Automotive Service: Inspection, Maintenance, Repair, Sixth Edition
By Tim Gilles
Table of Contents
Preface Xvi
Acknowledgements Xviii
Dedication Xxiii
About The Author Xxiii
Features Of The Text Xxiv
Section 1
THE AUTOMOBILE INDUSTRY
CHAPTER 1
Introduction to the Automobile 2
Introduction 2 • Body and Chassis 2 • Engine Parts
and Operation 3 • Engine Support Systems 5 •
The Powertrain 9 • Accessory Systems 10
CHAPTER 2
Automotive Careers and Technician Certification 16
Introduction 16 • Automotive Career
Opportunities 16 • Technician Certification
and Licensing 19 • Technician Skill Levels and
Pay 22 • Other Areas of Specialization 22 •
Other Automotive Careers 23 • On the Job as an
Automotive Technician 24
SECTION 2
SHOP PROCEDURES, SAFETY, TOOLS, AND EQUIPMENT
CHAPTER 3
Shop Safety 31
Introduction 31 • General Personal Safety 31 •
Fire Safety 33 • Evacuation Plan 33 • Fire
Extinguishers 33 • Flammable Materials 35 •
Fuel Fires 35 • Electrical Fires 37 • Shop
Habits 37 • Electrical Safety Precautions 38 •
Cooling Fan Safety 39 • Coolant Burns 39 •
General Hand Tool Safety 39 • Puller Safety 41 •
Machinery Safety 41 • Electric Drill Safety 41 •
Grinder Safety 41 • Wire Wheel Safety 41 •
Compressed Air Safety 42 • Impact Wrench
Safety 42 • Air Chisel Safety 42 • Die Grinder/
Air Drill Safety 42 • Press Safety 43 • General
Lifting Safety 43 • Hydraulic Floor Jack ( Service
Jack) Safety 43 • Shop Crane (Engine Hoist)
Safety 44 • Transmission Jack Safety 45 • Battery
Safety 45 • Refrigerant Safety 46 • General Safety
Around Automobiles 46 • Hot Tank Safety
Precautions 46 • Hazardous Materials and
Environmental Safety 47 • Hazardous
Communication Standards 48 • Safety Data
Sheets 48 • Hazardous Materials Common to the
Automotive Industry 49 • Cleaning Solvent Safety
Precautions 50 • Skin Care Safety Precautions 51 •
Breathing Safety 51 • Welding Safety 52
CHAPTER 4
Shop Management, Service Records, and Parts 55
Introduction 55 • Customer Relations 55 • Service
Records 56 • Keep the Car Clean 57 • Linen
Service 58 • Wholesale and Retail Distribution of
Auto Parts 58
CHAPTER 5
Locating Service Information and
Specifications 62
Introduction 62 • Service Literature 62 •
Manufacturers’ Service Information 64 •
Generic Service Manuals 64 • Lubrication and
Maintenance Service Specifications 64 • Owner’s
Manual 65 • Owners’ Workshop Manuals 67 •
Electronic Service Information 67 • Technical
Service Bulletins 68 • Hotline Services 69 • Trade
Magazines and Internet 70
CHAPTER 6
Measuring Tools and Systems 72
Introduction 72 • Metric System 72 • Measuring
Tools 73 • Precision Measuring Tools 74
CHAPTER 7
Hardware, Fasteners, Drills, and Thread Repair 87
Introduction 87 • Characteristics of Fasteners 87 •
Fastener Failures 91 • Drill Bits 92 • Taps
and Threads 94 • Dies 97 • Repairing Broken
Fasteners 97
CHAPTER 8
Shop Tools 106
Introduction 106 • Tools of the Trade 106 •
Pullers 118 • Air Tools 120 • Special Service
Tools 124
CHAPTER 9
General Shop Equipment 126
Shop Equipment 126 • Hydraulic Equipment 126 •
Shop Electric Machinery 132 • Other Electric
Equipment 134 • Other Shop Equipment 135
CHAPTER 10
Cleaning Equipment and Methods 142
Introduction 142 • General Shop Housekeeping
Practices 142 • Cleaning Methods 143 • Cleaning
the Outside of the Engine 144 • Environmental
Concerns with Engine Cleaning 144 • Cleaning
Internal Parts 144 • Chemical Cleaning 145 •
Thermal Cleaning 152 • Vibratory
Parts Cleaners 153 • Other Cleaning
Methods 153 • Marking Clean Parts 154
CHAPTER 11
Lifting Equipment and Air Compressors 155
Introduction 155 • Lift Types 155 • Frame-Contact
Lifts 155 • Wheel-Contact Lifts 158 • Wheel-Free
Jacks 158 • In-Ground Lifts 159 • Surface Mount
Lifts 160 • Lift Safety 161 • Air Compressors 163
SECTION 3
VEHICLE INSPECTION (LUBRICATION/ SAFETY CHECK)
CHAPTER 12
Engine Lubrication 168
Introduction 168 • Engine Oil 168 •
Engine Oil Licensing and Certification 172 •
Oil Additives 174 • Changing Engine Oil 178 •
Oil Filter 181 • Changing the Oil Filter 184
CHAPTER 13
Underhood and Body Inspection (Vehicle on
Ground) 188
Introduction 188 • Brake System Inspection 188 •
On-Ground Steering and Suspension Checks 190 •
Fuel System Inspection 192 • Cooling System
Inspection 193 • Belt Inspection 194 • Electrical
System Inspection 195 • Check Operation of
Lights 196 • Visibility Checks 197 • Other Safety
Checks and Service 199
CHAPTER 14
Undercar Inspection and Service 205
Introduction 205 • Tire Visual Inspection 205 •
Undercar Brake Checks 206 • Exhaust System
Inspection 207 • Chassis Lubrication 208 •
Suspension and Steering Checks 210 • Driveline
Checks 212
SECTION 4
ENGINE OPERATION
CHAPTER 15
Introduction to the Engine 219
Introduction 219 • Basic Engine Operation 219 •
Four-Stroke Engine Operation 220 • Engine
Upper End 221 • Valve Train 221 • Cylinder
Head 222 • Engine Front 225 • Cylinder Block
Assembly (Lower End) 225 • Short Block and
Long Block 227
CHAPTER 16
Engine Classifications and Types 232
Introduction 232 • Engine Classifications 232 •
Cylinder Arrangement 232 • Firing Order 234 •
Engine Cooling 235 • Valve Location 235 •
Camshaft Location 236 • Other Cylinder Head
Variations 237 • Combustion Chamber
Designs 237 • Spark and Compression
Ignition 239 • Alternate Engines 240
CHAPTER 17
Engine Size and Measurements 244
Introduction 244 • Engine Size
Measurements 244 • Compression
Ratio 246 • Physical Principles of
Work 248 • Torque 249 • Horsepower 249 •
Dynamometer 250 • Dynamometer Safety
Concerns 254 • Engine Efficiency 255 • Mean
Effective Pressure 256
CHAPTER 18
Engine Upper End 258
Introduction 258 • Cylinder Head
Construction 258 • Valve Guides 259 •
Valve Guide Seals 259 • Valves 261 • Retainers
and Valve Locks 264 • Valve Springs 264 •
Pushrods and Rocker Arms 265 • Camshaft 266 •
Number of Cams and Lobes 266 • Camshaft
Performance 267 • Valve Lifters and
Lash Adjusters 269 • Roller Cam and
Lifters 270 • Hydraulic Lifters 270 • Camshaft
Drives 271 • Valve Timing 274 • Variable Valve
Timing 275 • Electric Cam Phasers 278 • Active
Fuel Management 279
CHAPTER 19
Engine Lower End and Lubrication System
Theory 283
Introduction 283 • Cylinder Block
Construction 283 • Core Plugs 284 • Cylinder
Bore 285 • Cylinder Sleeves 285 • Main Bearing
Caps 285 • Lifter Bores 285 • Crankshaft
Design 285 • Crankshaft End
Thrust 287 • Direction of Crankshaft
Rotation 287 • Vibration Damper 287 • Crankshaft
Hardness 288 • Bearings 288 • Connecting
Rods 290 • Pistons 291 • Piston
Head 291 • Piston Ring Grooves 291 • Heat
Transfer 292 • Cast and Forged
Pistons 293 • Piston Skirt 293 • Piston
Pin Offset 294 • Piston Pins 295 • Piston
Rings 296 • Compression
Rings 296 • Compression Ring
Design 297 • Oil Control Rings 299 • Engine
Balancing 299 • The Lubrication System 300 • Oil
Pumps 300 • Pressure Relief Valve 302 • Oil
Pump Screen By-Pass Valve 302 • Oil
Pressure 303 • Windage Tray and Baffles 303 • Dry
Sump Lubrication Systems 304 • Semi-Dry
Sump 305
SECTION 5
COOLING SYSTEM, BELTS, HOSES, AND
PLUMBING
CHAPTER 20
Cooling System Theory 308
Introduction 308 • Liquid and Air Cooling 308 •
Liquid Cooling System Parts 308 • Cooling
System Circulation 309 • Coolant 310 • Racing
Coolants 311 • Heat-Transferability of Water
and Coolant 311 • Cooling System Pressure
Cap 314 • Coolant Recovery System 315 •
Radiator 316 • Thermostat 317 • Temperature
Warning Light or Gauge 320 • Fans 321 • Fan
Clutch 322 • Radiator Shroud 322 • Heater
Core 322
CHAPTER 21
Cooling System Service 325
Introduction 325 • Diagnosing Cooling
System Problems 325 • Radiator
Cap 327 • Coolant Service 329 • Testing
Coolant Condition and Strength 334 • Thermostat
Service 338 • Locating Leaks 340 • External
Leaks 341 • Internal Leaks 342 • Recovery Tank
Service 345 • Cooling System Repairs 345 • Water
Pump Service 347 • Electric Cooling Fan
Service 349 • Heater Core Service 349
CHAPTER 22
Automotive Belts 353
Introduction 353 • Belt Material 353 • V-Ribbed
Belts 353 • Serpentine Belt Drive 353 • Stretch
Belts 353 • Timing Belts 354 • Drive Belt
Service 356 • Belt Inspection and Adjustment 357 •
Replacing Belts 358
CHAPTER 23
Automotive Hoses 365
Introduction 365 • Hose Construction 365 •
Hose Size 365 • Unreinforced Hose 365 •
Radiator Hose 365 • Hose Types 365 • Hose
Clamps 369 • Hoses 371 • Hose Inspection
and Service 372 • Replacing Hoses 373 •
High-Performance Hoses and Fittings 376
CHAPTER 24
Automotive Plumbing: Tubing and Pipe 380
Introduction 380 • Tubing 380 • Flared
Connections 382 • Compression Fittings 383 •
Pipe Fittings 385 • Shutoff Valves 385 • Tubing
Service 386 • Installing Tubing 390 • Transmission
Oil Cooler Line Repairs 390 • Nylon Fuel Injection
Tubing 391 • Pipe Service 391
SECTION 6
ELECTRICAL SYSTEM
THEORY AND SERVICE
CHAPTER 25
Basic Electrical System Theory and Repairs 394
Introduction 394 • Electron
Flow 394 • Basic Automotive Electrical
System 396 • Electrical Terms 397 • Circuitry
and Ohm’s Law 401 • Magnetic
Fields 403 • Capacitors 405 • Automotive
Electronics 405 • Basic Electrical
Tests 406 • Voltage Drop Testing 407
CHAPTER 26
Battery Fundamentals 416
Introduction 416 • Battery Parts and Operation 417 •
Battery Recharging and Discharging 420 •
Battery Capacity Ratings 422 • Battery Types 423 •
Battery Plate Size 426 • Battery Selection 427 •
Battery Service Life 427 • Battery Cables 428 •
Battery Holddowns 429 • Reasons for Battery
Failure 429 • Electric Vehicle Battery Types 429
CHAPTER 27
Battery Service 431
Introduction 431 • Battery Inspection 432 • Battery
Service 432 • Replacing a Battery 435 • Battery
Testing: Measuring Battery State of Charge (SOC) 441 •
Battery Charging 446 • Battery Chargers 447 •
Storing a Vehicle 451 • Battery Capacity Tests 451 •
Battery Testing Using an Amp Clamp 454 • Battery
Drain Test/Parasitic Load 454 • Battery Jump-
Starting 455
CHAPTER 28
Starting System Fundamentals 459
Introduction 459 • Starter Motor 459 • Starter
Motor Fundamentals 459 • Starter Drives 462 •
Starter Electrical Circuit 463 • Gear Reduction
Starters 466 • Brushless DC Motors 466
CHAPTER 29
Starting System Service 468
Introduction 468 • Starting System
Service 468 • Starting System Tests 469 • Cranking
Voltage and Amperage Test 470 • Circuit Resistance
Test 470 • No-Crank Tests 473 • Solenoid
Problems 474 • Starter Repair 475 • Starter
Disassembly 475 • Starter Drive
Service 476 • Starter Reassembly 478
CHAPTER 30
Charging System Fundamentals 480
Introduction 480 • Charging System 480 • AC
Generator/Alternator 481 • Alternator Pulleys 485 •
AC Generator Bearings 485 • AC Generator Fan 486 •
Voltage Regulator 486 • Computer-Controlled Voltage
Regulation 487 • Charging System Indicators 490 •
High-Voltage Charging Systems 491
CHAPTER 31
Charging System Service 493
Introduction 493 • Charging System Service 493 •
Preliminary Charging System Tests 494 • Testing
the Charging System 495 • Charging System Output
Tests 495 • Regulated Voltage Test 497 • Diode
Tests 499 • Charging System Voltage Drops 500 •
AC Generator Service and Repair 502 • AC
Generator Reassembly 505
CHAPTER 32
Lighting and Wiring Fundamentals 508
Introduction 508 • Wire and Cable 508 • Circuit
Protection Devices 509 • Lighting 511 •
Headlamps 512 • Taillights 521 • Incandescent
Light Bulb Identification 522 • Turn Signals 524 •
Signal Flasher Operation 524 • Hazard Flashers 525 •
Back-Up Lights 525 • Electrical Instrumentation and
Instrument Panel 529 • Miscellaneous Gauges 531
CHAPTER 33
Lighting and Wiring Service 536
Analyzing Electrical Problems 536 • Wiring
Service 536 • Trim Removal 538 • Crimp
Terminals 540 • Selecting Replacement Wire 545 •
Adding Electrical Accessories 545 • Soldering 545 •
Broken or Damaged Ground Straps 548 • Wiring for
a Trailer or RV Tow Car 549 • Circuit Testing and
Service 550 • Finding Grounds 550 • Fuse Testing
and Service 550 • Fuse Link Service 552 •
Headlamp Service 552 • Headlamp Aiming 554 •
Tail Lamp and Park Light Service 557 • LED
Service 558 • Stoplight Switch Service 558 •
Back-Up Lights 558 • Turn Signal Switch 559 •
Signal Flasher/Relay 559 • Locating a Signal
Flasher 560 • Windshield Washer Service 560 •
Horn Service 561 • Gauge Testing 561
CHAPTER 34
Safety, Security, Comfort Systems, and Electrical
Accessories 564
Introduction 564 • Supplemental Restraint
Systems 564 • Active and Passive Restraints 564 •
Restraint System Service 575 • Security, Navigation,
and Electrical Accessories 578 • Security Systems 578 •
GPS Vehicle Tracking/ Navigation Systems 584 •
Other Comfort Systems 587 • Vehicle Audio
Systems 587 • Cruise Control 604 • Body Electronic
System Testing and Service 606 • Precollision/
Collision Avoidance Systems 606 • Lane Departure
Warning System 607 • Autonomous Driving
Vehicles 607 • The Future of Autonomous Vehicles 608
SECTION 7
HEATING AND AIR CONDITIONING
CHAPTER 35
Heating and Air-Conditioning Fundamentals 612
Introduction 612 • Sources of Heat 612 •
Ventilation 612 • Heating 613 • Air Distribution
System 613 • Air Conditioning 615 • Air-
Conditioning Principles 616 • Heat Transfer 616 •
Humidity 617 • States of Matter 617 • Latent
Heat 617 • Air-Conditioning System
Operation 618 • Reducing Humidity 619 •
Compressing the Refrigerant 620 •
Transferring Refrigerant Heat to Outside
Air 620 • Flow Control Devices 622 •
Air-Conditioning Compressors 625 •
Compressor Lubrication 628 • Muffler 628 •
Accumulator or Receiver/Dryer 629 • Evaporator
Icing Control 630 • System Switches 631 •
Heating and Air-Conditioning Controls 632 •
Automatic Air-Conditioning Sensors 633 •
Refrigerants and the Environment 634 •
Temperature and Pressure 637
CHAPTER 36
Heating and Air-Conditioning Service 640
Heater Service 640 • Air-Conditioning
Service 640 • Air-Conditioning System
Service and Diagnosis 641 • System
Performance Test 642 • Pressure
Testing 642 • Static Pressure Reading 644 •
Diagnosing HVAC Electronic Problems 649 •
Air Distribution System Diagnosis 650 • Leak
Detection 656 • Common Air-Conditioning
Component Problems 659 • Refrigerant
Oil 660 • Evaporator Problems 661 •
Thermal Expansion Valve or Orifice Tube
Problems 662 • Compressor Service 663 •
Evacuating a System 668 • Evacuate the
System 669 • Air-Conditioning Service
Equipment 670 • Refrigerant Charging 670 •
Follow-Up 672 • Refrigerant Storage 673 •
R-1234YF Service 673
SECTION 8
ENGINE PERFORMANCE DIAGNOSIS: THEORY
AND SERVICE
CHAPTER 37
Ignition System Fundamentals 677
Introduction 677 • Basic Ignition System 677 •
Primary Circuit 677 • Secondary Ignition
Parts 680 • Spark Plugs 681 • Electronic
Ignitions 683 • Electronic Ignition Variations 686 •
Ignition Modules 690 • Ignition Timing 690 •
Detonation Sensor 692 • Distributorless
Ignition 692
CHAPTER 38
Ignition System Service 697
Ignition System Service and Repairs 697 • Spark
Plug Service 697 • Spark Plug Diagnosis 698 •
Installing Spark Plugs 701 • Repairing Damaged
Spark Plug Threads 702 • Spark Plug Cable
Service 704 • Ignition Timing 706 • Electronic
Ignition Distributor Service 706 • Static
Timing 709 • Electronic Ignition System
Service 709 • Lab Scope Testing 712 • Types
of Scope Patterns 713 • Other Scope
Tests 717 • Other Diagnostic Instruments 718
CHAPTER 39
Petroleum Fuels and Alternative Fuel
Technologies 720
Introduction 720 • Crude Oil 720 • Diesel Engines
and Diesel Fuel 721 • Gasoline 725 • Air-Fuel
Mixture 728 • Spark Knocks, Carbon Noise,
and Abnormal Combustion 729 • Abnormal
Combustion 730 • Excessive Carbon Buildup 733 •
Regular Versus Premium Fuels 733 • Octane
Standards 734 • Gasoline Additives 735 •
Reformulated Gasolines 735 • Oxygenated Fuels/
Alcohols 735 • Alternative Fuels 737 •
Natural Gas 738 • Compressed Natural Gas 739 •
Refueling CNG 740 • Liquified Natural Gas 742 •
Engine Rebuilding Concerns with Alternative Fuel
Engines 743 • Hydrogen 743
CHAPTER 40
Fuel System Fundamentals, Gasoline and Diesel 745
Introduction 745 • Fuel System 745 • Fuel
Tanks 745 • Fuel Lines, Hoses, and
Fittings 746 • Fuel Pumps 746 • Fuel Filters 747 •
Fuel Injection and Carburetion 748 • Pressure
Regulator Operation 753 • Electronic Fuel System
Operation 754 • Airflow Measurement 755 •
Idle Speed Control 756 • Fuel Pump Control
Module 757 • Computer-Controlled Fuel
Systems 758 • Feedback Fuel Systems 758 •
Diesel Fuel Systems 763 • Diesel Fuel
Subsystem 765 • Diesel Fuel Filters 765
CHAPTER 41
Fuel System Service 768
Introduction 768 • Fuel Supply System
Service 768 • Fuel Filter Service 772 • Throttle
Linkage 772 • Fuel System Problems and
Service 772 • Exhaust Gas Analysis 774 • Fuel
Injection Diagnosis and Service 774 • EFI Computer
Self-Diagnostics (OBD) 775 • Air-Fuel Mixture
Problems 775 • Injector Problems 778 • Throttle
Plate Service 781 • EFI Adjustments 782 • Sensor
Service 783 • Throttle Position Sensor 783 •
Oxygen Sensor Service 783 • Coolant Temperature
Sensor 785 • Inlet Air Temperature Sensor 785 •
Map Sensor Diagnosis 785 • Mass Airflow
(MAF) Sensor Diagnosis 786 • Testing Other
Sensors 787 • Computer Service 787 • Mechanical
Injection 787 • Carbon Deposit Service 788 •
Diesel Engine Fuel Service 788
CHAPTER 42
Intake and Exhaust Systems/Turbochargers and
Superchargers 792
Introduction 792 • Intake System Fundamentals 792 •
Manifolds 793 • Intake Manifolds 793 • Exhaust
System Fundamentals 797 • Exhaust Manifolds 797 •
Exhaust Tubing 798 • Exhaust System Service 800 •
Turbochargers and Superchargers 802 •
Turbochargers 803 • Aftercooler/Intercooler 807 •
Belt-Driven Superchargers/Blowers 812
CHAPTER 43
Emission Control System Fundamentals, Gasoline
and Diesel 819
Introduction 819 • Air Pollution 819 • Automotive
Emissions 819 • Pollution Control 821 •
Automobile Emission Control Systems 821 •
Crankcase Ventilation 822 • PCV Valve Testing 824 •
Exhaust Gas Recirculation 824 • EGR System
Operation 826 • Computer-Controlled EGR
Systems 827 • Catalytic Converter 828 • Types
of Catalytic Converters 829 • Evaporative
Controls 832 • Other Parts of the Fuel Tank
System 834 • On-Board Diagnostics 835 •
Engine Emission Modifications 835 • Diesel Engine
Emission Control 836
CHAPTER 44
Emission Control System Service 841
Introduction 841 • Inspecting Emission Control
Systems 841 • Computer-Controlled Emission
Service 842 • Crankcase Ventilation System
Service 842 • Evaporative Control System
Service 843 • Evaporative System Maintenance 844 •
Evaporative System Problem Diagnosis 844 • EGR
System Service 846 • Air Injection System
Service 848 • Catalytic Converter Service 849 •
Converter Testing 849 • Catalytic Converter
Replacement 850 • Analyzing Exhaust
Emissions 850 • Emission Analyzers 851 •
Hydrocarbons 852 • Carbon Monoxide
(CO) 853 • Carbon Dioxide 853 • Oxygen
(O2) 855 • Oxides of Nitrogen 855 • Catalytic
Converter Tests 858 • Diesel Emission Control
Service 860 • Diesel Exhaust Fluid (DEF)
Service 860 • Diesel Particulate Filter Service 861
CHAPTER 45
Electronics and Computer Systems
Fundamentals 864
Introduction 864 • Semiconductors 864 •
Diodes 865 • Transistors 867 • Electronic
Instrument Displays 868 • Automotive Computer
Systems 868 • Parts of a Computer System 869 •
On-Board Computer 870 • Information
Processing 871 • Computer Memory 872 •
Communication Rate 873 • Sensors and
Actuators 873 • Types of Sensors 874 •
Thermistors 874 • Voltage Dividers 874 •
Piezoelectric and Piezoresistive Sensors 874 •
Heated Resistive Sensors 875 • Variable DC
Frequency Sensors 875 • Voltage Generators 875 •
Wheatstone Bridges 876 • Switches 876 • Types
of Actuators 877 • Solenoid Actuators 877 • Relay
Actuators 877 • Motor Actuators 877 • Actuator
Switches/Modules 878 • Adaptive Strategy 879 •
Ignition Advance 880 • Knock Sensor 880 •
Electronic Throttle Control/Drive-By-Wire 881 •
On-Board Diagnostics 881 • Diagnostic Trouble
Codes 881 • Computer Self-Diagnostics 881 •
Multiplexing 881 • Network Sizes and Types 883 •
CAN Systems 883 • Supplemental Data Bus
Networks 887 • Telematics 889 • Wireless
Networks 889 • DSRC 890
CHAPTER 46
Electronics and Computer Systems Service 892
Introduction 892 • Inspection Sequence 892 •
Perform Diagnostic Tests 893 • On-Board
Diagnostics 894 • Reading Trouble Codes 895 •
Scan Tools 896 • Breakout Box 897 • Retrieving
Trouble Codes 897 • Working with Codes 898 •
Erasing Trouble Codes 898 • Scan Tool
Snapshot 898 • Closed Loop 900 • Fuel Trim
Diagnosis 901 • Digital Waveforms 902 •
Logic Probe 907 • Sensor and Actuator
Testing 907 • Diagnosing Sensor Problems 907 •
Sensor Tests 908 • Oxygen Sensor 908 • Load
Sensors 911 • Map Sensor 911 • Baro
Sensors 912 • Vacuum Sensors 912 • Throttle
Position Sensor 912 • Coolant Temperature
Sensor 913 • Air Temperature Sensors 914 • Airflow
Sensor Service 915 • Knock Sensor Service 916 •
Actuator Service 917 • Repair the Problem 917 •
Computer Wiring Service 917 • Static Electricity 921 •
Electrical Damage to a Circuit 921
CHAPTER 47
Advanced Emissions and On-Board Diagnostics
(OBD) 926
Introduction 926 • History of On-Board
Diagnostics 926 • OBD II Operation 927 • Society
of Automotive Engineers (SAE) Standards 928 •
Trouble Codes and the Malfunction Indicator
Lamp 930 • OBD II Codes 931 • OBD II Diagnostic
Testing 933 • Emission Testing Programs 942
CHAPTER 48
Diagnosing Engine Performance Problems 945
Introduction 945 • Visual Checks 945 • Ignition
System Checks 945 • Engine Performance
Testing 946 • Compression Loss 946 • Vacuum
Testing 947 • Other Vacuum
Tests 948 • Compression Problems 949 • Cylinder
Leakage Test 955 • Carbon-Related Problems 956
SECTION 9
AUTOMOTIVE ENGINE SERVICE AND REPAIR
CHAPTER 49
Diagnosing Engine Mechanical Problems 959
Introduction 959 • Diagnosing Problems Before
a Repair 959 • Oil Consumption 959 • Causes
of Oil Consumption 960 • Testing for Oil
Leaks 963 • Engine Performance and Compression
Loss 964 • Engine Noises 964 • Engine
Knocks 965 • Oil Pressure Problems 969 • Cooling
System Problems 970 • Internal Engine
Leakage 970 • Seized Engine 971 • Electronic
Failures/Engine Damage 973 • Engine Performance
and Fuel Mixture Problems 973
CHAPTER 50
Engine Removal and Disassembly 975
Introduction 975 • Engine Removal 975 •
Engine Disassembly 988 • Engines with
Pushrods 990 • Overhead Cam Cylinder Head
Removal 992 • Cylinder Block Disassembly 994
CHAPTER 51
Engine Sealing, Gaskets, Fastener Torque 1001
Introduction 1001 • Clamping Force 1001 •
Torque and Friction 1001 • Torque Wrenches 1002 •
Torque-To-Yield 1003 • Torque by Degrees 1004 •
Fastener Clamping Load 1004 • Gaskets and
Seals 1005 • Cleaning the Head 1009 • Head
Gasket Installation 1011 • Other Engine
Gaskets 1012 • Valve Cover, Timing Cover, and Oil
Pan Service 1012 • Gasket Sealers 1016 • Silicone
RTV Sealant 1018 • Seals 1019 • Rear Main
Seals 1020 • Transmission Front Pump Seal 1022
CHAPTER 52
Engine Diagnosis and Service: Cylinder Head and
Valve Train 1024
Introduction 1024 • Head Disassembly 1024 •
Carbon Removal 1028 • Cylinder Head
Inspection 1029 • Resurfacing by Grinding, Cutting,
or Sanding 1031 • Straightening Cylinder
Heads 1031 • Crack Inspection 1032 • Crack
Repair 1033 • Checking Valve Springs 1033 •
Checking Valve Stems 1034 • Valve Guide
Service 1034 • Guide Repair 1034 • Grinding
Valves 1035 • Grinding Valve Seats 1038 •
Checking Valve Stem Installed Height 1038 • Solvent
Testing the Valve and Seat 1040 • Reassembling the
Head 1040 • Valve Guide Seal Installation 1040 •
Install the Valve and Spring Assembly 1041 •
Pushrod Engine Rocker Arm Service 1041 • Inspect
Pushrods 1041 • Inspect OHC Camshaft 1041 •
Reassembling OHC Heads 1042 • Camshaft
Service 1044 • Lifter Service 1044 • Cam and Lifter
Break-In 1045 • Timing Chain and Belt Service 1045 •
Timing Belt Service 1045 • Timing Belt
Replacement 1046 • Timing Chain Service 1048
CHAPTER 53
Engine Diagnosis and Service: Block, Crankshaft,
Bearings, and Lubrication System 1053
Introduction 1053 • Cleaning the Block 1053 • Oil
and Water Plug Removal 1053 • Oil Gallery
Plug Installation 1055 • Inspect and Clean
Lifter Bores 1055 • Checking Main Bearing
Bore Alignment 1055 • Check the Deck
Surface for Flatness 1057 • Clean All
Threaded Holes 1057 • Inspecting Cylinder
Bores 1057 • Measuring the Bore 1058 • Deglazing
the Cylinder Bore 1059 • Clean the Block of
Grit 1060 • Boring for Oversized Pistons 1061 •
Block Distortion 1062 • Honing After Boring 1063 •
Sleeves 1064 • Cam Bearing Installation (Cam-In-
Block Engines) 1064 • Front Cam Bearing
Installation 1065 • Checking Crankshaft
Condition 1066 • Crankshaft and Bearing
Wear 1067 • Crankshaft Journal Tolerance 1068 •
Regrinding the Crankshaft 1069 • Measuring
Bearing Clearance with Plastigage 1069 •
Lubrication System Service 1070 • Checking Oil
Pumps for Wear 1071 • Oil Pump Screen
Service 1071 • Oil Pump Failure 1072 • Installing
the Oil Pump 1073
CHAPTER 54
Engine Diagnosis and Service: Piston, Piston Rings,
Connecting Rod, Engine Balancing 1075
Introduction 1075 • Piston Service 1075 • Piston
Ring Service 1078 • Installing Pins in Connecting
Rods 1080 • Installing Rings on Pistons 1080 •
Oil Ring Installation 1080 • Connecting Rod
Service 1082 • Engine Balancing Service 1084
CHAPTER 55
Ordering Parts, Short and Long Blocks, Engine
Assembly 1089
Introduction 1089 • Ordering Parts 1089 • Engine
Kits 1089 • Determining Part Sizes 1091 • Types
of Engine Rebuilds 1091 • Selecting the Correct
Replacement Engine 1092 • Warranty 1092 •
Reassembly 1092 • Begin Reassembly 1092 •
Prepare the Crankshaft for Installation 1093 •
Install the Crank 1094 • Install the Cylinder
Heads 1102 • Install OHC Heads 1102 • Install
the Cam Drive (Pushrod Engines) 1103 • Install
the Oil Pump 1103 • Install the Timing
Cover 1103 • Install the Crankshaft Damper/
Pulley 1104 • Install the Oil Pan 1104 • Install
the Intake Manifold 1105 • Install the Thermostat
and Water Outlet Housing 1106 • Completing the
Assembly 1106 • Install Exhaust Manifold(s) 1106
CHAPTER 56
Engine Installation, Break-In, and In-Chassis
Repairs 1109
Introduction 1109 • Engine
Installation 1109 • Install Engine
Mounts 1109 • Install the Engine 1109 • Priming
the Lubrication System 1111 • Pressure
Priming 1111 • Install Valve Covers 1112 •
Ignition System Installation and Timing 1112 •
Engine Starting and Initial Break-in 1112 • Valve
Clearance Adjustment 1114 • Road Test and
Break-in 1114 • Final Inspection 1114 • Returning
the Car to the Customer 1114 • Engine Repair—
Engine in the Vehicle 1115 • Valve Job or Head
Gasket Repair 1115 • Valve Job or Complete
Engine Overhaul 1116 • Head Gasket Problems 1116 •
In-Chassis Lower End Repairs 1116 • Removing the
Oil Pan 1116 • Remove the Piston and Rod
Assembly 1118 • Remove the Timing Cover 1118 •
Freewheeling and Interference Engines 1119 •
Replace the Timing Components 1119 • Crankshaft
Seal Replacement 1119 • Flywheel Ring Gear
Service 1119
SECTION 10
BRAKES AND TIRES
CHAPTER 57
Brake Fundamentals 1123
Introduction 1123 • Brake Linings 1123 • Drum
and Disc Brakes 1124 • Hydraulic Brake System
Operation 1124 • Hydraulic Brake Fluid 1126 •
Brake Hose 1127 • Brake Tubing 1128 • Hydraulic
System Operation 1128 • Low Brake Pedal 1129 •
Split Hydraulic System 1132 • Quick Take-Up
Master Cylinder 1133 • Drum Brakes 1133 •
Drum Brake Adjustment 1135 • Disc Brakes 1136 •
Hydraulic System Valves and Switches 1140 • Power
Brakes 1143 • Parking Brake 1146 • Types of
Parking Brakes 1147 • Stoplight Switches 1149 •
Brake Pedal Position Sensor 1149 • Antilock
Brakes 1149
CHAPTER 58
Brake Service 1152
Introduction 1152 • Brake Inspection 1152 •
Check Brake Pedal Feel 1152 • Master Cylinder
Inspection 1152 • Brake Diagnosis 1154 •
Undercar Checks 1155 • Disc Brake
Inspection 1155 • Inspecting Drum Brake
Assemblies 1159 • Brake Fluid Service 1161 •
Routine Brake Fluid Replacement 1161 • Brake
Fluid Testing 1162 • Bleeding Brakes 1163 • Brake
Bleeding Methods 1164 • Drum Brake
Adjustment 1168 • Master Cylinder Service 1169 •
Master Cylinder Removal 1169 • Master Cylinder
Disassembly 1169 • Bench Bleeding a Master
Cylinder 1170 • Brake Job 1171 • Drum Brake
Lining Removal 1172 • Reassembling a Wheel
Cylinder 1174 • Removing Wheel Cylinders 1174 •
Replacing Drum Brake Shoes 1174 • Adjusting
Drum Brake Clearance 1175 • Drum and Rotor
Service 1175 • Drum Service 1177 • Rotor
Service 1179 • On-Vehicle Rotor Machining 1181 •
Disc Brake Service 1182 • Rear Disc Pad
Installation 1184 • Rebuilt Calipers 1185 • Disc
Caliper Rebuilding 1185 • Selecting Brake
Linings 1187 • Disc Brake Noise 1189 • Parking
Brake Cable Service 1191 • Vacuum Power Brake
Service 1191 • Brake Warning Lamp Diagnosis 1195 •
Antilock Brake System (ABS) Service 1196
CHAPTER 59
Antilock Brakes, Traction, and Stability
Control 1198
Introduction 1198 • Antilock Brakes 1198 • Parts
of an Antilock Brake System 1199 • Types
of Antilock Brake Systems 1202 • Antilock
Brake System Operation 1204 • Traction
Control System 1206 • Antilock Brake (ABS)
Service 1207 • ABS Brake Fluid Service 1210
CHAPTER 60
Bearings, Seals, and Greases 1218
Introduction 1218 • Plain Bearings 1218 •
Frictionless Bearings 1218 • Bearing Loads 1219 •
Ball Bearings 1219 • Roller Bearings 1220 • Wheel
Bearings 1222 • Greases 1223 • Wheel Bearing
Seals 1227 • Seal Materials and Design 1228 •
Seal Tolerance 1228 • Wheel Bearing Diagnosis
and Service 1228 • Wheel Bearing Adjustment 1229 •
Disc Brake Caliper Removal 1232 • Repacking
Wheel Bearings 1232 • Bearing Inspection and
Diagnosis 1234 • Diagnosing Wheel Bearing
Noise 1236 • Replacing Bearing Races 1236 •
Servicing Front-Wheel-Drive Bearings 1238
CHAPTER 61
Tire and Wheel Theory 1240
Introduction 1240 • Tire Construction 1240 •
Tubeless Tires 1241 • Tire Tread 1241 • Tire
Tread Material 1242 • Tire Cord 1243 • Tire Ply
Design 1243 • Tire Sidewall Markings 1244 •
Euro-Metric Commercial Tires 1245 •
Load Rating 1249 • Tire Life and Age 1250 •
All-Season Tires 1251 • Snow Tires 1251 •
Tire Pressure Monitoring System 1253 • Uniform
Tire Quality Grading 1255 • Changing Tire
Size 1255 • Wheels 1257 • Custom Wheels 1258 •
Lug Studs 1259 • Lug Nuts 1259 • Tire Valve
Stems 1259
CHAPTER 62
Tire and Wheel Service 1262
Introduction 1262 • Tire Inflation 1262 •
Checking Air Pressure 1262 • Adjusting Tire
Pressure 1264 • Tire Wear 1266 • Sidewall
Checks 1267 • Tire Age 1267 • Tire
Rotation 1267 • Removing and Tightening
Lug Nuts 1269 • Tire Rotation with
TPMS 1270 • Repairing Wheel Studs 1271 •
Removing and Mounting Tires on Rims 1271 •
Inspecting the Tire and Wheel 1274 • Valve Stem
Service 1274 • Rubber Lubricant 1276 • Install the
Tire 1277 • Mounting High-Performance
Tires 1280 • Bead Roller Tire Changer 1280 •
Installing the Valve Core 1281 • Tire Runout 1281 •
Tire Repair 1282 • Repairing a Tire 1283 •
Preparing a Tire for Repair 1284 • Patching a
Tire 1285 • Tire and Wheel Balance 1286 • Types
of Wheel Balance 1288 • Couple Imbalance 1289 •
Dynamic Balance 1289 • Using a Computer
Balancer 1291 • Centering the Wheel on the
Balancer 1291 • Match Mounting 1294 • Force
Variation 1294 • Installing the Wheel 1294 • Tire
Pressure Monitoring System Service 1296 • TPMS
Service 1300 • TPMS Service 1301
SECTION 11
SUSPENSION, STEERING, ALIGNMENT
CHAPTER 63
Suspension Fundamentals 1307
Introduction 1307 • Suspension 1307 • Frame and
Suspension Designs 1308 • Springs 1308 •
Suspension Construction 1310 • Independent
and Solid Axle Suspensions 1311 • Suspension
Types 1312 • High-Performance Suspensions 1314 •
Shock Absorbers 1314 • Hydraulic Shock Absorber
Operation 1315 • Compression and Rebound
Resistance 1317 • Bump Stops and Limiters 1318 •
Gas Shocks 1318 • Other Front End Parts 1319 •
Stabilizer Bar 1319 • Air Shocks/Leveling
Devices 1320 • Suspension Leveling
Systems 1322 • Active Suspensions 1326
CHAPTER 64
Suspension System Service 1328
Introduction 1328 • Diagnosing Suspension System
Problems 1328 • Shock Absorber Service 1329 •
Testing Shock Absorbers 1329 • Macpherson Strut
Service 1332 • Inspect the Upper Strut Bearing 1333 •
Install the Coil Spring 1333 • Reinstall the Strut
Assembly 1334 • Suspension Bushing
Service 1334 • Strut Rod Bushing Service 1335 •
Stabilizer Bar Service 1335 • Spindle Service 1336 •
Ball Joint Service 1336 • Measuring Ball Joint
Wear 1337 • Separating Tapered Connections 1337 •
Replacing a Ball Joint 1338 • Coil Spring
Service 1338 • Adjusting Spring Height 1340 •
Coil Spring Replacement 1340 • SLA Coil Spring
Replacement 1340 • Wheel Alignment 1343 •
Electronic Suspension Service 1343 • Electronically
Controlled Shock Absorbers 1344
CHAPTER 65
Steering Fundamentals 1346
Steering Systems 1346 • Steering Gears 1346 •
Recirculating Ball and Nut Steering Gear 1347 •
Rack-and-Pinion Steering 1347 • Steering
Linkage 1348 • Parallelogram Steering Linkage 1348 •
Ball Sockets 1348 • Tie-Rods 1348 • Steering
Arm 1350 • Rack-and-Pinion Steering
Linkage 1350 • Steering Column 1351 • Power
Steering 1352 • Power Steering Pump 1353 • Types
of Power Steering 1354 • Electronically Controlled
Variable Effort Power Steering 1355 • Electronically
Controlled Steering Systems 1357
CHAPTER 66
Steering System Service 1362
Introduction 1362 • Fluid Level Checks 1362 •
Type of Fluid 1362 • Diagnosing Steering
Problems 1363 • Noise Diagnosis 1363 • Hard
Steering 1363 • Tire Wear 1363 • Steering
Part Inspection 1363 • Steering Linkage
Inspection 1363 • Steering Gear Looseness 1363 •
Parallelogram Steering Inspection 1364 • Rack-and-
Pinion Steering Linkage Inspection 1364 • Steering
Linkage Repairs 1364 • Idler Arm Replacement 1365 •
Pitman Arm Replacement 1365 • Tie-Rod
End Replacement 1365 • Rack-and-Pinion
Tie-Rods 1366 • Steering Wheel, Column, and Air
Bag Service 1367 • Air Bag Service 1367 • Steering
Wheel Service 1369 • Steering Column
Service 1369 • Steering Gear Service 1370 •
Rack-and-Pinion Service 1370 • Rack-and-Pinion
Steering Looseness 1370 • Power Steering System
Service 1371 • Power Steering System Flushing 1371 •
Bleeding Air from the Hydraulic System 1372 •
Power Steering Pump Replacement 1372 • Repairing
Power Steering Pump Oil Leaks 1372 • Power
Steering Pressure Diagnosis 1373 • Power Steering
Pump Service 1374 • Power Steering Hoses 1374 •
Refilling the Power Steering System 1375 • Power
Steering Gear Service 1375 • Replacing Rackand-
Pinion Units 1375 • Variable Power Steering
Service 1377 • Electronically Controlled Power
Steering System Service 1377
CHAPTER 67
Wheel Alignment Fundamentals 1379
Introduction 1379 • Wheel Alignment
Angles 1379 • Toe 1379 • Camber 1380 •
Caster 1381 • Steering Axis Inclination 1382 •
Scrub Radius 1383 • Turning Radius 1384 •
Geometric Centerline and Thrust Angle 1385 •
Tracking 1385 • Setback 1385 • Special Handling
Characteristics 1386
CHAPTER 68
Wheel Alignment Service 1388
Introduction 1388 • Prealignment Inspection 1388 •
Tire Wear Inspection 1388 • Ride Height
Check 1390 • Toe Change 1390 • Torque
Steer 1391 • Suspension Looseness 1391 •
Test Drive 1392 • Tire Checks 1392 •
Inspection Checklist 1393 • Wheel Alignment
Procedures 1393 • Measuring Alignment 1394 •
Measuring Camber 1395 • Measuring Caster 1396 •
Road Crown and Pull 1396 • Measuring
Steering Axis Inclination 1399 • Measuring
Toe 1400 • Adjusting Toe 1401 • Centering a
Steering Wheel 1403 • Recalibrating Steering
Position 1404 • Checking for Toe Change 1404 •
Measuring Turning Radius 1404 • General
Wheel Alignment Rules 1405 • Four-Wheel
Alignment 1406 • Performing a Four-Wheel
Alignment 1407 • Compensating the Alignment
Heads 1408 • Measuring Caster and Camber 1408 •
Adjusting Rear-Wheel Alignment 1409
SECTION 12
DRIVETRAIN
CHAPTER 69
Clutch Fundamentals 1413
Introduction 1413 • Clutch Parts and Operation 1413 •
Clutch Disc 1414 • Pressure Plate 1415 • Types of
Clutch Covers 1415 • Coil Spring Clutch 1415 •
Diaphragm Clutch 1416 • Pilot Bearing or
Bushing 1418 • Release Bearing 1418 • Clutch
Fork 1419 • Clutch Release Methods 1419 • Clutch
Cable 1419 • Hydraulic Clutch Operation 1420 •
Clutch Free Travel 1420 • Dual Clutch
Transmissions 1421
CHAPTER 70
Clutch Diagnosis and Service 1423
Introduction 1423 • Diagnosis of Clutch
Problem 1423 • Clutch Noises 1423 • Transmission
Noise 1424 • Pedal Problems 1424 • Slipping
Clutch 1424 • Dragging Clutch 1425 • Oily
Clutch Facings 1425 • Damaged Friction
Surfaces 1426 • Chattering or Grabbing Clutch 1426 •
Clutch Service 1427 • Servicing Hydraulic
Components 1427 • Clutch Replacement 1428 •
Removing a Transmission or Transaxle 1429 •
Clutch Removal 1429 • Flywheel Removal 1430 •
Flywheel Starter Ring Gear Replacement 1430 •
Flywheel Installation 1431 • Inspect New
Parts 1431 • Pilot Bearing and Bushing
Service 1432 • Clutch Disc Service 1433 •
Clutch Cover/Pressure Plate Service 1433 •
Clutch Installation 1433 • Release Bearing
Service 1435 • Clutch Housing Installation 1436
CHAPTER 71
Manual Transmission Fundamentals 1439
Introduction 1439 • Purpose of a
Transmission 1439 • Using Gears to Increase
Torque 1439 • Gear Ratio 1440 • Transmission
Gear Ranges 1440 • Fifth Gear 1441 •
Overdrive 1441 • Final Drive Ratio 1441 • Gear
Types and Operation 1441 • Spur Gears 1442 •
Helical Gears 1443 • Idler Gears 1443 •
Transmission Parts 1443 • Transmission
Lubrication 1444 • Transmission Bearings 1444 •
Transmission Gears and Shafts 1445 • Synchronizer
Assembly 1445 • Gear Shift Mechanisms 1447 •
Shift Patterns 1448 • Transmission Power Flow 1449 •
Four-Speed Transmission Power Flow 1449 •
Five-Speed Transmission 1452 • Speedometer
Output 1452 • Switches and Sensors 1453
CHAPTER 72
Manual Transmission Diagnosis and Repair 1455
Introduction 1455 • Transmission Diagnosis 1455 •
Lubricant Checks 1456 • Transmission
Removal 1456 • Transmission Disassembly 1457 •
Disassemble the Mainshaft Assembly 1459 •
Synchronizer Service 1459 • Synchronizer
Inspection 1460 • Inspect Blocker Rings 1461 •
Inspect Input Shaft and Mainshaft 1461 • Replace
Worn Bearings 1462 • Reassemble the
Transmission 1462 • Reassemble the
Synchronizers 1462 • Reassemble the
Mainshaft 1462 • End Play 1463 • Needle Bearing
Installation 1463 • Install New Gaskets 1464 •
Complete the Transmission Reassembly 1464 •
Install the Transmission 1465 • Add
Lubricant 1465 • Test Drive 1465
CHAPTER 73
Automatic Transmission Fundamentals 1468
Introduction 1468 • Automatic Transmission
Parts 1468 • Power Transmission 1469 •
Flexplate 1469 • Torque Converter 1470 • Torque
Multiplication 1470 • Torque Converter
Operation 1470 • Stator Clutch Operation 1473 •
Stall Speed 1473 • Lock-Up Torque
Converters 1474 • Planetary Gears 1475 • Simple
Planetary Gearset 1475 • Simple Planetary
Operation 1476 • Simpson Compound Planetary
Operation 1477 • Driving and Holding
Devices 1482 • Clutches 1482 • Clutch
Operation 1482 • One-Way Clutches 1484 • Dog
Clutches 1484 • Accumulator 1486 • Hydraulic
System 1486 • Fluid Pump 1486 • Types of
Pumps 1486 • Transmission Valves 1488 •
Pressure Regulator 1488 • Hydraulic Valve
Body 1489 • Transmission Automatic Shift
Selection 1490 • Automatic Transmission Fluid
(ATF) 1491 • Automatic Transmission
Cooling 1491 • Auxiliary Cooler/Heat
Exchanger 1494 • Park Pawl 1494 • Electronic
Automatic Transmissions 1494 • Electronic
Automatic Transmission Operation 1497 •
Electronic Torque Converter Control 1498 •
Electronic Pressure Control 1498 •
Transmission Shift Control 1498 • Continuously
Variable Transmission 1500 • Hybrid Planetary
Transmission Operation 1501
CHAPTER 74
Automatic Transmission Diagnosis and Service 1503
Introduction 1503 • Automatic Transmission
Identification 1503 • Automatic Transmission
Maintenance 1504 • Transmission Fluid
Service 1504 • Fluid Level 1505 • Check Fluid
Condition 1505 • Changing Transmission
Fluid 1506 • Transmission Filter Service 1506 •
Remove and Replace the Filter 1507 • Refill the
Transmission 1507 • Diagnosing and Repairing
Leaks 1508 • Leaks from the Converter
Housing 1508 • Pump Bushing Replacement 1511 •
Reinstalling the Transmission 1511 • Rear Oil Seal
and Bushing Replacement 1512 • Automatic
Transmission Problem Diagnosis 1512 •
Test-Drive 1513 • Slippage 1513 • Transmission
Drainback 1513 • Noises 1517 • Flexplate 1517 •
Transmission Tests 1517 • Valve Body
Removal 1520 • Electronic Transmission
Service 1522 • More Tests Before Transmission
Removal 1525 • Hybrid Automatic Transmission
Service 1525 • Remanufactured Automatic
Transmissions and Transaxles 1525 • Transmission
Rebuilding 1525 • Transmission Reassembly 1528
CHAPTER 75
Driveline Operation 1531
Introduction 1531 • Driveshaft (RWD) 1531 • Slip
Yoke 1532 • Universal Joints 1533 • Two-Piece
Driveshaft 1534 • Driveshaft Angle 1535 •
Constant Velocity Joints 1536 • Differential 1537 •
Differential Construction 1538 • Differential
Housing 1538 • Differential Operation 1539 •
Differential Gears 1540 • Gearsets 1540 • Axle
Ratio 1541 • Limited-Slip Differential 1541 • Types
of Limited-Slip Differentials 1541 • Viscous
Coupling Differentials 1546 • Drive Axles and
Bearings 1547 • Semi-Floating Axle Bearing
Types 1547 • Independent Rear Suspension
Axles 1548 • Gear Oils 1548 • Four-Wheel
Drive 1549 • Four-Wheel-Drive Axle
Assembly 1549 • Transfer Case 1550 •
Locking Hubs 1552 • All-Wheel Drive 1552
CHAPTER 76
Driveline Diagnosis and Service 1556
Introduction 1556 • Driveshaft Diagnosis 1556 •
Universal Joint Diagnosis and Service 1557 •
Driveshaft Service 1557 • Universal Joint
Disassembly 1557 • Universal Joint Reassembly 1559 •
Driveshaft Installation 1561 • Two-Piece Driveshaft
Service 1561 • Differential and Axle Diagnosis and
Service 1561 • Problem Diagnosis 1561 • Axle
Bearing Diagnosis 1562 • Axle Bearing Service 1563 •
Removing a Bearing-Retained Axle 1563 • Axle
Bearing Replacement 1564 • Axle Bearing
Installation 1565 • Reinstall the Axle 1565 •
Full-Floating Axle Service 1566 • Differential
Pinion Seal Replacement 1567 • Differential
Repair 1568 • Removing a Third Member 1568 •
Disassembling a Salisbury Axle 1569 • Clean and
Inspect Parts 1569 • Differential Reassembly 1570 •
Adjusting a Differential 1570 • Pinion Gear
Depth 1570 • Ring Gear Backlash 1571 • Side
Bearing Preload 1572 • Contact Pattern 1573 •
Backlash Pattern Change 1574 • Pinion Depth
Pattern Change 1574 • Pinion Bearing Preload 1575 •
Ring and Pinion Noise 1575 • Four-Wheel-Drive
Service and Repair 1575
CHAPTER 77
Front-Wheel-Drive (Transaxle and CV Joint)
Fundamentals 1581
Introduction 1581 • Front-Wheel Drive 1581 •
Manual Transaxles 1582 • Shift Linkage 1582 •
Transaxle Differential 1582 • Transaxle Power
Flow 1583 • Automatic Transaxle 1586 • Front
Drive Axles 1587 • Axle Shaft Parts 1587 •
CV Joint Construction 1588 • Axle
Shafts 1590 • CV Joint Boots 1590
CHAPTER 78
Front-Wheel-Drive (Transaxle and CV Joint)
Service 1592
Introduction 1592 • Transaxle and Front-Wheel-
Drive Service and Repair 1592 • Leaking CV Joint
Boot 1592 • CV Joint Boot Service 1592 • Axle
Inspection and Diagnosis 1593 • CV Joint
Diagnosis 1593 • Axle Shaft Removal 1593 •
CV Joint Replacement 1596 • Fixed Joint
Disassembly and Inspection 1597 • CV Joint
Boot Clamps 1599 • Servicing an Inner
Tripod Joint 1600 • Double Offset Plunge
Joints 1601 • Cross Groove Joint Service 1601 •
Rebuilt Halfshafts 1601 • Installing the Axle 1601 •
Transaxle Repair 1601 • Transaxle Removal 1602 •
Manual Transaxle Repair 1602 • Automatic
Transaxle Repair 1602 • Transaxle Differential Side
Bearing Adjustment 1603 • Install the Transaxle 1604
CHAPTER 79
Driveline Vibration and Service 1606
Vibration Analysis 1606 • Types of Vibrations 1607 •
Vibration Test Instruments 1607 • Vibration and
Frequency 1608 • Driveshaft Runout 1610 • Other
Causes of Vibration 1610 • Driveshaft
Balance 1610 • Driveshaft Angle 1612
SECTION 13
HYBRID AND ELECTRIC VEHICLES
CHAPTER 80
Hybrid Electric Vehicle Fundamentals 1617
Introduction to Hybrid Vehicles 1617 • Series and
Parallel Hybrids 1618 • Hybrid Types and
Levels 1622 • Battery Types: Hybrid Electric
Vehicle and Others 1628 • Capacitors in
Hybrid Vehicles 1632 • Supercapacitors/
Ultracapacitors 1632 • Hybrid Brushless
DC Motors 1634 • Hybrid Vehicle Air
Conditioning 1634 • Hybrid Vehicle
Brakes 1634 • Hybrid Planetary Transmission
Operation 1635
CHAPTER 81
Hybrid Vehicle Safety and Service 1640
Hybrid Vehicle Safety and Service 1640 • Hybrid
Electrical Shock Hazard 1644 • High
Voltage Precautions 1646 • Hybrid Battery
Service 1651 • Hybrid High-Voltage Battery
Service 1653 • High-Voltage Battery
Rebuilding 1655
CHAPTER 82
New Vehicle Technologies: Battery Electric, Fuel Cell
Electric, and Hydraulic Hybrid 1660
Introduction to Battery and Fuel Cell Electric
Vehicles 1660 • Battery Electric Vehicles 1660 •
Lithium-Ion Batteries 1663 • Electric
Vehicle Battery Construction 1666 • Plug-In
Hybrids 1668 • Energy Cost and Electric Vehicle
Economy 1668 • Extended Range Electric
Vehicles 1669 • Electric Vehicle Charging
Systems 1670 • Standards For EV Electrical
Connectors 1672 • Motor/Machine for Electric
Vehicles 1675 • EV Motor Types 1675 •
EV Motor Construction 1678 • Inverter/
Converter/Electronic Controls 1679 • Electric
Vehicle Service 1681 • Fuel Cell Electric Vehicles
(FCEVs) 1682 • Hydraulic Hybrid Vehicles 1684
APPENDIX 1687
GLOSSARY 1700
INDEX 1734
NOTE TO STUDENT: Learn to use the index. It has been constantly updated and will help you find what you need in the book.