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AUTOMOTIVE SERVICE
Tim GillesProfessorSanta Barbara City CollegeASE Master Automotive Technician, ASE Master Automotive Machinist
Fourth Edition
Australia • Brazil • Japan • Korea • Mexico • Singapore • Spain • United Kingdom • United States
• Inspection • Maintenance • Repair
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© 2012 Delmar, Cengage Learning
ALL RIGHTS RESERVED. No part of this work covered by the copyright herein may be reproduced, transmitted, stored, or used in any form or by any means graphic, electronic, or mechanical, including but not limited to photocopying, recording, scanning, digitizing, taping, Web distribution, information networks, or information storage and retrieval systems, except as permitted under Section 107 or 108 of the 1976 United States Copyright Act, without the prior written permission of the publisher.
Library of Congress Control Number: 2010930758
ISBN-13: 978-1-1111-2861-6
ISBN-10: 1-1111-2861-8
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Automotive Service: Inspection, Maintenance, Repair, 4th EditionTim Gilles
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iii
TABLE OF
CONTENTSPREFACE xvACKNOWLEDGMENTS xviiDEDICATION xxABOUT THE AUTHOR xxFEATURES OF THE TEXT xxi
SECTION 1THE AUTOMOBILE INDUSTRY
CHAPTER 1Introduction 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 2Automotive Careers and Technician Certifi cation 15
Introduction 15 • Automotive Career Opportunities 15 • Technician Certifi cation 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
SECTION 2SHOP PROCEDURES, SAFETY, TOOLS, AND EQUIPMENT
CHAPTER 3Shop Safety 25
Introduction 25 • General Personal Safety 25 • Fire Safety 27 • Fire Extinguishers 27 • Flammable Materials 29 • Fuel Fires 29 • Electrical Fires 30 • Shop Habits 30 • Electrical Safety Precautions 31 • Cooling Fan Safety 32 • Coolant Burns 32 • General Hand Tool Safety 33 • Vise Safety 33 • Puller Safety 33 • Machinery Safety 33 • Electric Drill Safety 34 • Grinder Safety 34 • Wire Wheel Safety 34 • Compressed
Air Safety 34 • Impact Wrench Safety 35 • Air Chisel Safety 35 • Die Grinder/Air Drill Safety 35 • Press Safety 35 • General Lifting Safety 36 • Hydraulic Floor Jack (Service Jack) Safety 36 • Shop Crane (Engine Hoist) Safety 36 • Transmission Jack Safety 37 • Battery Safety 37 • Refrigerant Safety 39 • General Safety around Automobiles 39 • Hot Tank Safety Precautions 39 • Hazardous Materials and Environmental Safety 39 • Hazardous Communication Standards 41 • Material Safety Data Sheets 41 • Hazardous Materials Common to the Automobile Industry 42 • Cleaning Solvent Safety Precautions 43 • Skin Care Safety Precautions 43 • Breathing Safety 43
CHAPTER 4Shop 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 5Locating Service Information and Specifi cations 53
Introduction 53 • Service Literature 53 • Manufacturers’ Service Information 55 • Generic Service Manuals 55 • Lubrication Service Manual 57 • Owner’s Manual 57 • Owners’ Workshop Manuals 57 • Electronic Service Information 57 • Technical Service Bulletins 59 • Hot Line Services 60 • Trade Magazines 61
CHAPTER 6Measuring Tools and Systems 62
Introduction 62 • Metric System 62 • Measuring Tools 63 • Precision Measuring Tools 64
CHAPTER 7Hardware, 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 8Shop Tools 93
Introduction 93 • Tools of the Trade 93 • Hand Tools 93 • Pullers 104 • Air Tools 106 • Special Service Tools 110
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CHAPTER 9General Shop Equipment 112
Shop Equipment 112 • Hydraulic Equipment 112 • Shop Electric Machinery 117 • Other Electric Equipment 120 • Other Shop Equipment 120
CHAPTER 10Cleaning Equipment and Methods 124
Introduction 124 • General Shop Housekeeping Practices 124 • Cleaning Methods 125 • Cleaning the Outside of the Engine 126 • Environmental Concerns with Engine Cleaning 126 • Cleaning Internal Parts 126 • Chemical Cleaning 127 • Thermal Cleaning 134 • Vibratory Parts Cleaners 135 • Other Cleaning Methods 135 • Marking Clean Parts 135
CHAPTER 11Lifting Equipment and Air Compressors 137
Introduction 137 • Lift Types 137 • Frame-Contact Lifts 138 • Wheel-Contact Lifts 139 • Wheel-Free Jacks 140 • In-Ground Lifts 140 • Surface Mount Lifts 142 • Lift Safety 143 • Air Compressors 144
SECTION 3VEHICLE INSPECTION (LUBRICATION/SAFETY CHECK)
CHAPTER 12Engine Lubrication 149
Introduction 149 • Engine Oil 150 • Engine Oil Licensing and Certifi cation 153 • Oil Additives 154 • Changing Engine Oil 157 • Oil Filter 159 • Changing the Oil Filter 161
CHAPTER 13Underhood 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 14Undercar 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
SECTION 4ENGINE OPERATION
CHAPTER 15Introduction 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 16Engine Classifi cations and Advanced Transportation Technologies 207
Introduction 207 • Engine Classifi cations 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 17Engine 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 Effi ciency 236 • Mean Effective Pressure 238
CHAPTER 18Engine Upper End 240
Introduction 240 • Cylinder Head Construction 240 • Valve Guides 241 •
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Valve Guide Seals 241 • Valves 243 • Retainers and Valve Locks 246 • Valve Springs 246 • Pushrods and Rocker Arms 247 • Camshaft 248 • Number of Cams and Lobes 248 • Camshaft Performance 249 • Valve Lifters and Lash Adjusters 250 • Roller Cam and Lifters 251 • Hydraulic Lifters 251 • Camshaft Drives 253 • Valve Timing 255 • Variable Valve Timing 256 • Active Fuel Management/Displacement on Demand 258
CHAPTER 19Engine 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 Baffl es 281 • Dry Sump Lubrication Systems 281
SECTION 5COOLING SYSTEM, BELTS, HOSES, AND PLUMBING
CHAPTER 20Cooling 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 21Cooling System Service 300
Introduction 300 • Diagnosing Cooling System Problems 300 • Radiator Cap 301 • Coolant Service 303 • Testing Coolant Condition and Strength 307 • Thermostat Service 310 • Locating Leaks 313 • External Leaks 313 • Internal Leaks 314 • Recovery Tank Service 317 • Cooling System Repairs 317 • Water Pump Service 318 • Electric Cooling Fan Service 320 • Heater Core Service 320
CHAPTER 22Automotive 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 23Automotive 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 24Automotive Plumbing: Tubing and Pipe 345
Introduction 345 • Tubing 345 • Flared Connections 347 • Compression Fittings 348 • Pipe Fittings 349 • Shutoff Valves 351 • Tubing Service 351 • Installing Tubing 354 • Transmission Oil Cooler Line Repairs 355 • Nylon Fuel Injection Tubing 355 • Pipe Service 356
SECTION 6ELECTRICAL SYSTEM THEORY AND SERVICE
CHAPTER 25Basic Electrical System Theory and Repairs 358
Introduction 358 • Electron Flow 358 • Basic Automotive Electrical System 360 • Electrical Terms 362 • Circuitry and Ohm’s Law 365 • Magnetic Fields 366 • Capacitors 368 • Automotive Electronics 368 • Basic Electrical Tests 369
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CHAPTER 26Battery 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 27Battery Service 392
Introduction 392 • Battery Inspection 393 • Battery Service 393 • Replacing a Battery 395 • Battery Testing: Measuring a Battery’s State of Charge 400 • Battery Charging 404 • Storing a Vehicle 406 • Battery Capacity Tests 406 • Battery Drain Test/Parasitic Load 408 • Battery Jump-Starting 409 • Hybrid Battery Service 410
CHAPTER 28Starting 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 29Starting 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 30Charging 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 31Charging 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 32Lighting and Wiring Fundamentals 458
Introduction 458 • Wire and Cable 458 • Circuit Protection Devices 459 • Lighting 461 • Headlamps 461 • Taillights 466 • Light Bulb Identifi cation 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 33Lighting and Wiring Service 480
Analyzing Electrical Problems 480 • Wiring Service 480 • Crimp Terminals 482 • Selecting Replacement Wire 484 • Adding Electrical Accessories 484 • Soldering 486 • Broken or Damaged Ground Straps 488 • Circuit Testing and Service 489 • Finding Grounds 489 • Fuse Testing and Service 489 • Fuse Link Service 490 • Headlamp Service 490 • Headlamp Aiming 492 • Tail Lamp and Park Light Service 495 • LED Service 496 • Stoplight Switch Service 496 • Back-Up Lights 496 • Turn Signal Switch 497 • Signal Flasher/Relay 497 • Locating a Signal Flasher 498 • Instrument Panel Bulbs 498 • Windshield Washer Service 498 • Horn Service 499 • Gauge Testing 499
CHAPTER 34Safety, 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
SECTION 7HEATING AND AIR CONDITIONING
CHAPTER 35Heating 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 •
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Spark Plugs 624 • Repairing Damaged Spark Plug Threads 626 • Spark Plug Cable Service 626 • Distributor Ignition Service 628 • Ignition Timing 629 • Electronic Ignition Distributor Service 629 • Other Distributor Repair Service 631 • Distributor Installation 631 • Static Timing 631 • Electronic Ignition System Service 632 • Types of Scope Patterns 636 • Oscilloscope Tests 637 • Other Scope Tests 640 • Other Diagnostic Instruments 640
CHAPTER 39Petroleum 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
CHAPTER 40Fuel 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 • Airfl ow Measurement 673 • Idle Speed Control 674 • Fuel Pump Control Module 675 • Computer-Controlled Fuel Systems 675 • Feedback Fuel Systems 676
CHAPTER 41Fuel 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 Sensor 697 • Inlet Air Temperature Sensor 698 • MAP Sensor Diagnosis 698 • Mass Airfl ow (MAF) Sensor Diagnosis 699 • Testing Other Sensors 699 • Computer Service 700 • Mechanical Injection 700 • Carbon Deposit Service 701
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 • Muffl er 557 • Accumulator or Receiver/Dryer 557 • Evaporator Icing Control 559 • System Switches 560 • Heating and Air-Conditioning Controls 560 • Automatic Air-Conditioning Sensors 561 • Refrigerants and the Environment 563 • Temperature and Pressure 564
CHAPTER 36Heating 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 Orifi ce 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 Retrofi t 596
SECTION 8ENGINE PERFORMANCE DIAGNOSIS: THEORY AND SERVICE
CHAPTER 37Ignition 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 38Ignition System Service 621
Ignition System Service and Repairs 621 • Spark Plug Service 621 • Spark Plug Diagnosis 622 • Installing
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Piezoelectric and Piezoresistive Sensors 778 • Heated Resistive Sensors 778 • Variable DC Frequency Sensors 778 • Voltage Generators 778 • Wheatstone Bridges 779 • Switches 779 • Types of Actuators 780 • Solenoid Actuators 780 • Relay Actuators 781 • Motor Actuators 781 • Actuator Switches/Modules 781 • Adaptive Strategy 781 • Ignition Advance 782 • Knock Sensor 782 • Electronic Throttle Control/Drive-by-Wire 782 • On-Board Diagnostics 783 • Diagnostic Trouble Codes 783 • Computer Self-Diagnostics 783 • Multiplexing 784 • Network Sizes and Types 785 • CAN Systems 785 • Supplemental Data Bus Networks 789 • Telematics 791 • Wireless Networks 791
CHAPTER 46Electronics and Computer Systems Service 794
Introduction 794 • Inspection Sequence 794 • Perform Diagnostic Tests 796 • On-Board Diagnostics 796 • Reading Trouble Codes 797 • Scan Tools 797 • Breakout Box 799 • Retrieving Trouble Codes 799 • Working with Codes 799 • Erasing Trouble Codes 799 • Scan Tool Snapshot 800 • Closed Loop 802 • Fuel Trim Diagnosis 802 • Digital Waveforms 804 • Logic Probe/Power Probe 807 • Sensor and Actuator Testing 808 • Diagnosing Sensor Problems 808 • Sensor Tests 809 • Oxygen Sensor 809 • Load Sensors 811 • MAP Sensor 812 • BARO Sensors 812 • Vacuum Sensors 812 • Throttle Position Sensor 813 • Coolant Temperature Sensor 813 • Air Temperature Sensors 815 • Airfl ow 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 47Advanced Emissions and On-Board 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
CHAPTER 48Diagnosing 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
CHAPTER 42Intake and Exhaust Systems/Turbochargers and Superchargers 703
Introduction 703 • Intake System Fundamentals 703 • Manifolds 704 • Intake Manifolds 704 • Exhaust System Fundamentals 708 • Exhaust Manifolds 708 • Exhaust Pipes 709 • Exhaust System Service 711 • Turbochargers and Superchargers 712 • Turbochargers 713 • Belt-Driven Superchargers/Blowers 722
CHAPTER 43Emission Control System Fundamentals 727
Introduction 727 • Air Pollution 727 • Automotive Emissions 727 • Pollution Control 729 • Automobile Emission Control Systems 729 • Crankcase Ventilation 730 • Air Injection System 732 • Aspirator Valve or Pulse Air System 733 • Exhaust Gas Recirculation 733 • EGR System Operation 734 • Computer-Controlled EGR Systems 735 • Catalytic Converter 736 • Types of Catalytic Converters 737 • Evaporative Controls 739 • Other Parts of the Fuel Tank System 742 • On-Board Diagnostics 743 • Engine Emission Modifi cations 743
CHAPTER 44Emission Control System Service 746
Introduction 746 • Inspecting Emission Control Systems 746 • Computer-Controlled Emission Service 747 • Crankcase Ventilation System Service 747 • Evaporative Control System Service 748 • Evaporative System Maintenance 749 • Evaporative System Problem Diagnosis 749 • EGR System Service 751 • Air Injection System Service 753 • Catalytic Converter Service 754 • Converter Testing 754 • Catalytic Converter Replacement 754 • Analyzing Exhaust Emissions 755 • Emission Analyzers 756 • Hydrocarbons 757 • Carbon Monoxide (CO) 758 • Carbon Dioxide 758 • Oxygen (O2) 760 • Oxides of Nitrogen 760 • Catalytic Converter Tests 762
CHAPTER 45Electronics and Computer Systems Fundamentals 767
Introduction 767 • Semiconductors 767 • Diodes 768 • Transistors 770 • Electronic Instrument Displays 771 • Automotive Computer Systems 771 • Parts of a Computer System 772 • On-Board Computer 772 • Information Processing 774 • Computer Memory 774 • Communication Rate 776 • Sensors and Actuators 776 • Types of Sensors 777 • Thermistors 777 • Voltage Dividers 777 •
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Valve Guide Service 925 • Guide Repair 926 • Grinding Valves 927 • Grinding Valve Seats 928 • Checking Valve Stem Installed Height 929 • Solvent Testing the Valve and Seat 929 • Reassembling the Head 930 • Valve Guide Seal Installation 931 • Install the Valve and Spring Assembly 931 • Pushrod Engine Rocker Arm Service 932 • Inspect Pushrods 932 • Inspect OHC Camshaft 932 • Reassembling OHC Heads 932 • Camshaft Service 934 • Lifter Service 934 • Cam and Lifter Break-In 935 • Timing Chain and Belt Service 935 • Timing Belt Service 935 • Timing Belt Replacement 936 • Timing Chain Service 938
CHAPTER 53Engine Diagnosis and Service: Block, Crankshaft, Bearings, and Lubrication System 943
Introduction 943 • Cleaning the Block 943 • Oil and Water Plug Removal 943 • Oil Gallery Plug Installation 945 • Inspect and Clean Lifter Bores 945 • Checking Main Bearing Bore Alignment 945 • Check the Deck Surface for Flatness 947 • Clean All Threaded Holes 947 • Inspecting Cylinder Bores 947 • Measuring the Bore 948 • Deglazing the Cylinder Bore 949 • Clean the Block of Grit 951 • Boring for Oversized Pistons 951 • Block Distortion 952 • Honing after Boring 953 • Sleeves 954 • Cam Bearing Installation (Cam-in-Block Engines) 954 • Front Cam Bearing Installation 956 • Checking Crankshaft Condition 956 • Crankshaft and Bearing Wear 957 • Crankshaft Journal Tolerance 958 • Regrinding the Crankshaft 958 • Measuring Bearing Clearance with Plastigage 959 • Lubrication System Service 961 • Checking Oil Pumps for Wear 961 • Oil Pump Screen Service 962 • Oil Pump Failure 962 • Installing the Oil Pump 963
CHAPTER 54Engine 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 55Ordering Parts, Short and Long Blocks, Engine Assembly 978
Introduction 978 • Ordering Parts 978 • Engine Kits 978 • Determining Part Sizes 979 • Types of Engine Rebuilds 980 • Selecting the Correct
Problems 849 • Cylinder Leakage Test 851 • Carbon-Related Problems 852
SECTION 9AUTOMOTIVE ENGINE SERVICE AND REPAIR
CHAPTER 49Diagnosing Engine Mechanical Problems 855
Introduction 855 • Diagnosing Problems before a Repair 855 • Oil Consumption 855 • Causes of Oil Consumption 856 • Testing for Oil Leaks 858 • Engine Performance and Compression Loss 859 • Engine Noises 860 • Engine Knocks 860 • Oil Pressure Problems 864 • Cooling System Problems 865 • Internal Engine Leakage 865 • Seized Engine 867 • Electronic Failures/Engine Damage 867 • Engine Performance and Fuel Mixture Problems 868
CHAPTER 50Engine 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 51Engine 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 52Engine Diagnosis and Service: Cylinder Head and Valve Train 916
Introduction 916 • Head Disassembly 916 • Carbon Removal 920 • Cylinder Head Inspection 921 • Resurfacing by Grinding, Cutting, or Sanding 922 • Straightening Cylinder Heads 922 • Crack Inspection 923 • Crack Repair 924 • Checking Valve Springs 924 • Checking Valve Stems 924 •
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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 58Brake Service 1038
Introduction 1038 • Brake Inspection 1038 • Check Brake Pedal Feel 1038 • Master Cylinder Inspection 1038 • Brake Diagnosis 1040 • Undercar Checks 1040 • Disc Brake Inspection 1040 • Inspecting Drum Brake Assemblies 1044 • Brake Fluid Service 1047 • Routine Brake Fluid Replacement 1047 • Bleeding Brakes 1048 • Brake Bleeding Methods 1049 • Adjusting Brakes 1053 • Master Cylinder Service 1054 • Master Cylinder Removal 1054 • Master Cylinder Disassembly 1054 • Bench Bleeding a Master Cylinder 1055 • Brake Job 1056 • Drum Brake Lining Removal 1056 • Rebuilding Hydraulic Cylinders 1057 • Reassembling a Wheel Cylinder 1058 • Removing Wheel Cylinders 1059 • Replacing Drum Brake Shoes 1059 • Adjusting Drum Brake Clearance 1059 • Drum and Rotor Service 1060 • Drum Service 1061 • Rotor Service 1063 • On-Vehicle Rotor Machining 1065 • Disc Brake Service 1066 • Rear Disc Pad Installation 1068 • Rebuilt Calipers 1069 • Disc Caliper Rebuilding 1069 • Selecting Brake Linings 1071 • Disc Brake Noise 1072 • Parking Brake Cable Service 1074 • Vacuum Power Brake Service 1074 • Brake Warning Lamp Diagnosis 1079 • Antilock Brake System (ABS) Service 1079
CHAPTER 59Antilock 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
CHAPTER 60Bearings, 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 •
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 56Engine Installation, Break-In, and In-Chassis Repairs 997
Introduction 997 • Engine Installation 997 • Install Engine Mounts 997 • Install the Engine 997 • Priming the Lubrication System 999 • Pressure Priming 999 • Install Valve Covers 1000 • Ignition System Installation and Timing 1000 • Engine Starting and Initial Break-In 1001 • Valve Clearance Adjustment 1002 • Road Test and Break-In 1002 • Final Inspection 1002 • Returning the Car to the Customer 1003 • Engine Repair—Engine in the Vehicle 1003 • Valve Job or Head Gasket Repair 1003 • Valve Job or Complete Engine Overhaul 1004 • Head Gasket Problems 1004 • In-Chassis Lower End Repairs 1004 • Removing the Oil Pan 1004 • Remove the Piston and Rod Assembly 1006 • Remove the Timing Cover 1006 • Freewheeling and Interference Engines 1006 • Replace the Timing Components 1006 • Crankshaft Seal Replacement 1007 • Flywheel Ring Gear Service 1007
SECTION 10BRAKES AND TIRES
CHAPTER 57Brake 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
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Suspension Construction 1182 • Suspension Types 1184 • High-Performance Suspensions 1185 • Shock Absorbers 1186 • Hydraulic Shock Absorber Operation 1187 • Compression and Rebound Resistance 1189 • Bump Stops and Limiters 1189 • Gas Shocks 1190 • Air Shocks/ Leveling Devices 1191 • Other Front End Parts 1192 • Stabilizer Bar 1192 • Suspension Leveling Systems 1192
CHAPTER 64Suspension System Service 1199
Introduction 1199 • Diagnosing Suspension System Problems 1199 • Shock Absorber Service 1200 • Testing a Shock 1200 • Macpherson Strut Service 1202 • Inspect the Upper Strut Bearing 1204 • Install the Coil Spring 1204 • Reinstall the Strut Assembly 1204 • Suspension Bushing Service 1204 • Strut Rod Bushing Service 1205 • Stabilizer Bar Service 1205 • Spindle Service 1206 • Ball Joint Service 1206 • Measuring Ball Joint Wear 1207 • Separating Tapered Connections 1208 • Replacing a Ball Joint 1208 • Coil Spring Service 1209 • Adjusting Spring Height 1209 • Coil Spring Replacement 1209 • SLA Coil Spring Replacement 1210 • Wheel Alignment 1212 • Electronic Suspension Service 1212 • Electronically Controlled Shock Absorbers 1213
CHAPTER 65Steering 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 66Steering 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
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 61Tire 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 62Tire and Wheel Service 1145
Introduction 1145 • Tire Infl ation 1145 • Checking Air Pressure 1145 • Adjusting Tire Pressure 1147 • Tire Wear 1148 • Sidewall Checks 1149 • Tire Rotation 1149 • Removing and Tightening Lug Nuts 1151 • Repairing Wheel Studs 1152 • Removing and Mounting Tires on Rims 1153 • Inspecting the Tire and Wheel 1156 • Valve Stem Service 1156 • Rubber Lubricant 1157 • Install the Tire 1157 • Mounting High-Performance Tires 1160 • Bead Roller Tire Changer 1161 • Tire Runout 1161 • Tire Repair 1162 • Repairing a Tire 1163 • Preparing a Tire for Repair 1164 • Patching the Tire 1165 • Tire and Wheel Balance 1166 • Types of Wheel Balance 1168 • Couple Imbalance 1169 • Dynamic Balance 1170 • Computer Balancers 1170 • Centering the Wheel on the Balancer 1170 • Match Mounting 1173 • Force Variation 1173 • Installing the Wheel 1174 • Tire Pressure Monitoring System Service 1175
SECTION 11SUSPENSION, STEERING, ALIGNMENT
CHAPTER 63Suspension Fundamentals 1179
Introduction 1179 • Suspension 1179 • Frame and Suspension Designs 1180 • Springs 1180 •
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SECTION 12DRIVETRAIN
CHAPTER 69Clutch 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 70Clutch Diagnosis and Service 1290
Introduction 1290 • Diagnosis of Clutch Problem 1290 • Clutch Noises 1290 • Transmission Noise 1291 • Pedal Problems 1291 • Slipping Clutch 1291 • Dragging Clutch 1291 • Oily Clutch Facings 1292 • Damaged Friction Surfaces 1292 • Chattering or Grabbing Clutch 1293 • Clutch Service 1293 • Servicing Hydraulic Components 1294 • Clutch Replacement 1295 • Removing a Transmission or Transaxle 1295 • Clutch Removal 1295 • Flywheel Removal 1297 • Flywheel Starter Ring Gear Replacement 1297 • Flywheel Installation 1297 • Inspect New Parts 1298 • Pilot Bushing Service 1298 • Clutch Disc Service 1299 • Clutch Cover/Pressure Plate Service 1299 • Clutch Installation 1299 • Release Bearing Service 1301 • Clutch Housing Installation 1302
CHAPTER 71Manual Transmission Fundamentals 1305
Introduction 1305 • Purpose of a Transmission 1305 • Using Gears to Increase Torque 1306 • Gear Ratio 1306 • Transmission Gear Ranges 1307 • Overdrive 1307 • Final Drive Ratio 1308 • Gear Types and Operation 1308 • Spur Gears 1309 • Helical Gears 1309 • Idler Gears 1309 • Transmission Parts 1309 • Transmission Lubrication 1310 • Transmission Bearings 1310 • Transmission Gears and Shafts 1310 • Synchronizer Assembly 1312 • Gear Shift Mechanisms 1314 • Shift
Steering Linkage Inspection 1234 • Steering Linkage Repairs 1234 • Idler Arm Replacement 1234 • Pitman Arm Replacement 1235 • Tie-Rod End Replacement 1235 • Rack-and-Pinion Tie-Rods 1236 • Steering Wheel, Column, and Air Bag Service 1236 • Air Bag Service 1236 • Steering Wheel Service 1239 • Steering Column Service 1239 • Steering Gear Service 1239 • Manual Rack Service 1240 • Rack-and-Pinion Looseness 1240 • Power Steering System Service 1240 • Power Steering System Flushing 1240 • Bleeding the System of Air 1241 • Power Steering Pump Replacement 1242 • Repairing Power Steering Pump Oil Leaks 1242 • Power Steering Pressure Diagnosis 1242 • Power Steering Pump Service 1243 • Power Steering Hoses 1244 • Refi lling 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 67Wheel Alignment Fundamentals 1248
Introduction 1248 • Wheel Alignment Angles 1248 • Toe 1248 • Camber 1249 • Caster 1250 • Steering Axis Inclination 1251 • Scrub Radius 1252 • Turning Radius 1253 • Tracking 1254 • Setback 1254 • Special Handling Characteristics 1254
CHAPTER 68Wheel Alignment Service 1257
Introduction 1257 • Prealignment Inspection 1257 • Tire Wear Inspection 1257 • Ride Height Check 1259 • Toe Change 1259 • Torque Steer 1260 • Suspension Looseness 1260 • Test Drive 1261 • Tire Checks 1261 • Inspection Checklist 1262 • Wheel Alignment Procedures 1262 • Measuring Alignment 1263 • Measuring Camber 1264 • Measuring Caster 1264 • Road Crown and Pull 1264 • Measuring Steering Axis Inclination 1267 • Measuring Toe 1267 • Adjusting Toe 1268 • Centering a Steering Wheel 1271 • Checking for Toe Change 1272 • Measuring Turning Radius 1272 • General Wheel Alignment Rules 1273 • Four-Wheel Alignment 1274 • Performing a Four-Wheel Alignment 1275 • Compensating the Alignment Heads 1275 • Measuring Caster and Camber 1276 • Adjusting Rear-Wheel Alignment 1276
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CHAPTER 74Automatic Transmission Diagnosis and Service 1367
Introduction 1367 • Automatic Transmission Identifi cation 1368 • Automatic Transmission Maintenance 1368 • Transmission Fluid Service 1368 • Fluid Level 1369 • Check Fluid Condition 1369 • Changing Transmission Fluid 1369 • Transmission Filter Service 1370 • Remove and Replace the Filter 1371 • Refi ll the Transmission 1371 • Diagnosis and Repair of Leaks 1372 • Leaks from the Converter Housing 1372 • Transmission Cooler Line Leak 1372 • VSS/Speedometer Drive Gear Leak 1373 • Shift Lever Seal Replacement 1373 • Pump Seal Replacement 1373 • Front Seal Replacement 1374 • Pump Bushing Replacement 1374 • Reinstalling the Transmission 1375 • Rear Oil Seal and Bushing Replacement 1376 • Automatic Transmission Problem Diagnosis 1376 • Slippage 1377 • Transmission Drainback 1377 • Noises 1380 • Flexplate 1380 • Transmission Tests 1380 • Valve Body Removal 1382 • Transmission Adjustments 1382 • Electronic Transmission Service 1384 • More Tests before Transmission Removal 1387 • Hybrid Automatic Transmission Service 1387 • Remanufactured Automatic Transmissions and Transaxles 1387 • Transmission Rebuilding 1388 • Transmission Reassembly 1390
CHAPTER 75Driveline 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
CHAPTER 76Driveline Diagnosis and Service 1413
Introduction 1413 • Driveshaft Diagnosis 1413 • Universal Joint Diagnosis and Service 1414 •
Patterns 1315 • Transmission Power Flow 1315 • Four-Speed Transmission Power Flow 1316 • Five-Speed Transmission 1318 • Speedometer Drive 1318 • Switches and Sensors 1318
CHAPTER 72Manual 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 73Automatic Transmission Fundamentals 1334
Introduction 1334 • Automatic Transmission Parts 1334 • Power Transmission 1335 • Flexplate 1335 • Torque Converter 1336 • Torque Multiplication 1336 • Torque Converter Operation 1337 • Stator Clutch Operation 1339 • Stall Speed 1340 • Lock-Up Torque Converters 1340 • Planetary Gears 1341 • Simple Planetary Gearset 1341 • Simple Planetary Operation 1342 • Compound Planetary Operation (Simpson) 1343 • Driving and Holding Devices 1345 • Clutches 1345 • Clutch Operation 1346 • One-Way Clutches 1347 • Bands 1348 • Accumulator 1348 • Hydraulic System 1349 • Fluid Pump 1349 • Types of Pumps 1349 • Transmission Valves 1351 • Pressure Regulator 1351 • Hydraulic Valve Body 1352 • Transmission Automatic Shift Selection 1352 • Governor 1353 • Vacuum Modulator 1354 • Kickdown Valve 1354 • Automatic Transmission Fluid (ATF) 1355 • Automatic Transmission Cooling 1355 • Auxiliary Cooler/Heat Exchanger 1356 • Park Pawl 1356 • Electronic Automatic Transmissions 1356 • Electronic Automatic Transmission Operation 1359 • Electronic Torque Converter Control 1359 • Electronic Pressure Control 1359 • Transmission Shift Control 1360 • Continuously Variable Transmission 1362 • Hybrid Planetary Transmission Operation 1362
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xiv TABLE OF CONTENTS
CHAPTER 78Front-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 • Double Offset Plunge Joints 1456 • Cross Groove Joint Service 1457 • Rebuilt Halfshafts 1457 • Installing the Axle 1457 • Transaxle Repair 1457 • Transaxle Removal 1458 • Manual Transaxle Repair 1458 • Automatic Transaxle Repair 1458 • Transaxle Differential Side Bearing Adjustment 1458 • Install the Transaxle 1458
CHAPTER 79Driveline Vibration and Service 1461
Vibration Analysis 1461 • Types of Vibrations 1462 • Vibration Test Instruments 1463 • Vibration and Frequency 1463 • Driveshaft Runout 1465 • Other Causes of Vibration 1465 • Driveshaft Balance 1465 • Driveshaft Angle 1467
APPENDIX 1470
GLOSSARY 1482
INDEX 1520
Driveshaft Service 1414 • Universal Joint Disassembly 1415 • Universal Joint Reassembly 1416 • Driveshaft Installation 1417 • Two-Piece Driveshaft Service 1418 • Differential and Axle Diagnosis and Service 1418 • Problem Diagnosis 1418 • Axle Bearing Diagnosis 1419 • Axle Bearing Service 1420 • Removing a Bearing-Retained Axle 1420 • Axle Bearing Replacement 1421 • Axle Bearing Installation 1422 • Reinstall the Axle 1423 • Full-Floating Axle Service 1423 • Differential Pinion Seal Replacement 1424 • Differential Repair 1425 • Removing a Third Member 1425 • Disassembling a Salisbury Axle 1425 • Clean and Inspect Parts 1426 • Differential Reassembly 1427 • Adjusting a Differential 1427 • Pinion Gear Depth 1427 • Ring Gear Backlash 1428 • Side Bearing Preload 1428 • Contact Pattern 1430 • Backlash Pattern Change 1430 • Pinion Depth Pattern Change 1430 • Pinion Bearing Preload 1431 • Ring and Pinion Noise 1432 • Four-Wheel-Drive Service and Repair 1432
CHAPTER 77Front-Wheel-Drive (Transaxle and CV Joint)Fundamentals 1437
Introduction 1437 • Front-Wheel Drive 1437 • Manual Transaxles 1438 • Shift Linkage 1438 • Transaxle Differential 1439 • Transaxle Power Flow 1440 • Automatic Transaxle 1442 • Front Drive Axles 1443 • Axle Shaft Parts 1443 • CV Joint Construction 1444 • Axle Shafts 1446 • CV Joint Boots 1446
NOTE TO STUDENT: Learn to use the index. It has been constantly updated and will help you find what you need in the book.
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Automotive Service: Inspection, Maintenance, Repair, 4th edition evolved in part from my participation in a successful articulation program between local high schools and the community college where I have been a teacher for over 37 years. The text and art manu-scripts of this best-selling book have once again been updated and improved in this fourth edition revision. An array of excellent technical reviews by a dedicated group of professional teachers and technicians ensures that this is the most technically accurate and up-to-date comprehensive automotive textbook available in the marketplace. The text has been written from a care-fully detailed outline to allow each chapter to follow a logical, easy-to-understand path. Many new original color photographs and sketches have been added to update and supplement earlier material.
The transportation industry in North America is vast, with one in every six people contributing to it in some way. These include people of many levels of understanding and ability. With that in mind, the introductory fundamentals chapters are written at a lower level for all the students, whereas the service chapters are for those who have mastered the intro-ductory material.
As a teacher, my philosophy is to challenge the best students in anticipation that the rest will be brought to a higher level: “A rising tide raises all boats.”
The text can be used for a variety of educational purposes, including:
■ As a basic text in any automotive repair class■ To educate entry-level or apprentice technicians■ To prepare more experienced technicians for ASE
certification
Automotive Service: Inspection, Maintenance, Repair, 4th edition is divided into 79 chapters that cover the NATEF Auto General Service Technician Program Standards and A1–A8 (the eight ASE automotive specialty areas). Advanced engine performance and emission controls are also covered in detail. In addition to coverage of the usual repairs performed in almost any automotive repair facility, the reader is introduced to the most frequently performed inspection and service procedures—from safety inspections to tire and wheel service.
The automotive repair industry of today contin-ues to evolve into more of a maintenance industry as vehicles last longer and require fewer repairs. Long-term customer relationships, ethics, and professional-ism have become even more important to the success of a business. There are also environmental concerns today that were not a part of the industry of the past. The text includes chapters on safety, hand tools, and vehicle maintenance and lubrication that are more
comprehensive than those found in most comparable texts. An accompanying lab manual emphasizes the NATEF Auto General Service Technician Program Standards, those jobs done in service stations, fast-lube outlets, or mass merchandisers (such as Sears, Goodyear, Firestone, or Kmart). An additional lab workbook, Automotive Service Job Sheets for NATEF Task Mastery, covers the eight main ASE system areas.
Automobiles have become so complex in the last 30 years that to remain competent many of today’s technicians specialize in one or more systems of the car. Basic theory of all automotive and light truck systems is covered so that service personnel will under-stand the function of the parts being serviced. When working in the industry, there is often no time for basic theory. Therefore, automotive class work could be the one and only chance students have to learn how sys-tems operate so they can become better diagnosticians in the future.
This book is comprehensive in that it deals with the entire car and aims to teach theory of vehicle systems at an introductory student level, followed by service, diag-nosis, and light repairs at a more advanced student level.
Most of the systems used in automobiles today are strikingly similar. Repair techniques universal to all automobiles are discussed and procedures or condi-tions unique to only one specifi c automobile make are purposely avoided. The reader is encouraged to refer to the service and repair information for the specifi c vehicle in question.
A major challenge for me as an automotive author is to keep the scope of the book from growing out of control by expanding into areas of in-service train-ing best covered by manufacturers and aftermarket educators. My objective is to take an abundance of sometimes complicated information and condense and simplify that information so it can be understood by a student preparing for job-entry level. Following the completion of this text, better students will be at a high job-entry level, at a skill level suitable for entry as an apprentice in one or more of the specialty areas of automotive repair in a new car dealership or an independent repair shop.
A primary objective of this book is to help the reader develop confi dence in both thinking skills and problem-solving ability. One unique aspect of auto-motive education is that many automotive graduates venture into other professions and skilled trades, such as engineering or construction. They will fi nd much of the material learned in automotive classes to be very valuable and useful in their chosen fi elds. This aspect of the student’s education is especially valuable when one considers how middle school and high school industrial arts programs have been scaled back in recent
PREFACE
xv
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years. Dealing with such things as tools, soldering, basic electrical repairs, and repairing broken fasteners helps to provide some measure of practical education.
The tremendous decline in the number of corner gasoline service stations has resulted in a loss of those jobs formerly available in abundance to students. Suc-cessful service personnel who possess necessary basic automotive skills must continually learn new things in order to progress into other (higher-paying) specialty areas. The Lab Manual to Accompany Automotive Service contains service jobs that students should be able to perform before enrolling in an advanced automotive specialty area class.
UPDATES AND ENHANCEMENTS TO THE FOURTH EDITION
■ New and updated information on hybrid vehicles and alternative fuels.
■ New coverage on the latest information on engine oils and coolants.
■ Vehicle electronics coverage has been improved and increased throughout.
■ New and updated engine performance and electronics coverage includes technology advances in onboard diagnostics, misfire detection, variable valve timing, displacement on demand, adaptive strategies, the latest CAN systems, drive-by-wire, and wide-band oxygen sensors.
■ Chassis and powertrain coverage includes updated information on stability control and traction control systems, electronic suspension systems, electric steering, and electronic transmission and all-wheel drive.
■ Updated comfort and safety topics include the newest developments in air conditioning, supplemental restraints, lighting, entertainment systems, and adaptive cruise control.
■ New science, math, and history notes have been added.
■ The Instructor Resources DVD and and other new and greatly enhanced supplements are designed to improve the organization and quality of time spent in the classroom and shop (see the Supplements page for more detail).
■ All automotive terms, abbreviations, and acronyms used in this text comply with the SAE Technical Standards Board Publication SAE J1930.
ACKNOWLEDGMENTSI would like to extend special thanks to the following individuals, organizations, and companies:
■ Delmar, Cengage Learning Senior Product Manager Matt Thouin for his helpful, positive attitude. Matt’s dedication to excellence and his efficiency
and organizational skills were very important to the overall improvement of this fourth edition.
■ Denise Denisoff and Chris Shortt, developmental editors in earlier editions of the text.
■ Cheri Plasse and Joan Conlon, Content Project Managers, who managed the art, design, and production of the text. Cheri has worked on several of my projects in the past and is always a pleasure to work with.
■ Bill Clark and the staff at MPS who worked tirelessly behind the scenes. Their professional talent and effort with the text and art ensure a quality final product.
■ Sharon Rounds, who worked tirelessly behind the scenes securing art permissions.
■ Araceli Popen, who has been copyeditor on several of my books, making certain that everything is accurate and in order.
■ Cheryl Weakliem, my editorial assistant, for her excellent reviews, suggestions, and text edits in the areas of electricity, air conditioning, and science. Cheryl is a chemistry teacher with a PhD in Chemistry and an associate degree in Automotive Technology.
■ Friends and colleagues Bob Stockero and Dave Brainerd of Santa Barbara City College and Chuck Rockwood of Ventura College for their continuous input and support. All three provided in-depth reviews and excellent suggestions to this edition of the text.
■ Members of the North American Council of Automotive Teachers (NACAT) and California Automotive Teachers (CAT), who provided a vast amount of input.
■ Students in the Automotive program at Santa Barbara City College, who provided continuous feedback and suggestions for improvement.
■ Physics professor Mike Young of Santa Barbara City College for his help with the Science Notes.
■ Jack Rosebro of Perfect Sky, Inc., who helped with reviews of the hybrid vehicle material.
■ Bernie Carr, Senior Engineer at Bosch Diagnostics/Vetronix in Santa Barbara, who reviewed and helped with controller area networks (CAN) and other vehicle electronics material.
■ Staff at all of the campuses of Universal Technical Institute, who provided helpful reviews of the manuscript.
■ Tom Butera has volunteered in my class since he retired after 31 years as the owner of a NAPA store, preceded by many years as an owner of four Texaco service stations. Parts people know lots of things about the automotive industry and Tom brings many things to class to share with me and my students.
From Tim Gilles
xvi PREFACE
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APPENDIXThe contributions of the following reviewers are gratefully acknowl-edged for their invaluable input during the development of this revision. In addition, the author and publisher would like to thank the reviewers who offered feed-back for previous editions:
David AmesEvergreen Valley CollegeSan Jose, CA
David BrainerdGoleta, CA
Al Carroll Edgecombe Community CollegeTarboro, NC
Andrew CaweltiOxnard CollegeOxnard, CA
Tim Dwyer Oklahoma State Technical CollegeOkmulgee, OK
Julia JohnsonSkyline CollegeSan Bruno, CA
Anthony Kossmann Hudson Valley Community CollegeTroy, NY
Gary NeilRenton Technical CollegeRenton, WA
James PosickDaytona Beach State CollegeDaytona Beach, FL
Charles RockwoodVentura CollegeVentura, CA
Gary Semerdjian Imported Automotive Service and Santa Barbara City CollegeSanta Barbara, CA
Robert StockeroSanta Barbara City CollegeSanta Barbara, CA
FROM ATI SCHOOLS AND COLLEGES:
Luis BariniOakland Park, FL
Arnold BurkettOklahoma City, OK
Craig CouchOklahoma City, OK
Andre CovasOakland Park, FL
Robert DryjaDallas, TX
Secundino GarzaCorpus Christi, TX
Ryder GoinDallas, TX
Jonathan KloepferOakland Park, FL
Bruce LazarusOakland Park, FL
Herbert LeistSan Antonio, TX
Marion McKnightWaco, TX
Herbey PenaCorpus Christi, TX
Vincent SeinaOakland Park, FL
John TappanSan Antonio, TX
Douglas WalterHouston, TX
FROM UNIVERSAL TECHNICAL INSTITUTE:
Joseph AlveySacramento, CA
David AndersonOrlando, FL
John ArchambaultMooresville, NC
Leonardo AvalosAvondale, AZ
Jared AventSacramento, CA
Fred BachrodtAvondale, AZ
Jack BatsonRancho Cucamonga, CA
David BeamExton, PA
Oliver BeckhamHouston, TX
Vince BlanchardSacramento, CA
Terry BorkmanAvondale, AZ
William M. BrownRancho Cucamonga, CA
Benson BunkMooresville, NC
Thomas ClarkRancho Cucamonga, CA
James CollExton, PA
Jon CombsAvondale, AZ
James CoombesExton, PA
Phillip CooperMooresville, NC
Jeffrey CovingtonMooresville, NC
William CrawfordAvondale, AZ
David CubillasAvondale, IL
Darren CulverHouston, TX
Ben CurtisMooresville, NC
Russell CurtisGlendale Heights, IL
ACKNOWLEDGMENTS
xvii
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xviii TABLE OF CONTENTS
Eric DaviesExton, PA
Steve DaviesExton, PA
Steve DavisAvondale, AZ
Ken DeLanoMooresville, NC
Andre DemersMooresville, NC
Dennis DenzGlendale Heights, IL
Thomas DevittMooresville, NC
Lawrence DoranSacramento, CA
Anthony EddinsNorwood, MA
Robert EgliAvondale, AZ
Steven FairExton, PA
Eric FeltmanOrlando, FL
Martin Flannery, Jr.Exton, PA
James FlockhartAvondale, AZ
John FourneratHouston, TX
Matthew FranchettiNorwood, MA
Scott FrenchOrlando, FL
Ryan GalattiExton, PA
Jessie GaleyMooresville, NC
Steve GarnerSacramento, CA
John GlusicaMooresville, NC
Roy GreathouseSacramento, CA
Steven GreenspanGlendale Heights, IL
Joe GrossoExton, PA
Gregory GunterExton, PA
Luciano GurrolaAvondale, AZ
Luis GuzmanOrlando, FL
Mark HallSacramento, CA
Terrance HaltomSacramento, CA
Richard Hamilton, Jr.Mooresville, NC
Ricky HarrisonHouston, TX
Michael HechtHouston, TX
William HoffmanGlendale Heights, IL
Jason HoldawayMooresville, NC
Thomas IngallsMooresville, NC
Rodger JerlsRancho Cucamonga, CA
William JonesRancho Cucamonga, CA
Scott KeelHouston, TX
W. Scott KeeneGlendale Heights, IL
Nathan KulpExton, PA
Dave LejaGlendale Heights, IL
Matthew LokaiMooresville, NC
Kenneth LowellNorwood, MA
Andrew MartinRancho Cucamonga, CA
Bobby MastersonHouston, TX
Cory MathisGlendale Heights, IL
Robert McCorkellExton, PA
Brendan McCormickExton, PA
Brian McHughOrlando, FL
Danny McKaySacramento, CA
David McLoudNorwood, MA
Donald McNabbHouston, TX
James MellenthinGlendale Heights, IL
Steven MichelsenGlendale Heights, IL
Kara MoonPhoenix, AZ
Jason MoslerAvondale, AZ
Charles NanceRancho Cucamonga, CA
Francis O’ConnellExton, PA
Michael PairGlendale Heights, IL
Louis PhistryAvondale, AZ
Ken NagelGlendale Heights, IL
Steve NelsonAvondale, AZ
Mark NeradGlendale Heights, IL
xviii ACKNOWLEDGMENTS
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William C. NiemeyerGlendale Heights, IL
Douglas PergramGlendale Heights, IL
Clayton PerkinsAvondale, AZ
Todd PetersonNorwood, MA
John Pfi ngstagPhoenix, AZ
Richard PloeserAvondale, AZ
James PollardHouston, TX
Daniel PoorNorwood, MA
George PotterGlendale Heights, IL
Juan RamosGlendale Heights, IL
Carroll RandallMooresville, NC
Timothy RaynerSacramento, CA
Salvatore ReinaAvondale, AZ
Paul RoheRancho Cucamonga, CA
Dominick Saffi otiOrlando, FL
Kurt SaverienSacramento, CA
Edward ScarbroughGlendale Heights, IL
Donald SeeneMooresville, NC
Brian ShefmanExton, PA
Charles SiegelOrlando, FL
Aaron SmithMooresville, NC
Marvin SmithMooresville, NC
Everett Jay SinonMooresville, NC
Michael SorensenSacramento, CA
Anthony Spadafi naGlendale Heights, IL
William SpiekermanAvondale, AZ
Mike StatzerAvondale, AZ
Chris StyffeNorwood, MA
John TagliniNorwood, MA
Adam TaylorNorwood, MA
Andy TaylorMooresville, NC
George TimmisOrlando, FL
Bob TroxlerChino Hills, CA
Ray TourtelotteMooresville, NC
Robert VendittiExton, PA
Steven VolkmanOrlando, FL
Joseph WalkerOrlando, FL
Don WalterRancho Cucamonga, CA
Wayne WaltersMooresville, NC
Thomas WellsHouston, TX
Robert WildOrlando, FL
David WinfreyNorwood, MA
Randy WornerHouston, TX
Mark YarnallExton, PA
ACKNOWLEDGMENTS xix
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xx TABLE OF CONTENTS
DEDICATION The completion of this book was made possible with help from a great many individuals. Automotive Service: Inspection, Maintenance, Repair, 4th edition is dedicated to them and to my wife, Joy. Her organizational skills and able assistance have been invaluable. Writing a 1,500-page comprehensive text-book with many thousands of photos and sketches is a daunting task. I would not be able to concentrate as much of my time on the important upgrading and editorial work if I did not have Joy organizing the art package and submit-ting fi nal manuscript changes to the publisher. She retired from her full-time job to help with this project and has been especially helpful.
Tim Gilles has authored and coauthored several textbooks. He has been an auto-motive teacher since 1973 and is a professor in the Automotive Technology Department at Santa Barbara City College. He earned a Bachelor of Arts degree from Long Beach State University and a Master of Arts degree in Occupational Education from Chicago State University. He holds the industry certifi cations of ASE Master Engine Machinist and ASE Master Automotive Technician.
Tim has been active in professional associations for many years, as presi-dent and board member of the California Automotive Teachers (CAT) and as a board member and election committee chair of the North American Council of Automotive Teachers (NACAT). He is a frequent seminar presenter at association conferences. Tim has been a longtime member of the California Community College Chancellor’s Trade and Industry Advisory Committee. He is active in industry associations, including AERA, ARC, and IATN, and has served several terms as education representative on the board of the Santa Barbara Chapter of the Independent Automotive Professionals Association (IAPA).
Table of Contents XXxx ACKNOWLEDGMENTS
ABOUT THE AUTHOR
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xxi
FEATURES
OBJECTIVES
Each chapter begins with a list of the most impor-tant points discussed in the chapter. This list of objectives is intended to provide the student with a general idea of what he or she will be studying.
KEY TERMS
Each chapter contains a list of new terms to know. These terms are highlighted in bold in the text. Defi nitions of these terms can be found in the glossary.
CAUTIONS
Cautions are urgent warnings that personal injury or property damage could occur if careful preven-tive steps are not taken.
SHOP TIPS
Appropriate shop tips are described throughout the text. These tips provide shortcuts and empha-size fi ne-tuning procedures to shop practices com-monly performed by experienced technicians.
NOTES
Notes are used throughout the text to highlight especially important topics.
VINTAGE SYSTEM NOTES
Boxed information on vintage systems (and related parts) puts today’s newer technologies in historical perspective and offers insights into the development of the automobile. Vintage notes are not only interesting but may even help the reader repair or restore vintage cars. This has become an important part of many automotive businesses.
OF THE TEXT
149
can pass before the engine’s oil pump can distribute oil
to the entire engine. During this interval, called dry
start, parts can rub and wear results.NOTE: The amount of wear that occurs during this short
amount of time is equivalent to that caused by hundreds of
miles of freeway driving. Most vehicle manufacturers now
specify the use of thinner oils, which reach engine compo-
nents more quickly after startup.
INTRODUCTION In theory, all moving parts are separated by a thin
layer of oil (Figure 12.1). Oil is supplied to engine
parts by an oil pump (Figure 12.2). If oil is properly
maintained so dirt cannot accumulate, then very little
wear should occur. The life expectancy of an engine in
the 1960s was about 100,000 miles. Today, a properly
maintained engine can last twice as long with less wear.
Under normal conditions, the only time a breakdown
in lubrication occurs is just after an engine is started
in the morning. The crankshaft rests on its bearings
until a wedge of oil is reestablished after pressurized
oil reaches the bearings (Figure 12.3). A few seconds
anti-drainback valveAPIboundary lubricationby-pass oil fi lter
by-pass valvecrankcasedry startfull-fl ow oil fi lter
multiple viscositypolymerviscosityviscosity index
KEY TERMS
CHAPTER 12
OBJECTIVESUpon completion of this chapter, you should be able to:
■ Describe engine lubrication under different service conditions.
■ Select the correct engine oil to use.■ Describe the operation of different types of oil fi lters.
Engine Lubrication
Oil pump
Pickupscreen
Oil pan
Oil filter
Figure 12.2 Oil is circulated through the system by an
oil pump.
Stationary bearing
Shaft
Oil tends to resistmovement on bearingand journal surfaces
Most slippageoccurs near thecenter of the oil film
Figure 12.1 Moving parts are separated by a thin fi lm
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Automotive Hoses 341
Apply some rubber cement gasket sealer to new hose connections to prevent air leakage
when using a constant diameter or screw clamp.
SHOPTIPSHOPTIP
Be certain that a newly installed hose does not contact drive belts, fuel lines, or the radiator cooling fan.
SAFETYNOTESAFETYNOTE
Replacing a Heater HoseSometimes the heater hoses on a car are two different
diameters. The size is determined by the I.D. of the hose.
Hose comes in long rolls. Be sure that you select the cor-
rect size hose before cutting it off the main hose roll.
Twist the old heater hose to loosen it. If it does not
remove easily, cut it carefully with a sharp knife. When
installing the new section of hose, check the following:
■ Be certain that the hose does not interfere with
manifolds, drive belts, or spark plug cables.■ Check to see that the hose will not be damaged by
movement of the engine or accessories.Position the screw side of a screw clamp for easy
access. On lower radiator hoses, an extra-long screw-
driver or ¼" drive socket and extension can be used
to tighten the hose clamp from the top of the engine
compartment. Be sure the screw on the hose clamp is
positioned so it cannot accidentally come into contact
with the cooling fan.
When a hose is diffi cult to install, apply a small amount of soap to the connection.
SHOPTIPSHOPTIP
By-Pass Hose ReplacementObtain the correct replacement hose and compare
it to the existing hose (Figure 23.16). Sometimes
Figure 23.15 Clean the hose fi tting before installing the
new hose. The
Gate
s Cor
pora
tion
by-pass hoses must be cut to length. Use the old hose
as a template.
Do not try to substitute an unmolded hose for a molded by-pass hose. It can
fold when bent, restricting coolant fl ow.
CAUTIONCAUTION
Power Steering Hose ServiceWhen checking a power steering hose, look for signs
of leakage or dampness at the connections. Also, look
for signs of deterioration, such as cracks, signs of
rubbing, or swelling. A failed pressure hose can leak,
blowing oil onto an exhaust manifold, where it can
cause a fi re.
Power steering fl uid, which is not fl am-mable at engine operating tempera-
ture, is fl ammable at temperatures a little above 300°F (lower than the temperature of
an exhaust manifold).
CAUTIONCAUTION
Purchase the correct replacement hose and replace
the old one. Parts stores have extensive illustrated list-
ings for power steering hoses. It is also a good idea to
compare the new hose to the old hose to be sure that
the length and fi ttings are identical.
Exact replacement hydraulic hoses are sometimes not avail able. Some businesses
have special equip ment for making hydrau-
lic hoses. Check with a business that deals
with heavy truck, industrial, or farm implement
accounts.
SHOPTIPSHOPTIP
Replacement hose
Old hoseFigure 23.16 Compare the old hose to the new hose
before installing it. © C
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Cooling System Service 319
Drain the coolant into a clean drain pan. This is especially important if it is to be
reused, if the customer has recently had the
coolant changed, for instance. The customer will
most likely be unhappy if he or she is billed again
for new coolant.
SHOPTIPSHOPTIP
Loosen and remove all of the fasteners. Then
remove the pump and clean all remnants of the old
gasket off the engine. Be careful not to accidentally
gouge aluminum parts.Inspect the Old PumpInspect the old pump. Water pump impellers are made
of steel or plastic. Carefully inspect the impeller for ero-
sion, looseness, or breakage. If pieces break off the impel-
ler they will go into the block and, possibly, the radiator. Selecting a Replacement PumpReplacement water pumps are usually new, although
rebuilt pumps are available for some vintage engines.
When buying a rebuilt pump, the old one must be
turned in as a core, which is an old rebuildable part.
Carefully compare the new pump with the old one,
before leaving the parts store, if possible.
In some applications that use serpentine belts, the water pump is driven from the
bottom side, using the back of the belt. The
water pump turns the opposite direction of
a V-belt-driven pump. Be sure the correct pump is
installed or the impeller will be rotating backward,
resulting in engine overheating.
SHOPTIPSHOPTIP
Installing the New PumpSome water pumps have a steel cover plate attached
to the back. Check to see that the screws that hold
the cover are tight. Be sure that all gasket material is
thoroughly removed from the surface where the water
pump mates to the block. Be careful that any O-rings,
hoses, or gaskets are not damaged or forced during
assembly. Water pumps are often sealed to the block
with an artifi cial rubber O-ring. If the pump uses a
paper gasket, glue it to the pump with rubber cement.
If a chemical gasket is specifi ed, be sure that the sur-
faces of the pump and block have been cleaned of all
oil and coolant so that the chemical can stick. Verify
that the pump is perfectly fl at against the block before
tightening any fasteners.Refi lling the Cooling SystemFill the radiator with clean coolant mixed in the cor-
rect proportion. Inspect the hose from the radiator
■ A pump seal can fail because of bearing failure,
corrosion of the shaft, or dirt.■ The seal can become red hot if it is run without
coolant when a radiator boils over. Adding cold
water to an overheated system can shock the hot
seal, causing it to crack.■ When a vehicle sits for a prolonged period with a
dry or dirty cooling system, the water pump seal
sometimes sticks to the shaft. When the engine is
started, it breaks loose, resulting in a leak.Worn BearingA worn water pump shaft bearing can be a result of seal
failure. With the engine running, a stethoscope can be
used to listen to a bad bearing. Before replacing a pump,
loosen the drive belt and feel for roughness in the bear-
ing. It should turn freely and smoothly, without end play.Worn or Broken ImpellerSometimes a water pump impeller can be loose or bro-
ken, but this is rare. Look for water pump action in the
radiator with the engine warm and running. A broken
impeller can cause vibration and engine overheating,
especially at freeway speeds.Water Pump ReplacementThere are various types of water pump installations on
new vehicles. When in doubt about the procedure to
follow for pump removal, consult the service informa-
tion for the vehicle. When the engine does not have a
single serpentine drive belt, there are times when other
accessory belts must be removed to get to the belt that
drives the pump. When loosening belts, loosen the
accessory attachment bolts only slightly, just enough
to be able to move the accessory.
Look here for leakageFigure 21.37 The pump seal has failed when leakage is
evident at the vent hole. Tim G
illes
CH021.indd 319
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318 CHAPTER 21
NOTE: Some technicians routinely replace steel core
plugs in cast iron blocks with brass ones that will not
corrode. If coolant is regularly maintained, this is an
unnecessary practice. It is a good idea for boat engines,
however.
WATER PUMP SERVICECoolant pumps have been traditionally called water
pumps. They are often replaced after many years
and miles of service when they begin to leak or make
noise.
Leaking Water PumpSome pumps have a vent hole or weep hole in the
bottom of the pump (Figure 21.37). Leakage from
a water pump will usually be visible from the hole.
A water pump leak can also appear to be from the
lower radiator hose. Use a mirror to look at the weep
hole. Pressurize the system if necessary with a pressure
tester.
An apprentice technician was overhaul-ing an engine and removed the core plugs. The wall of one of the cylinders was posi-tioned directly behind a core plug. The
core plug became wedged between the block and the
cylinder wall, so he forced it out. A cylinder wall is not
very rigid and can easily become distorted when some-
thing is forced against it.During reassembly, the apprentice attempted to rein-
stall the piston and rings, but the piston would not fi t
easily into the cylinder. When the shop master techni-
cian measured the cylinder, he found that it was out
of round by 0.005". The piston clearance specifi cation
was 0.002". The block had to be sent out to a machine
shop for boring and honing because the cylinder wall
had been distorted during core plug removal.
CASEHISTORYCASEHISTORY
Core Plug InstallationBefore installing a core plug in an iron block, clean the
opening in the block with sandpaper or emery cloth.
Put some sealer on the sides of the new core plug and
pound it into place with a core plug driver or a socket
that fi ts loosely into the inside diameter of the plug
(Figure 21.35). Check to see that the driver contacts
the core plug only on its inside surface and not on its
outer sealing edge. Be careful to drive the core plug
straight into its bore. A core plug seals on its outer lip.
It is correctly installed when the lip is against the bore.
Pound it in until the outside sealing edge is just below
the chamfer that is on the outside of the core plug bore
(Figure 21.36).
Core plug opening Back side of cylinder
Figure 21.34 This cylinder wall casting is directly behind
the core plug opening, making core plug removal more
diffi cult.
Tim G
illes
Figure 21.35 Drive in the core plug. Be sure to use a
brass hammer to avoid damaging the tool.
Tim G
illes
Figure 21.36 Installing a core plug. Install the core plug
until it is all the way into the hole.
Outsideof block
.020"minimum
Chamfer
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264 CHAPTER 19
Studs
Bolts
BoltsFigure 19.5 These main bearing caps have four studs
and two more from the side.
Tim G
illes
clearance, just enough to allow oil to leak below to
lubricate the camshaft lobes.CRANKSHAFT DESIGNThe crankshaft converts the reciprocating (up-and-
down) motion of the pistons to rotary motion. The
polished crankshaft bearing surfaces are called journals. Main Bearing JournalsThe main bearing journals are the ones that support the
crankshaft as it turns in the block. The journals that
are in line on the same axis as the front and rear jour-
nals are all main bearing journals.Rod Bearing JournalsJournals that are offset from the main bearing journal
centerline are called rod journals or crankpins. Connect-
ing rod journals transfer up-and-down motion between
the crankshaft and connecting rod. Rod journals are
also known as crankpins. As described in Chapter 15,
connecting rod journals are offset at 90-degree angles
for eight cylinders, 120-degree angles for even-fi re six
cylinders, and 180-degree angles for four cylinders.
The crankshaft has oil passages drilled from the main
journals to the rod journals. This allows ilsure to reach the co
VINTAGE ENGINESAlmost all vintage engines suffered from taper and
out-of-round cylinder wall wear. Older engines used
piston rings that had higher tension than today’s
rings. A bigger factor in cylinder wall wear in older
engines, however, was that they used a fuel deliv-
ery system that had a carburetor with a choke. The
choke closed off incoming air to provide a richer
mixture for better cold driveability. A carburetor
choke is nowhere near as effi cient, however, in
delivering fuel to a cold engine as a fuel injection
system. Oil cannot be burned from the surface of a
cylinder wall, but it can be washed away by fuel and
then burned in the combustion chamber. When an
engine was cold, the carburetor would routinely
provide too much fuel. This would wash oil from
the cylinder walls, leaving them susceptible to
increased wear.
When piston-to-cylinder-wall clearance is within
specifi cations, out-of-round wear is minimal. When
there is excessive piston skirt clearance, out-of-round
wear can result when the piston tilts from one side to
the other as it stops and changes direction at the top
of the cylinder.CYLINDER SLEEVESAluminum blocks usually have permanently installed
iron cylinder sleeves. Heavy-duty engines and some
vintage automotive engines use replaceable cylinder
bores, called wet or dry sleeves. When a cylinder wall
is cracked or rusted or the block has a serious defect,
if the wear in all the other cylinders is acceptable the
damaged cylinder can be bored oversize for installa-
tion of a pressed-fi t dry sleeve (see Chapter 53). Some
heavy-duty engines use removable wet sleeves that dif-
fer from conventional sleeves in that they only contact
the block at the upper and lower ends of the cylinder
to prevent coolant leakage. MAIN BEARING CAPSAt the factory, main bearing bores are machined with
the bearing caps in place. Main caps are not inter-
changeable and must be returned to the same bearing
bores from which they were removed. Two-bolt main
bearing caps are the norm, but some hperformance and lb
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SAFETY NOTES
Safety is the number-one priority in an automo-tive shop. There are numerous safety notes placed throughout the text. Most of the safety notes have been taken from real-world experiences and many are accompanied by actual case histories.
CASE HISTORIES
Case histories are presented throughout the text. These true stories recount actual automotive situ-ations encountered by the author in over 30 years in automotive service. Case histories present the reader with examples of the pattern of critical thinking skills required to diagnose automotive problems.
SCIENCE, HISTORY, COMPUTER SYSTEM, AND MATH NOTES
These notes are included when interesting top-ics relating to them are covered in the text. The objective of these features is to pique the student’s interest and show a correlation between his or her automotive studies and these areas of learning.
REVIEW QUESTIONS
These questions guide the student to the most important points in the chapter and act as a check for understanding of the material. Each chapter’s review questions are presented in the same order in which they appear in the chapter. This pro-vides an instructor with the fl exibility to assign portions of the chapter to read and then follow up with a few of the study questions.
ASE-STYLE REVIEW QUESTIONS
These questions are designed to provide prepa-ration for the certifi cation examinations admin-istered by the National Institute for Automotive Service Excellence (ASE). The ASE test is a task-ori-ented test (the test taker is supposed to be able to relate to shop-oriented questions), so the practice tests should help the student in becoming famil-iar with accepted trade procedures.
Automotive Plumbing: Tubing and Pipe 351
Do not replace steel tubing fuel or brake
lines with copper. As copper line fl exes
and vibrates, it work hardens and can
crack.
SAFETYNOTE
SAFETYNOTE
Cutting Tubing
When tubing is cut to length, it must be square on the
end. A tubing cutter is good for this (Figure 24.22).
Using a hacksaw will leave a rough edge that might not
be square. Dressing the end of the tubing with a fi le can
leave metal chips in the end of the tube. If the metal chips
are not removed, serious damage to parts can result.
When cutting tubing with a tubing cutter, the
tool is tightened against the tubing. Then it is rolled
around the tubing while continuously tightening the
handle to advance the cutter as it moves further into
the tubing. Be careful not to advance the cutter too fast
as it fi nishes cutting through the tubing. If the cutter
breaks through too fast, the tubing can be damaged.
After the tubing has been cut, a burr usually
remains on the end. Most tubing cutters have a reamer
blade for removing the burr (Figure 24.23). Be sure to
remove metal chips from the end of the tubing after
completing the cut.
Some tubing cutters are very small. In tight quar-
ters, these can be used for repairing damaged tubing on
the vehicle. The tubing cutter shown in Figure 24.24
is especially handy for this.
Bending Tubing
Be especially aware when bending tubing because too
sharp a bend can kink and restrict the tubing. A tubing
bender can be used to form tubing (Figure 24.25).
Tubing can also be bent by holding it over a large piece
of pipe and slowly forming it. Use the tubing being
replaced as a guide and be careful not to bend the tub-
ing too sharply.
Install the fi ttings and fl are both ends before
bending the tubing. Otherwise, if the bend is too
SHUTOFF VALVES
Shutoff valves, also called draincocks, are often found
on the bottom of a radiator. Turning the end of the
valve one way or the other opens it or closes it. Plastic
radiator tanks usually have a plastic drain valve.
TUBING SERVICE
Tubing is purchased in 25-foot rolls or in straight precut
lengths with fl are fi ttings at each end. Precut brake tub-
ing usually has a short fl are nut at one end and a long
fl are nut at the other end. If the tubing being replaced
has bends, measure it using a piece of string to deter-
mine the correct length.
When unrolling bulk tubing, be careful not to kink
it. Unroll it in the same direction that it was rolled.
When fi ttings are to be installed on the line, add an addi-
tional 1⁄8" at each end for the fl are to be formed (¼" total).
Flared tubing is held tightly against a seat in the
fi tting. Always use two wrenches when loosening a
fl ared tubing connection. Use a tubing wrench or
fl are-nut wrench and an open-end wrench. The sec-
ond wrench holds the female part of the fi tting. If the
female fi tting is allowed to turn when the male fl are
fi tting is turned with a wrench, the tubing will kink.
Damaged steel fuel lines can be cut and repaired,
or new lines can be fabricated using a fl aring tool. Use
only seamless steel tubing.
Long nipple
Close nipple
(b)
(a)
Figure 24.20 Pipe nipples.
Dana
Cor
pora
tion
3/4"
1/2"
3/8"
Figure 24.21 Internal pipe wrenches.
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Figure 24.22 Using a tubing cutter to cut tubing.
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314 CHAPTER 21INTERNAL LEAKS
A leaking head gasket or a crack in a cylinder head or
bore can result in an internal leak (Figure 21.28).
When there is an internal leak, coolant will fl ow into
the cylinder during the intake stroke and when the
engine is off. During combustion, exhaust gas is forced
into the cooling system and can appear as bubbles in
the radiator (Figure 21.29). There are several tests
that can be done to confi rm an internal leak.
An effective way of determining whether
coolant is leaking into a cylinder is as follows:
■ Pressurize the cooling system with a
cooling system pressure tester.
■ Allow the vehicle to sit overnight with the
cooling system pressurized.
■ Remove all of the spark plugs.
■ Hold paper in front of the spark plug holes
while cranking the engine. If coolant is leaking
into a cylinder, the paper in front of that spark
plug hole will become wet.
SHOPTIPSHOPTIP
Bubble Test
Look for bubbles in the radiator when the engine is
warm and under a load. Rapidly accelerating the engine
is usually enough of a load to produce the bubbles.
NOTE: Cracks tend to leak more when the engine is cold.
After warmup, the crack closes.
When pressure caused by a combustion leak
exceeds the pressure of the radiator cap spring, the
radiator cap will spew coolant. To verify that this is
caused by combustion pressure, put the radiator over-
fl ow hose into a container of water while the engine
A student wanted to replace leaking core
plugs on the back of the block between the
engine and the transmission. He removed
the automatic transmission from the car
and removed the fl explate from the back of the crank-
shaft. Unfortunately, the block he was working on did
not have core plugs on the back. When he pressurized
the cooling system, he found that a core plug behind
one of the engine mounts on the side of the block was
leaking. Coolant was running down the edge of the
oil pan to the rear of the block, where it appeared to
be coming from behind the fl ywheel. If he had used a
pressure tester and fl ashlight to lo cate the leak before
attempting the repair, he would have saved a good deal
of needless work.
CASEHISTORY
CASEHISTORY
Coolant Outlet Housing Inspection
Inspect the coolant outlet (thermostat) housing for leaks
or damage. Aluminum housings sometimes suffer elec-
trolysis damage. When replacing a coolant outlet hous-
ing, install an aluminum housing on an aluminum head
and an iron housing on an iron head. Be sure to position
the hose clamp in the correct place to prevent corrosion
between the hose and the housing (Figure 21.27).
WrongRight
Crevice
Ridge
Corrosion
Figure 21.27 Failure to position the hose clamp near the
ridge on the outlet housing leads to corrosion.
Tim G
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Figure 21.28 When there is an internal leak, coolant
will fl ow into the cylinder when the engine is off and dur-
ing the intake stroke. During combustion, exhaust gas
migrates into the cooling system.
Combustion
chamber
Cooling
system
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Safety, Security, Comfort Systems, and Electrical Accessories 513
the bladder and pressure sensor. The occupant-sensing
module is sometimes called the occupant classifi cation
module.Another method of weight sensing uses a strain
gauge at each corner of the seat frame (Figure
34.26) where they support the seat. A circuit board
bonded to each gauge has a metallic foil grid that
changes resistance under strain. When the weight on
the seat changes, sensor voltage output information
to the occupant-sensing module changes as well.
Driver- and passenger-side seat track position sensors
are also part of some systems. All of this information
is analyzed by the computer when it deploys the air
bags.
Figure 34.24 A warning light illuminates when the pas-
senger seat is occupied and the air bag is disabled.
Tim G
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Module
Sensor
Bladder
Figure 34.25 Parts of an occupant-sensing seat.
Delp
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■■ SCIENCE AND MATH NOTE ■■
Air bag deployment is based on the rate of change in
acceleration measured by the accelerometer. The rate
of change, called JERK, is mapped through time by a
mathematical algorithm. The algorithm, based on a
genetic model, is used to make the complex decisions
during a crash regarding whether, and how to, deploy
the system. The algorithm improves each year as more
is learned about crash protection.
The computer repeatedly monitors the acceler-
ometer value during fractions of a second. In GM’s
system, when an average of four consecutive samples
exceeds a force of 1–2 g, the algorithm is enabled and
determines whether a deployment should occur. This
decision is made very fast (in less than 20 mS). An air
bag is usually fully infl ated within 50 mS of impact. A
millisecond is 1/1000 of a second. Fully infl ating an air
bag in 50/1000 of a second is remarkable.
Although the mathematical calculations regard-
ing crashes are becoming more sophisticated with
experience, accidents like collisions with a tree or pole
are diffi cult for the algorithm to resolve because they
provides a slower event. Imagine driving into a saw
blade that cuts the car in half but does not provide the
accelerometer with a measurable “g” force.
Newer systems are able to consider vehicular forces
during a rollover. An angular rate sensor tells how
quickly the vehicle is rolling over and how many times
it rolls. It includes automatic fuel cutoff and automatic
battery disconnect. Current systems allow the air bag
to stay infl ated for up to 7 seconds. Chances of a roll-
over lasting longer than this are remote.
When a vehicle has a satellite communication sys-
tem, computers that are part of the air bag system can
sense that an accident has occurred and send emer-
gency vehicles to the site.
Radar-based systems can sense when a vehicle will
not be able to stop in time to avoid an accident and
the computer will begin air bag deployment. The same
system is used for adjustable distance cruise control,
discussed later.
Figure 34.26 A strain gauge used at the corners of a
passenger seat frame for occupant sensing.
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344 CHAPTER 23
REVIEW QUESTIONS
1. Hoses are sized by their inside/outside (circle
one) diameter.
2. What special feature allows formable hose to
bend without kinking?
3. The inside of transmission oil cooler hose can
withstand constant temperatures of up to ____°.
4. When there are two hoses in a power steering
system, what are they for?
5. What is the name of the type of hose clamp to
use for fuel injection system hoses?
6. What is a drawback to screw tower hose
clamps?
7. On a conventional flow cooling system, which
radiator hose suffers the most abuse, the upper
or the lower? Why?
8. If a hose does not come off a radiator fitting
easily, what should be done?
9. What can happen if a regular hose is substituted
for a molded by-pass hose?
10. Can power steering fluid catch fire?
ASE-STYLE REVIEW QUESTIONS
1. Which of the following statements is/are true
about a fuel hose?
a. It can be used to replace a damaged section
of transmission oil cooler tubing.
b. Fuel injection hoses have pressure in them
even when the engine is off.
c. Both A and B
d. Neither A nor B
2. Technician A says that a worm gear clamp is
the best style to use in a fuel injection system.
Technician B says that for a hose clamp to work
properly, it should be positioned on top of the
sealing ridge on the connection. Who is right?
a. Technician A c. Both A and B
b. Technician B d. Neither A nor B
3. All of the following are true statements about
hoses except:
a. On a conventional fl ow cooling system, a
lower radiator hose is more likely to leak
air than an upper hose after a new hose
shrinks.
b. Brake hose has either raised ribs or stripes
to help guard against twisting it during
installation.
c. Clamps used on neoprene radiator hoses
do not have to be retightened because this
kind of hose does not shrink like EPDM
hose.
d. A power steering return line often has a
hose clamp, rather than a crimped fi tting.
4. Which of the following can cause damage to a
rubber hose?
a. Heat c. Coolant
b. Oil d. A and B only
5. Technician A says that a defective brake hose
can cause delayed engagement of the brake.
Technician B says that a defective brake hose
can prevent brakes from releasing. Who is
right?
a. Technician A c. Both A and B
b. Technician B d. Neither A nor B
CH023.indd 344
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FEATURES OF THE TEXT xxiii
SUPPLEMENTS
■ Instructor Resources—The fourth edition Instructor Resources DVD includes an Instructor’s Guide in Microsoft Word, a Computerized Test Bank in ExamView with hundreds of modifiable questions (true/false, fill-in-the-blank, and ASE-style multiple choice), chapter presentations in PowerPoint with full-color images, video clips and animations, a searchable Image Library of hundreds of full-color photos and line art from the core text, and Correlation Grids to the NATEF Automobile Program Standards.
■ CourseMate—The all new CourseMate for Automotive Service, 4th edition, offers students and instructors access to important tools and resources, all in an online environment. The CourseMate includes an Interactive eBook for Automotive Service, Fourth Edition, nearly 300 videos and animations, interactive quizzes, flashcards, an interactive glossary, and an Engagement Tracker tool for monitoring students’ progress in the CourseMate product.
■ WebTutor Advantage—Newly available for Automotive Service is the WebTutor Advantage for the Blackboard online course management system. The WebTutor includes chapter presentations in PowerPoint, end-of-chapter review questions, pretests and posttests, discussion springboard topics, and more, all designed to enhance the classroom and shop experience.
■ Lab Manual—The Lab Manual includes Worksheets that define each lab procedure, presented in increasing levels of difficulty. Each project or lab assignment is built upon the next in a logical sequence in much the same manner as science instructional programs are constructed, and the reader completes one task before progressing to the next one. In addition, a variety of illustrations support the Worksheets and help visual learners better understand the jobs. The Worksheets are keyed to the NATEF Auto General Service Technician Programs Standards where applicable.
■ Automotive Service Job Sheets for NATEF Task Mastery—The Job Sheets in this manual cover all P-1, P-2, and most P-3 procedures as identified by the most recent NATEF Automobile Program Standards. Full-color illustrations offer visual support to the Job Sheets, and the sequence of topics follows that of the core text. Each Job Sheet includes a simple and clear rating rubric for instructor evaluation of student performance on the task, and a supplemental CD-ROM includes NATEF task-tracking software for easy recording of students’ mastery of the procedures.
Teaching aids/Handouts:Safety tests (due today)safety transparencies (in file with safety tests)
Wheel lug torque handoutHydraulics TransparencyGousha Lift Transparencies - cover lift points onlyLesson:Students will meet in the classroom at the beginning of each lab day. We will see who brought in cars
and reassign jobs to any groups where the assigned person did not bring a car. The LTA or teacher will
inform the security guard at the kiosk that no permits are to be honored unless they have a handwrit-
ten note from the instructor giving permission to be late. The reason for this is that the people who are
tardy will already have had their project reassigned to another person in the group.
❏ Check add cards to see that they have been processed by admissions
❏ Spend about 45 minutes covering lift points, the Car Care Guide (lift points only). Demo the lifts
and jacks.❏ Show the lab manual, go over lab assignment sheet #1, and the lab schedule. There is a lab assign-
ment sheet for each week’s lab. All labs must be completed before other lab projects can be under-
taken. ❏ Describe the difference between 10 ton, 2 ton, and 1 1/2 ton Jacks, use transparency.
❏ Tell personal stories related to safety as you read each safety test question and put the answer on
the board for them to copy onto the copy of the test that will be saved in our file.
Go to lab for the demo and return to class afterward for the safety presentation
❏ Safety test from book. Pass out the safety test and have them fill them in. Put all answers to safe-
ty test on board. Most of them were covered last time during the service station safety section.
Put a wrong answer on the board, even though you read the right sentence. Substituting “acid”
for “water” works well. See how many of them write the wrong word down because they were
not paying attention. Try it again and you’ll probably still catch some of them. Have them cor-
rect each others’ test and then fix any wrong answers.
❏ Describe the Starburst symbol on a can of oil.
❏ Tell people bringing oil changes to look up their oil capacity in the Car Care Guide first, or bring
5 quarts to be safe. Next class is lecture/demo only. Oil changes will be half of the class after it.
Find one student who wants to bring in a car with oil and a filter to have demonstrated next class (lec-
ture day).
❏ After the safety test have a shop tour.❏ If time remains after the tour, they can complete their jacking and lifting assignments and get their
shop workbooks signed off Demo:Show them how to locate lift points for their vehicle in the Car Care Guide. Look up the lift points for
the demo shop cars, Xerox them and have them inside the windshield so you can show the beginners
where the lift points are and what the sheet that they should be xeroxing looks like.
000
Part III: Lesson Plans - Fundamentals Of Automotive Servicing ■
▲ LAB # 1 RACK/JACKS/SAFETY/SPEC MANUALS
OBJECTIVE:Upon completion of this assignment, you will be able to connect an oil pressure gauge to measure
an engine oil pressure. This task will help prepare you to pass the ASE certification examination in
engine repair.
DIRECTIONS:Before beginning this lab assignment, review the worksheet completely. Fill in the information in the
spaces provided as you complete each task.TOOLS AND EQUIPMENT REQUIRED:Safety glasses, fender covers, hand tools, flare nut wrenches, oil pressure gauge, shop towel
PROCEDURE:Vehicle year Make
Model
Repair Order # Engine
# of Cylinders 1. Locate the oil pressure specification in the service manual and record the information below.
Which manual was used? The specification was located on page number Minimum psi at
rpmMaximum psi at
rpm2. Open the hood and place fender covers on the fenders and front body parts.
Yes No 3. Engine temperature:Cold
Warm 4. The vehicle is equipped with an:Oil pressure gauge Indicator light
5. Check the operation of the oil pressure light. Turn the ignition key on and the engine off. Does
the indicator light glow?Yes No Not equipped
6. Locate the sending unit on the engine.On what part of the engine is it located?
443
ASE Lab Preparation Worksheets: Service Area 8
■
Instructor OK _______________________ Score ____________ASE LAB PREPARATION WORKHEET # 8-11
Checking Engine Oil PressureName______________________________ Class ______________________
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