Auto Diagnosis, Service, and Repair (7TH)

Auto Diagnosis, Service, and Repair (7TH)

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  • 製本 Hardcover:ハードカバー版/ページ数 1024 p.
  • 言語 ENG,ENG
  • 商品コード 9781566379106
  • DDC分類 629.2872

Table of Contents

Section 1 Introduction to Automotive Diagnosis,
Service, and Repair
Introduction to the Automotive Service and 15 (10)
Repair Industry
Automotive Service 15 (1)
Automotive Service Positions 15 (2)
Helpers
Installers
Technicians
Other Opportunities in the Auto Service 17 (1)
Industry
Service Manager
Sales Person
Parts Person
Self-Employment
Types of Auto Service Facilities 18 (2)
New-Vehicle Dealerships
Chain and Department Store Auto Service
Centers
Specialty Shops
Independent Shops
Government Agencies
Technician Training Opportunities 20 (2)
Training to become a Technician
Training for Experienced Technicians
ASE Certification Tests 22 (3)
Safety and Environmental Protection 25 (12)
Accidents 25 (4)
Preventing Accidents
Proper Shopkeeping
Following Proper Work Procedures
Personal Protective Equipment
Preventing Environmental Damage 29 (2)
Ways of Damaging the Environment 31 (6)
Careless Waste Disposal
Improper Vehicle Repair Procedures
Following Proper Environmental Procedures
Basic Tools and Service Information 37 (24)
Buy High-Quality Tools
Proper Care Is Essential 37 (1)
Types of Tools 37 (16)
Hand Tools
Power Tools
Hydraulically Operated Tools
Other Tools Will Follow
Service Information 53 (8)
Factory Service Manuals
General Service Manual
Specialized Manual
Schematics
Troubleshooting Charts
Telephone Hotlines
Internet Resources
Training Materials
Care of Service Information
Precision Tools and Test Equipment 61 (18)
Tool Storage 61 (1)
Handling Tools 61 (1)
Checking for Accuracy 62 (1)
Precision Measuring Tools 62 (8)
Outside Micrometer
Reading the Micrometer
Using an Outside Micrometer
Digital Micrometers
Inside Micrometer
Micrometer Depth Gauge
Dial Indicator
Other Useful Measuring Tools
Inside and Outside Calipers
Dial Calipers
Feeler Gauges
Wire Gauge
Screw Pitch Gauge
Telescoping Gauge
Steel Rules
Spring Scale
Steel Straightedge
Temperature Is Important
Other Automotive Measuring Equipment 70 (9)
Pressure Gauges
Compression Gauge
Vacuum Gauge
Oil Pressure Tester
Fuel Pressure Tester
Electrical Testers
Test Light
Jumper Wire
Multimeter
Ohmmeter
Voltmeter
Ammeter
Tachometer
Scan Tools
Waveform Meters
Jacks, Lifts, and Holding Fixtures 79 (10)
Lifting Equipment 79 (4)
Hand Jack
Hydraulic Floor Jack
Jack Stands
End Lifts
Double-Post Frame Lift
Double-Post Suspension Lift
Parallelogram Lifts
Drive-On Lift
Choice of Lifts
Safety Considerations 83 (1)
Specialty Lifting Equipment 83 (2)
Power Train Lift
Transmission Jack
Portable Crane and Chain Hoist
Extension Jack
Repair Stands
Hand Lifting 85 (4)
Cleaning Equipment and Techniques 89 (10)
Types of Cleaning Equipment 89 (1)
Cleaning Precautions
Types of Cleaning Systems 90 (9)
Mechanical Cleaning Systems
Liquid Cleaning Systems
Steam Cleaning
High-Pressure Spray Cleaning
Low-Pressure Spray Cleaning
Parts Washers
High-Pressure Parts Washer
Hot Tank Cleaning
Cold Soak Cleaning
Vapor Cleaning
Brake Washer
Welding Equipment and Techniques 99 (14)
Preparing the Joint for Welding 99 (1)
Welding Techniques 99 (1)
Backhand and Forehand Methods
Uphill and Downhill Welding
Welding Processes 100 (1)
MIG Welding 100 (1)
TIG Welding 100 (1)
Plasma Cutting 101 (1)
Arc Welding 102 (3)
Arc Welding Setup
Arc Welding Rods
Protective Equipment
Arc Welding Techniques
Work Should Be Clean
Safety Rules for Arc Welding
Preventing Damage to the Arc Welder,
Vehicle, and the Surrounding Area
Oxyfuel Gas Welding 105 (4)
Setting up Oxyacetylene Equipment
Adjusting Gas Pressure
Lighting the Torch
Adjusting the Flame
Shutting Down the Torch
Using the Oxyacetylene Cutting Torch
Basic Safety Rules for Oxyacetylene
Equipment
Brazing 109 (4)
Braze Welding
Brazing Rod
Brazing Flux
Sources of Heat for Brazing
Brazing Technique
Braze Welding Technique
Fasteners, Gaskets, and Sealants 113 (30)
Types of Fasteners 113 (4)
Machine Screws
Sheet Metal Screws
Bolts
Studs
Removing Broken Studs or Screws
Nuts
Repairing Threads
Bolt and Screw Terminology 117 (2)
Head Markings
Major and Minor Diameters
Thread Pitch
Thread Series
Right-Hand and Left-Hand Threads
Nut Terminology 119 (1)
Class and Fit
Locking Devices 119 (1)
Self-Locking Nuts
Self-Locking Screws
Lock Washers
Palnuts
Cotter Pin
Special Locking Compounds
Other Types of Fasteners 120 (2)
Keys, Splines, and Pins
Snap Rings
Setscrews
Rivets
Fasteners and Torque 122 (6)
Torquing Fasteners
Using a Torque Wrench
Torque Extensions
Gaskets and Sealants 128 (4)
Gaskets
Gaskets Installation Techniques
Use of Sealants 132 (1)
Using Rubber Gaskets
Holding the Gasket during Assembly
Use Proper Sequence and Torque
Stamped Parts Require Extra Care
Steps in Proper Gasket Installation
Analyze Gasket Failure
Retorquing
Oil Seals 133 (4)
Oil Seal Construction and Materials
Oil Seal Designs
Other Types of Oil and Grease Seals
Oil Seal Removal
Seal Installation
Mounting Sleeves
Steps in Seal Installation
Other Information on Seal Installation
O-Ring Seal Construction
O-Ring Operation
O-Ring Installation Steps
O-Ring Failure Diagnosis
Adhesives and Sealants 137 (1)
Form-in-Place Gaskets 138 (5)
Tubing and Hose 143 (18)
Tubing Material 143 (1)
Copper Tubing
Steel Tubing
Plastic Tubing
Tubing Fittings and Connectors 144 (4)
Flare Fitting
Forming the Flare
Compression Fittings
Specialty Fittings
T-, Swivel, and O-Ring Fittings
Connectors, Unions, and Elbows
Distribution Blocks
Shutoff and Drain Cocks
Push-On Fittings
Working with Tubing 148 (4)
Cutting Tubing
Cleaning Tubing
Bending Tubing
Installation Tubing
Hose 152 (9)
Cooling System and Heater Hose
Refrigerant Hose
Nonreinforced Hose
Fuel System Hose
Power Steering and Brake Hose
Lubrication Hose
Hose End Fittings
Mounting Hoses
Hose Condition
Storing Hose
Friction and Antifriction Bearings 161 (22)
Major Classes of Bearings 161 (1)
Bearing Load
Friction Bearings 162 (7)
Friction Bearing Failure
Friction Bearing Installation
Bearing Spread
Bearing Crush
Bearing Oil Clearance
Checking Bearing Clearance
Undersize Bearings
Antifriction Bearings 169 (14)
Removing Bearings
Antifriction Bearing Service
Antifriction Bearing Failure
Bearing Lubrication
Bearing Installation
Preventive Maintenance 183 (26)
Preventive Maintenance 183 (1)
Maintenance Schedules
Engine Lubrication System Service 183 (3)
Engine Oils
Viscosity
Oil Grades
Checking Engine Oil Level 186 (1)
Determining when Oil Should Be Changed
Changing the Oil and Filter 187 (1)
Checking the Oil Cooler
Other Services during Oil and Filter Change 188 (9)
Checking the Crankcase Ventilation System
Checking the Fuel Filters
Air Cleaner Service
Lubricating Suspension and Steering
Linkage
Lubricating the Driveline
Lubricating Body Hinge Pivot Points and
Lock Mechanisms
Lubricating the parking Brake Cable
Checking Fluids
Checking Automatic Transmission
Transaxle Fluid
Checking Gearbox Fluid Levels
Checking Coolant Level and Condition
Checking Power Steering Fluid Levels
Checking Brake Fluid Levels
Checking Washer Solution
Changing Fluids 197 (3)
Changing Engine Coolant
Changing Automatic Transmission
Transaxle Fluid and Filter
Changing Gearbox Fluid
Changing Brake Fluid
General Vehicle Inspection 200 (4)
Drive Belt Inspection
Coolant Hose Inspection
Checking Tire Condition
Tire Rotation
Inspecting Brakes
Inspecting Suspension Parts
Inspecting Steering Parts
Battery Maintenance
Other Maintenance Procedures 204 (5)
Section 2 Electrical/Electronic Systems
Wire and Wiring 209 (16)
Primary Wire 209 (10)
Primary Wire Construction
Wire Size
Wiring Harness
Wiring Diagrams
Primary Wire Terminals
Joining Primary Terminals and Wires
Crimping Terminals
Soldering
Secondary Wire 219 (1)
Printed Circuit 220 (1)
Troubleshooting Wiring 220 (1)
Checking Wires and Connections 220 (1)
Checking for Continuity 220 (5)
Chassis Electrical Service 225 (26)
Chassis Wiring 225 (4)
Using Wiring Schematics
Fuses, Fusible Links, and Circuit Breakers
Chassis Wiring Service
Vehicle Lights and Switches 229 (3)
Safety Lights
Daytime Running Lamps
Brake Lights and Switches
Turn Signals, Flasher Lights, and Switches
Instrument Panel Lights
Convenience Lights
Vehicle Light Service
Instrument Panel Gauges 232 (1)
Chassis-Mounted Motors 233 (1)
Windshield Wiper Motors and Controls
Power Window, Tailgate, Convertible Top,
and Sunroof Motors
Power Antenna Motors and Switches
Electric Motor Service 234 (2)
Chassis-Mounted Solenoids and Relays 236 (1)
Power Door Lock Solenoids and Switches
Trunk Release Solenoids
Solenoid Service
Control Relays
Security Systems 237 (2)
Pass Key Systems
Remote Keyless Entry System
Radios and Sound Systems 239 (1)
Horns 239 (1)
Rear Window and Mirror Defrosters 239 (1)
Body Computer Systems 240 (11)
Air Bag Systems
Air Bag Operation
Disabling and Enabling Air Bag Systems
Troubleshooting Air Bag Systems
Servicing a Deployed Air Bag
Air bag Service Precautions
Cruise Control
Cruise Control Service
Charging and Starting System Service 251 (28)
Battery Service 251 (7)
Batteries Can Be Dangerous
Check Electrolyte Level
Checking Battery Condition
Checking Open Circuit Voltage before
Testing
Electrical Load Test
Specific Gravity Test
Built-in Hydrometer
Battery Charging
Slow Charging
Fast Charging
Trickle Charging
Battery Storage
Battery Selection
Battery Additives
Battery Temperature Sensor
Battery Removal and Installation
Battery Drains
Jump Starting with a Booster Battery
Charging System Service 258 (6)
Charging System Problems
Undercharging or No Charging
Overcharging
Noisy Alternator
Ammeter or Indicator Light Problems
Alternator Service Precautions
Checking Alternator Output
Voltage Regulator Service
Charge Indicator Light
Computerized Charging System
Check Alternator Charging Circuit for
Excessive Resistance
Alternator Disassembly and Overhaul
Starting System Service 264 (15)
Always Check the Battery First
Checking Starter Circuit
Solenoids, Relays, and Switches
Starter Load Test
Starter No-Load and Stall Torque (Locked
Armature) Tests
Starter Disassembly
Testing the Armature for Short Circuits
Checking the Armature for Grounds
Inspecting the Commutator Bars for Opens
Test Field Coils for Opens
Test Field Coils for Grounds
Check Brushes
Testing the Starter Solenoid
Other Starter Checks
Starter Assembly
Testing the Starter
Installing the Starter
Computer System Diagnosis and Repair 279 (34)
Diagnosing Computer Control System Problems 279 (2)
Retrieving Trouble Codes 281 (4)
The Trouble Code Retrieval Process
Diagnostic Trouble Code Format
OBD I and OBD II Code Formats
Interpreting Trouble Codes
Hard and Intermittent Codes
Other Scan Tool Information 285 (1)
Testing Sensors 286 (11)
Testing Oxygen Sensors
Testing Mass Airflow (MAF) Sensors
Testing manifold Absolute Pressure (MAP)
Sensors
Testing Temperature Sensors
Testing Pressure Sensors
Testing Throttle Position Sensors
Testing Crankshaft and Camshaft Position
and Speed Sensors
Testing Knock Sensor
Testing Vehicle Speed Sensors
Checking the ECM 297 (1)
Checking Actuators 298 (2)
Testing Solenoids and Relays
Testing Motors
Adjusting Sensors 300 (1)
Throttle Position Sensor Adjustment
Adjusting Crankshaft and Camshaft
Position Sensors
Replacing Computer System Components 300 (6)
Input Sensor Replacement
Oxygen Sensor Replacement
MAF and MAP Sensor Replacement
Throttle Position Sensor Replacement
Temperature Sensor Replacement
Knock Sensor Replacement
Crankshaft
Camshaft Position Sensors
ECM Service
Updating ECM Information
Replacing a PROM
Replacing a Knock Sensor Module
Flash Programming a Computer
Actuator Replacement 306 (1)
Replacing a Solenoid
Replacing a Relay
Replacing a Motor
Follow-up for Computer Control System 307 (6)
Repairs
ECM Relearn Procedures
OBD II Drive-Cycle Test
Section 3 Engine Performance and Driveability
Ignition System Service 313 (28)
Types of Ignition Systems 313 (2)
Ignition System Problem Diagnosis 315 (8)
Troubleshooting a No-Start Condition:
Spark Test
Testing, Replacing, and Adjusting
Ignition System Components
Checking the Ignition System with an 323 (4)
Oscilloscope
Secondary Pattern
Pattern Presentations
Primary Pattern
Typical Oscilloscope Patterns and Their
Meanings
Setting Ignition Timing 327 (3)
Checking Ignition Timing
Setting Ignition Timing
Spark Advance Mechanisms
Overhauling Distributors 330 (1)
Removing the Distributor
Disassembling the Distributor
Assembling the Distributor
Installing the Distributor (Engine
Undisturbed)
Installing the Distributor (Engine
Disturbed)
Timing the Distributor
Servicing Spark Plugs 331 (10)
Spark Plug Service Life
Removing Spark Plugs
Examining Spark Plugs
Cleaning Spark Plugs
Plug Size, Reach, Heat Range, and Type
Gapping Plugs
Installing Plugs
Fuel Delivery 341 (16)
Relieving System Pressure 341 (1)
Fuel Tanks 342 (2)
Draining the Tank
Tank Removal
Cleaning the Fuel Tank
Tank Repair
Cold Patching
Expanded (Bulged) Fuel Tank
Removing a Dent in the Fuel Tank
Installing the Fuel Tank
Fuel Line Service 344 (3)
Cleaning Fuel Lines
Repairing Damaged Fuel Line
Fuel Pump Service 347 (6)
Mechanical Fuel Pump Repair
Pump Fluid Pressure Test
Pump Volume Test
Pump Removal
Rebuilding Mechanical Fuel Pumps
Pump Installation
Electric Fuel Pump Repair
Testing Electric Fuel Pumps
Electric Fuel Pump Service
Electric Fuel Pump Inertia Switch
Fuel Filter Service 353 (4)
Fuel Injection System Service 357 (30)
Electronic Fuel Injection Systems 357 (1)
Throttle Body Fuel Injection
Multiport Fuel Injection
Central Point Fuel Injection
Fuel Injection System Components 358 (2)
Fuel Injectors
Fuel Pumps
Pressure Regulators
Returnless Fuel Systems
Throttle Bodies and Related Components
ECM
Input Sensors
Fuel System Safety 360 (1)
Electronic Fuel Injection Diagnosis 360 (6)
Initial System Inspection
Using a Scan Tool
Checking Fuel Trim
Checking Fuel Injection System Pressure
checking the Fuel Pressure Regulator
Checking a Returnless Fuel System
Checking Fuel Injector Operation
Checking Injectors on the Vehicle
Using Noid Lights
Checking Injector Windings
Isolating the Source of the Problem
Performing an Injector balance Test
Using Waveform Meters to Check Fuel
Injection Components
Checking for Deposits in the Throttle Body
Checking Idle Speed Control Devices
Electronic Fuel Injection System Service 366 (5)
Removing Pressure
Cleaning Fuel Injectors
Cleaning Throttle Valves and Bodies
Removing and Replacing Fuel Injectors
Removing and Replacing Fuel Pressure
Regulators
Overhauling Throttle Bodies
Converting MAF System to Calculated Charge
Mechanical Fuel Injection System 371 (1)
Mechanical Injection Fuel Flow Control
Cold Start Injector
Mechanical Fuel Injection System Service 372 (1)
Mechanical Fuel Injection Diagnosis
Mechanical Fuel Injection System
Adjustments
Airflow Sensor
Pressure Regulator and Injector
Replacement
Installing an Aftermarket Fuel Injection 373 (1)
System
Diesel Fuel Injection Systems 374 (1)
Diesel Injection System Service 375 (12)
Diesel Engine Electronics
Stopping a Runaway Diesel Engine
Diesel Injector Service
Testing Injectors
Cleaning Injectors
Injector Pump Service
Injection Pump Removal and Replacement
Injection Pump Overhaul
Purging the Injection System
Servicing Diesel Glow Plugs
Exhaust System Service 387 (16)
Exhaust System Service 387 (8)
Exhaust Manifold
Heat Control Valve
Exhaust System Components
Exhaust System Tools
Exhaust System Service
Turbochargers and Superchargers 395 (8)
Turbochargers
Superchargers
Turbocharger Service
Supercharger Service
Driveability Diagnosis 403 (14)
Introduction 403 (1)
Driveability Diagnosis versus Tune-up 403 (1)
Driveability Diagnosis 403 (7)
The Seven-Step Diagnostic Process
The Importance of Follow-Up
Maintenance Tune-up 410 (7)
Specifications
Checklist for Maintenance Tune-ups
Solicit Owner Comments
Service Records
Road Testing
Chassis Dynamometer Road Test
Emission System Testing and Service 417 (22)
State Emissions Tests 417 (4)
Types of Emissions Tests
Equipment Used to Perform Tests
Performing Emissions Tests
Preparing a Vehicle for Emissions Testing 421 (1)
Checking Emissions in the Shop 421 (1)
Diagnosing Emission Control System Problems 422 (1)
Emission Informaion Label
OBD II Emissions Systems Monitoring
Retrieving Trouble Codes
Emission Control System Service 422 (17)
Devices for Heating Intake Air
Exhaust Gas Recirculation
OBD II EGR System Monitoring
Air Injection System
OBD II Air Injection System Monitoring
Catalytic Converter
OBD II Catalyst Monitoring
Vapor Control Devices
Section 4 Engine Repair
Engine Mechanical Troubleshooting 439 (14)
Steps for Diagnosing Engine Problems 439 (14)
Work Logically
Preliminary Checks
Check the Engine's Mechanical Condition
Performing a Compression Test
Using a Cylinder Leakage Detector
Using a Vacuum Gauge
Checking Oil Pressure
Engine Noise Diagnosis
Cooling System Service 453 (26)
The Need for a Cooling system 453 (1)
Cooling System Service 453 (19)
Dealing with an Overheated Engine
Antifreeze
Long-life Coolants
Mixing Antifreeze
Useful Life of Antifreeze
Checking Antifreeze
Cooling System Maintenance
Coolant Replacement
Bleeding the Cooling System
System Flushing
Finding Leaks in the Cooling System
Pressure Testing the Cooling System
Radiator Pressure Caps
Checking for Internal Leaks with Test
Chemicals
Hose Replacement
Belt Replacement
Adjusting Belt Tension
Fan Service
Thermostat Service
OBD II Thermostat Monitor
Checking Thermostats
Radiator Removal and Replacement
Coolant Pump Service
Freeze Plug Repair
Air-Cooled Systems 472 (7)
Cleaning Fins on an Air-cooled Engine
Replacing Blower Belt
Replacing Blower and Bearing
Replacing Thermostat
Engine Removal, Disassembly, and Inspection 479 (18)
General Removal Procedures 479 (1)
Support the Transmission or Transaxle
Protect the Vehicle
Disconnect all Attached Wiring, Tubing,
Houses, and Controls
Engine Removal from Top 480 (2)
Attach a Lifting Device
Position the Lift
Lift the Engine
Engine Removal From Under the Vehicle 482 (1)
Safety Rules for Pulling Engines
Rebuild or Replace? 483 (1)
Engine Disassembly and Inspection 483 (9)
Place the Engine on a Stand
Intake and Plenum Removal
Cylinder Head Removal
Camshaft Timing Mechanism Removal
Oil Pan Removal
Oil Pump Removal
Removing the Crankshaft
Piston Removal
Engine Block Cleaning
Checking for Cracks and Warpage 492 (5)
Crack Detection Methods
Checking Block for Cracks
Checking Cylinder Head for Cracks
Checking Crankshaft for Cracking
Checking Block and Head Surfaces for
Warpage
Cylinder Head and Valve Service 497 (20)
Cylinder Head Reconditioning 497 (12)
Valve Reconditioning
Valve Guides
Valve Seats
Valve Seat Service
Rocker Arm Stud Service
Valve Spring Service
Cylinder Head Assembly 509 (3)
Valve Stem Seals
Checking Installed Height of Valve Spring
Reinstalling the Head on the Engine 512 (1)
Valve Service with Head on Engine 512 (5)
Engine Block, Crankshaft, and Lubrication 517 (34)
System Service
Engine Block Service 517 (8)
Check Main Bearing Bores
Cylinder Service
Cylinder Reconditioning
Installing In-Block Camshaft Bearings
Camshaft Rear Bearing Core Plug or Oil
Seal Plug
Crankshaft Service 525 (2)
Check Main and Rod Journals for Finish
and Accuracy
Regrinding a Crankshaft
Polishing the Journals
Main Bearing Insert Installation 527 (1)
Installing the Crankshaft
Checking Bearing Clearance
Rear Main Bearing Oil Seals 528 (5)
Wick Seals
Synthetic Seals
Checking Cranshaft Endplay
Measuring Crankshaft Main
Journals---Engine in Car
Removing Crankshaft Main Bearing Upper
Inserts---Engine in Car
Rolling in a New Bearing Insert---Engine
in Car
Checking Main Bearing Clearance---Engine
in Car
Installing a Rear Main Bearing Oil
Seal---Engine in Car
Checklist for Crankshaft and Bearing Service 533 (1)
Connecting Rod Service 533 (2)
Piston Service 535 (8)
Inspect Pistons
Piston Pins
Assembling Connecting Rod and Piston
Ring Service
Installing Rod and Piston Assembly
Balance Shaft Service 543 (1)
Oil Pumps 543 (8)
Pump Installation
Valve Train and Intake Service 551 (24)
Interference and Noninterference Engines 551 (1)
Camshaft Service 551 (4)
Checking Journal-to-Bearing Clearance
Inspecting the Camshaft
Camshaft Drive Thrust Direction
Checking Cam Lobe Lift
Installing the Camshaft
Lifter Service 555 (4)
Servicing Hydraulic Lifters
Installing Hydraulic Lifters
Overhead Camshaft Hydraulic Lifters
Roller Lifters
Servicing Mechanical Lifters
Servicing Rocker Arms and Related Components 559 (1)
Rocker Arm Inspection
Inspecting Push Rods
Assembling and Installing Rocker Arm
Assemblies
Installing Ball Stud-Type Rocker Arms
Servicing the Camshaft Drive Components 560 (1)
Camshaft Drive Service with Engine in 560 (10)
Vehicle
Removing the Vibration Damper
Removing the Front Cover
Servicing the Timing Gears
Servicing the Timing Belt and Sprocket
Servicing Timing Chain and Sprocket
Removing and Replacing Front Cover Oil
Seal
Installing the Front Cover
Camshaft and Valve Train Service Checklist 570 (1)
Camshaft Drive Components
Rocker Arms
Rocker Shaft and Ball Studs
Push Rods
Lifters
General
Intake Manifold and Intake Plenum Service 571 (4)
Engine Assembly, Installation, and Break-In 575 (12)
Typical Engine Assembly Sequence 575 (1)
Cover Engines for Protection
Adjusting Valve Lash for Hydraulic Lifters 576 (1)
Lifter Must Be on Cam Lobe Base Circle
Lifter Plunger Must Be at the Top of
Travel
Adjusting Valve Lash for Mechanical Lifters 577 (1)
Cold and Hot Clearance Settings
Direct Acting Overhead Camshaft Adjustments 578 (1)
Engine Installation 578 (3)
Attach Lift Equipment
Installation with Transmission or
Transaxle in Car
Installation with Transmission or
Transaxle on Bench
Installation with Transmission or
Transaxle on Engine
Position Engine Carefully
Connect All Wiring, Hoses, Tubing, and
Linkages
An Overhauled Engine Needs Instant
Lubrication
Pressurizing the Engine Lubrication System
Pressurizer as a Bearing Leak Detector
Fill with Oil
Fill the Cooling System
Check the Fuel Tank
Check the Battery
Double-Check before Starting
Starting the Engine 581 (1)
Proper Break-In
Run the Engine at Fast Idle
Provide Adequate Ventilation
Make Final Adjustments
Do a Road Test/Break-In Run
Dynamometer Break-In
Deliver the Vehicle to the Owner 582 (5)
Ring Seating Takes Time
The Engine Needs Help
Section 5 Manual Drive Train and Axles
Clutch and Flywheel Service 587 (20)
Clutch Service 587 (20)
Determining the Reason for Clutch Failure
Removing the Clutch
Sanding Clutch Friction Surfaces
Inspecting the Flywheel-to-Clutch
Friction Surface
Checking Flywheel Runout
Mounting the Flywheel
Removing the Flywheel Ring Gear
Installing the Ring Gear
Checking the Pressure Plate Assembly
Rebuilding a Pressure Plate Assembly
Replacing the Clutch Pilot Bushing or
Bearing
Aligning the Clutch Housing as Necessary
Installing the Clutch Disc and Pressure
Plate Assembly
Clutch Break-In
Steam Cleaning Precautions
Manual Transmission and Transaxle Service 607 (20)
Transmission and Transaxle Designs 607 (2)
Manual Transmission Types
Manual Transaxle Types
Servicing Manual Transmissions and 609 (18)
Transaxles
Talk with the Owner
Check Clutch and Shift Linkage
Road-Test when Possible
Remove Transmission or Transaxle
Clean Exterior
Flush Interior
Inspect Gears, Shafts, Synchronizers, and
Other Parts
Disassembly Procedure
Manufacturer's Service Manuals
General Disassembly Procedures
Clean All Parts Thoroughly
Inspect Internal Parts
Inspect Input Shaft
Inspect Extension Housing or CV Axle
Housing
Inspect Output Shaft and Gears
Inspect Countershaft and Gears
Inspect Reverse Idler Gear
Inspect Synchronizers
Inspect Transaxle Chain and Sprockets or
Gears
Inspect Transaxle Differential Unit
Check Case and Housings for Cracks and
Burrs
Obtain and Check New Parts
Use New Snap Rings, Thrust Washers, and
Gaskets
Seal and Stake Pins
Check for Cracks
Transmission or Transaxle Reassembly
General Internal Part Installation
Procedures
Lubricate Assembled Internal Parts
Install Shift Cover
Install Transmission or Transaxle
Adjust Shift Linkage
Fill Transmission or Transaxle
Road Test
Section 6 Automatic Transmission and Transaxle
Automatic Transmission and Transaxle Service 627 (30)
Automatic Transmissions and Transaxles 627 (6)
Torque Converters
Planetary Gearsets and Holding Members
Hydraulic Control System
Electronic Control System
Transmission and Transaxle Designs
Automatic Transmission and Transaxle Service 633 (24)
Transmission and Transaxle Service Basics
Transmission and Transaxle Service Tools
Transmission and Transaxle Identification
Aluminum Parts
Diagnosing Transmission and Transaxle
Problems
In-Vehicle Repairs
Axle and Driveline Service 657 (44)
Rear-Wheel Drive Shaft Service 657 (8)
Cross-and-Roller Universal Joint
Constant-Velocity Universal Joint
Removing Rear Drive Shaft
Repairing Cross-and-Roller U-Joints
Repairing Rear-Wheel Drive
Constant-Velocity Universal Joints
Drive Shaft Installation
Drive Shaft Balance
Drive Shaft Angle
Front-Wheel Drive CV Axle Service 665 (4)
Removing CV Axles
CV Axle Installation
Servicing Axle Shafts 669 (8)
Modern Side Axles
Axles for Independent Rear Suspensions
Flanged End Side Axle Removal
C-Lock Axle Removal
Tapered End Axle Removal
Broken Axle Removal
Axle Shaft Inspection
Axle Oil Seal Replacement
Rear Wheel Bearing Replacement
Axle Installation
Check Axle Endplay
Ring and Pinion, Differential Unit Service 677 (24)
Troubleshooting
Service Operations
Ring and Pinion, Differential Removal
Differential Disassembly, Inspection, and
Repair
New Ring Gear Installation
Pinion Drive Gear Removal
Installing New Pinion Bearings
Installing Differential Case in the
Carrier (Threaded Adjuster Type)
Installing the Differential Case in the
Carrier--Shim Preload Adjustment
Checking the Tooth Contact Pattern
Limited Slip Differential Service
Drive Axle Lubrication
Four-Wheel Drive Service 701 (22)
Four-Wheel Drive Components 701 (16)
Part-Time Transfer Case Operation
Full-Time Four-Wheel Drive
Electronic Transfer Cases
Transfer Case Service
Electronic Transfer Case Problems
Input Sensor Problems
Output Motor Problems
Control Computer Problems
Wiring and Connector Problems
Transfer Case Electrical Checks
Using Scan Tools to Check the Transfer
Case
Transfer Case Overhaul
General Disassembly Procedures
Cleaning and Inspecting Parts
Obtain New Parts
Transfer Case Reassembly
Transfer Case Installation
Road Test
Locking Hubs 717 (1)
Locking Hub Service
Vacuum Motor Service 718 (5)
Section 7 Brakes
Brake Service 723 (44)
Brake Inspection 724 (1)
Brake Pedal and Master Cylinder
Brake Light Switch and Bulbs
Wheel Cylinders and Brake Shoe Assemblies
Brake Drums
Disc Brakes
Seals
Parking Brake
Brake Lines and Hoses
Chassis
Road Test
Brake Hydraulic System Operation 725 (18)
Brake Fluid
Brake Fluid Will Ruin Paint
Flushing the System
Master Cylinder Operation
Dual-Piston Master Cylinder
Compact Master Cylinder
Quick Take-Up Master Cylinder
Checking Master Cylinder
Master Cylinder Repair
Adjusting Brake Pedal Height
Adjusting Brake Pedal Free Travel
Wheel Cylinder Operation
Wheel Cylinder Service
Disc Brake Caliper Service
Servicing Brake Lines and Hose
Servicing Brake System Hydraulic Valves
Proportioning Valve
Dual Proportioning Valve
Height-Sensing Proportioning Valve
Disc Brake Metering Valve
Pressure Differential Switch
Combination Valve
Bleeding the Brakes
Bleeding Anti-Lock Brake Systems
Brake Friction Member Service 743 (9)
Brake Shoe Removal
Changing Disc Brake Pads
Breaking in a New Set of Brake Linings or
Brake Pads
Brake Drum and Rotor Service
Parking Brake Adjustments 752 (1)
Adjusting Rear Wheel Parking Brake
Adjusting Disc-Brake-Type Parking Brake
Power Brake Service 753 (14)
Checking Power Brake Operation
Power Booster Maintenance
Hydraulic Power Booster
Anti-Lock Brake and Traction Control System 767 (18)
Service
Anti-Lock Brake Systems 767 (12)
Always Obtain a Service Manual
The Reason for Anti-Lock Brakes
Anti-Lock Brake System Components
Anti-Lock Brake Operation
Anti-Lock Brake System Maintenance
Troubleshooting Anti-Lock Brakes
Retrieving Trouble Codes
Checking Wheel Speed Sensors
Checking Control Module
Checking Hydraulic Actuator
Replacing ABS Parts
Replacing a Speed Sensor
Replacing a Toothed Rotor
Replacing a G-Force Sensor
Replacing a Control Module
Replacing Hydraulic System Components
Traction Control Systems 779 (1)
Traction Control System Components
Traction Control System Maintenance
Troubleshooting Traction Control Systems
Replacing Traction Control System
Components
Foundation Brake Service on Vehicles 780 (2)
Equipped with ABS or Traction Control
Bleeding an Anti-Lock Brake System 782 (3)
Section 8 Suspension and Steering
Suspension System Service 785 (26)
Front Suspension Systems 785 (14)
Conventional Suspensions
Front Coil Spring Service
Torsion Bar Service
MacPherson Strut Service
Shock Absorber Service
Checking Shock Absorbers and Strut Dampers
Ball Joint Service
Steering Knuckle
Control Arm Removal
Strut Rods and Bushings
Stabilizer Bar Bushings
Rear Suspension Systems 799 (5)
Rear Leaf Spring Service
Replacing Rear Suspension Control Arms
and/or Bushings
Automatic Level Control 802 (2)
Height Control Sensor
Air-Operated Struts and Shocks
Automatic Level Control Service
Computerized Ride Control Systems 804 (7)
Ride Control System Troubleshooting
Steering System Service 811 (30)
Types of Steering Systems 811 (1)
Steering Column and Steering Wheel 811 (1)
Conventional Steering Gears 812 (9)
Steering Gear Inspection
Manual Steering Gear
Conventional Power Steering Service
Rack-and-Pinion Steering Gears 821 (2)
Manual Rack-and-Pinion Steering Gear
Overhaul
Rack-and-Pinion Power Steering
Power Steering Pumps 823 (7)
Power Steering Pump Belt
Power Steering Service
Power Steering Pump Overhaul
Power Steering Hoses
Power Steering Coolers and Switches
Steering Linkage 830 (4)
Steering Linkage Service
Electronic Assist Steering 834 (7)
Electronic Assist Steering Service
Wheel and Tire Service 841 (22)
Wheel Bearings 841 (10)
Tapered Roller Bearing Service
Sealed Ball and Roller Bearings
Replacing Sealed Bearings---Rear
Nondriving Axles
Vehicle Wheel Rims 851 (1)
Wheel Rim Size
Wheel Torquing
Checking for Whel Damage
Wheel Lug Service 851 (1)
Vehicle Tires 852 (11)
Tire Cord Construction
Tire Rating Information
Tire Quality Grading
Special Service Tires
Tire Selection
Tire Pressure
Tire Rotation
Tire Demounting and Mounting
Repairing a Punctured Tire
Tire Inflation Following Mounting
Tire Wear Patterns
Wheel and Tire Balance
Measuring Wheel and Tire Runout
Balancing Techniques
Wheel Alignment 863 (22)
Defining Wheel Alignment 863 (5)
Major Alignment Angles
Caster
Camber
Steering Axis Inclination
Setback
Toe
Toe-Out on Turns
Tire Scrubbing
Wheel Tracking
Types of Wheel Alignment
Wheel Alignment Equipment
Performing Wheel Alignments 868 (17)
Prealignment Checks
Final Preparation for Wheel Alignment
Alignment Specifications
Alignment Setup
Runout Compensation
Measuring, Recording, and Adjusting
Alignment
Rear Wheel Adjustment
Front Wheel Alignment
Section 9 Heating and Air Conditioning
Air Conditioning and Heater Service 885 (42)
Principles of Air Conditioning 885 (3)
Types of Air Conditioning Systems
Air Conditioning Cycle
Refrigerants 888 (3)
R-134a
R-12 and Blended Refrigerants
Refrigerants and Governmental Regulation
Handling Refrigerants
Manifold Gauge
Refrigerant Oils 891 (1)
Components of the Air Conditioning System 892 (8)
Compressor
Condenser
Refrigerant Flow Restrictor
Evaporator
Lines and Hoses
Receiver-Drier
Accumulator
Service Fittings
Evaporator Pressure Controls
Pressure and Temperature Controls
Pressure Cutoff Switches
Temperature Sensors
Pressure Relief Devices
Air Conditioning System Service 900 (9)
Safety Rules
Proper System Operation
Testing System Performance
Refrigerant Identification
Leak Detection
Refrigerant Recovery/Recycling
Checking Compressor Oil Level
Evacuating the System
Refrigerant Changing
Using a Refrigerant Service Center
Charging with the Manifold Gauge
Refrigeration System Purging
Adding Oil by Injection
Air Conditioning Component Service 909 (6)
Service Fitting Precautions
Compressor Replacement
Expansion Valve and Orifice Tube Service
Replacing Hose and Tubing
Condenser Service
Accumulator/Receiver-Drier Service
Control Head Replacement
Evaporator Service
Retrofitting 915 (2)
Heater System 917 (1)
Checking Heater Operation
Heater Shut-Off Valve
Heater Core Service
Blower Motor Service
Air Distribution and Control System Service 918 (1)
Air Distribution Wiring and Vacuum Circuits 919 (8)
Air Distribution System Ductwork
Section 10 Career Preparation
Repair Orders and Cost Estimates 927 (6)
Repair Orders 927 (2)
Determining Labor Costs
Determining Part Costs
Determining Outside Service Costs
Other Charges
Calculating Sales Tax
Cost Estimates 929 (4)
Estimating Labor
Estimating Parts Prices
Adding Other Costs
Finishing the Cost Estimate
Get an OK for Additional Costs
ASE Certification 933 (10)
Reasons for ASE Tests 933 (1)
Applying for the ASE Tests 934 (1)
Taking the ASE Tests 935 (2)
One-Part Questions
Two-Part Questions
Negative Questions
Incomplete Sentence Questions
Test Results 937 (1)
Other ASE Tests 937 (2)
Recertification Tests 939 (4)
Appendix A. Carburetor Service 943 (12)
Appendix B. OBD II Diagnostic Codes 955 (8)
Appendix C. Conversion Charts 963 (8)
Dictionary of Automotive Terms 971 (40)
Acknowledgments 1011(2)
Index 1013