Sách dạy nghề ô tô (tập 2) (Automotive mechanics volume I, part 1 to part 6)

Automotive Mechanics: Volume II

contents
Preface
Acknowledgments

xiii
xiv

Part 1 · Engine construction and overhaul
1

The engine assembly
The engine assembly
Engine components
V-type engine assembly
Engine systems
Engine configurations
Cylinder arrangements
Engine design features
Automotive engines
Technical terms
Review questions

3
4
4
9
9
12
14

16
18
18
19

2

Cylinder head and valves
Cylinder heads
Combustion chambers
Engine valves
Valve trains for OHV engines
Hydraulic valve lifters for OHV engines
Valve trains for OHC engines
Hydraulic lash adjusters for OHC engines
Camshafts
Camshaft drives and timing
Drives for DOHC
Tensioners and dampers
Variable valve timing
Valve-timing diagram
Engine illustrations
Technical terms
Review questions

21
22
24
26
30

31
32
33
34
35
39
40
41
44
45
45
46

3

Cylinder-head and valve service
Cylinder-head service
Dismantling the valve mechanism
Removing and dismantling cylinder heads
Installing cylinder heads
Valve-clearance adjustments
Servicing valves and springs
Servicing rocker-arm assemblies
Servicing hydraulic lifters and lash adjusters
Valve refacers and refacing
Valve-seat reconditioning
Valve-seat cutters
Servicing valve guides
Servicing valve-seat inserts
Camshaft service

Technical terms
Review questions
Cylinder block, crankshaft and bearings
Cylinder blocks
Cylinder-block construction
Cylinder sleeves
Cylinder surface-finish
Crankshafts
Crankshaft bearings
Cylinder block and crankcase design
Engine vibration and balance

49
50
51
53
55
57
58
60
60
62
63
65
66
68
69
71
71
73

74
75
77
78
79
81
84
84

4


Balance of reciprocating parts
Balance shafts
Technical terms
Review questions

87
88
88
88

5

Cylinder-block, crankshaft and bearing service
Servicing cylinder blocks
Checking and measuring cylinders
Hones and honing cylinders
Reboring cylinders
Servicing cylinder sleeves

Crankshaft service
Servicing main bearings
Analysing bearing failures
Technical terms
Review questions

91
92
93
95
97
98
100
101
105
107
107

6

Pistons, connecting rods and bearings
Pistons
Control of piston temperature
Piston designs
Piston rings
Piston-ring sets
Piston pins
Connecting rods
Forces in a connecting-rod assembly
Connecting-rod bearings

Technical terms
Review questions

109
110
111
113
114
116
117
118
119
120
120
120

7

Piston, connecting-rod and bearing service
Dismantling the piston assembly
Removing and replacing piston pins
Piston measurement and clearance
Fitting piston rings
Installing rings on a piston
Installing pistons in cylinders
Installing connecting-rod bearings
Checking connecting-rod bearings
Connecting-rod alignment
Analysing piston, ring and cylinder problems
Technical terms

Review questions

121
122
122
124
126
127
127
128
129
130
131
133
133

8

General engine service
Reasons for dismantling an engine
Types of engine work
Sequence of engine work
Diagnosing and checking
Dismantling procedure
Cleaning and inspecting
Taking measurements
Working with bolts and fasteners
Reconditioning or renewing parts
Reassembling and adjusting
Finalising and checking

Technical terms
Review questions

135
136
136
138
138
140
140
143
145
148
148
149
150
150

9

Engine measurement and performance
Basic terms and definitions
Engine terms and definitions
Engine power
Engine torque and power
Engine efficiency
Performance ratings
Technical terms
Review questions

153
154
155
156
158
159
160
161
161

10

Rotary engine
Basic rotary engine
Parts of the rotary engine
Engine strokes
Engine operation

163
164
164
166
167


Construction of a rotary engine
Cooling system
Lubricating system
Intake and exhaust systems
Fuel system

Ignition system
Engine assembly
Service requirements
Technical terms
Review questions

168
171
173
174
174
175
175
176
178
178

Part 2 · Fuel and engine management
11

Carburettors
Basic carburettors
Carburettor systems
Carburettor construction
Single-barrel and multibarrel carburettors
Two-stage carburettor operation
Throttle-valve operation
Mixture correction
Automatic chokes
Manual chokes

Other carburettor components
Technical terms
Review questions

183
184
184
185
186
186
191
193
195
198
198
200
201

12

Carburettor service
Checking linkages and controls
Automatic chokes
General carburettor checks
Idle adjustments
Carburettor components
Major carburettor service
Dismantling a carburettor
Cleaning and inspecting
Reassembling a carburettor

Removing and installing a carburettor
Carburettor problems
Technical terms
Review questions

203
204
205
206
207
209
209
211
212
213
213
214
215
215

13

Electronic fuel injection and engine management
Basic principles of EFI
Types of EFI systems
Block diagrams of an EFI system
Operation of a multipoint EFI system
Components of an EFI system
Engine management
Electronic concentrated control system

Sequential multipoint fuel injection system
Other features of engine control systems
Throttle-body injection (TBI)
Servicing engine control systems
Locating basic faults
Fault diagnosis
Testing equipment
Technical terms
Review questions

217
218
218
220
222
224
229
231
234
235
241
242
244
245
246
248
248

14

Ignition systems
Ignition system components and their function
Types of ignition systems
Breaker ignition systems
Electronic ignition systems
Direct ignition systems
Coil-on-plug ignition systems
Integrated ignition systems
Ignition timing
Ignition service – general
Spark plug service
Distributor service
Fault diagnosis
Diagnostic equipment

249
250
254
255
256
259
262
263
264
267
267
269
271
273

Technical terms
Review questions

273
274

15

Emission controls
Motor vehicle pollution: sources
Evaporative-control system
Crankcase ventilation
Exhaust emissions
Catalytic converters
Engine management
Engine design
Carburettor engines: emission systems
Other emission-system devices
Emission standards
Servicing emission controls
Diagnosis guides
Technical terms
Review questions

277
278
278
281
282

283
284
286
288
291
292
293
295
297
297

16

Induction systems, turbochargers and
superchargers
Engine design features
Turbocharging and supercharging
Turbochargers
Turbocharger construction and operation
Turbocharger control
Twin-scroll turbocharger
Intercooler
Operating a turbocharged engine
Service requirements for turbochargers
Superchargers
Supercharger construction and operation
Supercharger control
Service requirements for superchargers
Supercharger installation
Technical terms

Review questions

299
300
301
301
303
304
307
307
309
309
309
310
311
313
313
313
314

Maintenance and diagnosis: petrol engines
Maintenance
Diagnosing problems
Diagnosis chart
EFI system diagnosis
Engine noises
Engine analysis and tune-up equipment
Engine analyser ignition display
Connecting the engine analyser to the engine
Display patterns for ignition conditions

Electronic ignition and EFI patterns
Scan tools
Exhaust-gas analyser
Meters and gauges
Electrical measuring instruments
Technical terms
Review questions

317
318
319
319
324
325
327
327
331
331
332
333
334
334
337
338
338

17

Part 3 · Diesel engines
18

Diesel engines: features
Comparison of diesel and petrol engines
Four-stroke diesel engines
Two-stroke diesel engines
Scavenging
Types of combustion chambers
Combustion chambers
Devices to assist starting
Combustion of fuel in the engine
Turbochargers and blowers
Turbocharged diesel engines
Other engine design features
Technical terms
Review questions

341
342
342
342
345
345
346
348
349
351
352
352
354
355

19

Diesel fuel systems

357


20

Diesel fuel systems: general
Fuel injection systems
Fuel supply pumps
Fuel filters
Injectors
Types of injectors
Distributor injection pumps: axial type
Governor for axial pumps
Complete axial distributor pump
Distributor injector pumps: radial type
Radial pump schematic: operation
Common-rail injection systems
Injectors for common-rail systems
Basic in-line injection pumps
In-line pump construction
In-line pump installation
Electronic diesel control
Injection pumps with electronic control
Technical terms
Review questions

358
359
361
363
365
366
369
371
373
373
375
376
380
382
383
384
384
386
387
387

Diesel fuel system service
Servicing fuel filters
Bleeding and checking the fuel system
Injector service
Removing and installing injectors
Servicing injectors
Injector testing
Injector faults

Removing and installing injection pumps
Spill-timing an in-line pump
Injection pump servicing
Diesel engine problems
Checking diesel electronic controls
Technical terms
Review questions

389
390
391
392
393
394
397
398
398
401
402
404
406
406
407

Part 4 · Automatic transmissions and drive
21

Automatic transmissions: torque converters
Automatic transmissions and transaxles
Hydraulic couplings

Torque converter construction
Torque converter operation
Torque multiplication
Stator and one-way clutch action
Lock-up torque converters
Technical terms
Review questions

411
412
413
414
415
417
417
418
419
421

22

Automatic transmissions: mechanical
Transmission and transaxle arrangements
Planetary gears
Simplified planetary gear operation
Compound planetary gears
Transmission with compound planetary gears
Power flow in compound planetary gearing
Planetary gears with a common sun gear
Transaxle gearing with a common sun gear

Four-speed transmissions
Four-speed automatic transmission with compound planetary gears
Four-speed automatic transaxle with compound planetary gears
Transaxle with helical gears
Complete automatic transaxles
Continuously variable transaxle (CVT)
Technical terms
Review questions

423
424
424
426
427
428
429
431
433
435
436
438
439
441
442
446
446

23

Automatic transmissions: hydraulics and controls

Automatic transmission control
Simple hydraulic system
Hydraulic system components

449
450
451
452


Hydraulic valve operation
Hydraulic system diagram
System components: oil pumps
Hydraulic system: valves
Hydraulic system: governors
Hydraulic actuators
Hydraulic-circuit diagrams
Electronic control of transmission
Electronic control systems
Location of electronic components
Solenoid-operated shifts
Electronic control of converter clutch
Determining shift points
Adaptive shift strategy
Adaptive controls
Technical terms
Review questions

453
455

455
457
460
462
463
466
468
472
472
473
474
475
476
477
477

24

Automatic transmission service
Maintenance
Checking and changing the fluid
Automatic transmission fluids
Fluid problems
Extra cooling and filtering
Transmission adjustments
Brake band adjustments
Fault diagnosis and checks
Road testing
Diagnosing problems
Transmission overhaul

Transmission construction
Technical terms
Review questions

479
480
480
482
484
485
486
490
491
493
496
499
499
500
501

25

Four-wheel drive and all-wheel drive
Drive-line arrangements
Transmission with gear transfer
Transfer case with chain drive
Centre differentials
Transaxle centre differentials
Viscous couplings
Transfer unit with chain and viscous coupling

Suspension arrangements
Four-wheel-drive service
All-wheel drive
Types of all-wheel-drive systems
Technical terms
Review questions

505
506
507
510
514
514
514
516
519
521
524
524
530
530

Part 5 · Electrical systems
26

Starting system
Basic starter motor
Basic motor principles
Starter motor operation
Starter motor characteristics

Direct-drive starters
Reduction-type starters
Starting electrical system
Removing and installing starters
Dismantling starters
Cleaning and testing
Starter circuit checks
Bench tests
Flywheel ring gear
Starter problems
Starter construction
Technical terms
Review questions

533
534
535
536
537
538
539
539
541
542
543
545
546
546
547
547

548
548

27

Charging system
The charging system
Generating principles
Simple alternator

551
552
552
554


Changing ac to dc (rectification)
Alternator construction
Rectification and diodes
Voltage regulation
Alternator and regulator circuit
Vibrating-contact regulator
Servicing the charging system
Alternator checks
Alternator service
Regulator service
Charging-system problems
Technical terms
Review questions

555
556
558
559
561
563
564
565
566
568
569
569
570

28

Body-electrical systems
Wiring systems
Wiring harness
Electrical circuit diagrams
Electrical symbols and circuits
Electrical circuit components
Fuses and fusible links
Fuse and relay locations
Lamps and bulbs
Headlamps
Exterior and interior lamps
Body electronic module (BEM): overview
CAN bus system
Technical terms

Review questions

571
572
573
574
578
579
581
583
584
585
587
589
591
592
593

29

Body-electrical service
Replacing bulbs
Headlamp aiming
Replacing exterior and interior bulbs
Fitting accessories and making connections
Trailer electrical connections
Servicing harnesses and connectors
Checking fuses and fusible links
Checking relays
Basic electrical faults

Electrical circuit faults
Locating faults in circuits
General circuit checks
Precautions with electronic components
Use of test instruments
Technical terms
Review questions

595
596
597
599
601
602
603
603
605
605
606
607
610
610
611
612
612

30

Instruments and indicators
Instrument panel

Instrument panel construction
Instruments with magnetic operation
Instruments with thermal operation
Mechanical gauges
Digital electronic instruments
Electronic instrument systems
Warning lights and indicators
Operation of warning lights and indicators
Checking instruments and indicators
Checking electronic instruments
Technical terms
Review questions

615
616
616
618
621
622
624
625
626
629
630
632
632
632

31

Body-electrical components
Windscreen wipers
Wiper motors
Wiper motor circuits
Windscreen washers
Windscreen wiper and washer controls
Rear-window defoggers
Horns
Central door-locking
Power windows
Electric mirrors
Other electrical components

635
636
637
638
640
641
641
642
643
645
647
647


Technical terms
Review questions

648
648

Part 6 · Safety, security and convenience
32

Braking: ABS, traction control and vehicle stability
Antilock braking system (ABS)
ABS operation
Main ABS components
Electronic brake-force distribution (EBD)
Hydraulic proportioning valves
Traction control system (TCS)
Traction control with vacuum components
Electronic stability program (ESP)
Service points
Technical terms
Review questions

651
652
653
656
656
658
659
661
663
665
666

666

33

Air conditioning
Heat
Principles of operation
High- and low-pressure sides
System components
Refrigerant and compressor oil
Air-conditioner controls
Air-conditioner electrical circuit
Automatic climate control
Inspection and maintenance
Servicing the system
Fault diagnosis
Technical terms
Review questions

667
668
668
669
670
676
677
678
679
682
683

686
687
687

34

Seat belts and seating
Using seat belts
Inertia-reel seat belts
Seat-belt lockers or grabbers
Seat-belt rip-stitching
Pretensioned seat belts
Seat-belt load limiter
Seat-belt anchors
Checking seat belts
Child restraints
Seating
Technical terms
Review questions

689
690
690
691
691
692
694
695
696
697

697
698
698

35

Supplemental restraint systems (SRS) and
occupant safety
Air bags
Deployment of a driver’s air bag
Driver’s air-bag system
Driver’s air-bag assembly
Passenger’s air bag
Front air-bag system
Air-bag sensors
Air-bag electrical circuit
Side air bags
Hybrid air bags
Complete SRS
Mechanically activated air bags
Effects of deployed air bags
Air-bag service
Fault diagnosis
Deploying air bags prior to disposal
Air-bag do’s and don’ts
Occupant safety items
Technical terms
Review questions

699

700
700
701
701
702
704
704
706
707
708
709
709
710
711
713
713
714
715
717
717

Remote locking, immobilisers and security
Remote door-locking
Basic remote locking system

719
720
720

36

Central door-locking system
Servicing keypads and keyheads
Vehicle immobilisers
An immobiliser system
Immobiliser with transponder key
Features of immobiliser systems
Validation of a security code
Keypad operation and programming
Fault diagnosis
Alarm systems
About electronic control modules
Steering locks
Technical terms
Review questions

721
722
723
725
726
727
728
729
730
730
731
732
733

733

37

Cruise controls and trip computers
Cruise control
Cruise control components
Cruise control switches
Operating a cruise control
Types of cruise control systems
Arrangement of vacuum-type cruise control
Vacuum cruise control schematic
Cruise control for diesel
Possible cruise control problems
Trip computers
Using a trip computer
Instrument panel displays
Other trip computer features
Possible trip computer problems
Technical terms
Review questions

735
736
736
737
738
739
740
741

743
744
744
744
745
745
747
747
747

38

Audio systems
Radio reception
AM and FM signals
Conditions affecting radio reception
Noise suppression on the vehicle
Audio controls
Audio security
Audio problems
Technical terms
Review questions

749
750
750
751
752
752
753

754
756
756

Glossary
Index

757
769