A Practical Approach to Motor Vehicle Engineering and Maint.

370 Pages·2005·17.53 MB·English

by  A. Bonnick, D. Newbold

A Practical Approach to
Motor Vehicle Engineering
and Maintenance

A Practical Approach to
Motor Vehicle Engineering
and Maintenance
Second Edition
Derek Newbold
Formerly of Hinckley College
Allan Bonnick,
M.Phil, B.Sc, C.Eng, M.I.Mech.Eng
Formerly Principal Lecturer at Eastbourne College of Arts and Technology
AMSTERDAM.BOSTON.HEIDELBERG.LONDON.NEWYORK.OXFORD
PARIS.SANDIEGO.SANFRANCISCO.SINGAPORE.SYDNEY.TOKYO
ElsevierButterworth-Heinemann
LinacreHouse,JordanHill,OxfordOX28DP
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FirstpublishedbyArnold2000
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Secondedition2005
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Contents
Foreword viii
Foreword to second edition ix
Acknowledgements x
Introduction to the retail motor industry and Health & Safety at Work 1
Detail of the motor vehicle maintenance and repair industry
An introduction to Health & Safety at Work
1 Engines and lubrication 11
Engine construction
Four stroke and two stroke cycles
Valve timing – variable valve timing
Combustion
Lubrication and lubrication systems
2 Cooling systems 58
Cooling system terminology
Liquid (water) cooled system
Air-cooled system
Anti-freeze
Specific heat capacity
Fans and pumps
3 Fuel systems 85
Petrol fuel system
Petrol injection
Carburettors
Diesel fuel systems
Direct injection – indirect injection
Common rail fuel system
4 Engine air supply and exhaust systems 128
Engine air supply – air filters – manifolds
Exhausts systems – silencers
Oxygen sensor
Air flow meters
Turbo-charger
5 Transmission systems 141
Clutch
Gearbox
Fluid flywheel and torque convertor
Transmission systems – drive shafts
vi Contents
Hub types – semi-floating, fully floating, three-quarter floating
Gear ratios – torque multiplication
6 Suspension systems 170
Non-independent – leaf spring suspension
Independent suspension
Leaf spring construction
Dampers (shock absorbers)
7 Braking systems 186
Hydraulic braking systems
Drum brakes
Disc brakes
Master cylinder
Wheel cylinders
Brake fluid
Braking efficiency
8 Steering, wheels and tyres 200
Ackerman principle
Steering angles
Steering geometry
Track adjustment
Steering boxes
Toe-out on turns
9 Electrical and electronic principles 224
Principles of magnetism and electricity
Introductory electronics
Computer controlled systems
Networking and CAN
Multiplexing
Meters
10 Electrical and electronic systems 243
Alternator
Battery
Charging system
Starting systems
Electrical principles
11 Ignition systems 260
Ignition systems – coil, capacitor (condenser)
Electronic ignition systems, non-electronic ignition systems
Fault tracing and service and maintenance procedures
Sensors and pulse generators
Ignition timing
Diagnostic trouble codes
12 Electrical systems and circuits 297
Central locking
Screen wipers
Vehicle security alarm
Electric windows
Screen washers
Contents vii
Electric mirrors
Vehicle lighting systems
Supplementary restraint systems – airbags and seatbelt pre-tensioners
13 Measuring instruments and measurement 331
Micrometers
Vernier calipers
Feeler gauges
Number approximations – typical motor vehicle measurements
Electrical test meters
14 Organisations and qualifications 348
Organisations in the motor trade
Qualifications and careers
Answers to self assessment questions 351
Index 353
Foreword
Althoughthisbookhasbeenwrittenmainlyfor she understands the subject and uses the key
those who wish to gain an NVQ in motor vehi- words, it will be very difficult for the assessor
clework,itisequallysuitableforawidevariety to give marks. Remember the key words and
of people who are undertaking the City & you will be half-way there. Some of the words
Guilds, BTEC as well those who just want to usedarespecifictothemotorvehicleandtothe
know about cars to enable them to undertake NVQ.Wehavetriedtoexplainthoserelatingto
their own servicing with a greater degree of the motor vehicle in the text and those relating
confidence. It can be used in schools, colleges totheNVQinaglossaryattheendofthebook.
and garage workshops as each task is being There are a number of practical assignments
undertaken. and learning tasks in each chapter. If these are
It covers the fundamental principles for each undertaken in a realistic way, they will enable
system found in the motor vehicle. It is by no the student to complete the task repeatedly, up
means exhaustive, but it does allow the student to an acceptable standard, without supervision,
to take simple steps in understanding how each which is therequirement ofthe NVQ.
system works. The workshop job sheet should contain all
The NVQ qualification is not as daunting as the elements of the performance criteria as
manypeoplethink.Themainproblemseemsto requested in the NVQ. They should be signed
beinthegainingofevidenceandtheassembling by both the person undertaking the task (you)
of a portfolio, so, with this in mind, there are a and the assessor/supervisor to say the task has
number of exercises at the end of each section been completed satisfactorily.
for the student to complete. The evidence The illustrations have been selected to give
required by the NVQ assessor from the student the maximum amount of support when learn-
willbegainedgraduallyandbuiltintoastudent ing about new topics. We advise students to
portfolio. Each completed job sheet (suitably attempt the learning tasks when they have
signed after the job has been checked) should completed the related section of their training
showevidenceofwhatyouhavedone,howyou and education.
diditandthatitwascompletedtoasatisfactory Thisbookisbasedonmanyyearsofteaching
standard. When the student feels confident and helping students and apprentices who have
enough to complete the task alone then he or gone on to become successful and valued
she may request an assessment. Examples of mechanics. Some of them have become owners
assessmentsaregiveninthebooktoshowwhat of their own motor vehicle workshops, each in
might be required by the assessor. turnhasappreciatedthetrainingthatwasgiven
Thetexthasanumberofwordsandsentences tothemintheirearlyyears.Ourhopeisthatthis
that are highlighted when they first appear in book will enable a wider variety of people to
the text. These are mostly key words that will achieve their hopes and ambitions.
help the student to remember what is essential
fromthetext.Nomatterhowmuchthestudent Derek Newbold
‘waffles’whenansweringquestions,unlessheor Allan Bonnick
Foreword to second edition
In order to take account of feedback from maintenance aspects are covered and a range
practising teachers and to allow for develop- of learning tasks and self assessment question
ments in technology, education and training is included.
this 2nd edition includes coverage of develop-
ments such as; variable value timing, on board Allan Bonnick
diagnostics, computer controlled systems etc. 2005