Auto Diagnosis, Service, and Repair

by ;
Format: Hardcover
Pub. Date: 2002-02-01
Publisher(s): Goodheart-Willcox Pub
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Summary

Intended for beginners who need to learn the fundamentals of automotive repair.

Table of Contents

Section 1 Introduction to Automotive Diagnosis, Service, and Repair
Introduction to the Automotive Service and Repair Industry
15(10)
Automotive Service
15(1)
Automotive Service Positions
15(2)
Helpers
Installers
Technicians
Other Opportunities in the Auto Service Industry
17(1)
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 Repairs
307(6)
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 Oscilloscope
323(4)
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 System
373(1)
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 System Service
517(34)
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 Vehicle
560(10)
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 Transaxles
609(18)
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 Service
767(18)
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 Equipped with ABS or Traction Control
780(2)
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

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