Automotive Service, Inspection, Maintenance,
Repair
4th Edition
Tim Gilles
ISBN-10: 1-111-12861-8
ISBN-13: 978-1-111-12861-6
Cover image from Amazon.com
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
Automotive Technology, Principles, Diagnosis,
and Service
5th Edition
James D. Halderman
ISBN-10: 0-13-399461-9
ISBN-13: 978-0-13-399461-2
Chapter 1 – Automotive Background and
Overview – 1
Historical Background – 1
Bodies – 2
Chassis Systems Overview – 2
Frames – 3
Engine Design Evolution – 4
Engine Systems Overview – 5
Powertrain Overview – 5
Electrical/Electronic Systems Overview – 6
Heating, Ventilation, and Air Conditioning
Overview – 6
Eight Areas of Automotive Service – 6
Chapter 2 – Careers in the Automotive Service
Industry – 8
The Need For Automotive Technicians – 8
The Need For Continuous Vehicle Service – 8
Technician Work Sites – 9
Technician Job Classifications – 10
Parts-Related Position – 13
Sales Jobs—Used Vehicles; New Vehicles – 14
Other Careers in the Automotive Industry – 14
Typical Automotive Organization Arrangements –
14
Chapter 3 – Starting a Career in the
Automotive Industry – 16
Preparing for an Automotive Service Career – 16
Developing an Employment Plan – 17
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 – 33
Vise Safety – 33
Puller Safety – 33
Machinery Safety – 33
Electric Drill Safety – 34
Grinder Safety – 34
Wire Wheel Safety – 34
Compressed Air Safety – 34
Preparing a Resume – 18
Preparing a Cover Letter – 19
Contacting Potential Employers – 20
Completing the Employment Application – 20
The Interview – 20
After the Interview – 20
Accepting Employment – 20
Technician Pay Methods – 20
Payroll Deductions – 21
Housing and Living Expenses – 22
Becoming a Shop Owner – 22
Chapter 4 – Working as a Professional Service
Technician – 24
Professionalism – 24
Communications – 24
What Happens the First Day? – 26
Duties of a Service Technician – 27
Flagging a Work Order – 28
Sublet Repairs – 29
Parts Replacement – 29
Working With A Mentor – 30
Teamwork – 31
Goal Setting and Business Meetings – 31
Advancement Skills – 31
Housekeeping Duties – 31
Self-Management – 32
Job Evaluation – 32
Chapter 5 – Technician Certification – 34
Automobile Technician Certification Tests – 34
Questions Often Asked – 36
Test-Taking Tips – 37
Canada’s Automotive Apprenticeship Program
(Red Seal) – 40
Re-Certification – 40
Chapter 6 – Shop Safety – 41
Personal Protective Equipment – 41
Safety Tips For Technicians – 42
Cleaning Methods and Processes – 43
Electrical Cord Safety – 44
Jump-Starting and Battery Safety – 44
Fire Extinguishers – 45
Fire Blankets – 46
First Aid and Eye Wash Stations – 46
Chapter 7 – Environmental and Hazardous
Materials – 48
Hazardous Waste – 48
Federal and State Laws – 48
Asbestos Hazards – 49
Used Brake Fluid – 50
Used Oil – 50
Solvents – 51
Coolant Disposal – 52
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
Lead-Acid Battery Waste – 53
Fuel Safety and Storage – 53
Airbag Handling – 54
Used Tire Disposal – 54
Air-Conditioning Refrigerant Oil Disposal – 54
Chapter 4 – Working as a Professional Service
Technician – 24
Professionalism – 24
Communications – 24
What Happens the First Day? – 26
Duties of a Service Technician – 27
Flagging a Work Order – 28
Sublet Repairs – 29
Parts Replacement – 29
Working With A Mentor – 30
Teamwork – 31
Goal Setting and Business Meetings – 31
Advancement Skills – 31
Housekeeping Duties – 31
Self-Management – 32
Job Evaluation – 32
Chapter 15 – Service Information – 119
Vehicle Service History Records – 120
Owner’s Manuals – 120
Lubrication Guides – 120
Service Manuals – 120
Advantages of Hard Copy Versus Electronic
Service Information – 122
Disadvantages of Hard Copy Versus Electronic
Service Information – 122
Labor Guide Manuals – 122
Electronic Service Information – 122
Hotline Services – 124
Specialty Repair Manual – 124
Aftermarket Supplies Guides and Catalogs – 124
Chapter 16 – Vehicle Identification and
Chapter 6 – Measuring Tools and Systems – 62
Introduction – 62
Metric System – 62
Measuring Tools – 63
Precision Measuring Tools – 64
Emission Ratings – 125
Parts of a Vehicle – 125
Front-Wheel Drive Versus Rear-Wheel Drive –
125
Vehicle Identification – 126
Vehicle Safety Certification Label – 126
VECI Label – 126
Emission Standards in the United States – 127
Calibration Codes – 128
Casting Numbers – 128
Chapter 17 – Preventative Maintenance and
Service Procedures – 130
Preventative Maintenance – 130
Getting Ready for Service – 130
Safety Inspection – 131
Windshield Wiper and Washer Fluid Service – 131
Cabin Filter Replacement – 132
Air Filter Inspection/Replacement – 132
Brake Fluid Inspection – 133
Engine Oil Inspection – 134
Cooling System Inspection – 136
Automatic Transmission Fluid Check – 138
Power Steering Fluid – 139
Accessory Drive Belt Inspection – 139
Tire and Wheel Service – 140
Chassis Lubrication – 143
Differential Fluid Check – 144
Manual Transmission/Transaxle Lubricant Check
– 144
Under-Vehicle Inspection – 145
Chapter 12 – Measuring Systems and Tools –
97
English Customary Measuring System – 97
Metric System of Measure – 98
Linear Measurements (Tape Measure/Rule) – 98
Micrometer – 99
Telescopic Gauge – 100
Small-Hole Gauge – 100
Vernier Dial Caliper – 102
Feeler Gauge – 102
Straightedge – 103
Dial Indicator – 103
Dial Bore Gauge – 103
Depth Micrometer – 103
Chapter 13 – Scientific Principles and Materials
– 105
Scientific Method – 105
Energy Principles – 106
Torque – 106
Work – 106
Power – 107
Horsepower – 107
Chapter 7 – Hardware, Fasteners, Drills, and
Thread Repair – 76
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
Introduction – 93
Tools of the Trade – 93
Hand Tools – 93
Pullers – 104
Air Tools – 106
Special Service Tools – 110
Newton’s Law of Motion – 108
Kinetic Energy – 108
Inertia – 109
Mechanical Principles – 109
Heat and Temperature – 110
Acids and Bases – 111
Gas Laws – 112
Sound and Acoustics – 112
Plastics – 112
Iron and Steel – 113
SAE Steel Designations – 113
Aluminum and Aluminum Alloys – 113
Chapter 14 – Math, Charts, and Calculations –
114
Decimals – 115
Percentage – 115
Scientific Notation – 115
Adding and Subtracting – 115
Fractions – 116
Multiplying and Dividing – 116
Mathematical Formulas – 116
Fuel Economy Calculator – 116
Gear Ratios – 117
Graphs, Charts, and Diagrams – 117
Chapter 8 – Fasteners and Thread Repair – 57
Threaded Fasteners – 58
Metric Bolts – 58
Grades of Bolts – 58
Tensile Strength – 59
Nuts – 60
Taps and Dies – 60
Thread Pitch Gauge – 61
Sheet Metal Screws – 62
Washers – 62
Snap Rings and Clips – 62
How to Avoid Broken Fasteners – 64
Thread Repair Inserts – 64
Chapter 9 – Hand Tools – 68
Wrenches – 68
Ratchets, Sockets, and Extensions – 69
Screwdrivers – 72
Hammers and Mallets – 72
Pliers – 73
Cutters – 75
Punches and Chisels – 75
Removers – 76
Hacksaws – 77
Basic Hand Tool List – 78
Tool Sets and Accessories – 78
Seal Pliers and Drivers – 79
Electrical Hand Tools – 79
Safety Tips For Using Hand Tools – 80
Hand Tool Maintenance – 80
Chapter 10 – Power Tools and Shop Equipment
– 82
Air Compressor – 82
Air and Electrically Operated Tools – 82
Trouble Lights – 84
Bench/Pedestal Grinder – 84
Bench Vise – 85
Hydraulic Presses – 85
Portable Crane and Chain Hoist – 85
Engine Stands – 86
Care and Maintenance of Shop Equipment – 86
Chapter 9 – General Shop Equipment – 112
Chapter 10 – Power Tools and Shop Equipment
Shop Equipment – 112
– 82
Hydraulic Equipment – 112
Air Compressor – 82
Shop Electric Machinery – 117
Air and Electrically Operated Tools – 82
Other Electric Equipment – 120
Trouble Lights – 84
Other Shop Equipment – 120
Bench/Pedestal Grinder – 84
Bench Vise – 85
Hydraulic Presses – 85
Portable Crane and Chain Hoist – 85
Engine Stands – 86
Care and Maintenance of Shop Equipment – 86
Chapter 10 – Cleaning Equipment and Methods Chapter 29 – Engine Cleaning and Crack
– 124
Detection – 272
Introduction – 124
Introduction – 272
General Shop Housekeeping Practices – 124
Mechanical Cleaning – 272
Cleaning Methods – 125
Chemical Cleaners – 273
Cleaning the Outside of the Engine – 126
Spray and Steam Washing – 274
Environmental Concerns with Engine Cleaning –
Thermal Cleaning – 274
126
Tank and Vapor Cleaning – 275
Cleaning Internal Parts – 126
Ultrasonic and Vibratory Cleaning – 275
Chemical Cleaning – 127
Crack Detection – 276
Thermal Cleaning – 134
Crack Repair – 276
Vibratory Parts Cleaners – 135
Other Cleaning Methods – 135
Marking Clean Parts – 135
Chapter 11 – Lifting Equipment and Air
Chapter 11 – Vehicle Lifting and Hoisting – 91
Compressors – 137
Floor Jack – 91
Introduction – 137
Creepers – 92
Lift Types – 137
Vehicle Hoists – 92
Frame-Contact Lifts – 138
Drive-On Ramps – 94
Wheel-Contact Lifts – 139
Wheel-Free Jacks – 140
In-Ground Lifts – 140
Surface Mount Lifts – 142
Lift Safety – 143
Air Compressors – 144
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 22 – Engine Oil – 198
Introduction – 198
Properties of Engine Oil – 198
SAE Rating – 199
API Rating – 199
ILSAC Oil Rating – 200
European Oil Rating System – 200
Japanese Oil Ratings – 201
Engine Oil Additives – 201
Oil Brand Compatibility – 202
Synthetic Oil – 202
Vehicle-Specific Specifications – 203
High Mileage Oils – 204
Oil Filters – 204
Oil Change – 204
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
Chapter 17 – Preventative Maintenance and
Service Procedures – 130
Preventative Maintenance – 130
Getting Ready for Service – 130
Safety Inspection – 131
Windshield Wiper and Washer Fluid Service – 131
Cabin Filter Replacement – 132
Air Filter Inspection/Replacement – 132
Brake Fluid Inspection – 133
Engine Oil Inspection – 134
Cooling System Inspection – 136
Automatic Transmission Fluid Check – 138
Power Steering Fluid – 139
Accessory Drive Belt Inspection – 139
Tire and Wheel Service – 140
Chassis Lubrication – 143
Differential Fluid Check – 144
Manual Transmission/Transaxle Lubricant Check
– 144
Under-Vehicle Inspection – 145
Chapter 17 – Preventative Maintenance and
Service Procedures – 130
Preventative Maintenance – 130
Getting Ready for Service – 130
Safety Inspection – 131
Windshield Wiper and Washer Fluid Service – 131
Cabin Filter Replacement – 132
Air Filter Inspection/Replacement – 132
Brake Fluid Inspection – 133
Engine Oil Inspection – 134
Cooling System Inspection – 136
Automatic Transmission Fluid Check – 138
Power Steering Fluid – 139
Accessory Drive Belt Inspection – 139
Tire and Wheel Service – 140
Chassis Lubrication – 143
Chapter 14 – Undercar Inspection and Service
– 180
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
Differential Fluid Check – 144
Manual Transmission/Transaxle Lubricant Check
– 144
Under-Vehicle Inspection – 145
Chapter 24 – Intake and Exhaust Systems – 219
Air Intake Filtration – 219
Throttle-Body Injection Intake Manifolds – 221
Port Fuel-Injection Intake Manifolds – 222
Exhaust Gas Recirculation Passages – 223
Exhaust Manifolds – 224
Mufflers – 225
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
Chapter 18 – Gasoline Engine Operation, Parts,
and Specifications – 146
Purpose and Function – 147
Energy and Power – 147
Engine Construction Overview – 147
Engine Parts and Systems – 147
Four-Stroke Cycle Operation – 149
Engine Classification and Construction – 149
Engine Measurement – 152
Compression Ratio – 155
Torque and Horsepower – 157
Chapter 89 – Introduction to Hybrid Vehicles –
983
Hybrid Vehicles – 983
Electric Vehicles – 983
Driving and Owning a Hybrid Electric Vehicle –
984
Classifications of Hybrid Electric Vehicles – 985
Belt Alternator Starter Systems – 987
Common Features of Most Hybrids – 989
Levels of Hybrid Vehicles – 989
Chapter 90 – Hybrid Safety and Service
Procedures – 991
High-Voltage Safety – 991
High-Voltage Safety Equipment – 992
Electric Shock Potential – 993
De-Powering the High-Voltage System – 995
Collision and Repair Industry Issues – 995
Moving and Towing a Hybrid – 996
Removing the High-Voltage Batteries – 996
Routine Service Procedures – 997
Chapter 91 – Fuel Cells and Advanced
Technologies – 1002
Fuel-Cell Technology – 1003
PEM Fuel Cells – 1004
Fuel-Cell Vehicle Systems – 1006
Hydraulic Hybrid Storage System – 1010
HCCI – 1011
Plug-In Hybrid Electric Vehicles – 1011
The Future For Electric Vehicles – 1012
Wind Power – 1013
Hydroelectric Power – 1013
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
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 18 – Gasoline Engine Operation, Parts,
and Specifications – 146
Purpose and Function – 147
Energy and Power – 147
Engine Construction Overview – 147
Engine Parts and Systems – 147
Four-Stroke Cycle Operation – 149
Engine Classification and Construction – 149
Engine Measurement – 152
Compression Ratio – 155
Torque and Horsepower – 157
Chapter 30 – Cylinder Head and Valve Guide
Service – 280
Introduction – 280
Cylinder Heads – 280
Intake and Exhaust Ports – 283
Cylinder Head Passages – 284
Cylinder Head Servicing – 285
Aluminum Cylinder Head Straightening – 286
Cylinder Head Resurfacing – 287
Intake Manifold Alignment – 288
Valve Guides – 289
Valve Guide Replacement – 291
Chapter 31 – Valve and Valve Seat Service –
293
Intake and Exhaust Valves – 294
Valve Seats – 296
Valve Fault Diagnosis – 296
Valve Springs – 297
Valve Keepers and Rotators – 299
Valve Reconditioning Procedure – 300
Valve Face Grinding – 300
Valve Seat Reconditioning – 301
Valve Guide Pilots – 303
Valve Seat Grinding Stones – 304
Valve Seat Cutters – 305
Valve Seat Testing – 305
Valve Seat Replacement – 306
Valve Stem Height – 307
Installed Height – 307
Valve Stem Seals – 308
Installing the Valves – 310
Chapter 32 – Camshafts and Valve Trains – 314
Camshaft – 315
Camshaft Design – 315
Camshaft Drives – 317
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
Camshaft Movement – 319
Rocker Arms – 320
Pushrods – 322
Overhead Camshaft Valve Trains – 323
Camshaft Specifications – 323
Lifters or Tappets – 326
Valve Train Lubrication – 327
Valve Train Problem Diagnosis – 328
Camshaft Removal – 328
Measuring Camshafts – 329
Selecting a Camshaft – 329
Variable Valve Timing – 330
Variable Lift and Cylinder Deactivation Systems –
334
Chapter 23 – Lubrication System Operation
and Diagnosis – 210
Introduction – 211
Lubrication Principles – 211
Engine Lubrication Systems – 211
Oil Pumps – 212
Oil Passages – 215
Oil Pans – 217
Dry Sump Systems – 217
Oil Coolers – 218
Chapter 28 – Engine Removal and Disassembly
– 261
Engine Repair Options – 262
Engine Removal – 263
Engine Disassembly – 264
Disassembly of the Short Block – 266
Rotating Engine Assemblies Removal – 267
Cylinder Head Disassembly – 267
Chapter 33 – Pistons, Rings, and Connecting
Rods – 336
Pistons – 337
Piston Construction – 337
Piston Pins – 340
Piston Pin Retaining Methods – 341
Piston Rings – 342
Piston Ring Construction – 344
Connecting Rods – 345
Connecting Rod Service – 347
Piston and Rod Assembly – 348
Piston Ring Service – 349
Chapter 34 - Engine Blocks – 351
Engine Blocks – 351
Engine Block Service – 356
Block Preparation For Assembly – 362
Chapter 35 - Crankshafts, Balance Shafts, and
Bearings – 364
Crankshaft – 365
Crankshaft Construction – 366
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
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
Crankshaft Oiling Holes – 367
Engine Crankshaft Types – 367
Counterweights – 369
Externally and Internally Balanced Engines – 369
Engine Balance – 370
Balance Shafts – 371
Crankshaft Service – 372
Engine Bearings – 374
Bearing Clearance – 377
Camshaft Bearings – 379
Chapter 38 - Engine Installation and Break-In –
415
Preinstallation Checklist – 415
Transmission Installation – 415
Dressing the Engine – 417
Engine Installation – 417
Engine Start – 418
Break-In Precautions – 419
Chapter 20 – Coolant – 175
Types of Coolant – 176
Water – 178
Coolant Freezing/Boiling Temperatures – 178
Coolant Testing – 179
Coolant Replacement Issues – 181
Chapter 21 – Cooling System Operation and
Diagnosis – 182
Cooling System – 182
Cooling System Operation – 183
Thermostats – 183
Radiators – 186
Pressure Caps – 187
Coolant Recovery Systems – 188
Water Pumps – 189
Coolant Flow in the Engine – 190
Cooling Fans – 191
Heater Cores – 192
Cooling System Testing – 192
Coolant Temperature Warning Light – 194
Cooling System Inspection – 194
Cooling System Service – 195
Chapter 20 – Coolant – 175
Types of Coolant – 176
Water – 178
Coolant Freezing/Boiling Temperatures – 178
Coolant Testing – 179
Coolant Replacement Issues – 181
Chapter 21 – Cooling System Operation and
Diagnosis – 182
Cooling System – 182
Cooling System Operation – 183
Thermostats – 183
Radiators – 186
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
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
Pressure Caps – 187
Coolant Recovery Systems – 188
Water Pumps – 189
Coolant Flow in the Engine – 190
Cooling Fans – 191
Heater Cores – 192
Cooling System Testing – 192
Coolant Temperature Warning Light – 194
Cooling System Inspection – 194
Cooling System Service – 195
Chapter 27 – In-Vehicle Engine Service – 252
Thermostat Replacement – 253
Water Pump Replacement – 253
Intake Manifold Gasket Inspection – 254
Intake Manifold Gasket Replacement – 254
Timing Belt Replacement – 255
Hybrid Engine Precautions – 255
N/A
N/A
Chapter 39 – Electrical Fundamentals – 420
Introduction – 420
Electricity – 421
How Electrons Move Through a Conductor – 423
Units of Electricity – 424
Sources of Electricity – 425
Conductors and Resistance – 426
Magnetic Fields – 366
Capacitors – 368
Automotive Electronics – 368
Basic Electrical Tests – 369
Resistors – 427
Chapter 40 – Electrical Circuits and Ohm’s
Law – 428
Circuits – 428
Circuit Fault Types – 429
Ohm’s Law – 431
Watt’s Law – 432
Chapter 41 – Series, Parallel, and SeriesParallel Circuits – 434
Series Circuits – 434
Ohm’s Law and Series Circuits – 434
Kirchhoff’s Voltage Law – 435
Series Circuit Laws – 436
Series Circuit Examples – 437
Parallel Circuits – 438
Kirchhoff’s Current Law – 438
Parallel Circuit Laws – 438
Determining Total Resistance in a Parallel Circuit
– 438
Parallel Circuit Examples – 440
Series-Parallel Circuits – 441
Solving Series-Parallel Circuit Problems – 442
Series-Parallel Circuit Examples – 442
Chapter 42 – Circuit Testers and Digital Meters
– 444
Fused Jumper Wire – 444
Test Lights – 445
Logic Probe – 446
Digital Multimeters – 446
Inductive Ammeters – 450
Diode Check, Pulse Width, and Frequency – 450
Electrical Unit Prefixes – 451
How To Read Digital Meters – 452
Chapter 43 – Oscilloscopes and Graphing
Multimeters – 460
Types of Oscilloscopes – 461
Scope Setup and Adjustment – 462
DC and AC Coupling – 462
Pulse Trains – 463
Number of Channels – 464
Triggers – 464
Using a Scope – 465
Graphing Multimeter – 466
Graphing Scan Tools – 466
Chapter 46 – Capacitance and Capacitors – 493
Capacitance – 493
Capacitor Construction and Operation – 494
Factors of Capacitance – 495
Uses For Capacitance – 495
Capacitors in Circuits – 496
Chapter 47 – Magnetism and Electromagnetism
– 498
Chapter 26 – Battery Fundamentals – 378
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
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
Fundamentals of Magnetism – 498
Electromagnetism – 500
Uses of Electromagnetism – 502
Electromagnetic Induction – 504
Ignition Coils – 504
Electromagnetic Interference – 506
Chapter 48 – Electronic Fundamentals – 509
Semiconductors – 509
Summary of Semiconductors – 510
Diodes – 510
Zener Diodes – 511
High-Voltage Spike Protection – 512
Diode Ratings – 513
Light-Emitting Diodes – 513
Photodiodes – 514
Photoresistors – 514
Silicon-Controlled Rectifiers – 515
Thermistors – 515
Rectifier Bridges – 515
Transistors – 516
Field-Effect Transistors – 517
Phototransistor – 518
Integrated Circuits – 518
Transistor Gates – 518
Operational Amplifiers – 519
Electronic Component Failure Causes – 519
How to Test Diodes and Transistors – 520
Converters and Inverters – 521
Electrostatic Discharge – 523
Chapter 50 – Batteries – 538
Introduction – 538
Battery Construction – 538
How a Battery Works – 540
Specific Gravity – 540
Valve Regulated Lead-Acid Batteries – 542
Causes and Types of Battery Failure – 542
Battery Ratings – 542
Battery Sizes – 543
Chapter 51 – Battery Testing and Service – 544
Battery Service Safety Considerations – 545
Symptoms of a Weak or Defective Battery – 545
Battery Maintenance – 545
Battery Voltage Test – 546
Hydrometer Testing – 547
Battery Load Testing – 547
Electric Conductance Testing – 548
Battery Charging – 549
Battery Capacity Tests – 406
Battery Drain Test/Parasitic Load – 408
Battery Jump-Starting – 409
Hybrid Battery Service – 410
Battery Charge Time – 550
Jump Starting – 550
Battery Electrical Drain Test – 552
Battery Symptom Guide – 555
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
Chapter 52 – Cranking System – 556
Cranking Circuit – 556
Computer-Controlled Starting – 557
Starter Motor Operation – 558
How the Starter Motor Works – 560
Gear-Reduction Starters – 561
Starter Drives – 562
Positive Engagement Starters – 564
Solenoid-Operated Starters – 564
Chapter 53 – Cranking System Diagnosis and
Service – 566
Starting System Troubleshooting Procedure – 566
Voltage Drop Testing – 566
Control Circuit Testing – 568
Starter Amperage Test – 569
Starter Removal – 569
Starter Motor Service – 570
Bench Testing – 571
Starter Installation – 571
Starter Drive-To-Flywheel Clearance – 571
Starting System Symptom Guide – 572
Chapter 54 – Charging System – 577
Principles of Alternator Operation – 578
Alternator Construction – 578
Alternator Overrunning Pulleys – 578
Alternator Components and Operation – 579
How an Alternator Works – 581
Alternator Output Factors – 583
Alternator Voltage Regulation – 583
Alternator Cooling – 585
Computer-Controlled Alternators – 585
Chapter 55 – Charging System Diagnosis and
Service – 587
Charging System Testing and Service – 588
Drive Belt Inspection and Adjustment – 589
AC Ripple Voltage Check – 590
Testing AC Ripple Current – 590
Charging System Voltage Drop Testing – 591
Alternator Output Test – 592
Minimum Required Alternator Output – 593
Alternator Removal – 593
Alternator Disassembly – 594
Testing the Rectifier – 596
Reassembling the Alternator – 596
Remanufactured Alternators – 597
Alternator Installation – 597
Chapter 32 – Lighting and Wiring
Fundamentals – 458
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 44 – Automotive Wiring and Wire
Repair – 467
Automotive Wiring – 467
Ground Wires – 468
Battery Cables – 469
Jumper Cables – 469
Fuses and Circuit Protection Devices – 469
Terminals and Connectors – 474
Wire Repair – 475
Electrical Conduit – 477
Chapter 45 – Wiring Schematics and Circuit
Testing – 479
Wiring Schematics and Symbols – 479
Schematic Symbols – 480
Relay Terminal Identification – 485
Locating an Open Circuit – 486
Common Power or Ground – 487
Circuit Troubleshooting Procedure – 488
Locating a Short Circuit – 489
Electrical Troubleshooting Guide – 491
Step-By-Step Troubleshooting Procedure – 492
Chapter 58 – Horn, Wiper, and Blower Motor
Circuits – 646
Horns – 646
Windshield Wiper and Washer System – 648
Rain Sense Wiper System – 653
Blower Motor – 654
Electrical Accessory Symptom Guide – 656
Chapter 33 – Lighting and Wiring Service – 480 Chapter 44 – Automotive Wiring and Wire
Analyzing Electrical Problems – 480
Repair – 467
Wiring Service – 480
Automotive Wiring – 467
Crimp Terminals – 482
Ground Wires – 468
Selecting Replacement Wire – 484
Battery Cables – 469
Adding Electrical Accessories – 484
Jumper Cables – 469
Soldering – 486
Fuses and Circuit Protection Devices – 469
Broken or Damaged Ground Straps – 488
Terminals and Connectors – 474
Circuit Testing and Service – 489
Wire Repair – 475
Finding Grounds – 489
Electrical Conduit – 477
Fuse Testing and Service – 489
Chapter 56 – Lighting and Signaling Service –
Fuse Link Service – 490
604
Headlamp Service – 490
Introduction – 605
Headlamp Aiming – 492
Exterior Lighting – 605
Tail Lamp and Park Light Service – 495
Bulb Numbers – 605
LED Service – 496
Brake Lights – 608
Turn Signal Switch – 497
Turn Signals – 610
Signal Flasher/Relay – 497
Headlights – 611
Locating a Signal Flasher – 498
High-Intensity Discharge Headlights – 614
Instrument Panel Bulbs – 498
LED Headlights – 615
Windshield Washer Service – 498
Headlight Aiming – 615
Horn Service – 499
Adaptive Front Lighting System – 616
Gauge Testing – 499
Daytime Running Lights – 617
Dimmer Switches – 617
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
Courtesy Lights – 617
Illuminated Entry – 617
Fiber Optics – 617
Automatic Dimming Mirrors – 617
Feedback – 620
Lighting System Diagnosis – 620
Lighting System Symptom Guide – 620
Chapter 57 – Driver Information and
Navigation Service – 625
Dash Warning Symbols – 625
Oil Pressure Warning Devices – 628
Temperature Lamp Diagnosis – 628
Brake Warning Lamp – 628
Analog Dash Instruments – 629
Network Communication – 629
Stepper Motor Analog Gauges – 629
Head-Up Display – 630
Night Vision – 632
Digital Electronic Display Operation – 633
Electronic Speedometers – 635
Electronic Odometers – 636
Electronic Fuel Level Gauges – 637
Navigation and GPS – 637
Onstar – 639
Backup Camera – 640
Backup Sensors – 641
Lane Departure Warning System – 641
Electronic Dash Instrument Diagnosis and
Troubleshooting – 642
Maintenance Reminder Lamps – 642
Chapter 59 – Accessory Circuits – 657
Cruise Control – 658
Troubleshooting Cruise Control – 659
Electronic Throttle Cruise Control – 659
Radar Cruise Control – 659
Precollision System – 662
Heated Rear Window Defoggers – 662
Heated Mirrors – 663
Homelink Garage Door Opener – 664
Power Windows – 664
Power Seats – 666
Electrically Heated Seats – 668
Heated and Cooled Seats – 669
Heated Steering Wheel – 669
Adjustable Pedals – 670
Outside Folding Mirrors – 670
Electric Power Door Locks – 671
Keyless Entry – 671
Antitheft Systems – 678
Electrical Accessory Symptom Guide – 683
Chapter 60 – Airbags and Pretensioner Circuits
– 686
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
Air-Conditioning Principles – 545
Heat Transfer – 545
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
Safety Belts and Retractors – 687
Front Airbags – 687
Airbag Diagnosis Tools and Equipment – 691
Airbag System Service – 693
Driver Side Airbag Module Replacement – 694
Safety When Manually Deploying Airbags – 695
Occupant Detection Systems – 695
Seat and Side Curtain Airbags – 696
Event Data Recorders – 697
Chapter 61 – Audio System Operation and
Diagnosis – 698
Audio Fundamentals – 699
Radios and Receivers – 700
Antennas – 700
Antenna Diagnosis – 701
Speakers – 702
Speaker Types – 704
Sound Levels – 704
Crossovers – 704
Aftermarket Sound System Upgrade – 705
Voice Recognition – 706
Bluetooth – 707
Satellite Radio – 707
Radio Interference – 708
Chapter 62 – Heating and Air-Conditioning
Components and Operation – 712
Purpose and Function – 712
Heating System – 714
Air-Conditioning Refrigeration Cycle – 715
Expansion Valve Systems – 715
Orifice Tube Systems – 716
Thermostatic Control – 716
Refrigerants – 718
Refrigerants and the Environment – 719
Refrigerant Oils – 720
Condenser – 720
Evaporator – 720
Receiver-Drier – 721
Accumulator – 722
Refrigerant Lines and Hoses – 723
Thermostatic Expansion Valves – 723
Fixed-Orifice Tubes – 725
Compressors – 725
Compressor Controls – 729
Chapter 63 – Automatic Air-Conditioning
System Operation – 731
Airflow Management – 731
Automatic Air Conditioning – 732
Actuators – 732
Cabin Filters – 732
Vacuum Control Circuits – 733
Electric Servomotor Circuits – 733
Temperature and Pressure – 564
Chapter 36 – Heating and Air-Conditioning
Service – 567
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 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
Ignition System Service and Repairs – 621
Spark Plug Service – 621
Spark Plug Diagnosis – 622
Installing Spark Plugs – 624
Blower Motor Control – 734
Dual-Zone Climate Controls – 734
Rear Air-Conditioning System – 735
Recirculation Operation – 735
Hybrid Electric Vehicle Heating and Cooling
Systems – 736
Chapter 64 – Heating and Air-Conditioning
System Diagnosis – 737
HVAC Diagnostic Procedure – 737
Heater Diagnosis – 737
Check A/C System Performance – 740
Temperature and Pressure Measurements – 740
Chapter 65 – Heating and Air-Conditioning
Service – 745
Blower Motor Service – 746
Cooling System Service – 746
Refrigerant Recovery Process – 746
Evacuation Procedures – 748
Noncondensable Gases – 748
Refrigerant Recycling – 749
Recharging a System – 750
Retrofitting a CFC-12 System To a HFC-134A
System – 751
Compressor Service – 751
Condenser Service – 751
Evaporator Service – 751
Receiver/Drier or Accumulator/Drier Service –
752
Orifice Tube/Expansion Valve Service – 753
Chapter 69 – Ignition System Components and
Operation – 781
Ignition System – 782
Ignition Switching and Triggering – 783
Distributor Ignition – 785
Waste-Spark Ignition Systems – 787
Coil-On-Plug Ignition – 788
Knock Sensors – 791
Ignition Control Circuits – 793
Chapter 70 - Ignition System Diagnosis and
Service – 794
Checking for Spark – 794
Ignition Coil Testing – 795
Ignition Sensor Testing – 796
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 39 – Petroleum Fuels and Alternative
Fuel Technologies – 642
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
Spark Plug Wire Inspection – 799
Spark Plugs – 801
Ignition Timing – 804
Firing Order – 805
Distributor Indexing – 805
No-Start Diagnosis – 806
Ignition Scope Testing – 807
Scope-Testing a Waste-Spark System – 811
Scope-Testing a COP System – 811
Ignition System Symptom Guide – 811
Chapter 19 – Diesel Engine Operation and
Diagnosis – 158
Diesel Engines – 158
Three Phases of Combustion – 161
Fuel Tank and Lift Pump – 161
Injection Pump – 161
Heui System – 162
Diesel Injector Nozzles – 164
Glow Plugs – 164
Engine-Driven Vacuum Pump – 166
Diesel Fuel Heaters – 166
Accelerator Pedal Position Sensor – 166
Diesel Engine Turbochargers – 166
Exhaust Gas Recirculation – 167
Diesel Particulate Matter – 168
Diesel Oxidation Catalyst – 168
Diesel Exhaust Particulate Filter – 169
Selective Catalytic Reduction – 170
Diesel Exhaust Smoke Diagnosis – 171
Diesel Performance Diagnosis – 172
Compression Testing – 173
Glow Plug Resistance Balance Test – 173
Injector Pop Testing – 173
Diesel Emission Testing – 174
Chapter 66 – Gasoline – 754
Gasoline – 754
Refining – 755
Volatility – 756
Gasoline Combustion Process – 757
Normal and Abnormal Combustion – 758
Octane Rating – 759
High-Altitude Octane Requirements – 759
Gasoline Additives – 760
Gasoline Blending – 761
Reformulated Gasoline – 762
Testing Gasoline For Alcohol Content – 762
General Gasoline Recommendations – 763
Chapter 67 – Alternative Fuels – 766
Ethanol – 767
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
Cellulose Ethanol – 767
E85 – 768
Alternative-Fuel Vehicles – 768
Methanol – 771
Propane – 772
Compressed Natural Gas – 772
Liquefied Natural Gas – 774
P-Series Fuels – 774
Synthetic Fuels – 774
Safety Precautions When Working with
Alternative Fuels – 776
Chapter 68 – Diesel and Biodiesel Fuels – 777
Diesel Fuel – 777
Biodiesel – 779
E-Diesel Fuel – 780
Chapter 77 – Fuel Pumps, Lines, and Filters –
860
Fuel Delivery System – 860
Fuel Tanks – 860
Rollover Leakage Protection – 862
Fuel Lines – 862
Electric Fuel Pumps – 864
Fuel Filters – 869
Fuel-Pump Testing – 870
Fuel-Pump Current Draw Test – 873
Fuel-Pump Placement – 874
Chapter 78 – Fuel-Injection Components and
Operation – 875
Electronic Fuel-Injection Operation – 875
Speed-Density Fuel-Injection Systems – 876
Mass Airflow Fuel-Injection Systems – 877
Throttle-Body Injection – 877
Port-Fuel Injection – 878
Fuel-Pressure Regulator – 879
Vacuum-Biased Fuel-Pressure Regulator – 880
Electronic Returnless Fuel System – 881
Mechanical Returnless Fuel System – 881
Demand Delivery System (DDS) – 881
Fuel Injectors – 883
Central Port Injection – 883
Fuel-Injection Modes of Operation – 884
Idle Control – 885
Stepper Motor Operation – 885
Chapter 79 – Gasoline Direct-Injection Systems
– 887
Direct Fuel Injection – 887
Direct-Injection Fuel Delivery System – 887
Gasoline Direct-Injection Fuel Injectors – 889
Modes of Operation – 889
Piston Top Designs – 890
Lexus Port- and Direct-Injection Systems – 890
Engine Start Systems – 891
Chapter 41 – Fuel System Service – 683
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 Sensors – 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
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
Gasoline Direct-Injection Service – 891
Chapter 80 – Electronic Throttle Control
System – 892
Electronic Throttle Control (ETC) System – 893
Normal Operation of the ETC System – 893
Accelerator Pedal Position Sensor – 893
Throttle Body Assembly – 894
Throttle Position (TP) Sensor – 895
Diagnosis of Electronic Throttle Control Systems
– 896
ETC Throttle Follower Test – 898
Servicing Electronic Throttle Systems – 898
Chapter 81 – Fuel-Injection System Diagnosis
and Service – 900
Port Fuel-Injection Pressure Regulator Diagnosis –
900
Diagnosing Electronic Fuel-Injection Problems
Using Visual Inspection – 901
Scan Tool Vacuum Leak Diagnosis – 902
Port Fuel-Injection System Diagnosis – 902
Testing For an Injector Pulse – 903
Checking Fuel-Injector Resistance – 904
Measuring Resistance of Grouped Injectors – 905
Measuring Resistance of Individual Injectors – 905
Pressure-Drop Balance Test – 905
Injector Voltage-Drop Tests – 907
Scope-Testing Fuel Injectors – 907
Idle Air Speed Control Diagnosis – 908
Fuel-Injection Service – 908
Fuel-System Scan Tool Diagnostics – 912
Chapter 24 – Intake and Exhaust Systems – 219
Air Intake Filtration – 219
Throttle-Body Injection Intake Manifolds – 221
Port Fuel-Injection Intake Manifolds – 222
Exhaust Gas Recirculation Passages – 223
Exhaust Manifolds – 224
Mufflers – 225
Chapter 25 – Turbocharging and
Supercharging – 227
Introduction – 228
Forced Induction Principles – 228
Superchargers – 230
Turbochargers – 230
Boost Control – 232
Turbocharger Failures – 234
Nitrous Oxide – 235
Chapter 43 – Emission Control System
Fundamentals – 727
Introduction – 727
Air Pollution – 727
Automotive Emissions – 727
Pollution Control – 729
Automotive 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
Chapter 82 – Vehicle Emission Standards and
Testing – 918
Emission Standards in the United States – 919
European Standards – 919
Exhaust Analysis Testing – 920
Exhaust Analysis and Combustion Efficiency –
923
HC Too High – 924
CO Too High – 924
Measuring Oxygen (O2) and Carbon Dioxide
(CO2) – 925
Photochemical Smog Formation – 925
Testing for Oxides of Nitrogen – 926
Chapter 83 – Evaporative Emission Control
Systems – 927
Evaporative Emission Control System – 928
Nonenhanced Evaporative Control Systems – 929
Enhanced Evaporative Control System – 930
Leak Detection Pump System – 931
Onboard Refueling Vapor Recovery – 931
Diagnosing the EVAP System – 931
Evaporative System Monitor – 932
Typical EVAP Monitor – 933
EVAP System-Related Diagnostic Trouble Codes
– 934
Chapter 84 – Exhaust Gas Recirculation
Systems – 935
Exhaust Gas Recirculation Systems – 936
OBD-II EGR Monitoring Strategies – 938
Diagnosing a Defective EGR System – 940
EGR-Related OBD-II Diagnostic Trouble Codes –
941
Chapter 85 – Positive Crankcase Ventilation
and Secondary Air-Injection Systems – 942
Crankcase Ventilation – 942
PCV-Related Diagnostic Trouble Codes – 945
Secondary Air-Injection System – 945
Secondary Air-Injection System Diagnosis – 947
SAI-Related Diagnostic Trouble Codes – 947
Chapter 86 – Catalytic Converters – 948
Catalytic Converters – 949
OBD-II Catalytic Converter Performance – 950
Diagnosing Catalytic Converters – 952
Catalytic Converter Replacement Guidelines – 954
Chapter 82 – Vehicle Emission Standards and
Testing – 918
Emission Standards in the United States – 919
European Standards – 919
Exhaust Analysis Testing – 920
Exhaust Analysis and Combustion Efficiency –
923
HC Too High – 924
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 – 758
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
CO Too High – 924
Measuring Oxygen (O2) and Carbon Dioxide
(CO2) – 925
Photochemical Smog Formation – 925
Testing for Oxides of Nitrogen – 926
Chapter 83 – Evaporative Emission Control
Systems – 927
Evaporative Emission Control System – 928
Nonenhanced Evaporative Control Systems – 929
Enhanced Evaporative Control System – 930
Leak Detection Pump System – 931
Onboard Refueling Vapor Recovery – 931
Diagnosing the EVAP System – 931
Evaporative System Monitor – 932
Typical EVAP Monitor – 933
EVAP System-Related Diagnostic Trouble Codes
– 934
Chapter 84 – Exhaust Gas Recirculation
Systems – 935
Exhaust Gas Recirculation Systems – 936
OBD-II EGR Monitoring Strategies – 938
Diagnosing a Defective EGR System – 940
EGR-Related OBD-II Diagnostic Trouble Codes –
941
Chapter 85 – Positive Crankcase Ventilation
and Secondary Air-Injection Systems – 942
Crankcase Ventilation – 942
PCV-Related Diagnostic Trouble Codes – 945
Secondary Air-Injection System – 945
Secondary Air-Injection System Diagnosis – 947
SAI-Related Diagnostic Trouble Codes – 947
Chapter 86 – Catalytic Converters – 948
Catalytic Converters – 949
OBD-II Catalytic Converter Performance – 950
Diagnosing Catalytic Converters – 952
Catalytic Converter Replacement Guidelines – 954
Chapter 71 – Computer Fundamentals – 812
Computer Fundamentals – 812
Computer Functions – 813
Digital Computers – 814
Computer Input Sensors – 816
Computer Outputs – 816
Voltage Dividers – 777
Piezoelectric and Piezoresistive Sensors – 778
Heated Resistive Sensors – 778
Variable DC Frequency Sensors – 778
Voltage Generators – 778
Wheatstone Bridges – 779
Switches – 779
Types of Actuation – 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
Chapter 72 – Temperature Sensors – 819
Engine Coolant Temperature Sensors – 819
Testing the Engine Coolant Temperature Sensor –
820
Intake Air Temperature Sensor – 823
Testing the Intake Air Temperature Sensor – 825
Transmission Fluid Temperature Sensor – 825
Cylinder Head Temperature Sensor – 826
Engine Fuel Temperature (EFT) Sensor – 826
Exhaust Gas Recirculation (EGR) Temperature
Sensor – 826
Engine Oil Temperature Sensor – 827
Temperature Sensor Diagnostic Trouble Codes –
827
Chapter 73 – Throttle Position (TP) Sensors –
828
Throttle Position Sensor Construction – 828
TP Sensor Computer Input Functions – 829
PCM Uses For the TP Sensor – 829
Testing the Throttle Position Sensor – 830
TP Sensor Diagnostic Trouble Codes – 831
Chapter 74 – MAP/BARO Sensors – 832
Air Pressure—High and Low – 833
Principles of Pressure Sensors – 833
Construction of Manifold Absolute Pressure
(MAP) Sensors – 834
PCM Uses of the MAP Sensor – 835
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 OnBoard Diagnostics (OBD) – 827
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
Barometric Pressure Sensors – 837
Testing the MAP Sensor – 837
Fuel-Rail Pressure Sensor – 838
MAP/BARO Diagnostic Trouble Codes – 838
Chapter 75 – Mass Airflow Sensors – 840
Airflow Sensors – 840
Mass Airflow Sensor Types – 840
Karman Vortex Sensors – 841
PCM Uses For Airflow Sensors – 842
Testing Mass Airflow Sensors – 842
MAF Sensor Contamination – 844
MAF-Related Diagnostic Trouble Codes – 844
Chapter 76 – Oxygen Sensors – 845
Oxygen Sensors – 846
Titania Oxygen Sensor – 848
PCM Uses of the Oxygen Sensor – 849
Oxygen Sensor Diagnosis – 850
Post Catalytic Converter Oxygen Sensor Testing –
853
Wide-Band Oxygen Sensor – 853
Dual Cell Planar Wide-Band Sensor Operation –
855
Dual Cell Diagnosis – 856
Single Cell Wide-Band Oxygen Sensors – 857
Wide-Band Oxygen Pattern Failures – 858
Oxygen Sensor-Related Diagnostic Trouble Codes
– 859
Chapter 49 – CAN and Network
Communications – 524
Module Communications and Networks – 524
Network Fundamentals – 524
Module Communications Configuration – 525
Network Communications Classifications – 526
General Motors Communications Protocols – 527
Ford Network Communications Protocols – 529
Chrysler Communications Protocols – 530
Controller Area Network – 530
Honda/Toyota Communications – 532
European BUS Communications – 532
Network Communications Diagnosis – 534
OBD-II Data Link Connector – 536
Chapter 87 – On-Board Diagnosis – 957
On-Board Diagnostics Generation-II (OBD-II)
Systems – 958
Diagnostic Executive and Task Manager – 958
Monitors – 959
OBD-II Monitor Information – 959
Enabling Criteria – 960
OBD-II DTC Numbering Designation – 961
OBD-II Freeze-Frame – 962
Enabling Conditions – 962
PCM Tests – 963
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 Problems – 849
Cylinder Leakage Test – 851
Carbon-Related Problems – 852
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
Global OBD-II – 964
Diagnosing Problems Using Mode Six – 964
Chapter 88 – Scan Tools and Engine
Performance Diagnosis – 965
The Eight-Step Diagnostic Procedure – 966
Scan Tools – 971
Retrieval of Diagnostic Information – 971
Troubleshooting Using Diagnostic Trouble Codes
– 972
Flash Code Retrieval On OBD-I General Motors
Vehicles – 973
Retrieving Ford Diagnostic Codes – 973
Flash Code Retrieval On Chrysler Vehicles – 975
OBD-II Diagnosis – 975
OBD-II Active Tests – 977
Service/Flash Programming – 978
Manufacturer’s Diagnostic Routines – 980
Completing System Repairs – 980
Procedures For Resetting the PCM – 981
Road Test (Drive Cycle – 981
Chapter 88 – Scan Tools and Engine
Performance Diagnosis – 965
The Eight-Step Diagnostic Procedure – 966
Scan Tools – 971
Retrieval of Diagnostic Information – 971
Troubleshooting Using Diagnostic Trouble Codes
– 972
Flash Code Retrieval On OBD-I General Motors
Vehicles – 973
Retrieving Ford Diagnostic Codes – 973
Flash Code Retrieval On Chrysler Vehicles – 975
OBD-II Diagnosis – 975
OBD-II Active Tests – 977
Service/Flash Programming – 978
Manufacturer’s Diagnostic Routines – 980
Completing System Repairs – 980
Procedures For Resetting the PCM – 981
Road Test (Drive Cycle – 981
Chapter 26 – Engine Condition Diagnosis – 237
Typical Engine-Related Complaints – 237
Engine Smoke Diagnosis – 237
The Driver is Your Best Resource – 238
Visual Checks – 238
Engine Noise Diagnosis – 240
Oil Pressure Testing – 241
Oil Pressure Warning Lamp – 242
Compression Test – 242
Wet Compression Test – 243
Running (Dynamic) Compression Test – 244
Cylinder Leakage Test – 244
Cylinder Power Balance Test – 245
Power Balance Test Procedure – 245
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 –
921
Straightening Cylinder Heads – 922
Crack Inspection – 923
Crack Repair – 924
Checking Valve Springs – 924
Checking Valve Stems – 924
Valve Guide Service – 925
Guide Repair – 926
Grinding Valves – 927
Vacuum Tests – 245
Exhaust Restriction Test – 247
Testing Back Pressure with a Vacuum Gauge –
248
Testing Back Pressure with a Pressure Gauge –
248
Diagnosing Head Gasket Failure – 248
Dash Warning Lights – 249
Chapter 28 – Engine Removal and Disassembly
– 261
Engine Repair Options – 262
Engine Removal – 263
Engine Disassembly – 264
Disassembly of the Short Block – 266
Rotating Engine Assemblies Removal – 267
Cylinder Head Disassembly – 267
Chapter 36 - Gaskets and Sealants – 381
Introduction – 381
Head Gaskets – 381
Cover Gasket Materials – 383
Gasket Failures – 384
Oil Seals – 385
Assembly Sealants – 385
Chapter 26 – Engine Condition Diagnosis – 237
Typical Engine-Related Complaints – 237
Engine Smoke Diagnosis – 237
The Driver is Your Best Resource – 238
Visual Checks – 238
Engine Noise Diagnosis – 240
Oil Pressure Testing – 241
Oil Pressure Warning Lamp – 242
Compression Test – 242
Wet Compression Test – 243
Running (Dynamic) Compression Test – 244
Cylinder Leakage Test – 244
Cylinder Power Balance Test – 245
Power Balance Test Procedure – 245
Vacuum Tests – 245
Exhaust Restriction Test – 247
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
Testing Back Pressure with a Vacuum Gauge –
248
Testing Back Pressure with a Pressure Gauge –
248
Diagnosing Head Gasket Failure – 248
Dash Warning Lights – 249
Chapter 29 – Engine Cleaning and Crack
Detection – 272
Introduction – 272
Mechanical Cleaning – 272
Chemical Cleaners – 273
Spray and Steam Washing – 274
Thermal Cleaning – 274
Tank and Vapor Cleaning – 275
Ultrasonic and Vibratory Cleaning – 275
Crack Detection – 276
Crack Repair – 276
Chapter 30 – Cylinder Head and Valve Guide
Service – 280
Introduction – 280
Cylinder Heads – 280
Intake and Exhaust Ports – 283
Cylinder Head Passages – 284
Cylinder Head Servicing – 285
Aluminum Cylinder Head Straightening – 286
Cylinder Head Resurfacing – 287
Intake Manifold Alignment – 288
Valve Guides – 289
Valve Guide Replacement – 291
Chapter 31 – Valve and Valve Seat Service –
293
Intake and Exhaust Valves – 294
Valve Seats – 296
Valve Fault Diagnosis – 296
Valve Springs – 297
Valve Keepers and Rotators – 299
Valve Reconditioning Procedure – 300
Valve Face Grinding – 300
Valve Seat Reconditioning – 301
Valve Guide Pilots – 303
Valve Seat Grinding Stones – 304
Valve Seat Cutters – 305
Valve Seat Testing – 305
Valve Seat Replacement – 306
Valve Stem Height – 307
Installed Height – 307
Valve Stem Seals – 308
Installing the Valves – 310
Chapter 32 – Camshafts and Valve Trains – 314
Camshaft – 315
Camshaft Design – 315
Camshaft Drives – 317
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
Camshaft Movement – 319
Rocker Arms – 320
Pushrods – 322
Overhead Camshaft Valve Trains – 323
Camshaft Specifications – 323
Lifters or Tappets – 326
Valve Train Lubrication – 327
Valve Train Problem Diagnosis – 328
Camshaft Removal – 328
Measuring Camshafts – 329
Selecting a Camshaft – 329
Variable Valve Timing – 330
Variable Lift and Cylinder Deactivation Systems –
334
Chapter 26 – Engine Condition Diagnosis – 237
Typical Engine-Related Complaints – 237
Engine Smoke Diagnosis – 237
The Driver is Your Best Resource – 238
Visual Checks – 238
Engine Noise Diagnosis – 240
Oil Pressure Testing – 241
Oil Pressure Warning Lamp – 242
Compression Test – 242
Wet Compression Test – 243
Running (Dynamic) Compression Test – 244
Cylinder Leakage Test – 244
Cylinder Power Balance Test – 245
Power Balance Test Procedure – 245
Vacuum Tests – 245
Exhaust Restriction Test – 247
Testing Back Pressure with a Vacuum Gauge –
248
Testing Back Pressure with a Pressure Gauge –
248
Diagnosing Head Gasket Failure – 248
Dash Warning Lights – 249
Chapter 34 - Engine Blocks – 351
Engine Blocks – 351
Engine Block Service – 356
Block Preparation For Assembly – 362
Chapter 35 - Crankshafts, Balance Shafts, and
Bearings – 364
Crankshaft – 365
Crankshaft Construction – 366
Crankshaft Oiling Holes – 367
Engine Crankshaft Types – 367
Counterweights – 369
Externally and Internally Balanced Engines – 369
Engine Balance – 370
Balance Shafts – 371
Crankshaft Service – 372
Engine Bearings – 374
Bearing Clearance – 377
Camshaft Bearings – 379
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 Parts Size – 979
Types of Engine Rebuilds – 980
Selecting the Correct 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 26 – Engine Condition Diagnosis – 237
Typical Engine-Related Complaints – 237
Engine Smoke Diagnosis – 237
The Driver is Your Best Resource – 238
Visual Checks – 238
Engine Noise Diagnosis – 240
Oil Pressure Testing – 241
Oil Pressure Warning Lamp – 242
Compression Test – 242
Wet Compression Test – 243
Running (Dynamic) Compression Test – 244
Cylinder Leakage Test – 244
Cylinder Power Balance Test – 245
Power Balance Test Procedure – 245
Vacuum Tests – 245
Exhaust Restriction Test – 247
Testing Back Pressure with a Vacuum Gauge –
248
Testing Back Pressure with a Pressure Gauge –
248
Diagnosing Head Gasket Failure – 248
Dash Warning Lights – 249
Chapter 37 - Engine Assembly and
Dynamometer Testing – 388
Details, Details, Details – 388
Short Block Preparation – 388
Cylinder Head Preparation – 390
Trial Assembly – 391
Final Short Block Assembly – 392
Installing the Camshaft – 397
Piston/Rod Installation – 397
Cylinder Head Installation – 400
Torque-To-Yield Head Bolts – 403
Valve Train Assembly – 404
Final Assembly – 406
Dynamometer Testing – 410
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
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
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 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 27 – In-Vehicle Engine Service – 252
Thermostat Replacement – 253
Water Pump Replacement – 253
Intake Manifold Gasket Inspection – 254
Intake Manifold Gasket Replacement – 254
Timing Belt Replacement – 255
Hybrid Engine Precautions – 255
Chapter 38 - Engine Installation and Break-In –
415
Preinstallation Checklist – 415
Transmission Installation – 415
Dressing the Engine – 417
Engine Installation – 417
Engine Start – 418
Break-In Precautions – 419
Chapter 92 – Braking System Components and
Performance Standards – 1015
Fundamentals of Brake Systems – 1016
Brake Design Requirements – 1017
Brake System Categories – 1017
Antilock Brake System Overview – 1018
Federal Brake Standards – 1019
Brake Repair and the Law – 1020
Chapter 93 – Braking System Principles – 1021
Energy Principles – 1022
Inertia – 1023
Mechanical Principles – 1023
Friction Principles – 1024
Friction and Heat – 1025
Deceleration Rates – 1026
Chapter 94 – Brake Hydraulic Systems – 1027
Hydraulic Principles – 1027
Pascal’s Law – 1028
Master Cylinders – 1031
Master Cylinder Designs – 1034
Diagnosing and Troubleshooting Master Cylinders
– 1037
Master Cylinder Service – 1038
Chapter 95 – Hydraulic Valves and Switches –
1040
Introduction – 1041
Residual Check Valve – 1041
Pressure-Differential Switch (Brake Warning
Switch) – 1041
Brake Fluid Level Sensor Switch – 1042
Proportioning Valve – 1043
Electronic Brake Proportioning – 1046
Metering Valve (Hold-Off) Operation ) 1046
Combination Valve – 1048
Brake Light Switch – 1048
Chapter 96 – Brake Fluid and Lines – 1050
Brake Fluid – 1050
Brake Fluid Service Procedures and Precautions –
1054
Rubber Types – 1054
Brake Lines – 1054
Chapter 99 – Drum Brakes – 1087
Drum Brake Advantages – 1087
Drum Brake Disadvantages – 1089
Drum Brake Parts – 1089
Drum Brake Shoes – 1091
Drum Brake Parts – 1093
Non-Servo Brake Design – 1094
Dual-Servo Brake Design – 1095
Automatic Brake Adjusters – 1097
Chapter 101 – Disc Brakes – 1114
Disc Brakes – 1115
Disc Brake Construction – 1118
Disc Brake Pads – 1118
Brake Rotors – 1122
Caliper Design – 1122
Rear Disc Brakes – 1126
Chapter 103 – Parking Brake Operation,
Diagnosis, and Service – 1145
Parking Brake Standards – 1145
Pedals, Levers, and Handles – 1145
Parking Brake Warning Lamp – 1147
Parking Brake Linkages – 1147
Front and Rear Entry Parking Brake Cables – 1149
Drum Parking Brakes – 1149
Caliper-Activated Disc Parking Brakes – 1150
Rear Disc Brake Service – 1153
Parking Brake Cable Adjustment – 1153
Electric Parking Brake – 1156
Chapter 105 – Power Brake Unit Operation,
Diagnosis, and Service – 1195
The Need For Power Brake Assist – 1196
Principles of Vacuum – 1196
Vacuum Booster Theory – 1197
Charcoal Filter – 1198
Vacuum Check Valve – 1199
Vacuum Brake Booster Operation – 1199
Dual- (Tandem-) Diaphragm Vacuum Boosters –
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
1201
Brake Assist Systems – 1201
Vacuum Booster Operation Test – 1202
Vacuum Booster Leak Test – 1202
Hydraulic System Leak Test – 1202
Pushrod Clearance Adjustment – 1202
Vacuum Booster Disassembly and Service – 1203
Hydro-Boost Hydraulic Brake Booster – 1203
Hydro-Boost Symptom-Based Guide – 1207
Chapter 106 – ABS Components and Operation
– 1208
Antilock Braking System – 1208
ABS Operation – 1210
System Configurations – 1211
ABS Components – 1212
ABS Control Module – 1214
Hydraulic Modulator Assembly – 1214
Brake Pedal Feedback – 1217
Brake Pedal Travel Switch (Sensor) – 1217
Tire Pressure Monitoring (TPMS) – 1217
Chapter 97 – Brake Bleeding Methods and
Procedures – 1061
Brake Bleeding – 1061
Brake Bleeder Valve Loosening Methods – 1062
Bleeding Sequence – 1063
Manual Bleeding – 1063
Vacuum Bleeding – 1064
Gravity Bleeding – 1065
Pressure Bleeding – 1066
Hydraulic ABS Service – 1067
Brake Fluid Replacement/Flushing – 1069
Chapter 100 – Drum Brake Diagnosis and
Service – 1101
Drum Brake Faults – 1101
Drum Brake Diagnosis – 1101
Brake Drum Removal – 1101
Drum Brake Disassembly – 1103
Inspecting the Backing Plate – 1104
Drum Brake Lining Inspection – 1104
Brake Spring Inspection – 1105
Wheel Cylinder Inspection – 1105
Drum Brake Hardware Kit – 1107
Inspecting the Drum Brake Shoes – 1107
Brake Parts Cleaning – 1107
Reassembling the Drum Brake – 1108
Adjusting Drum Brakes – 1108
Lubrication Checklist – 1109
Drum Brake Symptom-Based Guide – 1109
Chapter 102 – Disc Brakes Diagnosis and
Service – 1128
Disc Brake Diagnostic Procedure – 1128
Visual Inspection – 1128
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
Disc Brake Caliper Service – 1130
Servicing Disc Brake Calipers – 1132
Disc Brake Squeal Correction – 1137
Disc Brake Symptom Guide – 1138
Chapter 103 – Parking Brake Operation,
Diagnosis, and Service – 1145
Parking Brake Standards – 1145
Pedals, Levers, and Handles – 1145
Parking Brake Warning Lamp – 1147
Parking Brake Linkages – 1147
Front and Rear Entry Parking Brake Cables – 1149
Drum Parking Brakes – 1149
Caliper-Activated Disc Parking Brakes – 1150
Rear Disc Brake Service – 1153
Parking Brake Cable Adjustment – 1153
Electric Parking Brake – 1156
Chapter 104 – Machining Brake Drums and
Rotors – 1157
Brake Drums – 1158
Brake Drum and Rotor Damage – 1158
Brake Drum Distortion – 1159
Removing Drums – 1161
“Machine To” Versus “Discard” – 1161
Machining Brake Drums – 1162
Disc Brake Rotors – 1164
Disc Brake Rotor Distortion – 1166
Disc Brake Rotor Thickness – 1167
When the Rotors Should Be Machined – 1167
Rotor Finish – 1168
Machining a Disc Brake Rotor – 1170
On-The-Vehicle Rotor Machining – 1175
Chapter 107 – ABS Diagnosis and Service –
1220
ABS Diagnostic Procedure – 1221
Brake Warning Lamp Operation – 1221
Thorough Visual Inspection – 1221
Test Drive and Verify the Fault – 1222
Retrieving Diagnostic Trouble Codes – 1223
Kelsey-Hayes Antilock (Nonintegral) – 1223
Bosch 2 ABS (Nonintegral) – 1224
Teves Mark IV – 1225
Delphi (Delco) ABS-VI (Nonintegral) – 1225
Wheel Speed Sensor Diagnosis – 1227
Wheel Speed Sensor Adjustment – 1228
OBD-II ABS Diagnosis – 1229
ABS Safety Precautions – 1231
Chapter 108 – Electronic Stability Control
Systems – 1232
The Need For Electronic Stability Control – 1232
Federal Motor Vehicle Safety Standard (FMVSS)
No. 126 – 1233
Sine with Dwell Test – 1233
Names of Various ESC Systems – 1234
ESC Sensors – 1234
Traction Control – 1236
ESC/TC Diagnosis – 1238
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
Disc Brake Caliper Removal – 1114
Repacking Wheel Bearings – 1114
Bearing Inspection and Diagnosis – 1116
Diagnosing Wheel Bearing Noise – 1119
Replacing Bearing Races – 1120
Servicing Front-Wheel-Drive Bearings – 1120
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 98 – Wheel Bearings and Service –
1070
Antifriction Bearings – 1071
Bearing Greases – 1072
Bearing Diagnosis – 1074
Wheel Bearing Service – 1075
Sealed Bearing Replacement – 1078
Rear Drive Axle Classifications – 1079
Rear Axle Bearing and Seal Replacement – 1080
Bearing Failure Analysis – 1082
Chapter 109 – Tires and Wheels – 1239
Introduction To Tires – 1240
Parts of a Tire – 1240
Tire Molding – 1242
Tire Size Designations – 1243
Load Index and Equivalent Loads – 1246
Speed Ratings – 1246
Tire Pressure and Traction – 1246
Tire Conicity and Ply Steer – 1247
Vehicle Handling and Tire Slip Angle – 1249
Rim Width and Tire Size – 1249
Uniform Tire Quality Grading System – 1250
All-Season Tire Designation – 1250
DOT Tire Code – 1251
Spare Tires – 1251
Run-Flat Tires – 1252
General Motors TPC Rating – 1253
Tire Selection Considerations – 1253
Wheels – 1254
Tire Valves – 1257
Unsprung Weight – 1257
Lug Nuts – 1257
Chapter 110 – Tire Pressure Monitoring
Systems – 1261
Need For Tire Pressure Monitoring – 1261
Indirect TPMS – 1262
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 – 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
Chapter 63 – Suspension Fundamentals – 1179
Introduction – 1179
Suspension – 1179
Frame and Suspension Design – 1180
Springs – 1180
Suspension Construction – 1182
Suspension Types – 1184
High-Performance Suspensions – 1185
Shock Absorbers – 1186
Hydraulic Shock Absorber Operation – 1187
Compression and Rebound Resistance – 1189
Direct TPMS – 1263
Identifying a Vehicle with TPMS – 1264
TPMS Pressure Sensors – 1264
TPMS Sensor Operation – 1265
TPMS Receiver – 1266
Direct TPMS Diagnosis – 1266
Installing a New Pressure Sensor – 1266
TPMS Diagnostic Tools – 1267
TPMS Sensor Activations – 1267
TPMS Relearn Procedure – 1268
TPMS Sensor Service Tools – 1268
Chapter 111 – Tire and Wheel Service – 1270
Introduction – 1270
Tire Inflation – 1270
Nitrogen Inflation – 1271
Tire Mounting Recommendations – 1272
Wheel Mounting Torque – 1273
Tire Rotation – 1274
Tire Inspection – 1276
Radial Runout – 1276
Lateral Runout – 1277
Tire Balancing – 1278
Replacement Wheels – 1281
Tire Repair – 1281
Chapter 112 – Suspension System Principles
and Components – 1288
Introduction – 1289
Frame Construction – 1289
Platforms – 1290
Unsprung Weight – 1290
Types of Suspensions – 1290
Hooke’s Law – 1291
Coil Springs – 1291
Leaf Springs – 1295
Torsion Bars – 1297
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
Suspension Principles – 1298
Steering Knuckles – 1299
Control Arms – 1299
Ball Joints – 1300
Strut Rods – 1301
Stabilizer Bars – 1301
Shock Absorbers – 1302
Struts – 1304
Bump Stops – 1308
Chapter 115 – Electronic Suspension Systems –
1343
The Need For Electronic Suspensions – 1343
Electronic Suspension Controls and Sensors –
1343
Electronic Suspension System Actuators – 1348
Types of Electronic Suspension – 1349
Automatic Level Control (ALC) – 1354
Magneto-Rheological (MR) Suspension – 1355
Troubleshooting Rear Electronic Leveling Systems
– 1356
Chapter 113 – Front Suspensions and Service –
1311
Front Suspension Types – 1312
Short/Long-Arm Suspensions – 1313
Strut Suspension – 1314
Servicing the Suspension System – 1315
Road Test Diagnosis – 1316
Dry Park Test (Suspension) 1317
Visual Inspection – 1317
Ball Joints – 1318
Kingpin Diagnosis and Service – 1322
Shock Absorbers and Struts – 1323
Macpherson Strut Replacement – 1324
Stabilizer Bar Link and Bushing Service – 1326
Strut Rod Bushings – 1327
Front Coil Springs – 1327
Steering Knuckles – 1328
Torsion Bars – 1329
Control Arm Bushings – 1330
Chapter 114 – Rear Suspensions and Service –
1335
Solid Rear Axles – 1335
Leaf Spring Rear Suspensions – 1336
Trailing Arm Rear Suspensions – 1337
Semi-Trailing Arm Rear Suspensions – 1338
Independent Rear Suspensions – 1338
Semi-Independent Rear Suspensions – 1339
Rear Suspension Service – 1340
Rear Shock Replacement – 1341
Rear Spring Replacement – 1341
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
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 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
Chapter 116 – Steering Columns and Gears –
1358
Steering Wheels – 1358
Steering Columns – 1358
Conventional Steering Gears – 1363
Recirculating Ball Steering Gear – 1364
Steering Gear Adjustments – 1366
Rack-And-Pinion Steering Gear – 1367
Rack-And-Pinion Adjustments – 1369
Chapter 117 – Steering Linkage and Service –
1372
Steering Linkage – 1372
Rack-And-Pinion Inner Tie Rod Ends – 1373
Front Steer Versus Rear Steer – 1375
Four-Wheel Steering Systems – 1375
Steering Linkage Lubrication – 1378
Dry Park Test – 1379
Common Wear Items – 1380
Under-Vehicle Inspection – 1380
Steering Linkage Replacement – 1382
Chapter 118 – Electric and Hydraulic Power
Steering Systems – 1388
Power Steering Hydraulic Systems – 1388
Power Steering Pump and Reservoir – 1388
Power Steering Hoses – 1392
Integral Power Steering – 1392
Variable-Effort Steering – 1396
Electric Power Steering System – 1399
Self-Parking System – 1401
Electrohydraulic Power Steering – 1402
Power Steering Diagnosis and Troubleshooting –
1402
Power Steering Hoses – 1244
Refilling the Power Steering System – 1244
Power Steering Gear Service – 1244
Replacing Rack-and-Pinion Units – 1244
Variable Power Steering Service – 1246
Electronically Controlled Power Steering System
Service – 1246
Chapter 67 – Wheel Alignment Fundamentals –
1248
Wheel Alignment Angles – 1248
Toe – 1248
Camber – 1248
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 – 1273
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
Chapter 119 – Wheel Alignment Principles –
1413
Definition of a Wheel Alignment – 1413
Alignment-Related Problems – 1413
Alignment Angles – 1414
Steering Axis Inclination (SAI) – 1421
Included Angle – 1421
Scrub Radius – 1422
Turning Radius (Toe-Out On Turns) – 1424
Setback – 1424
Thrust Angle – 1425
Tracking – 1425
Four-Wheel Alignment – 1426
Chapter 120 – Alignment Diagnosis and Service
– 1427
Need For Proper Alignment – 1427
Prealignment Correction Techniques – 1427
Prealignment Checks – 1428
Lead/Pull – 1429
Memory Steer – 1429
Torque Steer – 1430
Alignment Specifications – 1431
Alignment Setup Procedures – 1432
Measuring Camber, Caster, SAI, Toe, and TOOT –
1433
Specifications Versus Alignment Readings – 1434
Checking For Bent Struts, Spindles, or Control
Arms – 1434
Checking Frame Alignment of Front-Wheel-Drive
Vehicles – 1434
Types of Alignments – 1434
Sample Alignment Specifications and Readings –
1437
Adjusting Rear Camber – 1438
Guidelines For Adjusting Front Camber/SAI and
Included Angle – 1440
Front Camber/Caster Adjustment Methods – 1441
Adjusting Front Camber/Caster – 1442
Setting Toe – 1442
Centering the Steering Wheel – 1444
Steering Wheel Removal – 1444
Tolerance Adjustment Procedure – 1447
Aftermarket Alignment Methods – 1447
Aligning Electronic-Suspension Vehicles – 1447
Aligning Modified Vehicles – 1447
Hidden Structural Damage Diagnosis – 1449
Alignment Guide – 1449
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 Installation – 1299
Release Bearing Service – 1301
Clutch Housing Installation – 1302
Chapter 71 – Manual Transmission
Fundamentals – 1305
Introduction – 1305
Purpose of a Transmission – 1305
Using Gears to Increase Torque – 1306
Chapter 121 – Clutches – 1454
Purpose and Function of a Clutch – 1454
Component Parts and Operation of a Clutch
Assembly – 1454
Clutch Problem Diagnosis – 1462
Clutch Replacement – 1464
Clutch Pedal Adjustment – 1465
Bleeding the Hydraulic Clutch – 1466
Clutch Symptom Guide – 1467
Chapter 121 – Clutches – 1454
Purpose and Function of a Clutch – 1454
Component Parts and Operation of a Clutch
Assembly – 1454
Clutch Problem Diagnosis – 1462
Clutch Replacement – 1464
Clutch Pedal Adjustment – 1465
Bleeding the Hydraulic Clutch – 1466
Clutch Symptom Guide – 1467
Chapter 122 – Manual
Transmissions/Transaxles – 1471
The Need For a Transmission – 1472
Gear Types – 1472
Gear Ratios – 1473
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 Patterns – 1315
Transmission Power Flow – 1315
Four-Speed Transmission Power Flow – 1316
Five-Speed Transmission – 1318
Speedometer Drive – 1318
Switches and Sensors – 1318
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
Torque, Speed, and Power – 1475
Transmission Construction – 1476
Torque Flow Through a Manual Transmission –
1476
Speed Gears – 1477
Synchronizer Parts and Operation – 1477
Five-Speed Transmission Torque Flow – 1480
Manual Transaxle Construction – 1482
Transmission/Transaxle Removal – 1482
Transmission/Transaxle Disassembly – 1484
Hard-To-Shift Problem Diagnosis – 1485
Manual Transmission Installation – 1486
Gear Lubrication – 1487
Chapter 122 – Manual
Transmissions/Transaxles – 1471
The Need For a Transmission – 1472
Gear Types – 1472
Gear Ratios – 1473
Torque, Speed, and Power – 1475
Transmission Construction – 1476
Torque Flow Through a Manual Transmission –
1476
Speed Gears – 1477
Synchronizer Parts and Operation – 1477
Five-Speed Transmission Torque Flow – 1480
Manual Transaxle Construction – 1482
Transmission/Transaxle Removal – 1482
Transmission/Transaxle Disassembly – 1484
Hard-To-Shift Problem Diagnosis – 1485
Manual Transmission Installation – 1486
Gear Lubrication – 1487
Chapter 127 – Automatic
Transmission/Transaxle Principles – 1551
Background – 1551
Torque Converters – 1551
Lockup Torque Converter – 1556
Shift Modes – 1557
Planetary Gear Sets – 1558
Compound Planetary Gear Set – 1559
Automatic Transaxles – 1561
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
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 Fluid Service – 1370
Remove and Replace the Filter – 1371
Refill the Transmission – 1371
Diagnosis and Repair of Leaks – 1372
Leaks from the Converter Housing – 1372
VSS/Speedometer Drive Gear Leak – 1373
Shift Lever Seal Replacement – 1373
Pump Seal Replacement – 1373
Nonplanetary Gear Automatic Transaxles – 1561
Continuously Variable Transmission – 1561
Dual Clutch Automatic Transmissions – 1565
Chapter 128 – Hydraulic Components and
Control Systems – 1567
Automatic Transmission Fluid – 1567
Automatic Transmission Fluid Cooler – 1568
Pump – 1569
Apply or Holding Devices – 1571
Bands – 1571
Multiple-Plate Clutches – 1572
Accumulators – 1574
One-Way Clutches – 1575
Valve Body – 1576
Hydraulically Controlled Transmission Valves –
1577
Electronically Controlled Transmissions – 1580
Typical Torque Flow – 1582
Chapter 129 – Automatic
Transmission/Transaxle Diagnosis and InVehicle Service – 1586
Transmission Problem Diagnosis – 1586
Fluid Leak Diagnosis – 1591
In-Vehicle Service – 1594
Chapter 130 – Automatic
Transmission/Transaxle Unit Repair – 1598
Verify the Need For Unit Repair – 1598
Removing the Automatic Transmission/Transaxle
For Service – 1599
Automatic Transmission/Transaxle Disassembly –
1600
Reassembling an Automatic
Transmission/Transaxle – 1604
Flushing the Cooler and Torque Converter – 1607
Dynamometer Testing the Automatic
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
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
Four-Wheel-Drive Axle Assembly – 1407
Transfer Case – 1408
Locking Hubs – 1409
All-Wheel Drive – 1410
Transmission/Transaxle – 1608
Reinstalling the Automatic
Transmission/Transaxle – 1608
Road Test – 1608
Chapter 123 – Drive Axle Shafts and CV Joints
– 1494
Introduction – 1495
Driveshaft Design – 1495
Driveshaft Balance – 1496
U-Joint Design and Operation – 1496
Constant Velocity Joints – 1498
Chapter 125 – Drive Axles and Differentials –
1516
Differentials – 1517
Parts of a Differential – 1517
Differential Gear Ratios – 1519
Differentials – 1519
Limited Slip Differentials – 1520
Differential Components – 1521
Differential Axle Bearings – 1523
Differential Identification – 1524
Determining the Axle Ratio of a Differential –
1524
Rear End Noise Diagnosis – 1525
Differential Inspection – 1525
Tooth Contact Pattern Test – 1526
Differential Disassembly – 1526
Pinion Shaft Bearing Replacement – 1526
Drive Pinion Depth – 1526
Pinion Gear Preload – 1528
Checking and Correction Backlash – 1529
Setting Side Bearing Preload – 1530
Reassembly of the Differential Assembly – 1531
Differential Lubricant – 1532
Chapter 126 – Four-Wheel-Drive and AllWheel Drive – 1534
Four-Wheel-Drive Systems – 1534
Chapter 76 – Driveline Diagnosis and Service –
1413
Introduction – 1413
Driveshaft Diagnosis – 1413
Universal Joint Diagnosis and Service – 1414
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
Disassembly 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
All-Wheel Drive – 1537
Front and Rear Differential Axle Ratios – 1537
Transfer Case – 1537
Interaxle Differential – 1541
Four-Wheel-Drive Axles – 1542
Transfer Case Service and Problem Diagnosis –
1543
Diagnosing and Servicing Locking Hubs – 1544
Transfer Case Service – 1545
Chapter 124 – Drive Axle Shafts and CV Joint
Service – 1503
U-Joint Fault Symptoms – 1503
Driveshaft and U-Joint Inspection – 1504
U-Joint Replacement – 1506
U-Joint Working Angles – 1508
CV Joint Diagnosis – 1508
Replacement Shaft Assemblies – 1509
CV Joint Service – 1509
Chapter 123 – Drive Axle Shafts and CV Joints
– 1494
Introduction – 1495
Driveshaft Design – 1495
Driveshaft Balance – 1496
U-Joint Design and Operation – 1496
Constant Velocity Joints – 1498
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-Wheel-Drive 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
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
Chapter 124 – Drive Axle Shafts and CV Joint
Service – 1503
U-Joint Fault Symptoms – 1503
Driveshaft and U-Joint Inspection – 1504
U-Joint Replacement – 1506
U-Joint Working Angles – 1508
CV Joint Diagnosis – 1508
Replacement Shaft Assemblies – 1509
CV Joint Service – 1509
Chapter 124 – Drive Axle Shafts and CV Joint
Service – 1503
U-Joint Fault Symptoms – 1503
Driveshaft and U-Joint Inspection – 1504
U-Joint Replacement – 1506
U-Joint Working Angles – 1508
CV Joint Diagnosis – 1508
Replacement Shaft Assemblies – 1509
CV Joint Service – 1509