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Modern Auomative Technology PDF
Modern Auomative Technology PDF
Modern
Automotive Technology
Fundamentals, service, diagnostics
The German edition was written by technical instructors, engineers and technicians
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 pub-
lisher are excluded.
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
Foreword
1
"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 compre-
hensible 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, electromag-
netic compatibility and comfort and convenience systems such as adaptive cruise control, parking assis-
tance 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.
Abbreviations
A/C Air conditioning CPU Central processing unit EMS Electronic engine
A/F Air/fuel (mixture) CR Common rail management system
ABC Active body control CS Crankshaft Eo Exhaust valve opens
ABS Antilock braking system CSR Conti support ring EOBD European on board
ABV Automatic braking-force CV Commercial vehicle diagnosis
distribution CV Check valve EP Exhaust passage
(German: Automatische CVlft Check valve left EPHS Electrically powered
Bremskraftverteilung ) hydraulic steering
CVrt Check valve right
AC Alternating current EPS Electro-pneumatic control
CVT Continuous variable
ACC Adaptive cruise control system
transmission
ACEA Association des ESP Electronic stability
Constructeurs Europens program
DA Drive axle
de l'automobile ETC Electronic throttle control
DC Direct current
ACS Automatic clutch system ETN European type number
DI Direct injection
AD Analogue-digital EV Exhaust valve
(converter) DME Digital motor electronics
FA Front axle
ADSL Asymmetrical digital DOHC Double overhead
FB Function button
subscriber line camshaft
FDI Fuel direct injection
AGM Absorbing glas mat DOT Department of Transport
FF Freeform (reflector)
ALDBFR Automatic load- DSC Dynamic stability control
DSG Direct-shift gearbox FH Flat hump
dependent brake-force
DSP Dynamic shift-program FL Front left
regulator
selection FOC Fibre-optic cable
ALSD Automatic limited-slip
differential DSST Dunlop self-supporting FOT Fibre-optical transceiver
AM Amplitude modulation technology FR Front right
API American Petroleum FSI Fuel stratified injection
Institute EBS Electronic braking system FWD Four wheel drive
ASC Anti-stability control Ec Exhaust valve closes
ASTM American Society for ECE Economic Commission GDI Gasoline direct injection
Testing and Materials for Europe GFRP Glass-fibre-reinforced
ATF Automatic transmission ECM Electronic clutch plastic
fluid management GI General inspection
ATS Adaptive transmission ECS Electronic clutch system GMR Automatic regulation of
control (system) ECU Electronic control unit yaw moment (German:
EDC Electronic diesel control Giermomentregelung)
BAS Brake assistant EDP Electronic data GPS Global positioning system
BDC Bottom dead centre processing GVWR Gross vehicle weight
EDTC Engine-drag torque rating
CA Crankshaft angle control
CS Camshaft EEPROM Electrically erasable HF High frequency
CAN Controller area network programmable read-only HFM Hot-film air-mass meter
memory
CBS Combined brake system HGV Heavy goods vehicle
EGR Exhaust gas recirculation
CC Cruise control HNS Homogeneous
EGS Electronic gearbox numerically calculated
CDI Capacitive discharge
control unit (German: surface
ignition
Elektronisches
CFPP Cold filter plugging point HS High-solid (paints)
Getriebesteuergert)
CFRP Carbon-fibre-reinforced HTHS High temperature,
EH Extended hump
plastic high shear
EHB Electro-hydraulic braking
CH Combination hump HV Hybrid vehicle
system
CIH Camshaft in head EI Emissions inspection
CIP Continuous improvement IC Integrated circuit
ELSD Electronic limited-slip
process differential Ic Inlet valve closes
CN Cetane number EMC Electro-magnetic IC Individual control
CNG Compressed natural gas compatibility IDI Indirect injection
5
Abbreviations
IHPF Internal high-pressure OBD On board diagnosis SBC Sensotronic brake control
forming OD Outside diameter SC Signal conditioning
Io Inlet valve opens OHC Overhead camshaft SCR Selective catalytic
IP Inlet passage OHV Overhead valves reduction
IPO Input/Processing/Output ON Octane number SCV Solenoid control valve
(principle) OV Outlet valve SDC Semi-drop centre
IS Input shaft OVlft Outlet valve left SE Sensor
ISAD Integrated starter SI Safety inspection
alternator damper SLC Select-low control
PBC Parking-brake circuit
IV Inlet valve SoC State of charge
PC Planet carriers
IVlft Inlet valve left SPI Single-point injection
PCU Pump control unit
Ivrt Inlet valve right SRR Short-range radar
PDA Personal digital assistant
PEM Proton exchange SRS Safety restraint systems
LA Lifting axle membran SSlft Speed sensor left
LD Low density PES Poly ellipsoid system SSR Self-supporting run-flat
LDR Light depending resistor (reflector) tyres
LED Light emitting diode PIN Personal identification SSrt Speed sensor right
LEV Low-emission vehicle number SV Solenoid valve
LF Low frequency PM Particulate matter SV Side valve
LI Load index POF Plastic optical fibre SW Short wave
LIN Local interconnect POT Plastic optical transceiver SWR Stationary wave ratio
network PR Ply rating
LNG Liquefied natural gas PTC Positive temperature Tc Transfer passage closes
LS Limited slip coefficient TCS Traction control system
LSG Laminated safety glass PWM Pulse width modulation TDC Top dead centre
LU Logical unit TIG Tungsten-inert gas
LW Long wave QA Quality assurance TL Tubeless
QM Quality management To Transfer passage opens
MAF Mass air flow TP Transfer passage
MAG Metal-active-gas RA Rear axle TPC Tyre-pressure check
(welding) RDS Radio data system TSG Toughened safety glass
MC Microcomputer RHD Right-hand driver TWI Treadwear indicator
MC Main cylinder RL Rear left
ME Motor electronics RLFS Return-less-fuel system UIS Unit injector system
MED Motor electronics direct RON Research-octane number UPS Unit pump system
injection ROP Roll-over protection
MG Motor generator ROV Rotating high voltage VDC Vehicle dynamics
MIG Metal-inert-gas (welding) distribution controller
MIL Malfunction indicator (German: Rotierende VDR Voltage-dependent
lamp Hochspannungs- resistor
verteilung)
MON Motor-octane number VF Variable focus (reflector)
RR Rear right
MOST Media-oriented system VHF Very high frequency
transport RRC Radio remote control
VT Viscosity temperature
MPI Multi-point injection RUV Static high voltage
VTec Variable valve timing and
distribution
MS Medium-solid (paints) lift electronic control
(German: Ruhende
MW Medium wave Hochspannungs- VTG Variable turbine geometry
verteilung)
NF Non-ferrous WIG Wolfram-inert-gas
SAC Self-adjusting clutch (welding)
NLGI National Lubrication
Grease Institute SAE Society of Automotive
NLS Needle lift sensor Engineers
NTC Negative temperature SAM Signal acquisition and
coefficient actuation module
6 Contributing companies
We wish to thank the companies listed below for providing technical advice, information, photographs and
illustrations.
7.3.3 Forming under compressive conditions 107 10.5 Timing diagram . . . . . . . . . . . . . . . . . . . 192
7.3.4 Straightening . . . . . . . . . . . . . . . . . . . . . . 109 10.6 Cylinder numbering, firing orders . . . 192
7.3.5 Sheet-metal working processes . . . . . . . 109 10.7 Engine-performance curves . . . . . . . . 194
7.4 Separating by cutting . . . . . . . . . . . . . . . 113 10.8 Stroke-to-bore ratio, power output
7.4.1 Basics of cutting-shaping . . . . . . . . . . . . 113 per litre, weight-to-power ratio . . . . . . 195
7.4.2 Cutting-shaping by hand . . . . . . . . . . . . . 113
7.4.3 Basics of cutting-shaping
with machine tools . . . . . . . . . . . . . . . . . 120 11 Mechanical engine components 196
7.5 Separating by dividing . . . . . . . . . . . . . . 129
11.1 Cylinder, cylinder head . . . . . . . . . . . . . 196
7.5.1 Cropping . . . . . . . . . . . . . . . . . . . . . . . . . . 129
11.1.1 Functions, stresses and strains . . . . . . 196
7.5.2 Wedge-action cutting . . . . . . . . . . . . . . . 130
11.1.2 Cylinder types . . . . . . . . . . . . . . . . . . . . .196
7.6 Joining . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
11.1.3 Cylinder head . . . . . . . . . . . . . . . . . . . . . 198
7.6.1 Categorisation of connections . . . . . . . . 131
11.1.4 Cylinder-head gasket . . . . . . . . . . . . . . 199
7.6.2 Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
11.1.5 Crankcase . . . . . . . . . . . . . . . . . . . . . . . . 200
7.6.3 Screwed joints . . . . . . . . . . . . . . . . . . . . . 133
11.1.6 Engine suspension . . . . . . . . . . . . . . . . 200
7.6.4 Pin connections . . . . . . . . . . . . . . . . . . . . 138
11.2 Engine-cooling systems . . . . . . . . . . . . 204
7.6.5 Riveted joints . . . . . . . . . . . . . . . . . . . . . . 139
11.2.1 Types of cooling . . . . . . . . . . . . . . . . . . 204
7.6.6 Clinching . . . . . . . . . . . . . . . . . . . . . . . . . . 140
11.2.2 Air cooling . . . . . . . . . . . . . . . . . . . . . . . 205
7.6.7 Shaft-hub connections . . . . . . . . . . . . . . 141
11.2.3 Liquid cooling . . . . . . . . . . . . . . . . . . . . 205
7.6.8 Press-fit joints . . . . . . . . . . . . . . . . . . . . . . 142
11.2.4 Pump-cooling components . . . . . . . . . 206
7.6.9 Snap-in connections . . . . . . . . . . . . . . . . 142
11.2.5 Map-controlled cooling systems . . . . . 211
7.6.10 Soldering . . . . . . . . . . . . . . . . . . . . . . . . . 143
11.2.6 Map-cooling components . . . . . . . . . . 211
7.6.11 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
11.3 Crankshaft drive . . . . . . . . . . . . . . . . . . 213
7.6.12 Gluing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
11.4 Dual-mass flywheel . . . . . . . . . . . . . . . 225
7.7 Coating . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
11.5 Engine lubricating systems . . . . . . . . . 226
11.6 Engine timing gear . . . . . . . . . . . . . . . . 232
8 Material science 154 11.7 Charge optimisation . . . . . . . . . . . . . . . 238
8.1 Properties of materials . . . . . . . . . . . . . . 154
8.2 Categorisation of materials . . . . . . . . . . 158
8.3 Structure of metallic materials . . . . . . . . 159 12 Mixture formation 247
8.4 Ferrous products . . . . . . . . . . . . . . . . . . . 161 12.1 Fuel-supply systems in
8.4.1 Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 spark-ignition engines . . . . . . . . . . . . . .247
8.4.2 Cast-iron materials . . . . . . . . . . . . . . . . . 161 12.2 Mixture formation in spark-ignition
8.4.3 Influence of additives on engines . . . . . . . . . . . . . . . . . . . . . . . . . . 252
ferrous products . . . . . . . . . . . . . . . . . . . 163 12.3 Carburettor . . . . . . . . . . . . . . . . . . . . . . . 255
8.4.4 Designation of ferrous products . . . . . . 163 12.4 Petrol injection . . . . . . . . . . . . . . . . . . . . 257
8.4.5 Categorisation and application 12.4.1 Basic principles of petrol injection . . . 257
of steels . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 12.4.2 Design and function of
8.4.6 Commercial forms of steel . . . . . . . . . . . 167 electronic petrol injection . . . . . . . . . . 259
8.4.7 Heat treatment of 12.4.3 Operating-data acquisition . . . . . . . . . 260
ferrous products . . . . . . . . . . . . . . . . . . . 167 12.4.4 Single-point injection . . . . . . . . . . . . . . 266
8.5 Non-ferrous metals . . . . . . . . . . . . . . . . . 171 12.4.5 LH-Motronic . . . . . . . . . . . . . . . . . . . . . . 270
8.6 Plastics . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 12.4.6 ME-Motronic . . . . . . . . . . . . . . . . . . . . . 276
8.7 Composite materials . . . . . . . . . . . . . . . . 176 12.4.7 MED-Motronic . . . . . . . . . . . . . . . . . . . . 280
12.4.8 KE-Jetronic . . . . . . . . . . . . . . . . . . . . . . . 286
9 Friction, lubrication, bearings, seals 177 12.5 Mixture formation in diesel engines . 288
9.1 Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 12.5.1 Combustion sequence in a
9.2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . 178 diesel engine . . . . . . . . . . . . . . . . . . . . . 288
9.3 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . 179 12.5.2 Failures in combustion sequence . . . . 288
9.4 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 12.5.3 Comparison of injection processes . . . 289
12.5.4 Inlet-passage control . . . . . . . . . . . . . . 290
12.5.5 Start-assist systems . . . . . . . . . . . . . . . 290
10 Design and operating principle
12.5.6 Nozzle-holder assembly . . . . . . . . . . . . 292
of a four-stroke engine 183
12.5.7 Injection systems for
10.1 Spark-ignition engine . . . . . . . . . . . . . . . 183 passenger-car diesel engines . . . . . . . 294
10.2 Diesel engine . . . . . . . . . . . . . . . . . . . . . . 185 12.5.7.1 Axial-piston distributor pump
10.3 General physical and with mechanical control . . . . . . . . . . . . 294
chemical principles . . . . . . . . . . . . . . . . . 185 12.5.7.2 Electronic diesel control (EDC) . . . . . . 298
10.4 Pressure-volume diagram 12.5.7.3 Electronically controlled axial-piston
(p -V diagram) . . . . . . . . . . . . . . . . . . . . . 190 distributor injection pump (VE-EDC) . 299
Table of contents 9
1 Motor vehicle 1
1.2 Motor vehicle classifications Commercial vehicles. These are designed to trans-
1 port people and cargo and for pulling trailers. Pas-
senger cars are not classified as commercial vehi-
Roadgoing or highway vehicles is a category com-
cles.
prising all vehicles designed for road use, as op-
posed to operation on tracks or rails (Fig. 1). Single-track vehicles
Motorcycles are single-track vehicles with 2 wheels. A
The basic division is into two classes, motor vehicles sidecar may be attached to the motorcycle, which re-
and trailers. Motor vehicles always possess an integral mains classified as such provided that the tare weight
mechanical propulsion system. of the combination does not exceed 400 kg. A motor-
cycle can also be employed to pull a trailer. Single-track
Roadgoing vehicles vehicles include
Motor vehicles Trailer vehicles
Motorcycles. These are equipped with permanent,
fixed-location components (fuel tank, engine) locat-
Vehicle combination ed adjacent to the knees as well as footrests.
Motor scooters. Because the operator's feet rest on
Motor vehicles Semitrailers a floor panel, there are no fixed components at knee
Passenger cars level on these vehicles.
Drawbar trailers Bicycles with auxiliary power plants.These vehicles
Commercial vehicles exhibit the same salient features as bicycles, such as
Centre-axle pedals (mopeds, motor bicycle, etc.).
Motor buses trailers
Trucks
1.3 Design of the motor vehicle
Tractors
The motor vehicle consists of component assem-
Motorcycles
blies and their individual components.
Fig. 1: Overview of roadgoing vehicles The layout of the individual assemblies and their rela-
tive positions is not governed by invariable standards.
Dual-track vehicles Thus, for example, the engine may be designed as an
Motor vehicles with more than two wheels can be found independent assembly, or it may be integrated as a sub-
in dual-track and multiple-track versions. These include: assembly within a larger powertrain unit.
Passenger cars. These are primarily intended for use One of the options described in this book is to divide the
in transporting people, as well as their luggage and vehicle into 5 main assembly groups: engine, drivetrain,
other small cargo. They can also be used to pull trail- chassis, vehicle body and electrical system.
ers. The number of seats, including that of the dri- The relationships between the assemblies and their
ver, is restricted to nine. constituent components are illustrated in Fig. 2.
Motor vehicle
Engine Drivetrain Vehicle Suspension Electrical
body system
Internal-combustion engine Electric motor Clutch Wheel
Frame suspension Power
Reciprocating- Stator Variable-ratio generators
Rotary engine gearbox
piston engine, Body Suspension
Wankel engine
petrol/diesel engine Rotor Damping Electrical
Hydrodynamic loads/
Cylinders Housing Control torque Steering consumers
electronics converter
Crankshaft drive Rotor Brakes
Power Automatic
Engine management Eccentric shaft supply gearbox Wheels
Tyres
Mixture preparation Propeller shaft
Lubrication Differential
Exhaust system
Transmission unit:
e.g. suspension
Transmission unit:
e.g. drivetrain
1.4.1 Technical systems The rectangle symbolises the system limit (hypotheti-
cal boundary) that delineates the border separating
Every machine forms a complete technical system. each individual technical system from other systems
and/or the surrounding environment.
Characteristics of technical systems:
Defined system borders delineate their limits The distinctive, defining features of the individual
relative to the surrounding environment. system include:
They possess input and output channels. Input (input variables or parameters) entering
The salient factor defining system operation is from beyond the system limits
the total function, and not the individual func- Processing within the system limits
tion, which is discharged internally, within the Output (output variables or parameters) issued
system. and relayed to destinations lying outside the
limits of the system (IPO concept)
A rectangle is employed in graphic portrayals of techni-
cal systems (Fig. 2).
GMR
ESP
ABS
Hydraulic control unit
with integrated controller
Engine V
management AB
T
C
Lateral-acceleration
S
sensor
E
S
P
Driver
side
airbag
ECU for Seat with integrated Crash sensor,
airbag side airbag driver side airbag
Subfunction: Relays mechanical energy from the
power unit to the drive wheels Subfunction: Passive protection for vehicle occupants
1 Motor vehicle 15
1
Complete system, motor vehicle
Operational units
Subsystems
Input Output Input. The factors operating on the input side of the
gearbox are engine speed, engine torque and engine
System limit
power.
Processing. The crankshaft's rotation speed and the
Processing torque it transfers undergo a transformation process
Exhaust within the gearbox.
Air gas
+ + Output. The elements exiting the subsystem on the
Motor vehicle
Fuel system Travelling output side include output-shaft speed, output torque
motion
and output power as well as heat.
(chemically (mechanical
combined energy)
Efficiency level. The efficiency of the drivetrain is re-
energy) duced by energy losses sustained within the gearbox.
Environment (air, road)
The "gearbox" subsystem is connected to the drive
wheels via other subsystems, such as the propeller
Fig. 2: System: Motor vehicle shaft, final-drive unit, and half shafts.
16 1 Motor vehicle
6
1.4.5 Using technical systems
4
Extensive familiarity with technical systems is essential
for the operation and maintenance of motor vehicles. 2
The manufacturer provides operating instructions 7,400 kg 3,860 kg 2,180 kg
(owner's manual) to help ensure that its vehicles oper- 5,830 kg 2,820 kg 1,750 kg
ate with optimal safety, security and reliability, while
also observing the interests of the natural environment. Fig. 1: Correct load distribution on a crane hoist
Operating instructions contain, among other informa-
tion: REVIEW QUESTIONS
System descriptions 1 What are the parameters that define a technical sys-
tem?
Explanations of functions and operation
2 What is the IPO concept?
System descriptions
3 What are the names of the operational units in the
Operating diagrams motor vehicle?
Instructions on correct operation and use of the 4 Name three subsystems in the motor vehicle, and de-
controls scribe the corresponding input and output variables.
Maintenance and service inspection schedules 5 What is the primary function of an energy-processing
system?
Instructions for responding to malfunctions
6 What information is available in the operating instruc-
Information on approved fluids, lubricants and
tions (vehicle owner's manual)?
service materials, such as engine oils
18 1 Motor vehicle
New service concepts This gives the service representative time to order any
The service date is calculated on the basis of data col- required replacement parts such as brake pads and to 1
lected on the actual condition of wearing parts, fluids consult the customer in advance concerning a conve-
and lubricants, as well as information on the vehicle's nient service date.
operating conditions. When defined by this demand- Early recognition of potential problems is intended to
based service concept, service and maintenance are help avoid repairs stemming from vehicle breakdowns.
carried out only when needed, for instance, when a Additional advantages include:
component reaches its wear limit, or a fluid or lubricant Precisely defined dates
has reached the end of its service life. Minimal waiting times
A new feature is provided by the on-board computer, No information loss
which transmits coded data on the customer and the Flexible service
extent of the required service to the service facility.
Self-diagnosis: Interrogate fault memories of Cooling system: Check coolant level and antifreeze;
all systems setpoint value: 25 C
(insert printout at back of logbook wallet) Actual value (measured value): C
Vehicle from the outside Dust and pollen filter: Replace filter element
(every 12 months or every 15,000 km)
Door arresters and retaining bolts: lubricate
Toothed belt for camshaft drive:
Windscreen wash/wipe system and
Check condition and tension
headlight washer system:
Check function and spray-nozzle setting Air filter:
Clean housing and replace filter element
Windscreen wiper blades:
Check for damage, check home position; in event Fuel filter: Replace
of rubbing wiper blades: Check contact angle Power steering: Check fluid level
Tyres Brake-fluid level (dependent on brake-pad wear):
Tyres: Check condition, tyre tread pattern and Check
inflation pressure, enter tread depth Battery: Check
FL mm FR mm Idle speed: Check
RL mm RR mm Headlight adjustment / documentation /
final inspection
Vehicle from below
Engine oil: Drain or draw off, replace oil filters Headlight adjustment: Check
Manual gearbox / axle drive: Check oil level Date / Signature (final inspection)
1.6 Filter, body and maintenance Adhesive filters. These are usually wet air filters. Contam-
inants such as dust adhere to the filter surface on contact.
Filters installed in the motor vehicle guard against Magnetic filter. The filter (for instance, on the oil drain
contaminants and impurities by providing protec- plug) attracts and retains ferromagnetic contaminants
tion for the engine, other vehicle components, and suspended in the flowing medium.
the vehicle's occupants. Centrifugal filter. The object medium (such as air) is
Motor vehicle filters (Fig. 1) can be classified according placed in a state of rotation. Centrifugal force propels
to two criteria. These are the filtration concept and the the contaminants onto the filter's walls, where they set-
medium being filtered. tle as deposits.
Filtration concepts. Solid contaminants are filtered from Filter types include
flowing media such as air, oil, fuel and water by: Air and exhaust-gas filters
Screen filtration, using sieve-type filter screens and Fuel filters
fibre filters, etc. Filters for lubricating oils
Adhesive filtration, including wet filters Interior filters, such as pollen, smog and ozone filters
Magnetic filtration, as with magnetic separators Hydraulic filters, for ATF, etc.
Centrifugal filtration, with centrifugal filters, etc.
Strainers (filter screens). Filter mesh dimensions smal-
ler than the contaminants facilitate filtration (Fig. 2). 1.6.1 Air filters