6. Figure 17–1 Before service begins be sure to cover the seats, floor, and steering wheel with protective covering. Figure 17–2 An exhaust hose should be connected to the tailpipe(s) whenever the engine is being run indoors. Continued
7. 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. What is the Magnuson-Moss Act?
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13. Figure 17–6 A master brake cylinder with transparent reservoir. The brake fluid should be between the “MAX” and “MIN” levels indicated on the reservoir. CAUTION: Do not overfill a brake master cylinder. The brake fluid gets hotter as the brakes are used and there must be room in the master cylinder reservoir for the brake fluid to expand. Continued
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35. Figure 17–14 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 OIL FILTERS Oil is pumped from the oil pan through the filter before it goes into the lubricating system passages. The filter is made from either closely packed cloth fibers or a porous paper. These particles are so small they can flow through the bearing oil film and not touch the surfaces, and so do no damage. Large particles are trapped by the filter while microscopic particles will flow through the filter pores.
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37. 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. Does the Oil Filter Remove all the Dirt?
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39. Figure 17–13 (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. 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. The Pick Trick (a) (b)
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43. 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. What is “Pet Friendly” Antifreeze? CAUTION: Some vehicle manufacturers do not recommend the use of propylene glycol coolant. Check the recommendation in the owner’s manual or service information before using it in a vehicle . Continued
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45. CAUTION: The coolant level should only be checked when the engine is cool. Removing the pressure cap from a hot engine will release the cooling system pressure when the coolant temperature is above its atmospheric boiling temperature. When the cap is removed, the pressure will instantly drop to atmospheric pressure level, causing the coolant to boil immediately. Vapors from the boiling liquid will blow coolant from the system. Coolant will be lost, and a person may be injured or burned by the high-temperature coolant that is blown out of the filler opening. 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. Quick-and-Easy Cooling System Problem Diagnosis
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47. Figure 17–19 This old upper hose had a split, causing coolant to squirt out. 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 . The Cut and Peel Trick
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51. NOTE: Chrysler warns that color and smell should not be used to determine the condition of ATF4 used in most Chrysler-built vehicles since the 2000 model year. The dyes and additives can change during normal use and it is not an indication of fluid contamination. Always follow the vehicle manufacturer’s recommendation. Continued 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 manufacturer’s recommended interval even though, to the naked eye, the fluid looks okay. The Paper Towel Test
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55. Figure 17–22 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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57. Figure 17–23 (a) Windshield washer fluid caps are usually labeled with this symbol. Figure 17–23 (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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60. 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 V’s of the belt and the angle of the V’s 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. The Hand Cleaner Trick
61. Figure 17–25 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 17–26 Always check the belt routing whenever replacing or checking the operation or noise in the accessory drive belts. Continued
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68. Figure 17–29 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: Radial tires can cause radial pull due to their construction. If the wheel alignment is correct, try to correct a pull by rotating the tires front to rear or, if necessary, side to side.
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70. Figure 17–30 (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 17–30 (b) An assortment of torque limiting adapters.
71. 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. Two Quick Checks
72. 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. Waiting for the Second Click Story
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74. Figure 17–32 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.
75. Figure 17–33 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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77. Figure 17–34 A hand-operated grease gun being used to lubricate a grease fitting on a pitman arm. CAUTION: If too much grease is forced into a sealed grease boot, the boot itself may rupture requiring the entire joint to be replaced.
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84. Figure 17–38 A visual Inspection should include checking differential fluid, especially after noting that a leak has occurred. NOTE: The reason for the low fluid level should be determined. If repairs are not completed immediately, additional differential fluid should be added by pumping it into the differential through the inspection hole.
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88. 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. Use a Hydrocarbon Detector Figure 17–39 An electronic hand-held hydrocarbon tester is an excellent tool to use to check for possible gasoline leaks from lines or components.