Automotive Encyclopedia ; Goodheart-Willcox

This sample chapter is for review purposes only. Copyright © The Goodheart-Willcox Co., Inc. All rights reserved.

2

Automotive Encyclopedia

Goodheart-Willcox

Automotive

Encyclopedia Toboldt Johnson Gauthier

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.

2006 Edition Copyright © 2006 by The Goodheart-Willcox Company, Inc. Previous editions copyright 2000, 1995, 1989, 1983, 1981, 1979, 1977, 1972, 1970, 1968 All rights reserved. No part of this work may be reproduced, stored, or transmitted in any form or by any electronic or mechanical means, including information storage and retrieval systems, without the prior written permission of The Goodheart-Willcox Company, Inc. Manufactured in the United States of America ISSN 1080-627-X

Publisher The Goodheart-Willcox Company, Inc. Tinley Park, Illinois www.g-w.com

International Standard Book Number 1-59070-422-3 1 2 3 4 5 6 7 8 9 10—06—10 09 08 07 06 05

This sample chapter is for review purposes only. Copyright © The Goodheart-Willcox Co., Inc. All rights reserved.

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Automotive Encyclopedia

Introduction

In recent years, there have been significant changes in the design and construction of automobiles. Although these changes have increased dependability, improved fuel economy, reduced emissions, and enhanced safety, they have made it more difficult to troubleshoot and repair late-model vehicles. Therefore, a thorough knowledge of the fundamentals of vehicle construction, operation, and service is more important than ever before. Automotive Encyclopedia is a book of fundamentals. It explores the many sciences involved in vehicle operation: electricity and electronics, computers, hydraulics, pneumatics, internal combustion, power transmission, and steering and suspension geometry. Automotive Encyclopedia also covers vehicle design, operation, troubleshooting, service, and repair. This information establishes the foundation on which a thorough knowledge of automotive technology is based. Once these fundamentals are mastered, knowledge gained through experience will enable you to troubleshoot and service late-model vehicles. Each chapter of Automotive Encyclopedia opens with a list of learning objectives. These objectives identify the skills you should be able to master after completing

the chapter. Important technical terms are listed at the beginning of each chapter and are printed in bold italic type when introduced in the body of the text. Additionally, safety is stressed in the appropriate sections. Review questions are provided at the end of each chapter to help you evaluate your understanding of important concepts. The 2006 edition of Automotive Encyclopedia has been updated to reflect the most recent changes in the automotive field. It includes information on the latest developments in automotive technology, such as OBD II diagnostics, antilock brakes, side air bags, refrigerant recovery and recycling, and automotive waste disposal. Full color has been used throughout this edition of Automotive Encyclopedia to enhance illustrations and highlight important information. Automotive Encyclopedia is designed to be used by students interested in entering the field of automotive technology. It can also be used by technicians preparing for ASE certification or who need to brush up on certain topics. William K. Toboldt Larry Johnson W. Scott Gauthier

Acknowledgments

The publication of a book of this nature would not be possible without the assistance of many segments of the automotive industry. The authors and the publisher would like to thank the following companies, organizations, and agencies for their contributions to Automotive Encyclopedia. AC-Rochester Accurate Instruments AC-Delco Alfred Teves Corp. Allen Test Products Div., Allen Group Ammco Tools, Inc. Audi of America, Inc. Auto-Test Battery Council International BMW Brake Systems, Inc. Buick Cadillac Carter Central Foundry Div., General Motors Corp. Central Tools Century Mfg. Co. Champion Spark Plug Co. Chevrolet Chilton’s Motor/Age Christie Electric Corp. C-R Industries Curtis-Wright DaimlerChrysler Dayco Corp. Deere & Co. Delco-Remy Div., General Motors Corp. Detroit Diesel Corp. DeVilbiss Dodge ESB Incorporated Everco Federal Mogul Fel-Pro, Inc. Firestone Tire & Rubber Co. Fisher Body Div., General Motors Corp. Ford Motor Co. Gates Rubber Co. General Electric Corp. General Motors Corp.* Goodyear Tire & Rubber Co. Hein-Werner Hercules Motor

Hofmann Corp. Honda Hunter Engineering Co. Huth Mfg. Co. Jeep Kwik-Way Lexus Lincoln Div. of McNeil Corp. Linde Div. of Union Carbide Lisle Co. LORS Machinery, Inc. L.S. Starrett Co. Marson Corp. Mazda Nilfisk of America, Inc. Nissan Oatey Co. OTC Tools and Equipment Peerless Instrument Co. Perfect Circle Peugeot, Inc. Pontiac Porsche PPG Industries, Inc. Robert Bosch Corporation Robinair Div., SPX Corp. Rochester Rubber Manufacturers Association Safety-Kleen Sealed Power Sioux S-K Tools Snap-on Tools Corp. Star Machine and Tool Co. Sun Electric Corp. Sunnen Co. Tecumseh Products Co. 3M Co. Tire Guides, Inc., Boca Raton, FL 2005 Tire Guide-www.tireguides.com Toyota Motor Sales, U.S.A. Inc. Triad U.S. Sales Co. VICA Volkswagen of America, Inc. Winona Van Norman * Portions of the materials contained in this text have been reprinted with the permission of General Motors Corporation, Service Technology Group.

This sample chapter is for review purposes only. Copyright © The Goodheart-Willcox Co., Inc. All rights reserved.

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Table of Contents

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Automotive Encyclopedia

7

Engine Fundamentals

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1

Automotive Safety

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13

Safety 13 Right-to-Know Laws 15 Proper Disposal of Automotive Wastes Fire Prevention 16 Ventilation 16 Jacks and Lifts 16 Tool Safety 16 Dress Properly 18 Lift Properly 19 Welding Safety 19

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2 Owner’s Manuals, Service Manuals, and Repair Manuals Introduction 21 Owner’s Manuals 21 Service Manuals and Repair Manuals Technical Service Bulletins 22 Flat Rate Manual 24 Computerized Service Information 25 On-line Services 25 Technical Assistance Hotlines 25

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Automotive Tools

Tools 29 Wrenches 29 Sockets and Ratchets 31 Specialty Wrenches 32 Pliers 33 Screwdrivers 34 Hammers 35 Electric Drills 38 Impact Wrenches 38 Files 39 Retrieving Tools 40 Soldering Tools 40 Hacksaws 41 Taps and Dies 42 Cleaning Equipment 43

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21 22

Fasteners, Seals, and Gaskets

Fasteners 47 Threaded Fasteners Keys and Pins 52 Snap Rings 52 Rivets 52 Adhesives 53 Sealants 53 Seals 53 Gaskets 55

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59

Meters, Testers, and Analyzers

Automotive Meters, Testers, and Analyzers Analog and Digital Meters 65 Multimeters 66 Test Light 67 Tachometers 67 Dwell Meters 67 Battery/Starter Testers 67 Timing Light 68 Oil Pressure Gauge 68 Fuel Pressure Gauge 69 Compression Gauge 69 Vacuum Gauge 69 Vacuum Tester 69 Exhaust Gas Analyzers 69 Oscilloscopes 70 Scan Tools 71 Engine Analyzers 71

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61

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Measuring Engine Performance

Engine Performance 85 Bore, Stroke, Displacement Compression Ratio 88 Engine Efficiency 88 Brake Horsepower 89 Engine Torque 90 Rated Horsepower 90 Indicated Horsepower 90 Friction Horsepower 91

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Measuring Instruments 59 Micrometers 59 Telescoping Gauges and Small Hole Gauges Vernier Calipers 61 Dial Gauges 62 Feeler Gauge 62

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Measuring Instruments

73

Engine Fundamentals 73 Engine Fuels 73 Engine Design 73 Reciprocating Engines 74 Engine Components 74 Combustion Chamber Design 79 Engine Operating Sequence 81

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88

11 Engine Removal, Disassembly, and Cleaning

Engine Top End Construction

Engine Top End 93 Cylinder Heads 93 Intake Manifolds 94 Exhaust Manifolds 94 Valve Trains 94 Cam Functions 95 Camshafts 96 Camshaft Bearings 97 Camshaft Drive Mechanisms 97 Valves 98 Valve Springs 102 Valve Lifters 102 Valve Seals 104 Valve Retainers and Keepers 104 Rocker Arms 104 Push Rods 104

10 Engine Bottom End Construction 107 Engine Bottom End 107 Engine Block Construction 107 Crankshafts 108 Vibration Dampers 111 Connecting Rods 112 Piston Construction 112 Piston Rings 113 Compression Rings 113 Oil Control Rings 114 Piston Pins 115 Flywheels 116 Balance Shafts 116 Bearings 118 Main Bearing Caps and Seals

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Engine Removal 123 Engine Disassembly 124 Cleaning 127 Inspection and Measurement

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128

Engine Top End Service

131

Engine Top End Service 131 Cylinder Head Service 131 Valve Seat Reconditioning 133 Valve Guide Service 134 Valve Service 137 Valve Spring Service 139 Valve Operating Mechanisms 142 Push Rod Service 143 Rocker Arm Service 143 Lifter Service 143 Camshaft Service 145 Camshaft Bearings 146 Timing Belt Service 147 Timing Chain Service 147 Timing Gear Service 148 Head Bolt Torque 148

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120

123

Engine Bottom End Service

Engine Bottom End Service 151 Engine Block Service 151 Cylinder Reconditioning 153 Crankshaft Service 156 Bearing Clearance 158 Bearing Removal 159 Replacement of Inserts 159 Piston Service 165 Piston Ring Service 166 Connecting Rod Service 170 Piston Pin Service 171 Balancing Engines 173

151

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Table of Contents

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Engine Lubrication

177

19 Fuel Supply Systems, Intake Systems, Superchargers, and Turbochargers 243

Oil

177 Properties of Engine Oil 177 Selecting Viscosities 178 Oil Service Classifications 178 Oil Changes 180 Oil Filters 180 Lubricating Methods 180

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Engine Cooling Systems

187

Cooling Systems 187 Water Pumps 189 Belts 189 Hoses and Clamps 191 Radiators 192 Automatic Transmission Fluid Cooler 193 Closed Cooling Systems 193 Radiator Caps 193 Cooling Fans 194 Thermostats 196 Heater Core 197 Antifreeze Solutions 197 Air-cooled Engines 199 Cooling System Testing 200 Cooling System Troubleshooting 202 Cooling System Flush 203

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Diesel and Other Engines

Diesel Engines 207 Truck Engines 209 Racing Engines 210 Rotary Engines 210 Miller-Cycle Engines 214 Variable-Compression Engines Hybrid Vehicles 215 Fuel Cell Vehicles 216

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207

Electricity 219 Insulators 221 Conductors 221 Volts, Amperes, Ohms 221 Types of Electrical Circuits 222 Magnetism 223 Electronics 227

Automotive Fuels

235

259 259

21 Carburetor Fundamentals and Service 275 Carburetors 275 Carburetor Circuits 277 Air/Fuel Mixture 287 Stoichiometric Mixture 288 Computerized Systems 288 Electro-Mechanical Carburetors Carburetor Service 290

215

Automotive Fuels 235 Volatility 235 Combustion of Gasoline 237 Antiknock Qualities 239 Fuel Additives 240 Lead-free Gasoline 240 Alcohol as a Fuel 240 Diesel Fuels 241 Liquefied Petroleum Gas (LPG)

Fuel Injection Systems

Fuel Injection 259 Classifying Gasoline Injection Systems Servicing Fuel Injection Systems 264 On-Board Diagnostic Systems 265 Verifying Fuel Injector Operation 265 Checking Fuel Pressure 266 Injector Balance Test 266 Relieving EFI System Pressure 266 Servicing Fuel Injectors 268 Rebuilding a Throttle Body 270 Methods of Diesel Injection 270

17 Fundamentals of Electricity, Magnetism, and Electronics 219

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Fuel Pumps 243 Mechanical Fuel Pump 243 Electric Fuel Pumps 244 Fuel Filters 245 Fuel Gauges 246 Intake Systems 248 Air Filters 248 Intake Manifold 249 Superchargers 251 Turbochargers 254

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Automotive Encyclopedia

22 Ignition System Fundamentals and Service 301

24 Starting System Fundamentals and Service 339

Ignition System Operation 301 Ignition Coils 302 Distributor Cap 302 Rotor 302 Spark Plug Wires 303 Spark Plugs 303 Ignition Timing 306 Specific Ignition Systems 307 Breaker Point Ignition 307 Electronic Ignition 309 Computerized Ignition Systems 312 Distributorless Ignition 312 Direct Ignition 314 Ignition System Service 315 Performing a Spark Test 315 Ignition Coil Service 315 Distributor Cap and Rotor Service 316 Spark Plug Service 316 Spark Plug Wire Service 319 Pickup Coil Service 319 Contact Point and Condenser Service 320 Adjusting Ignition Timing 321 Testing Centrifugal and Vacuum Distributor Advance Systems 322 Ignition Control Module Service 322 Distributors and Direct Ignition System Service 322

Starting System Fundamentals 339 Starting Motor Operating Principles 339 Starting Motor Types 343 Starting Motor Internal Circuits 343 Neutral Safety Switch 347 Troubleshooting the Starting System 347 Starter Maintenance 348 Starting Motor Tests 348

23 Batteries and Battery Service 325 Batteries 325 Battery Construction 325 Maintenence-free Batteries 327 Battery Voltage and Capacity 329 Battery Ratings 329 Battery Inspection 330 Battery Testing 330 Jump Starting an Engine 336

25 Charging System Fundamentals 353 Charging Systems 353 Alternator Construction 356 Alternator Operation 357 Voltage Regulators 359 Voltage Regulator Types 359 Computer-Controlled Voltage Regulation 42-Volt Electrical Systems 364

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367 368

27 Computer System Fundamentals and Service 375 Computer Control Systems 375 Components of a Computer Control System 377 Sensors 377 Electronic Control Module Operation 382 Actuators 384 Computer Control System Troubleshooting 386 On-Board Diagnostic Systems 386 Diagnostic Trouble Codes 386 Activating Self-Diagnostic Systems 387 Using Diagnostic Information 389 Sensor Service 390 Actuator Service 394 Electronic Control Module Troubleshooting 394

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241

Charging System Service

Charging System Testing and Service 367 Charging System Inspection 367 Charging System Precautions and Tests Alternator Removal 369 Alternator Disassembly 370 Bench Tests 370 Repairs/Replacement 372 Alternator Reassembly 372 Alternator Reinstallation 372

364

Exhaust Systems

397

Exhaust Systems 397 Exhaust Manifold 397 Mufflers 398 Catalytic Converters 399 Exhaust System Corrosion 400 Servicing Exhaust Systems 402

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Table of Contents

29

Emission Controls

405

Introduction 405 Automotive Emission Standards 405 Positive Crankcase Ventilation 406 Exhaust Emission Controls 408 Precombustion Controls 408 Post-combustion Controls 413

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Engine Troubleshooting

421

Engine Troubleshooting 421 Test Equipment 421 Effect of Emission Controls 421 Strategy-Based Diagnostics 422 Self-diagnosis 422 Troubleshooting Charts 422

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Driveability and Tune-up

Driveability and Tune-up 433 Tune-up Test Procedure 435 Checking Compression Pressure Using a Vacuum Gauge 440 Tuning Emission Controls 441

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Clutches

440

443

Purpose of the Clutch 443 Design and Construction 443 Parts Location and Relationship Clutch Service 451 Clutch Adjustment 452 Clutch Overhaul 453 Clutch Troubleshooting 454

443

33 Manual Transmission Fundamentals 457 Manual Transmissions 457 Application of Torque 457 Gear Usage 457 Three-speed Manual Transmission 458 Helical Gears 459 Synchronizing Clutch 460 Four-speed Manual Transmission 460 Overdrive Revival 460 Planetary Gear Systems 461 Transmission Overdrives 463 Five-speed Overdrive Transmission 464

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Automotive Encyclopedia

34 Manual Transmission Service 469

35 Automatic Transmission Fundamentals 487

Manual Transmission Maintenance 469 Check Fluid Level 470 Replace the Rear Seal 470 Test the Gearshift Operation 470 Check Clutch Pedal Free Play 470 Manual Transmission Troubleshooting 470 Manual Transmission Service 472 Removal of Transmission From Car 472 Disassembly: Three-speed Manual Transmission 473 Clean and Check: Three-speed Manual Transmission 473 Reassembly: Three-speed Manual Transmission 475 Disassembly: Four-speed Manual Transmission 477 Clean and Check: Four-speed Manual Transmission 479 Reassembly: Four-speed Manual Transmission 479 Disassembly: Five-speed Manual Transmission 480 Clean and Check: Five-speed Manual Transmission 483 Reassembly: Five-speed Manual Transmission 483 Reinstallation of the Transmission in the Car

Automatic Transmissions 487 Fluid Couplings 487 Torque Converters 488 Automatic Transmission Operation 490 Actions of Key Elements 491 Automatic Transmission Operation 497 Other Automatic Transmissions 500 Electronic Transmission Control 500 Continuously Variable Transmissions 500

36 Automatic Transmission Service 507

484

Automatic Transmission Maintenance and Service 507 Check ATF Level 508 Check ATF Condition 508 Inspect for ATF Leaks 509 Test for Broken Transmission Mount 510 Changing Automatic Transmission Fluid 511 Adjust Bands 512 Adjust Engine Curb Idle Speed 513 Throttle Linkage Adjustment 514 Gearshift Linkage Adjustment 515 Troubleshooting Tips 515 Road Testing 516 Stall Testing 516 Air Pressure Testing 517 Testing Electronically Controlled Transmissions 518

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Transaxles

521

Transaxles 521 Transaxle Construction 521 Transaxle Operation 523 Manual Transaxle Troubleshooting 528 Manual Transaxle Maintenance 529 Automatic Transaxle Troubleshooting 531 Automatic Transaxle Maintenance 532

38 Driveline, Universal Joints, Differentials, and Driving Axles 537 Drivelines 537 Universal Joints 538 Drive Shaft 538 Differential 538 Driving Axles 539 Torque Transfer or Drive 541 Hotchkiss Drive 541 Torque Tube Drive 542 Control Arm Drive 542 Slip Joints 542 Constant Velocity Joints 543 Transfer Cases 543 Center Bearings 543 Differentials and Axles 543 Limited-Slip Differentials 547 Front-wheel Drive Driveline 548

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Driveline Service

553

Driveline Service 553 Drive Shaft 553 Universal Joint Service 554 Center Bearing Service 555 Differentials 555 Transaxle Lubrication 558 Wheel Bearing Lubrication 559 Driving Axles 560

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Four-wheel Drive Systems

Four-wheel Drive/All-wheel Drive 569 Four-wheel Drive Systems 570 Four-wheel Drive Componenets 570 Four-wheel Drive Service 576

41 Suspension and Steering Systems 579 Suspension and Steering Systems 579 Front Suspension Systems 584 Rear Suspension Systems 585 Steering Systems 588 Suspension and Steering Service 596 Troubleshooting Suspension 597 Troubleshooting Manual Steering 598 Troubleshooting Power Steering 599

569

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Table of Contents

42

Tires and Tire Service

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601

48

Tires 601 Tire Types and Basic Structure 601 Tread Patterns 603 Tire Markings 603 Tire Service 607 Improvements and Advances 612

43

Wheel Alignment

46 44 Wheel Alignment Correction 625

Hydraulics and Pneumatics

Hydraulics 637 Transmission of Forces 638 Movement of Liquid 640 Application of Hydraulic Principles 640 Pneumatics 641 Effect of Atmospheric Pressure 642 Effect of Vacuum 642 Compressed Air 643 Principle of the Siphon 643 Venturi Tube 644 Boyle’s Law 644 Charles’ Law 645

Safety Systems

709

51 Body Repairing and Refinishing 757 715

49 Lamps, Lighting Circuits, Wiring, Horns, Wipers, and Washers 723

Wheel Alignment 615 Wheel Balance and Unbalance 616 Car Weight Balance 617 Wheelbase—Tread Width 617 Rear-wheel Track 618 Springs 619 Suspension Height 619 Shock Absorber Action 619 Front-wheel Angularity 620

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Automotive Encyclopedia

Safety Systems 709 Seat Belt Systems 710 Air Bag Systems 712 Energy Absorbing Bumper Systems Other Safety Features 717

615

Wheel Alignment Correction 625 Rear-wheel Drive/Front-wheel Drive Alignment Front-Wheel Drive—Alignment 632 Rear Wheel Alignment 632 Alignment Troubleshooting 634

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637

Automotive Brakes

647

Fundamentals of Automotive Brake Systems Braking System Operation 649 Brake Lining Materials 650 Disc Brakes 651 Drum Brakes 653 Brake Hydraulic System 656 Disc Brake Calipers 662 Wheel Cylinders 662 Brake Lines, Hoses, and Fittings 663 Power Brakes 663 Anti-lock Brake Systems 666 Brake Service 668 Hydraulic System Service 668 Disc Brake Service 670 Drum Brake Service 673 Power Brake System Service 680 Troubleshooting and Servicing Anti-lock Brake Systems 682

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Lamps and Lighting Circuits 723 Fuses and Circuit Breakers 724 Headlamp Types 724 Daytime Running Lamps 724 Lamp Switches 725 Fog Lamps 728 Direction Signal Switch 728 Stoplight Switch 728 Lamp Service 728 Wires and Cables 734 Lighting Wire Sizes 734 Resistor Ignition Cable 736 Wiring Harnesses and Connectors 736 Horns 737 Horn Troubleshooting 739 Principles of a Direct Current (DC) Motor 739 Wiper Motor Construction 739 Troubleshooting 741 Windshield Washers 741

647

Automotive Air Conditioning

50 Speedometers and Cruise Control Systems 745

685

Automobile Air Conditioning 685 Principles of Air Conditioning 686 Automobile Heating Systems 688 Types of Refrigerant 694 The Need for Refrigerant Oil 700 Air Conditioning Service Tools and Equipment 701 Servicing the Air Conditioning System 702 Discharging and Recovering Refrigerant 703 Evacuating the Air Conditioning System 703 Charging the Air Conditioning System 703 Retrofitting R-12 Air Conditioning Systems 704 Troubleshooting Heating Systems 704 Troubleshooting Air Conditioning Systems 704 Automatic Temperature Control 705

Analog Speedometers 745 Speedometer Operation 745 Inspection and Lubrication 747 Speedometer Cable 747 Digital Speedometers 748 Light Emitting Diode 748 Liquid Crystal Display 750 Vacuum Fluorescent Display 750 Cathode Ray Tube 750 Digital Odometers 750 Troubleshooting 750 Cruise Control Systems 751 Cruise Control System Service 753

Body Work 757 Hammers, Spoons, and Dolly Blocks 758 Using Pull Rods and Slide Hammers 759 Body Filler 759 Filing and Sanding 761 Patching Rusted Areas 763 Replacing Panels 763 Welding 764 Painting 768 Masking 769 Spray Guns 770 Tips on Spraying 770 Refinishing Materials 772 Matching Colors 774 Preparing Old Finishes for Paint 775 Soft Body Parts 778 Identifying Plastics 778 Repairing Water and Dust Leaks 779 Drain Locations 780

52 Career Opportunities and Technician Certification 783 Automotive Careers 783 The Job Market 784 Job Descriptions 785 Entrepreneurship 789 Technician Certification 790

Appendix

793

Dictionary of Automotive Terms Index

815

797