Halderman J.D., Linder J. Automotive Fuel and Emissions Control Systems
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ix
chapter 1 Service Information, Tools, and Safety 1
chapter 2 Environmental and Hazardous Materials 35
chapter 3 Gasoline Engine Operation and Specifications 46
chapter 4 Diesel Engine Operation and Diagnosis 60
chapter 5 Gasoline 81
chapter 6 Alternative Fuels 95
chapter 7 Diesel and Biodiesel Fuels 108
chapter 8 Intake and Exhaust Systems 113
chapter 9 Turbocharging and Supercharging 123
chapter 10 Engine Condition Diagnosis 135
chapter 11 On-Board Diagnosis 153
chapter 12 CAN and Network Communications 162
chapter 13 Temperature Sensors 179
chapter 14 Throttle Position Sensors 190
chapter 15 MAP/BARO Sensors 196
chapter 16 MASS AIRFLOW Sensors 205
chapter 17 Oxygen Sensors 212
chapter 18 Wide-Band Oxygen Sensors 229
chapter 19 Fuel Pumps, Lines, and Filters 238
chapter 20 Fuel-Injection Components and Operation 256
chapter 21 Gasoline Direct-Injection Systems 270
chapter 22 Electronic Throttle Control System 277
chapter 23 Fuel-Injection System Diagnosis and Service 286
chapter 24 Vehicle Emission Standards and Testing 306
chapter 25 Evaporative Emission Control Systems 317
chapter 26 Exhaust Gas Recirculation Systems 327
chapter 27 Positive Crankcase Ventilation and Secondary Air-Injection Systems 335
BRIEF CONTENTS
x BRIEF CONTENTS
chapter 28 Catalytic Converters 343
chapter 29 Ignition System Operation and Diagnosis 354
chapter 30 Scan tools and Engine Performance Diagnosis 378
chapter 31 Hybrid Safety and Service Procedures 397
chapter 32 Fuel Cells and Advanced Technologies 410
appendix NATEF Task Correlation Chart 425
English Glossary 428
Spanish Glossary 437
Index 449
xi
Used Oil 38
Solvents 39
Coolant Disposal 40
Lead-Acid Battery Waste 41
Fuel Safety and Storage 41
Airbag Handling 42
Used Tire Disposal 42
Air-Conditioning Refrigerant Oil Disposal 42
SUMMARY 45
REVIEW QUESTIONS 45
CHAPTER QUIZ 45
chapter 3
GASOLINE ENGINE OPERATION
AND SPECIFICATIONS 46
Objectives 46
Key Terms 46
Purpose and Function 46
Energy and Power 46
Engine Construction Overview 46
Engine Parts and Systems 47
Four-Stroke Cycle Operation 49
Engine Classification and Construction 49
Engine Measurement 54
Compression Ratio 55
Torque and Horsepower 58
SUMMARY 59
REVIEW QUESTIONS 59
CHAPTER QUIZ 59
chapter 4
DIESEL ENGINE OPERATION
AND DIAGNOSIS 60
Objectives 60
Key Terms 60
Diesel Engines 60
Three Phases of Combustion 62
Fuel Tank and Lift Pump 63
Injection Pump 63
HEUI System 64
CONTENTS
chapter 1
SERVICE INFORMATION,
TOOLS, AND SAFETY 1
Objectives 1
Key Terms 1
Vehicle Identification 1
Service Information 3
Threaded Fasteners 4
Hand Tools 7
Basic Hand Tool List 16
Tool Sets and Accessories 17
Electrical Hand Tools 18
Hand Tool Maintenance 18
Trouble Lights 19
Air and Electrically Operated Tools 19
Personal Protective Equipment 21
Safety Precautions 22
Vehicle Protection 23
Safety Lifting (Hoisting) a Vehicle 23
Jacks and Safety Stands 25
Drive-On Ramps 26
Electrical Cord Safety 26
Jump-Starting and Battery Safety 27
Fire Extinguishers 27
Fire Blankets 28
First Aid and Eye Wash Stations 28
Hybrid Electric Vehicle Safety Issues 29
SUMMARY 34
REVIEW QUESTIONS 34
CHAPTER QUIZ 34
chapter 2
ENVIRONMENTAL AND
HAZARDOUS MATERIALS 35
Objectives 35
Key Terms 35
Hazardous Waste 35
Federal and State Laws 35
Asbestos Hazards 36
Used Brake Fluid 38
xii CONTENTS
Ethanol 95
Cellulose Ethanol 96
E85 96
Alternative-Fuel Vehicles 97
Methanol 100
Propane 101
Compressed Natural Gas 102
Liquefied Natural Gas 103
P-Series Fuels 103
Synthetic Fuels 104
Safety Procedures When Working
with Alternative Fuels 106
SUMMARY 106
REVIEW QUESTIONS 106
CHAPTER QUIZ 107
chapter 7
DIESEL AND BIODIESEL
FUELS 108
Objectives 108
Key Terms 108
Diesel Fuel 108
Biodiesel 110
E-Diesel Fuel 112
SUMMARY 112
REVIEW QUESTIONS 112
CHAPTER QUIZ 112
chapter 8
INTAKE AND EXHAUST
SYSTEMS 113
Objectives 113
Key Terms 113
Air Intake Filtration 113
Throttle-Body Injection Intake
Manifolds 115
Port Fuel-Injection Intake Manifolds 116
Exhaust Gas Recirculation
Passages 118
Exhaust Manifolds 118
Mufflers 120
SUMMARY 121
REVIEW QUESTIONS 122
CHAPTER QUIZ 122
Diesel Injector Nozzles 66
Glow Plugs 67
Engine-Driven Vacuum Pump 67
Diesel Fuel Heaters 68
Accelerator Pedal Position Sensor 68
Diesel Engine Turbochargers 69
Exhaust Gas Recirculation 70
Diesel Particulate Matter 71
Diesel Oxidation Catalyst 71
Diesel Exhaust Particulate Filter 71
Selective Catalytic Reduction 74
Diesel Exhaust Smoke Diagnosis 74
Diesel Performance Diagnosis 75
Compression Testing 75
Glow Plug Resistance Balance Test 77
Injector Pop Testing 77
Diesel Emission Testing 78
SUMMARY 79
REVIEW QUESTIONS 79
CHAPTER QUIZ 79
chapter 5
GASOLINE 81
Objectives 81
Key Terms 81
Gasoline 81
Refining 81
Volatility 83
Gasoline Combustion Process 84
Normal and Abnormal Combustion 85
Octane Rating 86
High-Altitude Octane Requirements 87
Gasoline Additives 87
Gasoline Blending 89
Reformulated Gasoline 89
Testing Gasoline for Alcohol Content 90
General Gasoline Recommendations 91
SUMMARY 94
REVIEW QUESTIONS 94
CHAPTER QUIZ 94
chapter 6
ALTERNATIVE FUELS 95
Objectives 95
Key Terms 95
CONTENTS xiii
chapter 11
ON-BOARD DIAGNOSIS 153
Objectives 153
Key Terms 153
On-Board Diagnostics Generation-II (OBD-II)
Systems 153
Diagnostic Executive and Task Manager 154
Monitors 154
OBD-II Monitor Information 155
Enabling Criteria 156
OBD-II DTC Numbering Designation 157
OBD-II Freeze-Frame 158
Enabling Conditions 158
PCM Tests 159
GLOBAL OBD-II 160
Diagnosing Problems Using Mode Six 161
SUMMARY 161
REVIEW QUESTIONS 161
CHAPTER QUIZ 161
chapter 12
CAN AND NETWORK
COMMUNICATIONS 162
Objectives 162
Key Terms 162
Module Communications and Networks 162
Network Fundamentals 162
Module Communications Configuration 163
Network Communications
Classifications 165
General Motors Communications
Protocols 165
Ford Network Communications
Protocols 168
Chrysler Communications
Protocols 169
Controller Area Network 170
Honda/Toyota Communications 172
European Bus Communications 172
Network Communications
Diagnosis 173
OBD-II Data Link Connector 176
SUMMARY 177
REVIEW QUESTIONS 177
CHAPTER QUIZ 178
chapter 9
TURBOCHARGING AND
SUPERCHARGING 123
Objectives 123
Key Terms 123
Introduction 123
Forced Induction Principles 123
Superchargers 125
Turbochargers 127
Boost Control 129
Turbocharger Failures 130
Nitrous Oxide 132
SUMMARY 133
REVIEW QUESTIONS 134
CHAPTER QUIZ 134
chapter 10
ENGINE CONDITION
DIAGNOSIS 135
Objectives 135
Key Terms 135
Typical Engine-Related Complaints 135
Engine Smoke Diagnosis 135
The Driver Is Your Best Resource 136
Visual Checks 136
Engine Noise Diagnosis 138
Oil Pressure Testing 139
Oil Pressure Warning Lamp 140
Compression Test 140
Wet Compression Test 142
Running (Dynamic) Compression Test 142
Cylinder Leakage Test 143
Cylinder Power Balance Test 144
Power Balance Test Procedure 144
Vacuum Tests 144
Exhaust Restriction Test 146
Testing Back Pressure with a Vacuum Gauge 147
Testing Back Pressure with a Pressure
Gauge 147
Diagnosing Head Gasket Failure 147
Dash Warning Lights 148
SUMMARY 151
REVIEW QUESTIONS 151
CHAPTER QUIZ 151
xiv CONTENTS
Barometric Pressure Sensor 201
Testing the MAP Sensor 202
Fuel-Rail Pressure Sensor 203
MAP/BARO Diagnostic Trouble Codes 203
SUMMARY 203
REVIEW QUESTIONS 203
CHAPTER QUIZ 204
chapter 16
MASS AIRFLOW SENSORS 205
Objectives 205
Key Terms 205
Airflow Sensors 205
Mass AirFlow Sensor Types 205
Karman Vortex Sensors 207
PCM Uses for Airflow Sensors 207
Testing Mass Airflow Sensors 208
MAF Sensor Contamination 209
MAF-Related Diagnostic Trouble Codes 210
SUMMARY 210
REVIEW QUESTIONS 210
CHAPTER QUIZ 211
chapter 17
OXYGEN SENSORS 212
Objectives 212
Key Terms 212
Oxygen Sensors 212
Zirconia Oxygen Sensors 213
Titania Oxygen Sensor 214
Closed Loop and Open Loop 214
PCM Uses of the Oxygen Sensor 214
Oxygen Sensor Diagnosis 215
Oxygen Sensor Waveform Analysis 218
Hash 221
Negative O2S Voltage 224
Low O2S Readings 225
High O2S Readings 225
Post-Catalytic Converter Oxygen Sensor Testing 226
Oxygen Sensor Visual Inspection 226
O2S-Related Diagnostic Trouble Codes 227
SUMMARY 227
REVIEW QUESTIONS 227
CHAPTER QUIZ 228
chapter 13
TEMPERATURE SENSORS 179
Objectives 179
Key Terms 179
Engine Coolant Temperature Sensors 179
Testing the Engine Coolant Temperature
Sensor 180
Intake Air Temperature Sensor 184
Testing the Intake Air Temperature Sensor 186
Transmission Fluid Temperature Sensor 186
Cylinder Head Temperature Sensor 187
Engine Fuel Temperature (EFT) Sensor 187
Exhaust Gas Recirculation (EGR) Temperature Sensor 187
Engine Oil Temperature Sensor 188
Temperature Sensor Diagnostic Trouble Codes 188
SUMMARY 188
REVIEW QUESTIONS 188
CHAPTER QUIZ 189
chapter 14
THROTTLE POSITION
SENSORS 190
Objectives 190
Key Terms 190
Throttle Position Sensor Construction 190
TP Sensor Computer Input Functions 191
PCM Uses for the TP Sensor 191
Testing the Throttle Position Sensor 192
Testing a TP Sensor Using the Min/Max Function 193
Testing the TP Sensor Using a Scan Tool 193
TP Sensor Diagnostic Trouble Codes 194
SUMMARY 194
REVIEW QUESTIONS 194
CHAPTER QUIZ 194
chapter 15
MAP/BARO SENSORS 196
Objectives 196
Key Terms 196
Air Pressure—High and Low 196
Principles of Pressure Sensors 196
Construction of MAP Sensors 196
PCM Uses of the MAP Sensor 199
CONTENTS xv
Throttle-Body Injection 258
Port Fuel Injection 258
Fuel-Pressure Regulator 261
Vacuum-Biased Fuel-Pressure Regulator 262
Electronic Returnless Fuel System 262
Mechanical Returnless Fuel System 263
Demand Delivery System 263
Fuel Injectors 264
Central Port Injection 265
Fuel-Injection Modes of Operation 266
Idle Control 266
Stepper Motor Operation 267
SUMMARY 268
REVIEW QUESTIONS 268
CHAPTER QUIZ 268
chapter 21
GASOLINE DIRECT-INJECTION
SYSTEMS 270
Objectives 270
Key Terms 270
Direct Fuel Injection 270
Direct-Injection Fuel Delivery System 271
GDI Fuel Injectors 272
Modes of Operation 272
Piston Top Designs 273
Lexus Port-and Direct-Injection Systems 274
Engine Start System 274
GDI Service 275
SUMMARY 275
REVIEW QUESTIONS 276
CHAPTER QUIZ 276
chapter 22
ELECTRONIC THROTTLE
CONTROL SYSTEM 277
Objectives 277
Key Terms 277
Electronic Throttle Control (ETC) System 277
Normal Operation of the ETC System 277
Accelerator Pedal Position Sensor 278
Throttle Body Assembly 278
TP Sensor 280
Diagnosis of ETC Systems 281
chapter 18
WIDE-BAND OXYGEN
SENSORS 229
Objectives 229
Key Terms 229
Terminology 229
Need For Wide-Band Sensors 229
Conventional O2S Review 230
Dual-Cell Planar Wide-Band Sensor Operation 232
Dual-Cell Diagnosis 234
Digital Multimeter Testing 234
Single-Cell Wide-Band Oxygen Sensors 234
Wide-Band Oxygen Sensor Pattern Failures 236
SUMMARY 236
REVIEW QUESTIONS 237
CHAPTER QUIZ 237
chapter 19
FUEL PUMPS, LINES,
AND FILTERS 238
Objectives 238
Key Terms 238
Fuel Delivery System 238
Fuel Tanks 238
Rollover Leakage Protection 240
Fuel Lines 240
Electronic Fuel Pumps 243
Fuel Filters 248
Fuel Pump Testing 248
Fuel pump Current Draw Test 253
Fuel pump Replacement 254
SUMMARY 254
REVIEW QUESTIONS 254
CHAPTER QUIZ 255
chapter 20
FUEL-INJECTION COMPONENTS
AND OPERATION 256
Objectives 256
Key Terms 256
Electronic Fuel-Injection Operation 256
Speed-Density Fuel-Injection Systems 256
Mass Airflow Fuel-Injection Systems 258
xvi CONTENTS
Photochemical Smog Formation 313
Testing for Oxides of Nitrogen 314
SUMMARY 315
REVIEW QUESTIONS 315
CHAPTER QUIZ 316
chapter 25
EVAPORATIVE EMISSION
CONTROL SYSTEMS 317
Objectives 317
Key Terms 317
Evaporative Emission Control System 317
Nonenhanced Evaporative Control Systems 318
Enhanced Evaporative Control System 319
Leak Detection Pump System 321
Onboard Refueling Vapor Recovery 321
Diagnosing The Evap System 322
Evaporative System Monitor 323
Typical Evap Monitor 324
Evap System-Related Diagnostic Trouble Codes 325
SUMMARY 325
REVIEW QUESTIONS 326
CHAPTER QUIZ 326
chapter 26
EXHAUST GAS RECIRCULATION
SYSTEMS 327
Objectives 327
Key Terms 327
Exhaust Gas Recirculation Systems 327
OBD-II EGR Monitoring Strategies 330
Diagnosing a Defective EGR System 331
EGR-Related OBD-II Diagnostic Trouble Codes 333
SUMMARY 333
REVIEW QUESTIONS 334
CHAPTER QUIZ 334
chapter 27
POSITIVE CRANKCASE
VENTILATION AND SECONDARY
AIR-INJECTION SYSTEMS 335
Objectives 335
Key Terms 335
ETC Throttle Follower Test 283
Servicing Electronic Throttle Systems 283
SUMMARY 284
REVIEW QUESTIONS 284
CHAPTER QUIZ 284
chapter 23
FUEL-INJECTION SYSTEM
DIAGNOSIS AND SERVICE 286
Objectives 286
Key Terms 286
Port Fuel-Injection Pressure Regulator
Diagnosis 286
Diagnosing Electronic Fuel-Injection Problems
Using Visual Inspection 287
Scan Tool Vacuum Leak Diagnosis 288
Port Fuel-Injection System Diagnosis 289
Testing for an Injector Pulse 289
Checking Fuel-Injector Resistance 291
Measuring Resistance of Grouped Injectors 291
Measuring Resistance of Individual Injectors 292
Pressure-Drop Balance Test 293
Injector Voltage-Drop Tests 293
Scope-Testing Fuel Injectors 294
Idle Air Speed Control Diagnosis 295
Fuel-Injection Service 296
Fuel-System Scan Tool Diagnostics 299
SUMMARY 305
REVIEW QUESTIONS 305
CHAPTER QUIZ 305
chapter 24
VEHICLE EMISSION STANDARDS
AND TESTING 306
Objectives 306
Key Terms 306
Emission Standards in the United States 306
European Standards 308
Exhaust Analysis Testing 308
Exhaust Analysis and Combustion
Efficiency 311
HC Too High 312
CO Too High 312
Measuring Oxygen and Carbon Dioxide 313
CONTENTS xvii
chapter 30
SCAN TOOLS AND ENGINE
PERFORMANCE
DIAGNOSIS 378
Objectives 378
Key Terms 378
The Eight-Step Diagnostic Procedure 378
Scan Tools 384
Retrieval of Diagnostic Information 384
Troubleshooting Using Diagnostic
Trouble Codes 385
Flash Code Retrieval on OBD-I General
Motors Vehicles 386
Retrieving Ford Diagnostic Codes 387
Flash Code Retrieval on Chrysler Vehicles 388
OBD-II Diagnosis 388
OBD-II Active Tests 391
Service/Flash Programming 392
Manufacturer’s Diagnostic Routines 394
Completing System Repairs 394
Procedures for Resetting the PCM 395
Road Test (Drive cycle) 395
SUMMARY 396
REVIEW QUESTIONS 396
CHAPTER QUIZ 396
chapter 31
HYBRID SAFETY AND SERVICE
PROCEDURES 397
Objectives 397
Key Terms 397
High-Voltage Safety 397
High-Voltage Safety Equipment 397
Electric Shock Potential 399
De-Powering the High-Voltage
System 399
Collision and Repair Industry
Issues 401
Moving and Towing a Hybrid 401
Removing the High-Voltage Batteries 402
Routine Service Procedures 403
SUMMARY 408
REVIEW QUESTIONS 408
CHAPTER QUIZ 408
Crankcase Ventilation 335
PCV-Related Diagnostic Trouble
Codes 338
Secondary Air-Injection System 339
Secondary Air-Injection System
Diagnosis 340
Sai-Related Diagnostic Trouble
Code 341
SUMMARY 341
REVIEW QUESTIONS 341
CHAPTER QUIZ 342
chapter 28
CATALYTIC CONVERTERS 343
Objectives 343
Key Terms 343
Catalytic Converters 343
OBD-II Catalytic Converter
Performance 345
Diagnosing Catalytic Converters 346
Catalytic Converter Replacement
Guidelines 348
SUMMARY 352
REVIEW QUESTIONS 352
CHAPTER QUIZ 352
chapter 29
IGNITION SYSTEM OPERATION
AND DIAGNOSIS 354
Objectives 354
Key Terms 354
Ignition System 354
Ignition Switching and Triggering 356
Distributor Ignition 360
Waste-Spark Ignition Systems 361
Coil-On-Plug Ignition 363
Knock Sensors 365
Ignition System Diagnosis 367
Spark Plug Wire Inspection 369
Spark Plugs 372
Ignition Timing 375
Ignition System Symptom Guide 376
SUMMARY 377
REVIEW QUESTIONS 377
CHAPTER QUIZ 377
xviii CONTENTS
Wind Power 422
Hydroelectric Power 422
SUMMARY 424
REVIEW QUESTIONS 424
CHAPTER QUIZ 424
appendix
NATEF TASK CORRELATION CHART 425
ENGLISH GLOSSARY 428
SPANISH GLOSSARY 437
INDEX 449
chapter 32
FUEL CELLS AND ADVANCED
TECHNOLOGIES 410
Objectives 410
Key Terms 410
Fuel-Cell Technology 410
Pem Fuel Cells 412
Fuel-Cell Vehicle Systems 413
Hydraulic Hybrid Storage System 419
HCCI 419
Plug-In Hybrid Electric Vehicles 420
The Future for Electric Vehicles 420