Automotive Service : Inspection, Maintenance, and Repair

by Gilles,Tim

• ISBN13: 9780827373549
• ISBN10: 0827373546
• Edition: 1st
• Format: Hardcover
• Copyright: 1998-06-24
• Publisher: Cengage Learning

Summary

Automotive Service: Inspection, Maintenance & Repair covers the fundamentals of operation and repair for all major systems of the modern automobile. This comprehensive text introduces the fundamentals of systems and progresses onto diagnosis and service with thousands of lavish, full-color illustrations, Shop Tips, Safety Notes, and review questions to aid in comprehension. Traditional and new topics have been integrated in a concise, easy-to-read format: OBD II, ABS, engine performance, safety, and shop tools. Structured around the eight ASE automotive test areas, this book helps users prepare for ASE certification.

Table of Contents

Preface	xvi
Acknowledgments	xvll
Dedication	xvll
Features of the Text	xvlll
SECTION 1 THE AUTOMOBILE INDUSTRY
Introduction to the Automobile	2	(13)
Introduction	2	(1)
Body and Chassis	2	(1)
Engine Parts and Operation	3	(1)
Engine Support Systems	4	(6)
The Powertrain	10	(1)
Accessory Systems	10	(1)
History and Development of the Automobile	11	(4)
Automotive Careers and Technician Certification	15	(9)
Introduction	15	(1)
Automotive Career Opportunities	15	(2)
Technician Certification and Licensing	17	(2)
Technician Skill Levels and Pay	19	(1)
Other Areas of Specialization	19	(1)
Other Automotive Careers	20	(1)
On the Job as an Automotive Technician	21	(1)
Summary	22	(2)
SECTION 2 SHOP PROCEDURES, SAFETY, TOOLS, AND EQUIPMENT
Shop Management, Service Records, and Parts	24	(7)
Introduction	24	(1)
Customer Relations	24	(1)
Service Records	25	(1)
Caring for the Car	26	(1)
Linen Service	26	(1)
Wholesale and Retail Distribution of Auto Parts	27	(4)
Locating Service Information and Specifications	31	(9)
Introduction	31	(1)
Service Information	31	(1)
Manufacturers' Service Manuals	32	(3)
Generic Service Manuals	35	(1)
Lubrication Service Manual	36	(1)
Owner's Manual	36	(1)
Owners' Workshop Manuals	36	(1)
Microfiche	36	(1)
CD-ROM Compact Disk Service Information	37	(1)
Parts and Labor Estimating (Flat-Rate) Manuals	37	(1)
Technical Service Bulletins	37	(1)
Hot Line Services	38	(1)
Trade Magazines	38	(2)
Measuring Tools and Systems	40	(13)
Introduction	40	(1)
Metric System	40	(1)
Measuring Tools	41	(1)
Precision Measuring Tools	41	(12)
Hardware, Fasteners, Drills, and Thread Repair	53	(14)
Introduction	53	(1)
Characteristics of Fasteners	53	(3)
Fastener Failures	56	(1)
drill Bits	56	(3)
Taps and Threads	59	(2)
Dies	61	(1)
Repairing Broken Fasteners	62	(5)
Shop Tools	67	(18)
Introduction	67	(1)
Tools of The Trade	67	(1)
Hand Tools	67	(11)
Pullers	78	(3)
Air Tools	81	(2)
Special Service Tools	83	(2)
General Shop Equipment	85	(12)
Shop Equipment	85	(1)
Hydraulic Equipment	85	(4)
Shop Electric Machinery	89	(4)
Other Electric Equipment	93	(1)
Other Shop Equipment	93	(4)
Cleaning Equipment and Methods	97	(14)
Introduction	97	(1)
General Shop Housekeeping Practices	97	(1)
Cleaning Methods	98	(1)
Cleaning the Outside of the Engine	99	(3)
Environmental Concerns with Engine Cleaning	102	(1)
Cleaning Internal Parts	102	(1)
Chemical Cleaning	102	(7)
Thermal Cleaning	109	(1)
Vibratory Parts Cleaners	109	(1)
Other Cleaning Methods	109	(2)
Lifting Equipment and Air Compressors	111	(11)
Introduction	111	(1)
Lift Types	111	(1)
Framecontact Lifts	111	(2)
Wheel-contact Lifts	113	(1)
Wheel-free Jacks	114	(1)
In-ground Lifts	114	(2)
Surface Mount Lifts	116	(1)
Lift Safety	116	(2)
Air Compressors	118	(4)
Shop Safety	122	(19)
Introduction	122	(1)
General Personal Safety	122	(2)
Fire Safety	124	(1)
Fire Extinguishers	124	(2)
Flammable Materials	126	(1)
Fuel Fires	126	(1)
Electrical Fires	127	(1)
Shop Habits	128	(1)
Hazardous Materials	128	(1)
Hot Tank Safety Precautions	129	(1)
Cleaning Solvent Safety Precautions	129	(1)
Skin Care Safety Precautions	129	(1)
Carburetor Cleaner Safety	130	(1)
Breathing Safety	130	(1)
Electrical Safety Precautions	131	(1)
Cooling Fan Safety	132	(1)
Coolant Burns	132	(1)
General Hand Tool Safety	132	(1)
Vise Safety	133	(1)
Puller Safety	133	(1)
Machinery Safety	133	(1)
Electric Drill Safety	133	(1)
Grinder Safety	133	(1)
Wire Wheel Safety	134	(1)
Compressed Air Safety	134	(1)
Impact Wrench Safety	134	(1)
Air Chisel Safety	134	(1)
Die Grinder/Air Drill Safety	135	(1)
Press Safety	135	(1)
General Lifting Safety	135	(1)
Hydraulic Floor Jack [Service Jack] Safety	135	(1)
Shop Crane [Engine Hoist] Safety	136	(1)
Transmission Jack Safety	136	(1)
Battery Safety	136	(1)
Refrigerant Sasfety	137	(1)
General Safety Around Automobiles	138	(3)
SECTION 3 VEHICLE INSPECTION [LUBRICATION/SAFETY CHECK]
Engine Lubrication	141	(11)
Introduction	141	(1)
Engine Oil	141	(3)
Oil Service Ratings	144	(1)
Oil Additives	144	(2)
Synthetic Oils	146	(1)
Changing Engine Oil	146	(2)
Oil Filter	148	(2)
Changing the Oil Filter	150	(2)
Underhood and Body Inspection [Car on Ground]	152	(15)
Introduction	152	(1)
Brake System Inspection	152	(3)
On-Ground Steering and Suspension Checks	155	(1)
Fuel System Inspection	156	(1)
Cooling System Inspection	156	(2)
Belt Inspection	158	(1)
Electrical System Inspection	158	(1)
Body Checks	159	(1)
Visibility Checks	160	(2)
Other Safety Checks and Service	162	(5)
Undercar Inspection and Service	167	(13)
Introduction	167	(1)
Tire Visual Inspection	167	(1)
Undercar Brake Checks	168	(1)
Exhaust System Inspection	169	(1)
Chassis Lubrication	169	(2)
Suspension and Steering Checks	171	(2)
Drive Line Checks	173	(7)
SECTION 4 ENGINE OPERATION AND SERVICE
Introduction to the Engine	180	(12)
Introduction	180	(1)
Basic Engine Operation	180	(1)
Four-Stroke Engine Operation	181	(1)
Engine Upper End	182	(1)
Valve Train	182	(1)
Cylinder Head	183	(2)
Engine Front	185	(1)
Cylinder Block Assembly [Lower End]	186	(1)
Short Block and Long Block	187	(3)
Summary	190	(2)
Engine Classifications	192	(9)
Introduction	192	(1)
Engine Classifications	192	(1)
Cylinder Arrangement	192	(1)
Firing Order	193	(1)
Engine Cooling	194	(1)
Valve Location	194	(1)
Camshaft Location	195	(3)
Other Cylinder Head Variations	198
Combustion Chamber Designs	197	(1)
Spark and Compression Ignition	198	(1)
Alternate Engines	198	(2)
Summary	200	(1)
Engine Size and Measurements	201	(10)
Introduction	201	(1)
Engine Size Measurements	201	(1)
Compression Ratio	202	(1)
Physical Principles of Work	203	(1)
Torque	204	(1)
Horsepower	204	(1)
Dynamometer	205	(3)
Engine Efficiency	208	(1)
Mean Effective Pressure	209	(2)
Engine Upper End	211	(19)
Introduction	211	(1)
Cylinder Head Construction	211	(1)
Valve Guides	211	(1)
Valve Guide Seals	212	(2)
Valves	214	(3)
Retainers and Keepers	217	(1)
Valve Springs	217	(1)
Rocker Arms	218	(1)
Camshaft	219	(1)
Number of Cams and Lobes	219	(1)
Fuel Pump Eccentric	220	(1)
Distributor and Oil Pump Drives	220	(1)
Camshaft Performance	220	(1)
Valve Timing	221	(2)
Valve Lifters	223	(1)
Hydraulic Lifters	223	(2)
Roller Cam and Lifters	225	(1)
Regrinding Cams	226	(1)
Cam Drives	226	(4)
Engine Lower End and Lubrication System Theory	230	(20)
Introduction	230	(1)
Cylinder Block Construction	230	(1)
Core Plugs	230	(1)
Cylinder Bore	230	(1)
Cylinder Sleeves	230	(1)
Main Bearing Caps	231	(1)
Lifter Bores	232	(1)
Crankshaft Design	232	(1)
Crankshaft End Thrust	233	(1)
Direction of Crankshaft Rotation	233	(1)
Vibration Damper	233	(1)
Crankshaft Hardness	234	(1)
Bearings	234	(1)
Connecting Rods	235	(1)
Pistons	236	(1)
Piston Head	237	(1)
Piston Ring Grooves	237	(1)
Cast and Forged Pistons	237	(1)
Piston Skirt	238	(2)
Piston Pin Offset	240	(1)
Wrist Pins	240	(1)
Piston Rings	241	(1)
Compression Rings	241	(1)
Compression Ring Design	241	(1)
Compression Ring Materials and Coatings	242	(1)
Oil Control Rings	243	(1)
Engine Balancing	244	(1)
The Lubrication System	244	(1)
Oil Pumps	244	(1)
Pressure Relief Valve	245	(1)
Oil Pump Screen Bypass Valve	245	(1)
Oil Pressure	245	(2)
High-Volume Oil Pumps	247	(1)
Windage Tray and Braffles	247	(3)
SECTION 5 COOLING AND FUEL SYSTEM THEORY AND SERVICE
Cooling System Theory	250	(11)
Introduction	250	(1)
Liquid and Air Cooling	250	(1)
Liquid Cooling System Parts	250	(1)
Cooling System Circulation	250	(2)
Coolant	252	(1)
Radiator Cap	253	(1)
Coolant Recovery System	254	(1)
Radiator	254	(1)
Regulating Engine Temperature	255	(2)
Temperature Warning Light or Gauge	257	(1)
Fans	257	(1)
Fan Clutch	258	(1)
Radiator Shroud	259	(1)
Heater Core	259	(2)
Cooling System Service	261	(17)
Introduction	261	(1)
Diagnosing Cooling System Problems	261	(2)
Radiator Cap	263	(1)
Coolant Service	264	(3)
Thermostat	267	(2)
Locating Leaks	269	(1)
External Leaks	269	(1)
Internal Leaks	270	(3)
Recovery Tank Service	273	(1)
Cooling System Repairs	273	(1)
Coolant Pump Service	274	(1)
Fans	275	(1)
Fan Inspection	275	(1)
Fan Clutch Inspection	275	(1)
Electric Cooling Fan Service	276	(1)
Heater Core Service	276	(2)
Automotive Belts	278	(9)
Introduction	278	(1)
Belt Material	278	(1)
V-Belt	278	(1)
V-Ribbed Belts	278	(1)
Serpentine Belt Drive	278	(1)
Timing Belts	279	(2)
Drive Belt Service	281	(1)
Belt Inspection and Adjustment	281	(1)
Replacing Belts	282	(2)
Belt Tension	284	(1)
Timing Belt Service	285	(2)
Automotive Hoses	287	(10)
Introduction	287	(1)
Hose Theory	287	(1)
Hose Size	288	(1)
Unreinforced Hose	288	(1)
Radiator Hose	288	(1)
Hose Types	288	(3)
Hose Clamps	291	(1)
Hose Inspection	291	(2)
Replacing Hoses	293	(4)
Automotive Plumbing: Tubing and Pipe	297	(11)
Introduction	297	(1)
Tubing	297	(2)
Flared Connections	299	(1)
Compression Fittings	300	(1)
Pipe Fittings	301	(1)
Shutoff Valves	302	(1)
Tubing Service	302	(3)
Installing Tubing	305	(1)
Transmission Oil Cooler Line Repairs	305	(1)
Nylon Fuel Injection Tubing	305	(1)
Pipe Service	306	(2)
Fuels, Octane, Abnormal Combustion	308	(16)
Introduction	308	(1)
Crude Oil	308	(2)
Gasoline	310	(2)
Air/Fuel Mixture	312	(1)
Gasoline Engine Run-on	313	(1)
Spark Knocks, Carbon Noise, Abnormal Combustion	313	(1)
Abnormal Combustion	314	(2)
Excessive Carbon Buildup	316	(1)
Regular versus Premium Fuels	316	(1)
Octane Standards	317	(1)
Gasoline Additives	317	(1)
Oxygenated Fuels	318	(1)
Reformulated Gasolines	318	(1)
Diesel Engines and Diesel Fuel	319	(2)
Alternative Fuels	321	(3)
Fuel System Fundamentals	324	(16)
Introduction	324	(1)
Fuel System	324	(1)
Fuel Tanks	325	(1)
Fuel Lines, Hoses, and Fittings	325	(1)
Mechanical Fuel Pump	325	(1)
Electric Fuel Pump	325	(1)
Fuel Filters	326	(1)
Carburetors and Fuel Injection	327	(1)
Carburetors	327	(5)
Fuel Injection	332	(1)
Electronic Fuel System Operation	333	(1)
Air Flow Measurement	333	(2)
Idle Speed Control	335	(1)
Fuel Pump Relay	335	(1)
Computer Controlled Fuel Systems	335	(1)
Feedback Fuel Systems	335	(5)
Fuel System Service	340	(18)
Introduction	340	(1)
Fuel Supply System Service	340	(2)
Fuel Filter Service	342	(1)
Throttle Linkage	343	(1)
Carburetor Problems and Service	343	(1)
Causes of Rich and Lean Conditions	344	(1)
Exhaust Gas Analysis	344	(1)
Carburetor Rebuilding	345	(1)
Engine Starting Procedures	345	(1)
Fuel Injection Diagnosis and Service	345	(1)
EFI Comptuer Self-Diagnostics	346	(1)
Air/Fuel Mixture Problems	346	(1)
Testing a Pressure Regulator	347	(1)
Injector Problems	347	(3)
Throttle Plate Service	350	(1)
EFI Adjustments	350	(1)
Sensor Service	351	(1)
Throttle Position Sensor	351	(1)
Oxygen Sensor Service	351	(2)
Coolant Temperature Sensor	353	(1)
Inlet Air Temperature Sensor	353	(1)
MAP Sensor Diagnosis	353	(1)
Mass Air Flow [MAF] Sensor Diagnosis	354	(1)
Testing Other Sensors	355	(1)
Computer Service	355	(1)
Mechanical Injection	355	(1)
Carbon Deposit Service	356	(2)
Intake and Exhaust Systems/ Turbochargers and Superchargers	358	(17)
Introduction	358	(1)
Intake System Fundamentals	358	(1)
Manifolds	359	(1)
Intake Manifolds	359	(3)
Exhaust System Fundamentals	362	(1)
Exhaust Manifolds	362	(1)
Exhaust Pipes	363	(2)
Turbocharger Fundamentals	365	(2)
Supercharger Fundamentals	367	(1)
Exhaust System Service	368	(2)
Heat Riser Service	370	(1)
Turbocharger Service	370	(2)
Supercharger Service	372	(3)
SECTION 6 ELECTRICAL SYSTEM THEORY AND SERVICE
Basic Electrical System Theory and Repairs	375	(16)
Introduction	375	(1)
Electron Flow	375	(2)
Basic Automotive Electrical System	377	(1)
Electrical Terms	378	(3)
Circuitry and Ohm's Law	381	(1)
Magnetic Fields	382	(2)
Capacitors	384	(1)
Automotive Electronics	384	(1)
Basic Electrical Tests	385	(6)
Battery Fundamentals	391	(10)
Introduction	391	(1)
Battery Parts and Operation	392	(4)
Battery Capacity Ratings	396	(1)
Battery Types	396	(2)
Battery Plate Size	398	(1)
Battery Selection	398	(1)
Battery Service Life	399	(1)
Battery Cables	399	(1)
Battery Hold-Downs	399	(1)
Reasons for Battery Failure	400	(1)
Battery Service	401	(17)
Introduction	401	(1)
Battery Inspection	401	(1)
Battery Service	402	(1)
Replacing a Battery	403	(5)
Battery Testing: Measuring a Battery's State of Charge	408	(2)
Battery Charging	410	(3)
Storing A Vehicle	413	(1)
Battery Capacity Test	413	(1)
Battery Drain Test	414	(1)
Battery Jump Starting	415	(3)
Starting System Fundamentals	418	(7)
Introduction	418	(1)
Starter Motor	418	(1)
Starter Motor Fundamentals	419	(2)
Starter Drives	421	(1)
Starter Electrical Circuit	421	(3)
Gear Reduction Starters	424	(1)
Starting System Service	425	(9)
Introduction	425	(1)
Starting System Service	425	(1)
Starting System Tests	425	(1)
Cranking Voltage and Amperage Test	426	(1)
Cranking Speed	427	(1)
Circuit Resistance Test	428	(1)
No-Crank Tests Using a Test Light	429	(1)
Solenoid Problems	429	(1)
Starter Repair	430	(1)
Starter Disassembly	430	(1)
Starter Drive Service	430	(2)
Starter Reassembly	432	(1)
Pinion Clearance Tests	432	(2)
Charging System Fundamentals	434	(9)
Introduction	434	(1)
Charging System	434	(1)
Direct Current [DC] Generators	435	(1)
Alternators	435	(4)
Alternator Bearings	439	(1)
Voltage Regulator	439	(1)
Charging System Indicators	440	(3)
Charging System Service	443	(7)
Introduction	443	(1)
Charging System Service	443	(1)
Testing the Charging System	443	(2)
Charging System Output Test	445	(1)
Regulator Voltage Setting Check	445	(1)
Alternator Full-Field Test	445	(1)
Charging System Voltage Drops	446	(1)
Alternator Service and Repair	447	(1)
Alternator Dissassembly	447	(1)
Alternator Reassembly	448	(1)
Diode Noises	448	(2)
Lighting and Wiring Fundamentals	450	(10)
Introduction	450	(1)
Wire and Cable	450	(1)
Circuit Protection Devices	450	(2)
Lighting	452	(1)
Headlamps	452	(2)
Tail Lights	454	(1)
Identification of Light Bulbs	454	(1)
Turn Signals	455	(1)
Signal Flasher Operation	455	(1)
Hazard Flashers	455	(1)
Wipers and Horn	456	(4)
Lighting and Wiring Service	460	(14)
Analyzing Electrical Problems	460	(1)
Wiring Service	460	(1)
Crimp Terminals	460	(1)
Selecting Replacement Wire	461	(1)
Adding Electrical Accessories	462	(2)
Soldering	464	(1)
Broken or Damaged Ground Straps	465	(1)
Circuit Testing and Service	466	(1)
Finding Grounds	466	(1)
Fuse Testing and Service	466	(1)
Fuse Link Service	467	(1)
Headlamp Service	467	(1)
Headlight Aiming	468	(1)
Tail and Park Light Bulb Service	469	(1)
Stoplight Switch Service	470	(1)
Back-Up Lights	470	(1)
Turn Signal Switch	470	(1)
Signal Flasher	471	(1)
Locating a Signal Flasher	471	(1)
Dash Light Bulbs	471	(1)
Horn Service	471	(3)
SECTION 7 ENGINE PERFORMANCE DIAGNOSIS: THEORY AND SERVICE
Ignition System Fundamentals	474	(18)
Introduction	474	(1)
Basic Ignition System	474	(1)
Primary Circuit	474	(3)
Secondary Circuit	477	(1)
Distributor	477	(1)
Secondary Ignition Parts	477	(1)
Spark Plugs	477	(3)
Mechanical and Electronic Ignitions	480	(1)
Resistor Bypass	481	(1)
Electronic Ignition	482	(1)
Electronic Ignition Variations	482	(3)
Resistor Circuit	485	(1)
Advance Mechanisms	486	(2)
Detonation Sensor	488	(1)
Distributorless Ignition	488	(4)
Ignition System Service	492	(19)
Ignition System Service and Repairs	492	(1)
Spark Plug Service	492	(1)
Spark Plug Diagnosis	493	(2)
Installing Spark Plugs	495	(1)
Repairing Damaged Spark Plug Threads	496	(1)
Spark Plug Cable Service	496	(1)
Distributor Service	497	(1)
Ignition Timing	498	(1)
Distributor Advance Service	499	(1)
Contact Point Distributor Service	500	(1)
Electronic Ignition Distributor Service	501	(2)
Other Distributor Service	503	(1)
Distributor Installation	503	(1)
Static Timing	503	(1)
Computerized Ignition System Service	504	(1)
Engine Analyzer	504	(1)
Oscilloscope	504	(2)
Types of Scope Patterns	506	(1)
Oscilloscope Tests	507	(1)
Scope Diagnosis of Engine Problems	508	(1)
Scope Diagnosis of Ignition Problems	508	(1)
Stress Test	508	(1)
Other Scope Tests	508	(1)
Other Diagnosis Instruments	509	(2)
Emission Control System Fundamentals	511	(18)
Introduction	511	(1)
Air Pollution	511	(1)
Automotive Emissions	511	(2)
Pollution Control	513	(1)
Automobile Emission Control Systems	513	(1)
Crankcase Ventilation	513	(1)
Air Injection System	514	(1)
Aspirator Valve or Pulse Air System	515	(2)
Exhaust Gas Recirculation	517	(1)
EGR System Operation	517	(1)
Thermal Vacuum Switch	518	(1)
Computer Controlled EGR Systems	518	(1)
Catalytic Converter	519	(1)
Types of Catalytic Converters	520	(1)
Air Switching Valve	521	(1)
Evaporative Controls	522	(1)
Sealing the System	523	(1)
Other Parts of the Fuel Tank System	524	(1)
Heated Air Inlet	525	(1)
On Board Diagnostics	525	(1)
Engine Emission Modifications	526	(3)
Emission Control System Service	529	(15)
Introduction	529	(1)
Inspecting Emission Control Systems	529	(1)
Crankcase Ventilation System Service	529	(1)
Testing the PCV System	530	(1)
Evaporative Control System Service	531	(1)
Evaporative System Maintenance	532	(1)
Diagnosis of Evaporative System Problems	532	(1)
Heated Air Inlet System Service	532	(1)
Early Fuel Evaporation Service	533	(1)
EGR System Service	533	(1)
Diagnosing EGR Problems	533	(1)
Air Injection System Service	534	(1)
Catalytic Converter Service	535	(1)
Converter Testing	535	(1)
Converter Replacement	535	(1)
Computer Controlled Emission Service	535	(1)
Analyzing Exhaust Emissions	535	(2)
Emission Analyzer	537	(1)
Hydrocarbons	537	(1)
Carbon Dioxide	538	(1)
Carbon Monoxide (CO)	539	(1)
Oxygen (O2)	539	(1)
Oxides of Nitrogen	540	(1)
Catalytic Converter Test With Analyzer	541	(1)
CO2 Converter Test	542	(2)
Diagnosing Engine Performance Problems	544	(10)
Introduction	544	(1)
Visual Checks	544	(1)
Ignition System Checks	544	(1)
Engine Performance Testing	545	(1)
Compression Loss	546	(1)
Vacuum Testing	546	(1)
Vacuum Tests For Valves Problems	547	(1)
Other Vacuum Tests	547	(1)
Compression Problems	547	(1)
Diagnosing Engine Compression Problems	547	(2)
Compression Test Procedure	549	(1)
Cylinder Leakage Test	550	(1)
Carbon Related Problems	551	(3)
Diagnosing Engine Mechanical Problems	554	(15)
Introduction	554	(1)
Diagnosing Problems Before a Repair	554	(1)
Oil Consumption	554	(1)
Causes of Oil Consumption	555	(2)
Oil Leak Testing	557	(2)
Engine Performance and Compression Loss	559	(1)
Engine Noises	559	(1)
Engine Knocks	560	(3)
Oil Pressure Problems	563	(1)
Cooling System Problems	564	(1)
Internal Engine Leakage	564	(1)
Seized Engine	565	(1)
Electronic Failures/Engine Damage	566	(1)
Engine Performance and Fuel Mixture Problems	566	(3)
SECTION 8 AUTOMOTIVE ENGINE SERVICE AND REPAIR
Engine Removal and Disassembly	569	(16)
Introduction	569	(1)
Engine Removal	569	(8)
Engine Disassembly	577	(1)
Engines With Pushrods	578	(1)
Overhead Cam Engines	578	(2)
Cylinder Block Disassembly	580	(5)
Engine Sealing, Gaskets, Fastener Torque	585	(18)
Introduction	585	(1)
Torque and Friction	585	(1)
Torque Wrenches	585	(2)
Torque-to-Yield	587	(1)
Torque by Degrees	587	(1)
Fastener Clamping Load	588	(1)
Gaskets	588	(1)
Overtorquing	588	(3)
Embossed Steel Head Gasket	591	(1)
Non-Retorque Head Gaskets	592	(1)
Surface Texture	593	(1)
Cleaning the Head	593	(1)
Other Engine Gaskets	593	(2)
Gasket Sealers	595	(2)
RTV Sealant	597	(1)
Seals	597	(1)
Front Seals	597	(1)
Rear Main Seals	598	(3)
Transmission Front Pump Seal	601	(2)
Engine Diagnosis and Service: Cylinder Head and Vavle Train	603	(18)
Introduction	603	(1)
Head Disassembly	603	(3)
Carbon Removal	606	(1)
Cylinder Head Inspection	607	(1)
Resurfacing by Grinding, Cutting, or Sanding	607	(1)
Straightening Cylinder Heads	608	(1)
Crack Inspection	608	(1)
Crack Repair	609	(1)
Checking Valve Springs	610	(1)
Checking Valve Stems	610	(1)
Valve Guide Service	610	(1)
Guide Repair	611	(1)
Grinding Valves	611	(1)
Grinding Valve Seats	612	(1)
Checking Installed Height of the Valve Stem	613	(1)
Solvent Testing the Valve and Seat	614	(1)
Reassembling the Head	614	(1)
Valve Guide Seal Installation	614	(1)
Install the Valve and Spring Assembly	615	(1)
Rocker Arm Service	615	(1)
Inspect Pushrods	615	(1)
Inspect OHC Camshaft	615	(1)
Reassembling OHC Heads	615	(2)
Camshaft Service	617	(1)
Lifter Service	617	(1)
Cam and Lifter Break-ln	617	(1)
Timing Gear, Chain, and Belt Service	617	(1)
Timing Belt Service	618	(1)
Timing Belt Replacement	618	(1)
Timing Chain Service	619	(1)
Valve Cover Service	619	(2)
Engine Diagnosis and Service: Block, Crankshaft, Bearings and Lubrication System	621	(18)
Introduction	621	(1)
Cleaning the Block	621	(1)
Oil and Water Plug Removal	621	(1)
Oil and Water Plug Installation	622	(1)
Inspect and Clean Lifter Bores	623	(1)
Checking Main Bearing Bore Alighment	623	(2)
Check the Deck Surface for Flatness	625	(1)
Clean Bolt Holes	625	(1)
Inspecting Cylinder Bores	625	(1)
Measuring the Bore	626	(1)
Deglazing the Cylinder Bore	627	(1)
Clean the Block of Grit	628	(1)
Boring for Oversized Pistons	628	(1)
Block Distortion	628	(1)
Honing after Boring	629	(1)
Sleeves	630	(1)
Cam Bearing Installation	630	(2)
Front Cam Bearing Installation	632	(1)
Checking Crankshaft Condition	632	(1)
Crankshaft and Bearing Wear	633	(1)
Crankshaft Journal Tolerance	634	(1)
Regrinding the Crankshaft	634	(1)
Measuring Bearing Clearance with Plastigage	634	(1)
Lubrication System Service	635	(1)
Checking Oil Pumps for Wear	636	(1)
Oil Pump Screen Service	636	(1)
Oil Pump Failure	636	(1)
Installing the Oil Pump	637	(2)
Engine Diagnosis and Service: Piston, Piston Rings, Connecting Rod, Engine Balancing	639	(13)
Introduction	639	(1)
Piston Service	639	(4)
Piston Ring Service	643	(1)
Installation of Pistons and Rings	644	(1)
Installing Rings on Pistons	644	(1)
Oil Ring Installation	644	(2)
Connecting Rod Service	646	(2)
Engine Balancing Service	648	(2)
Advanced Balancing Information	650	(2)
Ordering Parts, Short and Long Blocks, Engine Assembly	652	(16)
Introduction	652	(1)
Ordering Parts	652	(1)
Engine Kits	652	(1)
Determining Part Sizes	652	(3)
Short Blocks	655	(1)
Long Blocks	655	(1)
Selecting the Corect Replacement Engine	655	(1)
Warranty	655	(1)
Reasembly	655	(1)
Begin Reassembly	656	(1)
Install the Cam	656	(1)
Prepare the Crankshaft for Installation	657	(1)
Install the Crank	658	(5)
Install the Cylinder Heads	663	(1)
Install OHC Heads	663	(1)
Install the Cam Drive (Pushrod Engines)	663	(1)
Install Valve Train Parts	664	(1)
Install the Oil Pump	664	(1)
Install the Timing Cover	664	(1)
Install the Damper	665	(1)
Install the Oil Pan	665	(1)
Install the Intake Manifold	665	(1)
Install the Thermostat and Water Outlet Housing	666	(1)
Install the Fuel Pump	666	(1)
Completion of Assembly	666	(1)
Install Exhaust Manifold(s)	666	(2)
Engine Installation, Break-In, and In-Chassis Repairs	668	(15)
Introduction	668	(1)
Engine Installation	668	(1)
Install Engine Mounts	668	(1)
Install the Engine	668	(1)
Install the Carburetor	669	(1)
Priming the Lubrication System	670	(1)
Pressure Priming	670	(1)
Install Valve Covers	671	(1)
Install the Distributor	671	(1)
Engine Starting and Initial Break-In of the Camshaft	672	(1)
Valve Clearance Adjustment	673	(1)
Road Test and Break-In	673	(1)
Final Inspection	674	(1)
Returning the Car to the Customer	674	(1)
Engine Repair---Engine in the Vehicle	674	(1)
Valve Job or Head Gasket Repairs	674	(1)
Valve Job or Complete Engine Overhaul	675	(1)
Head Gasket Problems	676	(1)
In-Chassis Lower End Repairs	676	(1)
Removing the Oil Pan	676	(1)
Remove the Piston and Rod Assebly	677	(1)
Remove the Timing Cover	678	(1)
Freewheeling and Interference Engines	678	(1)
Replace the Timing Components	679	(1)
Crankshaft Seal Replacement	679	(1)
Flywheel Ring Gear Service	680	(3)
SECTION 9 MISCELLANEOUS CHASSIS THEORY AND SERVICE
Brakes Fundamentals	683	(23)
Introduction	683	(1)
Brake Linings	683	(1)
Brake Hydraulics	684	(1)
Brake Fluid	685	(1)
Brake Hoses	686	(1)
Master Cylinder Operation	687	(1)
Low Pedal Master Cylinder Action	688	(1)
Tandem Master Cylinder	688	(3)
Drum Brakes	691	(2)
Disc Brakes	693	(4)
Power Brakes	697	(1)
Parking Brake	698	(1)
Stoplight Switches	699	(1)
Anti-Lock Brakes	699	(1)
Types of ABS	700	(2)
ABS Components	702	(1)
ABS Operation	703	(3)
Brake Service	706	(27)
Brake Inspection	706	(1)
Check Brake Pedal Feel	706	(1)
Master Cylinder Inspection	706	(2)
Brake Diagnosis	708	(1)
Under Car Checks	708	(2)
Brake Fluid Service	710	(1)
Bleeding Brakes	710	(2)
Adjusting Brakes	712	(1)
Brake Lining Inspection	713	(1)
Master Cylinder Service	714	(1)
Master Cylinder Removal	714	(1)
Master Cylinder Disassembly	715	(1)
Residual Check Valve Service	715	(1)
Bench Bleeding the Master Cylinder	716	(1)
Brake Job	716	(1)
Selecting Linings	717	(1)
Drum Brake Lining Removal	718	(1)
Rebuilding Hydraulic Cylinders	718	(1)
Reassembling a Wheel Cylinder	719	(1)
Removing Wheel Cylinders	720	(1)
Replacing Drum Brake Shoes	720	(1)
Checking Return Spring Condition	721	(1)
Installing Self-Adjusters	721	(1)
Adjusting Drum Brake Clearance	721	(1)
Drum and Rotor Service	722	(1)
Drum Service	722	(1)
Rotor Service	723	(2)
Disc Brake Service	725	(1)
Rear Disc Parking Brake Caution	726	(1)
Disc Brake Caliper Rebuilding	726	(1)
Assemble the Caliper	727	(1)
Disc Brake Noise	728	(1)
Install the Caliper	728	(1)
Break-in New Linings	729	(1)
Service the Parking Brake Cable	729	(1)
Power Brake Booster Service	730	(1)
Anti-Lock Brake System [ABS] Service	731	(2)
Bearings, Seals, and Greases	733	(20)
Introduction	733	(1)
Plain Bearings	733	(1)
Frictionless Bearings	733	(1)
Direction of Bearing Load	734	(1)
Ball Bearings	734	(1)
Roller Bearings	735	(2)
Wheel Bearings	737	(1)
Greases	738	(3)
Wheel Bearing Seals	741	(1)
Seal Materials	742	(1)
Seal Tolerance	743	(1)
Wheel Bearing Diagnosis and Service	743	(1)
Wheel Bearing Adjustment	744	(1)
Selecting and Installing a Cotter Pin	744	(1)
Repacking Wheel Bearings	745	(1)
Bearing Inspection and Diagnosis	746	(3)
Repacking Disc Brake Wheel Bearings	749	(1)
Diagnosing Wheel Bearing Noise	749	(1)
Replacing Bearing Races	749	(1)
Servicing Front Wheel Drive Bearings	750	(3)
Tire and Wheel Theory	753	(12)
Introduction	753	(1)
Tire Construction	753	(1)
Tubeless Tires	753	(1)
Traction	754	(1)
Tire Tread	754	(1)
Tire Tread Material	754	(1)
Tire Cord	755	(1)
Tire Ply Design	755	(1)
Switching to Radials	756	(1)
Tire Sidewall Markings	756	(3)
All-Season Tires	759	(1)
Tire Quality Grading	759	(1)
Changing Tire Size	759	(2)
Wheels	761	(1)
Custom Wheels	761	(1)
Lug Studs	762	(1)
Lug Nuts	762	(1)
Tire Valve Stems	763	(1)
Retreads	763	(2)
Tire and Wheel Service	765	(22)
Introduction	765	(1)
Tire Inflation	765	(1)
Checking Air Pressure	765	(1)
Tire Wear	766	(1)
Sidewall Checks	766	(1)
Tire Rotation	766	(1)
Removing and Tightening Lug Nuts	767	(2)
Reparing Wheel Studs	769	(1)
Removing and Mounting Tires on Rims	769	(2)
Inspecting the Tire and Wheel	771	(1)
Valve Stem Replacement	771	(1)
Rubber Lube	772	(1)
Install the Tire	772	(3)
Tire Runout	775	(1)
Tire Repair	775	(1)
Repairing a Tire	776	(1)
Preparing the Tire for Repair	777	(1)
Patching the Tire	778	(1)
Tire and Wheel Balance	779	(1)
Types of Wheel Balance	779	(1)
On-The-Car Balancers	780	(1)
Couple Imbalance	781	(1)
Dynamic Balance	781	(1)
Computer Balancers	782	(1)
Centering the Wheel on the Balancer	782	(2)
Match Mounting	784	(1)
Mounting the Wheel on the Car	784	(3)
SECTION 10 SUSPENSION, STEERING, ALIGNMENT
Suspension Fundamentals	787	(13)
Introduction	787	(1)
Suspension	787	(1)
Frame and Suspension Designs	788	(1)
Independent and Solid Axle Suspensions	788	(1)
Springs	788	(1)
Suspension Construction	789	(1)
Suspension Types	790	(1)
Shock Absorbers	790	(2)
Hydraulic Shock Absorber Operation	792	(1)
Shock Ratio	793	(1)
Aeration of Fluid	793	(1)
Gas Shocks	793	(1)
Air Shocks/Leveling Devices	794	(1)
MacPherson Strut Shocks	795	(1)
Other Front End Parts	795	(1)
Stabilizer Bar	795	(2)
Suspension Leveling Systems	797	(1)
Automatic Suspension Leveling	797	(1)
Active Suspension	798	(2)
Suspension System Service	800	(11)
Introduction	800	(1)
Diagnosing Suspension System Problems	800	(1)
Shock Absorber Service	800	(1)
Testing a Shock	801	(1)
MacPherson Strut Service	802	(1)
Add Oil to Strut Body	803	(1)
Bushing Service	803	(1)
Control Arm Bushings	803	(1)
Stabilizer Bar Service	804	(1)
Spindle Service	804	(1)
Ball Joint Service	804	(1)
Measuring Ball Joint Wear	805	(1)
Separating Ball Joint Tapers	806	(1)
Replacing the Ball Joint	806	(1)
Coil Spring Service	807	(1)
Adjusting Spring Height	807	(1)
SLA Coil Spring Replacement	808	(1)
Wheel Alignment	809	(2)
Steering Fundamentals	811	(15)
Steering Systems	811	(1)
Steering Gears	811	(1)
Recirculating Ball Steering Gear	811	(1)
Rack and Pinion Steering	812	(1)
Steering Linkage	812	(1)
Parallelogram Steering Linkage	813	(1)
Ball Sockets	814	(1)
Tie Rods	814	(1)
Steering Arm	814	(1)
Rack and Pinion Steering Linkage	814	(1)
Steering Column	814	(1)
Steering Shaft	815	(1)
Power Steering	816	(1)
Power Steering Pump	816	(1)
Types of Power Steering	817	(3)
Variable Effort Power Steering	820	(1)
Four Wheel Steering	820	(2)
Types of Four Wheel Steering	822	(1)
Hydraulic Four Wheel Steering	822	(1)
Electronically Controlled Four Wheel Steering	822	(4)
Steering Service	826	(13)
Introduction	826	(1)
Fluid Level Checks	826	(1)
Type of Fluid	826	(1)
Diagnosing Steering Problems	826	(1)
Noise Diagnosis	826	(1)
Steering Part Inspection	826	(1)
Hard Steering	827	(1)
Tire Wear	827	(1)
Steering Linkage Inspection	827	(1)
Steering Gear Looseness	827	(1)
Parallelogram Inspection	827	(1)
Rack and Pinion Steering Linkage Inspection	828	(1)
Steering Linkage Repairs	828	(1)
Idler Arm Replacement	829	(1)
Pitman Arm Replacement	829	(1)
Tie Rod End Replacement	829	(1)
Rack and Pinion Tie Rods	830	(1)
Steering Wheel, Column, and Air Bag Service	831	(1)
Air Bags	831	(1)
Steering Wheel Service	832	(1)
Steering Column Service	832	(1)
Steering Gear Service	833	(1)
Manual Rack Service	833	(1)
Rack and Pinion Looseness	833	(1)
Power Steering System Service	833	(1)
Power Steering Hoses	834	(1)
Power Steering Gear Service	834	(1)
Replacing Rack and Pinion Units	835	(2)
Flushing the Hydraulic System	837	(1)
Bleeding the System	837	(1)
Variable Power Steering Service	837	(2)
Wheel Alignment Fundamentals	839	(8)
Introduction	839	(1)
Alignment Angles	839	(1)
Toe	839	(1)
Camber	840	(1)
Caster	840	(2)
Steering Axis Inclination	842	(1)
Scrub Radius	843	(1)
Turning Radius	844	(1)
Tracking	844	(1)
Set-back	845	(1)
Special Handling Characteristics	845	(2)
Wheel Alignment Service	847	(14)
Introduction	847	(1)
Pre-Alignment Inspection	847	(1)
Tire Wear Inspection	847	(1)
Ride Height Check	848	(1)
Toe Change	849	(1)
Torque Steer	849	(1)
Suspension Looseness	849	(1)
Test Drive	850	(1)
Ball Joints	850	(1)
Wheel Alignment Procedures	851	(1)
Measuring Alignment	851	(1)
Measuring Camber	852	(1)
Caster Measurement	852	(1)
Measuring Turning Radius	852	(1)
Adjusting Camber and Caster	853	(1)
Road Crown and Pull	853	(1)
Plan Ahead	853	(1)
Measuring Steering Axis Inclination	854	(1)
Measuring Included Angle	855	(1)
Measuring Toe	855	(1)
Adjusting Toe	855	(2)
Centering the Steering Wheel	857	(1)
Toe Change Check	857	(1)
Four Wheel Alignment	857	(1)
General Wheel Alignment Rules	858	(3)
SECTION 11 DRIVE TRAIN
Clutch Fundamentals	861	(10)
Introduction	861	(1)
Clutch Parts and Operation	861	(1)
Clutch Disc	861	(1)
Pressure Plate	862	(1)
Types of Clutch Covers	863	(1)
Coil Spring Clutch	863	(1)
Release Levers	863	(1)
Diaphragm Clutch	864	(1)
Pilot Bearing or Bushing	865	(1)
Release Bearing	865	(1)
Self-Centering Release Bearing	866	(1)
Other Release Bearings	866	(1)
Clutch Fork	866	(1)
Clutch Release Methods	866	(1)
Mechanical Linkage	867	(1)
Clutch Cable	867	(1)
Hydraulic Clutch Operation	867	(1)
Clutch Free Play	868	(3)
Clutch Diagnosis and Service	871	(14)
Introduction	871	(1)
Diagnosis of Clutch Problems	871	(1)
Clutch Noises	871	(1)
Transmission Noise	872	(1)
Pedal Problems	872	(1)
Slipping Clutch	872	(1)
Dragging Clutch	872	(1)
Oily Clutch Facings	873	(1)
Damaged Friction Surfaces	873	(1)
Chattering or Grabbing Clutch	873	(1)
Clutch Service	874	(1)
Servicing Hydraulic Components	874	(2)
Clutch Replacement	876	(1)
Remove the Transmission or Transaxle	876	(1)
Clutch Removal	876	(1)
Flywheel Removal	877	(1)
Flywheel Starter Ring Gear Replacement	877	(1)
Flywheel Installation	878	(1)
Inspect New Parts	878	(1)
Pilot Bushing Service	878	(1)
Clutch Disc Service	878	(1)
Clutch Cover/Pressure Plate Service	879	(1)
Clutch Installation	879	(2)
Release Bearing Service	881	(1)
Clutch Housing Installation	882	(3)
Manual Transmission Fundamentals	885	(17)
Introduction	885	(1)
Purpose of a Transmission	886	(1)
Using Gears to Increase Torque	886	(1)
Gear Ratio	886	(1)
Transmission Gear Ranges	887	(1)
Overdrive	887	(1)
Close and Wide Ratio	887	(1)
Final Drive Ratio	887	(1)
Gear Types and Operation	888	(1)
Spur Gears	888	(1)
Helical Gears	889	(1)
Idler Gears	889	(1)
Transmission Parts	890	(1)
Transmission Lubrication	891	(1)
Transmission Bearings	891	(1)
Transmission Gears and Shafts	891	(1)
Synchronizer Assembly	892	(2)
Gear Shift Mechanisms	894	(1)
Shift Pattern	895	(1)
Transmission Power Flow	895	(1)
Four-speed Transmission Power Flow	896	(2)
Five-speed Transmission	898	(2)
Speedometer Drive	900	(1)
Switches	900	(2)
Manual Transmission Diagnosis and Repair	902	(11)
Introduction	902	(1)
Transmission Diagnosis	902	(1)
Lubricant Checks	903	(1)
Transmission Removal	903	(1)
Transmission Disassembly	904	(1)
Disassemble the Mainshaft Assembly	905	(1)
Synchronizer Service	906	(1)
Synchronizer Inspection	906	(1)
Inspect Blocker Rings	907	(1)
Inspect Input Shaft and Mainshaft	907	(1)
Replace Worn Bearings	908	(1)
Reassemble the Transmission	908	(1)
Reassemble the Synchronizers	908	(1)
Reassemble the Mainshaft	908	(1)
End Play	909	(1)
Needle Bearing Installation	909	(1)
Install New Gaskets	910	(1)
Install the Transmission	911	(1)
Transmission Linkage Adjustment	911	(1)
Add Lubricant	911	(1)
Test Drive	911	(2)
Automatic Transmission Fundamentals	913	(24)
Introduction	913	(1)
Automatic Transmission Parts	913	(1)
Power Transmission	914	(1)
Flexplate	914	(1)
Torque Converter	914	(1)
Torque Multiplication	915	(1)
Torque Converter Operation	915	(1)
Torque Converter Stator	915	(1)
Stator Operation	916	(1)
Stator Clutch Operation	917	(1)
Stall Speed	917	(1)
Lock-up Converters	918	(1)
Automatic Transmission Components	918	(2)
Planetary Gears	920	(1)
Simple Planetary Gear set	920	(1)
Simple Planetary Operation	920	(2)
Compound Planetary Operation	922	(1)
Driving and Holding Devices	923	(1)
Clutches	923	(1)
Clutch Operation	923	(1)
One-way Clutches	924	(1)
Bands	925	(1)
Band Operation	926	(1)
Accumulator	926	(1)
Hydraulic System	926	(1)
Fluid Pump	926	(1)
Types of Pumps	927	(1)
Pump Operation	927	(1)
Transmission Valves	928	(1)
Pressure Regulator	929	(1)
Hydraulic Valve Body	929	(1)
Transmission Automatic Shift Selection	930	(1)
Governor	931	(1)
Vacuum Modulator	931	(1)
Kickdown Valve	932	(1)
Automatic Transmission Fluid [ATF]	932	(1)
Automatic Transmission Cooling	932	(1)
Auxiliary Cooler/Heat Exchanger	933	(1)
Park Pawl	933	(1)
Electronic Automatic Transmissions	933	(2)
Continuously Variable Transmission	935	(2)
Automatic Transmission Diagnosis and Service	937	(17)
Introduction	937	(1)
Automatic Transmission Maintenance	937	(1)
Transmission Fluid Service	937	(1)
Fluid Level	938	(1)
Check Fluid Condition	938	(1)
Changing Transmission Fluid	938	(1)
Transmission Filter Service	939	(1)
Remove and Replace the Filter	939	(1)
Refill the Transmission	940	(1)
Diagnosis and Repair of Leaks	940	(1)
Leaks From the Converter Housing	941	(1)
Transmission Cooler Line Leak	941	(1)
Speedometer Drive Gear Leak	941	(1)
Shift Lever Seal Replacement	942	(1)
Pump Seal Replacement	942	(1)
Front Seal Replacement	942	(1)
Pump Bushing Replacement	943	(1)
Reinstalling the Transmission	943	(1)
Rear Oil Seal and Bushing Replacement	944	(1)
Automatic Transmission Problem Diagnosis	944	(1)
Slippage	945	(1)
Morning Sickness	945	(1)
Transmission Drainback	945	(1)
Shift Feel	945	(1)
Improper Shift Points	945	(1)
Vacuum Modulator Diagnosis and Adjustment	945	(1)
Noises	946	(1)
Flexplate	946	(1)
Transmission Tests	947	(1)
Valve Body Removal	948	(1)
Transmission Adjustments	949	(1)
Linkage Adjustment	949	(1)
Neutral Safety Switch	949	(1)
Throttle Valve Adjustment	949	(1)
Band Clearance Adjustment	949	(1)
Transmission Rebuilding	950	(1)
Seak Kit Overhaul	950	(1)
Valve Body Service	950	(1)
Clutch Pack Service	950	(1)
Bushing Service	951	(1)
Transmission Reassembly	952	(2)
Driveline Operation	954	(21)
Introduction	954	(1)
Driveshaft	954	(1)
Slip Yoke	954	(1)
Universal Joints	955	(1)
Two-Piece Driveshaft	956	(1)
Driveshaft Angle	957	(1)
Constant Velocity Joints	958	(1)
Differential	958	(1)
Differential Construction	959	(1)
Differential Housing	960	(1)
Differential Operation	961	(1)
Differential Gears	962	(1)
Gear Sets	962	(1)
Axle Ratio	963	(1)
Limited Slip Differential	963	(1)
Types of Limited Slip Differentials	963	(3)
Drive Axles and Bearings	966	(1)
Semi-Floating Axle Bearing Types	966	(1)
C-Lock Axle	966	(1)
Independent Rear Suspension	966	(1)
Gear Oils	966	(2)
Four Wheel Drive	968	(1)
Four Wheel Drive Axle Assembly	968	(1)
Transfer Case	968	(3)
Locking Hubs	971	(1)
All Wheel Drive	971	(4)
Driveline Diagnosis and Service	975	(21)
Introduction	975	(1)
Driveshaft Diagnosis	975	(1)
Driveshaft Service	976	(1)
Universal Joint Diagnosis and Service	976	(1)
Universal Joint Disassembly	976	(2)
Universal Joint Reassembly	978	(1)
Driveshaft Installation	979	(1)
Two-Piece Driveshaft Service	980	(1)
Differential and Axle Diagnosis and Service	980	(1)
Problem Diagnosis	980	(1)
Axle Bearing Diagnosis	980	(1)
Axle Bearing Service	981	(1)
C-Lock Axle Removal and Replacement	982	(1)
Axle Bearing Replacement	983	(1)
Axle Bearing Installation	984	(1)
Reinstall the Axle	984	(1)
Full Floating Axle Service	984	(1)
Differential Pinion Seal Replacement	985	(2)
Differential Repair	987	(1)
Removing a Third Member	987	(1)
Disassembling a Salisbury Axle	987	(2)
Clean and Inspect Parts	989	(1)
Differential Reassembly	989	(1)
Adjusting a Differential	989	(1)
Pinion Gear Depth	989	(1)
Ring Gear Backlash	990	(1)
Side Bearing Preload	991	(1)
Contact Pattern	992	(1)
Pinion Bearing Preload	993	(1)
Ring and Pinion Noise	994	(2)
Front Wheel Drive (Transaxle and CV Joint) Fundamentals	996	(11)
Introduction	996	(1)
Front Wheel Drive	997	(1)
Manual Transaxle	998	(1)
Shift Linkage	999	(1)
Transaxle Differential	999	(1)
Transaxle Power Flow	1000	(2)
Automatic Transaxle	1002	(1)
Front Drive Axles	1002	(1)
Axle Shaft Parts	1002	(2)
CV Joint Construction	1004	(1)
Axle Shafts	1005	(1)
CV Joint Boots	1006	(1)
Front Wheel Drive (Transaxle and CV Joint) Service	1007	(11)
Introduction	1007	(1)
Transaxle and Front Wheel Drive Service and Repair	1007	(1)
Leaking CV Joint Boot	1007	(1)
Boot Kits	1007	(1)
CV Joint Boot Clamps	1007	(1)
Axle Inspection and Diagnosis	1008	(1)
CV Joint Diagnosis	1008	(1)
Axel Shaft Removal	1008	(3)
CV Joint Replacement	1011	(1)
Fixed Joint Disassembly and Inspection	1012	(1)
Servicing an Inner Tripod Joint	1013	(1)
Double Offset Plunge Joints	1014	(1)
Cross Groove Joint Service	1014	(1)
Rebuilt Half Shafts	1014	(1)
Installing the Axle	1015	(1)
Transaxle Repair	1015	(1)
Transaxle Removal	1015	(1)
Transaxle Service	1015	(1)
Install the Transaxle	1016	(2)
Driveline Vibration Service	1018	(10)
Vibration Analysis	1018	(1)
Types of Vibrations	1019	(1)
Vibration Test Instruments	1019	(1)
Vibration and Frequency	1020	(2)
Driveshaft Runout	1022	(1)
Other Causes of Vibration	1022	(1)
Driveshaft Balance	1022	(2)
Driveshaft Angle	1024	(4)
SECTION 12 COMOFORT SYSTEMS AND VEHICLE ELECTRONICS
Heating and Air Conditioning Fundamentals	1028	(20)
Introduction	1028	(1)
Sources of Heat	1028	(1)
Ventilation	1028	(1)
Heating	1029	(1)
Air Conditioning	1030	(1)
Air Conditioning Principles	1030	(1)
Heat Transfer	1031	(1)
Humidity	1031	(1)
States of Matter	1031	(1)
Latent Heat	1031	(2)
Air Conditioning System Operation	1033	(1)
Absorbing Heat	1033	(1)
Reducing Humidity	1033	(1)
Compressing the Refrigerant	1034	(1)
Transferring Refrigerant Heat to Outside Air	1034	(1)
Air Conditioning System Parts	1035	(1)
Flow Control Devices	1035	(3)
Air Conditioning Compressors	1038	(2)
Compressor Lubrication	1040	(1)
Muffler	1040	(1)
Accumulator or Receiver Dryer	1041	(2)
Evaporator Icing Control	1043	(1)
System Switches	1043	(1)
Heating and Air Conditioning Controls	1044	(1)
Refrigerants and the Environment	1044	(1)
Temperature and Pressure	1045	(1)
Pressure	1046	(2)
Heating and Air Conditioning Service	1048	(18)
Heater Service	1048	(1)
Air Conditioning Service	1048	(1)
Air Conditioning System Testing	1049	(1)
Testing Air Conditioning Efficiency	1050	(1)
Air Discharge Temperatures	1050	(1)
Clutch Cycling Times	1050	(1)
Pressure Testing	1050	(3)
Static Pressure Reading	1053	(1)
Operating Performance Test	1054	(1)
System Operating Pressures	1054	(1)
Leak Detection	1054	(1)
Location of Leaks	1055	(1)
Common Air Conditioning Component Problems	1056	(1)
Refrigerant Oil	1057	(1)
Evaporator Problems	1058	(1)
Expansion Valve or Orifice Tube Problems	1058	(1)
Compressor Problems	1058	(3)
Evacuating and Recharging	1061	(1)
Vacuuming a System	1061	(1)
Evacuate the System	1062	(1)
Modern Air Conditioning Equipment	1062	(1)
Recharging the System	1063	(1)
Recycling and Retrofit	1063	(1)
Computer Control Problems	1064	(2)
Automotive Computers and Electronics Fundamentals	1066	(17)
Introduction	1066	(1)
Semiconductors	1066	(1)
Diodes	1067	(1)
Transistors	1068	(2)
LEDs	1070	(1)
Automotive Computer Systems	1070	(1)
Parts of a Computer System	1071	(1)
Onboard Computer	1071	(1)
Information Processing	1072	(1)
Computer Memory	1073	(1)
Communication Rate	1074	(1)
Sensors and Actuators	1074	(1)
Types of Sensors	1074	(1)
Thermistors	1075	(1)
Voltage Dividers	1075	(1)
Piezoelectric and Piezoresistive Sensors	1075	(1)
Heated Resistive Sensors	1076	(1)
Variable DC Frequency Sensors	1076	(1)
Voltage Generators	1076	(1)
Switches	1076	(1)
Types of Actuators	1077	(1)
Solenoid Actuators	1077	(1)
Relay Actuators	1077	(1)
Motor Actuators	1077	(1)
Switch Actuators/Modules	1078	(1)
Adaptive Strategy	1079	(1)
On Board Diagnostics	1080	(1)
Computer Fault Codes	1080	(1)
Computer Self-Diagnostics	1080	(1)
Multiplexing	1081	(2)
Electronic and Computer System Service	1083	(22)
Introduction	1083	(1)
Inspection Sequence	1083	(1)
Perform Diagnostic Tests	1084	(1)
Onboard Diagnostics	1084	(1)
Reading Trouble Codes	1085	(1)
Scan Tools	1086	(1)
Breakout Box	1087	(1)
Retrieving Codes	1087	(1)
Working With Codes	1088	(1)
Erasing Trouble Codes	1088	(1)
Scan Tool Snapshot	1089	(1)
Confirm Closed Loop	1089	(1)
Check For Closed Loop	1090	(1)
Scan Tool Diagnosis of 02 Feedback	1091	(1)
Digital Storage Oscilloscope	1092	(1)
Sensor and Actuator Testing	1093	(1)
Diagnosing Sensor Problems	1093	(1)
Sensor Tests	1093	(1)
Oxygen Sensor	1094	(1)
Load Sensors	1095	(1)
MAP Sensor	1095	(1)
BARO Sensors	1096	(1)
Vacuum Sensors	1096	(1)
Throttle Position Sensor	1096	(1)
Coolant Temperature Sensor	1097	(1)
Air Temperature Sensors	1098	(1)
Air Flow Sensor Service	1099	(1)
Knock Sensor Service	1100	(1)
Actuator Service	1100	(1)
Repair the Problem	1100	(1)
Computer Wiring Service	1100	(2)
Computer Service	1102	(1)
Static Electricity	1102	(1)
Electrical Damage to a Circuit	1103	(2)
Appendix	1105	(12)
ASE Task List	1117	(28)
Glossary	1145	(44)
Index	1189