Professional Documents
Culture Documents
Student Workbook
LV05
Routine
Maintenance
LV05/SWB
Student Workbook for Technical Certificates
In Light Vehicle Maintenance and Repair
MODULE LV05
ROUTINE MAINTENANCE
Contents
Page Page
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Introduction
Within this module the following learning objectives will be covered:
• identify the regulations relating to the repair and use of light vehicles.
All items discussed within this module need to be supported with practical
exercises in the workshop.
Pre-delivery Service
The pre-delivery service is the first service undertaken by the dealership upon
delivery of the vehicle from the factory. This service is required to check that
the vehicle is in perfect condition before it is delivered to the customer.
Vehicles are checked before leaving the factory, but they then undergo
lengthy transportation before reaching their final destination and for this
reason a pre-delivery service is needed.
Due to the length of time that a vehicle may be either stored or in transit,
various protection items are either fitted or, in some cases, protection items
are removed.
The tyres are inflated above the standard pressure to reduce damage. The
tyre pressures must be adjusted accordingly, otherwise the customer will
experience poor ride quality and uneven tyre wear.
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Anti rust covers are fitted to each of the front and rear discs by the factory, to
eliminate the build up of rust on the discs. These anti rust covers must be
removed before the vehicle is driven any distance as the brakes will overheat
due to lack of cooling. Some manufacturers attach warning labels to the
windscreen of the vehicle to warn the driver that anti rust covers are fitted.
Plastic covers protect the inside of the vehicle, and these again must be
removed before the vehicle is delivered to the customer. Be careful when
removing these covers, as it is easy to damage the material that they protect.
Sharp implements should not be used when removing these covers.
A wax coating is used to protect the exterior paint finish of the vehicle, and as
with the previous items this needs to be removed before delivery to the
customer. De-waxing agents are usually needed to remove the wax fully, and
caution must be taken not to damage the paint finish.
Items that were not fitted by the factory, like mirrors and wheel covers must be
fitted, and any transit fuses must be replaced with the correct amperage fuse.
Finally the pre-delivery service must be carried out. Carrying out a pre-
delivery service in the correct order will help reduce the time needed to
complete the task; an example of this is given below.
Vehicle exterior
• lights
• exterior finish (paint/body work)
• doors
• bonnet
• boot
• tail gate
• exterior glass
• fuel flap.
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Bonnet raised and engine stopped
• engine coolant
• windscreen washer fluid
• engine oil
• brake and clutch fluid
• power steering fluid
• battery terminal
• fit transit fuse
• wiring connectors
• hose connectors.
Under vehicle
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Vehicle interior
• seats
• seat belts
• seat belt hangers
• interior electrical systems.
Road test
• brakes
• clutch
• engine performance
• transmission
• differential
• any transfer boxes
• steering
• suspension
• any body noise.
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Final inspection
• remove all plastic coverings
• inspect all the interior parts for installation, quality of fit and cleanliness
• wash exterior of vehicle and check paint finish
• inspect all exterior body parts for installation, quality of fit and damage
• fit carpets and mats.
Each manufacturer will have their own pre-delivery check sheets although the
majority of the items listed will be the same for all manufacturers. On this and
the following pages there are examples of a pre-delivery form used by BMW
and Lexus.
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Routine Maintenance
Seat covers
Floor mats
Wing covers
Over a period of time the condition of a vehicle will slowly deteriorate. For this
reason all manufacturers have a service schedule for each vehicle. This
reduces the wear on components and enhances the reliability of the vehicle.
As no two vehicles are driven under the same conditions or by the same
person, uniform wear on components cannot be guaranteed. Routine
maintenance enables the dealership to monitor the condition of the vehicle,
adjust and change components, monitor the level of and change lubricants as
required and report any items that may need changing before the next
service. By carrying out these services the vehicle should be kept in the best
possible condition for the customer, and it will also conform to local laws and
regulations.
Before any work can start on the vehicle, it is essential that the vehicle is
protected from any dirt that may be present on either the inside or outside of
the vehicle. The exterior of the vehicle also needs to be protected against
scratches, which may occur while the technician is working. Keeping the
customer happy is important and no customer likes to return to a dirty vehicle.
To protect the vehicle, covers are placed on the front and rear wings, seats,
floor mats and the steering wheel.
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Why regularly service vehicles?
There are several reasons why we need to regularly service vehicles, these
include:
• safety
• reliability
• optimised performance.
It sounds like sales talk, but if you can carry out a service at a high standard,
with an added personal touch, the customer will continue bringing their vehicle
to your dealership. The more customers you retain, the more lucrative your
company will be and you will benefit from this.
Fig 6
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Throughout the servicing procedure you must be aware of the maintenance
items. The manufacturer’s specific service check sheet will list all items to be
carried out. These can be broken down to the following:
• lubricate
• check
• replace
• change
• inspect
• adjust
• tighten.
It is in your best interest to carry out the service within the manufacturer’s time
constraint. Every task has a set time allowance laid out by the manufacturer,
and working in an efficient manner will ensure that all customers will receive
their vehicles at the promised handover time. Below is an example of the
service intervals and the time allocated for a Toyota Yaris.
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The intervals and time allocated will change, depending on the manufacturer
and the type of vehicle.
So how can you arrange a service so that you cut the time to a minimum?
The easiest way to reduce the duration of a service is to limit the times that
the vehicle is lifted and lowered on a ramp. Consider the lost time you spend
idle waiting for a vehicle to be lifted to a comfortable working height. This is
time that is better spent carrying out work on that vehicle. If you only need to
lift and lower the vehicle once, you could save more than ten minutes.
Generally you have to drive the vehicle into the workshop. This is the ideal
time to check the interior, the electrical systems, the brake and clutch freeplay
and hand brake travel.
When you get out of the vehicle a check should be carried out on wiper
blades, condition of light lenses and the exterior body. You need to look for
dents, chips and scratches which may lead to corrosion. This will shorten the
life of the vehicle and a customer will not always know they have this damage
or the importance of knowing it.
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Now would be the time to lift the vehicle on to the ramp. The oil can be left to
drain, whilst an under body check is carried out. Waiting for the oil to drain is
a waste of time. It is good to fill this time with productive work. The checks
you carry out will identify any additional work that may need to be done. This
can be raised with the Service Adviser early on in the service, so that the
customer can be contacted. If additional work is carried out while you have
the vehicle already on your ramp, the work will be completed in a quicker time,
which will satisfy the customer on receipt of the bill. This is also a good time
to go to the Parts Department. There are very few dealerships that have the
Parts Department bring the parts to you. This is also time wasting.
After checking the front and rear brakes whilst lowering the vehicle, an under
bonnet check needs to be carried out. Check all fluid levels, fill engine oil to
correct level, go around the vehicle and torque the wheel nuts and check tyre
conditions.
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The final part of the service is the road test. Check for abnormal noises,
steering pulls and correct operation of all vehicle systems.
When parking the vehicle outside the dealership it is advisable to reverse into
a parking space. This gives the customer a hassle free drive away. The last
reminder of their visit will be a pleasant one.
To assist the technician with the completion of the service, the manufacturer
produces a document called a service sheet. This service sheet is a tick
sheet that outlines what needs to be checked at what interval. Examples of a
BMW and Toyota service sheet are shown on the next two pages.
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Other documentation that is available to the technician are technical bulletins
and various workshop manuals. The technical bulletins will help the
technician to stay up to date with any modifications to either the vehicle or the
workshop manuals. They will also contain any recall information relating to
the vehicle, which may enable the technician to carry out these modifications
while the vehicle is in for service. This benefits the customer, as they do not
have to return the vehicle to the dealership, to have modifications carried out.
Finally when the service is complete a job card will need to be completed
outlining what has been done and any other work that is needed. It is
essential that all documentation is completed fully as it enables the customer
to see exactly what has been done to the vehicle.
If other work is needed on the vehicle then the customer must be kept
informed. The customer may decide that the extra work should be carried out
while the vehicle is in for service, or they may decide to do it at a later date.
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Progress check 1
Answer the following questions:
1. Can you think what constitutes as a road or environmental condition,
which may change a service interval? Make a list below.
Check wipers
Change oil filter
Inspect suspension
Check brake pedal free-play
Check and adjust tyre pressures
Inspect seat belts
Top up washer fluid
Check and clean out rear brakes
Check exhaust for corrosion and alignment
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Routine Maintenance Checks
The following checks are taken in order from a Lexus 10,000 miles check
sheet. Although some of the items checked may differ between
manufacturers, most basic items are generic.
Engine oil performs many functions within the engine and needs to be
changed periodically. Its functions include:
Precautions:
• allow the oil to cool for a few minutes before it is drained to reduce the
chances of getting burnt
• keep vehicle level when checking oil level
• check that the oil warning light goes out when the vehicle is started after
the oil has been replenished
• dispose of the oil in the correct manner (never pour into the drainage
system).
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Gearbox oil level/gearbox and differential leakage
As with the engine oil, the oil within the gearbox and differential will deteriorate
over a period of time. It is important that the oil within the gearbox and
differential is at the correct level, and that the viscosity of the oil does not
change. The oil in the gearbox and differential is used to lubricate all of the
gears and bearings, if the level becomes low then these will be subject to
seizure.
Precautions:
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Dampness on the underside of the
differential and gearbox
When the level has been checked it is also important to visually check around
both the gearbox and differential for any signs of leaks. These normally take
the form of moisture around the lower part of the unit.
The power steering fluid, as with most fluids, is visually checked during each
of the service intervals. If the power steering fluid becomes low, then the
amount of pressure generated will not be enough to operate the system and
the steering will become hard. Another indication for the driver that the power
steering fluid has become low is that it will make abnormal noises. A
technician will be aware of this if it is reported prior to the service.
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Fig 16
Precautions:
• on full lock can raise the temperature of the power steering fluid, but this
should not be done for more than ten seconds or damage may occur
• holding the steering on full lock can also be used to pressure the system
when checking for leaks
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Brake and clutch fluid
The brake fluid is used to operate the brakes, and both the reservoir and
brake lines must stay within a given range at all times. If the fluid becomes
low the brakes will not operate causing a serious malfunction. Unlike the
power steering fluid the brake fluid needs changing periodically. This is due to
the brake fluid having hygroscopic properties. Hygroscopic properties mean
that it will absorb airborne moisture causing its boiling point to lower. If the
boiling point is lowered then the brake fluid becomes prone to vapour lock
under severe operation causing the brakes to become inoperative. The clutch
also uses brake fluid so the same checks apply
Precautions:
• When checking the brake fluid level, if it is low then before topping up,
check that the brake pads and shoes are not worn. If the brake fluid is
topped up when the pads are worn, when they are changed the fluid will
flow over the top of the reservoir, if left it will cause damage to the paint on
which it spills.
• If the fluid is low and the pads and shoes are not worn, then a thorough
check for leaks needs to be carried out.
• Always use new brake fluid and not old brake fluid that has been stored for
a long time. This is because brake fluid is a hygroscopic fluid.
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Valve clearance
In order for the engine to run correctly the valves must open and close at the
correct time and when closed they must form an airtight seal between
themselves and the valve seat. To enable this to happen there is a gap left
between the valve bucket and the camshaft lobe. Alternatively, on older
engines the gap may be between rocker arm and the top of the valve, or
between the rocker arm and the camshaft lobe.
This gap enables the various components to expand due to heat expansion
when the engine is at normal running temperature. As an engine gets older
the various components associated with valve operation become worn,
causing an increase in valve clearance. This increase in clearance can lead
to loss in engine performance and rattle noise from the tappets.
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Precautions:
• when the number one cylinder is at TDC exhaust/inlet adjust the valve
clearance of the corresponding cylinder (on a four cylinder engine number
four cylinder), as both valves will be closed due to the cylinder being at
TDC compression/combustion.
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Coolant level
The coolant level as with other fluids is checked visually during each of the
periodic services. The coolant level will naturally drop over a long period of
time so it must be replenished when required. Low coolant level may also
indicate a leak or fault within the engine, this will be discussed within Cooling
Systems (2) LV21 and Engines (2) LV20.
Fig 21
Precautions:
When removing the radiator cap when the engine is hot, great caution must
be used. The following procedure must be used:
• start to loosen the cap slowly until steam starts to come out
• loosen the cap further until steam starts to come out again
• continue this procedure until the cap is released and no steam is being
emitted.
Replenish the coolant with the correct coolant fluid as some fluids are water
based and some fluids are oil based. If the engine is using oil based coolant
there is usually a sticker under the bonnet to warn the driver. When
replenishing the coolant fluid make sure the correct amount of antifreeze is
added.
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Drive belts
Drive belts as with other components on the vehicle become worn as they
become older. These drive belts or auxiliary belts are used to drive
components such as, the alternator, power steering pump, air conditioning
compressor and water pump. Over a period of time these belts become
stretched and cracked causing a loss in drive to the component. For this
reason they must be changed periodically, and visually checked during each
service.
Precautions:
• if the belt is to tight then damage may be caused to the bearings within the
component
• if the belt is to loose then the component will not operate correctly and a
whistling noise will be heard (this whistling noise can also be caused by
the belt becoming old and hard)
• check the difference in tension between an old belt and a new belt.
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Timing belt
The timing belt must be changed at the intervals laid down by the
manufacturer. When the timing belt becomes worn it can become cracked or
damaged, or in severe cases the teeth may physically come away from the
belt. Depending on the vehicle and manufacturer the amount of damage that
this may cause can vary from no damage, to complete destruction of the
engine. As the compression ratios on modern engines are now higher for
both petrol and diesel, the clearance between the valves and the pistons has
been reduced, so the amount of damage caused is generally very high.
Precautions:
• follow manufacturer’s procedures for the removal and refit of the cam belt
• remove any oil or water from the components on which the belt will run.
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Spark plugs
The period between changing spark plugs has extended over the past few
years. This is due to the use of better materials and the introduction of
platinum tipped spark plugs. The spark plug works in the hottest part of the
engine and is subject to temperatures in excess of 2000°C and pressures
over 40 kg/cm².
As the spark plug wears the distance between the centre electrode and the
ground electrode increases, this causes a reduction in the strength of the
spark, which can lead to engine misfire. Similar problems may occur when
the spark plug becomes contaminated with carbon residue left over from the
combustion process.
Precautions:
• platinum tipped plugs should not be cleaned using a spark plug cleaner
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EGR and charcoal canister
Charcoal canister
The charcoal canister forms part of the fuel system and is used to collect the
petrol vapours generated within the petrol tank. The petrol vapours or
hydrocarbons are collected within the charcoal canister and then condensed.
When the engine is running the petrol vapours are drawn through the throttle
body and into the combustion chamber where they are burnt as part of the
combustion process. Charcoal canisters were introduced to reduce
hydrocarbons emissions as on older systems the petrol vapours were vented
to the atmosphere.
The exhaust gas re-circulation system is fitted to reduce the NOx gasses
generated by the engine during the combustion process. The EGR system
reintroduces some of the exhaust gas back in to the combustion chamber. As
the exhaust gas is comprised mainly of carbon dioxide and water, this has the
effect of cooling the combustion chamber, thus reducing NOx.
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Fuel filters
Fuel filters are fitted to both petrol and diesel engines and they are used to
remove any dirt or water from the fuel. If dirty fuel is able to get past the fuel
filter then clogging of the injectors or the carburettor may occur on a petrol
engine. On a diesel engine the injectors may also clog, although other
problems may occur including wearing of parts, seizing of precision parts and
engine misfire. The fuel filters must be changed periodically, due to the
accumulation of dirt and water within the fuel filter. If the fuel filter becomes
blocked there will be a loss in engine performance. On some diesel engines
the water can be drained from the bottom of the fuel filter and this lengthens
the service life of the filter.
Precautions
• when disconnecting the fuel filter on a petrol engine, place a rag over the
pipe - this is needed as a small amount of pressure may be left in the line
and this could spray out
• when changing a diesel fuel filter, filling the new filter with clean fuel before
Fig 26 fitting will reduce the time needed to bleed the system
• be careful not to damage any fuel pipes when removing or refitting the fuel
filter.
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Air filter
The air filter like the fuel filter stops dust and dirt from entering the engine.
The air filter is placed before the throttle body and intake manifold to remove
all contamination before it enters the combustion chamber. Any dust entering
the combustion chamber will cause rapid wear of the cylinder. If the air filter
becomes clogged then engine performance will decrease and this is why it
needs to be changed periodically.
Brake system
At all service intervals the entire brake system must be visually checked for
leaks. As the brake system operates on pressure generated within the master
cylinder and passing through pipes to the brake cylinder, any leaks will cause
a drop in pressure. If brake pressure is lost then the brake system will fail
creating a very dangerous situation for the driver.
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Precautions:
• when inspecting brake hoses use a mirror to check the rear side of the
hose
• make sure that there is adequate light to enable the checks to be carried
out fully
• check the brake pipes for leaks, cracks, splits and bulges.
The brake pedal is an essential part of the braking system, so it must be kept
adjusted to the correct height. If the brake pedal is adjusted too high then it
will take the driver extra time to reach the brake pedal from the accelerator. If
the brake pedal is too low, then the amount of force generated during braking
will be insufficient. When the pedal is adjusted correctly it will have the correct
amount of free play and reserve distance. Free play is needed otherwise the
master cylinder piston would always have pressure applied to it, which would
cause brake drag. Reserve distance is needed to check that there is enough
travel in the brake pedal to apply the correct amount of pressure to the brake
cylinders.
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Brakes pads and discs
The brake disc is sandwiched between the two brake pads which have
pressure applied to them by the cylinder piston to cause the vehicle to stop.
This braking action causes friction between the disc and the pads and this in
turn causes wear on both items. As the brake pads are made of a softer
material than the brake disc they tend to wear more quickly. For this reason
they need to be checked periodically.
Precautions:
• visually check the pads through the inspection hole (minimum thickness
normally between 1mm and 3mm)
• be careful not to damage the brake hoses when removing the calliper
• apply brake grease to the back of the pads to reduce brake squeal
• check the brake master cylinder fluid level when the brake pads have been
replaced.
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Exhaust system
The securing point on the exhaust system needs to be checked for damage,
as does the system itself for leaks.
The ball joints need to be checked at given intervals, as wear to these joints
will cause abnormal noise and make the vehicle unstable to drive. On some
older models it may be a requirement to grease the ball joint during the
service.
The drive shaft boots require checking for splits and damage. If the boots
become damaged then grease will leak out, and dirt and contamination will
get in. When the drive shaft bearings become contaminated they will not
move smoothly, causing abnormal noise and vibration.
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Front and rear suspension operation
First, carry out a visual inspection on the vehicle when it is in place on level
ground. The vehicle should sit level and not slope to either side. Then
bounce both the front and rear of the vehicle, checking that it returns to the
level position after approximately one and a half oscillations.
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Battery electrolyte levels
Precautions:
• do not use tap water as the impurities within the water will reduce battery
performance
• do not overfill the battery as it may overflow and cause damage to metal
parts
• the battery electrolyte consists of distilled water and sulphuric acid, so if it
comes in to contact with the skin rinse with water immediately
• if the electrolyte comes into contact with the eyes then flush out with water
and seek medical advice
• check the battery case for cracks or damage while visually checking the
electrolyte level.
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Oil cooler, heater and fuel system
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Tyre condition and tyre pressure
The tyres are the only component on the vehicle that come into contact with
the road. It is the friction between the tyre and the road that determines the
way in which the vehicle handles, and how quickly the vehicle can stop. The
tyre also acts as part of the suspension system reducing the amount of road
shock that is transmitted to the vehicle body. If the tyre has been over inflated
then the ride will be hard, the centre tread of the tyre will wear and the
handling capabilities of the vehicle will be reduced. Under inflation will cause
high rolling resistance resulting in heavy steering, excessive tread wear on the
outer edges of the tyre and an excessive build up of heat within the tyre at
high speeds.
As well as the tyre pressure, the tyre condition must also be checked. If the
tyre demonstrates uneven wear then there could be numerous causes, from
suspension and steering faults to tyre pressure. Another possible cause is
that the tyre has been used in the same position for a long period of time, so it
is beneficial to rotate the tyres. The final check on the tyre should be a tread
depth check, to make sure the tyre is legal.
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When all of the checks have been carried out, the wheel nuts should first be
slackened and then re-tightened to the correct torque as given by the
manufacturer.
Listed below are the checks associated with the steering linkage and steering
wheel free play.
Moving the steering wheel in all directions can check the steering wheel
installation. This test will also check that the main shaft bearing is not loose,
and that the steering wheel is secured correctly to the main shaft.
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Steering wheel free play can be checked while sitting in the same position.
Place the steering wheel in the straight-ahead position and check that the
front wheels correspond to the steering wheel. Now move the steering wheel
slightly to the left or right without the wheels actually moving. Check the
manufacturer’s specifications for the amount of free play there should be. If
there is excessive free play then one of the following problems may have
occurred:
Wear in the steering linkage can be checked by raising the front of the vehicle
off the ground and moving the wheels back and forth. If there is excessive
movement then either wheel bearings or worn steering linkage is a possible
cause. Either using a two-poster ramp or a trolley jack can raise the front of
the vehicle; if a trolley jack is used then axle stands must be used to support
the vehicle.
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As with the steering linkage the wheel bearing play can be checked, by first
raising the front of the vehicle off the ground, and then gripping the wheel at
the top and bottom and seeing if there is any play in the wheel. If there is play
then the same task must be carried out with the brakes applied. If the amount
of play is reduced and not eliminated totally then it is probably not a wheel-
bearing fault.
The front and rear lights are important for both the driver of the vehicle and
other road users. They enable the driver to drive with clear vision at night,
and alert other drivers to manoeuvres that the vehicle is going to make. If any
of the systems are operating incorrectly then driving can become extremely
dangerous. In order for the lights to be checked correctly the aid of a second
technician may be necessary.
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The following lights need to be checked as part of the service:
Door hinges
Lubricating the door hinges guarantees correct operation of all the doors.
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Windscreen washers and wipers
As with the electrical system the windscreen wipers and washers are essential
for safe driving in varying weather conditions. The operation of the washer
pump should be checked, along with the operation of the windscreen wipers.
The windscreen wipers themselves should be checked for splits or wear.
Other checks include noise during operation and the wiper arm mounting nuts
for tightness.
All front and rear seat belts now have to be worn by law, so it is essential that
they are checked for operation. They must also be checked for wear, and the
anchor point bolts must be checked for security.
Fig 50
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Body damage and corrosion
When the vehicle is first produced all the panels are treated to try to prevent
them from rusting. Over a period of time dirt, moisture and road salt will
accumulate on some areas of the vehicle, and also the paint and underseal
will become chipped due to stones being thrown up from the road. This
accumulation of contaminants and damage will cause corrosion to occur. For
this reason the body panels and the underside of the vehicle needs to be
checked for rust.
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MOT
The MOT is the final part of the routine maintenance schedule, below is a list
of points that outline the MOT process.
• the first test is required when the vehicle reaches three years old (there
are different rules if the vehicle is used as a taxi)
• giving advice/taking disciplinary action where tests are not being carried
out to the required standards
If you consider that a vehicle incorrectly failed the MOT, then an appeal form
VT17 is available from the MOT station. Alternatively an enquiry line (0845
6005977) is available. The complaint must be registered within 14 days and a
recheck will be carried out within 5 days.
Duplicate certificates can be issued from the MOT station that carried out the
original test on the vehicle. If the MOT station has closed down then the local
VOSA office should be able to help.
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Roadside checks may also be carried out on vehicles. These checks are
carried out against the following regulations, dependent on the class of
vehicle:
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Items checked during the MOT:
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Progress check 2
1. When carrying out a service, what tasks need to be carried out on the
following vehicle systems: vehicle body, tyres, brakes?
a) _________________________ b) _________________________
c) _________________________ d) _________________________
7. What is the minimum thickness that you would accept for disc pad
linings?
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Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
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