EUROPA REFERENCE BOOKS for Automotive Technology

Modern Automotive Technology

Fundamentals, service, diagnostics

1st English edition

The German edition was written by technical instructors, engineers and technicians Editorial office (German edition): R. Gscheidle, Studiendirektor, Winnenden Stuttgart

VERLAG EUROPA-LEHRMITTEL Nourney, Vollmer GmbH & Co. KG Dsselberger Strasse 23 42781 Haan-Gruiten Germany Europa No.: 23018

Original title: Fachkunde Kraftfahrzeugtechnik, 28th edition 2004 Authors: Fischer, Richard Gscheidle, Rolf Heider, Uwe Hohmann, Berthold Keil, Wolfgang Mann, Jochen Pichler, Wolfram Schlgl, Bernd Siegmayer, Paul Wimmer, Alois Wormer, Gnter Oberstudienrat Studiendirektor Kfz-Elektriker-Meister, Trainer Audi AG Oberstudienrat Studiendirektor Dipl.-Gwl., Studienrat Ing. (grad.), Studiendirektor Dipl.-Gwl., Studienrat Dipl.-Ing., Studiendirektor Oberstudienrat Dipl.-Ingenieur Polling Mnchen Winnenden Stuttgart Neckarsulm Oedheim Eversberg Meschede Mnchen Schorndorf Stuttgart Pullach Mnchen Rastatt Gaggenau Langenalb Pforzheim Stuttgart Karlsruhe

Head of working group and editorial office: Rolf Gscheidle, Studiendirektor, Winnenden Stuttgart Illustrations: Drawing office of Verlag Europa-Lehrmittel, Leinfelden-Echterdingen

All information given in this book corresponds to the state of the art. All testing, measuring and repair work on a specific vehicle must be carried out in accordance with the manufacturer's specifications. The work described is performed at the user's own risk. Warranty claims against the authors or the publisher are excluded. English edition: Modern Automotive Technology - Fundamentals, service, diagnostics
1st edition 2006 Impression 5 4 3 2 1 All impressions of the same edition can be used in parallel, as they do not differ from each other except with regard to the correction of printing errors.

ISBN 3-8085-2301-8
All rights reserved. This book is protected by copyright. Any commercial use beyond the legally specified uses requires written approval from the publisher. Cover design and illustration using photographs and illustrations provided by Audi AG Ingolstadt Neckarsulm, Bayerische Motorenwerke AG Munich, Neoman Bus GmbH Stuttgart, DaimlerChrysler AG Stuttgart, Volkswagen AG Wolfsburg.

2006 by Verlag Europa-Lehrmittel, Nourney, Vollmer GmbH & Co. KG, 42781 Haan-Gruiten, Germany http://www.europa-lehrmittel.de

Translation: STAR Deutschland GmbH, Member of the STAR Group Typesetting: STAR Deutschland GmbH, Member of the STAR Group Print: Media Print Informationstechnologie, D-33100 Paderborn, Germany

Foreword

Foreword
"Modern Automotive Technology" is a standard work covering the subject of automotive technology. This first English edition is based on the 28th German edition of the title "Fachkunde Kraftfahrzeugtechnik". It has for many years proven to be a highly popular textbook used for training and further education. It provides apprentices, trainees, teachers and all those interested in this subject with the necessary theoretical knowledge in order to gain a firm grasp of the practical and technical skills involved. Fundamental, technical connections between individual systems are presented in a clear and comprehensible way. The book is intended to be used as a reference work by employees in the automotive industry and in motor-vehicle service outlets, by teachers, apprentices, trainees and automotive-technology students to help them look up information and supplement their technical knowledge. The work is intended to be used by all those interested in automotive technology as a means of extending their technical knowledge through private study. The 22 chapters are logically arranged by subject and in their objectives are geared towards the changes in content that have occurred in the field of automotive technology. The book is particularly suitable for practically orientated training in all matters pertaining to motor vehicles. This work covers the latest developments in automotive technology, such as, for example, service and maintenance of vehicle systems, management, communication, FSI engines, supercharging technology, common-rail systems, twin-clutch gearboxes, electronic transmission control, electronic brake systems, compressed-air monitoring systems, adaptive cornering lights, high-frequency technology, electromagnetic compatibility and comfort and convenience systems such as adaptive cruise control, parking assistance and navigation. A large chapter is devoted to the subject of electrical engineering. Here, the detailed coverage of the fundamentals of electrical engineering forms the basis for all the crucial issues and topics pertaining to automotive electrics, up to and including data transmission in motor vehicles. A separate chapter is devoted to the increasing importance in engineering of comfort and convenience technology. Reference is made to German and European standards in the chapters on environmental protection and occupational safety, emissions-control engineering, braking technology and motorcycle engineering. However, the standards applicable in the respective individual countries are binding. The work features numerous coloured pictures, drawings and system diagrams as well as particularly clearly and comprehensibly laid-out tables. These will help the reader to digest and comprehend the complex subject matter. The work has been written and compiled in close co-operation with the automotive trade and industry by a team of educationally experienced vocational-school teachers, engineers and master tradesmen. The authors and the publishers will be grateful for any suggestions and constructive comments. We would like to thank all the companies and organisations who have kindly contributed pictures and technical documents.

The Authors of the Automotive Technology Team

Summer 2006

Abbreviations
A/C A/F ABC ABS ABV Air conditioning Air/fuel (mixture) Active body control Antilock braking system Automatic braking-force distribution (German: Automatische Bremskraftverteilung ) AC Alternating current ACC Adaptive cruise control ACEA Association des Constructeurs Europens de l'automobile ACS Automatic clutch system AD Analogue-digital (converter) ADSL Asymmetrical digital subscriber line AGM Absorbing glas mat ALDBFR Automatic loaddependent brake-force regulator ALSD Automatic limited-slip differential AM Amplitude modulation API American Petroleum Institute ASC Anti-stability control ASTM American Society for Testing and Materials ATF Automatic transmission fluid ATS Adaptive transmission control (system) BAS BDC CA CS CAN CBS CC CDI CFPP CFRP CH CIH CIP CN CNG Brake assistant Bottom dead centre Crankshaft angle Camshaft Controller area network Combined brake system Cruise control Capacitive discharge ignition Cold filter plugging point Carbon-fibre-reinforced plastic Combination hump Camshaft in head Continuous improvement process Cetane number Compressed natural gas CPU CR CS CSR CV CV CVlft CVrt CVT Central processing unit Common rail Crankshaft Conti support ring Commercial vehicle Check valve Check valve left Check valve right Continuous variable transmission Drive axle Direct current Direct injection Digital motor electronics Double overhead camshaft Department of Transport Dynamic stability control Direct-shift gearbox Dynamic shift-program selection Dunlop self-supporting technology EMS Eo EOBD EP EPHS EPS ESP ETC ETN EV FA FB FDI FF FH FL FOC FOT FR FSI FWD GDI GFRP GI GMR Electronic engine management system Exhaust valve opens European on board diagnosis Exhaust passage Electrically powered hydraulic steering Electro-pneumatic control system Electronic stability program Electronic throttle control European type number Exhaust valve Front axle Function button Fuel direct injection Freeform (reflector) Flat hump Front left Fibre-optic cable Fibre-optical transceiver Front right Fuel stratified injection Four wheel drive Gasoline direct injection Glass-fibre-reinforced plastic General inspection Automatic regulation of yaw moment (German: Giermomentregelung) Global positioning system Gross vehicle weight rating High frequency Hot-film air-mass meter Heavy goods vehicle Homogeneous numerically calculated surface High-solid (paints) High temperature, high shear Hybrid vehicle Integrated circuit Inlet valve closes Individual control Indirect injection

DA DC DI DME DOHC DOT DSC DSG DSP DSST

EBS Ec ECE

Electronic braking system Exhaust valve closes Economic Commission for Europe ECM Electronic clutch management ECS Electronic clutch system ECU Electronic control unit EDC Electronic diesel control EDP Electronic data processing EDTC Engine-drag torque control EEPROM Electrically erasable programmable read-only memory EGR Exhaust gas recirculation EGS Electronic gearbox control unit (German: Elektronisches Getriebesteuergert) EH Extended hump EHB Electro-hydraulic braking system EI Emissions inspection ELSD Electronic limited-slip differential EMC Electro-magnetic compatibility

GPS GVWR

HF HFM HGV HNS

HS HTHS HV IC Ic IC IDI

Abbreviations
IHPF Io IP IPO IS ISAD IV IVlft Ivrt LA LD LDR LED LEV LF LI LIN LNG LS LSG LU LW MAF MAG MC MC ME MED MG MIG MIL MON MOST MPI MS MW NF NLGI NLS NTC Internal high-pressure forming Inlet valve opens Inlet passage Input/Processing/Output (principle) Input shaft Integrated starter alternator damper Inlet valve Inlet valve left Inlet valve right Lifting axle Low density Light depending resistor Light emitting diode Low-emission vehicle Low frequency Load index Local interconnect network Liquefied natural gas Limited slip Laminated safety glass Logical unit Long wave Mass air flow Metal-active-gas (welding) Microcomputer Main cylinder Motor electronics Motor electronics direct injection Motor generator Metal-inert-gas (welding) Malfunction indicator lamp Motor-octane number Media-oriented system transport Multi-point injection Medium-solid (paints) Medium wave Non-ferrous National Lubrication Grease Institute Needle lift sensor Negative temperature coefficient OBD OD OHC OHV ON OV OVlft PBC PC PCU PDA PEM PES PIN PM POF POT PR PTC PWM QA QM RA RDS RHD RL RLFS RON ROP ROV On board diagnosis Outside diameter Overhead camshaft Overhead valves Octane number Outlet valve Outlet valve left Parking-brake circuit Planet carriers Pump control unit Personal digital assistant Proton exchange membran Poly ellipsoid system (reflector) Personal identification number Particulate matter Plastic optical fibre Plastic optical transceiver Ply rating Positive temperature coefficient Pulse width modulation Quality assurance Quality management Rear axle Radio data system Right-hand driver Rear left Return-less-fuel system Research-octane number Roll-over protection Rotating high voltage distribution (German: Rotierende Hochspannungsverteilung) Rear right Radio remote control Static high voltage distribution (German: Ruhende Hochspannungsverteilung) Self-adjusting clutch Society of Automotive Engineers Signal acquisition and actuation module SBC SC SCR SCV SDC SE SI SLC SoC SPI SRR SRS SSlft SSR SSrt SV SV SW SWR Tc TCS TDC TIG TL To TP TPC TSG TWI UIS UPS VDC VDR VF VHF VT VTec VTG WIG SAC SAE SAM Sensotronic brake control Signal conditioning Selective catalytic reduction Solenoid control valve Semi-drop centre Sensor Safety inspection Select-low control State of charge Single-point injection Short-range radar Safety restraint systems Speed sensor left Self-supporting run-flat tyres Speed sensor right Solenoid valve Side valve Short wave Stationary wave ratio Transfer passage closes Traction control system Top dead centre Tungsten-inert gas Tubeless Transfer passage opens Transfer passage Tyre-pressure check Toughened safety glass Treadwear indicator Unit injector system Unit pump system Vehicle dynamics controller Voltage-dependent resistor Variable focus (reflector) Very high frequency Viscosity temperature Variable valve timing and lift electronic control Variable turbine geometry Wolfram-inert-gas (welding)

RR RRC RUV

Contributing companies We wish to thank the companies listed below for providing technical advice, information, photographs and illustrations.
Alfa-Romeo-Automobile Mailand/Italien Aprilia Motorrad-Vertrieb Dsseldorf Aral AG, Bochum Audatex Deutschland, Minden Audi AG, Ingolstadt Neckarsulm Autokabel, Hausen Autoliv, Oberschleiheim G. Auwrter GmbH & Co (Neoplan) Stuttgart BBS Kraftfahrzeugtechnik, Schiltach BEHR GmbH & Co, Stuttgart Beissbarth GmbH Automobil Servicegerte Mnchen BERU, Ludwigsburg Aug. Bilstein GmbH & Co KG Ennepetal Boge GmbH, Eitdorf/Sieg Robert Bosch GmbH, Stuttgart Bostik GmbH, Oberursel/Taunus BLACK HAWK, Kehl BMW Bayerische Motoren-Werke AG Mnchen/Berlin CAR-OLINER, Kungsr, Schweden CAR BENCH INTERNATIONAL.S.P .A. Massa/Italien Continental Teves AG & Co, OHG, Frankfurt Celette GmbH, Kehl Citroen Deutschland AG, Kln DaimlerChrysler AG, Stuttgart Dataliner Richtsysteme, Ahlerstedt Deutsche BP AG, Hamburg DUNLOP GmbH & Co KG, Hanau/Main ESSO AG, Hamburg FAG Kugelfischer Georg Schfer KG aA Ebern J. Eberspcher, Esslingen EMM Motoren Service, Lindau Ford-Werke AG, Kln Carl Freudenberg Weinheim/Bergstrae GKN Lbro, Offenbach / Main Getrag Getriebe- und Zahnradfarbrik Ludwigsburg Girling-Bremsen GmbH, Koblenz Glasurit GmbH, Mnster/Westfalen Globaljig, Deutschland GmbH Cloppenburg Glyco-Metall-Werke B.V. & Co KG Wiesbaden/Schierstein Goetze AG, Burscheid Grau-Bremse, Heidelberg Gutmann Messtechnik GmbH, Ihringen Hazet-Werk, Hermann Zerver, Remscheid HAMEG GmbH, Frankfurt/Main Hella KG, Hueck & Co, Lippstadt Hengst Filterwerke, Nienkamp Fritz Hintermayr, Bing-Vergaser-Fabrik Nrnberg HITACHI Sales Europa GmbH Dsseldorf HONDA DEUTSCHLAND GMBH Offenbach/Main Hunger Maschinenfabrik GmbH Mnchen und Kaufering IBM Deutschland, Bblingen IVECO-Magirus AG, Neu-Ulm ITT Automotive (ATE, VDO, MOTO-METER, SWF , KONI, Kienzle) Frankfurt/Main IXION Maschinenfabrik Otto Hfner GmbH & Co Hamburg-Wandsbeck Jurid-Werke, Essen Kawasaki-Motoren GmbH, Friedrichsdorf Knecht Filterwerke GmbH, Stuttgart Knorr-Bremse GmbH, Mnchen Kolbenschmidt AG, Neckarsulm KS Gleitlager GmbH, St. Leon-Rot KTM Sportmotorcycles AG Mattighofen/sterreich Khnle, Kopp und Kausch AG Frankenthal/Pfalz Lemmerz-Werke, Knigswinter LuK GmbH, Bhl/Baden MAHLE GmbH, Stuttgart Mannesmann Sachs AG, Schweinfurt Mann und Hummel, Filterwerke Ludwigsburg MAN Maschinenfabrik Augsburg-Nrnberg AG Mnchen Mazda Motors Deutschland GmbH Leverkusen MCC Mikro Compact Car GmbH Bblingen Messer-Griesheim GmbH Frankfurt/Main Metzeler Reifen GmbH Mnchen Michelin Reifenwerke KGaA Karlsruhe Microsoft GmbH, Unterschleiheim Mitsubishi Electric Europe B.V. Ratingen Mitsubishi MMC, Trebur MOBIL OIL AG, Hamburg NGK/NTK, Ratingen Adam Opel AG, Rsselsheim OSRAM AG, Mnchen OMV AG, Wien Peugeot Deutschland GmbH Saarbrcken Pierburg GmbH, Neuss Pirelli AG, Hchst im Odenwald Dr. Ing. h.c. F. Porsche AG Stuttgart-Zuffenhausen Renault Nissan Deutschland AG Brhl Samsung Electronics GmbH, Kln SATA Farbspritztechnik GmbH & Co Kornwestheim SCANIA Deutschland GmbH Koblenz SEKURIT SAINT-GOBAIN Deutschland GmbH, Aachen Siemens AG, Mnchen SKF Kugellagerfabriken GmbH Schweinfurt SOLO Kleinmotoren GmbH Maichingen Stahlwille E. Wille Wuppertal Steyr-Daimler-Puch AG Graz/sterreich Subaru Deutschland GmbH Friedberg SUN Elektrik Deutschland Mettmann Suzuki GmbH Oberschleiheim/Heppenheim Technolit GmbH, Grolder Telma Retarder Deutschland GmbH Ludwigsburg Temic Elektronik, Nrnberg TOYOTA Deutschland GmbH, Kln VARTA Autobatterien GmbH Hannover Vereinigte Motor-Verlage GmbH & Co KG Stuttgart ViewSonic Central Europe, Willich Voith GmbH & Co KG, Heidenheim Volkswagen AG, Wolfsburg Volvo Deutschland GmbH, Brhl Wabco Westinghouse GmbH Hannover Webasto GmbH, Stockdorf Yamaha Motor Deutschland GmbH Neuss ZF Getriebe GmbH, Saarbrcken ZF Sachs AG, Schweinfurt ZF Zahnradfabrik Friedrichshafen AG Friedrichshafen/Schwbisch Gmnd

Table of contents

7
3.2.3 Customer complaints and remedial action claims . . . . . . . . . . . . . . . . 3.3 Personnel leadership . . . . . . . . . . . . . . . . . 3.4 Staff conduct . . . . . . . . . . . . . . . . . . . . . . . . 3.5 Teamwork . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 Order processing . . . . . . . . . . . . . . . . . . . . 3.7 Data processing in a car dealership . . . . . 3.8 Quality management in automotive service operations . . . . . . . . . . . . . . . . . . . . 4 4.1 4.2 4.3 Basics of information technology

Table of contents
Abbreviations 4, 5

Contributing companies . . . . . . . . . . . . . . . . . . . . . 6 1 1.1 1.2 1.3 1.4 1.4.1 1.4.2 1.4.3 1.4.4 1.4.5 1.5 1.6 1.6.1 1.6.2 1.6.3 1.6.4 1.6.5 1.6.6 1.7 1.7 .1 1.7 .2 1.7 .3 1.7 .4 1.7 .5 1.7 .6 1.7 .7 2 2.1 2.1.1 2.1.2 2.1.3 2.1.4 2.2 2.2.1 2.2.2 2.2.3 2.2.4 Motor vehicle Evolution of the motor vehicle . . . . . . . . . Motor vehicle classifications . . . . . . . . . . . Design of the motor vehicle . . . . . . . . . . . The motor vehicle as technical system . . Technical systems . . . . . . . . . . . . . . . . . . . . Motor vehicle system . . . . . . . . . . . . . . . . . Subsystems in the motor vehicle . . . . . . . Classifications of technical systems and subsystems by processing mode . . . Using technical systems . . . . . . . . . . . . . . . Service and maintenance . . . . . . . . . . . . . Filter, body and maintenance . . . . . . . . . . Air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . Oil filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic filters . . . . . . . . . . . . . . . . . . . . . . Interior filters . . . . . . . . . . . . . . . . . . . . . . . . Service and maintenance . . . . . . . . . . . . . Fluids and lubricants, auxiliary materials Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuels for spark-ignition engines . . . . . . . . Diesel fuels . . . . . . . . . . . . . . . . . . . . . . . . . . Oils and lubricants . . . . . . . . . . . . . . . . . . . Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . Brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . Environmental protection, occupational safety Environmental protection in automotive service operations . . . . . . . . . Environmental pollution . . . . . . . . . . . . . . Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . End-of-life vehicle disposal . . . . . . . . . . . . Recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . Occupational safety and accident prevention . . . . . . . . . . . . . . . . . . Safety signs . . . . . . . . . . . . . . . . . . . . . . . . . Accident causes . . . . . . . . . . . . . . . . . . . . . Safety measures . . . . . . . . . . . . . . . . . . . . . Safe handling of hazardous materials . . . . . . . . . . . . . . . . . . . . . . . . . . . Business organisation, communications Basics of business organisation . . . . . . . . Organisation of a car dealership . . . . . . . . Aspects of the business organisation . . . Communication . . . . . . . . . . . . . . . . . . . . . Basics of communication . . . . . . . . . . . . . . Consultations . . . . . . . . . . . . . . . . . . . . . . . . 11 11 12 12 13 13 13 15 16 17 18 20 20 21 22 22 22 22 23 23 25 26 27 32 33 33

50 50 51 52 53 56 59 63 63 63 64 64 65 66 67 68 69

Hardware and software . . . . . . . . . . . . . . . IPO concept . . . . . . . . . . . . . . . . . . . . . . . . . Internal data representation within the computer . . . . . . . . . . . . . . . . . . 4.4 Numeric systems . . . . . . . . . . . . . . . . . . . . 4.5 Structure of the computer system . . . . . . 4.6 Data communications . . . . . . . . . . . . . . . . 4.6.1 Data transfer . . . . . . . . . . . . . . . . . . . . . . . . 4.6.2 Remote data transmission . . . . . . . . . . . . . 4.7 Data integrity assurance and data protection . . . . . . . . . . . . . . . . . . . 5 5.1 5.1.1 5.1.2 5.2 5.2.1 5.2.2 5.2.3 5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 6 6.1 6.2 6.3 6.4 6.5 7 Open- and closed-loop control technology Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Open-loop control . . . . . . . . . . . . . . . . . . . . Closed-loop control . . . . . . . . . . . . . . . . . . Structure and components of the open-loop control system . . . . . . . . . . . . . Signalling devices, signal types and signal conversion . . . . . . . . . . . . . . . . . . . . Control elements . . . . . . . . . . . . . . . . . . . . . Actuators and drive elements . . . . . . . . . . Control types . . . . . . . . . . . . . . . . . . . . . . . . Mechanical control systems . . . . . . . . . . . Pneumatic and hydraulic control systems . . . . . . . . . . . . . . . . . . . . . . Electric control systems . . . . . . . . . . . . . . . Gate-logic control systems . . . . . . . . . . . . Process-sequence control . . . . . . . . . . . . . Test technology Basics of linear test technology . . . . . . . . Measuring instruments . . . . . . . . . . . . . . . Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tolerances and fits . . . . . . . . . . . . . . . . . . . Scribing . . . . . . . . . . . . . . . . . . . . . . . . . . . . Production engineering

70 70 70 71 73 73 75 76 77 77 78 83 85 86 87 87 89 94 95 98 99

34 34 34 34 37 38 40 40 41 41 42 43 43 43 44 46 46 47

3 3.1 3.1.1 3.1.2 3.2 3.2.1 3.2.2

Categorisation of manufacturing processes . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 7 .2 Creative forming . . . . . . . . . . . . . . . . . . . . 101 7 .3 Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 7 .3.1 Forming under bending conditions . . . . 105 7 .3.2 Forming under combination of tensile and compressive conditions . . . . . . . . . . 106

7 .1

8
7 .3.3 7 .3.4 7 .3.5 7 .4 7 .4.1 7 .4.2 7 .4.3 Forming under compressive conditions Straightening . . . . . . . . . . . . . . . . . . . . . . Sheet-metal working processes . . . . . . . Separating by cutting . . . . . . . . . . . . . . . Basics of cutting-shaping . . . . . . . . . . . . Cutting-shaping by hand . . . . . . . . . . . . . Basics of cutting-shaping with machine tools . . . . . . . . . . . . . . . . . 7 .5 Separating by dividing . . . . . . . . . . . . . . 7 .5.1 Cropping . . . . . . . . . . . . . . . . . . . . . . . . . . 7 .5.2 Wedge-action cutting . . . . . . . . . . . . . . . 7 .6 Joining . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 .6.1 Categorisation of connections . . . . . . . . 7 .6.2 Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 .6.3 Screwed joints . . . . . . . . . . . . . . . . . . . . . 7 .6.4 Pin connections . . . . . . . . . . . . . . . . . . . . 7 .6.5 Riveted joints . . . . . . . . . . . . . . . . . . . . . . 7 .6.6 Clinching . . . . . . . . . . . . . . . . . . . . . . . . . . 7 .6.7 Shaft-hub connections . . . . . . . . . . . . . . 7 .6.8 Press-fit joints . . . . . . . . . . . . . . . . . . . . . . 7 .6.9 Snap-in connections . . . . . . . . . . . . . . . . 7 .6.10 Soldering . . . . . . . . . . . . . . . . . . . . . . . . . 7 .6.11 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 .6.12 Gluing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 .7 Coating . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 8.1 8.2 8.3 8.4 8.4.1 8.4.2 8.4.3 8.4.4 8.4.5 8.4.6 8.4.7 8.5 8.6 8.7 9 9.1 9.2 9.3 9.4 10 10.1 10.2 10.3 10.4 Material science Properties of materials . . . . . . . . . . . . . . Categorisation of materials . . . . . . . . . . Structure of metallic materials . . . . . . . . Ferrous products . . . . . . . . . . . . . . . . . . . Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cast-iron materials . . . . . . . . . . . . . . . . . Influence of additives on ferrous products . . . . . . . . . . . . . . . . . . . Designation of ferrous products . . . . . . Categorisation and application of steels . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercial forms of steel . . . . . . . . . . . Heat treatment of ferrous products . . . . . . . . . . . . . . . . . . . Non-ferrous metals . . . . . . . . . . . . . . . . . Plastics . . . . . . . . . . . . . . . . . . . . . . . . . . . Composite materials . . . . . . . . . . . . . . . . Friction, lubrication, bearings, seals Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Design and operating principle of a four-stroke engine Spark-ignition engine . . . . . . . . . . . . . . . Diesel engine . . . . . . . . . . . . . . . . . . . . . . General physical and chemical principles . . . . . . . . . . . . . . . . . Pressure-volume diagram (p -V diagram) . . . . . . . . . . . . . . . . . . . . . 107 109 109 113 113 113 120 129 129 130 131 131 132 133 138 139 140 141 142 142 143 144 151 152 154 154 158 159 161 161 161 163 163 165 167 167 171 173 176 177 177 178 179 182 10.5 10.6 10.7 10.8

Table of contents Timing diagram . . . . . . . . . . . . . . . . . . . Cylinder numbering, firing orders . . . Engine-performance curves . . . . . . . . Stroke-to-bore ratio, power output per litre, weight-to-power ratio . . . . . . Mechanical engine components 192 192 194 195 196

11 11.1 11.1.1 11.1.2 11.1.3 11.1.4 11.1.5 11.1.6 11.2 11.2.1 11.2.2 11.2.3 11.2.4 11.2.5 11.2.6 11.3 11.4 11.5 11.6 11.7 12 12.1

Cylinder, cylinder head . . . . . . . . . . . . . 196 Functions, stresses and strains . . . . . . 196 Cylinder types . . . . . . . . . . . . . . . . . . . . .196 Cylinder head . . . . . . . . . . . . . . . . . . . . . 198 Cylinder-head gasket . . . . . . . . . . . . . . 199 Crankcase . . . . . . . . . . . . . . . . . . . . . . . . 200 Engine suspension . . . . . . . . . . . . . . . . 200 Engine-cooling systems . . . . . . . . . . . . 204 Types of cooling . . . . . . . . . . . . . . . . . . 204 Air cooling . . . . . . . . . . . . . . . . . . . . . . . 205 Liquid cooling . . . . . . . . . . . . . . . . . . . . 205 Pump-cooling components . . . . . . . . . 206 Map-controlled cooling systems . . . . . 211 Map-cooling components . . . . . . . . . . 211 Crankshaft drive . . . . . . . . . . . . . . . . . . 213 Dual-mass flywheel . . . . . . . . . . . . . . . 225 Engine lubricating systems . . . . . . . . . 226 Engine timing gear . . . . . . . . . . . . . . . . 232 Charge optimisation . . . . . . . . . . . . . . . 238 Mixture formation 247

183 183 185 185 190

Fuel-supply systems in spark-ignition engines . . . . . . . . . . . . . .247 12.2 Mixture formation in spark-ignition engines . . . . . . . . . . . . . . . . . . . . . . . . . . 252 12.3 Carburettor . . . . . . . . . . . . . . . . . . . . . . . 255 12.4 Petrol injection . . . . . . . . . . . . . . . . . . . . 257 12.4.1 Basic principles of petrol injection . . . 257 12.4.2 Design and function of electronic petrol injection . . . . . . . . . . 259 12.4.3 Operating-data acquisition . . . . . . . . . 260 12.4.4 Single-point injection . . . . . . . . . . . . . . 266 12.4.5 LH-Motronic . . . . . . . . . . . . . . . . . . . . . . 270 12.4.6 ME-Motronic . . . . . . . . . . . . . . . . . . . . . 276 12.4.7 MED-Motronic . . . . . . . . . . . . . . . . . . . . 280 12.4.8 KE-Jetronic . . . . . . . . . . . . . . . . . . . . . . . 286 12.5 Mixture formation in diesel engines . 288 12.5.1 Combustion sequence in a diesel engine . . . . . . . . . . . . . . . . . . . . . 288 12.5.2 Failures in combustion sequence . . . . 288 12.5.3 Comparison of injection processes . . . 289 12.5.4 Inlet-passage control . . . . . . . . . . . . . . 290 12.5.5 Start-assist systems . . . . . . . . . . . . . . . 290 12.5.6 Nozzle-holder assembly . . . . . . . . . . . . 292 12.5.7 Injection systems for passenger-car diesel engines . . . . . . . 294 12.5.7 .1 Axial-piston distributor pump with mechanical control . . . . . . . . . . . . 294 12.5.7 .2 Electronic diesel control (EDC) . . . . . . 298 12.5.7 .3 Electronically controlled axial-piston distributor injection pump (VE-EDC) . 299

Table of contents 12.5.7 .4 Radial-piston distributor injection pump (VP44) . . . . . . . . . . . . . 300 12.5.7 .5 Unit-injector system . . . . . . . . . . . . . . . 302 12.5.7 .6 Common-rail system . . . . . . . . . . . . . . 304 16.5.5 Continuously variable automatic transmission with pushbelt or link chain . . . . . . . . . . . . . . . . . . . . . . . . 374 Propeller shafts, drive shafts, joints . 376 Final drive . . . . . . . . . . . . . . . . . . . . . . . 379 Differential . . . . . . . . . . . . . . . . . . . . . . . 382 Differential locks . . . . . . . . . . . . . . . . . . 383 All-wheel drive . . . . . . . . . . . . . . . . . . . 387 Vehicle body Vehicle body/bodywork . . . . . . . . . . . Separate construction . . . . . . . . . . . . . Partially self-supporting construction Self-supporting construction . . . . . . . Materials in body making . . . . . . . . . . Safety in vehicle manufacturing . . . . Damage assessment and measurement . . . . . . . . . . . . . . . . . . . . Accident repairs to selfsupporting bodies . . . . . . . . . . . . . . . . Corrosion protection on motor vehicles . . . . . . . . . . . . . . . . . . . Vehicle paintwork . . . . . . . . . . . . . . . . . Chassis 390 390 390 390 390 391 393 400 404 409 410 414

13 13.1 13.2 13.2.1 13.2.2 13.2.3 13.2.4 13.3 13.3.1 13.3.2

Pollutant reduction Exhaust system . . . . . . . . . . . . . . . . . . . Pollutant reduction in a spark-ignition engine . . . . . . . . . . . . . . Exhaust-gas composition . . . . . . . . . . Procedures for reducing pollutants . . Diagnosis and maintenance (EI) . . . . . European On-Board Diagnosis (EOBD) . . . . . . . . . . . . . . . . . . . . . . . . . . Pollutant reduction in a diesel engine . . . . . . . . . . . . . . . . . . . . . Exhaust-gas composition . . . . . . . . . . Procedures for reducing pollutants . .

309 309 312 312 314 319 320 324 324 324

16.6 16.7 16.8 16.9 16.10 17 17 .1 17 .1.1 17 .1.2 17 .1.3 17 .1.4 17 .1.5 17 .1.6 17 .1.7 17 .2

14 14.1 14.2

Two-stroke spark-ignition engine, rotary engine

326

17 .3 18 18.1 18.2 18.3 18.4 18.5 18.6 18.6.1 18.6.2 18.6.3 18.6.4 18.7 18.8 18.8.1 18.8.2 18.8.3 18.8.4 18.8.5 18.9 18.9.1 18.9.2 18.9.3 18.9.4 18.10 18.10.1 18.10.2 18.10.3 18.10.4 18.10.5 18.10.6 18.10.7 18.10.8

Two-stroke engine . . . . . . . . . . . . . . . . 326 Rotary engine . . . . . . . . . . . . . . . . . . . . 333

15 15.1 15.2 15.3 15.4 15.5 15.6

Alternative drive concepts Alternative sources of energy . . . . . . . Natural-gas drives . . . . . . . . . . . . . . . . . Hybrid drives . . . . . . . . . . . . . . . . . . . . . Drives with fuel cells . . . . . . . . . . . . . . . Internal-combustion engines with hydrogen mode . . . . . . . . . . . . . . . . . . . Internal-combustion engines with vegetable-oil mode . . . . . . . . . . . . . . . . Drivetrain Types of drive . . . . . . . . . . . . . . . . . . . . Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . Friction clutch . . . . . . . . . . . . . . . . . . . . Double-plate clutch . . . . . . . . . . . . . . . . Twin clutch . . . . . . . . . . . . . . . . . . . . . . . Multi-plate clutch . . . . . . . . . . . . . . . . . Magnetic-particle clutch . . . . . . . . . . . . Automatic clutch system (ACS) . . . . . . Function checks on friction clutches . . . . . . . . . . . . . . . . . . . . . . . . . Variable-speed gearbox . . . . . . . . . . . . Manual variable-speed gearbox . . . . . Automatic gearbox . . . . . . . . . . . . . . . . Automated manual gearbox . . . . . . . . Stepped automatic gearbox with hydrodynamic converter . . . . . . . Electrohydraulic transmission control . . . . . . . . . . . . . . . . . . . . . . . . . . Adaptive transmission control . . . . . .

335 335 335 337 339 339 339 340 340 342 342 348 348 349 349 350 351 352 353 358 358 360 366 373

16 16.1 16.2 16.2.1 16.2.2 16.2.3 16.2.4 16.2.5 16.2.6 16.2.7 16.3 16.4 16.5 16.5.1 16.5.2 16.5.3 16.5.4

Driving dynamics . . . . . . . . . . . . . . . . . 414 Basic principles of steering . . . . . . . . . 416 Wheel adjustments . . . . . . . . . . . . . . . . 417 Computerised axle alignment . . . . . . . 420 Steering gear . . . . . . . . . . . . . . . . . . . . 421 Steering systems . . . . . . . . . . . . . . . . . 421 Hydraulic rack-and-pinion steering . . 421 Electro-hydraulic power steering Servotronic . . . . . . . . . . . . . . . . . . . . . . 422 Electric power steering Servolectric . . . . . . . . . . . . . . . . . . . . . . 423 Active steering . . . . . . . . . . . . . . . . . . . 423 Wheel suspension . . . . . . . . . . . . . . . . 424 Suspension . . . . . . . . . . . . . . . . . . . . . . 428 Function of the suspension . . . . . . . . 428 Operating principle of the suspension 428 Types of springs . . . . . . . . . . . . . . . . . . 430 Vibration dampers . . . . . . . . . . . . . . . . 434 Active Body Control (ABC) . . . . . . . . . 438 Wheels and tyres . . . . . . . . . . . . . . . . . 441 Wheels . . . . . . . . . . . . . . . . . . . . . . . . . 441 Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . 442 Run-flat systems . . . . . . . . . . . . . . . . . 448 Compressed-air monitoring systems 449 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . 451 Braking . . . . . . . . . . . . . . . . . . . . . . . . . 453 Hydraulic brake . . . . . . . . . . . . . . . . . . 453 Brake-circuit configuration . . . . . . . . . 454 Master cylinder . . . . . . . . . . . . . . . . . . 454 Drum brake . . . . . . . . . . . . . . . . . . . . . . 456 Disc brake . . . . . . . . . . . . . . . . . . . . . . . 458 Brake pads . . . . . . . . . . . . . . . . . . . . . . 460 Diagnosis and maintenance of the hydraulic brake system . . . . . . . . . . . . 461

10
18.10.9 18.10.10 18.10.11 18.10.12 18.10.13 18.10.14 18.10.15 18.10.16 18.10.17 19 19.1 19.1.1 19.1.2 19.1.3 19.1.4 19.1.5 19.1.6 19.1.7 Power-assisted brake . . . . . . . . . . . . . Braking-force distribution . . . . . . . . . . Mechanically operated brake . . . . . . . Basics of the electronic chassis control systems . . . . . . . . . . . . . . . . . . Antilock-braking system (ABS) . . . . . Brake assistant (BAS) . . . . . . . . . . . . . Traction-Control System (TCS) . . . . . Vehicle Dynamics Control ESP , DSC . . . . . . . . . . . . . . . . . . . . . . Sensotronic Brake Control (SBC) . . . . Electrical engineering 463 464 465 466 467 471 471 473 474 476 476 477 477 479 481 481 482 483 491 492 494 496 497 497 499 500 500 502 512 512 522 523 525 532 539 547 554 571 575 580 582 592 20.2.3 20.3 20.3.1 20.3.2 20.3.3 20.3.4 20.3.5 20.4 20.4.1 20.4.2 20.4.3 20.5 20.5.1 20.5.2 20.5.3 21 21.1 21.2 21.3 21.4 21.5 21.6 21.7 21.8 21.9 21.10 21.11 21.12 21.13 21.14 22 22.1 22.2 22.3 22.3.1 22.3.2 22.3.3 22.3.4 22.3.5 22.4 22.5 22.5.1 22.5.2 22.5.3 22.6

Table of contents Alarm system . . . . . . . . . . . . . . . . . . . . . 607 Comfort and convenience systems . . . 609 Electric power windows . . . . . . . . . . . . 609 Convertible roof actuation . . . . . . . . . . . 611 Electric power seats . . . . . . . . . . . . . . . . 612 Electronic windscreen wiper . . . . . . . . 612 Electric adjustable exterior mirrors . . 613 Driver assistance systems . . . . . . . . . . 614 Cruise control system . . . . . . . . . . . . . . 614 Adaptive Cruise Control (ACC) . . . . . . 614 Parking assistance system . . . . . . . . . . 615 Infotainment system . . . . . . . . . . . . . . . 615 Operating and travel data display . . . . 615 Navigation systems . . . . . . . . . . . . . . . . 615 Mobile phones . . . . . . . . . . . . . . . . . . . 617 Motorcycle technology Types of motorcycle . . . . . . . . . . . . . . . Motorcycle engines . . . . . . . . . . . . . . . Exhaust system . . . . . . . . . . . . . . . . . . . Mixture formation . . . . . . . . . . . . . . . . . Engine cooling . . . . . . . . . . . . . . . . . . . Engine lubrication . . . . . . . . . . . . . . . . . Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive train . . . . . . . . . . . . . . . . . . . . . . . Electrical system . . . . . . . . . . . . . . . . . . Dynamics of vehicular operation . . . . Motorcycle frames . . . . . . . . . . . . . . . . Wheel location, suspension and damping . . . . . . . . . . . . . . . . . . . . . . . . . Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheels, tyres . . . . . . . . . . . . . . . . . . . . . Commercial vehicle technology 618 618 621 621 622 623 623 624 625 627 630 631 632 634 636 639

General of the electrical engineering Voltage . . . . . . . . . . . . . . . . . . . . . . . . . Electrical current . . . . . . . . . . . . . . . . . Electrical resistance . . . . . . . . . . . . . . . Ohm's law . . . . . . . . . . . . . . . . . . . . . . . Power, work, efficiency . . . . . . . . . . . . Resistor circuits . . . . . . . . . . . . . . . . . . Measurements in electrical circuits . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1.8 Properties of electrical current . . . . . . 19.1.9 Protection against the hazards of electrical current . . . . . . . . . . . . . . . . . 19.1.10 Voltage generation . . . . . . . . . . . . . . . 19.1.11 Alternating voltage and alternating current . . . . . . . . . . . . . . . . 19.1.12 Three-phase AC voltage and three-phase current . . . . . . . . . . . . . . . 19.1.13 Magnetism . . . . . . . . . . . . . . . . . . . . . . 19.1.14 Self-induction . . . . . . . . . . . . . . . . . . . . 19.1.15 Capacitor . . . . . . . . . . . . . . . . . . . . . . . 19.1.16 Electrochemistry . . . . . . . . . . . . . . . . . 19.1.17 Electronic components . . . . . . . . . . . . 19.2 Applications of electrical engineering 19.2.1 Circuit diagrams . . . . . . . . . . . . . . . . . . 19.2.2 Signal transmitters . . . . . . . . . . . . . . . 19.2.3 Relays . . . . . . . . . . . . . . . . . . . . . . . . . . 19.2.4 Lighting in the motor vehicle . . . . . . . 19.2.5 Power supply and vehicle electrical system . . . . . . . . . . . 19.2.6 Alternator . . . . . . . . . . . . . . . . . . . . . . . 19.2.7 Electric motors . . . . . . . . . . . . . . . . . . . 19.2.8 Ignition systems . . . . . . . . . . . . . . . . . . 19.2.9 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . 19.2.10 High-frequency technology . . . . . . . . 19.2.11 Electromagnetic compatibility . . . . . . 19.2.12 Data transmission in motor vehicles 19.2.13 Measuring, testing, diagnosis . . . . . . 20 20.1 20.2 20.2.1 20.2.2

Comfort and convenience technology 596 Ventilation, heating, surrounding air, air conditioning . . . . . . . . . . . . . . . . . . 596 Antitheft systems . . . . . . . . . . . . . . . . . 603 Central locking system . . . . . . . . . . . . 603 Vehicle immobiliser . . . . . . . . . . . . . . . 605

Categorisation . . . . . . . . . . . . . . . . . . . . 639 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . 640 Injection systems for CV diesel engines . . . . . . . . . . . . . . . . . 640 Injection system with inline injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 641 Control sleeve inline fuel-injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 646 Unit pump systems . . . . . . . . . . . . . . . 646 Auxiliary starting assistance systems 648 Reduction of harmful emissions on CV- diesel engines . . . . . . . . . . . . . . 649 Drive train . . . . . . . . . . . . . . . . . . . . . . . 651 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . 654 Suspension . . . . . . . . . . . . . . . . . . . . . . 654 Wheels and tyres . . . . . . . . . . . . . . . . . 657 Air-brake system (brake system with external power source) . . . . . . . . 658 Starting systems for commercial vehicles . . . . . . . . . . . . . . . . . . . . . . . . . 670 Keyword index 674

23

11

1 Motor vehicle
1.1 Evolution of the motor vehicle
1860 The Frenchman Lenoir constructs the first fully operational internal-combustion engine; this powerplant relies on city gas as its fuel source. Thermal efficiency is in the 3 % range. Otto and Langen display an improved internalcombustion engine at the Paris International Exhibition. Its thermal efficiency is approximately 9 %.
Fig. 3: Ford Model T and VW Beetle

1867

1897 1899 1913

Fig. 1: Daimler motorcycle and Benz motor carriage

1876

Otto builds the first gas-powered engine to utilise the four-stroke compression cycle. At virtually the same time Clerk constructs the first gas-powered two-stroke engine in England. Daimler and Maybach develop the first highspeed four-cycle petrol engine using a hot-tube ignition system. The first self-propelled motorcycle from Daimler. First self-propelled three-wheeler from Benz (patented in 1886) (Fig. 1). First four-wheeled motor carriage with petrol engine from Daimler (Fig. 2). Bosch invents the magneto ignition. Dunlop in England produces the first pneumatic tyres. Maybach invents the spray-nozzle carburettor. Diesel patents his design for a heavy oil-burning powerplant employing the self-ignition concept. MAN presents the first workable diesel engine.

1916 1923 1936 1938 1949 1950

1883

1885

1886 1887 1889 1893 1893

1954

First Electromobile from Lohner-Porsche (Fig. 2). Fiat Automobile Factory founded in Turin. Ford introduces the production line to automotive manufacturing. Production of the Tin Lizzy (Model T, Fig. 3). By 1925, 9,109 were leaving the production line each day. The Bavarian Motor Works are founded. First motor lorry powered by a diesel engine produced by Benz-MAN (Fig. 4). Daimler-Benz inaugurates series-production of passenger cars propelled by diesel engines. The VW Works are founded in Wolfsburg. First low-profile tyre and first steel-belted radial tyre produced by Michelin. First gas-turbine propulsion unit for automotive application makes its debut at Rover in England. NSU-Wankel constructs the rotary engine (Fig. 4).

Benz-MAN lorry, 5 K 3 1st diesel lorry, 1923

NSU Spider with Wankel engine, 1963, 500 cc, 37 kW at 6,000 rpm, 153 km/h

Fig. 4: Diesel-engined lorry Passenger car with Wankel rotary engine

1897

1966 1970 1978 1984 1985

Fig. 2: Daimler motor carriage and the first Electromobile

1997

Electronic fuel injection (D-Jetronic) for standard production vehicles produced by Bosch. Seatbelts for driver and front passengers. Initial application of the ABS Antilock Braking System in passenger cars. Debut of the airbag and seatbelt tensioning system. Advent of a catalytic converter designed for operation in conjunction with closed-loop mixture control, intended for use with unleaded fuel. Electronic suspension control systems.

12

1 Motor vehicle

1.2 Motor vehicle classifications

Roadgoing or highway vehicles is a category comprising all vehicles designed for road use, as opposed to operation on tracks or rails (Fig. 1). The basic division is into two classes, motor vehicles and trailers. Motor vehicles always possess an integral mechanical propulsion system.
Roadgoing vehicles Motor vehicles Trailer vehicles

Commercial vehicles. These are designed to transport people and cargo and for pulling trailers. Passenger cars are not classified as commercial vehicles.

Single-track vehicles
Motorcycles are single-track vehicles with 2 wheels. A sidecar may be attached to the motorcycle, which remains classified as such provided that the tare weight of the combination does not exceed 400 kg. A motorcycle can also be employed to pull a trailer. Single-track vehicles include Motorcycles. These are equipped with permanent, fixed-location components (fuel tank, engine) located adjacent to the knees as well as footrests. Motor scooters. Because the operator's feet rest on a floor panel, there are no fixed components at knee level on these vehicles. Bicycles with auxiliary power plants. These vehicles exhibit the same salient features as bicycles, such as pedals (mopeds, motor bicycle, etc.).

Vehicle combination Motor vehicles Passenger cars Commercial vehicles Motor buses Trucks Tractors Motorcycles Centre-axle trailers Semitrailers Drawbar trailers

1.3 Design of the motor vehicle

The motor vehicle consists of component assemblies and their individual components. The layout of the individual assemblies and their relative positions is not governed by invariable standards. Thus, for example, the engine may be designed as an independent assembly, or it may be integrated as a subassembly within a larger powertrain unit. One of the options described in this book is to divide the vehicle into 5 main assembly groups: engine, drivetrain, chassis, vehicle body and electrical system. The relationships between the assemblies and their constituent components are illustrated in Fig. 2.

Fig. 1: Overview of roadgoing vehicles

Dual-track vehicles
Motor vehicles with more than two wheels can be found in dual-track and multiple-track versions. These include: Passenger cars. These are primarily intended for use in transporting people, as well as their luggage and other small cargo. They can also be used to pull trailers. The number of seats, including that of the driver, is restricted to nine.
Motor vehicle Engine
Internal-combustion engine Reciprocatingpiston engine, petrol/diesel engine Cylinders Crankshaft drive Engine management Rotary engine Wankel engine Housing Rotor Eccentric shaft Power supply Electric motor Stator Rotor Control electronics

Drivetrain
Clutch

Vehicle body
Frame

Suspension
Wheel suspension Suspension Damping Steering Brakes

Electrical system
Power generators Electrical loads/ consumers

Variable-ratio gearbox Hydrodynamic torque converter Automatic gearbox Propeller shaft Final-drive unit Differential

Body

Wheels Tyres

Mixture preparation Cooling Lubrication Exhaust system

Fig. 2: Design of the motor vehicle

1 Motor vehicle

13

1.4 The motor vehicle as technical system

Safety equipment: e.g. airbag; seat-belt tensioner Support and bearing unit: e.g. body

Open and closed-loop control units: e.g. antilock braking system

Transmission unit: e.g. suspension

Transmission unit: e.g. drivetrain

Drive unit: engine

Transmission unit: e.g. suspension

Fig. 1:The motor vehicle as a system with operational units

1.4.1 Technical systems

Every machine forms a complete technical system. Characteristics of technical systems: Defined system borders delineate their limits relative to the surrounding environment. They possess input and output channels. The salient factor defining system operation is the total function, and not the individual function, which is discharged internally, within the system. A rectangle is employed in graphic portrayals of technical systems (Fig. 2).
Air Motor vehicle Kinetic energy Exhaust gas Fuel System limit Heat

The rectangle symbolises the system limit (hypothetical boundary) that delineates the border separating each individual technical system from other systems and/or the surrounding environment. The distinctive, defining features of the individual system include: Input (input variables or parameters) entering from beyond the system limits Processing within the system limits Output (output variables or parameters) issued and relayed to destinations lying outside the limits of the system (IPO concept)

1.4.2 Motor vehicle system

The motor vehicle is a complex technical system in which various subsystems operate in harmony to discharge a defined function. The function of the passenger car is to transport people, while the function of the motor lorry, or truck, is to carry cargo.

Fig. 2: Basic system portrait using a motor vehicle as an example

Operational units within the motor vehicle

Systems designed to support operational processes are combined in operational units (Fig. 1). Familiarity with the processes performed in operational units such as the engine, drivetrain, etc. can enhance our under-

Input and output variables are represented by arrows. The number of arrows varies according to the number of input and output variables.

14

1 Motor vehicle standing of the complete system represented by the motor vehicle in its implications for maintenance, diagnosis and repair. The concept is suitable for application with any technical system. Among the operational units that comprise the motor vehicle are the: Power unit Power-transfer assembly Support and load-bearing structure Electro-hydraulic systems (open and closed-loop systems, etc.) Electrical and electronic systems (such as safety devices) Each operational unit acts as a subsystem by assuming a specific function. Operational unit: Vehicle structure as support structure, exemplified by body

Subfunction: Support function, support for all subsystems Operational unit: Electro-hydraulic systems (open and closed-loop control systems, such as ABS, ESP , etc.)

Operational unit: Power unit engine

Steering-wheelangle sensor

2 pressure sensors on tandem master cylinder

Yaw-rate sensor

Wheel-speed sensor

GMR

Hydraulic control unit with integrated controller

ABS

ESP

Engine management

V AB

T C S E S P
ABS: + ABV: + TCS: + GMR: = ESP:
Lateral-acceleration sensor

Subfunction: Provides energy for propulsion purposes Operational unit: Power-transfer assembly, such as drivetrain

Antilock Braking System Automatic regulation of braking-force distribution Traction Control System Automatic regulation of yaw moment Electronic Stability Program

Subfunction: Active occupant protection, improvements in dynamic response Operational unit: Electr., electron. systems (safety and security devices, such as airbags, seatbelt tensioners)
Seat belt

Driver side airbag

Subfunction: Relays mechanical energy from the power unit to the drive wheels

ECU for airbag

Seat with integrated side airbag

Crash sensor, driver side airbag

Subfunction: Passive protection for vehicle occupants

1 Motor vehicle

15

1
Complete system, motor vehicle

Operational units

Power unit: engine

Power-transfer assembly: drivetrain

Suspension

Support and loadbearing structure: vehicle body

Electrical system

Subsystems

e.g.: Engine management Crankshaft assembly Engine lubrication Engine cooling Exhaust system Air systems

e.g.: Clutch system Gearbox Propeller shafts Final-drive unit

e.g.: Suspension Brakes Wheels Tyres

e.g.: Body Side-impact protection Frame

e.g.: Lights Ignition Datatransmission systems Comfort and convenience systems

Fig. 1:The motor vehicle as composite system

Various subsystems must operate together for the motor vehicle to discharge its primary functions (Fig. 1). Reducing the scale of the system's limits shifts the focus to progressively smaller subsystems, ultimately leading to the level of the individual component.

1.4.3 Subsystems in the motor vehicle

Each subsystem is subject to the IPO concept (Fig. 3).
System limit

The motor vehicle as a complete system

Defining the limits of the system to coincide with those of the overall vehicle produces boundaries in which the system's limits border on environmental entities such as air and the road surface. On the input side, air and fuel are the only factors entering from beyond the system's limits, while exhaust gas joins kinetic and thermal energy outside this boundary on the output side (Fig. 2, Fig. 3).
Engine Clutch Axle drive Drive wheels

Gearbox Propeller shaft

Engine speed Engine torque Engine power

Gearbox

Output speed Output torque Output power

Input

Processing

Output

Fig. 3: Subsystem: Gearbox

Input
System limit

Output

Processing
Air + Fuel (chemically combined energy) Environment (air, road) Exhaust gas + Travelling motion (mechanical energy)

Motor vehicle system

Input. The factors operating on the input side of the gearbox are engine speed, engine torque and engine power. Processing. The crankshaft's rotation speed and the torque it transfers undergo a transformation process within the gearbox. Output. The elements exiting the subsystem on the output side include output-shaft speed, output torque and output power as well as heat. Efficiency level. The efficiency of the drivetrain is reduced by energy losses sustained within the gearbox.
The "gearbox" subsystem is connected to the drive wheels via other subsystems, such as the propeller shaft, final-drive unit, and half shafts.

Fig. 2: System: Motor vehicle

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1.4.4 Classifications of technical systems and subsystems by processing mode

Technical systems (Fig. 1) are classified according to the type of processing within overall systems: Material-processing systems such as the fuel-supply system Energy-processing systems such as the internalcombustion engine Information-processing systems such as the onboard computer, the steering system, etc.

Examples of material-processing systems within the motor vehicle: Lubrication system, in which the oil pump provides the motive power for material propulsion. Cooling system, in which the water pump transports a medium to support thermal transfer.

Energy-processing systems
Energy-processing systems transform energy from an external source from one form into another. This class embraces all manner of power-generation machines, including internal-combustion engines and electric motors, steam engines and gas power plants, as well as energy units such as heat pumps, photovoltaic systems and fuel cells. In the realm of energy conversion the operative distinction is between: Heat engines, such as spark-ignition and diesel engines, and gas turbines Hydraulically powered machines, such as water turbines Wind-energy devices, such as wind-powered generators Solar-energy converters, such as photovoltaic systems Fuel cells Within the internal-combustion engine, the fuel's chemical energy is initially converted into thermal energy before undergoing a second transformation to emerge as kinetic energy (Fig. 2).
Fuel/air mixture Chemical energy

Information processing

Material processing

Energy processing

Fig. 1: Systems classified according to processing mode

Material-processing systems
Material-processing systems modify materials in their geometrical configuration (reshaping) or transport them from one position to another (repositioning). Transport media and basic machinery are employed to convey substances and materials. Machine tools assume responsibility for shaping materials. To cite an example: in the material-transport process, a pump induces motion in a static fluid (gasoline in the fuel tank) in order to transport it to the fuel-injection system. A precondition for this processing operation is provision of electrical energy to the operational machinery, such as a fuel pump, that is responsible for the process. Overview of material-processing systems: Machines for reshaping include machine tools such as drills, mills and lathes as well as the equipment found in foundries and stamping works such as metal presses. Machines for repositioning include all conveyors, transporters and machines employed in the transport of solid materials (conveyor belts, fork lift trucks, trucks, passenger cars), liquids (pumps) and gases (fans, turbines).

Combustion Thermal energy Conrod force

Torque at crankshaft

Mechanical energy

Fig. 2: Energy processing in the spark-ignition engine

This process can generate additional substances and information. Because these are of secondary significance in the operation of the energy-processing machine, they are not usually primary objects of attention. The flow of substances and materials (entry of fuel and emission of exhaust gases) and the flow of information (fuel-air mixture, engine-speed control, steering, etc.) all assume the role of secondary functions. Energy-processing system. The primary focus is on converting chemical energy contained in fuel into kinetic energy to propel the vehicle, with the internal-combustion engine serving as the energy-processing system.

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Technical data Emergency service addresses

Information-processing systems
They monitor, process and relay information and data and support communications. Information-processing and relay systems, such as electronic control units (ECU), CAN bus controllers and diagnostic equipment (testers) assume vital significance in the maintenance of modern vehicles. Information. Knowledge concerning conditions and processes. Examples from within the vehicle include information on engine temperature, driving speed, load factor, etc. required to support vehicle operation. This information can be relayed from one electronic control unit to another. The data are registered in the form of signals. Signals. Signals are data portrayed in physical form. Within the motor vehicle, sensors generate signals to represent parameters such as rotational speed, temperature and throttle-valve position. Examples of information-processing systems in motor vehicles: Engine control unit. The engine-management ECU registers and processes an entire array of relevant data in order to adapt engine performance to provide ideal operation under any given conditions. On-board computer. Among its functions are to furnish the driver with information on average and current fuel consumption, estimated cruising range, average speed and outside temperature.

Operation. Motor vehicles and machines should be operated by qualified and duly-authorised persons only. Among the applicable stipulations the driver of a passenger car operating on public roads must be in possession of the required Class B driving licence. lift platforms and hydraulic hoists in automotive service facilities are to be operated exclusively by individuals over 18 years of age who have also received corresponding instruction in and authorisation for its use. the driver of a truck equipped with a crane must be in possession of a crane operator's licence. This stipulation is intended to ensure that drivers of crane-equipped trucks have received the required training for operating lifts and hoisting equipment, and will provide the vehicle with the correct supplementary support (Fig. 1) whilst simultaneously observing all applicable accident-prevention regulations and operating the crane in a professional manner.
0 2 4 5,950 kg 58.4 kN 6,600 kg 64.7 kN 6 8 10 m 12 14 m 12 10 8 6 4 2 7,400 kg 3,860 kg 2,180 kg 5,830 kg 2,820 kg 1,750 kg

1.4.5 Using technical systems

Extensive familiarity with technical systems is essential for the operation and maintenance of motor vehicles. The manufacturer provides operating instructions (owner's manual) to help ensure that its vehicles operate with optimal safety, security and reliability, while also observing the interests of the natural environment. Operating instructions contain, among other information: System descriptions Explanations of functions and operation System descriptions Operating diagrams Instructions on correct operation and use of the controls Maintenance and service inspection schedules Instructions for responding to malfunctions Information on approved fluids, lubricants and service materials, such as engine oils

Fig. 1: Correct load distribution on a crane hoist

REVIEW QUESTIONS
1 What are the parameters that define a technical system? 2 What is the IPO concept? 3 What are the names of the operational units in the motor vehicle? 4 Name three subsystems in the motor vehicle, and describe the corresponding input and output variables. 5 What is the primary function of an energy-processing system? 6 What information is available in the operating instructions (vehicle owner's manual)?

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1.5 Service and maintenance

Professional-quality service and maintenance, performed in accordance with the manufacturer's instructions (by the factory service organisation, etc.) are vital elements in ensuring continued vehicle safety and in maintaining the validity of the manufacturer's warranty. The manufacturer issues service and maintenance schedules, spare part catalogues and repair instructions to guide and support these activities. This documentation is available in many forms, including repair manuals, microfiche files and menu-guided computer programs designed to run on personal computers (PCs). Service and maintenance. Service procedures include: Inspections, such as test procedures General maintenance, comprising oil changes, lubrication and cleaning Remedial action, such as repairs and component replacement Aftersales service. Vehicle manufacturers and automotive repair operations offer professional service to their customers. Among the services offered by these facilities is to perform the prescribed preparations on new vehicles prior to delivery to the customer. Professional technicians also carry out service and maintenance processes that the vehicle operator may not be able to perform. In the official service and maintenance guidelines the manufacturer defines an action catalogue intended to ensure unrestricted functionality and maintain the vehicle's value. The individual procedures are contained in the service and maintenance schedules for the specific vehicles. Service intervals can be defined according to the following criteria: Invariable, time-based service intervals (maintenance schedule) Flexible service intervals New service concepts Service, maintenance and inspection operations must be performed in accordance with defined schedules. Once operations have been carried out, they should be confirmed in a service record and signed by the responsible service technician.

Flexible service intervals

Modern engine-management systems have allowed the advent of a new service concept characterised by adaptive scheduling. This concept reflects each individual vehicle's requirements based on its actual operating conditions. In addition to mileage, the system records and evaluates a variety of other factors (influencing variables) for inclusion in its calculations. A display then provides the driver with prompt notice as the inspection date approaches (Fig. 1). The process culminates with execution of the prescribed operations at the service facility in accordance with the service inspection schedule (Fig. 1, Page 19). Oil change intervals. Two methods are available for defining oil change intervals: A virtual database, derived from such factors as mileage, overall fuel consumption and oil temperature curves, provides an index indicating how much the oil ages over a given period. The actual condition of the oil, meaning the quality and level of the oil as determined via the oil level sensor, in combination with the mileage and the registered engine load factors. Brake pad wear. Brake pad wear is monitored electrically. When the brake pad reaches its wear limit a contact wire within the pad is perforated. The system then considers such factors as braking frequency, the duration of brake actuations and mileage in calculating the theoretically available mileage reserves, which are then reflected in the replacement intervals displayed to the driver. Interior (passenger compartment) filter wear status. Data gleaned from the outside air temperature sensor, information on heater use, use of the recirculated-air mode, vehicle speed, fan blower speed, mileage and dates all flow into calculations to determine the period remaining until the dust and pollen filter will be due for replacement.

Brake fluid Engine oil Rear brake pads Spark plugs

12 months

Microfilters

Maintenance schedule
It furnishes information on the specified service and inspection intervals by specifying (for example) a major inspection for every 20,000 km or 12 months. Service inspection schedule. This schedule defines the contents and lists the procedures included in the service inspection (Fig. 1, Page 19).

Fig. 1:Wear indicators

Sparking plug replacement intervals are still based on mileage, with new plugs specified after a specific distance, such as 100,000 km. Replacement dates for fluids and lubricants, such as the coolant and brake fluid, are defined according to time, for instance, at intervals of 2 or 4 years.

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This gives the service representative time to order any required replacement parts such as brake pads and to consult the customer in advance concerning a convenient service date. Early recognition of potential problems is intended to help avoid repairs stemming from vehicle breakdowns. Additional advantages include: Precisely defined dates Minimal waiting times No information loss Flexible service

New service concepts

The service date is calculated on the basis of data collected on the actual condition of wearing parts, fluids and lubricants, as well as information on the vehicle's operating conditions. When defined by this demandbased service concept, service and maintenance are carried out only when needed, for instance, when a component reaches its wear limit, or a fluid or lubricant has reached the end of its service life. A new feature is provided by the on-board computer, which transmits coded data on the customer and the extent of the required service to the service facility.

Service inspection schedule

Job no.: km reading/ mileage: , Vehicle model: Vehicle age: Vehicle owner: Additional work, e.g. emissions inspection OK not OK Rectified

Brake system: Visually check for leaks and damage Front and rear brake pads: Check thickness Undercoating: Visually check for damage Exhaust system: Visually check for leaks and damage Track-rod ends: Check play, mounting and sealing gaiters; axle joints: visually check sealing gaiters for leaks and damage

Servicing to be carried out

Electrical system
Front lights. Check function: Parking lights, dipped beam, main beam, fog lamps, direction indicators and hazard-warning signals Rear lights. Check function: Brake lights, tail lights, reversing lights, fog warning lamp, number-plate lights, luggage-compartment light, parking lights, direction indicators and hazard-warning signals Interior and glove-compartment lights, cigarette lighter, signal horn and telltale lamps: Check function Self-diagnosis: Interrogate fault memories of all systems (insert printout at back of logbook wallet)

Engine compartment
Engine oil: Check oil level (during inspection service with filter change, change oil) Engine and components in engine compartment (from above): Visually check for leaks and damage Windscreen wash/wipe system: Top up fluid Cooling system: Check coolant level and antifreeze; setpoint value: 25 C Actual value (measured value): C Dust and pollen filter: Replace filter element (every 12 months or every 15,000 km) Toothed belt for camshaft drive: Check condition and tension Air filter: Clean housing and replace filter element Fuel filter: Replace Power steering: Check fluid level Brake-fluid level (dependent on brake-pad wear): Check Battery: Check Idle speed: Check Headlight adjustment / documentation / final inspection Headlight adjustment: Check Service sticker: Enter date/mileage for next service (also brake-fluid renewal) on sticker and attach sticker to door pillar (B-pillar) Take vehicle for test drive Date / Signature (mechanic) Date / Signature (final inspection)

Vehicle from the outside

Door arresters and retaining bolts: lubricate Windscreen wash/wipe system and headlight washer system: Check function and spray-nozzle setting Windscreen wiper blades: Check for damage, check home position; in event of rubbing wiper blades: Check contact angle

Tyres
Tyres: Check condition, tyre tread pattern and inflation pressure, enter tread depth FL RL mm mm FR RR mm mm

Vehicle from below

Engine oil: Drain or draw off, replace oil filters Engine and components in engine compartment: Visually check for leaks and damage V-belts, ribbed V-belts: Check condition and tension Gearbox, final-drive unit and joint boots: Visually check for leaks and damage Manual gearbox / axle drive: Check oil level

Fig. 1: Service inspection schedule

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1 Partial-flow centrifugal oil filter 2 Electronicsbox filter 3 Water separator 4 Air filter with service indicator 5 Air-filter element 6 Coolant filter 7 Inline fuel filter 8 Washer-fluid filter 9 Diesel-filter module 10 Metal-free fuel-filter element 1 1 Cylinder-head cover with integrated oil separator 12 Oil-mist separator

4 3

10 12 1 1

13 In-tank petrolfilter element 14 Tank-ventilation filter 15 Urea filter for SCR catalysts 16 Interior filter 13

2 1

17 Gear-oil filter 18 Steeringhydraulics filter 19 Brakehydraulics filter

25 24 23 14

20 Suspensionhydraulics filter 21 Desiccant box 22 Easy-change oil filter 23 Oil-filter module 24 Metal-free oil-filter element 25 System for crankcase ventilation with multi-cyclone filter

22

21

20

19

18

17

16

15

Fig. 1: Filters in modern motor vehicles

1.6 Filter, body and maintenance

Filters installed in the motor vehicle guard against contaminants and impurities by providing protection for the engine, other vehicle components, and the vehicle's occupants. Motor vehicle filters (Fig. 1) can be classified according to two criteria. These are the filtration concept and the medium being filtered. Filtration concepts. Solid contaminants are filtered from flowing media such as air, oil, fuel and water by: Screen filtration, using sieve-type filter screens and fibre filters, etc. Adhesive filtration, including wet filters Magnetic filtration, as with magnetic separators Centrifugal filtration, with centrifugal filters, etc. Strainers (filter screens). Filter mesh dimensions smaller than the contaminants facilitate filtration (Fig. 2).

Adhesive filters. These are usually wet air filters. Contaminants such as dust adhere to the filter surface on contact. Magnetic filter. The filter (for instance, on the oil drain plug) attracts and retains ferromagnetic contaminants suspended in the flowing medium. Centrifugal filter. The object medium (such as air) is placed in a state of rotation. Centrifugal force propels the contaminants onto the filter's walls, where they settle as deposits. Filter types include Air and exhaust-gas filters Fuel filters Filters for lubricating oils Interior filters, such as pollen, smog and ozone filters Hydraulic filters, for ATF , etc.

1.6.1 Air filters

The purpose of the air filter is to cleanse induction air of impurities while simultaneously subduing induction roar. Airborne dust particles are minute in size (0.005 mm to 0.05 mm). The air can also contain quartz. Dust concentrations vary considerably according to vehicle operating conditions (motorway, construction site). Should it enter the oil, this dust would form an abrasive film, leading to extreme wear, especially on the cylinder walls, the pistons and the valve guides.

Mesh

Direction of flow

Contaminant Strainer

Fig. 2: Operational concept of the filter screen