Table of Contents
Automotive Safety 13
Safety 13
Right-to-Know Laws 15
Proper Disposal of Automotive Wastes 15
Fire Prevention 16
Ventilation 16
Jacks and Lifts 16
Tool Safety 16
Dress Properly 18
Lift Properly 19
Welding Safety 19
Owner's Manuals, Service Manuals, and Repair Manuals 21
Introduction 21
Owner's Manuals 21
Service Manuals and Repair Manuals 22
Technical Service Bulletins 22
Flat Rate Manual 24
Computerized Service Information 25
On-line Services 25
Technical Assistance Hotlines 25
Automotive Tools 29
Tools 29
Wrenches 29
Sockets and Ratchets 31
Specialty Wrenches 32
Pliers 33
Screwdrivers 34
Hammers 35
Electric Drills 38
Impact Wrenches 38
Files 39
Retrieving Tools 40
SolderingTools 40
Hacksaws 41
Taps and Dies 42
Cleaning Equipment 43
Fasteners, Seals, and Gaskets 47
Fasteners 47
Threaded Fasteners 47
Keys and Pins 52
Snap Rings 52
Rivets 52
Adhesives 53
Sealants 53
Seals 53
Gaskets 55
Measuring Instruments 59
Measuring Instruments 59
Micrometers 59
Telescoping Gauges and Small Hole Gauges 61
Vernier Calipers 61
Dial Gauges 62
Feeler Gauge 62
Meters, Testers, and Analyzers 65
Automotive Meters, Testers, and Analyzers 65
Analog and Digital Meters 65
Multimeters 66
Test Light 67
Tachometers 67
Dwell Meters 67
Battery/Starter Testers 67
Timing Light 68
Oil Pressure Gauge 68
Fuel Pressure Gauge 69
Compression Gauge 69
Vacuum Gauge 69
Vacuum Tester 69
Exhaust Gas Analyzers 69
Oscilloscopes 70
Scan Tools 71
Engine Analyzers 71
Engine Fundamentals 73
Engine Fundamentals 73
Engine Fuels 73
Engine Design 73
Reciprocating Engines 74
Engine Components 74
Combustion Chamber Design 79
Engine Operating Sequence 81
Measuring Engine Performance 85
Engine Performance 85
Bore, Stroke, Displacement 88
Compression Ratio 88
Engine Efficiency 88
Brake Horsepower 89
Engine Torque 90
Rated Horsepower 90
Indicated Horsepower 90
Friction Horsepower 91
Engine Top End Construction 93
Engine Top End 93
Cylinder Heads 93
Intake Manifolds 94
Exhaust Manifolds 94
Valve Trains 94
Cam Functions 95
Camshafts 96
Camshaft Bearings 97
Camshaft Drive Mechanisms 97
Valves 98
Valve Springs 102
Valve Lifters 102
Valve Seals 104
Valve Retainers and Keepers 104
Rocker Arms 104
Push Rods 104
Engine Bottom End Construction 107
Engine Bottom End 107
Engine Block Construction 107
Crankshafts 108
Vibration Dampers 111
Connecting Rods 112
Piston Construction 112
Piston Rings 113
Compression Rings 113
Oil Control Rings 114
Piston Pins 115
Flywheels 116
Balance Shafts 116
Bearings 118
Main Bearing Caps and Seals 120
Engine Removal, Disassembly, and Cleaning 123
Engine Removal 123
Engine Disassembly 124
Cleaning 127
Inspection and Measurement 128
Engine Top End Service 131
Engine Top End Service 131
Cylinder Head Service 131
Valve Seat Reconditioning 133
Valve Guide Service 134
Valve Service 137
Valve Spring Service 139
Valve Operating Mechanisms 142
Push Rod Service 143
Rocker Arm Service 143
Lifter Service 143
Camshaft Service 145
Camshaft Bearings 146
Timing Belt Service 147
Timing Chain Service 147
Timing Gear Service 148
Head Bolt Torque 148
Engine Bottom End Service 151
Engine Bottom End Service 151
Engine Block Service 151
Cylinder Reconditioning 153
Crankshaft Service 156
Bearing Clearance 158
Bearing Removal 159
Replacement of Inserts 159
Piston Service 165
Piston Ring Service 166
Connecting Rod Service 170
Piston Pin Service 171
Balancing Engines 173
Engine Lubrication 177
Oil 177
Properties of Engine Oil 177
Selecting Viscosities 178
Oil Service Classifications 178
Oil Changes 180
Oil Filters 180
Lubricating Methods 180
Engine Cooling Systems 187
Cooling Systems 187
Water Pumps 189
Belts 189
Hoses and Clamps 191
Radiators 192
Automatic Transmission Fluid Cooler 193
Closed Cooling Systems 193
Radiator Caps 193
Cooling Fans 194
Thermostats 196
Heater Core 197
Antifreeze Solutions 197
Air-cooled Engines 199
Cooling System Testing 200
Cooling System Troubleshooting 202
Cooling System Flush 203
Diesel and Other Engines 207
Diesel Engines 207
Truck Engines 209
Racing Engines 210
Rotary Engines 210
Miller-Cycle Engines 214
Variable-Compression Engines 215
Hybrid Vehicles 215
Fuel Cell Vehicles 216
Fundamentals of Electricity, Magnetism, and Electronics 219
Electricity 219
Insulators 221
Conductors 221
Volts, Amperes, Ohms 221
Types of Electrical Circuits 222
Magnetism 223
Electronics 227
Automotive Fuels 235
Automotive Fuels 235
Volatility 235
Combustion of Gasoline 237
Antiknock Qualities 239
Fuel Additives 240
Lead-free Gasoline 240
Alcohol as a Fuel 240
Diesel Fuels 241
Liquefied Petroleum Gas (LPG) 241
Fuel Supply Systems, Intake Systems, Superchargers, and Turbochargers 243
Fuel Pumps 243
Mechanical Fuel Pump 243
Electric Fuel Pumps 244
Fuel Filters 245
Fuel Gauges 246
Intake Systems 248
Air Filters 248
Intake Manifold 249
Superchargers 251
Turbochargers 254
Fuel Injection Systems 259
Fuel Injection 259
Classifying Gasoline Injection Systems 259
Servicing Fuel Injection Systems 264
On-Board Diagnostic Systems 265
Verifying Fuel Injector Operation 265
Checking Fuel Pressure 266
Injector Balance Test 266
Relieving EFI System Pressure 266
Servicing Fuel Injectors 268
Rebuilding a Throttle Body 270
Methods of Diesel Injection 270
Carburetor Fundamentals and Service 275
Carburetors 275
Carburetor Circuits 277
Air/Fuel Mixture 287
Stoichiometric Mixture 288
Computerized Systems 288
Electro-Mechanical Carburetors 288
Carburetor Service 290
Ignition System Fundamentals and Service 301
Ignition System Operation 301
Ignition Coils 302
Distributor Cap 302
Rotor 302
Spark Plug Wires 303
Spark Plugs 303
Ignition Timing 306
Specific Ignition Systems 307
Breaker Point Ignition 307
Electronic Ignition 309
Computerized Ignition Systems 312
Distributorless Ignition 312
Direct Ignition 314
Ignition System Service 315
Performing a Spark Test 315
Ignition Coil Service 315
Distributor Cap and Rotor Service 316
Spark Plug Service 316
Spark Plug Wire Service 319
Pickup Coil Service 319
Contact Point and Condenser Service 320
Adjusting Ignition Timing 321
Testing Centrifugal and Vacuum Distributor Advance Systems 322
Ignition Control Module Service 322
Distributors and Direct Ignition System Service 322
Batteries and Battery Service 325
Batteries 325
Battery Construction 325
Maintenence-free Batteries 327
Battery Voltage and Capacity 329
Battery Ratings 329
Battery Inspection 330
Battery Testing 330
Jump Starting an Engine 336
Starting System Fundamentals and Service 339
Starting System Fundamentals 339
Starting Motor Operating Principles 339
Starting Motor Types 343
Starting Motor Internal Circuits 343
Neutral Safety Switch 347
Troubleshooting the Starting System 347
Starter Maintenance 348
Starting Motor Tests 348
Charging System Fundamentals 353
Charging Systems 353
Alternator Construction 356
Alternator Operation 357
Voltage Regulators 359
Voltage Regulator Types 359
Computer-Controlled Voltage Regulation 364
42-Volt Electrical Systems 364
Charging System Service 367
Charging System Testing and Service 367
Charging System Inspection 367
Charging System Precautions and Tests 368
Alternator Removal 369
Alternator Disassembly 370
Bench Tests 370
Repairs/Replacement 372
Alternator Reassembly 372
Alternator Reinstallation 372
Computer System Fundamentals and Service 375
Computer Control Systems 375
Components of a Computer Control System 377
Sensors 377
Electronic Control Module Operation 382
Actuators 384
Computer Control System Troubleshooting 386
On-Board Diagnostic Systems 386
Diagnostic Trouble Codes 386
Activating Self-Diagnostic Systems 387
Using Diagnostic Information 389
Sensor Service 390
Actuator Service 394
Electronic Control Module Troubleshooting 394
Exhaust Systems 397
Exhaust Systems 397
Exhaust Manifold 397
Mufflers 398
Catalytic Converters 399
Exhaust System Corrosion 400
Servicing Exhaust Systems 402
Emission Controls 405
Introduction 405
Automotive Emission Standards 405
Positive Crankcase Ventilation 406
Exhaust Emission Controls 408
Precombustion Controls 408
Post-combustion Controls 413
Engine Troubleshooting 421
Engine Troubleshooting 421
Test Equipment 421
Effect of Emission Controls 421
Strategy-Based Diagnostics 422
Self-diagnosis 422
Troubleshooting Charts 422
Driveability and Tune-up 433
Driveability and Tune-up 433
Tune-up Test Procedure 435
Checking Compression Pressure 440
Using a Vacuum Gauge 440
Tuning Emission Controls 441
Clutches 443
Purpose of the Clutch 443
Design and Construction 443
Parts Location and Relationship 443
Clutch Service 451
Clutch Adjustment 452
Clutch Overhaul 453
Clutch Troubleshooting 454
Manual Transmission Fundamentals 457
Manual Transmissions 457
Application of Torque 457
Gear Usage 457
Three-speed Manual Transmission 458
Helical Gears 459
Synchronizing Clutch 460
Four-speed Manual Transmission 460
Overdrive Revival 460
Planetary Gear Systems 461
Transmission Overdrives 463
Five-speed Overdrive Transmission 464
Manual Transmission Service 469
Manual Transmission Maintenance 469
Check Fluid Level 470
Replace the Rear Seal 470
Test the Gearshift Operation 470
Check Clutch Pedal Free Play 470
Manual Transmission Troubleshooting 470
Manual Transmission Service 472
Removal of Transmission From Car 472
Disassembly: Three-speed Manual Transmission 473
Clean and Check: Three-speed Manual Transmission 473
Reassembly: Three-speed Manual Transmission 475
Disassembly: Four-speed Manual Transmission 477
Clean and Check: Four-speed Manual Transmission 479
Reassembly: Four-speed Manual Transmission 479
Disassembly: Five-speed Manual Transmission 480
Clean and Check: Five-speed Manual Transmission 483
Reassembly: Five-speed Manual Transmission 483
Reinstallation of the Transmission in the Car 484
Automatic Transmission Fundamentals 487
Automatic Transmissions 487
Fluid Couplings 487
Torque Converters 488
Automatic Transmission Operation 490
Actions of Key Elements 491
Automatic Transmission Operation 497
Other Automatic Transmissions 500
Electronic Transmission Control 500
Continuously Variable Transmissions 500
Automatic Transmission Service 507
Automatic Transmission Maintenance and Service 507
Check ATF Level 508
Check ATF Condition 508
Inspect for ATF Leaks 509
Test for Broken Transmission Mount 510
Changing Automatic Transmission Fluid 511
Adjust Bands 512
Adjust Engine Curb Idle Speed 513
Throttle Linkage Adjustment 514
Gearshift Linkage Adjustment 515
Troubleshooting Tips 515
Road Testing 516
Stall Testing 516
Air Pressure Testing 517
Testing Electronically Controlled Transmissions 518
Transaxles 521
Transaxles 521
Transaxle Construction 521
Transaxle Operation 523
Manual Transaxle Troubleshooting 528
Manual Transaxle Maintenance 529
Automatic Transaxle Troubleshooting 531
Automatic Transaxle Maintenance 532
Driveline, Universal Joints, Differentials, and Driving Axles 537
Drivelines 537
Universal Joints 538
Drive Shaft 538
Differential 538
Driving Axles 539
Torque Transfer or Drive 541
Hotchkiss Drive 541
Torque Tube Drive 542
Control Arm Drive 542
Slip Joints 542
Constant Velocity Joints 543
Transfer Cases 543
Center Bearings 543
Differentials and Axles 543
Limited-Slip Differentials 547
Front-wheel Drive Driveline 548
Driveline Service 553
Driveline Service 553
Drive Shaft 553
Universal Joint Service 554
Center Bearing Service 555
Differentials 555
Transaxle Lubrication 558
Wheel Bearing Lubrication 559
Driving Axles 560
Four-wheel Drive Systems 569
Four-wheel Drive/All-wheel Drive 569
Four-wheel Drive Systems 570
Four-wheel Drive Componenets 570
Four-wheel Drive Service 576
Suspension and Steering Systems 579
Suspension and Steering Systems 579
Front Suspension Systems 584
Rear Suspension Systems 585
Steering Systems 588
Suspension and Steering Service 596
Troubleshooting Suspension 597
Troubleshooting Manual Steering 598
Troubleshooting Power Steering 599
Tires and Tire Service 601
Tires 601
Tire Types and Basic Structure 601
Tread Patterns 603
Tire Markings 603
Tire Service 607
Improvements and Advances 612
Wheel Alignment 615
Wheel Alignment 615
Wheel Balance and Unbalance 616
Car Weight Balance 617
Wheelbase-Tread Width 617
Rear-wheel Track 618
Springs 619
Suspension Height 619
Shock Absorber Action 619
Front-wheel Angularity 620
Wheel Alignment Correction 625
Wheel Alignment Correction 625
Rear-wheel Drive/Front-wheel Drive Alignment 625
Front-Wheel Drive-Alignment 632
Rear Wheel Alignment 632
Alignment Troubleshooting 634
Hydraulics and Pneumatics 637
Hydraulics 637
Transmission of Forces 638
Movement of Liquid 640
Application of Hydraulic Principles 640
Pneumatics 641
Effect of Atmospheric Pressure 642
Effect of Vacuum 642
Compressed Air 643
Principle of the Siphon 643
Venturi Tube 644
Boyle's Law 644
Charles' Law 645
Automotive Brakes 647
Fundamentals of Automotive Brake Systems 647
Braking System Operation 649
Brake Lining Materials 650
Disc Brakes 651
Drum Brakes 653
Brake Hydraulic System 656
Disc Brake Calipers 662
Wheel Cylinders 662
Brake Lines, Hoses, and Fittings 663
Power Brakes 663
Anti-lock Brake Systems 666
Brake Service 668
Hydraulic System Service 668
Disc Brake Service 670
Drum Brake Service 673
Power Brake System Service 680
Troubleshooting and Servicing Anti-lock Brake Systems 682
Automotive Air Conditioning 685
Automobile Air Conditioning 685
Principles of Air Conditioning 686
Automobile Heating Systems 688
Types of Refrigerant 694
The Need for Refrigerant Oil 700
Air Conditioning Service Tools and Equipment 701
Servicing the Air Conditioning System 702
Discharging and Recovering Refrigerant 703
Evacuating the Air Conditioning System 703
Charging the Air Conditioning System 703
Retrofitting R-12 Air Conditioning Systems 704
Troubleshooting Heating Systems 704
Troubleshooting Air Conditioning Systems 704
Automatic Temperature Control 705
Safety Systems 709
Safety Systems 709
Seat Belt Systems 710
Air Bag Systems 712
Energy Absorbing Bumper Systems 715
Other Safety Features 717
Lamps, Lighting Circuits, Wiring, Horns, Wipers, and Washers 723
Lamps and Lighting Circuits 723
Fuses and Circuit Breakers 724
Headlamp Types 724
Daytime Running Lamps 724
Lamp Switches 725
Fog Lamps 728
Direction Signal Switch 728
Stoplight Switch 728
Lamp Service 728
Wires and Cables 734
Lighting Wire Sizes 734
Resistor Ignition Cable 736
Wiring Harnesses and Connectors 736
Horns 737
Horn Troubleshooting 739
Principles of a Direct Current (DC) Motor 739
Wiper Motor Construction 739
Troubleshooting 741
Windshield Washers 741
Speedometers and Cruise Control Systems 745
Analog Speedometers 745
Speedometer Operation 745
Inspection and Lubrication 747
Speedometer Cable 747
Digital Speedometers 748
Light Emitting Diode 748
Liquid Crystal Display 750
Vacuum Fluorescent Display 750
Cathode Ray Tube 750
Digital Odometers 750
Troubleshooting 750
Cruise Control Systems 751
Cruise Control System Service 753
Body Repairing and Refinishing 757
Body Work 757
Hammers, Spoons, and Dolly Blocks 758
Using Pull Rods and Slide Hammers 759
Body Filler 759
Filing and Sanding 761
Patching Rusted Areas 763
Replacing Panels 763
Welding 764
Painting 768
Masking 769
Spray Guns 770
Tips on Spraying 770
Refinishing Materials 772
Matching Colors 774
Preparing Old Finishes for Paint 775
Soft Body Parts 778
Identifying Plastics 778
Repairing Water and Dust Leaks 779
Drain Locations 780
Career Opportunities and Technician Certification 783
Automotive Careers 783
The Job Market 784
Job Descriptions 785
Entrepreneurship 789
Technician Certification 790
Appendix 793
Dictionary of Automotive Terms 797
Index 815
