Hillier's Fundamentals of Motor Vehicle Technology: Powertrain Electronics (Book 2), 5th Edition

256 Pages·2006·13.74 MB·English

by  Peter Coombes

Hillier’s
Fundamentals of
Motor Vehicle
Technology
Book 2
Powertrain
Electronics
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Hillier’s
Fundamentals of
Motor Vehicle
Technology
5th Edition
Book 2
Powertrain
Electronics

V.A.W. Hillier, Peter Coombes & David Rogers
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Text © V. A. W. Hillier 1966, 1972, 1981, 1991, 2006, P. Coombes 2006,
D.R. Rogers 2006
The rights of V. A. W. Hillier, P. Coombes and D.R. Rogers to be identified as authors
of this work has been asserted by them in accordance with the Copyright, Designs
and Patents Act 1988.
All rights reserved. No part of this publication may be reproduced or transmitted in
any form or by any means, electronic or mechanical, including photocopy,
recording or any information storage and retrieval system, without permission in
writing from the publisher or under licence from the Copyright Licensing Agency
Limited, of 90 Tottenham Court Road, London W1T 4LP.
Any person who commits any unauthorised act in relation to this publication may
be liable to criminal prosecution and civil claims for damages.
First published in 1966 by:
Hutchinson Education
Second edition 1972
Third edition 1981 (ISBN 0 09 143161 1)
Reprinted in 1990 (ISBN 0 7487 0317 9) by Stanley Thornes (Publishers) Ltd
Fourth edition 1991
Fifth edition published in 2006 by:
Nelson Thornes Ltd
Delta Place
27 Bath Road
CHELTENHAM
GL53 7TH
United Kingdom
06 07 08 09 10 / 10 9 8 7 6 5 4 3 2 1
A catalogue record for this book is available from the British Library
ISBN 0 7487 8099 8
Cover photograph: Aston Martin V12 Vanquish by David Kimber/Car and Bike
Photo Library
Page make-up by GreenGate Publishing Services, Tonbridge, Kent
Printed and bound in Slovenia by Korotan – Ljubljana Ltd
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CONTENTS
List of abbreviations vi
4
ENGINE MANAGEMENT – DIESEL INJECTION
Acknowledgements vii
Modern diesel fuel systems 163
1
INTRODUCTION TO POWERTRAIN ELECTRONICS
The rotary diesel injection pump 165
Cold-start pre-heating systems 172
Application of electronics and computers 1
Electronic control of diesel injection
‘Electronic systems’ or ‘computer (common rail systems) 174
controlled systems’ 3
Electronic control units (ECUs) 6
5
TRANSMISSION
Sensors: a means of providing information 11
Examples of different types of sensor 13
Purpose of the transmission system 186
Obtaining information from analogue
and digital sensor signals 22 Transmission types 187
Actuators: producing movement and History of electronic control 188
other functions 26 Multiplexing 189
Examples of different types of actuators 30 Sensors and actuators used in
ECU/actuator control signals 32 transmission systems 192
Clutch electronic control 201
2 Manual gearbox electronic control 204
ENGINE MANAGEMENT – SPARK IGNITION
Torque converter electronic control 210
Automatic gearbox transmission
Emissions, reliability and durability 37
management 212
Electronic ignition systems
Continuously variable transmission
(early generations) 42
(CVT) 220
Computer controlled ignition systems 61
Light hybrid powertrain technology
Distributorless and direct ignition (starter–generator) 226
systems 68
Electronic differential and four-wheel
Spark plugs 73 drive control 229
Transmission diagnostics 233
3 ENGINE MANAGEMENT – PETROL Transmission summary 235

Introduction to electronic petrol
injection systems 77 Index 237
Petrol injection system examples
(multi-point injection) 97
Single-point (throttle body)
petrol injection 112
Direct petrol injection 115
Emissions and emission control
(petrol engines) 124
Engine management (the conclusion) 148
Engine system self-diagnosis (on-board
diagnostics) and EOBD 150
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LIST OF ABBREVIATIONS
4WD four-wheel drive HCCI homogeneous charge compression ignition
ABD automatic brake differential HEGO heated exhaust gas oxygen (Ford)
ABS anti-lock braking system HT high tension
AC alternating current IC internal combustion
A/D analogue to digital ISG integrated starter–generator
ASR traction control LED light emitting diode
ATF automatic transmission fluid LOS limited operating strategy
CAN controller area network LSD limited slip differential
CBW clutch-by-wire MAP manifold absolute pressure
CD capacitor discharge MIL malfunction indicator lamp
CI compression ignition MTM mechatronics transmission module
CO carbon monoxide N nitrogen
2
CO carbon dioxide NO nitric oxide
2
CPU central processing unit NO nitrogen dioxide
2
CSC cornering stability control NO oxides of nitrogen
x
CTX constantly variable transaxle (Ford) NTC negative temperature coefficient
CVT continuously variable transmission O oxygen
2
DC direct current OBD on-board diagnostics
DDC dynamic drift control OHC overhead cam
DRP dynamisches repelprogramm – German for Pb lead
dynamic control program PCU powertrain control unit
ppm parts per million
DSG direct-shift gearbox
PTM Porsche traction management
EBD electronic brake force distribution
PWM pulse width modulated
ECU electronic control unit
SAE Society of Automotive Engineers (USA)
EDC electronic diesel control
SUV sports utility vehicle
EDL electronic differential lock
RPM revolutions per minute (abbreviated to
EEC European Economic Community (now EU)
rev/min when used with a number)
EGR exhaust gas recirculation
TCS traction control system
EOBD European on-board diagnostics
TCU transmission control unit
ESP electronic stabilisation programme
TDC top dead centre
EU European Union
VBA variable bleed actuator
EUDC European extra-urban driving cycle
VE verteiler – German for distributor (VE is used
EVAP evaporative emissions
by Bosch for a type of diesel injection pump)
GT grand touring
WOT wide open throttle
H O water
2
HC hydrocarbon
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ACKNOWLEDGEMENTS
We should like to thank the following companies for Every effort has been made to trace the copyright
permission to make use of copyright and other material: holders but if any have been inadvertently overlooked
the publishers will be pleased to make the necessary
Audi AG
arrangement at the first opportunity.
BMW (UK) Ltd
Although many of the drawings are based on
Robert Bosch Ltd
commercial components, they are mainly intended to
Butterworth-Heinemann
illustrate principles of motor vehicle technology. For this
Haldex Traction AB
reason, and because component design changes so
Haynes Publishing Group
rapidly, no drawing is claimed to be up to date.
Jaguar Cars Ltd
Students should refer to manufacturers’ publications for
LuK GmbH & Co
the latest information.
Porsche Cars (GB) Ltd
Siemens VDO Automotive
Toyota (GB)Ltd
Valeo
Volkswagen (UK) Ltd
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INTRODUCTION TO
1

r
e
POWERTRAIN
t
p
a
h
ELECTRONICS
C
what is covered in this chapter . . .
Application of electronics and computers
‘Electronic systems’ or ‘computer controlled systems’
Electronic control units (ECUs)
Sensors: a means of providing information
Examples of different types of sensor
Obtaining information from analogue and digital sensor signals
Actuators: producing movement and other functions
Examples of different types of actuators
ECU/actuator control signals
1.1 APPLICATION OF ELECTRONICS AND COMPUTERS
1.1.1 The increased use of electronic 1.1.2 Why use electronics and
and computer controlled computer control?
systems
Most people who witnessed the cultural and
technological changes that occurred during the last 30
Modern motor vehicles are fitted with a wide range of
years of the twentieth century would probably regard
electronic and computer controlled systems. This book
the electronics revolution as having had the greatest
details most of these systems and explains their
impact on their working lives, significantly affecting the
operation, as well as giving guidance on maintenance,
rest of their lives as well. Although we are primarily
fault finding and diagnosis.
concerned with the motor vehicle here, electronics have
However, it is important to remember that
had a substantial and fundamental impact on the way
electronic or computer control of a system is often
we live and particularly on the way we work. Electronic
simply a means of improving the operation or efficiency
systems affect almost all aspects of our lives, with the
of an existing mechanical system. Therefore many
design and production of consumer products being
mechanical systems are also covered, especially where
particularly affected. Domestic goods, entertainment
their function and capability has been improved
systems and children’s toys have all changed
through the application of electronics and computer
dramatically because of electronics. While all of the
control. See Hillier’s Fundamentals of Motor Vehicle
above examples are obvious and important, electronics
Technology Book 1 for explanations of the basic
has also enabled computers to become everyday
mechanical systems that still form a fundamental part
commodities for professional and personal use.
of motor vehicle technology.
Why have electronics had such an impact on our
There are of course many electronic systems that do
lives and the things we buy and use? A simple answer
not influence or control mechanical systems; these pure
could be that they are now much more affordable, but
electric/electronic systems are also covered.
this alone would not be a complete answer. The
There are many reasons for the increased use of
application of electronics to so many products has
electronic systems. Although vehicle systems differ
enabled dramatic improvements in the capability and
considerably in function and capability, they rely on the
function of almost all such products. A simple
same fundamental electrical and electronic principles
example is the process of writing a letter, which
that must be fully understood before a vehicle technician
progressed from being hand written to being created
can work competently on a modern motor vehicle.
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2 Introduction to powertrain electronics Fundamentals of Motor Vehicle Technology: Book 2
Figure 1.1 Components used in a typical modern electronic computer controlled vehicle system (engine management system)
on a mechanical typewriter. The mechanical 1.1.3 Why use electronics and
typewriter was improved by the use of electronics, but computer control on the motor
the introduction of the computer allowed businesses
vehicle?
and then individuals to produce letters with much
greater stylistic freedom. The computer allows the
Since the late 1960s motor vehicles have been fitted
user to correct errors, check spelling, change the
with an increasing range of electronics and computer
layout and achieve a more professional letter than
control. Cost and size reductions are obviously
was ever possible with any of the previous methods.
important because of the production volumes of
This book has been produced using computers, with
vehicles, space considerations and the need to keep
the author typing the original text and producing
down the price paid by consumers (the people and
some of the illustrations on computer. The original
companies that buy the vehicles).
documents were then passed electronically (by e-mail)
to the production company, which used computers to Reducing emissions and improving safety
create the final style and prepare the book ready for Electronics and electronic control (or computer
printing (the printer also uses computers and control) have become increasingly necessary in motor
electronics). vehicles. For example, without electronic control of
Apart from the quality improvements already vehicle systems (primarily the engine management
mentioned computers have brought greatly increased and emission control systems), emissions from engines
speed; this book would have taken much longer to write could not have been reduced by so much. Legislation
and produce without the benefit of electronics and has imposed tighter control on emissions; a balance
computers. This is true of virtually everything that has been struck between what is wanted and what can
makes use of electronics. Speed and efficiency are be achieved. The legislators seek continued reductions
important, but improvements in almost every way can in emissions and the vehicle manufacturers have been
be achieved using electronics and computers. able to achieve tremendous results, but without
So if we go back and again ask the question ‘Why electronics it would not have been possible to reduce
use electronic control?’ we can perhaps now provide a emissions to anywhere close to the current low levels.
number of answers, including improvements in speed, Safety is another area where electronics have
in capability or function and in quality. The fact that enabled improvements. The design of a motor vehicle
electronics are now much more affordable and is very dependent on computers that can analyse data
electronic components considerably smaller than in and then help to incorporate improved safety into the
the past, facilitates wide use of electronics, resulting in basic vehicle structure. Safety systems such as anti-lock
all of those benefits so far discussed and many more. brakes (ABS) and airbag systems could not function