Automotive Fuel Systems and Emission Controls Package Book

CLASSROOM MANUAL

PART ONE.

1. Introduction to Fuel Systems and Emission Controls.

   Air Pollution — A Perspective

   Major Pollutants

   Pollution and the Automobile

   Smog — Climatic Reaction with Air Pollutants

   Air Pollution Legislation and Regulatory Agencies

   Automotive Emission Controls

   Review Questions

2. Engine Operating Principles.

   Engine Operation

   Major Engine Components

   Cylinder Arrangement

   Engine Displacement and Compression Ratio

   Engine Cooling System

   Engine Lubrication System

   Engine-Ignition Synchronization

   Initial Timing

   Other Engine Types

   Review Questions

3. Engine Air-Fuel Requirements.

Air Pressure — High and Low

Airflow Requirements

Introduction to Electronic Engine Controls

The Intake System

Fuel Composition

Reformulated Fuels

Review Questions

PART TWO.

4. Fuel Delivery Systems.

   Fuel Tanks and Lines

   Fuel Lines

   Fuel Line Layout

   Evaporative Emission Control Systems

   Fuel Pumps and Filters

   Pump Types

   Mechanical Fuel Pumps

   Electric Fuel Pumps

   Fuel Filters

   Review Questions

5. Engine Management Systems.

   Electronic Control Systems

   Electrical Review

   ComputerControl

   Parts of a Computer

   Data Lines

   Fuel Control Operating Modes

   Review Questions

6. Engine Management Input Devices.

   Electrical Operation of Input Devices

   Critical Sensor Inputs

   Engine Coolant Temperature Sensor

   Throttle Position Sensor

   Manifold Air Pressure Sensor

   Mass Air Flow Sensor

   Ignition Reference Signal

   Oxygen Sensors

   Review Questions

7. Engine Management Output Devices.

   Low-Side Drivers

   High-Side Drivers

   Pulse Width Modulation

   Critical Outputs

   Review Questions

8. Electronic Engine Control Systems.

   Computer Functions — A Review

   Basic Engine Operating Modes

   Air-Fuel Ratio, Timing, and EGR Effects on Operation

   Full Function Control Systems

   Common Components

   System Actuators

   History of Engine Control Systems

   On-Board Diagnostics (OBD) Systems

   Review Questions

9. Gasoline Fuel Injection Systems.

   Fuel Injection Operating Requirements

   Advantages of Fuel Injection

   Types of Fuel Injection Systems

   Common Subsystems and Components

   Specific Systems

   Trends

   Review Questions

10. Supercharging and Turbocharging.

   Engine Compression

   The Benefits of Air-Fuel Mixture Compression

   Supercharging

Turbochargers

   Turbocharger Controls

   Review Questions

PART THREE.

11. Variable, Flexible, and Bi-Fuel Systems.

   Variable or Flexible Fuel Vehicles

   M85 and Methanol-Blended Fuels

   Methanol and Automobile Engines

   Common Subsystems and Components

   General Motors VFV Fuel System

   Ford Flexible Fuel System

   E-85 Vehicles

   Bi-Fuel Vehicles

   Review Questions

12. Emissions, Five Gas Theory, and I/M Programs.

   Emissions, Five Gas Theory, and I/M Programs

   The Combustion Process

   The Five Gases

   Inspection/Maintenance Programs (I/M)

   I/M Test Programs

   Review Questions

13. Positive Crankcase Ventilation, Air-Injection Systems, Catalytic Converters, and Exhaust Gas Recirculation.

   Crankcase Ventilation

   Air Injection

   Catalytic Converters

   Exhaust Gas Recirculation

   Review Questions

14. The Ignition Primary Circuit and Components.

   Need for High Voltage

   High Voltage Through Induction

   Basic Circuits and Current

   Primary Circuit Components

   Monitoring Ignition Primary Circuit Voltages

   Review Questions

15. The Ignition Secondary Circuit and Components.

   Ignition Coils

   Distributor Cap and Rotor

   Ignition Cables

   Spark Plugs

   Spark Plug Construction

   Ignition Polarity

   Review Questions

16. Electronic Ignition Systems.

   Basic Electronic Ignition Systems

   Control Modules and Primary Circuitry

   Triggering Devices and Ignition Timing

   Electronic Ignition Dwell, Timing, and Advance

   Original Equipment Electronic Distributor Ignition Systems

   Original Equipment Distributorless Ignition Systems

   Review Questions

Glossary of Technical Terms.

Answers to Review Questions.

Appendix A. OBD II Diagnostic Codes.

Appendix B. Evaporative System Pressure Conversion Chart.

Appendix C. Major Elements of Operating I/M Programs.

Appendix D. Vehicle Manufacturer Service Information.

Appendix E. Automotive Fuel & Emissions Related Websites.

Appendix F. Links to State Emission Programs.

Index.

SHOP MANUAL

PART ONE — INTRODUCTION TO FUEL AND EMISSION SYSTEM SERVICE.

1. Vacuum Control Diagnosis.

   Engine Vacuum

   Vacuum Sources

   Testing Engine Vacuum

   Testing Vacuum Components

2. Fuel and Emission System Test Equipment.

   The Pressure Gauge as Test Equipment

   Cylinder Leakage Testing

   Engine Power Balance Testing

   Infrared Exhaust Analyzers

   Basic Exhaust Analyzers

   Programmed Special Test Analyzers

   Sources of Specifications and Service Procedures

PART TWO - FUEL SYSTEM SERVICE AND TESTING.

3. Fuel System Inspection and Testing.

   Fuel System Inspection

   Evaporative Emission Control System Maintenance

   Electric Fuel Pump Test

   Testing a Fuel Pump Using Amperage Draw

   Thermostatically Controlled Air Cleaner Service

4. Fuel System Component Replacement.

   Fuel System Safety

   Fuel Tank Replacement

   Fuel Line Replacement

   Fuel Pump Replacement

   Air Cleaner Service

   Air Intake Throttle Body Service

   Air Intake Throttle Body Removal & Installation

   Intake Manifold Removal & Installation

   Throttle Linkage

PART THREE — ELECTRONIC ENGINE CONTROL SYSTEM TESTING AND SERVICE.

5. Electronic Engine Control and Fuel System Service.

   Troubleshooting Principles

   Area Test and Pinpoint Test

   Electronic System Service Precautions

   Self Diagnostic Systems

   Troubleshooting and Testing Procedures

   Scan Tools

   Electronic Control Systems Service

   OBD II Summary

6. Testing Engine Management Input Devices.

   Using Trouble Code Charts

   Current versus History Codes

   Non-OBD II Vehicles

   OBD II Vehicles

   Testing Switched Inputs

   Analog Inputs

   Digital Inputs

   Testing Temperature Sensors

   Testing a Throttle Position Sensor

   Testing Manifold Absolute Sensors

   Testing Mass Airflow Sensors

   Testing Oxygen Sensors

   Testing Other Inputs

7. Testing Engine Management Output Devices.

   Low-Side and High-Side drivers

   Testing PCM Outputs

   Testing Fuel Injector Circuits

   Testing the Idle Air Control Output

   Testing PCM Controlled Relays

   Testing a Pulse Width Modulation Solenoid

   Testing an Electronic Exhaust Gas Recirculation Valve

   Testing the Ignition Control Output

   Testing Electronic Throttle Actuators

8. Gasoline Fuel Injection Testing.

   Fuel Injection Safety

   Electronic System Safety

   EFI Troubleshooting Strategy

   Electronics

   Fuel Systems

   Pressure Testing

   Fuel Injector Cleaning

   Basic Idle Adjustments

   Throttle Body Injector Unit Overhaul

9. Turbocharger and Supercharger Testing and Service.

   Turbocharger Safety

   Why Turbochargers Fail

   Troubleshooting a Turbocharger

   Replacing Turbocharger Components

   Supercharger Service and Diagnosis

PART FOUR — EMISSION TESTING& EMISSION CONTROL SYSTEM TESTING AND SERVICE.

10. Emission Testing.

   The Emission Analyzer

   Units of Measurements

   Portable Five-Gas Analyzers

   Gas Analyzer Calibration

   Preconditioning the Vehicle

   Performing a Two-Speed Tailpipe Test

   Performing an ASM 5015 Test or Similar Test

   Performing an OBD II I/M Test

   Diagnosing Emissions Failures

   Common Causes of High HC

   Common Causes for Low CO₂

   Common Causes for Low O₂ and High CO

   Common Causes for High O₂ and Low CO

   Common Causes for High NOx

11. Testing and Servicing PCV, AIR, EGR, and Catalytic Converters.

   Positive Crankcase Ventilation Service

   PCV Visual Inspection

   Functional Test

   PCV Valve Service

   Secondary Air Injection (AIR) Systems

   Electric Air Pump

   Belt-Driven Air Pump

   Diagnosis and Testing

   OBD II Air System Monitor Diagnostics — Electric Air Pump (EAP)

   OBD II Air System Monitor Diagnostics — Belt-Driven Pump

   Basic Components

   Air Injection System Service

   Air Pump Service

   Exhaust Gas Recirculation (EGR) Service

   Differential Exhaust Pressure Feedback EGR (Ford DPFE System)

   Backpressure Transducer System (Chrysler)

   ODB II System Monitor

   Linear EGR System (GM)

   EGR System Service

   Catalytic Converter Systems

   Catalyst Testing

   OBD II System Monitor

   Testing a Converter by Temperature

   Converter Service

PART FIVE — IGNITION and ELECTRONIC CONTROL SYSTEM SERVICE.

12. Ignition System Inspection, Diagnosis, and Testing.

   Ignition Service safety

   Inspection and Diagnosis

   Oscilloscope Diagnosis

   Component Testing

   Electrical Noise

13. Ignition System and Distributor Service.

   Primary Supply Circuit Service

   Ignition Control Module Service

   Speed and Reference Sensor Service

   Ignition Coil Service

   Ignition Cable Service

   Distributor Cap and Rotor Service

   Spark Plug Service

   Distributor Removal and Inspection

   Distributor Disassembly and Assembly

   Distributor Installation

   Distributor Overhaul Procedures