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AutomotiveTechnicianTraining:PracticalWorksheetsLevel2

AutomotivepracticalworksheetsforstudentsatLevel2ThisLevel2studentworksheetsbookcontainstasksthathelpyoudeveloppracticalskillsandprepareyouforassessment.Thetasksalsoreinforcetheautomotivetheorythatyouwilllearnonlineandintheclassroom.Eachworksheetcoversindividualtopicsinastep-by-stepmanner,detailinghowtocarryoutallthemostimportanttaskscontainedwithinthesyllabus.Alongsideeachoftheseworksheetsisajobcardthatcanbefilledinandusedasevidencetowardsyourqualification.

EndorsedbytheInstituteoftheMotorIndustryforalltheirLevel2automotivecourses.

Step-by-stepguidestothepracticaltasksrequiredforallLevel2qualifications.

Jobsheetsforstudentstocompleteandfeedbacksheetsforassessorstocomplete.

TomDentonistheleadingUKautomotiveauthorwithateachingcareerspanninglecturertoheadofautomotiveengineeringinalargecollege.Hisrangeofautomotivetextbookspublishedsince1995arebestsellersandledtohisauthoringoftheAutomotiveTechnicianTrainingmultimediasystemthatisincommonuseintheUK,USAandseveralothercountries.TomnowworksastheeLearningDevelopmentManagerfortheInstituteoftheMotorIndustry(IMI).


AutomotiveTechnicianTraining

PracticalWorksheetsLevel2

TomDenton


Firstpublished2015byRoutledge

2ParkSquare,MiltonPark,Abingdon,OxonOX144RN

andbyRoutledge

711ThirdAvenue,NewYork,NY10017

RoutledgeisanimprintoftheTaylor&FrancisGroup,aninformabusiness

©2015TomDenton

TherightofTomDentontobeidentifiedasauthorofthisworkhasbeenassertedbyhiminaccordancewithsections77and78oftheCopyright,DesignsandPatentsAct1988.

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ISBN:978-1-138-85237-2(pbk)

ISBN:978-1-315-72351-8(ebk)

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ContentsPracticalWorksheets–Level2

Engines

Chassis

Transmission

Electrical


PracticalWorksheets–Level2

IntroductionThepurposeofthisworksheetsbookistoprovidearangeofpracticalactivitiesthatwillenableyoutodevelopyourabilitiesasatechnician.Thetasksarealignedwithrecognizedvocationalqualifications.However,therearefarmoretaskswithinthisworkbookthanarerequiredbytheawardingbodyfortheachievementofaVocationallyRecognizedQualification–becausethemoreyoupractise,themoreskillsyouwilldevelop.

TheworksheetsarepresentedasthreeseparatebooksatLevel1,Level2andLevel3tofollowtherecognizedqualifications.Withineachleveltherearetasksforthemajorautomotiveareas:Engines,Chassis,TransmissionandElectrical.ThetasksrangefromcomponentidentificationtoremovalandrefitatLevel1and2,anddiagnosisofcomplexsystemfaultsatLevel3.

Ablankjobcardandassessorreportareprovidedwitheachworksheet.Thisshouldbecopiedandthenfilledinalongsidethetaskyouarecompleting,includingallrelevantdetailsregardingthevehicle,thefaultandtherectificationprocedurewhereappropriate.Youshouldwritedownadescriptionoftheworkthatyoudidtocompletethetaskincludinganytechnicaldatathatyousourced,anydifficultiesthatyouencounteredandhowyouovercamethem.Ifyouhadanyhealthandsafetyissuestoaddress,i.e.disposalofwastematerialsorclearingupspillages,thiswillhelpdemonstrateyourcompetence.Bycompletingjobcardsthoroughlyatthisstageofyourcareerasatechnician,youwillbewellpreparedforthetimewhenyouarerequiredtocompletejobcardsintheworkplace.Thiscanbeveryimportant,forexample,ifawarrantyjobcardisnotaccuratethenthemanufacturerwillnotpayfortheclaim.Anexampleofacompletedjobcardisshownonpage7.

Forteacher/lecturers,thisworkbookmorethancoverstherequirementsforVocationalQualifications.Usingthefollowingtrackingdocumentyoucannoteprogressandalsocross-referencethehighlightedworksheetsthatdirectlyrelatetotheawardingbodyrequiredpracticaltasks.

Tracking


ImportantnotesaboutpracticalworkSafety

Workingonvehiclesisperfectlysafeaslongasyoufollowproperprocedures.Foralloftheworksheetsinthisbookyoumusttherefore:

Complywithpersonalandenvironmentalsafetypracticesassociatedwithclothing;eyeprotection;handtools;powerequipment;properventilation;andthehandling,storage,anddisposalofchemicals/materialsinaccordancewithallappropriatesafetyandenvironmentalregulations.

Therearesomespecificrecommendationsbelowbutyoushouldalsorefertotheothertextbooksoronlineresourcesforadditionalinformation.

Personalprotectiveequipment(PPE),suchassafetyclothing,isveryimportanttoprotectyourself.Somepeoplethinkitcleverortoughnottouseprotection.Theyareverysadandwilldieorbeinjuredlongbeforeyou!Somethingsareobvious,suchaswhenholdingahotorsharpexhaustyouwouldlikelybeburntorcut!Otherthingssuchasbreathinginbrakedust,orworkinginanoisyarea,donotproduceimmediatelynoticeableeffectsbutcouldaffectyoulaterinlife.


Eyeprotectionandglovesinuse

Fortunatelytheriskstoworkersarenowquitewellunderstoodandwecanprotectourselvesbeforeitistoolate.Inthefollowingtable,IhavelistedanumberofitemsclassedasPPE(personalprotectiveequipment)togetherwithsuggesteduses.Youwillseethattheuseofmostitemsisplaincommonsense.

Equipment Notes Suggestedorexampleswhereused

Eardefenders

Mustmeetappropriatestandards Whenworkinginnoisyareasorifusinganairchisel

Facemask Forindividualpersonaluseonly Dustyconditions.Whencleaningbrakesorifpreparingbodywork

Highvisibilityclothing

Fluorescentcolourssuchasyellowororange

Workingintrafficsuchaswhenonabreakdown

Leatherapron

Shouldbereplacedifitisholedorwornthin

Whenweldingorworkingwithveryhotitems

Leathergloves

Shouldbereplacedwhentheybecomeholedorwornthin

Whenweldingorworkingwithveryhotitemsandalsoifhandlingsharpmetalwork


Lifejacket Mustmeetcurrentstandards Usewhenattendingvehiclebreakdownsonferries!

Overalls Shouldbekeptcleanandbeflameproofifusedforwelding

Theseshouldbewornatalltimestoprotectyourclothesandskin.IfyougettoohotjustwearshortsandaT-shirtunderneath

Rubberorplasticapron

Replaceifholed Useifyoudoalotofworkwithbatteryacidorwithstrongsolvents

Rubberorplasticgloves

Replaceifholed Glovesmustalwaysbeusedwhenusingdegreasingequipment

Safetyshoesorboots

Strongtoecapsarerecommended Workinginanyworkshopwithheavyequipment

Safetygoggles

Keepthelensescleanandpreventscratches

Alwaysusegoggleswhengrindingorwhenanyriskofeyecontamination.Cheapplasticgogglesaremucheasiertocomebythanneweyes

Safetyhelmet

Mustbetocurrentstandards Undervehicleworkinsomecases

Weldinggogglesorweldingmask

Checkthegogglesaresuitableforthetypeofwelding.GasweldinggogglesareNOTgoodenoughwhenarcwelding

Youshouldwearweldinggogglesoruseamaskevenifyouareonlyassistingbyholdingsomething

Also,aswellasyourownprotectionyoushouldalwaysuseaprotectionkitforthevehicle:floormats,wingcoversandseatcoversforexample.

Toolsandequipment

Tocarryoutanyworkyouwillneedastandardtoolkitandinsomecasesadditional‘special’toolswillberequired.Makesureyouhaveaccesstoallnecessaryequipmentbeforestartingwork.Afewexamplesarementionedbelowbutyoushouldalsorefertotheothertextbooksoronlineresourcesforadditionalinformation.

Usinghandtoolsissomethingyouwilllearnbyexperience,butanimportantfirststepistounderstandthepurposeofthecommontypes.Thissectionthereforestartsbylistingsomeofthemorepopulartools,withexamplesoftheiruse,andendswithsomegeneraladviceandinstructions.


Toolkit

Practiseuntilyouunderstandtheuseandpurposeofthefollowingtoolswhenworkingonvehicles.

Handtool Exampleusesand/ornotes

Adjustablespanner(wrench)

Anidealstandbytoolandusefulforholdingoneendofanutandbolt.

Open-endedspanner

Usefornutsandboltswhereaccessislimitedoraringspannercan’tbeused.

Ringspanner Thebesttoolforholdinghexagonboltsornuts.Iffittedcorrectlyitwillnotslipanddamagebothyouandthebolthead.

Torquewrench Essentialforcorrecttighteningoffixings.Thewrenchcanbesetinmostcasesto‘click’whentherequiredtorquehasbeenreached.Manyfittersthinkitisclevernottouseatorquewrench.Goodtechniciansrealizethebenefits.

Socketwrench Oftencontainaratchettomakeoperationfareasier.

Hexagonsocketspanner

Socketsareidealformanyjobswhereaspannercan’tbeused.Inmanycasesasocketisquickerandeasierthanaspanner.Extensionsandswiveljointsarealsoavailabletohelpreachthatawkwardbolt.


Airwrench Theseareoftenreferredtoaswheelguns.Air-driventoolsaregreatforspeedingupyourworkbutitiseasytodamagecomponentsbecauseanairwrenchisverypowerful.Onlyspecial,extrastrong,high-qualitysocketsshouldbeused.

Blade(engineer’s)screwdriver

Simplecommonscrewheads.Usethecorrectsize!

Pozidrive,Philipsandcrossheadscrewdrivers

BettergripispossibleparticularlywiththePozidrivebutlearnnottoconfusethetwoverysimilartypes.Thewrongtypewillslipanddamagewilloccur.

Torx® SimilartoahexagontoollikeanAllenkeybutwithfurtherflutescutintheside.Itcantransmitgoodtorque.

Specialpurposewrenches

Manydifferenttypesareavailable.Asanexamplemolegripsareveryusefultoolsastheyholdlikepliersbutcanlockinposition.

Pliers Theseareusedforgrippingandpullingorbending.Theyareavailableinawidevarietyofsizes.Theserangefromsnipenose,forelectricalwork,toengineerspliersforlargerjobssuchasfittingsplitpins.

Levers Usedtoapplyaverylargeforcetoasmallarea.Ifyourememberthisyouwillrealizehow,ifincorrectlyapplied,itiseasytodamageacomponent.

Hammer Anybodycanhitsomethingwithahammer,butexactlyhowhardandwhereisagreatskilltolearn!

Generaladviceandinstructionsfortheuseofhandtools(takenfrominformationprovidedbySnap-on):

Onlyuseatoolforitsintendedpurpose

Alwaysusethecorrectsizetoolforthejobyouaredoing

Pullaspannerorwrenchratherthanpushingwheneverpossible

Donotuseafileorsimilarwithoutahandle

Keepalltoolscleanandreplacetheminasuitableboxorcabinet

Donotuseascrewdriverasaprybar

Lookafteryourtoolsandtheywilllookafteryou!

Information

Beforestartingworkyoushouldalwaysmakesureyouhavethecorrect


informationtohand.Thiscanbeintheformofaworkshopmanualoracomputer-basedsource.

Theworksheetsinthisbookareageneralguidesomakesurethecorrectinformation,proceduresanddatafortheparticularvehicleyouareworkingonareavailablebeforeyoustartwork.

Autodataonlineinformation


Jobcard:example

Assessorreport:example


EnginesWorksheet1:Routinevehiclemaintenanceinspections/service

ProcedureGeneralvisualinspection–listenforabnormalnoises.

Visual/oillevelandcondition.Replaceoilandfilteratspecifiedintervals.

Visual/inspectionsforoilleakage.

Visual/inspectionofexhaustsmoke–atidlespeedatmid-enginespeed(3000rpm)onoverrunduringroadtest.

Engineoilpressuretest–checkwarninglightoperates(attachapressuregaugeandadapterandtachometer)–pressureatidlespeed–stabilizedpressure–stabilizedpressureenginerpm.

Crankcaseventilationsystem–checkconditionofhoses(visualandremovehosesandvalves)–orificetoinletmanifoldclear–aircleanercondition–controlvalvecondition.

Checkcoolantlevelandspecificgravity.

Checkbrakeoperationandpad/disccondition–recordthickness.

Checktyretreaddepths.

Torquewheelnuts–includetorquefiguresandcalibrationdateoftorquewrench.

Additionalitems–seemanufacturer’sschedule.


Jobcard

Assessorreport


Worksheet2:Vehicleinspections

ProcedureGeneralvisualinspection–listenforabnormalnoises.

Checkbrakeoperationandpad/disccondition–recordthickness.

Checktyretreaddepths.

Torquewheelnuts–includetorquefiguresandcalibrationdateoftorquewrench.

Additionalitems–seemanufacturer’sscheduledependingupontypeofinspection–pre-andpost-work,pre-deliveryinspection(PDI),pre-purchaseinspection(PPI),preMOT,visualhealthcheck(VHC)orpostrepair.


Jobcard

Assessorreport


Worksheet3:Adjustvalveclearances(OHV)

ProcedureRunengineandlistenforabnormalnoisesfromtopofengine.Checkfor

misfire/cylinderbalance.Disconnectbatteryearth/groundcable.Removerockercover.

Measurewithfeelergaugesallvalveclearancesatthe‘back-of-the-cam’(heel)position.Checkmanufacturer’srecommendedprocedureforpositioningtheengine,e.g.ruleofnineorvalvesrockingmethod.

Adjusteachvalveusingaspecialtoolorwrenchandscrewdriverasappropriate.Notethatinletandexhaustsettingsmayvary.

Refitallandrunenginetocheckfornoiseormisfire.


Jobcard

Assessorreport


Worksheet4:Inspectcamshaftlobes,journalsandbearings,auxiliaryshafts,bearingsanddrive

ProcedureStriptoaccessthecamshaft.Checktheendfloatbeforeremoving.

Removecamshaftandvisuallyinspectforconditionofbearingjournalsandcamlobes.Inspectretaining/thrustplateforwear.

Inspectbearingsintheengineblockorhead.Lookforwear,scoring,pitting,orotherdeterioration.

Laythecamshaftinoiledpapersupportsinveeblocksonasurfacetable.Assembleadialtestindicator(DTI)toabaseandzerooncentrejournal.Rotateshaftandobservevariationinneedlepositiontoindicateiftheshaftisbent.

Measureandrecordcamliftonalllobes.Comparewithmanufacturer’sdata.

Measurecamjournalswithexternalmicrometerandrecordresults.Measureforovality.Measureinternaldimensionsofbearingsandrecord.Comparereadingswithmanufacturer’sdataforsizeandweartolerances.

Reassembleshaftandothercomponents.Runengineandlistenforabnormalnoises.


Theinspectionofauxiliaryshaftsisasimilarprocedure.


Jobcard

Assessorreport


Worksheet5:Removeandreinstallengine(RWD)withouttransmission

ProcedureObtaincrane,slingandliftingeyeswithaSWLinexcessofengineweight.

Disconnectbatteryearth/groundcable.Fitliftingeyestoengineaspermanufacturer’sinstructions.Labelanddisconnectallelectricalcablestoengineincludingenginegroundcable.Labelanddisconnectallvacuumpipestoengine.Removeairintakeductingandaircleaner,blankoffopenpipes.

Depressurize,labelanddisconnectfuellinestoengine,blankoffpipes.Labelanddisconnectthrottle/chokeandothercontrolcables.Disconnectexhaustdownpipeatmanifoldflange.Remove,ifnecessary,thestartermotorandclutchoperatingmechanism(cableorhydraulic).Slackenallclutchhousingboltsandremoveallbuttwo,oneeitherside.Slackenandremove,ifsafetodoso,theenginemountingnutsfromtheundersideofvehicle.

Whenallundersideworkiscompleted,drainthecoolantandremoveradiatorandallhoses.Whenairconditioningisfitted,donotdisconnectrefrigerantpipes/hosesbeforeremovingrefrigerant(specialisttask).If


possible,removeandsupportthecompressorwithhosesattached.

Attachslingtoliftingeyesandcrane,tensionsling.Checkallconnectionstoenginehavebeendisconnected.Removeenginemountingnuts/boltsifnotalreadyremoved.Operatecranetoliftengineclearofmountings.Putajackunderthegearboxandliftslightly.Removeremainingclutchhousingbolts.Pullengineforwardawayfromthegearbox.Liftslowlyandsteadilymakingsurethattheenginedoesnotgetcaughtinthecompartment.

Beforereplacingtheengine,checkthealignmentoftheclutchcentreplateandspigot(pilot)bushorbearinginthecrankshaft.Checktheenginetoclutchhousinglocatingdowelsareinplace.Selectfirstorsecondgearinthegearbox.Toreplace,carefullylowertheengineintothecompartmentandpushontothegearbox.Keeptheengineandgearboxsquareandcentralized.Rotatetheenginecrankshafttoaligntheclutchandgearboxinputshaftsplines.

Pushtheenginefullyhomeontothelocatingdowelsandfittwoboltstoclutchhousingandtighten.Removethejackfromunderthegearboxandlowerengineintothemountings.Fitandtightenenginemountingnuts/boltsandremovecraneandsling.Replaceallcomponentsinreverseorder.Makeasystematiccheckofallcomponentsforcorrectfittingandsecurity.Roadtestandrecheckunderbonnet.


Jobcard

Assessorreport


Worksheet6:Removeandreinstalltransverseengineandtransmission(FWD)withcrane

ProcedureObtaincrane,slingandliftingeyeswithaSWLinexcessofengineweight.

Disconnectbatteryearth/groundcable.Fitliftingeyestoengineaspermanufacturer’sinstructions.

Labelanddisconnectallelectricalcablestoengineincludingenginegroundcable.Labelanddisconnectallvacuumpipestoengine.Removeairintakeductingandaircleaner,blankoffopenpipes.Depressurize,labelanddisconnectfuellinestoengine,blankoffpipes.Labelanddisconnectthrottle/chokeandothercontrolcables.Disconnectexhaustdownpipeatmanifoldflange.

Disconnectthegearchangeremotelinkageatthegearbox.Removethespeedodrivecable.Disconnecttheclutchcableorhydrauliccylindercompletewithpipes.Removethedriveshaftsfromthefinaldrive(catchoil).Fitdummyshaftstoretainsunwheels.Slackenandremove,ifsafetodoso,theenginemountingnutsfromtheundersideofvehicle.

Whenallundersideworkiscompleted,drainthecoolantandremoveradiatorandallhoses.Whenairconditioningisfitted,donotdisconnect


refrigerantpipes/hosesbeforeremovingrefrigerant(specialisttask).Ifpossible,removeandsupportthecompressorwithhosesattached.

Attachslingtoliftingeyesandcrane,tensionsling.Checkallconnectionstoengineandgearboxhavebeendisconnected.Removeenginemountingnuts/boltsifnotalreadyremoved.Operatecranetoliftengineclearofmountings.Liftslowlyandsteadilymakingsurethattheengineandgearboxdonotgetcaughtinthecompartment.

Toreplace,carefullylowertheengineandgearboxintothecompartmentandlocateontotheenginemountings.Fitenginemountingnuts/boltsandtighten.Removecraneandsling.Refitdriveshaftsandcheckandtopupgearboxoil.Replaceallcomponentsinreverseorder.Makeasystematiccheckofallcomponentsforcorrectfittingandsecurity.Startandrunengine,bleedcoolingsystem,ifnecessary,checkforcorrectoperation.Roadtestandrecheckunderbonnet.


Jobcard

Assessorreport


Worksheet7:Removeandreinstalltransverseengineandtransmissionontotrolley(includesfrontframeandsuspension,OBD1ornewer)

ProcedurePlacevehicleonasuitableliftwiththeliftingpointscorrectlypositioned(see

workshopmanual).Obtainspecialorsuitabletrolley.

Disconnectbatterygroundcable.Underneaththevehicleremoveexhaustdownpipe,gearchangelinkage,speedocable,clutchcontrolcableorhydraulics,steeringcolumncouplingandbrakeconnections(hosesorpipes).Blankoffpipes.

Underthebonnetlabelanddisconnectelectricalterminals,vacuumconnections,fuelfeedandreturnpipes(plugorcappipes),airducting,throttleandothercontrolcables.Draincoolantandremoveradiatorandhoses.

Whenairconditioningisfitted,donotdisconnectrefrigerantpipes/hosesbeforeremovingrefrigerant(specialisttask).Ifpossible,removeandsupportthecompressorwithhosesattached.

Checkallconnectionstotheengine,transmissionandsubframehavebeen


disconnected.

Lowervehiclesothatthesubframerestsonthetrolley.Undoandremovesubframetochassismountingbolts.

Note:checkthatboltsarenotsupportingaloadbeforeremoval.

Carefullyliftthevehicleawayfromthesubframe,watchingthattheengineandtransmissiondoesnotcatchintheenginecompartment.

Refitandreassembleinthereverseorder.Tightenallnuts/boltstospecifiedtorquesettings.Makeasystematiccheckofallcomponentsforcorrectfittingandsecurity.

Bleedandcheckbrakes.Checkfrontwheelalignment.Runtheengine,bleedcoolingsystem,ifnecessary,andcheckforcorrectoperation.

Roadtestandrecheckallworkunderthevehicleandunderthebonnet.


Jobcard

Assessorreport


Worksheet8:Inspectandreplacesump,covers,gasketsandseals

ProcedureDisconnectbatterygroundcable.

Papergaskets–removecover/housingandcleanoldgasketmaterialandsealantfrombothgasketfaces.Checkfacesforflatness,rectifyasnecessary.Fitnewgasketwithsealant,ifspecified,refitboltsandtightentospecifiedtorque.

Rubbergaskets–removecover/housingandcleanoldgasketmaterialfrombothfaces.Checkgasketfacesforflatness,rectifyasnecessary.Fitnewgasketwithoutsealanttocleananddryfaces,refitboltsandtightenuntilgasketispinched.Donotovertighten.

Corkgaskets–removecover/sumpandcleanoldgasketmaterialandsealantfrombothgasketfaces.Checkfacesforflatness,rectifyasnecessary.Fitnewgasketwithsealant,ifspecified,refitboltsandtightentospecifiedtorqueandinsequence.

Formedinplacegaskets(tubeapplied)–removecover/sumpandcleanoldgasketsealantfrombothfaces.Checkfacesforflatness,rectifyasnecessary.Applysealantbeadgasketsaspermanufacturer’sinstructions.


Fitandtorqueinsequencewithin3minutes.

Oilseals–theseareusedwithgasketsforsealingaroundbearingcapsandoilmouldedrubberpans.Fitwithrecommendedsealantsordryandthenfitothertypeofgasketsandsump.Fitandtorqueboltsinsequence.Checksealsdonotsqueezeout.

Oilseals(lip)–removepulleyfromhousingandinspectsealland.Useaspecialtooltoextracttheseal.Pressinnewsealtoshoulderorspecifieddepth.Lubricate(inblock)sealwithcleanengineoil.Cleanandlubricatesealland,refitpulleyandtorquebolt.


Jobcard

Assessorreport


Worksheet9:Removeandreplacecrankshaft,vibrationdamper,flywheelandclutchpilotbush/bearing

ProcedureRemovegearboxandclutch,stripundersideofengine,sumpandfrontcover

toaccesscrankshaft.Checkandrecordtheendfloatonthecrankshaft.Undofrontpulley/vibrationdamperbolt(lockflywheeltoaidundoingofbolt).Pulloffpulley/damperandinspectseallandandpulleyveefaces.Removethefrontcoverandtimingbeltorchain.Checkandmarkdirectionofrotationandtiming.Removeboltssecuringtheflywheel/flexplate/driveplateandcarefullyremoveflywheeltakingweightinbothhands.Removerearmainoilsealhousing.Inspectflywheel.

Checkthebigendandmainbearingcapsforposition(No.1,2,etc.)andslidetothefrontofengine.Ifnotmarked,markwithdotswithacentrepunchorsimilar.Removebigendbearingcapsandlayoutinorder.Removemainbearingcapsandlayoutinorder.Liftoutcrankshaft.Ifworkingbelowvehicle,removecentrebearingandcrankshafttogether.Inspectcrankshaftforsurfacecracksandjournaldamage.Removeallbearingshellsiftheyaretobereplaced.Checkoilpassagecondition.Measurejournalwear.Fitnewbearingsintoconnectingrodsandmainbearings


caps,locatetangsandoilwayholes.Checknewbearingsfor‘nip’byassemblingfingertightandcheckingcapgapwithfeelergauge.

Pulloutclutchpilotbearingfromcrankshaft.Ifabush,fillwithgreaseandpunchinwithasuitablemandreltopushoutbush.Otherwiseusespecialpuller.Checknewbearingfitsgearboxinputshaftandthenfitintocrankshaft.Thereisnobush/bearingonsometransaxlesandautogearboxes.

Fitnewoilsealstofrontandrearhousingsoraroundcrankshaftifappropriate.Lubricateallbearingsandjournalswithcleanengineoil.Fitcrankshaftintomainbearingsintheblock.Checkendfloat.Fitmainbearingcapsandtightentheboltstothespecifiedtorqueandcheckenginerotation.Fitbigendbearingcapsandtightentotorqueandcheckenginerotation(fittimingchain).Fitfrontandrearmaincovers,centralizeandtightenboltsinsequenceandtotorque.Fitflywheel/driveplatetodowelsandfitbolts,applysealantorthreadlockingcompound,ifspecified.Tightenboltsinsequenceandtotorque.Checkrunout.Fittimingbeltandpulleysandcovers.Fitpulley/vibrationdamper.Beforefittingnewoilfilter,primethepumpwithcleanengineoilthroughtheoilfeedholetotheoilfilter.Fitfilter.Makeasystematiccheckofallcomponentsforcorrectfittingandsecurity.Fitgearbox,sump/sumpandothercomponents.Fillenginewithoil,startandrunengineandcheckforcorrectoperation.


Jobcard

Assessorreport


Worksheet10:Inspectcrankshaftcondition,journalandbearingdimensionsandwear

ProcedureStriptoaccessthecrankshaft.Checkendfloatandgeneralconditionbefore

removing.Checkallbearingcapsaremarkedforpositionandlocationtothefrontoftheengine.

Removecrankshaftandbearings.Visuallyinspectbearingsforcondition,wearandabnormalmarkings.

Visuallyinspectthecrankshaftjournalsandthrustfacesforscores,pittingandabnormalwearorunevenmarkings.

Laythecrankshaftinoiledpapersupportsinveeblocksonasurfacetable.Setupadialtestindicator(DTI)onabase.Measurethecrankshaftforbow(supportends–rotateandmeasurecentre)andtwist(comparematchedpairsofjournals,1&4,2&3,etc.).

Measureandrecordalljournalsizesfornominalsize,taperandovality.Comparewithmanufacturer’sdataforweartolerances.

Checkoilwaysinthecrankshaftareclearandclean.Flushthroughwithlowpressurejetoncleaningtank.


Ifcrankshaftisreground,washthoroughlybeforerefitting.Fitcorrectbearings(undersizeifcrankshafthasbeenreground).Checkonjournalsbeforefitting.

Lubricateallbearingswithcleanengineoil.Check‘nip’ofbearingsbeforetightening.Torquebearingcapboltstospecifiedtorqueandcheckenginerotates.Check‘feel’ofbearingsandendfloatofcrankshaftbeforereassemblingengine.

Whentheengineisrunningcheckforabnormalnoisesandcorrectoperation.


Jobcard

Assessorreport


Worksheet11:Inspectpistons,pistonringsandconnectingrodsandbearings

ProcedureRemovecylinderheadandsumptoaccesspistonsandconnectingrods.

Beforeremovingpistonschecktheconditionofthepistoncrownsandthe‘fit’ofthepistonsinthecylinderbores.Rockthepistonsfromsidetosideto‘feel’thefreeplay.

Visuallyinspectcylinderboresforscores,indicatingbrokenpistonrings,andforunevenweartooneside,indicatingmisalignmentorabentconnectingrod.Beforeremovingtheconnectingrodbigendbearingcapscheckforfreeplayby‘feel’bypullingandpushingtheconnectingrodonthecrankshaftjournal.Checkendfloatbysidetosidemovementandfeelergauge.Comparewithmanufacturer’sdata.

Removeconnectingrodsandpistons.Visuallyinspectthebigendbearingsforunevenwearindicatingapossiblebentconnectingrod.Visuallyinspectthecylinderboreformatchedwear.Visuallyinspectthecrankshaftjournalsandbearings.Ifthebearingsareworn,measurethecrankshaftjournalsandcomparewiththemanufacturer’sspecificationsandtolerancesforfittingnewbearingswithoutregrindingthecrankshaft.


Cleanthepistoncrownandinspectforburningoroverheatingdamage,pitting,particledamagesuchasbrokenpistonringsandotherdeterioration.

Visuallycheckandmeasurepistonringgroovesandringlandforcondition.Lookforopeningortaperoftheringgroovescausedbytheringsrocking.Lookforringbreakageandparticlescuttingthroughtheringland.

Removethepistonfromtheconnectingrod.Checkthe‘fit’ofthepistonpintotheconnectingrodlittleendbearing/bushandinthepiston.

Ifthepistonisserviceableandnewringsaretobefitted,measurethecylinderboresandcomparewiththemanufacturer’sspecificationsandtolerancelimitsfornewrings.

Gapnewringsinthecylinder.Cleanthepistonringgroovesusingaspecialtool.Fitringstopistonsandreassembleengine.Runengineandcheckforabnormalnoisesandcorrectoperation.


Jobcard

Assessorreport


Worksheet12:RemoveandreplacecylinderheadsOHV

ProcedureCheckpermissibleconditionsforheadremoval–allowenginetocoolif

required.Disconnectbatterygroundcable.

Labelandremoveallelectricalterminalstocomponentsoncylinderheadandmanifolds.Labelandremoveallvacuumpipes/hosestocylinderheadandmanifolds.Removedistributorcapandsparkplugleads.

Obtainacleandraintrayanddrainenginecoolant.Removeradiator,top,bypassandheaterhoses.

Removeairintakeducts,aircleaner,andPCVhosesasnecessary,etc.Labelandremovethrottleandchokecables.Removecarburettor/monopointinjectorbody/inletmanifoldandinjectors–blankoffallfuelpipes.

Removeexhaustatdownpipeflangeormanifoldtohead,pullclearofcylinderhead.Removerockercoverandrockershaft.Shakethepushrodstofreethemfromthefollowers.Removepushrodsandstoreinorder(drilledblockorsimilar)sothattheycanbereplacedinexactlythesamepositions.


Workinginthereverseordertothetighteningsequence,undothecylinderheadboltsbyasmallamount(¼ofaturn).Fullyundoandremoveheadbolts.Layoutinorderiftheboltsarereusable.Noteanyboltsthatdonotruncleanlyintheirthreads.Cleanthreads.Liftoffcylinderhead(twistfirstifwetlinersarefitted).Cleanfacesofthecylinderheadandblockandinspect.Plugwaterjackettopreventparticlesofdirtentering.

Fitnewcylinderheadgasket–followmanufacturer’sinstructions–useguidestudsifnecessary.Lowerheadintoplaceonlocatingdowels.Fitheadboltsanddoupfingertight.Followmanufacturer’sinstructionsforheadbolttighteningsequenceandtorquesettings.Refitpushrods,rockershaftandrockers;adjustvalveclearances(lash).Refitrockercover.Refitexhaust,inlet,fuelelectricalandcoolantcomponents.Topupcoolant.Runengine,bleedheaterifnecessary,recheckcoolantlevelandcoolantcirculation.Listentoengineforabnormalnoisesandoil/coolantleaksandoperationofwarninglights/gauges.

Roadtestandcheckoperationofengine,coolanttemperature,heateroperation,etc.Recheckafterroadtestinsideenginecompartmentforoil/coolantleaks,securityofalldisturbedcomponentsandfittingsandcleanliness–rectifyandrecheckifnecessary.


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Worksheet13:RemoveandreplacecylinderheadsOHC

ProcedureCheckpermissibleconditionsforheadremoval–allowenginetocoolif

required.Disconnectbatterygroundcable.Labelandremoveallelectricalterminalstocomponentsoncylinderheadandmanifolds.Labelandremoveallvacuumpipes/hosestocylinderheadandmanifolds.Removedistributorcapandsparkplugleads.Obtainacleandraintrayanddrainenginecoolant.Removeradiator,top,bypassandheaterhoses.Removeairintakeducts,aircleaner,andPCVhosesasnecessary,etc.Labelandremovethrottleandchokecables.Removecarburettor/monopointinjectorbody/inletmanifoldandinjectors–blankoffallfuelpipes.

Removeexhaustatdownpipeflangeormanifoldtohead,pullclearofcylinderhead.Removecamhousingcoverandgasket.Removefront/camshaftdrivebeltcover–markdirectionofrotation(DOR)onbeltandturnenginetoaligntimingmarks.Slackentensionerandremovebelt.Donotturnthecrankshaftorcamshaftbeforetheheadisremoved.Returntothispositionbeforetheheadisreplaced.Workinginthereverseordertothetighteningsequence,undothecylinderheadboltsbyasmallamount(¼ofaturn).Fullyundoandremoveheadbolts.Layoutinorder


iftheboltsarereusable.Noteanyboltsthatdonotruncleanlyintheirthreads.Cleanthreads.Liftoffcylinderhead(twistfirstifwetlinersarefitted).Cleanfacesofthecylinderheadandblockandinspect.Plugwaterjackettopreventparticlesofdirtentering.

Fitnewcylinderheadgasket–followmanufacturer’sinstructions–useguidestudsifnecessary.Checkandpositioncrankshaftandcamshafttoaligntimingmarks.Lowerheadintoplaceonlocatingdowels.Fitheadboltsanddoupfingertight.Followmanufacturer’sinstructionsforheadbolttighteningsequenceandtorquesettings.Refitcamshaftdrivebelt,checktimingmarksalign;tensionbeltandrotatefortwoorthreerevolutions,rechecktimingandbelttension.Fitcamhousingcoverwithnewgasket.

Refitexhaust,inlet,fuelelectricalandcoolantcomponents.Topupcoolant.Runengine,bleedheaterifnecessary,recheckcoolantlevelandcoolantcirculation.Listentoengineforabnormalnoisesandoil/coolantleaksandoperationofwarninglights/gauges.

Roadtestandcheckoperationofengine,coolanttemperature,heateroperation,etc.Recheckafterroadtestinsideenginecompartmentforoil/coolantleaks,securityofalldisturbedcomponentsandfittingsandcleanliness–rectifyandrecheckifnecessary.


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Worksheet14:Removeandreplacecamfollowersincludinghydraulictappets

ProcedureRunengineandlistenforabnormalnoisesfromvalvemechanism.Strip

enginetoaccesscamfollowers–insideofengine(OHV)orincylinderhead(OHC).

Alternatives–removepushrodsandsidecovers–liftoutfollowers.OHV–removecylinderheadandliftoutfollowers–removeinletmanifoldandcovers(veeengines)andliftoutfollowers.

Alternatives–caminheadandrockeractuation–removerockerswhicharecamfollowersOHC–directactingcamsrequireremovalofthecamshafttoaccesscamfollowers.

Checkcamfollowersbeforeremoval,forfreeplayacrosstheboreandthatthefollowerisfreetorotate.

Liftoutfollowersandlayoutinorder(theymustbereplacedinexactlythesameposition).Checkthrustfacesandsidesofcamfollowersandthecamlobes.Inspectforsignsthatindicatethatthefollowerhasorhasnotbeenrotating.


Forhydraulictappets/followerscheckoilfeedholesintheblock/head/tappetareclean.Followthemanufacturer’sinstructionsforstrippingandinspectinghydraulictappets.

Lubricateallpartsbeforeandduringassemblywithcleanengineoil.Replacefollowers/tappetsincorrectposition.Reassembleothercomponentsinreverseorder.Checkandadjustvalveclearances.

Refitanyotherpartsandbatterygroundcable.

Startandrunengine–checkforcorrectoperation.

Roadtestandrecheck.


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Worksheet15:Performcylindercompressiontests;determinenecessaryaction

ProcedureCheckenginemanufacturer’sdataforsuitabilityofthistestandchecking

conditions(coldorhot).DisconnectLT(lowtension)orprimarycircuitfeedatcoiltopreventHTcurrent.(LTfeedfromcoiltodistributor).

Removeallsparkplugs.

ConnectcompressiontesterintoNo.1sparkplughole.Fullyopenthrottle.

Crankengineforthreeorfourrevolutions,recordinitial(firstrevolution)andfinalcompressionreading.(Seekassistanceifnecessarytoholdthethrottleandtocranktheengine.)

Repeatforallothercylindersandrecordreadings.

Ifsomereadingsarelow,putasmalldropofcleanengineoilintothecylinderandrepeattest.Recordresults.

Repeatforallcylinders.

Comparedryandwetreadingswithothercylindersandwiththeenginemanufacturer’sspecifications.


Refitsparkplugs,HTleadsandcoilLTlead–checkenginestartsandruns.


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Worksheet16:Removeandreplaceoilpumpsanddrivemechanisms–timeoilpumpanddistributorshaft

ProcedureOilpumpdrivesdistributor.Iftheoilpumpandthedistributorsharethe

samedrivefromthecamshaft,positiontheenginesothatNo.1cylinderisatTDConthecompressionstroke.Removethedistributorcapandmarkorrecordthepositionofthedistributorandrotorarm.Removethedistributorandrecordthepositionofthedrivedogs(large‘D’position).Replacedoilpumpmustreturntothispositionwhenreassembled.

Ontheundersideoftheenginedisconnectandremovetheoilpickuppipeandstrainer.Undoandremovetheoilpumpsecuringboltsandremovethepump.Cleanoldgasketfrommatingfaces.Stripandinspectpump.Refitpumpwithnewgasketor‘O’ringandsealantonlyifspecified.Turndrivegeartothetimingpositionandeasehomeonthecamshaftgear.Checkthe‘D’drivesdogpositioninthedistributor-housingbore.Correctifnecessarybypullingbackandturningthegearappropriately.Whenthedistributordriveiscorrectlypositionedfitandtightensthesecuringboltstothespecifiedtorque.


Fitthepickuppipeandstrainerusingnewsealsandtightensecuringbolts.Refitthedistributorandsetignitiontiming.Finallyadjusttimingwhentheengineisrunning.

Oilpumpnottimed.Iftheoilpumpisdrivenfromthecrankshaftorcamshaftoranauxiliaryshaftindependentlyoftheignitionsystem,thepumpdrivemechanismneednotbetimed.Removepickuppipeandstrainerifnecessary.Undooilpumpsecuringboltsandremove.Cleanoldgasketsor‘O’ringsfrompumpandengine.Stripandinspectoilpump.Primenewpumpwithcleanengineoil.Fitnewgasketsor‘O’ringsandsealantonlyifspecified.Turndrivetolocatewithdrivegear,dogor‘D’driveandfitpump.Fitandtightensecuringboltstospecifiedtorque.Reassembleengineandtopupwithengineoil.Beforefittingnewoilfilter,primethepumpwithcleanengineoilthroughtheoilfeedholetotheoilfilter.Fitfilter.Startandrunengine–ifoilwarninglightdoesnotgooutinnormaltimestoptheengineandinvestigate.Lookundertheengineforoilleaksassoonastheoilwarninglightgoesout.


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Worksheet17:Removeandreplaceoilfilters,oilcoolersandturbochargers

ProcedureAllowenginetostandandcooldownbeforestartingwork.Componentscan

beveryhot.Disconnectbatterygroundlead.

Placeadraintraybelowworkareatocatchoil.Useasmalltray/containertocatchoilimmediatelybelowworkarea.

Manyoilfeedpipesandhosesareheldwithaunionnut.Usetwospanners,onetoholdthepipeorhoseorconnectorandtheothertoundotheunionnut.Undothehighestpointfirsttoallowthepipe/hosetodrainbeforeremoval.

Undothelowestpointandcatchlostoilandwithdrawthepipe/hose.Avoidbendingordistortingpipes.

Draincoolantfromcoolingsystemtooilcircuitheatexchangersanddisconnecthoses.Undosecuringboltsonalltypesofoilcoolers/heatexchangersandremove.

Refitoilcoolers/heatexchangers,refitandtightensecuringbolts.

Refitpipes/hosesbyassemblingbothendsbeforetightening.Checkthe


alignmentandroutingofthepipe/hosebeforetighteningtheunionnuts.Usetwospanners,onetoholdthepipe,hoseorconnectorandtheothertodouptheunionnut.

Checkandtopupoil(andcoolant)level.

Runengineandcheckforoil(coolant)leaks.


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Worksheet18:Removeandreplaceoilpressureswitchandoilpressuregaugesenderunits

ProcedureAllowenginetostandandcooldownbeforestartingwork.Componentscan

beveryhot.Disconnectbatterygroundlead.

Placeadraintraybelowworkareatocatchoil.Useasmalltray/containertocatchoilimmediatelybelowworkarea.

Disconnecttheelectricalfeedtotheoilpressureswitchorelectronicsensor.Undotheswitchusingaspanneronthehexagonattheendofthethreadedinserttotheoilgallery.

Carryoutapressuretestiflowoilpressureissuspected.Thistestswouldbesensiblebutnotrequirediftheoilswitchwerebeingreplacedbecauseofleakage.

Refitbyscrewinginthenewswitchorsensoruntilitistightinthetaperedthreadortightonanewsealingwasher.

Reconnectthebatteryandruntheenginetochecktheoperationofthewarninglightorpressuregauge.Checktheswitchforoilleaks.

Checkandtopupoillevel.


Theoillevelsensorwillbelocatedintheengineblockorsump.Lookupandfollowthemanufacturer’sinstructionsforthistask.


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Worksheet19:Inspectcoolingsystem,pressuretest,checkcoolantconditionandantifreeze

ProcedureObtainasuitablecoolingsystempressuretesterandanethyleneglycol

coolanthydrometer.Removetheradiatororexpansiontankcap.Checkthecoolantforlevel,colourandcontaminationsuchasoilorrustanddirt.

Checktheethyleneglycolcontentwiththehydrometer–adjustfortemperature–andcomparewithmanufacturer’sspecifications(usuallybetween25%and50%dependingontheareaofvehicleoperation).

Topupthecoolantifnecessaryandattachthepressuretesterusingasuitableadapterinthefillerneck.

Applyapressureequaltothesystemoperatingpressure,whichisshownontheradiatorfillercap–butshouldbecheckedfromthemanufacturer’sdata.Donotexceedthestatedpressure.Observethereadingonthetesterpressuregauge–itshouldremainstable.Ifthegaugereadingdrops,lookforagoodconnectiontothesystemandthenforleaksinthesystem.

Lookatallhoses,pipes,joints,gaskets,thewaterpump,theheaterandwatervalveforexternalleaks.Lookinsidethevehicleundertheheaterforleaksfromtheheatermatrix.Ifnoexternalleaksarevisible,checkthecoolant


foroilcontamination(possibleinternalleaks.)Applyapressureofabouthalftheoperatingpressureandruntheengine.Lookforarapidpressurerise,whichwouldindicateacylinderheadgasketleakorcrackbetweenthecylinderorcylinderheadandthewaterjacket.

Ifthepressureremainsstablebutinternalleakageissuspected,useacombustiongasdetectorkitwiththepressuretester.Ifthetestfluidchangescolourduringthetest,combustiongaseshavebeendetectedinthecoolantconfirminganinternalleak.

Fittheradiator/expansiontankpressurecaptothetesterusinganappropriateadapterandcheckthattheoperatingpressureisheldatthespecifiedvalue.Removethecapandcheckthevacuumvalvesealoperationandcondition.Compareallfindingswithmanufacturer’sdata.Reportfaultsfound.


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Worksheet20:Removeandreplacedrivebeltsandpulleys

ProcedureDisconnectbatteryearthorgroundlead.Identifythedrivebeltforthewater

pump–V,serpentineortoothedbeltforthecamshaftdrive.

Forwaterpumpsdrivenbythecamshaftdrivetoothedbelt,followthemanufacturer’sinstructionstoaccessthebelt.Matchthetimingmarksorfitthelocatingdowelsorpegsandmarkthedirectionofrotationonthebeltbeforeremoving.

Fortimedandnon-timedbelts,slackenthetensionerandremovethebelt.Thetensionermaybeatensioningpulleyormaybelinkedtoacomponentsuchasthealternator.Removeanyothercomponentthatpreventsremovalofthebelt.Liftoffandremovethebelt.

Fitthenewbeltandadjustthetensiontothemanufacturer’sspecification.Forveebeltsthecorrecttensionisusuallyabout13mmor½inchoffreeplayonthelongestside.Fortoothedbeltsuseatensiongaugeoradjustsothatthebeltcanbetwistedthrough90°onthelongside.

Tightenthetensionersecuringbolts.Refitothercomponentsinreverseorder.Runtheengineandcheckforabnormalnoises.Awhinewouldindicate


thatthebelttensionistootightandaslappingnoiseofthebeltagainstthecoverindicatesthatthebeltistooloose.


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Worksheet21:Removeandreplaceradiatorandelectricfanmotorandswitches

ProcedureDisconnectbatteryearthorgroundlead.Drainradiatorcoolantintoaclean

draintray.Undoandremovetop,bottomandexpansiontankhoseclipsandpulloffhoses.Disconnecttheelectricalterminalblocktothemotorandswitch.Leavethecowl,motorandswitchinplace.Removetheradiatorandcowlasanassembly.

Forradiatorswithintegraltransmissionoilcooling,clampthefeedandreturnhoses,undothehoseclipsandpulloffthehoses.Catchthelostoilinacleandraintray.Orundotheunionnutsonsteelpipesandremovethepipes.Catchthelostoilinadraintray.

Forradiatorswithanairconditioningradiatororcondenserattachedtothecoolingradiator,undotheattachingscrewsandsupportthecondenser.Donotundotheairconditionerrefrigerantpipesunlessthesystemhasbeendischarged(specialistoperation).

Undoandremovetheradiatorsecuringboltsandremovewiththebrackets.Carefullyliftouttheradiatorassembly.Detachthecowl,motorandfanfromtheradiator.Markallboltsorscrewsforreplacementinexactlythe


sameplaces.Unscrewtheswitchfromtheradiator.

Reassembleinthereverseorder.Ensurethatthecorrectboltsorscrewsarereplacedintheiroriginalpositions.Someboltsmaybelongerthanothersandcanpuncturetheradiatoriffittedincorrectly.

Refillthecoolingsystem.Topupwithacorrectwaterandantifreezemixturetomakegoodanyspiltorlostcoolantduringdraining.Runtheengineandbleedairfromthesystemifnecessary.

Roadtestandchecktheenginetemperaturegauge,theheateroperationforhot,coldandintermediatesettings.Checkairflowtemperatureagreeswithheatersettings.

Afterroadtesting,visuallyrecheckthesystemforleaks.

Allowtheenginetocoolandcheckthecoolantlevel.Topupifnecessary.Donotoverfill.


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Worksheet22:Removeandreplacewaterpumpandenginedrivenfan

ProcedureDisconnectbatteryearthorgroundlead.Drainthecoolantintoacleandrain

tray.Identifythelocationofthewaterpumpanddrivebeltarrangement.Forwaterpumpsdrivenbythecamshaftdrivetoothedbelt,followthemanufacturer’sinstructionstoaccessthebelt.Matchthetimingmarksorfitthelocatingdowelsorpegsandmarkthedirectionofrotationonthebeltbeforeremoving.Forengine-drivenfansattachedtothewaterpumpdrivepulley,undothesecuringboltsandpulloffthefan.Forsomethermostaticviscousfansthehubwillhavetobedrawnfromthespindleafterthewaterpumphasbeenremoved.

Fortimedandnon-timedbelts,slackenthetensionerandremovethebelt.Thetensionermaybeatensioningpulleyormaybelinkedtoacomponentsuchasthealternator.Removeanyothercomponentthatpreventsremovalofthebelt.Liftoffandremovethebelt.Undoandremovethesecuringboltsforthewaterpump.Keepinordersothattheyarereturnedtotheiroriginalpositions–manyvehicleshavedifferentlengthboltsaroundthewaterpump.Easeoutthewaterpump.Theycanbetightwhencorrosionhasbondedthepumpintotheengineblock.Usea


penetratingfluidandleveroutortwistcarefullytoreleasethetightness.Ifverytight,checkthatallboltshavebeenremoved!

Checkthegasketforsignsofleakage.Whereboltsrunintothewaterjacket,checkthatthethreadsarecleanandthattheboltsrunfreely.Cleanthreadsifnecessary.Cleanandcheckthatthematingfacesareingoodcondition.Refitthepumpusinganewgasketorsealandasoftsettingsealantonthegasketandallboltsthatrunintothewaterpassages.Tightenboltstomanufacturer’sspecifications.

Refitthedrivebeltandadjustthetensiontothemanufacturer’sspecification.ForVbeltsthecorrecttensionisusuallyabout13mmor½inchoffreeplayonthelongestside.Fortoothedbeltsuseatensiongaugeoradjustsothatthebeltcanbetwistedthrough90°onthelongside.Refillthecoolingsystem.Topupwithacorrectwaterandantifreezemixturetomakegoodanyspiltorlostcoolantduringdraining.Runtheengineandbleedairfromthesystemifnecessary.

Roadtestandchecktheenginetemperaturegauge,theheateroperationforhot,coldandintermediatesettings.Checkairflowtemperatureagreeswithheatersettings.

Afterroadtesting,visuallyrecheckthesystemforleaks.

Allowtheenginetocoolandcheckthecoolantlevel.Topupifnecessary.Donotoverfill.


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Worksheet23:Inspect,cleanorrenewandgapsparkplugs

ProcedureCheckage/mileageofsparkplugsfromcustomerrecords.Check

manufacturer’sdataforcorrectplugsforvehicle.

Checksecurityofsparkplugleadsduringdisconnection–noteandrectifyanylooseconnections.Useanappropriatedeepsockettoremovethesparkplugs.Noteanytightthreadsandrectifybeforereassembly.Layoutplugsinorderfordiagnosisofplugorenginecondition.

Inspectplugsforcondition–erosionofelectrodes,carbonfouling,damagedinsulation,threadconditionandtightnessofthreadedterminals.Checksealingwasherortaperseatcondition.

Lookalsoforsymptomsofengineorfuelsystemfaults.Blacksootydepositsindicatearichfuelmixture,blackoilydepositsindicatepistonringorinletvalvestemwear,white/brownsootydepositsindicateaweakmixtureandoverheating.Investigatefaultsfound,replaceplugs.

Plugsingoodconditioncanbecleanedandre-gappedwithafeelergauge.Allneworreplacedplugsshouldbegappedtothemanufacturer’sspecificationbeforefitting.


Adjusttheearth/groundelectrodetogiveagapbetweenthecentreandearth/groundelectrodes.Donotexertaforceonthecentreelectrode,eitherleveroutwithasuitabletooltoincreasethegaportapinonasolidobjecttoreducethegap.Checkwithafeelerorgapgauge.

Lubricatethethreadsofplugsbeingfittedintoaluminiumcylinderheads(graphiteorhigh-meltingpointgreaseasspecifiedbythemanufacturer).Fitintocylinderheadandhandtightenbeforefinallytighteningwithatorquewrench.Ensurecorrecttorqueforwasherortaperseattypes.

Reconnectleadsandchecksecurity–leadsmustbetightandmakeagoodelectricalconnection.

Runengine/roadtestandcheckforcorrectoperation.


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Worksheet24:Removeandreplacecoil,primaryandsecondarycircuitcomponents

ProcedureDisconnectbatterygroundlead.Identifytypeofignitionsystem.

Labelanddisconnectcablestocoil,primaryandsecondarycircuitcomponents.Undoandremovecoilsecuringscrewsandremovecoil.Inspectcoilinsulationandterminalsforcondition.Whenreplacingacoilalwayscheckthatthecorrecttypeistobefitted.Checkpolarity,voltsandohms.

Identifyprimarycircuitcablesandcomponents–ballastresistor,startersolenoidleads,cables,switches,etc.Replaceasperthemanufacturer’sinstructions.

Identifysecondarycircuitwiresandcomponents,pulloutterminalconnectorsandundosecuringscrewsorclipsandremovecomponents,distributorcap,rotor,plugwiresandplugs.

Inspectandtestcomponents.Replaceinreverseorder,reconnectbatterygroundlead,runengineandcheckforcorrectoperation.


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Worksheet25:Replaceand/orcleanfuelfilters

ProcedureForgasolinefuelsystems,disconnectthebatteryearthlead.Depressurizefuel

systemifnecessary.Applyvacuumtopressureregulatororcoverwithragandundoafuelsupplyunion.

Forgasolinefilterelementsinfuelpumpsandcarburettorinlets,removethecover,catchspiltfuel,cleanoutsedimentchamberandwatertrapandcleanwithairline,cleanfilterwithairline.Checksealandreplaceifnecessary.Refitfilterandcover,andtightensecuringscrews.

Forinlinefilters,eitherdisconnectthefuellineabovethetankorpinchaflexiblehosewithabrakepipeclampbeforeremovingthefilterinordertopreventfueldraining.Removethepipesorhosesoneachendofthefilter,fitnewfilterobservingthedirectionofflowarrowonthefilter.

Forcanistertypefilters,undothecanisterbodywithastrapwrenchorbyhand.Draincanisterfromdrainvalveintoasuitablesmalldraintray.Undovalveandunscrewthefilterbodytoprovideanairgap.Allowtodrainbeforedoingupthedrainvalvepriortoremoval.

Forreplaceablefiltersinacanisterbowl,undothesecuringscrewandlowerthebowl,catchthespiltfuelinadraintray.


Cleanoutthebowl–checkthatthespringandplateareinposition–replacethesealingringsandfilter,fitinpositionandlooselytightensecuringscrew.Twistthebowltoseatthesealingringsandthenfinallytightenthesecuringscrew.

Runengineandcheckforcorrectoperation.


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Worksheet26:Removeandreplacemultipointinjectioncomponents

ProcedureDisconnectthebatterygroundlead.Ensureaverycleanworkenvironment.

Cleanpartsbeforeremoval.

Thefuelsupplycomponentsareanelectricrotaryfuelpumpfittedinsidethefueltank,aninlinefilter,thefuelpressureregulatorandtheinjectorvalvesonthefuelrailovertheinletmanifold,andthefuelsupplyandreturnpipesandhoses.

Identifythelocationoffuelsupplycomponentsanddisconnectandcaporplugfuelpipes/hosestopreventlossoffuelandtokeepclean.Undosecuringdevices/clamps/screwsandundounionnutsonpipestoremovecomponents.Inspect.

Thefuelrail,pressureregulatorandinjectorscanberemovedasasingleunitandcanbestrippedforcleaningandreplacementofparts.Followmanufacturer’sinstructions.

Airsupplycomponentsaretheairboxandaircleanerhousingandfilterelement,ducting,theairtemperaturesensorandcontrolflap,theairflowsensor,thethrottlebodyassemblyandtheinletmanifold.


Identifythelocationoftheairsupplycomponentsanddisconnectducting,securingscrewsandbrackets,electricalterminalblocks,etc.andremovecomponents.Inspect.

Theelectroniccomponentsarethecontrolrelayinthemainfusebox,theelectroniccontrolunit(ECU/ECM),sensorsforairchargetemperature,massairflowmeter,enginetemperature,throttlevalveswitchforthrottlepositions,exhaustoxygen/lambda,andothers(seemanuals).

Theactuatorsincludetheinjectors,auxiliaryairvalveoridlespeedcontrolvalve,andthecontroldevicesforemissioncontrolsystems.

Identifythelocationoftheelectroniccomponentsandremoveandreplaceinaccordancewiththemanufacturer’sinstructions.Inspectcomponents.

Afterreassemblyrunengine,checkforfuelleaksandcarryoutbasicidleandmixture(gasanalysis)adjustments.


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Worksheet27:RemoveandreplaceelectronicsensorsandECUs

ProcedureFollowthemanufacturer’stechnicaldataforthecorrectproceduresto

identifyremoveandreplaceignitionsystemandassociatedsystemssensors.

Manysensorsareheldinplacewithoneortwoscrews/bolts.Othersarethreadedandscrewdirectlyintotheengine,airintakeduct,exhaustmanifold,etc.Disconnectcableterminationblocks,undoandremovesensors.

LocateECUanddisconnectmaincableterminalblock.UndoandremovesecuringscrewsandremoveECU.Inspectterminalsocketsandpins.

Refitinreverseorder.Usesealantonsensorthreadsifspecified.Checkforthecorrectfittingofspacers,alignments,airgapsandpositionsaspermanufacturer’sspecifications.Takecarewhenreconnectingtoprotectterminalsocketsandpinsfromdamage.

Checkcorrectoperationofsensorsusingagraphingmultimeter(GMM),digitalstorageoscilloscope(DSO)orscantool.Compareresultstomanufacturer’sspecifications.


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Worksheet28:Removeandreplacefuelinjectionairsupplycomponents

ProcedureDisconnectthebatteryground/earthlead.Identifythetypeoffuelinjection

systemanddepressurizeinaccordancewiththemanufacturer’sinstructions.Applyavacuumtothepressureregulator.

Undothesecuringscrews/clipsontheairintakeducting,aircleanerandresonators.Removecomponentsandinspectforcondition,cleanlinessandsealingatthejoints.

Labelanddisconnectthevacuumpipes/hosesandtheelectricalterminalblockstotheairflowmeter,throttlebody,auxiliaryairvalve,coldstartvalveandfuelinjectors.Undoandremovethethrottlecableandcruisecontrollinkages.

Undoandremovethesecuringscrewsfortheairflowmeterandthethrottlebodyandtheductinginbetween.Removecomponentsandinspect.

Undoorunclipthesecuringdevicesforthefuelrail/pipesandfuelinjectorsandremove.Inspectsealing‘O’rings.Check,cleanandtestinjectorsbeforereplacement.


Undoandremovetheplenumchamberandinletmanifoldsecuringboltsandpulloffcomponents,inspectforconditionandflatnessofgasketfacesandsealingringgroovesandmatchingbores.

Reassembleinreverseorderusingnewgasketsandsealingrings–lubricategasketsandsealswithlithium-basedgreasetoaidfittingandsealing.Checkonreassemblyforcorrectpositioningandsealingofcomponents.

Reconnectvacuumpipes/hoses,cablesandelectricalterminalblocks.Checkthrottlecableadjustmentforspecifiedfreeplayatidleandthrottlefullyopenedatthewideopenthrottleposition.

Runengineandcheckforcorrectoperation.Listenforunevenrunning,flatspotsandhesitation.Carryoutexhaustgasanalysisandadjustwhennecessary.


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Worksheet29:Inspectfuelsystemforleaksandconditionofpipesandhoses,etc.

ProcedureThisisavisualinspectionandcheckforfuelodourunderthevehicleandin

theenginecompartment.

Raisethevehicleontoaxlestandsoravehiclehoist.Openthebonnet.Followthefuellinesfromthetanktothecarburettoroffuelinjectioncomponents.Lookcarefullyatallpipesandhoses.

Lookfromthefillernecktothetank,atthetank,andthefeedandreturnpipes.

Lookforwashedareas,stainsandfuelodourandanyothersignsofleakage.Checkfordamage,routingandchaffing.Lookforcorrosion,perishing,leaksatjointsandsecurityofhoseclipsandpipesecuringclips.

Lookatthefueltanksecurity,andforleaksfromthefuelgaugesenderunitgasketandoutletpipe.

Inspectthevapourlines,vapourtrapandthefillercapfitandconditionofthesealingring.Moderntanksholdasmallpressureorvacuumundersomeconditions.Thereisoftenarushofairasthefillercapisremoved–


thisisnormal.

Reportanydefectsfound.


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Worksheet30:Removeandreplaceallpartsofcatalystexhaustsystemincludinglambda/heatedexhaustgasoxygen(HEGO)sensor

ProcedureThistaskissimilartothereplacementofanon-catalystsystembutwith

additionalitemsofthesensors,catalyticconverterandheatshields.

Theconvertercanusuallyberemovedfromthesystembyundoingtheballjointorflangejointboltsateachendandthemountingbracketboltsandthenloweringthecatalystoutofthesystem.Becarefultoprovidefullsupportforthecatalyst.Inspectforconditioninsideandout.

Toremovethelambda/HEGOsensors,disconnecttheterminalblockanduseasuitablespannerorspecialtool(seemanufacturer’sdata)tounscrewthesensor.Undothesecuringscrewsforheatshieldsandlowerthemfromtheirmountingbrackets.Checkfordamageorcorrosiontotheheatshieldsandthesupportingbrackets.

Refitheatshieldsinreverseorderensuringthecorrectclearancebetweentheheatshieldandthevehiclefloor.Refitsensorswithanewsealingwasher/gasketifrequiredandtightentothespecifiedtorque.Reconnecttheelectricalterminalblock.


Refitthecatalyticconverterusingnewgasketsorsealingcompound(seemanufacturer’sdata).Refitthemountingbracketandhangersandchecktheairgapbetweentheconverterandtheheatshieldandtheheatshieldandbody(veryimportant).

Refitandalignallexhaustsystemwithnewclampsandmountings/hangersandtightenclampbolts.Checkthattheexhaustisclearofthebody,steeringandsuspensioncomponentsandbrakepipesandanyothercomponents.Checkforsuspensiontravelbutjudginglowestsuspensionposition.

Runtheengineandcheckforleaks.Carryoutanexhaustgasanalysistoensurecorrectoperationofthelambda/HEGOsensorsandthecatalyticconverter.


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Worksheet31:Checkoperationofpositivecrankcaseventilationsystem

ProcedureObtaindriverinformationonoilandfuelconsumption.Botharelikelytobe

highifthesystemisblocked.

RunengineandlookforblueexhaustsmokeandsmokeleakagefromPCVpipesandhoses.ExhaustsmokeandenginesmokecanindicateablockedPCVsystem.Inspecttheaircleanerelementforoilcontamination.Ifcontaminatedcheckoilseparator.

IdentifyPCVsystemtype(valveorrestrictedorificeintoinletmanifold).Visuallyinspectallpipesandhosesforcondition,blockage,fitontoconnectors(leakage),andoilcontamination–pulloffpipesinturntoassessinternalandexternalcondition.

Cleanorreplacepipes/hosesifrequired.CleanorreplacePCVairintakefilter(integralwithoilfillercaponsomeengines).

PulloutandopenPCVvalve,cleanandcheckoperationorremovevalveandshaketocheckthatthevalveisfree,listenforarattle.Checkthatairflowistowardmanifoldoraircleaner.Or,checkrestrictedorificeintocarburettororinletmanifoldiscleanandclear,blowthroughandlisten.


Cleanoutifnecessary(donotincreasediameterbydrillingclearwithoversizedrill).

Reconnectallpipesandrunengine.Checkforvacuumatfeedintoinletmanifold.Checkforsymptomsofblockedvalveororifice–roughorunevenidle,stallingatlowspeeds,oilleaks,andsmokefromengineoilfillercap.


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Worksheet32:Checkexhaustsystemforcondition,leaks,blockageandsecurity

ProcedureOpenbonnet–runengineandaccelerateengineandlistenforabnormal

noises–exhaustblow,squeal,screech,excessivenoiselevelandthattheenginerevsfreely(possibleblockage).

Allowtheenginetoidle–coverthetailpipeoutletwithaclothpad–listenforexhaustblow.

Inspectunderthebonnetforexhaustmanifoldgasketleaks–lookfortell-taleblackmarkingsfromalooseorbrokenjoint.

Underthevehiclefollowtheexhaustpipesalong–lookatthedown/frontpipetoexhaustmanifoldjointandallthepipetopipeorpipetosilencer/muffler/catalyst/resonator/etc.joints.Lookfortelltaleblackmarkingsfromloose,brokenorbadlysealedjoints.

Lookcloselyattheskinofallpipes,silencers,mufflers,catalysts,resonators,etc.Lookforcorrosion,holesorotherdamageordeterioration.

Lookcloselyatthefitting,security,conditionandpositioningofheatshields.Thesemustbeinplacetoprotectflammablematerialsinsidethevehicle


(sounddeadening,etc.)fromignitionfromthehightemperatureofexhaustsandcatalyticconverters.

Lookcloselyatallexhaustmountingbracketsandrubbermountingcomponents(hangers)forfitting,corrosion,perishing,separation,tension,etc.Onturbochargedenginescheckthedown/frontpipesupportbracketforconditionandsecurity.

Checkthepositionandroutingoftheexhaustforknockingonthebodyorchassisandforfoulingonothercomponentssuchasbrakepipes,steering,suspension,axle,etc.

Ifblockageissuspected,exhaustgasleaksinfrontoftheblockagearelikely.Disconnectapipeatasuitablepositioninfrontoftheblockageandchecktheflowthroughtheremainderofthesystemwithanairlineblower–plugthepipearoundtheblowerwithaclothpad.


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Worksheet33:Removeandreplacesupercharger

ProcedureDisconnectbatterygroundlead.Disconnectandremoveairductingtothe

supercharger.

Dependingonthetypeofsupercharger,identifyaligningmarksonthepulleyand/orgearsandthedirectionofrotationofthedrivebelt.Aligntimingmarksifnecessary,markdirectionofrotationonthedrivebelt,slackenthedrivebelttensionerandremovethebelt.

Undoandremoveoilfeedandreturnpipes.

Undobolts/nutssecuringthesuperchargerandremove.Liftthesuperchargerfromtheadapterormountingplateontheairintaketotheengine.

Replaceinreverseorderusingnewgasketsandtightenbolts/nutstothemanufacturer’sspecifiedtorquesettingsandinsequence(centreoutwards).Refitandadjustthetensionofthedrivebelt(observedirectionofrotation).

Runengineandcheckforcorrectoperationoftheengineandthesupercharger.


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Worksheet34:Removeandreplaceexhaustgasrecirculation(EGR)components

ProcedureDisconnectbatterygroundlead.IdentifythetypeandlocationoftheEGR

componentsfromavehicleworkshopmanual.

Forvacuum-controlledEGRsystems,labelanddisconnectthevacuumandelectricalconnectionsatthevacuumcontrolsolenoidvalve.Undothesecuringscrewsandremovethesolenoidvalve.

LabelandremovethevacuumandelectricalterminalsfromtheEGRvalveandEGRvalvepositionsensor(integralwiththeEGRvalveonclosed-loopsystems).

UndoandremovetheexhaustoutletpipetotheEGRvalveandthefeedpipetotheinletmanifold.UndotheEGRvalveandremove.

Reassembleinreverseorderusingnewgasketsandsealsasnecessary.

ForelectronicEGRvalves,disconnecttheelectricalterminalblockandtheexhaustoutletandinletmanifoldfeedpipes.Removethesecuringdeviceandremovethevalve(therearenoseparatecontrolsolenoidorvacuumpipes).


RunengineandcheckforcorrectoperationoftheengineandEGRsystem.


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Worksheet35:Removeandreplacebattery,batterycablesandsecuringdevices

ProcedureOpenbonnet/bonnettoaccessthebattery.Checkthegeneralconditionon

andaroundthebattery.Fitmemorykeeper(ifavailable).Disconnecttheearthorgroundleadandthenthesupplyleadfromthebattery.

Undoandremovethebatteryretainingstraps,clampsandbracketsandremove.Removeanyobstructionsthatmaypreventthebatterybeingliftedout.Plantheremovalsothatthelift,routeandnewpositionofthebatteryareknownbeforehand.Keepingthebatteryaslevelaspossibleliftupfromthecarrierandliftoutfromthevehicle.Placethebatteryonabenchorothersuitableplace.

Ifitisnecessarytousealiftingtoolonthebattery,ensurethatitiscorrectlylocatedonthebatterycasing,issecureandwillnotcrushorotherwisedamagethebattery.

Beverycarefulnottospillbatteryacid.Ifacidissplitorhasbeenlostfromthebattery,treattheareawithasolutionofbakingsodaandwaterorammoniaandwater(analkalinetoneutralizetheacid).Treatbaremetalandrepaintifnecessary.Removecontaminatedclothingandrinseas


quicklyaspossible.Rinseacidfromskinimmediately.Ifacidburnsareexperienced,seekmedicalattention.

Removeallcablesbyundoingsecuringbolts/nutsorpullingapartattheterminalorterminalblock.Cleanallterminalsandconnectionstoensuregoodcurrentflow.

Reconnectandcheckthetightnessofallpushfitterminals.Coatwithpetroleumjellyorwaterrepellent.

Refitthebattery,andiffittingareplacement,ensurethatthenewbatterymatchestheoldbatteryforcasingdimensions,Ahcapacity,andthetypeandpositionoftheterminalposts.Fitretainingstraps/clampsandtighten.Donotovertightenasbatterydamagecanoccur.

Refitthebatterysupplyleadandtheearthorgroundlead.Coattheterminalswithpetroleumjelly.

Startandruntheengineandcheckthattheenginestartermotoroperatedcorrectlyandthatthegenerator/ignitionwarninglightcameonandwentoutastheenginespeedincreased.Restoreelectronicmemoryfunctionsifmemorykeepernotavailable.


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Worksheet36:Inspectbatteriesforcondition,securityandstateofcharge

ProcedureOpenbonnettoaccessthebattery.Checkthegeneralconditiononand

aroundthebattery.Checkthealternatordrivebeltforconditionandtension.Lookatthebatteryforsignsofleakagefromthecasing.Abuild-upofalightcolouredcorrosivesubstanceindicatesthepresenceofbatteryacid.Lookatthesecuringstrapsandbracketsforsecurityandcondition.Lookatthebatterycablesforcondition,securityandcorrosion.Lookattheearthorgroundleadconnectiontothevehiclebodyforcondition,securityandcorrosion.Makeageneralcheckofallcablestothestarterandalternatorandtheengineearthorgroundlead.

Checktheelectrolytelevelandspecificgravity(relativedensity)withahydrometer.Orcheckthebuilt-inhydrometeronmaintenance-freebatteries.Greendotforcharged,blackforpartiallychargedandyellowforinternalfaultswherethebatteryshouldnotberecharged.Carryoutbatterycapacitytestandconfirmithasacapacityrecommendedbythevehiclemanufacturer.Checkthevoltagewithadigitalvoltmeter.Comparewiththemanufacturer’sspecifications.Conventionalleadacid12voltbatteriesshouldread13to13.2voltswhenfullycharged.Maintenance-


free12voltbatteriesshouldread12.8voltswhenfullycharged.

Carryoutahighratedischargetestonlyonafullychargedbattery.Connectthetesterfollowingthemanufacturer’sinstructions.Observepolarity.Setamperageto3xbatteryAhrate.Carryouttestfollowingtheequipmentmanufacturer’sinstructions.Donotexceedtesttime.Conventionalbatteriescanbe‘fastcharged’usingahighoutput(amps)fastcharger.Connectandchargeatthecurrent(amps)andtimespecifiedbythefastchargermanufacturer.Disconnectthebatteryleadsbeforeconnectingtothefastcharger.

Donotallowthebatterytooverheat.Usethetemperatureprobeiffittedtothecharger.Donotfastchargemaintenance-freebatteriesunlesspermittedbythemanufacturer.Slow(lowcurrent–amps)chargingofconventionalleadacidandmaintenance-freebatteriescanbecarriedoutsingularlyortwoormoreofasimilartypeandatasimilarstateofchargecanbeconnectedtogether.

Connectasinglebatterytoachargerobservingthepolarityofthechargerandthebattery.Red(+)topositive,black(−)tonegative.Setthechargerto1/10thofthebatteryAh(amphour–10hourrating)andchargefor15hoursforafullydischargedbattery.Formultiplebatterycharging,connectbatteriesinparallelfora12voltcharger.For24voltchargers,connecttwo12voltbatteriesinseries.Fourbatteriesareconnectedinseriesandparallel.SetthechargerateaccordingtothenumberandAhratingsofthebatteries.


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Worksheet37:Removeandreplacealternatorstripandreplacebrushes,regulatoranddiodepack

ProcedureDisconnectthebatteryearthorgroundlead.Unplugthemulti-socketonthe

rearofthealternatororlabelanddisconnectthecables.Slackenthealternatorsecuringbolts,includingthedrivebeltadjusterstrapbolts.Markthedirectionofrotationonthebelt.Slackenthedrivebelttensionandremovethebelt.Inspectthedrivebeltanddrivepulleysforsignsofwear,damageandslipping(glazingonsides).

Holdthealternatorsecureandremovethesecuringbolts.Liftoutthealternator.Checkthespindlebearingsbyrotatingandlisteningandfeelingforunevenandlumpymovement.Checkthealternatorcasingfordamage.Toremovethepulley,holdthespindlewithakeyorwrenchandawrenchonthepulleysecuringnut.Ifthespindlecannotbeheld,fitanoldbeltaroundthepulleyandholdthebeltinaviceandthenturnthepulleysecuringnutwithawrench.Pulloffthepulley.Useapullerifnecessary.Liftoutthewoodruffkeyifthecasingistobeseparated.Thebrushesareusuallyintegralwiththeregulatoronmodernalternators.Undothesecuringscrewsontherearofthealternatorandliftouttheregulatorandbrushassembly.Inspectthebrushesforlengthand


condition.Inspecttheslipringsontherotor.Removetherearcover.Undoandremovethethroughboltsholdingthecasinghalves.Carefullyseparatethecasingmakingsurethatthestatorremainsintherearcasingandattachedtothediodepack.Pullouttherotorfrominsidethestator.

Removethecirclipsretainingthebearings,ineachcasinghalfandgentlytapoutthebearings.Checkthatthebearingshavenotbeenspinninginthecasing.Fitnewbearingsandpackwithgrease.Fitnewcirclipsandseals.Pre-packedandintegralsealbearingsaresometimesused.Whereadiodepackisavailableasareplacement,partundotheretainingscrewsholdingthediodepacktotherearcasingandunsoldertheolddiodeswheretheyattachtothestator.Re-solderthenewdiodesusingaheatsinksuchasapairofplierstopreventheatdamagetothediodes.

Reassemblethealternatorinthereverseorder.Spinbeforerefittingtocheckforabnormalnoises.Carryoutabenchtestiftheequipmentisavailable.Refitinthereverseorderandadjustthedrivebelttension.Runtheengineandcheckthatthegenerator/ignitionwarninglightcomesonandthengoesoutastheenginespeedincreases.Connectadigitalvoltmeterandclamponammeterandcheckthatthealternatoroutputiscorrect.Comparewithmanufacturer’sdata.


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Worksheet38:Removeandreplacealternatorcircuitcables/components

ProcedureDisconnectthebatteryearthorgroundlead.

Apartfromthealternator,themaincomponentsarethealternatoroutputcabletothebattery,thebatteryfeedtotheignitionswitch,theignitionswitch,generatorwarninglightandthefeedtothefieldterminalonthealternator.

Followthemanufacturer’sinstructionsforreplacementoftheignitionswitchandthefasciaforaccesstothewarninglightbulbandprintedcircuitboardontherearoftheinstrumentpanel.Inspecttheprintedcircuit,bulbholderandinstrumentsmulti-sockettermination.

Labelandremovecables.

Reassembleinreverseorder.Runtheengineandchecktheoperationofthealternatorandchargecircuit.

Ifreplacinganoldtypegeneratorofadynamotype,itisimportantthatthefieldcoilsarepolarized.Takealivefeedwithajumpleadfromthebatteryfeedterminaldirectlytothefieldcoilterminalafterreconnectingthe


batteryleadsbutbeforeconnectingthefieldterminal.Holdincontactfor30seconds.


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Worksheet39:Removeandreplacepre-engagedstartermotorandreplacesolenoid

ProcedureChecktheconditionofthebatteryandtheoperationofthestartermotor

beforeremoval.Disconnectthebatteryearthorgroundlead.Labelanddisconnectthecablesonthesolenoid–solenoidfeedfromthestarterswitchandLTignitionfeedtobypasstheballastresistor.Disconnectthemainsupplyfeedcabletothestarterateitherend(mostconvenient).Removeanycomponentsthatrestrictremovalofthestartermotor.Undothestartermotorsecuringbolts.(Socketwrenchesandextensionsareusefultogainaccessbetweenthestartermotorbodyandtheengineblock).Carefullyremovethestartermotor.Inspectthedrivepinion(gear)andtheonewayclutch.Checkthestartermotorcasingandfittingflangefordamage.Checkthestarterringgearontheflywheelthroughtheholewherethestartermotorfits.Turntheengineatleastonefullrevolution.

Checkallgearteethforchippedorworndownsectionsbothonindividualteethandaroundthefullcircumferenceofthegear.Unevenwearinoneplaceisafrequentdefect.Lookattheteethforwearmarksthatshowthatthestarterpinionhasbeenfullyinmesh.Tostripthemotor,fitintoabenchviceandsecure.Toremovethesolenoid,undothefeedcableinto


themotorandpullbackoutoftheway.Undotheretainingscrewsinthecasing.Carefullypulloutthesolenoiddisconnectingtheplungerfromthepiniongearengagementlever.Tostripthemotor,removethethroughboltsandtherearcoverandbrushes.Thebrushesmaybeavailableasreplacementparts.Followthemanufacturer’sinstructionsforreplacement.Cleanandinspectthecommutator,armatureandspindlebearings.Pullthepinioncasing,pinion,engagementleverandarmaturefromthemaincasingandfieldcoils.Followthemanufacturer’sinstructionsforreplacingthedrivepinionandone-wayclutch.

Reassembleinreverseorder.Carryoutabenchtestwiththestartersecurelyheldinabenchvice.Connectabatterywithjumpleadstothestarter.Negativecabletothebatterynegativeandthestartercasing.Positiveleadonlytothebatterypositiveandthenkeeptheleadclearuntiltesting.Avoidanyconnectionofthepositiveleadtothestartercasing,viceorbench.Testthesolenoidoperationbytouchingtheleadtothesolenoidterminal,whichshouldclick,andthepinionmovealongthespindletotheengagedposition.Thespindlemayslowlyrevolveonsomemotors.

Testthemotoroperationbytouchingtheleadtothemotorterminal.Themotorshouldrunatfullspeed.Connecttheleadtothesolenoidinputterminal.Thesolenoidshouldnotoperateandthemotorshouldnotrun.Useajumpleadtoconnectafeedtothesolenoidlowcurrentterminal.Thesolenoidshouldoperateandthemotorshouldrun.Refitthestartermotortotheengineandchecktheoperation.


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ChassisWorksheet40:Removeandrefitfrontsuspensionstrutandspring

ProcedureRemoval.Applythehandbrake,jackupthefrontofthecarandsupporton

stands.Removetheroadwheel.Topreventthelowerarmassemblyhangingdownwhilstthestrutisremoved,screwawheelboltintothehub,thenwrapapieceofwirearoundtheboltandtieittothecarbody.Thiswillsupporttheweightofthehubassembly.Unclipthebrakehoseandwiringharnessfromanyclipsonthebaseofthestrut.Slackenandremovethelowerboltssecuringthesuspensionstruttothesteeringknuckle.Fromwithintheenginecompartment,unscrewthestrutuppermountingnutsandthencarefullylowerthestrutassemblyoutfromunderneaththewing.

Overhaul.Warning:beforedismantlingthefrontsuspensionstrut,aspecialtooltoholdthecoilspringincompressionmustbeobtained.Anyattempttodismantlethestrutwithoutsuchatoolislikelytoresultindamageand/orinjury.Withthestrutremovedfromthecar,cleanawayallexternaldirtandthenmountituprightinavice.Fitthespringcompressor,andcompressthecoilspringuntilalltensionisrelievedfromtheupperspringseat.Removethecapfromthetopofthestruttogainaccesstothestrutuppermountingretainingnut.Slackenthenutwhilstholdingthestrutpiston.

Removethemountingnutandwasher,andliftofftherubbermountingplate.Removethegasketanddishedwasherfollowedbytheupperspringplateandupperspringseat.Liftoffthecoilspringandremovethelowerspringseat.Examineallthecomponentsforwear,damageordeformation,andchecktheuppermountingbearingforsmoothnessofoperation.Renewasnecessary.

Examinethestrutforsignsoffluidleakage.Checkthestrutpistonforsignsofpittingalongitsentirelength,andcheckthestrutbodyforsignsofdamage.Whileholdingitinanuprightposition,testtheoperationofthestrutbymovingthepistonthroughafullstroke,andthenthroughshortstrokes(50to100mm).Inbothcases,theresistancefeltshouldbesmooth


andcontinuous.Renewiftheresistanceisjerky,unevenorifthereisanyvisiblesignofwearordamage.Ifanydoubtexistsabouttheconditionofthecoilspring,carefullyremovethespringcompressors,andcheckthespringfordistortionandsignsofcracking.Renewthespringifitisdamaged.

Fitthespringseatandcoilspringontothestrut,makingsurethespringendiscorrectlylocatedagainstthestrutstop.Fittheupperspringplate,aligningitsstopwiththatoftheseat,andfitthedishedwasherandgasketfollowedbytheuppermountingplate.Locatethewasheronthestrutpiston,thenfitthemountingplatenutandtightenittothespecifiedtorque.Refitallinreverseorder.


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Worksheet41:Removeandrefitrearsuspensionspring

ProcedureNote:proceduresvarysocheckthemanufacturer’sdatabeforestartingwork.

Removal:

•Chockthefrontwheels,jackuptherearofthecarandsupportonstands.Removetheroadwheel.Ifnecessary,removetheboltsandplatessecuringthedriveshafttothefinaldriveunitflange.Freethedriveshaftandsupportitbytyingittothecarunderbodyusingapieceofwire.

•Positionajackunderneaththerearofthetrailingarm,andsupporttheweightofthearm.

•Slackenandremovethedamper/shockabsorberlowermountingbolt.

•Slowlylowerthetrailingarm.Keepaneyeonthebrakepipe/hosetoensurenoexcessstrainisplacedonit,untilitispossibletowithdrawthecoilspring.Removethespringseats.

•Inspectthespringcloselyforsignsofdamage,suchascracking,andcheckthespringseatsforsignsofwear.


•Renewworncomponentsasnecessary.

Refitting:

•Fittheupperandlowerspringseats,makingsuretheyarecorrectlylocated.

•Engagethespringwithitsupperseat.

•Holdthespringinpositionandcarefullyraisethetrailingarmwhilstaligningthecoilspringwithitslowerseat.

•Raisethearmfullyandrefitthedamper/shockabsorberlowermountingbolt,tighteningittothecorrecttorque.

•Ifremoved,connectthedriveshafttothefinaldriveunit.

•Refittheroadwheelthenlowerthecartotheground.Tightenthewheelboltstothespecifiedtorque.


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Worksheet42:Remove,inspectandreplacelowersuspensionarm,bushesandballjoint

ProcedureRemove:

•Disconnectthebattery,applythehandbrakeandslackentheroadwheelnuts.Raisethefrontofthevehicle,supportitonaxlestandsandremovethefrontwheels.

•Removestabilizerandtiebarattachmentstothelowerarm.Usingballjointsplitter,disconnecttrackrodendfromsteeringarm.Placescrewjackunderhubassemblyandslightlycompressspring.

•Removeupperandlowershockabsorbermountingsandremoveshockabsorber.

•Fitspringcompressorandcompresscoilspring.Usingballjointsplitter,disconnectlowerarmballjointwhilstsupportinglowerarm.

•Removecoilspringfromvehicleandspringcompressorsfromspring.Removelowerarmpivotboltandlowerarmfromvehicle.

Inspect:


•Inspectlowerarm,springinsulator,bushingandballjoint–replaceasappropriate.

Note:Replacementofbushesandballjointsisonlypossibleonsomevehicles.Refertomanufacturer’sproceduresifpossible.

•Inspectcoilspring.

Refit:

•Refittingisadirectreversaloftheaboveprocedure.

Note:Thespringmustbecompressedtoapproximatelykerbweightpositionbeforerefitting.

•Thenutsonthelowerpivotboltmustbetightenedtothecorrecttorquewhenthevehiclehasbeenloweredontoitswheels.Checkcastorandwheelalignment.Resetifrequired.

Note:Wheelalignmentmustbemeasuredandresetaftercastorhasbeenadjusted.


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Worksheet43:Remove,inspectandreplacerearsuspensioncontrolarmandbushes

ProcedureRemove:

•Disconnectthebattery,applythehandbrakeandslackentheroadwheelnuts.Raisethefrontofthevehicle,supportitonaxlestandsandremovethefrontwheels.Removestabilizerattachmentstothelowerarm.Clampflexiblebrakepipeanddisconnectfromconnectoronshockabsorber.

•Positionjackunderlowerarmtotakeweight,removetiebartobodyretentionbolt.Removelowerarmpivotboltandlowershockabsorber/strutconnection.Slowlylowerjackandremovelowerarmandcoilspring.

Inspect:

•Inspectthelowerarmandbushes,springinsulatorandspring.Replaceasnecessary.

Note:Replacementofbushesisonlypossibleonsomevehicles.Refertomanufacturer’sproceduresifpossible.


Refit:

•Repositionlowerarm,springinsulatorandspringonjackandraiseintoposition.Refitlowerarmpivotboltandlowershockabsorber/strutconnection.

Note:Thelowerpivotboltmustbetightenedtothecorrecttorquewhenthevehiclehasbeenloweredontoitswheels.

•Refittiebartobodyretentionmounting,tighteningtothecorrecttorque.Connectflexiblebrakepipe.

•Refitstabilizerattachmentstothelowerarmtighteningtothecorrecttorque.

•Bleedthebrakes.

•Lowerthevehicletotheground.Tightenthelowerpivotbolttothecorrecttorque.Tightenthewheelboltstothecorrecttorque.

•Checkandadjustrearwheelcamber,alignmentandthrustangle.

Note:Itisnotpossibletoadjustrearwheelalignmentonsomevehicles.Itisessentialtofitallwashersandspacersinexactlythesameorderastheywerebeforethecommencementoftherepairoperation.


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Worksheet44:Remove,inspectandreplacerearMcPhersonstrutandspring

ProcedureRemove:

•Disconnectthebattery,applythehandbrakeandslackentheroadwheelnuts.Raisetherearofthevehicle,supportitonaxlestandsandremovethewheels.

•Uncliptheflexiblebrakehoseandwiringharnessfromanyclipsonthebaseofthestrut.

•Positionjackunderlowerarm.Thiswillsupporttheweightofthehubassembly.

•Fromwithintheboot,unscrewthestrutuppermountingnuts.

•Slackenandremovetheboltssecuringthesuspensionstruttothehubassemblyandthencarefullylowerthestrutassemblyoutfromunderneaththewing.

Inspect/overhaul:

•Warning:beforedismantlingthefrontsuspensionstrut,aspecialtoolto


holdthecoilspringincompressionmustbeobtained.Anyattempttodismantlethestrutwithoutsuchatoolislikelytoresultindamageand/orinjury.

•Withthestrutremovedfromthecar,cleanawayallexternaldirtandthenmountituprightinavice.Fitthespringcompressor,andcompressthecoilspringuntilalltensionisrelievedfromtheupperspringseat.

•Removethemountingnutandwasher,andliftofftherubbermountingplate.Removethegasketanddishedwasherfollowedbytheupperspringplateandupperspringseat.Liftoffthecoilspringandremovethelowerspringseat.

•Examineallthecomponentsforwear,damageordeformation.Renewasnecessary.

•Examinethestrutforsignsoffluidleakage.Checkthestrutpistonforsignsofpittingalongitsentirelength,andcheckthestrutbodyforsignsofdamage.Whileholdingitinanuprightposition,testtheoperationofthestrutbymovingthepistonthroughafullstroke,andthenthroughshortstrokes(50to100mm).Inbothcases,theresistancefeltshouldbesmoothandcontinuous.Renewiftheresistanceisjerky,unevenorifthereisanyvisiblesignofwearordamage.

•Ifanydoubtexistsabouttheconditionofthecoilspring,carefullyremovethespringcompressors,andcheckthespringfordistortionandsignsofcracking.Renewthespringifitisdamagedordistorted,orifthereisanydoubtastoitscondition.Inspectallothercomponentsfordamageordeterioration,andrenewanythataresuspect.

•Fitthespringseatandcoilspringontothestrut,makingsurethespringendiscorrectlylocatedagainstthestrutstop.

•Fittheupperspringplate,aligningitsstopwiththatoftheseat,andfitthedishedwasherandgasketfollowedbytheuppermountingplate.Locatethewasheronthestrutpiston,thenfitthemountingplatenutandtightenittothespecifiedtorque.

•Ensurethespringendsandseatsarecorrectlylocated,thencarefullyreleasethecompressorandremoveitfromthestrut.

Refitting:

•Manoeuvrethestrutassemblyintoposition,andfittheuppermountingnuts.


•Refittheboltssecuringthesuspensionstruttothehubassembly.

•Tightenthestrutupperandlowermountingnutstothespecifiedtorque.

•Clipthehose/wiringbackontothestrut,thenrefittheroadwheel.Lowerthecartothegroundandtightenthewheelboltstothecorrecttorque.


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Worksheet45:Removeandreplacepitmanarm,relayrod,idlerarmandsteeringdamper

ProcedureRemoval:

•Disconnectthebattery,applythehandbrakeandslackentheroadwheelnuts.Raisethefrontofthevehicle,supportitonaxlestandsandremovethefrontwheels.

•Disconnecttherelayarmballjointsfromthepitmanarmandidlerarm.Marktherelativepositionofthepitmanarmtotherockershaftandthenremovethepitmanarmusingasuitablepuller.

•Removetheidlerarmandmountings.Removesteeringlinkagedamper/shockabsorber.

Inspect:

•Inspectthesteeringboxsealsforleakage,theballjointsforplayandtheidlerarmbushesforplay.

•Adjustpinionwormbearingpre-loadandsectorlash.

•Examinethesteeringdamperforsignsoffluidleakage.Checkthepiston


forsignsofpittingalongitsentirelength,andcheckthebodyforsignsofdamage.Testtheoperationofthedamper/shockabsorberbymovingthepistonthroughafullstroke,andthenthroughshortstrokes.Inbothcases,theresistancefeltshouldbesmoothandcontinuous.Renewiftheresistanceisjerky,unevenorifthereisanyvisiblesignofwearordamage.

Refit:

•Refittingisadirectreversaloftheremovalprocedure.Allfixingsshouldbetightenedtothemanufacturer’srecommendedtorquesettings.

•Refittheroadwheel.Lowerthecartothegroundandtightenthewheelboltstothecorrecttorque.

•Checkwheelalignment.Resetifnecessary.


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Worksheet46:Remove,overhaulandrefitsteeringrack

ProcedureRemove:

•Disconnectthebattery,applythehandbrakeandslackenthefrontroadwheelnuts.Raisethefrontofthevehicle,supportitonstandsandremovethefrontwheels.Disconnecttheballjointsfromthesteeringlevers.Pullbackthecarpetanddisconnecttheintermediateshaftuniversaljointfromthepinionshaft.Removethesteeringrackmountingbolts,clampplateandplasticseating.Manoeuvretherackandpinionclearofthebody.

•Withdrawthesteeringrackfromthepassenger’sordriver’ssideoftheenginecompartmentasappropriate.Removetherackpinioncoverseal.

Overhaul:

•Removebothballjointsfromthetie-rodsandremovethesealsandclipsfromtheendsoftherackhousing.Holdtherackinasoft-jawedviceandunscrewtheballhousingfromtherack.

•Tightentheballhousingontotherack,tothecorrecttorqueandsecure


bystakingtheedgeoftheballhousingintothegrooveintherack.Replenishanylubricantlost,andfittheracksealsandretainingclips.Screwtheballjointlocknutsontothetie-rodsandscreweachballjointonanequalamount.

Refit:

•Fitthesteeringrackthroughthepassenger’sordriver’ssideoftheenginecompartment.Positionthepinioninthebodyapertureandlooselyfittheboltsonthepinionsideoftherack.Fittheplasticseatingandclamp;fullytightentheclampbolts,tothecorrecttorque.Finally,tightentheboltsonthepinionsideoftheracktothecorrecttorque.

•Centralizetherack.Fitthepinioncoverplate,positionthesteeringwheelinthestraight-aheadpositionandconnecttheuniversaljointtothepinionshaft.Fittheclampbolt.Securethesounddeadeningmaterialaroundthepinionshaftandfitthecarpet.

•Connectthesteeringballpinstothesteeringlevers.Fittheroadwheels,lowerthevehicletotheground,andtightenthewheelnutstothecorrecttorque.Connectthebattery.Checkand,ifnecessary,adjustthefrontwheelalignment.


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Worksheet47:Remove,inspectandrefitPASpump

ProcedureRemoval:

•Removethecapfromthefluidreservoir.

•Usingsuitablewrench,holdtheadaptorandremovethehigh-pressurehose.Disconnectthelow-pressurehoseanddrainthefluidintoacontainer.Blankoffthehosesandpumptopreventtheingressofdustanddirt.Replacethereservoircap.

•Slackenandremovetheadjustmentbolts,situatedunderneaththepump.Removethedrivebelt.Removethetwopivotbolts,withdrawthepumpandbracketfromthevehicle.

Inspect:

•Checkconditionofdrivebelt,pumppulley,pumpmounts,sealsandgaskets,andhosesandfittings.

Refit:

•Fitthepumpassemblytotheenginebracket,feedingthedrivebeltoverthepulley,locateandsecurethetwopivotboltsbutdonotfullytighten.Fittheadjustmentbolts.Checkpulleyalignment.


•Adjustthedrivebelttothecorrecttensionandtightenthepivotnutsandbolts.

•Removetheblankingplugs,connecttheinlethosetotheadaptorandtightentothecorrecttorque.

•Fillthefluidreservoirtothe‘MAX’mark,andfitthefillercap.Donotoverfill.

•Checksystemoperationandcheckforleaks.


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Worksheet48:Removeandrefitwheelbearings

ProcedureFronthubassembly.Applythehandbrakeandslackenthefrontroadwheel

nuts,raisethefrontofthevehicle,supportitonstandsandremovetheroadwheel.Removethedriveshaftnutsplitpin,useanassistanttoapplyfirmpressuretothebrakepedaland,whilethebrakeisapplied,unscrewthedriveshaftnut.Removethebrakecaliperandsupportittopreventstrainingthehose.Removethedisc.Usingaballjointbreakertool,disconnecttheballjointfromthesteeringlever.Unscrewthenutsandremovetheboltstoreleasethestrutfromthehubassembly.Unscrewthenutandremovetheclampbolt,securingthelowerballjointtothehubassemblyand,usingasuitableleverplacedbetweenthelowerarmandtheanti-rollbar,leverdownwardstoreleasetheballjointfromthehub.Removethehubassemblyfromthedriveshaft.

Extracttheinneroilsealandspacerandtheouteroilseal.Driveoutoneofthebearings,invertthehubanddriveouttheremainingbearing.Inspectthebearingsforsignsofwearanddamage,renewasnecessary.Packthebearingswithsuitablegreaseandpressthemintothehub.Fittheoilsealspaceragainsttheinnerbearing.Fittheoilseals.Locatethehubonthedriveshaft,fittheflatwasheranddriveshaftnutandtightenthenut


fingertight.Fitthehubassemblytothelowerballjoint,fittheclampboltandtightenthenut.Fitthehubtothestrut,fittheboltsandtightenthenutstothecorrecttorque.Connecttheballjointtothesteeringleverandfitandtightenthenut.Fitthedisctothedriveflangeandtightenthesecuringscrews.Fitthebrakecaliper.Useanassistanttoapplyfirmpressuretothebrakepedaland,whilethebrakeisapplied,tightenthedriveshaftnuttothecorrecttorque.Lockthenutwithanewsplitpin.

Rearhubassembly.Chockthefrontwheelsandslackentherearwheelnuts,raisetherearofthevehicle,supportitonstandsandremovetheroadwheel.Withdrawthegreaseretainercapfromthecentreofthehubandextractthesplitpinfromthestubshaft.Unscrewthehubnut,removetheflatwasherandwithdrawthehubandbrakedrumassembly.Extractthehuboilseal,drivetheinnerbearingoutandcollectthespacer.Invertthehubandbrakedrumassemblyanddriveouttheouterbearing.Inspectthebearingsforsignsofwearanddamage.

Packthebearingswithsuitablegreaseandpresstheouterbearingintothehubwiththesidemarked‘thrust’facingoutwards.Invertthehub,fitthespacerandpresstheinnerbearing,withthesidemarked‘thrust’outwardsintothehub.Dipthenewoilsealinoilandpressitintothehub(sealinglipfacinginwards).Refitallinreverseorder.


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Worksheet49:Checksteeringcomponents

ProcedureSteeringwheelalignment–roadtest–spokesshouldbealignedwhen

travellingstraightahead.

Columnsecurity–rockupanddown/sidetoside.Checkadjustmentissecure.

Freeplay–movementofwheelwithoutroadwheelsmoving.Normallyshouldbesmall(2.5cm/1inmax.).

Steeringshaftandjoints–sidetosidemovementtestsbearings.RockingmovementtotestUJs.

Rack/boxsecurity–checkmountingboltsandrubbercomponents.

Rackgaiters/boxseals–lookforsplitsandoilleaks.

Balljoints/trackrodends–assteeringwheelisrocked,lookforexcessive‘lift’inthejoints.

Swiveljoints/kingpins–jackandsupportvehicle.Rockwheeltopandbottom.Lookfromtheinsidetocheckmovement.Verylittleifanyshouldbeobserved.


Wheelbearings–asabove.


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Worksheet50:Measureandadjusttracking(toe-in/out),usingopticalgauges

ProcedureCarryoutbasicchecksasdescribedinthe‘Checksteeringcomponents’

worksheet.

Setthearmstothewheelsizeandthenzerothetrackinggaugesbyplacingthetipsofthearmstogether.

Rollthevehiclebackandforthtomakesurethesteeringisnotunderstress.

Positionthegaugestothewheelsandtakeareading.Comparetospecifications.

Ifadjustmentisrequired,checkthepositionofthesteeringwheel.Adjustmentismadebychangingtheoveralllengthofthetrackrod.

Ifthespokesareeven,makeequaladjustmentstoeachendofthetrackrod.

IfthespokesareNOTeven,turnthewheeluntiltheyareandthenmakeadjustmentstoeachendofthetrackrodsuchastobringthewheelstothecorrectposition.

Toadjusttrackrodlength,undothelocknutsandthenturntherod,whichis


threadedintothetrackrodend.

Tightenthelocknutsandcheckthealignmentagain(fromstep3).

Carryoutfurtheradjustmentifrequired–itisquiteusualforaccurateadjustmenttoneedtwoorthreechanges.

Secureallcomponentsandremovegauges.


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Worksheet51:Servicediscbrakesandmeasurebrakediscthicknessandrunout

ProcedureJackupandsupportthevehicleonstandsoruseasuitablehoist.Removethe

appropriatewheels.

Inspectthebrakepads.Recommendationsvaryslightlybutinmostcases,thepadsshouldbereplacediftheliningislessthan1.5mm.Methodsofpadremovalvarysocheckthemanufacturer’sdata.However,mosttypesarequitesimple.Themethoddescribedhererelatestothetypewherepartofthecaliperisremoved.

Turnthesteeringtoalockpositiontoalloweasyaccesstothecaliperandpads.Washthecaliperandpadassemblyusingaproprietarybrakecleanerorsuitableextractor.

Ifnecessary,removesomebrakefluidfromthereservoir.Thisisbecausewhenthepistonispushedbacktoallownewpadstobefitted,fluidcanoverflow.Ifaretainingboltclipisfitted,itshouldberemoved.Undobothcaliperpistonfixingbolts.ManytypesrequireanAllenkey.

Rocktheassemblysidetoside.Thismovesthepadsandpushesthepistonin,justfarenoughtoallowthecaliperpistontoberemoved.Withdrawthe


pads.Useasmalllevertohelpifaspringclipholdsoneofthepadsintothepiston.Keepthepadstoshowtothecustomerifnecessaryandthendisposeoftheminlinewithcurrentregulations.Examinethediscforgroovesandcorrosion.

Inspectthesurfaceofthediscforsignsofcrackingandgrooves.Smallgroovesaretobeexpectedafteraperiodofuse.Groovesdeeperthanabout0.4mmareusuallyconsideredexcessive.

Usingamicrometer,measurethethicknessofthediscatseveraldifferentplacesaroundthedisc,towardsthecentreandtowardstheouteredge.

Comparethereadingstothemanufacturer’sspecifications.Somemanufacturersstamptheminimumthicknessjustinsidethecentreofthedisc.

Mountadialgauge(dialindicator)onamagnetic,orotherappropriatetypeofstand,withtheplungerrunningabout15mminfromtheouteredgeofthedisc.

Zerothegaugeandrotatethedisc.Takenoteofchangesinthedialgaugereading.Refinishagrooveddiscifallowable.Consultmanufacturer’srecommendations.Refertothemanufacturer’sspecificationsformaximumallowablerunout.Asaguide,0.15mmisusuallyconsideredthelimit.Replacediscswithexcessiverunout.

UseaG/Cclamptopushthecaliperpistonfullyhome.Fitthenewpadsinpositiontogetherwithanti-squealshimsiffitted.Somemanufacturersrecommendthatcoppergreasebeappliedtothebackandsidesofeachpad.Takecarenottocontaminatethelining.Repeattheprocessontheothersideofthevehicle.Padsonbothsidesmustalwaysbereplacedasaset.

Refitthecaliperandtightenallboltstotherecommendedtorque.Pumpthebrakepedaluntilitfeelshard.Thisistomakesurethepadsaremovedfullyintoposition.Doublecheckcorrectfitmentandthenrefittheroadwheelsandtightenwheelnutstorecommendedtorque.Lowerthevehicletotheground.


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Worksheet52:Servicedrumbrakes

ProcedureJackupandsupportthevehicleonstandsoruseasuitablehoist.Removethe

appropriatewheels.Releasetheparkingbrake.Removethecapthatprotectsthehubnut.Removethelockingtaborpinifused.Undothenutandremovetheouterbearing.Removethedrumtogetherwiththeinnerbearing.Or,removethedrumfixingscrewandremovethedrum.

Washthebackplate,shoesanddrumassemblyusingaproprietarybrakecleanerorsuitableextractor.Inspectthebrakeshoes.Recommendationsvaryslightly,butinmostcases,theshoesshouldbereplacediftheliningislessthanabout1.5mm.Methodsofshoeremovalvarysocheckthemanufacturer’sdata.Inspectbrakedrumforgrooving.Refinishagrooveddrumwithabrakedrumlatheifallowable.Consultmanufacturer’srecommendations.Removetheshoehold-downfixingsiffitted.Theseusuallytwistorpullfree.Notethepositionoftheshoereturnspringsandremovethemwithspecialbrakespringtoolifnecessary.Removethehandbrakecable.Onsomevehicles,theshoescanberemovedtogetherwiththehandbrakecable,adjusterandreturnsprings,whichcanthenbetakenoff.

Checkthewheelcylindersforleaksbypeelingbackthedustseals.The


cylindersshouldbeoverhauledorreplacedifleaksaredetected.Discardtheoldshoesinlinewithcurrentregulationsbutkeepthemforthecustomertoexamineifnecessary.Cleanoffthebackplate.Applyspecialgreasetotheshoecontactpoints.Notethatordinarygreasewillnotstandthehightemperatures.Fitthereturnspringsandadjustertothenewshoes.Fittheshoestothebackplate,makingsuretheyfitintothelowerpivotandwheelcylinderslots.Useashoeretractortolevertheshoesintoplace.

Refitthehandbrakecableandshoehold-downclips.Makesuretheshoesarecentralized.Preadjustbrakeshoesandparkingbrakebeforeinstallingbrakedrum/hubassemblyandwheelbearing.Refitthedrum,bearingsandnut.Tightentothecorrecttorque.Or,refitthedrumandfixingscrew.

Pumpthebrakepedaluntilitfeelshard.Thisistomakesuretheshoesareadjustedandmovedfullyintoposition.Checkforcorrectfitmentandthatthedrumspinsfreely,thenrefittheroadwheelstighteningtothecorrecttorque.Lowerthevehicletotheground.Roadtesttoensurecorrectoperation.Remembertocheckthehandbrakeoperationandadjustthecableifnecessary.


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Worksheet53:Remove,overhaulandrefitbrakecaliper

ProcedureRemove(notethatfixingmethodsvarysorefertomanufacturer’s

procedures):

•Raiseandsupportthevehicle.Removethewheel.Cleanawayanydustusingaproprietarycleaningsystem.Undothesecuringboltsandinspectthemforwearordamage.Removethebrakepads.Clamptheflexiblebrakepipeusingaproperpipeclamp.Undothepipefromthecaliper.

Overhaul:

•Toremovethepistonfromthecaliperitisusuallynecessarytodirectcompressedairintotheflexiblepipeconnectiononthecaliper.Uselotsofpaperorragstocatchlostfluidandprotectthepiston.Itmaybeexpelledwithquitesomeforce–takecare.Removetherubberdustsealiffitted.

•Dependingondesign,thepistonsealwillbepartofthepistonorpartofthecalipercylinder.Notecarefullyhowitisfittedandremovewithaplasticorwoodedtool.


•Inspectthepistonandboreforsignsofscratches,corrosionorexcessivewear.Ifanyseriousdamageisnoted,thecompleteunitshouldbereplaced.Lightcorrosionmayberemovedusingahoningtoolorveryfineemerypaper.

•Thoroughlycleanallpartsusingbrakefluidorabrakesystemcleaner.Donotusepetroleum-basedsolvents.Cleanlinessisveryimportant.Lubricatethenewpistonsealwithcleanbrakefluidandinstallit.Makesureitisfittedthecorrectwayround.Refitthepistonintothecylinder.

Refit:

•Screwtheflexiblepipeintothecaliperandrefitthecalipermountingbolts.Makesurethepipeconnectionissecure.Refitthepadsandsecureinpositionasrequired.Removethebrakepipeclamp.Thesystemwillnowrequirebleedingtoremoveair.

•Thismaybedoneusingapressurebleederorasimpletubeandbottlesystem!Wherejustonecornerofthecarhasbeendisturbed,andapipeclampused,itisusuallypossibletojustbleedthatpart.Iftheageofthebrakefluidisunknown,itisadvisabletoflushthehydraulicsystemandbleedthecompletesystem.

Note:brakefluidishygroscopic,thismeansthatitwillabsorbmoisturefromtheatmosphere.Useonlybrakefluidfromanewcontaineroronethatisknowntohavebeenrecentlyopened.

•Connectasmallpipetothebleednippleandplacetheotherendintoaclearbottlethatispartfullwithcleanbrakefluid.Releasethebleednipple–abouthalfaturnisusuallyenough.Getanassistanttopumpthebrakepedalslowly,whilstmakingsurethefluidreservoirremainstoppedoff.

•Watchthebottleandwhennomoreairisbeingexpelled,getyourassistanttoholdthebrakepedaldown–andthentightenthebleednipple.

•Makesurethereservoiristoppeduptothecorrectlevelandcheckthatthebrakepedalfeelshardwhenoperated.Checkforleaks,refitthewheelandlowerthecartotheground.


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Worksheet54:Removeandrefitbrakemastercylinder

ProcedureRemoval:

•Removefluidfromreservoirandplaceragstocollectspillages.Removeanyancillaryequipmentsoastogainaccesstothemastercylinderpipesandconnections.Disconnectanywarninglightwires.

•Undothebrakepipeunionsandmakesurebrakefluiddoesnotcontactpaintwork.Mostcylinderscannowberemovedbyundoingthetwomainsecuringnutsorbolts(checkspecs).Ifnecessary,removetheunitfromthevehicle.

Refit:

•Ifrequiredbythemanufacturer,benchbleedthereplacementmastercylinder.Usespecialpipestoconnecttheoutletsbackintothereservoirtodothis.Refittingisnowareversaloftheremovingprocess.Thesystemwillnowrequirebleedingtoremoveair.Thismaybedoneusingapressurebleederorasimpletubeandbottlesystem.Iftheageofthebrakefluidisunknown,itisadvisabletoflushthehydraulicsystemandbleedthecompletesystem.


Note:checkthemanufacturer’sspecs,becausesomesystemsshouldbebledinaparticularsequence.

Note:brakefluidishygroscopic,thismeansthatitwillabsorbmoisturefromtheatmosphere.Useonlybrakefluidfromanewcontaineroronethatisknowntohavebeenrecentlyopened.Donotstorebrakefluidforlongperiodsoftime.

•Connectasmallpipetothebleednippleandplacetheotherendintoaclearbottlethatispartfullwithcleanbrakefluid.Releasethebleednipple–abouthalfaturnisusuallyenough.Getanassistanttopumpthebrakepedalslowly,whilstmakingsurethefluidreservoirremainstoppedoff.

•Watchthebottleandwhennomoreairisbeingexpelled,getyourassistanttoholdthebrakepedaldown–andthentightenthebleednipple.

•Makesurethereservoiristoppedofftothecorrectlevelandcheckthatthebrakepedalfeelshardwhenoperated.Checkforleaksand‘road’testtoensurecorrectoperation.


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Worksheet55:Checkvacuumservounitoperation

ProcedureEnsurethattheengineisingoodrunningorderbecausethevacuumservois

poweredbyaconnectiontotheintakemanifold.Checkforairleaksasfootpressureisapplied.

Checkservooperationbyapplyingpressuretothepedalandstartingtheengine.Yourfootshouldmovefurtherdownastheenginestartsandservoassistanceisapplied.Itmaynotbenecessarytocheckfurtherifthistestresultissatisfactory.However,athoroughtestisalwaysadvisable.

Shutofftheengineandwaitfiveminutes.Applythebrakesandcheckthatservoassistanceisavailableforatleastoneapplication.Thisindicatesagoodairseal,ifvacuumisretained.

Connectavacuumgaugetotheinletmanifoldandnotethereadingwiththeenginerunningatidle.Areadingofabout0.5baristypical.

Connectavacuumgaugetotheservopipe,afterthecheckvalve,andnotethereadingwiththeenginerunningatidle.Thereadingshouldbethesameasbefore.Ifnot,checkthepipeforkinks,blockages.

Makesurethecheckvalveblockswhenyoublowfromthemanifoldend.Replaceifinanydoubt.


Reconnectallpartsandcheckforleaks.


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Worksheet56:Inspect,testandreplacebrakewarninglights

ProcedureCheckstoplightoperationandadjustswitchposition.Removethetwowires

fromthestoplightswitchandbridgethemtogetherwithafusedjumperwire.Theignitionmayneedtobeswitchedon.Thestoplightsshouldlight.Ifnot,tracethecircuitforabreakstartingwiththefuse.

Ifthelightsworkwhentheswitchisbridged,theswitchneedsreplacingoradjusting.Mostswitchesarepositionedabovethebrakepedalandhaveascrewedbodywithadjustingnuts.Theseswitchesmakecontactastheplungerspringsout.Adjusttheswitchpositionsothatthelugonthebrakepedalallowstheplungertomoveassoonasthepedalispusheddown.Checkthattheswitchisnottoosensitive,suchthatthelightsflashonduetovibrationforexample.Secureallwiresandadjustingnuts–checkoperationagain.

Checkparkingbrakeindicatorlight/audiblewarning–thisisagenerictestroutine;refertomanufacturer’sproceduresandcircuitsforspecificdetails.Applythehandbrake.Switchtheignitiononbutdonotstarttheengine.Checkthattheparkingbrakewarninglightisilluminatedonthe


dashboard.Ifthewarninglightdoesnotilluminate,checkswitchadjustment,ifOK,simplybridgingtheswitchcontactwillconfirmasoundcircuit.Releasethehandbrakeandcheckthewarninglightextinguishes.Ifnot,checkswitchadjustment.

Forvehiclesfittedwithanaudiblewarningdevice,starttheengineanddrivevehiclefromitspositionofrestwiththehandbrakepartiallyapplied.Theaudiblewarningdeviceshouldbeheard.Checkbrakewarninglight–thisisagenerictestroutine;refertomanufacturer’sproceduresandcircuitsforspecificdetails.Releaseparkingbrakeandswitchignition.

Checkthatthegeneralbrakewarninglightisnotilluminatedonthedashboard.Ifilluminated,checkfrontbrakepadsforwear,andthemastercylinderfluidlevel.Correctasappropriate.


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Worksheet57:Measuretyretreadandreportoncondition

ProcedureCheck:NSF,OSF,NSR,OSR.

Checkandreportminimumtreaddepth.

Checkandreportcondition.

Checksuitabilityforvehicle.

Manufacturer’swheelnuttorque.

Setwheelnuttorque.

Manufacturer’spressure.

Check/adjustpressure.

Reporttocustomer.


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TransmissionWorksheet58:Removeandrefitgearchangemechanism

ProcedureRemove:

•Disconnecttheearth/groundcablefromthebattery.

•Onsomecars,itwillbenecessarytoremovethepassenger’sordriver’sseat.Disconnectanyelectricalwires.

•Removetheknobatthetopofthegearlever.Mostwillunscrewbutsomeareheldwithasmallscrew.

•Removeconsolecovers,gaitersandpanelsasnecessarytogainaccess.

•Disconnecttheshiftrodleversorunscrewtheballjointcoverasappropriate.

•Disconnecttheelectricalwiringfortheoverdriveswitch(iffitted).

•Removethegearlever.

Refit:

•Placethegearleverinpositionandinstalltheballjointcoverorshiftrodlevers.

•Adjustthelinkageifnecessary.

•Connecttheoverdriveelectricalswitchwiring(ifdisconnected).

•Reinstallthecovers,panelsandothercomponentsasappropriate.


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Worksheet59:Removeandrefittransmissiongearbox(transaxletype)

ProcedureRemove:

•Supportthevehicleonasuitablehoist.Fitcarprotectionkitasrequiredanddisconnectthebattery.Remembertofitamemorykeeperifnecessary.Drainthegearboxoil.

•Removeanyancillarycomponentsasnecessarythatalloweasieraccess–theexhaustforexample.

•Markthegearchangelinkageandthenremovepartsasrequired.Removetheminimumnumberofpartsorremovethelinkageasacompleteunitwherepossible.Thismakesrefittingeasier.

•Onsomevehicles,itisnecessarytoremovethesuspensionononesidetoallowaccesstothegearbox,andforremovalofthedriveshafts.Removethedriveshafts(aseparateworksheetisavailable).

•Removethespeedometercableorspeedsensor.Removethereverse(backup)lightswitchwires.Tiethesecomponentsoutofthewayifnecessary.Removethestartermotorifnecessary.


•Fitenginesupportbarasrequired;removeandinspectmountings,andcrossmembers.Supportthegearboxonatransmissionjackifnecessaryandremovethegearboxorbellhousingbolts.

•Movethegearboxstraightoutoftheclutchassembly,awayfromthevehicleandplaceonasuitablebench.

Refit:

•Asusual–refittingisareversaloftheremovalprocess!However,itisnormaltoremoveandchecktheclutchassembly.Whenthisisrefitted,makesureitisalignedcorrectlybecausethismakesrefittingthegearboxmucheasier.

•Remembertorefillwiththecorrectlubricantandthatallfixingsaretightenedcorrectly.

•Aroadtestisrecommendedtoensurecorrectoperationwhenthejobiscompleted.


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Worksheet60:Replaceclutchassembly

ProcedureObtainandfollowmanufacturer’sprocedures.Disconnectbattery(ground

first),fittingamemorykeeperifnecessary.Raisevehicle.Removestarteranddrivelinecomponents.

Removeclutchcable/slavecylinderandtransmission–followingprocedures.

Removeclutchforkandreleasebearingassembly.Removeanydustusingrecommendedhealthprocedures.

Marktheclutchcoverifnecessaryandremovetheringofbolts.

Removeclutchcoverandplate.

Inspect,repair,replaceasnecessary(itisusualtoreplaceasaset).Inspectengineblock,clutch(bell)housingandtransmission/transaxlecasematingsurfaces.Inspect,removeorreplacecrankshaftpilotbearingorbushingasapplicable.

Checkconditionofflywheelusingdialgauge(seenextworksheet).Checkringgearforwearandcracks(measureringgearrunout).Measurecrankshaftendplay.

Usingalignmenttool,replacenewdiscandcover.


Refitallinreverseprocedure.

Bleedclutchhydraulicsystem.Testoperation.Roadtestandreportfindings.


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Worksheet61:Removeandrefitwheelbearings

ProcedureFronthubassembly:

•Applythehandbrakeandslackenthefrontroadwheelnuts,raisethefrontofthevehicle,supportitonstandsandremovetheroadwheel.Removethedriveshaftnutsplitpin,useanassistanttoapplyfirmpressuretothebrakepedaland,whilethebrakeisapplied,unscrewthedriveshaftnut.Removethebrakecaliperandsupportittopreventstrainingthehose.Removethedisc.

•Usingaballjointbreakertool,disconnecttheballjointfromthesteeringlever.Unscrewthenutsandremovetheboltstoreleasethestrutfromthehubassembly.

•Unscrewthenutandremovetheclampboltsecuringthelowerballjointtothehubassemblyand,usingasuitableleverplacedbetweenthelowerarmandtheanti-rollbar,leverdownwardstoreleasetheballjointfromthehub.Removethehubassemblyfromthedriveshaft.

•Extracttheinneroilsealandspacerandtheouteroilseal.Driveoutoneofthebearings,invertthehubanddriveouttheremainingbearing.Inspectthebearingsforsignsofwearanddamage,renewasnecessary.


Packthebearingswithsuitablegreaseandpressthemintothehub.Fittheoilsealspaceragainsttheinnerbearing.Fittheoilseals.

•Locatethehubonthedriveshaft,fittheflatwasheranddriveshaftnutandtightenthenutfingertight.Fitthehubassemblytothelowerballjoint,fittheclampboltandtightenthenut.Fitthehubtothestrut,fittheboltsandtightenthenutstothecorrecttorque.

•Connecttheballjointtothesteeringleverandfitandtightenthenut.Fitthedisctothedriveflangeandtightenthesecuringscrews.Fitthebrakecaliper.Useanassistanttoapplyfirmpressuretothebrakepedaland,whilethebrakeisapplied,tightenthedriveshaftnuttothecorrecttorque.Lockthenutwithanewsplitpin.Fittheroadwheelandnuts.

Rearhubassembly:

•Chockthefrontwheelsandslackentherearwheelnuts,raisetherearofthevehicle,supportitonstandsandremovetheroadwheel.Withdrawthegreaseretainercapfromthecentreofthehubandextractthesplitpinfromthestubshaft.

•Unscrewthehubnut,removetheflatwasherandwithdrawthehubandbrakedrumassembly.Extractthehuboilseal,drivetheinnerbearingoutandcollectthespacer.Invertthehubandbrakedrumassemblyanddriveouttheouterbearing.Inspectthebearingsforsignsofwearanddamage,renewasnecessary.

•Packthebearingswithsuitablegreaseandpresstheouterbearingintothehubwiththesidemarked‘thrust’facingoutwards.Invertthehub,fitthespacerandpresstheinnerbearing,withthesidemarked‘thrust’outwardsintothehub.Dipthenewoilsealinoilandpressitintothehub(sealinglipfacinginwards).

•Fitthehubandbrakedrumassemblytothestubshaft,fittheflatwasherandfitandtightenthehubnuttothecorrecttorque.Lockthenutwithanewsplitpin.Measuredriveaxleflangerunoutandshaftendplay.Fitthegreaseretainercap,thenfittheroadwheelandnuts.


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Worksheet62:Removeandrefitdriveshaft

ProcedureApplythehandbrakeandslackentheroadwheelnuts.

Raisethefrontofthevehicle,supportitonstandsandremovetheroadwheel.

Removethedriveshaftnutsplitpinorlocktab.

Useanassistanttoapplythefootbrakeandthenremovethedriveshaftnutandwasher.

Splitthesteeringtrackrodendfromthesteeringarmandremoveit.

Removetheboltssecuringthehubtothesuspensionstrut.

Pivotthehuboutwardstothelimitofitsmovementbuttakecarenottostrainthebrakehose.

Manoeuvrethedriveshaftfromthehub.

Carefullyleverbetweenthedriveshaftinnerjointandthedifferentialhousingtoreleasethespringring.Withdrawthedriveshaft.

Torefit,slidetheshaftintothedifferentialhousinguntilthespringringengages.


Manoeuvretheouterendofthedriveshaftintothehubandfitthenutandwasher.Anewnutmayberequiredbysomemanufacturers.

Refitthesuspensionstrutandthesteeringjoint.

Useanassistanttoapplythefootbrakeandthentightenthedriveshaftnuttothespecifiedtorque.Fitanewsplitpinorknockinthetabasrequired.

Refittheroadwheelandlowerthevehicle.Torquethewheelnutsandroadtest.


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Worksheet63:Removeandrefitfinaldriveanddifferential(FWDandRWD)

ProcedureRemoveFWD:

•Draintheoilfromthegearboxandrefitthedrainplug.Removethegearboxfromthevehicle.Positionthegearboxonitsbellhousingfaceandremovethegearcase,selectorshaftsandforks,themainshaftandcountershaft.Liftoutthefinaldrivegearanddifferentialassembly.

•Removetherollerbearingfromthebellhousing.Removethecarrierbearings.Removethedifferentialoilseals.Removetheboltssecuringthefinaldrivegeartothedifferentialhousingandwithdrawthefinaldrivegear.

•Removetherollpinsecuringthedifferentialpinionshaftandremovethepinionshaft.Removetheplanetgears,thrustwashersandthesungears.Cleanallcomponentsandexamineforwearanddamage.

RefitFWD:

•Fitthepinionrollerbearingtothebellhousing.Lubricateandfitthesungearsandplanetgearsandthedifferentialpinionshaft.Ensurethatthe


rollpinholeisalignedwiththedifferentialhousingandfitanewrollpin.Selectathrustwasher,whichwillprovidethecorrectbacklash.

•Thrustwasherdimensionsmustbeequalinbothgears.Backlashmaybecheckedusingthevehicledriveshaftinnercouplingstocentralizethesungears.

•Ensurethatthematingfacesofthefinaldrivegearandthedifferentialhousingarecleanandfreeofburrs.Fitthefinaldrivegearandsecuretheboltstothecorrecttorque.Fitthecarrierbearings.Fitthefinaldriveanddifferentialassemblytothebellhousing.Fitthegearcaseandsecureittothebellhousing.

•Ensurethatthefinaldriveassemblyisfullyinpositioninthebellhousing.Checktheclearancebetweenthegearcasecarrierbearingandthegearcasebearingrecess.

•Ifthereisnoclearanceorexcessiveclearance,slackenthegearcaseboltsandremovethecircliptypeshimthroughtheoilseallocation.Substituteanalternativeshimasrequired,tightenthegearcaseboltsandrecheckfinaldriveendfloat.

•Fitthedifferentialoilsealsusingspecialtoolsasrequired.Lubricatetheseallips.Fitthegearboxcomponents.Applysealanttothegearcasefaceandfitthegearcase.Fitthegearboxtothevehicleandfillwiththecorrectgradeandquantityofoil.

RemoveRWD:

•Jackupandsupportonstands.Removethewheels.Undoandremovebrakedrums.Inspectwheelstudsandreplaceifthreadsarewornordamaged.

•Unscrewtheboltsholdingthebearingclampandpulloutthehalfshafts.Aslidehammermayberequired.Removethepropshaft.

•Drainoilfromtheunitifpossible–oruseatraytocatchtheoilasthewholeunitisremoved.Undotheringofboltsaroundthefinaldrivehousing.Removethefinaldriveassembly–withassistanceifnecessary.Cleanoffanyoldgaskets.Inspectandreplaceseals.Renewgasketsandusesealantasrequired.

RefitRWD:

•Thisisareversaloftheremovalprocess.Topupwiththecorrectnewoil.Measureflangerunoutandshaftendplay.


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Worksheet64:Inspectandmeasurebacklash,finaldrivetoothwearandpiniontorque

ProcedureRemovefinaldriveanddifferentialassemblyfromthevehicle.Notethatthe

figureslistedherearetypicalbutalwaysrefertodataspecifictothevehicle.

Backlashdescribesthemovementofthecrownwheelbeforeitcontactsandmovesthepinion.Itisadjustedbysettingthepositionofthetwomainbearings.

Tightenbearingcapboltsandslackenoffagain.Thentightenthecapboltsfingertight.

Screwthetwoadjustingnuts,withaspecialtoolifnecessary,lightlyagainstthebearings.

Setadialgaugeonamagneticstandandagainstonetoothofthecrownwheel.

Tightentheadjustingnutonthecrownwheelsideuntilabacklashof0.01mmisobtained.

Next,preloadthebearingonthedifferentialside.


Measurethebacklashatfouropposingpointsandadjustthenutuntilareadingof0.1to0.2mmisobtained.

Spinthepiniongearseveraltimes,recheckandtightenthebearingcapstotheprescribedtorque.

Coatthecrownwheelteethwithtouch-uppaintor‘engineer’sblue’.Spinthedriveflangeseveraltimeswhilebrakingthecrownwheelwithahardwoodwedge.Checkthewearpatternandadjustthebacklashasrequiredwithinthespecifiedlimitsasnecessary.

Fitlocktabstothemainadjustingnuts.

Finally,measurethedrivepinionturningtorque.Ifthisisincorrect,anewcollapsiblespacermustbefittedandthepinionnuttorqueset.Alternatively,shimsareusedtosetthepinion.

Refittothevehicleandtopupwithoil.Usenewgasketsasrequired.


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Worksheet65:Removeandreplacepropshaftandreplaceuniversaljoint(UJ)andcentrebearing

ProcedureRemoval:

•Jackupvehicleandsupportonaxlestands.Ifnecessarydisconnectexhausttoimproveaccessandremovalofpropshaft.MarktherearUJflangeandfinaldriveflangeinrelationtoeachother.Removeboltssecuringthepropshafttothefinaldrive.Removeboltssecuringthecentrebearingtoitssupportbracketontheunderbody,notingthelocationandnumberofslottedshimsbetweenthebearingandbracket.

•Disconnectthepropshaftfrontendfromthegearboxbypullingtheshaftrearwards.Topreventlossoftransmissionoil,asuitableplugshouldbeinsertedintotheoilseal.

Replacementofuniversaljoint:

Note:notalluniversaljointsarereplaceable.Ifnot,areplacementpropshaftwillneedtobeobtained.CleanawayalltracesofdirtfromthefourUJcirclipsandremove.Iftheyaredifficulttoremove,tapthebearingsurfacerestingonthespiderwithamallet.


•Removethebearingcupsandneedlerollersbytappingtheyokeateachbearingwithamallet.Withthebearingcupsremoved,extractthespiderfromtheyokes.Thoroughlycleantheyokes,journalsandcirclipgrooves.Fitthenewspiderontheyoke.Refitthebearingcupsonthespiderandpressthebearingshomeusingapressorvice.Replacethecirclips.

Replacementofcentrebearing

•Markthefrontandrearsectionsofthepropshaftinrelationtoeachother,andalsomarkthepositionoftheU-shapedwasherlocatedbeneaththeheadoftheboltinthecentreUJ.

•LoosentheboltinthecentralUJsothattheU-shapedwashercanberemoved.WiththeU-shapedwasherremoved,slidetherearsectionofthepropshaftfromthefront.Removethecentrebearingusingasuitablepuller.Refittingisareversalofremoval.EnsuretheU-shapedwasherisfittedinthepreviouslymarkedposition.

Refittingthepropshaft

•Refittingisareversalofremoval.Ensurethatpreviouslynotedslottedshimsarereturnedtotheiroriginallocation.Usingastraightedgeofsuitablelength,checkthatthetwosectionsofthepropshaftarealigned.Checkmanufacturer’sdataformaximumjointangles.Adjustmentwillbebyaddingorremovingshimsfromthecentrebearing.Checktransmissionfluidlevel.


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ElectricalWorksheet66:Removeandrefitelectricalcomponents

ProcedureCheckdataforlocationoffusebox.

Switchonthecircuitundertestandtheignitionifnecessary.

Checkforvoltageatbothsidesofthefuse,fusiblelinkorcircuitbreakerwithameteroratestlamp.Ceramicandglassfuseshavemetalcontacts;bladefuseshavesmalltestpointsateachsideontopofthefuse.

Removethefuseusingaclippullerifnecessary.Replacewithoneoftherecommendedvalue.

Checkbulbreplacementmethods.Mostrearlightsareaccessiblefrombehindthelightclusterinsidethevehicle.Headlightbulbsusuallyhaveasmallcoverthatshouldberemoved.Sideandindicatorlightunitsareoftenremovedasaunitafteraspringclipisreleased.

Checkbulbsbyeyebutalsowithanohmmeter–afewohmswillindicatethatthebulbisingoodorder.Donottouchtheglassofaheadlightbulb.Thiscancreatealocalizedhotspotduetogreasecontaminationandcausethebulbtoblow.Cleanoffcarefullyiftouchedaccidentally.

Replacefaultybulbswithonesofthecorrectrating(voltageandwattage)aswellasthecorrectfitting.Insomecases,thebulbsarecoloured.

Checkalllightsforcorrectoperation.


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Worksheet67:Removeandrefitelectricalcomponents

ProcedureThisworksheetisgenericandcanbeappliedtomanysystems.However,

refertomanufacturer’sproceduresforspecificinformation.

Fitamemorykeepertopreventchangingstoredsettingsinelectroniccontrolunitsandincarentertainmentsystems.

Removethebatteryearth/groundlead.

Ifremovingthebattery,disconnectthesupplyconnection,removethecasingclampandremovethebattery.Takecaretokeepitlevelsothatnoelectrolyte(sulphuricacid)isspilt.

Forothercomponents,disconnecttheirsupplywires.Makinganoteorsuitablesketchwherenecessaryoftheconnectionswillsavetimewhenrefitting.

Forsomecomponents,itmaybenecessarytoremoveotherpartstoalloweasyaccess.Forexample,anexhaustshieldmayneedtoberemovedbeforethealternatorcanbedisconnected.

Disconnectlinkagesand/orperipherals.


Undoallmountingsandremovetheunitfromthevehicle.

Refittingisareversaloftheremovalprocess.

Thelastjobisalwaystoreconnectthebatteryearth/groundlead.


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Worksheet68:Removeandreplaceheadlightunit

ProcedureFitmemorykeeperanddisconnectthebatteryearth/groundlead.

Removecoversasrequiredanddisconnectwirestolights.

Removegrilland/ortrimasnecessaryforaccesstolightunitfixings.

Undoboltsand/orclipsandremovelightunitfromthecar.

Refittingisareverseoftheremovalprocess.

Notethatsomemanufacturersrequirespecialcontactgreasetobeappliedtotheterminals.Thismakesforagoodelectricalcontactandkeepswaterout.

Checkandadjustalignment.

Checkallotherlights.


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Worksheet69:Removeandrefitflasherunit

ProcedureNotethatiftheleftorrightindicators,orthehazardswork,theunitis

probablyfunctioningcorrectly.Rememberthataflasherunitisdesignedtoflashatadifferentratewhenabulbisblown.

Flasherunitsareusuallylocatedeitheraspartofthefuseboxoronthesteeringcolumn.

Removecoversorshroudsasnecessary.

Mosttypesofflasherunitsimplypulloutofthesocket.

Replacebypushingthenewunitintotheholder.

Makesurethenewunitisthecorrectoneforthevehicle.Notethatmorepowerfulunitsmayberequiredifatowingsocketisfitted.

Afterrenewal,makesureindicatorsandhazardlightsoperate.


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Worksheet70:Removeandrefitwindscreenwipermotor

ProcedureNote:thisisagenericprocedureforamotorthatcanbeaccessedfromtheenginecompartment;refertothespecificmanufacturer’sinstructions.Switchofftheignition.Markthepositionofthewiperbladeswithmaskingtape,andremovethewiperarms.

Raisethebonnetandremoverubberstripand/orcoversfromtheheating/ventilationsystemarea.

Removewipermotorcoverpanels.

Removeretainingscrewsasappropriateandremovethewiringharnessplugfromthemotor.

Unscrewthelargenutonthewiperspindles.

Slackenandremovethemotormountingbracketscrews.

Manoeuvrethemotoranddrivelinkageoutfromitsfittings,andremovefromthevehicle.

Undothenutonthewiperspindleaftermarkingthepositionofthecrank


arm.Unscrewthemotorfixingboltsandremovethemotor.

Refittingisareversaloftheremovalprocess.However,notethefollowingpoints.

Connectthemotortotheharnessandrunit(withoutthelinkage)untilitstopsinthe‘park’positionasnormal.Disconnectfromthewiring.

Refitthecrankandlinkageexactlyasitwasremoved.

Afterrefittingthemotorandlinkage,runthemotorandmakesurethemovementiscorrectbeforerefittingthearmsandblades.

Finally,fitthearmsandblades,wetthescreenandcheckforcorrectoperationatallspeedsandsettings.Checkthatthebladesparkcorrectly.


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Worksheet71:Inspectandmeasurewipermotoroperation

ProcedureNote:wipersshouldnotbeoperatedforlongperiodsonadryscreen.Takeextracarewhenoperatingwiperswiththelinkageexposedasitiseasytotrapyourhandsandcauseinjury.

Runthroughthewasherandwiperoperationstocheckforcorrectoperation.Mostwipershaveaslow,fast,intermittentandwash/wipefacility.

Checkthatthebladesparkwhentheswitchisturnedoff.

Switchofftheignition.

Connectanammeterinserieswiththemotorsupply.Thiscanbeinplaceofthefuseifnecessary,byusingsuitableadapters.

Runthewipersateachspeedafterwettingthescreen(usingthewashersisprobablyeasiest).

Measurethecurrentdraw.Readingswillvary,butfiguresintheregionof12Aormorearetobeexpected.

Alowreadingwouldindicateahighresistanceinthecircuit.


Inspectthecircuitandmakesureconnectionsareclean.Connectingavoltmeteracrossaconnectionisagoodwayoftestingit.Areadingofalmostzerovoltsistobeexpectedwhenthemotorisoperating.


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Worksheet72:Checkcentraldoorlockingandalarmoperation

ProcedureNote:differentsystemsoperateindifferentwayssocheckspecificdataasnecessary.

Useascantoolwhereappropriatetocheckforalarm/centrallockingstoredfaultcodes.

Closeallthedoorsandoperatethecentrallockingfromthedriver’sdoorlockusingthekeymanually.Alldoorsandthetailgateshouldlock.Ifadoublelockingsystemisfitted,turningthekeyagaindoublelocksallopenings.

Checkmanuallythatalldoorsandopeningshavelocked.

Repeattheaboveprocedureusingtheremotekeyifavailable.

Repeatagainfromthepassenger’sdoorlock.

Openoneofthewindowsandthenfullylockthecar.

Reachinsidethecar.Ifamovementsensorisincorporated,thealarmwillsound!Ifnot,reachinandopenthedoorfromtheinside.Thealarmshouldnowsound!Presstheremoteorusethekeyinthedriver’sdoorto


reset.

Closeallwindowsandlockthecar.


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Worksheet73:Removeandrefitcentraldoorlockingactuator

ProcedureNote:thisisagenericprocedure;refertothespecificmanufacturer’sdatafordetailedinstructions.

Fitamemorykeeperanddisconnectthebatteryearth/ground.

Removetheinteriordoorhandles,locklevercovers,windowwinderandplasticboxes,etc.asrequired.

Usingaflatforkedleverundertheplasticclips,removetheinteriordoortrimpanel.

Iffitted,removetheplasticwaterproofingcover.Takecarenottotearthisorbepreparedtorenewasrequired.

Makesurethewindowisfullyclosedtoallowaccessintothedoorcavity.

Note:theinsideedgesofthedoorstructureareoftensharp.Wearprotectiveglovesasnecessary.

Tracethewiresfromthelockactuatoranddisconnectthemultiplug.Onsomecars,thisispartoftheactuator,butonothers,itmaybeinsidethe


sillareaorevenunderthecarpetsbeneaththeseats.

Unscrewtheactuatorfixingsandunhookitfromthepullrod.

Removetheactuatorfromthevehicle.



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Worksheet74:Removeandrefitfueltanksenderunit

ProcedureFitmemorykeeperanddisconnectthebatteryearth/groundlead.

Supportvehicleonhoist.

Drainfuelfromthetankusingspecialequipment.

Ifnecessary,disconnectfuellinesandfillercomponents.

Removefueltank(somesendersareaccessiblewithoutremovingthetank,checkmanufacturer’sdata).

Removewiresfromsenderunit.

Undotheringofboltsandremovesender.

Useanewgasketandsealantwhenrefitting.

Ensurethenewsenderispositionedcorrectly.



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Worksheet75:Removeandrefittemperaturesensor

ProcedureFitcoversasrequiredtokeeppaintworkclean.

Removecapfromcoolantheadertank(vehiclemustbecold)andthenreplaceit.Thiswillensurethatthereisnopressureinthesystemandwillminimizecoolantloss.

Disconnectwire(s)fromsenderunit.

Preparenewunitforinstallationbyapplyingsealanttothethreads(ifrequired).Followmanufacturer’sguidance.

Removeoldsensorfromtheengine(usuallyatthefrontofthehead)andreplacenewoneimmediately.

Torquetospecifiedvalue.

Reconnectwire(s).

Topupcoolingsystem.

Startengineandrunuptotemperature.Checkforcorrectgaugeoperationandleaks.


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Worksheet76:Checkoperationofheatingandventilationsystem

ProcedureStarttheengineandrununtilitiswarm(useextractionifindoors).

Checkthattheboosterfanrunsatallspeeds.SwitchoffACiffitted.

Setthetemperaturecontroltocoldandthefanspeedtoamediumsetting.

Runthroughalldirectionsettingsandcheckthatcoolairissupplied.

Setthetemperaturecontroltohotandthefanspeedtoamediumsetting.

Runthroughalldirectionsettingsandcheckthathotairissupplied.

Checkthatarangeoftemperaturescanbeselectedandthatexternalorrecirculatedaircanbeused.

Makesureallventilationgrillsopenandallowdirectionalcontrol.

Checkheatedrearscreenoperation.

Checkheatedfrontscreenoperation(iffitted).


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Worksheet77:Inspectheatercontrolsandheaterblowermotor

ProcedureObtaininformationfromthedriverregardingheaterfunction.Turnthe

heatercontroltothecoldestsetting(withairconditioningoff).Checkthattheenginewarmuptimeiscorrectbyfeelingthatthetophoseremainscooluntilthethermostatbeginstoopen.Thetophoseshouldthenrapidlyheatup.Ifindoubt,applyathermometertothetophoseorintheradiatorheadertanktocheckenginetemperature.

Checkengineheattemperaturerange.Leaveonthecoldsettingandruntheblowermotoratallspeedsinitsrange.Doesairattheoutsidetemperatureflowfromtheheaterducts?Ifyes,thecoldadjustmentiscorrect.

Ifwarmairflowsfromtheheater,checkandadjustthetemperaturecontrolcabletotheairmixtureflapintheheaterortothewatercontrolvalve.Ifthisdoesnotgivecoldair,thesealsonthecontrolflaporinthewatercontrolvalveareprobablydefective.Turntheheatcontroltothehottestpositionandcheckforhotairfromtheheaterductswiththeblowermotoroperating.

Checkthatastheheatcontrolismovedslowlytowardsthecoldposition,the


airtemperaturefromtheheaterductsbecomessteadilycooler.Forwatercontrolvalveandautomaticsystemssomedelayinreducingthetemperaturemayoccur.Tocheckautomatictemperaturesystemsallowtheenginetocool.Setthetemperaturecontroltoanintermediatepositionandcheckthattheairtemperatureremainsstableastheenginewarmsup.

Checktheairdirectionalcontrolbyselectingeachpositioninturnandfeelingforairflowfromtheappropriatepositions.Ifincorrect,movethecontrolslightlytoeithersideoftheproperpositiontofindtheadjustmenterrorandthenadjustthecableaccordingly.

Iftheheaterblowermotorfailstooperate,checkthefuseandelectricalfeedtothefusebox.

Ifcorrect,checkforvoltageatthemotorterminalblockwithavoltmeterortestlamp.Followawiringdiagramforfeedandearthorgroundcables.Checkearthorgroundcontinuity.

Ifvoltageiscorrectattheterminalblockandearthorgroundiscontinuous,checkthemotorbrushesandcommutatorforcondition.Brushesmaybeavailableasareplacementpartbutusuallyaneworreplacementmotorwillberequired.


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Worksheet78:Checkoperationofin-carheatingincludingairdistributionandfanoperation

ProcedureSetheatcontroltothecoldestsettingandruntheengineuptonormal

operatingtemperature.Astheengineheatsup,checktheairdistributioncontrolandheaterblowermotoroperation.

Checkinsidetheenginecompartmentthattheheaterfeedandreturnhosesarehotandcold,respectively,forwatervalvetypesandthatbothhosesarehotforairmixingtypes.

Keepingtheheatsettingonthecoldestposition,turnontheblowerfanandcheckthattheairflowfromtheheaterissimilartotheoutsideairtemperature.

Checkthatthefanincreasesinspeedforeachofthespeedsettingsandthattheairflowincreasesasthemotorspeedincreases.

Movetheheatsettingprogressivelyfromthecoldesttothehottestsettingandfeeltheairflowforagradualincreaseintemperature.Donotoperatetheairconditioningsystemiffitted.

Checktheairdistributioncontrolbymovingtoeachpositioninturnand


checkingthatairflowisdirectedfromthecorrectoutlets.

Forair-cooledenginesitisimportanttocheckforexhaustgasleakageinsidetheheatexchanger.Checktheheateroutletsforodour.

Alternatively,forincreasedsafety,useagasanalyserwiththeprobeinsertedintoasidewindow.Sealthewindowopeningwithtape.Settheheatercontrolstothehighesttemperature.Runtheengineandlookforthepresenceofexhaustgasesinthevehicleinterior.CheckforCO,whichistoxic.


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