`
`Publisher
`The Goodheart—Willcox Company, Inc.
`Tinley Park, Illinois
`
`BMW v. Paice, IPR2020-00994
`BMW1094
`Page 1 of 66
`
`BMW v. Paice, IPR2020-00994
`BMW1094
`Page 1 of 66
`
`

`

`Copyright 1994
`by
`
`THE GOODHEART-WILLCOX COMPANY, INC.
`
`Previous editions copyright 1990, 1985
`
`Ail rights reserved. No part of this book may be reproduced.
`stored in a retrieval system, or transmitted in any form or by
`any means, electronic, mechanical, photocopying, recording,
`or otherwise, without the prior Written permission of The
`Goodheart-Willcox Company, Inc. Manufactured in the United
`States of America.
`
`Library of Congress‘Catalog Card Number 92-46515
`International Standard Book Number 07870067043-0
`
`678910 94
`
`9796
`
`Library of Congress Cataloging in Publication Data
`
`92745515CIP
`
`Duffy, James E.
`Modern automotive technology / by James E.
`Duffy
`
`cm.
`p.
`Rev. ed. of: Modern automotive mechanics.
`c1990.
`includes index.
`ISBN 0787006-04370
`1. Automobiles. 2. Automobiles—Maintenance
`and repair.
`I. Duify, James E. Modern automotive mechanics.
`11. Title.
`TL146.DB4 1994
`629.28'722-—d020
`
`BMWlV. Paice, |PR2020-00994
`BMW1094
`Page 2 of 66
`
`BMW v. Paice, IPR2020-00994
`BMW1094
`Page 2 of 66
`
`

`

`
`
`Power Tools
`
`and Equipment
`
`After studying this chapter, you will be able to:
`DList
`the most commonly used power tools and
`equipment.
`:5 Describe the uses for power tools and equipment.
`3 Compare the advantages of one type of too] over
`another.
`3- Explain safety rules that pertain to power tools and
`equipment.
`
`
`
`To be a productive mechanic in today’s auto shop,
`you must know when and how to use power tools and
`equipment. They increase the ease and speed of many
`repair operations.
`Power tools are tools using electricity, compressed
`air, or hydraulics (liquid confined under pressure).
`Large shop tools such as floor jacks, parts cleaning
`tanks, and steam cleaners, are classified as shop
`equipment.
`This chapter stresses the importance of properly
`selecting and using power tools and equipment. They
`can be very dangerous if misused. Always follow the
`operating instructions for the particular tool or piece
`of equipment. If in doubt, ask your instructor for a
`demonstration.
`
`AIR COMPRESSOR
`
`An air compressor is the source of compressed
`(pressurized) air for the auto shop. Look at Fig. 4-1.
`An air compressor normally has an electric motor that
`spins an air pump. The air pump forces air into a large,
`metal storage tank. Metal air lines feed out from the
`tank to several locations in the shop. The mechanic can
`then cormect flexible air hoses to the metal lines.
`An air compressor turns ON and OFF automatical-
`1y to maintain a preset pressure in the system.
`
`DANGER! Shop air pressure is usually around 100
`to 150 psi (689 to l 034 kPa). This is enough pressure
`to severely injure or kill. Respect shop air pressure!
`
`Air hoses
`
`High pressure air hoses are connected to the metal
`lines from the air compressor. Since they are flexible,
`they allow the mechanic to take a source of air pressure
`to the vehicle being repaired. Quick-disconnect type cou—
`plings are used on air hoses. To connect or disconnect
`an air hose, slide back the outer fitting sleeve and push
`or pull on the hose.
`
`\
`
`AIR TOOL
`
`LUBRICATOR
`
`\_
`
`AIH
`
`ELECTRIC
`MOTOR
`AIR PRESSURE
`
`REGULATOR
`
`FILTER
`
`
`
`AIR LINE
`
`AIR HOSE
`
`thud—a ll
`
`
`
`Fig. 4— 7. Basic parts of a typical shop air pressure system. Air compressor develops air pressure. Filter removes moisture. Regulator
`allows mechanic to control system pressure. Metal line and flexible hose carry air to tool. (Florida Dept. of Voc. Ed.)
`
`
`
`
`
`Power Tools and Equipment 43
`BMW v.
`ice |PR2 2 -
`
`
`
`
`
`BMW v. Paice, IPR2020-00994
`BMW1094
`Page 3 of 66
`
`

`

`AIR TOOLS
`
`Air ratchet
`
`.
`
`Air tools, also called pneumatic tools, use air
`pressure for operation. They are labor—saving‘tools,
`well worth their cost.
`
`Always lubricate an air tool before use. Squirt a few
`drops of air tool oil (light oil) into the air inlet fitting.
`This protects the internal parts of the tool, increasing
`service life and tool power,
`‘
`
`Air wrenches (impact wrenches)
`Air wrenches or impact wrenches provide a very fast
`means of installing or removing threaded fasteners.
`Look at Fig. 4—2A and B. An impact wrench uses com-
`pressed air to rotate a driving head. The driving head
`holds a socket which fits on the fastener head.
`A button or switch on the air wrench controls the
`direction of rotation. In one position,
`the impact
`tightens the fastener. The impact loosens the fastener
`in the other direction.
`
`Impact wrenches come in 3/8, 1/2, and 3/4 in. drive
`sizes. A 3/8 drive impact is ideal for smaller bolts
`(sockets between 1/4 and 9/16 in. for example). The
`1/ 2 in. drive is general purpose for medium to large
`fasteners (head sizes between 1/2 and 1 in.). The 3/4
`in. drive impact is for extremely large fasteners and
`is NOT commonly used in auto service.
`
`CAUTION! Until you become familiar with the
`operation of an air wrench, be careful not to over—
`tighten bolts and nuts or leave them too loose. It is
`easy to strip or break fasteners with an air tool.
`
`
`
`Fig. 4—2. Air wrenches, A — 1/2 in. drive impact wrench. B —
`3/8 drive impact wrench. C — 3/8 in. drive air ratchet.
`(Hennessy industries, Inc. and SnapeOn Tools}
`
`44 Modern Automotive Technology
`
`An air ratchet is a special impact type wrench de-
`signed for working in tight quarters. Look at Fig. 4—2C.
`It is very slim and will fit into small areas. For instance,
`an air ratchet is commonly used when removing water
`pumps. It will fit between the radiator and engine
`easily.
`An air ratchet normally has a 3/8 in. drive. It does
`not have very much turning power. Final tightening
`and initial loosening must be done by hand.
`
`Impact sockets and extensions
`Special impact sockets and extensions must be used
`with air wrenches. They are thicker and much stronger
`than conventional sockets and extensions. A conven—
`tional socket can be ruined or broken by the hammer-
`ing blows of an impact wrench.
`Special impact sockets and extensions are easily iden-
`tified. They are usually FLAT BLACK, not chrome.
`
`Air hammer (Chisel)
`An air hammer or chisel is useful during various driv-
`ing and cutting operationsoLook at Fig. 4-3. The air
`hammer is capable of producing about 1000 to 4000
`
`
`
`Fig. 4-3. Air hammer is being used to quickly drive bushing out
`of suspension arm. Wear safety glasses. (Moog)
`
`impacts per minute. Several different cutting or ham-—_
`mering attachments are available. Select the correct on '
`for the job.
`
`CAUTION! Never turn an air hammer 0N unles
`
`the tool is pressed tightly against the workpiece. If not,
`the tool head can fly out of the hammer with great
`force — as if shot from a gun!
`
`Blow gun
`An air powered blow gun is commonly used to dr‘
`and clean parts washed in solvent. See Fig. 4-4. It i
`also used to blow dust and loose dirt off a part before
`disassembly.
`
`BMW v. Paioe, IPR2020-00994
`BMW1094
`Page 4 of 66
`
`BMW v. Paice, IPR2020-00994
`BMW1094
`Page 4 of 66
`
`

`

`A rotary brush, Fig. 46, is used in an air or electric .
`drill for rapid cleaning'of parts. Ittwill quickly rub off
`old gasket material, carbon deposits on engine parts,
`and rust, with a minimum amount of effort.
`CAUTION! Only use a high speed type rotary brush
`in an air drill. A brush designed for an electric drill
`may fly apart. To be safe, always adjust an air drill
`to the SLOWEST ACCEPTABLE SPEED.
`
`ROTARY
`BRUSH
`
`
`
`Fig. 476. Rotary brush is commonly used in a drill for cleaning
`off old gaskets or carbon. Wear eye protection.l
`
`A rotary file or stone can be used in either an air
`drill, electric drill, or an air (die) grinder, Fig. 4-7. It
`is handy for removing metal burrs and nicks.
`Make sure the stone is not turned too fast by the
`air tool. Normally the speed specifications (maximum
`allowable rotating speed) will be printed on the file or
`stone container.
`
`Fig. 4-7. Die grinder with a high speed stone installed. This
`tool is used for removing burrs and for other smoothing opera-
`tions. {Robert Bosch)
`
` B
`
`Fig. 474. A — Blow gun, commonly used to blow parts clean
`and dry after washing in solvent. B i Solvent gun can be
`used to wash parts. (Sinks)
`
`When using a blow gun, wear eye protection. Direct
`the blast of air away from yourself and others. DO not
`blow brake and clutch parts clean. These parts cen—
`rain asbestos, a cancer causing substance.
`
`Air drill
`
`An air drill is excellent for many repairs because of
`its power output and speed adjustment capabilities. Its
`power and rotating speed can be set to match the job
`at hand. Look at Fig. 4—5. With the right attachment,
`air drills can drill holes, grind, polish, and clean parts.
`
` i
`
`AIR INLET
`FITTING
`
`ESPEED CONTROL
`VALVE
`
`
`
`
` ‘
`
`TOOL
`REST GUARD
`
`Fig. 4-5. Air drill speed can be adiusted. it is capable of very
`high turning force. (Hennessy industries, inc.)
`
`Fig. 48. Bench grinder stone is used to sharpen tools. Brush
`can be used to clean and polish small parts. Keep shields, tool
`rests, and guards in place. (Sioux Tools)
`
`Power Tools and Equipment 45
`BMW v. Paice, |PR2020—00994
`BMW1094
`Page 5 of 66
`
`BMW v. Paice, IPR2020-00994
`BMW1094
`Page 5 of 66
`
`

`

`BENCH GRINDER
`
`A bench grinder, Fig. 4-8, can be used for grinding,
`cleaning, or polishing operations. The hard grinding
`wheel is used for sharpening or deburring. The soft wire
`wheel is for cleaning and polishing.
`A few BENCH GRINDER RULES to follow are:
`l. Wear eye protection and keep your hands away
`from the stone and brush.
`2. Keep the tool rest adjusted close to the stone and
`brush. If the rest
`is NOT up close, the part can
`catch in the grinder.
`3. Do NOT use the wire wheel to clean soft metal
`parts (aluminum pistons or brass bushings, for ex-
`ample). The rubbing, abrasive action of the wheel
`can remove metal, scuff, and ruin the part. Use
`a solvent and a dull hand scraper on soft metal
`parts that could be damaged.
`4. Make sure the grinder shields are in place.
`
`DRILLS
`
`Twist drills or drill bits are used to drill holes in metal
`and plastic parts. They fit into either an electric or air
`powered drill, Fig. 4-9. Drill bits are commonly made
`of either carbon steel or high speed steel. High speed
`steel is better because of its resistance to heat. It will
`not lose its hardness when slightly overheated.
`
`POINT
`FLUTE
`
`BODY
`
`
`MARGIN
`
`DmLL \
`SIZE
`
`
`
`
`MARGIN
`
`TOP VIEW
`
`
`
`CHUCK.
`
`C
`
`Fig. 4- 10. Portable electric drills. A ~ Smell, 3/8 in. drill. B —
`Larger, 1/2 in. drill. C ~ Key is used to tighten bit in chuck.
`(Robert Boschl
`
`SPEED CHANG E
`CONTROL
`
`
`
`TABLE
`
`SHANK
`
`MARGIN
`
`
`
`SIDE VIEW
`
`Fig. 4-9. Study basic parts of drill bit. {Florida Dept. of Vac. .Ed. )
`
`Portable electric drill
`A drill bit is chucked (mounted) and rotated by an
`electric drill, Fig. 4—10. A special key must be used to
`tighten the drill bit in the drill. A portable electric drill
`will work fine on most small drilling operations.
`
`Drill press
`A large drill press is needed for drilling large holes,
`deep holes, or a great number of holes in several parts,
`Fig. 4-11. The drill press handle allows the bit to be
`pressed into the work with increased force. Also, the
`drill chuck will accept very large bits.
`
`46 Modern Automotive Technology
`
`Fig. 4- T 1. Note parts of drill press. It is for drilling deep or large
`holes when part will fit on table. (Florida Dept. of Vac. Edi
`
`A few DRILL PRESS RULES to follow include:
`1. Secure the part to be drilled in a vise or with C—
`clamps.
`2. Use a center punch to indent the part and start the
`hole.
`L.)
`. Remove the key before turning on the drill.
`4. To prevent possible injury, release drilling pressure
`right before the bit breaks through the bottom of
`the part. A drill bit tends to catch when breaking
`
`
`
`BMW v. Paioe, IPR2020-00994
`BMW1094
`Page 6 of 66
`
`BMW v. Paice, IPR2020-00994
`BMW1094
`Page 6 of 66
`
`

`

`through. This can cause the drill or part to rotate
`dangerously.
`:7 Oil the bit as needed.
`
`TIRE CHANGER
`
`A tire changer is a common piece of shop equipment
`used to remove and replace tires on wheels. Some are
`hand-operated and others use air pressure. Do not at-
`tempt to operate a tire changer without proper super-
`vision. Follow the directions provided with the changer.
`
`BUMPER LIFTS
`
`lifts or jacks, either air or manually
`Bumper
`powered, are used to raise one end of a car. Lifting
`pads fit under the front or rear bumper. See Fig. 4-12A.
`When raising the front of a car, place the transmis—
`SlOH in neutral and release the parking brake. This will
`let the vehicle roll and will prevent the car from pull—
`ing Off the lift.
`After raising, secure on jack stands. Place in park.
`Apply the emergency brake and block the wheels.
`
`FLOOR JACKS
`
`Afloor jack is also used to raise either tlie'front,
`sides, or rear of a vehicle. Look at Fig. 4—-12B.
`
`
`
`
`
`SADDLES
`
`
`
`
`
`To avoid vehicle damage, place the jack saddle under
`a solid part of the car {frame, suspension arm, rear
`axle). If you are NOT careful, it is very easy to smash
`an oil pan, muffler. floor pan, or other sheet metal
`part.
`As with a bumper jack, the vehicle should be free
`to roll while being raised. After raising, place the vehi-
`cle on jack stands. Block wheels and place in park.
`Normally, to raise the vehicle, you must turn the jack
`handle or knob clockwise and pump the handle. To
`lower, turn the pressure relief valve counterclockwise
`slowly.
`
`JACK STANDS
`
`Jack stands support a vehicle during repair. After
`raising it with a jack, place stands under the vehicle,
`Fig. 14—12C. It is NOT SAFE to work under vehicles
`held by a floor jack or bumper lift.
`Note! The next chapter details the use of lifts, jacks,
`and jack stands.
`
`TRANSMISSION JACK
`
`Special transmission jacks are designed for remov—
`ing and installing transmissions. One type is similar to
`a floor jack. However, the saddle is enlarged to fit the
`bottom of a transmission.
`
`Another type of transmission jack is used when the
`car is raised on a vehicle lift, Fig. 4—13. It has a long
`post which can reach high into the air to support the
`transmission.
`
`ENGINE CRANE
`
`A portable engine crane is used to remove and in-
`stall engines, Fig. 4-14. It has a hydraulic hand jack
`
`
`
`Fig. 4—72. Vehicle lifting equipment A i Bumper lift. 5’ e
`Floorjack is for raising car only. C 7 Jack stands are needed
`before working under car.
`(Florida Dept. of Voc. Ed.)
`
`removing,
`Fig. 4773. Transmission jack is designed for
`transporting, and installing transmissions when using an
`overhead lift. Hydraulic lift is foot operated and raises to height
`of 72 in.
`(OTC Div. of SPX Corp.)
`
`Power Tools and Equipment 47
`
`BMW v. Paice, IPR2020-00994
`BMW1094
`Page 7 of 66
`
`BMW v. Paice, IPR2020-00994
`BMW1094
`Page 7 of 66
`
`

`

` ENGINE
`
`ARBOR PRESS
`
`VAn arbor press performs the same function as a
`hydraulic press but at lower pressures. It is a hand—
`operated, mechanical press for smaller jobs.
`
`ENGINE STAND
`
`An engine stand is used to hold an engine while it
`is overhauled (rebuilt) or repaired. The engine bolts
`to the stand. For convenience, the engine can usually
`be rotated and held 'in different positions.
`
`COLD SOLVENT TANK
`
`Fig. 4-14. Hydraulic engine crane can be used to lift heavy ob—
`jects such as engines,
`transmissions,
`transaxles, rear axle
`assemblies.
`
`A cold solvent tank, Fig. 4-16, removes grease and
`oil from parts. After removing all old gaskets and
`scraping off excess grease, you can scrub the parts clean
`
`for raising and a pressure release valve for lowering.
`An engine crane is also handy for lifting heavy engine
`parts (intake manifolds, cylinder heads), transmissions,
`and transaxles.
`
`HYDRAULIC PRESS
`
`A hydraulic press is used to install or remove gears,
`pulleys, bearings, seals, and other parts requiring high
`pushing force. One is shown in Fig. 4—15.
`A hydraulic press uses a hand jack. By pumping the
`jack, press-fit parts can be pushed apart or together.
`A valve releases pressure.
`NOTE! A hydraulic press can exert TONS OF
`FORCE. Wear face protection and use recommended
`procedures.
`
`I,
`
`PRESSURE__V
`GAUGE
`
`,L PUMP
`HANDLE
`
`.-
`'
`. /
`
`
`
`
`ONlOFF
`VALVE
`
`
`
`Fig. 4-15. Hydraulic press is needed for numerous pressing
`operations. It is commonly used to remove and install bearings,
`bushings, seals, and other pressedron parts. Note! Double-
`check lock pins before using press. if not installed, cables in
`unit could snap. (Dake Corp.)
`
`48 Modern Automotive Mechanics
`
`
`
`Fig. 4-16. Cold solvent tank is for removing oil and light grease
`from parts. Unit sprays filtered solvent on parts. Rub parts with
`brush for rapid cleaning.
`(Build—All}
`
`in the solvent. A blow gun is normally used to remove
`the solvent.
`
`STEAM CLEANER AND HIGH PRESSURE WASHER
`
`A steam cleaner or high pressure washer are used
`to remove heavy deposits of dirt, grease, and oil from
`the outside of large assemblies (engines, transmissions,
`transaxles). Look at Fig. 4-17. For environmental
`reasons, it is often advisable to wire brush and collect
`oil—soaked dirt before steaming or washing.
`DANGER! A steam cleaner operates at relatively
`high pressures and temperatures. Follow your safety
`rules and specific operating instructions.
`
`OXYACETYLENE TORCH
`
`An oxyacetylene torch outfit can be used to cut,
`bend, and weld or braze (join) metal parts, Fig. 4—18.
`Its rapid cutting action is extremely beneficial. For ex—
`
`BMW v. Paioe, IPR2020—00994
`BMW1094
`Page 8 of 66
`
`BMW v. Paice, IPR2020-00994
`BMW1094
`Page 8 of 66
`
`

`

`
`
`Fig. 4- l 7. High pressure washer will remove greasy buildup
`on outside of assemblies before teardown. (Sioux Tools)
`
`MAtN
`
`
`ONlOFF
`TORCH
`
`
`REGULATOR VALVE
`FLAME
`GAUGES
`
`CONTROL
`
`VALVES
`PRESSURE
`REGULATOR
`VALVE
`
`
`
`.1
`
`
`
`
`
`
`
`
`240 VOLT
`ELECTRICAL
`OUTLET
`
`SWITCH
`
`ELECTRODE
`HOLDER
`
`
`
`
`
`
`
`CLAMP
`l\GROUND
`
`Fig. 4- 78. Top. Oxyacetylene outfir can be used for Cutting
`or Welding metal. Bottom. Study basic parts of arc Welder. (Sun)
`
`
`
`ample, a cutting torch is often used to remove old,
`deteriorated exhaust systems. Tremendous heat is pro—
`duced by burning acetylene gas and oxygen.
`
`ARC WELDER
`
`. An arc welder is also used to weld metal parts
`together, Fig. 4-18. It uses high electric current and the
`resulting electric arc to produce welding heat.
`If at all possible, you should take a welding course
`in school. This will help prepare you for auto
`mechanics. DO NOT attempt to weld or cut until prop-
`erly trained.
`
`SOLDERING GUN
`
`A soldering gun or iron is normally used to solder
`(join) wires, Fig. 4~19. An electric current heats the tip
`of the gun. Then, the hot gun tip can be used to heat
`the wires and melt the solder. When the solder solidifies
`(hardens), a strong, solid connection is produced.
`
`BATTERY CHARGER
`
`A battery charger is used to recharge (energize) a
`discharged (dc-energized) car battery. It forces current
`back through the battery. Normally, the red charger
`lead connects to the battery positive (+) terminal. The
`black charger lead connects to the negative (—) battery
`terminal.
`WARNING! Always connect the battery charger
`leads to the battery BEFORE turning the charger ON.
`This will prevent sparks that could ignite any battery
`gas. The gases around the top of a battery can
`EXPLODE violently.
`
`DROP LIGHT
`
`A drop light, Fig. 4—20, provides a portable source
`of illumination (light). The light can be taken to the
`repair area under the vehicle, hood, or engine.
`
`
`SOLDERING IRON
`POWER CORD
`
`TIP
`A
`
`
`TIF'
`
`SOLDERING IRON
`HEATS TERMINAL
`
`
`
`
`FEMALE
`SLIDE
`TERMINAL
`
`B
`
`SOLDER
`MELTS AND
`JOINS TWO
`
`ONlOFF
`TRIGGER
`
`Fig. 4719. A i Soldering iron and soldering gun. B i Solder-
`ing iron or gun produces enough hear to melt solder forjoining
`wires and small metal terminals. (Florida Dept. of Voc. Ed.)
`
`Power Tools and Equipment 49
`
`BMW v. Paice, lPR2020-00994
`BMW1 094
`Page 9 of 66
`
`BMW v. Paice, IPR2020-00994
`BMW1094
`Page 9 of 66
`
`

`

`SLIDE
`
`Fig. 4-20. A 7 Drop light. B — Drop or extension cord. C #
`Three-prong adapter with ground terminal and ground wire for
`safety. D — Fluorescent drop light. (Florida Dept. of Voc. Ed.)
`
`WHEEL PULLERS
`
`Wheel pullers are needed to remove seals, gears,
`pulleys, steering wheels, axles, and other pressed-on
`parts. A few puller types are pictured in Fig. 4-21.
`Special pulling operations will be covered in later
`chapters.
`DANGER! Pullers can exert TONS OF FORCE.
`They must be used properly to prevent injury or part
`damage. Wear eye protection!
`
`JUMPER CABLES
`
`Jumper cables are used to start engines with a dead
`(discharged) battery. The cables can be connected be—
`tween the dead battery and another battery. This will
`let you crank and start the vehicle. See Fig. 4-22.
`When connecting jumper cables, connect positive to
`positive and negative to negative. Also, keep sparks
`away from the dead battery. Connect the negative cable
`to the vehicle frame so that any sparks will not occur
`near the battery.
`
`CREEPER
`
`A creeper is useful when working under a car sup-
`ported on jack stands, Fig. 4-23A. It lets the techni-
`cian easily roll under vehicles without getting dirty.
`
`Stool creeper
`A stool creeper allows the technician to sit while
`working on parts low to the ground. See Fig. 4-23B.
`For example, a stool creeper is often used on brake
`repairs. The brake parts and tools can be placed on
`the creeper. The service technician can sit and still be
`eye level with the brake assembly.
`
` SCREW
`ROLL—AROUND CART
`
`Fig. 4-21. A ; Three—jaw puller, B _ Slide hammer puller.
`C r Power puller.
`{OTC Div. of SPX Corp.
`
`'
`A larger roll—around cart 01' table 15 handy fOI' tak-
`ing a number of tools to the job. One is pictured in
`
`Fig. 422. Jumper cables are for emergencystarting. Connec
`red lead to positive terminal of both batteries. Black is {of
`negative and ground.
`(Snap-On Tools)
`
`50 Modern Automotive Technology
`
`BMW v. Paioe, IPR2020-00994
`BMW1094
`Page 10 of 66
`
`BMW v. Paice, IPR2020-00994
`BMW1094
`Page 10 of 66
`
`

`

`
`
`Fig. 4-23. A w Creeper is for working under car. B ~ Stool
`creeper is commonly used during brake and suspension repairs.
`You can sit on the stool and stare tools on bottom.
`(Shep-On Tools)
`
`Fig. 425. Always take good care of customer’s car. A —
`Fender covers protect paint from nicks and dents. B — Seat
`cover protects upholstery from dirty work clothes.
`(Snap-On Tools}
`
`Fig. 4—24. Since the technician is working on a car raised
`on a lift, the cart positions all of the needed tools
`within “hand’s reach.” This saves time and effort.
`
`FENDER COVERS
`
`workclothes. The covers are normally used while driv-
`ing the vehicle in and out of the shop or while work-
`ing in the passenger compartment. Look at Fig. 4—25B.
`
`KNOW TH ESE TERMS
`
`Fender covers are placed over fenders, upper grille,
`or other body sections to protect them. They protect
`the finish from nicks and scratches. See Fig. 4-25A.
`Never lay your tools on a painted surface. Scratches
`could result.
`
`Air compressor, Air tool, Impact socket, Blow gun,
`Rotary brush, Engine crane, Hydraulic press, Solvent
`tank, Battery charger, Drop .light, Wheel puller,
`Jumper cables, Creeper, Fender cover.
`
`Seat covers
`Seat covers are placed over seats to protect them
`from dirt, oil, and grease that might be on your
`
`
`
`Fig. 424. Roll-around cart allows you to take several tools to
`car. This saves several trips to tool box.
`
`REVIEW QUESTIONS
`
`,
`1. Power tools use
`or— as sources of energy.
`2. Shop air pressure is only about 25 psi or 172 kPa
`and cannot cause injuries. True or False?
`3. Which of the following is NOT a commonly used
`air tool?
`c. Air chisel.
`3. Impact wrench.
`Cl. Air saw.
`b. Air ratchet.
`4. A—___ is used to blow dirt off
`parts and to dry parts after cleaning.
`5 . A rotary brush is used in an electric or air drill for
`rapid cleaning of parts. True or False?
`6. List four important rules for a bench grinder.
`7. List five important rules for a drill press.
`8. Use this tool to support the car while working
`under the car.
`
`c. Transmission jack.
`a. Floor jack.
`d. Bumper jack.
`_
`b. Jack stands.
`9. Explain the use of a solvent tank.
`10. What are wheel pullers for?
`
`ACTIVITIES FOR CHAPTER 4-
`
`1. Using an automotive tool catalog, develop a list
`of power
`tools needed to equip the school’s
`automotive repair shop. Find prices and add up
`the cost.
`2. Research safety literature on power equipment used
`in an automotive repair facility.
`21. Develop a bibliography of resources for safe
`use of power equipment.
`b. Develop a list of safety rules for their use.
`
`Power Tools and Equipment
`BMW v. Paice, lPR2020-00994
`BMW1094
`Page 11 of 66
`
`BMW v. Paice, IPR2020-00994
`BMW1094
`Page 11 of 66
`
`

`

`
`
`I
`
`
`
`EXhaust
`Systems,
`Turbocharging
`
`After studying this chapter, you will be able to:
`DDescribe the basic parts of an exhaust system.
`aCompare exhaust system design differences.
`gPerform exhaust system repairs.
`[jExplain the fundamental parts of a turbocharging
`system.
`DDescribe the construction and operation of a tur-
`bocharger and wastegate.
`.
`I] Remove and replace a turbocharger and wastegate.
`DDernonstrate an understanding of safety procedures
`for working on exhaust systems and turbochargers.
`
`This chapter begins by covering the basic parts of
`an exhaust system. It then explains how to repair the
`system by replacing rusted or damaged components.
`The second part of the chapter covers turbocharging.
`
`BASIC EXHAUST SYSTEMS
`
`An exhaust system quiets engine operation and car-
`ries exhaust fumes to the rear of the vehicle. The parts
`of a typical exhaust system are shown in Fig. 25—1. They
`include:
`
`1. EXHAUST MANIFOLD (connects cylinder head
`exhaust ports to header pipe).
`2. HEADER PIPE (steel tubing that carries exhaust
`gases from exhaust manifold to catalytic converter
`or muffler).
`3. CATALYTIC CONVERTER (device for remov-
`ing pollutants from engine exhaust).
`4. INTERMEDIATE PIPE (tubing sometimes used
`between header pipe and muffler or catalytic con-
`verter and muffler).
`
`CYLINDER HEAD
`MUFFLER
`
`HEAT
`SHIELD
`
`EXHAUST
`MANIFOLD
`
`
`HANGER
`ASSEMBLY )é 0
`
`
`
`TAILPIPE
`
`
`
`
`EXHAUST on
`
`HEADER PIPE
`FLANGE
`
`
`MUFFLER
`EXHAUST 0R
`
`
`HEADER PIPE
`
`
`
`
`CATALYTIC
`
`CONVERTER
`
`IF USED, INTERMEDIATE
`PIPE HERE
`
`
`
`Fig. 257?. Note parts of typical exhaust system. Exhaust comes out of cylinder head, into manifofld, and then through system.
`(Chrysler Corp.)
`
`Exhaust Systems, Turbocharging 319
`
`
`
`BMW v. Paice, IPR2020-00994
`BMW1094
`Page 12 of 66
`
`

`

`5 . MUFFLER (metal chamber for damping pressure
`pulsations to reduce exhaust noise).
`6. ,TAILPIPE (tubing that carries exhaust from muf—
`fler to rear of car body).
`'
`7. HANGERS (devices for securing exhaust system
`to underside of car body).
`8. HEAT SHIELDS (metal plates that prevent ex—
`haust heat from transferring into another object).
`9. MUFFLER CLAMPS (U-bolts for connecting
`parts of exhaust system together).
`When an engine is running, extremely hot gases blow
`out of the cylinder head exhaust ports. The gases enter
`the exhaust manifold. They flow through the header
`pipe, catalytic converter, intermediate pipe, muffler,
`and out the tailpipe.
`
`Exhaust back pressure
`Exhaust back pressure is the amount of pressure
`developed in the exhaust system when the engine is run-
`ning. High back pressure reduces engine power. A well
`designed exhaust system should have LOW back
`pressure.
`The restriction of the exhaust pipes, catalytic con-
`verter, and muffler contribute to exhaust back pressure.
`Larger pipes and a free-flowing muffler, for example,
`would reduce back pressure.
`
`Single and dual exhaust systems
`A single exhaust system has one path for exhaust
`flow through the system. Typically, it has only one
`header pipe, main catalytic converter, muffler, and
`tailpipe. The most common type, it is used from the
`smallest four—cylinder engines, on up to large V—S
`engines.
`.
`A dual exhaust system has two separate exhaust
`paths to reduce back pressure. It is two single exhaust
`systems combined into one. A dual exhaust system is
`sometimes used on high performance cars with large
`V—6 or V-8 engines. It lets the engine “breath” better
`at high rpm.
`A crossover pipe normally connects the right and left
`side header pipes to equalize back pressure in a dual
`system. This also increases engine power slightly.
`
`EXHAUST MANIFOLD
`
`SENSOR
`
`OXYGEN
`
`lower right shows exhaust manifold which being:
`Fig. 25-2.
`over exhaust ports on side of cylinder head. No te ox vgen Se",
`sor at end of manifold.
`(Chrysler Corp.)
`
`Exhaust manifold heat valve
`An exhaust manifold heat valve forties hot exhaust
`gases to flow into the intake manifold to aid cold
`weather starting. Look at Fig. 25—3.
`A butterfly valve may be located in the outlet of the
`exhaust manifold. A heat sensitive spring or a vacuum
`diaphragm and temperature sensing vacuum switch
`may operate the valve.
`
`POWEFI HEAT CONTROL VALVE
`
`FROM
`COOLANT commonest,- g
`ENGINE VACUUM
`SWITCH
`
`HOU ING T
`3
`Fl 5 BETW
`MANIFOLD AND
`HEADER PIPE
`
`EEN
`
`VACUUM ACTUATOR
`
`\
`
` ,.
`
`SHUT-OFF
`W BLADE
`
`Fig. 253. Heat control valve, sometimes called heat riser,
`forces hot exhaust gases into intake manifold, This helps tangle?"
`run smoothly. Valve opens as engine warms up. (Chryslel'
`
`An exhaust manifold bolts to the cylinder head to
`enclose the exhaust port openings, Fig. 25—2. The
`manifold is usually made of cast iron. It is sometimes
`made of stainless steel or lightweight steel tubing. The
`cylinder head mating surface is machined smooth and
`flat. An exhaust manifold gasket is commonly used be-
`tween the cylinder head and manifold to help prevent
`leakage.
`The outlet end of the exhaust manifold has a single
`round opening with provisions for stud bolts or cap
`screws. A gasket or O-ring (doughnut) seals the con-
`nection between the exhaust manifold outlet and header
`pipe to prevent leakage.
`
`When the engine is cold, the heat valve is closed. Th]?
`increases EXHAUST BACK PRESSURE. Hot gasfli
`blow into an exhaust passage in the intake manifold;
`Fig. 25-4. This warms the floor of the intake manifol.
`to hasten fuel vaporization. The heat valve opens
`the engine warms up.
`
`EXHAUST PIPES
`
`The exhaust pipes (header pipe, intermediate pill,
`and tailpipe) are usually made of rust resistant 513'“
`tubing. The inlet end of the header pipe has a flanl‘,
`for securing the pipe to the exhaust manifold studfi,
`
`320 Modern Automotive Technology
`
`
`
`BMW v. Paioe, IPR2020-00994
`BMW1094
`Page 13 of 66
`
`BMW v. Paice, IPR2020-00994
`BMW1094
`Page 13 of 66
`
`

`

`CARBURETOH\
`0R
`THROTTLE
`aoov ‘
`
`
`
`
`
`AIR»FUEL MIXTURE CHAMBERS
`BEING HEATED
`
`
`
`
`ENGINE INTAKE
`MANIFOLD
`
`HOT EXHAUST WHEN
`HEAT VALVE IS SHUT
`
`Fig} 25.4_ Hear control valve causes back pressure in exhaust
`system. This directs a large amount of hot exhaust into
`chamber in bottom of intake manifold. This actions warms and
`helps vaporize fuel. (Pontiac)
`
`SOUND OR
`RESONANCE
`CHAMBER
`-
`
`
`
`
`EAFFLES
`
`MUFFLER
`SHELL
`
`
`
`PYHEX THERMAL PACKING
`RATED T0 1200°F or 650°C
`
`OUTLET
`
`
`SOUND 0R RESONANCE
`CHAMBER
`
`Fig. 25-1. One end of each pipe may be enlarged to
`fit over the end of the next pipe.
`
`HEAT SHIELDS
`
`Fig. 255. Basic muffler contains baffles, resonance chambers,
`and acoustic tubes to reduce exhaust noise.
`(American Exhaust Industries)
`
`Heat shields are located where the exhaust system
`(especially catalytic converter and muffler) are close
`to the car body. The shields prevent too much heat
`from transferring into the car body or ground. Refer
`to Fig. 25-1.
`DANGER! Always reinstall all exhaust system heat
`shields. Without a heat shield, car undercoating,
`carpeting, dry leaves on the ground, and other flam-
`mable materials could catch on fire!
`
`CATALYTIC CONVERTER
`
`A catalytic converter is used to reduce the amount
`of exhaust pollutants entering the atmosphere. One Or
`more catalytic converters can be located in the exhaust
`system, Fig. 25—1.
`_ For details of catalytic converters, refer to Chapters
`39 and 40 which cover emission control systems.
`
`MUFFLERS
`
`_A muffler reduces the pressure pulses and resulting
`{Imse produced by the engine exhaust. When an engine
`13 running, the exhaust valves are rapidly opening and
`C103mg. Each time an exhaust valve opens, a blast of
`'hOt gas shoots out of the engine. Without a muffler,
`these exhaust gas pulsations are very loud.
`Flg- 25-5 shows the inside of a muffler. Note how
`:ChamberS, tubes, holes, and baffles are arranged to
`.
`[ Cancel Out the pressure pulsations in the exhaust.
`
`EXHAUST SYSTEM SERVICE
`
`Exlmust system service is usually needed when a com-
`
`
`
`ponent in the system rusts and begins to leak. Because
`engine combustion produces water and acids, an ex-
`haust system can fail in a relatively short time.
`DANGER! A leaking exhaust system could harm the
`passengers of a car. Since engine exhaust is poisonous,
`a leaky exhaust can allow toxic gases to flow through
`any opening in the body and into the passenger
`compartment.
`
`Exhaust system inspection
`To inspect an exhaust system, raise the car on a lift.
`Using a drop light, closely inspect the system for prob-
`lems (rusting, loose connections, leaks