected to a vehicle system, underthe Diagnosis tab, there are several TestSteps, one of which is Actuators. It’simportant to explain how this can be useful ina fault diagnosis situation (see Fig 1).

A technician may be faced with an enginefault that could be related to, for instance, aninjector. In other tests, such as Actual Values,the engine is required to run in order toproduce data for you to analyse. However, ifthe engine will not run, this is not possible.

The Actuator Test allows you to send adirect command to a specific component, by-passing the switching side of the system, tocause it to operate. The engine doesn’t needto run and you can command the componentor circuit to function straight away withoutwaiting. You can therefore see whether thereis an issue with the performance or functionof the component.

Another good example is if you suspectthere is an issue with the engine cooling fan.

Without waiting for the engine to reach therequired temperature, you can just use theActuator Test to command the electric fanoperation directly. If the fan operates, thenyou know that it is a problem in another partof the circuit. If it doesn’t, you can performfurther tests on the fan itself, and you havesaved some time in doing so. Without this testyou would’ve had to wait for the engine towarm up, and also you can’t be sure when thefan would have cut in so you may not beready to test or observe the operation.

These Actuator Tests could be used tocheck many other systems (depending onwhat the particular vehicle supports) such asan EGR valve in the engine managementsystem, a headlamp bulb in the body orlighting control or an electric windowregulator in a door control ECU.

Decision makingWhen fault-finding, the result of an ActuatorTest can help your diagnostic process anddecision making, depending on the outcomeas to whether the fault may be on the input oroutput side of the ECU in the circuit. You’rein control of the test and can check theoperation of a component when you’reexpecting it to happen.

You can also simultaneously set up anoscilloscope and/or current clamp to measurethe voltage and amps in the circuit when thecomponent operates while the vehicle is staticin the workshop. It might not be practical todo this whilst driving on a road test, however.

The Bosch KTS 570 has a built-in twochannel oscilloscope/multi-meter in the VCI(vehicle communication interface), which wewill cover the use of in a later article. For theexpert diagnostic technicians out there whodo in depth, advanced system and componenttesting, we recommend the FSA 500 engine

analyser that works in unison withESI[tronic] 2.0 (see Fig 2); this tool isespecially useful in a situation where paralleltesting is required.

Sometimes, there are certain preconditionsrequired for an Actuator Test to be performedsuccessfully and the on screen instructionsmust always be followed, otherwise the testmay fail (see Fig 3).

Another point to consider is that if theengine is not to be run during the test, a goodbattery voltage is essential. We recommendthat a quality battery support unit, such as theBosch BAT490, is used.

On most vehicle systems, you can pickand choose the components you want toactuate by selecting them from a list (see Fig4). Some vehicles offer a pre-determinedoutput test sequence which will operate thesupported items one by one; this routine hasbeen designed that way by the manufacturer.

In ESI 2.0, most Actuator Tests willautomatically show some relevant ActualValues together with the actuation process onscreen to give you further evidence of theeffectiveness of the test. This is beneficial, as

KTS DIAGNOSTICS MADE ‘ESI’PART 6: ACTUATORS, FUNCTION TESTS, ADJUSTMENTS/SETTINGS & SPECIAL FUNCTIONS

This regular series of technical articles from Bosch focuses on how to get the best out of its ESI[tronic] 2.0 software, which is

used in conjunction with the KTS range of diagnostic tools for vehicle fault diagnosis and service function procedures.

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ROBERT BOSCH

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sometimes you can’t physically see or hearthe component that you’re testing, such as theheated seat element (see Fig 5). You can alsouse the F7 (List) soft key to choose your ownvalues to be displayed during the test if youwould prefer.

You will notice that once the Actuator Testis complete you have the option to confirm ifthe test was activated or not. If you click‘Yes’ then a ‘+’ (plus) symbol was shownbefore that actuator name, indicating that it isactivated (see Fig 6). Pressing F4 (store)when you’re finished will add the actuatorresults to the protocol report that wementioned in the second part of this ‘KTSmade ESI’ series. You can then print theprotocol off to show the results to yourcustomer as evidence of which componentswere tested.

Specific test planNext on the main Test Steps selection list isFunction tests and this basically does whatthe name suggests. These tests are diagnosticroutines that will use a specific test plan todetermine the operation state of a componentor system. For instance, in Bosch ESI 2.0 youwill see bespoke braking tests for BoschABS/ESP systems that are best performed ona ‘roller brake tester’. Other function testscould be available, such as cylinder balancingor a systems output self-test. These can be avaluable aid in fault finding work and thenlater confirming a repair to the vehicle.

Adjustments/settings are diagnosticprocedures where stored values can be resetor changed within the control unit. Forexample, this could be a service lamp reset orcomponent adaptations; fuel quantity

adjustment (injector IMA coding) if a newdiesel injector has been fitted; TPMS codingif a tyre pressure sensor has been replaced; orrain/light sensor adaptation if the windscreenhas been renewed. A selection of furtheroptions are visible in Fig 7.

Special functions are advanced andspecialist operations that require attention todetail in order to perform the tasks. Thiscould be a diesel particulate filter (DPF)regeneration or ESP brake system fluidbleeding. This type of function should onlybe performed by qualified and experiencedtechnicians who must follow the testerinstructions carefully. Often an assistant isrequired to help get the job done.

Certain routines will only work if the setpreconditions are followed (see Fig 8). In theESI 2.0 Function tests, Adjustment/settingsand Special functions, the pre-conditions arealways stated in the information text screens

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VEHICLETROUBLESHOOTERDIAGNOSTIC TECHNIQUES

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“Function tests can be acrucial aid in fault findingwork and then confirminga repair to the vehicle.”

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that precede the start of the routine. If theKTS detects that the preconditions are notmet it will delay the start of the test anddisplay on screen the values that are outside

of their expected range so that you can rectifythe situation and continue with the function

The Service tasks tab in ESI 2.0 is also avery useful feature which provides a quick link

to perform a vehicle service related task byselecting from the categorised function list(see Fig 9). This is helpful, for example, whenyou’re not sure where to reset the service light.

Nowadays this could be in the instrumentcluster, body computer or engine ECU. Byusing the Service tasks menu the selectionprovides a shortcut straight to the correctsystem and will reduce the number of clicksthat are required.

We hope that this article shows you howthe ESI 2.0 software used with Bosch KTS isso much more than just a code reader or scantool. See you in the next edition!

To request further details about the KTS

range of diagnostic tools, available from

Bosch, circle 068

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PREVIOUS ARTICLES CAN BE SEEN AT: WWW.BOSCH-WORKSHOPWORLD.CO.UK (UNDER ‘NEWS’)

OR BY VISITING: WWW.PMMONLINE.CO.UK.

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