Automotive Technology A Systems Approach Edition Jack Erjavec ISBN-10: 1-4283-1149-1 ISBN-13: 978-1-4283-1149-7 5th
Cover image from Amazon.com Chapter 1 – Careers in the Automotive Industry - 1 Objectives – 1 The Automotive Industry – 1 Job Classifications – 9 Related Career Opportunities – 12 Training for a Career in Automotive Service – 14 ASE Certification – 15
Chapter 2 – Workplace Skills – 19 Objectives – 19 Seeking and Applying for Employment – 19 Accepting Employment – 26 Working as a Technician – 27 Communications – 29 Solving Problems and Critical Thinking – 31 Professionalism – 32 Interpersonal Relationships – 34
Automotive Technology, Principles, Diagnosis, and Service th 5 Edition James D. Halderman ISBN-10: 0-13-399461-9 ISBN-13: 978-0-13-399461-2
Chapter 2 – Careers in the Automotive Service Industry – 8 The Need For Automotive Technicians – 8 The Need For Continuous Vehicle Service – 8 Technician Work Sites – 9 Technician Job Classifications – 10 Parts-Related Position – 13 Sales Jobs—Used Vehicles; New Vehicles – 14 Other Careers in the Automotive Industry – 14 Typical Automotive Organization Arrangements – 14 Chapter 5 – Technician Certification – 34 Automobile Technician Certification Tests – 34 Questions Often Asked – 36 Test-Taking Tips – 37 Canada’s Automotive Apprenticeship Program (Red Seal) – 40 Re-Certification – 40 Chapter 3 – Starting a Career in the Automotive Industry – 16 Preparing for an Automotive Service Career – 16 Developing an Employment Plan – 17 Preparing a Resume – 18 Preparing a Cover Letter – 19 Contacting Potential Employers – 20 Completing the Employment Application – 20 The Interview – 20 After the Interview – 20 Accepting Employment – 20 Technician Pay Methods – 20 Payroll Deductions – 21 Housing and Living Expenses – 22
Chapter 3 – Automotive Systems – 37 Objectives – 37 Historical Background – 37 Design Evolution – 38 Body Shapes – 39 The Basic Engine – 41 Engine Systems – 43 Electrical and Electronic Systems – 46 Heating and Air-Conditioning Systems – 49 Drivetrain – 50 Running Gear – 53 Hybrid Vehicles – 55 Chapter 4 – Hand Tools and Shop Equipment Objectives – 59 Measuring Systems – 59 Fasteners – 60 Measuring Tools – 67 Hand Tools – 75 Shop Equipment – 86 Power Tools – 88 Jacks and Lifts – 89 Service Information – 92
Becoming a Shop Owner – 22 Chapter 4 – Working as a Professional Service Technician – 24 Professionalism – 24 Communications – 24 What Happens the First Day? – 26 Duties of a Service Technician – 27 Flagging a Work Order – 28 Sublet Repairs – 29 Parts Replacement – 29 Working With A Mentor – 30 Teamwork – 31 Goal Setting and Business Meetings – 31 Advancement Skills – 31 Housekeeping Duties – 31 Self-Management – 32 Job Evaluation – 32 Chapter 1 – Automotive Background and Overview – 1 Historical Background – 1 Bodies – 2 Chassis Systems Overview – 2 Frames – 3 Engine Design Evolution – 4 Engine Systems Overview – 5 Powertrain Overview – 5 Electrical/Electronic Systems Overview – 6 Heating, Ventilation, and Air Conditioning Overview – 6 Eight Areas of Automotive Service – 6 Chapter 8 – Fasteners and Thread Repair – 57 Threaded Fasteners – 58 Metric Bolts – 58 Grades of Bolts – 58 Tensile Strength – 59 Nuts – 60 Taps and Dies – 60 Thread Pitch Gauge – 61 Sheet Metal Screws – 62 Washers – 62 Snap Rings and Clips – 62 How to Avoid Broken Fasteners – 64 Thread Repair Inserts – 64 Chapter 9 – Hand Tools – 68 Wrenches – 68 Ratchets, Sockets, and Extensions – 69 Screwdrivers – 72 Hammers and Mallets – 72 Pliers – 73 Cutters – 75 Punches and Chisels – 75
Chapter 3 – Automotive Systems – 37 Objectives – 37 Historical Background – 37 Design Evolution – 38 Body Shapes – 39 The Basic Engine – 41 Engine Systems – 43 Electrical and Electronic Systems – 46 Heating and Air-Conditioning Systems – 49 Drivetrain – 50 Running Gear – 53 Hybrid Vehicles – 55 Chapter 4 – Hand Tools and Shop Equipment Objectives – 59 Measuring Systems – 59 Fasteners – 60 Measuring Tools – 67 Hand Tools – 75 Shop Equipment – 86 Power Tools – 88 Jacks and Lifts – 89 Service Information – 92
Becoming a Shop Owner – 22 Chapter 4 – Working as a Professional Service Technician – 24 Professionalism – 24 Communications – 24 What Happens the First Day? – 26 Duties of a Service Technician – 27 Flagging a Work Order – 28 Sublet Repairs – 29 Parts Replacement – 29 Working With A Mentor – 30 Teamwork – 31 Goal Setting and Business Meetings – 31 Advancement Skills – 31 Housekeeping Duties – 31 Self-Management – 32 Job Evaluation – 32 Chapter 1 – Automotive Background and Overview – 1 Historical Background – 1 Bodies – 2 Chassis Systems Overview – 2 Frames – 3 Engine Design Evolution – 4 Engine Systems Overview – 5 Powertrain Overview – 5 Electrical/Electronic Systems Overview – 6 Heating, Ventilation, and Air Conditioning Overview – 6 Eight Areas of Automotive Service – 6 Chapter 8 – Fasteners and Thread Repair – 57 Threaded Fasteners – 58 Metric Bolts – 58 Grades of Bolts – 58 Tensile Strength – 59 Nuts – 60 Taps and Dies – 60 Thread Pitch Gauge – 61 Sheet Metal Screws – 62 Washers – 62 Snap Rings and Clips – 62 How to Avoid Broken Fasteners – 64 Thread Repair Inserts – 64 Chapter 9 – Hand Tools – 68 Wrenches – 68 Ratchets, Sockets, and Extensions – 69 Screwdrivers – 72 Hammers and Mallets – 72 Pliers – 73 Cutters – 75 Punches and Chisels – 75
Hacksaws – 77 Basic Hand Tool List – 78 Tool Sets and Accessories – 78 Seal Pliers and Drivers – 79 Electrical Hand Tools – 79 Safety Tips For Using Hand Tools – 80 Hand Tool Maintenance – 80 Chapter 10 – Power Tools and Shop Equipment – 82 Air Compressor – 82 Air and Electrically Operated Tools – 82 Trouble Lights – 84 Bench/Pedestal Grinder – 84 Bench Vise – 85 Hydraulic Presses – 85 Portable Crane and Chain Hoist – 85 Engine Stands – 86 Care and Maintenance of Shop Equipment – 86 Chapter 11 – Vehicle Lifting and Hoisting – 91 Floor Jack – 91 Creepers – 92 Vehicle Hoists – 92 Drive-On Ramps – 94 Chapter 12 – Measuring Systems and Tools – 97 English Customary Measuring System – 97 Metric System of Measure – 98 Linear Measurements (Tape Measure/Rule) – 98 Micrometer – 99 Telescopic Gauge – 100 Small-Hole Gauge – 100 Vernier Dial Caliper – 102 Feeler Gauge – 102 Straightedge – 103 Dial Indicator – 103 Dial Bore Gauge – 103 Depth Micrometer – 103 Chapter 5 – Diagnostic Equipment and Special Tools Objectives – 99 Engine Repair Tools – 99 Electrical/Electronic System Tools – 106 Engine Performance Tools – 110 Transmission and Driveline Tools – 119 Suspension and Steering Tools – 121 Brake System Tools – 124 Heating and Air-Conditioning Tools – 128 Chapter 6 – Working Safely in the Shop – 134 Objectives – 134 Personal Safety – 134 Tool and Equipment Safety – 138 Work Area Safety – 144
Chapter 6 – Shop Safety – 41 Personal Protective Equipment – 41 Safety Tips For Technicians – 42 Cleaning Methods and Processes – 43 Electrical Cord Safety – 44
Regulations – 148 Right-to-Know Law – 148
Chapter 7 – Preventative Maintenance and Basic Services – 153 Objectives – 153 Repair Orders – 153 Vehicle Identification – 156 Preventative Maintenance – 157 Basic Services – 159 Hybrid Vehicles – 180 Additional PM Checks – 182
Fire Extinguishers – 45 Fire Blankets – 46 First Aid and Eye Wash Stations – 46 Chapter 7 – Environmental and Hazardous Materials – 48 Hazardous Waste – 48 Federal and State Laws – 48 Asbestos Hazards – 49 Used Brake Fluid – 50 Used Oil – 50 Solvents – 51 Coolant Disposal – 52 Lead-Acid Battery Waste – 53 Fuel Safety and Storage – 53 Airbag Handling – 54 Used Tire Disposal – 54 Air-Conditioning Refrigerant Oil Disposal – 54 Chapter 15 – Service Information – 119 Vehicle Service History Records – 120 Owner’s Manuals – 120 Lubrication Guides – 120 Service Manuals – 120 Advantages of Hard Copy Versus Electronic Service Information – 122 Disadvantages of Hard Copy Versus Electronic Service Information – 122 Labor Guide Manuals – 122 Electronic Service Information – 122 Hotline Services – 124 Specialty Repair Manual – 124 Aftermarket Supplies Guides and Catalogs – 124 Chapter 16 – Vehicle Identification and Emission Ratings – 125 Parts of a Vehicle – 125 Front-Wheel Drive Versus Rear-Wheel Drive – 125 Vehicle Identification – 126 Vehicle Safety Certification Label – 126 VECI Label – 126 Emission Standards in the United States – 127 Calibration Codes – 128 Casting Numbers – 128 Chapter 17 – Preventative Maintenance and Service Procedures – 130 Preventative Maintenance – 130 Getting Ready for Service – 130 Safety Inspection – 131 Windshield Wiper and Washer Fluid Service – 131 Cabin Filter Replacement – 132 Air Filter Inspection/Replacement – 132 Brake Fluid Inspection – 133 Engine Oil Inspection – 134
Chapter 8 – Basic Theories and Math Objectives – 186 Matter – 186 Energy – 188 Volume – 191 Force – 193 Time – 195 Motion – 195 Work – 197 Waves and Oscillations – 202 Light – 205 Liquids – 205 Gases – 207 Heat – 209 Chemical Properties – 211 Electricity and Electromagnetism – 215
Chapter 9 – Automotive Engine Designs and Diagnosis – 220 Objectives – 220 Introduction to Engine – 220 Engine Classifications – 221 Engine Measurement and Performance – 228 Diesel Engines – 232 Other Automotive Power Plants – 236
Cooling System Inspection – 136 Automatic Transmission Fluid Check – 138 Power Steering Fluid – 139 Accessory Drive Belt Inspection – 139 Tire and Wheel Service – 140 Chassis Lubrication – 143 Differential Fluid Check – 144 Manual Transmission/Transaxle Lubricant Check – 144 Under-Vehicle Inspection – 145 Chapter 13 – Scientific Principles and Materials – 105 Scientific Method – 105 Energy Principles – 106 Torque – 106 Work – 106 Power – 107 Horsepower – 107 Newton’s Law of Motion – 108 Kinetic Energy – 108 Inertia – 109 Mechanical Principles – 109 Heat and Temperature – 110 Acids and Bases – 111 Gas Laws – 112 Sound and Acoustics – 112 Plastics – 112 Iron and Steel – 113 SAE Steel Designations – 113 Aluminum and Aluminum Alloys – 113 Chapter 14 – Math, Charts, and Calculations – 114 Decimals – 115 Percentage – 115 Scientific Notation – 115 Adding and Subtracting – 115 Fractions – 116 Multiplying and Dividing – 116 Mathematical Formulas – 116 Fuel Economy Calculator – 116 Gear Ratios – 117 Graphs, Charts, and Diagrams – 117 Chapter 18 – Gasoline Engine Operation, Parts, and Specifications – 146 Purpose and Function – 147 Energy and Power – 147 Engine Construction Overview – 147 Engine Parts and Systems – 147 Four-Stroke Cycle Operation – 149 Engine Classification and Construction – 149
Engine Diagnostics – 241 Evaluating the Engine’s Condition – 247 Noise Diagnosis – 249
Chapter 10 – Engine Disassembly and Cleaning – 255 Objectives – 255 Removing an Engine – 255 Engine Disassembly and Inspection – 262 Cleaning Engine Parts – 264 Crack Detection – 269
Chapter 11 – Lower End Theory and Service – 275 Objectives – 275 Short Block Disassembly – 276 Cylinder Block – 279 Cylinder Block Reconditioning – 281
Compression Ratio – 155 Torque and Horsepower – 157 Chapter 19 – Diesel Engine Operation and Diagnosis – 158 Diesel Engines – 158 Three Phases of Combustion – 161 Fuel Tank and Lift Pump – 161 Injection Pump – 161 Heui System – 162 Diesel Injector Nozzles – 164 Glow Plugs – 164 Engine-Driven Vacuum Pump – 166 Diesel Fuel Heaters – 166 Accelerator Pedal Position Sensor – 166 Diesel Engine Turbochargers – 166 Exhaust Gas Recirculation – 167 Diesel Particulate Matter – 168 Diesel Oxidation Catalyst – 168 Diesel Exhaust Particulate Filter – 169 Selective Catalytic Reduction – 170 Diesel Exhaust Smoke Diagnosis – 171 Diesel Performance Diagnosis – 172 Compression Testing – 173 Glow Plug Resistance Balance Test – 173 Injector Pop Testing – 173 Diesel Emission Testing – 174 Chapter 28 – Engine Removal and Disassembly – 261 Engine Repair Options – 262 Engine Removal – 263 Engine Disassembly – 264 Disassembly of the Short Block – 266 Rotating Engine Assemblies Removal – 267 Cylinder Head Disassembly – 267 Chapter 29 – Engine Cleaning and Crack Detection – 272 Introduction – 272 Mechanical Cleaning – 272 Chemical Cleaners – 273 Spray and Steam Washing – 274 Thermal Cleaning – 274 Tank and Vapor Cleaning – 275 Ultrasonic and Vibratory Cleaning – 275 Crack Detection – 276 Crack Repair – 276 Chapter 32 – Camshafts and Valve Trains – 314 Camshaft – 315 Camshaft Design – 315 Camshaft Drives – 317 Camshaft Movement – 319 Rocker Arms – 320
Crankshaft – 292 Crankshaft Inspection and Rebuilding – 294 Installing Main Bearings and Crankshaft – 296 Piston and Piston Rings – 302 Installing Pistons and Connecting Rods – 307 Inspection of Camshaft and Related Parts – 310 Installation of Camshaft and Related Parts – 311 Crankshaft and Camshaft Timing – 312 Oil Pumps – 313 Oil Pump Service – 315 Installing the Oil Pump – 318
Chapter 12 – Upper End Theory and Service Objectives – 322 Cylinder Head – 322 Combustion Chamber – 323 Intake and Exhaust Valves – 324 Variable Valve Timing – 330 Cylinder Head Disassembly – 335 Inspection of the Valve Train – 339 Servicing Cylinder Heads – 344 Reconditioning Valves – 347 Valve Guide Reconditioning – 349
Overhead Camshaft Valve Trains – 323 Camshaft Specifications – 323 Lifters or Tappets – 326 Valve Train Lubrication – 327 Valve Train Problem Diagnosis – 328 Camshaft Removal – 328 Measuring Camshafts – 329 Selecting a Camshaft – 329 Variable Valve Timing – 330 Variable Lift and Cylinder Deactivation Systems – 334 Chapter 33 – Pistons, Rings, and Connecting Rods – 336 Pistons – 337 Piston Construction – 337 Piston Pins – 340 Piston Pin Retaining Methods – 341 Piston Rings – 342 Piston Ring Construction – 344 Connecting Rods – 345 Connecting Rod Service – 347 Piston and Rod Assembly – 348 Piston Ring Service – 349 Chapter 34 - Engine Blocks – 351 Engine Blocks – 351 Engine Block Service – 356 Block Preparation For Assembly – 362 Chapter 35 - Crankshafts, Balance Shafts, and Bearings – 364 Crankshaft – 365 Crankshaft Construction – 366 Crankshaft Oiling Holes – 367 Engine Crankshaft Types – 367 Counterweights – 369 Externally and Internally Balanced Engines – 369 Engine Balance – 370 Balance Shafts – 371 Crankshaft Service – 372 Engine Bearings – 374 Bearing Clearance – 377 Camshaft Bearings – 379 Chapter 30 – Cylinder Head and Valve Guide Service – 280 Introduction – 280 Cylinder Heads – 280 Intake and Exhaust Ports – 283 Cylinder Head Passages – 284 Cylinder Head Servicing – 285 Aluminum Cylinder Head Straightening – 286 Cylinder Head Resurfacing – 287 Intake Manifold Alignment – 288 Valve Guides – 289
Reconditioning Valve Seats – 351 Valve Stem Seals – 354 Assembling the Cylinder Head – 355
Chapter 13 – Engine Sealing and Reassembly – 361 Objectives – 361 Torque Principles – 361 Gaskets – 364 Specific Engine Gaskets – 367 Adhesives, Sealants, and Other Chemical Sealing Materials – 371 Oil Seals – 374 Engine Reassembly – 375 Installing the Engine – 385
Valve Guide Replacement – 291 Chapter 31 – Valve and Valve Seat Service – 293 Intake and Exhaust Valves – 294 Valve Seats – 296 Valve Fault Diagnosis – 296 Valve Springs – 297 Valve Keepers and Rotators – 299 Valve Reconditioning Procedure – 300 Valve Face Grinding – 300 Valve Seat Reconditioning – 301 Valve Guide Pilots – 303 Valve Seat Grinding Stones – 304 Valve Seat Cutters – 305 Valve Seat Testing – 305 Valve Seat Replacement – 306 Valve Stem Height – 307 Installed Height – 307 Valve Stem Seals – 308 Installing the Valves – 310 Chapter 36 - Gaskets and Sealants – 381 Introduction – 381 Head Gaskets – 381 Cover Gasket Materials – 383 Gasket Failures – 384 Oil Seals – 385 Assembly Sealants – 385 Chapter 37 - Engine Assembly and Dynamometer Testing – 388 Details, Details, Details – 388 Short Block Preparation – 388 Cylinder Head Preparation – 390 Trial Assembly – 391 Final Short Block Assembly – 392 Installing the Camshaft – 397 Piston/Rod Installation – 397 Cylinder Head Installation – 400 Torque-To-Yield Head Bolts – 403 Valve Train Assembly – 404 Final Assembly – 406 Dynamometer Testing – 410 Chapter 38 - Engine Installation and Break-In – 415 Preinstallation Checklist – 415 Transmission Installation – 415 Dressing the Engine – 417 Engine Installation – 417 Engine Start – 418 Break-In Precautions – 419
Chapter 14 – Lubricating and Cooling Systems – 393 Objectives – 393 Lubrication System – 393 Engine Lubrication Diagnosis and Service – 398 Cooling Systems – 400 Cooling System Diagnosis – 409 Inspection of Cooling System – 411 Testing for Leaks – 416 Cooling System Service – 420
Chapter 20 – Coolant – 175 Types of Coolant – 176 Water – 178 Coolant Freezing/Boiling Temperatures – 178 Coolant Testing – 179 Coolant Replacement Issues – 181 Chapter 21 – Cooling System Operation and Diagnosis – 182 Cooling System – 182 Cooling System Operation – 183 Thermostats – 183 Radiators – 186 Pressure Caps – 187 Coolant Recovery Systems – 188 Water Pumps – 189 Coolant Flow in the Engine – 190 Cooling Fans – 191 Heater Cores – 192 Cooling System Testing – 192 Coolant Temperature Warning Light – 194 Cooling System Inspection – 194 Cooling System Service – 195 Chapter 22 – Engine Oil – 198 Introduction – 198 Properties of Engine Oil – 198 SAE Rating – 199 API Rating – 199 ILSAC Oil Rating – 200 European Oil Rating System – 200 Japanese Oil Ratings – 201 Engine Oil Additives – 201 Oil Brand Compatibility – 202 Synthetic Oil – 202 Vehicle-Specific Specifications – 203 High Mileage Oils – 204 Oil Filters – 204 Oil Change – 204 Chapter 23 – Lubrication System Operation and Diagnosis – 210 Introduction – 211 Lubrication Principles – 211 Engine Lubrication Systems – 211 Oil Pumps – 212 Oil Passages – 215 Oil Pans – 217 Dry Sump Systems – 217 Oil Coolers – 218 Chapter 27 – In-Vehicle Engine Service – 252 Thermostat Replacement – 253 Water Pump Replacement – 253 Intake Manifold Gasket Inspection – 254 Intake Manifold Gasket Replacement – 254
Timing Belt Replacement – 255 Hybrid Engine Precautions – 255
Chapter 15 – Basics of Electrical Systems – 433 Objectives – 433 Basics of Electricity – 433 Electrical Terms – 435 Ohm’s Law – 438 Circuits – 440 Circuit Components – 444
Chapter 16 – General Electrical System Diagnostics and Service – 457 Objectives – 457 Electrical Problems – 457 Electrical Wiring Diagrams – 460 Electrical Testing Tools – 461 Using Multimeters – 465 Using Lab Scopes – 474 Testing Basic Electrical Components – 478 Troubleshooting Circuits – 482 Testing for Common Problems – 486 Connector and Wire Repairs – 490
Chapter 39 – Electrical Fundamentals – 420 Introduction – 420 Electricity – 421 How Electrons Move Through a Conductor – 423 Units of Electricity – 424 Sources of Electricity – 425 Conductors and Resistance – 426 Resistors – 427 Chapter 40 – Electrical Circuits and Ohm’s Law – 428 Circuits – 428 Circuit Fault Types – 429 Ohm’s Law – 431 Watt’s Law – 432 Chapter 41 – Series, Parallel, and SeriesParallel Circuits – 434 Series Circuits – 434 Ohm’s Law and Series Circuits – 434 Kirchhoff’s Voltage Law – 435 Series Circuit Laws – 436 Series Circuit Examples – 437 Parallel Circuits – 438 Kirchhoff’s Current Law – 438 Parallel Circuit Laws – 438 Determining Total Resistance in a Parallel Circuit – 438 Parallel Circuit Examples – 440 Series-Parallel Circuits – 441 Solving Series-Parallel Circuit Problems – 442 Series-Parallel Circuit Examples – 442 Chapter 42 – Circuit Testers and Digital Meters – 444 Fused Jumper Wire – 444 Test Lights – 445 Logic Probe – 446 Digital Multimeters – 446 Inductive Ammeters – 450 Diode Check, Pulse Width, and Frequency – 450 Electrical Unit Prefixes – 451 How To Read Digital Meters – 452 Chapter 43 – Oscilloscopes and Graphing Multimeters – 460 Types of Oscilloscopes – 461 Scope Setup and Adjustment – 462 DC and AC Coupling – 462 Pulse Trains – 463 Number of Channels – 464
Chapter 17 – Batteries: Theory, Diagnosis, and Service – 501 Objectives – 501 Introduction – 501 Basic Battery Theory – 501 Battery Ratings – 504 Common Types of Batteries – 505 High-Voltage Batteries – 507 Lead-Acid Batteries – 507 High-Voltage Batteries – 507 Servicing and Testing Batteries – 513 Nickel-Based Batteries – 524 Lithium-Based Batteries – 526 Isolating High-Voltage Systems – 528 Jump-Starting – 530
Triggers – 464 Using a Scope – 465 Graphing Multimeter – 466 Graphing Scan Tools – 466 Chapter 44 – Automotive Wiring and Wire Repair – 467 Automotive Wiring – 467 Ground Wires – 468 Battery Cables – 469 Jumper Cables – 469 Fuses and Circuit Protection Devices – 469 Terminals and Connectors – 474 Wire Repair – 475 Electrical Conduit – 477 Chapter 45 – Wiring Schematics and Circuit Testing – 479 Wiring Schematics and Symbols – 479 Schematic Symbols – 480 Relay Terminal Identification – 485 Locating an Open Circuit – 486 Common Power or Ground – 487 Circuit Troubleshooting Procedure – 488 Locating a Short Circuit – 489 Electrical Troubleshooting Guide – 491 Step-By-Step Troubleshooting Procedure – 492 Chapter 47 – Magnetism and Electromagnetism – 498 Fundamentals of Magnetism – 498 Electromagnetism – 500 Uses of Electromagnetism – 502 Electromagnetic Induction – 504 Ignition Coils – 504 Electromagnetic Interference – 506 Chapter 50 – Batteries – 538 Introduction – 538 Battery Construction – 538 How a Battery Works – 540 Specific Gravity – 540 Valve Regulated Lead-Acid Batteries – 542 Causes and Types of Battery Failure – 542 Battery Ratings – 542 Battery Sizes – 543 Chapter 51 – Battery Testing and Service – 544 Battery Service Safety Considerations – 545 Symptoms of a Weak or Defective Battery – 545 Battery Maintenance – 545 Battery Voltage Test – 546 Hydrometer Testing – 547 Battery Load Testing – 547 Electric Conductance Testing – 548 Battery Charging – 549 Battery Charge Time – 550
Jump Starting – 550 Battery Electrical Drain Test – 552 Battery Symptom Guide – 555 Chapter 18 – Starting and Traction Motor Systems – 536 Objectives – 536 Basics of Electromagnetism – 536 Starting Motors – 539 Starting System – 542 Starter Circuit – 543 Control Circuit – 546 Starting System Testing – 547 Starter Motor Service – 554
Chapter 19 – Charging Systems – 571 Objectives – 571 Alternating Current Charging Systems – 571 AC Generator Operation – 575 Voltage Regulation – 577 New Developments – 580 Preliminary Checks – 582 General Testing Procedures – 586 AC Generator Service – 588
Chapter 52 – Cranking System – 556 Cranking Circuit – 556 Computer-Controlled Starting – 557 Starter Motor Operation – 558 How the Starter Motor Works – 560 Gear-Reduction Starters – 561 Starter Drives – 562 Positive Engagement Starters – 564 Solenoid-Operated Starters – 564 Chapter 53 – Cranking System Diagnosis and Service – 566 Starting System Troubleshooting Procedure – 566 Voltage Drop Testing – 566 Control Circuit Testing – 568 Starter Amperage Test – 569 Starter Removal – 569 Starter Motor Service – 570 Bench Testing – 571 Starter Installation – 571 Starter Drive-To-Flywheel Clearance – 571 Starting System Symptom Guide – 572 Chapter 54 – Charging System – 577 Principles of Alternator Operation – 578 Alternator Construction – 578 Alternator Overrunning Pulleys – 578 Alternator Components and Operation – 579 How an Alternator Works – 581 Alternator Output Factors – 583 Alternator Voltage Regulation – 583 Alternator Cooling – 585 Computer-Controlled Alternators – 585 Chapter 55 – Charging System Diagnosis and Service – 587 Charging System Testing and Service – 588 Drive Belt Inspection and Adjustment – 589 AC Ripple Voltage Check – 590 Testing AC Ripple Current – 590 Charging System Voltage Drop Testing – 591 Alternator Output Test – 592 Minimum Required Alternator Output – 593 Alternator Removal – 593 Alternator Disassembly – 594 Testing the Rectifier – 596 Reassembling the Alternator – 596 Remanufactured Alternators – 597 Alternator Installation – 597
Chapter 20 – Lighting Systems – 596 Objectives – 596 Lamps – 596 Headlights – 597 Headlight Service – 605 Other Light Bulbs – 610 Interior Light Assemblies – 610 Rear Exterior Lights – 612 Basic Lighting System Diagnosis – 619
Chapter 21 – Electrical Instrumentation – 624 Objectives – 624 Instrument Panels – 624 Gauges – 625 Basic Information Gauges – 627 Indicator and Warning Devices – 630 Driver Information Centers – 635 General Diagnosis and Testing – 637
Chapter 22 – Basics of Electronics and Computer Systems – 640 Objectives – 640 Capacitors – 640 Semiconductors – 642 Computer Basics – 646 On-Board Diagnostics – 656
Chapter 56 – Lighting and Signaling Service – 604 Introduction – 605 Exterior Lighting – 605 Bulb Numbers – 605 Brake Lights – 608 Turn Signals – 610 Headlights – 611 High-Intensity Discharge Headlights – 614 LED Headlights – 615 Headlight Aiming – 615 Adaptive Front Lighting System – 616 Daytime Running Lights – 617 Dimmer Switches – 617 Courtesy Lights – 617 Illuminated Entry – 617 Fiber Optics – 617 Automatic Dimming Mirrors – 617 Feedback – 620 Lighting System Diagnosis – 620 Lighting System Symptom Guide – 620 Chapter 57 – Driver Information and Navigation Service – 625 Dash Warning Symbols – 625 Oil Pressure Warning Devices – 628 Temperature Lamp Diagnosis – 628 Brake Warning Lamp – 628 Analog Dash Instruments – 629 Network Communication – 629 Stepper Motor Analog Gauges – 629 Head-Up Display – 630 Night Vision – 632 Digital Electronic Display Operation – 633 Electronic Speedometers – 635 Electronic Odometers – 636 Electronic Fuel Level Gauges – 637 Navigation and GPS – 637 Onstar – 639 Backup Camera – 640 Backup Sensors – 641 Lane Departure Warning System – 641 Electronic Dash Instrument Diagnosis and Troubleshooting – 642 Maintenance Reminder Lamps – 642 Chapter 46 – Capacitance and Capacitors – 493 Capacitance – 493 Capacitor Construction and Operation – 494 Factors of Capacitance – 495 Uses For Capacitance – 495 Capacitors in Circuits – 496 Chapter 48 – Electronic Fundamentals – 509
Protecting Electronic Systems – 662 Diagnosing BCMs – 663 Testing Electronic Circuits and Components – 664
Chapter 23 – Electrical Accessories – 670 Objectives – 670 Windshield Wiper/Washer Systems – 670 Horns/Clocks/Cigarette Lighter Systems – 677 Cruise (Speed) Control Systems – 678 Sound Systems – 682 Power Lock Systems – 684 Power Windows – 684 Power Seats – 687 Power Mirror System – 690 Rear-Window Defrosters and Heated Mirror
Summary of Semiconductors – 510 Diodes – 510 Zener Diodes – 511 High-Voltage Spike Protection – 512 Diode Ratings – 513 Light-Emitting Diodes – 513 Photodiodes – 514 Photoresistors – 514 Silicon-Controlled Rectifiers – 515 Thermistors – 515 Rectifier Bridges – 515 Transistors – 516 Field-Effect Transistors – 517 Phototransistor – 518 Integrated Circuits – 518 Transistor Gates – 518 Operational Amplifiers – 519 Electronic Component Failure Causes – 519 How to Test Diodes and Transistors – 520 Converters and Inverters – 521 Electrostatic Discharge – 523 Chapter 49 – CAN and Network Communications – 524 Module Communications and Networks – 524 Network Fundamentals – 524 Module Communications Configuration – 525 Network Communications Classifications – 526 General Motors Communications Protocols – 527 Ford Network Communications Protocols – 529 Chrysler Communications Protocols – 530 Controller Area Network – 530 Honda/Toyota Communications – 532 European BUS Communications – 532 Network Communications Diagnosis – 534 OBD-II Data Link Connector – 536 Chapter 71 – Computer Fundamentals – 812 Computer Fundamentals – 812 Computer Functions – 813 Digital Computers – 814 Computer Input Sensors – 816 Computer Outputs – 816 Chapter 58 – Horn, Wiper, and Blower Motor Circuits – 646 Horns – 646 Windshield Wiper and Washer System – 648 Rain Sense Wiper System – 653 Blower Motor – 654 Electrical Accessory Symptom Guide – 656 Chapter 59 – Accessory Circuits – 657 Cruise Control – 658 Troubleshooting Cruise Control – 659 Electronic Throttle Cruise Control – 659
Systems – 691 Other Electronic Systems – 692 Security and Antitheft Devices – 697
Chapter 24 – Restraint Systems: Theory, Diagnosis, and Service – 704 Objectives – 704 Seat Belts – 704 Seat Belt Service – 706 Air Bags – 708 Electrical System Components – 712 Diagnosis – 716 Servicing the Air Bag System – 718 Other Protection Systems – 719 Chapter 25 – Engine Performance Systems – 725 Objectives – 725 Ignition Systems – 725 Fuel System – 728 Air Induction System – 729 Emission Control Systems – 729 Engine Control Systems – 731 On-Board Diagnostic Systems – 736
Radar Cruise Control – 659 Precollision System – 662 Heated Rear Window Defoggers – 662 Heated Mirrors – 663 Homelink Garage Door Opener – 664 Power Windows – 664 Power Seats – 666 Electrically Heated Seats – 668 Heated and Cooled Seats – 669 Heated Steering Wheel – 669 Adjustable Pedals – 670 Outside Folding Mirrors – 670 Electric Power Door Locks – 671 Keyless Entry – 671 Antitheft Systems – 678 Electrical Accessory Symptom Guide – 683 Chapter 61 – Audio System Operation and Diagnosis – 698 Audio Fundamentals – 699 Radios and Receivers – 700 Antennas – 700 Antenna Diagnosis – 701 Speakers – 702 Speaker Types – 704 Sound Levels – 704 Crossovers – 704 Aftermarket Sound System Upgrade – 705 Voice Recognition – 706 Bluetooth – 707 Satellite Radio – 707 Radio Interference – 708 Chapter 60 – Airbags and Pretensioner Circuits – 686 Safety Belts and Retractors – 687 Front Airbags – 687 Airbag Diagnosis Tools and Equipment – 691 Airbag System Service – 693 Driver Side Airbag Module Replacement – 694 Safety When Manually Deploying Airbags – 695 Occupant Detection Systems – 695 Seat and Side Curtain Airbags – 696 Event Data Recorders – 697 Chapter 87 – On-Board Diagnosis – 957 On-Board Diagnostics Generation-II (OBD-II) Systems – 958 Diagnostic Executive and Task Manager – 958 Monitors – 959 OBD-II Monitor Information – 959 Enabling Criteria – 960 OBD-II DTC Numbering Designation – 961 OBD-II Freeze-Frame – 962
OBD-II Monitoring Capabilities – 740 OBD-II Self-Diagnostics – 747 Basic Diagnosis of Electronic Engine Control Systems – 749 Diagnosing OBD-II Systems – 751 Diagnosing OBD-I Systems – 759
Chapter 26 – Detailed Diagnosis and Sensors – 764 Objectives – 764 Using Scan Tool Data – 764 Symptom-Based Diagnosis – 768 Basic Testing – 770 Diagnosis of Computer Voltage Supply and Ground Wires – 771 Switches – 774 Temperature Sensors – 775 Pressure Sensors – 778 Mass Airflow (MAF) Sensors – 783 Oxygen Sensors (O2S) – 785 Position Sensors – 794 Speed Sensors – 797 Position/Speed Sensors – 799 Knock Sensor (KS) – 802 Computer Outputs and Actuators – 803 Testing Actuators – 804
PCM Tests – 963 Global OBD-II – 964 Diagnosing Problems Using Mode Six – 964 Chapter 88 – Scan Tools and Engine Performance Diagnosis – 965 The Eight-Step Diagnostic Procedure – 966 Scan Tools – 971 Retrieval of Diagnostic Information – 971 Troubleshooting Using Diagnostic Trouble Codes – 972 Flash Code Retrieval On OBD-I General Motors Vehicles – 973 Retrieving Ford Diagnostic Codes – 973 Flash Code Retrieval On Chrysler Vehicles – 975 OBD-II Diagnosis – 975 OBD-II Active Tests – 977 Service/Flash Programming – 978 Manufacturer’s Diagnostic Routines – 980 Completing System Repairs – 980 Procedures For Resetting the PCM – 981 Road Test (Drive Cycle – 981 Chapter 26 – Engine Condition Diagnosis – 237 Typical Engine-Related Complaints – 237 Engine Smoke Diagnosis – 237 The Driver is Your Best Resource – 238 Visual Checks – 238 Engine Noise Diagnosis – 240 Oil Pressure Testing – 241 Oil Pressure Warning Lamp – 242 Compression Test – 242 Wet Compression Test – 243 Running (Dynamic) Compression Test – 244 Cylinder Leakage Test – 244 Cylinder Power Balance Test – 245 Power Balance Test Procedure – 245 Vacuum Tests – 245 Exhaust Restriction Test – 247 Testing Back Pressure with a Vacuum Gauge – 248 Testing Back Pressure with a Pressure Gauge – 248 Diagnosing Head Gasket Failure – 248 Dash Warning Lights – 249 Chapter 72 – Temperature Sensors – 819 Engine Coolant Temperature Sensors – 819 Testing the Engine Coolant Temperature Sensor – 820 Intake Air Temperature Sensor – 823 Testing the Intake Air Temperature Sensor – 825 Transmission Fluid Temperature Sensor – 825 Cylinder Head Temperature Sensor – 826 Engine Fuel Temperature (EFT) Sensor – 826
Chapter 27 – Ignition Systems – 810 Objectives – 810 Basic Circuitry – 810 Ignition Components – 813 Spark Plugs – 815 Triggering and Switching Devices – 819 Engine Position Sensors – 820
Exhaust Gas Recirculation (EGR) Temperature Sensor – 826 Engine Oil Temperature Sensor – 827 Temperature Sensor Diagnostic Trouble Codes – 827 Chapter 73 – Throttle Position (TP) Sensors – 828 Throttle Position Sensor Construction – 828 TP Sensor Computer Input Functions – 829 PCM Uses For the TP Sensor – 829 Testing the Throttle Position Sensor – 830 TP Sensor Diagnostic Trouble Codes – 831 Chapter 74 – MAP/BARO Sensors – 832 Air Pressure—High and Low – 833 Principles of Pressure Sensors – 833 Construction of Manifold Absolute Pressure (MAP) Sensors – 834 PCM Uses of the MAP Sensor – 835 Barometric Pressure Sensors – 837 Testing the MAP Sensor – 837 Fuel-Rail Pressure Sensor – 838 MAP/BARO Diagnostic Trouble Codes – 838 Chapter 75 – Mass Airflow Sensors – 840 Airflow Sensors – 840 Mass Airflow Sensor Types – 840 Karman Vortex Sensors – 841 PCM Uses For Airflow Sensors – 842 Testing Mass Airflow Sensors – 842 MAF Sensor Contamination – 844 MAF-Related Diagnostic Trouble Codes – 844 Chapter 76 – Oxygen Sensors – 845 Oxygen Sensors – 846 Titania Oxygen Sensor – 848 PCM Uses of the Oxygen Sensor – 849 Oxygen Sensor Diagnosis – 850 Post Catalytic Converter Oxygen Sensor Testing – 853 Wide-Band Oxygen Sensor – 853 Dual Cell Planar Wide-Band Sensor Operation – 855 Dual Cell Diagnosis – 856 Single Cell Wide-Band Oxygen Sensors – 857 Wide-Band Oxygen Pattern Failures – 858 Oxygen Sensor-Related Diagnostic Trouble Codes – 859 Chapter 69 – Ignition System Components and Operation – 781 Ignition System – 782 Ignition Switching and Triggering – 783 Distributor Ignition – 785 Waste-Spark Ignition Systems – 787 Coil-On-Plug Ignition – 788
Distributor Ignition System Operation – 822 Electronic Ignition Systems – 823 EI System Operation – 827
Knock Sensors – 791 Ignition Control Circuits – 793
Chapter 28 – Ignition System Diagnosis and Service – 836 Objectives – 836 Misfires – 836 General Ignition System Diagnosis – 837 Visual Inspection of Ignition Systems – 837 No-Start Diagnosis – 842 Diagnosing with an Engine Analyzer – 844 Diagnosing with a DSO or GMM – 852 Ignition Timing – 854 Basic Primary Circuit Components – 857 Distributor Service – 863 Secondary Circuit Testing and Service – 863
Chapter 70 - Ignition System Diagnosis and Service – 794 Checking for Spark – 794 Ignition Coil Testing – 795 Ignition Sensor Testing – 796 Spark Plug Wire Inspection – 799 Spark Plugs – 801 Ignition Timing – 804 Firing Order – 805 Distributor Indexing – 805 No-Start Diagnosis – 806 Ignition Scope Testing – 807 Scope-Testing a Waste-Spark System – 811 Scope-Testing a COP System – 811 Ignition System Symptom Guide – 811 Chapter 77 – Fuel Pumps, Lines, and Filters – 860 Fuel Delivery System – 860 Fuel Tanks – 860 Rollover Leakage Protection – 862 Fuel Lines – 862 Electric Fuel Pumps – 864 Fuel Filters – 869 Fuel-Pump Testing – 870 Fuel-Pump Current Draw Test – 873 Fuel-Pump Placement – 874 Chapter 78 – Fuel-Injection Components and Operation – 875 Electronic Fuel-Injection Operation – 875 Speed-Density Fuel-Injection Systems – 876 Mass Airflow Fuel-Injection Systems – 877 Throttle-Body Injection – 877 Port-Fuel Injection – 878 Fuel-Pressure Regulator – 879 Vacuum-Biased Fuel-Pressure Regulator – 880 Electronic Returnless Fuel System – 881 Mechanical Returnless Fuel System – 881 Demand Delivery System (DDS) – 881 Fuel Injectors – 883 Central Port Injection – 883 Fuel-Injection Modes of Operation – 884 Idle Control – 885 Stepper Motor Operation – 885 Chapter 79 – Gasoline Direct-Injection Systems – 887 Direct Fuel Injection – 887 Direct-Injection Fuel Delivery System – 887
Chapter 29 – Fuel Delivery Systems – 874 Objectives – 874 Basic Fuel System Diagnosis – 875 Guidelines for Safely Working on Fuel Systems – 875 Fuel Tanks – 876 Filler Caps – 879 Fuel Lines and Fittings – 881 Fuel Filters – 884 Fuel Pumps – 886 Chapter 30 – Electronic Fuel Injection – 899 Objectives – 899 Basic EFI – 900 Throttle Body Injection (TBI) – 905 Port Fuel Injection (PFI) – 907 Central Multiport Fuel Injection (CMFI) – 912 Gasoline Direct-Injection Systems – 913 Light- and Medium-Duty Diesel Fuel Injection – 918
Gasoline Direct-Injection Fuel Injectors – 889 Modes of Operation – 889 Piston Top Designs – 890 Lexus Port- and Direct-Injection Systems – 890 Engine Start Systems – 891 Gasoline Direct-Injection Service – 891 Chapter 80 – Electronic Throttle Control System – 892 Electronic Throttle Control (ETC) System – 893 Normal Operation of the ETC System – 893 Accelerator Pedal Position Sensor – 893 Throttle Body Assembly – 894 Throttle Position (TP) Sensor – 895 Diagnosis of Electronic Throttle Control Systems – 896 ETC Throttle Follower Test – 898 Servicing Electronic Throttle Systems – 898 Chapter 31 – Fuel Injection System Diagnosis Chapter 81 – Fuel-Injection System Diagnosis and Service – 922 and Service – 900 Objectives – 922 Port Fuel-Injection Pressure Regulator Diagnosis – Preliminary Checks – 923 900 Basic EFI System Checks – 924 Diagnosing Electronic Fuel-Injection Problems Injector Service – 935 Using Visual Inspection – 901 Fuel Rail, Injector, and Regulator Service – 937 Scan Tool Vacuum Leak Diagnosis – 902 Electronic Throttle Controls – 941 Port Fuel-Injection System Diagnosis – 902 Idle Speed Checks – 943 Testing For an Injector Pulse – 903 Checking Fuel-Injector Resistance – 904 Measuring Resistance of Grouped Injectors – 905 Measuring Resistance of Individual Injectors – 905 Pressure-Drop Balance Test – 905 Injector Voltage-Drop Tests – 907 Scope-Testing Fuel Injectors – 907 Idle Air Speed Control Diagnosis – 908 Fuel-Injection Service – 908 Fuel-System Scan Tool Diagnostics – 912 Chapter 32 – Intake and Exhaust Systems – 949 Chapter 24 – Intake and Exhaust Systems – 219 Objectives – 949 Air Intake Filtration – 219 Vacuum Systems – 949 Throttle-Body Injection Intake Manifolds – 221 Air Induction System – 951 Port Fuel-Injection Intake Manifolds – 222 Intake Manifold – 952 Exhaust Gas Recirculation Passages – 223 Forced Induction Systems – 955 Exhaust Manifolds – 224 Turbochargers – 956 Mufflers – 225 Chapter 25 – Turbocharging and Superchargers – 962 Exhaust System Components – 965 Supercharging – 227 Catalytic Converters – 966 Introduction – 228 Exhaust System Service – 970 Forced Induction Principles – 228 Superchargers – 230 Turbochargers – 230 Boost Control – 232 Turbocharger Failures – 234 Nitrous Oxide – 235
Chapter 33 – Emission Control Systems – 978 Objectives – 978 Pollutants – 978 Emission Control Devices – 982 Evaporative Emission Control Systems – 985 Precombustion Systems – 988 Postcombustion Systems – 995 Diesel Emission Controls – 1001
Chapter 34 – Emission Control Diagnosis and Service – 1009 Objectives – 1009 I/M 240 Test – 1009 Testing Emissions – 1012 Basic Inspection – 1015 Evaporative Emission Control System Diagnosis and Service – 1018 PCV System Diagnosis and Service – 1023 EGR System Diagnosis and Service – 1025 Catalytic Converter Diagnosis – 1032 Air System Diagnosis and Service – 1034
Thermostat Replacement – 253 Water Pump Replacement – 253 Intake Manifold Gasket Inspection – 254 Intake Manifold Gasket Replacement – 254 Timing Belt Replacement – 255 Hybrid Engine Precautions – 255 Chapter 82 – Vehicle Emission Standards and Testing – 918 Emission Standards in the United States – 919 European Standards – 919 Exhaust Analysis Testing – 920 Exhaust Analysis and Combustion Efficiency – 923 HC Too High – 924 CO Too High – 924 Measuring Oxygen (O2) and Carbon Dioxide (CO2) – 925 Photochemical Smog Formation – 925 Testing for Oxides of Nitrogen – 926 Chapter 83 – Evaporative Emission Control Systems – 927 Evaporative Emission Control System – 928 Nonenhanced Evaporative Control Systems – 929 Enhanced Evaporative Control System – 930 Leak Detection Pump System – 931 Onboard Refueling Vapor Recovery – 931 Diagnosing the EVAP System – 931 Evaporative System Monitor – 932 Typical EVAP Monitor – 933 EVAP System-Related Diagnostic Trouble Codes – 934 Chapter 84 – Exhaust Gas Recirculation Systems – 935 Exhaust Gas Recirculation Systems – 936 OBD-II EGR Monitoring Strategies – 938 Diagnosing a Defective EGR System – 940 EGR-Related OBD-II Diagnostic Trouble Codes – 941 Chapter 85 – Positive Crankcase Ventilation and Secondary Air-Injection Systems – 942 Crankcase Ventilation – 942 PCV-Related Diagnostic Trouble Codes – 945 Secondary Air-Injection System – 945 Secondary Air-Injection System Diagnosis – 947 SAI-Related Diagnostic Trouble Codes – 947 Chapter 86 – Catalytic Converters – 948 Catalytic Converters – 949 OBD-II Catalytic Converter Performance – 950 Diagnosing Catalytic Converters – 952 Catalytic Converter Replacement Guidelines – 954
Chapter 35 – Fuels and Other Energy Sources – Chapter 66 – Gasoline – 754 1040 Gasoline – 754 Objectives – 1040 Refining – 755 Crude Oil – 1040 Volatility – 756 Gasoline – 1043 Gasoline Combustion Process – 757 Basic Gasoline Additives – 1044 Normal and Abnormal Combustion – 758 Oxygenates – 1045 Octane Rating – 759 Gasoline Quality Testing – 1046 High-Altitude Octane Requirements – 759 Alternatives to Gasoline – 1047 Gasoline Additives – 760 Diesel Fuel – 1051 Gasoline Blending – 761 Electric Vehicles – 1053 Reformulated Gasoline – 762 Hybrid Electric Vehicles – 1054 Testing Gasoline For Alcohol Content – 762 Fuel Cell Electric Vehicles – 1062 General Gasoline Recommendations – 763 Chapter 67 – Alternative Fuels – 766 Ethanol – 767 Cellulose Ethanol – 767 E85 – 768 Alternative-Fuel Vehicles – 768 Methanol – 771 Propane – 772 Compressed Natural Gas – 772 Liquefied Natural Gas – 774 P-Series Fuels – 774 Synthetic Fuels – 774 Safety Precautions When Working with Alternative Fuels – 776 Chapter 68 – Diesel and Biodiesel Fuels – 777 Diesel Fuel – 777 Biodiesel – 779 E-Diesel Fuel – 780 Chapter 89 – Introduction to Hybrid Vehicles – 983 Hybrid Vehicles – 983 Electric Vehicles – 983 Driving and Owning a Hybrid Electric Vehicle – 984 Classifications of Hybrid Electric Vehicles – 985 Belt Alternator Starter Systems – 987 Common Features of Most Hybrids – 989 Levels of Hybrid Vehicles – 989 Chapter 90 – Hybrid Safety and Service Procedures – 991 High-Voltage Safety – 991 High-Voltage Safety Equipment – 992 Electric Shock Potential – 993 De-Powering the High-Voltage System – 995 Collision and Repair Industry Issues – 995 Moving and Towing a Hybrid – 996 Removing the High-Voltage Batteries – 996 Routine Service Procedures – 997 Chapter 91 – Fuel Cells and Advanced Technologies – 1002
Chapter 36 – Clutches – 1071 Objectives – 1071 Operation – 1071 Clutch Service Safety Precautions – 1079 Clutch Maintenance – 1079 Clutch Problem Diagnosis – 1080 Clutch Service – 1084
Chapter 37 – Manual Transmissions and Transaxles – 1092 Objectives – 1092 Transmission Versus Transaxle – 1092 Gears – 1096 Basic Gear Theory – 1097 Transmission/Transaxle Design – 1099 Synchronizers – 1101 Gearshift Mechanisms – 1103 Transmission Power Flow – 1104 Transaxle Power Flows – 1108 Final Drive Gears and Overall Ratios – 111 2 Electrical Systems – 1112
Chapter 38 – Manual Transmission/Transaxle Service – 1116 Objectives – 1116 Lubricant Check – 1116 In-Vehicle Service – 1118 Diagnosing Problems – 1119 Transmission/Transaxle Removal – 1124 Cleaning and Inspection – 1125 Disassembly and Reassembly of the Differential Case – 1131 Reassembly/Reinstallation of Transmission/Transaxle – 1134
Fuel-Cell Technology – 1003 PEM Fuel Cells – 1004 Fuel-Cell Vehicle Systems – 1006 Hydraulic Hybrid Storage System – 1010 HCCI – 1011 Plug-In Hybrid Electric Vehicles – 1011 The Future For Electric Vehicles – 1012 Wind Power – 1013 Hydroelectric Power – 1013 Chapter 121 – Clutches – 1454 Purpose and Function of a Clutch – 1454 Component Parts and Operation of a Clutch Assembly – 1454 Clutch Problem Diagnosis – 1462 Clutch Replacement – 1464 Clutch Pedal Adjustment – 1465 Bleeding the Hydraulic Clutch – 1466 Clutch Symptom Guide – 1467 Chapter 122 – Manual Transmissions/Transaxles – 1471 The Need For a Transmission – 1472 Gear Types – 1472 Gear Ratios – 1473 Torque, Speed, and Power – 1475 Transmission Construction – 1476 Torque Flow Through a Manual Transmission – 1476 Speed Gears – 1477 Synchronizer Parts and Operation – 1477 Five-Speed Transmission Torque Flow – 1480 Manual Transaxle Construction – 1482 Transmission/Transaxle Removal – 1482 Transmission/Transaxle Disassembly – 1484 Hard-To-Shift Problem Diagnosis – 1485 Manual Transmission Installation – 1486 Gear Lubrication – 1487 Chapter 122 – Manual Transmissions/Transaxles – 1471 The Need For a Transmission – 1472 Gear Types – 1472 Gear Ratios – 1473 Torque, Speed, and Power – 1475 Transmission Construction – 1476 Torque Flow Through a Manual Transmission – 1476 Speed Gears – 1477 Synchronizer Parts and Operation – 1477 Five-Speed Transmission Torque Flow – 1480 Manual Transaxle Construction – 1482 Transmission/Transaxle Removal – 1482 Transmission/Transaxle Disassembly – 1484
Hard-To-Shift Problem Diagnosis – 1485 Manual Transmission Installation – 1486 Gear Lubrication – 1487 Chapter 39 – Drive Axles and Differentials – 1138 Objectives – 1138 Front-Wheel-Drive (FWD) Axles – 1138 Types of CV Joints – 1139 Front-Wheel-Drive Applications – 1140 CV Joint Service – 1142 Rear-Wheel Drive Shafts – 1147 Operation of U-Joints – 1149 Types of U-Joints – 1151 Diagnosis of Drive Shaft and U-Joint Problems – 1152 Differentials and Drive Axles – 1153 Limited-Slip Differentials – 1160 Axle Shafts – 1161 Servicing the Final Drive Assembly – 1164 Diagnosing Differential Noises – 1169
Chapter 123 – Drive Axle Shafts and CV Joints – 1494 Introduction – 1495 Driveshaft Design – 1495 Driveshaft Balance – 1496 U-Joint Design and Operation – 1496 Constant Velocity Joints – 1498 Chapter 124 – Drive Axle Shafts and CV Joint Service – 1503 U-Joint Fault Symptoms – 1503 Driveshaft and U-Joint Inspection – 1504 U-Joint Replacement – 1506 U-Joint Working Angles – 1508 CV Joint Diagnosis – 1508 Replacement Shaft Assemblies – 1509 CV Joint Service – 1509 Chapter 125 – Drive Axles and Differentials – 1516 Differentials – 1517 Parts of a Differential – 1517 Differential Gear Ratios – 1519 Differentials – 1519 Limited Slip Differentials – 1520 Differential Components – 1521 Differential Axle Bearings – 1523 Differential Identification – 1524 Determining the Axle Ratio of a Differential – 1524 Rear End Noise Diagnosis – 1525 Differential Inspection – 1525 Tooth Contact Pattern Test – 1526 Differential Disassembly – 1526 Pinion Shaft Bearing Replacement – 1526 Drive Pinion Depth – 1526 Pinion Gear Preload – 1528 Checking and Correction Backlash – 1529 Setting Side Bearing Preload – 1530 Reassembly of the Differential Assembly – 1531 Differential Lubricant – 1532 Chapter 40 – Automatic Transmissions and Chapter 127 – Automatic Transaxles – 1173 Transmission/Transaxle Principles – 1551 Objectives – 1173 Background – 1551 Torque Converter – 1174 Torque Converters – 1551 Lockup Torque Converter – 1178 Lockup Torque Converter – 1556 Planetary Gears – 1178 Shift Modes – 1557 Compound Planetary Gear Sets – 1181 Planetary Gear Sets – 1558 Honda’s Nonplanetary-Based Transmission – 1186 Compound Planetary Gear Set – 1559
Continuously Variable Transmissions (CVT) – Automatic Transaxles – 1561 1186 Nonplanetary Gear Automatic Transaxles – 1561 Planetary Gear Controls – 1189 Continuously Variable Transmission – 1561 Transmission Clutches – 1191 Dual Clutch Automatic Transmissions – 1565 Bearings, Bushings, and Thrust Washers – 1193 Chapter 128 – Hydraulic Components and Control Systems – 1567 Snaprings – 1195 Gaskets and Seals – 1196 Automatic Transmission Fluid – 1567 Final Drives and Differentials – 1199 Automatic Transmission Fluid Cooler – 1568 Hydraulic System – 1199 Pump – 1569 Application of Hydraulics in Transmissions – 1200 Apply or Holding Devices – 1571 Pressure Boosts – 1204 Bands – 1571 Shift Quality – 1204 Multiple-Plate Clutches – 1572 Hydraulic Circuits – 1205 Accumulators – 1574 One-Way Clutches – 1575 Valve Body – 1576 Hydraulically Controlled Transmission Valves – 1577 Electronically Controlled Transmissions – 1580 Typical Torque Flow – 1582 Chapter 41 – Electronic Automatic Chapter 128 – Hydraulic Components and Transmissions – 1216 Control Systems – 1567 Objectives – 1216 Automatic Transmission Fluid – 1567 Transmission Control Module – 1217 Automatic Transmission Fluid Cooler – 1568 Hybrid Transmissions – 1228 Pump – 1569 Basic EAT Testing – 1232 Apply or Holding Devices – 1571 Converter Clutch Control Diagnostics – 1236 Bands – 1571 Detailed Testing of Inputs – 1238 Multiple-Plate Clutches – 1572 Detailed Testing of Actuators – 1240 Accumulators – 1574 One-Way Clutches – 1575 Valve Body – 1576 Hydraulically Controlled Transmission Valves – 1577 Electronically Controlled Transmissions – 1580 Typical Torque Flow – 1582 Chapter 42 – Automatic Transmission and Chapter 129 – Automatic Transaxle Service – 1245 Transmission/Transaxle Diagnosis and InObjectives – 1245 Vehicle Service – 1586 Identification – 1245 Transmission Problem Diagnosis – 1586 Basic Diagnostics – 1245 Fluid Leak Diagnosis – 1591 Fluid Leaks – 1250 In-Vehicle Service – 1594 Road Testing the Vehicle – 1252 Chapter 130 – Automatic Transmission/Transaxle Unit Repair – 1598 Checking the Torque Converter – 1253 Diagnosing Hydraulic and Vacuum Control Verify the Need For Unit Repair – 1598 Systems – 1256 Removing the Automatic Transmission/Transaxle Common Problems – 1259 For Service – 1599 Linkages – 1260 Automatic Transmission/Transaxle Disassembly – 1600 Reassembling an Automatic Transmission/Transaxle – 1604 Flushing the Cooler and Torque Converter – 1607 Dynamometer Testing the Automatic
Reinstalling the Automatic Transmission/Transaxle – 1608 Road Test – 1608 Chapter 43 – Four- and All-Wheel Drive – 1271 Objectives – 1271 Types of Four-Wheel Drives – 1271 Four-Wheel-Drive Systems – 1272 Transfer Case – 1277 Interaxle Differentials – 1277 Locking Hubs – 1282 Four-Wheel-Drive Passenger Cars – 1282 All-Wheel-Drive Systems – 1284 Diagnosing 4WD and AWD Systems – 1284 Servicing 4WD Vehicles – 1288 Chapter 44 – Tires and Wheels – 1297 Objectives – 1297 Wheels – 1297 Tires – 1298 Tire Ratings and Designations – 1303 Tire/Wheel Runout – 1309 Tire Replacement – 1310 Tire Repair – 1311 Installation of Tire/Wheel Assembly on the Vehicle – 1314 Tire/Wheel Assembly Service – 1315 Wheel Bearings – 1316
Chapter 126 – Four-Wheel-Drive and AllWheel Drive – 1534 Four-Wheel-Drive Systems – 1534 All-Wheel Drive – 1537 Front and Rear Differential Axle Ratios – 1537 Transfer Case – 1537 Interaxle Differential – 1541 Four-Wheel-Drive Axles – 1542 Transfer Case Service and Problem Diagnosis – 1543 Diagnosing and Servicing Locking Hubs – 1544 Transfer Case Service – 1545 Chapter 98 – Wheel Bearings and Service – 1070 Antifriction Bearings – 1071 Bearing Greases – 1072 Bearing Diagnosis – 1074 Wheel Bearing Service – 1075 Sealed Bearing Replacement – 1078 Rear Drive Axle Classifications – 1079 Rear Axle Bearing and Seal Replacement – 1080 Bearing Failure Analysis – 1082 Chapter 109 – Tires and Wheels – 1239 Introduction To Tires – 1240 Parts of a Tire – 1240 Tire Molding – 1242 Tire Size Designations – 1243 Load Index and Equivalent Loads – 1246 Speed Ratings – 1246 Tire Pressure and Traction – 1246 Tire Conicity and Ply Steer – 1247 Vehicle Handling and Tire Slip Angle – 1249 Rim Width and Tire Size – 1249 Uniform Tire Quality Grading System – 1250 All-Season Tire Designation – 1250 DOT Tire Code – 1251 Spare Tires – 1251 Run-Flat Tires – 1252 General Motors TPC Rating – 1253 Tire Selection Considerations – 1253 Wheels – 1254 Tire Valves – 1257 Unsprung Weight – 1257 Lug Nuts – 1257 Chapter 110 – Tire Pressure Monitoring Systems – 1261 Need For Tire Pressure Monitoring – 1261
Indirect TPMS – 1262 Direct TPMS – 1263 Identifying a Vehicle with TPMS – 1264 TPMS Pressure Sensors – 1264 TPMS Sensor Operation – 1265 TPMS Receiver – 1266 Direct TPMS Diagnosis – 1266 Installing a New Pressure Sensor – 1266 TPMS Diagnostic Tools – 1267 TPMS Sensor Activations – 1267 TPMS Relearn Procedure – 1268 TPMS Sensor Service Tools – 1268 Chapter 111 – Tire and Wheel Service – 1270 Introduction – 1270 Tire Inflation – 1270 Nitrogen Inflation – 1271 Tire Mounting Recommendations – 1272 Wheel Mounting Torque – 1273 Tire Rotation – 1274 Tire Inspection – 1276 Radial Runout – 1276 Lateral Runout – 1277 Tire Balancing – 1278 Replacement Wheels – 1281 Tire Repair – 1281 Chapter 45 – Suspension Systems – 1323 Chapter 112 – Suspension System Principles Objectives – 1323 and Components – 1288 Frames – 1323 Introduction – 1289 Suspension System Components – 1324 Frame Construction – 1289 MacPherson Strut Suspension Components – 1331 Platforms – 1290 Independent Front Suspension – 1334 Unsprung Weight – 1290 Basic Front-Suspension Diagnosis – 1337 Types of Suspensions – 1290 Front-Suspension Component Servicing – 1339 Hooke’s Law – 1291 Rear-Suspension Systems – 1345 Coil Springs – 1291 Semi-Independent Suspension – 1348 Leaf Springs – 1295 Electronically Controlled Suspensions – 1351 Torsion Bars – 1297 Servicing Electronic Suspension Components – Suspension Principles – 1298 1355 Steering Knuckles – 1299 Active Suspensions – 1357 Control Arms – 1299 Ball Joints – 1300 Strut Rods – 1301 Stabilizer Bars – 1301 Shock Absorbers – 1302 Struts – 1304 Bump Stops – 1308 Chapter 113 – Front Suspensions and Service – 1311 Front Suspension Types – 1312 Short/Long-Arm Suspensions – 1313 Strut Suspension – 1314 Servicing the Suspension System – 1315 Road Test Diagnosis – 1316
Chapter 46 – Steering Systems – 1363 Objectives – 1363 Manual-Steering Systems – 1363 Power-Steering Systems – 1370 Electronically Controlled Power-Steering Systems – 1375 Steering System Diagnosis – 1378 Diagnosis – 1379 Specific Checks – 1382 Steering System Servicing – 1388 Power-Steering System Servicing – 1390 Four-Wheel Steering Systems – 1393
Dry Park Test (Suspension) 1317 Visual Inspection – 1317 Ball Joints – 1318 Kingpin Diagnosis and Service – 1322 Shock Absorbers and Struts – 1323 Macpherson Strut Replacement – 1324 Stabilizer Bar Link and Bushing Service – 1326 Strut Rod Bushings – 1327 Front Coil Springs – 1327 Steering Knuckles – 1328 Torsion Bars – 1329 Control Arm Bushings – 1330 Chapter 114 – Rear Suspensions and Service – 1335 Solid Rear Axles – 1335 Leaf Spring Rear Suspensions – 1336 Trailing Arm Rear Suspensions – 1337 Semi-Trailing Arm Rear Suspensions – 1338 Independent Rear Suspensions – 1338 Semi-Independent Rear Suspensions – 1339 Rear Suspension Service – 1340 Rear Shock Replacement – 1341 Rear Spring Replacement – 1341 Chapter 115 – Electronic Suspension Systems – 1343 The Need For Electronic Suspensions – 1343 Electronic Suspension Controls and Sensors – 1343 Electronic Suspension System Actuators – 1348 Types of Electronic Suspension – 1349 Automatic Level Control (ALC) – 1354 Magneto-Rheological (MR) Suspension – 1355 Troubleshooting Rear Electronic Leveling Systems – 1356 Chapter 116 – Steering Columns and Gears – 1358 Steering Wheels – 1358 Steering Columns – 1358 Conventional Steering Gears – 1363 Recirculating Ball Steering Gear – 1364 Steering Gear Adjustments – 1366 Rack-And-Pinion Steering Gear – 1367 Rack-And-Pinion Adjustments – 1369 Chapter 117 – Steering Linkage and Service – 1372 Steering Linkage – 1372 Rack-And-Pinion Inner Tie Rod Ends – 1373 Front Steer Versus Rear Steer – 1375 Four-Wheel Steering Systems – 1375 Steering Linkage Lubrication – 1378 Dry Park Test – 1379
Chapter 47 – Wheel Alignment – 1402 Objectives – 1402 Alignment Geometry – 1403 Prealignment Inspection – 1407 Wheel Alignment Equipment – 1409 Alignment Machines – 1410 Performing an Alignment – 1411 Four-Wheel-Drive Vehicle Alignment – 1421
Under-Vehicle Inspection – 1380 Steering Linkage Replacement – 1382 Chapter 118 – Electric and Hydraulic Power Steering Systems – 1388 Power Steering Hydraulic Systems – 1388 Power Steering Pump and Reservoir – 1388 Power Steering Hoses – 1392 Integral Power Steering – 1392 Variable-Effort Steering – 1396 Electric Power Steering System – 1399 Self-Parking System – 1401 Electrohydraulic Power Steering – 1402 Power Steering Diagnosis and Troubleshooting – 1402 Chapter 119 – Wheel Alignment Principles – 1413 Definition of a Wheel Alignment – 1413 Alignment-Related Problems – 1413 Alignment Angles – 1414 Steering Axis Inclination (SAI) – 1421 Included Angle – 1421 Scrub Radius – 1422 Turning Radius (Toe-Out On Turns) – 1424 Setback – 1424 Thrust Angle – 1425 Tracking – 1425 Four-Wheel Alignment – 1426 Chapter 120 – Alignment Diagnosis and Service – 1427 Need For Proper Alignment – 1427 Prealignment Correction Techniques – 1427 Prealignment Checks – 1428 Lead/Pull – 1429 Memory Steer – 1429 Torque Steer – 1430 Alignment Specifications – 1431 Alignment Setup Procedures – 1432 Measuring Camber, Caster, SAI, Toe, and TOOT – 1433 Specifications Versus Alignment Readings – 1434 Checking For Bent Struts, Spindles, or Control Arms – 1434 Checking Frame Alignment of Front-Wheel-Drive Vehicles – 1434 Types of Alignments – 1434 Sample Alignment Specifications and Readings – 1437 Adjusting Rear Camber – 1438 Guidelines For Adjusting Front Camber/SAI and Included Angle – 1440 Front Camber/Caster Adjustment Methods – 1441 Adjusting Front Camber/Caster – 1442
Chapter 48 – Brake Systems – 1424 Objectives – 1424 Friction – 1424 Principles of Hydraulic Brake Systems – 1427 Hydraulic Brake Systems Components – 1429 Master Cylinders – 1430 Master Cylinder Operation – 1433 Hydraulic Tubes and Hoses – 1435 Hydraulic System Safety Switches and Valves – 1437 Drum and Disc Brake Assemblies – 1440 Hydraulic System Service – 1442 Power Brakes – 1449 Pushrod Adjustment – 1450 Hydraulic Brake Boosters – 1451 Electric Parking Brakes – 1453
Setting Toe – 1442 Centering the Steering Wheel – 1444 Steering Wheel Removal – 1444 Tolerance Adjustment Procedure – 1447 Aftermarket Alignment Methods – 1447 Aligning Electronic-Suspension Vehicles – 1447 Aligning Modified Vehicles – 1447 Hidden Structural Damage Diagnosis – 1449 Alignment Guide – 1449 Chapter 92 – Braking System Components and Performance Standards – 1015 Fundamentals of Brake Systems – 1016 Brake Design Requirements – 1017 Brake System Categories – 1017 Antilock Brake System Overview – 1018 Federal Brake Standards – 1019 Brake Repair and the Law – 1020 Chapter 93 – Braking System Principles – 1021 Energy Principles – 1022 Inertia – 1023 Mechanical Principles – 1023 Friction Principles – 1024 Friction and Heat – 1025 Deceleration Rates – 1026 Chapter 94 – Brake Hydraulic Systems – 1027 Hydraulic Principles – 1027 Pascal’s Law – 1028 Master Cylinders – 1031 Master Cylinder Designs – 1034 Diagnosing and Troubleshooting Master Cylinders – 1037 Master Cylinder Service – 1038 Chapter 95 – Hydraulic Valves and Switches – 1040 Introduction – 1041 Residual Check Valve – 1041 Pressure-Differential Switch (Brake Warning Switch) – 1041 Brake Fluid Level Sensor Switch – 1042 Proportioning Valve – 1043 Electronic Brake Proportioning – 1046 Metering Valve (Hold-Off) Operation ) 1046 Combination Valve – 1048 Brake Light Switch – 1048 Chapter 96 – Brake Fluid and Lines – 1050 Brake Fluid – 1050 Brake Fluid Service Procedures and Precautions – 1054 Rubber Types – 1054 Brake Lines – 1054 Chapter 97 – Brake Bleeding Methods and
Chapter 49 – Drum Brakes – 1457 Objectives – 1457 Drum Brake Operation – 1457 Drum Brake Components – 1458 Drum Brake Designs – 1460 Road Testing Brakes – 1464 Drum Brake Inspection – 1464 Brake Shoes and Linings – 1472 Wheel Cylinder Inspection and Servicing – 1475 Drum Parking Brakes – 1475
Brake Bleeding – 1061 Brake Bleeder Valve Loosening Methods – 1062 Bleeding Sequence – 1063 Manual Bleeding – 1063 Vacuum Bleeding – 1064 Gravity Bleeding – 1065 Pressure Bleeding – 1066 Hydraulic ABS Service – 1067 Brake Fluid Replacement/Flushing – 1069 Chapter 104 – Machining Brake Drums and Rotors – 1157 Brake Drums – 1158 Brake Drum and Rotor Damage – 1158 Brake Drum Distortion – 1159 Removing Drums – 1161 “Machine To” Versus “Discard” – 1161 Machining Brake Drums – 1162 Disc Brake Rotors – 1164 Disc Brake Rotor Distortion – 1166 Disc Brake Rotor Thickness – 1167 When the Rotors Should Be Machined – 1167 Rotor Finish – 1168 Machining a Disc Brake Rotor – 1170 On-The-Vehicle Rotor Machining – 1175 Chapter 105 – Power Brake Unit Operation, Diagnosis, and Service – 1195 The Need For Power Brake Assist – 1196 Principles of Vacuum – 1196 Vacuum Booster Theory – 1197 Charcoal Filter – 1198 Vacuum Check Valve – 1199 Vacuum Brake Booster Operation – 1199 Dual- (Tandem-) Diaphragm Vacuum Boosters – 1201 Brake Assist Systems – 1201 Vacuum Booster Operation Test – 1202 Vacuum Booster Leak Test – 1202 Hydraulic System Leak Test – 1202 Pushrod Clearance Adjustment – 1202 Vacuum Booster Disassembly and Service – 1203 Hydro-Boost Hydraulic Brake Booster – 1203 Hydro-Boost Symptom-Based Guide – 1207 Chapter 99 – Drum Brakes – 1087 Drum Brake Advantages – 1087 Drum Brake Disadvantages – 1089 Drum Brake Parts – 1089 Drum Brake Shoes – 1091 Drum Brake Parts – 1093 Non-Servo Brake Design – 1094 Dual-Servo Brake Design – 1095 Automatic Brake Adjusters – 1097 Chapter 100 – Drum Brake Diagnosis and
Service – 1101 Drum Brake Faults – 1101 Drum Brake Diagnosis – 1101 Brake Drum Removal – 1101 Drum Brake Disassembly – 1103 Inspecting the Backing Plate – 1104 Drum Brake Lining Inspection – 1104 Brake Spring Inspection – 1105 Wheel Cylinder Inspection – 1105 Drum Brake Hardware Kit – 1107 Inspecting the Drum Brake Shoes – 1107 Brake Parts Cleaning – 1107 Reassembling the Drum Brake – 1108 Adjusting Drum Brakes – 1108 Lubrication Checklist – 1109 Drum Brake Symptom-Based Guide – 1109 Chapter 103 – Parking Brake Operation, Diagnosis, and Service – 1145 Parking Brake Standards – 1145 Pedals, Levers, and Handles – 1145 Parking Brake Warning Lamp – 1147 Parking Brake Linkages – 1147 Front and Rear Entry Parking Brake Cables – 1149 Drum Parking Brakes – 1149 Caliper-Activated Disc Parking Brakes – 1150 Rear Disc Brake Service – 1153 Parking Brake Cable Adjustment – 1153 Electric Parking Brake – 1156 Chapter 50 – Disc Brakes – 1481 Chapter 101 – Disc Brakes – 1114 Objectives – 1481 Disc Brakes – 1115 Disc Brake Components and Their Functions – Disc Brake Construction – 1118 1481 Disc Brake Pads – 1118 Rear-Wheel Disc Brakes – 1486 Brake Rotors – 1122 Disc Brake Diagnosis – 1488 Caliper Design – 1122 Service Guidelines – 1490 Rear Disc Brakes – 1126 General Caliper Inspection and Servicing – 1491 Chapter 102 – Disc Brakes Diagnosis and Service – 1128 Rear Disc Brake Calipers – 1498 Rotor Inspection – 1499 Disc Brake Diagnostic Procedure – 1128 Rotor Service – 1501 Visual Inspection – 1128 Disc Brake Caliper Service – 1130 Servicing Disc Brake Calipers – 1132 Disc Brake Squeal Correction – 1137 Disc Brake Symptom Guide – 1138 Chapter 51 – Antilock Brake, Traction Control, Chapter 106 – ABS Components and Operation and Stability Control Systems – 1506 – 1208 Objectives – 1506 Antilock Braking System – 1208 Antilock Brakes – 1506 ABS Operation – 1210 ABS Components – 1507 System Configurations – 1211 Types of Antilock Brake Systems – 1511 ABS Components – 1212 ABS Operation – 1512 ABS Control Module – 1214 Automatic Traction Control – 1519 Hydraulic Modulator Assembly – 1214
Antilock Brake System Service – 1523 Diagnosis and Testing – 1524 Testing Traction and Stability Control Systems – 1530 New Trends – 1531
Chapter 52 – Heating and Air-Conditioning – 1535 Objectives – 1535 Ventilation System – 1535 Automotive Heating Systems – 1536 Heating System Service – 1539 Theory of Automotive Air-Conditioning – 1541 Refrigerants – 1542 Basic Operation of an Air-Conditioning System – 1544 Compressors – 1546 Condenser – 1550 Receiver/Dryer – 1552 Thermostatic Expansion Valve/Orifice Tube – 1552 Evaporator – 1553 Refrigerant Lines – 1554 Air-Conditioning Systems and Controls – 1555 Temperature Control Systems – 1557
Brake Pedal Travel Switch (Sensor) – 1217 Tire Pressure Monitoring (TPMS) – 1217 Chapter 107 – ABS Diagnosis and Service – 1220 ABS Diagnostic Procedure – 1221 Brake Warning Lamp Operation – 1221 Thorough Visual Inspection – 1221 Test Drive and Verify the Fault – 1222 Retrieving Diagnostic Trouble Codes – 1223 Kelsey-Hayes Antilock (Nonintegral) – 1223 Bosch 2 ABS (Nonintegral) – 1224 Teves Mark IV – 1225 Delphi (Delco) ABS-VI (Nonintegral) – 1225 Wheel Speed Sensor Diagnosis – 1227 Wheel Speed Sensor Adjustment – 1228 OBD-II ABS Diagnosis – 1229 ABS Safety Precautions – 1231 Chapter 108 – Electronic Stability Control Systems – 1232 The Need For Electronic Stability Control – 1232 Federal Motor Vehicle Safety Standard (FMVSS) No. 126 – 1233 Sine with Dwell Test – 1233 Names of Various ESC Systems – 1234 ESC Sensors – 1234 Traction Control – 1236 ESC/TC Diagnosis – 1238 Chapter 62 – Heating and Air-Conditioning Components and Operation – 712 Purpose and Function – 712 Heating System – 714 Air-Conditioning Refrigeration Cycle – 715 Expansion Valve Systems – 715 Orifice Tube Systems – 716 Thermostatic Control – 716 Refrigerants – 718 Refrigerants and the Environment – 719 Refrigerant Oils – 720 Condenser – 720 Evaporator – 720 Receiver-Drier – 721 Accumulator – 722 Refrigerant Lines and Hoses – 723 Thermostatic Expansion Valves – 723 Fixed-Orifice Tubes – 725 Compressors – 725 Compressor Controls – 729 Chapter 63 – Automatic Air-Conditioning System Operation – 731 Airflow Management – 731 Automatic Air Conditioning – 732
