Classroom Manual for Automotive Suspension & Steering Systems
Contents
Chapter 1
Safety . . . . . . . . . . . . . . . . . . . . . . . . . .1
- Introduction 2
- Occupational Safety and Health Act 2
- Shop Hazards 2 • Shop Safety Rules 3
- Air Quality 5
- Shop Safety Equipment 6
- Shop Layout 9 • Safety in the Automotive Shop 10
- General Shop Safety 10
- Personal Safety 11 • Electrical Safety 13
- Gasoline Safety 13
- Fire Safety 14
- Vehicle Operation 15
- Housekeeping Safety 16
- Air Bag Safety 17
- Lifting and Carrying 19
- Hand Tool Safety 20 • Lift Safety 21
- Hydraulic Jack and Safety Stand Safety 21
- Power Tool Safety 22
- Compressed-Air Equipment Safety 23
- Cleaning Equipment Safety and Environmental Considerations 23
- Hazardous Waste Disposal 26
- Case Study 29
- Terms to Know 29
- Summary 30
- ASE-Style Review Questions 31
Chapter 2
Tools and Shop Procedures. . . . . . . . . . . .39
- Using Suspension and Steering Equipment 39
- Measuring Systems 39
- Basic Diagnostic Procedure 41
- Suspension and Steering Tools 42
- Hydraulic Pressing and Lifting Equipment 55
- Suspension and Steering Service, Diagnostic, and Measurement Tools 59
- Employer and Employee Obligations 70
- National Institute for Automotive Service Excellence (ASE) Certification 72
- Service Manuals 74
- Case Study 80
- Terms to Know 81
- Summary 81
- ASE-Style Review Questions 82
Chapter 3
Wheel Bearing and Seal Service . . . . . . . . . . . . . .89
- Diagnosis of Bearing Defects 89
- Service and Adjustment of Tapered Roller Bearing-Type Wheel Bearings 90
- Wheel Hub Unit Diagnosis 97
- Front Drive Axle Diagnosis 99
- Drive Axle Removal 99
- Special Procedures for Drive Axle Removal 100
- Front Wheel Bearing Hub Unit Removal and Replacement 102
- Rear-Axle Bearing and Seal Service, Rear-Wheel-Drive Cars 104
- Case Study 108
- Terms to Know 108
- ASE-Style Review Questions 108
- ASE Challenge Questions 110
Chapter 4
Tire and Wheel Servicing and Balancing . . . . . .120
- Tyre Noises and Steering Problems 120
- Tire Rotation 122
- Tyre and Wheel Service Precautions 124
- Wheel Rim Service 130
- Tire Remounting Procedure 131
- Diagnosing and Servicing Tire Pressure Monitoring Systems 132
- Tire and Wheel Runout Measurement 138
- Tread Wear Measurement 140
- Preliminary Wheel Balancing Checks 141
- Tire Inflation Pressure 142
- Static and Dynamic Wheel Balance Procedure 143
- Electronic Wheel Balancers with Lateral Force Measurement (LFM) and Radial Force Variation Capabilities 145
- On Car Wheel Balancing 149
- Vibration Diagnosis 150
- Case Study 156
- Terms to Know 156
- ASE-Style Review Questions 157
- ASE Challenge Questions 158
Chapter 5
Shock Absorber and Strut Diagnosis and Service. . .171
- ShockAbsorber Visual Inspection 171
- Shock-Absorber or Strut Bounce Test 172
- Shock-Absorber Manual Test 172
- Air Shock Absorber Diagnosis and Replacement 174
- Shock Absorber Replacement 174
- Diagnosis of Front Spring and Strut Noise 174
- Strut Removal and Replacement 176
- Removal of Strut from Coil Spring 177
- Strut Disposal Procedure 179
- Installation of Coil Spring on Strut 179
- Installation of Strut-and-Spring Assembly in Vehicle 181
- Rear Strut Replacement 183
- Installing Strut Cartridge, Off-Car 183
- Installing Strut Cartridge, On-Car 184
- Diagnosis of Electronically Controlled Shock Absorbers 187
- Case Study 188
- Terms to Know 189
- ASE-Style Review Questions 189
- ASE Challenge Questions 190
Chapter 6
Front Suspension System Service . . . . . . .201
- Curb Riding Height Measurement 201
- Front Suspension Diagnosis and Service 202
- Control Arm Diagnosis and Service 213
- Removing and Replacing Longitudinally Mounted Torsion Bars 222
- Case Study 224
- Terms to Know 224
- ASE-Style Review Questions 225
- ASE Challenge Questions 226
Chapter 7
Rear Suspension Service . . . . . . . . . . . . . . . . . . . . . . . . . .235
- Lower Control Arm and Ball Joint Diagnosis and Replacement
- Rear Leaf-Spring Diagnosis and Replacement 247
- Track Bar Diagnosis and Replacement 248
- Stabilizer Bar Diagnosis and Service 248
- Rear Suspension Tie Rod Inspection and Replacement 250
- Case Study 250
- Terms to Know 250
- ASE-Style Review Questions 251
- ASE Challenge Questions 252
Chapter 8
Computer-Controlled Suspension System Service . . . . .259
- Preliminary Inspection of Computer-Controlled Suspension Systems 259
- Programmed Ride Control System Diagnosis 260
- Electronic Air Suspension Diagnosis and Service 261
- Servicing and Diagnosing Vehicle Dynamic Suspension Systems 269
- Diagnosis of Electronic Suspension Control Systems 274
- Scan Tool Diagnosis of Electronic Suspension Control 276
- Case Study 284
- Terms to Know 285
- ASE-Style Review Questions 286
- ASE Challenge Questions 287
Chapter 9
Steering Column and Linkage Diagnosis and Service. .295
- Air Bag Deployment Module, Steering Wheel, and Clock Spring Electrical Connector Removal and Replacement 295
- Typical Procedure for Removing a Steering Wheel 298
- Steering Column Service 300
- Steering Column Removal and Replacement 300
- Collapsible Steering Column Inspection 301
- Tilt Steering-Column Disassembly 302
- Tilt Steering-Column Inspection and Parts Replacement 304
- Tilt SteeringColumn Assembly 305
- Steering-Column Flexible Coupling and Universal Joint Diagnosis and Service 307
- Steering-Column Diagnosis 309
- Steering Linkage Diagnosis and Service 313
- Case Study 321
- Terms to Know 321
- ASE-Style Review Questions 321
- ASE Challenge Questions 322
Chapter 10
Power Steering Pump Diagnosis and Service . . . .335
- Power-Steering Pump Belt Service 335
- Power-Steering Pump Fluid Service 338
- PowerSteering Pump Diagnosis 340
- Power Steering Pump Service 345
- Inspecting and Servicing Power Steering Lines and Hoses 348
- Power Steering Hose Replacement 349
- Hybrid Electric Vehicle (HEV) and Electrohydraulic Power Steering (EHPS) Diagnosing and Servicing Procedures 350
- Case Study 358
- Terms to Know 358
- ASE-Style Review Questions 358
- ASE Challenge Questions 359
chpt 11
Recirculating Ball Steering Gear Diagnosis and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
- Power Recirculating Ball Steering Gear Diagnosis 369
- Power-Recirculating Ball Steering Gear Replacement 370
- Power-Recirculating Ball Steering Gear Adjustments 371
- Power Recirculating Ball Steering Gear Oil Leak Diagnosis 375
- PowerRecirculating Ball Steering Gear Seal Replacement 375
- Case Study 378
- Terms to Know 378
- ASE-Style Review Questions 378
- ASE Challenge Questions 379
chpt 12
Rack and Pinion Steering Gear Diagnosis and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
- Manual or Power Rack and Pinion Steering Gear On-Car Inspection 387
- Manual or Power Rack and Pinion Steering Gear Removal and Replacement 389
- Manual-Rack and Pinion Steering Gear Diagnosis and Service 395
- Diagnosis of Power Steering, Steering Column, and Suspension Systems 407
- Diagnosis of Magnasteer Systems 408
- Diagnosisof Rack-Drive Electronic Power Steering 409
- Diagnosis ofColumn-Drive Electronic Power Steering 411
- Active Steering System Preliminary Diagnosis 414
- Case Study 417
- Terms to Know 417
- ASE-Style Review Questions 418
- ASE Challenge Questions 419
chpt 13
Electronic Four-Wheel Steering Diagnosis and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
- Preliminary Inspection 432
- Quadrasteer Diagnosis 434
- Electronically Controlled Four-Wheel Steering Diagnosis 437
- Rear Steering Actuator Service 439
- Diagnosis of Four-Wheel Active Steering (4WAS) System 446
- Case Study 451
- Terms to Know 451
- ASE-Style Review Questions 452
- ASE Challenge Questions 453
chpt 14
Frame Diagnosis and Service . . . . . . . . . . . . . . . . . . . . .461
- Indications of Frame Damage 461
- Frame Diagnosis 461
- Checking Frame Alignment 462
- Measuring Unitized Body Alignment 468
- Case Study 474
- Terms to Know 474
- ASE-Style Review Questions 475
- ASE Challenge Questions 476
chpt 15
Four-Wheel Alignment Procedure. . . . . . . . . . . . . . . . . .485
- Wheel Alignment Preliminary Diagnosis and Inspection 485
- Four-Wheel Alignment with Computer Alignment Systems 491
- Wheel Alignment Screens 497
- Adjustment Screens 502
- Diagnostic Drawing and Text Screens 506
- Checking Toe Change and Steering Linkage Height 508
- Bent Front Strut Diagnosis 510
- Case Study 511
- Terms to Know 511
- ASE-Style Review Questions 512
- ASE Challenge Questions 513
chpt 16
Four-Wheel Alignment Adjustments. . . . . . . . . . . . . . . .523
- Wheel Alignment Procedure 523
- Camber Adjustment 524
- Caster Adjustment Procedure 531
- Setback Measurement and Correction Procedure 534
- Steering Axis Inclination (SAI) Correction Procedure 537
- Toe Adjustment 537
- Manual Steering Wheel Centering Procedure 539
- Causes of Improper Rear Wheel Alignment 541
- Rear Suspension Adjustments 541
- Rear Wheel Tracking Measurement with a Track Gauge 547
- Case Study 552
- Terms to Know 554
- ASE-Style Review Questions 555
- ASE Challenge Questions 556
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