chap17 pps Automotive technology at University of Cambridge

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Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition
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OBJECTIVES:
After studying Chapter 17, the reader should
be able to:

• Prepare for ASE Engine Repair (A1)

•
•

certification test content area “A” (General
Engine Diagnosis) and content area “D”
(Lubrication and Cooling Systems Diagnosis
and Repair).
Perform routine fluid and service checks.
Describe how to install wheels and tighten lug
nuts using a torque wrench and the proper
sequence.
Continued

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OBJECTIVES:
• Describe the proper procedure for changing

•

the engine oil and performing complete
chassis system lubrication and under-vehicle
inspection.
Beginning automotive service technicians are
often required to perform routine service
operations. It is the purpose of this chapter to
introduce the reader to these various service
procedures.

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KEY TERMS:
air filter • alamite fittings • algorithm • American
Petroleum Institute (API) • American Society for Testing
Materials (ASTM)
antidrainback valve • Association des Constructeurs
Européens d’Automobiles (ACEA) • automatic
transmission fluid (ATF) • brake fluid • bypass
cabin filter • dipstick • DOT 3 • DOT 4 • DOT 5 • National
Lubricating Grease Institute (NLGI) • penetration test •
polyglycol • serpentine
(Poly V) • silicone brake fluid • syncromesh transmission
fluid (STF) • viscosity • winter (W) • Zerk fittings
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GETTING READY FOR SERVICE
Before service work is done, protect the vehicle inside by using
commercially available plastic or paper protective coverings for
seats, floor, and steering wheel.

The hood must be opened, and often struts holding a hood are weak
or defective. Therefore, always make sure the hood is securely held.
Connect an exhaust system hose to the tailpipe(s) before work is
started that will involve operating the engine.
Do No Harm
As stated in the Hippocratic oath, a doctor agrees first to do no harm to the
patient during treatment. Service technicians should also try to do no harm
to the vehicle while it is being serviced.
Always ask, “Am I going to do any harm if I do this?” before you do it.
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Figure 17–2 An exhaust hose should be connected to the
tailpipe(s) whenever the engine is being run indoors.

Figure 17–1 Before service
begins be sure to cover the
seats, floor, and steering
wheel with protective covering.

Continued
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What is the Magnuson-Moss Act?
The Magnuson-Moss Act was passed into law in 1975 and allows the use
of nonoriginal equipment replacement parts during the service or repair of
a vehicle without losing the factory warranty. This means that any oil or air
filter, spark plug, or other service part can be used unless the vehicle
manufacturer furnishes these parts for free during the warranty period. The
vehicle manufacturer cannot deny paying a warranty claim for a fault
unless the replacement part is proved to be the cause of the condition
needed to be covered by the warranty. Therefore, it is up to the business
owner, service manager, or the technician to determine if the replacement
part is of good quality. While this is very difficult or impossible, unless
defects are obviously visible, the best solution is to use the original
equipment manufacturer (OEM) parts or service parts from a well-known
company.

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WIPER BLADE INSPECTION & REPLACEMENT
Windshield wiper blades are constructed of rubber and tend to
become brittle due to age. Wiper blades should be cleaned
whenever the vehicle is cleaned using water and a soft cloth.

Figure 17–3 Installing a wiper
blade insert into a wiper arm.

Continued
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Wiper blade or blade insert replacement includes:
Turn the ignition switch to on (run).
Turn the wiper switch on and operate the wipers.
When the wipers are located in an easy-to-reach location, turn
the ignition switch off. The wipers should stop.
Remove the insert or the entire arm as per the instructions on
the replacement windshield wiper blade package.
After double-checking that the wiper is securely attached, turn
the ignition switch on (run).
Turn the wiper switch off and allow the wipers to reach the

park position. Check for proper operation.

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CABIN AND AIR FILTER REPLACEMENT
A cabin filter is used in heating, ventilation, and air-conditioning
(HVAC) systems in the outside air passage. Some could include
activated charcoal to eliminate odors. The cabin air filter should be
changed about every two years or every 24,000 miles (39,000 km).
The cabin filter can be accessed from:
Under the hood at the cowl (bulkhead)

Under the dash, usually behind the glove (instrument panel)
compartment
Figure 17–4 A cabin filter can be
accessed either through the glove
compartment or under the hood on
most vehicles.
Continued
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(a)
An air filter filters dirt

from the air before it enters
the intake system. It should
be replaced according to
manufacturer’s
recommendations.
Figure 17–5 (a) A typical dirty air filter. (b) Always check the inlet passage leading to the air filter
for debris that can reduce airflow to the engine.

Many recommend replacing
the filter every 30,000 miles
(50,000 km) or even more
frequently under dusty
conditions. Many techs
advise do so yearly.
(b)
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BRAKE FLUID LEVEL INSPECTION
Brake fluid transmits the force of the driver’s foot on the brake
pedal to each individual wheel brake. It should be checked when
engine oil is changed (every 3,000 miles [4,800 km] or every three
months, whichever occurs first). Two types of master cylinders:
Transparent Reservoir Allows viewing of brake fluid (and
hydraulic clutch master cylinder if so equipped) without
having to remove the cover of the reservoir. The level should
be between the MIN (minimum) level indicated and the MAX
(maximum) level indicated on the clear plastic reservoir.
Metal or Nontransparent Plastic Reservoir Used on older
vehicles; requires the cover be removed to check the fluid
level. The level of fluid should be 1/4”(6 mm) from the top.
Continued
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Figure 17–6
A master brake cylinder with
transparent reservoir. The brake
fluid should be between the “MAX”
and “MIN” levels indicated on the
reservoir.

CAUTION: Do not overfill a brake master cylinder. The brake fluid gets
hotter as the brakes are used and there must be room in the master cylinder
reservoir for the brake fluid to expand.
Continued
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BRAKE FLUID TYPES
Brake fluid is made from a combination
of various types of glycol, which is a
non-petroleum-based fluid. It is a
polyalkylene-glycol ether mixture
called polyglycol.
All polyglycol brake fluid is
clear to amber in color.
All brake fluid must meet Federal Motor
Vehicle Safety Standard 116. The SAE
and DOT have established brake fluid
specification standards.
Figure 17–7 DOT 3 brake fluid. Always use brake fluid from a sealed container because the
fluid absorbs moisture from the air. Such contaminated brake fluid has a lower boiling point
and can cause rust to form in the brake system components.
Continued
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Dot 3 The brake fluid most often used is DOT 3. It can absorb
2% of its volume in water per year. Moisture is absorbed by the
brake fluid through microscopic seams in the brake system and
around seals.
Over time, water will corrode the system and thicken brake fluid.
The moisture also can cause a spongy brake pedal action due to
reduced vapor-lock temperature.
CAUTION: DOT 3 brake fluid is a very strong solvent and can remove
paint! Care is required when working with DOT 3 brake fluid to avoid
contact with the vehicle’s painted surfaces. It also takes the color out of

leather shoes.

Continued
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Dot 4 Formulated for use by all vehicles, imported or domestic is
type DOT 4 brake fluid. Commonly called LMA (low moisture
absorption) because it does not absorb water as fast as DOT 3.
The cost of DOT 4 is approximately double the cost of DOT 3.
Dot 5 Commonly called silicone brake fluid, DOT 5 is made
from polydimethylsiloxanes. It does not absorb water and is called

nonhygroscopic. DOT 5 fluid does not mix with DOT 3 or DOT 4
brake fluids. DOT 5 brake fluid is purple (violet) in color
NOTE: Even though DOT 5 does not normally absorb water, it is still

tested using standardized SAE procedures in a humidity chamber. After a
fixed amount of time, the brake fluid is measured for boiling point. Since it
has had a chance to absorb moisture, the boiling point after this sequence
is called the minimum wet boiling point.
Continued
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Dot 5.1 A non-silicone-based polyglycol fluid, DOT 5.1 is clear
to amber in color. This severe duty fluid has a boiling point of
over 500°F, equal to the boiling point of silicone-based DOT 5
fluid. Unlike DOT 5, DOT 5.1 can be mixed with DOT 3 or DOT
4 according to the brake fluid manufacturer’s recommendations.

Brake Fluid Boiling
Points

CAUTION: Some vehicle manufacturers such as Chrysler do not
recommend the use of or the mixing of other types of polyglycol brake
fluid and specify the use of DOT 3 brake fluid only. Always follow the
vehicle manufacturer’s recommendation.
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ENGINE OIL LEVEL AND CONDITION
The oil level should be checked with the vehicle is on level
ground and after the engine has been off for several minutes.
Remove the oil level indicator, called a dipstick, wipe the oil
off, and reinsert it all the way down.

Figure 17–8 A typical engine oil
level indicator (dipstick).

Continued
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Once again remove the dipstick and check where the oil level
touches the indicator. The “add” mark is usually at the one quart
low point. If oil needs added, use the proper oil and add to the
engine through the oil fill opening.

Figure 17–9 The oil level should read no higher than the “MAX” level and no lower than the
“MIN” level when the vehicle is parked on a level surface and the oil has had some time to sit
with the engine off. This time is necessary to allow the oil to flow from the upper region if the
engine down into the oil pan.
Continued
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ENGINE OIL CHANGES
Most experts recommend that engine oil be replaced and a new
filter installed every 3,000 miles (4,800 km) or three months.
Most vehicle manufacturers recommend that the oil be changed
according to a “normal” or “severe use” schedule.

See this chart on
Page 123 of your
textbook.

Continued
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VISCOSITY OF OIL (SAE RATING)
The word viscosity means resistance to flow. An oil with a high
viscosity has a higher resistance to flow and is thicker than a lowerviscosity oil.
Oil is tested and assigned a viscosity number according to standards
by the SAE. Tested at two different temperatures, it is assigned a
number based on flow characteristics. Thin oil is assigned a lower
number and thicker oil is a higher number.
Oil tested at 0°F (-18°C) has the letter W after its number. The W
represents winter. For example, a SAE 10W engine oil was tested
at 0°F and assigned a thickness rating of 10. Oil tested at 212°F
(100°C) has no letter after its number. SAE 30 oil is tested at 212°F.
Continued
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Multi-Viscosity Engine Oils Viscosity index (VI) improvers can
be added to engine oil to prevent it from becoming thin at higher
temperatures.
For example, SAE 5W oil with the VI improvers added can be rated
as a SAE 30 when tested at 212°F. Because of the wide range of
temperatures at which this oil can function, multi-viscosity oils such
as 5W-30 and 10W-30 are often the only oils recommended for use.
NOTE: Some vehicle manufacturers such as Ford and Honda recommend

the exclusive use of SAE 5W-20 or SAE 0W-20 engine oil. The owner’s
manual warns that this is the only viscosity that is acceptable to use under
all temperatures and operating conditions. Always follow the vehicle
manufacturer’s recommended engine oil and viscosity.
Continued
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QUALITY OF OIL (API RATING)
Although generally difficult to purchase low-quality oil, it is
possible to select the incorrect grade for the intended application.
The quality rating is established by test procedures set up by the
American Petroleum Institute (API), formerly the American
Society for Testing and Materials (ASTM), with the cooperation
of the SAE.
In gasoline engine oil ratings, the letter “S” means service, but it
can be remembered as standing for oil to be used in spark ignition
engines.
The rating system is open-ended, so newer, improved ratings can
be readily added as necessary.
Continued
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SA Straight mineral oil (no additives), not suitable for use in any
engine
SB Nondetergent oil with additives to control wear and oil
oxidation
SC Obsolete (1964)
SD Obsolete (1968)
SE Obsolete (1972)
SF Obsolete (1980)
SG Obsolete (1988)
SH Obsolete (1993)

SJ Obsolete (1997)
SL 2001 to 2004
Figure 17–10 API doughnut for a SAE 5W-30, SM
engine oil. When compared to a reference oil, the
SM 2004
“energy conserving” designation indicates a 1.1%
Continued

better fuel economy for SAE 10W-30 oils and 0.5%
better fuel economy for SAE 5W-30 oils.

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Diesel classifications begin
with the letter
“C”, which stands for
commercial, but can
also stand for oil to be
used in compression
ignition or diesel
engines.

See this chart on
Page 124 of your
textbook.

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