Automotive Encyclopedia

\ Automotive Safety     13\ Safety     13\ Right-to-Know Laws     15\ Proper Disposal of Automotive Wastes     15\ Fire Prevention     16\ Ventilation     16\ Jacks and Lifts     16\ Tool Safety     16\ Dress Properly     18\ Lift Properly     19\ Welding Safety     19\ Owner's Manuals, Service Manuals, and Repair Manuals     21\ Introduction     21\ Owner's Manuals     21\ Service Manuals and Repair Manuals     22\ Technical Service Bulletins     22\ Flat Rate Manual     24\ Computerized Service Information     25\ On-line Services     25\ Technical Assistance Hotlines     25\ Automotive Tools     29\ Tools     29\ Wrenches     29\ Sockets and Ratchets     31\ Specialty Wrenches     32\ Pliers     33\ Screwdrivers     34\ Hammers     35\ Electric Drills     38\ Impact Wrenches     38\ Files     39\ Retrieving Tools     40\ SolderingTools     40\ Hacksaws     41\ Taps and Dies     42\ Cleaning Equipment     43\ Fasteners, Seals, and Gaskets     47\ Fasteners     47\ Threaded Fasteners     47\ Keys and Pins     52\ Snap Rings     52\ Rivets     52\ Adhesives     53\ Sealants     53\ Seals     53\ Gaskets     55\ Measuring Instruments     59\ Measuring Instruments     59\ Micrometers     59\ Telescoping Gauges and Small Hole Gauges     61\ Vernier Calipers     61\ Dial Gauges     62\ Feeler Gauge     62\ Meters, Testers, and Analyzers     65\ Automotive Meters, Testers, and Analyzers     65\ Analog and Digital Meters     65\ Multimeters     66\ Test Light     67\ Tachometers     67\ Dwell Meters     67\ Battery/Starter Testers     67\ Timing Light     68\ Oil Pressure Gauge     68\ Fuel Pressure Gauge     69\ Compression Gauge     69\ Vacuum Gauge      69\ Vacuum Tester     69\ Exhaust Gas Analyzers     69\ Oscilloscopes     70\ Scan Tools     71\ Engine Analyzers     71\ Engine Fundamentals     73\ Engine Fundamentals     73\ Engine Fuels     73\ Engine Design     73\ Reciprocating Engines     74\ Engine Components     74\ Combustion Chamber Design     79\ Engine Operating Sequence     81\ Measuring Engine Performance     85\ Engine Performance     85\ Bore, Stroke, Displacement     88\ Compression Ratio     88\ Engine Efficiency     88\ Brake Horsepower     89\ Engine Torque     90\ Rated Horsepower     90\ Indicated Horsepower     90\ Friction Horsepower     91\ Engine Top End Construction     93\ Engine Top End     93\ Cylinder Heads     93\ Intake Manifolds     94\ Exhaust Manifolds     94\ Valve Trains     94\ Cam Functions     95\ Camshafts     96\ Camshaft Bearings      97\ Camshaft Drive Mechanisms     97\ Valves     98\ Valve Springs     102\ Valve Lifters     102\ Valve Seals     104\ Valve Retainers and Keepers     104\ Rocker Arms     104\ Push Rods     104\ Engine Bottom End Construction     107\ Engine Bottom End     107\ Engine Block Construction     107\ Crankshafts     108\ Vibration Dampers     111\ Connecting Rods     112\ Piston Construction     112\ Piston Rings     113\ Compression Rings     113\ Oil Control Rings     114\ Piston Pins     115\ Flywheels     116\ Balance Shafts     116\ Bearings     118\ Main Bearing Caps and Seals     120\ Engine Removal, Disassembly, and Cleaning     123\ Engine Removal     123\ Engine Disassembly     124\ Cleaning     127\ Inspection and Measurement     128\ Engine Top End Service     131\ Engine Top End Service     131\ Cylinder Head Service     131\ Valve Seat Reconditioning      133\ Valve Guide Service     134\ Valve Service     137\ Valve Spring Service     139\ Valve Operating Mechanisms     142\ Push Rod Service     143\ Rocker Arm Service     143\ Lifter Service     143\ Camshaft Service     145\ Camshaft Bearings     146\ Timing Belt Service     147\ Timing Chain Service     147\ Timing Gear Service     148\ Head Bolt Torque     148\ Engine Bottom End Service     151\ Engine Bottom End Service     151\ Engine Block Service     151\ Cylinder Reconditioning     153\ Crankshaft Service     156\ Bearing Clearance     158\ Bearing Removal     159\ Replacement of Inserts     159\ Piston Service     165\ Piston Ring Service     166\ Connecting Rod Service     170\ Piston Pin Service     171\ Balancing Engines     173\ Engine Lubrication     177\ Oil     177\ Properties of Engine Oil     177\ Selecting Viscosities     178\ Oil Service Classifications      178\ Oil Changes     180\ Oil Filters     180\ Lubricating Methods     180\ Engine Cooling Systems     187\ Cooling Systems     187\ Water Pumps     189\ Belts     189\ Hoses and Clamps     191\ Radiators     192\ Automatic Transmission Fluid Cooler     193\ Closed Cooling Systems     193\ Radiator Caps     193\ Cooling Fans     194\ Thermostats     196\ Heater Core     197\ Antifreeze Solutions     197\ Air-cooled Engines     199\ Cooling System Testing     200\ Cooling System Troubleshooting     202\ Cooling System Flush     203\ Diesel and Other Engines     207\ Diesel Engines     207\ Truck Engines     209\ Racing Engines     210\ Rotary Engines     210\ Miller-Cycle Engines     214\ Variable-Compression Engines     215\ Hybrid Vehicles     215\ Fuel Cell Vehicles     216\ Fundamentals of Electricity, Magnetism, and Electronics     219\ Electricity      219\ Insulators     221\ Conductors     221\ Volts, Amperes, Ohms     221\ Types of Electrical Circuits     222\ Magnetism     223\ Electronics     227\ Automotive Fuels     235\ Automotive Fuels     235\ Volatility     235\ Combustion of Gasoline     237\ Antiknock Qualities     239\ Fuel Additives     240\ Lead-free Gasoline     240\ Alcohol as a Fuel     240\ Diesel Fuels     241\ Liquefied Petroleum Gas (LPG)     241\ Fuel Supply Systems, Intake Systems, Superchargers, and Turbochargers     243\ Fuel Pumps     243\ Mechanical Fuel Pump     243\ Electric Fuel Pumps     244\ Fuel Filters     245\ Fuel Gauges     246\ Intake Systems     248\ Air Filters     248\ Intake Manifold     249\ Superchargers     251\ Turbochargers     254\ Fuel Injection Systems     259\ Fuel Injection     259\ Classifying Gasoline Injection Systems     259\ Servicing Fuel Injection Systems      264\ On-Board Diagnostic Systems     265\ Verifying Fuel Injector Operation     265\ Checking Fuel Pressure     266\ Injector Balance Test     266\ Relieving EFI System Pressure     266\ Servicing Fuel Injectors     268\ Rebuilding a Throttle Body     270\ Methods of Diesel Injection     270\ Carburetor Fundamentals and Service     275\ Carburetors     275\ Carburetor Circuits     277\ Air/Fuel Mixture     287\ Stoichiometric Mixture     288\ Computerized Systems     288\ Electro-Mechanical Carburetors     288\ Carburetor Service     290\ Ignition System Fundamentals and Service     301\ Ignition System Operation     301\ Ignition Coils     302\ Distributor Cap     302\ Rotor     302\ Spark Plug Wires     303\ Spark Plugs     303\ Ignition Timing     306\ Specific Ignition Systems     307\ Breaker Point Ignition     307\ Electronic Ignition     309\ Computerized Ignition Systems     312\ Distributorless Ignition     312\ Direct Ignition     314\ Ignition System Service     315\ Performing a Spark Test     315\ Ignition Coil Service     315\ Distributor Cap and Rotor Service     316\ Spark Plug Service     316\ Spark Plug Wire Service     319\ Pickup Coil Service     319\ Contact Point and Condenser Service     320\ Adjusting Ignition Timing     321\ Testing Centrifugal and Vacuum Distributor Advance Systems     322\ Ignition Control Module Service     322\ Distributors and Direct Ignition System Service     322\ Batteries and Battery Service     325\ Batteries     325\ Battery Construction     325\ Maintenence-free Batteries     327\ Battery Voltage and Capacity     329\ Battery Ratings     329\ Battery Inspection     330\ Battery Testing     330\ Jump Starting an Engine     336\ Starting System Fundamentals and Service     339\ Starting System Fundamentals     339\ Starting Motor Operating Principles     339\ Starting Motor Types     343\ Starting Motor Internal Circuits     343\ Neutral Safety Switch      347\ Troubleshooting the Starting System     347\ Starter Maintenance     348\ Starting Motor Tests     348\ Charging System Fundamentals     353\ Charging Systems     353\ Alternator Construction     356\ Alternator Operation     357\ Voltage Regulators     359\ Voltage Regulator Types     359\ Computer-Controlled Voltage Regulation     364\ 42-Volt Electrical Systems     364\ Charging System Service     367\ Charging System Testing and Service     367\ Charging System Inspection     367\ Charging System Precautions and Tests     368\ Alternator Removal     369\ Alternator Disassembly     370\ Bench Tests     370\ Repairs/Replacement     372\ Alternator Reassembly     372\ Alternator Reinstallation     372\ Computer System Fundamentals and Service     375\ Computer Control Systems     375\ Components of a Computer Control System     377\ Sensors     377\ Electronic Control Module Operation     382\ Actuators     384\ Computer Control System Troubleshooting     386\ On-Board Diagnostic Systems     386\ Diagnostic Trouble Codes     386\ Activating Self-Diagnostic Systems     387\ Using Diagnostic Information     389\ Sensor Service     390\ Actuator Service     394\ Electronic Control Module Troubleshooting     394\ Exhaust Systems     397\ Exhaust Systems     397\ Exhaust Manifold     397\ Mufflers     398\ Catalytic Converters     399\ Exhaust System Corrosion     400\ Servicing Exhaust Systems     402\ Emission Controls     405\ Introduction     405\ Automotive Emission Standards     405\ Positive Crankcase Ventilation     406\ Exhaust Emission Controls     408\ Precombustion Controls     408\ Post-combustion Controls     413\ Engine Troubleshooting     421\ Engine Troubleshooting     421\ Test Equipment     421\ Effect of Emission Controls     421\ Strategy-Based Diagnostics     422\ Self-diagnosis     422\ Troubleshooting Charts     422\ Driveability and Tune-up     433\ Driveability and Tune-up     433\ Tune-up Test Procedure     435\ Checking Compression Pressure     440\ Using a Vacuum Gauge     440\ Tuning Emission Controls     441\ Clutches     443\ Purpose of the Clutch     443\ Design and Construction     443\ Parts Location and Relationship     443\ Clutch Service     451\ Clutch Adjustment     452\ Clutch Overhaul     453\ Clutch Troubleshooting     454\ Manual Transmission Fundamentals     457\ Manual Transmissions     457\ Application of Torque     457\ Gear Usage     457\ Three-speed Manual Transmission     458\ Helical Gears     459\ Synchronizing Clutch     460\ Four-speed Manual Transmission     460\ Overdrive Revival     460\ Planetary Gear Systems     461\ Transmission Overdrives     463\ Five-speed Overdrive Transmission     464\ Manual Transmission Service     469\ Manual Transmission Maintenance     469\ Check Fluid Level     470\ Replace the Rear Seal      470\ Test the Gearshift Operation     470\ Check Clutch Pedal Free Play     470\ Manual Transmission Troubleshooting     470\ Manual Transmission Service     472\ Removal of Transmission From Car     472\ Disassembly: Three-speed Manual Transmission     473\ Clean and Check: Three-speed Manual Transmission     473\ Reassembly: Three-speed Manual Transmission     475\ Disassembly: Four-speed Manual Transmission     477\ Clean and Check: Four-speed Manual Transmission     479\ Reassembly: Four-speed Manual Transmission     479\ Disassembly: Five-speed Manual Transmission     480\ Clean and Check: Five-speed Manual Transmission     483\ Reassembly: Five-speed Manual Transmission     483\ Reinstallation of the Transmission in the Car     484\ Automatic Transmission Fundamentals     487\ Automatic Transmissions     487\ Fluid Couplings     487\ Torque Converters     488\ Automatic Transmission Operation     490\ Actions of Key Elements     491\ Automatic Transmission Operation     497\ Other Automatic Transmissions     500\ Electronic Transmission Control      500\ Continuously Variable Transmissions     500\ Automatic Transmission Service     507\ Automatic Transmission Maintenance and Service     507\ Check ATF Level     508\ Check ATF Condition     508\ Inspect for ATF Leaks     509\ Test for Broken Transmission Mount     510\ Changing Automatic Transmission Fluid     511\ Adjust Bands     512\ Adjust Engine Curb Idle Speed     513\ Throttle Linkage Adjustment     514\ Gearshift Linkage Adjustment     515\ Troubleshooting Tips     515\ Road Testing     516\ Stall Testing     516\ Air Pressure Testing     517\ Testing Electronically Controlled Transmissions     518\ Transaxles     521\ Transaxles     521\ Transaxle Construction     521\ Transaxle Operation     523\ Manual Transaxle Troubleshooting     528\ Manual Transaxle Maintenance     529\ Automatic Transaxle Troubleshooting     531\ Automatic Transaxle Maintenance     532\ Driveline, Universal Joints, Differentials, and Driving Axles     537\ Drivelines      537\ Universal Joints     538\ Drive Shaft     538\ Differential     538\ Driving Axles     539\ Torque Transfer or Drive     541\ Hotchkiss Drive     541\ Torque Tube Drive     542\ Control Arm Drive     542\ Slip Joints     542\ Constant Velocity Joints     543\ Transfer Cases     543\ Center Bearings     543\ Differentials and Axles     543\ Limited-Slip Differentials     547\ Front-wheel Drive Driveline     548\ Driveline Service     553\ Driveline Service     553\ Drive Shaft     553\ Universal Joint Service     554\ Center Bearing Service     555\ Differentials     555\ Transaxle Lubrication     558\ Wheel Bearing Lubrication     559\ Driving Axles     560\ Four-wheel Drive Systems     569\ Four-wheel Drive/All-wheel Drive     569\ Four-wheel Drive Systems     570\ Four-wheel Drive Componenets     570\ Four-wheel Drive Service     576\ Suspension and Steering Systems     579\ Suspension and Steering Systems     579\ Front Suspension Systems     584\ Rear Suspension Systems     585\ Steering Systems     588\ Suspension and Steering Service     596\ Troubleshooting Suspension     597\ Troubleshooting Manual Steering     598\ Troubleshooting Power Steering     599\ Tires and Tire Service     601\ Tires     601\ Tire Types and Basic Structure     601\ Tread Patterns     603\ Tire Markings     603\ Tire Service     607\ Improvements and Advances     612\ Wheel Alignment     615\ Wheel Alignment     615\ Wheel Balance and Unbalance     616\ Car Weight Balance     617\ Wheelbase-Tread Width     617\ Rear-wheel Track     618\ Springs     619\ Suspension Height     619\ Shock Absorber Action     619\ Front-wheel Angularity     620\ Wheel Alignment Correction     625\ Wheel Alignment Correction     625\ Rear-wheel Drive/Front-wheel Drive Alignment     625\ Front-Wheel Drive-Alignment     632\ Rear Wheel Alignment      632\ Alignment Troubleshooting     634\ Hydraulics and Pneumatics     637\ Hydraulics     637\ Transmission of Forces     638\ Movement of Liquid     640\ Application of Hydraulic Principles     640\ Pneumatics     641\ Effect of Atmospheric Pressure     642\ Effect of Vacuum     642\ Compressed Air     643\ Principle of the Siphon     643\ Venturi Tube     644\ Boyle's Law     644\ Charles' Law     645\ Automotive Brakes     647\ Fundamentals of Automotive Brake Systems     647\ Braking System Operation     649\ Brake Lining Materials     650\ Disc Brakes     651\ Drum Brakes     653\ Brake Hydraulic System     656\ Disc Brake Calipers     662\ Wheel Cylinders     662\ Brake Lines, Hoses, and Fittings     663\ Power Brakes     663\ Anti-lock Brake Systems     666\ Brake Service     668\ Hydraulic System Service     668\ Disc Brake Service     670\ Drum Brake Service     673\ Power Brake System Service     680\ Troubleshooting and Servicing Anti-lock Brake Systems     682\ Automotive Air Conditioning     685\ Automobile Air Conditioning     685\ Principles of Air Conditioning     686\ Automobile Heating Systems     688\ Types of Refrigerant     694\ The Need for Refrigerant Oil     700\ Air Conditioning Service Tools and Equipment     701\ Servicing the Air Conditioning System     702\ Discharging and Recovering Refrigerant     703\ Evacuating the Air Conditioning System     703\ Charging the Air Conditioning System     703\ Retrofitting R-12 Air Conditioning Systems     704\ Troubleshooting Heating Systems     704\ Troubleshooting Air Conditioning Systems     704\ Automatic Temperature Control     705\ Safety Systems     709\ Safety Systems     709\ Seat Belt Systems     710\ Air Bag Systems     712\ Energy Absorbing Bumper Systems     715\ Other Safety Features     717\ Lamps, Lighting Circuits, Wiring, Horns, Wipers, and Washers     723\ Lamps and Lighting Circuits     723\ Fuses and Circuit Breakers      724\ Headlamp Types     724\ Daytime Running Lamps     724\ Lamp Switches     725\ Fog Lamps     728\ Direction Signal Switch     728\ Stoplight Switch     728\ Lamp Service     728\ Wires and Cables     734\ Lighting Wire Sizes     734\ Resistor Ignition Cable     736\ Wiring Harnesses and Connectors     736\ Horns     737\ Horn Troubleshooting     739\ Principles of a Direct Current (DC) Motor     739\ Wiper Motor Construction     739\ Troubleshooting     741\ Windshield Washers     741\ Speedometers and Cruise Control Systems     745\ Analog Speedometers     745\ Speedometer Operation     745\ Inspection and Lubrication     747\ Speedometer Cable     747\ Digital Speedometers     748\ Light Emitting Diode     748\ Liquid Crystal Display     750\ Vacuum Fluorescent Display     750\ Cathode Ray Tube     750\ Digital Odometers     750\ Troubleshooting     750\ Cruise Control Systems      751\ Cruise Control System Service     753\ Body Repairing and Refinishing     757\ Body Work     757\ Hammers, Spoons, and Dolly Blocks     758\ Using Pull Rods and Slide Hammers     759\ Body Filler     759\ Filing and Sanding     761\ Patching Rusted Areas     763\ Replacing Panels     763\ Welding     764\ Painting     768\ Masking     769\ Spray Guns     770\ Tips on Spraying     770\ Refinishing Materials     772\ Matching Colors     774\ Preparing Old Finishes for Paint     775\ Soft Body Parts     778\ Identifying Plastics     778\ Repairing Water and Dust Leaks     779\ Drain Locations     780\ Career Opportunities and Technician Certification     783\ Automotive Careers     783\ The Job Market     784\ Job Descriptions     785\ Entrepreneurship     789\ Technician Certification     790\ Appendix     793\ Dictionary of Automotive Terms     797\ Index     815