6) Perform Underchassis Preventive Maintenance

COMPETENCY-BASED
LEARNING MATERIALS
Sector: LAND TRANSPORT

Distinctive Area of Competence and Qualifications:
Automotive Servicing NC II
Unit of Competency:
Perform Underchassis Preventive Maintenance
Module Title:
PERFORMING UNDERCHASSIS PREVENTIVE MAINTENANCE
TECHNICAL EDUCATION AND SKILLS DEVELOPMENT AUTHORITY

East Service Road, South Superhighway, Taguig City, Metro Manila
NATIONAL CERTIFICATE LEVEL II
QUALIFICATION LEVEL
COMPETENCY-BASED LEARNING MATERIALS

No. Basic Competencies Module Title Code
1. Receive and Response to Receiving and Responding to 500311101
Workplace Communication Workplace Communication
2. Work with Others Working with Others 500311102
3. Demonstrate Work Values Demonstrating Work Values 500311103
4. Practice Housekeeping Practicing Housekeeping Procedures 500311104
Procedures
No. Common Competencies Module Title Code

1. Apply Appropriate Applying Appropriate ALT723201
Sealant/Adhesive Sealant/Adhesive
2. Move and Position Vehicle Moving and Positioning Vehicle ALT723202
3. Perform Housekeeping Performing Housekeeping ALT311201
4. Perform Mensuration and Performing Mensuration and ALT311202

Calculation Calculation
5. Perform Safety Practices Performing Safety Practices ALT311203
6. Read, Interpret and Apply Reading, Interpreting and Applying ALT723203

Specifications and Manuals Specifications and Manuals
7. Use and Apply Using and applying ALT723204
Lubricant/Coolant Lubricant/Coolant
8. Perform Shop Maintenance Performing Shop Maintenance ALT723205
No. Core Competencies Module Title Code

Perform Diesel Engine Tune Performing Diesel Engine Tune Up ALT723302
Up
Perform Gas Engine Tune Up Performing Gas Engine Tune Up ALT723303
Service Automotive Battery Servicing Automotive Battery ALT723304
Service Ignition System Servicing Ignition System ALT723305a
Test & Repair Wiring/Lighting Testing & Repairing Wiring/Lighting ALT723305b
Systems Systems
Perform Underchassis Performing Underchassis ALT723306
Preventive Maintenance Preventive Maintenance
HOW TO USE THIS COMPETENCY BASED LEARNING MODULE
Welcome to the Module: Performing Underchassis Preventive Maintenance. This module

contains training materials and activities for you to complete.
The unit of competency " Perform Underchassis Preventive Maintenance NC I" contains the
knowledge, skills and attitudes required for Automotive Servicing NC II . It is one of the Core
Modules at National Certificate Level II (NC II ).
You are required to go through a series of learning activities in order to complete each learning
outcome of the module. In each learning outcome there are Information Sheets, Resource Sheets
and Reference Materials for further reading to help you better understand the required activities.
Follow these activities on your own and answer the self-check at the end of each learning
outcome. Get the answer key from your instructor and check your work honestly. If you have
questions, please don’t hesitate to ask your facilitator for assistance.
Recognition of Prior Learning (RPL)

You may already have some or most of the knowledge and skills covered in this module because
you have:
 been working for someone
 already completed training in this area
If you can demonstrate to your trainer that you are competent in a particular skill or skills, talk
to him/her about having them formally recognized so you won’t have to do the same training
again. If you have qualifications or Certificates of Competency from previous trainings, show
them to your trainer. If the skills you acquired are still relevant to this module, they may become
part of the evidence you can present for RPL.
At the end of this learning material is a Learner’s Diary, use this diary to record important dates,
jobs undertaken and other workplace events that will assist you in providing further details to
your trainer or assessors. A Record of Achievement is also provided for your trainer to complete
once you completed the module.
This learning material was prepared to help you achieve the required competency, in
Performing Underchassis preventive Maintenance NC II. This will be source of information
for you to acquire the knowledge and skills in this particular trade independently and your own
pace with minimum supervision or help from your instructor.
In doing the activities to complete the requirements of this module, please be guided by the
following:
 Talk to your trainer and agree on how you will both organize the training under this module.
Read through the module carefully. It is divided into sections that cover all the skills and
knowledge you need to successfully complete.
 Work through all information and complete the activities in each section. Read the
information sheets and complete the self-checks provided in this module.
 Most probably your trainer will also be your supervisor or manager. He/She is there to
support you and show you the correct way to do things. Ask for help.
 Your trainer will tell you about the important things you need to consider when you are
completing the activities and it is important that you listen and take notes.
 You will be given plenty of opportunities to ask questions and practice on the job. Make sure
you practice your new skills during regular work shifts. This way you will improve both
your speed and memory and also your confidence.
 Talk to more experienced work mates and ask for their guidance.
 Use self-check questions at the end of each section to test your own progress.
 When you are ready, ask your trainer to watch you perform the activities outlined in this
module.
 As you work through the activities, ask for written feedback on your progress. Your trainer
keeps feedback/pre-assessment reports for this reason. When you have completed this
learning material and feel confident that you have had sufficient knowledge and skills, your
trainer will arrange an appointment with a registered assessor to assess you. The results of
the assessment will be recorded in your Competency Achievement Record.
TABLE OF CONTENTS
QUALIFICATION : Automotive Servicing NC II
UNIT OF COMPETENCY : Perform Underchassis Preventive Maintenance
MODULE TITLE : Performing Underchassis Preventive Maintenance
ELEMENTS PERFORMANCE CRITERIA PAGE

1. Check Clutch Clutch fluid level is checked and maintain between
fluid and minimum and maximum.
Lines Clutch lines are checked for twist and bends.
Clutch cover must be fitted in the cap
Clutch fluid is used
2. Inspect Brake Brake fluid level is checked and maintain between
System the minimum and maximum, and clear, undiluted
fluid is used.
Brake lines and hoses are checked and freed of twist
and bends
Brake pedal free play specified
Brakes operations are checked and tested Hydraulic
fluid used/change without spillage and at the level
specified.
Brake pedal/height/pre-play checked and adjusted
Bleed hydraulic brake
Bleed hydraulic brake
Emergency brake functions is checked
Points of adjustment of emergency brake is
identified
3. Inspect/chan Gear oil is inspected
ge/ The vehicle is positioned
transmission Transmission gear selected and used is clear and not
differential diluted with other substances.
gear oil Grade/classification and level of gear oil used must
be in accordance with manufacturers’ specification.
4. Inspect/repla Power steering linkages and connections inspected
ce power Vehicle is parked and engine running is ran at idle
steering fluid speed
Fluid is inspected/replaced
5. Check/Re-fill 5.1 ATF checked and replenished to required level
automatic
transmission
fluid
6. Inspect/Blee Air tank inspected and bleed
d Air tank
7. Check tire Tires are inspected for damage or deformities and
and tire free of solid object.
pressures Tire pressure is checked and maintained
Tire rotation is performed
8. Check under Bolts/nuts including tire studs bolts/nuts are
chassis body checked
bolts and Body bolts/nut torque is checked and maintained
nuts Checking procedure according to manufacturer’s
specifications.
Tightness of the bolts is determined by the sound
produced by tapping lightly bolts/nuts with pointed
hammer.
9. Performing Replace engine oil
every 10 k Replace oil filter
kilometre Replace drain plug washer
vehicle
Replace fuel filter
check- up
Perform wheel alignment
Clean all the breaks
Perform tire rotation
PERFORMANCE CRITERIA
All standard of performance for Perform Underchassis Preventive Maintenance is in

accordance with the company standard operating procedure and manufacturers’ specification
Manuals using the specific tools and equipment.
1. Check Clutch Fluid and Lines

1.1 Clutch fluid level is checked and maintained between minimum and maximum.
1.2 Clutch lines are checked for twist and bends.
1.3 Clutch cover must be fitted in the cap.
1.4 Clutch fluid is used.
2. Inspect Brake System

2.1 Brake fluid level is checked and maintained between the minimum and maximum,
and clear, undiluted fluid is used.
2.2 Brake lines or hoses are checked and freed of twist and bends.
2.3 Brake pedal free play specified.
2.4 Brakes operation is checked and tested.
2.5 Hydraulic fluid used/changed without spillage and at the level specified.
2.6 Brake pedal/height/pre-play checked and adjusted
2.7 Bleed hydraulic brake.
2.8 Emergency brake functions are checked.
2.9 Points of adjustment of emergency brake are identified.
3. Inspect/Change Transmission/Differential Gear Oil

3.1 Gear oil is inspected.
3.2 The vehicle is position.
3.3 Transmission Gear selected and used is clear and not diluted with other substances.
3.4 Grade/Classification and level of gear oil used must be in accordance with
manufacturer’s specification
4. Inspect/Replace Power Steering Fluid

4.1 Power steering linkages and connections inspected
4.2 Vehicle is parked and engine running is ran at idle speed
4.3 Fluid is inspected /replaced.
5. Check/Re-fill automatic Transmission Fluid
5.1 ATF checked and replenished to required level
6. Inspect/Bleed Air Tank

6.1 Air tank is inspected and bleed.
7. Check Tires and Tire Pressure

7.1 Tires is inspected for damage or deformities and free of solid object.
7.2 Tire pressure is checked and maintained.
7.3 Tire rotation is performed.
8. Check Underchassis Body Bolts and Nuts

8.1 Bolts/nuts including tire studs bolts/nuts are checked
8.2 Body bolts/nuts torque is checked and maintained.
8.3 Checking procedure according to manufacturer’s specifications.
8.4 Tightness of the bolts is determined by the sound produced by tapping lightly
bolts/nuts with pointed hammer.
9. Performing every 10 k kilometre vehicle check- up

9.1 Replace engine oil
9.2 Replace oil filter
9.3 Replace drain plug washer
9.4 Replace fuel filter
9.5 Perform wheel alignment
9.6 Clean all the breaks
9.7 Perform tire rotation
Program/Course : Automotive Servicing NC II
Unit of Competency : PERFORM UNDERCHASSIS PREVENTIVE MAINTENANCE
LEARNING OUTCOME 1 : CHECK CLUTCH FLUID AND LINES
PERFORMANCE CRITERIA:
1.1 Clutch fluid level is checked and maintained between minimum and maximum.
1.2 Clutch lines are checked for twist and bends.
1.3 Clutch cover must be fitted in the cap.
1.4 Clutch fluid is used.
RESOURCES:
Jack Erjavec and Robert scharff, Automotive Technology, A system Approach, 2nd Ed.
Crouse, W.H. and Anglin, D.L., Automotive Mechanics, 10th Ed.,
Santos, G.N. and Lebron G.B., Chemistry.
Don Kowels, Basic Automotive Service and Maintenance.
INFORMATION SHEET : 1
CLUTCH
The clutch is used on vehicles with manual transmission/transaxles. It is used to
mechanically connect the engine’s flywheel to the transmission/transaxle input shaft (Figure 3-
31). It does this trough the use of the special friction plate that is splined to the input shaft.
When the clutch is engaged, the friction plate contacts the flywheel, transferring power
through the plate to the input shaft.
CLUTCH MAINTENANCE
All clutches required checking and adjustment of linkage at regular intervals. Vehicles
with external clutch linkage require periodic lubrication.
CLUTCH LINKAGE ADJUSTMENT

Except for systems with self-adjusting mechanisms, the release bearing should not touch the
pressure plate release levers when the clutch is engage (pedal up). Clearance between these
parts prevents premature clutch plate, pressure plate, and release bearing wear. As the clutch
disc wears and becomes thinner, this clearances changes.
Clearance can be ensured by adjusting the clutch linkage so the pedal has a specified
amount of play or free play. Free travel is the distance a clutch pedal moves when depressed,
before the clutch fork begins to move the release bearing.
To check the pedal play, use a tape measure or ruler. Place the tape measure or ruler
beside the clutch pedal and the end against the floor of the vehicle and note the reading (Figure
28-16). Then, depress the clutch pedal just enough to take up the pedal play and note the
reading again. The difference between the two readings is the amount of pedal play.
Adjustment should be performed when the pedal play is not correct or when the clutch
does not engage or disengage properly. To adjust clutch pedal play, refer to the manufacturer’s
service manual for the correct procedure and adjustment point locations. Often pedal play can
be increased or decreased by turning a threaded fastener located either under the dash at the
clutch pedal or where the linkage attaches to the clutch fork.
Clean the linkage with a shop towel and solvent, if necessary, before checking it and
replacing any damaged or missing parts or cables. Check hydraulic linkage systems for leaks at
the clutch master cylinder, hydraulic hose, and slave cylinder. Then adjust the linkage to
provide the manufacturer’s specified clutch pedal play.
EXTERNAL CLUTCH LINKAGE LUBRICATION

External clutch linkage should be lubricated at regular intervals, such as during chassis
lubrication. Refer to the vehicle’s service manual to determine the proper lubricant. Many
clutches linkages use the same chassis grease that is used for suspension parts and U-joints.
Lubricate all the sliding surfaces and pivot points in the clutch linkage (Figure 28-17). The
linkage should be move freely after lubrication.
On vehicles with hydraulic clutch linkage, check the clutch master cylinder reservoir fluid
level. It should be approximately ¼ inch from the top of the reservoir. It must be refilled, used
approved brake fluid. Also, since the clutch master cylinder does not consume fluid, check the
leaks in the master cylinder, connecting flexible lines, and slave cylinder, if the fluid is low.
SELF CHECK : 1
Program/Course : Automotive Servicing NC I
ANSWER SHEET : 1
OPERATION SHEET : 1
LEARNING OUTCOME 2 : INSPECT BRAKE SYSTEM
2.1 Brake fluid level is checked and maintain between the minimum and maximum, and
clear, undiluted fluid is used.
2.2 Brake lines and hoses are checked and freed of twist and bends
2.3 Brake pedal free play specified
2.4 Brakes operations is checked and tested Hydraulic fluid used/change without spillage
and at the level specified.
2.5 Brake pedal/height/pre-play checked and adjusted
2.6 Bleed hydraulic brake
2.7 Bleed hydraulic brake
2.8 Emergency brake functions is checked
2.9 Points of adjustment of emergency brake is identified
RESOURCES:
LEARNING OUTCOME 2 : INSPECT BRAKE SYSTEM
BRAKE SYSTEM
BRAKE FLUID. Brake fluid is the lifeblood of any hydraulic brake system and is what
makes the system operate properly.
Modern brake fluid is specially blended to enable it to perform a variety of functions.
Brake fluid must be able to move freely at extremely high temperature (500ºF) and at
very low temperatures (-104 ºF). Brake fluid must also serve as a lubricant to the many
parts with which it comes into contact to ensure smooth and even operation. IN
addition, brake fluid must fight corrosion and rust in the brake lines and various
assemblies and components in services. Another important property of brake fluid is
that it must resist evaporation. All brake fluids are hydroscopic; that is, they readily
absorb water. This is why brake fluid should always be kept in the sealed container and
should not be exposed to outside air for limited period of time.
Brake Pedal.
The brake pedal is where the brakes’ hydraulic system gets its start. When the brake
pedal is depressed, force is applied to the master cylinder. On a basic hydraulic brake
system (where there is no power assist), the force applied is transmitted mechanically.
As the pedal in Figure 38-14 pivots, the force applied to it is multiplied mechanically.
The force that the pushrod applies to the master cylinder piston is, therefore, much
more greater than the force applied to the brake pedal. (Figure 38-12 and 13).
LEARNING OUTCOME 3 : INSPECT/CHANGE TRANSMISSION/DIFFERENTIAL GEAR
OIL
3.1 Gear oil is inspected.
3.2 The vehicle is position.
3.3 Transmission Gear selected and used is clear and not diluted with other substances.
3.4 Grade/Classification and level of gear oil used must be in accordance with
manufacturer’s specification
RESOURCES:
OIL
When properly operated and maintained, a manual transmission/transaxle lasts for the
life of the vehicle without the major breakdown. All units are designed so the external parts
operate in a bath of oil circulated by the motion of the gears and shafts. Some units also use a
pump to circulate oil to critical wear areas that require more lubrication than the natural
circulation provides.
Maintaining good internal lubrication is the key to long transmission/transaxle life. If
the amount of oil falls below minimum levels, or if the oil becomes too dirty, problems result.
LUBRICANT CHECK
The transmission/transaxle gear oil level should be checked at the intervals specified in the
service manual. Normally, these range from every 7,500 to 30,000 miles. For service
convenience, many units are now designed with a dipstick and filler tube accessible from
beneath the hood (Figure 30-1). Check the oil with the engine off and the vehicle resting on the
level grade. If the engine has been running, wait 2 to 3 minutes before checking the gear oil
level.
Some vehicles have no dipstick. Instead, the vehicle must be placed on a lift, and the oil
level checked through the fill plug opening of the side of the unit (Figure 30-2). Clean the area
around the plug before loosing and removing it. Insert a finger or bent rod into the hole to
check the level. The oil may not be hot. Lubricant should be level with, or not more than ½
inch below the fill hole. Add the proper grade lubricant as needed using a filler pump.
Manual transmission/transaxle lubricants in the use today include single and multiple
viscosity gear oils, engine oils, and automatic transmission fluid. Always refer to the service
manual to determine the correct lubricant and viscosity range for the vehicle and operating
conditions (Figure 30-3).
Lubricant Replacement
Transmission/transaxle lubricant should be changed at the manufacturer’s specified
intervals. Typical intervals are 24,000 or 30,000 miles of every 2 years. Vehicles used for
towing trailers, off-road operation, or continuous stop-and-go driving may require shorter
change intervals.
Drive the vehicle to warm the lubricant before placing the vehicle on the hoist. Clean
and remove the drain plug and allow the lubricant to drain into a clean catch pan. Inspect the
lubricant for metal particles, which may appear as a shiny, metallic color in the lubricant. Large
amounts of metal particles indicate severe bearing, synchronizer, gear, or housing wear.
Once all lubricant has drained, replace the washer or apply a recommended sealant to
the threads on the drain plug and replace it. Tighten the drain plug to the recommended
torque. Fill the transmission or transaxle with the proper lubricant.
SELF CHECK : 3
OIL
ANSWER SHEET : 3
OIL
LEARNING OUTCOME 4 : INSPECT/REPLACE POWER STEERING FLUID
4.1 Power steering linkages and connections inspected
4.2 Vehicle is parked and engine running is ran at idle speed
4.3 Fluid is inspected/replaced.
RESOURCES:
POWER STEERING
The power-steering unit is designed to reduce the amount of effort required to turn the
steering wheel. It also reduces driver fatigue on long drives and makes it easier to steer the
vehicle at slow road speeds, particularly during parking.
Power steering can be broken down into two design arrangements: conventional and
non-conventional or electronically controlled. In the conventional arrangement hydraulic
power used to assist the driver. In the non-conventional arrangement, an electric motor and
electronic controls provide power assistance in steering.
Conventional Power-Steering Systems

There are several power steering systems in use on passenger cars and light-duty tracks.
The most common ones are the external-piston linkage, integral piston, and power-assisted
rack and pinion system (Figure 37-26).
Power Steering Pump
The steering pump is used to develop hydraulic flow, which provides the force needed
to operate the steering gear. The pump is belt driven from the engine crankshaft, providing
flow anytime the engine is running. It is usually mounted near the front of the engine (Figure
37-28).
There are four general types of power-steering pumps: roller, vane, slipper, and gear
(Figure 37-29). Functionally, all pumps operate in the same basic manner. Hydraulic fluid for
the power-steering pump is stored in a reservoir. Fluid is routed to and from the pump by
hoses and lines. Excessive pressure is controlled by a relief valve.
SELF CHECK : 4
ANSWER SHEET : 4
LEARNING OUTCOME 5 : CHECK/REFILL AUTOMATICE TRANSMISSION FLUID
5.1 ATF checked and replenished to required level
RESOURCES:
AUTOMATIC TRNAMISSION FLUID

ATF can be petroleum based, partially synthetic, or totally synthetic-based oil. All
domestic automobile manufacturers require a petroleum-based fluid in their automatic
transmissions; however, some imported vehicles require the use of a partially synthetic fluid.
ATF is a compound liquid that also includes special additives, which allow the lubricant
to better meet the flow and friction requirements of an automatic transmission. ATF is
normally dyed red, primary to help distinguish it from the engine oil when determining the
source of fluid leaks.
Petroleum-based ATF typically has a clear red color and will darken when it is
burnt or become milky when contaminated by water. Synthetic ATF is normally a darker red
than petroleum-based fluid. Synthetic fluids tend to look and smell burnt after normal use;
therefore, the appearance and smell of these fluids is not a good indicator of the fluid’s
condition.
The various chemicals added to ATF ensure the durability and overall performance of
the fluid. Zinc, phosphorous, and sulphur are commonly added to reduce friction. Detergent
additives are added to ATF to help keep the transmission parts clean. Also added are
dispersant that keeps contaminants suspended in the fluid so they can be trapped by the filter.
FLUID SERVICE
The ATF level should be checked at regular mileage and time intervals. The dipstick is
located on the transmission housing at the end of the engine opposite the belts and pulleys.
Make sure the vehicle is level. On most automobiles, the ATF level can be checked
accurately only when the transmission is at operating temperature. For most vehicles, the
engine must be running and the shift lever placed in either park or neutral, as specified by the
vehicle manufacturer, with the parking brake applied. Markings on a dipstick indicate add
levels, plus full levels for fluid when cool, warm, or hot (Figure 33-3).
Some dipsticks have readings on both sides. Others have readings on only one side. On
some vehicles with automatic transaxles, the cold fluid level might be higher than the hot fluid
level. Refer to the manufacturers’ service manual and service bulletins for specific information.
To check the fluid level, start the engine and bring it to the operating temperature.
Remove the dipstick and wipe it clean with a lint-free cloth or paper towel. Reinsert the
dipstick fully. Remove it again and note the reading.
SELF CHECK
: 5
ANSWER SHEET : 5
LEARNING OUTCOME 6 : INSPECT/BLEED AIR TANK
6.1 Air tank inspected and bleed.
RESOURCES:
LEARNING OUTCOME 6 : INSPECT/BLEED AIR TANK
AIR INJECTION SYSTEMS

One of the earliest methods used to reduce the amount of hydrocarbons (HC) and
carbon monoxide (CO) in the exhaust was by forcing fresh air into the exhaust system after
combustion. This additional fresh air causes further oxidation and burning of the unburned
hydrocarbons and carbon monoxide. The process is much like blowing on a dwindling fire.
Oxygen in the air combines with the HC and CO to continue the burning that reduces the HC
and CO concentrations. This allows them to oxidize and produce harmless water vapour and
carbon dioxide.
The system can be equipped with or without an external air pump. Formal names of the
pump systems include Air Injection Reaction (AIR) by General Motors. Thermactor Emission
(TE) by Ford, Air Guard by American Motors, and Air Injection Systems by Chrysler. The
nonpump systems are often identified on the underhood label by the terms pulse, aspirator,
suction, or reed air injection.
Pump Type
A typical system with an air pump is shown in Figure 26-25. System components include the
following: Air pump, Air control Valve (or Air-Switching Valve, thermal Vacuum Switch, Air By-
Pass Valve (or Diverter Valve), One-Way check Valve, Hoses and Nozzles.
LEARNING OUTCOME 7 : CHECK TIRES AND TIRE PRESSURES
7.1 Tires are inspected for damage or deformities and free of solid object.
7.2 Tire pressure is checked and maintained.
7.3 Tire rotation is performed.
RESOURCES:
INFORMATION SHEET
LEARNING OUTCOME 7 : CHECK TIRES AND TIRE PRESSURES
TIRES
The primary purpose of tires is to provide traction. Tires also help the suspension absorb road
shocks, but this is a side benefit. They must perform under a variety of conditions. The road
might be wet or dry; paved with asphalt, concrete, or gravel; or there might be no road at all.
The car might be travelling slowly on a straight road, or moving quickly through curves or over
hills. All of these conditions call for special requirements that must be present, at least to some
degree, in all tires.
In addition to providing good traction, tires are also designed to carry the weight of the
vehicle, withstand side trust over varying speeds and conditions, and transfer braking and
driving torque to the road.
Types of construction
There are three types of tire construction in use today (Figure 35-5). They are bias ply, belted
bias ply, and radial ply tires.
Tire Ratings and Designations (Figure 35-7)

TIRE CARE
To maximize tire performance, inspect the signs of improper inflation and uneven wear, which
can indicate a need for balancing, rotation, or front suspension alignment. Tire should be
checked frequently for cuts, stone bruises, abrasions, blisters, and objects that might have
become imbedded in the thread. More frequent inspections are recommended when rapid or
extreme temperature changes occur, or where the road surfaces are rough or occasionally
littered with debris.
To clean tires, use a mild soap and water solution only. Rinse thoroughly with clear
water. Do not use any caustic solutions or abrasive materials. Never use steel wool or wire
brushes. Avoid gasoline, paint thinner, and similar materials having a mineral oil base. These
materials are harmful to the tires and eventually discolour the whitewalls and raised letters.
Inflation Pressure. (Figure 35-11 and Table 35-5)

LEARNING OUTCOME 8 : CHECK UNDERCHASSIS BODY BOLTS & NUTS
8.1 Bolts/nuts including tire studs bolts/nuts are checked
8.2 Body bolts/nuts torque is checked and maintained.
8.3 Checking procedure according to manufacturer’s specifications.
8.4 Tightness of the bolts is determined by the sound produced by tapping lightly
bolts/nuts with pointed hammer.
RESOURCES:
Introduction
Automotive components are held together with fasteners. As a technician, you will spend much
of your day removing and replacing fasteners. These small parts are very important. If fasteners
are not used properly, the components they hold together can fail.
Many different types of a fasteners are used on an automobile (Figure 5-1). Fasteners can
be divided into two basic groups. Threaded fasteners use the clamping force from the threads to
hold parts together. No threaded fasteners hold parts together without threads. Both types are
discussed in the following sections.
Threaded Fasteners
Threads provide a mechanical advantage to hold parts. The geometry behind threads was
developed a long time ago, around 200 B.C. They were used by the ancient Romans to press the
grapes for wine.
Threaded fasteners are the most common fastener type. They are spirals called threads to
wedge parts together. The common types o threaded fasteners are screw, bolts, studs, and nuts
and are shown in Figure 5-1.
Figure 5-1 Common types of threaded automotive fasteners.

Hardness and Strength
Bolts and hex head screws used for different parts of the automobile have different strength
requirements. A hex head cap screw used to hold on an engine flywheel must be much stronger
than one used to hold on a headlight. On the other hand, the fasteners made to hold on the
flywheel are much more expensive than the ones used on the headlight.
The strength or quality of fasteners is identified by grade marking on the fasteners. The
marking are different for U.S. (English) and metric fasteners. The U.S. (English) grade markings
for bolts and hex head cap screw are shown (Figure 5-17). The standards are set by the Society
of Automotive Engineers (SAE). The systems use marks on the head of the bolt or the next head
cap screw. Unfortunately, the system is confusing because the number of marks and the grade
number do not agree. A grade0,1, and 2 bolt has no markings on the head and is not very strong.
A bolt with 3 marks is called a grade 5 bolt and is much stronger than a grade 1. The strongest
bolt for automotive use has six marks and is called a grade 8. The chart in figure 5-17 also
describes the material each grade is made from the tensile strength. Tensile strength is the
amount of pressure the fasteners can take before it breaks.
Metric fasteners use property class numbers to indicate their strength. These numbers are
stamped on the head of the bolt or hex head cap screw. Typical metric bolt strength numbers are
shown (Figure 5-18). The higher the property class number, the stronger the fastener. A 10.9
fastener is much is much stronger than one marked 4.6. A metric fastener without a number
would be the same as a grade 0 U.S. (English) fastener. Metric studs have a marking system on
the end of the stud that shows their property class number, as shown in Figure 5-18.
Common Metric Head Sizes

Wrench Size Wrench Size
9 mm 19 mm
10 mm 20 mm
11 mm 21 mm
12 mm 22 mm
13 mm 23 mm
14 mm 24 mm
15 mm 26 mm
16 mm 27 mm
17 mm 29 mm
18 mm 30 mm
32 mm
Figure 5-16 Common metric head and wrench sizes.
Figure 5-17 Grade marking system for U.S. (English) bolts and hex head cap screw.
Figure 5-18 Grade marking system for metric bolts, hex, head cap screw, and studs.
Figure 5-19 Grade marking system used for U.S. (English) and metric nuts.
WARNING: Always replace the fasteners with the same strength (grade markings) as
the one they replace. Failure to do so may cause the par to fail.
Nuts are also graded according to the same grading system as shown (Figure 5-19). Nuts
must have the same grade as the bolts or studs with which they are used. English nuts have dots
that represent grade markings. Three dots represent a grade 5. Sit dots represent a grade8.
Metric nuts have numbers that represent strength. The number on the nut is its property class
number. In both systems the higher the number or the more dots, the stronger the nut.
Using a Pitch Gauge

WARNING: Always start threaded fasteners several turns into their mating threads by
hand. Never start a fastener with a wrench. If the fastener is the wrong thread size, the
threads can be damaged by the force of the wrench.
There are two different threads system in use, each with fine and coarse threads, which
can cause a great deal of confusion. Metric threads cannot be used with English threads. Fine
threads cannot be used with coarse threads. These different types of threads can make it difficult
for the technician to tell one thread from another.
A thread pitch gauge (Figure 5-20) is used to identify fasteners. Is has a number of
blades with teeth. The thread size is written on the blade. By matching the teeth on the blade
with threads on a fastener, you can determine thread size. Pitch gauges are made for both metric
and English threads.
Fastener Torque
Each threaded fastener on an automobile must be tightened just the correct amount. Untightened
fasteners can loosen and cause parts to fail. Fasteners that are tightened too tightly can damage
the part of the fastener and cause the parts to fail. Overtightening causes it to stretch like those
shown (Figure 5-21). These no longer have the strength they had before the overtightening.
Figure 5-20 A pitch gauge is used to match Figure 5-21 These fasteners have the threads
Threads for identification. (Courtesy off distorted and stretched from over tightening.
Central Tools)
To avoid these problems, fasteners must be tightened with a torque wrench. There are
torque specifications charts for each important fastener in the service manual for the car you are
working on. Always follow these specifications.
Figure 5-22 Repairing minor thread damage with a tap. (Courtesy of J.P. Industries, Inc.)
SELFCHECK : 8
Module title : Performing Underchassis Preventive Maintenance
Answer the following Questions:

1. What is used to measure clutch pedal play?
2. When the clutch pedal is released on hydraulic clutch linkage, the

a. master cylinder piston is released by spring tension
b. master cylinder piston is released by hydraulic pressure
c. slave cylinder is released by hydraulic pressure
d. slave cylinder piston does not move
3. Insufficient clutch pedal clearance results in _________.

a. gear clashing while shifting transmission
b. a noisy front transmission bearing
c. premature release bearing failure
d. premature pilot bearing failure
4. Technician A says an oil-soaked clutch disc can cause clutch chatter. Technician B says
clutch chatter can be caused by loose bell housing bolts. Who is correct?
a. Technician A c. Both A and B
b. Technician B d. Neither A nor B
5. When making clutch adjustment, it is necessary to ______________.

a. Measure the clutch pedal free play
b. Lubricate the clutch linkage
c. Check hydraulic fluid level
d. Place the transmission in reverse
6. Technician A uses an impact wrench to tighten all non-critical bolts. Technician B uses a
torque wrench to tighten all bolts that have a torque specification. Who is correct?
a. Technician A c. Both A and B
b. Technician B d. Neither A nor B
ANSWER SHEET : 8
Module title : Performing Underchassis Preventive Maintenance
1. Tape measure and ruler
2. C
3. A
4. A
5. A
6. B
LEARNING OUTCOME 9 : PERMORMING EVERY 10 K KILOMETRE VEHICLE CHECK- UP
1.1 Replace engine oil
1.2 Replace oil filter
1.3 Replace drain plug washer
1.4 Replace fuel filter
1.5 Perform wheel alignment
1.6 Clean all the breaks
1.7 Perform tire rotation
RESOURCES:
LEARNING OUTCOME 9 : PERMORMING EVERY 10 K KILOMETRE VEHICLE
INTRODUCTION:
Preventive maintenance (PM) involves performing certain services to a vehicle on a regularly

schedule basis, before there is any assign of trouble. Regular inspection and routine
maintenance can prevent major breakdown and expensive repairs. They also keep car and
trucks efficiently and safety.
Engine Oil
Perhaps the PM Service that is best known by the public is changing the engine’s oil and filter.
Since oil is the lifeblood of an engine, it is critical that the oil be changed on a regular basis.
Photo Sequence 1 shows the steps involved in changing the engine oil and the oil filter.
Whenever this procedure is done, make sure the new engine oil has the correct rating for the
vehicle.
Program/Course : Automotive Servicing NC
PROCEDURE OF CHANGE OIL, CHANGE OIL FILTER AND DRAIN PLUG WASHER
REPLACEMENT
P1-6 While the oil is

draining, use an oil filter
wrench to loosen and
P1-1 Always makes sure the vehicle is P1-2 The tools and other items needed to P1-3 Place the oil drain pan under
remove the oil filter
Positioned safely on a lift or supported change the engine’s oil and oil filter are the drain plug before beginning to
by jack stand before working under it. rags, a funnel, an oil filter wrench, safety drain the oil.
Before raising the vehicle, allow the glasses, and a wrench for the drain plug.
engine to run awhile. After it is warm,
turn off the engine.
P1-4 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
P1-5 Make sure the drain pan is
pan.
positioned so it can catch all of
the oil
P1-7 Make sure the oil filter seal came off P 1-8 Wipe the entire oil filter sealing P1- 9 Install the new oil filter and
with the filter. Then place filter into the area on the engine block. Then apply hand tighten it. Oil filter should be
drain pan so it can drain .After it has new filter seal. tightening according to the direction
completely drained, discard the filter given on the filter.
according to local regulation.
P1-11 The drain plug should tighten P1-12 With the oil filter and drain
P 1-10 Prior to installing the drain
according to the manufacture’s plug installed, lower the vehicles
plug wipes off the threads and
recommendations. Overtightening can and remove the oil filter cap.
sealing surface with clean rugs.
cause thread damage, while
undertightening can cause oil leak.
P1-13 Carefully pours the oil P1-14 After the recommended P1-15 Start the engine and allow it to
into the engine. The use of a amount of oil has been put in reach normal operating temperature.
funnel usually keeps oil from the engine, check the oil level. While the engine is running, check the
spilling on the engine. 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
P1-16 After the engine has been

turned off, recheck the oil filter
level and correct it as necessary.
PERFORM WHEEL ALIGNMENT
Swift and sure steering responses are needed at today’s driving speeds. To accomplish this, the
wheels must be in alignment. Wheel alignment allows the wheels to roll without scuffing, dragging, or
slipping on different types or road conditions. Proper alignment of both the front and the rear wheels
ensures greater safety in driving, easier steering, longer tire life, reduction in fuel consumption, and less
strain on the parts that make up the steering and suspension systems of the vehicle. There are a
multitude of angles and specification that the automotive manufacturers must consider when designing
a car. The multiple functions of the suspension system complicate things a great deal for design
engineers. They must take into account more than basic geometry. Durably, maintenance, tire wear,
available space, and production cost are all critical elements. Most elements contain a degree of
compromise in order to satisfy the minimum requirements of each.
TABLE 45 – 1 EFFECTS OF INCORRECT

WHEEL ALIGNMENT
Problem Effect
Incorrect camber setting Tire wear
Ball point / wheel bearing wear
Pull to side of most positive /
least negative camber
Too much positive caster Hard steering
Excessive road shock
Wheel shimmy
Too much negative caster Wander
Weave
Instability at high speeds
Unequal caster Pull to side most negative /
least positive caster
Incorrect SAI Instability
Poor return
Pull to side of lesser inclination
Hard steering
Incorrect toe setting Tire wear
Incorrect turning radius Tire wear
Squeal in turns
TABLE 45 – 2 ALIGNMENT ANGLE DIAGNOSTIC CHART
Suspension Included Probable Cause
Systems SAI Camber Angle
Short Arm / Correct Less Less Bent knuckle

Long Arm Less Greater Correct Bent lower control arm
Suspension Greater Less Correct Bent upper control arm
Less Greater Greater Bent knuckle
MacPherson Correct Less Less Bent knuckle and/or bent strut

Strut Correct Greater Greater Bent knuckle and/or bent strut
Suspension Less Greater Correct Bent control arm or strut tower (out at top)
Greater Less Correct Strut tower (in at top)
Greater Greater Greater Strut tower (in at top) and spindle and/or bent strut
Less Greater Greater Bent control arm or strut tower (out at top) plus
bent knuckle and/or bent strut
Less Less Less Strut tower (out at top) and knuckle and/or strut
bent or bent control arm
Twin I – Beam Correct Greater Greater Bent knuckle
Suspension Greater Less Correct Bent I beam
Less Greater Correct Bent I beam
Less Greater Greater Bent knuckle
NEW ALIGNMENT MACHINE

TYPICAL PROCEDURE FOR PERFORMING FOUR-WHEEL ALIGNMENT WITH A COMPUTER WHEEL
ALIGNER
Position the vehicle on the alignment rack Make sure the front tires are positioned
Properly on the turn tables.
Position the rear wheels on the slip plates. Attach the wheel units.
select the vehicle make and model year. Check the items on the screen during the
Preliminary inspection
Display the ride height screen. Check the Display the wheel runout compensation
tire condition for each tire on the tire screen.
Condition screen.
Display the turning angle screen and Display the front-and rear wheel alignment
perform turning angle check. angle screen.
Display the adjustment screen.

SELF CHECK : 9
LEARNING OUTCOME 9 : PERMORMING EVERY 10K KILOMETRE VEHICLE
ANSWER SHEET : 9
OPERATION SHEET : 9

6) Perform Underchassis Preventive Maintenance

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COMPETENCY-BASED

Sector: LAND TRANSPORT

TECHNICAL EDUCATION AND SKILLS DEVELOPMENT AUTHORITY

COMPETENCY-BASED LEARNING MATERIALS

No. Common Competencies Module Title Code

3. Perform Housekeeping Performing Housekeeping ALT311201

4. Perform Mensuration and Performing Mensuration and ALT311202

6. Read, Interpret and Apply Reading, Interpreting and Applying ALT723203

No. Core Competencies Module Title Code

Welcome to the Module: Performing Underchassis Preventive Maintenance. This module

Recognition of Prior Learning (RPL)

ELEMENTS PERFORMANCE CRITERIA PAGE

All standard of performance for Perform Underchassis Preventive Maintenance is in

1. Check Clutch Fluid and Lines

2. Inspect Brake System

3. Inspect/Change Transmission/Differential Gear Oil

4. Inspect/Replace Power Steering Fluid

6. Inspect/Bleed Air Tank

7. Check Tires and Tire Pressure

8. Check Underchassis Body Bolts and Nuts

9. Performing every 10 k kilometre vehicle check- up

CLUTCH LINKAGE ADJUSTMENT

EXTERNAL CLUTCH LINKAGE LUBRICATION

Conventional Power-Steering Systems

AUTOMATIC TRNAMISSION FLUID

AIR INJECTION SYSTEMS

Tire Ratings and Designations (Figure 35-7)

Inflation Pressure. (Figure 35-11 and Table 35-5)

Figure 5-1 Common types of threaded automotive fasteners.

Common Metric Head Sizes

Using a Pitch Gauge

Answer the following Questions:

2. When the clutch pedal is released on hydraulic clutch linkage, the

3. Insufficient clutch pedal clearance results in _________.

5. When making clutch adjustment, it is necessary to ______________.

1. Tape measure and ruler

Preventive maintenance (PM) involves performing certain services to a vehicle on a regularly

P1-6 While the oil is

P1-4 Loosen the drain plug with the

P1-16 After the engine has been

TABLE 45 – 1 EFFECTS OF INCORRECT

Short Arm / Correct Less Less Bent knuckle

MacPherson Correct Less Less Bent knuckle and/or bent strut

NEW ALIGNMENT MACHINE

Display the adjustment screen.

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