Chpt 10 Vehicle Maintenance

7/30/2019 Chpt 10 Vehicle Maintenance

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After studying this chapter, you will be able to:Check a car's fluid levels.Explain the importance of vehicle maintenance.Locate fluid leaks .Replace engine oil and filter.Change automatic transmission fluid and filter.Perform a grease job.Inspect for general problems with hoses, belts,and other components.Demonstrate safe practices while working withvehicle t1uids.Correctly answer ASE certification test questionson fluid service and vehicle maintenance.

Vehicle fluids include engine oil, coolant, brakefluid, transmission fluid, power steering fluid, and otherliquids . All automotive technicians will, at some time,service vehicle fluids. Service station attendants, apprentices, and even experienced technicians must check, add ,or replace fluids.

Many technicians' first job is as a service stationattendant. They "cut their teeth" doing fluid service,grease jobs, and light mechanical repairs. Therefore, thischapter is extremely important. It is your chance to learnfluid service and prepare for what may be your first job.Study this material carefully.

The last section of the chapter discusses recycling. Tohelp save our environment, you should recycle as manyautomotive parts and materials as possible. Plasticb ~ l m p e r s , batteries, tires, and used fluids can all be recycled into new products. Find recyclers in your area whocan take your used parts and make them into new products. This will help prevent larger landfills . It will alsosave energy because less energy is often needed to manufacture new products from recycled ones.

Vehicle Maintenance,Eluid Service, andRecycling

Lubrication ServiceLubrication service is vital to keeping a vehicle in

good working order. A technician must be familiar withall aspects of lubrication service, which include:

Checking fluid levels and conditions. Adding fluids as needed. Changing engine oil and filter. Changing automatic transmission fluid. Lubricating (greasing) certain chassis parts. Locating fluid leaks and other obvious problems . Following state regulations for recycling and dis

posal of fluids.

Vehicle MaintenanceVehicle maintenance includes any operation that

will keep a vehicle in good operating condition. Withoutproper care, the life of an automobile may be reduced bythousands of miles. For example, fluids can become contaminated and change chemically after prolonged use. Thiscan cause wear, corrosion, and mechanical failure of parts.

Tech Tip!A wise saying goes, "You can pay now or youcan pay later." In the automotive field, thismeans that the customers can pay a little nowfor maintenance or pay much more later forrepairs. A poorly serviced vehicle will wear outand break down sooner than a well-maintainedvehicle. In the long run, vehicle maintenancesaves the customer money.

Fluid ServiceA service manual contains detailed information on

how to check fluid levels. The manual will usuallydescribe:

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Engine oildipstick Battery

128 Section 1 Introduction to Automotive Technology

Engine coolantreservoir

WindshieldBrake fluid washer

Figure 10-1. A service manual gives the locations of all fluidcheckpOints. This manual illustration shows engine compartment fluid check pOints. (VW)

Location of fluid check points, Figure 10-l. Location of fluid fill points. Correct interval (time or mileage) between fluid

checks and changes. Correct type and quantity of fluid to be used.This information varies from vehicle to vehicle. For

example, a diesel engine may require more frequent oilchanges than a gasoline engine. Automatic transmissionor transax le fluids, differential lubricants, and otherfluids can vary in chemical content.

Tech Tip! A car's warranty may become void if incompatible fluids, incorrect service procedures, or improper intervals are used. For this reason, refer to the manufacturer's recommendations when servicing fluids.

Fluid capacity is the maximum amount of fluid areservoir or assembly will hold. The vehicle manufacturer will list fluid capacities for the engine, transmissionltransaxle, and other components or systems.Checking Engine Oil

To check engine oil, warm the engine to operatingtemperature. Shut off the engine and allow it to sit for afew minutes. Locate and remove the engine oil dipstick.Wipe off the dipstick and replace it all the way into itstube. Pull the dipstick back out and hold it over your shoprag. See Figure 10-2.

A

B

cFigure 10-2. Check the amount of oil in the engine using thedipstick. A-Locate the dipstick and remove it from the engine.B-Wipe the oil from the dipstick; then reinsert the dipstick in itstube. C-Remove the dipstick and check the oil level. Hold thedipstick over a shop rag to prevent oil from dripping onto theengine or the shop floor.


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Chapter 10 Vehicle Maintenance, Fluid Service , and Recycling 129

As shown in Figure 10-3, the oil level should bebetween the ADD (LOW) and FULL marks on the dipstick. Before reinstalling the dipstick, inspect the condition of the oil. The oil should not be too thick or thin,smell like gasoline, or be too dirty.

Warning! Be careful when checking or changing vehicle fluids. At operating temperature, oil and other fluids can be hot enough to burn your hand.

I f the oil level is low, you must add the correctamount and type of oil. I f the oil level is down to theADD mark, typically one quart is needed. If the dipstickreads halfway between ADD and FULL, you would needto add only one-half quart.

Never add too much oil to an engine . Pour in onlyenough oil to reach the FULL mark. Overfilling cancause oil foaming (the oil absorbs air bubbles), whichreduces the oil's lubricating ability.

Adding engine oilTo add engine oil, obtain the right kind of oil. Look

for a lubrication sticker in the engine compartment or onthe driver's door. Use the same type of oil that wasinstalled during the last oil change, if possible.

To add oil to the engine, remove the oil cap, which isusually on the valve cover. Install a small , clean funnelinto the engine opening. Without spiUing, pour the oilslowly into the funnel and engine filler tube or opening.

Changing Engine Oil and FilterWhen changing engine oil, make sure the engine is

warm and the vehicle is sitting level. This will ensure thatmore of the oil contaminants are suspended in the oil andare drained out of the engine. I f the oil is cold, the oil willdrain more slowly and debris will settle to the bottom ofthe oil pan.

Figure 10-3. Oil should be between the ADD and FULL marks.Be sure to check the condition of the oil before reinserting thedipstick.

To change the engine oil:1. Warm up the engine.2. Raise the car on a lift or place it on jack

stands in a level position.3. Place a catch pan under the oil drain plug.4. Unscrew the plug and allow enough time

for the oil to drain completely. SeeFigure 10-4.

5. Reinstall the drain plug. Be careful. Thethreads in the pan and on the plug can stripeasily. Apply only enough torque to drawthe plug tight and prevent leakage. Astripped oil drain plug can damage the oilpan threads.

6. Position your catch pan under the oilfil tef.

7. Using an oil filter wrench, as in Figure 10-5,unscrew the filter.

An oil pan drain plug will strip easily. Looking at ,t from the front, tum the plug counterclockwise for removal. L o o s e ~ ~rain plugBe careful , at first the hot oil will pour out to one side of the pan.

Oil catch -------..pan

Engineoil pan

Oil pan

Do notovertightendrain plug

Figure 10-4. To drain the engine oil, remove the oil pan drainplug. Allow the oil to pour into a catch pan . Be careful not toovertighten the drain plug. Its threads will strip out easily.(Subaru)


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B filter c O-ringFigure 10-5. Changing the engine oil filter. A-An oil filterwrench is needed to unscrew the oil filter. B -Turn in a counterclockwise direction. C-When installing a new filter, coat theO-ring seal with clean oil and only hand tighten the filter . (Lisle)

8. Obtain the correct replacement filter. Compare the old and new filters. Make sure therubber O-ring on the new filter has the samediameter as the O-ring on the old filter.

9. Wipe some clean oil on the O-ring andinstall the new filter.

W. Tighten the filter by hand only, not withthe filter wrench. Overtightening willsmash the O-ring and cause leakage.

11 . Lower the car to the ground and add thecorrect amount and type of oil.

12. Start the engine and make sure the oil pressure light goes out.13. Let the engine run while checking for leaksunder the engine.

14. Shut off the engine and check the oil levelagain.

Automatic TransmissionlTransaxle Fluidand Filter Service

Like engine oil, automatic transmission and transaxlefluid should be checked and changed at specified intervals.

The fluid can become contaminated (filled) with metal,dirt, moisture, and friction material (nonmetallic, heatresistant fibrou s substance) from internal parts. This cancau se rapid part wear and premature transmission failure.

To check the fluid in an automatic transmission ortransaxle , warm up the engine and move the gear selectorthrough all positions. Apply the parking brake. Place thetransmission in park and block the wheels.With the engine still running, locate the transmissiondipstick . See Figure 10-6. It is normally behind theengine, near the front of the transmission.

Tech Tip!Don ' t "go crazy" looking for the transmissiondipstick on some new cars and trucks. You maynot find one. Some transmissions and transaxlesare sealed at the factory. They are designed tonot require fluid changes and periodic checkingof fluid level.

Figure 10-6. An automatic transmission fluid dipstick is normally behind engine, on the side. Check it with the engine running and the transmission in park. If needed, add the correctfluid . (Saab)

Pull out the dipstick . Wipe it off and reinsert it intothe tube. Remove the dipstick again and hold it over ashop rag. The fluid should read between the ADD andFULL marks. Also, in spect the fluid for discoloration andodor. If it smells burned or looks dirty, the fluid should bechanged.

It is very easy to overfill an automatic transmission.Seldom do you have to add a full quart. Normally, if thedipstick reads ADD, only a fraction of a quart is neededto fill the transmission. Sometimes, instructions arewritten on the dipstick. I f in doubt, check a shopmanual.


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Chapter lO Vehicle Maintenance, Fluid Service, and Recycling 131

To change the fluid and filter in an automatictransmission or transaxle:

1. Warm the engine and transmission or transaxle.

2. Raise the vehicle.3. Remove all but one of the bolts securing

the transmission pan, Figure 10-7. Becareful not to spill the hot transmissionfluid. It can cause painful burns!

4. Loosen but do not remove the last pan boltwhile holding the pan in place with ashop rag.

5. Allow the pan to drop and let the fluid pour into a catch pan.

6. Unscrew the last pan bolt and remove thepan. If needed, replace or clean the trans-mission filter, Figure 10-8.

.....-----7.:---j

Attachingscrew

ScrewdriverFigure 10-8. Some manufacturers recommend periodicreplacement of the automatic transmission fi'lter. It is locatedinside the transmission pan. Tighten all fasteners to specswhen assembling.

7. Scrape the old gasket off the transmissionpan and housing.

8. Position the new pan gasket using anapproved sealer. Use the sealer sparingly.You do not want any to squeeze out of thegasket and into the transmission ortransaxle housing.

9. Start all the pan bolts with your fingers.10. Tighten the pan bolts in a crisscross patternto their recommended torque specification.Overtightening can split the gasket or dis-tort the transmission pan.

11. I f recommended, drain the torque converter(fluid coupling in front of the transmission).A drain plug may be located in the con-verter. It is usually under a rock shield onthe front of the transmission housing.

12. Refill the transmission with the correcttype and amount of transmission fluid. I frequired, check a service manual fordetails. In most cases, you must pour freshfluid into the dipstick tube.

13. Start the engine and shift through the gears.14. Check under the car for leaks and check

the fluid level.

Manual Transmission Fluid ServiceTo check the fluid in a manual transmission, locate and

remove the transmission fill plug, Figure 10-9. It is nor-mally on one side of the transmission. Generally, warmfluid should be even with the fill hole. With the transmis-sion cold, the fluid can be slightly below the fill hole.

Some manufacturers suggest that manual transmis-sion fluid be changed periodically; others do not. I f a fluid

Manual

GearoilFillplugDrain plug~

Figure 10-9. A manual transmission will have a fill plug forchecking the fluid level. The fluid should be almost even with thehole when the fluid is warm. Check the service manual fordetails. (DaimlerChrysler)


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I\ ~ - ............=-=

Differential drain hole


change is needed, remove the drain plug on the bottom ofthe transmission case and allow all the fluid to pour intoyour catch pan. Replace the drain plug and install the righttype and quantity of fluid . Lubricate the gear shift mechanism and clutch release as described in a service manual.

Some new transnussions and transaxles are designedto never need fluid replacement with normal use . Theyare permanently sealed. The chemical makeup of thefluid, improved filtering, and less part wear have allowedthis technological advance.

Differential Fluid ServiceTo measure the fluid level in a differential (rear axle

assembly), remove the fill plug. It will normally be on thefront, back, or side of the differential. See Figure 10-10.The lubricant should be even with the fill hole when hot.When cold, it should be slightly below the hole.

At the manufacturer's recommended chancre intervalremove the drain plug. It will be on the bottom of the differential. After draining, reinstall the plug and fill the differential with the proper lubricant. I f a drain plug is notprovided, a special siphon (suction) gun can be used todraw out the old fluid.

Caution!Positive-traction, or limited-slip, differentials(both wheels turn for added traction) oftenrequire a special lubricant. Refer to the vehicleidentification number, a service manual, andChapter 62, Differential and Rear-Drive AxleDiagnosis and Repair, for details. I f you installthe wrong lubricant, differential action and traction can be adversely affected .

Axle

Drive shaftFigure 10-10. The differential fill hole allows for a check of thelubricant level. Do not accidentally remove the drain plug.(Subaru)

Checking Engine CoolantEngine coolant (mixture of water and antifreeze) is

used in an engine's cooling system. Engine coolant mustbe changed periodically. After prolonged use, the cool antwill deteriorate. It can become very corrosive and filledwith rust. This may result in premature water pump , thermostat, and radiator failure.

Warning! Never remove a radiator cap while the engine or radiator is hot. Boiling coolant can spray out of the radiator, causing serious burns.

To check the coolant level , look at the side of theplastic overflow tank connected to the radiator. SeeFigure 10-11. The coolant should be between the hot andcold marks on the side of the tank. When an overflowtank is used, the radiator cap does not need to be removedto check coolant level.

Some older cars do not use an overflow tank. In thiscase, the radiator cap must be removed to check thecoolant level. The coolant should be about an inch(25 mm) down in the radiator. Also, inspect the conditionof the coolant, Figure 10-12. I f rusty, the coolant shouldbe drained and replaced. Watch for system leaks.Checking Power Steering Fluid

Power steering fluid level should be checked regularly. The engine should not be running when checkingpower steering fluid . If the fluid is contained in a clearplastic reservoir, simply compare the fluid level to themarkings on the side of the reservoir. See Figure 10-13A.

Figure 10-11. Modern cooling systems have a reservoir tank.You can check the coolant level without removing the radiatorcap. On older systems, remove the cap only after the enginehas COOled .


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Warm engine /Dipstick

Chapter 10 Vehicle Maintenance, Fluid Service, and Recycling 133

Figure 10-12. Check the condition of the coolant in the reser-voir or the radiator. If the coolant is rusty, it should be drainedand replaced.

In some vehicles, the level is checked by removing a dip-stick from the power steering pump, Figure 10-13B.Check the fluid level on the dipstick. If low, inspect forleaks and add the correct type and amount of powersteering fluid.

Checking Brake FluidThe amount of brake fluid in a master cylinder should

be inspected at least twice a year. Look at Figure 10-14.The master cylinder is normally mounted on the firewall(body section between the engine and the passengercompartment).

When the master cylinder reservoir is clear plastic,simpiy compare the fluid level to the markings on thereservoir. The fluid should be between the ADD andFULL marks.

With many master cylinders, you must remove thereservoir cover to check the fluid. Generally, the fluidshould be about 1/4" (about 6 mm) down from the top ofthe master cylinder. Add the recommended type of brakefluid as needed.

Caution!Never let anything (oil, grease, dirt) contami-nate the brake fluid. Oil and grease, forexample, will attack the rubber parts in thebrake system. Major repairs would be neededand the vehicle could lose braking ability.

Checking Hydraulic Clutch FluidSome manual transmission clutches do not use

mechanical linkage rods or cables. Instead, they use a

Power steeringpump( /

Cold engineBFigure 10-13. Checking power steering fluid. A-Comparingthe fluid level to markings on the side of the reservoir. 8 -0nsome vehicles, the power steering pump has a cap with a dip-stick. Check the fluid with the engine off. Compare the fluid levelto markings on the dipstick. (Subaru)

Figure 10-14. Check the brake fluid at the master cylinderreservoir. The master cylinder is mounted on the firewall, infront of the driver. The maximum fluid level is often indicated onthe side of the reservoir. If not, fluid should be slightly below thethe top of the reservoir.


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hydraulic system to disengage the clutch. A clutch mastercylinder, similar to a brake master cylinder, produceshydraulic pressure to activate the clutch release. The fluidin the clutch master cylinder should be checked. If low,add brake fluid to fill the reservoir almost full. Alwayswatch for leaks.

Checking Manual Steering Box FluidManual steering box fluid is checked by removing

either a fill plug or designated bolt from the top of thebox. See Figure 10-15. The lubricant should be almosteven with the plug or bolt opening. I f not, add the recommended fluid.

Checking Windshield Washer SolventThe windshield washer solution is normally visible

through the side of the plastic storage tank. Refer back toFigure 10-1. I f low, add an approved washer solution.The solution will aid windshield cleaning and also prevent ice formation in cold weather.

Checking BatteryNew cars use maintenance-free batteries, which do

not require an electrolyte (acid) check. However, makesure that the battery terminals and case top are clean. Abattery post and cable cleaning tool can be used on corroded connections. If the top of the battery is dirty, it canbe cleaned with a solution of baking soda and water. SeeFigure 10-16.

Manual steering boxFill hole

Fill bolt - - - - - - ' r - : i i ~ ...-

Lubricantlevel

Figure 10-15. The manual steering box will have a bolt or plugfor checking the lubricant. If needed, fill with recommended typeof fluid up to the fill hole. (DaimlerChrysler)

B

Figure 10-16. Checking battery condition is important tovehicle maintenance. Battery problems are the number onecause of engine "no start" problems. A-A dirty battery top willdrain the battery. Corroded terminals prevent charging andstarting. B -A post cleaning tool will remove corrosion from thesurfaces of posts and cable ends. C-Wash the top 0f the bat-tery with baking soda and secure terminals.


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Chapter 10 Vehicle Maintenance, F1uid Service, and Recycling 135

Filter ServiceQuite often, various filters used in a vehicle are

replaced during lubrication service. Besides the engineoil and transmission filters, the technician may need tochange or clean the air and fuel filters.

I f an air filter is extremely dirty, it is normallyreplaced. However, some manufacturers permit light dirtand dust to be blown from the filter. Special foam or oilbath (oil-filled) air filters can be cleaned as described ina service manual.

Fuel filters can be located almost anywhere in thefuel circuit. Modern fuel systems often use inline fuel filters between the fuel tank and the engine. In older systems, the fuel filter can be located at the inlet to thethrottle body injector or in the carburetor. Most fuel systems also have a fuel strainer on the pickup tube in the fueltank. Refer to the service manual for exact filter locations.

Warning! Hold a shop rag around fuel line fittings when loosening. This will keep fuel from spraying out, preventing a possible explosion and fire .

Chassis LubricationChassis lubrication generally involves greasing

high-friction points on the vehicle. It may also involvelubricating locks, hinges, latches, and other body parts.Chassis lubrication is often done when the engine oil andfilter are serviced.Grease Job

During a grease job, you must lubricate high-frictionpivot points on the suspension, steering, and drive train

Greasefittingson upperand lowerball joints

systems. Most service manuals illustrate which partsmust be lubricated, Figure 10-17.

A grease gun, Figure 10-18, is used to force lubricant (chassis grease) into small fittings. Inject only enoughgrease to fill the cavity in the part. Overgreasing can sometimes rupture the rubber boot surrounding the joint.

Body LubricationWhen performing a complete chassis lubrication job,

you should also lubricate high-friction points on thebody (hinges and latches on doors, hood, and trunk).See Figure 10-19. This will help prevent squeakingdoors, sticking hinges, and wear problems.

Figure 10-18. This technician is using a power grease gun tolubricate fittings on a suspension system.

L . . : = = ~ = = = ; " ) Red dotsindicatepossiblegreasefittingr;:==:::;:;::===::J locations

Check for greasefittings at tie-rod endsFigure 10-17. A grease job involves lubricating the pivot points shown. Some cars have more grease fittings than others. Checkclosely.


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B~ _______ hood l a t c h ~~ ~ : : : : -

c oFig. 10-19. During lubrication service , lubricate body components to prevent squeaks and wear. A-Lubricating hood andtrunk hinges. B-Using wax on door strikers. C-Place a dab ofgrease on door hinges. D -The hood latch is a common rustproblem. (Volvo)

Be careful to always use the prescribed lubricant.Normally, rubber and plastic Palts will deteriorate ifexposed to petroleum-based lubricants (oils and grease).Silicone lubricant should be used on plastic and rubbercomponents. The most common types of body lubricantsare listed below:

Engine oil-used on hard-to-reach high-frictionpoints.

Graphite-excellent for door and trunk locks. Itwill not collect dust and dilt, which could upsetlock operation.

Dry stick (wax) lubricant-desirable on doorlatches and strikers (post that engages the doorlatch). See Figure 10-19. It will not stain clothing.

Chassis grease-good aU-around body lubricant.It can be used on easy-to-reach hinges and latches.

Silicone lubricant-often comes in a spray can.It is especially suited for rubber door weatherstripping and windows. It is a dry lubricant thatwill not soil windows and clothing.

Service IntervalsA service interval is the amount of time (in months)

or the number of miles between recommended servicechecks or maintenance operations. The factory servicemanual will give exact intervals for the particular make,model, and year of vehicle. New vehicles tend to havelonger intervals before service is required.Figure 10-20 shows the service manual recommendations for chassis maintenance on one vehicle. Note theintervals for each service operation. They are typical.r!l Note!Chapter 47, Engine Tune-Up, gives general

engine maintenance intervals. Refer to thischapter if needed .

10

94"

Component Service Interval1 Axle differential V- 5000 mi (8000 km)-. T 30,000 mi (48000 km) 2. Bearings,

.... L!C /a . 30,000 mi (48 000 km)front wheel3. Body lubrication " GC /b 15,000 mi (24000 km)4. Brake inspection V- c 15,000 mi (24 000 km)5. Clutch lever .... 2! 1 30,000 mi (48000 km)6. Exhaust systeminspection V- d 15,000 mi (24 000 km)7. Manual steering gear V e 5000 mi (8 000 km) 8. Manual transmission V 5000 mi (8 000 km)9. Spare tire V- I. 7500 mi (12 000 km)

10. Steering , \" 9 15,000 mi (24 000 km)suspension, andchassis " 22 l h. 30,000 mi (48 000 km)Figure 10-20. Study the chassis maintenance information froma service manual. Recommendations for other parts of the carare also given in the manual. (DaimlerChrysler)


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As you perform lubrication service or any kind ofany signs of wear, deteri

loose parts, or leaks. Check the condition of fanyou are working.

Hose inspection includes checking for hardening, softening, cracking, splitting, or othersigns of impending failure. See Figure 10-21.Squeeze all the hoses. I f the hoses are deteriorating (hard or soft), inform the customer or shopsupervisor of the problem.

Drive belt inspection includes looking for splitting, tears, cuts, and wear. I f worn or loose, thebelt may slip and squeal. Refer to Figure 10-22.

Wiring inspection involves looking for improperrouting, cracked or brittle insulation, or otherobvious problem signs. Make sure wires are awayfrom all moving or hot parts.

Tire inspection is done by looking for excessivewear, improper inflation, or physical damage.This is very important from a safety standpoint.

Steering system inspection includes checking forexcessive wear and play in moving parts. Thesteering wheel should not move more than aboutan inch (25 mm) without causing front wheelmovement. If it does, wear in the steering mechanism is indicated.

Exhaust system illspectioll involves looking fordamaged, rusted, or leaking parts. The exhaustsystem should be inspected any time a vehicle israised on a lift. Poisonous exhaust fumes make a

Fan Coolantbelt hoseFigure 10-21. Check the condition of all hoses and belts.Inspect belts for glazing, cracking, and fraying . Feel hoses forhardening or softening. Look for leaks. (Gates Rubber Co.)

Alternator/waterAdjusting bolt "\ pump belt~

CheckloosenessMountingboltFigure 10-22. Belts should not be too loose or too tight. Toadjust, loosen correct mounting bolts and the adjustment bolt.Using directions in service manual, pry the component outwardand tighten the adjusting bolt. Then, tighten the mounting bolts.Recheck belt tightness. (Honda)

leaking exhaust system very dangerous. Look forrust holes in the pipes, muffler, and other parts.

When working on a vehicle, be ale11 for these kindsof problems. This will show the shop supervisor and thecustomer that you are a concerned, competent technician.

Fluid LeaksFluid leaks result from bad gaskets, seals, or hoses;

cracks in parts; and similar troubles. Leaks are verycommon problems that should be corrected. SeeFigure 10-23. To become good at leak detection andcorrection, you should:

Become familiar with the color, smell, and feel(texture) of the different fluids. Then, you will beable to quickly identify a fluid leak. Does thefluid feel more like water or oil? Dab a whitepaper towel into a puddle of fluid to show itscolor more accurately. Oil will be slippery to thetouch and will be dark brown or black if used foran extended period of time. I f the fluid is clear orbrown and feels "squeaky" when rubbed betweenyour fingers, it is probably brake fluid orhydraulic clutch fluid. Antifreeze can be green,orange, or rust colored and will feel slick.Automatic transmission fluid can be dark brown,red, or dark green with some friction material feel(gritty). Power steering fluid can be amber, red, orclear and will feel like transmission fluid.


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Figure 10-23. When working under a vehicle, always look forsigns of fluid leakage and other obvious problems. Inspectrubber boots and hoses for signs of damage.

Fluid leaks tend to flow downward and to the rearof the vehicle. For this reason, look for leaksabove and in front of where you find fluid dripping off the vehicle.

I f multiple leaks are indicated, fix the leak locatedthe highest and farthest forward on the vehicle.Then, repair other leaks.

If the leaking part is badly soiled, clean the areathoroughly. Then it will be easier to see freshfluid leaking out of the part.

The most frequent cause of fluid leakage is brokengaskets and worn seals. Replacement will usuallycorrect the problem. However, you should alwayscheck the parts for warpage, cracks, and dents.

Some stop-leak products are designed to reconditionthe leaking seal. I f the seal has hardened and shrunk insize, stop-leak chemicals can fix the leak with little timeand effort. I f the seal is torn or the part is warped, stopleak products will not work.

Other stop-leak products (for the cooling system, forexample) contain small particles (fibrous or metallicmaterials) that collect at and fill the opening causing theleak. These materials can also act as a conditioner or rustpreventative.

Tech Tip! Stop-leak products will not work on hose leaks and large leaks from metal parts. These products are designed to work on small seepage problems. Refer to the manufacturer's recommendations on stop-leak products.

Noise Detection and LocationAbnOlmal noises are unwanted sounds that indicate

part wear or other mechanical problems. They arecommon to almost all systems of a vehicle. Wheninspecting a vehicle, listen for unusual sounds (knocks,clunks, rattles, clicks, and hisses). As you work, alwayslisten for abnormal noises.A stethoscope (similar to that used by a doctor tolisten to a patient's heart) is commonly used by an autotechnician. It will help the technician pinpoint the sourceof internal part noises. To use the stethoscope, touch theprobe on the component near the unwanted sound,Figure 10-24. Move the stethoscope around until thesound is the loudest.

A long screwdriver can be used in place of a stethoscope. Place the tip of the screwdriver on the part. Placethe handle next to your ear. Sound will travel through thescrewdriver and permit noise diagnosis. Make sure youkeep the screwdriver away from moving parts or youcould be injured .

A section of vacuum hose, Figure 10-25, is a handydevice for finding sounds not coming from internal parts.The hose is useful for locating hissing sounds , rattles,whines, and squeaks. Place one end of the hose to yourear. Then, move the other end around the area of thesound. When the noise becomes the loudest, you have

Figure 10-24. A stethoscope can be used to quickly find knocksand ratlles inside components. Move the tip around on parts.When noise becomes the loudest, you have found the sourceof the problem.


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Figure 10-25. A piece of vacuum hose can be used like astethoscope to find external noises. It will find vacuum leaks,squeaks, wind noise, and other abnormal sounds.

pinpointed the problem. Again, keep the hose away frommoving or hot parts. By removing the metal end from astethoscope, you can also listen for these kinds of noises.

Recycling and Disposal of Auto ShopWastes

Recycling and the proper disposal of auto shopwastes are needed to help save our planet's naturalresources and to reduce the amount of materials beingsent to landfills. Laws have been passed that require specific procedures when handling and discarding potentially harmful materials. The following sectionssummarize this important information.

Auto Shop WastesAutomotive maintenance may generate hazardouswastes that come under the requirements of the Resource

Conservation and Recovery Act. This federal act coversbusinesses that generate, transport, and manage hazardous wastes. Any business that maintains or repairsvehicles, heavy equipment, or farm equipment is classified as a vehicle maintenance facility by this act.

Vehicle maintenance fluid and solid wastes include: Used motor oil (combustible and may contain

toxic chemicals).

Other discarded lubricants, such as transmissionand differential fluids (like motor oil, may containtoxic chemicals).

Used parts. Cleaners and degreasers that are contaminated

from parts-cleaning operations. Carburetor and fuel injection system cleaners(contain flammable or combustible liquids). Rust removers (may contain strong acidic or alka

line solutions). Paint thinners or reducers (may be ignitable or

contain toxic additives). Worn out batteries (lead and toxic chemicals). Tires and catalytic converters.Repair and maintenance facilities (service stations,

automotive dealerships, independent auto repairshops, etc .) that generate 220 lb. (100 kg) of hazardouswaste monthly must file a Uniform Hazardous WasteManifest before removing the wastes. The manifest mustlist the proper Department of Transportation (DOT)shipping descriptions for a number of wastes. Tableslisting these descriptions are available from each state'shazardous waste management agency or a regionalEPA office.

However, EPA regulations also state that no manifestis needed for used oil or lead-acid batteries if they aresent for recycling. In such cases, the material is notregarded as hazardous. Your state may have its ownrequirements; check with your state hazardous wastemanagement agency.

Unless recycled for scrap metal, used oil filters areconsidered hazardous waste. If not recycled, they must belisted on the monthly manifest as hazardous. Before disposal, filters should be gravity drained so they do notcontain free-flowing oil. Store them uncrushed in aclosed, labeled container for pickup by a recycler.Recycling Motor Oil

Used motor oil is considered hazardous waste unlessit is destined to be recycled. The old oil should be storedin an approved container for recycling. One gallon ofused motor oil can be refined into two and one-half quartsof high-quality motor oil. It takes about 40 gallons ofcrude oil to produce this much motor oil. Recycling oldoil not only saves our environment from pollution, but italso helps save our natural resources. Always send usedmotor oil to a recycling center! Put the oil in an approvedcontainer. Some recycling companies provide a pickupservice, while others require you to take the old oil totheir facility.


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Recycling CoolantsAntifreeze has been classified as a hazardous waste

due to heavy metal and chlorinated solvents that it picksup circulating through cooling systems. It should neverbe mixed with used oil. The entire mixture would then beclassified as a hazardous waste, even though the used oilmay not be, under federal regulations.

Regulations require that spent antifreeze solutions becollected by a registered hazardous waste hauler. Severalmajor companies offer pickup and recycling services.Recycling Refrigerants

Refrigerants , such as R-12 and R-134a, removedfrom automotive air conditioning systems during servicing should not be vented to the atmosphere. State regulations require that refrigerants be recovered andrecycled. See Figure 10-26.

As you will learn in later chapters, systems are nowavailable for recovering, cleaning, and recycling airconditioning refrigerants .

Figure 10-26. A recovery station will pull old refrigerant out ofthe air conditioning system. The machine will then treat usedrefrigerant for reuse in the vehicle. (RTI)

Other Automotive RecyclablesOther recyclable materials that are commonly

removed from service during maintenance and repair ofvehicles include:

Catalytic converters, which contain platinum. Worn tires, which can be sold to a retreader (i f the

carcass is sound) or to a shredder. Shreddedrubber is an ingredient in road resurfacing materials and other products that give the rubber asecond use.

Batteries can be recycled and used to make newbatteries. This saves lead, acid, and other matetials from adding to our waste disposal problems.

Brake shoes can be recycled and sold as cores formaking reconditioned brake shoes.

Many small assemblies (alternators, starters,master cylinders, etc.) can be recycled and madeinto rebuilt parts. Plastic bumpers and other body parts can be recycled into a variety of new products.

Dutyty ,s GOJLoge.Problem: Ms. Jones brought her 2005 ChevroletTrailblazer in for repai r because she noticed a puddleof fluid on her garage floor.Diagnosis: Duff, the shop own er, questions Ms. Jonesto find out more about what is wrong with the vehicle.He asks her about unu su al so unds an d odors. He alsoas ks if she knows approximately where the fluid isleaking from (front of eng ine, back of en gine, rightside, left side, etc.). Ms . Jones says the puddle seemsto be coming from the left front corner of the vehicleand th at she often hears a growling noise when dr iv ingarou nd corners. After listening carefu lly to Ms. Jones,Duff suspects that th e power steering system might beleaking and that the growling noise may be caused byair in the power steering system. Duff then turns therepair ove r to the shop's su spension and steeringtechnician. Du ff discusses the symptoms with her an dtells her what he thinks the problem is.

The technician ch ecks for dripping un der theengine compartment and finds a small fresh puddlethat looks and smells like power steering fluid. Shethen opens the hood and looks for the source of theleak. As she feels around the power steering pumpand hoses, she finds a leak at the hose behind thepower steering pump. She then starts the en gine and


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uses a lighted mirror to observe the fluid dripping fromthe crimped metal fitting on the hose.Repair: The technician orders and installs a newpower steering hose. She then fills the system withfluid, starts the engine, and rotates the steering wheelback-and-forth between the stops to purge air from thesystem . After test d riving the vehicle, she lets it run forapproximately 15 minutes and then rechecks thesystem for leaks. After ve rifying that the problem hasbeen co rrected, the technician rechecks the powersteering fluid level and releases the vehicle to thecustomer.

Summary Vehicle fluids include engine oil, coolant, brake

fluid, transmission fluid, power steering fluid,and other liquids.Vehicle maintenance includes any operation thatwill keep a vehicle in good operating condition.

A car's warranty can become void if improperfluids or incorrect service procedures or intervalsare used.

Be careful! Oil and other fluids at operating temperature can be hot enough to burn.

EPA (Environmental Protection Agency) guidelines and state regulations affect how you musthandle and dispose of used fluids, solvents, andother shop chemicals.

Never remove a radiator cap while the engine orradiator is hot. Boiling coolant can spray out ofthe radiator, causing serious burns.

Hold a shop rag around fuel line fittings when. loosening. This will keep fuel from spraying orleaking out, preventing a possible explosion andfire.

During a grease job, you must lubricate highfriction pivot points on the suspension, steering,and drive train systems. Wheel bearings are usually packed (filled) withgrease during lubrication service.

As you perform a lublication job or any kind ofauto repair, always watch for mechanical problems. Visually inspect the vehicle for any signs ofwear, deterioration, loose parts, or leaks.A stethoscope (similar to that used by a doctor tolisten to a patient's heart) is commonly used by atechnician.

A section of vacuum hose can be used as a handydevice for finding sounds not coming from insideparts.

Important TermsVehicle fluids Silicone lubricantLubrication service Service intervalVehicle maintenance Hose inspectionOil foaming Drive belt inspectionStripped oil drain plug Wiring inspectionGrease job Tire inspectionGrease gun Steering systemEngine oil inspectionGraphite Exhaust systemDry stick (wax) inspection

lubricant Fluid leaksChassis grease Stop-leak products

Review Questions-Chapter 10Please do not write in this text. Place your answers

on a separate sheet of paper.1. What seven steps does lubrication service typi

cally involve?2. __ includes any operation that will

keep the car in good operating condition.3. When checking engine oil, allow the engine to

cool completely. True or False?4. What can happen when too much oil is added in

an engine?5. Which of the following should /lot be done

when changing an engine's oil and filter?(A) Torque the drain plug only enough to pre

vent leaking and loosening.(B) Use an oil filter wrench to remove the old

filter.(C) Wipe clean engine oil on the new filter

O-ring seal.(D) Use a filter wrench to tighten the filter.

6. The automatic transmission dipstick is normallylocated in front of the engine. True or False?7. Check automatic transmission or transaxle fluidwith the engine running. Check engine oil withthe engine off. True or False?

8. Explain how to check the following:(A) Engine coolant level and condition.(B) Power steering fluid.(C) Brake fluid.(D) Manual steering fluid.(E) Battery condition.


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9. A(n) ____ involves lubricating thesteering, suspension, and drive train of a vehicle.

10. List and explain the use of five lubricants.11. A(n)____ is the amount of time between

recommended service or maintenance opera-tions.

12. Describe six general inspection points thatshould be checked during vehicle maintenance.

13. Which of the following should be done to helpwith leak detection and troubleshooting skills?(A) Become famjiiar with the color and smell

of different fluids.(B) Trace the problem to the highest point ofwetness or leakage.

(C) Clean the area around the leak if the leak isdifficult to isolate.

(D) All of the above.14. A(n)__ s commonly used to find the source

of noises inside parts.15. List four automotive items that should be

recycled.

ASE Type Questions1. During a complete lubrication service, all of the

following are done except:(A) change engine oil.(B) change oi l jiltel:(C) check alljluid levels.(D) check ride height.

2. During an oil change, Technician A says to usean oil filter wrench to remove the old oil filter.Technician B says to apply a little oil to the sealon the new filter to aid installation. Who iscorrect?(A) A only.(B) B only.(C) Both A and B.(D) Neither A nor B.

3. When changing engine oil, Technician A saysthe engine oil should be cool. Technician B saysthe oil should be warm. Who is correct?(A) A only.(B) B only.(C) Both A and B.(D) Neither A nor B.

4. When checking automatic transmission fluid,the following should be done.(A) Engine off, transmission in park.(B) Engine running, transmission in park.(C) Engine off, transmission in neutral.(D) Engine on, transmission ill neutral.

5. Engine coolant consists of:(A) water and antifreeze.(B) oil and antifreeze.(C) water and stop leak.(D) water only.

Activities-Chapter 101. On a vehicle chosen by your instructor, deter-

mine the capacity of the cooling system. Thendetermine the amounts of water and antifreezeneeded to produce a salsa mixture.

2. Survey the motor oils offered for sale at a localoutlet. Determine the cost to change the motoroil in a vehicle named by your instructor. Addlabor cost at $36/hour.

3. Change the oil and filter on a vehicle designatedby your instructor.

Chpt 10 Vehicle Maintenance

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Transcript of Chpt 10 Vehicle Maintenance