Automotive Technology: A Systems Approach

1665 Pages·2009·93.21 MB·English

by  Jack Erjavec

AUTOMOTIVE
TECHNOLOGY
A SYSTEMS APPROACH
5 t h E d i t i o n
Jack Erjavec
Australia • Brazil • Japan • Korea • Mexico • Singapore • Spain • United Kingdom • United States
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AUTOMOTIVE TECHNOLOGY: © 2010 Delmar, Cengage Learning
A Systems Approach, 5e
ALL RIGHTS RESERVED. No part of this work covered by the copyright herein
Jack Erjavec
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CCOONNTTEENNTTSS
Table of Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . .iii Using Service Information . . . . . . . . . . . . . . . . xiv
Photo Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . .x Performance Tips . . . . . . . . . . . . . . . . . . . . . . . . xiv
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi “Go To” Feature. . . . . . . . . . . . . . . . . . . . . . . . . . xiv
About the Book . . . . . . . . . . . . . . . . . . . . . . . . . . . xi Photo Sequences. . . . . . . . . . . . . . . . . . . . . . . . . .xv
New to This Edition. . . . . . . . . . . . . . . . . . . . . . . . xi Hybrid Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . .xv
Organization and Goals of This Edition . . . . . .xii Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xv
Acknowledgments. . . . . . . . . . . . . . . . . . . . . . . .xiii Case Studies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xv
About the Author. . . . . . . . . . . . . . . . . . . . . . . . .xiii Key Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xv
Features of the Text. . . . . . . . . . . . . . . . . . . . . . . . . xiv Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xv
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv Review Questions . . . . . . . . . . . . . . . . . . . . . . . . .xv
Cautions and Warnings . . . . . . . . . . . . . . . . . . . xiv ASE-Style Review Questions . . . . . . . . . . . . . . . .xv
Shop Talk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv Metric Equivalents . . . . . . . . . . . . . . . . . . . . . . . .xv
Customer Care. . . . . . . . . . . . . . . . . . . . . . . . . . . xiv Supplements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi
SECTION 1 AUTOMOTIVE TECHNOLOGY 1
CHAPTER 1 Careers Engine 41 ■ Engine Systems 43 ■ Electrical and
Electronic Systems 46 ■ Heating and Air-Conditioning
in the Automotive
Systems 49 ■ Drivetrain 50 ■ Running Gear 53
Industry 1
■ Hybrid Vehicles 55 ■ Key Terms 56 ■ Summary 56
■ Review Questions 57
Objectives 1 ■ The Automotive
Industry 1 ■ Job Classifications 9
CHAPTER 4 Hand Tools
■ Related Career Opportunities 12
■ Training for a Career in Automotive Service 14 ■ ASE and Shop Equipment 59
Certification 15 ■ Key Terms 16 ■ Summary 16
Objectives 59 ■ Measuring Systems 59 ■ Fasteners 60
■ Review Questions 17
■ Measuring Tools 67 ■ Hand Tools 75 ■ Shop
Equipment 86 ■ Power Tools 88 ■ Jacks and Lifts 89
CHAPTER 2 Workplace Skills 19
■ Service Information 92 ■ Key Terms 96 ■ Summary 96
Objectives 19 ■ Seeking and Applying for Employment 19 ■ Review Questions 96
■ Accepting Employment 26 ■ Working as a
Technician 27 ■ Communications 29 ■ Solving CHAPTER 5 Diagnostic
Problems and Critical Thinking 31 ■ Professionalism 32
Equipment and Special Tools 99
■ Interpersonal Relationships 34 ■ Key Terms 34
■ Summary 34 ■ Review Questions 35 Objectives 99 ■ Engine Repair Tools 99 ■ Electrical/
Electronic System Tools 106 ■ Engine Performance
CHAPTER 3 Automotive Tools 110 ■ Transmission and Driveline Tools 119
■ Suspension and Steering Tools 121 ■ Brake System
Systems 37
Tools 124 ■ Heating and Air-Conditioning Tools 128
Objectives 37 ■ Historical Background 37 ■ Design ■ Key Terms 131 ■ Summary 131 ■ Review
Evolution 38 ■ Body Shapes 39 ■ The Basic Questions 132
iii
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iv CONTENTS
CHAPTER 6 Working Safely ■ Additional PM Checks 182 ■ Key Terms 182
■ Summary 183 ■ Review Questions 183
in the Shop 134
CHAPTER 8 Basic Theories
Objectives 134 ■ Personal Safety 134 ■ Tool and
Equipment Safety 138 ■ Work Area Safety 144 and Math 186
■ Manufacturers’ Warnings and Government
Regulations 148 ■ Right-to-Know Law 148 ■ Key
Objectives 186 ■ Matter 186 ■ Energy 188
Terms 151 ■ Summary 151 ■ Review Questions 151
■ Volume 191 ■ Force 193 ■ Time 195
CHAPTER 7 Preventive Mainte- ■ Motion 195 ■ Work 197 ■ Waves and
Oscillations 202 ■ Light 205 ■ Liquids 205
nance and Basic Services 153
■ Gases 207 ■ Heat 209 ■ Chemical Properties 211
Objectives 153 ■ Repair Orders 153 ■ Vehicle ■ Electricity and Electromagnetism 215 ■ Key Terms 216
Identification 156 ■ Preventive Maintenance 157 ■ Summary 217 ■ Review Questions 219
■ Basic Services 159 ■ Hybrid Vehicles 180
SECTION 2 ENGINES 220
CHAPTER 9 ■ Review Questions 320 ■ ASE-Style Review
Questions 321
Automotive Engine
Designs and
CHAPTER 12 Upper End
Diagnosis 220
Theory and Service 322
Objectives 220 ■ Introduction
Objectives 322 ■ Cylinder Head 322 ■ Combustion
to Engines 220 ■ Engine
Chamber 323 ■ Intake and Exhaust Valves 324
Classifications 221 ■ Engine
■ Variable Valve Timing 330 ■ Cylinder Head
Measurement and Performance 228 ■ Diesel
Disassembly 335 ■ Inspection of the Valve Train 339
Engines 232 ■ Other Automotive Power Plants 236
■ Servicing Cylinder Heads 344 ■ Reconditioning
■ Engine Identification 240 ■ Engine Diagnostics 241
Valves 347 ■ Valve Guide Reconditioning 349
■ Evaluating the Engine’s Condition 247 ■ Noise
■ Reconditioning Valve Seats 351 ■ Valve Stem Seals 354
Diagnosis 249 ■ Case Study 252 ■ Key Terms 252
■ Assembling the Cylinder Head 355 ■ Case Study 356
■ Summary 252 ■ Review Questions 253 ■ ASE-Style
■ Key Terms 358 ■ Summary 358 ■ Review
Review Questions 254
Questions 358 ■ ASE-Style Review Questions 359
CHAPTER 10 Engine
CHAPTER 13 Engine Sealing
Disassembly and Cleaning 255
and Reassembly 361
Objectives 255 ■ Removing an Engine 255 ■ Engine
Objectives 361 ■ Torque Principles 361 ■ Gaskets 364
Disassembly and Inspection 262 ■ Cleaning Engine
■ Specific Engine Gaskets 367 ■ Adhesives, Sealants,
Parts 264 ■ Crack Detection 269 ■ Case Study 271
and Other Chemical Sealing Materials 371 ■ Oil
■ Key Terms 272 ■ Summary 272 ■ Review
Seals 374 ■ Engine Reassembly 375 ■ Installing the
Questions 272 ■ ASE-Style Review Questions 273
Engine 385 ■ Case Study 390 ■ Key Terms 390
CHAPTER 11 Lower End ■ Summary 390 ■ Review Questions 391 ■ ASE-Style
Review Questions 391
Theory and Service 275
Objectives 275 ■ Short Block Disassembly 276 CHAPTER 14 Lubricating
■ Cylinder Block 279 ■ Cylinder Block Reconditioning 281
and Cooling Systems 393
■ Camshafts 285 ■ Crankshaft 292 ■ Crankshaft
Inspection and Rebuilding 294 ■ Installing Main Objectives 393 ■ Lubrication System 393 ■ Engine
Bearings and Crankshaft 296 ■ Piston and Piston Lubrication Diagnosis and Service 398 ■ Cooling
Rings 302 ■ Installing Pistons and Connecting Rods 307 Systems 400 ■ Cooling System Diagnosis 409
■ Inspection of Camshaft and Related Parts 310 ■ Inspection of Cooling System 411 ■ Testing for
■ Installation of Camshaft and Related Parts 311 Leaks 416 ■ Cooling System Service 420 ■ Case
■ Crankshaft and Camshaft Timing 312 ■ Oil Pumps 313 Study 429 ■ Key Terms 430 ■ Summary 430
■ Oil Pump Service 315 ■ Installing the Oil Pump 318 ■ Review Questions 431 ■ ASE-Style Review
■ Case Study 318 ■ Key Terms 319 ■ Summary 319 Questions 432
Copyright 2009 Cengage Learning, Inc. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part.
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CONTENTS v
SECTION 3 ELECTRICITY 433
CHAPTER 15 Regulation 577 ■ New Developments 580 ■ Preliminary
Checks 582 ■ General Testing Procedures 586 ■ AC
Basics of Electrical
Generator Service 588 ■ Case Study 593 ■ Key Terms 593
Systems 433
■ Summary 593 ■ Review Questions 593 ■ ASE-Style
Review Questions 594
Objectives 433 ■ Basics of
Electricity 433 ■ Electrical
Terms 435 ■ Ohm’s Law 438 CHAPTER 20 Lighting
■ Circuits 440 ■ Circuit
Systems 596
Components 444 ■ Key Terms 454 ■ Summary 454
■ Review Questions 455 ■ ASE-Style Review Objectives 596 ■ Lamps 596 ■ Headlights 597
Questions 455 ■ Headlight Service 605 ■ Other Light Bulbs 610
■ Interior Light Assemblies 610 ■ Rear Exterior
CHAPTER 16 General
Lights 612 ■ Basic Lighting System Diagnosis 619
Electrical System Diagnostics ■ Case Study 621 ■ Key Terms 621 ■ Summary 621
and Service 457 ■ Review Questions 621 ■ ASE-Style Review
Questions 622
Objectives 457 ■ Electrical Problems 457 ■ Electrical
Wiring Diagrams 460 ■ Electrical Testing Tools 461
CHAPTER 21 Electrical
■ Using Multimeters 465 ■ Using Lab Scopes 474
■ Testing Basic Electrical Components 478 Instrumentation 624
■ Troubleshooting Circuits 482 ■ Testing for Common
Objectives 624 ■ Instrument Panels 624 ■ Gauges 625
Problems 486 ■ Connector and Wire Repairs 490
■ Basic Information Gauges 627 ■ Indicator and
■ Case Study 497 ■ Key Terms 498 ■ Summary 498
Warning Devices 630 ■ Driver Information Centers 635
■ Review Questions 498 ■ ASE-Style Review
■ General Diagnosis and Testing 637 ■ Case Study 637
Questions 499
■ Key Terms 637 ■ Summary 637 ■ Review
CHAPTER 17 Batteries: Theory, Questions 638 ■ ASE-Style Review Questions 639
Diagnosis, and Service 501
CHAPTER 22 Basics of
Objectives 501 ■ Introduction 501 ■ Basic Battery
Theory 501 ■ Battery Ratings 504 ■ Common Types of Electronics and Computer
Batteries 505 ■ High-Voltage Batteries 507 ■ Lead- Systems 640
Acid Batteries 507 ■ Servicing and Testing Batteries 513
■ Nickel-Based Batteries 524 ■ Lithium-Based Objectives 640 ■ Capacitors 640 ■ Semiconductors 642
Batteries 526 ■ Isolating High-Voltage Systems 528 ■ Computer Basics 646 ■ On-Board Diagnostics 656
■ Jump-Starting 530 ■ Case Study I 532 ■ Case ■ Multiplexing 658 ■ Protecting Electronic Systems 662
Study II 532 ■ Key Terms 533 ■ Summary 533 ■ Diagnosing BCMs 663 ■ Testing Electronic Circuits
■ Review Questions 534 ■ ASE-Style Review and Components 664 ■ Key Terms 667 ■ Summary 667
Questions 534 ■ Review Questions 668 ■ ASE-Style Review
Questions 669
CHAPTER 18 Starting and
Traction Motor Systems 536
CHAPTER 23 Electrical
Objectives 536 ■ Basics of Electromagnetism 536 Accessories 670
■ Starting Motors 539 ■ Starting System 542 ■ Starter
Objectives 670 ■ Windshield Wiper/Washer
Circuit 543 ■ Control Circuit 546 ■ Starting System
Systems 670 ■ Horns/Clocks/Cigarette Lighter
Testing 547 ■ Starter Motor Service 554 ■ Case
Systems 677 ■ Cruise (Speed) Control Systems 678
Study 558 ■ High-Voltage Motors 560 ■ Key Terms 567
■ Sound Systems 682 ■ Power Lock Systems 684
■ Summary 567 ■ Review Questions 568 ■ ASE-Style
■ Power Windows 684 ■ Power Seats 687 ■ Power
Review Questions 569
Mirror System 690 ■ Rear-Window Defrosters and
CHAPTER 19 Charging Heated Mirror Systems 691 ■ Other Electronic
Equipment 692 ■ Security and Antitheft Devices 697
Systems 571
■ Case Study 700 ■ Key Terms 701 ■ Summary 701
Objectives 571 ■ Alternating Current Charging ■ Review Questions 701 ■ ASE-Style Review
Systems 571 ■ AC Generator Operation 575 ■ Voltage Questions 702
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vi CONTENTS
CHAPTER 24 Restraint Systems: Components 712 ■ Diagnosis 716 ■ Servicing the Air
Bag System 718 ■ Other Protection Systems 719 ■ Case
Theory, Diagnosis, and Service 704
Study 722 ■ Key Terms 722 ■ Summary 722 ■ Review
Objectives 704 ■ Seat Belts 704 ■ Seat Belt Questions 723 ■ ASE-Style Review Questions 724
Service 706 ■ Air Bags 708 ■ Electrical System
SECTION 4 ENGINE PERFORMANCE 725
CHAPTER 25 or GMM 852 ■ Ignition Timing 854 ■ Basic Primary
Circuit Components 857 ■ Distributor Service 863
Engine Performance
■ Secondary Circuit Tests and Service 863 ■ Case
Systems 725
Study 871 ■ Key Terms 871 ■ Summary 871
■ Review Questions 872 ■ ASE-Style Review
Objectives 725 ■ Ignition
Questions 873
Systems 725 ■ Fuel System 728
■ Air Induction System 729
CHAPTER 29 Fuel Delivery
■ Emission Control Systems 729
Systems 874
■ Engine Control Systems 731 ■ On-Board Diagnostic
Systems 736 ■ System Operation 739 ■ OBD-II
Objectives 874 ■ Basic Fuel System Diagnosis 875
Monitoring Capabilities 740 ■ OBD-II Self-
■ Guidelines for Safely Working on Fuel Systems 875
Diagnostics 747 ■ Basic Diagnosis of Electronic Engine
■ Fuel Tanks 876 ■ Filler Caps 879 ■ Fuel Lines and
Control Systems 749 ■ Diagnosing OBD-II
Fittings 881 ■ Fuel Filters 884 ■ Fuel Pumps 886
Systems 751 ■ Diagnosing OBD-I Systems 759 ■ Case
■ Case Study 896 ■ Key Terms 896 ■ Summary 896
Study 760 ■ Key Terms 760 ■ Summary 760 ■ Review
■ Review Questions 897 ■ ASE-Style Review
Questions 761 ■ ASE-Style Review Questions 762
Questions 897
CHAPTER 26 Detailed
CHAPTER 30 Electronic
Diagnosis and Sensors 764
Fuel Injection 899
Objectives 764 ■ Using Scan Tool Data 764
Objectives 899 ■ Basic EFI 900 ■ Throttle Body
■ Symptom-Based Diagnosis 768 ■ Basic Testing 770
Injection (TBI) 905 ■ Port Fuel Injection (PFI) 907
■ Diagnosis of Computer Voltage Supply and Ground
■ Central Multiport Fuel Injection (CMFI) 912
Wires 771 ■ Switches 774 ■ Temperature Sensors 775
■ Gasoline Direct-Injection Systems 913 ■ Light- and
■ Pressure Sensors 778 ■ Mass Airflow (MAF) Sensors 783
Medium-Duty Diesel Fuel Injection 918 ■ Case Study 919
■ Oxygen Sensors (O S) 785 ■ Position Sensors 794
2 ■ Key Terms 919 ■ Summary 919 ■ Review
■ Speed Sensors 797 ■ Position/Speed Sensors 799
Questions 920 ■ ASE-Style Review Questions 920
■ Knock Sensor (KS) 802 ■ Computer Outputs and
Actuators 803 ■ Testing Actuators 804 ■ Case Study 807
CHAPTER 31 Fuel Injection System
■ Key Terms 807 ■ Summary 807 ■ Review
Diagnosis and Service 922
Questions 808 ■ ASE-Style Review Questions 808
Objectives 922 ■ Preliminary Checks 923 ■ Basic EFI
CHAPTER 27 Ignition Systems 810
System Checks 924 ■ Injector Service 935 ■ Fuel Rail,
Objectives 810 ■ Basic Circuitry 810 ■ Ignition Injector, and Regulator Service 937 ■ Electronic Throttle
Components 813 ■ Spark Plugs 815 ■ Triggering and Controls 941 ■ Idle Speed Checks 943 ■ Case Study 946
Switching Devices 819 ■ Engine Position Sensors 820 ■ Key Terms 946 ■ Summary 947 ■ Review
■ Distributor Ignition System Operation 822 Questions 947 ■ ASE-Style Review Questions 948
■ Electronic Ignition Systems 823 ■ EI System
CHAPTER 32 Intake and
Operation 827 ■ Case Study 832 ■ Key Terms 833
■ Summary 833 ■ Review Questions 833 ■ ASE-Style Exhaust Systems 949
Review Questions 834
Objectives 949 ■ Vacuum Systems 949 ■ Air Induction
CHAPTER 28 Ignition System System 951 ■ Intake Manifolds 952 ■ Forced
Induction Systems 955 ■ Turbochargers 956
Diagnosis and Service 836
■ Superchargers 962 ■ Exhaust System Components 965
Objectives 836 ■ Misfires 836 ■ General Ignition ■ Catalytic Converters 966 ■ Exhaust System Service 970
System Diagnosis 837 ■ Visual Inspection of Ignition ■ Case Study 974 ■ Key Terms 974 ■ Summary 974
Systems 837 ■ No-Start Diagnosis 842 ■ Diagnosing ■ Review Questions 975 ■ ASE-Style Review
with an Engine Analyzer 844 ■ Diagnosing with a DSO Questions 976
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CONTENTS vii
CHAPTER 33 Emission System Diagnosis and Service 1025 ■ Catalytic
Converter Diagnosis 1032 ■ Air System Diagnosis and
Control Systems 978
Service 1034 ■ Case Study 1037 ■ Key Terms 1037
Objectives 978 ■ Pollutants 978 ■ Emission Control ■ Summary 1037 ■ Review Questions 1038 ■ ASE-
Devices 982 ■ Evaporative Emission Control Style Review Questions 1038
Systems 985 ■ Precombustion Systems 988
CHAPTER 35 Fuels and
■ Postcombustion Systems 995 ■ Diesel Emission
Controls 1001 ■ Case Study 1006 ■ Key Terms 1006 Other Energy Sources 1040
■ Summary 1006 ■ Review Questions 1007 ■ ASE-
Objectives 1040 ■ Crude Oil 1040 ■ Gasoline 1043
Style Review Questions 1007
■ Basic Gasoline Additives 1044 ■ Oxygenates 1045
CHAPTER 34 Emission Control ■ Gasoline Quality Testing 1046 ■ Alternatives to
Gasoline 1047 ■ Diesel Fuel 1051 ■ Electric
Diagnosis and Service 1009
Vehicles 1053 ■ Hybrid Electric Vehicles 1054 ■ Fuel
Objectives 1009 ■ I/M 240 Test 1009 ■ Testing Cell Electric Vehicles 1062 ■ Case Study 1067
Emissions 1012 ■ Basic Inspection 1015 ■ Evaporative ■ Key Terms 1067 ■ Summary 1068 ■ Review
Emission Control System Diagnosis and Service 1018 Questions 1069 ■ ASE-Style Review Questions 1069
■ PCV System Diagnosis and Service 1023 ■ EGR
SECTION 5 MANUAL TRANSMISSIONS AND TRANSAXLES 1071
CHAPTER 36 CHAPTER 38 Manual Transmission/
Clutches 1071 Transaxle Service 1116
Objectives 1071 ■ Operation 1071 Objectives 1116 ■ Lubricant Check 1116 ■ In-Vehicle
■ Clutch Service Safety Service 1118 ■ Diagnosing Problems 1119
Precautions 1079 ■ Clutch ■ Transmission/Transaxle Removal 1124 ■ Cleaning
Maintenance 1079 ■ Clutch and Inspection 1125 ■ Disassembly and Reassembly of
Problem Diagnosis 1080 ■ Clutch the Differential Case 1131 ■ Reassembly/Reinstallation
Service 1084 ■ Key Terms 1088 ■ Case Study 1089 of Transmission/Transaxle 1134 ■ Case Study 1135
■ Summary 1089 ■ Review Questions 1090 ■ Key Terms 1135 ■ Summary 1135 ■ Review
■ ASE-Style Review Questions 1090 Questions 1136 ■ ASE-Style Review Questions 1136
CHAPTER 37 Manual CHAPTER 39 Drive Axles
Transmissions and Transaxles 1092 and Differentials 1138
Objectives 1092 ■ Transmission Versus Transaxle 1092 Objectives 1138 ■ Front-Wheel-Drive (FWD) Axles 1138
■ Gears 1096 ■ Basic Gear Theory 1097 ■ Transmission/ ■ Types of CV Joints 1139 ■ Front-Wheel-Drive
Transaxle Design 1099 ■ Synchronizers 1101 Applications 1140 ■ CV Joint Service 1142 ■ Rear-
■ Gearshift Mechanisms 1103 ■ Transmission Power Wheel Drive Shafts 1147 ■ Operation of U-Joints 1149
Flow 1104 ■ Transaxle Power Flows 1108 ■ Final Drive ■ Types of U-Joints 1151 ■ Diagnosis of Drive Shaft and
Gears and Overall Ratios 1112 ■ Electrical Systems 1112 U-Joint Problems 1152 ■ Differentials and Drive
■ Case Study 1113 ■ Key Terms 1113 ■ Summary 1113 Axles 1153 ■ Limited-Slip Differentials 1160 ■ Axle
■ Review Questions 1114 ■ ASE-Style Review Shafts 1161 ■ Servicing the Final Drive Assembly 1164
Questions 1115 ■ Diagnosing Differential Noises 1169 ■ Case Study 1170
■ Key Terms 1170 ■ Summary 1170 ■ Review
Questions 1171 ■ ASE-Style Review Questions 1172
SECTION 6 AUTOMATIC TRANSMISSIONS AND TRANSAXLES 1173
CHAPTER 40 Converter 1178 ■ Planetary Gears 1178 ■ Compound
Planetary Gear Sets 1181 ■ Honda’s Nonplanetary-
Automatic
Based Transmission 1186 ■ Continuously Variable
Transmissions and
Transmissions (CVT) 1186 ■ Planetary Gear
Transaxles 1173 Controls 1189 ■ Transmission Clutches 1191
■ Bearings, Bushings, and Thrust Washers 1193
Objectives 1173 ■ Torque
■ Snaprings 1195 ■ Gaskets and Seals 1196 ■ Final
Converter 1174 ■ Lockup Torque
Drives and Differentials 1199 ■ Hydraulic System 1199
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viii CONTENTS
■ Application of Hydraulics in Transmissions 1200 the Vehicle 1252 ■ Checking the Torque Converter 1253
■ Pressure Boosts 1204 ■ Shift Quality 1204 ■ Diagnosing Hydraulic and Vacuum Control Systems 1256
■ Hydraulic Circuits 1205 ■ Case Study 1212 ■ Key ■ Common Problems 1259 ■ Linkages 1260 ■ Case
Terms 1212 ■ Summary 1212 ■ Review Questions 1213 Study 1268 ■ Key Terms 1269 ■ Summary 1269
■ ASE-Style Review Questions 1214 ■ Review Questions 1269 ■ ASE-Style Review
Questions 1270
CHAPTER 41 Electronic
CHAPTER 43 Four- and
Automatic Transmissions 1216
All-Wheel Drive 1271
Objectives 1216 ■ Transmission Control Module 1217
■ Hybrid Transmissions 1228 ■ Basic EAT Testing 1232 Objectives 1271 ■ Types of Four-Wheel Drives 1271
■ Converter Clutch Control Diagnostics 1236 ■ Detailed ■ Four-Wheel-Drive Systems 1274 ■ Transfer Case 1277
Testing of Inputs 1238 ■ Detailed Testing of ■ Interaxle Differentials 1277 ■ Locking Hubs 1282
Actuators 1240 ■ Case Study 1241 ■ Key Terms 1242 ■ Four-Wheel-Drive Passenger Cars 1282 ■ All-Wheel-
■ Summary 1242 ■ Review Questions 1243 Drive Systems 1284 ■ Diagnosing 4WD and AWD
■ ASE-Style Review Questions 1244 Systems 1284 ■ Servicing 4WD Vehicles 1288 ■ Case
Study 1294 ■ Key Terms 1294 ■ Summary 1294
CHAPTER 42 Automatic ■ Review Questions 1294 ■ ASE-Style Review
Questions 1295
Transmission and Transaxle
Service 1245
Objectives 1245 ■ Identification 1245 ■ Basic
Diagnostics 1245 ■ Fluid Leaks 1250 ■ Road Testing
SECTION 7 SUSPENSION AND STEERING SYSTEMS 1297
CHAPTER 44 ■ Case Study 1359 ■ Key Terms 1359 ■ Summary 1359
■ Review Questions 1360 ■ ASE-Style Review
Tires and Wheels
Questions 1361
1297
Objectives 1297 ■ Wheels 1297 CHAPTER 46
■ Tires 1298 ■ Tire Ratings and Steering Systems 1363
Designations 1303 ■ Tire/Wheel
Runout 1309 ■ Tire Replace- Objectives 1363 ■ Manual-Steering Systems 1363
ment 1310 ■ Tire Repair 1311 ■ Installation of Tire/ ■ Power-Steering Systems 1370 ■ Electronically
Wheel Assembly on the Vehicle 1314 ■ Tire/Wheel Controlled Power-Steering Systems 1375 ■ Steering
Assembly Service 1315 ■ Wheel Bearings 1316 ■ Case System Diagnosis 1378 ■ Diagnosis 1379 ■ Specific
Study 1320 ■ Key Terms 1320 ■ Summary 1320 Checks 1382 ■ Steering System Servicing 1388
■ Review Questions 1321 ■ ASE-Style Review ■ Power-Steering System Servicing 1390 ■ Four-Wheel
Questions 1322 Steering Systems 1393 ■ Case Study 1398 ■ Key
Terms 1398 ■ Summary 1398 ■ Review Questions 1399
■ ASE-Style Review Questions 1400
CHAPTER 45
Suspension Systems 1323
CHAPTER 47
Objectives 1323 ■ Frames 1323 ■ Suspension System
Wheel Alignment 1402
Components 1324 ■ MacPherson Strut Suspension
Components 1331 ■ Independent Front Objectives 1402 ■ Alignment Geometry 1403
Suspension 1334 ■ Basic Front-Suspension ■ Prealignment Inspection 1407 ■ Wheel Alignment
Diagnosis 1337 ■ Front-Suspention Component Equipment 1409 ■ Alignment Machines 1410
Servicing 1339 ■ Rear-Suspension Systems 1345 ■ Performing an Alignment 1411 ■ Four-Wheel-Drive
■ Semi-Independent Suspension 1348 ■ Electronically Vehicle Alignment 1421 ■ Case Study 1421
Controlled Suspensions 1351 ■ Servicing Electronic ■ Key Terms 1421 ■ Summary 1422 ■ Review
Suspension Components 1355 ■ Active Suspensions 1357 Questions 1422 ■ ASE-Style Review Questions 1422
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CONTENTS ix
SECTION 8 BRAKES 1424
CHAPTER 48 CHAPTER 50 Disc Brakes 1481
Brake Systems 1424
Objectives 1481 ■ Disc Brake Components and
Their Functions 1481 ■ Rear-Wheel Disc
Objectives 1424 ■ Friction 1424
Brakes 1486 ■ Disc Brake Diagnosis 1488 ■ Service
■ Principles of Hydraulic Brake
Guidelines 1490 ■ General Caliper Inspection and
Systems 1427 ■ Hydraulic Brake
Servicing 1491 ■ Rear Disc Brake Calipers 1498
System Components 1429
■ Rotor Inspection 1499 ■ Rotor Service 1501 ■ Case
■ Master Cylinders 1430 ■ Master
Study 1503 ■ Key Terms 1503 ■ Summary 1503
Cylinder Operation 1433 ■ Hydraulic Tubes and
■ Review Questions 1504 ■ ASE-Style Review
Hoses 1435 ■ Hydraulic System Safety Switches and
Questions 1504
Valves 1437 ■ Drum and Disc Brake Assemblies 1440
■ Hydraulic System Service 1442 ■ Power Brakes 1449
■ Pushrod Adjustment 1450 ■ Hydraulic Brake
CHAPTER 51 Antilock Brake,
Boosters 1451 ■ Electric Parking Brakes 1453 ■ Case
Traction Control, and Stability
Study 1454 ■ Key Terms 1454 ■ Summary 1454
■ Review Questions 1455 ■ ASE-Style Review Control Systems 1506
Questions 1456
Objectives 1506 ■ Antilock Brakes 1506 ■ ABS
Components 1507 ■ Types of Antilock Brake
CHAPTER 49 Drum Brakes 1457 Systems 1511 ■ ABS Operation 1512 ■ Automatic
Traction Control 1519 ■ Automatic Stability
Objectives 1457 ■ Drum Brake Operation 1457
Control 1521 ■ Antilock Brake System Service 1523
■ Drum Brake Components 1458 ■ Drum Brake
■ Diagnosis and Testing 1524 ■ Testing Traction and
Designs 1460 ■ Road Testing Brakes 1464 ■ Drum
Stability Control Systems 1530 ■ New Trends 1531
Brake Inspection 1464 ■ Brake Shoes and Linings 1472
■ Case Study 1532 ■ Key Terms 1532 ■ Summary 1532
■ Wheel Cylinder Inspection and Servicing 1475
■ Review Questions 1533 ■ ASE-Style Review
■ Drum Parking Brakes 1475 ■ Case Study 1477
Questions 1533
■ Key Terms 1478 ■ Summary 1478 ■ Review
Questions 1478 ■ ASE-Style Review Questions 1479
SECTION 9 PASSENGER COMFORT 1535
CHAPTER 52 CHAPTER 53 Air-Conditioning
Heating and Air- Diagnosis and Service 1565
Conditioning 1535
Objectives 1565 ■ Service Precautions 1565
■ Refrigerant Safety Precautions 1566 ■ Guidelines for
Objectives 1535 ■ Ventilation
Converting (Retrofitting) R-12 Systems to R-134a 1567
System 1535 ■ Automotive
■ Initial System Checks 1568 ■ Diagnosis 1571
Heating Systems 1536 ■ Heating
■ Performance Testing 1572 ■ Leak Testing 1575
System Service 1539 ■ Theory of
■ Emptying the System 1578 ■ General Service 1579
Automotive Air-Conditioning 1541 ■ Refrigerants 1542
■ Recharging the System 1587 ■ Climate Control
■ Basic Operation of an Air-Conditioning System 1544
Systems 1590 ■ Case Study 1591 ■ Key Terms 1592
■ Compressors 1546 ■ Condenser 1550 ■ Receiver/
■ Summary 1592 ■ Review Questions 1593 ■ ASE-
Dryer 1552 ■ Thermostatic Expansion Valve/Orifice
Style Review Questions 1594
Tube 1552 ■ Evaporator 1553 ■ Refrigerant Lines 1554
■ Air-Conditioning Systems and Controls 1555
■ Temperature Control Systems 1557 ■ Case Study 1561 Appendix A: Decimal and Metric Equivalents. . 1596
■ Key Terms 1562 ■ Summary 1562 ■ Review Appendix B: General Torque Specifications . . 1597
Questions 1563 ■ ASE-Style Review Questions 1563
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1598
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1623
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