Chapter 09

Vehicle Protection and Jack and Lift Safety

 

Learning Objectives

After reading this chapter, you will be able to:

• 9-01 Prepare vehicle for service and return to customer.
• 9-02 Operate jacks, engine hoists, and stands.
• 9-03 Operate hoists and describe use of inspection pits.

 

ASE Education Foundation Tasks

The following ASE Education Foundation Automobile Accreditation Tasks are covered in this chapter:

• IA6 Perform common fastener and thread repair, to include: remove broken bolt, restore internal and external threads, and repair internal threads with thread insert.

 

Readings and Preparation

• Review all instructional materials, including the chapter in Fundamentals of Automotive Maintenance and Light Repair, Second Edition, and all related presentation support materials.

 

Support Materials

• Lecture PowerPoint presentation, including all Skill Drills

 

Pre-Lecture

• You Are the Automotive Technician
  • A progressive case study that encourages critical thinking skills.
  • Direct students to read the “You Are the Automotive Technician” scenario found at the beginning of each chapter.
  • Group Activity: Direct students to review the discussion questions at the end of the scenario and prepare a response to each question. Facilitate a class discussion centered on the questions.
  • Homework Assignment: Ask students to turn in their comments on the questions.
• Teaching Tip: Explain to students how this material applies to the workplace. Provide an example of a situation to make it relevant and meaningful. How does it fit into the broader picture? Is it building on something they already know? Will it help them master a skill? Students need to understand that what we are teaching is of importance on the job. This is fairly easy to do by describing a few real world situations with customer vehicles being damaged in the shop. You can also describe a scary jack or hoist scenario you have seen.

 

Lecture

9-01 Prepare vehicle for service and return to customer.

 

• The service advisor should perform a vehicle walk-around with the customer, noting required maintenance, repairs, and existing damage.
• Fender, seat, carpet, and steering wheel covers are used to prevent damage to the engine bay and passenger compartment while servicing the vehicle.
• Prevent corrosives and greases from coming into contact with areas of the vehicle that are not designed for them.
• Make sure all vehicle protection covers, tools, and old parts, oil or grease marks are removed prior to releasing the vehicle to the customer.
• To minimize accidental mechanical damage, follow shop and manufacturer procedures and use tools and equipment correctly.
• Only authorized, fully trained, and licensed drivers should be allowed to test-drive vehicles or move them.

9-02 Operate jacks, engine hoists, and stands.

 

• Lifting equipment, designed to lift and securely hold loads, includes vehicle lifts, floor jacks, jack stands, engine and component hoists, chains, slings, and shackles.
• Each piece of lifting equipment is designed for a specific purpose and has an operating capacity expressed as the safe working load (SWL).
• Lifting equipment maintenance inspections may be according to operator recommendations or because of statutory inspection and certification requirements.
• A vehicle jack, which may be hydraulic, pneumatic, or mechanical, is used to raise part of a vehicle from the ground. A jack stand is used to support the weight of the vehicle.
• Vehicles should only be lifted from those areas specified by the manufacturer.
• The load rating of engine hoists or mobile floor cranes must be greater than the weight of the object to be lifted.
• Engine stands, which support an engine when it is being worked on while out of the vehicle, must have a rating higher than the weight of the engine.

9-03 Operate hoists and describe use of inspection pits.

 

• Vehicle lifts, classified as in-ground and above ground, raise whole vehicles off the ground so that a technician can work on the underside of the vehicle.
• Vehicle lifts should be periodically inspected and certified and should only be used to lift vehicles lighter than the maximum weight rating specified.
• The most common types of vehicle lifts in use are single-post, two-post, and four-post lifts; scissor lifts; parallelogram lifts; and mobile or specialty lifts.
• Vehicle inspection pits are trenches built into the floor area of a vehicle repair bay and allow access to the underside of the vehicle without the need for a lift or jack.

 

Post-Lecture

This section contains various student-centered end-of-chapter activities designed as enhancements to the instructor’s presentation. As time permits, these activities may be presented in class. They are also designed to be used as homework activities.

 

1. Direct students to read and individually answer the question sets located in the Wrap-Up section at the end of each chapter. Allow approximately 10–20 minutes for this part of the activity.
2. Facilitate a class review and discussion of the answers, allowing students to correct responses as may be needed. Use the answers noted in the Answer Key to assist in building this review.
3. You may wish to ask students to complete this activity on their own and turn in their answers on a separate piece of paper.

 

Review Questions

This question set is designed to assist students in understanding the chapter content by asking knowledge-based comprehension questions.

 

1. All of the following are good practices when a customer drops a vehicle for service, EXCEPT:
   1. Do a walk around to look for damage.
   2. Install seat covers.
   3. Use floor mats to protect the carpet.
   4. Set the radio to your preferred station.

 

2. What is used to protect the vehicle when working under the hood?
   1. Shop rags
   2. Oil drip cloth
   3. Fender covers
   4. A bright light

 

3. Before returning the vehicle to the customer, the technician should:
   1. clean the vehicle.
   2. clean the tools.
   3. wash the bay.
   4. reset the trip meter.

 

4. When using a two-post lift:
   1. raise the vehicle to working height and shake the vehicle to see if it is stable.
   2. raise the vehicle a few inches off the floor and shake the vehicle gently to see if it is stable.
   3. the arms automatically align themselves with the vehicle lift points.
   4. the vehicle is driven onto two long narrow platforms.

 

5. When using a jack to lift a vehicle so a tire can be removed, which piece of equipment should also be used?
   1. A second jack
   2. A rated lifting pad
   3. Jack stands
   4. Fender covers

 

6. When multiple pieces of lifting equipment are used, the SWL is:
   1. that of the piece with the lowest rating.
   2. the sum of the SWLs of the individual pieces.
   3. that of the piece with the highest rating.
   4. the average of the SWLs of the individual pieces.

 

7. When fastening an engine to a stand, what grade bolt should be used?
   1. Grade 2
   2. Grade 3
   3. Grade 5
   4. Does not matter

 

8. What must be built into every vehicle lift in the shop?
   1. Computer controls
   2. Air-powered cylinder
   3. Color-coded controls
   4. Mechanical locking device

 

9. Four-post lifts are ideal for all of the following types of work, EXCEPT:
   2. oil changes.
   3. exhaust work.
   4. brake work.

 

10. When driving a vehicle over an inspection pit:
    1. have a spotter guide you.
    2. make sure the lights in the pit are off.
    3. drive as quickly as you can.
    4. make sure a person is in the pit.

 

ASE Technician A/Technician B Style Questions

This question set is designed to assist students in gaining a further understanding of and familiarity with ASE Technician A/Technician B questions.

 

1. Technician A says that harmful vapors can collect in an inspection pit. Technician B says that electric powered tools should be used in inspection pits. Who is correct?
   1. Technician A
   2. Technician B
   3. Both A and B
   4. Neither A nor B

 

2. Technician A says that vehicle positioning is not very critical on two-post lifts. Technician B says to make sure all the locks on a four-post lift disengage when lowering. Who is correct?
   1. Technician A
   2. Technician B
   3. Both A and B
   4. Neither A nor B

 

3. Technician A says that vehicle lifts should be inspected and certified every year. Technician B says that lifts should be raised slightly to undo the safety locks when lowering a vehicle. Who is correct?
   1. Technician A
   2. Technician B
   3. Both A and B
   4. Neither A nor B

 

4. Technician A says lifting chains should be rated higher than the object being lifted. Technician B says that extending the lifting arm on an engine hoist increases its capacity. Who is correct?
   1. Technician A
   2. Technician B
   3. Both A and B
   4. Neither A nor B

 

5. Technician A says that symmetrical two-post lifts allow the vehicle to be positioned farther back on the lift. Technician B says to use the lift points specified by the manufacturer. Who is correct?
   1. Technician A
   2. Technician B
   3. Both A and B
   4. Neither A nor B

 

6. Technician A says when using jack stands, make sure they are level on the ground. Technician B says to make sure the jack stands are on a solid, hard surface. Who is correct?
   1. Technician A
   2. Technician B
   3. Both A and B
   4. Neither A nor B

 

7. Technician A says to return the vehicle to the customer in a better shape than when it was dropped off. Technician B says to use seat covers, steering wheel covers, and floor mats on customer vehicles. Who is correct?
   1. Technician A
   2. Technician B
   3. Both A and B
   4. Neither A nor B

 

8. Technician A says to do a walk around the vehicle with the customer to note any problems. Technician B says to check for dirty finger prints before returning the vehicle to the customer. Who is correct?
   1. Technician A
   2. Technician B
   3. Both A and B
   4. Neither A nor B

 

9. Technician A says some brake fluids can cause damage to painted surfaces. Technician B says that it is generally best to clean up any brake fluid spills on painted surfaces after it has sat for a while. Who is correct?
   1. Technician A
   2. Technician B
   3. Both A and B
   4. Neither A nor B

 

10. Technician A says that fender covers with magnetic strips can end up scratching the paint. Technician B says that your back pocket is a good place to keep a screw driver. Who is correct?
    1. Technician A
    2. Technician B
    3. Both A and B
    4. Neither A nor B

 

Assignments

• Review all materials from this chapter and be prepared for a chapter quiz to be administered (date to be determined by instructor).
• Direct students to read the next chapter in Fundamentals of Automotive Maintenance and Light Repair, Second Edition, as listed on your syllabus to prepare for the next class session.

Chapter 06

Hand and Measuring Tools

 

Learning Objectives

After reading this chapter, you will be able to:

• 6-01 Identify basic hand tool safety.
• 6-02 Identify basic wrenches and sockets.
• 6-03 Identify other basic hand tools.
• 6-04 Identify basic hammers and struck tools.
• 6-05 Identify basic taps, dies, and specialty tools.
• 6-06 Measure precisely using measuring tools.
• 6-07 Measure precisely using other measuring tools.

 

Readings and Preparation

• Review all instructional materials, including the chapter in Fundamentals of Automotive Maintenance and Light Repair, Second Edition, and all related presentation support materials.

 

Support Materials

• Lecture PowerPoint presentation, including all Skill Drills

 

Pre-Lecture

• You Are the Automotive Technician
  • A progressive case study that encourages critical thinking skills.
  • Direct students to read the “You Are the Automotive Technician” scenario found at the beginning of each chapter.
  • Group Activity: Direct students to review the discussion questions at the end of the scenario and prepare a response to each question. Facilitate a class discussion centered on the questions.
  • Homework Assignment: Ask students to turn in their comments on the questions.
• Teaching Tip: Explain to students how this material applies to the workplace. Provide an example of a situation to make it relevant and meaningful. How does it fit into the broader picture? Is it building on something they already know? Will it help them master a skill? Students need to understand that what we are teaching is of importance on the job. This can be done by discussing real world experiences with selecting the right tools, and their use, to reinforce the concepts presented.

 

Lecture

6-01 Identify basic hand tool safety.

 

• Almost all shop tasks involve some sort of tool or equipment, making their purchase, use, and maintenance very important to the overall performance of the shop.
• It is critical to have an attitude of safety because tools can injure or kill if used improperly.
• Always follow tool/equipment instructions and use recommended personal protective equipment (PPE).
• Inspect tools for damage before and after using them; clean and return them to their correct storage locations once tasks are completed.
• Use safe procedures for handling tools and equipment, and seek assistance if required when using tools that are heavy or awkward to operate.
• It is critical to use a tool in the way it was designed to be used to do the job safely.
• Lockout or tag-out reduces the risk of technicians inadvertently using unsafe tools, material, or equipment.
• Lockout involves physically securing a piece of equipment.
• Tag-out involves affixing a clear and obvious label to the piece of equipment describing the fault found, the name of the person who found the fault, and a warning not to use the equipment.
• Toolboxes need to be durable enough to handle the weight of the tools, have enough capacity to hold all the required tools, and be easy to open and close.
• Specialty tools are usually available for shared use and should be inspected and stored properly after each use.

6-02 Identify basic wrenches and sockets.

 

• Tools, measuring instruments, and fasteners are available in two size designations:
  • The United States customary system (USCS), also called the standard system
  • The metric system
• Tools can be identified by their size markings, by manufacturer specifications, or by measuring the item and comparing the size to thread and fastener charts.
• There are three common types of wrenches:
  • Box-end wrench
  • Open-end wrench
  • Combination wrench
• Box-end wrenches can be hard to use once the fastener has been loosened because it has to be lifted off the head to be moved to a new position.
• Open-end wrenches grip the fastener at only two points between parallel flats and might have two different-sized heads on each end or the same-sized head at two different angles.
• The combination wrench has an open-end head at one end and a box-end head at the other, usually of the same size, making it quite versatile.
• A flare nut wrench grips five of the six points on the fastener and hence has better grip than an open-end wrench; it is also called a flare tubing wrench because the open end allows it to be placed over pipes or tubing.
• The open-end adjustable wrench or crescent wrench has a movable jaw that can be adjusted by turning an adjusting screw to fit any fastener size in its range.
• A ratcheting box-end wrench has an inner piece that grips the fastener and rotates within a housing, so it does not need to be removed to be repositioned.
• A ratcheting open-end wrench has one of the sides partially removed so only the bottom one-third grips the point of the fastener.
  • This wrench is not designed to be used on extremely tight fasteners; however, it is useful in blind places where a socket or ratcheting box-end wrench cannot be used.
• Pipe wrenches are used to grip and turn pipes with their hardened serrated jaw, which can be threaded in or out to adjust its size to fit different pipe sizes; as the handle pivots slightly, increasing the pressure on it tightens the grip.
  • Available in different lengths based on the amount of leverage required
  • Increasing the pressure increases the chances of marking or even gouging metal out of the pipe
• An oil filter wrench grips the oil filter and makes it easier to remove; they are available in various designs and sizes with some being adjustable to fit many filter sizes.
  • Should not be used to tighten the filter, only to remove it
  • Most filters should be installed and tightened by hand
• Choosing the correct wrench for a job usually depends on how tight the fastener is and how much room there is to get the wrench on the fastener and turn it.
• Sockets fit onto fasteners snugly and grip all six corners.
  • Available in a variety of configurations and are usually purchased in sets because individual sockets fit a particular size nut or bolt
• An impact wrench exerts more torque on a socket than turning it by hand, requiring special, stronger sockets.
• Six- and four-point sockets have the strongest grip on the fasteners but fit on the fastener in only half the positions as a twelve- and eight-point socket, making them harder to use in places where the ratchet handle is restricted.
• For fasteners threaded down a stud or bolt, a deep socket is required to be able to reach the nut.
• Other tools are made with square drives to be used in place of sockets, such as crow’s foot wrenches with open-end, box-end, or flare-nut wrenches.
• Other accessory sockets include Allen sockets, Torx sockets, and screwdriver sockets.
• Ratchet mechanisms are of two types: a coarse-tooth ratchet, which is strong but requires more space to swing the handle to catch the next tooth, or a fine-tooth ratchet, which requires less room to swing the handle but is not as strong.
• A breaker bar gives the most leverage for heavy tightening or loosening, and a sliding T-handle can be used if this is not available.
• Many different length extensions are available and can be connected to get just the right length required.
• A flexible joint can be used if an object is in the way. The socket can be turned even though the driver is no longer in line with the fastener.
• Five common types of flexible joints: U-joint, CV, wobble extension, cable extension, and flex socket.
• A lug wrench has special lug-sized sockets attached permanently to it, with one common model having four different-sized sockets, one on each arm.
• An impact wrench should not be used to tighten lug nuts; they should be properly torqued using a torque wrench.
• A torque wrench or tension wrench is used to tighten fasteners to a predetermined torque.
• Torque wrenches are of various types: beam type, clicker, dial, and electronic.
• The clicker-style torque wrench uses an adjustable clutch that slips when a preset torque, which can be set on the handle, is reached.
• The dial torque wrench turns a dial that indicates how much torque is applied and has a moveable indicator that stays at the highest reading so the torque achieved can be seen even after the wrench is released.
• A digital torque wrench produces an audible beep when the desired torque is achieved, making it easy to use in situations where a scale or dial cannot be read.

6-03 Identify other basic hand tools.

 

• Pliers are hand tools made of two pieces of strong steel joined at a fulcrum point and designed to hold, cut, or compress materials.
• Combination pliers are most commonly used in the shop and offer two gripping surfaces: one for flat objects and one for rounded objects.
• Arc joint pliers have moveable pivots, often called Chanellocks™, with parallel jaws whose size can be increased or decreased for a wider grip.
• Needle-nose pliers have long, pointed jaws to reach into tight spots or hold small items.
• Flat-nose pliers have a square end or nose and are used to bend wires or thin steel sheets accurately along a straight edge.
• Diagonal cutting pliers are used for cutting wire or cotter pins, but should not be used on hard or heavy-gauge materials because this can damage the cutting surfaces.
• End-cutting pliers, also known as nippers, have a cutting edge at right angles to their length to cut through soft metal objects sticking out from a surface.
• Snap ring pliers can be of internal and external type and have pins that fit into the holes of a snap ring.
• Locking pliers, also called vice grips, are used to hold one or more objects, freeing up one hand while working.
• Allen wrenches, sometimes called Allen or hex keys, are used to tighten or loosen fasteners with Allen heads, which are internal hexagonal recesses.
• The most common screwdriver is the flat-blade screwdriver, which is available in a variety of sizes and lengths, so the correct one should be chosen that is almost as wide and thick as the slot in the fastener.
• A fastener with a cross-shaped recess requires a Phillips head screwdriver or a Pozidriv screwdriver, which needs to be held with the tip centered on the fastener.
• The offset screwdriver fits into spaces where a straight screwdriver cannot; it has two offset ends that are at ninety degrees to each other so they can be used alternately.
• A ratcheting screwdriver is a screwdriver handle with a selection of removable flat and Phillips heads. It engages in one direction and freewheels in the other, depending on how the slider is set, allowing the fastener to be turned without removing the tip from the head.
• An impact driver is used when a screw or bolt is rusted or corroded in place or overtightened, because the force of the hammer forcing the bit into the screw while twisting makes it more likely for the screw to break loose.
• Magnetic pickup tools have a magnet attached at the end of a telescopic swivel joint, strong enough to pick up screws, bolts, sockets, and other ferrous metals.
• Mechanical fingers are designed to extract or insert objects in tight spaces with expanding, grappling fingers on one end and at the other end a push mechanism to expand the fingers, along with a retracting spring to contract them.
• Bolt cutters have compound joints and long handles for the leverage and cutting pressure needed to cut heavy wire, non-hardened rods, bolts, and other heavy gauge materials.
• Tin snips are used to cut thin sheet metal with lighter versions available to follow the outline of gaskets.
• Aviation snips are designed to cut soft metal and are easy to use because they are double pivoted for extra leverage with handles spring loaded in the open position.
• Pry bars are constructed of strong metal and come in a variety of shapes and sizes, many with a slightly bent, tapered end and a plastic handle at the other.
• A roll bar is a pry bar with one end sharply curved and tapered and the other end tapered to a dull point, which is used to align larger holes such as transmission bell housings and engine mounts.
• A gasket scraper has a comfortable handle at one end and a hardened sharpened blade at the other designed to remove a gasket on cast iron surfaces and non-critical aluminum sealing surfaces such as thermostat housings.
• Plastic gasket scrapers are needed to remove gaskets from critical sealing surfaces such as aluminum head gaskets.
• Files are designed to remove small amounts of material from the surface of a workpiece and differ in shape as well as in the amount of material removed with each stroke.
• Teeth on a coarse-grade file are larger with greater space between them and remove more metal with each stroke, whereas teeth on a smooth-grade file are smaller, closer together, and remove less material with each stroke, but leave a smoother finish.
• Safe edge files have one smooth edge that allows filing up to an edge without damaging it.
• A warding file is thinner than other files and comes to a point for working in narrow slots.
• A square file has teeth on all four sides for use in a square or rectangular hole.
• A triangular file has three sides so it can cut into internal corners without removing material from the sides.
• Curved files are round or half round, with half-round files used in concave hollows or acute internal corners and the fully round file used to make holes bigger or file inside concave surfaces with tight radii.
• Thread files are available in standard or metric configurations and are used to clean clogged or distorted threads on bolts and studs.
• Each file has eight different surfaces that match different thread dimensions, so care must be taken to use the correct face.

6-04 Identify basic hammers and struck tools.

 

• A ball-peen hammer, or engineer’s hammer, has a hardened steel head with one flat face and one rounded face; it can be used to drive a punch or peen a rivet.
• A soft face hammer may have a head made of very soft material such as rubber or plastic or slightly harder materials such as brass or copper.
• Soft-faced hammers should be used when only a tap is needed to position a component and where a steel hammer might mark or damage the part.
• A sledgehammer is used when a large chisel needs a strong blow; it is made of high-carbon steel and is like a small mallet with two square faces.
• A dead blow hammer is designed not to bounce back when it hits something, making it ideal for dislodging stuck parts.
• A cold chisel is used to cut cold metals; it has a blade made of high-quality steel with a tempered, hardened cutting edge of about 70 degrees.
• A spring-loaded chisel is used in places where a hammer cannot be swung and works by drawing back and releasing a weighted hammerhead connected to a spring.
• A cross-cut chisel has a sharpened edge across the blade width and narrows down along the stock, making it good for getting into grooves.
• Punches transmit a hammer’s striking power at exactly one point through the soft upper end down to the hardened, high-carbon steel tip.
• A prick punch is very sharp and is used to mark points on an object so they will not rub off.
• A center punch is not as sharp and makes a bigger indentation that centers the drill bit at the point where a hole is required to be drilled.
• A drift punch is used to get a pin moving. It has a tapered shank and a slightly hollow tip, which does not spread the tip of the pin and makes it an even tighter fit.
• A pin punch has a long, slender shaft with straight sides and is available in a number of diameters to work with different-sized pins and rivets.
• Special punches called wad punches or hollow punches are used to make holes in soft sheet materials; they have hollow ends and are used with a soft surface under the work area.
• Number and letter punches are available in boxed sets and are used to mark engine components such as connecting rods.

6-05 Identify basic taps, dies, and specialty tools.

 

• Taps and dies can be used to form threads so they can fasten things together, with the tap being used to cut female threads and the die being used for male threads.
• A taper tap narrows at the tip, making it easier to start straight when cutting threads in a new hole, and also making it less likely to break the tip off because it removes material in a less aggressive manner.
• An intermediate tap is more aggressive than a taper tap, although it can also be used as a starter tap.
• A bottoming tap is used to cut holes to the very bottom of a blind hole. It has a flat bottom and is virtually impossible to use in a new, unthreaded hole.
• A thread chaser cleans up the threads of a hole to make sure they are free from dirt and debris, so the bolt does not encounter any excessive resistance.
• Dies cut external threads on metal shanks or bolts and come with a setscrew that allows the user to adjust the size of the die, so the threads cut will be the right fit for the hole.
• A tap handle holds the squared end of the tap securely in its right-angled jaw, making it easier to turn and cut the thread.
• A T-shaped tap handle is convenient to use in tighter spaces because its handle is not long, but is more difficult to turn and guide accurately.
• A die stock is used to hold the die when cutting a brand new thread on a blank rod or shaft with the die being held in place by a thumb screw.
• A screw extractor can be used to remove screws and bolts that have broken off in threaded holes.
• One type of screw extractor uses a left-hand tapered thread and is screwed into a hole drilled in the bolt, gripping the broken part of the bolt and unscrewing it.
• Other types use a hardened tapered square shank or vertical splines, which grip the bolt when hammered into the hole drilled in it, thus allowing it to be unthreaded.
• A bench vice can be used to hold anything that fits in its jaws.
• An offset vice can be used to grip materials too awkward to grip vertically in a plain vice.
• A drill vice is designed to hold material on a drill worktable; it can be moved on the bed until the precise drilling point is located and tightened down by bolts.
• A C-clamp can be used to hold parts together while they are being assembled, drilled, or welded and can be taken where needed because it is portable.
• Pullers are universal tools that can be used for removing bearings, bushings, pulleys, and gears and commonly have two or three legs that grip or push the part to be removed.
• Gear pullers are designed to connect to a component either externally or internally and consist of three main parts: jaws, a cross arm, and a forcing screw.
• The forcing screw is a long, fine-threaded bolt that is applied to the center of the cross-arm; it applies a very large force to the component being removed when turned.
• The cross-arm attaches the jaws to the forcing screw, and if it has four arms, three are spaced 120 degrees apart and one is 180 degrees apart from one arm, allowing the puller to be used as a two- or three-arm puller.
• A tube flaring tool is used to flare the end of a tube so it can be connected to another tube or component.
• There are three common types of flares:
  • A single flare is for tube systems with low pressure, like fuel lines.
  • The double flare is for higher pressures, such as in brake systems
  • The ISO flare, or bubble flare, is the metric version used in brake systems.
• A tubing cutter consists of a sharpened wheel that, when rotated, is forced into the pipe by a screw until it cuts through.
• A blind rivet has two main pieces: a body that forms the finished rivet and a mandrel that is discarded when riveting is complete.
• A pop rivet gun is convenient for riveting light materials.

6-06 Measure precisely using measuring tools.

 

• Precision measuring tools are accurate to much smaller dimensions than can be measured with steel rules or measuring tapes, in some cases down to 1/10,000 of an inch or 1/1000 of a millimeter.
• Measuring tapes are of various lengths with 16 to 25 feet or 5 to 8 meters being common.
• Steel rulers are commonly of 12, 24, or 36 inches in length and are used to measure and mark out items.
• Micrometers can measure down to a resolution of 1/1000 of an inch or 1/100 of a millimeter with Vernier micrometers equipped with Vernier scales being able to measure down to 1/10,000 of an inch or 1/1000 of a millimeter.
• Outside, inside, and depth micrometers measure outside dimensions, inside dimensions, and depth, respectively.
• A metric micrometer uses a different thread pitch than a standard micrometer, with the standard micrometer measuring 0.025 inches for every one rotation and the metric micrometer measuring 0.5 mm for the same rotation.
• Telescoping gauges can be used to measure distances in awkward spots, like at the bottom of a cylinder, and they have expanding spring-loaded plungers that can be released or locked with a screw on the handle, the distance between which can then be measured.
• Split ball gauges are used to measure small holes where telescoping gauges cannot fit and consist of a split ball mechanism that can be fitted into the bore and expanded until there is a slight drag, then measured with a micrometer.
• A dial bore gauge combines a telescoping gauge and a dial indicator in one instrument, allowing the inside diameter of bores to be measured with a high degree of speed and accuracy.
• A dial bore gauge is typically accurate to 5/10,000 of an inch or 1/100 of a millimeter and can measure whether a cylinder is worn, tapered, or out-of-round.

6-07 Measure precisely using other measuring tools.

 

• Vernier calipers are a precision instrument that can measure inside, outside, and depth dimensions in one tool.
• To ensure accurate measurement, it is important to repeat measurements and compare.
• A dial gauge or dial indicator has a spring-loaded, rounded, or pointed contact end connected to a dial that indicates its movement in and out as it rests against an object.
• A dial gauge may have two needles, with the second, smaller needle indicating the coarse reading and the larger needle indicating the fine reading.
• Dial gauges can measure with an accuracy of 0.001 to 0.01 mm and come with various attachments and support arms to configure them for specific measuring tasks.
• Straight edges are made from hardened steel and machined so that the edge is perfectly straight.
  • Used to check the flatness of surfaces such as the amount of warpage on the surface of a cylinder head
• Feeler gauges or feeler blades are flat metal strips of varying thickness used to measure the width of gaps.
• Wire feeler gauges are made with hardened wire of specific thickness and can be used to measure gaps that are not parallel, such as spark plug gaps. Because they are round, they can find the minimum gap much more accurately.

 

Post-Lecture

This section contains various student-centered end-of-chapter activities designed as enhancements to the instructor’s presentation. As time permits, these activities may be presented in class. They are also designed to be used as homework activities.

 

1. Direct students to read and individually answer the question sets located in the Wrap-Up section at the end of each chapter. Allow approximately 10–20 minutes for this part of the activity
2. Facilitate a class review and discussion of the answers, allowing students to correct responses as may be needed. Use the answers noted in the Answer Key to assist in building this review.
3. You may wish to ask students to complete this activity on their own and turn in their answers on a separate piece of paper.

 

Review Questions

This question set is designed to assist students in understanding the chapter content by asking knowledge-based comprehension questions.

 

1. Technician tool purchases are considered:
   1. an investment.
   2. a liability.
   3. a waste of money.
   4. a last-resort option.

 

2. Which of the following is NOT a type of socket?
   1. Impact-rated socket
   2. Adjustable socket
   3. Shallow socket
   4. Six-point socket

 

3. Which of these would you use for a wider grip and a tighter squeeze on parts too big for conventional pliers?
   1. Diagonal cutting pliers
   2. Combination pliers
   3. Arc joint pliers
   4. Snap ring pliers

 

4. Which tool would be best used to remove a threaded fastener that has a cross-shaped recess on the head?
   1. Straight screwdriver
   2. Offset slotted screwdriver
   3. Phillips screwdriver
   4. Allen screwdriver

 

5. Which tool would be best used to make external threads on a steel rod?
   1. A tap
   2. A thread maker
   3. A thread file
   4. A die

 

6. All of the following are steps for properly using a micrometer EXCEPT:
   1. Verify that the micrometer is zeroed.
   2. Verify that the measuring surfaces are clean.
   3. Use the ratchet to run the micrometer down.
   4. Turn the thimble an additional 0.005″ to take up any slack.

 

7. When would a technician use a dial indicator?
   1. Checking for runout
   2. Checking the diameter of a part
   3. Measuring spark plug gap
   4. Measuring angles on parts

 

8. Which style of torque wrench is the simplest and least expensive?
   1. Clicker
   2. Dial
   3. Beam
   4. Electronic

 

9. The depth of blind holes in housings can best be measured using (a):
   1. measuring tape.
   2. steel rule.
   3. dial bore gauge.
   4. Vernier calipers.

 

10. When a large chisel needs a really strong blow, use a:
    2. hard rubber hammer.
    3. dead blow hammer.
    4. Ball-peen hammer.

 

ASE Technician A/Technician B Style Questions

This question set is designed to assist students in gaining a further understanding of and familiarity with ASE Technician A/Technician B questions.

 

1. Technician A says that proper maintenance and inspection is required on tools regularly. Technician B says that tools don’t wear out, so extra time is not needed for inspection. Who is correct?
   1. Technician A
   2. Technician B
   3. Both A and B
   4. Neither A nor B

 

2. Two techs are measuring a cylinder bore down to 0.001″. Technician A says that a tape measure will work. Technician B says that a telescopic gauge and micrometer will work. Who is correct?
   1. Technician A
   2. Technician B
   3. Both A and B
   4. Neither A nor B

 

3. Two technicians are discussing hammers. Technician A says a dead blow hammer reduces rebound of the hammer. Technician B says that a dead blow hammer should be used with a chisel to cut the head of a bolt off. Who is correct?
   1. Technician A
   2. Technician B
   3. Both A and B
   4. Neither A nor B

 

4. Two technicians are threading a hole in a steel part. Technician A says to consult a tap drill chart to determine the proper-sized drill bit. Technician B says that the tap needs to be lubricated when cutting threads. Who is correct?
   1. Technician A
   2. Technician B
   3. Both A and B
   4. Neither A nor B

 

5. Two technicians are about to measure runout on a rotating surface. Technician A says to use a micrometer and telescoping gauge. Technician B says to use a Vernier caliper. Who is correct?
   1. Technician A
   2. Technician B
   3. Both A and B
   4. Neither A nor B

 

6. Technician A says that files are made to be used without handles. Technician B says that thread files are used for cutting threads in new holes. Who is correct?
   1. Technician A
   2. Technician B
   3. Both A and B
   4. Neither A nor B

 

7. Technician A says that a Vernier caliper is a precision measuring tool if used properly. Technician B says a Vernier caliper can measure outside diameter, inside diameter, and depth. Who is correct?
   1. Technician A
   2. Technician B
   3. Both A and B
   4. Neither A nor B

 

8. When using tools in the shop, Technician A says a safe attitude will help you avoid accidents. Technician B says that whereas tools are a technician’s best friend, if used improperly, they can injure or kill you. Who is correct?
   1. Technician A
   2. Technician B
   3. Both A and B
   4. Neither A nor B

 

9. Technician A says that a roll bar is sharply curved on one end and tapered to a dull point on the other end. Technician B says that metal gasket scrapers should be used on aluminum surfaces. Who is correct?
   1. Technician A
   2. Technician B
   3. Both A and B
   4. Neither A nor B

 

10. Technician A says that a beam-style torque wrench tightens the bolt automatically by itself. Technician B says a digital torque wrench usually gives an audible signal when it reaches the preset torque. Who is correct?
    1. Technician A
    2. Technician B
    3. Both A and B
    4. Neither A nor B

 

Assignments

• Review all materials from this chapter and be prepared for a chapter quiz to be administered (date to be determined by instructor).
• Direct students to read the next chapter in Fundamentals of Automotive Maintenance and Light Repair, Second Edition, as listed on your syllabus to prepare for the next class session.

Chapter 05

Vehicle Service Information and Diagnostic Process

 

Learning Objectives

After reading this chapter, you will be able to:

• 5-01 Utilize information systems.
• 5-02 Identify vehicle information.
• 5-03 Complete a repair order.
• 5-04 Explain strategy-based diagnosis and the 3 C’s.

 

Readings and Preparation

• Review all instructional materials, including the chapter in Fundamentals of Automotive Maintenance and Light Repair, Second Edition, and all related presentation support materials.

 

Support Materials

• Lecture PowerPoint presentation, including all Skill Drills

 

Pre-Lecture

• You Are the Automotive Technician
  • A progressive case study that encourages critical thinking skills.
  • Direct students to read the “You Are the Automotive Technician” scenario found at the beginning of each chapter.
  • Group Activity: Direct students to review the discussion questions at the end of the scenario and prepare a response to each question. Facilitate a class discussion centered on the questions.
  • Homework Assignment: Ask students to turn in their comments on the questions.
• Teaching Tip: Explain to students how this material applies to the workplace. Provide an example of a situation to make it relevant and meaningful. How does it fit into the broader picture? Is it building on something they already know? Will it help them master a skill? Students need to understand that what we are teaching is of importance on the job. This is pretty easy to do with service information, vehicle information, repair orders, and the diagnostic process. Give students some real world examples of both positive and negative scenarios to help them see the relevance of this content.

 

Lecture

5-01 Utilize information systems.

 

• Modern vehicles have complex computer-controlled systems that allow them to have more built-in features.
• Having complete and accurate vehicle and service information is critical to performing any service or maintenance-related task.
• Various sources of information are increasingly available online and can also be obtained through books and manuals.
• The owner’s manual contains warranty and service information, an overview of the controls and features of the vehicle; proper operation and maintenance procedures; and some technical specifications, such as fuel, lubricant, and coolant capacities.
• Shop manuals may be produced by the vehicle manufacturers or by independent companies and specify the procedures to maintain, repair, and diagnose specific vehicles.
• Information in shop manuals is systematic, identifying special tools, safety precautions, and specifications relevant to the task. Information is organized according to vehicle systems.
• Service information programs can be used to gather the same information, are easier to search, and can provide additional resources such as illustrations, photos, and charts.
• Technical service bulletins (TSBs) issued by manufacturers provide information to technicians about unexpected problems, updated parts and changes, or updates to repair procedures.
• Service campaigns and recalls are conducted either mandatorily or voluntarily when a safety issue is discovered with a particular vehicle.
• Labor guides list how much time is required for a standard or warranty-related service or repair and can be used to give the customer a cost estimate.
• Parts programs are electronic versions of parts manuals and contain diagrams of each part in an assembly along with a part number.

5-02 Identify vehicle information.

 

• Vehicle identification numbers (VINs) are unique serial numbers assigned to every vehicle produced.
  • Used to determine the service and ownership history of the vehicle
  • Inscribed on major vehicle parts so they can be uniquely traced back to a specific vehicle
• Information labels fitted to the vehicle to provide easy access to information:
  • Tire inflation pressures
  • Vehicle weight and load-carrying capacity
  • Emission calibrations
  • Engine coolant requirements
  • Air-conditioning refrigerant type and quantity
• The VIN is 17 characters, usually located behind the front left corner of the windshield, and is of one of two standards—the North American VIN system or the ISO Standard 3779.
• The characters in the VIN refer to information such as the country of manufacture, the manufacturer, and the type of vehicle.
• The production date code is usually located on the driver’s side door pillar (B pillar) and listed as Date of Manufacture or Manufacture Date.
• The vehicle emission control information (VECI) label is usually located inside the engine compartment and includes information such as engine specifications and certification.
• The vehicle safety certification (VSC) label is located on the driver’s side door pillar, or on the side of the door next to the pillar, and provides information such as the month and year of manufacture, gross vehicle weight rating, and sometimes tire information.

5-03 Complete a repair order.

 

• A repair order includes customer and vehicle details, a record of the customer’s concerns, the cause of the concern, the correction for it, the hours of labor, and parts used.
• Repair orders are legal documents and should be stored safely, whether they are paper or electronic repair orders.
• The repair orders contain various sections that need to be filled out appropriately: customer, vehicle, requested service, parts, and accounting.
• The service history is a complete list of all servicing and repairs that have been carried out on a vehicle and can provide valuable information to the technicians conducting repairs.
• Manufacturers usually store all service history performed at their dealerships on a corporate server, which can be accessed from any of their dealerships, and use this to evaluate warranty claims.

5-04 Explain Strategy-Based Diagnosis and the 3 C’s.

 

• Diagnosis of problems can be hard to perform in a timely and efficient manner, and a proven plan can greatly simplify the process of strategically solving problems.
• Strategy-based diagnosis involves the following steps:
  • Verify customer concern
  • Research possible faults
  • Focused testing
  • Perform repair
  • Verify repair
• A record of the repair is required to inform the customer about the work performed as well as warranty and other liability issues.
• Information recorded on the repair order is based on three C’s:
  • Concern
  • Cause
  • Correction
• This provides a summary of the repair and needs to be as short as possible, yet contain all the information needed to understand what is included.
• Concern is the description of the customer’s understanding of the problem; it is written by the service advisor once a clear understanding of the problem has been gained.
• Cause is the actual fault causing the concern as diagnosed by the technician.
• Correction is the description of what is needed or what was performed to fix the customer’s documented concern.

 

Post-Lecture

This section contains various student-centered end-of-chapter activities designed as enhancements to the instructor’s presentation. As time permits, these activities may be presented in class. They are also designed to be used as homework activities.

 

1. Direct students to read and individually answer the question sets located in the Wrap-Up section at the end of each chapter. Allow approximately 10–20 minutes for this part of the activity
2. Facilitate a class review and discussion of the answers, allowing students to correct responses as may be needed. Use the answers noted in the Answer Key to assist in building this review.
3. You may wish to ask students to complete this activity on their own and turn in their answers on a separate piece of paper.

 

Review Questions

This question set is designed to assist students in understanding the chapter content by asking knowledge-based comprehension questions.

 

1. Owner’s manuals contain important information about a vehicle. Which item can be found in the owner’s manual?
   1. A list of common faults
   2. Engine rebuilding specifications
   3. Maintenance information
   4. Emission control diagnosis

 

2. Shop manuals are broken into sections based on the vehicle systems. Which section would contain information on replacing the water pump?
   1. Engine system
   2. Diagnostic procedures
   3. Electrical systems
   4. Fluids and capacities

 

3. A vehicle has after-market wheels with wheel locks. When looking up the removal time in a labor guide, how would it be listed?
   1. Hazard time
   2. Optional time
   3. Standard time
   4. Additional time

 

4. The vehicle identification number is essential to determine what options are on a vehicle. What else can the VIN provide?
   1. Engine identification
   2. Mileage information
   3. Owner information
   4. Service location identification

 

5. The Vehicle Safety Certification certifies that the vehicle meets FMVS standards. What other information does the VSC typically identify?
   1. Fluid capacities
   2. Maintenance recommendations
   3. Tire inflation pressures
   4. Crash test certification

 

6. A repair order contains a great deal of information about the vehicle and the customer. What else can be found on the work order?
   1. Listing for other local shops
   2. Accounting and payment information
   3. Customer satisfaction survey
   4. Shop safety procedures

 

7. Which of the following is NOT a step in a strategy-based diagnosis process?
   1. Focused testing
   2. Perform the repair
   3. Verify the repair
   4. Substitute parts

 

8. Labor guides generally provide information on:
   1. repair specifications.
   2. standard or warranty-related repair time.
   3. service intervals.
   4. hourly rates for different shops.

 

9. The repair order is a legal document and may be used in court. What information is required on the work order to be legal?
   1. Date of vehicle purchase
   2. Dealership of original purchase
   3. Warranty history from other dealers
   4. Complete vehicle information

 

10. Many technicians use a consistent format, 3 C’s, for documentation of information on work orders. What do the 3 C’s represent?
    1. Correction, concern, comments
    2. Concern, cause, correction
    3. Customer, cause, concern
    4. Concern, correction, clear

 

ASE Technician A/Technician B Style Questions

This question set is designed to assist students in gaining a further understanding of and familiarity with ASE Technician A/Technician B questions.

 

1. Technician A says that in the past, service information was only listed in books. Technician B says that online service information is usually better because publishers can update it when needed. Who is correct?
   1. Technician A
   2. Technician B
   3. Both A and B
   4. Neither A nor B

 

2. Technician A says that scheduled service charts list specifications such as spark plug gap. Technician B says that scheduled service charts list the service required at various mileage intervals. Who is correct?
   1. Technician A
   2. Technician B
   3. Both A and B
   4. Neither A nor B

 

3. Technician A says that the VIN provides information related to seat restraints. Technician B says that the VIN can be used to check the service history for the vehicle. Who is correct?
   1. Technician A
   2. Technician B
   3. Both A and B
   4. Neither A nor B

 

4. Technician A says that a repair order contains information documenting the work performed on a vehicle. Technician B says that the repair order lists the steps a technician will need to follow to diagnose the vehicle. Who is correct?
   1. Technician A
   2. Technician B
   3. Both A and B
   4. Neither A nor B

 

5. Technician A says that looking at the vehicle service history can help diagnose a vehicle fault. Technician B says that service history can be found by looking it up in shop manuals. Who is correct?
   1. Technician A
   2. Technician B
   3. Both A and B
   4. Neither A nor B

 

6. Technician A says that a strategy-based diagnostic procedure means you only have to do one test to determine the problem. Technician B says that using a consistent process to diagnose a vehicle can simplify the diagnosis. Who is correct?
   1. Technician A
   2. Technician B
   3. Both A and B
   4. Neither A nor B

 

7. Technician A says to verify the repair is complete before returning the vehicle. Technician B says that the root cause of the problem should be determined. Who is correct?
   1. Technician A
   2. Technician B
   3. Both A and B
   4. Neither A nor B

 

8. Technician A says that a technical service bulletin may contain updated service or repair procedures. Technician B says that TSBs are only issued once the vehicle is out of warranty. Who is correct?
   1. Technician A
   2. Technician B
   3. Both A and B
   4. Neither A nor B

 

9. Technician A says to have a customer initial or sign the repair order if repairs are declined. Technician B says that if a customer authorizes repairs, document it on the work order. Who is correct?
   1. Technician A
   2. Technician B
   3. Both A and B
   4. Neither A nor B

 

10. Technician A says that the production date is the date the vehicle was manufactured. Technician B says that the model year may be different from the production date. Who is correct?
    1. Technician A
    2. Technician B
    3. Both A and B
    4. Neither A nor B

 

Assignments

• Review all materials from this chapter and be prepared for a chapter quiz to be administered (date to be determined by instructor).
• Direct students to read the next chapter in Fundamentals of Automotive Maintenance and Light Repair, Second Edition, as listed on your syllabus to prepare for the next class session.

1.https://mycareertech.com/v/z2yvpx/shop-and-personal-safety

2.https://mycareertech.com/t/z2yvpx/shop-and-personal-safety

please watch the safety video and then do the test, you must score a 100, no if no and and no buts, keep taking the test