Automotive Encyclopedia: Fundamental Principles, Operation, Construction, Service, and Repair

by Toboldt, William K.; Johnson, Larry; Gauthier, W. Scott

• ISBN13: 9781566377133
• ISBN10: 1566377137
• Edition: 10th
• Format: Hardcover
• Copyright: 2000-04-01
• Publisher: Goodheart-Willcox Pub

Summary

A complete automotive library all in one book. In addition to exploring the many sciences involved in vehicle operation, this text also details the design, construction, operation, troubleshooting, service, and repair of today's cars and light trucks. Previous edition: c1995.

Table of Contents

Automotive Safety	13	(8)
Safety	13	(8)
Right-to-know Laws	15	(1)
Proper Disposal of Automotive Wastes	15	(1)
Fire Prevention	16	(1)
Ventilation	16	(1)
Jacks and Lifts	16	(1)
Tool Safety	16	(2)
Dress Properly	18	(1)
Lift Properly	19	(1)
Welding Safety	19	(2)
Owner's Manuals, Service Manuals, and Repair Manuals	21	(8)
Introduction	21	(4)
Owner's Manuals	21	(1)
Service Manuals and Repair Manuals	22	(1)
Technical Service Bulletins	22	(2)
Flat Rate Manual	24	(1)
Computerized Service Information	25	(1)
On-line Services	25	(1)
Technical Assistance Hotlines	25	(4)
Automotive Tools	29	(18)
Tools	29	(18)
Wrenches	29	(4)
Pliers	33	(1)
Screwdrivers	34	(1)
Hammers	35	(3)
Electric Drills	38	(1)
Impact Wrenches	38	(1)
Files	39	(1)
Retrieving Tools	40	(1)
Soldering Tools	40	(1)
Hacksaws	41	(1)
Taps and Dies	42	(1)
Cleaning Equipment	43	(4)
Fasteners, Seals, and Gaskets	47	(12)
Fasteners	47	(6)
Threaded Fasteners	47	(5)
Keys and Pins	52	(1)
Snap Rings	52	(1)
Rivets	52	(1)
Adhesives	53	(1)
Seals	53	(2)
Gaskets	55	(4)
Measuring Instruments	59	(6)
Measuring Instruments	59	(6)
Micrometers	59	(2)
Telescoping Gauges and Small Hole Gauges	61	(1)
Vernier Calipers	61	(1)
Dial Gauges	62	(1)
Feeler Gauge	62	(3)
Meters, Testers, and Analyzers	65	(8)
Automotive Meters, Testers, and Analyzers	65	(3)
Ammeter/Voltmeter Operation	66	(1)
Ohmmeter Operation	67	(1)
Multimeters	67	(1)
Tachometers	67	(1)
Dwell Meters	68	(1)
Battery/Starter Testers	68	(1)
Timing Light	68	(1)
Exhaust Gas Analyzers	69	(1)
Oscilloscopes	69	(1)
Scan Tools	70	(1)
Engine Analyzers	70	(3)
Engine Fundamentals	73	(12)
Engine Fundamentals	73	(12)
Engine Fuels	73	(1)
Engine Design	73	(1)
Reciprocating Engines	74	(1)
Engine Components	74	(5)
Combustion Chamber Design	79	(2)
Engine Operating Sequence	81	(4)
Measuring Engine Performance	85	(8)
Engine Performance	85	(8)
Bore, Stroke, Displacement	88	(1)
Compression Ratio	88	(1)
Engine Efficiency	88	(1)
Brake Horsepower	89	(1)
Engine Torque	90	(1)
Rated Horsepower	90	(1)
Indicated Horsepower	90	(1)
Friction Horsepower	91	(2)
Engine Top End Construction	93	(14)
Engine Top End	93	(1)
Cylinder Heads	93	(1)
Intake Manifolds	94	(1)
Exhaust Manifolds	94	(1)
Valve Trains	95	(1)
Camshafts	96	(2)
Camshaft Bearings	98	(1)
Camshaft Drive Mechanisms	98	(1)
Valves	98	(6)
Valve Springs	102	(1)
Valve Lifters	102	(1)
Valve Seals	103	(1)
Valve Retainers and Keepers	103	(1)
Rocker Arms	104	(1)
Push Rods	104	(3)
Engine Bottom End Construction	107	(18)
Engine Bottom End	107	(1)
Engine Block Construction	107	(1)
Crankshafts	108	(3)
Vibration Dampers	111	(1)
Connecting Rods	111	(1)
Piston Construction	112	(1)
Piston Rings	113	(2)
Compression Rings	114	(1)
Oil Control Rings	114	(1)
Piston Pins	115	(1)
Flywheels	116	(1)
Balance Shafts	116	(2)
Bearings	118	(7)
Main Bearing Caps and Seals	120	(5)
Engine Removal, Disassembly, and Cleaning	125	(8)
Engine Removal	125	(1)
Engine Disassembly	126	(3)
Cleaning	129	(1)
Inspection and Measurement	130	(3)
Engine Top End Service	133	(20)
Engine Top End Service	133	(1)
Cylinder Head Service	133	(6)
Valve Seat Reconditioning	135	(1)
Valve Guide Service	136	(3)
Valve Service	139	(5)
Valve Spring Service	141	(3)
Valve Operating Mechanisms	144	(3)
Push Rod Service	145	(1)
Rocker Arm Service	145	(1)
Lifter Service	145	(2)
Camshaft Service	147	(3)
Camshaft Bearings	148	(1)
Timing Belt Service	149	(1)
Timing Chain Service	149	(1)
Timing Gear Service	150	(1)
Head Bolt Torque	150	(3)
Engine Bottom End Service	153	(26)
Engine Bottom End Service	153	(1)
Engine Block Service	153	(5)
Cylinder Reconditioning	155	(3)
Crankshaft Service	158	(9)
Bearing Clearance	160	(1)
Bearing Removal	161	(1)
Replacement of Inserts	161	(6)
Piston Service	167	(1)
Piston Ring Service	168	(4)
Connecting Rod Service	172	(1)
Piston Pin Service	173	(2)
Balancing Engines	175	(4)
Engine Lubrication	179	(10)
Oil	179	(1)
Properties of Engine Oil	179	(1)
Selecting Viscosities	180	(1)
Oil Service Classifications	180	(2)
Oil Changes	181	(1)
Oil Filters	182	(1)
Lubricating Methods	182	(7)
Engine Cooling Systems	189	(20)
Cooling Systems	189	(20)
Water Pumps	191	(1)
Belts	191	(2)
Hoses and Clamps	193	(1)
Radiators	194	(1)
Automatic Transmission Fluid Cooler	195	(1)
Closed Cooling Systems	195	(1)
Radiator Caps	195	(1)
Cooling Fans	196	(2)
Thermostats	198	(1)
Heater Core	199	(1)
Antifreeze Solutions	199	(2)
Air-cooled Engines	201	(2)
Cooling System Testing	203	(1)
Cooling System Troubleshooting	204	(1)
Cooling System Flush	205	(4)
Diesel and Other Engines	209	(12)
Diesel Engines	209	(2)
Truck Engines	211	(1)
Racing Engines	212	(1)
Turbines	212	(1)
Rotary Engines	213	(6)
Ceramic Engines	219	(2)
Fundamentals of Electricity, Magnetism, and Electronics	221	(16)
Electricity	221	(4)
Insulators	223	(1)
Conductors	223	(1)
Volts, Amperes, Ohms	223	(1)
Types of Electrical Circuits	224	(1)
Magnetism	225	(4)
Electronics	229	(8)
Automotive Fuels	237	(8)
Automotive Fuels	237	(8)
Volatility	237	(2)
Combustion of Gasoline	239	(2)
Antiknock Qualities	241	(1)
Fuel Additives	242	(1)
Lead-free Gasoline	242	(1)
Alcohol as a Fuel	242	(1)
Diesel Fuels	243	(1)
Liquefied Petroleum Gas (LPG)	243	(2)
Fuel Supply Systems, Intake Systems, Superchargers, and Turbochargers	245	(16)
Fuel Pumps	245	(2)
Mechanical Fuel Pump	245	(1)
Electric Fuel Pumps	246	(1)
Fuel Filters	247	(1)
Fuel Gauges	248	(2)
Intake Systems	250	(3)
Air Filters	250	(1)
Intake Manifold	251	(2)
Superchargers	253	(3)
Turbochargers	256	(5)
Fuel Injection Systems	261	(16)
Fuel Injection	261	(5)
Classifying Gasoline Injection Systems	261	(5)
Servicing Fuel Injection Systems	266	(6)
On-Board Diagnostic Systems	266	(1)
Verifying Fuel Injector Operation	267	(1)
Checking Fuel Pressure	267	(1)
Injector Balance Test	268	(1)
Relieving EFI System Pressure	268	(2)
Servicing Fuel Injectors	270	(2)
Rebuilding a Throttle Body	272	(1)
Diesel Injection	272	(5)
Carburetors	277	(26)
Carburetors	277	(26)
Carburetor Circuits	279	(10)
Air/Fuel Mixture	289	(1)
Stoichiometric Mixture	290	(1)
Computerized Systems	290	(1)
Electro-Mechanical Carburetors	290	(2)
Carburetor Service	292	(11)
Ignition System Fundamentals and Service	303	(24)
Ignition System Operation	303	(6)
Ignition Coils	304	(1)
Distributor Cap	304	(1)
Rotor	304	(1)
Spark Plug Wires	305	(1)
Spark Plugs	305	(3)
Ignition Timing	308	(1)
Specific Ignition Systems	309	(6)
Breaker Point Ignition	309	(1)
Electronic Ignition	310	(4)
Computerized Ignition Systems	314	(1)
Distributorless Ignition	315	(1)
Direct Ignition	315	(1)
Ignition System Service	315	(2)
Performing a Spark Test	315	(2)
Ignition Coil Service	317	(1)
Distributor Cap and Rotor Service	318	(1)
Spark Plug Service	318	(1)
Spark Plug Wire Service	319	(2)
Pickup Coil Service	321	(1)
Contact Point and Condenser Service	322	(1)
Adjusting Ignition Timing	323	(1)
Testing Centrifugal and Vacuum Distributor Advance Systems	324	(1)
Ignition Control Module Service	324	(3)
Batteries and Battery Service	327	(14)
Batteries	327	(14)
Battery Functions	327	(1)
Sizes and Types	327	(1)
Battery Construction	327	(4)
Battery Voltage and Capacity	331	(1)
Battery Ratings	332	(1)
Battery Inspection	332	(1)
Battery Testing	332	(6)
Jump Starting an Engine	338	(3)
Starting System Fundamentals and Service	341	(14)
Starting System Fundamentals	341	(8)
Starting Motor Operating Principles	341	(4)
Starting Motor Types	345	(1)
Starting Motor Internal Circuits	345	(4)
Neutral Safety Switch	349	(1)
Troubleshooting the Starting System	349	(6)
Starter Maintenance	350	(1)
Starting Motor Tests	350	(5)
Charging System Fundamentals	355	(14)
Charging Systems	355	(6)
Alternator Construction	358	(1)
Alternator Operation	359	(2)
Voltage Regulators	361	(8)
Voltage Regulator Types	361	(6)
Computer-controlled Voltage Regulation	367	(2)
Charging System Service	369	(8)
Charging System Testing and Service	369	(8)
Charging System Inspection	369	(1)
Charging System Precautions and Tests	369	(2)
Alternator Removal	371	(1)
Alternator Disassembly	372	(1)
Bench Tests	373	(1)
Repairs/Replacement	373	(1)
Alternator Reassembly	374	(1)
Alternator Reinstallation	374	(3)
Computer System Fundamentals and Service	377	(22)
Computer Control Systems	377	(2)
Components of a Computer Control System	379	(8)
Sensors	379	(5)
Electronic Control Module	384	(2)
Actuators	386	(1)
Computer Control System Troubleshooting	387	(12)
On-board Diagnostic Systems	388	(1)
Diagnostic Trouble Codes	388	(1)
Activating Self-diagnostic Systems	389	(2)
Using Diagnostic Information	391	(2)
Sensor Service	393	(3)
Actuator Service	396	(1)
Electronic Control Module Troubleshooting	396	(3)
Exhaust Systems	399	(8)
Exhaust Systems	399	(5)
Exhaust Manifold	399	(1)
Mufflers	400	(1)
Catalytic Converters	401	(1)
Exhaust System Corrosion	402	(2)
Servicing Exhaust Systems	404	(3)
Emission Controls	407	(18)
Introduction	407	(1)
Automotive Emission Standards	407	(18)
Positive Crankcase Ventilation	408	(1)
Exhaust Emission Controls	409	(1)
Precombustion Controls	410	(5)
Post-combustion Controls	415	(10)
Engine Troubleshooting	425	(12)
Engine Troubleshooting	425	(12)
Test Equipment	425	(1)
Effect of Emission Controls	425	(1)
Strategy-based Diagnostics	426	(1)
Self-diagnosis	426	(1)
Troubleshooting Charts	426	(11)
Engine Driveability and Tune-up	437	(10)
Driveability and Tune-up	437	(10)
Tune-up Test Procedure	439	(5)
Checking Compression Pressure	444	(1)
Using a Vacuum Gauge	444	(1)
Tuning Emission Controls	445	(2)
Clutches	447	(14)
Purpose of the Clutch	447	(8)
Design and Construction	447	(1)
Parts Location and Relationship	447	(8)
Clutch Service	455	(6)
Clutch Adjustment	456	(1)
Clutch Overhaul	457	(1)
Clutch Troubleshooting	458	(3)
Manual Transmission Fundamentals	461	(12)
Manual Transmissions	461	(12)
Application of Torque	461	(1)
Gear Usage	461	(1)
Three-speed Manual Transmission	462	(1)
Helical Gears	463	(1)
Synchronizing Clutch	464	(1)
Four-speed Manual Transmission	464	(1)
Overdrive Revival	464	(1)
Planetary Gear Systems	465	(2)
Transmission Overdrives	467	(1)
Five-speed Overdrive Transmission	468	(5)
Manual Transmission Service	473	(18)
Manual Transmission Maintenance	473	(1)
Check Fluid Level	474	(1)
Replace the Rear Seal	474	(1)
Test the Gearshift Operation	474	(1)
Check Clutch Pedal Free Play	474	(1)
Manual Transmission Troubleshooting	474	(2)
Manual Transmission Service	476	(15)
Removal of Transmission From Car	476	(1)
Disassembly: Three-speed Manual Transmission	477	(1)
Clean and Check: Three-speed Manual Transmission	477	(2)
Reassembly: Three-speed Manual Transmission	479	(2)
Disassembly: Four-speed Manual Transmission	481	(2)
Clean and Check: Four-speed Manual Transmission	483	(1)
Reassembly: Four-speed Manual Transmission	483	(1)
Disassembly: Five-speed Manual Transmission	484	(3)
Clean and Check: Five-speed Manual Transmission	487	(1)
Reassembly: Five-speed Manual Transmission	487	(1)
Reinstallation of the Transmission in the Car	488	(3)
Automatic Transmission Fundamentals	491	(20)
Automatic Transmissions	491	(3)
Fluid Couplings	491	(1)
Torque Converters	492	(2)
Automatic Transmission Operation	494	(17)
Actions of Key Elements	495	(6)
Automatic Transmission Operation	501	(3)
Other Automatic Transmissions	504	(1)
Electronic Transmission Control	504	(1)
Continuously Variable Transmissions	504	(7)
Automatic Transmission Service	511	(14)
Automatic Transmission Maintenance and Service	511	(4)
Check ATF Level	512	(1)
Check ATF Condition	512	(1)
Inspect for ATF Leaks	513	(1)
Test for Broken Transmission Mount	514	(1)
Changing Automatic Transmission Fluid	515	(4)
Adjust Bands	516	(1)
Adjust Engine Curb Idle Speed	517	(1)
Throttle Linkage Adjustment	518	(1)
Gearshift Linkage Adjustment	519	(1)
Troubleshooting Tips	519	(6)
Road Testing	520	(1)
Stall Testing	520	(1)
Air Pressure Testing	521	(1)
Testing Electronically Controlled Transmissions	522	(3)
Transaxles	525	(16)
Transaxles	525	(16)
Transaxle Construction	525	(2)
Transaxle Operation	527	(5)
Manual Transaxle Troubleshooting	532	(1)
Manual Transaxle Maintenance	533	(2)
Automatic Transaxle Troubleshooting	535	(1)
Automatic Transaxle Maintenance	536	(5)
Driveline, Universal Joints, Differentials, and Driving Axles	541	(16)
Drivelines	541	(16)
Universal Joints	542	(1)
Drive Shaft	542	(1)
Differential	542	(1)
Driving Axles	543	(2)
Torque Transfer or Drive	545	(1)
Hotchkiss Drive	545	(1)
Torque Tube Drive	546	(1)
Control Arm Drive	546	(1)
Slip Joints	546	(1)
Constant Velocity Joints	547	(1)
Transfer Cases	547	(1)
Center Bearings	547	(1)
Differentials and Axles	547	(4)
Limited-Slip Differentials	551	(1)
Front-wheel Drive Driveline	552	(5)
Driveline Service	557	(16)
Driveline Service	557	(16)
Drive Shaft	557	(1)
Universal Joint Service	558	(1)
Center Bearing Service	559	(1)
Differentials	559	(3)
Transaxle Lubrication	562	(1)
Wheel Bearing Lubrication	563	(1)
Driving Axles	564	(9)
Four-wheel Drive Systems	573	(10)
Four-wheel Drive/All-wheel Drive	573	(10)
Four-wheel Drive Systems	574	(6)
Four-wheel Drive Service	580	(3)
Suspension and Steering Systems	583	(24)
Suspension and Steering Systems	583	(24)
Front Suspension Systems	588	(1)
Rear Suspension Systems	589	(3)
Steering Systems	592	(9)
Suspension and Steering Service	601	(1)
Troubleshooting Suspension	602	(1)
Troubleshooting Manual Steering	603	(1)
Troubleshooting Power Steering	603	(4)
Tires, Tire Service	607	(14)
Tires	607	(14)
Tire Types and Basic Structure	607	(2)
Tread Patterns	609	(1)
Tire Sizes	610	(1)
Tire Service	611	(7)
Improvements and Advances	618	(3)
Wheel Alignment	621	(10)
Wheel Alignment	621	(10)
Wheel Balance and Unbalance	622	(1)
Car Weight Balance	623	(1)
Wheelbase-Tread Width	623	(1)
Rear-wheel Track	624	(1)
Springs	625	(1)
Suspension Height	625	(1)
Shock Absorber Action	625	(1)
Front-wheel Angularity	626	(5)
Wheel Alignment Correction	631	(12)
Wheel Alignment Correction	631	(12)
Rear-wheel Drive/Front-wheel Drive Alignment	631	(7)
Front-Wheel Drive-Alignment	638	(1)
Rear Wheel Alignment	638	(2)
Alignment Troubleshooting	640	(3)
Hydraulics and Pneumatics	643	(10)
Hydraulics	643	(10)
Transmission of Forces	644	(2)
Movement of Liquid	646	(1)
Application of Hydraulic Principles	646	(1)
Pneumatics	647	(1)
Effect of Atmospheric Pressure	648	(1)
Effect of Vacuum	648	(1)
Compressed Air	649	(1)
Principle of the Siphon	649	(1)
Venturi Tube	650	(1)
Boyle's Law	650	(1)
Charles' Law	651	(2)
Automotive Brakes	653	(40)
Fundamentals of Automotive Brake Systems	653	(21)
Braking System Operation	655	(1)
Brake Lining Materials	656	(1)
Disc Brakes	657	(2)
Drum Brakes	659	(3)
Brake Hydraulic System	662	(5)
Disc Brake Calipers	667	(1)
Wheel Cylinders	667	(2)
Brake Lines, Hoses, and Fittings	669	(1)
Power Brakes	669	(3)
Anti-lock Brake Systems	672	(2)
Brake Service	674	(19)
Hydraulic System Service	675	(2)
Disc Brake Service	677	(3)
Drum Brake Service	680	(6)
Power Brake System Service	686	(4)
Troubleshooting and Servicing Anti-lock Brake Systems	690	(3)
Automotive Air Conditioning	693	(24)
Automobile Air Conditioning	693	(17)
Principles of Air Conditioning	694	(2)
Automobile Heating Systems	696	(1)
Types of Refrigerant	697	(11)
The Need for Refrigerant Oil	708	(1)
Air Conditioning Service Tools and Equipment	709	(1)
Servicing the Air Conditioning System	710	(7)
Discharging and Recovering Refrigerant	711	(1)
Evacuating the Air Conditioning System	711	(1)
Charging the Air Conditioning System	711	(1)
Retrofitting R-12 Air Conditioning Systems	712	(1)
Troubleshooting Heating Systems	712	(1)
Troubleshooting Air Conditioning Systems	712	(1)
Automatic Temperature Control	713	(4)
Safety Systems	717	(14)
Safety Systems	717	(14)
Seat Belt Systems	718	(2)
Air Bag Systems	720	(3)
Energy Absorbing Bumper Systems	723	(2)
Other Safety Features	725	(6)
Lamps, Lighting Circuits, Wiring, Horns, Wipers, and Washers	731	(22)
Lamps and Lighting Circuits	731	(10)
Fuses and Circuit Breakers	732	(1)
Headlamp Types	732	(1)
Daytime Running Lamps	732	(1)
Lamp Switches	733	(3)
Fog Lamps	736	(1)
Direction Signal Switch	736	(1)
Stoplight Switch	736	(1)
Lamp Service	736	(5)
Wires and Cables	741	(4)
Lighting Wire Sizes	741	(2)
Resistor Ignition Cable	743	(1)
Wiring Harnesses and Connectors	743	(2)
Horns	745	(2)
Horn Troubleshooting	746	(1)
Principles of a Direct Current (DC) Motor	747	(2)
Wiper Motor Construction	747	(1)
Troubleshooting	748	(1)
Windshield Washers	749	(4)
Speedometers and Cruise Control Systems	753	(12)
Analog Speedometers	753	(3)
Speedometer Operation	753	(2)
Inspection and Lubrication	755	(1)
Speedometer Cable	755	(1)
Digital Speedometers	756	(3)
Light Emitting Diode	756	(2)
Liquid Crystal Display	758	(1)
Vacuum Fluorescent Display	758	(1)
Cathode Ray Tube	758	(1)
Digital Odometers	758	(1)
Troubleshooting	758	(1)
Cruise Control Systems	759	(6)
Cruise Control System Service	761	(4)
Body Repairing and Refinishing	765	(26)
Body Work	765	(11)
Hammers, Spoons, and Dolly Blocks	766	(1)
Using Pull Rods and Slide Hammers	767	(1)
Body Filler	767	(2)
Filing and Sanding	769	(2)
Patching Rusted Areas	771	(1)
Replacing Panels	771	(1)
Welding	772	(4)
Painting	776	(10)
Masking	777	(1)
Spray Guns	778	(1)
Tips on Spraying	778	(2)
Refinishing Materials	780	(2)
Matching Colors	782	(1)
Preparing Old Finishes for Paint	783	(3)
Soft Body Parts	786	(1)
Identifying Plastics	786	(1)
Repairing Water and Dust Leaks	787	(1)
Drain Locations	788	(3)
Career Opportunities and Technician Certification	791	(10)
Automotive Careers	791	(7)
The Job Market	792	(1)
Job Descriptions	793	(4)
Entrepreneurship	797	(1)
Technician Certification	798	(3)
Appendix	801	(4)
Dictionary of Automotive Terms	805	(24)
Index	829