Automotive Technology: A Systems Approach, Volume 2

Front Cover
Cengage Learning, 2005 - Technology & Engineering - 1401 pages
12 Reviews
The leading authority on service and repair procedures for contemporary automobiles remains the most technically comprehensive on the market! The fourth edition of Automotive Technology: A Systems Approach has been updated to reflect the most recent technological developments in the industry, featuring state-of-the-art coverage of hybrid vehicles, GPS systems, electronic ignition systems, DIS, fuel injection systems, and more. This enhanced presentation of the theory, diagnosis, and service of automobiles and light trucks takes into account all the latest trends, including variable valve timing, lift and variable compression ratios, fuels and alternative energy sources, as well as the latest engine designs and technologies. The essential must have information contained in this book will help readers understand and efficiently diagnose and service yesterdays, todays, and tomorrows automotive systems and vehicles.
 

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I remember both hating and loving this book in college. I learned a lot from it and it's set up in a practical way....It's tips on each page really helped. Not only does it work well as its own tool ... Read full review

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Contents

Workplace Skills
17
Accepting Employment 23 Working as an Automotive Technician
26
Thinking 26 Professionalism 29 Interpersonal Relationships
33
Objectives 35 Personal Safety 35 Tool and Equipment Safety
39
and Government Regulations 45 RighttoKnow Law
46
Automotive Systems
53
Advances 57 The Basic Engine 57 Engine Systems
59
Changing the Oil and Oil Filter
72
Throttle Body Fuel Injection 717 Port Fuel Injection
720
Sequential Fuel Injection Systems 723 Central Multiport Fuel
726
Input Sensors 727 Case Study 732 Key Terms
732
Fuel Injection System
735
Typical Procedure for Testing Injector Balance
746
Objectives 735 Preliminary Checks 735 Service Precautions
749
Removing and Replacing a Fuel Injector on a PFI System
752
Performing a Scan Tester Diagnosis of an Idle Air Control Motor
756

CHAPTERS Hand Tools
80
Repairing Damaged Threads with a Tap
86
Using a Micrometer
90
Measuring Tools 87 Hand Tools 95 Shop Equipment
107
Information Bill Key Terms 113 Summary 114 Review
115
Objectives 117 Engine Repair Tools 117 ElectricalElectronic
126
Diagnosing Engine Ignition Electrical and Fuel Systems with an Engine Analyzer
128
Transmission and Driveline Tools 134 Suspension and Steering
145
Objectives 148 Matter 148 Energy 149 Volume
151
Force 153 Time 155 Motion 155 Work 158 Waves
168
Heat 169 Chemical Properties 171 Electricity
177
Conducting a Cylinder Compression Test
194
Engine Disassembly
206
Objectives 206 Removing an Engine 206 Engine Disassembly
224
Objectives 227 Cylinder Block 227 Cylinder Block
245
Checking Main Bearing Clearance with Plastigage
252
Piston Rings 254 Installing Pistons and Connecting Rods
256
Installing a Piston and Rod Assembly
258
Cylinder Heads
263
and Valve Train 273 Aluminum Cylinder Heads
276
Resurfacing Cylinder Heads 277 Grinding Valves 279 Valve
284
Measuring and Fitting Valve Springs
290
Case Study 292 Key Terms 294 Summary 294 Review
295
Oil Pump 303 Oil Pump Inspection and Service 305 Installing
331
Adhesives Sealants and Other Chemical Sealing Materials
341
Replacing a Timing Belt on an OHC Engine
348
Oil Seals 343 Engine Reassembly 345 Installing the Engine
355
Objectives 359 Basics of Electricity 359 Electrical Terms
361
Electromagnetism Basics 377 Key Terms
380
Objectives 382 Computers 382 Integrated Circuits
386
Microprocessor Operation 387 Multiplexing 397 Key Terms
402
Performing a Voltage Drop Test
410
Objectives 404 Electrical Problems 404 Electrical Wiring
415
Components 421 Troubleshooting Circuits 424 Protecting
428
Soldering Two Copper Wires Together
430
Terms 434 Summary 434 Review Questions
435
Theory
437
Typical Procedure for Cleaning a Battery Case Tray and Cables
448
Routine Inspections 447 Routine Cleaning 447 Battery Testing
450
Voltage Drop Testing of a Starter Circuit
472
Typical Procedure for Disassembling a DelcoRemy Starter
478
Control Circuit 467 Starting System Testing 468 Starter
480
Typical Procedure for Inspecting Removing Replacing and Adjusting a Drive Belt
496
Typical Procedure for Disassembling a Ford IAR AC Generator
500
Objectives 483 Alternating Current Charging Systems 483
504
Removing a Multifunction Switch
522
Objectives 506 Lamps 506 Headlights 506 Headlight
529
Bench Testing a Fuel Gauge Sending Unit
538
Devices 537 Driver Information Centers 541 General
543
Typical Procedure for Replacing a Servo Unit
557
Objectives 545 Body Control Modules 545 Windshield
560
Typical Procedure for Grid Wire Repair
568
Case Study 573 Key Terms 574 Summary 574 Review
575
Removing an Air Bag Module
591
ENGINE PERFORMANCE
595
Timing 597 Basic Circuitry 598 Ignition Components
601
Ignition System
629
Objectives 629 Combustion 629 General Ignition System
639
Timing 646 Setting Ignition Timing 646 DI and El Systems
648
Secondary Component Tests and Service 656 Specific
655
Installing a Distributor and Setting the Timing of an Engine
658
System Service 663 Case Study 668 Key Terms
668
Objectives 671 AirFuel Mixtures 671 Gasoline 672 Fuel
677
Renewable Fuels 680 Electric Vehicles 681 Hybrid Electric
690
Removing a Fuel Filter on an EFI Vehicle
701
Checking Fuel Pressure on a PFI System
705
Objectives 691 General Fuel System Diagnosis 691 Fuel
711
Objectives 761 The Air Induction System 761 Exhaust System
783
Evaporative Emission Control Systems 789 Precombustion
803
Diagnosing a Positive Back Pressure EGR Valve
817
Diagnosing an EGR Vacuum Regulator Solenoid
820
Spark Control Systems 819 Intake Heat Control Diagnosis
828
System Operation 839 OBDII Standards
841
Monitoring Capabilities 844 OBDII Diagnostics 850 OBDII
856
Diagnosing with a Scan Tool
862
Performing KOEO and KOER Tests
864
OBDII System Diagnosis and Service 866 OBD II Diagnostics
876
Testing an Oxygen Sensor
884
Testing a Ford MAP Sensor
891
AND TRANSAXLES
900
Installing and Aligning a Clutch Disc
915
Manual Transmissions
920
Synchronizers 927 Gearshift Mechanisms
929
Final Drive Gears and Overall Ratios 936 Electrical Systems
937
Disassembling a Typical Transaxle
950
Removal 948 Cleaning and Inspection 949 Disassembly
954
Reassembling a Typical Transaxle
956
Drive Axles
961
Removing and Replacing a CV Joint Boot
968
Objectives 961 FrontWheelDrive FWD Axles 961 Types
975
Disassembling a Single Universal Joint
976
Reassembling a Single Universal Joint
977
LimitedSlip Differentials 981 Axle Shafts 983 Servicing
988
Measuring and Adjusting Backlash and SideBearing Preload on a Final Drive Assembly with a Shim Pack
989
Final Drive Assembly with Adjusting Nuts
990
AND TRANSAXLES
994
Automatic Transmission
1043
Fluid Leaks 1046 Basic EAT Testing 1048 Preliminary
1065
Typical Procedure for Overhauling a 4T60E Transaxle
1068
Key Terms 1071 Summary 1071 Review Questions
1071
LockingUnlocking Hubs 1078 Conventional FourWheel Drive
1080
Typical Procedure for Disassembling a Warner 1356 Transfer Case
1084
Typical Procedure for Reassembling a Warner 1356 Transfer Case
1086
Drive Systems 1082 Case Study 1089 Key Terms
1089
SYSTEMS
1091
Objectives 1092 Wheels 1092 Tires 1093 Tire Repair
1101
Dismounting and Mounting a Tire on a Wheel Assembly
1103
Service 1105 Wheel Bearings 1106 Case Study 1109
1110
Objectives 1112 Frames 1112 Suspension System
1118
Measuring Front and Rear Curb Riding Height
1126
Measuring the Lower Ball Joint Radial Movement on a MacPherson Strut Front Suspension
1129
Removing and Replacing a MacPherson Strut
1133
Suspension Inspection 1125 FrontSuspension Component
1140
Steering Systems
1146
Objectives 1146 ManualSteering Systems 1146 Power
1170
Wheel Alignment
1177
Objectives 1177 Alignment Geometry 1178 Prealignment
1183
Typical Procedure for Performing FourWheel Alignment with a Computer Wheel Aligner
1186
FourWheel Drive Vehicle Alignment 1192 Case Study
1192
Objectives 1196 Friction 1196 Principles of Hydraulic Brake
1199
Master Cylinder Operation 1201 Hydraulic Tubes and Hoses
1205
Typical Procedure for Bench Bleeding a Master Cylinder
1210
Drum and Disc Brake Assemblies 1207 Hydraulic System
1218
Disc Brakes
1243
Disc Brake Diagnosis 1247 Service Precautions
1250
Removing and Replacing Brake Pads
1254
General Caliper Inspection and Servicing 1251 Rotor Inspection
1260
Automatic Traction Control 1277 Automatic Stability
1269
Control 1278 Antilock Brake System Service 1280 Diagnosis
1288
Heating and Air
1314
Objectives 1314 Maintenance Precautions 1314 Refrigerant
1321
Evacuating and Recharging an AC System with Recycling and Charging Stations
1325
Diagnostic and Troubleshooting Procedures 1326 Electrical
1329
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About the author (2005)

Jack Erjavec has become a fixture in the automotive textbook publishing world. He has decades of experience as a technician, educator, author, and editor, and has authored or co-authored more than 30 automotive textbooks and training manuals. Erjavec holds a master's degree in vocational and technical education from Ohio State University, and he spent twenty years at Columbus State Community College as an instructor and administrator. A long-time affiliate of the North American Council of Automotive Teachers, he also served as executive vice-president for the organization and spent several years on its board of directors. Erjavec is also associated with ATMC, SAE, ASA, ATRA, AERA, and other automotive professional associations.

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