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RESTRICTED JA102 Automotive Workshop Practice 1

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Version: 080510_1.1_Effective:1 December 2011 RESTRICTED

POLYTECHNICS MINISTRY OF HIGHER EDUCATION MALAYSIA DEPARTMENT OF MECHANICAL ENGINEERING

COURSE : JA102 AUTOMOTIVE WORKSHOP PRACTICE 1

INSTRUCTIONAL DURATION : 15 WEEKS

CREDIT(S) : 2

PREREQUISITE(S) : NONE

SYNOPSIS

AUTOMOTIVE WORKSHOP PRACTICE 1 provides basic automotive related skills

which focus safety practice on health and environment, use of basic measuring tools

and equipments in mechanical and electrical system, perform minor service of petrol

engine and chassis work and exposure to basic welding and fitting processes.

COURSE LEARNING OUTCOMES ( CLO )

Upon completion of this course, students should be able to:-

1. Explain and apply safety practice on health, environment and equipment.(C2)

2. Identify and operate basic measurement tools, minor service petrol engine and

service tire and suspension system.(P1)

3. Perform fitting and welding works according to Standard Operation

Procedure.(P2)

4. Practice safety procedure correctly in the workshop according to the workshop

safety regulation.(A2)


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SUMMARY ( 00 LECTURE : 60 TUTORIAL)

RTA

1.0

SAFETY, HEALTH AND ENVIROMENT

(00 : 02)

The topic covers basic knowledge of OSHA, NIOSH, DOSH, and put personal, environment, equipments, workplace safety into practice

2.0 TOOLS AND EQUIPMENTS (00 : 02)

The topic covers the usage of basic measuring tools such as vernier caliper, micrometer, dial gauge, feeler gauge and analog and digital multimeter

3.0 ENGINE (00 : 10)

The topic covers the minor service of petrol engine, checking, draining and refilling engine oil and replacing oil filter. Perform top overhaul SOHC engine, perform ignition system check and perform cooling system service

4.0 CHASIS (00 : 10)

The topic covers tyre servicing and perform suspension system servicing

5.0 WELDING (00 : 18) The topic exposes the students to basic gas and arc welding

processes involving various types of joining metals

6.0 FITTING (00 : 18)

The topic exposes the students to fitting works involving the use of various hand tools, measuring tools, marking out, testing tools and drilling machine

RTA : Recommended Time Allocation


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SYLLABUS 1.0 SAFETY, HEALTH AND ENVIROMENT

1.1 Identify Safety, Health and Environment in workshop practice 1.1.1 State briefly on OSHA, NIOSH and DOSH

1.2 Observe Safety, Health, and Environment in workshop practice 1.2.1 Adapt personnel safety, health and welfare 1.2.2 Adapt equipment safety and maintenance 1.2.3 Adapt workplace safety, health and welfare 1.2.4 Follow emergency procedures in case of accident 1.2.5 Follow safety procedures in case of accident 1.2.6 Follow hazardous storage and disposal procedures

2.0 TOOLS AND EQUIPMENT

2.1 Identify basic automotive tools

2.1.1 Apply correct usage of basic automotive tools 2.1.1.1 Wrenches 2.1.1.2 Pliers 2.1.1.3 Hammers 2.1.1.4 Screwdrivers 2.1.1.5 Floor jack 2.1.1.6 Safety stand etc.

2.2 Operate basic measurement tools 2.2.1 Use Vernier caliper 2.2.2 Use Micrometer 2.2.3 Use Dial gauge 2.2.4 Use Bore gauge 2.2.5 Use Feeler gauge 2.2.6 Use Analog and Digital Multimeter (DMM)

3.0 ENGINE

3.1 Perform minor service of petrol engine 3.1.1 Perform engine oil level check 3.1.2 Perform engine oil draining 3.1.3 Replacing oil filter 3.1.4 Perform engine oil filling

3.2 Perform top overhaul of SOHC engine

3.2.1 Perform cylinder compression test 3.2.2 Dismantling engine external components 3.2.3 Dismantling and reassemble timing belt 3.2.4 Perform valve clearance setting 3.2.5 Perform engine tune-up

3.3 Perform ignition system check 3.3.1 Dismantle and visually inspect spark plug 3.3.2 Perform spark plug gap check


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3.3.3 Perform visual inspection on high tension cables for crack and burns

3.3.4 Execute spark trigger test

3.4 Perform cooling system service 3.4.1 Execute cooling system draining, flushing and refilling 3.4.2 Execute coolant bleeding procedures

4.0 CHASIS

4.1 Perform Tyre Servicing

4.1.1 Remove wheels from vehicle 4.1.2 Check wheel bearing 4.1.3 Remove and reinstall tyre from rim by using tyre changer 4.1.4 Check and correct tyre pressure 4.1.5 Execute on-wheel balancing and/or off-wheel balancing 4.1.6 Execute wheel rotation procedure 4.1.7 Conduct wheel alignment procedure 4.1.8 Check and adjust toe-in, toe-out, camber and caster

4.2 Perform Suspension system servicing

4.2.1 Conduct suspension system check 4.2.2 Remove and dismantle front suspension system and its

components 4.2.3 Dismantle spring from absorber 4.2.4 Reinstall or replace front suspension system components 4.2.5 Remove and dismantle rear suspension system and its

components 4.2.6 Reinstall or replace rear suspension system components

5.0 WELDING

5.1 Practice Oxy acetylene welding 5.1.1 Ignite and adjust flame for different types of welding job 5.1.2 Select proper filler rods and use it to get a neat and correct

bead flow 5.1.2 Weld an open square butt joint with full penetration throughout

the point 5.1.3 Weld open corner joint with full penetration throughout the joint 5.1.4 Keep the workshop clean and safe

5.2 Practice arc welding

5.2.1 Deposit stringer beads using correct electrode size and amperage selection for different types of recommended metal thickness

5.2.2 Weld a close square butt joint with straight, smooth and convex bead throughout the joint

5.2.3 Weld an open corner joint with straight convex bead surface 5.2.4 Keep the workshop clean and safe


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6.0 FITTING

6.1 Perform fitting works

6.1.1 Flat file , square and form surfaces using various types of files 6.1.2 Mark out parallel, vertical and different angular lines with scriber

on work piece 6.1.3 Chisel off metal using various types of chisels 6.1.4 Execute Cutting mild steel plates using a hacksaw 6.1.5 Drilling holes using bench drilling machine. 6.1.6 Execute Treading of metric internal V thread using various taps

sizes. 6.1.7 Adapt Measuring of work piece dimensions using steel rule,

external micrometer, vernier caliper and vernier height gauge. 6.1.8 Testing of finished work piece dimensions using gauges and

templates


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ASSESSMENT The course is assessed through coursework. ASSESSMENT SPECIFICATION TABLE (AST)

CONTEXT

CLO

ASSESSMENT METHODS FOR COURSEWORK (CA)

CL

O 1

CL

O 2

CL

O 3

CL

O 4

Practical Task Report

*(5) 70% *(5) 30%

Safety, Health Enviroment And Welfare

√

√

Tools And Equipment √

√ √

Engine

√

√ √

√ √

Chasis

√

√ √

√ √

Welding

√

√ √

√ √

Fitting

√

√ √

√ √

Remark: CLO1 : Explain and apply safety practice on health, environment and equipment. CLO2 : Identify and operate basic measurement tools, minor service petrol engine and service tire and suspension system. CLO3 : Perform fitting and welding works according to Standard Operation Procedure CLO4 : Practice safety procedure correctly in the workshop according to the workshop safety

regulation. *(x) refers to the quantity of assessment


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REFERENCES James D. Halderman (2000), Automotive Chasis System. 2nd Edetion, Upper Saddle

River, New Jersy

Glencoe (2004), Automotive Excellence. Part 1, The Mc Graw Hill Companies

J. Reimpel and H. Stoll (2001), The Automotive Chassis. 2nd Edition, Butterworth Heinemann

Ron Chappell (2001), Automotive Excellence. Volume 1, Glencoe and The Mc Graw

Hill Companies James G. Hughes (2000), Guide To The Automobile Certification Examination. 5th

Edition, Upper Saddle River, New Jersey Ed. May & Les Simpson :2007 Automotive Mechanics ; Volume 2 : Mc. Graw Hill,

Vocational Education and training, TAFE Collage Australia. Chapman, W.A.J, (1996). Workshop Technology Part 1. ELBS

Chapman, W.A.J, (1996). Workshop Technology Part 2. ELBS


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MATRIX OF COURSE LEARNING OUTCOMES (CLO) VS PROGRAMME LEARNING OUTCOMES (PLO)

Course Learning Outcome (CLO) Compliance to PLO Recommended

Delivery Methods

Assessment LO-1 LO-2 LO-3 LO-4 LO-5 LO-6 LO-7 LO-8 LO-9

1 Explain and apply safety practice on health, environment and equipment

√

Interactive Lecture,

Discussion, Demonstration and Practical.

Report.

C1

2 Identify and operate basic measurement tools, minor service petrol engine and service tire and suspension system

√

Practical Task and Report.

P1

3 Perform fitting and welding works according to Standard Operation Procedure.

√

Practical Task and Report. P2

4 Practice safety procedure correctly in the workshop according to the workshop safety regulation

√

Practical task A2

Total 1 2 1

Remark :

LD1 Knowledge LD2 Practical Skills LD3 Communication Skills LD4 Critical Thinking and Problem Solving Skills LD5 Social Skills and Responsibilities LD6 Continuous Learning and Information Management Skills LD7 Management and Entrepreneurial Skills LD8 Professionalism, Ethics and Moral LD9 Leadership and Teamwork Skills


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DISTRIBUTION OF STUDENT LEARNING TIME ACCORDING TO COURSE LEARNING - TEACHING ACTIVITY

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