and five accompanying study guides

533 Pages·2011·46.17 MB·English

OTHEll. BOOKS BY WILLIAM H. CROUSE
Automotive Mechanics
and five accompanying study guides:
WOll.KBOOI( FOR AUTOMOTIVE CHASSIS
WOll.KBOOI( FOR AUTOMOTIVE ELEcnHCITY
WOll.KBOOK FOR AUTOMOTIVE ENGINES
WOll.KBOOI( FOR AUTOMOTIVE SERVICE
AND TROUBLESHOOTING
WOll.KBOOI( FOR AUTOMOTIVE TOOLS
Everyday Automobile Repairs
AUTOMOTIVE
ENGINES
Construction, Operation
and Maintenance
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. SECOND EDITION
Date:
William H. Crouse
ABOUT THE AUTHOR
Behind William H. Crouse's clear technical writing is a background of
sound mechanical engineering training as well as a variety of practical indus
trial experiences. He spent a year after finishing high school working in a
tinplate mill, summers, while still in school, working in General Motors plants,
and three years working in the Delco-Remy Division shops. Later he became
Director of Field Education in the Delco-Remy Division of General Motors
Corporation, which gave him an opportunity to develop and use his natural
writing talent in the preparation of service bulletins and educational literature.
During the war years, he wrote a number of technical manuals for the Armed
Forces. After the war, he became Editor of Technical Education Books for
the McGraw-Hill Book Company. He has contributed numerous articles to
automotive and engineering magazines and has written several outstanding
books: Automotive Mechanics, Electrical Appliance Servicing, Everyday Au
tomobile Repairs, Everyday Household Appliance Repairs, and Understanding
Science. .
William H. Crouse's outstanding work in the automotive field has earned for
him membership in the Soci~ty of Automotive Engineers and in the American
Society for Engineering Education.
AUTOMOTIVE ENGINES
Copyright © 1959 by the McGraw-Hill Book Company, Inc.
Copyright © 1955 by the McGraw-Hill Book Company, Inc. Printed in the
United States of America. All rights reserved. This book, or parts thereof, may not
be reproduced in any form without permission of the publishers.
Library of Congress Card Number: 58-11978
VI
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THE MAPLE PRESS COMPANY, YORK, PA.
How to study this book
THIS IS one of a series of five books covering in detail the con
struction, operation, and maintenance of automobiles. The five
books are designed to give you the complete background of infor
mation you need to become an automotive mechanic. Furthermore,
the comprehensive coverage of the subject matter in the books
should make them a valuable addition to the library of anyone
interested in any phase of automobile engineering, manufacturing,
sales, service, and operation.
GETTING PRACTICAL EXPERIENCE
Of course, these books alone will not make you an automotive
mechanic, just as books alone do not make an airplane pilot or a
dentist or an architect the expert he is. Practice also is required,
practice in handling automotive parts and automotive tools and in
following automotive servicing procedures. The books will give you
the theoretical background you need, but you should seek out
means of getting practice, also. If you are taking a regular course in
automotive mechanics, you will get practical experience in the
school automotive shop. But if you are not taking a regular course
in a school, you may still be able to make use of the facilities of any
nearby school with an automotive shop. Perhaps you will meet
others who are taking an automotive mechanics course and can talk
over any problems you have. This often clears up difficult points. A
local garage or service station is a good source of practical informa
tion. If you can get acquainted with the automotive mechanics
there, so much the better. Watch them as they work; notice how
they do things. Then go home and think about it. Perhaps the
mechanics will let you handle various parts and pOSSibly even help
with some of the servicing jobs.
[vJ
How to Study This Book
SERVICE PUBLICATIONS
\Vhile you are in the service shop, try to get a chance to study
the various publications they receive. Automobile manufacturers,
as well as suppliers of parts, accessories, and tools, publish shop
manuals, service bulletins, and parts catalogues. All these are
designed to help service personnel do a better job. In addition,
numerous automotive magazines are published which deal with the
problems and methods of automotive service. All these publications
will be of great value to you; study them carefully.
These various activities will help you gain practical experience in
automotive mechanics. Sooner or later this experience, plus the
knowledge that you have gained in studying the five books in the
McGraw-Hill Automotive Mechanics Series, will permit you to step
into the automotive shop on a full-time basis. Or, if you are already
in the shop, you will be equipped to step up to a better and a more
responsible job.
CHECKING UP ON YOURSelF
Every few pages in the book you are given the chance to check
the progress you are making by answering a series of questions.
There are two types of tests, progress quizzes and chapter check
ups. Each progress quiz should be taken just after you have
completed the pages preceding it. The quizzes allow you to check
yourself as you finish a lesson. On the other hand, the chapter
checkups may cover several lessons since they are review tests of
entire chapters. Since they are review tests, you should review the
entire chapter by rereading it or at least paging through it to check
important points before trying the test. If any of the questions
stump you, reread the pages in the book that will give you the
answer. This sort of review is very valuable and will help you fix in
your mind the essential information you will need when you go into
the automotive shop. Do not write in the book. Instead, write down
your answers in a notebook.
KEEPING A NOTEBOOK
\ Most of the questions require a written answer. It would be well
for you to keep a notebook and for you to write the answers in the
[vi]
How to Study This Book
notebook. Also, you can write down in the notebook important
facts that you pick up from reading the book or from working in the
shop. As you do this, you will Rnd that the notebook will become a
valuable source of information to which you can refer. Use a loose
leaf, ring-binder type of notebook so that you can insert or remove
pages and thereby add to and improve your notebook.
GLOSSARY AND INDEX
There is a list of automotive terms in the back of the book, along
with their definitions. Whenever you have any doubt about the
meaning of some term or what purpose some automotive part has,
you can refer to this list, or Glossary. Also, in the back of the book
you will find an Index. This Index will help you look up anything
in the book that you are not sure about. For example, if you wanted
to refresh your mind on how some component works, you could
locate the explanation quickly by looking in the Index to find what
pages the information is on.
AUTOMOTIVE TOOLS
Notice that the Automotive Engines book has a chapter on auto
motive tools. This chapter is an important one and should be studied
along with any of the books in the McGraw-Hill Automotive
Mechanics Series. In other words, the information in this chapter
on tools applies to all service operations on the car, and not just to
engine service.
McGRAW-HILL AUTOMOTIVE MECHANICS SERIES
The five books in the McGraw-Hill Automotive Mechanics Series,
of which this is one, are deSigned to be a complete library in auto
motive mechanics. Their purpose is to supply the technical back
ground needed by anyone entering the field of automotive servicing.
Although the five books are closely correlated, each is complete in
itself and can serve as a text in the particular specialty it covers.
There are, unavoidably, some slight duplications in the books; these
were necessary to make each book a complete text in itself. The
duplications will serve as a review for the student and will thus help
him remember essential points on the construction and operation of
automotive engines.
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How to Study This Book
And now, good luck to you. You are engaged in the study of a
fascinating, complex, and admirable mechanism-the automobile.
Your studies can lead you to success in the automotive field, a field
where opportunities are great. For it is the man who knows-the
man who can do things-who moves ahead. Let this man be you.
WILLIAM H. CROUSE
Contents
v
How to Study This Book .
Preface to the Second Edition xiv
Acknowledgments xv
1. FUNDAMENTAL PRINCIPLES 1
1. Purpose of This Book. 11. The Thermometer as an Application
2. What Our Universe Is Made of. of the Expansion Effect.
3. Atoms. 18. The Thermostat as an Application
of the Expansion Effect.
4. Size of Atoms.
19. What Is Meant by "Physical
5. The Hydrogen Atom.
Principles."
6. Helium.
20. Gravity.
7. More Complex Atoms.
21. Atmospheric Pressure.
8. Molecules.
22. Vacuum.
9. Combustion.
23. Work.
10. The Nature of Heat.
24. Energy.
11. Change of State.
25. Power.
12. Producing Change of State.
26. Horsepower.
13. Light and Heat Radiations.
27. Inertia.
14. ExpanSion of Solids Due to Heat.
28. Torque.
15. ExpanSion of Liquids and Gases
29. Friction.
Due to Heat.
16. Increase of Pressure with
Temperature. .
.
2. AUTOMOBILE COMPONENTS 29
30. Components of the Automobile. 40. Clutch.
81. Frame and Chassis. 41. Transmission.
82. Engine Support. 42. Gears.
83. Springs. 43. Operation of Transmission.
84. Shock Absorbers. 44. Other Transmissions.
35. Steering System. 45. Propeller Shaft.
36. Brakes. 46. Differential.
37. Tires. 47. Body.
38. Body Supports. 48. Accessories.
39. Power Train.
3. ENGINE FUNDAMENTALS 64
49. The Engine Cylinder. 51. The Valves.
50. Reciprocating to Rotary Motion. 52. Engine Operation.
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Contents
53. Multiple-cylinder Engines. 59. Lubrication System.
54. Flywheel. 60. Electric System.
55. Engine Accessories. 61. Operation of Ignition System.
56. Fuel System. 62. Operation of Ignition-advance
57. Other Fuel Systems. Mechanisms.
58. Exhaust System. 63. Cooling System.
4. ENGINE-PERFORMANCE MEASUREMENTS 103
64. Bore and Stroke. 73. Dynamometer Test r,csu!is.
65. Piston Displacement. 74. Indicated Horsepower.
66. Compression Ratio. 75. Frictional Horsepower.
67. Effect of Increasing Compression 76. Relating bhp, ihp, and fhp.
Ratio. 77. SAE Horsepower.
68. Delivery of Air-Fuel Mixture. 78. Torque.
69. Volumetric Efficiency. 79. Torque Compared with Brake
70. Engine Power Output. Horsepower.
71. Determining Brake Horsepower. 80. Engine Efficiency.
72. Dynamometer Rating of Engine 81. Over -all Efficiency.
Horsepower.
5. ENGINE TYPES 1$
82. Cylinder Arrangements. 86. Classification by Fuel.
83. Valve Arrangements. 87. Diesel Engine.
84. Cooling. 88. Gas Turbine.
85. Classification by Cycles. 89. Free-piston Engine.
6. ENGINE CONSTRUCTION and COMPONENTS 151
90. Engine Construction. 100. Crankshaft.
91. Engine Cylinder Block. 101. Vibration Dampener.
92. Cylinder-block Materials and 102. Engine Bearings.
Machining. 103. Engine-bearing Lubrication.
93. Cylinder Heads. 104. Engine-bearing Types.
94. Gaskets. 105. Bearing Requirements.
95. Oil Pan. 106. Bearing Materials.
96. Exhaust Manifold. 107. Bearing Loading.
97. Exhaust System. 108. The Effective Bearing Load.
98. Intake Manifold. 109. The Bearing-load Graph.
99. Manifold Heat Control.
7. PISTONS and VALVES. 194
110. Connecting Rod. 116. Replacement Rings.
111. Pistons and Piston Rings. 117. Pistons.
112. Piston Rings. 118. Piston Clearance.
113. Compression Rings. 119. Cam-ground Pistons.
114. Oil-control Rings. 120. Piston Heads and Skirts ••
115. Effect of Speed on Oil Control. 121. Cams and Camshaft.
,
,
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Contents
122. Valves. 128. F-head Valve Trains.
123. Valve Cooling. 129. Valve Rotation.
124. Sodium-cooled Valve. 130. Valve Rotators.
125. Valve Seat. 131. Hydraulic Valve Lifter.
126. L-head Valve Train. 132. Valve Timing.
127. I-head Valve Train. 133. Cam Contours.
8. AUTOMOTIVE-ENGINE FUELS and FUEL SYSTEMS . 244
134. Carburetor Circuits. 145. Automotive-engine Fuels.
135. Air Cleaner. 146. Diesel-engine Fuel.
136. Float Circuit. 147. Liquefied Petroleum Gas.
137. Idle and Low-speed Circuit. 148. Gasolinc.
138. Low-speed Circuit. 149. Volatility.
139. High-speed, Part-load Circuit. 150. Antiknock Value.
140. High-speed, Full-power Circuit. 151. Octane and Engine Compression
141. Accelerating-pump Circuit. Ratio.
142. Choke. 152. Harmful Chemicals and Gum.
143. Gasoline Fuel-injection Systems. 153. Fuel-system Troubles.
144. Other Carburetor Controls.
9. AUTOMOTIVE-ENGINE COOLING SYSTEMS 271
154. Purpose of the Cooling System. 158. Radiator Pressure Cap.
155. Water Pump and Engine Fan. 159. Antifreeze Solutions.
156. Radiator. 160. Cooling-system Troubles.
157. Thermostat.
10. AUTOMOTIVE LUBRICANTS and LUBRICATING SYSTEMS 280
161. Friction. 166. Oil Filters.
162. Purposes of the Lubricating Oil. 167. Crankcase Ventilation.
163. Types of Lubricating Systems. 168. Source and Properties of Oil.
164. Oil Pumps. 169. Automotive Lubricants.
165. Relief Valve. 170. Lubricating-system Troubles.
11. ENGINE-TESTING PROCEDURES and TOOLS . 297
171. Engine-testing Procedures. 176. Exhaust-gas Analyzer.
172. Instruments Used in Engine 177. Ignition Timing.
Testing. 178. Electrical Checks.
173. Tachometer. 179. Chassis Dynamometer.
174. Cylinder Compression Tester. 180. The Tune-up Procedure.
175. Engine Vacuum Gauge. 181. Test Reports.
12. DIAGNOSING ENGINE TROUBLES 814
182. How to Study This Chapter. 185. Engine Will Not Turn Over.
183. Need for Logical Procedure. 186. Engine Turns Over Slowly but
184. Engine Trouble-shooting Chart. Does Not Start.
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