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Copyright, ii
Preface, iii
In-Text Features, iv
Supplements, vi
Acknowledgments, vii
Chapter 1. Shop Safety, 1
Objectives, 1
Key Terms, 1
Personal Protective Equipment, 2
Safety Tips for Technicians, 3
Cleaning Methods and Processes, 3
Electrical Cord Safety, 5
Jump-Starting and Battery Safety, 5
Fire Extinguishers, 6
Fire Blankets, 7
First Aid and Eye Wash Stations, 7
Summary, 9
Review Questions, 9
Chapter Quiz, 9
Chapter 2. Environmental and Hazardous Materials, 11
Objectives, 11
Key Terms, 11
Occupational Safety and Health Act, 12
Hazardous Waste, 12
Resource Conservation and Recovery Act (RCRA), 12
Clean Air Act, 13
Material Safety Data Sheets (MSDSs), 13
The Dangers of Exposure to Asbestos, 13
Asbestos OSHA Standards, 14
Asbestos EPA Regulations, 14
Asbestos Handling Guidelines, 14
Used Brake Fluid, 15
Used Oil, 15
Disposal of Used Oil, 15
Used Oil Storage, 15
Solvents, 16
Solvent Hazardous and Regulatory Status, 17
Used Solvents, 17
Coolant Disposal, 18
Lead–Acid Battery Waste, 18
Battery Hazardous and Regulatory Status, 18
Battery Handling and Storage, 19
Fuel Safety and Storage, 19
Airbag Handling, 19
Used Tire Disposal, 20
Air-Conditioning Refrigerant Oil Disposal, 20
Summary, 26
Review Questions, 26
Chapter Quiz, 27
Chapter 3. Fasteners and Thread Repair, 28
Objectives, 28
Key Terms, 28
Threaded Fasteners, 29
Metric Bolts, 29
Grades of Bolts, 30
Tensile Strength, 31
Nuts, 31
Taps and Dies, 32
Thread Pitch Gauge, 33
Sheet Metal Screws, 34
Washers, 34
Snap Rings and Clips, 35
How to Avoid Broken Fasteners, 37
Thread Repair Inserts, 38
Summary, 41
Review Questions, 41
Chapter Quiz, 41
Chapter 4. Hand Tools, 43
Objectives, 43
Key Terms, 43
Wrenches, 44
Ratchets, Sockets, and Extensions, 45
Screwdrivers, 48
Hammers and Mallets, 50
Pliers, 51
Cutters, 53
Punches and Chisels, 54
Removers, 55
Hacksaws, 56
Basic Hand Tool List, 57
Tool Sets and Accessories, 57
Seal Drivers and Pullers, 58
Electrical Hand Tools, 59
Safety Tips for Using Hand Tools, 60
Hand Tool Maintenance, 60
Summary, 61
Review Questions, 61
Chapter Quiz, 61
Chapter 5. Power Tools and Shop Equipment, 63
Objectives, 63
Key Terms, 63
Air Compressor, 64
Air and Electrically Operated Tools, 64
Trouble Lights, 66
Bench/Pedestal Grinder, 67
Bench Vise, 67
Hydraulic Presses, 68
Portable Crane and Chain Hoist, 68
Engine Stands, 69
Care and Maintenance of Shop Equipment, 69
Summary, 74
Review Questions, 74
Chapter Quiz, 74
Chapter 6. Vehicle Lifting and Hoisting, 76
Objectives, 76
Key Terms, 76
Floor Jack, 77
Creepers, 77
Vehicle Hoists, 77
Drive-On Ramps, 80
Summary, 84
Review Questions, 84
Chapter Quiz, 84
Chapter 7. Measuring Systems and Tools, 86
Objectives, 86
Key Terms, 86
English Customary Measuring System, 87
Metric System of Measure, 87
Linear Measurements (Tape Measure/Rule), 87
Micrometer, 88
Telescopic Gauge, 90
Small-Hole Gauge, 91
Vernier Dial Caliper, 91
Feeler Gauge, 91
Straightedge, 91
Dial Indicator, 94
Dial Bore Gauge, 94
Depth Micrometer, 94
Summary, 95
Review Questions, 95
Chapter Quiz, 95
Chapter 8. Service Information, 97
Objectives, 97
Key Terms, 97
Vehicle Service History Records, 98
Owner’s Manuals, 98
Lubrication Guides, 98
Service Manuals, 98
Advantages of Hard Copy versus Electronic Service Information, 100
Disadvantages of Hard Copy versus Electronic Service Information, 100
Types of Service Information, 101
Labor Guide Manuals, 101
How to Use Hard Copy Manuals, 102
Electronic Service Information, 103
Hotline Services, 104
Specialty Repair Manuals, 105
Aftermarket Supplies Guides and Catalogs, 105
Summary, 105
Review Questions, 106
Chapter Quiz, 106
Chapter 9. Vehicle Identification and Emission Ratings, 107
Objectives, 107
Key Terms, 107
Parts of a Vehicle, 108
Front-Wheel Drive versus Rear-Wheel Drive, 108
Vehicle Identification, 108
Vehicle Safety Certification Label, 109
VECI Label, 109
Emission Standards in the United States, 109
Calibration Codes, 111
Casting Numbers, 111
Summary, 112
Review Questions, 113
Chapter Quiz, 113
Chapter 10. Gasoline Engine Operation, Parts, and Specifications, 114
Objectives, 114
Key Terms, 114
Energy and Power, 115
Engine Construction Overview, 115
Four-Stroke Cycle Operation, 117
The 720° Cycle, 117
Engine Classification and Construction, 117
Engine Rotation Direction, 121
Bore, 121
Stroke, 122
Engine Displacement, 122
Compression Ratio, 124
The Crankshaft Determines the Stroke, 124
Torque, 125
Power, 125
Horsepower and Altitude, 126
Summary, 126
Review Questions, 126
Chapter Quiz, 127
Chapter 11. Gasoline and Alternative Fuels, 128
Objectives, 128
Key Terms, 128
Automotive Fuel Refining, 129
Gasoline, 129
Volatility, 129
Distillation Curve, 131
Normal and Abnormal Combustion, 132
Octane Rating, 134
Gasoline Grades and Octane Number, 134
Octane Improvers, 135
Oxygenated Fuels, 135
Alcohol Additives—Advantages and Disadvantages, 136
Testing Gasoline for Alcohol Content, 137
Combustion Chemistry, 137
Air–Fuel Ratios, 138
High-Altitude Octane Requirements, 139
Reformulated Gasoline, 139
General Gasoline Recommendations, 140
Alternative Fuels, 141
P-Series Fuels, 149
Biodiesel, 153
E-Diesel Fuel, 154
Synthetic Fuels, 155
Safety Procedures When Working with Alternative-Fuel Vehicles, 156
Summary, 158
Review Questions, 158
Chapter Quiz, 158
Chapter 12. Diesel Engine Operation and Diagnosis, 160
Objectives, 160
Key Terms, 160
Diesel Engines, 161
Three Phases of Combustion, 162
Diesel Engine Construction, 162
Heui System, 164
Diesel Injector Nozzles, 165
Diesel Injector Nozzle Operation, 167
Glow Plugs, 167
Engine-Driven Vacuum Pump, 169
Heated Intake Air, 169
Accelerator Pedal Position Sensor, 169
Soot or Particulate Matter, 170
Diesel Oxidation Catalyst (DOC), 170
Diesel Exhaust Particulate Filter (DPF), 170
Ash Loading, 173
Diesel Exhaust Smoke Diagnosis, 173
Scan Tool Diagnosis, 173
Compression Testing, 174
Glow Plug Resistance Balance Test, 174
Injector Pop Testing, 174
Diesel Emission Testing, 175
Summary, 176
Review Questions, 177
Chapter Quiz, 177
Chapter 13. Cooling System Operation and Diagnosis, 178
Objectives, 178
Key Terms, 178
Cooling System Purpose and Function, 179
Low-Temperature Engine Problems, 179
High-Temperature Engine Problems, 179
Cooling System Design, 180
Thermostat Temperature Control, 181
Testing the Thermostat, 183
Thermostat Replacement, 184
Antifreeze/Coolant, 184
Types of Coolant, 185
Antifreeze Can Freeze, 186
Hydrometer Testing, 187
Recycling Coolant, 187
Disposing of Used Coolant, 187
Radiator, 188
Pressure Cap, 188
Surge Tank, 190
Metric Radiator Caps, 190
Coolant Recovery System, 191
Pressure Testing, 191
Coolant Dye Leak Testing, 192
Water Pump Operation, 192
Coolant Flow in the Engine, 194
Water Pump Service, 194
Cooling Fans, 196
Thermostatic Fans, 196
Electronically Controlled Cooling Fan, 197
Heater Core, 198
Heater Problem Diagnosis, 198
Coolant Temperature Warning Light, 199
Common Causes of Overheating, 199
Cooling System Maintenance, 199
Flush and Refill, 201
Burping the System, 201
Hoses, 202
Back Flushing a Radiator, 202
Cleaning the Radiator Exterior, 203
Summary, 205
Review Questions, 205
Chapter Quiz, 205
Chapter 14. Lubrication System Operation and Diagnosis, 207
Objectives, 207
Key Terms, 207
Lubrication Purpose and Fundamentals, 208
Lubrication Principles, 208
Engine Lubrication Systems, 208
Properties of Engine Oil, 209
SAE Rating, 209
API Rating, 209
ILSAC Oil Rating, 210
European Oil Ratings, 211
Japanese Oil Ratings, 211
Engine Oil Additives, 211
Oil Brand Compatibility, 212
Synthetic Oil, 212
Oil Temperature, 213
Oil Change Intervals, 214
Oil Change Procedure, 214
Oil Filters, 216
Changing Oil in a Turbocharged Engine, 216
Oil Pumps, 218
Oil Pressure Regulation, 219
Factors Affecting Oil Pressure, 219
Oil Pump Checks, 220
Oil Passages in the Block, 221
Valve Train Lubrication, 223
Oil Pans, 223
Dry Sump System, 224
Oil Coolers, 226
Oil Pressure Warning Lamp, 227
Summary, 228
Review Questions, 228
Chapter Quiz, 228
Chapter 15. Starting and Charging System Operation and Diagnosis, 230
Objectives, 230
Key Terms, 230
Purpose of a Battery, 231
How a Battery Works, 231
Specific Gravity, 232
Absorbed Glass Mat (AGM) Battery, 233
Battery Ratings, 233
Battery Service, 234
Jump Starting, 238
Cranking Circuit, 238
Starting System Troubleshooting, 240
Starter Amperage Testing, 241
Bench Testing, 241
AC Generators, 241
Summary, 252
Review Questions, 253
Chapter Quiz, 253
Chapter 16. Ignition System Operation and Diagnosis, 255
Objectives, 255
Key Terms, 255
Ignition System Operation, 256
Ignition Coils, 256
Distributor Ignition, 261
Waste-Spark Ignition Systems, 264
Coil-on-Plug Ignition, 267
Checking for Spark, 267
Electronic Ignition Troubleshooting Procedure, 269
Ignition Coil Testing Using an Ohmmeter, 269
Pickup Coil Testing, 270
Testing Magnetic Sensors, 270
Testing Hall-Effect Sensors, 271
Testing Optical Sensors, 271
Ignition System Diagnosis Using Visual Inspection, 271
Testing for Poor Performance, 272
Testing for a No-Start Condition, 272
Firing Order, 273
Spark Plug Wire Inspection, 273
Spark Plug Service, 273
Quick and Easy Secondary Ignition Tests, 276
Ignition Timing, 277
Ignition System Troubleshooting Guide, 280
Summary, 283
Review Questions, 283
Chapter Quiz, 283
Chapter 17. Emission Control Devices Operation and Diagnosis, 285
Objectives, 285
Key Terms, 285
Exhaust Gas Recirculation Systems, 286
Controlling NO_x, 286
EGR System Operation, 287
Positive and Negative Backpressure EGR Valves, 287
Computer-Controlled EGR Systems, 288
OBD-II EGR Monitoring Strategies, 290
Diagnosing a Defective EGR System, 292
Crankcase Ventilation, 294
PCV Valves, 294
Orifice-Controlled Systems, 295
Positive Crankcase Ventilation (PCV) System Diagnosis, 296
PCV Monitor, 298
Air Pump System, 298
Air Distribution Manifolds and Nozzles, 298
Air Pump System Diagnosis, 302
Catalytic Converters, 303
Ceramic Monolith Catalytic Converter, 303
OBD-II Catalytic Converter Performance, 305
Converter-Damaging Conditions, 305
Diagnosing Catalytic Converters, 306
OBD-II Catalytic Converter Monitor, 308
Catalytic Converter Replacement Guidelines, 309
Summary, 310
Review Questions, 310
Chapter Quiz, 310
Chapter 18. Intake and Exhaust Systems, 312
Objectives, 312
Key Terms, 312
Air Intake Filtration, 313
Engine Air Temperature Requirements, 314
Throttle-Body Injection Intake Manifolds, 315
Port Fuel-Injection Intake Manifolds, 316
Variable Intakes, 316
Plastic Intake Manifolds, 316
Exhaust Gas Recirculation Passages, 317
Upper and Lower Intake Manifolds, 318
Exhaust Manifold Design, 318
Exhaust Manifold Gaskets, 320
Mufflers, 320
Summary, 322
Review Questions, 322
Chapter Quiz, 322
Chapter 19. Turbocharging and Supercharging, 324
Objectives, 324
Key Terms, 324
Airflow Requirements, 325
Supercharging Principles, 325
Superchargers, 326
Turbochargers, 328
Boost Control, 330
Turbocharger Failures, 332
Nitrous Oxide, 333
Summary, 335
Review Questions, 335
Chapter Quiz, 335
Chapter 20. Engine Condition Diagnosis, 337
Objectives, 337
Key Terms, 337
Typical Engine-Related Complaints, 338
Engine Smoke Diagnosis, 338
The Driver Is Your Best Resource, 338
Visual Checks, 339
Engine Noise Diagnosis, 340
Oil Pressure Testing, 342
Oil Pressure Warning Lamp, 342
Compression Test, 342
Wet Compression Test, 344
Running (Dynamic) Compression Test, 345
Cylinder Leakage Test, 345
Cylinder Power Balance Test, 346
Power Balance Test Procedure, 346
Vacuum Tests, 347
Exhaust Restriction Test, 349
Testing Back Pressure with a Vacuum Gauge, 350
Testing Back Pressure with a Pressure Gauge, 350
Diagnosing Head Gasket Failure, 350
Dash Warning Lights, 351
Summary, 354
Review Questions, 354
Chapter Quiz, 354
Chapter 21. Engine Disassembly, Cleaning, and Crack Detection, 356
Objectives, 356
Key Terms, 356
Engine Removal, 357
Engine Disassembly, 358
Checking Cylinder Bore, 359
Removing the Oil Pan, 359
Removing the Cylinder Ridge, 359
Removing the Pistons, 360
Removing the Harmonic Balancer, 360
Removing the Timing Chain and Camshaft, 360
Removing the Main Bearing and Crankshaft, 361
Remove and Disassemble the Cylinder Head, 361
Mechanical Cleaning, 362
Chemical Cleaners, 363
Solvent-Based Cleaning, 363
Water-Based Chemical Cleaning, 363
Spray Washing, 363
Steam Cleaning, 364
Thermal Cleaning, 364
Cold Tank Cleaning, 364
Hot Tank Cleaning, 365
Vapor Cleaning, 365
Ultrasonic Cleaning, 365
Vibratory Cleaning, 365
Blasters, 365
Visual Inspection, 366
Magnetic Crack Inspection, 366
Dye-Penetrant Testing, 366
Fluorescent-Penetrant Testing, 367
Pressure Testing, 367
Crack Repair, 367
Crack-Welding Cast Iron, 367
Crack-Welding Aluminum, 368
Crack Plugging, 368
Summary, 372
Review Questions, 372
Chapter Quiz, 372
Chapter 22. Cylinder Head and Valve Guide Service, 374
Objectives, 374
Key Terms, 374
Cylinder Heads, 375
Multiple-Valve Combustion Chamber, 377
Intake and Exhaust Ports, 378
Cylinder Head Coolant Passages, 380
Lubricating Overhead Valves, 381
Removing the Overhead Camshaft, 381
Disassembly of the Cylinder Head, 381
Cylinder Head Reconditioning Sequence, 382
Cylinder Head Resurfacing, 382
Aluminum Cylinder Head Straightening, 383
Resurfacing Methods, 384
Surface Finish, 384
Correcting Intake Manifold Alignment, 386
Valve Guides, 387
Valve Stem-to-Guide Clearance, 387
Measuring Valve Guides for Wear, 388
Oversize Stem Valves, 388
Valve Guide Knurling, 389
Valve Guide Replacement, 390
Valve Guide Inserts, 391
Spiral Bronze Insert Bushings, 394
Summary, 397
Review Questions, 397
Chapter Quiz, 397
Chapter 23. Valve and Seat Service, 399
Objectives, 399
Key Terms, 399
Intake and Exhaust Valves, 400
Valve Size Relationships, 400
Valve Design, 400
Valve Materials, 401
Sodium-Filled Valves, 402
Valve Seats, 402
Valve Inspection, 403
Valve Springs, 408
Valve Spring Inspection, 408
Valve Keepers, 410
Valve Rotators, 410
Valve Reconditioning Procedure, 410
Valve Face Grinding, 412
Valve Seat Reconditioning, 413
Valve Guide Pilots, 416
Valve Seat Grinding Stones, 417
Dressing the Grinding Stone, 418
Valve Seat Grinding, 419
Narrowing the Valve Seat, 419
Valve Seat Cutters, 420
Valve Seat Testing, 420
Valve Seat Replacement, 421
Valve Stem Height, 424
Checking Installed Height, 424
Valve Stem Seals, 425
Types of Valve Stem Seals, 426
Installing the Valves, 427
Flow Testing Cylinder Heads, 429
Cylinder Head Flow versus Horsepower, 429
Summary, 435
Review Questions, 435
Chapter Quiz, 435
Chapter 24. Camshafts and Valve Trains, 437
Objectives, 437
Key Terms, 437
Camshaft Purpose and Function, 438
Camshaft Location, 438
Camshaft Problem Diagnosis, 438
Camshaft Removal, 439
Camshaft Design, 439
Composite Camshafts, 441
Camshaft Lubrication, 442
Fuel-Pump Eccentrics, 442
Camshaft Drives, 442
Camshaft Chain Drives, 444
Camshaft Belt Drives, 445
Camshaft Movement, 446
Lifter Rotation, 446
Camshaft Lift, 447
Rocker Arms, 448
Pushrods, 450
Overhead Camshaft Valve Trains, 452
Camshaft Specifications, 453
Cam Timing Specifications, 455
Measuring and Regrinding Camshafts, 456
Installing the Camshaft, 456
Degreeing the Camshaft, 458
Variable Valve Timing, 461
Variable Valve Timing and Lift, 465
Lifters or Tappets, 467
Solid Lifters, 467
Hydraulic Lifters, 468
Lifter Preload, 469
Determining Lifter Preload, 471
Determining Proper Lifter Travel, 471
Valve Noise Diagnosis, 472
Mechanical Lifter Service, 472
Hydraulic Lifter Service, 473
Hydraulic Valve Lifter Installation, 473
Bleeding Hydraulic Lifters, 473
Valve Train Lubrication, 473
Summary, 475
Review Questions, 476
Chapter Quiz, 476
Chapter 25. Pistons, Rings, and Connecting Rods, 477
Objectives, 477
Key Terms, 477
Purpose and Function of Pistons, Rings, and Connecting Rods, 478
Piston and Rod Removal, 478
Piston Design, 479
Piston Heads, 480
Cam Ground Pistons, 481
Piston Finish, 481
Piston Head Size, 482
Piston Strut Inserts, 482
Hypereutectic Pistons, 482
Forged Pistons, 482
Piston Pins, 482
Piston Pin Retaining Methods, 485
Piston Ring Grooves, 486
Piston Rings, 486
Compression Rings, 487
Piston Service, 490
Connecting Rods, 490
Connecting Rod Design, 492
Rod Twist, 493
Connecting Rod Service, 494
Piston and Rod Assembly, 494
Piston Ring Service, 495
Summary, 497
Review Questions, 497
Chapter Quiz, 497
Chapter 26. Engine Blocks, 499
Objectives, 499
Key Terms, 499
Engine Blocks, 500
Engine Block Service, 505
Block Cleaning and Preparation for Assembly, 512
Summary, 521
Review Questions, 521
Chapter Quiz, 522
Chapter 27. Crankshafts and Bearings, 523
Objectives, 523
Key Terms, 523
Crankshaft, 524
Crankshaft Construction, 526
V-8 Crankshafts, 527
Four-Cylinder Engine Crankshafts, 527
Five-Cylinder Engine Crankshafts, 527
Three-Cylinder Engine Crankshafts, 527
Odd-Firing 90-Degree V-6 Engine Crankshafts, 527
Even-Firing 90-Degree V-6 Engine Crankshafts, 528
Sixty-Degree V-6 Engine Crankshafts, 528
Counterweights, 528
Externally and Internally Balanced Engines, 530
Crankshaft Oiling Holes, 531
Crankshaft Inspection, 531
Crankshaft Grinding, 532
Welding a Crankshaft, 533
Stress Relieving the Crankshaft, 534
Engine Bearings, 534
Bearing Construction, 537
Bearing Manufacturing, 539
Bearing Clearance, 539
Bearing Spread and Crush, 539
Camshaft Bearings, 541
Summary, 544
Review Questions, 544
Chapter Quiz, 545
Chapter 28. Engine Balancing and Balance Shafts, 546
Objectives, 546
Key Terms, 546
Engine Balance, 547
Balance Shafts, 547
Balancing an Engine, 548
Summary, 555
Review Questions, 555
Chapter Quiz, 555
Chapter 29. Preparation for Assembly, 557
Objectives, 557
Key Terms, 557
Details, Details, Details, 558
Short Block Preparation, 558
Cylinder Head Preparation, 560
Trial Assembly, 560
Check the Angle Between Heads, 562
Painting the Engine, 562
Gaskets and Clamping Force, 562
Summary, 565
Review Questions, 565
Chapter Quiz, 565
Chapter 30. Engine Blueprinting and Assembly, 567
Objectives, 567
Key Terms, 567
Blueprinting, 568
Block Preparation, 568
Installing Cups and Plugs, 568
Installing Cam Bearings, 569
Causes of Premature Bearing Failure, 570
Measuring Main Bearing Clearance, 570
Correcting Bearing Clearance, 571
Lip Seal Installation, 572
Rope Seal Installation, 572
Installing the Crankshaft, 573
Measuring Thrust Bearing Clearance, 574
Tightening Procedure for the Main Bearing, 574
Installing Timing Chains and Gears, 574
Piston Fitting, 575
Installing Piston and Rod Assemblies, 576
Installing the Camshaft for Overhead Cam Engines, 579
Head Gaskets, 580
Multilayered Steel Gaskets, 581
Installing the Head Gasket, 581
Head Bolt Torque Sequence, 582
Torque-to-Yield Bolts, 582
Timing Drives for Overhead Cam Engines, 583
Lifter and Pushrod Installation, 584
Hydraulic Lifters, 585
Solid Lifters, 585
Assembly Sealants, 586
Installing Manifolds, 586
Cover Gasket Materials, 587
Installing Timing Covers, 588
Installing the Vibration Damper, 589
Installing the Oil Pump, 589
The Oil Pan, 589
Installing the Water Pump, 590
Engine Painting, 590
Checking for Proper Oil Pressure, 590
Setting Initial Ignition Timing, 591
Summary, 597
Review Questions, 597
Chapter Quiz, 597
Chapter 31. Engine Installation and In-Vehicle Service, 599
Objectives, 599
Key Terms, 599
Preinstallation Checklist, 600
Manual Transmission Installation, 600
Automatic Transmission Installation, 601
Starter, 601
Accessories, 602
Engine Installation, 602
Cooling System, 602
Fuel and Emission Controls, 602
Electrical System, 603
Engine Start, 603
Normal Operating Temperature, 603
How to Warm Up a Cold Engine, 604
Break-In Precautions, 604
Summary, 616
Review Questions, 616
Chapter Quiz, 616
Appendix 1. Timing Belt Replacement Guide, 619
Appendix 2. ASE Test Correlation Chart, 625
Appendix 3. NATEF Task List, 628
English Glossary, 631
Spanish Glossary, 647
Index, 667

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