A Practical Approach to Motor Vehicle Engineering and Maintenance

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A Practical Approach to Motor Vehicle Engineering and Maintenance

Third Edition

Allan Bonnick Derek Newbold

AMSTERDAM  BOSTON  HEIDELBERG  LONDON  NEW YORK  OXFORD PARIS  SAN DIEGO  SAN FRANCISCO  SINGAPORE  SYDNEY  TOKYO
Butterworth-Heinemann is an imprint of Elsevier

Butterworth-Heinemann is an imprint of Elsevier The Boulevard, Langford Lane, Kidlington, Oxford, OX5 1GB, UK 225 Wyman Street, Waltham, MA 02451, USA First published by Arnold 2000 Reprinted 2002, 2003, 2004 Second edition 2005 Third edition 2011 Copyright 2011 Allan Bonnick and Derek Newbold. Published by Elsevier Ltd. All rights reserved The rights of Allan Bonnick and Derek Newbold to be identied as the authors of this work has been asserted in accordance with the Copyright, Designs and Patents Act 1988 No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or any information storage and retrieval system, without permission in writing from the publisher. Details on how to seek permission, further information about the Publishers permissions policies and our arrangement with organizations such as the Copyright Clearance Center and the Copyright Licensing Agency, can be found at our website: www.elsevier.com/permissions This book and the individual contributions contained in it are protected under copyright by the Publisher (other than as may be noted herein). Notices Knowledge and best practice in this eld are constantly changing. As new research and experience broaden our understanding, changes in research methods, professional practices, or medical treatment may become necessary. Practitioners and researchers must always rely on their own experience and knowledge in evaluating and using any information, methods, compounds, or experiments described herein. In using such information or methods they should be mindful of their own safety and the safety of others, including parties for whom they have a professional responsibility. To the fullest extent of the law, neither the Publisher nor the authors, contributors, or editors, assume any liability for any injury and/or damage to persons or property as a matter of products liability, negligence or otherwise, or from any use or operation of any methods, products, instructions, or ideas contained in the material herein. British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library Library of Congress Control Number: 2011924728 ISBN: 978-0-08-096998-5 For information on all Butterworth-Heinemann publications visit our website at www.elsevierdirect.com Printed and bound in the UK 11 12 13 14 10 9 8 7 6 5 4 3 2 1

Contents
Foreword Acknowledgements Introduction to the retail motor industry and Health and Safety at Work 1 Vehicle layouts and some simple vehicle structures Light vehicles Vehicle structure Passenger protection Vehicle shape End-of-Life Vehicles Directive Layout of engine and driveline Self-assessment questions 2 Engine principles Engine details The four-stroke Otto cycle The two-stroke cycle Two-stroke engine with valves Rotary engines The Atkinson engine cycle Self-assessment questions 3 The main moving parts of an engine Valves Cam and follower Valve springs Valve operating mechanisms The camshaft drive Pistons The crankshaft and ywheel assembly The connecting rod Self-assessment questions 4 Multi-cylinder engines Cylinder arrangements Engine structure e the main xed parts Self-assessment questions 5 Firing orders and engine balance Firing orders Crankshaft layout Vibrations and engine balance Self-assessment questions xiii xiv xv 1 1 1 1 4 4 5 7 8 8 8 14 15 16 16 17 19 19 19 20 22 23 25 30 30 32 37 37 37 46 47 47 47 48 53

vi 6

Contents Crankshaft, camshaft, and valve operating mechanisms Crankshaft Camshaft Self-assessment questions 54 54 58 62 67 67 68 69 69 69 70 70 70 70 71 72 74 74 75 76 77 80 81 81 82 82 82 83 84 85

A petrol fuel system The fuel tank Pump details Fuel return Mechanical fuel pump Pipes Filters Carbon canister Inertia switch Working with petrol Maintenance and repair Self-assessment questions

Motor fuels Fuels Factors affecting exhaust emissions Emissions and their causes Methods of controlling exhaust emissions Self-assessment questions

Carburettors The simple carburettor Rich or weak mixture Keeping the mixture strength constant Constant-choke carburettor Cold starts, idling, progression, and acceleration Constant-vacuum carburettor Self-assessment questions

10 Petrol injection e introduction Petrol injection systems Types of petrol injection system Single-point injection Multi-point injection Direct petrol injection Fuel system maintenance and repair Self-assessment questions 11 Air supply and exhaust systems Engine air supply systems (carburettor) Fuel-injected engine air intake system Variable-length induction tract Turbocharging Practical assignment e air supply and exhaust systems Self-assessment questions

87 87 89 89 91 96 97 100 101 101 103 104 105 107 108

Contents 12 Lubricants and engine lubrication Lubricants Boundary lubrication Hydrodynamic lubrication Sources of oil Types of oil Handling oil and disposal of waste Lubrication system Self-assessment questions 13 Cooling systems Overheating Heat transfer Over-cooling Types of cooling systems Engine air-cooling system Liquid cooling Comparison of air- and water-cooled systems Radiator and heater matrix Water pump Thermostat Pressurized cooling systems Fans and their operations Corrosion in the cooling system Antifreeze Engine temperature gauge Engine core plugs Servicing and maintaining the cooling system Heating and ventilation Interior heating and air-conditioning Heat losses Practical assignment e cooling systems Practical assignment e liquid cooling systems Self-assessment questions

vii 110 110 111 111 111 112 113 113 122 126 126 127 127 128 128 130 131 132 134 135 136 138 142 142 143 144 145 149 149 153 154 155 156

14 Internal combustion engines Engine power Dynamometers for high-speed engines Self-assessment questions

158 158 158 167

15 The compression ignition engine e diesel engine The four-stroke compression ignition engine The Diesel cycle and the dual combustion cycle The two-stroke CIE Diesel engine construction Turbulence Combustion in a compression ignition engine Diesel fuel and products of combustion Emissions limits Emissions control on the CIE Self-assessment questions

168 168 168 170 170 171 173 174 174 174 176

viii

Contents 177 177 189 193

16 Diesel fuel systems Diesel fuel systems Common rail diesel fuel system Self-assessment questions

17 Engine fault diagnosis Engine faults Mechanical condition Summary Self-assessment questions 18 Transmission The clutch Operating mechanisms Matching the engine to the road-going needs of the vehicle A basic gearbox The constant mesh and synchromesh gearbox Overdrive Transmitting the power to the driving wheels Propeller shafts and drive shafts Constant-velocity universal joints Axles and axle casings Final drive Differential Rear hub bearing and axle shaft arrangements Types of bearings used in the transmission system Practical assignment e removing a clutch Practical assignment e removing and retting a gearbox Practical assignment e axles and nal drives Self-assessment questions 19 Electronically controlled automatic transmission Fluid couplings Automatic gearbox Maintenance and fault tracing Self-assessment questions 20 Suspension systems Unsprung mass Non-independent suspension systems Independent suspension Suspension dampers Maintenance checks Practical assignment e suspension system Self-assessment questions 21 Braking systems Vehicle braking systems Types of brakes Hydraulic operation of brakes

198 198 198 204 205 208 208 211 213 214 215 219 219 225 225 227 227 228 229 231 235 235 235 236 237 237 239 243 246 248 248 248 250 257 260 260 261 263 263 263 264

Contents Wheel cylinders The handbrake Split braking systems The tandem master cylinder The brake uid reservoir Brake pipes and hoses The brake servo Brake adjustment Wear indicators Stop lamp switch Brake pressure control valve Brake uid Braking efciency Anti-lock braking system (ABS) Bleeding the brakes Practical assignment Self-assessment questions 22 Steering, wheels, and tyres Light vehicle steering layouts Steering geometry Ackermann principle Centre-point steering Steering roll radius Castor Wheel alignment Steering gearboxes Front-hub assemblies Light vehicle wheels Types of car wheels Wire wheels Wheel nut torque Tyres Wheel and tyre balance Tyre maintenance Self-assessment questions Practical assignment e steering worksheet 23 Power-assisted steering Hydraulic power-assisted steering ECU-controlled power-assisted steering Electric power-assisted steering Four-wheel steering Diagnostics Self-assessment questions 24 Computer (ECU)-controlled systems The fundamental parts of a computer A practical automotive computer system Engine management systems Traction control Electric throttle Stability control Self-assessment questions

ix 265 265 265 266 267 267 267 269 270 270 270 271 271 272 274 274 275 276 277 278 278 279 280 281 282 282 288 288 290 291 291 291 293 294 295 300 302 302 303 303 304 309 309 310 310 311 318 320 320 322 323

Contents 324 324 324 325 328 329 332 336 342

25 Electrical and electronic principles Electric current Electromotive force Effects of electric current e using electricity Measuring current and voltage Electricity and magnetism Alternating current Electronic principles Self-assessment questions

26 Vehicle electrical systems Vehicle batteries The alternator The starter motor Self-assessment questions

346 346 350 356 360

27 Ignition systems Ignition systems for spark ignition engines Fault tracing, maintenance, and repair of ignition systems Fault tracing in contact breaker ignition systems Some practical applications, i.e. doing the job Self-assessment questions

361 361 369 380 384 390

28 Electrical systems and circuits Central door-locking systems Screen wipers Screen washers Anti-theft devices Electrically operated door mirrors Electric horns Electrically operated windows Lighting Circuits and circuit principles Instrumentation Supplementary restraint systems (SRS) Self-assessment questions

392 392 393 396 399 399 400 402 402 408 416 418 422

29 Electrical and electronic fault diagnosis Diagnostics on ECU-controlled systems On-board diagnostics (OBD) Fault tracing in electrical circuits Self-assessment questions 30 Nuts, bolts, and spanners Dimensions of nuts, bolts, and spanners Screw threads Studs Lock nuts and other securing devices

424 424 424 426 433 434 434 434 434 435

Contents Taps and dies Drilling and tapping sizes Removing broken studs Thread restoration Screws Bolt, stud, and screw strength Tightening torques Self-assessment questions 31 Measuring instruments and measurement Measuring instruments Pressure gauges Belt tension gauge Cathode ray oscilloscope Digital multimeter Self-assessment questions 32 Motor industry organizations and career paths Qualications Modern motor vehicle qualications Career prospects Motor industry organizations Appendix A Appendix B List of acronyms Index

xi 435 436 436 436 437 438 438 439 441 441 448 450 450 451 455 457 457 457 458 459 460 462 463 465

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