Hybrid and alternative fuel vehicles

HYBRID AND

ALTERNATIVE FUEL

VEHICLES

Second Edition

James D. Halderman

Tony Martin

Prentice Hall

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iii

PROFESSIONAL TECHNICIAN SERIES Part of Pearson

Automotive’s Professional Technician Series, the second edition

of Hybrid and Alternative Fuel Vehicles represents the future of

automotive textbooks. The series includes textbooks that cover

all 8 areas of ASE certification plus additional titles covering

common courses.

Current revisions are written by a team of very experienced

writers and teachers. The series is also peer reviewed for tech￾nical accuracy.

UPDATES TO THE SECOND EDITION

New design.

Total of 18 chapters.

Five new chapters include:

Gasoline (Chapter 4)—Expanded content on gasoline￾related material. This allows the instructor flexibility in as￾signing reading assignments and helps make teaching

and learning more concisely matched to a given topic.

Alternative Fuels (Chapter 5)—Expanded content to

make teaching and learning easier.

Diesel and Biodiesel Fuels (Chapter 6)—An entire

chapter devoted to fuel-related content makes it

easier for students to learn.

Hybrid Safety and Service Procedures (Chapter 12)—

Instructors and reviewers requested this chapter to help

meet the need for a chapter that includes all of the safety

and service issues for hybrid electric vehicles.

First Responder Procedures (Chapter 13)—This chapter

was created with input from and reviewed by actual

fire and emergency personnel to ensure accuracy.

Batteries content (Chapter 7) has been completely

updated.

More study questions have been added, due to

expanded chapters and content, making self-evaluation

easier.

A COMPLETE INSTRUCTOR AND STUDENT SUPPLE￾MENTS PACKAGE All Professional Technician textbooks

are accompanied by a full set of instructor and student supple￾ments. Please see page vi for a detailed list of supplements.

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

students and beginning technicians need more training in diag￾nostic procedures and skill development. To meet this need and

demonstrate how real-world problems are solved, “Real World

Fix” features are included throughout and highlight how real-life

problems are diagnosed and repaired.

The following pages highlight the unique core features that

set the Professional Technician Series book apart from other

automotive textbooks.

PREFACE

iv IN-TEXT FEATURES

IN-TEXT FEATURES

TECH TIPS feature real-world advice and “tricks of the

trade” from ASE-certified master technicians.

REAL WORLD FIXES present students with actual automo￾tive service scenarios and show how these common (and some￾times uncommon) problems were diagnosed and repaired.

FREQUENTLY ASKED QUESTIONS are based on the au￾thor’s own experience and provide answers to many of the most

common questions asked by students and beginning service

technicians.

SAFETY TIPS alert students to possible hazards on the job

and how to avoid them.

OBJECTIVES AND KEY TERMS appear

at the beginning of each chapter to help stu￾dents and instructors focus on the most impor￾tant material in each chapter. The chapter

objectives are based on specific ASE and

NATEF tasks.

chapter 1

CARBON-BASED

FUELS AND THE

ENVIRONMENT

After studying Chapter 1, the reader will be

able to:

1. Describe the role of hybrid and alternative fuel

vehicles in today’s society.

2. Identify carbon-based fuels.

3. Describe how organic materials decompose into

carbon-based fuels.

4. Explain the difference between carbon-based

and non-carbon-based energy sources.

5. Explain the federal and California Air Resources

Board emission standards.

6. List alternatives to carbon-based fuels.

7. List the factors that will be needed to reduce the

carbon footprint.

OBJECTIVES

AT-PZEV 5

Bin Number 5

CAA 4

CARB 4

Carbohydrates 2

Carbon 2

Carbon Dioxide 3

Carbon Footprint 13

Carbon Monoxide 3

EPA 4

Global Warming 15

Greenhouse Gas (GHG) 9

Hydrocarbons 3

ILEV 5

IPCC 11

Irradiance 9

Kyoto Protocol 11

LEV 4

Nitrogen 2

NLEV 5

ODS 11

Organic 2

Oxygen 2

Ozone 8

Peak Oil 14

pH 12

PM 4

PZEV 5

Smog 3

Soot 14

Stratosphere 9

SULEV 4

Tier 4

TLEV 4

Troposphere 9

ULEV II 4

Ultraviolet (UV)

Radiation 9

UVA 9

UVB 9

UVC 9

VOC 11

ZEV 4

KEY TERMS

1

Shop Cloth Disposal

Always dispose of oily shop cloths in an enclosed

container to prevent a fire. SEE FIGURE 1-69.

Whenever oily cloths are thrown together on the floor

or workbench, a chemical reaction can occur, which

can ignite the cloth even without an open flame. This

process of ignition without an open flame is called

spontaneous combustion.

SAFETY TIP

Use the KISS Test Method

Engine testing is done to find the cause of an engine

problem. All the simple things should be tested first.

Just remember KISS—“keep it simple, stupid.” A

loose alternator belt or loose bolts on a torque con￾verter can sound just like a lifter or rod bearing.

TECH TIP

Three Brake Jobs in 40,000 Miles

A service technician was asked to replace the front disc

brake pads on a Pontiac Grand Am because the sen￾sors were touching the rotors and making a squealing

sound. This was the third time that the front brakes

needed to be replaced. Previous brake repairs had been

limited to replacement of the front disc brake pads only.

REAL WORLD FIX

How Many Types of Screw Heads

Are Used in Automotive Applications?

There are many, including Torx, hex (also called

Allen), plus many others used in custom vans and

motor homes. SEE FIGURE 1–9.

? FREQUENTLY ASKED QUESTION

IN-TEXT FEATURES v

NOTES provide students with additional technical informa￾tion to give them a greater understanding of a specific task or

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 pre￾sented in the chapter and test themselves to see

how much they’ve learned.

CAUTIONS alert students about potential damage to the ve￾hicle that can occur during a specific task or service procedure.

WARNINGS alert students to potential dangers to them￾selves during a specific task or service procedure.

HYBRID SAFETY AND SERVICE PROCEDURES 249

STEP BY STEP

Petroleum on the leather protector’s surfaces will 7 damage the rubber glove underneath.

Glove powder (glove dust) should be used to absorb 8 moisture and reduce friction.

Put on the gloves and tighten the straps on the back of 9 the leather protectors.

Technicians MUST wear HV gloves and leather

protectors whenever working around the 10 high-voltage areas of a hybrid electric vehicle.

HV gloves and leather protectors should be placed

in a canvas storage bag when not in use. Note the 11 ventilation hole at the bottom of this bag.

Make sure that the rubber gloves are not folded

when placed in the canvas bag. Folding increases

mechanical stress on the rubber and can lead to

premature failure of the glove material.

12

248 CHAPTER 12

HV GLOVE USE

The cuff of the rubber glove should extend at least 1 1/2 inch beyond the cuff of the leather protector.

To determine correct glove size, use a soft tape to

measure around the palm of the hand. A measurement 2 of 9 inches would correspond with a glove size of 9.

The glove rating and the date of the last test should be 3 stamped on the glove cuff.

Start with a visual inspection of the glove fingertips, 4 making sure that no cuts or other damage is present.

The damage on this glove was easily detected with a

simple visual inspection. Note that the rubber glove

material can be damaged by petroleum products,

detergents, certain hand soaps, and talcum powder.

Manually inflate the glove to inspect for pinhole leaks.

Starting at the cuff, roll up the glove and trap air at the

finger end. Listen and watch carefully for deflation of the

glove. If a leak is detected, the glove must be discarded.

5 6

Do not use incandescent trouble lights around

gasoline or other flammable liquids.

WARNING

NOTE: A claw hammer has a claw used to remove nails

and is not used for automotive service.

CAUTION: Professional repair shops do not use ramps

because they are dangerous to use. Use only with ex￾treme care.

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, lineman’s, diago￾nal, needle nose, and locking pliers.

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

cutters, punches, chisels, and hacksaws.

12. Hybrid electric vehicles should be de-powered if any of the

high voltage components are going to be serviced.

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 rat￾ing 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 combi￾nation open and box end.

4. An adjustable wrench should only be used where the

proper size 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.

16 CHAPTER 1

SUMMARY

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?

1. List three precautions that must be taken whenever hoist￾ing (lifting) a vehicle.

2. Describe how to determine the grade of a fastener, includ￾ing 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.

REVIEW QUESTIONS

7. The proper term for Vise Grips is ________.

a. Locking pliers b. Slip joint pliers

c. Side cuts d. Multigroove adjustable pliers

8. Two technicians are discussing torque wrenches. Techni￾cian A says that a torque wrench is capable of tightening a

fastener with more torque than a conventional breaker bar

or ratchet. Technician B says that a torque wrench should

be calibrated regularly for the most accurate results. Which

technician is correct?

a. Technician A only c. Both Technicians A and B

b. Technician B only d. Neither Technician A nor B

9. What type of screwdriver should be used if there is very

limited space above the head of the fastener?

a. Offset screwdriver c. Impact screwdriver

b. Stubby screwdriver d. Robertson screwdriver

10. What type of hammer is plastic coated, has a metal casing

inside, and is filled with small lead balls?

a. Dead-blow hammer c. Sledge hammer

b. Soft-blow hammer d. Plastic hammer

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

the vehicle can often be found in the ________.

a. Service manual c. Owner's manual

b. Shop manual d. All of the above

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

a. At neck or head level c. Overhead by about 1 foot

b. At knee or ankle level d. At chest or elbow level

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

a. A UNC symbol c. Strength letter codes

b. Lines on the head d. The coarse threads

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

______.

a. Cap screw c. Machine screw

b. Stud d. Crest fastener

5. When working with hand tools, always ________.

a. Push the wrench—don’t pull toward you

b. Pull a wrench—don’t push a wrench away from you

6. The proper term for Channel Locks is ________.

a. Vise Grips c. Locking pliers

b. Crescent wrench d. Multigroove adjustable pliers

CHAPTER QUIZ

INSTRUCTOR SUPPLEMENTS The instructor supplement

package has been completely revamped to reflect the needs of

today’s instructors. The all new Online Instructor’s Resource

Manual (ISBN: 0-13-512326-7) is the cornerstone of the package.

To access supplementary materials online, instructors

need to request an instructor access code. Go to www.

pearsonhighered.com/irc, where you can register for an instruc￾tor access code. Within 48 hours after registering, you will receive

a confirming e-mail, including an instructor access code. Once

you have received your code, go to the site and log on for full

instructions on downloading the materials you wish to use.

Here you will find:

PowerPoint presentations

Image Library containing every image in the book for use

in class or customized PowerPoints

Test Generator software and test bank

NATEF Correlated Task Sheets (also available as a printed

supplement [ISBN: 0-13-512325-9])

vi SUPPLEMENTS

SUPPLEMENTS

STUDENT SUPPLEMENTS NO MORE CDs!!

As a result of extensive student input, Pearson is no longer

binding CDs into automotive students’ textbooks. Today’s stu￾dent has more access to the internet than ever so all supple￾mental materials are downloadable at the following site for no

additional charge:

www.pearsoned.com/autostudent

On the site, students will find:

PowerPoint presentations

Chapter review questions and quizzes

English and Spanish glossaries

A full Spanish translation of the text

A large number of people and organizations have cooperated in

providing the reference material and technical information used

in this text. The authors wish to express sincere thanks to the

following organizations for their special contributions.

Automotion, Inc.

BP

Carl McClure, Honda Training Center

Chevron

DaimlerChrysler

Stephen Ellis, Honda

Ford Motor Company

General Motors Corporation

Curt Henriott, Ford

Honda

Tim Jones, Honda Training Center

Chris Karr, Ford

Rex Kent, Sinclair Community College, Dayton, Ohio

Andy Knevel, Toyota

Lloyd Koppes, Toyota

NEDRA

Adam Pietrzak, General Motors

Richard Reaves

SAE

Toyota

Craig Van Batenburg, ACDC

Bob Van Horn, General Motors

Society of Automative Engineers (SAE)

Toyota Motor Sales, USA, Inc.

TECHNICAL AND CONTENT REVIEWERS The fol￾lowing people reviewed the manuscript before production and

checked it for technical accuracy and clarity of presentation.

Their suggestions and recommendations were included in the

ACKNOWLEDGMENTS vii

ACKNOWLEDGMENTS

final draft of the manuscript. Their input helped make this text￾book clear and technically accurate while maintaining the

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

author so popular.

Ed Avella

Lincoln Technical Institute—Columbia Campus

Al Clarke

Lane Community College

Al Forte

Odessa College

Thomas Grothous

University of Northwestern Ohio

Steve Klausing

University of Northwestern Ohio

Andy O’Neal

University of Northwestern Ohio

SPECIAL THANKS The authors wish to thank Blaine

Heeter, Mike Garblik, and Chuck Taylor of Sinclair Community

College in Dayton, Ohio, and James (Mike) Watson, who helped

with many of the photos.

Thanks to Richard Krieger, Michigan Institute of Technol￾ogy, for his excellent review of the manuscript and his helpful

suggestions.

Most of all, we would like to thank our wives, Lara Martin

and Michelle Halderman, for all their hard work.

—James D. Halderman

—Tony Martin

JIM HALDERMAN brings a world of experience, knowledge,

and talent to his work. His automotive service experience in￾cludes working as a flat-rate technician, a business owner, and

a professor of automotive technology at a leading U.S. commu￾nity 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 Uni￾versity in Oxford, Ohio. Jim also holds a U.S. Patent for an elec￾tronic 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 pub￾lished by Prentice Hall.

Jim has presented numerous technical seminars to na￾tional audiences, including the California Automotive Teachers

(CAT) and the Illinois College Automotive Instructor Association

(ICAIA). He is also a member and presenter at the North Ameri￾can Council of Automotive Teachers (NACAT). Jim was also

named Regional Teacher of the Year by General Motors Corpo￾ration and outstanding alumni of Ohio Northern University.

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

two children. You can reach Jim at

[email protected]

ABOUT THE AUTHORS

TONY MARTIN Tony Martin is the department head and

primary instructor for the Automotive Technology program at

the University of Alaska Southeast in Juneau, Alaska. He started

his career with 10 years in heavy-duty diesel, graduating from

the Interprovincial Apprenticeship program in Canada.

His experience includes two years working as a gas tur￾bine technician in Alaska’s Cook Inlet oilfield. Tony has been

teaching automotive and diesel technology for 13 years, with

the first 5 years spent on Alaska’s North Slope as a faculty

member at Ilisagvik College in Barrow.

He has a Bachelor’s Degree in Technology and an AAS

Degree in Diesel Technology from the University of Alaska–

Anchorage, as well as 19 ASE certifications (CMAT, CMTT, L1,

and L2). Tony is a Contributing Editor for Motor Age magazine,

writing mostly on diesel and hybrid technology topics. Tony is

also a member of NACAT and presents regularly at its national

conferences. Tony and his family (wife Lara and five children)

live in Juneau, Alaska.

You can reach Tony at

[email protected]

viii ABOUT THE AUTHORS

ix

chapter 1 Carbon-Based Fuels and the Environment 1

chapter 2 Introduction to Hybrid Vehicles 18

chapter 3 Internal Combustion Engine Systems 30

chapter 4 Gasoline 65

chapter 5 Alternative Fuels 82

chapter 6 Diesel and Biodiesel Fuels 98

chapter 7 Hybrid Batteries and Battery Service 104

chapter 8 Electric Motors, Generators, and Controls 132

chapter 9 Regenerative Braking Systems 155

chapter 10 Hybrid Vehicle Transmissions and Transaxles 168

chapter 11 Hybrid Vehicle Heating and Air Conditioning 206

chapter 12 Hybrid Safety and Service Procedures 236

chapter 13 First Responder Procedures 251

chapter 14 Honda Hybrid Vehicles 262

chapter 15 Toyota/Lexus Hybrid Vehicles 283

chapter 16 Ford/Mercury Hybrid Vehicles 308

chapter 17 General Motors Hybrid Vehicles 324

chapter 18 Fuel Cells and Advanced Technologies 339

appendix 1 Hybrid Vehicle Diagnostic Trouble Codes 357

English Glossary 361

Spanish Glossary 370

Index 381

BRIEF CONTENTS

chapter 1

CARBON-BASED FUELS

AND THE ENVIRONMENT 1

Objectives 1

Key Terms 1

The Purpose of Hybrid and Alternative-Fuel Vehicles 2

Carbon-Based Society 2

Chemical Fundamentals of Carbon-Based Society 2

The Clean Air Act Establishes the Framework 4

Emission Standards in the United States 4

European Standards 8

Ozone 8

Ultraviolet Radiation Absorption 9

Kyoto Protocol 11

Health Effects of Air Pollution 11

Acid Rain 12

Carbon Footprint 13

Global Warming 15

SUMMARY 17

REVIEW QUESTIONS 17

CHAPTER QUIZ 17

chapter 2

INTRODUCTION TO HYBRID

VEHICLES 18

Objectives 18

Key Terms 18

Hybrid Vehicle 19

Driving and Owning a Hybrid Electric Vehicle 21

Classifications of Hybrid Electric Vehicles 22

Belt Alternator Starter Systems 24

Levels of Hybrid Vehicles 27

SUMMARY 28

REVIEW QUESTIONS 28

CHAPTER QUIZ 28

chapter 3

INTERNAL COMBUSTION

ENGINE SYSTEMS 30

Objectives 30

Key Terms 30

Hybrid Internal Combustion Engines (ICE) 31

Engine Fundamentals 31

Atkinson Cycle 33

Engine Specifications 35

Torque, Work, and Power 37

Hybrid Engine Design Features 39

Hybrid Engine Lubrication System 44

Engine Oil 45

Synthetic Oil 48

Oil Change Intervals 49

Hybrid Engine Ignition System 49

Oxygen Sensors 53

Wide-Band Oxygen Sensor 55

Fuel Injection Systems 57

Mechanical Returnless Fuel System 58

Gasoline Direct Injection 58

Demand Delivery System (DDS) 59

Electronic Returnless Fuel System 59

Fuel Injectors 60

Electronic Throttle Control 61

SUMMARY 64

REVIEW QUESTIONS 64

CHAPTER QUIZ 64

chapter 4

GASOLINE 65

Objectives 65

Key Terms 65

Gasoline 66

Refining 66

Volatility 68

Gasoline Combustion Process 70

Normal and Abnormal Combustion 71

Octane Rating 72

Gasoline Additives 73

x

CONTENTS

High-Altitude Octane Requirements 73

Gasoline Blending 75

Testing Gasoline for Alcohol Content 76

Reformulated Gasoline 76

General Gasoline Recommendations 78

SUMMARY 81

REVIEW QUESTIONS 81

CHAPTER QUIZ 81

chapter 5

ALTERNATIVE FUELS 82

Objectives 82

Key Terms 82

Introduction 83

Ethanol 83

Cellulose Ethanol 84

E85 85

Alternative-Fuel Vehicles 85

Methanol 90

Propane 91

Compressed Natural Gas (CNG) 91

Liquefied Natural Gas (LNG) 93

P-Series Fuels 94

Synthetic Fuels 95

Safety Procedures When Working with Alternative Fuels 96

SUMMARY 97

REVIEW QUESTIONS 97

CHAPTER QUIZ 97

chapter 6

DIESEL AND BIODIESEL FUELS 98

Objectives 98

Key Terms 98

Diesel Fuel 99

Biodiesel 101

chapter 7

HYBRID BATTERIES AND BATTERY

SERVICE 104

Objectives 104

Key Terms 104

Introduction 105

Evolution of Battery Technology 105

Lead–Acid Batteries 106

Nickel-Cadmium 107

Nickel-Metal Hydride 107

Lithium-Ion 108

Lithium-Polymer 109

Zinc-Air 110

Sodium-Sulfur 110

Sodium-Metal-Chloride 111

Battery Comparsion 111

Role of the Auxiliary Battery in the Hybrid System 112

Lead–Acid Technology 112

Battery Ratings 114

Lead–Acid Battery Safety Precautions 115

Lead–Acid Battery Testing 118

Valve Regulated Lead Acid 121

Role of the HV Battery in the Hybrid System 123

High-Voltage (HV) Battery Construction 124

HV Battery Cooling 127

HV Battery Service 129

SUMMARY 130

REVIEW QUESTIONS 130

CHAPTER QUIZ 130

chapter 8

ELECTRIC MOTORS, GENERATORS,

AND CONTROLS 132

Objectives 132

Key Terms 132

Fundamentals of Magnetism 133

Electromagnetism 135

Electromagnetic Induction 137

Electric Motors 138

CONTENTS xi

REVIEW QUESTIONS 103

CHAPTER QUIZ 103

E-DIESEL FUEL 103

SUMMARY 103

xii CONTENTS

Brushless Motors 140

Motor Control 143

Capacitors in Hybrid Controllers 146

Converters and Inverters 149

Electric Power Steering 151

SUMMARY 154

REVIEW QUESTIONS 154

CHAPTER QUIZ 154

chapter 9

REGENERATIVE BRAKING

SYSTEMS 155

Objectives 155

Key Terms 155

Introduction 156

Principles of Regenerative Braking 156

Types of Regenerative Braking Systems 158

Battery Charging During Regeneration 159

Regenerative Braking Systems 160

How the Regeneration System Works 163

Deceleration Rates 164

Engine Design Changes Related to Regenerative

Braking 164

Servicing Regenerative Braking Systems 165

SUMMARY 166

REVIEW QUESTIONS 166

CHAPTER QUIZ 166

chapter 10

HYBRID VEHICLE TRANSMISSIONS

AND TRANSAXLES 168

Objectives 168

Key Terms 168

Introduction 169

Manual Versus Automatic 169

Why a Transmission Is Necessary 170

Manual Transaxles 171

Service 177

Conventional Automatic Transmissions 178

GM Silverado/Sierra Hybrid Automatic Transmission 183

Honda Accord Hybrid Five-Speed Automatic

Transmission 185

Continuously Variable Transmissions (CVTS) 189

Toyota/Lexus Power-Split System 190

Ford Escape Hybrid ECVT 197

Honda Belt-and-Pulley CVT 199

SUMMARY 204

REVIEW QUESTIONS 204

CHAPTER QUIZ 205

chapter 11

HYBRID VEHICLE HEATING

AND AIR CONDITIONING 206

Objectives 206

Key Terms 206

Introduction 207

Hybrid Ice Cooling Systems 207

Cooling System Components 208

Coolant Heat Storage System (2004–2009 Prius) 216

Cabin Heating Systems 220

Hybrid Electrical System Cooling 222

Hybrid Air-Conditioning Systems 224

A/C Components 227

SUMMARY 235

REVIEW QUESTIONS 235

CHAPTER QUIZ 235

chapter 12

HYBRID SAFETY AND SERVICE

PROCEDURES 236

Objectives 236

Key Terms 236

High-Voltage Safety 237

High-Voltage Safety Equipment 237

Electric Shock Potential 239

DE-Powering the High-Voltage System 241

Collision and Repair Industry Issues 242

Moving and Towing a Hybrid 242

Removing the High-Voltage Batteries 243

Routine Service Procedures 245

SUMMARY 250

REVIEW QUESTIONS 250

CHAPTER QUIZ 250

Lexus RX400H/Toyota Highlander Hybrid 297

Toyota Camry Hybrid 299

Lexus GS450H 300

Maintenance and Service Procedures 300

SUMMARY 306

REVIEW QUESTIONS 306

CHAPTER QUIZ 307

chapter 16

FORD/MERCURY HYBRID

VEHICLES 308

Objectives 308

Key Terms 308

Introduction 309

Full Hybrid 310

Electromechanical CVT 312

Electric Traction Motor 314

Generator Motor 314

High-Voltage Battery Pack 315

12-Volt Battery 317

Electronic Controller 317

Electric Power Assist Steering (EPAS) 318

Regenerative Braking System (RBS) 319

Service Procedures 319

SUMMARY 322

REVIEW QUESTIONS 323

CHAPTER QUIZ 323

chapter 17

GENERAL MOTORS HYBRID

VEHICLES 324

Objectives 324

Key Terms 324

Introduction 325

Chevrolet/GMC Parallel Hybrid Truck 325

Electrohydraulic Power Steering 329

PHT Hybrid Systems 331

Saturn VUE and Chevrolet Malibu Hybrids 332

General Motors Two-Mode Hybrid 334

SUMMARY 337

REVIEW QUESTIONS 338

CHAPTER QUIZ 338

chapter 13

FIRST RESPONDER

PROCEDURES 251

Objectives 251

Key Terms 251

Hybrid Electric Vehicle Incidents 252

First Responder Procedures 252

Electric Shock Potential 255

Emergency Response 257

Fire 258

Hazmat Issues 259

Submerged or Partially Submerged Vehicle 259

Alternative-Fuel Vehicle Issues 259

SUMMARY 261

REVIEW QUESTIONS 261

CHAPTER QUIZ 261

chapter 14

HONDA HYBRID VEHICLES 262

Objectives 262

Key Terms 262

Background 263

Body/Interior Features 265

Power Train Features 271

Safety Procedures 277

Service Features 277

SUMMARY 281

REVIEW QUESTIONS 281

CHAPTER QUIZ 282

chapter 15

TOYOTA/LEXUS HYBRID

VEHICLES 283

Objectives 283

Key Terms 283

Toyota Prius 284

Driving a Toyota Hybrid Electric Vehicle 289

Cold-Start Emission Controls 290

Fuel System Components 291

High-Voltage Battery Pack 292

The Toyota Hybrid System 294

CONTENTS xiii

chapter 18

FUEL CELLS AND ADVANCED

TECHNOLOGIES 339

Objectives 339

Key Terms 339

Fuel-Cell Technology 340

PEM Fuel Cells 342

Direct Methanol Fuel Cells 343

Fuel-Cell Vehicle Systems 344

Fuel-Cell Hybrid Vehicles 345

Hydrogen Storage 348

Hydraulic Hybrid Storage System 350

HCCI 351

xiv CONTENTS

Plug-in Hybrid Electric Vehicles 351

The Future for Electric Vehicles 352

Wind Power 354

Hydroelectric Power 354

SUMMARY 356

REVIEW QUESTIONS 356

CHAPTER QUIZ 356

appendix 1

HYBRID VEHICLE DIAGNOSTIC TROUBLE CODES 357

ENGLISH GLOSSARY 361

SPANISH GLOSSARY 370

INDEX 381