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أخوانى فى الله أحضرت لكم كتاب Auto Fundamentals How and why of the design, construction, and operation of automobiles. Applicable to all makes and models. Martin W. Stockel Automotive Writer Martin T. Stockel Automotive Writer Chris Johanson ASE Certified Master Automobile Technician
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Contents Chapter 1 Building an Engine 11 What Is an Engine? 11 Internal Combustion Engine / Building an Engine on Paper / What to use for Fuel / The Basic Force of an Engine / Trapping the Explosion / A Simple Engine / Name the Parts / Fastening the Parts / Lengthen the Piston / Getting Fuel into the Engine / Removable Cylinder Head / Fuel Intake and Exhaust Passages / Valves Four-Stroke Cycle 16 Vacuum Is the Clue / You Already Have a Vacuum Pump / Where Is Your Vacuum Pump / Stroke No. 1— The Intake Stroke / Stroke No. 2—The Compression Stroke / Stroke No. 3—The Power Stroke / Stroke No. 4—The Exhaust Stroke / Completed Cycle / Cycle Repeated What Opens and Closes the Valves? 20 Camshaft / Valve Lifter / Camshaft Speed / Turning the Camshaft / Timing the Valves The Flywheel 23 Engine Will Run Smoothly Basic Engine Completed 24 Chapter 2 Design, Construction, Application of Engine Components 27 The Engine Block 27 Cylinders 28 Cylinder Sleeves Pistons 29 Piston Materials / Piston Expansion Problems / Partial Skirt Piston / Piston Temperature / Piston Construction / Piston Head Shape / Piston Rings / Types of Rings / Piston Pins Connecting Rods 39 Connecting Rod Construction / Connecting Rod Bearings Crankshaft 41 Main Bearings / Crankshaft Throws / Crank Vibration Vibration Damper 42 Balance Shafts / Drilled, Ground, and Polished Timing Gear or Sprocket 43 Flywheel 44 4 Camshaft 44 Valves 45 Valve Seats / Valve Guides / Valve Springs Mechanical Valve Lifters 47 Hydraulic Valve Lifters 47 Turning Reduces Valve Wear / Valve Timing / Variable Valve Timing Cylinder Head 50 Oil Pan 50 Timing Gear Cover 50 Gaskets 50 Sealants 50 Seals 51 Other Parts 51 Chapter 3 Engine Classification, Parts Identification 55 Cycle Classification 55 Two-Stroke Cycle Engine Valve Location Classifications 56 L-Head, T-Head, and F-Head Designs / l-Head / Overhead Valve Adjustment / Valve-to-Piston Clearanc? / Detonation and Preignition Combustion Chamber Design 60 Ricardo Combustion Chamber / Hemispherical Combustion Chamber / Wedge Shape Combustion Chamber Cylinder Classification 62 Inline Engine / V-Type Engine / Horizontal-Opposed Engines Firing Order 62 Cooling Classification 62 Fuel Classification 63 Engine Mounting 63 Alternative Engines 63 Two-Stroke and Four-Stroke Cycle Diesel Engines / Rotary Engines / Miller-Cycle Engines / Variable Compression Engines / Natural Gas Engines Experimental Engines 65 New Technologies 68 Hybrid Vehicles / Fuel Cell Vehicles Identification and Classification 685 Chapter 4 Safety, Lab Procedures 73 Preventing Accidents 73 Kinds of Accidents / How Accidents Happen / Results of Accidents Keep Safety in Mind 74 Reducing the Possibility of Accidents / Dressing Safely for Work / Keep a Neat Shop / Identifying Unsafe Conditions / Waste Chemical Disposal / Follow Proper Work Procedures / Do the Job Right Chapter 5 Tool Identification and Use 81 What to Look for in a Tool 81 Tool Material / Tool Construction Tool Handling and Storage 81 Types of Tools 81 Hammers / Chisels / Punches / Files / Drills / Reamers / Impact Wrench / Hacksaws / Vise / Taps / Dies / Cleaning Tools / Pliers / Screwdrivers / Wrenches / Other Useful Wrenches / Torque Wrenches / Sockets and Ratchets / Pullers / Soldering Equipment Measuring Tools 92 Micrometers / Inside and Outside Calipers / Dividers / Dial Indicator / Dial Calipers / Feeler Gauges / Electrical Testers / Pressure Gauges / Other Diagnostic Equipment Chapter 6 Engine Tests and Measurements 101 What is Horsepower? 101 Horsepower Formula / Potential Horsepower / Thermal Efficiency / Mechanical Efficiency / Practical Efficiency / Indicated Horsepower / Brake Horsepower / Gross and Net Horsepower Ratings / Frictional Horsepower / Torque / Torque and Brake Horsepower Are Not the Same Volumetric Efficiency 105 Engine Size (Displacement) 105 Cylinder Bore and Piston Stroke Compression Ratio 106 Chapter 7 Electrical System Fundamentals 109 Basic Electricity 109 The Electron Theory / Conventional Theory / Matter / Atoms / Electrical Current / Current Flow / Voltage / Electrical Resistance / Test Meters / Materials Used for Conductors / Insulators / Electrical Circuits / Series-Parallel Circuit / Vehicle Chassis Can Act as a Ground Wire / Ohm’s Law / Magnetism / Magnetic Domains Basic Automotive Electronics 116 Diodes / Transistors Chapter 8 Ignition Systems 121 High Voltage Is Necessary 121 Primary Circuit 122 Battery / Ignition Switch / Resistors / Ignition Coil / Methods of Current Interruption / Distributorless Ignition System / Direct Ignition System / Primary Circuit Complete Secondary Circuit 129 Spark Plug Construction / Spark Plug Heat Range / Resistor Spark Plugs / Directional Spark Plugs / Spark Plug Injectors / Distributor Cap / Rotor / Spark Plug Wires Ignition Timing and Advance 134 Setting Basic Timing / Timing Advance Mechanisms Chapter 9 Fuel Injection Systems 141 Providing the Correct Air-Fuel Mixture 141 Fuel Injection 141 Direct and Indirect Injection / Mechanical and Electronic Injection / Computer-Controlled Electronic Fuel Injection System Pulse Fuel Injection 143 Timed and Non-Timed Pulse Fuel Injection Types of Pulse Fuel Injection Systems 143 Throttle Body Injection System / Multiport Fuel Injection Pulse Fuel Injection System Components 144 Air Induction System / Fuel Delivery System / Engine Control Computer / Electronic Sensors Continuous Fuel Injection System 150 Fuel Flow Control / Complete Air-Fuel Control Unit Diesel Fuel Injection 154 Diesel Fuel / Overall Diesel Fuel System / Injector Pump Types / Distributor Type Injection Pump / Other Pump Features / Diesel Injector Types / Glow Plugs and Intake Air Heaters / Diesel Engine Electronics Superchargers and Turbochargers 160 Superchargers / Turbochargers Chapter 10 Fuel Supply and Carburetors 165 Fuel Supply System 165 Fuel Tank / Gasoline Pickup Tube / How Gasoline Leaves the Tank / Electric Fuel Pump / Fuel Filter / Fuel Lines / Vapor Lock Eliminators Carburetors 171 Build a Carburetor / Basic Carburetor Is Complete / Correcting the Remaining Faults / Carburetor Circuits / Intake Manifold Design Air Cleaners 185 Air Cleaner Element Carburetor Classifications 185 Airflow Direction / Number of Throats6 Chapter 11 Cooling Systems 193 The Need for a Cooling System 193 Two Methods of Cooling 193 Liquid-Cooled Engines / First Job Complete Air-Cooled Engines 206 Moving The Air / A Thermostat Is Sometimes Used Chapter 12 Lubrication Systems 211 The Need for a Lubrication System 211 Friction / How Friction is Reduced / Bearing Construction and Friction Engine Oil 212 Engine Oil Has Several Jobs / Refining Engine Oil / Oil Viscosity / Engine Oil Service Classification / Oil Change Intervals Engine Lubrication Systems 215 How Oil Works / Three Types of Lubrication Systems / Components of the Pressure-Splash System / Pressure Relief Valve / Oil Galleries and Lines / Oil Enters Bearing / Hydraulic Valve Lifters Oil Filtration 221 Oil Filters Crankcase Ventilation 223 Oil Seals 224 Oil Pressure Indicators 224 Dipstick 225 Cooling the Oil 226 Chapter 13 Exhaust Systems 229 Purpose of the Exhaust System 229 Exhaust System Designs 229 Single Exhaust System / Dual Exhaust System Exhaust System Components 230 Exhaust Manifolds / Exhaust Pipes / Catalytic Converters / Mufflers / Resonators / Tailpipes / Hangers / Heat Shields Exhaust System Materials 233 Sealing the Exhaust System 234 Exhaust Pipe-to-Manifold Connections / Pipe-to-Pipe Connections / Other Connections Chapter 14 Emission Systems 239 The Need for Emission Controls 239 Emission Control Systems 239 Engine Modifications and Controls 239 Engine Modifications / Fuel System Controls / Spark Timing Controls / Exhaust Gas Recirculation (EGR) External Cleaning Systems 244 Air Injection System / Pulse Air Injection / Catalytic Converter / Multiple Converters / Diesel Catalytic Converters Fuel Vapor Controls 251 Positive Crankcase Ventilation / Evaporation Control System (ECS) Computer-Controlled Emission Systems 255 Emission Systems Caution 256 Chapter 15 Computer Systems 259 Computers on Modern Vehicles 259 Electronic Control Unit (ECU) / Computer Control Operation / Input Sensors / Output Devices / Ignition Devices / On-Board Diagnostic Systems Static Electricity 273 Electromagnetic Interference Chapter 16 Charging and Starting Systems 277 Battery 277 Battery Cells / Battery Construction / Battery Chemical Action / Parasitic Battery Loads / Identifying Battery Terminals / Dry-Charged Battery Charging System 282 Alternator / Alternator Control Starter System 290 Starter Motor Principles / Starter Motor Construction / Starter Drive System / Starter Solenoid / Starter Actuating Switches 42-Volt Electrical Systems 298 Integral Starter Alternators 298 Chapter 17 Chassis Electrical 303 Chassis Wiring 303 Wire Sizes / Wiring Harness / Many Circuits / Color Coding / Terminal Blocks and Junction Blocks Circuit Protection Devices 306 Vehicle Lights and Light Switches 307 Headlights / Stoplights and Switches / Turn Signals anc Switches / Backup Lights and Switches / Dashboard Lights / Convenience Lights Chassis Mounted Solenoids and Relays 312 Motor Control Relays / Trunk Release Solenoids / Power Door Lock Solenoids and Switches Horns and Horn Relays 313 Rear Window and Mirror Defrosters 313 Chassis Mounted Motors 313 Windshield Wiper Motors and Controls / Power Window, Tailgate, Sliding Door, and Sunroof Motors / Convertible Top Motors and Switches / Power Antenna Motors and Switches Electric Gauges 316 Cruise Control 316 Vehicle Speed Sensor / Operator Controls and Contrc Module / Throttle Actuator / Adaptive Cruise Control Air Bag Systems 316 Diagnostic Control Module / Impact Sensors / Coil Assembly and Inflator Module / Air Bag Operation / Side Air BagsChapter 18 Engine Clutches 323 Clutch Purpose 323 Clutch Construction 323 Flywheel / Clutch Disc / Pressure Plate Assembly / Clutch Release Lever Operating Mechanism / Clutch Housing and Input Shaft (Clutch Shaft) / Complete Assembly / Other Types of Clutches Clutch Operation 329 Clutch Pedal Linkage 330 Mechanical Linkage / Hydraulic Linkage / Self-Adjusting Clutch Clutch Cooling 332 Riding the Clutch / Will a Clutch Explode? Chapter 19 Manual Transmissions and Transaxles 335 Manual Transmissions and Transaxles 335 The Engine Needs Help 335 How is Torque Multiplied / Torque Multiplication through Gears / Transmission Cases / Transmission Construction / Synchronizing Mechanism / Transmission Operation / Four-Speed Transmission / Five-Speed Transmission Manual Transaxles 346 Transaxle Cases / Transaxle Gear and Synchronizer Operation / Five-Speed Transmission and Transaxle / Transmission and Transaxle Shift Mechanism / Manual Transmission and Transaxle Lubrication Speed Shifting 351 Chapter 20 Four-Wheel Drive 355 -urposes of the Four-Wheel Drive 355 Four-Wheel Drive Components 355 Four-Wheel Drive Designs 355 Transfer Case 355 Full-Time Transfer Case / Full-Time Transfer Case Operation / Part-Time Transfer Case / Part-Time Transfer Case Selection Control / Transfer Case Lubrication Locking Hubs 363 Chapter 21 Automatic Transmissions and Transaxles 367 - 'ansmissions and Transaxles 367 Automatic Transmission and Transaxle Components “ orque Converter 369 Building a Torque Converter / Stator / Torque Converter Operation / Torque Multiplication Curve / Lockup Torque Converters 3lanetary Gearsets 373 Torque Increase / Planetary Gearsets in Automatic Transmissions Holding Members 376 Bands / Multiple Disc Clutch / Overrunning Clutches Hydraulic Control System 380 Fluid Pump / Control Valves / Simple Hydraulic System / Transmission and Transaxle Shifting / Complete Control Circuit / Manual Shift Programs / Transmission Case Transmission Lubrication 391 Fluid Filter Fluid Cooling 391 Chapter 22 Axles and Drives 395 Rear Wheel Drive Shafts 395 Drive Shafts / Drive Shaft Must Be Flexible / Universal Joint / Slip Yoke / How the Wheels Drive the Vehicle / Hotchkiss Drive / Universal Joint Can Cause Fluctuating Shaft Speed Constant Velocity (CV) Axles 399 CV Axle Shafts / Types of CV Joints / CV Joint Boots Rear-Wheel Drive Axle Assemblies 402 Rear-Wheel Drive Axle Components 403 Axle Housing / Solid Axles / Independent Axles / Types of Axles / Differential Construction / Ring and Pinion / Differential Operation / Differential Carrier and Bearings / Limited-Slip Differential / Ring and Pinion Adjustments / Gear Ratio / Axle Lubrication / Transaxle Differential Assembly Four-Wheel Drive Front Drive Axles 415 Front Axle Steering Provision Chapter 23 Brakes 419 Hydraulic Basics 419 Air Is Compressible, Liquids Are Not / Liquids Can Transmit Motion and Force / Liquids Can Increase Force / Liquids Can Decrease Force / Hydraulic Principles in Vehicle Brake Systems / Brake Fluid Master Cylinder 421 Master Cylinder Construction / Dual Brake System / Quick Take-Up Master Cylinder / Master Cylinder Operation Brake System Hydraulic Control Valves 426 Proportioning Valve / Height Sensing Proportioning Valve / Disc Brake Metering Valve / Pressure Differential Switch / Combination Valve / Brake Lines / Brake Hoses Disc Brake Calipers 430 Caliper Operation Wheel Cylinders 431 Wheel Cylinder Construction / Wheel Cylinder Operation / Hydraulic System Failure / Hydraulic System Must Be Free of Air / Hydraulic System Vapor Lock Brake Friction Members 433 Coefficient of Friction / Friction Linings / Brake Fade Disc Brake Assembly 434 Brake Pad Construction / Braking Ratio / Backing Plate8 Drum Brake Assembly 435 Brake Shoe Assembly / Brake Drum / Drum Brake Operation / Drum Brake Arrangement / Self-Adjusting Brakes / Parking Brakes Power Brake Systems 439 Vacuum-Assisted Power Booster 439 Vacuum Power Booster Construction / Vacuum Power Booster Operation / Other Vacuum Booster Types / Vacuum Reservoir / Booster Failure Hydraulic Pressure-Operated Power Booster 442 Hydraulic Power Booster Operation / Hydraulic Accumulator Anti-Lock Brake Systems (ABS) 444 Anti-Lock Brake System Components / Anti-Lock Brake Operation Traction Control Systems 445 Brake Lights 448 Chapter 24 Suspension Systems 453 The Need for a Suspension System 453 Sprung Weight / Unsprung Weight Suspension System Components 453 Vehicle Frames Springs 455 Leaf Springs / Coil Springs Shock Absorbers 457 Shock Absorber Control Action / Shock Absorber Construction / Shock Absorber Operation Air Shock Absorbers 459 Control Arms and Struts / Ball Joints / Stabilizer Bars Front Suspension Systems 463 Conventional Independent Front Suspension 463 Coii Spring Front Suspension / Torsion Bar Front Suspension / MacPherson Strut Front Suspension / Solid Axle Front Suspension Rear Suspension Systems 468 Solid Rear Axle Suspensions / Independent Rear Suspensions Suspension Lubrication 469 Automatic Level Control 471 Automatic Level Control Operation / Air Compressor / Height Control Valve Computerized Ride Control Systems 474 Chapter 25 Steering Systems 479 Steering System 479 Spindle and Steering Arm Assembly Steering Linkage 480 Parallelogram Linkage / Parallelogram Component Arrangement / Rack-and-Pinion Linkage /Four-Wheel Steering Systems Steering Wheel, Steering Shaft, and Steering Gear 485 Steering Wheel / Steering Shaft / Steering Gear / Manual Rack-and-Pinion Steering Gear Power Steering 489 Road Feel / Power Steering Components / Self-Contained Power Steering Gear Componei Inline Unit with Torsion Bar and Rotating Spool Rack-and-Pinion Power Steering / Power Steeri Pumps / Power Steering Hoses and Tubing / Pc Steering Systems Can Be Operated Manually / Steering Fluids / Electronic Steering Control / E Power Steering Systems Chapter 26 Wheels and Tires 503 Wheels 503 Steel Wheels / Custom Wheels / Wheel Rim Siz Wheel Lug Bolts and Nuts Wheel Hubs and Bearings 505 Wheel Bearings / Bearing Retaining Devices Tires 506 Tire Construction / Tire Rating Information / Tire Grading / Special Service Tires / Determining th Correct Tire for a Vehicle / Tire Valves / Tire Pres Important / Tire Rotation / Tire Runout and Bala! High Speeds and Overloading Produce Heat an Excessive Wear Chapter 27 Wheel Alignment 515 Purpose of Wheel Alignment 515 Wheel Alignment Angles 515 Types of Wheel Alignment / Alignment Measurer Values / Caster / Camber / Steering Axis Inclinat Toe / Toe-Out on Turns / Slip Angles Steering Geometry 520 Alignment Adjustments / Thrust Angle / Front Wf Adjustments / Rear Wheel Adjustment Tire Wear Patterns and Alignment 526 Alignment Equipment 526 Check for Worn Parts before Alignment Other Factors That Can Affect Alignment 528 Chapter 28 Air Conditioning and Heating 531 Purposes of Automotive Air Conditioning 531 Principles of Refrigeration 531 What Is Cooling? / Effects of Heat / Transference Heat / Conduction / Convection / Radiation / Hea Transfer Is From Hot to Cold / States of Matter / 1 Heat / Pressure-Temperature Relationship / Type Refrigerant How the Refrigeration System Works 534 Types of Refrigeration Systems Major Components of the Air Conditioning System Compressor / Basic Compressor Designs / Press Relief Valve / Compressor Magnetic Clutch / Condenser / Refrigerant Flow Restrictor / Evapor Blower Motor / Lines and Hoses / Receiver-Dehyc Accumulator / Evaporator Pressure Controls9 Service Valves 546 Refrigerant Oil 546 Refrigerant Handling Precautions 548 Retrofitting 548 Heater Systems 548 Air Distribution and Control 548 Cabin Filters Heater-Air Conditioning Control Systems 550 Wiring and Vacuum Systems 3everage Coolers 550 Chapter 29 ASE Certification 555 Reasons for ASE Tests 555 Applying for the ASE Tests 555 Taking the ASE Test 557 Test Question Examples Test Results 557 Recertification Tests 558 Chapter 30 Career Opportunities 561 A Vast Field 561 Types of Automotive Service Careers 561 Light Repair Technician / Heavy Repair Technician / Areas of Specialization / Supervisory Positions / Small Shop Technician / Overall Job Picture Working Conditions 563 Wages 563 Working Hours 564 Availability of Employment 564 How Does a Person Become an Automotive Technician 564 Stay in High School / What to Take While in School / Use Your Counselor and Instructors / Studies After Graduation / Vocational Schools and Colleges / Apprentice Programs Additional Training Information 566 Plan Your Career Early 567 Keep Up-to-Date 567 Conversion Tables 569 Dictionary of Automotive Terms 577 Acknowledgments 597 Index 599
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