Chapter 8

Preventative Maintenance
and Basic Services

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

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Repair Order Video

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

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 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
• Parts that are rebuilt have a core charge
• Some states require the old parts be made
available to the customer

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 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

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 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

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

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Locating The VIN Video

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 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

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VIN Characters
(Cont.)

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 Preventive Maintenance
• Also called PM service
• Providing certain services on a routine basis
• Regular inspection and maintenance can
prevent more serious breakdown

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 Preventive Maintenance (Cont.)
• Typical PM schedule
based on time and
mileage
• Oil life index and
service codes are
common

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

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 Safety Inspection
• Required by some states
• Sample inspection points

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

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Always Use

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Always Use

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 Engine Oil
• Specially formulated
lubricant
• American Petroleum
Institute (API) rated
• Society of Automotive
Engineers (SAE) rated
• SAE rating is the weight
– Example - 5W30

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 American Petroleum Institute (API)
Ratings
• S-class for
passenger cars
and spark
ignition engines
• C-class for HD,
commercial, and
compression
ignition engines
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Society of Automotive Engineers (SAE)
Ratings
• Establishes oil viscosity ratings
• Viscosity is the measurement of the oils
resistance to flow
• The viscosity rating is critically important with
newer engines
• Both the API and SAE logo will appear on
certified oil products

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 Engine Oil (Cont.)
• ILSAC ratings developed
by domestic and
Japanese manufactures
• Vehicle manufacturer
ratings
• ACEA ratings for
European vehicles

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 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
manufactures
• Approval ratings found on label

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

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Oil Functions Video

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

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Synthetic Oil (Cont.)

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 Oil and Filter Change
• A critical regular
maintenance procedure
• Check and record oil level
and condition before
change
• Drain oil completely –
inspect/replace drain
plug washer

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 Oil and Filter Change (Cont.)
• Replace filter – double
check the gasket
• Wipe off filter
mounting base on
engine
• Pre-fill filter if possible

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Cartridge Filters
• Replace and lubricate
the O-rings on filter and
housing
• Torque housing to
specifications

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 Oil and Filter Change (Cont.)
• 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

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Replacing an Oil Filter Video

Click on image above to play video

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 Knowledge Check
• Describe the functions of engine oil.
• Why is it important to use the correct oil for
the vehicle?

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 Cooling System
• 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

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 Visual Leak Inspection
• Perform a visual
inspection of hoses and
for signs of leaks
• Small leaks may show
traces of coolant or
corrosion

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 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

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 Coolant Types (Cont.)
• 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

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Coolant Warning

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 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

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Coolant Testing

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 Knowledge Check
• Technician A says universal coolants can be
used in all makes and models. Technician B
says some engines have specific coolant
requirements. Who is correct?

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 Drive Belts
• V-belts and
serpentine belts
are used to drive
accessories such
as power steering

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 Drive Belt Inspection
• Inspect for wear, damage, and alignment

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 Drive Belts (Cont.)
• Proper belt tension is critical for proper
accessory operation and belt life
• Tension can be applied via an automatic
tensioner or manually by adjustment
• Some vehicles stretch fit belts
• Stretch fit belts cannot be removed and
reinstalled

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Common Belt Arrangements

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 Air Filter
• Removes dirt and other contaminates from
the incoming air
• Require periodic replacement
• Some vehicles use an airflow restriction
indicator to determine replacement

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Battery Inspection Items

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

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

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

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 Brake Fluid
• Checked at the master cylinder 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

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Common Brake Fluids

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 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

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 Diesel Exhaust Fluid (DEF)
• Mixture of pure
water and urea
• Stored in on-board
tank
• Requires refilling
every 5000 – 7000
miles

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 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
• Never refill washer fluid reservoir with water
or anti-freeze

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 Tire Rotation

• Proper inflation
and periodic
rotation will
extend tire tread
life
• Typical tire
rotation pattern

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 Lug Nut Torque

• Wheel fasteners must be properly torqued any

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

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Lug Nut Torque Patterns

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 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

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 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

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 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

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HEV Warning Decal

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 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

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© 2015 Cengage Learning. All Rights Reserved. May not be scanned, copied,
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Special HEV Considerations (Cont.)
• The ICE are typically modified versions of
other engines from the manufacturer
• Often require specific fluids
• May maintain heated coolant circulation after
vehicle is shut down
• Battery cooling system may require filter
service or replacement

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Two Different Coolants and Cooling
Systems on a Hybrid

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 Knowledge Check
• Explain how hybrid vehicles may have
different service requirements compared to
non-hybrid vehicles.

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