Prelims.qxd 4/22/04 3:00 PM Page i Automobile Electrical and Electronic Systems Third edition This page intentionally left blank Prelims.qxd 4/22/04 3:00 PM Page iii Automobile Electrical and Electronic Systems Third edition Tom Denton BA, AMSAE, MITRE, Cert.Ed. Associate Lecturer, Open University AMSTERDAM BOSTON HEIDELBERG LONDON NEW YORK OXFORD PARIS SAN DIEGO SAN FRANCISCO SINGAPORE SYDNEY TOKYO Prelims.qxd 4/22/04 3:00 PM Page iv Elsevier Butterworth-Heinemann Linacre House, Jordan Hill, Oxford OX2 8DP 200 Wheeler Road, Burlington, MA 01803 First published in Great Britain in 1995 by Arnold, a member of Hodder Headline plc. Second edition, 2000 Third edition, 2004 Copyright © 1995, 2000, 2004, Tom Denton. All rights reserved The right of Tom Denton to be identified as the author of this work has been asserted in accordance with the Copyright, Designs and Patents Act 1988 No part of this publication may be reproduced in any material form (including photocopying or storing in any medium by electronic means and whether or not transiently or incidentally to some other use of this publication) without the written permission of the copyright holder except in accordance with the provisions of the Copyright, Designs and Patents Act 1988 or under the terms of a licence issued by the Copyright Licensing Agency Ltd, 90 Tottenham Court Road, London, England W1T 4LP. Applications for the copyright holder’s written permission to reproduce any part of this publication should be addressed to the publisher. Permissions may be sought directly from Elsevier’s Science and Technology Rights Department in Oxford, UK: phone: (ϩ44) (0) 1865 843830; fax: (ϩ44) (0) 1865 853333; e-mail: [email protected]. You may also complete your request on-line via the Elsevier Science homepage (http://www.elsevier.com), by selecting ‘Customer Support’ and then ‘Obtaining Permissions’. British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library ISBN 0 7506 62190 For information on all Butterworth-Heinemann publications visit our website at: www.bh.com Composition by Charon Tec Pvt. Ltd Printed and bound in Great Britain Prelims.qxd 4/22/04 3:00 PM Page v Contents Preface ix Introduction to the third edition x Acknowledgements xi 1 Development of the automobile electrical system 1 1.1 A short history 1 1.2 Where next? 8 1.3 Self-assessment 10 2 Electrical and electronic principles 11 2.1 Safe working practices 11 2.2 Basic electrical principles 11 2.3 Electronic components and circuits 18 2.4 Digital electronics 26 2.5 Microprocessor systems 30 2.6 Measurement 35 2.7 Sensors and actuators 36 2.8 New developments 50 2.9 Diagnostics – electronics, sensors and actuators 52 2.10 New developments in electronic systems 54 2.11 Self-assessment 55 3 Tools and test equipment 57 3.1 Basic equipment 57 3.2 Multimeters 59 3.3 Specialist equipment 61 3.4 Dedicated equipment 66 3.5 On-board diagnostics 68 3.6 Case studies 69 3.7 Diagnostic procedures 72 3.8 New developments in test equipment 77 3.9 Self-assessment 80 4 Electrical systems and circuits 82 4.1 The systems approach 82 4.2 Electrical wiring, terminals and switching 83 4.3 Multiplexed wiring systems 91 4.4 Circuit diagrams and symbols 97 4.5 Case study 98 4.6 Electromagnetic compatibility (EMC) 100 4.7 New developments in systems and circuits 103 4.8 Self-assessment 108 5 Batteries 110 5.1 Vehicle batteries 110 5.2 Lead-acid batteries 111 5.3 Maintenance and charging 112 5.4 Diagnosing lead-acid battery faults 113 Prelims.qxd 4/22/04 3:00 PM Page vi vi Contents 5.5 Advanced battery technology 115 5.6 Developments in electrical storage 119 5.7 New developments in batteries 124 5.8 Self-assessment 127 6 Charging systems 128 6.1 Requirements of the charging system 128 6.2 Charging system principles 129 6.3 Alternators and charging circuits 130 6.4 Case studies 136 6.5 Diagnosing charging system faults 139 6.6 Advanced charging system technology 139 6.7 New developments in charging systems 143 6.8 Self-assessment 148 7 Starting systems 149 7.1 Requirements of the starting system 149 7.2 Starter motors and circuits 151 7.3 Types of starter motor 155 7.4 Case studies 161 7.5 Diagnosing starting system faults 165 7.6 Advanced starting system technology 165 7.7 New developments in starting systems 167 7.8 Self-assessment 168 8 Ignition systems 170 8.1 Ignition fundamentals 170 8.2 Electronic ignition 174 8.3 Programmed ignition 180 8.4 Distributorless ignition 184 8.5 Direct ignition 185 8.6 Spark-plugs 185 8.7 Case studies 189 8.8 Diagnosing ignition system faults 195 8.9 Advanced ignition technology 196 8.10 New developments in ignition systems 197 8.11 Self-assessment 197 9 Electronic fuel control 199 9.1 Combustion 199 9.2 Engine fuelling and exhaust emissions 205 9.3 Electronic control of carburation 208 9.4 Fuel injection 210 9.5 Diesel fuel injection 214 9.6 Case studies 219 9.7 Diagnosing fuel control system faults 236 9.8 Advanced fuel control technology 236 9.9 New developments 237 9.10 Self-assessment 238 10 Engine management 240 10.1 Combined ignition and fuel management 240 10.2 Exhaust emission control 244 10.3 Control of diesel emissions 248 10.4 Complete vehicle control systems 248 10.5 Case study – Mitsubishi GDI 251 Prelims.qxd 4/22/04 3:00 PM Page vii Contents vii 10.6 Case study – Bosch 258 10.7 Diagnosing engine management system faults 271 10.8 Advanced engine management technology 274 10.9 New developments in engine management 282 10.10 Self-assessment 289 11 Lighting 291 11.1 Lighting fundamentals 291 11.2 Lighting circuits 299 11.3 Gas discharge and LED lighting 299 11.4 Case studies 302 11.5 Diagnosing lighting system faults 310 11.6 Advanced lighting technology 310 11.7 New developments in lighting systems 312 11.8 Self-assessment 315 12 Auxiliaries 317 12.1 Windscreen washers and wipers 317 12.2 Signalling circuits 321 12.3 Other auxiliary systems 322 12.4 Case studies 324 12.5 Diagnosing auxiliary system faults 328 12.6 Advanced auxiliary systems technology 329 12.7 New developments in auxiliary systems 330 12.8 Self-assessment 331 13 Instrumentation 333 13.1 Gauges and sensors 333 13.2 Driver information 337 13.3 Visual displays 339 13.4 Case studies 343 13.5 Diagnosing instrumentation system faults 346 13.6 Advanced instrumentation technology 346 13.7 New developments in instrumentation systems 348 13.8 Self-assessment 355 14 Air conditioning 356 14.1 Conventional heating and ventilation 356 14.2 Air conditioning 358 14.3 Other heating systems 360 14.4 Case studies 361 14.5 Diagnosing air conditioning system faults 365 14.6 Advanced temperature control technology 366 14.7 New developments in temperature control systems 367 14.8 Self-assessment 368 15 Chassis electrical systems 370 15.1 Anti-lock brakes 370 15.2 Active suspension 374 15.3 Traction control 375 15.4 Automatic transmission 377 15.5 Other chassis electrical systems 379 15.6 Case studies 383 15.7 Diagnosing chassis electrical system faults 391 15.8 Advanced chassis systems technology 393 15.9 New developments in chassis electrical systems 395 15.10 Self-assessment 401 Prelims.qxd 4/22/04 3:00 PM Page viii viii Contents 16 Comfort and safety 403 16.1 Seats, mirrors and sun-roofs 403 16.2 Central locking and electric windows 405 16.3 Cruise control 407 16.4 In-car multimedia 409 16.5 Security 416 16.6 Airbags and belt tensioners 418 16.7 Other safety and comfort systems 421 16.8 Case studies 425 16.9 Diagnosing comfort and safety system faults 436 16.10 Advanced comfort and safety systems technology 437 16.11 New developments in comfort and safety systems 439 16.12 Self-assessment 441 17 Electric vehicles 443 17.1 Electric traction 443 17.2 Hybrid vehicles 446 17.3 Case studies 446 17.4 Advanced electric vehicle technology 453 17.5 New developments in electric vehicles 455 17.6 Self-assessment 456 18 World Wide Web 457 18.1 Introduction 457 18.2 Automotive technology – electronics 457 18.3 Self-assessment 458 Index 459 Prelims.qxd 4/22/04 3:00 PM Page ix Preface In the beginning, say 115 years ago, a book on vehicle Current and older systems are included to aid the electrics would have been very small. A book on reader with an understanding of basic principles. vehicle electronics would have been even smaller! To set the whole automobile electrical subject in As we continue our drive into the new millennium, context, the first chapter covers some of the signif- the subject of vehicle electrics is becoming ever icant historical developments and dares yet again to larger. Despite the book likewise growing larger, some speculate on the future … aspects of this topic have inevitably had to be glossed What will be the next major step in automobile over, or left out. However, the book still covers all of electronic systems? I predicted that the ‘auto-PC’ the key subjects and students, as well as general read- and ‘telematics’ would be key factors last time, and ers, will find plenty to read in the new edition. this is still the case. However, as 42 V systems come This third edition has once again been updated on line, there will be more electrical control of and extended by the inclusion of more case studies systems that until recently were mechanically or and technology sections in each chapter.