Hatch S.N. Computerized engine controls
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COMPUTERIZED
ENGINE CONTROLS
Eighth Edition
Steve V. Hatch
Lincoln College of Technology, Denver Campus
Formerly
Denver Automotive and Diesel College
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Computerized Engine Controls,
Eighth Edition
Steve V. Hatch
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iii
Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . vii
Acknowledgments . . . . . . . . . . . . . . . . xi
Chapter 1: A Review of Electricity
and Electronics . . . . . . . . . . . . . . . . . . 1
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Key Terms . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Electrical Circuits versus
Electronic Circuits . . . . . . . . . . . . . . . . . . 2
Electron Theory . . . . . . . . . . . . . . . . . . . . . . 3
Electrical Theory . . . . . . . . . . . . . . . . . . . . . 5
Electrical Circuits . . . . . . . . . . . . . . . . . . . 14
Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Circuit Faults . . . . . . . . . . . . . . . . . . . . . . . 20
Semiconductors . . . . . . . . . . . . . . . . . . . . 22
Integrated Circuits . . . . . . . . . . . . . . . . . . . 37
The Digital Age . . . . . . . . . . . . . . . . . . . . . 37
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Diagnostic Exercise . . . . . . . . . . . . . . . . . 39
Review Questions . . . . . . . . . . . . . . . . . . . 39
Chapter 2: Computers in Cars . . . . . . 43
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . 43
Key Terms . . . . . . . . . . . . . . . . . . . . . . . . . 43
Why Computers? . . . . . . . . . . . . . . . . . . . 43
How Computers Work . . . . . . . . . . . . . . . . 47
Functions of the Engine Computer . . . . . . 61
Controlling Exhaust Gasses . . . . . . . . . . . 63
Closed Loop and Open Loop
Operation . . . . . . . . . . . . . . . . . . . . . . . 64
The PCM and Exhaust Emissions . . . . . . 66
Attitude of the Technician . . . . . . . . . . . . . 66
System Diagnosis and Service . . . . . . . . . 66
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Diagnostic Exercise . . . . . . . . . . . . . . . . . 68
Review Questions . . . . . . . . . . . . . . . . . . . 68
Chapter 3: Common Components for
Computerized Engine Control Systems 71
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . 71
Key Terms . . . . . . . . . . . . . . . . . . . . . . . . . 71
Common Features . . . . . . . . . . . . . . . . . . 71
Sensing Devices . . . . . . . . . . . . . . . . . . . . 74
Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . 93
System Diagnosis and Service . . . . . . . . . 96
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Diagnostic Exercise . . . . . . . . . . . . . . . . . 99
Review Questions . . . . . . . . . . . . . . . . . . . 99
Chapter 4: Common Operating
Principles for Computerized Engine
Control Systems . . . . . . . . . . . . . . . . 103
Objectives . . . . . . . . . . . . . . . . . . . . . . . . 103
Key Terms . . . . . . . . . . . . . . . . . . . . . . . . 103
Electronic Fuel Injection System
Operating Principles . . . . . . . . . . . . . . 103
Ignition System Operating Principles . . . 116
Emission-Control Systems . . . . . . . . . . . 122
Variable Valve Timing . . . . . . . . . . . . . . . 130
42-V Systems . . . . . . . . . . . . . . . . . . . . . 130
Summary . . . . . . . . . . . . . . . . . . . . . . . . . 132
Diagnostic Exercise . . . . . . . . . . . . . . . . 132
Review Questions . . . . . . . . . . . . . . . . . . 132
Chapter 5: Diagnostic Concepts . . . . 135
Objectives . . . . . . . . . . . . . . . . . . . . . . . . 135
Key Terms . . . . . . . . . . . . . . . . . . . . . . . . 135
Types of Faults . . . . . . . . . . . . . . . . . . . . 135
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Diagnostic Trouble Codes . . . . . . . . . . . . 136
Data Streams . . . . . . . . . . . . . . . . . . . . . 138
Functional Tests . . . . . . . . . . . . . . . . . . . 138
Technical Service Bulletins . . . . . . . . . . . 139
Pinpoint Testing . . . . . . . . . . . . . . . . . . . . 139
Flowcharts . . . . . . . . . . . . . . . . . . . . . . . . 144
Electrical Schematics . . . . . . . . . . . . . . . 144
Other General Diagnostic Concepts . . . . 146
Summary . . . . . . . . . . . . . . . . . . . . . . . . . 147
Diagnostic Exercise . . . . . . . . . . . . . . . . 147
Review Questions . . . . . . . . . . . . . . . . . . 147
Chapter 6: Diagnostic Equipment . . . 149
Objectives . . . . . . . . . . . . . . . . . . . . . . . . 149
Key Terms . . . . . . . . . . . . . . . . . . . . . . . . 149
Scan Tools. . . . . . . . . . . . . . . . . . . . . . . . 149
Breakout Boxes . . . . . . . . . . . . . . . . . . . . 153
Non-Powered Test Lights . . . . . . . . . . . . 154
Logic Probes . . . . . . . . . . . . . . . . . . . . . . 155
Digital Volt-Ohmmeters . . . . . . . . . . . . . . 156
Digital Storage Oscilloscopes . . . . . . . . . 166
Safety Considerations When
Using a DVOM or DSO . . . . . . . . . . . . 180
Gas Analyzers . . . . . . . . . . . . . . . . . . . . . 181
Summary . . . . . . . . . . . . . . . . . . . . . . . . . 181
Diagnostic Exercises . . . . . . . . . . . . . . . . 181
Review Questions . . . . . . . . . . . . . . . . . . 181
Chapter 7: Exhaust Gas Analysis . . . 185
Objectives . . . . . . . . . . . . . . . . . . . . . . . . 185
Key Terms . . . . . . . . . . . . . . . . . . . . . . . . 185
Theory of Gas Analysis . . . . . . . . . . . . . . 185
Measured Gasses . . . . . . . . . . . . . . . . . . 187
Gas Analyzers . . . . . . . . . . . . . . . . . . . . . 192
Diagnosing with the Gasses . . . . . . . . . . 195
Summary . . . . . . . . . . . . . . . . . . . . . . . . . 197
Diagnostic Exercise . . . . . . . . . . . . . . . . 198
Review Questions . . . . . . . . . . . . . . . . . . 198
Chapter 8: OBD II Self-Diagnostics . . 201
Objectives . . . . . . . . . . . . . . . . . . . . . . . . 201
Key Terms . . . . . . . . . . . . . . . . . . . . . . . . 201
CARB/EPA/SAE/OBD Background . . . . . 201
Why OBD II? . . . . . . . . . . . . . . . . . . . . . . 202
What Does OBD II Do? . . . . . . . . . . . . . . 202
Standardization . . . . . . . . . . . . . . . . . . . . 204
Monitoring Conditions . . . . . . . . . . . . . . . 212
Setting DTCs and Turning on the Mil . . . 214
Diagnostic Management Software . . . . . 215
OBD II Monitors . . . . . . . . . . . . . . . . . . . 216
Cold Start Emissions Reduction . . . . . . . 225
Diagnostic Equipment . . . . . . . . . . . . . . . 226
Summary . . . . . . . . . . . . . . . . . . . . . . . . . 228
Diagnostic Exercise . . . . . . . . . . . . . . . . 228
Review Questions . . . . . . . . . . . . . . . . . . 228
Chapter 9: Multiplexing Concepts . . . 231
Objectives . . . . . . . . . . . . . . . . . . . . . . . . 231
Key Terms . . . . . . . . . . . . . . . . . . . . . . . . 231
Multiplexing Overview . . . . . . . . . . . . . . . 232
Multiplex System Designs . . . . . . . . . . . . 234
Multiplexing Protocols . . . . . . . . . . . . . . . 236
Communication on a J1850 VPW
Data Bus . . . . . . . . . . . . . . . . . . . . . . . 238
Communication on a CAN Data Bus . . . . 240
Multiplexing Variations . . . . . . . . . . . . . . 241
Other Bosch Protocols . . . . . . . . . . . . . . 243
Diagnosis of Multiplexed Circuits . . . . . . 243
Summary . . . . . . . . . . . . . . . . . . . . . . . . . 244
Diagnostic Exercise . . . . . . . . . . . . . . . . 244
Review Questions . . . . . . . . . . . . . . . . . . 245
Chapter 10: General Motors’
Electronic Fuel Injection . . . . . . . . . . 247
Objectives . . . . . . . . . . . . . . . . . . . . . . . . 247
Key Terms . . . . . . . . . . . . . . . . . . . . . . . . 247
Powertrain Control Module . . . . . . . . . . . 248
Operating Modes . . . . . . . . . . . . . . . . . . 250
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Body Control Module . . . . . . . . . . . . . . . 277
System Diagnosis and Service . . . . . . . . 279
Summary . . . . . . . . . . . . . . . . . . . . . . . . . 285
Diagnostic Exercise . . . . . . . . . . . . . . . . 286
Review Questions . . . . . . . . . . . . . . . . . . 286
Chapter 11: General Motors and
Port Fuel Injection . . . . . . . . . . . . . . 289
Objectives . . . . . . . . . . . . . . . . . . . . . . . . 289
Key Terms . . . . . . . . . . . . . . . . . . . . . . . . 289
Powertrain Control Module . . . . . . . . . . . 290
iv Contents
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Operating Modes . . . . . . . . . . . . . . . . . . 291
Fuel Supply System . . . . . . . . . . . . . . . . 292
Injectors . . . . . . . . . . . . . . . . . . . . . . . . . 295
Throttle Body . . . . . . . . . . . . . . . . . . . . . . 295
Non-PCM Emission Controls . . . . . . . . . 296
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . 307
System Diagnosis and Service . . . . . . . . 328
Summary . . . . . . . . . . . . . . . . . . . . . . . . . 333
Diagnostic Exercise . . . . . . . . . . . . . . . . 334
Review Questions . . . . . . . . . . . . . . . . . . 334
Chapter 12: Advanced General Motors
Engine Controls . . . . . . . . . . . . . . . . 337
Objectives . . . . . . . . . . . . . . . . . . . . . . . . 337
Key Terms . . . . . . . . . . . . . . . . . . . . . . . . 337
Northstar Engine Overview . . . . . . . . . . . 338
Northstar Inputs/Outputs . . . . . . . . . . . . . 342
Cadillac LH2 Northstar Upgrades . . . . . . 353
Cadillac HFV6 . . . . . . . . . . . . . . . . . . . . . 357
GM Generation III Small-Block V8s . . . . 357
GM Generation IV Small-Block V8s . . . . 360
GM Active Fuel Management
System . . . . . . . . . . . . . . . . . . . . . . . . 360
Flywheel Alternator Starter System . . . . . 362
Belt Alternator Starter System . . . . . . . . . 367
GM Voice-Recognition/Navigational
System . . . . . . . . . . . . . . . . . . . . . . . . 368
System Diagnosis and Service . . . . . . . . 368
Summary . . . . . . . . . . . . . . . . . . . . . . . . . 369
Diagnostic Exercise . . . . . . . . . . . . . . . . 370
Review Questions . . . . . . . . . . . . . . . . . . 370
Chapter 13: Ford’s Electronic Engine
Control IV (EEC IV) . . . . . . . . . . . . . . 373
Objectives . . . . . . . . . . . . . . . . . . . . . . . . 373
Key Terms . . . . . . . . . . . . . . . . . . . . . . . . 373
Powertrain Control Module . . . . . . . . . . . 376
Operating Modes . . . . . . . . . . . . . . . . . . 376
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . 399
System Diagnosis and Service . . . . . . . . 427
Summary . . . . . . . . . . . . . . . . . . . . . . . . . 438
Diagnostic Exercise . . . . . . . . . . . . . . . . 438
Review Questions . . . . . . . . . . . . . . . . . . 438
Chapter 14: Ford’s Electronic Engine
Control V (EEC V) . . . . . . . . . . . . . . . 441
Objectives . . . . . . . . . . . . . . . . . . . . . . . . 441
Key Terms . . . . . . . . . . . . . . . . . . . . . . . . 441
Engine Controls . . . . . . . . . . . . . . . . . . . 442
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . 445
Emissions Controls . . . . . . . . . . . . . . . . . 450
Advanced Ford Computer System
Features . . . . . . . . . . . . . . . . . . . . . . . 454
System Diagnosis and Service . . . . . . . . 465
Summary . . . . . . . . . . . . . . . . . . . . . . . . . 466
Diagnostic Exercise . . . . . . . . . . . . . . . . 467
Review Questions . . . . . . . . . . . . . . . . . . 467
Chapter 15: Chrysler Corporation
Fuel Injection Systems . . . . . . . . . . . 471
Objectives . . . . . . . . . . . . . . . . . . . . . . . . 471
Key Terms . . . . . . . . . . . . . . . . . . . . . . . . 471
Powertrain Control Module . . . . . . . . . . . 472
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 477
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . 489
Chrysler Multiplexing Systems . . . . . . . . 500
Advanced Chrysler Electronic
Systems . . . . . . . . . . . . . . . . . . . . . . . 501
System Diagnosis and Service . . . . . . . . 504
Summary . . . . . . . . . . . . . . . . . . . . . . . . . 507
Diagnostic Exercise . . . . . . . . . . . . . . . . 508
Review Questions . . . . . . . . . . . . . . . . . . 508
Chapter 16: European (Bosch)
Engine Control Systems . . . . . . . . . . 511
Objectives . . . . . . . . . . . . . . . . . . . . . . . . 511
Key Terms . . . . . . . . . . . . . . . . . . . . . . . . 511
System Overview . . . . . . . . . . . . . . . . . . 512
Continuous Injection System . . . . . . . . . 515
Pulsed Systems . . . . . . . . . . . . . . . . . . . 516
Motronic . . . . . . . . . . . . . . . . . . . . . . . . . 518
Electronic Control Unit . . . . . . . . . . . . . . 518
Operating Modes . . . . . . . . . . . . . . . . . . 519
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 523
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . 527
Bosch OBD II Update . . . . . . . . . . . . . . . 535
System Diagnosis and Service . . . . . . . . 536
Summary . . . . . . . . . . . . . . . . . . . . . . . . . 536
Contents v
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Diagnostic Exercise . . . . . . . . . . . . . . . . 536
Review Questions . . . . . . . . . . . . . . . . . . 537
Chapter 17: Asian Computer Control
Systems . . . . . . . . . . . . . . . . . . . . . . 541
Objectives . . . . . . . . . . . . . . . . . . . . . . . . 541
Key Terms . . . . . . . . . . . . . . . . . . . . . . . . 541
Nissan: Electronic Concentrated
Control System . . . . . . . . . . . . . . . . . . 542
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 544
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . 550
System Diagnosis and Service . . . . . . . . 555
Toyota Computer-Controlled System . . . 555
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 556
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . 558
System Diagnosis and Service . . . . . . . . 566
Honda: Programmed Fuel Injection . . . . 568
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 568
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . 572
Honda’s VTEC Systems . . . . . . . . . . . . . 575
System Diagnosis and Service . . . . . . . . 581
Summary . . . . . . . . . . . . . . . . . . . . . . . . . 581
Diagnostic Exercise . . . . . . . . . . . . . . . . 582
Review Questions . . . . . . . . . . . . . . . . . . 582
Chapter 18: Alternative Power
Sources . . . . . . . . . . . . . . . . . . . . . . 585
Objectives . . . . . . . . . . . . . . . . . . . . . . . . 585
Key Terms . . . . . . . . . . . . . . . . . . . . . . . . 585
Honda Insight, Civic, and Accord
Hybrids . . . . . . . . . . . . . . . . . . . . . . . . 587
Toyota Hybrid System . . . . . . . . . . . . . . . 590
Ford Escape Hybrid . . . . . . . . . . . . . . . . 594
Fuel Cell Vehicles . . . . . . . . . . . . . . . . . . 596
Flexible Fuel Vehicles . . . . . . . . . . . . . . . 600
System Diagnosis and Service . . . . . . . . 601
Summary . . . . . . . . . . . . . . . . . . . . . . . . . 602
Diagnostic Exercise . . . . . . . . . . . . . . . . 602
Review Questions . . . . . . . . . . . . . . . . . . 602
Appendix A: Approach
to Diagnostics . . . . . . . . . . . . . . . . . 605
Narrowing Down the Area of
the Problem . . . . . . . . . . . . . . . . . . . . 605
Pinpoint Testing . . . . . . . . . . . . . . . . . . . . 609
Additional Information Concerning
Soft Fault Diagnosis . . . . . . . . . . . . . . 613
Summary . . . . . . . . . . . . . . . . . . . . . . . . . 613
Appendix B: Terms and Acronyms . . 615
Appendix C: Automotive-Related
Web Addresses . . . . . . . . . . . . . . . . 623
Glossary . . . . . . . . . . . . . . . . . . . . . 625
Index . . . . . . . . . . . . . . . . . . . . . . . 643
vi
Contents
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vii
Preface
The application of the microprocessor with its
related components and circuits has made auto-
motive technology exciting, fast paced, and more
complicated. Recent technological developments
and those that will follow require entry-level au-
tomotive service technicians to be well trained in
the principles of automotive technology and to
be career-long students. Those who respond to
this requirement will find the task challenging but
achievable and rewarding.
This text was written in response to a widely
recognized need within the industry: to help
student-technicians get a commanding grasp of
how computerized engine control systems work
and how to diagnose problems within them.
The student-technician who studies this text will
soon come to realize that no single component
or circuit on any given computerized engine
control system, other than the computer itself, is
complicated.
Computerized Engine Controls is written with
the assumption that the reader is familiar with the
basic principles of traditional engine, electrical
system, and fuel system operation. Although ev-
erything here is within the grasp of a good techni-
cian, this is not a beginner’s book.
A computerized engine control system does in
fact become an integral part of an engine’s electri-
cal and fuel system, but it is much too significant
and complex to be taught as just a single unit in
an engine performance textbook or class. For
purposes of instruction, we have taken this topic
out of context and examined it as a stand-alone
control system. Once the student-technician fully
understands the system’s purpose, operation,
and diagnostic approach, the diagnostic proce-
dures in the service manual will put the system
back in its proper perspective as an integral part
of the engine’s support system.
Computerized Engine Controls presents each
popular, multifunction computer control system in
a separate chapter. Each system is fully covered,
with enough specific information and detail to en-
able the reader to get a complete and clear picture
of how the system works. This text is written with
the premise that understanding how the overall
system works, and what it should be doing, not
only makes the diagnostic process easier, but
also makes the diagnostic literature much easier
to understand. Correctly interpreting directions
for diagnostic procedure is often a problem if the
technician is not aware of what the procedure is
trying to measure, what normal readings or re-
sponses should be, or what conditions will cause
abnormal readings or responses.
The chapters of this edition contain:
• Objectives. Objectives are provided at
the beginning of each chapter to help the
reader identify the major concepts to be pre-
sented.
• Key Terms. Terms that are unique to comput-
erized engine control systems are provided at
the beginning of each chapter as Key Terms
and then appear in boldface type at their
first use in the chapter. These Key Terms are
also provided in the Glossary, along with their
definitions.
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• Diagnostic & Service Tips. These tips offer
helpful advice for the technician on diagnos-
ing and servicing vehicles, as well as ad-
dressing customer concerns.
• Chapter Articles. Chapter Articles give addi-
tional nice-to-know information about techni-
cal topics covered in the chapter.
• Summary. Each chapter contains a Summary
near the end to review the major concepts
presented in that chapter.
• Diagnostic Exercise. A Diagnostic Exercise is
provided near the end of each chapter, apply-
ing a real-life scenario to one of the concepts
covered in that chapter.
• Review Questions. Review Questions are
provided at the end of each chapter to help
a reader assess his/her recall and compre-
hension of the material read in each chapter,
as well as to reinforce the concepts covered
in each chapter. Without exception, all of
these Review Questions have been written
in a multiple-choice format, the type of ques-
tion that would be found on an ASE test.
Personal safety concerns peculiar to specific
computerized engine control systems are high-
lighted where applicable. The book follows the
industry standards for how to use the following
terms:
• Warnings indicate that failure to observe
correct diagnostic or repair procedures could
result in personal injury or even death.
• Cautions indicate that failure to observe cor-
rect diagnostic or repair procedures could
result in damage to tools, equipment, or the
vehicle being serviced.
Each student should be aware that while
working with computerized controls is not inher-
ently dangerous, failure to observe recognized
safety practices is. There are, unfortunately, many
more injuries and accidents in the automotive re-
pair business than there should be. Good safety
practices, if learned early in a student’s career,
literally can be lifesaving later on.
New to This Edition
In accordance with several reviewers’ re-
quests, the original introduction has been trans-
formed into the new Chapter 1 with chapter ques-
tions following. This chapter has been updated in
several areas so as to help electrical concepts
come alive for the reader. With Chapter 1 having
laid the foundation for understanding semicon-
ductors, Chapter 2 now includes a discussion of
logic gates so as to help take the magic out of the
computer.
Countless other changes have also been
made throughout this textbook. The chapters with
the most changes are the generic chapters—Chap-
ters 1 through 9 and Chapter 18—although some
information was updated in the manufacturer-
s pecific chapters as well, particularly Chapters 12,
14, and 17. Appendix A has been revised to flow
more efficiently for the reader. And one more ap-
pendix has been added, Appendix C, with a list of
some automotive-related web addresses. These
changes and additions have been made so as to
make this textbook the most comprehensive auto-
motive textbook that you will read this year.
SUGGESTIONS ON HOW
TO USE THIS TEXT
The reader should begin by reading Chap-
ters 1 through 9, preferably in the sequence
they exist in the textbook, as they contain in-
formation that pertains to all makes of vehicles.
Reading these chapters will also provide some
background that will make understanding spe-
cific system designs and diagnostic strategies
easier when reading the product-specific chap-
ters of this book. The remaining chapters, which
are specific to individual systems, can be read in
any order, though most students will find it much
easier to read a manufacturer’s set of chapters
in chronological sequence, the way they appear
in the book. Generally, systems become more
complex over time. The newer, more complex
systems become easier to understand if the
viii Preface
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Licensed to:
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reader has proficient background knowledge of
the earlier, simpler systems. Many students may
not wish to study each specific chapter, or their
instructors may not choose to assign the study
of each chapter. We suggest, however, that at
least three of the specific system chapters be se-
lected for study. Remaining chapters can then be
skimmed or serve as a reference for future use.
Finally, “Appendix A: Approach to Diagnos-
tics,” which offers a strategy-based diagnostic
approach, should be read to help the reader
apply the information contained within the chap-
ters of this book to a live vehicle. “Appendix B:
Terms and Acronyms” provides a central location
where the reader can look up many of the terms
and acronyms that relate to automotive electronic
systems. And, as noted earlier, the new Appen-
dix C contains a list of automotive-related web
addresses.
Preface ix
Copyright 2009 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part.
Licensed to:
iChapters User