Ebook Automotive engines diagnosis, repair and rebuilding (6th edition): Part 1

Chapter 3 deals with engine problem diagnosis that can be performed before engine repair while the engine is still running. The chapter has been designed so that it can be used as a r[r]

A U T O M O T I V E E N G I N E S

DIAGNOSIS, REPAIR AND REBUILDING

6 T H E D I T I O N

T I M G I L L E S

Santa Barbara City College Santa Barbara, CA

Automotive Engines: Diagnosis,

Repair and Rebuilding, 6th Edition

Tim Gilles

Vice President, Career and Professional Editorial: Dave Garza

Director of Learning Solutions: Sandy Clark

Executive Editor: David Boelio Managing Editor: Larry Main Senior Product Manager:

Matthew Thouin

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Manager: Deborah S Yarnell Marketing Coordinator: Mark Pierro Production Director: Wendy Troeger Production Manager: Mark Bernard Content Project Manager:

Christopher Chien Art Director: Benj Gleeksman Cover image: David Kimble Illustration

© 2011 Delmar, Cengage Learning

ALL RIGHTS RESERVED No part of this work covered by the copyright herein may be reproduced, transmitted, stored, or used in any form or by any means graphic, electronic, or mechanical, including but not limited to photocopying, recording, scanning, digitizing, taping, Web distribution, information networks, or information storage and retrieval systems, except as permitted under Section 107 or 108 of the 1976 United States Copyright Act, without the prior written permission of the publisher

Library of Congress Control Number: 2009936231 ISBN-13: 978-1-4354-8641-6

ISBN-10: 1-4354-8641-2

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DEDICATION

The completion of this book was made possible with the help of a great many individuals Automotive Engines is dedicated to them and especially to my parents, for the inspiration, and to my wife, Joy, and children, Jody and Terri, without whose help the book would not have been completed Special appre-ciation is due to my wife, Joy, who has managed the organization of the art package, spending countless after-work and weekend hours developing and organizing all the spreadsheets, captions, photos, and sketches, making cer-tain they are in their correct locations—a substantial task

This book is also dedicated to four important mentors: Lloyd Corliss, my first automotive teacher, who shared his love of engines and whose integ-rity and example inspired me to become an automotive teacher; Roger Ayles-worth, who became a big brother to me while I worked in his automotive business and who shared, by example, his attitude that, with knowledge, a good mechanic can fix just about anything; and Bob Barkhouse, another big brother and good friend Bob is a retired automotive teacher and the author of a very fine best-selling textbook on the upper end of engines His example is one of generosity He has been a big help and an inspiration to me and countless other teachers My good friend and mentor, Joe Schuit, has been helping the engine-rebuilding students at Santa Barbara City College in my engine rebuild-ing classes since shortly after he retired from his automotive machine shop business Joe is an inventor with a gifted mind for automotive engines and an enthusiasm that is contagious A day never goes by without Joe sharing some-thing new and valuable from his vast library of knowledge and experience

“In memory of our friend, Jimmy Stephens (1964-2009),

v

Contents

Dedication ■ iii

Preface ■ ix

About This Book ■ ix

Features of the Text ■ xii

About the Author ■ xv

ASE Certification Tests ■ xvi

Acknowledgments ■ xvii

S E C T I O N 1

Engine Construction, Diagnosis, Disassembly, and Inspection 1

CHAPTER Engine Operation 2

Simple Engine ■ Four Stroke Engine Operation ■ Cylinder Arrangement ■

Valvetrain ■ Cylinder Block ■ Front-Wheel Drive ■ Engine Classifications ■

Combustion Chamber Designs ■ Direction of Crankshaft Rotation ■ Firing

Order ■ Engine Cooling ■ Spark and Compression Ignition ■ Putting It All

Together ■ High-Performance Engine Trivia ■ Study Questions ■ ASE-Style

Review Questions

CHAPTER Engine Shop Safety 26

General Shop Health and Safety ■ Shop Cleanliness ■ Fire Prevention ■ Tool

and Equipment Safety ■ Lifting Equipment ■ Other Shop Equipment Safety ■

Hazardous Materials ■ Engine Shop Safety Test

CHAPTER Diagnosing Engine Problems 54

Diagnosing Problems Before a Repair ■ Oil Consumption ■ Oil Leaks ■ Fuel

Mixture Problems ■ Compression Loss ■ Engine Noises ■ Oil Pressure

Problems ■ Cooling System Problems ■ Electronic Failures/Engine Damage ■

Study Questions ■ ASE-Style Review Questions

CHAPTER Engine Removal, Disassembly, Inspection,

and In-Chassis Repairs 98

Service Information ■ Service Literature ■ Service Records ■ Engine

Removal ■ Front-Wheel Drive Engine and Transaxle Removal ■ Engine

Disassembly ■ Ordering Parts ■ Types of Engine Rebuilds ■ Major

Engine Repair—Engine in the Vehicle ■ Study Questions ■ ASE-Style

vi • CONTENTS

CHAPTER Cleaning the Engine 153

Cleaning Methods ■ Cleaning the Inside of the Engine ■ Study

Questions ■ ASE-Style Review Questions

CHAPTER Measuring 171

Metric System ■ Measuring Tools ■ Precision Measuring Tools ■ Study

Questions ■ Vernier Caliper Practice ■ Micrometer Practice

S E C T I O N 2

The Breathing System 185

CHAPTER Cylinder Head: Parts and Service 186

Cylinder Head Material ■ Head Disassembly ■ Carbon Removal ■

Crack Inspection ■ Crack Repair ■ Valve Guide Inspection ■ Valve

Guide Repair ■ Reaming Valve Guides ■ Valve Guides and Seals ■

Resurfacing Heads ■ Study Questions ■ ASE-Style Review Questions

CHAPTER Cylinder Head: Springs, Valves, and Valve Seats 223

Valve Springs ■ Pushrods ■ Rocker Arms ■ Valves and Valve

Service ■ Valve Seats and Service ■ Reassembling the Head ■ Study

Questions ■ ASE-Style Review Questions

CHAPTER Camshafts, Lifters, Timing Belts, and Chains 267

Camshaft ■ Controlling Camshaft End Thrust ■ Valve Lash (Clearance) ■

Valve Lifters ■ Hydraulic Lifters and Lash Adjusters ■ Hydraulic

Lifter Operation ■ Valve Timing ■ Roller Cam and Lifters ■ Cam Drives ■

Timing Chains and Belts ■ Timing the Cam to the Crank ■ Timing Belts ■

Timing Belt Replacement ■ Study Questions ■ ASE-Style Review Questions

CHAPTER 10 Engine Power and Performance 312

Intake and Exhaust Manifolds ■ Engine Modifications to Improve

Breathing ■ Exhaust Manifolds ■ Turbochargers and Superchargers ■

Belt-Driven Superchargers/Blowers ■ Camshaft and Engine Performance ■

Checking Camshaft Timing ■ Camshaft Phasing, Lobe Centers, and Lobe

Spread ■ Variable Valve Timing ■ Active Fuel Management/Displacement

on Demand ■ Power and Torque ■ Measuring Torque and Horsepower ■

Dynamometer Safety Concerns ■ Study Questions ■ ASE-Style Review

CONTENTS • vii

S E C T I O N 3

Cylinder Block Assembly 377

CHAPTER 11 Cylinder Block: Inspection and Service 378

Cleaning the Block ■ Oil and Water Plugs ■ Oil Jet Cooling ■ Aligning

Dowels on the Back of the Block ■ Main Bearing Caps and Registers ■ Main

Bearing Bore Alignment ■ Decking the Block ■ Inspecting Cylinder

Bores ■ Deglazing Cylinders ■ Reboring Cylinders ■ Honing Cylinders

to Size ■ Chamfering the Cylinder ■ Cylinder Sleeves ■ Lifter

Bores ■ Final Block Preparation ■ Cam Bearings ■ Study Questions ■

ASE-Style Review Questions

CHAPTER 12 Crankshaft, Bearings, and Engine Balancing 415

Crankshaft Design ■ Crankshaft End Thrust ■ Checking Crankshaft

Condition ■ Other Crankshaft Modifications ■ Checking Bearing

Clearance ■ Crankshaft Design and Engine Balance ■ Engine Balancing ■

Study Questions ■ ASE-Style Review Questions

CHAPTER 13 Pistons, Rings, and Connecting Rods 458

Pistons ■ Piston Rings ■ Piston Pins ■ Connecting Rods ■ Study

Questions ■ ASE-Style Review Questions

CHAPTER 14 Lubrication 498

Oil ■ Engine Oil ■ Engine Oil Licensing and Certification ■ Oil

Additives ■ Changing Engine Oil ■ Oil Pumps ■ Priming the

Lubrication System ■ Oil Filter ■ Changing the Oil Filter ■

Crankcase Ventilation ■ Study Questions ■ ASE-Style Review Questions

CHAPTER 15 Cooling System 534

Types of Cooling Systems ■ Accessory Belts ■ Thermostat ■

Thermostat Bypass ■ Radiators ■ Cooling System Pressure Cap ■

Radiator Fan ■ Coolant ■ Coolant Service ■ Study Questions ■

ASE-Style Review Questions

S E C T I O N 4

Engine Repair and Reassembly 579

CHAPTER 16 Engine Hardware: Fasteners,

Thread Repair, and Gaskets 580

Characteristics of Fasteners ■ Bolt Stretch ■ Torque and Friction ■ Drill

Bits ■ Taps, Threads, and Dies ■ Repairing Broken Fasteners and

Damaged Threads ■ Automotive Tubing Repair ■ Gaskets ■ Gasket

viii • CONTENTS

CHAPTER 17 Reassembly and Starting 638

Warranty ■ Reassembly ■ Completion of Assembly ■ Engine

Installation ■ Ignition System Installation and Timing ■ Engine

Starting and Break-In ■ Final Inspection and Cleaning ■ Study

Questions ■ ASE-Style Review Questions

Appendix ■ 683

Glossary ■ 701

ix

Preface

ABOUT THIS BOOK

It is often said that engines never change Although large changes are not the norm, the internal combustion (IC) engine is constantly evolving When the first edi-tion of this text was written in 1980, futurists were quesedi-tioning whether the four stroke cycle engine would still be around in 20 years The long history of this well-proven engine has shown continuous small refinements, and it is still the engine that powers most of today’s vehicles Compared with the engines that powered the muscle cars of 1980, today’s engines are more refined, lighter, and offer improved performance and durability

Automotive Engines, Sixth Edition provides the reader with the comprehensive knowledge needed to repair and rebuild these automotive engines The most com-plete book of its kind, it takes a generic, rather than product-specific, approach The text provides all of the need-to-know information in an easy-to-understand format Much effort has gone into organizing this book to make it easily readable, like a story To facilitate learning, all items related to a given topic are included within a single chapter Appropriate for entry-level as well as more experienced technicians and machinists, this text also provides opportunities for the reader to develop criti-cal diagnostic and problem-solving skills

Organization of This Edition

This text is divided into four sections and is designed so that the student can begin working in the shop right away Section covers engine construction, disas-sembly, inspection, and parts ordering Diagnosis techniques, both before and after disassembly, are covered in detail Also included are repair procedures that can be performed while the engine is still in the vehicle Tools and equipment procedures, as well as safety issues, are covered throughout Section deals with the breathing system This includes the valvetrain and manifolds Cylinder head repair, as well as camshafts and turbochargers, are also discussed in this section Section discusses the cylinder block assembly with a focus on lower-end repair procedures The lubri-cation and cooling systems are also covered Section deals with final reassembly and starting the engine Gaskets and miscellaneous repair procedures are covered in this section as well

New to This Edition

This sixth edition of Automotive Engines has been updated and refined to reflect

x • PREFACE

easier for students to survey each chapter by looking at the photos and captions before reading the text

The design and engineering of the internal combustion engine is continuing to evolve, with high-performance sport compact cars becoming a larger share of the engine repair and enhancement market Vehicle restoration also accounts for a sub-stantial part of the industry In response to reviewer comments, these and other areas have been addressed in this revision of the text

Some of the new changes are listed next:

• New or updated case histories highlight real-world situations, providing more

critical thinking practices

• An updated and expanded high-performance chapter, including more detailed

information on engine breathing, including intake and exhaust manifolds, flow benches, turbocharging, supercharging, advance materials, and high-performance camshaft information

• Updates to the engine diagnosis chapter present the material the way it is

pre-sented in class Students need to learn to diagnose an engine during disassembly so they can assess its suitability for repair prior to spending a lot of money and wasting a lot of time Analyzing unusual wear or part failure will also help them correct problems so they not recur

• New up-to-date information on cooling and lubrication systems has been added

to this edition of the text Engines last far longer than they did 25 years ago, so maintenance has become more important to vehicle owners Cooling system fail-ures that result in serious engine damage have become more common

• New Vintage Engines additions help put newer technologies in historical

per-spective by offering interesting facts about older technologies while separating them from the core text

Use of the Text

A goal of Automotive Engines is to fill the needs of many, merging commonplace

and vintage content with the latest high-tech information Some schools have smaller engine course offerings, whereas others have large programs with classes of long enough duration to complete the entire text Some instructors will choose to assign certain chapters, leaving others for an introductory course Others will use some chapters in a prerequisite introductory engines course, saving others for an advanced engine-rebuilding course For instance, Chapter covers all of the camshaft-related items that would be needed for an entry-level automotive apprentice, whereas the new Chapter 17, Engine Power and Performance, consists of more advanced techni-cal material for aspiring engine machinists and high-performance specialists

There are many new and updated photos of engine disassembly and reassembly on newer vehicles The camshaft chapter emphasizes timing belt service, including cam lobe position identification, so you can be sure you are doing the right thing This is something all good technicians should know, but many not

PREFACE • xi

use of a particular machine are avoided because they are available in the manual that comes with the machine

The primary aim of the text is to provide a student with adequate preparation for entry-level employment with emphasis on the ASE A1 and M1 engine assembly specialist areas The text also provides a foundation for the M2 and M3 areas, espe-cially in regard to ASE test preparation

To the Student

xii

Shop Tips

Found throughout the chapters, these tips cover things commonly performed by experienced technicians

Features of the Text

Learning the theory, diagnosis, and repair proce-dures for today’s complex engines can be challeng-ing To guide readers through this material, a series of features are included that will ease the teaching and learning processes

Objectives

Each chapter begins with a list of objectives The objectives state the expected outcome that will result from completing a thorough study of the con-tents of the chapter

54

CONTENTS

• Diagnosing Problems before a Repair • Oil Consumption

• Oil Leaks • Fuel Mixture Problems • Compression Loss • Engine Noises

• Oil Pressure Problems • Cooling System Problems • Electronic Failures/Engine Damage

OBJECTIVES

Upon completion of this chapter, you should be able to:

• Use engine diagnostic tools and equipment safely and properly

• Diagnose engine and related problems and determine the proper repair procedure

INTRODUCTION

This chapter focuses on how to troubleshoot problems on a running engine Also discussed are some of the external causes of engine problems that

can result in a repeat of a previous engine failure, if allowed to continue unresolved Internal engine parts are shown here to illustrate some of the causes and results of these problems Internal problem

diagnosis after disassembly is also covered in more detail in subsequent chapters

It is very important that you diagnose the cause of a problem before performing a repair It is not unusual for an inexperienced technician to spend many hours of work only to discover that the repair was unnecessary

Five major diagnosis areas are covered: • Possible reasons for oil consumption • Causes of rough running or a loss of engine

power • Engine noises

• Oil pressure problems • Cooling system problems

There are many causes of engine problems Some are the result of normal wear and tear or a lack of maintenance Engine problems also might be due to previous work on the engine Problems that appear to be engine-related can also be caused by other automotive specialty areas, such as the transmission or emission controls Some-times a problem with a system causes an engine to fail If the problem is not taken care of, the fail-ure will recur

Diagnosing Engine Problems

VINTAGE ENGINES

In the past, gasoline stations provided underhood service, and most of them had an adjoining service facility

Today many of the service facilities have been conver

ted to mini-markets

One result of self-service is that eng

ines are suffering from a lack of maintenance

C H A PT E R 3

11/14/09 1:43:34 PM

CHAPTER Diagnosing Engine Problems • 85

it is advanced to the furthest point without causing detonation Modern computer-controlled engines use a detonation sensor (

Figure 3.53), sometimes called a knock sensor When it senses the vibration caused by detonation, the computer retards the igni-tion timing until the spark knock goes away The computer continually relearns the best timing for the fuel by advancing the timing until detonation occurs and then retarding the spark slightly until detonation stops All modern automotive engines have this capability Manufacturers recommend fuel of a particular octane rating for each of their vehi-cles When fuel of a lower octane rating is used, the timing will be adjusted to a lower amount of advance The price is a slight penalty in fuel econ-omy and performance

Older engines required more spark advance to com-plete combustion by the targeted point of 11–14° after TDC On modern engines, to help speed up normal combustion and prevent detonation, the spark plug location is often centrally located, or there are multiple spark plugs This is more efficient mechanically because firing the spark closer to TDC means that the piston is not working against com-pression for as long a time One of the advantages of a four-valve pent-roof combustion chamber is its faster burn time

Sometimes the pistons and cylinder head absorb the sound of engine knock, making it inaudible This condition is called cold knock or inaudible ping Other times the rattling that results from deto-nation can be very loud The noise is caused by vibration of the combustion chamber walls

When the air-fuel mixture detonates, the explo-sion is instantaneous and the loss of power can result in serious engine damage, including broken pistons, piston rings, and head gasket failure

SHOP TIPS

• Spark plugs are a window to combustion chamber action

Figure 3.52 shows spark plug conditions that resulted during preignition and detonation

• Dynamometers (see Chapter

0) are used to test eng ines under load Experienced dyno operators know that the temperature of exhaust gas in a detonating eng

ine will drop

Fuel Octane, Spark Advance, and Detonation

Octane rating is a measurement of a fuel’s ability to resist explosion under pressure Design engineers test an engine on a dynamometer, using fuels of dif-ferent octanes Difdif-ferent spark advances are tested at various speeds and loads to determine the engine’s highest torque output Ignition timing is best when

VINTAGE ENGINES

Before sophisticated computer-controlled spark timing, a common cause of detonation was over-advanced ignition timing

FIGURE 3.52 Damage due to (a) preignition and (b) detonation (a)

(b)

FEATURES OF THE TEXT • xiii

Key Terms

Each chapter ends with a list of the terms that were introduced in the chapter These terms are highlighted in the text upon first use

Safety Notes and Cautions

Safety is a major concern in any automotive shop, so safety notes and cautions are listed throughout to focus the reader’s attention on impor-tant safety information

Vintage Engines

These text boxes place newer technologies in historical perspective by offering interesting facts about older technologies while separating them from the core text

CHAPTER Diagnosing Eng

ine Problems • 69

overheat Converter overheating can be minimized by dis-connecting the smog pump during the test

SHOP TIP

Using an oscilloscope when per

forming a power balance test allows the height of the firing lines to be observed A poorly performing cylinder with a high firing line can indi-cate a lean air-fuel mixture; a low firing line can be indica-tive of low compression

The cylinder power balance test can also be done with the engine running at higher speeds than idle Compare results at low and higher speed

An engine with a burned valve will perform poorly at low engine rpm but would improve at higher rpm A leaking valve does not have as sig-nificant an effect at higher speed as it does at low speed because the air coming into the engine and leaving it is moving too fast and has a much higher volume

A restriction in the intake, like that caused by a worn cam lobe, with hydraulic adjustment will result in little change in engine operation at idle The problem will become gradually more pro-nounced as speed is increased

EGR leaks not respond when you richen the mix-ture like air leaks The cylinder causing the rise

in engine rpm is the one from which the exhaust gas for the EGR valve was picked up Retest at cruise rpm and the problem will disappear

CAUTION

Cylinders should be shor

ted for only a few seconds at most Raw fuel entering the cataly

tic converter can cause it to FIGURE 3.21 Electronic cylinder power balance W

hen an injector is

disabled, engine rpm should drop

(Courtesy of Tim Gilles)

VINTAGE ENGINES

Prior to OBD II, manual power balance testing was a routine procedure On eng ines

with contact point distributors, it was a common practice to disconnect each spark plug wire on an idling engine and note the rpm drop Y

ou can perform a power balance test on cars equipped with electronic ignition electronically

Allowing the coil to produce ignition sparks while spark plug cables are disconnected can increase current flow in the coil to the point where the coil and igni-tion module can be ruined Eng

ine analyzers and hand-held scan tools have a feature that auto-matically shorts out cylinders, one at a time, without removing spark plug cables

It is important that each cylinder be shor

ted for the same leng

th of time and that the speed of the

engine returns to normal before shor

ting the next cylinder

The test is most effective when done at

the lowest engine speed possible (5 00–600 rpm)

Vehicles equipped with computer-controlled fuel systems will automatically raise the eng ine idle to

compensate as each cylinder is g

rounded out Disabling the computer’s spark advance is required to perform this test Consult service literature for the correct procedure

11/14/09 1:44:08 PM

Case Histories

These true stories describe automotive situa-tions encountered by the author They provide the reader with insight into the critical thinking skills necessary to diagnose automotive engine problems

CHAPTER Diagnosing Eng

ine Problems • 95 The results of the test include information about the viscosity (thickness) of the oil (Oil is covered in detail in Chapter 14.) Thicker oil is due to oxida-tion, usually from heat Thickening must be less than 30% of the original viscosity Thinner oil is usually due to fuel dilution, either from an accu-mulation of short trips or from a defect in the engine’s fuel system

Other results of an oil analysis include the oil’s moisture content (which should be less than 2%) or the presence of antifreeze/coolant, either of which could indicate internal coolant leaks The test also gives results in parts per million of the presence of metals such as iron, chromium, copper, aluminum, and tin from worn or failing engine parts Also included is silicon, which is sand or dirt High amounts of iron indicate excessive wear to cylinder walls Aluminum can indicate piston wear and chromium can indicate wear to chrome piston rings Excessive copper in an oil sample can be due to a new oil cooler on the engine After a first oil change, this should no longer be a problem because the inside of the oil cooler will oxidize during nor-mal use When lead and copper are found in the sample, this can be due to engine bearing wear or failure

that the catalytic converter could overheat and melt, causing exhaust system backpressure

Oil Analysis

Large fleets use oil analysis to determine when to change oil They put hundreds of thou-sands of miles on their engines and the engines have very large crankcase capacities In addition to telling when the oil’s additives are depleting, oil analysis performed by testing laboratories can also tell if there is potential mechanical trouble on the horizon

A sample of about ounces is sent to the labora-tory The oil is collected when the engine is at oper-ating temperature The lab is given information on the original viscosity of the oil, how long it has been since the last oil change, and how many miles are on the engine

Fleets often sample oil using a suction tube inserted into the dipstick tube Be sure that the sam-ple is not taken from the bottom of the oil pan This will not yield an accurate result If the oil sample is taken through the oil pan drain opening, remove at least quart of oil so that dirt deposits are washed away from the drain opening

KEY TERMS

ATF black light testing block check tester

cranking vacuum test cross fluid contamination

EGR

intake manifold vacuum PCV

seized engine

STUDY QUESTIONS

When an engine runs for a long period with an excessively lean air-fuel mixture, what kind of engine damage can result?

Carbon has built up in the neck area of a valve What is the most probable cause? If a spark plug is oil-fouled with carbon on only

one side, what could be the cause? At the end of a spark plug deposit test, what must

be done before the engine is accelerated off idle?

A roar will be heard through the engine’s air intake when the _ system is restricted What happens to the outside of an exhaust pipe

at the point of an internal restriction? During a compression test, remove all of the

_ _ so the starter can crank the engine easily

How many compression strokes (minimum) should the engine crank during a compression test?

11/14/09 1:45:09 PM

34 • SE

CTION I Engine Construction, Diagnosis, Disassembly , and Inspection

drill) W

hen he plugged the drill into the wall, he was holding it in his hand and received a dangerous electrical shock Luckily he was not seriously injured.

General Hybrid Safety

If you ev er work on a hybr

id electrical system,

your life will depend on kno wing wha

t and when

somethin

g is safe to touch V oltage can ran

ge up to

650 volts and 60 amps instantly

This can be deadly

All hybr id manufac

turers pro vide ample inform

a-tion on the Internet to allo w fire departm

ents and

other em

ergency personnel easy access for t raining

Toyota em ergency inform

ation is a vailable a

t the

followin g Web site: http://

techinfo.to yota.com

SAFETY NOTE

Orange means high voltage Do not forget this! Figure 2.1

5

shows typical orange-colored high-voltage connections in a hybrid vehicle

Electric Shock

Twelve-v olt direc

t current (DC) elec trical

sys-tems like the ones used in a

utomobiles are not

capa-ble of induc ing ser

ious elec

trical shock, unless the

engine has a dist ributorless ignit

ion or is a

high-voltage hybr id Shop equipm

ent, ho wever, is po

w-ered by either 110-v olt or 220-v

olt alterna ting

current Ele

ctric shock hazards can be minimized when usin

g electrical tools by not standin g in water

To prev ent a spark f

rom jumpin g from the outlet to

the plug, be sure tha

t a tool is not in the “on ”

posi-tion before y

ou plug it into the outlet Three-wire elec

trical tools are the best choice for

commercial w ork The ext

ra terminal is connec ted

to ground ( Figure 2.14

) If you use a hom

eowner-type tool with a tw

o-wire plug, it should be double

insula ted Tradit

ional a utomot

ive wir ing color is

black for ground and red for posit ive, but in

com-mercial wir

ing the green wire is for ground

CASE HISTOR Y

An electrical plug on a drill with a metal housing was damaged, requiring replacement A mechanic

bought a new three-wire plug, cut and stripped the wires and installed it on the cord He had been

working on cars for many years and was used to the color code used around automotive batt

eries

When he connect

ed the black wire to the ground

terminal, he was actually connecting one of the hot leads to ground (also the housing of the metal

Ground socket

Ground ter minal

FIGURE 2

.14 The third wire terminal is for g round

Orange cab les

FIGURE 2

.15 High-voltage cables on hybrid vehicles are orange Accidental contact can kill you!

(Courtesy of Tim Gilles)

026-053.indd 34

xiv • FEATURES OF THE TEXT

Instructor Resources

An Instructor Resources CD is available to instructors and includes the following compo-nents: an electronic Instructor’s Guide with answers to all end-of-chapter questions, Word files of all end-of-chapter questions, a computerized test bank in ExamView with hundreds of questions for quizzes or exams, chapter presentations in PowerPoint for each chapter of the text, a search-able Image Library with hundreds of illustrations to support in-class presentations, a NATEF corre-lation grid connecting the chapter content with the most current A1 task list, and electronic job sheets to guide students through common engine diagno-sis and repair procedures

Notes

Throughout the text, notes are included to call attention to need-to-know information

ASE-Style Review Questions

Each appropriate chapter concludes with ten ASE-style review questions to help the reader pre-pare for the ASE Certification Exam

Study Questions

At the end of each chapter, there are 15 study questions of varying types The questions provide an opportunity for reinforcement and review of key concepts presented in the chapter

420 • SECTION III Cylinder

Block Assembly

NOTE

When ringing a crankshaft, the sprocket or gear must be removed first, or the crankshaft will sound like it is cracked Hang the crankshaft by a wire Holding it by hand will deaden the sound

A dull sound indica

tes the presence of a crack

A forged crankshaft will

ve a sharper soundin g

ring than a cast crankshaft

NOTE

Some crankshafts require very careful handling If you dam-age a tone ring for a crankshaft position sensor like the one shown in Figure 12.1

6, you can cause a drivability problem due to the confusing signals received by the PCM

A more accurate way to check for cracks is the wet Magnaflux

® magnetic particle inspec tion

method (Figure 12.17)

• A magnetic field is induced in the crankshaft by spraying the crankshaft with a mixture of iron particles suspended in a liqui

d

• Then a black light is used to detec t the cracks

NOTES

Magnaflux will not locate pinholes and casting defects It only works for cracks

Before checking a burned crankshaft for cracks with Magnaflux, grind it first

attempt it because they find it more economical to replace the crankshaft

Another method of st

raightening crankshafts is

with a special press

(Figure 12.14) The press will work with forged crankshafts but will likely break a cast crankshaft

A crankshaft tha

t is only slightly bent can often

be reground straight, but this has its limita tions

Rebuilders sometimes insist on receivin g a

crank-shaft core that is standard or 0.010 " under to allow for the possibilit

y that a crankshaft slightly out of

alignment can be correc ted by regrinding

Checking for Cracks

When a crankshaft is sev

erely worn, it will ve

suffered poundin

g because the engine was opera ted

with excessive clearance There is a higher likelihood this crankshaft to be cracked A crankshaft burned from oil starvation is not as likely to be cracked

A crankshaft can be checked for obvious cracks by “ringing” the counterw

eights with a light tap of

a hammer (Figure 12.15) FIGURE 12.14 A crankshaft straightening press used on forged crankshafts that are bent

Hydraulic press Press arm WRONG Wire RIGHT

FIGURE 12.15 Ringing a crankshaft to check for cracks A dull sound indicates a crack Suspend the crankshaft with wire Holding it with your hand will invalidate the test (

Courtesy of Tim Gilles

)

11/27/09 6:56:31 PM 456 • SE

CTION III Cylinder

Block Assembly

bearing crush bearing spread

end thrust

externally balanced fillet radius

locating lug or tan g

Rockw ell “C” scale torsional vibra

tion

STUDY Q UESTIONS Wha

t is another nam

e for the rod journal?

Wha t is the nam

e of the rounded area a t the edge

of each bear ing journal?

Wha t is the dif

ference in appearance betw een an

in-line en

gine rod journal and a V8 rod journal?

Which crankshaft is st ronger

, cast or forged?

Wha t is the term tha

t descr ibes the crankshaft

being pushed forw

ard by the clutch or torque

converter?

When a rod journal is tapered, wha t should be

checked as a possible ca use?

List (in inches) the dif

ferent undersizes to which

a crankshaft can be reground Wha

t are the nam es of tw

o types of hardenin g?

a b The hardness spec

ification is usually giv en on

the _ “C” scale

KEY TERMS

10 Wha

t part of the crankshaft can be rolled with a hydraulic roller to increase crankshaft st

rength?

11 How much thicker than standard w ould a 0.020’

’

undersized bear ing insert be?

12 When there is less clearance, will a Plast igage

reading be wi der or narro

wer?

13 Wha t are three propert

ies of a bear ing?

a b

c 14 Norm

al main bear

ing wear is on the _

a top b bottom 15 Nam

e three t

ypes of scales used in en gine bal-ancing a b c ASE-S

TYLE R EVIEW Q

UESTIONS

An en

gine has a burned thrust m ain bear

ing

Technic ian A sa

ys that this can be ca used by a

driver who “r ides” the clutch T

echnic ian B sa

ys

that this can be ca used by insuf

ficient clutch

pedal-f ree trav

el Who is r ight?

a Technic ian A only b Technic

ian B only c Both A and B

d Neither A nor B Technic

ian A sa ys tha

t norm al main bear

ing

wear is on the top T echnician B sa

ys that w orn lower m

ain bear ings can be ca

used by luggin g

the engine Who is r ight?

a Technic ian A only b Technic

ian B only c Both A and B

d Neither A nor B Technic

ian A sa ys that bear

ings ve a soft

sur-face tha t flows

away from high spots in case of a

nick in the crankshaft T echnic

ian B sa ys that

dirt can be absorbed into the crankshaft journal surface Who is r

ight?

415-457.indd 456

xv

Tim Gilles has authored and coauthored several textbooks He has been an automo-tive teacher since 1973 and is currently a professor in the Automoautomo-tive Technology Department at Santa Barbara City College He has a Master of Arts degree in Occu-pational Education from Chicago State University and a Bachelor of Arts degree from Long Beach State University He holds the industry certifications of ASE Mas-ter Engine Machinist and ASE MasMas-ter Automotive Technician

Tim has been active in professional associations for many years, serving as pres-ident and board member of the California Automotive Teachers (CAT) and as a board member and election committee chair of the North American Council of Automotive Teachers (NACAT) He is a frequent seminar presenter at association conferences Tim has been a longtime member of the California Community College Chancellor’s Trade and Industry Advisory Committee He is active in industry asso-ciations, including AERA, ARC, and IATN and has served several terms as educa-tion representative on the board of the Santa Barbara Chapter of the Independent Automotive Professionals Association (IAPA)

xvi

The National Institute for Automotive Service Excellence (ASE) certifies automotive technicians in the eight specialty areas of automotive repair Tests are given twice a year at locations throughout the country and on the Internet To become certified in one of the specialty areas, you must correctly answer between 60% and 70% of the questions, depending on the difficulty of the particular test To become a Master Auto Technician, you must pass all eight tests To receive certification, you must also have at least years of automotive work experience School training can count as one of the years If you not have the work experience, you can still take the tests ASE will provide you with the test results and will certify you as soon as your expe-rience requirement is met

ASE and AERA have developed an Engine Machinist test series The three tests in the series are Cylinder Head Specialist, Cylinder Block Specialist, and Engine Assembly Specialist Passing machinist tests in all three of the areas qualifies you as a Master Engine Machinist Tests are administered as part of the regular ASE Tech-nician test series

Many employers ask for ASE certification when they advertise a job opening ASE certification provides a technician or machinist with a means of showing a pro-spective employer that he or she has a validated training background The practice tests at the end of the chapters in this text provide examples of the types of questions that will be found on the ASE A1 test on Engine Repair and ASE M1–3 tests on Engine Machining Sample ASE Engine Machinist test questions and explanations are included at the back of the book

xvii

The author and publisher would like to offer special thanks to the following reviewers for their com-ments, criticisms, and suggestions on the sixth and prior editions of this text

Sixth edition reviewers: Henry Baboolal

University of Northwestern Ohio Lima, OH

Jim Brandon

Linn State Technical College Linn, MO

David Christen

University of Northwestern Ohio Lima, OH

Earl Comer

University of Northwestern Ohio Lima, OH

Dave Hagen

AERA Engine Builders Association Crystal Lake, IL

Tim LeVan

University of Northwestern Ohio Lima, OH

Jason Norris

Pasadena City College Pasadena, CA

Richard Rackow

Moraine Valley Community College Palos Hills, IL

Chuck Rockwood Ventura College Ventura, CA Michael White

University of Northwestern Ohio Lima, OH

Reviewers prior to the sixth edition:

Steve Bertram, Palomar College, San Marcos, CA David Christen, University of Northwestern Ohio, Lima, OH

Kenneth P Dytrt, Pennsylvania College of Technology, Williamsport, PA

Dimitri Elgin, D Elgin Cams, Redwood City, CA Gary Engberg, Northeast Metro Technical College, White Bear Lake, MN

John Kraemer, Western Iowa Tech Community College, Sioux City, IA Norman Laws, Professor Emeritus, Chicago State University

Larry Leavitt, Pennsylvania College of Technology, Williamsport, PA

Wilmer Martin, Automotive Training Center J C Mitchell, Gaston College

Ted Nicoll, Central Missouri State University Jerry Norris, Southeast Community College, Milford, NE

Joe Polich, President, Production Engine Rebuilders Association

Fred Raadsheer, British Columbia, Institute of Technology, Vancouver, BC Robert D Raduechel, Modesto Junior College Butch Reilly, Spokane Community College, Spokane, WA

Chuck Rockwood, Ventura College, Ventura, CA Charles Romack, Southern Illinois University Jerry Rosenquist, Fel-Pro/Federal-Mogul Raymond K Scow Sr., Truckee Meadows Community College

Gary Semerdjian, Santa Barbara City College, Santa Barbara, CA

xviii • ACKNOWLEDGMENTS

Jason Spohr, Pasadena City College, Pasadena, CA Bill J Steen, Yuba College, Marysville, CA

Forrest J Stewardson, Mayo Technical College Don Sykora, Morton College, Cicero, IL John Thorp, Illinois Central College, Peoria, IL Christopher VanStavoren, Pennsylvania College of Technology, Williamsport, PA

Bob Warnke, Hutchinson Technical College

The author would also like to thank the mem-bers of the AERA for the tremendous job they in sharing technical information through their organi-zation AERA associate members from industry and manufacturing have been extremely helpful in pro-viding illustrations and technical help Dave Hagen,

AERA Technical Support Manager, has made count-less helpful suggestions for improvement of this

and earlier editions of Automotive Engines.

The author would especially like to thank his Delmar Cengage Learning team—Matt Thouin, Barbara LeFleur, Chris Chien, Mark Bernard, Dave Boelio, and Sandy Clark—for their exceptional effort and dedication in bringing this revision to publication Special thanks are due to Matt Thouin, my product manager Matt has very capably

man-aged this sixth edition revision of Automotive

1

SECTION 1

Engine Construction, Diagnosis, Disassembly,

and Inspection OVERVIEW

Automotive Engines is a book about the diagnosis, repair,