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Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition 2008
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
By James D. Halderman Pearson
PearsonPrentice
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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
2
Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition 2008
2009Pearson
PearsonEducation,
Education,Inc.
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By James D. Halderman Pearson
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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.

3
Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition 2008
2009Pearson
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By James D. Halderman Pearson
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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


Europens dAutomobiles (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
4
Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition 2008
2009Pearson
PearsonEducation,
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By James D. Halderman Pearson
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GETTING READY FOR SERVICE
Beforeserviceworkisdone,protectthevehicleinsidebyusing
commerciallyavailableplasticorpaperprotectivecoveringsfor
seats,floor,andsteeringwheel.

Thehoodmustbeopened,andoftenstrutsholdingahoodareweak
ordefective.Therefore,alwaysmakesurethehoodissecurelyheld.
Connectanexhaustsystemhosetothetailpipe(s)beforeworkis
startedthatwillinvolveoperatingtheengine.

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.
5
Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition 2008
2009Pearson
PearsonEducation,
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By James D. Halderman Pearson
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Figure 172 An exhaust hose should be connected to the
tailpipe(s) whenever the engine is being run indoors.

Figure 171 Before service


begins be sure to cover the
seats, floor, and steering wheel
with protective covering.

Continued
6
Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition 2008
2009Pearson
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By James D. Halderman Pearson
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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.

7
Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition 2008
2009Pearson
PearsonEducation,
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By James D. Halderman Pearson
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WIPER BLADE INSPECTION & REPLACEMENT
Windshieldwiperbladesareconstructedofrubberandtendto
becomebrittleduetoage.Wiperbladesshouldbecleaned
wheneverthevehicleiscleanedusingwaterandasoftcloth.

Figure 173 Installing a wiper


blade insert into a wiper arm.

Continued
8
Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition 2008
2009Pearson
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Wiperbladeorbladeinsertreplacementincludes:

Turntheignitionswitchtoon(run).
Turnthewiperswitchonandoperatethewipers.
Whenthewipersarelocatedinaneasytoreachlocation,turn
theignitionswitchoff.Thewipersshouldstop.
Removetheinsertortheentirearmaspertheinstructionson
thereplacementwindshieldwiperbladepackage.
Afterdoublecheckingthatthewiperissecurelyattached,turn
theignitionswitchon(run).
Turnthewiperswitchoffandallowthewiperstoreachthe
parkposition.Checkforproperoperation.

9
Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition 2008
2009Pearson
PearsonEducation,
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By James D. Halderman Pearson
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CABIN AND AIR FILTER REPLACEMENT
Acabinfilterisusedinheating,ventilation,andairconditioning
(HVAC)systemsintheoutsideairpassage.Somecouldinclude
activatedcharcoaltoeliminateodors.Thecabinairfiltershouldbe
changedabouteverytwoyearsorevery24,000miles(39,000km).
Thecabinfiltercanbeaccessedfrom:
Underthehoodatthecowl(bulkhead)
Underthedash,usuallybehindtheglove(instrumentpanel)
compartment

Figure 174 A cabin filter can be


accessed either through the glove
compartment or under the hood on
most vehicles.

Continued
10
Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition 2008
2009Pearson
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(a)
Anairfilterfiltersdirt
fromtheairbeforeitenters
theintakesystem.Itshould
bereplacedaccordingto
manufacturers
recommendations.
Figure 175 (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.

Manyrecommendreplacing
thefilterevery30,000miles
(50,000km)orevenmore
frequentlyunderdusty
conditions.Manytechs
advisedosoyearly.
(b)
11
Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition 2008
2009Pearson
PearsonEducation,
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By James D. Halderman Pearson
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BRAKE FLUID LEVEL INSPECTION
Brakefluidtransmitstheforceofthedriversfootonthebrake
pedaltoeachindividualwheelbrake.Itshouldbecheckedwhen
engineoilischanged(every3,000miles[4,800km]oreverythree
months,whicheveroccursfirst).Twotypesofmastercylinders:
TransparentReservoirAllowsviewingofbrakefluid(and
hydraulicclutchmastercylinderifsoequipped)without
havingtoremovethecoverofthereservoir.Thelevelshould
bebetweentheMIN(minimum)levelindicatedandtheMAX
(maximum)levelindicatedontheclearplasticreservoir.
MetalorNontransparentPlasticReservoirUsedonolder
vehicles;requiresthecoverberemovedtocheckthefluid
level.Theleveloffluidshouldbe1/4(6mm)fromthetop.

Continued
12
Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition 2008
2009Pearson
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Figure 176
A master brake cylinder with
transparent reservoir. The brake
fluid should be between the MAX
and MIN levels indicated on the
reservoir.

CAUTION: Donotoverfillabrakemastercylinder.Thebrakefluidgets
hotterasthebrakesareusedandtheremustberoominthemastercylinder
reservoirforthebrakefluidtoexpand.

Continued
13
Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition 2008
2009Pearson
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BRAKE FLUID TYPES
Brakefluidismadefromacombination
ofvarioustypesofglycol,whichisa
nonpetroleumbasedfluid.Itisa
polyalkyleneglycolethermixture
calledpolyglycol.
Allpolyglycolbrakefluidis
cleartoamberincolor.
AllbrakefluidmustmeetFederalMotor
VehicleSafetyStandard116.TheSAE
andDOThaveestablishedbrakefluid
specificationstandards.
Figure 177 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
14
Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition 2008
2009Pearson
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Dot3ThebrakefluidmostoftenusedisDOT3.Itcanabsorb
2%ofitsvolumeinwaterperyear.Moistureisabsorbedbythe
brakefluidthroughmicroscopicseamsinthebrakesystemand
aroundseals.

Overtime,waterwillcorrodethesystemandthickenbrakefluid.
Themoisturealsocancauseaspongybrakepedalactiondueto
reducedvaporlocktemperature.

CAUTION: DOT3brakefluidisaverystrongsolventandcanremove
paint!CareisrequiredwhenworkingwithDOT3brakefluidtoavoid
contactwiththevehiclespaintedsurfaces.Italsotakesthecoloroutof
leathershoes.

Continued
15
Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition 2008
2009Pearson
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Dot4Formulatedforusebyallvehicles,importedordomesticis
typeDOT4brakefluid.CommonlycalledLMA(lowmoisture
absorption)becauseitdoesnotabsorbwaterasfastasDOT3.
ThecostofDOT4isapproximatelydoublethecostofDOT3.

Dot5Commonlycalledsiliconebrakefluid,DOT5ismade
frompolydimethylsiloxanes.Itdoesnotabsorbwaterandiscalled
nonhygroscopic.DOT5fluiddoesnotmixwithDOT3orDOT4
brakefluids.DOT5brakefluidispurple(violet)incolor

NOTE: EventhoughDOT5doesnotnormallyabsorbwater,itisstill
testedusingstandardizedSAEproceduresinahumiditychamber.Aftera
fixedamountoftime,thebrakefluidismeasuredforboilingpoint.Sinceit
hashadachancetoabsorbmoisture,theboilingpointafterthissequence
iscalledtheminimumwetboilingpoint.

Continued
16
Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition 2008
2009Pearson
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Dot5.1Anonsiliconebasedpolyglycolfluid,DOT5.1isclear
toamberincolor.Thisseveredutyfluidhasaboilingpointof
over500F,equaltotheboilingpointofsiliconebasedDOT5
fluid.UnlikeDOT5,DOT5.1canbemixedwithDOT3orDOT
4accordingtothebrakefluidmanufacturersrecommendations.

Brake Fluid Boiling


Points

CAUTION: SomevehiclemanufacturerssuchasChryslerdonot
recommendtheuseoforthemixingofothertypesofpolyglycolbrake
fluidandspecifytheuseofDOT3brakefluidonly.Alwaysfollowthe
vehiclemanufacturersrecommendation.
17
Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition 2008
2009Pearson
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ENGINE OIL LEVEL AND CONDITION
Theoillevelshouldbecheckedwiththevehicleisonlevel
groundandaftertheenginehasbeenoffforseveralminutes.
Removetheoillevelindicator,calledadipstick,wipetheoil
off,andreinsertitallthewaydown.

Figure 178 A typical engine oil


level indicator (dipstick).

Continued
18
Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition 2008
2009Pearson
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Onceagainremovethedipstickandcheckwheretheoillevel
touchestheindicator.Theaddmarkisusuallyattheonequart
lowpoint.Ifoilneedsadded,usetheproperoilandaddtothe
enginethroughtheoilfillopening.

Figure 179 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
19
Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition 2008
2009Pearson
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ENGINE OIL CHANGES
Mostexpertsrecommendthatengineoilbereplacedandanew
filterinstalledevery3,000miles(4,800km)orthreemonths.
Mostvehiclemanufacturersrecommendthattheoilbechanged
accordingtoanormalorsevereuseschedule.

Seethischarton
Page123ofyour
textbook.

Continued
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Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition 2008
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VISCOSITY OF OIL (SAE RATING)
Thewordviscositymeansresistancetoflow.Anoilwithahigh
viscosityhasahigherresistancetoflowandisthickerthanalower
viscosityoil.

Oilistestedandassignedaviscositynumberaccordingtostandards
bytheSAE.Testedattwodifferenttemperatures,itisassigneda
numberbasedonflowcharacteristics.Thinoilisassignedalower
numberandthickeroilisahighernumber.

Oiltestedat0F(18C)hastheletterWafteritsnumber.TheW
representswinter.Forexample,aSAE10Wengineoilwastested
at0Fandassignedathicknessratingof10.Oiltestedat212F
(100C)hasnoletterafteritsnumber.SAE30oilistestedat212F.
Continued
21
Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition 2008
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MultiViscosityEngineOilsViscosityindex(VI)improverscan
beaddedtoengineoiltopreventitfrombecomingthinathigher
temperatures.

Forexample,SAE5WoilwiththeVIimproversaddedcanberated
asaSAE30whentestedat212F.Becauseofthewiderangeof
temperaturesatwhichthisoilcanfunction,multiviscosityoilssuch
as5W30and10W30areoftentheonlyoilsrecommendedforuse.

NOTE: SomevehiclemanufacturerssuchasFordandHondarecommend
theexclusiveuseofSAE5W20orSAE0W20engineoil.Theowners
manualwarnsthatthisistheonlyviscositythatisacceptabletouseunder
alltemperaturesandoperatingconditions.Alwaysfollowthevehicle
manufacturersrecommendedengineoilandviscosity.

Continued
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Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition 2008
2009Pearson
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QUALITY OF OIL (API RATING)
Althoughgenerallydifficulttopurchaselowqualityoil,itis
possibletoselecttheincorrectgradefortheintendedapplication.

Thequalityratingisestablishedbytestproceduressetupbythe
AmericanPetroleumInstitute(API),formerlytheAmerican
SocietyforTestingandMaterials(ASTM),withthecooperation
oftheSAE.

Ingasolineengineoilratings,theletterSmeansservice,butit
canberememberedasstandingforoiltobeusedinsparkignition
engines.

Theratingsystemisopenended,sonewer,improvedratingscan
bereadilyaddedasnecessary.
Continued
23
Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition 2008
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SAStraightmineraloil(noadditives),notsuitableforuseinany
engine
SBNondetergentoilwithadditivestocontrolwearandoil
oxidation
SCObsolete(1964)
SDObsolete(1968)
SEObsolete(1972)
SFObsolete(1980)
SGObsolete(1988)
SHObsolete(1993)
SJObsolete(1997)
SL2001to2004 Figure 1710 API doughnut for a SAE 5W-30, SM
SM2004 engine oil. When compared to a reference oil, the
energy conserving designation indicates a 1.1%
better fuel economy for SAE 10W-30 oils and 0.5%
better fuel economy for SAE 5W-30 oils.
Continued
24
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Dieselclassificationsbegin
withtheletter
C,whichstandsfor
commercial,butcan
alsostandforoiltobe
usedincompression
ignitionordiesel
engines.

Seethischarton
Page124ofyour
textbook.

25
Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition 2008
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ILSAC OIL RATING
TheInternationalLubricantStandardizationandApproval
Committee(ILSAC)developedanoilratingthatconsolidates
theSAEviscosityratingandtheAPIqualityrating.

Ifanengineoilmeetsthestandards,
astarburstsymbolisdisplayedon
thefrontoftheoilcontainer.

TheoriginalGF1(gasolinefueled)
ratingwasupdatedtoGF2in1997,
toGF3in2001,andGF4in2004.

Figure 1711 The International Lubricant Standardization and Approval Committee (ILSAC)
starburst symbol. This symbol is on the front of the container means the oil is acceptable for
use in almost any gasoline engine.
26
Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition 2008
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How Does an Oil Life Monitor Work?
While some manufacturers such as Mercedes, use a sensor to measure
oil temperature, most vehicle oil change monitors function two ways:

1. Vehicle mileage. The most commonly used vehicle service monitoring


system. When a certain number of miles has occurred since it was reset,
the control (usually the power train control modulePCM) will turn on a
dash light that states that maintenance is required.
2. Oil life computer program. A computer program is used to determine
the life of the engine oil. For example, when the oil change warning light
is reset, the oil life is reset to 100%. Then the power train control module
(PCM) tracks the number of engine starts, outside temperature, intake air
temperature (IAT) sensor input, as well as miles traveled. Because long
drives are easier on engine oil than short stop-and-go driving, the PCM
deducts numbers faster during this condition.

27
Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition 2008
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SYNTHETIC ENGINE OIL
AccordingtoSAEpublications,engineoilisclassifiedintogroups:
GroupIMineral,nonsynthetic,baseoilwithfewifany
additives.Suitableforlightlubricatingandrustprotection;
nottobeusedinanengine.
GroupIIMineraloilswithqualityadditivepackages.
MostoftheconventionalengineoilsareGroupII.
GroupIIIHydrogenated(hydroisomerized)synthetic
compoundscommonlyreferredtoashydrowaxesor
hydrocrackedoil.Thelowestcostsyntheticengineoils,such
asCastrolSyntec.

Continued
28
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GroupIVSyntheticoilsmadefrommineraloiland
monomolecularoilcalledpolyalphaolefinorPAO.Mobil1isan
exampleofaGroupIVsyntheticoil.
GroupVNonmineralsourcessuchasalcoholfromcorn
calleddiestersorpolyolesters.AnexampleisRedLinesynthetic.

Figure 1712
Mobil 1 synthetic engine oil is used by
several vehicle manufacturers in new
engines.

Continued
29
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GroupsIII,IV,andVareallconsideredtobesyntheticbecausethe
molecularstructureofthefinishedproductdoesnotoccurnaturally
andismanmadethroughchemicalprocesses.

AllsyntheticengineoilsperformbetterthanGroupII(mineral)oils
especiallywhentestedtotheNoackVolatilityTestASTMD5800.
Thisproceduremeasurestheabilityofanoiltostayingradeafter
beingheatedto300F(150C)foronehour.

Theoilismeasuredforpercentageofweightloss.Asthelighter
componentsboiloff,theviscositywillincrease.Ifyoustartwithan
SAE5Woil,itcouldtestasa15Woreven20Wtheendofthetest.

Itisimportantthattheoilyoubuystaysingradefortheproper
lubricationofyourengine.

30
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Anadvantageofusingsyntheticengineoilisabilitytoremainfluid
atverylowtemperatures.Thischaracteristicofmakesitpopularin
climateswherecoldenginecrankingisimportant.
Amajordisadvantageiscost.Syntheticengineoilscancostfouror
fivetimesasmuchasGroupIImineralengineoils.Somesynthetics
areblendedwithGroupIIoilsandmustbelabeledblends.

Use Synthetic Engine Oil in Lawn Equipment


Most 4-cycle lawn and garden equipment engines are air cooled and
operate hotter than many liquid cooled engines. Lawn mowers and other
small engines are often operated near or at maximum speed and power
output for hours at a time. These operating conditions are hard on any
engine oil. Try using a synthetic oil. The cost is not as big a factor because
most small 4-cycle lawn mower engines require only about 1/2 quart ( 1/2
liter) of oil. The synthetic oil is able to perform under high temperatures
better than conventional mineral oils..
31
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EUROPEAN OIL RATING SYSTEM
AssociationdesConstructeurs
EuropensdAutomobiles
(ACEA)ratesoil:

SeethesechartsonPage125
ofyourtextbook.
32
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Make Sure the Oil Meets Specific Vehicle
Specifications
Some oils can meet the industry specifications, such as SAE, API, and/or
ILSAC ratings, but not pass the tests specified by the manufacturer. The
standard should meet those of the manufacturer, which include:

BMWLonglife 98 and longlife-01 (abbreviated LL-01), LL-04


General MotorsGM 6094M, GM 4718M (synthetic oil specification)
General MotorsGM LL-A-25 (gasoline engines) & GM LL-B-25 for
GM vehicles equipped with diesel or European-built engines
FordWSS-M2C153-H, WSS-M2C929-A (low viscosity rating
SAE 5W-20), WSS-M2C930-A, WSS-M2C931-A, and WSS-M2C934-A
ChryslerMS-6395 (2005 vehicles, MS-10725
Mercedes229.3, 229.5, 229.1, 229.3, 229-31, 229.5, and 229.51
Volkswagen (VW & Audi)502.00, 505.00, 505.01, 503, 503.01, 505,
506 diesel, 506.1 diesel, and 507 diesel
HondaHTO-06

33
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ENGINE OIL DISPOSAL
Allusedengineoilshouldbedisposedorrecycledaccordingto
federal,state,orlocalrulesandregulations.Usedengineoilis
consideredhazardousduetodissolvedmetalsandacidscreated
inanoperatingengine.

Follow the Seasons


Vehicle owners often forget when they last changed the oil. This is
particularly true of the person who owns or is responsible for several
vehicles. A helpful method for remembering when the oil should be
changed is to change the oil at the start of each season of the year.
Spring (March 21) Fall (September 21)
Summer (June 21) Winter (December 21)
Remembering that the oil needs to be changed on these dates helps
owners budget for the expense and the time needed.
34
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OIL FILTERS
Oilispumpedfromtheoilpanthroughthefilterbeforeitgoes
intothelubricatingsystempassages.Thefilterismadefrom
eithercloselypackedclothfibersoraporouspaper.

Largeparticlesaretrappedbythefilter
whilemicroscopicparticleswillflow
throughthefilterpores.
Theseparticlesaresosmalltheycan
flowthroughthebearingoilfilmand
nottouchthesurfaces,andsodono
damage.
Figure 1714 A cutaway of a typical spin-on oil filter. Engine oil enters the filter through the small
holes around the center of the filter and flows through the pleated paper filtering media and out
through the large hole in the center of the filter. The center metal cylinder with holes is designed
to keep the paper filter from collapsing under the pressure.
Continued
35
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Manyoilfiltersareequippedwithanantidrainbackvalvethatpreventsoil
fromdrainingoutofthefilterwhentheengineisshutoff.Thisvalvekeepsoil
inthefilterandallowstheenginetoreceiveimmediatelubricationassoonas
theenginestarts.

Theengineorfilterhasabypassthat
willallowoiltogoaroundthefilter
element.Itallowstheenginetobe
lubricatedwithdirtyoil,ratherthan
havingnolubrication,ifthefilter
becomesplugged.

Theoilalsogoesthroughthebypass
whentheoiliscoldandthick.

Figure 1715 A rubber diaphragm acts as an antidrainback valve to keep the oil in the filter
when the engine is stopped and the oil pressure drops to zero.
Continued
36
Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition 2008
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Does the Oil Filter Remove all the Dirt?
Many persons believe oil filters will remove all dirt from the oil being
circulated through the filtering material. Most will filter particles that are
about 10 to 20 microns in size. A micron is a millionth of a meter, or
0.000039 inch. Most dirt and carbon particles that turn engine oil black are
less than a micron in size. In other words, it takes about 3,000,000 (three
million) of these carbon particles to cover a pinhead. To help visualize how
small a micron is: a typical human hair is 60 microns in diameter. In fact,
anything smaller than 40 microns is not visible to the human eye.
Dispersants are added to engine oil to prevent dirt from adhering together
to form sludge. It is the same dispersant additive that prevents dirt from
being filtered or removed by other means. If an oil filter could filter particles
down to one micron in size, the engine would not receive sufficient oil
through the filter for lubrication. Oil recycling companies use special
chemicals to break down dispersants, which permits dirt in the oil to
combine into larger units that can be filtered or processed out.

37
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Mostenginemanufacturersrecommendfilterchangesateveryother
oilchangeperiod.Correctoilfilterselectionincludesusingafilter
withaninternalbypasswhentheengineisnotequippedwithone.
Oilfiltersshouldbe
crushedand/ordrained
ofoilbeforediscarding.

Aftertheoilhasbeen
drained,thefiltercan
usuallybedisposedof
asregularmetalscrap,
byfollowingproper
disposalprocedures.
Figure 1716 A typical filter crusher. The hydraulic ram
forces out most of the oil from the filter. The oil is trapped
underneath the crusher and is recycled.

38
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The Pick Trick
Removing an oil filter that is installed upside down can be a real mess.
When this design filter is loosened, oil flows out from around the sealing
gasket. To prevent this from happening, use a pick and poke a hole in the
top of the filter. The hole allows air to get into the filter, allowing oil to drain
back into the engine rather than remain in the filter. After punching the
hole, wait several minutes to allow time oil to drain down into the engine.

(a)

(b)
Figure 1713 (a) A pick is pushed through the top of an oil filter that is positioned vertically.
(b) When the pick is removed, a small hole allows air to get into the top of the filter which then
allows the oil to drain out of the filter and back into the engine.
39
Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition 2008
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TYPES OF COOLANTS
Antifreezecoolantcontainsabout93%ethyleneglycol,pluswater
andadditives.Therearethreebasictypesofcoolantavailable,
groupedaccordingtoadditivesforrustandcorrosionprotection.

InorganicAdditiveTechnology(IAT)Conventionalcoolant
usedforover50years.Additivesusedtoprotectagainstrustand
corrosionincludephosphateandsilicates,whichhavebeenfound
tobethecauseoferosiveweartowaterpumpimpellers.

ThecolorofIATcoolantisusuallygreen.Phosphatesinthese
coolantscancausedepositstoformifusedwithhardwater.

Continued
40
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OrganicAcidTechnology(OAT)Usesorganicacidstohelp
protectmetalsinthecoolingsystemfromcorrosion.OATcoolant
isusuallyorange.DEXCOOLisanexampleofanOATcoolant.

Figure 1717
Since the mid-1990s, many vehicle
manufacturers have been using
antifreeze coolant that is silicate
and phosphate free. Check the
owners manual for the spec for
the recommended engine coolant.

Continued
41
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HybridOrganicAcidTechnology(HOAT)Coolantcontains
organicacidsforcorrosionprotectionplusalowamountof
silicates.HOATcoolantscanbegreen,orange,yellow,gold,pink,
red,orblue.Examples:
VW/Audipink
Mercedesyellow
Fordyellow
Hondablue(TYPE2)
Europeanblue
Asianredcontainsnosilicatesbuthassomephosphate

Continued
42
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What is Pet Friendly Antifreeze?
Conventional ethylene glycol antifreeze, regardless of the additives used,
is attractive to pets and animals because it is sweet. Ethylene glycol is fatal
to any animal if swallowed and therefore, any spill should be cleaned up
quickly. Another type of antifreeze coolant, called propylene glycol, is less
attractive to pets and animals because it is less sweet, but is still harmful if
swallowed. This type of coolant should not be mixed with ethylene glycol
coolant.

CAUTION: Somevehiclemanufacturersdonotrecommendtheuseof
propyleneglycolcoolant.Checktherecommendationintheowners
manualorserviceinformationbeforeusingitinavehicle.

Continued
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ANTIFREEZE/COOLANT DISPOSAL
Usedcoolantdrainedfrom Figure 1718 Used antifreeze coolant should be
kept separate and stored in a leak-proof container
vehiclescanusuallybe until it can be recycled or disposed of according
to federal, state, and local laws. Note that the
disposedofbycombiningit storage barrel is placed inside another container
withusedengineoil. to catch any coolant that may spill out of the
inside barrel.

Equipmentusedforrecycling
theusedengineoilcaneasily
separatethecoolantfromthe
wasteoil.

Checkwithrecycling
companiesfortheexact
methodrecommendedfor
disposalinyourarea.
44
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CAUTION: Thecoolantlevelshouldonlybecheckedwhentheengine
iscool.Removingthepressurecapfromahotenginewillreleasethe
coolingsystempressurewhenthecoolanttemperatureisaboveits
atmosphericboilingtemperature.Whenthecapisremoved,thepressure
willinstantlydroptoatmosphericpressurelevel,causingthecoolantto
boilimmediately.Vaporsfromtheboilingliquidwillblowcoolantfrom
thesystem.Coolantwillbelost,andapersonmaybeinjuredorburnedby
thehightemperaturecoolantthatisblownoutofthefilleropening.

Quick-and-Easy Cooling System Problem


Diagnosis
If overheating occurs in slow stop-and-go traffic, the usual cause is low
airflow through the radiator. Check for airflow blockages or cooling fan
malfunction. If overheating occurs at highway speeds, the cause is usually
a radiator or coolant circulation problem. Check for a restricted or clogged
radiator.
45
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RADIATOR AND HEATER HOSES
Upperandlowerradiatorhosesmustbepliable,yetnotsoft.The
lowerhosemusthaveaspringinsidetopreventthehosefrom
beingsuckedclosed,sincehoseisattachedtothesuctionsideof
thewaterpump.Thebypasshoseandheaterhoseshavea1/2,5/8,
or3/4insidediameterandconnecttheenginecoolingsystemtothe
heatercore.

Allautomotivehoseisconstructedofrubberwithreinforcing
fabricweavingforstrength.Allhosesshouldbeinspectedforleaks
(especiallynearclamps),cracks,swollenareasindicatingbroken
reinforcingmaterial,andbrittle,soft,andswollensections.

Usingahandoperatedpressurepumpattachedtotheradiator
openingisanexcellentwaytocheckforleaks.
Continued
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The Cut and Peel Trick
It is often difficult to remove a radiator or heater hose from the fittings on
the radiator or heater core. To avoid possible damage to expensive
radiator or heater cores, do not pull or twist the hose to remove it. Simply
use a utility knife and slit the hose lengthwise and then use your finger to
peel the hose off of the radiator or heater core. Although this procedure will
not work if the hose is to be reused, it is a real time saver when it comes to
replacing old hoses.

Figure 1719 This old upper hose had a split,


causing coolant to squirt out.

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AUTOMATIC TRANSMISSION FLUID CHECK
Theautomatictransmissionfluid(ATF)isanotherimportant
fluidthatshouldbecheckedregularly.Mostautomatic
transmissionfluidlevelsshouldbecheckedwiththevehicle
shouldbeparkedonalevelsurface,atnormaloperating
temperature,withtheenginerunning.Thetransmissionshouldbe
inneutralorpark,asspecifiedbythemanufacturer.

NOTE: HondaandAcuramanufacturersusuallyspecifythatthe
transmissionfluidbecheckedwiththeengineoff.Therecommended
procedureisusuallystampedonthetransmissiondipstickorwritteninthe
ownersmanualand/orservicemanual.

Continued
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TochecktheATF,starttheengine,movethegearselectortoall
gearpositionsandreturntoparkorneutral,asspecified.Remove
thetransmission/transaxledipstickandwipeitoffusingaclean
cloth.Reinsertthedipstickuntilfullyseated.Removeagainand
notethelevel.

Figure 1720
A typical automatic
transmission dipstick.

NOTE: Theaddmarkonmostautomatictransmission/transaxle
dipsticksmeanthat1/2quart(1/2liter)ofautomatictransmissionfluid
needstobeadded.
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Donotoverfillanyautomatictransmission/transaxleJust
1/2quarttoomuchaddedbymistakecouldcausethefluidto
foam.Foamingiscausedbythemovingpartsinsidethe
transmission/transaxle,whichstirupthefluidandintroduceair
intoit.Thisfoamyfluidcannotadequatelylubricateoroperate
thehydraulicclutchesthatmaketheunitfunctioncorrectly.
SmelltheATFonthedipstickIfburnedorrancid,further
serviceoftheautomatictransmission/transaxlewillbe
necessary.
LookatthecolorofthefluidItshouldberedorlightbrown.
Darkbrownorblackcolorindicatessevereoxidation,usually
causedbytoohighanoperatingtemperature.Furtherservice
anddiagnosisoftheautomatictransmission/transaxlewillbe
required.

Continued
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NOTE: Chryslerwarnsthatcolorandsmellshouldnotbeusedto
determinetheconditionofATF4usedinmostChryslerbuiltvehicles
sincethe2000modelyear.Thedyesandadditivescanchangeduring
normaluseanditisnotanindicationoffluidcontamination.Always
followthevehiclemanufacturersrecommendation.

The Paper Towel Test


New ATF will penetrate a paper towel better than used oxidized ATF. To
compare old fluid with new, place three drops of new fluid on a paper towel
and three drops of used ATF on the paper towel about 3 inches from the
first sample. Wait for 30 minutes. The new ATF will have expanded
(penetrated through the paper towel) much further than the old, oxidized
fluid. This test can be used to convince a customer that the ATF should be
changed according to the vehicle manufacturers recommended interval
even though, to the naked eye, the fluid looks okay.

Continued
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TYPES OF AUTOMATIC TRANSMISSION FLUID
Automatictransmissionfluidishighqualityoilthathasadditives
thatresistoxidation,inhibitrustformation,andallowthefluidto
floweasilyatalltemperatures.Itisdyedredforidentification.
VariousmanufacturersrecommendaparticulartypeofATFbased
mainlyonfrictioncharacteristics.Frictionisneededbetweenthe
bands,plates,andclutchesofanautomatictransmission/transaxle.
NonfrictionmodifiedDoesnotcontainanyfrictionreducing
additives.TypeFisanexampleofanonfrictionmodified
ATF.ItwasprimarilyusedinbandtypeFordautomatic
transmissionsuntil1977.
FrictionmodifiedThisfluidtypehasadditivesthatreduce
friction.DexronIIIandMerconVareexamplesof
frictionmodifiedATF.
Continued
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NOTE: MerconreplacedearlierFordATFspecsforCJ,H,andMV.

Highlyfrictionmodified
Hasadditionalfrictionreducing
additivesbeyondthosespecified
forafrictionmodifiedATF.

DexronVI,ChryslerMopar7176,
ATF2,ATF3,ATF4,Honda,and
ToyotaspecificATFareexamples
offluidsthatarehighlyfriction
modified.

Figure 1721 Honda ATF is highly friction modified and should be used in all Honda vehicles.
Substituting another type of ATF can cause harsh shifting or shudders during acceleration.
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POWER STEERING FLUID
Thecorrectpowersteeringfluidiscriticaltotheoperationand
servicelifeofthepowersteeringsystem!Theexactfluidtouse
variesbymanufacturer,sometimesbetweenmodelsmadebythe
samevehiclemanufacturer,becauseofdifferencesamongvarious
steeringcomponentmanufacturers.

NOTE: Remember,multiplepurposepowersteeringfluiddoesnotmean
allpurposepowersteeringfluid.Alwaysconsultthepowersteering
reservoircap,servicemanual,orownersmanualfortheexactfluidtobe
usedinthevehiclebeingserviced.

Continued
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Figure 1722 Many vehicles use a combination filler cap and level indicator (dipstick) that
shows the amount of power steering fluid in the reservoir. The power steering fluid should
also be checked for color that could indicate wear in the system or contamination.

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WINDSHIELD WASHER FLUID
Windshieldwasherfluidlevelshouldbecheckedregularlyand
refilledasnecessary.Useonlyfluidthatisrecommendedforuse
invehiclewashersystems.Mostwasherfluidlookslikeblue
water.Itisactuallywaterwithanalcoholadditivetoprevent
freezingandhelpcleanthewindshieldbydissolvingbugs,etc.

CAUTION: Somemixedfluidsareforsummeruseonlyanddonot
containantifreezeprotection.Readthelabelcarefully!Somefluidsmust
bemixedwithwaterbecausetheyareinconcentratedform.Followthe
directionsonthecontainerexactly.Ifnotenoughwaterisused,the
additivesinthewasherfluidcoulddamagethepaintontheroofandtrunk
lid.Windshieldwasherfluidmayalsobeflammablebecauseitoften
containsalcohol.Keepthefluidawayfromopenflamesorexcessiveheat.

Continued
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Figure 1723 (a) Windshield washer
fluid caps are usually labeled with
this symbol.

Figure 1723 (b) use the recommended


windshield washer fluid. Do not use water
in climates where freezing temperatures
are possible or damage to the reservoir,
pump, and lines could result when the
Water freezes and expands.

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ACCESSORY DRIVE BELT INSPECTION
Thereshouldbeamaximumof1/2playwhenabeltisdepressed
midwaybetweenpulleys.Airconditioning(A/C)andpower
steering(PS)beltsusuallymustbeeventighter.

AnA/Cbeltmusttransferapproximately12horsepowerwhenever
theA/Cisbeingused.Thiscouldnotbeaccomplishedwithabelt
whichdependedontightnessalone.MostVbelts(nameddueto
theirshape)are34degreesattheV.

Thepulleytheyridethroughisgenerally36degrees.This2
degreedifferenceresultsinawedgingactionandmakespower
transmissionpossible,butisalsothereasonwhyVbeltsmustbe
closelyinspected.

Continued
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Itisgenerallyrecommendedthatallbelts,includingtheserpentine
(orPolyV)beltsbereplacedeveryfouryears.Whenabeltthat
turnsthewaterpumpbreaks,theenginecouldoverheatcausing
seriousdamage.Ifonebeltbreaks,itoftencausesotherbeltsto
becometangled,causingthemtobreak.

Figure 1724
A special tool is useful when installing a new
accessory drive belt. The long-handled wrench
fits the hole in the belt tensioner.

NOTE: Often,beltnoisesoundsexactlylikeanoisybearing.Therefore,
beforeyoustartremovingandreplacingparts,trythehandcleanertrick.
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The Hand Cleaner Trick
Lower-than-normal alternator output could be a loose or slipping drive belt.
All belts (V and serpentine multigroove) use an interference angle between
the angle of the Vs of the belt and the angle of the Vs on the pulley. A belt
wears this interference angle off the edges of the V of the belt. As a result,
the belt may start to slip and make a squealing sound even if tensioned
properly.

A common trick used to determine if the noise is belt related is to use grit-
type hand cleaner or scouring powder. With the engine off, sprinkle some
powder onto the pulley side of the belt. Start the engine. The excess
powder will fly into the air, so get out from under the hood when the engine
starts. If the belts are now quieter, it was the glazed belt making the noise.

Often, grit from the hand cleaner will remove glaze from the belt and the
noise will not return. If the belt is worn or loose, the noise will return and
the belt should be replaced.

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Figure 1725 Typical worn serpentine
accessory drive belt. A defective or
worn belt can cause a variety of
noises, including squealing and
severe knocking similar to a main
bearing knock, if glazed or loose.

Figure 1726 Always check the


belt routing whenever replacing
or checking the operation or
noise in the accessory drive belts.

Continued
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BeltTensionMeasurementTherearefourwaysmanufacturersspecify
thatbelttensioniswithinfactoryspecifications:

BelttensiongaugeNeededtoachievespecifiedbelttension.
Installthebeltandoperateenginewithallaccessoriesturned
on,toruninthebeltforatleastfiveminutes.Adjusttension
oftheaccessorydrivebelttofactoryspecsoruseatableforan
exampleofpropertensionbasedonbeltsize.Replaceany
serpentinebeltwithmorethanthreecracksinanyoneribthat
appearsina3inchspan.

SeethetableonPage131
ofyourtextbook.

Continued
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MarksonatensionerManytensionershavemarksthat
indicatenormaloperatingtensionrangeforbelt.Check
serviceinformationforthelocationofthetensionermark.
TorquewrenchreadingSomemanufacturersspecifyabeam
typetorquewrenchbeusedtodeterminetorqueneededtorotate
thetensioner.Ifthetorquereadingisbelowspecs,thetensioner
mustbereplaced.
DeflectionDepressthebelt
betweenthetwopulleysthe
farthestapart.Theflexor
deflectionshouldbe1/2.
Figure 1727 A spring-loaded
accessory drive belt tensioner.

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CHECKING TIRE PRESSURE
Tirepressuresshouldbecheckedwhenthetiresarecold.Asa
vehicleisdriven,theflexingofthetireandfrictionbetweenthetire
andtheroadcausesanincreaseintemperature.

Asthetireheatsup,theairinsidethetireincreasesintemperature.
Theincreasedtemperatureincreasestheairpressureinsidethetire.
Theairpressuretypicallyincreasesinpressure4to6psi
afterthevehiclehasbeendrivenseveralmiles.

Ifairremovedfromthehottire,thetirewouldbeunderinflated.

Thetirepressurespecifiedisforatirethathasnotbeendrivenand
isthereforecold,sotheairpressureshouldbecheckedbeforethe
vehiclehasbeendrivenmorethan2miles(3km).
Continued
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Useagoodqualitytirepressuregaugeandpushitagainstthetire
valvestemafterremovingthecap.Comparethepressurereading
withspecifiedtirepressure,locatedonaplacardattachedtothe
driversdoorordoorpostorintheglovecompartment.

Figure 1728
Many manufacturers print
the recommended tire
pressure on a placard
attached to the drivers
door or door jamb.

NOTE: Tirepressurechangesaccordingtoairtemperatureabout1psiper
10F;therefore,duringachangeofseasonthetirepressurehastobe
adjusted.Forexample,whenthesummertemperatureof80Fchangesto
40Finthefall,thetirepressurewilldropabout4psi(8040=40).
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Therecommendationsoftenspecifyadifferentpressureforfront
andreartires.Thisisveryimportanttorememberwhenthetires
arebeingrotated.Tirepressureshouldbecheckedandadjustedif
necessaryafteratirerotationhasbeencompleted.

Therecommendationoftenincludesastatementabouttirepressures
touseifoperatingunderallhighwaydrivingconditionsoroperating
thevehicleinafullyloadedcondition.

Specificationsfortheseconditionscommonlyincludeincreasingthe
pressure(usuallyabout4to6psior27to41kPa).

CAUTION: Donotinflatetirestothemaximumratingonthetire
sidewall.Eventhoughthispressurerepresentsthemaximumtirepressure,
inflatingthetirestothispressureusuallyresultsinaveryhardrideand
oftenunacceptablehandling.
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TIRE ROTATION
Toassurelonglifeandeventirewear,rotateeachtiretoanother
location.Somerearwheeldrivevehiclesmayshowprematuretire
wearonfronttires.Usuallystartingontheoutertreadrow,itcan
appearasfronttoback(high&low)wearpatternontreadblocks.

Theseblocksoftreadrubberaredeformedduringcornering,
stopping,andturning,whichcancausetirenoiseand/ortire
roughness.Shoulderwearonfronttiresisnormal,andcanbe
reducedbyproperinflation,alignment,andtirerotation.

HINT: Tohelprememberwhentorotatetires,itshouldbedoneatevery
otheroilchange.Mostmanufacturersrecommendchangingtheengineoil
every3,000miles(4,800km)oreverythreemonthsandrecommendtire
rotationevery6,000(9,600km)milesoreverysixmonths.
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Figure 1729 The preferred method most often recommended is the modified X method. Using
this method, each tire eventually is used at each of the four wheel locations. An easy way to
remember the sequence, whether front wheel drive or rear wheel drive, is to say to yourself,
Drive wheels straight, cross the nondrive wheels.

NOTE: Radialtirescancauseradialpullduetotheirconstruction.Ifthe
wheelalignmentiscorrect,trytocorrectapullbyrotatingthetiresfrontto
rearor,ifnecessary,sidetoside.
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WHEEL MOUNTING TORQUE
Makecertainthewheelstudsarecleananddryandtorquedto
manufacturersspecs.Mostvehiclesspecifyatighteningtorqueof
between80and100lbft.Alwaystightenlugnutsgraduallytighterin
propersequence(tightenonenut,skipone,andtightenthenextnut),
tohelppreventwarpingbrakedrumsorrotors,orbendingawheel.

CAUTION: Mostmanufacturerswarnthatthewheelstudsshouldnotbe
oiledorlubricatedwithgreasebecausethiscancausethewheellugnutsto
loosenwhiledriving.

NOTE: Anytimeyouinstallabrandnewsetofaluminumwheels,retorque
thewheelsafterthefirst25miles.Thesoftaluminumoftencompresses
slightly,looseningthetorqueonthewheels.
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Figure 1730 (a) A torque absorbing
adapter (often called a torque stick)
being used to tighten lug nuts. The
adapter should not be held as it could
change the torque calibration or cause
personal injury if the adapter were to
break.

Figure 1730 (b) An assortment of torque


limiting adapters.

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Two Quick Checks
If the vehicle is hoisted on a frame-contact lift, spin each tire to check that
the brakes are not dragging. You should be able to turn all four wheels by
hand if the parking brake is off and the transmission is in neutral. Also,
when spinning the tire, look over the top of the tire to check if it is round.
An improperly mounted or out-of-round tire can be detected by watching
for the outside of the tire to move up and down as it is being rotated.

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Waiting for the Second Click Story
A student service technician was observed applying a lot of force to a
torque wrench attached to a wheel lug nut. When the instructor asked what
he was doing, the student replied that he was turning the lug nut tighter
until he heard a second click from the torque wrench.

This was confusing to the instructor until the student explained that he had
heard a second click of the torque wrench during the demonstration. The
instructor at once realized that the student had heard a click when the
proper torque was achieved, plus another click when the force on the
torque wrench was released.

No harm occurred to the vehicle because all the lug nuts were reinstalled
and properly torqued. The instructor learned that a more complete
explanation for the use of click-type torque wrenches was needed.

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TIRE INSPECTION
Alltiresshouldbecarefullyinspectedforfaultsinthetireitselfor
forsignsthatsomethingmaybewrongwiththesteeringor
suspensionsystemsofthevehicle.

Figure 1731 All tires should be checked


for wear by observing the wear bars.
These strips cause the tire to be bald
in this area when the tire tread depth
is less than 2/32.

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Figure 1732 This tire is worn on the outside. If both front tires are worn the same way,
then excessive toe-in is most likely the cause. If just one tire shows this type of wear, then
the camber is not correct and the vehicle should be inspected for a fault in the suspension
system.

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Figure 1733 This tire should be replaced. The unusual wear pattern indicates a possible
fault with the tire itself or a suspension fault that has caused the wheel/tire assembly to wear
unevenly.

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CHASSIS LUBRICATION
Chassislubricationreferstogreasingofpartsthatrubagainsteach
other,orinstallinggreaseintoapivot(orballjoints)througha
greasefitting.

GreasefittingsarealsocalledZerkfittings(namedforOscarU.
Zerk)orAlamitefittings(manufacturerofearlygreasefittings).
Thesefittingscontainaonewaycheckvalvetopreventthegrease
fromescaping.

Greasefittingsareusedonsteeringcomponents,suchastierod
ends,andinsuspensionballjoints,whichrequirelubricationto
preventwearandnoisecausedbytheactionofaballrotating
withinajointduringvehicleoperation.
Continued
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Figure 1734 A hand-operated grease gun being used to lubricate a grease fitting on a pitman arm.

CAUTION: Iftoomuchgreaseisforcedintoasealedgreaseboot,the
bootitselfmayrupturerequiringtheentirejointtobereplaced.
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CHASSIS GREASE
Vehiclemanufacturersspecifytypeandconsistencyofgreasefor
eachapplication.Thetechshouldknowwhatthesespecsmean.

Greaseisanoilwithathickeningagentaddedtoallowittobe
installedinplaceswherealiquidlubricantwouldnotstay.Greases
arenamedfortheirthickeningagent,suchasaluminum,barium,
calcium,lithium,orsodium.

TheAmericanSocietyforTestingMaterials(ASTM)specifies
theconsistencyofgreaseusingapenetrationtest.TheNational
LubricatingGreaseInstitute(NLGI)usesthepenetrationtestasa
guidetoassignthegreaseanumber.Lownumbersareveryfluid,
highernumbersmorefirmorhard.Mostvehiclemanufacturers
specifyNLGI#2forwheelbearingandchassislubrication.
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NLGIalsospecifiesgreasebyitsuse:
TheGCdesignationisacceptableforwheelbearings.
TheLBdesignationisacceptableforchassislubrication
ManygreasesarelabeledwithbothGCandLBandareacceptable
forbothwheelbearingsandchassisuse,suchasinlubricatingball
joints,tierodends,etc.

Figure 1735 Most vehicle manufacturers


recommend use of grease rated NLGI #2
and GC for wheel bearing, and LB for
chassis lubrication. Many greases have
both designations and are acceptable for
use as wheel bearing grease as well as
chassis grease for ball joints and tie-rod
ends.

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OTHER UNDER-THE-VEHICLE LUBRICATION
CHECKS
Otheritemsunderneaththevehiclethatmayneedcheckingor
lubricatinginclude:
Shockabsorbersandsprings

Figure 1736 This broken coil spring


was found during an under-vehicle
Inspection. The owner was unaware
of the problem and it did not make
any noise.

Continued
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Thetransmission/transaxleshiftlinkage
(checkmanualforcorrectlubricanttouse)
Exhaustsystemincludingallpipesandhangers
Parkingbrakecableguides

CAUTION: Donotlubricateplasticcoatedparkingbrakecables.The
lubricantcandestroytheplasticcoating.

Figure 1737 This corroded muffler was found


during a visual inspection and yet was not
detected by the driver because it was relatively
quiet.

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DIFFERENTIAL FLUID CHECK
Rearwheeldrivevehiclesuseadifferentialatthereartochange
thedirectionofpowerflowfromtheenginetotherearwheels.

Thedifferentialalsoprovidesgearreductiontoincreaseengine
torqueappliedtothedrivewheels.Fourwheeldrivevehiclesalso
useadifferentialatthefrontofthevehicleinadditiontothe
differentialintherear.Tocheckthedifferentialfluidleveland
condition,performthefollowing:
Tocheckthedifferentialfluidlevelandcondition,performthe
following:

Tocheckthedifferentialfluidlevelandcondition,safelyhoistthe
vehicle,andperformproceduresfollowing.

Continued
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Visuallycheckforanysignsofleakage.
Removetheinspectionplugfromthesideofthedifferential
assembly.
Insertyoursmallfingerintotheholeinthehousingandthen
removeyourfinger.
1. Ifthedifferentialfluidisonyourfinger,thenthelevelofthe
fluidisOK.Rubthefluidbetweenyourfingers.Ifthefluid
isnotgrittyfeeling,reinstalltheinspectionplug.Ifthefluid
isgrittyfeeling,furtherservicewillbenecessarytodetermine
andcorrectthecause.
2. Ifthedifferentialfluidisnotonyourfinger,thenthelevelof
thefluidistoolow.

Continued
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Figure 1738
A visual Inspection should
include checking differential
fluid, especially after noting
that a leak has occurred.

NOTE: Thereasonforthelowfluidlevelshouldbedetermined.Ifrepairs
arenotcompletedimmediately,additionaldifferentialfluidshouldbe
addedbypumpingitintothedifferentialthroughtheinspectionhole.

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DIFFERENTIAL LUBRICANTS
Alldifferentialsusehypoidgearsetsandaspeciallubricantis
necessarybecausethegearsbothrollandslidebetweentheir
meshedteeth.GearlubesarespecifiedbytheAmerican
PetroleumInstitute(API).Mostdifferentialsrequire:

SAE80W90GL5or
SAE75W90GL5or
SAE80WGL5

Limitedslipdifferentials(abbreviatedLSD)usuallyuseanadditive
thatmodifiesfrictioncharacteristicsoftherearaxlelubricantto
preventchatteringwhilecornering.

Continued
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MANUAL TRANSMISSION/TRANSAXLE
LUBRICANT CHECK
Manualtransmissions/transaxlesmayuseanyoneofthefollowing
lubricants:
Gearlube(usuallySAE80W90)
Automatictransmissionfluid(ATF)
Engineoil(usuallySAE5W30)
Manualtransmissionfluid(calledsynchromeshtransmission
fluid(STF)SimilartoATFwithspecialadditivestoease
shiftingespeciallywhencold)

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Tocheckmanualtransmissions/transaxleslubricant,performthe
following:

Hoistthevehiclesafely.
Locatethetransmission/transaxleinspection(fill)plug.Consult
thefactoryservicemanualfortheproperplugtoremoveto
checkthefluidlevel.
Ifthefluiddripsoutofthehole,thentheleveliscorrect.Ifthe
fluidrunsoutofthehole,thelevelistoofull.Allowittoflow
out)untilitstops.Thecorrectleveloffluidisatthebottomof
theinspectionhole.
Iflow,firstdeterminethecorrectfluidtouseandthenfilluntil
thefluidlevelisatthebottomoftheinspectionholeoruntilthe
fluidrunsoutoftheinspectionhole.

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Use a Hydrocarbon Detector
One of the many items that should be inspected while underneath the
vehicle is the condition of all the fuel lines. Many gasoline (fuel) leaks do
not show as wet areas. A hydrocarbon detector available from automotive
test equipment suppliers is an excellent tool to use to locate small gasoline
leaks that may not be visible.

Figure 1739 An electronic hand-held


hydrocarbon tester is an excellent tool
to use to check for possible gasoline
leaks from lines or components.

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PHOTO SEQUENCE Oil Change

Continued
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PHOTO SEQUENCE Oil Change (cont.)

Continued
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PHOTO SEQUENCE Oil Change (cont.)

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SUMMARY
1. Priortoservicingavehicle,protectivecoveringsshouldbe
usedonthesteeringwheel,seats,andfloor.

2. Brakefluidshouldbecheckedregularlyandnotfilledabove
1/4fromthetopofthereservoirorabovethemaximum
lineimprintedonthesideofthemastercylinder.

3. MostvehiclemanufacturersspecifyDOT3brakefluid.

4. MostvehiclemanufacturersspecifySAE5W30or10W30
engineoilwithanAPIratingofSMandanILSACratingof
GF4.

Continued
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SUMMARY (cont.)
5. Theengineoilshouldbechangedmorefrequentlyifthe
vehicleisdrivenundersevereconditionssuchasstopandgo
citytypedriving.

6. Whenreplacinganyradiatororheaterhose,theendofthe
hoseshouldbecuttopreventpossibledamagetotheradiator
orheatercore.

7. Alwaysusethespecifiedautomatictransmissionfluidwhen
toppingofforwhenchangingthefluid.Usingthewrongtype
ofATFcancausethetransmissiontoshifttooharshlyor
causeavibrationwhenthetransmissionshifts.

Continued
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SUMMARY (cont.)
8. Thetirepressureshouldbecheckedwhenthetiresarecold,and
thetiresshouldbeinflatedtothepressurespecifiedonthedoor
placardorintheownersmanual.

9. Tiresshouldberotatedevery5,000to7,000miles(8,000to
11,000km)orateveryotheroilchange.

10. Wheelsshouldalwaysbetightenedwithatorquewrenchtothe
propertorqueandinastarpattern.

11. Allgreasefittingsshouldbecleanedbeforeusingagreasegunto
lubricateanygreaseablejointsunderthevehicle.

Continued
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SUMMARY (cont.)
12. MostdifferentialsrequireaSAE80W90GL5rated
lubricant.

13. Manualtransmissions/transaxlesmayrequireoneofseveral
differentlubricantsincludinggearlubesuchasSAE80W90,
ATF,engineoil(SAE5W30),orspecialmanual
transmissionfluid.

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end

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