A Practical Approach to Motor Vehicle Engineering and Maintenance, Third Edition (Allan Bonnick) (z-lib.org)

476 Index transfer box, 222, 222f, 223f
viscous coupling and epicyclic differential, 224e5
Phasing, 182 Powerbus, 317f
Photo-diode, 339 Pre-ignition, 127, 388e9
Pick-up assembly, 364f causes, 42
Piezo-electric combustion knock sensor, 369f Pressure cap, 136e7, 137f
Pinking, 388 testing, 146, 146f
Pintaux nozzles, 187e8, 187f Pressure checks, 246
Pintle, 187, 187f cooling system, 146
Pipes/pipelines, 69e70 Pressure gauges, 448e9
Piston rings, 27e29, 29f engine compression test, 448, 449f
oil pressure checks, 448e9, 449f
side clearance of, 29e30, 30f, 33f radiator pressure cap test, 449, 449f
Piston skirt, 27, 27f Pressure plate, 208
Pressure-regulating valve, 192
damage at, 30f Pressure regulator, 90
Piston slap, 27 Pressure-relief valve, 118, 118f
Pistons, 25e30, 26f, 49e50 Pressure test on cooling system, 146
Pressure valve, 136
condition checks, 29e30 Pressurized cooling system, 136e8, 137f
diameter measurement, 29, 29f fully-sealed system, 138
melting temperature, 25e6, 26f pressure cap, 136e7, 137f
offset gudgeon pin, 27, 28f semi-sealed system, 138, 138f
position sensor, 94 Pre-tensioner
structure, 26e7, 27f operation of, 420f
thermal expansion, 26 pyrotechnic seatbelt pre-tensioners, 422
thrust side of, 27, 28f Primary circuit, 362f, 363f
Pivot points, 281 Primary force, 49, 49f
Plain bearings, 231 Primary winding, 325, 333
Plastigage, 56 Problem solving, six step approach, 380
Platinum, 78 Progression, 83, 84f
Plenum chamber, 128 Propeller shafts, 225, 225f
Plug reach, 378 Protection diode, in cable connector, 416f
Plunge joints, 226e7 Pulse generators, 369
Ply, 291 Pulse width modulation, 95
Pneumatic spring, 254 Pump-assisted circulation, 130e1, 131f
Polarity, 363 Purging the canister, 70
Policy Pyrotechnic device, for air bags inflation, 421f
Pyrotechnic seatbelt pre-tensioners, 422
company, xvi
safety, xvi, xix Quality control, xxiii
Poor coolant circulation, 147e9 Quartz halogen bulb
blocked air passages through radiator grill, 149
blocked radiator, 148e9, 148f locating, 404f
defective fan, 147 twin-filament headlamp bulb, 404, 404f
defective thermostat, 147
defective water pump, 147 Rack and pinion gearbox, 285e6
electric fan, 147e8, 148f Rack and pinion steering, 286f, 305f
Poor starting, 389 Radial flow fan, 129, 130f
Poppet valves, 19 Radial flow pump, 135, 135f
Positive castor, 281 Radiator, 132e4, 133f
Potentiometer, 104
Potentiometer-type air-flow sensor cross-flow, 133, 133f
oscilloscope trace for, 425f film core, 132
Pour point depressants, 112 separate coolant tubes, 132e3
Power-assisted steering, 302e9 separate expansion or header tanks, 133, 134f
control valve, 303f tube and corrugated film, 132, 134f
diagnostics, 309 tube and fin, 132
ECU-controlled, 303, 304f Radiator blinds and shutters, 141, 142f
electric, 303e4, 305f Radiator matrix, 132e4
four-wheel steering, 304e9, 305f, 306f Radio interference, 384
hydraulic, 302e3 Random access memory (RAM), 310
problems, 308t Read-only memory (ROM), 310
Power curves, 164, 196f Rear engine, rear wheel drive layout, 6, 7f
Power resistors, 325 advantages, 6
Power transmission disadvantages, 6
by clutch, 213 Rear fog lamp circuit, 407f
to driving wheels, 219e25 Rear hub bearing and axle shaft arrangements, 229e30
fully floating axle, 230, 233f
differential lock, 222 lubrication, 230
four-wheel drive, 221e2
front-wheel drive, 219e20
occasional four-wheel-drive system, 222
permanent four-wheel drive system, 222, 223
rear-wheel drive, 220e1, 222f

semi-floating axle, 229, 233f Index 477
three-quarter floating axle, 229e30, 233f
Rear main steering angle sensor, 307e9, 308f Scavenging, 42
Rear screen washer, 396, 397f Scottish Vocational Qualification (SVQ), 457
Rear steering actuator, 307, 307f Screen washers, 396e9
Rear wheel drive, 5e6, 220e1
Rear-wheel drive system electrical defects, 397
effects of, 397
gearbox, 220e1 electrical overload, 397
with coil spring suspension, 221, 222f
maintenance and repair, 396e7
Rear wheel suspension steer, 255, 256f, 257f mechanical defects, 397e9
Reception, xxi
Reciprocating engines, 8 arms, 399
Recirculating ball gearbox, 284e5, 285f blades, 397e9
Records, xxiii linkage, 399
Rectifier, 353e4 motor defects, 397
Refrigerant, 149 motor, 397
Regenerative braking, 394, 396f switch, 397
Regular customers, xxii rear screen washer, 396
Regulating valve, 184 repairs and fault tracing, 397
Relay, 330 Screen wipers, 393e6, 395f
Release bearing, 208 blades parking, 393e4
Relief value, 114 control of, 393
Reluctor, 364f operating current testing using ammeter, 398f
Remote central locking system, 394f operation, 393
intermittent operation, 395e6
block circuit diagram for, 393f two-speed operation, 395
Resistance, 99 regenerative braking, 394
Screws, 437e8, 439f
tests for, 428, 428f heads, 439f
at control unit and sensor, 428, 429f strength, 438, 439f
threads, 434
Resistance value, 326, 429 pitch and angle, 435f
Resistors, 325e6 pitch gauges, 435f
Sealed beam units, 404e5, 405f
colour coding of, 326f Seals, 40, 58, 58f, 62f
in parallel, 328, 328f Second gear ratio, 220f
in series, 327e8, 327f Secondary cell, 346
Retarders, 263 Secondary force, 49, 49f
Reverse gear arrangement, 216, 218f balancer, 50, 51f
Rhodium, 78 Secondary ignition circuit, 362
Ride height, 300f Secondary voltage, 361e2
Ride height levellers, 256 Secondary winding, 333, 325
Ridge dodger, 28 Selective catalyst reduction (SCR) system, 78e9, 79f, 175e6
Road springs, 258 Self adjusting hydraulic tappet, 23, 23f
Road test, 246 Self induction, 362
Rocker cover, 38e9, 39f Semiconductors, 324
Rocker shaft, 284 Semi-permanent keep alive memory (KAM), 310
Roller bearings, 231 Semi-sealed pressurized cooling system, 138, 138f
Roller-type brake tester, 271f Sensor tests, 430
Rolling friction, 110, 111f Sensors, 192e3, 427
Rotary engines, 16, 16f flap, 104
Rotary fuel injection pump, 184e5, 184f, 185f, 186f unit, 416
Sequential injection, 92
injectors, 185e8 Service bay, xxiii, xxiv
operation method, 186 Shaft lubrication, 111f
Rotary pump, 117e18, 117f Shells, 324
Rotor arm, 375f Short-circuit, 329, 329f
Rotor checking, 381e2 Shroud, 139
Rotor field winding, 354 Shutter, 141
Rotor of alternator, 352e3, 353f Shuttle valve solenoid, 272
Routine maintenance, 198 Side impact protection, 4, 4f
Routine service, 61 Silencer, 102
Rubber bushes, 253 Silicon, 324, 337
Rubber suspension, 253, 253f Silicone fluid, 141
Rule of, 9, 61 Simple carburettor, 81e2, 81f
Running on, 388 limitation of, 81e2, 82f
Rust and corrosion inhibitors, 112 Single-acting wheel cylinder, 265
Rzeppa joint, 227 Single-cylinder engine rotating parts, balance of, 50
Rzeppa-type CV joint, 226, 226f couples, 50, 52f
crankshaft damper, 52, 52f
SAE viscosity classification, 112 dual mass flywheel, 52e3, 53f
Safe working practices, 384
Safety (Health and Safety at Work), xv, 204

478 Index voltage test, 358f
Starting, 107
Single-cylinder engine rotating parts, balance of (Continued )
individual components, 50e1 failure, 389
torsional vibration, 52, 52f problems, 389
vibration damper, 52, 53f Static timing, 384e5, 385f

Single coil spring, 21, 22f checking, with engine running, 386
Single-hole injectors, 187 Hall effect pulse generator, 371, 371f
Single point injection, 89e1, 90f variable-reluctance pulse generator, 371
setting, 385
emissions and control by feedback, 90e1 Stator, 353, 353f
global warming and CO2, 91 Steering
Single-row deep groove radial or journal bearing, 231, 234f
Six-cylinder-in-line crankshaft and firing order, 47e8, 48f Ackerman layout, 278, 278f, 279f
Six diode rectifier, 353e4, 354f alignment, tracking and toe in, 282
Six step approach to problem solving, 380 angles, 297f
Sliding contacts, 111 beam-axle, 276f
Sliding mesh gearbox centre-point, 279e80
four gear ratios of, 216f gearboxes, 282e7
Slip, 44, 212, 238e9
Slip ring, 355 ball-joints, 287, 287f
Slow running, idling system, 75 cam and peg, 284
Solenoid, 95, 330, 358f rack and pinion, 285e6, 286f
shift valves, 245f recirculating ball, 284e5, 285f
Solenoid contacts, 358e9 steering rack adjustment, 286e7, 286f, 287f
Spanners worm and roller, 284, 285f
dimensions of, 434 geometry, 278
layouts, for light vehicle, 277, 277f
and thread diameter, 435t rack adjustment, 286e7, 286f, 287f
Spark gap (electrode gap), 378, 377f roll radius, 280, 280f, 281f
Spark ignition, 361e9, 362f toe-out on turns, 282
Spark timing, 12e14 track, 294
Sparking plugs, 376 Stop and tail lamps, 404
Stop lamp switch, 270
cleaning, 379e80 Stratified charge formation, 96
compression pressure, 376e8, 377f Streamlining, 4
construction, 377f Stroboscopic timing lamp, 386f
electrodes gap, 379e80 Studs, 434, 435f
electrodes polarity, 363
gasket or tapered seat, 378e9, 379f removal of broken, 436
heat range of, 378, 378f removers, 434
maintenance and servicing, 379e80, 379f, 380f strength, 438
over-heated, 389 SU carburettor, 85
plug reach, 378, 378f Sulphur dioxide, 77
spark gap, 377f, 378 Sump, 46, 46f, 114
temperature, 376 Supplementary restraint systems (SRS), 418e22
testing, 380
Specific fuel consumption vs. engine speed, 163e4, 164f, 164t air bags and seat-belt pre-tensioners, 420e1
Specific gravity, relative density, 349 rotary coupler, 421
Specific heat capacity (SHC), 153
Speed sensor, 308f components, 420f, 421
Spigot bearing, 57, 208 handling, 421
Spill cut-off, 180 safety precautions, 421e2
Spill timing, 183, 183f storage, 421e2
Splash lubrication, 116f
Split axle casing, 227, 228f Surge protection in relay, 333e4, 334f
Split braking systems, 265e6 Suspension arm, 221, 254
Suspension dampers, 248
diagonal split, 266
front/rear split, 266, 266f gas-pressurized dampers, 258
Split casing, 227 materials used in, 258e60
Spur gear, 117 operation, checking, 258
Squish, 43, 171 twin-tube telescopic damper, 257e8
Stability control, 322e3, 322f Suspension links, 258
CAN connections for, 322f Suspension systems, 248e62
Stall test, 245e6
Stalling speed, 237 alignment and geometry, 260
Starter motor, 356e60, 356f independent, 250e7
circuits, testing, 357 maintenance checks, 260
gear ratio, 356f materials used, 258e60
operating lever, 357f non-independent, 248e50
pinion over-run protection, 357f suspension dampers, 248
starter solenoid, 357f unsprung mass, 248
starter terminal voltage, 357e9 Swept volume, 8
Swing beam steering, 278f
Swivel axis inclination, 280
Synchromesh gearbox, 215e16

Synthetic oil, 112e13 Index 479
grades, 113
Transistor, 339, 340f
Tandem master cylinder, 266e7, 267f circuit used in automotive applications, 340
Taper roller bearing, 232e4, 234f current flow in, 339, 340f
Tapered-type plug seat, 378e9, 379f current gain in, 339
Tappet rotation, 60e1
Tapping drill, 436 Transistors, 95, 339, 340, 341e2
Tapping sizes, 436, 437t Transmission, 208e36
Taps, 435, 437f
Telescopic shock absorber, 259f axles and axle casings, 227
Temperature coefficient of resistance, 329, 329f clutch, 208e11
Temperature indicators, 143 constant mesh and synchromesh gearbox, 215e19
Temperature sensor, 94 constant-velocity universal joints, 225e7
Test card, 359 differential, 228e9
Texa OBD data logger, 432f engine match to road-going needs, 213e14
Theft alarm circuit, 400f
Thermal efficiency, 42, 165 gear ratio, 214
leverage and torque, 214
indicated, 165 final drive, 227e8
Thermal type gauges, 416e17, 418f gearbox, 214e15
operating mechanisms, 211e13
vacuum fluorescent display gauge, 417e18 adjustment, 211e12
vehicle condition monitoring (VCM), 418 clutch drag, 212
voltage stabilizer, 417 clutch faults, 212
Thermistor, 94, 417 clutch slip, 212
Thermo-start unit, 188, 189f hydraulic linkage, 211, 211f, 212f
Thermostat, 135e6 mechanical linkage, 211, 212f
multiple-plate clutches, 213
bellows type, 135e6, 136f power transmission by clutch, 213
testing, 136, 136f vibration or judder, 213
wax type, 135, 135f overdrive, 219
Thermo-syphon system, 130 power transmission to driving wheels, 219e25
Third differential, 222, 224f propeller shafts and drive shafts, 225
Thread restoration, 436e7 rear hub bearing and axle shaft arrangements,
die nut, 437, 438f
file, 436e7 229e30
helicoil inserts, 437, 438f Tread wear patterns, 294, 294f
Three-way catalyst (TWC), 78f, 175
Throat, 74 inflation pressures, 294
Throttle, electric motor, 320e1 Truth tables, 342, 343f
Throttle body injection, 89 Turbocharging, 105e6, 106f
Throttle butterfly valve, 320
Throttle position sensor, 93, 93f, 104, 104f intercooler, 107, 107f
maintenance, 107
testing for, 451f wastegate, 107, 107f
Throttle valve, 81, 83, 87, 106f Turbulence, 42
Tightening torque, 438, 439t diesel engine, 172
Time constant for inductive circuit, 334 Turns ratio, 333
Time-division multiplexing, 317 Twin-filament headlamp bulb, ordinary, 403
Timing device, 177 Twin-tube telescopic damper, 257e8
Timing diagram, 10, 12f Twisted pair, 314f
Timing light, 385f Two-plate clutch, 213f
Timing marks, 12, 13f, 371, 384, 385f Two-speed wiper control, 395, 396f
Timing of spark, 374 Two stroke compression ignition engine, 170, 170f
Toe-in optical alignment gauge, 283f, 294, 295f Two-stroke cycle, 14
Toe-out angle on turns, 282, 284f, 294, 296f first stroke, 14e15
Tolerance, 453 second stroke, 15
Torque, 214, 214f Two-stroke engine, 15f, 16f
compression ignition engine, 170
converter, 238, 239f with valves, 15e16
vs. engine speed, 163, 163f Tyres, 291e3
Torsion bar, 250, 251f balance, 293
Torsional vibration, 52, 52f cross-ply tyre, 291, 292, 292f
Total loss lubrication, 122 inspection for wear and damage, 294
Tracking, 277, 282 load and speed ratings, 292e3
Tracta constant velocity joint, 226, 226f maintenance, 294e5
Traction control, 320, 320f, 321f markings, 293f
Tractive effort, 214f pressures, 294e5
Transfer gearbox, 6, 222, 223f radial-ply tyre, 291, 292, 292f
Transfer pump, 184 regulations, 293
Transformer, 332e3, 333f sizes, 292
Transient voltages, 414 tread wear indicators (TWI), 293

Unitary construction, 1, 3f
Universal joint

480 Index and engine balance, 49e53
pistons and connecting rods, 49e50
Universal joint (Continued ) single-cylinder engine rotating parts,
constant-velocity, 225 balance of, 50
Hooke’s type, 225
Viscosity index improvers, 244
Unsprung mass, 248 Viscosity modifiers, 112
Viscosity of oil, 111
V engine, 37, 38f
V8 crankshaft and firing order, 48, 48f and temperature, 112, 112f
Vacuum advance mechanism, checking, 386 Viscous coupling, 224e5, 224f
Vacuum fluorescent display gauge, 417e18 Volt, 325
Vacuum valve, 136 Voltage
Valve clearance, 61, 61f
amplifier, 340, 340f
shims, 60f divider, 341, 341f
Valve collets, 19 drop test, 427, 427f
Valve control methods, 11
Valve gear layout, 60f engine to chassis earth lead, 427
Valve guide, 21f at lamp connections, 425e6
measurement, 328e9
condition check, 39e40, 41f regulator, 354
Valve oil seals stabilizer, 417
surge protection, by Zener diode, 416f
condition check, 40, 41f Voltaic oxygen sensor, 92, 92f
Valve overlap, 10 Voltmeter, 328, 328f, 335, 382f
Valve period, 10 Volume control screw, 438
Valve seating, 187 Volumetric efficiency, 163, 163f
Valve springs, 20e2
Wankel-type rotary engine, 16f
double springs, 21e2, 22f Warm-up, 102
single coil spring, 21, 22f Washer, spring, 435, 436f
variable rate spring, 21, 22f Wastegate, 107, 107f
Valve stem seals, 19, 62f Water cooling system. See Liquid cooling system
Valve surge, 21 Water pump, 134e5
Valve timing, 10
diagrams, 10 axial flow, 134e5
and emissions, 11e12 radial flow, 135, 135f
setting, 10e11, 13f Watt, 327e8
Valve timing actuator, 12, 14f Wear indicators, 270, 270f
Valve train, 59e60 Wear properties, 210
Valves, 19, 20f Wedge-shaped chamber, 43
operating mechanisms, 22e3 Weiss CV joint, 227
operations, 21f Wheel alignment, 282
seats, 20f track adjustment, 282
toe-out angle on turns, 282, 284f
condition check, 40, 40f, 41f, 42f Wheel and tyre balance, 293
Vane-type pump, 118, 118f Wheel balancer, 293
Vapour lock, 70 Wheel cylinders, 265
Variable rate spring, 21, 22f double-acting, 265, 265f
Variable reluctance pulse generator, 370 single-acting, 265
Variable resistor sender unit, 418f Wheel nut torque, 291
Variable valve lift, 12, 13f Wheel sensors, 272, 273f
Variable valve timing, 12, 13f, 14f Wheel speed sensor, 272e4
Variable-length induction tract, 104e5, 106f Wheel trims, 291f
Vee cylinder arrangements, 38f Wheels
Vegetable oil, 111e12 types, 290, 290f
Vehicle alternator, 332f Wiggle test, 430, 430f
Vehicle braking systems, 263 Wind tone horns, 401
Vehicle condition monitoring (VCM), 418 Windows, electrically operated, 402, 402e3f
Vehicle construction, 1 Windscreen wipers, 396
Vehicle electrical systems, 346e59 Wire wheels, 291, 291f
Wiring diagram. See Circuits
alternator, 350e6 Wiring harness, 411
batteries, 346e50 Wiring loom, 413f
starter motor, 356e60, 356f Workshop activities, xxii
Vehicle frame, 3f Worm and roller gearbox, 284, 285f
Vehicle hoists, xvii Woven linings, 210
Vehicle shape, 4
Vehicle structure, 1 Zener diode, 338, 339f, 416f
force that act on, 2f Zero emission vehicles (ZEVs), 80
Ventilation, 149, 150f Zirconia, 318
Vernier calipers, 441
reading in, 441e2, 443f
Vibration damper, 52, 53f
Vibrations