CHAPTER Measuring and checking LEARNING OBJECTIVES On completing this chapter, you will be able to: Seo Cee eC u cco Pe ee ene cae ane Some of the components in a vehicle need to be measured and checked to ensure that they are still serviceable. Measuring and checking are important procedures that must be performed accurately, and at regular intervals, according to the specifications set down in the workshop manual. This ensures the safe and continued operation of the vehicle. The specifications provide Information about the type, size, capacity and dimensions of each component, and specify the clearance or setting of an adjustment. Wear limits, that indicate when a component must be replaced, are also provided in the workshop manual. Measuring instruments ‘The complexity of systems in the automotive industry results in the use of a wide range of measuring instruments. Some are relatively simple and, when used correctly, provide accurate measurements and results. However, in situations where accuracy is critical, precision instruments are used. These require a greater level of understanding of their use. The following describes a range of common measuring tools. Steel rule This is the basic measuring instrument. It is used for general measurements where great accuracy is not required, Stee rules are usually 150mm or 300 mm long, and are graduated in millimetres and half-millimetres. ‘When turned on its edge, a steel rule can be used as a straightedge to check the flatness of a surface. Feeler gauges Feeler gauges are strips or blades of hardened ste! that are fabricated to an accurate thickness. They are used to ‘measure small clearances such as bearing clearances, valve clearances (Figure 5.1), piston ring and spark plug ‘maps. With the correct clearance, the feeler gauge should slide between the two parts with a slight resistance. For ease of selection, feeler gauge blades are grouped together in order of size. The thickness of each blade is marked in millimetres, although some feeler gauges also include imperial measuring units. The blades can be used individually, but for larger measurements two or more can be used together. pe tana hit: To ensure that feeler gauges do not rust, they should be wiped clean with a rust preventative before storing.68 Parr Introduction to motor vehicles When used with a steel rule as a straightedge, feeler gauges can be used to check that a component, such as a cylinder head is not warped or that an oil pump gear has the correct end clearance (see Figure 5.14) Micrometers are precision-measuring instruments that are designed to take extremely accurate measurements. (Gown to one-hundredth of a millimetre, or 0.01 mm). There are a number of different types of micrometers, The selection of the appropriate one will depend on the component being measured. The automotive service and repair industry generally uses the outside micrometer (for external measurements) and the inside micrometer (for internal measurements). ‘Where more specialised measurements are required, a ut range of specialised micrometers can be used. Figure 5.1 Checking valve clearance with a feeler ‘gauge suUTTERSTOCK Handy hint: Micrometers are precision instruments. They must be treated properly to maintain their accuracy and to prevent them from being damaged. \ \ Outside micrometers 4A umee Figure 5.2 shows the construction of an outside micrometer. Itis a sctew-type instrument consisting fame of a frame with an anvil and a threaded sleeve which carries the spindle. Turning the knurled part of the thimble screws the spindle towards or away from Figure 5.2 Parts of an outsice micrometer the anvil. ‘The correct use of an outside micrometer requires a number of steps: (Check for zero error (see ‘Accuracy and care of micrometers), ‘Support the component to be measured Hold the micrometer by the heat-resistant pad located on the frame, Ensure that the micrometer Is held squarely against the component. Using the knurled cap on the end of the thimble, rotate the thimble In the desired direction. ‘When the spindle isin close contact with the component being measured, stop turning the thimble. ‘urn the ratchet untl the spindle and anvil ae lightly In contact with the object being measured. Read the measurement from the scales marked on the sleeve and the thimble (see ‘Reading micrometers) @Vounwnas Sizes of outside micrometers Outside micrometers are available in a variety of sizes. Three examples are shown in Figure 5.3. They are identified by their range of measurement, For example, Figure 5.3(a) is a standard 0-25 mm micrometer, Figure 5.3(b) is a 25-50 mm micrometer and is shown with the C spanner and setting bar that are required to check the device for accuracy. Figure 5.3(c) is an adjustable micrometer. It has four replaceable anvils, enabling it to measure a wide range of dimensions. Whenever the anvils are changed, the micrometer must be calibrated using setting bars for accuracy. fy Handy hint: Setting bars are gauges that have been made to an accurate length. Electronic digital micrometers Most measurement instruments are available with electronic LED displays similar to the one in Figure 5.4. More accurate than standard micrometers, they can be calibrated to read metric or imperial dimensions,Casowex 5 Measuring and checking 69 =—— (0) (o) —— —- i cc) Figure 5.3 Three sizes of micrometers (a) 0-25 mm (b) 25-50 min (¢) 25~100 mm usr TOO.S ‘Measurements are taken using the same method as for the outside micrometer. The micrometer is set to zero by a simple press of a button each time it is used. LY Grouse racy and care of mi An outside micrometer must be checked for accuracy — before use by testing for zero error. If the micrometer Figure 5.4 Electronic cigtal micrometer with LED dlsploy is not calibrated to zero prior to use, it will nt provide "ete or Imperial graduations swoon an accurate measurement. The most common method of doing this is: 4 Hold the micrometer by the heat~esistant pad on the frame. 2 Clean the anvil and spindle surfaces with # soft cloth. 3 Using the knurled cap on the end of the thimble, rotate the thimble so the spindle moves towards the anvil If calibrating a micrometer with a range of 25 mm and above, place the setting bar in between the anvil and spindle at this point When the spindle is in close contact with the component being measured, stop tuning the thimble. Turn the ratchet until the spindle and anvil are lightly in contact. With the anvil and spindle closed, the 0 reading on the sleeve should align with the reading on the thimble. Ifthe 0 readings do not align between the spindle and thimble, use the adjusting spanner to rotate the sleeve so that the 0 on the datum line aligns with the O on the thimble. Noon Micrometers should be handled carefully and stored correctly to preserve their aecuracy. They should be kept clean and not be overtightened or strained. Handy hint: Outside micrometers should always be left with a gap between the spindle and the anvit when not in use.70 Pauw Introduction to motor vehicles Proper care of a micrometer ensure accurate measurements, This includes the following: 1 Clean the micrometer before and after use. 2 Donot touch the measuring surfaces. 3 Store the micrometer properly. 4 Never use a micrometer as a clamp or tighten the measuring surfaces too tightly around the object. being measured 5 Donet drop the tool. 6 Always check the calibration before use. Handy hint: If a micrometer (or any type of measuring equipment) is found to be faulty, it should be removed from service immediately and tagged for repair. A micrometer has two scales that provide the measurement: one on the sleeve and the other on the thimble. ‘The sleeve of an outside micrometer has the main scale marked on the datum line. (The datum line is the horizontal base line.) The thimble has the secondary scale marked around its edge. As it is rotated, the main scale line moves, proving the reading Metric micrometer With a metric micrometer (Figure 5.5), the main scale on the sleeve has a datum line running through its middle which shows both 1 mm and 0.5 mm divisions. The millimetre divisions are above the datum line ‘and each fifth division is identified by the respective number. The half-millimetre divisions are below the datum line and are not numbered. ‘The scale marked around the thimble has fifty divisions, each representing 0,01 mm. Therefore, one full {urn of the thimble represents 0.50 mm. (One full turn of the thimble moves the datum line 0.50 mm along the main scale; two full turns move it 1 mm. Reading a metric micrometer The main scale is read to the edge of the thimble and the thimble reading is added. The procedure is as follows: : ‘whole 1 From the sleeve, read the number of whole- rritimetres milimetze divisions which are visible on the main scale above the datum line. 2 Add to this @ half-milimetre division if one is tie Visible on the main scale below the datum line. 3 From the thimble, note the division that coincides. with the datum line and add this to the previous readings. a wi thie Example star, ehisions rnnimerres FS ey For the micrometer shown in Figure 5.5, the —— readings taken in order are: Figure 5.5 The divisions ofa standard metre micrometer 9 whole milimetres = 200 mm [—aemmine ‘thalf-milimetre = 0.50 mm 48 thimble divisions of 0.01 = 0.48 mm 8 mm Example 2 ‘The scales of the micrometer in Figure 5.6 show the readings of: main-scale 1.00 mm divisions: 10.00 mm main-scole 0.50 mm division: 0.50 mm thimble cvisions: 016 mm O16 men Figure 5.6 Metric micrometer scales~the readin 10.56 mm sche les-the eacing mim, shown is 10.66 mmVernier calipers Vernier calipers are precision instruments that provide readings in steps of 0.05 mm of, in some instruments, 0.02 mm. The measuring scale on a vernier caliper consists of a graduated bar with both a fixed and a sliding jaw. The frame includes the main scale and the outside sliding jaw includes the vernier scale. The parts of a vernier caliper are shown in Figure 5.7. The object to be measured is placed between the two jaws, and the sliding jaw carefully adjusted until both jaws are in contact with the object (Figure 5.8). The measurement can then be read directly from the scales of the instrument, Both external and internal measurements can be taken. For internal measuring, the ends of the jaws are shaped to suit. Some calipers have scales for both external and internal measurements. ‘The sliding jaw has @ small rod which extends or retracts from the end of the frame, and this can be used to measure the depth or height of a component, Reading the scales Figure 5.9 shows the main scale that reads in whole millimetres and the vernier scale that reads in increments of 0.02 mm ‘To read the measurement shown on the vernier caliper in Figure 5.9, the following steps can be appli 1 Look at the main scale, 2 Identify the increment number that the 0 on the vernier scale has elther stopped on or gone past. In this example, the 0 on the vernier scale is between 13 and 14 mm. So the reading is ‘above 13 mm but under 14 mm, 3 Identity the vernier scale reading which will provide a reading to the nearest 0.02 of a millimetre (0.20 mm). On this vernier scale, the divisions are numbered 1 through 0 10 and each division has ¢ value of 0.02 mm. 4 Determine the value on the vernier scale by Identifying a vernier graduation that lines up precisely with one of the graduations on the main scale, Curren 5 Measuring and checking 71 Inside jaS main scale frame vernier scale sliding Jaw ‘outside jaws Figure 5.7 Parts ofa vernier caliper smow A EusSTER Figure 5.8 Using vernier calipers to measure the length fof a valve spring A. main scale Tn (AL ce B. vernier scale Figure 5.9 Seale of vernier A ~ main scale, each division is 1 mm; B — vemier scale, each division Is 0.02 mm; the teading shown is 13.40 mm 5 In this example, the vernier scale is exactly lined up with the 4, which determines that it is 0.40 mm, 6 Add the 13 mm and 0.40 mm to provide a measurement totalling 13.40 mm. 7 Therefore, the measurement shown in Figure 5:9 is 13.40 mm, If the depth gauge function on the vernier caliper is being used, the same steps apply to obtain the ‘measurement reading72 Past Introduction to motor vehicles Example For Figure 5.9, this is: main-scale divisions: 13.00 mm vernier divisions: 0.40 mm 13.40 mm Care of vernier calipers Vernier calipers are an casy measuring device to maintain. After use, wipe the vernier caliper with a soft cloth to remove any contaminated residue. Lubricate the sliding frame to ensure that the vernier scale slides smoothly. Ensure that the locking screw on the vernier is secure and store the vernier caliper away from moisture, Most vernier calipers are supplied in a protective case, and this is an ideal storage method. Adial gauge and its use A dial gauge is a versatile device that can be used for checking a range of automotive systems and components. It has a face, or dial (Figure 5.10(a), plunger and pointer. As the plunger is moved up or down, both the main and secondary dials in the face of the gauge move. displaying how far the plunger has bezel clamp large pointer bezel or ring plunger (0) Figure 5.10 Dial gauges (a) analog (b) digltal ust rootsCCuapren 5 Measuring and checking 73 travelled. Digital dial gauges offer the benefit of a very simple zero function and can also read in both metric and imperial units. Gear backlash, end play in shafts, cylinder block deck clearances and runout of a rotating part can all be measured using a dial gauge. Figure 5.11 shows ‘one being used to check flywheel runout. With the dial gauge mounted by a magnetic base, the gauge is set to zero, the flywheel rotated and the changes in ‘gauge readings are noted. Accylinder-bore gauge isa special arrangement of dial gauge that enables readings of the cylinder bore tobe taken (Figure 5.12). The gauge is used to check both ovality and taper within the bore to determine, the amount of eylinder wear. The cylinder bore dial Figure 5-*4 Atel gauge being used to check Mywneel gauge has a long extension, and movement of the plunger at the lower end of the gauge is transferred up through the extension to the dial gauge at the top. Plungers of different lengths can be fitted to suit different-sized cylinder bores. Chr Ore Reading the scales ‘The dial is marked with divisions of 0.01 mm, and a pointer, operated by a plunger, is moved around it to indicate the reading, A smaller pointer on the face of the dial gauge counts the number of full rotations of the large pointer in 1 mm divisions. ‘The instrument is clamped or supported so that the plunger can be set against the part being checked. The bezel (ring) on the edge of the dial is then tured to set it to zero (that is, the “0” on the dial is set in line with the pointer, ‘A dial gauge shows variations in movement from the zero setting. These variations are transferred Figure 8.12 Using a cial gauge to check eyinder bore from the plunger to the pointer or display. for wear ter will show a plus reading on one side of zero and a minus reading on Handy hint: The p« the other ‘To set up and read a dial gauge, follow these steps: 1 Mouint the dial gauge on the magnetic base, tool post end holding frame, Accuracy will depend on the stability with which the dial gauge is mounted. 2 Position the indicator so that the plunger is parallel to the direction of the component being measured. 3 Make adjustments to the magnetic base, post and arm so that the plunger and stem will detect any motion in the component. 4 The plunger of the dial indicator can determine movement in both directions. Move the dial gauge towards the component being measured so that it provides e reading midway within the measurement scale on the dia. 5 Calibrate the device to zero. This is done by rotating the ring on the edge of the lal face so that the ‘0" on the dial is set inline with the large pointer. 6 Move the component being measured and record the reading on the dial. Depending on the movement in the component, the dial gauge will record measurements in either a positive or negative direction. Care of dial gauges Dial gauges are precision instruments and it is important to maintain them correctly, After using the device, wipe it with a soft cloth to remove any contaminated residue. Lubricate the plunger to ensure that it slides smoothly. Store the dial gauge away from moisture, preferably in a protective case.74 Paer Introduction to motor vehicles ‘There are oceasions—such as carrying out a modification or fabricating a component—that require marking of measuring. The following are some commonly used tools. Rules and tapes Steel rules are usually 150 mm or 300 mm long, and are graduated in millimetres and half-millimetres. ‘They are used for all normal workshop measurements. For longer measurements, such as obtaining the track or wheelbase of a vehicle, a steel tape is used. Its flexibility means it can measure curved surfaces or larger round objects. Steel try square A steel try square checks right angles. A try square has a stock with a blade at 90°. Its used when a line is to be scribed at right angles to the edge of the work. It is also used for checking internal and external right angles. ‘To check an external angle, the inside of the stock of the try square is held firmly against one finished surface, with the blade slightly clear of the work. The work is held up to the light, and the blade of the square brought slowly down to contact the surface being checked. An internal angle is checked in a similar ‘manner with the outside of the square. Handy hint: the square, If the two surfaces being checked are square, no light will show under the blade of Combination set A combination set (Figure 5.13) has three separate heads, each of which can be fitted to a graduated steel blade to form a combination square, a centre square or a protractor. 1, Combination square. The square head, when fitted to the blade, can be used to mark out or check angles ‘of 90° and 45°. The head can be moved along the blade and so used as @ depth gauge, with the measured depth shown directly on the blade. 2 Centre squore. This head is V-shaped and, when fitted to the blade, the ‘V'Is bisected by the edge of the blade. To locate the centre of @ round bar or disc: (a) place the blade flat on the end of the bar with the V-head in contact withthe bar (0) scribe a ine along the edge of the blade (this is. the diameter of the circular end) A second line scribed approximately at right angles will intersect the fist line at the centre of the circle, 3 Protractot. The protractor head has a scale ‘graduated in degrees so that the blade can be set at any angle to it. Angles can be marked out or checked by using the protractor ina similar manner to a try square. Straightedge == A straightedge is used for checking the flatness ofa (@ surface. For a small surface, a steel rule or the blade of atry square may be used. The clearance between the steel rule and the component is checked to see if. light an be seen under the ste! cult For larger surfaces, along stel staightedge is used. This is placed on its edge and a feeler gauge used to measure any irregularities between the - mpebinoton oar the Sraighedge and the surface. Surfaces such asthe T@WE 1S Combinations. The upper teaon face of a cylinder head are checked along their (square (c} centre square (d) steel blade. The lower length and also diagonally in this way (Figure 5.14). illustration shows the squares fitted to the blade SNAP-ONCuarren S Measuring and checking 75. Figure 5.14 Using straightedge and feeler gauges to _—_—Figure 5.15 Digital thermometer used to check exhaust check the flatness of a cylinder head manifold temperature re 5.16 Pressure gauge connected to check the Figure 5.17 Performance testing an air-conditioning engine oll pressure srurrerstock system using a vacuum gauge SHUTIERSTOCK ‘Temperature measurement Many systems and components rely on a change in temperature for their correct operation. An air- conditioning system, for example, reduces cabin temperature during operation and a shock absorber increases temperature. Degrees Celsius (°C) is the temperature scale used in the metric system. “Many other systems and components can have their operation checked using a thermometer (Figure 5.15). These include: + cooling system thermostats + Intercoolersfheat exchangers + tyres and whee! alignment + transmission ol Pressure measurement Pressure applied in vehicle systems is measured in two forms. 1 Pressures above atmospheric pressure such as oll pressure in Figure 516 are measured in positive kilo pascals (+KPa). (For positive pressures, the ‘+ symbol is not normally used) 2 Pressures below atmospheric pressure such as in al-conditioning systems in (Figure 517) are measured in negative kilo pascals (~kPa) or mm of Hg (mercury) ofp Vane Hit: Negrive pressures are normaly called wocuum76 Paar 1 Introduction to motor vehicles ‘The pascal (Pa) is the basic unit of pressure measurement in the metric system. It is the force of [newton (N) applied to an area of | metre squared (m’). Therefore 1 Pa = 1 Nm? In practice, this a very small unit of measurement and the unit pascals x 1000 (or kPa) is used. ‘Atmospheric pressure Atmospheric pressure varies with altitude and temperature. Air pressure decreases above sea level and increases below sea level. Cooler air is denser than hot air and would have a higher air pressure. SUMMARY "Now that you have completed this chapter you can transfer your knowledge into practical tuations within an ‘automotive service and repair context. You will be able to: select the correct measuring device for the required task demonstrate the correct use of the measuring cevice demonstrate the correct way to read a range of measuring devices + identify basic maintenance requirements for measuring equipment demonstrate the correct way to store measuring equipment. REVIEW QUESTIONS @voununs 10 " 12 1B “ \Whatis a feeler gouge and what might it be used to measure? For what purposes would a vemier caliper be used? What would it mean fa micrometer had a zero error? \Whatis the name of the section on the micrometer which shows 1.0 mm and 0.5 mm divisions? Provide three examples of the components that can be measured using an outside micrometer. Explain how to correctly calibrate an electronic micrometer. Provide three examples of items that can be measured using a dial gauge. For what purposes are dial gauges usec? Whetis the purpose of the small pointer on a dial gauge? Which measuring instrument has 8 stec! rod that can be used as a depth gauge? For what purposes would a try square be used within the automotive repair industry? Explain the use of a straight edge. What other measuring instrument can be used to assist wth checking ‘manufacturer specifications? How would a surface be checked for flatness? What are vee blocks?