1. Principles of Automotive Technology period 1 (Kingsville Independent School District)

Due: 10/11/2025

Tue, 07 Oct 2025 06:42:13 PDT

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.

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.
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.
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.

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.

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

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.

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.

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

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.

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

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

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

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.

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

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

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

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

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

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

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

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

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

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 10

Vehicle Maintenance Inspection

Learning Objectives

After reading this chapter, you will be able to:

10-01 Perform in-vehicle inspection.
10-02 Perform fluid inspection.
10-03 Perform belt, hose, and air filter/cabin air filter inspection.
10-04 Perform under-vehicle inspection.
10-05 Perform exterior vehicle inspection.

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. You can help them gain this understanding by describing vehicle damage you’ve seen that was caused by lack of proper maintenance.

Lecture

10-01 Perform in-vehicle inspection.

Inspection forms can be paper forms or electronic forms filled out on a tablet or computer that also allow technicians to include written notes and pictures.
In-vehicle inspections include instrument cluster and warning light checks, how the pedals feel and how the vehicle sounds, as well as horns and interior light functioning.
Changes in how the brake pedal travels or its resistance can indicate a problem in the braking system, whereas unusual noises could indicate a worn brake lining.
Instrument panel warning lamps can indicate faults with various systems on the vehicle.
The Onboard Diagnostic System II (OBDII) tests and analyzes each of the engine’s systems while the vehicle is being operated and will set and store diagnostic trouble codes (DTCs) if a fault is detected.
If the malfunction indicator lamp (MIL) is illuminated, retrieve any DTCs stored in the vehicle’s computer memory to determine which faults have been detected in the system.

10-02 Perform fluid inspection.

Component damage or failure is often caused by low fluid levels in the related system.
Fluids to be inspected include engine oil and coolant, brake fluid, power steering fluid, transmission fluid, and windshield washer fluid.
Most of the fluids in a vehicle get old and wear out, requiring replacement.
The engine oil level should be checked because if the level is too low, the oil pump will starve, and if the level is too high, the oil will be churned into foam by the crankshaft.
Low engine coolant levels indicate a leak to be repaired; the coolant’s freeze protection should be measured with a refractometer.
Brake fluid and power steering fluid need to be checked regularly; a dark color typically indicates a need to change them.
Transmission fluid has to be checked periodically to ensure it is at the correct level because if the level is too low, slipping and shift timing faults can result, whereas if it is too high, slipping clutches can result.
Diesel exhaust fluid is consumed over time and has to be replenished periodically.

10-03 Perform belt, hose, and air filter/cabin air filter inspection.

Engine drive belts, which operate accessories such as the water pump, power steering pump, air conditioner compressor, and alternator, typically need to be replaced at about five years of age.
The main types of accessory drive belts, the V-type and the serpentine type, must be periodically checked for cracks, oil soaking, glazing, tears, and bottoming out.
Radiator hoses and smaller heater hoses should be replaced if they bulge or if there is a difference in stiffness.
Air filters, mounted either on top of the engine or within the air induction system, have to be replaced when they become dirty.
Air filters should be checked for cracks or holes because dust and grit in the air will shorten the life of the engine.
The cabin air filter should be inspected during every service and replaced according to the manufacturer’s specified interval.

10-04 Perform under-vehicle inspection.

The under-vehicle inspection is required because major vehicle systems may not be accessible from above.
The inspection should focus on the tires, fluid level of the manual transmission or transaxle, differential fluid level, fluid leaks, suspension, engine, transmission, and exhaust.
Tires are checked for age, pressure, wear patterns, damage, and tread depth.
While diagnosing leaks, identify the fluid that is leaking. Also determine the cause and location of the leak.
Focus on wear and other types of damage in tie-rods and tie-rod ends, the idler arm, the pitman arm, and the steering gear or rack-and-pinion during the steering and suspension system inspection.
Drive axles and driveshafts should not have dents, cracks, or worn-out joints.
Torn or cracked mounts, coolant hoses, or belts, or looseness in the clutch mechanism indicates problems that need service.

10-05 Perform exterior vehicle inspection.

The vehicle’s exterior should be inspected visually each time it comes in for a service.
Shock absorbers and struts should not have wet-looking patches, noise or movement in the mounting, or excessive oscillation.
The exterior lighting system consisting of headlights, taillights, turn signals, side markers, brake lights, license plate lights, and back-up lights should be inspected to ensure all are in working condition.
Windshield wiper blades should not be missing, torn, damaged, or have loss of resilience in the material, and should typically be less than a year old.

Post-Lecture

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.
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.
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.

Most shops use inspection forms when inspecting vehicles because:
1. they slow the technician down.
2. they ensure a thorough and efficient inspection.
3. technicians are typically lazy.
4. technicians can’t write very well.

If the malfunction indicator lamp is illuminated while the vehicle is being operated:
1. shut the engine off immediately.
2. try revving the engine to see if the lamp goes off.
3. retrieve any DTCs with a scan tool.
4. step on the brake pedal very firmly for at least 10 seconds.

When checking engine oil, it is important that the level be:
1. between the minimum and maximum lines.
2. higher than the maximum line.
3. at least 1/4'' below the minimum line.
4. not touching the bottom of the dipstick.

What is the main reason that brake fluid needs to be changed periodically?
1. The boiling point increases too high.
2. It becomes too thin (viscosity).
3. It absorbs water (hygroscopic).
4. It ruins the brake lining.

When checking a serpentine belt for bottoming out:
1. use a straight edge across the belt ridges and measure the depth of the grooves.
2. twist the belt 90 degrees and see if cracks appear in the ridges.
3. measure the width of the belt to see if it has stretched too far.
4. use a small tool that should sit higher than the ridges in the belt.

A good way to test the integrity of exhaust pipes is to:
1. heat it up with a propane torch.
2. squeeze the pipe with arc joint pliers.
3. use a pry bar to see if the pipe will bend.
4. fill it with water and see if any leaks out.

How should you inspect an air filter to see if it needs to be replaced?
1. Wash it in the sink and see how water flows through it.
2. Use an air nozzle to blow air through it.
3. You can’t see light through it very well.
4. Air filters can’t be inspected; just replace them.

All of the following systems should be checked as part of an under-vehicle inspection, EXCEPT:
1. The steering system
2. The suspension system
3. The exhaust system
4. The electrical system

All of the following statements are true, EXCEPT:
1. The wiper blade should be flexible and not torn.
2. The wiper blades should be checked as part of an exterior inspection.
3. While checking, operate the wipers when they are dry.
4. Never bend the arms to make better contact with the windshield.

Which of these is normally reddish in color?
1. Engine oil
2. Brake fluid
3. Automatic transmission fluid
4. Gear lube

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.

Technician A says very wet fluid on struts or shocks is typically normal. Technician B says that shock absorbers can be tested with a bounce test. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Technician A says that improper handling of a windshield wiper can lead to a broken windshield. Technician B says that when testing wipers, even if they wipe cleanly, replace them anyway. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Two technicians are discussing steering system inspection. Technician A says to wiggle the front tires side-to-side while feeling for play in the joints. Technician B says that there are usually wear marks on the parts that indicate excessive movement. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Technician A says that when the engine is started, the amber anti-lock brake system (ABS) warning lamp should come on, stay on for a few seconds, and then go off, indicating a successfully completed preliminary self-check. Technician B says that if a fault is detected in the system, the warning lamp will blink five times. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Technician A says that coolant freeze protection can be measured with a hydrometer. Technician B says that coolant freeze protection can be measured with a refractometer. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Technician A says that operating the brake pedal can indicate a hydraulic brake problem. Technician B says that high-pitched scraping noises could indicate worn brake lining. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Technician A says the date code of the tire can be found on the tire sidewall. Technician B says the recommended tire pressure can be found on the tire sidewall. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Technician A says the cabin air filter can be inspected similar to an engine air filter. Technician B says the cabin air filter should be changed about every 4 or 5 years. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Technician A says that Stretch-Fit belts use a spring-loaded tensioner to keep them tight. Technician B says that a bottomed-out belt can be fixed by tightening it. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Technician A says diesel exhaust fluid helps to control oxides of nitrogen. Technician B says that diesel exhaust fluid should be replenished during oil changes. 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 11

Communication and Employability Skills

Learning Objectives

After reading this chapter, you will be able to:

11-01 Demonstrate active listening skills.
11-02 Demonstrate effective speaking skills.
11-03 Demonstrate employability skills.
11-04 Demonstrate effective reading and researching skills.
11-05 Demonstrate effective writing skills.

ASE Education Foundation Tasks

There are no ASE Education Foundation Automobile Accreditation Tasks covered in this chapter.

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 especially critical in the soft skills areas. That is an area where students need to know that their future boss is going to expect them to communicate like a reasonable adult and show up on time.

Lecture

11-01 Demonstrate active listening skills.

An active listener focuses all attention on the speaker, including verbal and nonverbal messages.
Barriers that can disrupt the listening process can include mental barriers or thoughts and feelings, such as assumptions, emotions, and prejudices, as well as physical barriers.
Flow of communication includes giving the speaker undivided attention and providing listening feedback.
Nonverbal feedback includes nodding while listening, gesturing while speaking, facial expressions, eye contact, and body posture.
Empathy means breaking down or putting aside existing mental barriers.
Verbal feedback includes validating or supporting statements.

11-02 Demonstrate effective speaking skills.

Speaking is a three-step process that involves thinking about the message, accurately presenting the message, and ensuring the message is correctly understood.
Thinking on your feet encompasses tactics such as relaxing, listening, and pausing when required.
The tone of voice indicates current emotional state, so even in disagreement, use empathizing statements before offering a solution.
Three kinds of questions can be asked: open questions which encourage people to speak freely, closed questions to establish facts and details, and yes-or-no questions to clarify.
Phone communication consists of three parts: greeting, exchanging messages, and finishing the call.
Giving and receiving clear, logical instructions means that the instructions should contain information about who, what, when, where, and why, and direction on how a task should be completed as well as clarifying questions to ensure the message is understood properly.
Developing a well-functioning team requires good leadership and followership skills as well as commitment to the team and its goals.

11-03 Demonstrate employability skills.

Typical employment requirements include being over 18 years, having a license and a clean driving record, and being drug and alcohol free.
Honesty, integrity, reliability, and quality are important requirements for a technician.
To look professional, ensure personal hygiene, wear clothing appropriate for the job, and keep a clean work environment.
Punctuality is an important nonverbal message in a business environment.
The quality of customer service influences people to buy products or services, so the customer satisfaction index (CSI) is an important tool to evaluate individual technicians and the entire service facility.
When working with customers, identify their greatest need, so you can serve them properly and keep customer satisfaction high.

11-04 Demonstrate effective reading and researching skills.

Interpreting written information, such as service information, technical service bulletins, emails, voicemails, and work orders, involves good reading comprehension.
The three common reading methods are selective reading, comprehending, and absorbing.
To use selective reading, skim through table of contents, index, introduction, headings, and the body of the text to find the required information.
To use the comprehending method of reading, pay attention to punctuation and structure of the sentences.
The absorbing reading method involves reading the information methodically, visualizing what is being said in written form, rereading if required, memorizing the pictured information, and reviewing the information regularly to retain it over time.
Research helps determine the real reason for a problem; look for information on how to resolve it and put together a diagnostic plan to find the solution.
Computer service information, shop manuals, aftermarket manuals, and owner manuals are good resources for information on vehicle systems and how to operate them; for example, the locations of major components and lifting points; vehicle care and maintenance; vehicle specifications; as well as diagnostic and repair information.
For troubleshooting, technical assistance on the phone or the Internet is available at a small fee, whereas other sources of information can include technical chat rooms and forums of the International Automotive Technicians Network.

11-05 Demonstrate effective writing skills.

Technicians fill out repair orders, which are legal documents that document their findings, conclusions, and any repairs undertaken.
Business letters need to be structured logically, be devoid of jargon, and to the point.
A work order should contain the customer’s concern, cause of such concern, and the action taken to correct it.
Safety inspection forms and defective equipment reports need to be completed on a regular basis with lockout or isolation tags being attached to such defective equipment.
An accident report should include: the date and time when the accident happened, the location where the accident happened, the name of the person who was injured, the name of any witnesses, the details of the accident, any first aid treatment provided, and any medical assistance rendered.
To complete a vehicle inspection report, inspect: fluids, belts, and hoses, steering and suspension system, brakes, drive line, fuel system, exhaust system, tires, lighting system, electrical system, visibility, seat belts, and the like.

Post-Lecture

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
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.
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.

The active listener should focus their attention:
1. on taking notes.
2. on formulating a response.
3. on the customer.
4. on customer posture.

When listening to a customer problem, how should the service advisor gather more information?
1. Research the situation on the Internet.
2. Tell the customer what you think the problem is.
3. Have the customer describe it to another service advisor.
4. Ask open-ended questions.

All of the following are types of questions, EXCEPT:
1. Sequential questions
2. Open questions
3. Closed questions
4. Yes-or-no questions

All of the following are steps in the speaking process, EXCEPT:
1. Think about the message.
2. Say the first thing that comes to mind.
3. Accurately present the message.
4. Check whether the message was understood.

When a shop hires a technician, one of the largest hurdles to overcome is:
1. lack of required tools.
2. the new technician is too young.
3. having a clean driving record.
4. reliable transportation.

Which method of reading is used when reading the instructions for a diagnostic test?
1. Selective
2. Comprehending
3. Absorbing
4. Reasoning

What is one of the most important tasks a technician performs on a daily basis?
1. Cleaning up the work area
2. Avoiding excessive breaks
3. Writing
4. Watching

When would selective reading be used?
1. When looking up a specification
2. When looking up diagnostic information
3. When reading a chapter in a textbook
4. When learning how a new system works.

When a technician encounters faulty equipment, what is the procedure for dealing with it?
1. Repair it
2. Use it till it breaks
3. Leave it until later
4. Lock out/Tag out

All of the following are employment requirements for a technician, EXCEPT:
1. Being drug and alcohol free
2. Having all of your ASE certifications
3. Having a clean driving record
4. Having honesty, integrity, reliability, and quality

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.

Technician A says a vehicle inspection form is used to bring needed repairs to the attention of the customer. Technician B says that by following an inspection form the technician can test all the components in a systematic way. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Technician A says that most people believe in nonverbal communication more than the actual words. Technician B says that verbal feedback is not important as long as eye contact is maintained. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Technician A says that it is OK to lose your temper while on the phone because the person can’t see you. Technician B says that if there is a need to keep a person on hold for an extended time, offer to call them back, and then do it. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Technician A says that with supporting statements, the service writer can demonstrate they understand, but want more information. Technician B says that with validating statements, the service writer can show empathy for the person speaking. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Technician A says that technical assistance hotlines send professionals to your shop to diagnose difficult problems. Technician B says that technical assistance hotlines can save a technician a lot of time when diagnosing difficult problems. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Technician A says that open-ended questions encourage people to speak freely, so you can gather insights and opinions. Technician B says that closed-ended questions will provide facts and details. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Technician A says that taking personal texts and phone calls during work is OK. Technician B says that showing up to work on time every day is an employability skill. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Technician A says that maintaining a professional hairstyle is an important employability trait. Technician B says that taking showers daily is an important employability trait. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Technician A says that repair orders are legal documents so they have to be filled out accurately and carefully. Technician B says that ensuring the repair order is well written, clear, and concise promotes a professional reputation. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Technician A says that what most information technicians have to read is written at a very high level. Technician B says that technicians spend a lot of time researching information. 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.

Due: 10/04/2025

Tue, 23 Sep 2025 12:22:14 PDT

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

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
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.
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.

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

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

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

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

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

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.

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

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

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.

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.

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

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

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

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

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

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

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

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

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

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 07

Power Tools and Equipment

Learning Objectives

After reading this chapter, you will be able to:

7-01 Identify and safely operate battery charging and jump-starting equipment.
7-02 Identify and safely operate air tools.
7-03 Use cutting and grinding tools.
7-04 Perform a solder repair.
7-05 Operate cleaning equipment.

ASE Education Foundation Tasks

There are no ASE Education Foundation Automobile Accreditation Tasks covered in this chapter.

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 how power tools and equipment can not only increase productivity, but also create safety issues.

Lecture

7-01 Identify and safely operate battery charging and jump-starting equipment.

Batteries are used in vehicles and rechargeable tools and extreme caution should be taken when working with or around them.
There are various types of battery chargers; fast chargers have a high current output and charge a battery quickly, whereas slow chargers have lower current output but put less stress on the battery.
Smart chargers use microprocessors that check and control the charging rate to ensure that the battery receives optimal charge, depending on its state.
Most motor vehicle batteries are 12 volts but store a lot of energy, making them very dangerous.
High voltage battery packs, such as those fitted to hybrid vehicles, can have operating voltages of 200 to 600 volts, creating a greater shock hazard.
Rapidly charging or discharging a lead-acid battery generates heat and hydrogen and increases the risk of distorting the plates inside the battery, even causing an explosion should they touch.
A battery is drained by any device that remains on when the engine is not running.
Slow charging a battery is preferable as it puts less stress on the battery and removing the negative battery terminal prevents any excessive voltage from the battery charger from being applied to the vehicle’s systems.
Using a memory saver or memory minder prevents loss of learned data and other information due to removal of the battery.
Batteries can be connected in series or parallel; when connected in series two 12-volt batteries have an output of 24 volts, whereas in parallel they have an output of 12 volts.
Jump-starting a vehicle is the process of using the electric energy from a vehicle with a charged battery to start a vehicle with a discharged battery.
This puts stresses on both vehicles as during cranking the battery, voltage falls very low, loading the alternator; when the vehicle stops cranking, the voltage shoots up quickly, which could potentially damage components in either vehicle.
Never attempt to jump-start a frozen battery.
It is better to allow the running vehicle to charge the drained battery for a few minutes before attempting to crank the engine.
Some jumper cables have a built-in or auxiliary surge protector, and jump boxes may be used instead of jumper cables to start a vehicle without the need for another vehicle.
When using a jump box it should be placed in a secure position away from belts and pulleys to prevent it from falling over when the vehicle starts.

7-02 Identify and safely operate air tools.

Air tools are lighter and more powerful than electric tools and have a lower risk of producing sparks and shocks.
Air tools have to be connected to an air hose, which can impede mobility, and are louder than their electric counterparts; they also require daily lubrication and regular maintenance.
The compressed air system is made up of a compressor, a pressure regulator, air hose or piping, and the tool being used.
The air compressor has a storage tank and is driven by an electric motor or gasoline engine.
Compressors may be of piston type or scroll type and a pressure regulator controls the air pressure supplied to the distribution system.
Compressed air can be dangerous at the pressures used in shops, so air equipment should be handled carefully
Air driers are used to remove the water compressed with the air from the atmosphere and may be standalone devices or incorporated into a filter regulator system.
A chiller type drier chills the hot compressed air and forces condensation to occur at a higher rate, removing all traces of moisture from the air.
Automatic oilers regularly supply small amounts of oil into the stream of compressed air, which is transported with the air to the tool or equipment.
Air tools have quick-connect fittings so that various tools can be used on the same air hose.
The air impact wrench or impact gun or rattle gun can be set to spin in either direction with a valve to roughly control the amount of torque it applies.
The air ratchet is used on smaller nuts and bolts, and once loosened spins them off much quicker than possible by hand.
It can also be used to install nuts and bolts, being reversible, and is useful in situations where space is restricted.
An air hammer or air chisel is useful for cutting and driving and is available with several bits, depending on the job.
An air drill can be used to drill holes, grind, polish, and clean parts and has a lower risk of producing sparks, which is particularly useful when working around flammable liquids or batteries.
It does not need a live electric cable or get hot with heavy use, like electric power drills.
A blowgun or air nozzle controls the flow of compressed air, using a lever or a valve, and is used to blast dirt and debris out of confined spaces.
Hydraulic presses generate many tons of force and are used to press fit or remove parts such as those designed with an interference fit.
They can be very dangerous to operate as they can cause components to shatter, or cause components that slip to be thrown great distances, or break and crush bones.

7-03 Use cutting and grinding tools.

Electric power tools present a shock hazard and should be inspected for frayed wires and missing ground terminals.
They should not be used in explosive environments or without proper training.
Cordless drills are more versatile, though limited by their power rating, whereas corded drills are used when moderate power or extended drilling is required.
Portable drills are sized according to their chuck size, which is usually marked on the body of the drill or chuck, along with the speeds at which it turns.
The chuck is tightened using a chuck key which has teeth that mesh with teeth on the chuck, or by hand in case of a keyless chuck.
Some portable drills have only two operating speeds whereas most have a variable speed rating that is determined by how far the trigger is moved.
A drill press is used for more accurate drilling with greater control, and it has a worktable with a vise to secure the job at a fixed angle to the drill bit.
The drill bit can be fed at a controlled rate and can be set to operate at different drilling speeds.
Morse taper is a system for securing drill bits to drills.
The shank of the drill bit is tapered and fits snugly into the drill spindle, which has a similar taper on its inner surface.
A multi-fluted tapered hole drill is used to enlarge a hole drilled in sheet metal and can be used to drill several sizes of holes, depending on how deep the bit is moved into the material.
A drilling speed chart is usually supplied with the drill press and compares drill sizes and metals to show the proper drill speed.
Lubricants help cool the cutting edge of the drill bit and lubricate it, with each metal requiring its own type of lubricant.
Power grinders are sized by the largest grinding wheel or disc that can be fitted to it, and they may be portable or fixed to a bench or pedestal.
A maximum safe operating speed is printed on grinding wheels and discs and should never be exceeded, as this could cause them to disintegrate.
Appropriate eye protection must be worn when using grinders, and all wheel guards and shields must be positioned correctly and firmly in place.
Grinding wheels come in grades from coarse to fine, depending on the size of the abrasive grains that are bonded together to make the wheel. They also range in hardness, depending on the material of the abrasive and bonding material.
An angle grinder uses discs rather than wheels and is used when the bench grinder is not appropriate.
During grinding, the face of the disc is used rather than the edge, causing a lot of noise and throwing sparks for a distance of several feet; hence, proper PPE should be used.
Straight grinders use conventional grinding wheels, though the wheel diameter is limited to 4.75 inches or 126 mm. In many cases the grinders have a long shaft that moves the grinding wheel away from the motor, making it easy to get into recessed areas.
Hand-held cutoff wheels are powered by air or electricity; they use a special thin grinding disc to cut and are useful for jobs that cannot be reached with a hacksaw.

7-04 Perform a solder repair.

Solder is a mixture of metals with low melting points and is used to join metals together; it may be made of tin and lead, tin and copper, or tin, copper, and silver.
Solder is a relatively soft compound and not used to make joints in situations where high stresses are involved.
In automotive applications, solder may come in the form of a wire and requires the use of an external flux cleaning agent of rosin if soldering electrical connections, or an acid if soldering non-electrical connections.
The solder can also be hollow with a rosin core or an acid core.
The process of soldering involves heating the metals so that the solder melts and fills the spaces between the metals, holding them together and transmitting electricity when used in electric circuits.
The temperature of the soldering operation is critical, as if it is too hot the solder can run off the joint and overheat electronic components and if not hot enough does not flow well or make good contact with the metal surfaces and tends to glob up.
A heat dam can be used to protect electronic components by absorbing some of the heat from the wires being soldered and preventing it from travelling to the components.
Heat is provided by an electric or butane soldering iron or gun, with basic soldering irons being manually heated and more sophisticated ones electrically operated with a thermostat to control tip temperatures.
Soldering irons can have a fixed tip size or interchangeable tips for different kinds of jobs.
A desoldering tool can be used to suck up melted solder being removed.
Heat shrink tubing or electrical tape can be used to protect soldered joints.

7-05 Operate cleaning equipment.

Pressure washers are powered by electric motors or gasoline engines fitted to high pressure pumps which take water at normal pressure and deliver it at a higher pressure of over 2000 psi or 13,790 kPa.
The cleaning gun may have a provision for detergent to be injected into the water stream or for the water to be heated, which helps remove accumulated dirt, grime, oil, and grease.
Pressure washers can be dangerous due to the high pressures they produce, and proper PPE should be used when working with them.
Spray wash cabinets spray high-temperature, high-pressure cleaning solution onto parts inside a sealed cabinet.
They are closed units and available in a variety of sizes to accommodate different-sized parts; they have a filtering system to reduce the frequency of cleaning solution changes.
Solvent tanks may have a pump that pushes solvent out of a nozzle that can be directed to the parts being cleaned, and a brush used to loosen the grease and grime.
Other solvent tanks are designed so parts can be immersed in them on racks or suspended from wires and soaked for a period of time.
They may have agitation systems or use heated cleaning fluid to speed up the process, and have circulation systems with filters to extend the life of the solvent.
Brake washers are used to wash brake dust from wheel brake units and their components, and are usually designed to operate at low pressures and use a variety of water-based cleaning agents.
Brake washers prevent brake dust from entering the shop environment by wetting down the dust on brake parts and washing it into the cleaning tray; a low-pressure air nozzle may be used to blow excess fluid from the components into a catch tray.
Sand or bead blasters use high pressure to blast small abrasive particles to clean the surface of parts, either in a specially designed cabinet or using a portable open-air blaster.
The sand or bead blaster cabinet has a hand-operated nozzle, a viewing port, and a foot-operated control switch with tough rubber gloves sealed into openings, allowing the technician’s hands to be protected while inside the cabinet.
Wet sand or bead blasters reduce the amount of dust produced during blasting.

Post-Lecture

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
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.
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.

When charging a battery, you should do all of the following EXCEPT:
1. Disconnect the negative battery terminal while charging.
2. Slow charge it if possible.
3. Charge a frozen battery to unfreeze it.
4. Use a memory saver to retain electronic memory settings.

When jump-starting a vehicle:
1. make the last connection to a good ground on the engine block.
2. connect the red jumper lead to the negative battery terminals.
3. make sure the bumpers on both cars are firmly touching.
4. connect the black jumper lead to the positive battery terminals.

Which of these is used for driving and cutting?
1. Air drill
2. Air ratchet
3. Air hammer
4. Air nozzle

All of the following are true about electric power tools EXCEPT:
1. They can be battery operated.
2. They should be lubricated daily.
3. They should be inspected for missing ground terminals.
4. They should never be used in explosive environments.

What should be done before using an impact wrench?
1. Add a few drops of air tool oil to the air fitting.
2. Fill the impact wrench with cooling fluid.
3. Install a standard chrome socket on the drive.
4. Wrap the socket with duct tape to prevent shattering.

When grinding metal on a bench grinder:
1. make sure there is no gap between the wheel and tool rest.
2. stand off to the side the entire time.
3. grind on both sides of the wheel.
4. stop and dip it regularly in the water pot.

Which solder should be used on electrical solder repairs?
1. Acid core
2. Rosin core
3. Solid solder
4. Hollow solder

After a solder repair is completed, how should the repair be protected?
1. No protection is required
2. Dielectric grease and RTV sealant
3. Heat shrink tubing with sealant
4. Duct tape

Which of the following is a true statement about spray wash cabinets?
1. They reduce the labor required to clean parts.
2. They use low-temperature, low-pressure cleaning solution.
3. They leave a dirty residue on the parts.
4. They are not sealed, so they can make a mess on the floor.

Pressure washers use a high-powered spray to remove dirt and grime from parts. All of the following are safety precautions EXCEPT:
1. Be careful where you point the nozzle.
2. Test the temperature of the wand before you pick it up.
3. Use of a cleaning agent requires referencing an SDS.
4. Use the pressure washer for getting grease off your hands.

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.

Technician A says solvent tanks may use flammable solvents or chemicals. Technician B says there must be adequate ventilation when using solvent tanks. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Technician A says when performing a brake job, it is acceptable to blow off the brake dust. Technician B says to use a brake washer to catch the brake dust for proper disposal.
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Technician A says that when soldering electrical wires, rosin flux must be used. Technician B says that a heat dam is used to prevent heat from traveling to the electronic component when soldering. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Technician A says to have a firm grip on an angle grinder when you turn it on to compensate for torque. Technician B says to check the area where the sparks are going to fly for flammables. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Technician A says that heat shrink tubing is used to protect a solder joint. Technician B says that a desoldering tool uses acid to remove solder. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

When using a bench grinder, if the protective guard is in the way, Technician A says that the guard may be removed. Technician B says that the guard is to protect the operator if the grinding wheel shatters. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Technician A says that air tools and equipment require regular application of lubricating oil to reduce wear and tear. Technician B says that some compressed air systems use an inline water trap that needs to be drained periodically. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Technician A says that when using an impact wrench, the maximum torque setting will provide the proper torque. Technician B says that impact wrenches are acceptable for taking up the looseness in a nut or bolt, but a torque wrench is required for final tightening. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Technician A says that after charging and reinstalling a vehicle battery, it is good practice to clean the battery terminals and posts. Technician B says that fast charging a vehicle battery extends its life. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Technician A says that when jump-starting a vehicle, a spark may ignite the hydrogen gas. Technician B says to use an engine ground away from the battery to minimize the possibility of an explosion. 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 08

Fasteners and Thread Repair

Learning Objectives

After reading this chapter, you will be able to:

8-01 Identify threaded fasteners.
8-02 Identify non-threaded fasteners.
8-03 Replace threaded fasteners.
8-04 Repair damaged fastener threads.

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 with fasteners. Share an experience with the hassle of removing a broken off fastener and the amount of time it added to the job.

Lecture

8-01 Identify threaded fasteners.

Bolts, studs, and nuts are threaded fasteners designed to clamp objects together.
The main groups that monitor and set the standards for fasteners are the American Society for Testing and Materials (ASTM), the International Organization for Standardization (ISO), and the Society of Automotive Engineers (SAE).
Fasteners can have either standard or metric threads and are designated based on their thread diameter, thread pitch, length, and grade.
Failure to use the proper fasteners for the application usually results in failure of the component.
Bolt grade indicates whether the fastener meets the strength requirements of that grade.
Bolt strength is measured using tensile strength, shear strength, proof load, fatigue strength, torsional strength, ductility, and toughness.
Nuts consist of locking nuts, castle nuts, and specialty nuts.
Washers, categorized as flat washers, lock washers, and star washers, need to match the grade of the corresponding nut or bolt, to maximize the clamping force on the component.
Screws include machine screws, self-tapping screws, trim screws, and sheet metal screws.

8-02 Identify non-threaded fasteners.

Non-threaded fasteners are used to hold bearings, U-joints, brackets, and other components in place, to prevent nuts from loosening up, or to retain a piece of trim.
Common types of non-threaded fasteners include snap rings, pins, circlips, e-clips, and clips.
Snap rings can be either internal or external types, to either hold a part in place or prevent the part from traveling beyond a certain point.
Pins used to retain parts include cotter pins, roll pins, and spiral pins.
Clips are designed to be installed quickly without great precision in placement and include push clips, Christmas trees, and plastic retainers.

8-03 Replace threaded fasteners.

Torque is the twisting force applied to a fastener by the torque wrench.
Torque charts typically specify bolt diameter, threads per inch, grade, and maximum torque setting for both dry and lubricated bolts and nuts.
Threaded fasteners are designed to be tightened to a specified torque, depending on the job at hand, the grade or hardness of the material they are made from, their size, and the thread type.
Threaded fasteners getting torqued go through the rundown phase, alignment phase, elastic phase, and plastic or yield phase.
Torque-to-yield, where a fastener is torqued to, or just beyond, its yield point, requires a torquing procedure called torque angle.

8-04 Repair damaged fastener threads.

The process of repairing a thread should start with attempting to remove the broken bolt without damaging the threads.
Causes of broken bolts include fasteners that are rusted or corroded in place, so both loosening and tightening the bolt may be required to remove it.
Heat can loosen bolts and can be applied either by an oxyacetylene torch or inductive heater.
Thread repair is used in situations where a thread is damaged and cannot be replaced easily. It can be done by either reshaping the threads or using a helical or sleeve-type thread insert.

Post-Lecture

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
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.
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.

What are the three groups that establish the standards for fastener specifications?
1. ISO, ASE, ASTM
2. ASTM, ISO, EIO
3. SAE, ISO, ASTM
4. SAE, EIO, ASE

How can a person distinguish a metric fastener?
1. Grade number on the head
2. Number of threads per inch
3. Hash marks on the bolt head
4. Color code on one side

What are the two main thread pitch designations used for SAE fasteners?
1. SAE, UAE
2. UNF, UNC
3. UNC, ISO
4. UNF, AST

Snap rings:
1. fit under nuts to spread out the clamping force.
2. are used to retain plastic trim pieces in a vehicle.
3. are threaded into place.
4. fit inside a groove.

When replacing a threaded fastener, where would you most likely find torque specifications?
1. Service manual
2. Owner’s manual
3. Go by rule-of-thumb
4. Another technician

When torqueing fasteners, it is critical to:
1. torque it well past its yield point.
2. lubricate the threads.
3. always use new bolts.
4. use the correct grade bolt.

Which threaded fasteners cannot be reused?
1. Torque-to-stretch
2. Torque–to-yield
3. Torque-to-specification
4. Dry torque fasteners

All of the following are ways to avoid breaking a stuck bolt, EXCEPT:

Use penetrating oil and let it sit for a while.
Try both tightening and loosening the bolt.
Use a breaker bar and just keep increasing the torque.
Use an inductive heater to heat the bolt up.

When using a thread insert:
1. a bolt of at least one size larger diameter will need to be used.
2. the hole will need to be drilled about twice as deep as the original.
3. a nut must be used to secure the thread insert in the hole.
4. the thread insert replaces the damaged internal threads.

All of the following can be used to remove a broken bolt, EXCEPT:

Use a new bolt to push the old bolt out.
Use a screw extractor.
Use a hammer and small center punch.
Use curved jaw channel lock pliers.

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.

Technician A says that a thread insert can be used to repair damaged internal threads. Technician B says a thread file may be used to repair lightly damaged external threads. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Technician A says to use heat to help remove a broken fastener. Technician B says that broken bolts mean the part must be replaced. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Technician A says that a grade-5 bolt has five hash marks on the head. Technician B says that the diameter of a bolt is measured across the outside diameter of the threads. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Technician A says when heating a broken fastener, induction heating works best. Technician B says the oxy-acetylene torch may cause damage to other components. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Technician A says torque angle means that a fastener is torqued to a specified torque and then turned a certain number of degrees further. Technician B says torque-to-yield bolts can be reused because they are made to stretch. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Technician A says fasteners should always be lubricated when tightened. Technician B says lubricating the fastener will change the clamp load of the fastener. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Technician A says non-threaded fasteners are designed to firmly clamp parts together. Technician B says a cotter pin is designed to be reusable. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Technician A says it is essential to wear safety glasses when working with snap rings. Technician B says that roll pins are typically used to hold one part to another. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Technician A says that lock washers are usually considered to be reusable. Technician B says washers are graded the same as nuts and bolts. Who is correct?
1. Technician A
2. Technician B
3. Both A and B
4. Neither A nor B

Technician A says a lower grade bolt can be used in place of a higher-grade bolt. Technician B says nuts used should be the same grade as the bolt. 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.

Due: 09/27/2025

Mon, 22 Sep 2025 06:40:58 PDT

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

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
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.
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.

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

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

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

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

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

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

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

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.

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

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.

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

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

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

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

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

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

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

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

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

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.

Due: 08/16/2025

Tue, 12 Aug 2025 15:35:16 PDT

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