Computerized engine controls

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COMPUTERIZED

ENGINE CONTROLS

Ninth Edition

Steve V. Hatch

Lincoln College of Technology, Denver Campus

Formerly

Denver Automotive and Diesel College

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Library of Congress Control Number: 2011921992

ISBN-13: 978-1-1111-3490-7

ISBN-10: 1-1111-3490-1

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Computerized Engine Controls,

Ninth Edition

Steve V. Hatch

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vii

Preface

The application of the microprocessor with

its related components, circuits, and systems has

made automotive technology exciting, fast paced,

and more complicated. Technological advance￾ments continue to add complexity to the modern

automobile at record-setting rates and show no

signs of slowing down. Ultimately, the technol￾ogy requires that entry-level automotive service

technicians must be well trained in the principles

of automotive technology and must continue to

upgrade their training throughout their careers.

Those who do this will find the task challenging,

but achievable and rewarding.

This text was written in response to a widely

recognized need within the industry: to help stu￾dents and technicians get a commanding grasp

of how computerized engine control systems op￾erate and how to diagnose problems associated

with them. The student/technician who studies

this text will soon come to realize that no single

component or circuit on any given computerized

engine control system, other than the computer

itself, is complicated.

Computerized Engine Controls is written with

the assumption that the reader is familiar with the

basic principles of traditional engine, electrical

system, and fuel system operation. Although ev￾erything here is within the grasp of a good techni￾cian, this textbook is not a beginner’s book.

Computerized Engine Controls contains eleven

generic chapters (Chapters 1 through 9, 17, 18)

and seven system-specific chapters (Chapters 10

through 16). Emphasis should be placed on the

generic chapters due to the standardization that

OBD II brought to our vehicles back in 1996. While

there are differences between manufacturers, the

reality is that there are more similarities than dif￾ferences. Even prior to OBD II implementation,

the input and output sides of the various com￾puter systems were more similar than different.

OBD II standards then standardized the diagnos￾tic end of these systems. As a result, the reader

should begin by concentrating on the first nine

generic chapters, then study the system-specific

chapters that are of interest, and read the final

two chapters last.

The chapters of this edition contain:

• Objectives. Objectives are provided at the

beginning of each chapter to help the reader

identify the major concepts to be presented.

• Key Terms. Terms that are unique to comput￾erized engine control systems are provided at

the beginning of each chapter as Key Terms

and then appear in boldface type at their first

use in the chapter. These Key Terms are also

provided in the Glossary, along with their

definitions.

• Diagnostic & Service Tips. These tips offer

helpful advice for the technician on diagnosing

and servicing vehicles, as well as addressing

customer concerns.

• Chapter Articles. Chapter articles give addi￾tional nice-to-know information about technical

topics covered in the chapter.

• Summary. Each chapter contains a Summary

to review the major concepts presented in

that chapter.

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viii Preface

• Diagnostic Exercise. A Diagnostic Exercise

is provided after the Summary of each chapter,

applying a real-life scenario to a concept of

importance to today’s technicians.

• Review Questions. Review Questions are

provided at the end of each chapter to help

the reader assess his/her recall and compre￾hension of the material in each chapter, as

well as to reinforce the concepts covered. All

of these Review Questions have been written

in a multiple-choice format—the type of ques￾tion that would be found on an ASE test.

Personal safety concerns peculiar to specific

computerized engine control systems are high￾lighted where applicable. The book follows the

industry standards for how to use the following

terms:

• Warnings indicate that failure to observe cor￾rect diagnostic or repair procedures could re￾sult in personal injury or death.

• Cautions indicate that failure to observe cor￾rect diagnostic or repair procedures could re￾sult in damage to tools, equipment, or the ve￾hicle being serviced.

Each student should be aware that while

working with computerized controls is not inher￾ently dangerous, failure to observe recognized

safety practices is. There are, unfortunately, many

more injuries and accidents in the automotive re￾pair business than there should be. Good safety

practices, if learned early in a student’s career,

can literally be lifesaving later on.

New to This Edition

Additional material on air/fuel ratio sensors

is now provided in Chapter 3. Chapter 8, Under￾standing OBD II, with a slight modification in the

chapter’s title since the previous edition, has also

been totally revamped so as to flow in a more logi￾cal sequence for the reader. Necessary updates

have also been added to this chapter, including

the cylinder imbalance monitor and Global OBD

II Mode $0A. Chapter 10 (on GM TBI systems)

and Chapter 11 (on GM PFI systems) from the

eighth edition have been combined into one chap￾ter (Chapter 10) to reduce the emphasis on TBI

systems. Much of the material in these two chap￾ters in past editions was repetitiove, with the PFI

chapter referring to the TBI chapter many times.

Finally, Appendix A from the eighth edition has

now been turned into a final chapter, Chapter

18, and has been revamped with much material

added. A portion has also been added to Chap￾ter 18 that specifically deals with the diagnosis of

emission program failures. Other additions to this

chapter include chapter objectives, key terms, a

diagnostic exercise, and 20 chapter questions.

Countless other changes have also been

made throughout this textbook. Acronyms are

now found in Appendix A, and automotive-re￾lated web addresses are now found in Appen￾dix B. These changes and additions have been

made in order to make this textbook the most

comprehensive automotive textbook that you will

read this year.

SUGGESTIONS ON HOW

TO USE THIS TEXT

The reader should begin by reading

Chapters 1 through 9, preferably in the sequence

they exist in the textbook, as they contain informa￾tion that pertains to all makes of vehicles. Reading

these chapters will also provide some background

that will make understanding specific system

designs and diagnostic strategies easier when

reading the system-specific chapters of this book.

Chapters 10 through 16, which are specific to in￾dividual manufacturers’ systems, can be read in

any order, though most students will find it much

easier to read a manufacturer’s set of chapters in

chronological sequence, the way they appear in

the book. Generally, systems become more com￾plex over time. The newer, more complex systems

become easier to understand if the reader has

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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,

simpler systems. Many students may not wish to

study each chapter, or their instructors may not

choose to assign the study of each chapter. We

suggest, however, that at least three of the specific

system chapters be selected for study. Chapter 17

on alternative power sources, although a generic

chapter, can also be considered an optional chap￾ter, although most readers will find this chapter

enjoyable. Finally, the student/technician should

read Chapter 18 as a final chapter—this chapter

provides much information on how to apply the

material presented throughout the textbook to a

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).

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iii

Contents

Preface . . . . . . . . . . . . . . . . . . . . . . . vii

Acknowledgments . . . . . . . . . . . . . . . . xi

Chapter 1: A Review of Electricity

and Electronics . . . . . . . . . . . . . . . . . . 1

Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Key Terms . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Electrical Circuits versus

Electronic Circuits . . . . . . . . . . . . . . . . . . 2

Electron Theory . . . . . . . . . . . . . . . . . . . . . . 3

Electrical Theory . . . . . . . . . . . . . . . . . . . . . 5

Electrical Circuits . . . . . . . . . . . . . . . . . . . 14

Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Circuit Faults . . . . . . . . . . . . . . . . . . . . . . . 20

Semiconductors . . . . . . . . . . . . . . . . . . . . 22

Integrated Circuits . . . . . . . . . . . . . . . . . . . 36

The Digital Age . . . . . . . . . . . . . . . . . . . . . 38

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Diagnostic Exercise . . . . . . . . . . . . . . . . . . 39

Review Questions . . . . . . . . . . . . . . . . . . . 39

Chapter 2: Computers in Cars . . . . . . 43

Objectives . . . . . . . . . . . . . . . . . . . . . . . . . 43

Key Terms . . . . . . . . . . . . . . . . . . . . . . . . . 43

Why Computers? . . . . . . . . . . . . . . . . . . . 43

How Computers Work . . . . . . . . . . . . . . . . 47

Functions of the Engine Computer . . . . . . 62

Controlling Exhaust Gasses . . . . . . . . . . . 64

Closed-Loop and Open-Loop

Operation . . . . . . . . . . . . . . . . . . . . . . . 65

The PCM and Exhaust Emissions . . . . . . 67

Attitude of the Technician . . . . . . . . . . . . . 67

System Diagnosis and Service . . . . . . . . . 67

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Diagnostic Exercise . . . . . . . . . . . . . . . . . . 69

Review Questions . . . . . . . . . . . . . . . . . . . 69

Chapter 3: Common Components

for Computerized Engine

Control Systems . . . . . . . . . . . . . . . . . 73

Objectives . . . . . . . . . . . . . . . . . . . . . . . . . 73

Key Terms . . . . . . . . . . . . . . . . . . . . . . . . . 73

Common Features . . . . . . . . . . . . . . . . . . 73

Sensing Devices . . . . . . . . . . . . . . . . . . . . 76

Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . 99

System Diagnosis and Service . . . . . . . . 102

Summary . . . . . . . . . . . . . . . . . . . . . . . . . 104

Diagnostic Exercise . . . . . . . . . . . . . . . . . 105

Review Questions . . . . . . . . . . . . . . . . . . 105

Chapter 4: Common Operating

Principles for Computerized

Engine Control Systems . . . . . . . . . . 109

Objectives . . . . . . . . . . . . . . . . . . . . . . . . 109

Key Terms . . . . . . . . . . . . . . . . . . . . . . . . 109

Fuel Volatility and Fuel Octane . . . . . . . . 110

Electronic Fuel Injection System

Operating Principles . . . . . . . . . . . . . . 111

Ignition System Operating

Principles . . . . . . . . . . . . . . . . . . . . . . 125

Emission-Control Systems . . . . . . . . . . . 132

Variable Valve Timing . . . . . . . . . . . . . . . 138

42 V Systems . . . . . . . . . . . . . . . . . . . . . 139

Summary . . . . . . . . . . . . . . . . . . . . . . . . . 141

Diagnostic Exercise . . . . . . . . . . . . . . . . . 141

Review Questions . . . . . . . . . . . . . . . . . . 141

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iv Contents

Chapter 5: Diagnostic Concepts . . . . 145

Objectives . . . . . . . . . . . . . . . . . . . . . . . . 145

Key Terms . . . . . . . . . . . . . . . . . . . . . . . . 145

Types of Faults . . . . . . . . . . . . . . . . . . . . 145

Diagnostic Trouble Codes . . . . . . . . . . . . 146

Data Streams . . . . . . . . . . . . . . . . . . . . . 147

Functional Tests . . . . . . . . . . . . . . . . . . . 148

Technical Service Bulletins . . . . . . . . . . . 148

Pinpoint Testing . . . . . . . . . . . . . . . . . . . . 148

Flowcharts . . . . . . . . . . . . . . . . . . . . . . . . 153

Electrical Schematics . . . . . . . . . . . . . . . 155

Other General Diagnostic

Concepts . . . . . . . . . . . . . . . . . . . . . . . 155

Summary . . . . . . . . . . . . . . . . . . . . . . . . . 156

Diagnostic Exercise . . . . . . . . . . . . . . . . . 156

Review Questions . . . . . . . . . . . . . . . . . . 156

Chapter 6: Diagnostic Equipment . . . 159

Objectives . . . . . . . . . . . . . . . . . . . . . . . . 159

Key Terms . . . . . . . . . . . . . . . . . . . . . . . . 159

Scan Tools . . . . . . . . . . . . . . . . . . . . . . . . 159

Breakout Boxes . . . . . . . . . . . . . . . . . . . . 163

Non-Powered Test Lights . . . . . . . . . . . . 164

Logic Probes . . . . . . . . . . . . . . . . . . . . . . 165

Digital Volt/Ohm Meters . . . . . . . . . . . . . . 166

Digital Storage Oscilloscopes . . . . . . . . . 175

Safety Considerations When Using

A DVOM or DSO . . . . . . . . . . . . . . . . . 190

Gas Analyzers . . . . . . . . . . . . . . . . . . . . . 191

Summary . . . . . . . . . . . . . . . . . . . . . . . . . 191

Diagnostic Exercise . . . . . . . . . . . . . . . . . 191

Review Questions . . . . . . . . . . . . . . . . . . 191

Chapter 7: Exhaust Gas Analysis . . . 195

Objectives . . . . . . . . . . . . . . . . . . . . . . . . 195

Key Terms . . . . . . . . . . . . . . . . . . . . . . . . 195

Theory of Gas Analysis . . . . . . . . . . . . . . 195

Measured Gasses . . . . . . . . . . . . . . . . . . 197

Gas Analyzers . . . . . . . . . . . . . . . . . . . . . 202

Diagnosing with the Gasses . . . . . . . . . . 206

Summary . . . . . . . . . . . . . . . . . . . . . . . . . 209

Diagnostic Exercise . . . . . . . . . . . . . . . . . 209

Review Questions . . . . . . . . . . . . . . . . . . 209

Chapter 8: Understanding OBD II . . . 213

Objectives . . . . . . . . . . . . . . . . . . . . . . . . 213

Key Terms . . . . . . . . . . . . . . . . . . . . . . . . 213

CARB/EPA/SAE/OBD Background . . . . . 213

Why OBD II? . . . . . . . . . . . . . . . . . . . . . . 214

What Does OBD II Do? . . . . . . . . . . . . . . 214

Diagnostic Management Software . . . . . 215

Standardization . . . . . . . . . . . . . . . . . . . . 219

OBD II Monitors . . . . . . . . . . . . . . . . . . . 224

The Ten Global Modes of OBD II . . . . . . 235

Cold Start Emissions Reduction . . . . . . . 239

Reducing the Escape of HC

Emissions During Refueling . . . . . . . . 240

OBD III . . . . . . . . . . . . . . . . . . . . . . . . . . 241

Summary . . . . . . . . . . . . . . . . . . . . . . . . . 241

Diagnostic Exercise . . . . . . . . . . . . . . . . . 241

Review Questions . . . . . . . . . . . . . . . . . . 241

Chapter 9: Multiplexing Concepts . . . 245

Objectives . . . . . . . . . . . . . . . . . . . . . . . . 245

Key Terms . . . . . . . . . . . . . . . . . . . . . . . . 245

Multiplexing Overview . . . . . . . . . . . . . . . 245

Multiplex System Designs . . . . . . . . . . . . 248

Multiplexing Protocols . . . . . . . . . . . . . . . 250

Communication on a J1850 VPW

Data Bus . . . . . . . . . . . . . . . . . . . . . . . 252

Communication on a CAN

Data Bus . . . . . . . . . . . . . . . . . . . . . . . 254

Multiplexing Variations . . . . . . . . . . . . . . . 256

Fiber Optic Protocols . . . . . . . . . . . . . . . 258

Other Bosch Protocols . . . . . . . . . . . . . . 258

Diagnosis of Multiplexed Circuits . . . . . . 259

Summary . . . . . . . . . . . . . . . . . . . . . . . . . 260

Diagnostic Exercise . . . . . . . . . . . . . . . . . 260

Review Questions . . . . . . . . . . . . . . . . . . 260

Chapter 10: General Motors’

Electronic Engine Controls . . . . . . . . 263

Objectives . . . . . . . . . . . . . . . . . . . . . . . . 263

Key Terms . . . . . . . . . . . . . . . . . . . . . . . . 263

Powertrain Control Module . . . . . . . . . . . 264

Operating Modes. . . . . . . . . . . . . . . . . . . 265

Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

Fuel Management Systems . . . . . . . . . . 277

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Contents v

Idle Speed Control . . . . . . . . . . . . . . . . . 288

Spark Management Systems . . . . . . . . . 290

Emission Control Systems . . . . . . . . . . . 301

Other PCM-Controlled Systems . . . . . . . 310

Body Control Module . . . . . . . . . . . . . . . 316

System Diagnosis and Service . . . . . . . . 320

PCM, PROM, and CALPAK Service . . . . 323

Summary . . . . . . . . . . . . . . . . . . . . . . . . . 328

Diagnostic Exercise . . . . . . . . . . . . . . . . . 328

Review Questions . . . . . . . . . . . . . . . . . . 328

Chapter 11: Advanced General

Motors Engine Controls . . . . . . . . . . 331

Objectives . . . . . . . . . . . . . . . . . . . . . . . . 331

Key Terms . . . . . . . . . . . . . . . . . . . . . . . . 331

Northstar Engine Overview . . . . . . . . . . . 332

Northstar Inputs/Outputs . . . . . . . . . . . . . 336

Cadillac LH2 Northstar Upgrades . . . . . . 347

Cadillac HFV6 . . . . . . . . . . . . . . . . . . . . . 351

GM Generation III Small-Block V8s . . . . . 351

GM Generation IV Small-Block V8s . . . . 354

GM Active Fuel Management

System . . . . . . . . . . . . . . . . . . . . . . . . 354

Flywheel Alternator Starter System . . . . 356

Belt Alternator Starter System . . . . . . . . 361

Chevrolet Volt . . . . . . . . . . . . . . . . . . . . . 363

GM Voice-Recognition/ Navigational

System . . . . . . . . . . . . . . . . . . . . . . . . 364

System Diagnosis and Service . . . . . . . . 365

Summary . . . . . . . . . . . . . . . . . . . . . . . . . 366

Diagnostic Exercise . . . . . . . . . . . . . . . . . 366

Review Questions . . . . . . . . . . . . . . . . . . 366

Chapter 12: Ford’s Electronic

Engine Control IV (EEC IV) . . . . . . . . 371

Objectives . . . . . . . . . . . . . . . . . . . . . . . . 371

Key Terms . . . . . . . . . . . . . . . . . . . . . . . . 371

Powertrain Control Module . . . . . . . . . . . 372

Operating Modes. . . . . . . . . . . . . . . . . . . 373

Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 379

Fuel Management Systems . . . . . . . . . . 398

Idle Speed Control . . . . . . . . . . . . . . . . . 402

Spark Management Systems . . . . . . . . . 403

Emission Control Systems . . . . . . . . . . . 414

Other PCM-Controlled Systems . . . . . . . 420

System Diagnosis and Service . . . . . . . . 425

Summary . . . . . . . . . . . . . . . . . . . . . . . . . 436

Diagnostic Exercise . . . . . . . . . . . . . . . . . 436

Review Questions . . . . . . . . . . . . . . . . . . 436

Chapter 13: Ford’s Electronic

Engine Control V (EEC V) . . . . . . . . . 439

Objectives . . . . . . . . . . . . . . . . . . . . . . . . 439

Key Terms . . . . . . . . . . . . . . . . . . . . . . . . 439

Engine Controls Inputs . . . . . . . . . . . . . . 440

Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 440

Fuel Management Systems . . . . . . . . . . 443

Idle Speed Control . . . . . . . . . . . . . . . . . 446

Ignition Systems . . . . . . . . . . . . . . . . . . . 447

Emission Control Systems . . . . . . . . . . . 448

Advanced Ford Computer

System Features . . . . . . . . . . . . . . . . . 452

Body Control Modules . . . . . . . . . . . . . . . 460

Voice Recognition/Navigational

Systems . . . . . . . . . . . . . . . . . . . . . . . 461

AdvanceTrac™ System . . . . . . . . . . . . . . 462

EcoBoost Engine . . . . . . . . . . . . . . . . . . 463

CVPI Fire-Suppression System . . . . . . . 463

System Diagnosis and Service . . . . . . . . 464

Summary . . . . . . . . . . . . . . . . . . . . . . . . . 465

Diagnostic Exercise . . . . . . . . . . . . . . . . . 466

Review Questions . . . . . . . . . . . . . . . . . . 466

Chapter 14: Chrysler Corporation

Fuel Injection Systems . . . . . . . . . . . 469

Objectives . . . . . . . . . . . . . . . . . . . . . . . . 469

Key Terms . . . . . . . . . . . . . . . . . . . . . . . . 469

Powertrain Control Module . . . . . . . . . . . 470

Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 475

Fuel Management Systems . . . . . . . . . . 488

Idle Speed Control . . . . . . . . . . . . . . . . . 491

Spark Management Systems . . . . . . . . . 492

Emission Control Systems . . . . . . . . . . . 495

Other PCM-Controlled Systems . . . . . . . 497

Chrysler Multiplexing Systems . . . . . . . . 499

Advanced Chrysler Electronic

Systems . . . . . . . . . . . . . . . . . . . . . . . 499

System Diagnosis and Service . . . . . . . . 502

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vi Contents

Chapter 17: Alternative Power

Sources . . . . . . . . . . . . . . . . . . . . . . 583

Objectives . . . . . . . . . . . . . . . . . . . . . . . . 583

Key Terms . . . . . . . . . . . . . . . . . . . . . . . . 583

Honda Insight, Civic, and Accord

Hybrids . . . . . . . . . . . . . . . . . . . . . . . . 585

Toyota Hybrid System . . . . . . . . . . . . . . . 588

Ford Escape Hybrid . . . . . . . . . . . . . . . . 593

Allison Two-Mode Hybrids . . . . . . . . . . . . 595

Fuel Cell Vehicles . . . . . . . . . . . . . . . . . . 595

Flexible Fuel Vehicles . . . . . . . . . . . . . . . 599

System Diagnosis and Service . . . . . . . . 600

Summary . . . . . . . . . . . . . . . . . . . . . . . . . 601

Diagnostic Exercise . . . . . . . . . . . . . . . . . 601

Review Questions . . . . . . . . . . . . . . . . . . 601

Chapter 18: Approach

to Diagnostics . . . . . . . . . . . . . . . . . 605

Objectives . . . . . . . . . . . . . . . . . . . . . . . . 605

Key Terms . . . . . . . . . . . . . . . . . . . . . . . . 605

Narrowing Down the Area

of the Problem . . . . . . . . . . . . . . . . . . 605

Pinpoint Testing . . . . . . . . . . . . . . . . . . . . 609

Diagnosing Intermittent Symptoms . . . . . 614

Testing Catalytic Converters . . . . . . . . . . 615

EVAP System Tests . . . . . . . . . . . . . . . . . 618

Diagnosing Air/Fuel Ratio Problems . . . . 620

Diagnosing an Emission

Test Failure . . . . . . . . . . . . . . . . . . . . . 623

Reprogramming a Computer . . . . . . . . . . 626

The Three Essential Tools of Electronic

System Diagnosis . . . . . . . . . . . . . . . . 629

Other Diagnostic Resources . . . . . . . . . . 630

Summary . . . . . . . . . . . . . . . . . . . . . . . . . 630

Diagnostic Exercise . . . . . . . . . . . . . . . . . 631

Review Questions . . . . . . . . . . . . . . . . . . 631

Appendix A: Terms and Acronyms . . . 635

Appendix B: Automotive-Related

Web Addresses . . . . . . . . . . . . . . . . 643

Glossary . . . . . . . . . . . . . . . . . . . . . 645

Index . . . . . . . . . . . . . . . . . . . . . . . 663

Summary . . . . . . . . . . . . . . . . . . . . . . . . . 505

Diagnostic Exercise . . . . . . . . . . . . . . . . . 506

Review Questions . . . . . . . . . . . . . . . . . . 506

Chapter 15: European (Bosch)

Engine Control Systems . . . . . . . . . . 509

Objectives . . . . . . . . . . . . . . . . . . . . . . . . 509

Key Terms . . . . . . . . . . . . . . . . . . . . . . . . 509

System Overview . . . . . . . . . . . . . . . . . . 510

Continuous Injection System. . . . . . . . . . 513

Pulsed Systems . . . . . . . . . . . . . . . . . . . 514

Motronic . . . . . . . . . . . . . . . . . . . . . . . . . 516

Electronic Control Unit . . . . . . . . . . . . . . 516

Operating Modes. . . . . . . . . . . . . . . . . . . 519

Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 521

Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . 524

Bosch Obd II Update . . . . . . . . . . . . . . . . 533

System Diagnosis and Service . . . . . . . . 534

Summary . . . . . . . . . . . . . . . . . . . . . . . . . 535

Diagnostic Exercise . . . . . . . . . . . . . . . . . 535

Review Questions . . . . . . . . . . . . . . . . . . 535

Chapter 16: Asian Computer

Control Systems . . . . . . . . . . . . . . . . 539

Objectives . . . . . . . . . . . . . . . . . . . . . . . . 539

Key Terms . . . . . . . . . . . . . . . . . . . . . . . . 539

Nissan: Electronic Concentrated

Control System (ECCS) . . . . . . . . . . . 540

Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 542

Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . 549

System Diagnosis and Service . . . . . . . . 553

Toyota Computer-Controlled

System (TCCS) . . . . . . . . . . . . . . . . . . 554

Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 554

Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . 557

System Diagnosis and Service . . . . . . . . 564

Honda: Programmed Fuel

Injection (PGM-FI) . . . . . . . . . . . . . . . 565

Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 565

Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . 569

Honda’s VTEC Systems . . . . . . . . . . . . . 573

System Diagnosis and Service . . . . . . . . 578

Summary . . . . . . . . . . . . . . . . . . . . . . . . . 579

Diagnostic Exercise . . . . . . . . . . . . . . . . . 579

Review Questions . . . . . . . . . . . . . . . . . . 579

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1

Chapter 1

A Review of Electricity and Electronics

OBJECTIVES

Upon completion and review of this chapter, you should be able to:

❑ Understand the conceptual differences between the terms

electrical/and electronic.

❑ Understand how a compound is different from an element.

❑ Define the difference between an element and a compound.

❑ Describe the importance of an atom’s valence ring as it pertains

to electrical theory.

❑ Understand the relationship between voltage, resistance, and

amperage.

❑ Define circuit types in terms of series circuits and parallel circuits.

❑ Understand the construction and operation of semiconductors

such as diodes and transistors.

❑ Define the difference between an analog voltage signal and a

digital voltage signal.

❑ Describe the relationship between a variable frequency, variable

duty cycle, and variable pulse width.

KEY TERMS

Amp or Ampere

Amperage

Analog

Armature

Clamping Diode

Compound

Digital

Diode

Dual In-Line Package (DIP)

Electrical

Electromotive Force

Electronic

Element

Free Electrons

H-Gate

Integrated Circuit (IC)

Molecule

Negative Ion

Ohm

Ohm’s Law

Permeability

Positive Ion

Reluctance

Resistance

Semiconductors

Solenoid

Transistor

Valence Ring

Volt

Voltage or Voltage Potential

Voltage Drop

The earliest automobiles had little in the way

of electrical systems, but as the automobile has

become more complicated and as more acces￾sories have been added, electrical and electronic

systems have replaced mechanical methods of con￾trol on today’s vehicles. Additional electronic control

systems have made and will continue to make the

automobile comply with government standards and

consumer demands. Today, most major automotive

systems are controlled by computers.

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2 Chapter 1 A Review of Electricity and Electronics

This increased use of electrical and elec￾tronic systems means two things for the automo￾tive service technician: First, to be effective, all

service technicians need skills in electrical diag￾nosis and repair, almost regardless of the techni￾cian’s service specialty; second, technicians with

such skills will command significantly greater fi￾nancial rewards and will deserve them.

There are several principles by which electri￾cal systems operate, but they are all fairly simple;

learning them is not difficult. As each principle

is introduced to you through your reading or in

class, ask questions and/or read until you under￾stand it. Review the principles often and practice

the exercises that your instructor assigns.

ELECTRICAL CIRCUITS VERSUS

ELECTRONIC CIRCUITS

The differences between electrical circuits

and electronic circuits are not always clear-cut.

This has led to some confusion about the use of

terms and how an electronic system differs from

an electrical system. Perhaps the comparisons in

the following table will help.

Think of electrical circuits as the muscle and

electronic circuits as the brain. Electrical circuits

have been used in the automobile since the first one

came off the assembly line, but electronic circuits

have been added to the automobile in more recent

years. For example, interior lighting circuits began

on the automobile as simple electrical circuits and

without any electronic control. But, more often than

not, interior lighting systems on today’s vehicles are

controlled electronically by a computer.

Even though the use of solid-state compo￾nents may often be used as a criterion to identify

an electronic circuit, solid-state components,

such as power transistors, may also be used in

an electrical circuit. A power transistor is a type

of transistor designed to carry larger amounts of

amperage than are normally found in an elec￾tronic circuit. A power transistor is essentially a

highly reliable relay.

Ultimately, an electrical circuit is a circuit

that performs work through a load device. An

electronic circuit is used to intelligently control

an electrical circuit. Therefore, an electrical cir￾cuit may or may not be under the control of an

electronic circuit.

It should also be noted that a component

identified as an electronic device always needs

a proper power (positive) and ground (negative)

just to power up properly, whether it is a small

integrated circuit (IC) chip or a complex, sophis￾ticated computer. If either one is lacking it cannot

do its assigned job properly.

Electrical Circuits Electronic Circuits

Do physical work: heat, light, and electro￾magnetism used to create movement.

Communicate information: voltages or on/off

signals.

Use electromechanical devices: motors,

solenoids, relays.

Use solid-state devices (semiconductors) with

no moving parts, such as transistors and

diodes.

Operate at relatively high current or amperage. Operate at relatively low current or amperage.

Have relatively low resistance (ohms). Have relatively high resistance (ohms).

May or may not be controlled by an electronic

circuit.

Are used to control electrical circuits.

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Chapter 1 A Review of Electricity and Electronics 3

not have a neutron. The next smallest and lightest

atom is the helium atom. It has two protons, two

neutrons, and two electrons (Figure 1–2). Since

the hydrogen atom is the smallest and lightest,

and since it has one electron and one proton, it is

given an atomic number of 1. Since helium is the

next lightest, it has an atomic number of 2. Every

atom has been given an atomic number that indi￾cates its relative size and weight (or its mass) and

the number of electrons, protons, and neutrons it

contains. An atom usually has the same number

of electrons, protons, and neutrons.

Elements

Once the three different bits of matter are

united to form an atom, two or more atoms com￾bine to form a molecule. If all of the atoms in the

molecule are the same, the molecule is called an

element. Which element it is depends on how

many protons, neutrons, and electrons the atoms

contain. There are more than a hundred differ￾ent elements. Some examples of elements are

gold, lead, iron, and sodium. Examples of other

elements that are of concern to an automotive

technician include hydrogen, carbon, nitrogen,

oxygen, and silicon. An element, then, is a pure

substance whose molecules contain only one

kind of atom.

ELECTRON THEORY

Molecules and Atoms

A study of electricity begins with the smallest

pieces of matter. All substances—air, water, wood,

steel, stone, and even the various substances that

our bodies are made of—are made of the same

bits of matter. Every substance is made of units

called molecules. A molecule is a unit formed by

combining two or more atoms; it is the smallest

unit that a given substance can be broken down

to and still exhibit all of the characteristics of that

substance. For example, a molecule of water, or

H2O, is made up of two atoms of hydrogen and

one atom of oxygen (H is the chemical symbol

for hydrogen and O is the chemical symbol for

oxygen). If a molecule of water is broken down

into its component atoms, it is no longer water.

As molecules are made up of atoms, atoms

are in turn made up of:

• electrons, or negatively charged particles

• protons, or positively charged particles

• neutrons, or particles with no charge; at the

level of atomic activity concerning us here,

neutrons just add mass to the atom

The smallest and lightest atom is the hydro￾gen atom. It contains one proton and one elec￾tron (Figure 1–1); it is the only atom that does

Figure 1–1 Hydrogen atom. © Cengage Learning 2012

Electron

Proton

Orbit path

Figure 1–2 Helium atom. © Cengage Learning 2012

Electrons

Protons

Orbit path

Neutrons

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4 Chapter 1 A Review of Electricity and Electronics

fact, they are sometimes said to move at nearly the

speed of light. These characteristics work together

to explain many of the behaviors of an atom that

make current flow. Current is defined as a mass of

free electrons moving in the same direction.

There are two types of current: direct current

(DC) and alternating current (AC). Direct current

always flows in one direction. Current from a bat￾tery is the best example. Most of the devices in

an automobile use DC. Circuits with alternating

current repeatedly switch the polarity of the circuit

so that current flow (electron movement) reverses

direction repeatedly. The power available from

commercial utility companies is AC and cycles

(changes polarity) 60 times per second. This is

known as 60 Hertz (Hz) AC voltage. One cycle

occurs when the current switches from forward to

backward to forward again. The car’s alternator

(an AC generator) produces AC current, which is

converted to DC before it leaves the alternator.

The fast-moving electron wants to move in a

straight line, but its attraction to the proton nucleus

makes it act like a ball tied to the end of a string

twirled around. The repulsive force between the

electrons keeps them spread as far apart as their

attraction to the nucleus will allow.

The fewer electrons there are in the outer shell

of the atom and the more layers of electrons there

Compounds

A substance such as water, which contains hy￾drogen and oxygen atoms, is called a compound.

Examples of other compounds that are of con￾cern to an automotive technician include carbon

dioxide, carbon monoxide, hydrocarbons, and ox￾ides of nitrogen. Therefore, compounds consist of

two or more elements.

Molecules

A molecule consists of a minimum of two

atoms that are chemically bonded together; it is

electrically stable, with a neutral charge. A mole￾cule may contain two or more identical atoms and

therefore be an element, such as an oxygen mol￾ecule (O2), or it may have atoms of two or more

elements and therefore be a compound, such as

water (H2O).

Atomic Structure and Electricity

Notice in Figure 1–1 and Figure 1–2 that the

protons and neutrons are grouped together in the

center of each atom, which is called the nucleus of

the atom. The electrons travel around the nucleus

of the atom in an orbit, similar to the way that the

Earth travels around the sun. But because an atom

usually has several electrons orbiting around its

nucleus, the electrons form in layers, rather than

all of them traveling in the same orbit (Figure 1–3).

Some, however, share the same orbit, as seen in

Figure 1–3. For the purposes of this text, only the

electrons in the last layer are of any real impor￾tance. This layer is often called the outer shell or

valence ring. The student should realize that we

are speaking very loosely here when we describe

electrons in shells having orbits. For our pur￾poses, this simple explanation (a model once

called the Rutherford atom) satisfactorily conveys

the nature of the electron.

As mentioned, electrons are negatively charged

and protons are positively charged. You have prob￾ably heard or know that like charges repel and un￾like charges attract. Electrons are always moving; in

Figure 1–3 Layers of electrons around a copper

atom nucleus. © Cengage Learning 2012

1st layer (2 electrons)

2nd layer (8 electrons)

3rd layer (18 electrons)

Outer layer (1 electron)

Nucleus

(29 protons)

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Chapter 1 A Review of Electricity and Electronics 5

in the wire. Actually, this resistance has two func￾tions. It limits current flow so as to keep the wire

from burning open and it also turns the current

flow into some type of useful work—heat, light, or

electromagnetism.

It is the voltage potential that makes current

flow. Actually, three factors must be present for

an electrical circuit to work properly. These three

factors are voltage potential, resistance to flow,

and current flow, as demonstrated in the following

example:

Suppose that you have a glass of your

favorite lemonade sitting on your patio table

on a nice summer day. Suppose that there

is a straw sitting in the glass of lemonade.

There is atmospheric pressure acting on

the lemonade in the glass and therefore

at the lower end of the straw. There is also

are under the outer shell, the weaker is the bond

between the outer electrons and the nucleus. If

one of these outer electrons can somehow be

broken free from its orbit, it will travel to a neigh￾boring atom and fall into the outer shell there, re￾sulting in two unbalanced atoms. The first atom is

missing an electron. It is now positively charged

and is called a positive ion. The second atom

has an extra electron. It is negatively charged and

is called a negative ion. Ions are unstable. They

want either to gain an electron or to get rid of one

so that they are balanced.

ELECTRICAL THEORY

Voltage Potential

An atom that is a positive ion has positive

potential. It has more positive charge than neg￾ative charge because it has more protons than

electrons. Suppose that this atom is at one end of

a circuit (Figure 1–4). Further suppose that there

is a negative ion at the other end of the circuit in

that this atom has an extra electron, thus giving it

a negative potential. Because of the difference in

potential at the two ends of the circuit, an electron

at the negatively charged end will start moving

toward the positively charged end. The greater

the difference in potential (the greater the num￾ber of opposite-charged ions) at each end of the

circuit, the greater the number of electrons that

will start to flow. This potential difference between

the two charges is commonly known as voltage

potential.

An example can be created by attaching

something between the two ends of a circuit

that will produce positive and negative ions. This

is what a battery or generator does in a circuit

(Figure 1–4). If you connect both ends of a copper

wire to a battery, the voltage potential will cause

electron flow through the wire. However, because

the wire will not be able to handle the electron flow

that the battery can provide, it will burn open very

quickly. Therefore some kind of resistance, or

opposition to a steady electric current, is needed

Figure 1–4 Negative versus positive potential.

© Cengage Learning 2012

Light bulb

Electron flow from

negative to positive

Light bulb

Electron flow from

negative to positive

Atom with

negative charge

(– ion)

Atom with

positive charge

(+ ion)

Negative ions at

negative terminal

Positive ions at

positive terminal Battery

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