AUTOMOTIVE CHASSIS SYSTEMS
EIGHTH EDITION
James D. Halderman
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Library of Congress Cataloging-in-Publication Data Names: Halderman, James D., author. Title: Automotive chassis systems / James D. Halderman. Description: Eighth edition. | Hoboken, New Jersey : Pearson, 2020. | Includes index. Identifiers: LCCN 2019033326 | ISBN 9780135758571 (paperback) | ISBN 9780135758526 (epub) Subjects: LCSH: Automobiles—Chassis. Classification: LCC TL255 .H33 2020 | DDC 629.2/4—dc23 LC record available at https://lccn.loc.gov/2019033326
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ISBN-10: 0-13-575857-2 ISBN-13: 978-0-13-575857-1
A01_HALD8571_08_SE_FM.indd 2 15/10/19 6:53 PM BRIEF CONTENTS
chapter 1 Service Information, Work Orders, and Vehicle Identification 1
chapter 2 Tools and Safety 9
chapter 3 Environmental and Hazardous Materials 42
chapter 4 Braking System Components and Performance Standards 53
chapter 5 Braking Principles and Friction Materials 61
chapter 6 Brake Hydraulic Systems 72
chapter 7 Hydraulic Valves and Switches 90
chapter 8 Brake Fluid and Lines 104
chapter 9 Brake Bleeding Methods and Procedures 118
chapter 10 Wheel Bearings and Service 130
chapter 11 Drum Brakes 149
chapter 12 Drum Brake Diagnosis and Service 165
chapter 13 Disc Brakes 182
chapter 14 Disc Brake Diagnosis and Service 196
chapter 15 Parking Brake Operation, Diagnosis, and Service 214
chapter 16 Machining Brake Drums and Rotors 230
chapter 17 Power Brake Unit Operation, Diagnosis, and Service 272
chapter 18 ABS Components and Operation 287
chapter 19 ABS Diagnosis and Service 303
chapter 20 Electronic Stability Control Systems 315
chapter 21 Regenerative Braking Systems 324
chapter 22 Tires and Wheels 335
chapter 23 Tire-Pressure Monitoring Systems 360
chapter 24 Tire and Wheel Service 374
chapter 25 Suspension System Components and Operation 399
chapter 26 Front Suspension and Service 424
chapter 27 Rear Suspension and Service 454
BRIEF CONTENTS iii
A01_HALD8571_08_SE_FM.indd 3 15/10/19 6:53 PM chapter 28 Electronic Suspension Systems 466
chapter 29 Steering Columns and Gears 483
chapter 30 Steering Linkage and Service 500
chapter 31 Hydraulic Power Steering Systems 518
chapter 32 Electric Power Steering Systems 543
chapter 33 Driveshafts and CV Joints 551
chapter 34 Driveshaft and CV Joint Service 562
chapter 35 Wheel Alignment Principles 576
chapter 36 Alignment Diagnosis and Service 592
chapter 37 Vibration and Noise Diagnosis and Correction 624
APPENDIX 1 SAMPLE BRAKES (A5) ASE-TYPE CERTIFICATION TEST WITH ANSWERS 638
APPENDIX 2 SAMPLE SUSPENSION AND STEERING (A4) ASE-TYPE CERTIFICATION TEST 642
APPENDIX 3 2017 ASE A4 CORRELATION CHART 646
APPENDIX 4 2017 ASE A5 CORRELATION CHART 650
GLOSSARY 654
INDEX 666
iv BRIEF CONTENTS
A01_HALD8571_08_SE_FM.indd 4 15/10/19 6:53 PM CONTENTS
chapter 1 ■■ Electrical Cord Safety 32 ■■ Jump Starting and Battery Safety 32 SERVICE INFORMATION, WORK ■■ Fire Extinguishers 33 ■■ Fire Blankets 34 ORDERS, AND VEHICLE ■■ First Aid and Eye Wash Stations 34 ■■ Hybrid Electric Vehicle Safety IDENTIFICATION 1 Issues 35 ■■ Learning Objectives 1 Summary 40 ■■ Key Terms 1 Review Questions 40 ■■ Owner’s Manuals 1 Chapter Quiz 40 ■■ Service Information 2 ■■ Technical Service Bulletins 2 ■■ Recalls and Campaigns 2 chapter 3 ■■ Work Order 3 ■■ Service Records 3 ENVIRONMENTAL AND ■■ Additional Information 5 ■■ Parts of a Vehicle 5 HAZARDOUS MATERIALS 42 ■■ Front-Wheel Drive Versus Rear-Wheel ■■ Learning Objectives 42 Drive 5 ■■ Key Terms 42 ■■ Vehicle Identification 5 ■■ Hazardous Waste 42 ■■ Vehicle Safety Certification Label 7 ■■ Federal and State Laws 42 ■■ VECI Label 7 ■■ Asbestos Hazards 44 ■■ Used Brake Fluid 45 Summary 7 ■■ Used Oil 45 Review Questions 8 ■■ Solvents 46 Chapter Quiz 8 ■■ Coolant Disposal 47 ■■ Lead-Acid Battery Waste 48 chapter 2 ■■ Fuel Safety and Storage 48 ■■ Airbag Handling 49 TOOLS AND SAFETY 9 ■■ Used Tire Disposal 49 ■■ Air-Conditioning Refrigerant Oil ■■ Learning Objectives 9 Disposal 50 ■■ Key Terms 9 Summary 52 ■■ Threaded Fasteners 9 Review Questions 52 ■■ Hand Tools 13 Chapter Quiz 52 ■■ Screwdrivers 16 ■■ Torx 18 ■■ Pliers 19 chapter 4 ■■ Basic Hand Tool List 22 ■■ Tool Sets and Accessories 23 BRAKING SYSTEM COMPONENTS ■■ Electrical Hand Tools 23 ■■ Hand Tool Maintenance 25 AND PERFORMANCE ■■ Trouble Lights 25 STANDARDS 53 ■■ Air and Electrically Operated Tools 25 ■■ Personal Protective Equipment 27 ■■ Learning Objectives 53 ■■ Safety Precautions 28 ■■ Key Terms 53 ■■ Vehicle Protection 29 ■■ Fundamentals of Brake Systems 53 ■■ Safety Lifting (Hoisting) a Vehicle 29 ■■ Brake Design Requirements 55 ■■ Jacks and Safety Stands 31 ■■ Brake System Categories 55 ■■ Drive-On Ramps 31 ■■ Antilock Brake System Overview 55
v
A01_HALD8571_08_SE_FM.indd 5 15/10/19 6:53 PM ■■ Federal Brake Standards 57 ■■ Brake Fluid Level Sensor 91 ■■ Brake Repair and The Law 59 ■■ Proportioning Valve 92 ■■ Electronic Brake Proportioning 97 Summary 59 ■■ Metering Valve (Hold-Off) Operation 98 Review Questions 60 ■■ Combination Valves 100 Chapter Quiz 60 ■■ Brake Pedal Position Sensor/Switch 101 chapter 5 Summary 102 Review Questions 102 BRAKING PRINCIPLES AND Chapter Quiz 102 FRICTION MATERIALS 61 chapter 8 ■■ Learning Objectives 61 ■■ Key Terms 61 BRAKE FLUID AND LINES 104 ■■ Energy and Work 61 ■■ Learning Objectives 104 ■■ Inertia 62 ■■ Key Terms 104 ■■ Coefficient of Friction 63 ■■ Brake Fluid 104 ■■ Brake Fade 64 ■■ Brake Fluid Specifications 104 ■■ Deceleration Rates 65 ■■ Brake Fluid Service Procedures 108 ■■ Brake Friction Materials 65 ■■ Rubber Types 109 ■■ Asbestos 66 ■■ Brake Lines 110 ■■ Semimetallic Friction Materials 66 ■■ Non-Asbestos/Ceramic Friction Materials 67 Summary 116 ■■ Carbon Fiber Friction Materials 67 Review Questions 117 ■■ Brake Pads and Environmental Concerns 68 Chapter Quiz 117 ■■ Edge Codes 69 Summary 70 chapter 9 Review Questions 70 Chapter Quiz 71 BRAKE BLEEDING METHODS chapter 6 AND PROCEDURES 118 ■■ Learning Objectives 118 BRAKE HYDRAULIC ■■ Key Terms 118 ■■ Brake Bleeding 118 SYSTEMS 72 ■■ Brake Bleeder Valve Loosening Methods 119 ■■ Learning Objectives 72 ■■ Bleeding Sequence 120 ■■ Key Terms 72 ■■ Manual Bleeding 121 ■■ Hydraulic Principles 72 ■■ Vacuum Bleeding 121 ■■ Pascal’s Law 73 ■■ Gravity Bleeding 122 ■■ Master Cylinders 76 ■■ Pressure Bleeding 124 ■■ Diagnosing Master Cylinders 84 ■■ Hydraulic ABS Service 126 ■■ Master Cylinder Service 86 ■■ Brake Fluid Replacement/Flushing 127
Summary 88 Summary 128 Review Questions 88 Review Questions 129 Chapter Quiz 88 Chapter Quiz 129
chapter 7 chapter 10 HYDRAULIC VALVES AND WHEEL BEARINGS AND SWITCHES 90 SERVICE 130 ■■ Learning Objectives 90 ■■ Learning Objectives 130 ■■ Key Terms 90 ■■ Key Terms 130 ■■ Pressure-Differential Switch (Brake Warning Switch) 90 ■■ Antifriction Bearings 130
vi CONTENTS
A01_HALD8571_08_SE_FM.indd 6 15/10/19 6:53 PM ■■ Bearing Greases 133 chapter 13 ■■ Seals 134 ■■ Bearing Diagnosis 134 DISC BRAKES 182 ■■ Wheel Bearing Service 135 ■■ ■■ Sealed Bearing Replacement 139 Learning Objectives 182 ■■ Rear Drive Axle Classifications 139 ■■ Key Terms 182 ■■ Rear Axle Bearing and Seal Replacement 140 ■■ Disc Brakes 182 ■■ Bearing Failure Analysis 142 ■■ Disc Brake Construction 186 ■■ Disc Brake Pads 186 Summary 147 ■■ Brake Rotors 189 Review Questions 147 ■■ Disc Brake Designs 189 Chapter Quiz 147 ■■ Rear Disc Brakes 193
Summary 194 chapter 11 Review Questions 195 DRUM BRAKES 149 Chapter Quiz 195 ■■ Learning Objectives 149 chapter 14 ■■ Key Terms 149 ■■ Drum Brakes 149 DISC BRAKE DIAGNOSIS AND ■■ Drum Brake Advantages 149 ■■ Drum Brake Disadvantages 149 SERVICE 196 ■■ Backing Plate and Wheel Cylinders 151 ■■ Learning Objectives 196 ■■ Drum Brake Shoes 153 ■■ Key Terms 196 ■■ Non-Servo Brake Design 156 ■■ Disc Brake Diagnostic Procedures 196 ■■ Dual-Servo Brake Design 158 ■■ Visual Inspection 196 ■■ Automatic Brake Adjusters 159 ■■ Disc Brake Caliper Service 198 Summary 163 ■■ Servicing Disc Brake Calipers 200 Review Questions 163 ■■ Disc Brake Squeal Correction 206 Chapter Quiz 164 ■■ Disc Brake Symptom Guide 207
Summary 212 chapter 12 Review Questions 212 Chapter Quiz 212 DRUM BRAKE DIAGNOSIS AND SERVICE 165 chapter 15 ■■ Learning Objectives 165 PARKING BRAKE ■■ Key Terms 165 ■■ Drum Brake Diagnosis 165 OPERATION, DIAGNOSIS, ■■ Brake Drum Removal 166 AND SERVICE 214 ■■ Drum Brake Disassembly 167 ■■ Inspecting the Backing Plate 168 ■■ Learning Objectives 214 ■■ Drum Brake Lining Inspection 169 ■■ Key Terms 214 ■■ Brake Spring Inspection 169 ■■ Parking Brake Standards 214 ■■ Wheel Cylinder Inspection 170 ■■ Pedals, Levers, and Handles 215 ■■ Drum Brake Hardware Kit 172 ■■ Parking Brake Warning Lamp 217 ■■ Inspecting the Drum Brake Shoes 172 ■■ Parking Brake Linkages 217 ■■ Brake Parts Cleaning 172 ■■ Front and Rear Entry Parking Brake Cables 219 ■■ Lubrication Checklist 173 ■■ Drum Parking Brakes 219 ■■ Reassembling the Drum Brake 173 ■■ Caliper-Actuated Disc Parking Brakes 220 ■■ Adjusting Drum Brakes 174 ■■ Parking Brake Cable Adjustment 225 ■■ Drum Brake Fault Symptom Guide 175 ■■ Electric Parking Brake 226
Summary 180 Summary 228 Review Questions 180 Review Questions 229 Chapter Quiz 180 Chapter Quiz 229
CONTENTS vii
A01_HALD8571_08_SE_FM.indd 7 15/10/19 6:53 PM chapter 16 chapter 18 MACHINING BRAKE DRUMS ABS COMPONENTS AND AND ROTORS 230 OPERATION 287 ■■ Learning Objectives 230 ■■ Learning Objectives 287 ■■ Key Terms 230 ■■ Key Terms 287 ■■ Brake Drums 230 ■■ Antilock Brake System 287 ■■ Brake Drum and Rotor Damage 231 ■■ ABS Parts Involved 289 ■■ Brake Drum Distortion 232 ■■ ABS Channels 290 ■■ Removing Drums 234 ■■ NonIntegral ABS 291 ■■ “Machine To” Versus “Discard” 234 ■■ ABS Controller Inputs and Outputs 292 ■■ Machining Brake Drums 235 ■■ Wheel Speed Sensors 292 ■■ Disc Brake Rotors 236 ■■ Hydraulic Modulator Assembly 294 ■■ Disc Brake Rotor Distortion 238 ■■ Advanced ABS Functions 297 ■■ Carbon-Ceramic Rotors 241 ■■ Automatic Emergency Braking 298 ■■ Disc Brake Rotor Thickness 241 Summary 301 ■■ When the Rotors Should Be Machined 241 Review Questions 301 ■■ Rotor Finish 242 Chapter Quiz 301 ■■ Qualifying a Brake Lathe 243 ■■ Machining a Disc Brake Rotor 244 ■■ On-the-Vehicle Rotor Machining 249 chapter 19
Summary 270 Review Questions 270 ABS DIAGNOSIS AND Chapter Quiz 270 SERVICE 303 ■■ Learning Objectives 303 chapter 17 ■■ Key Terms 303 ■■ ABS Fault Diagnosis 303 POWER BRAKE UNIT ■■ Retrieving ABS Codes on Older Vehicles 305 ■■ ABS Diagnosis 306 OPERATION, DIAGNOSIS, ■■ Wheel Speed Sensor Diagnosis 309 AND SERVICE 272 ■■ Hydraulic ABS Service 311 ■■ ABS Safety Precautions 313 ■■ Learning Objectives 272 ■■ Key Terms 272 Summary 313 ■■ The Need for Power Brake Assist 272 Review Questions 313 ■■ Principles of Vacuum 273 Chapter Quiz 313 ■■ Vacuum Booster Theory 274 ■■ Vacuum Check Valve 275 chapter 20 ■■ Vacuum Brake Booster Operation 276 ■■ Dual- (Tandem-) Diaphragm Vacuum Boosters 277 ELECTRONIC STABILITY ■■ Brake Assist System 278 ■■ Vacuum Booster Operation Test 278 CONTROL SYSTEMS 315 ■■ Vacuum Booster Leak Test 279 ■■ Learning Objectives 315 ■■ Hydraulic System Leak Test 279 ■■ Key Terms 315 ■■ Pushrod Clearance Adjustment 279 ■■ The Need for Electronic Stability Control 315 ■■ Vacuum Booster Disassembly and Service 280 ■■ Federal Motor Vehicle Safety Standard (FMVSS) ■■ Hydro-Boost Hydraulic Brake Booster 281 No. 126 316 ■■ Hydro-Boost Symptom-Based Guide 285 ■■ Sine with Dwell Test 316 Summary 285 ■■ ESC Sensors 318 Review Questions 286 ■■ Traction Control 319 Chapter Quiz 286 ■■ ESC/TC Diagnosis 322
viii CONTENTS
A01_HALD8571_08_SE_FM.indd 8 15/10/19 6:53 PM Summary 322 ■■ Tire Valves 354 Review Questions 323 ■■ Unsprung Weight 355 Chapter Quiz 323 ■■ Lug Nuts 355
Summary 359 chapter 21 Review Questions 359 Chapter Quiz 359 REGENERATIVE BRAKING SYSTEMS 324 chapter 23 ■■ Learning Objectives 324 TIRE-PRESSURE MONITORING ■■ Key Terms 324 ■■ Introduction 324 SYSTEMS 360 ■■ Principles of Regenerative Braking 324 ■■ Learning Objectives 360 ■■ Types of Regenerative Braking Systems 326 ■■ Key Terms 360 ■■ Battery Charging During Regeneration 327 ■■ Need for Tire Pressure ■■ Regenerative Braking Systems 328 Monitoring 360 ■■ How the Regeneration System Works 328 ■■ TREAD Act 362 ■■ Deceleration Rates 331 ■■ Indirect TPMS 362 ■■ Engine Design Changes Related to ■■ Direct TPMS 363 Regenerative Braking 331 ■■ TPMS Pressure Sensors 364 ■■ Servicing Regenerative Braking ■■ TPMS Sensor Operation 365 Systems 331 ■■ TPMS Receiver 366 ■■ TPMS Diagnosis 367 Summary 333 ■■ TPMS Sensor Activations 368 Review Questions 333 ■■ TPMS Diagnostic Tools 368 Chapter Quiz 333 ■■ Sensor Replacement Options 369 ■■ TPMS Sensor Relearn 370 chapter 22 ■■ TPMS Sensor Service Tools 371
Summary 372 TIRES AND WHEELS 335 Review Questions 373 ■■ Learning Objectives 335 Chapter Quiz 373 ■■ Key Terms 335 ■■ Introduction to Tires 335 chapter 24 ■■ Parts of a Tire 335 ■■ Tire Molding 338 TIRE AND WHEEL ■■ Service Description 340 ■■ High-Flotation Tire Sizes 340 SERVICE 374 ■■ Load Index and Equivalent Loads 341 ■■ Learning Objectives 374 ■■ Speed Ratings 341 ■■ Key Terms 374 ■■ Tire Pressure and Traction 342 ■■ Tire Service and Proper Inflation 374 ■■ Rim Width and Tire Size 342 ■■ Nitrogen Inflation 375 ■■ Uniform Tire Quality Grading ■■ Tire Inspection 376 System 343 ■■ Wheel Removal/Installation 377 ■■ All-Season Tire Designation 345 ■■ Tire Rotation 379 ■■ Types of Tires 345 ■■ Radial Runout 380 ■■ DOT Tire Code 345 ■■ Lateral Runout 381 ■■ Tire Conicity and Ply Steer 346 ■■ Tire Replacement 382 ■■ Vehicle Handling and Tire ■■ Tire Balancing 385 Slip Angle 347 ■■ Wheel Weights 385 ■■ Spare Tires 347 ■■ Wheel/Tire Balancers 388 ■■ Run-Flat Tires 348 ■■ Tire Repair 389 ■■ General Motors TPC Rating 349 ■■ Tire Selection Considerations 350 Summary 397 ■■ Noise-Reducing Tires 351 Review Questions 397 ■■ Wheels 351 Chapter Quiz 397
CONTENTS ix
A01_HALD8571_08_SE_FM.indd 9 15/10/19 6:53 PM chapter 25 Summary 452 Review Questions 452 SUSPENSION SYSTEM COMPONENTS Chapter Quiz 452 AND OPERATION 399 chapter 27 ■■ Learning Objectives 399 ■■ Key Terms 399 REAR SUSPENSION AND ■■ Introduction 399 ■■ Frame Construction 399 SERVICE 454 ■■ Platforms 401 ■■ Learning Objectives 454 ■■ Unsprung Weight 401 ■■ Key Terms 454 ■■ Types of Suspensions 401 ■■ Solid Rear Axles 454 ■■ Hooke’s Law 402 ■■ Leaf Spring Rear Suspensions 455 ■■ Coil Springs 402 ■■ Trailing Arm Rear Suspensions 456 ■■ Leaf Springs 406 ■■ Semi-Trailing Arm Rear Suspensions 457 ■■ Torsion Bars 409 ■■ Independent Rear Suspensions 457 ■■ Suspension Principles 409 ■■ Semi-Independent Rear Suspensions 458 ■■ Steering Knuckles 411 ■■ Rear Suspension Service 458 ■■ Control Arms 412 ■■ Rear Shock Replacement 459 ■■ Ball Joints 412 ■■ Rear Spring Replacement 461 ■■ Strut Rods 413 ■■ Stabilizer Bars 415 Summary 464 ■■ Shock Absorbers 415 Review Questions 464 ■■ Struts 418 Chapter Quiz 464 ■■ Bump Stops 418
Summary 423 chapter 28 Review Questions 423 Chapter Quiz 423 ELECTRONIC SUSPENSION SYSTEMS 466 chapter 26 ■■ Learning Objectives 466 ■■ Key Terms 466 FRONT SUSPENSION AND ■■ The Need for Electronic Suspensions 466 ■■ Electronic Suspension Controls and Sensors 466 SERVICE 424 ■■ Electronic Suspension System Actuators 472 ■■ Learning Objectives 424 ■■ Types of Electronic Suspension 474 ■■ ■■ Key Terms 424 Automatic Level Control (ALC) 478 ■■ ■■ Front Suspension Types 424 Troubleshooting Rear Electronic Leveling ■■ Short-/Long-Arm Suspensions 425 Systems 480 ■■ ■■ Strut Suspension 427 Magneto-Rheological (MR) Suspension 480 ■■ Servicing the Suspension System 428 Summary 482 ■■ Road Test Diagnosis 428 Review Questions 482 ■■ Dry Park Test (Suspension) 430 Chapter Quiz 482 ■■ Visual Inspection 431 ■■ Ball Joints 432 ■■ Kingpin Diagnosis and Service 438 chapter 29 ■■ Shock Absorbers and Struts 438 ■■ MacPherson Strut Replacement 440 STEERING COLUMNS ■■ Stabilizer Bar Links AND GEARS 483 and Bushings 442 ■■ Strut Rod Bushings 442 ■■ Learning Objectives 483 ■■ Front Coil Springs 443 ■■ Key Terms 483 ■■ Steering Knuckles 445 ■■ Steering Wheels 483 ■■ Torsion Bars 446 ■■ Steering Wheel Removal 484 ■■ Control Arm Bushings 446 ■■ Steering Columns 485
x CONTENTS
A01_HALD8571_08_SE_FM.indd 10 15/10/19 6:53 PM ■■ Conventional Steering Gears 489 ■■ Electric Power Steering Overview 543 ■■ Recirculating Ball Steering Gear 492 ■■ EPS System Parts and Operation 544 ■■ Steering Gear Adjustments 493 ■■ Steering Shaft Torque Sensor 547 ■■ Rack-and-Pinion Steering Gear 495 ■■ Steering Wheel Position Sensor 547 ■■ Rack-and-Pinion Adjustments 498 ■■ Power Steering Motor 547 ■■ Power Steering Control Module (PSCM) 547 Summary 499 ■■ EPS Diagnosis 548 Review Questions 499 ■■ Self-Parking System 548 Chapter Quiz 499 ■■ Electrohydraulic Power Steering 549 chapter 30 Summary 550 Review Questions 550 STEERING LINKAGE AND Chapter Quiz 550 SERVICE 500 chapter 33 ■■ Learning Objectives 500 ■■ Key Terms 500 DRIVESHAFTS AND CV JOINTS 551 ■■ Steering Linkage 500 ■■ Learning Objectives 551 ■■ Rack-and-Pinion Inner Tie Rod Ends 501 ■■ Key Terms 551 ■■ Front Steer Versus Rear Steer 503 ■■ Driveshafts 551 ■■ Four-Wheel Steering Systems 504 ■■ Driveshaft Balance 551 ■■ Steering Linkage Lubrication 505 ■■ U-Joint Design and Operation 552 ■■ Dry Park Test 506 ■■ Double-Cardan Joints 555 ■■ Common Wear Items 508 ■■ Constant Velocity Joints 555 ■■ Under-Vehicle Inspection 508 ■■ Steering Linkage Replacement 510 Summary 560 Review Questions 560 Summary 517 Chapter Quiz 560 Review Questions 517 Chapter Quiz 517 chapter 34 chapter 31 DRIVESHAFT AND CV JOINT HYDRAULIC POWER STEERING SERVICE 562 SYSTEMS 518 ■■ Learning Objectives 562 ■■ Learning Objectives 518 ■■ Key Terms 562 ■■ Key Terms 518 ■■ U-Joint Diagnosis 562 ■■ Hydraulic Power Steering Systems 518 ■■ Driveshaft and U-Joint Inspection 563 ■■ Power Steering Pump and Reservoir 519 ■■ U-Joint Replacement 564 ■■ Integral Power Steering 522 ■■ U-Joint Working Angles 566 ■■ Variable-Effort Steering 526 ■■ CV Joint Diagnosis 567 ■■ Power Steering Diagnosis 531 ■■ Replacement Shaft Assemblies 567 ■■ ■■ Power Steering Fluid 532 CV Joint Service 568
Summary 541 Summary 575 Review Questions 541 Review Questions 575 Chapter Quiz 541 Chapter Quiz 575
chapter 32 chapter 35 ELECTRIC POWER STEERING WHEEL ALIGNMENT SYSTEMS 543 PRINCIPLES 576 ■■ Learning Objectives 543 ■■ Learning Objectives 576 ■■ Key Terms 543 ■■ Key Terms 576
CONTENTS xi
A01_HALD8571_08_SE_FM.indd 11 15/10/19 6:53 PM ■■ Definition of a Wheel Alignment 576 Summary 622 ■■ Alignment-Related Problems 576 Review Questions 622 ■■ Camber 577 Chapter Quiz 622 ■■ Caster 579 ■■ Toe 582 ■■ Steering Axis Inclination 585 chapter 37 ■■ Included Angle 586 ■■ Scrub Radius 586 VIBRATION AND NOISE DIAGNOSIS ■■ Turning Radius (Toe-Out on Turns) 588 AND CORRECTION 624 ■■ Setback 589 ■■ Thrust Angle 589 ■■ Learning Objectives 624 ■■ Tracking 590 ■■ Key Terms 624 ■■ Four-Wheel Alignment 590 ■■ Causes of Vibration and Noise 624 ■■ Test-Drive 625 Summary 591 ■■ Neutral Run-Up Test 627 Review Questions 591 ■■ Vibration During Braking 627 Chapter Quiz 591 ■■ Vibration Speed Ranges 627 ■■ Vibration Frequency 630 chapter 36 ■■ Correcting Driveline Angles 632 ■■ Checking Driveshaft Runout 632 ALIGNMENT DIAGNOSIS ■■ Measuring Driveshaft U-Joint Phasing 632 ■■ Checking Companion Flange Runout 632 AND SERVICE 592 ■■ Balancing the Driveshaft 633 ■■ Noise Diagnosis 633 ■■ Learning Objectives 592 ■■ Noise Correction 634 ■■ Key Terms 592 ■■ Purpose of an Alignment 592 Summary 637 ■■ Prealignment Correction Techniques 592 Review Questions 637 ■■ Prealignment Checks 592 Chapter Quiz 637 ■■ Lead/Pull 594 ■■ Memory Steer 595 ■■ Torque Steer 595 appendix 1 ■■ Alignment Specifications 597 SAMPLE BRAKES (A5) ASE-TYPE CERTIFICATION TEST ■■ Alignment Setup Procedures 598 WITH ANSWERS 638 ■■ Measuring Camber, Caster, SAI, Toe, and TOOT 599 ■■ Specifications Versus Alignment Readings 600 ■■ Checking for Bent Struts, Spindles, appendix 2 or Control Arms 600 SAMPLE SUSPENSION AND STEERING (A4) ASE-TYPE ■■ Checking Frame Alignment of Front-Wheel-Drive Vehicles 601 CERTIFICATION TEST 642 ■■ Types of Alignments 602 ■■ Adjusting Rear Camber 605 appendix 3 ■■ Guidelines for Adjusting Front Camber/SAI and Included Angle 606 2017 ASE A4 CORRELATION CHART 646 ■■ Front Camber/Caster Adjustment Methods 607 ■■ Adjusting Front Camber/Caster 608 appendix 4 ■■ Setting Toe 608 ■■ Centering the Steering Wheel 610 2017 ASE A5 CORRELATION CHART 650 ■■ Tolerance Adjustment Procedure 611 ■■ Aligning Electronic-Suspension Vehicles 612 GLOSSARY 654 ■■ Aligning Modified Vehicles 613 ■■ Hidden Structural Damage Diagnosis 616 ■■ Reset Steering Angle Sensor (SAS) 616 INDEX 666
xii CONTENTS
A01_HALD8571_08_SE_FM.indd 12 15/10/19 6:53 PM PREFACE
NEW TO THIS EDITION. Based on the suggestions and ASE CORRELATED This comprehensive textbook is recommendations from automotive instructors and reviewers, divided into sections that correspond to the two areas of cer- the following changes have been made to the eighth edition: tifications (A4 and A5) as specified by the National Institute for The number of chapters has been increased from 35 to 37 Automotive Service Excellence (ASE). The areas of the ASE to help meet the latest ASE tasks. The new chapters include: material certification test are listed in the objectives at the beginning of each chapter, and all laboratory worksheets are Chapter 1—Service Information, Work Orders, and Vehicle correlated to the ASE Task Sheets. Identification Chapter 37—Vibration and Nosie Diagnosis and Correction A COMPLETE INSTRUCTOR AND STUDENT SUPPLE Over 40 new full-color photos and line drawings to make MENT PACKAGE Please see page viii for a detailed list of the subject come alive. supplements. Updated throughout and correlated to the latest ASE tasks. New Case Studies included in this edition covering the A FOCUS ON DIAGNOSIS AND PROBLEM SOLVING “three Cs” (Complaint, Cause, and Correction). The primary focus of this textbook is to satisfy the need for New OSHA hazardous chemical labeling requirements problem diagnosis. Time and again, the author has heard that added to Chapter 2. technicians need more training in diagnostic procedures and The chapter on brake principles (Chapter 5) has been ex- skill development. To meet this need and to help illustrate panded to include the details on brake friction materials, how real problems are solved, diagnostic stories are included which are now in one location, instead of being repeated throughout. Each new topic covers the parts involved, as well in the drum and disc brake chapters. as their purpose, function, and operation, and how to test and diagnose each system. Qualifying brake lathe information added to Chapter 16. The following pages highlight the unique core features that Additional content on snap-in and clamp-on TPMS sen- set this book apart from other automotive textbooks. sors, plus updated relearn procedures, in Chapter 23.
xiii
A01_HALD8571_08_SE_FM.indd 13 15/10/19 6:53 PM IN-TEXT FEATURES
SAFETY TIP chapter SERVICE INFORMATION, WORK ORDERS, AND Shop Cloth Disposal 1 VEHICLE IDENTIFICATION Always dispose of oily shop cloths in an enclosed con- LEARNING OBJECTIVES: After studying this chapter, the reader should be able to: ● Discuss the importance of vehicle owner’s manuals, service Explain vehicle identification, vehicle safety certification label, tainer to prevent a fire. SEE FIGURE 1–69. Whenever records, and service information. and the VECI label. Explain the different types of service information. Discuss the different types of emission standards. Describe vehicle recalls and campaigns. Explain calibration codes and casting numbers. oily cloths are thrown together on the floor or workbench, Discuss the importance of the work order. This chapter will help prepare for the Suspension and Steering Explain why service records are important. (A4) and Brakes (A5) ASE certification test. Discuss the parts of a vehicle, and differentiate between a chemical reaction can occur, which can ignite the cloth, front-wheel drive and rear-wheel drive.
KEY TERMS: Campaign 2• Country of origin 6• Flat rate 3•Gross axle weight rating (GAWR) 7•Gross vehicle weight rating even without an open flame. This process of ignition with- (GVWR) 7• Model year (MY) 6• Owner’s manual 1• Recall 2• Repair order (RO) 3•Service information 2• Technical service bulletin (TSB) 2• Vehicle emissions control information (VECI) 7• Vehicle identification number (VIN) 6•Work order 3 out an open flame is called spontaneous combustion.
OWNER’S MANUALS
CONTENT The owner’s manual is the instructional booklet that comes with every new vehicle and includes important in- formation. It has been said by many automotive professional technicians and service advisors that the owner’s manual is not read by many vehicle owners. Most owners’ manuals contain all SAFETY TIPS alert students to possible hazards on the job or most of the following information. 1. Meaning of dash symbols 2. How to reset the maintenance reminder light and how to avoid them. 3. Specifications, including viscosity of oil needed and num- ber of quarts (liters) 4. Tire pressures and standard, as well as optional, tire sizes 5. Maintenance schedule for all fluids, including coolant, brake fluid, automatic transmission fluid, and differential fluid 6. How to program the remote control, as well as the power windows and door locks FIGURE 1–1 The owner’s manual has a lot of information 7. How to reset the tire pressure monitoring system (TPMS) pertaining to the operation, as well as the maintenance and after a tire rotation SEE FIGURE 1–1. resetting procedures, that technicians often need. CASE STUDY
Real World Fixes SERVICE INFORMATION, WORK ORDERS, AND VEHICLE IDENTIFICATION 1 Present students with actual automotive service scenarios and show how these common (and LEARNING OBJECTIVES AND KEY sometimes uncommon) problems were diagnosed TERMS appear at the beginning of each chapter and repaired. Each case study includes the “Three Cs” to help students and instructors focus on the most (Complaint, Cause and Correction) important material in each chapter. The chapter objectives are based on specific ASE tasks.
CASE STUDY present students with actual automotive sce- narios and show how these common (and sometimes uncom- mon) problems were diagnosed and repaired. TECH TIP
Right to Tighten FREQUENTLY ASKED QUESTION Whenever removing any automotive component, it is ? wise to screw the bolts back into the holes a couple of threads by hand. This ensures that the right bolt is What Is an “SST?” used in its original location. Vehicle manufacturers often specify a special service tool (SST) to properly disassemble and assemble components, such as transmissions and other com- TECH TIP feature real-world advice and “tricks of the trade” ponents. These tools are also called special tools and from ASE-certified master technicians. are available from the vehicle manufacturer or their tool supplier, such as Kent-Moore and Miller tools.
FREQUENTLY ASKED QUESTIONS are based on the author’s own experience and provide answers to many of the most common questions asked by students and beginning service technicians.
xiv IN-TEXT FEATURES
A01_HALD8571_08_SE_FM.indd 14 15/10/19 6:53 PM NOTE: Most of these “locking nuts” are grouped to-
gether and are commonly referred to as prevailing REVIEW QUESTIONS
torque nuts. This means that the nut holds its tight- 1. What is included in the vehicle owner’s manual that could 4. What should the service technician include on the work be helpful for a service technician? order? 2. Why is factory service information the most detailed of all 5. What are the major pieces of information that are included ness or torque and does not loosen with movement service information? in the vehicle identification number (VIN)? 3. What customer information needs to be included on a or vibration. repair order (RO)?
NOTES provide students with additional technical informa- CHAPTER QUIZ 1. What type of information is commonly included in the own- 6. What should the service technician document on the work tion to give them a greater understanding of a specific task or er’s manual that would be a benefit to service technicians? order? a. Maintenance reminder light reset procedures a. The results of any inspections and tests b. Tire pressure monitoring system reset procedures b. What was replaced or serviced procedure. c. Maintenance items specifications c. The dimensions of the related component and com- d. All of the above parison to factory specifications 2. Two technicians are discussing the need for the history d. Any of the above of the vehicle. Technician A says that an accident could 7. The labor rate for each operation is included on the work cause faults due to hidden damage. Technician B says order and is added by the ______. that some faults could be related to a previous repair. a. service technician Which technician is correct? b. service advisor a. Technician A only c. shop owner or designated warranty person b. Technician B only d. Any of the above CAUTION: Never use hardware store (nongraded) c. Both Technicians A and B 8. Which of the following are performed at no cost to the d. Neither Technician A nor B vehicle owner? 3. A campaign (recall) is mailed to the owner of a vehicle from a. TSBs c. Either a or b bolts, studs, or nuts on any vehicle steering, suspen- the ______. b. Campaigns (recalls) d. Neither a nor b a. vehicle manufacturer 9. The first character of the vehicle identification number is sion, or brake component. Always use the exact size b. local dealer the country of origin. Where was the vehicle built that has c. federal government a “5” as the first character? d. state or local government a. United States c. Mexico and grade of hardware that is specified and used by 4. Technical service bulletins (TSBs) are issued by the b. Canada d. Japan ______10. The VECI label includes all except ______. the vehicle manufacturer. a. vehicle manufacturer a. engine identification b. local dealer b. horsepower and torque rating of the engine c. federal government c. California emission standard d. state or local government d. Federal (EPA emission standard 5. Four tenths of an hour is how many minutes? a. 14 c. 34 CAUTIONS alert students about potential damage to the ve- b. 24 d. 44 hicle that can occur during a specific task or service procedure.
WARNING
Do not use incandescent trouble lights around 8 CHAPTER 1 gasoline or other flammable liquids. The liquids can cause the bulb to break and the hot filament can ignite the flammable liquid, which can cause THE REVIEW QUESTIONS AND CHAPTER QUIZ at personal injury, or even death. the end of each chapter help students review the material pre- sented in the chapter and test themselves to see how much they’ve learned.
WARNINGS alert students to potential dangers to them- selves during a specific task or service procedure.
TIRE MOUNTING STEP BY STEP
To remove the tire from the wheel, position the The tire tool (flat bar) is placed between the bead A typical tire-changing machine showing the re- The foot-pedal controls allow the service techni- arm of the changer against the rim of the wheel of the tire and the wheel. Using tire lubricant can volving table and movable arm used to remove a cian to break the tire bead, damp the wheel (rim) to the machine, rotate the tire/wheel assembly, 7 and lock in position. 8 help prevent damage to the tire. 1 tire from the wheel. 2 and still have both hands free.
Using a tire valve removal tool, unscrew the valve The valve core removed from the tire valve. Allow The foot-pedal that causes the table to rotate is Reposition the tire tool to remove the lower core using extreme caution because the valve is all of the air in the tire to escape. depressed and the tire is removed from the wheel. bead of the tire from the wheel. 3 under pressure and can be forced outward and 4 9 10 cause personal injury.
A bead breaker is being used to separate the tire After breaking the beads from both sides of the As the table of the tire changer is rotated, the Before installing a tire, inspect and clean the from the bead seat of the wheel. Repeat as needed to tire, install the wheel/tire assembly flat onto the tire is released from the wheel and can be bead seat. 5 break the bead on both sides of the wheel. 6 machine and, using the foot-pedal control, lock 11 12 the wheel to the changer.
392 CHAPTER24 TIRE AND WHEE ERVICE 393
STEP-BY-STEP photo sequences show in detail the steps involved in performing a specific task or service procedure.
IN-TEXT FEATURES xv
A01_HALD8571_08_SE_FM.indd 15 15/10/19 6:53 PM SUPPLEMENTS
RESOURCES IN PRINT AND ONLINE Automotive Technology NAME OF SUPPLEMENT PRINT ONLINE AUDIENCE DESCRIPTION Instructor ✔ Instructors NEW! The Ultimate teaching aid: Chapter Resource Manual summaries, key terms, chapter learning 0135758602 objectives, and lecture resources. TestGen ✔ Instructors Test generation software and test bank 0135758696 for the text. PowerPoint Presentation ✔ Instructors Slides include a lecture outline of the 0135758955 text to help instructors with in class instruction. Image Bank ✔ Instructors All of the images from the textbook to 0135758556 create customized slides. ASE Task Sheets—for ✔ Instructors Downloadable ASE task sheets for instructors easy customization. 0135758777 ASE Task Sheets—for ✔ Students Student’s can purchase a study activity Students manual that correlates ASE Automobile 0135764343 Standards to chapters and page num- bers in the text. VitalSource eBook ✔ Students An alternative to purchasing the print 0135257492 textbook, students can save up to 50% off the suggested list price of the print text. Visit www.vitalsource.com All online resources can be downloaded from the Instructor’s Resource Center: www.pearsonhighered.com Search for your specific title there and select the Resources.
ACKNOWLEDGMENTS
A large number of people and organizations have cooperated easy-to-read style that has made other books from the same in providing the reference material and technical information author so popular. used in this text. The author wishes to express sincere thanks Jim Anderson to the following individuals and organizations for their special Greenville High School contributions: Victor Bridges Steve Cartwright—Federal-Mogul Umpqua Community College Brad Halderman—Hankook Tires Matt Dixon Joe Palazzolo—GKN Driveline Southern Illinois University Dave Fox—Hunter Engineering Dr. Roger Donovan Carl Borsani—Graphic Home Illinois Central College A. C. Durdin TECHNICAL AND CONTENT REVIEWERS The follow- Moraine Park Technical College ing people reviewed the manuscript before production and Al Engledahl checked it for technical accuracy and clarity of presentation. College of Dupage Their suggestions and recommendations were included in the Orlando Grijalva final draft of the manuscript. Their input helped make this Tarrant County College, South textbook clear and technically accurate while maintaining the Larry Hagelberger Upper Valley Joint Vocational School
xvi ACKNOWLEDGMENTS
A01_HALD8571_08_SE_FM.indd 16 15/10/19 6:53 PM Oldrick Hajzler Alexis I. Skriloff James. Red River College Special thanks to instructional designer Betsy Hoffman Mark Spisak Vermont Technical College Central Piedmont Community College Richard Krieger Chuck Taylor Michigan Institute of Technology Sinclair Community College Steven T. Lee Omar Trinidad Lincoln Technical Institute Southern Illinois University Carlton H. Mabe, Sr. Walter Varella Virginia Western Community College Trident Technical College Roy Marks Mitchell Walker Owens Community College St. Louis Community College at Forest Park Tony Martin Jennifer Wise University of Alaska Southeast Sinclair Community College Kerry Meier San Juan College PHOTO SEQUENCES The author wishes to thank Brad Jim Morton Halderman, Alyssa Williams, Carl Borsani, and Chuck Taylor of Automotive Training Center (ATC) Sinclair Community College in Dayton, Ohio, plus Steve Cartwright Fritz Peacock who helped with many of the photos. Indiana Vocational Technical College Dennis Peter NAIT (Canada) SPECIAL THANKS The author wishes to thank Chuck Greg Pfahl Taylor of Sinclair Community College in Dayton, Ohio, plus Miami-Jacobs Career College Greg Pfahl and Curt Ward who helped with many of the Steve Polley photos. A special thanks to Tom Birch, Dick Krieger, and Pittsburgh State University Jeff Rehkopf for their detailed and thorough review of the Kenneth Redick manuscript before publication. Most of all, we wish to thank Hudson Valley Community College Michelle Halderman for her assistance in all phases of manu- Jeff Rehkopf script preparation. Florida State College —James D. Halderman
ABOUT THE AUTHOR
JIM HALDERMAN brings a world of experience, knowledge, and talent to his work. His automotive service experience in- cludes working as a flat-rate technician, a business owner, and a professor of Automotive Technology. He has a Bachelor of Science Degree from Ohio North- ern University and a Master’s Degree from Miami University in Oxford, Ohio. Jim also holds a U.S. Patent for an electronic transmission control device. He is an ASE-certified Master Au- tomotive Technician (A1-A9), plus G1, L1, and L3. Jim is the author of 18 Automotive textbooks; all published by Pearson Education. Jim has presented numerous technical seminars to national audiences, including the California Automo- tive Teachers (CAT) and the Illinois College Automotive Instructor Association (ICAIA). He is also a member and presenter at the North American Council of Automotive Teachers (NACAT). Jim was also named Regional Teacher of the Year by General Motors Corporation and a member of the advisory board for Technologi- cal Studies department at Ohio Northern University. Jim and his wife, Michelle, live in Dayton, Ohio. You can reach Jim at:
ABOUT THE AUTHOR xvii
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