You are on page 1of 53

kap all covers 6/9/03 9:48 am Page 9

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

Introduction 3 Brake pedal free play 35


Brake pads and discs 36
Pre-delivery Services: 3 Exhaust system 37
Vehicle exterior 4 Ball joint and drive shafts 37
Bonnet raised and engine stopped 5 Front and rear suspension operation 38
Bonnet raised and engine running 5 Battery electrolyte levels 39
Under vehicle 5 Oil cooler, heater and fuel system 40
Vehicle interior 6 Tyre condition and tyre pressure 41
Road test 6 Steering wheel free play and linkage 42
Final inspection 7 Electrical systems and lights 44
Door hinges 45
Routine Maintenance: 11 Windscreen washers and wipers 46
Why regularly service vehicles? 12 Seat belts and anchorage points 46
Progress check 1 20 Body damage and corrosion 47

Routine Maintenance Checks: 21 The MOT: 48


Engine oil and filter change 21 Items checked during the MOT 50
Gearbox oil level/gearbox and Progress check 2 51
differential leakage 22
Power steering fluid level 23
Brake and clutch fluid 25
Valve clearance 26
Coolant level 28
Drive belts 29
Timing belt 30
Spark plugs 31
EGR and charcoal canister 32
Fuel filters 33
Air filter 34
Brake system 34

-1-
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
-2-
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
Introduction
Within this module the following learning objectives will be covered:

• explain the purpose of routine maintenance

• identify sources of information relating to vehicle maintenance

• describe the purpose and methods of vehicle inspection

• explain the need for vehicle protection prior to maintenance activities

• 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.

Routine maintenance is required to keep the vehicle in a roadworthy condition


throughout its serviceable life. A maintenance schedule begins with a pre-
delivery service when the vehicle is new, and then continues at predetermined
intervals, as the vehicle gets older. When the vehicle becomes three years
old it is required to undertake an MOT. After its first MOT it is required to
undertake further MOT’s annually.

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.

-3-
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
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.

-4-
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
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.

Bonnet raised and engine running

• engine condition (abnormal noise)


• manual transmission or automatic transmission fluid level
• any fluid leaks.

Under vehicle

• any fluid leaks


• exhaust system
• removal of disc brake anti rust covers
• removal of suspension transit chocks (some manufacturers)
• wheel nuts (torque)
• tyres
• install additional parts supplied (which require the vehicle to be raised).

-5-
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
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.

-6-
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
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.

-7-
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
-8-
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
-9-
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
- 10 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
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.

- 11 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
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.

One of the main requirements of a vehicle technician is to visually check


systems and components to ensure they are in correct working order.
Prolonged usage of a vehicle without inspection may result in excessive
damage to working parts with costly repairs, or replacement of components.
Manufacturers dictate a required length of time between services and
maximum distance which the vehicle may be driven until it needs to be
inspected by a technician. The manufacturers decide the service intervals
depending on the usage of the specific vehicle, the road conditions and the
environmental conditions.

Fig 6

- 12 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
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.

As the only technician checking the vehicle at this time it is important to


understand how essential it is to carry out a thorough check. The customer
fully relies on your expertise to ensure their vehicle is in the best condition it
can be. If we put this into context we can compare the situation with going to
the dentist. A dentist is a specialist, and is trusted by us to carry out his/her
job to a high standard without fault. Like this, you as a motor vehicle
technician, are a specialist in your own field. Customers bring their car to you
because you are able to maintain its condition, thus keeping the overall cost of
maintenance low.

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.

• 10,000 = 0.5hrs labour


• 20,000 = 1.3hrs labour
• 30,000 = 0.5hrs labour
• 40,000 = 1.4hrs labour
• 50,000 = 0.5hrs labour.

- 13 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
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.

What is the best way to do this?

Let’s look at an example of how to carry out a service efficiently.

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.

- 14 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
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.

- 15 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
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.

- 16 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
- 17 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
- 18 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
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.

From a dealership perspective it enables them to have an audit trail to log


what has been done to the vehicle over a period of time. Also, if the customer
returns the vehicle with a fault then past work can be cross-referenced to
make sure that checks have not been missed.

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.

When informing the customer of either a delay in completion of the service or


extra work then basic information must be available. The customer will need
to know how long the work will take, the type of work that needs to be
undertaken, and if it is extra work then the cost involved.

- 19 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
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.

2. Listed below are tasks to be carried out throughout a service. Number


them in the order you would complete them.
Example:
Check lights 1
Inspect rear brakes 3
Drain engine oil 2

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

3. List four reasons why we regularly service vehicles:

4. Why are pre-delivery services carried out?

5. What items are checked as part of the vehicle exterior pre-delivery


service?

6. At what vehicle age is the first MOT carried out?

- 20 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
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 and filter change

Engine oil performs many functions within the engine and needs to be
changed periodically. Its functions include:

• lubrication, which reduces both wear and friction


• cooling, by using the oil to transfer heat from high temperature areas of the
engine to the sump, where the oil is cooled by air rushing over the sump
• sealing of the combustion chamber to retain the high-pressure gas
• the removal of carbon generated in the combustion process
• the prevention of corrosion of internal metal parts.

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).

- 21 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
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:

• use the correct oil as indicated by the manufacturer


• make sure the vehicle is level when checking the oil
• if a magnetic drain plug is installed then clean metal particles from the
drain plug before re-installation.

- 22 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
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.

Power steering fluid level

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.

- 23 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved

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

• only use the power steering fluid recommended by the manufacturer.

- 24 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
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.

• When changing brake fluid follow the manufacturer’s workshop manual.

- 25 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
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.

- 26 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
Precautions:

• follow manufacturer’s procedures when adjusting the valve clearance

• 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.

• all cylinders can be adjusted using the method above

• for ‘V’ engines the cylinders may need to be adjusted individually.

- 27 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
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:

• place a thick cloth over the radiator cap

• start to loosen the cap slowly until steam starts to come out

• leave the cap in that position until the steam stops

• loosen the cap further until steam starts to come out again

• leave the cap in that position until the steam stops

• 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.

- 28 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
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:

• adjust the belt to the correct tension as detailed in the manufacturers


literature

• 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.

- 29 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
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

• do not bend or twist the belt

• do not allow the belt to be contaminated with either oil or water

• remove any oil or water from the components on which the belt will run.

- 30 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
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:

• take precautions when installing spark plugs into an aluminium cylinder


head, as damage to the threads may occur

• platinum tipped plugs should not be cleaned using a spark plug cleaner

• if the electrode gap exceeds the maximum specified by the manufacturer


then it must be replaced and not adjusted. Fig 24

- 31 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
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.

- 32 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
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.

- 33 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
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.

- 34 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
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.

Brake pedal free play

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.

- 35 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
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

• use a micrometer to measure the thickness of the disc

• use a dial gauge to check the disc for run out

• 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.

- 36 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
Exhaust system

The securing point on the exhaust system needs to be checked for damage,
as does the system itself for leaks.

Ball joint and drive shafts

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.

- 37 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
Front and rear suspension operation

The suspension system consists of shock absorbers, springs, connecting rods


and arms. These items reduce the road vibrations generated when the
vehicle is travelling, from reaching the driver. The suspension system is very
closely linked to the steering system, so any faults on the suspension system
will cause vehicle control problems for the driver.

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.

- 38 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
Battery electrolyte levels

The battery is fitted to the vehicle to supply power to various components


including the lights, starting system and ignition system. When the vehicle is
running the alternator takes over this job, as well as supplying power to the
battery to recharge it. As the battery is constantly charged and discharged
there is a constant chemical reaction within the battery. This chemical
reaction generates heat causing some of the battery electrolyte to be lost.
This loss of electrolyte increases as ambient air temperature increases, so the
battery electrolyte levels need to be checked periodically. Inspection of the
electrolyte level is carried out visually. If assessment of the battery’s state of
charge as a whole, needs to be carried out, a heavy discharge test needs to
be performed. If the specific gravity (state of charge), of the individual cells
needs to be measured, a hydrometer must be used.

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.

- 39 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
Oil cooler, heater and fuel system

A visual inspection must be carried out on all of the systems above so as to


limit the possibility of failure. If leaks occur in the oil cooler and/or heating
system, failure of the internal engine components could occur.

- 40 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
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.

Worn due to incorrect camber


Worn
W orn due to incorrect camber
when tyre wear has only occurred
on one edge of one tyre on one
side of the axle.

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.

- 41 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
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.

Steering wheel free play and linkage

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.

- 42 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
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:

• worn steering linkage


• steering wheel not secured properly
• worn wheel bearings
• worn steering rack, or incorrect adjustment of steering gear
• loose main shaft joint.

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.

- 43 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
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.

Electrical systems and lights

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.

- 44 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
The following lights need to be checked as part of the service:

• side lights front and rear


• number plate lights
• combination meter lights
• headlights (high beam, low beam and high beam flash)
• indicators left and right
• reverse lights
• stop lights
• hazard warning light
• interior lights.

As part of the electrical system the horn should also be checked.

Door hinges

Lubricating the door hinges guarantees correct operation of all the doors.

- 45 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
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.

Seat belts and anchorage points

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

- 46 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
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.

- 47 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
MOT
The MOT is the final part of the routine maintenance schedule, below is a list
of points that outline the MOT process.

• MOT test is required to keep vehicles in a roadworthy condition

• the first test is required when the vehicle reaches three years old (there
are different rules if the vehicle is used as a taxi)

• after three years the vehicle must be tested on an annual basis

• all the items tested must meet the legal requirements

• there are approximately 19,000 approved MOT test stations

• Vehicle and Operator Services Agency (VOSA) is the Government agency


responsible for supervising the MOT scheme

VOSA is responsible for:

• authorising MOT stations

• setting standards for testing

• training authorised examiners

• visiting garages on a regular basis to carry out checks to ensure testing


standards are maintained

• giving advice/taking disciplinary action where tests are not being carried
out to the required standards

• dealing with appeals and complaints from MOT customers

• conducting roadside checks on emissions.

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.

- 48 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
Roadside checks may also be carried out on vehicles. These checks are
carried out against the following regulations, dependent on the class of
vehicle:

• EEC Directives 3820/85 and 3821/85 – Driver hours and tachographs


• Public Passenger Vehicles Act 1986
• Road Vehicles – Construction and Use Regulations 1996
• Road Traffic Act 1988
• The Goods Vehicle – Plating and Testing Act 1988
• Vehicle Excise and Regulations Act 1994.

- 49 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
Items checked during the MOT:

• vehicle identification number


• registration plate
• lights
• steering and suspension
• wipers and washers
• windscreen
• horn
• seatbelts
• seats
• fuel systems
• exhaust emissions
• exhaust system
• vehicle structure
• doors/mirrors
• wheels and tyres
• brakes.

- 50 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
Progress check 2

Answer the following questions:

1. When carrying out a service, what tasks need to be carried out on the
following vehicle systems: vehicle body, tyres, brakes?

2. Give a brief explanation as to why vehicle protection is fitted prior to


carrying out routine maintenance:

3. Name four types of manufacturers documentation that supports the


routine maintenance process:

4. What regulations are associated with roadside checks?

5. What items should be checked in a cooling system when the vehicle is


being serviced?

a) _________________________ b) _________________________

c) _________________________ d) _________________________

6. What safety precautions should be taken when handling batteries?

7. What is the minimum thickness that you would accept for disc pad
linings?

- 51 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved
- 52 -
Copyright © Automotive Skills 2003 LV05: Routine Maintenance Issue 1
All Rights Reserved

You might also like