Chapter 1 The Automobile PDF
Chapter 1 The Automobile PDF
Chapter 1 The Automobile PDF
Duffy
Automotive Writer
Publisher
The Goodheart-Willcox Company, Inc.
Tinley Park, Illinois
www.g-w.com
Copyright © 2009
by
ISBN 978-1-59070-956-6
5 6 7 8 9 - 0 9 - 13 12 11
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 pre-
cautions and warnings described in this book or that might also be indicated in undertaking the activities and exercises described herein to min-
imize 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,
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reliance upon the information, instructions, procedures, warnings, cautions, applications, or other matter contained in this book. The publisher
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Duffy, James E.
Modern automotive technology / James E. Duffy. — 7th ed.
p. cm.
Includes index.
ISBN 978-1-59070-956-6
1. Automobiles—Design and construction. 2. Automobiles—
Maintenance and repair. 3. Automobiles. I. Title.
TL146.D84 2009
629.2' 3—dc22 2008007116
Introduction
Welcome to the exciting, challenging world of auto- Each automotive system is presented in two or more
motive technology! You have selected a rewarding field chapters. The first chapter explains the construction and
of study. operation of a specific system. The following chapter
Modern Automotive Technology is an easy-to- expands on this by detailing the troubleshooting and
understand, up-to-date book summarizing the operation repair of the same system.
and repair of all makes and models of vehicles. The text
uses a building-block approach that starts with the simple Type Styles Used in This Text
and progresses gradually to the more complex. Short sen-
Various type styles are used throughout this text to
tences, concise definitions, and thousands of color illus-
emphasize words, identify important terms, and highlight
trations will help you learn quickly and easily.
figure references.
Modern Automotive Technology is a valuable refer-
Italic type is used to emphasize words and terms. For
ence for anyone interested in the operation, construction,
example, the word not is often printed in italic type when
and repair of automobiles and light trucks. Vehicle
it is imperative that an operation be avoided.
owners who need a general guide to automotive service
Important terms appear in bold-italic type. These
will find the book both interesting and informative. Those
terms are defined when introduced and most are listed in
who are preparing for a career in automotive technology
the Important Terms list at the end of the chapter, as well
will find the text a "must." Experienced technicians can
as in the Glossary at the back of the text. Study the bold-
use it when preparing for the ASE certification tests.
italic terms carefully.
No longer can the untrained person hope to fix the
Figure references in the body of the text and in the
modern automobile. Multiple on-board computers are
captions always appear in bold type. This makes them
now used to monitor and control the engine, transmission,
easy to identify.
suspension, braking, emission control, and other systems.
Although computer systems are discussed in almost
every chapter, three chapters—Chapter 17, Computer Chapter Components
System Fundamentals; Chapter 18, On-Board Diag- Each chapter opens with a list of learning objectives.
nostics and Scan Tools; and Chapter 19, Computer These objectives identify the topics covered and goals to
System Service—explain the operation and service of be achieved in the chapter. Review the objectives before
these important systems in detail. reading the chapter to determine what you can expect to
Additionally, Chapter 46, Advanced Diagnostics, learn. After completing the chapter, read the objectives
emphasizes the use of the latest diagnostic equipment and once more and make sure you have met each objective.
techniques to locate engine performance problems. A few A summary is found at the end of each chapter. The
of the other topics discussed in the text include anti-lock summary highlights the material covered in the chapter.
brakes, four-wheel steering, four-valve cylinders, active Review the summary after completing a chapter.
suspension systems, passive restraint systems, security A list of important terms is also included at the end
systems, and navigation systems. of each chapter. The terms in the list appear in the
The 2009 edition of Modern Automotive order in which they are presented in the chapter. After
Technology is organized around the eight ASE automo- completing a chapter, review each term. If a term cannot
bile test areas and is correlated to the NATEF Task List. be defined, review the related section in the chapter.
Conventional review questions, as well as a separate Warning!
section of ASE-type questions, are presented at the end of Always wear eye protection when cleaning
each chapter. After completing a chapter, answer all the parts with power tools. Metal bristles, bits of
questions on a separate sheet of paper. This is a great way carbon, or metal pieces from a broken tool or
of reviewing the material presented in the chapter. It will part can fly into your face.
also help prepare you for the types of questions encoun-
Other warning icons used in this text include:
tered on the ASE certification tests.
Each chapter closes with a number of activities. Face shield required.
These activities are automotive-related exercises that
emphasize math and communication skills, as well as
Respirator required.
improve performance on the job.
Section 11
Suspension, Steering, and Brakes
Chapter 65. Tire, Wheel, and Wheel Bearing
Fundamentals 1241
Chapter 66. Tire, Wheel, and Wheel Bearing
Service 1257
Chapter 67. Suspension System Fundamentals 1280
Expanded Contents
Section 1 Chapter 4 47
Introduction to Automotive Technology Power Tools and Equipment
Compressed-Air System 47
Chapter 1 1 Air Tools 48
T h e Automobile Electric Tools 50
Parts, Assemblies, and Systems 1 Hydraulic Tools 52
Hybrid Vehicle 18 Shop Equipment 53
Workplace Skills 57
Chapter 2 22
Chapter 5 60
Automotive Careers and A S E Certification
The Automotive Technician 22 The Auto Shop and Safety
Preparing for a Career in Automotive Technology 27 Auto Shop Layout 60
ASE Certification 27 Shop Safety 62
Entrepreneurship 31 Types of Accidents 62
Workplace Skills 31 General Safety Rules 66
Customer Relations 67
Chapter 3 34
Chapter 6 70
Basic Hand Tools
Tool Rules 34 Automotive Measurement and Math
Tool Storage 34 Measuring Systems 70
Wrenches 35 Measuring Tools 72
Screwdrivers 38 Other Measurements and Measuring Tools 77
Pliers 39 Using Basic Mathematics 79
Hammers 40 Workplace Skills 82
Chisels and Punches 40
Files 42 Chapter 7 85
Saws 43 Service Information and Work Orders
Holding Tools 43 Service Manuals 85
Cleaning Tools 44 Using a Service Manual 90
Probe and Pickup Tools 44 Service Publications 92
Pry Bars 45 Technical Assistance Hotlines 92
Workplace Skills 45 Computer-Based Service Data 94
Work Orders 94
Workplace Skills 95
Chapter 8 97 Typical Automotive Engines 173
Basic Electricity and Electronics Workplace Skills 175
Electricity 97
Automotive Electronics 100 Chapter 13 182
Automotive Wiring 103 Engine Top End Construction
Basic Electrical Tests 105 Cylinder Head Construction 182
Oscilloscope 107 Valve Train Construction 185
Scan Tools 108 Intake Manifold Construction 195
Customer Relations 108 Exhaust Manifold Construction 196
Workplace Skills 196
Chapter 9 111
Fasteners, Gaskets, Seals, and Sealants Chapter 14 199
Fasteners 111 Engine Bottom End Construction
Washers 113 Cylinder Block Construction 200
Machine Screws 114 Piston Construction 201
Sheet Metal Screws 114 Piston Ring Construction 204
Nonthreaded Fasteners 114 Piston Pin Construction 206
Torquing Bolts and Nuts 115 Connecting Rod Construction 207
Thread Repairs 117 Crankshaft Construction 209
Removing Damaged Fasteners 119 Engine Bearing Construction 209
Gaskets and Seals 120 Rear Main Bearing Oil Seal Construction 212
Workplace Skills 124 Select-Fit Parts 213
Balancer Shafts 213
Chapter 10 127 Workplace Skills 214
Vehicle Maintenance, Fluid Service, and
Recycling Chapter 15 217
Lubrication Service 127 Engine Front End Construction
Vehicle Maintenance 127 Vibration Damper Construction 217
Fluid Service 127 Camshaft Drive Construction 218
Filter Service 135 Duff's Garage 222
Chassis Lubrication 135
Service Intervals 136 Chapter 16 225
General Inspection and Problem Location 137 Engine Size and Performance
Recycling and Disposal of Auto Shop Wastes 139
Measurements
Duff's Garage 140
Engine Size Measurement 225
Force, Work, and Power 226
Section 2
Compression Ratio 227
Engines Engine Torque 228
Horsepower 228
Chapter 11 145 Engine Efficiency 230
Engine Fundamentals Industry Trend 231
Engine Operation 145
Engine Bottom End 146
Section 3
Engine Top End 152
Engine Front End 156 Computer Systems
Workplace Skills 157
Chapter 17 235
Chapter 12 162 Computer System Fundamentals
Engine Design Classifications Cybernetics 235
Engine Classifications 162 Computer Advantages 236
Cylinder Arrangement 162 Digital Electronics 237
Alternative Engines 169 Integrated Circuits 239
Computer Signals 239 Chapter 22 340
Computer System Operation 243 Gasoline Injection Fundamentals
Sensors 244 Gasoline Injection Fundamentals 340
Computers 249 Gasoline Injection Classifications 342
Actuators 255 Throttle Body and Multiport Injection 342
Highway History 257 Gasoline Injection Controls 344
Electronic Fuel Injection 345
Chapter 18 267
Engine Sensors 348
On-Board Diagnostics and Scan Tools Injector Pulse Width 354
On-Board Diagnostic Systems 261 Throttle Body Injection 355
Scanning Computer Problems 265 Engine Idle Speed Control 357
Energizing OBD I Systems without a Scan Tool 274 Continuous Throttle Body Injection 358
Erasing Trouble Codes 277 Electronic Multiport Injection 358
Duff's Garage 278 Air-Fuel Emulsion Injector 358
Unitized Multiport Injection 358
Chapter 19 282 Injector Resistor Pack 362
Computer System Service Airflow-Sensing Multiport EFI 362
Preliminary Visual Inspection 282 Pressure-Sensing Multiport EFI 364
Computer System Circuit Problems 283 Hydraulic-Mechanical Continuous Injection
Sensor and Actuator Problems 284 System 364
Sensor Service 285 Fuel Accumulator 366
Actuator Service 288 Direct Gasoline Injection 366
Computer Industry Trend 367
Service 291
Duff's Garage Chapter 23 371
295 Gasoline Injection Diagnosis and Repair
Computer
Gasoline Injection Problem Diagnosis 371
System
Fuel Pressure Regulator Service 374
Sensor and
Injector Problems 376
Actuator
Throttle Body Injector Service 376
Diagnosis
Servicing EFI Multiport Injectors 378
298
Engine Sensor Service 384
Control Module Service 388
Section 4 Gasoline Injection Adjustments 389
Fuel Systems Testing Idle Control Motor 390
Multiport Throttle Body Service 391
Chapter 20 301 Duff's Garage 391
Automotive Fuels, Gasoline and Diesel Gasoline Injection System Diagnosis 392
Combustion
Chapter 24 396
Petroleum (Crude Oil) 301
Gasoline 301 Carburetor Operation and Service
Diesel Fuel 307 Basic Carburetor 396
Alternative Fuels 310 Carburetor Problem Diagnosis 403
Duff's Garage 312 Highway History 408
Chapter 33 548
Chapter 28 473
Charging System Diagnosis, Testing,
Automotive Batteries
Battery Principles 473
and Repair
Battery Functions 474 Charging System Diagnosis 548
Battery Construction 475 Charging System Precautions 550
Wet- and Dry-Charged Charging System Tests 550
Alternator Service 556
Batteries 478
Regulator Service 562
Maintenance-Free Battery 479
Duff's Garage 562
Gel Battery 479
Charging System Diagnosis 565
Absorbed Glass Mat Battery 479
Battery Ratings 479 Chapter 34 567
Battery Temperature and Efficiency 480
Ignition System Fundamentals
Focus on Hybrids 480
Functions of an Ignition System 567
Basic Ignition System 567
Ignition System Supply Voltage 568
Chapter 29 483 Primary and Secondary Circuits 569
Battery Testing and Service Ignition Coil 569
Battery Maintenance 483 Ignition Distributors 572
Jump Starting 491 Contact Point Ignition System 573
Battery Load Test 492 Electronic Ignition System 573
Activating Dry-Charged Battery 494 Distributor Cap and Rotor 576
Removing and Replacing a Battery 494 Secondary Wires 578
Duff's Garage 494 Spark Plugs 579
Battery Diagnosis 498 Ignition Timing 581
Crankshaft-Triggered Ignition 584
Chapter 30 499 Distributorless Ignition System 585
Starting System Fundamentals Direct Ignition System 587
Starting System Principles 499 Dual Spark Plug Ignition 590
Starting Motor Construction 504 Multiple Discharge Ignition 591
Focus on Hybrids 509 Engine Firing Order 591
Chapter 35 595 Reminder System 683
Cruise Control Systems 683
Ignition System Problems, Testing, and
Power Mirrors 687
Repair
Cellular Mobile Telephone 687
Ignition System Problem Diagnosis 595
Driver Information Center 688
Preliminary Checks of Ignition System 595
Vehicle Degaussing 688
Evaluating the Symptoms 599
Duff's Garage 688
Spark Plug Service 600
Sound System Diagnosis 693
Secondary Wire Service 602
Power Accessory Diagnosis 693
Distributor Service 603
Distributor Cap and Rotor Service 605
Chapter 38 694
Electronic Ignition Distributor Service 606
Pickup Coil Service 606 Hybrid Drive System Operation and Repair
Contact Point Distributor Service 608 Introduction 694
Dwell 610 Hybrid System Voltages 698
Ignition Timing Adjustment 611 Hybrid Drive Assemblies 699
Testing Centrifugal and Vacuum Distributor Advance Hybrid Service Safety 709
Systems 614 Hybrid Problem Diagnosis 711
Removing the Ignition Distributor 615 Hybrid Battery Pack Service 711
Rebuilding a Distributor 615 Checking HV Battery Relays and Contactors 715
Ignition Supply Voltage Test 618 Servicing Hybrid Power Cables 716
Ignition Coil (Coil Pack) Service 618 Servicing the Power Control Module 716
Ignition Switch Service 619 Servicing the Hybrid Cooling System 716
Ignition Control Module Service 620 Servicing the Motor-Generator 717
Distributorless Ignition System Service 621 Hybrid Wiring Problems 718
Direct Ignition System Service 622
Duff's Garage 622
Ignition System Diagnosis 627 Section 6
Cooling and Lubrication Systems
Chapter 36 631
Lights, Instrumentation, Wipers, and Chapter 39 725
Horns—Operation and Service Cooling System Fundamentals
Lighting Systems 632 Cooling System Functions 725
Light System Service 641 Cooling System Operation 726
Instrumentation 647 Cooling System Types 727
Windshield Wipers 654 Basic Cooling System 727
Horns 658 Closed and Open Cooling Systems 733
Theft-Deterrent Systems 659 Cooling System Instrumentation 738
Finding Common Electrical Problems 659 Antifreeze 739
Duff's Garage 661 Block Heater 740
Headlamp Diagnosis 665 Focus on Hybrids 740
Turn Signal Diagnosis 666
Chapter 40 745
Chapter 37 667 Cooling System Testing, Maintenance, and
Sound Systems and Power Accessories Repair
Sound Systems 667 Cooling System Problem Diagnosis 745
Power Seats 674 Cooling System Problems 746
Power Windows 675 Water Pump Service 750
Power Door Locks 678 Thermostat Service 751
Power Trunk Release 681 Cooling System Hose Service 754
Power Steering Wheel 681 Radiator and Pressure Cap Service 755
Rear Window Defogger 681 Fan Belt Service 756
Heated Windshield 683 Engine Fan Service 757
Freeze Plug Service 758 Chapter 44 831
Coolant Service 759 Emission Control System Testing, Service,
Flushing a Cooling System 761
and Repair
Temperature Gauge Service 762
Computer-Controlled Emission System Service 831
Duff's Garage 763
Emission Maintenance Reminder 832
Cooling System Diagnosis 766
Inspecting Emission Control Systems 832
Exhaust Gas Analyzer 833
Chapter 41 768
State Emissions Testing Programs 837
Lubrication System Fundamentals Vacuum Solenoid Service 840
Lubrication System Functions 768 PCV System Service 842
Lubrication System Operation 768 Evaporative Emissions Control System Service 843
Positive Crankcase Ventilation System 780 Thermostatic Air Cleaner System Service 844
Oil Pressure Indicator 781 EGR System Service 845
Industry Trend 783 Air Injection System Service 846
Pulse Air System Service 847
Chapter 42 786 Catalytic Converter Service 847
Lubrication System Testing, Service, and Oxygen Sensor Service 849
Repair Emission Control Information
Lubrication System Problem Diagnosis 786 Sticker 852
Engine Oil and Filter Service 790 OBD II Drive Cycle 852
Oil Pan Service 791 Duff's Garage 853
Oil Pump Service 793 Emission Control System
Pressure Relief Valve Diagnosis 856
Service 797
Oil Pressure Indicator and Gauge
Service 798
Section 8
PCV Valve Service 799
Duff's Garage 799 Engine Performance
Lubrication System
Diagnosis 801 Chapter 45 859
Engine Performance and Driveability
Locating Engine Performance Problems 859
Section 7 Typical Performance Problems 863
Emission Control Systems Other Performance Problems 866
Workplace Skills 866
Chapter 43 803 Engine Performance Diagnosis 870
Emission Control Systems
Chapter 46 871
Air Pollution 803
Motor Vehicle Emissions 803 Advanced Diagnostics
Engine Modifications Related to Emission Advanced Diagnostics 871
Control 805 Duff's Garage 896
Vehicle Emission Control Systems 806
Positive Crankcase Ventilation (PCV) 806 Chapter 47 901
Evaporative Emissions Control Systems 808 Engine Tune-Up
Exhaust Gas Recirculation (EGR) 811 Engine Tune-Up 901
Air Injection System 815 General Tune-Up Rules 903
Pulse Air System 817 Tune-Up Safety Rules 903
Thermostatic Air Cleaner System 818 Typical Tune-Up
Catalytic Converter 818 Procedures 904
Computerized Emission Control Systems 821 Diesel Engine Tune-Up (Maintenance) 908
OBD II Emission System Monitoring 826 Engine Tune-Up (Maintenance) Intervals 909
Highway History 828 Duff's Garage 909
Section 9 Valve Adjustment 993
Engine Service and Repair Installing Valve Covers 996
Duff's Garage 997
Chapter 48 913
Chapter 52 1001
Engine Mechanical Problems
Engine Front End Service and Engine
Why Is Diagnosis Important? 913
Installation
Symptoms of Engine Mechanical Problems 913
Timing Chain Service 1001
Decide What Type of Engine Repair Is Needed 920
Timing Gear Service 1003
Evaluating Engine Mechanical Problems 920
Crankshaft Front Seal Service 1004
Service Manual Troubleshooting Charts 926
Engine Front Cover Service 1006
Duff's Garage 926
Timing Belt Service 1007
Compression Test Results 930
Complete Engine Assembly 1011
Cylinder Leakage Test Results 930
Installing the Engine 1011
Chapter 49 937 Engine Break-In 1012
Duff's Garage 1012
Engine Removal, Disassembly, and Parts
Cleaning
Engine Removal 931 Section 10
Engine Disassembly 937 Drive Trains and Axles
Cleaning Engine Parts 942
Industry Trend 945 Chapter 53 1017
Clutch Fundamentals
Chapter 50 948 Clutch Principles 1017
Engine Bottom End Service Clutch Construction 1019
Do You Need Review? 948 Workplace Skills 1028
Cylinder Block Service 948
Balancer Shaft Service 954 Chapter 54 1031
Piston Service 954 Clutch Diagnosis and Repair
Piston Pin Service 956 Diagnosing Clutch Problems 1031
Connecting Rod Service 958 Servicing a Clutch 1037
Piston Ring Service 958 Duff's Garage 1043
Crankshaft Service 960 Clutch Diagnosis 1047
Installing a Piston and Rod Assembly 964
Torque-to-Yield Bolts 966 Chapter 55 1049
Engine Balancing 966 Manual Transmission Fundamentals
Final Assembly of Engine 967 Basic Transmission Parts 1049
Workplace Skills 967 Purpose of a Manual Transmission 1049
Gear Fundamentals 1050
Chapter 51 971 Manual Transmission Construction 1052
Engine Top End Service Transmission Types 1060
Cylinder Head Service 971 Transmission Power
Diesel Precombustion Chamber Service 974 Flow 1060
Valve Guide Service 974 Speedometer Drive 1066
Valve Grinding 976 Manual Transmission
Valve Seat Reconditioning 979 Switches 1066
Testing Valve Springs 983 Workplace Skills 1066
Assembling Cylinder Head 984
Camshaft Service 987 Chapter 56 1070
Lifter Service 988 Manual Transmission Diagnosis and Repair
Push Rod Service 989 Manual Transmission Problem Diagnosis 1070
Rocker Arm Assembly Service 989 Manual Transmission Problems 1070
Engine Top End Reassembly 989 Transmission Identification 1072
Manual Transmission Service 1072 Front Drive Axle—Four-Wheel-Drive Vehicles 1168
Adjusting Transmission Linkage 1078 Workplace Skills 1168
Duff's Garage 1078
Chapter 62 1173
Manual Transmission/Transaxle Diagnosis 1081
Differential and Rear Drive Axle Diagnosis
Chapter 57 1083 and Repair
Automatic Transmission F u n d a m e n t a l s Differential and Rear Axle Problem Diagnosis 1173
Basic Automatic Transmission 1083 Differential Maintenance 1175
Hydraulic System 1095 Rear Axle Service 1176
Parking Pawl 1100 Differential Service 1179
Automatic Transmission Power Flow 1100 Duff's Garage 1187
Electronic Transmission Control 1100 Rear Axle Diagnosis 1191
Continuously Variable Transmission 1103
Chapter 63 1193
Complete Transmission Assemblies 1105
Highway History 1105 Transaxle and Front Drive Axle
Fundamentals
Chapter 58 1110 Transaxle 1193
Automatic Transmission Service Manual Transaxle 1195
Automatic Transmission Identification 1110 Automatic Transaxle 1201
Automatic Transmission Diagnosis 1110 Front Drive Axle Assembly 1210
Automatic Transmission Maintenance 1116 Focus on Hybrids 1213
Major Transmission Service 1123 Chapter 64 1217
Duff's Garage 1124
Automatic Transmission and Transaxle Diagnosis 1130 Transaxle and Front Drive Axle Diagnosis
a n d Repair
Chapter 59 1131 Transaxle Problem Diagnosis 1217
Drive Shafts and Transfer C a s e s Front Drive Axle Problems 1219
Drive Shaft Assembly 1131 Transaxle Maintenance 1219
Drivelines 1137 Front Drive Axle Service 1222
Transfer Cases 1137 Transaxle Removal 1228
Industry Trend 1141 Transaxle Service 1228
Transaxle Installation 1229
Chapter 60 1144 Duff's Garage 1229
Drive Shaft and Transfer C a s e Diagnosis, Automatic Transmission and Transaxle Diagnosis 1236
Service, a n d Repair
Drive Shaft Problems 1144 Section 11
Drive Shaft Inspection 1145 Suspension, Steering, and Brakes
Drive Shaft Maintenance 1147
Drive Shaft Service 1147 Chapter 65 1241
Transfer Case Service 1150 Tire, W h e e l , and W h e e l Bearing
Duff's Garage 1151 Fundamentals
Drive Line Problem Diagnosis 1155 Tires 1241
Transfer Case Diagnosis Part-Time Drive 1155 Wheels 1248
Transfer Case Diagnosis Full-Time Drive 1156 Valve Stems and Cores 1249
Lug Nuts, Studs, and Bolts 1250
Chapter 61 1157
Wheel Weights 1250
Differential and Rear Drive Axle Hub and Wheel Bearing Assemblies 1250
Fundamentals Highway History 1253
Basic Rear Drive Axle Assembly 1157
Chapter 66 1257
Differential Construction 1158
Differential Action 1162 Tire, W h e e l , and W h e e l Bearing Service
Limited-Slip Differentials 1162 Tire, Wheel, and Wheel Bearing Diagnosis 1257
Rear Drive Axles 1166 Wheel Cover Removal and Installation 1260
Tire Maintenance 1260 Electronic Steering Assist 1341
Measuring Tire and Wheel Runout 1261 Four-Wheel Steering Systems 1342
Wheel Balance 1262 Industry Trend 1344
Mounting and Dismounting Tires 1265
Chapter 70 1347
Tire Puncture Repair 1266
Wheel Bearing Service 1268 Steering System Diagnosis and Repair
Duff's Garage 1273 Steering System Problem Diagnosis 1347
Tire, Wheel, and Bearing Diagnosis 1277 Steering System Maintenance 1349
Steering Column Service 1350
Chapter 67 1280 Manual Steering Gearbox Service (Recirculating-Ball
Suspension System Fundamentals Type) 1351
Functions of a Suspension System 1280 Steering Linkage Service 1353
Basic Suspension System 1280 Manual Rack-and-Pinion Service 1355
Independent and Nonindependent Suspension Power Steering System Service 1356
Systems 1281 Duff's Garage 1360
Understeer and Oversteer 1281 Manual and Power Steering Systems Diagnosis 1366
Suspension System Springs 1282
Suspension System Construction 1284 Chapter 71 1369
Long-Short Arm Suspension 1289 Brake System Fundamentals
Torsion Bar Suspension 1289 Basic Brake System 1369
MacPherson Strut Suspension 1289 Braking Ratio 1371
Pickup Truck Suspension Systems 1289 Brake System Hydraulics 1371
Rear Suspension Systems 1289 Brake System Components 1372
Suspension Leveling Systems 1291 Parking Brakes 1388
Electronic Suspension System 1295 Focus on Hybrids 1389
Active Suspension System 1297
Highway History 1298 Chapter 72 1394
Brake System Diagnosis and Repair
Chapter 68 1302 Brake System Problem Diagnosis 1394
Suspension System Diagnosis and Repair Brake System Inspection 1396
Suspension System Diagnosis 1302 Vacuum Booster Service 1398
Shock Absorber Service 1302 Hydraulic Booster Service 1399
Suspension Spring Service 1304 Master Cylinder Service 1399
Ball Joint Service 1308 Brake System Bleeding 1401
Suspension Bushing Service 1310 Brake Line and Hose Service 1403
MacPherson Strut Service 1312 Disc Brake Service 1403
Wheel Alignment is Needed 1315 Brake Disc (Rotor) Service 1405
Computerized Suspension Diagnosis 1316 Drum Brake Service 1410
Duff's Garage 1319 Parking Brake Adjustment 1416
Suspension System Diagnosis 1323 Duff's Garage 1417
Brake System Diagnosis 1421
Chapter 69 1324
Steering System Fundamentals Chapter 73 1422
Functions of a Steering System 1324 Anti-Lock Brakes, Traction Control, and
Basic Steering Systems 1324 Stability Control
Steering Column Assembly 1325 Anti-Lock Brake Systems (ABS) 1422
Steering Gear Principles 1327 Traction and Stability Control Systems 1430
Steering Linkage (Worm-type Gearbox) 1329 ABS Service 1433
Manual Rack-and-Pinion Steering 1330 Traction and Stability Control System Service 1439
Integral-Piston Power Steering System Final System Check 1441
(Linkage Type) 1336 Duff's Garage 1441
External Cylinder Power Steering (Linkage Type) 1337 Anti-Lock Brake and Traction Control System
Power Rack-and-Pinion Steering 1338 Diagnosis 1444
Chapter 74 1445 Duff's Garage 1512
Wheel Alignment Climate Control System Diagnosis 1517
Wheel Alignment Principles 1445
Caster 1445 Section 13
Camber 1447 Safety, Security, and Navigation Systems
Toe 1447
Steering Axis Inclination 1448 Chapter 77 1521
Setback 1448 Restraint Systems
Toe-Out on Turns (Turning Radius) 1449 Vehicle Collisions 1521
Tracking 1449 Active and Passive Restraints 1523
Prealignment Inspection 1449 Seat Belt Systems 1523
Adjusting Wheel Alignment 1452 Knee Diverter 1523
Wheel Alignment Tools and Equipment 1455 Air Bag Systems 1525
Alignment Machines 1457 Air Bag Sensors 1529
Road Test after Alignment 1460 Air Bag Controller 1530
Duff's Garage 1460 Industry Trend 1531
Wheel Alignment Diagnosis 1465
Chapter 78
Section 12 1534
Heating and Air Conditioning Restraint System
Service
Chapter 75 1469 Seat Belt Service 1534
Heating and Air Conditioning Air Bag System Service 1535
Fundamentals Air Bag Module Service 1536
Principles of Refrigeration 1469 Air Bag Sensor Service 1538
Basic Refrigeration Cycle 1471 Air Bag Controller Service 1540
Automotive Air Conditioning System 1473 Duff's Garage 1540
Air Conditioning System Controls 1480 Restraint System Diagnosis 1543
Service Valves 1483
Chapter 79 1544
Heating System 1483
Heating and Air Conditioning Controls 1483 Security and Navigation Systems,
Ducts and Vents 1486 New and Future Technologies
Passenger Compartment Filters 1486 Security Systems 1544
Solar Ventilation 1486 Navigation Systems 1547
Focus on Hybrids 1488 Future Systems 1548
Alternate Power Sources 1551
Chapter 76 1493 Industry Trend 1554
Security System Diagnosis 1556
Heating and Air Conditioning Service
Inspecting an Air Conditioning System 1493 Chapter 80 1557
Refrigerant Safety Precautions 1495
Career Success
R-134a Service Differences 1495
Traits of Desirable Employees 1557
Testing an Air Conditioning System 1497
Earnings 1559
Recovering Refrigerant 1502
Types of Shops 1559
Common A/C Component Problems 1503
Getting a Job as an Automobile Technician 1560
Evacuating an Air Conditioning System 1507
Charging an Air Conditioning
System 1507 Reference Section 1564
Adding Refrigerant Oil 1509 Glossary of Terms 1568
A/C System Service Rules 1509 Internet Resources 1589
Heater Service 1510 Acknowledgments 1590
Electronic Climate Control Index 1591
Service 1511
Section 1
Introduction to Automotive
Technology
1. The Automobile
2. Automotive Careers and ASE Certification
3. Basic Hand Tools
4. Power Tools and Equipment
5. The Auto Shop and Safety
6. Automotive Measurement and Math
7. Service Information and Work Orders
8. Basic Electricity and Electronics
9. Fasteners, Gaskets, Seals, and Sealants
10. Vehicle Maintenance, Fluid Service, and Recycling
This section will give you the knowledge needed to secure an entry-level
job. It will also lay the groundwork for later chapters, which provide in-
depth coverage of automotive technology.
The Automobile
Intake manifold
Throttle body
Fuel in Fuel filter Fuel injector
Air in
Transmission Engine
Clutch
Drive axle assembly
Drive train
system
Figure 1-2. Note the general location of the major vehicle systems. Study the flow of fuel, air, exhaust, and power.
Engine
Transmission
Drive shaft
Muffler
Frame
Gas tank
Tire
Wheel
Sheet metal
panels
C-pillar
B-pillar
A-pillar
Door
beams
Figure 1-3. Compare body-over-frame and unibody construction. A—In body-over-frame construction, the chassis parts bolt to a
strong perimeter frame. The body bolts to this thick steel frame. B—Unibody vehicles do not have a separate perimeter frame.
Chassis components bolt directly to the unibody assembly. (DaimlerChrysler, Saab)
In body-over-frame construction, the frame consists vehicles are not as strong as those with body-over-frame
of thick steel members. The chassis parts and the body construction. See Figure 1-3B.
bolt to this frame. Also called full frame construction or
perimeter frame construction, this design is heavy but Body Types
strong. Body-over-frame construction is used on full-size Automobiles are available in several body types,
cars, vans, pickup trucks, and sport-utility vehicles including the sedan, hardtop, convertible, hatchback, and
(SUVs). See Figure 1-3A. station wagon. In addition, the minivan, the sport-utility
With unibody construction, sheet metal body panels vehicle, and the pickup truck have become increasingly
are welded together to form the body and frame. Also popular.
called space frame construction or unitized construction, A sedan is a car that has front and back seats
this is the most common type of configuration used to and will carry four to six people. It has center body pil-
build small and medium passenger cars. Unibody con- lars, or "B" pillars, between the front and rear doors,
struction reduces weight, improves fuel economy, and Figure 1-4A. Both two-door and four-door sedans are
has a high strength-to-weight ratio. However, unibody available.
Figure 1-4. Note the various vehicle body styles. A—Sedan. B—Convertible. C—Hatchback. D—Station wagon. E—Minivan.
F—Sport-utility vehicle. (Toyota, Ford, Honda, Mazda)
A hardtop is similar to the sedan, but it has no "B" Engine
pillars. Hardtop vehicles are also available in both two-
The engine provides the energy to propel (move) the
and four-door models.
vehicle and operate the other systems. Most engines con-
A convertible has a vinyl or cloth top that can be
sume gasoline or diesel fuel. The fuel burns in the engine
raised and lowered. A convertible has no door pillars,
to produce heat. This heat causes gas expansion, creating
and its strength is designed into the frame or floor pan.
pressure inside the engine. The pressure moves internal
Although most convertibles are two-door models,
engine parts to produce power. See Figure 1-6.
Figure 1-4B, a few four-door convertibles have been
The engine is usually located in the front portion of
produced.
the body. Placing the heavy engine in this position makes
A hatchback, or liftback, has a large rear door for
the vehicle safer in the event of a head-on collision. In a
easy access when hauling items. This style car is avail-
few vehicles, the engine is mounted in the rear to improve
able in three- and five-door models, Figure 1-4C.
handling. Refer to Figure 1-7.
A station wagon has a long, straight roof that extends
to the rear of the vehicle. Station wagons have large rear
Basic Engine Parts
interior compartments and come in two- and four-door
The basic parts of a simplified one-cylinder engine
models. Some station wagons have space for up to nine
are shown in Figure 1-8. Refer to this illustration as each
passengers, see Figure 1-4D.
part is introduced.
The minivan is similar to the station wagon, but it
has a higher roofline for more headroom and cargo space. • The block is metal casting that holds all the other
Most minivans are designed to carry seven passengers. engine parts in place.
See Figure 1-4E. • The cylinder is a round hole bored (machined) in
Sport-utility vehicles are often equipped with four- the block. It guides piston movement.
wheel-drive systems and have a tall body design. They • The piston is a cylindrical component that trans-
provide the comfort of a passenger car, the interior fers the energy of combustion (burning of air-fuel
space of a station wagon, and the durability of a truck, mixture) to the connecting rod.
Figure 1-4F.
• The rings seal the small gap around the sides of
Common names for various automobile body parts
the piston. They keep combustion pressure and oil
are shown in Figure 1-5. Note that a vehicle's right and
from leaking between the piston and the cylinder
left sides are denoted as if you were sitting in the car
wall (cylinder surface).
looking forward.
• The connecting rod links the piston to the
crankshaft.
• The crankshaft changes the reciprocating (up-
Front bumper and-down) motion of the piston and rod into
useful rotary (spinning) motion.
Left front Right front
fender fender
Hood
Figure 1-5. The right and left sides of a vehicle are denoted as Figure 1-6. An automotive engine commonly burns gasoline or
if you were sitting forward inside passenger compartment. diesel fuel to produce power. (Ford)
• The cylinder head covers and seals the top of the Four-Stroke Cycle
cylinder. It also holds the valves, rocker arms, and Automobile engines normally use a four-stroke
often, the camshaft. cycle. Four separate piston strokes (up or down move-
ments) are needed to produce one cycle (complete series
• The combustion chamber is a small cavity (hollow
of events). The piston must slide down, up, down, and up
area) between the top of the piston and the bottom
again to complete one cycle.
of the cylinder head. The burning of the air-fuel
mixture occurs in the combustion chamber. As the four strokes are described below, study the
simple drawings in Figure 1-9.
• The valves open and close to control the flow of
1. The intake stroke draws the air-fuel mixture
the air-fuel mixture into the combustion chamber
into the engine's combustion chamber. The
and the exhaust gases out of the combustion
piston slides down while the intake valve is
chamber.
open and the exhaust valve is closed. This pro-
• The camshaft controls the opening of the valves. duces a vacuum (low-pressure area) in the
• The valve springs keep the valves closed when cylinder. Atmospheric pressure (outside air
they do not need to be open. pressure) can then force air and fuel into the
combustion chamber.
• The rocker arms transfer camshaft action to the
valves. 2. The compression stroke prepares the air-fuel
mixture for combustion. With both valves
• The lifters, or followers, ride on the camshaft and
closed, the piston slides upward and compresses
transfer motion to the other parts of the valve
(squeezes) the trapped air-fuel mixture.
train.
• The flywheel helps keep the crankshaft turning
smoothly. It also provides a large gear for the
starting motor.
Lifters Rocker arms
Camshaft
Valve spring
Valves
Cylinder
head
Combustion
Front engine, front-wheel drive Transverse chamber
engine mounting
Block
Piston
Piston
Cylinder
rings
Connecting
rod
Front engine, rear-wheel drive Longitudinal
engine mounting
Crankshaft
Flywheel
Rear engine, rear-wheel drive
Figure 1-7. The engine can be located in the front or rear of the Figure 1-8. Memorize the basic parts of this one-cylinder
vehicle. (Dana Corp.) engine.
Both
Intake Exhaust
valves
valve valve
closed
open closed
Air-fuel Air-fuel
mixture mixture
pulled into compressed
cylinder
1—Intake stroke. Intake valve open. Exhaust valve closed. 2—Compression stroke. Both valves are closed. Piston slides
Piston slides down, forming vacuum in cylinder. Atmospheric up and pressurizes air-fuel mixture. This readies mixture for
pressure pushes air and fuel into combustion chamber. combustion.
Both
valves Intake Exhaust
closed valve valve
closed open
Spark plug
fires, mixture
burns and
expands
Piston forces
rod down
and turns Piston slides up
crankshaft and pushes
burned gases out
3—Power stroke. Spark plug sparks. Air-fuel mixture burns. 4—Exhaust stroke. Exhaust valve opens. Intake valve remains
High pressure forces piston down with tremendous force. closed. Piston slides up, pushing burned gases out of cylinder.
Crankshaft rotates under power. This prepares combustion chamber for another intake stroke.
Figure 1-9. A gasoline engine normally operates on a four-stroke cycle. Study the series of events.
3. The power stroke produces the energy to operate valve is open and the intake valve is closed. The
the engine. With both valves still closed, the burned fuel mixture is pushed out of the engine
spark plug arcs (sparks) and ignites the com- and into the exhaust system.
pressed air-fuel mixture. The burning fuel During engine operation, these four strokes are
expands and develops pressure in the combustion repeated over and over. With the help of the heavy fly-
chamber and on the top of the piston. This pushes wheel, this action produces smooth, rotating power
the piston down with enough force to keep the output at the engine crankshaft.
crankshaft spinning until the next power stroke. Obviously, other devices are needed to lubricate the
4. The exhaust stroke removes the burned gases engine parts, operate the spark plug, cool the engine, and
from the combustion chamber. During this provide the correct fuel mixture. These devices will be
stroke, the piston slides up while the exhaust discussed shortly.
Automotive Engines because there is less time (degrees of crankshaft rotation)
Unlike the basic one-cylinder engine just discussed, between power strokes. Additional cylinders also
automotive engines are multi-cylinder engines, which increase power output.
means they have more than one piston and cylinder. An actual automotive engine is pictured in
Vehicles commonly have 4-, 6-, 8-, or 10-cylinder Figure 1-10. Study the shape, location, and relationship
engines. The additional cylinders smooth engine operation of the major parts.
Intake
valve
Exhaust
valve
Cylinder
Exhaust
manifold
Piston
Connecting
rod
Oil Cylinder
filter block
Crankshaft
Oil pan
Figure 1-10. Automotive engines are multi-cylinder engines. Locate the major parts and visualize their operation. (Ford)
Computer System Tech Tip!
Learn all you can about electricity and elec-
The computer system uses electronic and electrical tronics. Nearly every automotive system is now
devices to monitor and control various systems in the monitored or controlled by a computer. It is
vehicle, including the fuel, ignition, drive train, safety, almost impossible to service any system of a car
and security systems. See Figure 1-11. The use of com- without handling some type of electric or elec-
puter systems has improved vehicle efficiency and tronic component. This book covers electronics
dependability. Additionally, most of these systems have in almost every chapter.
self-diagnostic capabilities. There are three major parts of
an automotive computer system:
Fuel System
• Sensors—input devices that can produce or
The fuel system must provide the correct mixture of
modify electrical signals with a change in a
air and fuel for efficient combustion (burning). This
condition, such as motion, temperature, pressure,
system must add the right amount of fuel to the air
etc. The sensors are the "eyes, ears, and nose" of
entering the cylinders. This ensures that a very volatile
the computer system.
(burnable) mixture enters the combustion chambers.
• Control module—computer (electronic circuit) The fuel system must also alter the air-fuel ratio
that uses signals from input devices (sensors) to (percentage of air and fuel) with changes in operating
control various output devices. The control conditions (engine temperature, speed, load, and other
module is the "brain" of the computer system. variables).
• Actuators—output devices, such as small electric There are three basic types of automotive fuel systems:
motors, that can move parts when energized by gasoline injection systems, diesel injection systems, and
the control module. The actuators serve as the carburetor systems. Look at the three illustrations in
"hands and arms" of the computer system. Figure 1-12.
A modern car can have several control modules and
dozens of sensors and actuators. These components will Gasoline Injection System
be detailed throughout this book. Modern gasoline injection systems use a control
module, sensors, and electrically operated fuel injectors
(fuel valves) to meter fuel into the engine. This is the
most common type of fuel system on gasoline, or spark
Sensing Control Output
ignition, engines. See Figure 1-12A.
Door lock
solenoid
An electric fuel pump forces fuel from the fuel tank
Control module (actuator) to the engine. The control module, reacting to electrical
(computer) data it receives from the sensors, opens the injectors for
the correct amount of time. Fuel sprays from the open
injectors, mixing with the air entering the combustion
chambers.
A throttle valve controls airflow, engine speed, and
engine power. When the throttle valve is open for more
Gear shift engine power output, the computer holds the injectors
sensor open longer, allowing more fuel to spray out. When the
throttle valve is closed, the computer opens the injectors
for only a short period of time, reducing power output.
The throttle valve (air valve) is connected to the
Vehicle accelerator pedal. When the pedal is pressed, the throttle
speed valve opens to increase engine power output.
sensor
Figure 1-11. This computer-controlled lock system automati- Diesel Injection System
cally locks the doors as soon as the vehicle starts moving. A diesel fuel system is primarily a mechanical
When the gear shift sensor and the vehicle speed sensor send system that forces diesel fuel (not gasoline) directly into
the correct signals to the control module, the module energizes
the solenoid (actuator). The solenoid then converts the elec-
the combustion chambers. Unlike the gasoline engine,
trical signal from the control module to a linear motion, locking the diesel engine does not use spark plugs to ignite the
the doors. air-fuel mixture. Instead, it uses the extremely high
When open, fuel injector
(fuel valve) sprays fuel
toward intake valve Spark plug
ignites mixture
Throttle
valve
Electric
fuel pump
Gasoline
from tank
Wires to
engine
sensors
Computer
A—Gasoline injection system. Engine sensors feed information (electrical signals) to computer about engine conditions.
Computer can then open injector for right amount of time. This maintains correct air-fuel ratio. Spark plug ignites fuel.
High-pressure
mechanical pump
No throttle used
C—Carburetor fuel system. Fuel pump fills carburetor with fuel. When air flows through carburetor, fuel is pulled into engine in
correct proportions. Throttle valve controls airflow and engine power output.
Figure 1-12. Note the three basic types of fuel systems. Compare differences.
pressure produced during the compression stroke to Electrical System
heat the air in the combustion chamber. The air is
squeezed until it is hot enough to ignite the fuel. Refer The vehicle's electrical system consists of several
to Figure 1-12B. subsystems (smaller circuits): ignition system, starting
system, charging system, and lighting system. Each sub-
When the mechanical pump sprays the diesel fuel into
system is designed to perform a specific function, such as
a combustion chamber, the hot air in the chamber causes
"fire" the spark plugs to ignite the engine's fuel mixture,
the fuel to begin to burn. The burning fuel expands and
rotate the crankshaft to start the engine, illuminate the
forces the piston down on the power stroke. Electronic
highway for safe night driving, etc.
devices are commonly used to monitor and help control
the operation of today's diesel injection systems.
Ignition System
Carburetor Fuel System An ignition system is needed on gasoline engines to
The carburetor fuel system uses engine vacuum ignite the air-fuel mixture. It produces an extremely high
(suction) to draw fuel into the engine. The amount of air- voltage surge, which operates the spark plugs. A very hot
flow through the carburetor determines the amount of electric arc jumps across the tip of each spark plug at the
fuel used. This automatically maintains the correct air- correct time. This causes the air-fuel mixture to burn,
fuel ratio. Refer to Figure 1-12C. expand, and produce power. Study Figure 1-13.
Either a mechanical or an electric fuel pump draws With the ignition switch on and the engine running,
fuel out of the tank and delivers it to the carburetor. The the system uses sensors to monitor engine speed and other
engine's intake strokes form a vacuum inside the intake operating variables. Sensor signals are fed to the control
manifold and carburetor. This causes gasoline to be drawn module. The control module then modifies and amplifies
from the carburetor and into the air entering the engine. (increases) these signals into on-off current pulses that
Control module
Ignition coil
Secondary
Ignition wire
switch
Spark plug
Trigger
Resistor wheel
Electric arc
Battery
Crankshaft
position sensor
Figure 1-13. The ignition system is used on gasoline engines to start combustion. The spark plug must fire at the correct time during
the compression stroke. A crankshaft position sensor or a distributor operates the ignition module. The module operates the ignition
coil. The coil produces high voltage for the spark plugs.
trigger the ignition coil. When triggered, the ignition coil produce electricity to recharge the battery and operate
produces a high voltage output to "fire" the spark plugs. other electrical needs of the vehicle. A voltage regulator,
When the ignition key is turned off, the coil stops func- usually built into the alternator, controls the voltage and
tioning and the spark-ignition engine stops running. current output of the alternator.
Voltage
regulator
Ignition Ignition
switch switch
Alternator
Flywheel
gear
Starting Drive
motor belt
Battery Battery
Figure 1-14. Note the basic actions and components of the starting and charging systems.
radiator. The coolant collects heat from the hot engine gases from the engine exhaust manifold to the tailpipe.
parts and carries it back to the radiator. Learn the names of the parts.
The radiator allows the coolant heat to transfer into Various emission control systems are used to reduce
the outside air. An engine fan draws cool air through the the amount of toxic (poisonous) substances produced by
radiator. The thermostat controls coolant flow and engine an engine. Some systems prevent fuel vapors from
temperature. It is usually located where the top radiator entering the atmosphere (air surrounding the earth).
hose connects to the engine. Other emission control systems remove unburned and
The lubrication system reduces friction and wear partially burned fuel from the engine exhaust. Later chap-
between internal engine parts by circulating filtered ters cover these systems in detail.
engine oil to high-friction points in the engine. The lubri-
cation system also helps cool the engine by carrying heat Drive Train Systems
away from internal engine parts.
Study the parts and operation of the lubrication The drive train transfers turning force from the engine
system shown in Figure 1-16. Note how the oil pump crankshaft to the drive wheels. Drive train configurations
pulls oil out of the pan and pushes it to various moving vary, depending on vehicle design. See Figure 1-18.
parts of the engine. The drive train parts commonly found on a front-
engine, rear-wheel-drive vehicle include the clutch, trans-
mission, drive shaft, and rear axle assembly. The drive
Exhaust and Emission Control Systems train parts used on most front-engine, front-wheel-drive
The exhaust system quiets the noise produced during vehicles include the clutch, transaxle, and drive axles.
engine operation and routes engine exhaust gases to the Refer to Figure 1-18 as these components and assem-
rear of the vehicle body. Figure 1-17 illustrates the basic blies are discussed.
parts of an exhaust system. Trace the flow of exhaust
Clutch
The clutch allows the driver to engage or disengage
Hot coolant the engine and manual transmission or transaxle. When
the clutch pedal is in the released position, the clutch
Radiator
locks the engine flywheel and the transmission input
shaft together. This causes engine power to rotate the
transmission gears and other parts of the drive train to
Fan propel the vehicle. When the driver presses the clutch
Water
pedal, the clutch disengages power flow and the engine
pump
no longer turns the transmission input shaft and gears.
Airflow to Transmission
remove heat The transmission uses various gear combinations, or
from coolant ratios, to multiply engine speed and torque to accommo-
Engine
water
date driving conditions. Low gear ratios allow the vehicle
jacket to accelerate quickly. High gear ratios permit lower
engine speed, providing good gas mileage.
A manual transmission lets the driver change
gear ratios to better accommodate driving conditions,
Figure 1-19. An automatic transmission, on the other
Cooled coolant
hand, does not have to be shifted by the driver. It uses an
Fan belt internal hydraulic system and, in most cases, electronic
controls to shift gears. The input shaft of an automatic
transmission is connected to the engine crankshaft
through a torque converter (fluid coupling) instead of a
clutch. The elementary parts of an automatic transmis-
Crankshaft
sion are pictured in Figure 1-20.
Figure 1-15. The cooling system must protect the engine from
the heat of combustion. Combustion heat could melt and ruin Drive Shaft
engine parts. The system must also speed warm-up and main- The drive shaft, or propeller shaft, transfers power
tain a constant operating temperature. Study the part names. from the transmission to the rear axle assembly. Look at
To turbocharger
Camshaft (for exhaust valves)
Lash
adjusters
Valve
Camshaft (for intake valves)
Relief
valve
Oil pump
Crankshaft
Oil screen
Figure 1-16. The lubrication system uses oil to reduce friction and wear. The pump forces oil to high-friction points.
Tailpipes
Mufflers Catalytic converters Header pipes
Figure 1-17. The exhaust system carries burned gases to the rear of the vehicle. It also reduces engine noise. (Nissan)
Transmission Clutch Engine
Engine Front
Differential
drive
Clutch Manual transaxle axle
Manual
transmission
Drive shaft
Differential
Figure 1-18. The drive train transfers engine power to the drive wheels. Study the differences between the two common types of
drive trains. A—Front-engine, rear-wheel-drive vehicle. B— Front-engine, front-wheel-drive vehicle.
Gears
Transmission case
Figure 1-19. A manual transmission uses gears and shafts to achieve various gear ratios. The speed of the output shaft compared
to the speed of the input shaft varies in each gear position. This allows the driver to change the amount of torque going to the drive
wheels. In lower gears, the car accelerates quickly. When in high gear, engine speed drops while vehicle speed stays high for good
fuel economy. (Ford)
Torque converter
Transaxle
(fluid clutch) The transaxle consists of a transmission and a dif-
ferential in a single housing. Although a few rear-wheel-
Bands Gearsets drive vehicles are equipped with transaxles, they are
most commonly used with front-wheel-drive vehicles,
Output
shaft Figure 1-22. Both manual and automatic transaxles are
available. The internal parts of a modern transaxle
assembly are illustrated in Figure 1-23.
Transverse
(sideways)
mounted
Figure 1-21. It is a hollow metal tube with two or more engine
universal (swivel) joints. The universal joints allow the
rear suspension to move up and down without damaging
the drive shaft.
Rear axle
assembly
Transmission
Engine
Drive Drive
Universal-joint shaft Differential wheel
Figure 1-21. The drive shaft sends power to the rear axle assembly. The rear axle assembly contains the differential and two axles
that turn the rear drive wheels. (Lexus)
Differential Suspension, Steering, and Brake Systems
assembly
The suspension, steering, and brake systems are the
movable parts of the chassis. They bolt or anchor to the
frame and provide important functions that will be
explained in the following sections.
Suspension System
The suspension system allows the vehicle's wheels
and tires to move up and down with little effect on body
movement. This makes the vehicle's ride smooth and
safe. The suspension system also prevents excessive body
Transmission lean when turning corners quickly.
Power assembly
As you can see in Figure 1-24, various springs, bars,
output to
drive axle swivel joints, and arms make up the suspension system.
Engine
Suspension
system
spring
Power
steering
pump
Tire
Shock
absorber
Transaxle
Steering
Steering system
Wheel gear
Front drive Suspension tie rod
axle system control arm
Figure 1-24. The suspension and steering systems mount on the frame. Study the part names. (Saab-Scania)
Brake System • High voltage cables—large diameter, insulated
The brake system produces friction to slow or stop the conductors that carry voltage between the motor-
vehicle. When the driver presses the brake pedal, fluid pres- generator, hybrid control module, and battery
sure actuates a brake mechanism at each wheel. These pack.
mechanisms force friction material (brake pads or shoes) • Hybrid control module—high power electrical-
against metal discs or drums to slow wheel rotation. electronic circuits that manage the flow of electrical
Figure 1-25 shows the fundamental parts of a brake energy through a vehicle's electrical-mechanical
system. drive train.
• Hybrid battery pack—large set of battery cells
Accessory and Safety Systems that can store huge amounts of electrical energy
and output high current and voltage to help propel
Common accessory systems include the air condi-
the vehicle.
tioner, sound system, power seats, power windows, and
rear window defogger. Common safety systems include • Internal combustion engine—gasoline or diesel
seat belts, air bags, and security systems. See Figure 1-26. engine that propels the vehicle at cruising speeds
and drives the motor-generator.
Hybrid Vehicle During acceleration, hybrid vehicles rely on the
motor-generator for propulsion. Then, when the vehicle
Most auto manufacturers now build and sell hybrid reaches a specific speed (or the battery pack becomes dis-
vehicles. A hybrid vehicle uses two methods of propul- charged), the internal combustion engine takes over. In
sion—an internal combustion engine and a large electric addition to propelling the vehicle, the engine also spins
motor-generator—to help improve vehicle performance the motor-generator's armature. This causes the motor-
(acceleration), increase fuel economy (gas mileage), and generator to produce electricity to recharge the battery
reduce emissions (air pollution). See Figure 1-27. pack for the next vehicle acceleration cycle.
The fundamental parts of a hybrid vehicle include: During braking, the rotational force of the vehicle's
• Motor-generator—device that can propel the drive axles spins the motor-generator's armature, causing
vehicle like a motor or produce electrical energy the motor-generator to produce electrical energy to
like an alternator. recharge the battery. This is known as regenerative
Brake rotor
Emergency brake
or disc
Brake booster
Wheel
Master
cylinder
Wheel
hub
Brake
lines
Brake
pedal Tire
Rotor
Hydraulic or disc
Caliper Brake
unit
caliper
Figure 1-25. When the brake pedal is pressed, pressure is placed on a confined fluid. The fluid pressure transfers through the
system to operate the brakes. An emergency brake is a mechanical system that applies the rear wheel brakes. A—Complete system.
B—Close-up. (Cadillac, Nissan)
braking. Since it takes considerable torque to rotate the
armature, the motor-generator resists drive axle rotation
to help slow and stop the vehicle.
Highway History
Early automobile manufacturers originated in var-
ious ways. In many instances, they evolved from
bicycle makers, carriage and wagon makers, and
other types of industry. Early motorcars were similar to
Front horse-drawn buggies, but they were equipped with
air bags noisy gasoline-powered engines, steam engines, or
electric motors and batteries. A single lever called a
tiller was used to steer the vehicle and another lever
was used to apply the brakes.
Summary
• The body and frame support, stop, and enclose
the vehicle.
• The engine provides dependable, efficient power
Side-impact
air bags for the vehicle.
• The intake stroke draws the air-fuel mixture into
the engine combustion chamber.
• The compression stroke prepares the fuel mixture
for combustion.
• The power stroke produces the energy to operate
Figure 1-26. Various safety systems are used on modern vehi-
cles to protect both the driver and the passengers. This vehicle the engine.
is equipped with both front and side-impact air bags. (Audi) • The exhaust stroke must remove the burned gases
from the engine cylinders.
• The computer system uses electronic and elec-
Internal combustion
trical devices to monitor and control various sys-
engine
tems in the vehicle.
• The fuel system provides the correct mixture of
air and fuel for efficient combustion.
• Electrical systems operate the electrical-electronic
devices.
• The cooling system maintains a constant engine
operating temperature.
• The lubrication system reduces friction between
internal engine parts.
• Emission control systems reduce air pollution
produced by the vehicle.
• Drive train systems transfer turning force from
Motor-generator
Continuously the engine crankshaft to the drive wheels.
variable transmission • Suspension, steering, and brake systems support
and control the vehicle.
Figure 1-27. This hybrid power train contains an internal com-
bustion engine, a motor-generator, and a continuously variable • Accessory and safety systems increase passenger
transaxle. (Honda) comfort, safety, security and convenience.
4. Explain the engine's four-stroke cycle.
Important Terms
5. Most car engines are multi-cylinder engines.
Automobile Gasoline injection
True or False?
Technology systems
Part Diesel fuel system 6. List and describe the three common types of
Component Carburetor fuel system fuel systems.
Assembly Ignition system 7. A diesel engine does not use spark plugs. True
System Starting system or False?
Frame Charging system 8. The car's electrical system consists of the:
Body Lighting system (A) ignition, starting, lubrication, and lighting
Chassis Cooling system systems.
Body-over-frame Lubrication system (B) ignition, charging, lighting, and hydraulic
construction Exhaust system systems.
Unibody construction Emission control (C) lighting, charging, starting, and ignition
Engine systems systems.
Four-stroke cycle Drive train (D) None of the above.
Intake stroke Suspension system
9. The system reduces the amount of
Compression stroke Steering system
toxic substances released by the vehicle.
Power stroke Brake system
Exhaust stroke Accessory systems 10. What is the difference between a manual trans-
Multi-cylinder engines Safety systems mission and an automatic transmission?
Computer system Hybrid vehicle 11. A one-piece drive shaft rotates the drive wheels
Fuel system Regenerative braking on most front-wheel drive cars. True or False?
Air-fuel ratio 12. A rear axle assembly contains two and
a(n) .
Review Questions—Chapter 1 13. Explain the term "transaxle."
Please do not write in this text. Place your answers 14. The suspension system mounts the car's wheels
solidly on the frame. True or False?
on a separate sheet of paper.
1. What is an automotive system? 15. List four accessory systems.
2. Automotive parts and systems can be grouped 16-25. Identify the parts and systems illustrated
into ten categories. Name them. below. Write the numbers 16-25 on your paper.
3. Which of the following is not part of an engine? Then write the correct letter and words next to
(A) Block. each number.
(B) Piston.
(C) Muffler.
(D) Crankshaft.
Can you identify the following parts and systems? (A) Starting system. (B) Charging system. (C) Drive train. (D) Fuel system.
(E) Cooling system. (F) Engine. (G) Ignition system. (H) Lubrication system. (I) Exhaust system. (J) Intake manifold.
7. Tests show that an engine is not getting spark
ASE-Type Questions at the spark plugs. Technician A says it could
be due to the diesel injection system.
Technician B says to test the ignition coil. Who
1. A vehicle is brought into the shop with a slip-
is right?
ping clutch. Technician A says that the clutch
(A) A only.
is part of the drive train system. Technician B
(B) Bonly.
says that the clutch is part of the suspension
(C) Both A and B.
system. Who is correct?
(D) Neither A nor B.
(A) A only.
(B) Bonly. 8. A car with a dead battery is brought into
(C) Both A and B. the shop. Technician A says to check the
(D) Neither A nor B. output of the alternator. Technician B says to
2. When the internal body structure of a vehicle check the condition of the spark plugs. Who
is used as its frame, it is called: is right?
(A) unibody construction. (A) A only.
(B) body-frame construction. (B) Bonly.
(C) integral construction. (C) Both A and B.
(D) body-over-frame construction. (D) Neither A nor B.
3. The controls the opening of engine's 9. Since an automatic transmission does not have
valves. to be shifted by hand, Technician A believes it
(A) camshaft uses a hydraulic system to shift gears.
Technician B believes it uses oil pressure to
(B) crankshaft
shift gears. Who is right?
(C) valve springs
(D) combustion chamber (A) A only.
(B) Bonly.
4. Which piston stroke of the four-stroke cycle (C) Both A and B.
prepares the fuel mixture for combustion?
(D) Neither A nor B.
(A) Power.
(B) Intake. 10. A transaxle case contains both the:
(C) Exhaust. (A) carburetor and drive shaft.
(D) Compression. (B) transmission and differential.
(C) multi-cylinder engine and clutch.
5. All of the following are major components in (D) suspension components and brakes.
the computer system except:
(A) regulators.
(B) sensors. Activities—Chapter 1
(C) actuators.
(D) computer. 1. Draw an automotive engine and drive train and
label the parts. Then describe how the power is
6. Each of the following is a basic type of auto- transferred from the engine to the drive wheels.
motive fuel system except:
2. Using illustrations from the text, produce over-
(A) carburetor.
head transparencies of the four-stroke cycle and
(B) auto injection.
demonstrate the cycle to your class.
(C) diesel injection.
(D) gasoline injection. 3. Arrange a field trip to tour an automobile
assembly plant or to an auto shop.