A Simple Serial Data Interface for

OBD-I Compliant
General Motors Vehicles
(1982-1995)

Jason M. Reizner, BMA

Project Documentation

prepared for:
Prof. Dipl.-Ing. Jan Sieber
Physical Computing
Winter Semester 2010-11
Fakultt Mediengestaltung
Bauhaus-Universitt Weimar

Table of Contents
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Parts List & Schematic. . . . . . . . . . . . . . . . . . . . . . . 4
Construction of Prototype . . . . . . . . . . . . . . . . . . . . 5
Completed Prototype. . . . . . . . . . . . . . . . . . . . . . . . 6
Test Scenario. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Deployment & Connection. . . . . . . . . . . . . . . . . . . . 8
Data Acquisition & Analysis. . . . . . . . . . . . . . . . . . . 10
Supplemental Technical Information. . . . . . . . . . . . 14

Introduction
Beginning with the 1982 model year, General Motors introduced its
implementation of first-generation On-Board Diagnostics (OBD-I)
on vehicles equipped with computer-controlled engines. This
proprietary system, initially known as Assembly Line Data Link
(ALDL), provides digital access to real-time operational data of the
engine or powertrain control module. Unlike contemporary secondgeneration systems (OBD-II), however, which feature a governmentmandated, publicly available hardware interface and data protocol
common to all manufacturers, ALDL was never intended for use
outside of General Motors, and its specifications were never officially
published. Consequently, devices for interfacing ALDL were initially
only available from GM at significant cost.
Fortunately, due to its relative market ubiquity and primitive serial
data structure, the ALDL protocol was eventually reverse-engineered,
and its specifications have been made available to both enthusiasts
and third-party developers. This information has been used to
independently design the hardware and software necessary to
interface ALDL with a standard personal computer, and to extract,
analyze and log the resulting datastream. The combination of
free or low-cost datalogging software and an inexpensive, easily
constructible hardware interface can effectively duplicate the
functionality that has been widely-available through commodity OBDII diagnostic devices.
Early versions of the ALDL system communicated over a serial
datastream at 160-baud, however systems on vehicles manufactured
after 1986 used a significantly faster 8192-baud speed. Hardware
interface designs based on a TTL-to-RS232 IC, such as the MAX232,
have been in circulation for some time, however, a much simpler,
yet equally effective design based on readily-available discrete
components simplifies construction and substantially reduces cost.
Using a combination of NPN transistors, resistors and a switching
diode, it is possible to both invert the ALDL signal and convert its
voltage level to make it suitably compatible with standard PC RS232
serial hardware, and intelligible to datalogging software.

Parts List & Schematic

3x 10K 1/2W resistors
2x 2N3904 NPN transistors
1x 1N914 switching diode
1x DB9 female connector body
1x 12V cigarette lighter plug
1x pre-drilled circuit board or breadboard
6ft./2m 24 AWG solid copper wire
1x OBD-I compliant GM vehicle
1x RS232-equipped PC
1x Compatible datalogging software

(TTS DataMaster Version 4 is used below)

+12VDC
Chassis
GND

RS232
RxD

ALDL
Data
RS232
TxD
ALDL
GND

RS232
GND

Construction of Prototype

Completed Prototype
RS232
GND

RS232
Tx

RS232
Rx

ALDL
Data

ALDL
GND

Chassis
GND
+12
VDC
6

Test Scenario
As a proof of concept, the interface is being utilized to access realtime diagnostic data from the digital powertrain control module (PCM)
of a 1995 Chevrolet K1500 Suburban equipped with an LO5 throttle
body-injected 5.7L V8.

The vehicle owner has complained of recent diminished average

fuel economy and an increased rich odor in tailpipe emissions,
although overall engine performance and driveability do not appear
to be affected. A cursory visual inspection of ignition, fuel delivery
and emissions control systems yields no outwardly apparent defects.
A review of total mileage and vehicle maintenance records suggest
the vehicles oxygen sensor (also referred to in Europe as a lambda
sensor) may be outside its normal service life, typically 60,000 miles
(~100,000 km).
The oxygen sensor is an intrinsic component in contemporary engine
management schemes. Using an electrochemical probe mounted
in the exhaust stream, it provides continuous feedback regarding
the engines present air-fuel mixture ratio by varying signal voltage
supplied to the PCM. As the unit ages, its overall output voltage
gradually decreases, eventually indicating a persistent, erroneous
lean mixture condition, or lack of fuel. Consequently, the engine
management system will unnecessarily compensate by increasing the
amount of fuel supplied, resulting in an actual rich condition.
Before replacing the suspect component, the present health of the
oxygen sensor can be verified by examining operating parameters
observed directly from the powertrain control module.
7

Deployment & Connection

fig. 1:
Situate interface in vehicle, ensuring it is
insulated from chassis ground

fig. 2:
Attach DB9 connector to computer serial port

fig. 3:
Insert vehicle serial line into terminal M
and ground line into terminal A on the
ALDL (Assembly Line Data Link) Connector

fig. 4:
Insert 12V plug into cigarette lighter
or accessory power port
8

Deployment & Connection

fig. 5:
Turn ignition switch to ON, but do not start engine

fig. 6:
Verify interface is functioning properly

fig. 7:
Open datalogging software, start engine

Data Acquisition & Analysis

fig. 1: A functional oxygen sensor will produce voltages that rapidly cycle between 100 and
999 mV. Although voltages do appear to cycle sinusoidally, initial testing indicates a minimum
voltage below specification (27 mV), and a long-term mixture enrichment correction value
exceeding 3% (133 observed/128 baseline) which indicates the engine is compensating for a
perceived lean mixture.

10

Data Acquisition & Analysis

fig. 2: Separate testing after thoroughly warming the engine indicates a maximum oxygen
sensor voltage that does not rise over 881 mV, corroborating earlier data suggesting a faulty part
incapable of proper voltage levels.

11

Data Acquisition & Analysis

fig. 3: Continued analysis again indicates a minimum oxygen sensor voltage that drops well
below 100 mV (22 mV), confirming the part should be replaced.

12

Data Acquisition & Analysis

fig. 4: After several minutes of operation, long- and short-term mixture enrichment correction
values rise above 3% of baseline, demonstrating that the engine is consistently compensating
for a perceived lean mixture by adding additional fuel, and accounting for the symptoms of
decreased fuel economy and rich odor of tailpipe emissions. A replacement oxygen sensor has
been ordered and will rectify the issue.

13

Supplemental Technical Information

Source: 1995 C/K Truck Factory Service Manual

fig. 1:
ALDL connector terminal identification

fig. 2:
Acceptable PCM values

14

Supplemental Technical Information

Vehicle Underhood Emissions Certification

15