Automobile Electrical and Electronic Systems

1 Automobile Electrical and Electronic SystemsThird 4/22/04 3:00 PM Page iThis page intentionally left blank Automobile Electrical and ElectronicSystemsThird editionTom Denton BA,AMSAE,MITRE, Lecturer, Open UniversityAMSTERDAM BOSTON HEIDELBERG LONDON NEW YORK OXFORDPARIS SAN DIEGO SAN FRANCISCO SINGAPORE SYDNEY 4/22/04 3:00 PM Page iiiElsevier Butterworth-HeinemannLinacre House, Jordan Hill, Oxford OX2 8DP200 Wheeler Road, Burlington, MA 01803 First published in Great Britain in 1995 by Arnold, a member of Hodder Headline edition, 2000 Third edition, 2004 Copyright 1995, 2000, 2004, Tom Denton. All rights reservedThe right of Tom Denton to be identified as the author of this work has been assertedin accordance with the Copyright, Designs and Patents Act 1988No 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.

2 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: ( 44) (0) 1865 843830; fax: ( 44) (0) 1865 853333; e-mail: You may also complete your request on-line via the Elsevier Science homepage ( ), by selecting Customer Support and then Obtaining Permissions .British Library Cataloguing in Publication DataA catalogue record for this book is available from the British LibraryISBN 0 7506 62190 Composition by Charon Tec Pvt. LtdPrinted and bound in Great BritainFor information on all Butterworth-Heinemann publicationsvisit our website at: 4/22/04 3:00 PM Page ivContentsPrefaceixIntroduction to the third editionxAcknowledgementsxi1 Development of the Automobile Electrical short next?

3 And Electronic working Electrical components and and electronics, sensors and developments in Electronic and test developments in test Systems and Systems wiring, terminals and wiring diagrams and compatibility (EMC) developments in Systems and and lead-acid battery 4/22/04 3:00 PM Page battery in Electrical developments in of the charging system and charging charging system charging system developments in charging of the starting motors and of starter starting system starting system developments in starting ignition system ignition developments in ignition fuel fuelling and exhaust control of fuel fuel control system fuel control ignition and fuel emission of diesel vehicle control study Mitsubishi 4/22/04 3.

4 00 PM Page study Bosch engine management system engine management developments in engine discharge and LED lighting system lighting developments in lighting washers and auxiliary auxiliary system auxiliary Systems developments in auxiliary and instrumentation system instrumentation developments in instrumentation heating and heating air conditioning system temperature control developments in temperature control Electrical chassis Electrical chassis Electrical system chassis Systems developments in chassis Electrical 4/22/04 3:00 PM Page vii16 Comfort and , mirrors and locking and electric and belt safety and comfort comfort and safety system comfort and safety Systems developments in comfort and safety electric vehicle developments in electric Wide technology 4/22/04 3:00 PM Page viiiIn the beginning, say 115 years ago, a book on vehicleelectrics would have been very small.

5 A book onvehicle electronics would have been even smaller!As we continue our drive into the new millennium,the subject of vehicle electrics is becoming everlarger. Despite the book likewise growing larger, someaspects of this topic have inevitably had to be glossedover, or left out. However, the book still covers all ofthe key subjects and students, as well as general read-ers, will find plenty to read in the new third edition has once again been updatedand extended by the inclusion of more case studiesand technology sections in each chapter. Multiplechoice questions have also been added to most chap-ters. Subject coverage soon gets into a good depth;however, the really technical bits are kept in a sepa-rate section of each chapter so you can miss themout if you are new to the have concentrated, where possible, on underlyingelectrical and Electronic principles.

6 This is becausenew Systems are under development all the and older Systems are included to aid thereader with an understanding of basic set the whole Automobile Electrical subject incontext, the first chapter covers some of the signif-icant historical developments and dares yet again tospeculate on the future ..What will be the next major step in automobileelectronic Systems ? I predicted that the auto-PC and telematics would be key factors last time, andthis is still the case. However, as 42 V Systems comeon line, there will be more Electrical control of Systems that until recently were mechanically orhydraulically operated steer-by-wire, for exam-ple. Read on to learn more ..Also, don t forget to visit where comments, questions andcontributions are always welcome. You will alsofind lots of useful information, updates and newsabout new books, as well as automotive softwareand web Denton, 4/22/04 3:00 PM Page ixThe book has grown again!

7 But then it was alwaysgoing to, because Automobile Electrical and elec-tronic Systems have grown. I have included just abit more coverage of basic Electrical technology inresponse to helpful comments received. This can beused as a way of learning the basics of Electrical andelectronic theory if you are new to the subject, or asan even more comprehensive reference source forthe more advanced user. The biggest change is thateven more case studies are included, some very newand others tried and tested but they all illustrateimportant has been a significant rationalization ofmotor vehicle qualifications since the second , with the move towards Technical Certifi-cates, this book has become more appropriatebecause of the higher technical content. AE&ES3 isideal for all MV qualifications, in particular: All maintenance and repair routes through themotor vehicle NVQ and Technical Certificates.

8 BTEC/Edexcel National and Higher Nationalqualifications. International MV qualifications such as C&G3905. Supplementary reading for MV degree needs of these qualifications are met becausethe book covers theoretical and practical sections are included for new users andadvanced sections are separated out for moreadvanced users, mainly so the new users are notscared off! Practice questions (written and multiplechoice) are now included that are similar to thoseused by awarding letting me know when you find the oddmistake or typo, but also let me know about new andinteresting technology as well as good web sites. I will continue to do the same on my site so keepdropping Denton, 2004 Introduction to the third 4/22/04 3:00 PM Page xI am very grateful to the following companies whohave supplied information and/or permission toreproduce photographs and/or diagrams, figurenumbers are as listed:AA Photo Library ; AC Delco Inc.

9 ; AlpineAudio Systems Ltd. ; Autodata Ltd. (table); Autologic Data Systems Ltd.; BMW UKLtd. ; C&K Components Inc. ; Citro n UKLtd. , , ; Clarion Car Audio Ltd. , ; Delphi Automotive Systems Inc. ;Eberspaecher GmbH. ; Fluke Instruments UKLtd. ; Ford Motor Company Ltd. , , , , ; General Motors , , , ; GenRad Ltd. , , ; Hella UK , ; Honda Cars UK Ltd. , ;Hyundai UK Ltd. ; Jaguar Cars Ltd. , , , ; Kavlico Corp. ; Lucas , , , , , , , , , , , , , , , , , , , , , , , , , , , , ; LucasVarity Ltd. , , , , , , ; Mazda Cars UK Ltd. , , ;Mercedes Cars UK Ltd. , , , ;Mitsubishi Cars UK Ltd. to ; NGK PlugsUK Ltd. , , , , , ; NissanCars UK Ltd. ; Peugeot UK Ltd. ; PhilipsUK Ltd.

10 ; Pioneer Radio Ltd. , , ; Porsche Cars UK Ltd. , ; RobertBosch GmbH. , , , , , , , , , , , , , , ;Robert Bosch Press Photos , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , ; Robert BoschUK Ltd. , , , , ; Rover Cars , , , , , , , , , , , , , , , , , , ; Saab Cars UK Ltd. , ;Scandmec Ltd. ; Snap-on Tools Inc. , ;Sofanou (France) ; Sun Electric UK Ltd. ;Thrust SSC Land Speed Team ; Toyota Cars UKLtd. , , , ; Tracker UK Ltd. ;Unipart Group Ltd. ; Valeo UK Ltd. , , , , , , , , , , , ; VDO Instruments ; Volvo CarsLtd. , , , , , ; ZFServomatic Ltd. if not all the companies here have goodweb pages.