Automotive Service: Inspection, Maintenance, Repair

Cover
Contents
Preface
Acknowledgements
Dedication
About the Author
Features of the Text
Section 1: The Automobile Industry
	Chapter 1: Introduction to the Automobile
		Introduction
		Body and Chassis
		Engine Parts and Operation
		Engine Support Systems
		The Powertrain
		Accessory Systems
	Chapter 2: Automotive Careers and Technician Certification
		Introduction
		Automotive Career Opportunities
		Technician Certification and Licensing
		Technician Skill Levels and Pay
		Other Areas of Specialization
		Other Automotive Careers
		On the Job As An Automotive Technician
Section 2: Shop Procedures, Safety, Tools, and Equipment
	Chapter 3: Shop Safety
		Introduction
		General Personal Safety
		Fire Safety
		Evacuation Plan
		Fire Extinguishers
		Flammable Materials
		Fuel Fires
		Electrical Fires
		Shop Habits
		Electrical Safety Precautions
		Cooling Fan Safety
		Coolant Burns
		General Hand Tool Safety
		Puller Safety
		Machinery Safety
		Electric Drill Safety
		Grinder Safety
		Wire Wheel Safety
		Compressed Air Safety
		Impact Wrench Safety
		Air Chisel Safety
		Die Grinder/Air Drill Safety
		Press Safety
		General Lifting Safety
		Hydraulic Floor Jack (Service Jack) Safety
		Shop Crane (Engine Hoist) Safety
		Transmission Jack Safety
		Battery Safety
		Refrigerant Safety
		General Safety Around Automobiles
		Hot Tank Safety Precautions
		Hazardous Materials and Environmental Safety
		Hazardous Communication Standards
		Material Safety Data Sheets
		Hazardous Materials Common to the Automotive Industry
		Cleaning Solvent Safety Precautions
		Skin Care Safety Precautions
		Breathing Safety
		Welding Safety
	Chapter 4: Shop Management, Service Records, and Parts
		Introduction
		Customer Relations
		Service Records
		Keep the Car Clean
		Linen Service
		Wholesale and Retail Distribution of Auto Parts
	Chapter 5: Locating Service Information and Specifications
		Introduction
		Service Literature
		Manufacturers’ Service Information
		Generic Service Manuals
		Lubrication and Maintenance Service Specifications
		Owner’s Manual
		Owners’ Workshop Manuals
		Electronic Service Information
		Technical Service Bulletins
		Hotline Services
		Trade Magazines and Internet
	Chapter 6: Measuring Tools and Systems
		Introduction
		Metric System
		Measuring Tools
		Precision Measuring Tools
	Chapter 7: Hardware, Fasteners, Drills, and Thread Repair
		Introduction
		Characteristics of Fasteners
		Fastener Failures
		Drill Bits
		Taps and Threads
		Dies
		Repairing Broken Fasteners
	Chapter 8: Shop Tools
		Introduction
		Tools of the Trade
		Pullers
		Air Tools
		Special Service Tools
	Chapter 9: General Shop Equipment
		Shop Equipment
		Hydraulic Equipment
		Shop Electric Machinery
		Other Electric Equipment
		Other Shop Equipment
	Chapter 10: Cleaning Equipment and Methods
		Introduction
		General Shop Housekeeping Practices
		Cleaning Methods
		Cleaning the Outside of the Engine
		Environmental Concerns With Engine Cleaning
		Cleaning Internal Parts
		Chemical Cleaning
		Thermal Cleaning
		Vibratory Parts Cleaners
		Other Cleaning Methods
		Marking Clean Parts
	Chapter 11: Lifting Equipment and Air Compressors
		Introduction
		Lift Types
		Frame-Contact Lifts
		Wheel-Contact Lifts
		Wheel-Free Jacks
		In-Ground Lifts
		Surface Mount Lifts
		Lift Safety
		Air Compressors
Section 3: Vehicle Inspection (Lubrication/Safety Check)
	Chapter 12: Engine Lubrication
		Introduction
		Engine Oil
		Engine Oil Licensing and Certification
		Oil Additives
		Changing Engine Oil
		Oil Filter
		Changing the Oil Filter
	Chapter 13: Underhood and Body Inspection (Vehicle On Ground)
		Introduction
		Brake System Inspection
		On-Ground Steering and Suspension Checks
		Fuel System Inspection
		Cooling System Inspection
		Belt Inspection
		Electrical System Inspection
		Check Operation of Lights
		Visibility Checks
		Other Safety Checks and Service
	Chapter 14: Undercar Inspection and Service
		Introduction
		Tire Visual Inspection
		Undercar Brake Checks
		Exhaust System Inspection
		Chassis Lubrication
		Suspension and Steering Checks
		Driveline Checks
Section 4: Engine Operation
	Chapter 15: Introduction to the Engine
		Introduction
		Basic Engine Operation
		Four-Stroke Engine Operation
		Engine Upper End
		Valve Train
		Cylinder Head
		Engine Front
		Cylinder Block Assembly (Lower End)
		Short Block and Long Block
	Chapter 16: Engine Classi Cations and Types
		Introduction
		Engine Classifications
		Cylinder Arrangement
		Firing Order
		Engine Cooling
		Valve Location
		Camshaft Location
		Other Cylinder Head Variations
		Combustion Chamber Designs
		Spark and Compression Ignition
		Alternate Engines
	Chapter 17: Engine Size and Measurements
		Introduction
		Engine Size Measurements
		Compression Ratio
		Physical Principles of Work
		Torque
		Horsepower
		Dynamometer
		Dynamometer Safety Concerns
		Engine Efficiency
		Mean Effective Pressure
	Chapter 18: Engine Upper End
		Introduction
		Cylinder Head Construction
		Valve Guides
		Valve Guide Seals
		Valves
		Retainers and Valve Locks
		Valve Springs
		Pushrods and Rocker Arms
		Camshaft
		Number of Cams and Lobes
		Camshaft Performance
		Valve Lifters and Lash Adjusters
		Roller Cam and Lifters
		Hydraulic Lifters
		Camshaft Drives
		Valve Timing
		Variable Valve Timing
		Electric Cam Phasers
		Active Fuel Management
	Chapter 19: Engine Lower End and Lubrication System Theory
		Introduction
		Cylinder Block Construction
		Core Plugs
		Cylinder Bore
		Cylinder Sleeves
		Main Bearing Caps
		Lifter Bores
		Crankshaft Design
		Crankshaft End Thrust
		Direction of Crankshaft Rotation
		Vibration Damper
		Crankshaft Hardness
		Bearings
		Connecting Rods
		Pistons
		Piston Head
		Piston Ring Grooves
		Heat Transfer
		Cast and Forged Pistons
		Piston Skirt
		Piston Pin Offset
		Piston Pins
		Piston Rings
		Compression Rings
		Compression Ring Design
		Oil Control Rings
		Engine Balancing
		The Lubrication System
		Oil Pumps
		Pressure Relief Valve
		Oil Pump Screen By-Pass Valve
		Oil Pressure
		Windage Tray and Baffles
		Dry Sump Lubrication Systems
Section 5: Cooling System, Belts, Hoses, and Plumbing
	Chapter 20: Cooling System Theory
		Introduction
		Liquid and Air Cooling
		Liquid Cooling System Parts
		Cooling System Circulation
		Coolant
		Cooling System Pressure Cap
		Coolant Recovery System
		Radiator
		Thermostat
		Temperature Warning Light Or Gauge
		Fans
		Fan Clutch
		Radiator Shroud
		Heater Core
	Chapter 21: Cooling System Service
		Introduction
		Diagnosing Cooling System Problems
		Radiator Cap
		Coolant Service
		Testing Coolant Condition and Strength
		Thermostat Service
		Locating Leaks
		External Leaks
		Internal Leaks
		Recovery Tank Service
		Cooling System Repairs
		Water Pump Service
		Electric Cooling Fan Service
		Heater Core Service
	Chapter 22: Automotive Belts
		Introduction
		Belt Material
		V-Ribbed Belts
		Serpentine Belt Drive
		Stretch Belts
		Timing Belts
		Drive Belt Service
		Belt Inspection and Adjustment
		Replacing Belts
	Chapter 23: Automotive Hoses
		Introduction
		Hose Construction
		Hose Size
		Unreinforced Hose
		Radiator Hose
		Hose Types
		Hose Clamps
		Hoses
		Hose Inspection and Service
		Replacing Hoses
		High-Performance Hoses and Fittings
	Chapter 24: Automotive Plumbing: Tubing and Pipe
		Introduction
		Tubing
		Flared Connections
		Compression Fittings
		Pipe Fittings
		Shutoff Valves
		Tubing Service
		Installing Tubing
		Transmission Oil Cooler Line Repairs
		Nylon Fuel Injection Tubing
		Pipe Service
Section 6: Electrical System Theory and Service
	Chapter 25: Basic Electrical System Theory and Repairs
		Introduction
		Electron Flow
		Basic Automotive Electrical System
		Electrical Terms
		Circuitry and Ohm’s Law
		Magnetic Fields
		Capacitors
		Automotive Electronics
		Basic Electrical Tests
		Voltage Drop Testing
	Chapter 26: Battery Fundamentals
		Introduction
		Battery Parts and Operation
		Battery Recharging and Discharging
		Battery Capacity Ratings
		Battery Types
		Battery Plate Size
		Battery Selection
		Battery Service Life
		Battery Cables
		Battery Holddowns
		Reasons For Battery Failure
		Electric Vehicle Battery Types
	Chapter 27: Battery Service
		Introduction
		Battery Inspection
		Battery Service
		Replacing A Battery
		Battery Testing: Measuring Battery State of Charge (SOC)
		Battery Charging
		Battery Chargers
		Storing A Vehicle
		Battery Capacity Tests
		Battery Testing Using An Amp Clamp
		Battery Drain Test/Parasitic Load
		Battery Jump-Starting
	Chapter 28: Starting System Fundamentals
		Introduction
		Starter Motor
		Starter Motor Fundamentals
		Starter Drives
		Starter Electrical Circuit
		Gear Reduction Starters
		Brushless DC Motors
	Chapter 29: Starting System Service
		Introduction
		Starting System Service
		Starting System Tests
		Cranking Voltage and Amperage Test
		Circuit Resistance Test
		No-Crank Tests
		Solenoid Problems
		Starter Repair
		Starter Disassembly
		Starter Drive Service
		Starter Reassembly
	Chapter 30: Charging System Fundamentals
		Introduction
		Charging System
		AC Generator/Alternator
		Alternator Pulleys
		AC Generator Bearings
		AC Generator Fan
		Voltage Regulator
		Computer-Controlled Voltage Regulation
		Charging System Indicators
		High-Voltage Charging Systems
	Chapter 31: Charging System Service
		Introduction
		Charging System Service
		Preliminary Charging System Tests
		Testing the Charging System
		Charging System Output Tests
		Regulated Voltage Test
		Diode Tests
		Charging System Voltage Drops
		AC Generator Service and Repair
		AC Generator Reassembly
	Chapter 32: Lighting and Wiring Fundamentals
		Introduction
		Wire and Cable
		Circuit Protection Devices
		Lighting
		Headlamps
		Taillights
		Incandescent Light Bulb Identification
		Turn Signals
		Signal Flasher Operation
		Hazard Flashers
		Back-Up Lights
		Electrical Instrumentation and Instrument Panel
		Miscellaneous Gauges
	Chapter 33: Lighting and Wiring Service
		Analyzing Electrical Problems
		Wiring Service
		Trim Removal
		Crimp Terminals
		Selecting Replacement Wire
		Adding Electrical Accessories
		Soldering
		Broken Or Damaged Ground Straps
		Circuit Testing and Service
		Finding Grounds
		Fuse Testing and Service
		Fuse Link Service
		Headlamp Service
		Headlamp Aiming
		Tail Lamp and Park Light Service
		LED Service
		Stoplight Switch Service
		Back-Up Lights
		Turn Signal Switch
		Signal Flasher/Relay
		Locating A Signal Flasher
		Windshield Washer Service
		Horn Service
		Gauge Testing
	Chapter 34: Safety, Security, Comfort Systems, and Electrical Accessories
		Introduction
		Supplemental Restraint Systems
		Active and Passive Restraints
		Restraint System Service
		Security, Navigation, and Electrical Accessories
		Security Systems
		Vehicle Tracking/Navigation Systems
		Other Comfort Systems
		Vehicle Audio Systems
		Cruise Control
		Collision Avoidance Systems
		Lane Departure Warning System
Section 7: Heating and Air Conditioning
	Chapter 35: Heating and Air-Conditioning Fundamentals
		Introduction
		Sources of Heat
		Ventilation
		Heating
		Air Distribution System
		Air Conditioning
		Air-Conditioning Principles
		Heat Transfer
		Humidity
		States of Matter
		Latent Heat
		Air-Conditioning System Operation
		Reducing Humidity
		Compressing the Refrigerant
		Transferring Refrigerant Heat to Outside Air
		Flow Control Devices
		Air-Conditioning Compressors
		Compressor Lubrication
		Muffler
		Accumulator Or Receiver/Dryer
		Evaporator Icing Control
		System Switches
		Heating and Air-Conditioning Controls
		Automatic Air-Conditioning Sensors
		Refrigerants and the Environment
		Temperature and Pressure
	Chapter 36: Heating and Air-Conditioning Service
		Heater Service
		Air-Conditioning Service
		Air-Conditioning System Service and Diagnosis
		System Performance Test
		Pressure Testing
		Static Pressure Reading
		Diagnosing HVAC Electronic Problems
		Air Distribution System Diagnosis
		Leak Detection
		Common Air-Conditioning Component Problems
		Refrigerant Oil
		Evaporator Problems
		Thermal Expansion Valve or Orifice Tube Problems
		Compressor Service
		Evacuating and Recharging
		Vacuuming A System
		Evacuate the System
		Air-Conditioning Service Equipment
		Refrigerant Charging
		Follow-Up
		Refrigerant Storage
		Recycling and Retrofit
Section 8: Engine Performance Diagnosis: Theory and Service
	Chapter 37: Ignition System Fundamentals
		Introduction
		Basic Ignition System
		Primary Circuit
		Secondary Ignition Parts
		Spark Plugs
		Electronic Ignitions
		Electronic Ignition Variations
		Ignition Modules
		Ignition Timing
		Detonation Sensor
		Distributorless Ignition
	Chapter 38: Ignition System Service
		Ignition System Service and Repairs
		Spark Plug Service
		Spark Plug Diagnosis
		Installing Spark Plugs
		Repairing Damaged Spark Plug Threads
		Spark Plug Cable Service
		Distributor Ignition Service
		Ignition Timing
		Electronic Ignition Distributor Service
		Other Distributor Repair Service
		Distributor Installation
		Static Timing
		Electronic Ignition System Service
		Oscilloscope Testing
		Types of Scope Patterns
		Other Scope Tests
		Other Diagnostic Instruments
	Chapter 39: Petroleum Fuels and Alternative Fuel Technologies
		Introduction
		Crude Oil
		Diesel Engines and Diesel Fuel
		Gasoline
		Air-Fuel Mixture
		Spark Knocks, Carbon Noise, and Abnormal Combustion
		Abnormal Combustion
		Excessive Carbon Buildup
		Regular Versus Premium Fuels
		Octane Standards
		Gasoline Additives
		Reformulated Gasolines
		Oxygenated Fuels/Alcohols
		Alternative Fuels
		Natural Gas
		Compressed Natural Gas
		Refueling CNG
		Liquified Natural Gas
		Engine Rebuilding Concerns With Alternative Fuel Engines
		Hydrogen
	Chapter 40: Fuel System Fundamentals, Gasoline and Diesel
		Introduction
		Fuel System
		Fuel Tanks
		Fuel Lines, Hoses, and Fittings
		Fuel Pumps
		Fuel Filters
		Fuel Injection and Carburetion
		Pressure Regulator Operation
		Electronic Fuel System Operation
		Airflow Measurement
		Idle Speed Control
		Fuel Pump Control Module
		Computer-Controlled Fuel Systems
		Feedback Fuel Systems
		Diesel Fuel Systems
		Diesel Fuel Subsystem
		Diesel Fuel Filters
	Chapter 41: Fuel System Service
		Introduction
		Fuel Supply System Service
		Fuel Filter Service
		Fuel System Problems and Service
		Throttle Linkage
		Exhaust Gas Analysis
		Fuel Injection Diagnosis and Service
		EFI Computer Self-Diagnostics (OBD)
		Air-Fuel Mixture Problems
		Injector Problems
		Throttle Plate Service
		EFI Adjustments
		Sensor Service
		Throttle Position Sensor
		Oxygen Sensor Service
		Coolant Temperature Sensor
		Inlet Air Temperature Sensor
		Map Sensor Diagnosis
		Mass Airflow (MAF) Sensor Diagnosis
		Testing Other Sensors
		Computer Service
		Mechanical Injection
		Carbon Deposit Service
		Diesel Engine Fuel Service
	Chapter 42: Intake and Exhaust Systems/ Turbochargers and Superchargers
		Introduction
		Intake System Fundamentals
		Manifolds
		Intake Manifolds
		Exhaust System Fundamentals
		Exhaust Manifolds
		Exhaust Tubing
		Exhaust System Service
		Turbochargers and Superchargers
		Turbochargers
		Aftercooler/Intercooler
		Belt-Driven Superchargers/Blowers
	Chapter 43: Emission Control System Fundamentals, Gasoline and Diesel
		Introduction
		Air Pollution
		Automotive Emissions
		Pollution Control
		Automobile Emission Control Systems
		Crankcase Ventilation
		PCV Valve Testing
		Exhaust Gas Recirculation
		EGR System Operation
		Computer-Controlled EGR Systems
		Catalytic Converter
		Types of Catalytic Converters
		Evaporative Controls
		Other Parts of the Fuel Tank System
		On-Board Diagnostics
		Engine Emission Modifications
		Diesel Engine Emission Control
	Chapter 44: Emission Control System Service
		Introduction
		Inspecting Emission Control Systems
		Computer-Controlled Emission Service
		Crankcase Ventilation System Service
		Evaporative Control System Service
		Evaporative System Maintenance
		Evaporative System Problem Diagnosis
		EGR System Service
		Air Injection System Service
		Catalytic Converter Service
		Converter Testing
		Catalytic Converter Replacement
		Analyzing Exhaust Emissions
		Emission Analyzers
		Hydrocarbons
		Carbon Monoxide
		Carbon Dioxide
		Oxygen
		Oxides of Nitrogen
		Catalytic Converter Tests
		Diesel Emission Control Service
		Diesel Exhaust Fluid (DEF) Service
		Filling the DEF Tank
		Diesel Particulate Filter Service
	Chapter 45: Electronics and Computer Systems Fundamentals
		Introduction
		Semiconductors
		Diodes
		Transistors
		Electronic Instrument Displays
		Automotive Computer Systems
		Parts of A Computer System
		On-Board Computer
		Information Processing
		Computer Memory
		Communication Rate
		Sensors and Actuators
		Types of Sensors
		Thermistors
		Voltage Dividers
		Piezoelectric and Piezoresistive Sensors
		Heated Resistive Sensors
		Variable Dc Frequency Sensors
		Voltage Generators
		Wheatstone Bridges
		Switches
		Types of Actuators
		Solenoid Actuators
		Relay Actuators
		Motor Actuators
		Actuator Switches/Modules
		Adaptive Strategy
		Ignition Advance
		Knock Sensor
		Electronic Throttle Control/Drive-By-Wire
		On-Board Diagnostics
		Diagnostic Trouble Codes
		Computer Self-Diagnostics
		Multiplexing
		Network Sizes and Types
		CAN Systems
		Supplemental Data Bus Networks
		Telematics
		Wireless Networks
		DSRC
	Chapter 46: Electronics and Computer Systems Service
		Introduction
		Inspection Sequence
		Perform Diagnostic Tests
		On-Board Diagnostics
		Reading Trouble Codes
		Scan Tools
		Breakout Box
		Retrieving Trouble Codes
		Working With Codes
		Erasing Trouble Codes
		Scan Tool Snapshot
		Closed Loop
		Fuel Trim Diagnosis
		Digital Waveforms
		Logic Probe/Power Probe
		Sensor and Actuator Testing
		Diagnosing Sensor Problems
		Sensor Tests
		Oxygen Sensor
		Load Sensors
		Map Sensor
		Baro Sensors
		Vacuum Sensors
		Throttle Position Sensor
		Coolant Temperature Sensor
		Air Temperature Sensors
		Airflow Sensor Service
		Knock Sensor Service
		Actuator Service
		Repair the Problem
		Computer Wiring Service
		Static Electricity
		Electrical Damage to A Circuit
	Chapter 47: Advanced Emissions and On-Board Diagnostics (OBD)
		Introduction
		History of On-Board Diagnostics
		OBD II Operation
		Society of Automotive Engineers (SAE) Standards
		Trouble Codes and the Malfunction Indicator Lamp
		OBD II Codes
		OBD II Diagnostic Testing
		Emission Testing Programs
	Chapter 48: Diagnosing Engine Performance Problems
		Introduction
		Visual Checks
		Ignition System Checks
		Engine Performance Testing
		Compression Loss
		Vacuum Testing
		Other Vacuum Tests
		Compression Problems
		Cylinder Leakage Test
		Carbon-Related Problems
Section 9: Automotive Engine Service and Repair
	Chapter 49: Diagnosing Engine Mechanical Problems
		Introduction
		Diagnosing Problems Before A Repair
		Oil Consumption
		Causes of Oil Consumption
		Testing For Oil Leaks
		Engine Performance and Compression Loss
		Engine Noises
		Engine Knocks
		Oil Pressure Problems
		Cooling System Problems
		Internal Engine Leakage
		Seized Engine
		Electronic Failures/Engine Damage
		Engine Performance and Fuel Mixture Problems
	Chapter 50: Engine Removal and Disassembly
		Introduction
		Engine Removal
		Engine Disassembly
		Engines With Pushrods
		Overhead Cam Cylinder Head Removal
		Cylinder Block Disassembly
	Chapter 51: Engine Sealing, Gaskets, Fastener Torque
		Introduction
		Clamping Force
		Torque and Friction
		Torque Wrenches
		Torque-to-Yield
		Torque By Degrees
		Fastener Clamping Load
		Gaskets and Seals
		Cleaning the Head
		Head Gasket Installation
		Other Engine Gaskets
		Valve Cover, Timing Cover, and Oil Pan Service
		Gasket Sealers
		Silicone RTV Sealant
		Seals
		Rear Main Seals
		Transmission Front Pump Seal
	Chapter 52: Engine Diagnosis and Service: Cylinder Head and Valve Train
		Introduction
		Head Disassembly
		Carbon Removal
		Cylinder Head Inspection
		Resurfacing By Grinding, Cutting, Or Sanding
		Straightening Cylinder Heads
		Crack Inspection
		Crack Repair
		Checking Valve Springs
		Checking Valve Stems
		Valve Guide Service
		Guide Repair
		Grinding Valves
		Grinding Valve Seats
		Checking Valve Stem Installed Height
		Solvent Testing the Valve and Seat
		Reassembling the Head
		Valve Guide Seal Installation
		Install the Valve and Spring Assembly
		Pushrod Engine Rocker Arm Service
		Inspect Pushrods
		Inspect OHC Camshaft
		Reassembling OHC Heads
		Camshaft Service
		Lifter Service
		Cam and Lifter Break-In
		Timing Chain and Belt Service
		Timing Belt Service
		Timing Belt Replacement
		Timing Chain Service
	Chapter 53: Engine Diagnosis and Service: Block, Crankshaft, Bearings, and Lubrication System
		Introduction
		Cleaning the Block
		Oil and Water Plug Removal
		Oil Gallery Plug Installation
		Inspect and Clean Lifter Bores
		Checking Main Bearing Bore Alignment
		Check the Deck Surface For Flatness
		Clean All Threaded Holes
		Inspecting Cylinder Bores
		Measuring the Bore
		Deglazing the Cylinder Bore
		Clean the Block of Grit
		Boring For Oversized Pistons
		Block Distortion
		Honing After Boring
		Sleeves
		Cam Bearing Installation (cam-In-Block Engines)
		Front Cam Bearing Installation
		Checking Crankshaft Condition
		Crankshaft and Bearing Wear
		Crankshaft Journal Tolerance
		Regrinding the Crankshaft
		Measuring Bearing Clearance With Plastigage
		Lubrication System Service
		Checking Oil Pumps For Wear
		Oil Pump Screen Service
		Oil Pump Failure
		Installing the Oil Pump
	Chapter 54: Engine Diagnosis and Service: Piston, Piston Rings, Connecting Rod, Engine Balancing
		Introduction
		Piston Service
		Piston Ring Service
		Installing Pins In Connecting Rods
		Installing Rings On Pistons
		Oil Ring Installation
		Connecting Rod Service
		Engine Balancing Service
	Chapter 55: Ordering Parts, Short and Long Blocks, Engine Assembly
		Introduction
		Ordering Parts
		Engine Kits
		Determining Part Sizes
		Types of Engine Rebuilds
		Selecting the Correct Replacement Engine
		Warranty
		Reassembly
		Begin Reassembly
		Prepare the Crankshaft For Installation
		Install the Crank
		Install the Cylinder Heads
		Install OHC Heads
		Install the Cam Drive (Pushrod Engines)
		Install the Oil Pump
		Install the Timing Cover
		Install the Crankshaft Damper/Pulley
		Install the Oil Pan
		Install the Intake Manifold
		Install the Thermostat and Water Outlet Housing
		Completing the Assembly
		Install Exhaust Manifold(s)
	Chapter 56: Engine Installation, Break-In, and In-Chassis Repairs
		Introduction
		Engine Installation
		Install Engine Mounts
		Install the Engine
		Priming the Lubrication System
		Pressure Priming
		Install Valve Covers
		Ignition System Installation and Timing
		Engine Starting and Initial Break-In
		Valve Clearance Adjustment
		Road Test and Break-In
		Final Inspection
		Returning the Car to the Customer
		Engine Repair—Engine In the Vehicle
		Valve Job Or Head Gasket Repair
		Valve Job Or Complete Engine Overhaul
		Head Gasket Problems
		In-Chassis Lower End Repairs
		Removing the Oil Pan
		Remove the Piston and Rod Assembly
		Remove the Timing Cover
		Freewheeling and Interference Engines
		Replace the Timing Components
		Crankshaft Seal Replacement
		Flywheel Ring Gear Service
Section 10: Brakes and Tires
	Chapter 57: Brake Fundamentals
		Introduction
		Brake Linings
		Drum and Disc Brakes
		Hydraulic Brake System Operation
		Hydraulic Brake Fluid
		Brake Hose
		Brake Tubing
		Hydraulic System Operation
		Low Brake Pedal
		Split Hydraulic System
		Quick Take-Up Master Cylinder
		Drum Brakes
		Drum Brake Adjustment
		Disc Brakes
		Hydraulic System Valves and Switches
		Hydraulic Control Valves
		Power Brakes
		Parking Brake
		Types of Parking Brakes
		Stoplight Switches
		Antilock Brakes
	Chapter 58: Brake Service
		Introduction
		Brake Inspection
		Check Brake Pedal Feel
		Master Cylinder Inspection
		Brake Diagnosis
		Undercar Checks
		Disc Brake Inspection
		Inspecting Drum Brake Assemblies
		Brake Fluid Service
		Routine Brake Fluid Replacement
		Brake Fluid Testing
		Bleeding Brakes
		Brake Bleeding Methods
		Drum Brake Adjustment
		Master Cylinder Service
		Master Cylinder Removal
		Master Cylinder Disassembly
		Bench Bleeding A Master Cylinder
		Brake Job
		Drum Brake Lining Removal
		Reassembling A Wheel Cylinder
		Removing Wheel Cylinders
		Replacing Drum Brake Shoes
		Adjusting Drum Brake Clearance
		Drum and Rotor Service
		Drum Service
		Rotor Service
		On-Vehicle Rotor Machining
		Disc Brake Service
		Rear Disc Pad Installation
		Rebuilt Calipers
		Disc Caliper Rebuilding
		Selecting Brake Linings
		Disc Brake Noise
		Parking Brake Cable Service
		Vacuum Power Brake Service
		Brake Warning Lamp Diagnosis
		Antilock Brake System (ABS) Service
	Chapter 59: Antilock Brakes, Traction, and Stability Control
		Introduction
		Antilock Brakes
		Antilock Brake System Components
		Types of Antilock Brake Systems
		Antilock Brake System Operation
		Traction Control System
		Antilock Brake (ABS) Service
		ABS Brake Fluid Service
	Chapter 60: Bearings, Seals, and Greases
		Introduction
		Plain Bearings
		Frictionless Bearings
		Bearing Loads
		Ball Bearings
		Roller Bearings
		Wheel Bearings
		Greases
		Wheel Bearing Seals
		Seal Materials and Design
		Seal Tolerance
		Wheel Bearing Diagnosis and Service
		Wheel Bearing Adjustment
		Disc Brake Caliper Removal
		Repacking Wheel Bearings
		Bearing Inspection and Diagnosis
		Diagnosing Wheel Bearing Noise
		Replacing Bearing Races
		Servicing Front-Wheel-Drive Bearings
	Chapter 61: Tire and Wheel Theory
		Introduction
		Tire Construction
		Tubeless Tires
		Tire Tread
		Tire Tread Material
		Tire Cord
		Tire Ply Design
		Tire Sidewall Markings
		Load Rating
		All-Season Tires
		Snow Tires
		Tire Pressure Monitoring System
		Uniform Tire Quality Grading
		Changing Tire Size
		Wheels
		Custom Wheels
		Lug Studs
		Lug Nuts
		Tire Valve Stems
	Chapter 62: Tire and Wheel Service
		Introduction
		Tire Inflation
		Checking Air Pressure
		Adjusting Tire Pressure
		Tire Wear
		Sidewall Checks
		Tire Rotation
		Removing and Tightening Lug Nuts
		Repairing Wheel Studs
		Removing and Mounting Tires On Rims
		Inspecting the Tire and Wheel
		Valve Stem Service
		Rubber Lubricant
		Install the Tire
		Mounting High-Performance Tires
		Bead Roller Tire Changer
		Tire Runout
		Tire Repair
		Repairing A Tire
		Preparing A Tire For Repair
		Patching the Tires
		Tire and Wheel Balance
		Types of Wheel Balance
		Couple Imbalance
		Dynamic Balance
		Using A Computer Balancer
		Centering the Wheel On the Balancer
		Match Mounting
		Force Variation
		Installing the Wheel
		Tire Pressure Monitoring System Service
		TPMS Service
Section 11: Suspension, Steering, Alignment
	Chapter 63: Suspension Fundamentals
		Introduction
		Suspension
		Frame and Suspension Designs
		Springs
		Suspension Construction
		Independent and Solid Axle Suspensions
		Suspension Types
		High-Performance Suspensions
		Shock Absorbers
		Hydraulic Shock Absorber Operation
		Compression and Rebound Resistance
		Bump Stops and Limiters
		Gas Shocks
		Other Front End Parts
		Stabilizer Bar
		Air Shocks/Leveling Devices
		Suspension Leveling Systems
		Active Suspensions
	Chapter 64: Suspension System Service
		Introduction
		Diagnosing Suspension System Problems
		Shock Absorber Service
		Testing Shock Absorbers
		Macpherson Strut Service
		Inspect the Upper Strut Bearing
		Install the Coil Spring
		Reinstall the Strut Assembly
		Suspension Bushing Service
		Strut Rod Bushing Service
		Stabilizer Bar Service
		Spindle Service
		Ball Joint Service
		Measuring Ball Joint Wear
		Separating Tapered Connections
		Replacing A Ball Joint
		Coil Spring Service
		Adjusting Spring Height
		Coil Spring Replacement
		SLA Coil Spring Replacement
		Wheel Alignment
		Electronic Suspension Service
		Electronically Controlled Shock Absorbers
	Chapter 65: Steering Fundamentals
		Steering Systems
		Steering Gears
		Recirculating Ball and Nut Steering Gear
		Rack-and-Pinion Steering
		Steering Linkage
		Parallelogram Steering Linkage
		Ball Sockets
		Tie-Rods
		Steering Arm
		Rack-and-Pinion Steering Linkage
		Steering Column
		Power Steering
		Power Steering Pump
		Types of Power Steering
		Electronically Controlled Variable Effort Power Steering
		Electronically Controlled Steering Systems
	Chapter 66: Steering System Service
		Introduction
		Fluid Level Checks
		Type of Fluid
		Diagnosing Steering Problems
		Noise Diagnosis
		Hard Steering
		Tire Wear
		Steering Part Inspection
		Steering Linkage Inspection
		Steering Gear Looseness
		Parallelogram Steering Inspection
		Rack-and-Pinion Steering Linkage Inspection
		Steering Linkage Repairs
		Idler Arm Replacement
		Pitman Arm Replacement
		Tie-Rod End Replacement
		Rack-and-Pinion Tie-Rods
		Steering Wheel, Column, and Air Bag Service
		Air Bag Service
		Steering Wheel Service
		Steering Column Service
		Steering Gear Service
		Rack-and-Pinion Service
		Rack-and-Pinion Steering Looseness
		Power Steering System Service
		Power Steering System Flushing
		Bleeding Air From the Hydraulic System
		Power Steering Pump Replacement
		Repairing Power Steering Pump Oil Leaks
		Power Steering Pressure Diagnosis
		Power Steering Pump Service
		Power Steering Hoses
		Refilling the Power Steering System
		Power Steering Gear Service
		Replacing Rack-and-Pinion Units
		Variable Power Steering Service
		Electronically Controlled Power Steering System Service
	Chapter 67: Wheel Alignment Fundamentals
		Introduction
		Wheel Alignment Angles
		Toe
		Camber
		Caster
		Steering Axis Inclination
		Scrub Radius
		Turning Radius
		Geometric Centerline and Thrust Angle
		Tracking
		Setback
		Special Handling Characteristics
	Chapter 68: Wheel Alignment Service
		Introduction
		Prealignment Inspection
		Tire Wear Inspection
		Ride Height Check
		Toe Change
		Torque Steer
		Suspension Looseness
		Test Drive
		Tire Checks
		Inspection Checklist
		Wheel Alignment Procedures
		Measuring Alignment
		Measuring Camber
		Measuring Caster
		Road Crown and Pull
		Measuring Steering Axis Inclination
		Measuring Toe
		Adjusting Toe
		Centering A Steering Wheel
		Recalibrating Steering Position
		Checking For Toe Change
		Measuring Turning Radius
		General Wheel Alignment Rules
		Four-Wheel Alignment
		Performing A Four-Wheel Alignment
		Compensating the Alignment Heads
		Measuring Caster and Camber
		Adjusting Rear-Wheel Alignment
Section 12: Drivetrain
	Chapter 69: Clutch Fundamentals
		Introduction
		Clutch Parts and Operation
		Clutch Disc
		Pressure Plate
		Types of Clutch Covers
		Coil Spring Clutch
		Diaphragm Clutch
		Pilot Bearing Or Bushing
		Release Bearing
		Clutch Fork
		Clutch Release Methods
		Clutch Cable
		Hydraulic Clutch Operation
		Clutch Free Travel
		Dual Clutch Transmissions
	Chapter 70: Clutch Diagnosis and Service
		Introduction
		Diagnosis of Clutch Problem
		Clutch Noises
		Transmission Noise
		Pedal Problems
		Slipping Clutch
		Dragging Clutch
		Oily Clutch Facings
		Damaged Friction Surfaces
		Chattering Or Grabbing Clutch
		Clutch Service
		Servicing Hydraulic Components
		Clutch Replacement
		Removing A Transmission Or Transaxle
		Clutch Removal
		Flywheel Removal
		Flywheel Starter Ring Gear Replacement
		Flywheel Installation
		Inspect New Parts
		Pilot Bushing Service
		Clutch Disc Service
		Clutch Cover/Pressure Plate Service
		Clutch Installation
		Release Bearing Service
		Clutch Housing Installation
	Chapter 71: Manual Transmission Fundamentals
		Introduction
		Purpose of A Transmission
		Using Gears to Increase Torque
		Gear Ratio
		Transmission Gear Ranges
		Overdrive
		Final Drive Ratio
		Gear Types and Operation
		Spur Gears
		Helical Gears
		Idler Gears
		Transmission Parts
		Transmission Lubrication
		Transmission Bearings
		Transmission Gears and Shafts
		Synchronizer Assembly
		Gear Shift Mechanisms
		Shift Patterns
		Transmission Power Flow
		Four-Speed Transmission Power Flow
		Five-Speed Transmission
		Speedometer Drive
		Switches and Sensors
	Chapter 72: Manual Transmission Diagnosis and Repair
		Introduction
		Transmission Diagnosis
		Lubricant Checks
		Transmission Removal
		Transmission Disassembly
		Disassemble the Mainshaft Assembly
		Synchronizer Service
		Synchronizer Inspection
		Inspect Blocker Rings
		Inspect Input Shaft and Mainshaft
		Replace Worn Bearings
		Reassemble the Transmission
		Reassemble the Synchronizers
		Reassemble the Mainshaft
		End Play
		Needle Bearing Installation
		Install New Gaskets
		Complete the Transmission Reassembly
		Install the Transmission
		Add Lubricant
		Test Drive
	Chapter 73: Automatic Transmission Fundamentals
		Introduction
		Automatic Transmission Parts
		Power Transmission
		Flexplate
		Torque Converter
		Torque Multiplication
		Torque Converter Operation
		Stator Clutch Operation
		Stall Speed
		Lock-Up Torque Converters
		Planetary Gears
		Simple Planetary Gearset
		Simple Planetary Operation
		Compound Planetary Operation (Simpson)
		Driving and Holding Devices
		Clutches
		Clutch Operation
		One-Way Clutches
		Bands
		Accumulator
		Hydraulic System
		Fluid Pump
		Types of Pumps
		Transmission Valves
		Pressure Regulator
		Hydraulic Valve Body
		Transmission Automatic Shift Selection
		Automatic Transmission Fluid (ATF)
		Automatic Transmission Cooling
		Auxiliary Cooler/Heat Exchanger
		Park Pawl
		Electronic Automatic Transmissions
		Electronic Automatic Transmission Operation
		Electronic Torque Converter Control
		Electronic Pressure Control
		Transmission Shift Control
		Continuously Variable Transmission
		Hybrid Planetary Transmission Operation
	Chapter 74: Automatic Transmission Diagnosis and Service
		Introduction
		Automatic Transmission Identification
		Automatic Transmission Maintenance
		Transmission Fluid Service
		Fluid Level
		Check Fluid Condition
		Changing Transmission Fluid
		Transmission Filter Service
		Remove and Replace the Filter
		Refill the Transmission
		Diagnosis and Repair of Leaks
		Leaks From the Converter Housing
		Transmission Cooler Line Leaks
		VSS/Speedometer Drive Gear Leak
		Shift Lever Seal Replacement
		Pump Seal Replacement
		Front Seal Replacement
		Pump Bushing Replacement
		Reinstalling the Transmission
		Rear Oil Seal and Bushing Replacement
		Automatic Transmission Problem Diagnosis
		Slippage
		Transmission Drainback
		Noises
		Flexplate
		Transmission Tests
		Valve Body Removal
		Electronic Transmission Service
		More Tests Before Transmission Removal
		Hybrid Automatic Transmission Service
		Remanufactured Automatic Transmissions and Transaxles
		Transmission Rebuilding
		Transmission Reassembly
	Chapter 75: Driveline Operation
		Introduction
		Driveshaft (RWD)
		Slip Yoke
		Universal Joints
		Two-Piece Driveshaft
		Driveshaft Angle
		Constant Velocity Joints
		Differential
		Differential Construction
		Differential Housing
		Differential Operation
		Differential Gears
		Gearsets
		Axle Ratio
		Limited-Slip Differential
		Types of Limited-Slip Differentials
		Viscous Coupling Differentials
		Drive Axles and Bearings
		Semi-Floating Axle Bearing Types
		Independent Rear Suspension Axles
		Gear Oils
		Four-Wheel Drive
		Four-Wheel-Drive Axle Assembly
		Transfer Case
		Locking Hubs
		All-Wheel Drive
	Chapter 76: Driveline Diagnosis and Service
		Introduction
		Driveshaft Diagnosis
		Universal Joint Diagnosis and Service
		Driveshaft Service
		Universal Joint Disassembly
		Universal Joint Reassembly
		Driveshaft Installation
		Two-Piece Driveshaft Service
		Differential and Axle Diagnosis and Service
		Problem Diagnosis
		Axle Bearing Diagnosis
		Axle Bearing Service
		Removing A Bearing-Retained Axle
		Axle Bearing Replacement
		Axle Bearing Installation
		Reinstall the Axle
		Full-Floating Axle Service
		Differential Pinion Seal Replacement
		Differential Repair
		Removing A Third Member
		Disassembling A Salisbury Axle
		Clean and Inspect Parts
		Differential Reassembly
		Adjusting A Differential
		Pinion Gear Depth
		Ring Gear Backlash
		Side Bearing Preload
		Contact Pattern
		Backlash Pattern Change
		Pinion Depth Pattern Change
		Pinion Bearing Preload
		Ring and Pinion Noise
		Four-Wheel-Drive Service and Repair
	Chapter 77: Front-Wheel-Drive (Transaxle and CV Joint) Fundamentals
		Introduction
		Front-Wheel Drive
		Manual Transaxles
		Shift Linkage
		Transaxle Differential
		Transaxle Power Flow
		Automatic Transaxle
		Front Drive Axles
		Axle Shaft Parts
		CV Joint Construction
		Axle Shafts
		CV Joint Boots
	Chapter 78: Front-Wheel-Drive (Transaxle and CV Joint) Service
		Introduction
		Transaxle and Front-Wheel-Drive Service and Repair
		Leaking CV Joint Boot
		CV Joint Boot Service
		Axle Inspection and Diagnosis
		CV Joint Diagnosis
		Axle Shaft Removal
		CV Joint Replacement
		Fixed Joint Disassembly and Inspection
		CV Joint Boot Clamps
		Servicing An Inner Tripod Joint
		Double Offset Plunge Joints
		Cross Groove Joint Service
		Rebuilt Halfshafts
		Installing the Axle
		Transaxle Repair
		Transaxle Removal
		Manual Transaxle Repair
		Automatic Transaxle Repair
		Transaxle Differential Side Bearing Adjustment
		Install the Transaxle
	Chapter 79: Driveline Vibration and Service
		Vibration Analysis
		Types of Vibrations
		Vibration Test Instruments
		Vibration and Frequency
		Driveshaft Runout
		Other Causes of Vibration
		Driveshaft Balance
		Driveshaft Angle
Section 13: Hybrid and Electric Vehicles
	Chapter 80: Hybrid Electric Vehicle Fundamentals
		Introduction to Hybrid Vehicles
		Series and Parallel Hybrids
		Hybrid Types and Levels
		Battery Types: Hybrid Electric Vehicle and Others
		Capacitors In Hybrid Vehicles
		Supercapacitors/Ultracapacitors
		Hybrid Brushless DC Motors
		Hybrid Vehicle Air Conditioning
		Hybrid Vehicle Brakes
		Hybrid Planetary Transmission Operation
	Chapter 81: Hybrid Vehicle Safety and Service
		Hybrid Vehicle Safety and Service
		Hybrid Electrical Shock Hazard
		High Voltage Precautions
		Hybrid Battery Service
		Hybrid High-Voltage Battery Service
		High-Voltage Battery Rebuilding
	Chapter 82: New Vehicle Technologies: Battery and Fuel Cell Electric and Hydraulic Hybrid
		Introduction to Battery and Fuel Cell Electric Vehicles
		Battery Electric Vehicles
		Lithium-Ion Batteries
		Electric Vehicle Battery Construction
		Plug-In Hybrids
		Energy Cost and Electric Vehicle Economy
		Extended Range Electric Vehicles
		Electric Vehicle Charging Systems
		Standards For EV Electrical Connectors
		Motor/Machine For Electric Vehicles
		EV Motor Types
		EV Motor Construction
		Inverter/Converter/Electronic Controls
		Electric Vehicle Service
		Fuel Cell Electric Vehicles (FCEVs)
		Hydraulic Hybrid Vehicles
Appendix
Glossary
Index