Automotive Technology Basic Worksheets - Europa
Titelei Schueler Titel Lehrer 10.09.20 14:08 Seite IEUROPA REFERENCE BOOKSfor Automotive TechnologyAutomotive TechnologyBasic WorksheetsAuthors:Fischer, RichardGscheidle, TobiasHeider, UweHohmann, Bertholdvan Huet, AchimKeil, WolfgangLohuis, RainerMann, JochenSchlögl, BerndWimmer, AloisStudiendirektorDipl.-Gewerbelehrer, StudiendirektorKfz-Elektriker-Meister, Trainer Audi AGOberstudiendirektorDipl.-Ingenieur, StudiendirektorOberstudiendirektorDipl.-Ingenieur, OberstudienratDipl.-Gewerbelehrer, StudiendirektorDipl.-Gewerbelehrer, StudiendirektorOberstudienratPolling – MunichSindelfingen – StuttgartNeckarsulm – OedheimEversbergOberhausen – EssenMunichHückelhovenSchorndorf – StuttgartRastatt – GaggenauBerghülenHead of working group and editorial office:Rolf Gscheidle, Studiendirektor, Winnenden, GermanyGraphic design:Design office of Verlag Europa-Lehrmittel, Ostfildern, GermanyAll rights reserved. This book is protected by copyright. Any commercial use beyond the legally specified uses requireswritten approval from the publisher.1st English edition 2015, corrected reprint 2020Impression 5 4 3 2All impressions of the same edition can be used in parallel, as they do not differ from each other except with regard to thecorrection of printing errors. 2015 by Verlag Europa-Lehrmittel, Nourney, Vollmer GmbH & Co. KG, 42781 Haan-Gruiten, Germanyhttp://www.europa-lehrmittel.deTypesetting: rkt, 51379 Leverkusen, Germany – www.rktypo.comCover design: braunwerbeagentur, 42477 Radevormwald, GermanyCover photo: BMW AG, Munich, Germany.Printing: RCOM Print GmbH, 97222 Würzburg-Rimpar, GermanyEuropa-No.: 22486ISBN 978-3-8085-2248-6VERLAG EUROPA-LEHRMITTEL · Nourney, Vollmer GmbH & Co. KGDüsselberger Straße 23 · 42781 Haan-Gruiten, Germany
Titelei Schueler Titel Lehrer 10.09.20 14:08 Seite IIPreface"Automotive Technology – Basic Worksheets" contains worksheets for the following subject areas:Service, Repairs, Diagnosis, Conversions and Retrofits.The worksheets are designed to form a foundation for operational situations. In each subject area, practical situations serve as an introduction to the topical contents. Comprehensive assignments provide the necessary basic technical knowledge. The learning situationsfound at the beginning of each topic can then be solved with this basic knowledge. Clearly outlined assignments can be solved independently in groups or with an instructor with thehelp of the "Modern Automotive Technology" textbook as well as the reference table. Circuit diagrams, maintenance schedules and work plans as well as functional descriptions arechosen such that they can be processed similarly to comparable job-related workflows. With the help of the accompanying ESI-Tronic CD, the student can obtain information and work oncustomised exercises. Content on operational organisation, operational communication and quality management can befound in the Service worksheets in the form of practical tasks. An example of a vehicle registration certificate, Part I, for registered vehicles in Europe, can befound on the inside back cover. Such documents are required to identify the vehicle during repairwork and in locating spare parts in dealerships and auto parts stores.The following tasks are given in the four subject areas:1 SERVICEMaintaining and inspecting vehicles and systems according to specifications.2 REPAIRSChecking, disassembling, exchanging and assembling simple components and systems.3 DIAGNOSISIdentify and eliminate malfunctions4 CONVERSIONSAND RETROFITSPerforming customer-driven conversionsThe worksheets, along with other vehicle technology textbooks such as "Modern Automotive Technology", Verlag Europa-Lehrmittel (ISBN 978-3-8085-23025), form a complete unit.They are intended to help in carrying out practice-orientated lessons.The AuthorsFall 2015
Titelei Schueler Titel Lehrer 10.09.20 14:08 Seite IIIContentsWorksheets1 SERVICE3 DIAGNOSISMaintaining and inspecting vehiclesand systems according to specificationsIdentify and eliminate malfunctionsMotor vehicle system, Sheets 1 2 . . . . . . . .Motor vehicle classifications, Dimensions . .Evolution of the motor vehicle . . . . . . . . . . . .Four-stroke spark-ignited engine,Sheets 1 5 . . . . . . . . . . . . . . . . . . . . . . . . .Ignition interval, firing order, Sheets 1 3 . .PV diagram, Sheets 1 2 . . . . . . . . . . . . . . . .Four-stroke diesel engine, Sheets 1 2 . . . . .Signs: prohibition, warning, rules and rescueVehicle lifting platform operatinginstructions, Sheets 1 2 . . . . . . . . . . . . . .Workshop safety regulations, Sheets 1 2 . .High voltage safety, Sheets 1 2 . . . . . . . . . .Electrical current safety measures . . . . . . . . .Fluids and additives, Sheets 1 3 . . . . . . . . .First aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vehicle registration certificate . . . . . . . . . . . . .Workshop information system, Sheets 1 7Inspections, Sheets 1 4 . . . . . . . . . . . . . . . .Cooling system maintenance, Sheets 1 4 .Drive belt changes, Sheets 1 2 . . . . . . . . . .Oil and filter changes, Sheets 1 4 . . . . . . .Battery maintenance, Sheets 1 2 . . . . . . . .Wheels and tyres, Sheets 1 4 . . . . . . . . . . .Brakes, Sheets 1 4 . . . . . . . . . . . . . . . . . . . .Changing brake fluid, Sheets 1 2 . . . . . . . .Windscreen wipers, Sheets 1 2 . . . . . . . . . .Vehicle care, Sheets 1 6 . . . . . . . . . . . . . . . .Work order processing, Sheets 1 4 . . . . . . .Quality management, Sheets 1 2 . . . . . . . .Workshop tests, Sheets 1 2 . . . . . . . . . . . . .5 16789 1314 1517 1819 202122 2324 2526 272829 31323334 4041 4445 4849 5051 5455 5657 6061 6465 6667 6869 7475 7879 8081 82Motor vehicle electrical components . . . . . . .121Electrical loads . . . . . . . . . . . . . . . . . . . . . . . . .122Electrical voltage, Sheets 1 3 . . . . . . . . . . . 123 125Electrical current, Sheets 1 2 . . . . . . . . . . . . 126 127Electrical power . . . . . . . . . . . . . . . . . . . . . . . .128Electrical resistance, Sheets 1 2 . . . . . . . . . 129 130Ohm's Law . . . . . . . . . . . . . . . . . . . . . . . . . . . .131Electrical resistor circuits . . . . . . . . . . . . . . . .132Electrical circuits, Sheets 1 5 . . . . . . . . . . . . 133 137Ignition switch, Sheets 1 2 . . . . . . . . . . . . . . 138 139Battery safety terminal . . . . . . . . . . . . . . . . . .140Electromagnetism, Sheets 1 2 . . . . . . . . . . 141 142Induction, Sheets 1 2 . . . . . . . . . . . . . . . . . . 143 144Troubleshooting, Sheets 1 4 . . . . . . . . . . . . 145 148Light test, Sheets 1 2 . . . . . . . . . . . . . . . . . . 149 150Troubleshooting lighting equipment,Sheets 1 2 . . . . . . . . . . . . . . . . . . . . . . . . . 151 152Fundamentals of electronics , Sheets 1 6 . 153 158Electronics troubleshooting, Sheets 1 2 . . . 159 160Oscilloscope, Sheets 1 2 . . . . . . . . . . . . . . . 161 162Fundamentals of controls , Sheets 1 3 . . . . 163 165Cruise control equipment, Sheets 1 2 . . . . 166 167Fundamentals of pneumaticsand hydraulics , Sheets 1 3 . . . . . . . . . . . 168 170Cylinder control, Sheets 1 2 . . . . . . . . . . . . 171 172Bus door control, Sheets 1 3 . . . . . . . . . . . . 173 175Loading platform, Sheets1 4 . . . . . . . . . . . 176 1794 CONVERSIONSAND RETROFITSPerforming customer-driven conversions2 REPAIRSChecking, disassembling, exchanging andassembling simple components and systemsChecking and measuring, Sheets 1 2 . . . . .Drilling and threading, Sheets 1 10 . . . . . .Thread repair . . . . . . . . . . . . . . . . . . . . . . . . . .Torque, Sheets 1 3 . . . . . . . . . . . . . . . . . . . .Making brake lines, Sheets 1 3 . . . . . . . . . .Section repair, Sheets 1 5 . . . . . . . . . . . . . .Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inner door assembly, Sheets 1 3 . . . . . . . .Materials overview . . . . . . . . . . . . . . . . . . . . .Materials, Sheets 1 4 . . . . . . . . . . . . . . . . . .Non-ferrous metals . . . . . . . . . . . . . . . . . . . . .Chassis, corrosion protection, Sheets 1 2 .Motor vehicle plastics . . . . . . . . . . . . . . . . . . .Material properties . . . . . . . . . . . . . . . . . . . . . .83 18485 1949596 19899 101102 106107108 110111112 115116117 118119120Wheel and tyre conversions, Sheets 1 6 . . 181 186Parking assistance, Sheets 1 4 . . . . . . . . . . 187 190Fog lights, Sheets 1 4 . . . . . . . . . . . . . . . . . . 191 194Trailer equipment, Sheets 1 4 . . . . . . . . . . . 195 198Trailer coupling, Sheets 1 2 . . . . . . . . . . . . . 199 200
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LF 1 005-082 Lernfeld 1 005-064 10.09.20 14:09 Seite 5Name:1 SERVICEClass:Motor vehicle systemDate:Sheet No.:Sheet 1The use of technical terms is required in on- and off-the-job communication.Identify the parts and component groups.2.Fill in the table with the correct part and its function.Reprints, even in parts, require the publisher's permission.Copyright 2015 by Springs,dampersSteeringLightingequipmentBrakes5
LF 1 005-082 Lernfeld 1 005-064 10.09.20 14:09 Seite 6Name:1 SERVICEClass:Motor vehicle system3.Date:Sheet No.:Sheet 2Identify the numbered drivetrain subsystems in the table and fill in their functions.15867rgyene red yots icallm lche n fuei2NumberlabelsSubsystem14FunctionConverts stored chemical energy into mechanical propulsion.Clutch3Distributes torque to the front and rear axles in all-wheel-drive vehicles.456784.Collect sensor data, calculate control device parameters, control actuators.In the picture, fill in the vehicle material flow for air, fuel and exhaust and the energy flow.Air-fuelmixtureEngineTransmissionClutchFuel tankWheelPlanetary gearsMulti-disc clutchSwitching valvesUseful work: Sparkignition engine 32%Diesel engine 43%10%drivetrainlossChemically storedenergy5.How much fuel energy reaches the wheel? How high are the losses? Fill in the table.Exhaust, cooling, radiation losses in %Spark-ignitionengine6Diesel engineDriving power at the wheel in %Spark-ignitionengineDiesel engineReprints, even in parts, require the publisher's permission.Copyright 2015 by Europa-Lehrmittel273rgy toene rted alev nicconecha onm moti
LF 1 005-082 Lernfeld 1 005-064 10.09.20 14:09 Seite 7Name:1 SERVICEClass:Date:Sheet No.:2.Fill in the dimensions in the table and add mm or degrees.992729490179647534930 164888029151926Vehicle lengthReprints, even in parts, require the publisher's permission.Copyright 2015 by Europa-Lehrmittel10094804Rear seat heightVehicle height3.28 761Europa10463575081700839Motor vehicles are divided into the following classifications.10591.902Motor vehicle classifications, Dimensions1648 mm2915 mmApproachangleIdentify the vehicles below and indicate their special features.Crossover4.Which drivetrains are built into today's vehicles?7
LF 1 005-082 Lernfeld 1 005-064 10.09.20 14:09 Seite 8Name:1 SERVICEClass:Date:Sheet No.:Evolution of the motor vehicle1.Which important machines did these individuals invent?PortraitInventionNikolaus August Otto1832 – 1891Reprints, even in parts, require the publisher's permission.Copyright 2015 by Europa-LehrmittelCarl Benz1844 – 1929Gottlieb Daimler1834 – 1900Rudolf Diesel1858 – 1913Robert Bosch1861 – 1942Wilhelm Maybach1846 – 19292.Use the reference book to determine power, displacement and power density for the pictured vehicles.Power in kW / HP888 / 120Displacement in î2.0Power density in kW/î77.5146.67
Sheet 1Enginepower controlcylinder arrangementcarburetioninjectioncompressed mediumcoolingignitioncylinder motionprocessCombustion enginecategorisationaccording to type of Vehicle1. Fill in the table.direct4-strokeClass:Name:twin-rotor engineDifferent engine concepts are used for vehicles. Combustion engines can be categorised according to various characteristics.4-stroke spark-ignition engine1 SERVICEReprints, even in parts, require the publisher's permission.Copyright 2015 by Europa-LehrmittelDate:Sheet No.:LF 1 005-082 Lernfeld 1 005-064 10.09.20 14:09 Seite 99
LF 1 005-082 Lernfeld 1 005-064 10.09.20 14:09 Seite 10Name:1 SERVICEClass:4-stroke spark-ignition engine2.Date:Sheet No.:Sheet 2The cylinder arrangements pictured below are common in 4-stroke piston engines.a. Match the engine picture to its construction with an arrow.b. Fill in the engine designation and give an example of an application plication90 3.Other cylinder arrangements are illustrated in the table below. These were or are seldom built.Fill in the table.FigureMatchingConstructionDescriptionDouble pistonengine with forkconnecting rodExampleapplicationTriumph; Puch; JavaMotorcycle enginesJunkers marine,stationary andaircraft enginesAircraft enginesSports cars10Reprints, even in parts, require the publisher's permission.Copyright 2015 by Europa-Lehrmittel15 Figure
LF 1 005-082 Lernfeld 1 005-064 10.09.20 14:09 Seite 11Name:1 SERVICEClass:4-stroke spark-ignition engineDate:Sheet No.:Sheet 3Reprints, even in parts, require the publisher's permission.Copyright 2015 by Europa-LehrmittelAs a part of communication within the workshop, it is necessary to be able to identify engine component groupsand parts in vehicle engine care and maintenance.1.Identify the component groups in the exploded views.2.In the simplified cross-section of a 4-stroke spark-ignition engine, identify the numbered parts and fill in themissing number for the parts given.3.Mark the crankshaft drive and engine control parts in different colours.16211112Engine case11315142345Crankshaft drive36677898104Engine control11109121351417 Speed sensor18 Spark plug19Intake manifold20 Oil-pump strainer/oil pump1521 Fuel injector1611
LF 1 005-082 Lernfeld 1 005-064 10.09.20 14:09 Seite 12Name:1 SERVICEClass:4-stroke spark-ignition engineDate:Sheet No.:Sheet 4Situation: You read the following in the magazine "Motor Sport": ".the new turbocharged 4-cylinder 4-stroke engineis a classic short-stroke engine with a 92 mm bore and 60.3 mm stroke. The 1596 cc engine has an 85 kWpower output and produces 250 Nm of torque. The compression ratio is 12 to 1. The average fuel economyis 6.1 litres to 100 km."1.Define the following engine-related terminology found in the text and include the respective notation:Stroke:Dead centre:Displacement:Compression space:Crank angle:2.3.Fill in the values corresponding to the terms below that are associated with a 4-stroke engine. An operating cycleconsisting of.strokescrank anglecamshaft rotationcam anglecrankshaft rotationsopening and closing of the inlet andexhaust valvesa) Identify the parameters in the table and enter them in the illustration.b) With the part dimensions from the illustration (scale 1:4), calculate Vh.NotationDescriptionDimensiondsVhVC26 cm3 -IV -EV -Cc12TDC–BDC–Reprints, even in parts, require the publisher's permission.Copyright 2015 by Europa-LehrmittelCompression ratio:
LF 1 005-082 Lernfeld 1 005-064 10.09.20 14:09 Seite 13Name:1 SERVICEClass:4-stroke spark-ignition engine4.Identify the individual strokes.5.Mark the cylinders and the crank circles with TDC and BDC.6.Mark the direction of cylinder movement with an arrow.7.Sketch in the connecting rod and crankshaft according to the cylinder's position.8.Sketch in the valves for each stroke.9.For each stroke, enter into the table– whether the inlet and exhaust valves are open or closed– at what crank angle the inlet and exhaust valves open or closeUse a reference table.10.Sheet No.:– the max. temperature in the cylinder– the max. pressure in the cylinder.Enter the open and close positions Io, Ic, Eo, Ec in the crank circle of the corresponding stroke.Use values from an engine in the reference table.Fill the cylinder above the piston with a different colour for each stroke.1st strokeReprints, even in parts, require the publisher's permission.Copyright 2015 by Europa-LehrmittelDate:Sheet 5IVEV2nd strokeIVEV3rd strokeIVEV4th strokeIVEVInlet valveInlet valveInlet valveInlet valveExhaust valveExhaust valveExhaust valveExhaust valveTemperature in cylinderTemperature in cylinderTemperature in cylinderTemperature in cylinderPressure in cylinderPressure in cylinderPressure in cylinderPressure in cylinder at Eo13
LF 1 005-082 Lernfeld 1 005-064 10.09.20 14:09 Seite 14Name:1 SERVICEClass:Ignition interval, firing orderDate:Sheet No.:Sheet 1Situation: In the course of servicing a VW Lupo, ignition cables have to be replaced.1.The new ignition cables are provided with the numbers 1 to 3.What do these numbers mean?322.The cylinder's numbering and the direction the cylinders are counted areDIN-specified.1a) Define cylinder 1 according to the standards.3.a) Fill in the cylinder numbering, rotational direction (clockwise) and the construction type of the engine conceptsshown according to the DIN Standard.b) Indicate the corresponding firing order.4.What does "firing order" mean?5.Calculate the number of power cycles per minute with an engine speed of 3000 1/min for a 3-cylinder engine andfor a 6-cylinder engine.Given:14Reprints, even in parts, require the publisher's permission.Copyright 2015 by Europa-Lehrmittelb) The engine rotates clockwise. What does this mean?
LF 1 005-082 Lernfeld 1 005-064 10.09.20 14:09 Seite 15Name:1 SERVICEClass:Ignition interval, firing order6.Date:Sheet No.:Sheet 2Describe the term ignition interval and calculate it for a 3-cylinder engine.Ignition interval 7.720 ᎏzThe crankshaft is cranked according to the ignition interval (figure).For clarity, the crankshaft is depicted in side and frontal (star diagram) views. The stroke order is Compressiona) Calculate the ignition interval and indicate the firing order.Reprints, even in parts, require the publisher's permission.Copyright 2015 by Europa-Lehrmittelb) Construct the position of the crank pins (star diagram). Transfer the cylinder numbering to the correspondingcrank pin on the star diagram.Note: Begin with the 1st cylinder. Construct the position of the next crank pin according to the firing order againstthe direction of rotation by the number of degrees of the ignition interval.c) Construct the crankshaft side view from the star diagram (with the help of lines).d) Label the individual stroke of each cylinder.Engine typeStar diagramIgnition intervalFiring orderCrankshaft side view11240 Firing order1–3–220 180 3360 540 720 540 720 12311420 180 360 3123415
16EVEV2IVIV3EV4IVIV5EVFiring order 1 – 2 – 4 – 5 – 3Combustion1Crank circleIgnition interval Strokes1 SERVICEClass:Date:Reprints, even in parts, require the publisher's permission.Copyright 2015 by Europa-LehrmittelEVExhaust valve opens 40 before BDCExhaust valve closes 10 after TDC54321Cyl.Ignition interval, firing orderIV1Intake valve opens 6 before TDCIntake valve closes 44 after BDCTimingf) Draw the intake and exhaust values in the correct position (the valvesshould be shown as clearly closed or open).e) Complete the table with each cylinder's work cycle; indicate the strokeswith corresponding colours.d)Indicate each piston's direction of movement with arrows.c) Fill in the crankshaft for cylinders 2 to 5; draw the corresponding piston andconnecting rod positions.b)Draw the crank arms for cylinders 2 to 5 onto the crank circle; number thecrank pins according to the firing order.a) Determine and fill in the firing order.8. The following illustration is a schematic diagram of the crankshaftmechanism for a five-cylinder four-stroke engine.LF 1 005-082 Lernfeld 1 005-064 10.09.20 14:09 Seite 16Name:Sheet 3Sheet No.:
LF 1 005-082 Lernfeld 1 005-064 10.09.20 14:09 Seite 17Name:1 SERVICEClass:PV diagramDate:Sheet No.:Sheet 1Situation: A spark-ignition engine
Preface "Automotive Technology – Basic Worksheets" contains worksheets for the following subject areas
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