‘Automotive Technology FTUN MYINT ETAY (MLE, MECHANICAL)Chapter (1) Chapter (2) Chapter (3) Chapter (4) Chapter (5) Chapter (6) Chapter (7) Chapter (8) Chapter (9) Chapter (10) Chapter (12) Chapter (12) Chapter (13) Chapter (14) Chapter (15) Chapter (16) Chapter (17) Chapter (18) Chapter (19) Chapter (20) Chapter (21) Chapter (22) Chapter (23) Chapter (24) Chapter (25) Chapter (26) Chapter (27), Chapter (28) Chapter (29) Chapter (30) Chapter (31) Chapter (32), Chapter (33) Chapter (34) Chapter (35) Chapter (36) Chapter (37) Chapter (38) Chapter (39) Chapter (40) Chapter (41) Chapter (42), Chapter (43) Chapter (44) Chapter (45) Chapter (46) Chapter (47) ‘Automotive Technology wo8or0 ‘Automotive Systems. Ss Hand Tools and Shop Equipment... ‘Automotive Engine Designs and Diagosi Diagnostic Equipment and Special Tools Working Safety in the Shop Preventive Maintanence and Basic Services Basic Theories and Math Engine Disassembly and Cleaning Lower End Theory and Service Upper End Theory and Service Engine Sealing and Reassembly Lubricating and Cooling Systems Basics of Electrical Systems General Electrical System Diagnostics and Service Batteries: Theory, Diagnostics and Service Starting and Traction Motor Systems Charging Systems Lighting Systems. Electrical Instrumentation Basics of Electronics and Computer Systems Electrical Accessories Restraint Systems: Theory, Diagnostics and Service Engine Performance Systems Detailed Diagnostics and Sersors Ignition Systems Ignition Systems Diagnostics and Service Fuel Delivery Systems Electronic Fuel Injection Fuel Injection System Diagnosis and Service Intake and Exhaust Systems Emission Control Systems Emission Control Diagnosis and Service Fuel and Other Energy Sources Clutches Manual Transmissions and Transaxles Manual Transmissions and Transaxles Service Drive Axles and Differentials ‘Automatic Transmissions and Transaxles Electronic Automatic Transmissions ‘Automatic Transmissions and Transaxles Service Four- and All-Wheel Drive Tires and Wheels ‘Suspension Systems Steering Systems Wheel Alignment Brake Systems Drum Brakes Hun Myint Htay (ME, Mechanical) Page 2 of 74‘Automotive Technology Chapter (48) Disc Brakes Chapter (49) Antilock Brake, Traction Control and Stability Control Systems Chapter (50) Heating and Air-Conditioning Chapter (51) Air-Conditioning Diagnosis and Service Hun Myint Htay (MLE, Mechanical) Page 3 of 74\utomotive Technology A Systems AUTOMOTIVE TECHNOLOGY A SYSTEMS APPROACH NOG ater AO Myint Hlay (ME, Mechanical) Page 4 of 74‘Automotive Technology CHAPTER (1) AUTOMOTIVE SYSTEMS 1.1. THE BASIC ENGINE cnmigpre} ogayproordigda§ mabcyScllarpSu anormaqgprmora}ics Seudméqegs cooidmigisil: gq Gr8EEr ahreqegdqroosionss og’ conbesloSopenoaenégs (Internal Combustion Engine) —spiipsooniqp: [gSfeqoloop5i mSqScdo8 BrecoakcdleBapeo{gEsQGs lola§cofees (GS 0951 ____ ratPhicogys FecSmriqchao> sohlGlAR: onfjenmeanramregSeopS: wap (6[elorgSe Bauiakqd} orcde8a0érsso80n soqcScogn mogopos(gScarScop$: ag04] soogSaySgonca09 meordaQliorg GulavaSe cooisSsnéqeogé _oacSaSqZacon} —cnoeGaSoxo(Carburetor}moc —_oxpogoauifie ewiqicdcopins od00r8 §8850x myGi§gSararqoicg§i}og’ ovoSocod (Spark Plug) g SiogoS cals SocortevlaSagars clolagcoo! sop51 Bacindyiog’ miqtade} corordijpadcRanocopllG: ode [8285m0 agGigss conigpiegdiiog’ cqSeudy SacS8eogSaogarccorapies [frcoree Beige ScoréredleSq}omo olelqg codlaogSe Hun Myint Htay (MLE, Mechanical) Page 5 of 74‘Automotive Technology 1.1.1. Cylinder Block (soco8sloveev208) woevdslorccoanie} wiqEorcorooiafesT hs modqéjeGBiaiin§é: GSvlarSu opfras (Cast tron) oSoupe8 soay8$ao8 (Aluminium) § oopScaoa05cloop§x socoSsloneavonSogé. eqgotag cqpsBapioyoigg soecladqor evloSoorrdlargSy odoartegeapioysicoacecySaySag. socoeslact lq Slaog§x socokslonccoadog’ m{enrondys8é pogeSiqains orSa0équlora5x cylinder Engine number crankcase Figure (1-2) soco8slgSayicleav. so qe onecv205§ 1.1.2. Cylinder Head (socéslus05) socvdsluraing socoEsloncarsaiaadTyo onSaakqplargsx socoSsloocaonig$ soco8sl wnoScho} Head Gasket Gf on5s0qulorp5u socoéslooaiogé Combustion Chamber so8o> I§lBt socv8slodo8 sofao0g05 Inlet Port, Exhaust Port qouclGolavaSe socoSslosaScRavaS: 9g§108 (Cast Iron) 2§6u705 soog8$028 (Aluminium) 3 oxpScaoon5claa—Se Figure (1-3) soco8slovecooe5s soevdslor054 Hun Myint Htay (MLE, Mechanical) Page 6 of 74‘Automotive Technology 1.1.3. Piston (o80028) ob0or8eB54§ soo8slendSleoiey$ Brecor8esloSeyslanpS+ oBoor8ar95 memrgip {Bs socvdslodog’ ongiordiqdiqgs copfeosiqslaopSe socoSslecoia}soleavasaa|Sogé vdoorEscosaseQ ( cndapiqytangS Intake Stroke, Compression Stoke, Power Stoke, Exhaust Stroke 20g soya [eScqular5x méicoSoo75036 oSoorEao95 cmociucin8 agos[fs Inlet Port géca{B: cco§sSs0c09 emogac} socodsleogé: ofcoulorpSu ogSioqeSgsioop5og’ oearéore5 mevleoSaR oges(&t Inlet Port Exhaust Port SoScg(§: ccogs8macqpmegoc} BaSEvlarpSu aocodslencgirfear> cavge8rreqpsocyo095 8 2 myGifoops laop5 B8aog{Fog= ovcSecosm SrocScor cGocoroce0) SiccosSavloScjco9 vbecé saculoggicvgie! clolaGclavgSn oSooréo09§ soocTenS of Giorodervams) SiecostiGreave Si8iege0ze8 Exhaust Port org aoeq|éao[asvasdh cyosusol s2pbu arfeSle$ oSoorkarpS snqiSadogé soconScavo08 ogoypicgdloog51 Figure (1-4) 0500086 1.1.4. Connecting Rods and Crankshaft oSooréijagegpiyorps wEqdadogé socvTesvonSa02 cgegprcgvlongSy 8socgon09 copSvoSyqeaon’ oodygaSivaaacR coabi{yilangsu ofoondoR ao§éig6 Crankshaft oR cab qaScB:ocp Connecting Rod § sooScontdlaop8u § (1-4) oBlaap§oln 1.1.5. Valve Train Intake Stroke 9 Exhaust Stroke cogy Inlet Port 4€ Exhaust Port cozavaS wogifafoScogéso BoSagScorqdlorgSu spoSoqSavr{gdic} Valve Train of aoTvloopSu ofreScaScoag Crankshaft 44 Camshaft o808 GoSconScostslaxpSn Inlet Port g Exhaust Port cope eo$§ sa8oShéaySo02t0] avabu géajéais oo8faonie8 coybopgecon8 Pushrod ones ScorslaopSu goSeqporadangiggo géqoedas, ono Camshaft § copSooSgeoT gongSequloop5e Figure (1-5) The valve train for one cylinder of an overhead valve engine Hun Myint Htay (MLE, Mechanical) Page 7 of 74‘Automotive Technology 1.1.6. Manifolds Intake Manifold g& Exhaust Manifold g8qQvloop5x socodslecosa}so8i<8 ageifour coorg gopSicorlaéic8e8 apScorclaap5u Figure (1-6) x{GoeqpEar5 aokroBoS8SGiGIE: ofeqpiar5 Bodcoo8SG(Gaclao—5u 1,2. ENGINE SYSTEMS enrich ogdorer ccperofGér [GSclorp5u EapaEqpc} oSoorse0g% gopS:ouT|EGé: GédtooeSu 1.2.1. Lubrication System wingfadcg’ vSoorkdafeas eadyogaSioagones allogey: soySoySoqearneftg engengs goSoobone ayogobconslangSn onggong gobchibgadiaocboocens sapaBfourqslangSs qeaps8eh wEqe8Ec§ collavaSe aoEqeSEoh Engine Block caxaeSuaozé Oil Pan Boge engfulangsu a8 qS8EcR aofodcons Oil fiter o8 (goSaaficoqularpSa Oil filter avpS wEqeBEdORE Slofeaos smpoScodfeneqrec8 eoScqoScosslo0p51 Oil fiero sosoScopSaScorqolaoa5a | oitter Piclup Figure (1-7) Oil flow in a typical engine's lubrication system 1.2.2. Cooling System ciqicsogé SiccordavloSapyoog BSgoroa8c0x syypigo (eScoTogulavpSu p8aayc8 soya} Cooling System of seo¥s{ajqolo0p51 Cooling System ogé cqoBSo8 (Radiator), eno} (Water Hun Myint Htay (MLE, Mechanical) Page 8 of 74‘Automotive Technology Pump), Radiator Hose, soSqScoscoonScdugSoqadlnSyo: (Water Jackets) o8 vlofdlaopSu oqa%Eabody sqgatargS casgyoScoaScarné yavons[gs cqobsoBaoccTonSozé Pressure Cap 08 cobs08c02%dl a0 oneSooosiog’ 08g: oagang hg SerecTgoaST: 08} cafrondl: eqcarepa: cgodags AVaogSu onate8 aSBiBrgs ogeSavoed08 aoudeory agoreggolgu aod qSearagorpar> ybqegile awigion sayganogSapSqoroa$coxp saqS:emiagaic8 olgScastonadfero$ Thermostat coa§oonc5 cr8coatilaap5i axoBeosaien Gfcoste) my@feqpody cqsooyoisocosigScuxs Cooling System o8 eoopScgScoulaopSs soqSiesn:0}§8écoqy0 sosny{eBivlo0p51 Figure (1-8) A typical engine cooling system Fuel and Air System eooshaniqiog’ ooSSoREBUIg(B BEBrrag mbqSodoqpaSarahaned §: SABhrqySorphenoySarS moohdapr moylySclaraSa Bjccor§ snggeryqradous copScorqolaaps oconfcopS: Bgocqpa$ a§edoq§ Air Filter o8 [goScooq¢la0951 1.23. Figure (1-9) The intake system for a V-10 Engine 1.2.4. Emission Control System wiqier odqoidfoSears BoSearadogé vfoSahoog§ (HC) Hydrocarbons, avoghGagacS G05 (CO) Canbonmonoxide, cxoonSsBaScap$aSo0§qé (NOx) Oxides of Nitrogen cog clogoivloop§u Hun Myint Htay (MLE, Mechanical) Page 9 of 74‘Automotive Technology Environmental Protection Agency axpScco0é|§: anotencqoSagoSes00 varnakrsBidlioooSagaage? Bf: aySeordlaog5n p8esoqE8e> Standard cog po'lgslG: coaiapoSaySageoge} aoScean8 axErSsooEcled (gfoopS [Ee trogen coypajcoton9§ gat a§{6(98: [eSla0p50 1.2.4.4, Catalytic Converter vadqeSioneory Catalytic Converter of oSewncBEicgé onbsnG(B: soofislangSe GoSaGooogs (HC) Hydrocarbons, osag§8eqon5<805 (CO) Canbonmonoxide, cszoSaSo3 caxphadcofiqe (NO) Oxides of Nitrogen coged caypacor8EvlonaSe 1.2.4.5. Air Injection System aopSgaSincopS: uBoSa§arag) (HC) Hydrocarbons of caypqjacron§ gas: [eSula—Se BoScercdc§ seosrfenaev:o}gaS: (GSvlaop5u 1.3, Exhaust System BoScorosocndmaerp wiqSodoys Exhaust Stroke oroq cpoSagoiakoSeass B:Srogooge8 cgoop}oorqpaqpaScaos8 opoScux{é: [@Sula0p$u Exhaust System 036 Exhaust Manifold sBoScex8#8:1 Bodcoohobi Catalyst Converten cog dIQvlaog5e Figure (1-10) A typical exhaust system on a late-model car 1.4.Electricl and Electronic Systems canta’ cnaieneScokmelf: cySobakiqposoorsya: epigaQvloop§n sa8meseoSqoicn 2009 (1) Ignition System, (2) Starting System, (3) Charging System, (4) Lighting System 4 so(gor 80025003 §ulooe5u 1.4.1, Ignition System Hun Myint Htay (MLE, Mechanical) Page 10 of 74‘Automotive Technology cr08cSniqiog’ ccogsSmeqomegars vSeordes Bs86ffidloo ovcSucoscray S:005$ Goloog5u Bo0Ss08qSyoe0r9 ovcSvcoSecGolu Ignition System og 2945008) Ignition Coll, Spark Plug cog6lGola095u Ignition Coil a> opeScoconeaa0§c8 Gaost 20000 aD64 D00000me8 afeadscuxslo095 1 wigs gjerasucdjecTyora5 Gi SiooSqgeod§fys ovoSvcvsen SrooScvi{eEio8 Ignition System of osTelaoeSi 1.4.1.1. Crankshaft Position Sensor Sensor sSareSyo sageooicganSapiedTadqiSeozy2 orSs08eonx: mdecoegeoge§ oBé:0r00} BRerseco:e0g08 osTlaog5e Crankshaft Position Sensor o} a>iéiq5og6 crdanélB: amféiqSooubSofeqpaScalBied ofEtorsa}s0§ soaceo: [gbclarp5u qcoaca0 soorEizoqjoS sacooScozo8 Electronic Engine Control Module( ECM) 2803 Gco:lapSu ECM a ao§aorcogs8 anafconesoa soorbisaqoScncodSengecTyongSQ speSsniffya Spark Plug iooScorqucdsforc§ cfs awisloresn miqsorsed: cmogafny Sevxslo0951 wiqalgsocToxo> socoéslecoiagisle Ignition Coil coo ogoSco2c009 G8 Distributor aocq Figure (1-11) An Ignition module and coil assembly for four cylinders: 1.4.2. Starting and Charging System (eSclor081 cBoBoroardapic$isakySo8 conS jaya feqors copgigodls Jrelesgrcd]n cno:eargecorepafofadessomsl acSoofoo aySodo8 Solennoid or relay 83 Sooxdlao_Su qoSccors0p§ sr0Sookao aySodd Starter Motor a803 ogpa5 cx008 pdcor20[a8 oorosorrevSoro.oqono mEqemr§Erg5as copSool§: oob§i@er (@dclor95u ‘ignition swt 7= SSPinion gear om Fiawe (12) A typical starting system FecBoBo}ancgo8 ancBcoffpoclclen ca aneScnfosoxc8 Ignition System soogcS sooSofiqyoafeosp cnuSeofinai§ olava5u oelajn$ cnoScnfnniaySiag AC Generator on5s06q Slaogsu qEgoqor20} soéqiSeo coréigEcorslorpSu Hun Myint Htay (MLE, Mechanical) Page 11 of 74‘Automotive Technology Figure (1-13) The major components of a late-model AC generator 1.4.3. Electronic Engine Controls (ECM) exaSEropoSeySojenoiecgrnihioR Electronic Engine Contrls (ECM) j “CHECK ENGINE” " SERVICE ENGINE SOON” eseogecl sodfeorlaog$s 08D Sannery $e e005 [afloo Diagnostic Trouble Code sBclan snuSzfffiyo ooofSeqancSeBom BRE 05s Figure (1-15) Atypical automotive computer 1.4.5, Heating and Air-Conditioning Systems 1.4.5.1. Heating Systems comic mysoropeyaGoclargss BfeoGeSy> vajiole 1.4.5.2, Air-Conditioning Systems crricdooriegsiofioon Rhergteyo spronfdle are sr oajtqt Gon sale, Semaine a oof somes gore fe aa cose encops: — Bdecgyoa}rcpadannieg}rjzm0707 lavas plogss qibinginas mye} gq GAR seals maGdoyulngs RB cah es apodeoon’ agoigSclangss ae BoSGrcogSeger> Closed loop. ee: atl wegbcySclaogss Beni mfirg Samfim Gerais 48BEiGolargss Evaporator Condenser Figure (1-16) A simple look at an air conditioning system. The blue signifies low pressure and the red is high pressure Hun Myint Htay (MLE, Mechanical) Page 13 of 74‘Automotive Technology hasan. ido singe tit Giclangse Seodnedttiges> aBeoofeq, wr, Md oie ee orl ea Betemagnnttanl ie er@Sesnrascon dlaoass 1452.2 aiededtae shee Gita exctée i ended igs aysiqsbenemanee cmeahictroys obeder joooS. Jeaoreaore0018 6 075 000% EY 8 Fogos. Hag afedend tntmend sattageesent mesa ol Refrigerant of Sancg wydij o§f Goycorrlaop5s Refrigerant cops: wegwdemegmey maps Bibs agaQs EvaporatorodScR soobagetclanase 1.4.5.2.3. Receiver/ Dryer egheouScorecgoSeorears Refrigerant eqpargs Receiver / Dryer deooseocifjoSzn§eol salt faster | One ced Daksa fells eeheafngl qldioidegs cemene eq eqog qpio gbugeoarel ange 1.4.52.4 Accumulator Accumulator aogS Receiver / Dryer apa wooyS opie eyocdo}recToxmreagy> order mopifgolooa$e 14525. erate Caden ae ote Tbe elo of = Evaporator 08 Refrigerant rqSqolooese ays memnbiej: mewicore set abe Glande 1.4,5.2.6 Sonfeapoas cooSenchf secon pon as es Dashboard meinen 1005 16299 S:094 205 pois wae es sigan ehoas eink Sos Aanebe geevoecosoel Beofeqeood (elagrieoG$ conse ecotemrecy afolooase 1A522, Retwaee nes eo tet 4 ; winged tag Se Soest ted mogaScfés Compressor Discharge Line [88s Receiver / Dryer ao8fgdclao—be oyrodojorsoh ex ~ | . bo ea ao at deere a GSA aS mee a8 maad Bich Hun Myint Htay (MLE, Mechanical) Page 14 of 74‘Automotive Technology CHAPTER (2) HAND TOOLS AND SHOP EQUIPMENT‘Automotive Technology 2.1, MEASURING SYSTEMS oBé:ox0qa5:09 83 oRétorogpS:gSqjeGulaop5u Imperial Unit} Metric Unit gSqj(gScloo Description Imperial Unit (soéo§qoSo95) Metric Unit (o5c09 5056) Length (socqpx) _| Inches, Feet, Yard (cooSei coi ofS) _ | Milimeter, Centimeter, Meter (8029) Weight (socoo§§) | Ounce, Pound, (axo801 col) Grams, Kilogram (091 Befoq5) neochclogy 4Sihuog’ vScoqSoyih GixoohryatoosAlorgSt gEiogSorg8_ sovScSBo5 Sosvadfeya$ snea2s805004 8zepec8 cyuSogga ogodgévlorp5u goon 1 0.09 Sor 0.9 oBcBonS 024348 Ghz08 dGhrorordehuelGosiesZEclora5e cooqpissdRrsaoxo0g§ 2 8000 = 9.97 conde (0008 19 80x = 9 X99.97 = ogb.ng coaSe) 2 BE = 2.Gog9 cBc8or (povon 19 BE = 9 X2.Gogg = e.0g8q o8c88020) apecor§ fanoBssoox0098 onBa$nq’=|.j056 colE(goes" w goBcSoq = 9 Xx J.jog =00.0 9 ovlé) [rem fe oom tw sane ‘aay 1% me | me ow to ast 102 0278N 1N 359702 Tio > 445N IN > 0225 'b TUF] HSXTIT] +32 TIT] SOx (TIF 1-32) Toxin 706mm 1 mivm or4i6ern ‘ibin 0113Nm Nm 8849 \bin Tb yy 1356Nm 1Nn yp (O7376 ibs 1 kgm 9807 1Nn (0102 kgm Tgfcm 0098mNm TmNm 10.204 af-cm_ 1 moiss 7.05 x 10-6 kgrr® Vign? 141643 moiss Voxin? 183 x 10-5 kgm? Tkge? 546x104 ozin? Torin? Rm = 706x10-3kgm” Vig? » 14160zins Vibin? 293 x 10-4 kgm? Vkgm? 418 Ibrin 1ibins? O13 kgm? 1 kgm? 885 bins? Yardstick Meter stick Fig (2.1) A meter stick has 1,000 increments known as milimeters and is slightly longer than a yardstick Hun Myint Htay (ME, Mechanica) Page 16 of 74‘Automotive Technology 2.1.1. FASTENERS Fastener aopSgo ooSgopoSicoga? ondgghor8go}qgamogeS $8é:a90q20705 000% aopSu qoicovoaxai{g2 2oqo5q8 (Threaded Fastener) yo: (gdulavpSe Ca} i + G50) ) —_—))) ‘Stud Capscrew —— Qj Gm Round head head a <= Om Quam = a cat Pan head Machine screws steromaes Qy—ufip yp xaje Sam cariego tat Flat ‘food head H— Torx” head bolt Fig (2.2) Common automotive threaded fasteners We Fig (2.3) Various sizes of pipe fittings used with lines and hoses Hun Myint Htay (MLE, Mechanical) Page 17 of 74‘Automotive Technology Bolt diameter 7 ZT = \ wrench [saan —e| Fig (2.4) Basic terminology for bolt identification 2.1.2. Bolts RoScRarpSyo erdecdagé ogodeslé§Gr Qoove aacalancalyaio8 soconSclgog® callgcontslaapS0 (2) Bolt Diameter (opoSajsoajéns 2poSemgoScoeari odeaprdio}e (2) Shank (poSeqpoiiog’ soqdoqSeavomBé (3) Bolt Length (ogoScqE:soqg5- Bolt Head o3 copfoc$Es!) (4) Head wrench size (Bolt Head cogeSeooatanpS soa}:Gva$ googoScoonx{g5a095) (5) Thread pitch (atofgsSendot crbeonocg frente Thread per inch) o8c0q5045 <5 BeB8Sor0fge coT[gclavaSe ‘Common English (US. Customary) Head Sizes Table (2.1) Standard Bolt Head Sizes Hun Myint Htay (ME, Mechanica) Page 18 of 74‘Automotive Technology Grade2GradeS Grade? Grade 8 ‘Customary (inch) bois—identilication marks correspond tw bolt sength—increasing numbers represent increasing strength. SSHVVBo Metric bots—identifcation class numbers correspond ‘bok strength—increasing numbers represent increasing Stengih Fig (2.5) Bolt grade markings i ofo58 socguSoongeBeo§Eq§ opoieclésog’ guloScl§larpSu 3}84vloSyo copSigSGyQulo0p5u mSv8qeSog5en Grade 2, 5, 7, 8[45 cvllelG: eScoqSogiqn Identification Class number 4.6, 4.8, 5.8, 8.8, 9.8, 10.9 exng5(gf cul[e{Golarp$u pow 110.9 22oSeqpErav_$ Tensile Strength 1,000 MPa (145,000 psi, Yield Strength 900 MPa (90% of 1,000) {sla>g51 10.9 opoSeqrEs enbaqaSiongs méofgeSagien Grade 8} Strength 7e8slangSs 409 (Nut) sBaopSy> opoSaqnErgogagi: soogeiaSfjolonase go5yzcogs: opo53s00g ofeSep aplepSu socne5s) afjoSlgforoanSGohopegeny> apodopabos[eforra}sevd 4050} ofo58G0r o> pbaqedgoSmcpgoReopsoreS oboS¥Gehqebonh Greco longdn oydoonbedl had oa coed: ofoo(g)aseqoloasy Table (2-1) Standard Nut Strength Markings roc pad stonk Tyee ed Fig (2.6) Bolt fillet detail Hun Myint Hiay (ME, Mechanical) Page 19 of 74‘Automotive Technology Semel 2.1.3. Tightening Bolts 2o5{5é: 05405008508 ogSorrr (GSecoaiq€ an.y soahiwoSulogsn 048or09 [BScomx§ cfoloopSu caoaSe§ Baodorn.008 8G: [BSconislen opoSgohyoS8roncSclangSu [6§GelgeSoimslys oqasqs aaqilaifrorciclarpSs cavapfasSocmaigs madqaG: goi(eoSqors sodScoodlanpsu Unsvetcned bot Threads are straight on line Stretched bott Threads are not straight on line Fig (2.7) A comparison of a stretched and an unstretched bolt. 2.1.4. Washers clqp Agpeadeavonsceg souosGB: GolaogSu Flat washer 205 poSgoHlesScRoSdlon opoSgoSecT soaSoqpaSge8yison§ aj:olaop5n Soft flat washer, compression washer (Spring washer) ool goo> c0r9 2205405 8: ao[BScqcoq8 af:clargSu Copperwasher eH:Eclqoo} swEqe znacvaedeR BErvforbo}eqapiiego afuolaraSe apobgoSnGoi(a)enci(eBreass agepdieoBiryo Fully Hardened Flat Washer cB af:qploop8u Lock washer o8 azoSgo8cogcR oufifclqon3a%. socyScySol sop5u 2.1.5. Other Common Fasteners 2.1.5.1. Nuts 4oSqhego8 cxoacdendgo [Bp§lE: mageSorag 988Ed}oop8u ou 2 2 o# Hexagonal nuts ot square nut Sweets version oes © § +e dD Leck roe Frelocked postion stating ck unt setng ra crown rat ‘Wing rut Fig (2.8) Many different types of nuts are used on automobiles. Each type has a specific purpose. Hun Myint Htay (ME, Mechanica) Page 20 of 74‘Automotive Technology 2.1.5.2. Studs Stud sfoopSyo a2oSeqprsiog€ a2oScsléiovld gSvcSoajiog’ sonSqScoaivloogSu Fig (2.8A) Stud Bolt 2.1.5.3. Cap Screws _ CapSctew sforeSya apoSampSiodeh moySaySfElG: GaeoonkogaSeslresld mogéreiac coontevlaS§ilanpSn salgoSan(e3508 LKey o8 soabifgsloopSe Fig (2.88) Cap Screw Fig (2.8C) Hex Key L Wrench 2.1.5.4, Setscrews Setscrew sBarpSya onoSeqpsiege aqo5cslEio0d soogktelGae5 coontedlaSgulaopSe solgod a2fe3So} L Key oR soog:{aisloop5u 2.1.5.5. Machine Screws Fig (2.80) Machine Serew Hun Myint Htay (MLE, Mechanical) Page 21 of 74‘Automotive Technology 2.1.5.6. Self-Tapping Screws eed Fig (2.8€) Self-Tapping Screw 2.1.6. Thread Lubricants and Sealants Page 22 of 74 Fig (2-9) A container of threadlocker. Hun Myint Htay (M.E,, Mechanica)‘Automotive Technology 2.1.7. Thread Pitch Gauge Thread Pitch Gaugec8 aoqaSqaaj o8o3 GEGiooga0§§ y§g§o¥Etor.¥Eclaa—Su Fig (2-9) A Thread Pitch Gauge 2.1.8. Taps and Dies t Die BarpSya wlgeqSqborsgqay> seo}i{G Tap BarpSyo soogiadqSodegqoys s0954 angie Fig 2-10) A tap and die set Hun Myint Hay (MLE, Mechanical) Page 23 of 74‘Automotive Technology _ Flute chips Fig (2-11) Metal chips are gathered into the flutes 2.1.9. Threaded Inserts Threaded insert BavgSyo sooydin Sah GAGES oafEodeqqrecgys Insert Thread Rod cB ondev: qolaoase Install insert Drill hole to ‘on mandrel proper size =. Insert Ou tang Install insert Tap hole to into threaded proper size hole Fig (2-12) Using a threaded insert to repair damaged threads. Hun Myint Htay (ME, Mechanical) Page 24 of 74‘Automotive Technology 2.1.10. Spark Plug Thread Repair Spark Plug [gioSo}aec] yo coqaSasfeygiaqa:oxc5ulaapSu G§lGsodees] Threaded Insert gpS:08 coo} fslaaSu Shop Talk P 1-1. Using a thread pitch gauge, determine the thread size of the fastener that should fit into the damages internal threads. qoSBrogorcar> 2009) 184 soqnSod08 coqaSen§ BésoradlogSu P 1.2, Select the correct size and type of tap for the threads and bore to be repaired, cnafr{op} 0008 tapo8 g§orfo}aogeSsoect ogeqslogSn { P13. Install the tap into a tap wrench. ' ono8 tap o8 tap wrench go orbs08clu | P14, Start the tap squarely in the threaded hole using a machinist {square asa guide | ond tap oh coorge§aysoas eoiod4Soj: oojusc: (oyEoge5) mahi{ofB: oor8epaSagérqulease =] Hun Myint Htay (MLE, Mechanical) Page 25 of 74‘Automotive Technology tap. Hl onc8 (th ha cdegepesprBesn$ qoScorSoscopSojsooREs cpa | agktclu soor05g] [@3Scoodlon eGokGSepafopoSors af gbroageyd | BELGE creSoajjzerané maegedsédlanaSe ' P 1.6. Drive the tap back out the hole by turning it counterclosewse. co05 (taph} goRooaBoscopSo3mo8siencs dgadifes cpaSaqodole 1.7. Clean the metal chips left by the tap out of the hole. on05 (taphie§cqe5[&: ccogoian aSoccorqpr} ooSego5odcln P 1.8. Inspect the threads left by the tap to be sure they are acceptable cn05 (taphiegagaScosteasomavlaSmn soogéiqSe8 edccorsln P 19, Test the threads by threading the correct fastener into the a ogooiad: sanScdc opundmahi{4 spoSeqscog§[Bs oppor threaded hole. ' odioni(aipfols ' Hun Myint Htay (ME, Mechanical) Page 26 of 74‘Automotive Technology Fig (2-12A) Spark plug thread tap Spark plug oordosaaslyo coafesageSaguSegeg oobefequln y§orfo} evoSvarsesrzae8 Goren Torque Wrench a{eSScorqsloase 4,csantaen 2 Matin 3. Fig (2-128) Torqur Wrench 2.2.MEASURING TOOLS 9 Digital s8qSooeS, sogacTaoacerp ogabagocpec8s socguSonne o§f:onacon8éulaxpSe i Fig (2-13) Graduations on a typical machinist’s rule Hun Myint Htay (MLE, Mechanical) Page 27 of 74‘Automotive Technology a ‘ter[-006 or Ose O7ae va Or ra aL OSst Toa eer [Ore eat wee [ ose ‘Br ca wen [ose z Tea 0sr eae ss ans ms 5 z sero war best a ea 0 co aioe es sno a Tine [oe 7 Tato [3 aeons yea 03th oe Dore: ce eet ost cs ee [rst oe Tato Fae raat Tae. sie 0 ee [0 ae oats Ese Tee [oe eer [0a a iva-[ose aa [Bae ora ae 0 geo Tor er [oa er [ae a Tne 0st ore | 05 ne iw [0 si 0a Fig (2-13A) Inch to mm Convension Chart Fig (2-13B) Digital Vernier Cliper 2.2.1. Vernier Caliper (v2$u2200050l) erfaromeoddlerdgargs sacgét: w[GEi aaqoSoBo§ oftora§Evla—Su Imperial Unit Metric Unit gSGzoo$: cIgclaoaSu eofussecanragé eoghEcarooccst} ogfEcsvo0ccn: (Stationary Scale and Movable Scale) §ulaoa5u Stationary je nse jaws ry? eamwith \ 3 main scale ’ ~ Metric scale Outside ‘Thumb t jaws: adjuster scale f Adjustable ow Inch Sle hay Fig (2-14) A vernier cal Hun Myint Htay (MLE, Mechanical) Page 28 of 74‘Automotive Technology Peoria: P 2.1, Clean the object you are measuring. Wipe it off to make sure there's no grease on it, and that there’s nothing in the way that will Interfere with an accurate measurement. REroroea§ ogaS:o} af gE:aqzeydcln 2.2.1.1. Measuring External Diamater (sofgc8 o88:0x{58s) P 2.2. Slide open the jaw. Place the large, sliding jaw around the outside of the object you are measuring. Lightly but firmly close the jaws around the object. Tighten the locking screw if there one. oBEtoroug§ ogaSio8 Fixed Jaw oociys anSoonx§ Sliding Jaw oF oghiGe mdcBo5cln P 2.3. Determine your whole number. The main scale on a Vernier caliper tells you the whole number plus the first decimal. To determine the whole number, concentrate on the inch divisions on the main scale. Find the 0 on the Vernier scale and compare it to its placement on the main (fixed) scale. For instance, if the 0 on the Vernier scale didn’t go past any full inch divisions (so it lies between Oand 1 on the main scale), your whole number is 0 inches. Hun Myint Htay (ME, Mechanica) Page 29 of 74‘Automotive Technology emeooidlgogé snevTuaiarpS coniua8 oB:o208E{Bi exxooSuaSarpS So88or008 oBé:or2d 20951 0.009 cooiee8 ogpSrahiobereroRElG: 0.0 Sc8SeromBoREroro§Evlon—5u Fixed Jaw y> etoooiea09 ‘conic main scale or bar scale cBcal[8: Sliding law go oqscostca00 oannte8 Vernier Scale cBesTol sop5u eoferoecmniccTen 008 (Bafole 0 8 (tenths of an inch) P 2.4. Determine the first decimal place. Use the tenth-of-an-inch divisions on the main scale to determine this number. Comparing the 0 on the Vernier scale to the main scale, look at how many full tenth-of-an-inch divisions the Vernier scale 0 has gone passed since the last inch division on the main scale. ‘The 0 on the Vernier scale hasn't gone past any full inch divisions, but it has passed 8 tenth-of-an- inch divisions (so it lies between 8 and 9 tenths) after the O-inch mark, so your number so far is 0.8 inches. cncondlgjogé 020958 svamrpSyafGcals cnSconiemo[apfaBocenjSaa{e$ o.ncoo8en8 sok a8ZEvlana5u Hun Myint Htay (M.E,, Mechanica) Page 30 of 74‘Automotive Technology P 2.5. Figure out the rough estimate of your second decimal place. Compare the 0 on the Vernier scale with the main scale again, and this time count how many hundredth-of-an-inch divisions the 0 has passed since the last full tenth-of-an-inch division. Then, multiply that by what each division represents (such as 0.025, 0.02, of 0.05 inches). soci OaoeS 89 S[ainigE GB: 48BoSeraoofaf onb8oSonf fs aopSt mg08 o.0 + 0.09 = 0.009 coodoaful[Bu 8 8 How Determine your second decimal and third decimal places. Now you are going to use the Vernier scale to determine a more precise measurement for the second and third decimal places. Compare the full Vernier scale (not just the 0) with the main scale, and find the first place where a line on the Vernier scale matches perfectly with a line on the main scale. Once you've found it, use the lines to count where on the Vernier scale the match occurs. + For instance, lines 1 to 9 represent 0,001 to 0.009, ines 10 to 19 represent 0.010 to 0.019, etc. © So, if your lines match at line 12 on the Vernier caliper, you will add 0.012 to your rough. measurement sooif: eafarsaecmsccTon smgo8ecg Bfreccntesloo saycSacgapaoqo}eqqpc§ pil Big z0u54Bo503 cafeja§uls srcoaScljaog 2 Bois apularpSs or88oSen§§e 0.000 [eSlgorSulen 0.09 cocboqplanp5u sontahicslEifajafolon 0.0 + 0109 + 0.00 = 0.08 coodoagolaopSe 04.8405 4.012=0862 inch 0862 inch Hun Myint Hiay (ME, Mechanica) Page 31 of 74‘Automotive Technology Example: 0.100" Main scale 0.005" Vernier 0.105" Overall 5 10 0.105" Reading Example: 7-000} Main scale 0.012" Vernier 4287" Overall 1@3 45 6 5 10 =| corr Readit A oe lr ng Fig (2-16) To get a final measurement, line up the vernier scale line that is exactly aligned with any line on the main scale 2.2.2. Dial Caliper (3EquScoc080!) Fig (2-17) A dial vernier caliper Hun Myint Hay (MLE, Mechanical) Page 32 of 74‘Automotive Technology 2.2.3, Outside Micrometer (cs2005s805§050§8000) ‘Anvil Locknut Sleeve Thimble Anvil Frame Rod point Insert rod here Shorthandle Body Fig (2-18) Major components of (A) an outside and (B) an inside micrometer Fig (2-19) Digital micrometer eliminates the need to do math, (SqjSor0Sa}zaScoxpoqaSeqpec§sor96!) © osm ° Fig (2-20) Reading a metric micrometer: (A) 10mm plus (B) 0.5mm plus (C) 0.01mm = 10.51mm, Hun Myint Htay (MLE, Mechanical) Page 33 of 74‘Automotive Technology Dutside Micromete 3-1 Micrometer can be used to measure the | meter of many different objects. By measuring | he diameter of a valve stem in two objects, the | ‘wear of the stem can be determined. | Boba§Scrnean$:{4(8: eoi00r8 anuScconSostayo + avedoRErcloude eovcr8sreunds} soa08cR0R cndf§s [garqaicSa8 lon oniagoro}on§ sqplo051 P 3-2 Because the diameter of a valve stem is less | han 1 inch, a O-to-L-inch outside micrometer Is | used. orton orbeocivoodScuSeasdfaje§ 0-9 ! coke SoSo§80r0 wafrlglopSe oy conSoQ(S: sao¥dimornaSaiias aBoSeqr 0.09 } Goodqelanasn P3-4o.goo cocde Hun Myint Htay (ME, Mechanica) Page 34 of 74‘Automotive Technology P350.999 coode P 3-6 o0r000808 Anvil Spindle (oxcop$ln P 3:7 oBo8ujorjsoS$ing Ratchet o8 (GaS:(GpSrepp§oln P 3-8 egayprqo§con§ Lock LevercR saa}:{Qjs11 Hun Myint Htay (MLE, Mechanical) Page 35 of 74‘Automotive Technology P 3-9 eniocrésaqié: 0.900) conde [gSuloopSu P 3:10 oxto0r8coooda0qiés If you are a machinist, manufacturing, or engine professional, exact measurements are an everyday must. When it comes to measuring cylindrical or spherical objects, an outside micrometer would be the best tool to use. A well calibrated micrometer can be difficult to use, but with patience and practice, this tool can be a part of your skill set. anéave oni [gsaoqpericarsad opfopadoa§cgdagorscurs05: maEq’} sooocSogrod:enqos: GeporBeuracSGSyaE apoSoqo¥E: BoBoyryeRErorayeyecg ofSveyoySegayasls socoEsl og! onbaprjeogoREi8 [Sjconpqs caanSahaSfaSaQSorux soomoéiahrogaSionde (gSclav—Se crnsét certighebnadfefsSeySernsa, obo§Sernnigino engl eobdartiocBdey lochs Seog afeqBrafeg’ — cgeSeqeorsleShouSs Scfog Eyeogcd0e sBoSaoBEron8qcldu Hun Myint Htay (MLE, Mechanical) Page 36 of 74‘Automotive Technology SoSorr0r8992 lodojmboinnGEscogi qoupScaccTmecTa0g [eSdlao—5u Gyod [edad BREclav—Su 068 Sleeve avTyo goSsooicoxtesroeecic§ BfrocnteGesT|G: Thimble coTy> goSoo.: cortcav.0sqi08 eafercecante§ coTuloopSu GeB0§8cr0008908 age00095 sacavSeisig crorgronpSimnjagao(ee cpoon8vl} ooBsimor.009§ (2) ScBEer0 QolorpSu eofareccic§ saBoSavlé: go BoScoaslarp51 Thimble o8 orbvcifgpsennc8 epofefoidlor o.g8 Siero equlovgSe eafusaoeantor88obon4 hiarg§ ong oB onl go 4 eaiefoSlen o.oo 8cB8or2 laogSn aB800§ Gico sogpSsabi08E:o08809 ovnanfgeclaopSu Fig (2-21) ogi (Goootaoa ool ocileip§gg a0Bob—gSBoSfearcchao$ q8c88or0} eofurceeen: (49) BoSRaofg§ Jo x0.09 = o.yo Ron9 avlEtcBaSag 7 + 0.J0 = 7.40 8c88000 [gScloopSu Hun Myint Htay (MLE, Mechanical) Page 37 of 74‘Automotive Technology 2.2.4. Inside Micrometer ewishos§oia§Sorrafors agqoupiaacRés caegdrooSo} ofr} écTo05u sonm carbraton Gauge Fig (2-22) An Inside Micrometer wEROSBoSoRSor208 carrcScGoSBoSsQSorovcSanohq8 afiofqul Gu socoofulogé go 88 Borome4 Goo BcBEors2008 oBEeREla>pSu Extension Tubes cogo caaSarc} sooSafrqilangs et & anbshoSgaSoQ8orss00hs{4) 2.2.4. Depth Micrometer 05 8050§Sooocmc0g8: 3ygoupSan088: aogahn? oBSor08 [al 205 Fig (2-23) A Depth Micrometer Hun Myint Hay (MLE, Mechanica) Page 38 of 74‘Automotive Technology Shop Talk (oSeqpsacoge[03)) cee ecto Be eee er Perey) pire Bee er ee enc 25 {4514 2.2.5. Telescoping Gauge Plungers Jo. Handle }<— Lock screw Fig (2-24) Parts of a telescoping gauge Telescoping gauge of snap gauge cfoopS: asl[EGuloop$u soguSsconienGjedopoSapS [Gol aoaSe 2.2.6. Small Hole Gauge Hun Myint Htay (MLE, Mechanical) Page 39 of 74‘Automotive Technology Hote gauge method tomeasire vale guide wear Fig (2-25) Insert the ball gauge into the bore to be measured. Then expand it, lock it, and remove it. Now measure it with an outside micrometer. small Hole Gauge «8 ball gauge ofcogS: esl[ejulovgSx soopfeavseuSea09 soogStosleS Bore soge8 oBE:orodla0—§1 2.2.7. Feeler Gauge Feeler Gauge sox avqaigns 3 cpScons coyeacBaenfulanaSn cacy 0.00) cocSernes 0.000 conbeme oogeScba>cafi cog opSsngSeoacbcomiangSe Boone B_ogortg$ss oghgcScioqpoara$ Clearance of ofS:orsmaheqepyoing® wai (afa}slongSe [goroaycqdc§scogqacop§: soa}rlofo3clao—S Fig (2-26) Typical feeler gauge set Hun Myint Htay (MLE, Mechanical) Page 40 of 74‘Automotive Technology 2.2.8. Straightedge Straightedge a8or pSrodgoEon§iG: o0FlgcooqpgoSoatsacqaRicoxi0} eatonfroded GEclaraSu oofoSaocick Soorengarey yoSgael aSueSedecoropns) ma}:fslooasn Fig (2-27) Using a feeler gauge and precision straightedge to check for warpage 2.2.9. Dial Indicator BEquSaaé8emorns§or c.coscoaiecgayysd cBEorfEaard opSoonsclaraSy 888 08 Qulaai s20}:{Gjea22¢qq>e03oe079 valve Lift, journal concentricity, flywheel 00} egepeogy> ofelongin clgprocSgcaScfseogencorp evSon} ofsnoaguscp offic8 scBSrobgso}cge— Fig (2-28) A dial indicator with a highly adaptive holding fixture Htun Myint Hay (ME, Mechanica) Page 41 of 74‘Automotive Technology Fig (2-29) This dial indicator setup will measure the amount this axle can move in and out 2.3, HAND TOOLS cnctegSc§icySc}a0d) cBaoSo}08E toosge8Quv00091 cBaoSo}aonSa}:oBQoove0q: anoi08 8:05 J cnnisdqiéa} ofaodo0e8 GforteorgoBGar.eog: ald gaRorrg20 soagSayiqars somdeGuleB} pS 2.3.1, Wrenches (205 qo508 so[ajoSsooneSeySue§ gat) sogecgegiopegdifgosp ocSodsoaga dyad [mp}ooqicloopSe Hun Myint Htay (MLE, Mechanical) Page 42 of 74‘Automotive Technology Fig (2-30) A Technians needs many different sets of wrenches. Hun Myint Htay (ME, Mechanica) Page 43 of 74‘Automotive Technology Fig (2-31) An open-end wrench grips only two sides of a fastener Fig (2-32) Sixpoint and twelve-point box-end wrenches are available 2.3.2. Adjustable-End Wrench gaecBesTo> Adjustable-End Wrench of sacguScrcgera}REeud sacguSoragayoSegoSayoe crdfcorrdrad mofiQiq’ ogor§e5 mohigiqeleSopsu It Fig (2-32A) Adjustable-End Wrench Hun Myint Htay (MLE, Mechanical) Page 44 of 74‘Automotive Technology At Fig (2-33) Top- A handy tool containing many different Allen wrenches. Bottom ~ Tee-handle Allen wrenches designed for better gripping and easier torque application. 2.3.3. Sockets and Rachets Top view 12-inch ‘square drive hole 9/16 inch across flats Fig (2-35) An assortment of rachets Hun Myint Htay (MLE, Mechanica) Page 45 of 74‘Automotive Technology Fig (2-36) A chromed deep-well socket and an impact socket. Fig (2-37) A typical set of socket drivers Fig (2-38) A flexible adapter is used when direct access to the bolt is not possible I Fig (2-38A) Socket adapters Hun Myint Hiay (M.E,, Mechanica) Page 46 of 74‘Automotive Technology 2.3.4, Torque Wrenches Torque Wrench oxo =205§ 40508 BoBoyrqleSodogqny> soah:GslorpSu Fig (2-39) The common types of troque wrenches Torque oof §zcogrmcor (ft-lb) &oupc5 (N-m)§ osT[GcloopSu "GRADE 5 COURSE THREAD "GRADE SFINE THREAD {|__| inte [_nim_{ intbe |)! _| intbs |__| insbs | {|__| ibs [im | tabs |/| | ttabs | nm | abs | | sete | 2a | a5 | io ||| aos | ae | 43 | ar | Fig (2-39A) Bolt and nut torque value chart for sample only. Hun Myint Htay (ME, Mechanical) Page 47 of 74‘Automotive Technology eee er Torque Wrench 299§:(015 ® Torque Wrench or8qgo (ft-lb) SBeuz05 (N-m) 3 ee [glao_5u DP saahefeGeovo corpanrg§:c8 saq’Gfooorcle % GFeoo:ear (N-m) ooapagordlen (BScvry2007OS9 qSe|S—GaSTE: 0029024$:0} empo5|GaGor. aodeyStaBBEclao—5e 2.3.5. Screwdrivers emyposopafafesTo} Screwdrivers. eavreuSedongecoteng [ejoSo}aos) o25:{ayslona5x Fig (2-40) The various screwdriver tips that are available. Blade shank Honde Blade tp Fig (2-41) The blade tip screwdriver is used with slotted head fasteners Screw Magnified head tp Fig (2-42) The tip of a Phillips screwdriver has four prongs that provide a good grip in the fastener. Hun Myint Htay (MLE, Mechanical) Page 48 of 74‘Automotive Technology 2.3.6. Impact Screwdriver 1 < Fig (2-43) (A) An impact screwdriver set. (B) An impact screwdriver automatically tries to rotate the screw when itis struck with a hammer. 2.3.7. Pliers Fig (2-44) Various types of pliers Fig (2-45) Snapring and retaining ring pliers Hun Myint Htay (ME, Mechanica) Page 49 of 74‘Automotive Technology 2.3.8, Hammers ~y mia’ al Fig (2-46) Various steel-faced hammers. Fig (2-47) Soft-faced hammers 2.3.9. Chisels and Punches 7 —— Center punch (showing included angle) Starting punch Pin punch’ TL Aligning punch ——— Straight shank brass punch Fig (2-48) Punches are defined by their shape and the diameter of the point. Hun Myint Htay (MLE, Mechanical) Page 50 of 74‘Automotive Technology 2.3.10. Removers crdloriyn od§goilajoio}aosl aoSedlé:afjecfoonSeoaSie0n0811 coonteeg yaSBicBoaoSenpS:annak: aguSogoSegen{gicied [gSord5olaoe5u cage soa}ifayqslarp5u 4e5eGoeScoon8on95 [gSc30001 Remover eo 2.3.10.1 Stud Remover Fig (2-49) Stud installation / remove tool || Fig (2-50) Srew extractors — Broken bolt with Serwenracir— | 5 heated the middle Fig (2-51) Using a screw extractor to remove a broken bolt. of:2go:0} apoSeqpEre} oxcBoSooqoSor. 9 facicae Hun Myint Htay (MLE, Mechanical) Page 51 of 74‘Automotive Technology 2.3.11, Hacksaws ($icg) ord] ofaadopcoqpecg (odGa00305 FErogo} saa}ifGloopSu (A) ~— Cuts this way |«——1"—_| |<—18 Teeth—>| |+~32 Teeth—+| Sheet Sheet metal metal Bad Good (B) (C) Fig (2-2) (A) The teeth on the blade in a hacksaw should face forward. (B) A coarse blade should not be used with sheet metal (C) A fine blade will work well with sheet metal. 2.3.12. Files (obo3:) vc82050} soegiavetacg eoSeya5§n0go3 obo Bt08 aficloreSu Handle \ \ Heel Face Edge Tip |-——Length_——+| t Tang O@m—A Round Half Flat Three- round square a or triangular 8 Fig (2-53) (A) Files come in a variety of shapes. Hun Myint Htay (MLE, Mechanical) Page 52 of 742.3.13, Gear and Bearing Pullers 5ee4 8a22003 goSeog yosoieasly> aroSuroqégors} [oSqclarsSu Fig (2-54) Using a slide hammer-type puller to remove a drive shaft. Fig (2-55) The jaws on this puller are r ‘eversible to allow for inside and outside pulls. 2.3.14. Trouble light Hun Myint Hiay (MLE, Mechanical) ‘Automotive Technology Page 53 of 74‘Automotive Technology 2.3.15. Creeper Fig (2-56) A creeper allows you to work comfortably and safety under a vehicle. 2.4, SHOP EQUIPMENT odeqpordqecnrélG: socySeyScorpeuSaGn’ coTGUloBEror0009§ BReracegi canbe BEogic0g! Borgo §cogoosuygacords$ ofaodclarpSe 2.4.1, Bench vises ogadscoge? Sody> ag6(G+ coajs{aysloogsu Hun Myint Htay (MLE, Mechanical) Page 54 of 74‘Automotive Technology 2.4.3. Presses (8005) Fig (2-57) A floor-mounted hydraulic press 2.4.4. ir-powered Grease Guns (so3:8cs1é:) ecossniapisada8 JonSaxgS cgGoqrSaoag ccomoicgloopS Hun Myint Htay (MLE, Mechanical) Page 55 of 74‘Automotive Technology 2.4.8, Oxyacetylene Torches (cxronSe8sxecSoc08{go5o08) Cylinder pressure gauge Working \ pressure Working \ gauge pressure gauge - 10) Cylinder _ Cutting pressure gauge ON Regulator torch control _— Acetylene eee + control Regulator ~~ Twin hose Acetylene Oxygen cylinder cylinder Fig (2-58) Oxyacetylene welding equipment shown with a cutting torch. 2.5. POWER TOOLS ao eerie eater! eect‘Automotive Technology 2.5.1. Impact Wrench (s2é:00398) wbiwaiagcR ccomni} wahiQGiqlaraSu caGoqaSsosgecoe§ aaérooSaso8 eco§a5§s005 2goSoo8s08corqslaogSi Fig (2-59) A typical air impact wrench 25.2. Air Ratchet Fig (2-60) An air ratchet. 2.5.3. Air Drill Fig (2-60A) An air drill tun Myint Hay (ME, Mechanica Page 57 of 74‘Automotive Technology 2.5.4. Blowgun Blowgun 3 coosmniy 09 qEiepSo}co0) soa}: fasloopSu Fig (2-61) Two types od air nozzles (blowgun) 2.5.5. Hydraulic Floor Jack Fig (2-62) Whatever you have raised a vehicle with a floor jack, the vehicle should be supported with jack stands. Fig (2-62A) Jack Stands Hun Myint Htay (MLE, Mechanical) paneer‘Automotive Technology 2.5.6. Lift Lift 88000 anain§ wor€(Gs costesanSEscogya woySopS8EF soahifGlSE: GSdlore5u Fig (2-63) An aboveground or surface mount Frame-contet lft. Fig (2-64) The typical setup for twin post lift Hun Myint Htay (ME, Mechanica) Page 59 of 74‘Automotive Technology Fig (2-65) Make sure the locking device or safety is fully engaged after the vehicle has been raised to the desired height. Hun Myint Htay (MLE, Mechanical) Page 60 of 74‘Automotive Technology 2.5.7. Portable Crane Fig (2-66) Portable crane (or) Engine crane 2.5.8. Engine Stands / Benches Fig (2-67) Engine Stands / Benches Hun Myint Htay (MLE, Mechanical) Page 61 of 74‘Automotive Technology CHAPTER (3) AUTOMOTIVE ENGINE DESIGNS ‘ . rae = VALVE mus metaxe SPARK em ae aa peer eee sear e ° age 62 of 74 Hun Myint Htay (ME, Mechanica)‘Automotive Technology CHAPTER (3) AUTOMOTIVE ENGINE DESIGNS AND DIAGNOSIS 3.1. Introduction to Engines Bacintqég’ cork asloBogecooa0E gs SroconkcleSopcoleee c{ehieogy> BocSco8 ySchav. ec ondjermieaotqrogScop$: s295,{o,eivlo098u Bacindg’} ccoibmiqimBor soqjaieagen moyozoé[gdoarsera5: ayoh’y soaydeyd}oe0r9 emeonnifeatg GolavaSe er0ibmriqiog’ —__o208s84Searo anno fjoSoro(Carburetorloney —_eapogcor(§s awiyicdcngiens od0028 [e§885ax0 myG§gGarmxqaicgGifog’ ovoSocos (Spark Plug) g &:ogo3, 208: BacoottedloSgons clolafieos! ao—50 SeSsrigSog’ mingaddh ecomrsfpcdrBorrmalls obonré B§885m0 mylhigs cooigpiogdifog’ gSeudy SacSa8rogSaayotecoreptcs [efrcoroolgesled SloScjoo0 olelgg, codloog5u Figure (3-1) Todays engines are comple, efclent machines SeyeocSeomeiqSoqganeS cog’ gSece: {B: opS8EgSsBorn08:c020la0 soco8slorecondSe wmbqsanccoooicGesTBs mE ySiBrapsoG GAdlargSe agfraS (Cast Iron) oSeup05 sooy8$ur8 (Aluminium) j orpScsoonSulavpSu socoéslonccoonSogé. onpgo eqpaSqp nesloyps edloSconrslaSs obeortegeypinyrtovomeySeySng. socoSsyps Tg Slaop8x socokslonccsonSog’ {GnronSys8é qpogeSiqains orSaok qulorg5x Figure (3-2) A cylinder block for an eight-cylinder engine (gScp:08:a0c08s1 ox6cos05 on809: Hiun Myint Hiay (ME, Mechanical) Page 63 of 74‘Automotive Technology socvdsler05af soovkslascorsdisacdTyo orso8qulargsx socoSslaocavanig§ socoésl woBoBoR Head Gasket [§ orbsn8qélarg5u soco8slusaiogé Combustion Chamber T&G: socv8sloin8 sof aoago5 Inlet Port, Exhaust Port qoiclgolavaSe socoéslusnSeavaS: 9g§108 (Cast Iron) 236u705 soog8$098 (Aluminium) § oxpScsoonSlaa—Se oS0oéBigs cocodsluraiferciegé SrocooScolaSoguloopSx obooréaa¢5 soamigrddg(Se movdslosog’ orkiordindiat copfenorqslanaSe. socodslacora}tslesvomEq\segé od eorecora5t4 B: cocgrqé:a0—$. Intake Stroke, Compression Stroke, Power Stroke, Exhaust Stroke cog seapp$oy [eSeqslargSy méicoSounSegé oSoortarg5 emoaSucia§ eges[G: Inlet Port gScq[B: ccogaSz0e0o negonf,socoEalanegSs oSeotlangse epfronSgSioorSeg’ oboorSareS mailonSf ogeeL net Port g§ Exhaust Port GoScg(S: ccogaScoonpaecgan$ 8a8Svlarp5n socokslenogerfea0> ccopeSrnceprcyoorg§ Sacre soyGifogs larg B8aagiEog® avoSocoSe BrocScor eGodcovou00) 8: cok asleo Soot oRogi E dlolagvlorp5x o8oorka9—8 mecToo8 08 (GforcSeovoms] B:econE:Gicase Sifrogoogo® Exhaust Port cog wEqSelgSucbng cpoSoBcl aoghn Jo¥lee oSoorsarp5 aaéqsodogé soeoodexo0S egoypreglorase Figure (3-3) A Cylinder head for a late-model inline four-cylinder engine (BegcooSecot apscsoonin€ a8 0008 slun084) 3.1.1. Engine Construction (soEqjSonpSacoaa5co3z§) cooiorormqSeogaras — gpStoasdlasonigdgloraesrodiconims — dlclepoSao:easc0c84 cr8§o0 crpScaoonhoonivlanpSi eqiegadsicorséisSaqiniaoq soapScoeagteontrygemomiqiécog B8SioqoS0x2 cpobapSconfajelaogSu cooSSencisasqecoze ccfulscons ag§:osapen: oyS$o05 ‘oa5n§ 8005: Fiber-reinforced plastic oo cqoSeySconfepolavaSu Figure (3-4) Atypical late-model engine (cooSScnc:s08qjSon5qul) Hun Myint Hay (MLE, Mechanica Page 64 of 74‘Automotive Technology 3.2. Engine Classification (mEySmaon§ravons8 gore swiciScoge? soBerc0xi@8 axoaohilaoBe: glGoxful 095 (A)Operational Cycle (aratsa8ySaorbqptayic8 4 Stroke a oxpSeavanSconsvlo0p8u onéjaoqStcuxa8e o}enicyScoga® 4 Stroke @§ orgSesoon5c02la9951) (8) Number of Cylinders (soco8 sleneqsoogeS) gctearccexx{a§ soco8sl gofer gofet gape! Bajs: ooh: 200g 9 joft o2095[G§ orgScsoocSfaqeloa5n (C) Cylinder Arrangement (socodslorpSea0005§) a28erson Flat (Opposed), inline, V-type. = Figure (3-7) V-6 Engine (soco8 slelGooSopic¥t GodeoE qj) Hun Myint Hay (MLE, Mechanica) Page 65 of 74‘Automotive Technology (0) Valve Train Type (en:say$ s2805c954) a8onaeni{9§ voisag§xa80548qj: 8012025 Overhead camshaft (OHC) 3 Overhead valve (OHV) o3 eéfesvlaose sprocket Figure (3-9) Overhead valve (OHV) Hun Myint Htay (ME, Mechanica) Page 66 of 74‘Automotive Technology (€) Ignition Type (so qj$o5yo Szo002$ ovla$o3§) Brecor8cdladagg gSeip§uloop5u Spark Ignition § Compression Ignition o8 [GSvla0p5u o2c8 sBookySog’ ove5vcvd§fG: Spark ignition oR a}zdlar5u BeuSsoEq\Sogé ovcsvcvdegd Compression lenition o8 aficloop81 (F) Cooling systems (so8ySo8 soeso: 20983 soqpSeacw: comes GolavpSu (6) Fuel type (soa§:fea00 Baoditsoent) corimein|sog’ mafi{ojesr> sSari§gsonigptys ooc8a8 soox0028eg) Soocq2: SeuSs81 0§8§:08 (eSlecloop5u 3.2.1 Four-Stroke Gasoline Engine (Gro0pSe0Sa8a08 98) 2008 orod8néqeorsor qorslarain onoiBardqyioz’ aBhecoc§ espeqo0r2 awiqicd copfovin evoiocaies S:ocScor(: SracoaEaclaSajax oldlagolax_5 Combustion Chamber a8arp5yo vd00r8085j socvEslurcSanfejorag pec: [@Svla0p5u vdoorsaforp5yo socaésl Bogé saconScaroahegeseao2m0qp [gclo0p5u oSvor8oreg. Reciprocating Motion of8: Rotary Motion qeanaé eGoE:edeurqilopin oBa§ efGo8rcd.con§ Crankshaft of aoo§:{odlo0p5u 838B g8gjpGeooSeop8: coqaSmexrcoregSeh a0}: opateaos Or Figure (3-10) The linear (reciprocating) motion of the piston is converted to rotary motion by the crankshaft (soconScsancSegegeovospegenag copSooSegcovomeges ayossadag abSigdeR soo}e{qis) 2e5) Sop: GolavpSu Inlet Valve adcooSesi cocaéslodo§ coog aBsacqpsacqoq§ copfovrqs seaf{ajsloopSu Exhaust Valve aBoSceava:c§ soaodsloda> Brccoo8[Gsoa00 calegeraomn|go0ze cpo'[gday s905:{apslo095u so0v8slorsategé 2495: Figure (3-11) A cutaway of an engine showing the intake passengers (blue) and valve and exhaust passage (red) and valve (w[gneqpiorpS aodsocSent} acogeanoicobifeslh: aofeqpSare5 BoSeneat} BoSc\rsz 609 ogaSagateao.c08: (8Ulor98) Hun Myint Htay (MLE, Mechanical) Page 67 of 74‘Automotive Technology cnirconSonry BoScesestecga—5 gyfalGh ooffarrcho$ wBoicacysoc0n1y2d Regd aoain eniqoiRangSaaBoSaySq} on8q5 Camshaft orcg sacqSepSulorp$1 ooSqSorp5. ooQesq5} GoSsocSconi8s aogjf BoSsoaySaySqulao_Su Cam aSor0 cndgSavTogé Roa cpmeco:$ulo051 Opening flank Nose / Closing 7 flanks fos casing _ Opening ramp ramp WF Heol Figure (3-12) The height and width of a cam lobe determine when and fow how long a valve will be open. (oSgSesTagarecoier ovdaocicg empegslGs og fteBobclen waryEayaiQr agracgagoSagatcleo ovgarciefrro$ on{o§8oSayoi0l 2095») cr1eagdeaboSeySor220g1 ovcivcrder SrocSor.ceg! oboortcgoypryeogarps voto freo8if cRodfgscgqcloaSe 3.2.1.1, Four-Stroke Cycle Stroke sor socoksladga soecTencgesvo03e0c8 (sf) emonSenaymecTaoBaynio}enagoiso coiSslang5y onffsqScncvgSo4(8: vBoortor zoesTexaoSogeyslangSt SrocnS{iah mBigSo> 48 oddcopSqalavaSa cndvoicopig® QGoSakeopSqcor gua} qyoSnkcopSqolangSe oopbox8qa0 0305 s008aRev—S qulovaSe 3.2.1.2. Flywheel Groopimiqsyo oopSordyyad Aclqorskeor mfoozSa}ignoagos copShEqh ccleGal consagSn QRdlclaf achEsBichedya aabyagafaconSeoniqularesy ecGésSicbeoadeavae§ anphoogieag socSzooySySfSctargSu Manual SurnevaoSprnoySeqbdpnE ySeogys ocBEsSicSa0—5 GBrer0c§ sahil: caScRBurrcnrcSgarcqSepSo}méqdag’ Flexplate } Torque Convertor cB e2ofilajb: coragiieaornedan soqpSeozen wc¥Es$icSaajgs moySoySuloop5e Figure (3-13) A typical iywheel Hun Myint Hay (ME, Mechanica) Page 68 of 74‘Automotive Technology 3.2.1.3. Intake Stroke wcmvsiiocySarp5 mi:oSoopS[gavlarp5u akicBoSoopSagé odoortmacT (top dead center) oe4 exoraocddfegesl§: plagigy> wércoodenigSeglf: ecogsBz0cqpm0090 ofeqpo8er.d] sop oSocntemanSenSagagaicavscfagae socodsledyo BaxctgpS:agaiclaoaSa GEvocooga> Baxt$ epicannd(aip§ cong Brreqpzreqoecg obespoScoodlaraSa onéjeaéqécogye orogajoqo( turbocharger) (Supercharger) cogorSandconiff: sodio8oSecySozé socoéslad odaqpaSylegeol’: méqclol BomrnéicovlaopSn sadioboSvaiSoSo}aee8 cooga8sacqpe0<40 (air-fuel mixture) cog ofcepoiaqcl 2051 o800n8 (bottom dead center) cqpoSo}ans] aadicorSe8oSagosdo0—54 A Figure (3-14) Intake Stroke 3.2.1.4, Compression Stroke 4E007S29—5 veer (bottom dead center) cncy sevTuaSoReorSegerare5i00 oorislGs mércboieatareS BoSaq(G GEE: socrkcledyo BoS8eqEfG80} ccogsBarcqpaae4o (air-fuel mixture) 08 vSocrécmcaconSucSagnz> 8:8Soyztclso_Su BcBoScar2d{agoe Ssxcrqsxcn> saydh§copS: G§oroicoaclar—$n odeors (top dead center) [empoScaromel Brecvakcdlocgg matad [edoqclu Figure (3-15) Compression Stroke Hun Myint Htay (MLE, Mechanical) Page 69 of 74‘Automotive Technology 3.2.1.5. Power Stroke AloaSa0~5 evcSoooSer Bro0§[Bt B:ccrs8eclobagars oorsefoidlavaSn Gércofeovoe00r cf oSeordevT axnSoqpoS: oSo0r8csroaSenSo8 ogogaiG slolagelooe5n [— seater | piston © Figure (3-16) Power Stroke 3.2.1.6. Exhaust Stroke oSoonéa095 (bottom dead center) cqpaSor} sBoScssocpSoontellGr socadalodag’ 8: acontedloSogoraehto$ 8:8 :003 anjfogSclor—Su B88:8:00g08 odoorercggizcqoScor crir0pSySeqmns wloSenda} BobcoodSGsmegagoSagazvlanp5s 8423 Gi00p6(gaje> VloloxS BS a eGoScloop5e iraxe SPARK VALVE = PLUG exnaust VALVE exaust GASES comsusrion GRAMBER PISTON D Figure (3-17) Exhaust Stroke Hun Myint Htay (MLE, Mechanical) Page 70 of 74‘Automotive Technology 3.2.1.7. Firing Order (socoSslcdgo S:scoo8aul oSaa0p§ s28.s008) nuderaoéaliq’ aooSsoovéslor Breorrkedloiajqoodorod} séqSegosoySayeego 03: exropo8egSconieé [aSlo0g5e gous soav8slocosofuc8i06 fSg8 Firing Order 1-3-4-2 cpoSconislan s0v8al§led (9) BreooasedlosagfBislon aoov€sljulod (9) S:ocoodedleSqjcloaSu slgoraoooésl cogarcr95i Biccoa8edloSo3o} UIclocpSucpoSeu} safgoroopdonggcen9 (gSaqolooase COMMON CYLINDER NUMBERING AND FIRING ORDER eas 4-Cylinder 6-Cylinder D@O® DQ2O@O® Firing 1-3-4-2 Firing 1-5-3-6-2-4 Order = 1-2-4-3 Order ve v8 @@@® Right Bank @@@®@ Right Bank @@® Left Bank @© © @ © Left Bank Firing 1-4-5-2-3-6 Firing 1-5—4-8-6-3-7-2 Order Order @@®© Right Bank ® @ @ @ Right Bank @@®© Left Bank ® © @ © Left Bank Firing 1-6-5-4-3-2 Firing 1-5—4-2-6-3-7-8 Order Order @ @® Right Bank @ @ © © Right Bank @ ©® Left Bank ®@O® Left Bank Firing 1-2-3-4-5-6 Firing 1-8-4-3-6-5-7-2 Order Order @@® Right Bank @@® © © Right Bank @ ©® Left Bank ®@O® Left Bank Firing 1-4-2-3-5-6 Firing 1-8-7-2-6-5-4-3 Order Order Figure (3-18) Examples of cylinder numbering and firing orders Hun Myint Htay (M.E,, Mechanica) Page 71 of 74‘Automotive Technology 3.2.1.8. Two-Stroke Gasoline Engine Two-Stroke Gasoline Engine o8 arsisEqSsogy2 vabisrecoani[gdcgul Gi co§éigSox80c5 copia’ cldlonG@BS quloop5u Exhaust ke port ~. AKU intake bypass ¥ port Crankcase Figure (3-19) A two-stroke cycle 3.2.1.9. Engine Rotation cwiyScogeaiefifiorpS gofconSobgeKGoti{G§ CounterClosewise copSeava! opSeso205o0xt lagu [aipfosoreBoqaagosslor —copSucSgoqoayarfEaole flywheel of mEqSuadcmofaiaSo calgien5 (aajulo> aSqSarp5 CounterClosewise copSefodos: 0888 claogSu 3.2.1.10. Combustion ewicycogyo Ignition System 8: cog encdeorgdloy So go eincSclagn eqaeSoos{g5¥Eoram coo} Sospaqao2n warakrons} BS emnogecgel$ Géxeahne Gggoarrkiggcd Srccon8avloSay{GErogSrcc7 ovd8ocoden SrooScor0081 85800010) covga8ercqpzoyo08 S:ecur8oud aogj$} crclyipSeoaSconSccostcrS:agaiQ: Combustion [Broas0é eqSanna8 aosco0954 1. Spark occurs 2. Combustion begins 3. Continues rapidly 4. And is completed Figure (3-20) Normal combustion. Hun Myint Htay (MLE, Mechanical) Page 72 of 74‘Automotive Technology 3.2.1.11. Engine Configurations (so8qjSoqidlQc200 aoco8 slao8s008) ewiqsqoiog’ socodsleogc8 Inline, V-type, slant, opposed cog Good soEcBEsy Shogo coapiai: oxpS esooe5fajelaagSn (I) Inline Engine sicGérécopS _ socofsleoin one iadyod saBankorpSesoonScostm _ socoél oniefeeegoS onfrgSorbeqaé sr slnsbnbg flog moves mevdslorecooe5 cn8qorpiiy2d s00903(8: oxpScavon$a00. upright position QoguloopSu mEchErjemeqSeogyo awo:a009|05 morgpSrajodcog Golar—Su aoormoqioSo socodslecg abanllrgSewanconiearndepes —_ eyabca SEs GELaEr=%g — cpSqora__ cyrSoglongSu aaienaere miqhtimlesefeos croicReopl: mlesorpSesoocSqensodfajo$ Aerodynamic covsoate8 og8i{Bt ayciqeavaqa: SapgclarpSi weqs$Sule caoo8 opfroyoiqeor.e0cr gaStovre§ qploapSu Figure (3-21) The cylinder block for an inline engine. (il) Vtype Engine GofoSmbqscrcorg soovdslaogeh V § cnpSesradiconlG: Bo Snijooey go Snfsee8 oneS exordiene or§éigSor8aqpés! soovdslurcSgdqGislanSi socoEalecge8 48caro0pSesmo0Sconxeie Geavlarg5n aoooéalaegic8 conkilG: orpSesmomcodtopza0305 way jeolasoh FALE: or—Sesooohhé coood{ano$ Aerodynamic coon: opfiffs ayctqaavom0n: SepSsclaaaSe Figure (3-22) A-type engine. Hun Myint Hay (MLE, Mechanical) Page 73 of 74‘Automotive Technology (III) Opposed Cylinder Engine EstaBrnaine stdecgh apyentistbongesobcnls 200 Aoferghewatina enfegborbeqnss ocak shinedy59 Figure (3-23) A horizontal opppsed cylinder engine, commonly called a boxer engine Hun Myint Htay (MLE, Mechanical) Page 74 of 74