Section 9
Engine Service and Repair
Chapter 48 913
Engine Mechanical Problems
Why Is Diagnosis Important? 913
Symptoms of Engine Mechanical Problems 913
Decide What Type of Engine Repair Is Needed 920
Evaluating Engine Mechanical Problems 920
Service Manual Troubleshooting Charts 926
Duff’s Garage 926
Compression Test Results 930
Cylinder Leakage Test Results 930
Chapter 49 931
Engine Removal, Disassembly, and Parts
Cleaning
Engine Removal 931
Engine Disassembly 937
Cleaning Engine Parts 942
Industry Trend 945
Chapter 50 948
Engine Bottom End Service
Do You Need Review? 948
Cylinder Block Service 948
Balancer Shaft Service 954
Piston Service 954
Piston Pin Service 956
Connecting Rod Service 958
Piston Ring Service 958
Crankshaft Service 960
Installing a Piston and Rod Assembly 964
Torque-to-Yield Bolts 966
Engine Balancing 966
Final Assembly of Engine 967
Workplace Skills 967
Chapter 51 971
Engine Top End Service
Cylinder Head Service 971
Diesel Precombustion Chamber Service 974
Valve Guide Service 974
Valve Grinding 976
Valve Seat Reconditioning 979
Testing Valve Springs 983
Assembling Cylinder Head 984
Camshaft Service 987
Lifter Service 988
Push Rod Service 989
Rocker Arm Assembly Service 989
Engine Top End Reassembly 989
Valve Adjustment 993
Installing Valve Covers 996
Duff’s Garage 997
Chapter 52 1001
Engine Front End Service and Engine
Installation
Timing Chain Service 1001
Timing Gear Service 1003
Crankshaft Front Seal Service 1004
Engine Front Cover Service 1006
Timing Belt Service 1007
Complete Engine Assembly 1011
Installing the Engine 1011
Engine Break-In 1012
Duff’s Garage 1012
Section 10
Drive Trains and Axles
Chapter 53 1017
Clutch Fundamentals
Clutch Principles 1017
Clutch Construction 1019
Workplace Skills 1028
Chapter 54 1031
Clutch Diagnosis and Repair
Diagnosing Clutch Problems 1031
Servicing a Clutch 1037
Duff’s Garage 1043
Clutch Diagnosis 1047
Chapter 55 1049
Manual Transmission Fundamentals
Basic Transmission Parts 1049
Purpose of a Manual Transmission 1049
Gear Fundamentals 1050
Manual Transmission Construction 1052
Transmission Types 1060
Transmission Power
Flow 1060
Speedometer Drive 1066
Manual Transmission
Switches 1066
Workplace Skills 1066
Chapter 56 1070
Manual Transmission Diagnosis and Repair
Manual Transmission Problem Diagnosis 1070
Manual Transmission Problems 1070
Transmission Identification 1072
xiv Expanded Contents