Automotive Chassis Systems

751 Pages·2009·48.772 MB·English

by  James D. Halderman

AUTOMOTIVE
CHASSIS SYSTEMS
F I F T H E D I T I O N
James D. Halderman
Prentice Hall
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10 9 8 7 6 5 4 3 2 1
ISBN 10: 0-13-508503-9
ISBN 13: 978-0-13-508503-5
PREFACE
PROFESSIONAL TECHNICIAN SERIES Part of Pearson ASE AND NATEF CORRELATED NATEF certified pro-
Automotive’s Professional Technician Series, the fifth edition of grams need to demonstrate that they use course material that
Automotive Chassis Systemsrepresents the future of automo- covers NATEF and ASE tasks. All Professional Technician text-
tive textbooks. The series is a full-color, media-integrated books have been correlated to the appropriate ASE and NATEF
solution for today’s students and instructors. The series task lists. These correlations can be found in two locations:
includes textbooks that cover all 8 areas of ASE certification, (cid:2) As an appendix to each book.
plus additional titles covering common courses.
(cid:2) At the beginning of each chapter in the Annotated
Current revisions are written by a team of very experienced
Instructor’s Guide.
writers and teachers. The series is also peer reviewed for tech-
nical accuracy.
A COMPLETE INSTRUCTOR AND STUDENT SUPPLE-
MENTS PACKAGE All Professional Technician textbooks
UPDATES TO THE FIFTH EDITION
are accompanied by a full set of instructor and student supple-
(cid:2) All content is correlated to the latest NATEF and ments. Please see page vi for a detailed list of supplements.
ASE tasks.
(cid:2) A dramatic, new full-color design enhances the subject A FOCUS ON DIAGNOSIS AND PROBLEM SOLVING
material. The Professional Technician Series has been developed to sat-
(cid:2) One entirely new chapter has been added on Electronic isfy the need for a greater emphasis on problem diagnosis.
Stability Control Systems(Chapter 20). This important Automotive instructors and service managers agree that stu-
new chapter covers the purpose, function, parts, and op- dents and beginning technicians need more training in diag-
eration of the electronic stability control system that uses nostic procedures and skill development. To meet this need and
the antilock brake system components to control vehicle demonstrate how real-world problems are solved, “Real World
stability. Fix” features are included throughout and highlight how real-life
problems are diagnosed and repaired.
(cid:2) Over 40 new color photos and line drawings have been
The following pages highlight the unique core features that
added to this edition.
set the Professional Technician Series book apart from other au-
(cid:2) Content has been streamlined for easier reading and
tomotive textbooks.
comprehension.
(cid:2) This text is fully integrated with MyAutomotiveKit, an online
supplement for homework, quizzing, testing, multimedia
activities, and videos.
(cid:2) Unlike other textbooks, this book is written so that the
theory, construction, diagnosis, and service of a particu-
lar component or system is presented in one location.
There is no need to search through the entire book for
other references to the same topic.
iii
IN-TEXT FEATURES
SAFETY TIP
chapter 1 Shop Cloth Disposal
SERVICE Always dispose of oily shop cloths in an enclosed
container to prevent a fire. (cid:3)SEE FIGURE 1–69.
INFORMATION,
Whenever oily cloths are thrown together on the floor
or workbench, a chemical reaction can occur, which
TOOLS, AND SAFETY
can ignite the cloth even without an open flame. This
process of ignition without an open flame is called
spontaneous combustion.
OBJECTIVES KEY TERMS
After studying Chapter 1, the reader will be Bench grinder 25 PPE 25
able to: Bolts 5 Pinch weld seam 28
1.Uvenhdicelres tiadnedn ttifhicea AtiSoEn aknndow thleed pgreo pcoern tuesnet ofofr BBruemakpe cr abpa r2 511 PPiltiecrhs 515 SAFETY TIPS alert students to possible hazards on the job
toolsand shop equipment. Calibration codes 3 Punches 18
2.Retrieve vehicle service information. Campaign 4 Ratchet 11 and how to avoid them.
3.Identify the strength ratings of threaded Casting number 3 Recall 4
fasteners. Cheater bar 13 Screwdrivers 13
4.Describe how to safely hoist a vehicle. CDrhivisee lssi ze1s9 11 SSnoicpkse t1 811 REAL WORLD FIX
5.Discuss how to safely use hand tools. Extensions 11 Socket adapter 13
6.Identify the personal protective equipment Eye wash station 34 Spontaneous
(PPE) that all service technicians should wear. Files 17 combustion 28
7.Describe what tool is the best to use for each job. Fire blanket 33 SST 22
8.Explain the difference between the brand name Fire extinguisher Stud 5 Three Brake Jobs in 40,000 Miles
(trade name) and the proper name for tools. classes 32 Tensile strength 6
9.Explain how to maintain hand tools. GAWR 3 Trouble light 23
10.Iwdheennti fwy othrkei npgre ocna uhtyiobnrisd tehlaetc strhico uvledh bicele fso.llowed GGHarVacWdkeRs a 6w3s 19 TUUSNNBCF 455 A service technician was asked to replace the front disc
Hammers 14 Universal joint 11 brake pads on a Pontiac Grand Am because the sen-
HEV 35 VECI 3
LED 23 VIN 2 sors were touching the rotors and making a squealing
Metric bolts 6 Washers 8
Nuts 8 Wrenches 9
sound. This was the third time that the front brakes
1 needed to be replaced. Previous brake repairs had been
limited to replacement of the front disc brake pads only.
When the caliper was removed and the pads
OBJECTIVES AND KEY TERMS appear at the beginning
inspected, it was discovered that a part of one pad
of each chapter to help students and instructors focus on the
had broken and a piece of the lining was missing.
most important material in each chapter. The chapter objectives
(cid:3)SEE FIGURE 13–15.
are based on specific ASE and NATEF tasks.
REAL WORLD FIXES present students with actual automo-
tive scenarios and shows how these common (and sometimes
uncommon) problems were diagnosed and repaired.
TECH TIP
?
FREQUENTLY ASKED QUESTION
It Just Takes a Second
How Many Types of Screw Heads Are Used
Whenever removing any automotive component, it is
inAutomotive Applications?
wise to screw the bolts back into the holes a couple
There are many, including Torx, hex (also called
of threads by hand. This ensures that the right bolt will
Allen), plus many others used in custom vans and
be used in its original location when the component
motor homes. (cid:3)SEE FIGURE 1–9.
or part is put back on the vehicle.
FREQUENTLY ASKED QUESTIONS are based on the au-
TECH TIPS feature real-world advice and “tricks of the
thor’s own experience and provide answers to many of the most
trade” from ASE-certified master technicians.
common questions asked by students and beginning service
technicians.
iv
IN-TEXT FEATURES
NOTE:Mostofthese“lockingnuts”aregroupedtogether
andarecommonlyreferredtoasprevailingtorquenuts.
SUMMARY
This means that the nut will hold its tightness or torque
1.Bolts, studs, and nuts are commonly used as fasteners in 6.Sockets are rotated by a ratchet or breaker bar, also called
the chassis. The sizes for fractional and metric threads are a flex handle.
andnotloosenwithmovementorvibration. different and are not interchangeable. The grade is the rat- 7.Torque wrenches measure the amount of torque applied to
ing of the strength of a fastener. a fastener.
2.Whenever a vehicle is raised above the ground, it must be 8.Screwdriver types include straight blade (flat tip) and Phillips.
NOTES provide students with additional technical informa- 3.sWnuarpteiopnnoc rhoteepsde anar tae an a dsv uabbiolasxbt aelenn tidina. lo speecnti oenn do,f bthoex beonddy, aonr dfr caomme.bi- 109..HPtylapiemerssm, aeinrresc laaun dudisn megf ausllll eipttos-oj ocl oinamnt,d em ianur aelt ivgaarvoraieoiltvayeb o,l efl is niinez esmsm aaannnyd’s wd, iedffiiegarhgetons-t.
tion to give them a greater understanding of a specific task or 4.Aprno paedrj ussiztea bisle n owtr aevnacihla bslheo.uld only be used where the 11.nOathl, enre ceodmlem-noons eh, aanndd tloocoklsin ign cpluliedres .snap-ring pliers, files,
5.Line wrenches are also called flare-nut wrenches, fitting cutters, punches, chisels, and hacksaws.
procedure. wfureeln ocrh reesfr,i goer rtaunbte li-nneust. wrenches and are used to remove 12.Hhiygbhr-ivdo eltlaegcetr icco vmehpiocnleesn stsh oaureld g boein dge t-op obwe esreerdv iicf eadn.y of the
REVIEW QUESTIONS
CAUTION: Never use hardware store (nongraded) 1.List three precautions that must be taken whenever hoist- 6.What are the other names for a line wrench?
ing (lifting) a vehicle. 7.What are the standard automotive drive sizes for sockets?
bolts, studs, or nuts on any vehicle steering, suspension, 2.Dhoewsctrhibeemhaorwkintogsdedtieffremribneetwtheeegnrafrdaectoiofnaaflaasntednmere,tinricclubdoilntsg. 8.Wmahlilceht? type of screwdriver requires the use of a hammer or
or brake component. Always use the exact size and 3.Listfouritemsthatarepersonalprotectiveequipment(PPE). 9.What is inside a dead-blow hammer?
4.List the types of fire extinguishers and their usage. 10.What type of cutter is available in left and right cutters?
5.Why are wrenches offset 15 degrees?
grade of hardware that is specified and used by the
CHAPTER QUIZ
vehicle manufacturer.
1.The correct location for the pads when hoisting or jacking 7.The proper term for Vise Grips is ________.
CAUTIONS alert students about potential damage to the ve- tah.e Sveerhviicclee mcaann uoaftlen be foundc i.n Othwe n_e_r_’s_ _m__a_n.ual ab..LSolipck-jionign tp plileiersrs cd..SMiduleti gcruotosve adjustable pliers
b.Shop manual d.All of the above 8.Two technicians are discussing torque wrenches. Tech-
2.Forthebestworkingposition,theworkshouldbe________. nician A says that a torque wrench is capable of tightening
hicle that can occur during a specific task or service procedure. a.At neck or head level a fastener with more torque than a conventional breaker
b.At knee or ankle level bar or ratchet. Technician B says that a torque wrench
c.Overhead by about 1 foot should be calibrated regularly for the most accurate
d.At chest or elbow level results. Which technician is correct?
3.A high-strength bolt is identified by ________. a.Technician A only c.Both Technicians A and B
a.A UNC symbol c.Strength letter codes b.Technician B only d.Neither Technician A nor B
b.Lines on the head d.The coarse threads 9.What type of screwdriver should be used if there is very
WARNING 4.A__ _fa_s_t_e_n_e.r that uses threads on both ends is called a laim.iOtefdfs sept asccere awbdorvivee rthe hce.adIm opf athcet sfacsretewnderri?ver
a.Cap screw c.Machine screw b.Stubby screwdriver d.Robertson screwdriver
b.Stud d.Crest fastener 10.What type of hammer is plastic coated, has a metal casing
5.When working with hand tools, always ________. inside, and is filled with small lead balls?
a.Push the wrench—don’t pull toward you a.Dead-blow hammer c.Sledgehammer
Do not use incandescent trouble lights around b.Pull a wrench—don’t push a wrench away from you b.Soft-blow hammer d.Plastic hammer
6.The proper term for Channel Locks is ________.
a.Vise Grips c.Locking pliers
gasoline or other flammable liquids. The liquids can b.Crescent wrench d.Multigroove adjustable pliers
cause the bulb to break and the hot filament can
SERVICE INFORMATION, TOOLS, AND SAFETY 39
ignite the flammable liquid which can cause
THE SUMMARY,REVIEW QUESTIONS,AND CHAPTER
personal injury or even death.
QUIZ at the end of each chapter help students review the ma-
terial presented in the chapter and test themselves to see how
WARNINGS alert students to potential dangers to them- much they’ve learned.
selves during a specific task or service procedure.
HOISTING THE VEHICLE STEP BY STEP
1The first step in hoisting a vehicle is to properly align 2Most vehicles will be correctly positioned when the left 7Position the pads under the vehicle under the recom- 8After being sure all pads are correctly positioned,use
the vehicle in the center of the stall. front tire is centered on the tire pad. mended locations. the electromechanical controls to raise the vehicle.
3Tbcohene rs oattrraumtcestd ioc tanon. a blleo wm ofovre md iann ay nddif foeurte annt dty mpeoss to pf avdehs iccalen 4Matthoro eehs fiottr f alatiemfntnsde n adoerafec ma ee savqsgeuaehirp iypcp lateeord t ws uw isoteihft hottho use tha cbollaoorutwd spy i.atnhdge e tphxateed an trsomi oc noosfn ttthahecat tlift 9Wporwwenuoois strrtehhkkht ii etdnnth hoggpeew a lo vedpnnevsa hoe.od inlIrcs.f l .uBtet hThn erehed a se evivu srever ehtehedhih ic ectiohlcl eenvel ee e trs oh ocfa iocaccfkoenhlestt e y.b,(c 3elikos0 rw t aecoeinm srsge e)tad heog e tfeiof f vd tiae htb nheiesyi cfg osdlretroeae uasbinnrledded, 10Iplcfoaa arndad sib.s uIeifnn ragdad eaidsr eiv ttdeihoh eani csap llies nch cwloehwia twhrnaoe.nulcdt e as iesfar anmme cteoe, spssplaarcreyea, dtthh teeh epflaadts
STEP-BY-STEP photo sequences show in
5Tthvhaeoelhils ifptcr alamedmsa .eenx yot efp naics kviouenhpsi ct rcluea.cn Tk ahsl,issvo ap nboses, iutaisonendd is stp ono egrtea duinet idali cttycoe ssasf etoly 6Atnrenuc caekds dosirat irvoyan nca llee eaqxruatiepnnpcseei.do nw mitha yr ubnen ninegc ebsosaarrdys ttoo hgoiviset tahe 1111Wsfohrhoeeu nuld st ihbneeg srtaehiresv eihcdye ds wrliagouhrlkitcl yi sl ea cvnoedmr tthpoel el ostewadfee,rtt yht heree h lveoeaishsteicdle b.e- 1122AlvAlviieefffftttthh eeaaiirrccrr eelllleeoo mm wwoouuooeettvvrr iieeoonnddffgg tt ootthhhhuueeeett ww oovvffooee ttrrhhhhkkiiccee ssll eewwttaa,,aallbbllyy..ee bbsseeuuffrrooeerr eeaa llddll rraaiivvrrmmiinnssgg ootthhff eetthhee detail the steps involved in performing a specific
CONTINUED(cid:4)
37 CHAPTER1 SERVICE INFORMATION, TOOLS, AND SAFETY38 task or service procedure.
v
IN-TEXT FEATURES
SUPPLEMENTS
INSTRUCTOR SUPPLEMENTS The instructor supple- MYAUTOMOTIVEKIT An offshoot of the extremely popular
ment package has been completely revamped to reflect the MyAutomotiveLab, these online kits can be used with all Pro-
needs of today’s instructors. The all new Annotated Instruc- fessional Technician Series textbooks for quizzing, testing,
tor’s Guide (ISBN 0-13-509346-5) is the cornerstone of the homework, and multimedia activities. All assignments are auto-
package and includes: matically graded and entered into a gradebook for the course.
In addition to assessment materials, MyAutomotiveKit includes:
(cid:2) Chapter openers that list
(cid:2) Interactive Animations
—NATEF/ASE tasks covered in the chapter
(cid:2) Two- to five-minute video clipsshowing procedures
—all key terms
(cid:2) A3D virtual garagethat simulates the shop experience
—all Chapter Objectives
in the real world by focusing on customer complaints,
(cid:2) The entire text (matching page numbers with student edi- conducting tests to determine the problem with the vehi-
tion) with margin notes. These notes include: cle, and submitting a written work order to the instructor.
—Tips for in-class demonstrations (cid:2) All materials are broken down by chapter for easy naviga-
tion and use.
—Suggested hands-on activities
To get instructor access to MyAutomotiveKit, please visit
—Cross-curricular activities
www.myautomotivekit.com
—Internet search tips
—Assessments
STUDENT SUPPLEMENTS NO MORE CDs!!
—Safety tips
As a result of extensive student input, Pearson is no longer bind-
—Classroom discussion questions ing CDs into automotive students’ textbooks. Today’s student
has more access to the Internet than ever, so all supplemental
(cid:2) A guide to using MyAutomotiveKit in the course
materials are downloadable at the following site for no addi-
tional charge:
Also, in every Professional Technician Series Annotated
www.pearsoned.com/autostudent
Instructor’s Guide there is an Instructor’s CDthat contains:
(cid:2) PowerPoint presentations*
On the site, students will find:
(cid:2) Image Library containing every image in the book for use
in class or customized PowerPoints* (cid:2) PowerPoint presentations
(cid:2) Test Generator software and test bank* (cid:2) Chapter review questions and quizzes
(cid:2) Chapter Quizzes (cid:2) English and Spanish Glossary
(cid:2) Chapter Review Questions (cid:2) A full Spanish translation of the text
(cid:2) English and Spanish Glossary* (cid:2) Links to MyAutomotiveKit
(cid:2) NATEF Correlated task Sheets* (also available as a
MYAUTOMOTIVEKIT FOR THE STUDENT For the stu-
printed supplement [ISBN: 0-13-509377-5])
dent, MyAutomotiveKit is a one-stop shop for homework,
(cid:2) NATEF/ASE Correlation Charts
quizzes, tests, and a new way of learning. Key concepts are
reinforced through media. Students will find part identification
* All of these are available for download from www.pearson-
activities, word search games, interactive animations, and a 3D
highered.com
virtual garage for help with diagnosis.
vi
SUPPLEMENTS
ACKNOWLEDGMENTS
A large number of people and organizations have cooperated in A. C. Durdin
providing the reference material and technical information used Moraine Park Technical College
in this text. The author wishes to express sincere thanks to the Herbert Ellinger
following organizations for their special contributions: Western Michigan University
ASE Al Engledahl
Automotion, Inc. College of Dupage
Automotive Parts Rebuilders Association (APRA)
Larry Hagelberger
Bendix
Upper Valley Joint Vocational School
British Petroleum (BP)
Oldrick Hajzler
Cooper Automotive Company
Red River College
CR Services
Dana Corporation Betsy Hoffman
Fluke Corporation Vermont Technical College
FMC Corporation Steven T. Lee
Ford Motor Company Lincoln Technical Institute
Hennessy Industries
Carlton H. Mabe, Sr.
Hunter Engineering Company
Virginia Western Community College
Lee Manufacturing Company
Roy Marks
MOOG Automotive Inc.
Owens Community College
Perfect Hofmann-USA
Tony Martin
SKF USA, Inc.
University of Alaska Southeast
Society of Automotive Engineers (SAE)
Specialty Products Company Kerry Meier
Tire and Rim Association, Inc. San Juan College
Toyota Motor Sales, USA, Inc. Fritz Peacock
TRW Inc. Indiana Vocational Technical College
Wurth USA, Inc.
Dennis Peter
NAIT (Canada)
TECHNICAL AND CONTENT REVIEWERS The following
Kenneth Redick
people reviewed the manuscript before production and
Hudson Valley Community College
checked it for technical accuracy and clarity of presentation.
Mitchell Walker
Their suggestions and recommendations were included in the
St. Louis Community College at Forest Park
final draft of the manuscript. Their input helped make this text-
book clear and technically accurate while maintaining the easy- Jennifer Wise
to-read style that has made other books from the same author Sinclair Community College
so popular. Special thanks to instructional designer Alexis I. Skriloff
Jim Anderson James.
Greenville High School
PHOTO SEQUENCES The author wishes to thank Blaine
Victor Bridges
Heeter, Mike Garblik, and Chuck Taylor of Sinclair Community
Umpqua Community College
College in Dayton, Ohio, and James (Mike) Watson who helped
Dr. Roger Donovan
with many of the photos.
Illinois Central College
Most of all, I wish to thank Michelle Halderman for her
assistance in all phases of manuscript preparation.
—James D. Halderman
vii
ACKNOWLEDGMENTS
ABOUT THE AUTHOR
JIM HALDERMANbrings a world of experience, knowledge,
and talent to his work. His automotive service experience in-
cludes working as a flat-rate technician, a business owner, and
a professor of automotive technology at a leading U.S. commu-
nity college for more than 20 years.
He has a Bachelor of Science Degree from Ohio Northern
University and a Masters Degree in Education from Miami
University in Oxford, Ohio. Jim also holds a U.S. Patent for
an electronic transmission control device. He is an ASE certified
Master Automotive Technician and Advanced Engine Perfor-
mance (L1) ASE certified.
Jim is the author of many automotive textbooks all pub-
lished by Prentice Hall.
Jim has presented numerous technical seminars to na-
tional audiences including the California Automotive Teachers
(CAT) and the Illinois College Automotive Instructor Association
(ICAIA). He is also a member and presenter at the North Ameri-
can Council of Automotive Teachers (NACAT). Jim was also
named Regional Teacher of the Year by General Motors Corpo-
ration and an outstanding alumnus of Ohio Northern University.
Jim and his wife, Michelle, live in Dayton, Ohio. They have
two children. You can reach Jim at
[email protected]
viii
ABOUT THE AUTHOR
BRIEF CONTENTS
chapter 1 Service Information, Tools, and Safety 1
chapter 2 Environmental and Hazardous Materials 40
chapter 3 Braking System Components and Performance Standards 54
chapter 4 Braking System Principles 63
chapter 5 Brake Hydraulic Systems 75
chapter 6 Hydraulic Valves and Switches 94
chapter 7 Brake Fluid and Lines 107
chapter 8 Brake Bleeding Methods and Procedures 122
chapter 9 Wheel Bearings and Service 134
chapter 10 Drum Brakes 155
chapter 11 Drum Brake Diagnosis and Service 175
chapter 12 Disc Brakes 193
chapter 13 Disc Brake Diagnosis and Service 211
chapter 14 Parking Brake Operation, Diagnosis, and Service 232
chapter 15 Machining Brake Drums and Rotors 248
chapter 16 Power Brake Unit Operation, Diagnosis, and Service 291
chapter 17 Regenerative Braking Systems 308
chapter 18 ABS Components and Operation 321
chapter 19 ABS Diagnosis and Service 338
chapter 20 Electronic Stability Control Systems 355
chapter 21 Tires and Wheels 366
chapter 22 Tire Pressure Monitoring Systems 397
chapter 23 Tire and Wheel Service 410
chapter 24 Suspension System Components and Operation 434
chapter 25 Front Suspension and Service 465
chapter 26 Rear Suspension and Service 497
chapter 27 Electronic Suspension Systems 509
ix