Automotive Engine Performance

by Halderman, James D.

• ISBN13: 9780131989351
• ISBN10: 0131989359
• Edition: 2nd
• Format: Paperback
• Copyright: 2007-01-01
• Publisher: Prentice Hall

Summary

Written in and for the 21st century, this comprehensive book is divided into chapters that correspond to the content area of certification as specified by the National Institute for Automotive Service Excellence (ASE) and the National Automotive Technicians Education Foundation (NATEF). The content area of all ASE material certification is listed in the objectives at the beginning of each chapter and all laboratory worksheets are correlated to the NATEF Task List. Terminology throughout reflects the SAE J-1930 standard.Engine Operation, Parts, and Specifications; Engine Condition Diagnosis; Engine Cooling System Operation and Diagnosis; Engine Lubrication System Operation and Diagnosis; Digital Meters and Oscilloscopes; Starting and Charging Systems Diagnosis; Ignition System Components and Operation; Ignition System Diagnosis and Service; Computer Fundamentals; Computer Sensor Operation, Diagnosis, and Service; Engine Fuels and Combustion; Computerized Carburetor Operation, Diagnosis, and Service; Electronic Fuel-Injection Operation, Diagnosis, and Service; Emission Control Device Operation, Diagnosis, and Service; On-Board Diagnostics II; Engine Performance Diagnosis and Testing.For service technicians.

Table of Contents

Service Information, Tools, and Safety	p. 1
Objectives	p. 1
Vehicle Identification	p. 2
Vehicle Safety Certification Label	p. 2
Veci Label	p. 2
Calibration Codes	p. 3
Casting Numbers	p. 3
Service Information	p. 3
Threaded Fasteners	p. 4
Metric Bolts	p. 5
Grades of Bolts	p. 6
Tensile Strength	p. 6
Nuts	p. 7
Washers	p. 8
Electrical Tools	p. 8
Basic Hand Tool List	p. 9
Tool Sets and Accessories	p. 15
Brand Name Versus Proper Term	p. 15
Safety Tips for Using Hand Tools	p. 17
Air and Electrically Operated Tools	p. 17
Personal Protective Equipment	p. 20
Safety in Lifting (Hoisting) a Vehicle	p. 23
Jacks and Safety Stands	p. 24
Drive-on Ramps	p. 25
Electrical Cord Safety	p. 25
Jump Starting and Battery Safety	p. 25
Fire Extinguishers	p. 26
Fire Blankets	p. 28
First Aid and Eye Wash Stations	p. 28
Hybrid Electric Vehicle Safety Issues	p. 30
Summary	p. 35
Review Questions	p. 35
Chapter Quiz	p. 35
Environmental and Hazardous Materials	p. 37
Objectives	p. 37
Occupational Safety and Health Act	p. 38
Hazardous Waste	p. 38
Resource Conservation and Recovery Act (RCRA)	p. 38
Clean Air Act	p. 39
Material Safety Data Sheets (MSDS)	p. 39
The Dangers of Exposure to Asbestos	p. 39
Asbestos OSHA Standards	p. 40
Asbestos EPA Regulations	p. 40
Asbestos Handling Guidelines	p. 40
Used Brake Fluid	p. 41
Used Oil	p. 41
Disposal of Used Oil	p. 41
Used Oil Storage	p. 41
Solvents	p. 42
Solvent Hazardous and Regulatory Status	p. 43
Used Solvents	p. 43
Coolant Disposal	p. 44
Lead-Acid Battery Waste	p. 44
Battery Hazardous and Regulatory Status	p. 44
Battery Handling and Storage	p. 45
Fuel Safety and Storage	p. 45
Airbag Handling	p. 45
Used Tire Disposal	p. 46
Air-Conditioning Refrigerant Oil Disposal	p. 46
Summary	p. 51
Review Questions	p. 52
Chapter Quiz	p. 52
Gasoline and Diesel Engine Operation	p. 53
Objectives	p. 53
Energy and Power	p. 54
4-Stroke Cycle Operation	p. 54
The 720[degree] Cycle Operation	p. 54
Engine Classification	p. 56
Engine Rotation Direction	p. 59
Bore	p. 59
Stroke	p. 60
Engine Displacement	p. 60
Compression Ratio	p. 61
The Crankshaft Determines the Stroke	p. 62
Torque	p. 63
Work	p. 64
Power	p. 64
Horsepower	p. 64
Horsepower and Altitude	p. 65
Diesel Engines	p. 65
Three Phases of Combustion	p. 67
Diesel Engine Construction	p. 67
Fuel Tank and Lift Pump	p. 68
Injection Pump	p. 69
Diesel Injector Nozzles	p. 70
Diesel Injector Nozzle Operation	p. 70
Glow Plugs	p. 71
Engine-Driven Vacuum Pump	p. 71
Diesel Engine Advantages	p. 72
Diesel Engine Disadvantages	p. 72
Summary	p. 73
Review Questions	p. 74
Chapter Quiz	p. 74
Cooling System Operation and Diagnosis	p. 77
Objectives	p. 77
Cooling System Purpose and Function	p. 78
Low-Temperature Engine Problems	p. 78
High-Temperature Engine Problems	p. 78
Cooling System Design	p. 79
Thermostat Temperature Control	p. 80
Testing the Thermostat	p. 82
Thermostat Replacement	p. 83
Antifreeze/Coolant	p. 84
Organic Additive Technology Coolant	p. 84
Antifreeze Can Freeze	p. 86
Hydrometer Testing	p. 86
Recycling Coolant	p. 86
Disposing of Used Coolant	p. 87
Radiator	p. 87
Pressure Cap	p. 88
Surge Tank	p. 89
Metric Radiator Caps	p. 89
Coolant Recovery System	p. 90
Pressure Testing	p. 90
Coolant Dye Leak Testing	p. 91
Water Pump Operation	p. 91
Coolant Flow in the Engine	p. 93
Water Pump Service	p. 94
Cooling Fans	p. 95
Thermostatic Fans	p. 96
Heater Core	p. 97
Heater Problem Diagnosis	p. 97
Coolant Temperature Warning Light	p. 98
Common Causes of Overheating	p. 98
Cooling System Maintenance	p. 98
Flush and Refill	p. 99
Burping the System	p. 99
Hoses	p. 100
Back Flushing a Radiator	p. 100
Cleaning the Radiator Exterior	p. 101
Summary	p. 103
Review Questions	p. 103
Chapter Quiz	p. 103
Lubrication System Operation and Diagnosis	p. 105
Objectives	p. 105
Lubrication Principles	p. 106
Engine Lubrication Systems	p. 106
Properties of Engine Oil	p. 107
SAE Rating	p. 107
API Rating	p. 107
ILSAC Oil Rating	p. 108
European Oil Ratings	p. 108
Japanese Oil Ratings	p. 109
Engine Oil Additives	p. 109
Oil Brand Compatibility	p. 110
Synthetic Oil	p. 110
Oil Temperature	p. 111
Oil Change Intervals	p. 111
Oil Change Procedure	p. 112
Oil Filters	p. 112
Changing Oil in a Turbocharged Engine	p. 113
Oil Pumps	p. 115
Oil Pressure Regulation	p. 116
Factors Affecting Oil Pressure	p. 117
Oil Pump Checks	p. 117
Oil Passages in the Block	p. 120
Valve Train Lubrication	p. 120
Oil Pans	p. 121
Oil Coolers	p. 122
Oil Pressure Warning Lamp	p. 122
Summary	p. 123
Review Questions	p. 124
Chapter Quiz	p. 124
Intake and Exhaust Systems	p. 127
Objectives	p. 127
Air Intake Filtration	p. 128
The Air Cleaner	p. 128
Engine Air Temperature Requirements	p. 129
Throttle-Body Injection Intake Manifolds	p. 130
Manifold Heat	p. 131
Port Fuel-Injection Intake Manifolds	p. 132
Plastic Intake Manifolds	p. 134
Exhaust Gas Recirculation Passages	p. 134
Upper and Lower Intake Manifolds	p. 134
Exhaust Manifold Design	p. 134
Exhaust Manifold Gaskets	p. 135
Mufflers	p. 137
Summary	p. 139
Review Questions	p. 139
Chapter Quiz	p. 139
Turbocharging and Supercharging	p. 141
Objectives	p. 141
Airflow Requirements	p. 142
Superchargers	p. 145
Turbochargers	p. 146
Boost Control	p. 148
Turbocharger Failures	p. 149
Summary	p. 150
Review Questions	p. 151
Chapter Quiz	p. 151
Engine Condition Diagnosis	p. 153
Objectives	p. 153
Typical Engine-Related Complaints	p. 154
Engine Smoke Diagnosis	p. 154
The Driver Is Your Best Resource	p. 155
Visual Checks	p. 155
Engine Noise Diagnosis	p. 157
Oil Pressure Testing	p. 158
Oil Pressure Warning Lamp	p. 160
Compression Test	p. 160
Wet Compression Test	p. 162
Running (Dynamic) Compression Test	p. 162
Cylinder Leakage Test	p. 163
Cylinder Power Balance Test	p. 164
Power Balance Test Procedure	p. 164
Vacuum Tests	p. 164
Exhaust Restriction Test	p. 167
Testing Back Pressure with a Vacuum Gauge	p. 167
Testing Back Pressure with a Pressure Gauge	p. 168
Timing Chain Slack Diagnosis	p. 168
Diagnosing Head Gasket Failure	p. 169
Dash Warning Lights	p. 170
Summary	p. 178
Review Questions	p. 178
Chapter Quiz	p. 178
Starting and Charging Systems Diagnosis	p. 181
Objectives	p. 181
Purpose and Function of a Battery	p. 182
Battery Ratings	p. 182
Symptoms of a Weak or Defective Battery	p. 182
Battery Service Safety Considerations	p. 183
Battery Visual Inspection	p. 183
Battery Voltage Test	p. 184
Battery Load Testing	p. 185
Conductance Testing	p. 185
Jump Starting	p. 187
Battery Charging	p. 188
Battery Service	p. 189
Battery Electrical Drain Test	p. 190
Battery Electrical Drain Testing Using an Ammeter	p. 193
Procedure for Battery Electrical Drain Test	p. 194
Finding the Source of the Drain	p. 194
Cranking Circuit	p. 195
Diagnosing Starter Problems Using Visual Inspection	p. 199
Starter Testing on the Vehicle	p. 199
Testing a Starter Using a Scan Tool	p. 199
Voltage-Drop Testing	p. 201
Starter Drive-to-Flywheel Clearance	p. 204
How a Generator Works	p. 207
Generator Construction	p. 210
Checking Charging System Voltage	p. 210
Testing a Generator Using a Voltmeter	p. 210
Testing a Generator Using a Scan Tool	p. 211
AC Ripple Voltage Check	p. 211
AC Current Check	p. 213
Charging System Voltage-Drop Testing	p. 215
Generator Output Test	p. 216
How to Determine Minimum Generator Output	p. 217
Testing a Generator Using a Scope	p. 218
Summary	p. 225
Review Questions	p. 225
Chapter Quiz	p. 225
Ignition System Components and Operation	p. 227
Objectives	p. 227
Ignition System Operation	p. 228
Ignition Coils	p. 228
Primary Circuit Operation	p. 231
Distributor Ignition	p. 234
Waste-Spark Ignition Systems	p. 238
Ignition Control Circuits	p. 240
Compression Sensing Ignition	p. 242
Coil-on-Plug Ignition	p. 242
Ion-Sensing Ignition	p. 244
Ignition Timing	p. 244
Initial Timing	p. 245
Knock Sensors	p. 245
Spark Plugs	p. 246
Summary	p. 247
Review Questions	p. 247
Chapter Quiz	p. 248
Ignition System Diagnosis and Service	p. 249
Objectives	p. 249
Checking for Spark	p. 250
Ignition Troubleshooting Procedure	p. 251
Ignition Coil Testing Using an Ohmmeter	p. 251
Pickup Coil Testing	p. 252
Current Ramping Ignition Coils	p. 252
Testing Magnetic Sensors	p. 254
Testing Hall-Effect Sensors	p. 254
Testing Optical Sensors	p. 256
Distributor Indexing	p. 257
Ignition System Diagnosis Using Visual Inspection	p. 257
Testing for Poor Performance	p. 257
Testing for a No-Start Condition	p. 260
Ignition System Service	p. 261
Firing Order	p. 261
Distributor Cap and Rotor Inspection	p. 261
Spark Plug Wire Inspection	p. 262
Spark Plug Service	p. 263
Quick and Easy Secondary Ignition Tests	p. 267
Ignition Timing	p. 268
Scope-Testing the Ignition System	p. 269
Reading the Scope on Display (Parade)	p. 276
Scope-Testing a Waste-Spark Ignition System	p. 279
Ignition System Troubleshooting Guide	p. 280
Summary	p. 283
Review Questions	p. 283
Chapter Quiz	p. 283
Computer Fundamentals	p. 285
Objectives	p. 285
Computer Control	p. 286
The Four Basic Computer Functions	p. 286
Digital Computers	p. 289
Computer Input Sensors	p. 291
Computer Outputs	p. 292
Module Communication	p. 292
SAE Communication Classifications	p. 293
Module Communication Diagnosis	p. 293
OBD-II Data Link Connector	p. 295
Summary	p. 296
Review Questions	p. 296
Chapter Quiz	p. 296
OBD II	p. 297
Objectives	p. 297
On-Board Diagnostics Generation-II (OBD-II) Systems	p. 298
Diagnostic Executive and Task Manager	p. 298
Monitors	p. 299
Diagnostic Trouble Code Priority	p. 300
OBD-II Monitor Information Summary	p. 300
Enabling Criteria	p. 300
OBD-II Drive Cycle	p. 301
OBD-II DTC Numbering Designation	p. 302
Freeze Frame and Failure Records	p. 304
The Need for Fuel Trim	p. 304
Mil On/Off and Drive Cycles	p. 305
Short-Term Fuel Trim	p. 305
Long-Term Fuel Trim	p. 306
Using Fuel Trim as a Diagnostic Aid	p. 306
Fuel Trim Cells	p. 307
Fuel Trim Cell Diagnosis	p. 307
Fuel Trim and Misfire Codes	p. 308
Generic OBD-II	p. 308
Diagnosing Problems Using Mode Six	p. 309
Summary	p. 309
Review Questions	p. 309
Chapter Quiz	p. 309
Computer Sensors	p. 311
Objectives	p. 311
Engine Coolant Temperature Sensors	p. 312
Stepped ECT Circuits	p. 312
Testing the Engine Coolant Temperature Sensor	p. 312
Intake Air Temperature Sensor	p. 317
Testing the Intake Air Temperature Sensor	p. 319
Temperature Sensor Diagnostic Trouble Codes	p. 319
Throttle-Position Sensors	p. 319
TP Sensor Computer Input Functions	p. 321
PCM Uses for the TP Sensor	p. 321
Testing the Throttle Position Sensor	p. 322
Testing a TP Sensor Using the Min/Max Function	p. 323
Testing the TP Sensor Using a Scan Tool	p. 324
TP Sensor Diagnostic Trouble Codes	p. 324
Manifold Absolute Pressure (Map) Sensors	p. 325
PCM Uses of the MAP Sensor	p. 329
Barometric Pressure Sensor	p. 330
Testing the MAP Sensor Using a DMM	p. 330
Testing the MAP Sensor Using a Scan Tool	p. 332
MAP/BARO Diagnostic Trouble Codes	p. 332
Air Flow Sensors	p. 332
Mass Air Flow Sensor	p. 333
Karman Vortex Sensors	p. 334
PCM Uses for Air Flow Sensors	p. 335
Testing Mass Air Flow Sensors	p. 335
MAF Sensor Output Test	p. 336
Oxygen Sensors	p. 339
Zirconia Oxygen Sensors	p. 341
Titania Oxygen Sensors	p. 341
Wide-Band Oxygen Sensors	p. 342
Closed Loop and Open Loop	p. 342
PCM Uses of the Oxygen Sensor	p. 342
Testing an Oxygen Sensor Using a Digital Voltmeter	p. 343
Testing the Oxygen Sensor Using the Min/Max Method	p. 344
Testing an Oxygen Sensor Using a Scan Tool	p. 346
Testing an Oxygen Sensor Using a Scope	p. 347
False 02S Readings	p. 351
Post-Catalytic Converter Oxygen Sensor Testing	p. 351
Oxygen Sensor Inspection	p. 351
Oxygen Sensor-Related Diagnostic Trouble Codes	p. 352
Summary	p. 360
Review Questions	p. 360
Chapter Quiz	p. 361
Engine Fuels and Combustion	p. 363
Objectives	p. 363
Gasoline	p. 364
Volatility	p. 364
Normal and Abnormal Combustion	p. 364
Octane Rating	p. 365
Gasoline Grades and Octane Number	p. 366
Octane Improvers	p. 366
Oxygenated Fuels	p. 367
Alcohol Additives-Advantages and Disadvantages	p. 368
Testing Gasoline for Alcohol Content	p. 368
Combustion Chemistry	p. 369
High-Altitude Octane Requirements	p. 369
Valve Recession and Unleaded Fuel	p. 370
Reformulated Gasoline	p. 370
General Gasoline Recommendations	p. 371
Summary	p. 373
Review Questions	p. 373
Chapter Quiz	p. 373
Fuel Delivery and Evaporative Control Systems	p. 375
Objectives	p. 375
Fuel Delivery System	p. 376
Fuel Tanks	p. 376
Fuel Lines	p. 378
Electric Fuel Pumps	p. 381
Fuel Filters	p. 384
Fuel Pump Testing	p. 386
Fuel Pump Current Draw Test	p. 393
Fuel Pump Replacement	p. 393
Need for Evaporative Emission Control	p. 394
Vapor Canister Storage	p. 395
Vapor Purging	p. 395
Evaporative Control Systems	p. 397
On-Board Refueling Vapor Recovery System	p. 397
Diagnosing the EVAP System	p. 399
Locating Leaks in the System	p. 400
Evaporative System Monitor	p. 400
Evap System-Related Diagnostic Trouble Codes (DTC)	p. 402
Summary	p. 403
Review Questions	p. 403
Chapter Quiz	p. 403
Fuel-Injection Components and Operation	p. 405
Objectives	p. 405
Electronic Fuel-Injection Operation	p. 406
Speed Density Fuel-Injection Systems	p. 406
Mass Air Flow Fuel-Injection Systems	p. 407
Throttle-Body Injection	p. 408
Port Fuel Injection	p. 410
Gasoline Direct Injection	p. 411
Fuel-Pressure Regulator	p. 412
Vacuum-Biased Fuel-Pressure Regulator	p. 413
Electronic Returnless Fuel System	p. 413
Mechanical Returnless Fuel System	p. 414
Demand Delivery System (DDS)	p. 415
Fuel Injectors	p. 415
Central Port Injection	p. 416
Fuel-Injection Modes of Operation	p. 417
Idle Control	p. 418
Stepper Motor Operation	p. 418
Summary	p. 420
Review Questions	p. 421
Chapter Quiz	p. 421
Fuel-Injection System Diagnosis and Service	p. 423
Objectives	p. 423
Port Fuel-Injection Pressure Regulator Diagnosis	p. 424
Diagnosing Electronic Fuel-Injection Problems Using Visual Inspection	p. 424
Scan Tool Vacuum Leak Diagnosis	p. 425
Port Fuel-Injection System Diagnosis	p. 426
Testing for an Injector Pulse	p. 427
Checking Fuel-Injector Resistance	p. 428
Measuring Resistance of Grouped Injectors	p. 435
Pressure-Drop Balance Test	p. 437
Injector Voltage-Drop Test	p. 437
Exhaust Gas Balance Test	p. 438
Scope Testing Fuel Injectors	p. 438
Injector Current Ramping	p. 441
Idle Air Speed Control Diagnosis	p. 442
Fuel-Injection Service	p. 444
Fuel-System Scan Tool Diagnostics	p. 448
Summary	p. 456
Review Questions	p. 456
Chapter Quiz	p. 456
Emission Control Devices Operation and Diagnosis	p. 459
Objectives	p. 459
Exhaust Gas Recirculation Systems	p. 460
Controlling NO[subscript x]	p. 460
EGR System Operation	p. 461
Positive and Negative Backpressure EGR Valves	p. 461
Computer-Controlled EGR Systems	p. 462
OBD-II EGR Monitoring Strategies	p. 464
Diagnosing a Defective EGR System	p. 466
EGR-Related OBD-II Diagnostic Trouble Codes	p. 467
Crankcase Ventilation	p. 468
PCV Valves	p. 468
Orifice-Controlled Systems	p. 469
Positive Crankcase Ventilation (PCV) System Diagnosis	p. 470
PCV Monitor	p. 471
PCV-Related Diagnostic Trouble Code	p. 472
Air Pump System	p. 472
Air Distribution Manifolds and Nozzles	p. 473
Air Pump System Diagnosis	p. 476
Air-Related Diagnostic Trouble Code	p. 477
Catalytic Converters	p. 477
Ceramic Monolith Catalytic Converter	p. 477
OBD-II Catalytic Converter Performance	p. 479
Converter-Damaging Conditions	p. 479
Diagnosing Catalytic Converters	p. 480
OBD-II Catalytic Converter Monitor	p. 482
Catalytic Converter Replacement Guidelines	p. 483
Catalytic Converter-Related Diagnostic Trouble Code	p. 483
Summary	p. 484
Review Questions	p. 484
Chapter Quiz	p. 484
Engine Performance Diagnosis	p. 487
Objectives	p. 487
The Eight-Step Diagnostic Procedure	p. 488
Troubleshooting Using Diagnostic Trouble Codes	p. 497
Retrieving General Motors OBD-I Codes	p. 498
Retrieving Ford EEC-IV Codes	p. 498
Retrieving DaimlerChrysler Codes	p. 501
OBD II	p. 501
Exhaust Analysis and Combustion Efficiency	p. 508
I/M 240	p. 510
Summary	p. 518
Review Questions	p. 518
Chapter Quiz	p. 518
English/Spanish Glossary	p. 521
Index	p. 535
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