Today's Technician: Automotive Engine Repair & Rebuilding, Classroom Manual and Shop Manual, Spiral Bound Version 6th Edition Chris Hadfield

Today’s Technician: Automotive Engine
Repair & Rebuilding, Classroom Manual

and Shop Manual, Spiral bound Version
6th Edition Chris Hadfield
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CLASSROOM
MANUAL
For Automotive Engine Repair & Rebuilding
SIXTH EDITION
CLASSROOM
MANUAL
For Automotive Engine Repair & Rebuilding
SIXTH EDITION
Chris Hadfield
Director, Minnesota Transportation Center of Excellence
Randy Nussler
South Puget Sound Community College & New Market Skills Center
Australia • Brazil • Japan • Korea • Mexico • Singapore • Spain • United Kingdom • United States
Today’s Technician: Automotive Engine © 2018, 2014 Cengage Learning
Repair & Rebuilding, Sixth Edition
ALL RIGHTS RESERVED. No part of this work covered by the copyright herein
Chris Hadfield
may be reproduced or distributed in any form or by any means, except as
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Notice to the Reader

Publisher does not warrant or guarantee any of the products described herein or perform any independent
analysis in connection with any of the product information contained herein. Publisher does not assume,
and expressly disclaims, any obligation to obtain and include information other than that provided to it by
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or reliance upon, this material.
Printed in the United States of America

Print Number: 01 Print Year: 2017
CONTENTS
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
CHAPTER 1 Automotive Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Terms to Know 1 • Introduction 1 • Basic Engine Operation 2 • Cooling System 6
• Lubrication System 6 • Engine Breathing 6 • Engine Performance 7 • Cylinder
Head 9 • Timing Mechanism 10 • Engine Block 11 • Summary 12 • Review
Questions 13
CHAPTER 2 Engine Repair and Rebuilding Industry . . . . . . . . . . . . . 15

Terms to Know 15 • Introduction 15 • Full-Service Repair Facilities 15
• Machine Shop and Engine Rebuild Facilities 17 • Engine Repair and Replacement
Specialty Facilities 18 • Engine and Component Remanufacturing Facilities 19
• Summary 20 • Review Questions 20
CHAPTER 3 Theory of Engine Operation . . . . . . . . . . . . . . . . . . . . . 22

Terms to Know 22 • Introduction 23 • Major Engine Components 23 • Engine
Operating Principles 27 • Behavior of Liquids and Gases 30 • Pressure and
Vacuum 30 • Boyle’s Law 31 • Engine Operation 31 • Engine Classifications 34
• Engine Vibration 38 • Engine Displacement 40 • Direction of Crankshaft
Rotation 42 • Engine Measurements 42 • Other Engine Designs 49 • Engine
Identification 52 • Summary 56 • Review Questions 56
CHAPTER 4 Engine Operating Systems . . . . . . . . . . . . . . . . . . . . . . 59

Terms to Know 59 • Introduction 60 • The Starting System 60 • Lubrication
Systems 65 • Cooling Systems 76 • Cooling Fans 88 • Lubrication and Cooling
Warning Systems and Indicators 90 • Fuel System 94 • Automotive Fuels 98
CHAPTER 5 Factors Affecting Engine Performance . . . . . . . . . . . . 105

Terms to Know 105 • Introduction 105 • Spark Plugs 106 • Combustion Chamber
Sealing 107 • Fuel and Combustion 111 • Engine Noises 115 • Summary 116
• Review Questions 116
CHAPTER 6 Engine Materials, Fasteners, Gaskets, and Seals . . . . . 118

Terms to Know 118 • Introduction 118 • Engine Materials 119 • Manufacturing
Processes 122 • Fasteners 126 • Gaskets, Seals, Sealants, and Adhesives 131
CHAPTER 7 Intake and Exhaust Systems. . . . . . . . . . . . . . . . . . . . . 141

Terms to Know 141 • Introduction 141 • Air Induction System 142 • Air Intake
Ductwork 143 • Air Cleaner/Filter 143 • Intake Manifold 146 • Intake Manifold
Tuning 147 • Vacuum Basics 149 • Vacuum Controls 149 • Turbochargers 150
• Superchargers 155 • Exhaust System Components 159 • Mufflers 163
v
vi
CHAPTER 8 Engine Configurations, Mounts,

and Remanufactured Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Terms to Know 168 • Introduction 168 • Engine Configurations 168
• Engine Mounts 170 • Remanufactured Engines 172 • Summary 175 • Review
Questions 175
CHAPTER 9 Cylinder Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

Terms to Know 177 • Introduction 177 • Cylinder Heads 178 • Cylinder
Head Component Relationships 189 • Combustion Chamber Designs 190
• The Combustion Process 194 • Multivalve Engines 197 • Summary 198
CHAPTER 10 Camshafts and Valvetrains . . . . . . . . . . . . . . . . . . . . . 200

Terms to Know 200 • Introduction 200 • Summary 214 • Review Questions 215
CHAPTER 11 Timing Mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . 217

Terms to Know 217 • Introduction 217 • Valve Timing Systems 217 •
Chain-Driven Systems 220 • Belt-Driven Systems 221 • Gear-Driven Systems 223
• Variable Valve Timing Systems 224 • Variable Valve Lift (Cam-Shifting) 226
• Variable Valve Timing and Lift Systems 226 • Summary 231 • Review Questions 231
CHAPTER 12 Engine Block Construction . . . . . . . . . . . . . . . . . . . . . 233

Terms to Know 233 • Introduction 233 • Block Construction 235 • Crankshaft 240
• Camshaft 245 • Lifter Bores 245 • Harmonic Balancing 245 • Flywheel 246
• Short Blocks, Long Blocks, and Crate Engines 247 • Summary 248
CHAPTER 13 Pistons, Rings, Connecting Rods, and Bearings . . . . . 250

Terms to Know 250 • Introduction 250 • Bearings 250 • Camshaft and Balance
Shaft Bearings 257 • Balance Shafts 257 • Pistons 257 • Piston Designs and
Construction 263 • Piston Rings 266 • Connecting Rods 268 • Summary 270
CHAPTER 14 Alternative Fuel and Advanced

Technology Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Terms to Know 272 • Introduction 272 • Alternative Fuel Vehicle Use 273
• Propane Vehicles 273 • E85 and Flexible Fuel Vehicles 276 • Compressed
Natural Gas Vehicles 278 • The Honda Civic GX CNG Vehicle 283 • Electric
Vehicles 284 • Hybrid Electric Vehicles 286 • Hev Operation 287 • Plug-In Hybrid
Electric Vehicles 294 • Fuel Cell Vehicles 295 • Summary 295 • Review Questions 296
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
PREFACE
Thanks to the support the Today’s TechnicianTM series has received from those who teach
automotive technology, Cengage Learning, the leader in automotive-related textbooks, is
able to live up to its promise to provide new editions of the series every few years. By
revising this series on a regular basis, we can respond to changes in the industry, changes
in technology, changes in the certification process, and to the ever-changing needs of
those who teach automotive technology.
The Today’s TechnicianTM series features textbooks and digital learning solutions that
cover all mechanical and electrical systems of automobiles and light trucks. The individual
titles correspond to the ASE (National Institute for Automotive Service Excellence) certi-
fication areas and are specifically correlated to the 2016 standards for Automotive Service
Technicians (AST), Master Automotive Service Technicians (MAST), and Maintenance
and Light Repair (MLR).
Additional titles include remedial skills and theories common to all of the certification
areas and advanced or specific subject areas that reflect the latest technological trends,
such as this updated title on engine repair.
Today’s Technician: Automotive Engine Repair and Rebuilding, 6th edition, is designed
to give students a chance to develop the same skills and gain the same knowledge that
today’s successful technicians have. This edition also reflects the changes in the guidelines
established by the National Automotive Technicians Education Foundation (NATEF).
The purpose of NATEF is to evaluate technician training programs against standards
developed by the automotive industry and recommend qualifying programs for certifica-
tion (accreditation) by ASE. Programs can earn ASE certification upon NATEF’s recom-
mendation. NATEF’s national standards reflect the skills that students must master. ASE
certification through NATEF evaluation ensures that certified training programs meet or
exceed industry-recognized, uniform standards of excellence.
The technician of today and for the future must know the underlying theory of all
automotive systems and be able to service and maintain those systems. Dividing the mate-
rial into two volumes, a Classroom Manual and a Shop Manual, provides the reader with
the information needed to begin a successful career as an automotive technician without
interrupting the learning process by mixing cognitive and performance learning objec-
tives into one volume.
The design of Cengage’s Today’s TechnicianTM series was based on features that are
known to promote improved student learning. The design was further enhanced by a
careful study of survey results, in which the respondents were asked to value particular
features. Some of these features can be found in other textbooks, while others are unique
to this series.
Each Classroom Manual contains the principles of operation for each system and
subsystem. The Classroom Manual also contains discussions on design variations of key
components used by the different vehicle manufacturers. It also looks into emerging
technologies that will be standard or optional features in the near future. This volume is
organized to build upon basic facts and theories. The primary objective of this volume is
to allow the reader to gain an understanding of how each system and subsystem operates.
This understanding is necessary to diagnose the complex automobiles of today and tomor-
row. Although the basics contained in the Classroom Manual provide the knowledge
needed for diagnostics, diagnostic procedures appear only in the Shop Manual. An
vii
viii
understanding of the underlying theories is also a requirement for competence in the

skill areas covered in the Shop Manual.
A spiral-bound Shop Manual delivers hands-on learning experiences with step-by-
step instructions for diagnostic and repair procedures. Photo Sequences are used to illus-
trate some of the common service procedures. Other common procedures are listed and
are accompanied with fine line drawings and photos that allow the reader to visualize and
conceptualize the finest details of the procedure. This volume also contains the reasons
for performing the procedures, as well as when that particular service is appropriate.
The two volumes are designed to be used together and are arranged in corresponding
chapters. Not only are the chapters in the volumes linked together, the contents of the
chapters are also linked. The linked content is indicated by marginal callouts that refer
the reader to the chapter and page where the same topic is addressed in the companion
volume. This valuable feature saves users the time and trouble of searching the index or
table of contents to locate supporting information in the other volume. Instructors will
find this feature especially helpful when planning the presentation of material and when
making reading assignments.
Both volumes contain clear and thoughtfully selected illustrations, many of which are
original drawings or photos specially prepared for inclusion in this series. This means that
the art is a vital part of each textbook and not merely inserted to increase the number of
illustrations.
The layout of Automotive Engine Repair & Rebuilding, 6th edition, is easy to follow
and consistent with the Today’s TechnicianTM series. Complex systems are broken into
easier-to-understand explanations. Industry standardized terms and vernacular are used
and explained in the text.
Jack Erjavec
HIGHLIGHTS OF THE NEW EDITION—CLASSROOM

MANUAL
The Classroom Manual for this edition of Today’s Technician: Automotive Engine Repair
and Rebuilding includes updated coverage of the NATEF AST, MAST, and MLR tasks
for engine repair and rebuilding. In addition to updated coverage of industry trends, new
information has been added on the following:
■ 0w16 oil
■ Engine design changes for gas direct injection (GDI)
■ EPDM belts
■ Stretch belts
■ Wet timing belts
■ Flat plane crankshafts
■ Cam-phaser design, operation, and service
■ Variable valve timing
■ Variable lift
■ Active fuel management
■ Variable cylinder displacement
HIGHLIGHTS OF THE NEW EDITION—SHOP MANUAL

Like all textbooks in the Today’s TechnicianTM series, the understanding acquired by read-
ing the Classroom Manual is required for competence in the skill areas covered in the
Shop Manual. Service information related to the topics covered in the Classroom Manual
ix
is included in this manual. In addition, several photo sequences are used to highlight
typical service procedures and provide the student the opportunity to get a realistic idea
of a procedure. The purpose of these detailed photo sequences is to show students what
to expect when they perform the same procedure. They can also provide a student with
familiarity of a system or type of equipment they may not be able to perform at their
school.
To stress the importance of safe work habits, Chapter 1 covers safety issues and has
been updated to include hybrid vehicle high-voltage safety. Included in this chapter are
common shop hazards, safe shop practices, safety equipment, and the legislation concern-
ing and the safe handling of hazardous materials and wastes.
Chapter 2 covers special tools and procedures. Procedures include the use of engine
condition and diagnostic test equipment, precision engine measuring tools and specialty
measuring tools, along with engine reconditioning tools and equipment.
The subsequent Shop Manual chapters synch up with those in the Classroom Manual,
and the related content of each manual’s chapters is linked by use of page references in the
margins. This allows the student to quickly cross-reference the theory with the practical.
Redundancy between the Classroom Manual and the Shop Manual has been kept to a
minimum; the only time theory is discussed again is if it is necessary to explain the diag-
nostic results or as an explanation of the symptom. Currently accepted service procedures
are used as examples throughout the text. These procedures also served as the basis for the
job sheets that are included in the textbook at the end of each chapter. Updated coverage
in the Shop Manual addresses:
■ Engine pre-oiling
■ Engine break-in
■ 500-mile service for newly rebuilt engines
■ HEV service and safety
■ Concerns related to improper oil service on hydraulically controlled systems
x
CLASSROOM MANUAL
Features of the Classroom Manual include the following:
CH AP TE R
3
THEORY O
F ENGINE
OPERATIO
N
Cognitive Objectives
Upon comple
tion and review
of this chapte
These objectives outline the chapter’s contents ■
■
Major engine
Basic engine
component
s.
r, you should
understand
and be able
to describe:
operation. compressio
and identify what students should know and ■ Basic
laws of phy
engine ope
ration.
sics involved
wit h
horsepower
los ses
n ratio, eng
and torque,
, mechanic
ine efficiency
horsepower
,
■ Eng the al efficiency
be able to do upon completion of the chapter. ine classific
the number
cylinders, cyli
ations accord
of cycles, the ing to
number of
■ The
rmal efficie
relationship
ncy.
between com
, and
ratio and eng

nder arrange ine power out pression
Each topic is divided into small units to and valvetra
■ The
in type.
four-stroke
ment, ■ Mecha
nical, volum
efficiencies,
put.
etric, and the
cycle theory and factors rmal
.
promote easier understanding and learning. ■ The
different cyli
and the adv nde
antages of
r arrangeme
nts
each.
■ The
basic operati
that affect
■ The each. engine des on of alterna

different valv igns, includ tive
modern eng etrains used diesel, and ing two-stroke
ines. in stratified cha ,
■ Eng
ine measurem ■ The rge.
internal com
bore and stro ent terms suc engine and ponents of
ke, displacem h as how they diff a diesel
ent, of a gas eng er from tho
ine. se
Terms To Kn
Terms to Know List

ow
Autoignition
temperature
Bore Engine bea
rings
Bottom dea Friction Potential ene
A list of key terms appears immediately Boyle’s law
d center (BD
C) Fuel injectio
n
Preignition
rgy
Brake horsep Glow plugs Reciprocating

after the Objectives. Students will see Coil
ower
Gross horsep
Horsepower
ower
Reed valve
Rotary valv
Compressio e
n-ignition (CI)
these terms discussed in the chapter. engines
Compressio
Hybrid electri
(HEV)
c vehicle
Spark-ignition
Stroke
(SI) engine
n ratio
Definitions can also be found in the Connecting
Crankshaft
rods
Indicated hor
Internal com
sepower
bustion eng
Thermal effi
Thermodyn
ciency
ine amics
Kinetic ene
Glossary at the end of the manual. Cycle
Detonation Law of con
rgy
servation of
Top dead cen
Torque
ter (TDC)
Displacement energy Transmission

Dual overhe Me cha nical efficie
ad cam ncy Transverse-m
Net horsep ounted eng
(DOHC) ower Vacuum ine
Engine Overhead cam
(OHC) Valve overlap
256 Chapter 13 Efficiency Oving
Part erhface
ead valve (OH Volumetric
V) efficiency (VE
Piston rings )
22 Wrist pin
11_ch03_hr_02
2-058.indd
22
Bearing
crown
Cross-References to
at the top
A multiple- e clearances ied.
Figure 13-10 ing. maintains clos
Bearing crown re most of the loads are appl
piece thrust bear Figure 13-11
the bearing, whe
and bottom of
the Shop Manual within the ran

ge of 0.0008
inch (0.0203
ck the manuf
mm) to 0.002 ons
acturer’s spe
inch
cificati
bea rin g clearances fall ical clearances; always che

oil typ haft or
These are just g on. t the cranks
References to the appropriate page (0.0508 mm).
for the engine
you are workin They are designed to wea to contaminated oil. Wh
wea r item . exp osure
r and protec
cam bea
en the
rings.
a e and , and
Bearings are after high mil
eag main, rod is
in the Shop Manual appear whenever camshaft. The
is disa
y do wear out
ssembled for
rep airs , it
you
is customary
wil
to replace the rance to ensure that it
l have to che
ck the clea
in Ch apter 13 of
the Shop
eng ine gs, ure
new bearin s this proced
necessary. Although the chapters of the Wh en
within the spe
fitt ing
cified range.
We wil l dis cus
Shop Manual
e 588 Manual.
two manuals are synchronized, material Chapter 13, pag
and Ov ers ize Bearings
to be usable
, bearings tha
t are 0.001 and
air serious
Undersize worn lightly
and polished ground to rep
haft has been generally available in
nks
covered in other chapters of the Shop When a cra nks haf
ers
t
ize
is
are often availab
le. If the
fitt
cra
ed. Th
0.002 inch und ersize bearings can be tric undersized bearings of the bearings is
ese bearings
are
ma y inc lud e 0.050,
und Me meter
journal wear, h undersize. the inside dia
Manual may be fundamental to the Undersize bear
ings
e outside 0.0 10, 0.0 20, and 0.030 inc
. Un der size
and 0.750 mm meter of the crankshaft
means that
journa ls. an oversized
have the sam dard
0.250, 0.500, line bored to
diameter as stan bear- the reduced
dia ck has been 40 inch.
0.030, and 0.0 These
topic discussed in the Classroom bearings, but
the
thick
ing material is crank-
er to smaller, to fit
Oversize bea rin gs may be used
when the blo
often ava ilab le in 0.010, 0.020,
0.750, and 1.0 00 mm.
e
bearings are ly 0.250, 0.500, ring. The use of oversiz
Manual. fit an undersize
shaft journ al. dia me ter. Oversize
Available me
rin gs hav
tric oversiz
e a larger out
ed bea rin gs are typical
sed dra
than the stan
side diameter tically as component rep
ma
dar d bea
. Som e
lacement has
bea
become
rings are stam
ped
in
Author’s Note
bea decrea ons rently
ings are bearings has chining operati g that is cur
Oversize bear dard and undersize ive than many complex ma ck the size of the bearin on it. Some
thicker than stan ide
outs
to increase the bear- more cost-ef
fect
that allows the
technician to
che
from the fac
tor y with the
size correlation size bear-
cian indicate
what
This feature includes
diameter of the size with a code e stam ped the tec hni this type of
rings com t helps talled in
ing to fit an over inside
bearing bore.
The use. New bea
have a stampin
engine blocks engine originally. If diff
g on them tha
erent sized bea it.
rings are ins simple explanations,
Margin Notes
same as or remove
diameter is the . e on the this ma rk
standard bear
ings ing cam change
engine, the tec
hnician should
ting rod and
main stories, or examples of
most connec en
erience that rication. Oft
The most important terms to know are AU TH OR ’S NOTE It has
s are caused by
been my exp
con tam ina ted engine oil
the oil pan,
or lack of lub
the coo lan t-co ntaminated
failure if it
complex topics. These
g fail ure slud ge in se of the
bearin r by the the cau y
highlighted and defined in the margin. the cause of
failure is clea
of oil in the
to determine
crankcase. Try life of the engine; these
the
days, that ma
e to discuss
the are included to help
oil, or the lack st bearings should last 0 km). Be sur
Mo 02 to 321,87
Common trade jargon also appears is premature.
reach 150,00
0 to 200,000
mil es (24 1,4
and filter cha
nges with you
r cus tom ers .
students understand
of regular oil
importance
in the margin and gives some of the difficult concepts.
common terms used for components. 4/3/17 8:29
PM
This helps students understand and 71.indd 256

h13 hr 250-2
speak the language of the trade,

especially when conversing with an
experienced technician.
xi
110
Chapte
r5
Figure 5-8
cause the A pitted valve fac
valve to bu e allows
rn. leakage tha
t will eventually
Misadj
tightly, it usted valves can
will be he also caus
perform ld open e valve lea
an lo kage and
strokes. ce through poor nger than it was burning.
In se designed If a valve
sive tem extreme cases, it aling of the co to. This is adjuste
perature can also m ca d
s. cause th bustion chambe n cause a reduct too
e valves r during io
to burn
if they ar the appr n in
e expose opriate
A Bit of History d to exce

s-
A BIT O
As recently FH ISTORY
This feature gives the student as early as as the mid-1980s
,
today’s en 60,000 or 75,00 it was not uncomm
gines can 0 mi on for en
run at lea les. Now due to
a sense of the evolution of the st 150,000 adva
gines to req
e requiring
uir
miles befor nces in materials e valve recondition
and ing
valve servi machining, most
automobile. This feature not Head G
aske
ce. of
t Damag
When a e
only contains nice-to-know context
of
head ga
sket leaks
, it can
adjoinin combustion ch pr
g cylinde amber se esent a whole
information, but also should significan
tly
rs. This
will
aling , a
also leak . This will caus lower the com re usually resu
failu
host of
different
sym
ou e pression lts in a lea ptoms. In the
to release t into the cool rough running
spark some interest in the coolant
pressure ing syste
m k
an
and a lac d combustion k between two
leaking in and coolant. Th . This can caus of power. Combu both cylinders
of
ket failu to the co e most co e the co stion ga
subject matter. re
th
situations the oil, and it
m
mixing wi is the presence of bustion chambe mon symptom
coolant
in the oi
m
r. Anothe
r
oling sy
of a blow
stem pr
n
ses can
essure ca
p
, a compl will look l. The oi common sympt head gasket is
of white ete engin fo amy and l dipstick om of head
, sweet-s wi
There is melling e rebuild may be brownish, like a ll show signs of gas-
a signific ex haust re qu ire co ffe em co ol ant
problem
s ex ant diffe to exit the tailpip d. This burning co ilkshake. In thes
sible caus ist with combu rence in e
cost, lab (Figure 5-9). olant caus
es cloud
e
es of low sti
with a re perform on chamber seali or, and techni s
alistic es ance, in ng . It wi qu e, de pending
timate. order to
offer the ll be your job to on what
customer reco
responsib gnize the pos-
le repair
options
58111_
ch05_h
r_105-117
.indd 110
116 Chapter 5
2/13/17
Figure 5-17
these created
The bearings
engine knocking
worn down to
on the left are om end.
from the bott
the copper underlayer;
Summary
be used in the
winter Each chapter concludes with
ity fuel should l should be
SUMMARY ■ Higher volatil
d starts; lower
volatility fue
HC emis- summary statements that
s that the ass ist col t excess ive
mance require t its support to mer to preven
■ Proper
engine perfor nd and tha used in the sum lock. es
chanically sou are three typ
engine is me
systems are
functio nin g as des igned.
perly sealed
sions and vap
■ Misfire,
or
preignition,
and detonation se serious
that can cau
contain the important topics
er must be pro combustion
bustion chamb formance. of abnormal
■ The com
to provide goo
d engine per
gs, and head gas
ket seal
.
engine damage ling or lubrication system defects.
in the coo
s can
ine
of the chapter. These are
or serious eng abnor-
Review Questions
g, rin ■ Failures
es, spark plu al combustion
■ The valv
the com bus tion chamber.
gasoline des
crib es its ability to
the greater
cause abnorm
■ Normal
engine wea r wil l eventually
formance.
lead to
designed to help the reader
■ The oct
ane rating of the number, reduced per
ng; the higher mal noises and
Short-answer essays, resist knocki
the resistance
to kno cki ng. review the contents.
fill-in-the-blanks, and multiple-
ESTIONS lanks
REVIEW QU Fill-in-the-B ket can cause
choice questions follow each er Essays 1. A leak pas
t the ______
_________ gas
mance.
Short-Answ er? engine perfor
bustion chamb compro ed mis
chapter. These questions are 1. What com
ponents sea
l the com
ur from imp
roper _________ ___
___ ___
2. The ______ ___ _______________, and plug
______,
blems can occ ____________ rk

2. What pro ition to the spa mber.
designed to accurately assess combustion
cha mb er sealing?
ned valve hav
e on engine
___ in add
____________ l seal the combustion cha
wal
ct will a bur and cylinder system and
3. What effe ____________
the student’s competence in the performance
?
octane rating describe?
ns in the ___
3. Malfunctio ______ system can cause
engine
s a gasoline’s the _________
4. What doe problems.
stated objectives at the beginning 5. What pro ble ms can occur wh
en fuel with
d?
an
mechanical
es of abnorm
al com bus tion are
volatility is use 4. Three typ ______, and
inappropriate ___,_________ occurs when a
of the chapter. 6. Define pre
ignition. ____________
____________
___. Preignitio
n
_________ the
spark.
star ts ___ ___
onation. flame front
7. Define det combustion
. hole in the top
of abnormal is like ly to burn a
some causes 5. _________
___ ___
8. Describe lead to?
pro ble ms can detonation of the piston.
ine
9. What eng ?
engine noises
ses abnormal
10. What cau
PM
2/13/17 12:11
7.indd 116
_hr_105-11
58111 ch05
xii
SHOP MANUAL
To stress the importance of safe work habits, the Shop Manual dedicates one full chapter to safety. Other important features
of this manual include:
CHA PTE R 10
VALVETRAIN SERVIC
E
Performance-Based
Objectives Upon completion and
review of this chapter,
you should understand
and be able to describ Basic Tools Lists
■ How to inspect the camsh e:
aft for ■ How to recond
These objectives define the ■
straightness.
replace studs.
ition rocker arms and Basic Tools
How to measure the camsh
and journals and determ
aft lobes ■ How to evaluate and measu
re valve
Basic mechanic’s
tool set Each chapter begins with
contents of the chapter and what repairs.
ine needed
springs. Service manual
■ How to inspec
t solid and hydraulic
■ How to adjust
the valvetrain during
installation of hydraulic
a list of the basic tools
the student should have learned lifters and determine neede
d repairs.
■
lifters.
■ How to perfor
m the leak-down test
hydraulic lifters and accura on
How to adjust valve cleara
engines using mechanical
nces on needed to perform the
upon completion of the chapter. the results.
tely interpret
■ How to prope
lifters.
rly reassemble the
■ How to inspec
t the pushrods and
determine needed repairs
cylind er head.
■ How to install
tasks included in the
. a cylinder head.
■ How to descri
be the methods used ■ How to replac
chapter.
Terms to Know List to e valve seals with the
correct rocker arm geom cylinder head installed
etry. on the engine.
322 Chapt er 7
that
Terms To Know that there are no DTCs and
harging system, be sure intake air tempera-
On a PCM-controlled turboc properly. A fault in the
Terms in this list are also defined Base circle
Camshaft
n systems are functioning
Lobe lift
the fuel and ignitio PCM to limitreboost pressu
example, could cause the Seat pressu
re. Repair all related
ture sensor, for
Nose harger .
mning the turboc
in the Glossary at the end of the Duration
Heel
malfunctions before conde
Open pressure
Overlap
Spring free length
Spring shims
Leak-down Turbocharg er Removal Spring squareness engine; for example,
manual. Lifter
Pushro
The turbocharg erdsremoval procedure
varies depending on the
facturer recommends the
engine be
some
Rocker arm
cars, such as a Nissan 300 ZX, the manu ations , the turbocharger may
on other applic
to the turbocharger. On removal proce-
removed to gain access vehicl e. Alway s follow the turbocharger
in the l turbocharger
INTRODUCTIO removed with the engine
be N The following is a typica
facturer’s service manual.
dure in the vehicle manu
The valvetrain works to al procedure:
remov open and close the valves
run, the components of at the propeand Asthe
drain
r time. cooling system.
the valvet rainthe
nnect negati
wear batter y cable,
andvestretch
the engine is
altered. 1. Disco , causin the valve harger .
pipe from thegturboc openin gand
This chapter discus2.sesDisconnect the exhaust to the
be engine block.
the metho rt bracke t between the turbocharger
semble the cylinder head,3. Remo ve the suppo
ds used to inspect and repair housin g on the turbocharger.
adjust thevalves
bolts from the oil drain back the valvetrain, reas- remove
worn valve stem seals on4. Removethe , diagno se a failed thead
coolan inlet tube
gasket nut
, andat the block outlet, and
the car.nnect harger replac e
as camshafts and lifters,5. Disco Remem turboc
theber, before deciding to rebuild compo
nents such
the cost of rebuil
uppor t bracke
ding compo t. related components.
of replacing them. These the tube-s nents must bracke t,
r box,red to the cost
be compa and
components air usuallcleaneyrbe eleme nt, air cleane m
rebuilding; however, there 6. Remove thecan purchased new at bodyexpen
le less electri cal connector, and vacuu
may be instan whenrator
cesaccele
the linkage, thrott se than
7. Disconnect rebuilding is a viable option
. e the three
hoses.
urboc harger inlet hose clamps, and remov
y-to-t
8. Loosen the throttle-bod s. Remove the throttle body.
manifold attaching screw
throttle-body-to-intake on the compressor wheel
harger discharge hose clamp
9. Loosen the lower turboc
screw. Remove
housing.
take-m anifold screws and the fuel line bracket 441
10. Remove the fuel-rail-to-in pull the fuel rail and injec-
shield-retaining clips, and
the two fuel-rail-bracket-to-heat- n with a piece of wire.
Special
58128_ch10_hr_441-494.indd
441 Tie the fuel rail in this positio
tors upward out of the way. housin g.
line from the turbocharger
11. Disconnect the oil supply heat shield.
old
12. Remove the intake manif harger and the water box.
Tools Lists 256 Chapter 13 13. Disconnect the coolant
Remove the line-support
return line from the turboc
bracket from the cylind
er head and remove the
to the exhaust manifold, and
line.
Special Tools retaining the turbocharger turbocharger down-

14. Remove the four nuts the manifold studs. Move the
from out of
Whenever a special tool Pressure gauge
Hand pressure pump
remove the turboc
ward toward the passen
harger
ger side of the vehicle, and then lift the
Parting face
unit up and
t.
Dial indicator the engine compartmen
is required to complete
ers after a turbocharger
returning vehicles to custom e with them. Remind
a task, it is listed in CUSTOMER CARE When
replacement, be sure to
discuss proper care and
wind
maintenanc
down before shutting the vehicle
the turbo to
them that they should allow idle for a minute after driv-
the margin next to the off. This simply means that
g the
they should let the engine
ignitio n off. You should also remind
them that regular oil
customer
Figureing before
13-10 turnin
A multip can help ensure that the
le-
turbocharger life. They
procedure. changes g. essential to
piece thrust bearinare
won’t be back anytime soon

for turbocharger service. Bearing
Figure 13-11 Bearin crown
g crown maintains close
and bottom of the bearin clearances at the top
g, where most of the
loads are applied.
oil bearingcharg er sCom ponent Inspection s
Turbo clearance fall within the rang s turbocharger disassembly, inspect the wheel
(0.0508 mm). Thes factur er recommend e of 0.0008 inch (0.02 with con-
If the vehicle emanu
for the
are just typic al clearances; alwaed.
remov
03 or
Lack of lubricant mm) to ation
lubric 0.002 inch gs.
engine you ending
thework
and shaft afterare housings are ys check the the end housin
Bear on. g failure, which leads to man ufact
wheel rub ons spec
urer’ ifications
ings areoil
a wear s in .bearin
resultitem
taminated
camshaft. They are designed
They do wear out after to wear and prote
engine is disassemb high mileage and expo ct the crankshaft
led for repairs, it is sure to contaminated or
Shop Manual When fitting new customary to repla oil. When the
bearings, you will ce the main, rod, and
Chapter 13, page 588 within the specified have to check the cam bearings.
range. We will discu clearance to ensure 4/4/17 6:18
Manual. ss this procedure that it is
in Chapter 13 of
the Shop
Undersize and Ove
Margin Note Undersize bearings
When a cranksha
0.002 inch undersize
rsize Bearings
ft is worn lightly and
are often available.
polished to be usab
le, bearings that are
have the same outsid journal wear, unde If the crankshaft has 0.001 and
rsize bearings can been ground to repa
The most important terms diameter as standard
bearings, but the bear-
e
0.010, 0.020, and
0.030 inch undersize
0.250, 0.500, and 0.750
be fitted. These bear
. Metric undersize
ings are generally
d bearings
ir serious
available in
ing material is thicke mm. Undersize mean
r to smaller, to fit the redu s that the inside diam may include 0.050,
to know are highlighted and fit an undersize crank-
shaft journal. Oversize bearings
diameter. Oversize
ced diameter of the
may be used when
crankshaft journals. eter of the bear ings is
the block has been
bearings are often line bored to an over
defined in the margin. Common Oversize bearings are
thicker than standard
Available metric over
bearings have a large
sized bearings are
available in 0.010
typically 0.250, 0.500
, 0.020 , 0.030, and 0.040
, 0.750, and 1.000 mm.
sized
inch.
r outside diameter
to increase the outsid and undersize bear than the standard These
trade jargon also appears in diameter of the bear-
ing to fit an oversize
e
more cost-effective
ings has decreased
than
dram atically as compone
bearing. The use
nt replacement has
of over size
bearing bore. The inside with a code that allow many complex machining operation become
s the technician to s. Some bearings are
the margins and gives some diameter is the same
standard bearings.
as
use. New bearings
engine blocks have
come stamped from
a stam
check the size of the
the factory with the
bearing that is curre
size correlation on
stamped
ntly in
ing came on the engin ping on them that helps the technicia it. Some
of the common terms used for engine, the technicia
e originally. If diffe
n should change this
rent sized bearings
n indicate what size
are installed in this
bear-
mark or remove it. type of
components. This feature helps AUTHOR’S NOT
E It has been my
experience that most
Author’s Note
students understand and speak bearing failures are
the cause of failure
caused by contamin
ated engine oil or
connecting rod and
main
oil, or the lack of oil
is clear by the sludg
e in the oil pan, the
lack of lubrication.
Often This feature includes simple
the language of the trade, is premature. Mos
in the crankcase. Try
t bear
coolant-contaminate
to determine the caus d
e of the failure if it
reach 150,000 to 200,0 ings should last the life of the engin
00 miles (241,402 e; these days, that explanations, stories, or examples
especially when conversing with importance of regu to
lar oil and filter chan 321,870 km). Be sure to discuss the
ges with your custo
may
mers.
of complex topics. These are
an experienced technician.
included to help students
58111_ch13_hr_250-2
71.indd 256
understand difficult concepts.
xiii
Photo Sequences
14 Chapter 1
PHOTO SEQUENCE
2
Typical Procedure for
Many procedures are illustrated in Lifting a Vehicle on a
Drive-On Hoist
detailed Photo Sequences. These

photographs show the students
what to expect when they perform
particular procedures. They also P2-1 Drive the vehicle onto
the
sure your wheels are centered hoist. Make P2-2 Place a wheel chock
behind the other
, and drive slow. end of the vehicle to ensure P2-3 Raise the vehicle to
If needed, stick your head
familiarize students with a system have an assistant help guide
out of the window or
in front of a moving vehicle.
you. Never stand
being lifted.
it doesn’t roll when a comfortable height.
or type of equipment that the

school might not have.
P2-4 Make sure that the locks

are set and the P2-5 Position the rolling jacks
hoist is level. Always rest the on a suitable
hoist on the locks. location. Check the service P2-6 Once the axle is to a
Most drive-on lifts are hydrauli manual for correct height
their locks are air operated
cally lifted, but locations. lower it and rest it on the locks.s you151
want it,
. era
Opair
jacks are ting System Most rolling
vicing Engine
operated and have manual locks.
and Ser
Diagnosing
NTINUED)
UENCE 5 (CO
PHOTO SEQ
References to the
Classroom Manual
battery.
P5-11 Verify
that the new
starter operates
without excess
properly and a few times.
noise by cran
king References to the appropriate
t the
P5-10 Reconnec the engine over
page in the Classroom Manual
Figure 1-11 Typical hydrauli
c floor jack.
rs is exc 1-12the
essive,
Figure
duce a high-
starter will pro the starter
too small,
Typical jack stands. Classroom Man
ual
e 60
appear whenever necessary.
the two gea clearance is rned Chapter 4, pag
ce between cranked. If the n switch is retu
If the clearan
pitched whine
while the eng
ine is bei ng
r the engine
starts and the ign itio
Although the chapters of the
hig h-p itch ed whine afte
will make a
to the RUN
position. two manuals are synchronized,
Service Tips 58128_ch01_hr_001-038.indd
14 se of drive hou
The major cau g gears. It is always bet
is too small
sing breakage have a little
ter to
a
material covered in other

SERVICE TIP pin ion and rin
wee n the ce.
Whenever a shortcut clearance bet than too small a clearan
more clearan
ce chapters of the Classroom
or special procedure is D SERVICE
Manual may be fundamental
TESTING AN
ION SYSTEM
appropriate, it is described in LUBRICAT
ent upon oil
clearances Bearings are
used to to the topic discussed in the
Testing re is depend es exces- s created
Oil Pressure life. Oil pressu ring becom carr y the load
the text. Generally, these tips Proper oil pre the
ial to engine
ssure is essent rance between a journa
clea ons
l and the bea
, how eve r, are the res
ult of bearin
p wea
g
r.
by rotational
forces.
Shop Manual.
and proper
deliver y. If low oil pre ssure conditi er oil gra de, and oil pum pera-
is lost. Not all level, improp tem
describe common procedures sive, pressure ses include improper oil
632
wear. OtherChapt
cau er 13
low oil pressu
re is thinnin
g oil as a result
of excessive
el will
mon cause of Too low a lev due
the oil level.
used by experienced Another com tion.
tures or gas
dilu
ssure is suspec
ted, begin by
che cki ng
e. If the oil
level is too hig
h, it ma y be
n misfire,
If low oil pre to aerate and lose volum age d fue l pump, ignitio y, check 5
technicians. cause the oil
pump
ering the cra
nkcase as a
to gasoline ent or engine flooding. If the
result of a dam condition are satisfactor 3
oil level and 1
Oil pressure
testing is
t from the 4 rmin
used 6to dete
e the
r, re 7sending uni gauge to
2 8 -
leaking injecto oil pre ssure gauge. the oil pressu re condition of the
bear
oil pressure
using an
pre ssu re test, remove rs, con nec t the oil pressu tch the ings and other inter
nal
To perform
an oil
the cor rec t size adapte as the eng ine idles. Wa the engi ne components.
e 4-20). Usi
ng
erve the gau
ge Increase
engine (Figur Start the engine, and obs
Pulley temperature.
sag e. exc ess ive drops due to res ults wit h the manu-
the oil pas s to note any are the test h the
engine warm gauge. Comp cifications wit
gauge as the observing the provide oil pressure spe After
to 2,000 while rs y warmed up. Bolt
engine rpm Manufacture be sure the engine is full confirm
cifications. re; engine, and
facturers’ spe l operating temperatu sending uni
t, sta rt the
at nor ma oil pre ssu re
Water
engine ll the
plete, reinsta pump
the test is com Intake
manifold
PM
4/4/17 4:49
Timing
cover
indd 151
r_135-226.
58128_ch04_h
Front cover
gasket
Cylinder
block
Figure 13-77 Water pump,

pulley, and timing cover installation.
Figure 13-78 Intake manifold
and typical torque sequence.
(Figure 13-79). Most gasket

s are marked to indicate
After testing the fit, remov proper direction for install
e the intake gasket. Apply ation.
the service manual. On sealer at any locations direct
V-type engines, the four ed in
and the engine block usuall intersection points of the
Caution y require sealer. On V-typ cylinder heads
end seals onto the block e engines, locate the front
Do not install the . In addition, the intake and rear
damper by striking it tabs that must fit into the manifold gasket may have
head gasket for proper alignment
with a hammer. The The studs will hold the gasket installation (Figure 13-80
).
Warnings and Cautions engines. On V-type engine in place while the manif
damper or crankshaft old is installed on most
s, the gasket may slip as in-line
may be damaged. prevent this, use an adhes the manifold is lowered
ive to hold the gasket in into place. To
position. Then install the place. Carefully lower the manif
fasteners and torque to old into
specifications.
Cautions appear throughout the WARNING If the cylind
intake manifold must be
er heads on a V-type engin
machined accordingly e have been machined,
the
text to alert readers to potentially manifold before reasse
well as reduced performan
mbly may cause oil and
so. Failure to machine
coolant leaks or consu
the intake
mption as
ce. Refer to Chapter 9
for more information.
hazardous materials or unsafe On fuel-injected engines,
install the fuel rail and the
the fasteners to the specif intake plenum and gasket
ied value. Next, install the . Torque
conditions. Warnings advise the Make sure to replace
camshaft-driven high-p
the high-pressure (2,000
throttle body assembly (Figur
psi) fuel lines when instal
e 13-81).
ressure pump onto the ling the
cylinder head of GDI (gasol
student of things that can go wrong if injection) systems.
Next, install the exhaust
manifold and gasket. Replac
ine direct
with the exhaust manifold. e all mounting hardware
instructions are not followed or if an The old fasteners may have
been weakened as a result
used
of the
incorrect part or tool is used.

58128_ch13_hr_587-658.indd
632
xiv
Case Studies 570 Chapter 12
CASE STUDY dam-

r was excessively scuffed and
Each chapter ends with a Inspection of a V8 engine
block indicated that one cylinde
hed the options available
and discussed them with the
customer.
to bore each cylinder
aged. The technician researc not feasibl e and having
of a new block was most
Case Study describing a It was decided that the cost
would require the purchase
of new pistons. In this instanc
g the block was the installa
e, it was decided that the
tion of a sleeve. After comple
ting
to turn
cost-effective method of repairin ons on the engine block, the technician was ready
particular vehicle problem all the required machin ing
her attention to the cranks
operati
haft. The inspec tion notes taken indicated that
one of
finish. All other main-bearing
the main-
journal s
grinding to restore its surface ian
bearing journals required fail in this manner, the technic
and the logical steps a were good. Realizing it is unusua
l to have only one bearing
very closely and discove red that the origina l bearing was undersize
noise
inspected the old bearing attempted to remove an engine
not ground. Someone had the journal
technician might use to solve even though the journal was
by simply installing a thicker
bearing to take up clearan
cranks
ce. The extra friction caused
haft position in the block,
all main-bearing journals were
ces were
in proper clearan
ASE-Style Review
to score. To mainta were installed, and oil
rd undersize, new bearings
the problem. These studies ground to the next standa
checked. By taking the time
to find what is in the best
interest of the customer, your
reputation
grow.
as an honest technician will
focus on system diagnosis Questions
skills and help students gain QUESTIONS
ASE-STYLE REVIEW the pistons should come Each chapter contains
4. Technician A says that
familiarity with the process. 1. Technician A says to revers cylinder head.
e the tightening
out the top of the block.
sequence when loosen ing the
the main caps starting
Technician B says to drive on the edge of the
to remove the pistons.
ASE-Style Review Questions
Technician B says to loosen piston skirt with a punch
and moving toward the
at the front of the engine
rear.
Who is correc t?
C. Both A and B
that reflect the performance
A. A only
Who is correct?
C. Both A and B B. B only
D. Neither A nor B
objectives listed at the
A. A only removed for inspection.
D. Neither A nor B 5. The crankshaft has been
B. B only
you can pry most
Technician A says the area aroun d the fillet is a
cracks.
beginning of the chapter.
2. Technician A says that common location for stress
harmonic balancers off
with two big pry bars.
can damage the
Techn ician B says a crack near
piston connecting-rod journa
the number 1
l may indicate a
These questions can be used
Technician B says that you
protect the threads while faulty vibration damper.
crankshaft if you do not
using a puller. Who is correct?
to review the chapter as well
Who is correct? C. Both A and B
A. A only
C. Both A and B
A. A only
B. B only
D. Neither A nor B as to prepare for the ASE
D. Neither A nor B
ready for inspection.
B. B only
the engine to
6. The cylinder block is
Technician A says that deck
warpage can be checked
certification exam.
3. Technician A says to rotate ing the timing and feeler gauge.
TDC number 1 before remov using a precision straightedge
bearing saddle
mechanism. Techn ician B says that the main
B says to make a menta l or written ent can be check ed with a precision
Technician . alignm
Name n of the timing marks and a feeler gauge .
note ____locatio
of the ________ straightedge
________ Who is correct?
Who is correct? ________
PERFORM C. Both A and ____B____
__ only C. Both A and B
A. A only ING AN A. ADa
er A nor B
Upon comp OILD. AN Neith A
DerFILTER
nor B te ______
________ D. Neith
B. B only letion of B. B only ____
change. this job sh CH AN
NATEF Co
This job
rrelation
eet, you sh
ould be ab
le to prope
G E
rly perform
an oil and 20
JO B SH EE
T Job Sheets
sheet addre filter
sses the fol
D.10.
This job
Perform
engine oil
lowing AS
T/ MAST tas
k for Engin
2/15/17 8:41 PM
Located at the end of
sheet addre and filter e Repair:
change.
D.5.
Perform
sses the fol
engine oil
lowing M
LR task for
Engine Re
each chapter, the Job
Tools an and filter pair:
• Technic
d Materia
ian’s tool
ls
change.
Sheets provide a format
• Shop rag set
• Correct
type of en
gine oil
for students to perform
• Service
• Oil filt
• Used oil
manual
er wrench procedures covered in the
container
• Torqu
e wrench chapter. A reference to the
Describe
the vehic
le being NATEF Tasks addressed by
ASE Challenge
Year ____ worked on
________ : Systems 189
________ ing Engine Operating
VIN ____ _ Make __ Diagnosing and Servic
________
________
________
________
________
___ Mod the procedure is included
Questions
Procedur _ En gine type el __ ________
e and size __ ________
Follow the
ASE CHA tructionsGE QUESTIO
insLLEN
below to
NS ________
________
________
___
__ heater core may be
on the Job Sheet.
1. Pull the complete
the it engag
oil es Technician B says that the
oil fill lev ng noise when
Each technical chapter 1. A__starte
the
r makes
________
flywh eel __
teeth.
__ __
grindi
a el ind ica tor (dipstic
k), an d
and filter
ch an ge leakin
.
g.
correc t?
Task Comp
leted
________
__ ____ shimm ednote the level andWho is
______ician says that it could__be C. Both A and B
ends with five ASE Techn
impro
__
______
perly.
________
A __
________
________
__
________
____gear
________
could
______
co ition
A. nd
__
A only of the oil.
__ __
B only ________ D. Neith er A nor B
__ says
ician B__ ____the
____that starter drive ______ ________ B. _____
challenge questions. 2. WTechn
ma
hat are the
be dama
nual for the
ged. AP I an d SAE rat
________
________
________
__
________
4. A custom
______light
______
come
er__says that his oil pressure warni
_______
s on while the car is idling . An
ng
oil
Who is correc cot?rrect infor ings for the oil yo ______ ________
_____low oil pressure.
These are not more ____ ________
A. A only ______________
________
matio C.
__D.
n)?
____
Both A and uBare going
er A nor B
pressu
to use (co
Techn
re
nsult
ician
test shows
theAser says that the engine bearings
may be
________ Neith
______ ________ vice
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SUPPLEMENTS
Instructor Resources
The Today’s TechnicianTM series offers a robust set of instructor resources, available online
at Cengage’s Instructor Resource Center and on DVD. The following tools have been
provided to meet any instructor’s classroom preparation needs:
■ An Instructor’s Guide including lecture outlines, teaching tips, and complete answers
to end-of-chapter questions.
■ PowerPoint presentations with images and animations that coincide with each
chapter’s content coverage.
■ Cengage Learning Testing Powered by Cognero® provides hundreds of test questions
in a flexible, online system. You can choose to author, edit, and manage Test Bank
content from multiple Cengage Learning solutions and deliver tests from your LMS,
or you can simply download editable Word documents from the DVD or Instructor
Resource Center.
■ An Image Gallery includes photos and illustrations from the text.
■ The Job Sheets from the Shop Manual are provided in Word format.
■ End-of-chapter Review Questions are provided in Word format, with a separate set
of text rejoinders available for instructors’ reference.
■ To complete this powerful suite of planning tools, correlation guides are provided to
the NATEF tasks and to the previous edition.
REVIEWERS
The author and publisher would like to extend special thanks to the following instructors
for reviewing this material:
Matthew Bockenfeld Todd Mikonis

Vatterott College—Joplin Joplin, MO Manchester Community College
Manchester, NH
David Chavez
Austin Community College Austin, TX Vincenzo Rigaglia
Bronx Community College Bronx, NY
Joseph Cortez
Reynolds Community College Richmond, Ronald Strzalkowski
VA Baker College of Flint Flint, MI
Jason S. Grice Michael White

Black Hawk College Galva, IL The University of Northwestern Ohio
Lima, OH
CHAPTER 1
AUTOMOTIVE ENGINES
Upon completion and review of this chapter, you should understand and be able to describe:
■ The purpose of the automotive engine. ■ The basics of the cylinder head and its
■ The basic operation of the internal related components.
combustion four-stroke engine. ■ The engine block and its related
■ The basic function of the cooling and components.
lubrication systems. ■ Many of the major components of the
■ The basic function of the intake and engine.
exhaust systems.
Terms To Know
Camshaft Intake manifold Powertrain
Combustion Internal combustion engine Powertrain control module
Combustion chamber (ICE) (PCM)
Cylinder Journals Pushrod
Cylinder head Overhead camshaft (OHC) Thermostat
engine Valve timing
Engine block
Piston Valvetrain
Exhaust manifold
INTRODUCTION
The automotive engine is the power source that drives the automobile. Today’s engines Internal combustion
are capable of providing good performance and smooth operation in a variety of ambi- engine (ICE) burns its
ent pressures and temperatures while accelerating, decelerating, cruising at high fuels within the engine.
The power that is used
speeds, or at idle. They also achieve good fuel economy and low toxic emissions. as a result of burning
While the basic operation of the four-stroke gasoline internal combustion engine that fuel is also devel-
(ICE) has not changed in more than 100 years, efficiency and power ratings have oped inside the engine.
In comparison, in an
increased more than 1,000 percent. Henry Ford’s Model T sported a 2.7-L engine external combustion
producing about 20 horsepower (hp). Today we commonly see more than 300 hp out engine the burning of
of the same size engine. fuel occurs in an external
source, or tank. The heat
Refinements to the base engine and its support systems have allowed the gains in is then transferred to a
performance, control of fuel consumption, and emissions. Lighter materials within the separate component
engine have allowed weight reductions. The precision and accuracy of the manufacturing where it can be used to
process of modern engines have increased, allowing tighter engine internal clearances. power the engine and
move parts. Examples of
The durability of engines has increased also due to improvements in the process of manu- external combustion
facturing materials and metals. With proper maintenance, most engines should provide engines would be steam
more than 150,000 miles of trouble-free service. Improved parts, new component designs, locomotives and the
Stirling engine.
advanced fluids, and electronic controls have allowed for fewer maintenance
1
2 Chapter 1
Figure 1-1 Today’s smaller engines can produce some hefty horsepower.
A powertrain includes
the engine and all the
components that deliver
that force to the road, requirements. Powertrains are now more than 95 percent cleaner in terms of toxic emis-
including the transmis- sions than those of the 1960s, while the number of vehicles on the road has more than
sion and axles. doubled.
This text will focus on the operation and service of these powerful and efficient new
The combustion cham- gasoline engines (Figure 1-1). You must thoroughly understand the operation of the
ber is a sealed area in engine and the functions of its components to become a skilled automotive diagnostic
the engine where the
burning (combustion) of
and repair technician. To provide good customer service and ensure proper engine per-
the air and fuel mixture formance, you must accurately diagnose faults and perform precise repairs of the engine
takes place. and its supporting systems. This chapter will highlight the contents of the classroom and
shop manuals. Each chapter in the classroom manual will explain the theory and operation
The piston is a round- of a system. The corresponding shop manual chapter will describe the diagnostic and
shaped part that is repair procedures and strategies for those systems.
driven up and down in
the engine cylinder bore.
An engine cylinder is a
BASIC ENGINE OPERATION
round hole bored into
the cylinder block. The The gas engine is often described as an air pump because it uses a tremendous amount
pistons are housed in of air. But to make power, it also uses a small percentage of gasoline. The engine pulls air
the cylinders. into a sealed combustion chamber through the intake system. The combustion chamber
is sealed on the bottom by the piston and its rings (Figure 1-2) and on the top by the
The powertrain control combustion chamber formed in the cylinder head (Figure 1-3).
module (PCM) is an Air enters into the cylinders as the pistons move downward. This creates a difference
onboard computer that in pressure between the cylinder and the atmosphere. The lower pressure area is in the
controls functions
related to the pow- cylinder. When the intake valve opens, the atmospheric pressurized (fresh) air rushes into
ertrain, such as fuel the cylinder via the intake manifold. Fuel is injected into the airstream near (or sometimes
delivery, spark timing, in) the combustion chambers. The timing and quantity of fuel delivery are precisely con-
temperature, and shift
points.
trolled by the powertrain control module (PCM).
The air and fuel mixture is then compressed to make it more combustible as the piston
moves toward the top of its travel. At the optimum instant, the PCM initiates ignition that
Combustion is the con- will deliver a spark to the spark plug. When the spark jumps across the gap of the spark
trolled burn created by
the spark igniting the plug, the air and fuel mixture is ignited and burns rapidly, and the engine harnesses some
hot, compressed air and of the heat energy available in the fuel. This rapid, but controlled, burning is called
fuel mixture in the com- combustion. The power of the expanding gases pushes down with a force comparable to
bustion chamber.
an elephant standing on top of the piston. The piston is connected to the crankshaft by a
Automotive Engines 3
Figure 1-3 The bottom of this cylinder head (shown) shows the four combustion
chambers sealed by the valves.
Figure 1-2 This piston and rings, with the connecting

rod attached, fit closely in the engine cylinder to seal
the bottom of the combustion chamber.
connecting rod (Figure 1-4). The crankshaft causes the engine to turn. Then the spent The crankshaft and
gases are allowed to exit the combustion chamber through the exhaust system. This pro- connecting rod work
cess is repeated in each of the engine cylinders to keep the crankshaft spinning. together to change
The engine valves allow airflow into and out of the combustion chamber. There are the reciprocating and
typically one or two intake valves per cylinder and one or two exhaust valves per cylinder linear motion of the
(Figure 1-5). Refer to Figure 1-3 to see the heads of the valves within the combustion piston into the rotary
chamber. The valves are opened by the camshaft (Figure 1-6). The camshaft is a gear, motion of the
crankshaft.
belt, or chain driven by the crankshaft. The relationship between the camshaft and crank-
shaft rotation creates the proper valve timing. It is carefully timed to ensure that the
valves open at the correct time. The camshaft has egg-shaped (or cam-shaped) lobes on The camshaft is a shaft
with eccentrically
it to force the opening of the valves. Valve springs close the valves. shaped lobes on it to
force the opening of the
valves.
Valve timing refers to

Connecting rod the relationship between
the rotation of the
crankshaft and
camshaft. That correct
relationship ensures
that the valves open at
the correct time.
Figure 1-4 The connecting rod connects the piston to the crankshaft. Figure 1-5 An engine valve.
4 Chapter 1
Figure 1-6 The camshaft has large, round journals that fit into bearings in the block and small, eccentrically shaped
lobes that open and close the valves.
Figure 1-7 This transversely mounted engine sits sideways in the engine compartment
with the transaxle bolted on its end.
Engine Location
Most engines are installed in the front of the vehicle. They may be installed longitudinally,
with the front of the engine toward the bumper and the rear toward the passenger
compartment, or transversely, with the engine placed in the engine compartment side-
ways. Trucks and rear-wheel drive (RWD) vehicles most commonly use a longitudinally
mounted engine. Many passenger vehicles and most front-wheel drive (FWD) vehicles
use a transversely mounted engine (Figure 1-7). This design allows a shorter hood line,
desired in today’s vehicles to provide greater passenger space. A few vehicles use a
mid-engine design, where the engine is placed between the rear axle and the driver. Often,
this well-balanced configuration is associated with modern sports cars.
Engines are held in place by motor mounts. These are attaching pieces with a flexible
rubber portion that isolates much of the engine vibration from the automobile frame and
passenger compartment. The mounts connect the engine to the vehicle chassis (Figure 1-8).
Engine Function
The engine is attached to the transmission through the flywheel and clutch on a
manual transmission (Figure 1-9) or through the flexplate and torque converter on
an automatic transmission. The engine delivers rotational speed and a twisting force
Rubber bushing
Engine mount
Figure 1-8 The engine mount has a rubber bushing to isolate the vibration of the engine
from the chassis.
Figure 1-9 The flywheel bolts to the crankshaft and is attached to

the transmission through the clutch on a manual transmission.
to spin the transmission components. The twisting force is called torque, and the
speed that develops is called horsepower. The transmission uses this torque and
horsepower and manipulates them to provide the appropriate level of torque and
speed to drive the wheels and propel the vehicle. The transmission multiplies the
torque of the engine through gear sets in the transmission and differential to allow
for good acceleration. In higher gear(s), torque is reduced and speed is increased to
improve fuel economy.
6 Chapter 1
Figure 1-11 The head gasket seals between the block and the cylinder head.
Figure 1-10 A thermostat.
COOLING SYSTEM
Combustion develops a tremendous amount of heat in the engine. The expansion of gases
from the heat pushes the piston down, but some of the heat is absorbed in the engine com-
ponents. A liquid cooling system is used on all current gas automobile engines to remove
excess heat from the engine. An engine belt or gear drives a water pump that circulates
coolant throughout the engine to keep all areas at an acceptable temperature, around
A thermostat is a 200°F (110°C). When the coolant reaches a certain temperature, a thermostat (Figure 1-10)
mechanical component opens to allow coolant to flow through the radiator to cool it down. Air flowing across the
that blocks or allows
coolant flow to the radiator lowers the temperature of the coolant; then the water pump pulls the coolant back
radiator. into the engine and recirculates it. The cooling system must retain heat to speed the warm-
up period to enhance combustion and lower emissions after cold starts. It must also main-
tain an even engine operating temperature for better engine efficiency. To prevent the
meltdown of components, the cooling system must remove excess heat.
Cooling system problems can cause very serious damage to an engine. Heat expan-
sion of parts can cause the engine to seize. When an engine overheats, it is likely to blow
the seal between the cylinder head and the cylinder block. That seal is the head gasket,
and replacement can cost several hundred dollars or more and many hours of work
(Figure 1-11).
LUBRICATION SYSTEM
The lubrication system is critical to reduce the tremendous friction created between the
moving components in the engine. This also reduces engine heat and wear. The oil pump
is mounted on the bottom of the engine or on the crankshaft to circulate engine oil under
pressure to all friction areas in the engine (Figure 1-12). The oil is then filtered to remove
particles of metal or debris that could damage finely machined engine components. The
oil travels through oil passages drilled throughout the engine to reach the crankshaft, the
camshaft, the cylinder walls, and other key friction areas. Just a few minutes of engine
operation without adequate lubrication can turn an engine into irreparable scrap metal.
Proper lubrication system maintenance is essential to the longevity of any engine.
The intake manifold ENGINE BREATHING

connects the air inlet
tubes to the cylinder Engine power is dependent on how well the engine can breathe. The intake and exhaust
head ports to equally systems provide the breathing tubes for the engine. The intake manifold connects the
distribute air to each air intake ductwork to the cylinder head (Figure 1-13). The intake manifold distributes
cylinder.
an equal amount of air to each cylinder. Ports into the combustion chamber allow fresh
Figure 1-12 This oil pump is driven off of the front of the crankshaft.
Figure 1-13 The intake manifold distributes air equally to the cylinders. Note that
this is for an eight-cylinder engine.
air to flow past the intake valves when they are open. The exhaust manifold connects The exhaust manifold
the exhaust ports on the cylinder head to the rest of the exhaust system. To a major degree, connects to the cylinder
the more air an engine can take in, the more power it can put out. The intake and exhaust head and acts as a
chamber to let exhaust
systems must flow freely to allow good airflow. Turbocharging and supercharging are gases exit the engine in
systems that increase airflow by forcing air under pressure into the intake. These systems an efficient and safe
dramatically increase engine power (Figure 1-14). manner.
Problems with the engine’s ability to breathe significantly affect engine performance.
Something as simple as a restricted air filter can cause the engine to barely run or even to
not start. You will learn simple maintenance procedures for the intake and exhaust
systems, as well as more sophisticated tests to diagnose tricky problems.
ENGINE PERFORMANCE
An engine has many required conditions to function as designed and deliver good perfor-
mance. An engine needs to have the combustion chamber well sealed to develop compres-
sion of the air and fuel mixture. The engine and intake system must be large enough to
8 Chapter 1
Figure 1-14 This supercharger creates powerful boost and acceleration.
accommodate and sealed tightly enough to maintain the low pressure needed for the
exchange of exhaust gases and fresh air in each cylinder for the engine’s given displace-
ment. The lubrication and cooling systems must be operating properly. Each engine
component must be within its operating tolerance to allow the engine as a whole to hold
together and run well (Figure 1-15). Problems in how the engine performs will keep you
busy as an engine technician.
To recommend repairs, you will need to learn how to evaluate the engine’s
mechanical condition. Vacuum tests and compression tests as well as listening and
smelling will be some of the weapons in your arsenal to correctly diagnose the cause
of engine problems (Figure 1-16). You must test and cross-check before you recom-
mend major engine repairs, trying to gather as much information as possible. You’ll
need a detailed diagnosis to be able to offer the customer an accurate estimate and to
Figure 1-15 This severely worn lifter would

cause poor engine performance. Figure 1-16 You will learn many different ways to analyze the engine.
be sure you correct the problem on the first try. Engine repairs can become very A cylinder head is the
costly; therefore, it is crucial that the diagnosis and repairs are performed with care large object that houses
and attention to detail. most of the valve train
and covers the combus-
tion chamber.
CYLINDER HEAD
If a cylinder head
The cylinder head houses the valves and often the camshaft. In this case it is called an contains the camshaft,
overhead camshaft (OHC) engine (Figure 1-17). In cases where the camshaft is in the it is called an overhead
camshaft (OHC)
block, the cylinder head still holds many of the valvetrain components. The pushrods, engine. The camshaft
lifters, rocker arms, and springs are all parts of the valvetrain because they work to open can also be located in
and close the valves. When the camshaft is in the block, as the high point of the camshaft the cylinder block.
lobe comes up, it pushes on a lifter, which acts like a plunger, to move the pushrod. The
pushrod is a simple, hollow rod that transfers the motion from the lifter to the rocker arm. The valvetrain is made
The rocker arm rides on a pivot. When the pushrod raises one end of the rocker, the other up of the components
end pushes down on the tip of the valve to open it, much like a typical first-class lever that open and close the
valves.
(Figure 1-18). In later chapters you will discover there are many different combinations
that the camshaft can be used in.
Problems within the cylinder head and valvetrain can be quite serious. A valve that is A pushrod is a long
not adjusted properly, for example, can cause that cylinder to drop in performance, tube that connects that
camshaft to the valve
become noisy, and cause the engine to run rough. During an engine overhaul, it is typical train components in the
to perform a valve job. This involves refinishing all the valves and their seats and replacing cylinder head. This is
the valve seals. This requires complete disassembly of the cylinder head and some preci- typically not used on an
OHC engine.
sion machining and repair (Figure 1-19).
Fulcrum (Pivot point)
Rocker
arm
Valve
spring
Valve
guide
Valve
Pushrod
Lifter
Camshaft
Rocker arms
Figure 1-18 The valvetrain components open
Figure 1-17 This OHC engine uses rocker arms to open the valves. the valve in response to the camshaft lobe.
10 Chapter 1
Figure 1-19 You will learn to use specialized equipment used in engine overhauling,
such as this valve grinder.
TIMING MECHANISM
As discussed earlier, proper valve timing is necessary to keep the valves opening and clos-
ing at the correct times. This is achieved by the timing mechanism. A sprocket or gear on
the crankshaft is attached by a gear, belt, or chain to a sprocket or gear on the camshaft
(Figure 1-20). Timing belts require periodic maintenance. When that is neglected, the
timing belt can snap, and serious engine damage can result. In some cases, the valves
contact the top of the pistons and bend, and a new set of valves is required (Figure 1-21).
Figure 1-20 The lower crankshaft gear turns at twice

the speed of the larger camshaft gear. Figure 1-21 Valve timing failures can be catastrophic.
In the worst cases, those valves damage the piston tops, and the whole engine needs to be
overhauled. Timing chains also wear out over time, and replacing them requires skill and
attention to detail. Variable valve timing systems increase performance and minimize
emissions. More and more vehicles employ these systems to vary the times when the
valves can be opened. This makes timing mechanism theory and service a new and more
complex challenge.
ENGINE BLOCK
The engine block is the main supporting structure of the engine (Figure 1-22). It holds The engine block is the
the pistons, connecting rods, crankshaft, and sometimes the camshaft. The cylinder main structure of the
engine that forms the
head bolts to the top of the block. The block is bored (drilled) to create cylinders. An combustion chamber
eight-cylinder engine has eight-cylinder bores (Figure 1-23). The pistons are pushed and houses the pistons,
up and down in the cylinders by the crankshaft. On the power stroke, the piston is actu- crankshaft, and con-
necting rods.
ally pushed down by the force of combustion to turn the crankshaft. Rings on the pistons
seal the small clearance between the cylinder walls. This prevents the hot, expanding
gases from combustion within the combustion chamber, which lets all the force act to
push the piston down. The rings also scrape excess oil from the cylinder walls so the oil
does not burn inside the combustion chamber. When oil is allowed to burn during
combustion, it forms blue smoke that exits the tailpipe. The block also holds the crank-
shaft in its main bore. The soft main bearings are placed within the main bore to provide
a place for the finely machined crankshaft journals to ride. The journals are the Main journals are round
machined round areas of the crankshaft that allow the bearings and bearing caps to bolt machined portions on
the centerline of the
around them and hold the crankshaft in the engine block. The clearance between the crankshaft where the
journals and the bearings must be just right: enough to allow adequate oil, but not so crankshaft is held in the
much that precious oil pressure leaks through excessive clearances. Crankshaft bearings main bore.
of the friction type are softer than the metal they support. Bearings protect the crank-
shaft from damage, but they also wear. When they wear excessively, they cause low oil
pressure and engine knocking.
Figure 1-23 The cylinder bores are finely finished to provide a good
Figure 1-22 An eight-cylinder engine block. sealing surface for the rings.
12 Chapter 1
Figure 1-24 This carriage is powered by one of Daimler’s first engines.
A BIT OF HISTORY
Jean-Joseph Lenoir created the first workable internal combustion engine in 1860. Nicholas Otto
was credited with creating the first four-stroke internal combustion engine back in 1876.
All previous internal combustion engines did not compress the air-fuel mixture. They attempted
to draw the air-fuel mixture in during a downward movement of the piston and then ignite the mixture.
The expansion of gases would force the piston down the rest of its travel. This design was used to
make the piston forceful on each downward stroke. The four-stroke engine, however, proved much
more efficient and powerful. Gottlieb Daimler received the first patent for the internal combustion
engine in 1885. The basic operation of today’s engines is still similar to those first four-stroke engines.
Figure 1-24 shows an early working model from Daimler’s workshop, which is now a museum.
An engine overhaul involves rebuilding the engine to nearly new condition. Each step
of engine repair requires careful inspection, measurement, and judgment. Together the
Today’s Technician Engine Repair & Rebuilding Classroom and Shop Manuals provide the
information needed to learn about component theory, operation, diagnosis, and the repair
procedures of modern engines. The text covers information on principles, safety, the
engine repair industry, ancillary systems, diagnosis, measuring and testing, removal,
service, installation, along with alternative fuel vehicle operation and service.
SUMMARY
■ Today’s smaller engines make more power with ■ The power of combustion pushes down on the
longer life, fewer emissions, and better fuel econ- piston. The piston is connected to the crankshaft
omy than their older counterparts. by the connecting rod.
■ The powertrain control module controls the ■ The intake and exhaust systems allow the engine to
engine’s operation. take in and expel the great quantity of air that the
■ The engine ignites a compressed air and fuel mix- engine needs to make power.
ture in a confined chamber to harness the heat ■ The cooling system prevents the meltdown of
energy of expanding gases. engine components.
Another random document with
no related content on Scribd:
The Project Gutenberg eBook of Leaves from
a middy's log
This ebook is for the use of anyone anywhere in the United
States and most other parts of the world at no cost and with
almost no restrictions whatsoever. You may copy it, give it away
or re-use it under the terms of the Project Gutenberg License
included with this ebook or online at www.gutenberg.org. If you
are not located in the United States, you will have to check the
laws of the country where you are located before using this
eBook.
Title: Leaves from a middy's log
Author: Arthur Lee Knight
Release date: September 28, 2023 [eBook #71750]
Language: English
Original publication: London: Thomas Nelson and Sons, 1896
Credits: Bob Taylor, hekula03 and the Online Distributed

Proofreading Team at https://www.pgdp.net (This book
was produced from images made available by the
HathiTrust Digital Library.)
*** START OF THE PROJECT GUTENBERG EBOOK LEAVES

FROM A MIDDY'S LOG ***
LEAVES FROM A MIDDY’S
LOG.
“In an agony of apprehension I knelt down at Charlie’s side.”
Page 33.
T. NELSON & SONS.
Leaves from a
Middy’s Log
BY
ARTHUR LEE KNIGHT

Author of “Adventures of a Midshipmite,” “The Rajah of Monkey Island,”
“The Cruise of the ‘Cormorant’.”
&c. &c.
THOMAS NELSON AND SONS

London, Edinburgh, and New York
1896
CONTENTS.
I. A STRANGE ADVENTURE, 9
II. WE STORM THE FORT, 26
III. A FIGHT FOR LIFE, 37
IV. WE RETURN ON BOARD, 43
V. THE NAVAL BRIGADE LANDS, 55
VI. “COLD PIG” AND “SLING THE MONKEY,” 62
VII. NED AND THE MULE-DRIVER, 68
VIII. “PREPARE FOR CAVALRY!” 78
IX. WE HEAR STRANGE NEWS, 86
X. A PERILOUS ADVENTURE, 96
XI. JIM BEDDOES’ YARN, 111
XII. TAKEN PRISONER, 124
XIII. NED IS FLOGGED, 137
XIV. IN THE PIRATES’ CAVERN, 146
XV. A MARCH TO THE COAST, 162
XVI. IN IRONS, 172
XVII. ON BOARD THE PIRATE BRIG, 177
XVIII. THE PIRATES’ ISLAND, 193
XIX. IN THE CRATER CAVE, 211
XX. THE ESCAPE FROM THE CAVE, 222
XXI. HUNTED BY BLOODHOUNDS, 236
XXII. A FIGHT WITH A BLOODHOUND, 244
XXIII. A RACE FOR LIFE, 255
XXIV. DEATH OF MIGUEL, 263
XXV. WE ESCAPE TO SEA, 271
XXVI. CONCLUSION, 279
LEAVES FROM A MIDDY’S LOG.
CHAPTER I.
A STRANGE ADVENTURE.
A T the time when the adventures which I am about to relate took

place, I, Jack Darcy, was serving as a midshipman on board
H.M.S. Rattler, a smart frigate of fifty guns, commanded by Captain
Graves, who was a very distinguished officer and much beloved by
all who served under him. Our vessel was attached to the North
American squadron, and consequently we often visited the West
Indies and cruised in the Caribbean Sea. On this particular occasion
we were lying at anchor in the commodious harbour of Havana, the
capital of the beautiful and fertile island of Cuba, which its Spanish
masters delight to call “the pearl of the Antilles.”
A few days after we had come to anchor in the harbour, I, in
company with some of my brother-middies, obtained leave to go
ashore and have a look at the city and its Spanish and Creole
inhabitants. As the reader may suppose, we found plenty to interest
and amuse us. The afternoon, however, turned out so hot that we
made up our minds to return on board the ship earlier than we had
intended; and with this in view, we sauntered down to the wharf
under a burning tropical sun to seek for a shore-boat. In a few
minutes, the placid waters of the harbour, glowing like molten gold
under the fierce rays of an almost vertical sun, opened out before us,
crowded with shipping of various nationalities, amid which our own
beautiful, shapely frigate was clearly discernible with her lofty
tapering spars and shining black hull, the latter relieved by the broad
white streak across the portholes, from which the open-mouthed
guns frowned menacingly.
“I say, Jack,” exclaimed one of my messmates, Charlie Balfour, as
we were steering our way through the piles of merchandise that lay
strewn on the wharves, “that looks uncommonly like the officers’
recall flying at the Rattler’s masthead. What can the meaning of it
be?”
We glanced in the direction of our ship, and sure enough there
flew the recall as a signal for every officer to return on board without
delay.
As we gazed a flash issued from one of the forecastle ports, and
the sullen boom of a signal-gun reverberated over the harbour and
died away in multitudinous echoes amongst the hills behind the city.
“Perhaps the flagship is coming in,” I suggested.
“Impossible, my dear fellow,” answered Charlie, who was a
particular friend of mine; “the admiral was at Halifax by last advices,
and was likely to remain there.”
“We shall soon solve the mystery, anyhow,” I answered, pointing
across the harbour, “for here comes my boat, the second cutter.”
A few minutes later, the craft in question glided alongside the
wharf, cleverly steered by Ned Burton, the coxswain.
“What’s up now, Ned?” we shouted in chorus; “why has the first
lieutenant hoisted the recall?”
The coxswain touched his hat as he answered, “There is a high
old row up somewhere along the coast, gentlemen; and the long and
the short of it is that the captain has ordered us round to Santiago—
leastways that’s the yarn upon the lower deck.”
At this moment a group of our wardroom officers hurried down to
the landing-stage, and we all sprang into the cutter, which was at
once pushed off into deep water and headed for the ship. The ten
lusty oarsmen gave way with a will, and sent the boat spinning along
at an exhilarating pace, whilst Ned Burton carefully steered her
through the maze of merchant shipping and fishing-craft that
thronged the harbour. In a quarter of an hour we were alongside the
Rattler, and found every one full of excitement, and a general
preparation for weighing anchor going forward.
It seemed that the crew of an English merchant vessel, more than
half of whom were foreigners, had mutinied upon the high seas, and
after murdering the captain and the first mate, and pitching their
bodies overboard, had taken charge of the ship, which had a very
valuable general cargo. They had run her into the harbour of
Santiago de Cuba, where, owing to the disturbed state of the island,
they imagined that they could perhaps dispose of the cargo, and
then either burn the ship and join the insurgents, or put to sea again
and trust to the hazardous chance of not falling in with an English
cruiser.
Fortunately, however, their diabolical schemes were nipped in the
bud by the successful escape of Mr. Osborne, the surgeon of the
vessel, whom the mutineers had kept in close confinement lest they
should require his services. On the arrival of the ship at Santiago,
the leading desperadoes went on shore to try to dispose of the
cargo. During their absence, the surgeon managed to give the others
the slip, and with considerable pluck swam to a small coasting-
steamer which was anchored not far off. The skipper of this craft had
easily been prevailed upon to steam off at once for Havana on the
promise of a reward; and to the surgeon’s delight he was soon en
route for the capital. On arriving at Havana, he at once reported
himself to Captain Graves, who paid the skipper of the steamer
handsomely for his co-operation; and after consulting with the
Captain-General of Cuba, he ordered the Rattler to hold herself in
readiness to proceed to Santiago.
As the sun sank to rest in a blaze of crimson glory which was
reflected in ruddy hues on city and shipping, and on the tranquil
waters of the harbour, we tripped our anchor and steamed slowly out
to sea. At the same time, the innumerable bells of Havana rang out
their confused and jangling summons to vespers from the church
and convent towers, their tones mellowed by distance as they came
sounding over the expansive bay. They seemed to be ringing out a
farewell to us as we faded from view in the short evanescent twilight,
which still glowed with some of the sunset’s rapidly-dissolving
glories.
We middies were of course full of excitement at the idea of fresh
adventures, and were burning to know what plans the captain had
laid for capturing this daring band of mutineers, who had had the
effrontery to murder their officers and seize the vessel on the high
seas.
It soon became known that Captain Graves designed to capture
these villains by means of a little strategy. He intended to enter
Santiago de Cuba under easy steam, after nightfall, so as not to
arouse suspicion on board the craft which had been thus cleverly
seized, and which was called the Flying-fish. It would then perhaps
be possible to seize the crew in their hammocks before any
resistance could be offered. Mr. Osborne, who accompanied us,
gave it as his opinion that, on learning of his escape, the mutineers
would probably be seized with alarm, and betake themselves
elsewhere. It was highly improbable, indeed, that they could know of
the presence of a British man-of-war in Cuban waters; but still they
would not unnaturally conjecture that some Spanish gunboats might
be sent in chase of them, as soon as the facts of the mutiny and
murders reached the ears of the Captain-General at Havana.
Fortunately for our scheme, there was no moon, though the stars
shone down with the sparkling brilliancy so remarkable in tropical
climes. The night, however, was sufficiently dark for our purpose;
and toward the end of the middle watch, the Rattler, like a giant
phantom-ship, glided almost imperceptibly into Santiago harbour,
with forecastlemen stationed at the small bower anchor, and armed
boats’ crews ready to go on any service at a moment’s notice.
The captain knew the Santiago de Cuba anchorage well, besides
being provided with excellent charts; so the frigate was taken in at
the dead of night without the slightest hesitation. Mr. Osborne
declared that he distinguished the Flying-fish in about the same
position in which he had left her; consequently we anchored as
quietly as possible a few lengths distant from her, and at once
proceeded to put our plan into execution.
The second cutter, the boat of which I was midshipman, was one
of those told off for the enterprise, so I hurriedly got my side-arms,
and mustered my crew preparatory to manning the boat. Mr. Giles,
the master-at-arms, supported by some ship’s corporals and
marines, was to go with me, taking handcuffs with him. Mr.
Thompson, the gunnery lieutenant, was to command the party, and,
in company with Mr. Osborne—who had provided himself with a
revolver—was to go in the first cutter with my chum, Charlie Balfour.
These two boats the captain considered quite sufficient for the duty,
especially as a complete surprise was intended, and it was known
that the mutineers were very imperfectly supplied with arms.
With muffled oars, and long steady strokes, we pulled away over
the star-begemmed waters for the long low vessel, which with her
clear-cut spars and rigging, and somewhat rakish appearance, more
nearly resembled a pirate than a peaceful merchantman.
All seemed silent as death. Not a voice broke the stillness that
reigned fore-and-aft. The crew were apparently wrapped in slumber.
The first cutter hooked on at the vessel’s starboard gangway,
whilst we made fast to port, and quickly scrambled on board. The
deck was deserted, and a deathlike stillness reigned throughout the
ship.
I met Mr. Thompson and his party at the main-hatchway, and we
proceeded to light some dark lanterns we had brought with us, and
get our revolvers ready for use.
“Mr. Osborne has sprained his ankle in getting out of the boat,”
whispered the gunnery lieutenant, “and he is in such pain that we left
him in the cutter in charge of the bowmen. We can manage all right
without him. Have you got the handcuffs ready, Mr. Giles?”
“All right, sir,” replied that officer in the same undertone, and he
held up to view the instruments in question, and chuckled audibly.
“Now, men, keep perfect silence,” continued Mr. Thompson, “and
we’ll surprise these fellows in their berths, and bundle them into the
boats before they can say ‘Jack Robinson.’ Follow me down the
main hatchway, and in the first place we’ll overhaul the cabins, for it’s
there the rascals are sleeping, I expect.”
With cautious and stealthy steps—having divested ourselves of
our shoes—we followed our leader below. At this moment we almost
betrayed ourselves through a clumsy marine knocking his head
against the ship’s bell, which hung at the foot of the ladder, and gave
out a metallic ring that could have been distinctly heard by any
wakeful person on the main-deck or in the cabins.
“Confound that bullet-headed lobster!” whispered Mr. Thompson
fiercely. “I’ll crack his skull in earnest for him if he doesn’t look out.”
The man, who had overheard this remark, and was ruefully
rubbing his head, slunk to the rear, and sheltered himself behind the
stalwart form of the master-at-arms.
“There are several men asleep in hammocks,” continued the
gunnery lieutenant, flashing his lantern as he spoke on the after part
of the deck.—“Mr. Darcy, you must take some of your crew and seize
the men that are in them. One of the corporals will go with you, and
two marines to handcuff them. I’ll push on with Mr. Balfour and
capture the mutineers that may be in the stateroom and the cabins,
and you can join me there as soon as possible.”
With a rush Ned Burton and my cutter’s crew surrounded the
unconscious sleepers, and hauled them with little ceremony out of
their hammocks; and thus before the men could recover from their
surprise, they were cleverly thrown down and handcuffed. Being half
dressed, they were all ready to be taken on board the Rattler; and I
was on the point of leaving them in charge of the marines, and
pushing on after Mr. Thompson, when one of them, who appeared
from his accent to be an American, broke out with an angry demand
as to the reason why he and his comrades had been taken
prisoners. I answered laconically that it was for murder and piracy
upon the high seas; and without paying any attention to a furious
rejoinder made by the fellow—who had a very unprepossessing
appearance—I hurried aft with Ned Burton and the rest of the blue-
jackets.
Having pushed open a door, I found myself in a very elegant
stateroom dimly lighted by two swinging lamps, which hung over a
table covered with the débris of what had apparently been a
sumptuous meal. Decanters and glasses sparkled in the rich dim
light, and fruit and sweetmeats were scattered about in profusion
over a snowy cloth of remarkably fine linen. Casting a hurried glance
around, I saw that the stateroom was handsomely and even
luxuriously furnished; everywhere signs of elegant taste were visible.
The bulkheads were painted grey and gold, and had a handsome
moulding running around them. The ports were draped with dainty
curtains, and pictures were suspended in every available space. A
rich carpet covered the deck, and was dotted with gipsy tables
covered with fancy china, stands for photographs, bowls of flowers,
and bric-à-brac.
“A curious place for mutineers this,” said I audibly, not a little
surprised at what I saw before me.
“Ay, they live like fighting-cocks, sir, there’s no question about that,
and they seem to have had a good tuck-in last night,” observed my
coxswain in a jocular tone. “Perhaps the gunnery lootenant will let us
finish up the scraps by-and-by.”
I was on the point of replying to Ned Burton, when a tremendous
hubbub and uproar commenced in the after-cabins opening from the
stateroom, to which Mr. Thompson had evidently penetrated with his
men. Angry shouts and furious oaths were heard, followed by the
sound of blows, the crashing of glass and furniture, and, more
appalling than anything else, the shrill screams of frightened women.
Recovering from our surprise, we were on the point of rushing to
our chief’s aid, when to our dismay the doors were burst open, and
the lieutenant and his men, with horror-struck countenances,
tumbled pell-mell into the stateroom, closely followed by a number of
excited-looking individuals arrayed only in their nightshirts, and
wielding chairs, walking-sticks, and any weapons that had come
conveniently to hand. In the distance, we caught a hasty glance of
two female forms retiring to the recesses of their sleeping-cabins.
From the hurried glance I had at their faces, they seemed pale with
alarm and dissolved in tears.
Directly my eye rested on the men who were following our party
out, I saw that some egregious mistake had been made; for they
were gentlemanly and superior-looking men, and were evidently as
much astonished at our appearance as we were at theirs.
Mr. Thompson immediately recovered his self-possession, and
ordered all the blue-jackets to leave the cabin, and wait for him
outside. He then advanced with every mark of concern to the man
who appeared to be the captain of the vessel, and offered the most
profuse apologies for the extraordinary blunder that had been made.
“As you can see, sir, by our uniforms,” he began, “we are British
naval officers. Acting on information which we had every reason to
believe genuine, we boarded your ship, imagining her to be an
English merchant vessel brought in here a few days ago by a
mutinous crew who had murdered their captain and the chief officer.
I can only say that I regret exceedingly the inconvenience and
annoyance you have been put to, and you must convey our most
heartfelt apologies to the ladies, who, I trust, will be none the worse
for their fright. Captain Graves will himself come on board and
personally make his excuses to-morrow; and of course any damage
that has been done will be paid for by our Government.”
The American captain—for such he was—could not forbear
smiling as he listened to Mr. Thompson’s narration.
“Stranger, I forgive you for this night’s work,” said he, “though I
must say it is rather uncomfortable to be roused out of a deep sleep
and arrested by a lot of fire-eaters like you and your men. I calculate
if the President heard of it, there’d be some dispatches passing
between the White House and St. James’s that wouldn’t be quite civil
in tone.”
Mr. Thompson again tendered his excuses, and prepared to
withdraw; but the American skipper and his friends, who had hastily
arrayed themselves in dressing-gowns, insisted on our taking a glass
of wine with them to show there was no ill-feeling, which we did,
though the gunnery lieutenant, I could see, was burning to retire from
a scene in which he had played so ridiculous a part.
“I calculate I can give you a hint as to the craft you’re looking for,”
remarked the skipper, as he quaffed his wine. “If I’m not mistaken,
she left this anchorage yesterday morning and steered in a southerly
direction. She is uncommonly like us in build, and much the same rig
aloft, but I’d lay a wager of a thousand dollars we could knock her
into fits, either running on a wind or close-hauled. If you capture her,
lieutenant, just bring the old hooker in here and we’ll have a racing
match.”
Mr. Thompson smiled and said he’d see about it, and we then
made our adieus and retired.
“Now, Mr. Darcy,” exclaimed my superior, as soon as we were out
of earshot, “what shall we do to that rascal Osborne, who misled us
so? I vote we string him up to the mainyard-arm as a terrible warning
to other crack-brained medicos. By the powers, there might have
been a pretty kettle of fish to fry if those Americans hadn’t turned up
trumps. I was just on the point of spitting that skipper on the end of
my sword when the fray began, and it was only when the master-at-
arms rushed into the cabin of one of the ladies, with a couple of
marines, and the handcuffs ready for slipping on, that her loud
shrieks proved to me that there was something wrong. The whole lot
of them then turned out, women and all, and attacked us like a lot of
furies. I believe one of my little fingers is broken.”
We found that Mr. Osborne had been conveyed on board the
Rattler again, so for the present he escaped the storm of resentment
that was brewing in the gallant gunnery lieutenant’s breast.
As I passed under the merchantman’s stern on the way back, I
deciphered her name by the aid of a lantern, and read, “Snapping
Turtle, of Boston;” so there was no doubt about her nationality.
Ned Burton told me that the Yankee sailors had been in an
ungovernable rage till Mr. Giles had come out and released them.
Even then they had poured out volleys of invective, and threats of
what their Government would do to avenge the insult they had
received. At last Ned, stung by their remarks, offered to fight the
biggest man amongst them with his fists. This offer they declined,
and immediately grew more amicable, exchanging tobacco and
compliments before our blue-jackets were ordered off to man the
boats.
So ended a truly ludicrous adventure, in which we all cut a sorry
figure, and from which we retired, as it were, with our tails between
our legs.
Long and loud were the peals of laughter that greeted us when we
regained the Rattler’s quarter-deck, where we found most of the

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Today's Technician: Automotive Engine Repair & Rebuilding, Classroom Manual and Shop Manual, Spiral Bound Version 6th Edition Chris Hadfield

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Today’s Technician: Automotive Engine

Repair & Rebuilding, Classroom Manual

Cengage Learning products are represented in Canada by Nelson Education, Ltd.

To learn more about Cengage Learning, visit www.cengage.com

Notice to the Reader

Printed in the United States of America

CHAPTER 1 Automotive Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

CHAPTER 2 Engine Repair and Rebuilding Industry . . . . . . . . . . . . . 15

CHAPTER 3 Theory of Engine Operation . . . . . . . . . . . . . . . . . . . . . 22

CHAPTER 4 Engine Operating Systems . . . . . . . . . . . . . . . . . . . . . . 59

CHAPTER 5 Factors Affecting Engine Performance . . . . . . . . . . . . 105

CHAPTER 6 Engine Materials, Fasteners, Gaskets, and Seals . . . . . 118

CHAPTER 7 Intake and Exhaust Systems. . . . . . . . . . . . . . . . . . . . . 141

CHAPTER 8 Engine Configurations, Mounts,

CHAPTER 9 Cylinder Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

CHAPTER 10 Camshafts and Valvetrains . . . . . . . . . . . . . . . . . . . . . 200

CHAPTER 11 Timing Mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . 217

CHAPTER 12 Engine Block Construction . . . . . . . . . . . . . . . . . . . . . 233

CHAPTER 13 Pistons, Rings, Connecting Rods, and Bearings . . . . . 250

CHAPTER 14 Alternative Fuel and Advanced

understanding of the underlying theories is also a requirement for competence in the

HIGHLIGHTS OF THE NEW EDITION—CLASSROOM

HIGHLIGHTS OF THE NEW EDITION—SHOP MANUAL

ratio and eng

■ The each. engine des on of alterna

Terms to Know List

Brake horsep Glow plugs Reciprocating

Displacement energy Transmission

the Shop Manual within the ran

bea rin g clearances fall ical clearances; always che

This helps students understand and 71.indd 256

speak the language of the trade,

A Bit of History d to exce

blems can occ ____________ rk

Special Tools retaining the turbocharger turbocharger down-

won’t be back anytime soon

detailed Photo Sequences. These

or type of equipment that the

P2-4 Make sure that the locks

material covered in other

Figure 13-77 Water pump,

(Figure 13-79). Most gasket

incorrect part or tool is used.

Case Studies 570 Chapter 12

CASE STUDY dam-

Matthew Bockenfeld Todd Mikonis

Jason S. Grice Michael White

Figure 1-2 This piston and rings, with the connecting

Valve timing refers to

Figure 1-9 The flywheel bolts to the crankshaft and is attached to

The intake manifold ENGINE BREATHING

Figure 1-14 This supercharger creates powerful boost and acceleration.

Figure 1-15 This severely worn lifter would

Fulcrum (Pivot point)

Figure 1-20 The lower crankshaft gear turns at twice

Figure 1-24 This carriage is powered by one of Daimler’s first engines.

Title: Leaves from a middy's log

Author: Arthur Lee Knight

Release date: September 28, 2023 [eBook #71750]

Original publication: London: Thomas Nelson and Sons, 1896

Credits: Bob Taylor, hekula03 and the Online Distributed

*** START OF THE PROJECT GUTENBERG EBOOK LEAVES

ARTHUR LEE KNIGHT