Download pdf - STUDENT INDUSTRIAL PROJECT REPORT_1.2

Muhamad Farith Bin Pauzi

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Mechanical Engineering

Industrial Internship Final Report (January 2014 – August 2014)

1

STUDENT INDUSTRIAL PROJECT REPORT

REVERSE-ENGINEERING OF AN ORIGINAL EQUIPMENT

MANUFACTURER (OEM) DIAGNOSTIC TESTER

ROBERT BOSCH SDN BHD

NAME : MUHAMAD FARITH BIN PAUZI

MATRIX ID : 14818

PROGRAMME : MECHANICAL ENGINEERING

DURATION : JANUARY 2014 – AUGUST 2014


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ACKNOWLEDGEMENT

The author would like to express immense gratitude to Mr. Lee Ping Kooi, Head of Department of

AA/SWA-TSS division for all the guidance, knowledge and useful advise that he has provided

throughout the 28 weeks of internship period in Robert Bosch Sdn. Bhd. Mr. Lee’s professionalism,

dedication and his spirit in Bosch is a great inspiration to the author.

The author would also like to thank his supervisor, Mr. Mogana Das, SD Technical Service officer for

providing the most of the technical knowledge and assistance throughout this internship. Mr. Mogana’s

unconditional guidance has taught the author about the part and parcel of the software development

process and its documentations. Furthermore his exceptional technical expertise in the automotive field is

truly helpful in making the author understands the nature and subsequently completing all the tasks.

Very special thanks to Mr. Charanjit, for providing unlimited support and information without hesitation

in many tasks. Mr. Charanjit’s supportive advice during internship increases the morale of the team to

work more on accomplishing task given. His expertise in automotive knowledge has been a very useful

input for the author in understanding the industry much better.

Besides that, the author would like to thank UTP supervisor, Dr Syed Ihtsham-ul-Haq Gilani. His advice

and guidance is valuable in ensuring the successful completion of the internship program in accordance

with guidelines drawn by UTP.

Last but not least, the author would like to thank his parents and family and friends for their moral and

financial support throughout the period of internship in Robert Bosch and also to express gratitude to

those who helped the author directly and indirectly to complete the Internship Program.


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TABLE OF CONTENTS

VERIFICATION STATEMENT……………………………………………………………………………………………………… 2

ACKNOWLEDGEMENT………………………………………………….............................................................. 3

TABLE OF CONTENTS……………………………………………………………………………………………………………….. 4

LIST OF FIGURES……………………………………………………………………………………………………………………….. 6

LIST OF TABLES…………………………………………………………………………………………………………………………. 7

BRIEF INTRODUCTION TO ROBERT BOSCH………………………………………………………………………………. 8

STUDENT INDUSTRIAL PROJECT REPORT

1. Abstract and Introduction...........................................................................................18

1.1. Objectives…………………………………….. ........................................ 20

1.2. Scope of Study ........................................................................................... 20

1.3. Problem Statement.....................................................................…………21

1.4. Relevancy of Project. ................................................................................. 22

2. Background and Literature Review.....................................................................…..23

3. Methadology .............................................................................................................. 27

4. Results and Discussion .............................................................................................. 37

5. Conclusion and Recommendation .............................................................................. 44

6. Safety Training and Value of Practical Experience ................................................... 45

6.1 Lesson Learnt and Experience Gained.......................................................48


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6.2. Leadership, Team Work and Individual Activities...................................49

6.3. Business Values, Ethics and Management Skills......................................50

6.4. Problems / Challenges Faced and Solutions..............................................51

7. References………………………………………………………………..................52

8. Appendices ................................................................................................................ 53


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LIST OF FIGURES

Figure 1: Bosch Automotive Products ………………………………… 11

Figure 2: Bosch Power Tools…............................................................. 11

Figure 3: Bosch Security Camera ….................................................... 11

Figure 4: Bosch Home Appliances ……………………………………..11

Figure 5: Robert Bosch Sdn Bhd ……….………………………….... 13

Figure 6: Directions to Robert Bosch Sdn …….……………………. 14

Figure 7: AA Division Board of Management.................................... 15

Figure 8: AA/SWA-TSS4 Organisation ............................................. 16

Figure 9: KTS 570 ….......................................................................... 19

Figure 10: Bosch KTS Competitors..........................……................... 23

Figure 11: System Difference of CAN and LIN …………................ 26

Figure 12: Reverse Engineering process Flow …………………....... 29

Figure 13: Tools used for Internship Project...................................... 32

Figure 14: 16-pin OBD Socket........................................................... 33

Figure 15: Location Of The 16-pin OBD Diagnostic Socket………….. 33

Figure 16: Schematic diagram of traces taking................................... 34

Figure 17: Connection to local cars with 16 pin OBD-socket............. 35


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Figure 18: Schematic diagram of simulation....................................... 36

Figure 19: Simulation connection........................................................ 37

Figure 20: Step 1 – Traces Taking....................................................... 38

Figure 21: Example of Traces (CAN-Line)......................................... 39

Figure 22: Step 2 – Simulation............................................................ 40

Figure 23: BDX Info............................................................................ 41

Figure 24: BDX Specification............................................................. 42

Figure 25: Bosch Values...................................................................... 43


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LIST OF TABLES

Table 1: Milestones of Bosch Automotive Products….………………............ 10

Table 2: Types of Car and Diesel Services…........................................... 13

Table 3: Bosch Safety Regulations………….............................……….. 46


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Brief Introduction to Robert Bosch

Robert Bosch GmbH Core Business

Robert Bosch GmbH, a German diversified technology-based corporation which produces large scale of

automotive and industrial products, such as household appliances, automotive component, power tools,

CCTV and security system. Bosch also explores the anti-lock braking system (ABS) industry, Electronic

Stability Programme (ESP) and has become a leader in specialized fields such as traction control systems

(TCS). Besides that, BOSCH provides cutting-edged technology as well. The most renowned news

among industries is the ‘Green Technology’ project – the use of renewable energy such as solar energy

and wind energy, in which BOSCH is looking forward to the future.

Types of Products

Bosch’s core products are mainly automotive components including brakes, controls, electrical drives,

electronics, fuel systems, generators, starter motors and steering systems. There are also industrial

products such as drives and controls, packaging technology and consumer goods. Not to forget building

products such as household appliances, power tools, security systems and thermo-technology.

Below are the milestones of Bosch automotive products.


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Year Product Description

1887 Low-voltage magneto for stationary internal combustion engines

1897 Installation of an ignition device in a motor vehicle

1902 Spark plugs and high-voltage magneto ignition system

1927 Fuel injection pumps for diesel engines

1951 Gasoline injection pumps for internal combustion engines

1957 Car transistor radios

1967 Jetronic injection system goes into series production

1974 Introduction of the ARI traffic information system

1976 Lambda sensors (oxygen sensors)

1978 ABS (antilock braking system)

1979 Motronic, a digital system to control gasoline injection and ignition

1986 Traction control system (TCS) and Electronic diesel control (EDC)

1989 Travel Pilot navigation system

1994 Diesel unit-injector system (UIS)

1995 Electronic stability program (ESP)

1996 VP44 high-pressure diesel-injection pump

1997 Common-rail high-pressure diesel direct-injection system


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2000 Adaptive cruise control (ACC) and DI Motronic gasoline system

2001 Electrohydraulic brake

2002 Electronic battery management (EBM)

2003 Third-generation common-rail system, with piezo in-line injectors

2004 Denoxtronic fuel-metering system for exhaust-gas treatment in commercial cars

2005 Night Vision on the basis of NIR (near-infrared)

2006 Bosch acquires Telex Communications, a maker of hearing aids, headsets and

audio equipment

2007 The Bosch Communications Systems business unit is created to manage the

brands and products of former Telex Communications

2008

Tata Nano, the $2,500 People’s Car powered by Bosch-designed engine is

unveiled at Auto Expo in New Delhi. Bosch plans to acquire majority stake in

Ersol photovoltaic.

2010 Bosch in e-mobility arena with new high performance electric drive for e-bikes

2011

Bosch Power Tools introduces new “Speed for Multi Construction” multi-

purpose hole saws

Bosch Packing Technology introduces Bosch’s new Intelligent Transport

System for a wide range of applications

Table 1: Milestones of BOSCH Automotive Products


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Figure 1: Bosch Automotive Products

Figure 2: Bosch Power Tools Figure 3: Bosch Security Camera

Figure 4: Bosch Home Appliances


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Types of Services

Bosch has more than 15000 car service workshops in more than 145 countries which is the largest

workshop organization in the world. With Bosch being the largest independent supplier worldwide for

original equipment for automotive manufacturers, high quality, affordable maintenance and repairs are

easily acquired. Then there is the Diesel service which provides all repairs and maintenance for diesel

systems. There is also Home Appliances service which provides warranty service and after-sales. Bosch

also provides Power Tools service and support for its own power tools industry. Trainings and also

Seminars are also offered and tailor made by Bosch for organizations and operations for maximum

efficiency.

Car Service Diesel Service

Inspection and oil service

Diagnosis and system tests for all mechanical Diesel

Systems

Maintenance and repairs Pump exchange programme

Mechanics and tires Component repair of conventional Diesel injection pumps

Electrical systems Maintenance and repair of the diesel technology

Petrol injection and Diesel

technology

Seasonal checks

Air conditioning

Car multimedia

Table 2: Types of Car and Diesel Service


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Robert Bosch Sdn Bhd.

Figure 5: Robert Bosch Sdn Bhd. in Petaling Jaya, Malaysia


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Figure 6: Directions to Robert Bosch

Robert Bosch Sdn. Bhd, formerly known as Robert Bosch (SEA) Pte. Ltd is located in Petaling Jaya,

Malaysia is a regional branch of BOSCH Group and it is responsible for trading of automotive original

equipment manufacturer (OEM) and aftermarket parts and also power tool equipments. Business has also

been expanded to other aspects since the launch of BOSCH security system and Bosch-Siemens home

appliances (BSH) to Malaysia market in 2003. In addition, there is an automotive training centre division

named technical service and support (TSS) which provides product training, gasoline and diesel training,

technical support and developing software for BOSCH diagnostic tester named KTS. The responsibility

of software development goes to the AA/SWA-TSS division.


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Software Development (AA/SWA-TSS4) Division

Board of management for AA-TSS Division

Figure 7: AA-TSS Division Board of Management


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The author is assigned to serve in Technical Service and Support (AA/SWA-TSS4) division throughout

his internship. This division is in charge of the research and development of BOSCH diagnostic tester

which named as KTS diagnostic tool for South West ASEAN market and also trainings for SIS to

customers and clients. Its responsibilities are:

i. Developing diagnostic software and analysis for the Bosch KTS diagnostic tool.

ii. Developing service information system (SIS),

iii. To guide and assist Bosch customer, wholesaler and IAM (Independent Aftermarket)

workshops


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Industrial Project Report

In this section, the author will further explain about author’s project, Reverse-Engineering of an

Original Equipment Manufacturer (OEM) Diagnostic Tester which he has been doing throughout the

28 weeks of industrial internship program in Robert Bosch Sdn. Bhd. The details are as follow:

i. SD Project - Software Validation Test

ii. Simulation of OE method

iii. Assist projects under collaboration with Proton

This industrial internship project relates directly to Bosch KTS customers. In Bosch perspective, after

identifying system problems from this project, SD developer can proceed to do analysis and fix the

problems. All these changes will be implemented into KTS Update CDs every quarter of the year and

distribute to the customers. In author’s perspective, it is a totally new field of knowledge for him to learn.

This project is not directly related to his studies because scope of the job the work here in Bosch is

mainly automotive however the author takes this initiative to learn the concepts and theories and try to

apply with full interest, additionally; it provides extra knowledge for him as well. Other than that the

author also has to create software called BDX for KTS Tool from scratch using the OE simulation and

trace. This is also called reverse engineering from the OE Tester. Another main task given to the author is

to assist his colleague in a few projects with Proton which are the ECUSpace, and also PADT-II

software. ECUSpace is Protons OE flashing software which means this software is able reprogram any

Proton vehicle’s ECU to the specifications required. PADT-II is the OE diagnostic software for Proton

vehicles which enables Proton’s service centers to diagnose their customer’s vehicles. Both softwares are

under the development of Bosch in collaboration with Proton.


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1. Abstract and Introduction

Nowadays, automotive technology is getting more and more advance where most of the cars are being

fitted with new and complex electronics systems and dozens of sensors whereby all these components are

controlled by their own respective electronic control unit (ECU). In this case, workshop mechanics today

are not able to troubleshoot some problems in modern cars as they are unable to directly see which part

of the components is actually in fault condition but with the assistance of a diagnostic tool, they can

communicate with the car and run diagnosis on the car to search for faults. In Bosch, there is a diagnostic

tool named KTS and is one of the most popular diagnostic tools available. Software development for

diagnostic tool is a never-ending process because there are always new cars being introduced in the

market, besides that; there are also new variants in some models once they have been launched. In order

to satisfy KTS customers’ needs, Bosch SD team is working on software development for the new cars in

the market as well as the new variants and system updates. A reverse-engineering method is conducted

by using Original Equipment Manufacturer (OEM) diagnostic tester to get data and then move on to

other development steps. Bosch KTS is a well rounded diagnostic tool because it covers almost every

vehicle brand in the world and this is significantly beneficial to the customer as compared to OEM testers

since OEM tester can only diagnose for their own vehicle brand.

Figure 9: KTS 570


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1.1.OBJECTIVE OF INDUSTRIAL INTERNSHIP

The main objective of industrial internship is to expose UTP students to the real working

environment in order to relate theoretical knowledge with application in industry. Through the industrial

training, students will be able to partake in activities to develop skills in work ethics, communication,

safety practices, management, etc. Apart from that, the industrial training also helps to establish a close

relationship between the industry and UTP.

The industrial internship program will also provide opportunity to UTP students to build a solid

understanding of the fundamentals of business and organization performance such as economic models

of business, competitive positioning and strategy execution. With this real life environment, as a student,

I hope to develop the ability to assess performance, interpret trends, explore the consequences of change

and make better decisions.

In the end, it is expected for the student to be able to:

1. Apply theoretical knowledge in industrial application

2. Acquire skills in communication, management and team-work

3. Practice ethical and professional work culture and

4. Implement Health Safety and Environment (HSE) practices at workplace


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OBJECTIVE OF INDUSTRIAL PROJECT

The objective of this project is to update Bosch diagnostic software on a list of particular vehicles. By

doing vehicle testing, the author is able to find out which vehicle has system problems and take down all

the necessary reports for further reference. At times customers of Bosch KTS Tool will also report if

there is a problem in diagnosing a vehicle which then the SD developer will have to check for the

problem in the system. The author also is required to create the software for a particular system if it has

not been implemented in the Bosch KTS Diagnostic Tool called the BDX. Additionally, the author also

has to assist in any project collaboration with external companies such as Proton during this internship.

The author will have to handle software testing with Proton since the project collaboration fall under TSS

department.

1.2.SCOPE OF STUDY

This project focuses on the area of BOSCH Automotive Aftermarket division, SWA-TSS or more

specifically vehicle diagnostics development. Vehicle diagnosis is such a wide area in automotive

industry that every manufacturer has their own division in vehicle diagnosis so that they can provide all

the necessary support to their own customers. Vehicle manufactures are constantly searching for cost-

effective ways to improve design, increase manufacturing efficiency and effectiveness, and also

supporting the dealerships in their efforts to improve customer satisfaction and maintain marquee loyalty.

Bosch modern automotive diagnostic systems, supported by efficient software applications development,

are able to deliver the variety of tools required to meet these needs with a right-first-time approach able

to deliver improved manufacturing and workshop productivity. With continuous improvements in design

and repair, quality of service can be maintained.


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1.3.PROBLEM STATEMENT

Bosch KTS diagnostic software covers almost every vehicle brand in the world. There are many Bosch

customers, not only KTS customers but also wholesalers, who buys the diagnostic testers. In other words,

Bosch diagnostic testers are popular and famous in the market and most of the workshops do have them

for their customers’ vehicle maintenance activity. So, software coverage test or validation test needs to be

done regularly in order to ensure all the software is working fine and being updated to satisfy customer’s

troubles. Problems such as ECU identification block codes and also actuators or special function faults

are the most common problems because vehicle manufacturers change their ECU data or use different

ECUs for the vehicle when a new variant is launched. In this case, diagnostic software which was

developed beforehand cannot work perfectly with the vehicle and so, a new validation must be done to

follow up with all these problems that happen in the market. Most of the vehicles on the road in ASEAN

market are mainly Japanese or Korean and Local made, such as Honda, Toyota, Mitsubishi, Hyundai,

Proton and also Perodua. Software testing for ASEAN market should focus more on these brands and

make sure all of the software is working fine and provides the best diagnostics quality for Bosch KTS

customers. However there are also Continental cars such as Audi, BMW, Peugeot and also Volkswagen

which Bosch does cover in its KTS diagnostic tool. Since there are many competitors in the market, KTS

needs to be updated frequently to be able to provide the best vehicle coverage out there to stay at the top

of the market.


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Competitors

CJ3-R Denso : DST2

Launch: X431

Figure 10: Bosch KTS competitors

1.4 RELEVANCY OF PROJECT

Since Bosch KTS Tool is known worldwide for its vehicle coverage in diagnostics, it is enormously

important that the updates for all new systems and also vehicles are always up to date and covered. This

would in fact ensure the branding of Bosch stays at the top of among its competitors in the automotive

industry. With new cars and new systems are being introduced and implemented frequently, this

diagnostics software update will always be an integral part of Bosch Automotive Division plans thus

making it a very significant and relevant task.


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2. Background and Literature Review

The Automotive industry is a very enormous business to begin with and a lot of new products ranging

from vehicles to spare parts to even small components such as fuses play a significant role in expanding

this industry. New systems are being introduced every now and then making the market more and more

competitive. As an engineering student, the scope of vehicle diagnostics in automotive industry is very

distinct and significant for those who want to be a part of this industry. As not only the knowledge from

this area is practiced, one can learn a lot from all the other departments ranging from service, training and

also products in the automotive industry.

The time frame for this project is from April to August 2013 which is four months approximately. Since

the author has already been in this company since January for his industrial training, the author has gotten

used to the job scope and task thus it is easier to be completed since he has the basics from the training

from January to April. A lot of knowledge and input has been given by the author’s supervisor, and also

colleagues in managing the task given. At the end, this internship project has been concluded

successfully without any difficulty.


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Literature Review

A literature review has been done on a topic called “Diagnostics for Automobiles – A Snapshot”, written

by K.Srirama Murthy and D.A.Satish from Dearborn Electronics. A brief explanation was made by the

author as below.

Nowadays, trying to make full use of complicated computer systems in vehicles to extract its data and

figure out how to solve any potential troubles in the vehicle is a tough challenge since there are dozens of

systems around it. It is important to understand the current condition of the car before it goes worse and

critical. Electronic control module (ECM) provides vital information regarding the vehicle health and

send warnings to the drivers so that precaution steps can be taken in advance.

Almost every modern vehicle is equipped with if not one but a few ECMs, which contains

microcontrollers with software programs and these programs provide diagnostic data to diagnostic testers

of the vehicle.

There are many services and functions in diagnostics, such as diagnostic trouble codes which stored

within a system can be viewed. Additionally, live data or actual values from vehicle like engine speed or

engine temperature can be read and evaluation can be made to check for errors.

CAN Bus (Controller Area Network) is an automotive network which has greater data transmitting

speed. It can operate up to 1Mbit/s and 500kb/s at least. CAN is not a complete network system where it

is only available in priority systems like Engine, Transmission and ABS as shown in Figure 4. Another

type of network is called LIN Bus (Local Interconnect Bus). It operates at a slower speed and only

connects to module which has lesser complexity and demands. Application such as door locks and power

windows use LIN bus network as they are much simpler systems compared to the engine.


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Figure 11: System Difference of CAN and LIN

Diagnostics has government-mandated standard such as OBD II (On Board Diagnostics Version 2) as

specified by CARB (California Air Resources Board) and EPA (Environmental Protection Agency) for

automobiles. OBD II is a special connector found under steering column, which it has a function of

specifying vehicle warning light called MIL (Malfunction Indicator Lamp). It displays a message like

“Service Engine Soon” if there is error in any of the systems. Details of error in the system will not be

shown through the lamp but it is available to diagnostic testers. Tester user need to refer to the trouble

code specifications to understand the error codes as displayed and find for troubleshooting solution.


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There are two types of diagnostics protocol which are KWP2000 (ISO 14230) and ISO 15765. KWP2000

specify common requirements of diagnostics which controls the functions of ECU (Electronic Control

Unit) in a vehicle. Information transfer in this protocol has two ways, either K-Line or L-Line. Usually

K-Line is used for communication on diagnosis maintenance activity as it is a two-way directional line. It

sends relevant information and maintaining communication for data transfer. L-Line is a one-way

directional line and therefore, it only used to send information.

ISO 15765, in other words, “Diagnostic on CAN”, manage to provide better capability in conveying long

messages. CAN is a two wired pair and nodes between them are equal. They receive all messages and

each node will decide whether or not to accept or ignore a message. Most CAN networks follow ISO

11898 specification.

Whenever a ECU performs a assessment and it fails, a error code will be stored and it will become a

trouble code (DTC) which the ECU will then alarm the vehicle user by enabling the MIL light for

example of when it is connected to a diagnostic tool, the codes will be able to be read.

As a conclusion, automobile diagnostic has become more and more important each day. Nowadays, most

of the systems in a vehicle use CAN (ISO 15765) protocol for ECU communication but there are still

some systems working by KWP2000. CAN protocol have better speed which can go up to 1Mbit/s and

so, it transfer data in a higher rate as compared to K – Line in KWP2000.


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3. Methodology

Key Milestone

On regards to this project dateline, a perfectly planned timeline has been scheduled in order to ensure that

all parts of this assessment are managed to be executed in an allocated specific time frame. All the

necessary works are systematically arrange in the key milestonein Appendix A-i. This key milestone is a

good prop to ensure that all the work will be guided accordingly within the time allocated. All the actual

activities might be testified earlier if there is a spare of time. However, there are circumstances that the

assessment may not be run accordingly to the designated key milestone due to factor that are nearly

negligible upon completing this project.

Gantt chart

Referring to Appendix A-ii, the training schedule has been done based on the projects which the author

has to undergo. The first 3 weeks would be training followed by all the vehicle testing and vehicle

validation. The author had to undergo testing in Proton on week 3 itself and continue till the end of the

internship. On week 9, the author received his BDX projects and it continued till the end of the internship

also. Vehicle testing and vehicle validation would be an ongoing process till the end with all the new

systems that need to be updated in the Bosch KTS software.


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The illustration below shows the complete Reverse Engineering process flow.

Figure 12: Reverse Engineering process Flow

Step 3

Analysis

Step 4

Documentation

Step 5

Vehicle Testing

Step 1

Taking Traces

Traces

Step 2

Simulation

Step 6

Project Release

Yes

Open

Points


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This is the reverse engineering method used to develop diagnostic software in the author’s industrial

internship project. Apart from learning the ways of doing software validation, the author do take the

initiative to improve himself on learning the concept and idea about how to develop a diagnostic

software. The author is assigned to handle a few software development systems namely ACU (Airbag

Control Unit), EPS (Electronic Power Steering), GSLU-2 (Gear Shift Lock Unit), and also AFC

(Advanced Function Control) for the new Proton car (Proton GSC) which will be launched in soon.

Additionally, the author is also helping his colleagues with all software validations for any car that

requires changes to be implemented.


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Tools Required

In this project, a few tools are used such as Bosch diagnostic tool, KTS 570, Samdia HSX, breaker box

and DC power supply. Additionally, OEM testers are used for development activity as well. Pictures

below show the image of the tools.

KTS 570 (PC – Based) Breaker Box

DC Power Supply Samdia HSX/ Samdia HS+


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OE Software ( IDS) SamDIA Software

ECU Figure 13: Tools used for Internship Project

Samdia HSX is a tool where it can read all the traces which are communication data between the vehicle

and the tester. Breaker box is used as a magnifying version of on-board diagnosis (OBD) cable where pin

assignment can be done individually to Samdia HSX. DC power supply is used when doing simulation. It

acts as a power bank for the diagnostic testers and Samdia HSX because all these tools are not connected

to vehicle anymore for this process. OBD cable is a cable where it has 16 pins, sharing the same concept

with breaker box. OBD plug can be found on driver side which looks like this:


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OBD Pin Assignment:-

Power supply: Pin no.16

Ground (-): Pin 4 & 5

K – Line: Pin 7

CAN – Line: Pin 6 & 14

Figure 14: OBD Pin Assignment

Location of OBD Diagnostic Socket (In General)

Figure 15: Location of OBD socket


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ECU

OBD Adapter Box

SamDia HS+ Interface

SamDia Analyzer:

Data collected

One-Way

communication

Two-Way Data

Transfer Two-Way Data

communication

Legend:

Pin-16: Power Supply (+)

Pin-4 and Pin-5: Ground (-)

Pin 6 Can High

OEM

Tester

Two-Way Data

communication

Device Setup for Traces Taking (Step 1 in SD Work Flow)

Figure 16: Schematic diagram of traces taking

Figure above shows the Step 1 of SD process flow. As mentioned earlier, Samdia Analyzer is used to

capture the trace between the Tester and ECU. Two way communications is happening between the OEM

tester and the ECU. The data transferred in hexadecimal value will show in SamDIA.


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Figure 17: Connection to local cars with 16 pin OBD-socket

to car

to laptop

HS+ Interface

Proton Tester

Connection between

HS+ Interface, OEM

Tester & Breaker Box

Laptop is installed Proton

tester’s software and Samdia

software.


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Device Setup for Simulation (Step 2 in SD Work Flow)

Figure 18: Schematic diagram of simulation

Figure above shows the Step 2 of SD process flow. Now SamDIA on simulation mode is having two way

data communication, where there is no ECU during this connection, and SamDIA is an acting ECU

where it gives the request and response instead of asking for the response. Therefore, one can actually

control the response message of simulator by modifying the hexadecimal digital value of particular data

byte.

ECU

OBD Adapter Box

SamDia HS+ Interface

SamDia Simulator:

Data sending and

receiving

Two-Way Data

Communication

Absence of

ECU Two-Way

Communication

Legend:

Pin-16: Power Supply (+)

Pin-4 and Pin-5: Ground (-)

Pin-6 Can High

Pin – 14 Can Low

Power

Supply

OEM

Tester


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Figure 19: Simulation connection

to laptop HS+ Interface

DC Power Supply

Proton Tester

Connection

between HS+

Interface, OEM

Tester & CARD

Box

Connection between

DC power Supply &

BreakerBox

Laptop is installed Proton

tester’s software and Samdia

software.


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OEM

Tester

ECU Request

Response

SamDia

Analyzer

4. Results and Discussions

Step 1 (Taking Traces)

This first step is performed to capture the all the communication data in hexadecimal value between

Original Equipment Manufacturer (OEM) tester and Electrical Control Unit (ECU) of the vehicle. In this

case, the OEM will communicate with all the system available in the vehicle, but in order to receive the

correct traces for specific system, CAN ID or K-Line request and respond have to be keyed in so that, the

traces just for that specific system for example Engine will be shown.

Traces, for identification, read diagnostic trouble code, erase diagnostic trouble code, actual values, and

actuator will be saved for further analysis. These data transferred between ECU and OEM will be

captured using a device called SamDIA which is connected to breakout box with the correct pin

assignment.

Figure 20: Step 1 – Traces Taking


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Figure 21: Example of Traces (CAN-Line)


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OEM

Tester

ECU

Request

Response

SamDia

Simulator Acting ECU

Absence of

ECU

Step 2 (Simulation)

Using the same device called SamDIA on simulation mode, communicate with the OEM is done without

the presence of ECU. Where the raw data of identification, read and clear DTC, as well as actual value

will be filled in manually on the request and the response column. It will be a challenge to communicate

with the OEM tester, because the SD developer is now behaving as an ECU that puts on the response. By

doing this SD developer could understand how the OEM and ECU communicates with each other.

Figure 22: Step 2 – Simulation


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Step 3 (Analysis)

In this step the SD developer will try to change the response instead of using the respond collected from

the trace. By doing this, the changes made can be seen in the OEM tracer. Actual values, actuators and

special functions are all analyzed in this step. The analysis mentioned consists of derivation of the

formula of particular data byte (for particular actual value), understanding of the working principle of

special functions on a vehicle and finding out the controlling bytes for actual values. Observation of the

changes for actual value in tester done by changing the hexadecimal value of particular data byte is

crucial in this step in order to obtain or calculate the relationship between the hexadecimal value and the

actual value in tester.

Step 4 (Documentation)

As Bosch is a worldwide organization, standards and requirement has to be followed with strict

procedure. Those analyzed data must be transformed or compiled in Bosch data exchange (BDX) before

it can be submitted to the programmer. This BDX is used until the developed software is released. The

programmer will only refer to the BDX received and implement those actual values. In this BDX, Bosch

has made the developer job slightly easier where, they have set those standard formats for CAN and K

data format. Therefore, it is a crucial document in software development process. Then, all the compiled

documents are sent to Germany or India for 2nd

stage software programming.


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Figure 23: BDX Info

This is the basic information that a BDX need, first of all the Info column should be filled up with the

title of the project with the project ID as well the author.


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Figure 24: BDX Specification

Specification requirement is the most important parameter in BDX where we should inform the

programmer, if it’s running on K-line or CAN-line as well as the pin connections and also the number of

controlling byte for Identification, Read DTC and Clear DTC.

For CAN-line there are several basic parameters where.

Battery supply (+) is pin 16

Ground (-) is Pin 4 and 5

Can high is Pin 6

Can Low is Pin 14


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In this Column also we have to fill in the Service Identifier Requests and also Response. This information

will be given in the specification manual. However not all request would be the same for each function.

Requests is 21

Response is 61

Step 5 (Vehicle Testing)

Finally, after the RBEI team from India, proceeds with the programming, they will not understand 100%

how does the car communicate with the tester. As in engineering field, the software developer will have

to explain some of the open points which they will send. After the Software developer has clarify all the

open points and explain in detail how the reverse engineering works does. The programmer will proceed

with the 1st stage programming and then, the software will out for release test. It has to be downloaded in

Bosch database which is located in Germany. By doing this, the developed software will be able to be

tested on the car using Bosch diagnostic tools (KTS). If the software is working perfectly, then the SD

has to write a report attached with the KTS report and CAS log. If the developed software doesn’t work

as how it should, then the SD has to proceed with taking traces and proceed with the BDX change to

know where this software fails. The testing results have to be documented and sent to Germany for

software approval while the software will be sent back to 2nd

stage programmers to reprogram the

modified version of diagnostic software.


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5. Conclusion and Recommendation

As a conclusion, this Industrial Internship Program was successfully completed. Practical experiences as

well as soft skills learned is lifetime knowledge, which is applicable to any industry or expertise. In

addition, the author was able to increase technical competency by acquiring knowledge and skills

required for successful accomplishment of projects, tasks and assignments. Theoretical knowledge

attained at learning institutions was also expanded when applied into practical tasks. Besides that,

participation in real based assignment gives an idea of the actual scenario that takes place at work.

Communication skills are one of the most important skills cultured over the entire internship period. The

Training Program has definitely enhanced the author’s communication skills as the author is able to

communicate confidently, accurately, fluently, and more effectively in a variety of professional and

business settings. During this training period the author is also able to demonstrate professional ethics,

leadership capacity and moral values in profession which leads to being very co-operative member, who

has the ability to work in a team.

Besides that, the author has possessed the ability to handle soft skills such as team management,

presenting and motivating. These soft skills competencies will definitely assist the author’s future

undertakings. Vehicle testing in Malaysia has proven to be useful in providing a benchmark on how

compatible the Bosch KTS diagnostic tester is among various car models here compare to other

aftermarket diagnostics testers. Many systems with new variants for the same car models are found and

reported to Germany for further software development. The presence of new variants for a system of a

particular car model is usually found when the cars are manufactured in different year. The introduction

of new variants could be due to improved technology or for cost-saving reason.

To make Bosch KTS diagnostic tool the world’s leading car diagnostics tool, a few steps can be

implemented such as having collaboration with all vehicle manufacturers for data sharing which would

enable Bosch to use such data for the KTS system. This could be done with more project collaborations

with vehicle manufacturers.


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6. Safety Training and Value of Practical Experience

Safety Regulations

Bosch strives to maintain a safe working environment for all employees. The correct safeguarding of

property and intellectual know-how is becoming increasingly important. Thus all employees are expected

to observe all safety precautions and regulations at all time while reporting any observations of unsafe

conditions to his or her superior immediately. Training on safety and health hazards are a must for all

employees to attend. During that training, the dos and don’ts’ of the company are highlighted. Regardless

of the position held, employees have to follow the rules of safety regulations no matter.

Safety Regulations Robert Bosch Sdn Bhd

1. Know your evacuation exit points and assembly point in the event of a fire drill / real fire. Refer

Appendix

2. In the event of a fire drill / real fire, do not take the lift, instead take the escape staircase

3. Replace / Report any electrical cords when insulation frays

4. Report problems with poor ventilation or odours immediately to the Facilities Department once spotted

5. Do not leave boxes and other materials in aisle, corridors or stairways that could block emergency

exits or access to fire extinguishers

6. Do not use extension cords unless authorized by Facilities Department

7. Do not overload on electrical socket outlets

8. Do not try to attempt to repair office electrical equipment if not properly trained

9. Do not run in aisle or staircases

10. Use trolley and similar equipment to move large or heavy items

Table 3: Bosch Safety Regulations


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Company SOP

The Bosch Values lay the foundation for our company’s behavior. They guide our actions and tell us

what is important to us and what we are committed to. Here as well, the main objective is to enhance the

company's competitiveness by clearly setting out the basic values which each associate has committed to

and puts into practice. Values act as a compass in times of change, and provide appropriate orientation.

They also point the direction which cultural change within the company is meant to take. The values are

designed to help shape cooperation among associates and to lay the foundation stone for the necessary

strong economic development of the company.

This means

Increasing performance ability by providing orientation and trust,

Increasing speed by reducing bureaucracy and controls,

Strengthening the identification of associates with an international and culturally diverse company.


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Figure 25: Bosch Values


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6.1 LESSONS LEARNT AND EXPERIENCE GAINED

28 weeks of internship is not sufficient to learn everything in this department, but this period has given

the author a valuable and beneficial experience where it has manage to change the author to be more

organized. The author is now able to think and react accordingly and make a draft planning when he

faces problems. When the author was assigned the internship project, he is able to find the cars needed

according to their availability in the market and do the needful arrangement on car rental. A list of cars

was assigned to be rented and the author manages to acquire most of the cars. Apart from being

organized, the author learnt to improve on his soft-skills and how to communicate with people. Working

in a multi-national company like Bosch has a lot of opportunities meeting people all around the world

like Thailand, Singapore and Germany and so on. Different cultures are important to be explored since

the world is very vast and diverse and by doing the internship project here, the author manage to

experience a difference culture. The author also learnt to be more initiative and more self-confident to

approach people, besides that, adapting to different culture is not so easy. The author has the chance to

meet his colleague from Robert Bosch India and mix around with him. This opportunity made the author

to learn more about India and learn to adapt to different people in this world. During this internship, the

author has to learn how to be economical in terms of expenditure since the allowance given is just

enough. He has to learn how to manage his money so that there is no excess expenditure compared to

incoming source. Other than that, the author also learnt that in the working environment, cost and

incomes plays a huge role in ensuring the sustainability of a business. Any cost incurred to the company

has to be recorded in a proper manner and standard and needs to be recorded. This allows a company or a

business to keep track if all in cost and incomes it incurs. This has taught the author to be wiser when

dealing with money.


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6.2 LEADERSHIP, TEAMWORK AND INDIVIDUAL ACTIVITIES

Throughout the internship program, the author learned about the team work and its importance as there is

no one man show in anywhere in this world. Teamwork or team spirit is important in a person’s career

path and good communication between people plays an essential role. Since the author worked in the

research and development division, which requires effort and cooperation of many parties, it is necessary

to practice teamwork. AA/SWA–TSS4 division consists of three personnel including the author.

Therefore, good communication between each person is very important to ensure efficient and productive

output of this division. Besides that, working in a team and information sharing saves time in problem

solving. Efficiency can be increased significantly when working together in a team to solve a particular

issue.

But at the same time, working alone is required as well, as good work delegation can result a better

effectiveness too. Some activities are best to be done individually. This can reduce the doubt on the

originality of the result and minimize the disagreement that might arise in teamwork activities. Besides

that, by working individually the author can learn to be responsible and mature to handle a particular

project. Decision making plays a role at the same time as the author can be more independent in his

work.

The author has also seen how to be a good leader when it comes to the working experience. He has seen

how his supervisor handles his workload and also managing a whole department with good continuity.

This has taught the author valuable amount of leadership skills that would be very useful in the future.


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6.3 BUSINESS VALUES, ETHICS AND MANAGEMENT SKILLS

The author has managed to learn technical skills from the practical point of view in order to conduct

vehicle diagnostic testing as well as software development project. Learning through working is a tough

experience because this field is totally a new experience to the author and had to learn everything from

scratch. But as time passes, the author manages to adapt well and learn all the skills required.

Work ethics always stay at a high priority because it reflects our attitude, behaviour, values,

communication skills and interaction of an individual. It is important to learn to posses good work ethics

in order to stay competitive in this world. Moreover, being proactive and positive is also very important.

One should not sit and wait for problems to happen and then find the solution, instead, precaution

measures should be taken and steps to solve problems must be planned in advance. Staying positive is an

important value nowadays and it is compulsory to master this skill to have a better opportunity in

working life.

Industrial Internship program has definitely improved the author’s communication skills and he is able to

speak more fluently and accurately compared to before. The author has learned ways of communicating

with people, as he needs to deal with a lot of vehicle rental companies. Other than that, the author has

also learned how to speak in a more official manner in the working environment when communicating

with superiors. The author also learnt how seniority in the company should be spoken to with respect

since respect is an important culture in Robert Bosch.

Time management is a very important attribute once in the working life. Thus the author have to learn

how to adapt to the changes of working life quickly and manage his time wisely so that it does not affect

the image of the author and also company. Time management in completing a particular task is the most

important since in this area of work, time is valuable. Every task given needs to be completed on time

and the author has managed to do that.


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The author has to learn to become very independent during this internship. A lot of new knowledge is

constantly being thought everyday which is very useful in this line of work. Thus he has to take his own

initiative to learn and absorb as much as possible in the required period of time.

6.4 PROBLEMS OR CHALLENGES FACED AND SOLUTIONS

Life is full of challenges which make us to be a better person. We learn and grow to be more matured and

wise to be able to handle anything that comes in your way. Therefore, the author has to learn and try to

make use of all the information and knowledge available to mange and handle task given to him

throughout his 28 weeks of internship program in Bosch. The concept of software development in

automotive is a new source of information and knowledge to the author compared to what is taught in the

university. The understanding of new subjects is the biggest challenge during the internship, however

working in Bosch enlightens the author into an utterly new field of priceless experience.

Since the author did not have any chance to undergo training with the previous intern, he had to learn

everything by himself with the guidance of his colleagues and supervisor. However, the author managed

to adapt to this division as soon as possible with the unconditional supervision. Later on, the author is

able to handle the given tasks independently and manage to complete them in time such as handling task

alone in Proton.

On the other hand, the author has learned technical skills from the practical point of view in order to

conduct vehicle diagnostic testing as well as software development project. The information has taught

the author a lot and has since been able to conduct vehicle diagnostic testing alone. This knowledge also

helps the author in understanding vehicles on the market much better.

Eventually, the author managed to solve all task given during internship period with success even though

some issues were faced during the beginning of the internship. The author is very grateful for the

opportunity to work here and learn all the useful information available.


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7. References

1. BOSCH Automotive Handbook, 6th Edition; Robert Bosch GmbH, Germany; 2004.

2. Control Unit Diagnostics via the OBD Interface; Robert Bosch GmbH, Germany; 2001.

3. UTP Internship Guidelines 2014

4. BOSCH GROUP - Invented for Life.

5. http://www.bosch.com/content/language2/html/index.htm

6. BOSCH MALAYSIA http://www.bosch.com.my/content/language1/html/867.htm

7. Inside Bosch

https://inside.bosch.com

8. http://www.deindia.com/images/downloads/whitepapers/Diganostcs_for_Automobiles-A_Snapshot.pdf

http://www.bosch.com/content/language2/html/index.htm

http://www.bosch.com.my/content/language1/html/867.htm

https://inside.bosch.com/


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8. Appendices

Appendix A – Key Milestone and Gantt Chart

Appendix B – Conversion Table

Appendix C – SD-Process Chart

Appendix D – Example of DTC Table

Appendix E – Types of KTS Testers


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Appendix A – i ; Key Milestone

TITLE WEEK 1 2 3 4 5 6 7 8 9 10 11 12

Study all the

previous paper

projects

Project planning

Further research

on vehicle testing

Information

gathering from

the vehicle

testing

Reverse engineer

the data collected

Transferring data

into software

Obtaining results

SIP report

documentation

SIP presentation


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Appendix A – ii ; Gantt Chart

WEEKS

1 2 3 4 5 6 7 8 9 10 11 12 AGENDA

Revise and study the file of

the company previous

project

Project title discussion and

identification of the project

title

Determine the scope and

the component selected

Analysis of the project

Extract all the data from

vehicle testing

Listing all the information

gathered from vehicle

testing

Reverse-engineer the data

from the original equipment

Transferring all the

parameters obtained into

the software

Study and analyze the

results

Perform any alteration for

the inaccurate part

Project report

documentation

Project presentation

SIP Report submission


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Appendix B – Conversion Table


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Appendix C – SD Process Flow Chart

Start SD Project

Taking traces by using SamDia HS+

interface

Connecting OEM tester to the OBD socket

of vehicle

Analyzing and deciphering the taken

traces

Creating

simulation

Analyzing and determining data by using

trial and error method

Preparing project specification includes

reports and tables

Programming new diagnostic software for

KTS

Testing

software

Releasing new software to market

End SD Project

Unsuccessful

Successful

Unsuccessful

Successful

Under responsibility of

software programming

division in other country

Under responsibility of

AA/SWA-TSS4 division in

RBMY


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Appendix D – Example of a DTC Table

Type DTC # OE Tester Text Fault Type

B 1093 Keyin Switch circuit Failure Short circuit to earth

B 1300 Interior Central Unlock Switch Circuit Failure Short circuit to earth

B 1301 Latch Door Unlock Circuit Failure Short circuit to earth

B 1310 Interior Cent Lock SW Fail & Latch Door SW Circuit

Fail Short circuit to earth

B 1317 Battery Voltage High High voltage

B 1318 Battery Voltage Low Low voltage

B 1319 Front Left Door Contact Circuit Failure Short circuit to earth

B 1327 Front Right Door Contact Circuit Failure Short circuit to earth

B 1331 Trunk Contact Circuit Failure Short circuit to earth

B 1335 Rear Right Door Contact Circuit Failure Short circuit to earth

B 1342 BCM Faulty faulty

B 1343 Rear Window defrost Circuit Failure Short circuit to earth

B 1499 Lamp Turn Signal Left Circuit Failure Open circuit/no signal

B 1503 Lamp Turn Signal Right Circuit Failure Open circuit/no signal

B 1519 Hood Contact Circuit Failure Short circuit to earth

B 1571 Rear Left Door Contact Circuit Failure Short circuit to earth

B 1611 Front Wiper Intermitent Circuit Failure Open circuit/no signal


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B 1612 Rear Wiper Circuit Failure Short circuit between ign. circuits

B 1615 Front Wiper Lo-Speed Circuit Failure Short circuit between ign. circuits

B 1616 Front Wiper Hi-Speed Circuit Failure Short circuit between ign. circuits

B 1681 Horn Switch Circuit Failure Short circuit to earth

B 1695 Front Fog Lamp Circuit Short circuit to earth

B 1875 Hazard Warning Switch Circuit Failure Short circuit to earth

B 2112 Front Washer Circuit Failure Short circuit between ign. circuits

B 2114 Rear Washer Circuit Failure Short circuit between ign. circuits

B 2116 Reverse Gear Switch Circuit Failure Short circuit between ign. circuits


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Appendix E - Different Types of KTS Testers