Automotive Technology Tech Manual

by Raadsheer, Fred; Erjavec, Jack

• ISBN13: 9781401848330
• ISBN10: 1401848338
• Edition: 4th
• Format: Paperback
• Copyright: 2004-08-04
• Publisher: Cengage Learning

Summary

Tech manual for learning automotive technology. Includes skill building features such as shop activities, case studies, review questions, an ASE prep test, and more. Previous edition: c2000. Three-hole punched with perforated pages.

Table of Contents

Preface	xv
SECTION 1 AUTOMOTIVE TECHNOLOGY	1	(77)
Careers in the Automotive Industry	2	(4)
Shop Activity 1--1	3	(1)
Shop Activity 1--2	3	(1)
Shop Activity 1--3	3	(1)
Review Questions	4	(2)
Workplace Skills	6	(7)
Shop Activity 2--1	7	(1)
Shop Activity 2--2	7	(1)
Shop Activity 2--3	7	(4)
Shop Activity 2--4	11	(1)
Review Questions	11	(2)
Working Safely in the Shop	13	(8)
Shop Activity 3--1	13	(1)
Shop Activity 3--2	14	(1)
Shop Activity 3--3	14	(3)
Shop Activity 3--4	17	(2)
Shop Activity 3--5	19	(1)
Review Questions	19	(2)
Automotive Systems and Preventive Maintenance	21	(9)
Shop Activity 4--1	21	(1)
Shop Activity 4--2	22	(1)
Shop Activity 4--3	22	(1)
Shop Activity 4--4	23	(4)
Job Sheet 4--1 Basic Preventive Maintenance Inspection	27	(2)
Review Questions	29	(1)
Hand Tools and Shop Equipment	30	(23)
Shop Activity 5--1	30	(1)
Shop Activity 5--2	31	(1)
Shop Activity 5--3	31	(1)
Shop Activity 5--4	31	(1)
Shop Activity 5--5	31	(2)
Job Sheet 5--1 Repairing and/or Replacing Damaged Threads	33	(4)
Job Sheet 5--2 Cutting with a Chisel	37	(2)
Job Sheet 5--3 Proper Use of a Vehicle Hoist	39	(2)
Job Sheet 5--4 Proper Use of a Hydraulic Floor Jack	41	(2)
Job Sheet 5--5 Proper Use of a Stationary Grinder	43	(4)
Job Sheet 5--6 Proper Use of a Service Manual	47	(2)
Job Sheet 5--7 Proper Use of Electronic Media	49	(2)
Review Questions	51	(2)
Diagnostic Equipment and Special Tools	53	(17)
Shop Activity 6--1	54	(3)
Job Sheet 6--1 Checking the Pressure in a Cooling System	57	(2)
Job Sheet 6--2 Understanding DMM Controls	59	(2)
Job Sheet 6--3 Identifying Special Drivetrain Tools	61	(2)
Job Sheet 6--4 Dismounting and Mounting a Tire from a Wheel	63	(2)
Job Sheet 6--5 Measuring Brake Rotor Thickness	65	(2)
Job Sheet 6--6 Checking the Clearance (Air Gap) of an Air-Conditioning Compressor's Clutch	67	(1)
Review Questions	68	(2)
Basic Theories and Math	70	(8)
Shop Activity 7--1	70	(1)
Shop Activity 7--2	70	(1)
Shop Activity 7--3	70	(1)
Shop Activity 7--4	70	(6)
Job Sheet 7--1 Charging a Battery
Job Sheet 7--2 Determine the A/C System Static Pressure with the Engine Off
Job Sheet 7--3 Demonstrate a Magnetic Field
Review Questions	76	(2)
SECTION 2 ENGINES	78	(117)
Automotive Engine Designs and Diagnosis	79	(12)
Shop Activity 8--1	80	(1)
Shop Activity 8--2	80	(1)
Shop Activity 8--3	80	(1)
Job Sheet 8--1 Performing a Cylinder Compression Test	81	(2)
Job Sheet 8--2 Performing a Cylinder Leakage Test	83	(4)
Job Sheet 8--3 Measuring Engine Oil Pressure	87	(2)
Case Study	89	(1)
Review Questions	89	(2)
Engine Disassembly	91	(17)
Shop Activity 9--1	91	(1)
Shop Activity 9--2	92	(1)
Job Sheet 9--1 Preparing Engine for Removal	93	(8)
Job Sheet 9--2 Removing and Disassembling the Cylinder Head	101	(4)
Job Sheet 9--3 Removing Cylinder Ring Ridge	105	(1)
Case Study	106	(1)
Review Questions	106	(2)
Short Blocks	108	(35)
Shop Activity 10--1	109	(1)
Shop Activity 10--2	110	(1)
Shop Activity 10--3	110	(1)
Shop Activity 10--4	110	(1)
Shop Activity 10--5	110	(1)
Shop Activity 10--6	110	(1)
Shop Activity 10--7	110	(1)
Job Sheet 10--1 Measuring Cylinder Bore	111	(4)
Job Sheet 10--2 Measuring Crankshaft Journals	115	(4)
Job Sheet 10--3 Measuring Crankshaft End Play	119	(2)
Job Sheet 10--4 Installing Pistons and Connecting Rods	121	(4)
Job Sheet 10--5 Measuring Camshaft Lobes/Cams and Bearing Journals	125	(4)
Case Study	129	(2)
Job Sheet 10--6 Installing Camshaft Bearings	131	(4)
Job Sheet 10--7 Inspecting and Replacing Camshaft Drives	135	(2)
Job Sheet 10--8 Testing for Worn Cam Lobes	137	(3)
Review Questions	140	(3)
Cylinder Heads and Valve Trains	143	(23)
Shop Activity 11--1	143	(1)
Shop Activity 11--2	144	(1)
Job Sheet 11--1 Inspecting Cylinder Head for Wear	145	(4)
Job Sheet 11--2 Inspecting and Testing Valve Springs for Squareness, Pressure, and Free Height Comparison	149	(2)
Job Sheet 11--3 Inspecting Valve Spring Retainers, Locks, and Valve Lock Grooves	151	(2)
Job Sheet 11--4 Replacing Valve Stem Seals in Vehicle	153	(2)
Job Sheet 11--5 Reconditioning Valve Faces	155	(4)
Job Sheet 11--6 Inspecting Valve Lifters, Pushrods, and Rocker Arms	159	(2)
Job Sheet 11--7 Reconditioning Valve Seats	161	(2)
Case Study 1	163	(1)
Case Study 2	164	(1)
Review Questions	164	(2)
Lubricating and Cooling Systems	166	(18)
Shop Activity 12--1	167	(1)
Shop Activity 12--2	167	(7)
Shop Activity 12--3	174	(1)
Shop Activity 12--4	174	(1)
Job Sheet 12--1 Servicing and Installing Oil Pump and Oil Pan	175	(4)
Job Sheet 12--2 Inspecting, Replacing, and Adjusting Drive Belts and Pulleys	179	(2)
Job Sheet 12--3 Cleaning, Inspecting, Testing, and Replacing Electric Cooling Fans and Cooling System-Related Temperature Sensors	181	(1)
Case Study	182	(1)
Review Questions	183	(1)
Engine Sealing and Reassembly	184	(11)
Shop Activity 13--1	184	(2)
Shop Activity 13--2	186	(1)
Job Sheet 13--1 Applying RTV Silicone Sealant	187	(2)
Job Sheet 13--2 Adjusting Valves on an OHC Engine	189	(1)
Review Questions	190	(1)
ASE Prep Test	191	(4)
SECTION 3 ELECTRICITY	195	(152)
Basics of Electrical Systems	196	(8)
Shop Activity 14--1	197	(3)
Shop Activity 14--2	200	(1)
Shop Activity 14--3	201	(2)
Review Questions	203	(1)
Basics of Electronics	204	(8)
Shop Activity 15--1	204	(1)
Shop Activity 15--2	205	(2)
Job Sheet 15--1 Testing for Continuity Across Electronic and Electrical Components and Circuits with an Ohmmeter	207	(3)
Review Questions	210	(2)
General Electrical System Diagnostics and Service	212	(17)
Job Sheet 16--1 Checking Continuity in a Circuit with a Test Light	215	(2)
Job Sheet 16--2 Testing for Voltage with a DMM	217	(2)
Job Sheet 16--3 Testing Voltage Drop Across Connectors	219	(2)
Job Sheet 16--4 Inspecting and Testing Fuses, Fusible Links, and Circuit Breakers	221	(1)
Job Sheet 16--5 Part Identification on a Wiring Diagram	222	(3)
Job Sheet 16--6 Using a DSO on Sensors and Switches	225	(2)
Review Questions	227	(2)
Batteries: Theory, Diagnosis, and Service	229	(13)
Shop Activity 17--1	229	(1)
Shop Activity 17--2	229	(1)
Shop Activity 17--3	230	(1)
Job Sheet 17--1 Removing, Cleaning, and Replacing a Battery	231	(4)
Job Sheet 17--2 Inspecting a Battery for Condition, State of Charge, and Capacity	235	(4)
Job Sheet 17--3 Charging a Maintenance-Free Battery	239	(2)
Case Study	241	(1)
Review Questions	241	(1)
Starting Systems	242	(14)
Shop Activity 18--1	243	(2)
Job Sheet 18--1 Removing, Inspecting, and Replacing a Starter Motor	245	(4)
Job Sheet 18--2 Testing the Starter and Starter Circuit	249	(4)
Job Sheet 18--3 Control Circuit Test	253	(1)
Case Study	254	(1)
Review Questions	255	(1)
Charging Systems	256	(26)
Shop Activity 19--1	257	(2)
Job Sheet 19--1 Visually Inspecting the Charging System	259	(2)
Job Sheet 19--2 Inspecting, Replacing, and Adjusting Drive Belts and Pulleys	261	(4)
Job Sheet 19--3 Removing and Replacing an AC Generator	265	(2)
Job Sheet 19--4 Testing the Charging System	267	(4)
Job Sheet 19--5 Disassembling and Assembling the AC Generator	271	(2)
Job Sheet 19--6 Inspecting, Cleaning, and Testing AC Generator Components	273	(7)
Case Studies	280	(1)
Review Questions	280	(2)
Lighting Systems	282	(17)
Shop Activity 20--1	282	(1)
Shop Activity 20--2	283	(6)
Job Sheet 20--1 Inspecting and Testing a Headlight Switch	289	(4)
Job Sheet 20--2 Aiming Headlights	293	(2)
Job Sheet 20--3 Adjusting or Replacing a Stop-Light Switch	295	(2)
Case Study	297	(1)
Review Questions	297	(2)
Electrical Instrumentation	299	(9)
Shop Activity 21--1	299	(6)
Job Sheet 21--1 Removing, Checking, and Replacing a Temperature Sending Unit	305	(1)
Review Questions	306	(2)
Electrical Accessories	308	(23)
Shop Activity 22--1	308	(11)
Job Sheet 22--1 Testing and Repairing a Rear-Window Defogger Grid	319	(2)
Job Sheet 22--2 Performing a Speed or Cruise Control Simulated Road Test	321	(4)
Job Sheet 22--3 Identifying the Source of Static on a Radio	325	(2)
Case Study	327	(2)
Review Questions	329	(2)
Restraint Systems	331	(16)
Shop Activity 23--1	331	(1)
Shop Activity 23--2	332	(1)
Job Sheet 23--1 Inspecting Seat Belts	333	(4)
Job Sheet 23--2 Working Safely Around Air Bags	337	(2)
Case Study	339	(1)
Review Questions	339	(2)
ASE Prep Test	341	(6)
SECTION 4 ENGINE PERFORMANCE	347	(117)
Ignition Systems and Ignition System Diagnosis and Service	348	(19)
Shop Activity 24/25--1	348	(1)
Shop Activity 24/25--2	349	(2)
Job Sheet 24/25--1 Scope Testing an Ignition System	351	(4)
Job Sheet 24/25--2 Testing an Ignition Coil	355	(2)
Job Sheet 24/25--3 Testing Individual Components	357	(4)
Job Sheet 24/25--4 Setting Ignition Timing	361	(2)
Job Sheet 24/25--5 Visually Inspecting an El System	363	(1)
Case Study	364	(1)
Review Questions	365	(2)
Fuels and Other Energy Sources	367	(6)
Shop Activity 26--1	368	(1)
Job Sheet 26--1 Testing the RVP of Gasoline	369	(2)
Case Study	371	(1)
Review Questions	371	(2)
Fuel Systems and Fuel System Diagnosis and Service	373	(9)
Shop Activity 27--1	374	(1)
Shop Activity 27--2	374	(1)
Job Sheet 27--1 Relieving Fuel System Pressure in an EFI System	375	(2)
Job Sheet 27--2 Testing Fuel Pump Pressure in an EFI System	377	(2)
Job Sheet 27--3 Replacing an In-Line Fuel Filter	379	(1)
Case Study	380	(1)
Review Questions	380	(2)
Electronic Fuel Injection and Fuel Injection System Diagnosis and Service	382	(20)
Shop Activity 28/29--1	383	(2)
Shop Activity 28/29--2	385	(4)
Shop Activity 28/29--3	389	(4)
Job Sheet 28/29--1 Visually Inspecting an EFI System	393	(2)
Job Sheet 28/29--2 Checking the Operation of the Fuel Injectors on an Engine	395	(2)
Job Sheet 28/29--3 Conducting an Injector Balance Test	397	(2)
Case Studies	399	(1)
Review Questions	399	(3)
Intake and Exhaust Systems	402	(8)
Shop Activity 30--1	402	(1)
Shop Activity 30--2	403	(2)
Job Sheet 30--1 Inspecting an Exhaust System	405	(2)
Case Study 1	407	(1)
Case Study 2	408	(1)
Review Questions	408	(2)
Emission Control Systems and Emission Control System Diagnosis and Service	410	(22)
Shop Activity 31/32--1	411	(1)
Shop Activity 31/32--2	411	(1)
Shop Activity 31/32--3	411	(1)
Shop Activity 31/32--4	412	(1)
Job Sheet 31/32--1 Checking the Emission Levels on an Engine	413	(8)
Job Sheet 31/32--2 Testing the Operation of a PCV System	421	(2)
Job Sheet 31/32--3 Testing the Operation of an EGR Valve	423	(4)
Job Sheet 31/32--4 Testing a Catalytic Converter for Efficiency	427	(3)
Case Study	430	(1)
Review Questions	430	(2)
On-Board Diagnostic Systems and On-Board Diagnostic System Diagnosis and Service	432	(32)
Shop Activity 33/34--1	438	(1)
Shop Activity 33/34--2	438	(1)
Job Sheet 33/34--1 Retrieving Diagnostic Trouble Codes (DTCs) from the Computer of an Engine Control System	439	(2)
Job Sheet 33/34--2 Testing an ECT Sensor	441	(2)
Job Sheet 33/34--3 Testing the Operation of a TP Sensor	443	(2)
Job Sheet 33/34--4 Testing an O2 Sensor	445	(4)
Job Sheet 33/34--5 Testing a MAP Sensor	449	(4)
Job Sheet 33/34--6 Conducting a Diagnostic Check on an Engine Equipped with OBD-II	453	(4)
Job Sheet 33/34--7 Monitoring the Adaptive Fuel Strategy on an OBD-II-Equipped Engine	457	(2)
Case Study 1	459	(1)
Case Study 2	459	(1)
Review Questions	459	(2)
ASE Prep Test	461	(3)
SECTION 5 MANUAL TRANSMISSIONS AND TRANSAXLES	464	(66)
Clutches	465	(24)
Shop Activity 35--1	465	(1)
Shop Activity 35--2	465	(4)
Job Sheet 35--1 Troubleshooting a Clutch Assembly	469	(6)
Job Sheet 35--2 Removing the Clutch	475	(4)
Job Sheet 35--3 Inspecting and Servicing the Clutch	479	(4)
Job Sheet 35--4 Reassembling and Installing the Clutch	483	(3)
Case Studies	486	(1)
Review Questions	487	(2)
Manual Transmission and Transaxles and Manual Transmission and Transaxle Service	489	(12)
Shop Activity 36/37--1	489	(1)
Shop Activity 36/37--2	490	(1)
Shop Activity 36/37--3	490	(1)
Job Sheet 36/37--1 Checking the Fluid Level in a Manual Transmission and Transaxle	491	(2)
Job Sheet 36/37--2 Inspecting and Adjusting Shift Linkage	493	(4)
Job Sheet 36/37--3 Road Testing a Vehicle for Transmission Problems	497	(2)
Case Studies	499	(1)
Review Questions	499	(2)
Drive Axles and Differentials	501	(29)
Shop Activity 38--1	501	(2)
Job Sheet 38--1 Inspecting and Diagnosing a Drive Axle	503	(2)
Job Sheet 38--2 Servicing Outer CV Joints	505	(6)
Job Sheet 38--3 Servicing Inner CV Joints	511	(4)
Job Sheet 38--4 Inspecting U-Joints and the Drive Shaft	515	(6)
Job Sheet 38--5 Road Testing Differential Noises	521	(2)
Job Sheet 38--6 Measuring and Adjusting Pinion Depth, Bearing Preload, and Backlash	523	(2)
Case Study 1	525	(1)
Case Studies 2 and 3	526	(1)
Review Questions	526	(1)
ASE Test Prep	527	(3)
SECTION 6 AUTOMATIC TRANSMISSIONS AND TRANSAXLES	530	(42)
Automatic Transmissions and Transaxles and Automatic Transmission/Transaxle Service	531	(29)
Shop Activity 39/40--1	534	(3)
Job Sheet 39/40--1 Visually Inspecting an Automatic Transmission	537	(2)
Job Sheet 39/40--2 Road Testing a Vehicle to Check the Operation of a Torque Converter Lockup Clutch	539	(2)
Job Sheet 39/40--3 Road Testing a Vehicle to Check the Operation of an Automatic Transmission	541	(4)
Job Sheet 39/40--4 Conducting a Stall Test	545	(2)
Job Sheet 39/40--5 Pressure Testing an Automatic Transmission	547	(4)
Job Sheet 39/40--6 Servicing a Valve Body	551	(4)
Job Sheet 39/40--7 Overhauling a Multiple-Disc Clutch Assembly	555	(3)
Case Study	558	(1)
Review Questions	558	(2)
Four- and All-Wheel Drive	560	(12)
Shop Activity 41--1	560	(1)
Shop Activity 41--2	560	(1)
Job Sheet 41--1 Inspecting the Fluid Level in a Transfer Case	561	(2)
Job Sheet 41--2 Road Testing a Transfer Case	563	(2)
Job Sheet 41--3 Replacing a Transfer Case Output Shaft Bushing and Seal	565	(3)
Case Study	568	(1)
Review Questions	568	(1)
ASE Prep Test	569	(3)
SECTION 7 SUSPENSION AND STEERING SYSTEMS	572	(66)
Tires and Wheels	573	(11)
Shop Activity 42--1	574	(1)
Shop Activity 42--2	574	(1)
Job Sheet 42--1 Inspecting Tires for Inflation and Wear	575	(2)
Job Sheet 42--2 Removing and Installing Front Wheel Bearings on a Rear-Wheel-Drive Vehicle	577	(4)
Job Sheet 42--3 Balancing a Tire and Wheel off the Vehicle	581	(1)
Case Study	582	(1)
Review Questions	582	(2)
Suspension Systems	584	(15)
Shop Activity 43--1	586	(3)
Job Sheet 43--1 Inspecting Suspension Components	589	(2)
Job Sheet 43--2 Removing and Replacing a Strut Assembly	591	(2)
Job Sheet 43--3 Replacing the Cartridge in a Strut Assembly	593	(2)
Job Sheet 43--4 Removing and Installing Control Arm Bushings on a Rear Coil-Spring-Type Suspension System	595	(2)
Review Questions	597	(2)
Steering Systems	599	(24)
Shop Activity 44--1	599	(1)
Shop Activity 44--2	600	(1)
Shop Activity 44--3	601	(8)
Job Sheet 44--1 Diagnosing, Removing, and Replacing an Idler Arm	609	(2)
Job Sheet 44--2 Removing and Replacing an Outer Tie-Rod End on a Parallelogram Steering Linkage System	611	(2)
Job Sheet 44--3 Flushing a Power-Steering System	613	(2)
Job Sheet 44--4 Testing the Pressure of a Power-Steering Pump	615	(4)
Job Sheet 44--5 Inspecting a Rack-and-Pinion Steering Gear	619	(2)
Review Questions	621	(2)
Wheel Alignment	623	(15)
Shop Activity 45--1	624	(3)
Job Sheet 45--1 Measuring Front and Rear Wheel Alignment Angles with a Computer-Based Wheel Aligner	627	(4)
Job Sheet 45--2 Centering a Steering Wheel	631	(2)
Case Study	633	(1)
Review Questions	633	(1)
ASE Prep Test	634	(4)
SECTION 8 BRAKES	638	(80)
Brake Systems	639	(19)
Shop Activity 46--1	640	(7)
Job Sheet 46--1 Bench Bleeding a Master Cylinder	647	(4)
Job Sheet 46--2 Pressure Bleeding a Hydraulic Brake System	651	(2)
Job Sheet 46--3 Performing a Power Vacuum Brake Booster Test	653	(4)
Case Study	657	(1)
Review Questions	657	(1)
Drum Brakes	658	(17)
Shop Activity 47--1	658	(1)
Shop Activity 47--2	658	(1)
Job Sheet 47--1 Inspecting and Servicing Duoservo Drum Brakes	659	(6)
Job Sheet 47--2 Inspecting and Servicing Nonservo Drum Brakes	665	(4)
Job Sheet 47--3 Adjusting and Replacing a Parking Brake Cable	669	(5)
Case Study	674	(1)
Review Questions	674	(1)
Disc Brakes	675	(27)
Shop Activity 48--1	676	(1)
Shop Activity 48--2	676	(3)
Job Sheet 48--1 Inspecting and Servicing Typical Disc Brakes	679	(10)
Job Sheet 48--2 Servicing a Single-Piston Rear Disc Brake Caliper	689	(4)
Job Sheet 48--3 Servicing Floating Rear Disc Brake Caliper	693	(4)
Job Sheet 48--4 Removing and Installing a Typical Hub and Rotor Assembly	697	(2)
Job Sheet 48--5 Inspecting and Measuring Disc Brake Rotors	699	(2)
Case Study	701	(1)
Review Questions	701	(1)
Antilock Brake, Traction Control, and Stability Control Systems	702	(16)
Shop Activity 49--1	702	(3)
Job Sheet 49--1 Performing ABS Tests Using a Scan Tool	705	(4)
Job Sheet 49--2 Monitoring the Operation of the ABS Solenoids Using a Lab Scope	709	(2)
Job Sheet 49--3 Testing a Wheel-Speed Sensor and Adjusting Its Gap	711	(2)
Case Study	713	(1)
Review Questions	713	(1)
ASE Prep Test	714	(4)
SECTION 9 PASSENGER COMFORT	718	(1)
Heating and Air-Conditioning and Heating and Air-Conditioning Diagnosis and Service	719	(2)
Shop Activity 50/51--1	721	(8)
Job Sheet 50/51--1 Identifying the Type of Air-Conditioning System in a Vehicle	729	(2)
Job Sheet 50/51--2 Identifying the Components in an Air-Conditioning System	731	(4)
Job Sheet 50/51--3 Conducting a Visual Inspection of an Air-Conditioning System	735	(4)
Job Sheet 50/51--4 Conducting a System Performance Test on an Air-Conditioning System	739	(2)
Job Sheet 50/51--5 Inspecting, Testing, and Servicing a Compressor Clutch	741	(2)
Job Sheet 50/51--6 Identifying and Recovering Refrigerant	743	(2)
Job Sheet 50/51--7 Recycling, Labeling, and Storing Refrigerant	745	(2)
Case Studies	747	(1)
Review Questions	747	(1)
ASE Prep Test	748