Automotive Engines Diagnosis Repair and Rebuilding 7th edition by Tim Gilles – Ebook PDF Instant Download/Delivery: 1285441745, 978-1285441740
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ISBN 10: 1285441745
ISBN 13: 978-1285441740
Author: Tim Gilles
This complete textbook provides detailed content on the theory of operation, diagnosis, repair, and rebuilding of automotive engines. In addition to essential technical expertise, the text helps users develop the skills and knowledge they need for professional success, including critical thinking and awareness of key industry trends and practices. The text emphasizes universal repair techniques and case histories based on real-world scenarios to prepare users for careers in the field. Instructor resources include lesson plans, customizable lab sheets that address NATEF Standards, a customizable test bank with questions based on chapter content, presentations in PowerPoint, and more. Now updated with new, full-color images and information on the latest trends, tools, and technology�including hybrid engines and high-performance components�AUTOMOTIVE ENGINES: DIAGNOSIS, REPAIR, REBUILDING, Seventh Edition, is the ideal resource for automotive programs who want a complete teaching package for their Engines course.
Automotive Engines Diagnosis Repair and Rebuilding 7th Table of contents:
Section 1. Engine Construction, Diagnosis, Disassembly, and Inspection
Chapter 1. Engine Operation
Simple Engine
Four Stroke Engine Operation
Cylinder Arrangement
Valvetrain
Cylinder Block
Sand Casting
Lost Foam Casting
Core Plugs and Gussets
V-Type Cylinder Banks
Short Block and Long Block
Front-Wheel Drive
Engine Classifications
Valve Arrangement
Cam-in-Block or Overhead Cam
Combustion Chamber Designs
Direction of Crankshaft Rotation
Firing Order
Companion Cylinders
Engine Cooling
Spark and Compression Ignition
Diesel Engine
Gasoline Direct Injection Systems
Two Stroke Cycle
Putting It All Together
High-Performance Engine Trivia
Key Terms
Study Questions
ASE-Style Review Questions
Chapter 2. Engine Shop Safety
General Shop Health and Safety
General Personal Safety
Eye Protection
Eyewash
Back Safety
Ear Protection
Clothing and Hair Protection
Shoes or Boots
Shop Cleanliness
Shop Towels
Spills and Oil Leaks
Absorbing Spills
Fire Prevention
Fire Extinguishers
Flammable Materials
Fuel Fires
Electrical Fires
Fuel Fires
Electric Shock
General Hybrid Safety
Coolant Burns
Cooling Fans
Safety Check before Test Drive
Tool and Equipment Safety
Hand Tool Safety
Puller Safety
Press Safety
Air Tool Safety
Impact Wrenches
Air Chisel
Die Grinder
Electric Machinery
General Machinery Safety
Drill Safety
Grinder Safety
Lifting Equipment
Hydraulic Jacks
Safety Stands/Jack Stands
Frame-Contact Lifts
Special Auxiliary Adapters/Extenders
Wheel-Contact Lifts
Wheels-Free Jacks
Center of Gravity
Lift Safety
Engine Hoist Safety
Engine Lifting Sling
Engine Stand
Other Shop Equipment Safety
Creepers
Battery Charger
Battery Acid
Electronic Engine Analyzers
Welding Safety
Cautions with Caustic Bases
Hot Tank Safety
Hazardous Materials and Environmental Safety
Bloodstream Hazards
Skin Damage
Hazardous Communication Standards
Material Safety Data Sheets
Interpreting an MSDS
Hazardous Materials Common to the Automotive Industry
Solvents
Hazards Related to Solvents
Cleaning Solvent Safety Precautions
Cleaning Solvent Safety
Skin Care Safety Precautions
Breathing Safety
Asbestos
Key Terms
Engine Shop Safety Test
Chapter 3. Diagnosing Engine Problems
Diagnosing Problems before a Repair
Oil Consumption
What is Acceptable Oil Consumption?
Bad Valve Guides or Seals
Oil Consumption from Piston Rings
Oil Consumption from Worn Compression Rings
Increased Oil Consumption after a Valve Job
Excessive Rod Bearing Clearance
Incorrect Engine Oil Dipstick
Plugged Cylinder Head Drainback Holes
Leaking V-Type Intake Manifold Gasket
Crankcase Pressure
Oil Leaks
Rear Crankshaft Seal Leaks
Fuel Mixture Problems
Oil/Fuel Wash
Oxygen Sensor Problems
Compression Loss
Compression Leaks
Breathing Problems
Testing for Compression Loss
Compression Test
Compression Test Procedure
Running Compression Test
Cylinder Power Balance Test
Electronic Cylinder Power Balance Testing
Relative Compression Test
Cylinder Leakage Test (CLT)
Engine Vacuum
Cranking Vacuum Test
Pressure Transducer Testing
Propane Enrichment Tester
Smoke Testing
Bore Scopes and Video Inspection Devices
Emission Analyzer Test
Engine Noises
Accessory Noises
Crankshaft Noises
Piston Noises
Valvetrain Noises
Spark Knocks, Carbon Noise, and Abnormal Combustion
Preignition
Detonation
Fuel Octane, Spark Advance, and Detonation
Broken Engine Mount
Broken Electrical Ground Connection
Oil Pressure Problems
Low Oil Pressure
High Oil Pressure
Cooling System Problems
Internal and External Cooling System Leakage
Cooling System Pressure Test
Other Causes of Overheating
Seized Engine
Electronic Failures/Engine Damage
Oil Analysis
Key Terms
Study Questions
ASE-Style Review Questions
Chapter 4. Engine Removal, Disassembly, Inspection, and In-Chassis Repairs
Service Information
Service Literature
Identifying the Vehicle
Engine Identification
Under-Hood Label
Electronic Service Information
Technical Service Bulletins
Hotline Services
Internet
Magazines
Parts and Labor Estimating
Service Records
Computer Records
Engine Removal
Separating the Engine and Transmission/Transaxle
Front-Wheel Drive Engine and Transaxle Removal
Removing the Transaxle
Rebuild or Replace?
Long Blocks
Short Blocks
Core Charge
Engine Disassembly
Cylinder Block Disassembly
Mark Main Bearing and Connecting Rod Caps
Remove and Inspect the Piston and Rod Assembly
Inspect the Piston, Rings, Rod, and Bearings
Remove the Crankshaft and Bearings
Reinstall the Main Bearing Caps in Their Proper Sequence on the Block
Remove the Camshaft
Remove and Label Cam Bearings
Remove Core Plugs
Clean the Engine
Ordering Parts
Replacement Engine Parts
Engine Kits
Cores
Removing the Crankshaft Timing Sprocket and Woodruff Key
Determining Part Sizes
Major Engine Repair—Engine in the Vehicle
Valve Job or Head Gasket Repair
Maintaining Valve Timing When a Head is Removed
Valve Job or Complete Engine Overhaul?
Head Gasket Problems
Rear Main Crankshaft Seal Replacement
Removing the Oil Pan
Remove the Piston and Rod Assembly
Rod Bearing Replacement
Main Bearing Replacement
Remove the Timing Cover
Timing Chain and Belt Service
Freewheeling and Interference Engines
Replace the Timing Components
Replace Crankshaft Seal
Flywheel Ring Gear Service
Heating a Ring Gear
Gasoline Direct Injection Service
GDI Intake Deposit Service
Key Terms
Study Questions
ASE-Style Review Questions
Chapter 5. Cleaning the Engine
Cleaning Methods
Chemical Cleaning
Cleaning with Bases
Cleaning with Acids
Cleaning with Solvents
Cleaning the Inside of the Engine
Chemical Cleaning
Alkaline Cleaning
Cleaning Aluminum
Hot Soak Tanks
Spray Washers
Preventing Rust
Caustic Tank Hazardous Waste
Manual Cleaning Methods
Cleaning Cast Iron Surfaces
Abrasive Blast Cleaning
Glass Bead Blasters
Soda Blaster
Airless Blaster
Thermal Cleaning/Pyrolytic Oven
Other Cleaning Methods
Marking Clean Parts
Key Terms
Study Questions
ASE-Style Review Questions
Chapter 6. Measuring
Metric System
Metric Engine Size Measurement
Metric Measuring
Measuring Tools
Feeler Gauges
Plastigage
Precision Measuring Tools
Vernier Caliper
Micrometer
Telescoping and Split Ball Gauges
Dial Indicators
Dial Bore Gauge
Other Indicator Types
Key Terms
Study Questions
ASE-Style Review Questions
Micrometer Practice
Section 2. The Breathing System
Chapter 7. Cylinder Head: Parts and Service
Cylinder Heads
Head Identification
Head Disassembly
Spring Removal Tools
Measuring Valve Stem Height
Carbon Removal
Removing Carbon from Combustion Chambers
Removing Carbon from Valves
Crack Inspection
Magnetic Crack Inspection
Dye Penetrant
Pressure Testing
Crack Repair
Threaded Plugs
Specialized Crack Stitching
Welding a Crack
Valve Guide Inspection
Remove Valve Guide Seals
Measure Valve Guide Wear
Valve Guide Repair
Valve Guide Knurling
Reaming Valve Guides
Replaceable Guides
Bronzewall
Replaceable Insert Valve Guides
Off-Center Guides
Honing Valve Guides
Valve Guides and Seals
Types of Valve Guide Seals
Positive Valve Guide Seals
Seal Quality
Replacing Valve Springs or Valve Guide Seals (Heads on Engine)
Resurfacing Heads
Checking Flatness
Why Do Head Gaskets Start to Leak?
Aluminum Head Warpage
Resurfacing by Grinding or Cutting
After Machining
Resurfacing V-Type Heads
Straightening Cylinder Heads
Resurfacing OHC Heads
Measuring Combustion Chamber Volume
Key Terms
Study Questions
ASE-Style Review Questions
Chapter 8. Cylinder Head: Springs, Valves, and Valve Seats
Generic Specifications and Guidelines
Valve Springs
Valve Spring Inspection
Racing Valve Springs
Checking Installed Height of Spring
Valve Retainers
Pushrods
Rocker Arms
Rocker Arm Materials
Rocker Arm Stud Service
Worn Rocker Arms
Rocker Arm Ratio
Roller Rocker Arms
Valves and Valve Service
Effect of Valve Lash on Cooling
Valve Damage
Valve Seat Wear
Temperature Protection/Valve Rotation
Exhaust and Intake Valves
Measuring the Valve Stem
Tapered Stems
Valve Stem Height/Rocker Arm Geometry
Grinding Valves
Using a Valve Grinder
Valve Margin
Valve Seats and Service
Repair Valve Guides before Machining Valve Seats
Pilots
Grinding or Cutting Seats
Dressing the Stone
Stone Holders
Seat Width
Seat Refinishing Angles
Lapping Valves
Three-Angle Valve Seat Machines
Replacing Valve Seats
Removing Valve Seats
Reassembling the Head
Engine Assembly Lubricants
Lubricating Valve Guides and Stems
Install Valve Guide Seals
Inspect Keepers/Valve Locks
Install the Valve and Spring Assembly
Reassembling OHC Heads
Valve Clearance Adjustment
Key Terms
Study Questions
ASE-Style Review Questions
Chapter 9. Camshafts, Lifters, Timing Belts, and Chains
Camshaft
Controlling Camshaft End Thrust
Thrust Clearance
Overhead Camshaft Thrust Control
Auxiliary Shaft
Valve Lash (Clearance)
Valve Lifters
Hydraulic Lifters and Lash Adjusters
Cam-in-Block Hydraulic Lifters
Hydraulic Lifter Operation
Lifter Leak-Down
OHC Lash Adjusters
Hydraulic Lifter Failure
Adjusting Hydraulic Lifter Lash
Hydraulic Lifter Pump-Up
Cam Lobe Shape
Lift and Duration
Overhead Camshafts
Valve Timing
Valve Overlap
Roller Cam and Lifters
Roller Lifter
Roller Camshaft
Cam Drives
Timing Chains and Belts
Freewheeling and Interference Engines
Camshaft Drive Sprockets
Installing the Crankshaft Gear or Sprocket
Timing Chains
Timing Chain Stretch
Timing Chain Tensioners
Timing Chain Guides
Timing the Cam to the Crank
Chain Drive Timing Marks
Locating TDC
Timing Belts
Timing Belt Inspection and Replacement
Timing Belt Replacement Interval
Timing Belt Material
Timing Belt Storage, Handling, and Inspection
Timing Belt Teeth
Timing Belt Cover
Timing Belt Replacement
Belt Tensioner Replacement
Setting Cam Phasing/Valve Timing
Turning the Camshaft(s)
Adjust Timing Belt Tension
Automatic Belt Tensioners
Tightening the Damper Bolt
Key Terms
Study Questions
ASE-Style Review Questions
Section 3. Cylinder Block Assembly
Chapter 10. Cylinder Block: Inspection and Service
Cleaning the Block
Check the Block for Cracks
Crack Repair
Oil and Water Plugs
Oil Jet Cooling
Aligning Dowels on the Back of the Block
Main Bearing Caps and Registers
Main Bearing Bore Alignment
Main Bearing Bore Roundness
Main Bearing Bore Realignment
Line Boring vs. Line Honing
Line Honing
Decking the Block
Inspecting Cylinder Bores
Cylinder Bore Wear Limits
Taper Limit with Low-Friction Rings
Taper and Out-of-Round Wear
Measuring the Bore
Deglazing Cylinders
Clean the Block of Grit
Reboring Cylinders
Ultrasonic Thickness Testing and Core Shift
Racing Blocks
Open Deck and Closed Deck Cylinder Blocks
Block Distortion
Torque Plates
Boring Procedure: Portable Boring Bar
Honing Cylinders to Size
Honing Cylinders
Hone Stones/Cylinder Surface Finish
Diamond Honing
Plateau Honing
Piston Clearance
Chamfering the Cylinder
Hard and Reinforced Cylinder Surfaces
Cylinder Sleeves
Lifter Bores
Final Block Preparation
Oil Gallery Plug Installation
Coolant Core Plug Installation
Cam Bearings
Cam Bearing Installation
Cam Bearing Installation Tools
Universal Cam Bearing Tool
Key Terms
Study Questions
ASE-Style Review Questions
Chapter 11. Crankshaft, Bearings, and Engine Balancing
Crankshaft Design
Counterweights
Cast or Forged Cranks
Crankshaft End Thrust
Checking Crankshaft Condition
Straightening a Crankshaft
Checking for Cracks
Vibration Damper
Crankshaft Wear
Shot Blasting a Crankshaft
Regrinding the Crankshaft
Crankshaft Rotation When Grinding
Oil Passage Chamfer
Polishing a Crankshaft
Microfinishing
Storing the Crankshaft
Welding Crankshafts
Crankshaft Hardness
Crankshaft Hard Chrome Plating
Measuring Crankshaft Hardness
Crankshaft Strength
Forged and Billet Crankshafts
Other Crankshaft Modifications
Stroker Crankshafts
Oversquare Engines
Counterweight Modifications
Rod Angle
Cross-Drilled Main Journals
Checking Bearing Clearance
Plastigage
Select-Fit Bearings
Bearing Inserts
Bearing Properties
Multilayered Bearings
Aluminum Bearings
Bearing Eccentricity
Inspecting Worn Engine Bearings
Thrust Bearing Wear
Electrical Grounds and Thrust Bearing Problems
Crankshaft Design and Engine Balance
V8 Crankshaft Design
Balance Shafts
Engine Balancing
Piston Weight
Types of Imbalance
Scales
Equalizing Part Weight
Bob Weights
Time Required for Balancing
Key Terms
Study Questions
ASE-Style Review Questions
Chapter 12. Pistons, Rings, and Connecting Rods
Pistons
Cast and Forged Pistons
Piston Head and Ring Grooves
Piston Head Shapes
Piston Skirt Surface Finish
Piston Coatings
Piston Clearance
Selective Fitting of Pistons to Bores
Piston Expansion Control
Skirt Types
Piston Pin Offset
Piston Weight
Center of Gravity Balancing
Piston Wear Problems
Ring Groove Wear/Side Clearance Check
Piston Service
Piston Rings
Ring Oversizes
Compression Rings
Ring Size Terminology
Ring Flutter
Piston Ring Materials and Coatings
High Strength Rings
Newer Piston Ring Designs
New OE Piston Rings
Plasma Ring Coatings
Oil Control Rings
Ring Wear
Ring Gap Clearance
Installing Rings on Pistons
Ring Gap Position
Piston Pins
Piston Pin Retaining Methods
Full-Floating Pins
Direction of Piston on Connecting Rod
Connecting Rods
Sintered Powder-Forged Fractured Rods
Forged Racing Rods
Rod Oil Holes
Preventing Piston Skirt Wear
Offset Connecting Rods
Rod Service
Key Terms
Study Questions
ASE-Style Review Questions
Chapter 13. Lubrication
Oil Pressure
Oil
Engine Oil
Oil Level
Oil Viscosity
Multiple Viscosity Oils
Oil Pressure
Engine Oil Licensing and Certification
Starburst Symbol
Oil Service Ratings
European ACEA Oils
Manufacturer-Specific Oil Standards
Energy-Efficient Oils
HTHS Viscosity Rating
Recycled Oil
Oil Additives
Detergents
Dispersants
Oxidation Inhibitors
Synthetic Oils
Changing Engine Oil
Benefits to Changing Oil
Oil Change Interval
Oil Analysis
Changing Brands of Oil
Changing Oil
Oil Condition Sensing
Oil Monitor Reset
Oil Pumps
Crankshaft-Driven Oil Pumps
Pressure Relief Valve
Oil Pressure
Pump Screen and Pump Failure
Air in the System
Checking Oil Pumps for Wear
Installing the Oil Pump
Positive Displacement Pumps
High-Volume Oil Pumps
Dry Sump Systems
Windage Tray and Baffles
Priming the Lubrication System
Pressure Priming
Oil Filter
Full-Flow Oil Filter
Variations in Filters
Changing the Oil Filter
Cartridge Oil Filters
Crankcase Ventilation
Key Terms
Study Questions
ASE-Style Review Questions
Chapter 14. Cooling System
Types of Cooling Systems
Cooling System Parts
Cooling System Circulation
Coolant Pump
Pump Seal and Weep Hole
Coolant Pump Failure
Accessory Belts
Belt Material
Accessory Drive Belt Service
Belt Inspection
Belt Replacement
Belt Tension
Spring-Loaded Tensioner Inspection
Spring-Loaded Tensioner Internal Damper
Belt Alignment
V-Ribbed Belt Replacement
Belt Tension
V-Ribbed Tension with Fixed Adjustment
Stretch Belts
Thermostat
Thermostat Operating Temperature
Thermostat Testing
Electric Thermostat
Thermostat Bypass
Reverse Flow Cooling Systems
Radiators
Radiator Inspection
Transmission Heat Exchanger (Oil Cooler)
Heater Core
Hoses
Hose Clamps
Cooling System Pressure Cap
Types of Pressure Caps
Radiator Cap Sealing Surfaces
Coolant Reservoir Cap
Coolant Recovery System
Pressure Testing
Radiator Fan
Belt-Driven Fans
Electric Fan
Fan Clutch
Fan Clutch Inspection
Coolant Temperature Sensor
Coolant
Coolant Boiling and Freezing Points
Coolant Color
Coolant Additive Package
Coolant Life
Differences in Coolant
Water Wetting Products
Electrolysis
Coolant Service
Coolant Inspection
Checking Coolant Conductivity
Coolant Change Interval
Draining Coolant
Cooling System Flush
Airlift Leak Check and Airlock Purge
Draining and Refilling a Cooling System
Coolant Exchanger
Aluminum Oxide Contamination
Testing Coolant Condition and Strength
Coolant Test Strips
Coolant Alkalinity (pH)
Coolant Density Testers
Hydrometer Testing
Refractometer Testing
Coolant Concentration
Which Coolant to Use?
HOAT Coolant
Bleeding Air from Coolant
Cavitation
Key Terms
Study Questions
ASE-Style Review Questions
Key Terms
Study Questions
ASE-Style Review Questions
Supplement. Supplemental Test Questions and Answers
Appendix
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