TechOne Automotive Engine Performance

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ISBN: 9781401834012 | 1401834019
Cover: Paperback
Copyright: 8/3/2004

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From problem replication through repair confirmation, this new book, TechOne: Automotive Engine Performance, presents a complete diagnostic process that equips readers with the skills and knowledge to troubleshoot problems encountered by today's automotive technicians. All-inclusive coverage explores each of the major systems controlled by the computer engine management system such as ignition fuel and emissions. Practical diagnostic methods are highlighted, giving users guidance as to when a test should be performed and what the expected results should be. Working through these procedures affords readers a strong foundation in engine performance that prepares them for more advanced courses of study.

Preface

About the Authors

xiii

Dedication

xiv

Acknowledgments

Features of the Text

xvi

Section 1: Safety and Communication

(22)

Safe Work Practices

(7)

Introduction

(1)

Eye Protection

(1)

Ear Protection

(1)

Clothing and Gloves

(1)

Safe Work Areas

(1)

Hazardous Materials

(1)

Fire Hazards and Prevention

(1)

Using a Fire Extinguisher

(1)

Lift Safety

(1)

Jack and Jack Stand Safety

(1)

Batteries

(1)

Air Bag Safety and Service Warnings

(1)

Summary

(1)

Review Questions

(1)

Working as an Engine Performance Technician

(5)

Introduction

(1)

Certification

(1)

Education

(1)

Job Expectations

(1)

Customer Contact

(1)

Specialization

(1)

Comebacks

(1)

Repair Order

(1)

Ethics

(1)

Pride in Your Work

(1)

Summary

(1)

Review Questions

(1)

Diagnostic Resources

(8)

Introduction

(1)

Information Resources

(4)

Diagnostic Process

(1)

Symptoms

(1)

Intermittent Diagnosis

(1)

Summary

(1)

Review Questions

(2)

Section 2: General Engine Diagnosis

(62)

Engine Overview

(7)

Introduction

(1)

Engine Identification

(1)

Fuel and Ignition Type

(1)

Displacement and Cylinder Arrangement

(1)

Camshaft and Valve Locations

(1)

Engine Location and Position

(1)

Mounting Position

(1)

Summary

(1)

Review Questions

(1)

Fundamental Engine Operating Principles

(6)

Introduction

(1)

Volume

(1)

Atmospheric Pressure and Vacuum

(1)

Liquids, Gases, and Combustion

(1)

Friction

(1)

Work and Force

(1)

Torque

(1)

Power

(1)

Energy

(1)

Energy Conversion

(1)

Summary

(1)

Review Questions

(1)

Engine Construction

(8)

Introduction

(1)

Cylinder Block

(1)

Crankshaft

(2)

Pistons and Connecting Rods

(1)

Cylinder Head

(1)

Valve Train

(1)

Balance Shafts

(1)

Covers

(1)

Gaskets

(1)

Summary

(1)

Review Questions

(2)

Support Systems

(10)

Introduction

(1)

Battery

(1)

Starting System

(1)

Lubrication System

(1)

Cooling System

(1)

Coolant

(1)

Water Pump

(1)

Thermostat

(1)

Radiator

(1)

Overflow and Reserve System

(1)

Cooling Fans

(1)

Summary

(1)

Review Questions

(2)

Engine Operation

(5)

Introduction

(1)

Piston Stroke

(1)

Cam Timing

(1)

Four-Stroke Operation

(2)

Stratified Charge

(1)

Miller Cycle

(1)

Summary

(1)

Review Questions

(1)

Support System Diagnosis

(8)

Introduction

(1)

Battery Diagnosis

(1)

Starter System Diagnosis

(1)

Cooling System Diagnosis

(3)

Leak Diagnosis

(1)

Engine Overheating

(1)

Summary

(1)

Review Questions

(1)

Basic Engine Testing

(7)

Introduction

(1)

Compression Testing

(3)

Cylinder Leakage Testing

(1)

Vacuum Gauge

(2)

Summary

(1)

Review Questions

(1)

Engine Diagnosis and Repair

(9)

Introduction

(1)

Engine Leak Diagnosis

(1)

Smoke Diagnosis

(1)

Misfire Diagnosis

(2)

No-Start Diagnosis

(1)

Timing Belt Service

(1)

Valve Adjustment

(2)

Summary

(1)

Review Questions

(1)

Section 3: Electronic Engine Management

(94)

Electricity and Electronics

(8)

Introduction

(1)

Electricity

(1)

Current

(1)

Resistance

(1)

Voltage

(1)

Voltage Drop

(1)

Production of Electricity

(1)

Ohm's Law

(1)

Circuits

(1)

Types of Electrical Circuits

(1)

Circuit Components

(2)

Summary

(1)

Review Questions

(1)

Automotive Computers

(7)

Introduction

(1)

The Powertrain Control Module

(1)

Input

(1)

Processing

(1)

Storage

(1)

Output

(1)

Operation

(1)

Modes of Operation

(1)

Self-Diagnosis

100

(1)

Summary

101

(1)

Review Questions

101

(1)

PCM Input Sensors and Signals

102

(18)

Introduction

102

(1)

Modified Voltage Input Signals

102

(1)

Air Conditioner Request

102

(1)

Battery Voltage (B+)

102

(1)

Brake Pedal Position Switch

103

(1)

Engine Coolant Temperature Sensor and Intake Air Temperature Sensor

103

(1)

Exhaust Gas Recirculation Backpressure Transducer

103

(2)

Exhaust Gas Recirculation Valve Position Sensor

105

(1)

Fuel Tank Pressure Sensor

106

(1)

Fuel Pump Feedback Circuit

106

(1)

Ignition Module

106

(1)

Mass Air Flow Sensor

106

(2)

Manifold Absolute Pressure, Barometric Pressure Sensor

108

(1)

Power Steering Pressure Switch

109

(1)

Throttle Position Sensor

109

(1)

Transmission Range Sensor

110

(1)

Methods of Voltage Generation

110

(1)

Hall Effect

110

(1)

Variable Reluctance

111

(1)

Voltage-Generating Sensors

112

(1)

Camshaft Position Sensor

112

(1)

Crankshaft Position Sensor

113

(1)

Knock Sensor

114

(1)

Oxygen Sensor and Heated Oxygen Sensor

115

(2)

Vehicle Speed Sensor

117

(1)

Summary

118

(1)

Review Questions

118

(2)

PCM Outputs

120

(15)

Introduction

120

(1)

Control

120

(1)

Relays

121

(1)

Actuators

121

(1)

A/C Clutch

122

(1)

Active Cylinder Control

122

(1)

Cooling Fans

122

(1)

Exhaust Gas Recirculation Valve

122

(3)

Emission Controls

125

(1)

Fuel Injectors

125

(1)

Fuel Pump

125

(2)

Generator

127

(1)

Idle Air Control Valve

127

(1)

Ignition Coils

128

(1)

Intake Manifold Runner Control

128

(1)

Malfunction Indicator Light

129

(1)

Ignition Module

130

(1)

Throttle Actuator Control

130

(1)

Variable Valve Timing

130

(3)

Summary

133

(1)

Review Questions

133

(2)

Related Systems

135

(7)

Introduction

135

(1)

Air Conditioning System

135

(1)

Electronically Controlled Transmission

136

(2)

Adaptive Learning

138

(1)

Antitheft Systems

139

(1)

Instrument Panel Cluster

139

(1)

Cruise Control

139

(1)

Audio Systems

139

(1)

Vehicle Network Systems

140

(1)

Summary

140

(1)

Review Questions

141

(1)

On-Board Diagnostics II

142

(8)

Introduction

142

(1)

Vehicle Requirements

142

(1)

Communication and the Diagnostic Link Connector

142

(1)

On-Board Diagnostics II Monitoring Conditions

143

(1)

Diagnostic Trouble Codes

144

(1)

Malfunction Indicator Light Operation

145

(1)

Freeze Frame

146

(1)

Failure Records

146

(1)

System Monitors

146

(2)

Diagnostic Executive

148

(1)

Summary

148

(1)

Review Questions

149

(1)

Diagnostic Equipment

150

(9)

Introduction

150

(1)

Jumper Wire

150

(1)

Connectors and Terminals

150

(1)

Sewing Pins

151

(1)

Test Lamp

151

(1)

Logic Probe

152

(1)

Digital Multimeter

153

(1)

Measuring Voltage

153

(1)

Voltage Drop

154

(1)

Ohmmeter

154

(1)

Amperage

155

(1)

Duty Cycle or Pulse Width Modulation

155

(1)

Oscilloscope

156

(1)

Breakout Box

157

(1)

Summary

157

(1)

Review Questions

157

(2)

Scan Tools

159

(6)

Introduction

159

(1)

Description and Operation

159

(4)

Scan Tool Accessories and Alternatives

163

(1)

Summary

163

(1)

Review Questions

164

(1)

Electronic Engine Management Diagnosis

165

(14)

Introduction

165

(1)

Diagnostic Procedure

165

(2)

Diagnostic Trouble Code Diagnosis

167

(1)

Diagnosis Without Diagnostic Trouble Codes

167

(2)

Component Diagnosis

169

(1)

Potentiometer Testing

169

(1)

Thermistor

170

(1)

Testing Manifold Absolute Pressure Sensors

170

(1)

Air Flow Sensors

171

(1)

Heated Oxygen Sensor Diagnosis

172

(1)

Relays

173

(2)

Testing the Powertrain Control Module

175

(1)

Summary

176

(1)

Review Questions

177

(2)

Section 4: Ignition Systems

179

(74)

Ignition System Theory and Operation

181

(21)

Introduction

181

(1)

Components

182

(1)

Primary and Secondary Electrical Systems

182

(1)

Ignition Coil

182

(4)

Types of Ignition Coils

186

(2)

Coil Triggering Circuits

188

(1)

Ignition Control Module

189

(1)

Ignition Timing

190

(1)

Spark Plug Function

191

(1)

Spark Plug Construction

191

(2)

Electrode Materials

193

(1)

Spark Plug Operating Temperature and Heat Range

194

(2)

Types of Ignition Systems

196

(3)

Summary

199

(1)

Review Questions

200

(2)

Distributor Ignition Systems

202

(18)

Introduction

202

(1)

Components of Distributor Ignition

202

(2)

Breaker Point Ignition

204

(2)

Base Ignition Timing

206

(1)

Mechanical and Vacuum Advance

206

(1)

Electronic Ignition Using a Distributor

206

(3)

Electronic Spark Advance

209

(1)

Types of Distributor Ignition Systems

210

(8)

Summary

218

(1)

Review Questions

219

(1)

Distributorless Ignition Systems

220

(14)

Introduction

220

(1)

Advantages of Using Distributorless Ignition Systems

220

(1)

Waste-Spark Ignition Systems

220

(1)

Components of a Waste-Spark Ignition System

221

(1)

System Specifics

221

(3)

Circuit Operation

224

(4)

Integrated Waste-Spark Ignition Systems

228

(1)

Coil-On-Plug Ignition Systems

228

(1)

System Specifics

229

(1)

Circuit Operation

229

(2)

Coil-Near-Plug Ignition Systems

231

(1)

Summary

231

(1)

Review Questions

232

(2)

Primary Ignition System Diagnosis and Service

234

(8)

Introduction

234

(1)

Charting a Course of Action

234

(1)

Checking for Spark

235

(1)

Ignition Coil Diagnostics

236

(2)

Checking Ignition Module Operation

238

(1)

Verifying Base Ignition Timing

239

(1)

Adjusting Base Ignition Timing

239

(1)

Summary

240

(1)

Review Questions

240

(2)

Secondary Ignition System Diagnosis and Service

242

(11)

Introduction

242

(1)

Inspecting Secondary Ignition Wires

242

(1)

Measuring Secondary Ignition Cable Resistance

243

(1)

Measuring Secondary Ignition Coil Resistance

244

(1)

Manually Firing the Ignition Coil

244

(1)

Distributor Cap and Rotor Inspection and Service

245

(1)

Spark Plug Inspection and Replacement

245

(3)

Testing the Ignition System Using an Oscilloscope

248

(2)

Waste-Spark Ignition Systems

250

(1)

Coil-On-Plug Ignition Systems

250

(1)

Coil-Near-Plug Ignition Systems

250

(1)

Interpreting the Results

250

(1)

On-Board Diagnostics II Misfire Monitors

251

(1)

Summary

251

(1)

Review Questions

251

(2)

Section 5: Fuel and Induction

253

(66)

Introduction to Fuel Systems

255

(14)

Introduction

255

(1)

Gasoline

255

(1)

Volatility

255

(1)

Detonation and Preignition

256

(1)

Octane Rating

257

(1)

Fuel Delivery

258

(1)

Primary Fuel Delivery

258

(1)

Fuel Tank

259

(1)

Fuel Sender

260

(2)

Fuel Pump

262

(1)

Mechanical Fuel Pump

263

(1)

Electric Fuel Pump

263

(1)

Fuel Pump Circuits

264

(1)

Fuel Filters

265

(1)

Fuel Lines

265

(2)

Summary

267

(1)

Review Questions

267

(2)

Air Induction and Exhaust Systems

269

(11)

Introduction

269

(1)

Volumetric Efficiency

269

(1)

Backpressure

269

(1)

Air Induction Systems

270

(2)

Exhaust System

272

(2)

Forced Induction

274

(1)

Supercharger

274

(1)

Turbocharger

275

(3)

Summary

278

(1)

Review Questions

278

(2)

Throttle Body Fuel Injection

280

(7)

Introduction

280

(1)

Throttle Body

280

(1)

Fuel Injector

280

(2)

Intake Manifold

282

(1)

Idle Air Control

282

(2)

Basic Fuel Control

284

(1)

Special Modes

285

(1)

Summary

285

(1)

Review Questions

286

(1)

Port Fuel Injection Systems

287

(13)

Introduction

287

(1)

Throttle Body

287

(1)

Fuel Injector

287

(2)

Fuel Pressure

289

(1)

Returnless Fuel Systems

290

(1)

Intake Manifolds

291

(1)

Port Fuel Injection Systems

291

(3)

Basic Fuel Control

294

(3)

Special Modes

297

(1)

Summary

298

(1)

Review Questions

298

(2)

Basic Fuel System Testing and Diagnosis

300

(12)

Introduction

300

(1)

Fuel System Diagnosis

300

(1)

Fuel Pressure Testing

301

(1)

Interpreting Results

302

(1)

Fuel Pump Volume

303

(1)

Basic Fuel Pump Circuit Diagnosis

304

(1)

Pressure Leakdown

304

(1)

Leaking Injectors

304

(2)

Fuel Pressure Regulator Diagnosis

306

(1)

Injector Testing

306

(2)

Fuel Injector Cleaning

308

(1)

Fuel Quality Diagnosis

309

(1)

Summary

310

(1)

Review Questions

310

(2)

Induction and Exhaust System Diagnosis

312

(7)

Introduction

312

(1)

Air Induction System

312

(1)

Throttle Body Service

312

(1)

Idle Air Control System Diagnosis

313

(2)

Exhaust System Inspection

315

(1)

Backpressure Testing

315

(1)

Testing the Forced Induction System

316

(1)

Driveability Symptoms

317

(1)

Summary

317

(1)

Review Questions

318

(1)

Section 6: Emissions Control

319

(58)

Introduction to Air Quality and Emissions Control Systems

321

(7)

Introduction

321

(1)

Air Quality Concerns

321

(1)

A Brief History of Emissions Control

321

(1)

Combustion Process

322

(2)

How Rich Air/Fuel Ratios Affect Combustion

324

(1)

How Lean Air/Fuel Ratios Affect Combustion

324

(1)

Vehicle Exhaust Emissions

324

(2)

Effects of Sulfur and Other Compounds on the Environment

326

(1)

Summary

326

(1)

Review Questions

326

(2)

Precombustion Emissions Control

328

(10)

Introduction

328

(1)

Changes in Engine Design

328

(1)

Spark Timing

329

(1)

Exhaust Gas Recirculation

329

(1)

Engine Operating Conditions

330

(1)

Exhaust Gas Recirculation Strategies

330

(2)

Types of EGR Valves

332

(2)

Digital EGR Valve

334

(1)

Diagnosing EGR System Faults Using a Scan Tool

335

(1)

Meeting NOx Emissions Requirements Without an EGR Valve

335

(1)

Summary

336

(1)

Review Questions

336

(2)

Evaporative Emissions Control

338

(7)

Introduction

338

(1)

Crankcase Evaporative Emissions

338

(1)

System Components

338

(2)

Orifice-Type PCV Systems

340

(1)

Separator PCV Systems

340

(1)

Fuel System Evaporative Emissions

340

(1)

Purpose of the Evaporative Emissions Control System

341

(1)

Components of the EVAP System

341

(1)

EVAP System Operation: Engine Off

342

(1)

EVAP System Operation: Engine Running

343

(1)

Summary

343

(1)

Review Questions

343

(2)

Postcombustion Emissions Control

345

(6)

Introduction

345

(1)

Exhaust Aftertreatment

345

(1)

Catalyst Elements

345

(1)

Three-Way Catalysts

346

(1)

TWC Design Improvements

346

(1)

Catalyst Operating Temperatures

347

(1)

Light-Off Catalysts

347

(1)

Catalyst Heat Shields

347

(1)

Catalyst Poisoning

347

(1)

Repairing Catalytic Converters

348

(1)

Air Injection Reaction Systems

348

(1)

PCM Strategies

349

(1)

Summary

349

(1)

Review Questions

350

(1)

Basic Emissions System Diagnosis

351

(5)

Introduction

351

(1)

Exhaust Gas Recirculation System Diagnosis and Repair

351

(1)

PCV System Diagnosis and Repair

352

(1)

EVAP Emissions System Diagnosis and Repair

353

(1)

EVAP Emissions System Failures

353

(1)

Testing the EVAP Emissions System for Proper Operation

353

(1)

Catalytic Converter Diagnosis and Repair

353

(1)

Air Injection Reaction Diagnosis and Repair

353

(1)

Summary

354

(1)

Review Questions

355

(1)

Specialized Emissions Diagnostics Equipment

356

(5)

Introduction

356

(1)

Service Publications

356

(1)

The Exhaust Gas Analyzer

356

(1)

Scan Tool

357

(1)

OBDII System Monitors

357

(2)

Pyrometer

359

(1)

Summary

359

(1)

Review Questions

359

(2)

Vehicle Emissions Testing

361

(16)

Introduction

361

(1)

Types of Emissions Tests

361

(2)

Two-Speed Idle (BAR 90) Test

363

(1)

IM240 Transient Emissions Testing

363

(1)

Emissions Failure Analysis

364

(1)

Relationship Among HC, CO, CO2, O2, and NOx

364

(1)

On-Board Diagnostics Emissions Testing

365

(1)

Evaporative Emissions Testing

365

(1)

Summary

366

(1)

Review Questions

366

(3)

Appendices

Appendix A ASE Practice Exam

369

(5)

Appendix B Internet Resources

374

(2)

Appendix C Conversion Charts

376

(1)

Bilingual Glossary

377

(14)

Index

391

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TechOne Automotive Engine Performance

Summary

Table of Contents

Supplemental Materials