xvi Modern Automotive Technology
Chapter 31
Starting System Diagnosis, Testing,
and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
Starting System Diagnosis . . . . . . . . . . . . . . . . . . . 515
Common 12-Volt Starting System Problems. 515
12-Volt Starting Headlight Test. . . . . . . . . . . . 516
Checking the 12-Volt Battery . . . . . . . . . . . . . 517
12-Volt Starting System Voltage Drop Tests . 518
12-Volt Battery Cable Service . . . . . . . . . . . . . . . . 519
Testing Battery Cables . . . . . . . . . . . . . . . . . . . 519
Replacing Battery Cables. . . . . . . . . . . . . . . . . 520
Starter Solenoid Service . . . . . . . . . . . . . . . . . . . . . 520
Testing the Starter Solenoid . . . . . . . . . . . . . . 520
Replacing the Starter Solenoid . . . . . . . . . . . . 520
Ignition Switch Service. . . . . . . . . . . . . . . . . . . . . . 521
Testing the Ignition Switch . . . . . . . . . . . . . . . 521
12-Volt Starter Relay Service . . . . . . . . . . . . . . . . . 521
Neutral Safety Switch Service . . . . . . . . . . . . . . . . 521
Testing the Neutral Safety Switch . . . . . . . . . 521
Adjusting the Neutral Safety Switch . . . . . . . 522
12-Volt Starter Service. . . . . . . . . . . . . . . . . . . . . . . 522
12-Volt Starting Motor Removal. . . . . . . . . . . 522
12-Volt Starting Motor Rebuild. . . . . . . . . . . . 522
Hybrid Starting System Diagnosis . . . . . . . . . . . . 528
Motor-Generator Problems . . . . . . . . . . . . . . . 528
Chapter 32
Charging System Technology . . . . . . . . . . . . . . 533
12-Volt Charging System Functions . . . . . . . . . . . 533
12-Volt Charging System . . . . . . . . . . . . . . . . . . . . 534
Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534
Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . 540
ECM Charging System Monitoring
and Control . . . . . . . . . . . . . . . . . . . . . . . . . . 542
Battery Thermistor . . . . . . . . . . . . . . . . . . . . . . 542
Fail-Safe Circuit. . . . . . . . . . . . . . . . . . . . . . . . . 542
Alternator Drive Belt . . . . . . . . . . . . . . . . . . . . 542
Charge Indicators . . . . . . . . . . . . . . . . . . . . . . . 543
Hybrid Charging Systems . . . . . . . . . . . . . . . . . . . 543
Chapter 33
Charging System Diagnosis, Testing,
and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 547
12-Volt Charging System Diagnosis . . . . . . . . . . . 547
Preliminary Inspection. . . . . . . . . . . . . . . . . . . 547
Scanning 12-Volt Charging Systems . . . . . . . 549
12-Volt Charging System Precautions . . . . . . . . . 549
12-Volt Charging System Tests . . . . . . . . . . . . . . . 549
12-Volt Charging System Output Test . . . . . . 550
Regulator Bypass Test . . . . . . . . . . . . . . . . . . . 551
12-Volt Charging System Scope Testing . . . . 552
12-Volt Charging System Voltmeter Test. . . . 552
12-Volt Circuit Resistance Tests . . . . . . . . . . . 552
Alternator Service . . . . . . . . . . . . . . . . . . . . . . . . . . 554
Alternator Removal . . . . . . . . . . . . . . . . . . . . . 555
Alternator Disassembly and Service . . . . . . . 555
Alternator Reassembly . . . . . . . . . . . . . . . . . . 559
Alternator Installation . . . . . . . . . . . . . . . . . . . 560
Voltage Regulator Service . . . . . . . . . . . . . . . . . . . 561
Hybrid Charging System Service . . . . . . . . . . . . . 562
Scanning Hybrid Charging Systems . . . . . . . 562
Measuring HV Battery Charging Voltage. . . 562
Measuring HV Charging Current . . . . . . . . . 564
Scope Testing a Hybrid Charging System. . . 565
Measuring Motor-Generator Resistance . . . . 566
Chapter 34
Ignition System Technology . . . . . . . . . . . . . . . 571
Ignition System Fundamentals . . . . . . . . . . . . . . . 571
Ignition System Operation . . . . . . . . . . . . . . . 572
Primary and Secondary Circuits . . . . . . . . . . 573
Ignition System Supply Voltage . . . . . . . . . . . 573
Bypass and Resistance Circuits . . . . . . . . . . . 573
Secondary Wires . . . . . . . . . . . . . . . . . . . . . . . . 573
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574
Ignition Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575
Ignition Coil Windings . . . . . . . . . . . . . . . . . . 575
Ignition Coil Operation . . . . . . . . . . . . . . . . . . 576
Ignition Coil Designs . . . . . . . . . . . . . . . . . . . . 577
Distributorless Ignition System. . . . . . . . . . . . . . . 577
Distributorless Ignition System Operation. . 578
Direct Ignition System . . . . . . . . . . . . . . . . . . . . . . 579
Ionization Knock Sensing . . . . . . . . . . . . . . . . 580
Dual Spark Plug Ignition. . . . . . . . . . . . . . . . . 581
Multiple Discharge Ignition . . . . . . . . . . . . . . 582
Distributor Ignition Systems . . . . . . . . . . . . . . . . . 582
Distributor Types . . . . . . . . . . . . . . . . . . . . . . . 582
Distributor Drives. . . . . . . . . . . . . . . . . . . . . . . 583
Contact Point Ignition Systems . . . . . . . . . . . 583
Electronic Ignition System. . . . . . . . . . . . . . . . 584
Crankshaft-Triggered Ignition . . . . . . . . . . . . 586
Distributor Cap and Rotor. . . . . . . . . . . . . . . . . . . 588
Engine Firing Order . . . . . . . . . . . . . . . . . . . . . . . . 588
Ignition Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 588
Electronic (Computer) Spark Advance . . . . . 589
Distributor Centrifugal
and Vacuum Advance. . . . . . . . . . . . . . . . . . 591
Base Ignition Timing . . . . . . . . . . . . . . . . . . . . 591