ZR 4
ZR 4
ZR 4
SAFETY PRECAUTIONS
IMPORTANT SAFETY INFORMATION ................................... 1
ABOUT THE
VEHICLES COVERED ............................................................. 2
CONTROLS AND INDICATORS .............................................. 3
DISPLAY FUNCTIONS ............................................................ 4
DISPLAY AND SETTINGS ........................................................ 5
ONBOARD DIAGNOSTICS
OBD2 TERMINOLOGY ............................................................ 7
DIAGNOSTIC TROUBLE CODES (DTCs) .............................. 8
OBD2 MONITORS ................................................................... 11
PREPARATION FOR TESTING
BEFORE YOU BEGIN .............................................................. 14
USING THE CODE READER
CODE RETRIEVAL PROCEDURE .......................................... 15
ERASING DIAGNOSTIC TROUBLE CODES (DTCs) ............. 20
ADDITIONAL FUNCTIONS
THE MAIN MENU ..................................................................... 22
VIEWING VEHICLE INFORMATION ....................................... 22
EVAP TEST .............................................................................. 25
VIEWING MONITOR ICON DESCRIPTIONS ......................... 26
VIEWING THE LED MEANING ................................................ 26
ADJUSTMENTS, SETTINGS AND LANGUAGE ..................... 27
OBD UPDATER ........................................................................ 29
WARRANTY AND SERVICING
TROUBLESHOOTING ............................................................. 29
LIMITED 90 DAY WARRANTY ................................................. 30
i ZR4
Safety Precautions
IMPORTANT SAFETY INFORMATION
1
About the Code Reader
VEHICLES COVERED
VEHICLES COVERED
The Code Reader is designed to work on all OBD2 compliant vehicles.
All 1996 and newer vehicles (cars and light trucks) sold in the United
States are OBD2 compliant. This includes all Domestic, Asian and
European vehicles. Coverage for new model vehicles may be limited
and will be available once released by the automaker. Availability is
typically 12 to 24 months after the release of the model year.
Some 1994 and 1995 vehicles are OBD2 compliant. To find out if a
1994 or 1995 vehicle is OBD2 compliant, check the following:
1. The Vehicle Emissions Control Information (VECI) Label. This
label is located under the hood or by the radiator of most vehicles. If
the vehicle is OBD2 compliant, the label will state “OBD II
Certified.”
SPARK PLUG
TYPE NGK BPRE-11 CATALYST
GAP: 1.1MM
2
About the Code Reader
CONTROLS AND INDICATORS
5 7
1
9 6
2 4
3
About the Code Reader
DISPLAY FUNCTIONS
DISPLAY FUNCTIONS
2 1
3
4 8
5
9
6 10
11
4
About the Code Reader
DISPLAY AND SETTINGS
5
About the Code Reader
DISPLAY AND SETTINGS
6
Onboard Diagnostics
OBD2 TERMINOLOGY
OBD2 TERMINOLOGY
The following terms and their definitions are related to OBD2 systems.
Read and reference this list as needed to aid in the understanding of
OBD2 systems.
Powertrain Control Module (PCM) - The PCM is the OBD2
accepted term for the vehicle’s “on-board computer.” In addition
to controlling the engine management and emissions systems,
the PCM also participates in controlling the powertrain
(transmission) operation. Most PCMs also have the ability to
communicate with other computers on the vehicle (ABS, ride
control, body, etc.).
Monitor - Monitors are “diagnostic routines” programmed into the
PCM. The PCM utilizes these programs to run diagnostic tests, and
to monitor operation of the vehicle’s emissions-related components
or systems to ensure they are operating correctly and within the
vehicle’s manufacturer specifications. Currently, up to fifteen
Monitors are used in OBD2 systems. Additional Monitors will be
added as the OBD2 system is further developed.
Not all vehicles support all fifteen Monitors.
Enabling Criteria - Each Monitor is designed to test
and monitor the operation of a specific part of the vehicle’s emissions
system (EGR system, oxygen sensor, catalytic converter, etc.). A
specific set of “conditions” or “driving procedures” must be met before
the computer can command a Monitor to run tests on its related
system. These “conditions” are known as “Enabling Criteria.” The
requirements and procedures vary for each Monitor. Some Monitors
only require the ignition key to be turned “On” for them to run and
complete their diagnostic testing. Others may require a set of complex
procedures, such as starting the vehicle when cold, bringing it to
operating temperature, and driving the vehicle under specific
conditions before the Monitor can run and complete its diagnostic
testing.
Monitor Has/Has Not Run - The terms “Monitor has run” or
“Monitor has not run” are used throughout this manual. “Monitor
has run,” means the PCM has commanded a particular Monitor to
perform the required diagnostic testing on a system to ensure the
system is operating correctly (within factory specifications). The term
“Monitor has not run” means the PCM has not yet commanded a
particular Monitor to perform diagnostic testing on its associated part
of the emissions system.
Trip - A Trip for a particular Monitor requires that the vehicle is
being driven in such a way that all the required “Enabling Criteria”
for the Monitor to run and complete its diagnostic testing are met.
The “Trip Drive Cycle” for a particular Monitor begins when the
ignition key is turned “On.” It is successfully completed when all the
“Enabling Criteria” for the Monitor to run and complete its diagnostic
testing are met by the time the ignition key is turned “Off.” Since
each of the fifteen monitors is designed to run diagnostics and
testing on a different part of the engine or emissions system, the
“Trip Drive Cycle” needed for each individual Monitor to run and
complete varies.
7
Onboard Diagnostics
DIAGNOSTIC TROUBLE CODES (DTCs)
8
Onboard Diagnostics
DIAGNOSTIC TROUBLE CODES (DTCs)
Generic DTCs are codes that are used by all vehicle manu-
facturers. The standards for generic DTCs, as well as their
definitions, are set by the Society of Automotive Engineers (SAE).
Manufacturer-Specific DTCs are codes that are controlled by the
vehicle manufacturers. The Federal Government does not require
vehicle manufacturers to go beyond the standardized generic
DTCs in order to comply with the new OBD2 emissions standards.
However, manufacturers are free to expand beyond the
standardized codes to make their systems easier to diagnose.
The 3rd character is a letter or a numeric digit (0 thru 9, A thru F). It
identifies the specific system or sub-system where the problem is
located.
The 4th and 5th characters are letters or numeric digits (0 thru 9, A
thru F). They identify the section of the system that is malfunctioning.
B - Body P0201
C - Chassis
P - Powertrain
U - Network
0 - Generic
1 - Manufacturer Specific
2 - Generic ("P" Codes) and Manufacturer
Specific ("B", "C" and "U" Codes)
3 - Includes both Generic and Manufacturer
Specific Codes
9
Onboard Diagnostics
DIAGNOSTIC TROUBLE CODES (DTCs)
10
Onboard Diagnostics
OBD2 MONITORS
If the conditions that caused the MIL to light are no longer present
for the next three trips in a row, the computer automatically turns the
MIL “Off” if no other emissions-related faults are present. However,
the DTCs remain in the computer’s memory as a history code for 40
warm-up cycles (80 warm-up cycles for fuel and misfire faults). The
DTCs are automatically erased if the fault that caused them to be
set is not detected again during that period.
Misfire and fuel system faults require three trips with “similar
conditions” before the MIL is turned “Off.” These are trips where the
engine load, RPM and temperature are similar to the conditions
present when the fault was first found.
After the MIL has been turned off, DTCs and Freeze Frame
data stay in the computer’s memory.
Erasing the DTCs from the computer’s memory can also turn off the
MIL. See ERASING DIAGNOSTIC TROUBLE CODES (DTCs) on
page 20, before erasing codes from the computer’s memory. If a
Diagnostic Tool or Code Reader is used to erase the codes, Freeze
Frame data will also be erased.
OBD2 MONITORS
Currently, fifteen Monitors are supported by OBD2 systems. Additional
monitors may be added as a result of Government regulations as the
OBD2 system grows and matures. Not all vehicles support all fifteen
Monitors. Additionally, some Monitors are supported by “spark ignition”
vehicles only, while others are supported by “compression ignition”
vehicles only.
Monitor operation is either “Continuous” or “Non-Continuous,”
depending on the specific monitor.
Continuous Monitors
Three of these Monitors are designed to constantly monitor their
associated components and/or systems for proper operation.
Continuous Monitors run constantly when the engine is running. The
Continuous Monitors are:
Comprehensive Component Monitor (CCM)
Misfire Monitor
Fuel System Monitor
Non-Continuous Monitors
11
Onboard Diagnostics
OBD2 MONITORS
The table below lists current OBD2 Monitors, and indicates the following
for each Monitor:
A. Monitor Type (how often does the Monitor run; Continuous or
Once per trip)
B. Number of trips needed, with a fault present, to set a pending DTC
C. Number of consecutive trips needed, with a fault present, to
command the MIL “On” and store a DTC
D. Number of trips needed, with no faults present, to erase a Pending
DTC
E. Number and type of trips or drive cycles needed, with no faults
present, to turn off the MIL
F. Number of warm-up periods needed to erase the DTC from the
computer’s memory after the MIL is turned off
12
Onboard Diagnostics
OBD2 MONITORS
Name of
Monitor A B C D E F
Comprehensive
Continuous 1 2 1 3 40
Component Monitor
Misfire Monitor 3 - similar
Continuous 1 2 1 80
(Type 1 and 3) conditions
Misfire Monitor 3 - similar
Continuous 1 80
(Type 2) conditions
Fuel System Monitor 3 - similar
Continuous 1 1 or 2 1 80
conditions
Catalytic Converter Once per
1 2 1 3 trips 40
Monitor trip
Oxygen Sensor Once per
1 2 1 3 trips 40
Monitor trip
Oxygen Sensor Once per
1 2 1 3 trips 40
Heater Monitor trip
Exhaust Gas
Once per
Recirculation (EGR) 1 2 1 3 trips 40
trip
Monitor
Evaporative
Once per
Emissions Controls 1 2 1 3 trips 40
trip
Monitor
Secondary Air Once per
1 2 1 3 trips 40
System (AIR) Monitor trip
NMHC Monitor Once per
1 2 1 3 trips 40
trip
NOx Adsorber Once per
1 2 1 3 trips 40
Monitor trip
Boost Pressure Once per
1 2 1 3 trips 40
System Monitor trip
Exhaust Gas Sensor Once per
1 2 1 3 trips 40
Monitor trip
PM Filter Monitor Once per
1 2 1 3 trips 40
trip
13
Preparation for Testing
BEFORE YOU BEGIN
14
Using the Code Reader
CODE RETRIEVAL PROCEDURE
15
Using the Code Reader
CODE RETRIEVAL PROCEDURE
16
Using the Code Reader
CODE RETRIEVAL PROCEDURE
The green, yellow and red LEDs are used (with the LCD
display) as visual aids to make it easier to determine
engine system conditions.
17
Using the Code Reader
CODE RETRIEVAL PROCEDURE
18
Using the Code Reader
CODE RETRIEVAL PROCEDURE
19
Using the Code Reader
ERASING DIAGNOSTIC TROUBLE CODES (DTCs)
If DTC’s were retrieved and you are going to perform the repairs
yourself, proceed by consulting the Vehicle’s Service Repair
Manual for testing instructions, testing procedures, and flow
charts related to retrieved code(s).
20
Using the Code Reader
ERASING DIAGNOSTIC TROUBLE CODES (DTCs)
21
Additional Functions
THE MAIN MENU - EVAP TEST
22
Additional Functions
VIEWING VEHICLE INFORMATION
23
Additional Functions
VIEWING VEHICLE INFORMATION
24
Additional Functions
VIEWING VEHICLE INFORMATION
EVAP TEST
The EVAP Test function lets you initiate a leak test for the vehicle's
EVAP system.
The Code Reader does not perform the leak test, but signals
to vehicle's on-board computer to initiate the test. The vehicle
manufacturer determines the criteria and method for stopping
the test once it has been started. BEFORE using the EVAP
Test function, refer to the vehicle's service repair manual to
determine the procedures necessary to stop the test.
1. From the Main Menu, use the DOWN
button as necessary, to highlight
EVAP Test, then press the ENTER
button.
2. A "One moment please..." message
displays while the request is sent to the
vehicle's on-board computer.
Some vehicle manufacturers do not
allow Code Reader’s or other
external devices to control vehicle
systems. If the EVAP Test is not
supported by the vehicle under test,
an advisory message shows on the
Code Reader's display. Press the
ENTER button to return to the
Main Menu.
25
Additional Functions
EVAP TEST
26
Additional Functions
ADJUSTMENTS, SETTINGS AND LANGUAGE
2. When you have finished viewing the LED definitions, press the
ENTER button to return to the Main Menu.
27
Additional Functions
ADJUSTMENTS, SETTINGS AND LANGUAGE
28
Additional Functions
OBD UPDATER / TROUBLESHOOTING
Press and hold the ENTER button to exit the Menu mode.
OBD UPDATER
Use these procedures to verify your tool’s firmware is current, and to
perform firmware updates when available.
1. Visit www ZurichDiagnostics.com, download and install the latest
version of OBD Updater.
2. Connect your tool to your PC using a Mini USB cable and run the
OBD Updater software.
3. Follow the on-screen prompts to install the firmware update.
If no update is available, the software displays the message
“No updates available.”
TROUBLESHOOTING
Q: Why can I not erase some codes?
A: Unlike other codes which can be removed from the vehicle’s
control module, PERMANENT codes cannot. This holds true
regardless of the tool being used or color of the status LED display.
PERMANENT codes will automatically erase when the control
module no longer detects the fault that originally caused the code.
29
Warranty and Servicing
This warranty gives you specific legal rights and you may also have
other rights which vary from state to state.
SERVICE PROCEDURES
If you have any questions, require product use or general information
please contact:
Harbor Freight Technical Support – 888-866-5797
Web: www.zurichdiagnostics.com
30
63808