Automobile Mechanical and Electrical Systems

Description

The third edition of Automobile Mechanical and Electrical Systems concentrates on core technologies to provide the essential information required to understand how different vehicle systems work. It gives a complete overview of the components and workings of a vehicle from the engine through to the chassis and electronics. It also explains the necessary tools and equipment needed in effective car maintenance and repair, and relevant safety procedures are included throughout. Designed to make learning easier, this book contains: Photographs, flow charts and quick reference tables Detailed diagrams and clear descriptions that simplify the more complicated topics and aid revision Useful features throughout, including definitions, key facts and ‘safety first’ considerations. In full colour and with support materials from the author’s website (www.automotive-technology.org), this is the guide no student enrolled on an automotive maintenance and repair course should be without. Cover Half Title Title Copyright Contents Preface About the authors Acknowledgements 1 Overview and introduction 1.1 Vehicle categories 1.1.1 Layouts 1.1.2 Types and sizes 1.1.3 Body design 1.1.4 Chassis type and body panels 1.1.5 Main systems 1.1.6 Summary 1.2 The motor industry 1.2.1 Introduction 1.2.2 Types of motor vehicle companies 1.2.3 Company structure 1.2.4 Role of a franchised dealer 1.2.5 Reception and booking systems 1.2.6 Parts department 1.2.7 Estimating costs and times 1.2.8 Job cards and systems 1.2.9 Invoicing 1.2.10 Warranties 1.2.11 Digital workshop system 1.3 Working safely 1.3.1 Introduction 1.3.2 The key UK regulations and laws 1.3.3 Health and safety law: what you need to know 1.3.4 Personal protective equipment (PPE) 1.3.5 Identifying and reducing hazards 1.3.6 Moving loads 1.3.7 Vehicle safety 1.3.8 Safety procedures 1.3.9 Fire 1.3.10 Clean working environment 1.3.11 Signage 1.3.12 Environmental protection 1.3.13 High voltage vehicles 1.4 Basic science, materials, mathematics and mechanics 1.4.1 Introduction 1.4.2 Units 1.4.3 Velocity and acceleration 1.4.4 Friction 1.4.5 Pressure 1.4.6 Centre of gravity or centre of mass 1.4.7 Oscillation 1.4.8 Energy, work and power 1.4.9 Force and torque 1.4.10 Mass, weight and force 1.4.11 Volume and density 1.4.12 Heat and temperature 1.4.13 Percentages 1.4.14 Fractions 1.4.15 Ratios 1.4.16 Areas 1.4.17 Volumes 1.4.18 Indices 1.4.19 Drawings 1.4.20 Mechanical machines 1.4.21 Gears 1.4.22 Hydraulics 1.4.23 Materials and properties 1.5 Tools and equipment 1.5.1 Hand tools 1.5.2 Test equipment 1.5.3 Workshop equipment 1.6 Workshop bench skills 1.6.1 Introduction 1.6.2 Fitting and machining 1.6.3 Filing and grinding 1.6.4 Drilling 1.6.5 Cutting 1.6.6 Thread cutting 1.6.7 Joining 1.6.8 Nuts and bolts 1.6.9 Adhesives 1.6.10 Soldering 1.6.11 Brazing 1.6.12 Welding 1.6.13 Shrinking 1.6.14 Compression fitting 1.6.15 Riveting 1.6.16 Gaskets 1.6.17 Sealants 1.6.18 Oil seals 1.7 Servicing and inspections 1.7.1 Introduction 1.7.2 Rules and regulations 1.7.3 Service sheets 1.7.4 Road test 1.7.5 Effects of incorrect adjustments 1.7.6 Maintenance and inspections 1.7.7 Information sources 1.8 Diagnostic techniques 1.8.1 Introduction and diagnostic process 1.8.2 Electrical diagnostics 1.8.3 Multimeters 1.8.4 Oscilloscopes 2 Engine systems 2.1 Engine mechanical 2.1.1 Introduction and operating cycles 2.1.2 Engine operating details 2.1.3 Engine components 2.1.4 Variable valve timing 2.1.5 Variable compression (VC) engine 2.1.6 Belt-in-oil (BIO) or wet cambelts 2.1.7 Camless engines 2.2 Engine lubrication 2.2.1 Friction and lubrication 2.2.2 Methods of lubrication 2.2.3 Lubrication system 2.2.4 Oil filters 2.2.5 Oil pumps 2.2.6 Oil viscosity and grades 2.2.7 Mineral, synthetic or fully synthetic? 2.3 Engine cooling 2.3.1 Introduction 2.3.2 System operation 2.3.3 Interior heater 2.3.4 Thermal management system (TMS) 2.4 Air supply, exhaust and emissions 2.4.1 Air pollution and engine combustion 2.4.2 Worldwide harmonized light vehicles test procedure 2.4.3 Reducing pollution 2.4.4 Air supply system 2.4.5 Exhaust systems 2.4.6 Catalyst systems 2.4.7 Emission control systems 2.4.8 Turbocharging and supercharging 2.4.9 Electrical pressure chargers 2.4.10 Diesel particulate filters (DPF) and selective catalytic reduction (SCR) 2.4.11 Cooled EGR 2.5 Fuel systems 2.5.1 Introduction 2.5.2 Electronic fuel injection 2.5.3 Diesel fuel injection systems 2.5.4 Coding components 2.6 Ignition systems 2.6.1 Ignition overview 2.6.2 Electronic ignition 2.6.3 Distributorless ignition system (DIS) 2.6.4 Coil on plug (COP) direct ignition system 2.6.5 Spark plugs 2.7 Electric and hybrid cars 2.7.1 Types of electric vehicle 2.7.2 The EV experience 2.8 Engine systems: new developments and updates 2.8.1 Spark plug electrode designs 2.8.2 V6 diesel with electric turbocharging 2.8.3 Water injection 2.8.4 Cylinder deactivation 2.8.5 Dynamic skip fire 2.8.6 Oil filter modules 2.8.7 Miller cycle 2.8.8 Spark Controlled Compression Ignition (SPCCI) 3 Electrical systems 3.1 Electrical and electronic principles 3.1.1 Electrical fundamentals 3.1.2 Electrical components and circuits 3.1.3 Electronic components 3.2 Engine electrical 3.2.1 Batteries 3.2.2 The main types of 12 V car batteries 3.2.3 Starting system 3.2.4 Charging system 3.2.5 48 V technology 3.3 Lighting and indicators 3.3.1 Lighting systems 3.3.2 Stoplights and reverse lights 3.3.3 Interior lighting 3.3.4 Lighting circuits 3.3.5 Indicators and hazard lights 3.4 Body electrical and electronic systems 3.4.1 Washers and wipers 3.4.2 Horns 3.4.3 Obstacle avoidance 3.4.4 Cruise control 3.4.5 Seats, mirrors, sunroofs, locking and windows 3.4.6 Screen heating 3.4.7 Security systems 3.4.8 Safety systems 3.4.9 Mobile multimedia 3.5 Monitoring and instrumentation 3.5.1 Sensors 3.5.2 Gauges 3.5.3 Global Positioning System (GPS) 3.5.4 Laser head-up displays (HUDs) 3.5.5 Connected vehicles 3.5.6 Hacking and cybersecurity 3.5.7 Automotive software updates 3.6 Air conditioning 3.6.1 Air conditioning fundamentals 3.6.2 Air conditioning components 3.6.3 Heat pumps 3.7 Electrical systems: new developments and updates 3.7.1 Touchscreen with haptic feedback 3.7.2 Navigation and the new NDS data standard 3.7.4 Alternator developments 3.7.5 Electronic starter motor control and stop-start system 3.7.6 Advanced driver assistance systems (ADAS) 3.7.7 Adaptive headlamps 4 Chassis systems 4.1 Suspension 4.1.1 Overview of suspension 4.1.2 Dampers/shock absorbers 4.1.3 Suspension layouts 4.1.4 Active suspension 4.2 Steering 4.2.1 Introduction to steering 4.2.2 Steering racks and boxes 4.2.3 Steering geometry 4.2.4 Power steering 4.3 Brakes 4.3.1 Disc, drum and parking brakes 4.3.2 Hydraulic components 4.3.3 Brake servo operation 4.3.4 Braking force control 4.3.5 Anti-lock brake systems 4.3.6 Traction control 4.4 Wheels and tyres 4.4.1 Wheels and rims 4.4.2 Tyre basics 4.4.3 Tread patterns 4.4.4 Tyre pressure monitoring 4.4.5 Tyre pressure monitoring and the law in Europe 4.4.6 Spare wheels and extended mobility 4.5 Chassis systems: new developments and updates 4.5.1 Electric power steering 4.5.2 Electronic parking brake 4.5.3 Carbon ceramic brakes 4.5.4 Antilock braking system (ABS) update 4.5.5 Predictive active ride control 5 Transmission systems 5.1 Manual transmission clutch 5.1.1 Clutch operation 5.1.2 Types of clutch 5.2 Manual transmission gearbox 5.2.1 Gearbox operation 5.2.2 Gear change mechanisms 5.2.3 Gears and components 5.3 Automatic transmission 5.3.1 Introduction and torque converter 5.3.2 Automatic transmission components 5.3.3 Constantly variable transmission 5.3.4 Direct shift gearbox 5.4 Transmission driveline 5.4.1 Propshafts and driveshafts 5.4.2 Wheel bearings 5.4.3 Four-wheel drive 5.5 Final drive and differential 5.5.1 Final drive 5.5.2 Differential 5.6 Transmission systems: new developments and updates 5.6.1 Electronic clutch 5.6.2 Automatic transmission with nine speeds 6 Emerging technologies 6.1 Safety 6.1.1 Risks of working with EVs and other technologies 6.1.2 IMI TechSafe™ 6.2 Electric and hybrid vehicles overview 6.2.1 Electric vehicle market 6.2.2 The EV experience 6.2.3 History 6.3 Electric vehicle systems and components 6.3.1 Types of electric vehicles 6.3.2 Identifying electric and hybrid vehicles 6.3.3 High-voltage components 6.3.4 Motors and batteries overview 6.3.5 Charging 6.4 Advanced driver assistance systems overview 6.4.1 Introduction 6.4.2 Systems 6.4.3 Radar 6.4.4 Camera 6.5 Alternative fuels 6.5.1 Ethanol 6.5.2 Biodiesel 6.5.3 Natural gas 6.5.4 Propane or liquified petroleum gas 6.5.5 Hydrogen 6.5.6 Summary 7 Automotive Technology Academy 7.1 Introduction 7.2 Resources Index