1. Chapter 7 Preventative Maintenance and Basic Services

2. Repair Orders (RO) Also called service orders or work orders.work orders Written for every vehicle. Contains customer information. Describes concerns and requests. Describes cost estimate. ROs are legal documents.

3. Shop Management Systems Most shops use computerized systems. Contains customer database. Can be used to track parts and labor operations.

4. Parts Replacement R&R means to remove and replace a part. Parts supplied by the original equipment manufacturer are called OEM or OE parts. Non OE parts are called aftermarket parts.aftermarket Parts that are rebuilt have a core charge. Some states require the old parts be made available to the customer.

5. Sublet Repairs Performed by another shop or person. Vehicle may be sent to a specialty shop. Example - a glass company is brought into a shop to replace a cracked windshield. Sublet repair costs are added to the estimate and RO.

6. Estimating Repair Costs For legal and customer relation issues, estimates must be calculated as accurately as possible. Some states allow up to a 10% difference in final cost while other states do not allow any difference. Document all needed service and repairs.Document

7. Vehicle Identification Exact vehicle information is necessary to accurately diagnose and repair. Vehicle identification numbers (VIN) placed in several locations on the vehicle.vehicle Newer vehicles use a bar code with the VIN.

8. VIN Characters First – Country of origin Second – Manufacturer Third – Vehicle type or manufacturing division Fourth through Eighth – Vehicle features Ninth – Check digit Tenth – Model year Eleventh – Manufacturing plant Twelfth through Seventeenth – Production sequence

9. VIN Characters (cont’d)

10. Preventive Maintenance Also called PM service. Providing certain services on a routine basis. Regular inspection and maintenance can prevent more serious breakdown. Typical PM schedule based on time and mileage.

11. Typical Preventative Maintenance Checks Engine oil Cooling system Drive belts Transmission fluid Battery Power steering fluid Brake fluid Windshield washer fluid Wiper blades Tires

12. Safety Inspection Required by some states. Sample inspection points.

13. Basic Services Services as part of a PM program are usually non-corrective. Inspection may lead to the discovery of necessary repairs.

14. Always Use…

15. …and

16. Engine Oil Refined from crude oil.crude oil Specially formulated. American Petroleum Institute (API) rated. Society of Automotive Engineers (SAE) rated. ILSAC rated. Synthetic oils.

17. Oil Formulations Can flow easily through the engine.engine Lubricates without foaming. Reduces friction and wear.friction Prevents rust and corrosion formation. Cools parts it flows over. Keeps internal engine parts clean.clean

18. American Petroleum Institute (API) Ratings S-class for passenger cars and spark ignition engines. C-class for HD, commercial, and compression ignition engines.

19. Society of Automotive Engineers (SAE) Ratings Establishes oil viscosity ratings. Viscosity is the measurement of the oils resistance to flow.Viscosity The viscosity rating is critically important with newer engines.viscosity rating Both the API and SAE logo will appear on certified oil products.

20. ILSAC and ACEA International Lubrication Standardization and Approval Committee (ILSAC) rating a combination of API and SAE ratings. ACEA rating formed by group of European and Asian manufactures. Approval ratings found on label.label

21. Synthetic Oils Derived from a chemical process. Produces products that are not naturally occurring. Synthetic oils improve fuel mileage and performance. performance Higher costs than traditional oils. Synthetic/traditional blends available.

22. Oil and Filter Change A critical regular maintenance procedure. Drain oil completely – inspect/replace drain plug washer.washer Replace filter – double check the gasket.filtergasket Refill engine with correct amount of specified oil. Start engine – check for leaks and oil pressure warning light or gauge. Stop engine and recheck oil level and for leaks.oil level

23. Cooling System Perform a visual inspection of hoses and for signs of leaks. Never open a cooling system when coolant is hot – severe burns and injuries may result. Check coolant level, type, and condition. Top coolant level off in radiator and reservoir.

25. Coolant Types Ethylene Glycol – most common green type. Propylene Glycol – similar to ethylene glycol but should not be mixed. Phosphate Free – Ethylene glycol without phosphates. Organic Acid Technology (OAT) – contains no phosphates or silicones.

26. Coolant Types (cont’d) Hybrid Organic Acid Technology (HOAT) – similar to OAT but with additives to be less abrasive to water pumps. Many manufacturers have very specific coolant requirements. Do not mix or interchange coolants – severe engine damage may result.

27. Coolant Condition Test coolant protection factor with a hydrometer or refractometer. Coolants which require mixing should be mixed with distilled water. Coolant pH level and protection can be checked with test strips.

29. Drive Belts V-belts and serpentine belts are used to drive accessories such as power steering.V-belts serpentine belts Inspect for wear, damage, and alignment.wearalignment Proper belt tension is critical for proper accessory operation and belt life.tension Tension can be applied via an automatic tensioner or manually by adjustment.automatic tensioneradjustment

30. Air Filter Removes dirt and other contaminates from the incoming air. Require periodic replacement.replacement Some vehicles use an airflow restriction indicator to determine replacement.airflow restriction indicator Shine a light through filter element – if no light passes through, replace the filter.

31. Battery Inspection Items

32. Automatic Transmission Fluid (ATF) Colored red to reduce confusion. Follow manufacturer’s procedures to obtain an accurate reading.reading Many manufacturers require special fluids. Do not mix or interchange ATF types. Incorrect fluid usage can cause severe damage.

33. Manual Transmission Fluid Many types of lubricants used. Always refer to the service information for proper checking procedures and fluid recommendations.

34. Power Steering Fluid Check fluid level. Determine proper fluid type if fluid needs to be added.

35. Brake Fluid Checked at the master cylinder reservoir.reservoir Clean caps if they have to be removed to check fluid level. Brake fluid is non-petroleum based – do not ever mix or replace brake fluid with a petroleum product. Use the recommended DOT grade fluid.recommended

36. Clutch Master Cylinder Vehicles with hydraulically operated clutch systems. Uses a clutch master cylinder and clutch slave cylinder. Clutch master cylinder operates like a brake master cylinder. Normally brake fluid is used in this system.

37. Windshield Wipers/Washers Visually inspect blades for tearing or damage – both front and rear systems. Turn wipers/washers on to check actual performance. Replace blades or inserts as needed.blades or inserts Never refill washer fluid reservoir with water or anti-freeze.

38. Tire Rotation Proper inflation and periodic rotation will extend tire tread life. Typical tire rotation pattern.

39. Lug Nut Torque Wheel fasteners must be properly torqued any time a wheel is removed.properly Torque wrenches or torque sticks can be used.torque sticks Failure to properly tighten wheel fasteners can cause wheel, hub, and brake rotor damage. Wheel and tire could fall off while driving.

40. Chassis Lubrication Less common due to lubed for life components. Chassis grease is injected into grease fittings also called zerk fittings. Typically found on ball joints, tie-rod ends, and u-joints.

42. Greases Produced from oil and thickening agents or can be synthetic. Categorized by a National Lubricating Grease Institute (NLGI) number. Refer to manufacturers service information for correct grease applications.

43. Hybrid Vehicle (HEV) Service Most services are performed in same way as conventional vehicle services. Exceptions are for the high-voltage (HV) system and components. Hybrid system and components not usually serviced by technicians. Locate, read, and understand all warnings and precautions before attempting service.warnings

44. Special HEV Considerations Engine off driving – some HEVs will drive on electric propulsion only so the typical engine noise is not present. Idle stop-start operation – all HEVs use idle stop-start to save fuel. The ICE will shut off and restart based on need. Ensure the “Ready” light is off before beginning service.Ready

45. The ICE are typically modified versions of other engines from the manufacturer. Often require specific fluids.fluids May maintain heated coolant circulation after vehicle is shut down. Battery cooling system may require filter service or replacement. Special HEV Considerations (cont’d)

55. Note: does not include 0W20 oils

59. Oil flow is from the outside in

60. Ensure old gasket is not stuck to mounting surface. Lubricate new gasket with clean engine oil.

73. Be sure to read and follow all guidelines when using torque sticks.

74. HEV Underhood Warning Decal