FPA-460/3-75-009-b
August 1975
ACTUAL AND RECOMMENDED
MAINTENANCE PRACTICES
FOR LIGHT-DUTY VEHICLES
FOR 1975 AND LATER
MODEL YEARS
VOLUME II
D.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Air and Waste Management
Office of Mobile Source Air Pollution Control
Certification and Surveillance Division
Ann Arbor, Michigan 48105
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EPA-460/3-75-009-B
ACTUAL AND RECOMMENDED
MAINTENANCE PRACTICES
FOR LIGHT-DUTY VEHICLES
FOR 1975 AND LATER
MODEL YEARS
VOLUME II
by
Charles W. Sims
Bendix Launch Support Division
Cocoa Beach, Florida 32931
Contract No. 68-03-0453
Project No. WA73-R513
EPA Project Officer: Leonard D. Verrelli
Prepared for
U. S. ENVIRONMENTAL PROTECTION AGENCY
Office of Air and Waste Management
Office of Mobile Source Air Pollution Control
Certification and Surveillance Division
Ann Arbor , Michigan 48105
August 1975
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This report is issued by the Environmental Protection Agency to report
technical data of interest to a limited number of readers. Copies are
available free of charge to Federal employees, current contractors and
grantees, and nonprofit organizations - as supplies permit - from the
Air Pollution Technical Information Center, Environmental Protection
Agency, Research Triangle Park, North Carolina 27711; or, for a
fee, from the National Technical Information Service, 5285 Port Royal
Road, Springfield, Virginia 22161.
This report was furnished to the Environmental Protection Agency by
Bendix Launch Support Division, Cocoa Beach, Florida 32931, in fulfillment
of Contract No. 68-03-0453. The contents of this report are repro-
duced herein as received from Bendix Launch Support Division. The
opinions, findings, and conclusions expressed are those of the author
and not necessarily those of the Environmental Protection Agency.
Mention of company or product names is not to be considered as an
endorsement by the Environmental Protection Agency.
Publication No. EPA-460/3-75-009-b
11
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PREFACE
The purpose of this report is to present findings, conclusions, and substan-
tiating data gathered by the Bendix Corporation, Launch Support Division,
during a 1-year contract performance period, 9 May 1974 through 9 May 1975,
on the actual and recommended maintenance practices for light-duty vehicles
for 1975 and later-model years.
The report consists of two volumes. Volume I contains ten chapters which
encompass the Introduction, Summary, Conclusions, the discussion of the
performance of six of the seven tasks enumerated in the Introduction, and
finally, Survey Findings. It also contains two appendixes, an automotive
diagnostic equipment index, and the individual tally sheets on which the
results of the consumer, commercial, and dealer surveys have b.een consolij-
dated. j
Volume II contains the seventh task listed in the Introduction, the review
and analysis of the 1974 Durability Test scheduled service records.
This study was performed for the l>. S. Environmental Protection Agency (EPA),
Office of Air and Water Programs, Office of Mobile Source Pollution Control ,
Certification and Surveillance Division. The Technical Project Officer was
Mr. L. D. Verrelli. The report will provide EPA with valid, current infor-
mation on consumer and commercial automotive activities.
m
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TABLE OF CONTENTS
VOLUME I
Title Page
Disclaimer Page
Preface
Table of Contents iv
List of Figures vii
List of Tables vii
Chapter
I Introduction 1
A. Background 1
B. Scope 2
C. Contract Organization 3
II Summary 9
III Conclusions 11
/
IV Perform a Field Survey of Actual and Recommended
Maintenance Practices for Light-Duty Vehicles for
1975 and Later-Model Years (Task 1) 13
A. Introduction 13
B. Field Survey Preparation 16
C. Consumer Field Survey 17
D. Commercial Field Survey 17
E. Summary 18
V Determine the Type of Diagnostic Equipment Expected to
Be Procured for 1975 Vehicles and Later-Model years
(Task 2) 23
A. Introduction 23
B. New-Car Dealers 23
C. Franchised Diagnostic Centers 23
D. Mass Merchandisers 24
E. Independents 24
F. Summary 24
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TABLE OF CONTENTS
(continued)
VI Determine the Current Availability of Automotive
Diagnostic Equipment and Project Future Availability
(Task 3) . 25
A. introduction 25
B. Automobile and Diagnostic Equipment Manufacturers 25
C. Summary 27
VII Determine the Type of Automotive Maintenance and
Diagnostic Evaluations Presently Being Performed and
Whether Maintenance Practices Are Expected to Change
for the 1975 and Later-Model Vehicles (Task 4) 29
A. Introduction 29
B. Vehicle Manufacturers 29
C. Maintenance Service Centers 29
D. Summary 32
VIII Determine Consumers' Automotive Habits and Practices
Relative to Vehicle Make, Age, and Original Cost
(Task 5) 33
A. Introduction 33
B. Consumer Survey 34
C. Summary , 35
IX Determine the Competence Level That Will Be Required
of Mechanics to Maintain the 1975 and Later Model
Automobiles (Task 6) 45
A. Introduction 45
B. General Background . 45
C. Current Mechanic Competency Review 45
D. Future Mechanic Competency Level 48
E. Summary 50
X Survey Findings 51
A. Introduction . 51
B. Tally Sheets 51
C. Summary 55
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TABLE OF CONTENTS
(continued)
Appendix .
A Automotive Diagnostic Equipment Index, March 1975 57
A. Automotive Engine Analyzers 59
B. Engine and Chassis Dynamometers 73
C. Exhaust Emission Analyzers 79
D. Individual Engine Diagnostic and Analytical Components 83 i
B Tally Sheets : 87 '
Consumer Consolidated Tally Sheets 88
Commercial Consolidated Tally Sheets 108
Dealer Consolidated Tally Sheets 148
VOLUME II
Chapter
XI Develop a Method to Review and Analyze the 1974 Environ-
mental Protection Agency Durability Test Maintenance
Records (Task 7) 1
A. Introduction 1
B. Development of the Method 1
C. Summary 1
D. Conclusions 1
E. 1974 Durability Test Comparison Chart Index 2
vr
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LIST OF FIGURES
Page
14
Management/Mechanic Ratio and Percentages Prevalent in the
Service Industry 31
LIST OF TABLES
Table
1 Consumer Maintenance Habits - Selection of Maintenance
Methods Compared With Local Vehicle Inspection Regulations 36
2A.2B Consumer Maintenance Habits by Vehicle Year Model 37,38
3A.3B Consumer Maintenance Habits by Vehicle Size 39,40
4 Consumer Maintenance Habits by Vehicle Manufacturer/Group 41
5 Consumer Maintenance Habits by Geographical Location,
Services Accomplished By 42
6 Consumer Maintenance Habits by Geographical Location,
Service Performed By 43
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CHAPTER XI
DEVELOP A METHOD TO REVIEW AND ANALYZE
THE 1974 ENVIRONMENTAL PROTECTION AGENCY
DURABILITY TEST MAINTENANCE RECORDS (TASK 7)
A. INTRODUCTION
In 1974, the EPA conducted a durability test on all vehicles manufac-
tured and/or sold in the United States. The task attempted in this
chapter is to review, to show the variances, records of scheduled main-
tenance operations recommended by automobile manufacturers, owners'
handbook recommendations, and the scheduled maintenance actually per-
formed during the 1974 durability tests.
B. DEVELOPMENT OF THE METHOD
It was determined that a practical way to properly evaluate the manu-
facturers' maintenance programs was to perform an individual analysis
of the manufacturers' historical records for every engine family sub-
jected to the durability test.
An interim worksheet was developed and completed for each engine within
each engine family of each manufacturer. The information was recorded
according to the actual mileage intervals at which scheduled maintenance
was performed.
The basic information from each interim worksheet was totalled, collated,
and transferred to individual corresponding charts (Durability Test
Comparison Charts). These charts are shown at the end of this chapter.
Each chart is identified by manufacturer, model, engine CID, and identi-
fication number, and contains at the bottom of the chart the 47 most
common maintenance functions found in the owners' handbooks for the auto-
mobiles and engine families listed. Under each maintenance function are
listed the following: Durability test (the recommended durability main-
tenance schedule), Owner's Handbook (owner's manual), and Actual (the
scheduled maintenance actually performed during the 1974 Durability Test.
The numbers at the left of the chart (1 through 9, or 2 through 18) rep-
resent the actual number of times the particular maintenance function
was performed during a 50,000-mile period.
C. SUMMARY
The durability records obtained from the EPA consisted of 72 engine
families encompassing 162 vehicles from 32 vehicle manufacturers. Data
accumulated from the durability records is displayed in the Durability
Test Comparison Charts which are shown at the end of this chapter.
D. CONCLUSIONS
The differences in the vehicle manufacturers' durability test reporting
did not provide adequate or significantly consistent variances to allow
values to be assigned to highlight a condition. As a result, each chart
must be reviewed independently. To illustrate this point, one of the
most frequent and basic maintenance requirements (oil change) was reviewed;
it provided the following results: 25 percent of the vehicle manufacturers
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accomplished oil changes as recommended in the handbook; 45 percent failed
to accomplish the changes; 5 percent changed the oil more frequently than
recommended; and 25 percent could not be determined because of insufficient
data.
Durability test records that were provided indicate that not one manufac-
turer accomplished all the maintenance operations as recommended in the
vehicle owner's handbook.
E. 1974 DURABILITY TEST COMPARISON CHART INDEX
Manufacturer
American Motors
Engine Family
3.802 L (232 CID)
Vehicle Number Page
A2A057E139615 8
A2A057E139632 12
A3A057E299694 16
A4A087A112223 20
American Motors 4.228 L (258 CID)
A2A157A147538 24
A2A157A147568 28
A2A157A147606 32
American Motors 4.982 L (304 CID) A2A157H147543 36
A3A797H208016 40
American Motors 5.899 L (360 CID)
A3A057N205723 44
A3A157P204937 48
A3A157P206276 52
A3A857212931 56
J3A252WP56385 60
American Motors 6.571 L (401 CID) A3A1572300187 64
Audi
Audi
1.472 L (89.8 CID)
1.876 L (114.5 CID)
8432069877
8432118297
8432118298
8432121945
8131086149
8131102812
8131126712
8531103558
68
72
76
80
84
88
92
96
-------
Manufacturer
BMW
Engine Family
Vehicle Number Page
1.988 L (121.3 CID) 2508016 100
2588094 104
2760013 108
2760065 112
2763360 116
BMW
Buick
Buick
Cadillac
Chevrolet
Chevrolet
Chevrolet
Chrysler
Datsun
2.982 L (182.0 CID)
5.735 L (350 CID)
7.456 L (455 CID)
7.735 L (472 CID)
2.294 L (140 CID)
4.097 L (250 CID)
5.735 L (350 CID)
4.179 L (225 CID)
5.211 L (318 CID)
5.899 L (360 CID)
6.555 L (400 CID)
7.21 L (440 CID)
1,29 L (78.7 CID)
2763377
2763732
2764445
3101188
313001
4102
4114
420
4202
5114
5124
1102
1122
1142
1201
1402
1412
1414
1422
1432
VL29C3B1 30211
WH23G2A124512
VS29H3B2 18486
DP43M3D1 22640
CH43T2C1 40106
A345
F901
120
124
128
132
136
140
144
148
152
156
160
164
168
172
176
180
184
188
192
196
200
204
208
212
216
220
224
3
-------
Manufacturer
Engine Family
Vehicle Number Page
Datsun
1.952 L (119.1 CID) B961
B964
228
232
Dodge
1.598 L (97.5 CID)
A535107180
A535109395
236
240
Dodge
1.995 L (121.75 CID) A115AF000011 244
A115AF000012 248
Dodge
Ferrari
Fiat
7.21 L (440 CID)
DP43T3D122639 252
2.418 L (147.55 CID) 01020
1.29 L (78.70 CID) 1226075
1226493
256
260
264
Fiat
1.592 L (97.17 CID) 1270012
1273904
268
272
Ford
Ford
2.0 L (122 CID)
2.3 L (140 CID)
31P21-2.0-8
31P31-2.3-1
4P1-2.3-10G
276
280
284
Ford
2.8 L (171 CID)
31P37-2.8-2
4Z1-2.8-51H
288
292
Ford
Ford
3.277 L (200 CID) 31Q12-200-7
296
3.933 L (240 CID) 21F04-1-240-1 300
21F04-1-240-3 304
Ford
4.097 L (250 CID)
4Q1-250-4-41F 308
4Q1-250-54E 312
Ford
4.916 L (300 CID) 31F02-300-1
316
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Manufacturer
Ford
Ford
Ford
Ford
Ford
Jensen
Lotus
Luv
Maserati
Engine Family
4.949 L (302 CID)
5.752 L (351 CID)
5.90/6.39 L
(360/390 CID)
6.555 L (400 CID)
7.538 L (460 CID)
1.975 L (120.5 CID)
1.557 L (95.0 CID)
1.816 L (110.8 CID)
4.932 L (301 CID)
Vehicle Number
23030-302-1
23031-302-3
4E1-302-20D
24A53-351W-1
28A57-351W-2
3073-351CJ-3
34A56-351C-16
4A1-351C-12F
4A1-351C-21F
4A1-351C-22F
37F76-360-20
4A1-400-10D
3M51-460-1
32M79-460-11
DVF111K
EXE751J
2735R
2588R
369244
7008220661 R
CLN 1428200026
CLN 1428200028
176
348
810
Pagi
320
324
328
332
336
340
344
348
352
356
360
364
368
372
376
380
384
388
392
396
400
404
408
412
416
Mazda
1.147 L (70 CID) S124W127735 420
S124W127737 424
Mazda
1.311 L'(80 CID) LA22S110003 428
LA23S100002 432
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Manufacturer
Mazda
Mazda
Mercedes-Benz
Oldsmobile
Oldsmobile
Opel
Pontiac
Pontiac
Porsche
Renault
Renault
Engine Family
1.586 L (96.8 CID)
1.796 L (109.6 CID)
4.523 L (276 CID)
5.735 L (350 CID)
7.456 L (455 CID)
1.898 L (115.8 CID)
5.735 L (350 CID)
6.555 L (400 CID)
7.456 L (455 CID)
2.686 L (163.9 CID)
1.565 L (95.5 CID)
1.647 L (100.5 CID)
Vehicle Number
SN3A101769
SN3A109483
SGTAME39827
SGTAME39917
A- 30
A-31
A-43
310
3102
320
3222
3232
6102
2104
210
220
2214
119.110.001
911.030.0738
911.410.0013
911.411.0015
911.430.0014
911.431.0012
9800038
9800040
616
801
8308713
960052
Pagi
436
440
444
448
452
456
460
464
468
472
476
480
484
488
492
496
500
504
508
512
516
520
524
528
532
536
540
544
548
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Manufacturer
Engine Family Vehicle Number Page
Rolls Royce
Saab
Toyota
Toyota
Toyota
Toyota
Toyota
Volkswagen
Volkswagen
Volkswagen
Volvo
Volvo
6.751 L (412 CID)
Not available
1.167 L (71.2 CID)
1.588 L (96.9 CID)
1.966 L (120 CID)
2.563 L (156.4 CID)
3.879 L (236.7 CID)
1.584 L (96.66 CID)
1.793 L (109.4 CID)
1.794 L (109.5 CID)
1.983 L (121 CID)
2.982 L (182 CID)
SRA12315
Not available
KE20249212
TE21051796
TE21633368
RT85010803
RT85010877
MX 120000 11
MX 130000 10
FJ401158
FJ401 34707
1332183418
1332219635
2232185939
2232186717
2232018131
2232019298
4732909270
164878
167140
168709
174330
12239
60226
62350
79686
552
556
560
564
568
572
576
580
584
588
592
596
600
604
608
612
616
620
624
628
632
636
640
644
648
652
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BIBLIOGRAPHIC DATA
SHEET '
1. Report
EPA-460/3-75-009B
3. Recipient's Accession No.
4. Title and Subtitle
Actual and Recommended Maintenance Practices for Light-Duty
Vehicles for 1975 and Later-Model Years
5. Report Date
6.
7. Author(s)
Charles W. Sims
8. Performing Organization Kept.
No.
9. Performing Organization Name and Address
The Bendix Corporation, Launch Support Division
.-.'*
10. Project/Task/Work Unit No.
11. Contract/Grant No.
12. Sponsoring Organization Name and Addres*
U. S. Environmental Protection Agency
Office of Air and Water Programs, Office of Mobile Source
Pollution Control, Certification and Surveillance Division
Ann Arbor, Michigan 48105
13. Type of Report & Period
Covered Final Report
July 1974 to July 1975
14.
15. Supplementary Notes
16. Abstracts '/\ survey was made to determine the actual and recommended maintenance prac-
tices for light-duty vehicles for 1975 and later-model years. Data was gained through
consumers, new-car dealerships, manufacturers, service stations, diagnostic centers,
specialty shops, independent service stations, and mass merchandisers, literature re-
search, and data evaluation. The following conclusions were reached. Automotive ser-
vice requirements are becoming more complex. Diagnostic centers are diversifying into
diagnostic, service, and repair facilities. Automobile dealerships employ the highest
percentage of classified or rated mechanics and are more fully equipped than other
classifications. Current and future requirements can be met by the diagnostic equip-
ment industry. The majority of automobile owners are unwilling to voluntarily replace
a malfunctioning catalytic converter
17. Key Words and Document Analysis. 17o. Descriptors
17b. Identifiers/Open-Ended Terms
17c. COSATI Field/Group
18. Availability Statement
Unlimited
19.. Security Class (This
Report)
UNCLASSIFIED
20. Security Class (This
Page
UNCLASSIFIED __
21. No. of Pages
22. Price
FORM NTI5-33 (REV. 10-73)
ENDORSED BY ANSI AND UNESCO. ggg THIS FORM MAY BE REPRODUCED
USCOMM-OC 82S5-P74
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