Table Of Content

,., . , ~m~· ~'b 1I!.",mB:""" 1 I \ \ \ \ MANUAL - - -- COMPLETE MANUAL Updated and Expanded Illustrations by LEONELLO CALVETTI, RON CARBONE, PAUL DIMARE, STEVE KARP, DON MANNES, RUSSELL J. VON SAUERS AND JEFF TRISH HEARST BOOKS A Division of Sterling Publishing Co., Inc. NEW YORK COMPLETE CAR CARE MANUAL Updated & Expanded Copyright © 2003, 2005 by Hearst Communications, Inc. All rights reserved. The written instructions, illustrations, and photographs in this volume are intended for the personal use of the reader and may be reproduced for that purpose only. Any other use, especially commercial use, is forbidden under law without the written permission of the copyright holder. Every effort has been made to ensure that all the information in this book is accurate. However, due to differing conditions, tools, and individual skills, the publisher cannot be responsible for any injuries, losses, and/or other damages that may result frol11 the use of the information in this book. Produced by Bishop Books 777 Westchester Avenue, Suite 100 White Plains, New York 10604 The Library of Congress has cataloged the first hard cover edition as follows: Popular mechanics complete car care manual / Illustrations by Russel]. Von Sauers, Ron Carbone, and Don Mannes. p. cm. ISBN 1-58816-260-5 1. Automobiles-Maintenance and repair Amateurs' manuals. I. Popular mechanics. TL152.P625 2003 629.28'72-dc21 2003050841 10 9 8 7 6 5 4 3 2 1 Published by Hearst Books A Division of Sterling Publishing Co., Inc. 387 Park Avenue South, New York, NY 10016 Popular Mechanics is a trademark owned by Hearst Magazines Property, Inc., in USA, and Hearst Communications, Inc., in Canada. Hearst Books is a trademark owned by Hearst Communications, Inc. www.popularmechanics.com For information about custom editions, special sales, premium and corporate purchases, please contact Sterling Special Sales Department at 800-805-5489 or [email protected]. Distributed in Canada by Sterling Publishing G/o Canadian Manda Group, 165 Dufferin Street Toronto, Ontario, Canada M6K 3H6 Distributed in Australia by Capricorn Link (Australia) Pty. Ltd. P.O. Box 704, Windsor, NSW 2756 Australia Manufactured in China ISBN 1-58816-439-X Contents 2 Maintenance Basics 88 Engine 138 Drivetrain 158 Electrical and Electronic Systems 214 Chassis 254 Interior and Exterior 314 Appendix I '-- Foreword For almost 100 years, the editors of Popular Mechanics have made car care and maintenance a central component of the magazine. From the very beginning, we understood just how pas sionate readers were about their cars, and just how far they would go to protect, repair, and maintain their beloved vehicles. How else to explain an executive trading in his workday suit for a pair of overalls and spending his Saturday afternoons hunkered down under the hood of his car? For some of our readers, saving money is no doubt a major motivation. But for most, working on their cars is a labor of love, pure and simple. That, and they want to make sure the repair is done right. The cars may have changed over the years, but the dedication of readers has been a constant. And Popular Mechanics has been a partner all the way, delivering the hands-on information car enthusiasts need to get the job done right. We understand that the key to any successful piece of advice is clarity. So we strive to make sure our instructions and our illustrations are legible and to the point. We hope you'll find those quali ties in evidence in the pages that follow. You'll find chapters on all the basic car components engine, chassis, electrical system, drivetrain, and interior/exterior-as well as an opening chapter on the essential maintenance information that every owner should know. Each project is labeled "easy," "moderate," or "difficult" to allow you to make your own decision as to whether you have the requisite expertise, not to mention the time and energy, to undertake a given procedure. So, whether you're breaking out the brand-new wrenches from your first tool set, or sliding under a car on your creeper for the umpteenth time, you'll find this book to be an indispensable reference source, packed with easy-to-follow, step-by-step instructions that take the mystery out of auto maintenance and save you money. And, should you decide that a given repair is a bit too tricky for you, the book will arm you with the knowledge necessary to discuss the work intelligently with your professional mechanic. Our goal is a simple one: We want to provide you with the information you need to keep that treasured car of yours in peak condition regardless of its make, model, or age. We know how much you love your car and how dedicated you are to maintaining it. We're hoping our book provides you with a way to put that dedication into action. THE EDITORS Popular Mechanics 1 2