9781401848330

Automotive Technology Tech Manual

by ;
  • ISBN13:

    9781401848330

  • ISBN10:

    1401848338

  • Edition: 4th
  • Format: Paperback
  • Copyright: 2004-08-04
  • Publisher: Cengage Learning
  • View Upgraded Edition

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Supplemental Materials

What is included with this book?

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

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