Advanced Automotive Fault Diagnosis: Automotive Technology: Vehicle Maintenance and Repair

Description

Learn all the skills you need to pass Level 3 and 4 Vehicle Diagnostic courses from IMI, City and Guilds and BTEC, as well as higher levels, ASE, AUR and other qualifications. Advanced Automotive Fault Diagnosis explains the fundamentals of vehicle systems and components and examines diagnostic principles as well as the latest techniques employed in effective vehicle maintenance and repair. Diagnostics, or fault finding, is an essential part of an automotive technician's work, and as automotive systems become increasingly complex there is a greater need for good diagnostics skills. For students new to the subject, this book will help to develop these skills, but it will also assist experienced technicians to further improve their performance and keep up with recent industry developments. Checked and endorsed by the Institute of to him to ensure that it is ideal for both independent and tutor-based study Diagnostics case studies to help you put the principles covered into real-life context Useful margin features throughout, including definitions, key facts and 'safety first' considerations   Cover Half Title Title Page Copyright Page Table of Contents Preface Acknowledgements 1 Introduction 1.1 Diagnosis 1.1.1 Introduction 1.2 Safe working practices 1.2.1 Risk assessment and reduction 1.3 Terminology 1.3.1 Introduction 1.3.2 Diagnostic terminology 1.3.3 General terminology 1.4 Report writing 1.4.1 Introduction 1.4.2 Main headings of a report 1.4.3 Example report 1.5 Autonomous driving 1.5.1 First steps 1.5.2 Levels of driving automation 2 Diagnostic techniques 2.1 Introduction 2.1.1 Logic 2.1.2 Information 2.1.3 Where to stop? 2.2 Diagnostic process 2.2.1 Six-stage process 2.2.2 The art of diagnostics 2.2.3 Concern, cause, correction 2.2.4 Root cause analysis 2.2.5 Summary 2.3 Diagnostics on paper 2.3.1 Introduction 2.3.2 Examples 2.3.3 How long is a piece of string? 2.4 Mechanical diagnostic techniques 2.4.1 Check the obvious first 2.4.2 Noise, vibration and harshness 2.4.3 Noise conditions 2.4.4 Vibration conditions 2.4.5 Road test 2.4.6 Engine noises 2.4.7 Sources of engine noise 2.5 Electrical diagnostic techniques 2.5.1 Check the obvious first 2.5.2 Test lights and analogue meters – warning 2.5.3 Generic electrical testing procedure 2.5.4 Volt drop testing 2.5.5 Testing for short circuits to earth 2.5.6 On and off load tests 2.5.7 Black box technique 2.5.8 Sensor to ECU method 2.5.9 Flight recorder tests 2.5.10 Faultfinding by luck – or is it logic? 2.5.11 Colour codes and terminal numbers 2.5.12 Back probing connectors 2.6 Fault codes 2.6.1 Fast and slow 2.6.2 Fault code examples 2.6.3 Clearing 2.7 Systems 2.7.1 What is a system? 2.7.2 Vehicle systems 2.7.3 Open-loop systems 2.7.4 Closed-loop systems 2.7.5 Block diagrams 2.8 Data sources 2.8.1 Introduction 2.8.2 Autodata 2.8.3 Bosch ESItronic 2.9 Summary 3 Tools and equipment 3.1 Basic equipment 3.1.1 Introduction 3.1.2 Basic hand tools 3.1.3 Accuracy of test equipment 3.1.4 Multimeters 3.1.5 Logic probe 3.2 PicoScope oscilloscope kits 3.2.1 Introduction 3.2.2 Scan tool or scope? 3.2.3 New features 3.2.4 Waveform library 3.2.5 PicoDiagnostics 3.2.6 Pressure sensor 3.2.7 Noise and vibration 3.3 Scanners/Fault code readers and analysers 3.3.1 On-board diagnostics introduction 3.3.2 Serial port communications 3.3.3 OBD2 signal protocols 3.3.4 Entry-level scanners 3.3.5 Bosch KTS diagnostic equipment 3.3.6 Engine analysers 3.4 Emission testing 3.4.1 Introduction 3.4.2 Exhaust gas measurement 3.4.3 Exhaust analyser 3.4.4 Emission limits 3.5 Pressure testing 3.5.1 Introduction 3.5.2 Automotive pressure oscilloscope transducer 4 Sensors, actuators and oscilloscope diagnostics 4.1 Introduction 4.2 Sensors 4.2.1 Introduction and sensor diagnostics 4.2.2 Inductive sensors 4.2.3 Variable resistance 4.2.4 Hot wire airflow sensor 4.2.5 Thermistors 4.2.6 Hall effect sensors 4.2.7 Piezo accelerometer 4.2.8 Oxygen sensors 4.2.9 Pressure sensors 4.2.10 Variable capacitance 4.2.11 Optical sensors 4.2.12 Dynamic position sensors 4.2.13 Rain sensor 4.3 Actuators 4.3.1 Introduction 4.3.2 Testing actuators 4.3.3 Motorised and solenoid actuators 4.3.4 Solenoid actuators 4.3.5 Thermal actuators 4.4 Engine waveforms 4.4.1 Ignition primary 4.4.2 Ignition secondary 4.4.3 Diesel glow plugs 4.4.4 Alternator waveform 4.4.5 Relative compression petrol 4.5 Communication networks 4.5.1 CAN 4.5.2 LIN 4.5.3 FlexRay 4.6 Summary 5 On-board diagnostics 5.1 History 5.1.1 Introduction 5.1.2 Vehicle emissions and environmental health 5.1.3 History of the emissions control legislation 5.1.4 Introduction of vehicle emissions control strategies 5.2 What is on-board diagnostics? 5.2.1 OBD scenario example 5.2.2 Origins of OBD in the United States 5.2.3 P-code composition 5.2.4 European on-board diagnostics and global adoption 5.2.5 Summary 5.3 Petrol/Gasoline on-board diagnostic monitors 5.3.1 Introduction 5.3.2 Legislative drivers 5.3.3 Component monitoring 5.3.4 Rationality testing 5.3.5 Circuit testing 5.3.6 Catalyst monitor 5.3.7 Evaporative system monitor 5.3.8 Fuel system monitoring 5.3.9 Exhaust gas recirculation monitor 5.3.10 Secondary air monitor 5.3.11 Monitors and readiness flags 5.4 Misfire detection 5.4.1 Misfire monitor 5.4.2 Crank speed fluctuation 5.4.3 Ionising current monitoring 5.4.4 Cylinder pressure sensing 5.4.5 Exhaust pressure analysis 5.5 OBD summary 5.5.1 OBD2 5.5.2 EOBD 5.5.3 Features and technology of current systems 5.6 Driving cycles 5.6.1 Introduction 5.6.2 Europe 5.6.3 United States 5.7 Future developments in diagnostic systems 5.7.1 OBD3 5.7.2 Diesel engines 5.7.3 Rate-based monitoring 5.7.4 Model-based development 5.7.5 OBD security 5.8 Summary 6 Engine systems 6.1 Introduction 6.2 Engine operation 6.2.1 Four-stroke cycle 6.2.2 Cylinder layouts 6.2.3 Camshaft drives 6.2.4 Valve mechanisms 6.2.5 Valve and ignition timing 6.3 Diagnostics – engines 6.3.1 Systematic testing example 6.3.2 Test equipment 6.3.3 Test results 6.3.4 Engine fault diagnosis table 1 6.3.5 Engine fault diagnosis table 2 6.4 Fuel system 6.4.1 Introduction 6.4.2 Carburation 6.5 Diagnostics – fuel system 6.5.1 Systematic testing example 6.5.2 Test equipment 6.5.3 Test results 6.5.4 Fuel fault diagnosis table 1 6.5.5 Fuel fault diagnosis table 2 6.6 Introduction to engine management 6.7 Ignition 6.7.1 Basics 6.7.2 Advance angle (timing) 6.7.3 Electronic ignition 6.7.4 Hall effect distributor 6.7.5 Inductive distributor 6.7.6 Current-limiting and closed-loop dwell 6.7.7 Programmed ignition/electronic spark advance 6.7.8 Distributorless ignition 6.7.9 Direct ignition 6.7.10 Spark plugs 6.8 Diagnostics – ignition system 6.8.1 Testing procedure 6.8.2 Ignition fault diagnosis table 6.8.3 Ignition components and testing 6.8.4 DIS diagnostics 6.8.5 Spark plugs 6.9 Emissions 6.9.1 Introduction 6.9.2 Exhaust gas recirculation 6.9.3 Catalytic converters 6.10 Diagnostics – emissions 6.10.1 Testing procedure 6.10.2 Emissions fault diagnosis table 6.11 Fuel injection 6.11.1 Introduction 6.11.2 Injection systems 6.11.3 Fuel injection components 6.11.4 Fuel mixture calculation 6.12 Diagnostics – fuel injection systems 6.12.1 Testing procedure 6.12.2 Fuel injection fault diagnosis table 6.13 Diesel injection 6.13.1 Introduction 6.13.2 Electronic control of diesel injection 6.13.3 Common rail diesel systems 6.13.4 Diesel exhaust emissions 6.13.5 Catalytic converter diesel 6.13.6 Filters 6.14 Diagnostics – diesel injection systems 6.14.1 Test equipment 6.14.2 Diesel injection fault diagnosis table 6.14.3 Diesel engine smoke 6.14.4 Glow plug circuit 6.14.5 Diesel systems 6.15 Engine management 6.15.1 Introduction 6.15.2 Closed-loop lambda control 6.15.3 Engine management operation 6.15.4 Gasoline direct injection 6.15.5 ECU calibration 6.16 Diagnostics – combined ignition and fuel systems 6.16.1 Testing procedure 6.16.2 Combined ignition and fuel control fault diagnosis table 6.16.3 Fuel pump testing 6.16.4 Injector testing 6.16.5 ECU fuel trim diagnostics 6.17 Engine management and faultfinding information 6.17.1 Diagnosis charts 6.17.2 Circuit diagrams 6.17.3 Component testing data 6.18 Air supply and exhaust systems 6.18.1 Exhaust system 6.18.2 Catalytic converters 6.18.3 Air supply system 6.19 Diagnostics – exhaust and air supply 6.19.1 Systematic testing 6.19.2 Test results 6.19.3 Exhaust and air supply fault diagnosis table 1 6.19.4 Exhaust fault diagnosis table 2 6.20 Cooling 6.20.1 Air-cooled system 6.20.2 Water-cooled system 6.20.3 Sealed and semi-sealed systems 6.21 Diagnostics – cooling 6.21.1 Systematic testing 6.21.2 Test equipment 6.21.3 Test results 6.21.4 Cooling fault diagnosis table 1 6.21.5 Cooling fault diagnosis table 2 6.22 Lubrication 6.22.1 Lubrication system 6.22.2 Oil filters 6.22.3 Oil pumps 6.22.4 Crankcase ventilation engine breather systems 6.23 Diagnostics – lubrication 6.23.1 Systematic testing 6.23.2 Test equipment 6.23.3 Test results 6.23.4 Lubrication fault diagnosis table 1 6.23.5 Lubrication fault diagnosis table 2 6.24 Batteries 6.24.1 Safety 6.24.2 Lead-acid batteries 6.24.3 Battery rating 6.25 Diagnostics – batteries 6.25.1 Servicing batteries 6.25.2 Maintenance-free 6.25.3 Charging 6.25.4 Battery faults 6.25.5 Testing batteries 6.25.6 Battery diagnostics 6.26 Starting 6.26.1 Starter circuit 6.26.2 Inertia starters 6.26.3 Pre-engaged starters 6.26.4 Permanent magnet starters 6.26.5 Keyless starting system 6.27 Diagnostics – starting 6.27.1 Circuit testing procedure 6.27.2 Starting fault diagnosis table 6.28 Charging 6.28.1 Introduction 6.28.2 Basic principles 6.28.3 Rectification of AC to DC 6.28.4 Regulation of output voltage 6.28.5 Charging circuits 6.29 Diagnostics – charging 6.29.1 Testing procedure 6.29.2 Charging fault diagnosis table 7 Chassis systems 7.1 Brakes 7.1.1 Introduction 7.1.2 Principle of hydraulic braking 7.1.3 Disc and drum brake systems 7.1.4 Brake adjustments 7.1.5 Servo-assisted braking 7.2 Diagnostics – brakes 7.2.1 Systematic testing 7.2.2 Test equipment 7.2.3 Dial gauge 7.2.4 Test results 7.2.5 Brakes fault diagnosis table 1 7.2.6 Brakes fault diagnosis table 2 7.2.7 Brake hydraulic faults 7.3 Antilock brakes 7.3.1 Introduction 7.3.2 General system description 7.3.3 ABS components 7.4 Diagnostics – antilock brakes 7.4.1 Systematic testing procedure 7.4.2 Antilock brakes fault diagnosis table 7.4.3 Bleeding antilock brakes 7.5 Traction control 7.5.1 Introduction 7.5.2 Control functions 7.5.3 System operation 7.6 Diagnostics – traction control 7.6.1 Systematic testing 7.6.2 Traction control fault diagnosis table 7.7 Steering and tyres 7.7.1 Construction of a tubeless radial tyre 7.7.2 Steering box and rack 7.7.3 Power-assisted steering 7.7.4 Steering characteristics 7.7.5 Camber 7.7.6 Castor 7.7.7 Swivel axis inclination 7.7.8 Tracking 7.7.9 Scrub radius 7.8 Diagnostics – steering and tyres 7.8.1 Systematic testing 7.8.2 Test equipment 7.8.3 Four-wheel alignment 7.8.4 Test results 7.8.5 Tyres fault diagnosis table 7.8.6 Tyre inflation pressures 7.8.7 Steering fault diagnosis table 1 7.8.8 Steering, wheels and tyres fault diagnosis table 7.9 Suspension 7.9.1 Introduction 7.9.2 Suspension system layouts 7.9.3 Front axle suspensions 7.9.4 Rear axle suspensions 7.9.5 Anti-roll bar 7.9.6 Springs 7.9.7 Dampers 7.10 Diagnostics – suspension 7.10.1 Systematic testing 7.10.2 Test equipment 7.10.3 Test results 7.10.4 Suspension fault diagnosis table 1 7.10.5 Suspension fault diagnosis table 2 7.11 Active suspension 7.11.1 Active suspension operation 7.11.2 Delphi MagneRide case study 7.12 Diagnostics – active suspension 7.12.1 Systematic testing 7.12.2 Back to the black box 8 Electrical systems 8.1 Electronic components and circuits 8.1.1 Introduction 8.1.2 Components 8.1.3 Integrated circuits 8.1.4 Digital circuits 8.1.5 Electronic component testing 8.2 Multiplexing 8.2.1 Overview 8.2.2 Controller area network 8.2.3 CAN data signal 8.2.4 Local interconnect network 8.2.5 FlexRay 8.3 Diagnostics – multiplexing 8.4 Lighting 8.4.1 External lights 8.4.2 Lighting circuits 8.4.3 Gas discharge lighting 8.4.4 LED lighting 8.5 Diagnostics – lighting 8.5.1 Testing procedure 8.5.2 Lighting fault diagnosis table 8.5.3 Headlight beam setting 8.6 Auxiliaries 8.6.1 Wiper motors and linkages 8.6.2 Wiper circuits 8.6.3 Two-motor wiper system 8.6.4 Headlight wipers and washers 8.6.5 Indicators and hazard lights 8.6.6 Brake lights 8.6.7 Electric horns 8.6.8 Engine cooling fan motors 8.7 Diagnostics – auxiliary 8.7.1 Testing procedure 8.7.2 Auxiliaries fault diagnosis table 8.7.3 Wiper motor and circuit testing 8.8 In-car entertainment, security and communications 8.8.1 In-car entertainment 8.8.2 Security systems 8.8.3 Mobile communications 8.9 Diagnostics – ICE, security and communication 8.9.1 Testing procedure 8.9.2 ICE, security and communication system fault diagnosis table 8.9.3 Interference suppression 8.10 Body electrical systems 8.10.1 Electric seat adjustment 8.10.2 Electric mirrors 8.10.3 Electric sunroof operation 8.10.4 Door locking circuit 8.10.5 Electric window operation 8.11 Diagnostics – body electrical 8.11.1 Testing procedure 8.11.2 Body electrical systems fault diagnosis table 8.11.3 Circuit systematic testing 8.12 Instrumentation 8.12.1 Gauges 8.12.2 Digital instrumentation 8.12.3 Vehicle condition monitoring 8.12.4 Trip computer 8.12.5 Displays 8.13 Diagnostics – instruments 8.13.1 Testing procedure 8.13.2 Instrumentation fault diagnosis table 8.13.3 Black box technique for instrumentation 8.14 Heating, ventilation and air conditioning 8.14.1 Ventilation and heating 8.14.2 Heating system – water-cooled engine 8.14.3 Heater blower motors 8.14.4 Electronic heating control 8.14.5 Air conditioning introduction 8.14.6 Air conditioning overview 8.14.7 Automatic temperature control 8.14.8 Seat heating 8.14.9 Screen heating 8.15 Diagnostics – HVAC 8.15.1 Testing procedure 8.15.2 Air conditioning fault diagnosis table 8.15.3 Heating and ventilation fault diagnosis table 8.15.4 Air conditioning receiver 8.16 Cruise control 8.16.1 Introduction 8.16.2 System description 8.16.3 Components 8.17 Diagnostics – cruise control 8.17.1 Systematic testing 8.17.2 Cruise control fault diagnosis table 8.18 Airbags and belt tensioners 8.18.1 Introduction 8.18.2 Components and circuit 8.18.3 Seat belt tensioners 8.19 Diagnostics – airbags and belt tensioners 8.19.1 Systematic testing 8.19.2 Airbags and belt tensioners fault diagnosis table 8.19.3 Deactivation and activation procedures 9 Transmission systems 9.1 Manual transmission 9.1.1 Clutch 9.1.2 Manual gearbox 9.1.3 Drive shafts and wheel bearings 9.1.4 Final drive and differential 9.1.5 Four-wheel drive systems 9.2 Diagnostics – manual transmission 9.2.1 Systematic testing 9.2.2 Test equipment 9.2.3 Test results 9.2.4 Manual transmission fault diagnosis table 1 9.2.5 Manual gearbox fault diagnosis table 2 9.2.6 Clutch fault diagnosis table 9.2.7 Drive shafts fault diagnosis table 9.2.8 Final drive fault diagnosis table 9.3 Automatic transmission 9.3.1 Introduction 9.3.2 Torque converter operation 9.3.3 Epicyclic gearbox operation 9.3.4 Constantly variable transmission 9.3.5 Electronic control of transmission 9.3.6 Direct shift gearbox 9.4 Diagnostics – automatic transmission 9.4.1 Systematic testing 9.4.2 Test equipment 9.4.3 Test results 9.4.4 Automatic gearbox fault diagnosis table 1 9.4.5 Automatic gearbox fault diagnosis table 2 9.4.6 ECAT fault diagnosis table 9.4.7 Automatic transmission stall test 10 Learning activities and simulations 10.1 Introduction 10.2 Knowledge check questions 10.2.1 Chapter 1 Introduction 10.2.2 Chapter 2 Diagnostic techniques 10.2.3 Chapter 3 Tools and equipment 10.2.4 Chapter 4 Sensors, actuators and oscilloscope diagnostics 10.2.5 Chapter 5 On-board diagnostics 10.2.6 Chapter 6 Engine systems 10.2.7 Chapter 7 Chassis systems 10.2.8 Chapter 8 Electrical systems 10.2.9 Chapter 9 Transmission systems 10.3 Vehicle system diagnostic simulations 10.3.1 Introduction 10.3.2 Starting diagnostics 10.3.3 Charging diagnostics 10.3.4 Interior lighting diagnostics 10.3.5 Exterior lighting diagnostics 10.3.6 Screen wiper diagnostics 10.4 Software 10.5 Summary Glossary of abbreviations and acronyms Index