Preface |
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Acknowledgements |
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1 | (5) |
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2 | (3) |
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2 | (1) |
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1.1.2 Learning activities E 1 |
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2 | (1) |
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1.1.3 Visible thinking E 1 |
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3 | (2) |
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5 | (1) |
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6 | (14) |
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2.1 Personal and vehicle protection |
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7 | (2) |
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2.1.1 Personal protective equipment E 1 |
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7 | (1) |
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8 | (1) |
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8 | (1) |
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9 | (1) |
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2.2.1 Working environment E 1 |
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9 | (1) |
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2.2.2 Equipment maintenance E 1 |
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9 | (1) |
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10 | (3) |
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10 | (1) |
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2.3.2 Regulations and laws 1 |
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11 | (1) |
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2.3.3 Health and Safety law 1 |
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12 | (1) |
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13 | (5) |
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13 | (1) |
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2.4.2 High voltage vehicles 1 |
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14 | (1) |
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15 | (2) |
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17 | (1) |
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2.5 Personal responsibilities |
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18 | (2) |
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2.5.1 Safety procedures E 1 |
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18 | (1) |
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2.5.2 Environmental protection 1 |
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18 | (2) |
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20 | (17) |
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21 | (5) |
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3.2 Information and systems E 1 |
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26 | (1) |
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27 | (4) |
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31 | (4) |
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3.5 Working relationships |
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35 | (2) |
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35 | (1) |
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35 | (2) |
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37 | (32) |
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4.1 Hand tools and measuring |
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38 | (7) |
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38 | (3) |
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41 | (4) |
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45 | (8) |
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4.2.1 Workshop equipment E 1 |
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45 | (4) |
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49 | (4) |
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4.3 Materials and fabrication |
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53 | (16) |
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53 | (1) |
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4.3.2 Metal cutting and shaping E 1 |
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54 | (4) |
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58 | (1) |
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4.3.4 Nuts, screws, washers and bolts E 1 |
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58 | (5) |
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63 | (1) |
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4.3.6 Soldering, brazing and welding E 1 2 |
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64 | (1) |
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65 | (1) |
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66 | (1) |
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4.3.9 Gaskets, sealants and oil seals E 1 |
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67 | (2) |
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69 | (11) |
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70 | (5) |
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5.1.1 Maintenance and inspections E 1 |
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70 | (1) |
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70 | (2) |
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72 | (2) |
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74 | (1) |
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5.2 Servicing and Inspections |
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75 | (5) |
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75 | (1) |
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5.2.2 Rules and regulations 1 |
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76 | (1) |
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77 | (1) |
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78 | (1) |
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5.2.5 Effects of incorrect adjustments 1 |
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78 | (1) |
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5.2.6 Information sources E 1 |
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79 | (1) |
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80 | (141) |
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81 | (44) |
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6.1.1 Operating cycles E 1 |
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81 | (6) |
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6.1.2 Engine variations E 1 |
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87 | (6) |
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6.1.3 Engine operating details 1 |
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93 | (5) |
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6.1.4 Terminology and systems 1 |
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98 | (12) |
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6.1.5 Cylinder components 2 |
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110 | (1) |
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6.1.6 Valves and valve gear 2 |
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111 | (3) |
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114 | (7) |
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6.1.8 Cylinder deactivation 3 |
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121 | (1) |
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122 | (1) |
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123 | (1) |
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6.1.11 Variable compression (VC) engine 3 |
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124 | (1) |
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125 | (9) |
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6.2.1 Friction and lubrication E 1 |
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125 | (1) |
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6.2.2 Oils and specifications E 1 |
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126 | (1) |
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6.2.3 Lubrication system operation 1 |
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127 | (1) |
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6.2.4 Oil pumps and filtration 1 |
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128 | (2) |
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6.2.5 Oil lubrication systems 2 |
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130 | (2) |
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6.2.6 Other lubrication components 2 |
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132 | (1) |
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6.2.7 Oil filter modules 2 |
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133 | (1) |
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134 | (13) |
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6.3.1 Cooling introduction E 1 |
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134 | (3) |
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6.3.2 Components and operation 1 |
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137 | (3) |
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6.3.3 Cooling and heating 1 |
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140 | (1) |
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140 | (1) |
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141 | (4) |
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145 | (1) |
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6.3.7 Thermal management system (TMS) 3 |
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146 | (1) |
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147 | (37) |
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147 | (3) |
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6.4.2 Electronic fuel injection 1 2 |
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150 | (12) |
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6.4.3 Bosch DI-Motronic 3 |
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162 | (3) |
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6.4.4 Gasoline DI electronic control 3 |
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165 | (1) |
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6.4.5 Diesel introduction 1 |
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166 | (7) |
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173 | (3) |
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176 | (4) |
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6.4.8 Diesel injection pressure 3 |
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180 | (1) |
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6.4.9 Common rail intelligent injectors 3 |
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181 | (2) |
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6.4.10 Coding components 3 |
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183 | (1) |
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184 | (13) |
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6.5.1 Ignition overview E 1 |
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184 | (3) |
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6.5.2 Electronic Ignition 1 2 |
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187 | (3) |
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6.5.3 Electronic spark advance 2 |
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190 | (2) |
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6.5.4 Distributorless ignition 2 |
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192 | (1) |
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6.5.5 Coil on plug ignition 2 |
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193 | (1) |
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6.5.6 Spark plugs and leads 2 3 |
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194 | (2) |
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6.5.7 Spark plug electrode designs 3 |
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196 | (1) |
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6.5.8 Dynamic skip fire 3 |
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197 | (1) |
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6.6 Air supply, exhaust and emissions |
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197 | (24) |
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197 | (1) |
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6.6.2 Worldwide harmonized light vehicles test procedure 3 |
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198 | (1) |
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199 | (2) |
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6.6.4 Engine combustion 1 |
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201 | (1) |
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6.6.5 Environmental protection 1 |
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201 | (2) |
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203 | (3) |
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6.6.7 Exhaust systems E 1 |
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206 | (2) |
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208 | (2) |
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6.6.9 Diesel particulate filters (DPF) and selective catalytic reduction (SCR) 3 |
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210 | (3) |
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6.6.10 Emission control systems 3 |
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213 | (3) |
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216 | (1) |
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6.6.12 Pressure charging 3 |
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216 | (3) |
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6.6.13 Electrical pressure chargers 3 |
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219 | (2) |
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221 | (129) |
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7.1 Electrical and electronic principles |
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222 | (22) |
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7.1.1 Electricity and the atom E 1 |
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222 | (1) |
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7.1.2 Basic circuits and magnetism 1 |
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223 | (2) |
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7.1.3 Electrical components 1 |
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225 | (6) |
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7.1.4 Electronic components 2 |
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231 | (3) |
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234 | (4) |
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7.1.6 Central electrical control 3 |
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238 | (6) |
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244 | (29) |
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7.2.1 Battery introduction E 1 |
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244 | (2) |
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7.2.2 Battery types and charging 1 |
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246 | (3) |
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7.2.3 Absorbent glass mat (AGM) batteries 3 |
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249 | (1) |
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249 | (2) |
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251 | (1) |
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7.2.6 Starting system 1 2 |
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252 | (6) |
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7.2.7 Starting system testing 2 |
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258 | (1) |
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7.2.8 Charging system 1 2 3 |
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259 | (8) |
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7.2.9 Charging system testing 2 |
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267 | (2) |
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7.2.10 Stop-start control 3 |
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269 | (2) |
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7.2.11 Electronic starter motor control 3 |
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271 | (1) |
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272 | (1) |
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7.2.13 Jump start without a battery 3 |
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272 | (1) |
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7.3 Lighting and indicators |
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273 | (13) |
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7.3.1 Lighting systems E 1 |
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273 | (3) |
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7.3.2 Stoplights and reverse lights 31 |
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276 | (2) |
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7.3.3 Interior lighting 1 |
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278 | (1) |
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7.3.4 Lighting circuits 2 |
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279 | (1) |
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7.3.5 Indicators and hazard lights 2 3 |
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280 | (3) |
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7.3.6 Other lighting technology 3 |
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283 | (2) |
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7.3.7 BMW laser headlamps 3 |
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285 | (1) |
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286 | (21) |
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7.4.1 Washers, wipers and screens 1 2 |
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286 | (3) |
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7.4.2 Horns, obstacle avoidance and cruise control 1 2 |
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289 | (2) |
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7.4.3 Mobile multimedia 1 2 |
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291 | (2) |
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7.4.4 Seats, mirrors, roofs and locking 2 |
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293 | (4) |
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297 | (1) |
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7.4.6 Starting, alarming and locking 3 |
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298 | (4) |
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302 | (5) |
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7.5 Monitoring and instrumentation |
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307 | (22) |
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307 | (2) |
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309 | (3) |
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7.5.3 Instrument displays 1 2 |
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312 | (3) |
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7.5.4 Vehicle condition monitoring 2 |
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315 | (2) |
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7.5.5 Digital instrumentation system 3 |
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317 | (1) |
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7.5.6 Global positioning system 3 |
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318 | (4) |
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7.5.7 Drowsiness detection 3 |
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322 | (1) |
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7.5.8 Laser head-up displays (HUDs) 3 |
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323 | (1) |
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7.5.9 Connected vehicles 3 |
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324 | (3) |
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7.5.10 Hacking and cybersecurity 3 |
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327 | (2) |
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7.6 Heating, ventilation and AC |
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329 | (11) |
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7.6.1 Ventilation systems E 1 |
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329 | (1) |
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7.6.2 Vehicle heating E 1 2 |
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330 | (2) |
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7.6.3 Air conditioning fundamentals 2 |
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332 | (2) |
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7.6.4 Air conditioning components 3 |
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334 | (1) |
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7.6.5 Air conditioning systems 3 |
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335 | (2) |
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7.6.6 Other heating systems 3 |
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337 | (1) |
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338 | (2) |
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340 | (10) |
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340 | (2) |
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7.7.2 Controller area network (CAN) 3 |
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342 | (2) |
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344 | (1) |
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7.7.4 Local interconnect network (LIN) 3 |
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345 | (1) |
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346 | (2) |
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7.7.6 Other networking methods 3 |
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348 | (2) |
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350 | (81) |
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351 | (19) |
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8.1.1 Reasons for suspension E 1 |
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351 | (3) |
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354 | (4) |
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8.1.3 Dampers/shock absorbers 1 2 |
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358 | (3) |
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8.1.4 Front suspension layouts 2 |
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361 | (2) |
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8.1.5 Rear suspension layouts 2 |
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363 | (3) |
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8.1.6 Active suspension 3 |
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366 | (3) |
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369 | (1) |
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370 | (23) |
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8.2.1 Steering introduction E 1 |
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370 | (1) |
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8.2.2 Steering control 1 2 |
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371 | (2) |
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8.2.3 Steering components 1 2 |
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373 | (3) |
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8.2.4 Power steering introduction 1 2 |
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376 | (2) |
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8.2.5 Hydraulic power steering 2 |
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378 | (2) |
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8.2.6 Electric power steering 2 3 |
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380 | (4) |
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8.2.7 Steering geometry 2 |
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384 | (6) |
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8.2.8 Advanced wheel alignment 3 |
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390 | (3) |
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393 | (25) |
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8.3.1 Brakes introduction E 1 |
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393 | (2) |
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8.3.2 Disc, drum and parking brakes 1 2 |
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395 | (3) |
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8.3.3 Hydraulic components 1 2 |
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398 | (2) |
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8.3.4 Brake servo operation 2 |
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400 | (2) |
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8.3.5 Braking force control 2 |
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402 | (1) |
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8.3.6 Carbon ceramic brakes |
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403 | (1) |
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8.3.7 Anti-lock brake systems 2 3 |
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404 | (5) |
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409 | (3) |
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8.3.9 Electronic parking brakes |
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412 | (1) |
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8.3.10 Traction control 3 |
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413 | (2) |
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8.3.11 Electronic stability program 3 |
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415 | (3) |
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418 | (13) |
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418 | (3) |
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421 | (1) |
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8.4.3 Wheels and rims 1 2 |
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422 | (4) |
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8.4.4 Tyre pressure monitoring 2 |
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426 | (1) |
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8.4.5 Spare wheels and extended mobility 1 2 |
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427 | (1) |
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8.4.6 Wheel balancing 1 2 |
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428 | (3) |
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431 | (53) |
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432 | (11) |
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9.1.1 Purpose of the clutch E 1 |
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432 | (1) |
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9.1.2 Clutch mechanisms 1 |
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433 | (2) |
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9.1.3 Coil spring clutch 1 2 |
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435 | (1) |
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9.1.4 Diaphragm clutch 1 2 |
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436 | (4) |
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9.1.5 Other types of clutch 2 |
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440 | (2) |
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9.1.6 Electronic clutch 3 |
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442 | (1) |
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443 | (9) |
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9.2.1 Gearbox operation E 1 |
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443 | (2) |
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9.2.2 Gear change mechanisms 1 2 |
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445 | (2) |
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9.2.3 Gears and components 1 2 |
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447 | (1) |
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9.2.4 Synchromesh mechanisms 2 |
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448 | (2) |
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9.2.5 Front- and rear-wheel drive 2 |
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450 | (2) |
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9.3 Automatic transmission |
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452 | (18) |
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9.3.1 Torque converter 1 2 |
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452 | (2) |
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9.3.2 Automatic transmission operation 1 2 |
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454 | (3) |
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9.3.3 Electronic and hydraulic control 3 |
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457 | (2) |
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9.3.4 Constantly variable transmission 3 |
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459 | (3) |
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9.3.5 Transaxle transmission 3 |
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462 | (2) |
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9.3.6 Direct shift gearbox 3 |
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464 | (6) |
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470 | (9) |
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470 | (2) |
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472 | (1) |
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9.4.3 Rear-wheel drive bearings 1 2 |
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473 | (2) |
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9.4.4 Front-wheel drive bearings 1 2 |
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475 | (1) |
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9.4.5 Four-wheel drive systems 3 |
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476 | (3) |
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9.5 Final drive and differential |
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479 | (5) |
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479 | (1) |
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9.5.2 Differential operation 1 2 |
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480 | (2) |
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9.5.3 Limited slip differentials 3 |
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482 | (2) |
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484 | (63) |
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10.1 Diagnostic techniques |
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485 | (18) |
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10.1.1 Introduction 1 2 3 |
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485 | (1) |
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10.1.2 Equipment overview E 1 2 |
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486 | (1) |
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10.1.3 Diagnostic process 2 3 |
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487 | (3) |
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10.1.4 Mechanical diagnostics 3 |
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490 | (3) |
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10.1.5 Electrical diagnostics 3 |
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493 | (5) |
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10.1.6 Real world diagnostics 3 |
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498 | (4) |
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10.1.7 Pass-through overview 3 |
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502 | (1) |
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10.2 Diagnostic tools and methods |
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503 | (18) |
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503 | (2) |
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505 | (4) |
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509 | (1) |
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10.2.4 Other test equipment 2 3 |
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510 | (4) |
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10.2.5 Pressure analysis 3 |
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514 | (5) |
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10.2.6 Calibrating components 3 |
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519 | (2) |
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521 | (7) |
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10.3.1 On-board diagnostics 2 3 |
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521 | (1) |
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522 | (2) |
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524 | (2) |
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10.3.4 ECU fuel trim diagnostics 3 |
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526 | (2) |
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10.4 Oscilloscope diagnostics |
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528 | (19) |
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528 | (10) |
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538 | (3) |
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541 | (3) |
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10.4.4 Other components 3 |
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544 | (3) |
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11 A Trending future: Electric and hybrid vehicles and ADAS |
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547 | (19) |
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11.1 Electric and hybrid vehicles overview |
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548 | (3) |
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548 | (1) |
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11.1.2 Electric vehicle market 1 2 |
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548 | (1) |
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11.1.3 The EV experience 1 2 |
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548 | (1) |
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549 | (2) |
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11.2 Electric vehicle systems and components |
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551 | (4) |
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11.2.1 Types of electric vehicles 1 2 |
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551 | (1) |
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11.2.2 Identifying electric and hybrid vehicles 1 2 |
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552 | (1) |
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11.2.3 High voltage components 1 2 |
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553 | (1) |
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11.2.4 Motors and batteries overview 1 2 |
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553 | (1) |
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554 | (1) |
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555 | (2) |
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11.3.1 Risks of working with EVs 1 2 |
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555 | (2) |
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557 | (1) |
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11.4 Advanced driver assistance systems overview |
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557 | (6) |
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557 | (2) |
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559 | (2) |
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561 | (1) |
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562 | (1) |
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11.5 Alternative fuels 1 2 3 |
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563 | (3) |
Index |
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566 | |