© Cengage Learning. All rights reserved. No distribution allowed without express authorization.
AUTOMOTIVE SERVICE
• Inspection • Maintenance • Repair
Fourth Edition
Tim Gilles
Professor
Santa Barbara City College
ASE Master Automotive Technician,
ASE Master Automotive Machinist
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Automotive Service: Inspection,
Maintenance, Repair, 4th Edition
Tim Gilles
Vice President, Career and Professional
Editorial: Dave Garza
Director of Learning Solutions: Sandy Clark
Executive Editor: David Boelio
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TABLE OF
CONTENTS
© Cengage Learning. All rights reserved. No distribution allowed without express authorization.
PREFACE xv
ACKNOWLEDGMENTS xvii
DEDICATION xx
ABOUT THE AUTHOR xx
FEATURES OF THE TEXT xxi
SECTION 1
THE AUTOMOBILE INDUSTRY
CHAPTER 1
Introduction to the Automobile 2
Introduction 2 • Body and Chassis 2 • Engine Parts
and Operation 3 • Engine Support Systems 5 •
The Powertrain 9 • Accessory Systems 10 • History
and Development of the Automobile 10
CHAPTER 2
Automotive Careers and Technician
Certification 15
Introduction 15 • Automotive Career Opportunities
15 • Technician Certification and Licensing 17 •
Technician Skill Levels and Pay 19 • Other Areas of
Specialization 20 • Other Automotive Careers 21 •
On the Job as an Automotive Technician 22
Air Safety 34 • Impact Wrench Safety 35 • Air
Chisel Safety 35 • Die Grinder/Air Drill Safety 35 •
Press Safety 35 • General Lifting Safety 36 •
Hydraulic Floor Jack (Service Jack) Safety 36 •
Shop Crane (Engine Hoist) Safety 36 • Transmission
Jack Safety 37 • Battery Safety 37 • Refrigerant
Safety 39 • General Safety around Automobiles 39 •
Hot Tank Safety Precautions 39 • Hazardous
Materials and Environmental Safety 39 •
Hazardous Communication Standards 41 •
Material Safety Data Sheets 41 • Hazardous Materials
Common to the Automobile Industry 42 • Cleaning
Solvent Safety Precautions 43 • Skin Care Safety
Precautions 43 • Breathing Safety 43
CHAPTER 4
Shop Management, Service Records, and Parts 47
Introduction 47 • Customer Relations 47 • Service
Records 48 • Keep the Car Clean 49 • Linen
Service 49 • Wholesale and Retail Distribution of
Auto Parts 50
CHAPTER 5
Locating Service Information and
Specifications 53
Introduction 53 • Service Literature 53 •
Manufacturers’ Service Information 55 • Generic
Service Manuals 55 • Lubrication Service
Manual 57 • Owner’s Manual 57 • Owners’
Workshop Manuals 57 • Electronic Service
Information 57 • Technical Service Bulletins 59 •
Hot Line Services 60 • Trade Magazines 61
CHAPTER 6
Measuring Tools and Systems 62
SECTION 2
SHOP PROCEDURES, SAFETY, TOOLS,
AND EQUIPMENT
Introduction 62 • Metric System 62 • Measuring
Tools 63 • Precision Measuring Tools 64
CHAPTER 7
Hardware, Fasteners, Drills, and Thread Repair 76
CHAPTER 3
Shop Safety 25
Introduction 25 • General Personal Safety 25 •
Fire Safety 27 • Fire Extinguishers 27 •
Flammable Materials 29 • Fuel Fires 29 •
Electrical Fires 30 • Shop Habits 30 • Electrical
Safety Precautions 31 • Cooling Fan Safety 32 •
Coolant Burns 32 • General Hand Tool Safety 33 •
Vise Safety 33 • Puller Safety 33 • Machinery
Safety 33 • Electric Drill Safety 34 • Grinder
Safety 34 • Wire Wheel Safety 34 • Compressed
Introduction 76 • Characteristics of Fasteners 76 •
Fastener Failures 79 • Drill Bits 80 • Taps and
Threads 82 • Dies 84 • Repairing Broken
Fasteners 84
CHAPTER 8
Shop Tools 93
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Introduction 93 • Tools of the Trade 93 • Hand
Tools 93 • Pullers 104 • Air Tools 106 • Special
Service Tools 110
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CHAPTER 9
General Shop Equipment 112
CHAPTER 14
Undercar Inspection and Service 180
Shop Equipment 112 • Hydraulic Equipment
112 • Shop Electric Machinery 117 •
Other Electric Equipment 120 • Other Shop
Equipment 120
Introduction 180 • Tire Visual Inspection 180 •
Undercar Brake Checks 181 • Exhaust System
Inspection 182 • Chassis Lubrication 182 •
Suspension and Steering Checks 185 • Driveline
Checks 187
CHAPTER 10
Cleaning Equipment and Methods 124
Introduction 124 • General Shop Housekeeping
Practices 124 • Cleaning Methods 125 •
Cleaning the Outside of the Engine 126 •
Environmental Concerns with Engine Cleaning
126 • Cleaning Internal Parts 126 • Chemical
Cleaning 127 • Thermal Cleaning 134 •
Vibratory Parts Cleaners 135 • Other Cleaning
Methods 135 • Marking Clean Parts 135
CHAPTER 11
Lifting Equipment and Air Compressors 137
Introduction 137 • Lift Types 137 • FrameContact Lifts 138 • Wheel-Contact Lifts 139 •
Wheel-Free Jacks 140 • In-Ground Lifts 140 •
Surface Mount Lifts 142 • Lift Safety 143 •
Air Compressors 144
SECTION 3
VEHICLE INSPECTION (LUBRICATION/
SAFETY CHECK)
CHAPTER 12
Engine Lubrication 149
Introduction 149 • Engine Oil 150 •
Engine Oil Licensing and Certification 153 •
Oil Additives 154 • Changing Engine Oil 157 •
Oil Filter 159 • Changing the Oil Filter 161
CHAPTER 13
Underhood and Body Inspection
(Vehicle on Ground) 165
Introduction 165 • Brake System Inspection 165 •
On-Ground Steering and Suspension Checks 167 •
Fuel System Inspection 169 • Cooling System
Inspection 170 • Belt Inspection 171 • Electrical
System Inspection 172 • Check Operation of
Lights 172 • Visibility Checks 173 • Other Safety
Checks and Service 175
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SECTION 4
ENGINE OPERATION
CHAPTER 15
Introduction to the Engine 194
Introduction 194 • Basic Engine Operation 194 •
Four-Stroke Engine Operation 195 • Engine Upper
End 196 • Valve Train 196 • Cylinder Head 197 •
Engine Front 199 • Cylinder Block Assembly (Lower
End) 200 • Short Block and Long Block 201
CHAPTER 16
Engine Classifications and Advanced
Transportation Technologies 207
Introduction 207 • Engine Classifications 207 •
Cylinder Arrangement 208 • Firing Order 209 •
Engine Cooling 209 • Valve Location 210 •
Camshaft Location 211 • Other Cylinder Head
Variations 211 • Combustion Chamber Designs 212 •
Spark and Compression Ignition 213 • Alternate
Engines 215 • New Generation Vehicles 216 •
Regenerative Braking 216 • Hybrid Vehicles 216 •
Types of Hybrids 218 • Hybrid Vehicle Service and
Safety 221 • Hydraulic Hybrid Vehicles 222 •
Fuel Cell Electric Vehicles (FCEVs) 223
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iv
CHAPTER 17
Engine Size and Measurements 227
Introduction 227 • Engine Size Measurements 227 •
Compression Ratio 229 • Physical Principles of
Work 231 • Torque 231 • Horsepower 232 •
Dynamometer 233 • Dynamometer Safety
Concerns 236 • Engine Efficiency 236 • Mean
Effective Pressure 238
CHAPTER 18
Engine Upper End 240
Introduction 240 • Cylinder Head
Construction 240 • Valve Guides 241 •
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Valve Guide Seals 241 • Valves 243 • Retainers
and Valve Locks 246 • Valve Springs 246 •
Pushrods and Rocker Arms 247 • Camshaft 248 •
Number of Cams and Lobes 248 • Camshaft
Performance 249 • Valve Lifters and Lash
Adjusters 250 • Roller Cam and Lifters 251 •
Hydraulic Lifters 251 • Camshaft Drives 253 •
Valve Timing 255 • Variable Valve Timing 256 •
Active Fuel Management/Displacement on
Demand 258
CHAPTER 19
Engine Lower End and Lubrication System
Theory 262
Introduction 262 • Cylinder Block Construction
262 • Core Plugs 263 • Cylinder Bore 263 •
Cylinder Sleeves 264 • Main Bearing Caps 264 •
Lifter Bores 264 • Crankshaft Design 264 •
Crankshaft End Thrust 265 • Direction of
Crankshaft Rotation 266 • Vibration Damper
266 • Crankshaft Hardness 266 • Bearings 266 •
Connecting Rods 269 • Pistons 270 • Piston
Head 270 • Piston Ring Grooves 270 • Heat Transfer
270 • Cast and Forged Pistons 271 • Piston Skirt
271 • Piston Pin Offset 272 • Piston Pins 273 •
Piston Rings 274 • Compression Rings 274 •
Compression Ring Design 275 • Oil Control Rings
277 • Engine Balancing 277 • The Lubrication
System 278 • Oil Pumps 278 • Pressure Relief
Valve 280 • Oil Pump Screen By-Pass Valve 280 •
Oil Pressure 281 • Windage Tray and Baffles 281 •
Dry Sump Lubrication Systems 281
v
CHAPTER 21
Cooling System Service 300
Introduction 300 • Diagnosing Cooling
System Problems 300 • Radiator Cap 301 •
Coolant Service 303 • Testing Coolant Condition
and Strength 307 • Thermostat Service 310 •
Locating Leaks 313 • External Leaks 313 • Internal
Leaks 314 • Recovery Tank Service 317 • Cooling
System Repairs 317 • Water Pump Service 318 •
Electric Cooling Fan Service 320 • Heater Core
Service 320
CHAPTER 22
Automotive Belts 323
Introduction 323 • Belt Material 323 • V-Belts
323 • V-Ribbed Belts 324 • Serpentine Belt
Drive 325 • Stretch Belts 325 • Timing Belts
326 • Drive Belt Service 326 • Belt Inspection and
Adjustment 327 • Replacing Belts 328
CHAPTER 23
Automotive Hoses 334
Introduction 334 • Hose Construction 334 •
Hose Size 334 • Unreinforced Hose 334 •
Radiator Hose 334 • Hose Types 334 • Hose
Clamps 338 • Hose Inspection 339 • Replacing
Hoses 340
CHAPTER 24
Automotive Plumbing: Tubing and Pipe 345
Introduction 345 • Tubing 345 • Flared
Connections 347 • Compression Fittings 348 •
Pipe Fittings 349 • Shutoff Valves 351 • Tubing
Service 351 • Installing Tubing 354 • Transmission
Oil Cooler Line Repairs 355 • Nylon Fuel Injection
Tubing 355 • Pipe Service 356
SECTION 5
COOLING SYSTEM, BELTS, HOSES,
AND PLUMBING
CHAPTER 20
Cooling System Theory 285
Introduction 285 • Liquid and Air Cooling 285 •
Liquid Cooling System Parts 286 • Cooling System
Circulation 286 • Coolant 287 • Cooling System
Pressure Cap 290 • Coolant Recovery System 291 •
Radiator 292 • Thermostat 292 • Temperature
Warning Light or Gauge 295 • Fans 296 • Fan
Clutch 297 • Radiator Shroud 298 • Heater Core 298
SECTION 6
ELECTRICAL SYSTEM THEORY AND SERVICE
CHAPTER 25
Basic Electrical System Theory and Repairs 358
Introduction 358 • Electron Flow 358 • Basic
Automotive Electrical System 360 • Electrical Terms
362 • Circuitry and Ohm’s Law 365 • Magnetic
Fields 366 • Capacitors 368 • Automotive
Electronics 368 • Basic Electrical Tests 369
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CHAPTER 26
Battery Fundamentals 378
CHAPTER 32
Lighting and Wiring Fundamentals 458
Introduction 378 • Battery Parts and Operation
379 • Battery Recharging and Discharging 381 •
Battery Capacity Ratings 382 • Battery Types 384 •
Battery Plate Size 386 • Battery Selection 386 •
Battery Service Life 386 • Battery Cables 387 •
Battery Holddowns 388 • Reasons for Battery
Failure 388 • Hybrid Electric Vehicle and Other
Battery Types 388
Introduction 458 • Wire and Cable 458 • Circuit
Protection Devices 459 • Lighting 461 • Headlamps
461 • Taillights 466 • Light Bulb Identification
467 • Fiber Optics 468 • Turn Signals 469 •
Signal Flasher Operation 469 • Hazard Flashers
470 • Back-Up Lights 470 • Wipers and
Horn 470 • Miscellaneous Gauges 475
CHAPTER 27
Battery Service 392
Introduction 392 • Battery Inspection 393 • Battery
Service 393 • Replacing a Battery 395 • Battery
Testing: Measuring a Battery’s State of Charge 400 •
Battery Charging 404 • Storing a Vehicle 406 •
Battery Capacity Tests 406 • Battery Drain Test/
Parasitic Load 408 • Battery Jump-Starting 409 •
Hybrid Battery Service 410
CHAPTER 28
Starting System Fundamentals 414
Introduction 414 • Starter Motor 414 • Starter
Motor Fundamentals 414 • Starter Drives 417 •
Starter Electrical Circuit 417 • Gear Reduction
Starters 420 • Brushless DC Motors 421
CHAPTER 29
Starting System Service 423
Introduction 423 • Starting System Service 423 •
Starting System Tests 424 • Cranking Voltage and
Amperage Test 425 • Circuit Resistance Test 425 •
No-Crank Tests Using a Test Light 427 • Solenoid
Problems 427 • Starter Repair 429 • Starter
Disassembly 429 • Starter Drive Service 429 •
Starter Reassembly 430 • Pinion Clearance Tests 431
CHAPTER 30
Charging System Fundamentals 434
Introduction 434 • Charging System 434 • Direct
Current (DC) Generators 434 • AC Generator/
Alternator 435 • AC Generator Bearings 439 •
Voltage Regulator 440 • Charging System Indicators
442 • High-Voltage Charging Systems 443
CHAPTER 31
Charging System Service 447
Introduction 447 • Charging System Service 447 •
Testing the Charging System 447 • Charging System
Output Test 448 • Diode Tests 451 • Charging
System Voltage Drops 452 • AC Generator Service
and Repair 453 • AC Generator Reassembly 456
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CHAPTER 33
Lighting and Wiring Service 480
Analyzing Electrical Problems 480 • Wiring
Service 480 • Crimp Terminals 482 • Selecting
Replacement Wire 484 • Adding Electrical
Accessories 484 • Soldering 486 • Broken or
Damaged Ground Straps 488 • Circuit Testing and
Service 489 • Finding Grounds 489 • Fuse Testing
and Service 489 • Fuse Link Service 490 •
Headlamp Service 490 • Headlamp Aiming 492 •
Tail Lamp and Park Light Service 495 • LED
Service 496 • Stoplight Switch Service 496 • Back-Up
Lights 496 • Turn Signal Switch 497 • Signal
Flasher/Relay 497 • Locating a Signal Flasher 498 •
Instrument Panel Bulbs 498 • Windshield Washer
Service 498 • Horn Service 499 • Gauge Testing 499
CHAPTER 34
Safety, Security, Comfort Systems,and Electrical
Accessories 502
Introduction 502 • Supplemental Restraint Systems
502 • Active and Passive Restraints 503 • Restraint
System Service 513 • Security, Navigation, and
Electrical Accessories 515 • Security Systems 516 •
Vehicle Tracking/Navigation Systems 520 • Other
Comfort Systems 522 • Cruise Control 534 •
Collision Avoidance Systems 536 • Lane Departure
Warning System 537
© Cengage Learning. All rights reserved. No distribution allowed without express authorization.
vi
SECTION 7
HEATING AND AIR CONDITIONING
CHAPTER 35
Heating and Air-Conditioning Fundamentals 541
Introduction 541 • Sources of Heat 541 •
Ventilation 542 • Heating 542 • Air Distribution
System 543 • Air Conditioning 544 • AirConditioning Principles 545 • Heat Transfer 545 •
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vii
Humidity 546 • States of Matter 546 • Latent Heat
546 • Air-Conditioning System Operation 547 •
Absorbing Heat 548 • Reducing Humidity 548 •
Compressing the Refrigerant 548 • Transferring
Refrigerant Heat to Outside Air 548 • Flow Control
Devices 550 • Air-Conditioning Compressors 553 •
Compressor Lubrication 557 • Muffler 557 •
Accumulator or Receiver/Dryer 557 • Evaporator
Icing Control 559 • System Switches 560 • Heating
and Air-Conditioning Controls 560 • Automatic
Air-Conditioning Sensors 561 • Refrigerants and the
Environment 563 • Temperature and Pressure 564
Spark Plugs 624 • Repairing Damaged Spark Plug
Threads 626 • Spark Plug Cable Service 626 •
Distributor Ignition Service 628 • Ignition Timing
629 • Electronic Ignition Distributor Service 629 •
Other Distributor Repair Service 631 • Distributor
Installation 631 • Static Timing 631 • Electronic
Ignition System Service 632 • Types of Scope Patterns
636 • Oscilloscope Tests 637 • Other Scope Tests
640 • Other Diagnostic Instruments 640
CHAPTER 36
Heating and Air-Conditioning Service 567
Introduction 642 • Crude Oil 642 • Diesel
Engines and Diesel Fuel 645 • Gasoline 647 •
Air-Fuel Mixture 649 • Spark Knocks, Carbon Noise,
and Abnormal Combustion 650 • Abnormal
Combustion 651 • Excessive Carbon Buildup 654 •
Regular versus Premium Fuels 654 • Octane
Standards 655 • Gasoline Additives 655 •
Reformulated Gasolines 655 • Oxygenated Fuels/
Alcohols 655 • Alternative Fuels 657
Heater Service 567 • Air-Conditioning Service 567 •
Air-Conditioning System Service and Diagnosis 568 •
System Performance Test 569 • Pressure Testing 569 •
Static Pressure Reading 571 • Diagnosing HVAC
Electronic Problems 575 • Air Distribution System
Diagnosis 576 • Leak Detection 581 • Common
Air-Conditioning Component Problems 583 •
Refrigerant Oil 584 • Evaporator Problems 586 •
Thermal Expansion Valve or Orifice Tube Problems
586 • Compressor Service 587 • Evacuating and
Recharging 591 • Vacuuming a System 591 •
Evacuate the System 593 • Air-Conditioning Service
Equipment 594 • Refrigerant Charging 594 •
Follow-Up 596 • Refrigerant Storage 596 • Recycling
and Retrofit 596
CHAPTER 39
Petroleum Fuels and Alternative Fuel
Technologies 642
CHAPTER 40
Fuel System Fundamentals 663
Introduction 663 • Fuel System 663 • Fuel
Tanks 663 • Fuel Lines, Hoses, and Fittings 664 •
Fuel Pumps 664 • Fuel Filters 665 • Fuel Injection
and Carburetion 666 • Pressure Regulator
Operation 671 • Electronic Fuel System Operation
672 • Airflow Measurement 673 • Idle Speed
Control 674 • Fuel Pump Control Module 675 •
Computer-Controlled Fuel Systems 675 • Feedback
Fuel Systems 676
CHAPTER 41
Fuel System Service 683
SECTION 8
ENGINE PERFORMANCE DIAGNOSIS:
THEORY AND SERVICE
CHAPTER 37
Ignition System Fundamentals 600
Introduction 600 • Basic Ignition System 600 •
Primary Circuit 600 • Secondary Ignition Parts 603 •
Spark Plugs 604 • Electronic Ignitions 607 •
Electronic Ignition Variations 609 • Ignition
Modules 613 • Ignition Timing 613 • Detonation
Sensor 615 • Distributorless Ignition 615
CHAPTER 38
Ignition System Service 621
Introduction 683 • Fuel Supply System Service
683 • Fuel Filter Service 685 • Throttle Linkage
687 • Carburetor Problems and Service 687 •
Exhaust Gas Analysis 688 • Fuel Injection Diagnosis
and Service 689 • EFI Computer Self-Diagnostics
(OBD) 689 • Air-Fuel Mixture Problems 689 •
Injector Problems 691 • Throttle Plate Service 694 •
EFI Adjustments 695 • Sensor Service 695 •
Throttle Position Sensor 695 • Oxygen Sensor
Service 696 • Coolant Temperature Sensor 697 •
Inlet Air Temperature Sensor 698 • MAP Sensor
Diagnosis 698 • Mass Airflow (MAF) Sensor
Diagnosis 699 • Testing Other Sensors 699 •
Computer Service 700 • Mechanical Injection
700 • Carbon Deposit Service 701
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Ignition System Service and Repairs 621 • Spark Plug
Service 621 • Spark Plug Diagnosis 622 • Installing
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CHAPTER 42
Intake and Exhaust Systems/Turbochargers
and Superchargers 703
Introduction 703 • Intake System Fundamentals
703 • Manifolds 704 • Intake Manifolds 704 •
Exhaust System Fundamentals 708 • Exhaust
Manifolds 708 • Exhaust Pipes 709 • Exhaust
System Service 711 • Turbochargers and
Superchargers 712 • Turbochargers 713 •
Belt-Driven Superchargers/Blowers 722
CHAPTER 43
Emission Control System Fundamentals 727
Introduction 727 • Air Pollution 727 • Automotive
Emissions 727 • Pollution Control 729 •
Automobile Emission Control Systems 729 •
Crankcase Ventilation 730 • Air Injection System
732 • Aspirator Valve or Pulse Air System 733 •
Exhaust Gas Recirculation 733 • EGR System
Operation 734 • Computer-Controlled EGR Systems
735 • Catalytic Converter 736 • Types of Catalytic
Converters 737 • Evaporative Controls 739 • Other
Parts of the Fuel Tank System 742 • On-Board
Diagnostics 743 • Engine Emission Modifications 743
CHAPTER 44
Emission Control System Service 746
Introduction 746 • Inspecting Emission Control
Systems 746 • Computer-Controlled Emission
Service 747 • Crankcase Ventilation System Service
747 • Evaporative Control System Service 748 •
Evaporative System Maintenance 749 • Evaporative
System Problem Diagnosis 749 • EGR System Service
751 • Air Injection System Service 753 • Catalytic
Converter Service 754 • Converter Testing 754 •
Catalytic Converter Replacement 754 • Analyzing
Exhaust Emissions 755 • Emission Analyzers 756 •
Hydrocarbons 757 • Carbon Monoxide (CO) 758 •
Carbon Dioxide 758 • Oxygen (O2) 760 • Oxides of
Nitrogen 760 • Catalytic Converter Tests 762
CHAPTER 45
Electronics and Computer Systems
Fundamentals 767
Introduction 767 • Semiconductors 767 • Diodes
768 • Transistors 770 • Electronic Instrument
Displays 771 • Automotive Computer Systems 771 •
Parts of a Computer System 772 • On-Board
Computer 772 • Information Processing 774 •
Computer Memory 774 • Communication Rate
776 • Sensors and Actuators 776 • Types of Sensors
777 • Thermistors 777 • Voltage Dividers 777 •
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Piezoelectric and Piezoresistive Sensors 778 • Heated
Resistive Sensors 778 • Variable DC Frequency
Sensors 778 • Voltage Generators 778 • Wheatstone
Bridges 779 • Switches 779 • Types of Actuators
780 • Solenoid Actuators 780 • Relay Actuators
781 • Motor Actuators 781 • Actuator Switches/
Modules 781 • Adaptive Strategy 781 • Ignition
Advance 782 • Knock Sensor 782 • Electronic
Throttle Control/Drive-by-Wire 782 • On-Board
Diagnostics 783 • Diagnostic Trouble Codes 783 •
Computer Self-Diagnostics 783 • Multiplexing
784 • Network Sizes and Types 785 • CAN Systems
785 • Supplemental Data Bus Networks 789 •
Telematics 791 • Wireless Networks 791
CHAPTER 46
Electronics and Computer Systems Service 794
Introduction 794 • Inspection Sequence 794 •
Perform Diagnostic Tests 796 • On-Board Diagnostics
796 • Reading Trouble Codes 797 • Scan Tools 797 •
Breakout Box 799 • Retrieving Trouble Codes 799 •
Working with Codes 799 • Erasing Trouble Codes
799 • Scan Tool Snapshot 800 • Closed Loop 802 •
Fuel Trim Diagnosis 802 • Digital Waveforms 804 •
Logic Probe/Power Probe 807 • Sensor and Actuator
Testing 808 • Diagnosing Sensor Problems 808 •
Sensor Tests 809 • Oxygen Sensor 809 • Load
Sensors 811 • MAP Sensor 812 • BARO Sensors
812 • Vacuum Sensors 812 • Throttle Position
Sensor 813 • Coolant Temperature Sensor 813 •
Air Temperature Sensors 815 • Airflow Sensor
Service 816 • Knock Sensor Service 816 • Actuator
Service 817 • Repair the Problem 817 • Computer
Wiring Service 818 • Static Electricity 821 •
Electrical Damage to a Circuit 822
CHAPTER 47
Advanced Emissions and On-Board Diagnostics
(OBD) 827
© Cengage Learning. All rights reserved. No distribution allowed without express authorization.
viii
Introduction 827 • History of On-Board Diagnostics
827 • OBD II Operation 828 • Society of Automotive
Engineers (SAE) Standards 829 • Trouble Codes
and the Malfunction Indicator Lamp 831 • OBD II
Codes 832 • OBD II Diagnostic Testing 833 •
Emission Testing Programs 841
CHAPTER 48
Diagnosing Engine Performance Problems 845
Introduction 845 • Visual Checks 845 • Ignition
System Checks 845 • Engine Performance Testing
846 • Compression Loss 846 • Vacuum Testing
847 • Other Vacuum Tests 848 • Compression
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Problems 849 • Cylinder Leakage Test 851 •
Carbon-Related Problems 852
SECTION 9
© Cengage Learning. All rights reserved. No distribution allowed without express authorization.
AUTOMOTIVE ENGINE SERVICE AND REPAIR
CHAPTER 49
Diagnosing Engine Mechanical Problems 855
Introduction 855 • Diagnosing Problems before a
Repair 855 • Oil Consumption 855 • Causes of Oil
Consumption 856 • Testing for Oil Leaks 858 •
Engine Performance and Compression Loss 859 •
Engine Noises 860 • Engine Knocks 860 • Oil
Pressure Problems 864 • Cooling System Problems
865 • Internal Engine Leakage 865 • Seized Engine
867 • Electronic Failures/Engine Damage 867 •
Engine Performance and Fuel Mixture Problems 868
CHAPTER 50
Engine Removal and Disassembly 870
Introduction 870 • Engine Removal 870 • Engine
Disassembly 882 • Engines with Pushrods 885 •
Overhead Cam Cylinder Head Removal 887 •
Cylinder Block Disassembly 888
CHAPTER 51
Engine Sealing, Gaskets, Fastener Torque 894
Introduction 894 • Clamping Force 894 •
Torque and Friction 894 • Torque Wrenches 895 •
Torque-to-Yield 896 • Torque by Degrees 897 •
Fastener Clamping Load 897 • Gaskets and Seals
898 • Cleaning the Head 902 • Head Gasket
Installation 904 • Other Engine Gaskets 904 •
Valve Cover, Timing Cover, and Oil Pan Service 904 •
Gasket Sealers 909 • Silicone-RTV Sealant 910 •
Rear Main Seals 913 • Transmission Front Pump
Seal 914
CHAPTER 52
Engine Diagnosis and Service: Cylinder Head
and Valve Train 916
Introduction 916 • Head Disassembly 916 •
Carbon Removal 920 • Cylinder Head Inspection
921 • Resurfacing by Grinding, Cutting, or Sanding
922 • Straightening Cylinder Heads 922 • Crack
Inspection 923 • Crack Repair 924 • Checking
Valve Springs 924 • Checking Valve Stems 924 •
ix
Valve Guide Service 925 • Guide Repair 926 •
Grinding Valves 927 • Grinding Valve Seats 928 •
Checking Valve Stem Installed Height 929 • Solvent
Testing the Valve and Seat 929 • Reassembling the
Head 930 • Valve Guide Seal Installation 931 •
Install the Valve and Spring Assembly 931 • Pushrod
Engine Rocker Arm Service 932 • Inspect Pushrods
932 • Inspect OHC Camshaft 932 • Reassembling
OHC Heads 932 • Camshaft Service 934 • Lifter
Service 934 • Cam and Lifter Break-In 935 •
Timing Chain and Belt Service 935 • Timing Belt
Service 935 • Timing Belt Replacement 936 •
Timing Chain Service 938
CHAPTER 53
Engine Diagnosis and Service: Block, Crankshaft,
Bearings, and Lubrication System 943
Introduction 943 • Cleaning the Block 943 • Oil
and Water Plug Removal 943 • Oil Gallery Plug
Installation 945 • Inspect and Clean Lifter Bores
945 • Checking Main Bearing Bore Alignment 945 •
Check the Deck Surface for Flatness 947 • Clean
All Threaded Holes 947 • Inspecting Cylinder
Bores 947 • Measuring the Bore 948 • Deglazing
the Cylinder Bore 949 • Clean the Block of Grit 951 •
Boring for Oversized Pistons 951 • Block Distortion
952 • Honing after Boring 953 • Sleeves 954 •
Cam Bearing Installation (Cam-in-Block Engines)
954 • Front Cam Bearing Installation 956 •
Checking Crankshaft Condition 956 • Crankshaft
and Bearing Wear 957 • Crankshaft Journal
Tolerance 958 • Regrinding the Crankshaft 958 •
Measuring Bearing Clearance with Plastigage 959 •
Lubrication System Service 961 • Checking Oil Pumps
for Wear 961 • Oil Pump Screen Service 962 • Oil
Pump Failure 962 • Installing the Oil Pump 963
CHAPTER 54
Engine Diagnosis and Service: Piston, Piston
Rings, Connecting Rod, Engine Balancing 965
Introduction 965 • Piston Service 965 • Piston
Ring Service 968 • Installing Pins in Connecting
Rods 970 • Installing Rings on Pistons 970 •
Oil Ring Installation 970 • Connecting Rod
Service 971 • Engine Balancing Service 973
CHAPTER 55
Ordering Parts, Short and Long Blocks, Engine
Assembly 978
Introduction 978 • Ordering Parts 978 • Engine
Kits 978 • Determining Part Sizes 979 • Types of
Engine Rebuilds 980 • Selecting the Correct
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TABLE OF CONTENTS
Replacement Engine 981 • Warranty 981 •
Reassembly 981 • Begin Reassembly 981 • Prepare
the Crankshaft for Installation 982 • Install the
Crank 983 • Install the Cylinder Heads 990 • Install
OHC Heads 990 • Install the Cam Drive (Pushrod
Engines) 991 • Install the Oil Pump 992 • Install
the Timing Cover 992 • Install the Damper 992 •
Install the Oil Pan 993 • Install the Intake Manifold
993 • Install the Thermostat and Water Outlet
Housing 993 • Completing the Assembly 994 •
Install Exhaust Manifold(s) 994
CHAPTER 56
Engine Installation, Break-In, and In-Chassis
Repairs 997
Introduction 997 • Engine Installation 997 • Install
Engine Mounts 997 • Install the Engine 997 •
Priming the Lubrication System 999 • Pressure
Priming 999 • Install Valve Covers 1000 • Ignition
System Installation and Timing 1000 • Engine
Starting and Initial Break-In 1001 • Valve Clearance
Adjustment 1002 • Road Test and Break-In 1002 •
Final Inspection 1002 • Returning the Car to the
Customer 1003 • Engine Repair—Engine in the
Vehicle 1003 • Valve Job or Head Gasket Repair 1003 •
Valve Job or Complete Engine Overhaul 1004 •
Head Gasket Problems 1004 • In-Chassis Lower
End Repairs 1004 • Removing the Oil Pan 1004 •
Remove the Piston and Rod Assembly 1006 •
Remove the Timing Cover 1006 • Freewheeling and
Interference Engines 1006 • Replace the Timing
Components 1006 • Crankshaft Seal Replacement
1007 • Flywheel Ring Gear Service 1007
SECTION 10
BRAKES AND TIRES
CHAPTER 57
Brake Fundamentals 1011
Introduction 1011 • Brake Linings 1011 • Drum and
Disc Brakes 1012 • Hydraulic Brake System Operation
1012 • Hydraulic Brake Fluid 1014 • Brake Hose
1015 • Brake Tubing 1015 • Hydraulic System
Operation 1016 • Low Brake Pedal 1016 • Split
Hydraulic System 1020 • Quick Take-Up Master
Cylinder 1020 • Drum Brakes 1021 • Drum Brake
Adjustment 1022 • Disc Brakes 1024 • Hydraulic
PRELIMS.indd x
System Valves and Switches 1027 • Hydraulic
Control Valves 1028 • Power Brakes 1030 • Parking
Brake 1033 • Types of Parking Brakes 1034 •
Stoplight Switches 1035 • Antilock Brakes 1035
CHAPTER 58
Brake Service 1038
Introduction 1038 • Brake Inspection 1038 • Check
Brake Pedal Feel 1038 • Master Cylinder Inspection
1038 • Brake Diagnosis 1040 • Undercar Checks
1040 • Disc Brake Inspection 1040 • Inspecting
Drum Brake Assemblies 1044 • Brake Fluid Service
1047 • Routine Brake Fluid Replacement 1047 •
Bleeding Brakes 1048 • Brake Bleeding Methods
1049 • Adjusting Brakes 1053 • Master Cylinder
Service 1054 • Master Cylinder Removal 1054 •
Master Cylinder Disassembly 1054 • Bench Bleeding
a Master Cylinder 1055 • Brake Job 1056 • Drum
Brake Lining Removal 1056 • Rebuilding Hydraulic
Cylinders 1057 • Reassembling a Wheel Cylinder
1058 • Removing Wheel Cylinders 1059 • Replacing
Drum Brake Shoes 1059 • Adjusting Drum Brake
Clearance 1059 • Drum and Rotor Service 1060 •
Drum Service 1061 • Rotor Service 1063 •
On-Vehicle Rotor Machining 1065 • Disc Brake
Service 1066 • Rear Disc Pad Installation 1068 •
Rebuilt Calipers 1069 • Disc Caliper Rebuilding
1069 • Selecting Brake Linings 1071 • Disc Brake
Noise 1072 • Parking Brake Cable Service 1074 •
Vacuum Power Brake Service 1074 • Brake Warning
Lamp Diagnosis 1079 • Antilock Brake System (ABS)
Service 1079
CHAPTER 59
Antilock Brakes, Traction, and Stability
Control 1081
Introduction 1081 • Antilock Brakes 1081 • Antilock
Brake System Components 1082 • Types of Antilock
Brake Systems 1084 • Two-Wheel ABS 1087 •
Antilock Brake System Operation 1088 • Traction
Control System 1091 • Antilock Brake (ABS) Service
1092 • ABS Brake Fluid Service 1094
© Cengage Learning. All rights reserved. No distribution allowed without express authorization.
x
CHAPTER 60
Bearings, Seals, and Greases 1102
Introduction 1102 • Plain Bearings 1102 •
Frictionless Bearings 1102 • Bearing Loads 1102 •
Ball Bearings 1102 • Roller Bearings 1104 • Wheel
Bearings 1106 • Greases 1107 • Wheel Bearing
Seals 1110 • Seal Materials and Design 1111 • Seal
Tolerance 1111 • Wheel Bearing Diagnosis and
Service 1112 • Wheel Bearing Adjustment 1113 •
20/12/10 10:03 AM
TABLE OF CONTENTS
Disc Brake Caliper Removal 1114 • Repacking Wheel
Bearings 1114 • Bearing Inspection and Diagnosis
1116 • Diagnosing Wheel Bearing Noise 1119 •
Replacing Bearing Races 1120 • Servicing FrontWheel-Drive Bearings 1120
© Cengage Learning. All rights reserved. No distribution allowed without express authorization.
CHAPTER 61
Tire and Wheel Theory 1124
Introduction 1124 • Tire Construction 1124 •
Tubeless Tires 1125 • Tire Tread 1125 • Tire Tread
Material 1126 • Tire Cord 1127 • Tire Ply Design
1127 • Tire Sidewall Markings 1128 • Load Rating
1133 • All-Season Tires 1134 • Snow Tires 1134 •
Tire Pressure Monitoring System 1137 • Uniform Tire
Quality Grading 1138 • Traction Grade 1138 •
Changing Tire Size 1138 • Wheels 1140 • Custom
Wheels 1141 • Lug Studs 1142 • Lug Nuts 1142 •
Tire Valve Stems 1142
CHAPTER 62
Tire and Wheel Service 1145
Introduction 1145 • Tire Inflation 1145 • Checking
Air Pressure 1145 • Adjusting Tire Pressure 1147 •
Tire Wear 1148 • Sidewall Checks 1149 • Tire
Rotation 1149 • Removing and Tightening Lug Nuts
1151 • Repairing Wheel Studs 1152 • Removing and
Mounting Tires on Rims 1153 • Inspecting the Tire
and Wheel 1156 • Valve Stem Service 1156 • Rubber
Lubricant 1157 • Install the Tire 1157 • Mounting
High-Performance Tires 1160 • Bead Roller Tire
Changer 1161 • Tire Runout 1161 • Tire Repair
1162 • Repairing a Tire 1163 • Preparing a Tire for
Repair 1164 • Patching the Tire 1165 • Tire and
Wheel Balance 1166 • Types of Wheel Balance
1168 • Couple Imbalance 1169 • Dynamic Balance
1170 • Computer Balancers 1170 • Centering the
Wheel on the Balancer 1170 • Match Mounting
1173 • Force Variation 1173 • Installing the Wheel
1174 • Tire Pressure Monitoring System Service 1175
xi
Suspension Construction 1182 • Suspension
Types 1184 • High-Performance Suspensions
1185 • Shock Absorbers 1186 • Hydraulic Shock
Absorber Operation 1187 • Compression and
Rebound Resistance 1189 • Bump Stops and
Limiters 1189 • Gas Shocks 1190 • Air Shocks/
Leveling Devices 1191 • Other Front End Parts
1192 • Stabilizer Bar 1192 • Suspension Leveling
Systems 1192
CHAPTER 64
Suspension System Service 1199
Introduction 1199 • Diagnosing Suspension System
Problems 1199 • Shock Absorber Service 1200 •
Testing a Shock 1200 • Macpherson Strut Service
1202 • Inspect the Upper Strut Bearing 1204 •
Install the Coil Spring 1204 • Reinstall the Strut
Assembly 1204 • Suspension Bushing Service 1204 •
Strut Rod Bushing Service 1205 • Stabilizer Bar
Service 1205 • Spindle Service 1206 • Ball Joint
Service 1206 • Measuring Ball Joint Wear 1207 •
Separating Tapered Connections 1208 • Replacing
a Ball Joint 1208 • Coil Spring Service 1209 •
Adjusting Spring Height 1209 • Coil Spring
Replacement 1209 • SLA Coil Spring Replacement
1210 • Wheel Alignment 1212 • Electronic
Suspension Service 1212 • Electronically Controlled
Shock Absorbers 1213
CHAPTER 65
Steering Fundamentals 1216
Steering Systems 1216 • Steering Gears 1216 •
Recirculating Ball and Nut Steering Gear 1217 •
Rack-and-Pinion Steering 1217 • Steering Linkage
1218 • Parallelogram Steering Linkage 1219 • Ball
Sockets 1219 • Tie-Rods 1219 • Steering Arm 1220 •
Rack-and-Pinion Steering Linkage 1221 • Steering
Column 1221 • Power Steering 1223 • Power
Steering Pump 1223 • Types of Power Steering
1224 • Electronically Controlled Variable Effort
Power Steering 1225 • Electronically Controlled
Steering Systems 1228
CHAPTER 66
Steering System Service 1232
SECTION 11
SUSPENSION, STEERING, ALIGNMENT
CHAPTER 63
Suspension Fundamentals 1179
Introduction 1232 • Fluid Level Checks 1232 •
Type of Fluid 1232 • Diagnosing Steering
Problems 1233 • Noise Diagnosis 1233 • Hard
Steering 1233 • Tire Wear 1233 • Steering Part
Inspection 1233 • Steering Linkage Inspection
1233 • Steering Gear Looseness 1233 •
Parallelogram Inspection 1233 • Rack-and-Pinion
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Introduction 1179 • Suspension 1179 • Frame
and Suspension Designs 1180 • Springs 1180 •
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TABLE OF CONTENTS
Steering Linkage Inspection 1234 • Steering Linkage
Repairs 1234 • Idler Arm Replacement 1234 •
Pitman Arm Replacement 1235 • Tie-Rod End
Replacement 1235 • Rack-and-Pinion Tie-Rods
1236 • Steering Wheel, Column, and Air
Bag Service 1236 • Air Bag Service 1236 • Steering
Wheel Service 1239 • Steering Column Service
1239 • Steering Gear Service 1239 • Manual Rack
Service 1240 • Rack-and-Pinion Looseness 1240 •
Power Steering System Service 1240 • Power Steering
System Flushing 1240 • Bleeding the System of Air
1241 • Power Steering Pump Replacement 1242 •
Repairing Power Steering Pump Oil Leaks 1242 •
Power Steering Pressure Diagnosis 1242 • Power
Steering Pump Service 1243 • Power Steering Hoses
1244 • Refilling the Power Steering System 1244 •
Power Steering Gear Service 1244 • Replacing Rackand-Pinion Units 1244 • Variable Power Steering
Service 1246 • Electronically Controlled Power
Steering System Service 1246
CHAPTER 67
Wheel Alignment Fundamentals 1248
Introduction 1248 • Wheel Alignment Angles
1248 • Toe 1248 • Camber 1249 • Caster
1250 • Steering Axis Inclination 1251 • Scrub
Radius 1252 • Turning Radius 1253 • Tracking
1254 • Setback 1254 • Special Handling
Characteristics 1254
CHAPTER 68
Wheel Alignment Service 1257
Introduction 1257 • Prealignment Inspection
1257 • Tire Wear Inspection 1257 • Ride Height
Check 1259 • Toe Change 1259 • Torque
Steer 1260 • Suspension Looseness 1260 • Test
Drive 1261 • Tire Checks 1261 • Inspection
Checklist 1262 • Wheel Alignment Procedures
1262 • Measuring Alignment 1263 • Measuring
Camber 1264 • Measuring Caster 1264 • Road
Crown and Pull 1264 • Measuring Steering Axis
Inclination 1267 • Measuring Toe 1267 •
Adjusting Toe 1268 • Centering a Steering Wheel
1271 • Checking for Toe Change 1272 • Measuring
Turning Radius 1272 • General Wheel Alignment
Rules 1273 • Four-Wheel Alignment 1274 •
Performing a Four-Wheel Alignment 1275 •
Compensating the Alignment Heads 1275 •
Measuring Caster and Camber 1276 • Adjusting
Rear-Wheel Alignment 1276
PRELIMS.indd xii
SECTION 12
DRIVETRAIN
CHAPTER 69
Clutch Fundamentals 1280
Introduction 1280 • Clutch Parts and Operation
1281 • Clutch Disc 1281 • Pressure Plate 1282 •
Types of Clutch Covers 1282 • Coil Spring Clutch
1283 • Diaphragm Clutch 1283 • Pilot Bearing
or Bushing 1285 • Release Bearing 1285 •
Clutch Fork 1286 • Clutch Release Methods 1286 •
Clutch Cable 1286 • Hydraulic Clutch Operation
1287 • Clutch Free Travel 1288 • Dual Clutch
Transmissions 1288
CHAPTER 70
Clutch Diagnosis and Service 1290
Introduction 1290 • Diagnosis of Clutch Problem
1290 • Clutch Noises 1290 • Transmission Noise
1291 • Pedal Problems 1291 • Slipping Clutch
1291 • Dragging Clutch 1291 • Oily Clutch
Facings 1292 • Damaged Friction Surfaces 1292 •
Chattering or Grabbing Clutch 1293 • Clutch
Service 1293 • Servicing Hydraulic Components
1294 • Clutch Replacement 1295 • Removing a
Transmission or Transaxle 1295 • Clutch Removal
1295 • Flywheel Removal 1297 • Flywheel Starter
Ring Gear Replacement 1297 • Flywheel Installation
1297 • Inspect New Parts 1298 • Pilot Bushing
Service 1298 • Clutch Disc Service 1299 • Clutch
Cover/Pressure Plate Service 1299 • Clutch
Installation 1299 • Release Bearing Service 1301 •
Clutch Housing Installation 1302
© Cengage Learning. All rights reserved. No distribution allowed without express authorization.
xii
CHAPTER 71
Manual Transmission Fundamentals 1305
Introduction 1305 • Purpose of a Transmission
1305 • Using Gears to Increase Torque 1306 •
Gear Ratio 1306 • Transmission Gear Ranges 1307 •
Overdrive 1307 • Final Drive Ratio 1308 • Gear
Types and Operation 1308 • Spur Gears 1309 •
Helical Gears 1309 • Idler Gears 1309 •
Transmission Parts 1309 • Transmission Lubrication
1310 • Transmission Bearings 1310 • Transmission
Gears and Shafts 1310 • Synchronizer Assembly
1312 • Gear Shift Mechanisms 1314 • Shift
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TABLE OF CONTENTS
Patterns 1315 • Transmission Power Flow 1315 •
Four-Speed Transmission Power Flow 1316 •
Five-Speed Transmission 1318 • Speedometer
Drive 1318 • Switches and Sensors 1318
© Cengage Learning. All rights reserved. No distribution allowed without express authorization.
CHAPTER 72
Manual Transmission Diagnosis and Repair 1322
Introduction 1322 • Transmission Diagnosis 1322 •
Lubricant Checks 1323 • Transmission Removal
1323 • Transmission Disassembly 1324 •
Disassemble the Mainshaft Assembly 1326 •
Synchronizer Service 1326 • Synchronizer
Inspection 1327 • Inspect Blocker Rings 1328 •
Inspect Input Shaft and Mainshaft 1328 • Replace
Worn Bearings 1328 • Reassemble the Transmission
1329 • Reassemble the Synchronizers 1329 •
Reassemble the Mainshaft 1329 • End Play 1329 •
Needle Bearing Installation 1329 • Install New
Gaskets 1330 • Complete the Transmission
Reassembly 1330 • Install the Transmission 1331 •
Add Lubricant 1332 • Test Drive 1332
CHAPTER 73
Automatic Transmission Fundamentals 1334
Introduction 1334 • Automatic Transmission Parts
1334 • Power Transmission 1335 • Flexplate 1335 •
Torque Converter 1336 • Torque Multiplication
1336 • Torque Converter Operation 1337 • Stator
Clutch Operation 1339 • Stall Speed 1340 • Lock-Up
Torque Converters 1340 • Planetary Gears 1341 •
Simple Planetary Gearset 1341 • Simple Planetary
Operation 1342 • Compound Planetary Operation
(Simpson) 1343 • Driving and Holding Devices
1345 • Clutches 1345 • Clutch Operation 1346 •
One-Way Clutches 1347 • Bands 1348 •
Accumulator 1348 • Hydraulic System 1349 • Fluid
Pump 1349 • Types of Pumps 1349 • Transmission
Valves 1351 • Pressure Regulator 1351 • Hydraulic
Valve Body 1352 • Transmission Automatic Shift
Selection 1352 • Governor 1353 • Vacuum
Modulator 1354 • Kickdown Valve 1354 •
Automatic Transmission Fluid (ATF) 1355 • Automatic
Transmission Cooling 1355 • Auxiliary Cooler/Heat
Exchanger 1356 • Park Pawl 1356 • Electronic
Automatic Transmissions 1356 • Electronic Automatic
Transmission Operation 1359 • Electronic Torque
Converter Control 1359 • Electronic Pressure
Control 1359 • Transmission Shift Control 1360 •
Continuously Variable Transmission 1362 • Hybrid
Planetary Transmission Operation 1362
xiii
CHAPTER 74
Automatic Transmission Diagnosis
and Service 1367
Introduction 1367 • Automatic Transmission
Identification 1368 • Automatic Transmission
Maintenance 1368 • Transmission Fluid Service
1368 • Fluid Level 1369 • Check Fluid Condition
1369 • Changing Transmission Fluid 1369 •
Transmission Filter Service 1370 • Remove and
Replace the Filter 1371 • Refill the Transmission
1371 • Diagnosis and Repair of Leaks 1372 • Leaks
from the Converter Housing 1372 • Transmission
Cooler Line Leak 1372 • VSS/Speedometer Drive Gear
Leak 1373 • Shift Lever Seal Replacement 1373 •
Pump Seal Replacement 1373 • Front Seal
Replacement 1374 • Pump Bushing Replacement
1374 • Reinstalling the Transmission 1375 •
Rear Oil Seal and Bushing Replacement 1376 •
Automatic Transmission Problem Diagnosis 1376 •
Slippage 1377 • Transmission Drainback 1377 •
Noises 1380 • Flexplate 1380 • Transmission Tests
1380 • Valve Body Removal 1382 • Transmission
Adjustments 1382 • Electronic Transmission Service
1384 • More Tests before Transmission Removal
1387 • Hybrid Automatic Transmission Service
1387 • Remanufactured Automatic Transmissions
and Transaxles 1387 • Transmission Rebuilding
1388 • Transmission Reassembly 1390
CHAPTER 75
Driveline Operation 1393
Introduction 1393 • Driveshaft (RWD) 1394 • Slip
Yoke 1394 • Universal Joints 1395 • Two-Piece
Driveshaft 1396 • Driveshaft Angle 1397 •
Constant Velocity Joints 1398 • Differential 1399 •
Differential Construction 1399 • Differential
Housing 1400 • Differential Operation 1401 •
Differential Gears 1402 • Gearsets 1402 • Axle
Ratio 1403 • Limited Slip Differential 1403 • Types
of Limited Slip Differentials 1403 • Drive Axles and
Bearings 1404 • Semi-Floating Axle Bearing Types
1405 • Independent Rear Suspension Axles 1406 •
Gear Oils 1406 • Four-Wheel Drive 1407 • FourWheel-Drive Axle Assembly 1407 • Transfer Case
1408 • Locking Hubs 1409 • All-Wheel Drive 1410
CHAPTER 76
Driveline Diagnosis and Service 1413
Introduction 1413 • Driveshaft Diagnosis 1413 •
Universal Joint Diagnosis and Service 1414 •
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TABLE OF CONTENTS
Driveshaft Service 1414 • Universal Joint
Disassembly 1415 • Universal Joint Reassembly
1416 • Driveshaft Installation 1417 • Two-Piece
Driveshaft Service 1418 • Differential and Axle
Diagnosis and Service 1418 • Problem Diagnosis
1418 • Axle Bearing Diagnosis 1419 • Axle Bearing
Service 1420 • Removing a Bearing-Retained Axle
1420 • Axle Bearing Replacement 1421 • Axle
Bearing Installation 1422 • Reinstall the Axle 1423 •
Full-Floating Axle Service 1423 • Differential
Pinion Seal Replacement 1424 • Differential Repair
1425 • Removing a Third Member 1425 •
Disassembling a Salisbury Axle 1425 • Clean and
Inspect Parts 1426 • Differential Reassembly 1427 •
Adjusting a Differential 1427 • Pinion Gear Depth
1427 • Ring Gear Backlash 1428 • Side Bearing
Preload 1428 • Contact Pattern 1430 • Backlash
Pattern Change 1430 • Pinion Depth Pattern
Change 1430 • Pinion Bearing Preload 1431 • Ring
and Pinion Noise 1432 • Four-Wheel-Drive Service
and Repair 1432
CHAPTER 77
Front-Wheel-Drive (Transaxle and CV Joint)
Fundamentals 1437
Introduction 1437 • Front-Wheel Drive 1437 •
Manual Transaxles 1438 • Shift Linkage 1438 •
Transaxle Differential 1439 • Transaxle Power Flow
1440 • Automatic Transaxle 1442 • Front Drive
Axles 1443 • Axle Shaft Parts 1443 • CV Joint
Construction 1444 • Axle Shafts 1446 • CV Joint
Boots 1446
CHAPTER 78
Front-Wheel-Drive (Transaxle and CV Joint)
Service 1448
Introduction 1448 • Transaxle and Front-WheelDrive Service and Repair 1448 • Leaking CV Joint
Boot 1448 • CV Joint Boot Service 1448 • Axle
Inspection and Diagnosis 1449 • CV Joint Diagnosis
1449 • Axle Shaft Removal 1450 • CV Joint
Replacement 1452 • Fixed Joint Disassembly and
Inspection 1453 • CV Joint Boot Clamps 1455 •
Servicing an Inner Tripod Joint 1456 • Double
Offset Plunge Joints 1456 • Cross Groove Joint
Service 1457 • Rebuilt Halfshafts 1457 • Installing
the Axle 1457 • Transaxle Repair 1457 • Transaxle
Removal 1458 • Manual Transaxle Repair 1458 •
Automatic Transaxle Repair 1458 • Transaxle
Differential Side Bearing Adjustment 1458 •
Install the Transaxle 1458
CHAPTER 79
Driveline Vibration and Service 1461
Vibration Analysis 1461 • Types of Vibrations
1462 • Vibration Test Instruments 1463 •
Vibration and Frequency 1463 • Driveshaft
Runout 1465 • Other Causes of Vibration
1465 • Driveshaft Balance 1465 • Driveshaft
Angle 1467
APPENDIX 1470
GLOSSARY 1482
INDEX 1520
NOTE TO STUDENT: Learn to use the index. It has
been constantly updated and will help you find what you
need in the book.
PRELIMS.indd xiv
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© Cengage Learning. All rights reserved. No distribution allowed without express authorization.
PREFACE
Automotive Service: Inspection, Maintenance, Repair, 4th
edition evolved in part from my participation in a
successful articulation program between local high
schools and the community college where I have been
a teacher for over 37 years. The text and art manuscripts of this best-selling book have once again been
updated and improved in this fourth edition revision.
An array of excellent technical reviews by a dedicated
group of professional teachers and technicians ensures
that this is the most technically accurate and up-todate comprehensive automotive textbook available in
the marketplace. The text has been written from a carefully detailed outline to allow each chapter to follow
a logical, easy-to-understand path. Many new original
color photographs and sketches have been added to
update and supplement earlier material.
The transportation industry in North America is
vast, with one in every six people contributing to it
in some way. These include people of many levels of
understanding and ability. With that in mind, the
introductory fundamentals chapters are written at a
lower level for all the students, whereas the service
chapters are for those who have mastered the introductory material.
As a teacher, my philosophy is to challenge the best
students in anticipation that the rest will be brought
to a higher level: “A rising tide raises all boats.”
The text can be used for a variety of educational
purposes, including:
■ As a basic text in any automotive repair class
■ To educate entry-level or apprentice technicians
■ To prepare more experienced technicians for ASE
certification
Automotive Service: Inspection, Maintenance, Repair, 4th
edition is divided into 79 chapters that cover the NATEF
Auto General Service Technician Program Standards
and A1–A8 (the eight ASE automotive specialty areas).
Advanced engine performance and emission controls
are also covered in detail. In addition to coverage of the
usual repairs performed in almost any automotive repair
facility, the reader is introduced to the most frequently
performed inspection and service procedures—from
safety inspections to tire and wheel service.
The automotive repair industry of today continues to evolve into more of a maintenance industry as
vehicles last longer and require fewer repairs. Longterm customer relationships, ethics, and professionalism have become even more important to the success
of a business. There are also environmental concerns
today that were not a part of the industry of the past.
The text includes chapters on safety, hand tools, and
vehicle maintenance and lubrication that are more
comprehensive than those found in most comparable
texts. An accompanying lab manual emphasizes the
NATEF Auto General Service Technician Program
Standards, those jobs done in service stations, fastlube outlets, or mass merchandisers (such as Sears,
Goodyear, Firestone, or Kmart). An additional lab
workbook, Automotive Service Job Sheets for NATEF Task
Mastery, covers the eight main ASE system areas.
Automobiles have become so complex in the last
30 years that to remain competent many of today’s
technicians specialize in one or more systems of the
car. Basic theory of all automotive and light truck
systems is covered so that service personnel will understand the function of the parts being serviced. When
working in the industry, there is often no time for basic
theory. Therefore, automotive class work could be the
one and only chance students have to learn how systems operate so they can become better diagnosticians
in the future.
This book is comprehensive in that it deals with the
entire car and aims to teach theory of vehicle systems at
an introductory student level, followed by service, diagnosis, and light repairs at a more advanced student level.
Most of the systems used in automobiles today are
strikingly similar. Repair techniques universal to all
automobiles are discussed and procedures or conditions unique to only one specific automobile make are
purposely avoided. The reader is encouraged to refer
to the service and repair information for the specific
vehicle in question.
A major challenge for me as an automotive author
is to keep the scope of the book from growing out of
control by expanding into areas of in-service training best covered by manufacturers and aftermarket
educators. My objective is to take an abundance of
sometimes complicated information and condense
and simplify that information so it can be understood
by a student preparing for job-entry level. Following
the completion of this text, better students will be at
a high job-entry level, at a skill level suitable for entry
as an apprentice in one or more of the specialty areas
of automotive repair in a new car dealership or an
independent repair shop.
A primary objective of this book is to help the
reader develop confidence in both thinking skills and
problem-solving ability. One unique aspect of automotive education is that many automotive graduates
venture into other professions and skilled trades, such
as engineering or construction. They will find much of
the material learned in automotive classes to be very
valuable and useful in their chosen fields. This aspect
of the student’s education is especially valuable when
one considers how middle school and high school
industrial arts programs have been scaled back in recent
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PREFACE
Not For Sale
years. Dealing with such things as tools, soldering, basic
electrical repairs, and repairing broken fasteners helps
to provide some measure of practical education.
The tremendous decline in the number of corner
gasoline service stations has resulted in a loss of those
jobs formerly available in abundance to students. Successful service personnel who possess necessary basic
automotive skills must continually learn new things in
order to progress into other (higher-paying) specialty
areas. The Lab Manual to Accompany Automotive Service
contains service jobs that students should be able to
perform before enrolling in an advanced automotive
specialty area class.
UPDATES AND ENHANCEMENTS
TO THE FOURTH EDITION
■ New and updated information on hybrid vehicles
and alternative fuels.
■ New coverage on the latest information on engine
oils and coolants.
■ Vehicle electronics coverage has been improved
and increased throughout.
■ New and updated engine performance and
electronics coverage includes technology advances
in onboard diagnostics, misfire detection, variable
valve timing, displacement on demand, adaptive
strategies, the latest CAN systems, drive-by-wire,
and wide-band oxygen sensors.
■ Chassis and powertrain coverage includes updated
information on stability control and traction
control systems, electronic suspension systems,
electric steering, and electronic transmission and
all-wheel drive.
■ Updated comfort and safety topics include
the newest developments in air conditioning,
supplemental restraints, lighting, entertainment
systems, and adaptive cruise control.
■ New science, math, and history notes have been
added.
■ The Instructor Resources DVD and and other new
and greatly enhanced supplements are designed to
improve the organization and quality of time spent
in the classroom and shop (see the Supplements
page for more detail).
■ All automotive terms, abbreviations, and acronyms
used in this text comply with the SAE Technical
Standards Board Publication SAE J1930.
ACKNOWLEDGMENTS
I would like to extend special thanks to the following
individuals, organizations, and companies:
■ Delmar, Cengage Learning Senior Product Manager
Matt Thouin for his helpful, positive attitude.
Matt’s dedication to excellence and his efficiency
PRELIMS.indd xvi
■
■
■
■
■
■
■
■
■
■
■
■
■
■
and organizational skills were very important to
the overall improvement of this fourth edition.
Denise Denisoff and Chris Shortt, developmental
editors in earlier editions of the text.
Cheri Plasse and Joan Conlon, Content Project
Managers, who managed the art, design, and
production of the text. Cheri has worked on
several of my projects in the past and is always a
pleasure to work with.
Bill Clark and the staff at MPS who worked
tirelessly behind the scenes. Their professional
talent and effort with the text and art ensure a
quality final product.
Sharon Rounds, who worked tirelessly behind the
scenes securing art permissions.
Araceli Popen, who has been copyeditor on several
of my books, making certain that everything is
accurate and in order.
Cheryl Weakliem, my editorial assistant, for her
excellent reviews, suggestions, and text edits in the
areas of electricity, air conditioning, and science.
Cheryl is a chemistry teacher with a PhD in
Chemistry and an associate degree in Automotive
Technology.
Friends and colleagues Bob Stockero and Dave
Brainerd of Santa Barbara City College and Chuck
Rockwood of Ventura College for their continuous
input and support. All three provided in-depth
reviews and excellent suggestions to this edition of
the text.
Members of the North American Council of
Automotive Teachers (NACAT) and California
Automotive Teachers (CAT), who provided a vast
amount of input.
Students in the Automotive program at Santa
Barbara City College, who provided continuous
feedback and suggestions for improvement.
Physics professor Mike Young of Santa Barbara City
College for his help with the Science Notes.
Jack Rosebro of Perfect Sky, Inc., who helped with
reviews of the hybrid vehicle material.
Bernie Carr, Senior Engineer at Bosch Diagnostics/
Vetronix in Santa Barbara, who reviewed and
helped with controller area networks (CAN) and
other vehicle electronics material.
Staff at all of the campuses of Universal Technical
Institute, who provided helpful reviews of the
manuscript.
Tom Butera has volunteered in my class since he
retired after 31 years as the owner of a NAPA store,
preceded by many years as an owner of four Texaco
service stations. Parts people know lots of things
about the automotive industry and Tom brings many
things to class to share with me and my students.
From Tim Gilles
© Cengage Learning. All rights reserved. No distribution allowed without express authorization.
xvi
20/12/10 10:03 AM
APPENDIX
ACKNOWLEDGMENTS
© Cengage Learning. All rights reserved. No distribution allowed without express authorization.
The contributions of the following
reviewers are gratefully acknowledged for their invaluable input
during the development of this
revision. In addition, the author
and publisher would like to thank
the reviewers who offered feedback for previous editions:
David Ames
Evergreen Valley College
San Jose, CA
David Brainerd
Goleta, CA
Al Carroll
Edgecombe Community
College
Tarboro, NC
Andrew Cawelti
Oxnard College
Oxnard, CA
Tim Dwyer
Oklahoma State Technical
College
Okmulgee, OK
Julia Johnson
Skyline College
San Bruno, CA
Anthony Kossmann
Hudson Valley Community
College
Troy, NY
Gary Neil
Renton Technical College
Renton, WA
FROM ATI SCHOOLS AND
COLLEGES:
Leonardo Avalos
Avondale, AZ
Luis Barini
Oakland Park, FL
Jared Avent
Sacramento, CA
Arnold Burkett
Oklahoma City, OK
Fred Bachrodt
Avondale, AZ
Craig Couch
Oklahoma City, OK
Jack Batson
Rancho Cucamonga, CA
Andre Covas
Oakland Park, FL
David Beam
Exton, PA
Robert Dryja
Dallas, TX
Oliver Beckham
Houston, TX
Secundino Garza
Corpus Christi, TX
Ryder Goin
Dallas, TX
Jonathan Kloepfer
Oakland Park, FL
Bruce Lazarus
Oakland Park, FL
Herbert Leist
San Antonio, TX
Marion McKnight
Waco, TX
Herbey Pena
Corpus Christi, TX
Vincent Seina
Oakland Park, FL
John Tappan
San Antonio, TX
Vince Blanchard
Sacramento, CA
Terry Borkman
Avondale, AZ
William M. Brown
Rancho Cucamonga, CA
Benson Bunk
Mooresville, NC
Thomas Clark
Rancho Cucamonga, CA
James Coll
Exton, PA
Jon Combs
Avondale, AZ
James Coombes
Exton, PA
Phillip Cooper
Mooresville, NC
Jeffrey Covington
Mooresville, NC
James Posick
Daytona Beach State College
Daytona Beach, FL
Douglas Walter
Houston, TX
Charles Rockwood
Ventura College
Ventura, CA
FROM UNIVERSAL
TECHNICAL INSTITUTE:
David Cubillas
Avondale, IL
Joseph Alvey
Sacramento, CA
Darren Culver
Houston, TX
David Anderson
Orlando, FL
Ben Curtis
Mooresville, NC
John Archambault
Mooresville, NC
Russell Curtis
Glendale Heights, IL
Gary Semerdjian
Imported Automotive Service
and Santa Barbara City College
Santa Barbara, CA
William Crawford
Avondale, AZ
Not For Sale
Robert Stockero
Santa Barbara City College
Santa Barbara, CA
PRELIMS.indd xvii
xvii
20/12/10 10:03 AM
Not For Sale
TABLE OF CONTENTS
ACKNOWLEDGMENTS
Eric Davies
Exton, PA
Roy Greathouse
Sacramento, CA
Kenneth Lowell
Norwood, MA
Steve Davies
Exton, PA
Steven Greenspan
Glendale Heights, IL
Andrew Martin
Rancho Cucamonga, CA
Steve Davis
Avondale, AZ
Joe Grosso
Exton, PA
Bobby Masterson
Houston, TX
Ken DeLano
Mooresville, NC
Gregory Gunter
Exton, PA
Cory Mathis
Glendale Heights, IL
Andre Demers
Mooresville, NC
Luciano Gurrola
Avondale, AZ
Robert McCorkell
Exton, PA
Dennis Denz
Glendale Heights, IL
Luis Guzman
Orlando, FL
Brendan McCormick
Exton, PA
Thomas Devitt
Mooresville, NC
Mark Hall
Sacramento, CA
Brian McHugh
Orlando, FL
Lawrence Doran
Sacramento, CA
Terrance Haltom
Sacramento, CA
Danny McKay
Sacramento, CA
Anthony Eddins
Norwood, MA
Richard Hamilton, Jr.
Mooresville, NC
David McLoud
Norwood, MA
Robert Egli
Avondale, AZ
Ricky Harrison
Houston, TX
Donald McNabb
Houston, TX
Steven Fair
Exton, PA
Michael Hecht
Houston, TX
James Mellenthin
Glendale Heights, IL
Eric Feltman
Orlando, FL
William Hoffman
Glendale Heights, IL
Steven Michelsen
Glendale Heights, IL
Martin Flannery, Jr.
Exton, PA
Jason Holdaway
Mooresville, NC
Kara Moon
Phoenix, AZ
James Flockhart
Avondale, AZ
Thomas Ingalls
Mooresville, NC
Jason Mosler
Avondale, AZ
John Fournerat
Houston, TX
Rodger Jerls
Rancho Cucamonga, CA
Charles Nance
Rancho Cucamonga, CA
Matthew Franchetti
Norwood, MA
William Jones
Rancho Cucamonga, CA
Francis O’Connell
Exton, PA
Scott French
Orlando, FL
Scott Keel
Houston, TX
Michael Pair
Glendale Heights, IL
Ryan Galatti
Exton, PA
W. Scott Keene
Glendale Heights, IL
Louis Phistry
Avondale, AZ
Jessie Galey
Mooresville, NC
Nathan Kulp
Exton, PA
Ken Nagel
Glendale Heights, IL
Steve Garner
Sacramento, CA
Dave Leja
Glendale Heights, IL
Steve Nelson
Avondale, AZ
John Glusica
Mooresville, NC
Matthew Lokai
Mooresville, NC
Mark Nerad
Glendale Heights, IL
PRELIMS.indd xviii
© Cengage Learning. All rights reserved. No distribution allowed without express authorization.
xviii
20/12/10 10:03 AM
© Cengage Learning. All rights reserved. No distribution allowed without express authorization.
ACKNOWLEDGMENTS
William C. Niemeyer
Glendale Heights, IL
Kurt Saverien
Sacramento, CA
Andy Taylor
Mooresville, NC
Douglas Pergram
Glendale Heights, IL
Edward Scarbrough
Glendale Heights, IL
George Timmis
Orlando, FL
Clayton Perkins
Avondale, AZ
Donald Seene
Mooresville, NC
Bob Troxler
Chino Hills, CA
Todd Peterson
Norwood, MA
Brian Shefman
Exton, PA
Ray Tourtelotte
Mooresville, NC
John Pfingstag
Phoenix, AZ
Charles Siegel
Orlando, FL
Robert Venditti
Exton, PA
Richard Ploeser
Avondale, AZ
Aaron Smith
Mooresville, NC
Steven Volkman
Orlando, FL
James Pollard
Houston, TX
Marvin Smith
Mooresville, NC
Joseph Walker
Orlando, FL
Daniel Poor
Norwood, MA
Everett Jay Sinon
Mooresville, NC
Don Walter
Rancho Cucamonga, CA
George Potter
Glendale Heights, IL
Michael Sorensen
Sacramento, CA
Wayne Walters
Mooresville, NC
Juan Ramos
Glendale Heights, IL
Anthony Spadafina
Glendale Heights, IL
Thomas Wells
Houston, TX
Carroll Randall
Mooresville, NC
William Spiekerman
Avondale, AZ
Robert Wild
Orlando, FL
Timothy Rayner
Sacramento, CA
Mike Statzer
Avondale, AZ
David Winfrey
Norwood, MA
Salvatore Reina
Avondale, AZ
Chris Styffe
Norwood, MA
Randy Worner
Houston, TX
Paul Rohe
Rancho Cucamonga, CA
John Taglini
Norwood, MA
Mark Yarnall
Exton, PA
Dominick Saffioti
Orlando, FL
Adam Taylor
Norwood, MA
xix
Not For Sale
PRELIMS.indd xix
20/12/10 10:03 AM
TABLE OF CONTENTS
ACKNOWLEDGMENTS
Table of Contents
DEDICATION
The completion of this book was made possible with help from a great many
individuals. Automotive Service: Inspection, Maintenance, Repair, 4th edition
is dedicated to them and to my wife, Joy. Her organizational skills and able
assistance have been invaluable. Writing a 1,500-page comprehensive textbook with many thousands of photos and sketches is a daunting task. I would
not be able to concentrate as much of my time on the important upgrading
and editorial work if I did not have Joy organizing the art package and submitting final manuscript changes to the publisher. She retired from her full-time
job to help with this project and has been especially helpful.
ABOUT THE
AUTHOR
Tim Gilles has authored and coauthored several textbooks. He has been an automotive teacher since 1973 and is a professor in the Automotive Technology
Department at Santa Barbara City College. He earned a Bachelor of Arts degree
from Long Beach State University and a Master of Arts degree in Occupational
Education from Chicago State University. He holds the industry certifications of
ASE Master Engine Machinist and ASE Master Automotive Technician.
Tim has been active in professional associations for many years, as president and board member of the California Automotive Teachers (CAT) and as a
board member and election committee chair of the North American Council of
Automotive Teachers (NACAT). He is a frequent seminar presenter at association
conferences. Tim has been a longtime member of the California Community
College Chancellor’s Trade and Industry Advisory Committee. He is active in
industry associations, including AERA, ARC, and IATN, and has served several
terms as education representative on the board of the Santa Barbara Chapter of
the Independent Automotive Professionals Association (IAPA).
PRELIMS.indd xx
XX
© Cengage Learning. All rights reserved. No distribution allowed without express authorization.
Not For Sale
xx
20/12/10 10:03 AM
FEATURES
OF THE TEXT
CHAPTE
R 12
Engine L
ubricatio
n
Each chapter begins with a list of the most important points discussed in the chapter. This list of
objectives is intended to provide the student with
a general idea of what he or she will be studying.
OBJECTIV
ES
Upon co
mpletion
of this ch
■ Describ
apter, yo
e engine
u should
lubrication
be able
■ Select
under dif
to:
the corre
ferent se
ct engin
rvice cond
■ Describ
e oil to us
e the op
itions.
e.
eration of
different
types of
oil filters.
KEY TERM
S
anti-drai
nback va
lve
API
boundary
lubrication
by-pass
oil filter
KEY TERMS
by-pass
valve
crankca
se
dry start
full-flow oil
filter
INTRODUC
TIO
N
In theory
, all mo
ving parts
layer of
oil (Figu
are separa
re 12.1)
parts by
. Oil is sup ted by a thin
an oil pu
mp (Figu
plied to
maintain
engine
re 12.2)
ed
. If oil is
wear shou so dirt cannot acc
prope
umulate,
ld occur.
then very rly
Th
the 1960
s was abou e life expectancy
litt
of an engin le
t 100,000
maintain
ed
miles. To
e in
day, a pro
Under no engine can last tw
perly
ice
rmal cond
itions, the as long with less
in lubric
ation occu
wear.
only tim
rs is just
e a break
in the mo
down
after an
rning. Th
engin
until a we
e
dge of oil crankshaft rests on e is started
oil reach
is reesta
its bearing
es the be
s
arings (Fi blished after pre
ssurized
Figure 23
gure 12
.3). A few
.15 Clean
new hose.
seconds
the hose
fitting
Automoti
ve Hoses
CAUTION Do not try
to substi
tute
hose
The Gates Corpo
CAUTIONS
Oil tends
to resist
movement
on
and journa bearing
l surfaces
before ins
talling
341
by-pass ho
ses must
be cut to
as a templa
length. Us
te.
e the old
hose
ration
Each chapter contains a list of new terms to
know. These terms are highlighted in bold in
the text. Definitions of these terms can be found
in the glossary.
Oil pump
the
an un
for
fold when a molded by-passOil molded
hofilte
bent, res
se.rIt can
tricting co
olant flow
.
Power Ste
ering
Hose Se
When ch
rvice
eck
of leakage ing a power steeri
or damp
ng hose,
ness at
loo
Picfor
kupsigns of
conn
panection k for signs
Apply som
deteriorati theOil
scr
rub
ee
s. Also, loo
e
nbing, or
on, such
rubber cem
new hose
swelling.
k
as crack
ent gasket
connection
A failed
s, signs
wi
sealer to Figureblo
when usi
oil onto
pre
s to preve
of
12.2 ng
ssu
re
ng a cons
Oil
hose can
cause a fi is circulatan exhaus
nt air lea
oil pump
tant diame
t
re.
ed
ka
ma
.
ge
thr
nif
ou
ter or screw
old, where leak,
gh the
Coolin
sysgtem
Sys
cla
it
tem
mp
can
by
Shaft
.
Service
an
Learning 2012
© Cengage
SHOP
TIP
Most slippag
occurs nea e
r the
center of
the oil film
319
CAUTION
SHOP
TIP
can pass
before the Power steering
fluid, wh
en
to the en
gin
ma
e’sat
ble
ich is not
Dr
oilen
tir
ain
pu
mpe can
the
flamcogin
ture,
e. is
start, pa e engin
ola
dis
Duflrin
ntop
era
int
butem
gma
is
te oil
o tin
rts can rubTh
g
thi
atricle
isam
sall
esp
int
ble
peraan
eci
abreu
at
dra
ovesed
an
tem
in pan.
y erv
d
cal
30
perta
we
imal,
NO
led
0°F
ratnt
po
ar
TE
ureifsdr
Figure 12
,
res
(lo
if thewe
: The am
lts, fuel lin
radiator co
aitylitt
s.me
an
tha
curult
.1 Movin
ex
ouola
n the
sto
co
is leto be
ntha
es, amount
ust
oling fan
of
tem
of oil.
nt
r
g parts are
we
ma
has rec
chan
peen
ar ge
nif
rat
tha
of time is
.
ureha
d,told
).urs
occ
tly
separated
ofd the
for
instan
stequ
durin
likiva
miles of fre mo
elylen
ce.g Th
by a thin
thies cu
bet to
untha
sho
ew
ha
Pu
film
t
rt
ay
sto
cau
pp
rch
for
dri
me
y
sed
ase
new
vin
if hebyorhush
r will
specifythe
the
g.co
co
Mo
ola
ndered
stctveh
theold
Replacing
rre
nt.
is sbil
useon
ofled ag
repicle
ofe.thi
lacem
maen
nutfac
nn
a Heater
nents ing
Pa
ain
er sto
rts
tur
oilres
ho
more
s, wh
seers
Hose
anno
quick
s for
Sometim
w lac
haich
d rep
ve rea
polywe
ch siv
exten
aftstesta
engeine
es the he
e
eridrtu
com
illu
compare Looser ner
p.hoses
ngrem
an
ater hoses
strate
po-d list
diameter
remov
thee ne
ove. Itall
on a car
s. The siz
is
als
w
o
the
ho
of
a gofas
the length
se to
e is determi
are
pump
the
odten
Hose come
the
ideers
an
gasketan
a
old
d
to
ned by the two different
cle
d fithe
ho
s in long
an
.
off
se
tting
to be
s gin
I.D. of the
aree.identi all rem
rolls. Be sur
rect size ho
318
en
sureofthat Then
nants
gouge alu
CHAPTER
calefu
ho
Be car
e that yo
se befor
CH012.in
. l no 14
the old
minum pa
dd 149
9
e cuttin21
u select the se.
t to acc
Twist the
rts.
g it off the
coridentally
main hose
remove eas old heater hose
InspEx
ecact
roll.
t the
to loosen
ily, cut it
rep
Ol
lac
d
it.
Pu
em
car
instalFig
Lo
If
m
en
efully
it does no
okwi
tp hydrauli
som
lingure
Inspe
heth
Cow
re afor
the
ct eti
me
t
the
plutio
lea
21ne
s
c
sh
gpuop
.37reThe
no
old
ka
arp
sec
ho
ge
t
■ Be ev
ening
pump
ses are
av. ail
knife. Whe
nmp
veelspe
ofhaste
of
cer
ab
ide
Wa
hose, ch
le.pu
taint
Baeck
sea
ter
n at
ck side of
So
n
or cia
thathe
meim
plalstieq
t the
mp
s fai
bu
vent
the fol
licsioho
sin
c.uip
cylinder
led
meull
hoho does l ha
manifold
Caref
pe
nty for
lleess
low
en
rs es
n, ses
ing:
are made
loo.sen
lea
Ch
s, drive be sele.
ma
not interf wh
inspe
eck
ess
ctkin
with
, or bre
theg im
NO
■ Check
hy
ere with kage is with
dra
a .bu
lerhe
akage
pe
avTE
: Som
03/1
lleuthe
ywitru
to see tha lts, or spark plug
2/10
sinces
r3:38
eind
for
If pie
ess bre
ck,int
tecust
ll go
PMerohnria
tha
accounts
cables.
t the hose
icil,
plu. y
t off
anor
moveme
o
gs
dethe
ak
s
the
als im
in
rou
blo
cas
tin
wi
nt of the
t iron blo ck anfar
ll not be
■ pu
pe
rep
d,m
im
poely
lacnt
cor
ple
Se
mp seal en
cks
da
ssi
e
rod
gin
me
lec
ma
bly
PositAion
steel l-cor
wi
e.
e
,
ge
tin
th
the rad
If Re
d by
can failor
ga
brass ones
coopl
e
essories.
lan
iat
corrothe
beacc
t
is
cau
ac
ew
un
access. On
tha
sionscr
reg
ne
em
se
sid
t wior.
ula
ces
Replacem sar y pra
of the she of a scr of bearing
ent Pu
rlymmaint
ll not
low rad
en
aft, or direw clamp failure,
cti
p
ain
t
ce.
wa
ho
ed,
driver■orThe seaer
It
iat
ter
or hoses,
this is an
t.
ver.
can beco
pumps isare
rebuiltwepu
a good ide
for easy
¼" drilve
an
me
mp
a
co
ex
usu
red
for
ola
s
tra
soc
to tighte
are availab
ally new, boat engin
ng screw
when akerad
t and exhot if it is-lo
When bu
n thentho
alt
le
es,
run
ho
ten
for
yin
ug
iat
wi
wa
sio
som
se clamp
h
or boils ovn can be thout
compartmeter to an
e vintage
turned WA
uilt pump
from the
TEgR aPUreb
overheat
en
Ad
in as
MP SE
top er.
guse
a core,
l,nt. Be
cod
positionsea
of thedin
e the scred system
RVIC,E the old one mugines.
sinsur
Coull
Caref
Re
wh
g it
ola
ed socau
pla
ich
gineld
cean
sh en
is
y nt
ment
■ W
pump
cra ew on thecan
st be
comp
k the
hen ita can
horeb
old
not to
with the
hose oc
se uilda
ares the
have
ho
accideck.
vehic
puemp
befor
clamp
nebe
cooli
ble part.
w en
leas.
is t
putra
vinTh
come int
dry
ey pa
mpdit
fan. le sits fornta
g the
ion
a lly
are
or ng
wi
pro
all
dirty
th
oft
y
o
lon
an
rts
ca
co
the
en if lac
d miles of
lled water
sto
ct
sometime cooling system, the ged perionta
ed . er old on
possi
d wi
e,
ser vice whre, rep
th a
noise.
s sticks to
many ye
water pu
en they bebleaft
ars
the shaft
started, it
gin to lea
. When the mp seal
When abreaks loo
k or make
In some
engine is
resulting
Leaking
264 hose is difse,
application
ficu
Wosm
in a leak.
lt to instal
CHAPTER
Wa
rn all
te
ou
be
Beam
r
s
nt
lts
Pump
that use
aring of soap to19
, the wa
l, apply a
Some
ser
ter
the conn
pe
pu
pu
bo
nti
A worn wa
mp
mp
ttom sid
ne
s e,
ection.
is
hausi
ve ng
ter pump
a ve
bo
watto
nt hole driven from the
the
term
shaft beari
failur
puof
or the
mpthtu
ck of
e rn
e.ure
pusmp (Fi ba
Fig
weep
Wi21
ng can be
th.34
theThi
hoTh
wa
a aV-b
belt.
the op
le ein the
ter
gupo
ensgin
elt
resit
used
a result of
-drpu
e run
21
the
cylind
ivemp
By-Pa
toco
n will .usuall
listVIplu
NTgAG
e .37
). ct
er nin
seal
dire
Atal
Leio
ssdif
wag,
a stin
aknagof
wa
ins
Ho
ll ca
stetho
aop
Be sur
terorpumppump
yebe
sereen
baEen
e from
GI
led
dEN
loosen
Reto
NE
be
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2/10 4:07
-fire
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they were ed to the same be erjournals
bearing cap
ges drille
to the rod
aring
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journals.
. Two-bolt
sure to rea
performan are the norm, bu
This allow
main
main
ch the co
t some h
ce and l
s il
b
Learning 2012
Cautions are urgent warnings that personal injury
or property damage could occur if careful preventive steps are not taken.
multiple
viscosity
polymer
viscosity
viscosity
index
SAFETY Be certain
tha
es not co t a newly installed
NOTE doSta
ntact dri
hose
tionary bea
or the
ve be
ring
© Cengage
SHOP
TIP
VINTAGE SYSTEM NOTES
Not For Sale
CH19.ind
PRELIMS.indd xxi
d 264
© Cengage
Learning 2012
Boxed information on vintage systems (and
related parts) puts today’s newer technologies in
historical perspective and offers insights into the
development of the automobile. Vintage notes
are not only interesting but may even help the
reader repair or restore vintage cars. This has
become an important part of many automotive
businesses.
Tim Gilles
CASE
HISTORY
Tim Gilles
Notes are used throughout the text to highlight
especially important topics.
SHOP
TIP
Learning 2012
NOTES
SHOP
TIP
© Cengage
Appropriate shop tips are described throughout
the text. These tips provide shortcuts and emphasize fine-tuning procedures to shop practices commonly performed by experienced technicians.
Tim Gilles
SHOP TIPS
Tim Gilles
© Cengage Learning. All rights reserved. No distribution allowed without express authorization.
OBJECTIVES
xxi
20/12/10 10:03 AM
Not For Sale
and Pipe
: Tubing
351
ing
ve Plumb
Automoti
Dana Corporation
Close nip
(b)
l or brake
tubing fue e flexes
lace steel
lin
Do not rep pper. As copper
d can
co
rdens an
ha
lines with
rk
wo
es, it
and vibrat
SAFETY NOTES
crack.
are on the
be squ
bing
).
, it must
Cutting Tu
re 24.22
to length
this (Figu
t
ing is cut
t might no
is good for
When tub
(a)
Safety is the number-one priority in an automotive shop. There are numerous safety notes placed
throughout the text. Most of the safety notes
have been taken from real-world experiences and
many are accompanied by actual case histories.
r
gh edge tha
ing cutte
can
end. A tub aw will leave a rou tubing with a file
cks
the
tal chips
nipples.
Using a ha essing the end of
e. If the me
.20 Pipe
. Dr
of the tub
ult.
d
res
Figure 24
en
be square
can
the
chips in
ge to parts
r, the
leave metal ed, serious dama
ing cutte
ov
led
th a tub
en it is rol
are not rem tting tubing wi
tubing. Th
g the
When cu
against the nuously tightenin into
d
ne
hte
r
nti
3/4"
tool is tig tubing while co
ves furthe fast
mo
it
as
cutter too
around the vance the cutter
ad
vance the
cutter
l not to ad
handle to
ing. If the
. Be carefu
gh the tub be damaged.
the tubing
ng throu
hes cutti
tubing can burr usually
1/2"
the
t,
as it finis
fas
cut, a
ough too
reamer
s been
breaks thr
rs have a
tubing ha
ing cutte
sure to
After the
d. Most tub gure 24.23). Be
after
on the en
(Fi
remains
the burr
the tubing
ing
of
ov
d
3/8"
en
rem
from the
blade for
ips
ch
tal
tight quarIn
remove me the cut.
.
all
on
very sm
ged tubing
completing ing cutters are
ing dama
.24
Some tub
d for repair own in Figure 24
can be use
sh
ters, these The tubing cutter
nches.
wre
le.
e
hic
pip
the ve AKS handy for this.
ad or
Internal
21
LE
linder he
ure 24.21
CHAP
FigTER
especially
ck in a cy
isAL
INTERN
314
21.28).
t or a cra
too
k (Figure
head gaske Tuint
intobecause
ernal lea
owing
ll fltub
ingan bing
wiing
A leaking Beult
ing
ntnd
ndin
olabe
co
en
the
ing. A tub
res
k,
wh
nd
en
lea
e
can
are
al
the tub
g cor
en fou
ern
y aw
bore
tridct wh
.25).
all
int
e an
VALVES replace leakin
aneci
d res
s, are oft
anok
gure 24
Beisesp
akekstr
then there
to led draincock
(Ficed
SHUTOFt Fwanted cal
intkin
s is for
gaing
en the
thecan
ce
end of
Whe
weing
g nd
usttub
pie
be
bet
m
ha
rin
the
o
a
ge
den
ck
ex
du
for
als
lar
,
in
stu
r
arp
blo
a
s,
to
c lindesh
A ff valve
leser
d
theiator. Turn
sticy
ustion
d ses it. Pla
bbov
buit
ck aofrad
mbuse
ove
ng
baof
cobe
as
the
ing
rem
g
ldi
ar
the
be
Shuto
can
He
rin
ho
pe
clo
.
on
er
ap
ing
Du
by
or
ion ens it
ts
plugsbottom transmiss
be. nd
bent
l testub
d can
car
.
e the
o be
gine is off
Usera
theine and the the other opfro
alsan
tem
tubm cthe
on eng
can
ng gsys
erengareit.sev
drain- valve en the coTu
or nsmission
olibin
Thmi
sti cra
).
y for
to bend the
plathe
e way
t
.29
wl
a
nk
tra
on
o
no
k.
21
slo
l
ve
c
int
d
lea
lve
ha
ati
re
efu
al
va the automks usually
e an
erncar
ck of
pipgu
d be
or
of (Fi
rm
ideananint
or tan late from the ba
gu
e
the radiat dolac
coanfi
to as
radiat
rking on did
ds befor
t
berep need
d the flexp
heEwas wo
both en
ckIC
t can
rized
blo
thacu
arply.
RV
and remove
theSE
prelsssu
is too
straight pre
herol
and flare
ate
or inind
NG
ing too sh
BIly,
When ot
tubthe bend
fortun
TU
fittings
badck.
, if eth
g beh
thease
shaft. Un
cut brake
er
in 25a-fo
rwise
pluen
tall the
onrch
e
Pre
he
gs
Ins
d.
cor
Ot
wh
plu
.
g
e
g
t
cor
each ck was d and a lon
g is, pu
ndfitha
the tubingdeterminin follows:
not have Tubintem
he fou
ttingseatof thet blo
e en
bending ive way of
at on
th fltsare
g sys s wi
laced
nuedg
er is as
the
on the sid
flarethe
e of
the coolinlength
An effect
being rep
o a cylind
moyun
ing to
has a shgort
engine all
down
with a
the tub
leaking int
red string to deterd. If it
one of theing usu
s runnin
appea
er en
ng system
coolant is
wa
of a
othck,
olant
where
piece
the cooli
at the
Co
a
e
t
d
g.
riz
ng
nu
blo
use
kin
ssu
usi
d
ter.
are
theasure it l. If he ha
lea
fl
of me
r s,
rea
k ■ Pre tem pressure tes
the
hee
kin
to
ore
yw
t with the
to
nd
fl
n
t
bef
be
igh
.
k careful no
the
oil pa
leabe
gthcat
has m behindrre
oling sys
sit overn
e the
co
ct len
.
to
,
fro
lo
led
le
co
l
ing
to
rol
hic
ing
the flashlight g bulk tub a good dea
ve
be com minean
t it was
d n unrollin have saved
Allow the
ssurized.
■diter he
ad
ection tha
system pre rk plugs.
pressure tes Wrep
e, add an
, he would same dir
les
. oling
the rolair
on the lin d (¼" total)co
l it in the
of the spa
rk plug ho king
installed
attemptingit. Un
me
Remove all
of the spa
gs are to be the flare to be for
work.
the
nt is lea
t in ■
r in front
sea
pe
a
of needlessWhen fittin
for
pa
e. If coola
d
st
rk
ld
a
■ Ho
1
the engin
at each en
ing
htly again
of that spa
ing
tig
nt
sen
nk
ld
fro
loo
cra
he
tional ⁄8"
in
while
ing is
paper
nches when wrench or
en
tio
Flared tub use
inder, the
ecwr
two
ingks
int
lea
ing Insp
me wet.
- o a cyl
a tub
ays
us
co
for
e
sec
be
e
Ho
Us
Alw
ng
ll
t
.
.
Th
usi
wi
ng
ion
Ou
fittitle
ect
at) ho
ench
c- .
ost
wrele
conn
plug hole
d fer
erm
the
ingt (th
Coolant ared nttub
en-en
s suf
opme
an eti
fitting. If
flcoola outleench ng
ansd som
oftthe
housrt tle
t wr
le flare
alentpaou
m housi theafem
Inspect the flare-nu
is
ola
the
Aluminu ch holds
enhe
ad ma
3 gine
ing coto
whm
n nu
k. le Test
en the51en
turmi
whies
or damage.onge.
e .
hen replacallowon
alu
will kin
d wr
or sor
ed
Wen
gining
an
iatces
bb
ing
en
l Ac
t tub
rad
Bu
tub
ion
ma
is using
the
ctrica
to cu
tting
tter the
to posit and repaired,
m ho
cuing
ench
elerat
andinEle
trolysis da femalu
sur,ethe
alemifinu
bb
wr
s,les
accing
. Be
tem
les.
a tub
cutsion
Sysbu
winthheaad
l an
ng ly
ok
ort
e for
d. Ra
ne
Usipid
Lo
Us
the bubb
corro
loa
cantbe
tur
Co
l.mf
.22
andiro
a24
ce
is
r
es
ity,
too
ing, instal fitting
on
ven
du
de
lin
cur
l
ure
ng
ng
pre
un
pro
Se
d
fue
flari
ce to d usi
ay,).
fet
n housi mageco
stectelpla
Sa
ng
drre
warm an Figough of a load to
ine is cold.
.27
21
eng
ate
and an iro
re
Da
the
ric
the
en
ng (Figu
re when
clamp in linesthe
usifab
is usually
hobe
.
to leak mo
wand can
the hose orho
nese
acks tend
steel tubing
the
leak
ck closes.
NOTE: Cr
between only seamless
mbustion the
up, the cra
by a co
After warm
spring,
re caused
ssu
iator cap
is
pre
When
that this
of the rad
Ridge
y
re
rif
ssu
ve
nt. To
overthe pre
radiator
exceeds
spew coola
re, put the
cap will
engine
ssu
or
iat
the
pre
rad
ile
ion
Crevice
water wh
combust
a
rners of
caused by
ntainer of
into a coe used at the cog.
dd 351
ug
CH024.in
flow hose
nt sensin
strain ga
Tim Gilles
CASE HISTORIES
Case histories are presented throughout the text.
These true stories recount actual automotive situations encountered by the author in over 30 years
in automotive service. Case histories present the
reader with examples of the pattern of critical
thinking skills required to diagnose automotive
problems.
CASE
HISTORY
Learning 2012
SHOP
TIP
Learning 2012
© Cengage
SCIENCE, HISTORY, COMPUTER
SYSTEM, AND MATH NOTES
5:27 PM
© Cengage
03/12/10
.26 A
occupa
Figure 34 seat frame for
er
passeng
TE ■■
MATH NO
nge in
CE AND
oling
rate of cha
CoIEN
■■ SC
sed on the
rate
Right
Wrong
REVIEW QUESTIONS
Tim Gilles
© Cengage
Learning 2012
Tim Gilles
r. The
nt is ba
tem
sys
loyme
eleromete
a
Air bag dep
by the acc
gh time by
measured
pped throu
a
acceleration
JERK, is ma
, based on
led
thm
cal
ori
e,
of chang
. The alg
isions
thm
dec
the pasori
x
en
ple
alg
wh
ke the com
thematical
illuminatesg is disabled.
ma
loy
ma
ht
to
dep
lig
d
ba
w to,
rning
del, is use
d the air
.24 A wa
er, and ho
genetic mo
Figure 34 t is occupied an
ing wheth
as more
tion
usard
reg
mb
Cosh
each year
cra
senger sea
r thm improves
during a
beori
e alg
Tham
. ch
n.
tio
tec
the system
pro
sh
about cra
is learned
olant
leak, co
elerinternal acc
and duroff
is an
there mo
gine is GM
nitors the
’s gas
When ed
ly
en the en
.28 rep
21
eat
exhaust
d. ,In
ure
onion
linder wh
Fig mputeor the cy
secust
a mb
ples
s of
g co
on
rin
sam
cti
e
Du
Thewilco
l flow int rin
fra
tiv
ke.
ns.ecu
duakegstro olinfou
tem
d
r co
sys
int
lue
an
g
va
the
led
r
of
ab
ing
co
ete
om
erage
o the
intav
thm is en
ar the
tesan
is
ori
en
ne
Th
gra
alg
wh
r.
mi
mp
,
cla
2 g, the
ld occu
system
the hose sion.
ent shou
air
force of 1–
position
rro
exceeds a whether a deploym s than 20 mS). An A
Failure to ng leads to co
.27
21
23 ure
usi
termines
fast (in les 50 mS of impact.
outlet ho
de
CHAPTER Fig
ry
ve
the
4
de
on
34
is ma
ridge
an air
03/12/10
se
d wi
hon
er thi
decision
inflate
inflating
tow
y ful
tolyscrew
ond. Fully
ack
is usuall
ba
le.
000 of a sec
is ga drawb
arkabich
ard6. What millisecond is 1/1 a second is rem
, wh
tem
lations reg th
sys
s?
ESTIONS
calcupe
e
ngma
00 of
mp
QU
rcl
al
oli
r
/10
wi
cla
(ci
tic
co
EW
50
d
w
de
VI
up
in
RE
bag entionahl flo
/outsi
, the
mathe
histicate
st abuse
nv houg the
Bladdered by their inside
more sop a tree or pole
7. On a co Alt
fers thebemo
coming
suf
are siz
y
hose sh
ions with
es are
1. Hoses
radiator
.
? idents like collisor fitting
hose to
because the
ing cra
meter
dd 314
er? Whyacc
iat to resolve
CH021.in
s formable
low
one) dia
rad
a saw
aori
thm
or theex
off
perience, t come
ture allow
alg
fea
ving into
l
the
dri
cia
no
spe
es
lt for
ficu
? t. Imagine
vide the
g?
se do
ne
dif
ho
pro
2. What
kin
can
do
or
t
en
a
are
ed
se
kin
ns
ev
If
no
be
r
ho
tut
ut Se
8.
es
r
t dosti
slowe
shou
a ld
is sub
at es
lf bu
oil coole
whvid
_°.
hase
bend witho
r ho
ce.
ulain
easily,pro
nsmission ures of up to ___
regcar
if athe
le “g” for
cuts
forces
ide of tra
ppten
tha
deha
bla
can
a measurab nsider vehicular
t temperat
3. The ins
thse?
steering
9. What
-parsswiho
d constan
to co
ls how
d byete
dule
a power
elerom
t.
ab
Moin
acclde
withstan
s are
chlefire? rate sensor tel
sing sea
cat
for a mo
tem
o hoses
sen
id
tw
sys
ntr
flu
times
lar
are
pa
weering
cu
Ne
there
An angu
r ste
how many atic
for
of? an oc
we
er.
d
y
to
rts
po
an
lov
4. When
the
n
Pa
er
mp
rol
are
.25
10. Ca
, wh
ureat34
rolling ov cutoff and autom
during a
of hose cla
systemFig
g
vehicle is
the type
atic fuel
?
the air ba
ickly the
name of
ses
tom
qu
ow
ho
the
au
all
is
es
s
t
g
system
includ
system
a roll5. Wha
nt-sensin
l injection
it rolls. It
ances of
. Current
e occupa
onds. Ch
use for fue
fication
disconnect
sensor. Th
sec
ssi
7
ry
re
cla
to
tte
ssu
nt
ba
up
ote.
er and pre called the occupa
ated for
s areorrem
hoses unication sysnethi
the bladd
s
to stay infl longer tha
radiatite
comm
sometime
this
g on neopren
a strain
tind
tem can
lasuse
because
s a satell
module is
overps
sing uses
le ha
air bag sys
hicret
ightened
vebe
ofethe
n a to
weight sen frame (Figurec. ClamWhe
EPDMand send emerpakrtlik
of NS
module. EWme
odTIO
QU
tt are
thES
t e
t haveute
rin
tha
d
no
sea
sh
rs
VI
rre
ard
e
er
do
RE
cu
th
no
tru
bo
oth
mp
coho
,of
er of
se does
rntem
nt has oc
A circuit
tem
ents is/eare
ASE-STYLEAn
costa
t.
ide
d
sea
ch
acc
at
ea
ll
kin
d th
e atfollowingey support th
ugthe
se that an to the site. often has aen a vehicle wi
gaof
sen
lic foil gri t on
se.
e sense wh ng.
ere th
ho
and
wh
s a medtal
hicles return lin
tion weigh
1. Which34.26l) ho
se?
uge ha
gency rvesteering
temsacan
ed fitti an accident
hen the
mage sec
a fueed to each galac
d systha
criemp
edear da
ationd. A powe
n tim
about bo
r-basehe
to avoid to aent. The same
strain.. W
orm
da
rep
r
nd
Ra
inf
to
t
un
d
in
tpu
, rat
p
ing
ge ym
be use istancecooler tub
da
deplo
can
g ma
se clample to sto can cau
seba
ntrol,
as well.
voltage ou thean
ho
anges res
oil
a. Itch
onge
not be ab low
cruise co
s, sensor
ing
in ch mges
ll begin air
re le
nsmissian
ssudu
fol
distance
uter wi
premo
sensors
ofthtra
the
mp
ing
e seat ch hont
h ofco
nsve
justable
-seha
ck position ati4.
ion
onWhic the se? is used for ad
cupa ses
oc
offe. seat tra
injeect
issid
r ho
tem
toel th
gin
ngeerthis inform e airrubbesys
b. Fu
en
Coolant
sse
of
the
c.
pa
All
er.
d
en
s.
lat
th
wh
r- an
enive
ev
Dr
dis
me system when it deploys
atcussed
d B only
a. He
B of so
d. A an
d rt
anpa
mputer
Ao
are
thals
ke hose
by the co
c. Bo
fective bra
b. Oil
alyAzed
aner
nor B
mp is
is ith
s that a de nt of the brake.
rm gear cla
ian A say
.
d. Ne
me
nic
ge
tem
ch
ga
hose
Te
sys
bags. A says that a wo
en
5.
03/12/10
delayed
tive brake
l injection to work
ian
se
fec
fue
nic
de
cau
a
ch
a
in
Te
is
at
can
2.
B says th
ing. Who
style to use t for a hose clamp of the
the best
Technician brakes from releas
on top
B says tha
ed
nt
ian
ion
ve
nic
right?
Tech
be posit
can pre
. Who is
it should
A and B
connection
properly,
right?
c. Both
ge on the
B
A and B
nician A
er A nor
sealing rid
c. Both
a. Tech
B
d. Neith
ian A
513
B
er A nor
34.inddTechnic
ian
ith
CH0
nic
Ne
ch
a.
d.
t
b. Te
ents abou
nician B
b. Tech
true statem
are
ing
the follow
3. All of
tem, a
ept:
cooling sys leak
hoses exc
nal flow
conventio se is more likely to se
a. On a
ho
w ho
or
ne
iat
a
rad
er
lower
hose aft
an upper
air than
ipes
ribs or str
shrinks.
her raised
ring
se has eit
ho
isting it du
ke
b. Bra
against tw
ard
gu
lp
to he
.
installation
Corrosion
These notes are included when interesting topics relating to them are covered in the text. The
objective of these features is to pique the student’s
interest and show a correlation between his or her
automotive studies and these areas of learning.
ration
Delphi Corpo
4:29 PM
03/12/10
xxii
PRELIMS.indd xxii
These questions guide the student to the most
important points in the chapter and act as a check
for understanding of the material. Each chapter’s
review questions are presented in the same order
in which they appear in the chapter. This provides an instructor with the flexibility to assign
portions of the chapter to read and then follow
up with a few of the study questions.
ASE-STYLE REVIEW QUESTIONS
4:36 PM
These questions are designed to provide preparation for the certification examinations administered by the National Institute for Automotive
Service Excellence (ASE). The ASE test is a task-oriented test (the test taker is supposed to be able to
relate to shop-oriented questions), so the practice
tests should help the student in becoming familiar with accepted trade procedures.
© Cengage Learning. All rights reserved. No distribution allowed without express authorization.
ple
SAFETY
NOTE
Long nipple
4:37 PM
dd 344
CH023.in
20/12/10 10:03 AM
FEATURES OF THE TEXT
© Cengage Learning. All rights reserved. No distribution allowed without express authorization.
SUPPLEMENTS
■ Instructor Resources—The fourth edition
Instructor Resources DVD includes an Instructor’s
Guide in Microsoft Word, a Computerized Test
Bank in ExamView with hundreds of modifiable
questions (true/false, fill-in-the-blank, and ASEstyle multiple choice), chapter presentations in
PowerPoint with full-color images, video clips
and animations, a searchable Image Library of
hundreds of full-color photos and line art from
the core text, and Correlation Grids to the NATEF
Automobile Program Standards.
■ CourseMate—The all new CourseMate for
Automotive Service, 4th edition, offers students and
instructors access to important tools and resources,
all in an online environment. The CourseMate
includes an Interactive eBook for Automotive
Service, Fourth Edition, nearly 300 videos and
animations, interactive quizzes, flashcards, an
interactive glossary, and an Engagement Tracker
tool for monitoring students’ progress in the
CourseMate product.
■ WebTutor Advantage—Newly available for
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the Blackboard online course management system.
The WebTutor includes chapter presentations
in PowerPoint, end-of-chapter review questions,
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topics, and more, all designed to enhance the
classroom and shop experience.
■ Lab Manual—The Lab Manual includes
Worksheets that define each lab procedure,
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project or lab assignment is built upon the next
in a logical sequence in much the same manner
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and the reader completes one task before progressing
to the next one. In addition, a variety of illustrations
support the Worksheets and help visual learners
better understand the jobs. The Worksheets are
keyed to the NATEF Auto General Service Technician
Programs Standards where applicable.
■ Automotive Service Job Sheets for NATEF
Task Mastery—The Job Sheets in this manual
cover all P-1, P-2, and most P-3 procedures as
identified by the most recent NATEF Automobile
Program Standards. Full-color illustrations offer
visual support to the Job Sheets, and the sequence
of topics follows that of the core text. Each Job
Sheet includes a simple and clear rating rubric for
instructor evaluation of student performance on
the task, and a supplemental CD-ROM includes
NATEF task-tracking software for easy recording of
students’ mastery of the procedures.
▲
LAB # 1
RACK/J
AC
Teaching
KS/SAFE
ai
TY/SPE
C MAN
UA
LS
Safety te ds/Handouts:
sts
safety tra (due today)
ns
Wheel lu parencies (in file
g torque
with safe
ha
ty tests)
Hydraul
ics Transp ndout
arency
Gousha
Lift Tran
sparenci
es - cove
r lift poin
Lesson:
ts only
Students
w
and reas ill meet in the cl
sign jobs
assroom
at
to any gr
inform th
oups whe the beginning of
e securit
re the as
y guard
ten note
signed pe each lab day. W
at the ki
fro
e
osk that
tardy will m the instructor
no perm rson did not brin will see who brou
giving pe
already ha
ght in ca
rm
ve had th
ission to its are to be hono g a car. The LTA
rs
be late.
eir projec
or teache
The reason red unless they
t reassig
❏ Check
have a ha r will
ned to an
add card
ndwritother pe for this is that th
s to see th
❏ Spend
rson in th
e people
at they ha
about 45
who are
e group.
minutes
ve been
and jack
covering
pr
lift points ocessed by adm
❏ Show s.
iss
, the Car
the la
Care Gui ions
ment shee b manual, go ov
de
(lift poin
er la
t for each
ts only).
taken.
week’s la b assignment sh
Demo th
b. All labs
eet #1, an
e lifts
❏ Descr
d
must be
ibe
completed the lab schedule
❏ Tell pe the difference be
. There is
before ot
rsonal st
tween 10
he
r
la
ories
b projects a lab assignton, 2 to
the boar
n, and 1
ca
d for them related to safety
n be unde
1/2 ton
as you re
rto copy on
Jacks, us
ad each
to the co
e transpa
Go to lab
safety te
py of the
rency.
for the de
st questio
test that
mo and
n and pu
will be sa
return to
t the answ
ved in ou
class afte
er on
❏ Safety
r file.
rward fo
test from
r the safe
book. Pa
ty test on
ty presen
ss ou
bo
tation
Put a wro ard. Most of th t the safety test an
em were
ng answ
d have th
er
for “wat
co
er” works on the board, ev vered last time em fill them in.
Put all
durin
en though
not payi
well. Se
ng attent
e how m
yo
u read th g the service stat answers to safeany of th
ion. Try
rect each
ion safety
e right se
em write
it again
others’ te
ntence.
an
❏ Descr
th
d
st
e
yo
Substitut section.
w
an
rong wor
u’ll prob
d th
ibe
ing “acid”
ably still
d
❏ Tell pe the Starburst sy en fix any wrong
catch som down because
mbol on
ople brin
an
sw
they
ers.
e of them
a can
ging
5 quarts
. Have th were
to be safe oil changes to lo of oil.
em corok up th
. Next cl
ass is lect
ei
Find one
ure/dem r oil capacity in
student
the Car Ca
o only. O
w
ho
il
re
w
ch
ture day)
ants to br
G
anges w
.
ill be half uide first, or br
ing in a ca
ing
of the clas
r with oi
l and a fil
s after it.
❏ After
ter to ha
the safety
ve
de
m
onstrated
❏ If tim
te
e remains st have a shop
ne
xt class (le
tour.
after
shop wor
ckbooks sig the tour, they can
complete
ned off
their jack
Demo:
ing and lif
ting assig
Show th
nments an
em how
to
d get thei
the dem
r
o shop ca locate lift points
for their
rs, Xerox
where th
ve
them an
e lift poin
d have th hicle in the Car
ts are an
Care Gui
em insid
d what th
de. Lo
e the
e sh
Instructor
OK ____ eet that they shou windshield so you ok up the lift poin
________
ld
ts
ca
________ be xeroxing look n show the begi for
nners
s like.
___ Scor
ASE LA
B
e
________
Checking PREPARATION
____
Engine O
WORKH
il Pres
EET # 8
-11
Part III: sure
Lesson Pl
________
ans - Fund
________
amentals
________
Of Autom
otive Serv
___ Clas
OBJECTI
icing ■
s ______
000
VE:
________
Upon co
________
mplet
Name___
ion of
an engine
oil pressu this assignmen
engine re
t,
re. This
pair.
task will you will be able
to connec
help prep
t
are you
DIRECTI
to pass th an oil pressure ga
ONS:
e ASE ce
uge to m
rtificatio
easure
Before be
n examin
gi
nn
in
ation in
g th
spaces pr
ovided as is lab assignmen
t, review
you com
plete each
the works
TOOLS
heet com
task.
AND EQ
pletely. Fi
UIP
ll in the in
Safety gl
formatio
asses, fend MENT REQUIR
n in the
ED
er covers
:
,
ha
nd tools,
PROCED
fla
re
U
nut wrenc
Vehicle ye RE:
he
s, oil pres
ar
sure gaug
e, shop to
Make
Repair O
wel
rder #
Model
Engine
1. Locate
#
of Cylin
the oil pr
ders
essure sp
ecificatio
Which m
n in the
anual was
service m
us
ed
an
?
ua
The spec
l and reco
ification
rd the in
was loca
formatio
ted on pa
Minimum
n below.
ge numbe
r
psi at
Maximum
rpm
ps
i
at
2. Open
the hood
rpm
and plac
e fender
Yes
covers on
No
the fend
ers and fro
3. Engine
nt body
tempera
parts.
ture:
Cold
Warm
4. The ve
hicle is eq
uipped w
ith an:
Oil pressu
re gauge
Indicato
r light
5. Check
the oper
ation
the indica
tor light of the oil pressu
re light.
glow?
Turn the
Yes
ignition
No
key on an
d the en
Not equi
gine off.
pped
Does
6. Locate
the send
ing unit
on
the engine
On what
part of th
.
e engine
is it loca
ted?
ASE Lab
Preparat
ion Wor
ksheet
s: Serv
ice
Area 8
Not For Sale
PRELIMS.indd xxiii
xxiii
■ 443
20/12/10 10:03 AM
© Cengage Learning. All rights reserved. No distribution allowed without express authorization.
Not For Sale
PRELIMS.indd xxiv
20/12/10 10:03 AM