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Computerized Engine Controls, Seventh Edition Steve V. Hatch and Dick H. King Vice President, Technology and Trades SBU: Alar Elken Editorial Director: Sandy Clark Senior Acquisitions Editor: David Boelio Developmental Editor: Sharon Chambliss Marketing Director: David Garza Channel Manager: Dennis Williams Marketing Coordinator: Mark Pierro Production Director: Mary Ellen Black Production Editor: Barbara L. Diaz Art & Design Specialist: Cheri Plasse Editorial Assistant: Andrea Domkowski
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NOTICE TO THE READER Publisher does not warrant or guarantee any of the products described herein or perform any independent analysis in connection with any of the product information contained herein. Publisher does not assume, and expressly disclaims, any obligation to obtain and include information other than that provided to it by the manufacturer. The reader is expressly warned to consider and adopt all safety precautions that might be indicated by the activities herein and to avoid all potential hazards. By following the instructions contained herein, the reader willingly assumes all risks in connection with such instructions. The publisher makes no representation or warranties of any kind, including but not limited to, the warranties of fitness for particular purpose or merchantability, nor are any such representations implied with respect to the material set forth herein, and the publisher takes no responsibility with respect to such material. The publisher shall not be liable for any special, consequential, or exemplary damages resulting, in whole or in part, from the readers use of, or reliance upon, this material.
Contents
Common Features . . . . . . . . . . . . . . . . . . 47 Sensing Devices . . . . . . . . . . . . . . . . . . . . 50 Actuators. . . . . . . . . . . . . . . . . . . . . . . . . . 67 System Diagnosis and Service. . . . . . . . . 71 Summary . . . . . . . . . . . . . . . . . . . . . . . . . 73 Diagnostic Exercise . . . . . . . . . . . . . . . . . 73 Review Questions . . . . . . . . . . . . . . . . . . . 73
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Other General Diagnostic Concepts . . . . 111 Summary . . . . . . . . . . . . . . . . . . . . . . . . 111 Diagnostic Exercises . . . . . . . . . . . . . . . 111 Review Questions . . . . . . . . . . . . . . . . . . 112
Contents
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 000 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . 000 System Diagnosis and Service. . . . . . . . 000 Summary . . . . . . . . . . . . . . . . . . . . . . . . 000 Diagnostic Exercise . . . . . . . . . . . . . . . . 000 Review Questions . . . . . . . . . . . . . . . . . . 000
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Continuous Injection System (CIS). . . . . 000 Pulsed Systems . . . . . . . . . . . . . . . . . . . 000 Motronic . . . . . . . . . . . . . . . . . . . . . . . . . 000 Control Unit. . . . . . . . . . . . . . . . . . . . . . . 000 Operating Modes . . . . . . . . . . . . . . . . . . 000 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 000 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . 000 Bosch OBD II Update . . . . . . . . . . . . . . . 000 System Diagnosis and Service. . . . . . . . 000 Summary . . . . . . . . . . . . . . . . . . . . . . . . 000 Diagnostic Exercise . . . . . . . . . . . . . . . . 000 Review Questions . . . . . . . . . . . . . . . . . . 000
Preface
The application of the microprocessor with its related components and circuits has made automotive technology exciting, fast paced and more complicated. Recent technological developments and those that follow will require entry level automotive 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 studenttechnicians get a commanding grasp of how computerized engine control systems work and how to diagnose problems within them. The studenttechnician who studies this text will soon come to realize that no single component or circuit within 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 everything here is within the grasp of a good technician, this is not a beginners book. A computerized engine control system does in fact become an integral part of an engines electrical and fuel system, but it is much too significant and complex to be taught as just a 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 controllevel system. Once the student-technician fully un-
derstands the systems purpose, operation and diagnostic approach, the diagnostic procedures in the service manual will put the system back in its proper perspective as an integral part of the engines 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 enable 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 diagnostic procedure directions is often a problem if the technician is not aware of what the procedure is trying to measure, what normal readings or responses 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 presented. Key Terms. Terms that are unique to computerized engine control systems are provided at the beginning of each chapter as a Key Term 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 and Service Tips. These tips offer helpful advice for the technician on diagnosing and servicing vehicles, as well as addressing customer concerns. Chapter Articles. Chapter Articles give additional nice-to-know information about technical 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 that applies 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 comprehension 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 multiplechoice format, the type of question that would be found on an ASE test. Personal safety concerns peculiar to specific computerized engine control systems are highlighted 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 correct diagnostic or repair procedures could result in damage to tools, equipment or the vehicle serviced. Each student should be aware that while working with computerized controls is not inherently dangerous, failure to observe recognized safety practices is. There are unfortunately many more injuries and accidents in the automotive repair business than there should be. Good safety practices, if learned early in a students career, literally can be life-saving later on.
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more complicated over time, and the later versions are easier to understand with a good 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 selected for study. Remaining chapters can then be skimmed or serve as a reference for future use. Finally, Appendix A: Approach to Diagnostics, which offers a strategy-based diagnostic approach, should be read to help the reader apply the information contained within the chapters of this book to a live vehicle. Also, 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.
Acknowledgments
I am very honored to be able to present a textbook of such magnitude as this. But there are those around me that I depend on greatly, and without which, this textbook would not be the success it is today. Many thanks to my family, my friends, and my colleagues who have so encouraged me. Many thanks to my students who, while they were in my classes over the years, asked the right questions that encouraged me to find the answer. And many thanks to my colleague, Kevin Dowell, who took the time out of his busy schedule to offer me technical advice in his area of expertise (and also took the time to gather some waveforms for me). I would also like to thank my wife, Geralyn, for her continual patience with the many hours that this effort has required of me, as well as for the great help that she was to me in performing many of the tasks associated with this type of work. And finally, many thanks to the following for their critical reviews and/or answers to questions concerning this text: Wane Boysun Montana State University-Northern Havre, MT David Byrd Wayne Community College Goldsboro, NC
Neal Clark Erie Community College Orchard Park, NY Ron Darby University of Southern Colorado Pueblo, CO Carl Hinkley Central Maine Technical College Auburn, ME Kevin Johnson Montana State University-Northern Havre, MT Donald Lumsdon Ivy Technical State College Lafayette, IN Bryan Ricco Spokane Community College Spokane, WA
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