INSTRUCTORS MANUAL TO ACCOMPANY

AUTOMOTIVE TECHNOLOGY
A SYSTEMS APPROACH
F O U R T H E D I T I O N

Dale McPherson
Eastern Idaho Technical College East Idaho Falls, Idaho

Jack Erjavec
Columbus State Community College Columbus, Ohio

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Instructors Manual to Accompany Automotive Technology: A Systems Approach, Fourth Edition Dale McPherson and Jack Erjavec Vice President, Technology and Trades SBU: Alar Elken Editorial Director: Sandy Clark Sr. Acquisitions Editor: David Boelio Developmental Editor: Christopher Shortt Marketing Director: Dave Garza COPYRIGHT 2005 by Thomson Delmar Learning, a division of Thomson Learning, Inc. Thomson, the Star logo, and Delmar Learning are trademarks used herein under license. Printed in the United States of America 1 2 3 4 5 XX 07 06 05 04 For more information contact Thomson Delmar Learning Executive Woods 5 Maxwell Drive, PO Box 8007, Clifton Park, NY 12065-8007 Or find us on the World Wide Web at www.delmarlearning.com Channel Manager: Bill Lawrensen Marketing Coordinator: Mark Pierro Production Director: Mary Ellen Black Production Editor: Barbara L. Diaz Art/Design Specialist: Rachel Baker Technology Project Manager: Kevin Smith Technology Project Specialist: Linda Verde Editorial Assistant: Kevin Rivenburg

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Library of Congress Cataloging-inPublication Data: Card Number: 1-4018-4831-1 ISBN: 1-4018-4832-X

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

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Contents

CHAPTER CHAPTER CHAPTER CHAPTER CHAPTER CHAPTER CHAPTER CHAPTER CHAPTER CHAPTER CHAPTER CHAPTER CHAPTER CHAPTER CHAPTER CHAPTER CHAPTER CHAPTER CHAPTER CHAPTER CHAPTER

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49

CHAPTER 50 CHAPTER 51

Fuel Injection System Diagnosis and Service . . . . . . . . . . . . . . . . 118 Intake and Exhaust Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Emission Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Emission Control System Diagnosis and Service . . . . . . . . . . . . . 130 On-Board Diagnostic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 On-Board Diagnostic System Diagnosis and Service . . . . . . . . . . 139 Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Manual Transmissions and Transaxles . . . . . . . . . . . . . . . . . . . . . 147 Manual Transmission/Transaxle Service. . . . . . . . . . . . . . . . . . . . 150 Drive Axles and Differentials . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 Automatic Transmissions and Transaxles . . . . . . . . . . . . . . . . . . . 158 Automatic Transmission and Transaxle Service . . . . . . . . . . . . . . 163 Four- and All-Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 Tires and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 Suspension Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 Steering Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 Drum Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 Disc Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 Antilock Brake, Traction Control, and Stability Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 Heating and Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 Heating and Air-Conditioning Diagnosis and Service. . . . . . . . . . 206

ASE Task Correlation Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 NATEF Task Correlation Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

PREFACE

Automotive Technology: A Systems Approach was developed as a complete learning package giving the instructor the tools needed for training students to become professional automotive technicians. The main text provides comprehensive, state-of-the-art coverage of both vehicles and repair procedures in a logical but flexible chapter arrangement. It is organized around the eight ASE areas. Both the text and Tech Manual emphasize professionalism and ASE certification. This Instructors Manual helps coordinate teaching activities ranging from lectures, to shop assignments, to testing and ASE certification. It contains the information needed to help gain the most value from the text. The Chapter Overview and Chapter Objectives give a brief orientation to the contents and purpose of each chapter. The Instructional Outline with Teaching Hints gives a complete outline of each chapters 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 Manual pages that are relevant to teaching the ASE and NATEF tasks listed.