`
`Publisher
`The Goodheart-Willcox Company, Inc.
`Tinley Park, lIilinois
`
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`
`Copyright 1994
`by
`
`THE GOGDHEART-WILLCOX COMPANY, INC.
`
`Previous editions copyright 1990, 1985
`
`All 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 Congrass Catalog Card Number 92-46515
`International Standard Book Number 0-87006-043-0
`
`678910 94
`
`9796
`
`Library of Congress Cataloging in Publication Data
`
`Duffy, James E.
`Modern automotive technology / by James E.
`Duffy
`
`cIP
`
`em.
`pb.
`Rev. ed. of: Modern automotive mechanics.
`c1990,
`includes index.
`ISBN 0-87006-043-0
`1. Automobiles. 2. Automobiles —-Maintenance
`and repair,
`|. Duffy, James E. Modern automotive mechanics.
`H. Title.
`TL146.084 1994
`629.28'722--dce20
`
`92-46575
`
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`
`Power Tools
`and Equipment
`
`AIR COMPRESSOR
`
`
`
`After studying this chapter, you will be able to:
`O List
`the most commonly used power tools and
`An air compressor is the source of compressed
`equipment.
`(pressurized) air for the auto shop. Look at Fig. 4-1.
`Cl Describe the uses for power tools and equipment.
`C1 Compare the advantages of one type of tool over
`An air compressor normally has an electric motor that
`another.
`spins an air pump. The air pumpforcesair intoalarge,
`O Explain safety rules that pertain to powertools and
`metal storage tank. Metalair lines feed out from the
`equipment.
`tank to several locations in the shop. The mechanic can
`then connect flexible air hoses to the metal lines.
`An air compressor turns ON and OFF automatical-
`ly to maintain a preset pressure in the system.
`
`To be a productive mechanic in today’s auto shop,
`you must know when and howto use powertools and
`equipment. They increase the ease and speed of many
`repair operations.
`Powertools 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 TOOL
`
`
`
`DANGER! Shop airpressure is usually around 100
`to 150 psi (689 to 1 034 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 theyare 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.
`
`ELECTRIC
`MOTOR
`
`AIR
`PUMP
`
`AIR PRESSURE
`
`REGULATOR
`
`FILTER
`
`LUBRICATOR
`
`AIR LINE
`
`
`AIR HOSEClow U
`
`Fig. 4-1. 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
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`AIR TOOLS
`
`Air tools, also called pneumatic tools, use air
`pressure for operation. They are labor-saving tools,
`well worth their cost.
`Alwayslubricate an air tool before use. Squirt a few
`dropsof 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.
`Lookat 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 comein 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 J 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 Snap-On Tools}
`
`44 Modern Automotive Technology
`
`Air ratchet
`An air roichet 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.
`Anair 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 extensionsare easily iden-
`tified. They are usually FLAT BLACK,not chrome.
`
`Air hammer (Chisel)
`An air hammerorchisel is useful during various driv-
`ing and cutting operations. Look at Fig. 4-3. The air
`hammeris 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 one:
`for the job.
`
`CAUTION! Neverturn an air hammer ON 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 dry
`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.
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`A rotary brush, Fig. 4-6, is used in an air or electric .
`drill for rapid cleaningof parts. It will quickly rub off
`old gasket material, carbon deposits on engine parts,
`and rust, with a minimum amount of effort.
`CAUTION! Onlyuse 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. 4-6. Rotary brush is commonly usedin a drill for cleaning
`off old gaskets or carbon. Wear eye protection!
`
`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 onthe 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)
`
`
`
`
` lel
`oer ie
`
`SWITCH
`
`ne
`TOOL
`REST GUARD
`
` B
`
`Fig. 4-4. A — Blow gun, commonly used to blow parts clean
`and dry after washing in solvent. B — Solvent gun can be
`used to wash parts. (Binks)
`
`Whenusing a blow gun, weareye protection. Direct
`the blast of air away from yourself and others. Do not
`blow brake and clutch parts clean. These parts con-
`tain asbestos, a cancer causing substance.
`
`Air drill
`An air drillis excellent for many repairs because of
`its power output and speed adjustment capabilities. Its
`powerand 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.
`
`
`
`.
`
`he _ON/OFF
`
`as ~=BUTTON
`
`/
`
` i ="
`VALVE
`
`AIR INLET
`FITTING
`iy_SPEED CONTROL
`
`Fig. 4-8. Air drill speed can be adjusted. It is capable of very
`high turning force. (Hennessy Industries, Inc.}
`
`Fig. 4-8. Bench grinder stone is used to sharpen tools. Brush
`can be used fo clean and polish small parts. Keep shields, tool
`rests, and guards in place. (Sioux Tools)
`
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`
` A
`
`B
`
`KEY
`
`“a
`
`c
`
`Fig. 4-10. Portable electric drilfs. A — Small, 3/8 in. drill. B —
`Larger, 1/2 in. drill. C — Keyis used to tighten bit in chuck.
`(Robert Bosch}
`
`CONTROL
`
` SPEED CHANGE
`
`<—<—— BASE
`
`TABLE
`
`Fig. 4-11. Note parts ofdriltpress. It is for drilling deep or large
`holes when part will fit on table. (Florida Dept. of Voc. Ed}
`
`A few DRILL PRESS RULESto follow include:
`1. Secure the part to be drilled in a vise or with C-
`clamps.
`2. Use acenter punch to indentthe part and start the
`hole.
`we
`_ Remove the key before turning on the drill.
`4, To preventpossible injury, release drilling pressure
`right before the bit breaks through the bottom of
`the part. A drill bit tends to catch when breaking
`
`
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`BENCH GRINDER
`
`A bench grinder, Fig. 4-8, can be used for grinding,
`cleaning, or polishing operations. The hard grinding
`wheelis used for sharpening or deburring. The soft wire
`wheel is for cleaning and polishing.
`A few BENCH GRINDER RULESto follow are:
`1. 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 NOTuse 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
`andplastic parts. They fit into either an electric or air
`powereddrill, Fig. 4-9. Drill bits are commonly made
`of either carbon steel or high speed steel. High speed
`steel is better because ofits resistance to heat. It will
`not lose its hardness whenslightly overheated.
`
`POINT
`FLUTE
`
`BODY
`
`MARGIN
`DRILL
`NN
`
`SIZE
`
`MARGIN
`
`TOP VIEW
`
`
` SHANK
`
`MARGIN
`
`SIDE VIEW
`
`Fig. 4-9. Study basic parts ofdrill bit. (Florida Dept. of Voc. 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 portableelectric 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 numberofholesin severalparts,
`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
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`through. This can.cause the drill or part to rotate
`dangerously.
`5. Oil the bit as needed.
`
`TIRE CHANGER
`
`A tire changer is a commonpiece of shop equipment
`used to remove and replace tires on wheels. Some are
`hand-operated and others use air pressure. Do notat-
`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. 412A.
`Whenraising the front of a car, place the transmis-
`sion in neutral and release the parking brake. This will
`jet 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
`
`A floor jack is also used to raise either the front,
`sides, or rear of a vehicle. Look at Fig. 4-12B.
`
`
` SADDLE
`
`SADDLE
`
`
`RELEASE
`
`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 pressurerelief 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 bumperlift.
`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 typeis similar to
`a floor jack. However, the saddle is enlarged tofit 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. 4-42. Vehicle lifting equipment A — Bumperlift. B —
`Floorjack is for raising car only. C — Jack stands are needed
`before working under car.
`{Florida Dept. of Vac. Ed.)
`
`removing,
`Fig. 4-13. Transmission jack is designed for
`transporting, and installing transmissions when using an
`overheadlift. Hydraulic lift is foot operated and raises to height
`of 721n.
`(OTC Div. of SPX Carp.)
`
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`
` ENGINE
`
`VALVE
`3 <—"
`Soeye we 5
`LEG
`
`
`
`Fig. 4-14. Hydraulic engine crane can be usedto lift heavy ob-
`jects such as engines,
`transmissions,
`transaxles, rear axle
`assemblies.
`
`for raising and a pressurerelease valve for lowering.
`Anenginecraneis also handy forlifting 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. Wearface protection and use recommended
`procedures.
`
`»=
`
`me
`
`<= PUMP
`
`HANDLE
`
`GAUGE
`
`
`PRESSURE_,
`
`ON/OFF
`VALVE
`
`<a tS
`MOVEABLE ~#-f==
`TABLE ~~»
`‘
`F
`Lock7 See
`PINS
`;
`ee
`
`
`
`Fig. 4-15. Hydraulic press is needed for numerous pressing
`operations. It is commonly used to remove and install bearings,
`bushings, seals, and other pressed-on parts. Note! Double-
`check lock pins before using press. if notinstalled, cables in
`unit could snap. (Dake Corp.)
`
`48 Modern Automotive Mechanics
`
`ARBOR PRESS
`An 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
`
`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
`
`
`
`Fig. 4-16. Cold solventtankis for removing oil andlight 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 andcollect
`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-
`
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`Fig. 4-17. High pressure washer will remove greasy buildup
`on outside of assemblies before teardown. (Sioux Tools)
`
`
`
`
`MAIN
`
`
`
`4
`ON/OFF
`REGULATOR VALVE
`
`
`FLAME
`GAUGES
`CONTROL
`VALVES
`PRESSURE
`REGULATOR
`VALVE
`
`f
`
`
`
`240 VOLT
`ELECTRICAL
`OUTLET
`
`SWITCH
`
`ELECTRODE
`HOLDER
`
`
`
`
`
`
`
`ample, a cutting torch is often used to remove old,
`deteriorated exhaust systems. Tremendousheatis 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 NOTattempt 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 soldersolidifies
`(hardens), a strong, solid connection is produced.
`
`BATTERY CHARGER
`
`A batiery charger is used to recharge (energize) a
`discharged (de-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
`EXPLODEviolently.
`
`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
`
`TIP
`
`
`
`
`SOLDERING IRON
`HEATS TERMINAL
`
`FEMALE
`SLIDE
`TERMINAL
`
`B
`
`SerneR
`MELTS AND
`JOINS. TWO
`
`ON/OFF
`TRIGGER
`
`
`
`onGROUND
`
`CLAMP
`
`Fig. 4-18. Top. Oxyacetylene outfit can be used for cutting
`or welding metal. Bottom. Study basic parts of arc welder. (Sun)
`
`Fig. 4-19. A — Soldering iron and soldering gun. B — Soider-
`ing iron or gun produces enough heat to melt solder forjoining
`wires and smail metal terminals. (Florida Dept. of Vac. Ed.)
`
`
`
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`SLIDE ADAPTER
`
`
`
`
`(Sra J
`
`
`Fig. 4-20. A — Drop light. B — Drop or extension cord. © —
`Three-prong adapter with ground terminal and ground wire for
`safety. D — Fluorescent droplight. (Florida Dept. of Voc. Ed.)
`
`WHEEL PULLERS
`
`Wheel pullers are needed to removeseals, 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
`
`Jumpercables are used to start engines with a dead
`(discharged) battery. The cables can be connected be-
`tween the dead battery and anotherbattery. 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 deadbattery. Connect the negative cable
`to the vehicle frame so that any sparks will not occur
`near the battery.
`
`CREEPER
`
`A creeperis 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 creeperis often used on brake
`repairs. The brake parts and tools can be placed on
`the creeper. The service technician cansit andstill be
`eye level with the brake assembly.
`
`ROLL-AROUND CART
`
`A largerroll-aroundcart or table is handy for tak-
`ing a numberoftools to the job. One is pictured in
`
`50 Modern Automotive Technology
`
`
`
`(OTC Div. of SPX Corp.
`
`Fig. 4-21. A — Three-jaw puller. B — Slide hammer puller.
`C — Power puller.
`
`Fig. 4-22. Jumper cables are for emergencystarting. Connec
`red lead to positive terminal of both batteries. Black is for
`negative and ground.
`(Snap-On Tools)
`
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`Fig. 4-23. A —~ Creeper is for working under car. 8 — Stool
`creeper is commonly used during brake and suspension repairs.
`You can sit on the stool and store tools on bottom.
`{Snap-On Tools}
`
`Fig. 4-25. 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 Toats}
`
`Fig. 4-24. Since the technician is working on a carraised
`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. Lookat Fig. 4-25B.
`
`KNOW THESE TERMS
`
`Fender covers are placed over fenders, uppergrille,
`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 tocl, 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. 4-24, Roll-around cart allows you to take several toals to
`car. This saves several trips ta toe! box.
`
`REVIEW QUESTIONS
`
`,
`1. Powertools use
`or__ oats 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.
`a. Impact wrench.
`d. Air saw.
`b. Air ratchet.
`4,A_is used to blow dirt off
`parts and to dry parts after cleaning.
`§. 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.
`a. 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
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`Exhaust
`Systems,
`Turbocharging
`
`After studying this chapter, you will be ableto:
`Describe the basic parts of an exhaust system.
`Compare exhaust system design differences.
`| Perform exhaust system repairs.
`oExplain the fundamental parts of a turbocharging
`system.
`O Describe the construction and operation of a tur-
`bocharger and wastegate.
`ORemove and replace a turbocharger and wastegate.
`oO Demonstrate 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 shownin Fig. 25-1. They
`include:
`1, EXHAUST MANIFOLD(connects cylinder head
`exhaust ports to header pipe).
`2. HEADERPIPE(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. INTERMEDIATEPIPE(tubing sometimes used
`between header pipe and muffler or catalytic con-
`verter and muffler).
`
`
`
`CYLINDER HEAD
`
`
`MUFFLER
`
`HANGER
`ASSEMBLY @
`
`@
`
`a\ =
`a
`
`EXHAUST
`plPe
`
`MANIFOLD
`
`
`
`
`
`
`
`
`EXHAUST OR
`HEADER PIPE
`FLANGE
`
`MUFFLER
`EXHAUST OR
`HEADER PIPE
`
`CATALYTIC
`
`
`CONVERTER
`
`
`IF USED, INTERMEDIATE
`PIPE HERE
`
`TAILPIPE
`
`Fig. 25-7, Note parts of typical exhaust system, Exhaust comesoutof cylinder head, into manifofid, and then through system.
`(Chrysier Corp.)
`
`
`
`Exhaust Systems, Turbocharging 319
`
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`5, MUFFLER(metal chamber for damping pressure
`pulsations to reduce exhaust noise).
`6. TAILPIPE (tubing thatcarries 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).
`Whenanengineis 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 engineis 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 commontype,it is used from the
`smallest four-cylinder engines, on up to large V-8
`engines.
`A dual exhaust system has two separate exhaust
`paths to reduce back pressure.It is two single exhaust
`systems combinedinto one. A dual exhaust system is
`sometimes used on high performancecars 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
`
`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
`madeofstainless steel or lightweight steel tubing. The
`cylinder head mating surfaceis 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.
`
`320 Modern Automotive Technology
`
`SENSOR
`
`OXYGEN
`
`Fig. 25-2. Lower right shows exhaust manifold which bolts
`over exhaust parts on side of cylinder head. Note oxygen sen.
`sor at end of manifold.
`(Chrysler Corp.)
`
`Exhaust manifold heat valve
`An exhaust manifold heat valve forces 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 ofthe
`exhaust manifold. A heat sensitive spring or a vacuum
`diaphragm and temperature sensing vacuum switch
`may operate the valve.
`
`POWER HEAT CONTROL VALVE
`
`FROM
`COOLANT CONTROLLED
`ENGINE VACUUM
`SWITCH
`
`HOUSING FITS BETWEEN
`MANIFOLD AND
`HEADERPIPE
`
`VACUUM ACTUATOR
`
`Fig. 25-3. Heat contro! valve, sometimes called heat risel,
`forces hot exhaust gases into intake manifold. This helps engine
`run smoothly. Valve opens as engine warms up. (Chrysler)
`
`Whentheengineis cold, the heat valveis closed. This
`increases EXHAUST BACK PRESSURE. Hot gasé
`blow into an exhaust passage in the intake manifold,
`Fig. 25-4. This warmsthe floor ofthe intake manifold
`to hasten fuel vaporization. The heat valve opens ®
`the engine warms up.
`
`EXHAUST PIPES
`
`The exhaust pipes (header pipe, intermediate pipe,
`andtailpipe) are usually made ofrust resistant steel
`tubing. The inlet end of the header pipe has a flange
`for securing the pipe to the exhaust manifold studs;
`
`
`
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`CARBURETOR.
`OR
`THROTTLE
`BODY |
`
`
`
`
`
`AIR-FUEL MIXTURE CHAMBERS
`
`BEING HEATED
`
`
`
`ENGINE INTAKE
`MANIFOLD
`
`HOT EXHAUST WHEN
`HEAT VALVE IS SHUT
`
`fig. 25-4. Heat 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)
`
`Fig. 25-1. One end of each pipe may be enlarged to
`fit over the end of the next pipe.
`
`HEAT SHIELDS
`
`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! Alwaysreinstall all exhaust system heat
`shields. Without a heat shield, car undercoating,
`carpeting, dry leaves on the ground, and other flam-
`mable materials could catch onfire!
`
`CATALYTIC CONVERTER
`
`A catalytic converter is used to reduce the amount
`of exhaust pollutants entering the atmosphere. Oneor
`more catalytic converters can be located in the exhaust
`system, Fig. 25-1.
`_ Fordetails of catalytic converters, refer to Chapters
`39 and 40 which cover emission control systems.
`
`MUFFLERS
`
`A muffler reduces the pressure pulses and resulting
`Noise produced by the engine exhaust. When an engine
`Stunning, the exhaust valves are rapidly opening and
`‘losing. Each time an exhaust valve opens, a blast of
`hot gas shoots out of the engine. Without a muffler,
`€se exhaust gas pulsations are very loud.
`Fig. 25-5 shows the inside of a muffler. Note how
`chambers, tubes, holes, and baffles are arranged to
`“ancel out the pressure pulsations in the exhaust.
`EXHAUST SYSTEM SERVICE
`
`|
`
`Exhaust System service is usually needed when a com-
`
`
`
`SOUND OR
`RESONANCE
`
`
`
`MUFFLER
`SHELL
`
`ACOUSTI
`
`
`
`
`
`
`PYREX THERMAL PACKING
`RATED TO 1200°F or 650°C
`
`OUTLET
`
`SOUND OR RESONANCE
`CHAMBER
`
`Fig. 25-5. Basic muffler contains baffles, resonance chambers,
`and acoustic tubes to reduce exhaust noise.
`(American Exhaust Industries)
`
`ponentin 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 ona lift.
`Using a droplight, closely inspect the system for prob-
`lems(rusting, loose connections, leaks). In particular,
`check around the muffler,all pipe connections, gaskets,
`and pipe bends.
`D