Auto Fundamentals

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Format: Hardcover
Pub. Date: 2004-01-01
Publisher(s): Goodheart-Willcox Pub
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Summary

Leads students through the design, construction, and operation of all major automotive systems.

Table of Contents

Building an Engine
11(16)
What Is an Engine?
11(5)
Internal Combustion Engine
Building an Engine on Paper
What to use for Fuel
The Basic Force of an Engine
Trapping the Explosion
A Simple Engine
Name the Parts
Fastening the Parts
Lengthen the Piston
Getting Fuel into the Engine
Removable Cylinder Head
Fuel Intake and Exhaust Passages
Valves
Four-Stroke Cycle
16(4)
Vacuum Is the Clue
You Already Have a Vacuum Pump
Where Is Your Vacuum Pump
Stroke No. 1---The Intake Stroke
Stroke No. 2---The Compression Stroke
Stroke No. 3---The Power Stroke
Stroke No. 4---The Exhaust Stroke
Completed Cycle
Cycle Repeated
What Opens and Closes the Valves?
20(3)
Camshaft
Valve Lifter
Camshaft Speed
Turning the Camshaft
Timing the Valves
The Flywheel
23(1)
Engine Will Run Smoothly
Basic Engine Completed
24(3)
Design, Construction, Application of Engine Components
27(28)
The Engine Block
27(1)
Cylinders
28(1)
Cylinder Sleeves
Pistons
29(10)
Piston Materials
Piston Expansion Problems
Partial Skirt Piston
Piston Temperature
Piston Construction
Piston Head Shape
Piston Rings
Types of Rings
Piston Pins
Connecting Rods
39(2)
Connecting Rod Construction
Connecting Rod Bearings
Crankshaft
41(1)
Main Bearings
Crankshaft Throws
Crank Vibration
Vibration Damper
42(1)
Balance Shafts
Drilled, Ground, and Polished
Timing Gear or Sprocket
43(1)
Flywheel
44(1)
Camshaft
44(1)
Valves
45(2)
Valve Seats
Valve Guides
Valve Springs
Mechanical Valve Lifters
47(1)
Hydraulic Valve Lifters
47(3)
Turning Reduces Valve Wear
Valve Timing
Variable Valve Timing
Cylinder Head
50(1)
Oil Pan
50(1)
Timing Gear Cover
50(1)
Gaskets
50(1)
Sealants
50(1)
Seals
51(1)
Other Parts
51(4)
Engine Classification, Parts Identification
55(18)
Cycle Classification
55(1)
Two-Stroke Cycle Engine
Valve Location Classifications
56(4)
L-Head, T-Head, and F-Head Designs
I-Head
Overhead Valve Adjustment
Valve-to-Piston Clearance
Detonation and Preignition
Combustion Chamber Design
60(2)
Ricardo Combustion Chamber
Hemispherical Combustion Chamber
Wedge Shape Combustion Chamber
Cylinder Classification
62(1)
Inline Engine
V-Type Engine
Horizontal-Opposed Engines
Firing Order
62(1)
Cooling Classification
62(1)
Fuel Classification
63(1)
Engine Mounting
63(1)
Alternative Engines
63(2)
Two-Stroke and Four-Stroke Cycle Diesel Engines
Rotary Engines
Miller-Cycle Engines
Variable Compression Engines
Natural Gas Engines
Experimental Engines
65(3)
New Technologies
68(1)
Hybrid Vehicles
Fuel Cell Vehicles
Identification and Classification
68(5)
Safety, Lab Procedures
73(8)
Preventing Accidents
73(1)
Kinds of Accidents
How Accidents Happen
Results of Accidents
Keep Safety in Mind
74(7)
Reducing the Possibility of Accidents
Dressing Safely for Work
Keep a Neat Shop
Identifying Unsafe Conditions
Waste Chemical Disposal
Follow Proper Work Procedures
Do the Job Right
Tool Identification and Use
81(20)
What to Look for in a Tool
81(1)
Tool Material
Tool Construction
Tool Handling and Storage
81(1)
Types of Tools
81(11)
Hammers
Chisels
Punches
Files
Drills
Reamers
Impact Wrench
Hacksaws
Vise
Taps
Dies
Cleaning Tools
Pliers
Screwdrivers
Wrenches
Other Useful Wrenches
Torque Wrenches
Sockets and Ratchets
Pullers
Soldering Equipment
Measuring Tools
92(9)
Micrometers
Inside and Outside Calipers
Dividers
Dial Indicator
Dial Calipers
Feeler Gauges
Electrical Testers
Pressure Gauges
Other Diagnostic Equipment
Engine Tests and Measurements
101(8)
What is Horsepower?
101(4)
Horsepower Formula
Potential Horsepower
Thermal Efficiency
Mechanical Efficiency
Practical Efficiency
Indicated Horsepower
Brake Horsepower
Gross and Net Horsepower Ratings
Frictional Horsepower
Torque
Torque and Brake Horsepower Are Not the Same
Volumetric Efficiency
105(1)
Engine Size (Displacement)
105(1)
Cylinder Bore and Piston Stroke
Compression Ratio
106(3)
Electrical System Fundamentals
109(12)
Basic Electricity
109(7)
The Electron Theory
Conventional Theory
Matter
Atoms
Electrical Current
Current Flow
Voltage
Electrical Resistance
Test Meters
Materials Used for Conductors
Insulators
Electrical Circuits
Series-Parallel Circuit
Vehicle Chassis Can Act as a Ground Wire
Ohm's Law
Magnetism
Magnetic Domains
Basic Automotive Electronics
116(5)
Diodes
Transistors
Ignition Systems
121(20)
High Voltage Is Necessary
121(1)
Primary Circuit
122(7)
Battery
Ignition Switch
Resistors
Ignition Coil
Methods of Current Interruption
Distributorless Ignition System
Direct Ignition System
Primary Circuit Complete
Secondary Circuit
129(5)
Spark Plug Construction
Spark Plug Heat Range
Resistor Spark Plugs
Directional Spark Plugs
Spark Plug Injectors
Distributor Cap
Rotor
Spark Plug Wires
Ignition Timing and Advance
134(7)
Setting Basic Timing
Timing Advance Mechanisms
Fuel Injection Systems
141(24)
Providing the Correct Air-Fuel Mixture
141(1)
Fuel Injection
141(2)
Direct and Indirect Injection
Mechanical and Electronic Injection
Computer-Controlled Electronic Fuel Injection System
Pulse Fuel Injection
143(1)
Timed and Non-Timed Pulse Fuel Injection
Types of Pulse Fuel Injection Systems
143(1)
Throttle Body Injection System
Multiport Fuel Injection
Pulse Fuel Injection System Components
144(6)
Air Induction System
Fuel Delivery System
Engine Control Computer
Electronic Sensors
Continuous Fuel Injection System
150(4)
Fuel Flow Control
Complete Air-Fuel Control Unit
Diesel Fuel Injection
154(6)
Diesel Fuel
Overall Diesel Fuel System
Injector Pump Types
Distributor Type Injection Pump
Other Pump Features
Diesel Injector Types
Glow Plugs and Intake Air Heaters
Diesel Engine Electronics
Superchargers and Turbochargers
160(5)
Superchargers
Turbochargers
Fuel Supply and Carburetors
165(28)
Fuel Supply System
165(6)
Fuel Tank
Gasoline Pickup Tube
How Gasoline Leaves the Tank
Electric Fuel Pump
Fuel Filter
Fuel Lines
Vapor Lock Eliminators
Carburetors
171(14)
Build a Carburetor
Basic Carburetor Is Complete
Correcting the Remaining Faults
Carburetor Circuits
Intake Manifold Design
Air Cleaners
185(1)
Air Cleaner Element
Carburetor Classifications
185(8)
Airflow Direction
Number of Throats
Cooling Systems
193(18)
The Need for a Cooling System
193(1)
Two Methods of Cooling
193(13)
Liquid-Cooled Engines
First Job Complete
Air-Cooled Engines
206(5)
Moving The Air
A Thermostat Is Sometimes Used
Lubrication Systems
211(18)
The Need for a Lubrication System
211(1)
Friction
How Friction is Reduced
Bearing Construction and Friction
Engine Oil
212(3)
Engine Oil Has Several Jobs
Refining Engine Oil
Oil Viscosity
Engine Oil Service Classification
Oil Change Intervals
Engine Lubrication Systems
215(6)
How Oil Works
Three Types of Lubrication Systems
Components of the Pressure-Splash System
Pressure Relief Valve
Oil Galleries and Lines
Oil Enters Bearing
Hydraulic Valve Lifters
Oil Filtration
221(2)
Oil Filters
Crankcase Ventilation
223(1)
Oil Seals
224(1)
Oil Pressure Indicators
224(1)
Dipstick
225(1)
Cooling the Oil
226(3)
Exhaust Systems
229(10)
Purpose of the Exhaust System
229(1)
Exhaust System Designs
229(1)
Single Exhaust System
Dual Exhaust System
Exhaust System Components
230(3)
Exhaust Manifolds
Exhaust Pipes
Catalytic Converters
Mufflers
Resonators
Tailpipes
Hangers
Heat Shields
Exhaust System Materials
233(1)
Sealing the Exhaust System
234(5)
Exhaust Pipe-to-Manifold Connections
Pipe-to-Pipe Connections
Other Connections
Emission Systems
239(20)
The Need for Emission Controls
239(1)
Emission Control Systems
239(1)
Engine Modifications and Controls
239(5)
Engine Modifications
Fuel System Controls
Spark Timing Controls
Exhaust Gas Recirculation (EGR)
External Cleaning Systems
244(7)
Air Injection System
Pulse Air Injection
Catalytic Converter
Multiple Converters
Diesel Catalytic Converters
Fuel Vapor Controls
251(4)
Positive Crankcase Ventilation
Evaporation Control System (ECS)
Computer-Controlled Emission Systems
255(1)
Emission Systems Caution
256(3)
Computer Systems
259(18)
Computers on Modern Vehicles
259(14)
Electronic Control Unit (ECU)
Computer Control Operation
Input Sensors
Output Devices
Ignition Devices
On-Board Diagnostic Systems
Static Electricity
273(4)
Electromagnetic Interference
Charging and Starting Systems
277(26)
Battery
277(5)
Battery Cells
Battery Construction
Battery Chemical Action
Parasitic Battery Loads
Identifying Battery Terminals
Dry-Charged Battery
Charging System
282(8)
Alternator
Alternator Control
Starter System
290(8)
Starter Motor Principles
Starter Motor Construction
Starter Drive System
Starter Solenoid
Starter Actuating Switches
42-Volt Electrical Systems
298(1)
Integral Starter Alternators
298(5)
Chassis Electrical
303(20)
Chassis Wiring
303(3)
Wire Sizes
Wiring Harness
Many Circuits
Color Coding
Terminal Blocks and Junction Blocks
Circuit Protection Devices
306(1)
Vehicle Lights and Light Switches
307(5)
Headlights
Stoplights and Switches
Turn Signals and Switches
Backup Lights and Switches
Dashboard Lights
Convenience Lights
Chassis Mounted Solenoids and Relays
312(1)
Motor Control Relays
Trunk Release Solenoids
Power Door Lock Solenoids and Switches
Horns and Horn Relays
313(1)
Rear Window and Mirror Defrosters
313(1)
Chassis Mounted Motors
313(3)
Windshield Wiper Motors and Controls
Power Window, Tailgate, Sliding Door, and Sunroof Motors
Convertible Top Motors and Switches
Power Antenna Motors and Switches
Electric Gauges
316(1)
Cruise Control
316(1)
Vehicle Speed Sensor
Operator Controls and Control Module
Throttle Actuator
Adaptive Cruise Control
Air Bag Systems
316(7)
Diagnostic Control Module
Impact Sensors
Coil Assembly and Inflator Module
Air Bag Operation
Side Air Bags
Engine Clutches
323(12)
Clutch Purpose
323(1)
Clutch Construction
323(6)
Flywheel
Clutch Disc
Pressure Plate Assembly
Clutch Release Lever Operating Mechanism
Clutch Housing and Input Shaft (Clutch Shaft)
Complete Assembly
Other Types of Clutches
Clutch Operation
329(1)
Clutch Pedal Linkage
330(2)
Mechanical Linkage
Hydraulic Linkage
Self-Adjusting Clutch
Clutch Cooling
332(3)
Riding the Clutch
Will a Clutch Explode?
Manual Transmissions and Transaxles
335(20)
Manual Transmissions and Transaxles
335(1)
The Engine Needs Help
335(11)
How is Torque Multiplied
Torque Multiplication through Gears
Transmission Cases
Transmission Construction
Synchronizing Mechanism
Transmission Operation
Four-Speed Transmission
Five-Speed Transmission
Manual Transaxles
346(5)
Transaxle Cases
Transaxle Gear and Synchronizer Operation
Five-Speed Transmission and Transaxle
Transmission and Transaxle Shift Mechanism
Manual Transmission and Transaxle Lubrication
Speed Shifting
351(4)
Four-Wheel Drive
355(12)
Purposes of the Four-Wheel Drive
355(1)
Four-Wheel Drive Components
355(1)
Four-Wheel Drive Designs
355(1)
Transfer Case
355(8)
Full-Time Transfer Case
Full-Time Transfer Case Operation
Part-Time Transfer Case
Part-Time Transfer Case Selection Control
Transfer Case Lubrication
Locking Hubs
363(4)
Automatic Transmissions and Transaxles
367(28)
Transmissions and Transaxles
367(2)
Automatic Transmission and Transaxle Components
Torque Converter
369(4)
Building a Torque Converter
Stator
Torque Converter Operation
Torque Multiplication Curve
Lockup Torque Converters
Planetary Gearsets
373(3)
Torque Increase
Planetary Gearsets in Automatic Transmissions
Holding Members
376(4)
Bands
Multiple Disc Clutch
Overrunning Clutches
Hydraulic Control System
380(11)
Fluid Pump
Control Valves
Simple Hydraulic System
Transmission and Transaxle Shifting
Complete Control Circuit
Manual Shift Programs
Transmission Case
Transmission Lubrication
391(1)
Fluid Filter
Fluid Cooling
391(4)
Axles and Drives
395(24)
Rear Wheel Drive Shafts
395(4)
Drive Shafts
Drive Shaft Must Be Flexible
Universal Joint
Slip Yoke
How the Wheels Drive the Vehicle
Hotchkiss Drive
Universal Joint Can Cause Fluctuating Shaft Speed
Constant Velocity (CV) Axles
399(3)
CV Axle Shafts
Types of CV Joints
CV Joint Boots
Rear-Wheel Drive Axle Assemblies
402(1)
Rear-Wheel Drive Axle Components
403(12)
Axle Housing
Solid Axles
Independent Axles
Types of Axles
Differential Construction
Ring and Pinion
Differential Operation
Differential Carrier and Bearings
Limited-Slip Differential
Ring and Pinion Adjustments
Gear Ratio
Axle Lubrication
Transaxle Differential Assembly
Four-Wheel Drive Front Drive Axles
415(4)
Front Axle Steering Provision
Brakes
419(34)
Hydraulic Basics
419(2)
Air Is Compressible, Liquids Are Not
Liquids Can Transmit Motion and Force
Liquids Can Increase Force
Liquids Can Decrease Force
Hydraulic Principles in Vehicle Brake Systems
Brake Fluid
Master Cylinder
421(5)
Master Cylinder Construction
Dual Brake System
Quick Take-Up Master Cylinder
Master Cylinder Operation
Brake System Hydraulic Control Valves
426(4)
Proportioning Valve
Height Sensing Proportioning Valve
Disc Brake Metering Valve
Pressure Differential Switch
Combination Valve
Brake Lines
Brake Hoses
Disc Brake Calipers
430(1)
Caliper Operation
Wheel Cylinders
431(2)
Wheel Cylinder Construction
Wheel Cylinder Operation
Hydraulic System Failure
Hydraulic System Must Be Free of Air
Hydraulic System Vapor Lock
Brake Friction Members
433(1)
Coefficient of Friction
Friction Linings
Brake Fade
Disc Brake Assembly
434(1)
Brake Pad Construction
Braking Ratio
Backing Plate
Drum Brake Assembly
435(4)
Brake Shoe Assembly
Brake Drum
Drum Brake Operation
Drum Brake Arrangement
Self-Adjusting Brakes
Parking Brakes
Power Brake Systems
439(1)
Vacuum-Assisted Power Booster
439(3)
Vacuum Power Booster Construction
Vacuum Power Booster Operation
Other Vacuum Booster Types
Vacuum Reservoir
Booster Failure
Hydraulic Pressure-Operated Power Booster
442(2)
Hydraulic Power Booster Operation
Hydraulic Accumulator
Anti-Lock Brake Systems (ABS)
444(1)
Anti-Lock Brake System Components
Anti-Lock Brake Operation
Traction Control Systems
445(3)
Brake Lights
448(5)
Suspension Systems
453(26)
The Need for a Suspension System
453(1)
Sprung Weight
Unsprung Weight
Suspension System Components
453(2)
Vehicle Frames
Springs
455(2)
Leaf Springs
Coil Springs
Shock Absorbers
457(2)
Shock Absorber Control Action
Shock Absorber Construction
Shock Absorber Operation
Air Shock Absorbers
459(4)
Control Arms and Struts
Ball Joints
Stabilizer Bars
Front Suspension Systems
463(1)
Conventional Independent Front Suspension
463(5)
Coil Spring Front Suspension
Torsion Bar Front Suspension
MacPherson Strut Front Suspension
Solid Axle Front Suspension
Rear Suspension Systems
468(1)
Solid Rear Axle Suspensions
Independent Rear Suspensions
Suspension Lubrication
469(2)
Automatic Level Control
471(3)
Automatic Level Control Operation
Air Compressor
Height Control Valve
Computerized Ride Control Systems
474(5)
Steering Systems
479(24)
Steering System
479(1)
Spindle and Steering Arm Assembly
Steering Linkage
480(5)
Parallelogram Linkage
Parallelogram Component Arrangement
Rack-and-Pinion Linkage
Four-Wheel Steering Systems
Steering Wheel, Steering Shaft, and Steering Gear
485(4)
Steering Wheel
Steering Shaft
Steering Gear
Manual Rack-and-Pinion Steering Gear
Power Steering
489(14)
Road Feel
Power Steering Components
Self-Contained Power Steering Gear Components
Inline Unit with Torsion Bar and Rotating Spool Valve
Rack-and-Pinion Power Steering
Power Steering Pumps
Power Steering Hoses and Tubing
Power Steering Systems Can Be Operated Manually
Power Steering Fluids
Electronic Steering Control
Electric Power Steering Systems
Wheels and Tires
503(12)
Wheels
503(2)
Steel Wheels
Custom Wheels
Wheel Rim Size
Wheel Lug Bolts and Nuts
Wheel Hubs and Bearings
505(1)
Wheel Bearings
Bearing Retaining Devices
Tires
506(9)
Tire Construction
Tire Rating Information
Tire Quality Grading
Special Service Tires
Determining the Correct Tire for a Vehicle
Tire Valves
Tire Pressure is Important
Tire Rotation
Tire Runout and Balance
High Speeds and Overloading Produce Heat and Excessive Wear
Wheel Alignment
515(16)
Purpose of Wheel Alignment
515(1)
Wheel Alignment Angles
515(5)
Types of Wheel Alignment
Alignment Measurement Values
Caster
Camber
Steering Axis Inclination
Toe
Toe-Out on Turns
Slip Angles
Steering Geometry
520(6)
Alignment Adjustments
Thrust Angle
Front Wheel Adjustments
Rear Wheel Adjustment
Tire Wear Patterns and Alignment
526(1)
Alignment Equipment
526(2)
Check for Worn Parts before Alignment
Other Factors That Can Affect Alignment
528(3)
Air Conditioning and Heating
531(24)
Purposes of Automotive Air Conditioning
531(1)
Principles of Refrigeration
531(3)
What Is Cooling?
Effects of Heat
Transference of Heat
Conduction
Convection
Radiation
Heat Transfer Is From Hot to Cold
States of Matter
Latent Heat
Pressure-Temperature Relationship
Types of Refrigerant
How the Refrigeration System Works
534(2)
Types of Refrigeration Systems
Major Components of the Air Conditioning System
536(10)
Compressor
Basic Compressor Designs
Pressure Relief Valve
Compressor Magnetic Clutch
Condenser
Refrigerant Flow Restrictor
Evaporator
Blower Motor
Lines and Hoses
Receiver-Dehydrator
Accumulator
Evaporator Pressure Controls
Service Valves
546(1)
Refrigerant Oil
546(2)
Refrigerant Handling Precautions
548(1)
Retrofitting
548(1)
Heater Systems
548(1)
Air Distribution and Control
548(2)
Cabin Filters
Heater-Air Conditioning Control Systems
550(1)
Wiring and Vacuum Systems
Beverage Coolers
550(5)
ASE Certification
555(6)
Reasons for ASE Tests
555(1)
Applying for the ASE Tests
555(2)
Taking the ASE Test
557(1)
Test Question Examples
Test Results
557(1)
Recertification Tests
558(3)
Career Opportunities
561(8)
A Vast Field
561(1)
Types of Automotive Service Careers
561(2)
Light Repair Technician
Heavy Repair Technician
Areas of Specialization
Supervisory Positions
Small Shop Technician
Overall Job Picture
Working Conditions
563(1)
Wages
563(1)
Working Hours
564(1)
Availability of Employment
564(1)
How Does a Person Become an Automotive Technician
564(2)
Stay in High School
What to Take While in School
Use Your Counselor and Instructors
Studies After Graduation
Vocational Schools and Colleges
Apprentice Programs
Additional Training Information
566(1)
Plan Your Career Early
567(1)
Keep Up-to-Date
567(2)
Conversion Tables 569(8)
Dictionary of Automotive Terms 577(20)
Acknowledgments 597(2)
Index 599

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