Automotive fuel and emissions control systems

SECOND EDITION

AUTOMOTIVE FUEL

AND EMISSIONS CONTROL

SYSTEMS

SECOND EDITION

James D. Halderman

Jim Linder

Upper Saddle River, New Jersey

Columbus, Ohio

Prentice Hall

Halderman, James D.

Automotive fuel and emissions control systems / James D. Halderman, Jim Linder.

p. cm.

Includes index.

ISBN 978-0-13-505481-9

1. Automobiles—Fuel systems. 2. Automobiles—Pollution control devices. I. Linder, Jim. II. Title.

TL214.F8H35 2009

629.25'3—dc22

2008034980

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10 9 8 7 6 5 4 3 2 1

ISBN-13: 978-0-13-505481-9

ISBN-10: 0-13-505481-8

■ Each technical topic is discussed in one place or chapter.

Unlike other textbooks, this book is written so that the

theory, construction, diagnosis, and service of a particu￾lar component or system is presented in one location.

There is no need to search through the entire book for

other references to the same topic.

ASE and NATEF Correlated

NATEF-certified programs need to demonstrate that they use

course materials that cover NATEF and ASE tasks. This text￾book has been correlated to the ASE and NATEF task lists and

offers comprehensive coverage of all tasks. A NATEF TASK

CORRELATION CHART and an ASE TEST CORRELATION

CHART are located in the appendices to the book.

A Complete Instructor and

Student Supplements Package

This textbook is accompanied by a full package of instructor

and student supplements. See page vi for a detailed list of all

supplements available with this book.

A Focus on Diagnosis

and Problem Solving

The Professional Technician series has been developed to

satisfy the need for a greater emphasis on problem diagnosis.

Automotive instructors and service managers agree that stu￾dents and beginning technicians need more training in diagnos￾tic procedures and skill development. To meet this need and

demonstrate how real-world problems are solved, complete

troubleshooting procedures are included throughout, and high￾lights on how real-life problems are diagnosed and repaired.

The following pages highlight the unique core features

that set the Professional Technician series apart from other au￾tomotive textbooks.

Professional Technician

Series

Part of Prentice Hall Automotive Professional Technician Se￾ries, the second edition of Automotive Fuel and Emissions

Control Systems presents students and instructors with a

practical, real-world approach to automotive technology and

service. The series includes textbooks that cover all eight ASE

certification test areas of automotive service: Engine Repair (A1),

Automotive Transmissions/Transaxles (A2), Manual Drive

Trains and Axles (A3), Suspension and Steering (A4), Brakes (A5),

Electrical/Electronic Systems (A6), Heating and Air Condi￾tioning (A7), and Engine Performance (A8).

Current revisions are written by the experienced authors

and peer reviewed by automotive instructors and experts in the

field to ensure technical accuracy.

Updates to the Second

Edition Include:

■ All content is correlated to 100% of the ASE and NATEF

tasks for the Automotive Engine Performance (A8) con￾tent area.

■ Expanded from 28 to 31 chapters, which makes it easier to

learn by having content separated into smaller segments.

■ Expanded coverage of alternative fuels.

■ Expanded coverage on diesel engines and diesel emis￾sion control systems.

■ Expanded content on hybrid electric vehicles.

■ New content includes: Fuel cells and advanced technolo￾gies, Network communication systems, Diagnosis of

network communication problems, P-type fuels, and

Biodiesel fuel.

■ Many new photographs and line drawings help students un￾derstand the content material and bring the subject alive.

■ Many new photo sequences help explain service

procedures.

PREFACE

iii

iv Preface

TECH TIPS feature real-world advice and “tricks of

the trade” from ASE-certified master technicians.

SAFETY TIPS alert students to possible hazards on

the job and how to avoid them.

REAL WORLD FIXES present students with actual

automotive service scenarios and show how these

common (and sometimes uncommon) problems

were diagnosed and repaired.

FREQUENTLY ASKED QUESTIONS are based on the

author’s own experience and provide answers to

many of the most common questions asked by

students and beginning service technicians.

OBJECTIVES and KEY TERMS appear at the

beginning of each chapter to help students and

instructors focus on the most important material in

each chapter. The chapter objectives are based on

specific ASE and NATEF tasks.

IN-TEXT FEATURES

It is sometimes confusing to know which way to rotate a

wrench or screwdriver, especially when the head of the

fastener is pointing away from you. To help visualize while

looking at the fastener, say “righty tighty, lefty loosey.”

Tech

Tip

RIGHT TO TIGHTEN

Safety

Tip

HAND SAFETY

Service technicians should wash their hands with soap

and water after handling engine oil or differential or

transmission fluids, or wear protective rubber gloves.

Another safety hint is that the service technician should

not wear watches, rings, or other jewelry that could

come in contact with electrical or moving parts of a

vehicle. See Figure 2-4.

Real World

Fix

THE STALLING HONDA

On a warm day in March, a customer walked into an au￾tomotive repair shop and asked for help. The car was

parked on the street just outside the shop. A service

technician accompanied the owner to check out the sit￾uation. The owner complained that the engine would

start, then immediately stall. The engine would again

start, and then stall during another attempt.

The service technician slid into the driver’s seat and

turned the ignition key. When the engine started, the

technician depressed the accelerator slightly and the en￾gine continued to run without any apparent problem.

The car owner had never depressed the accelerator

pedal and had never had any previous engine trouble.

The technician suspected winter-grade (high-RVP)

gasoline was the problem. The owner replied that the

present tank of fuel had been purchased during the last

week in February. The technician explained that the un￾commonly warm weather caused the fuel to vaporize in

the fuel rail. Enough condensed fuel was available to

start the engine, but the fuel injectors were designed to

handle liquid fuel—not vapor—so the engine stalled.

The technician was probably lucky because by the

third start enough of the remaining vapor had been

drawn into the engine that all that remained was liquid

gasoline.

Frequently

Asked Question

HOW MANY TYPES OF SCREW

HEADS ARE USED IN

AUTOMOTIVE APPLICATIONS?

Many types of screw heads are used, including Torx,

hex (also called Allen), and many others used in custom

vans and motorhomes. See Figure 1-10.

After studying Chapter 1, the reader will be able to:

1. Prepare for ASE knowledge content for vehicle identification and

the proper use of tools and shop equipment.

2. Retrieve vehicle service information.

3. Explain the strength ratings of threaded fasteners.

4. Describe how to safely hoist a vehicle.

5. Discuss how to safely use hand tools.

6. List the personal protective equipment (PPE) that all service

technicians should wear.

CHAPTER 1

SERVICE INFORMATION,

TOOLS, AND SAFETY

SERVICE INFORMATION,

7. Describe which tool is the best to use for each job.

8. Discuss how to safely use hand tools.

9. Explain the difference between the brand name (trade name) and

the proper name for tools.

10. Explain how to maintain hand tools.

11. Describe what precautions need to be followed when working on

hybrid electric vehicles (HEVs).

Adjustable Wrench (p. 9)

Breaker Bar (p. 10)

Bump Cap (p. 26)

Calibration Codes (p. 2)

Campaign (p. 4)

Cap Screw (p. 5)

Casting Number (p. 3)

Cheater Bar (p. 13)

Close-End Wrench (p. 8)

Combination Wrench (p. 9)

Crest (p. 5)

Drive Size (p. 10)

Extension (p. 10)

Eye Wash Station (p. 33)

Fire Blanket (p. 33)

Fire Extinguisher Classes (p. 32)

Flare-Nut Wrench (p. 10)

GAWR (p. 2)

Grade (p. 6)

GVWR (p. 2)

Metric Bolts (p. 6)

Open-End Wrench (p. 8)

Pinch Weld Seam (p. 29)

Pitch (p. 5)

PPE (p. 25)

Prevailing Torque Nut (p. 8)

Recall (p. 4)

Socket (p. 10)

Socket Adapter (p. 13)

Spontaneous Combustion (p. 27)

SST (p. 23)

Stud (p. 5)

Tensile Strength (p. 6)

TSB (p. 4)

UNC (p. 5)

UNF (p. 5)

Universal Joint (p. 10)

VECI (p. 2)

VIN (p. 2)

Wrench (p. 8)

OBJECTIVES

KEY TERMS

Preface v

NOTES provide students with additional technical

information to give them a greater understanding of

a specific task or procedure.

CAUTIONS alert students about potential damage

to the vehicle that can occur during a specific task or

service procedure.

WARNINGS alert students to potential harm to the

technician that could occur during a specific task or

service procedure.

STEP-BY-STEP photo sequences show in detail the

steps involved in performing a specific task or

service procedure.

The SUMMARY, REVIEW QUESTIONS,

AND CHAPTER QUIZ at the end of each chapter

help students review the material presented in the

chapter and test their mastery of the material.

NOTE: Most “locking nuts” are grouped together and are commonly

referred to as prevailing torque nuts.This means that the nut will

hold its tightness or torque and not loosen with movement or vibration.

Most prevailing torque nuts should be replaced whenever removed to ensure

that the nut will not loosen during service.Always follow the manufacturer’s

recommendations.Anaerobic sealers,such as Loctite,are used on the threads

where the nut or cap screw must be both locked and sealed.

CAUTION: Never use hardware store (nongraded) bolts, studs, or nuts

on any vehicle steering, suspension, or brake component. Always use the

exact size and grade of hardware that is specified and used by the vehicle

manufacturer.

WARNING: Hazardous waste disposal laws include serious penalties for any￾one responsible for breaking these laws.

Step 5 Record the AC frequency and subtract 50 from the

reading (e.g., 60.50 - 50.00 = 10.5). This number

Step 3 The first step is to measure the air frequency by select￾ing AC hertz on the meter.The air frequency should be

between 35 Hz and 48 Hz.

Step 2 This battery-powered tester uses light-emitting

diodes (LEDs), meter lead terminals, and two small

openings for the fuel sample.

Step 4 After verifying that the tester is capable of correctly

reading the air frequency, gasoline is poured into the

testing cell of the tool.

Step 1 A fuel composition tester is the recommended tool to

use to test the alcohol content of gasoline.

Step 6 Adding additional amounts of ethyl alcohol (ethanol)

increases the frequency reading.

TESTING FOR ALCOHOL CONTENT IN GASOLINE Step-by-Step

40 CHAPTER 1

Summary

1. Bolts, studs, and nuts are commonly used as fasteners in

the chassis. The sizes for fractional and metric threads are

different and are not interchangeable. The grade is the

rating of the strength of a fastener.

2. Whenever a vehicle is raised above the ground, it must

be supported at a substantial section of the body or frame.

3. Wrenches are available in open end, box end, and com￾bination open and box end.

4. An adjustable wrench should only be used when the

proper-size wrench is not available.

5. Line wrenches are also called flare-nut wrenches, fitting

wrenches, or tube-nut wrenches and are used to remove

fuel or refrigerant lines.

6. Sockets are rotated by a ratchet or breaker bar, also called

a flex handle.

7. Torque wrenches measure the amount of torque applied

to a fastener.

8. Screwdriver types include straight blade (flat tip) and

Phillips.

9. Hammers and mallets come in a variety of sizes and

weights.

10. Pliers are a useful tool and are available in many different

types, including slip-joint, multigroove, linesman’s, diag￾onal, needle-nose, and locking pliers.

11. Other common hand tools include snap-ring pliers, files,

cutters, punches, chisels, and hacksaws.

1. List three precautions that must be taken whenever hoisting

(lifting) a vehicle.

2. Describe how to determine the grade of a fastener, including

how the markings differ between fractional and metric bolts.

3. List four items that are personal protective equipment (PPE).

4. List the types of fire extinguishers and their usage.

5. Why are wrenches offset 15 degrees?

6. What are the other names for a line wrench?

7. What are the standard automotive drive sizes for sockets?

8. Which type of screwdriver requires the use of a hammer or

mallet?

9. What is inside a dead-blow hammer?

10. What type of cutter is available in left and right cutters?

Review Questions

1. The correct location for the pads when hoisting or jacking the

vehicle can often be found in the _____.

a. Service manual

b. Shop manual

c. Owner’s manual

d. All of the above

2. For the best working position, the work should be _____.

a. At neck or head level

b. At knee or ankle level

c. Overhead by about 1 foot

d. At chest or elbow level

3. A high-strength bolt is identified by _____.

a. A UNC symbol

b. Lines on the head

c. Strength letter codes

d. The coarse threads

4. A fastener that uses threads on both ends is called a

_____.

a. Cap screw

b. Stud

c. Machine screw

d. Crest fastener

Chapter Quiz

vi Preface

The comprehensive INSTRUCTOR’S MANUAL includes

chapter outlines, answers to all questions from the book,

teaching tips, and additional exercises.

Included with every copy of the book, access to the fol￾lowig website: www.pearsonhighered.com/autostudent.

This resource contains:

■ A complete text-specific TEST BANK WITH TEST

CREATION SOFTWARE

■ A comprehensive, text-specific POWERPOINT

PRESENTATION featuring much of the art from the

text as well as video clips and animations

■ An IMAGE LIBRARY featuring additional images to use

for class presentations

■ Additional student activities including CROSSWORD

PUZZLES, WORD SEARCHES, and other worksheets

■ A SAMPLE ASE TEST as well as the complete ASE

TASK LIST

Available to be packaged with the book, the STUDENT

WORKTEXT (NATEF CORRELATED TASK SHEETS), includes

100% of the job sheets tied to Automotive Electrical and Elec￾tronics Systems (A6) NATEF tasks. Contact your local Prentice

Hall representative for information on ordering the textbook

packaged with the student worktext.

SUPPLEMENTS

James Halderman

Jim Halderman brings a world of experience,knowledge,and talent to his work.

His automotive service experience includes working as a flat-rate dealership

technician, a business owner, and a professor of automotive technology at a

leading U.S. community college for more than 20 years.

He has a Bachelor of Science Degree from Ohio Northern University and a

Masters Degree in Education from Miami University in Oxford, Ohio. Jim also

holds a U.S. Patent for an electronic transmission control device. He is an ASE

certified Master Automotive Technician and Advanced Engine Performance (L1)

ASE certified.

Jim is the author of many automotive textbooks all published by Pearson

Prentice Hall Publishing Company.

Jim has presented numerous technical seminars to national audiences in￾cluding the California Automotive Teachers (CAT) and the Illinois College Auto￾motive Instructor Association (ICAIA) as well as a member and presenter at the

North American Council of Automotive Teachers (NACAT). Jim was also named

Regional Teacher of the Year by General Motors Corporation and outstanding

alumni of Ohio Northern University.

Jim and his wife, Michelle, live in Dayton, Ohio.They have two children.

Jim Linder

Jim Linder is the owner of Linder Technical Services,Inc.in Indianapolis,Indiana.

He is an ASE certified Master Automotive Technician and Advanced Engine

Performance (L1) ASE certified.

From an early start as a gas station service attendant, his entire career has

been automotive: Fleet Service Mechanic for the town of Speedway, IN for 7

years,Automotive Instructor at Lincoln Technical Institute for 8 years (specializing

in electrical and driveability),Training Manager,Training Developer and District

Sales Manager for Allen Test products for 8 years. As a current American Techni￾cian Training Program (ATTP) Master Instructor and Board Member on the Indiana

Department of Environmental Management (IDEM) Training Advisory Board, his

involvement in the industry remains constant.

ABOUT THE AUTHORS

Preface vii

A large number of people and organizations have cooperated

in providing the reference material and technical information

used in this text. The author wishes to express sincere thanks

to the following persons and organizations for their special

contributions:

Automotive Video, Inc. James (Mike) Watson

Automotion, Inc. John Forro

Bill Fulton John Thornton

Bruce Amacker Linder Technical Services, Inc.

Dan Marinucci Mark Warren

Dave Scaler Randy Dillman

Dr. Norman Nall Scot Manna

Fluke Tony Martin

Gary Smith

Technical and Content Reviewers

The following people reviewed the manuscript before produc￾tion and checked it for technical accuracy and clarity of presen￾tation. Their suggestions and recommendations were included

in the final draft of the manuscript. Their input helped make this

textbook clear and technically accurate while maintaining the

easy-to-read style that has made other books from the same

author so popular.

Jim Anderson

Greenville High School

Victor Bridges

Umpqua Community College

John Bronisz

Albuquerque Technical-Vocational Institute

Dr. Roger Donovan

Illinois Central College

A. C. Durdin

Moraine Park Technical College

Herbert Ellinger

Western Michigan University

Al Engledahl

College of Dupage

Gary Gage

Ferris State

James M. Gore

Albuquerque Technical-Vocational Institute

Larry Hagelberger

Upper Valley Joint Vocational School

Oldrick Hajzler

Red River College

Betsy Hoffman

Vermont Technical College

Joseph Kidd

Morrisville State College

Steven T. Lee

Lincoln Technical Institute

Carlton H. Mabe, Sr.

Virginia Western Community College

Roy Marks

Owens Community College

Tony Martin

University of Alaska Southeast

Kerry Meier

San Juan College

Fritz Peacock

Indiana Vocational Technical College

Dennis Peter

NAIT (Canada)

Kenneth Redick

Hudson Valley Community College

Mark Spisak

Central Piedmont Community College

Mitchell Walker

St. Louis Community College at Forest Park

Jennifer Wise

Sinclair Community College

Photo Sequences

We wish to thank Mike Garblik, Blaine Heeter, and Chuck

Taylor of Sinclair Community College, Dayton, Ohio, who

helped with many of the photos.

Special thanks to Richard Reaves for all of his help. Most

of all, we wish to thank Michelle Halderman for her assistance

in all phases of manuscript preparation.

James D. Halderman

Jim Linder

ACKNOWLEDGMENTS

This page intentionally left blank

Chapter 1 SERVICE INFORMATION, TOOLS,

AND SAFETY 1

Chapter 2 ENVIRONMENTAL AND HAZARDOUS

MATERIALS 42

Chapter 3 GASOLINE ENGINE OPERATION, PARTS,

AND SPECIFICATIONS 59

Chapter 4 DIESEL ENGINE OPERATION AND

DIAGNOSIS 73

Chapter 5 GASOLINE AND ALTERNATIVE FUELS 93

Chapter 6 INTAKE AND EXHAUST

SYSTEMS 120

Chapter 7 TURBOCHARGING AND

SUPERCHARGING 132

Chapter 8 ENGINE CONDITION DIAGNOSIS 143

Chapter 9 DIGITAL METERS 162

Chapter 10 OSCILLOSCOPES AND GRAPHING

MULTIMETERS 190

Chapter 11 COMPUTER FUNDAMENTALS 200

Chapter 12 NETWORK COMMUNICATIONS AND

DIAGNOSIS 207

Chapter 13 ON-BOARD DIAGNOSIS 225

Chapter 14 TEMPERATURE SENSORS 236

Chapter 15 THROTTLE POSITION (TP) SENSORS 248

Chapter 16 MAP/BARO SENSORS 259

Chapter 17 MASS AIR FLOW SENSORS 269

Chapter 18 OXYGEN SENSORS 278

Chapter 19 CRANKSHAFT AND CAMSHAFT

POSITION SENSORS 303

Chapter 20 IGNITION SYSTEM COMPONENTS AND

OPERATION 314

Chapter 21 IGNITION SYSTEM DIAGNOSIS AND

SERVICE 335

Chapter 22 FUEL PUMPS, LINES, AND FILTERS 362

Chapter 23 FUEL-INJECTION COMPONENTS AND

OPERATION 382

Chapter 24 FUEL-INJECTION SYSTEM DIAGNOSIS

AND SERVICE 401

Chapter 25 VEHICLE EMISSION STANDARDS AND

TESTING 424

Chapter 26 EVAPORATIVE EMISSION CONTROL

SYSTEMS 437

Chapter 27 EXHAUST GAS RECIRCULATION (EGR)

SYSTEMS 451

Chapter 28 POSITIVE CRANKCASE VENTILATION

(PCV) AND SECONDARY AIR INJECTION

(SAI) 462

Chapter 29 CATALYTIC CONVERTERS 474

Chapter 30 HYBRID ELECTRIC VEHICLE SAFETY

PROCEDURES 486

Chapter 31 FUEL CELLS AND ADVANCED

TECHNOLOGIES 501

Appendix 1 ASE TEST CORRELATION CHART 519

Appendix 2 NATEF TASK CORRELATION

CHART 522

ENGLISH GLOSSARY 525

SPANISH GLOSSARY 535

INDEX 549

BRIEF CONTENTS

ix

This page intentionally left blank

CONTENTS

Chapter 1 SERVICE INFORMATION, TOOLS,

AND SAFETY 1

Objectives 1

Key Terms 1

Vehicle Identification 2

Service Information 3

Threaded Fasteners 5

Hand Tools 8

Multigroove Adjustable Pliers 15

Basic Hand Tool List 20

Tool Sets and Accessories 20

Electrical Hand Tools 21

Safety Tips for Using Hand Tools 22

Hand Tool Maintenance 23

Air- and Electric-Operated Tools 23

Personal Protective Equipment 25

Safety in Lifting (Hoisting) a Vehicle 27

Jacks and Safety Stands 30

Drive-On Ramps 30

Electrical Cord Safety 30

Jump Starting and Battery Safety 31

Fire Extinguishers 32

Fire Blankets 33

First Aid and Eye Wash Stations 33

Hybrid Electric Vehicle Safety Issues 34

Summary 40

Review Questions 40

Chapter Quiz 40

Chapter 2 ENVIRONMENTAL AND HAZARDOUS

MATERIALS 42

Objectives 42

Key Terms 42

Occupational Safety and Health Act 43

Hazardous Waste 43

Resource Conservation and Recovery Act

(RCRA) 43

Clean Air Act 44

Material Safety Data Sheets (MSDSs) 44

The Dangers of Exposure to Asbestos 44

Asbestos OSHA Standards 45

Asbestos EPA Regulations 45

Asbestos Handling Guidelines 45

Used Brake Fluid 46

Used Oil 46

Disposal of Used Oil 46

Used Oil Storage 47

Solvents 47

Solvent Hazardous and Regulatory

Status 48

Used Solvents 48

Coolant Disposal 49

Lead–Acid Battery Waste 49

Battery Hazardous and Regulatory

Status 49

Battery Handling and Storage 50

Fuel Safety and Storage 50

Airbag Handling 50

Used Tire Disposal 51

Air-Conditioning Refrigerant Oil

Disposal 51

Summary 57

Review Questions 57

Chapter Quiz 58

Chapter 3 GASOLINE ENGINE OPERATION, PARTS,

AND SPECIFICATIONS 59

Objectives 59

Key Terms 59

Energy and Power 60

Engine Construction Overview 60

Four-Stroke Cycle Operation 61

The 720° Cycle 62

Engine Classification and Construction 64

Engine Rotation Direction 66

Bore 66

Stroke 67

xi

xii Contents

Engine Displacement 67

Compression Ratio 69

The Crankshaft Determines the Stroke 70

Torque 70

Power 71

Horsepower and Altitude 71

Summary 71

Review Questions 72

Chapter Quiz 72

Chapter 4 DIESEL ENGINE OPERATION

AND DIAGNOSIS 73

Objectives 73

Key Terms 73

Diesel Engines 74

Three Phases of Combustion 75

Diesel Engine Construction 75

Fuel Tank and Lift Pump 76

Injection Pump 76

HEUI System 77

Diesel Injector Nozzles 78

Diesel Injector Nozzle Operation 80

Glow Plugs 80

Engine-Driven Vacuum Pump 81

Diesel Fuel 81

Diesel Fuel Specific Gravity Testing 83

Diesel Fuel Heaters 83

Heated Intake Air 83

Accelerator Pedal Position Sensor 83

Soot or Particulate Matter 84

Diesel Oxidation Catalyst (DOC) 85

Diesel Exhaust Particulate Filter (DPF) 85

Ash Loading 88

Diesel Exhaust Smoke Diagnosis 88

Scan Tool Diagnosis 88

Compression Testing 88

Glow Plug Resistance Balance Test 89

Injector Pop Testing 89

Diesel Emission Testing 90

Summary 91

Review Questions 91

Chapter Quiz 92

Chapter 5 GASOLINE AND ALTERNATIVE FUELS 93

Objectives 93

Key Terms 93

Automotive Fuel Refining 94

Gasoline 94

Volatility 94

Distillation Curve 96

Normal and Abnormal Combustion 96

Octane Rating 97

Gasoline Grades and Octane Number 99

Octane Improvers 99

Oxygenated Fuels 100

Alcohol Additives—Advantages and

Disadvantages 101

Testing Gasoline for Alcohol Content 102

Combustion Chemistry 103

Air–Fuel Ratios 103

High-Altitude Octane Requirements 104

Reformulated Gasoline 104

General Gasoline Recommendations 104

Alternative Fuels 105

P-Series Fuels 112

Biodiesel 113

E-Diesel Fuel 115

Synthetic Fuels 115

Safety Procedures When Working with

Alternative Fuel Vehicles 116

Summary 118

Review Questions 118

Chapter Quiz 118

Chapter 6 INTAKE AND EXHAUST SYSTEMS 120

Objectives 120

Key Terms 120

Air Intake Filtration 121

Engine Air Temperature Requirements 122

Throttle-Body Injection Intake Manifolds 123

Port Fuel-Injection Intake Manifolds 124

Variable Intakes 124

Plastic Intake Manifolds 124

Exhaust Gas Recirculation Passages 125

Upper and Lower Intake Manifolds 126

Exhaust Manifold Design 127

Exhaust Manifold Gaskets 128

Mufflers 128

Summary 130

Review Questions 131

Chapter Quiz 131

Chapter 7 TURBOCHARGING AND

SUPERCHARGING 132

Objectives 132

Key Terms 132

Airflow Requirements 133

Supercharging Principles 133

Contents xiii

Superchargers 134

Turbochargers 136

Boost Control 138

Turbocharger Failures 140

Summary 141

Review Questions 141

Chapter Quiz 142

Chapter 8 ENGINE CONDITION DIAGNOSIS 143

Objectives 143

Key Terms 143

Typical Engine-Related Complaints 144

Engine Smoke Diagnosis 144

The Driver is Your Best Resource 144

Visual Checks 145

Engine Noise Diagnosis 146

Oil Pressure Testing 148

Oil Pressure Warning Lamp 148

Compression Test 148

Wet Compression Test 150

Running (Dynamic) Compression

Test 151

Cylinder Leakage Test 151

Cylinder Power Balance Test 152

Power Balance Test Procedure 152

Vacuum Tests 153

Exhaust Restriction Test 155

Testing Back Pressure with a Vacuum

Gauge 156

Testing Back Pressure with a Pressure

Gauge 156

Diagnosing Head Gasket Failure 156

Dash Warning Lights 157

Summary 160

Review Questions 160

Chapter Quiz 160

Chapter 9 DIGITAL METERS 162

Objectives 162

Key Terms 162

Test Lights 163

Digital Multimeters 164

AC/DC Clamp-On Digital Multimeter 169

Electrical Unit Prefixes 172

How to Read Digital Meters 173

Summary 188

Review Questions 188

Chapter Quiz 188

Chapter 10 OSCILLOSCOPES AND GRAPHING

MULTIMETERS 190

Objectives 190

Key Terms 190

Oscilloscopes 191

Oscilloscope Display Grid 191

Graphing Multimeter 197

Summary 198

Review Questions 198

Chapter Quiz 198

Chapter 11 COMPUTER FUNDAMENTALS 200

Objectives 200

Key Terms 200

Computer Control 201

The Four Basic Computer Functions 201

Digital Computers 202

Computer Outputs 205

Fuel Control System Operating Modes 205

Summary 206

Review Questions 206

Chapter Quiz 206

Chapter 12 NETWORK COMMUNICATIONS

AND DIAGNOSIS 207

Objectives 207

Key Terms 207

Need for Module Communications and

Networks 208

Types of Communications 208

Module Communications Configuration 209

SAE Communications Classifications 209

General Motors Module Communications

Protocols 210

Ford Network Communications Protocols 214

Chrysler Communications Protocols 215

Chrysler Programmable Controller

Interface 215

European Bosch Bus Communications 217

Honda/Toyota Communications 217

Identifying the Bus 218

Additional Bus Protocols 218

Network Communications Diagnosis 219

Terminating Resistors 221

OBD-II Data Link Connector 222

Summary 223

Review Questions 223

Chapter Quiz 224

xiv Contents

Chapter 13 ON-BOARD DIAGNOSIS 225

Objectives 225

Key Terms 225

On-Board Diagnostics Generation-II

(OBD-II) Systems 226

Diagnostic Executive and Task

Manager 226

Monitors 227

OBD-II Monitor Information 228

Enabling Criteria 229

OBD-II DTC Numbering Designation 230

Diagnostic Trouble Code Priority 230

Enabling Conditions Or Criteria 231

Generic OBD-II 233

Diagnosing Problems Using Mode Six 234

Summary 234

Review Questions 234

Chapter Quiz 234

Chapter 14 TEMPERATURE SENSORS 236

Objectives 236

Key Terms 236

Engine Coolant Temperature Sensors 237

Stepped ECT Circuits 237

Testing the Engine Coolant Temperature

Sensor 238

Intake Air Temperature Sensor 242

Testing the Intake Air Temperature

Sensor 244

Transmission Fluid Temperature Sensor 244

Temperature Sensor Diagnostic Trouble

Codes 246

Summary 246

Review Questions 246

Chapter Quiz 247

Chapter 15 THROTTLE POSITION (TP)

SENSORS 248

Objectives 248

Key Terms 248

Throttle Position Sensors 249

TP Sensor Computer Input Functions 249

PCM Uses for the TP Sensor 250

Testing the Throttle Position Sensor 250

Testing a TP Sensor Using the Min/Max

Function 251

Testing the TP Sensor Using a Scan

Tool 252

TP Sensor Diagnostic Trouble Codes 253

Summary 257

Review Questions 257

Chapter quiz 257

Chapter 16 MAP/BARO SENSORS 259

Objectives 259

Key Terms 259

Air Pressure—High and Low 260

Principles of Pressure Sensors 260

Construction of Manifold Absolute Pressure

(MAP) Sensors 261

PCM Uses of the MAP Sensor 264

Barometric Pressure Sensor 265

Testing the MAP Sensor 266

Fuel-Rail Pressure Sensor 267

MAP/BARO Diagnostic Trouble Codes 267

Summary 267

Review Questions 268

Chapter Quiz 268

Chapter 17 MASS AIR FLOW SENSORS 269

Objectives 269

Key Terms 269

Air Flow Sensors 270

Mass Air Flow Sensor Types 270

Karman Vortex Sensors 271

PCM Uses for Air Flow Sensors 272

Testing Mass Air Flow Sensors 273

MAF Sensor Contamination 274

MAF-Related Diagnostic Trouble Codes 275

Summary 276

Review Questions 276

Chapter Quiz 276

Chapter 18 OXYGEN SENSORS 278

Objectives 278

Key Terms 278

Oxygen Sensors 279

Zirconia Oxygen Sensors 280

Titania Oxygen Sensor 281

Wide-Band Oxygen Sensors 281

Closed Loop and Open Loop 282

PCM Uses of the Oxygen Sensor 282

Oxygen Sensor Diagnosis 282

Oxygen Sensor Waveform Analysis 287

Hash 288