Automotive Technology: A Systems Approach

Title Page
Copyright Page
Contents
Photo Sequences
Preface
	About the Book
	New to this Edition
	Organization and Goals of this Edition
	Acknowledgments
	About the Author
Features of the Text
	Objectives
	The Three Cs
	Cautions and Warnings
	Shop Talk
	Customer Care
	Tool Care
	Using Service Information
	Performance Tips
	“Go To” Feature
	Photo Sequences
	Procedures
	Key Terms
	Summary
	Review Questions
	ASE-Style Review Questions
	Metric Equivalents
Supplements
	Tech Manual
	Instructor Resources
	Mindtap for Automotive
Section 1: Automotive Technology
	Chapter 1: Careers In The automotive Industry
		Objectives
		The Automotive Industry
		Job Classifications
		Related Career Opportunities
		Training for a Career in Automotive Service
		ASE Certification
		ASE Tests
		ASE Education Foundation Program Accreditation
		Key Terms
		Summary
		Review Questions
	Chapter 2: Workplace Skills
		Objectives
		Seeking and Applying for Employment
		Accepting Employment
		Working as a Technician
		Communications
		Solving Problems and Critical Thinking
		Professionalism
		Interpersonal Relationships
		Key Terms
		Summary
		Review Questions
	Chapter 3: Basic Theoriesand Math
		Objectives
		Matter
		Energy
		Volume
		Force
		Time
		Motion
		Work
		Waves and Oscillations
		Light
		Liquids
		Gases
		Heat
		Chemical Properties
		Electricity and Electromagnetism
		Key Terms
		Summary
		Review Questions
	Chapter 4: Automotive Systems
		Objectives
		Historical Background
		Design Evolution
		Body Shapes
		The Basic Engine
		Engine Systems
		Electrical and Electronic Systems
		Heating and Air-Conditioning Systems
		Drivetrain
		Running Gear
		Hybrid Vehicles
		Alternative Fuels
		Key Terms
		Summary
		Review Questions
	Chapter 5: Hand Tools And Shop Equipment
		Objectives
		Measuring Systems
		Fasteners
		Measuring Tools
		Hand Tools
		Shop Equipment
		Power Tools
		Jacks and Lifts
		Service Information
		Key Terms
		Summary
		Review Questions
	Chapter 6: Diagnostic Equipment And Special Tools
		Objectives
		Engine Repair Tools
		Electrical/Electronic System Tools
		Engine Performance Tools
		Pressure Transducer
		Transmission and Driveline Tools
		Suspension and Steering Tools
		Brake System Tools
		Heating and Air- Conditioning Tools
		Key Terms
		Summary
		Review Questions
	Chapter 7: Working Safely In The Shop
		Objectives
		Personal Safety
		Tool and Equipment Safety
		Work Area Safety
		Manufacturers’ Warnings and Government Regulations
		OSHA
		Right-To-Know Law
		Key Terms
		Summary
		Review Questions
	Chapter 8: Preventive Maintenance And Basic Services
		Objectives
		Repair Orders
		Vehicle Identification
		Preventive Maintenance
		Basic Services
		Additional PM Checks
		Key Terms
		Summary
		Review Questions
Section 2: Engines
	Chapter 9: Automotive Engine Designs And Diagnosis
		Objectives
		Introduction to Engines
		Engine Classifications
		Engine Measurement and Performance
		Diesel Engines
		Other Automotive Power Plants
		Engine Identification
		Engine Diagnostics
		Evaluating the Engine’s Condition
		Noise Diagnosis
		Key Terms
		Summary
		Review Questions
		ASE - Style Review Questions
	Chapter 10: Engine Disassembly And Cleaning
		Objectives
		Removing an Engine
		Engine Disassembly and Inspection
		Cleaning Engine Parts
		Crack Detection
		In-Vehicle Engine Service
		Cylinder Head
		Key Terms
		Summary
		Review Questions
		ASE - Style Review Questions
	Chapter 11: Lower End Theory And Service
		Objectives
		Short Block Disassembly
		Cylinder Block
		Cylinder Block Reconditioning
		Crankshaft
		Crankshaft Inspection and Rebuilding
		Installing Main Bearings and Crankshaft
		Piston and Piston Rings
		Installing Pistons and Connecting Rods
		Installation of Camshaft and Related Parts
		Crankshaft and Camshaft Timing
		Oil Pump Service
		Installing the Oil Pump
		Key Terms
		Summary
		Review Questions
		ASE - Style Review Questions
	Chapter 12: Upper End Theory And Service
		Objectives
		Camshafts
		Cylinder Head
		Intake and Exhaust Valves
		Cylinder Head Disassembly
		Inspection of the Valve Train
		Inspection of Camshaft and Related Parts
		Servicing Cylinder Heads
		Valve Stem Seals
		Assembling the Cylinder Head
		Key Terms
		Summary
		Review Questions
		ASE - Style Review Questions
	Chapter 13: Engine Sealing And Reassembly
		Objectives
		Torque Principles
		Gaskets
		Specific Engine Gaskets
		Adhesives, Sealants, and Other Sealing Materials
		Oil Seals
		Engine Reassembly
		Installing the Engine
		Key Terms
		Summary
		Review Questions
		ASE - Style Review Questions
	Chapter 14: Lubricating And Cooling Systems
		Objectives
		Lubrication System
		Flushing the System
		Cooling Systems
		Cooling System Diagnosis
		Inspection of Cooling System
		Testing for Leaks
		Cooling System Service
		Key Terms
		Summary
		Review Questions
		ASE - Style Review Questions
Section 3: Electricity
	CHAPTER 15: Basics of Electrical Systems
		Objectives
		Basics of Electricity
		Electrical Terms
		Ohm’s Law
		Circuits
		Circuit Components
		Key Terms
		Summary
		Review Questions
		ASE-Style Review Questions
	CHAPTER 16: General Electrical System Diagnostics and Service
		Objectives
		Electrical Problems
		Electrical Wiring Diagrams
		Electrical Testing Tools
		Using Multimeters
		Using Lab Scopes
		Testing Basic Electrical Components
		Troubleshooting Circuits
		Testing for Common Problems
		Connector and Wire Repairs
		Key Terms
		Summary
		Review Questions
		ASE-Style Review Questions
	CHAPTER 17: Batteries: Theory, Diagnosis, and Service
		Objectives
		Basic Battery Theory
		Battery Hardware
		Battery Ratings
		Common Types of Batteries
		Lead-Acid Batteries
		Servicing and Testing Batteries
		Jump-Starting
		KeyTerms
		Summary
		Review Questions
		ASE-Style Review Questions
	CHAPTER 18: Starting and Motor Systems
		Objectives
		Basics of Electromagnetism
		Starting Motors
		Starting System
		Starter Motor Circuit
		Control Circuit
		Starting System Testing
		Key Terms
		Summary
		Review Questions
		ASE-Style Review Questions
	CHAPTER 19: Charging Systems
		Objectives
		Alternating Current Charging Systems
		AC Generator Operation
		Voltage Regulation
		Current Trends
		Preliminary Checks
		General Testing Procedures
		AC Generator Service
		Key Terms
		Summary
		Review Questions
		ASE-Style Review Questions
	CHAPTER 20: Lighting Systems
		Objectives
		Automotive Lamps
		Headlights
		Headlight Switches
		Automatic Light Systems
		Headlight Service
		Headlight Replacement
		Basic Lighting System Diagnosis
		Rear Exterior Lights
		Interior Light Assemblies
		Key Terms
		Summary
		Review Questions
		ASE-Style Review Questions
	CHAPTER 21: Instrumentation and Information Displays
		Objectives
		Instrument Panels
		Displays
		Mechanical Gauges
		Electronic Instrument Clusters
		Basic Information Gauges
		Indicator and Warning Devices
		Driver Information Centers
		Key Terms
		Summary
		Review Questions
		ASE-Style Review Questions
	CHAPTER 22: Basics of Electronics and Computer Systems
		Objectives
		Capacitors
		Semiconductors
		Computer Basics
		Multiplexing
		Protecting Electronic Systems
		Diagnosing Modules and Networks
		Testing Electronic Circuits and Components
		Key Terms
		Summary
		Review Questions
		ASE-Style Review Questions
	CHAPTER 23: Electrical Accessories
		Objectives
		Windshield Wiper/Washer Systems
		Horns/Clocks/Cigarette Lighter Systems
		Cruise (Speed) Control Systems
		Adaptive Cruise Control
		Sound Systems
		Telematics
		Navigation Systems
		Power Lock Systems
		Power Windows
		Power Seats
		Power Mirror System
		Rear-Window Defrosters and Heated Mirror Systems
		Other Electronic Equipment
		Garage Door Opener System
		Security and Antitheft Devices
		Key Terms
		Summary
		Review Questions
		ASE-Style Review Questions
Section 4: ENGINE PERFORMANCE
	CHAPTER 24: Engine Performance Systems
		Objectives
		Ignition Systems
		Fuel System
		Air Induction System
		Emission Control Systems
		Engine Control Systems
		Computer Logic
		On-Board Diagnostic Systems
		System Operation
		Obd Ii Monitoring Capabilities
		Obd II Self-Diagnostics
		MIL
		Basic Diagnosis of Electronic Engine Control Systems
		Diagnosing Obd II Systems
		Key Terms
		Summary
		Review Questions
		ASE-Style Review Questions
	CHAPTER 25:Detailed Diagnosis and Sensors
		Objectives
		Using Scan Tool Data
		Symptom-Based Diagnosis
		Basic Testing
		Diagnosis of Computer Voltage Supply and Ground Wires
		Switches
		Temperature Sensors
		Pressure Sensors
		Mass Airflow (MAF) Sensors
		Oxygen Sensors (O2S)
		Testing Air-Fuel Ratio (A/F) Sensors
		Position Sensors
		EGR Valve Position Sensor
		Speed Sensors
		Position/Speed Sensors
		Knock Sensor (KS)
		Computer Outputs and Actuators
		Testing Actuators
		Key Terms
		Summary
		Review Questions
		ASE-Style Review Questions
	CHAPTER 26: Ignition Systems
		Objectives
		Basic Circuitry
		Ignition Components
		Triggering and Switching Devices
		Engine Position Sensors
		Distributor Ignition System Operation
		Electronic Ignition Systems
		EI System Operation
		Key Terms
		Summary
		Review Questions
		ASE-Style Review Questions
	CHAPTER 27: Ignition System Diagnosis and Service
		Objectives
		Misfires
		General Ignition System Diagnosis
		Ignition System Inspection
		No-Start Diagnosis
		Diagnosing with an Engine Analyzer
		Diagnosing with a Dso or Gmm
		Ignition Timing
		Diagnosing Primary Circuit Components
		Secondary Circuit Tests and Service
		Key Terms
		Summary
		Review Questions
		ASE-Style Review Questions
	CHAPTER 28: Gasoline, Diesel, and Other Fuels
		Objectives
		Crude Oil
		Gasoline
		Basic Gasoline Additives
		Oxygenates
		MTBE
		Gasoline Quality Testing
		Alternatives to Gasoline
		Diesel Fuel
		Diesel Engines
		Diesel Fuel Injection
		Diesel Emission Controls
		Diagnostics
		Key Terms
		Summary
		Review Questions
		ASE-Style Review Questions
	CHAPTER 29: Fuel Delivery Systems
		Objectives
		Guidelines for Safely Working on Fuel Systems
		Fuel Tanks
		Filler Caps
		Fuel Lines and Fittings
		Fuel Filters
		Fuel Pumps
		Key Terms
		Summary
		Review Questions
		ASE-Style Review Questions
	CHAPTER 30: Electronic Fuel Injection
		Objectives
		Basic Efi
		Throttle Body Injection (TBI)
		Port Fuel Injection (PFI)
		Pressure Regulators
		Central Port Injection (Cpi)
		Gasoline Direct-Injection Systems
		Key Terms
		Summary
		Review Questions
		ASE-Style Review Questions
	CHAPTER 31: Fuel Injection System Diagnosis and Service
		Objectives
		Preliminary Checks
		Basic Efi System Checks
		Injector Service
		Fuel Rail, Injector, and Regulator Service
		Electronic Throttle Controls
		Idle Speed Checks
		Key Terms
		Summary
		Review Questions
		ASE-Style Review Questions
	CHAPTER 32: Intake and Exhaust Systems
		Objectives
		Vacuum Systems
		Air Induction System
		Induction Hoses
		Intake Manifolds
		Forced Induction Systems
		Turbochargers
		Superchargers
		Exhaust System Components
		Catalytic Converters
		Exhaust System Service
		Key Terms
		Summary
		Review Questions
		ASE-Style Review Questions
	CHAPTER 33: Emission Control Systems
		Objectives
		Pollutants
		Emission Control Devices
		Evaporative Emission Control Systems
		Precombustion Systems
		Postcombustion Systems
		Diesel Emission Controls
		Key Terms
		Summary
		Review Questions
		ASE-Style Review Questions
	CHAPTER 34: Emission Control Diagnosis and Service
		Objectives
		OBD II Test
		Testing Emissions
		Basic Inspection
		Evaporative Emission Control System Diagnosis and Service
		Pcv System Diagnosis and Service
		Egr System Diagnosis and Service
		Catalytic Converter Diagnosis
		Air System Diagnosis and Service
		Key Terms
		Summary
		Review Questions
		ASE-Style Review Questions
	CHAPTER 35: Hybrid Vehicles
		Objectives
		Hybrid Vehicles
		Hybrid Technology
		Accessories
		HVAC
		GM’s Series Hybrids
		GM’s Parallel Hybrids
		Honda’s IMA System
		IMA
		Toyota’s Power-Split Hybrids
		Ford Hybrids
		4WD
		Porsche and Volkswagen Hybrids
		Hyundai and Kia Hybrids
		Nissan/Infiniti Hybrids
		Bmw Hybrids
		Mercedes-Benz Hybrids
		Maintenance and Service
		Key Terms
		Summary
		Review Questions
		ASE-Style Review Questions
	CHAPTER 36: Electric Vehicles
		Objectives
		A Look at History
		Zero-
 Emissions Vehicles
		Major Parts
		Battery Charging
		Accessories
		HVAC
		Driving a BEV
		Ford Focus
		Nissan
 Leaf
		Mitsubishi i-MiEV
		Tesla
		Honda Fit Ev
		Basic Diagnosis
		Fuel Cell Vehicles
		Fuel Cells
		Current FCEVs
		Toyota
		Honda
		Hyundai
		Prototype Fcevs
		Audi
		Daimler
		Key Terms
		Summary
		Review Questions
		ASE-Style Review Questions
Section 5: MANUAL TRANSMISSIONS AND TRANSAXLES
	CHAPTER 37: Clutches
		Objectives
		Operation
		Clutch Service Safety Precautions
		Clutch Maintenance
		Clutch Problem Diagnosis
		Clutch Service
		Linkage Service
		Key Terms
		Summary
		Review Questions
		ASE-Style
 Review Questions
	CHAPTER 38: Manual Transmissions and Transaxles
		Objectives
		Transmission Versus Transaxle
		Gears
		Basic Gear
 Theory
		Transmission/Transaxle Design
		Synchronizers
		Gearshift Mechanisms
		Transmission Power Flow
		Transaxle Power
 Flows
		Final Drive Gears and Overall Ratios
		Dual Clutch Transmissions
		Electrical Systems
		Key Terms
		Summary
		Review Questions
		ASE-Style
 Review Questions
	CHAPTER 39: Manual Transmission/Transaxle Service
		Objectives
		Lubricant Check
		In-Vehicle
 Service
		Diagnosing Problems
		Transmission/Transaxle Removal
		Cleaning and
 Inspection
		Disassembly and Reassembly of the Differential Case
		Reassembly/Reinstallation of Transmission/Transaxle
		Key Term
		Summary
		Review Questions
		ASE-Style
 Review Questions
	CHAPTER 40: Drive Axles and Differentials
		Objectives
		Basic Diagnosis and Service
		Front-Wheel Drive (Fwd) Axles
		Types of CV
 Joints
		Front-Wheel Drive Applications
		CV Joint Service
		Rear-Wheel Drive Shafts
		Operation of U-Joints
		Types of U-Joints
		Diagnosis of Drivetrain Problems
		Final Drives and
 Drive Axles
		Limited-Slip Differentials
		Axle
 Shafts
		Servicing the Final Drive Assembly
		Key Terms
		Summary
		Review
 Questions
		ASE-Style Review Questions
Section 6: AUTOMATIC TRANSMISSIONS AND TRANSAXLES
	CHAPTER 41: Automatic Transmissions and Transaxles
		Objectives
		Torque Converter
		Lockup
 Torque Converter
		Planetary Gears
		Compound Planetary Gearsets
		Honda’s
 Nonplanetary-Based Transmission
		Continuously Variable Transmissions (CVT
		Planetary Gear Controls
		Transmission
 Clutches
		Bearings, Bushings, and Thrust
 Washers
		Snaprings
		Gaskets and
 Seals
		Final Drives and Differentials
		Hydraulic System
		Application of Hydraulics in
 Transmissions
		Pressure Boosts
		Shift
 Quality
		Gear Changes
		Key Terms
		Summary
		Review Questions
		ASE-Style
 Review Questions
	CHAPTER 42: Electronic Automatic Transmissions
		Objectives
		Transmission Control Module
		Hybrid Transmissions
		Basic Eat Testing
		Converter Clutch Control Diagnostics
		Detailed
 Testing of Inputs
		Detailed Testing of
 Actuators
		Key Terms
		Summary
		Review Questions
		ASE-Style Review
 Questions
	CHAPTER 43: Automatic Transmission and Transaxle Service
		Objectives
		Identification
		Basic
 Service
		Basic Diagnostics
		Visual
 Inspection
		Road Testing the Vehicle
		Checking the Torque Converter
		Diagnosing
 Hydraulic and Vacuum Control Systems
		Common Problems
		Linkages
		Replacing, Rebuilding, and Installing a
 Transmission
		Key Term
		Summary
		Review Questions
		ASE-Style Review
 Questions
	CHAPTER 44: Four- and All-Wheel Drive
		Objectives
		Types of Drives
		4WD
 Drivelines
		Interaxle (Center) Differentials
		Audi’s Quattro System
		Helical Center
 Differential
		Torque Vectoring
		Diagnosing
 4WD and Awd Systems
		Servicing 4WD
 Vehicles
		Key Terms
		Summary
		Review Questions
		ASE-Style Review
 Questions
Section 7: SUSPENSION AND STEERING SYSTEMS
	CHAPTER 45: Tires and Wheels
		Objectives
		Wheels
		Tires
		Tire Ratings and Designations
		Tire Pressure Monitor (Tpm) Systems
		Tire/Wheel Runout
		Tire Replacement
		Tire/Wheel Assembly Service
		Tire Repair
		Wheel Bearings
		Key Terms
		Summary
		Review Questions
		ASE-Style Review Questions
	CHAPTER 46: Suspension Systems
		Objectives
		Frames
		Suspension System Components
		Independent Front Suspension
		Basic Front-Suspension Diagnosis
		Front-Suspension Component Servicing
		Rear-Suspension Systems
		Semi-Independent Suspension
		Electronically Controlled Suspensions
		Servicing Electronic Suspension Components
		Active Suspensions
		Key Terms
		Summary
		Review Questions
		ASE-Style Review Questions
	CHAPTER 47: Steering Systems
		Objectives
		Mechanical Steering Systems
		Power-Steering Systems
		Electronically Controlled Power-Steering Systems
		Steering System Diagnosis
		Diagnosis
		Specific Checks
		Steering System Servicing
		Power-Steering System Servicing
		Four-Wheel Steering Systems
		Key Terms
		Summary
		Review Questions
		ASE-Style Review Questions
	CHAPTER 48: Restraint Systems: Theory, Diagnosis, and Service
		Objectives
		Seat Belts
		Seat Belt Service
		Air Bags
		Electrical System Components
		Diagnosis
		Servicing the Air Bag System
		Other Protection Systems
		Key Terms
		Summary
		Review Questions
		ASE-Style Review Questions
	CHAPTER 49: Wheel Alignment
		Objectives
		Wheel Alignment
		Alignment Geometry
		Prealignment Inspection
		Wheel Alignment Equipment
		Alignment Machines
		Performing an Alignment
		Four-Wheel Drive Vehicle Alignment
		Key Terms
		Summary
		Review Questions
		ASE-Style Review Questions
Section 8: BRAKES
	CHAPTER 50: Brake Systems
		Objectives
		Friction
		Principles of Hydraulic Brake Systems
		Hydraulic Brake System Components
		Master Cylinders
		Master Cylinder Operation
		Fast-Fill and Quick Take-Up Master Cylinders
		Central-Valve Master Cylinders
		Hydraulic Tubes and
 Hoses
		Hydraulic System Safety Switches and Valves
		Drum and Disc Brake Assemblies
		Hydraulic System Service
		Power Brakes
		Pushrod Adjustment
		Hydraulic Brake Boosters
		Electric Parking Brakes
		Key Terms
		Summary
		Review Questions
		ASE-Style Review Questions
	CHAPTER 51: Drum Brakes
		Objectives
		Drum Brake Operation
		Drum
 Brake Components
		Drum Brake Designs
		Road Testing Brakes
		Drum Brake Inspection
		Brake Shoes and Linings
		Wheel Cylinder Inspection and Servicing
		Drum Parking Brakes
		Key Terms
		Summary
		Review Questions
		ASE-Style Review Questions
	CHAPTER 52: Disc Brakes
		Objectives
		Disc Brake Components and their Functions
		Rear-Wheel Disc Brakes
		Disc Brake Diagnosis
		Service Guidelines
		General Caliper Inspection and Servicing
		Rear Disc Brake Calipers
		Rotor Inspection
		Rotor Service
		Key Terms
		Summary
		Review Questions
		ASE-Style Review Questions
	CHAPTER 53: Antilock Brake, Traction Control, and Stability Control Systems
		Objectives
		Antilock Brakes
		Types of
 Antilock Brake Systems
		Abs Operation
		Automatic Traction Control
		Automatic Stability Control
		Antilock Brake System Service
		Diagnosis and Testing
		Testing Traction and Stability Control Systems
		New Trends
		Key Terms
		Summary
		Review Questions
		ASE-Style Review Questions
Section 9: PASSENGER COMFORT
	CHAPTER 54: Heating and Air Conditioning
		Objectives
		Ventilation System
		Automotive Heating Systems
		Heating System Service
		Theory of Automotive Air Conditioning
		Refrigerants
		Basic Operation of an Air-Conditioning System
		Compressors
		Condenser
		Receiver/Dryer
		Thermostatic Expansion Valve/Orifice Tube
		Evaporator
		Refrigerant Lines
		Air-Conditioning Systems and Controls
		Temperature Control Systems
		Key Terms
		Summary
		Review Questions
		ASE-Style Review Questions
	CHAPTER 55: Air-Conditioning Diagnosis and Service
		Objectives
		Service Precautions
		Refrigerant Safety Precautions
		Initial System Checks
		Diagnosis
		Performance Testing
		Leak Testing
		Emptying the System
		General Service
		Recharging the System
		Climate Control Systems
		Summary
		Review Questions
		ASE-Style Review Questions
Appendix A: Decimal and Metric Equivalents
Appendix B: General Torque Specifications
Glossary
Index