Automotive Service Technician Level 2

Transcription

1 Automotive Service Technician Level 2

2 Automotive Service Technician Unit: A6 Customer Relations Level: Two Duration: 7 hours Theory: Practical: 7 hours 0 hours Overview: This unit of instruction is designed to help the Automotive Service Technician apprentice develop interpersonal skills that facilitate effective and positive interaction with customers and industry peers. Percent of Objectives and Content: Unit Mark (%) 1. Describe aspects of public relations and customer service. 40% a. Today s auto technician b. Effective public relations c. Professionalism d. Creating trust e. Listening skills f. Telephone etiquette g. Customer appreciation h. Use of appropriate language i. Positive attitude j. Your role as a professional 2. Describe basic communications principles and practices. 60% a. Types of communications Verbal Non-verbal communications Awareness of non-verbal codes Your own non-verbal vocabulary b. Factors influencing interpersonal communication Self-awareness Self-concept Self-esteem c. Interpersonal skills Assertiveness Supportiveness Feedback d. Small group interaction Small group characteristics Small group types 1

3 Panels Discussion groups Committees Group roles Task roles Maintenance roles Negative individual roles e. Small group interaction Conformity Cohesiveness Consensus Conflict *** 2

4 Automotive Service Technician Unit: B2 Engine Diagnosis and Repair Level: Two Duration: 42 hours Theory: Practical: 20 hours 22 hours Overview: This unit of instruction is designed to provide the Automotive Service Technician apprentice with the knowledge and hands-on skills required to diagnose and repair engine systems. Percent of Objectives and Content: Unit Mark (%) 1. Describe and perform the diagnosis and evaluation of engine problems. 16% a. Noises Piston slap Ring noise Piston pin knock Ring noise Rod-bearing noise Main or thrust-bearing noise Valve train noise Abnormal combustion noises Related accessory noises b. Cylinder balance Procedures for various fuel and ignition systems Evaluate results c. Vacuum tests Cranking vacuum test Idle and running test Restricted exhaust test Effects of valve train problems on vacuum readings d. Crankcase pressure testing Verification of PCV system operation Identification of cylinder sealing problems External oil leak diagnosis e. Compression tests Test preparation procedures (fuel and ignition system) Test procedures Interpretation of test results f. Cylinder leakdown tests 3

5 Procedures and precautions Interpretation of results g. Oil pressure tests Engine preparations Procedures and evaluations h. Cooling system: external leaks Visual inspection Pressure testing Black light dye i. Cooling system: internal leaks (procedures, precautions and evaluation of results) Pump gauge method Chemical method Cylinder pressure tests Coolant in engine oil Oil in cooling system Excessive steam discharge from exhaust Piston and combustion chamber corrosion Bearing failure 2. Describe and perform the removal and inspection of engine components. 25% a. Disassembly Precaution and procedures Procedures for removal of engine components and assembly b. Short block Block -Visual inspection (thread condition, cracks) -Cranks, pistons, rods -Connecting rods -Oil pump (visual inspection, measurement, pickup condition) Block measurements -Deck flatness -Cylinder wear (walls, bore inspection, bore surface finish) -Block warpage -Crack detection and inspection -Bearing bore condition and alignment Crankshaft -Visual inspection (includes: mounting flanges, threaded holes, crack detection) -Journal wear and abnormal bearing wear -Crankshaft warpage (alignment) Rod assembly -Connecting rod (alignment, bore condition, size and fasteners) Piston and pin -Visual inspection (cracked skirt, ring groove wear and damage) -Measurement c. Cylinder heads Removal procedures Disassembly procedures and precautions (component inspection and evaluation, wear and damage of components) Visual inspection; physical damage (warpage, cracks) d. Valve train and camshafts (inspection and testing) Visual inspection general Disassembly procedures Bearing wear Journal and thrust wear 4

6 Valve train components: rocker arm assemblies (wear points: valve stem and pushrod; excessive clearance; loose mounting stud and bolt; plugged oil feed) Valve train components: pushrods (bent, grooves and tip wear, nicks and grooves at ends) Valve train components: spring assembly (broken or damaged parts, proper tension and free length) Valve train components: broken and damaged retainers and keepers Valve train components - Lifters (wearing, scoring or pitting) - Excessive loading (mismatched valve springs, old lifters on new camshaft, new lifters on old camshaft) Valve train components - Camshaft warpage and alignment - Plugged oil feed - Correct cam lift (broken and damaged parts, lobe and lifter wear) e. Timing components Timing belt: check for wear and damage - Gear and tension - Pulleys and guides Timing chain Variable valve timing components 3. Describe and perform general cleaning procedures. 9% a. Chemical solvents: equipment and procedures Chemical cleaning machines Soak tanks Hot spray tanks Citrus chemicals, salt baths b. Thermal cleaning c. Abrasive cleaning: abrasive blaster and parts tumbler d. Usage and precautions: aluminum oxide, sandpaper or cleaning discs e. Vibratory and ultrasonic cleaning 4. Describe the service operations of key engine components. 6% a. Cylinder head Warpage repair procedures (straightening, resurfacing) Crack repair; furnace and TIG welding Valve guide service procedures Valve seat service procedures Valve service procedures b. Cam bearings Removal and replacement: procedures and equipment Overhead cam bearing bore reconditioning procedures c. Block Short block service equipment - Line boring or honing - Deck resurfacing, cutters, grinders and sanders - Cylinder (integral and liner) - Cylinder service (ridge removal, deglazing, boring, honing) Crankshaft - Service equipment - Grinding, cutting, polishing - Straightening, welding - Balancing Connecting rod service equipment 5

7 - Straightening connecting rod aligner (bend, twist) - Resizing (grinder and precision hone) Piston, pin and ring service equipment Camshaft - Service equipment - Straightening, grinding, cutting, polishing 5. Describe and perform assembly of short block components. 11% a. Plugs, block heaters, oil gallery plugs Sealing and fastening procedures and precautions b. Piston clearance c. Main bearing clearance Crank end play d. Ring side clearance e. Ring end gap and ring placement (staggering) f. Installation of pistons Connecting rod clearance Connecting rod side play g. Oil pump clearance (internal) h. Camshaft installation Avoidance of damaging bearings Adequate clearance between camshaft gear and backing plate Installation of timing chains and belts 6. Describe and perform assembly of valve train components. 11% a. Valve stem height b. Valve spring installed height c. Cam assembly and prelube d. Valve clearance adjustment (OH cam) 7. Describe and perform cylinder head installation. 11% a. Preparation, procedures, precautions b. Cam and auxiliary shaft timing procedures c. Valve clearance adjustments 8. Describe and perform engine installation, adjustments, startup and break-in. 11% a. Proper engine alignment b. Cooling system filling and bleeding c. Static timing adjustment d. Prelube oil system e. Fuel system precautions f. Proper startup procedures g. Final inspection *** 6

8 Automotive Service Technician Unit: D1 Vehicle Suspension Level: Two Duration: 21 hours Theory: Practical: 11 hours 10 hours Overview: This unit of instruction is designed to provide the Automotive Service Technician apprentice with the knowledge and skills required to understand, diagnose, repair and service vehicle suspension systems. Percent of Objectives and Content: Unit Mark (%) 1. Describe suspension system fundamentals. 10% a. Hook s Law b. Centre of gravity c. Centrifugal force d. Inertia e. Levers f. Friction Static Kinetic Coefficient g. Characteristics of suspension materials Spring steel Tempered steel Synthetic rubber Fibre composites Pneumatics and hydraulics 2. Describe suspension system types. 10% a. Independent b. Semi-independent c. Solid axles 3. Describe suspension system components. 20% a. Frames and chassis types Unitized body Full frame Axles, control arms, coil and leaf springs 7

9 b. Spring types Coil Leaf Torsion bar Air springs c. Shock absorbers d. Ball joint e. Control arms and bushings f. Stabilizers Radius rods Strut rods Track bars 4. Describe electronically controlled suspension systems. 10% a. Computer-controlled suspension components Compressor Sensors Electronic shock absorbers Electronic struts Computer control module Electronic leveling control 5. Perform inspection and testing procedures on suspension system components and subassemblies. a. Appropriate safety procedure b. Suspension systems Visual inspection Trim height Corrosion Abnormal noises c. Springs Spring condition and deflection Corrosion Abnormal noises d. Shock absorbers and struts Leaks Action Attachment e. Ball joints Radial check Axial check Inspection of wear indicators f. Perform suspension system inspection Control arm bushing Control arm sag Tires and rims Hubs and bearings 25% 6. Perform the servicing of suspension components. 25% a. Removal and replacement of coil springs McPherson struts 8

10 SLA Modified struts b. Removal and replacement of shock absorbers c. Adjusting and replacing torsion bars d. Control arms and bushings Ball joints and kingpins e. Strut rod and trackbar bushings f. Sway bar bushings and linkages g. Gas struts Strut mounts Bearing plates h. Servicing electronic suspension components Air compressor Charger Mounting brackets Height sensors Air springs Air lines and connections *** 9

11 Automotive Service Technician Unit: D2 Steering Gears (Power and Manual) Level: Two Duration: 28 hours Theory: Practical: 14 hours 14 hours Overview: This unit is designed to provide the motor vehicle body repair apprentice with an overview of stationary glass. Topics will include: describing characteristics of stationary glass, structure/integrity of stationary glass, determining if to repair or replace stationary glass, installation methods, the use of components, accessories, tools, and equipment in replacing stationary glass, removal and installation of stationary glass, and detecting leaks around stationary glass. Percent of Objectives and Content: Unit Mark (%) 1. Describe steering column construction, operation, and service. 10% a. Purpose of steering column b. Steering column components Steering wheel Lower and upper covers Driver s airbag safety precautions Manual and automatic transmission column shift Emergency flasher control, turn signal switch, ignition key, lights, horn, windshield wipers and washers, anti-theft transmission lock Steering coupler and u-joints c. Variations in steering column design Fixed column Telescoping column Tilt column Modular column 2. Describe the operation and perform the servicing of manual steering gears. 10% a. Purpose of manual steering gear b. Recirculating ball c. Rack and pinion d. Dismantling, inspection, reassembly and adjustment of manual steering gears 3. Describe power steering systems fundamentals. 10% a. Hydraulic principles b. Hydraulic fluids 10

12 4. Describe the construction of power steering systems. 10% a. Power steering pumps Gear Vane Roller Slipper b. Power steering lines, hoses and coolers c. Control valves Pressure relief Flow control Rotary spool directional control valve Axial spool directional control valve 5. Describe the operation of power steering systems. 10% a. Integral piston system b. Power-assisted rack and pinion system c. Variable-effort steering control 6. Perform diagnosis and repair of power steering system. 50% a. Pumps b. Racks c. Lines d. Hoses e. Control valves f. Checking and adjustment of drive belt tension g. Dismantling, inspection, reassembly and adjustment of integral power steering system assembly *** 11

13 Automotive Service Technician Unit: D3 Steering Linkage and Geometry Level: Two Duration: 21 hours Theory: Practical: 13 hours 8 hours Overview: This unit of instruction is designed to provide the Automotive Service Technician apprentice with the theoretical and hands-on skills required to diagnose and repair steering linkage and geometry. Percent of Objectives and Content: Unit Mark (%) 1. Describe the operation and service of steering linkage. 60% a. Parallelogram steering linkage Linkage placed behind vs. front-of-wheel suspension Pitman arm (wear vs. nonwear) Idler arm Steering links b. Rack and pinion steering linkage Design and construction of rack vs. pitman arm / idler arm / centre link 2. Perform inspection and testing procedures on steering linkage components 24% a. Visual inspection b. Steering component integrity Excessive steering wheel play Tie rod wear Idler arm wear Pitman Pully and drifting Shimmy 3. Remove and replace steering linkage. 16% a. Pitman arm b. Idler arm c. Tie rods (inner, outer and sleeves) d. Steering linkages e. Steering dampers *** 12

14 Automotive Service Technician Unit: D4 Wheel Alignment Level: Two Duration: 35 hours Theory: Practical: 14 hours 21 hours Overview: This unit of instruction is designed to provide the Automotive Service Technician apprentice with the knowledge and skills required to perform wheel alignments. Percent of Objectives and Content: Unit Mark (%) 1. Describe wheel alignment theory, angles and suspension geometry. 16% a. Centre of gravity b. Decimals, fractions, negative fractions c. Metric d. Centrifugal force e. Vehicle alignment angles and measurements Caster Camber Toe Steering axis inclination Included angle Turning radius Ride height Thrust line Centre line Setback Track 2. Describe types of vehicle suspension alignment. 8% a. Two-wheel geometric centre line alignment b. Two-wheel thrust alignment c. Four-wheel thrust alignment d. Four-wheel geometric centre alignment 3. Describe wheel alignment adjustments and procedures. 8% a. Shim adjustments b. Eccentric adjustments c. Strut rod adjustments 13

15 d. Elongated holes (slots) 4. Describe operation of alignment equipment; perform inspection, diagnostic procedures and alignment angles. a. Operating procedures of alignment equipment b. Suspension component checks Visual Ride height Tire pressure Angles 38% 5. Describe and perform alignment procedures 30% a. Observations Equipment setup Alignment readings Specifications comparison Adjustment changes b. Vehicle alignment: adjustments and corrections Chassis trim height Rear wheels, camber and toe settings Front wheels, caster, camber, toe steering axis inclination and turning angles c. Diagnosis of steering and alignment complaints *** 14

16 Automotive Service Technician Unit: E3 Semiconductors, Cranking and Charging Systems Level: Two Duration: 54 hours Theory: Practical: 41 hours 13 hours Overview: This unit of instruction is designed to provide the Automotive Service Technician apprentice with the theoretical and hands-on skills required to diagnose and repair problems related to semiconductors, cranking and charging systems. Percent of Objectives and Content: Unit Mark (%) 1. Describe semiconductor design. 18% a. Semiconductor material Crystal material Sand silica or silicon Doping of silicon (adding phosphorus, boron, etc.) b. N-type semiconductor c. P-type semiconductor d. Diode construction Joining of P and N material Blocking and passing of current Design of electrical check valve Forward and reverse bias e. Diode types and applications Conventional diode Zener diode 2. Describe transistors. 18% a. Purpose and design Use in solid circuitry Change from a resistor to conductor Construction: joining of three semiconductor chips NPN PNP Bonding of chips Small wire attached to each type material b. Transistor connections Emitter 15

17 Collector Base c. Transistor operation d. Common types of transistors Signal transistor Power transistor 3. Describe common types of semiconductors. 8% a. Thyristors b. Hall-effect chip c. Piezo crystals d. Photonic semiconductors Light emitting diodes Photoresistors Fiber optics Solar cells Photodiodes Phototransistors 4. Define the purpose and fundamentals of cranking systems. 4% a. Cranking motors b. Control systems 5. Describe the design and operation of cranking motor circuits and drives. 4% a. Starter circuit Battery and cables Relay controlled cranking circuits Solenoid controlled cranking circuits Combination relay and solenoid-controlled cranking circuits Control circuits (starting safety switch) Antitheft (brief introduction) b. Cranking motors Motor components Gear reduction Permanent magnet type Positive engagement moveable pole shoe drive Series-wound Compound wound c. Cranking motor drives Over-running clutch 6. Describe the factors affecting cranking system operation. 4% a. Temperature b. Battery conditions and ratings c. Engine loads d. Oxidation and corrosion of connections e. Cable sizes and condition f. Excessive cranking time and overheating 7. Perform the inspection and testing of cranking motor circuits and drives. 13% a. Cranking system visual inspection 16

18 b. Battery load test (verification of capacity and performance to application) c. Cranking circuit voltage drop tests d. Cranking system current draw test e. Relay and solenoid tests Winding resistance Current draw f. Procedures for removing and replacing a cranking motor g. Disassembly and reassembly procedures on cranking motors h. Major component test and inspection of cranking motors Armature for shorts, opens, ground, alignment Field coils for shorts, opens, ground Pole shoes Bushings and bearings Brushes and springs Solenoids i. Cranking motor no-load tests (comparison of results to specifications) j. Importance of pinion to ring gear clearances for proper gear tooth contact k. Ring gear tooth inspection l. Engine cranking speed test 8. Describe the fundamentals of charging systems and control circuits. 4% a. Alternators (AC generators) b. Voltage regulation c. Factors affecting voltage and amperage output Battery condition and temperature Circuit condition Engine speeds Hysteresis 9. Describe the design and function of alternators, voltage regulators and charging systems. a. Charging systems by field control A type B type Computer controlled b. AC generator (alternator) construction Rectifier Diodes Stator Delta Wye Rotor -Field winding -Poles Brush assemblies -Bearings -Pulleys -End frame assemblies -Cooling fans c. Voltage regulators External electronic Internal electronic d. Indicators 17 11%

19 10. Describe and perform inspection and testing procedures on charging systems. 16% a. Visual inspection Belt tension and alignment Connections and wiring Battery and alternator capacity b. Charging system testing Battery load test Charging system current and voltage output test Regulator bypass test Diode tests Circuit and ground resistance c. Analyze test results d. Removal and replacement procedures precautions e. Disassembly and testing of components Rotor field tests Rectifier diodes Stator f. Alternator bench testing: output current *** 18

20 Automotive Service Technician Unit: E4 Principles of Ignition System Operation Level: Two Duration: 21 hours Theory: Practical: 21 hours 0 hours Overview: This unit of instruction is designed to provide the Automotive Service Technician apprentice with the knowledge and skills required to understand and diagnose a variety of ignition systems. Percent of Objectives and Content: Unit Mark (%) 1. Define the fundamentals and purpose of distributor-type and distributorless ignition systems and controls. a. Combustion burn time b. Engine load and spark timing c. Factors that affect ignition timing Engine speed, engine load, engine temperature, and altitude Air and fuel ratio (AFR) d. Distributor-type systems e. Distributorless ignition systems 50% 2. Describe the various types of ignition components. 50% a. Coils E-core and conventional Primary and secondary wirings b. Triggering devices Magnetic pulse generator Hall Effect device Optical device c. Spark timing advance mechanisms Mechanical Vacuum Computer-controlled d. Secondary voltage circuit High tension spark plug wires Spark plugs (construction) *** 19

21 Automotive Service Technician Unit: F2 Drive line, Differentials and CV Boots Level: Two Duration: 30 hours Theory: Practical: 15 hours 15 hours Overview: This unit of instruction is designed to provide the Automotive Service Technician apprentice with the knowledge and hands-on skills required to diagnose, service and repair problems related to drive lines, differentials and CV boots. Percent of Objectives and Content: Unit Mark (%) 1. Describe the fundamentals of drive line systems. 5% a. Relationship of drive shaft speed and balance b. Centrifugal force c. Linear and angular movement 2. Describe and identify the design and components of RWD drive line systems. 18% a. Housing types Integral b. Final drive Spur bevel Spiral bevel Helical Hypoid c. Gear set identification Hunting Non-hunting Partial hunting d. Differential assembly components Drive pinion and ring gears Differential pinions, side gears and pinion shaft -Limited slip differentials (clutch packs and brake cones) Pinion shaft e. Drive pinion mounting Straddle Overhung f. Universal joints Single Double-cardan g. Drive axles and retention 20

22 h. Axle shafts Live vs. dead axles Full floating ¾ floating Semi-floating - Loaded types - Viscous - Centrifugal Independently suspended axles Axle shaft bearings (radial vs. thrust loading) i. Lubricating oils and additives 3. Describe the operation of RWD drive line systems. 10% a. Drive shaft Slip yoke Multipiece driveshafts b. Fluctuation drive shaft speed c. Universal joints d. Final drive assemblies e. Differential assemblies (including limited slip) 4. Perform inspection, testing and disassembly procedures on RWD drive assemblies. a. Visual inspection b. Drive line angle measurements c. Drive line alignment d. Trim height and frame altitude e. Drive line phasing f. Drive assemblies: diagnosis of vibration and noise Worn, loose and damaged bearings Gear noise g. Differentials: diagnosis of noise Damaged differential gears and pinion shaft Excessive clearance between pinion and ring gear Excessive wear or loose and broken parts Loose parts striking together Vibrations or chattering around corner: clutch packs or cones h. Disassembly, inspection and reassembly Separation of shims, cups and caps Uniform torque and alignment while installing ring gear Timing marks used to align ring gears Adjustment of gear depth (shims), bearing preload Gear patterns and backlash Bearing damage Ring and pinion gears: excessive runout and side play Shim wear and damage i. Driveshafts and universal joints Analysis of various noises, roughness, vibrations, play Runout in drive shaft Excess undercoating, dents, missing weights on driveshaft Replacement of hanger bearings 22% 21

23 5. Describe and demonstrate the lubrication of RWD drive line system components. 2% a. Lubricating universal joints b. Venting service c. Final drive lubrication 6. Recondition or repair RWD drive line system components. 10% a. Final drive and differential assemblies Limited slip differential assembly (loading, unloading and locking type) Inspection of gear tooth contact pattern Inspection of pinion bearing preload adjustment Gear backlash Differential case bearing preload 7. Describe the design of FWD assemblies. 10% a. Front wheel drive axles Half shafts Constant velocity (inboard and outboard, fixed and plunge, ball-type) Bearings CV joint boots Vibration damper Torque steer: causes and solutions 8. Describe and perform CV joint inspection. 23% a. CV joint boot inspection and check Splits Cracks Tears Punctures Missing clamps Loose clamps Water contamination CV joint servicing tips - Avoidance of pulling on drive shaft - Torquing of hub nut - Avoidance of impact gun to remove or replace axle nut - Antilock brake care (speed sensors, tone ring, wires) - Rechecking of alignment Procedure for boot replacement - Manufacturers recommendations - Removal of axle - Removal of boot clamp - Mark on axle to position on shaft - Removal of circlip to separate the joint from shaft - Removal of old boot - Placement of new boot in proper location and clamp installation - Installation of new clip and clips - Installation of joint onto the shaft - Installation of entire grease package - Purging boot of air - Installation of boot and clamp b. Rationale for high temperature and use of special lubricant Heat generated in CV joint *** 22

24 Automotive Service Technician Unit: F3 Engine Clutches Level: Two Duration: 14 hours Theory: Practical: 14 hours 0 hours Overview: This unit of instruction is designed to provide the Automotive Service Technician apprentice with the knowledge required to diagnose and service engine clutches. Percent of Objectives and Content: Unit Mark (%) 1. Describe the fundamentals of push-type clutches and flywheel assemblies. 25% a. Clamping force b. Mechanical advantage (levers and hydraulics) c. Static and sliding friction d. Coefficient of friction e. Friction and heat f. Centrifugal force 2. Describe the design and operation of push-type clutches and flywheel assemblies. 25% a. Push-type (clutch assemblies) b. Disengagement c. Flywheel Pilot bushing Dual mass d. Pressure plate Coil spring plate assembly Diaphragm spring pressure plate assembly e. Clutch friction disc assembly Cushioning springs Hubs f. Release bearing and bearing support collar g. Clutch fork and pivot h. Clutch linkage Shaft and lever linkage Cable linkage Self-adjusting clutch Hydraulic clutch linkage i. Bell and clutch housings 23

25 3. Describe inspection, testing and diagnostic procedures on push-type clutches and flywheel assemblies. a. Visual inspection b. Test clutch and control operation c. Diagnose clutch condition Slippage Drag and binding Chatter Pedal pulsation Vibration Noises d. Lubrication practices e. Hydraulics f. Clutch and housing alignment and concentricity 25% 4. Describe repairs on push-type clutches and flywheel assemblies. 25% a. Manufacturers service literature b. Clutch maintenance Adjustment Lubrication c. Fluid levels d. Clutch service Removing clutch e. Machining practices f. Performance testing g. Failure analysis *** 24

26 Automotive Service Technician Unit: J1 Body and Trim Level: Two Duration: 7 hours Theory: Practical: 4 hours 3 hours Overview: This unit of instruction will help the Automotive Service Technician apprentice develop the knowledge and skills required to repair and service vehicle body and trim. Percent of Objectives and Content: Unit Mark (%) 1. Describe the purpose, construction, types and styles of various body and trim components. a. Weather stripping b. Adhesives c. Fasteners and retainers (trim related) d. Windows and regulators e. Interior and exterior trim 18% 2. Describe and diagnose body and trim part problems. 42% a. Wind noise b. Water leaks c. Dust d. Techniques to isolate and minimize squeaks and rattles 3. Perform inspection and adjustments. 25% a. Fit (water and dust tight) b. Appearance c. Noise allocation and repair d. Headlamp alignment e. Body panel alignment 4. Describe installation of body trim and components. 15% a. Carpeting b. Panels, upholstery, seats, hardware, chrome, moldings c. Procedures for moveable glass installation d. Smooth and leak free window operation e. Techniques for repair of water and dust leaks *** 25