automotive electrical and engine performancechapter 44 scan tools and engine performance diagnosis...

AUTOMOTIVE ELECTRICAL AND ENGINE

PERFORMANCEE I G H T H E D I T I O N

James D. Halderman

A01_HALD4809_08_SE_FM.indd 1 04/02/19 8:42 PM

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Library of Congress Cataloging-in-Publication Data

Names: Halderman, James D., author.Title: Automotive electrical and engine performance / James D. Halderman.Description: Eigth edition. | Boston : Pearson, [2018]Identifiers: LCCN 2018022216| ISBN 9780135224809 | ISBN 0135224802Subjects: LCSH: Automobiles—Motors—Maintenance and repair. | Automobiles—Electric equipment—Maintenance and repair. | Automobiles—Performance.Classification: LCC TL210 .H2885 2018 | DDC 629.2/72—dc23 LC record available at https://lccn.loc.gov/2018022216

1 18

ISBN 10: 0-13-522480-2ISBN 13: 978-0-13-522480-9


BRIEF CoNTENTS iii

BRIEF CONTENTS chapter 1 Service Information, Tools, and Safety 1

chapter 2 Environmental and Hazardous Materials 39

chapter 3 Electrical Fundamentals 52

chapter 4 Electrical Circuits and Ohm’s Law 63

chapter 5 Series, Parallel, and Series-Parallel Circuits 71

chapter 6 Circuit Testers and Digital Meters 84

chapter 7 Oscilloscopes and Graphing Multimeters 105

chapter 8 Automotive Wiring and Wire Repair 114

chapter 9 Wiring Schematics and Circuit Testing 130

chapter 10 Capacitance and Capacitors 150

chapter 11 Magnetism and Electromagnetism 157

chapter 12 Electronic Fundamentals 172

chapter 13 Computer Fundamentals 193

chapter 14 CAN and Network Communications 202

chapter 15 Batteries 221

chapter 16 Battery Testing and Service 231

chapter 17 Cranking System 247

chapter 18 Cranking System Diagnosis and Service 262

chapter 19 Charging System 277

chapter 20 Charging System Diagnosis and Service 291

chapter 21 Lighting and Signaling Circuits 313

chapter 22 Driver Information and Navigation Systems 334

chapter 23 Safety, Comfort, and Convenience Circuits 352

chapter 24 Air Management System 381

chapter 25 Immobilizer Systems 394

chapter 26 Airbag and Pretensioner Circuits 404


iv BRIEF CoNTENTS

chapter 27 Audio System Operation and Diagnosis 420

chapter 28 Gasoline, Alternative Fuels, and Diesel Fuels 438

chapter 29 Ignition System Components and Operation 463

chapter 30 Ignition System Diagnosis and Service 481

chapter 31 Temperature Sensors 502

chapter 32 Throttle Position (TP) Sensors 515

chapter 33 MAP/BARO Sensors 522

chapter 34 Mass Air Flow Sensors 532

chapter 35 Oxygen Sensors 539

chapter 36 Fuel Pumps, Lines, and Filters 557

chapter 37 Fuel-Injection Components and Operation 575

chapter 38 Gasoline Direct-Injection Systems 590

chapter 39 Electronic Throttle Control System 599

chapter 40 Fuel-Injection System Diagnosis and Service 608

chapter 41 Vehicle Emissions Standards, and Testing 629

chapter 42 Emission Control Devices Operation and Diagnosis 639

chapter 43 On-Board Diagnosis 668

chapter 44 Scan Tools and Engine Performance Diagnosis 678

chapter 45 Hybrid Safety and Service Procedures 698

chapter 46 Fuel Cells and Advanced Technologies 714

appendix 1 Electrical/Electronic Systems (A6) Sample ASE Certification Test and Answers 730

appendix 2 Sample Engine Performance (A8) Certification-Type Test 735

appendix 3 2017 ASE A6 Correlation Chart 740

appendix 4 2017 ASE A8 Correlation Chart 744

Glossary 748

Index 757


CoNTENTS v

■■ Asbestos Hazards 42■■ Used Brake Fluid 43■■ Used oil 43■■ Solvents 44■■ Coolant Disposal 45■■ Lead-Acid Battery Waste 46■■ Fuel Safety and Storage 47■■ Airbag Handling 47■■ Used Tire Disposal 48■■ Air-Conditioning Refrigerant oil Disposal 48

Summary 50review QueStionS 50Chapter Quiz 51

chapter 3

ELECTRICAL FUNDAMENTALS 52■■ Learning objectives 52■■ Key Terms 52■■ Introduction 53■■ Electricity 53■■ How Electrons Move Through a Conductor 56■■ Units of Electricity 57■■ Sources of Electricity 59■■ Conductors and Resistance 60■■ Resistors 61


chapter 4

ELECTRICAL CIRCUITS AND OHM’S LAW 63

■■ Learning objectives 63■■ Key Terms 63■■ Circuits 64■■ Circuit Fault Types 64■■ ohm’s Law 67■■ Watt’s Law 68


CONTENTSchapter 1

SERVICE INFORMATION, TOOLS, AND SAFETY 1

■■ Learning objectives 1■■ Key Terms 1■■ Vehicle Identification 2■■ Service Information 3■■ Threaded Fasteners 4■■ Hand Tools 8■■ Screwdrivers 11■■ Torx 14■■ Pliers 15■■ Basic Hand Tool List 18■■ Tool Sets and Accessories 20■■ Electrical Hand Tools 20■■ Hand Tool Maintenance 21■■ Trouble Lights 21■■ Air and Electrically operated Tools 22■■ Personal Protective Equipment 24■■ Safety Precautions 25■■ Vehicle Protection 26■■ Safety Lifting (Hoisting) a Vehicle 26■■ Jacks and Safety Stands 28■■ Drive-on Ramps 28■■ Electrical Cord Safety 28■■ Jump Starting and Battery Safety 29■■ Fire Extinguishers 30■■ Fire Blankets 31■■ First Aid and Eye Wash Stations 31■■ Hybrid Electric Vehicle Safety Issues 33


chapter 2

ENVIRONMENTAL AND HAZARDOUS MATERIALS 39

■■ Learning objectives 39■■ Key Terms 39■■ Hazardous Waste 40■■ Federal and State Laws 40


vi CoNTENTS

■■ DC and AC Coupling 108■■ Pulse Trains 108■■ Number of Channels 109■■ Triggers 111■■ Using a Scope 111■■ Graphing Multimeter 111■■ Graphing Scan Tools 111


chapter 8

AUTOMOTIVE WIRING AND WIRE REPAIR 114

■■ Learning objectives 114■■ Key Terms 114■■ Automotive Wiring 115■■ Ground Wires 116■■ Battery Cables 117■■ Jumper Cables 117■■ Fuses and Circuit Protection Devices 118■■ Terminals and Connectors 123■■ Wire Repair 125■■ Electrical Conduit 128


chapter 9

WIRING SCHEMATICS AND CIRCUIT TESTING 130

■■ Learning objectives 130■■ Key Terms 130■■ Wiring Schematics and Symbols 131■■ Schematic Symbols 133■■ Relay Terminal Identification 138■■ Locating an open Circuit 141■■ Common Power or Ground 141■■ Circuit Troubleshooting Procedure 143■■ Locating a Short Circuit 144■■ Electrical Trouble shooting Guide 147■■ Step-By-Step Troubleshooting Procedure 147


chapter 5

SERIES, PARALLEL, AND SERIES-PARALLEL CIRCUITS 71

■■ Learning objectives 71■■ Key Terms 71■■ Series Circuits 72■■ ohm’s Law and Series Circuits 72■■ Kirchhoff’s Voltage Law 73■■ Series Circuit Laws 74■■ Series Circuit Examples 75■■ Parallel Circuits 76■■ Kirchhoff’s Current Law 76■■ Parallel Circuit Laws 76■■ Determining Total Resistance in a Parallel Circuit 77■■ Parallel Circuit Examples 79■■ Series-Parallel Circuits 80■■ Solving Series-Parallel Circuit Problems 80■■ Series-Parallel Circuit Examples 80


chapter 6

CIRCUIT TESTERS AND DIGITAL METERS 84

■■ Learning objectives 84■■ Key Terms 84■■ Fused Jumper Wire 85■■ Test Lights 85■■ Logic Probe 87■■ Digital Multimeters 87■■ Inductive Ammeters 92■■ Diode Check, Duty Cycle and Frequency 93■■ Electrical Unit Prefixes 94■■ How to Read Digital Meters 95


chapter 7

OSCILLOSCOPES AND GRAPHING MULTIMETERS 105

■■ Learning objectives 105■■ Key Terms 105■■ Types of oscilloscopes 106■■ Scope Setup and Adjustments 106


CoNTENTS vii

■■ Thermistors 181■■ Rectifier Bridges 181■■ Transistors 182■■ Field-Effect Transistors 183■■ Phototransistors 183■■ Integrated Circuits 184■■ Transistor Gates 185■■ operational Amplifiers 186■■ Electronic Component Failure Causes 186■■ How to Test Diodes and Transistors 188■■ Converters and Inverters 189■■ Electrostatic Discharge 191


chapter 13

COMPUTER FUNDAMENTALS 193■■ Learning objectives 193■■ Key Terms 193■■ Computer Fundamentals 194■■ Computer Functions 194■■ Digital Computers 195■■ Computer Input Sensors 197■■ Computer outputs 198


chapter 14

CAN AND NETWORK COMMUNICATIONS 202

■■ Learning objectives 202■■ Key Terms 202■■ Module Communications and Networks 203■■ Network Fundamentals 203■■ Module Communications Configuration 204■■ Network Communications Classifications 207■■ General Motors Communications Protocols 207■■ Ford Network Communications Protocols 209■■ Chrysler Communications Protocols 210■■ Controller Area Network 212■■ Honda/Toyota Communications 213■■ European Bus Communications 213■■ Network Communications Diagnosis 215■■ oBD-II Data Link Connector 218

chapter 10

CAPACITANCE AND CAPACITORS 150

■■ Learning objectives 150■■ Key Terms 150■■ Capacitance 151■■ Capacitor Construction and operation 151■■ Factors of Capacitance 153■■ Uses for Capacitors 154■■ Capacitors in Circuits 155


chapter 11

MAGNETISM AND ELECTROMAGNETISM 157

■■ Learning objectives 157■■ Key Terms 157■■ Fundamentals of Magnetism 158■■ Electromagnetism 160■■ Uses of Electromagnetism 163■■ Electromagnetic Induction 165■■ Ignition Coils 166■■ Electromagnetic Interference 169


chapter 12

ELECTRONIC FUNDAMENTALS 172

■■ Learning objectives 172■■ Key Terms 172■■ Semiconductors 173■■ Summary of Semiconductors 174■■ Diodes 174■■ Zener Diodes 176■■ High-Voltage Spike Protection 176■■ Diode Ratings 178■■ Light-Emitting Diodes 179■■ Photodiodes 179■■ Photoresistors 180■■ Silicon-Controlled Rectifiers 180


viii CoNTENTS

■■ Computer-Controlled Starting 249■■ Starter Motor operation 250■■ How the Starter Motor Works 252■■ Gear-Reduction Starters 255■■ Starter Drives 255■■ Starter Solenoids 257■■ Stop/Start System 258


chapter 18

CRANKING SYSTEM DIAGNOSIS AND SERVICE 262

■■ Learning objectives 262■■ Key Terms 262■■ Starting System Troubleshooting Procedure 263■■ Voltage Drop Testing 264■■ Control Circuit Testing 266■■ Starter Amperage Test 266■■ Starter Removal 267■■ Starter Motor Service 267■■ Bench Testing 269■■ Starter Installation 270■■ Starter Drive-To-Flywheel Clearance 270■■ Starting System Symptom Guide 271


chapter 19

CHARGING SYSTEM 277■■ Learning objectives 277■■ Key Terms 277■■ Principle of Alternator operation 278■■ Alternator Construction 278■■ Alternator overrunning Pulleys 278■■ Alternator Components and operation 280■■ How an Alternator Works 281■■ Alternator output Factors 285■■ Alternator Voltage Regulation 285■■ Alternator Cooling 287■■ Computer-Controlled Alternators 287



chapter 15

BATTERIES 221■■ Learning objectives 221■■ Key Terms 221■■ Introduction 222■■ Battery Construction 222■■ How a Battery Works 225■■ Specific Gravity 225■■ Battery Construction Type 227■■ Causes and Types of Battery Failure 228■■ Battery Ratings 228■■ Battery Sizes 229


chapter 16

BATTERY TESTING AND SERVICE 231

■■ Learning objectives 231■■ Key Terms 231■■ Battery Service Safety Considerations 232■■ Symptoms of a Weak or Defective battery 232■■ Battery Maintenance 233■■ Battery Voltage Test 234■■ Hydrometer Testing 235■■ Battery Load Testing 235■■ Electronic Conductance Testing 237■■ Battery Charging 238■■ Battery Charge Time 239■■ Jump Starting 240■■ Battery Electrical Drain Test 241■■ Maintaining Electronic Memory Functions 242■■ Battery Symptom Guide 245


chapter 17

CRANKING SYSTEM 247■■ Learning objectives 247■■ Key Terms 247■■ Cranking Circuit 248


CoNTENTS ix


chapter 22

DRIVER INFORMATION AND NAVIGATION SYSTEMS 334

■■ Learning objectives 334■■ Key Terms 334■■ Dash Warning Symbols 335■■ Steering Wheel Controls 336■■ Voice Activation 336■■ Maintenance Indicators 337■■ Analog And Digital Displays 337■■ Head-Up Display 338■■ Night Vision 338■■ Electronic Displays 339■■ Virtual Display 340■■ Touch Screens 341■■ Speedometers/odometers 341■■ Dash Gauges 343■■ Backup Camera 344■■ Parking Assist Systems 345■■ Lane Departure Warning 346■■ Navigation And GPS 346■■ Telematics 348


chapter 23

SAFETY, COMFORT, AND CONVENIENCE CIRCUITS 352

■■ Learning objectives 352■■ Key Terms 352■■ Horns 353■■ Horn Diagnosis 353■■ Windshield Wipers 354■■ Windshield Washers 356■■ Rain-sense Wipers 358■■ Cruise Control 360■■ Radar Cruise Control 362■■ Heated Rear Window Defoggers 365■■ Heated Mirrors 366■■ Power Windows 366■■ Electric Power Door Locks 368■■ Trunk/lift Gate Locks 369

chapter 20

CHARGING SYSTEM DIAGNOSIS AND SERVICE 291

■■ Learning objectives 291■■ Key Terms 291■■ Charging System Testing and Service 292■■ Drive Belt Inspection and Adjustment 293■■ AC Ripple Voltage Check 295■■ Testing AC Ripple Current 296■■ Charging System Voltage Drop Testing 296■■ Alternator output Test 298■■ Minimum Required Alternator output 299■■ Alternator Removal 299■■ Alternator Disassembly 300■■ Testing the Rectifier 302■■ Reassembling the Alternator 303■■ Alternator Installation 304


chapter 21

LIGHTING AND SIGNALING CIRCUITS 313

■■ Learning objectives 313■■ Key Terms 313■■ Lighting Systems 314■■ Bulb Numbers 315■■ Led Lighting 316■■ Brake Lights 317■■ Turn Signals 318■■ Daytime Running Lights 320■■ Headlights 321■■ High-intensity Discharge Headlights 323■■ LED Headlights 324■■ Adaptive Front Lighting System 324■■ Automatic Headlights 325■■ Headlight High/low Beam Switch 326■■ Auto Dimming Headlights 326■■ Headlight System Diagnosis 326■■ Headlight Aiming 328■■ Fog and Driving Lights 328■■ Automatic Dimming MIrrors 329■■ Courtesy Lights 329■■ Illuminated Entry 330■■ Lighting System Diagnosis 330


x CoNTENTS

chapter 26

AIRBAG AND PRETENSIONER CIRCUITS 404

■■ Learning objectives 404■■ Key Terms 404■■ Safety Belts and Retractors 405■■ Front Airbags 406■■ Airbag Diagnosis Tools and Equipment 410■■ Airbag System Service 413■■ Driver Side Airbag Module Replacement 414■■ Safety When Manually Deploying Airbags 415■■ occupant Detection Systems 415■■ Seat and Side Curtain Airbags 417■■ Event Data Recorders 417


chapter 27

AUDIO SYSTEM OPERATION AND DIAGNOSIS 420

■■ Learning objectives 420■■ Key Terms 420■■ Audio Fundamentals 421■■ Radios and Receivers 423■■ Antennas 423■■ Antenna Diagnosis 424■■ Speakers 426■■ Speaker Types 428■■ Sound Levels 428■■ Crossovers 429■■ Aftermarket Sound System Upgrade 429■■ Voice Recognition 431■■ Bluetooth 432■■ Satellite Radio 432■■ Radio Interference 434


■■ Power Sun Roof/ moon Roof 369■■ Sun Shades 370■■ Power Seats 370■■ Electrically Heated Seats 373■■ Heated and Cooled Seats 373■■ Heated Steering Wheel 374■■ Adjustable Pedals 374■■ Folding outside Mirrors 375■■ Keyless Entry 375■■ Garage Door opener 377■■ Remote Start 378


chapter 24

AIR MANAGEMENT SYSTEM 381■■ Learning objectives 381■■ Key Terms 381■■ Introduction 382■■ Airflow Control 383■■ Air Temperature Control 384■■ Air Filtration 385■■ Cases and Ducts 385■■ Plenum and Control Doors 385■■ NonElectrical HVAC Controls 388■■ Electronic HVAC Controls 388■■ Blower Motor 391


chapter 25

IMMOBILIZER SYSTEMS 394■■ Learning objectives 394■■ Key Terms 394■■ Vehicle Security Systems 395■■ Immobilizer Systems 395■■ Chrysler Immobilzer System 399■■ Ford Pats System 400■■ General Motors Antitheft System 400■■ Testing Immobilizer Systems 400



CoNTENTS xi

■■ Coil-on-Plug Ignition 475■■ Ion-Sensing Ignition 476■■ Ignition Timing 477■■ Knock Sensors 478■■ Spark Plugs 479


chapter 30

IGNITION SYSTEM DIAGNOSIS AND SERVICE 481

■■ Learning objectives 481■■ Key Terms 481■■ Checking for Spark 482■■ Electronic Ignition Troubleshooting Procedure 483■■ Ignition Coil Testing Using an ohmmeter 483■■ Testing Magnetic Sensors 484■■ Testing Hall-Effect Sensors 484■■ Ignition System Diagnosis Using Visual Inspection 485■■ Testing for Poor Performance 486■■ Testing for A No-Start Condition 486■■ Distributor Indexing 487■■ Secondary Ignition Inspection 488■■ Spark Plug Service 490■■ Quick and Easy Secondary Ignition Tests 492■■ Ignition Timing 493■■ Scope-Testing The Ignition System 494■■ Scope-Testing a Waste-Spark Ignition System 499■■ Scope-Testing a Coil-on-Plug Ignition System 500■■ Ignition System Symptom Guide 500


chapter 31

TEMPERATURE SENSORS 502■■ Learning objectives 502■■ Key Terms 502■■ Engine Coolant Temperature Sensors 503■■ Testing the Engine Coolant Temperature Sensor 504■■ Intake Air Temperature Sensor 509■■ Testing the Intake Air Temperature Sensor 510■■ Transmission Fluid Temperature Sensor 511■■ Cylinder Head Temperature Sensor 512■■ Engine Fuel Temperature (EFT) Sensor 512■■ Exhaust Gas Recirculation (EGR) Temperature Sensor 512

chapter 28

GASOLINE, ALTERNATIVE FUELS, AND DIESEL FUELS 438

■■ Learning objectives 438■■ Key Terms 438 ■■ Introduction 439■■ Gasoline 439■■ Refining 439■■ Volatility 439■■ Air-Fuel Ratios 441■■ Normal and Abnormal Combustion 441■■ octane Rating 442■■ Gasoline Additives 444■■ Gasoline Blending 444■■ Testing Gasoline for Alcohol Content 445■■ General Gasoline Recommendations 446■■ E85 448■■ Alternative Fuel Vehicles 449■■ Methanol 450■■ Propane 451■■ Compressed Natural Gas 451■■ Liquefied Natural Gas 454■■ P-Series Fuels 454■■ Synthetic Fuels 455■■ Safety Procedures When Working With Alternative Fuels 456

■■ Diesel Fuel 456■■ Biodiesel 458■■ E-Diesel Fuel 459


chapter 29

IGNITION SYSTEM COMPONENTS AND OPERATION 463

■■ Learning objectives 463■■ Key Terms 463■■ Ignition System 464■■ Ignition System operation 465■■ Ignition Coils 465■■ Ignition Switching and Triggering 467■■ Primary Circuit operation 467■■ Distributor Ignition Systems 469■■ Waste-Spark Ignition Systems 471■■ Ignition Control Circuits 474■■ Compression-Sensing Ignition 475


xii CoNTENTS

■■ PCM Uses for Airflow Sensors 534■■ Testing Mass AirFlow Sensors 535■■ MAF Sensor Contamination 536■■ Maf Sensor Scope Testing 537■■ MAF-Related Diagnostic Trouble Codes 537


chapter 35

OXYGEN SENSORS 539■■ Learning objectives 539■■ Key Terms 539■■ oxygen Sensors 540■■ Titania oxygen Sensor 542■■ PCM Uses of the oxygen Sensor 543■■ oxygen Sensor Diagnosis 544■■ Post-Catalytic Converter oxygen Sensor Testing 549■■ Wide-Band oxygen Sensors 550■■ Dual Cell Planar Wide-Band Sensor operation 551■■ Dual Cell Diagnosis 552■■ Single Cell Wide-Band oxygen Sensors 554■■ Wide-Band oxygen Pattern Failures 555■■ oxygen Sensor– Related Diagnostic Trouble Codes 555


chapter 36

FUEL PUMPS, LINES, AND FILTERS 557

■■ Learning objectives 557■■ Key Terms 557■■ Fuel Delivery System 558■■ Fuel Tanks 558■■ Rollover Leakage Protection 560■■ Fuel Lines 560■■ Electric Fuel Pumps 562■■ Fuel Filters 567■■ Fuel-Pump Testing 567■■ Fuel-Pump Current Draw Test 572■■ Fuel-Pump Replacement 573


■■ Engine oil Temperature Sensor 513■■ Temperature Sensor Diagnostic Trouble Codes 513


chapter 32

THROTTLE POSITION (TP) SENSORS 515

■■ Learning objectives 515■■ Key Terms 515■■ Throttle Position Sensor Construction 516■■ TP Sensor Computer Input Functions 516■■ PCM Uses for the TP Sensor 517■■ Testing the Throttle Position Sensor 517■■ Testing a TP Sensor Using the Min/Max Function 519■■ Testing the TP Sensor Using a Scan Tool 519■■ TP Sensor Diagnostic Trouble Codes 520


chapter 33

MAP/BARO SENSORS 522■■ Learning objectives 522■■ Key Terms 522■■ Air Pressure—High and Low 523■■ Principles of Pressure Sensors 524■■ Construction of Manifold Absolute Pressure Sensors 524■■ PCM Uses of the MAP Sensor 526■■ Barometric Pressure Sensor 527■■ Testing the MAP Sensor 528■■ MAP/BARo Diagnostic Trouble Codes 530


chapter 34

MASS AIR FLOW SENSORS 532■■ Learning objectives 532■■ Key Terms 532■■ Speed Density Systems 533■■ Mass AirFlow Sensor Types 533■■ Karman Vortex Sensors 534


CoNTENTS xiii

■■ Electronic Throttle Control (ETC) System 600■■ Normal operation of the ETC System 600■■ APP Sensor 601■■ Throttle Body Assembly 601■■ Throttle Position (TP) Sensor 603■■ Diagnosis of ETC Systems 603■■ ETC Throttle Follower Test 605■■ Servicing Electronic Throttle Systems 605


chapter 40

FUEL-INJECTION SYSTEM DIAGNOSIS AND SERVICE 608

■■ Learning objectives 608■■ Key Terms 608■■ Port Fuel-Injection Pressure Regulator Diagnosis 609■■ Diagnosing Electronic Fuel-Injection Problems 609■■ Fuel-Injection System Diagnosis 611■■ Testing for an Injector Pulse 612■■ Checking Fuel-Injector Resistance 613■■ Pressure-Drop Balance Test 615■■ Injector Voltage- Drop Tests 615■■ Scope-Testing Fuel Injectors 616■■ Idle Air Speed Control Diagnosis 617■■ Fuel-Injection Service 618■■ Fuel-System Scan Tool Diagnostics 621


chapter 41

VEHICLE EMISSIONS STANDARDS, AND TESTING 629

■■ Learning objectives 629■■ Key Terms 629■■ Normal Engine Combustion 630■■ Exhaust Analysis And Combustion Efficiency 631■■ Catalytic Converter 631■■ Exhaust Analysis As A Diagnostic Tool 632■■ Engine Fault Possibilities 633■■ Emission Standards 635■■ European Standards 636■■ Vehicle Emission Testing 637

chapter 37

FUEL-INJECTION COMPONENTS AND OPERATION 575

■■ Learning objectives 575■■ Key Terms 575■■ Electronic Fuel-Injection operation 576■■ Speed-Density Fuel-Injection Systems 577■■ Mass Airflow Fuel-Injection Systems 578■■ Throttle-Body Injection 578■■ Port Fuel Injection 579■■ Fuel-Pressure Regulator 580■■ Vacuum-Biased Fuel-Pressure Regulator 582■■ Electronic Returnless Fuel System 582■■ Mechanical Returnless Fuel System 583■■ Demand Delivery System (DDS) 583■■ Fuel Injectors 584■■ Central Port Injection 585■■ Fuel-Injection Modes of operation 586■■ Idle Control 587


chapter 38

GASOLINE DIRECT-INJECTION SYSTEMS 590

■■ Learning objectives 590■■ Key Terms 590■■ Direct Fuel Injection 591■■ Direct-Injection Fuel Delivery System 591■■ GDI Fuel Injectors 594■■ Modes of operation 594■■ Piston Top Designs 594■■ Port- and Direct-Injection Systems 595■■ Engine Start System 596■■ GDI Issues 596■■ GDI Service 596


chapter 39

ELECTRONIC THROTTLE CONTROL SYSTEM 599

■■ Learning objectives 599■■ Key Terms 599


xiv CoNTENTS

■■ oBD-II DTC Numbering Designation 673■■ oBD-II Freeze-Frame 673■■ Enabling Conditions 674■■ PCM Tests 675■■ Global oBD-II 676■■ Diagnosing Problems Using Mode Six 676


chapter 44

SCAN TOOLS AND ENGINE PER-FORMANCE DIAGNOSIS 678

■■ Learning objectives 678■■ Key Terms 678■■ The Eight-Step Diagnostic Procedure 679■■ Scan Tools 685■■ Retrieval of Diagnostic Information 685■■ Troubleshooting Using Diagnostic Trouble Codes 686■■ Retrieving Codes Prior To 1996 687■■ DLC Locations 688■■ oBD-II Diagnosis 688■■ oBD-II Active Tests 692■■ Service/Flash Programming 693■■ Manufacturer’S Diagnostic Routines 695■■ Completing System Repairs 695■■ Procedures For Resetting The PCM 695■■ Road Test (Drive Cycle) 696


chapter 45

HYBRID SAFETY AND SERVICE PROCEDURES 698

■■ Learning objectives 698■■ Key Terms 698■■ High-Voltage Safety 699■■ High-Voltage Safety Equipment 699■■ Safety Interlock System 701■■ Loss of Insulation Test 701■■ Electric Shock Potential 702■■ Depower the High-Voltage System 705■■ Collision and Repair Industry Issues 705■■ Moving and Towing a Hybrid 706■■ Removing the High-Voltage Batteries 706■■ Routine Service Procedures 707


chapter 42

EMISSION CONTROL DEVICES OPERATION AND DIAGNOSIS 639

■■ Learning objectives 639■■ Key Terms 639■■ Introduction 640■■ Smog 640■■ Exhaust Gas Recirculation Systems 640■■ oBD-II EGR Monitoring Strategies 643■■ Diagnosing a Defective EGR System 644■■ EGR-Related oBD-II Diagnostic Trouble Codes 646■■ Crankcase Ventilation 646■■ PCV System Diagnosis 648■■ PCV-Related Diagnostic Trouble Code 650■■ Secondary Air-Injection System 650■■ Secondary Air-Injection System Diagnosis 651■■ SAI-Related Diagnostic Trouble Code 652■■ Catalytic Converters 652■■ Diagnosing Catalytic Converters 655■■ Catalytic Converter Replacement Guidelines 657■■ Catalytic Converter-Related Diagnostic Trouble Code 658■■ Evaporative Emission Control System 658■■ Nonenhanced Evaporative Control Systems 660■■ Enhanced Evaporative Control System 660■■ Leak Detection Pump System 661■■ onboard Refueling Vapor Recovery 661■■ State Inspection EVAP Tests 662■■ Diagnosing the EVAP System 662■■ Evaporative System Monitor 663■■ Typical EVAP Monitor 664■■ EVAP System-Related Diagnostic Trouble Codes 665


chapter 43

ON-BOARD DIAGNOSIS 668■■ Learning objectives 668■■ Key Terms 668■■ on-Board Diagnostics Generation-II (oBD-II) Systems 669■■ Diagnostic Executive and Task Manager 669■■ Monitors 670■■ oBD-II Monitor Information 671■■ Enabling Criteria 671


CoNTENTS xv

appendix 1ELECTRICAL/ELECTRONIC SYSTEMS (A6) SAMPLE ASE-TYPE CERTIFICATION TEST AND ANSWERS 730

appendix 2SAMPLE ASE-TYPE CERTIFICATION ENGINE PERFORMANCE (A8) TEST 735

appendix 32017 ASE A6 CORRELATION CHART 740

appendix 42017 ASE A8 CORRELATION CHART 744

GLOSSARY 748

INDEX 757


chapter 46

FUEL CELLS AND ADVANCED TECHNOLOGIES 714

■■ Learning objectives 714■■ Key Terms 714■■ Fuel-Cell Technology 715■■ PEM Fuel Cells 716■■ Fuel-Cell Vehicle Systems 718■■ Hydraulic Hybrid Storage System 724■■ HCCI 724■■ Plug-In Hybrid Electric Vehicles 725■■ Electric Vehicles 725■■ Wind Power 728■■ Hydroelectric Power 728



ACKNOWLEDGMENTS

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 individuals for their special contributions:

Carl Borsani- Graphic HomeRandy Briggs, Car Quest Technical Institute

Randy Dillman

Rick Escalambre, Skyline College

Bill Fulton, ohio Automotive Technology

Jim Linder, Linder Technical Services

Scot Manna

Dan Marinucci, Communique’

Albin Moore

Jim Morton, Automotive Training Center (ATC)

Dr. Norman Nall

Dave Scaler, Mechanic’s Education Association

John Thornton, Autotrain

Mark Warren

SPECIAL THANKS The author wishes to thank Chuck Taylor of Sinclair Community College in Dayton, ohio, and Greg Pfahl who helped with many of the photos. A special thanks to Dick Krieger, Tom Birch. Curt Ward, and Jeff Rehkopf for their detailed and thorough review of the manuscript before publication. Most of all, I wish to thank Michelle Halderman for her assistance in all phases of manuscript preparation.

—James D. Halderman

JIM HALDERMAN brings a world of experience, knowl-edge, and talent to his work. His automotive service experi-ence includes working as a flat-rate technician, a business owner, and a professor of automotive technology at a leading U.S. community college.

He has a bachelor of science degree from ohio Northern University and a master’s degree from Miami University 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 is also Advanced Engine Performance (L1) ASE certified. Jim is the author of many au-tomotive textbooks, all published by Pearson Education. Jim has presented numerous technical seminars to national audi-ences, including the California Automotive Teachers (CAT) and the Illinois College Automotive Instructor Association (ICAIA). He is also 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 a member of the advisory committee for the department of technology at 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 AUTHOR

xvi ABoUT THE AUTHoR


PREFACE xvii

PREFACE

UPDATES TO THE EIGHTH EDITION

The following changes and updates have been made to the new eighth edition based on requests from instructors and readers from throughout North America.

■" over 75 new full color line drawings and photos have been added to the new edition to help bring the subject to life.

■" Updated throughout and correlated to the latest ASE/NATEF tasks.

Automotive Electrical and Engine Performance covers content and topics specified for both Electrical/Electronic System (A6) and Engine Performance (A8) by ASE/NATEF, as well as the practical skills that students must master to be successful in the industry. With this textbook, students preparing for the au-tomotive profession get a firm background in the principles and practices of diagnosing and troubleshooting automotive electri-cal, electronic, and computer systems. The book is written in a clear, concise format at a level of detail that far exceeds most other texts. Well-known author, Jim Halderman, uses his help-ful real-world tips and visuals to bring concepts to life and guide students through the procedures they’ll use on the job.

■" The number of chapters has increased from 43 to 46 chapters by splitting up larger chapters and placing the content into shorter more concise chapters.

■" A new chapter on Safety, Comfort and Convenience Accessories (Chapter 23) has been added.

■" A new chapter called Air Management Systems (Chapter 24) has been added.

■" Immobilizer Systems (Chapter 25) has been added to the new edition.

■" The ignition system chapter was split into two shorter chapters (Chapters 29 and 30) to make teaching and learning this topic easier.

■" The new Tier 3 emission standards have been added (Chapter 41)


xviii IN-TEXT FEATURES

IN-TEXT FEATURES

LEARNING 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 tasks.

1

chapter 1

SERVICE INFORMATION, TOOLS, AND SAFETY

Bench grinder 23

Bolts 4

Breaker bar 10

Bump cap 24

Calibration codes 3

Campaign 4

Casting number 3

Cheater bar 13

Chisels 18

Drive sizes 10

Extensions 10

Eye wash station 32

Files 17

Fire blanket 31

Fire extinguisher classes 30

GAWR 2

Grade 6

GVWR 2

Hacksaws 18

Hammers 13

HEV 33

LED 22

Metric bolts 6

Nuts 7

PPE 24

Pinch weld seam 27

Pitch 5

Pliers 15

Punches 17

Ratchet 10

Recall 4

Screwdrivers 11

Snips 17

Socket 10

Socket adapter 13

Spontaneous combustion 26

SST 21

Stud 4

Tensile strength 6

Trouble light 21

TSB 4

UNC 5

UNF 5

Universal joint 10

VECI 2

VIN 2

Washers 7

Wrenches 8

KEY TERMS

After studying this chapter, the reader will be

able to:

1. Locate and interpret vehicle and major

component identification numbers.

2. Identify the strength ratings of threaded

fasteners.

3. Explain the difference between the brand name

(trade name) and the proper name for tools.

4. Describe what tool is the best to use for

each job.

5. Explain how to maintain hand tools.

6. Identify the personal protective equipment

(PPE) that all service technicians should wear.

7. Discuss how to safely use hand tools.

8. Describe how to safely hoist a vehicle.

This chapter will help you understand the ASE content

knowledge for vehicle identification and the proper use

of tools and shop equipment.

LEARNING OBJECTIVES

TECH TIP feature real-world advice and “tricks of the trade”

from ASE-certified master technicians.

Right to Tighten

It is sometimes confusing which way to rotate a

wrench or screwdriver, especially when the head of

the fastener is pointing away from you. To help visu-

alize while looking at the fastener, say “righty tighty,

lefty loosey.”

TECH TIP

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

SAFETY TIPS alert students to possible hazards on the job

and how to avoid them.

Shocking Experience

A customer complained that after driving for a while,

he got a static shock whenever he grabbed the

door handle when exiting the vehicle. The customer

thought that there must be an electrical fault and that

the shock was coming from the vehicle itself. In a

way, the shock was caused by the vehicle, but it was

not a fault. The service technician sprayed the cloth

seats with an anti-static spray and the problem did

not reoccur. Obviously, a static charge was being cre-

ated by the movement of the driver’s clothing on the

seats and discharged when the driver touched the

metal door handle. ● SEE FIGURE 9–39.

Summary:

■ Complaint—Vehicle owner complained that he got

shocked when the door handle was touched.

■ Cause—Static electricity was found to be the

cause and not a fault with the vehicle.

■ Correction—The seats and carpet were sprayed

with an anti-static spray and this corrected the

concern.

CASE STUDY

CASE STUDY present students with actual automotive

scenarios and show how these common (and sometimes

uncommon) problems were diagnosed and repaired.


IN-TEXT FEATURES xix

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

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.

NOTES provide students with additional technical

information to give them a greater understanding of a specific

task or procedure.

NOTE: A parallel circuit drops the voltage from source voltage to zero (ground) across the resistance in each leg of the circuit.

CAUTION: Never use hardware store (nongraded)

bolts, studs, or nuts on any vehicle steering, suspen-

sion, or brake component. Always use the exact size

and grade of hardware that is specified and used by the

vehicle manufacturer.

CAUTIONS alert students about potential damage to

the vehicle that can occur during a specific task or service

procedure.

Do not touch any orange wiring or component

without following the vehicle manufacturer’s proce-

dures and wearing the specified personal protec-

tive equipment.

WARNING

WARNINGS alert students to potential dangers to

themselves 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.

100 CHAPTER 6

DIGITAL METER USAGE

2

3 4

5 6

For most electrical measurements, the black meter lead is inserted in the terminal labeled “COM” and the red meter lead is inserted into the terminal labeled “V”.

To use a digital meter, turn the power switch and select the unit of electricity to be measured. In this case, the rotary switch is turned to select DC volts V.

For most automotive electrical use, such as measuring battery voltage, select DC volts.

Connect the red meter lead to the positive (+) terminal of a battery and the black meter lead to

-) terminal. The meter reads the voltage di�erence between the leads.

This jump start battery unit measures 13.151

voltage scale.

1

Another meter (Fluke 87 III) displays four digits when measuring the voltage of the battery jump start unit.

▶

CIRCUIT TESTERS AND DIGITAL METERS 101

7 8

9 10

11 12

STEP-BY-STEP (CONTINUED)

To measure resistance, turn the rotary dial to the ohm (Æ) symbol. With the meter leads separated, the meter display reads OL (over limit).

The meter can read your own body resistance if you grasp the meter lead terminals with your fingers.

Æ.

When measuring anything, be sure to read the symbol on the meter face. In this case, the meter reading is 291.10 kÆ.

A meter set on ohms can be used to check the resistance of a light bulb filament. In this case, the meter reads 3.15 ohms. If the bulb were bad (filament open), the meter would display OL.

A digital meter set to read ohms should measure 0.00 as shown when the meter leads are touched together.

The large letter V means volts and the wavy symbol over the V means that the meter measures alternating current (AC) voltage if this position is selected.

THE REVIEW QUESTIONS AND CHAPTER QUIZ at the

end of each chapter help students review the material presented in

the chapter and test themselves to see how much they’ve learned.

SERVICE INFORMATION, TOOLS, AND SAFETY 37

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 combi-nation open and box end.

4. An adjustable wrench should only be used when 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.

SUMMARY

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, 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.

REVIEW QUESTIONS

1. Why are wrenches offset 15 degrees?

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

3. Which type of screwdriver requires the use of a hammer or mallet?

4. What is inside a dead-blow hammer?

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

CHAPTER QUIZ

1. The correct location for the pads when hoisting or jacking the vehicle can often be found in the ______________.a. service manualb. shop manual

c. owner’s manuald. All of the above

2. For the best working position, the work should be ______________.a. at neck or head levelb. at knee or ankle levelc. overhead by about 1 footd. at chest or elbow level

3. A high-strength bolt is identified by ______________.a. a UNC symbolb. lines on the headc. strength letter codesd. the coarse threads

4. A fastener that uses threads on both ends is called a ______________.a. cap screwb. stud

c. machine screwd. crest fastener

5. Wrenches are made from_______.a. cast from nickel steelb. forged alloy steelc. machined from billet steeld. cast from chrome steel

6. The proper term for Channel Locks is ______________.a. vise Gripsb. crescent wrenchc. locking pliersd. multigroove adjustable pliers

7. The proper term for Vise Grips is ______________.a. locking pliersb. slip-joint pliersc. side cutsd. multigroove adjustable pliers


xx INSTRUCToR RESoURCES

INSTRUCTOR RESOURCES

RESOURCES IN PRINT AND ONLINEAutomotive Technology

NAME OF SUPPLEMENT PRINT ONLINE AUDIENCE DESCRIPTION

Instructor Resource Manual013525745X

✔ Instructors NEW! The Ultimate teaching aid: Chapter summaries, key terms, chapter learning objectives, and lecture resources.

TestGen0135257999

✔ Instructors Test generation software and test bank for the text.

PowerPoint Presentation0135257409

✔ Instructors Slides include a lecture outline of the text to help instructors with in class instruction.

Image Bank0135257433

✔ Instructors All of the images from the textbook to create customized slides.

ASE Task Sheets – for instructors0135257638

✔ Instructors Downloadable ASE task sheets for easy customization.

ASE Task Sheets – for Students0135257417

✔ Students Student’s can purchase a study activity man-ual that correlates ASE Automobile Standards to chapters and page numbers in the text.

VitalSource eBook0135257492

✔ Students An alternative to purchasing the print textbook, students can save up to 50% off the suggested list price of the print text. Visit www.vitalsource.com

All online resources can be downloaded from the Instructor’s Resource Center: www.pearsonhighered.com/ automotive Search for your specific title there and select the Resources.


TECHNICAL AND CoNTENT REVIEWERS xxi

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 AndersonGreenville High School

Victor BridgesUmpqua Community College

Dr. Roger DonovanIllinois Central College

A. C. DurdinMoraine Park Technical College

Al EngledahlCollege of Dupage

Larry HagelbergerUpper Valley Joint Vocational School

Oldrick HajzlerRed River College

Betsy HoffmanVermont Technical College

Richard KriegerMichigan Institute of Technology

Steven T. LeeLincoln Technical Institute

Carlton H. Mabe, Sr.Virginia Western Community College

Roy Marksowens Community College

Tony MartinUniversity of Alaska Southeast

Kerry MeierSan Juan College

Fritz PeacockIndiana Vocational Technical College

Dennis PeterNAIT (Canada)

Greg PfahlMiami-Jacobs Career College

Kenneth RedickHudson Valley Community College

Jeff RehkopfFlorida State College

Mitchell WalkerSt. Louis Community College at Forest Park

Curt WardJoliet Junior College

Jennifer WiseSinclair Community College


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