TODAY'S TECHNICIAN: AUTOMOTIVE ENGINE REPAIR & REBUILDING, CLASSROOM MANUAL AND SHOP MANUAL, Sixth Edition, delivers the theory and skills you need to repair and service modern automotive engines as a professional technician, along with proven preparation for the Automotive Service Excellence (ASE) certification exam. Using a logical, system-specific approach, the text covers engine construction and operation, intake and exhaust systems, and engine repair, as well as the basics of engine rebuilding. Drawing on decades of shop and classroom experience, the authors provide valuable, forward-looking industry insights on topics such as advances in hybrid technology, factors affecting engine performance, and the design and function of modern engine components. Long known for its technical accuracy and concise writing style, the Sixth Edition of this reader-friendly text includes extensive updates to reflect the latest ASE Education Foundation standards, new information on current industry trends and developments, additional drawings and photos, and a variety of electronic learning tools.
Author(s): Chris Hadfield, Randy Nussler
Edition: 6
Publisher: Cengage Learning
Year: 2017
Language: English
Pages: 1040
Classroom Manual
Cover
Contents
Preface
Chapter 1: Automotive Engines
Terms to Know
Introduction
Basic Engine Operation
Cooling System
Lubrication System
Engine Breathing
Engine Performance
Cylinder Head
Timing Mechanism
Engine Block
Summary
Review Questions
Chapter 2: Engine Repair and Rebuilding Industry
Terms to Know
Introduction
Full-Service Repair Facilities
Machine Shop and Engine Rebuild Facilities
Engine Repair and Replacement Specialty Facilities
Engine and Component Remanufacturing Facilities
Summary
Review Questions
Chapter 3: Theory of Engine Operation
Terms to Know
Introduction
Major Engine Components
Engine Operating Principles
Behavior of Liquids and Gases
Pressure and Vacuum
Boyle's Law
Engine Operation
Engine Classifications
Engine Vibration
Engine Displacement
Direction of Crankshaft Rotation
Engine Measurements
Other Engine Designs
Engine Identification
Summary
Review Questions
Chapter 4: Engine Operating Systems
Terms to Know
Introduction
The Starting System
Lubrication Systems
Cooling Systems
Cooling Fans
Lubrication and Cooling Warning Systems and Indicators
Fuel System
Automotive Fuels
Summary
Review Questions
Chapter 5: Factors Affecting Engine Performance
Terms to Know
Introduction
Spark Plugs
Combustion Chamber Sealing
Fuel and Combustion
Engine Noises
Summary
Review Questions
Chapter 6: Engine Materials, Fasteners, Gaskets, and Seals
Terms to Know
Introduction
Engine Materials
Manufacturing Processes
Fasteners
Gaskets, Seals, Sealants, and Adhesives
Summary
Review Questions
Chapter 7: Intake and Exhaust Systems
Terms to Know
Introduction
Air Induction System
Air Intake Ductwork
Air Cleaner/Filter
Intake Manifold
Intake Manifold Tuning
Vacuum Basics
Vacuum Controls
Turbochargers
Superchargers
Exhaust System Components
Mufflers
Summary
Review Questions
Chapter 8: Engine Configurations, Mounts, and Remanufactured Engines
Terms to Know
Introduction
Engine Configurations
Engine Mounts
Remanufactured Engines
Summary
Review Questions
Chapter 9: Cylinder Heads
Terms to Know
Introduction
Cylinder Heads
Cylinder Head Component Relationships
Combustion Chamber Designs
The Combustion Process
Multivalve Engines
Summary
Review Questions
Chapter 10: Camshafts and Valvetrains
Terms to Know
Introduction
Summary
Review Questions
Chapter 11: Timing Mechanisms
Terms to Know
Introduction
Valve Timing Systems
Chain-Driven Systems
Belt-Driven Systems
Gear-Driven Systems
Variable Valve Timing Systems
Variable Valve Lift (Cam-Shifting)
Variable Valve Timing and Lift Systems
Summary
Review Questions
Chapter 12: Engine Block Construction
Terms to Know
Introduction
Block Construction
Crankshaft
Camshaft
Lifter Bores
Harmonic Balancing
Flywheel
Short Blocks, Long Blocks, and Crate Engines
Summary
Review Questions
Chapter 13: Pistons, Rings, Connecting Rods, and Bearings
Terms to Know
Introduction
Bearings
Camshaft and Balance Shaft Bearings
Balance Shafts
Pistons
Piston Designs and Construction
Piston Rings
Connecting Rods
Summary
Review Questions
Chapter 14: Alternative Fuel and Advanced Technology Vehicles
Terms to Know
Introduction
Alternative Fuel Vehicle Use
Propane Vehicles
E85 and Flexible Fuel Vehicles
Compressed Natural Gas Vehicles
The Honda Civic GX CNG Vehicle
Electric Vehicles
Hybrid Electric Vehicles
HEV Operation
Plug-In Hybrid Electric Vehicles
Fuel Cell Vehicles
Summary
Review Questions
Glossary
Index
Shop Manual
Cover
Contents
Preface
Chapter 1: Safety and Shop Practices
Terms to Know
Introduction
Personal Safety
Lifting and Carrying
Hand Tool Safety
Power Tool Safety
Compressed Air Equipment Safety
Lift Safety
Jack and Jack Stand Safety
Engine Lift Safety
Cleaning Equipment Safety
Hazardous Waste
Vehicle Operation
Work Area Safety
Hybrid Vehicle High-Voltage Safety
ASE-Style Review Questions
ASE Challenge Questions
Chapter 2: Engine Rebuilding Tools and Skills
Terms to Know
Introduction
Units of Measure
Engine Diagnostic Tools
Exhaust Gas Analyzers
Engine Analyzer
Engine Measuring Tools
Special Hand Tools
Engine and Chassis Dynamometers
Special Reconditioning Tools and Equipment
Working as a Professional Technician
Service Information
ASE-Style Review Questions
Chapter 3: Basic Testing, Initial Inspection, and Service Procedures
Terms to Know
Introduction
Proper Vehicle Care
Writing a Service Repair Order
Test-Driving for Engine Concerns
Identifying the Area of Concern
ASE-Style Review Questions
ASE Challenge Questions
Chapter 4: Diagnosing and Servicing Engine Operating Systems
Terms to Know
Introduction
Battery Safety
Battery Testing
Battery Testing Series
Starting System Tests and Service
Lubrication System Testing and Service
Cooling System Testing and Service
Gallery and Casting Plugs
Leak Diagnosis
Warning Systems Diagnosis
ASE-Style Review Questions
ASE Challenge Questions
Chapter 5: Diagnosing Engine Performance Concerns
Terms to Know
Introduction
Spark Plug Evaluation and Power Balance Testing
Spark Plugs
Power Balance Testing
Exhaust Gas Analyzers
Engine Smoking
Improper Combustion
Compression Testing
Wet Compression Test
Running Compression Test
Cylinder Leakage Testing
Engine Noise Diagnosis
ASE-Style Review Questions
ASE Challenge Questions
Chapter 6: Repair and Replacement of Engine Fasteners, Gaskets, and Seals
Terms to Know
Introduction
Thread Repair
Gasket Installation
Cylinder Head Gasket Installation
Oil Pan Gasket Installation
Valve Cover Gasket Replacement
Seal Installation
Using Adhesives, Sealants, and Liquid Gasket Makers
ASE-Style Review Questions
ASE Challenge Questions
Chapter 7: Intake and Exhaust System Diagnosis and Service
Terms to Know
Introduction
Air Cleaner Service
Vacuum System Diagnosis and Troubleshooting
Vacuum Tests
Intake Manifold Service
Exhaust System Service
Turbocharger Diagnosis
Supercharger Diagnosis and Service
ASE-Style Review Questions
ASE Challenge Questions
Chapter 8: Engine Removal, Engine Swap, and Engine Installation
Terms to Know
Introduction
Preparing the Engine for Removal
Removing the Engine
Typical Procedure for RWD Engine Removal
Installing a Remanufactured Engine
Installing the Engine
Engine Start-Up and Break-In
ASE-Style Review Questions
ASE Challenge Questions
Chapter 9: Cylinder Head Disassembly, Inspection, and Service
Terms to Know
Introduction
Disassembling the Cylinder Head
Valve Inspection
Cylinder Head Inspection
Machine Shop Services
Straightening Aluminum Cylinder Heads
Resurfacing Cylinder Heads
Valve Guide Repair
Replacing Valve Seats
Refinishing Valves and Valve Seats
ASE-Style Review Questions
ASE Challenge Questions
Chapter 10: Valvetrain Service
Terms to Know
Introduction
Inspecting and Servicing the Valvetrain
Inspecting and Servicing Valvetrain Components, OHV Engine
Replacing Rocker ARM Studs
Cylinder Head Reassembly
Valve Adjustment
Adjusting Mechanical Followers with Shims
Adjusting Valve Clearance Using Adjustable Rocker Arms
On-Car Service
Valve Spring Replacement
ASE-Style Review Questions
ASE Challenge Questions
Chapter 11: Timing Mechanism Service
Terms to Know
Introduction
Symptoms of a Worn Timing Mechanism
Symptoms of a Jumped or Broken Timing Mechanism
Timing Chain Inspection
Timing Belt Inspection
Timing Gear Inspection
Sprocket Inspection
Tensioner Inspection
Timing Chain Guide Inspection
Reuse versus Replacement Decisions
Timing Mechanism Replacement
Timing Chain Replacement on OHC Engines
Timing Belt Replacement
Timing Chain or Gear Replacement on Camshaft-in-the-Block Engines
Timing Chain Replacement on Engines with OHC and Balance Shafts
Timing Chain Replacement on Engines with VVT Systems
ASE-Style Review Questions
ASE Challenge Questions
Chapter 12: Inspecting, Disassembling, and Servicing the Cylinder Block Assembly
Terms to Know
Introduction
Engine Preparation
Cylinder Head Removal
Timing Mechanism Disassembly
Engine Block Disassembly
Inspecting the Cylinder Block
Inspecting the Crankshaft
Inspecting the Harmonic Balancer and Flywheel
Servicing the Cylinder Block Assembly
Camshaft and Balance Shaft Bearing Service
Reconditioning Crankshafts
Installing Oil Gallery Plugs and Core Plugs
ASE-Style Review Questions
ASE Challenge Questions
Chapter 13: Short Block Component Service and Engine Assembly
Terms to Know
Introduction
Inspecting Crankshaft Bearings
Inspecting the Pistons and Connecting Rods
Piston Assembly Service
Engine Block Preparation
Installing the Main Bearings and Crankshaft
Installing the Pistons and the Connecting Rods
Completing the Block Assembly
Valve Timing and Installing Valvetrain Components
Checking and Adjusting Valve Clearance
Completing the Engine Assembly
ASE-Style Review Questions
ASE Challenge Questions
Chapter 14: Alternative Fuel and Advanced Technology Vehicle Service
Terms to Know
Introduction
Servicing Propane-Fueled Engines
Servicing CNG Vehicles
Servicing Hybrid Electric Vehicles
Servicing the Toyota Prius
Cooling System Service
Servicing the Honda Civic Hybrid
HEV Warranties
ASE-Style Review Questions
ASE Challenge Questions
Appendix A: ASE Practice Exam
Appendix B: Special Tools Suppliers
Appendix C: Manufacturers' Service Information Centers
Appendix D: Metric Conversion Charts
Appendix E: Engine Specifications Chart
Glossary
Index
