Author: 978-1-64564-690-7

The student Shop Manual contains a series of Job Sheets that provide hands-on practice of skills and procedures aligned to the ASE Education Foundation Tasks. The jobs engage students with the practical skills needed to succeed and are designed to be accomplished in one or two lab sessions. The Shop Manual Job Sheets are intended to be completed in a shop setting under the guidance of an instructor. Pages can be printed on demand for assignment, or students can complete their assignments online using embedded form fields and then print or e-mail the responses for grading.

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Table of Contents

Abbreviated Contents

Modern Automotive Technology 10e, Shop Manual

• Front Matter
• Project 1 Preparing to Service a Vehicle
• • Job 1—Perform Safety and Environmental Inspections
  • Job 2—Interpret Vehicle Numbers, Use Service Information, and Prepare a Work Order
• Project 2 Removing and Replacing Gaskets, Seals, and Bearings
• • Job 3—Remove and Install a Gasket
  • Job 4—Remove and Install a Seal
  • Job 5—Remove and Replace a Bearing
• Project 3 Performing Oil Changes and Checking an Engine for Leaks
• • Job 6—Change Oil and Filter
  • Job 7—Inspect an Engine for Leaks
• Project 4 Diagnosing Engine Problems
• • Job 8—Perform a Vacuum Test and a Power Balance Test
  • Job 9—Perform a Cranking Compression Test, Running Compression Test, and a Cylinder Leakage Test
  • Job 10—Perform an Oil Pressure Test
  • Job 11—Verify Warning Indicator Operation and Retrieve Trouble Codes
• Project 5 Removing and Disassembling an Engine
• • Job 12—Remove an Engine
  • Job 13—Disassemble an Engine
• Project 6 Performing Bottom End Service
• • Job 14—Inspect the Block, Crankshaft, and Bearings
  • Job 15—Repair Damaged Threads
  • Job 16—Measure Cylinder Wear and Hone Cylinders
  • Job 17—Inspect Connecting Rods
  • Job 18—Inspect Pistons and Replace Piston Rings
  • Job 19—Inspect Balance Shafts, Vibration Damper, and Oil Pump
• Project 7 Servicing the Cylinder Head(s) and Valve Train
• • Job 20—Disassemble and Inspect a Cylinder Head
  • Job 21—Inspect and Service Valve Train Parts
  • Job 22—Resurface and Inspect Valves and Valve Seats
  • Job 23—Assemble a Cylinder Head
  • Job 24—Inspect Valve Timing Components
  • Job 25—Adjust Valves
  • Job 26—Replace Valve Seals with the Cylinder Head Installed
• Project 8 Reassembling and Reinstalling an Engine
• • Job 27—Reassemble the Engine’s Bottom End
  • Job 28—Install the Cylinder Head(s) and Valve Train
  • Job 29—Complete the Engine Reassembly
  • Job 30—Reinstall the Engine
• Project 9 Servicing a Cooling System
• • Job 31—Inspect and Test a Cooling System; Identify Causes of Engine Overheating
  • Job 32—Flush and Bleed a Cooling System
  • Job 33—Replace Belts and Hoses
  • Job 34—Replace a Coolant Pump
  • Job 35—Replace a Radiator
  • Job 36—Remove and Replace a Thermostat
• Project 10 Inspecting, Replacing, and Aligning Powertrain Mounts
• • Job 37—Inspect Powertrain Mounts
  • Job 38—Replace and Align Powertrain Mounts
• Project 11 Diagnosing Transmission and Transaxle Problems
• • Job 39—Use the Seven-Step Diagnostic Process to Identify Transmission/Transaxle Problems
  • Job 40—Perform Transmission/Transaxle Pressure Tests
• Project 12 Servicing a Transaxle Final Drive
• • Job 41—Service a Planetary-Type Final Drive
  • Job 42—Service a Helical Gear Final Drive
  • Job 43—Service a Hypoid Gear Final Drive
• Project 13 Servicing an Automatic Transmission or Transaxle
• • Job 44—Change Transmission/Transaxle Oil and Filter
  • Job 45—Adjust Transmission Linkage and Bands and Neutral Safety Switch/Range Switch
  • Job 46—Service an Oil Cooler and Lines
  • Job 47—Service Speedometer Drive and Driven Gears
  • Job 48—Service Electronic and Electrical Components
  • Job 49—Service Vacuum Modulators and Governors
• Project 14 Removing an Automatic Transmission or Transaxle
• • Job 50—Remove an Automatic Transmission
  • Job 51—Remove an Automatic Transaxle
• Project 15 Rebuilding an Automatic Transmission
• • Job 52—Disassemble and Inspect an Automatic Transmission
  • Job 53—Service Automatic Transmission Components and Rebuild Subassemblies
  • Job 54—Reassemble an Automatic Transmission
• Project 16 Rebuilding an Automatic Transaxle
• • Job 55—Disassemble and Inspect an Automatic Transaxle
  • Job 56—Service Automatic Transaxle Components and Rebuild Subassemblies
  • Job 57—Reassemble an Automatic Transaxle
• Project 17 Installing an Automatic Transmission or Transaxle
• • Job 58—Install an Automatic Transmission
  • Job 59—Install an Automatic Transaxle
• Project 18 Correcting Noise, Vibration, and Harshness Problems
• • Job 60—Diagnose a Drive Train Problem
  • Job 61—Check and Correct Drive Shaft Runout
  • Job 62—Check and Adjust Drive Shaft Angles
  • Job 63—Check and Adjust Drive Shaft Balance
• Project 19 Performing Manual Drive Train Service
• • Job 64—Diagnose and Service Linkage and Switches/Sensors
  • Job 65—Diagnose Drive Train Component Leakage
• Project 20 Servicing Drive Shafts and CV Axles
• • Job 66—Remove, Inspect, and Reinstall U-Joints and a Drive Shaft
  • Job 67—Remove, Inspect, and Reinstall a CV Axle
  • Job 68—Diagnose and Service CV Axle Shaft Bearings and Seals
• Project 21 Removing a Manual Transmission or Transaxle
• • Job 69—Remove a Manual Transmission
  • Job 70—Remove a Manual Transaxle
• Project 22 Servicing a Clutch
• • Job 71—Diagnose Clutch Problems
  • Job 72—Adjust Clutch Pedal Free Play
  • Job 73—Bleed a Hydraulic Clutch System
  • Job 74—Remove a Clutch
  • Job 75—Inspect and Repair a Clutch
  • Job 76—Install a Clutch
• Project 23 Rebuilding and Installing a Manual Transmission or Transaxle
• • Job 77—Disassemble and Inspect a Manual Transmission
  • Job 78—Reassemble and Install a Manual Transmission
  • Job 79—Disassemble and Inspect a Manual Transaxle
  • Job 80—Reassemble and Install a Manual Transaxle
• Project 24 Servicing a Transfer Case
• • Job 81—Inspect, Remove, and Replace a Transfer Case
  • Job 82—Overhaul a Transfer Case
  • Job 83—Service Transfer Case Shift Controls, Locking Hubs, and Wheel Bearings
• Project 25 Servicing Rear-Wheel Drive Axles and Differentials
• • Job 84—Remove, Service, and Install Retainer-Type and C-Lock Axles
  • Job 85—Remove and Replace an Independent Rear Axle Shaft
  • Job 86—Remove a Rear Axle Assembly
  • Job 87—Disassemble and Inspect a Differential
  • Job 88—Reassemble and Adjust a Differential
  • Job 89—Install a Rear Axle Assembly
• Project 26 Diagnosing and Servicing General Steering and Suspension Concerns
• • Job 90—Diagnose Steering and Suspension Problems
  • Job 91—Lubricate Steering and Suspension
  • Job 92—Service Tapered Roller Wheel Bearings
• Project 27 Servicing the Steering System
• • Job 93—Inspect a Steering Column
  • Job 94—Service a Steering Column
  • Job 95—Remove and Replace a Rack-and-Pinion Steering Gear and Inner Tie Rods
  • Job 96—Remove and Replace Steering Linkage Components
  • Job 97—Test a Power Steering System
• Project 28 Servicing a Suspension System
• • Job 98—Replace Strut Rods, Stabilizer Bars, and Bushings
  • Job 99—Replace Ball Joints, Control Arms, and Bushings
  • Job 100—Replace Coil Springs
  • Job 101—Inspect and Replace MacPherson Strut Components
  • Job 102—Inspect and Replace Shock Absorbers
• Project 29 Performing Alignment and Tire Service
• • Job 103—Perform an Alignment
  • Job 104—Inspect Tires and Rims
  • Job 105—Remove and Install a Tire on a Rim; Repair a Punctured Tire
  • Job 106—Rotate and Balance Tires
• Project 30 Performing General Brake System Diagnosis and Service
• • Job 107—Diagnose a Brake System
  • Job 108—Inspect and Replace Wheel Studs
  • Job 109—Service Wheel Bearings
  • Job 110—Service a Parking Brake
• Project 31 Servicing a Brake Hydraulic System
• • Job 111—Diagnose Brake Hydraulic System Problems
  • Job 112—Replace Brake Lines, Hoses, and Valves
  • Job 113—Service a Master Cylinder
  • Job 114—Service a Power Assist System
  • Job 115—Bleed a Brake System
• Project 32 Servicing Drum Brakes
• • Job 116—Service Drum Brakes
  • Job 117—Machine a Brake Drum
• Project 33 Servicing Disc Brakes
• • Job 118—Service Disc Brakes
  • Job 119—Overhaul a Disc Brake Caliper
  • Job 120—Machine a Brake Rotor
• Project 34 Servicing Anti-lock Braking, Traction Control, and Electronic Stability Control Systems
• • Job 121—Identify and Inspect ABS, TCS, and ESC System Components
  • Job 122—Bleed an ABS System
  • Job 123—Adjust Speed Sensor Clearance
  • Job 124—Diagnose ABS/TCS/ESC Problems
• Project 35 Performing General Electrical System Diagnosis and Service
• • Job 125—Check for Parasitic Battery Load
  • Job 126—Service Wiring and Wiring Connectors
  • Job 127—Inspect and Test a Battery
  • Job 128—Service a Battery
  • Job 129—Jump Start a Vehicle
• Project 36 Diagnosing and Servicing a Starting System
• • Job 130—Inspect, Test, and Diagnose a Starting System
  • Job 131—Replace a Starter Relay or Solenoid
  • Job 132—Replace an Ignition Switch or Neutral Safety Switch
  • Job 133—Replace a Starter
• Project 37 Diagnosing and Servicing a Charging System
• • Job 134—Inspect, Test, and Diagnose a Charging System
  • Job 135—Replace an Alternator
• Project 38 Diagnosing and Servicing a Lighting System
• • Job 136—Diagnose Lighting System Problems
  • Job 137—Replace and Aim Headlights
• Project 39 Diagnosing and Servicing Gauges and Warning Lights
• • Job 138—Diagnose Instrument Panel Warning Light Problems
  • Job 139—Check Electromechanical Gauge Operation
  • Job 140—Check Electronic Gauge Operation
  • Job 141—Replace a Warning Light Sensor or Gauge Sensor
• Project 40 Diagnosing and Servicing Horns and Windshield Washers/Wipers
• • Job 142—Check and Service a Horn
  • Job 143—Check and Correct the Operation of Windshield Washers and Wipers
• Project 41 Diagnosing and Servicing Accessories
• • Job 144—Diagnose and Service Power Windows and Power Door Locks
  • Job 145—Diagnose a Cruise Control Problem
  • Job 146—Diagnose Problems with a Radio/Sound System
  • Job 147—Disable and Enable an Air Bag System
  • Job 148—Diagnose an Air Bag System
  • Job 149—Use a Scan Tool to Determine a Body Electrical Problem
  • Job 150—Diagnose a Body Control Module and Module Communication Errors
  • Job 151—Check the Operation of Anti-Theft and Keyless Entry Systems
• Project 42 Diagnosing and Servicing an Air Conditioning System
• • Job 152—Diagnose an Air Conditioning System
  • Job 153—Diagnose Heating and Air Conditioning Control Systems
  • Job 154—Recover Refrigerant, and Evacuate and Recharge an Air Conditioning System
  • Job 155—Remove and Replace a Compressor and Compressor Clutch
  • Job 156—Remove and Replace Air Conditioning System Components
  • Job 157—Manage Refrigerant and Maintain Refrigerant Handling Equipment
• Project 43 Diagnosing and Servicing a Heating and Ventilation System
• • Job 158—Inspect and Service Heater Components
  • Job 159—Inspect and Service Air Handling Components
• Project 44 Diagnosing General Engine Concerns
• • Job 160—Diagnose Engine Performance Problems
  • Job 161—Use a Scan Tool to Access and Reprogram a Vehicle Computer
  • Job 162—Use a 4- or 5-Gas Analyzer to Check Emission System Operation
  • Job 163—Diagnose an NVH Problem
• Project 45 Diagnosing and Repairing an Ignition System
• • Job 164—Inspect and Test an Ignition System’s Secondary Circuit Components and Wiring
  • Job 165—Inspect and Test an Ignition System’s Primary Circuit Components and Wiring
• Project 46 Diagnosing and Servicing Fuel and Air Induction Systems
• • Job 166—Test Fuel Quality
  • Job 167—Test and Replace Fuel Supply System Components
  • Job 168—Inspect and Service a Throttle Body
  • Job 169—Check Idle Speed Motor or Idle Air Control
  • Job 170—Check Fuel Injector Waveforms and Perform a Fuel Injector Balance Test
  • Job 171—Remove and Replace a Fuel Injector
  • Job 172—Check Supercharger and Turbocharger Operation
• Project 47 Diagnosing and Servicing an Exhaust System
• • Job 173—Inspect and Test an Exhaust System
  • Job 174—Replace Exhaust System Components
• Project 48 Diagnosing and Servicing Emissions Control Systems
• • Job 175—Test and Service an EGR Valve
  • Job 176—Test and Service an Air Pump and Air Injection System
  • Job 177—Test and Service a Catalytic Converter
  • Job 178—Test and Service Positive Crankcase Ventilation (PCV) and Evaporative Emissions Control Systems