Table Of Content

A Practical Approach to Motor Vehicle Engineering and Maintenance A Practical Approach to Motor Vehicle Engineering and Maintenance Second Edition Derek Newbold Formerly of Hinckley College Allan Bonnick, M.Phil, B.Sc, C.Eng, M.I.Mech.Eng Formerly Principal Lecturer at Eastbourne College of Arts and Technology AMSTERDAM.BOSTON.HEIDELBERG.LONDON.NEWYORK.OXFORD PARIS.SANDIEGO.SANFRANCISCO.SINGAPORE.SYDNEY.TOKYO ElsevierButterworth-Heinemann LinacreHouse,JordanHill,OxfordOX28DP 30CorporateDrive,Burlington,MA01803 FirstpublishedbyArnold2000 Reprinted2002,2003,2004 Secondedition2005 Copyright(cid:1)2005,DerekNewboldandAllanBonnick.Allrightsreserved. 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Applicationsforthecopyrightholder’swrittenpermissiontoreproduce anypartofthispublicationshouldbeaddressedtothepublisher PermissionsmaybesoughtdirectlyfromElsevier’sScience&Technology RightsDepartmentinOxford,UK:phone:(þ44)(0)1865843830, fax:(þ44)1865(0)853333,e-mail:[email protected] completeyourrequeston-lineviatheElsevierhomepage (http://www.elsevier.com),byselecting‘CustomerSupport’andthen ‘ObtainingPermissions’ BritishLibraryCataloguinginPublicationData AcataloguerecordforthisbookisavailablefromtheBritishLibrary LibraryofCongressCataloguinginPublicationData AcataloguerecordforthisbookisavailablefromtheLibraryofCongress ISBN0750663146 ForinformationonallElsevierButterworth-Heinemann publicationsvisitourwebsiteathttp://books.elsevier.com TypesetbyIntegraSoftwareServicesPvt.Ltd,Pondicherry,India www.integra-india.com PrintedandboundinGreatBritian Working together to grow libraries in developing countries www.elsevier.com | www.bookaid.org | www.sabre.org Contents Foreword viii Foreword to second edition ix Acknowledgements x Introduction to the retail motor industry and Health & Safety at Work 1 Detail of the motor vehicle maintenance and repair industry An introduction to Health & Safety at Work 1 Engines and lubrication 11 Engine construction Four stroke and two stroke cycles Valve timing – variable valve timing Combustion Lubrication and lubrication systems 2 Cooling systems 58 Cooling system terminology Liquid (water) cooled system Air-cooled system Anti-freeze Specific heat capacity Fans and pumps 3 Fuel systems 85 Petrol fuel system Petrol injection Carburettors Diesel fuel systems Direct injection – indirect injection Common rail fuel system 4 Engine air supply and exhaust systems 128 Engine air supply – air filters – manifolds Exhausts systems – silencers Oxygen sensor Air flow meters Turbo-charger 5 Transmission systems 141 Clutch Gearbox Fluid flywheel and torque convertor Transmission systems – drive shafts vi Contents Hub types – semi-floating, fully floating, three-quarter floating Gear ratios – torque multiplication 6 Suspension systems 170 Non-independent – leaf spring suspension Independent suspension Leaf spring construction Dampers (shock absorbers) 7 Braking systems 186 Hydraulic braking systems Drum brakes Disc brakes Master cylinder Wheel cylinders Brake fluid Braking efficiency 8 Steering, wheels and tyres 200 Ackerman principle Steering angles Steering geometry Track adjustment Steering boxes Toe-out on turns 9 Electrical and electronic principles 224 Principles of magnetism and electricity Introductory electronics Computer controlled systems Networking and CAN Multiplexing Meters 10 Electrical and electronic systems 243 Alternator Battery Charging system Starting systems Electrical principles 11 Ignition systems 260 Ignition systems – coil, capacitor (condenser) Electronic ignition systems, non-electronic ignition systems Fault tracing and service and maintenance procedures Sensors and pulse generators Ignition timing Diagnostic trouble codes 12 Electrical systems and circuits 297 Central locking Screen wipers Vehicle security alarm Electric windows Screen washers Contents vii Electric mirrors Vehicle lighting systems Supplementary restraint systems – airbags and seatbelt pre-tensioners 13 Measuring instruments and measurement 331 Micrometers Vernier calipers Feeler gauges Number approximations – typical motor vehicle measurements Electrical test meters 14 Organisations and qualifications 348 Organisations in the motor trade Qualifications and careers Answers to self assessment questions 351 Index 353 Foreword Althoughthisbookhasbeenwrittenmainlyfor she understands the subject and uses the key those who wish to gain an NVQ in motor vehi- words, it will be very difficult for the assessor clework,itisequallysuitableforawidevariety to give marks. Remember the key words and of people who are undertaking the City & you will be half-way there. Some of the words Guilds, BTEC as well those who just want to usedarespecifictothemotorvehicleandtothe know about cars to enable them to undertake NVQ.Wehavetriedtoexplainthoserelatingto their own servicing with a greater degree of the motor vehicle in the text and those relating confidence. It can be used in schools, colleges totheNVQinaglossaryattheendofthebook. and garage workshops as each task is being There are a number of practical assignments undertaken. and learning tasks in each chapter. If these are It covers the fundamental principles for each undertaken in a realistic way, they will enable system found in the motor vehicle. It is by no the student to complete the task repeatedly, up means exhaustive, but it does allow the student to an acceptable standard, without supervision, to take simple steps in understanding how each which is therequirement ofthe NVQ. system works. The workshop job sheet should contain all The NVQ qualification is not as daunting as the elements of the performance criteria as manypeoplethink.Themainproblemseemsto requested in the NVQ. They should be signed beinthegainingofevidenceandtheassembling by both the person undertaking the task (you) of a portfolio, so, with this in mind, there are a and the assessor/supervisor to say the task has number of exercises at the end of each section been completed satisfactorily. for the student to complete. The evidence The illustrations have been selected to give required by the NVQ assessor from the student the maximum amount of support when learn- willbegainedgraduallyandbuiltintoastudent ing about new topics. We advise students to portfolio. Each completed job sheet (suitably attempt the learning tasks when they have signed after the job has been checked) should completed the related section of their training showevidenceofwhatyouhavedone,howyou and education. diditandthatitwascompletedtoasatisfactory Thisbookisbasedonmanyyearsofteaching standard. When the student feels confident and helping students and apprentices who have enough to complete the task alone then he or gone on to become successful and valued she may request an assessment. Examples of mechanics. Some of them have become owners assessmentsaregiveninthebooktoshowwhat of their own motor vehicle workshops, each in might be required by the assessor. turnhasappreciatedthetrainingthatwasgiven Thetexthasanumberofwordsandsentences tothemintheirearlyyears.Ourhopeisthatthis that are highlighted when they first appear in book will enable a wider variety of people to the text. These are mostly key words that will achieve their hopes and ambitions. help the student to remember what is essential fromthetext.Nomatterhowmuchthestudent Derek Newbold ‘waffles’whenansweringquestions,unlessheor Allan Bonnick Foreword to second edition In order to take account of feedback from maintenance aspects are covered and a range practising teachers and to allow for develop- of learning tasks and self assessment question ments in technology, education and training is included. this 2nd edition includes coverage of develop- ments such as; variable value timing, on board Allan Bonnick diagnostics, computer controlled systems etc. 2005