Major General Mulugeta Buli

Poly-Technic College
Vehicle Servicing (Level-1)

Performing Periodic Service

(29 hrs.)

Prepared By: Tarekegn Mengesha

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LO 1: Prepare For Work
 Periodic maintenance is a strategy that requires maintenance
tasks to be performed at set time intervals while the vehicle is
operational.
 Similar to scheduled maintenance, periodic maintenance activities

are planned ahead of time and are performed with or without signs
of deterioration.
 The time interval and frequency of service tasks are the basic

necessity for a vehicle to last, based on the parameters it was built,

thus, the schedule is specific for each vehicle model and variant.

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 Periodic services are those services performed not to correct

problems but rather to prevent them.

 All of these services may be performed by technicians in many

different types of service facilities dealerships, independents, and

specialty shops.
 Stamped service history documents proving that all required

periodic maintenance works have been performed at service

workshops the first thing a tech needs to worry about is Company
resources, and Repair guides and service plans.

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Repair guides and service plans

 A repair guides is written for every vehicle brought into the

shop for service repair guide may also be called service or

work orders (WO).

 WOs contain information about the customer, the vehicle, the

customer’s concern or request, an estimate of the cost for the

services, and the time the services should be completed WOs

are legal documents that are used for many other purposes,

such as payroll and general record keeping.

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 Legally, a WO protects the shop and the customer. Although every shop may enter

different information onto the original WO, most WOs contain the following
information:
 Complete customer information

 Complete vehicle identification

 The service history of the vehicle

 The customer’s complaint

 The preliminary diagnosis of the problem

 An estimate of the costs of the parts involved in the service

 The time the services should be completed

 The actual services performed with their cost

 The parts replaced during the services

 Recommendations for future services

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Standard/special tools
 Technical information, Procedures and devices for measuring and
testing
 A replacement vehicle should be returned under full and complete
conditions same as it was delivered to you.
 Replacement vehicle should be returned with a fuel level same as when
it was delivered to you.
 Vehicle should be returned on the specified date.

 Drivers are held responsible for transition and any traffic fines imposed
to the vehicle.
 Technical systems and subsystems for Maintenance

 auxiliary materials, Spare part and material requisitioning lists

 Health and safety at work and prevention of accidents

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Safety precautions in service operations
 Do not operate the engine for an extended period of time without
proper exhaust ventilation Warming-up the Engine With-Out Proper
Exhaust Ventilation Will Produce Carbon Monoxide
 Before jacking up the vehicle, apply wheel chocks or other tire blocks
to the wheels to prevent the vehicle from moving. After jacking up the
vehicle, support the vehicle weight with safety stands at the points
designated for proper lifting and towing before working on the
vehicle.
 When removing a heavy component such as the engine or transaxle /
transmission, take care not to lose your balance and drop it. Also, do
not allow it to hit against adjacent parts, especially brake tube and
brake cylinder.
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 Before starting repair, which does not require battery power,

always turn off the ignition switch, then disconnect the ground
cable from the battery to prevent accidental short circuit.
 To prevent serious burns, avoid contact with hot metal parts such

as the radiator exhaust manifold, tail pipe and muffler. “Do not
remove the radiator cap when the engine is hot”.
 To prevent scratches and soiling, protect fenders, upholstery and

carpeting with appropriate covers before starting servicing. “Take

caution that keys, buckets, or buttons do not scratch the paint”

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 Clean all dis-assembled parts in the designated liquid or solvent

prior to inspection or assembly.

 Use approved bonding agent, sealants or their equivalents when

required.
 Replace oil seals, gaskets, packing, O-rings, locking washers,

cotter pins, self-locking nuts, etc. as instructed and discard used

ones.
 Use only the lubricants specified in the applicable section or those

indicated under “Recommended fuel and lubricants”.

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  Do not touch the terminals of electrical components which utilize

microcomputers such as electronic control units. “Static electrical

charges stored in your body may damage internal electronic
components”.
 After disconnecting vacuum hose or air hose, attach tag, which

indicates the proper connection to prevent in correct connection.

 The use of the proper tools and recommended essential tools should be

used where specified for proper, safe and efficient service repair.
 When effecting repairs on the fuel, oil, water, vacuum or exhaust

systems, make certain to check all affected lines for leaks.

 Dispose drained oil or used solvent for cleaning parts in an appropriate

manner.
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 Performing Inspection
 Checks of various systems and areas of a vehicle

 The exact systems and subsystems that are inspected

vary. The inspections are part of the vehicle registration
process. Often automobile dealers are required to
complete a safety inspection on all used vehicles before
they are sold and report the results to the customer.
Block Diagrams, Flow Charts, Maintenance Schedules
 Block diagnosis chart
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 Flow chartsTree Diagnosis Chart

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  Illustrated Diagnosis Chart

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 Maintenance schedules

15 Notes this maintenance schedule is depend on only for one model.

 Changing Brake Parts

Purpose of Braking System

 The braking system is designed to decrease the speed of a vehicle using
kinetic (in motion) friction and keep it from rolling when stopped using
static (at rest) friction.
 Friction is the force that resists motion between two touching objects.

 Friction between brake components slows or stops a vehicle by

transferring the energy of motion (kinetic energy) to heat (thermal
energy).
 This heat must be dissipated by the brake system into the air. Unlike the
lubrication system, where minimizing friction is the goal, the braking
system is designed to use friction for control.

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  Stop the vehicle by converting the kinetic energy of the vehicle to heat
energy. Heat energy is created in the brakes by friction. Friction is
created between a moving and a non-moving surface at each wheel to
generate the heat.
 Disc and drum brakes are the most common type of braking systems
used.
 Factors affecting Braking
Weight of vehicle.
Type of friction material.
Tire traction.
Road surface
Incline or decline of road. (gravity)
Pressure applied
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 Types of Braking Systems
Drum brakes
 Drum brakes are an older style of brake, not common on today’s

vehicles.
 When they are used it is only on the rear axle.

 They don’t use brake pads as the friction material. Instead of a

caliper that clamps brake pads against a rotor, a drum brake

system has a wheel cylinder with pistons that push brake shoes
out against the inside of a spinning drum.
 This contact slows and stops the rotation of the brake drum and

the wheel.
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 Disc brake
 Disc brakes are found on most vehicles today. They are mounted on the front

axle and often the rear as well.

 To stop a wheel (and your car), a disc brake uses a caliper fitted with brake

pads to grab a spinning disc, or rotor.

 The caliper is an assembly mounted to the vehicle with a bracket so it frames

the rotor. It looks and functions like a c-clamp.

 It contains:

 Brake pads: metal plates bonded with material that provides stopping friction.
 One or two pistons to push the brake pads against the rotor when you brake.
 A bleeder screw to allow for servicing the brakes and replacing the fluid.
 A rubber piston seal that prevents brake fluid leakage and retracts the piston
when the brakes release.
20 A dust boot to keep contaminants out of the cylinder.
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 Outside The Vehicle
The maintenance items listed here should be performed from time to time, unless
otherwise specified.

Item Description
Tires Check the pressure with a gauge periodically when at a service
station, including the spare, and adjust to the specified pressure if
necessary. Check carefully for damage, cuts or excessive wear.

Windshield wiper Check for cracks or wear if they do not wipe properly.
blades
Doors and engine Check that all doors, the engine hood, the trunk lid and back door
hood operate properly. Also ensure that all latches lock securely.
Lubricate if necessary. Make sure that the secondary latch keeps
the hood from opening when the primary latch is released. When
driving in areas using road salt or other corrosive materials, check
for lubrication frequently
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Tire rotation Tires should be rotated every 10,000 km (6,000 miles)
 Inside The Vehicle
The maintenance items listed here should be checked on a regular basis, such as when
performing periodic maintenance, cleaning the vehicle, etc.

Items Description

Lamps Make sure that the headlamps, stop lamps, tail lamps, turn signal lamps,
and other lamps are all operating properly and installed securely. Also check
headlamp aim.

Warning lamps Make sure that all warning lamps and chimes are operating properly.
and
chimes
Steering wheel Check for change in the steering conditions, such as excessive free play,
hard steering or strange noises.
Free play: Less than 35 mm (1.38 in)

Seat belts Check that all parts of the seat belt system (e.g. buckles, anchors, adjusters
and retractors) operate properly and smoothly, and are installed securely.
Check the belt webbing for cuts, fraying, wear or damage.
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 Under The Hood and Vehicle

The maintenance items listed here should be checked periodically e.g. each time
you check the engine, oil or refuel.

Items Description
Windshield washer Fluid Check that there is adequate fluid in the tank.

Engine coolant level Check the coolant level when the engine is cold.
Engine oil level Check the level after parking the vehicle on a level spot
and turning off the engine.

Brake and clutch Make sure that the brake and clutch fluid levels are
fluid levels between the “MAX” and
“MIN” lines on the reservoir
Battery Check the fluid level in each cell. It should be between
the “MAX” and “MIN” lines.
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  General maintenance includes those items which should be

checked during the normal day-to-day operation of the vehicle.

 They are essential if the vehicle is to continue operating properly.

Set Back Maintenance Indicators

Gauges

 Instruments are arranged on the instrument panel in front of the

driver's seat to enable the driver to grasp the vehicle status easily.
 The instrument panel uses meter (gauge) display and light display.

 The meter (gauge) display for detailed indication of the status at

each moment generally consists of the following meters and gauges:

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  Speedometer: Consists of the speedometer indicating the
vehicle speed, the odometer indicating the distance
travelled, and the trip meter, which can be reset 0 as desired.
 Tachometer: Indicates the engine speed in rpm (revolutions
per minute).
 Voltmeter: Indicates the battery voltage or alternator out-
put voltage.
 Oil pressure gauge: Indicates the engine oil pressure.
 Fuel gauge: Indicates the fuel level in the fuel tank.
 Water (Engine coolant temperature gauge: Indicates the
engine coolant temperature.
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Engine Oil
 Great advances have been made over the last 20 years with
the quality of engine oils and many now contain additives to
improve the life and operating viscosity of the oil.
 Modem semi and full synthetic oils now allow one type of oil
to be used with extremes of temperature ranges to ensure easy
starting
 when cold and high lubrication protection when warm.
 It’s therefore most important that manufacturer
recommended oil service interval times be adhered to. in order
to avoid problems.
 Different oil types should not be mixed in the engine.
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 Oil Filter
 The oil biter collects all the small items of residue mat are produced with the

normal working operation of the internal combustion engine.

 The filter will hold pieces in suspense to be discarded when the filter is

changed.
 Required to be changed in accordance with manufacturers recommended

service intervals. Always use manufacturers original filters.

Fuel Filters
 Many vehicles can have two fuel filters mounted under the bonnet, one as a pre

filter and the second as a main filter. Both have throwaway elements and the main
filter also incorporates a drain point and water indicator unit
 If you have reason to doubt the quality of the fuel or experience engine running

problems check these items and change as required by service recommendations.

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Always have new filters available as they cannot be cleaned.
 Air Filter
 Toyota air filters are of the cyclonic type to ensure that large particles that

enter the area tall to the bottom of the filter bowl and can be easily removed from
the system.
 Filters should be examined and replaced regularly in dusty conditions.

 The air filters can be washed out with water and left to dry (based on the 70

Series).

Coolant
 Toyota vehicles are filled with a 50-50 mix of water and long life coolant and

the level has to be topped up to ensure engines run at the correct temperature.
 The coolant no; only acts as anti-freeze for the winter but also as a corrosion

inhibitor, so even In hot climates it Is Important that the correct balance Is kept in
the cooling system.
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WARNING
 Do not remove radiator cap when engine is hot
 Thermostats should NOT be removed in hot climates

 Do not allow to drain onto the ground as it can be poisonous to animals

Tires

 Check for correct inflation pressure, damage to tread and sidewalls including the

spare wheel.

 Check location of tool kit including jack operation and availability of tire

inflation device.

 Lowering tire pressures will assist traction oft-road.

Electrical Items
 Before any journey check operation of all lights including warning lights, wipers and
communications equipment.
 Check security of battery and the terminals. Ensure that you carry spare buts and fuses.
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 Generally the following should be checked:
→ Engine oil level - If too low, top up with correct oil type from sealed container

→ Expansion tank level - Check in between the two levels and top up with coolant if

required. Check return pipe is present.

→ Brake and clutch fluid- Top up as required with fluid from a dean tin. Brake fluid is

hydroscopic and contaminated liquid will have a lower boiling point causing brake
fade.
→ Belts- Check belts for condition and security. Do not over tighten.

→ Battery- Check for security. fluid level and terminal condition

→ Leaks - Inspect under the engine compartment for leaks and evidence of oil or water

→ Exhaust - Run up engine and listen for leaks from manifold area

→ Other fluid levels - Top up power steering flu, washer bottle etc

→ Fuel filters - Check for leaks and water in main filter and if fitted. If the second filter.

Drain as required
→ Wiring - Visual check of ail wiring looms and electrical cables.
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 Method of Changing the Oil and Oil Filter
1. Always make sure the vehicle is positioned safely on a lift or supported
by jack stands before working under it. Before raising the vehicle, allow
the engine to run awhile. After it is warm, turn off the engine.
2. The tools and other items needed to change the engine’s oil and oil filter
are rags, a funnel, an oil filter wrench, safety glasses, and a wrench for
the drain plug
3. Place the oil drain pan under the drain plug before beginning to drain
the oil.
4. Loosen the drain plug with the appropriate wrench. After the drain plug
is loosened, quickly remove it so the oil can freely drain from the oil
pan.
5. Make sure the drain pan is positioned so it can catch all of the oil.

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 6. While the oil is draining, use an oil filter wrench to loosen and remove
the oil filter
7. Make sure the oil filter seal came off with the filter. Then place the
filter into the drain pan so it can drain. After it has completely drained,
discard the filter according to local regulations.
8. Wipe off the oil filter sealing area on the engine block. Then apply a
coat of clean engine oil onto the new filter’s seal.
9. Install the new filter and handtighten it. Oil filters should be tightened
according to the directions given on the filter.
10. Prior to installing the drain plug, wipe off its threads and sealing
surface with a clean rag.
11.Tighten the drain plug according to the manufacturer’s
recommendations. Overtightening can cause thread damage, whereas
undertightening can cause an oil leak.
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 12. With the oil filter and drain plug installed, lower the vehicle and
remove the oil filler cap.
13. Carefully pour the oil into the engine. The use of a funnel usually
keeps oil from spilling on the engine.
14. After the recommended amount of oil has been put in the engine,
check the oil level.
15. Start the engine and allow it to reach normal operating
temperature. While the engine is running, check the engine for oil
leaks, especially around the oil filter and drain plug. If there is a
leak, shut down the engine and correct the problem.
16. After the engine has been turned off, recheck the oil level and
correct it as necessary.
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 Typical Procedure for Inspecting, Removing, Replacing, and
Adjusting a Drive Belt
1. Inspect the belt by looking at both sides.
2. Look for signs of glazing.
3. Look for signs of tearing or cracking
4. To replace a worn belt, locate the tensioner or generator pulley
5. Loosen the hold-down fastener for the tensioner or generator pulley
6. Pry the tensioner or generator pulley inward to release the belt tension
and remove the belt.
7. Match the old belt up for size with the new replacement belt.
8. Observe the belt routing diagram in the engine compartment.
9. Install the new belt over each of the drive pulleys. Often the manufacturer
recommends a sequence for feeding the belt around the pulleys.

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 10. Pry out the tensioner or generator pulley to put tension on the
belt.
11. Install the belt squarely in the grooves of each pulley
12. Measure the belt deflection in its longest span. If a belt tension
gauge is available, use it and compare the tension to specifications.
13. Pry the tensioner or generator pulley to adjust the belt to
specifications.
14. Tighten the tensioner or generator pulley fastener.

15. Start the engine and check the belt for proper operation.

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 Finding and Evaluating Your Belt
1. Park your car in a well-lit place. This will make it easier
to work under the hood. You can also use a drop light or other
supplemental lighting if you deem it necessary.
2. Locate the belt in question. Most belts will be found on the
side of the engine block. Serpentine belts are easily identified
because they weave through several pulleys. V-belts are looped
around two pulleys and there are two or more belts
overlapping at a point, forming a V-shape. You should replace
the belt:
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  if it is frayed or tearing.
 if it has cracks or missing chunks.
 if the belt has coolant or oil on it.
 These conditions make the belt incapable of properly running its

components, which can lead to major problems for your engine. If

for any reason you cannot locate an accessory belt or gain easy
access to it then you should take your vehicle to professional.

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 Method of- changing brake system parts
Servicing Disc Brakes
1. Loosen the lugs. While the car is on the ground, you should use a lug
wrench or an impact wrench to loosen the lug nuts. Doing it this way
prevents the tires from spinning. This helps break the lugs loose more
efficiently and more safely.
2. Jack up the car. Consult your service manual for safe jacking points.
Slide the jack under the car and position it directly under the jacking
point. Jack the car up and secure it with jack stands.
3. Remove the wheels. Now that the car is lifted, the weight will no
longer be on the tires. You can finish removing the lugs either by hand or
with your wrench. Then, simply slide the wheel away from the wheelbase.
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 4. Locate the brake caliper. Now that you have the wheel off, you
will be looking directly at your brake rotor. Mounted on the rotor
(usually to the right) you will see your brake caliper. The brake
caliper holds the brake pads against the rotor on either side.
5. Remove the brake caliper as a single unit. Brake calipers differ
slightly from car to car, but they are always held in place by bolts or
clips. These are usually located at the top and bottom of the caliper.
Once the bolts and/or clips are removed, the caliper can be pulled
away from the rotor. You do not need to disconnect the brake line
from the caliper, but you should tie it up with wire or cord so that it
doesn’t get kinked or damaged.

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 6. Inspect the brake pads for wear or damage. Some brake pads
have a groove in the middle that serves as an indicator for wear. If
the groove is nearly gone, the pads are in need of changing. In any
case, if the pad is less than ¼ inch thick or is chipped or damaged, it
needs replaced.
7. Make note of any damage on the calipers. Your calipers should
not need replaced, as they are designed to last for the life of the car.
That being said, if there is damage on the caliper it might need
replaced. Also, it is possible that the bolts or pins that hold the
caliper in place could be damaged. If this is the case you will need to
replace those.
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 8. Take a close look at the brake rotor. The brake disc, or
rotor, is another important part of the braking system. When
the brakes are applied, the pads press down on the rotor to
create the friction needed for stopping. This generates a lot of
pressure and heat. If your rotors are not thick enough, or if
they have grooves or chips in them, they will need to be
replaced.
 Minimum rotor thickness is generally stamped on the
outside of the disc and can be measured using a micrometer,
a side caliper, or a tape measurer. The micrometer is the
easiest and most accurate measurement.
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  Servicing Drum Brakes

1. Remove the wheels. The drum brake is located behind the

wheel. Once the wheel is out of the way, you will have access to
the brake drum.
2. Remove the drum. Removing the drum will provide you
access to the inner workings of your brakes, which are mounted
on the backing plate. To do this, you will need to first remove the
dust cap in the center. Underneath, there will be a retaining nut
and cotter pin. Use pliers to remove the cotter pin and a socket to
remove the nut. The drum should now slide off.
 If you have trouble sliding the drum off, check to be sure there
are not additional bolts or clips holding it to the hub.
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  It is possible for the brake shoes to get stuck against the drum. In

this case, you will need to remove the rubber plug on the back of
the backing plate to gain access to the brake shoe adjuster. Use a
flathead screwdriver or brake adjuster bar to retract them.
3. Inspect the brake shoes. The brake shoe liners should not be
less than the minimum recommended thickness. For the leading
brake shoe (the one closest to the front of the car) this is usually
around 1/8 inch. For the trailing brake shoe (the one closest to the
back of the car) this is usually around 7/64 inch. Check your service
manual for your car’s exact specifications and replace any brake
liners that do not meet that standard.
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 4. Identify and inspect your return springs. These springs are
responsible for returning the brake shoes to their proper resting location
after you remove your foot from the brake pedal. It is important that these
springs are not damaged or loose. As long as the springs are still tight and
are not damaged or overly rusted, you can continue to use them.
 If you need to remove the springs to replace them, or so that you can

remove and replace your brake shoes, using brake spring pliers can
make this a breeze.
5. Change your wheel cylinder. It is best practice to change the wheel
cylinder anytime you have the brake drums off. The brakes will continue to
work as long as the cylinder does not leak or stick, but it is impossible to
look at the cylinder and determine how much wear is on the inside.
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 To replace the wheel cylinder, you will need to first remove the brake
line with a wrench.
 Next, unbolt the cylinder from the backing plate by removing the one or
two bolts that hold it there. Install the new cylinder by bolting it into
place where the original was, and then connecting the brake line.
Brake Fluid
 Brake fluid levels are checked at the master cylinder. Older master

cylinders are made of cast iron or aluminum and have a metal bail that
snaps over the master cylinder cover to hold it in place. Normally the
bail can be moved in only one direction.
 Once moved out of the way, the master cylinder cover can be removed.

Once removed, the fluid levels can be checked.

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 Newer master cylinders have a metal or plastic reservoir mounted above the

cylinder. The reservoir will have one or two caps. To check the fluid level in
the metal reservoir, the cap must be removed.
 Most often the caps are screwed on. The caps on some plastic reservoirs

have snaps to hold them. Unsnap the cap to check the fluid. It is important to
clean the area around the caps before removing them.
 This prevents dirt from falling into the reservoir. A rubber diaphragm

attached to the inside of the caps is designed to stop dirt, moisture, and air
from entering into the reservoir. Make sure the diaphragm is not damaged.
While checking the fluid level, look at the color of the fluid.
 Brake fluid tends to absorb moisture and its color gives clues as to the

moisture content of the fluid. Dark- or brown-colored fluid indicates

contamination; the system must be flushed and the fluid replaced.
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  There are basically four types of brake fluids: DOT 3, DOT 4, DOT 5,

and DOT 5.1. The specifications for all automotive brake fluids are defined
by Society of Automotive Engineers (SAE) Standard.
 Checking Brake Fluid Level and Leaks

If fluid level is extremely low, check brake system for leaks.

 Checking Brake Lines and Cables

Check brake fluid lines and parking brake cables for improper attachment, leaks,
chafing, abrasions, deterioration, etc.
 Changing Brake Fluid

1. Drain brake fluid from each air bleeder valve.

2. Refill until new brake fluid comes out from each air bleeder valve. Use same
procedure as in bleeding hydraulic system to refill brake fluid.
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  NOTE: Refill with recommended brake fluid.
See “RECOMMENDED FLUIDS AND LUBRICANTS”.
 Never reuse drained brake fluid.

 Be careful not to splash brake fluid on painted areas.

Power-Steering Fluid
 Now locate the power-steering pump. The level of power-steering

fluid is checked with the engine off. The filler cap on the power-
steering pump normally has a dipstick.
 Unscrew the cap and check the level. The level of the fluid is

normally checked when the engine is warm. If the fluid is cold it

will read lower than normal.
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  Add fluid as necessary. Sometimes the fluid used in these systems

is ATF; check the service manual for the proper fluid type before
adding fluid.
Clutch Fluid
 On some vehicles with a manual transmission, there is another but

smaller master cylinder close to the brake master cylinder.

 This is the clutch master cylinder. Its fluid level needs to be

checked, which is done in the same way as brake fluid.

 In most cases, the clutch master cylinder uses the same type of

fluid as the brake master cylinder. However, check this out before
adding any fluid.
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Tires
 The vehicle’s tires should be checked for damage and wear. Tires

should have at least 1⁄16 of tread remaining. Any less and the tire
should be replaced. Tires have “tread wear indicators” molded
into them. When the wear bar shows across the width of the tread,
the tire is worn beyond its limits.
 Most shops use a tire wear gauge, which gives an accurate

measurement of the tread depth. Also, check the tires for bulges,
nails, tears, and other damage. All of these indicate the tire should
be replaced.
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 Periodic Maintenance manual
 Follow the Maintenance Schedule Suggested in Your Vehicle’s
Owner’s Manual Your vehicle also requires maintenance tasks that
are performed less frequently, but are vital to allowing your
automobile to live a long and fruitful life.
 These tasks include oil changes, tire rotations, replacing
transmission fluid, and the like.
Repair Manuals
 Not as detailed as factory manuals
 One set may include data an all American cars produced for
several years

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 More economical to purchase than factory manuals
 Battery maintenance

1. Check for cracks in the battery case and for broken terminals.
Either may allow electrolyte leakage. The battery must be replaced.

2. Check for cracked or broken cables or connections. Replace, as

needed.

3. Check for corrosion on terminals and dirt or acid on the case top.
Clean the terminals and case top with a mixture of water and baking
soda or ammonia. A wire brush is needed for heavy corrosion on the
terminals.

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 4. Check for a loose battery hold-down and loose cable
connections. Tighten, as needed.

5. Check the level of electrolyte. The level can be viewed through

the translucent plastic case or by removing the vent caps and
looking directly into each cell. The proper level is 1/2" above the
separators. If necessary, add distilled water to each low cell. Avoid
overfilling. When water is added, always charge the battery to
make sure the water and acid mix.

6. Check for cloudy or discolored electrolyte caused by

overcharging or vibration. This could cause high self-discharge.
The problem should be corrected and the battery replaced.
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 7. Check the condition of plates and separators. Plates should

alternate dark (+) and light (-). If all are light, severe

undercharging is indicated. Cracked separators may allow shorts.

The battery should be replaced. An undercharging problem should

be corrected.

8. Check the tension and condition of the alternator drive belt. A

loose belt must be tightened. It will prevent proper charging. A belt

too tight will reduce alternator life. It should be loosened to specs. A

frayed or glazed belt will fail during operation. Replace it.

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 Communications and documentation systems
 Communication with the customer during the maintenance service

 Definition about the communication with the customer during the

maintenance service:
 Contact to the customer during the maintenance service might be

necessary because of the following reasons: something unexpected in the

car comes up, there are no required parts for the repairing, the foreman or
the mechanic needs additional information about the car.
 In this section there are the sentence beginnings and answers related to

communication with the customer during the maintenance service.

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  The main message of the answers is that customers want that they are

contacted:
1. If the time reserved for the maintenance service exceeds.
2. If there are something unpredicted faults found.
3. If the costs are higher than expected
Electrical safety precaution

1. Do not go near broken or dangling Electrical wires

2. To prevent electrical shocks, never touch any electrical equipment with wet hands

3. When disconnecting a plug, do not pull on the cord, pull on the plug itself

4. Do not route an electrical cord through wet or oil soaked areas, through heated

surfaces, or around sharp corners

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 NOTE:

 If encountered any of the situations shown below, the following

actions must be taken:

 Report the matter to the instructor after switching off the switch.

 Report any blown fuse to the instructor, do not attempt to repair or replace it.

Equipment safety sign

Use possibilities of electronic data processing

 The last thing a technician wants to do when a vehicle comes into the shop is

create problems. This is especially true when it comes to electronic components.

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  You should be aware of the ways to protect electrical systems and electronic
components during storage and repair. Keep the following in mind at all times:

 Vehicle computer-controlled systems should avoid giving and receiving jump-

starts due to the possibility of damage caused by voltage spikes.

 Do not connect or disconnect electronic components with the key on.

 Never touch the electrical contacts on any electrical or electronic part. Skin oils

can cause corrosion and poor contacts.

 Be aware of any part that the manufacturer has marked with a code or symbol

to warn technicians that it is sensitive to electrostatic discharge.

 Before touching a computer, always touch a good ground first. This safely

discharges any static electricity. Static electricity can generate up to 25,000

volts and can easily damage a computer.

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  Tool companies offer static-proof work mats that allow work

inside the vehicle without the fear of creating static electricity.

 Tool companies also have grounding wrist straps. A wire connects

the wrist strap to a good ground.

 Never allow grease, lubricants, or cleaning solvents to touch the

end of the sensor or its electrical connector.

 Be careful not to damage connectors and terminals when

removing components. This may require special tools.

 When procedures call for connecting test leads, or wires, to

electrical connections, use care and follow the manufacturer’s

instructions. Identify the correct test terminals before connecting
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the test leads.
  Do not connect jumper wires across a sensor unless indicated in the

service manual to do so.

 Never apply 12 volts directly to an electronic component unless

instructed to do so.
 Never use a test light to test electronic ignition orany other computer-

controlled system unless instructed to do so.

 Accidentally touching two terminals at the same time with a test

probe can cause a short circuit.

 The sensor wires should never be rerouted. When replacing wiring,

always check the service manual and follow the routing instructions.
 Disconnect any module that could be affected by welding,
hammering, grinding, sanding, or metal straightening
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Computerized Shop Management Systems

 Today, most service facilities use computerized shop management

software. The information for the completion of an RO is input on

the computer’s keyboard.

 The software package also helps in the estimation of repair costs.

The software also takes information from the RO and saves it in

various files.

 These files are used for many purposes, such as schedule

reminders, bookkeeping, vehicle/owner history, and tracking

employee productivity. Notes can also be added to the RO (these
63 do not appear on the RO).
  These personal notes can be used to remind the shop of

commitments made to the customer, any special information about

the customer and/or the vehicle, and any abnormal events that took
place during the customer’s last visit to the shop.
 When the customer arrives at the shop, the computer can quickly

recall all pertinent information about the vehicle.

 Typically, all the service writer needs to do is key in the vehicle’s

license number, the vehicle’s identification number, or the owner’s

name.
 If the customer has been to the shop before, all information will

be available to the service writer.

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 LO 2: Carry-out service and Maintenance activities
Identify systems, subsystems, functional units and the interaction
system
Battery
The battery is the main source of electrical energy for the vehicle. It is very
important that it is inspected and checked on a regular basis.
Charging System
Introduction
 A charging system output test measures the maximum current the alternator

can produce at a specified voltage or maximum load. A charging system output

test should be done when generator voltage low and current is suspected.
 A load tester, VAT tester, or ammeter may be used to measure the current.

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  Procedures differ with non-inductive testers. Always check the

operating directions of the tester before connecting to charging

components.
 When using an ammeter to perform an output test, calculate the

charging system output by adding the two ammeter readings together and
compare these figures with the manufacturer’s specifications to determine
needed tests and repairs.
 For instance, if the system tests low, a regulator voltage and regulator

bypass test is usually required to determine if the alternator, regulator, or

circuit wiring is at faults.
 Some guidelines to prevent damage to the charging and other electrical

systems
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 Drive Belts
 Drive belts have been used for many years. V-belts and V-ribbed
(serpentine) belts are used to drive water pumps, power steering pumps,
air-conditioning compressors, generators, and emission control pumps.
Heat has adverse effects on drive belts and they tend to over cure due to
excessive heat.
 This causes the rubber to harden and crack. Excessive heat normally
comes from slippage. Slippage can be caused by improper belt tension or
oily conditions.
 Drive belts can be used to drive a single part or a combination of parts.
An engine can have three or more V-belts. In some cases, two matched
belts are used on the same pulley set.
 This increases the strength of the belt and pulley connection and
provides redundancy in case a belt breaks.
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  Engine Oil

Engine oil is a clean or refined form of crude oil. Crude oil, when taken out of the
ground, is dirty and does not work well as a lubricant for engines. Crude oil must
be refined to meet industry standards. Engine oil (often called motor oil) is just
one of the many products that come from crude oil.

Engine oil is specially formulated so that it:

 Can flow easily through the engine

 Provides lubrication without foaming

 Reduces friction and wear

 Prevents the formation of rust and corrosion

 Cools the engine parts it flows over

 Keeps internal engine parts clean

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 Chassis Lubrication
 A PM procedure that is becoming less common because of changing

technology is chassis lubrication. However, all technicians should know

how to do this.
 During the lubrication procedure, grease is forced between two surfaces

that move or rub against each other.

 The grease reduces the friction produced by the movement of the parts.

 During a chassis lube, grease is forced into a pivot point or joint

through a grease fitting.

 Grease fittings are found on steering and suspension parts, which need

lubrication to prevent wear and noise caused by their action during vehicle
operation.
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 Cooling System
 Whenever you change an engine’s oil, you should also do a visual inspection of

the different systems under the hood, including the cooling system.
 Inspect all cooling system hoses for signs of leakage and/or damage. Replace
all hoses that are swollen, cracked, or show signs of leakage.
Windshield Wipers
 Check the condition of the windshield wipers. Wiper blades can become dull,

torn, or brittle. If they are, they should be replaced. Also, check the condition of
the wiper arms.
 Look for signs of distortion or damage. Also, check the spring on the arm. This
spring is designed to keep the wiper blade fairly tight against the windshield. If the
spring is weak or damaged, the blade will not do a respectable job cleaning the
glass
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 Windshield Washer Fluid
 The last fluid level to check is the windshield washer fluid.

Visually check the level and add as necessary.

 Always use windshield washer fluid and never add water to the

washer fluid reservoir, especially in cold weather. The water can

freeze and crack the tank or clog the washer hoses and nozzles.

Tires

 The vehicle’s tires should be checked for damage and wear.

 Tires should have at least 1⁄16 of tread remaining. Any less and

the tire should be replaced.

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  Tires have “tread wear indicators” molded into them. When the
wear bar shows across the width of the tread, the tire is worn
beyond its limits.
 Most shops use a tire wear gauge, which gives an accurate
measurement of the tread depth Also, check the tires for bulges,
nails, tears, and other damage.
 All of these indicate the tire should be replaced. Inflation Check the
inflation of the tires. To do this, use a tire pressure gauge. Press the
gauge firmly onto the tire’s valve stem.
 The air pressure in the tire will push the scale out of the tool. The
highest number shown on the scale is the air pressure of the tire.
Compare this reading with the specifications for the tire.
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 Tire Rotation
 To equalize tire wear, most car and tire manufacturers recommend

that the tires be rotated. Front and rear tires perform different jobs
and can wear differently, depending on driving habits and the type
of vehicle.
 In an RWD vehicle, for instance, the front tires usually wear

along the outer edges, primarily because of the scuffing and

slippage encountered in cornering.
 The rear tires wear in the center because of acceleration thrusts.

To equalize wear, it is recommended that tires be rotated

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 Inflation
 Check the inflation of the tires. To do this, use a tire pressure
gauge. Press the gauge firmly onto the tire’s valve stem. The air
pressure in the tire will push the scale out of the tool.
 The highest number shown on the scale is the air pressure of the
tire. Compare this reading with the specifications for the tire.
 The correct tire pressure is listed in the vehicle’s owner’s manual
or on a decal (placard) stuck on the driver’s doorjamb. The air
pressure rating on the tire is not the amount of pressure the tire
should have.
 Rather this rating is the maximum pressure the tire should ever
have when it is cold.
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Additional PS Checks
 The following PS checks are in addition to those items specified by the

manufacturer. These should be performed at these suggested time

intervals to help ensure safe and dependable vehicle operation.
Time: While operating the vehicle
 Pay attention to and note any changes in the sound of the exhaust or any

smell of exhaust fumes in the vehicle

 Check for vibrations in the steering wheel. Notice any increased

steering effort or looseness in the steering wheel.

 Notice if the vehicle constantly turns slightly or to one side of the road.

 When stopping, listen and check for strange sounds, pulling to one side,

increased brake pedal travel, or hard-to-push brake pedal

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  If any slipping or changes in the operation of the transmission occur, check the

transmission fluid level

 Check for fluid leaks under the vehicle. (Water dripping from the air-
conditioning system after use is normal.
 Check the automatic transmission’s park function.

 Check the parking brake.

 Time: At least monthly

 Check the operation of all exterior lights, including the brake lights, turn signals,

and hazard warning flashers

 Time: At least twice a year
 Check the pressure in the spare tire.
 Check headlight alignment.
 Check the muffler, exhaust pipes, and clamps
 Inspect the lap/shoulder belts for wear
 Check the radiator, heater, and air-conditioning hoses for leaks or damage.
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  Time: At least once a year

 Lubricate all hinges and all outside key locks.

 Lubricate the rubber weather strips for the doors.

 Clean the body’s water drain holes.

 Lubricate the transmission controls and linkage.

 Analyse internal work order and Select servicing tools

General instructions
1. Use fender seat and floor covers to keep the vehicle cleaned prevent
damage
2. during disassembly. Keep parts in order for reassembly.
3. Before performing electrical or fuel work, disconnect the negative (-)
battery cable.
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4. Check hose and wiring connectors to make sure that they are
secure and correct.
5. Always replace gaskets and D-rings with new ones.
6. Always use sealer on gaskets to prevent leaks.
7. Carefully observe all specifications for bolt torques. Always use a
torque wrench.
8. Use of Special Service Tools (SST) may be required depending
,

on the nature of the repair. Be sure to use the SST where specified,
and follow the proper work procedure.
9. Care must be taken when jacking up and supporting the vehicle
be sure to lift and support the vehicle at the proper locations
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 (a) If the vehicle is to be jacked up only at the front or rear
end, be sure to block the wheels in order to ensure safety.
(b) Always use a hydraulic hoist or jack stand. It is extremely
dangerous to work on a vehicle supported only by a jack,
even for a small job that can be finished quickly.
 Select necessary service tools

- Hand tools

- Measuring tools

- Power tools and others necessary tools.

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 Inspect the condition of components
 Inspection the vehicle

 Engine Off

 Check belts, tensioners, and pulleys; check and adjust belt tension;
check belt alignment
 Check engine oil level and condition; check dipstick seal

 Take an engine oil sample

 Check engine for oil, coolant, air, and fuel exhaust leaks

 Change engine oil and filters; visually check oil for coolant or fuel
contamination; inspect and clean magnetic drain plugs
 Check engine compartment wiring harnesses, connectors, and seals for
damage and proper routing
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  Check starter, mounting, and connections

 Check alternator, mountings, wiring and wiring routing

 Check windshield washer fluid level; fill as necessary

 Check master cylinder fluid level and condition

 Check hydraulic clutch slave and master cylinders, lines,

fittings, and hoses, if applicable

 Check brake assist system (booster), hoses, and control valves;

check reservoir fluid level and condition

 Check power steering fluid and filter

 Check power steering pump, mounting, and hoses for leaks,

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condition, and routing; check fluid level
  Check steering gear for leaks and secure mounting

 Check steering shaft U-joints, pinch bolts, splines, Pitman arm-to-steering

connector shaft, tie rod ends, and linkages

 Check A/C condenser and lines for condition and visible leaks; check

mountings

 Check A/C compressor and lines for condition and visible leaks; check

mountings

 Check fuel pump and fuel line mountings

 Check water separator/fuel heater; replace fuel filter(s); prime and bleed fuel

system

 Service or replace air filter as needed; check and reset air filter restriction

indicator
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 Check turbocharger for leaks; check mountings and connections
  Check radiator (including air flow restriction, leaks, and

damage) and mountings Service coolant filter

 Check coolant recovery system

 Check coolant hoses and clamps

 Check coolant for contamination, additive package

concentration, and protection level (freeze point)

 Pressure test cooling system and radiator cap

 Check fan assembly and shroud

 Inspect water pump for leaks and bearing play

 Inspect and service crankshaft ventilation system

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 Engine On

 Check engine for oil, coolant, air, and fuel and exhaust leaks

 Check air induction system; piping, charge air cooler, hoses, clamps, and

mounting; check for air restrictions and leaks

 Check transmission oil level, type, and condition (automatic transmissions)

 Check/record alternator current and voltage output (alternator current/voltage

output tests)

 Check A/C system condition and operation; check A/C monitoring system, if

applicable

 Check operation of engine compression/exhaust brake

 Check operation of fan clutch

 Check HVAC air inlet filters and ducts; service as needed.

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 Replace system components

Replace windshield Wipers

 Visibility is a must whenever you’re on the road. And your window to the outside

world is your windshield. Keeping it in excellent order is partly the job of your
windshield wiper.
 Now, remember that these wipers are not exactly very durable so they tend to wear

out a little faster than other components of your car. The good news is that they’re a lot
easier to replace, too.
 If your windshield is already getting streaky or that it makes a squeaking, grating

noise every time it is switched on, then it’s time to replace it.
 Buy a replacement wiper blade that is recommended for your vehicle. And while

you’re replacing your wipers, why don’t you give your windshield a thorough cleaning
both inside and out.

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 Replace air filter
 A dirty air filter could reduce horsepower and reduce life of your

car so it’s really important to change your air filter every 6 months.
1. Obtain the Air filter first before throwing out the old one.
2. Open your hood and look for the air box, Check owner’s manual
for the location of the air box.
3. Once you found the air box, there should be clamps or screws that
seal the air box closed.
4. Unscrew or unclasp the air box so you can access air filter.
5. Pull the top cover open until the air filter is accessible.
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 6. Once you get it open, remove the old air filter and compare its size and
dimensions to the new one. (The new air filter should look exactly as the stock
filter). Discard or Recycle old filter.
7. Place in the new air filter and make sure it fits snug and fits really well.
8. After placing the air filter, reverse the steps of opening which means close the
box up, re-clamp or screw the box closed and shut the hood.

Example: Replacing cabin air filter

This is one of the easiest and most practical ways to keep everyone safe and
comfy inside your car’s cabin. The current recommendation is to replace your
cabin air filter every 12 months or every 12,000 miles, whichever comes first.
However, you can always refer to your owner’s manual for the recommended
schedule of cabin air filter replacement.

87
 Replace broken indicator
Bulbs
 These fixtures in your vehicle are very important and as such should

never be overlooked in your car maintenance checklist.

 Indicator or signal lights inform other motorists of the direction you are

planning to go to. This way they will also know what to do.
 For example, if you’re signaling left, then they should know not to

overtake and to start slowing down to compensate for your own reduction in
speed.
 The thing is that if the indicator light to the direction where you’re

turning is flashing a lot faster than when you switch on to the other
direction, it simply means you have a blown light bulb.
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  The great news is that today’s cars come with lighting modules

that are can be easily replaced without having to go to the shop.

 A word of caution though, it is important to use only the kind of

bulb that is specific to your vehicle’s make.

 And if you can remember we did mention in the beginning that

reading your vehicle owner’s manual can help you a great deal in
your basic car maintenance chores.
 Additionally, the manual will also tell you exactly how to

access and replace these lights.

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 LO 3: Apply Quality Standards
3.1 Carry out measures and Perform vehicle care

 Car care is definitely a win-win situation. Besides helping the

environment, a properly maintained and operated vehicle will run

more efficiently, will be safer, and will last longer—up
Basic car safety checklist
 Seatbelts – check tension and belt buckle operation
 External Lights – replace bulbs if necessary
 Handbrake – ensure that it can hold he vehicle on a slope
 Windscreens & mirrors – check windscreens and mirrors for cracks
 Windscreen wipers – check wear on wiper blades, replace if necessary
 Horn – ensure this works
 Tires – ensure tires are at the correct pressures, check tread wear
 Spare tire & jack – ensure they are operational, check toolkit
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 Fluids checklist

 Engine oil

 Radiator coolant

 Brake fluid

 Power steering fluid

 Windscreen washer fluid

 Clutch fluid (manual cars)

 Gearbox oil

 Differential fluid

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Tires checklist
Tire pressures
Tread wear and tread depth
Spare tire
Car jack and tools
Lights checklist
Headlights
Indicators/hazard lights
Brake lights
Reverse lights
Park & Fog lights
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 Other general things to check
 Radiator hoses – check for leaks and cracking

 Engine air filter – check that it is clean

 Battery – look for corrosion around terminals

 Fan belts – ensure none are loose or squeaking on start-up

 Unusual engine noises- hard to start, ticking, hissing or clunking

 Ensure that child seats are fitted correctly.

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  Remember, how your car runs, how you drive it, and how its fluids, old
parts, and tires are disposed of all have serious consequences on the
environment.
3.2 Quality standard

 AQ: - means in many products and services, quality standards are set by

H&S legislation and enforced by Trading Standards officers.

 The student must tell material properties to product and process quality.

These are the factors that must be taken into consideration when choosing
the right material.
1. Selection of material
2. Testing of material
3. Cost of material

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 Selection of material:

 Material selection is one of the most common tasks for this

competency.

 The ability to evaluate the material’s impact on the performance

of a product. Sometimes, buyers are also considering the name of

the company.

 Which are producing great quality of materials and are known

in the market?

 E.g. HP for printer and Intel for some computer hardware

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 2. Testing of material:

 The testing of material properties is widely understood to be the key to obtain

material interactions.

 Material testing also provides information on the quality of received and

outgoing products. Inspection test equipment and techniques are demonstrated
for a wide range of materials
 3. Cost of material:

 Cost of material is also considered when buying or selecting materials. The

amount may vary but never taken for granted the quality and the reliability of the
material.
 People look for places which can get together their standards and right cost for

materials to buy.

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  The characteristic of the materials to be used for

specific project must be:

Of Good Quality

Reliable

Suitable for the Application/Purposes

Low Cost

 Of good quality:

This is the most important factor when choosing materials

to buy.
Products with good quality are lifelong and safe to use.
97
Reliable: It means that you can be sure that it will perform its function
well.
Suitable for the application/purposes: Choose the materials which are
very necessary to make the project possible.
Low cost: It doesn’t mean that you will choose for the less expensive
one and reject the quality.
Error Identification and Reporting
A. Receiving Materials:
 Match the packing slip to the items received and ensures that the
materials are destined on tour department.
 That you are receiving the materials indicated on the purchase order with
regard to quantity and discount.
 That the materials are in acceptable condition. That term regarding
installation and/or set-up of equipment are met
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 B. Receiving Reports
Whenever goods are received:
 The person receiving the goods must document, using the
administrative software, that all goods were received for each requisition
before any payment can be made to the vendor.
 Any exceptions must be noted so that partial payments can be processed

or substandard goods can be returned.

C. Return of Merchandise:
 When merchandise is received which is incomplete or defective, the

supervisor will return the materials to the supplier or to the store.

 Where it was bought and makes planning with the vendor for

replacement.
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 D. Make an Inventory (list) Report of the Materials:
 All materials received must be listed and be reported to monitor

how many materials are already on hand, purchased or damaged.

Effective management checks are an important. They are also
useful in identifying training needs; indicating possible
weaknesses
 Work instruction may be:

• Verbal (oral)-Written

• In English-In a community language

• Provided visually e.g. Video, OHS signs, symbols and other

pictorial, presentation, etc.

100
 Controlling Risks In The Work Area May Include:
• Application of the hierarchy of control, namely:

– Eliminate the risk-Reduce/minimise the risk through

– Engineering controls-Administrative controls

– Personal protective equipment

 Reports identifying workplace hazards may be verbal or

written and may include:

• Face to face-Phone messages

• Notes

• Memos

• Specially designed report forms

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 The Quality checker will record:
• date of receipt
• Name of the materials purchased

• Quantity

• official receipt number

• signature of the person who buy

• signed his name afterwards

 The Quality checker will identify if the materials are in good

condition or not.
• If not needing for replacements.

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 This will also be recorded on his report
  Workplace Procedure:

• Is a set of written instructions that identifies the health and safety

issues that may happen from the jobs?

A SAFE WORKING PROCEDURE SHOULD BE WRITTEN
WHEN:
• designing a new job or task

• changing a job or task

• Introducing new equipment

• reviewing a procedure when problems have been identified.

E.g. from an accident or incident investigation

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  The safe working procedure should identify:

 the equipment to be used in these tasks

 the control measures that have been formulated for these tasks

 any training or qualification needed to undertake the task

 the personal protective equipment to be damaged

 action to be undertaken to address safety issues that may happen

while undertaking the task

1. Identify hazards and assess risk.
• Identify hazards in the work area and during the performance of

workplace duties.
• Assess level of risk
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 2. Follow procedures and strategies for risk control.
• Report hazards in the work area.
• Follow workplace procedures and work instructions to controlling risks.
• Whenever necessary, within the scope of responsibilities
• Dealing with hazards and incidents, fire and/or other emergencies.
3. Contribute to OHS in the workplace.
• Describe employee rights regarding discussion on OHS matters.
• Raise task and/or job specific OHS issues with appropriate people.
• Contribute to participative arrangement for OHS management.
• Provide feedback to supervisor on hazards with organisational OHS
policies and procedures

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 Conducting discussions and communication rules Communication

 Communication is an important part of our daily life.

 We use communication to let other people know our thoughts and feelings

and to convey messages.

 To have a co-operative, positive working environment, communication

must be effective and efficient.
Type of communication

1. Nonverbal Communication

 Nonverbal messages are unspoken and more difficult to interpret than verbal

messages, but are just as important.

 This is particularly true when you think that someone is saying

one thing and showing body language that tells a different story.
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  This is particularly true when you think that someone is saying one thing and

showing body language that tells a different story.

 Nonverbal cues are often neglected during interpersonal communication. A type

of unspoken communication is writing.

 Communication in writing is powerful and lasting. Whether you write a letter, a

memo, or an email message, written communication can be recalled word for

word.
 Spoken communication is often misquoted and misremembered. Writing lasts a

long time. So, think carefully about written communication.

2. Verbal Communication
i. Face to face
ii. Telephone
iii.Conference or meeting
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 --------THE END--------

-------THANK YOU-------
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