Professional Documents
Culture Documents
Duffy
Automotive Writer
Publisher
Copyright 2009 by
The Goodheart-Willcox Company, Inc. Brand Disclaimer: Brand names, company names, and illustrations for products and services included in this text are provided for educational purposes only and do not represent or imply endorsement or recommendation by the author or the publisher. The Goodheart-Willcox Company, Inc. Safety Notice: The reader is expressly advised to carefully read, understand, and apply all safety precautions and warnings described in this book or that might also be indicated in undertaking the activities and exercises described herein to minimize risk of personal injury or injury to others. Common sense and good judgment should also be exercised and applied to help avoid all potential hazards. The reader should always refer to the appropriate manufacturer's technical information, directions, and recommendations; then proceed with care to follow specific equipment operating instructions. The reader should understand these notices and cautions are not exhaustive. The publisher makes no warranty or representation whatsoever, either expressed or implied, including but not limited to equipment, procedures, and applications described or referred to herein, their quality, performance, merchantability, or fitness for a particular purpose. The publisher assumes no responsibility for any changes, errors, or omissions in this book. The publisher specifically disclaims any liability whatsoever, including any direct, indirect, incidental, consequential, special, or exemplary damages resulting, in whole or in part, from the reader's use or reliance upon the information, instructions, procedures, warnings, cautions, applications, or other matter contained in this book. The publisher assumes no responsibility for the activities of the reader.
Library of Congress Cataloging-in-Publication Data Duffy, James E. Modern automotive technology / James E. Duffy. 7th ed. p. cm. Includes index. ISBN 978-1-59070-956-6 1. AutomobilesDesign and construction. 2. Automobiles Maintenance and repair. 3. Automobiles. I. Title. TL146.D84 2009 629.2' 3dc22 2008007116
Introduction
Welcome to the exciting, challenging world of automotive technology! You have selected a rewarding field of study. Modern Automotive Technology is an easy-tounderstand, up-to-date book summarizing the operation and repair of all makes and models of vehicles. The text uses a building-block approach that starts with the simple and progresses gradually to the more complex. Short sentences, concise definitions, and thousands of color illustrations will help you learn quickly and easily. Modern Automotive Technology is a valuable reference for anyone interested in the operation, construction, and repair of automobiles and light trucks. Vehicle owners who need a general guide to automotive service will find the book both interesting and informative. Those who are preparing for a career in automotive technology will find the text a "must." Experienced technicians can use it when preparing for the ASE certification tests. No longer can the untrained person hope to fix the modern automobile. Multiple on-board computers are now used to monitor and control the engine, transmission, suspension, braking, emission control, and other systems. Although computer systems are discussed in almost every chapter, three chaptersChapter 17, Computer System Fundamentals; Chapter 18, On-Board Diagnostics and Scan Tools; and Chapter 19, Computer System Serviceexplain the operation and service of these important systems in detail. Additionally, Chapter 46, Advanced Diagnostics, emphasizes the use of the latest diagnostic equipment and techniques to locate engine performance problems. A few of the other topics discussed in the text include anti-lock brakes, four-wheel steering, four-valve cylinders, active suspension systems, passive restraint systems, security systems, and navigation systems. The 2009 edition of Modern Automotive Technology is organized around the eight ASE automobile test areas and is correlated to the NATEF Task List.
Each automotive system is presented in two or more chapters. The first chapter explains the construction and operation of a specific system. The following chapter expands on this by detailing the troubleshooting and repair of the same system.
Chapter Components
Each chapter opens with a list of learning objectives. These objectives identify the topics covered and goals to be achieved in the chapter. Review the objectives before reading the chapter to determine what you can expect to learn. After completing the chapter, read the objectives once more and make sure you have met each objective. A summary is found at the end of each chapter. The summary highlights the material covered in the chapter. Review the summary after completing a chapter. A list of important terms is also included at the end of each chapter. The terms in the list appear in the order in which they are presented in the chapter. After completing a chapter, review each term. If a term cannot be defined, review the related section in the chapter.
Conventional review questions, as well as a separate section of ASE-type questions, are presented at the end of each chapter. After completing a chapter, answer all the questions on a separate sheet of paper. This is a great way of reviewing the material presented in the chapter. It will also help prepare you for the types of questions encountered on the ASE certification tests. Each chapter closes with a number of activities. These activities are automotive-related exercises that emphasize math and communication skills, as well as improve performance on the job.
Warning! Always wear eye protection when cleaning parts with power tools. Metal bristles, bits of carbon, or metal pieces from a broken tool or part can fly into your face. Other warning icons used in this text include: Face shield required.
Respirator required.
Special Notices
There are a variety of special notices used throughout this text. These notices contain technical information, cautions, warnings, and references to pertinent material in other parts of the text. The notices are identified by color and by an icon. A note may contain a reference to another section of the text that relates to the subject at hand. It may also highlight important technical information. For example: Note! For more information on on-board diagnostics, refer to Chapter 18, On-board Diagnostics and Scan Tools. A caution identifies a situation that may cause damage to a vehicle, equipment, or tools if the proper procedures are not followed. For example: Caution! Tighten an alternator belt only enough to prevent slippage. Overtightening is a common mistake that can quickly ruin alternator bearings. Cautions that warn against certain procedures or activities are identified by a "do not" icon: Caution! Do not disconnect the EFI harness terminal when the ignition switch is in the on position. This can damage the control module. A warning identifies repair operations that can result in personal injury if proper procedures or safety measures are not followed. For example: Warning! A steam cleaner operates at high pressures and temperatures. Follow the manufacturer's safety rules and operating instructions. When a warning refers to a particular danger or warns reader to wear protective gear, specific icons are used to help clearly identify the hazard. For example:
Fire hazard.
Explosion hazard.
Tech tips provide supplemental technical information and service hints related to the procedure or system being explained. For example: Tech Tip! Oxygen sensors should be replaced at periodic intervals. After prolonged service, they become coated with exhaust byproducts. As this happens, fuel economy and emissions will be adversely affected. If gas mileage is 10% to 15% lower than normal, suspect the oxygen sensor of slow response.
Repair Procedures
Procedures present common service and repair operations in an easy-to-follow, step-by-step format. For example: To perform an injector balance test: 1. Connect a pressure gauge to the test fitting on the fuel rail. 2. Close off the valve for measuring fuel volume if provided on the fuel gauge assembly. 3. Connect the balance tester wiring to the injectors or injector in question.
4. Turn the ignition key on to pressurize the system. Then, turn the ignition key off. 5. Press the injector balance tester button while watching the pressure gauge drop. 6. Record the pressure drop reading. 7. Repeat this on the other fuel injectors. This will allow you to measure how much fuel each injector is feeding into the engine when energized.
Customer CareHelps develop skills required to effectively interact with customers. Highway HistoryChronicles important milestones in the automobile industry. Accident ReportsEmphasizes the importance of working safely. Focus on HybridsHighlights the technologies used in hybrid gas-electric vehicles.
Troubleshooting Charts
Troubleshooting charts have been added to the end of each service chapter. These charts will help the reader diagnose and repair common problems.
Color Use
Color is used extensively throughout this text to enhance understanding and highlight important information. In illustrations, dark yellow is used for primary emphasis in illustrations and blue is used for secondary emphasis. Other colors are used as needed to help clarify the illustrations. For example, red arrows are often used to show motion. Color is also used to represent different pressures, states of matter, temperatures, etc.
Duff's Garage
This feature is designed to help reinforce logical troubleshooting techniques. Each Duff's Garage presents a common automotive problem, details the procedure for pinpointing the source trouble, and provides an overview of the necessary repairs.
Accident Report, Customer Care, Highway History, Industry Trends, Workplace Skills, and Focus on Hybrids Features
The new edition of the text contains a variety of features designed to generate interest in the field of automotive technology and cultivate the skills needed to succeed as an automotive technician. These features include: Industry TrendsHighlights new and emerging technologies in the automotive industry. Workplace SkillsHelps cultivate the skills needed to become a successful automotive technician.
Brief Contents
Section 1
Chapter 22. Gasoline Injection Fundamentals 340 Chapter 23. Gasoline Injection Diagnosis and Repair 371 Chapter 24. Carburetor Operation and Service 396 Chapter 25. Diesel Injection Fundamentals 410 Chapter 26. Diesel Injection Diagnosis, Service, and Repair 429 Chapter 27. Exhaust Systems, Turbochargers, and Superchargers 449 Section 5
Electrical Systems
Chapter Chapter Chapter Chapter Chapter Chapter 28. 29. 30. 31. 32. 33. Automotive Batteries 473 Battery Testing and Service 483 Starting System Fundamentals 499 Starting System Testing and Repair 513 Charging System Fundamentals 532 Charging System Diagnosis, Testing, and Repair 548 Ignition System Fundamentals 567 Ignition System Problems, Testing, and Repair 595 Lights, Instrumentation, Wipers, and HornsOperation and Service 631 Sound Systems and Power Accessories 667 Hybrid Drive System Operation and Service 694 Section 6
Engines
Chapter Chapter Chapter Chapter Chapter Chapter 11. 12. 13. 14. 15. 16. Engine Fundamentals 145 Engine Design Classifications 162 Engine Top End Construction 182 Engine Bottom End Construction 199 Engine Front End Construction 217 Engine Size and Performance Measurements 225 Section 3
Chapter 34. Chapter 35. Chapter 36. Chapter 37. Chapter 38.
Computer Systems
Chapter 17. Computer System Fundamentals 235 Chapter 18. On-Board Diagnostics and Scan Tools 261 Chapter 19. Computer System Service 282 Section 4
Fuel Systems
Chapter 20. Automotive Fuels, Gasoline and Diesel Combustion 301 Chapter 21. Fuel Tanks, Pumps, Lines, and Filters 315
Section 7
Engine Performance
Chapter 45. Engine Performance and Driveability Chapter 46. Advanced Diagnostics 871 Chapter 47. Engine Tune-Up 901 Section 9 859
Chapter 68. Suspension System Diagnosis and Repair 1302 Chapter 69. Steering System Fundamentals 1324 Chapter 70. Steering System Diagnosis and Repair 1347 Chapter 71. Brake System Fundamentals 1369 Chapter 72. Brake System Diagnosis and Repair 1394 Chapter 73. Anti-Lock Brakes, Traction Control, and Stability Control 1422 Chapter 74. Wheel Alignment 1445 Section 12
1280
Expanded Contents
Section 1 Introduction to Automotive Technology Chapter 1 T h e Automobile Parts, Assemblies, and Systems Hybrid Vehicle 18 Chapter 2 1 1
Chapter 4 Power Tools and Equipment Compressed-Air System 47 Air Tools 48 Electric Tools 50 Hydraulic Tools 52 Shop Equipment 53 Workplace Skills 57 Chapter 5 The Auto Shop and Safety Auto Shop Layout 60 Shop Safety 62 Types of Accidents 62 General Safety Rules 66 Customer Relations 67 Chapter 6 Automotive Measurement and Math Measuring Systems 70 Measuring Tools 72 Other Measurements and Measuring Tools 77 Using Basic Mathematics 79 Workplace Skills 82 Chapter 7 Service Information and Work Orders Service Manuals 85 Using a Service Manual 90 Service Publications 92 Technical Assistance Hotlines 92 Computer-Based Service Data 94 Work Orders 94 Workplace Skills 95
47
22 60
Automotive Careers and A S E Certification The Automotive Technician 22 Preparing for a Career in Automotive Technology 27 ASE Certification 27 Entrepreneurship 31 Workplace Skills 31 Chapter 3 Basic Hand Tools Tool Rules 34 Tool Storage 34 Wrenches 35 Screwdrivers 38 Pliers 39 Hammers 40 Chisels and Punches 40 Files 42 Saws 43 Holding Tools 43 Cleaning Tools 44 Probe and Pickup Tools 44 Pry Bars 45 Workplace Skills 45 34
70
85
Chapter 8 Basic Electricity and Electronics Electricity 97 Automotive Electronics 100 Automotive Wiring 103 Basic Electrical Tests 105 Oscilloscope 107 Scan Tools 108 Customer Relations 108 Chapter 9 Fasteners, Gaskets, Seals, and Sealants Fasteners 111 Washers 113 Machine Screws 114 Sheet Metal Screws 114 Nonthreaded Fasteners 114 Torquing Bolts and Nuts 115 Thread Repairs 117 Removing Damaged Fasteners 119 Gaskets and Seals 120 Workplace Skills 124 Chapter 10 Vehicle Maintenance, Fluid Service, and Recycling Lubrication Service 127 Vehicle Maintenance 127 Fluid Service 127 Filter Service 135 Chassis Lubrication 135 Service Intervals 136 General Inspection and Problem Location 137 Recycling and Disposal of Auto Shop Wastes 139 Duff's Garage 140 Section 2 Engines Chapter 11 Engine Fundamentals Engine Operation 145 Engine Bottom End 146 Engine Top End 152 Engine Front End 156 Workplace Skills 157 Chapter 12 Engine Design Classifications Engine Classifications 162 Cylinder Arrangement 162 Alternative Engines 169
97
173
182
Engine Top End Construction Cylinder Head Construction 182 Valve Train Construction 185 Intake Manifold Construction 195 Exhaust Manifold Construction 196 Workplace Skills 196 111 Chapter 14 Engine Bottom End Construction Cylinder Block Construction 200 Piston Construction 201 Piston Ring Construction 204 Piston Pin Construction 206 Connecting Rod Construction 207 Crankshaft Construction 209 Engine Bearing Construction 209 Rear Main Bearing Oil Seal Construction 212 Select-Fit Parts 213 Balancer Shafts 213 Workplace Skills 214 Chapter 15 Engine Front End Construction Vibration Damper Construction 217 Camshaft Drive Construction 218 Duff's Garage 222 Chapter 16 Engine Size and Performance Measurements Engine Size Measurement 225 Force, Work, and Power 226 Compression Ratio 227 Engine Torque 228 Horsepower 228 Engine Efficiency 230 Industry Trend 231 Section 3 Computer Systems Chapter 17 162 Computer System Fundamentals Cybernetics 235 Computer Advantages 236 Digital Electronics 237 Integrated Circuits 239 235 225 217 199
127
145
Computer Signals 239 Computer System Operation Sensors 244 Computers 249 Actuators 255 Highway History 257 Chapter 18
Chapter 22 243
340
267
282
Fuel Systems
Chapter 20 301
Chapter 26
429
Chapter 31
513
Section 5
Electrical Systems
Chapter 28
Automotive Batteries
Battery Principles 473 Battery Functions 474 Battery Construction 475 Wet- and Dry-Charged Batteries 478 Maintenance-Free Battery 479 Gel Battery 479 Absorbed Glass Mat Battery 479 Battery Ratings 479 Battery Temperature and Efficiency Focus on Hybrids 480
480
Chapter 29
483
Chapter 35
595
Ignition System Problems, Testing, and Repair Ignition System Problem Diagnosis 595 Preliminary Checks of Ignition System 595 Evaluating the Symptoms 599 Spark Plug Service 600 Secondary Wire Service 602 Distributor Service 603 Distributor Cap and Rotor Service 605 Electronic Ignition Distributor Service 606 Pickup Coil Service 606 Contact Point Distributor Service 608 Dwell 610 Ignition Timing Adjustment 611 Testing Centrifugal and Vacuum Distributor Advance Systems 614 Removing the Ignition Distributor 615 Rebuilding a Distributor 615 Ignition Supply Voltage Test 618 Ignition Coil (Coil Pack) Service 618 Ignition Switch Service 619 Ignition Control Module Service 620 Distributorless Ignition System Service 621 Direct Ignition System Service 622 Duff's Garage 622 Ignition System Diagnosis 627
Chapter 36 631
Reminder System 683 Cruise Control Systems 683 Power Mirrors 687 Cellular Mobile Telephone 687 Driver Information Center 688 Vehicle Degaussing 688 Duff's Garage 688 Sound System Diagnosis 693 Power Accessory Diagnosis 693 Chapter 38 694
Hybrid Drive System Operation and Repair Introduction 694 Hybrid System Voltages 698 Hybrid Drive Assemblies 699 Hybrid Service Safety 709 Hybrid Problem Diagnosis 711 Hybrid Battery Pack Service 711 Checking HV Battery Relays and Contactors 715 Servicing Hybrid Power Cables 716 Servicing the Power Control Module 716 Servicing the Hybrid Cooling System 716 Servicing the Motor-Generator 717 Hybrid Wiring Problems 718
Section 6
Cooling and Lubrication Systems Lights, Instrumentation, Wipers, and HornsOperation and Service Lighting Systems 632 Light System Service 641 Instrumentation 647 Windshield Wipers 654 Horns 658 Theft-Deterrent Systems 659 Finding Common Electrical Problems 659 Duff's Garage 661 Headlamp Diagnosis 665 Turn Signal Diagnosis 666
Chapter 37 667 Chapter 39 725
Cooling System Fundamentals Cooling System Functions 725 Cooling System Operation 726 Cooling System Types 727 Basic Cooling System 727 Closed and Open Cooling Systems 733 Cooling System Instrumentation 738 Antifreeze 739 Block Heater 740 Focus on Hybrids 740
Chapter 40 745
Sound Systems and Power Accessories Sound Systems 667 Power Seats 674 Power Windows 675 Power Door Locks 678 Power Trunk Release 681 Power Steering Wheel 681 Rear Window Defogger 681 Heated Windshield 683
Cooling System Testing, Maintenance, and Repair Cooling System Problem Diagnosis 745 Cooling System Problems 746 Water Pump Service 750 Thermostat Service 751 Cooling System Hose Service 754 Radiator and Pressure Cap Service 755 Fan Belt Service 756 Engine Fan Service 757
Freeze Plug Service 758 Coolant Service 759 Flushing a Cooling System 761 Temperature Gauge Service 762 Duff's Garage 763 Cooling System Diagnosis 766 Chapter 41 Lubrication System Fundamentals Lubrication System Functions 768 Lubrication System Operation 768 Positive Crankcase Ventilation System 780 Oil Pressure Indicator 781 Industry Trend 783 Chapter 42 Lubrication System Testing, Service, and Repair Lubrication System Problem Diagnosis 786 Engine Oil and Filter Service 790 Oil Pan Service 791 Oil Pump Service 793 Pressure Relief Valve Service 797 Oil Pressure Indicator and Gauge Service 798 PCV Valve Service 799 Duff's Garage 799 Lubrication System Diagnosis 801 786 768
Chapter 44
831
Emission Control System Testing, Service, and Repair Computer-Controlled Emission System Service 831 Emission Maintenance Reminder 832 Inspecting Emission Control Systems 832 Exhaust Gas Analyzer 833 State Emissions Testing Programs 837 Vacuum Solenoid Service 840 PCV System Service 842 Evaporative Emissions Control System Service 843 Thermostatic Air Cleaner System Service 844 EGR System Service 845 Air Injection System Service 846 Pulse Air System Service 847 Catalytic Converter Service 847 Oxygen Sensor Service 849 Emission Control Information Sticker 852 OBD II Drive Cycle 852 Duff's Garage 853 Emission Control System Diagnosis 856
Section 8 Engine Performance Chapter 45 Engine Performance and Driveability Locating Engine Performance Problems 859 Typical Performance Problems 863 Other Performance Problems 866 Workplace Skills 866 Engine Performance Diagnosis 870 Chapter 46 Advanced Diagnostics Advanced Diagnostics 871 Duff's Garage 896 Chapter 47 Engine Tune-Up Engine Tune-Up 901 General Tune-Up Rules 903 Tune-Up Safety Rules 903 Typical Tune-Up Procedures 904 Diesel Engine Tune-Up (Maintenance) 908 Engine Tune-Up (Maintenance) Intervals 909 Duff's Garage 909 901 871 859
Section 7 Emission Control Systems Chapter 43 Emission Control Systems Air Pollution 803 Motor Vehicle Emissions 803 Engine Modifications Related to Emission Control 805 Vehicle Emission Control Systems 806 Positive Crankcase Ventilation (PCV) 806 Evaporative Emissions Control Systems 808 Exhaust Gas Recirculation (EGR) 811 Air Injection System 815 Pulse Air System 817 Thermostatic Air Cleaner System 818 Catalytic Converter 818 Computerized Emission Control Systems 821 OBD II Emission System Monitoring 826 Highway History 828 803
Section 9
Valve Adjustment 993 Installing Valve Covers 996 Duff's Garage 997 Chapter 52 1001
Clutch Fundamentals
Clutch Principles 1017 Clutch Construction 1019 Workplace Skills 1028 Chapter 54 1031 1031
971
1070
Manual Transmission Service 1072 Adjusting Transmission Linkage 1078 Duff's Garage 1078 Manual Transmission/Transaxle Diagnosis Chapter 57
Front Drive AxleFour-Wheel-Drive Vehicles Workplace Skills 1168 1081 1083 Chapter 62
1168 1173
Automatic Transmission F u n d a m e n t a l s Basic Automatic Transmission 1083 Hydraulic System 1095 Parking Pawl 1100 Automatic Transmission Power Flow 1100 Electronic Transmission Control 1100 Continuously Variable Transmission 1103 Complete Transmission Assemblies 1105 Highway History 1105 Chapter 58 Automatic Transmission Service Automatic Transmission Identification 1110 Automatic Transmission Diagnosis 1110 Automatic Transmission Maintenance 1116 Major Transmission Service 1123 Duff's Garage 1124 Automatic Transmission and Transaxle Diagnosis Chapter 59 Drive Shafts and Transfer C a s e s Drive Shaft Assembly 1131 Drivelines 1137 Transfer Cases 1137 Industry Trend 1141 Chapter 60 1144 1110
Differential and Rear Drive Axle Diagnosis and Repair Differential and Rear Axle Problem Diagnosis 1173 Differential Maintenance 1175 Rear Axle Service 1176 Differential Service 1179 Duff's Garage 1187 Rear Axle Diagnosis 1191 Chapter 63 Transaxle and Front Drive Axle Fundamentals Transaxle 1193 Manual Transaxle 1195 Automatic Transaxle 1201 Front Drive Axle Assembly 1210 Focus on Hybrids 1213 Chapter 64 1217 1193
1130 1131
Transaxle and Front Drive Axle Diagnosis a n d Repair Transaxle Problem Diagnosis 1217 Front Drive Axle Problems 1219 Transaxle Maintenance 1219 Front Drive Axle Service 1222 Transaxle Removal 1228 Transaxle Service 1228 Transaxle Installation 1229 Duff's Garage 1229 Automatic Transmission and Transaxle Diagnosis Section 11 Suspension, Steering, and Brakes Chapter 65 Tire, W h e e l , and W h e e l Bearing Fundamentals Tires 1241 Wheels 1248 Valve Stems and Cores 1249 Lug Nuts, Studs, and Bolts 1250 Wheel Weights 1250 Hub and Wheel Bearing Assemblies 1250 Highway History 1253 Chapter 66 Tire, W h e e l , and W h e e l Bearing Service Tire, Wheel, and Wheel Bearing Diagnosis 1257 Wheel Cover Removal and Installation 1260 1257 1241
Drive Shaft and Transfer C a s e Diagnosis, Service, a n d Repair Drive Shaft Problems 1144 Drive Shaft Inspection 1145 Drive Shaft Maintenance 1147 Drive Shaft Service 1147 Transfer Case Service 1150 Duff's Garage 1151 Drive Line Problem Diagnosis 1155 Transfer Case Diagnosis Part-Time Drive 1155 Transfer Case Diagnosis Full-Time Drive 1156 Chapter 61 Differential and Rear Drive Axle Fundamentals Basic Rear Drive Axle Assembly 1157 Differential Construction 1158 Differential Action 1162 Limited-Slip Differentials 1162 Rear Drive Axles 1166 1157
1236
Tire Maintenance 1260 Measuring Tire and Wheel Runout 1261 Wheel Balance 1262 Mounting and Dismounting Tires 1265 Tire Puncture Repair 1266 Wheel Bearing Service 1268 Duff's Garage 1273 Tire, Wheel, and Bearing Diagnosis 1277 Chapter 67 1280
Electronic Steering Assist 1341 Four-Wheel Steering Systems 1342 Industry Trend 1344 Chapter 70 1347
1439
1337
Chapter 74 Wheel Alignment Wheel Alignment Principles 1445 Caster 1445 Camber 1447 Toe 1447 Steering Axis Inclination 1448 Setback 1448 Toe-Out on Turns (Turning Radius) 1449 Tracking 1449 Prealignment Inspection 1449 Adjusting Wheel Alignment 1452 Wheel Alignment Tools and Equipment 1455 Alignment Machines 1457 Road Test after Alignment 1460 Duff's Garage 1460 Wheel Alignment Diagnosis 1465 Section 12 Heating and Air Conditioning Chapter 75 Heating and Air Conditioning Fundamentals Principles of Refrigeration 1469 Basic Refrigeration Cycle 1471 Automotive Air Conditioning System 1473 Air Conditioning System Controls 1480 Service Valves 1483 Heating System 1483 Heating and Air Conditioning Controls 1483 Ducts and Vents 1486 Passenger Compartment Filters 1486 Solar Ventilation 1486 Focus on Hybrids 1488 Chapter 76 Heating and Air Conditioning Service Inspecting an Air Conditioning System 1493 Refrigerant Safety Precautions 1495 R-134a Service Differences 1495 Testing an Air Conditioning System 1497 Recovering Refrigerant 1502 Common A/C Component Problems 1503 Evacuating an Air Conditioning System 1507 Charging an Air Conditioning System 1507 Adding Refrigerant Oil 1509 A/C System Service Rules 1509 Heater Service 1510 Electronic Climate Control Service 1511
1445
1517
Safety, Security, and Navigation Systems Chapter 77 Restraint Systems Vehicle Collisions 1521 Active and Passive Restraints Seat Belt Systems 1523 Knee Diverter 1523 Air Bag Systems 1525 Air Bag Sensors 1529 Air Bag Controller 1530 Industry Trend 1531 Chapter 78 1534 Restraint System Service Seat Belt Service 1534 Air Bag System Service 1535 Air Bag Module Service 1536 Air Bag Sensor Service 1538 Air Bag Controller Service 1540 Duff's Garage 1540 Restraint System Diagnosis 1543 Chapter 79 Security and Navigation Systems, New and Future Technologies Security Systems 1544 Navigation Systems 1547 Future Systems 1548 Alternate Power Sources 1551 Industry Trend 1554 Security System Diagnosis 1556 Chapter 80 Career Success Traits of Desirable Employees 1557 Earnings 1559 Types of Shops 1559 Getting a Job as an Automobile Technician Reference Section Glossary of Terms Internet Resources Acknowledgments Index 1591 1564 1568 1589 1590 1557 1544 1521
1523
1469
1493
1560
Section 1
1. The Automobile 2. Automotive Careers and ASE Certification 3. Basic Hand Tools 4. Power Tools and Equipment 5. The Auto Shop and Safety 6. Automotive Measurement and Math 7. Service Information and Work Orders 8. Basic Electricity and Electronics 9. Fasteners, Gaskets, Seals, and Sealants 10. Vehicle Maintenance, Fluid Service, and Recycling
We are truly living in a "world of wheels." Every day, millions of people depend on their cars, trucks, vans, and sport-utility vehicles as their primary means of transportation. As a result, economic experts predict a strong demand for skilled automobile technicians and related professionals for the foreseeable future. You have chosen to study an area of employment that pays well and will require thousands of new graduates yearly. Section 1 will introduce you to the "basics" of automotive technology. It contains information on automobile construction and operation, ASE certification, safety, tools, service information, electricity, and vehicle maintenance. This section will give you the knowledge needed to secure an entry-level job. It will also lay the groundwork for later chapters, which provide indepth coverage of automotive technology.
The Automobile
After studying this chapter, you will be able to: Identify and locate the most important parts of a vehicle. Describe the purpose of the fundamental automotive systems. Explain the interaction of automotive systems. Describe major automobile design variations. Comprehend later text chapters with a minimum amount of difficulty. Correctly answer ASE certification test questions that require a knowledge of the major parts and systems of a vehicle. The term automobile is derived from the Greek word autos, which means self, and the French word mobile, which means moving. Today's "self-moving" vehicles are engineering marvels of safety and dependability. Over the last century, engineers and skilled workers the world over have used all facets of technology (the application of math, science, physics, and other subjects) to steadily give us a better means of transportation. You are about to begin your study of the design, construction, service, maintenance, and repair of the modern automobile. This chapter provides a "quick look" at the major automotive systems. By knowing a little about each of these systems, you will be better prepared to learn the more detailed information presented later in this text. Today, failure of one system can affect the operation of a seemingly unrelated system. This makes a thorough understanding of how the whole automobile works especially important. Tech Tip! Try to learn something new about automotive technology every day. In addition to studying this book and doing the hands-on activities, read automotive magazines, "surf' the Internet, and watch "motor-sport" television programs. This will help you become a better technician by increasing your knowledge daily.
Assembly Figure 1-1. An assembly is a group of parts that work together to perform a function. For example, an engine is an assembly that contains pistons, which convert the fuel's heat energy into useable kinetic energy (motion). As you will learn, an engine has many other parts. (Saturn)
For example, your vehicle's steering system contains the steering wheel, steering shaft, steering gears, linkage rods, and other parts. These parts allow you to control the direction of the wheels and tires for maneuvering (turning) your vehicle. Another example of a familiar system is the brake system. This system is a group of parts that performs a very important taskslowing and stopping your vehicle quickly and safely. Figure 1-2 shows the major systems of a vehicle. Memorize the name and general location of each system. Automotive parts and systems can be organized into ten major categories: Body and framesupport and enclose the vehicle. Engineprovides dependable, efficient power for the vehicle. Computer systemsmonitor and control various vehicle systems. Fuel systemprovides a combustible air-fuel mixture to power the engine. Electrical systemgenerates and/or distributes the power needed to operate the vehicle's electrical and electronic components. Cooling and lubrication systemsprevent engine damage and wear by regulating engine operating temperature and reducing friction between internal engine parts.
Exhaust and emission control systemsquiet engine noise and reduce toxic substances emitted by the vehicle. Drive train systemstransfer power from the engine to the drive wheels. Suspension, steering, and brake systemssupport and control the vehicle. Accessory and safety systemsincrease occupant comfort, safety, security, and convenience.
Throttle body
Air in Fuel tank Fuel system Ignition system Transmission Drive train system Clutch Engine
Fuel pump
Starting system Exhaust manifold Oil pan Catalytic converter Cooling system Charging system
Figure 1-2. Note the general location of the major vehicle systems. Study the flow of fuel, air, exhaust, and power.
Engine
Frame
Gas tank
Tire
Wheel
Figure 1-3. Compare body-over-frame and unibody construction. AIn body-over-frame construction, the chassis parts bolt to a strong perimeter frame. The body bolts to this thick steel frame. BUnibody vehicles do not have a separate perimeter frame. Chassis components bolt directly to the unibody assembly. (DaimlerChrysler, Saab)
In body-over-frame construction, the frame consists of thick steel members. The chassis parts and the body bolt to this frame. Also called full frame construction or perimeter frame construction, this design is heavy but strong. Body-over-frame construction is used on full-size cars, vans, pickup trucks, and sport-utility vehicles (SUVs). See Figure 1-3A. With unibody construction, sheet metal body panels are welded together to form the body and frame. Also called space frame construction or unitized construction, this is the most common type of configuration used to build small and medium passenger cars. Unibody construction reduces weight, improves fuel economy, and has a high strength-to-weight ratio. However, unibody
vehicles are not as strong as those with body-over-frame construction. See Figure 1-3B.
Body Types
Automobiles are available in several body types, including the sedan, hardtop, convertible, hatchback, and station wagon. In addition, the minivan, the sport-utility vehicle, and the pickup truck have become increasingly popular. A sedan is a car that has front and back seats and will carry four to six people. It has center body pillars, or "B" pillars, between the front and rear doors, Figure 1-4A. Both two-door and four-door sedans are available.
Figure 1-4. Note the various vehicle body styles. ASedan. BConvertible. CHatchback. DStation wagon. EMinivan. FSport-utility vehicle. (Toyota, Ford, Honda, Mazda)
A hardtop is similar to the sedan, but it has no "B" pillars. Hardtop vehicles are also available in both twoand four-door models. A convertible has a vinyl or cloth top that can be raised and lowered. A convertible has no door pillars, and its strength is designed into the frame or floor pan. Although most convertibles are two-door models, Figure 1-4B, a few four-door convertibles have been produced. A hatchback, or liftback, has a large rear door for easy access when hauling items. This style car is available in three- and five-door models, Figure 1-4C. A station wagon has a long, straight roof that extends to the rear of the vehicle. Station wagons have large rear interior compartments and come in two- and four-door models. Some station wagons have space for up to nine passengers, see Figure 1-4D. The minivan is similar to the station wagon, but it has a higher roofline for more headroom and cargo space. Most minivans are designed to carry seven passengers. See Figure 1-4E. Sport-utility vehicles are often equipped with fourwheel-drive systems and have a tall body design. They provide the comfort of a passenger car, the interior space of a station wagon, and the durability of a truck, Figure 1-4F. Common names for various automobile body parts are shown in Figure 1-5. Note that a vehicle's right and left sides are denoted as if you were sitting in the car looking forward.
Engine
The engine provides the energy to propel (move) the vehicle and operate the other systems. Most engines consume gasoline or diesel fuel. The fuel burns in the engine to produce heat. This heat causes gas expansion, creating pressure inside the engine. The pressure moves internal engine parts to produce power. See Figure 1-6. The engine is usually located in the front portion of the body. Placing the heavy engine in this position makes the vehicle safer in the event of a head-on collision. In a few vehicles, the engine is mounted in the rear to improve handling. Refer to Figure 1-7.
Front bumper Left front fender Right front fender Hood
Gasoline
(Carbon) (Hydrogen) Air (Oxygen) (Nitrogen) (Argon) (Carbon Dioxide) (etc.)
Nitrogen Water
Left rear door Left rear quarter Trunk lid Rear bumper
(Hydrogen) (Oxygen)
Combustion
Pollutants
(Hydrocarbons) (Carbon Monoxide) (Oxides of Nitrogen) Figure 1-6. An automotive engine commonly burns gasoline or diesel fuel to produce power. (Ford)
Figure 1-5. The right and left sides of a vehicle are denoted as if you were sitting forward inside passenger compartment.
The cylinder head covers and seals the top of the cylinder. It also holds the valves, rocker arms, and often, the camshaft. The combustion chamber is a small cavity (hollow area) between the top of the piston and the bottom of the cylinder head. The burning of the air-fuel mixture occurs in the combustion chamber. The valves open and close to control the flow of the air-fuel mixture into the combustion chamber and the exhaust gases out of the combustion chamber. The camshaft controls the opening of the valves. The valve springs keep the valves closed when they do not need to be open. The rocker arms transfer camshaft action to the valves. The lifters, or followers, ride on the camshaft and transfer motion to the other parts of the valve train. The flywheel helps keep the crankshaft turning smoothly. It also provides a large gear for the starting motor.
Four-Stroke Cycle
Automobile engines normally use a four-stroke cycle. Four separate piston strokes (up or down movements) are needed to produce one cycle (complete series of events). The piston must slide down, up, down, and up again to complete one cycle. As the four strokes are described below, study the simple drawings in Figure 1-9. 1. The intake stroke draws the air-fuel mixture into the engine's combustion chamber. The piston slides down while the intake valve is open and the exhaust valve is closed. This produces a vacuum (low-pressure area) in the cylinder. Atmospheric pressure (outside air pressure) can then force air and fuel into the combustion chamber. 2. The compression stroke prepares the air-fuel mixture for combustion. With both valves closed, the piston slides upward and compresses (squeezes) the trapped air-fuel mixture.
Lifters Camshaft
Rocker arms
Block
Cylinder
Crankshaft
Rear engine, rear-wheel drive Figure 1-7. The engine can be located in the front or rear of the vehicle. (Dana Corp.)
Flywheel Figure 1-8. Memorize the basic parts of this one-cylinder engine.
1Intake stroke. Intake valve open. Exhaust valve closed. Piston slides down, forming vacuum in cylinder. Atmospheric pressure pushes air and fuel into combustion chamber. Both valves closed
2Compression stroke. Both valves are closed. Piston slides up and pressurizes air-fuel mixture. This readies mixture for combustion. Intake valve closed Exhaust valve open
Spark plug fires, mixture burns and expands Piston forces rod down and turns crankshaft
Piston slides up and pushes burned gases out 4Exhaust stroke. Exhaust valve opens. Intake valve remains closed. Piston slides up, pushing burned gases out of cylinder. This prepares combustion chamber for another intake stroke.
3Power stroke. Spark plug sparks. Air-fuel mixture burns. High pressure forces piston down with tremendous force. Crankshaft rotates under power.
Figure 1-9. A gasoline engine normally operates on a four-stroke cycle. Study the series of events.
3. The power stroke produces the energy to operate the engine. With both valves still closed, the spark plug arcs (sparks) and ignites the compressed air-fuel mixture. The burning fuel expands and develops pressure in the combustion chamber and on the top of the piston. This pushes the piston down with enough force to keep the crankshaft spinning until the next power stroke. 4. The exhaust stroke removes the burned gases from the combustion chamber. During this stroke, the piston slides up while the exhaust
valve is open and the intake valve is closed. The burned fuel mixture is pushed out of the engine and into the exhaust system. During engine operation, these four strokes are repeated over and over. With the help of the heavy flywheel, this action produces smooth, rotating power output at the engine crankshaft. Obviously, other devices are needed to lubricate the engine parts, operate the spark plug, cool the engine, and provide the correct fuel mixture. These devices will be discussed shortly.
Automotive Engines
Unlike the basic one-cylinder engine just discussed, automotive engines are multi-cylinder engines, which means they have more than one piston and cylinder. Vehicles commonly have 4-, 6-, 8-, or 10-cylinder engines. The additional cylinders smooth engine operation
because there is less time (degrees of crankshaft rotation) between power strokes. Additional cylinders also increase power output. An actual automotive engine is pictured in Figure 1-10. Study the shape, location, and relationship of the major parts.
Throttle valve
Intake manifold
Exhaust manifold
Oil pan Figure 1-10. Automotive engines are multi-cylinder engines. Locate the major parts and visualize their operation. (Ford)
Computer System
The computer system uses electronic and electrical devices to monitor and control various systems in the vehicle, including the fuel, ignition, drive train, safety, and security systems. See Figure 1-11. The use of computer systems has improved vehicle efficiency and dependability. Additionally, most of these systems have self-diagnostic capabilities. There are three major parts of an automotive computer system: Sensorsinput devices that can produce or modify electrical signals with a change in a condition, such as motion, temperature, pressure, etc. The sensors are the "eyes, ears, and nose" of the computer system. Control modulecomputer (electronic circuit) that uses signals from input devices (sensors) to control various output devices. The control module is the "brain" of the computer system. Actuatorsoutput devices, such as small electric motors, that can move parts when energized by the control module. The actuators serve as the "hands and arms" of the computer system.
Tech Tip! Learn all you can about electricity and electronics. Nearly every automotive system is now monitored or controlled by a computer. It is almost impossible to service any system of a car without handling some type of electric or electronic component. This book covers electronics in almost every chapter.
Fuel System
The fuel system must provide the correct mixture of air and fuel for efficient combustion (burning). This system must add the right amount of fuel to the air entering the cylinders. This ensures that a very volatile (burnable) mixture enters the combustion chambers. The fuel system must also alter the air-fuel ratio (percentage of air and fuel) with changes in operating conditions (engine temperature, speed, load, and other variables). There are three basic types of automotive fuel systems: gasoline injection systems, diesel injection systems, and carburetor systems. Look at the three illustrations in Figure 1-12.
A modern car can have several control modules and dozens of sensors and actuators. These components will be detailed throughout this book.
Sensing
Control
Vehicle speed sensor Figure 1-11. This computer-controlled lock system automatically locks the doors as soon as the vehicle starts moving. When the gear shift sensor and the vehicle speed sensor send the correct signals to the control module, the module energizes the solenoid (actuator). The solenoid then converts the electrical signal from the control module to a linear motion, locking the doors.
When open, fuel injector (fuel valve) sprays fuel toward intake valve Throttle valve
Wires to engine sensors Computer AGasoline injection system. Engine sensors feed information (electrical signals) to computer about engine conditions. Computer can then open injector for right amount of time. This maintains correct air-fuel ratio. Spark plug ignites fuel. Mechanical injection nozzle sprays fuel into combustion chamber Injection line
Air enters
No throttle used
Only air flows past intake valve and into combustion chamber Air compressed so tight it becomes red hot
BDiesel injection system. High-pressure mechanical pump sprays fuel directly into combustion chamber. Piston squeezes and heats air enough to ignite diesel fuel. Fuel begins to burn as soon as it touches heated air. Note that no throttle valve or spark plug is used. Amount of fuel injected into chamber controls diesel engine power and speed. Air enters filter Fuel line Carburetor
Fuel pulled into airstream by vacuum Throttle controls airflow and engine speed Air-fuel mixture flows to cylinder
Low-pressure mechanical fuel pump Gasoline from tank Mixture ignited by spark plug
CCarburetor fuel system. Fuel pump fills carburetor with fuel. When air flows through carburetor, fuel is pulled into engine in correct proportions. Throttle valve controls airflow and engine power output. Figure 1-12. Note the three basic types of fuel systems. Compare differences.
pressure produced during the compression stroke to heat the air in the combustion chamber. The air is squeezed until it is hot enough to ignite the fuel. Refer to Figure 1-12B. When the mechanical pump sprays the diesel fuel into a combustion chamber, the hot air in the chamber causes the fuel to begin to burn. The burning fuel expands and forces the piston down on the power stroke. Electronic devices are commonly used to monitor and help control the operation of today's diesel injection systems.
Electrical
System
The vehicle's electrical system consists of several subsystems (smaller circuits): ignition system, starting system, charging system, and lighting system. Each subsystem is designed to perform a specific function, such as "fire" the spark plugs to ignite the engine's fuel mixture, rotate the crankshaft to start the engine, illuminate the highway for safe night driving, etc.
Ignition switch
Secondary wire
Spark plug
Resistor
Trigger wheel
Electric arc Battery Crankshaft position sensor Figure 1-13. The ignition system is used on gasoline engines to start combustion. The spark plug must fire at the correct time during the compression stroke. A crankshaft position sensor or a distributor operates the ignition module. The module operates the ignition coil. The coil produces high voltage for the spark plugs.
trigger the ignition coil. When triggered, the ignition coil produces a high voltage output to "fire" the spark plugs. When the ignition key is turned off, the coil stops functioning and the spark-ignition engine stops running.
produce electricity to recharge the battery and operate other electrical needs of the vehicle. A voltage regulator, usually built into the alternator, controls the voltage and current output of the alternator.
Starting System
The starting system has a powerful electric starting motor that rotates the engine crankshaft until the engine "fires" and runs on its own power. The major parts of the starting system are shown in Figure 1-14A. A battery provides the electricity for the starting system. When the key is turned to the start position, current flows through the starting system circuit. The starting motor is energized, and the starting motor pinion gear engages a gear on the engine flywheel. This spins the crankshaft. As soon as the engine starts, the driver must shut off the starting system by releasing the ignition key.
Lighting System
The lighting system consists of the components that operate a vehicle's interior and exterior lights (fuses, wires, switches, relays, etc.). The exact circuit and part configurations will vary from one model to another. The exterior lights typically include the headlights, turn signals, brake lights, parking lights, backup lights, and side marker lights. The interior lights include the dome light, trunk light, instrument panel lights, and other courtesy lights.
Charging System
The charging system is needed to replace electrical energy drawn from the battery during starting system operation. To re-energize the battery, the charging system forces electric current back into the battery. The fundamental parts of the charging system are shown in Figure 1-14B. Study them! When the engine is running, a drive belt spins the alternator pulley. The alternator (generator) can then
Ignition switch
Figure 1-14. Note the basic actions and components of the starting and charging systems.
radiator. The coolant collects heat from the hot engine parts and carries it back to the radiator. The radiator allows the coolant heat to transfer into the outside air. An engine fan draws cool air through the radiator. The thermostat controls coolant flow and engine temperature. It is usually located where the top radiator hose connects to the engine. The lubrication system reduces friction and wear between internal engine parts by circulating filtered engine oil to high-friction points in the engine. The lubrication system also helps cool the engine by carrying heat away from internal engine parts. Study the parts and operation of the lubrication system shown in Figure 1-16. Note how the oil pump pulls oil out of the pan and pushes it to various moving parts of the engine.
gases from the engine exhaust manifold to the tailpipe. Learn the names of the parts. Various emission control systems are used to reduce the amount of toxic (poisonous) substances produced by an engine. Some systems prevent fuel vapors from entering the atmosphere (air surrounding the earth). Other emission control systems remove unburned and partially burned fuel from the engine exhaust. Later chapters cover these systems in detail.
Clutch
The clutch allows the driver to engage or disengage the engine and manual transmission or transaxle. When the clutch pedal is in the released position, the clutch locks the engine flywheel and the transmission input shaft together. This causes engine power to rotate the transmission gears and other parts of the drive train to propel the vehicle. When the driver presses the clutch pedal, the clutch disengages power flow and the engine no longer turns the transmission input shaft and gears.
Water pump
Fan
Transmission
The transmission uses various gear combinations, or ratios, to multiply engine speed and torque to accommodate driving conditions. Low gear ratios allow the vehicle to accelerate quickly. High gear ratios permit lower engine speed, providing good gas mileage. A manual transmission lets the driver change gear ratios to better accommodate driving conditions, Figure 1-19. An automatic transmission, on the other hand, does not have to be shifted by the driver. It uses an internal hydraulic system and, in most cases, electronic controls to shift gears. The input shaft of an automatic transmission is connected to the engine crankshaft through a torque converter (fluid coupling) instead of a clutch. The elementary parts of an automatic transmission are pictured in Figure 1-20.
Crankshaft Figure 1-15. The cooling system must protect the engine from the heat of combustion. Combustion heat could melt and ruin engine parts. The system must also speed warm-up and maintain a constant operating temperature. Study the part names.
Drive Shaft
The drive shaft, or propeller shaft, transfers power from the transmission to the rear axle assembly. Look at
To turbocharger
Camshaft (for exhaust valves)
Oil filter
Piston
Oil screen
Figure 1-16. The lubrication system uses oil to reduce friction and wear. The pump forces oil to high-friction points.
Intermediate pipes
Exhaust manifolds
Figure 1-17. The exhaust system carries burned gases to the rear of the vehicle. It also reduces engine noise. (Nissan)
Transmission
Clutch
Engine
Differential
Manual transmission
Drive shaft
Differential
Dead axle
Figure 1-18. The drive train transfers engine power to the drive wheels. Study the differences between the two common types of drive trains. AFront-engine, rear-wheel-drive vehicle. B Front-engine, front-wheel-drive vehicle.
Figure 1-19. A manual transmission uses gears and shafts to achieve various gear ratios. The speed of the output shaft compared to the speed of the input shaft varies in each gear position. This allows the driver to change the amount of torque going to the drive wheels. In lower gears, the car accelerates quickly. When in high gear, engine speed drops while vehicle speed stays high for good fuel economy. (Ford)
Transaxle
The transaxle consists of a transmission and a differential in a single housing. Although a few rear-wheeldrive vehicles are equipped with transaxles, they are most commonly used with front-wheel-drive vehicles, Figure 1-22. Both manual and automatic transaxles are available. The internal parts of a modern transaxle assembly are illustrated in Figure 1-23.
Figure 1-20. An automatic transmission serves the same function as a manual transmission. However, it uses a hydraulic pressure system to shift gears. (Ford)
The front drive axles connect the transaxle differential to the hubs and wheels of the vehicle. These axles are equipped with constant-velocity joints, which allow the front wheels to be turned to the left or right and to move up and down.
Figure 1-21. It is a hollow metal tube with two or more universal (swivel) joints. The universal joints allow the rear suspension to move up and down without damaging the drive shaft.
Transaxle
Figure 1-22. Front-wheel-drive vehicles do not have a drive shaft or a rear drive axle assembly. The complete drive train is in the front of the vehicle. (Ford)
Transmission Engine
Universal-joint
Drive shaft
Differential
Drive wheel
Figure 1-21. The drive shaft sends power to the rear axle assembly. The rear axle assembly contains the differential and two axles that turn the rear drive wheels. (Lexus)
Differential assembly
Suspension System
The suspension system allows the vehicle's wheels and tires to move up and down with little effect on body movement. This makes the vehicle's ride smooth and safe. The suspension system also prevents excessive body lean when turning corners quickly. As you can see in Figure 1-24, various springs, bars, swivel joints, and arms make up the suspension system.
Transmission assembly
Housing or case
Steering System
The steering system allows the driver to control vehicle direction by turning the wheels right or left. It uses a series of gears, swivel joints, and rods to do this. Study the names of the parts in Figure 1-24.
Figure 1-23. A transaxle contains a transmission and a differential in one housing. (Ford)
Tire
Wheel
Steering gear
Figure 1-24. The suspension and steering systems mount on the frame. Study the part names. (Saab-Scania)
Brake System
The brake system produces friction to slow or stop the vehicle. When the driver presses the brake pedal, fluid pressure actuates a brake mechanism at each wheel. These mechanisms force friction material (brake pads or shoes) against metal discs or drums to slow wheel rotation. Figure 1-25 shows the fundamental parts of a brake system.
High voltage cableslarge diameter, insulated conductors that carry voltage between the motorgenerator, hybrid control module, and battery pack. Hybrid control modulehigh power electricalelectronic circuits that manage the flow of electrical energy through a vehicle's electrical-mechanical drive train. Hybrid battery packlarge set of battery cells that can store huge amounts of electrical energy and output high current and voltage to help propel the vehicle. Internal combustion enginegasoline or diesel engine that propels the vehicle at cruising speeds and drives the motor-generator.
Hybrid Vehicle
Most auto manufacturers now build and sell hybrid vehicles. A hybrid vehicle uses two methods of propulsionan internal combustion engine and a large electric motor-generatorto help improve vehicle performance (acceleration), increase fuel economy (gas mileage), and reduce emissions (air pollution). See Figure 1-27. The fundamental parts of a hybrid vehicle include: Motor-generatordevice that can propel the vehicle like a motor or produce electrical energy like an alternator.
During acceleration, hybrid vehicles rely on the motor-generator for propulsion. Then, when the vehicle reaches a specific speed (or the battery pack becomes discharged), the internal combustion engine takes over. In addition to propelling the vehicle, the engine also spins the motor-generator's armature. This causes the motorgenerator to produce electricity to recharge the battery pack for the next vehicle acceleration cycle. During braking, the rotational force of the vehicle's drive axles spins the motor-generator's armature, causing the motor-generator to produce electrical energy to recharge the battery. This is known as regenerative
Wheel Master cylinder Wheel hub Brake lines Brake pedal Tire
Hydraulic unit
Brake caliper
Figure 1-25. When the brake pedal is pressed, pressure is placed on a confined fluid. The fluid pressure transfers through the system to operate the brakes. An emergency brake is a mechanical system that applies the rear wheel brakes. AComplete system. BClose-up. (Cadillac, Nissan)
braking. Since it takes considerable torque to rotate the armature, the motor-generator resists drive axle rotation to help slow and stop the vehicle.
Highway History
Early automobile manufacturers originated in various ways. In many instances, they evolved from bicycle makers, carriage and wagon makers, and other types of industry. Early motorcars were similar to horse-drawn buggies, but they were equipped with noisy gasoline-powered engines, steam engines, or electric motors and batteries. A single lever called a tiller was used to steer the vehicle and another lever was used to apply the brakes.
Summary
The body and frame support, stop, and enclose the vehicle. The engine provides dependable, efficient power for the vehicle. The intake stroke draws the air-fuel mixture into the engine combustion chamber. The compression stroke prepares the fuel mixture for combustion. The power stroke produces the energy to operate the engine. The exhaust stroke must remove the burned gases from the engine cylinders. The computer system uses electronic and electrical devices to monitor and control various systems in the vehicle. The fuel system provides the correct mixture of air and fuel for efficient combustion. Electrical systems operate the electrical-electronic devices. The cooling system maintains a constant engine operating temperature. The lubrication system reduces friction between internal engine parts. Emission control systems reduce air pollution produced by the vehicle. Drive train systems transfer turning force from the engine crankshaft to the drive wheels. Suspension, steering, and brake systems support and control the vehicle. Accessory and safety systems increase passenger comfort, safety, security and convenience.
Figure 1-26. Various safety systems are used on modern vehicles to protect both the driver and the passengers. This vehicle is equipped with both front and side-impact air bags. (Audi)
Continuously variable transmission
Motor-generator
Figure 1-27. This hybrid power train contains an internal combustion engine, a motor-generator, and a continuously variable transaxle. (Honda)
Important Terms
Automobile Technology Part Component Assembly System Frame Body Chassis Body-over-frame construction Unibody construction Engine Four-stroke cycle Intake stroke Compression stroke Power stroke Exhaust stroke Multi-cylinder engines Computer system Fuel system Air-fuel ratio Gasoline injection systems Diesel fuel system Carburetor fuel system Ignition system Starting system Charging system Lighting system Cooling system Lubrication system Exhaust system Emission control systems Drive train Suspension system Steering system Brake system Accessory systems Safety systems Hybrid vehicle Regenerative braking
4. Explain the engine's four-stroke cycle. 5. Most car engines are multi-cylinder engines. True or False? 6. List and describe the three common types of fuel systems. 7. A diesel engine does not use spark plugs. True or False? 8. The car's electrical system consists of the: (A) ignition, starting, lubrication, and lighting systems. (B) ignition, charging, lighting, and hydraulic systems. (C) lighting, charging, starting, and ignition systems. (D) None of the above. 9. The system reduces the amount of toxic substances released by the vehicle. 10. What is the difference between a manual transmission and an automatic transmission? 11. A one-piece drive shaft rotates the drive wheels on most front-wheel drive cars. True or False? 12. A rear axle assembly contains two a(n) . 13. Explain the term "transaxle." 14. The suspension system mounts the car's wheels solidly on the frame. True or False? 15. List four accessory systems. 16-25. Identify the parts and systems illustrated below. Write the numbers 16-25 on your paper. Then write the correct letter and words next to each number. and
Review QuestionsChapter 1
Please do not write in this text. Place your answers on a separate sheet of paper. 1. What is an automotive system? 2. Automotive parts and systems can be grouped into ten categories. Name them. 3. Which of the following is not part of an engine? (A) Block. (B) Piston. (C) Muffler. (D) Crankshaft.
Can you identify the following parts and systems? (A) Starting system. (B) Charging system. (C) Drive train. (D) Fuel system. (E) Cooling system. (F) Engine. (G) Ignition system. (H) Lubrication system. (I) Exhaust system. (J) Intake manifold.
ASE-Type Questions
1. A vehicle is brought into the shop with a slipping clutch. Technician A says that the clutch is part of the drive train system. Technician B says that the clutch is part of the suspension system. Who is correct? (A) A only. (B) Bonly. (C) Both A and B. (D) Neither A nor B. 2. When the internal body structure of a vehicle is used as its frame, it is called: (A) unibody construction. (B) body-frame construction. (C) integral construction. (D) body-over-frame construction. 3. The controls the opening of engine's valves. (A) camshaft (B) crankshaft (C) valve springs (D) combustion chamber 4. Which piston stroke of the four-stroke cycle prepares the fuel mixture for combustion? (A) Power. (B) Intake. (C) Exhaust. (D) Compression. 5. All of the following are major components in the computer system except: (A) regulators. (B) sensors. (C) actuators. (D) computer. 6. Each of the following is a basic type of automotive fuel system except: (A) carburetor. (B) auto injection. (C) diesel injection. (D) gasoline injection.
7. Tests show that an engine is not getting spark at the spark plugs. Technician A says it could be due to the diesel injection system. Technician B says to test the ignition coil. Who is right? (A) A only. (B) Bonly. (C) Both A and B. (D) Neither A nor B. 8. A car with a dead battery is brought into the shop. Technician A says to check the output of the alternator. Technician B says to check the condition of the spark plugs. Who is right? (A) A only. (B) Bonly. (C) Both A and B. (D) Neither A nor B. 9. Since an automatic transmission does not have to be shifted by hand, Technician A believes it uses a hydraulic system to shift gears. Technician B believes it uses oil pressure to shift gears. Who is right? (A) A only. (B) Bonly. (C) Both A and B. (D) Neither A nor B. 10. A transaxle case contains both the: (A) carburetor and drive shaft. (B) transmission and differential. (C) multi-cylinder engine and clutch. (D) suspension components and brakes.
ActivitiesChapter 1
1. Draw an automotive engine and drive train and label the parts. Then describe how the power is transferred from the engine to the drive wheels. 2. Using illustrations from the text, produce overhead transparencies of the four-stroke cycle and demonstrate the cycle to your class. 3. Arrange a field trip to tour an automobile assembly plant or to an auto shop.