Welcome to AfterSalesTraining Preface

Welcome to AfterSalesTraining Preface
MG Rover Group are constantly seeking ways to improve the specification and design of its vehicles and alterations take place continually. Whilst every effort is made to produce up to date literature, this training workbook should not be regarded as an infallible guide to current specification, nor does it constitute an offer for the fitment of any particular system or component. All rights reserved. no part of this Workbook may be reproduced without prior permission of – MG Rover Group Ltd PO Box 41 Lickey Road Longbridge Birmingham B31 2TB England This Training Workbook is designed to support AfterSalesTraining courses and is issued as part of the training programme. It may be used to compliment other literature available but the Repair Operations Manual should always be consulted prior to servicing or repair work. © MG ROVER GROUP LIMITED – July 2002 AfterSalesTraining R 321 Introduction to T4 Diagnostics

R 321 Introduction to T4 Diagnostics

Contents Page T4 Intro to Diagnostics Contents History of TESTBOOK 05
Hand Held Tester 10 Practical Exercise 1 14 Microcheck 15 Toolbox 20 Printers 24 Using T4 26 Cabling 37 Discs 45 System Diagnostics 47 Central Coding Key 54 Practical Exercise 2 58 Configuration 59 RAVE 62 Problems 67 Wiring Diagrams 70 Practical Exercise 3 73 Practical Exercise 4 74 Practical Exercise 5 75 Practical Exercise 6 76 Practical Exercise 7 77 Notes Pages 78 Contents Page R 321 Introduction to T4 Diagnostics

R 321 Introduction to T4 Diagnostics

History of TESTBOOK TESTBOOK 1 Launched in Feb 1993
Capacitive Touch screen 120 Mbytes hard disk CD ROM Operates on Windows 3.1 History of TESTBOOK As technology has evolved in vehicle electronics, the need for more complex diagnostic test equipment is essential for the interrogation and diagnosis of the electrical systems to be found on modern vehicles. TESTBOOK is a diagnostic information system, developed by Rover Group in collaboration with Hewlett Packard. TESTBOOK 1 was launched in February 1993 and world wide roll out was completed by June This was launched into the dealer network to replace Microcheck and Cobest. TESTBOOK 1 specification is as follows : 486SX 25MHz processor 4 Mbytes RAM (updated to 20 Mbytes during 1995) VGA capacitive touch screen (640 x 480 pixels), 32 grey scale 120 Mbytes hard disk CD-ROM MS DOS 5/Windows 3.1 (updated to Win 95 in October 1997) R 321 Introduction to T4 Diagnostics

History of TESTBOOK TESTBOOK 2 Launched in July 1997
Resistive touch screen 14 Gbyte hard disk CD ROM Windows 95 R 321 Introduction to T4 Diagnostics

History of TESTBOOK Hewlett Packard withdrew from diagnostics in 2001
TESTBOOK is a registered trade mark of HP MG Rover Group required new supplier of diagnostic equipment OMITEC developed new hardware To replace TESTBOOK History TESTBOOK is an instrument which enables the diagnostic technician to locate and repair faults on complex modern vehicles. TESTBOOK can interrogate ECM`s and retrieve fault codes, test system components, guide the technician through a thorough fault explorer, reset warning lights, and clear fault codes.TESTBOOK can also be used to display Information. TESTBOOK is a registered trade mark of Hewlett Packard. In 2001 HP decided to withdraw from manufacturing diagnostic equipment. MG Rover therefore had to locate a new source to supply diagnostic equipment and software to support all of its range of vehicles, both past, present and future. OMITEC were appointed by MG Rover to provide diagnostics and software for the dealer network and to produce an all new diagnostic tester. OMITEC had past links with Rover Group as they had manufactured the MICROCHECK hand held tester previously used in dealerships. As TESTBOOK was a registered trademark owned by Hewlett Packard, MG Rover were unable to continue using it and a new name and logo were required. This new hardware was developed with a new name and logo – T4 R 321 Introduction to T4 Diagnostics

Introduction toT4 Rolled out in 2001 Available as : Full Kit
T4 Specifications T4 Was rolled out to the dealer network in the summer of 2001at various centres around the U.K . It is available either as a full kit or an upgrade version, which utilises the old TestBook trolley. The T4 diagnostic system utilises a laptop style computer. The main system processor for the T4 laptop PC is a Pentium III, 700 MHz microprocessor with 128 MB of system RAM. The processor also features SpeedStep technology which enables the user the option of choosing between two processor performance modes: 700 MHz when the laptop is connected to the main AC power supply to provide high performance processing. 550 MHz when the laptop PC is operating using its internal battery. This allows a better balance between processor performance and extended life. Internal memory is expandible to 512 MB using 100MHz SDRAM and 2 memory sockets on the system board. The internal 10GB hard disk supports the operating system, applications and data. The 24X/10X variable CD ROM drive allows the dealership technician to upgrade the software. T4 contains an internal rechargeable lithium-Ion ( 8 cell ) battery which allows it to operate away from the main AC power supply for short periods of time. The battery has an express charge feature which enables battery recharge in about an hour. R 321 Introduction to T4 Diagnostics

Introduction toT4 - Why dealerships require T4
T4 Improves customer retention through “right first time repairs”. T4 Enhances your credibility through technical proficiency. T4 It is essential that all dealerships have T4 in their workshops to enable customer retention through right first time repairs. T4 gives the dealerships the edge over other garages in their area and enhances its credibility through technical proficiency. Word of mouth is a good form of positive advertising and this only comes from customer satisfaction. T4 is invaluable for retrieving fault codes and for diagnosing, fixing and sub sequentially clearing those codes. However T4 also gives the technician the opportunity to validate the quality of used MG Rover vehicles by way of the “ System Test “. This is the latest model in a series of advanced vehicle diagnostic tools. The TestBook™ programme has successfully applied the most recent advances in Information Technology to provide easy to use diagnostic tools for the rapid analysis, servicing and repair of a sophisticated range of modern day vehicles. T4 is a portable computer-based diagnostic tool designed to assist a service technician to perform the diagnostic analyses of electrical systems, engine management systems, transmission systems and a range of other electronic based control systems utilised in automotive vehicles. T4 offers the ability via a vehicle "system test” to validate the quality of used vehicles. R 321 Introduction to T4 Diagnostics

T4 HHT Introduction toT4 T 4 Introduction to - Hand Held Tester
AfterSales Training T Introduction to 4 - Hand Held Tester T4 Used to programme Plips on current Lucas 5AS systems. Lead no.s : ? MG Rover Ireland RAVE Intro to T4 Richard Hales Hand Held Tester The T4 Hand Held Tester is a diagnostic tool that provides a quick and accurate means of displaying diagnostic information. It is programmed with the T4 laptop PC and with software provided on regularly updated CD-ROM’s. One of the primary features of the new T4 diagnostic system is the inclusion of the T4 Hand Held Tester which allows the technician to interrogate any vehicle equipped with a J 1962 Diagnostic connector. The Hand Held Tester provides a convenient, easy to use, portable solution for many diagnostic applications encountered in an automotive technician`s daily routine. The T4 Hand Held Tester is powered directly from a vehicle`s J1962 diagnostic connector, and operates as a stand alone unit to provide generic scan-tool functionality as well as fault code retrieval / diagnosis, live data and basic configuration functions for a wide range of systems. New and revised programs can be quickly and easily down loaded to the T4 Hand Held Tester. The new software code Is electronically transferred from the T4 laptop PC via an Ethernet connection to the Vehicle Communication Serial Interface (VCSI) on the dedicated diagnostic port and into the T4 hand held tester via the printed circuit board which interfaces between the T4 hand held tester and its diagnostic port. HHT R 321 Introduction to T4 Diagnostics

Introduction toT4 - Hand Held Tester
AfterSales Training T Introduction to 4 - Hand Held Tester Also used to interrogate EMS & EOBD data on all ECD 3 Used to reprogramme PLIPS on Rover 25 & 45 Lucas 5AS systems. Lead no : ? Also used to interrogate EMS EOBD on all ECD 3 vehicles. vehicles. A generic scan tool. Lead no : ? MG Rover Ireland RAVE Intro to T4 Richard Hales Hand Held Tester (HHT) The Hand Held Tester was originally available to support Plip reprogramming and to be a generic EOBD scan-tool only. However the provision for more diagnostics on the Hand Held Tester are planned for future projects. For Plip reprogramming use lead numbers: For EOBD scan-tool use lead number: R 321 Introduction to T4 Diagnostics

MAC Address: Address of T4 docking station IP Address: ? Hand Held Tester The T4 Hand Held Tester display screen uses a backlit LCD display with four rows of twenty characters. The “MAC” address is the code of the T4 that it is linked to. I.e. It is possible to have more than one HHT in the dealership working from the same T4, in this case they would all have the same MAC address on them. Note: It is very important that the “IP” address is not changed by unauthorised personal, as this could result in communication errors. The IP address for MG Rover Hand Held Tester is : R 321 Introduction to T4 Diagnostics

MAC Address: Address of T4 docking station IP Address: ? Hand Held Tester Keypad The table above details the T4 Hand Held Tester keypad and its functionality with respect to its on screen display and program functionality. Note: Each key of the T4 Hand Held Tester may have several functions, depending on the diagnostic procedure being implemented. R 321 Introduction to T4 Diagnostics

Hand Held Tester Exercise
Practical Exercise 1 Using the Hand Held Tester 1. Programme a new Lucas 5AS plip to a vehicle. Record the T4 cable numbers required to carry out this task below. Question Up to how many Plips can you programme to a vehicle? 2. Check the Engine management for any “P” codes using the Hand Held Tester and record them below. Locate the faults, repair and clear the faults. Record the T4 cable numbers required to carry out this task. Introduction toT4 - Hand Held Tester Hand Held Tester Exercise R 321 Introduction to T4 Diagnostics

Introduction toT4 - Microcheck
TIM Unit : Technical Interface Microcheck. Uses ports 3 and 4 to communicate with legacy vehicles. For existing Microcheck : Must use old NO.1 comms. Lead DTC 0007A VCSI DTC 0006A Technical Interface MICROCHECK The Technical Interface for MICROCHECK (TIM) unit is located on the rear of the T4 trolley. It allows T4 to emulate MICROCHECK. The TIM unit utilises ports 3 & 4 to communicate with MG Rover legacy vehicles through various serial diagnostic ports. Port 3 is used for communication to the vehicle via the blue banded number 1 communication lead (DTC 0007A) and the vehicle communication Serial Interface (known as the “ Brick “ DTC 0006A). Also required is the serial lead for the particular application i.e. DTC 0017A for use on ABS 2E systems. The cabling guide will give full details of application and connections to ensure that the correct cables are fitted to the vehicle being diagnosed. Note: Ensure that there are no cables connected to port 3 whilst the Microcheck is loading its programme. Failure to observe this warning will result in the operator damaging the TIM unit. Port 4 is used to communicate to the vehicle via MICROLINK (SMD 4073) using the white banded number 4 leads (DTC 0010A & DTC 0011A). Also required is the interface lead for the particular application. i.e. SMD 4073/5 for use with Rover 827 Electronic Automatic Transmission. R 321 Introduction to T4 Diagnostics

To select the Microcheck feature using T4 carry out the following steps : At the welcome screen select Toolbox. This will then cause the basic Toolbox section to be displayed. From the available options select MICROCHECK. The display will show the connection procedure. Press continue and the screen will show the system selection screen. At the system selection screen select the system you wish to test. After a period of 60 seconds and then a further 3 seconds loading time the MICROCHECK screen will be displayed. When the MICROCHECK screen is displayed using T4, its physical appearance will be very similar to a conventional hand held MICROCHECK screen. Existing TIM Unit R 321 Introduction to T4 Diagnostics

TIM Unit : Technical Interface Microcheck. Uses ports 3 and 4 to communicate with legacy vehicles. For new T4 Microcheck : Must use new communication blue Lead : ? T4 MICROCHECK When using MICROCHECK from a full T4 kit the unit has some internal differences. On the front of the unit is printed “ For T4 system use only “. and “use DTC 4007B cable “. This informs the user that the MICROCHECK unit must be correctly connected using the appropriate cable. The correct number 1 blue communication lead for the new Microcheck is : Note: If the incorrect cable is used, it will lead to communication failure. R 321 Introduction to T4 Diagnostics

For T4 System Use Only R 321 Introduction to T4 Diagnostics

Microcheck System Selection Screen
Introduction toT4 - Microcheck Microcheck System Selection Screen MICROCHECK Diagnostics The above screen displays the full diagnostic capability if MICROCHECK. To carry out these diagnostics for legacy vehicles (pre 1995, prior to the introduction of the J 1962 Diagnostic connector) using a serial lead connection or serial interface. R 321 Introduction to T4 Diagnostics

Introduction toT4 - Toolbox
The Toolbox module provides the T4 user with access to various measurement tools, these include: Voltmeter DC Voltmeter AC Ammeter Ohmmeter Vacuum, measured in kilopascals (kPa) Pressure, measured in Bar Also available through Toolbox is “MICROCHECK”, provided that the Microcheck software disc (DRX 003) has been inserted at the welcome screen. Note: Crypton and Bear engine analysers previously used on TESTBOOK 1, will not operate on T4. R 321 Introduction to T4 Diagnostics

Testbook Inductive Amp Clamp Range 0 – 500 Amps No Need to Break into Circuit Arrow must Face Current Flow T4 Amps Clamp An inductive type Ammeter is designed to clamp around a wire that is to be tested. It measures current by means of the magnetic flux generated around the conductor. The amount of magnetic flux generated will be proportional to the amount of current flowing through the conductor. T4 is equipped with an inductive Ammeter in the form of its “Amps Clamp”. The clamp is used to measure current up to 500 Amps. This capability provides considerable benefits over the Ammeter facility incorporated into most multimeters, which are often limited to the amount of current that they are able to measure. Inductive Ammeters also provide an additional benefit over conventional ammeters, as they do not need to be connected in series with the circuit being measured. Therefore, it is not necessary to disconnect any part of the circuit in order to use the ammeter and it can simply be clamped around the wire of the circuit being measured. The T4 “Amps clamp”, is usually positioned around the negative battery terminal as close to the terminal as possible with the arrow pointing towards the negative battery terminal. To connect the “Amps clamp” (part no. DTT 0002A) to T4, use number 2 grey lead (part no. DTC 0013A) and plug into the docking station number 2 port. From the main menu on the system selection screen, select the “Toolbox” icon and then the Ammeter icon. R 321 Introduction to T4 Diagnostics

Roving Probes The roving probes are used by the operator to take measurements of Volts or Ohms whilst in fault explorer or directly from “Toolbox”. The roving probes (part number ) have a grey coloured band with a number 2 around the end of the lead. This lead connects directly into port 2 of the T4 docking station. There is an adapter kit that plugs on the end of the red and black leads (part number DTC 0036A) to allow access to all connectors found on the vehicle. Note: Before using these leads, a calibration window automatically appears requesting the operator to hold together and “ press done”. Once completed the probes are calibrated and ready for use. Roving Probes Probes Kit R 321 Introduction to T4 Diagnostics

Pressure/Vacuum Transducer Pressure/Vacuum Connector Kit
Introduction toT4 - Toolbox Pressure/Vacuum Transducer This tool is accessed from the “Toolbox” menu on T4. It gives the operator the choice of testing the vehicle for pressure or vacuum. Pressure readings will be displayed in “BAR” and vacuum in “KILO PASCALS”. Examples of use are: Measuring fuel pressure Measuring manifold pressure The “Transducer” (part number DTT 0001A) plugs either directly into port 2 of the docking station, or if longer cabling is required into the grey number 2 cable (part number DTC 0013A). The connector kit is designed to accommodate various tests, the part numbers are: DTC 0026A Pressure fitting ( Schrader valve ) DTC 0016A Vacuum fitting ( pipes & valve ) Adaptor kit ( “T” pieces & different size pipe ) Pressure/Vacuum Transducer Pressure/Vacuum Connector Kit R 321 Introduction to T4 Diagnostics

Printer screen Introduction toT4 - Microcheck
Hewlett Packard DeskJet Portable The printer used for the original TESTBOOK 1 is utilised on all T4 upgrades and is a Hewlett Packard DeskJet portable. The online and power LED`s must be lit before printing a page. Printer Buttons & LED`s Press the Settings button to move the print carriage to the print cartridge loading position to change print cartridges (change pen function). Press the Settings button again to return the print carriage to its home position. R 321 Introduction to T4 Diagnostics

Printer screen Introduction toT4 - Microcheck HP DeskJet 350
The printer used in conjunction with T4 is the Hewlett Packard DeskJet 350. The printer allows the operator to choose inkjet print cartridges (either black or colour). Both cartridges are supplied with a full T4 kit, with a black inkjet cartridge recommended for diagnostic printouts and colour when printing from RAVE. The printer is very simple to use with only 3 buttons required for operation.The right hand button switches the printer on, the middle button ejects the paper/feeder and the left hand button allows the operator to change the inkjet print cartridge. The printer is powered via the main T4 master switch, a transformer supplies 10.6 volts to the unit. It communicates via a printer lead which connects directly to the T4 parallel port. Tips for Printing ddon't leave paper in the feed tray, this becomes damp and hinders the performance. Allow the printer to print the page required,before attempting to print another. Only load 5 sheets in the tray at a time. Note If printing problems occur, a fix disc is available from the Helpdesk. R 321 Introduction to T4 Diagnostics

Introduction toT4 To Switch T4 on push button 1 and hold for 2 Seconds. T4 Uses a Dell PC Laptop. Pentium III, 700MHz Microprocessor with 128MB of RAM Powering T4 T4 is normally powered from a main AC power supply point. T4 contains its own power supply transformer to convert the main AC power supply to the correct voltage levels. When T4 is powered from the AC power supply, a green indicator light emitting diode (LED) is illuminated on the front panel of the laptop PC and on the front of the T4 Hand Held Tester Diagnostic Port to indicate that T4 is operating using “External Power”. The T4 laptop PC also contains an internal lithium-ion battery that prevents the unit from shutting off for short periods of time when you need to disconnect it from the external power supply. When T4 is powered from its internal battery supply, an amber LED is illuminated on the front panel of the laptop PC and on the front edge of the T4 Hand Held Tester Diagnostic Port to indicate that the T4 is operating using “Internal Power”. To switch T4 on, press the “ON/OFF” button on the front panel, which is located beneath the display screen. IMPORTANT: To turn T4 off, first return to the “Welcome Screen”, then select the “Shutdown” button. T4 will shutdown automatically after the “shutdown” button is pressed. CAUTION: To avoid the risk of corrupting T4 data files, always follow the recommended shutdown procedure. R 321 Introduction to T4 Diagnostics

Introduction toT4 Diagnostic System 4.04 Welcome to T4 Main Menu
Turning on T4. When T4 is switched ON, a number of self-test and set-up screens will be automatically displayed on the screen. The first T4 screen you can use is the “Welcome to T4 Main Menu” screen. Select the Diagnostic System key to proceed. Note DO NOT select the configuration button on the “Welcome to T4 Main Menu” screen unless specifically instructed to do so by the Helpdesk. Do not confuse this button with the configuration button on the Diagnostic System Control Panel, they have entirely different functions. Additional icons for RAVE and HHT will appear on this screen whilst the relevant CD is in the drive. The top icon displays the RDS software version number which is currently 4.04. Click on this icon to progress into T4 diagnostics. R 321 Introduction to T4 Diagnostics

Introduction toT4 Start Screen
At the start screen the diagnostic technician can see the manufacturer marques icon (Rover/MG) and also the CD prefix number ( e.g.DRM0017U) in the viewing area. The release notes for the disc are available by clicking on the information icon in the viewing area. Note The CD must only be removed and inserted at this screen. R 321 Introduction to T4 Diagnostics

Introduction toT4 1 Title area 2 View area 3 Control panel
Screen Format Most screens displayed on the T4 display screen have three main sections: • TITLE AREA (top band) • VIEW AREA (middle band) • CONTROL PANEL (bottom band) Title Area - this is the top portion of the screen, and includes the Screen Number displayed in the top left-hand corner, and the Screen Title displayed in the top middle of the display screen. The software version number is displayed in the bottom right corner of the screen. Note Screen Numbers are needed to identify screens if you need to contact the T4 Helpdesk. View Area - is the middle portion of the screen, the technical information and other documents are displayed in this section. Control Panel - is the bottom part of the display screen and contains up to eight option buttons. The fifth button from the left is always the “HELP” button. Selecting HELP at any time provides an on-line description of the current screen. If there is no special information available for a particular screen, a standard RDS help message will appear on the display screen. R 321 Introduction to T4 Diagnostics

Introduction toT4 Not available on latest CD - ROM`s.
Icon for diagnostic routines to guide you to a technical solution. Volt, Ohm and Amp meters, Pressure/Vacuum gauge and Microcheck. Key Functions Buttons Technical Information Provides service repair documents. To activate this function, the relevant Technical Information CD for the vehicle must be installed in the T4 CD-ROM drive. When a diagnostic CD is loaded in the CD-ROM drive, this button will be faded out. Latest CD releases contain diagnostics only, therefore this icon is seldom used. Diagnostic System T4 provides a range of diagnostic routines to guide you to a technical solution. Vehicle diagnostics CD must be loaded into the CD drive to activate this function. Toolbox The Toolbox provides various measurement and analysis tools for measuring vehicle parameters (e.g. Microcheck, Volt / Ohm / Amp and Vacuum/Pressure meters). Expert Toolbox Used to access the expert toolbox system for vehicle diagnostics. Note Expert Toolbox is no longer used with latest CD discs. Not used on latest CD - ROM`s. R 321 Introduction to T4 Diagnostics

Introduction toT4 Used to return to the welcome screen. T4 main menu.
Performs tests on T4 hardware and software. Control Panel Buttons Exit Used to return to the “Welcome to T4 Main Menu”. Integrity Test If there appears to be a problem with T4, this feature performs tests on some of T4’s hardware and software to make sure that its functionality is correct. TESTBOOK Tutorial Not currently active. Not currently active. R 321 Introduction to T4 Diagnostics

Introduction toT4 Provides help screens to provide the user with information always 5th button from the left. Facility to print form to be filled in and faxed to the help desk. T4 set up screen. Allows T4 to be customised with personal preferences and dealership information. Control Panel Buttons Help Provides Help screens to support the user with information about the various display meanings and vehicle diagnostics. Help Desk Automatically prints a copy of the Helpdesk Information sheet, with some fields already completed. Configuration Allows T4 to be customised with the end-user’s personal preferences and dealership information. R 321 Introduction to T4 Diagnostics

Introduction toT4 Configuration Password
After selecting the configuration icon from the diagnostics menu, enter the password if applicable. A suggestion would be to either use your corporate ID or not enter a password at all. This would prevent a lock out caused by dealership staff unaware of the correct password. If a lockout is experienced at this stage, a password can be obtained from the Helpdesk. R 321 Introduction to T4 Diagnostics

Introduction toT4 Configuration Screen Qwerty
Select this option to change between a conventional (QWERTY) keyboard or a keyboard based on alphabetical order. The keyboard will be automatically displayed whenever T4 requires an input, such as a VIN code entry. Size Not applicable on T4. Sound Enables the sound to be switched ON or OFF; a cross appears next to the speaker icon when the sound is switched OFF and a tick appears next to the speaker icon when the sound is switched ON - Not used on T4. Set Logging Level Use to enable the data logging feature. T4 activities can be recorded at different levels of detail. The pre-set value for this is “minimum” to prevent T4’s memory from being overloaded, and consequently slowing down the operation performance times. R 321 Introduction to T4 Diagnostics

Introduction toT4 Configuration Screen Enter Date and Time
Used to set the correct date and local time. CAUTION: Do not make adjustments without first consulting the Helpdesk.This facility allows a maximum of 2 days only to be corrected. Set Configuration Password Provides an option to install security codes to prevent unauthorised re-setting of T4 configurations. Align Touch Not used on T4. Hard Disk Scan Used to Scan and/or defrag the Hard Disk. This is recommended to be used once a week in order to keep the T4 operating to its full capacity. R 321 Introduction to T4 Diagnostics

Introduction toT4 Configuration Screen Enter Dealership Information
This facility enables the user to enter dealership information into the T4 memory. Selection of this option invokes six empty fields numbered from one to six, which relate to the following boxes on the Helpdesk Information Sheet: • Dealer Name • Corporate ID • Telephone Number • Fax Number • Contact 1 • T4 Serial / Model Number This information is used when T4 automatically prints a Helpdesk form. Keyboard Language Used to set the language version. Set Printer Type and Paper Do not adjust these settings unless changing a printer and/or instructed to do so by Helpdesk. Install RAVE Software Not currently used on T4. Note T4 will automatically detect when a RAVE CD is loaded in the CD-ROM drive and carry out an auto-run set-up. R 321 Introduction to T4 Diagnostics

Introduction toT4 - Cabling Guide
T4 docking station incorporates the Vehicle Communication Serial Interface (VCSI) DTC 4007B New blue No1 comms lead plugs into docking station port 1 for all diagnostics T4 Docking Station The Hand Held Tester and diagnostic ports are located on the T4 trolley. The new type docking station contains the Vehicle Communication Serial Interface (VCSI), therefore the need for the in line cable version of the VCSI (DTC 0006A) is no longer required. A brand new No. 1communications cable has been introduced, Part No. DTC 4007B. This lead uses 11pins where as the old No. 1lead (DTC 0007A) uses only 10 pins. Note It is imperative that this new lead is not connected to the old VCSI (brick), as pin out damage to the lead will result. The vehicle communication serial interface allows T4 to communicate with specified electronic control units (ECU`s) and other devices that follow the ISO 9141 standard. This international standard specifies the requirements for setting up the interchange of digital information between on-board ECU`s of road vehicles and diagnostic testers. Data is electronically transferred from the vehicle via the diagnostic cable into the VCSI in the docking station. This information is transferred to the T4 laptop via the dedicated Ethernet connection lead. No. 2 lead is still utilised by the Grey measurement lead (DTC 0013A). i.e. for use with Ammeter etc. DTC 0006A (BRICK) & DTC 0007A (OLD No1 LEAD) plugs into TIM unit (early type ) R 321 Introduction to T4 Diagnostics

J1962 Serial Leads (Diagnostic Socket) In 1995 European legislation led to all vehicles sharing a common type of serial communication port (or connector). The J1962 serial connector is a 16 pin diagnostic port. In order for T4 to communicate with all the diagnostics on MG Rover vehicles, coloured cables are utilised for selection of different derivatives and systems. Complete below the coloured leads and their applications: DTC 0060A DTC 0061A DTC 0062B DTC 0064A DTC 0065A R 321 Introduction to T4 Diagnostics

T4 lead Boxes B1 DTT 0002A (Amps clamp). B (probe kit). DTC 0036A (probe connectors). B3 DTC 0058A (adaptor). DTC 0060A (yellow). DTC 0061A (blue). DTC 0062B (green). DTC 0064A (grey). DTC 0065A (red). B4 DTC 0017A (R/800 CCU) DTC 0018A (ABS 2E) DTC 0019A (5AS) DTC 0055A (SPI) DTC 0056A (CDL) B5 DTC 0053A (EGR) DTC 0054A (MPI) B6 DTC 4013A (EOBD) Hand Held Tester DTC 4014A (PLIPS) C Vacuum Pressure Transducer Introduction toT4 - Cabling Guide T4 lead boxes R 321 Introduction to T4 Diagnostics

T4 lead Boxes A1 DTC 4007B (No 1 communications blue lead T4 only) A2 DTC 0013A (No 2 grey lead) A3 DTC 0010A (No 4 white lead) Microcheck DTC 0011A (Micro-link lead) DTC 0012A (Power lead box) A4 DTC 0006A (VCSI) DTC 0007A (Old No. 1 Lead) DTC 0008A (MEMS Lead) Introduction toT4 - Cabling Guide T4 lead boxes R 321 Introduction to T4 Diagnostics

Vehicle Identification Number PREFIX numbers for latest vehicle VIN`s 4th & 5th letters of VIN Number RF Rover 25 & MG ZR RT Rover 45 & MG ZS RJ Rover 75 & Tourer. MG ZT & ZT-T RD MG F & MG TF Vehicle Identification Numbers All MG Rover vehicles have VIN numbers which are used by T4 to identify the model of any vehicle. Below are the prefix numbers of the latest MG Rover models: RF Rover 25 and MG ZR RT Rover 45 and MG ZS RJ Rover 75 and Tourer. MG ZT and MG ZTT RD MG F and MG TF R 321 Introduction to T4 Diagnostics

Cabling Guide Introduction toT4 Cabling Guide Older models VIN prefix
VIN Prefix ( for legacy vehicles ). R 321 Introduction to T4 Diagnostics

Cabling Guide Introduction toT4 - Cabling Guide Cabling Guide R 321
Introduction to T4 Diagnostics

This example shows the cabling required between T4 and the vehicles serial diagnostic port. This cabling shown above would be used for diagnostics on MEMS MPI/SPI for Metro (VIN prefix XP) from 1994 model onwards. R 321 Introduction to T4 Diagnostics

Introduction toT4 – Discs
DJR _ _ _ _ diagnostic disc Rover 25, 45, 75 and Tourer (all model years). DRM _ _ _ _ _ diagnostic disc MG ZR, ZS, ZT, ZTT MG F and MG TF.(all model years). Diagnostic Discs T4 uses vehicle diagnostic and repair information, which is supplied on Compact Discs (CD`s). It is paramount that the correct type of disc and disc number is used for the application of the vehicle under test. Always use the latest CD for all diagnostics, unless otherwise directed by the Helpdesk. The pre fix for all Rover diagnostics is: DJR, The pre fix for all MG diagnostics is:DRM. The latest diagnostic discs are: Rover 25, 45, 75 and Tourer (all model years) : MG ZR, ZS, ZT, ZTT, MGF and MGTF (all model years): R 321 Introduction to T4 Diagnostics

Introduction toT4 – Discs
DRE _ _ _ _ diagnostics (Legacy models). DRX _ _ _ _ Microcheck (Legacy models). Diagnostic Discs The pre fix for all Legacy diagnostics is : DRE. And the pre fix for Microcheck diagnostics is : DRM. The latest Legacy disc is: The Microcheck disc is: Always remove the CD from the disk drive before moving the T4 laptop PC long distances. This is achieved by pressing the “eject” button on the CD drive or alternately press <Fn><F10> on the laptop keyboard when the welcome screen is shown on the T4 laptop display. Note T4 must must be displaying the welcome screen before the eject button on the CD drive will eject the CD. The eject button will not operate at any other screen, nor will it eject with T4 switched off. When the CD-ROM drive is active, the drive access light on the PC`s front panel will blink. Only have the latest CD`s in close proximity to your T4, store old CD`s in a safe place away from inadvertent use which could lead to configuration errors and communication problems. These discs could be required for use if requested by the T4 Helpdesk. R 321 Introduction to T4 Diagnostics

Introduction toT4 – System Diagnostics
Model Derivative Select vehicle model and derivative, then select continue. Model Derivative Selection After selecting Diagnostic System from the Welcome T4 Main Menu, T4 prompts the operator to enter the model and derivative information. Use the scroll bar to make your selection and click on continue to progress through the programme. Its important to note that you have inserted the correct brand and latest diagnostic CD into the drive previously. R 321 Introduction to T4 Diagnostics

Enter VIN: Key in the full Vehicle identification number Then select continue. Entering VIN Always key in the full vehicle identification number, this ensures that the vehicle is validated with the ECM`s on the vehicle. R 321 Introduction to T4 Diagnostics

Confirm vehicle information Confirm VIN Check that all the information displayed on the screen is correct for the vehicle and then select Continue. R 321 Introduction to T4 Diagnostics

AfterSales Training Introduction toT4 – System Diagnostics Introduction to T 4 – System Diagnostics MG Rover Ireland RAVE Intro to T4 Richard Hales System Diagnostics Icons displayed in the viewing area of the screen allows the operator to select the vehicle system to be diagnosed or interrogated. Some diagnostics communicate directly with the system ECM, i.e. (MEMS), whilst others perform what we call “signature analysis”, where by the T4 programme prompts the operator to switch systems on and then ask`s for a response on the outcome. This type of diagnostics is where the T4 cannot communicate directly with the system`s ECM, I.e. (wash/wipe). R 321 Introduction to T4 Diagnostics

System Diagnostic Menu After selecting the system to diagnose this standard screen is displayed, showing the following Icons : Fault Code Diagnostics Reads the fault codes from the selected ECU. If faults are stored, they can be investigated in turn by using “Fault Explorer” and rectified. You are then given the option to clear the fault codes or exit the diagnostic leaving the codes present. System Test Performs all the tests on the system in turn. Any faults found during these can be investigated in turn by using Fault Explorer and rectified. You are then given the option to clear the fault codes or exit the diagnostic leaving the codes present. Sub System Test Allows you to select individual diagnostics from the tests carried out in System Test. Any faults found during these can be investigated in turn by using “Fault Explorer”. You are then given the option to clear the fault codes or exit the diagnostic leaving the code present. R 321 Introduction to T4 Diagnostics

System Diagnostic Menu
Real Time Display Real time display shows live data from various components covered by the system under test. i.e. A MEMS system Coolant temperature Stepper motor position Note During normal operation with the vehicle stationery, the screen will display a road speed of less than 2 KPH. Touch the real time display to show more detail for that parameter. Force Outputs Allows you to force ECU outputs On/Off. Examples of these could be : Cooling fan speeds Warning lights Vehicle Maintenance Allows you to carry out maintenance tasks on the system currently being worked on. Examples of these are: Clear fault flags ECM checks and renewal R 321 Introduction to T4 Diagnostics

Vehicle Maintenance The ECM can be re-configured from this screen. In particular under the “ECM Checks and Renewal” Icon is where a system ECM must be replaced from. Note Engine management systems are only programmable once. You must not exchange ECM`s from vehicle to vehicle. This Icon allows you to carry out the following maintenance tasks. · Immobilisation Learn · Clear Fault Codes · ECU Type Information · Reset Closed Throttle Position · Adjust Throttle Stop Setting · ECM Checks and Renewal · Reset Fuelling Adaptions · Reset Flywheel Adaptions · Reset Idle Adaptions · Reset Adaptions for New Engine · Set Service Ignition Offset R 321 Introduction to T4 Diagnostics

Introduction to T4 - Central Coding Key
ZCS codes German for central coding key. The DNA blueprint of the vehicle. Consists of GM,SA & VN data. Central Coding Key The central key is information relating to the ECU's and systems fitted to the vehicle. It could be described as the DNA blueprint of the vehicle. T4 uses this information to establish the validity of the ECU’s and systems fitted to the vehicle and will only display the relevant system icons appropriate to the vehicle specification. Previously T4 was programmed to display all systems that could be fitted to the vehicle regardless of whether the system was actually fitted to the vehicle. R 321 Introduction to T4 Diagnostics

AfterSales Training Introduction to T4 - Central Coding Key Introduction to T 4 - Central Coding Key ZCS codes ZCS codes R75 : - ZCS held in 3 modules: MG Rover Ireland RAVE Intro to T4 Richard Hales Central Coding Key The central coding key is stored in three ECU`s on Rover 75,Tourer and MG ZT, MG ZTT derivatives. They are: 1 2 3 R 321 Introduction to T4 Diagnostics

AfterSales Training Introduction to T4 - Central Coding Key Introduction to T 4 - Central Coding Key ZCS codes ZCS codes R25/45 : - ZCS held in 2 modules: German for central coding key. The DNA blueprint of the vehicle. Consists of GM,SA & VN data. MG Rover Ireland RAVE Intro to T4 Richard Hales Central Coding Key The central coding key is stored in two ECM`s on Rover 25, Rover 45 and MG ZR, MGZS derivatives. They are : 1 2 Note There are no ZCS codes held in any ECM`s on MGF or MGTF vehicles. R 321 Introduction to T4 Diagnostics

Introduction toT4 - Central Coding Key
ZCS codes GM code = Model and derivative information. i.e. C SA code = What's fitted. i.e B9000 VN code = Computer check sum. i.e Central Coding Key The ZCS codes are made up of GM data, SA data and VN data. GM is the abbreviation for the German word “Grundmerkmal” which translated means “Ground Features”. This information informs T4 what the vehicle is, i.e. A Rover 45, 1.8ltr, K series, RHD, unleaded fuel and manual transmission. SA is the abbreviation for the German word “Sonderausstattung” which translated means “Special Equipment”.This information informs the T4 what`s fitted to the vehicle. i.e. Side air bags, Battery alarm, ABS, Air Conditioning, Cruise Control, ECD3 and 3 door variants. VN is the abbreviation for the German word “Versionsnummer” which translated means “Version Number”. Otherwise known as a computer check sum number. R 321 Introduction to T4 Diagnostics

Practical Exercise 2 Introduction toT4 - Central Coding Key
Using T4 obtain the vehicles ZCS code and the market programme. Use this worksheet to record the information on. Vehicle Details Vehicle Derivative Registration Number Chassis Number ZCS Code GM Number SA Number VN Number Vehicle Market Questions Which icon on T4 did you find the information under? List the T4 screen number of the ZCS details. Introduction toT4 - Central Coding Key Practical Exercise 2 R 321 Introduction to T4 Diagnostics

ZCS codes GM code = Model and derivative information. i.e. C SA code = What's fitted. i.e B9000 VN code = Computer check sum. i.e Diagnostic System Selection (Rover 25 & MG ZR) When configuring a Rover 25 or MG ZR, the above screen shows the icon to be selected. From this icon the programme will run through market programming as well as the Lucas 5AS configuration. This is a mandatory operation carried out at PDI. The vehicles central coding key information is accessed and displayed from the vehicle configuration icon. Note The PDI icon is only available from using disc DJR 0009 onwards. Transit mode icons are not currently active. R 321 Introduction to T4 Diagnostics

ZCS codes GM code = Model and derivative information. i.e. C SA code = What's fitted. i.e B9000 VN code = Computer check sum. i.e Diagnostic System Selection (Rover 45 & MG ZS) When configuring a Rover 45 or MG ZS, the above screen shows the icon to be selected. From this icon the programme will run through market programming as well as the Lucas 5AS configuration. This is a mandatory operation carried out at PDI. The vehicles central coding key information is also accessed and displayed from the vehicle configuration icon. Note The PDI icon is only available from using disc DJR 0009 onwards. Transit mode icons are not currently active. R 321 Introduction to T4 Diagnostics

ZCS codes GM code = Model and derivative information. i.e. C SA code = What's fitted. i.e B9000 VN code = Computer check sum. i.e Diagnostic System Selection (MG TF) When configuring a MG TF, the above screen shows the “PDI” icon to be selected. It can be seen that the “Configuration” icon is missing, this is due to the fact that MGF and MGTF have no central coding key. From the PDI icon the programme will run through market programming and Lucas 5AS configuration. This is a mandatory operation carried out at PDI. Note This icon is only available from disc DRM 0017 onwards, Previously market programming of the Lucas 5AS was carried out by selecting the Security Icon. R 321 Introduction to T4 Diagnostics

Introduction toT4 - RAVE
This stands for Rovers Advanced Viewing Environment. RAVE is a program for viewing technical information. The information contained within this program applies equally to all MG Rover Group products. Every vehicle model is supported with a suite of printed technical support literature. In the past, this information has been in paper based manuals. This totals approximately 3000 pages of printed material for each vehicle in the range! RAVE collects all this information, for every vehicle in the range and places it on a single CD-ROM. A CD-ROM can contain in excess of pages of technical information. RAVE can be viewed on any P.C with the minimum specification: Intel 486 DX2/66 or equivalent 16mb RAM 10mb Free disk space CD-Rom drive (4 x speed or better) SVGA Graphics adaptor (800 x 600 resolution with 256 colours) Windows 95 / 98, NT 4.0 operating system T4 satisfies all these requirements. R 321 Introduction to T4 Diagnostics

Rover Advanced Viewing Environment CD - ROM (READ ONLY MEMORY) Contains : Workshop manuals Overhaul manuals Electrical library Electrical circuit diagrams Owners handbook PDI & Maintenance sheets Accessory fitting instructions T4 Diagnostic system user manual RAVE The technical information typically consists of: Workshop manuals Overhaul manuals Electrical library Electrical circuit diagrams Owners handbook PDI & Maintenance sheets Accessory fitting instructions T4 diagnostic system user manual R 321 Introduction to T4 Diagnostics

EL Electrical Library Contains : Introduction Fuse details Earth points & headers Description & operation Connector applicability Connector details Rover Advanced Viewing Environment RAVE The ELECTRICAL LIBRARY is intended to assist in diagnosing electrical faults, and should be used in conjunction with the Electrical Circuit Diagrams. The ELECTRICAL LIBRARY is divided into the following sections. 1. INTRODUCTION – Includes Electrical Precautions, a list of Abbreviations and general information on how to use this document. 2. FUSE DETAILS – Provides details of location, rating in Amperes, and circuit(s) protected. 3. EARTH POINTS AND HEADERS – Provides details of earth points and earth headers, including a plan view of the vehicle to aid location. 4. DESCRIPTION AND OPERATION – Provides an explanation of how each of the systems operate. 5. CIRCUIT REFERENCE NUMBERS – Provides a list of circuit reference numbers against a model or feature to which they apply. 6. CONNECTOR DETAIL – Details of connectors including a location photograph, face view and pin-out table. Note Before starting electrical checks on the vehicle, ensure that relevant mechanical functions operate satisfactorily. R 321 Introduction to T4 Diagnostics

Introduction to T4 - RAVE
Cav : Pin location Col : Colour of wire CCT : Applicable to derivatives RAVE 1. Cav: The connector pin (cavity) number. 2. Col: The colour of wire populating the connector pin. 3. Cct: Identifies the model or feature which uses the wire. 'ALL' means applicable to all models in the range fitted with the feature or system in question. In instances where different models, features or systems require different colour wires to be fitted in a cavity, each instance of the cavity is included in the Pin-out table. Note Wires may not be fitted to all cavities R 321 Introduction to T4 Diagnostics

Introduction to T4 - RAVE
Rover Advanced Viewing Environment Wiring Diagrams Contains : Individual circuit diagrams for each model All in colour Facility to print RAVE Previous wiring diagrams, took the form of one black and white diagram for the whole of the vehicle on a single drawing. This was OK then, but as technology has evolved, and the vehicles electrical system is now very complex, there has been the need to split up the circuits in order to read them easily. RAVE has the facility for you to obtain a coloured print out of the individual circuit that you require in order to help diagnose the customers problem. R 321 Introduction to T4 Diagnostics

Introduction to T4 - Problem Solving
Delegate Exercise Question How would you proceed to solve a customers complaint of HRW inoperative on a Rover 45? Delegate Exercise Question How would you proceed to solve a customers complaint of heated rear window inoperative on their Rover 45 ? Using the space below, list the steps that you would take in order to solve the customers complaint: R 321 Introduction to T4 Diagnostics

Introduction to T4 - Problem Solving
HELPDESK Phone Fax Use form available by printing from T4. R 321 Introduction to T4 Diagnostics

No Comms Form Introduction to T4 - Problem Solving R 321

MG Rover Wiring Colours
Introduction to T4 - Wiring Diagrams MG Rover Wiring Colours B Black G Green K Pink LG Light Green N Brown O Orange P Purple R Red S Slate(grey) U Blue W White Y Yellow Wire Colour Codes The following list contains wire colour codes used on the vehicle harnesses. R 321 Introduction to T4 Diagnostics

Introduction to T4 - Wiring Diagrams

Practical Exercise 3 Practical Exercise 3
Using T4 work your way through the following faults as a group. Print off a copy of the relevant circuit diagram from RAVE before you proceed through the diagnostic. Please record your diagnostic path on this worksheet. MGTF EPAS inoperative Cooling fan inoperative Practical Exercise 3 R 321 Introduction to T4 Diagnostics

Using T4 work your way through the following faults as a group. Print off a copy of the relevant circuit diagram from RAVE before you proceed through the diagnostic. Please record your diagnostic path on this worksheet. Rover 45 Drivers window inoperative Fault on front wipers Practical Exercise 4 R 321 Introduction to T4 Diagnostics

Using T4 work your way through the following faults as a group. Print off a copy of the relevant circuit diagram from RAVE before you proceed through the diagnostic. Please record your diagnostic path on this worksheet. Rover 25 Engine will not start SRS light stays on Practical Exercise 5 R 321 Introduction to T4 Diagnostics

Using T4 work your way through the following faults as a group. Print off a copy of the relevant circuit diagram from RAVE before you proceed through the diagnostic. Please record your diagnostic path on this worksheet. MG ZR ABS light stays on Heated rear window inoperative Practical Exercise 6 R 321 Introduction to T4 Diagnostics

Using T4 carry out a “system test” of the 5AS alarm, check the trigger store and retrieve and record the key access code below : Vehicle derivative Vehicle VIN Result of system test Result of trigger store Key access code Practical Exercise 7 R 321 Introduction to T4 Diagnostics

AfterSalesTraining Notes Page R 321 Introduction to T4 Diagnostics

Welcome to AfterSalesTraining Preface

Similar presentations

Presentation on theme: "Welcome to AfterSalesTraining Preface"— Presentation transcript:

Similar presentations

About project

Feedback

Log in

Auth with social network:

Welcome to AfterSalesTraining Preface

Similar presentations

Presentation on theme: "Welcome to AfterSalesTraining Preface"— Presentation transcript:

Similar presentations

About project

Feedback