jack erjavec auto tech book

8/18/2019 Jack Erjavec Auto Tech Book

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Automotive Technology A Systems Approach

5th Edition

Jack Erjavec

ISBN-10: 1-4283-1149-1ISBN-13: 978-1-4283-1149-7

Cover image from Amazon.com

Automotive Technology, Principles, Diagnosis,

and Service

5th

Edition

James D. Halderman ISBN-10: 0-13-399461-9

ISBN-13: 978-0-13-399461-2

Chapter 1 – Careers in the Automotive

Industry - 1 Objectives – 1

The Automotive Industry – 1Job Classifications – 9

Related Career Opportunities – 12Training for a Career in Automotive Service – 14

ASE Certification – 15

Chapter 2 – Careers in the Automotive Service

Industry – 8 The Need For Automotive Technicians – 8

The Need For Continuous Vehicle Service – 8Technician Work Sites – 9

Technician Job Classifications – 10Parts-Related Position – 13

Sales Jobs—Used Vehicles; New Vehicles – 14Other Careers in the Automotive Industry – 14

Typical Automotive Organization Arrangements –

14 Chapter 5 – Technician Certification – 34 Automobile Technician Certification Tests – 34

Questions Often Asked – 36Test-Taking Tips – 37

Canada’s Automotive Apprenticeship Program(Red Seal) – 40Re-Certification – 40

Chapter 2 – Workplace Skills – 19

Objectives – 19Seeking and Applying for Employment – 19

Accepting Employment – 26Working as a Technician – 27

Communications – 29Solving Problems and Critical Thinking – 31

Professionalism – 32Interpersonal Relationships – 34

Chapter 3 – Starting a Career in the

Automotive Industry – 16 Preparing for an Automotive Service Career – 16

Developing an Employment Plan – 17Preparing a Resume – 18

Preparing a Cover Letter – 19Contacting Potential Employers – 20

Completing the Employment Application – 20The Interview – 20

After the Interview – 20Accepting Employment – 20

Technician Pay Methods – 20Payroll Deductions – 21

Housing and Living Expenses – 22


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Becoming a Shop Owner – 22

Chapter 4 – Working as a Professional Service

Technician – 24

Professionalism – 24Communications – 24

What Happens the First Day? – 26Duties of a Service Technician – 27

Flagging a Work Order – 28

Sublet Repairs – 29Parts Replacement – 29Working With A Mentor – 30

Teamwork – 31Goal Setting and Business Meetings – 31

Advancement Skills – 31Housekeeping Duties – 31

Self-Management – 32Job Evaluation – 32

Chapter 3 – Automotive Systems – 37 Objectives – 37

Historical Background – 37Design Evolution – 38

Body Shapes – 39The Basic Engine – 41

Engine Systems – 43Electrical and Electronic Systems – 46

Heating and Air-Conditioning Systems – 49Drivetrain – 50

Running Gear – 53Hybrid Vehicles – 55

Chapter 1 – Automotive Background and

Overview – 1

Historical Background – 1Bodies – 2

Chassis Systems Overview – 2Frames – 3

Engine Design Evolution – 4Engine Systems Overview – 5

Powertrain Overview – 5Electrical/Electronic Systems Overview – 6

Heating, Ventilation, and Air ConditioningOverview – 6

Eight Areas of Automotive Service – 6

Chapter 4 – Hand Tools and Shop Equipment Objectives – 59Measuring Systems – 59

Fasteners – 60Measuring Tools – 67

Hand Tools – 75Shop Equipment – 86

Power Tools – 88Jacks and Lifts – 89

Service Information – 92

Chapter 8 – Fasteners and Thread Repair – 57 Threaded Fasteners – 58Metric Bolts – 58

Grades of Bolts – 58Tensile Strength – 59

Nuts – 60Taps and Dies – 60

Thread Pitch Gauge – 61Sheet Metal Screws – 62

Washers – 62Snap Rings and Clips – 62

How to Avoid Broken Fasteners – 64Thread Repair Inserts – 64

Chapter 9 – Hand Tools – 68 Wrenches – 68

Ratchets, Sockets, and Extensions – 69Screwdrivers – 72

Hammers and Mallets – 72Pliers – 73

Cutters – 75Punches and Chisels – 75

Removers – 76


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Hacksaws – 77

Basic Hand Tool List – 78Tool Sets and Accessories – 78

Seal Pliers and Drivers – 79Electrical Hand Tools – 79

Safety Tips For Using Hand Tools – 80Hand Tool Maintenance – 80

Chapter 10 – Power Tools and Shop Equipment

– 82 Air Compressor – 82Air and Electrically Operated Tools – 82

Trouble Lights – 84Bench/Pedestal Grinder – 84

Bench Vise – 85Hydraulic Presses – 85

Portable Crane and Chain Hoist – 85Engine Stands – 86

Care and Maintenance of Shop Equipment – 86 Chapter 11 – Vehicle Lifting and Hoisting – 91

Floor Jack – 91Creepers – 92Vehicle Hoists – 92

Drive-On Ramps – 94 Chapter 12 – Measuring Systems and Tools – 97

English Customary Measuring System – 97Metric System of Measure – 98

Linear Measurements (Tape Measure/Rule) – 98Micrometer – 99

Telescopic Gauge – 100Small-Hole Gauge – 100

Vernier Dial Caliper – 102Feeler Gauge – 102

Straightedge – 103Dial Indicator – 103

Dial Bore Gauge – 103Depth Micrometer – 103

Chapter 5 – Diagnostic Equipment and Special

Tools

Objectives – 99Engine Repair Tools – 99

Electrical/Electronic System Tools – 106

Engine Performance Tools – 110Transmission and Driveline Tools – 119Suspension and Steering Tools – 121

Brake System Tools – 124Heating and Air-Conditioning Tools – 128

Chapter 6 – Working Safely in the Shop – 134

Objectives – 134Personal Safety – 134

Tool and Equipment Safety – 138Work Area Safety – 144

Manufacturers’ Warnings and Government

Chapter 6 – Shop Safety – 41

Personal Protective Equipment – 41Safety Tips For Technicians – 42

Cleaning Methods and Processes – 43Electrical Cord Safety – 44

Jump-Starting and Battery Safety – 44


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Regulations – 148

Right-to-Know Law – 148

Fire Extinguishers – 45

Fire Blankets – 46First Aid and Eye Wash Stations – 46

Chapter 7 – Environmental and Hazardous

Materials – 48

Hazardous Waste – 48Federal and State Laws – 48

Asbestos Hazards – 49

Used Brake Fluid – 50Used Oil – 50Solvents – 51

Coolant Disposal – 52Lead-Acid Battery Waste – 53

Fuel Safety and Storage – 53Airbag Handling – 54

Used Tire Disposal – 54Air-Conditioning Refrigerant Oil Disposal – 54

Chapter 7 – Preventative Maintenance and

Basic Services – 153

Objectives – 153Repair Orders – 153

Vehicle Identification – 156Preventative Maintenance – 157

Basic Services – 159Hybrid Vehicles – 180

Additional PM Checks – 182

Chapter 15 – Service Information – 119 Vehicle Service History Records – 120

Owner’s Manuals – 120Lubrication Guides – 120

Service Manuals – 120Advantages of Hard Copy Versus Electronic

Service Information – 122Disadvantages of Hard Copy Versus Electronic

Service Information – 122Labor Guide Manuals – 122

Electronic Service Information – 122Hotline Services – 124

Specialty Repair Manual – 124

Aftermarket Supplies Guides and Catalogs – 124 Chapter 16 – Vehicle Identification and

Emission Ratings – 125

Parts of a Vehicle – 125Front-Wheel Drive Versus Rear-Wheel Drive –125

Vehicle Identification – 126Vehicle Safety Certification Label – 126

VECI Label – 126Emission Standards in the United States – 127

Calibration Codes – 128

Casting Numbers – 128 Chapter 17 – Preventative Maintenance and

Service Procedures – 130

Preventative Maintenance – 130Getting Ready for Service – 130

Safety Inspection – 131Windshield Wiper and Washer Fluid Service – 131

Cabin Filter Replacement – 132Air Filter Inspection/Replacement – 132

Brake Fluid Inspection – 133Engine Oil Inspection – 134


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Cooling System Inspection – 136

Automatic Transmission Fluid Check – 138Power Steering Fluid – 139

Accessory Drive Belt Inspection – 139Tire and Wheel Service – 140

Chassis Lubrication – 143Differential Fluid Check – 144

Manual Transmission/Transaxle Lubricant Check

– 144Under-Vehicle Inspection – 145

Chapter 8 – Basic Theories and Math

Objectives – 186Matter – 186

Energy – 188Volume – 191

Force – 193Time – 195

Motion – 195Work – 197

Waves and Oscillations – 202Light – 205

Liquids – 205Gases – 207

Heat – 209Chemical Properties – 211

Electricity and Electromagnetism – 215

Chapter 13 – Scientific Principles and Materials

– 105 Scientific Method – 105

Energy Principles – 106Torque – 106

Work – 106Power – 107

Horsepower – 107 Newton’s Law of Motion – 108

Kinetic Energy – 108Inertia – 109

Mechanical Principles – 109Heat and Temperature – 110

Acids and Bases – 111Gas Laws – 112

Sound and Acoustics – 112Plastics – 112

Iron and Steel – 113SAE Steel Designations – 113

Aluminum and Aluminum Alloys – 113

Chapter 14 – Math, Charts, and Calculations –114 Decimals – 115

Percentage – 115Scientific Notation – 115Adding and Subtracting – 115

Fractions – 116Multiplying and Dividing – 116

Mathematical Formulas – 116Fuel Economy Calculator – 116

Gear Ratios – 117

Graphs, Charts, and Diagrams – 117

Chapter 9 – Automotive Engine Designs and

Diagnosis – 220

Objectives – 220Introduction to Engine – 220

Engine Classifications – 221Engine Measurement and Performance – 228

Diesel Engines – 232Other Automotive Power Plants – 236

Engine Identification – 240

Chapter 18 – Gasoline Engine Operation, Parts,

and Specifications – 146

Purpose and Function – 147Energy and Power – 147

Engine Construction Overview – 147Engine Parts and Systems – 147

Four-Stroke Cycle Operation – 149Engine Classification and Construction – 149

Engine Measurement – 152


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Engine Diagnostics – 241

Evaluating the Engine’s Condition – 247 Noise Diagnosis – 249

Compression Ratio – 155

Torque and Horsepower – 157 Chapter 19 – Diesel Engine Operation and

Diagnosis – 158 Diesel Engines – 158

Three Phases of Combustion – 161Fuel Tank and Lift Pump – 161

Injection Pump – 161

Heui System – 162Diesel Injector Nozzles – 164Glow Plugs – 164

Engine-Driven Vacuum Pump – 166Diesel Fuel Heaters – 166

Accelerator Pedal Position Sensor – 166Diesel Engine Turbochargers – 166

Exhaust Gas Recirculation – 167Diesel Particulate Matter – 168

Diesel Oxidation Catalyst – 168Diesel Exhaust Particulate Filter – 169

Selective Catalytic Reduction – 170Diesel Exhaust Smoke Diagnosis – 171Diesel Performance Diagnosis – 172

Compression Testing – 173Glow Plug Resistance Balance Test – 173

Injector Pop Testing – 173Diesel Emission Testing – 174

Chapter 10 – Engine Disassembly and Cleaning

– 255 Objectives – 255

Removing an Engine – 255

Engine Disassembly and Inspection – 262Cleaning Engine Parts – 264Crack Detection – 269

Chapter 28 – Engine Removal and Disassembly

– 261 Engine Repair Options – 262

Engine Removal – 263

Engine Disassembly – 264Disassembly of the Short Block – 266Rotating Engine Assemblies Removal – 267

Cylinder Head Disassembly – 267 Chapter 29 – Engine Cleaning and Crack

Detection – 272

Introduction – 272Mechanical Cleaning – 272

Chemical Cleaners – 273Spray and Steam Washing – 274

Thermal Cleaning – 274

Tank and Vapor Cleaning – 275Ultrasonic and Vibratory Cleaning – 275Crack Detection – 276

Crack Repair – 276

Chapter 11 – Lower End Theory and Service –

275

Objectives – 275Short Block Disassembly – 276

Cylinder Block – 279Cylinder Block Reconditioning – 281

Camshafts – 285

Chapter 32 – Camshafts and Valve Trains – 314 Camshaft – 315

Camshaft Design – 315Camshaft Drives – 317

Camshaft Movement – 319Rocker Arms – 320

Pushrods – 322


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Crankshaft – 292

Crankshaft Inspection and Rebuilding – 294Installing Main Bearings and Crankshaft – 296

Piston and Piston Rings – 302Installing Pistons and Connecting Rods – 307

Inspection of Camshaft and Related Parts – 310Installation of Camshaft and Related Parts – 311

Crankshaft and Camshaft Timing – 312

Oil Pumps – 313Oil Pump Service – 315Installing the Oil Pump – 318

Overhead Camshaft Valve Trains – 323

Camshaft Specifications – 323Lifters or Tappets – 326

Valve Train Lubrication – 327Valve Train Problem Diagnosis – 328

Camshaft Removal – 328Measuring Camshafts – 329

Selecting a Camshaft – 329

Variable Valve Timing – 330Variable Lift and Cylinder Deactivation Systems –334

Chapter 33 – Pistons, Rings, and Connecting

Rods – 336

Pistons – 337Piston Construction – 337

Piston Pins – 340Piston Pin Retaining Methods – 341

Piston Rings – 342Piston Ring Construction – 344

Connecting Rods – 345Connecting Rod Service – 347Piston and Rod Assembly – 348

Piston Ring Service – 349 Chapter 34 - Engine Blocks – 351

Engine Blocks – 351Engine Block Service – 356

Block Preparation For Assembly – 362 Chapter 35 - Crankshafts, Balance Shafts, and

Bearings – 364 Crankshaft – 365

Crankshaft Construction – 366Crankshaft Oiling Holes – 367

Engine Crankshaft Types – 367Counterweights – 369

Externally and Internally Balanced Engines – 369Engine Balance – 370

Balance Shafts – 371Crankshaft Service – 372

Engine Bearings – 374Bearing Clearance – 377

Camshaft Bearings – 379

Chapter 12 – Upper End Theory and Service Objectives – 322Cylinder Head – 322

Combustion Chamber – 323Intake and Exhaust Valves – 324

Variable Valve Timing – 330Cylinder Head Disassembly – 335

Inspection of the Valve Train – 339Servicing Cylinder Heads – 344

Reconditioning Valves – 347Valve Guide Reconditioning – 349

Chapter 30 – Cylinder Head and Valve GuideService – 280 Introduction – 280

Cylinder Heads – 280Intake and Exhaust Ports – 283

Cylinder Head Passages – 284Cylinder Head Servicing – 285

Aluminum Cylinder Head Straightening – 286Cylinder Head Resurfacing – 287

Intake Manifold Alignment – 288Valve Guides – 289


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Reconditioning Valve Seats – 351

Valve Stem Seals – 354Assembling the Cylinder Head – 355

Valve Guide Replacement – 291

Chapter 31 – Valve and Valve Seat Service –

293

Intake and Exhaust Valves – 294Valve Seats – 296

Valve Fault Diagnosis – 296Valve Springs – 297

Valve Keepers and Rotators – 299

Valve Reconditioning Procedure – 300Valve Face Grinding – 300Valve Seat Reconditioning – 301

Valve Guide Pilots – 303Valve Seat Grinding Stones – 304

Valve Seat Cutters – 305Valve Seat Testing – 305

Valve Seat Replacement – 306Valve Stem Height – 307

Installed Height – 307Valve Stem Seals – 308

Installing the Valves – 310Chapter 13 – Engine Sealing and Reassembly –

361 Objectives – 361

Torque Principles – 361Gaskets – 364

Specific Engine Gaskets – 367Adhesives, Sealants, and Other Chemical Sealing

Materials – 371Oil Seals – 374

Engine Reassembly – 375

Installing the Engine – 385

Chapter 36 - Gaskets and Sealants – 381

Introduction – 381Head Gaskets – 381

Cover Gasket Materials – 383Gasket Failures – 384

Oil Seals – 385Assembly Sealants – 385

Chapter 37 - Engine Assembly and

Dynamometer Testing – 388

Details, Details, Details – 388

Short Block Preparation – 388Cylinder Head Preparation – 390Trial Assembly – 391

Final Short Block Assembly – 392Installing the Camshaft – 397Piston/Rod Installation – 397

Cylinder Head Installation – 400Torque-To-Yield Head Bolts – 403

Valve Train Assembly – 404Final Assembly – 406

Dynamometer Testing – 410

Chapter 38 - Engine Installation and Break-In –415 Preinstallation Checklist – 415

Transmission Installation – 415Dressing the Engine – 417

Engine Installation – 417Engine Start – 418

Break-In Precautions – 419


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Chapter 14 – Lubricating and Cooling Systems

– 393 Objectives – 393

Lubrication System – 393Engine Lubrication Diagnosis and Service – 398

Cooling Systems – 400Cooling System Diagnosis – 409

Inspection of Cooling System – 411

Testing for Leaks – 416Cooling System Service – 420

Chapter 20 – Coolant – 175

Types of Coolant – 176Water – 178

Coolant Freezing/Boiling Temperatures – 178Coolant Testing – 179

Coolant Replacement Issues – 181 Chapter 21 – Cooling System Operation and

Diagnosis – 182

Cooling System – 182Cooling System Operation – 183Thermostats – 183

Radiators – 186Pressure Caps – 187

Coolant Recovery Systems – 188Water Pumps – 189

Coolant Flow in the Engine – 190Cooling Fans – 191

Heater Cores – 192Cooling System Testing – 192

Coolant Temperature Warning Light – 194Cooling System Inspection – 194Cooling System Service – 195

Chapter 22 – Engine Oil – 198 Introduction – 198

Properties of Engine Oil – 198SAE Rating – 199

API Rating – 199ILSAC Oil Rating – 200

European Oil Rating System – 200Japanese Oil Ratings – 201

Engine Oil Additives – 201Oil Brand Compatibility – 202

Synthetic Oil – 202Vehicle-Specific Specifications – 203

High Mileage Oils – 204Oil Filters – 204

Oil Change – 204 Chapter 23 – Lubrication System Operation

and Diagnosis – 210 Introduction – 211

Lubrication Principles – 211

Engine Lubrication Systems – 211Oil Pumps – 212Oil Passages – 215

Oil Pans – 217Dry Sump Systems – 217

Oil Coolers – 218 Chapter 27 – In-Vehicle Engine Service – 252

Thermostat Replacement – 253Water Pump Replacement – 253

Intake Manifold Gasket Inspection – 254Intake Manifold Gasket Replacement – 254


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Timing Belt Replacement – 255

Hybrid Engine Precautions – 255

Chapter 15 – Basics of Electrical Systems – 433

Objectives – 433Basics of Electricity – 433

Electrical Terms – 435Ohm’s Law – 438

Circuits – 440Circuit Components – 444

Chapter 39 – Electrical Fundamentals – 420

Introduction – 420Electricity – 421

How Electrons Move Through a Conductor – 423Units of Electricity – 424

Sources of Electricity – 425Conductors and Resistance – 426

Resistors – 427 Chapter 40 – Electrical Circuits and Ohm’s

Law – 428 Circuits – 428

Circuit Fault Types – 429Ohm’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 – 434Kirchhoff’s Voltage Law – 435

Series Circuit Laws – 436Series Circuit Examples – 437

Parallel Circuits – 438Kirchhoff’s Current Law – 438

Parallel Circuit Laws – 438Determining Total Resistance in a Parallel Circuit

– 438Parallel Circuit Examples – 440

Series-Parallel Circuits – 441Solving Series-Parallel Circuit Problems – 442

Series-Parallel Circuit Examples – 442

Chapter 16 – General Electrical System

Diagnostics and Service – 457 Objectives – 457

Electrical Problems – 457Electrical Wiring Diagrams – 460

Electrical Testing Tools – 461Using Multimeters – 465

Using Lab Scopes – 474Testing Basic Electrical Components – 478

Troubleshooting Circuits – 482Testing for Common Problems – 486

Connector and Wire Repairs – 490

Chapter 42 – Circuit Testers and Digital Meters

– 444 Fused Jumper Wire – 444

Test Lights – 445Logic Probe – 446

Digital Multimeters – 446Inductive Ammeters – 450

Diode Check, Pulse Width, and Frequency – 450Electrical Unit Prefixes – 451

How To Read Digital Meters – 452 Chapter 43 – Oscilloscopes and Graphing

Multimeters – 460 Types of Oscilloscopes – 461

Scope Setup and Adjustment – 462DC and AC Coupling – 462

Pulse Trains – 463 Number of Channels – 464


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Triggers – 464

Using a Scope – 465Graphing Multimeter – 466

Graphing Scan Tools – 466 Chapter 44 – Automotive Wiring and Wire

Repair – 467 Automotive Wiring – 467

Ground Wires – 468

Battery Cables – 469Jumper Cables – 469Fuses and Circuit Protection Devices – 469

Terminals and Connectors – 474Wire Repair – 475

Electrical Conduit – 477 Chapter 45 – Wiring Schematics and Circuit

Testing – 479 Wiring Schematics and Symbols – 479

Schematic Symbols – 480Relay Terminal Identification – 485

Locating an Open Circuit – 486Common Power or Ground – 487Circuit Troubleshooting Procedure – 488

Locating a Short Circuit – 489Electrical Troubleshooting Guide – 491

Step-By-Step Troubleshooting Procedure – 492 Chapter 47 – Magnetism and Electromagnetism

– 498 Fundamentals of Magnetism – 498

Electromagnetism – 500Uses of Electromagnetism – 502

Electromagnetic Induction – 504Ignition Coils – 504

Electromagnetic Interference – 506

Chapter 17 – Batteries: Theory, Diagnosis, and

Service – 501 Objectives – 501

Introduction – 501Basic Battery Theory – 501

Battery Ratings – 504Common Types of Batteries – 505

High-Voltage Batteries – 507

Lead-Acid Batteries – 507High-Voltage Batteries – 507Servicing and Testing Batteries – 513

Nickel-Based Batteries – 524Lithium-Based Batteries – 526

Isolating High-Voltage Systems – 528Jump-Starting – 530

Chapter 50 – Batteries – 538 Introduction – 538Battery Construction – 538

How a Battery Works – 540Specific Gravity – 540

Valve Regulated Lead-Acid Batteries – 542Causes 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 – 545Battery Maintenance – 545

Battery Voltage Test – 546Hydrometer Testing – 547

Battery Load Testing – 547Electric Conductance Testing – 548

Battery Charging – 549Battery Charge Time – 550


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Jump Starting – 550

Battery Electrical Drain Test – 552Battery Symptom Guide – 555

Chapter 18 – Starting and Traction Motor

Systems – 536 Objectives – 536

Basics of Electromagnetism – 536Starting Motors – 539

Starting System – 542Starter Circuit – 543

Control Circuit – 546Starting System Testing – 547

Starter Motor Service – 554

Chapter 52 – Cranking System – 556

Cranking Circuit – 556Computer-Controlled Starting – 557

Starter Motor Operation – 558How the Starter Motor Works – 560

Gear-Reduction Starters – 561Starter Drives – 562

Positive Engagement Starters – 564Solenoid-Operated Starters – 564

Chapter 53 – Cranking System Diagnosis and

Service – 566

Starting System Troubleshooting Procedure – 566Voltage Drop Testing – 566

Control Circuit Testing – 568

Starter Amperage Test – 569Starter Removal – 569Starter Motor Service – 570

Bench Testing – 571Starter Installation – 571

Starter Drive-To-Flywheel Clearance – 571Starting System Symptom Guide – 572

Chapter 19 – Charging Systems – 571 Objectives – 571

Alternating Current Charging Systems – 571AC Generator Operation – 575

Voltage Regulation – 577 New Developments – 580

Preliminary Checks – 582General Testing Procedures – 586

AC Generator Service – 588

Chapter 54 – Charging System – 577 Principles of Alternator Operation – 578

Alternator Construction – 578Alternator Overrunning Pulleys – 578

Alternator Components and Operation – 579How an Alternator Works – 581

Alternator Output Factors – 583Alternator Voltage Regulation – 583

Alternator Cooling – 585Computer-Controlled Alternators – 585

Chapter 55 – Charging System Diagnosis and

Service – 587

Charging System Testing and Service – 588Drive Belt Inspection and Adjustment – 589

AC Ripple Voltage Check – 590Testing AC Ripple Current – 590

Charging System Voltage Drop Testing – 591Alternator Output Test – 592

Minimum Required Alternator Output – 593Alternator Removal – 593

Alternator Disassembly – 594Testing the Rectifier – 596

Reassembling the Alternator – 596Remanufactured Alternators – 597

Alternator Installation – 597


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Chapter 20 – Lighting Systems – 596

Objectives – 596Lamps – 596

Headlights – 597Headlight Service – 605

Other Light Bulbs – 610Interior Light Assemblies – 610

Rear Exterior Lights – 612

Basic Lighting System Diagnosis – 619

Chapter 56 – Lighting and Signaling Service –

604 Introduction – 605

Exterior Lighting – 605Bulb Numbers – 605

Brake Lights – 608Turn Signals – 610

Headlights – 611

High-Intensity Discharge Headlights – 614LED Headlights – 615Headlight Aiming – 615

Adaptive Front Lighting System – 616Daytime Running Lights – 617

Dimmer Switches – 617Courtesy Lights – 617

Illuminated Entry – 617Fiber Optics – 617

Automatic Dimming Mirrors – 617Feedback – 620

Lighting System Diagnosis – 620Lighting System Symptom Guide – 620

Chapter 21 – Electrical Instrumentation – 624 Objectives – 624

Instrument Panels – 624Gauges – 625

Basic Information Gauges – 627Indicator and Warning Devices – 630

Driver Information Centers – 635General Diagnosis and Testing – 637

Chapter 57 – Driver Information and

Navigation Service – 625

Dash Warning Symbols – 625Oil Pressure Warning Devices – 628

Temperature Lamp Diagnosis – 628Brake Warning Lamp – 628

Analog Dash Instruments – 629 Network Communication – 629

Stepper Motor Analog Gauges – 629

Head-Up Display – 630 Night Vision – 632Digital Electronic Display Operation – 633

Electronic Speedometers – 635Electronic Odometers – 636Electronic Fuel Level Gauges – 637

Navigation and GPS – 637Onstar – 639

Backup Camera – 640Backup Sensors – 641

Lane Departure Warning System – 641

Electronic Dash Instrument Diagnosis andTroubleshooting – 642Maintenance Reminder Lamps – 642

Chapter 22 – Basics of Electronics and

Computer Systems – 640 Objectives – 640

Capacitors – 640Semiconductors – 642

Computer Basics – 646On-Board Diagnostics – 656

Multiplexing – 658

Chapter 46 – Capacitance and Capacitors – 493

Capacitance – 493Capacitor Construction and Operation – 494

Factors of Capacitance – 495Uses For Capacitance – 495

Capacitors in Circuits – 496 Chapter 48 – Electronic Fundamentals – 509

Semiconductors – 509


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Protecting Electronic Systems – 662

Diagnosing BCMs – 663Testing Electronic Circuits and Components – 664

Summary of Semiconductors – 510

Diodes – 510Zener Diodes – 511

High-Voltage Spike Protection – 512Diode Ratings – 513

Light-Emitting Diodes – 513Photodiodes – 514

Photoresistors – 514

Silicon-Controlled Rectifiers – 515Thermistors – 515Rectifier Bridges – 515

Transistors – 516Field-Effect Transistors – 517

Phototransistor – 518Integrated Circuits – 518

Transistor Gates – 518Operational Amplifiers – 519

Electronic Component Failure Causes – 519How to Test Diodes and Transistors – 520

Converters and Inverters – 521Electrostatic Discharge – 523 Chapter 49 – CAN and Network

Communications – 524 Module Communications and Networks – 524

Network Fundamentals – 524Module Communications Configuration – 525

Network Communications Classifications – 526General Motors Communications Protocols – 527

Ford Network Communications Protocols – 529Chrysler Communications Protocols – 530

Controller Area Network – 530Honda/Toyota Communications – 532

European BUS Communications – 532 Network Communications Diagnosis – 534

OBD-II Data Link Connector – 536 Chapter 71 – Computer Fundamentals – 812

Computer Fundamentals – 812Computer Functions – 813

Digital Computers – 814Computer Input Sensors – 816

Computer Outputs – 816

Chapter 23 – Electrical Accessories – 670 Objectives – 670Windshield Wiper/Washer Systems – 670

Horns/Clocks/Cigarette Lighter Systems – 677Cruise (Speed) Control Systems – 678

Sound Systems – 682Power Lock Systems – 684

Power Windows – 684Power Seats – 687

Power Mirror System – 690Rear-Window Defrosters and Heated Mirror

Chapter 58 – Horn, Wiper, and Blower MotorCircuits – 646 Horns – 646

Windshield Wiper and Washer System – 648Rain Sense Wiper System – 653

Blower Motor – 654Electrical Accessory Symptom Guide – 656

Chapter 59 – Accessory Circuits – 657 Cruise Control – 658

Troubleshooting Cruise Control – 659Electronic Throttle Cruise Control – 659


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Systems – 691

Other Electronic Systems – 692Security and Antitheft Devices – 697

Radar Cruise Control – 659

Precollision System – 662Heated Rear Window Defoggers – 662

Heated Mirrors – 663Homelink Garage Door Opener – 664

Power Windows – 664Power Seats – 666

Electrically Heated Seats – 668

Heated and Cooled Seats – 669Heated Steering Wheel – 669Adjustable Pedals – 670

Outside Folding Mirrors – 670Electric Power Door Locks – 671

Keyless Entry – 671Antitheft Systems – 678

Electrical Accessory Symptom Guide – 683 Chapter 61 – Audio System Operation and

Diagnosis – 698 Audio Fundamentals – 699

Radios and Receivers – 700Antennas – 700Antenna Diagnosis – 701

Speakers – 702Speaker Types – 704

Sound Levels – 704Crossovers – 704

Aftermarket Sound System Upgrade – 705Voice Recognition – 706

Bluetooth – 707Satellite Radio – 707

Radio Interference – 708Chapter 24 – Restraint Systems: Theory,

Diagnosis, and Service – 704

Objectives – 704Seat Belts – 704Seat Belt Service – 706

Air Bags – 708Electrical System Components – 712

Diagnosis – 716Servicing the Air Bag System – 718

Other Protection Systems – 719

Chapter 60 – Airbags and Pretensioner Circuits

– 686

Safety Belts and Retractors – 687Front Airbags – 687Airbag Diagnosis Tools and Equipment – 691

Airbag System Service – 693Driver Side Airbag Module Replacement – 694

Safety When Manually Deploying Airbags – 695Occupant Detection Systems – 695

Seat and Side Curtain Airbags – 696

Event Data Recorders – 697Chapter 25 – Engine Performance Systems –


Ignition Systems – 725Fuel System – 728

Air Induction System – 729Emission Control Systems – 729

Engine Control Systems – 731On-Board Diagnostic Systems – 736

System Operation – 739

Chapter 87 – On-Board Diagnosis – 957

On-Board Diagnostics Generation-II (OBD-II)Systems – 958

Diagnostic Executive and Task Manager – 958Monitors – 959

OBD-II Monitor Information – 959Enabling Criteria – 960

OBD-II DTC Numbering Designation – 961OBD-II Freeze-Frame – 962

Enabling Conditions – 962


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OBD-II Monitoring Capabilities – 740

OBD-II Self-Diagnostics – 747Basic Diagnosis of Electronic Engine Control

Systems – 749Diagnosing OBD-II Systems – 751

Diagnosing OBD-I Systems – 759

PCM Tests – 963

Global OBD-II – 964Diagnosing Problems Using Mode Six – 964

Chapter 88 – Scan Tools and Engine

Performance Diagnosis – 965

The Eight-Step Diagnostic Procedure – 966Scan Tools – 971

Retrieval of Diagnostic Information – 971

Troubleshooting Using Diagnostic Trouble Codes – 972Flash Code Retrieval On OBD-I General Motors

Vehicles – 973Retrieving Ford Diagnostic Codes – 973

Flash Code Retrieval On Chrysler Vehicles – 975OBD-II Diagnosis – 975

OBD-II Active Tests – 977Service/Flash Programming – 978

Manufacturer’s Diagnostic Routines – 980Completing System Repairs – 980

Procedures For Resetting the PCM – 981Road Test (Drive Cycle – 981

Chapter 26 – Detailed Diagnosis and Sensors –

764

Objectives – 764Using Scan Tool Data – 764

Symptom-Based Diagnosis – 768Basic Testing – 770

Diagnosis of Computer Voltage Supply andGround Wires – 771

Switches – 774

Temperature Sensors – 775Pressure Sensors – 778Mass Airflow (MAF) Sensors – 783

Oxygen Sensors (O2S) – 785Position Sensors – 794Speed Sensors – 797

Position/Speed Sensors – 799Knock Sensor (KS) – 802

Computer Outputs and Actuators – 803Testing Actuators – 804

Chapter 26 – Engine Condition Diagnosis – 237 Typical Engine-Related Complaints – 237

Engine Smoke Diagnosis – 237The Driver is Your Best Resource – 238

Visual Checks – 238Engine Noise Diagnosis – 240

Oil Pressure Testing – 241Oil Pressure Warning Lamp – 242

Compression Test – 242

Wet Compression Test – 243Running (Dynamic) Compression Test – 244Cylinder Leakage Test – 244

Cylinder Power Balance Test – 245Power Balance Test Procedure – 245Vacuum Tests – 245

Exhaust Restriction Test – 247Testing Back Pressure with a Vacuum Gauge –

248Testing Back Pressure with a Pressure Gauge –

248

Diagnosing Head Gasket Failure – 248Dash Warning Lights – 249 Chapter 72 – Temperature Sensors – 819

Engine Coolant Temperature Sensors – 819Testing the Engine Coolant Temperature Sensor –

820Intake Air Temperature Sensor – 823

Testing the Intake Air Temperature Sensor – 825Transmission Fluid Temperature Sensor – 825

Cylinder Head Temperature Sensor – 826Engine Fuel Temperature (EFT) Sensor – 826


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Exhaust Gas Recirculation (EGR) Temperature

Sensor – 826Engine 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 – 829PCM Uses For the TP Sensor – 829Testing the Throttle Position Sensor – 830

TP Sensor Diagnostic Trouble Codes – 831 Chapter 74 – MAP/BARO Sensors – 832

Air Pressure—High and Low – 833Principles of Pressure Sensors – 833

Construction of Manifold Absolute Pressure(MAP) Sensors – 834

PCM Uses of the MAP Sensor – 835Barometric Pressure Sensors – 837

Testing the MAP Sensor – 837Fuel-Rail Pressure Sensor – 838MAP/BARO Diagnostic Trouble Codes – 838

Chapter 75 – Mass Airflow Sensors – 840 Airflow Sensors – 840

Mass Airflow Sensor Types – 840Karman Vortex Sensors – 841

PCM Uses For Airflow Sensors – 842Testing Mass Airflow Sensors – 842

MAF Sensor Contamination – 844MAF-Related Diagnostic Trouble Codes – 844

Chapter 76 – Oxygen Sensors – 845 Oxygen Sensors – 846

Titania Oxygen Sensor – 848PCM Uses of the Oxygen Sensor – 849

Oxygen Sensor Diagnosis – 850Post Catalytic Converter Oxygen Sensor Testing –

853Wide-Band Oxygen Sensor – 853

Dual Cell Planar Wide-Band Sensor Operation –855

Dual Cell Diagnosis – 856

Single Cell Wide-Band Oxygen Sensors – 857Wide-Band Oxygen Pattern Failures – 858Oxygen Sensor-Related Diagnostic Trouble Codes

– 859

Chapter 27 – Ignition Systems – 810

Objectives – 810Basic Circuitry – 810

Ignition Components – 813Spark Plugs – 815

Triggering and Switching Devices – 819Engine Position Sensors – 820

Chapter 69 – Ignition System Components and

Operation – 781 Ignition System – 782

Ignition Switching and Triggering – 783Distributor Ignition – 785

Waste-Spark Ignition Systems – 787Coil-On-Plug Ignition – 788


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Distributor Ignition System Operation – 822

Electronic Ignition Systems – 823EI System Operation – 827

Knock Sensors – 791

Ignition Control Circuits – 793

Chapter 28 – Ignition System Diagnosis and


Misfires – 836General Ignition System Diagnosis – 837

Visual Inspection of Ignition Systems – 837 No-Start Diagnosis – 842

Diagnosing with an Engine Analyzer – 844Diagnosing with a DSO or GMM – 852

Ignition Timing – 854Basic Primary Circuit Components – 857

Distributor Service – 863Secondary Circuit Testing and Service – 863

Chapter 70 - Ignition System Diagnosis and

Service – 794 Checking for Spark – 794

Ignition Coil Testing – 795Ignition Sensor Testing – 796

Spark Plug Wire Inspection – 799Spark Plugs – 801

Ignition Timing – 804Firing Order – 805

Distributor Indexing – 805 No-Start Diagnosis – 806

Ignition Scope Testing – 807Scope-Testing a Waste-Spark System – 811

Scope-Testing a COP System – 811

Ignition System Symptom Guide – 811Chapter 29 – Fuel Delivery Systems – 874 Objectives – 874

Basic Fuel System Diagnosis – 875Guidelines for Safely Working on Fuel Systems –

875Fuel Tanks – 876

Filler Caps – 879Fuel Lines and Fittings – 881

Fuel Filters – 884Fuel Pumps – 886

Chapter 77 – Fuel Pumps, Lines, and Filters –

860

Fuel Delivery System – 860Fuel Tanks – 860

Rollover Leakage Protection – 862Fuel Lines – 862

Electric Fuel Pumps – 864Fuel Filters – 869

Fuel-Pump Testing – 870Fuel-Pump Current Draw Test – 873

Fuel-Pump Placement – 874Chapter 30 – Electronic Fuel Injection – 899

Objectives – 899Basic EFI – 900

Throttle Body Injection (TBI) – 905Port Fuel Injection (PFI) – 907

Central Multiport Fuel Injection (CMFI) – 912Gasoline Direct-Injection Systems – 913

Light- and Medium-Duty Diesel Fuel Injection –918

Chapter 78 – Fuel-Injection Components and

Operation – 875 Electronic Fuel-Injection Operation – 875

Speed-Density Fuel-Injection Systems – 876Mass Airflow Fuel-Injection Systems – 877

Throttle-Body Injection – 877Port-Fuel Injection – 878

Fuel-Pressure Regulator – 879Vacuum-Biased Fuel-Pressure Regulator – 880

Electronic Returnless Fuel System – 881

Mechanical Returnless Fuel System – 881Demand Delivery System (DDS) – 881Fuel Injectors – 883

Central Port Injection – 883Fuel-Injection Modes of Operation – 884

Idle Control – 885Stepper Motor Operation – 885

Chapter 79 – Gasoline Direct-Injection Systems

– 887

Direct Fuel Injection – 887Direct-Injection Fuel Delivery System – 887


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Gasoline Direct-Injection Fuel Injectors – 889

Modes of Operation – 889Piston Top Designs – 890

Lexus Port- and Direct-Injection Systems – 890Engine 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 – 893Accelerator Pedal Position Sensor – 893

Throttle Body Assembly – 894Throttle Position (TP) Sensor – 895

Diagnosis of Electronic Throttle Control Systems –896

ETC Throttle Follower Test – 898Servicing Electronic Throttle Systems – 898

Chapter 31 – Fuel Injection System Diagnosis

and Service – 922

Objectives – 922Preliminary Checks – 923

Basic EFI System Checks – 924Injector Service – 935

Fuel Rail, Injector, and Regulator Service – 937Electronic Throttle Controls – 941

Idle Speed Checks – 943

Chapter 81 – Fuel-Injection System Diagnosis

and Service – 900

Port Fuel-Injection Pressure Regulator Diagnosis –900

Diagnosing Electronic Fuel-Injection ProblemsUsing Visual Inspection – 901

Scan Tool Vacuum Leak Diagnosis – 902Port Fuel-Injection System Diagnosis – 902

Testing For an Injector Pulse – 903Checking Fuel-Injector Resistance – 904

Measuring Resistance of Grouped Injectors – 905Measuring Resistance of Individual Injectors – 905

Pressure-Drop Balance Test – 905

Injector Voltage-Drop Tests – 907Scope-Testing Fuel Injectors – 907Idle Air Speed Control Diagnosis – 908

Fuel-Injection Service – 908Fuel-System Scan Tool Diagnostics – 912

Chapter 32 – Intake and Exhaust Systems – 949 Objectives – 949

Vacuum Systems – 949Air Induction System – 951

Intake Manifold – 952Forced Induction Systems – 955

Turbochargers – 956Superchargers – 962

Exhaust System Components – 965Catalytic Converters – 966

Exhaust System Service – 970

Chapter 24 – Intake and Exhaust Systems – 219 Air Intake Filtration – 219

Throttle-Body Injection Intake Manifolds – 221Port Fuel-Injection Intake Manifolds – 222

Exhaust Gas Recirculation Passages – 223Exhaust Manifolds – 224

Mufflers – 225 Chapter 25 – Turbocharging and

Supercharging – 227 Introduction – 228

Forced Induction Principles – 228Superchargers – 230

Turbochargers – 230Boost Control – 232

Turbocharger Failures – 234 Nitrous Oxide – 235

Chapter 27 – In-Vehicle Engine Service – 252


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Thermostat Replacement – 253

Water Pump Replacement – 253Intake Manifold Gasket Inspection – 254

Intake Manifold Gasket Replacement – 254Timing Belt Replacement – 255

Hybrid Engine Precautions – 255

Chapter 33 – Emission Control Systems – 978

Objectives – 978

Pollutants – 978Emission Control Devices – 982Evaporative Emission Control Systems – 985

Precombustion Systems – 988Postcombustion Systems – 995

Diesel Emission Controls – 1001

Chapter 82 – Vehicle Emission Standards and

Testing – 918

Emission Standards in the United States – 919European Standards – 919Exhaust Analysis Testing – 920

Exhaust Analysis and Combustion Efficiency –923

HC Too High – 924CO Too High – 924

Measuring Oxygen (O2) and Carbon Dioxide(CO2) – 925

Photochemical Smog Formation – 925Testing for Oxides of Nitrogen – 926

Chapter 34 – Emission Control Diagnosis andService – 1009

Objectives – 1009I/M 240 Test – 1009

Testing Emissions – 1012Basic Inspection – 1015

Evaporative Emission Control System Diagnosisand Service – 1018

PCV System Diagnosis and Service – 1023EGR System Diagnosis and Service – 1025

Catalytic Converter Diagnosis – 1032

Air System Diagnosis and Service – 1034

Chapter 83 – Evaporative Emission ControlSystems – 927

Evaporative Emission Control System – 928 Nonenhanced Evaporative Control Systems – 929

Enhanced Evaporative Control System – 930Leak Detection Pump System – 931

Onboard Refueling Vapor Recovery – 931Diagnosing the EVAP System – 931

Evaporative System Monitor – 932Typical EVAP Monitor – 933

EVAP System-Related Diagnostic Trouble Codes

– 934 Chapter 84 – Exhaust Gas Recirculation

Systems – 935

Exhaust Gas Recirculation Systems – 936OBD-II EGR Monitoring Strategies – 938

Diagnosing a Defective EGR System – 940EGR-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 – 945Secondary Air-Injection System – 945

Secondary Air-Injection System Diagnosis – 947SAI-Related Diagnostic Trouble Codes – 947

Chapter 86 – Catalytic Converters – 948 Catalytic Converters – 949

OBD-II Catalytic Converter Performance – 950Diagnosing Catalytic Converters – 952

Catalytic Converter Replacement Guidelines – 954


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Chapter 35 – Fuels and Other Energy Sources –


Crude Oil – 1040Gasoline – 1043

Basic Gasoline Additives – 1044Oxygenates – 1045

Gasoline Quality Testing – 1046

Alternatives to Gasoline – 1047Diesel Fuel – 1051Electric Vehicles – 1053

Hybrid Electric Vehicles – 1054Fuel Cell Electric Vehicles – 1062

Chapter 66 – Gasoline – 754

Gasoline – 754Refining – 755

Volatility – 756Gasoline Combustion Process – 757

Normal and Abnormal Combustion – 758Octane Rating – 759

High-Altitude Octane Requirements – 759

Gasoline Additives – 760Gasoline Blending – 761Reformulated Gasoline – 762

Testing Gasoline For Alcohol Content – 762General Gasoline Recommendations – 763

Chapter 67 – Alternative Fuels – 766 Ethanol – 767

Cellulose Ethanol – 767E85 – 768

Alternative-Fuel Vehicles – 768Methanol – 771

Propane – 772Compressed Natural Gas – 772Liquefied Natural Gas – 774

P-Series Fuels – 774Synthetic Fuels – 774

Safety Precautions When Working withAlternative Fuels – 776

Chapter 68 – Diesel and Biodiesel Fuels – 777 Diesel Fuel – 777

Biodiesel – 779E-Diesel Fuel – 780

Chapter 89 – Introduction to Hybrid Vehicles –983

Hybrid Vehicles – 983Electric Vehicles – 983

Driving and Owning a Hybrid Electric Vehicle –984

Classifications of Hybrid Electric Vehicles – 985Belt Alternator Starter Systems – 987

Common Features of Most Hybrids – 989Levels of Hybrid Vehicles – 989

Chapter 90 – Hybrid Safety and Service

Procedures – 991 High-Voltage Safety – 991High-Voltage Safety Equipment – 992

Electric Shock Potential – 993De-Powering the High-Voltage System – 995

Collision and Repair Industry Issues – 995Moving and Towing a Hybrid – 996

Removing the High-Voltage Batteries – 996Routine Service Procedures – 997

Chapter 91 – Fuel Cells and Advanced

Technologies – 1002


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Fuel-Cell Technology – 1003

PEM Fuel Cells – 1004Fuel-Cell Vehicle Systems – 1006

Hydraulic Hybrid Storage System – 1010HCCI – 1011

Plug-In Hybrid Electric Vehicles – 1011The Future For Electric Vehicles – 1012

Wind Power – 1013

Hydroelectric Power – 1013Chapter 36 – Clutches – 1071 Objectives – 1071

Operation – 1071Clutch Service Safety Precautions – 1079

Clutch Maintenance – 1079Clutch Problem Diagnosis – 1080

Clutch Service – 1084

Chapter 121 – Clutches – 1454 Purpose and Function of a Clutch – 1454

Component Parts and Operation of a ClutchAssembly – 1454

Clutch Problem Diagnosis – 1462Clutch Replacement – 1464

Clutch Pedal Adjustment – 1465Bleeding the Hydraulic Clutch – 1466

Clutch Symptom Guide – 1467

Chapter 37 – Manual Transmissions and

Transaxles – 1092 Objectives – 1092

Transmission Versus Transaxle – 1092Gears – 1096

Basic Gear Theory – 1097Transmission/Transaxle Design – 1099

Synchronizers – 1101Gearshift Mechanisms – 1103

Transmission Power Flow – 1104Transaxle Power Flows – 1108

Final Drive Gears and Overall Ratios – 1112

Electrical Systems – 1112

Chapter 122 – Manual

Transmissions/Transaxles – 1471 The Need For a Transmission – 1472

Gear Types – 1472Gear Ratios – 1473

Torque, Speed, and Power – 1475Transmission Construction – 1476

Torque Flow Through a Manual Transmission –1476

Speed Gears – 1477Synchronizer Parts and Operation – 1477

Five-Speed Transmission Torque Flow – 1480

Manual Transaxle Construction – 1482Transmission/Transaxle Removal – 1482Transmission/Transaxle Disassembly – 1484

Hard-To-Shift Problem Diagnosis – 1485Manual Transmission Installation – 1486

Gear Lubrication – 1487

Chapter 38 – Manual Transmission/Transaxle


Lubricant Check – 1116In-Vehicle Service – 1118

Diagnosing Problems – 1119Transmission/Transaxle Removal – 1124

Cleaning and Inspection – 1125Disassembly and Reassembly of the Differential

Case – 1131Reassembly/Reinstallation of

Transmission/Transaxle – 1134

Chapter 122 – Manual

Transmissions/Transaxles – 1471 The Need For a Transmission – 1472

Gear Types – 1472Gear Ratios – 1473

Torque, Speed, and Power – 1475Transmission Construction – 1476

Torque Flow Through a Manual Transmission –1476

Speed Gears – 1477Synchronizer Parts and Operation – 1477

Five-Speed Transmission Torque Flow – 1480Manual Transaxle Construction – 1482

Transmission/Transaxle Removal – 1482Transmission/Transaxle Disassembly – 1484


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Hard-To-Shift Problem Diagnosis – 1485

Manual Transmission Installation – 1486Gear Lubrication – 1487

Chapter 39 – Drive Axles and Differentials –


Front-Wheel-Drive (FWD) Axles – 1138Types of CV Joints – 1139

Front-Wheel-Drive Applications – 1140CV Joint Service – 1142

Rear-Wheel Drive Shafts – 1147Operation of U-Joints – 1149

Types of U-Joints – 1151Diagnosis of Drive Shaft and U-Joint Problems –

1152Differentials and Drive Axles – 1153

Limited-Slip Differentials – 1160

Axle Shafts – 1161Servicing the Final Drive Assembly – 1164Diagnosing Differential Noises – 1169

Chapter 123 – Drive Axle Shafts and CV Joints

– 1494 Introduction – 1495

Driveshaft Design – 1495Driveshaft Balance – 1496

U-Joint Design and Operation – 1496Constant Velocity Joints – 1498

Chapter 124 – Drive Axle Shafts and CV Joint

Service – 1503

U-Joint Fault Symptoms – 1503Driveshaft and U-Joint Inspection – 1504

U-Joint Replacement – 1506U-Joint Working Angles – 1508

CV Joint Diagnosis – 1508

Replacement Shaft Assemblies – 1509CV Joint Service – 1509 Chapter 125 – Drive Axles and Differentials –

1516 Differentials – 1517

Parts of a Differential – 1517Differential Gear Ratios – 1519

Differentials – 1519Limited Slip Differentials – 1520

Differential Components – 1521Differential Axle Bearings – 1523

Differential Identification – 1524Determining the Axle Ratio of a Differential –

1524Rear End Noise Diagnosis – 1525

Differential Inspection – 1525Tooth Contact Pattern Test – 1526

Differential Disassembly – 1526Pinion Shaft Bearing Replacement – 1526

Drive Pinion Depth – 1526Pinion Gear Preload – 1528

Checking and Correction Backlash – 1529Setting Side Bearing Preload – 1530

Reassembly of the Differential Assembly – 1531Differential Lubricant – 1532

Chapter 40 – Automatic Transmissions and

Transaxles – 1173

Objectives – 1173Torque Converter – 1174

Lockup Torque Converter – 1178Planetary Gears – 1178

Compound Planetary Gear Sets – 1181Honda’s Nonplanetary-Based Transmission – 1186

Chapter 127 – Automatic

Transmission/Transaxle Principles – 1551

Background – 1551Torque Converters – 1551

Lockup Torque Converter – 1556Shift Modes – 1557

Planetary Gear Sets – 1558Compound Planetary Gear Set – 1559


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Continuously Variable Transmissions (CVT) –

1186Planetary Gear Controls – 1189

Transmission Clutches – 1191Bearings, Bushings, and Thrust Washers – 1193

Snaprings – 1195Gaskets and Seals – 1196

Final Drives and Differentials – 1199

Hydraulic System – 1199Application of Hydraulics in Transmissions – 1200Pressure Boosts – 1204

Shift Quality – 1204Hydraulic Circuits – 1205

Automatic Transaxles – 1561

Nonplanetary Gear Automatic Transaxles – 1561Continuously 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 – 1569Apply or Holding Devices – 1571Bands – 1571

Multiple-Plate Clutches – 1572Accumulators – 1574

One-Way Clutches – 1575Valve Body – 1576

Hydraulically Controlled Transmission Valves –1577

Electronically Controlled Transmissions – 1580Typical Torque Flow – 1582

Chapter 41 – Electronic AutomaticTransmissions – 1216

Objectives – 1216Transmission Control Module – 1217

Hybrid Transmissions – 1228Basic EAT Testing – 1232

Converter Clutch Control Diagnostics – 1236Detailed Testing of Inputs – 1238

Detailed Testing of Actuators – 1240

Chapter 128 – Hydraulic Components andControl Systems – 1567

Automatic Transmission Fluid – 1567Automatic Transmission Fluid Cooler – 1568

Pump – 1569Apply or Holding Devices – 1571

Bands – 1571Multiple-Plate Clutches – 1572

Accumulators – 1574One-Way Clutches – 1575

Valve Body – 1576

Hydraulically Controlled Transmission Valves –1577Electronically Controlled Transmissions – 1580

Typical Torque Flow – 1582

Chapter 42 – Automatic Transmission and

Transaxle Service – 1245 Objectives – 1245

Identification – 1245Basic Diagnostics – 1245

Fluid Leaks – 1250Road Testing the Vehicle – 1252

Checking the Torque Converter – 1253Diagnosing Hydraulic and Vacuum Control

Systems – 1256Common Problems – 1259

Linkages – 1260

Chapter 129 – Automatic

Transmission/Transaxle Diagnosis and In-

Vehicle Service – 1586

Transmission Problem Diagnosis – 1586Fluid Leak Diagnosis – 1591

In-Vehicle Service – 1594 Chapter 130 – Automatic

Transmission/Transaxle Unit Repair – 1598 Verify the Need For Unit Repair – 1598

Removing the Automatic Transmission/TransaxleFor Service – 1599

Automatic Transmission/Transaxle Disassembly –1600

Reassembling an AutomaticTransmission/Transaxle – 1604

Flushing the Cooler and Torque Converter – 1607Dynamometer Testing the Automatic

Transmission/Transaxle – 1608


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Reinstalling the Automatic

Transmission/Transaxle – 1608Road Test – 1608

Chapter 43 – Four- and All-Wheel Drive – 1271

Objectives – 1271Types of Four-Wheel Drives – 1271

Four-Wheel-Drive Systems – 1272Transfer Case – 1277

Interaxle Differentials – 1277Locking Hubs – 1282

Four-Wheel-Drive Passenger Cars – 1282All-Wheel-Drive Systems – 1284

Diagnosing 4WD and AWD Systems – 1284Servicing 4WD Vehicles – 1288

Chapter 126 – Four-Wheel-Drive and All-

Wheel Drive – 1534 Four-Wheel-Drive Systems – 1534

All-Wheel Drive – 1537Front and Rear Differential Axle Ratios – 1537

Transfer Case – 1537Interaxle Differential – 1541

Four-Wheel-Drive Axles – 1542Transfer Case Service and Problem Diagnosis –

1543Diagnosing and Servicing Locking Hubs – 1544

Transfer Case Service – 1545

Chapter 44 – Tires and Wheels – 1297

Objectives – 1297

Wheels – 1297Tires – 1298Tire Ratings and Designations – 1303

Tire/Wheel Runout – 1309Tire Replacement – 1310

Tire Repair – 1311Installation of Tire/Wheel Assembly on the

Vehicle – 1314Tire/Wheel Assembly Service – 1315

Wheel Bearings – 1316

Chapter 98 – Wheel Bearings and Service –

1070

Antifriction Bearings – 1071Bearing Greases – 1072Bearing Diagnosis – 1074

Wheel Bearing Service – 1075Sealed Bearing Replacement – 1078

Rear Drive Axle Classifications – 1079Rear Axle Bearing and Seal Replacement – 1080

Bearing Failure Analysis – 1082 Chapter 109 – Tires and Wheels – 1239

Introduction To Tires – 1240Parts of a Tire – 1240

Tire Molding – 1242Tire Size Designations – 1243

Load Index and Equivalent Loads – 1246Speed Ratings – 1246

Tire Pressure and Traction – 1246Tire Conicity and Ply Steer – 1247

Vehicle Handling and Tire Slip Angle – 1249Rim Width and Tire Size – 1249

Uniform Tire Quality Grading System – 1250All-Season Tire Designation – 1250

DOT Tire Code – 1251Spare Tires – 1251

Run-Flat Tires – 1252General Motors TPC Rating – 1253

Tire Selection Considerations – 1253Wheels – 1254

Tire Valves – 1257Unsprung Weight – 1257

Lug Nuts – 1257 Chapter 110 – Tire Pressure Monitoring

Systems – 1261 Need For Tire Pressure Monitoring – 1261


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Indirect TPMS – 1262

Direct TPMS – 1263Identifying a Vehicle with TPMS – 1264

TPMS Pressure Sensors – 1264TPMS Sensor Operation – 1265

TPMS Receiver – 1266Direct TPMS Diagnosis – 1266

Installing a New Pressure Sensor – 1266

TPMS Diagnostic Tools – 1267TPMS Sensor Activations – 1267TPMS Relearn Procedure – 1268

TPMS Sensor Service Tools – 1268 Chapter 111 – Tire and Wheel Service – 1270

Introduction – 1270Tire Inflation – 1270

Nitrogen Inflation – 1271Tire Mounting Recommendations – 1272

Wheel Mounting Torque – 1273Tire Rotation – 1274

Tire Inspection – 1276Radial Runout – 1276Lateral Runout – 1277

Tire Balancing – 1278Replacement Wheels – 1281

Tire Repair – 1281

Chapter 45 – Suspension Systems – 1323 Objectives – 1323

Frames – 1323Suspension System Components – 1324

MacPherson Strut Suspension Components – 1331

Independent Front Suspension – 1334Basic Front-Suspension Diagnosis – 1337Front-Suspension Component Servicing – 1339

Rear-Suspension Systems – 1345Semi-Independent Suspension – 1348Electronically Controlled Suspensions – 1351

Servicing Electronic Suspension Components –1355

Active Suspensions – 1357

Chapter 112 – Suspension System Principles

and Components – 1288

Introduction – 1289Frame Construction – 1289

Platforms – 1290

Unsprung Weight – 1290Types of Suspensions – 1290Hooke’s Law – 1291

Coil Springs – 1291Leaf Springs – 1295Torsion Bars – 1297

Suspension Principles – 1298Steering Knuckles – 1299

Control Arms – 1299Ball Joints – 1300

Strut Rods – 1301

Stabilizer Bars – 1301Shock Absorbers – 1302Struts – 1304

Bump Stops – 1308 Chapter 113 – Front Suspensions and Service –

1311 Front Suspension Types – 1312

Short/Long-Arm Suspensions – 1313Strut Suspension – 1314

Servicing the Suspension System – 1315Road Test Diagnosis – 1316


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Dry Park Test (Suspension) 1317

Visual Inspection – 1317Ball Joints – 1318

Kingpin Diagnosis and Service – 1322Shock Absorbers and Struts – 1323

Macpherson Strut Replacement – 1324Stabilizer Bar Link and Bushing Service – 1326

Strut Rod Bushings – 1327

Front Coil Springs – 1327Steering Knuckles – 1328Torsion Bars – 1329

Control Arm Bushings – 1330 Chapter 114 – Rear Suspensions and Service –

1335 Solid Rear Axles – 1335

Leaf Spring Rear Suspensions – 1336Trailing Arm Rear Suspensions – 1337

Semi-Trailing Arm Rear Suspensions – 1338Independent Rear Suspensions – 1338

Semi-Independent Rear Suspensions – 1339Rear Suspension Service – 1340Rear 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 – 1348Types of Electronic Suspension – 1349

Automatic Level Control (ALC) – 1354Magneto-Rheological (MR) Suspension – 1355

Troubleshooting Rear Electronic Leveling Systems – 1356

Chapter 46 – Steering Systems – 1363 Objectives – 1363

Manual-Steering Systems – 1363Power-Steering Systems – 1370

Electronically Controlled Power-Steering Systems – 1375

Steering System Diagnosis – 1378

Diagnosis – 1379Specific Checks – 1382Steering System Servicing – 1388

Power-Steering System Servicing – 1390Four-Wheel Steering Systems – 1393

Chapter 116 – Steering Columns and Gears –

1358

Steering Wheels – 1358Steering Columns – 1358

Conventional Steering Gears – 1363Recirculating Ball Steering Gear – 1364

Steering Gear Adjustments – 1366

Rack-And-Pinion Steering Gear – 1367Rack-And-Pinion Adjustments – 1369 Chapter 117 – Steering Linkage and Service –

1372 Steering Linkage – 1372

Rack-And-Pinion Inner Tie Rod Ends – 1373Front Steer Versus Rear Steer – 1375

Four-Wheel Steering Systems – 1375Steering Linkage Lubrication – 1378

Dry Park Test – 1379Common Wear Items – 1380


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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 – 1388Power Steering Hoses – 1392

Integral Power Steering – 1392

Variable-Effort Steering – 1396Electric Power Steering System – 1399Self-Parking System – 1401

Electrohydraulic Power Steering – 1402Power Steering Diagnosis and Troubleshooting –

1402

Chapter 47 – Wheel Alignment – 1402

Objectives – 1402Alignment Geometry – 1403

Prealignment Inspection – 1407Wheel Alignment Equipment – 1409

Alignment Machines – 1410Performing an Alignment – 1411

Four-Wheel-Drive Vehicle Alignment – 1421

Chapter 119 – Wheel Alignment Principles –

1413 Definition of a Wheel Alignment – 1413

Alignment-Related Problems – 1413Alignment Angles – 1414

Steering Axis Inclination (SAI) – 1421Included Angle – 1421

Scrub Radius – 1422Turning Radius (Toe-Out On Turns) – 1424

Setback – 1424Thrust Angle – 1425

Tracking – 1425Four-Wheel Alignment – 1426

Chapter 120 – Alignment Diagnosis and Service

– 1427

Need For Proper Alignment – 1427

Prealignment Correction Techniques – 1427Prealignment Checks – 1428Lead/Pull – 1429

Memory Steer – 1429Torque Steer – 1430Alignment Specifications – 1431

Alignment Setup Procedures – 1432Measuring Camber, Caster, SAI, Toe, and TOOT –

1433Specifications Versus Alignment Readings – 1434

Checking For Bent Struts, Spindles, or Control

Arms – 1434Checking Frame Alignment of Front-Wheel-DriveVehicles – 1434

Types of Alignments – 1434Sample Alignment Specifications and Readings –

1437Adjusting Rear Camber – 1438

Guidelines For Adjusting Front Camber/SAI andIncluded Angle – 1440

Front Camber/Caster Adjustment Methods – 1441Adjusting Front Camber/Caster – 1442


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Setting Toe – 1442

Centering the Steering Wheel – 1444Steering Wheel Removal – 1444

Tolerance Adjustment Procedure – 1447Aftermarket Alignment Methods – 1447

Aligning Electronic-Suspension Vehicles – 1447Aligning Modified Vehicles – 1447

Hidden Structural Damage Diagnosis – 1449

Alignment Guide – 1449Chapter 48 – Brake Systems – 1424 Objectives – 1424

Friction – 1424Principles of Hydraulic Brake Systems – 1427

Hydraulic Brake Systems Components – 1429Master Cylinders – 1430

Master Cylinder Operation – 1433Hydraulic Tubes and Hoses – 1435

Hydraulic System Safety Switches and Valves –1437

Drum and Disc Brake Assemblies – 1440Hydraulic System Service – 1442

Power Brakes – 1449Pushrod Adjustment – 1450

Hydraulic Brake Boosters – 1451Electric Parking Brakes – 1453

Chapter 92 – Braking System Components and

Performance Standards – 1015

Fundamentals of Brake Systems – 1016Brake Design Requirements – 1017

Brake System Categories – 1017Antilock Brake System Overview – 1018

Federal Brake Standards – 1019Brake Repair and the Law – 1020

Chapter 93 – Braking System Principles – 1021 Energy Principles – 1022

Inertia – 1023Mechanical Principles – 1023

Friction Principles – 1024Friction and Heat – 1025

Deceleration Rates – 1026 Chapter 94 – Brake Hydraulic Systems – 1027

Hydraulic Principles – 1027Pascal’s Law – 1028

Master Cylinders – 1031Master Cylinder Designs – 1034

Diagnosing and Troubleshooting Master Cylinders

– 1037Master Cylinder Service – 1038 Chapter 95 – Hydraulic Valves and Switches –

1040 Introduction – 1041Residual Check Valve – 1041

Pressure-Differential Switch (Brake WarningSwitch) – 1041

Brake Fluid Level Sensor Switch – 1042Proportioning Valve – 1043

Electronic Brake Proportioning – 1046

Metering Valve (Hold-Off) Operation ) 1046Combination Valve – 1048Brake Light Switch – 1048

Chapter 96 – Brake Fluid and Lines – 1050 Brake Fluid – 1050

Brake Fluid Service Procedures and Precautions –1054

Rubber Types – 1054Brake Lines – 1054

Chapter 97 – Brake Bleeding Methods and

Procedures – 1061


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Brake Bleeding – 1061

Brake Bleeder Valve Loosening Methods – 1062Bleeding Sequence – 1063

Manual Bleeding – 1063Vacuum Bleeding – 1064

Gravity Bleeding – 1065Pressure Bleeding – 1066

Hydraulic ABS Service – 1067

Brake Fluid Replacement/Flushing – 1069 Chapter 104 – Machining Brake Drums and

Rotors – 1157

Brake Drums – 1158Brake Drum and Rotor Damage – 1158

Brake Drum Distortion – 1159Removing Drums – 1161

“Machine To” Versus “Discard” – 1161Machining Brake Drums – 1162

Disc Brake Rotors – 1164Disc Brake Rotor Distortion – 1166

Disc Brake Rotor Thickness – 1167When the Rotors Should Be Machined – 1167Rotor Finish – 1168

Machining a Disc Brake Rotor – 1170On-The-Vehicle Rotor Machining – 1175

Chapter 105 – Power Brake Unit Operation,

Diagnosis, and Service – 1195

The Need For Power Brake Assist – 1196Principles of Vacuum – 1196

Vacuum Booster Theory – 1197Charcoal Filter – 1198

Vacuum Check Valve – 1199Vacuum Brake Booster Operation – 1199

Dual- (Tandem-) Diaphragm Vacuum Boosters –1201

Brake Assist Systems – 1201Vacuum Booster Operation Test – 1202

Vacuum Booster Leak Test – 1202Hydraulic System Leak Test – 1202

Pushrod Clearance Adjustment – 1202Vacuum Booster Disassembly and Service – 1203

Hydro-Boost Hydraulic Brake Booster – 1203

Hydro-Boost Symptom-Based Guide – 1207Chapter 49 – Drum Brakes – 1457 Objectives – 1457

Drum Brake Operation – 1457Drum Brake Components – 1458

Drum Brake Designs – 1460Road Testing Brakes – 1464

Drum Brake Inspection – 1464Brake Shoes and Linings – 1472

Wheel Cylinder Inspection and Servicing – 1475Drum Parking Brakes – 1475

Chapter 99 – Drum Brakes – 1087 Drum Brake Advantages – 1087

Drum Brake Disadvantages – 1089Drum Brake Parts – 1089

Drum Brake Shoes – 1091Drum Brake Parts – 1093

Non-Servo Brake Design – 1094Dual-Servo Brake Design – 1095

Automatic Brake Adjusters – 1097 Chapter 100 – Drum Brake Diagnosis and


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Service – 1101

Drum Brake Faults – 1101Drum Brake Diagnosis – 1101

Brake Drum Removal – 1101Drum Brake Disassembly – 1103

Inspecting the Backing Plate – 1104Drum Brake Lining Inspection – 1104

Brake Spring Inspection – 1105

Wheel Cylinder Inspection – 1105Drum Brake Hardware Kit – 1107Inspecting the Drum Brake Shoes – 1107

Brake Parts Cleaning – 1107Reassembling the Drum Brake – 1108

Adjusting Drum Brakes – 1108Lubrication Checklist – 1109

Drum Brake Symptom-Based Guide – 1109 Chapter 103 – Parking Brake Operation,

Diagnosis, and Service – 1145 Parking Brake Standards – 1145

Pedals, Levers, and Handles – 1145Parking Brake Warning Lamp – 1147Parking Brake Linkages – 1147

Front and Rear Entry Parking Brake Cables – 1149Drum Parking Brakes – 1149

Caliper-Activated Disc Parking Brakes – 1150Rear Disc Brake Service – 1153

Parking Brake Cable Adjustment – 1153Electric Parking Brake – 1156

Chapter 50 – Disc Brakes – 1481

Objectives – 1481

Disc Brake Components and Their Functions –1481Rear-Wheel Disc Brakes – 1486

Disc Brake Diagnosis – 1488Service Guidelines – 1490General Caliper Inspection and Servicing – 1491

Rear Disc Brake Calipers – 1498Rotor Inspection – 1499

Rotor Service – 1501

Chapter 101 – Disc Brakes – 1114

Disc Brakes – 1115

Disc Brake Construction – 1118Disc Brake Pads – 1118Brake Rotors – 1122

Caliper Design – 1122Rear Disc Brakes – 1126 Chapter 102 – Disc Brakes Diagnosis and

Service – 1128 Disc Brake Diagnostic Procedure – 1128

Visual Inspection – 1128Disc Brake Caliper Service – 1130

Servicing Disc Brake Calipers – 1132

Disc Brake Squeal Correction – 1137Disc Brake Symptom Guide – 1138

Chapter 51 – Antilock Brake, Traction Control,

and Stability Control Systems – 1506

Objectives – 1506Antilock Brakes – 1506

ABS Components – 1507Types of Antilock Brake Systems – 1511

ABS Operation – 1512Automatic Traction Control – 1519

Automatic Stability Control – 1521

Chapter 106 – ABS Components and Operation

– 1208

Antilock Braking System – 1208ABS Operation – 1210

System Configurations – 1211ABS Components – 1212

ABS Control Module – 1214Hydraulic Modulator Assembly – 1214

Brake Pedal Feedback – 1217


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Antilock Brake System Service – 1523

Diagnosis and Testing – 1524Testing Traction and Stability Control Systems –

1530 New Trends – 1531

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 – 1221Thorough Visual Inspection – 1221

Test Drive and Verify the Fault – 1222

Retrieving Diagnostic Trouble Codes – 1223Kelsey-Hayes Antilock (Nonintegral) – 1223Bosch 2 ABS (Nonintegral) – 1224

Teves Mark IV – 1225Delphi (Delco) ABS-VI (Nonintegral) – 1225

Wheel Speed Sensor Diagnosis – 1227Wheel Speed Sensor Adjustment – 1228

OBD-II ABS Diagnosis – 1229ABS Safety Precautions – 1231

Chapter 108 – Electronic Stability Control

Systems – 1232

The Need For Electronic Stability Control – 1232Federal Motor Vehicle Safety Standard (FMVSS) No. 126 – 1233

Sine with Dwell Test – 1233 Names of Various ESC Systems – 1234

ESC Sensors – 1234Traction Control – 1236

ESC/TC Diagnosis – 1238

Chapter 52 – Heating and Air-Conditioning –

1535

Objectives – 1535

Ventilation System – 1535Automotive Heating Systems – 1536Heating System Service – 1539

Theory of Automotive Air-Conditioning – 1541Refrigerants – 1542Basic Operation of an Air-Conditioning System –

1544Compressors – 1546

Condenser – 1550Receiver/Dryer – 1552

Thermostatic Expansion Valve/Orifice Tube –

1552Evaporator – 1553Refrigerant Lines – 1554

Air-Conditioning Systems and Controls – 1555Temperature Control Systems – 1557

Chapter 62 – Heating and Air-Conditioning

Components and Operation – 712

Purpose and Function – 712

Heating System – 714Air-Conditioning Refrigeration Cycle – 715Expansion Valve Systems – 715

Orifice Tube Systems – 716Thermostatic Control – 716Refrigerants – 718

Refrigerants and the Environment – 719Refrigerant Oils – 720

Condenser – 720Evaporator – 720

Receiver-Drier – 721

Accumulator – 722Refrigerant Lines and Hoses – 723Thermostatic Expansion Valves – 723

Fixed-Orifice Tubes – 725Compressors – 725

Compressor Controls – 729 Chapter 63 – Automatic Air-Conditioning

System Operation – 731 Airflow Management – 731

Automatic Air Conditioning – 732Actuators – 732


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Cabin Filters – 732

Vacuum Control Circuits – 733Electric Servomotor Circuits – 733

Blower Motor Control – 734Dual-Zone Climate Controls – 734

Rear Air-Conditioning System – 735Recirculation Operation – 735

Hybrid Electric Vehicle Heating and Cooling

Systems – 736Chapter 53 – Air-Conditioning Diagnosis and

Service – 1565

Objectives – 1565Service Precautions – 1565

Refrigerant Safety Precautions – 1566Guidelines for Converting (Retrofitting) R-12

Systems to R-134a – 1567Initial System Checks – 1568

Diagnosis – 1571Performance Testing – 1572

Leak Testing – 1575Emptying the System – 1578

General Service – 1579Recharging the System – 1587

Climate Control Systems – 1590


System Diagnosis – 737

HVAC Diagnostic Procedure – 737Heater Diagnosis – 737

Check A/C System Performance – 740Temperature and Pressure Measurements – 740


Service – 745

Blower Motor Service – 746Cooling System Service – 746

Refrigerant Recovery Process – 746Evacuation Procedures – 748

Noncondensable Gases – 748Refrigerant Recycling – 749

Recharging a System – 750Retrofitting a CFC-12 System To a HFC-134A

System – 751Compressor Service – 751

Condenser Service – 751Evaporator Service – 751

Receiver/Drier or Accumulator/Drier Service –

752Orifice Tube/Expansion Valve Service – 753

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