Modern Automotive Technology Automotive Technology, Principles, Diagnosis,

7th
Edition and Service
James E. Duffy 5th Edition
ISBN-13: 978-1-59070-956-6 James D. Halderman
ISBN-10: 0-13-399461-9
ISBN-13: 978-0-13-399461-2

Cover image from Amazon.com

Chapter 1 – The Automobile – 1
Parts, Assemblies, and Systems – 1
Hybrid Vehicle – 18
Chapter 2 – Automotive Careers and ASE
Certification – 22
The Automotive Technician – 22
Preparing for a Career in Automotive Technology
– 27
ASE Certification – 27
Entrepreneurship – 31
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 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 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
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 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 – Basic Hand Tools – 34 Chapter 9 – Hand Tools – 68
Tool Rules – 34 Wrenches – 68
Tool Storage – 34 Ratchets, Sockets, and Extensions – 69
Wrenches – 35 Screwdrivers – 72
Screwdrivers – 38 Hammers and Mallets – 72
Pliers – 39 Pliers – 73
Hammers – 40 Cutters – 75
Chisels and Punches – 40 Punches and Chisels – 75
Files – 42 Removers – 76
Saws – 43 Hacksaws – 77
Holding Tools – 43 Basic Hand Tool List – 78
Cleaning Tools – 44 Tool Sets and Accessories – 78
Probe and Pickup Tools – 44 Seal Pliers and Drivers – 79
Pry Bars – 45 Electrical Hand Tools – 79
Safety Tips For Using Hand Tools – 80
Hand Tool Maintenance – 80
Chapter 4 – Power Tools and Equipment – 47 Chapter 10 – Power Tools and Shop Equipment
Compressed-Air System – 47 – 82
Air Tools – 48 Air Compressor – 82
Electric Tools – 50 Air and Electrically Operated Tools – 82
Hydraulic Tools – 52 Trouble Lights – 84
Shop Equipment – 53 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 5 – The Auto Shop and Safety – 60 Chapter 6 – Shop Safety – 41
Auto Shop Layout – 60 Personal Protective Equipment – 41
Shop Safety – 62 Safety Tips For Technicians – 42
Types of Accidents – 62 Cleaning Methods and Processes – 43
General Safety Rules – 66 Electrical Cord Safety – 44
Customer Relations – 67 Jump-Starting and Battery Safety – 44
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 6 – Automotive Measurement and Chapter 12 – Measuring Systems and Tools –
Math – 70 97
Measuring Systems – 70 English Customary Measuring System – 97
Measuring Tools – 72 Metric System of Measure – 98
Other Measurements and Measuring Tools – 77 Linear Measurements (Tape Measure/Rule) – 98
Using Basic Mathematics – 79 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 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 7 – Service Information and Work Chapter 15 – Service Information – 119
Orders – 85 Vehicle Service History Records – 120
Service Manuals – 85 Owner’s Manuals – 120
Using a Service Manual – 90 Lubrication Guides – 120
Service Publications – 92 Service Manuals – 120
Technical Assistance Hotlines – 92 Advantages of Hard Copy Versus Electronic
Computer-Based Service Data – 94 Service Information – 122
Work Orders – 94 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 8 – Basic Electricity and Electronics – Chapter 39 – Electrical Fundamentals – 420
97 Introduction – 420
Electricity – 97 Electricity – 421
Automotive Electronics – 100 How Electrons Move Through a Conductor – 423
Automotive Wiring – 103 Units of Electricity – 424
Basic Electrical Tests – 105 Sources of Electricity – 425
Oscilloscope – 107 Conductors and Resistance – 426
Scan Tools – 108 Resistors – 427
Customer Relations – 108 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 Series-
Parallel 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
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 9 – Fasteners, Gaskets, Seals, and Chapter 8 – Fasteners and Thread Repair – 57
Sealants – 111 Threaded Fasteners – 58
Fasteners – 111 Metric Bolts – 58
Washers – 113 Grades of Bolts – 58
Machine Screws – 114 Tensile Strength – 59
Sheet Metal Screws – 114 Nuts – 60
Nonthreaded Fasteners – 114 Taps and Dies – 60
Torquing Bolts and Nuts – 115 Thread Pitch Gauge – 61
Thread Repairs – 117 Sheet Metal Screws – 62
Removing Damaged Fasteners – 119 Washers – 62
Gaskets and Seals – 120 Snap Rings and Clips – 62
How to Avoid Broken Fasteners – 64
Thread Repair Inserts – 64
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 10 – Vehicle Maintenance, Fluid Chapter 7 – Environmental and Hazardous
Service, and Recycling – 127 Materials – 48
Lubrication Service – 127 Hazardous Waste – 48
Vehicle Maintenance – 127 Federal and State Laws – 48
Fluid Service – 127 Asbestos Hazards – 49
Filter Service – 135 Used Brake Fluid – 50
Chassis Lubrication – 135 Used Oil – 50
Service Intervals – 136 Solvents – 51
General Inspection and Problem Location – 137 Coolant Disposal – 52
Recycling and Disposal of Auto Shop Waste – 139 Lead-Acid Battery Waste – 53
Fuel Safety and Storage – 53
Airbag Handling – 54
Used Tire Disposal – 54
Air-Conditioning Refrigerant Oil Disposal – 54
Chapter 17 – Preventative Maintenance and
Service Procedures – 130
Preventative Maintenance – 130
Getting Ready for Service – 130

Chapter 11 – Engine Fundamentals – 145
Engine Operation – 145
Engine Bottom End – 146
Engine Top End – 152
Engine Front End – 156
Chapter 12 – Engine Design Classifications –
162
Engine Classifications – 162
Cylinder Arrangement – 162
Alternative Engines – 169
Typical Automotive Engines – 173
Chapter 13 – Engine Top End Construction –
182
Cylinder Head Construction – 182
Valve Train Construction – 185
Intake Manifold Construction – 195
Exhaust Manifold Construction – 196
Chapter 14 – Engine Bottom End Construction
– 199
Cylinder Block Construction – 200
Piston Construction – 201
Piston Ring Construction – 204
Piston Pin Construction – 206
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
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 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 Measurement – 152
Compression Ratio – 155
Torque and Horsepower – 157
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 Measurement – 152
Compression Ratio – 155
Torque and Horsepower – 157
Chapter 24 – Intake and Exhaust Systems – 219
Air Intake Filtration – 219
Throttle-Body Injection Intake Manifolds – 221
Port Fuel-Injection Intake Manifolds – 222
Exhaust Gas Recirculation Passages – 223
Exhaust Manifolds – 224
Mufflers – 225
Chapter 34 - Engine Blocks – 351
Engine Blocks – 351
Engine Block Service – 356
Block Preparation For Assembly – 362
Chapter 33 – Pistons, Rings, and Connecting
Rods – 336
Connecting Rod Construction – 207 Pistons – 337
Crankshaft Construction – 209 Piston Construction – 337
Engine Bearing Construction – 209 Piston Pins – 340
Rear Main Bearing Oil Seal Construction – 212 Piston Pin Retaining Methods – 341
Select-Fit Parts – 213 Piston Rings – 342
Balancer Shafts – 213 Piston Ring Construction – 344
Connecting Rods – 345
Connecting Rod Service – 347
Piston and Rod Assembly – 348
Piston Ring Service – 349
Chapter 15 – Engine Front End Construction – Chapter 32 – Camshafts and Valve Trains – 314
217 Camshaft – 315
Vibration Damper Construction – 217 Camshaft Design – 315
Camshaft Drive Construction – 218 Camshaft Drives – 317
Camshaft Movement – 319
Rocker Arms – 320
Pushrods – 322
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 16 – Engine Size and Performance Chapter 13 – Scientific Principles and Materials
Measurements – 225 – 105
Engine Size Measurement – 225 Scientific Method – 105
Force, Work, and Power – 226 Energy Principles – 106
Compression Ratio – 227 Torque – 106
Engine Torque – 228 Work – 106
Horsepower – 228 Power – 107
Engine Efficiency – 230 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 17 – Computer System Fundamentals
– 235
Cybernetics – 235
Computer Advantages – 236
Digital Electronics – 237
Integrated Circuits – 239
Computer Signals – 239
Computer System Operation – 243
Sensors – 244
Computers – 249
Actuators – 255
Chapter 18 – On-Board Diagnostics and Scan
Tools – 261
On-Board Diagnostic Systems – 261
Scanning Computer Problems – 261
Scanning Computer Problems – 265
Energizing OBD I Systems without a Scan Tool –
274
Erasing Trouble Codes – 277
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
Semiconductors – 509
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 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

Chapter 19 – Computer System Service – 282
Preliminary Visual Inspection – 282
Computer System Circuit Problems – 283
Sensor and Actuator Problems – 284
Sensor Service – 285
Actuator Service – 288
Computer Service – 291
Computer System Sensor and Actuator Diagnosis
– 298
Enabling Conditions – 962
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 71 – Computer Fundamentals – 812
Computer Fundamentals – 812
Computer Functions – 813
Digital Computers – 814
Computer Input Sensors – 816
Computer Outputs – 816
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
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

Chapter 20 – Automotive Fuels, Gasoline and
Diesel Combustion – 301
Petroleum (Crude Oil) – 301
Gasoline – 301
Diesel Fuel – 307
Alternative Fuels – 310
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 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 Measurement – 152
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

Chapter 21 – Fuel Tanks, Pumps, Lines, and
Filters – 315
Fuel Supply System – 315
Fuel Supply System Service – 324
Workplace Skills – 335
Fuel Delivery System Diagnosis – 339
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 66 – Gasoline – 754
Gasoline – 754
Refining – 755
Volatility – 756
Gasoline Combustion Process – 757
Normal and Abnormal Combustion – 758
Octane Rating – 759
High-Altitude Octane Requirements – 759
Gasoline Additives – 760
Gasoline Blending – 761
Reformulated Gasoline – 762
Testing Gasoline For Alcohol Content – 762
General Gasoline Recommendations – 76
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 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

Chapter 22 – Gasoline Injection Fundamentals
– 340
Gasoline Injection Fundamentals – 340
Gasoline Injection Clarifications – 342
Throttle Body and Multiport Injection – 342
Gasoline Injection Controls – 344
Electronic Fuel Injection – 345
Engine Sensors – 348
Injector Pulse Width – 354
Throttle Body Injection – 355
Engine Idle Speed Control – 357
Continuous Throttle Body Injection – 358
Electronic Multiport Injection – 358
Air-Fuel Emulsion Injector – 358
Unitized Multiport Injection – 358
Injector Resistor Pack – 362
Airflow-Sensing Multiport EFI – 362
Pressure-Sensing Multiport EFI – 364
Hydraulic-Mechanical Continuous Injection
System – 364
Fuel Accumulator – 366
Direct Gasoline Injection – 366
Chapter 23 – Gasoline Injection Diagnosis and
Repair – 371
Gasoline Injection Problem Diagnosis – 371
Fuel Pressure Regulator Service – 374
Injector Problems – 376
Throttle Body Injector Service – 376
Servicing EFI Multiport Injectors – 378
Engine Sensor Service – 384
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
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 81 – Fuel-Injection System Diagnosis
and Service – 900
Port Fuel-Injection Pressure Regulator Diagnosis –
900
Diagnosing Electronic Fuel-Injection Problems
Using Visual Inspection – 901
Scan Tool Vacuum Leak Diagnosis – 902
Port Fuel-Injection System Diagnosis – 902
Control Module Service – 388
Gasoline Injection Adjustments – 389
Testing Idle Control Motor – 390
Multiport Throttle Body Service – 391
Gasoline Injection System Diagnosis – 392
Chapter 24 – Carburetor Operation and
Service – 396
Basic Carburetor – 396
Carburetor Problem Diagnosis – 403
Chapter 25 – Diesel Injection Fundamentals –
410
Basic Diesel Injection System – 410
Diesel Injection System Accessories – 422
Piezo Diesel Injectors – 424
Chapter 26 – Diesel Injection Diagnosis,
Service, and Repair – 429
Diesel Injection Maintenance – 429
Diesel Injection Diagnosis – 430
Diesel Injection Service – 434
Diesel Engine Diagnosis – 447
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
N/A
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 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

Chapter 27 – Exhaust Systems, Turbochargers,
and Superchargers – 449
Exhaust Systems – 449
Exhaust System Service – 452
Superchargers and Turbochargers – 455
Chapter 28 – Automotive Batteries – 473
Battery Principles – 473
Battery Functions – 474
Battery Construction – 475
Wet- and Dry-Charged Batteries – 478
Maintenance-Free Batteries – 479
Gel Battery – 479
Absorbed Glass Mat Battery – 479
Battery Ratings – 479
Battery Temperature and Efficiency – 480
Chapter 29 – Battery Testing and Service – 483
Battery Maintenance – 483
Jump Starting – 491
Battery Load Test – 492
Activating Dry-Charged Battery – 494
Removing and Replacing a Battery – 494
Battery Diagnosis – 498
Chapter 30 – Starting System Fundamentals –
499
Starting System Principles – 499
Starting Motor Construction – 504
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 25 – Turbocharging and
Supercharging – 227
Introduction – 228
Forced Induction Principles – 228
Superchargers – 230
Turbochargers – 230
Boost Control – 232
Turbocharger Failures – 234
Nitrous Oxide – 235
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 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

Chapter 31 – Starting System Testing and
Repair – 513
Starting System Diagnosis – 513
Battery Cable Service – 517
Starter Solenoid Service – 517
Ignition Switch Service – 518
Starter Relay Service – 518
Neutral Safety Switch Service – 518
Starter Service – 519
Starting System Diagnosis – 531
Chapter 32 – Charging System Fundamentals –
532
Basic Charging System Parts – 532
Charging System Functions – 533
Types of Charging Systems – 533
Alternator Operation – 534
Alternator Construction – 535
Charge Indicators – 543
Chapter 33 – Charging System Diagnosis,
Testing, and Repair – 548
Charging System Diagnosis – 548
Charging System Precautions – 550
Charging System Tests – 550
Alternator Service – 556
Regulator Service – 562
Charging System Diagnosis – 565
Chapter 34 – Ignition System Fundamentals –
567
Functions of an Ignition System – 567
Basic Ignition System – 567
Ignition System Supply Voltage – 568
Primary and Secondary Circuits – 569
Ignition Coil – 569
Ignition Distributors – 572
Contact Point Ignition System – 573
Electronic Ignition System – 573
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 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
Knock Sensors – 791
Ignition Control Circuits – 793
Distributor Cap and Rotor – 576
Secondary Wires – 578
Spark Plugs – 579
Ignition Timing – 581
Crankshaft-Triggered Ignition – 584
Distributorless Ignition System – 585
Direct Ignition System – 587
Dual Spark Plug Ignition – 590
Multiple Discharge Ignition – 591
Engine Firing Order – 591

Chapter 35 – Ignition System Problems, Chapter 70 - Ignition System Diagnosis and

Testing, and Repair – 595 Service – 794
Ignition System Problem Diagnosis – 595 Checking for Spark – 794
Preliminary Checks of Ignition System – 595 Ignition Coil Testing – 795
Evaluating the Symptoms – 599 Ignition Sensor Testing – 796
Spark Plug Service – 600 Spark Plug Wire Inspection – 799
Secondary Wire Service – 602 Spark Plugs – 801
Distributor Service – 603 Ignition Timing – 804
Distributor Cap and Rotor Service – 606 Firing Order – 805
Electronic Ignition Distributor Service – 606 Distributor Indexing – 805
Pickup Coil Service – 606 No-Start Diagnosis – 806
Contact Point Distributor Service – 608 Ignition Scope Testing – 807
Dwell – 610 Scope-Testing a Waste-Spark System – 811
Ignition Timing Adjustment – 611 Scope-Testing a COP System – 811
Testing Centrifugal and Vacuum Distributor Ignition System Symptom Guide – 811
Advance Systems – 614
Removing the Ignition Distributor – 615
Rebuilding a Distributor – 615
Ignition Supply Voltage Test – 618
Ignition Coil (Coil Pack) Service – 618
Ignition Switch Service – 619
Ignition Control Module Service – 620
Distributorless Ignition System Service – 621
Direct Ignition System Service – 622
Ignition System Diagnosis – 627
Chapter 36 – Lights, Instrumentation, Wipers, Chapter 56 – Lighting and Signaling Service –
and Horns—Operation and Service – 631 604
Lighting Systems – 632 Introduction – 605
Light System Service – 641 Exterior Lighting – 605
Instrumentation – 647 Bulb Numbers – 605
Windshield Wipers – 654 Brake Lights – 608
Horns – 658 Turn Signals – 610
Theft-Deterrent Systems – 659 Headlights – 611
Finding Common Electrical Problems – 659 High-Intensity Discharge Headlights – 614
Headlamp Diagnosis – 665 LED Headlights – 615
Turn Signal Diagnosis – 666 Headlight Aiming – 615
Adaptive Front Lighting System – 616
Daytime Running Lights – 617
Dimmer Switches – 617
Courtesy Lights – 617
Illuminated Entry – 617

Chapter 37 – Sound Systems and Power
Accessories – 667
Sound Systems – 667
Power Seats – 674
Power Windows – 675
Power Door Locks – 678
Power Trunk Release – 681
Power Steering Wheel – 681
Rear Window Defogger – 681
Heated Windshield – 683
Reminder System – 683
Cruise Control Systems – 683
Power Mirrors – 687
Cellular Mobile Telephone – 687
Driver Information Center – 688
Vehicle Degaussing – 688
Sound System Diagnosis – 693
Power Accessory Diagnosis – 693
Fiber Optics – 617
Automatic Dimming Mirrors – 617
Feedback – 620
Lighting System Diagnosis – 620
Lighting System Symptom Guide – 620
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 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 59 – Accessory Circuits – 657
Cruise Control – 658
Troubleshooting Cruise Control – 659
Electronic Throttle Cruise Control – 659
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

Chapter 38 – Hybrid Drive System Operation
and Repair – 694
Introduction – 694
Hybrid System Voltages – 698
Hybrid Drive Assemblies – 699
Hybrid Service Safety – 709
Hybrid Problem Diagnosis – 711
Hybrid Battery Pack Service – 711
Checking HV Battery Relays and Contactors – 715 Common Features of Most Hybrids – 989
Servicing Hybrid Power Cables – 716
Servicing the Power Control Module – 716
Servicing the Hybrid Cooling System – 716
Servicing the Motor-Generator – 717
Hybrid Wiring Problems – 718
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 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
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
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 39 – Cooling System Fundamentals –
725
Cooling System Functions – 725
Cooling System Operation – 726
Cooling System Types – 727
Basic Cooling System – 727
Closed and Open Cooling Systems – 733
Cooling System Instrumentation – 738
Antifreeze – 739
Block Heater – 740
Chapter 40 – Cooling System Testing,
Maintenance, and Repair – 745
Cooling System Problem Diagnosis – 745
Cooling System Problems – 746
Water Pump Service – 750
Thermostat Service – 751
Cooling System Hose Service – 754
Radiator and Pressure Cap Service – 755
Fan Belt Service – 756
Engine Fan Service – 757
Freeze Plug Service – 758
Coolant Service – 759
Flushing a Cooling System – 761
Temperature Gauge Service – 762
Cooling System Diagnosis – 766
Chapter 41 – Lubrication System
Fundamentals – 768
Lubrication System Functions – 768
Lubrication System Operation – 768
Positive Crankcase Ventilation System – 780
Oil Pressure Indicator – 781
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 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 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 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

Chapter 42 – Lubrication System Testing,
Service, and Repair – 786
Lubrication System Problem Diagnosis – 786
Engine Oil and Filter Service – 790
Oil Pan Service – 791
Oil Pump Service – 793
Pressure Relief Valve Service – 797
Oil Pressure Indicator and Gauge Service – 798
PCV Valve Service – 799
Lubrication System Diagnosis – 801
Chapter 43 – Emission Control Systems – 803
Air Pollution – 803
Motor Vehicle Emissions – 803
Engine Modifications Related to Emission Control
– 805
Vehicle Emission Control Systems – 806
Positive Crankcase Ventilation (PCV) – 806
Evaporative Emissions Control Systems – 808
Exhaust Gas Recirculation (EGR) – 811
Air Injection System – 815
Pulse Air System – 817
Thermostatic Air Cleaner System – 818
Catalytic Converter – 818
Computerized Emission Control Systems – 821
OBD II Emission System Monitoring – 826
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 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 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

Chapter 44 – Emission Control System Testing,
Service, and Repair – 831
Computer-Controlled Emission System Service –
831
Emission Maintenance Reminder – 832
Inspecting Emission Control Systems – 832
Exhaust Gas Analyzer – 833
State Emissions Testing Programs – 837
Vacuum Solenoid Service – 840
PCV System Service – 842
Evaporative Emissions Control System Service –
843
Thermostatic Air Cleaner System Service – 844
EGR System Service – 845
Air Injection System Service – 846
Pulse Air System Service – 846
Catalytic Converter Service – 847
Oxygen Sensor Service – 849
Emission Control Information Sticker – 852
OBD II Drive Cycle – 852
Emission Control System Diagnosis – 856
Chapter 45 – Engine Performance and
Driveability – 859
Locating Engine Performance Problems – 859
Typical Performance Problems – 863
Other Performance Problems – 866
Engine Performance Diagnosis – 870
Chapter 46 – Advanced Diagnostics – 871
Advanced Diagnostics – 871
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 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 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 87 – On-Board Diagnosis – 957
On-Board Diagnostics Generation-II (OBD-II)
Systems – 958
Diagnostic Executive and Task Manager – 958
Monitors – 959

Chapter 47 – Engine Tune-Up – 901
Engine Tune-Up – 901
General Tune-Up Rules – 903
Tune-Up Safety Rules – 903
Typical Tune- Up Procedures – 904
Diesel Engine Tune-Up (Maintenance) – 908
Engine Tune-Up (Maintenance) Intervals – 909
Chapter 48 – Engine Mechanical Problems –
913
Why Is Diagnosis Important? – 913
Symptoms of Engine Mechanical Problems – 913
Decide What Type of Engine Repair Is Needed –
920
Evaluating Engine Mechanical Problems – 920
Service Manual Troubleshooting Charts – 926
Compression Test Results – 930
Cylinder Linkage Test Results – 930
Chapter 49 – Engine Removal, Disassembly,
and Parts Cleaning – 931
Engine Removal – 931
Engine Disassembly – 937
Cleaning Engine Parts – 942
OBD-II Monitor Information – 959
Enabling Criteria – 960
OBD-II DTC Numbering Designation – 961
OBD-II Freeze-Frame – 962
Enabling Conditions – 962
PCM Tests – 963
Global OBD-II – 964
Diagnosing Problems Using Mode Six – 964
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 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 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 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

Chapter 50 – Engine Bottom End Service – 948
Do You Need Review? – 948
Cylinder Block Service – 948
Balancer Shaft Service – 954
Piston Service – 954
Piston Pin Service – 956
Connecting Rod Service – 958
Piston Ring Service – 958
Crankshaft Service – 960
Installing a Piston and Rod Assembly – 964
Torque-to-Yield Bolts – 966
Engine Balancing – 966
Final Assembly of Engine – 967
Chapter 51 – Engine Top End Service – 971
Cylinder Head Service – 971
Diesel Precombustion Chamber Service – 974
Valve Guide Service – 974
Valve Grinding – 976
Valve Seat Reconditioning – 979
Testing Valve Springs – 983
Assembling Cylinder Head – 984
Camshaft Service – 987
Lifter Service – 988
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 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 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 30 – Cylinder Head and Valve Guide
Service – 280
Introduction – 280
Push Rod Service – 989
Rocker Arm Assembly Service – 989
Engine Top End Reassembly – 989
Valve Adjustment – 993
Installing Valve Covers – 996
Chapter 52 – Engine Front End Service and
Engine Installation – 1001
Timing Chain Service – 1001
Timing Gear Service – 1003
Crankshaft Front Seal Service – 1004
Engine Front Cover Service – 1006
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
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 32 – Camshafts and Valve Trains – 314
Camshaft – 315
Camshaft Design – 315
Camshaft Drives – 317
Camshaft Movement – 319
Rocker Arms – 320
Pushrods – 322
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 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
Timing Belt Service – 1007
Complete Engine Assembly – 1011
Installing the Engine – 1011
Engine Break-In – 1012
Chapter 53 – Clutch Fundamentals – 1017
Clutch Principles – 1017
Clutch Construction – 1019
Chapter 54 – Clutch Diagnosis and Repair –
1031
Diagnosing Clutch Problems – 1031
Servicing a Clutch – 1037
Clutch Diagnosis – 1047
Chapter 55 – Manual Transmission
Fundamentals – 1049
Basic Transmission Parts – 1049
Purpose of a Manual Transmission – 1049
Gear Fundamentals – 1050
Manual Transmission Construction – 1052
Transmission Types – 1060
Transmission Power Flow – 1060
Speedometer Drive – 1066
Manual Transmission Switches – 1066
Hybrid Engine Precautions – 255
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 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 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

Chapter 56 – Manual Transmission Diagnosis
and Repair – 1070
Manual Transmission Problem Diagnosis – 1070
Manual Transmission Problems – 1070
Transmission Identification – 1072
Manual Transmission Service – 1072
Adjusting Transmission Linkage – 1078
Manual Transmission/Transaxle Diagnosis – 1081
Chapter 57 – Automatic Transmission
Fundamentals – 1083
Basic Automatic Transmission – 1083
Hydraulic System – 1095
Parking Pawl – 1100
Automatic Transmission Power Flow – 1100
Electronic Transmission Control – 1100
Continuously Variable Transmission – 1103
Complete Transmission Assemblies – 1105
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 127 – Automatic
Transmission/Transaxle Principles – 1551
Background – 1551
Torque Converters – 1551
Lockup Torque Converter – 1556
Shift Modes – 1557
Planetary Gear Sets – 1558
Compound Planetary Gear Set – 1559
Automatic Transaxles – 1561
Nonplanetary Gear Automatic Transaxles – 1561
Continuously Variable Transmission – 1561
Dual Clutch Automatic Transmissions – 1565
Chapter 128 – Hydraulic Components and
Control Systems – 1567
Automatic Transmission Fluid – 1567
Automatic Transmission Fluid Cooler – 1568
Pump – 1569
Apply or Holding Devices – 1571
Bands – 1571
Multiple-Plate Clutches – 1572
Accumulators – 1574
One-Way Clutches – 1575
Valve Body – 1576
Hydraulically Controlled Transmission Valves –
1577
Electronically Controlled Transmissions – 1580
 Typical Torque Flow – 1582

Chapter 58 – Automatic Transmission Service – Chapter 129 – Automatic

1110
Automatic Transmission Identification – 1110
Automatic Transmission Diagnosis – 1110
Automatic Transmission Maintenance – 1116
Major Transmission Service – 1123
Automatic Transmission and Transaxle Diagnosis Chapter 130 – Automatic
– 1130
Chapter 59 – Drive Shafts and Transfer Cases – Chapter 123 – Drive Axle Shafts and CV Joints
1131
Drive Shaft Assembly – 1131
Drivelines – 1137
Transfer Cases – 1137
Chapter 60 – Drive Shaft and Transfer Case
Diagnosis, Service, and Repair – 1144
Drive Shaft Problems – 1144
Drive Shaft Inspection – 1145
Drive Shaft Maintenance – 1147
Drive Shaft Service – 1147
Transfer Case Service – 1150
Drive Line Problem Diagnosis – 1155
Transfer Case Diagnosis Part-Time Drive – 1155 CV Joint Service – 1509
Transfer Case Diagnosis Full-Time Drive – 1156
Chapter 61 – Differential and Rear Drive Axle Chapter 125 – Drive Axles and Differentials –
Fundamentals – 1157
Basic Rear Drive Axle Assembly – 1157
Differential Construction – 1158
Differential Action – 1162
Limited-Slip Differentials – 1162
Rear Drive Axles – 1166
Front Drive Axle—Four-Wheel-Drive Vehicles –
1168
Transmission/Transaxle Diagnosis and In-
Vehicle Service – 1586
Transmission Problem Diagnosis – 1586
Fluid Leak Diagnosis – 1591
In-Vehicle Service – 1594
Transmission/Transaxle Unit Repair – 1598
Verify the Need For Unit Repair – 1598
Removing the Automatic Transmission/Transaxle
For Service – 1599
Automatic Transmission/Transaxle Disassembly –
1600
Reassembling an Automatic
Transmission/Transaxle – 1604
Flushing the Cooler and Torque Converter – 1607
Dynamometer Testing the Automatic
Transmission/Transaxle – 1608
Reinstalling the Automatic
Transmission/Transaxle – 1608
Road Test – 1608
– 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
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

Chapter 62 – Differential and Rear Drive Axle
Diagnosis and Repair – 1173
Differential and Rear Axle Problem Diagnosis –
1173
Differential Maintenance – 1175
Rear Axle Service – 1176
Differential Service – 1179
Rear Axle Diagnosis – 1191
Chapter 63 – Transaxle and Front Drive Axle
Fundamentals – 1193
Transaxle – 1193
Manual Transaxle – 1195
Automatic Transaxle – 1201
Front Drive Axle Assembly – 1210
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 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 126 – Four-Wheel-Drive and All-
Wheel 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 64 – Transaxle and Front Drive Axle
Diagnosis and Repair – 1217
Transaxle Problem Diagnosis – 1217
Front Drive Axle Problems – 1219
Transaxle Maintenance – 1219
Front Drive Axle Service – 1222
Transaxle Removal – 1228
Transaxle Service – 1228
Transaxle Installation – 1229
Automatic Transmission and Transaxle Diagnosis
– 1236
Chapter 65 – Tire, Wheel, and Wheel Bearing
Fundamentals – 1241
Tires – 1241
Wheels – 1248
Valve Stems and Cores – 1249
Lug Nuts, Studs, and Bolts – 1250
Wheel Weights – 1250
Hub and Wheel Bearing Assemblies – 1250
Chapter 126 – Four-Wheel-Drive and All-
Wheel 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 66 – Tire, Wheel, and Wheel Bearing Chapter 98 – Wheel Bearings and Service –
Service – 1257 1070
Tire, Wheel, and Wheel Bearing Diagnosis – 1257 Antifriction Bearings – 1071
Wheel Cover Removal and Installation – 1260 Bearing Greases – 1072
Tire Maintenance – 1260 Bearing Diagnosis – 1074
Measuring Tire and Wheel Runout – 1261 Wheel Bearing Service – 1075
Wheel Balance – 1262 Sealed Bearing Replacement – 1078
Mounting and Dismounting Tires – 1265 Rear Drive Axle Classifications – 1079
Tire Puncture Repair – 1266 Rear Axle Bearing and Seal Replacement – 1080
Wheel Bearing Service – 1268 Bearing Failure Analysis – 1082
Tire, Wheel, and Bearing Diagnosis – 1277
Chapter 67 – Suspension System Fundamentals Chapter 112 – Suspension System Principles
– 1280 and Components – 1288
Functions of a Suspension System – 1280 Introduction – 1289
Basic Suspension System – 1280 Frame Construction – 1289
Independent and Nonindependent Suspension Platforms – 1290
Systems – 1281 Unsprung Weight – 1290
Understeer and Oversteer – 1281 Types of Suspensions – 1290
Suspension System Springs – 1282 Hooke’s Law – 1291
Suspension System Construction – 1284 Coil Springs – 1291
Lon-Short Arm Suspension – 1289 Leaf Springs – 1295
Torsion Bar Suspension – 1289 Torsion Bars – 1297
MacPherson Strut Suspension – 1289 Suspension Principles – 1298
Pickup Truck Suspension Systems – 1289 Steering Knuckles – 1299
Rear Suspension Systems – 1289 Control Arms – 1299
Suspension Leveling Systems – 1291 Ball Joints – 1300
Electronic Suspension System – 1295 Strut Rods – 1301
Active Suspension System – 1297 Stabilizer Bars – 1301
Shock Absorbers – 1302
Struts – 1304
Bump Stops – 1308
Chapter 113 – Front Suspensions and Service –

Chapter 68 – Suspension System Diagnosis and
Repair – 1302
Suspension System Diagnosis – 1302
Shock Absorber Service – 1302
Suspension Spring Service – 1304
Ball Joint Service – 1308
Suspension Bushing Service – 1310
MacPherson Strut Service – 1312
Wheel Alignment is Needed – 1315
Computerized Suspension Diagnosis – 1316
Suspension System Diagnosis – 1323
1311
Front Suspension Types – 1312
Short/Long-Arm Suspensions – 1313
Strut Suspension – 1314
Servicing the Suspension System – 1315
Road Test Diagnosis – 1316
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 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
Dry Park Test (Suspension) 1317
Visual Inspection – 1317
Ball Joints – 1318
Kingpin Diagnosis and Service – 1322
Shock Absorbers and Struts – 1323

Chapter 69 – Steering System Fundamentals –
1324
Functions of a Steering System – 1324
Basic Steering Systems – 1324
Steering Column Assembly – 1325
Steering Gear Principles – 1327
Steering Linkage (Worm-type Gearbox) – 1329
Manual Rack-and-Pinion Steering – 1330
Integral-Piston Power Steering System (Linkage
Type) – 1336
External Cylinder Power Steering (Linkage Type)
– 1337
Power Rack-and-Pinion Steering – 1338
Electronic Steering Assist – 1341
Four-Wheel Steering Systems – 1342
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
Common Wear Items – 1380
Under-Vehicle Inspection – 1380
Steering Linkage Replacement – 1382
Chapter 118 – Power-Assisted Steering
Operation and Service – 1388
Power Steering Hydraulic Systems – 1388

Chapter 70 – Steering System Diagnosis and
Repair – 1347
Steering System Problem Diagnosis – 1347
Steering System Maintenance – 1349
Steering Column Service – 1350
Manual Steering Gearbox Service (Recirculating-
Ball Type) – 1351
Steering Linkage Service – 1353
Manual Rack-and-Pinion Service – 1355
Power Steering System Service – 1356
Manual and Power Steering Systems Diagnosis –
1366
Chapter 71 – Brake System Fundamentals –
1369
Basic Brake System – 1369
Braking Ratio – 1371
Brake System Hydraulics – 1371
Brake System Components – 1372
Parking Brakes – 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 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
Common Wear Items – 1380
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 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 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 101 – Disc Brakes – 1114
Disc Brakes – 1115
Disc Brake Construction – 1118
Disc Brake Pads – 1118
Brake Rotors – 1122
Caliper Design – 1122
Rear Disc Brakes – 1126
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

Chapter 72 – Brake System Diagnosis and
Repair – 1394
Brake System Problem Diagnosis – 1394
Brake System Inspection – 1396
Vacuum Booster Service – 1398
Hydraulic Booster Service – 1399
Brake System Bleeding – 1401
Brake Line and Hose Service – 1403
Disc Brake Service – 1403
Brake Disc (Rotor) Service – 1405
Drum Brake Service – 1410
Parking Brake Adjustment – 1416
Brake System Diagnosis – 1421
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 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 97 – Brake Bleeding Methods and
Procedures – 1061
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 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 102 – Disc Brakes Diagnosis and
Service – 1128
Disc Brake Diagnostic Procedure – 1128
Visual Inspection – 1128
Disc Brake Caliper Service – 1130
Servicing Disc Brake Calipers – 1132
Disc Brake Squeal Correction – 1137
Disc Brake Symptom Guide – 1138
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 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

Chapter 73 – Anti-Lock Brakes, Traction
Control, and Stability Control – 1422
Anti-Lock Brake Systems (ABS) – 1422
Traction and Stability Control Systems – 1430
ABS Service – 1433
Traction and Stability Control System Service –
1439
Final System Check – 1441
Anti-Lock Brake and Traction Control System
Diagnosis – 1444
Chapter 74 – Wheel Alignment – 1445
Wheel Alignment Principles – 1445
Caster – 1445
Camber – 1447
Toe – 1447
Steering Axis Inclination – 1448
Hydro-Boost Symptom-Based Guide – 1207
Chapter 106 – ABS Components and Operation
– 1208
Antilock Braking System – 1208
ABS Operation – 1210
System Configurations – 1211
ABS Components – 1212
ABS Control Module – 1214
Hydraulic Modulator Assembly – 1214
Brake Pedal Feedback – 1217
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 119 – Wheel Alignment Principles –
1413
Definition of a Wheel Alignment – 1413
Alignment-Related Problems – 1413
Alignment Angles – 1414
Steering Axis Inclination (SAI) – 1421
Setback – 1448
Toe-Out on Turns (Turning Radius) – 1449
Tracking – 1449
Prealignment Inspection – 1449
Adjusting Wheel Alignment – 1452
Wheel Alignment Tools and Equipment – 1455
Alignment Machines – 1457
Road Test after Alignment – 1460
Wheel Alignment Diagnosis – 1465
Chapter 75 – Heating and Air Conditioning
Fundamentals – 1469
Principles of Refrigeration – 1469
Basic Refrigeration Cycle – 1471
Automotive Air Conditioning System – 1473
Air Conditioning System Controls – 1480
Service Valves – 1483
Heating System – 1483
Heating and Air Conditioning Controls – 1483
Ducts and Vents – 1486
Passenger Compartment Filters – 1486
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
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 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
Solar Ventilation – 1486
Chapter 76 – Heating and Air Conditioning
Service – 1493
Inspecting an Air Conditioning System – 1493
Refrigerant Safety Precautions – 1495
R-134a Service Differences – 1495
Testing an Air Conditioning System – 1497
Recovering Refrigerant – 1502
Common A/C Component Problems – 1503
Evacuating and Air Conditioning System – 1507
Charging an Air Conditioning System – 1507
Adding Refrigerant Oil – 1509
A/C System Service Rules – 1509
Heater Service 1510
Electronic Climate Control Service – 1511
Climate Control System Diagnosis – 1517
Chapter 77 – Restraint Systems – 1521
Vehicle Collisions – 1521
Active and Passive Restraints – 1523
Seat Belt Systems – 1523
Knee Diverter – 1523
Air Bag Systems – 1525
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
Actuators – 732
Cabin Filters – 732
Vacuum Control Circuits – 733
Electric Servomotor Circuits – 733
Blower Motor Control – 734
Dual-Zone Climate Controls – 734
Rear Air-Conditioning System – 735
Recirculation Operation – 735
Hybrid Electric Vehicle Heating and Cooling
Systems – 736
Chapter 64 – Heating and Air-Conditioning
System Diagnosis – 737
HVAC Diagnostic Procedure – 737
Heater Diagnosis – 737
Check A/C System Performance – 740
Temperature and Pressure Measurements – 740
Chapter 65 – Heating and Air-Conditioning
Service – 745
Blower Motor Service – 746
Cooling System Service – 746
Refrigerant Recovery Process – 746
Evacuation Procedures – 748
Noncondensable Gases – 748
Refrigerant Recycling – 749
Recharging a System – 750
Retrofitting a CFC-12 System To a HFC-134A
System – 751
Compressor Service – 751
Condenser Service – 751
Evaporator Service – 751
Receiver/Drier or Accumulator/Drier Service –
752
Orifice Tube/Expansion Valve Service – 753
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
Air Bag Sensors – 1529
Air Bag Controller – 1530
Chapter 78 – Restraint System Service – 1534
Seat Belt Service – 1534
Air Bag System Service – 1535
Air Bag Module Service – 1536
Air Bag Sensor Service – 1538
Air Bag Controller Service – 1540
Restraint System Diagnosis – 1543
Chapter 79 – Security and Navigation Systems,
New and Future Technologies – 1544
Security Systems – 1544
Navigation Systems – 1547
Future Systems – 1548
Alternate Power Sources – 1551
Security System Diagnosis – 1556
Chapter 80 – Career Success – 1557
Traits of Desirable Employees – 1557
Earnings – 1559
Types of Shops – 1559
Getting a Job as an Automobile Technician – 1560
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 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 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 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
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