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Courtesy Inspection Report

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1 Courtesy Inspection Report

2 Purpose Every vehicle that enters the shop must have a completed Courtesy Inspection Report The Courtesy Inspection Report identifies any problems or damage to the vehicle that was present when the vehicle arrived at PCI The report also provides the owner of the vehicle with written documentation of any safety or service concerns that were observed by the technician prior to any service on the vehicle.

3 VIN number Every vehicle manufactured since 1981 has a unique 17 character Vehicle Identification Number [VIN] The VIN number may be needed to find service procedures and specifications in AllData, Identifix and for ordering parts The VIN number is also needed when setting up a scan tool to interface with the vehicles computer network The VIN number is found on the left side of the windshield [drivers side] and also on the drivers door pillar

4 Model Year The model year is the 10th digit of the VIN

5 Model year in the VIN number

6 Model Year The model year can also be found on the emissions placard normally located under the hood on top of the radiator support panel This placard is often called the VECI lable [Vehicle Emission Control Information]

7 Parking brake Prior to driving the car into the shop apply the parking brake when the vehicle stopped in an area where there is room for the vehicle to move safely if the parking brake does not hold Put the transmission into drive and release the foot brake The vehicle should not move when there is no pressure applied to the gas pedal

8 Parking brake It should take about 5 clicks in the parking brake ratchet for the brake to be tight enough to prevent the vehicle from moving.

9 Parking brake – manual transmission
Find a place in the parking lot where it will be safe to test the parking brake Apply the parking brake With the engine running put the transmission into 1st gear Without depressing the gas pedal slowly engage the clutch The engine should stall and the vehicle should not move If the vehicle moves the parking brake is not working properly

10 Parking brake After testing the it’s holding ability release the parking brake and check to see if the vehicle rolls freely Vehicles with automatic transmissions should creep normally when the foot brake is released Vehicles with manual transmissions should coast when the vehicles is moving slowly [ 1 to 2 mph] and the clutch pedal is fully depressed

11 Warning lights As you are driving the vehicle into the shop check the instrument panel for any unusual warning lights

12 Brake warning light If the brake warning light remains illuminated when the parking brake is off it is likely that there is a problem with the brake hydraulic system If the fluid level in the master cylinder reservoir is low enough to trip the warning light there is a leak somewhere in the brake hydraulic system

13 Brake warning light Some vehicles have two brake warning lights
Parking brake indicator Hydraulic system failure indicator Some vehicles have two brake warning lights One light is used to indicate if the parking brake is set The other light indicates a brake hydraulic system failure

14 Brake pad warning light
Some vehicles have wear sensors embedded in brake pads When the pads wear down to the minimum thickness the warning light is tripped A separate warning indicator light is used to distinguish pad wear from hydraulic failure

15 ABS warning light If the ABS warning light is illuminated when the brakes are not applied and the car is not in motion there is a failure in the ABS system If the ABS system is deactivated the brakes will work normally but if a wheel were to begin to lock during a stop the ABS system could not prevent the wheel from locking, which could result in a loss of steering control The ABS warning light will usually flash when a fault is detected. On some vehicle the ABS light will flash a code indicating what component has failed

16 Tire pressure warning indicator
All cars built since MY 2007 have a wireless Tire Pressure Monitoring System [TPMS] The TPMS warning light illuminates when the pressure in any tire drops below 80% of the nominal air pressure Resetting the tires to the correct pressure should turn the warning light off

17 Charging system indicator
The charging system indicator illuminates when the charging system voltage drops below 13.5 volts A broken serpentine belt is the most common cause of a charging system failure but a defective alternator / voltage regulator can also cause the light to come on Since the serpentine belt also drives the water pump and power steering pump the vehicle should never be driven when this light is illuminated

18 Oil pressure warning indicator
The oil pressure indicator is typically illuminated when oil pressure is below 10 psi When oil pressure is between 10 and 15 psi the light may flicker Driving the vehicle with an illuminated oil pressure light could severely damage the engine

19 Coolant temperature warning light
The coolant temperature warning light normally illuminates when the temperature of the coolant exceeds 230 degrees F. Some vehicles have a coolant level sensor that has a slightly different symbol and normally is labeled ‘low coolant’ or ‘check coolant’ Never open the radiator cap when the engine is hot!

20 SIR warning light The air bag system is called the Supplementary Inflatable Restraint system [SIR] If the SIR light is illuminated the system has failed its power on self test and the SIR system has been disabled by the SIR module In the event of an accident none of the air bags will inflate In some systems the SIR light flashes when a system failure is detected and is illuminated constantly if the SIR module is disconnected

21 Check Engine light The ‘Check Engine’ light indicates that the vehicle’s self diagnostics system has detected a failure that will cause the vehicle’s emissions to exceed 150% of the federal emissions limits for that model / year The vehicle will not pass a state emissions test if the check engine light is illuminated In most cases you can continue to drive the vehicle although performance and fuel economy may be diminished

22 Check Engine light A flashing ‘Check Engine’ light indicates a engine misfire that is severe enough to damage the catalytic converter. The vehicle should not be driven until the misfire has been repaired If the ‘Check Engine’ light is illuminated connect a scan tool to the vehicle’s OBDII diagnostic connector to read the code

23 Service reminder lights
Service reminder lights are commonly used for oil change intervals and are driven by the accumulated mileage since the service reminder was reset Some service reminders such as belt wear indicators are driven by sensors that are triggered when a component reaches it’s wear limit

24 Warning light prove out mode
The instrument control module sends power to all of the warning lights in the instrument cluster for about 3 seconds after the ignition key is turned from off to run This allows the operator and the service technician to verify that all of the bulbs [LEDs] in the instrument cluster are working properly

25 Record any illuminated warning lights
If there are any warning lights illuminated in the comments block of the inspection report

26 Check the operation of the lights
If the bay that you are working in does not have convex mirrors at both ends you will need an assistant to help you check the lights Turn the headlight switch to the parking light position to check the operation of the front and rear parking lights and side marker lights Most modern cars have 2 bulbs at each corner – one facing forward or back and the other facing toward the side. Make sure both bulbs are working

27 Parking lights This vehicle’s headlight control module sends low current to the high beam bulb when the light switch is in the parking light position Wide dispersion forward facing bulb Narrow dispersion high beam bulb projects light up to ½ mile Wide dispersion sideways facing bulb

28 License plate lights The license plate lights are powered by the parking light circuit If there are two bulbs both must be working

29 Brake lights With the parking lights turned on have your assistant press the brake pedal and check that all 3 brake lights illuminate If any of the parking lights go out when the brake lights turn on there is likely a bad ground in the parking/brake light circuit

30 Turn signals With the key in the run position and the headlights turned on apply the turn signals The turn signals should cycle once every two seconds. The cycle rate in a left turn should be the same as in a right turn The indicator lights in the instrument cluster should flash at the same rate as the bulbs Vehicles with side marker lights or lights incorporated in the outside mirrors should flash in unison with the front and rear turn signal lights

31 Turn signals The functioning of the turn signal lights should be checked with the parking lights on and off A bad ground in the light assembly is often only apparent when the parking lights are on The intensity of the right side turn signal light should be the same as the left side light This may occur if the wrong type of bulb is installed It can also be caused by a bad ground The turn signals should also be checked with the brake pedal depressed A bad ground in the brake light wiring can effect the operation of the turn signals

32 Backup lights Put the transmission in reverse [key in run - engine off] and check to see if the reverse lights operate On a manual transmission vehicle you will normally need to depress the clutch pedal fully to get the gear selector to fully engage reverse gear. If the gear lever is not fully engaged the back up light switch will not turn on

33 Headlights low beam Turn the headlight switch on and operate the high/low beam stalk Check the operation of the high and low beams and check that the intensity of the lights is the same – left and right

34 Headlights high beam Ideally the headlights are projected onto the garage door or a uncluttered wall to determine if there are major problems with headlight aiming. Any irregularities in headlight aiming should be noted

35 Headlights – instrument lights
With the headlights turned on make sure all the instrument lights are working [light bulbs that illuminated analog gauges]. Blown bulb in this quadrant Turn the instrument light dimmer to the max and observe the gauges to see that all of them are illuminated

36 Headlight covers Dull, scratched and yellowed headlight lenses [clear plastic covers over the reflector] should be noted

37 Dome light The light in the ceiling of the vehicle is called the ‘dome light’ Make sure it illuminates when the door is opened and goes out when the door is closed If the dome light does not operate make sure it has not been turned off manually by operating the manual control switch on the light

38 Wipers and washers With the ignition key in the run position operate the wipers on all speeds Make sure the wiper arms return to the ‘park’ position at the base of the windshield when the wiper switch is turned off Operate the washer pump and make sure the washer nozzles are not plugged up and are properly aimed

39 Rear wiper / washer Don’t forget to check the operation of the rear wiper / washer

40 Wipers and washers Observe the windshield while operating the washers. Heavy streaks of liquid on the windshield are evidence of worn wiper blades If the vehicle is equipped with a rear window wiper/washer check it’s operation as well

41 Horn Operate the horn and listen to the tone
Most vehicles have dual horns produce two distinct tones that together make a more pleasant sound If the horn sounds weak or anemic its possible that only one of the horns is working

42 Centering the vehicle on the lift
A B PCAUTO The vehicle must be positions as close as possible to the center of the lift

43 Setting the vehicle on a lift
Have a spotter help guide you onto the lift The vehicle must be centered on the lift. If the distance between the drivers door and the left lift post is 2’6’’ and the passenger side is 3’6” the vehicle must be backed off the lift and repositioned so that the distance between the doors and post is nearly equal

44 Centering the vehicle on the lift
A B The vehicle must not be at an angle to the center line of the lift

45 Centering the vehicle on the lift
The weight of most passenger vehicles is concentrated toward the front of the vehicle The vehicle should be placed so that the center of gravity is as close as possible to a line connecting the centers of the two lift posts A tire stop plate is normally bolted to the floor where the left front tire should be positioned to set the vehicles center of gravity between the lift posts. Vehicles with long wheel bases or with a neutral or rearward weigh bias should be place so the left front tire is in front of the tire stop Tire stop

46 Tire stop Most passenger cars are properly positioned when the left front tire is centered in the tire stop

47 Tire stop position Tire stop Wheel base less than 105”
Wheel base 105” to 127” Wheel base larger than 127”

48 Jacking points For most unibody vehicles the pads for the lift arms should be placed directly under the pinch weld at the bottom of the rocker panel

49 Pinch weld Rocker panel Floor panel Pinch weld The pinch weld is the point on the car body where the floor connects to the rocker panels The rocker panels on a unit body vehicle are made of heavy gauge steel and are the ideal location for the lift pads to support the weight of the vehicle

50 Lift pad properly positioned on the pinch weld

51 Jacking points Wheel arch Pinch weld Rocker panel The lift pads should be placed as close as possible to the wheel arch but still underneath the pinch weld

52 Jacking points -Full frame vehicles
Older domestic rear drive passenger cars, pickup trucks and larger SUVs often have frames The lift pads must be setup on the frame and not on the rocker panels

53 Jacking points -Full frame vehicles
Body bushing [mount] Rocker panel Frame rail The rocker panels on vehicles with full frames are made of light gauge metal and will bend if vehicle is raised with the lift pads in contact with them If the rocker panel extends below the frame rail the lift pads will need to be screwed upward so that the rocker panel does not contact the lift arm

54 Jacking points -Full frame vehicles
Rocker panel Frame rail Extension Pickup trucks and full size vans often have frame rails that are several inches inboard and several inches above the rocker panels To prevent damage to the rocker panels when lifting the vehicle lift pad extensions are attached to the lift pad

55 Lift pad extensions Note damage to rocker panel when vehicle was raised without pad extensions

56 Lift arm position Front For maximum stability and safety the arms of the lift should be extended as far apart as possible

57 Unstable - lift arm position
Front If the lift arms are too close together the vehicle becomes unstable. There is a possibility of the vehicle could fall off of the lift

58 Rear suspension dead axle
Other pick up points Front sub-frame Rear suspension dead axle In some cases we wont be able to use the pinch weld while still having the lift arms spread as wide as possible The front sub-frame is robust enough to allow it to be used as an alternative lifting point Some parts of the rear suspension can also be used as lifting points. Check with you instructor before raising the vehicle

59 The vehicle must be level
Do not raise a vehicle in a upward or downward pitch attitude In this configuration the vehicle could slide off of the lift pads. This could result in personnel injury and damage to the vehicle

60 Test the vehicle setup by shaking
Once your satisfied that the vehicle and lift pads are positioned properly raise the vehicle about 18” off the floor and shake it by pressing up and down and side to side on the bumpers If the vehicle moves or if on of the lift pads is not in contact with the pinch weld or frame lower the vehicle and re-position the lift pads

61 Pneumatic safety latch release button
Raising the vehicle Pump motor switch Pneumatic safety latch release button Depressing the pneumatic safety latch release while the pump motor is operating will reduce the noise level while the vehicle is raised

62 Hydraulic control valve
Lowering the vehicle Hydraulic control valve The pneumatic safety release must be depressed while the hydraulic control valve is activated

63 Droplights You can’t perform a visual inspection of the undercarriage of vehicle in the dark. A droplight is one of the most important tools in the technicians toolbox Corded incandescent droplights are still commonly used in the trade but the heat produced by the bulb can burn skin and can damage plastic vehicle components In incandescent drop light should never be used around flammable liquids [gasoline, motor oil, solvents etc.]

64 LED rechargeable work light
Rechargeable LED work lights are popular because: They generate very little heat They can last for several hours on an overnight charge They operate at low voltage levels which makes them much safer when working around flammable liquids Cordless design makes them much easier to use in tight places [under the dash etc.]

65 Visual undercarriage inspection

66 Brake inspection The condition of the front brake pads can sometimes be seen through the wheel spokes with the aid of a small flashlight.

67 Brake Inspection Anchor bracket The amount of pad wear can also be visually gauged by how far the pad has recessed into the anchor bracket Brake Pad

68 Brake inspection Plastic pad wear gauges can be used to measure pad thickness.

69 Brake Inspection The thickness of the inboard pad can often be seen with the aid of a small flashlight

70 Check for brake drag Check the amount of drag in the brakes as you rotate the wheels by hand If there is a large amount of drag when you try to rotate the wheels there could be a binding caliper or frozen parking brake cables.

71 Flexible brake hoses Check the flexible brake hoses for cracking, blistering and twisting.

72 Steel brake lines Check the steel brake lines for evidence of leakage or excessive rust at the hydraulic connections.

73 Check for brake fluid leaks
Check the bottom of the backing plate for evidence of brake fluid. Leaking fluids will collect at the bottom of the backing plate

74 Rear brake inspection Parking brake lever should contact the stop on the cable bracket Check for fluid leakage from the shock absorber seal Check the rear calipers for evidence of fluid leaks, loose caliper mounting bolts and sticking or frozen parking brake cables. You can sometimes get a glimpse of the thickness of the inboard pads without removing the wheels.

75 Steering rack boots The rubber boots that protect the inner tie rod ends should be inspected for tears and damage. Fluid leaking from the boot on a hydraulic power steering rack indicates leaking rack seals.

76 Steering rack fluid leaks
Front sub-frame Power Steering fluid dripping down the side of the rack housing can usually be traced to the pinion shaft seal.

77 Check the upper part of the shock absorber for evidence of leaking fluid.
Check the shock bushings [top and bottom] for splitting and cracking. Shock Absorbers

78 Shock bushings Rubber bushing Inspect the shock absorber bushings [upper and lower ends] for evidence of cracking or other damage

79 Strut seal is inside the boot
Check for strut leaks Strut boot Strut seal is inside the boot Check the area near the strut seal for evidence of fluid leaks. Check the strut boot for tears or deterioration.

80 Stabilizer link bushings
Stabilizer bar links Inspect the stabilizer [sway] bar links and the four link bushings for splitting and cracking. Stabilizer bar Stabilizer link bushings

81 Tie rod inspection Push Pull Grab a hold of the tire at 3 o’clock and 9 o’clock and twist back and forth to see if there is play in the tie rods

82 Ball joint inspection Push Grab a hold of the tire at 12 o’clock and 6 o’clock and push/pull to see if there is play in the ball joints Some suspension types need to be tested with the weight of the vehicle supported by the control arms Pull

83 Tie rod visual inspection
Visually inspect the tie rod ends for torn boots and other damage

84 Tie rod shake test Shake the tie rod up and down and side to side to check for looseness in the tie rod ends

85 Damaged tie rod boots Check the tie rods and ball joints for split or damaged tie rod boots.

86 Ball joint visual inspection
Visually inspect the ball joint boots for leaks and tears

87 Fluid leaks Examine the oil pan and the sides of the engine block for fluid leaks.

88 Fluid leaks from bellhousing
Bell housing drain hole Most vehicles have a small drain hole at the bottom of the transmission bellhousing. Engine oil dripping from this hole indicates a leaking rear main [engine] seal. Transmission fluid would indicate a leaking torque converter hub seal and possibly a bad torque converter hub bushing.

89 Outboard constant velocity joints
Check for rips, tears and grease leaking out of the outboard CV joints.

90 Inboard constant velocity joint boots
Check for leaking axle seals Check for grease leaking out of the rubber boots in the inboard CV joints.

91 Checking Universal joints
Pinion flange Rust around the trunions indicates the u-joint has failed Twist the drive shaft back and forth while holding the pinion flange to see if there is any play in the u-joint.

92 Rubber universal joints
Check for signs of cracking here Check pinion seal for leakage Rubber universal joints should be checked for signs of cracking.

93 Catalytic converter rattle test
Rap on the bottom of the catalytic converter with your fist If is a rattling noise is heard the converter may be damaged If the converter is hot use a rubber mallet

94 Exhaust system inspection
Grab a hold of the exhaust pipes a several points and shake it side to side and up and down If a clunking noise is heard there may be broken exhaust hangers

95 Tire inspection Tread depth Tire damage Abnormal wear patterns
Inflation pressure

96 Tire tread depth gauge Tread depth gauge measure the depth of the tire grooves in 1/32” increments

97 Poor man’s tread depth gauge
2/32” A penny can be used as a simple gauge to evaluate tread depth

98 Tire inflation pressure
The correct tire inflation pressures are listed in the tire placard which is located on the drivers door jamb

99 Tire inflation pressure
The tire pressure printed on the sidewall should never be used as the basis for the tire pressure setting. The tire pressure setting is determined by the weight of the vehicle and the design of the tire

100 Measuring tire pressure
To measure tire pressure hold the end of the tire pressure gauge firmly against the tire stem

101 Adding pressure Each line on the scale equals 2 psi
Read the scale here Each line on the scale equals 2 psi The gauge here reads 24 psi

102 Adding pressure Air pressure is added to the tire using a ‘tire chuck’
Hold the chuck firmly against the tire stem for a few seconds to raise tire pressure 5 psi

103 Setting correct tire pressure
Excess pressure can be bled off by depressing the Schrader valve for a few seconds The pin on the back of the pressure gauge is provided for this purpose

104 Abnormal tire wear patterns
Under inflation Over inflation This tire was driven for an extended period with low air pressure This tire was driven for an long time with too much air pressure

105 Toe out wear Left Right When the inside edges of both tires on an axle are excessively worn the vehicle is in need of a wheel alignment.

106 Toe in wear Left Right Excessive wear on the outside edges of both tires on an axle are also caused by alignment problems In this case the wheels are towed in

107 Edge wear on only one tire
If only one tire shoe evidence of edge wear it is likely the result of excessive positive or negative camber on that wheel An alignment is needed to correct this problem

108 Sidewall scuffing Check the inside sidewalls of the front tires and the inner fender wells for evidence of scuffing between the fender and tire Suspension modifications, incorrect tires or incorrect rims can allow the tires to rub against the fenders during hard cornering

109 Under hood fluid checks and visual inspection

110 Engine oil level Not all modern cars have a dipstick for the oil level
Some late model cars have an oil level sensor in the oil pan If the oil level drops below a minimum value a warning light [message] will appear on the instrument cluster

111 Engine oil level The twist in the dipstick keeps the dipstick from contacting the inner surface of the dipstick tube preventing false readings Dots on the dipstick are used to indicate the minimum and maximum level Some dipsticks have marks for hot and cold levels

112 Oil viscosity If the oil level needs to be topped off the correct oil viscosity is printed on the oil filler cap

113 Dipstick o-ring The dipstick is sealed to the dipstick tube by an o-ring Make sure the dipstick is pushed all the way down into the dipstick tube so that air cannot enter the crankcase through the tube This could cause a drivability problem and could trigger the ‘check engine’ light. Also, the PCV [Positive Crankcase Ventilation] system will not function as designed is loose

114 Removing radiator cap Never remove the radiator cap when the engine is hot Serious personal injury can result if the cap is remove while the engine is still hot Wait until the upper radiator hose is warm to the touch before removing the cap

115 Checking the level of coolant
The coolant in the expansion tank is normally visible from the outside The expansion tank provides room for the coolant to expand as the engine heats up Full line

116 Radiator should be full
The radiator should be full to the top If it is not and the expansion tank has a normal coolant level the radiator cap is faulty or the filler neck in the radiator is damaged

117 Surge tank Many cooling systems use a pressurized tank to allow for coolant expansion The pressure cap is located on the surge tank and it replaces the radiator cap The surge tank is normally located on the inner fender or firewall Threaded pressure cap

118 Topping off antifreeze
If coolant needs to be add check AllData for the correct antifreeze type There are four common types of antifreeze used in modern cars and although they all chemically compatible it is a best practice to use the same type of antifreeze as the manufacture recommends when topping off the coolant level The color of the antifreeze varies among brands and is not a good indicator of the type of antifreeze

119 Checking antifreeze concentration
A hydrometer, refractometer or antifreeze tester should be used to check if the antifreeze concentration is sufficient to prevent the coolant from freezing in sub zero weather A freezing point of -40 degrees Fahrenheit or lower is recommended for all vehicles

120 Brake fluid level The brake fluid reservoir is translucent which allows you to see the fluid level without removing the cap. If the fluid level is between the Min and Max line do not top off The fluid level drops as the pads wear. If fluid is added to the reservoir the extra fluid will overflow and may leak onto the paintwork when new pads are installed If the fluid level is below the Min line there is a hydraulic leak that must be repaired before the vehicle is driven Max line

121 Clutch master cylinder
If the fluid in the clutch master cylinder is below the Min line there is a leak in the hydraulic clutch system that must be repaired

122 Power steering fluid level
Most late model cars have a remote power steering reservoir mounted on the inner fender Older cars and trucks normally have the PS fluid reservoir mounted directly on the pump

123 Windshield washer fluid
Sometimes the tank is mounted behind the fender well where the fluid level cannot be seen A dipstick in the cap is used to measure the fluid level

124 Automatic transmission fluid
Most vehicles require that the ATF [Automatic Transmission Fluid] level be checked with the engine running and the transmission hot The ATF level is best checked after the vehicle has been driven for about 5 miles Many FWD cars have thermostatic valves that have thermostatic valves the alter the fluid levels in different sections of the transaxle as temperature changes

125 Auto trans fluid level, color and smell
The fluid level should be at the full / hot mark after 5 miles of driving The fluid color should be pink and should not have any bubbles or foam Fluid that is black and smells burnt is cause for concern and should be noted on the report

126 Radiator hose condition
The radiator hoses should be examined for cracking and swelling Radiator hoses deteriorate from the inside out A bad hose can often be detected by squeezing the end of the hose near the radiator A bad hose is soft and squishy compared to a new hose

127 Heater hoses The heater hoses should be visually inspected for cracks and loose or damaged hose clamps

128 Accessory drive belts On manually tensioned belts you should not be able to twist the belt with your fingers more than 90 degrees

129 Accessory drive belts Drive belts should be checked for condition and tension [manually tensioned belts] The lower radiator hose will not collapse when squeezed because it has an internal spring

130 Battery terminals and hold down
Visually inspect the battery terminals for corrosion Check to see if terminals are tight by twisting them with your fingers Make sure the battery hold down holds the battery firmly on the battery tray

131 Complete the report Anything that you find that is out of the ordinary should be written on the inspection report If necessary use the back side of the report for additional comments


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