INSTRUCTOR’S MANUALTO ACCOMPANY

AUTOMOTIVE TECHNOLOGY

A SYSTEMS APPROACHF O U R T H E D I T I O N

Dale McPhersonEastern Idaho Technical College

East Idaho Falls, Idaho

Jack ErjavecColumbus State Community College

Columbus, Ohio

A u s t r a l i a C a n a d a M e x i c o S i n g a p o r e S p a i n U n i t e d K i n g d o m U n i t e d S t a t e s

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Instructor’s Manual to Accompany Automotive Technology: A Systems Approach, Fourth EditionDale McPherson and Jack Erjavec

Vice President, Technology andTrades SBU:Alar Elken

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Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

CHAPTER 1 Careers in the Automotive Industry . . . . . . . . . . . . . . . . . . . . . . . . . 1CHAPTER 2 Workplace Skills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5CHAPTER 3 Working Safely in the Shop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9CHAPTER 4 Automotive Systems and Preventive Maintenance . . . . . . . . . . . . . 13CHAPTER 5 Hand Tools and Shop Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . 17CHAPTER 6 Diagnostic Equipment and Special tools . . . . . . . . . . . . . . . . . . . . 22CHAPTER 7 Basic Theories and Math . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27CHAPTER 8 Automotive Engine Designs and Diagnosis . . . . . . . . . . . . . . . . . . 32CHAPTER 9 Engine Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37CHAPTER 10 Short Blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41CHAPTER 11 Cylinder Heads, camshafts, and Valve Trains . . . . . . . . . . . . . . . . . 46CHAPTER 12 Lubricating and Cooling Systems . . . . . . . . . . . . . . . . . . . . . . . . . . 51CHAPTER 13 Engine Sealing and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 55CHAPTER 14 Basics of Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59CHAPTER 15 Basics of Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63CHAPTER 16 General Electrical System Diagnostics and Service . . . . . . . . . . . . 67CHAPTER 17 Batteries: Theory, Diagnosis, and Service . . . . . . . . . . . . . . . . . . . . 71CHAPTER 18 Starting Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75CHAPTER 19 Charging Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79CHAPTER 20 Lighting Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82CHAPTER 21 Electrical Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86CHAPTER 22 Electrical Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90CHAPTER 23 Restraint Systems: Theory, Diagnosis, and Service . . . . . . . . . . . . . 95CHAPTER 24 Ignition Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99CHAPTER 25 Ignition System Diagnosis and Service . . . . . . . . . . . . . . . . . . . . . 102CHAPTER 26 Fuels and Other Energy Sources . . . . . . . . . . . . . . . . . . . . . . . . . 107CHAPTER 27 Fuel Delivery Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111CHAPTER 28 Electronic Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

CONTENTS

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CHAPTER 29 Fuel Injection System Diagnosis and Service . . . . . . . . . . . . . . . . 118CHAPTER 30 Intake and Exhaust Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123CHAPTER 31 Emission Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127CHAPTER 32 Emission Control System Diagnosis and Service . . . . . . . . . . . . . 130CHAPTER 33 On-Board Diagnostic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 134CHAPTER 34 On-Board Diagnostic System Diagnosis and Service . . . . . . . . . . 139CHAPTER 35 Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144CHAPTER 36 Manual Transmissions and Transaxles . . . . . . . . . . . . . . . . . . . . . 147CHAPTER 37 Manual Transmission/Transaxle Service. . . . . . . . . . . . . . . . . . . . 150CHAPTER 38 Drive Axles and Differentials . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154CHAPTER 39 Automatic Transmissions and Transaxles . . . . . . . . . . . . . . . . . . . 158CHAPTER 40 Automatic Transmission and Transaxle Service . . . . . . . . . . . . . . 163CHAPTER 41 Four- and All-Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168CHAPTER 42 Tires and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171CHAPTER 43 Suspension Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174CHAPTER 44 Steering Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179CHAPTER 45 Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183CHAPTER 46 Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187CHAPTER 47 Drum Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191CHAPTER 48 Disc Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195CHAPTER 49 Antilock Brake, Traction Control, and Stability

Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199CHAPTER 50 Heating and Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . 203CHAPTER 51 Heating and Air-Conditioning Diagnosis and Service. . . . . . . . . . 206

ASE Task Correlation Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

NATEF Task Correlation Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

iv Contents

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Automotive Technology: A Systems Approach was developed as a complete learning pack-age giving the instructor the tools needed for training students to become professionalautomotive technicians. The main text provides comprehensive, state-of-the-art coverageof both vehicles and repair procedures in a logical but flexible chapter arrangement. It isorganized around the eight ASE areas. Both the text and Tech Manual emphasize profes-sionalism and ASE certification.

This Instructor’s Manual helps coordinate teaching activities ranging from lectures, toshop assignments, to testing and ASE certification. It contains the information needed tohelp gain the most value from the text.

• The Chapter Overview and Chapter Objectives give a brief orientation to the contentsand purpose of each chapter.

• The Instructional Outline with Teaching Hints gives a complete outline of each chap-ter’s contents and includes suggested assignments from the text and the Tech Manual,plus hints for improving student comprehension.

• The Tech Manual correlation lists the salient points included in the job sheets.

• The Shop Hints gives suggestions for making your labs run smoothly.

• The Answers sections provide the correct responses to the review questions, and often,the rationale for the correct answer.

• The ASE and NATEF Task Correlation Chart provides the textbook and Tech Manualpages that are relevant to teaching the ASE and NATEF tasks listed.

PREFACE

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