Identifying engines

SummaryMulti-cylinder engines are produced in four common configurations. They are: Inline, "Vee", Horizontally Opposed, Rotary.Multi-cylinder engines are produced in four common configurations. They are: Inline "Vee" Horizontally Opposed RotaryInline

Inline engines can be found in 2, 3, 4, 5, and 6 cylinder configurations. There have been inline 8 cylinder engines, but they are too long to fit into an engine bay of a conventional modern car.Cylinders arranged side by side in a single row identify the 'Inline' engine. They can be mounted longitudinally (lengthwise) or transversely (sideways) in the engine bay. However, it is uncommon to find a longer 6-cylinder engine mounted transversely.Vee

"Vee" engines are shorter than an equivalent capacity inline engine. They can be found in 2, 4, 6, 8, 10 and 12 cylinder configurations and consist of two banks of cylinders arranged in a Vee that is joined at the bottom. They are shorter than inline engines, because offsetting the wider top parts of alternate cylinders into the different arms of the Vee allows them to be connected closer together at the crankshaft.Vee engines can be mounted longitudinally (lengthwise) or transversely (sideways) in the engine bay. A V6 will have two banks of 3 cylinders, a V8 two banks of 4 cylinders.The angle of the "Vee" varies according to the number of cylinders. The natural angle for a V4 and V8 is 90. The natural angle for a V6 and V12 is 60 and for a V10 is 72. Some manufacturers vary their angles due to convenience or design requirements. Some manufacturers use 90 and 15 V6sHorizontally opposed

Horizontally opposed engines are commonly found in 2, 4, 6, and 12 cylinder configurations. Like a "Vee" engine, they have two banks, but in this case they are 180 apart. Unlike "Vee" engines their crankshaft differs in the way the pistons are paired. A Horizontally Opposed engine is only fitted longitudinally.Rotary

Rotary engines are very powerful for their size, but they do not use conventional pistons that slide back and forth inside a straight cylinder. Instead, a rotary engine uses a rotor which has three convex sides, attached to an eccentric shaft inside a specially shaped housing. As the rotor rotates, it covers and uncovers inlet and exhaust ports, and its curved shape alters the size of the working chambers, which are formed in the spaces between the outside of the rotor and the inside of the housing. For each complete rotation of the rotor, there are three power pulses, and three rotations of the shaft. Engine configurations

SummaryEngines have different layouts, depending on the vehicle application. Common arrangements include in-line, vee, flat or rotary.

The way engine cylinders are arranged is called the engine configuration.Tilting an engine reduces its height. This can reduce the height of the bonnet as well, which allows a more streamlined body shape.Tilting can be carried to an extreme by lying the engine completely on its side. It is then called a flat engine. This greatly reduces engine height.As the number of cylinders increases, the length of the block and the crankshaft can become a problem. One way to avoid this is with a V configuration. This design makes the engine block and the crankshaft shorter, and more rigid.In vehicle applications, the number of cylinders can vary, usually from 4, up to 12.Common angles between the banks of cylinders are 90 degrees and 60 degrees. V-type engines are wider than inline engines, and may also be lower.Horizontally-opposed engines have 2 banks of cylinders, 180 degrees apart, on opposite sides of the crankshaft. A useful design when little vertical space is available. It is shorter than a comparable in-line engine but wider than a V-type.A rotary engines uses a rotor in a housing, instead of a pistons in a cylinder. This provides a very compact power unit. Sedan

SummaryA sedan can also be referred to as a saloon or convertible.

A sedan has an enclosed body, with a maximum of 4 doors to allow access to the passenger compartment.The design also allows for storage of luggage or other goods. A sedan can also be referred to as a saloon, and traditionally has a fixed roof.There are soft-top versions of the same body design, except for having 2 doors, and these are commonly referred to as convertibles. Station wagon

SummaryA station wagon, or estate car, has a large rear door and a large baggage capacity.

A station wagon, or estate car, has increased luggage capacity, and a large rear door for access. The rear seats can usually be folded to increase luggage capacity even further. The roof is usually fixed. Coupe

SummaryA 2-door coupe, or sports car, normally has a more rigid structure than a sedan or saloon.

A coupe has just 2 doors. Reducing the number of doors to the passenger compartment makes the vehicle structure more rigid.Traditionally, it has 2 seats, with 2 smaller seats behind, for occasional use. In this form it is a close-coupled 4-seater, and can be made in a fixed head or drop-head configuration. A coupe is now regarded as being any fixed head vehicle with 2 doors. Hatch-back

SummaryA hatchback is a versatile vehicle, similar to a sedan but with some of the benefits of a station wagon.

Hatch-backs can have 3-door, and 5-door designs. Rear seats usually fold down to increase luggage area. They combine the benefits of sedans and station wagons, to make more versatile vehicles. Pick-up/utility

SummaryA pick-up truck or utility can carry heavier loads and has stronger suspension.

The pick-up, or utility, carries goods. Usually it has stronger chassis components and suspension than a sedan, to support greater Gross Vehicle Mass. Light vehicle vans

SummaryVans are designed for maximum cargo space, and are generally based on light vehicle configurations.

Light vehicle vans can be based on common sedan designs, or redesigned so that maximum cargo space is available. General goods transport vehicles

SummaryGoods vehicles are specifically designed to carry various types of cargo.

The bodies of commercial vehicles that transport goods are designed for that specific purpose. Tankers transport fluids.Tippers carry earth, or bulk grains.And flat-beds and vans are used for general goods transport.A goods transport vehicle can be a rigid vehicle, a rigid vehicle with a trailer, or an articulated vehicle.Articulated vehicles carry goods on a semi-trailer, with the power unit or prime mover connected to the semi-trailer by a coupling, called a 5th-wheel coupling.The 5th-wheel coupling lets the traction unit pivot on the semi-trailer. This gives more manoeuvrability than with rigid vehicles, or rigid-trailer combinations.A road train connects extra trailers by a small inter-connecting trailer called a dolly. It has a fifth-wheel coupling, and its connected to the leading trailer by a draw bar.Up to 3 trailer-and-dolly-sets can be drawn by 1 prime mover, and each set contains brakes for each wheel, and lights for each trailer.A B-Double vehicle has a 5th-wheel on the rear of the first trailer, and the 2nd trailer is coupled to the 5th-wheel. This removes the dolly wheels from the combined unit, which reduces the length of the vehicle. But since there are fewer supporting wheels, the vehicle payload is also reduced.Heavy goods vehicles can have normal control, with the operator seated behind the engine. A light-weight bonnet that can be tilted or raised allows easy access to the engine for servicing.In forward control, the operator cabin is mounted over the engine. This design gives greater load length to the vehicle. The cabin can be tilted for easy access to the engine. Some designs only have a hinged flap over the engine bay. Buses & coaches

SummaryBuses and coaches are passenger carrying vehicles - buses for commuter transport, coaches for longer distance travel.

Buses and coaches are usually 4-wheeled rigid vehicles, but a larger number of wheels and axles can be used.Sometimes articulated buses are used to increase capacity.Buses and coaches can be single-deck, or double-deck.Buses are commonly used in cities as commuter transport, while coaches are more luxurious, and used for long distances. Convertible

SummaryA convertible is an automobile built with a folding, retracting, or removable roof.

Aconvertible(commonly known as a 'cabriolet' in Europe) is an automobile that can 'convert' from an enclosed top vehicle into an open top vehicle by means of a roof that can be removed or retracted or folded away.The roofing material is most often a flexible fabric such as canvas or vinyl, and most convertibles have a mechanism driven by electric motors that retract or raise the roof cover.In some vehicles, known as 'hardtop convertibles' the roof can be a series of folding steel panels. When in place, the hard roof makes such vehicles look more like conventional fixed roof vehicles. In other vehicles, only a smaller section of the roof area is 'convertible'.Traditionally, the term'roadster'was applied to a vehicle with no permanent roof covering or side windows, but today that name is most often used to describe any 'convertible sportscar'. Truck

SummaryTrucks are commercial goods-carrying vehicles. They can be small and relatively light, or massive and powerful vehicles that can tow multiple heavy trailers.

'Truck' is the most common name applied to larger commercial vehicles in The US and Australia. A goods carrying vehicle in the UK is more likely to be called a 'lorry', or a 'heavy goods vehicle', or HGV. Lighter types of commercial vehicles are known by a variety of names that differ from place to place. For instance, a light commercial vehicle that may have a front cab configuration similar in size to a family sedan or an SUV but with an open top cargo area at the rear is known in the US as a 'pick-up', but in Australia and New Zealand it is called a 'ute' or utility vehicle.ConstructionMost heavier trucks share a common construction: they comprise a chassis with a cab; axles, suspension and wheels; and an engine and a drivetrain. The body or coachwork is usually customized for the particular goods that it will carry for instance, sealed tanks for liquids such as fuels; open trays for bulky general goods such as timber; or enclosed and refrigerated containers for perishable goods such as meat.ChassisA truck chassis usually consists of parallel steel beams held together with cross members. This forms the framework to which all the other components are attached.CabThe cab is the enclosed space where the driver sits. In larger long-haul vehicles, this will be a comfortable air-conditioned space that can even contain a sleeping compartment. A conventional truck cab is behind the engine which sits under a front hood or bonnet, as it would be in a passenger vehicle. In Europe, where truck lengths are more strictly regulated, it is much more common for the driver to sit on top of the engine and front axle in a cab which tilts forward to allow access to technicians. Light trucks such as pickup trucks can have a unibody cab like a passenger vehicle, attached to a half-chassis behind.EngineThere are fewer truck engine manufacturers than there are for passenger vehicles, and many trucks in the US and Australia are built using engines from a third party manufacturer such as Cummins, Navistar, or Caterpillar. Fully integrated trucks from a manufacturers such as Scania, MAN, Mercedes, or Volvo, are more common in Europe.Light trucks can use gasoline/petrol engines, but heavier trucks are mostly powered by four-stroke diesel engines with turbochargers and intercoolers, although there are alternatives such as the V12 diesel two-stroke engine from Detroit Diesel.DrivetrainLarger trucks usually have manual transmissions with several ranges and many more gears than passenger vehicles. To cope with the torque forces required to start heavy loads moving, truck transmissions are more strongly built than passenger vehicle transmissions. Automatic transmissions are becoming more common in all types of trucks.Truck types and examplesLight trucks pickups, minivansMedium trucks delivery vehicles, motor homesHeavy trucks concrete mixers, gasoline/petrol tankers, garbage trucksArticulated trucks, or semi-trailers car transporters, containersDoubles and 'Road Trains' trucks with multiple trailers for carrying livestock, grain, ore Vehicle closures

SummaryA vehicle body contains many openings apart from the vehicle doors. All of these openings have to be secured and may require a remote switch or lever to be activated.

A vehicle body contains many openings apart from the vehicle doors. They include engine compartment hoods, hatch and tailgate openings, fuel doors, and battery access covers.

All of these openings have to be secured and may require a remote switch or lever to be activated. In some cases the activation is by cable, others may use electric or vacuum solenoids.Some rear hatch openings have a hinged window incorporated, so the owner can have easy access without opening the entire door.Engine compartment hoods may use single or double acting hinges. Their release may be located inside the passenger compartment, under the dash, in the glove compartment or on a doorjamb.

Some manufacturers are no longer fitting an engine compartment release to their vehicles. The hood can only be released by the manufacturers scan tool or by a service key fitted into a secluded opening on the vehicle body (usually behind a manufacturers badge). Before opening the engine hood on these vehicles, check the owner's manual, or the manufacturers manual, as unauthorized access may void any vehicle warranty. Engine & transmission configurations

SummaryEngine and transmission layout can be longitudinal or lateral, depending on the vehicle application.

An engine can be located at the1. front2. middle, or3. rear of a vehicleAn engine located at the front can be mounted longitudinally, and can drive either the front, or the rear wheels. In 4-wheel-drive applications, it can drive both the front and rear wheels.Alternatively, the engine can be transverse, and drive either the front wheels only, or, in 4-wheel-drive applications, the front and rear wheels.Mid-engined vehicles have the engine in front of the rear wheels. The engine can be transverse or longitudinal, and usually drives the rear wheels only.Rear-engined vehicles have the engine mounted behind the rear wheels. The engine can be transverse or longitudinal, and usually drives the rear wheels only.The drive train transfers turning effort from the engine to the driving wheels.A drive train can include a clutch for manual transmission, or a torque converter for automatic transmission; a transmission, a drive shaft, final drive and differential gears, and driving axles.Alternatively, a transaxle may be used. A transaxle is a self-contained unit, with the transmission, final drive gears and differential located in one casing.It is usually used on front-engined, front-wheel-drive vehicles, or, rear-engined, rear-wheel-drive vehicles.It can also be used on front-engine, rear-wheel-drive vehicles, connected to the engine by a propeller shaft. Vehicle axles

SummaryVehicles can have different numbers or types of axles.

Vehicles can be described by the number of axles. Most light vehicles only have 2 axles. Most vehicles have 4 wheels but only 2 driving wheels.Some have 4 driving wheels, and these are commonly called 4-wheel-drive vehicles.On commercial vehicles, the load carried on a single axle is limited by law, so vehicles with extra axles are common. This layout has 6 wheels to support the vehicle but only 2 drive it. The extra axle at the rear is only used to support the weight of the vehicle. This extra axle is sometimes called a lazy axle. This is called a 6-by-2 vehicle.If the lazy axle is changed to a driving axle, this becomes a 6-by-4 vehicle.Some heavy goods vehicles have an extra steering axle, which allows more weight to be carried. Location of driving axles

SummaryVehicles can have single or multiple driving axles, depending on the vehicle design or purpose.

The location of the driving axle determines whether the vehicle is classified as1. rear-wheel drive2. front-wheel-drive3. 4-wheel drive4. all-wheel-driveRear-wheel-drive vehicles can use a conventional layout with the engine at the front of the vehicle. The torque from the engine is transmitted to the rear-mounted driving axle by propeller, or drive shaft. This spreads the weight of components throughout the vehicle.Some rear-wheel-drive vehicles have the engine at the rear, driving the wheels through a combination transmission and rear axle called a transaxle. The transaxle is lighter than a separate transmission and rear axle.Moving the engine to the rear allows a lower bonnet line, which improves aerodynamics. The increase in weight over the rear wheels can improve their traction.A vehicle which has the engine located behind the operators cabin, but forward of the rear driving axle is called a mid-engine, rear-wheel-drive vehicle.A mid-engine design locates the mass of the engine behind the driver but forward of the rear axle. This allows for a low bonnet profile, and good handling.Most goods-carrying, rigid commercial vehicles locate the engine near the front, and drive the rear axle by a 2-piece propeller shaft. The rear axle supports most of the goods, or payload.Mini-buses commonly locate the engine at the front of the vehicle, beneath the operators cabin, and drive the rear axle by a propeller-shaft.Larger buses and coaches locate the engine at the rear. This allows the vehicle to have a low floor, and removes much of the noise and vibration from the passenger compartment.Front-wheel-drive vehicles use the front wheels to pull the vehicle along. In light passenger vehicles it gives lighter body weight, and increased interior room.The engine and transaxle are at the front, and can be mounted laterally, that is, the engine is parallel to the front axle, or longitudinally where the engine is inline with the centre line of the vehicle. Transmissions & final drives

SummaryEngine torque is transmitted to the wheels through a different types of transmission and final drive.

A vehicle with a manual transmission uses a clutch to engage and disengage the engine from the drive train.Engine torque is transmitted through the clutch to the transmission or transaxle. The transmission contains sets of gears that increase or decrease the torque, before it is transmitted to the rest of the drive train. The lower the gear ratio selected, the higher the torque transmitted.A vehicle starting from rest needs a lot of torque, but once it is moving, it can maintain speed with only a relatively small amount of torque. A higher gear ratio can then be selected, and engine speed reduced.A conventional vehicle with the engine at the front and driving wheels at the rear, uses a drive shaft, called a propeller shaft, to transmit torque from the transmission to the final drive.The final drive provides a final gear reduction, to multiply the torque before applying it to the driving axles.On front-engined, rear-wheel-drive vehicles, the final drive changes the direction of the drive by 90 degrees.Inside the final drive, a differential gear set divides the torque to the axles, and allows for the difference in speed of each wheel when cornering.Commercial vehicles may use a 2-speed final drive. The low range provides more torque for lower speeds, and heavy loads.High range is used for higher speeds, and light loads. Axle shafts transmit the torque to the driving wheels.In a rear-wheel-drive vehicle, the axles can be solid, or contain joints to allow for movement of the suspension.For a front-wheel-drive vehicle, the drive shaft has universal joints to allow for suspension and steering movement.An automatic transmission or transaxle performs similar functions to a manual transmission or transaxle, except that gear selection is controlled either hydraulically, or electronically.The automatic transmission uses a torque converter, which acts as a hydraulic coupling to transfer the drive. 4-wheel drive transmission

Summary4-wheel and all-wheel drive vehicles transmit torque to more than one set of driving wheels.

A 4-wheel-drive vehicle has a propeller shaft, a final drive and differential gears, and axles for both the front and rear axle assemblies. A transfer case is attached to the transmission.Part-time 4-wheel-drive means the vehicle is usually in 2-wheel-drive, and switched to full-time when needed by engaging the transfer case. It locks the propeller shafts together, and directs torque through them to both axles. When disengaged, the vehicle transfer case is coupled to 1 propeller shaft only.When 4-wheel-drive is disengaged, most part-time, 4-wheel-drive vehicles drive the rear wheels.Constant-4-wheel-drive uses a third differential in the transfer case. It allows for the difference in speed between the front and rear wheels during cornering.The driver can still lock the front and rear axles together by moving a separate lever as in a conventional 4-wheel-drive or by moving the main gear selector. This is called a differential lock.Some full-time, 4-wheel-drive sedans use a front engine and transaxle, with a propeller shaft connected to drive the rear wheels.These cars are lighter and less rugged than conventional off-road types, and usually operate at higher speeds. The drive to all wheels provides better balanced handling, and traction for cornering in slippery conditions. Chassis

SummaryA chassis is an underlying supporting structure. A traditional chassis gives the vehicle structural strength, whereas modern vehicles integrate the bodywork into a single unit with the chassis so that the body becomes part of the structure of the vehicle rather than just an external skin.

A chassis is an underlying supporting structure such as a skeleton in an animal, or the metal frame in a television on which the circuit boards and other components are mounted.In a motor vehicle, a traditional chassis gave the vehicle structural strength as well as a platform on which to mount the engine, the wheels, the transmission, and all the other mechanical components. Also bolted onto this frame was the body, or coachwork. Originally made of wood, the vehicle chassis soon became an open steel ladder-frame structure.A separate chassis is still the preferred structural basis for commercial vehicles, which are often sold without a body at all but with the running gear mounted to a chassis only, or in a 'cowl-and-chassis' or 'cab-and-chassis' configuration so that specialized bodies can be fitted to them for different purposes.Body-on-frame used to be the preferred way of building passenger vehicles too, because it allowed new models of vehicles with different body styles to be released without having to retool most of the mechanical and structural components. In the 1960s, most manufacturers switched to vehicle designs which either partially or wholly integrated the bodywork into a single unit with the chassis so that the body became part of the structure of the vehicle rather than just an external skin.The idea of a single shell or 'monocoque' design was first used in aircraft, then spread to automobiles, and became popular with manufacturers because with less of a chassis component it was both quicker to manufacture and lighter in weight, therefore costing less in both material and labor. The spot-welded unit body process, known as 'Unibody', is the predominant vehicle construction technology today.High performance racing cars today have no chassis at all, their structural strength coming from their light, stiff, and stable body shells molded from newer lightweight materials such as carbon fiber reinforced plastics. Transmission components

SummaryWhen changing gears in a manual transmission, a stick shift and selectors are utilized. On a read-wheel drive vehicle the stick shift is normally mounted directly into the transmission itself. In other vehicles, the stick shift can be attached to the steering column.

When changing gears in a manual transmission, a stick shift and selectors are utilized.The selectors are mounted in the transmission, and allow the various gear ratios to be selected.In this example, the selector levers are connected to the stick shift inside the vehicle by selector rods.Inside the vehicle of a manual transmission, a stick shift is provided to allow the various gear positions to be selected.The stick shift is located on the floor beside the driver.On a Rear Wheel Drive vehicle with the stick shift located on the floor, it is normally mounted directly into the transmission itself.In other vehicles, the stick shift can be attached to the steering column, they can be connected to the transmission by means of selector rods or cables.Inside the vehicle equipped with automatic transmission, a gear selector is provided to allow the various gear positions to be selected. The gear selector can be located beside the driver on the floor, often referred to as a T Bar automatic. In other vehicles the gear selector is located on the steering column. In either situation, the selector is connected to the transmission by selector rods or, in some applications, by cables. Chassis configurations

SummaryVehicles can be described by the number of axles. Most light vehicles only have two axles.

Vehicles can be described by the number of axles. Most light vehicles only have 2 axles.This vehicle has 4 wheels but only 2 driving wheels.This one has 4 driving wheels, and is commonly called a 4-wheel drive vehicle.The location of the driving axle determines whether the vehicle is classified as: rear-wheel drive, front-wheel drive, 4-wheel drive, or all-wheel drive.Rear-wheel drive vehicles can use a conventional layout with the engine at the front of the vehicle. The torque from the engine is transmitted to the rear-mounted driving axle by propeller, or drive shaft. This spreads the weight of components throughout the vehicle.This rear-wheel drive vehicle has the engine at the rear, driving the wheels through a combination transmission and rear axle called a transaxle. The transaxle is lighter than a separate transmission and rear axle.Moving the engine to the rear allows a lower hood profile, which improves aerodynamics. The increase in weight over the rear wheels can improve their traction.This vehicle has the engine located behind the operator's cabin, but forward of the rear driving axle. This is called a mid-engine, rear-wheel drive vehicle. A mid-engine design locates the engine behind the driver but forward of the rear axle. This allows for a low hood profile, and good handling.Front-wheel drive vehicles use the front wheels to pull the vehicle along. In light passenger vehicles it gives lighter body weight, and increased interior room. The engine and transaxle are at the front, and can be mounted laterally, that is, the engine is parallel to the front axle, or longitudinally where the engine is inline with the center line of the vehicle. Carrying out a visual inspection

SummaryThe objective of this procedure is to show you how to carry out a preliminary visual inspection. Be sure to work in a systematic manner, or you could miss a faulty bulb or other component.Part 1. Preparation and safetyObjective Carry out a preliminary visual inspection.Personal safetyWhenever you perform a task in the workshop you must use personal protective clothing and equipment that is appropriate for the task and which conforms to your local safety regulations and policies. Among other items, this may include: Work clothing - such as coveralls and steel-capped footwear Eye protection - such as safety glasses and face masks Ear protection - such as earmuffs and earplugs Hand protection - such as rubber gloves and barrier cream Respiratory equipment - such as face masks and valved respiratorsIf you are not certain what is appropriate or required, ask your supervisor.Safety check Make sure that you understand and observe all legislative and personal safety procedures when carrying out the following tasks. If you are unsure of what these are, ask your supervisor.

Points to note Be sure to work in a systematic manner, or you could miss a faulty bulb or other component.

Part 2: Step-by-step instruction1. Prepare the vehicleOnce a month or prior to any long trip, a vehicle should be checked for overall roadworthiness. The following simple measures will ensure that the vehicle is able to undertake the trip, and provide a warning of potential problems that may need further attention.2. Walk around the vehicleBegin your inspection by walking around the vehicle, and observing any obvious items that need attention.3. Check exterior component and system operationCheck the body condition to make sure that all the body components are secure. Open and close doors to check that they are operating correctly. Push and pull on the bumpers or fenders and ensure they are secure. Inspect the external mirrors to ensure that they are secure and not broken. Inspecting under body components

SummaryThe objective of this procedure is to show you how to inspect all under body components. This is a systematic visual inspection of all major vehicle systems. Be prepared to note down any faults to discuss later with your supervisor.Part 1. Preparation and safetyObjective Inspect all under body components.Personal safetyWhenever you perform a task in the workshop you must use personal protective clothing and equipment that is appropriate for the task and which conforms to your local safety regulations and policies. Among other items, this may include: Work clothing - such as coveralls and steel-capped footwear Eye protection - such as safety glasses and face masks Ear protection - such as earmuffs and earplugs Hand protection - such as rubber gloves and barrier cream Respiratory equipment - such as face masks and valved respiratorsIf you are not certain what is appropriate or required, ask your supervisor.Safety check Make sure that you understand and observe all legislative and personal safety procedures when carrying out the following tasks. If you are unsure of what these are, ask your supervisor.

Points to note This is a systematic visual inspection of all major vehicle systems. Be prepared to note down any faults to discuss later with your supervisor. The steering area inspection includes tie-rods, tire and wheel assembly, suspension bushes, shock absorbers and brake hoses. In the transmission area, you'll be looking for fluid leaks, tightening mounting bolts, and inspecting the clutch mechanism or shift linkage. Clamps and bolts may need tightening on the exhaust system and manifold pipe. You'll also be looking for signs of exhaust leaks, corrosion or deterioration. You'll be checking for any excess movement in driveline shafts. Look for leaks around the differential and check the rear shock absorbers or leaf springs. The fuel tank must be secure and fuel lines inspected for damage or abrasion.

Part 2: Step-by-step instruction1. Begin under vehicle visual inspectionSafely raise the vehicle to a comfortable working height. Be ready to record any faults you find, and begin your inspection at either end of the vehicle. Whichever end you choose, work systematically in one direction. Note any problems you find and discuss them with your supervisor. Pay particular attention to any fluid leaks, which will probably be the easiest problems to spot.2. Check steering areaLocate the tie-rods and move them through their operating arc. The action should be smooth without binding. The tire and wheel assembly should also move in a forward and backward direction to detect lateral movement in the tie-rod end. Look carefully for missing or torn rubber boots around tie rod ends or the steering shaft. At the same time, check the security of the steering box mountings. Inspect any rubber suspension bush for swelling or damage, and check shock absorbers for signs of damage or leaks. Inspect any wiring harness that is accessible for any obvious damage. Check the brake hoses, looking for signs of cracking or abrasions3. Check transmission areaCheck the transmission mounting bolts for tightness. Trace and record the source of fluid leaks if you find any. With a manual transmission, check the clutch operating mechanism for looseness or binding. For an automatic transmission, check the shift linkage for smoothness of operation. If the transmission is electronically controlled, check any wiring for obvious damage.4. Check exhaust systemCheck the tightness of the flange bolts on the engine manifold pipe. Its also important to make sure all the clamps on the exhaust system are tight. If there is an exhaust leak, its usually identified by a blackish soot deposit at the source of the leak. Examine the catalytic converter, muffler and resonator for any signs of corrosion or deterioration. Check the tail pipe for any corrosion, and looseness in the mounting brackets or hangers.5. Check hand brake cablesInspect the hand brake cable to make sure its not frayed, damaged or binding.6. Check driveline shaftsOn any rear wheel drive vehicles, including pick-ups and SUVs, inspect the drive shaft universal joints for signs of excess movement or rust. Rusty powder marks near the front, and rear universal joints could indicate a rusted and/or seized universal joint. To check for wear, rotate the shaft and flange in opposite directions. There should be no movement in the joint. On four-wheel drive vehicles, repeat this procedure on the front drive shaft universals7. Check differential and rear suspension areaOn rear- wheel drive vehicles the rear axle housing supports the differential unit. On front-wheel drives, the differential is usually located in the transaxle housing. Inspect the pinion shaft oil seal for any obvious signs of leakage. Next, check the rear shock absorbers for any signs of physical damage or fluid leaks. Tighten all the suspension mounting bolts, noting any bolt that s loose. Inspect the suspension mounting bushes for any signs of deterioration or damage. This will include any control arms or struts. If the vehicle is fitted with leaf springs, inspect the leafs for any cracks or misalignment. On a front wheel drive vehicle, inspect the rear strut assembly for any physical damage or signs of fluid leaks. Inspect the brake hoses for any obvious signs of cracking or abrasion.8. Check fuel tank areaTighten the fuel tank mounting bolts or retaining clamp bolts, noting any bolt thats loose. Carefully check all the fuel lines for any signs of damage or abrasions that may cause a leak.9. Discuss problems with your supervisorAfter completing the inspection, discuss your list of problems with your supervisor to see what action can be taken to fix the problems Inspecting under body components

SummaryThe objective of this procedure is to show you how to inspect all under body components. This is a systematic visual inspection of all major vehicle systems. Be prepared to note down any faults to discuss later with your supervisor.Part 1. Preparation and safetyObjective Inspect all under body components.Personal safetyWhenever you perform a task in the workshop you must use personal protective clothing and equipment that is appropriate for the task and which conforms to your local safety regulations and policies. Among other items, this may include: Work clothing - such as coveralls and steel-capped footwear Eye protection - such as safety glasses and face masks Ear protection - such as earmuffs and earplugs Hand protection - such as rubber gloves and barrier cream Respiratory equipment - such as face masks and valved respiratorsIf you are not certain what is appropriate or required, ask your supervisor.Safety check Make sure that you understand and observe all legislative and personal safety procedures when carrying out the following tasks. If you are unsure of what these are, ask your supervisor.

Points to note This is a systematic visual inspection of all major vehicle systems. Be prepared to note down any faults to discuss later with your supervisor. The steering area inspection includes tie-rods, tire and wheel assembly, suspension bushes, shock absorbers and brake hoses. In the transmission area, you'll be looking for fluid leaks, tightening mounting bolts, and inspecting the clutch mechanism or shift linkage. Clamps and bolts may need tightening on the exhaust system and manifold pipe. You'll also be looking for signs of exhaust leaks, corrosion or deterioration. You'll be checking for any excess movement in driveline shafts. Look for leaks around the differential and check the rear shock absorbers or leaf springs. The fuel tank must be secure and fuel lines inspected for damage or abrasion.

Part 2: Step-by-step instruction1. Begin under vehicle visual inspectionSafely raise the vehicle to a comfortable working height. Be ready to record any faults you find, and begin your inspection at either end of the vehicle. Whichever end you choose, work systematically in one direction. Note any problems you find and discuss them with your supervisor. Pay particular attention to any fluid leaks, which will probably be the easiest problems to spot.2. Check steering areaLocate the tie-rods and move them through their operating arc. The action should be smooth without binding. The tire and wheel assembly should also move in a forward and backward direction to detect lateral movement in the tie-rod end. Look carefully for missing or torn rubber boots around tie rod ends or the steering shaft. At the same time, check the security of the steering box mountings. Inspect any rubber suspension bush for swelling or damage, and check shock absorbers for signs of damage or leaks. Inspect any wiring harness that is accessible for any obvious damage. Check the brake hoses, looking for signs of cracking or abrasions3. Check transmission areaCheck the transmission mounting bolts for tightness. Trace and record the source of fluid leaks if you find any. With a manual transmission, check the clutch operating mechanism for looseness or binding. For an automatic transmission, check the shift linkage for smoothness of operation. If the transmission is electronically controlled, check any wiring for obvious damage.4. Check exhaust systemCheck the tightness of the flange bolts on the engine manifold pipe. Its also important to make sure all the clamps on the exhaust system are tight. If there is an exhaust leak, its usually identified by a blackish soot deposit at the source of the leak. Examine the catalytic converter, muffler and resonator for any signs of corrosion or deterioration. Check the tail pipe for any corrosion, and looseness in the mounting brackets or hangers.5. Check hand brake cablesInspect the hand brake cable to make sure its not frayed, damaged or binding.6. Check driveline shaftsOn any rear wheel drive vehicles, including pick-ups and SUVs, inspect the drive shaft universal joints for signs of excess movement or rust. Rusty powder marks near the front, and rear universal joints could indicate a rusted and/or seized universal joint. To check for wear, rotate the shaft and flange in opposite directions. There should be no movement in the joint. On four-wheel drive vehicles, repeat this procedure on the front drive shaft universals7. Check differential and rear suspension areaOn rear- wheel drive vehicles the rear axle housing supports the differential unit. On front-wheel drives, the differential is usually located in the transaxle housing. Inspect the pinion shaft oil seal for any obvious signs of leakage. Next, check the rear shock absorbers for any signs of physical damage or fluid leaks. Tighten all the suspension mounting bolts, noting any bolt that s loose. Inspect the suspension mounting bushes for any signs of deterioration or damage. This will include any control arms or struts. If the vehicle is fitted with leaf springs, inspect the leafs for any cracks or misalignment. On a front wheel drive vehicle, inspect the rear strut assembly for any physical damage or signs of fluid leaks. Inspect the brake hoses for any obvious signs of cracking or abrasion.8. Check fuel tank areaTighten the fuel tank mounting bolts or retaining clamp bolts, noting any bolt thats loose. Carefully check all the fuel lines for any signs of damage or abrasions that may cause a leak.9. Discuss problems with your supervisorAfter completing the inspection, discuss your list of problems with your supervisor to see what action can be taken to fix the problems Measuring a wheelbase

SummaryThe wheelbase is the distance between the center of the front wheel and the center of the rear wheel and is normally the same on both sides of the vehicle. The objective of this procedure is to show you how to identify and measure the wheelbase.Part 1. Preparation and safetyObjective Identify and measure the wheelbase.Personal safetyWhenever you perform a task in the workshop you must use personal protective clothing and equipment that is appropriate for the task and which conforms to your local safety regulations and policies. Among other items, this may include: Work clothing - such as coveralls and steel-capped footwear Eye protection - such as safety glasses and face masks Ear protection - such as earmuffs and earplugs Hand protection - such as rubber gloves and barrier cream Respiratory equipment - such as face masks and valved respiratorsIf you are not certain what is appropriate or required, ask your supervisor.Safety check Make sure that you understand and observe all legislative and personal safety procedures when working around vehicle chassis components. If you are unsure of what these are, ask your supervisor.Points to note The vehicle chassis is the platform to which all the operating components and systems of the vehicle are attached. It is important that the chassis is straight and square so that steering and suspension components can operate in the intended manner. Manufacturers specify dimensions in relation to the location of the wheels. Two particular dimensions are: Wheelbase Track

The wheelbase is the distance between the center of the front wheel and the center of the rear wheel and is normally the same on both sides of the vehicle. Some vehicles may have different wheelbase measurements from left to right. This is the exception rather than the rule. Always check the manufacturer's specifications before you take the measurements. The track is the measurement between the center of the left wheel tread and the center of the right wheel tread. It is common for the front track and the rear track to differ. If the dimensions differ from the manufacturer's specifications, refer to your supervisor. Two other dimensions should be noted: The overall length of the vehicle. This is the distance between the front and rear extremities. The overall width of the vehicle. This is the distance from the extreme right side to the extreme left side of the vehicle, but not usually including the external mirrors. These measurements are particularly important for legislative purposes. A vehicle's overall length and width can determine the roads where it can legally operate. The majority of service departments will have some form of electronic equipment to measure the axle alignment. When there is no specialized equipment, a basic method of checking axle alignment or the wheelbase can be carried out with simple tools. We have outlined this procedure in this module. The procedure shown here is not the only measuring method, but shows how to carry out these checks if no specialized equipment is available. Carry out this procedure with specialized equipment if it is available and you have been trained to use it.

Part 2: Step-by-step instruction1. Prepare the vehiclePosition the vehicle on a flat surface with the road wheels pointing straight ahead. Engage the emergency brake and place the transmission in neutral or park, then turn off the ignition.2. Select appropriate measuring equipmentYou will need to prepare a measuring device. Such as a straight length of wood or steel with two moveable pointers attached.3. Compare distances between axles on both sidesPlace the length of steel, with the two moveable pointers attached, next to the front and rear wheels on one side of the vehicle. Align the two pointers to the centers of the front and rear axles. Tighten the pointers to the position of the axle centers. Alternatively, use a mechanics set-square to align the front and rear axle centers with the length of steel, and mark the steel with chalk or marking pencil. Move the measuring device to the other side of the vehicle and check to see if the pointers align with the axle centers on this side. Compare the two; they should be the same. If one side of the vehicle has wheels significantly closer together or further apart, refer this to your supervisor.4. Measure the wheelbase between marksRemove the length of steel and measure the distance between the two marks. This will give you the distance between the two wheel axles. Checking windshield washer liquid

SummaryThe objective of this procedure is to show you how to inspect and refill a windshield washer fluid reservoir. Remember to only use an approved windshield washer fluid.Part 1. Preparation and safetyObjective Inspect and refill a windshield washer fluid reservoir.Personal safetyWhenever you perform a task in the workshop you must use personal protective clothing and equipment that is appropriate for the task and which conforms to your local safety regulations and policies. Among other items, this may include: Work clothing - such as coveralls and steel-capped footwear Eye protection - such as safety glasses and face masks Ear protection - such as earmuffs and earplugs Hand protection - such as rubber gloves and barrier cream Respiratory equipment - such as face masks and valved respiratorsIf you are not certain what is appropriate or required, ask your supervisor.Safety check Make sure that you understand and observe all legislative and personal safety procedures when carrying out the following tasks. If you are unsure of what these are, ask your supervisor.

Points to note Only use an approved windshield washer fluid.

Part 2: Step-by-step instruction1. Locate washer fluid reservoirLocate the windshield wiper fluid container. This is normally found under the hood and is usually a plastic bottle or bag.2. Check the fluid levelSome vehicles have electrical sensors incorporated into the reservoir, and an indicator lamp on the inside of the vehicle will show the driver when the system needs to be filled. In most vehicles the fluid level is visible and a marker on the reservoir indicates the correct fluid level.3. Fill reservoirChoose an appropriate washer fluid. Some fluids are concentrated and need to be mixed with water. Never use laundry-washing detergent to top up the reservoir, as the chemicals in the detergent can be detrimental to the vehicle paintwork. Take care not to spill the fluid, and fill the reservoir to between the minimum and maximum marks. Checking & replacing wiper blades

SummaryThe objective of this procedure is to show you how to check the condition of windshield wiper blades and arms and change a windshield wiper blade. Never operate the wipers when they are dry because this may damage the blades or scratch the surface of the windshield.Part 1. Preparation and safetyObjective Check the condition of windshield wiper blades and arms and change a windshield wiper blade.Personal safetyWhenever you perform a task in the workshop you must use personal protective clothing and equipment that is appropriate for the task and which conforms to your local safety regulations and policies. Among other items, this may include: Work clothing - such as coveralls and steel-capped footwear Eye protection - such as safety glasses and face masks Ear protection - such as earmuffs and earplugs Hand protection - such as rubber gloves and barrier cream Respiratory equipment - such as face masks and valved respiratorsIf you are not certain what is appropriate or required, ask your supervisor.Safety check Make sure that you understand and observe all legislative and personal safety procedures when carrying out the following tasks. If you are unsure of what these are, ask your supervisor.

Points to note Never operate the wipers when they are dry because this may damage the blades or scratch the surface of the windshield. Never bend the arms to make better contact with the windshield. The arms are pre-tensioned by the manufacturer and damage could result. If the arms seem to have lost their spring tension, obtain a suitable replacement.

Part 2: Step-by-step instruction1. Check windshield wiper bladesLift the wiper arm away from the windshield and inspect the condition of the blades. Look for damage or loss of resilience in the material. Wet the windshield with a spray, or with the washers and switch the wipers on. If the windshield is being wiped cleanly, do not replace the blades. If the wiper blades are not wiping the glass evenly, or are smearing the windshield, you will need to replace the blades.2. Remove blade assemblyRemove the blade assembly. Depending on the vehicle, you may need to remove the wiper arm from its mounting, or you may be able to just undo a spring clip and remove the blade insert.3. Obtain replacement bladeCheck the shop manual and obtain the correct size replacement. New developments in blade design means that the profile of the new blade may not be identical to the original.4. Install insertsFeed the new inserts into the wiper arm, and make sure the clips fit snugly and engage properly.5. Test bladesWet the windshield again, and operate the wipers to check their performance, making sure they remove the water evenly. Checking a security system

SummaryThe objective of this procedure is to show you how to check an automotive security system on a vehicle. Transponders are designed to cope with normal operating stresses. If the transponder is not working properly you might need to replace its battery.Part 1. Preparation and safetyObjective Check an automotive security system on a vehicle.

Personal safetyWhenever you perform a task in the workshop you must use personal protective clothing and equipment that is appropriate for the task and which conforms to your local safety regulations and policies. Among other items, this may include: Work clothing - such as coveralls and steel-capped footwear Eye protection - such as safety glasses and face masks Ear protection - such as earmuffs and earplugs Hand protection - such as rubber gloves and barrier cream Respiratory equipment - such as face masks and valved respiratorsIf you are not certain what is appropriate or required, ask your supervisor.Safety check Make sure that you understand and observe all legislative and personal safety procedures when carrying out the following tasks. If you are unsure of what these are, ask your supervisor.Points to note Some systems are movement sensitive, so it is difficult to try to start the car from the inside. Your movement will set the alarm off. Some vehicle security transponders may not operate in some environments. This may be because there is strong electromagnetic interference in the area.

If a transponder does not seem to operate verify that it belongs to the vehicle you are attempting to unlock. It may be that a busy service advisor has mislabeled the key and transponder from another vehicle. Transponders are designed to cope with normal operating stresses. Do not drop them into liquid or subject them to extreme heat or force.

Part 2: Step-by-step instruction1. Set the security systemThis section deals with vehicle security and alarms. When the system is armed, an LED type light usually blinks on the dash. In some cases you will also hear an audible tone. Sit inside the vehicle with the doors shut. Lock the doors and activate the security system. This is usually done with a transponder. The transponder that turns the security system on and off is usually a small battery-powered device attached to the key ring, or built in to the ignition key itself.2. Test the security systemStart the engine. If the security system immobilizes the engine then this action should not be possible. If the security system is an audible alarm, it should now go off. If the security system works properly, move the vehicle to a different location - for instance, outside the workshop - and test it again. A transponder can suffer from electronic interference and may work better in some locations than others.3. Check transponder operationIf the security test fails, check whether or not the transponder has power and is operating correctly. If it operates the door locks as well as the security system, locking and unlocking the vehicle will confirm that the transponder is working.4. Replace transponder batteryIf the transponder is not working properly you might need to replace its battery. To do this, you will need to refer to the specific manufacturers specifications for changing the battery to re-test the unit.5. Action on failureIf either the security system or the transponder is not working, you should report it to your supervisor. Checking door hinges

SummaryThe objective of this procedure is to show you how to lubricate door hinges and locks and adjust jams. Different manufacturers use different forms of latches and locking mechanisms, so always make sure that you have the correct service manual for the job you are working on.Part 1. Preparation and safetyObjective Lubricate door hinges and locks and adjust jams.

Personal safetyWhenever you perform a task in the workshop you must use personal protective clothing and equipment that is appropriate for the task and which conforms to your local safety regulations and policies. Among other items, this may include: Work clothing - such as coveralls and steel-capped footwear Eye protection - such as safety glasses and face masks Ear protection - such as earmuffs and earplugs Hand protection - such as rubber gloves and barrier cream Respiratory equipment - such as face masks and valved respiratorsIf you are not certain what is appropriate or required, ask your supervisor.Safety check Make sure that you understand and observe all legislative and personal safety procedures when carrying out the following tasks. If you are unsure of what these are, ask your supervisor.Points to note Different manufacturers use different forms of latches and locking mechanisms. Always make sure that you have the correct service manual for the job you are working on. On vehicles with heavy doors, such as some older vehicles and convertibles, the door latch contains a locating wedge or pin. This locates the door when closed, and takes some of the strain off the hinges.

Part 2: Step-by-step instruction1. Check door for hinge wearOpen the door to approximately 45 degrees to the car body. Wear gloves when performing this test, in case there are any sharp edges underneath the door. Put your hand under the base of the door, and lift it gently against the hinges to see if there is excess wear in the pins. Some limited amount of wear is always present, and you will usually be able to move the door up and down a little at its outer edge. An excessive amount of movement means the door is worn and has dropped. Report this to your supervisor, as the hinges or door jams may need to be adjusted.2. Check door closureGently push the door closed. If the door shuts smoothly with a distinct click, then the door is catching the locking or latch mechanism as it is designed to do. Push the door in further, and you should hear a second click. This indicates that the door is adjusted correctly.3. Lubricate hingesFully open each door. Using a manufacturer-approved lubricant, apply it to the tops of each hinge. Generally, lower hinges have a door check roller, cam and spring incorporated into the assembly. You should also lubricate the roller part of the assembly. Now swing the door gently back and forth to allow the lubricant to penetrate into the hinges. Wipe any excess lubricant from the external parts of the hinges.4. Lubricate lock and latch mechanismUsing a manufacturers approved lubricant, apply it to each locking or latch mechanism. Generally the locking and latch mechanism is in the door itself, so the lock needs to be worked to allow the lubricant to penetrate into the mechanism. Operate the latch by opening and closing the door, and from both the outside and the inside of the vehicle. Wipe any excess lubricant from the external parts of the locking mechanism. Checking a seat belt

SummaryThe objective of this procedure is to show you how to check the condition and security of automotive seatbelts. Any seatbelt that has been involved in a severe impact may have been weakened and should be replaced.Part 1. Preparation and safetyObjective Check the condition and security of automotive seatbelts.Personal safetyWhenever you perform a task in the workshop you must use personal protective clothing and equipment that is appropriate for the task and which conforms to your local safety regulations and policies. Among other items, this may include: Work clothing - such as coveralls and steel-capped footwear Eye protection - such as safety glasses and face masks Ear protection - such as earmuffs and earplugs Hand protection - such as rubber gloves and barrier cream Respiratory equipment - such as face masks and valved respiratorsIf you are not certain what is appropriate or required, ask your supervisor.Safety check Make sure that you understand and observe all legislative and personal safety procedures when carrying out the following tasks. If you are unsure of what these are, ask your supervisor.Points to note Many vehicles have additional motorized mechanisms to help the seat belts operate. Always ensure that manufacturer's instructions are followed when lubricating and servicing these types of units. Any seatbelt that has been involved in a severe impact may have been weakened and should be replaced.

Part 2: Step-by-step instruction1. Check anchor points of seatbeltThere are three anchor points on lap and sash type seatbelts and two on lap only type seatbelts. First, check the side anchor bolt that holds the buckle end in place. Make sure it is sound and secure. Next, check the security of the bolt on the retractor housing. This is usually located near the bottom of the door panel next to the seat. Above the retractor is the upper anchor bolt. These bolts are sometimes adjustable in a slider unit. Check that this is also secure.2. Inspect seatbelt for fraying or wearingExamine the seatbelt material to see if there is any fraying or excessive wear. Check the seatbelt label for an expiry date. If the belt is past its use-by date, then report this to your supervisor, as the belt should be replaced.3. Check seatbelt retractionPull the seatbelt out slowly to check for smooth action. There should not be any sticking, which might indicate a faulty retractor. Do this three times to make sure that it is consistently smooth in operation.4. Check seatbelt lockingPull the seatbelt out quickly to see that it locks and releases. The belt should lock when pulled suddenly, which is vital during emergency braking or collisions.5. Check retractor operationIf the belt does not retract smoothly, remove the retractor housing and test it again. If the belt now retracts smoothly, then the retractor housing may need to be replaced. When the retractor is tilted beyond 45 degrees, the belt should remain locked. If the belt fails to function correctly, report it to your supervisor. Checking interior trim

SummaryThere are a number of different ways trim panels can be fixed in place, so refer to the shop manual for details of the panel fixing methods used in your vehicle. The objective of this procedure is to show you how to remove and replace interior trim components.Part 1. Preparation and safetyObjective Remove and replace interior trim components.

Personal safetyWhenever you perform a task in the workshop you must use personal protective clothing and equipment that is appropriate for the task and which conforms to your local safety regulations and policies. Among other items, this may include: Work clothing - such as coveralls and steel-capped footwear Eye protection - such as safety glasses and face masks Ear protection - such as earmuffs and earplugs Hand protection - such as rubber gloves and barrier cream Respiratory equipment - such as face masks and valved respiratorsIf you are not certain what is appropriate or required, ask your supervisor.Safety check Make sure that you understand and observe all legislative and personal safety procedures when carrying out the following tasks. If you are unsure of what these are, ask your supervisor.Points to note Different vehicles have different methods of trim fixture, although they all follow similar methods of removal. The vehicle manufacturer's manual will provide tips on the methods of removal. Many cars have electric window winder mechanisms with activation switches on the trim panels. Always make sure that you use the recommended procedure, so that you do not trap wires between the door inner panel and the trim panel. This could cause an electrical short and damage the vehicle.

Part 2: Step-by-step instruction1. Check fixing methodThere are a number of different ways trim panels can be fixed in place, so refer to the shop manual for details of the panel fixing methods used in your vehicle.2. Remove fittingsRemove any external fixtures on the panel, such as armrests or window winders, and place them in a safe clean place. These components may be held in place by screws or clips. Try not to damage them during removal.3. Obtain replacement clipsMany panels are held in place with clips in what look like keyholes. These clips are normally made out of plastic and they can easily be broken during removal, so always make sure you have some replacement clips for the re-assembly process. It is better to sacrifice a few replaceable clips than to risk damaging the panel itself.4. Remove panelMost manufacturers have a special tool for removing the panel clips. Gently slide the tool under the panel and work your way along it until you locate a clip. Remove the tool and then replace it over the clip. Press down and the clip should pop out of its location. Repeat the process around the panel until it is completely unfastened. Lower the window, place your hands on the side of the panel, and wiggle it upwards. This should lift the panel from its seating, allowing you to remove it.5. Replace panelTo replace the panel, make sure that all the panel clips are in place. Now lift the panel back in, and hook it over the inner door panel. Line up the clips with their location points and firmly push them into place. You will here a distinctive click as they lock in.6. Replace fittingsReplace the armrests and any other components, such as window winder mechanisms. Clean off any finger marks with an approved solvent and a cloth that will not damage the panel material. Checking driver's seat fabric

SummaryPoor seat condition can be the subject of a safety defect, making the vehicle unroadworthy. The objective of this procedure is to show you how to check the driver's seat for security and condition.Part 1. Preparation and safetyObjective Check the driver's seat for security and condition.Personal safetyWhenever you perform a task in the workshop you must use personal protective clothing and equipment that is appropriate for the task and which conforms to your local safety regulations and policies. Among other items, this may include: Work clothing - such as coveralls and steel-capped footwear Eye protection - such as safety glasses and face masks Ear protection - such as earmuffs and earplugs Hand protection - such as rubber gloves and barrier cream Respiratory equipment - such as face masks and valved respiratorsIf you are not certain what is appropriate or required, ask your supervisor.Safety check If you use glue to make small fabric or vinyl repairs, do this in a well-ventilated area. Make sure that you understand and observe all legislative and personal safety procedures when carrying out the following tasks. If you are unsure of what these are, ask your supervisor.Points to note If the existing seat cover is damaged, it is sometimes possible to make small repairs with some fabric or vinyl glue, depending on the original material. This will stop the nicks or small tears from getting any worse. If you do this, follow the instructions on how to apply the glue.

If the seat fabric is badly ripped, or you can see the springs or seat frame, you should take the seat to a specialized upholstery repair shop. In some places, it is a legal requirement that the seat be in a "secure condition", even if it has a fitted seat cover placed over the damage. Poor seat condition can be the subject of a safety defect, making the vehicle unroadworthy. You should check your local laws. If the driver's seat is damaged but still safe and structurally sound, it may be possible to swap it with the front passenger seat, if that one is in better condition. The passenger's comfort is less of a potential driving hazard.

Part 2: Step-by-step instruction1. Inspect visuallyIf a removable seat cover has been fitted, remove it so that you can see the original fabric. Inspect the seat for overall condition. The important thing to note is if the springs or frame inside the seat are visible through the fabric. If there are nicks or small tears, then note them down so that they can be reported to the customer.2. Check the seat securityNow, look at the seat runners and their fixtures. Check to see that they are mounted according to the manufacturers recommendations, and that the mounting points are free from corrosion or rust.3. Check the seat operationCheck that the seat adjustment features operate correctly, as shown in the drivers operation manual. If any of them fails to function properly, make a note on your work order and report the fault to your supervisor. Vehicle valet service

SummaryThe objective of this procedure is to show you how to wash, polish and detail a vehicle using the appropriate methods. You should always follow MSDS, HAZMAT and other related product information when storing any hazardous material.Part 1. Preparation and safetyObjective Wash, polish and detail a vehicle using the appropriate methods.Personal safetyWhenever you perform a task in the workshop you must use personal protective clothing and equipment that is appropriate for the task and which conforms to your local safety regulations and policies. Among other items, this may include: Work clothing - such as coveralls and steel-capped footwear Eye protection - such as safety glasses and face masks Ear protection - such as earmuffs and earplugs Hand protection - such as rubber gloves and barrier cream Respiratory equipment - such as face masks and valved respiratorsIf you are not certain what is appropriate or required, ask your supervisor.Safety check Mix any detergents according to manufacturer specifications. Keeping cleaners and solvents in workshop quantities can be a safety hazard, and so can disposing of impregnated cleaning cloths and product residues, unless correct procedures are followed. You should always follow MSDS, HAZMAT and other related product information when storing any hazardous material. For instance, there may be a limit on the amount of materials that may be kept a container/cupboard of a particular size, or there may be ventilation requirements. Consult your local legislative authority to get information on what you may and may not do in relation to the storage of hazardous materials. Cleaning chemicals and detergents are a potential environmental hazard. Make sure that the area used for washing and detailing a vehicle meets all local environmental regulations, particularly in regard to preventing contaminants from flowing into storm water drainage systems. Ideally, waste run-off should be collected in underground grease traps and treated before disposal. Use the recommended polishing cloth for the polish being used, and do not rub too hard when polishing the vehicle, so you do not damage the paintwork. It is important not to damage or tear the vehicle floor drain plugs (or bungs) during removal or installation as this can allow water in from the outside of the vehicle during rain or snow. The effect of this may not be immediately noticeable, however, over time, the gradual ingress of water can cause the carpets to rot and in extreme cases can cause the floor pan to rust out.

Some wheel covers simply pry off, some only come off when the wheel nuts are undone; so if you do need to remove them, carefully check the method of removal for the vehicle you are working on. If the wheel nuts have to be removed, make sure you use the correct safety procedures when loosening the nuts and raising the vehicle prior to removing them. Make sure that you understand and observe all legislative and personal safety procedures when carrying out the following tasks. If you are unsure of what these are, ask your supervisor.Points to note Cleaning chemicals and detergents are a potential environmental hazard. Make sure that the area used for washing and detailing a vehicle meets all local environmental regulations, particularly in regard to preventing contaminants from flowing into storm water drainage systems.

In this example, at a vehicle dealership, the waste run-off is collected in underground grease traps (below the metal cover plates) and treated before disposal. Use the proper polishing cloth; otherwise you could damage the paintwork. When polishing the vehicle, do not rub too hard. Some products can only be used in particular applications and so it is important that you select the correct product for the task. If you are unsure you should always seek advice from your supervisor.

Carpets There are usually two different types of carpet in a vehicle interior. The first of these are floor mats which are used as carpet protectors and take most of the wear from passengers feet. The second is the vehicle carpet itself which is normally fitted in the vehicle before the seats and center console and trim is installed. This carpet is there for its aesthetic effect, but it also provides a sound deadening covering layer between the passenger and the vehicle floor.

Wheels and tires Steel wheels normally have decorative wheel covers which are made of plastic or resin and are easy to clean with a brush and soapy water. The covers do not usually need to be removed for cleaning. Magnesium or aluminum alloy wheels do not have covers. If they are very dirty they will need to be cleaned with a special solution prior to normal washing. As there are many different products on the market make sure that you read and follow the correct application instructions. A finishing product such as tire black or tire shine can be applied to the tires. This can be applied by pressure pack spray or by hand with a brush dependent on the product. Choose an appropriate finishing product based on the type and durability of finish you want.

Dashboards Dashboards and instrument panel covers can be severely affected by ultra-violet rays and extreme cold and it is common to use protective agents on them. There are a range of products on the market and the instructions on the packs should be carefully read as the different products are not suitable for use on all materials. Never use such materials on steering wheels or pedal rubbers as they can remain slippery for some time and can be dangerous in operation as a result.

Carpets and cloth upholstery There are many cleaning and solvent based products for removing carpet and upholstery stains. Always follow the product information when applying such products as the different dyes used in carpets and fabrics can run as a result of the product use. Therefore you should always test for colour fastness in an unseen part of the carpet or fabric to ensure that the dye will not run when subjected to the cleaning material.

Leather upholstery Leather vehicle interiors and seats can be severely affected by ultra-violet rays and it is common to use protective agents on them. They are easier to clean than fabric seats as dirt generally sits on the surface of the leather - provided it has not been damaged. There are a range of products on the market and the instructions on the packs should be carefully read as the materials in different products may not be suitable for use in all locations on the vehicle.

Vehicle body tar Solvent products for removing tar from a vehicle body are all very similar. The important thing is to use a product that will remove the amount of tar adhering to the body without affecting the paint surface. Again, read the manufacturers instructions on the product very carefully, and follow them.

Part 2: Step-by-step instruction1. Wash and degreasePressure clean the outside of the vehicle thoroughly with plain water to remove all loose dust and street dirt. Wash under the wheel arches and inside the engine compartment. Mix the degreaser concentrate as recommended by the manufacturer. Spray the diluted degreaser all over the outside of the vehicle, including the road wheels and under the wheel arches. Let it work on the paintwork for a minute or so, to soften hardened or baked-on dirt and grease. Rinse the degreaser off with water using a pressure cleaner.If there are any signs of contaminants still on the paintwork, re-apply the degreaser, then wash it off again. You may need to carry out these steps a number of times until the contaminants soften and are rinsed away. Ensure that all the degreaser solution has been thoroughly rinsed off.Do not scratch the contaminant off with a scraper as this could easily damage the painted surface.2. Hand wash with suds solutionEnsure the detergent concentrate has been mixed according to the manufacturers specifications. Start at the top of the vehicle and work down. Do not rub the surface hard, and use your other hand to feel for the smoothness of the paint surface.Allow the detergent to work on the paintwork for a minute or so before rinsing. Rinse off the detergent suds with fresh water.3. Dry the vehicleUse two chamois cloths for drying - one for the paintwork, and the second for the road wheels and wheel arches. After drying off the water, check around the vehicle and clean off any water that may have come away from vehicle gutters and crevices. Dry inside all the door jams, in the boot and any other location where water could seep. If you find any spots of dirt still attached to the paint surface, gently remove them with a clean rag and a little kerosene.4. Hand polish the vehicleUse a piece of new, thin soft foam rubber to apply the polish. Apply the liquid polish using a very light circular rubbing action. Do not rub hard as this can score the paint surface.Using a soft cotton flannelette, remove the polish. It is a good idea to have a similar cloth in each hand. In this way, while you polish with one hand, you can lean on the vehicle to support yourself with the other hand without leaving greasy handprints. You can also swap polishing hands quickly if one gets tired. Check along the vehicle to ensure you have removed all the polish and that no imperfections show up in the paint or the panels.5. Clean all other surfacesIf there are any stickers on the glass area that should not remain there, remove them carefully with a razor blade, dampening them first if necessary.Using glass cleaner spray, carefully clean all the glass surfaces on the vehicle. Use a large wad of rolled up soft paper to clean the glass surfaces. As the paper becomes dirty and wet, tear off the outer layers to reveal clean, dry paper again.Clean and brush the tires with a suitable solution that will protect the rubber, and enhance its appearance. Wipe off any excess solution from the paintwork or wheels.6. Clean floor mats and carpetsRemove the floor mats and always clean them outside the vehicle. Vacuum the mats to remove loose dust and grit. Use an approved carpet cleaner and spray evenly over the mat. Using a clean, soft cloth, work the cleaner into the carpet and blot any residue.7. Detail the interiorRemove all interior containers for cleaning, noting their locating device. Spray an appropriate cleaner onto the dashboard and instrument panel and wipe clean using a soft, clean cloth before leaving the area to cure. Never use dashboard cleaners on steering wheels or pedal rubbers as they can remain slippery for some time.Clean and replace interior containers. You should hear the locating device click into place as it locates itself.On fabric seats, spray an appropriate fabric cleaner directly onto the seat. Massage the cleaner into the stain and allow it to stand for a few minutes and massage the stain again.Remove any excess cleaner with a damp absorbent cloth and allow the seat to dry before vacuuming. Repeat the process if necessary.On leather seats, apply an appropriate cleaner using a soft clean cloth and rub gently into the leather.Leave the cleaned leather to cure to form a protective layer on the seat and help protect it from further stains.8. Clean sunroof glassIf the sunroof is a fixed type, unclip and remove or slide back any shades or roof linings that cover the inside of the sunroof.Using the operation lever or the operation mechanism control, open the roof.Clean the glass on the sunroof using a recommended cleaning agent.Check and clean the channels on the vehicle that the sunroof locates in and ensure the drains are clear and able to take excess water away from the roof channel. Routine vehicle checks

SummaryThere are four manufacturer-recommended scheduled service types. They are: pre-delivery service, first service, distance-based service and time-based serviceScheduled servicingThere are four manufacturer-recommended scheduled service types. They are: Pre-delivery Service First Service Distance-based Service Time-based Service

Pre-delivery serviceA pre-delivery service is performed on a new vehicle before it is delivered to the customer. It is performed to check that the vehicle is in correct working order and is operating as the manufacturer intended. It is also the time to check that the required options are installed and dealer fitted accessories fitted.First serviceA first service is usually performed at around 1000 miles (m) or 1500 kilometers (km). Its function is to check the general condition of the vehicle, change the engine oil and make any minor adjustments. The owner may also require some early warranty repairs.Distance-based serviceDistance based services are used to maintain the vehicle at its optimum condition after a set amount of use. The distance between the services varies and can range from 3000 m or 5000 km upward depending on the manufacturer. Minor services are performed at shorter intervals, and major services performed at longer intervals. A major service includes the items performed at a minor service, but also includes other service items that need to be performed less frequently. At a service, lubricants can be changed, items such as spark plugs and filters replaced and adjustments and checks performed on components that wear out, such as brake pads and tires.

Time-based serviceTime based services protect a vehicle from deterioration over time rather than from the amount of use, which is measured by the distance traveled. These are performed when a vehicle is not used very much and travels only a small distance over a period of time. Minor services are performed at 6-month intervals. Major services are performed every 12 months. Lubricants and fluids have a service life and should be changed even if the vehicle has covered only a few miles or kilometers since the last service. Time based services are also performed on a seasonal basis, to prepare the vehicle for the onset of summer or winter.Non-scheduled servicingPre-trip checkOut of phase services are performed on a vehicle prior to a long trip and can involve a check of components as well as the replacement of drive belts, hoses, tires etc. If the vehicle is within 700 m (1000 km) of a scheduled service it is appropriate to perform all service tasks at this time. An out of phase service may also prepare the vehicle for travel into a different country or to a different climate and may include fitting driving or fog lamps, or altering the coolant mix.Routine vehicle checksThe vehicle owner is responsible for some routine checks. The checks should be performed weekly and include: Engine oil level Coolant level Battery electrolyte level Brake fluid level Tire pressure Screen washer fluid

These services require a small degree of skill and are often overlooked, resulting in minor breakdowns.