Motor Vehicle: Module A7L Routinely Service The Vehicle To Maintain Optimum Performance

MOTOR VEHICLE
E R EDUCA
TH T MODULE A7L
IO
R
FU
Routinely Service the Vehicle to

N
Maintain Optimum Performance

N AT I
M
TIU
O
N
R
AL S O
CON NVQ 2
NAME
EQUAL OPPORTUNITIES STATEMENT
The Further Education National Consortium believes that discrimination and prejudice on the
grounds of ethnicity, gender, religion, marital status, sexual orientation and social class is
incompatible with the principle of Equal Opportunities.
COPYRIGHT STATEMENT
No part of this publication may be reproduced or transmitted without the prior written consent of
the Board of Trustees for the Further Education National Consortium except as authorised by
the terms and conditions of membership of the Further Education National Consortium.
WARNING: THE UNAUTHORISED REPRODUCTION OR TRANSMISSION OF THIS PUBLICATION IS AN

INFRINGEMENT OF COPYRIGHT AND MAY RESULT IN CIVIL PROCEEDINGS AND A CRIMINAL PROSECUTION.
Written by John Prosser

for the National Consortium
Issued May 1995

ROUTINELY SERVICE THE VEHICLE TO MAINTAIN OPTIMUM PERFORMANCE MODULE A7L
CONTENTS
Introduction 2
Objectives 4
Range Statement 5
Reasons for Regular or Special Vehicle Inspections 6
Effects of Incorrect Adjustments Valve Clearances 8
Effects of Incorrect Adjustments Ignition Timing 9
Effects of Incorrect Adjustments Wheel Alignment 10
Effects of Incorrect Adjustments Tyre Pressure 11
Effects of Incorrect Adjustments Generator Drivebelt Tension 12
Identification Codes and Grades of Lubricants 14
General Legal Requirements for Cars 15
Interpretation of Vehicle Data 16
The Purpose of Vehicle Inspection Records 19
The Requirements of Customer Contracts 21
Test Yourself 22
1995 Further Education National Consortium Version 01
MOTOR VEHICLE LEVEL 2 MODULE A7L 1

INTRODUCTION
The purpose of this module is to help you to gain and record the
underpinning knowledge required for Module A7L in servicing and
repairs of light vehicles.
This module covers inspections carried out as part of the periodic

servicing of vehicles, fleet examinations or the valuation of used vehicles
prior to negotiating a trade-in deal or price. It also covers routine
adjustments to, and replacement of, components and materials carried
out as part of the scheduled servicing of vehicles.
As well as the underpinning knowledge, you will need at least eight items
of evidence which show that you can meet the performance criteria
specified for this module.
As you work your way through this module you will find activities. These
are to help you to assess your own understanding of the work and do not
count towards your formal assessment. The answers to these can be
found in the Review Pack. It is in your own interest to be honest with
yourself when doing these. Have a serious attempt at answering the
questions for yourself before looking in the Review Pack.
To complete this module you will need:
pen or pencil
access to some servicing schedules and technical data, such

as those produced by Autodata
a copy of Fundamentals of Motor Vehicle Technology (4th

edition) by VAW Hillier
a copy of Auto Mate by VAW Hillier
access to Road Vehicle Construction and Use Regulations

REQUIREMENTS FOR NVQ
You will need to collect evidence of your ability to meet the performance
criteria listed for this module and include them in your NVQ portfolio.
Suitable items of evidence may include:
copies of completed job cards, service schedules etc
testimonials from supervisors or customers
recorded observation by a trainer/lecturer
practical assessments
In order to prove that you really understand what you are doing, you will
also need to provide evidence that you have the underpinning technical
knowledge required for this work. This is the purpose of this module.
When you have finished this module and successfully completed the
assignment at the end, you will be ready to move on to the practical
competence activities providing you have the necessary training and
practice.
The results of the end test will be a useful addition to your NVQ portfolio.

OBJECTIVES
When you have completed this module you should be able to:
give reasons for regular or special vehicle inspections and

adjustments
state the effects of incorrect adjustments
identify codes and grade of lubricants
use parts lists and identification codes
state general legal requirements for cars
interpret vehicle data
state the purposes of vehicle inspection and service records
know the requirements of customer contracts

It should take you approximately 4 hours to complete this module but this
is only a guide and you should work at your own pace.

RANGE STATEMENT
This sets out the different circumstances for which you should be able to
apply your underpinning knowledge.
Vehicle Light passenger car and derivatives

(estate, van, pick-up etc). (You
should understand the differences
between different types of the same
vehicle, and that data and
specifications will be different.)
Methods Aural, visual and functional

assessment including damage,
corrosion, fluid levels, leaks, wear and
security. (You should be able to
detect faults and required adjustments
by listening to, looking at, and testing
the vehicle and systems.)
Adjustments Clearances, gaps, settings, alignment,

pressures, tensions and speeds
(including to valves, ignition, fuel/
emissions, brakes, transmission,
lights, tyres, steering, and body
fittings). (You should understand the
need for the adjustments listed, and
how to carry them out.)
Components & Materials Filters, drive belts, wiper blades,

brake linings/pads, lubricants and
fluids. (You should know how to
inspect and assess the components
listed.)
Equipment Test instruments, emission test

equipment, wheel alignment
equipment. (You should know how to
use any relevant test equipment.)
Records Vehicle inspection records, including

manufacturers, fleet, company/
customer job cards. (You should be
able to use and understand the
recording system used by your
employer.)

Information Sources Technical data, schedules of

inspection, Department of Transport,
on-board diagnostic displays. (You
should be able to find and apply the
correct technical data and servicing
schedule for the vehicles you work
on.)
REASONS FOR REGULAR OR SPECIAL

VEHICLE INSPECTIONS
WEAR AND DETERIORATION
As the vehicle operates, wear and deterioration of it's working

components inevitably takes place. Components will therefore need
adjustment or replacement from time to time.
OPTIMUM PERFORMANCE
Certain adjustments must be made to ensure that the vehicle will perform
at the best it's design will allow.
PREVENTIVE MAINTENANCE
The periodic planned replacement and/or adjustment of certain wearing

parts will improve reliability.
Clearly if a car is looked after properly by adequate servicing and early

replacement of defective parts, it will last longer and be more reliable.
For example, if a leaking induction manifold gasket was discovered
during a routine service, it could be put right before any further trouble
developed. However, if it was left unattended, the weaker air/fuel ratio

that would be delivered to the engine as a result of the fault could lead to
damage such as burned valves or even pistons.
Can you think of any similar examples?

Remember, when you are working on a car especially during a routine

service, you should be constantly looking for any developing problems.
If you find any, your customer should be pleased, as they will now have
the opportunity to do something about it before it develops into a more
serious (and expensive) problem. Also, your employers will be pleased,
as this gives an opportunity to sell more work. Not only will that make
your job more secure, but it will also increase the satisfaction you get
from doing it.
It is of course a legal requirement that cars are given a yearly DOT

(formerly MOT) test when they are three years old or more. The car is
not dismantled for this, so it is not a substitute for proper servicing, but at
least it is an opportunity for regular inspection and testing by someone
qualified to do it.
Apart from routine and regular servicing and inspections, you may be
required to do a special inspection from time to time. For example:
Sales Promotions A check on brakes, dampers, or cooling

system etc. Try not to see this just as an
opportunity to sell work, but also the benefits
of servicing and inspection. Don't just tell your
customer that they need (for example) a new
top hose explain what would have
happened if the fault had not been found.
Trade-in Appraisal You may be asked to look over a car which is

to be part exchanged for a newer one. There
is no pre-set schedule for this as in routine
servicing or DOT testing, and the time and
facilities you will have will vary with
circumstances. At the very least, you should
check for signs of body corrosion, undue
noises or excessive oil leaks. If this kind of
check is done regularly, it would be wise for

your service department to agree a checklist
with your sales department.
Appraisal for Again there is no pre-set schedule for this.

Prospective Purchase Remember that if you do this inspection for a
customer, you are entering into a contract and
will have legal responsibilities. This too
should be agreed between your service
department and the customer beforehand.

EFFECTS OF INCORRECT ADJUSTMENTS

VALVE CLEARANCES
The reasons for valve clearances and the effects of incorrect adjustment
are discussed on page 40 of Fundamentals of Motor Vehicle
Technology. Read this now then test your understanding by answering
the questions below.
ACTIVITY 1
1 Why must there always be a clearance in the valve operating

mechanism?
2 How can engine temperature affect valve clearances?
3 What will be the result of valve clearances which are too large?
4 What will be the result of valve clearances which are too small?
Check your answers with your Tutor


IGNITION TIMING
Setting of the ignition timing is discussed on page 65 of Auto Mate.

Read this section now to find the information to answer the following
questions.
ACTIVITY 2
1 What does it mean if the ignition timing is:
a over advanced?
b retarded?
2 What effects will be caused by over advanced ignition timing?

3 What effects will be caused by retarded ignition timing?


WHEEL ALIGNMENT
You can find a basic explanation of wheel alignment of page 125 of Auto
Mate, or, if you prefer, there is more detailed information on pages 323
and 324 of Fundamentals of Motor Vehicle Technology. Use either or
both of these to help you to answer the following questions.
ACTIVITY 3
1 How can wheel alignment be checked?
2 What are the effects of incorrect wheel alignment?
3 How can misalignment be identified during a visual inspection of

the vehicle?


TYRE PRESSURE
Tyre inflation pressure is discussed on pages 380 and 381 of

Fundamentals of Motor Vehicle Technology, also, uneven tread wear is
covered on page 382. Read these now, and then answer the following
questions.
ACTIVITY 4
1 What faults would cause the uneven tread

wear shown on the right?
2 What faults would cause the uneven tread

wear shown on the right?
3 As well as rapid and uneven tread wear, what other damage can be
done to the tyres by running them at too low a pressure?


GENERATOR DRIVEBELT TENSION
The generator drivebelt is still often called the fan belt, even though the
fan is now driven by a separate electric motor on most modern cars.
Adjustment of the belt is covered in the box headed Maintenance of the
charging system on page 149 of Auto mate. Read this now and then
answer the following questions.
ACTIVITY 5
1 How should the tension of a drivebelt be checked?
2 What will happen if the belt 'bottoms' on the pulley due to wear of
it's sides?
3 What would happen if an alternator drivebelt was set too slack?

Although it is not mentioned in the books recommended, see if you can

find the answer to one more question.
4 What would happen if an alternator drivebelt was set too tight?

SELF ASSESSMENT 1
There are a number of faults in the first column below. The effects listed
in the next column have been mixed up. Can you correctly match these
by writing in the right hand column which fault numbers would cause the
stated effect?
FAULTS EFFECTS CAUSE NO.
1 Valve clearances too Tyre blow-out due to

tight internal failure
2 Valve clearances too Engine overheating

loose
3 Ignition timing over Feathering of tyre tread

advanced inner edges
4 Ignition timing Burnt faces on exhaust

retarded valves
5 Toe-in excessive Premature wear of

alternator bearings
6 Toe-in insufficient Noisy operation of valves
7 Tyres over inflated Squeal when the engine

is revved with the headlights
on
8 Tyre pressures too low Feathering of tyre tread

outer edges
9 Alternator drivebelt too Engine pinking

loose
10 Alternator drivebelt too Excessive wear of centre

tight of tyre tread
Check your answers in the Review Pack

IDENTIFICATION CODES AND GRADES OF

LUBRICANTS
Information on classification of lubricants can be found in Fundamentals
of Motor Vehicle Technology in the following sections:
Engine lubricants ................................................ Pages 155 - 156

CI engine oils ..................................................... Page 182
Final drive oil ...................................................... Pages 294 - 295
Read these sections now to find the information for the following self
assessment.
SELF ASSESSMENT 2
1 What is meant by the term 'viscosity'?
2 State a classification for a typical multigrade engine oil.
3 List four additives used in modern engine oils.
4 In what ways is the engine oil for a CI engine different from that for
an SI engine?
5 Some axle mechanisms require a special EP oil. Why is it essential

that a standard oil is not used in these?

GENERAL LEGAL REQUIREMENTS FOR CARS

The construction and use regulations are the legal provision to ensure
that vehicles are manufactured and maintained to a roadworthy
standard. They are both complex and lengthy. It would be unreasonable
to expect a mechanic to be an expert in this law, but it is clearly desirable
that you should have a general knowledge of legal requirements. If you
have access to these regulations, read them now, then answer the
following questions.
SELF ASSESSMENT 3
1 How is the law likely to be broken if the engine breather system is

not properly maintained?
2 Find out what the maximum allowable exhaust emissions are for
petrol engined cars.
3 Briefly state what the law has to say about smoke emission from
diesel engined cars.

INTERPRETATION OF VEHICLE DATA
There are many ways of finding technical data and information for
vehicles. The most reliable way is to find the information from the
manufacturers' publications. If your place of employment or work
experience has a franchise with any particular manufacturer, you may
have access to such manuals through them. However, the cost of these
is very high, so if your company (or college) deals with various makes of
vehicle, a more economical, and equally reliable source of information,
would be a general data manual such as those published by Autodata or
Haynes.
Servicing schedules are used to make sure that when you service a
vehicle, the work you do is in line with the maker's recommendations. In
addition, they will give you a guideline of how long a service should take.
Like other technical data, the most reliable are those published by the
manufacturer, but general manuals like those published by Autodata are
more economical if a wide range is needed.
Parts manuals are normally used by personnel in the parts department.

It is however, useful for a mechanic to be able to use a catalogue to
identify correct replacements. The Autodata servicing guide provides
information on the necessary parts to carry out a service.
The activity on the following page is based on the Autodata technical

data book, and servicing guide. The answers should be the same
whatever source you use, but the answers that are shown in the Review
Pack are illustrated using extracts from the Autodata manuals.
Whichever source you use, you should bear in mind the following
guidelines.
Read and understand the instructions for using the manual. These
are normally printed in the first few pages. Ask for help if you have
difficulty with them.
Make sure you are looking at the right model, year, engine, size
and type as there are often many variations with different
specifications.
Don't mark the manual in any way. You may find this helpful for a
one off reading, but it will be a distraction to anyone using it
afterwards.

SELF ASSESSMENT 4
All of the following questions relate to a 1984 Ford Escort 1.3.
1 What is the basic ignition timing for this vehicle?
2 Should the ignition timing be checked with the vacuum pipe on or

off?
3 What readings will indicate that the centrifugal advance mechanism

is working properly?
4 How many degrees of advance is indicated by each pointer in the

timing cover?
5 How long should the 12,000 mile service take?

6 At which service intervals should the driveshaft seals/gaiters be

inspected?

7 How often should the brake fluid be renewed?
8 What are the correct spark plugs for this car?
9 What is the correct size of tyre for this car?
10 At which service intervals should the air filter element be renewed?


THE PURPOSE OF VEHICLE INSPECTION

RECORDS
These records are kept in many ways. The records you deal with may
vary according to the organisation you work for. Some of those you are
likely to use are:
manufacturers' service checklists
company service checklists
DOT checklists
The main purpose of these is to provide the mechanic or technician with

a means of keeping a record of the progress through a service or
inspection, thus reducing the chances of items being missed.
They are also eventually passed on to the customer as an assurance

that the jobs detailed on the list have all been properly completed.
There is usually a space on the list where comments can be made if

anything needs to be reported. However, it is important that reports are
also promptly pointed out to your supervisor so that the customer can be
informed in good time if necessary.
You are less likely to have direct involvement with customer follow-up
records which will be kept by the reception department whether on a
card file system, or a computer program. These record details of all jobs
done for each customer, and register the dates and mileages. The
information stored in this system is useful for the following purposes:
recording customer details such as address, telephone

number and account number
recording vehicle details such as make, model and chassis

number
recording details of previous work
providing information for reminders for service, DOT test, and

other work
providing information needed for warranty or guarantee claims

ASSIGNMENT
Answer one of the following:
1 Find out from your place of employment or work placement an

example of a service or inspection record, then describe what
happens to the document after the mechanic or technician has
completed it.
2 Find out how the customer follow-up system at your place of

employment or work experience is operated, then describe the
system using illustrations or copies as necessary.
3 Design a card which would be suitable for use in a customer follow-

up system.
When you have completed the assignment give it to your lecturer for
assessment and comments.
Check your work with your Tutor


THE REQUIREMENTS OF CUSTOMER

CONTRACTS
A contract is basically a legal binding agreement between two or more
parties. Either or any of the parties may be an individual, or a body such
as a business company.
IT IS IMPORTANT TO REMEMBER THAT A CONTRACT DOES NOT NECESSARILY

HAVE TO BE FORMAL, THAT IS WRITTEN OR SIGNED, TO BE LEGALLY BINDING.
IF ONE OF THE PARTIES DOES NOT COMPLETE THE CONTRACT, THEN THE OTHER
HAS THE RIGHT TO ' SUE': THAT IS TO TAKE THE GUILTY PARTY
TO COURT TO RECOVER ANY LOSSES
When you, or your company agree to do work for a customer, a legally

binding contract is formed between your company and the customer.
The customer has a legal right to expect the work required to be done
properly, and your company has the same right to expect to be paid for
the work.
It is essential therefore, to make sure that there is minimal chance for

misunderstanding when dealing with customers. Although principles
such as accurate assessment and recording of the customers'
requirements, and pointing out acceptable terms of payment, are dealt
with in the unit on reception, I would emphasise here the importance of
attention to these details.
Even if you do not have direct personal contact with your customers, you
still have contractual responsibilities if you carry out the work on
customers' cars. If, for any reason you do not carry out the work
entrusted to you to a standard required by your employer (and the
customer), you could find yourself in the middle of a legal action for
breach of contract.
In short, if your employer provides you with a set service schedule, you
should follow it properly.
To be or not to be that is the quest

Friends, Romans, Countrymen, le
me your ears, I come to bury Caes
not to praise him.
SUMMARY
* SUMMARY
The evil that men do lives on after
them but the good is oft interred
their bones.
Hark! What light through yonder
window breaks?
Whats in a name? A rose by any
name would smell as sweet.
There was a young man from Cape
Horn who wished hed never been
You have now completed the work required for the underpinning
knowledge to Module A7L Vehicle Servicing.
Now have a go at answering the Test Yourself questions on the following

page. You could include these in your portfolio of evidence.
TEST YOURSELF
1 The main reason for scheduled servicing of motor vehicles is to:

a ensure that all vehicles over three years old
are kept in a roadworthy condition
b provide the major source of work for garage
service departments
c ensure maximum serviceability through regular
renewal or adjustment of consumable items
d provide the customer with a set date on which they
can get non-urgent jobs done
2 During an inspection of a vehicle's braking system, you notice that

the wheel cylinders are starting to leak. If this is not attended to,
the fault could lead to:
a excessive wear of the brake lining
b failure of the affected brake unit
c seizure of the wheel cylinder
d brake failure
3 When inspecting a car for a customer to assess it's condition before

they decide whether or not to buy it, you should:
a carry out a dummy DOT inspection
b give it a full service

c be sure not to dismantle anything
d agree terms with your customer beforehand

4 If the specification for a particular car states that the ignition timing
should be set at 8 before TDC, and a mechanic sets it to 12
before TDC, it will be:
a over-advanced and cause fast tickover
b over-advanced and cause lack of power
c retarded, causing overheating
d retarded, causing poor starting
5 'Feathering' of the inner tread edges of a tyre would indicate that:

a the wrong tyres are fitted
b the tyres are over-inflated
c the wheel alignment is incorrect
d the wheel is out of balance
6 At intervals recommended by the vehicle manufacturer, a generator

drivebelt should be checked:
a for correct lubrication
b for it's condition and tension
c to ensure it reaches the bottom of the pulleys
d and adjusted to eliminate all free play
7 The pattern of tread

wear shown on this
diagram would suggest

that the:
a tyre has been over-inflated

b tyre has been under-inflated
c wheel alignment is incorrect
d wheel is out of balance

8 If the manufacturer's specifications for a particular car state that the

valve clearances should be checked with the engine hot, and a
mechanic adjusts them whilst cold:
a it will not make any difference
b they will be set too tight
c they will be set too loose
d the adjusters will not turn
9 An oil given the rating SAE 20W 50 would normally be used in:
a an engine
b a gearbox
c an axle
d a clutch
10 If the driver of a vehicle does not have it properly maintained, and

as a result, the exhaust emissions cause excessive pollution, they
would be committing an offence under the:
a Clean Air Act
b Road Traffic Offenders Act
c Transport Act
d Construction and Use Regulations
11 The main purpose of a vehicle servicing schedule is to:

a provide a record of work done for the office

b help staff to calculate the customers bill
c provide guidance and support for the mechanic
d enable the parts department to book out parts

12 A contract between a garage and it's customer:

a is only binding if the job card is signed
b should be signed in the presence of witnesses
c can be made over the telephone
d is formed by the shaking of hands

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MOTOR VEHICLE

Routinely Service the Vehicle to

Maintain Optimum Performance

EQUAL OPPORTUNITIES STATEMENT

WARNING: THE UNAUTHORISED REPRODUCTION OR TRANSMISSION OF THIS PUBLICATION IS AN

Written by John Prosser

Issued May 1995

MOTOR VEHICLE LEVEL 2 MODULE A7L 1

This module covers inspections carried out as part of the periodic

To complete this module you will need:

access to some servicing schedules and technical data, such

a copy of Fundamentals of Motor Vehicle Technology (4th

a copy of Auto Mate by VAW Hillier

access to Road Vehicle Construction and Use Regulations

MOTOR VEHICLE LEVEL 2 MODULE A7L 2

REQUIREMENTS FOR NVQ

copies of completed job cards, service schedules etc

testimonials from supervisors or customers

recorded observation by a trainer/lecturer

MOTOR VEHICLE LEVEL 2 MODULE A7L 3

give reasons for regular or special vehicle inspections and

state the effects of incorrect adjustments

identify codes and grade of lubricants

use parts lists and identification codes

state general legal requirements for cars

interpret vehicle data

state the purposes of vehicle inspection and service records

know the requirements of customer contracts

MOTOR VEHICLE LEVEL 2 MODULE A7L 4

Vehicle Light passenger car and derivatives

Methods Aural, visual and functional

Adjustments Clearances, gaps, settings, alignment,

Components & Materials Filters, drive belts, wiper blades,

Equipment Test instruments, emission test

Records Vehicle inspection records, including

MOTOR VEHICLE LEVEL 2 MODULE A7L 5

Information Sources Technical data, schedules of

REASONS FOR REGULAR OR SPECIAL

WEAR AND DETERIORATION

As the vehicle operates, wear and deterioration of it's working

The periodic planned replacement and/or adjustment of certain wearing

Clearly if a car is looked after properly by adequate servicing and early

developed. However, if it was left unattended, the weaker air/fuel ratio

Can you think of any similar examples?

MOTOR VEHICLE LEVEL 2 MODULE A7L 6

Remember, when you are working on a car especially during a routine

It is of course a legal requirement that cars are given a yearly DOT

Sales Promotions A check on brakes, dampers, or cooling

Trade-in Appraisal You may be asked to look over a car which is

check is done regularly, it would be wise for

Appraisal for Again there is no pre-set schedule for this.

MOTOR VEHICLE LEVEL 2 MODULE A7L 7

EFFECTS OF INCORRECT ADJUSTMENTS

1 Why must there always be a clearance in the valve operating

2 How can engine temperature affect valve clearances?

Check your answers with your Tutor

MOTOR VEHICLE LEVEL 2 MODULE A7L 8

EFFECTS OF INCORRECT ADJUSTMENTS

Setting of the ignition timing is discussed on page 65 of Auto Mate.

1 What does it mean if the ignition timing is:

2 What effects will be caused by over advanced ignition timing?

3 What effects will be caused by retarded ignition timing?

Check your answers with your Tutor