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AutomotiveTechnicianTraining:PracticalWorksheetsLevel2
AutomotivepracticalworksheetsforstudentsatLevel2ThisLevel2studentworksheetsbookcontainstasksthathelpyoudeveloppracticalskillsandprepareyouforassessment.Thetasksalsoreinforcetheautomotivetheorythatyouwilllearnonlineandintheclassroom.Eachworksheetcoversindividualtopicsinastep-by-stepmanner,detailinghowtocarryoutallthemostimportanttaskscontainedwithinthesyllabus.Alongsideeachoftheseworksheetsisajobcardthatcanbefilledinandusedasevidencetowardsyourqualification.
EndorsedbytheInstituteoftheMotorIndustryforalltheirLevel2automotivecourses.
Step-by-stepguidestothepracticaltasksrequiredforallLevel2qualifications.
Jobsheetsforstudentstocompleteandfeedbacksheetsforassessorstocomplete.
TomDentonistheleadingUKautomotiveauthorwithateachingcareerspanninglecturertoheadofautomotiveengineeringinalargecollege.Hisrangeofautomotivetextbookspublishedsince1995arebestsellersandledtohisauthoringoftheAutomotiveTechnicianTrainingmultimediasystemthatisincommonuseintheUK,USAandseveralothercountries.TomnowworksastheeLearningDevelopmentManagerfortheInstituteoftheMotorIndustry(IMI).
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AutomotiveTechnicianTraining
PracticalWorksheetsLevel2
TomDenton
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Firstpublished2015byRoutledge
2ParkSquare,MiltonPark,Abingdon,OxonOX144RN
andbyRoutledge
711ThirdAvenue,NewYork,NY10017
RoutledgeisanimprintoftheTaylor&FrancisGroup,aninformabusiness
©2015TomDenton
TherightofTomDentontobeidentifiedasauthorofthisworkhasbeenassertedbyhiminaccordancewithsections77and78oftheCopyright,DesignsandPatentsAct1988.
Allrightsreserved.Thepurchaseofthiscopyrightedmaterialconferstherightonthepurchasinginstitutiontophotocopypageswhichbearthecopyrightlineatthebottomofthepage.Nootherpartsofthisbookmaybereprintedorreproducedorutilisedinanyformorbyanyelectronic,mechanical,orothermeans,nowknownorhereafterinvented,includingphotocopyingandrecording,orinanyinformationstorageorretrievalsystem,withoutpermissioninwritingfromthepublishers.
Trademarknotice:Productorcorporatenamesmaybetrademarksorregisteredtrademarks,andareusedonlyforidentificationandexplanationwithoutintenttoinfringe.
BritishLibraryCataloguing-in-PublicationData
AcataloguerecordforthisbookisavailablefromtheBritishLibrary
LibraryofCongressCataloginginPublicationData
Acatalogrecordforthisbookhasbeenrequested
ISBN:978-1-138-85237-2(pbk)
ISBN:978-1-315-72351-8(ebk)
TypesetinUniversby
ServisFilmsettingLtd,Stockport,Cheshire
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ContentsPracticalWorksheets–Level2
Engines
Chassis
Transmission
Electrical
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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
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ImportantnotesaboutpracticalworkSafety
Workingonvehiclesisperfectlysafeaslongasyoufollowproperprocedures.Foralloftheworksheetsinthisbookyoumusttherefore:
Complywithpersonalandenvironmentalsafetypracticesassociatedwithclothing;eyeprotection;handtools;powerequipment;properventilation;andthehandling,storage,anddisposalofchemicals/materialsinaccordancewithallappropriatesafetyandenvironmentalregulations.
Therearesomespecificrecommendationsbelowbutyoushouldalsorefertotheothertextbooksoronlineresourcesforadditionalinformation.
Personalprotectiveequipment(PPE),suchassafetyclothing,isveryimportanttoprotectyourself.Somepeoplethinkitcleverortoughnottouseprotection.Theyareverysadandwilldieorbeinjuredlongbeforeyou!Somethingsareobvious,suchaswhenholdingahotorsharpexhaustyouwouldlikelybeburntorcut!Otherthingssuchasbreathinginbrakedust,orworkinginanoisyarea,donotproduceimmediatelynoticeableeffectsbutcouldaffectyoulaterinlife.
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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
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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.
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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.
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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
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informationtohand.Thiscanbeintheformofaworkshopmanualoracomputer-basedsource.
Theworksheetsinthisbookareageneralguidesomakesurethecorrectinformation,proceduresanddatafortheparticularvehicleyouareworkingonareavailablebeforeyoustartwork.
Autodataonlineinformation
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Jobcard:example
Assessorreport:example
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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.
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Jobcard
Assessorreport
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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.
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Jobcard
Assessorreport
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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.
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Jobcard
Assessorreport
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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.
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Theinspectionofauxiliaryshaftsisasimilarprocedure.
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Jobcard
Assessorreport
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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
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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.
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Jobcard
Assessorreport
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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
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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.
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Jobcard
Assessorreport
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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
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disconnected.
Lowervehiclesothatthesubframerestsonthetrolley.Undoandremovesubframetochassismountingbolts.
Note:checkthatboltsarenotsupportingaloadbeforeremoval.
Carefullyliftthevehicleawayfromthesubframe,watchingthattheengineandtransmissiondoesnotcatchintheenginecompartment.
Refitandreassembleinthereverseorder.Tightenallnuts/boltstospecifiedtorquesettings.Makeasystematiccheckofallcomponentsforcorrectfittingandsecurity.
Bleedandcheckbrakes.Checkfrontwheelalignment.Runtheengine,bleedcoolingsystem,ifnecessary,andcheckforcorrectoperation.
Roadtestandrecheckallworkunderthevehicleandunderthebonnet.
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Jobcard
Assessorreport
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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.
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Fitandtorqueinsequencewithin3minutes.
Oilseals–theseareusedwithgasketsforsealingaroundbearingcapsandoilmouldedrubberpans.Fitwithrecommendedsealantsordryandthenfitothertypeofgasketsandsump.Fitandtorqueboltsinsequence.Checksealsdonotsqueezeout.
Oilseals(lip)–removepulleyfromhousingandinspectsealland.Useaspecialtooltoextracttheseal.Pressinnewsealtoshoulderorspecifieddepth.Lubricate(inblock)sealwithcleanengineoil.Cleanandlubricatesealland,refitpulleyandtorquebolt.
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Jobcard
Assessorreport
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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
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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.
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Jobcard
Assessorreport
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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.
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Ifcrankshaftisreground,washthoroughlybeforerefitting.Fitcorrectbearings(undersizeifcrankshafthasbeenreground).Checkonjournalsbeforefitting.
Lubricateallbearingswithcleanengineoil.Check‘nip’ofbearingsbeforetightening.Torquebearingcapboltstospecifiedtorqueandcheckenginerotates.Check‘feel’ofbearingsandendfloatofcrankshaftbeforereassemblingengine.
Whentheengineisrunningcheckforabnormalnoisesandcorrectoperation.
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Jobcard
Assessorreport
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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.
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Cleanthepistoncrownandinspectforburningoroverheatingdamage,pitting,particledamagesuchasbrokenpistonringsandotherdeterioration.
Visuallycheckandmeasurepistonringgroovesandringlandforcondition.Lookforopeningortaperoftheringgroovescausedbytheringsrocking.Lookforringbreakageandparticlescuttingthroughtheringland.
Removethepistonfromtheconnectingrod.Checkthe‘fit’ofthepistonpintotheconnectingrodlittleendbearing/bushandinthepiston.
Ifthepistonisserviceableandnewringsaretobefitted,measurethecylinderboresandcomparewiththemanufacturer’sspecificationsandtolerancelimitsfornewrings.
Gapnewringsinthecylinder.Cleanthepistonringgroovesusingaspecialtool.Fitringstopistonsandreassembleengine.Runengineandcheckforabnormalnoisesandcorrectoperation.
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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.
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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
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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.
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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.
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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.
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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
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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.
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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
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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
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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
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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
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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.
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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.
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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.
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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.
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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–
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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.
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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.
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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
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(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).
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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
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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-
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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
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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
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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
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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
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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.
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•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:
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•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.
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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
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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.
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•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
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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
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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.
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•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
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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.
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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
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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
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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
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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.
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•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.
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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.
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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
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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.
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•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.
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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.
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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.
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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
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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.
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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.
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•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.
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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
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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.
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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
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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
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sillareaorevenunderthecarpetsbeneaththeseats.
Unscrewtheactuatorfixingsandunhookitfromthepullrod.
Removetheactuatorfromthevehicle.
Refittingisareversaloftheremovalprocess.
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Worksheet74:Removeandrefitfueltanksenderunit
ProcedureFitmemorykeeperanddisconnectthebatteryearth/groundlead.
Supportvehicleonhoist.
Drainfuelfromthetankusingspecialequipment.
Ifnecessary,disconnectfuellinesandfillercomponents.
Removefueltank(somesendersareaccessiblewithoutremovingthetank,checkmanufacturer’sdata).
Removewiresfromsenderunit.
Undotheringofboltsandremovesender.
Useanewgasketandsealantwhenrefitting.
Ensurethenewsenderispositionedcorrectly.
Refittingisareversaloftheremovalprocess.
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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
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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
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checkingthatairflowisdirectedfromthecorrectoutlets.
Forair-cooledenginesitisimportanttocheckforexhaustgasleakageinsidetheheatexchanger.Checktheheateroutletsforodour.
Alternatively,forincreasedsafety,useagasanalyserwiththeprobeinsertedintoasidewindow.Sealthewindowopeningwithtape.Settheheatercontrolstothehighesttemperature.Runtheengineandlookforthepresenceofexhaustgasesinthevehicleinterior.CheckforCO,whichistoxic.
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