Table of Contents
Dedication v
Preface xi
Features of the Text xiv
About the Author xvii
ASE Certification Tests xviii
Acknowledgments xix
Engine Construction, Diagnosis, Disassembly, and Inspection 1
Engine Operation 2
Simple Engine
Four Stroke Engine Operation
Cylinder Arrangement
Valvetrain
Cylinder Block
Front-Wheel Drive
Engine Classifications
Combustion Chamber Designs
Direction of Crankshaft Rotation
Firing Order
Engine Cooling
Spark and Compression Ignition
Putting it All Together
High-Performance Engine Trivia
Study Questions
ASE-Style Review Questions
Engine Shop Safety 25
General Shop Health and Safety
Shop Cleanliness
Fire Prevention
Tool and Equipment Safety
Lifting Equipment
Hazardous Materials
Engine Shop Safety Test
Diagnosing Engine Problems 52
Diagnosing Problems Before a Repair
Oil Consumption
Oil Leaks
Fuel Mixture Problems
Compression Loss
Engine Noises
Oil Pressure Problems
Cooling System Problems
Electronic Failures/Engine Damage
Study Questions
ASE-Style Review Questions
Engine Removal, Disassembly, Inspection, and In-Chassis Repairs 94
Service Information
Service Literature
Engine Removal
Front-Wheel Drive Engine and Transaxle Removal
Engine Disassembly
Ordering Parts
Major Engine Repair-Engine in the Vehicle
StudyQuestions
ASE-Style Review Questions
Cleaning the Engine 145
Cleaning Methods
Cleaning the Inside of the Engine
Study Questions
ASE-Style Review Questions
Measuring 163
Metric System
Measuring Tools
Precision Measuring Tools
Study Questions
The Breathing System 177
Cylinder Head: Parts and Service 178
Head Disassembly
Carbon Removal
Crack Inspection
Crack Repair
Valve Guide Inspection
Valve Guide Repair
Reaming Valve Guides
Valve Guide Seals
Resurfacing Heads
Study Questions
ASE-Style Review Questions
Cylinder Head: Springs, Valves, and Valve Seats 213
Valve Springs
Pushrods
Rocker Arms
Valves and Valve Service
Valve Seats and Service
Reassembling the Head
Study Questions
ASE-Style Review Questions
Camshafts, Lifters, Timing Belts, and Chains 255
Camshaft
Controlling Camshaft Thrust
Valve Lash (Clearance)
Valve Lifters
Hydraulic Lifters and Lash Adjusters
Hydraulic Lifter Operation
Valve Timing
Roller Cam and Lifters
Cam Drives
Timing Drive Maintenance
Timing the Cam to the Crank
Timing Belts
Timing Belt Replacement
A Study Questions
ASE-Style Review Questions
Engine Power Development: Manifolds, Superchargers, and Camshaft Performance 298
Intake and Exhaust Manifolds
Turbochargers and Superchargers
Turbochargers
Belt-Driven Superchargers/Blowers
Camshaft and Engine Performance
Checking Cam Timing
Camshaft Phasing, Lobe Centers, and Lobe Spread
Cylinder Heads with Multiple Valves
Variable Valve Timing
Displacement on Demand
Power and Power Measurement
Power and Torque
Horsepower
Measuring Torque and Horsepower
Study Questions
ASE-Style Review Questions
Cylinder Block Assembly 349
Cylinder Block: Inspection and Service 350
Cleaning the Block
Oil and Water Plugs
Main Bearing Caps
Main Bearing Bore Alignment
Decking the Block
Inspecting Cylinder Bores
Deglazing Cylinders
Reboring Cylinders
Honing Cylinders to Size
Chamfering the Cylinder
Cylinder Sleeves
Lifter Bores
Final Block Preparation
Cam Bearings
Study Questions
ASE-Style Review Questions
Crankshaft, Bearings, and Engine Balancing 383
Crankshaft Design
Crank End Thrust
Checking Crank Condition
Other Crankshaft Modifications
Bearings
Engine Balancing
Engine Balance
Study Questions
ASE-Style Review Questions
Pistons, Rings, and Connecting Rods 420
Pistons
Piston Rings
Wrist Pins
Connecting Rods
Study Questions
ASE-Style Review Questions
Lubrication 456
Oil
Engine Oil Licensing and Certification
Oil Pumps
Priming the System
Oil Filters
Crankcase Ventilation
Study Questions
ASE-Style Review Questions
Cooling System 485
Cooling System Circulation
Accessory Belts
Thermostat
Thermostat Bypass
Radiators
Radiator Fan
Ethylene Glycol Coolant
Coolant Service
Study Questions
ASE-Style Review Questions
Engine Repair and Reassembly 523
Engine Hardware: Fasteners, Thread Repair, and Gaskets 524
Characteristics of Fasteners
Bolt Stretch
Torque and Friction
Drill Bits
Taps, Threads, and Dies
Repairing Broken Fasteners and Damaged Threads
Automotive Tubing Repair
Gaskets
Cylinder Head Gaskets
Gasket Sealers
Seals
Study Questions
ASE-Style Review Questions
Reassembly and Starting 576
Warranty
Reassembly
Completion of Assembly
Engine Installation
Ignition System Installation and Timing
Engine Starting and Initial Break-in of the Camshaft
Final Inspection and Cleaning
Study Questions
ASE-Style Review Questions
Appendix 617
Glossary 635
Index 639