Part 1. Preparation and safety
Objective
- Carry out a preliminary visual inspection.
Personal safety
Whenever you perform a task in the workshop you must use personal protective clothing and equipment that is appropriate for the task and which conforms to your local safety regulations and policies. Among other items, this may include:
- Work clothing - such as coveralls and steel-capped footwear
- Eye protection - such as safety glasses and face masks
- Ear protection - such as earmuffs and earplugs
- Hand protection – such as rubber gloves and barrier cream
- Respiratory equipment – such as face masks and valved respirators
If you are not certain what is appropriate or required, ask your supervisor.
Safety check
- Make sure that you understand and observe all legislative and personal safety procedures when carrying out the following tasks. If you are unsure of what these are, ask your supervisor.
Points to note
- Be sure to work in a systematic manner, or you could miss a faulty bulb or other component.
Part 2: Step-by-step instruction
- Prepare the vehicle
Once a month or prior to any long trip, a vehicle should be checked for overall roadworthiness. The following simple measures will ensure that the vehicle is able to undertake the trip, and provide a warning of potential problems that may need further attention.
- Walk around the vehicle
Begin your inspection by walking around the vehicle, and observing any obvious items that need attention.
- Check exterior component and system operation
Check the body condition to make sure that all the body components are secure. Open and close doors to check that they are operating correctly. Push and pull on the bumpers or fenders and ensure they are secure. Inspect the external mirrors to ensure that they are secure and not broken.
Part 1. Preparation and safety
Objective
- Inspect all under body components.
Personal safety
Whenever you perform a task in the workshop you must use personal protective clothing and equipment that is appropriate for the task and which conforms to your local safety regulations and policies. Among other items, this may include:
- Work clothing - such as coveralls and steel-capped footwear
- Eye protection - such as safety glasses and face masks
- Ear protection - such as earmuffs and earplugs
- Hand protection – such as rubber gloves and barrier cream
- Respiratory equipment – such as face masks and valved respirators
If you are not certain what is appropriate or required, ask your supervisor.
Safety check
- Make sure that you understand and observe all legislative and personal safety procedures when carrying out the following tasks. If you are unsure of what these are, ask your supervisor.
Points to note
- This is a systematic visual inspection of all major vehicle systems. Be prepared to note down any faults to discuss later with your supervisor.
- The steering area inspection includes tie-rods, tire and wheel assembly, suspension bushes, shock absorbers and brake hoses.
- In the transmission area, you'll be looking for fluid leaks, tightening mounting bolts, and inspecting the clutch mechanism or shift linkage.
- Clamps and bolts may need tightening on the exhaust system and manifold pipe. You'll also be looking for signs of exhaust leaks, corrosion or deterioration.
- You'll be checking for any excess movement in driveline shafts.
- Look for leaks around the differential and check the rear shock absorbers or leaf springs.
- The fuel tank must be secure and fuel lines inspected for damage or abrasion.
Part 2: Step-by-step instruction
- Begin under vehicle visual inspection
Safely raise the vehicle to a comfortable working height. Be ready to record any faults you find, and begin your inspection at either end of the vehicle. Whichever end you choose, work systematically in one direction. Note any problems you find and discuss them with your supervisor. Pay particular attention to any fluid leaks, which will probably be the easiest problems to spot.
- Check steering area
Locate the tie-rods and move them through their operating arc. The action should be smooth without binding. The tire and wheel assembly should also move in a forward and backward direction to detect lateral movement in the tie-rod end. Look carefully for missing or torn rubber boots around tie rod ends or the steering shaft. At the same time, check the security of the steering box mountings. Inspect any rubber suspension bush for swelling or damage, and check shock absorbers for signs of damage or leaks. Inspect any wiring harness that is accessible for any obvious damage. Check the brake hoses, looking for signs of cracking or abrasions
- Check transmission area
Check the transmission mounting bolts for tightness. Trace and record the source of fluid leaks if you find any. With a manual transmission, check the clutch operating mechanism for looseness or binding. For an automatic transmission, check the shift linkage for smoothness of operation. If the transmission is electronically controlled, check any wiring for obvious damage.
- Check exhaust system
Check the tightness of the flange bolts on the engine manifold pipe. It’s also important to make sure all the clamps on the exhaust system are tight. If there is an exhaust leak, it’s usually identified by a blackish soot deposit at the source of the leak. Examine the catalytic converter, muffler and resonator for any signs of corrosion or deterioration. Check the tail pipe for any corrosion, and looseness in the mounting brackets or hangers.
- Check hand brake cables
Inspect the hand brake cable to make sure it’s not frayed, damaged or binding.
- Check driveline shafts
On any rear wheel drive vehicles, including pick-ups and SUV’s, inspect the drive shaft universal joints for signs of excess movement or rust. Rusty powder marks near the front, and rear universal joints could indicate a rusted and/or seized universal joint. To check for wear, rotate the shaft and flange in opposite directions. There should be no movement in the joint. On four-wheel drive vehicles, repeat this procedure on the front drive shaft universals
- Check differential and rear suspension area
On rear- wheel drive vehicles the rear axle housing supports the differential unit. On front-wheel drives, the differential is usually located in the transaxle housing. Inspect the pinion shaft oil seal for any obvious signs of leakage. Next, check the rear shock absorbers for any signs of physical damage or fluid leaks. Tighten all the suspension mounting bolts, noting any bolt that ‘s loose. Inspect the suspension mounting bushes for any signs of deterioration or damage. This will include any control arms or struts. If the vehicle is fitted with leaf springs, inspect the leafs for any cracks or misalignment. On a front wheel drive vehicle, inspect the rear strut assembly for any physical damage or signs of fluid leaks. Inspect the brake hoses for any obvious signs of cracking or abrasion.
- Check fuel tank area
Tighten the fuel tank mounting bolts or retaining clamp bolts, noting any bolt that’s loose. Carefully check all the fuel lines for any signs of damage or abrasions that may cause a leak.
- Discuss problems with your supervisor
After completing the inspection, discuss your list of problems with your supervisor to see what action can be taken to fix the problems
Measuring a wheelbase
Part 1. Preparation and safety
Objective
- Identify and measure the wheelbase.
Personal safety
Whenever you perform a task in the workshop you must use personal protective clothing and equipment that is appropriate for the task and which conforms to your local safety regulations and policies. Among other items, this may include:
- Work clothing - such as coveralls and steel-capped footwear
- Eye protection - such as safety glasses and face masks
- Ear protection - such as earmuffs and earplugs
- Hand protection – such as rubber gloves and barrier cream
- Respiratory equipment – such as face masks and valved respirators
If you are not certain what is appropriate or required, ask your supervisor.
Safety check
- Make sure that you understand and observe all legislative and personal safety procedures when working around vehicle chassis components. If you are unsure of what these are, ask your supervisor.
Points to note
- The vehicle chassis is the platform to which all the operating components and systems of the vehicle are attached. It is important that the chassis is straight and square so that steering and suspension components can operate in the intended manner.
- Manufacturers specify dimensions in relation to the location of the wheels. Two particular dimensions are:
- The wheelbase is the distance between the center of the front wheel and the center of the rear wheel and is normally the same on both sides of the vehicle.
- Some vehicles may have different wheelbase measurements from left to right. This is the exception rather than the rule. Always check the manufacturer's specifications before you take the measurements.
- The track is the measurement between the center of the left wheel tread and the center of the right wheel tread. It is common for the front track and the rear track to differ.
- If the dimensions differ from the manufacturer's specifications, refer to your supervisor.
- Two other dimensions should be noted:
- The overall length of the vehicle. This is the distance between the front and rear extremities.
- The overall width of the vehicle. This is the distance from the extreme right side to the extreme left side of the vehicle, but not usually including the external mirrors.
- These measurements are particularly important for legislative purposes. A vehicle's overall length and width can determine the roads where it can legally operate.
- The majority of service departments will have some form of electronic equipment to measure the axle alignment. When there is no specialized equipment, a basic method of checking axle alignment or the wheelbase can be carried out with simple tools. We have outlined this procedure in this module. The procedure shown here is not the only measuring method, but shows how to carry out these checks if no specialized equipment is available.
- Carry out this procedure with specialized equipment if it is available and you have been trained to use it.
Part 2: Step-by-step instruction
- Prepare the vehicle
Position the vehicle on a flat surface with the road wheels pointing straight ahead. Engage the emergency brake and place the transmission in neutral or park, then turn off the ignition.
- Select appropriate measuring equipment
You will need to prepare a measuring device. Such as a straight length of wood or steel with two moveable pointers attached.
- Compare distances between axles on both sides
Place the length of steel, with the two moveable pointers attached, next to the front and rear wheels on one side of the vehicle. Align the two pointers to the centers of the front and rear axles. Tighten the pointers to the position of the axle centers. Alternatively, use a mechanic’s set-square to align the front and rear axle centers with the length of steel, and mark the steel with chalk or marking pencil. Move the measuring device to the other side of the vehicle and check to see if the pointers align with the axle centers on this side. Compare the two; they should be the same. If one side of the vehicle has wheels significantly closer together or further apart, refer this to your supervisor.
- Measure the wheelbase between marks
Remove the length of steel and measure the distance between the two marks. This will give you the distance between the two wheel axles
Checking windshield washer liquid
Part 1. Preparation and safety
Objective
- Inspect and refill a windshield washer fluid reservoir.
Personal safety
Whenever you perform a task in the workshop you must use personal protective clothing and equipment that is appropriate for the task and which conforms to your local safety regulations and policies. Among other items, this may include:
- Work clothing - such as coveralls and steel-capped footwear
- Eye protection - such as safety glasses and face masks
- Ear protection - such as earmuffs and earplugs
- Hand protection – such as rubber gloves and barrier cream
- Respiratory equipment – such as face masks and valved respirators
If you are not certain what is appropriate or required, ask your supervisor.
Safety check
- Make sure that you understand and observe all legislative and personal safety procedures when carrying out the following tasks. If you are unsure of what these are, ask your supervisor.
Points to note
- Only use an approved windshield washer fluid.
Part 2: Step-by-step instruction
- Locate washer fluid reservoir
Locate the windshield wiper fluid container. This is normally found under the hood and is usually a plastic bottle or bag.
- Check the fluid level
Some vehicles have electrical sensors incorporated into the reservoir, and an indicator lamp on the inside of the vehicle will show the driver when the system needs to be filled. In most vehicles the fluid level is visible and a marker on the reservoir indicates the correct fluid level.
- Fill reservoir
Choose an appropriate washer fluid. Some fluids are concentrated and need to be mixed with water. Never use laundry-washing detergent to top up the reservoir, as the chemicals in the detergent can be detrimental to the vehicle paintwork. Take care not to spill the fluid, and fill the reservoir to between the minimum and maximum marks.
Checking & replacing wiper blades
Part 1. Preparation and safety
Objective
- Check the condition of windshield wiper blades and arms and change a windshield wiper blade.
Personal safety
Whenever you perform a task in the workshop you must use personal protective clothing and equipment that is appropriate for the task and which conforms to your local safety regulations and policies. Among other items, this may include:
- Work clothing - such as coveralls and steel-capped footwear
- Eye protection - such as safety glasses and face masks
- Ear protection - such as earmuffs and earplugs
- Hand protection – such as rubber gloves and barrier cream
- Respiratory equipment – such as face masks and valved respirators
If you are not certain what is appropriate or required, ask your supervisor.
Safety check
- Make sure that you understand and observe all legislative and personal safety procedures when carrying out the following tasks. If you are unsure of what these are, ask your supervisor.
Points to note
- Never operate the wipers when they are dry because this may damage the blades or scratch the surface of the windshield.
- Never bend the arms to make better contact with the windshield. The arms are pre-tensioned by the manufacturer and damage could result. If the arms seem to have lost their spring tension, obtain a suitable replacement.
Part 2: Step-by-step instruction
- Check windshield wiper blades
Lift the wiper arm away from the windshield and inspect the condition of the blades. Look for damage or loss of resilience in the material. Wet the windshield with a spray, or with the washers and switch the wipers on. If the windshield is being wiped cleanly, do not replace the blades. If the wiper blades are not wiping the glass evenly, or are smearing the windshield, you will need to replace the blades.
- Remove blade assembly
Remove the blade assembly. Depending on the vehicle, you may need to remove the wiper arm from its mounting, or you may be able to just undo a spring clip and remove the blade insert.
- Obtain replacement blade
Check the shop manual and obtain the correct size replacement. New developments in blade design means that the profile of the new blade may not be identical to the original.
- Install inserts
Feed the new inserts into the wiper arm, and make sure the clips fit snugly and engage properly.
- Test blades
Wet the windshield again, and operate the wipers to check their performance, making sure they remove the water evenly.
Checking a security system
Part 1. Preparation and safety
Objective
- Check an automotive security system on a vehicle.
Personal safety
Whenever you perform a task in the workshop you must use personal protective clothing and equipment that is appropriate for the task and which conforms to your local safety regulations and policies. Among other items, this may include:
- Work clothing - such as coveralls and steel-capped footwear
- Eye protection - such as safety glasses and face masks
- Ear protection - such as earmuffs and earplugs
- Hand protection – such as rubber gloves and barrier cream
- Respiratory equipment – such as face masks and valved respirators
If you are not certain what is appropriate or required, ask your supervisor.
Safety check
- Make sure that you understand and observe all legislative and personal safety procedures when carrying out the following tasks. If you are unsure of what these are, ask your supervisor.
Points to note
- Some systems are movement sensitive, so it is difficult to try to start the car from the inside. Your movement will set the alarm off.
- Some vehicle security transponders may not operate in some environments. This may be because there is strong electromagnetic interference in the area.
- If a transponder does not seem to operate verify that it belongs to the vehicle you are attempting to unlock. It may be that a busy service advisor has mislabeled the key and transponder from another vehicle.
- Transponders are designed to cope with normal operating stresses. Do not drop them into liquid or subject them to extreme heat or force.
Part 2: Step-by-step instruction
- Set the security system
This section deals with vehicle security and alarms. When the system is armed, an LED type light usually blinks on the dash. In some cases you will also hear an audible tone. Sit inside the vehicle with the doors shut. Lock the doors and activate the security system. This is usually done with a transponder. The transponder that turns the security system on and off is usually a small battery-powered device attached to the key ring, or built in to the ignition key itself.
- Test the security system
Start the engine. If the security system immobilizes the engine then this action should not be possible. If the security system is an audible alarm, it should now go off. If the security system works properly, move the vehicle to a different location - for instance, outside the workshop - and test it again. A transponder can suffer from electronic interference and may work better in some locations than others.
- Check transponder operation
If the security test fails, check whether or not the transponder has power and is operating correctly. If it operates the door locks as well as the security system, locking and unlocking the vehicle will confirm that the transponder is working.
- Replace transponder battery
If the transponder is not working properly you might need to replace its battery. To do this, you will need to refer to the specific manufacturers specifications for changing the battery to re-test the unit.
- Action on failure
If either the security system or the transponder is not working, you should report it to your supervisor.
