student workbook2

10-1831-T

2005 EditionStudent

Test Packet

AutomotiveTechnologyCurriculum

AutomotiveTechnologyCurriculum

Module 1: Introduction toAutomotive Technology

Module 1: Introduction toAutomotive Technology

70-1801-W

2006 EditionStudent

Workbook

IntroductIon to AutomotIve technology

�

Automotive Technology

Module 1: Introduction to Automotive Technology

Student Workbook

ProducedbytheInstructionalMaterialsLaboratory1400RockQuarryCenter

UniversityofMissouri-ColumbiaColumbia,MO65211

(800)669-2465

2006Edition

Catalogno.70-1801-W©2006.TheCuratorsoftheUniversityofMissouri.

AllRightsReserved.

TechnicalConsultants:

KenEstesRobinFerguson

SteveReese

ProjectCoordinator:EricaKassel

Editor:JanisLevsen

GraphicArtists:

ChrisBenedictJacquelineCraig

AutomotIve technology

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Name:

MODULE 1: INTRODUCTION TO AUTOMOTIVE TECHNOLOGYSTUDENT WORKBOOK TRACKING SHEET

Assignment Sheet Title of Assignment Sheet

InstructorGuidePage #

StudentWorkbook

Page #Date Instructor’s

Initials

AS1-L1-UI AutomotiveTechnologyField 11–14 W1–2AS1-L1-UII WorkSafetyintheShop 47–50 W3–4AS1-L2-UII SafetyFeaturesandEmergencyProcedures

intheShop59–62 W7–8

AS2-L2-UII ShopSafetyInspectionChecklist 63–66 W9–10AS1-L3-UII LiftingandSupportingVehicles 75–78 W11–12AS1-L4-UII HazardousMaterialRegulations 91–94 W15–16AS1-L1-UIII SolventsandSoaps 121–124 W17–18AS1-L2-UIII LubricantsandSpecialtyChemicals 133–136 W19–20AS1-L3-UIII Gases,Dust,andAcid 143–146 W21–22AS1-L1-UIV Wrenches 169–172 W23–24AS1-L2-UIV ScrewdriversandPliers 179–182 W25–26AS1-L3-UIV Hammers,Punches,andChisels 187–190 W27–28AS1-L1-UV SpecialtyToolUses 213–216 W29–30AS1-L2-UV CommonVehicleFasteners 227–230 W31–32AS1-L3-UV UseandCareofMeasuringTools 237–240 W33–34AS1-L1-UVI PowerToolsandTheirUses 265–268 W35–36AS1-L2-UVI ShopEquipmentUse 279–282 W37–38AS1-L1-UVII Vehicle Information and Identification 301–304 W39–40AS1-L1-UVIII CustomerService,WorkOrders,andVehicle

Preparation319–322 W41–42

Job Sheet Title of Job SheetInstructor

GuidePage #

StudentWorkbook

Page #Date Instructor’s

Initials

JS1-L1-UII IdentifyVehiclesEquippedWithaSupplementalRestraintSystem(SRS)andAntilockBrakeSystem(ABS)

51–52 W5–6

JS1-L3-UII LiftaVehicle 79–80 W13–14JS1-L1-UVIII CompleteaWorkOrderWithConcern,

Cause,andCorrection323–324 W43–44

JS2-L1-UVIII PerformaGeneralDiagnosis 325–326 W45–46


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automotIve technology fIeld

Directions —Answerthefollowingquestionsbywritingallresponsesonthissheet.

1. Inwhichthreetypesofbusinessesarethemajorityofautomotivetechniciansemployed?

A.

B.

C.

2. Namesixcareeropportunitiesdirectlyrelatedtotheautomotivetechnologyfield.

A.

B.

C.

D.

E.

F.

3. Whatkindoftrainingisrequiredformostjobsintheautomotivetechnology field?

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4. AnswerthefollowingquestionsaboutASE.

A. WhatdoesASEstandforandwhatistheorganization’spurpose?

B. Whataretheeightautomotiveareasthatanautomotivetechniciancan be certified in by ASE?

•

•

•

•

•

•

•

•

5. Whatisthegovernment’spredictionforthenumberofjobopportunitiesinautomotivetechnologyintheyearsthrough2014?


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as1-l1-uII

work safety In the shop

Directions — Answerthefollowingquestionsbywritingallresponsesonthissheet.

1. Namethetwofederalagenciesthatissuesafetyguidelinesfortheworkplaceanddescribethefocusofeachagency.

A.

B.

2. Writethereasonforeachsafetyrulebelow.

A. Donotwearjewelryintheshop.

B. Donotrunavehicleengineinsideaclosedgarageunlesshookeduptoexhaustventilationequipment.

C. Wearaparticlemaskwhendoingcleaningworkonbrakesorclutchparts.

D. Discard,repair,orreplaceworntools.

E. Donotuseanelectrodeholderthathasdamagedinsulation.

F. Handleacetyleneandoxygencylinderswithcare.

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3. Matchthepersonalprotectiveequipment(PPE)ontherightthatismostappropriateforthedescriptionontheleft.AllthePPEchoiceswillnotbeused.

_____A. Loudnoisecreatedbygrinder

_____B. Handlingofcausticchemicals

_____C. Streetclothescouldgetsoiled

_____D. Potentialforbreathingdust

_____E. Weareverydayintheshop

_____F. Potentialforchemicals splashingineyes

_____G. Workingaroundtoxicfumes

_____H. Flyingobjectscouldinjure theface

1. Air-supplied respirator 2. Apron

3. Earmuffs

4. Faceshield

5. Leathergloves

6. Protectiveeyewear

7. Respiratorymask

8. Rubbergloves

9. Shopcoat

10. Splash-resistantgoggles

11. Tintedgoggles

4. WhymusttheSRSbedisabledbeforeworkingonoraroundtheairbags?

5. WhatcanhappenifanABScomponentthatissupposedtobereplacedasanassemblyisdisassembled?


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Evaluation

Js1-l1-uII

IdentIfy vehIcles equIpped wIth a supplemental restraInt system (srs) and antIlock brake system (abs)

Equipment:

Personalprotectiveequipment(PPE)

Procedure:

1. WearPPEwhileperformingtheproceduresonthisjobsheet.

2. Researchapplicablevehicleserviceinformationsuchasvehicleservicehistory, VIN, certification labels, and calibration decals. Record the necessaryinformationinthefollowingspace.

3. Inthespacebelow,recordthedigitsintheVINthatindicateifthevehicleisequippedwithanSRSandABS.

4. Inthespacebelow,recordanyotherindicatorssuchassymbolsonthevehicleorwarningschematicsthatindicateifthevehicleisequippedwithanSRSandABS.

NOTE: An oversized steering wheel hub is not sufficient evidence that the vehicleisequippedwithanSRS.

Averageoftheaboveevaluations


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safety features and emergency procedures In the shop


1. Anautomotivetechnicianshouldknowthelocationofcertainareasorsafety-relateditemsinashop.Nameeightofthese.

A.

B.

C.

D.

E.

F.

G.

H.

2. Should a fire blanket be used on a burning person wearing synthetic clothing?Explainwhyorwhynot.

3. List the type of fire for the following classes of fires.

A. ClassA

B. ClassB

C. ClassC

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D. ClassD

4. Which type of fire extinguisher should be used for the following classes of fires?

A. ClassA

B. ClassB

C. ClassC

D. ClassD

5. Whatshouldbedonewhensomeonereceivesanimmobilizingelectricalshock?


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shop safety InspectIon checklIst

Directions —Performasafetyinspectionoftheschoolshoporanothershopspecified by the instructor. Use the checklist below to guide the inspection and record the findings.

Shop Layout and Emergency Procedures YES NOExits are clearly identified and visible?Exitsareclearofobstructions?Specific work areas (e.g., welding, grinding, painting) are clearlymarked?Instructorandstudentsknowemergencyevacuationroutesandprocedure?Emergencyphoneandnumbersarereadilyavailable?Notes:

Shop Cleanliness and OrderPathways,especiallytoexits,areclear?Floor,walls,andothersurfacesarefreeofpaintspills,grease,andoil?Workareasarefreeoftrashanddebris?Oilyragsaredisposedofinthepropercontainer?Notes:

Fire Protection Fireblanketisreadilyavailable?An adequate number of fire extinguishers are available?The correct types of fire extinguishers are available?Fireextinguishersareproperlymarkedandnotblockedbyobstructions?Fireextinguishersarefullycharged?Instructor and students are trained in using fire extinguishers?Firealarmsareclearlymarkedandreadilyaccessible?Notes:

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Hazardous Wastes and Materials YES NOStoragecontainersforhazardouswastesareclearlymarked?An MSDS is on file and readily available for every hazardousmaterialintheshop?Eyewashstationisavailableandoperational?Notes:

Tools and EquipmentToolsandequipmentareproperlystoredwhennotinuse?Toolsandequipmentareproperlymaintained?Safetyshields/guardsarepresentandintheproperposition?Cords,hoses,andpowerconnectionsareingoodcondition?Electricalequipmentisproperlygrounded?Notes:

First AidFirstaidstationisclearlymarkedandreadilyaccessible?Firstaidkitisfullystocked?Instructorandstudentsareawareofsuppliesavailableandknowhowtousethem?Notes:


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lIftIng and supportIng vehIcles


1. Define the following lift or support devices.

A. Jack

B. Lift

C. Safetystand

2. Listthreesafetyrulesforraisingavehiclewithalift.

A.

B.

C.

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3. List five safety rules for raising a vehicle with a hydraulic floor jack.

A.

B.

C.

D.

E.

4. Whataretorqueboxareas?

5. Chooseavehiclemakeandmodelandapieceofliftingequipmentforraisingthevehicle.Refertoserviceinformationforthevehicleandequipment specifications for the lifting equipment to complete the information below. Please be specific.

Makeandmodel:____________________

Device(s)usedtoraisethevehicle:

Properliftpointsonthevehiclefortheliftdevice:

Supportdevice(s)usedandproperlocations:


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Evaluation

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lIft a vehIcle

Equipment:

Personalprotectiveequipment(PPE)Vehicleliftingequipment

Procedure:

CAUTION: When lifting a vehicle, always use proper lifting equipment and observe all safety precautions.

CAUTION: Identification of proper lifting points is extremely important. Damage caused by improper lifting can be severe. Common sense, along with an understanding of vehicle construction and vehicle supporting techniques, must be used in each repair instance.

CAUTION: Never crawl under a vehicle held up only by a jack, either hydraulic or pneumatic. Always use safety stands to support the vehicle.

1. WearPPEwhileperformingtheproceduresonthisjobsheet.

2. Usingserviceinformation,locateaprocedureforliftingavehicle.Makesuretheprocedureisappropriateforthemakeandmodelofthevehicle.Havetheinstructorchecktheboxtoapprovetheprocedure.

Usingtheprocedure,liftthevehicle.



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as1-l4-uII

hazardous materIal regulatIons


1. Define the following terms.

A. Hazardousmaterial—

B. Toxic—

C. Flammable—

D. Corrosive—

E. Reactive—

2. Listthreethingsemployeesmustknowwhenworkinginashopwithhazardousmaterials.

A.

B.

C.

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3. DescribethepurposeofMSDSsandwheretheycanbefound.

4. Namethethreecategoriesofhazardouswastegenerators.

A.

B.

C.

5. Which category of hazardous waste generators does the typical shop fit in?


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as1-l1-uIII

solvents and soaps


1. List the five general rules for using chemicals.

A.

B.

C. D.

E.

2. Nametwowaysthataqueous-basedpartswasherislesshazardousthanpetroleum-basedpartswasher.

A.

B.

3.Onwhattypeofpartsisitsafetousedigestive-typecarburetorcleanerandwhy?

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4. Listtworeasonswhygasolineshouldneverbeusedasasolvent.

A.

B.

5. Whattypeoftowelshouldbeusedwithglasscleanerorwindshieldwasherfluid? Why?


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as1-l2-uIII

lubrIcants and specIalty chemIcals


1. Listthreereasonswhyoilisahazardouschemical.

A.

B.

C.

2. Whatarelightoilsusedforandwhatistheiradvantage?

3. Howdoestheviscosityofgearlubecomparetomotoroil?Whatvehiclecomponentsarelubricatedwithgearlube?

4. Inwhatsituationsisgreaseusedtolubricateautomotivepartsinsteadofoil?

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5. Whatisthedifferencebetweenanaerobicandanaerobicsealer?


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as1-l3-uIII

gases, dust, and acId


1. Whatarethreeharmfulgasespresentingasolineengines? A.

B.

C.

2. Whattypeofcontainermustgasolinebestoredin?

3. A. WhatisFreon?

B. WhatisR-134a?

4. Whatmaterialcontainedinbrakeandclutchliningscancauselungcancer?

5. Whyisbatteryacidhazardous?

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wrenches


1. Matchthetoolwithitsnamebyplacingtheappropriatenumberintheblank.Alltheillustrationswillnotbeused.

____A. Boxwrench

____B. Breakerbar

____C. Pipe wrench

____D. Ratchet

____E. Swivel socket

____F. Torque wrench

____G. Tubing wrench

1.

2.

3.

4.

5.

6.

7.

8.

9.


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2. WhatistheunitofmeasurementforthejawopeninginametricwrenchandaUSCSwrench?

3. Answerthefollowingquestionsaboutcommonwrenches.

A. Whichtypeofcommon,nonadjustablewrenchgripsboltsonallsides?

B. Which wrench is used for loosening or tightening steel line fittings?

4. Answerthefollowingquestionsaboutsocketwrenchesandtorquewrenches.

A. Whatarethetwobasicpartsofasocketwrench?

B. Whattwoadvantagesdosocketwrencheshaveovercommonwrenches?

C. Whichtypeofsockethandleprovidesmaximumleveragetoloosenabolt?

D. Whenaretorquewrenchesnecessaryinautomotivetasks?

E. Whatcanhappeniftoomuchortoolittletorqueisapplied?

5. Nameadisadvantageofanadjustablewrench.


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screwdrIvers and plIers



____A. Adjustable- jointpliers

____B. Locking pliers

____C. Long-nose pliers

____D. Nutdriver

____E. Phillips screwdriver

____F. Slip-joint pliers

____G. Snap-ring pliers

____H. Standard Screwdriver

1.

2.

3.

4.

5.

6.

7.

8.

9. 10.


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2. Whataretwothingstocheckwhenevaluatingifascrewdriverisrightforajob?

A.

B.

3. Whatsafetyfeatureshouldscrewdriversorpliershavewhenusingthemnearelectricalequipment?

4. Whichtypeofpliershasalongslotwithmanyadjustmentpositions?

5. Whichtypeofpliersis bestforgrippingtinypinsandparts?


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hammers, punches, and chIsels



____A. Ballpeen hammer

____B. Diamond- pointchisel

____C. Plastic-tip hammer

____D. Rubber mallet

____E. Sledge- hammer

____F. Standard chisel

____G. Starting punch

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1. 2.

3.

4.

5.

6.

7.

8.

9.


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2. Whichhammerisusedmostfordrivingchiselsandpunches?

3. Whichhammeriscommonlyusedforinstallingwheelcovers?

4. Whichpunchisusedformarkingthepositionofholesbeforedrilling?

5. Providetworeasonswhyitisunsafetouseapunchorchiselwithamushroomedhead?

A.

B.


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specIalty tool uses


1. Listthefunctionofthefollowingspecialcuttingtools.

A. Hacksaw

B. Tubingcutter

C. Handreamer

D. File

2. Listtheuseofeachelectricalsystemtoolbelow.

A. DMM

B. Scantool

C. Oscilloscope

D. Continuitylight

E. Timinglight

F. Remotestarterswitch

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3. Listthefunctionofthefollowingtoolsforbatterywork.

A. Cablepuller

B. Terminalandpostcleaner

C. Batteryliftingtoolandcarryingstrap

4. Describetheuseofeachlubricationtoollistedbelow.

A. Transmissionfunnel

B. Oil filter removing tool

C. Greasegun

5. Listthefunctionofthefollowingspecialtytoolsbelow.

A. Blowgun

B. C-clamp

C. Pullerset

D. Pressuregauges

E. Vacuumgauges


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common vehIcle fasteners


1. Matchthefastenerwithitsnamebyplacingtheappropriatenumberintheblank.Alltheillustrationswillnotbeused.

____A. External snapring

____B. Machine screw

____C. Metricbolt

____D. PlainFlat Washer

____E. Rivet

____F. Self-tapping screw

____G. Stud

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5.

6.

7.

8.

3.

4.

1. 2.

9.

10.


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2. AnswerthefollowingquestionsaboutUSCSandmetricbolts.

A. HowisthethreadsizedeterminedforUSCSandmetricbolts?

B. HowisboltstrengthindicatedforUSCSandmetricbolts?

3. Matchthedescriptionattherightwiththefastenerontheleft.Allthedescriptionswillnotbeused.

____A. Adhesive____B. Internal snapring

____C. Self-tapping screw

____D. Stud

____E. Washer

1. Makesitsownthreadswhendrivenintoasurface

2. Preventsnutfromdamagingthepartsurface

3. Bondstwosurfacestogether

4. Usefulforachievingaccuratealignmentofparts

5. Fitsinagrooveinsideanopening

6. Fitsinagrooveoutsideofapart

7. Duringinstallation,headlessendishammereduntilrounded

4. Whatisthefunctionofatap?

5. Whatisthefunctionofadie?


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as1-l3-uv

use and care of measurIng tools


1. Matchtheuseattherightwiththemeasuringtoolattheleft.Alltheuseswillnotbeused.

_____A. Dialindicator

_____B. Feelergauge

_____C. Inside micrometer

_____D. Outside micrometer

_____E. Depth micrometer

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1. Usedforpreciseoutsidemeasurementofparts

2. Usedforinside,outside,anddepthmeasurements

3. Measurespartmovement

4. Measureshowdeepaholeorcavityis

5. Measuresairgapsandclearancebetweenmovingparts

6. Measuresdiameterofahole

2. Listthebasicstepsinusingadialindicator.


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3. Givethecorrectmicrometerreadingforeachexamplebelow.Themicrometershownmeasuresfrom0into1in.

4. Whenusingprecisionmeasuringtools,howshouldtheybehandled?

5. Howshouldprecisionmeasuringtoolsbestored?


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power tools and theIr uses


1. Matchthepowertoolwithitsnamebyplacingtheappropriatenumberintheblank.Alltheillustrationswillnotbeused.

____A. Airchisel

____B. Airratchet

____C. Electricdrill

____D. Heatgun

____E. Impact wrench

____F. Tire burnishing tool

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8.

5.

6.

1.

2.

3. 4.


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2. Explainhowelectric,pneumatic,cordless,andhydraulictoolsarepowered?

3. Nametwoadvantagesthatpneumatictoolshaveoverelectrictools.

A.

B.

4. Matchthepowertoolstotheiruses.Alltheuseswillnotbeused.

____A. Airchisel

____B. Blowgun

____C. Heatgun

____D. Impact wrench

____E. Minidie grinder

____F. Powerdrill

____G. Tire burnishing tool

1. Drillsholesorremovesrust

2. Usedwithimpactsocketstoloosenortightennutsandbolts

3. Usesstandardsocketstoloosenandtightennutsandbolts

4. Breaksweldsloose,cutsrivets,andpunchesholes

5. Softens,loosens,orthawsvehiclecomponents

6. Preparesrubberforpatching

7. Cleansdustfromshopequipment

8. Cutsmetalandremovesgasketmaterial

5. Whatshouldtheoperatordoifanelectricorpneumaticdrilljams?


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as1-l2-uvI

shop equIpment use


1. Matchtheusewiththeshopequipmentbyplacingtheappropriatenumberintheblank.Alltheuseswillnotbeused.

____A. Benchgrinder

____B. Drillpress

____C. Floorjack

____D. Hoist

____E. Hydraulic press

____F. Lift

____G. Tiremachine

____H. Wheel balancer

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1. Distributesweightequallyaroundthewheel

2. Maintainstoolsthathavebecomedull

3. Drillsholesinmetalparts

4. Suppliescompressedairforpneumatictools

5. Removestiresfromwheels

6. Raisesthefront,rear,orsideofavehicle

7. Raisestheentirevehicle

8. Raisesheavyvehicleparts

9. Forcespartsontoandoffofshafts

2. Toavoidelectricshock,anoperatorofelectricalshopequipmentshouldnotstandon___________________________________________________.

3. Thefrontofeachwheelofabenchgrindershouldbeequippedwithwhatthreeparts?

A.

B.

C.


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4. Howdoesadrillpressoperatorkeepthepartsbeingdrilledfromspinningoutofcontrolandcuttingthehands?

5. Whichpieceofequipmentneedstheadditionalsupportofsafetystandsbeforeatechniciancanworkunderthevehicle?


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vehIcle InformatIon and IdentIfIcatIon


1. Whichsourceisthemostcomprehensiveandthebestsourceofinformationfor a specific vehicle?

2. Whataretechnicalservicebulletins(TSBs)?

3. Listthreeguidelinesforusingserviceinformation.

A.

B.

C.

4. Nametwovehiclecodes.

A.

B.

5. ListtwocommonplacesthataVINisfoundonavehicle.

A.

B.

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as1-l1-uvIII

customer servIce, work orders, and vehIcle preparatIon


1. Whydoesashoprequireautomotivetechnicianstotreatcustomersinafriendly,courteousmanner?

2. Howshouldanautomotivetechnicianrefertoacustomerwhenaddressinghimorher?

3. Explainwhatistypicallyinvolvedintheproceduresbelow.

A. Preparingthevehicleforservice

B. Preparingthevehicletoreturnittothecustomer

4. Listthreefunctionsofaworkorder.

A.

B.

C.

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5. ExplainwhatthethreeCsmeanindiagnosingavehicleproblem.


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Evaluation

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complete a work order wIth concern, cause, and correctIon

Directions:

1. Theinstructorwilllistarepair.Completetheworkorderonthefollowingpagefortherepair.

Toreceivecredit,allsectionsoftheworkordermustbecomplete.

Creditreceivedforcompletingworkorder


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Smith’s Automotive Repair

Customer’sName: Date:__________ Invoice#: ______

Address: __ Phone: ______________

Year/Make: Model: VIN: ______ Mileage: ______

ServiceWriter: Technician:

CustomerAuthorizationSignature: _____CustomerConcern:

VehicleServiceHistoryInformation:

RelatedTechnicalServiceBulletins:

DiagnosticProceduresPerformed:

Cause:

Correction:

Labor Procedures and Costs Estimated Actual

Outside Labor Procedures and Costs

Total Labor CostsParts CostsQuantity Part # Description

Total Parts CostsLabor TotalParts Total

Sales TaxGRAND TOTAL


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Js2-l1-uvIII

perform a general dIagnosIs

Equipment:

ServiceinformationsourcePenNotebookPersonalprotectiveequipment(PPE)

Procedure:

1. WearPPEwhileperformingallproceduresonthisjobsheet.

2. Identifytheconcern.Ifpossible,asktheowner/driverthefollowingquestions.

a. Underwhatconditionsdoestheproblemoccur?

b. Arethereunusualsounds?

c. Howlonghastheproblemexisted?Isitgettingworse?

3. Prepare the vehicle for service (fender covers, floor protectors, etc.) accordingtotheinstructor’sdirections.

4. Obtaintheinstructor’spermissiontoperformaroadtest.Havetheinstructorchecktheboxtoapprovetheroadtest.

5. Testdrivethevehicleundertheconditionsthattheproblemhas beenobserved.

CAUTION: Always obtain instructor’s approval before conducting a road test. Conduct the road test in an area with little or no traffic. Never exceed the legal speed limit during the road test. Always wear safety belts. An assistant should record all observations made during the road test. Do not attempt to drive and record results at the same time.

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6. Isolatethecauseoftheproblem.

a. Locate and interpret vehicle and major component identification numbers.

• VIN

• Vehicle certification labels

• Calibrationdecals

b. Researchapplicablevehicleandserviceinformation.

• Applicablecomponentsandtheiroperation

• Vehicleservicehistory

• Serviceprecautions

• Technicalservicebulletins

c. Performavisualinspectionoftheapplicablesystem.

• Lookfordamagedorbrokencomponents.

• Lookforwornormisalignedcomponents.

• Check fluid levels.

• Inspectrelatedelectricalsensors,corrector,controls,andwiring.

d. Testthesystemsandcomponentsthatcouldcausetheproblem.Eliminategoodcomponentsuntilthecauseisfound.

7. Determinethenecessaryaction.Describetheappropriateactionsbelow.

8. Preparethevehicletoreturnittothecustomer(removeprotectivecoversandanydirtorgrease,etc.)accordingtotheinstructor’sdirections.


student workbook2

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