COMPUTERIZED ENGINE CONTROLS Ninth Edition Steve V. Hatch Lincoln College of Technology, Denver Campus Formerly Denver Automotive and Diesel College Australia • Brazil • Japan • Korea • Mexico • Singapore • Spain • United Kingdom • United States Copyright 2011 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s). Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it. This is an electronic version of the print textbook. Due to electronic rights restrictions, some third party content may be suppressed. Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. The publisher reserves the right to remove content from this title at any time if subsequent rights restrictions require it. For valuable information on pricing, previous editions, changes to current editions, and alternate formats, please visit www.cengage.com/highered to search by ISBN#, author, title, or keyword for materials in your areas of interest. Copyright 2011 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s). Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it. Computerized Engine Controls, © 2012 Delmar, Cengage Learning Ninth Edition ALL RIGHTS RESERVED. No part of this work covered by the copyright Steve V. Hatch herein may be reproduced, transmitted, stored, or used in any form Vice President, Career and Professional or by any means graphic, electronic, or mechanical, including but not Editorial: Dave Garza limited to photocopying, recording, scanning, digitizing, taping, Web distribution, information networks, or information storage and retrieval Director of Learning Solutions: Sandy Clark systems, except as permitted under Section 107 or 108 of the 1976 Executive Editor: David Boelio United States Copyright Act, without the prior written permission of Managing Editor: Larry Main the publisher. Senior Product Manager: Sharon Chambliss For product information and technology assistance, contact us at Editorial Assistant: Jillian Borden Professional & Career Group Customer Support, 1-800-354-9706 Vice President, Career and Professional For permission to use material from this text or product, Marketing: Jennifer Baker submit all requests online at www.cengage.com/permissions Marketing Director: Deborah Yarnell Further permissions questions can be e-mailed to [email protected] Marketing Manager: Kathryn Hall Associate Marketing Manager: Mark Pierro Production Director: Wendy Troeger Library of Congress Control Number: 2011921992 Production Manager: Mark Bernard ISBN-13: 978-1-1111-3490-7 Senior Content Project Manager: ISBN-10: 1-1111-3490-1 Cheri Plasse Senior Art Director: Benjamin Gleeksman Cengage Learning Technology Project Manager: Christopher 5 Maxwell Drive Catalina Clifton Park, NY 12065-2919 USA Cengage Learning is a leading provider of customized learning solutions with offi ce locations around the globe, including Singapore, the United Kingdom, Australia, Mexico, Brazil and Japan. Locate your local offi ce at: international.cengage.com/region For your lifelong learning solutions, visit delmar.cengage.com Visit our corporate website at cengage.com. Notice to the Reader Publisher does not warrant or guarantee any of the products described herein or perform any independent analysis in connection with any of the product information contained herein. Publisher does not assume, and expressly disclaims, any obligation to obtain and include information other than that provided to it by the manufacturer. The reader is expressly warned to consider and adopt all safety precautions that might be indicated by the activities described herein and to avoid all potential hazards. By following the instructions contained herein, the reader willingly assumes all risks in connection with such instructions. The publisher makes no representations or warranties of any kind, including but not limited to, the warranties of fi tness for particular purpose or merchantability, nor are any such representations implied with respect to the material set forth herein, and the publisher takes no responsibility with respect to such material. The publisher shall not be liable for any special, consequential, or exemplary damages resulting, in whole or part, from the readers’ use of, or reliance upon, this material. Printed in the United States of America 1 2 3 4 5 XX 13 12 11 Copyright 2011 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s). Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it. Preface The application of the microprocessor with OBD II brought to our vehicles back in 1996. While its related components, circuits, and systems has there are differences between manufacturers, the made automotive technology exciting, fast paced, reality is that there are more similarities than dif- and more complicated. Technological advance- ferences. Even prior to OBD II implementation, ments continue to add complexity to the modern the input and output sides of the various com- automobile at record-setting rates and show no puter systems were more similar than different. signs of slowing down. Ultimately, the technol- OBD II standards then standardized the diagnos- ogy requires that entry-level automotive service tic end of these systems. As a result, the reader technicians must be well trained in the principles should begin by concentrating on the first nine of automotive technology and must continue to generic chapters, then study the system-specific upgrade their training throughout their careers. chapters that are of interest, and read the final Those who do this will find the task challenging, two chapters last. but achievable and rewarding. The chapters of this edition contain: This text was written in response to a widely recognized need within the industry: to help stu- • Objectives. Objectives are provided at the dents and technicians get a commanding grasp beginning of each chapter to help the reader of how computerized engine control systems op- identify the major concepts to be presented. erate and how to diagnose problems associated • Key Terms. Terms that are unique to comput- with them. The student/technician who studies erized engine control systems are provided at this text will soon come to realize that no single the beginning of each chapter as Key Terms component or circuit on any given computerized and then appear in boldfacetype at their first engine control system, other than the computer use in the chapter. These Key Terms are also itself, is complicated. provided in the Glossary, along with their Computerized Engine Controls is written with definitions. the assumption that the reader is familiar with the • Diagnostic & Service Tips. These tips offer basic principles of traditional engine, electrical helpful advice for the technician on diagnosing system, and fuel system operation. Although ev- and servicing vehicles, as well as addressing erything here is within the grasp of a good techni- customer concerns. cian, this textbook is not a beginner’s book. • Chapter Articles. Chapter articles give addi- Computerized Engine Controls containseleven tional nice-to-know information about technical generic chapters (Chapters 1 through 9, 17, 18) topics covered in the chapter. and seven system-specific chapters (Chapters 10 • Summary. Each chapter contains a Summary through 16). Emphasis should be placed on the to review the major concepts presented in generic chapters due to the standardization that that chapter. vii Copyright 2011 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s). Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it. viii Preface • Diagnostic Exercise. A Diagnostic Exercise the cylinder imbalance monitor and Global OBD is provided after the Summary of each chapter, II Mode $0A. Chapter 10 (on GM TBI systems) applying a real-life scenario to a concept of and Chapter 11 (on GM PFI systems) from the importance to today’s technicians. eighth edition have been combined into one chap- • Review Questions. Review Questions are ter (Chapter 10) to reduce the emphasis on TBI provided at the end of each chapter to help systems. Much of the material in these two chap- the reader assess his/her recall and compre- ters in past editions was repetitiove, with the PFI hension of the material in each chapter, as chapter referring to the TBI chapter many times. well as to reinforce the concepts covered. All Finally, Appendix A from the eighth edition has of these Review Questions have been written now been turned into a final chapter, Chapter in a multiple-choice format—the type of ques- 18, and has been revamped with much material tion that would be found on an ASE test. added. A portion has also been added to Chap- ter 18 that specifically deals with the diagnosis of Personal safety concerns peculiar to specific emission program failures. Other additions to this computerized engine control systems are high- chapter include chapter objectives, key terms, a lighted where applicable. The book follows the diagnostic exercise, and 20 chapter questions. industry standards for how to use the following Countless other changes have also been terms: made throughout this textbook. Acronyms are now found in Appendix A, and automotive-re- • Warnings indicate that failure to observe cor- lated web addresses are now found in Appen- rect diagnostic or repair procedures could re- dix B. These changes and additions have been sult in personal injury or death. made in order to make this textbook the most • Cautions indicate that failure to observe cor- comprehensive automotive textbook that you will rect diagnostic or repair procedures could re- read this year. sult in damage to tools, equipment, or the ve- hicle being serviced. SUGGESTIONS ON HOW Each student should be aware that while TO USE THIS TEXT working with computerized controls is not inher- ently dangerous, failure to observe recognized The reader should begin by reading safety practices is. There are, unfortunately, many Chapters 1 through 9, preferably in the sequence more injuries and accidents in the automotive re- they exist in the textbook, as they contain informa- pair business than there should be. Good safety tion that pertains to all makes of vehicles. Reading practices, if learned early in a student’s career, these chapters will also provide some background can literally be lifesaving later on. that will make understanding specific system designs and diagnostic strategies easier when reading the system-specific chapters of this book. New to This Edition Chapters 10 through 16, which are specific to in- Additional material on air/fuel ratio sensors dividual manufacturers’ systems, can be read in is now provided in Chapter 3. Chapter 8, Under- any order, though most students will find it much standing OBD II, with a slight modification in the easier to read a manufacturer’s set of chapters in chapter’s title since the previous edition, has also chronological sequence, the way they appear in been totally revamped so as to flow in a more logi- the book. Generally, systems become more com- cal sequence for the reader. Necessary updates plex over time. The newer, more complex systems have also been added to this chapter, including become easier to understand if the reader has Copyright 2011 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s). Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it. Preface ix proficient background knowledge of the earlier, chapter, can also be considered an optional chap- simpler systems. Many students may not wish to ter, although most readers will find this chapter study each chapter, or their instructors may not enjoyable. Finally, the student/technician should choose to assign the study of each chapter. We read Chapter 18 as a final chapter—this chapter suggest, however, that at least three of the specific provides much information on how to apply the system chapters be selected for study. Chapter 17 material presented throughout the textbook to a on alternative power sources, although a generic vehicle that is in your service bay. Copyright 2011 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s). Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it. Contents Preface . . . . . . . . . . . . . . . . . . . . . . . vii Summary . . . . . . . . . . . . . . . . . . . . . . . . . .68 Acknowledgments . . . . . . . . . . . . . . . .xi Diagnostic Exercise . . . . . . . . . . . . . . . . . .69 Review Questions . . . . . . . . . . . . . . . . . . .69 Chapter 1: A Review of Electricity Chapter 3: Common Components and Electronics . . . . . . . . . . . . . . . . . . 1 for Computerized Engine Objectives . . . . . . . . . . . . . . . . . . . . . . . . . .1 Key Terms . . . . . . . . . . . . . . . . . . . . . . . . . .1 Control Systems . . . . . . . . . . . . . . . . . 73 Electrical Circuits versus Objectives . . . . . . . . . . . . . . . . . . . . . . . . .73 Electronic Circuits . . . . . . . . . . . . . . . . . .2 Key Terms . . . . . . . . . . . . . . . . . . . . . . . . .73 Electron Theory . . . . . . . . . . . . . . . . . . . . . .3 Common Features . . . . . . . . . . . . . . . . . .73 Electrical Theory . . . . . . . . . . . . . . . . . . . . .5 Sensing Devices . . . . . . . . . . . . . . . . . . . .76 Electrical Circuits . . . . . . . . . . . . . . . . . . .14 Actuators . . . . . . . . . . . . . . . . . . . . . . . . . .99 Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . .20 System Diagnosis and Service . . . . . . . .102 Circuit Faults . . . . . . . . . . . . . . . . . . . . . . .20 Summary . . . . . . . . . . . . . . . . . . . . . . . . .104 Semiconductors . . . . . . . . . . . . . . . . . . . .22 Diagnostic Exercise . . . . . . . . . . . . . . . . .105 Integrated Circuits . . . . . . . . . . . . . . . . . . .36 Review Questions . . . . . . . . . . . . . . . . . .105 The Digital Age . . . . . . . . . . . . . . . . . . . . .38 Summary . . . . . . . . . . . . . . . . . . . . . . . . . .39 Chapter 4: Common Operating Diagnostic Exercise . . . . . . . . . . . . . . . . . .39 Principles for Computerized Review Questions . . . . . . . . . . . . . . . . . . .39 Engine Control Systems . . . . . . . . . . 109 Objectives . . . . . . . . . . . . . . . . . . . . . . . .109 Chapter 2: Computers in Cars . . . . . . 43 Key Terms . . . . . . . . . . . . . . . . . . . . . . . .109 Objectives . . . . . . . . . . . . . . . . . . . . . . . . .43 Fuel Volatility and Fuel Octane . . . . . . . .110 Key Terms . . . . . . . . . . . . . . . . . . . . . . . . .43 Electronic Fuel Injection System Why Computers? . . . . . . . . . . . . . . . . . . .43 Operating Principles . . . . . . . . . . . . . .111 How Computers Work . . . . . . . . . . . . . . . .47 Ignition System Operating Functions of the Engine Computer . . . . . .62 Principles . . . . . . . . . . . . . . . . . . . . . .125 Controlling Exhaust Gasses . . . . . . . . . . .64 Emission-Control Systems . . . . . . . . . . .132 Closed-Loop and Open-Loop Variable Valve Timing . . . . . . . . . . . . . . .138 Operation . . . . . . . . . . . . . . . . . . . . . . .65 42 V Systems . . . . . . . . . . . . . . . . . . . . .139 The PCM and Exhaust Emissions . . . . . .67 Summary . . . . . . . . . . . . . . . . . . . . . . . . .141 Attitude of the Technician . . . . . . . . . . . . .67 Diagnostic Exercise . . . . . . . . . . . . . . . . .141 System Diagnosis and Service . . . . . . . . .67 Review Questions . . . . . . . . . . . . . . . . . .141 iii Copyright 2011 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s). Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it. iv Contents Chapter 5: Diagnostic Concepts . . . . 145 Chapter 8: Understanding OBD II . . . 213 Objectives . . . . . . . . . . . . . . . . . . . . . . . .145 Objectives . . . . . . . . . . . . . . . . . . . . . . . .213 Key Terms . . . . . . . . . . . . . . . . . . . . . . . .145 Key Terms . . . . . . . . . . . . . . . . . . . . . . . .213 Types of Faults . . . . . . . . . . . . . . . . . . . .145 CARB/EPA/SAE/OBD Background . . . . .213 Diagnostic Trouble Codes . . . . . . . . . . . .146 Why OBD II? . . . . . . . . . . . . . . . . . . . . . .214 Data Streams . . . . . . . . . . . . . . . . . . . . .147 What Does OBD II Do? . . . . . . . . . . . . . .214 Functional Tests . . . . . . . . . . . . . . . . . . .148 Diagnostic Management Software . . . . .215 Technical Service Bulletins . . . . . . . . . . .148 Standardization . . . . . . . . . . . . . . . . . . . .219 Pinpoint Testing . . . . . . . . . . . . . . . . . . . .148 OBD II Monitors . . . . . . . . . . . . . . . . . . .224 Flowcharts . . . . . . . . . . . . . . . . . . . . . . . .153 The Ten Global Modes of OBD II . . . . . .235 Electrical Schematics . . . . . . . . . . . . . . .155 Cold Start Emissions Reduction . . . . . . .239 Other General Diagnostic Reducing the Escape of HC Concepts . . . . . . . . . . . . . . . . . . . . . . .155 Emissions During Refueling . . . . . . . .240 Summary . . . . . . . . . . . . . . . . . . . . . . . . .156 OBD III . . . . . . . . . . . . . . . . . . . . . . . . . .241 Diagnostic Exercise . . . . . . . . . . . . . . . . .156 Summary . . . . . . . . . . . . . . . . . . . . . . . . .241 Review Questions . . . . . . . . . . . . . . . . . .156 Diagnostic Exercise . . . . . . . . . . . . . . . . .241 Review Questions . . . . . . . . . . . . . . . . . .241 Chapter 6: Diagnostic Equipment . . . 159 Chapter 9: Multiplexing Concepts . . . 245 Objectives . . . . . . . . . . . . . . . . . . . . . . . .159 Objectives . . . . . . . . . . . . . . . . . . . . . . . .245 Key Terms . . . . . . . . . . . . . . . . . . . . . . . .159 Key Terms . . . . . . . . . . . . . . . . . . . . . . . .245 Scan Tools . . . . . . . . . . . . . . . . . . . . . . . .159 Multiplexing Overview . . . . . . . . . . . . . . .245 Breakout Boxes . . . . . . . . . . . . . . . . . . . .163 Multiplex System Designs . . . . . . . . . . . .248 Non-Powered Test Lights . . . . . . . . . . . .164 Multiplexing Protocols . . . . . . . . . . . . . . .250 Logic Probes . . . . . . . . . . . . . . . . . . . . . .165 Communication on a J1850 VPW Digital Volt/Ohm Meters . . . . . . . . . . . . . .166 Data Bus . . . . . . . . . . . . . . . . . . . . . . .252 Digital Storage Oscilloscopes . . . . . . . . .175 Communication on a CAN Safety Considerations When Using Data Bus . . . . . . . . . . . . . . . . . . . . . . .254 A DVOM or DSO . . . . . . . . . . . . . . . . .190 Multiplexing Variations . . . . . . . . . . . . . . .256 Gas Analyzers . . . . . . . . . . . . . . . . . . . . .191 Fiber Optic Protocols . . . . . . . . . . . . . . .258 Summary . . . . . . . . . . . . . . . . . . . . . . . . .191 Other Bosch Protocols . . . . . . . . . . . . . .258 Diagnostic Exercise . . . . . . . . . . . . . . . . .191 Diagnosis of Multiplexed Circuits . . . . . .259 Review Questions . . . . . . . . . . . . . . . . . .191 Summary . . . . . . . . . . . . . . . . . . . . . . . . .260 Diagnostic Exercise . . . . . . . . . . . . . . . . .260 Chapter 7: Exhaust Gas Analysis . . . 195 Review Questions . . . . . . . . . . . . . . . . . .260 Objectives . . . . . . . . . . . . . . . . . . . . . . . .195 Key Terms . . . . . . . . . . . . . . . . . . . . . . . .195 Chapter 10: General Motors’ Theory of Gas Analysis . . . . . . . . . . . . . .195 Electronic Engine Controls . . . . . . . . 263 Measured Gasses . . . . . . . . . . . . . . . . . .197 Objectives . . . . . . . . . . . . . . . . . . . . . . . .263 Gas Analyzers . . . . . . . . . . . . . . . . . . . . .202 Key Terms . . . . . . . . . . . . . . . . . . . . . . . .263 Diagnosing with the Gasses . . . . . . . . . .206 Powertrain Control Module . . . . . . . . . . .264 Summary . . . . . . . . . . . . . . . . . . . . . . . . .209 Operating Modes. . . . . . . . . . . . . . . . . . .265 Diagnostic Exercise . . . . . . . . . . . . . . . . .209 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . .267 Review Questions . . . . . . . . . . . . . . . . . .209 Fuel Management Systems . . . . . . . . . .277 Copyright 2011 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s). Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it. Contents v Idle Speed Control . . . . . . . . . . . . . . . . .288 Other PCM-Controlled Systems . . . . . . .420 Spark Management Systems . . . . . . . . .290 System Diagnosis and Service . . . . . . . .425 Emission Control Systems . . . . . . . . . . .301 Summary . . . . . . . . . . . . . . . . . . . . . . . . .436 Other PCM-Controlled Systems . . . . . . .310 Diagnostic Exercise . . . . . . . . . . . . . . . . .436 Body Control Module . . . . . . . . . . . . . . .316 Review Questions . . . . . . . . . . . . . . . . . .436 System Diagnosis and Service . . . . . . . .320 PCM, PROM, and CALPAK Service . . . .323 Chapter 13: Ford’s Electronic Summary . . . . . . . . . . . . . . . . . . . . . . . . .328 Engine Control V (EEC V) . . . . . . . . . 439 Diagnostic Exercise . . . . . . . . . . . . . . . . .328 Objectives . . . . . . . . . . . . . . . . . . . . . . . .439 Review Questions . . . . . . . . . . . . . . . . . .328 Key Terms . . . . . . . . . . . . . . . . . . . . . . . .439 Engine Controls Inputs . . . . . . . . . . . . . .440 Chapter 11: Advanced General Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . .440 Motors Engine Controls . . . . . . . . . . 331 Fuel Management Systems . . . . . . . . . .443 Objectives . . . . . . . . . . . . . . . . . . . . . . . .331 Idle Speed Control . . . . . . . . . . . . . . . . .446 Key Terms . . . . . . . . . . . . . . . . . . . . . . . .331 Ignition Systems . . . . . . . . . . . . . . . . . . .447 Northstar Engine Overview . . . . . . . . . . .332 Emission Control Systems . . . . . . . . . . .448 Northstar Inputs/Outputs . . . . . . . . . . . . .336 Advanced Ford Computer Cadillac LH2 Northstar Upgrades . . . . . .347 System Features . . . . . . . . . . . . . . . . .452 Cadillac HFV6 . . . . . . . . . . . . . . . . . . . . .351 Body Control Modules . . . . . . . . . . . . . . .460 GM Generation III Small-Block V8s . . . . .351 Voice Recognition/Navigational GM Generation IV Small-Block V8s . . . .354 Systems . . . . . . . . . . . . . . . . . . . . . . .461 GM Active Fuel Management AdvanceTrac™ System . . . . . . . . . . . . . .462 System . . . . . . . . . . . . . . . . . . . . . . . .354 EcoBoost Engine . . . . . . . . . . . . . . . . . .463 Flywheel Alternator Starter System . . . .356 CVPI Fire-Suppression System . . . . . . .463 Belt Alternator Starter System . . . . . . . .361 System Diagnosis and Service . . . . . . . .464 Chevrolet Volt . . . . . . . . . . . . . . . . . . . . .363 Summary . . . . . . . . . . . . . . . . . . . . . . . . .465 GM Voice-Recognition/ Navigational Diagnostic Exercise . . . . . . . . . . . . . . . . .466 System . . . . . . . . . . . . . . . . . . . . . . . .364 Review Questions . . . . . . . . . . . . . . . . . .466 System Diagnosis and Service . . . . . . . .365 Summary . . . . . . . . . . . . . . . . . . . . . . . . .366 Chapter 14: Chrysler Corporation Diagnostic Exercise . . . . . . . . . . . . . . . . .366 Fuel Injection Systems . . . . . . . . . . . 469 Review Questions . . . . . . . . . . . . . . . . . .366 Objectives . . . . . . . . . . . . . . . . . . . . . . . .469 Key Terms . . . . . . . . . . . . . . . . . . . . . . . .469 Chapter 12: Ford’s Electronic Powertrain Control Module . . . . . . . . . . .470 Engine Control IV (EEC IV) . . . . . . . . 371 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . .475 Objectives . . . . . . . . . . . . . . . . . . . . . . . .371 Fuel Management Systems . . . . . . . . . .488 Key Terms . . . . . . . . . . . . . . . . . . . . . . . .371 Idle Speed Control . . . . . . . . . . . . . . . . .491 Powertrain Control Module . . . . . . . . . . .372 Spark Management Systems . . . . . . . . .492 Operating Modes. . . . . . . . . . . . . . . . . . .373 Emission Control Systems . . . . . . . . . . .495 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . .379 Other PCM-Controlled Systems . . . . . . .497 Fuel Management Systems . . . . . . . . . .398 Chrysler Multiplexing Systems . . . . . . . .499 Idle Speed Control . . . . . . . . . . . . . . . . .402 Advanced Chrysler Electronic Spark Management Systems . . . . . . . . .403 Systems . . . . . . . . . . . . . . . . . . . . . . .499 Emission Control Systems . . . . . . . . . . .414 System Diagnosis and Service . . . . . . . .502 Copyright 2011 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s). Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it. vi Contents Summary . . . . . . . . . . . . . . . . . . . . . . . . .505 Chapter 17: Alternative Power Diagnostic Exercise . . . . . . . . . . . . . . . . .506 Sources . . . . . . . . . . . . . . . . . . . . . . 583 Review Questions . . . . . . . . . . . . . . . . . .506 Objectives . . . . . . . . . . . . . . . . . . . . . . . .583 Key Terms . . . . . . . . . . . . . . . . . . . . . . . .583 Chapter 15: European (Bosch) Honda Insight, Civic, and Accord Engine Control Systems . . . . . . . . . . 509 Hybrids . . . . . . . . . . . . . . . . . . . . . . . .585 Objectives . . . . . . . . . . . . . . . . . . . . . . . .509 Toyota Hybrid System . . . . . . . . . . . . . . .588 Key Terms . . . . . . . . . . . . . . . . . . . . . . . .509 Ford Escape Hybrid . . . . . . . . . . . . . . . .593 System Overview . . . . . . . . . . . . . . . . . .510 Allison Two-Mode Hybrids . . . . . . . . . . . .595 Continuous Injection System. . . . . . . . . .513 Fuel Cell Vehicles . . . . . . . . . . . . . . . . . .595 Pulsed Systems . . . . . . . . . . . . . . . . . . .514 Flexible Fuel Vehicles . . . . . . . . . . . . . . .599 Motronic . . . . . . . . . . . . . . . . . . . . . . . . .516 System Diagnosis and Service . . . . . . . .600 Electronic Control Unit . . . . . . . . . . . . . .516 Summary . . . . . . . . . . . . . . . . . . . . . . . . .601 Operating Modes. . . . . . . . . . . . . . . . . . .519 Diagnostic Exercise . . . . . . . . . . . . . . . . .601 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . .521 Review Questions . . . . . . . . . . . . . . . . . .601 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . .524 Bosch Obd II Update . . . . . . . . . . . . . . . .533 Chapter 18: Approach System Diagnosis and Service . . . . . . . .534 to Diagnostics . . . . . . . . . . . . . . . . . 605 Summary . . . . . . . . . . . . . . . . . . . . . . . . .535 Objectives . . . . . . . . . . . . . . . . . . . . . . . .605 Diagnostic Exercise . . . . . . . . . . . . . . . . .535 Key Terms . . . . . . . . . . . . . . . . . . . . . . . .605 Review Questions . . . . . . . . . . . . . . . . . .535 Narrowing Down the Area of the Problem . . . . . . . . . . . . . . . . . .605 Chapter 16: Asian Computer Pinpoint Testing . . . . . . . . . . . . . . . . . . . .609 Control Systems . . . . . . . . . . . . . . . . 539 Diagnosing Intermittent Symptoms . . . . .614 Objectives . . . . . . . . . . . . . . . . . . . . . . . .539 Testing Catalytic Converters . . . . . . . . . .615 Key Terms . . . . . . . . . . . . . . . . . . . . . . . .539 EVAP System Tests . . . . . . . . . . . . . . . . .618 Nissan: Electronic Concentrated Diagnosing Air/Fuel Ratio Problems . . . .620 Control System (ECCS) . . . . . . . . . . .540 Diagnosing an Emission Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . .542 Test Failure . . . . . . . . . . . . . . . . . . . . .623 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . .549 Reprogramming a Computer . . . . . . . . . .626 System Diagnosis and Service . . . . . . . .553 The Three Essential Tools of Electronic Toyota Computer-Controlled System Diagnosis . . . . . . . . . . . . . . . .629 System (TCCS) . . . . . . . . . . . . . . . . . .554 Other Diagnostic Resources . . . . . . . . . .630 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . .554 Summary . . . . . . . . . . . . . . . . . . . . . . . . .630 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . .557 Diagnostic Exercise . . . . . . . . . . . . . . . . .631 System Diagnosis and Service . . . . . . . .564 Review Questions . . . . . . . . . . . . . . . . . .631 Honda: Programmed Fuel Appendix A: Terms and Acronyms . . . 635 Injection (PGM-FI) . . . . . . . . . . . . . . .565 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . .565 Appendix B: Automotive-Related Outputs . . . . . . . . . . . . . . . . . . . . . . . . . .569 Honda’s VTEC Systems . . . . . . . . . . . . .573 Web Addresses . . . . . . . . . . . . . . . . 643 System Diagnosis and Service . . . . . . . .578 Summary . . . . . . . . . . . . . . . . . . . . . . . . .579 Glossary . . . . . . . . . . . . . . . . . . . . . 645 Diagnostic Exercise . . . . . . . . . . . . . . . . .579 Review Questions . . . . . . . . . . . . . . . . . .579 Index . . . . . . . . . . . . . . . . . . . . . . . 663 Copyright 2011 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s). Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it.