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Automotive engines theory and servicing 6th ed Edition
Halderman Digital Instant Download
Author(s): Halderman, James D;Mitchell, Chase
ISBN(s): 9780135036891, 0135036895
Edition: 6th ed
File Details: PDF, 35.88 MB
Year: 2008
Language: english
AUTOMOTIVE ENGINES
THEORY AND SERVICING
SIXTH EDITION
James D. Halderman
Upper Saddle River, New Jersey

Columbus, Ohio
Library of Congress Cataloging-in-Publication Data
Halderman, James D.
Automotive engines : theory and servicing / James D. Halderman. 6th ed.
p. cm.
Includes index.
ISBN 978-0-13-503689-1
1. Automobiles—Motors. 2. Automobiles—Motors—Maintenance and repair. I. Title.
TL210.H29 2009
629.25'040288--dc22
2008024507
Editor in Chief: Vernon Anthony

Acquisitions Editor: Wyatt Morris
Editorial Assistant: Christopher Reed
Production Coordination: Kelli Jauron, S4Carlisle Publishing Services
Project Manager: Holly Shufeldt
Operations Specialist: Laura Weaver
Art Director: Candace Rowley
Cover and Interior Design: Candace Rowley
Director of Marketing: David Gesell
Marketing Assistant: Les Roberts
This book was set in Weidemann by S4Carlisle Publishing Services and was printed and bound by Edwards Brothers. The cover
was printed by Phoenix Color Corp.
Copyright © 2009, 2005, 2001, 1997, 1991, 1981 by Pearson Education, Inc., Upper Saddle River, New Jersey
07458. Pearson Prentice Hall. All rights reserved. Printed in the United States of America. This publication is protected by
Copyright and permission should be obtained from the publisher prior to any prohibited reproduction, storage in a retrieval
system, or transmission in any form or by any means, electronic, mechanical, photocopying, recording, or likewise. For
information regarding permission(s), write to: Rights and Permissions Department.
Pearson Prentice Hall™ is a trademark of Pearson Education, Inc.

Pearson® is a registered trademark of Pearson plc
Prentice Hall® is a registered trademark of Pearson Education, Inc.
Pearson Education Ltd., London Pearson Education Australia Pty. Limited

Pearson Education Singapore Pte. Ltd. Pearson Education North Asia Ltd., Hong Kong
Pearson Education Canada, Inc. Pearson Educación de Mexico, S.A. de C.V.
Pearson Education—Japan Pearson Education Malaysia Pte. Ltd.
10 9 8 7 6 5 4 3 2 1
ISBN-13: 978-0-13-503689-1
ISBN-10: 0-13-503689-5
PREFACE
Professional Technician ■ A new chapter on preparation for assembly (Chapter 29)

Series details all of the steps and procedures that are needed to
successfully blueprint and assemble an engine.
Part of Prentice Hall Automotive’s Professional Technician ■ There is expanded coverage on variable valve timing and
Series, the sixth edition of Automotive Engines: Theory and variable displacement engines (Chapter 10).
Servicing presents students and instructors with a practical,
real-world approach to automotive technology and service.
ASE and NATEF Correlated
The series includes textbooks that cover all eight ASE certifi-
cation test areas of automotive service: Engine Repair (A1),
NATEF-certified programs need to demonstrate that they
Automotive Transmissions/Transaxles (A2), Manual Drive
use course materials that cover NATEF and ASE tasks. This
Trains and Axles (A3), Suspension and Steering (A4), Brakes
textbook has been correlated to the ASE and NATEF task
(A5), Electrical/Electronic Systems (A6), Heating and Air
lists and offers comprehensive coverage of all tasks. A
Conditioning (A7), and Engine Performance (A8).
NATEF TASK CORRELATION CHART and an ASE TEST
Current revisions are written by the experienced author
CORRELATION CHART are located in the appendices to
and peer reviewed by automotive instructors and experts in
the book.
the field to ensure technical accuracy.
updates to the sixth edition A Complete Instructor and

Student Supplements Package
The sixth edition has been updated throughout and now has
31 chapters compared to 24 chapters in the fifth edition. This textbook is accompanied by a full package of instructor
and student supplements. See page vi for a detailed list of all
■ An expanded chapter on shop safety includes how to supplements available with this book.
safely de-power hybrid electric vehicles (Chapter 1).
■ Information on hand tools (Chapter 4) and power
A Focus on Diagnosis
tools/shop equipment (Chapter 5) has been expanded
and now each is covered in a separate chapter. and Problem Solving
■ Service information (Chapter 8) and vehicle identifica-
The Professional Technician series has been developed to sat-
tion information (Chapter 9) are now in separate chap-
isfy the need for a greater emphasis on problem diagnosis.
ters to make learning and teaching this material easier.
Automotive instructors and service managers agree that students
■ Updated chapters on the cooling system (Chapter 13) and beginning technicians need more training in diagnostic
and the lubrication system (Chapter 14) include many procedures and skill development. To meet this need and
changes in the industry and systems. demonstrate how real-world problems are solved, the “Real
■ Expanded coverage on automotive fuels now includes World Fix” features are included throughout and highlight
all alternative fuels (Chapter 11). how real-life problems are diagnosed and repaired.
■ Expanded coverage on diesel engines includes the new The following pages highlight the unique core features
after-treatment devices needed for diesel engines to meet that set the Professional Technician series apart from other
the latest emissions standards (Chapter 12). automotive textbooks.
iii
iv Preface
IN-TEXT FEATURES
OBJECTIVES and KEY TERMS appear at
the beginning of each chapter to help
students and instructors focus on the most CHAPTER 1
important material in each chapter.The
chapter objectives are based on specific
ASE and NATEF tasks. SHOP SAFETY
OBJECTIVES
After studying Chapter 1, the reader will be able to: 3. Describe how to properly use a fire extinguisher.
4. Discuss shop safety procedures.
1. Identify situations where hearing protection should be worn.
2. Discuss how to safely handle tools and shop equipment.
KEY TERMS
Tech ANSI (p. 2) Microbes (p. 5)
Bump Cap (p. 2) “PASS” (p. 6)
Tip Decibel (dB) (p. 3)
Eye Wash Station (p. 7)
Personal Protective Equipment (PPE) (p. 2)
Spontaneous Combustion (p. 4)
Fire Blankets (p. 7)
PROFESSIONAL
BEHAVIOR IN THE
SHOP IS A MUST
To be respected as a professional service technician
and for safety, always behave in a professional manner.
These behaviors include, but are not limited, to the
following:
■
Show respect to other technicians and employees. Safety
For example, the shop owner or service manager
may not always be right, but they are always the
Tip
boss. COMPRESSED AIR SAFETY
■ Avoid horseplay or practical jokes.
■
Act as if a customer is observing your behavior at all
times because this is often the case. Improper use of an air nozzle can cause blindness or deaf-
ness. Compressed air must be reduced to less than 30 PSI
(206 kPa). See Figure 1-10. If an air nozzle is used to dry
TECH TIPS feature real-world advice and “tricks of
Real World and clean parts, make sure the air stream is directed away the trade” from ASE-certified master technicians.
Fix from anyone else in the immediate area. Coil and store air
hoses when they are not in use.
THE MYSTERIOUS
ENGINE VIBRATION
SAFETY TIPS alert students to possible hazards on
A Buick-built, 3.8-liter V-6 engine vibrated the whole car
after a new short block had been installed. The techni-
the job and how to avoid them.
Frequently
cian who had installed the replacement engine did all of
the following:
Asked Question
1. Checked the spark plugs
2. Checked the spark plug wires
REAL WORLD FIXES present students with actual
WHAT GRADE OF GASOLINE
DOES THE EPA USE WHEN automotive service scenarios and show how these
TESTING ENGINES?
common (and sometimes uncommon) problems
Due to the various grades and additives used in com-
mercial fuel, the government (EPA) uses a liquid called were diagnosed and repaired.
indolene. Indolene has a research octane number of
96.5 and a motor method octane rating of 88, which re-
sults in an R M 2 rating of 92.25.
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.
Preface v
NOTES provide students with additional technical

information to give them a greater understanding of NOTE: The release of only 1 gallon of used oil (a typical oil change) can
a specific task or procedure. make a million gallons of fresh water undrinkable.
CAUTIONS alert students about potential damage

to the vehicle that can occur during a specific task or
service procedure. CAUTION: Never use compressed air to blow brake dust. The fine, talc-
like brake dust can create a health hazard even if asbestos is not present or
WARNINGS alert students to potential harm to the is present in dust rather than fiber form.
technician that could occur during a specific task or
service procedure.
WARNING: Hazardous waste disposal laws include serious penalties for

anyone responsible for breaking these laws.
HEATING METAL Step-by-Step
STEP-BY-STEP photo sequences show in detail the

steps involved in performing a specific task or
service procedure.
Step 1 Heating attachments include ordinary heating tips Step 2 Note that while acetylene bottle pressures are relatively
(middle and right) and a “rosebud”(left).Ordinary heat- low,the oxygen bottle can be filled to over 2000 psi. This
ing tips work fine for most purposes,but occasionally the can represent a serious hazard if precautions are not
rosebud is utilized when a great deal of heat is needed. taken.Be absolutely certain that the bottles are chained
properly to the cart before attempting to move it!
Summary
1. All service technicians should wear safety glasses that 4. If a fire extinguisher is needed, remember: pull the safety
meet standard ANSI Z87.1. pin, aim the nozzle, squeeze the lever, and sweep the
2. Ear protection should be worn anytime the noise level is nozzle from side-to-side.
at 90 decibels (dB) or higher.
3. Safety should be exercised when working with electrical
cords or when jump-starting another vehicle.
Review Questions
1. List four items that are personal protective equipment (PPE). 3. What items are included in a typical first-aid box?
2. What are the types of fire extinguishers and their usage?
Step 3 Any time heating or cutting operations are being per- Step 4 Be sure to wear appropriate personal protective equip-
formed,be sure that any flammables have been removed ment during heating and cutting operations.
from the immediate area. A fire blanket may be placed
over floor drains or other objects to prevent fires.A fire ex-
tinguisher should be on hand in case of an emergency. Chapter Quiz
1. What do you call the service technician’s protective head 5. Two technicians are discussing the safe use of a wrench.
cover? Technician A says that a wrench should be pulled toward
a. Cap you. Technician B says that a wrench should be pushed away
from you. Which technician is correct?
b. Hat
a. Technician A only
c. Bump cap
b. Technician B only
d. Helmet
c. Both Technicians A and B
2. All safety glasses should meet the standards set by _____.
d. Neither Technician A nor B
a. ANSI
6. Exhaust hoses should be used because one of the exhaust gases
b. SAE
is deadly in high concentration. This gas is _____.
c. ASE
a. Carbon monoxide (CO)
d. DOT
b. Carbon dioxide (CO2)
3. When washing hands, the water should be at what tempera- c. Hydrocarbons (HC)
ture?
d. Oxides of nitrogen (NOX)
Step 5 Step 6 When heating steel, move the torch in a circular pat-
a. 98°F (37°C)
7. The process of combustion occurring without an open flame is
Note that heating operations should be performed b. 110°F (43°C)
tern to prevent melting of the metal. Don’t hold the called _____.
over steel or firebrick. Never heat or cut steel close to c. 125°F (52°C)
concrete,as it could cause the concrete to explode. torch too close to the work as this will cause a “snap- a. Direct ignition
d. 135°F (57°C)
ping”or “backfire”that can extinguish the flame. b. Non-open flame combustion
4. Hearing protection should be worn anytime the noise level c. Spontaneous combustion
exceeds _____.
d. Cold fusion
a. 60 dB
8. When using a fire extinguisher, what word can be used to
b. 70 dB
remember what to do?
The SUMMARY, REVIEW QUESTIONS, AND c. 80 dB

d. 90 dB
a. PASS
b. FIRE
CHAPTER QUIZ at the end of each chapter help c. RED

d. LEVER
students review the material presented in the

chapter and test their mastery of the material.
vi Preface
SUPPLEMENTS
The comprehensive INSTRUCTOR’S MANUAL includes access code. Within 48 hours after registering, you will re-
chapter outlines, answers to all questions from the book, ceive a confirming e-mail, including an instructor access
teaching tips, and additional exercises. code. Once you have received your code, go to the site and
An INSTRUCTOR’S RESOURCE CD-ROM features: log on for full instructions on downloading the materials
you wish to use.
■ A complete text-specific TEST BANK WITH TEST CRE- Available to be packaged with the book, the STUDENT
ATION SOFTWARE WORKTEXT (NATEF CORRELATED TASK SHEETS), includes
■ A comprehensive, text-specific POWERPOINT PRESEN- 100% of the job sheets tied to specific (A1) Engine Repair
TATION featuring much of the art from the text as well NATEF tasks. Contact your local Prentice Hall representative
as video clips and animations for information on ordering the textbook packaged with the
■ An IMAGE LIBRARY featuring additional images to use student worktext.
for class presentations Included with every copy of the book, access to the follow-
ing website: www.pearsoned.com/autostudent. This resource
■ Additional student activities including CROSSWORD
contains powerpoint presentations, crosswood puzzles, word
PUZZLES, WORD SEARCHES, and other worksheets
searches, a NATEF task checklist, a sample ASE test, and the
■ A SAMPLE ASE TEST as well as the complete ASE complete ASE task list.
TASK LIST
To access supplmentary materials online, instructors need

to request an instructor access code. Go to www.pearson-
highered.com/irc, where you can register for an instructor
Preface vii
ACKNOWLEDGMENTS
A large number of people and organizations have cooperated Jim Anderson
in providing the reference material and technical information Greenville High School
used in this text. The author wishes to express sincere thanks
to the following organizations for their special contributions: Victor Bridges
Umpqua Community College
Auto Parts Distributors
Automotion, Inc.
Automotive Engine Rebuilders Association John Bronisz
B-H-J Products, Inc. Albuquerque Technical-Vocational Institute
Camwerks Corporation
Castrol Incorporated Dr. Roger Donovan
Champion Spark Plug Company Illinois Central College
Chrysler Corporation
Clayton Manufacturing Company A. C. Durdin
Curtiss Wright Corporation Moraine Park Technical College
Dana Corporation
Defiance Engine Rebuilders Incorporated Herbert Ellinger
Dow Chemical Company Western Michigan University
Fel-Pro Incorporated
Ford Motor Company Al Engledahl
General Motors Corporation, Service and Parts College of Dupage
Operations
George Olcott Company Gary Gage
Goodson Auto Machine Shop Tools and Supplies Ferris State
Greenlee Brothers and Company
Jasper Engines and Transmissions James M. Gore
K-Line Albuquerque Technical-Vocational Institute
Linder Technical Services
Modine Manufacturing Company Larry Hagelberger
Neway Upper Valley Joint Vocational School
Parsons and Meyers Racing Engines
Prestolite Company Oldrick Hajzler
Rottler Manufacturing Red River College
Sealed Power Corporation
Society of Automotive Engineers Betsy Hoffman
Stanadyne Corporation Vermont Technical College
Sunnen Products Company
TRW, Michigan Division Joseph Kidd
Morrisville State College
Technical and Content Reviewers
Steven T. Lee
The following people reviewed the manuscript before production Lincoln Technical Institute
and checked it for technical accuracy and clarity of presentation.
Their suggestions and recommendations were included in the Carlton H. Mabe, Sr.
final draft of the manuscript. Their input helped make this Virginia Western Community College
textbook clear and technically accurate while maintaining the
easy-to-read style that has made other books from the same Roy Marks
author so popular. Owens Community College
viii Preface
Kerry Meier Photo Sequences

San Juan College
I wish to thank Chuck Taylor, Mike Garblik, and Blaine
Fritz Peacock Heeter, of Sinclair Community College, Dayton, Ohio, who
Indiana Vocational Technical College helped with many of the photos.
Special thanks to Richard Reaves and Tony Martin from
Dennis Peter the University of Alaska Southeast for all their help. Most of
NAIT (Canada) all, I wish to thank Michelle Halderman for her assistance in
all phases of manuscript preparation.
Kenneth Redick
Hudson Valley Community College James D. Halderman
Mark Spisak
Central Piedmont Community College
Mitchell Walker
St. Louis Community College at Forest Park
Jennifer Wise
Sinclair Community College
BRIEF CONTENTS
Chapter 1 SHOP SAFETY 1 Chapter 16 IGNITION SYSTEM OPERATION

AND DIAGNOSIS 255
Chapter 2 ENVIRONMENTAL AND HAZARDOUS
MATERIALS 11 Chapter 17 EMISSION CONTROL DEVICES
OPERATION AND DIAGNOSIS 285
Chapter 3 FASTENERS AND THREAD REPAIR 28
Chapter 18 INTAKE AND EXHAUST SYSTEMS 312
Chapter 4 HAND TOOLS 43
Chapter 19 TURBOCHARGING
Chapter 5 POWER TOOLS AND SHOP AND SUPERCHARGING 324
EQUIPMENT 63
Chapter 20 ENGINE CONDITION DIAGNOSIS 337
Chapter 6 VEHICLE LIFTING AND HOISTING 76
Chapter 21 ENGINE DISASSEMBLY, CLEANING,
Chapter 7 MEASURING SYSTEMS AND TOOLS 86 AND CRACK DETECTION 356
Chapter 8 SERVICE INFORMATION 97 Chapter 22 CYLINDER HEAD AND VALVE

GUIDE SERVICE 374
Chapter 9 VEHICLE IDENTIFICATION
AND EMISSION RATINGS 107 Chapter 23 VALVE AND SEAT SERVICE 399
Chapter 10 GASOLINE ENGINE OPERATION, Chapter 24 CAMSHAFTS AND VALVE

PARTS, AND SPECIFICATIONS 114 TRAINS 437
Chapter 11 GASOLINE AND ALTERNATIVE Chapter 25 PISTONS, RINGS, AND CONNECTING

FUELS 128 RODS 477
Chapter 12 DIESEL ENGINE OPERATION Chapter 26 ENGINE BLOCKS 499

AND DIAGNOSIS 160
Chapter 27 CRANKSHAFTS AND BEARINGS 523
Chapter 13 COOLING SYSTEM OPERATION
AND DIAGNOSIS 178 Chapter 28 ENGINE BALANCING AND BALANCE
SHAFTS 546
Chapter 14 LUBRICATION SYSTEM OPERATION
AND DIAGNOSIS 207 Chapter 29 PREPARATION FOR ASSEMBLY 557
Chapter 15 STARTING AND CHARGING SYSTEM Chapter 30 ENGINE BLUEPRINTING AND

OPERATION AND DIAGNOSIS 230 ASSEMBLY 567
ix
x Brief Contents
Chapter 31 ENGINE INSTALLATION AND IN-VEHICLE Appendix 3 NATEF TASK CORRELATION CHART 628
SERVICE 599
ENGLISH GLOSSARY 631
Appendix 1 TIMING BELT REPLACEMENT
GUIDE 619 SPANISH GLOSSARY 647
Appendix 2 ASE TEST CORRELATION CHART 625 INDEX 667

CONTENTS
Chapter 1 SHOP SAFETY 1 Battery Hazardous and Regulatory
Objectives 1 Status 18
Key Terms 1 Battery Handling and Storage 19
Personal Protective Equipment 2 Fuel Safety and Storage 19
Safety Tips for Technicians 3 Airbag Handling 19
Cleaning Methods and Processes 3 Used Tire Disposal 20
Electrical Cord Safety 5 Air-Conditioning Refrigerant Oil Disposal 20
Jump-Starting and Battery Safety 5 Summary 26
Fire Extinguishers 6
Review Questions 26
Fire Blankets 7
First Aid and Eye Wash Stations 7 Chapter Quiz 27
Summary 9 Chapter 3 FASTENERS AND THREAD REPAIR 28
Review Questions 9
Chapter Quiz 9 Objectives 28
Key Terms 28
Threaded Fasteners 29
Chapter 2 ENVIRONMENTAL AND HAZARDOUS Metric Bolts 29
MATERIALS 11 Grades of Bolts 30
Tensile Strength 31
Objectives 11 Nuts 31
Key Terms 11 Taps and Dies 32
Occupational Safety and Health Act 12 Thread Pitch Gauge 33
Hazardous Waste 12 Sheet Metal Screws 34
Resource Conservation and Recovery Act Washers 34
(RCRA) 12 Snap Rings and Clips 35
Clean Air Act 13 How to Avoid Broken Fasteners 37
Material Safety Data Sheets (MSDSs) 13 Thread Repair Inserts 38
The Dangers of Exposure to Asbestos 13
Asbestos OSHA Standards 14 Summary 41
Asbestos EPA Regulations 14 Review Questions 41
Asbestos Handling Guidelines 14 Chapter Quiz 41
Used Brake Fluid 15
Used Oil 15 Chapter 4 HAND TOOLS 43
Disposal of Used Oil 15
Used Oil Storage 15 Objectives 43
Solvents 16 Key Terms 43
Solvent Hazardous and Regulatory Status 17 Wrenches 44
Used Solvents 17 Ratchets, Sockets, and Extensions 45
Coolant Disposal 18 Screwdrivers 48
Lead–Acid Battery Waste 18 Hammers and Mallets 50
xi
xii Contents
Pliers 51 Linear Measurements (Tape

Cutters 53 Measure/Rule) 87
Punches and Chisels 54 Micrometer 88
Removers 55 Telescopic Gauge 90
Hacksaws 56 Small-Hole Gauge 91
Basic Hand Tool List 57 Vernier Dial Caliper 91
Tool Sets and Accessories 57 Feeler Gauge 91
Seal Drivers and Pullers 58 Straightedge 91
Electrical Hand Tools 59 Dial Indicator 94
Safety Tips for Using Hand Tools 60 Dial Bore Gauge 94
Hand Tool Maintenance 60 Depth Micrometer 94
Summary 61 Summary 95
Review Questions 61 Review Questions 95
Chapter Quiz 61 Chapter Quiz 95
Chapter 5 POWER TOOLS AND SHOP Chapter 8 SERVICE INFORMATION 97

EQUIPMENT 63
Objectives 97
Objectives 63 Key Terms 97
Key Terms 63 Vehicle Service History Records 98
Air Compressor 64 Owner’s Manuals 98
Air and Electrically Operated Tools 64 Lubrication Guides 98
Trouble Lights 66 Service Manuals 98
Bench/Pedestal Grinder 67 Advantages of Hard Copy versus Electronic
Bench Vise 67 Service Information 100
Hydraulic Presses 68 Disadvantages of Hard Copy versus
Portable Crane and Chain Hoist 68 Electronic Service Information 100
Engine Stands 69 Types of Service Information 101
Care and Maintenance of Shop Labor Guide Manuals 101
Equipment 69 How to Use Hard Copy Manuals 102
Summary 74 Electronic Service Information 103
Hotline Services 104
Review Questions 74 Specialty Repair Manuals 105
Chapter Quiz 74 Aftermarket Supplies Guides
and Catalogs 105
Chapter 6 VEHICLE LIFTING AND HOISTING 76 Summary 105
Objectives 76 Review Questions 106
Key Terms 76 Chapter Quiz 106
Floor Jack 77
Creepers 77 Chapter 9 VEHICLE IDENTIFICATION
Vehicle Hoists 77 AND EMISSION RATINGS 107
Drive-On Ramps 80
Objectives 107
Summary 84
Key Terms 107
Review Questions 84 Parts of a Vehicle 108
Chapter Quiz 84 Front-Wheel Drive versus Rear-Wheel
Drive 108
Chapter 7 MEASURING SYSTEMS AND TOOLS 86 Vehicle Identification 108
Vehicle Safety Certification Label 109
Objectives 86 VECI Label 109
Key Terms 86 Emission Standards in the United States 109
English Customary Measuring System 87 Calibration Codes 111
Metric System of Measure 87 Casting Numbers 111
Contents xiii
Summary 112 Biodiesel 153

Review Questions 113 E-Diesel Fuel 154
Synthetic Fuels 155
Chapter Quiz 113
Safety Procedures When Working with
Alternative-Fuel Vehicles 156
Chapter 10 GASOLINE ENGINE OPERATION, PARTS,
AND SPECIFICATIONS 114 Summary 158
Review Questions 158
Objectives 114 Chapter Quiz 158
Key Terms 114
Energy and Power 115 Chapter 12 DIESEL ENGINE OPERATION
Engine Construction Overview 115 AND DIAGNOSIS 160
Four-Stroke Cycle Operation 117
The 720° Cycle 117 Objectives 160
Engine Classification and Construction 117 Key Terms 160
Engine Rotation Direction 121 Diesel Engines 161
Bore 121 Three Phases of Combustion 162
Stroke 122 Diesel Engine Construction 162
Engine Displacement 122 Heui System 164
Compression Ratio 124 Diesel Injector Nozzles 165
The Crankshaft Determines the Stroke 124 Diesel Injector Nozzle Operation 167
Torque 125 Glow Plugs 167
Power 125 Engine-Driven Vacuum Pump 168
Horsepower and Altitude 126 Heated Intake Air 168
Summary 126 Accelerator Pedal Position Sensor 168
Review Questions 126 Soot or Particulate Matter 168
Diesel Oxidation Catalyst (DOC) 169
Chapter Quiz 127 Diesel Exhaust Particulate Filter (DPF) 170
Ash Loading 173
Chapter 11 GASOLINE AND ALTERNATIVE Diesel Exhaust Smoke Diagnosis 173
FUELS 128 Scan Tool Diagnosis 174
Compression Testing 174
Objectives 128 Glow Plug Resistance Balance Test 174
Key Terms 128 Injector Pop Testing 175
Automotive Fuel Refining 129 Diesel Emission Testing 175
Gasoline 129
Volatility 129 Summary 176
Distillation Curve 131 Review Questions 177
Normal and Abnormal Combustion 132 Chapter Quiz 177
Octane Rating 134
Gasoline Grades and Octane Chapter 13 COOLING SYSTEM OPERATION
Number 134 AND DIAGNOSIS 178
Octane Improvers 135
Oxygenated Fuels 135 Objectives 178
Alcohol Additives—Advantages and Key Terms 178
Disadvantages 136 Cooling System Purpose and Function 179
Testing Gasoline for Alcohol Low-Temperature Engine Problems 179
Content 137 High-Temperature Engine Problems 179
Combustion Chemistry 137 Cooling System Design 180
Air–Fuel Ratios 138 Thermostat Temperature Control 181
High-Altitude Octane Requirements 139 Testing the Thermostat 183
Reformulated Gasoline 139 Thermostat Replacement 184
General Gasoline Recommendations 140 Antifreeze/Coolant 184
Alternative Fuels 141 Types of Coolant 185
P-Series Fuels 149 Antifreeze Can Freeze 186
xiv Contents
Hydrometer Testing 187 Changing Oil in a Turbocharged Engine 216

Recycling Coolant 187 Oil Pumps 218
Disposing of Used Coolant 187 Oil Pressure Regulation 219
Radiator 188 Factors Affecting Oil Pressure 219
Pressure Cap 188 Oil Pump Checks 220
Surge Tank 190 Oil Passages in the Block 221
Metric Radiator Caps 190 Valve Train Lubrication 223
Coolant Recovery System 191 Oil Pans 223
Pressure Testing 191 Dry Sump System 224
Coolant Dye Leak Testing 192 Oil Coolers 226
Water Pump Operation 192 Oil Pressure Warning Lamp 227
Coolant Flow in the Engine 194 Summary 228
Water Pump Service 194
Cooling Fans 196
Thermostatic Fans 196 Chapter Quiz 228
Electronically Controlled Cooling
Fan 197 Chapter 15 STARTING AND CHARGING SYSTEM
Heater Core 198 OPERATION AND DIAGNOSIS 230
Heater Problem Diagnosis 198
Coolant Temperature Warning Light 199 Objectives 230
Common Causes of Overheating 199 Key Terms 230
Cooling System Maintenance 199 Purpose of a Battery 231
Flush and Refill 201 How a Battery Works 231
Burping the System 201 Specific Gravity 232
Hoses 202 Absorbed Glass Mat (AGM) Battery 233
Back Flushing a Radiator 202 Battery Ratings 233
Cleaning the Radiator Exterior 203 Battery Service 234
Summary 205 Jump Starting 238
Cranking Circuit 238
Starting System Troubleshooting 240
Chapter Quiz 205 Starter Amperage Testing 241
Bench Testing 241
Chapter 14 LUBRICATION SYSTEM OPERATION AC Generators 241
AND DIAGNOSIS 207 Summary 252
Objectives 207
Key Terms 207 Chapter Quiz 253
Lubrication Purpose and Fundamentals 208
Lubrication Principles 208 Chapter 16 IGNITION SYSTEM OPERATION
Engine Lubrication Systems 208 AND DIAGNOSIS 255
Properties of Engine Oil 209
SAE Rating 209 Objectives 255
API Rating 209 Key Terms 255
ILSAC Oil Rating 210 Ignition System Operation 256
European Oil Ratings 211 Ignition Coils 256
Japanese Oil Ratings 211 Distributor Ignition 261
Engine Oil Additives 211 Waste-Spark Ignition Systems 264
Oil Brand Compatibility 212 Coil-on-Plug Ignition 267
Synthetic Oil 212 Checking for Spark 267
Oil Temperature 213 Electronic Ignition Troubleshooting
Oil Change Intervals 214 Procedure 269
Oil Change Procedure 214 Ignition Coil Testing Using an
Oil Filters 216 Ohmmeter 269
Contents xv
Pickup Coil Testing 270 Summary 310

Testing Magnetic Sensors 270 Review Questions 310
Testing Hall-Effect Sensors 271
Chapter Quiz 310
Testing Optical Sensors 271
Ignition System Diagnosis Using Visual
Chapter 18 INTAKE AND EXHAUST SYSTEMS 312
Inspection 271
Testing for Poor Performance 272
Objectives 312
Testing for a No-Start Condition 272
Key Terms 312
Firing Order 273
Air Intake Filtration 313
Spark Plug Wire Inspection 273
Engine Air Temperature Requirements 314
Spark Plug Service 273
Throttle-Body Injection Intake Manifolds 315
Quick and Easy Secondary Ignition
Port Fuel-Injection Intake Manifolds 316
Tests 276
Variable Intakes 316
Ignition Timing 277
Plastic Intake Manifolds 316
Ignition System Troubleshooting
Exhaust Gas Recirculation Passages 317
Guide 280
Upper and Lower Intake Manifolds 318
Summary 283 Exhaust Manifold Design 318
Review Questions 283 Exhaust Manifold Gaskets 320
Chapter Quiz 283 Mufflers 320
Summary 322
Chapter 17 EMISSION CONTROL DEVICES Review Questions 322
OPERATION AND DIAGNOSIS 285 Chapter Quiz 322
Objectives 285 Chapter 19 TURBOCHARGING

Key Terms 285 AND SUPERCHARGING 324
Exhaust Gas Recirculation Systems 286
Controlling NOx 286 Objectives 324
EGR System Operation 287 Key Terms 324
Positive and Negative Backpressure EGR Airflow Requirements 325
Valves 287 Supercharging Principles 325
Computer-Controlled EGR Systems 288 Superchargers 326
OBD-II EGR Monitoring Strategies 290 Turbochargers 328
Diagnosing a Defective EGR System 292 Boost Control 330
Crankcase Ventilation 294 Turbocharger Failures 332
PCV Valves 294 Nitrous Oxide 333
Orifice-Controlled Systems 295
Summary 335
Positive Crankcase Ventilation (PCV) System
Diagnosis 296 Review Questions 335
PCV Monitor 298 Chapter Quiz 335
Air Pump System 298
Air Distribution Manifolds and Chapter 20 ENGINE CONDITION DIAGNOSIS 337
Nozzles 298
Air Pump System Diagnosis 302 Objectives 337
Catalytic Converters 303 Key Terms 337
Ceramic Monolith Catalytic Converter 303 Typical Engine-Related Complaints 338
OBD-II Catalytic Converter Engine Smoke Diagnosis 338
Performance 305 The Driver Is Your Best Resource 338
Converter-Damaging Conditions 305 Visual Checks 339
Diagnosing Catalytic Converters 306 Engine Noise Diagnosis 340
OBD-II Catalytic Converter Monitor 308 Oil Pressure Testing 342
Catalytic Converter Replacement Oil Pressure Warning Lamp 342
Guidelines 309 Compression Test 342
xvi Contents
Wet Compression Test 344 Crack Repair 367

Running (Dynamic) Compression Test 345 Crack-Welding Cast Iron 367
Cylinder Leakage Test 345 Crack-Welding Aluminum 368
Cylinder Power Balance Test 346 Crack Plugging 368
Power Balance Test Procedure 346 Summary 372
Vacuum Tests 347
Exhaust Restriction Test 349
Testing Back Pressure with a Vacuum Chapter Quiz 372
Gauge 350
Testing Back Pressure with a Pressure Chapter 22 CYLINDER HEAD AND VALVE GUIDE
Gauge 350 SERVICE 374
Diagnosing Head Gasket Failure 350
Dash Warning Lights 351 Objectives 374
Summary 354 Key Terms 374
Cylinder Heads 375
Multiple-Valve Combustion Chamber 377
Chapter Quiz 354 Intake and Exhaust Ports 378
Cylinder Head Coolant Passages 380
Chapter 21 ENGINE DISASSEMBLY, CLEANING, Lubricating Overhead Valves 381
AND CRACK DETECTION 356 Removing the Overhead Camshaft 381
Disassembly of the Cylinder Head 381
Objectives 356 Cylinder Head Reconditioning
Key Terms 356 Sequence 382
Engine Removal 357 Cylinder Head Resurfacing 382
Engine Disassembly 358 Aluminum Cylinder Head Straightening 383
Checking Cylinder Bore 359 Resurfacing Methods 384
Removing the Oil Pan 359 Surface Finish 384
Removing the Cylinder Ridge 359 Correcting Intake Manifold Alignment 386
Removing the Pistons 360 Valve Guides 387
Removing the Harmonic Balancer 360 Valve Stem-to-Guide Clearance 387
Removing the Timing Chain Measuring Valve Guides for Wear 388
and Camshaft 360 Oversize Stem Valves 388
Removing the Main Bearing Valve Guide Knurling 389
and Crankshaft 361 Valve Guide Replacement 390
Remove and Disassemble the Cylinder Valve Guide Inserts 391
Head 361 Spiral Bronze Insert Bushings 394
Mechanical Cleaning 362 Summary 397
Chemical Cleaners 363
Solvent-Based Cleaning 363
Water-Based Chemical Cleaning 363 Chapter Quiz 397
Spray Washing 363
Steam Cleaning 364 Chapter 23 VALVE AND SEAT SERVICE 399
Thermal Cleaning 364
Cold Tank Cleaning 364 Objectives 399
Hot Tank Cleaning 365 Key Terms 399
Vapor Cleaning 365 Intake and Exhaust Valves 400
Ultrasonic Cleaning 365 Valve Size Relationships 400
Vibratory Cleaning 365 Valve Design 400
Blasters 365 Valve Materials 401
Visual Inspection 366 Sodium-Filled Valves 402
Magnetic Crack Inspection 366 Valve Seats 402
Dye-Penetrant Testing 366 Valve Inspection 403
Fluorescent-Penetrant Testing 367 Valve Springs 408
Pressure Testing 367 Valve Spring Inspection 408
Contents xvii
Valve Keepers 410 Solid Lifters 467

Valve Rotators 410 Hydraulic Lifters 468
Valve Reconditioning Procedure 410 Lifter Preload 469
Valve Face Grinding 412 Determining Lifter Preload 471
Valve Seat Reconditioning 413 Determining Proper Lifter Travel 471
Valve Guide Pilots 416 Valve Noise Diagnosis 472
Valve Seat Grinding Stones 417 Mechanical Lifter Service 472
Dressing the Grinding Stone 418 Hydraulic Lifter Service 473
Valve Seat Grinding 419 Hydraulic Valve Lifter Installation 473
Narrowing the Valve Seat 419 Bleeding Hydraulic Lifters 473
Valve Seat Cutters 420 Valve Train Lubrication 473
Valve Seat Testing 420 Summary 475
Valve Seat Replacement 421
Valve Stem Height 424
Checking Installed Height 424 Chapter Quiz 476
Valve Stem Seals 425
Types of Valve Stem Seals 426 Chapter 25 PISTONS, RINGS, AND
Installing the Valves 427 CONNECTING RODS 477
Flow Testing Cylinder Heads 429
Cylinder Head Flow versus Horsepower 429 Objectives 477
Purpose and Function of Pistons, Rings,
and Connecting Rods 478
Chapter Quiz 435 Piston and Rod Removal 478
Piston Design 479
Chapter 24 CAMSHAFTS AND VALVE TRAINS 437 Piston Heads 480
Cam Ground Pistons 481
Objectives 437 Piston Finish 481
Key Terms 437 Piston Head Size 482
Camshaft Purpose and Function 438 Piston Strut Inserts 482
Camshaft Location 438 Hypereutectic Pistons 482
Camshaft Problem Diagnosis 438 Forged Pistons 482
Camshaft Removal 439 Piston Pins 482
Camshaft Design 439 Piston Pin Retaining Methods 485
Composite Camshafts 441 Piston Ring Grooves 486
Camshaft Lubrication 442 Piston Rings 486
Fuel-Pump Eccentrics 442 Compression Rings 487
Camshaft Drives 442 Piston Service 490
Camshaft Chain Drives 444 Connecting Rods 490
Camshaft Belt Drives 445 Connecting Rod Design 492
Camshaft Movement 446 Rod Twist 493
Lifter Rotation 446 Connecting Rod Service 494
Camshaft Lift 447 Piston and Rod Assembly 494
Rocker Arms 448 Piston Ring Service 495
Pushrods 450 Summary 497
Overhead Camshaft Valve Trains 452
Camshaft Specifications 453
Cam Timing Specifications 455 Chapter Quiz 497
Measuring and Regrinding Camshafts 456
Installing the Camshaft 456 Chapter 26 ENGINE BLOCKS 499
Degreeing the Camshaft 458
Variable Valve Timing 461 Objectives 499
Variable Valve Timing and Lift 465 Key Terms 499
Lifters or Tappets 467 Engine Blocks 500
xviii Contents
Engine Block Service 505 Chapter 29 PREPARATION FOR ASSEMBLY 557

Block Cleaning and Preparation
for Assembly 512 Objectives 557
Details, Details, Details 558
Short Block Preparation 558
Chapter Quiz 522 Cylinder Head Preparation 560
Trial Assembly 560
Chapter 27 CRANKSHAFTS AND BEARINGS 523 Check the Angle Between Heads 562
Painting the Engine 562
Objectives 523 Gaskets and Clamping Force 562
Key Terms 523 Summary 565
Crankshaft 524
Crankshaft Construction 526
V-8 Crankshafts 527 Chapter Quiz 565
Four-Cylinder Engine Crankshafts 527
Five-Cylinder Engine Crankshafts 527 Chapter 30 ENGINE BLUEPRINTING
Three-Cylinder Engine Crankshafts 527 AND ASSEMBLY 567
Odd-Firing 90-Degree V-6 Engine
Crankshafts 527 Objectives 567
Even-Firing 90-Degree V-6 Engine Key Terms 567
Crankshafts 528 Blueprinting 568
Sixty-Degree V-6 Engine Block Preparation 568
Crankshafts 528 Installing Cups and Plugs 568
Counterweights 528 Installing Cam Bearings 569
Externally and Internally Balanced Causes of Premature Bearing
Engines 530 Failure 570
Crankshaft Oiling Holes 531 Measuring Main Bearing Clearance 570
Crankshaft Inspection 531 Correcting Bearing Clearance 571
Crankshaft Grinding 532 Lip Seal Installation 572
Welding a Crankshaft 533 Rope Seal Installation 572
Stress Relieving the Crankshaft 534 Installing the Crankshaft 573
Engine Bearings 534 Measuring Thrust Bearing Clearance 574
Bearing Construction 537 Tightening Procedure for the Main
Bearing Manufacturing 539 Bearing 574
Bearing Clearance 539 Installing Timing Chains and Gears 574
Bearing Spread and Crush 539 Piston Fitting 575
Camshaft Bearings 541 Installing Piston and Rod Assemblies 576
Installing the Camshaft for Overhead Cam
Summary 544
Engines 579
Review Questions 544 Head Gaskets 580
Chapter Quiz 545 Multilayered Steel Gaskets 581
Installing the Head Gasket 581
Chapter 28 ENGINE BALANCING AND BALANCE Head Bolt Torque Sequence 582
SHAFTS 546 Torque-to-Yield Bolts 582
Timing Drives for Overhead Cam
Objectives 546 Engines 583
Key Terms 546 Lifter and Pushrod Installation 584
Engine Balance 547 Hydraulic Lifters 585
Balance Shafts 547 Solid Lifters 585
Balancing an Engine 548 Assembly Sealants 586
Installing Manifolds 586
Summary 555
Cover Gasket Materials 587
Review Questions 555 Installing Timing Covers 588
Chapter Quiz 555 Installing the Vibration Damper 589
Contents xix
Installing the Oil Pump 589 Engine Start 602

The Oil Pan 589 Normal Operating Temperature 603
Installing the Water Pump 590 How to Warm Up a Cold Engine 604
Engine Painting 590 Break-In Precautions 604
Checking for Proper Oil Pressure 590 Summary 616
Setting Initial Ignition Timing 591
Summary 597
Chapter Quiz 616
Chapter Quiz 597
Appendix 1 TIMING BELT REPLACEMENT
GUIDE 619
Chapter 31 ENGINE INSTALLATION AND IN-VEHICLE
SERVICE 599
Appendix 2 ASE TEST CORRELATION CHART 625
Objectives 599
Key Terms 599
Appendix 3 NATEF TASK CORRELATION
Preinstallation Checklist 600
CHART 628
Manual Transmission Installation 600
Automatic Transmission Installation 601
Starter 601 ENGLISH GLOSSARY 631
Accessories 602
Engine Installation 602
SPANISH GLOSSARY 647
Cooling System 602
Fuel and Emission Controls 602
Electrical System 602 INDEX 667
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CHAPTER 1
SHOP SAFETY
OBJECTIVES
After studying Chapter 1, the reader will be able to: 3. Describe how to properly use a fire extinguisher.
4. Discuss shop safety procedures.
1. Identify situations where hearing protection should be worn.
2. Discuss how to safely handle tools and shop equipment.
KEY TERMS
ANSI (p. 2) Microbes (p. 5)
Bump Cap (p. 2) “PASS” (p. 6)
Decibel (dB) (p. 3) Personal Protective Equipment (PPE) (p. 2)
Eye Wash Station (p. 7) Spontaneous Combustion (p. 4)
Fire Blankets (p. 7)
2 CHAPTER 1
PERSONAL PROTECTIVE
EQUIPMENT
Safety is not just a buzzword on a poster in the work area. Safe
work habits can reduce accidents and injuries, ease the work-
load, and keep employees pain free.
Safety Glasses
The most important personal protective equipment (PPE)
a technician should wear all the time are safety glasses, which
meet standard ANSI Z87.1. See Figure 1-1.
Steel-Toed Shoes
Steel-toed safety shoes are also a good investment. See Figure 1-2.
If safety shoes are not available, then leather-topped shoes
offer more protection than canvas or cloth.
FIGURE 1-2 Steel-toed shoes are a worthwhile investment to help
prevent foot injury due to falling objects. Even these well-worn shoes can
Gloves protect the feet of this service technician.
Wear gloves to protect your hands from rough or sharp sur-
faces. Thin rubber gloves are recommended when working
around automotive liquids such as engine oil, antifreeze, trans-
mission fluid, or any other liquids that may be hazardous. Sev-
eral types of gloves and their characteristics include:
■ Latex surgical gloves. These gloves are relatively inex-
pensive, but tend to stretch, swell, and weaken when
exposed to gas, oil, or solvents.
■ Vinyl gloves. These gloves are also inexpensive and are
not affected by gas, oil, or solvents.
■ Polyurethane gloves. These gloves are more expensive,
yet very strong. Even though these gloves are also not
affected by gas, oil, or solvents, they do tend to be slippery.
■ Nitrile gloves. These gloves are exactly like latex gloves,
but are not affected by gas, oil, or solvents, yet they tend
to be expensive. FIGURE 1-3 Protective gloves such as these vinyl gloves are available
in several sizes. Select the size that allows the gloves to fit snugly.Vinyl gloves
last a long time and often can be worn all day to help protect your hands from
dirt and possible hazardous materials.
■ Mechanic’s gloves. These gloves are usually made of syn-

thetic leather and spandex and provide thermo protection,
as well as protection from dirt and grime. See Figure 1-3.
Bump Cap
Service technicians working under a vehicle should wear a
FIGURE 1-1 Safety glasses should be worn at all times when working on bump cap to protect the head against under-vehicle objects
or around any vehicle or servicing any component. and the pads of the lift. See Figure 1-4.
Shop Safety 3
Tech
Tip
PROFESSIONAL
BEHAVIOR IN THE
SHOP IS A MUST
To be respected as a professional service technician
and for safety, always behave in a professional manner.
These behaviors include, but are not limited, to the
following:
■ Show respect to other technicians and employees.
FIGURE 1-4 One version of a bump cap is this padded plastic insert
For example, the shop owner or service manager
that is worn inside a regular cloth cap.
may not always be right, but they are always the
boss.
■ Avoid horseplay or practical jokes.
■ Act as if a customer is observing your behavior at all
times because this is often the case.
SAFETY TIPS FOR

TECHNICIANS
■ When lifting any object, get a secure grip with solid footing.
Keep the load close to your body to minimize the strain. Lift
with your legs and arms, not your back.
■ Do not twist your body when carrying a load. Instead,
pivot your feet to help prevent strain on the spine.
■ Ask for help when moving or lifting heavy objects.
■ Push a heavy object rather than pull it. (This is opposite
to the way you should work with tools—never push a
FIGURE 1-5 Remove all jewelry before performing service work on
wrench! If you do and a bolt or nut loosens, your entire
any vehicle.
weight is used to propel your hand(s) forward. This usu-
ally results in cuts, bruises, or other painful injury.)
■ Always connect an exhaust hose to the tailpipe of any
Hands, Jewelry, and Clothing
running vehicle to help prevent the buildup of carbon
monoxide inside a closed garage space. See Figure 1-6.
Remove jewelry that may get caught on something or act as a
conductor to an exposed electrical circuit. See Figure 1-5.
■ When standing, keep objects, parts, and tools with which
Take care of your hands. Keep your hands clean by wash- you are working between chest height and waist height.
ing with soap and hot water that is at least 110°F (43°C). If seated, work at tasks that are at elbow height.
Avoid loose or dangling clothing. Also, ear protection should ■ Always be sure the hood is securely held open. See
be worn if the sound around you requires that you raise your Figure 1-7.
voice (sound level higher than 90 decibels [dB]).
CLEANING METHODS
NOTE: A typical lawnmower produces noise at a level of about 110 dB. AND PROCESSES
This means that everyone who uses a lawnmower or other lawn or garden
equipment should wear ear protection. There are four basic types of cleaning methods and processes
used in vehicle service, including:
4 CHAPTER 1
HOOD STRUT
CLAMP
FIGURE 1-6 Always connect an exhaust hose to the tailpipe of the

engine of a vehicle to be run inside a building.
(b)
FIGURE 1-7b A commercially available hood clamp.This tool uses a

bright orange tag to help remind the technician to remove the clamp before
attempting to close the hood.The hood could be bent if force is used to close the
hood with the clamp in place.
Safety
Tip
SHOP CLOTH DISPOSAL
Always dispose of oily shop cloths in an enclosed container

to prevent a fire. See Figure 1-8. Whenever oily cloths are
thrown together on the floor or workbench, a chemical re-
action can occur which can ignite the cloth even without
(a) an open flame. This process of ignition without an open
flame is called spontaneous combustion.
FIGURE 1-7a A crude but effective method is to use locking pliers on
the chrome-plated shaft of a hood strut. Locking pliers should only be used on
defective struts because the jaws of the pliers can damage the strut shaft.
a chemical cleaner, such as a detergent, is added to the water
to help with cleaning.
Power Washing
Safe Use of Power Washers. Because water is being
Power washing uses an electric or gasoline powered compressor sprayed at high pressure, a face shield should be worn when
to increase the pressure of water and force it out of a nozzle. using a power washer to protect not only the eyes but to also
The pressure of the water itself is usually enough to remove protect the face in the event of the spray being splashed back
dirt, grease, and grime from vehicle components. Sometimes toward the technician. Also use a pressure washer in an area
Shop Safety 5
called microbes that eat oil and grease. The microbes live in
water and eat the hydrocarbons that are the basis of grease
and oil.
Safe Use of Chemical Cleaning. A face shield should be

worn when cleaning parts using a chemical cleaner. Avoid
spilling the cleaner on the floor to help prevent slipping acci-
dents. Clean and replace the chemical cleaner regularly.
Abrasive Cleaning
Abrasive cleaning is usually used to clean disassembled parts,
such as engine blocks. The abrasives used include steel shot,
ground walnut shells, or in the case of cleaning paint from a
vehicle body, baking soda can be used.
Safe Use of Abrasive Cleaners. Always wear a protec-

tive face shield and protective clothing, including gloves, long
FIGURE 1-8 All oily shop cloths should be stored in a metal container sleeves, and long pants.
equipped with a lid to help prevent spontaneous combustion.
Thermal Ovens
Tech Thermal cleaning uses heat to bake off grease and dirt with
special high-temperature ovens. This method of cleaning does
Tip require the use of expensive equipment but does not use any
hazardous chemicals and is environmentally safe.
POUND WITH
SOMETHING Safe Use of Thermal Ovens. Because thermal ovens op-
SOFTER erate at high temperatures, often exceeding 600°F (315°C),
the oven should be turned off and allowed to cool overnight
If you must pound on something, be sure to use a tool before removing the parts from the oven to avoid being
that is softer than what you are about to pound on to exposed to the high temperature.
avoid damage. Examples are given in the following
table.
ELECTRICAL CORD SAFETY
The Material
Being Pounded What to Pound With Use correctly grounded three-prong sockets and extension
Steel or cast Brass or aluminum hammer or cords to operate power tools. Some tools use only two-prong
iron punch plugs. Make sure these are double insulated and repair or re-
place any electrical cords that are cut or damaged to prevent
Aluminum Plastic or rawhide mallet or plas- the possibility of an electrical shock. When not in use, keep
tic-covered dead-blow hammer electrical cords off the floor to prevent tripping over them.
Plastic Rawhide mallet or plastic dead- Tape the cords down if they are placed in high foot traffic areas.
blow hammer
JUMP-STARTING AND
BATTERY SAFETY
where the runoff from the cleaning will not contaminate local
groundwater or cause harm to plants or animals. To jump-start another vehicle with a dead battery, connect
good-quality copper jumper cables as indicated in Figure 1-9
Chemical/Microbe Cleaning or use a jump box. The last connection made should always
be on the engine block or an engine bracket as far from the
Chemical cleaning involves one of several cleaning solutions, battery as possible. It is normal for a spark to be created when
including detergent, solvents, or small, living microorganisms the jumper cables finally complete the jumping circuit, and
6 CHAPTER 1
TO STARTER TO STARTER
MOTOR MOTOR
STEP 2 STEP 1
STARTING STALLED
VEHICLE VEHICLE
TO ENGINE TO ENGINE
GROUND STEP 3 GROUND
STEP 4
ENGINE BLOCK OR
METAL BRACKET
FIGURE 1-9 Jumper cable usage guide. ON ENGINE BLOCK
this spark could cause an explosion of the gases around the

battery. Many newer vehicles have special ground connec-
Safety tions built away from the battery just for the purpose of jump-
Tip starting. Check the owner’s manual or service information for
the exact location.
COMPRESSED AIR SAFETY Batteries contain acid and should be handled with care to
avoid tipping them greater than a 45-degree angle. Always re-
move jewelry when working around a battery to avoid the
Improper use of an air nozzle can cause blindness or deaf- possibility of electrical shock or burns, which can occur when
ness. Compressed air must be reduced to less than 30 PSI the metal comes in contact with a 12-volt circuit and ground,
(206 kPa). See Figure 1-10. If an air nozzle is used to dry such as the body of the vehicle.
and clean parts, make sure the air stream is directed away
from anyone else in the immediate area. Coil and store air
hoses when they are not in use. FIRE EXTINGUISHERS
There are four classes of fire extinguishers. Each class should
be used on specific fires only:
■ Class A is designed for use on general combustibles, such
as cloth, paper, and wood.
■ Class B is designed for use on flammable liquids and
greases, including gasoline, oil, thinners, and solvents.
■ Class C is used only on electrical fires.
■ Class D is effective only on combustible metals such as
powdered aluminum, sodium, or magnesium.
The class rating is clearly marked on the side of every fire

extinguisher. Many extinguishers are good for multiple types
of fires. See Figure 1-11.
When using a fire extinguisher, remember the word “PASS.”
P Pull the safety pin.

FIGURE 1-10 The air pressure going to the nozzle should be reduced A Aim the nozzle of the extinguisher at the base of
to 30 PSI or less. the fire.
Shop Safety 7
or Class C materials. A CO2 fire extinguisher works by

removing the oxygen from the fire and the cold CO2 also
helps reduce the temperature of the fire.
■ Dry chemical (yellow). A dry chemical fire extinguisher
is good for Class A, B, or C fires by coating the flammable
materials, which eliminates the oxygen from the fire. A
dry chemical fire extinguisher tends to be very corrosive
and will cause damage to electronic devices.
FIRE BLANKETS
Fire blankets are required to be available in the shop areas.
If a person is on fire, a fire blanket should be removed from its
storage bag and thrown over and around the victim to smother
the fire. See Figure 1-13 showing a typical fire blanket.
FIGURE 1-11 A typical fire extinguisher designed to be used on class
A,B,or C fires.
FIRST AID AND EYE WASH
STATIONS
All shop areas must be equipped with a first-aid kit and an eye
wash station centrally located and kept stocked with emer-
gency supplies.
First-Aid Kit
A first-aid kit should include:
■ Bandages (variety)
■ Gauze pads
■ Roll gauze
■ Iodine swab sticks
FIGURE 1-12 A CO2 fire extinguisher being used on a fire set in an ■ Antibiotic ointment
open steel drum during a demonstration at a fire department training center. ■ Hydrocortisone cream
■ Burn gel packets
■ Eye wash solution
S Squeeze the lever to actuate the extinguisher. ■ Scissors
S Sweep the nozzle from side-to-side.
■ Tweezers
See Figure 1-12. ■ Gloves
■ First-aid guide
Types of Fire Extinguishers See Figure 1-14. Every shop should have a person trained
in first aid. If there is an accident, call for help immediately.
Types of fire extinguishers include the following:
■
Water. A water fire extinguisher, usually in a pressur- Eye Wash Station
ized container, is good to use on Class A fires by reduc-
ing the temperature to the point where a fire cannot be An eye wash station should be centrally located and used
sustained. whenever any liquid or chemical gets into the eyes. If such an
■ Carbon dioxide (CO2). A carbon dioxide fire extin- emergency does occur, keep eyes in a constant stream of
guisher is good for almost any type of fire, especially Class B water and call for professional assistance. See Figure 1-15.
8 CHAPTER 1
Tech
Tip
MARK OFF THE
SERVICE AREA
Some shops rope off the service bay area to help keep
traffic and distractions to a minimum, which could pre-
vent personal injury. See Figure 1-16.
FIGURE 1-15 A typical eye wash station.Often a thorough flushing of

the eyes with water is the best treatment in the event of eye contamination.
FIGURE 1-13 A treated wool blanket is kept in this easy-to-open
wall-mounted holder and should be placed in a centralized location in
the shop.
FIGURE 1-14 A first-aid box should be centrally located in the shop FIGURE 1-16 This area has been blocked off to help keep visitors from
and kept stocked with the recommended supplies. the dangerous work area.
Shop Safety 9
Summary
1. All service technicians should wear safety glasses that 4. If a fire extinguisher is needed, remember: pull the safety
meet standard ANSI Z87.1. pin, aim the nozzle, squeeze the lever, and sweep the
2. Ear protection should be worn anytime the noise level is nozzle from side-to-side.
at 90 decibels (dB) or higher.
3. Safety should be exercised when working with electrical
cords or when jump-starting another vehicle.
Review Questions
1. List four items that are personal protective equipment (PPE). 3. What items are included in a typical first-aid box?
2. What are the types of fire extinguishers and their usage?
Chapter Quiz
1. What do you call the service technician’s protective head 5. Two technicians are discussing the safe use of a wrench.
cover? Technician A says that a wrench should be pulled toward
a. Cap you. Technician B says that a wrench should be pushed away
from you. Which technician is correct?
b. Hat
a. Technician A only
c. Bump cap
b. Technician B only
d. Helmet
c. Both Technicians A and B
2. All safety glasses should meet the standards set by _____.
d. Neither Technician A nor B
a. ANSI
6. Exhaust hoses should be used because one of the exhaust gases
b. SAE
is deadly in high concentration. This gas is _____.
c. ASE
a. Carbon monoxide (CO)
d. DOT
b. Carbon dioxide (CO2)
3. When washing hands, the water should be at what tempera- c. Hydrocarbons (HC)
ture?
d. Oxides of nitrogen (NOX)
a. 98°F (37°C)
7. The process of combustion occurring without an open flame is
b. 110°F (43°C)
called _____.
c. 125°F (52°C)
a. Direct ignition
d. 135°F (57°C)
b. Non-open flame combustion
4. Hearing protection should be worn anytime the noise level c. Spontaneous combustion
exceeds _____.
d. Cold fusion
a. 60 dB
8. When using a fire extinguisher, what word can be used to
b. 70 dB
remember what to do?
c. 80 dB
a. PASS
d. 90 dB
b. FIRE
c. RED
d. LEVER
10 CHAPTER 1
9. Which type of fire extinguisher is usable for most types of fires? 10. Which item is usually not included in a first-aid kit?
a. CO2 a. Eye wash solution
b. Dry chemical b. Antibiotic cream
c. Water c. Fire blanket
d. CO d. Bandages
CHAPTER 2
ENVIRONMENTAL AND
HAZARDOUS MATERIALS
OBJECTIVES
After studying Chapter 2, the reader will be able to: 3. Explain the term Material Safety Data Sheet (MSDS).
4. Identify hazardous waste materials in accordance with state and
1. Prepare for the ASE assumed knowledge content required by all federal regulations and follow proper safety precautions while
service technicians to adhere to environmentally appropriate handling hazardous waste materials.
actions and behavior.
5. Define the steps required to safely handle and store automotive
2. Define the Occupational Safety and Health Act (OSHA). chemicals and waste.
KEY TERMS
AGST (p. 15) MSDSs (p. 13)
Asbestosis (p. 13) OSHA (p. 13)
BCI (p. 19) RCRA (p. 12)
CAA (p. 13) Right-to-Know Laws (p. 13)
CFR (p. 12) Solvent (p. 16)
EPA (p. 12) Used Oil (p. 15)
HEPA Vacuum (p. 14) UST (p. 15)
Mercury (p. 20) WHMIS (p. 13)
12 CHAPTER 2
Safety and the handling of hazardous waste material are extre- Corrosive
mely important in the automotive shop. The improper han-
dling of hazardous material affects us all, not just those in the If a material burns the skin, or dissolves metals and other ma-
shop. Shop personnel must be familiar with their rights and re- terials, a technician should consider it hazardous. A pH scale
sponsibilities regarding hazardous waste disposal. Right-to- is used, with the number 7 indicating neutral. Pure water has
know laws explain these rights. Shop personnel must also be a pH of 7. Lower numbers indicate an acidic solution and
familiar with hazardous materials in the automotive shop, and higher numbers indicate a caustic solution. If a material re-
the proper way to dispose of these materials according to state leases cyanide gas, hydrogen sulfide gas, or similar gases when
and federal regulations. exposed to low-pH acid solutions, it is considered hazardous.
OCCUPATIONAL SAFETY Toxic

AND HEALTH ACT Materials are hazardous if they leak one or more of eight dif-
ferent heavy metals in concentrations greater than 100 times
The U.S Congress passed the Occupational Safety and
the primary drinking water standard.
Health Act in 1970. This legislation was designed to assist
and encourage the citizens of the United States in their
efforts to assure safe and healthful working conditions by Ignitable
providing research, information, education, and training in
the field of occupational safety and health, as well as to A liquid is hazardous if it has a flash point below 140°F
assure safe and healthful working conditions for working (60°C), and a solid is hazardous if it ignites spontaneously.
men and women by authorizing enforcement of the stan-
dards developed under the act. Since approximately 25% of
workers are exposed to health and safety hazards on the job, Radioactive
the standards are necessary to monitor, control, and educate
workers regarding health and safety in the workplace. Any substance that emits measurable levels of radiation is ra-
dioactive. When individuals bring containers of a highly ra-
dioactive substance into the shop environment, qualified
HAZARDOUS WASTE personnel with the appropriate equipment must test them.
WARNING: Hazardous waste disposal laws include serious penalties for

CAUTION: When handling hazardous waste material, one must always anyone responsible for breaking these laws.
wear the proper protective clothing and equipment detailed in the right-to-
know laws.This includes respirator equipment.All recommended procedures
must be followed accurately.Personal injury may result from improper cloth-
ing,equipment,and procedures when handling hazardous materials. RESOURCE CONSERVATION
AND RECOVERY ACT (RCRA)
Hazardous waste materials are chemicals, or components, that
Federal and state laws control the disposal of hazardous waste
the shop no longer needs that pose a danger to the environment
materials. Every shop employee must be familiar with these
and people if they are disposed of in ordinary garbage cans or
laws. Hazardous waste disposal laws include the Resource
sewers. However, one should note that no material is considered
Conservation and Recovery Act (RCRA). This law states
hazardous waste until the shop has finished using it and is ready
that hazardous material users are responsible for hazardous
to dispose of it. The Environmental Protection Agency
materials from the time they become a waste until the proper
(EPA) publishes a list of hazardous materials that is included in
waste disposal is completed. Many shops hire an independent
the Code of Federal Regulations (CFR). The EPA considers
hazardous waste hauler to dispose of hazardous waste mate-
waste hazardous if it is included on the EPA list of hazardous
rial. The shop owner, or manager, should have a written con-
materials, or it has one or more of the following characteristics.
tract with the hazardous waste hauler. Rather than have
hazardous waste material hauled to an approved hazardous
Reactive waste disposal site, a shop may choose to recycle the material
in the shop. Therefore, the user must store hazardous waste
Any material which reacts violently with water or other chem- material properly and safely, and be responsible for the trans-
icals is considered hazardous. portation of this material until it arrives at an approved
Environmental and Hazardous Materials 13
hazardous waste disposal site, where it can be processed

according to the law. The RCRA controls these types of auto-
motive waste:
■ Paint and body repair products waste
■ Solvents for parts and equipment cleaning
■ Batteries and battery acid
■ Mild acids used for metal cleaning and preparation
■ Waste oil, and engine coolants or antifreeze
■ Air-conditioning refrigerants and oils
■ Engine oil filters
The right-to-know laws state that employees have a
right to know when the materials they use at work are haz-
ardous. The right-to-know laws started with the Hazard Com-
munication Standard published by the Occupational Safety
and Health Administration (OSHA) in 1983. Originally,
this document was intended for chemical companies and man-
ufacturers that required employees to handle hazardous mate-
rials in their work situation. Meanwhile, the federal courts
have decided to apply these laws to all companies, including FIGURE 2-1 Material Safety Data Sheets (MSDSs) should be readily
automotive service shops. Under the right-to-know laws, the available for use by anyone in the area who may come into contact with haz-
employer has responsibilities regarding the handling of hazardous materials.
ardous materials by their employees. All employees must be
trained about the types of hazardous materials they will en-
counter in the workplace. The employees must be informed
about their rights under legislation regarding the handling of
hazardous materials. health hazards, medical conditions aggravated by exposure,
emergency and first-aid procedures, safe handling, and
spill/leak procedures.
CLEAN AIR ACT The employer also has a responsibility to make sure that
all hazardous materials are properly labeled. The label infor-
Air-conditioning (A/C) systems and refrigerant are regulated mation must include health, fire, and reactivity hazards posed
by the Clean Air Act (CAA), Title VI, Section 609. Techni- by the material, as well as the protective equipment necessary
cian certification and service equipment is also regulated. Any to handle the material. The manufacturer must supply all
technician working on automotive A/C systems must be cer- warning and precautionary information about hazardous ma-
tified. A/C refrigerants must not be released or vented into the terials. This information must be read and understood by the
atmosphere, and used refrigerants must be recovered. employee before handling the material.
MATERIAL SAFETY DATA THE DANGERS OF

SHEETS (MSDSS) EXPOSURE TO ASBESTOS
All hazardous materials must be properly labeled, and infor- Friction materials such as brake and clutch linings often con-
mation about each hazardous material must be posted on tain asbestos. While asbestos has been eliminated from most
Material Safety Data Sheets (MSDSs) available from the original-equipment friction materials, the automotive service
manufacturer. See Figure 2-1. In Canada, MSDSs are called technician cannot know whether or not the vehicle being
Workplace Hazardous Materials Information Systems serviced is or is not equipped with friction materials contain-
(WHMIS). ing asbestos. It is important that all friction materials be han-
The employer has a responsibility to place MSDSs where dled as if they do contain asbestos.
they are easily accessible by all employees. The MSDSs pro- Asbestos exposure can cause scar tissue to form in the
vide the following information about the hazardous material: lungs. This condition is called asbestosis. It gradually causes
chemical name, physical characteristics, protective handling increasing shortness of breath, and the scarring to the lungs is
equipment, explosion/fire hazards, incompatible materials, permanent.
14 CHAPTER 2
Even low exposures to asbestos can cause mesothelioma, ASBESTOS HANDLING

a type of fatal cancer of the lining of the chest or abdominal
cavity. Asbestos exposure can also increase the risk of lung GUIDELINES
cancer as well as cancer of the voice box, stomach, and large
intestine. It usually takes 15 to 30 years or more for cancer or The air in the shop area can be tested by a testing laboratory,
asbestos lung scarring to show up after exposure. (Scientists but this can be expensive. Tests have determined that asbestos
call this the latency period.) levels can easily be kept below the recommended levels by us-
Government agencies recommend that asbestos expo- ing a solvent or a special vacuum.
sure should be eliminated or controlled to the lowest level
possible. These agencies have developed recommenda-
NOTE: Even though asbestos is being removed from brake and clutch lin-
tions and standards that the automotive service technician
ing materials,the service technician cannot tell whether or not the old brake
and equipment manufacturer should follow. These U.S. pads,shoes,or clutch disc contain asbestos.Therefore,to be safe,the techni-
federal agencies include the National Institute for Occupa- cianshouldassumethatallbrakepads,shoes,orclutchdiscscontainasbestos.
tional Safety and Health (NIOSH), Occupational Safety
and Health Administration (OSHA), and Environmental
Protection Agency (EPA).
HEPA Vacuum
ASBESTOS OSHA A special high-efficiency particulate air (HEPA) vacuum
STANDARDS system has been proven to be effective in keeping asbestos ex-
posure levels below 0.1 fibers per cubic centimeter.
The Occupational Safety and Health Administration (OSHA)
has established three levels of asbestos exposure. Any vehi-
cle service establishment that does either brake or clutch
Solvent Spray
work must limit employee exposure to asbestos to less than
Many technicians use an aerosol can of brake cleaning solvent
0.2 fibers per cubic centimeter (cc) as determined by an air
to wet the brake dust and prevent it from becoming airborne.
sample.
Commercial brake cleaners are available that use a concen-
If the level of exposure to employees is greater than spec-
trated cleaner that is mixed with water. See Figure 2-2.
ified, corrective measures must be performed and a large fine
The waste liquid is filtered, and, when dry, the filter can
may be imposed.
be disposed of as solid waste.
NOTE: Research has found that worn asbestos fibers such as those from
automotive brakes or clutches may not be as hazardous as first believed.
Worn asbestos fibers do not have sharp, flared ends that can latch onto tis-
sue, but rather are worn down to a dust form that resembles talc. Grinding
or sawing operations on unworn brake shoes or clutch discs will contain
harmful asbestos fibers. To limit health damage, always use proper han-
dling procedures while working around any component that may contain
asbestos.
ASBESTOS EPA
REGULATIONS
The federal Environmental Protection Agency (EPA) has estab-
lished procedures for the removal and disposal of asbestos.
The EPA procedures require that products containing asbestos
be “wetted” to prevent the asbestos fibers from becoming air-
borne. According to the EPA, asbestos-containing materials
can be disposed of as regular waste. Only when asbestos be- FIGURE 2-2 All brakes should be moistened with water or solvent to
comes airborne is it considered to be hazardous. help prevent brake dust from becoming airborne.
■ Use. The second criterion is based on whether and how

CAUTION: Never use compressed air to blow brake dust. The fine, talc- the oil is used. Oils used as lubricants, hydraulic fluids, heat-
like brake dust can create a health hazard even if asbestos is not present or is transfer fluids, and for other similar purposes are consid-
present in dust rather than fiber form. ered used oil. Unused oil, such as bottom clean-out waste
from virgin fuel oil storage tanks or virgin fuel oil recovered
from a spill, does not meet the EPA’s definition of used oil
because these oils have never been “used.” The EPA’s def-
Disposal of Brake Dust inition also excludes products used as cleaning agents, as
well as certain petroleum-derived products such as an-
and Brake Shoes tifreeze and kerosene.
The hazard of asbestos occurs when asbestos fibers are air-
■ Contaminants. The third criterion is based on whether
borne. Once the asbestos has been wetted down, it is then or not the oil is contaminated with either physical or
considered to be solid waste, rather than hazardous waste. chemical impurities. In other words, to meet the EPA’s
Old brake shoes and pads should be enclosed, preferably in a definition, used oil must become contaminated as a result
plastic bag, to help prevent any of the brake material from be- of being used. This aspect of the EPA’s definition includes
coming airborne. Always follow current federal and local laws residues and contaminants generated from handling, stor-
concerning disposal of all waste. ing, and processing used oil.
USED BRAKE FLUID NOTE: The release of only 1 gallon of used oil (a typical oil change) can
make a million gallons of fresh water undrinkable.
Most brake fluid is made from polyglycol, is water soluble, and
can be considered hazardous if it has absorbed metals from the
brake system. If used oil is dumped down the drain and enters a sewage
treatment plant, concentrations as small as 50 to 100 PPM
■ Collect brake fluid in containers clearly marked to indicate
(parts per million) in the waste water can foul sewage treat-
that they are dedicated for that purpose.
ment processes. Never mix a listed hazardous waste, gasoline,
■ If your waste brake fluid is hazardous, manage it appro- waste water, halogenated solvent, antifreeze, or an unknown
priately and use only an authorized waste receiver for its waste material with used oil. Adding any of these substances
disposal. will cause the used oil to become contaminated, which classi-
■ If your waste brake fluid is nonhazardous (such as old, but fies it as hazardous waste.
unused), determine from your local solid waste collection
provider what should be done for its proper disposal.
■ Do not mix brake fluid with used engine oil.
DISPOSAL OF USED OIL
■ Do not pour brake fluid down drains or onto the ground. Once oil has been used, it can be collected, recycled, and
■ Recycle brake fluid through a registered recycler. used over and over again. An estimated 380 million gallons
of used oil are recycled each year. Recycled used oil can some-
times be used again for the same job or can take on a com-
USED OIL pletely different task. For example, used engine oil can be
re-refined and sold at the store as engine oil or processed for
Used oil is any petroleum-based or synthetic oil that has been furnace fuel oil. After collecting used oil in an appropriate
used. During normal use, impurities such as dirt, metal scrap- container (e.g., a 55-gallon steel drum), the material must be
ings, water, or chemicals can get mixed in with the oil. Even- disposed of in one of two ways:
tually, this used oil must be replaced with virgin or re-refined
oil. The EPA’s used oil management standards include a three- ■ Shipped offsite for recycling
pronged approach to determine if a substance meets the defi- ■ Burned in an onsite or offsite EPA-approved heater for
nition of used oil. To meet the EPA’s definition of used oil, a energy recovery
substance must meet each of the following three criteria:
■ Origin. The first criterion for identifying used oil is based USED OIL STORAGE
on the oil’s origin. Used oil must have been refined from
crude oil or made from synthetic materials. Animal and Used oil must be stored in compliance with an existing
vegetable oils are excluded from the EPA’s definition of underground storage tank (UST) or an aboveground
used oil. storage tank (AGST) standard, or kept in separate containers.
16 CHAPTER 2
After the oil has been drained from the oil filter, the
filter housing can be disposed of in any of the following ways:
■ Sent for recycling
■ Pickup by a service contract company
■ Disposed of in regular trash
SOLVENTS
The major sources of chemical danger are liquid and aerosol
brake cleaning fluids that contain chlorinated hydrocarbon
solvents. Several other chemicals that do not deplete the
ozone, such as heptane, hexane, and xylene, are now being
used in nonchlorinated brake cleaning solvents. Some
manufacturers are also producing solvents they describe as
FIGURE 2-3 A typical aboveground oil storage tank. environmentally responsible, which are biodegradable and
noncarcinogenic.
See Figure 2-3. Containers are portable receptacles, such as a

55-gallon steel drum. Sources of Chemical Poisoning
The health hazards presented by brake cleaning solvents occur
Keep Used Oil Storage Drums from three different forms of exposure: ingestion, inhalation,
in Good Condition and physical contact. It should be obvious that swallowing
brake cleaning solvent is harmful, and such occurrences are not
This means that they should be covered, secured from vandals, common. Still, brake cleaning solvents should always be han-
properly labeled, and maintained in compliance with local fire dled and stored properly, and kept out of the reach of children.
codes. Frequent inspections for leaks, corrosion, and spillage The dangers of inhalation are perhaps the most serious prob-
are an essential part of container maintenance. lem, as even very low levels of solvent vapors are hazardous.
Allowing brake cleaning solvents to come in contact with
the skin presents a danger because these solvents strip natural
Never Store Used Oil in Anything oils from the skin and cause irritation of the tissues, plus they
Other Than Tanks and Storage can be absorbed through the skin directly into the blood-
stream. The transfer begins immediately upon contact, and
Containers continues until the liquid is wiped or washed away.
There is no specific standard for physical contact with
Used oil may also be stored in units that are permitted to store
chlorinated hydrocarbon solvents or the chemicals replacing
regulated hazardous waste.
them. All contact should be avoided whenever possible.
The law requires an employer to provide appropriate protec-
Used Oil Filter Disposal tive equipment and ensure proper work practices by an em-
ployee handling these chemicals.
Regulations
Used oil filters contain used engine oil that may be hazardous. Effects of Chemical Poisoning
Before an oil filter is placed into the trash or sent to be recycled,
it must be drained using one of the following hot-draining The effects of exposure to chlorinated hydrocarbon and other
methods approved by the EPA: types of solvents can take many forms. Short-term exposure at
low levels can cause headache, nausea, drowsiness, dizziness,
■ Puncturing the filter anti-drainback valve or filter dome
lack of coordination, or unconsciousness. It may also cause
end and hot draining for at least 12 hours
irritation of the eyes, nose, and throat, and flushing of the face
■ Hot draining and crushing and neck. Short-term exposure to higher concentrations can
■ Dismantling and hot draining cause liver damage with symptoms such as yellow jaundice or
■ Any other hot draining method that will remove all the dark urine. Liver damage may not become evident until sev-
used oil from the filter eral weeks after the exposure.
Health Care Rights SOLVENT HAZARDOUS

The OSHA regulations concerning on-the-job safety place cer-
AND REGULATORY STATUS
tain responsibilities on the employer, and give employees spe-
Most solvents are classified as hazardous wastes. Other char-
cific rights. Any person who feels there might be unsafe
acteristics of solvents include the following:
conditions where he or she works, whether asbestos expo-
sure, chemical poisoning, or any other problem, should dis- ■ Solvents with flash points below 140°F (60°C) are consid-
cuss the issue with fellow workers, union representatives ered flammable and, like gasoline, are federally regulated
(where applicable), and his or her supervisor or employer. If no by the Department of Transportation (DOT).
action is taken and there is reason to believe the employer is ■ Solvents and oils with flash points above 140°F (60°C) are
not complying with OSHA standards, a complaint can be filed considered combustible and, like engine oil, are also reg-
with OSHA and it will investigated. ulated by the DOT. See Figure 2-5.
The law forbids employers from taking action against em-
ployees who file a complaint concerning a health or safety haz- It is the responsibility of the repair shop to determine if its
ard. However, if workers fear reprisal as the result of a spent solvent is hazardous waste. Waste solvents that are con-
complaint, they may request that OSHA withhold their names sidered hazardous waste have a flash point below 140°F (60°C).
from the employer. Hot water or aqueous parts cleaners may be used to avoid dis-
posing of spent solvent as hazardous waste. Solvent-type parts
cleaners with filters are available to greatly extend solvent life
and reduce spent-solvent disposal costs. Solvent reclaimers are
Safety available that clean and restore the solvent so that it lasts
indefinitely.
Tip
HAND SAFETY USED SOLVENTS
Used or spent solvents are liquid materials that have been gen-
Service technicians should wash their hands with soap erated as waste and may contain xylene, methanol, ethyl ether,
and water after handling engine oil or differential or and methyl isobutyl ketone (MIBK). These materials must be
transmission fluids, or wear protective rubber gloves. stored in OSHA-approved safety containers with the lids or caps
Another safety hint is that the service technician should closed tightly. These storage receptacles must show no signs of
not wear watches, rings, or other jewelry that could leaks or significant damage due to dents or rust. In addition, the
come in contact with electrical or moving parts of a
vehicle. See Figure 2-4.
FIGURE 2-4 Washing hands and removing jewelry are two impor-
tant safety habits all service technicians should practice. FIGURE 2-5 Typical fireproof flammable storage cabinet.
18 CHAPTER 2
FIGURE 2-7 Used antifreeze coolant should be kept separate and

stored in a leakproof container until it can be recycled or disposed of according
to federal, state, and local laws. Note that the storage barrel is placed inside
another container to catch any coolant that may spill out of the inside barrel.
FIGURE 2-6 All solvents and other hazardous waste should be
disposed of properly.
aluminum, copper, brass, and lead (from older radiators and
heater cores).
containers must be stored in a protected area equipped with sec- 1. Coolant should be recycled either onsite or offsite.
ondary containment or a spill protector, such as a spill pallet. 2. Used coolant should be stored in a sealed and labeled
Additional requirements include the following: container. See Figure 2-7.
3. Used coolant can often be disposed of into municipal
■ Containers should be clearly labeled “Hazardous Waste”
sewers with a permit. Check with local authorities and
and the date the material was first placed into the storage
obtain a permit before discharging used coolant into
receptacle should be noted.
sanitary sewers.
■ Labeling is not required for solvents being used in a parts
washer.
■ Used solvents will not be counted toward a facility’s LEAD–ACID BATTERY WASTE
monthly output of hazardous waste if the vendor under
contract removes the material. About 70 million spent lead–acid batteries are generated each
■ Used solvents may be disposed of by recycling with a year in the United States alone. Lead is classified as a toxic
local vendor, such as SafetyKleen, to have the used solvent metal and the acid used in lead–acid batteries is highly corro-
removed according to specific terms in the vendor agree- sive. The vast majority (95% to 98%) of these batteries are
ment. See Figure 2-6. recycled through lead reclamation operations and secondary
■ Use aqueous-based (nonsolvent) cleaning systems to help lead smelters for use in the manufacture of new batteries.
avoid the problems associated with chemical solvents.
BATTERY HAZARDOUS AND
COOLANT DISPOSAL REGULATORY STATUS
Coolant is a mixture of antifreeze and water. New antifreeze Used lead–acid batteries must be reclaimed or recycled in or-
is not considered to be hazardous even though it can cause der to be exempt from hazardous waste regulations. Leaking
death if ingested. Used antifreeze may be hazardous due to batteries must be stored and transported as hazardous waste.
dissolved metals from the engine and other components of Some states have more strict regulations, which require spe-
the cooling system. These metals can include iron, steel, cial handling procedures and transportation. According to the
Battery Council International (BCI), battery laws usually

include the following rules:
■ Lead–acid battery disposal is prohibited in landfills or in-
cinerators. Batteries are required to be delivered to a bat-
tery retailer, wholesaler, recycling center, or lead smelter.
■ All retailers of automotive batteries are required to post a
sign that displays the universal recycling symbol and indi-
cates the retailer’s specific requirements for accepting
used batteries.
CAUTION: Battery electrolyte contains sulfuric acid,which is a very cor-

rosive substance capable of causing serious personal injury, such as skin
burns and eye damage.In addition,the battery plates contain lead,which is
highly poisonous.For this reason,disposing of batteries improperly can cause
environmental contamination and lead to severe health problems.
BATTERY HANDLING
AND STORAGE
Batteries, whether new or used, should be kept indoors if possi-
ble. The storage location should be an area specifically designated
for battery storage and must be well ventilated (to the outside).
If outdoor storage is the only alternative, a sheltered and secured FIGURE 2-8 This red gasoline container holds about 30 gallons of
area with acid-resistant secondary containment is strongly rec- gasoline and is used to fill vehicles used for training.
ommended. It is also advisable that acid-resistant secondary
containment be used for indoor storage. In addition, batteries at higher temperatures. If gasoline containers are com-
should be placed on acid-resistant pallets and never stacked! pletely full, the gasoline will expand when the tempera-
ture increases. This expansion forces gasoline from the
can and creates a dangerous spill. If gasoline or diesel fuel
FUEL SAFETY AND STORAGE containers must be stored, place them in a designated stor-
age locker or facility.
Gasoline is a very explosive liquid. The expanding vapors that ■ Never leave gasoline containers open, except while filling
come from gasoline are extremely dangerous. These vapors
or pouring gasoline from the container.
are present even in cold temperatures. Vapors formed in gaso-
line tanks on many vehicles are controlled, but vapors from
■ Never use gasoline as a cleaning agent.
gasoline storage may escape from the can, resulting in a haz- ■ Always connect a ground strap to containers when filling
ardous situation. Therefore, place gasoline storage containers or transferring fuel or other flammable products from one
in a well-ventilated space. Although diesel fuel is not as container to another to prevent static electricity that could
volatile as gasoline, the same basic rules apply to diesel fuel result in explosion and fire. These ground wires prevent
and gasoline storage. These rules include the following: the buildup of a static electric charge, which could result
in a spark and disastrous explosion.
■ Approved gasoline storage cans have a flash-arresting
screen at the outlet. These screens prevent external igni-
tion sources from igniting the gasoline within the can AIRBAG HANDLING
when someone pours the gasoline or diesel fuel.
■ Technicians must always use red approved gasoline con- Airbag modules are pyrotechnic devices that can be ignited if
tainers to allow for proper hazardous substance identifica- exposed to an electrical charge or if the body of the vehicle is
tion. See Figure 2-8. subjected to a shock. Airbag safety should include the follow-
ing precautions:
■ Do not fill gasoline containers completely full. Always
leave the level of gasoline at least 1 inch from the top of 1. Disarm the airbag(s) if you will be working in the area
the container. This action allows expansion of the gasoline where a discharged bag could make contact with any
20 CHAPTER 2
part of your body. Consult service information for the

exact procedure to follow for the vehicle being serv-
iced. The usual procedure is to deploy the airbag using
a 12-volt power supply, such as a jump-start box, using
long wires to connect to the module to ensure a safe
deployment.
2. Do not expose an airbag to extreme heat or fire.
3. Always carry an airbag pointing away from your body.
4. Place an airbag module facing upward.
5. Always follow the manufacturer’s recommended proce-
dure for airbag disposal or recycling, including the proper
packaging to use during shipment.
6. Always wash your hands or body well if exposed to a
deployed airbag. The chemicals involved can cause skin
irritation and possible rash development.
7. Wear protective gloves if handling a deployed airbag.
FIGURE 2-9 Air-conditioning refrigerant oil must be kept separate
from other oils because it contains traces of refrigerant and must be treated as
USED TIRE DISPOSAL hazardous waste.
Used tires are an environmental concern for several reasons,

including the following: Tech
1. In a landfill, they tend to “float” up through the other
trash and rise to the surface.
Tip
2. The inside of tires traps and holds rainwater, which is a REMOVE
breeding ground for mosquitoes. Mosquito-borne dis- COMPONENTS THAT
eases include encephalitis and dengue fever. CONTAIN MERCURY
3. Used tires present a fire hazard and, when burned, create
a large amount of black smoke that contaminates the air. Some vehicles have a placard near the driver’s side door
Used tires should be disposed of in one of the following ways: that lists the components that contain mercury, a heavy
metal. See Figure 2-10.
1. Used tires can be reused until the end of their useful life. These components should be removed from the ve-
2. Tires can be retreaded. hicle before the rest of the body is sent to be recycled to
3. Tires can be recycled or shredded for use in asphalt. help prevent the release of mercury into the environment.
4. Derimmed tires can be sent to a landfill (most landfill
operators will shred the tires because it is illegal in many
states to landfill whole tires).
5. Tires can be burned in cement kilns or other power
plants where the smoke can be controlled.
6. A registered scrap tire handler should be used to trans-
port tires for disposal or recycling.
AIR-CONDITIONING
REFRIGERANT OIL
DISPOSAL
Air-conditioning refrigerant oil contains dissolved refrigerant
and is therefore considered to be hazardous waste. This oil
must be kept separate from other waste oil or the entire
amount of oil must be treated as hazardous. Used refrigerant
oil must be sent to a licensed hazardous waste disposal com- FIGURE 2-10 Placard near driver’s door listing the devices in the
pany for recycling or disposal. See Figure 2-9. vehicle that contain mercury.
Waste Chart
Tech
All automotive service facilities create some waste and while
Tip most of it is handled properly, it is important that all hazardous
and nonhazardous waste be accounted for and properly dis-
WHAT EVERY posed. See the chart for a list of typical wastes generated at au-
TECHNICIAN tomotive shops, plus a checklist for keeping track of how these
SHOULD KNOW wastes are handled.
The Hazardous Material Identification Guide (HMIG) is

the standard labeling for all materials. The service tech-
nician should be aware of the meaning of the label. See
Figure 2-11.
Hazardous Materials Identification Guide (HMIG)

HEALTH 4 - Extreme
TYPE HAZARD
FLAMMABILITY 3 - Serious
DEGREE
REACTIVITY 2 - Moderate
PROTECTIVE 1 - Slight
EQUIPMENT 0 - Minimal
HAZARD RATING AND PROTECTIVE EQUIPMENT

Health Flammable Reactive
Susceptibility of materials Susceptibility of materials
Type of Possible Injury
to burn to release energy
Highly Toxic. May be fatal on
Extremely flammable gas or liquid. Extreme. Explosive at room
4 short term exposure. Special
protective equipment required.
4 Flash Point below 73F. 4 temperature.
Serious. May explode if

Toxic. Avoid inhalation or skin Flammable. Flash Point 73F to
3 contact. 3 100F. 3 shocked, heated under
confinement or mixed w/ water.
Combustible. Requires moderate

Moderately Toxic. May be Moderate. Unstable, may
2 harmful if inhaled or absorbed. 2 heating to ignite. Flash Point
100F to 200F.
2 react with water.
Slightly Toxic. May cause slight Slightly Combustible. Requires Slight. May react if heated or
1 irritation. 1 strong heating to ignite. 1 mixed with water.
Minimal. All chemicals have a Minimal. Will not burn under Minimal. Normally stable,
0 slight degree of toxicity. 0 normal conditions. 0 does not react with water.
Protective Equipment
sp Vap n
Re t & atio
r
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FIGURE 2-11 The Environmental Protection Agency (EPA) Hazardous Materials Identification Guide is a standardized listing of the hazards and the protective
equipment needed.
22 CHAPTER 2
Typical Wastes Generated at Auto Repair Shops and Typical Category

(Hazardous or Nonhazardous) by Disposal Method
Typical Category if Not If Disposed in Landfill and

Mixed with Other Hazardous Not Mixed with a Hazardous
Waste Stream Waste Waste If Recycled
Used oil Used oil Hazardous waste Used oil
Used oil filters Nonhazardous solid waste, if Nonhazardous solid waste, if Used oil, if not drained
completely drained completely drained
Used transmission fluid Used oil Hazardous waste Used oil
Used brake fluid Used oil Hazardous waste Used oil
Used antifreeze Depends on characterization Depends on characterization Depends on characterization
Used solvents Hazardous waste Hazardous waste Hazardous waste
Used citric solvents Nonhazardous solid waste Nonhazardous solid waste Hazardous waste
Lead–acid automotive Not a solid waste if returned to Hazardous waste Hazardous waste
batteries supplier
Shop rags used for oil Used oil Depends on used oil Used oil
characterization
Shop rags used for solvent Hazardous waste Hazardous waste Hazardous waste
or gasoline spills
Oil spill absorbent material Used oil Depends on used oil Used oil
characterization
Spill material for solvent Hazardous waste Hazardous waste Hazardous waste
and gasoline
Catalytic converter Not a solid waste if returned to Nonhazardous solid waste Nonhazardous solid waste
supplier
Spilled or unused fuels Hazardous waste Hazardous waste Hazardous waste
Spilled or unusable paints Hazardous waste Hazardous waste Hazardous waste
and thinners
Used tires Nonhazardous solid waste Nonhazardous solid waste Nonhazardous solid waste
Consolidated Screening Checklist for Automotive Repair Facilities
1. Waste Management
Has the facility determined which wastes are hazardous wastes? yes/no
Waste Does the facility generate more than 100 kg (220 lbs.) of yes/no
Management hazardous waste per month?
If yes, does the facility have a U.S. EPA hazardous waste yes/no
generator I.D. number?
Are used oil containers and piping leak free, segregated, and yes/no
labeled “used oil”?
Are hazardous waste fluids mixed with used oil? yes/no
Used Oil Is used oil collected and sent offsite for recycling, or burned in recycle/onsite heater/burned
an onsite heater? offsite/other
Does the facility accept household used oil? yes/no
If yes, is it tested for hazardous waste (solvent/gasoline) yes/no
contamination?
Used Oil Are used oil filters completely drained before disposal? yes/no
Filters
How are used oil filters disposed of? scrap metal/service/trash/other
Is used antifreeze properly contained, segregated, and labeled? yes/no
Does the facility generate any antifreeze that is a hazardous yes/no/do not know
waste (>5 PPM lead)?
Used
Antifreeze If yes, is it recycled onsite in a closed-loop system? yes/no
If no, is it counted toward facility generator status? yes/no
If used antifreeze is not recycled onsite, how is it disposed of? recycled offsite/mixed with other
fluids/landfill/other
Are used solvents stored in proper containers and properly yes/no/N/A
labeled?
Used Solvents How are used solvents disposed of? service/mixed with other fluids/other
Does the facility have hazardous waste manifests for shipping yes/no/N/A
papers on file?
Does the facility return used batteries to new battery suppliers? yes/no/N/A
Batteries If not, how are used automotive batteries disposed of? recycle/hazardous waste landfill/other
Are used batteries contained and covered prior to disposal? yes/no
How are used rags and towels disposed of? laundry service/burned for heat/trash
Rags
How are used rags stored while onsite? separate container/shop trash can/floor
Tires How are used tires disposed of? resale/retreading/landfill/customer/

N/A/other
(Continued)
24 CHAPTER 2
Consolidated Screening Checklist for Automotive Repair Facilities (Continued)
Does the facility use sawdust or other absorbents for spills or yes/no
leaks?
Does the facility determine whether used absorbents are yes/no
Absorbents considered hazardous before disposal?
How are absorbents used for oil spills disposed of? N/A/burned for energy/disposed of as
hazardous waste/characterized as
nonhazardous and landfilled
2. Wastewater Management
How does the facility clean shop floor and surrounding area? uses dry cleanup/uses water
Are fluids (oil, antifreeze, solvent) allowed to enter floor drains yes/no/no floor drains onsite
for disposal?
How are fluids disposed of? municipal sanitary sewer/storm
Floor Drains sewer/street/other
and If floor drains discharge to municipal sanitary sewer, to storm yes/no
Wastewater sewer system, or the street, has the facility notified Publicly
Management Owned Treatment Works (POTW) about potential contamination
in wash water?
If drains discharge directly to surface waters or to an yes/no/N/A
underground injection well, does the facility have a National
Pollutant Discharge Elimination System (NPDES) (surface) or
UIC (underground) permit?
Does the facility store parts, fluids, and/or other materials yes/no
outside?
Stormwater
Are materials protected from rain/snow in sealed containers or yes/no/N/A
under tarp or roof?
3. Air Pollution Control
If the facility uses parts-cleaning sinks with halogenated solvents, yes/no/N/A
has the facility submitted a notification report to the EPA?
Parts Cleaners Are sinks kept closed and sealed except when actually used for yes/no
cleaning parts?
Does the facility follow required work and operational practices? yes/no
Are Mobile Vehicle Air Conditioning MVAC technicians trained yes/no/N/A
and certified by an accredited program?
Motor Vehicle If yes, are certificates on file? yes/no
Air
Conditioning Is CFC recovery and/or recycling equipment EPA approved? yes/no/N/A
(CFCs) Is equipment recovery/recycling or recovery only? (circle one) recovery/recycling/recovery only/N/A
If recovery only, is refrigerant reclaimed by an EPA-approved yes/no
reclaimer?
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Automotive Engines Diagnosis Repair Rebuilding 6th Edition

Automotive Chassis Systems 5th Edition James D. Halderman

Automotive Steering Suspension and Alignment 5th Edition

Diagnosis Tblshtg of Auto Elect Electronic Systs 6th ed.

The Science and Technology of Materials in Automotive

Automotive Technology A Systems Approach 6th Edition Jack

Automotive Paints and Coatings Streitberger H.-J. (Ed.)

Video and Camcorder Servicing and Technology 5th Edition

Upper Saddle River, New Jersey

Editor in Chief: Vernon Anthony

Pearson Prentice Hall™ is a trademark of Pearson Education, Inc.

Pearson Education Ltd., London Pearson Education Australia Pty. Limited

Professional Technician ■ A new chapter on preparation for assembly (Chapter 29)

updates to the sixth edition A Complete Instructor and

NOTES provide students with additional technical

CAUTIONS alert students about potential damage

WARNING: Hazardous waste disposal laws include serious penalties for

STEP-BY-STEP photo sequences show in detail the

The SUMMARY, REVIEW QUESTIONS, AND c. 80 dB

CHAPTER QUIZ at the end of each chapter help c. RED

students review the material presented in the

To access supplmentary materials online, instructors need

Kerry Meier Photo Sequences

Chapter 1 SHOP SAFETY 1 Chapter 16 IGNITION SYSTEM OPERATION

Chapter 8 SERVICE INFORMATION 97 Chapter 22 CYLINDER HEAD AND VALVE

Chapter 10 GASOLINE ENGINE OPERATION, Chapter 24 CAMSHAFTS AND VALVE

Chapter 11 GASOLINE AND ALTERNATIVE Chapter 25 PISTONS, RINGS, AND CONNECTING

Chapter 12 DIESEL ENGINE OPERATION Chapter 26 ENGINE BLOCKS 499

Chapter 15 STARTING AND CHARGING SYSTEM Chapter 30 ENGINE BLUEPRINTING AND

Appendix 2 ASE TEST CORRELATION CHART 625 INDEX 667

Pliers 51 Linear Measurements (Tape

Chapter 5 POWER TOOLS AND SHOP Chapter 8 SERVICE INFORMATION 97

Summary 112 Biodiesel 153

Hydrometer Testing 187 Changing Oil in a Turbocharged Engine 216

Pickup Coil Testing 270 Summary 310

Objectives 285 Chapter 19 TURBOCHARGING

Wet Compression Test 344 Crack Repair 367

Valve Keepers 410 Solid Lifters 467

Engine Block Service 505 Chapter 29 PREPARATION FOR ASSEMBLY 557

Installing the Oil Pump 589 Engine Start 602

■ Mechanic’s gloves. These gloves are usually made of syn-

SAFETY TIPS FOR

FIGURE 1-6 Always connect an exhaust hose to the tailpipe of the

FIGURE 1-7b A commercially available hood clamp.This tool uses a

Always dispose of oily shop cloths in an enclosed container

Safe Use of Chemical Cleaning. A face shield should be

Safe Use of Abrasive Cleaners. Always wear a protec-

this spark could cause an explosion of the gases around the

The class rating is clearly marked on the side of every fire

P Pull the safety pin.

or Class C materials. A CO2 fire extinguisher works by

FIGURE 1-15 A typical eye wash station.Often a thorough flushing of

OCCUPATIONAL SAFETY Toxic

WARNING: Hazardous waste disposal laws include serious penalties for

hazardous waste disposal site, where it can be processed

MATERIAL SAFETY DATA THE DANGERS OF

Even low exposures to asbestos can cause mesothelioma, ASBESTOS HANDLING