Hilliers fundamentals of motor vehicle technology  powertrain electronics

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Hillier’s Fundamentals of Motor Vehicle Technology Book Powertrain Electronics [647] Chapter 00.qxp 25/8/06 15:35 Page ii [647] Chapter 00.qxp 25/8/06 15:35 Page iii Hillier’s Fundamentals of Motor Vehicle Technology 5th Edition Book Powertrain Electronics V.A.W Hillier, Peter Coombes & David Rogers [647] Chapter 00.qxp 25/8/06 16:41 Page iv 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 09 143161 1) Reprinted in 1990 (ISBN 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 A catalogue record for this book is available from the British Library ISBN 7487 8099 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 [647] Chapter 00.qxp 25/8/06 15:35 Page v CONTENTS List of abbreviations Acknowledgements 1 11 13 22 26 30 32 37 42 61 68 73 77 97 112 115 124 148 150 Index 163 165 172 174 TRANSMISSION Purpose of the transmission system Transmission types History of electronic control Multiplexing Sensors and actuators used in transmission systems Clutch electronic control Manual gearbox electronic control Torque converter electronic control Automatic gearbox transmission management Continuously variable transmission (CVT) Light hybrid powertrain technology (starter–generator) Electronic differential and four-wheel drive control Transmission diagnostics Transmission summary ENGINE MANAGEMENT – PETROL Introduction to electronic petrol injection systems Petrol injection system examples (multi-point injection) Single-point (throttle body) petrol injection Direct petrol injection Emissions and emission control (petrol engines) Engine management (the conclusion) Engine system self-diagnosis (on-board diagnostics) and EOBD ENGINE MANAGEMENT – DIESEL INJECTION Modern diesel fuel systems The rotary diesel injection pump Cold-start pre-heating systems Electronic control of diesel injection (common rail systems) ENGINE MANAGEMENT – SPARK IGNITION Emissions, reliability and durability Electronic ignition systems (early generations) Computer controlled ignition systems Distributorless and direct ignition systems Spark plugs INTRODUCTION TO POWERTRAIN ELECTRONICS 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 vi vii 186 187 188 189 192 201 204 210 212 220 226 229 233 235 237 [647] Chapter 00.qxp 25/8/06 15:35 Page vi LIST OF ABBREVIATIONS 4WD ABD ABS AC A/D ASR ATF CAN CBW CD CI CO CO2 CPU CSC CTX CVT DC DDC four-wheel drive automatic brake differential anti-lock braking system alternating current analogue to digital traction control automatic transmission fluid controller area network clutch-by-wire capacitor discharge compression ignition carbon monoxide carbon dioxide central processing unit cornering stability control constantly variable transaxle (Ford) continuously variable transmission direct current dynamic drift control DRP dynamisches repelprogramm – German for dynamic control program DSG EBD ECU EDC EDL EEC EGR EOBD ESP EU EUDC EVAP GT H2O HC direct-shift gearbox electronic brake force distribution electronic control unit electronic diesel control electronic differential lock European Economic Community (now EU) exhaust gas recirculation European on-board diagnostics electronic stabilisation programme European Union European extra-urban driving cycle evaporative emissions grand touring water hydrocarbon HCCI HEGO HT IC ISG LED LOS LSD MAP MIL MTM N2 NO NO2 NOx NTC O2 OBD OHC Pb PCU ppm PTM PWM SAE SUV RPM TCS TCU TDC VBA VE WOT homogeneous charge compression ignition heated exhaust gas oxygen (Ford) high tension internal combustion integrated starter–generator light emitting diode limited operating strategy limited slip differential manifold absolute pressure malfunction indicator lamp mechatronics transmission module nitrogen nitric oxide nitrogen dioxide oxides of nitrogen negative temperature coefficient oxygen on-board diagnostics overhead cam lead powertrain control unit parts per million Porsche traction management pulse width modulated Society of Automotive Engineers (USA) sports utility vehicle revolutions per minute (abbreviated to rev/min when used with a number) traction control system transmission control unit top dead centre variable bleed actuator verteiler – German for distributor (VE is used by Bosch for a type of diesel injection pump) wide open throttle [647] Chapter 00.qxp 25/8/06 15:35 Page vii ACKNOWLEDGEMENTS We should like to thank the following companies for permission to make use of copyright and other material: Audi AG BMW (UK) Ltd Robert Bosch Ltd Butterworth-Heinemann Haldex Traction AB Haynes Publishing Group Jaguar Cars Ltd LuK GmbH & Co Porsche Cars (GB) Ltd Siemens VDO Automotive Toyota (GB) Ltd Valeo Volkswagen (UK) Ltd Every effort has been made to trace the copyright holders but if any have been inadvertently overlooked the publishers will be pleased to make the necessary arrangement at the first opportunity Although many of the drawings are based on commercial components, they are mainly intended to illustrate principles of motor vehicle technology For this reason, and because component design changes so rapidly, no drawing is claimed to be up to date Students should refer to manufacturers’ publications for the latest information [647] Chapter 00.qxp 25/8/06 15:35 Page viii Chapter [647] Chapter 01 25/8/06 15:36 Page INTRODUCTION TO POWERTRAIN ELECTRONICS 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 and computer controlled systems Modern motor vehicles are fitted with a wide range of electronic and computer controlled systems This book details most of these systems and explains their operation, as well as giving guidance on maintenance, fault finding and diagnosis However, it is important to remember that electronic or computer control of a system is often simply a means of improving the operation or efficiency of an existing mechanical system Therefore many mechanical systems are also covered, especially where their function and capability has been improved through the application of electronics and computer control See Hillier’s Fundamentals of Motor Vehicle Technology Book for explanations of the basic mechanical systems that still form a fundamental part of motor vehicle technology There are of course many electronic systems that not influence or control mechanical systems; these pure electric/electronic systems are also covered There are many reasons for the increased use of electronic systems Although vehicle systems differ considerably in function and capability, they rely on the same fundamental electrical and electronic principles that must be fully understood before a vehicle technician can work competently on a modern motor vehicle 1.1.2 Why use electronics and computer control? Most people who witnessed the cultural and technological changes that occurred during the last 30 years of the twentieth century would probably regard the electronics revolution as having had the greatest impact on their working lives, significantly affecting the rest of their lives as well Although we are primarily concerned with the motor vehicle here, electronics have had a substantial and fundamental impact on the way we live and particularly on the way we work Electronic systems affect almost all aspects of our lives, with the design and production of consumer products being particularly affected Domestic goods, entertainment systems and children’s toys have all changed dramatically because of electronics While all of the above examples are obvious and important, electronics has also enabled computers to become everyday commodities for professional and personal use Why have electronics had such an impact on our lives and the things we buy and use? A simple answer could be that they are now much more affordable, but this alone would not be a complete answer The application of electronics to so many products has enabled dramatic improvements in the capability and function of almost all such products A simple example is the process of writing a letter, which progressed from being hand written to being created [647] Chapter 05 234 25/8/06 16:35 Page 234 Transmission Fundamentals of Motor Vehicle Technology: Book A5S 440Z GS 8.55 GS 8.60.2 ECM main relay Range display Program display Diagnosis – programming + 87a M62 Range GT-1 Shift lock MV MV Manual gate STEPTRONIC CAN terminating resistor Prog switch E38-E31* Kick down Switch WITHOUT STEPTRONIC MV EDS + EDS HALL EFFECT BRAKE PEDAL SENSOR EDS 8.55 (CAN 60) 8,60.2 ASC EDS EDS DME CAN Wheel Power Speed Signals Oil temp Input speed Output speed Figure 5.68 Electronic system overview Valve body DISplus [647] Chapter 05 25/8/06 16:35 Page 235 Transmission summary Check resistances of sensors and actuators Depending upon the nature of the problem, it may be necessary to check various components for correct resistance readings with a multimeter Manufacturer information is essential for this to compare the measured value with the correct value Changes in ambient temperature can affect resistance readings in electromagnetic coils, so a realistic tolerance must be allowed for this To prevent damage to sensitive electronic components and false readings, general multimeter etiquette must be followed, with components completely disconnected from the circuit when they are checked Check signals (waveforms) and voltages at sensors and actuators However, just because a sensor or actuator has the correct resistance doesn’t mean that it is working properly when installed Intermittent faults are particularly difficult to find as they usually occur only when the vehicle is being operated Therefore, if possible, measure the signal at the sensor or actuator under running conditions In most cases, an oscilloscope will give much more information than a multimeter The voltage signals at some sensors and most actuators are quite dynamic in nature and a multimeter is not able to process the signal appropriately There are many portable, cheap oscilloscopes on the market ideal for this purpose and robust enough for workshop use Check system electronics via diagnostic interface Nearly all vehicle electronic systems have a diagnostic interface In newer vehicles (2001 on), this interface is a standardised on-board diagnostic (OBD) connector and there are a number of generic scan tools available that can access fault codes from the transmission ECU (as well as from the engine ECU) The fault codes have 5.14 a standardised protocol, which aids diagnostics quite considerably Older vehicles tend to have diagnostic interfaces specific to their manufacturer Generally, specific equipment protocols exist, which must be used to access the information On some vehicles (particularly Japanese ones) there is a blink code indication, which, although limited in the information it provides, can be a useful aid Diagnostics summary Irrespective of its type (CVT, DSG, etc.) an electronic transmission is a complex unit and a systematic approach is needed when dealing with any technical problems An electronic transmission is, though, simply a system (Figure 5.68) It has inputs which are processed, giving outputs with the desired reactions or responses From first principles, therefore, the inputs to the system must be confirmed as correct If this is so, then the outputs can be checked for correct action If actions are incorrect, then the actuators should be checked or tested If they are OK, then the connection between the actuators and ECU should be checked, etc., etc This approach will solve most problems that might occur Another point to consider when diagnosing faults is that a good understanding of the system and its inputs and outputs is especially important, with so many variables changing at the same time in such a complex way Make your life easy! Get as much information as possible about the system Try to get a good understanding of the system in overview and how all the components fit together and work together in normal operation This information can be obtained from the manufacturer through training documentation or from workshop manuals – as well as from good textbooks of course! Key Points possible a pressure gauge should be used to take readings under operating conditions, so that these can be compared with manufacturer specifications If there is a throttle cable, adjustment of this should be checked Incorrect adjustment can cause problems with shifting (shift points) 235 A logical approach is essential for diagnostics Consider systems as black boxes and check all inputs and outputs Understand the system operation as well as the diagnostic procedures Check sensor signals and supply signals using an oscilloscope as well as a multimeter TRANSMISSION SUMMARY 5.14.1 Outline of electronic control It is clear that the development of electronic control for transmission systems will continue to move at a swift pace Technical developments in mechatronics and microelectronics now allow great freedom and flexibility in terms of packaging of control units and interfacing between vehicle control systems These developments are making electronic control of the transmission, even automatic shifting, more attractive in markets where an automatic gearbox would once have been shunned, for example, in high performance cars Highly integrated vehicle systems can provide sophisticated control algorithms to improve driver [647] Chapter 05 16:35 Page 236 Transmission comfort and safety Together with adaptive strategies that take into account additional operating parameters and boundary conditions, systems can optimise vehicle performance In summary, the main types of transmission currently available are: ● ● ● manual constant mesh transmissions automatic transmissions, with a planetary gearbox and torque converter continuously variable transmissions, with a belt driven variator Electronically controlled transmissions, in conjunction with advanced powertrain control systems, can provide improved vehicle performance and efficiency The following powertrain systems have all seen the benefits of the implementation of electronic controls: ● ● ● ● ● manual transmission – electronic clutch and shifting for improved economy and/or vehicle performance automatic transmission – sophisticated shift strategies and control systems to improve efficiency and driver interaction continuously variable transmission – control of shifting to improve driver feel, and more control over hydraulics for greater efficiency four-wheel drive – improved traction and extended functionalities through integration with other control systems axle/traction control – better tractive force management on surfaces with limited or no grip Current developments show that integrated powertrain control will be the basis of future developments To improve performance, as well as to meet legislative requirements on harmful vehicle emissions, it is no longer appropriate to treat the powertrain system as separate, mechanically connected units (the combustion engine, gearbox, axle, etc.) The powertrain system, consisting of these elements, must be considered as a single unit and calibrated and optimised during development for significant improvements to be made 5.14.2 Future developments Vehicle manufacturers are under increasing pressure to reduce vehicle emissions Advanced powertrains will play a major part in achieving future goals of emission reduction and improved efficiency to conserve natural resources A critical factor to be overcome is the reduced efficiency of the combustion engine at low speeds, and its polluting effect at idle where no power is required at all by the vehicle for motion This is an area of great interest, with large potential for improvement, and the current trend is towards hybrid powertrains The hybrid vehicle combines the positive attributes of an electric drive (high efficiency, quiet, full torque at low/zero speed) with those of a Fundamentals of Motor Vehicle Technology: Book combustion engine (high specific power to size ratio, long driving range between refuelling) This technology needs a sophisticated control system for the prime movers to work together in a harmonious and efficient way This can easily be achieved with an electronic control system but there are a number of factors that impede the acceptance of this technology in the market place: ● ● ● battery technology – current units are expensive and heavy, and this technical hurdle must be overcome to move the technology forward significantly the existing electrical system voltage – the standard voltage for vehicle systems is 12 volts, which is far too low to transmit power efficiently at the level required for tractive force; higher voltage systems will be developed to cope with increasing power demands, which will be essential for the adoption of full hybrid systems motor size – although highly efficient, modern electric motors are still quite large relative to their power output; as technology develops, motors of the appropriate power rating will become smaller and will be easier to integrate into a combined vehicle propulsion system Manufacturers are currently working hard to overcome these issues, as well as introducing light hybrid systems that can be integrated within current vehicle ranges as an intermediate step This allows them to introduce the technology into the market place and gauge customer reaction to it Key Points 236 25/8/06 Transmission management is used primarily to improve economy and vehicle performance, as well as driver interaction Hybrid solutions are likely to be the future … Web links Transmission systems information www.zf.com www.porsche.com www.luk.de www.bosch.co.uk www.haldex-traction.com www.siemensvdo.com www.audi.com www.vw.com www.sae.org Teaching/learning resources Online learning material relating to transmission systems: www.auto-training.co.uk [647] Index.qxp 25/8/06 15:40 Page 237 INDEX absolute pressure sensors 19 AC motors, ISG systems 227 acceleration pedal position sensors 177 sensing 12 stoichiometric air:fuel ratios 84 accelerometers, knock pressure sensors 25 accumulator converters 135, 137–8 actuators 26–33 assemblies 197–8 common rail diesel systems 175 communication between ECUs 27 control signals 32–5 electrohydraulic assemblies 197–8, 209 Haldex coupling 233 injector 100, 106 non-mechanical 26–7 outputs 4–5 resistances, checking 235 simulation tests 156 single-point injection 113–14 status monitoring 197 transmission systems 196–201 wiring, M1.5 system 108 adaptive strategies 154–5 adaptive transmission control 214, 215 advance mechanisms 40, 47–8, 61–2 after treatment systems 128–30, 133–4 air bypass ports 94–5, 96 air conditioning control 3, 12 status signals 196 air:fuel ratios 21–2, 39 and dwell period 45–6 and pollutant levels 128, 143–4 and power control 119 and spark ignition 44 control 138–43 converter processes 134–5 diesel systems 163 fuel mixture maps 84 see also lambda values; mixtures air injection 114, 146–7 air mass control diesel systems 163, 177, 185 sensors 12, 20, 177, 185 hot wire/film 110–11 variables 83, 86 air temperature sensors 5, 12, 88, 97–9, 104–5, 114, 155 air valves 100–1, 102 airbag systems 2–3, 12 airflow, cylinder volumetric efficiency 119 airflow sensors 12, 19–21, 88, 97–8 airflow/temperature sensors 97–9, 104–5 analogue 23 direct injection systems 121 live data systems 155 M1.5 system 108 power supply 101 alternating current (AC) analogues 51 amplifiers ECUs 7–8 ignition 56–9 analogue sensor signals 9–10, 19, 22–5 MAP sensors 23, 111–12 rotational speed 14–15 speed/position 66 temperature 13–14, 23 throttle position 23 analogue to digital converters 10, 23–4, 192 aneroid capsules, pressure sensors 12 angular displacement torsion sensing 195 angular movement/position sensors 11–12 anti-lock braking systems (ABS) electronics 2–3 interface, VW DSG 209 sensors and 12 arcing, contact faces 42 atmospheric pressure sensors 19 Audi Multitronic transmission 223–4 automatic brake differential (ABD) 229, 231 automatic gearboxes electronic control 188 transmission management 212–16 automatic injection advance units 167, 168 automatic shifting hydraulic transmissions 187 automatic transmission 200, 207, 212–16 sensors and 12 auxiliary air valves 100–1, 102 ballast resistor ignition modules 56 basic fuel program, injection systems 83–4 batteries hybrid vehicles 236 live data systems 155 memory backup belt/chain drive transmissions 187 belt driven starter–generators 228 blink codes 150–1, 157–9 BMW Drivelogic feature 205 SMG system 205 bob weight and spring systems 61–2 boost pressure control, turbochargers 185 boost pressure sensors 5, 12 Borg Warner 55 gearbox 213 Bosch in-line diesel injection pump 164 K & KE Jetronic injection systems 77, 79 LE/LE2 systems 97–103 M1.5 system 103–9 Motronic engine management systems 148, 149 VE distributor pump 165 [647] Index.qxp 238 25/8/06 15:40 Page 238 Index brakes on/off signals 196 pedal position sensors 12 braking downshift, Tiptronic gearbox 216 broadband lambda sensors 142–3 burn off function, hotwire air mass sensors 110 burn times, ignition timing 46–7 butterflies, and cylinder volumetric efficiency 119 bypass port, mixture adjustment 98–9, 100 cam and rocker system pump drives 175 camshaft position sensors 5, 12, 16, 23–4, 25, 177, 181 camshaft speed/position sensors 23–4 capacitor discharge ignition (CD) 60 capsule type pressure sensors 18 carbon dioxide emission 125–6, 130 carbon monoxide emission 127, 129 diesel systems 163 carburettors 77, 78 alternatives to 40–2 and fuel efficiency 38–9 vs single-point injection 112–13 casing mounted ignition modules 58–9 catalysts 133, 136 catalytic converters 134–8 and mixture formation 117 operating temperatures 135–6 oxygen monitoring 5, 21–2 pre-cat control 22 post-cat monitoring 22 sensors 135–6 CD systems 60 centrifugal cancellation, hydraulic clutches 218–19 centrifugal governors, diesel pumps 167–9 chain drive, Multitronic transmission 223 charge time see dwell period chemical treatment, pollutants 128–30 circuits ECUs 7–8 fault recognition 153 monitoring 153 power transistors switching 8, 32–4 Fundamentals of Motor Vehicle Technology: Book closed crankcase ventilation systems 130 closed loop systems 57–8 operation 138–9 clutches 201 actuators 197, 198–9 electronic control 201–3 Haldex coupling 232 piston mechanisms 219 pressure control VW DSG MTM 209 slave cylinders 206 clutch-by-wire (CBW) transmission systems 201–3 clutch-to-clutch automatic transmission systems 217–19 code readers 150, 157, 159–60 coil on plug ignition systems 72–3 coils electronic switching 48 energy build up time 68 output improvement 57 wasted spark systems 71, 72–3 cold running auxiliary air valve 100–1 emission levels 131, 146 stoichiometric air:fuel ratios 84 cold starting diesel 165, 172–4 emission levels 131, 146 combustion efficiency 41, 116, 130 NOx formation 144 pilot injection 184 combustion chambers injection timing 118 diesel systems 164 pollutant reduction 129, 130 combustion knock 41, 116, 174 diesel knock 164, 174 sensors 25, 67 common rail diesel fuel systems 175–85 communication, standardisation 161 commutators 28 complex systems components, ECU control of 6–7 compression ratios 41, 116 compression stroke injection timing 118–19 compressors, air conditioning computer controlled systems computers see electronic control units (ECUs) concentric clutch release systems 198–9 constant energy ignition systems 58–9 contact breakers coil primary circuit 48–50 dwell angles 45–6 elimination 40 ignition systems 38–9 wear 42 contact brushes 28 contact-based temperature sensors 13 contaminants, catalytic converters 137 continuous fuel delivery systems 122 continuous rotation motors 31 continuously variable transmissions (CVTs) 187, 220–6 control signals 32–4 altering 34–5 M1.5 system 107 sequential systems 86 control spools, EDC systems 170–2 control unit temperature sensors, VW DSG MTM 209 controlled pressure difference 78 controller area network (CAN) systems 189–90 coolant temperature sensors 5, 12, 13, 88, 170–1, 177, 196 LE2 systems 99, 101 live data systems 155 M1.5 system 105, 108 single-point injection 114 cooling systems 42 cornering detection 215 crank position sensors 196 crankcase emissions, pollutant 125 crankshafts position sensors 5, 12, 109 position triggers 89–90 rotational sensors 14, 15–16, 25 speed/acceleration monitoring 162 speed/position sensors 11–12, 23–4, 65–6, 106 speed sensors 177, 181 creep regulation, VW DSG 207 current control systems feedback 57–8 contact breaker systems 42 cylinders injection systems 77, 78, 79, 116–19 [647] Index.qxp 25/8/06 15:40 Page 239 Index isolation 162 position reference points 15–16 pressure requirements 44 recognition sensors 72–3, 85, 181 valves, diesel systems 164 volumetric efficiency 119 damping chambers 98 dashboard warning lights 157–8, 161 DC/DC converters, ISG systems 227 deceleration, stoichiometric air:fuel ratios 84 delivery valves, diesel pumps 167 diagnostics capabilities, VW DSG 207 connector plugs, standardisation 161 EDC systems 172 electronic transmission control 216 on-board 150–1 transmissions 233–5 diaphragm type pressure sensors 18 diesel engines emissions legislation 38 injection systems 42, 77, 163–85 knock 164, 174 differential control, electronic 229–33 differentials, 4WD systems 231 digital pulses, Hall effect 54 digital signals 9–10, 19, 22, 25–6 MAP sensors 112 optical ignition triggers 54–6 digital timing control 63–4 digital to analogue converters 10, 192 diode control, wasted spark systems 72 direct acting clutch actuators 198 direct fuel injection (DI) 115, 116–24 diesel 174–5 engine management system 149 pre-heating systems 172 direct ignition systems 68–73 direct shift gearboxes (DSG) 191, 199–201, 207–10 disc valves 81, 82 distance travelled information 14 distributor-based systems 68–9 distributor body located sensors 66 distributor caps 52 distributor plunger drives 167 distributorless ignition systems 68–73 distributors, Hall effect pulse generators 25–6 double shift actuators 200–1 downshifting Tiptronic gearbox 216 uncontrolled 215 drive-by-wire systems 204 Drivelogic feature (BMW) 205 driver information 12, 190–1 driver input 5, 214 driver stage amplifiers, ECUs 7–8 driver’s lever position sensors 194 drivetrain torque sensors 195 driving members 201 driving modes, selectable, VW DSG 207 dual clutch systems 187, 203 actuation 198–9 dual-bed catalysts 134 duty cycles 33–5 dwell angles 45–6, 56 dwell control, ignition modules 57 dwell period 45–6, 68, 70–1 dynamic control program (DRP), Multitronic transmission 224 dynamic stability control (DSC) 205 dynamic vehicle control systems EGR see exhaust gas recirculation electric motor type actuators 4, 28–9, 31–2 electric vehicles, hybrid 226–9, 236 electrical actuation vs servo operation 196–7 electrical control, transmissions 188–9 electrical/electronic injection systems 77, 80, 81–90 electrical systems LE2 system 101–3 M1.5 system 107–9 electro-hydraulic shift mechanisms 205 electroactuators 198–201 electrodes, spark plugs 74, 75–6 electrohydraulic actuator assemblies 197–8 electrohydraulic transmissions 187 electromechanical actuators, clutch systems 202–3 239 electronic airflow sensors 20–1 electronic and mechanical sensing devices 12 electronic clutch management 201–5 electronic control units (ECUs) 4–5, 6–11 accumulator converters 138 actuator control signals 32–4 common rail systems 174–85 communication between 27 diesel systems 177–85 glow plugs 173–4 Haldex coupling 232–3 injection systems 80, 82–9, 177–85 integrated 148–50, 188–91, 202–3 lookup tables 63–4, 67 M1.5 system 109 monitoring, EDC systems 170–2 power supply, LE systems 103 powertrain control systems 202–3 sensor signals 192 shift control 205–6 system fault recognition 152–5 transmissions 188–91, 197–8, 214, 235–6 VW DSG 209 electronic diesel control (EDC) systems 170–2 electronic differential control 229–33 electronic differential lock (EDL) interface, VW DSG 209 electronic ignition systems 40–8 electronic manual gearboxes 204–10 electronic petrol injection systems 77–96 electronic shift control, manual gearboxes 204–5 electronic switching, coil primary circuit 48 electronic system overview 234 electronically assisted ignition 48–50 emergency operation 153–4 emission control 2, 6–7, 37–9, 125–8, 132–4, 236 after treatment 128–30 cold running 146 CVT systems 221 diesel systems 163 EDC systems 170 engine operation 131–2 (EVAP) systems 130 [647] Index.qxp 240 25/8/06 15:40 Page 240 Index injection systems 78 integrated 148–50 legislation 37–8, 160 petrol engines 124–47 sensors 12, 90 system actuators energy contact breaker systems 42 production, stratified mixture formation 117–18 regeneration, ISG systems 227 waste, distributor based systems 68 engine breather systems maintenance 39 engine intake pressure 12, 18, 93–4 engine knock pressure sensors 25 engine maintenance, and emissions 38–9 engine management systems 6, 11, 12 and fuel injection 78 load sensing 5, 12 interface, VW DSG 209 integrated 148–50, 188–91, 202–3 engine oil changing 39 temperature sensors 12 engine output, EDC systems 170 engine speed contact breaker systems 42 EDC systems 170 live data systems 155 sensors 5, 12, 105–6, 177, 181, 196 timing advance 61–2 trigger references 99–100 engine stop/start function, ISG systems 227 engine torque control 215 engine tuning, pollutant reduction 129 environmental pollutants 125–7 see also emission control epicyclic gears, automatic transmission 212 EU emissions legislation 126–7, 160, 163 European on-board diagnostics (EOBD) 160–2 evaporative emission (EVAP) control 134, 147 live data systems 155 M1.5 system 108 excess air factor, lambda scale 124–5 Fundamentals of Motor Vehicle Technology: Book excess fuel return pipes 93 exciter coils, rotational speed sensors 15 exhaust gas composition 125–6 oxygen sensors 5, 11–12, 21–2 pressure, and EGR 144–6 temperature sensors 11–12 exhaust gas recirculation (EGR) systems 130, 133, 143–6, 171–2 common rail systems 185 control systems 145–6 sensors 12 valves 5, 145 external drives, double shift drums 200 fault codes 150–1 accessing 157–60 memory, OBD system 216 standardisation 160–1 fault handling, transmissions 214 fault recognition 152–5 feedback current control systems 57–8 firing end configuration, spark plugs 74 firing voltage requirements 43–4 fixed dwell angle systems 56 fixed gear transmissions 187 flame speed 130 flap type airflow meters 19–20 flow type pumping 90–1 fluid temperature sensors 11–12 flyweights, centrifugal governors 167–9 flywheels as driving members 201 sensor locatedion 65–6 starter–generators 228 Ford CTX transmission 221 four-speed all clutch-to-clutch systems 217–19 four-wheel drive control 229–33 Haldex coupling 232 friction clutches 201 friction wheel variators 187 front-wheel drive vehicles CVT systems 220 gearboxes 217 fuel consumption/economy and CO2 emission 130 CVT systems 221 diesel systems 164 direct injection systems 116–19 electronic manual gearbox 205, 207 powertrain automation 204–5 stratified mixture formation 118 fuel delivery systems 77–8, 90–4 common rail diesel systems 175–6 control, precise 80 cut-offs, solenoid operated 165, 167 diesel 163–4 filters 80, 91–2 flow 90–1 gauges 10 pollutant reduction 125, 128, 129 quantity control actuators sealed 130 sensors 12, 18, 19 see also fuel injection systems fuel emissions see emission control fuel evaporative emission control (EVAP) systems 130 fuel injection systems 6–7, 30, 42, 77–8, 80, 83–4, 97–112 comparison 116–19 control 5, 177–85 driver control modules 181 duration control 86 EDC systems 181 live data systems 155 timing, direct injection systems 118–19 diesel 42, 163–85 direct fuel injection (DI) 115, 116–24, 149 diesel 174–5, 177–85 GDI systems 115–24 pre-heating systems 172 electrical/electronic 77, 80, 81–90 engine intake pressure 93–4 fuel/ignition control combination 148–9 fuel maps 83–4 fuel sprays 81–2 indirect, pre-heating 173 intermittent 78 multi-point 80, 97–112, 116 nozzle injectors 169–70 pilot/main 184–5 sensors 5, 11, 80, 87–90, 110–12, 121, 177–85 simplified 112–13 single-point 114–15 solenoid actuators valves 80 vaporisation 116, 120 [647] Index.qxp 25/8/06 15:40 Page 241 Index volume control, EDC systems 170 see also injection pumps; injectors fuel mixtures see air:fuel ratio; mixtures fuel pressure regulators 80, 93–4, 183 sensors 12, 19 systems, diesel 176–7 fuel pumps 90–1 continuous rotation motors 31 diesel rotary pumps 165–7 power supply, LE systems 101 wiring, M1.5 system 108 fuel rails 80, 93–4 common rail diesel systems 175–6 injector solenoid valves 81 rail sensors 121 fuelling references 84 full rotation motors 31, 32 gas temperature sensors 11–12 gasoline direct injection (GDI) systems 115–24 gear actuator valves, VW DSG MTM 209 gear ratios automatic transmission 214 Multitronic transmission 223 gear selection electronic transmission control 214 Honda system 217–18 Porsche PTM system 231 VW DSG 208–9 gear shift actuators 199–201, 221 high-performance vehicles 205 gear trains Borg Warner 55 gearbox 213 Honda system 217–18 gearboxes automatic, electronic control 188 electronic manual 204–10 information sharing 190–1 lightening 205 mode selection 205–6 RPM sensors 193 sensors 194, 196 sequential manual (SMG) 205 Tiptronic 216–17 transmission management 212–16 VW DSG 208 VW DSG MTM 209 glow plugs 133, 170, 173–4 governors, rotary diesel injection pumps 167–9 gradients detection, adaptive control 215 Haldex coupling 231–3 Hall effect 16 digital pulses 54 ignition triggers 16–17, 53–4 phase sensors 85 pulse generators 25–6, 53–4 rotational speed sensors 15, 16–17, 192, 193 speed/position sensors 65, 67 switches 53–4 Tiptronic gearbox operation 196 headlight circuits 3–4 heat ranges, spark plugs 75 heated exhaust gas oxygen (HEGO) sensors 22 heated step type lambda sensors 140–1 heater plugs 170, 173–4 heating, broadband sensors 143 high energy coils, ignition modules 57–8 high pressure pumps 181, 182 diesel 176, 177 direct injection systems 122–3 high speed switching, circuits high tension cables, ignition 68 high voltage rapid opening injectors 120 hill-holder function, VW DSG 207 homogeneous charge compression ignition (HCCI) 189 homogenous mixture formation 117 Honda clutch-to-clutch automatic transmission system 217–19 hot film sensors 111, 121 hot wire sensors 20–1, 110–11 hybrid electric vehicle 236 classification 226 powertrain technology 226–9 transmissions 189 hydraulic clutches 218–19 Haldex coupling 232 hydraulic pump and pressure accumulators 205 hydraulic shift transmissions 187 hydraulic system checks 233–4 hydraulics, Haldex coupling 231–3 hydrocarbon emissions 127 diesel systems 163 reduction methods 129–30 241 idle speed and pollutants 131–2 control 5, 94–6, 113 EDC systems 172 LE2 system 100–1 live data systems 155 M1.5 system 106–7, 108 crankshaft sensor 106 disconnection, torque converters 212 motors partial rotation 32 stepper 5, 32 rotary diesel injection pumps 169 stoichiometric air:fuel ratios 84 idle valves 94–5 ignition advance curves 61 ignition coils 29 as actuators 5, 27 M1.5 system 107, 108 monitoring 162 output voltage 44 ignition systems 40 computer controlled 61–7 constant energy 58 electronically assisted 48–50 fuel control combination 148–9 and fuel efficiency 38–9 modules/amplifiers 56–9 pollutant reduction 128 sensors 5, 12 ignition timing 45–8 actuators advance/retard 57 as after treatment 134 and cylinder pressure requirements 44 dwell time 42 pressure sensors 18 and engine intake depression Hall effect pulse generators 54 live data systems 155 pollutant reduction 129, 130 ignition triggers 89–90 Hall effect 16–17 inductive 50–3 single-point injection 114 immobiliser systems, EDC systems 172 improbable/implausible values 154 in-car entertainment systems in-line injection pumps, diesel 164 in-line transmissions 187 inductive sensors [647] Index.qxp 242 25/8/06 15:40 Page 242 Index analogue rotation 192–3 crankshaft speed/position 66 ignition systems 40 phase sensors 85 pulse generators 50–3 self-generating 52–3 injection pumps 116 high pressure 176 rotary diesel 167, 169 injection systems see fuel injection systems injectors 80–2 actuator LE2 system 100 M1.5 system 106 single-point injection 113 common rail systems 175–6, 183 direct injection systems 120 ECU switching 84 LE systems power supply 101 motion sensors, EDC systems 171, 172 nozzles 81–2 operation speed 82 common rail diesel systems 175 rotary diesel injection pumps 169–70 solenoid valves 81–2 timing 85–7 input shaft speed sensors, VW DSG MTM 209 input signals, ECUs 4–5 shift control 206 insulators, spark plugs 75 intake air temperature NOx reduction 130 sensors 12, 170–1, 177 intake manifold pressure sensors map sensors 111 and EGR 144–6 intake ports diesel systems 164 injection systems 77–80 pollutant reduction 129 intake system, auxiliary air valve 100–1 integrated control emission systems 148–50 ignition modules 58–9 powertrain systems 189–90, 202–3 starter–generator (ISG) systems 226–9 torque converter/starter–alternator Fundamentals of Motor Vehicle Technology: Book 212 intelligent powertrain management 229 interfaces Haldex coupling 232–3 VW DSG 209 interference suppression 48 intermittent injection 79 internal drives, double shift drums 200 Jaguar speed automatic gearbox 213 knock see combustion knock lambda sensors 5, 138–43 live data systems 155 M1.5 system 108 single-point injection 114 step type 141–2 see also oxygen sensors lambda values diesel systems 163 excess air factor 124–5 fuel mixture maps 84 lambda air:fuel ratio 21 lambda window 124–5 and pollutant levels 128 see also air:fuel ratios LE2 systems (Bosch) 97–103 lead emissions, origin/effects 127 leaded fuel, and catalytic converters 137 lean burn technology broadband sensors 142 emissions control 132–3 pollutant reduction 129, 130 LED optical ignition triggers 55 LED probes, blink codes 158–9 light hybrid powertrain technology 226–9 lighting systems 3–4, 9, 26–7 limited slip differentials (LSDs) 229 limp home mode 153–4, 215, 207 linear movement sensors 11–12 linear solenoids 96 linear speed information sharing 190–1 link plate chain drives 223 live data systems 155–7 live rear axle systems 230 load and pollutants 131 sensing 5, 12 stoichiometric air:fuel ratios 84 timing advance/retard 47 vacuum retard 62 locations, ignition modules 58 lock-up clutches 211–12, 215 lookup tables, ECU 63–4, 67 Los Angeles smog 38 low pressure pumping systems 121 lubricant viscosity, and system pressure 194 M1.5 system 103–9 magnetic fields actuators and 27–30 inductive pulse generators 50–1 magnetic sensors ignition systems 40 rotational speed sensors 14–15 magnetoelastic torque sensors 195 main injection 184–5 malfunction indicator lamps (MIL) 161 manifold absolute pressure (MAP) sensors 5, 19, 88, 170 analogue 23, 111–12 diesel fuel injection systems 177 live data systems 155 manifolds heating 173 single-point injection systems 115 pressure 93–4 direct injection systems 121 signals 196 manual checks, transmission diagnostics 233 manual idle speed adjustment 100 manual transmissions 187, 207 clutches 201–2 gear shift actuators 200 gearbox electronic control 204–10 selection 200 MAP sensors see manifold absolute pressure sensors mass airflow measurement 88 direct injection systems 121 sensors 20–1 signals 196 master cylinder assemblies 198 master references single coil systems 72–3 wasted spark systems 71 mechanical advance mechanisms 61–2 mechanical concentric clutch [647] Index.qxp 25/8/06 15:40 Page 243 Index release systems 198–9 mechanical friction clutches 201 mechanical ignition systems 42–3 mechanical injection systems 77 mechanical system checks 233–4 mechanical timing systems 61–3 mechanical type sensors 12 airflow sensors 19–20 pressure 18 mechatronic control units, integrated, VW DSG 207 mechatronic transmission management units 197–8, 209 memory, ECUs 8–9, 83, 216 Mercedes-Benz, fuel injection systems 77, 78 micro/mild hybrid systems 227 misfires and catalytic converters 136–7 monitoring 162 mixtures adjustment, LE2 system 98–9 control pollutant reduction 129, 130 power/torque regulation 119 enrichment, cold running 146 formation, direct injection systems 117–18 lean burn technology 132 rich, and cold-start 172 see also air:fuel ratios mode selection, gearboxes 205–6 modulating valves, VW DSG MTM 209 monoliths, catalytic converters 136 Motronic engine management system (Bosch) 103–9, 148 movement sensors 11–12 multi-plate clutches 203, 223 multi-point fuel injection (MPI) 97–112, 116 components 80 hotwire air mass sensors 110–11 MAP sensors 111–12 nozzle injectors 169–70 multi-stage transmissions 187 multimeters, duty cycle readings 34 multiple ignition coil systems 68–9 multiplexing control valves, VW DSG MTM 209 transmissions 189–91 Multitronic transmission (Audi) 223–4 narrow band sensors 139–42 needle valves 81, 82 negative sparks 70 negative temperature coefficient (NTC) sensors 13–14, 196 Nissan CVT system 224–5 nitrogen, in exhaust gas 125 nitrogen oxides (NOx) 127 accumulator converters 135, 137–8 emissions, diesel systems 163 formation 143–4 reduction methods 130 noise, direct injection systems 174 non-mechanical actuators 26–7 OBD system, fault memory 216 off-road vehicles, differential control 229–33 oil pressure control valves, VW DSG MTM 209 on/off actuators 197 on-board diagnostics (OBD) 22, 150–1 open circuits, fault recognition 153 open loop operation 138–9 opening time, injectors 82 operating conditions 62–3, 131 optical ignition triggers 54–6 optical speed/position sensors 66 oscillation frequency, step type lambda sensors 142 oscilloscope readings 34, 86, 87 outlet port valves, common rail diesel systems 175 output shaft speed sensors, VW DSG MTM 209 output signals amplifiers, ECUs 7–8 broadband sensors 143 D/A converters 10 ECU systems 4–5 sensors 192 overdrive systems 188, 189 oxidation 133 catalysts 134 oxides of nitrogen see nitrogen oxides oxygen reduction, exhausts 130 oxygen sensors 11–12, 21–2, 138–43 analogue signals 25 single-point injection 114 see also lambda sensors; lambda values 243 parallel shift gearboxes 210 partial rotation motors 31, 95–6 passwords, code readers 159 phase sensors 85 photochemical smog formation 38 phototransistors 55 pilot injection 184 phase control 174, 176 Pintaux injectors 173 pintle nozzle injectors 169–70, 173 planetary gears 187, 212 playback mode, data systems 156 plug gaps 43–4, 76 points ignition systems, and fuel efficiency 38–9 polarity, spark plug electrodes 76 pollutants see emission control Porsche Tiptronic gearbox operation 191, 196, 216–17 traction management (PTM) 230–1 port type injection systems 80, 117, 119–20 position reference points 15–16 position sensors 11–12, 17–18, 23–4, 195 positive crankcase ventilation (PCV) systems 130 positive displacement pumping 90–1 positive temperature coefficient (PTC) sensors 13–14 potentiometers airflow sensors 19, 97–8, 104–5 position sensing 25 throttle position 17–18, 88–9 power amplifiers, ECUs 7–8 power supply boost function, ISG systems 227 LE systems 101 loss, CVT systems 221–2 M1.5 system 108 regulation, mixture/throttle control 119 power transistors 8, 48–50 powertrains control units 190–1 light hybrid 226–9 transmission types 187 pre-heating systems, diesel 172–4 pre-ignition detection 41 pre-programmed driving modes, selectable, VW DSG 207 pressure accumulators 205 [647] Index.qxp 244 25/8/06 15:40 Page 244 Index pressure control carburettors 78 gearboxes 215 fuel 90, 93–4 VW DSG MTM 209 pressure sensors 12, 18–19, 67 analogue 25 direct injection systems 121 information sharing 190–1 pressure/vacuum sensors 11–12 transmission system 194–5 pressure systems, diesel 176–7 pressure valves, diesel pumps 167 programming, ECUs pulley assemblies, CVT systems 221–2 pulse air systems 146–7 pulse generators Hall effect 16–17, 53–4 ignition systems 40 inductive 50–3 signals 9–10, 33 pulse width modulated (PWM) signals 33, 193 pump based air injection systems 146 pump-turbine unit, torque converters 210–11 pumps common rail diesel systems 175–6 direct injection systems 121–3 elements 90–1 high pressure, diesel 176, 177, 181, 182 single high pressure 178–80 purge valve wiring, M1.5 system 108 racing engines capacitor discharge ignition 60 fuel injection systems 77, 78 radio interference, spark plugs 74 reference points crankshaft sensors 65–6 ECU monitoring 9–10 ignition timing 51–2 rotational angular position sensors 15 reference signal systems 65–7 sequential injection systems 85–6 reference voltages LE systems 101 ECU systems 13 references, master single coil systems 72–3 wasted spark systems 71 Fundamentals of Motor Vehicle Technology: Book regenerative retarders, ISG systems 228 relay operation headlight circuits LE systems 102 M1.5 system 108 reliability/durability issues 39–40 reluctors crankshaft sensors 65–6 inductive pulse generators 50–1 rotational speed sensors 14–15 remote ignition modules 58–9 resistance requirements 44 throttle position sensors 17 resistors ballast 56 spark plugs 74 temperature sensors 13 variable retarder function, ISG systems 227 retrofit gear shift actuators 199 returnless systems 93 reverse torque converters 212 road speed information 14 road tests, transmission diagnostics 233 road wheel rotational speed sensors 14 roller cell pumps 92 roller ring assemblies 167 rotary diesel injection pumps 165–72 rotary idle valves 32, 95–6 M1.5 system 106–7 rotary injection pumps, diesel 165–72 rotational sensors 11–12 angular position 15–18 rotational movement 11–12 speed sensors 14–18, 190–1, 192–3 rotor arms 52 elimination 68–9 energy waste 68 rotor discs, Hall effect sensors 16–17 safety systems electronic transmission control 215–16 integration 190, 230 VW DSG MTM 209 satellite navigation systems scan tools 150, 157, 159–60 seat sealing, spark plugs 74 secondary air injection 146–7 selectors assembly, electronic manual gearbox 207 control unit interface, VW DSG 209 sensors, VW DSG MTM 209 self-bleeding fuel systems 165 self-diagnosis systems 150–1, 154 self-generating inductive sensors 52–3 self-learning capability 205 semiconductor pressure sensing elements 195 sensors 4, 11–13 applications 11–12 ECU input 4–5, failure substitute values 215–6 inductive, self-generating 52–3 information sharing 190 MAP 111–12 M1.5 system 103–4 resistance checking 235 signals 22–6 analogue to digital converters 10 types 13–22 VW DSG MTM 209 sequential injection 85 sequential manual gearbox (SMG) 205 serial data systems 155–7 series resistance circuits 13 service adjust mode, data systems 156 servos 196–7 shaft layout, VW DSG 208 shaft torque sensing 195 sheathed-element glow plugs 174 shift control automatic transmission 214–15 electro-hydraulic 205 mode selection switches 194 quality 214 sensors 206 uncontrolled 215 shift curve adaptation, Tiptronic system 217 short circuits, fault recognition 153 shut-off valves, solenoid 167 sideways movement sensing 12 signals 5, 9–10, 22–5, 192 analogue to digital converters 10 broadband sensors 143 checking 154, 197, 235 ECUs communication 27 stepped 23, 141–2 [647] Index.qxp 25/8/06 15:40 Page 245 Index see also sensors; specific applications silver spark plug electrodes 75–6 simple multi-point injection with airflow sensor 97–103 simplified injection systems 112–13 simulation tests, actuator 156 simultaneous injection 85 LE2 system 100 M1.5 system 106 single barrel pumps 122–3 single-bed converters 134 single coil systems 68, 72–3 single high pressure pump system components 178–80 single hole nozzle injectors 169–70 single-point petrol injection 112–15 sliding mesh gearboxes 204 slip control, lock-up clutches 211–12 slip differentials, limited (LSDs) 229 smart sensor technology 192 smog 37–8 snapshot mode, data systems 156 solenoid actuators 4, 5, 27–8, 30–1, 196–7 solenoid injectors, single-point injection 113 solenoid operated fuel cut-offs 165 solenoid valves air 30–1 idle valves 95–6 injector 81–2 pulse air 146–7 solid state components, pressure sensors 18–19 soot emissions, diesel systems 163 spark advance maps 63–4 detection 162 duration 44–5 plugs 39, 73–6 positive and negative 70 quality 43 timing 46–8 speed, injector operation 82 speed/position sensors 192–3 analogue 23–5 crankshaft 65–6 single-point injection 114 speed-related timing advance 46–7 spin control, sensors and 12 sports map shift, Tiptronic gearbox 216 sports utility vehicles (SUVs) 229–33 spring pressure, clutch operation 201 stability control, sensors and 12 stalling, at idle speed 94 standardisation, on-board diagnostics 160–1 starter integration starter–alternator torque converters 212 starter–generator systems (ISG) 226–9 starting direct injection systems 124 electronic manual gearbox 207 rotary diesel injection pumps 169 voltages see reference voltages status monitoring, actuators 197 steering angle sensing 12 steering column control unit interface, VW DSG 209 step type sensors 139–42 stepped signals 9–10, 23 stepped transmission, tractive effort curves 220 stepper motors 29, 32 as actuators idle valves 94–5 stoichiometric air:fuel ratios 21, 84, 117–18, 124–5 stratified mixture formation 117–18 lean burn technology 132–3 pollutant reduction 129 substitute values, sensors 154, 215–6 substrates, catalytic converters 136 supercharger control sensors 12 switch-based temperature sensors 13 switches/switching and relays and sensors circuits, high speed coil primary circuit 48 digitally controlled ECU functioning as 32–4 Hall effect 53–4 power transistors 8, 48–50 throttle 88–9 wasted spark systems 71 synchromesh gearboxes 204 six speed, VW DSG 207 synchromesh transmissions 187 245 system components, M1.5 system 103, 105–9 system fault handling, VW DSG 207 system fault recognition 152–5 system faults, self-diagnosis 150–1 system layout, M1.5 system 103, 104 system LED, blink codes 158 system pressure, automatic transmission 214 temperature control, ECUs temperature sensors 11–12, 13–14 analogue signals 23 coolant 99 EDC systems 170–1 fault recognition in 152–3 information sharing 190–1 temperatures and catalytic converters 135–7 extremes, actuator operation 196 spark plugs and 73 terminology, code reading equipment 157 tests actuator simulation 156 emission regulations 126–7 fault codes access 157–60 routines 156–7 thermal afterburning 133 thermistors 13 thick film pressure sensing elements 195 three barrel pumps 122 three-phase AC motors, ISG systems 227 three-way catalytic converters 134–5 thresholds, digital signals 9–10 throttle body fuel injection (TBI) 112–15, 116 throttle butterflies 17 throttle control direct injection systems 120–1 power/torque regulation 119 throttle linkages, stepper motor action 94–5 throttle position sensors 5, 12, 17, 88–9 information sharing 190–1 live data systems 155 M1.5 system 105, 109 pedal sensors 205 signals 23, 196 single-point injection 114 variable resistors [647] Index.qxp 246 25/8/06 15:40 Page 246 Index throttle positioner systems 129 throttle switches 88–9 LE systems 99, 102 timing advance advance/retard 47 characteristics 63–4 EDC systems 172 rotary diesel injection pumps 167 timing control 61–4 ECU lookup tables 63–4, 67 ignition systems 40 injection systems 79 timing trigger systems see triggers Tiptronic gearbox operation 191, 196, 216–17 top dead centre (TDC) 15, 16, 25 toroidal variator drive (Torotrack) transmissions 187 torque 186 and emissions, diesel systems 163 boosters, ISG systems 228 control diesel rotary pumps 165 mixture/throttle control 119 converters 187, 212 electronic control 210–12 lock-up control 196, 211, 215, 224 turbine speed information 193 distribution, Porsche PTM system 231 sensors drivetrain 195 Multitronic transmission 223 transfer, CVT systems 223 torque/inertia ratio, electric motors 228 torsion angular displacement sensing 195 traction control adaptive control 215 ASR/ABD 229 (ESP) system interface, VW DSG 209 efficiency, 4WD systems 231 tractive effort curves 220 transient operation, clutches 206 transistors, switching 48–50 transmission systems 186–236 diagnostics 233–5 electronic switching 205 integration 188–91, 205 sensors 192–6, 195–6 splitting principle 209–10 Fundamentals of Motor Vehicle Technology: Book temperature monitoring 193–4 transverse drive vehicles, gearboxes 217 triggers circuits 50–3 discs 16–17, 65–6 Hall effect 16–17, 53–4 injection systems 89–90 optical 54–6 timing 65–7 LE2 system 99–100 M1.5 system 105–6 turbine/pump unit, torque converters 210–11 turbochargers boost pressure control 5, 185 sensors 12 twin clutch systems 187, 203 actuation 198–9 two-speed governors, rotary diesel injection pumps 167–9 two-stage current control process 86–7 unit injectors, common rail diesel systems 175–6 USA, emissions legislation 37, 38, 160 vacuum advance/retard mechanisms 62 vacuum sensors 11–12 valve timing electronic 42 NOx reduction 130, 134 variable control 149 valves 39 actuator, VW DSG MTM 5, 209 rotary idle 32 vanes airflow sensors 19–20, 97–8 Hall effect pulse generators 54 variable position bleed actuators 197–8 variable reluctance sensors 14–15, 51 variable resistors variable-ratio pulley assemblies 221–2 variables, injection ECUs 83 Variomatic CVT system 220, 221 VE distributor pumps 165–72 vehicle application software 159 vehicle speed monitoring 196 information sharing 190–1 speed sensors 12 vehicle stability control sensors 12 venturi 78 visual checks, transmission diagnostics 233 Volkswagen direct shift gearbox (DSG) 199, 207–10 electronic manual gearbox 205–7 voltages analogue pressure sensors 19 checking, sensors/actuators 235 ECUs 7–8 feedback control 57–8 ignition systems 29–30, 43–4 oscillation, rotational speed sensors 14–15 rapid opening injectors 120 threshold points, temperature sensors 23 throttle position sensors 17 volumetric efficiency, cylinders 119 Volvo Variomatic CVT system 220 warm-up maps, Tiptronic gearbox 216 washcoats, aluminium oxide 136 wasted spark ignition systems 68, 69–72 water in exhaust gas 125 waveform checking 235 weak mixtures, and CO2 emission 130 wet clutches twin clutch arrangement 203 VW DSG 209–10 wheel slip detection 215 wheel speed sensors 12, 24–5 information sharing 190–1 wheel spin control 12 windings, secondary 29 windscreen wipers wipers, potentiometer 17, 97–8, 104–5 wiring circuits Hall effect pulse generators 54 inductive pulse generators 52–3 LE2 system 101–3 M1.5 system 107–9 optical ignition triggers 55–6 worm gear drive actuators 198 Wright Brothers 77 zero voltage points 51–2 zirconium oxide oxygen sensors 21 [647] Index.qxp 25/8/06 15:40 Page 247 [647] Index.qxp 25/8/06 15:40 Page 248