COURSE OUTLINE (Page 1 of 9)

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1 Date form completed: 09/25/2016 (Page 1 of 9) Course Title: Automotive 2: Introduction to Maintenance Course Prefix & Number: AUTT 1120 Lecture: 8 Lab: 12 Credit Hours: 12 COURSE DESCRIPTION Skills students master include an understanding of basic theory and operation of engines, transmissions, and drivetrains including basic ignition systems, hydraulic principles, and related industry-established maintenance. Students perform brake rotor and drum resurfacing, study brake system components, and utilize a variety of testing equipment. COURSE REQUISITES: AUTT 1110 with a grade of C or better; or instructor approval - must be completed prior to taking this course. Recommended: MATH recommended either prior to or at the same time as this course, but not required. RATIONALE: This is the second in the series of six automotive repair courses. In this course, students learn how to perform basic maintenance and use industry standard equipment. Students are introduced to the theory of operation of powertrain systems. REQUIRED TEXTBOOK(s) and/or MATERIALS: Title: Edition: Author: Automotive Technology (MyAutoLab package) Current Halderman Publisher: Prentice Hall Materials: Electude software voucher, Safety glasses, approved clothing, steel toed shoes. Attached course outline written by: Al Cox Date: 09/25/2016 Reviewed/revised by: Kassie Nelson Date: 08/07/2018 Effective quarter of course outline: 17/FA Date: 09/25/2016 Academic dean (print): Scott Broady Academic dean signature: Scott Broady Date: 08/07/2018

2 (Page 2 of 9) COURSE PREFIX/NO: AUTT 1120 TITLE: Automotive 2: Introduction to Maintenance COURSE OBJECTIVES: Upon successful completion of this course, students will be able to: 1. Online testing for national certifications. 2. Describe theory of basic 4 stroke engine operation. 3. Demonstrate operation of basic ignition systems. 4. Explain theory of operation and perform replacement of timing belts and chains. 5. Demonstrate power flow through both manual and automatic transmissions. 6. Define the principles hydraulic theory as it pertains to transmissions. 7. Perform driveline services and adjustments. 8. Perform differential services and light repair. 9. Perform minor engine services and minor repair. 10. Identify the different types of braking systems in use. 11. Drum Brake diagnosis and repair 12. Disc brake diagnosis and repair. 13. Properly machine a brake drum and rotor to industry standards. 14. Miscellaneous (wheel bearings, parking brakes, electrical, etc.) diagnosis and repair. 15. Explain, identify, diagnose and repair Electronic Brake, Traction and Stability Control Systems. 16. Complete NATEF required documents to track student learning. TOPICAL UNIT OUTLINE with UNIT OBJECTIVES: Upon successful completion of these units, students will be able to: NOTE: the following items may be practiced in teams. When testing, each student must individually demonstrate mastery before moving forward to the next item except where indicated by an asterisk (*). On items where individual mastery may not be required, it may impact the student s grade and may limit the students progress or ability to use equipment. Sequence of learning may differ for each student. The sequence will be determined by the instructor. 1. Online testing for national certifications a. Sp/2 Online test must be current b. NC3* i. ProCut Oncar brake lathe ii. Vantage Pro 2. Describe theory of basic 4 stroke engine operation. a. Identify hybrid vehicle internal combustion engine service precautions b. Define the 4 strokes of Internal Combustion Engines (ICE) c. Name the parts of an ICE d. Analyze the relationships of ICE components 3. Demonstrate operation of basic ignition systems.

3 a. Identify the different types of ignition systems. b. Define the components of the different types of ignition systems. c. Explain the purpose of the different components. d. Analyze the relationship of the ignition system components. 4. Explain theory of operation and perform replacement of timing belts and chains. a. Explain the different types of ICE timing components. b. Describe the advantages and disadvantages of the different systems. c. Report the maintenance needs of the different systems. d. Perform timing belt and timing chain replacement on a trainer. 5. Demonstrate power flow through both manual and automatic transmissions. a. Explain the different methods of power transfer from the ICE to the transmission. b. Explain how clutches work c. Describe how torque convertors work. d. Analyze gear ratios. e. Demonstrate power flow through the gear ranges of a manual transmission. f. Demonstrate power flow through a planetary gear set. g. Identify the parts of manual, automatic and Constant Velocity Transmissions (CVT). h. Explain the function of bands, servos, clutches and one way clutches. i. Demonstrate the power flow through a Hybrid transmission using a classroom trainer. 6. Define the principles hydraulic theory. a. Define Pascal s Law. b. Apply Pascal s Law to vehicle systems of transmissions, brakes, power steering. 7. Perform driveline services and adjustments. a. Perform maintenance on the following: i. Manual transmissions ii. Automatic transmissions iii. Cooling systems iv. Power steering systems v. Brake systems vi. Differentials b. Analyze the powertrain systems for normal and abnormal wear. c. Describe the importance of routine maintenance on each system. 8. NC3 exams* (limited to 3 attempts per exam, non-resettable unless the class is retaken. May restrict students access to equipment if safety cannot be reasonably assured by the instructor) a. Procut on car brake lathe 9. Perform minor engine services and minor repair. a. Inspect engine assembly for fuel, oil, coolant, and other leaks; determine necessary action. b. Perform thermostat replacement. c. Perform cooling system pressure test. d. Perform cooling system pressure test. 10. Identify the different types of braking systems in use. a. Identify the differences between a front/rear and a diagonal split braking system. b. Explain why a diagonal braking system is used. c. Explain the difference between a combination and a 4-wheel disc braking system. 11. Drum Brake diagnosis and repair a. Diagnose poor stopping, noise, vibration, grabbing and pedal pulsation concerns. (Page 3 of 9)

4 (Page 4 of 9) b. Remove, clean, inspect and measure brake drum diameter and determine necessary action c. Refinish brake drum and measure final drum diameter. d. Remove, clean and inspect brake shoes and related brake hardware. e. Inspect wheel cylinders for leaks and proper operation and replace as necessary. f. Pre-adjust brake shoes and parking brake, install drums and do final adjustment. g. Install wheel and properly torque lug nuts. 12. Disc brake diagnosis and repair. a. Diagnose poor stopping, noise, vibration, pulling, grabbing, dragging, or pulsation concerns; determine necessary action. b. Remove and clean caliper assembly and inspect for damage and wear. c. Inspect and clean caliper mounting and slides. d. Remove, inspect and replace pads and retaining hardware. e. Lubricate and re-install caliper and hardware. f. Clean and inspect rotor thickness, variation and lateral run out. g. Remove and install brake rotor. h. Refinish rotor on vehicle, measure final rotor thickness and compare to specs. i. Refinish rotor off vehicle, measure final rotor thickness and compare to specs. j. Retract and re-adjust caliper piston on an integrated parking brake system. k. Measure brake pad wear, determine necessary action. l. Describe the importance of burnishing replacement brake pads. 13. Properly machine a brake drum and rotor to industry standards. a. Demonstrate how to measure drums and rotors using various measuring tools. b. Identify rotor and drum specifications to determine if machineable. c. Demonstrate lathe safety. d. Successfully machine a rotor and drum to industry standards. e. Explain how to properly use an on the car brake lathe. f. Demonstrate the proper use of the non-directional finish equipment. 14. Miscellaneous (wheel bearings, parking brakes, electrical, etc.) diagnosis and repair. a. Diagnose wheel bearing noise, shimmy and vibration concerns. b. Remove, clean, repack and install wheel bearings. c. Inspect parking brake cables and components for proper operation. d. Inspect parking brake operation and parking brake indicator light operation. e. Inspect operation of brake stop light system. f. Replace wheel bearing and race. g. Remove and re-install sealed wheel bearing assembly. 15. Explain, identify, diagnose and repair Electronic Brake, Traction and Stability Control Systems. a. ABS control units b. 2, 3, 4 channel ABS systems c. System actuators d. System sensors 16. Complete NATEF required documents to track student learning a. NATEF items included in this course: i. Research vehicle service information fluid type, internal engine operation, vehicle service history, service precautions, and technical service bulletins. AI-A-2 ii. Verify engine mechanical timing. AI-A-6

5 (Page 5 of 9) iii. Perform cooling system pressure and dye tests to identify leaks; check coolant condition and level; inspect and test radiator, pressure cap, coolant recovery tank, heater core and galley plugs; determine needed action. AI-D-1 iv. Identify causes of engine overheating. AI-D-2 v. Inspect, replace, and adjust drive belts, tensioners, and pulleys; Check pulley and belt alignment. AI-D-3 vi. Inspect and/or test coolant; drain and recover coolant; flush and refill cooling system; use proper fluid type per manufacturer specification; bleed air as required. AI-D-4 vii. Remove, inspect, and replace thermostat and gasket/seal. AI-D-7 viii. Inspect and test fan(s) (electrical or mechanical), fan clutch, fan shroud, and air dams; determine needed action. AI-D-8 ix. Perform oil pressure test, determine needed action. AI-D-9 x. Inspect auxiliary coolers; determine needed action. AI-D-11 xi. Inspect, test, and replace oil temperature and pressure switches and sensors. AI-D-12 xii. Research vehicle service information including fluid type, vehicle service history, service precautions, and technical service bulletins. AII-A-2 xiii. Diagnose fluid loss and condition concerns; determine needed action. AII-A-3 xiv. Inspect fluid level in a transmission/transaxle equipped with a dipstick. AII-A-4 xv. Inspect fluid level in a transmission/transaxle not equipped with a dipstick. AII-A-5 xvi. Diagnose transmission/transaxle gear reduction/multiplication concerns using driving, driven, and held member (power flow) principles. AII-A-10 xvii. Diagnose pressure concerns in a transmission using hydraulic principles (Pascal s Law). AII-A-12 xviii. Inspect for leakage; replace external seals, gaskets, and bushings. AII-B-2 xix. Drain and replace fluid and filter(s); use proper fluid type per manufacturer specification. AII-B-4 xx. Inspect, leak test, and flush or replace transmission/transaxle oil cooler, lines, and fittings. AII-C-2 xxi. Inspect, measure, clean, and replace valve body (includes surface, bores, springs, valves, switches, solenoids, sleeves, retainers, brackets, check valves/balls, screens, spacers and gaskets). AII-C-7 xxii. Research vehicle service information including fluid type, vehicle service history, service precautions, and technical service bulletins. AIII-A-2 xxiii. Check fluid condition; check for leaks; determine needed action. AIII-A-3 xxiv. Drain and refill manual transmission/transaxle and final drive unit; use proper fluid type per manufacturer specification. AIII-A-4 xxv. Diagnose clutch noise, binding, slippage, pulsation, and chatter; determine needed action. AIII-B-1 xxvi. Inspect clutch pedal linkage, cables, automatic adjuster mechanisms, brackets, bushings, pivots, and springs; perform needed action. AIII-B-2 xxvii. Check and adjust clutch master cylinder fluid level; check for leaks; use proper fluid type per manufacturer specifications. AIII-B-5 xxviii. Diagnose constant-velocity (CV) joint noise and vibration concerns; determine needed action. AIII-D-1 xxix. Diagnose universal joint noise and vibration concerns; perform needed action. AIII-D-2 xxx. Inspect, remove, and/or replace bearings, hubs, and seals. AIII-D-3

6 (Page 6 of 9) xxxi. Inspect, service, and replace shafts, yokes, boots, and universal/cv joints. AIII-D-4 xxxii. Check shaft balance and phasing; measure shaft runout; measure and adjust driveline angles. AIII-D-5 xxxiii. Clean and inspect differential case; Check for leaks; inspect housing vent. AIII-E1- xxxiv. Inspect and adjust differential case fluid level. AIII-E1-2 xxxv. Drain and refill differential case. AIII-E1-3 xxxvi. Inspect and replace drive axle wheel studs. AIII-E-3.1 xxxvii. Remove and replace drive axle shafts. AIII-E-3.2 xxxviii. Inspect and replace drive axle shaft seals, bearings, and retainers. AIII-E-3.3 xxxix. Identify and interpret brake system concerns; determine necessary action. AV-A-1 xl. Research vehicle service information including fluid type, vehicle service history, service precautions, and technical service bulletins. AV-A-2 xli. Describe procedure for performing a road test to check brake system operation including an anti-lock brake system (ABS). AV-A-3 xlii. Diagnose pressure concerns in the brake system using hydraulic principles (Pascal s Law). AV-B-1 xliii. Measure brake pedal height, travel, and free play (as applicable); determine needed action. AV-B-2 xliv. Check master cylinder for internal/external leaks and proper operation; determine needed action. AV-B-3 xlv. Remove, bench bleed, and reinstall master cylinder. AV-B-4 xlvi. Diagnose poor stopping, pulling or dragging concerns caused by malfunctions in the hydraulic system; determine needed action. AV-B-5 xlvii. Inspect brake lines, flexible hoses, and fittings for leaks, dents, kinks, rust, cracks, bulging, wear; and loose fittings/supports; determine needed action. AV-B-6 xlviii. Replace brake lines, hoses, fittings, and supports. AV-B-7 xlix. Fabricate brake lines using proper material and flaring procedures (double flare & ISO types). AV-B-8 l. Select, handle, store, and fill brake fluids to proper level; use proper fluid type per manufacturer specification. AV-B-9 li. Inspect, test, and/or replace components of brake warning light system. AV-B-10 lii. Identify components of hydraulic brake warning light system. AV-B-11 liii. Bleed and/or flush brake system. AV-B-12 liv. Test brake fluid for contamination. AV-B-13 lv. Diagnose poor stopping, noise, vibration, pulling, grabbing, dragging or pedal pulsation concerns; determine needed action. AV-C-1 lvi. Remove, clean, inspect, and measure brake drum diameter; determine serviceability. AV- C-2 lvii. Refinish brake drum and measure final drum diameter; compare with specification. AV- C-3 lviii. Remove, clean, inspect and/or replace brake shoes, springs, pins, clips, levers, adjusters/self-adjusters, other related brake hardware, and backing support plates; lubricate and reassemble. AV-C-4 lix. Inspect wheel cylinders for leaks and proper operation; remove and replace as needed. AV-C-5

7 lx. lxi. lxii. lxiii. lxiv. lxv. lxvi. lxvii. lxviii. lxix. lxx. lxxi. lxxii. lxxiii. lxxiv. lxxv. lxxvi. (Page 7 of 9) Pre-adjust brake shoes and parking brake; install brake drums or drum/hub assemblies and wheel bearings; perform final checks and adjustments. AV-C-6 Diagnose poor stopping, noise, vibration, pulling, grabbing, dragging, or pulsation concerns; determine needed action. AV-D-1 Remove and clean caliper assembly; inspect for leaks, damage, and wear to caliper housing; determine needed action. AV-D-2 Inspect caliper mounting and slides/pins for proper operation, wear, and damage; determine needed action. AV-D-3 Remove, inspect, and/or replace pads and retaining hardware; determine needed action. AV-D-4 Lubricate and reinstall caliper, pads, and related hardware; seat pads and inspect for leaks AV-D-5 Clean and inspect rotor and mounting surface; measure rotor thickness, thickness variation, and lateral runout; determine needed action. AV-D-6 Remove and reinstall rotor. AV-D-7 Refinish rotor on vehicle; measure final rotor thickness and compare with specification. AV-D-8 Refinish rotor off vehicle; measure final rotor thickness and compare with specification. AV-D-9 Retract and re-adjust caliper piston on an integrated parking brake system. AV-D-10 Check brake pad wear indicator; determine needed action. AV-D-11 Describe importance of operating vehicle to burnish/break-in replacement brake pads according to manufacturer s recommendations. AV-D-12 Check brake pedal travel with and without engine running to verify proper power booster operation. AV-E-1 Identify components of the brake power assist system (vacuum and hydraulic); check vacuum supply (manifold or auxiliary pump) to vacuum-type power. AV-E-2 Inspect vacuum-type power booster unit for leaks; inspect the check-valve for proper operation; determine needed action. AV-E-3 Inspect and test hydraulically-assisted power brake system for leaks and proper operation; determine necessary action. AV-E-4 lxxvii. Measure and adjust master cylinder pushrod length. AV-E-5 lxxviii. Diagnose wheel bearing noises, wheel shimmy, and vibration concerns; determine needed action. AV-F-1 lxxix. lxxx. lxxxi. Remove, clean, inspect, repack, and install wheel bearings; replace seals; install hub and adjust bearings. AV-F-2 Check parking brake system and components for wear, binding, and corrosion; clean, lubricate, adjust or replace as needed. AV-F-3 Check parking brake operation and parking brake indicator light system operation; determine needed action. AV-F-4 lxxxii. Replace wheel bearing and race. AV-F-6 lxxxiii. Remove, reinstall and/or replace sealed wheel bearing assembly AV-F-7 lxxxiv. Inspect and replace wheel studs. AV-F-8 lxxxv. Identify and inspect electronic brake control system components (ABS, TCS, ESC); determine needed action. AV-G-1 lxxxvi. Describe the operation of a regenerative braking system. AV-G-2

8 (Page 8 of 9) lxxxvii. Diagnose poor stopping, wheel lock-up, abnormal pedal feel, unwanted application, and noise concerns associated with the electronic brake control system; determine needed action. AV-G-3 lxxxviii. Diagnose electronic brake control system control(s) and components by retrieving diagnostic trouble codes, and/or using recommended test equipment; determine needed action. AV-G-4 lxxxix. Depressurize high-pressure components of an electronic brake control system. AV-G-5 xc. xci. xcii. xciii. Bleed the electronic brake control system hydraulic circuits. AV-G-6 Test, diagnose, and service electronic brake control system speed sensors (digital and analog), toothed ring (tone wheel), and circuits using a graphing multimeter (GMM)/digital storage oscilloscope (DSO) (includes output signal, resistance, shorts to voltage/ground, and frequency data). AV-G-7 Diagnose electronic brake control system braking concerns caused by vehicle modifications (tire size, curb height, final drive ratio, etc.). AV-G-8 Check electrical/electronic circuit waveforms; interpret readings and determine needed repairs. AVI-A-11 COURSE REQUIREMENTS and/or COMPREHENSIVE EVALUATION: Before a student may be allowed into the lab setting, the student must pass safety and item specific online and classroom training. Individual Mastery is defined as being able to perform the task, on their own, with minimal to no guidance from the instructor or team mates. Students are be evaluated on each item, mainly in a hands on setting, after the student has had time to practice both with the instructor and their team mates. Students may practice as many times as they deem necessary to feel comfortable enough to move to the examination phase. When a student is ready to be evaluated, the student should inform the instructor and instructor monitored evaluations begin. Students must show individual Mastery, to the instructor, of any required item, before moving on to the next item. Failing the Mastery examination, the instructor may give feedback to the student and designate a path for practicing before attempting Mastery again. Testing may not start over immediately. In some cases, the student may use video to demonstrate Mastery. Students must obtain instructor approval prior to attempting this submission method. Videos must be made in a college approve setting. Videos made at home or at an employer s work place will not be accepted or considered. Videos may be uploaded to the LMS by the student and evaluated by the instructor. It is the instructor s decision if the student can move forward before the task is evaluated. If the student fails to demonstrate Mastery by the video submission method, the student may need to go back and start the evaluation process over. COURSE OBJECTIVES/ASSESSMENT MEASURES: COURSE OBJECTIVES 1. Online testing for national certifications. Online test, SP/2, NC3 ASSESSMENT MEASURES 2. Describe theory of basic 4 stroke engine operation. Written or LMS assessment and hands on evaluation.

9 (Page 9 of 9) 3. Demonstrate operation of basic ignition systems. Written or LMS assessment and hands on evaluation. 4. Explain theory of operation and perform Written or LMS assessment and hands on evaluation. replacement of timing belts and chains. 5. Demonstrate power flow through both manual and Written or LMS assessment and hands on evaluation. automatic transmissions. 6. Define the principles hydraulic theory as it Written or LMS assessment and hands on evaluation. pertains to transmissions. 7. Perform driveline services and adjustments. Written or LMS assessment and hands on evaluation. 8. Perform differential services and light repair. Written or LMS assessment and hands on evaluation. 9. Perform minor engine services and minor repair. Written or LMS assessment and hands on evaluation. 10. Identify the different types of braking systems in Written or LMS assessment and hands on evaluation. use. 11. Drum Brake diagnosis and repair Written or LMS assessment and hands on evaluation. 12. Disc brake diagnosis and repair. Written or LMS assessment and hands on evaluation. 13. Properly machine a brake drum and rotor to Written or LMS assessment and hands on evaluation. industry standards. 14. Miscellaneous (wheel bearings, parking brakes, Written or LMS assessment and hands on evaluation. electrical, etc.) diagnosis and repair. 15. Explain, identify, diagnose and repair Electronic Written or LMS assessment and hands on evaluation. Brake, Traction and Stability Control Systems. 16. Complete NATEF required documents to track Written or LMS assessment and hands on evaluation. student learning.