Hillier's fundamentals of motor vehicle technology

544 Pages·2004·19.61 MB·English

Hillier’s
Fundamentals of
Motor Vehicle
Technology
Book 1
Hillier’s
Fundamentals of
Motor Vehicle
Technology
5th Edition
Book 1
V.A.W. Hillier & Peter Coombes
Text © V. A. W. Hillier 1966, 1972, 1981, 1991, 2004, P. Coombes 2004
The rights of V. A. W. Hillier and P. Coombes to be identified as authors of this work
has been asserted by them in accordance with the Copyright, Designs and
Patents Act 1988.
All rights reserved. No part of this publication may be reproduced or transmitted in
any form or by any means, electronic or mechanical, including photocopy,
recording or any information storage and retrieval system, without permission in
writing from the publisher or under licence from the Copyright Licensing Agency
Limited, of 90 Tottenham Court Road, London W1T 4LP.
Any person who commits any unauthorised act in relation to this publication may
be liable to criminal prosecution and civil claims for damages.
First published in 1966 by:
Hutchinson Education
Second edition 1972
Third edition 1981 ISBN 0 09 143161 1
Reprinted in 1990 (ISBN 0 7487 0317 9) by Stanley Thornes (Publishers) Ltd
Fourth edition 1991
Fifth edition published in 2004 by:
Nelson Thornes Ltd
Delta Place
27 Bath Road
CHELTENHAM
GL53 7TH
United Kingdom
04 05 06 07 08 / 10 9 8 7 6 5 4 3 2 1
A catalogue record for this book is available from the British Library
ISBN 0 7487 8082 3
Page make-up by GreenGate Publishing Services, Tonbridge, Kent
Printed and bound in Great Britain by Scotprint
CONTENTS
Preface vii Vehicle emissions 199
Acknowledgements ix The diesel four-stroke cycle in detail 205
Diesel combustion 207
1 VSTERHUICCLTEUERVEOLUTION, LAYOUT AND Diesel engine combustion chambers 208
Main components of the diesel engine 211
Vehicle evolution 1 Mechanical aspects of the diesel
Vehicle layout 5 fuel system 213
Vehicle structure 18 Electronic diesel fuel system 227
Routine maintenance 28 Diesel emissions 233
Routine engine maintenance 234
Routine maintenance of the petrol
2 ENGINES fuel system 238
Ignition systems – routine maintenance 241
The internal-combustion reciprocating Routine maintenance of the
engine 31 diesel engine 243
Working principles of the four-stroke Alternative types of engine and fuel 245
and two-stroke engine 35
Torque and power 40
Single-cylinder and multi-cylinder engines 46 3 TRANSMISSION SYSTEMS
Crankshafts 51
Connecting rods 56 The gearbox and gear ratios 255
Pistons, piston rings and gudgeon pins 58 Different types of gears and gearboxes 259
Intake, exhaust valves and valve springs 66 Drive configuration 261
Valve operating mechanisms 73 Rear-wheel drive layout 263
Intake manifolds 83 Front-wheel drive layout 267
Air cleaners and filters 86 Four-wheel drive layout 269
Exhaust systems, silencers and catalytic Single-plate clutches 269
converters 88 Multi-plate clutches 276
Engine lubricants 92 The sliding-mesh gearbox 277
The engine lubrication system 95 Constant-mesh and synchromesh
The engine cooling system 102 gearboxes 283
Supercharging and turbocharging Rear-, front- and four-wheel drive
(forced induction) 116 gearboxes 287
The petrol four-stroke cycle in detail: Automatic gearbox (gear system and
valve and ignition timing 123 fluid coupling) 291
Combustion and combustion chambers 128 Automatic gearbox (operation) 303
Intake manifold design – petrol engines 136 Electronically controlled gearboxes 319
The requirements of a fuel delivery system 141 Continuously variable transmission 324
The fuel supply system 144 Overdrive systems 327
Electronic petrol injection – multi-point 148 Propeller shafts and drive shafts 328
Electronic petrol injection – single point 155 Universal and constant velocity 330
Mechanical petrol injection 156 Final drive gears 336
The simple carburettor 159 The differential 340
Constant-choke carburettors 163 Rear axle construction 345
Variable choke – constant-depression Four-wheel drive systems 348
carburettors 169 Clutch routine maintenance 354
Ignition systems 174 Routine maintenance of manual
Engine management 189 and automatic gearboxes 356
vi Contents Fundamentals of Motor Vehicle Technology: Book 1
Routine maintenance of prop shaft Hydraulic brake operating systems 435
and drive shaft 357
Power assistance 441
Clutch fault diagnosis 358
Anti-lock braking systems 446
Manual gearbox fault diagnosis 359
Brake routine maintenance 451
Automatic gearbox fault diagnosis 360
6 BODY AND CHASSIS SYSTEMS
4 STEERING AND SUSPENSION SYSTEMS
Heating and ventilation 453
Directional control and steering systems 362
Air-conditioning 455
Camber, castor and swivel-axis inclination 367
Climate control 459
Steering system components 372
Heating and ventilation
Power assisted steering 376 – routine maintenance 461
Rear-wheel and four-wheel steering 381 Heating and ventilation – fault diagnosis 462
Steering systems and wheel alignment Passenger safety and restraint systems 463
– routine maintenance 384
Passenger safety and restraint systems
Suspension 388 – routine maintenance and diagnosis 468
The requirements of a spring 391
Types and characteristics of metal springs 391
7 VEHICLE ELECTRICAL SYSTEMS
Rubber suspension 394
Gas and air suspension 395 Introduction 469
Suspension dampers 398 Basic principles of electricity 470
Rigid axle suspension 401 Electrical circuits and calculations 476
Independent front suspension (IFS) 402 The battery 486
Independent rear suspension (IRS) 406 The charging system 490
Wheels 409 The starter system 496
Tyres 411 The lighting system 502
Wheel balance 416 Auxiliary lighting and equipment 508
Steering and suspension maintenance Electrical systems – routine maintenance 513
and diagnosis 418
8 BEARINGS
5 BRAKING SYSTEMS
Plain bearings 516
Braking principles 419
Ball and roller bearings 519
Brake operating systems 423
Drum brakes 426
Disc brakes 432 Index 523
PREFACE
Since 1966, many thousands of motor vehicle traditional mechanical systems as well as the new
technology students have relied on Fundamentals of electronic systems.
Motor Vehicle Technology to successfully complete their Because the mechanical aspects of the motor vehicle
studies. Therefore, a large percentage of professional have not changed too much, there was little of Vic
mechanics and technicians owe a debt of gratitude to Hillier’s original work that could be completely
Vic Hillier for producing the original and updated eliminated from this latest edition. However, the
editions. Whilst serving my apprenticeship with Ford dramatic increase in the use of ‘new’ technologies has
Motor Company Ltd, I was one of those many resulted in the need to produce two books. Book 1 is in
thousands of former students who made very good use fact similar to previous editions of Fundamentals of
of ‘Fundamentals’ and I was therefore privileged to be Motor Vehicle Technology but with updated information.
asked to work on the 5th edition of the book. Book 1 is also aligned with those topics that students
In just over a century of motor vehicle technology, will have to learn about in the earlier stages of their
there has probably been more identifiable change in the studies.
last 25 years than in all of the previous years. Whilst the Book 2 then follows on with greater depth and
mechanical aspects of motor vehicle technology have breadth for modern vehicle technologies and electronic
gone through an evolutionary process of change over a based systems, and Book 2 is therefore appropriate for
long period of time, the almost sudden introduction of the more advanced students and for existing
electronic vehicle systems has enabled and resulted in technicians who wish to develop their own knowledge
dramatic changes to the motor car. of the modern vehicle. Importantly, Book 2 also deals in
Importantly, however, many of the modern some depth with diagnosis of modern vehicle systems.
electronic systems simply function as enhancements to The workload of a modern technician embraces a
the same basic mechanical technologies that Vic Hillier considerable amount of diagnostic work and
wrote about in the first edition of his book. A good competence in diagnosis is an essential part of the
example is the use of electronic fuel injection systems, skilled technician’s capabilities.
which have completely replaced the carburettor as a Books 1 and 2 of Hillier’s ‘Fundamentals’ have been
means of delivering fuel to the petrol engine; but the structured to support the NVQ system and the syllabus
use of these modern electronic injection systems has not for the technical certificates. However, the books
made a fundamental difference to the basic engine maintain the tradition of the original Vic Hillier books
operation or construction. The same is true of virtually by providing the reader with a substantial amount of
every aspect of the motor vehicle, the electronic systems additional information that is not just interesting but it
enhance and improve the operation of the mechanical enables a much better understanding of how vehicles
systems, and therefore much of what Vic Hillier and vehicle systems function.
originally wrote about in the earlier editions of As well as recognising the efforts of Vic Hillier in
‘Fundamentals’ is still relevant and important for today’s producing the original content for the ‘Fundamentals’
vehicles. book, sincere thanks must go to Ian Gillgrass who has
Those new automotive technologies are used worked with me for a number of years. Ian has provided
because of a number of reasons, such as: improving much of the research information and contributed to
emissions, driver and passenger safety, as well as driver much of the content for this latest edition. Thanks must
and passenger comfort. Those new technologies are also go to those companies who have allowed us to use
very much dependent on electronics but to be information and illustrations within the books.
competent with modern electronic systems does not I hope that students and readers of the
mean that the mechanical systems can be ignored; they ‘Fundamentals’ Books 1 and 2 get as much benefit,
do still go wrong and the electronic systems function as knowledge and pleasure as I did when I used Vic
an integrated part of the mechanical systems (one does Hillier’s earlier editions as a student.
not function without the other). The modern technician
must therefore have a very good understanding of the Peter Coombes
ACKNOWLEDGEMENTS
I should like to thank the following companies for Mazda Cars (UK) Ltd
permission to make use of copyright and other material: Perkins Engines Ltd
Porsche Cars (Great Britain) Ltd
AE Group plc
Renold Ltd
Arriva plc
Rover Group plc
Automotive Products plc
Saab (Great Britain) Ltd
Borg Warner Ltd
Schrader Automotive Products Ltd
Robert Bosch Ltd
SKF Ltd
British Standards Institution
SU-Butec
Champion Sparking Plug Co Ltd
Alfred Teves GmbH
Alexander Duckham & Co Ltd
Toyota (GB) Ltd
Dunlop Ltd
Volkswagen (UK) Ltd
Eaton Ltd
Volvo Truck Corporation
EuroNCAP (European New Car Assessment
Volvo Bus Corporation
Programme)
Ford Motor Company Ltd Although many of the drawings are based on
GKN plc commercial components, they are mainly intended to
Honda (UK) Ltd illustrate principles of motor vehicle technology. For this
Jaguar Cars Ltd reason, and because component design changes so
Jensen Cars rapidly, no drawing is claimed to be up to date.
Johnson Matthey Incorporated Students should refer to manufacturers’ publications for
Lucas Industries the latest information.