Automotive Repair and Service Standards
Version 0.01
Submitted for review
By
Kenneth W. Brotman, founder
www.automotiveservice.org
© All rights reserved.
Introduction
In 1999, I read Modern Automotive Technology by James E. Duffy. It seemed well suited to generate an initial set of automotive repair standards from. So I did.
There was no definition of what constitutes a job done properly.
The purpose of the standards is to allow consumer advocates, judges, attorneys, investigative reporters, consumers, shop managers and technicians to have a clearly defined reference on what is acceptable and what is not.
If you have comments, please contact me. Make sure to reference the section(s) you are commenting on in your email.
Part I: General Service Standards (Non-system specific)
Part II: System Specific Standards
Part III: Shop Safety
Part IV: Service Advising
Part I: General Service Standards
(Non-System Specific)
Computer Control Systems
CC4.01 A visual inspection of questionable circuits and all related components should be one of the first steps in pinpointing a computer control system problem.
CC4.02 When diagnosing a computer control system, one of the first steps should be to verify that the supply voltage, grounds, and reference voltages (if any) are correct. Voltages that are too high can cause damage to electronic components. Voltages that are too low can cause malfunctions.
CC4.03 Unless the technician is very familiar with a vehicle's specific computer control system, the appropriate service manual should be consulted before attempting to test or service a computer control system. Incorrect procedures can destroy delicate computer control system components.
CC4.04 Whenever a instrument warning indicates that a trouble code is being stored in memory, the technician should, as part of the diagnostic procedure retrieve any stored codes, making note of them. Before the vehicle is returned to the customer following repairs, the codes should be cleared from the computer, and the vehicle operated long enough and in such a manner as to confirm that the problem is solved.
CC5.01 To reduce the risk of damage due to static electricity, always touch a good ground before handling the electronic control unit or a related electronic component.
Drive Belts
DB4.01 Accessory drive belts should not be periodically replaced. An accessory drive belt should only be replaced when it fails a visual inspection.
DB4.02 A drive belt should be replaced when found to be significantly glazed, burned, frayed, contaminated with oil, coolant, or other fluid, showing deep age cracks, cuts, abrasions or cord separation.
DB7.01 Proper belt tension is critical to long life of components. A reputable shop manual should be checked if there is any doubt about the proper tensioning.
DB7.02 A belt should be tightened only enough to prevent belt slippage or flap.
Replacement V-belts should be compared with old belt for not only length and width, but also proper pulley depth due to variations in belt angles between asian and other belt manufacturers.
DB8.01 When tightening a belt, care should be taken to pry only on reinforced or recommended points.
DB8.12 When tightening a power steering belt, do not pry on the side of the pump. The thin housing of the pump could dent, possibly ruining the pump.
Disassembly and Reassembly
DR3.01 When disassembling parts, care should be taken to keep any debris from falling into exposed openings.
DR3.02 A shop rag or other suitable material should be used to cover any exposed openings while parts are apart.
DR4.03 All surfaces that receive a hose or gasket should be inspected and cleaned to a smooth polished surface free of scale, old hose or gasket material or sharp metal edges that could prevent proper sealing.
DR4.04 All spacer shims necessary for the proper alignment and clearance of parts should be reinstalled.
DR4.05 All rubber spacer shims should be inspected for signs of deterioration and replaced as needed.
DR5.01 Select fit parts should be reinstalled in their original locations.
DR6.01 Upon disassembly of any system or component, all parts should be inspected for indications of mechanical problems as well as wear, fatigue and contamination of parts.
Fasteners
F4.01 A high grade bolt should never be replaced with a lower grade bolt.
F5.01 Thread types should never be interchanged where thread damage could result.
F10.01 A crisscross pattern should be used when multiple fasteners hold a part. Fasteners should be torqued a little at a time going over the bolts several times to assure correct tightening.
F10.02 A general torque value chart should only be used when manufacturer's specs are not available.
F10.03 Care should be taken to not overtighten bolts that hold a gasket between metal surfaces. Overtightening is the most common cause of gasket failure.
F12.01 Care should be taken to not over-tightened housings made of soft aluminum or "pot metal"
Final Inspection
When the vehicle repair or service is completed, the vehicle should be cleaned of any dirt, grease and other other substances.
Floor mats, seat covers, steering wheel covers, etc., should be removed from the vehicle before it is given back to the customer.
The vehicle should be test driven when necessary to confirm it has been returned to proper operation.
Gaskets and Seals
GS3.01 The area around a leaking part which is badly soiled should be thoroughly cleaned to make it easier to see if any fresh fluid leaks out after replacement.
GS4.01 If two surfaces are leaking, the part surfaces should be inspected closely for problems.
GS4.02 Mating surfaces should be cleaned to bare metal. All old gasket material must be scraped or wire brushed from the parts. Parts should then be washed in solvent and blow dried with compressed air.
GS4.03 Sealer should be used whenever two different gaskets come together or to aid in reassembly.
GS4.04 A gasket should not be reused. A used gasket will not form a proper seal when reinstalled.
GS4.05 Mating surfaces should be checked for warpage before installing a gasket.
GS4.06 Bent flanges (such as on valve covers or oil pans) must be straightened before installing a gasket.
GS4.07 Either a basic crisscross or factory recommended torque pattern should be used when tightening parts.
GS5.01 RTV sealer should be applied in a continuous bead approximately 1/8 in. (3 mm) in diameter. All mounting holes must be circled. Only use sensor safe RTV sealer when sealing non-cooling system components.
GS5.02 Rigid anaerobic sealer should not be used on flexible flanges.
GS7.01 When installing a new seal, the outside of the seal housing should be coated with an approved sealer and the inner lip of the seal should be coated with system fluid.
GS10.01 If a seal is leaking, inspect before disassembly for other problems besides a defective seal.
GS12.01 O-ring seals should be coated with system fluid (engine oil, diesel fuel, transmission fluid or type fluid used in component).
Hoses
H4.01 Hoses should not be periodically replaced. A hose should only be replaced when it fails a visual inspection or feels like it is breaking up inside.
H4.02 A hose should be replaced when found to be leaking, cracked, bulged, cut, hardened, softened, oil-soaked, swollen, chafed, burned, brittle, or deteriorated.
H4.13 When checking a coolant carrying hose, the entire length should be inspected and felt.
H8.01 Only a flare nut or tubing wrench should be used to tighten or break free a hose with threaded metal fittings to avoid rounding corners.
H8.02 A hose with threaded metal fittings should be started by hand to avoid crossthreading.
H12.01 Hose clamps should be positioned so that they are fully over the hose fittings.
H15.01 A radiator hose should not be removed by twisting it off as this may destroy the outlet. Instead, a sharp knife should be used to cut along the length of the the hose that is over the outlet, should the hose be stuck on the outlet.
Preventive Maintenance
PM2.01 Fluids should be checked and replaced at intervals recommended by the vehicle's maker.
PM3.01 Filters should be checked and replaced at intervals recommended by the vehicle's maker.
PM3.02 A filter should never be permanently eliminated or bypassed.
PM3.13 A paper element air filter can be cleaned by tapping it against a hard, flat surface to shake loose the dirt, then directing compressed air at the filter to blow off any remaining dirt. The nozzle of the compressed air should remain at leas 2" from the filter. The filter element should never be dipped in a solvent to clean it. The air filter should be replaced, not just cleaned, if it is believed that the vehicle operator will not have it checked again before the filter will have become too dirty.
PM3.14 It is acceptable to just replace an air filter, at the recommended interval, if the filter appears to have been on the vehicle for some time.
PM4.01 Ignition components should be checked and replaced at intervals recommended by the vehicle's maker.
Qualified Personnel
QP5.01 Specialized or Skilled Service Procedures should only be performed by skilled and properly trained personnel.
QP6.01 Automotive Technicians known to have comeback rates of higher than 4% should not be allowed to work on vehicles.
Recycling/Disposal of Fluids and Chemicals
Before disposal, oil filters should be gravity drained so that they do not contain free-flowing oil.
Replacement Parts
All replacement parts should be of the same or better quality as the original equipment parts used by the vehicle's manufacturer unless disclosed to and consented by the customer up front.
Before installing a replacement part, the new part should be compared with the old part to make sure it is correct.
Any parts to be reused should be cleaned and inspected.
All parts removed from a should be keep so organized that used parts can be returned to their correct positions.
Vehicle Preparation
Fender protectors should be used when procedures to be performed could cause an object to come in contact with and possibly damage the paint or a body part.
Belts should not be worn that can scratch or damage a vehicle.
Warrantees
W1.01 Except for some engine oils, all other items on a vehicle are designed to last for several years. Therefore, where the shop recommends and performs repairs, procuring and installing needed parts themselves and of the quality and brand of parts they recommend, a warranty of less than one year or 12,000 miles, whichever comes first, would be substandard.
Part II - System Specific Standards
Air Conditioning
AC2.01 A air conditioning system check should always include checking the refrigeration system with manifold gauges and leak detecter, checking the compressor clutch, compressor and drive belt, and checking the temperature at the a/c outlets.
AC4.01 Whenever the air conditioning system has been discharged or opened to the atmosphere, it must be evacuated and leak tested.
AC4.02 Whenever the air conditioning systeem has been opened to the atmosphere for a prolonged period, it should be flushed.
AC5.03 Refrigerant should be added to the suction side of the system with the engine running. Liquid refrigerant should not be allowed to enter the compressor.
AC5.13 When charging the system, the refrigerant container must be kept right-side up to assure that refrigerant vapor, not liquid refrigerant, enters the system.
AC6.02 The refrigerant oil should be checked anytime you add or replace the refrigerant.
AC80.03 An air conditioning system should be able to hold vacuum without dropping more than 2 to 3 in/hg in a five-minute period.
AC80.04 An air conditioning system should be considered leaking and in need of repair when more than one-half pound of refrigerant must be added per year.
AC80.05 An air conditioning system with stem type valves should never be operated in the frontseated position. Excessive pressure could build in the compressor, causing part overheating and damage.
Brakes
B4.01 Flushing is needed when the brake fluid is contaminated (filled with dirt, rust , corrosion, oil or water), when the fluid is 5 year old or sooner if recommended by the manufacturer. Each wheel cylinder or caliper should be bled until there is new clean fluid at each bleeder screw.
B4.02 A brake system flush generally is not cause for a customer make a special trip to the shop. The flush should be done in context of other, needed brake work, when it is more convenient and economical for the customer.
B5.01 Brake linings should be replaced when:
a) on drum brakes, any lining on the same axle has 1/16" or less in thickness as measured with a brake lining thickness gauge,
b) on disk brakes, any lining on the same axle at the thinnest part of the lining is no thicker than the metal shoe (approximately 1/8 in. or 3 mm) as measured with a brake lining thickness gauge,
c) any lining on the same axle has significant heat cracks, large chips, glazing or contamination by antifreeze, oil, grease, or differential fluid.
B5.03 Brakes should not squeak after being relined.
B5.06 Brake linings on the same axle (front or rear) should be replaced at the same time in order to assure even breaking and manageable preventive maintenance strategies.
B5.10 It is unacceptable to suggest to customers that all four wheels should receive new linings at the same time, regardless of the amount of wear on each.
B6.01 Rotors should only be replaced when a defect is discovered or when they are thinner than recommended by the manufacturer as measured with a micrometer.
B6.02 Rotors should only be resurfaced to correct runout, thickness variation or scoring. Rotors in good condition should not be resurfaced.
B6.03 It is unacceptable to suggest to customers that rotors should always be replaced when brakes are relined except on some european vehicles.
B12.03 Oil, grease and other contamination must be keep out of brake fluid. Rapid deterioration of the master cylinder cups could result in sudden loss of braking ability.
B17.03 A brake drum whose surface has only minor scratches, rust or gouging, is usable as is. It should not be resurfaced or replaced.
B17.04 When resurfacing a brake drum, machine as little material off as possible. Machine left and right-hand drums to the same diameter to help assure even, straight-line braking.
B17.07 If a drum is rusted to the axle flange, light taps with a hammer is acceptable. Hammer on the outside edge of the drum. Do not hammer on the inner lip of the drum or it can break.
B18.02 A wheel cylinder should be rebuilt or replaced if it shows any signs of leakage or sticking, or whenever new brake shoes are installed.
B18.03 A wheel cylinder should be rebuilt, if it can be done reliably, and otherwise replaced.
B18.11 After honing a wheel cylinder, it should be cleaned thoroughly with clean shop rags and brake fluid or an approved cleaning solvent.
B18.12 When rebuilding a wheel cylinder, parts should be coated with brake fluid and fit back into the cylinder.
B18.13 Before a wheel cylinder is disassembled, the backing plate should be wiped off with a shop rag. If coated with brake fluid or axle lubricant, the backing plate should be washed with an approved cleaner.
Clutch System
Oil or grease should never be allowed to come in contact with the friction surfaces of a clutch. The slightest amount of oil or grease could cause clutch slippage or grabbing. Hands and tools must be keep clean.
The clutch should never be allowed to slip for more than a second or two. The extreme heat generated by slippage could damage the flywheel or pressure plate surfaces.
The battery ground should always be disconnected when removing the clutch assembly to prevent accidental cranking of the engine, possible personal injury, and possible damage to the vehicle's wiring.
Following installation of clutch system components, the clutch pedal free travel should be checked and adjusted.
Following service of the clutch system, the vehicle should always be test driven.
If leakage of the hydraulic clutch system is indicated, inspect closely. Look behind the master cylinder and at the end of the slave cylinder.
After reassembly, the hydraulic clutch should be bleed to remove air from inside the hydraulic system.
Only the recommended type of fluid should be installed in an hydraulic clutch system. Also, oil, kerosene or grease must never enter the hydraulic system.
These substances can swell and deteriorate the rubber cups. Keep your hands clean.
During inspection and cleaning of clutch parts, wipe each part down with a clean rag.
When the clutch is removed, each component should be carefully inspected for wear and damage.
Whenever the clutch is disassembled, the rear of the engine and front of the transmission should be checked for oil leaks. If oil were to leak on a new clutch, it would ruin it.
The pressure plate bolts should be tightened in a crisscross pattern to apply equal stress on each bolt as the pressure plate spring(s) are compressed. When all the bolts are snug, they should then be torqued to specs.
A clutch pressure plate bolt should never be replaced with a weaker bolt. The special case hardened bolt recommended by the manufacturer should always be installed.
Sandpaper should be used to deglaze and polish the surface of the flywheel and face of pressure plate.
Cleaning solvent, which might contain traces of oil, should be kept off the friction surfaces (clutch disc, flywheel, and pressure plate surfaces).
It is acceptable to replace the friction disc anytime the clutch is torn down for repairs. They are reasonably inexpensive and highly prone to wear.
The pilot bearing should always be checked for wear during a clutch service. If inexpensive, it is acceptable to replace the pilot bearing anytime the clutch is disassembled for repairs.
It is acceptable to replace the throw-out bearing anytime the clutch is disassembled for repairs. The throw-out bearing is an inexpensive part, subjected to considerable wear and a frequent cause of clutch problems.
The throw out bearing should never be washed in cleaning solvent. This could wash the grease out of the bearing and ruin it.
When installing a new throw-out bearing, a small amount of high temperature grease should be placed on the fork pivot point to allow the bearing collar to slide freely on the transmission hub. To much grease must not be used, as it could contaminate and ruin the clutch disc.
If the flywheel is damaged or warped, it should be either replaced or resurfaced.
If the ring gear teeth on the flywheel is worn or chipped, a new ring gear should be installed.
When unbolting the pressure plate, a pilot shaft (clutch alignment tool or old transmission input shaft) should be slid into the clutch to keep the clutch disc from falling.
Each pressure plate bolt should be loosened a little at a time to avoid placing too much stress on any one bolt. The pressure plate should be held against the flywheel as the last bolt is removed.
The pressure plate and flywheel should be marked (with a hammer and center punch) to assure the correct balancing of the clutch when the same pressure plate is reinstalled.
Cooling System
CS2.01 A cooling system check should always include a system pressure test for leaks, inspection of belts and hoses, radiator cap test, inspection of coolant for contaminates, test of coolant protection level, confirmation of proper coolant flow, and a check for water pump bearing play.
CS2.02 After a repair is made to the cooling system, a cooling system check should always be done to confirm that no other problems exist.
CS3.01 After a cooling system repair or maintenance procedure and cooling system check, the vehicle should be allowed to completely cool down. The coolant level should then be rechecked to make sure that the coolant level did not drop down due to escaping air pockets that may have been in the system.
CS5.01 Antifreeze should be checked and changed at regular intervals, since with prolonged use, antifreeze will break down and become very corrosive.
CS5.02 Antifreeze should be changed if contaminated or when two years old.
CS5.03 Antifreeze should be considered contaminated and should be replaced when found to contain rust, oil, scale or transmission fluid.
If engine oil or transmission fluid is found in the cooling system all rubber hoses should be replaced.
CS5.04 Minimum antifreeze strength should be 20 to 30 degrees lower than the lowest normal temperature for the climate of the area. A 50/50 mix of antifreeze and water provides protection for most weather conditions in all but extreme climates.
CS5.05 Use only antifreeze of the type recommended by the vehicle's manufacturer. Check the vehicles service manual or the antifreeze label for details. Many vehicles use special alloys or aluminum which can easily corrode from use of improper type of antifreeze.
CS5.09 Antifreeze prevents rust and corrosion, lubricates the water pump, cools the engine and provides protection from ice formation. Therefore, plain water (free of antifreeze) should never be used in a cooling system.
CS8.10 Reverse flushing of the engine and radiator should be done when rust or scale is found in the system. In rare instances when the reverse flushing fails to clean the deposits from the radiator, the radiator must be removed and rodded out by a radiator repair shop.
CS8.11 A cooling system flush generally is not cause for a customer make a special trip to the shop. The flush should be done in context of other, needed cooling system work, when it is more convenient and economical for the customer.
CS8.12 When flushing the cooling system, make sure any valves in the line going to the heater core are open.
CS8.13 If the seams of the oil cooler should leak transmission fluid into the radiator, the cooling system, the automatic transmission, the torque converter, and the oil cooler lines must be flushed out.
CS12.01 When replacing the thermostat, make sure the thermostat housing is not warped. Place it on a flat surface and check for gaps between the housing and the surface. If warped, file the surface flat if possible, otherwise replace housing.
CS12.02 The thermostat should not be permanently removed from the vehicle. Sludge buildup in the engine oil and excessive production of hydrocarbons and carbon monoxide occur in an engine that seldom reaches satisfactory operating temperature.
CS12.03 A replacement thermostat should be selected to maintain a high engine operating temperature, and in accordance with the vehicle manufacturer's recommendations, to minimize sludge formation in the engine oil and to minimize the production of hydrocarbons and carbon monoxide.
CS13.01 The spring inside the lower radiator hose normally prevents hose collapse and should never be removed.
CS14.01 When removing a water pump, care should be taken to not allow coolant to get on the timing belt or drive belts.
CS23.11 If an electric fan, free of obstructions, fails to operate with voltage applied, the motor should be replaced.
CS23.21 An engine fan should be replaced if the blades are bent or cracked. A faulty engine fan can cause overheating, overcooling, vibration, and water pump wear or damage. A fan with cracked or bent blades is extremely dangerous. Broken blades can be thrown out with great force, causing severe lacerations or death.
CS23.51 If an electric fan does not function, the fuse, electrical connections and supply voltage to the motor should be checked.
CS24.05 A pinhole leak in a radiator should be soldered or sealed with an approved epoxy. The radiator should not be replaced due to a pinhole leak if the radiator can be repaired.
Electrical
E2.01 A charging system check should always include testing the voltage and current output of the alternator, checking the operation of the regulator, and inspecting the condition of the battery, cables, and drive belt.
E2.11 A starting system check should always include testing the voltage drop in the battery cables, connections, switch, solenoid, and starting motor, testing the amperage draw of the starting motor, and inspecting the condition of the cables and wires.
E3.01 When a battery is found to be discharged, the charging system should be checked for proper function and the electrical systems should be checked for electrical drains.
E3.02 If the top of the battery is dirty, it should be washed down with baking soda and water or a suitable battery cleaner.
E3.03 A replacement battery should have a power rating at least equal to factory recommendations.
E3.04 When adding water to a conventional battery, distilled water or a clean tap water should be used. Mineral water should not be used.
E3.10 When time allows, a battery should be charged slowly.
E3.11 Before load testing a battery, it should have an adequate charge. If the battery open circuit voltage is below 12.4 volts, charge the battery before load testing.
E3.12 The current draw to be used when load testing a battery should be calculated as follows:
a) three times the amp-hour rating, or b) one half the cold cranking amps rating.
E3.13 In load testing a battery, the correct load should be applied for 15 seconds. The load should then be completely removed to prevent further discharging of the battery. If the voltage reads below 9.5 volts at room temperature (70 degrees F, 21 degrees C, or above, adjusted for other temperatures), battery performance is poor.
E3.21 The battery tray and retainer should securely hold the battery in place.
E3.31 Battery terminals should be tightened just enough to secure the connection and should sit completely below the top of the battery posts.
E3.32 If a battery terminal is replace or cleaned due to excessive corrosion, a coating of petroleum jelly, white grease or other suitable substance should be used to keep acid fumes off the connections.
E4.01 Whenever two wires are made into a permanent connection, they should be soldered together, and the joint sealed in heat shrink whenever possible.
E4.02 Wiring with cracked or brittle insulation should be repaired whenever practical.
E4.03 Wiring should be routed away from all moving or hot parts.
E4.10 A short circuit is found on any computer control circuit wiring where the resistance, when checked with a ohmmeter, is less than several hundred thousand ohms.
E4.11 The voltage drop across any electrical connection should not exceed .1 volts. If the voltage drop is higher, look for loose connections, burned plug socket, or similar problems.
E4.12 An electrical short should never be trouble shot by applying power to the circuit.
E4.15 A wire should be repaired in any computer control circuit wiring where the resistance across the wire and connections is greater than 5 ohms. If the ends of the wire are far apart, the measurement can be taken by grounding one end of the wire. Attach one meter lead to the ungrounded end of the wire and the other lead to a common ground.
All wiring around the battery should be checked for corrosion.
Battery cables should be inspected several inches from terminal for signs of corrision.
E11.01 To prevent the starting motor from overheating, the starter should not be operated for more than 15 seconds at a time.
E84.01 When using a hydrometer or cell voltage tester, electrolyte must not be allowed to drip on the vehicle. Any acid must be immediately rinsed off.
Emission Control Systems
EM1.03 If the vehicle's exhaust emissions are higher than the value stated on the emission control sticker in the engine compartment or in a service manual, an adjustment or repair is needed.
EM1.04 No emission control system should be modified or made intentionally inoperative except where permitted by government agencies for specifically exempt off road uses.
Engine
EN3.01 All engine parts to be reused shall be thoroughly cleaned to remove old gasket material, contaminates and hard deposits.
EN3.02 Parts shall be cleaned in such a way that they are not nicked, gouged, bent, or otherwise damaged.
EN3.03 Engine parts which might be reused should first be inspected for wear or damage.
EN3.04 Engine parts which might be reused should be measured and compared with specifications whenever needed to assure proper alignment and sealing.
EN11.01 When ethylene glycol is found in the lubricating system, the following flushing procedure should be done after the cause of the coolant leak is corrected, unless another flushing procedure is recommended by the vehicle manufacturer.
a) drain the engine oil and replace the oil filter
b) fill the crankcase to the full mark with either ATF (automatic transmission fluid) or a mixture of 1-2 quarts kerosene, and 3 or more quarts light viscosity engine oil (SAE 10W or other light engine oil).
c) idle the engine with this flushing oil for about 10-20 minutes.
d) repeat with fresh flushing oil, if needed,
e) finally, drain the flushing oil, install another new oil filter, and refill crankcase with the correct engine oil.
EN14.01 Timing Belts must be replaced on a periodic rate, as recommended by the vehicle manufacturer. If the manufacturer does not specific a replacement interval, then replacement should be every 60,000 miles.
EN14.04 When a timing belt is being replaced, the water pump bearing play should be checked.
EN14.05 It is acceptable to recommend replacement of the water pump, if it is thought to have been in the car for several years, and if replacing the water pump at that time would probably result in lower overall maintenance costs for the motorist by saving the shop from having to go into that same part of the vehicle on a separate occasion in the near future.
EN14.12 During timing belt replacement, the old belt should be inspected for damage which might indicate mechanical problems. The sprocket condition should be also be checked. Look for leaking oil that can reach and ruin the belt. Turn the tensioner wheel, to make sure its bearing spins freely. Correct any problem that could reduce timing belt life.
EN14.13 Proper timing belt tension is critical to a long belt service life. A reputable shop manual should be checked if there is any doubt about the proper tensioning.
EN31.11 A transmission should not hang unsupported after engine removal.
EN32.11 During engine break-in, engine oil and filter should be changed after approximately 2000 miles of driving. This will help remove any particles in the oil.
EN32.12 During engine break-in, engine oil and other fluid levels should be checked frequently.
EN42.01 During engine assembly, tolerances should be measured, compared with specifications and corrected as needed to assure proper alignment and sealing.
EN43.02 The proper cylinder wall finish should have a pattern of diagonal crosshatch scratches, but no longitudinal scratches. This pattern permits rapid seating of rings, and helps retain a film of oil to provide lubrication for the ring face and prevent scoring of the cylinder.
EN43.03 After honing, the cylinder must be thoroughly cleaned to remove all honing grit.
EN43.04 Before any cylinder is refinished, all main bearing caps must be in place and tightened to the specified torque so the crankshaft bearing bores do not become distorted during the refinishing operation.
EN43.12 If more than .030" is removed (machined off) from a cylinder head, the opposite head and the intake manifold on a V-type engine should be resurfaced to realign the bolt holes and passages.
EN44.02 Before cleaning a cylinder block or head, the core hole plugs should be removed to permit the the cleaning solution to flush out any accumulation of rust and lime deposits.
EN44.03 When an cylinder block or head is cleaned, a visual inspection for external cracks and damage should be made.
EN44.04 New freeze plugs should always be installed after cleaning a cylinder block or head in either a hot or cold tank solution.
EN45.01 The manufacturers' instructions should always be followed when installing new rings.
EN45.02 Rings must never be stretched over the piston by hand. A ring expander should be used. Piston rings are fragile and can break easily or become distorted.
EN45.03 When new rings are installed in cylinders than have not been reconditioned, a hone should be run through the cylinder a few times to remove the glaze that formed on the cylinder wall during normal operation.
EN45.04 If necessary, minor increases in piston ring gap clearance can be made by filing the ends of the ring.
EN45.05 If the piston ring side clearance is not within specifications, it is not acceptable to file the width of the ring. New rings should be used.
EN45.11 Piston ring grooves must be thoroughly cleaned before installing new rings.
EN45.12 The depth of the ring groove must be checked when replacing rings. The groove must be deep enough to allow the ring to enter the groove below the surface of the ring land.
EN45.13 If there is excessive side clearance on any ring, it should be reconditioned or replaced.
EN45.14 New rings should never be installed in worn ring grooves. Poor oil economy, increased blowby, and shortened ring life would result.
EN45.31 A ring compressor should be used when inserting the piston with rings into the cylinder.
EN51.04 When cylinder head bolts extend through a water jacket, the threads of these bolts must be coated with RTV or a suitable sealer to keep coolant from seeping past the threads and into the crankcase.
EN52.02 The engine should be turned one complete revolution by hand after torquing the main bearing caps to help make sure they are in the right position.
EN53.02 The crankshaft should be rotated one complete revolution by hand after installing and torquing each rod cap to help make sure they are in the right position.
EN55.04 A dab of RTV should be placed on the rear main bearing cap to prevent oil leaks.
EN60.01 A bearing journal that is scored or is out-of-round must be reconditioned or replaced. The main bearings must fit the crankshaft journals all around the circumference with only enough clearance for a film of lubricating oil. Clearance between the journal and bearing should be compared with the car manufacturers specifications.
EN65.02 A valve should always be re-placed in the guide from which it was removed unless a new valve or guide is to be installed. Valve parts should not be mixed up.
EN65.11 If the valve stem is scored, pitted, bent, has a slight ridge or groove, or is worn more than .002", the valve should be discarded.
EN65.12 Before any measurement is made, a valve stem should be cleaned and polished. Additionally, the valve guide should be thoroughly cleaned of carbon deposits.
EN65.21 If the valve face is burned, badly warped, or worn to a thin margin, the valve should be discarded.
EN66.02 Valve springs should be replace if broken, not square on each end, or when not up to specifications. Both free length and spring strength should be measured.
EN66.03 It is an acceptable practice to replace valve springs periodically, on a case by case basis, while the valve assemblies are already disassembled, as a precaution to prevent unexpected failure.
EN67.02 Valve tappet adjustment should be made after the engine has reached operating temperatures.
EN69.02 The thrust plate should be replaced if end play is excessive.
EN83.02 If a blown head gasket, cracked block or cracked cylinder head is suspected, the engine oil and valve covers should be checked for the presence of antifreeze. Antifreeze, mixed with engine oil, can cause engine damage.
EN83.03 Deck warpage should be checked when a head gasket was found to be blown and leaking.
EN85.01 A wet compression test should be completed on a gasoline engine, if cylinder pressure reads below specs, to help determine which engine parts are causing the problems.
Exhaust System
EX2.01 The exhaust system must be repaired if any engine exhaust can flow through any opening in the body and into the passenger compartment. The customer should be advised to not drive the vehicle at all until the problem is corrected.
EX2.02 An exhaust system should be repaired to eliminate any leaks.
EX2.03 Loose exhaust system parts should be retightened.
EX3.01 All heat shields must be reinstalled.
EX4.01 Brass nuts should be used to hold exhaust flanges together, since they will not rust to the studs.
Fuel System
FS5.02 Route all fuel lines and hoses away from hot or moving parts.
FS13.02 Only approved synthetic rubber hoses should be used in the fuel system. Vacuum type rubber hose is not acceptable.
FS13.03 Fuel hose should be fully installed over the fitting barbs.
Fuel hose should be checked for
FS14.02 Metal fuel lines should be replaced when smashed, kinked, rusted or leaking.
FS14.03 Only approved double-wall steel tubing should be used for fuel lines. Do not use copper or plastic tubing.
FS14.04 Double-lap flares must be formed on the ends of the fuel line. Single lap flare is not approved for fuel line.
FS21.04 A sending unit float should be replaced if you hear liquid splashing while shaking the float next to your ear.
FS28.01 Before a mechanical fuel pump is replaced, it should be determined that the fuel tank has sufficient quantity of fuel and is properly vented, the fuel line between the pump and supply tank is not clogged and does not have an air leak, and that the condition of the fuel filter and flexible fuel line connecting the pump with the rigid fuel line leading to the supply tank are ok.
FS28.02 When a mechanical fuel pump can no longer supply fuel in sufficient volume, it should be replaced with a new unit.
FS28.03 After replacing a ruptured mechanical fuel pump, the engine oil should be checked for a gasoline smell. Fuel may have leaked through the diaphragm and down into the oil pan. If the engine oil is contaminated, the oil and filter should be changed after the fuel pump repair is completed.
FS28.80 If it is suspected that too much fuel is being supplied by a mechanical fuel pump, due to observed flooding of the carburetor, the fuel pump pressure should be checked and compared with specifications.
FS31.01 On computerized systems, where the idle speed is controlled by an idle speed motor, unless specifically stated by the vehicle's manufacturer, a technician should never attempt to adjust the idle speed. The cause of the problem, which might be mechanical (such as a vacuum leak), or electrical (the idle speed motor, a sensor, the computer), should be corrected restoring the system to proper function.
FS33.01 A fuel injector should be replaced if leaky, it's resistance is out of specs, or if cleaning fails to completely remove any restriction.
FS33.03 Fuel injector cleaning should only be done to correct an observed problem such as hard starting, stalling, or hesitation on acceleration, where the injector(s) are partially clogged. Fuel injector cleaning should not be done as a preventative measure when no problem currently exists.
FS33.04 The use of an inexpensive (less than $4.00 per treatment), effective fuel injector cleaner added to the gas tank with a full tank of gas, as a preventive measure, is acceptable.
Ignition System
IS13.01 A feeler gauge should be cleaned before inserting it in the points. Oil or grease will reduce the service life of the points.
IS14.01 A spark plug wire should be replaced if it has a burned or broken conductor, deteriorated insulation, or its resistance is out of specs. In the absence of a spark plug wire resistance specification, a guideline of not over 5,000 ohms per inch or over 100,000 ohms total should be used.
IS14.02 A spark plug wire should be replace with on of equal length.
IS14.03 Spark plug wires should be replaced one at a time.
IS14.04 Spark plug wires should be removed by grasping and pulling on the boot. A spark plug wire never should be removed by pulling on the wire. The conductor in the wire could break.
IS15.01 Spark plugs which are working properly should not be replaced in between intervals recommended by the vehicle's maker.
IS15.02 Unless specifically not recommended by the vehicle's manufacturer, a spark plug tip covered with carbon may be cleaned with a spark plug cleaner.
IS15.03 Whenever a spark plug is removed, it should be read to detect any engine, fuel system, or ignition system problem which may be present and if a problem is indicated, the cylinder from which the spark plug was removed should be noted.
IS15.04 When installing a spark plug, it should be started by threading it into the head a few turns by hand, with a spark plug socket or with a short piece of vacuum hose to help prevent thread damage which could result from crossthreading.
IS15.05 A distributor cap should only be replaced if carbon traces are found or it is cracked.
IS16.01 A distributor rotor should be replaced if carbon traces or cracks are found, and at intervals recommended by the vehicle's manufacturer.
IS17.01 A ignition pickup coil should be replaced if its resistance is lower or higher than the vehicle manufacturer's specifications.
IS82.01 Use of a heat gun or light bulb to warm the control unit during troubleshooting is acceptable so long as care is taken not to heat the unit past its normal operating temperature. Too much heat can ruined the device.
IS83.01 An engine should not be run for more than 15 seconds a spark plug wire off. Unburned fuel from the dead cylinder could foul and ruin the catalytic converter.
Lubrication System
LS1.01 After a oil change, the vehicle should be checked for oil leaks with the engine running.
LS2.01 Engine oil and oil filter should be changed at least as frequently as the maximum number of miles recommended by the auto maker.
LS2.02 An older, worn engine will contaminate the oil more quickly than a new engine and the engine oil and oil filter should be changed more frequently.
LS2.03 A vehicle driven for only short distances may not allow the engine to reach full operating temperature, causing the oil to be contaminated with fuel, moisture, and other substances more quickly. The engine oil and oil filter should be changed more frequently under these conditions.
LS2.11 The engine oil should be changed while warm, as this helps suspend debris in the oil and makes the oil drain more thoroughly.
LS2.15 The oil filter should only be hand tightened. A filter wrench can cause the canister to distort and leak.
LS3.01 Normally, the oil viscosity recommended by the auto maker should be used.
LS3.02 It is acceptable to use slightly thicker oil on very old, high mileage, worn engines to help seal the rings, provide better bearing protection, cut engine oil consumption and reduce smoking.
LS3.03 The oil service rating (set by the American Petroleum Institute) recommended by the car maker should be used. It is acceptable to use engine oil with a better service rating, but never a lower service rating.
LS4.01 Before installation, the filter o-ring should be wiped clean and lightly oil coated.
LS4.02 The condition of the drain plug threads and the o-ring washer should be checked. Replace them if needed.
LS4.03 Care should be taken to not over-tighten the oil pan drain plug. It can strip very easily, possibly causing pan damage.
LS9.01 Whenever a oil pan is removed, the pan should be checked for debris such as metal bits, plastic pieces or rubber particles which could indicate engine mechanical problems.
LS9.02 Before re-installing an oil pan, it should be washed thoroughly in cold soak cleaner.
LS9.03 Before re-installing an oil pan, the pan flange should be checked to make sure it is not bent, by laying the pan upside down on a flat workbench. If needed, the flange should be straightened with light hammer blows.
LS9.04 Either a gasket or chemical sealer should be used for the oil pan.
Steering and Suspension
SS3.01 Noticeable movement in a part is not grounds for replacement unless the amount of play is measured and found to be more than the specification listed in a reputable shop manual.
SS4.01 Alignment should be checked or adjusted when either:
a) parts affecting alignment are serviced such as ball joints, tie rods, tie rod ends, idler arms, drag links, control arms, strut rods, strut mounts, springs, strut assemblies, rack and pinion assemblies, torsion bars, spindles, axles, and bent wheels, or
b) or a condition exists indicating a possible improper wheel alignment such as uneven tire wear, vehicle pulling or drifting to one side, the steering wheel not appearing "centered", steering wheel not easily or readily returning to the straight-ahead position after a turn, steering wheel hard to turn, or unstable high-speed steering and/or handling.
SS4.11 Replacement of tires or shocks does not affect the alignment.
S21.04 A shock absorber should only be replaced if it fails a bounce test. A bounce test is performed by pushing up and down on each corner of the car body, then releasing the body and counting the number of times the car moves up and down. A shock absorber fails the bounce test if bounces more than two to three complete oscillations.
SS21.05 A shock absorber that appears to be leaking oil, but passes the bounce test should not be replaced.
SS23.02 A ball joint should be replaced if the amount of measured movement exceeds service manual specifications, or if wear indicators are present, if the shoulder on the joint is recessed.
SS23.05 When greasing a ball joint with a balloon seal (airtight seal), only enough grease should be injected to cause a slight enlargement of the seal. Too much grease can rupture the rubber boot.
SS23.12 A new cotter pin should always be used when a ball joint nut is removed. An old cotter pin could break, causing a serious accident.
SS41.01 Idler arm wear should be checked by applying moderate pressure to pull or push on the outer end with your hand. If measured movement of one thirty-second of an inch or more is found at the outer end, then the measured movement should be compared with the specification in a reputable manual. The idler arm should be replaced if the movement is greater than the specification listed.
SS42.02 Before loosening the tie-rod adjustment sleeve, measure or mark tie-rod length, allowing the new tie-rod to be set to about the same length as the old one.
SS43.03 When any of the hydraulic components (pump, hoses, power piston) are serviced, the power steering system should be bleed to assure that all the air is out of the lines, pump and gearbox.
SS43.83 When using a power steering pressure tester, care should be taken to not close the test valve too long (generally more than five seconds) to cause possible power steering pump overheating damage.
Tires
T1.01 Radial, bias ply, and belted bias tires should not be mixed on the same car except in emergencies.
T1.02 New tires should normally be installed in pairs on the same axle. If replacing only one tire, the tire having the most tread should be paired with it.
T1.03 Tires built by different manufacturers with identical T.P.C. Spec. No. can be interchanged on the same car even though the tread designs may differ.
T2.01 Tires should be inflated to manufacturer's recommendations. When tires are cold, inflation pressure should generally be 1 to 3 PSI below maximum listed air pressure to allow for tire heating, air expansion, and pressure increase.
T3.01 A tire should be replaced if any of the following conditions exists:
a) a localized worn spot exposes the ply or cord through the tread,
b) tread or sidewall cracks, cuts, or snags (as measured on the outside of the tire) in excess of one inch exists in any direction and deep enough to expose the body cords,
c) visible bumps, bulges, or knots exist which are apparently related to tread or sidewall separation or partial failure of the tire structure, including bead area.
d) on any tire without tread wear indicators, less than 2/32 (1/16) of an inch of tread design depth remains when measured (with a tread depth gauge) at the lowest points in any two adjacent major grooves in the center or middle of the tire,
e) on any tire with tread wear indicators, the tread wear indicators contact the road in any two adjacent major grooves in the center or middle of the tire.
T4.01 Tire rotation should be done at the rate and method recommended by the tire's manufacturer (generally every 6,000-8,000 miles), where such service will help even out tire wear and prevent premature failure of any one tire.
T4.02 Tire rotation generally should be done when most opportune to save the customer money on such service, so long as roughly following the rotation time table recommended by the tire's manufacturer.
T5.01 Wheels should be checked for proper balance anytime:
a) a tire is replaced,
b) a rim is replaced,
c) after an accident occurs, if a vibration is present and incorrect tire balance is suspected.
T5.02 Dynamic wheel balancing is preferred to static wheel balancing, however either is acceptable.
T6.02 The tire beads and wheel flange should always be lubricated with a proper lubricant such as a vegetable oil and soap solution during tire mounting. Antifreeze, motor oil, or other non-drying petroleum-based substances could cause tire deterioration or movement on the wheel and should never be used.
T6.03 A tire should only be mounted on a rim that is smooth and clean.
T12.01 A wheel should be replaced if bent, dented, heavily rusted, leaks air through welds, has excessive radial or lateral runout or elongated bolt holes.
T13.01 To correctly make a puncture repair, it must fill the injury to the tire, and soundly patch the inner liner.
T13.02 The safe and correct procedure for tire repair is to always remove the tire from the rim and make the repair from the inside.
T13.03 A repair should not be attempted to sidewalls or tires with punctures of larger than 1/2 in. (13mm).
Transmissions
TR2.01 Whenever a transmission is rebuilt, all gaskets and seals should be replaced. Even though a seal or gasket might not leak before teardown, it could start to leak after assembly.
TR23.01 When replacing a gear on the output shaft, you should also replace the matching gear on the countershaft. If a new gear is meshed with an old worn gear, gear noise can result.
Turbocharging
TU4.01 Only a soft wire brush and solvent should be used to clean turbo wheels. A hard metal object or sandpaper should not be used as they can cause an imbalance which could cause the wheel to vibrate and destroy the turbo.
Wipers
WI12.01 Windshield wipers inserts should be replaced if damaged, hardened or badly worn.
WI12.02 A Windshield wiper should be replaced if:
a) the portion of the rubber element that contacts the windshield is torn more than one inch on one end or is torn a total of one inch on both ends.
b) Any part of the rubber element is torn loose from the metal backing of the blade base.
c) Metal parts of the wiper blades or arms are damaged or come in contact with the windshield.
d) Wiper is incapable of adequately cleaning the windshield.
Part III - Shop Safety
109.01 To prevent and accident, wipe up spills as soon as they occur.
110.01 In an enclosed shop, a exhaust vent system should be used to trap and remove toxic fumes whenever a vehicle is running.
111.01 Care should be taken not to let hot fluids pour out onto your hand or arm when draining systems or pouring fluids.
112.01 Always follow manufacturer's instructions when using a cooling system cleaning agent. it can cause eye or skin burns.
113.01 Keep your hands away from a moving engine belt. The belt can pull your fingers into the pulleys, causing severe hand injuries.
113.02 Never remove a radiator cap when the engine is hot. The pressure release can make the coolant begin to boil and expand. Boiling coolant could spurt out of the filler neck causing severe burns.
113.03 Keep clothing, your hands, tools, and equipment away from a spinning engine fan. Stand behind, not over, the spinning fan blade, so that if a tool is dropped into the fan or a fan blade breaks off, your less likely to be hit or injured by flying parts.
121.01 When working around the alternator of cars equipped with a heated windshield, precautions should be taken to guard against possible electrocution. Some alternators aare made to produce 110 volts AC, which is enough voltage to cause a painful jolt or even death.
123.01 Be careful not to drop the starting motor during removal. It is heavy enough to cause serious injury.
124.01 Before connecting a battery charger to a battery, make sure the charger is turned off to prevent sparks.
124.02 Keep all sparks and flames away from the top of a battery. Hydrogen gas, produced by the chemical reaction in a battery is very flammable.
126.01 Parts of the exhaust system, especially the catalytic converter, can be very hot. Remember not to touch any component until after it has cooled.
130.01 A glow plug can reach temperatures over 1000 degrees Farenheit. Use caution when removing them from the engine.
131.01 High pressures are developed when pop testing a diesel injector nozzle. Keep your hands away from the fuel spraying out of the nozzle. It can puncture the skin.
132.01 Never place any part of your body under an engine held in the air. A heavy engine can chop off fingers, cripple or even kill you if dropped.
132.02 Never work on an engine that is held by a crane or hoist. The engine could shift and fall, damaging the engine or causing serious injury.
Part IV - Service Advising
Where two or more operations are performed on a vehicle and have overlapping labor times, a reasonable deduction should be made in the total times charged to the customer.
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