Shop Orientation. Chapter Objectives KEY TERMS

Transcription

1 C H A P T E R 3 Shop Orientation Chapter Objectives At the conclusion of this chapter you should be able to: Identify the job requirements, routines, and housekeeping procedures for automotive technicians. Identify basic hand and power tools and the correct operation for these tools. Demonstrate safe operation of vehicle hoists and jacking equipment. Identify and locate vehicle identification information. Identify and complete a repair order and maintain customer and technician records. KEY TERMS above-ground lift air hammer Allen wrench ball-peen hammer battery charger bench grinders calibration decal chain of command combination wrench dead blow hammer emissions decal entry-level employee impact wrench in-ground lift multimeter parts washer pliers puller punches rubber mallet screwdriver service order sockets test lights Torx drives VIN vise

2 44 Chapter 3 Shop Orientation While the automotive lab is often designed to mirror working in a real repair facility as much as possible, some differences are worth noting. Automotive training classes typically perform limited types of services on real customers vehicles. This is because the program instructors seek to provide the right kind and amount of experience to help the students. This places limits on what actual repairs can be made by the students so that they are not overwhelmed or put into situations in which they are not comfortable in performing certain tasks. This is different from how many repair facilities operate, especially at new car dealerships, where the shop and its technicians are expected to be able to accommodate whatever services and repairs are necessary. Orientation Even if as a student you have prior experience working on vehicles or even working in a shop, there are going to be certain rules, procedures, and practices that you will need to learn for each shop in which you work. Orienting yourself to how a shop operates is necessary so that you become a productive and important part of the overall team. Part of shop orientation is to help the instructor(s) learn what experiences the students have. While it is always a bonus to have students who already have some experience, it is important for those students to be openminded about learning or relearning certain tasks. Just because you or other students in the class may have done automotive work in the past, does not mean that it was done correctly and to professional standards. One of the main goals of the program instructor is to teach you how to perform repairs safely and by the manufacturer s recommended service procedures. Even if you know how to perform a certain task more quickly by taking a shortcut, that does not mean it will always be the best way to do that particular job. In fact, shortcuts performed incorrectly can often lead to additional problems to fix. Lab and Shop Operations Working in an automotive lab is different from working in an actual full-service shop. This is because the automotive technology course focuses on training students safely and properly so that they may become productive technicians. Figure 3-1 shows a typical automotive training lab environment. In the full-service shop, the expectation is that the technicians will be able to make a profit for the business. Because of these different expectations, the lab and the shop, while sharing many similarities, will have some operating differences. Lab Operation. Many factors determine how a lab operates. Among these are location, student population, FIGURE 3-1 An example of a college automotive lab. physical facilities, equipment, and funding. Many automotive technology programs provide both classroom and lab-based instruction. Future technicians should expect to spend time in a classroom learning fundamental skills and theory. This classroom knowledge is then added to the hands-on education in service procedures and how the procedures apply to automotive repair. A classroom may be used to have large group discussions, demonstrations, and instruction. The lab is where students will learn to apply classroom concepts and acquire hands-on skills. For training purposes, there should be a good supply of vehicles on which the students can practice their hands-on skills. Vehicles may be owned by the school (Figure 3-2) or may consist of live work, meaning cars and trucks owned by customers who bring them in for service. Students should have adequate time to practice their skills before applying them to real-world vehicles, though. An auto tech lab will typically consist of classroom discussion or instructor demonstration followed by student practice. It is important for the students to have FIGURE 3-2 Students should learn on school owned vehicles to practice their skills before working on actual customer vehicles.

3 Chapter 3 Shop Orientation 45 the necessary time to be able to work with the parts and systems being taught so that students develop an understanding of the parts and how each works together in a system and within the scope of the entire vehicle. Additionally, you will spend time each day in the care and cleanup of the lab and equipment. In most repair shops, technicians are responsible for maintaining and cleaning their own areas. This means that floors, tools, and equipment are cleaned regularly, and workbenches are kept clean and orderly. Shop Orientation. A real-world repair facility will operate differently than an auto tech class and lab. The primary objectives in a teaching environment are safety and education. In a repair shop the primary goals are to service and repair vehicles as quickly and efficiently as possible and to make a profit. While there should be a real-world correlation between the auto course and the repair shop, there will be differences in how each operates. In a teaching environment, the instructor and school staff are the people in charge (Figure 3-3). The students are similar to the shop employees and may have some input in the operation of the lab, but probably not a large amount. Students have to live by a code of conduct, school rules, and shop policies. Violation of those rules can result in discipline and loss of privileges. In a shop, there may be the shop owner, store manager, general manager, or service manager who is in control of the operation. The employees may have varying degrees of input in the shop operation. One big difference between school and work is that violations of the shop rules and policies can result in the employee being fired. Most students who are enrolled in or have completed an auto tech program often start in a repair shop as an entry-level employee. This often means that, since that person is an unknown quantity to the employer, the new FIGURE 3-3 In an automotive class, students are expected to act as professionals. employee must first complete a probationary period. During this time, which can last from 30 to 90 days, the employee is closely monitored for punctuality, dependability, and initiative, in addition to the performance of service and repair tasks. Once the employee proves he or she is responsible and an asset to the shop, an increase in pay may follow. Do not expect to be hired immediately as an experienced technician, nor expect to be offered large amounts of money when you are just entering the field. Even though you may have experience over and above an auto tech program, that usually does not mean much at the beginning. The owner or manager of the shop is taking a risk each time a new employee is hired. A technician may talk the talk, meaning that it sounds like he or she is experienced and knowledgeable, but in reality, may not be. It takes time to demonstrate to the owner or manager that you can work safely, productively, accurately, and well with other employees. Daily Routines Most auto tech courses have some type of daily routine that students follow. These routines will vary depending on the time of day the class meets, how many students are in the class, and the facilities in which the learning takes place. Starting the Day. Typically, the day will start with classroom time for attendance, assignments, lectures, demonstrations, and other items that may need to be addressed. Lab time may be structured by assignments, objectives, or projects. The end-of-the-class time usually includes time to clean up and restore the lab and equipment. Daily shop routines may start with employee meetings, team meetings, and work assignments. Many shops require the technicians to be responsible for keeping their work bays cleaned and organized, so the day typically concludes with some cleaning and preparing for the next day. Clean Up. A clean shop is much easier to maintain, is more productive, and is more professional than a cluttered and dirty shop. Regardless of whether you are in a 50-year-old auto tech lab or a state-of-the-art repair facility, cleanliness is everyone s responsibility. Students and employees are responsible for maintaining their own areas (Figure 3-4). Start by making sure your tools and the shop s tools are clean, organized, and returned to the proper locations. When you are working as a technician, your tools are used to earn your income. To be more productive, keep your tools clean and organized. If you have to spend time rummaging around in a disorganized toolbox looking for

4 46 Chapter 3 Shop Orientation Clean up area 1 Clean up area 2 Bay 1 Quick service Bench, tools Bay 2 Bay 3 Bay 4 Bay 5 Machine room Last name begins with Trash A -C Sweep D - F Sinks G Tools H - P Hoses R - T Misc U - Z Cleaner Bay 6 Alignment Service manager Customer waiting Parts Clean up area 3 Clean up area 4 Electrical area Bench FIGURE 3-4 An example of a shop clean up plan. a tool, you are losing money by prolonging the job you are working on instead of completing it and moving on to the next job. Just placing the tool on top of the toolbox or bench in the toolroom is not the same as returning it to its proper place. Each tool should have a specific location where it is stored. In addition to your tools, keep your immediate work area clean and organized. This not only helps your productivity, it presents a positive, professional image to those around you. Chain of Command. In a repair shop, the chain of command may be as few as just two people or a half-dozen levels between the technician and the upper management. Regardless of the depth of the chain of command, it is important to understand who is responsible for what and to whom. A technician working in a new car dealership may have an immediate supervisor, such as a team leader, who reports to a shop supervisor, who reports to the service manager, who reports to the service director, who reports to the general manager. Even though you may only deal with your immediate supervisor on a day-to-day basis, it is important to know who is also in your chain of command in the event that your supervisor is absent for some reason (Figure 3-5). After you have been working in a position for a while, you may be placed in a supervisory position over new employees or even be in charge of their training. If you do supervise others, be sure to treat them with the same respect with which you treat your supervisor. Make sure that they understand the day-to-day operation of the facility and how to perform their jobs. Job Requirements The requirements and expectations for entry-level jobs differ from those for an experienced technician. Entry-Level Jobs. All technicians start out somewhere at the entry level. Entry level means starting in the lowest-paid position. In the automotive service industry, this can mean starting work in several different ways, including as a technician s assistant (Figure 3-6) or in new car preparation. Some shops start their entry-level workers by assigning them to a more experienced technician who oversees their work and helps them learn to function in their new job. This is called mentoring and is an excellent way to learn your new job and to learn from an experienced technician. Mentoring also provides a safety net of someone who watches over the work you perform. In many shops, new entry-level employees have very limited responsibilities for servicing vehicles; instead they are first used to help with getting parts, moving vehicles, shuttling customers to and from the shop, and performing housekeeping duties. This allows the employer to see how they perform doing mundane tasks and provides insight into their work ethic. An employee who shows up on time every day, does all that is asked, and shows initiative is considered an asset and will usually be given more and more responsibility. At some shops, particularly at new car dealerships, a new employee may start by being assigned to new car preparation, often called a predelivery inspection or PDI. This requires getting vehicles that have just arrived from the manufacturer ready for sale. Often the PDI

5 Chapter 3 Shop Orientation 47 General Manager/Owner Service Manager Parts Department Manager Service Department Manager Body Shop Manager Tech Tech Tech Tech Tech FIGURE 3-5 The chain of command may be simple or complex depending on your place of employment. What is important to know is who you report to and who to go to with any problems. FIGURE 3-6 Entry-level technicians are often given basic tasks and have the lowest pay in the shop until they prove themselves as dependable employees. technician is responsible for removing exterior and interior protective coverings, installing hubcaps, checking fluids and tires, washing the vehicle, and other similar jobs. Employers may use this entry-level job as a way to determine the character and work ethic of the employee. Once you prove you are a productive asset to the company, better opportunities may arise. It is possible that a newly hired entry-level technician will have to earn a position in the shop. Every new employee is a risk for the employer since there are so many unknown qualities about the person. Until the employee demonstrates acceptable work behaviors over a period of time, many shops will not risk putting that person into a service position. Moreover, while it is important for the new employees to want to demonstrate their work ethic and skills, it is very important not to be boastful, making claims of knowledge and experience that are not true. The employer wants and expects honesty. If you cannot perform a certain skill, you need to make sure your employer knows that ahead of time. Do not exaggerate your abilities because when it comes time to show what you can or cannot do, your claims of skills that you have not acquired will likely cause your employer to reevaluate you and your employment. Lifelong Learning. If you are serious about being an automotive technician then you need to accept the necessity of lifelong learning. This means that you are not done with school upon graduation. Once you are working in the industry, you will need to maintain your skills as cars and trucks change from year to year. To do so will require that you attend training classes (Figure 3-7) FIGURE 3-7 Staying in the auto industry means you will have to continually update your knowledge and skills as new vehicles and technology are released.

6 48 Chapter 3 Shop Orientation provided by your employer (if offered) or by locating and attending classes on your own. Technicians who are working in new car dealerships can take online training and can attend update classes at regional training centers. This is necessary so that the technicians are familiar with the new models, systems, and components that appear each year. Technicians who work for independent and national corporations also attend classes to remain current. Training is similar to adding tools to your toolbox. As you accumulate more tools, you can perform more types of repairs, which allows you to earn more money. Training is basically the same. The more knowledge you have, the more skilled you become and the more money you can make. Technicians who do not believe in investing in proper tools or training are fooling themselves and are placing significant limits on what they can accomplish. Technician Tools Technicians can accumulate thousands of dollars in tools, from the most basic screwdrivers and pliers to specialty tools with only one purpose. Regardless of quality or brand name, all technicians take proper care of their tools, cleaning and maintaining them on a daily or weekly basis. A tool that is broken or damaged can result in lost productivity for the technician and could even cause personal injury or damage to a vehicle. The basic tools found in a technician s toolbox (Figure 3-8) consist of the following: Wrenches the most common type of wrenches used today are the combination wrenches. Figure 3-9 shows examples of different types of wrenches used by auto technicians. These have an enclosed end called a box end for high-torque uses, such as FIGURE 3-8 A technician s tools are as important as the knowledge and skills he or she has. Taking care of your tools is a priority as a technician.

7 Chapter 3 Shop Orientation 49 Box end Combination wrench Open end FIGURE 3-9 Combination wrenches are still common technician tools. Many different varieties of wrenches are available. when you are loosening or tightening a fastener. The opposite end is called the open end. The open end is useful once a fastener is loose to quickly remove it. Do not use the open end of a wrench to break loose or tighten a fastener because the open end can easily slip off, rounding the fastener s head and scuffing your knuckles. Most wrenches have the box end at an angle to the rest of the wrench, as shown in Figure This allows extra clearance for your hand when you are working. The box end of a wrench may have six points or 12 points. A sixpoint provides better grip, while the 12-point allows for easier access since the increased number of contact points allows for working in tighter spaces. Both are shown in Figure Socket sets sockets are used with a ratchet to quickly and safely loosen and tighten fasteners. FIGURE 3-11 Examples of six- and 12-point box end wrenches. Sockets come in deep, mid, and shallow depths, six and 12 points, chrome and impact grades, and in various drive sizes. Sockets allow better contact with the fastener than open-end wrenches and can be combined with extensions and other tools to gain better access and/or leverage. An example of a socket is shown in Figure The most common drive sizes for sockets are ¼, 3 8, and ½ inch. Technicians working on heavy duty trucks and commercial equipment often use ¾- and 1-inch drive socket sets. An example of a ½-inch drive is shown in Figure The ratchet allows for quick switching from one size socket to another and is a means 9/16-inch (14-mm) socket Top view 1/2-inch (12.7-mm) square drive hole 9/16 inch (14 mm) across flats Space 15 FIGURE 3-10 Most combination wrenches are offset to allow for clearance when working on a vehicle. 9/16-inch (14-mm) head bolt 9/16 inch (14 mm) across flats FIGURE 3-12 Sockets provide significant grip on a fastener but only if the correct size is used and if the socket is not worn out or damaged.

8 50 Chapter 3 Shop Orientation 1/2" lug Clockwise/ counterclockwise lever 1/2" hole Handle 17 mm hex socket end FIGURE 3-13 A ratchet is used to drive a socket either clockwise or counter clockwise. to switch from tightening to loosening with just a click of the ratchet selector. A variety of ratchets are shown in Figure Ratchets should be cleaned and lubricated regularly to stay in proper working condition. Sockets should be checked for cracks and worn teeth and replaced as needed. Socket sets usually include a variety of extensions in different lengths for getting additional working room or clearance. Screwdrivers the most common screwdrivers used in auto repair are the standard or straight, the Phillips, and Torx. A screwdriver similar to the Phillips, called a Reed and Prince, is sometimes required for some fasteners. Many technicians use cordless screwdrivers or drills with driver bits for work with screwdriver types of fasteners. Figure 3-15 shows a Magnified tip Screw head FIGURE 3-15 Phillips screw drivers are used in interior trim and exterior light assemblies and are used instead of standard or flat head screws because they are less prone to slipping. Magnified tip Screw head FIGURE 3-16 Torx heads use a six-sided star shaped driver. Torx screws are common in trim, lighting assemblies, and other applications. Phillips screwdriver, and Figure 3-16 shows a Torx screwdriver. Drivers many fasteners use six-sided drivers or Allen wrenches or Torx drives. These are commonly found on brake caliper bolts and engine fasteners. Allen drivers can be English or metric sizes, while Torx drives can be found in a tamper deterring safety Torx configuration. Figure 3-17 shows examples of various driver bits. FIGURE 3-14 There are as many types of ratchets available as there are sockets to use them on.

9 Chapter 3 Shop Orientation 51 Allen Flat Phillips Torx FIGURE 3-17 Drivers are used with ratchets and are common tools for brake service. pliers of varying types, from basic slip-joint and needle nose to snap ring and specialty pliers. The most commonly used types are slip-joint, needle nose, diagonal side cutting, and locking-jaw pliers. Figure 3-18 shows examples of different types of pliers. Each type has specific uses and limitations. ment of hammers, including ball-peen, dead blow, rubber mallets, plastic, and brass hammers. Each type of hammer has specific uses and precautions. A standard 16-ounce ball-peen hammer can be used while servicing ball joints and other suspension parts but should never be used on a machined surface or where the possibility of sparking or flaking can occur. A dead blow hammer is filled with lead shot and reduces the elastic rebound of the hammer. Dead blow hammers apply more force than a standard hammer. Rubber mallets are used when a surface could be marred by a harder hammer, such as when you are installing a hub cap. Plastic and brass hammers are used on soft or machined surfaces that could be damaged by other types of hammers. Figure 3-19 shows different types of hammers used by technicians. variety of tools for testing and repairing the vehicle s electrical system. A multimeter capable of measuring AC and DC volts, amperage, resistance, duty cycle, frequency, and temperature is often used. An example of a digital multimeter (DMM) is shown in Figure Test lights, jumper wires, terminal tool kits, soldering tools, and logic probes are also commonly used. These tools allow the technician Needle nose Combination Diagonal cutter Rib joint End cutter Adjusting screw Vise grip Release lever Compound cutter FIGURE 3-18 A wide variety of pliers are available for many different types of jobs. However, do not use pliers in place of a wrench or socket just because the pliers may be closer at hand. Pliers are not meant to be used to loosen or tighten nuts and bolts. Copyright 201 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the ebook and/or echapter(s).

10 52 Chapter 3 Shop Orientation FIGURE 3-19 Different types of hammers for different uses. Soft face hammers are used where a steel hammer will damage a surface or component. FIGURE 3-20 A digital multimeter is an essential tool for a technician. A quality meter will last many years. FIGURE 3-21 Test lights are used to show power, ground, and current flow. to safely test components of the electrical system without causing damage to the vehicle. Figure 3-21 shows an example of an unpowered test light, used for checking for power, ground, and current flow. Electrical tools and their uses are covered in detail in the electrical chapters. and efficiently as possible, technicians often use air or electric (battery or AC) tools. Air operated impact wrenches are used to remove lug nuts and other tight fasteners, while air ratchets are used to reduce the amount of time loosening and tightening fasteners. Air hammers are used with chisels and cutting bits on exhaust repairs or to separate bushings or suspension components. Air tools should be kept clean and should be lubricated before each use. Some common examples of air-powered tools are shown in Figure thousands of dollars worth of specialty tools. Often, a special wrench, socket, or other tool is required to FIGURE 3-22 Air tools save time and make many jobs much easier. However, it is important to properly maintain these tools and use them correctly to prevent damage to the vehicle. Copyright 201 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the ebook and/or echapter(s).

11 Chapter 3 Shop Orientation CENTER PUNCH (SHOWING INCLUDED ANGLE) STARTING PUNCH FIGURE 3-23 Pullers of different types and sizes are often necessary to perform many types of services and repairs. perform a repair properly. Among these are pullers used to remove harmonic balancers, hub bearings, bushings, and other components. A technician can acquire many different types of pullers, some for general use and some for very specific applications. An example of a puller being used to remove a front-wheel drive axle from the hub is shown in Figure Chisels, punches, and files chisels are used to remove rivets and spread apart pinch-bolt clamps; punches can be flat, centering, or drift types. Different types of chisels are shown in Figure RIVET BUSTER CHISEL DIAMOND POINT CHISEL PIN PUNCH ALIGNING PUNCH STRAIGHT SHANK BRASS PUNCH FIGURE 3-25 A selection of punches. Punches are used for driving out pins and aligning components. Punches are used to remove hollow rolled pins, cotter pins, or to create an indentation in preparation for drilling. A drift or aligning punch is used as an alignment tool to center holes for installation of a fastener. Various types of punches are shown in Figure Files are used to remove sharp edges and small metal fragments called burrs, to clean up the metal around a hole, or to file down slight imperfections. Files may also be used to dress the tips of screwdrivers, punches, and chisels. Different types of files are shown in Figure Brake tools are used to ease the removal of drum brake springs. Special adjusting tools, called brake spoons, are used to adjust rear brake shoe clearances. Many disc brake systems use Torx and Allen drive bolts to fasten brake caliper bolts. Brake tools are covered in more detail in the brake service chapters. Some examples of brake tools are shown in Figure Suspension tools, such as toe hooks, are used to adjust toe in/out on some steering linkages. Ball-joint ROUND NOSE CAPE CHISEL Flat Face CAPE CHISEL FLAT CHISEL LONG FLAT CHISEL FIGURE 3-24 Chisels must be kept dressed and in good condition for safe use. Round Half round Edge Tang Triangular Handle FIGURE 3-26 Files are often used to dress screw drivers, chisels and files. Files are also used to remove small slivers of metal, and to shape metal parts.

12 54 Chapter 3 Shop Orientation Spoon Retaining spring tools Wheel cylinder clamp Retaining spring pliers Return spring tool FIGURE 3-27 Brake tools make brake service easier, faster, and safer. FIGURE 3-28 This tool is used to separate tie rods and similar components without causing damage to threads, grease boots, and other components. FIGURE 3-29 Torque wrenches are a necessity for any technician. Using a torque wrench ensures a nut or bolt is not too tight or too loose. separators or presses are used to safely separate balljoint sockets used on front and rear suspension and steering components. An example of a tie-rod separator is shown in Figure Suspension and steering system tools are covered in more detail in their related service chapters. Torque wrenches are used to apply a very specific amount of torque to a fastener. Torque wrenches are available in ¼-inch drive up to 1-inch drive sizes. There are several types of torque wrenches commonly used in automotive repair; these are the beam, the click-type, the dial-type, and the digital-type, shown in Figure 3-29 and Figure Tap and die sets are used to repair damaged threads, both internal and external. Taps and dies, shown in Figure 3-31, are used to clean up (often called chasing) threads or to cut new threads. Taps and dies are made of hardened steel that is able to cut threads in a variety of metals. Taps are bolt shaped and are used on internal threads. Dies are round pieces of steel with the thread cutting edge in the center and

13 Chapter 3 Shop Orientation 55 FIGURE 3-30 A digital torque wrench can be used for footpounds, Newton-meters, or inch-pounds, making it a very versatile tool. Pull toward yourself when loosening FIGURE 3-33 When loosening or tightening a fastener, pull the wrench or ratchet toward your body instead of pushing away. This can save you from injury if the tool slips or the fastener lets go. FIGURE 3-31 Repairing damaged threads is a common procedure for a technician. Investing in a good quality tap and die set will make thread repairs faster and easier. are used to chase or cut threads on studs and bolts. Often thread files are contained in a tap and die set, as shown in Figure This special type of file is used to straighten damaged threads on bolts and studs. Tool Usage. Once you know what the tools are and what each tool does, you then need to be able to use the FIGURE 3-32 Damaged threads, studs, and bolts can often be repaired using a thread file. This type has eight different thread pitches. tool properly. Using a tool improperly can cause tool damage or failure, damage to the vehicle, and personal injury. The following are basic guidelines for proper tool usage: Wrenches always use the box end of a wrench when you are attempting to loosen a tight fastener. This is because the box end has more contact with the fastener and is less likely to slip off. Trying to loosen a stuck bolt or nut with the open end of a wrench will often cause the wrench to slip off, rounding the head of the fastener and possibly hurting your knuckles. The same applies if you are using a wrench to tighten a fastener. This is shown in Figure Screwdrivers do not use a screwdriver as a pry bar, chisel, or punch. This can easily damage the screwdriver and the vehicle. Use the screwdriver that has the best fit to the screw head. There are three common Phillips head screwdrivers, the number one, number two, and number three. A number one Phillips is the smallest of the three, while the number two is the most commonly used size. The number three Phillips screws are not common automotive fasteners. A type of screw head called a Reed and Prince, shown in Figure 3-34, looks very similar to a standard Phillips screw but requires a special driver. Using the incorrect type will damage the screw head. When you are using a screwdriver to tighten fasteners and even hose clamps, do not overtighten the screws. Screws are

14 56 Chapter 3 Shop Orientation FIGURE 3-34 Using a Phillips in place of a Reed and Prince screw driver can cause the head of the screw to strip. Make sure you are using the correct tool for the job. often used on plastic parts, and they can easily break if they are overtightened. When you are tightening worm-style hose clamps with a screwdriver or other driver, do not overtighten the clamp. Drivers be sure to use the correct size Allen and Torx drivers. Most Allen fasteners are metric, though many older vehicles have English or SAE-sized Allen bolts. Allen and Torx drivers are not interchangeable and will strip out the internal head of the bolt if they are used for the wrong application. Pliers never use pliers in place of the correct tool. This means do not loosen or tighten fasteners with pliers or use them to remove drum brake springs. Using pliers on nuts and bolts will quickly round the head of the fastener. Using pliers on brake springs can damage or cut the springs and can also cause the springs to fly off unpredictably. Hammers should be used only in certain situations, and only the correct hammer should be used. Most parts do not need to be hammered off of or onto the vehicle. If you find that a hammer is necessary to reinstall something, you need to recheck your work. Steel hammers should not be used on steel, plastic, or machined parts. Never use a steel hammer on threaded components, such as tie-rods, as the threads are easily flattened. When you are loosening or tightening a fastener, especially a very tight fastener, pull the tool toward yourself instead of pushing away. If the tool slips off or the fastener breaks free, applying a lot of force while pushing away can cause you to follow the movement of the tool, possibly injuring yourself. FIGURE 3-35 To set a click-type torque wrench, slide the sleeve down and turn the handle. Once the setting is made, release the sleeve to lock the handle in place. Click- and digital-type torque wrenches are set to alert the user once the preset torque has been reached. Neither these nor the beam- or dial-type torque wrenches prevent the user from applying too much torque, so caution must be used to not overtighten a fastener. To set a click-type torque wrench, first loosen the locking collar and rotate the handle clockwise until the desired torque setting is reached, shown in Figure Once it is set, lock the collar to prevent the torque setting from changing while you are using the torque wrench. Using the correct socket, apply torque to the fastener until the torque wrench clicks. Do not turn the fastener beyond this point. Once you are finished with all of the fasteners, unlock the collar and turn the handle all the way back down counterclockwise. This takes the tension off the internal spring inside of the torque wrench. To set a digital torque wrench, simply press the up and down buttons until the desired setting is reached. Apply torque until the wrench clicks or beeps and then reset the torque wrench to zero for storage. When you are using a beamtype torque wrench, you must watch the movement of the beam along the scale to determine when to stop applying torque, as shown in Figure Dial torque wrenches have an adjustable pointer on the dial that is set to the desired torque setting. As torque is applied to the wrench, the torque-indicating needle moves along the dial face. When the two pointers align, the fastener is torqued. An example of a dial torque wrench is shown in Figure Sooner or later you will encounter a damaged fastener or bolt hole. When this happens, you will likely need to use a tap and die set to correct the damage. When you are attempting to fix external threads, such as those shown in Figure 3-38, start by using a thread file. First, determine the thread size and pitch using a thread gauge, as shown in Figure Once the thread pattern is identified, select the correct thread file and start to work the file across the damaged threads while

15 Chapter 3 Shop Orientation 57 Torque scale FIGURE 3-38 Damaged threads are a common occurrence in the auto lab. FIGURE 3-36 Using a beam or dial torque wrench requires you to keep the tool in sight as you are tightening the fastener. FIGURE 3-39 Measure thread pitch using a thread pitch gauge. Gauges are either English or metric and measure in threads per inch (TPI) or threads per millimeter (TPMM). Align the gauge against the threads. If the two fit perfectly against each other, you have found the correct pitch. If gaps remain between the gauge and threads, keep checking until the correct pitch is found. FIGURE 3-37 A dial torque wrench requires keeping an eye on the dial while torquing the fastener. keeping the file perfectly in line with the threads, as shown in Figure If the threads are severely damaged, a die may be needed. Select the correct die that matches the thread pattern of the fastener. Next, slowly and carefully begin to thread the die onto the threads of the fastener, as shown in Figure Rotate the die one-quarter turn at a time, and then back the die off slightly. Repeat this

16 58 Chapter 3 Shop Orientation FIGURE 3-40 A thread file can be used to straighten damaged external threads. Select the correct file pitch and move the file back and forth across the damaged area to restore the threads. FIGURE 3-42 A tap is used to clean or cut new internal threads. After selecting the correct tap, start it into the hole and slowly work it down and back up. Blow metal debris out with a blow gun. REPAIRING THREADS WITH TAP AND DIES Die Die wrench It is common for the threads in a hole to become so damaged or stripped that they cannot be repaired. In this case, a threaded insert can often be used to fix the damage. A threaded insert kit, shown in Figure 3-43, contains an oversized tap, inserts, and insert installer. Some kits may contain the drill bit that is used to enlarge the hole in which the insert is installed. Figure 3-44 shows how a thread insert is installed. To begin, start by drilling the hole slightly oversized. The size of the drill bit that is needed is indicated on the insert kit. Be sure the hole is drilled straight and to the correct depth. Next, use the provided tap to cut new threads into the hole. Once the threads are cut, clean the hole using compressed air and FIGURE 3-41 To repair external threads with a die, select the correct size and start the die onto the threads. Work the die slowly tightening and then loosening and retightening until the damaged threads are repaired. process until the die has corrected the damaged threads and moves easily on the fastener. Using a tap is similar to using a die. First, select the correct size tap for the size of the threads needing repair. Carefully begin to thread the tap into the hole, working it slowly clockwise and then counterclockwise, as shown in Figure Ensure the tap is perfectly aligned with the hole since the tap can easily destroy the old threads and cut new threads if misaligned. Once the threads are repaired, use compressed air to blow any metal shavings from the hole. FIGURE 3-43 A thread insert kit is used to replace damaged threads and restore the hole to its original thread size. This is used when tapping the hole oversize and rethreading is not an option.

17 Chapter 3 Shop Orientation Drill hole to proper size 2. Install insert on mandrel 3. Tap hole to proper size 4. Install insert into threaded hole FIGURE 3-44 The basic steps for installing a thread insert begin with drilling the hole oversize and tapping the hole to accept the insert. Next, thread the insert into the hole and secure the insert in place. ensure that no metal shavings remain. Install the insert onto the installation tools and thread the insert down into the threads in the hole. Once the insert is seated, use a small chisel to remove the bottom tang of the insert to prevent interference with the fastener. Tool Maintenance. Tool safety begins with using the correct tool for the job. Shops and technicians invest thousands of dollars in tools, all for particular purposes. It is unwise to use tools inappropriately, since it can lead to damage to the tool, damage to a vehicle, and personal injury. All tools should be cleaned regularly and inspected for wear or damage. A tool that is worn excessively or is cracked or damaged can cause injury and damage to the vehicle on which the work is being performed. Sockets should be kept clean and inspected for cracks. A socket that is worn at the contact point with the fastener could slip, resulting in a rounded fastener and hurt hand. Ratchets should be cleaned, lubricated, and the ratcheting mechanism should be checked regularly. A damaged, dirty, or dry ratchet gear set can bind or break, resulting in hand injuries. Screwdrivers, punches, and chisels should be clean and dressed as needed. Dressing means maintaining the tips and edges in their original condition. Tools with worn or damaged tips can slip, causing damage to the fastener and the operator. An example of a damaged screwdriver tip is shown in Figure Pliers should be inspected regularly. Check the teeth and pivot for damage or wear. Dull diagonal cutting pliers should be either redressed or replaced. FIGURE 3-45 Damaged tools can cause personal injury and damage to the vehicle. Do not use damaged tools. Air tools should be oiled daily and checked for proper operation each time they are used. Water can accumulate in the compressed air system, ending up inside of the air tools. The water will cause the internal parts of the air tool to rust, damaging the tool. Water traps on the air lines or a dryer system help prevent water from making its way through the air lines and into the tools but do not guarantee total protection from moisture. Therefore, it is important to keep air tools properly oiled. Shop Tools Shop tools can be large pieces of equipment, such as lifts, air compressors, and alignment equipment, down to small specialty tools. Each shop will have different

18 60 Chapter 3 Shop Orientation criteria for what is a shop tool and what is a tool that is the technician s responsibility. Many shops have the philosophy that if a tool fits in the technician s toolbox, it is the responsibility of the technician to buy. Today, with the development of smaller, faster, and more complex diagnostic tools costing many thousands of dollars, that practice is changing in some shops. Shops and technicians must be careful not to fall into the new tool trap. Just because a new tool is available does not mean it is a good idea to purchase it. Each purchase, especially of expensive diagnostic equipment, should be carefully considered. As a technician or shop owner, ask yourself these questions before purchasing a tool or piece of equipment: Will the tool increase productivity or sales? How long before the tool pays for itself? What can the new tool do that an existing tool does not do? Questions like these should be answered honestly before any new major purchase. It is important to note here that many young technicians begin buying tools on credit, which can lead to financial problems as making payments on tools can consume a large amount of your paycheck. Do not be too eager to buy a lot of new tools, especially very expensive tools and toolboxes, just because you have started your first automotive job. Most shops will have the following pieces of equipment: tire mounting and balancing machines, shown in Figure 3-46, alignment machines, bench grinders, cleaning equipment, battery chargers, and lifting and jacking equipment. Tire dismounting and mounting is performed using special machines to make the process much easier and safer. Tire balancing machines are used to compensate for slight differences in weight distribution around the wheel and tire, which when rolling down the road, can cause vibration concerns. FIGURE 3-46 Common shop equipment includes tire mounting and balancing machines. Wheel alignment equipment, usually a dedicated hoist and an alignment computer, are used to correctly position the front and rear wheels and tires. This improves tire life and fuel economy. Wheel and tire service equipment are discussed in detail in later chapters. Bench grinders, like that shown in Figure 3-47, have one or two grinding stones or wire wheels driven by a powerful motor. Bench grinders are used to reshape metal and dress tools. The wire wheel can be used to remove rust and clean the threads on bolts. Inspect the grinding or wire wheels and the guards before using a bench grinder. Do not use it if a dressing wheel is damaged or if the guards are not in place. Before you use a grinder, you should put on a pair of mechanic s gloves to help prevent injury from flying debris and because the parts being ground tend to get hot. To use the grinding wheel, turn the power switch on, Shield Motor Grinding wheel Tool rest FIGURE 3-47 Bench grinders are used to clean parts, shape metal, and dress tools.

19 Chapter 3 Shop Orientation 61 FIGURE 3-48 Solvent cleaning tanks are used for light-duty cleaning of dirt, grease, and oil. and let the motor get up to speed. Next, place the object you are grinding on the tool rest in front of the grinding wheel. Slowly and carefully move the workpiece up to the grinding wheel. When you are finished, remove the workpiece and turn off the motor. Many shops will have some type of solvent-based cleaning equipment called a parts washer, like that shown in Figure Solvents can be either petroleum or water based. Parts are placed into the parts cleaner and the solvent and a brush are used to remove dirt, oil, grease, rust, or other substances. This type of cleaner should be used with chemical gloves to prevent skin reactions to the solvent. To use, locate the power switch to turn on the parts washer pump. Place the item being cleaned into the cleaning tray and use the solvent and brushes to clean the component. When you are finished, allow the solvent to drip from the part and clean out any mess left from the cleaning. Battery chargers are used to recharge a battery that has become discharged or to charge newly filled batteries. Chargers can be small, low amperage trickle type chargers, designed to deliver a small amount of current over many hours as shown in Figure 3-49, or larger output booster-style chargers, shown in Figure Most have the option to select the charge rate and amount of time for charging to occur. Before using a battery charger, inspect the power cord and the charging cables and clamps. Do not use a charger with damaged or frayed cords or damaged clamps. Make sure the charger is off and unplugged before you connect the charging clamps to the battery. Connect the positive clamp to the positive battery terminal first, then connect the negative charging clamp to the negative battery terminal. Plug the charger into the outlet, and set the charging rate and time as indicated on the charger. When you FIGURE 3-49 A trickle or slow charger supplies a couple of amps over a long period of time to recharge a battery slowly. This charger does not have an on/off switch so caution must be used when connecting and disconnecting. FIGURE 3-50 This type of battery charger can perform slow, fast, and even jump-start boosting power. Copyright 201 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the ebook and/or echapter(s).

20 62 Chapter 3 Shop Orientation FIGURE 3-51 A bench vise is used to hold objects securely in place while working. Do not overtighten the vise or close the jaws on machined components. are finished charging the battery, turn the charger off and unplug the power cord. Remove the negative clamp and then the positive clamp. Carefully wrap the power cord and charging cables around the handle. Do not clamp the charging clamps to the handle. Vises are used to hold an object, as shown in Figure The jaws of a vice may be steel, brass, wood, or aluminum depending on what it is designed to hold. Different jaws are used for different applications. Soft jaws, such as brass and aluminum, are used to hold something that can be damaged, such as a machined surface. Caution should be used to avoid accidentally pinching your fingers in a vice while clamping a work piece. To open the vise, turn the handle counterclockwise; to close it, turn the handle clockwise. When it is not in use, leave the vise jaws slightly loose and the handle pointing down. The shop will also be equipped with an air compressor and a network of air lines and hoses. The air compressor uses a large electric motor to draw in and compress air, similar to an internal combustion engine. The air compressor however, compresses the air and then stores it in a large tank. The tank is connected to the shop s air lines, to which the technician then connects his or her air tools, as shown in Figure Once the valve is opened, air pressure is available to operate the tool. Figure 3-53 shows how to properly connect an air tool to the compressed air system. Shop air pressure should be regulated at 90 psi at connection point. This provides adequate pressure to operate most air tools. Compressed air and blow guns should never be used to blow dirt and debris from your clothing or skin. The air pressure can force dirt into your skin, and FIGURE 3-52 The shop compressed air system has an air compressor, lines, and hoses. Pneumatic tools attach to the air hose using a special quick-disconnect fitting. Pull this sleeve back slightly to connect the air hose to the fitting Fitting on tool FIGURE 3-53 To attach the tool to the air hose, pull the sleeve away from the open end of the fitting and slide the fitting over the male fitting on the tool. Release the sleeve and the two fittings are locked together. if it is used around an open wound, face, or head, it can cause serious, even deadly injury. Some of the most important items in the shop are fender, seat, steering wheel, and floor covers. Fender covers, like that shown in Figure 3-54, are used to FIGURE 3-54 Fender covers are used to protect the vehicle s finish from damage. Copyright 201 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the ebook and/or echapter(s).

21 Chapter 3 Shop Orientation 63 FIGURE 3-55 Seat, steering wheel, and floor covers are used to protect the interior of the vehicle during service. protect the vehicle s finish and underhood components during service. Fender covers should always be placed over areas where work is being performed to prevent damage from dropped tools or chemical spills. Seat, steering wheel, and floor covers, shown in Figure 3-55, should be used whenever you are inside the customer s vehicle. Even though your uniform may look clean, dirt and oil may transfer from your clothing to the interior. Work boots tend to collect dirt and chemicals, so a floor mat should always be used to protect the vehicle s carpet. Customers appreciate having their vehicle returned to them as clean as (or even cleaner than) when it was dropped off for service. in some applications. These bolts cannot be reused once removed. The lines on an English or SAE bolt indicate the strength of the bolt. More lines mean that the bolt or nut can withstand greater clamping and twisting loads, which means more torque can be applied. Metric bolts are marked in numbers, such as 8.8 and 10.9, the higher number indicating a higherstrength bolt. Figure 3-60 shows how bolt strength affects its ability to withstand different forces before it reaches its failure point. Proof load is the amount Wrench pad Shank Threads Fasteners and Torque Fasteners, the nuts, bolts, screws, and other hardware that hold the vehicle together, are as important to the vehicle as any component or system. Fastener Basics. The most common type of fasteners used on cars and trucks are bolts and nuts, shown in Figure 3-56 and Figure Bolts are used to thread into a nut or a hole that has internal threads cut into the material, as shown in Figure Bolts and nuts are usually made of steel and vary in strength, as shown in Figure Be aware that some manufacturers install single-use aluminum bolts Fillet Washer face FIGURE 3-56 Bolts are one-piece of metal formed into a threaded section and a drive section.

22 64 Chapter 3 Shop Orientation Grade 2 Grade 5 Grade 8 Grade 5 Grade 8 Grade 5 Grade 8 Grade 5 Grade 8 FIGURE 3-57 Nuts are used on bolts and studs and are rated for the strength just as bolts are. Pre-cut threads match those of the bolt FIGURE 3-58 A bolt is made to thread into matching threads that are cut into a component or into a nut. of tension that can be applied to the fastener without any permanent damage. Over-tightening a bolt can cause the bolt to stretch before it actually breaks, as shown in Figure When this happens, the bolt loses clamping force and is significantly weakened as the bolt shank is stretched thin. Once a bolt reaches its breaking point, the bolt will break in two, releasing all of its clamping force. When this happens, the parts being held together are no longer held tightly around the area of the broken bolt. This can cause problems from fluid leaks to destroyed engines, depending on the location and purpose of the bolt. In addition to bolt grade markings, bolts are measured by their physical size, as shown in Figure When you are selecting a replacement bolt, you must first determine the correct size of the bolt. Begin by determining the thread pitch using a thread pitch gauge. Next, measure the diameter and the length of the bolt. Once you have determined the bolt grade, thread pitch, diameter, and length, select the correct replacement bolt. Do not substitute a lower-grade bolt in place of a highstrength bolt the weaker bolt may not be able to handle the torque applied to it and may break. Since the threads in a nut must correspond to the threads on a bolt or stud, you often will need to determine the thread pitch and size for a nut. This can be done with a thread pitch gauge and ruler. Some technicians determine thread size by matching the nut with a known bolt type. Find a bolt that matches the size and pitch of the threads in the nut and thread the nut onto the bolt. If the threads are correct, the nut should thread easily onto the bolt. Pay close attention if you are using a nut and bolt to find out the thread size as it is possible to install a nut that is too large over a bolt and incorrectly judge the size of the threads. Do not substitute a lower-grade nut in place of a high-strength Grade 2 Grade 5 Grade 8 Customary (inch) bolts - Identification marks correspond to bolt strength. Increasing numbers represent increasing strength Metric bolts - Identification class numbers correspond to bolt strength. Increasing numbers represent increasing strength. FIGURE 3-59 Bolt strength or grades are indicated by the marks or numbers on the head of the bolt.

23 Chapter 3 Shop Orientation 65 Clamp load (lbs) Elastic range Proof load Plastic range Yield point Ultimate tensile strength Failure point Normal torque (75% of proof load) Bolt elongation (in.) FIGURE 3-60 This chart illustrates as the load on a bolt increases, the greater the stress, which can lead to the bolt failing. Unstretched bolt Stretched bolt Threads are straight on line Threads are not straight on line FIGURE 3-61 Once a bolt is over-tightened and stretched, the bolt is weakened and must be replaced Millimeters M mm Pitch Diameter 12 Millimeters FIGURE 3-62 Determining bolt size requires measuring the thread pitch, length, and diameter. nut as this may cause the threads on the nut to strip as it is tightened. Screws, like those shown in Figure 3-63, are used either in situations where the screw cuts its own threads into a material, or in the case of machine screws, have bolt-like threads but are much smaller in diameter and have screw heads instead of bolt heads. Screws with screw heads, such as slotted, Phillips, Torx, and others, are used in low-torque applications, such as interior and exterior trim pieces. Fastener Torquing. Because fasteners have limits to how tight they can be torqued and because many components require significant clamping forces to remain tight, every fastener has a torque specification. Under-tightening does not supply enough clamping force and components can separate. This can be disastrous if the fasteners are the wheel lug nuts. Additionally, over-tightening a fastener can easily lead to breaking the fastener and the parts being secured, such as trim and other plastic components. To ensure that a fastener is tightened correctly, a torque-indicating tool called a torque wrench is used. These are torque-indicating because they provide the user with feedback about how much torque is being applied. They do not limit the torque, which is important to note because you can still over-torque and destroy a fastener with a torque wrench if it is used incorrectly. Torque wrenches are available in quarter-inch drive up to a 1-inch drive to fit any need.

24 66 Chapter 3 Shop Orientation Flat head Bolt Setscrews Round head Pan head self-tapping screws Round head Flat head Round head Fillister head Stud Capscrew Flat head Oval head Machine screws Carriage bolt Torx head bolt FIGURE 3-63 Screws are available in a wide variety of heads, threads, and sizes. The most common torque wrenches used today are the click and digital type. Click-type wrenches have an adjustable sleeve that is used to set the desired torque. Once it is set, tighten the fastener and listen for the click. You should be able to feel the torque wrench click in addition to hearing the click, though the feedback is less pronounced at lower torque settings. You will need to pay careful attention to a click-type torque wrench when you are using it at low torque settings. Digital wrenches have an LCD display and buttons to change the units and torque setting. This torque wrench can be set for footpounds, inch-pounds, and Newton-meters. Two other types of torque wrenches are the dial and beam types. These require the user to observe the dial or beam while applying torque, making them slightly more cumbersome to use. The dial has two indicator needles, one for the torque being applied and the other as the torque setting. To set this type, rotate the dial until the brass needle is on zero and turn the center knob and needle to the desired torque setting. When force is applied, the brass needle will rotate along the dial scale. When the brass needle reaches the preset point indicated by the silver needle, the torque setting has been reached. When using the beam-type wrench, watch the position of the pointer along the scale while applying torque, and stop when the desired amount is achieved. Torque Wrench Care. As with any tool, proper care and maintenance are important for torque wrenches if they are to maintain their calibration (Figure 3-64). Be careful not to drop torque wrenches on the floor. Also, do not use a torque wrench as a prybar or breaker bar. Inspect the wrench for proper operation of the ratcheting mechanism each time it is used. Make sure the adjustment sleeve on click-type wrenches moves smoothly and the locking collar locks and releases properly. Store the wrench in its case when not in use. Clean and oil the ratchet regularly. FIGURE 3-64 Having torque wrenches checked and calibrated annually is important to ensure proper operation and torque settings.

25 Chapter 3 Shop Orientation 67 Always store click-type wrenches with the adjustment set at the lowest possible position. Have the wrench checked and calibrated at least yearly. Keep the certification papers supplied by the company that performs the service. Keeping records of tool calibration is important for legal reasons if there is ever any question about how a repair was performed. Being able to prove that proper torque procedures were followed with a certified accurate tool may be your only defense in a legal dispute. Figure 3-66, have equal length swing arms, and vehicles can be placed onto the lift facing either direction. Asymmetrical lifts have unequal-length arms, with the front arms shorter than the rear arms, like the lift shown in Figure These lifts require the vehicle to be pulled in with the majority of the vehicle being located toward the rear of the lift. This places the heavier part of the vehicle, the engine compartment, closer to the uprights. Vehicle Lifting and Jacking One of the most frequent operations a technician will perform is the lifting and supporting of vehicles. For that reason, we will take a close look at the steps for safely lifting a vehicle. Lifts or hoists take many shapes. In-ground lifts can be single-post, twin-post, or in some older shops, twin axle lifts. In-ground lifts, like that shown in Figure 3-65, have the hydraulic cylinders buried in the concrete and the controls mounted above the ground. These lifts typically have two control levers, one to supply pressure to the lift and the other to control the lift speed and operation. The advantages of in-ground lifts are that there are no overhead crossbeams and they take up little floor space. The primary disadvantage is that if a leak occurs in the system, the concrete floor may have to be torn out for repairs. Newer styles of in-ground lifts are manufactured in self-contained modules that require less extensive plumbing and reduced cost. Above-ground lifts are of either a swing arm-type, such as two-post symmetrical and asymmetrical designs, or are a drive-on type, which may use a scissor or fourpost design. Two-post symmetrical lifts, shown in FIGURE 3-66 Symmetrical lifts have equal length arms. Short arms FIGURE 3-65 In-ground lifts may have one or two posts and take up very little floor space since most of the components are located in the floor. Long arms FIGURE 3-67 Asymmetrical lifts have shorter front arms and longer rear arms. This changes the way the vehicle is placed on the lift compared to symmetrical lifts.

26 68 Chapter 3 Shop Orientation 19 inches (483 mm) 30 inches (762 mm) FIGURE 3-68 Drive-on lifts are commonly used for wheel alignments and are available in many different types of configurations. Asymmetrical lifts have a smaller footprint, or less contact area to the floor, compared to symmetrical lifts. Because the uprights of asymmetrical lifts have less surface contact with the floor, the position of the vehicle and the load are different than on lifts with equal length arms. Be sure you understand how to properly position a vehicle on each type of lift before you attempt to raise the vehicle. Improper loading of the lift can cause the vehicle to fall off the lift or even lift failure. Drive-on lifts are often for heavier-duty applications and are capable of lifting larger loads than two-post lifts. Scissor and four-post lifts are often used for wheel alignment purposes, as shown in Figure Regardless of lift type, several safety precautions apply when using a lift. Do not attempt to operate a lift without first receiving instruction on its safe operation. Familiarize yourself with the lift controls and the lift operation. Understand how to correctly load the lift, set the swing arms and contact points, and operate the lift controls before use. Improper loading can cause the vehicle to overload the lift. The vehicle could fall from the lift or damage the lift if too much weight is placed incorrectly. Proper setting of the contact pads to the vehicle is critical. Improper placement can cause damage to the vehicle and could cause the vehicle to fall. Lift contact points are available from service information resources and from a lift guide available from the American Lift Institute. These references show the proper lifting and jacking points, as shown in Figure Some vehicles, like that shown in Figure 3-70, prominently show where to place the pads of a swing arm lift. Once the lift contact pads are set, raise the vehicle approximately 6 inches off the floor and stop. Recheck the contact points, and give the vehicle a bounce at the front or rear. If the contacts are correct and the vehicle is stable, continue to raise it to a working height. When the vehicle is at the desired height, lower the lift onto the mechanical safety locks. This provides greater stability for the lift and prevents the vehicle from dropping unexpectedly should there be a hydraulic failure. Drive on hoist Frame contact hoist Floor jack Outboard twin post hoist FIGURE 3-69 Identifying and using the correct lifting points on the vehicle is important to prevent damage to the vehicle, damage to the lift, and to prevent injury. FIGURE 3-70 Locate the lifting point on the vehicle as specified in a lift manual or service information. Never work on or under the vehicle until the lift is lowered onto the safety locks. Once the vehicle is secured and work begins, it is important to remember that some types of repairs will change the weight balance of the vehicle on the lift. For example, removing a rear axle assembly from a vehicle will significantly reduce the weight at the rear and may unbalance the load placed on the lift, allowing the car or truck to tilt forward. This can be extremely dangerous since the different weight distribution could cause the vehicle to fall off the lift. When you are ready to lower the vehicle, first make sure nothing is under the vehicle, such as another student,

27 Chapter 3 Shop Orientation 69 a toolbox or drain pan. Then raise the lift off the safety locks. Disengage the safety locks, and lower the vehicle to the floor. Make sure no one is standing near the vehicle and lift as it approaches the floor. Being too close to either could result in someone s foot getting trapped under a tire or swing arm. Using Floor Jacks. Using a floor jack and jack stands is also common in instructional labs and some repair facilities. Examine the condition of the floor jack prior to its use. Ensure that the casters (wheels) move freely and provide a full range of motion. The jack must be able to roll slightly when raising the vehicle. If the casters are frozen, the jack could bind and be kicked out from under the car. To raise the jack, turn the handle clockwise fully until it stops. Move the jack handle up and down to raise the jack, then turn the handle counterclockwise to lower the jack. The hydraulics should work smoothly and hold solidly. Any leak from the hydraulic cylinder can cause the jack to lose pressure and drop. Figure 3-71 shows the parts of the floor jack. FIGURE 3-71 A floor jack is used to raise a vehicle up off the floor. Once in place, jack stands are used to support the vehicle. Never work under a car or truck supported only with a hydraulic floor jack. Check each jack stand before use. Examine the lock and release mechanisms. The lock should fully catch the teeth of the jack. You should ensure that the jack stand is not damaged or bent and that there are no cracks in the welds. Faulty jack stands should be discarded. Using a weak or broken jack stand could allow the vehicle to drop, causing serious injury or death. Follow these steps, shown in Photo Sequence 1, to safely jack and support a vehicle. Floor jacks require periodic maintenance to ensure proper operation and a long service life. Lubricate the casters and jack pivot with the specified lubricants, usually a light oil for the casters and chassis grease for the pivots. Ensure the jack is not leaking hydraulic oil from the cylinder. Do not use a jack that is leaking as it could fail completely, allowing a vehicle to drop suddenly. Locating Vehicle Information Today s technicians have access to literally millions of pages of service information. Being able to quickly and accurately find the correct information is an important skill. Vehicle identification starts with figuring out the manufacturer and model of the vehicle. Determining more specific details is done by locating the various tags and decals located throughout the vehicle. Every vehicle sold in the United States is equipped with numerous identification tags and labels. Knowing the locations and the information that can be found on these labels will greatly decrease the amount of time you spend just trying to find basic information. Basic Vehicle Identification Before any services can be performed on a vehicle, you must know what type of vehicle you are working on. This may seem obvious, but due to the large number of makes and models on the market and that many vehicles look very similar to other vehicles of another brand, it is important to correctly identify vehicle types. Vehicle Types. Vehicles are generally classed by style and function. Passenger cars are often classed as coupes, sedans, hatchbacks, or as a type of crossover vehicle. Some examples of these vehicles are shown in Figure 3-72 through Figure SUVs and light trucks vary from two-door pickup trucks to eightpassenger four-door utility vehicles. Examples of SUVs and light trucks are shown in Figure 3-76 and Figure Cars and trucks are further categorized by drivetrain configuration, meaning whether a vehicle is front-wheel drive (FWD), rear-wheel drive (RWD), four-wheel drive

28 70 Chapter 3 Shop Orientation Photo Sequence 1 Using a Floor Jack and Jack Stands PS1-1 First, locate a suitable jacking point on the vehicle. For this vehicle, the body seam is used as a jacking point. PS1-2 Next, position the jack saddle on the contact point. Raise the jack until it contacts the vehicle and recheck the contact. PS1-3 Jack the vehicle up until the tire is off of the ground. You may need to raise or lower the vehicle slightly to properly place the jack stand. Place the jack handle up so it is not a tripping hazard. PS1-4 Locate a place to set the jack stand. These places will vary depending on the vehicle. Do not place the stand on components that will move, such as the rear suspension arm shown here. PS1-5 Set the jack stand to the desired height and position it so it will make solid contact with the vehicle. PS1-6 Slowly and carefully lower the vehicle onto the jack stand. Double check the contact between the jack and vehicle. Once you have verified the jack is well placed and secure, remove the floor jack.

29 Chapter 3 Shop Orientation 71 FIGURE 3-72 Coupes usually have two doors, a low roof line, and a very small back seat. FIGURE 3-76 Sport utility vehicles or SUVs may be carbased, such as the Honda CR-V, or truck based, such as Chevy Tahoe. FIGURE 3-73 A four-door car is often called a sedan but may also be called a four-door coupe. Sedans typically have a higher roof line and much more back seat room than a coupe. FIGURE 3-77 Trucks may be compact or large with many different combinations of passenger compartment and bed sizes. FIGURE 3-74 Hatchbacks can be three or five door models with a large rear opening for easy access to the cargo area. FIGURE 3-75 A crossover combines qualities of a coupe or sedan, a wagon, and a truck. (4WD), or all-wheel drive (AWD). Most passenger cars and some SUVs currently on the market are FWD vehicles, meaning that the engine and transmission sit in the front of the vehicle and drive the front wheels through short axles, shown in Figure Larger SUVs and light trucks, as well as some passenger cars, especially sports cars, have RWD configurations. These vehicles most often have the engine and transmission mounted in the front of the vehicle and drive the rear wheels, as shown in Figure Some sports cars use a mid- or rear-engine configuration and drive the rear wheels or all four wheels. Many SUVs and some passenger cars offer all-wheel drive. Many of these vehicles are based on FWD configurations and then add a method of applying power to the rear wheels for increased traction and safety. Basic Vehicle Identification. Begin by looking at the vehicle and locating manufacturer and model badges, as shown in Figure 3-80 and Figure If there is no manufacturer s name plate, check for badges on the hood, trunk, fenders, or wheels, as shown in Copyright 201 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the ebook and/or echapter(s).

30 72 Chapter 3 Shop Orientation Transaxle Engine Driving axle Driving axle Differential FIGURE 3-78 A front-wheel drive vehicle typically has the engine and transmission mounted transversely, meaning the front wheels are in line with the engine and transmission. Engine Rear axle shaft Transmission Differential Clutch Propeller shaft Rear axle housing FIGURE 3-80 Tags and emblems on the outside of the vehicle identify the manufacturer. In this example, Mercury was a division of the Ford Motor Company until FIGURE 3-79 Rear-wheel drive vehicles place the engine and transmission longitudinally along the centerline of the vehicle. Power from the transmission is transferred through a drive shaft to the rear differential and axles. Figure 3-82 and Figure Next, determine if any additional model details, such as EX, LX, SE, GT, or other similar designations are located on the vehicle. Examples of these are shown in Figure 3-84 through Figure These may be located on fenders or at the rear of the vehicle. Many times these model group types are important for correct parts ordering and labor calculations. Finally, it is good to know if the vehicle is a product or division of a manufacturer; for example, Chevrolet, FIGURE 3-81 GMC, a division of General Motors, only sells trucks. Buick, and Cadillac all are divisions of General Motors (GM). This information can be important because many vehicle models have an identical model sold by a different division. This information is on the door decal or underhood emission control sticker. The door decal shown in Figure 3-87 identifies the vehicle manufacturer

31 Chapter 3 Shop Orientation 73 FIGURE 3-82 Other ways in which manufacturers brand their vehicles are by using distinctive letters or symbols, such as this Honda. FIGURE 3-85 The model emblems may be located on the sides or rear of the vehicle. FIGURE 3-86 Other model designations include Customer, Limited, Touring, Special Edition, and similar titles. FIGURE 3-83 Center caps and hub caps are common places to find the manufacturer s emblem. FIGURE 3-84 Many vehicles have additional model designations such as GT, SE, or EX. There are many different designations, often indicating different levels of trim and or options. as Chrysler, yet the vehicle is sold and badged as a Volkswagen Routan minivan. This is only one example of the very common occurence of a vehicle not being exactly what it seems to be. FIGURE 3-87 This door decal contains information such as production date and tire specifications. VEHICLE IDENTIFICATION NUMBERS (VIN) Just as many items, such as TVs and computers, have serial numbers, so do cars, trucks, motorcycles, and other vehicles. These serial numbers contain a lot of information about the vehicle. As the number of vehicles produced and sold over the years has increased, the identification method has also changed. Since 1980, vehicles sold in the United States use a 17-digit identifier called the Vehicle Identification Number, or VIN. Copyright 201 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the ebook and/or echapter(s).

32 74 Chapter 3 Shop Orientation What Is the VIN? Each vehicle sold in the United States has a unique identification number, called the VIN. The VIN system has been in use since 1980 and contains 17 letters and numbers, which provide detailed information about each vehicle. An example of a VIN is shown in Figure Decoding the information in the VIN requires a chart like that shown in Figure The first three digits or letters denote the country of origin and manufacturer. The second digit is the manufacturer, the third is the division of the manufacturer, such as Buick is a division of GM. In some cases, the first two digits represent the country of manufacturer. The fourth and fifth digits designate the body or car type. The eighth digit is often the engine designation. The tenth represents the model year of the vehicle, and the last six digits are the actual number of the vehicle built of that type for that year. Locations. The federal government mandates that the VIN be placed in the left corner of the dash, near the A pillar, shown in Figure 3-90, for easy access. The VIN also appears on stickers on body panels, etched into glass, on firewalls, and on engines and transmissions. Newer vehicles often have a bar code with the VIN. This enables FIGURE 3-88 The VIN code contains a great deal of information about the car or truck. Common locations include on the dash by the driver s A pillar, door decals, and on the firewall. the vehicle information to be entered into a computer for service much faster than physically copying and retyping the VIN information. It also helps to reduce errors that can occur during the information entry process. 1G2FS32P8RE ORIGIN USA CANADA MANUFACTURER GENERAL G MOTORS 2 MAKE CHEVROLET PONTIAC VEHICLE LINE F/S FIREBIRD N/E GRAND AM BODY 1 2 DR COUPE 3 CONVERTIBLE CODE L P E ENGINE ENGINE RPO V8 L27 V8 LT1 SEQUENCE NO. LAST 6 DIGITS PLANT CODE PONTIAC EAST YEAR CHECK DIGIT 9 TH DIGIT FUEL SYS. MFI MFI DISP. 3.8L 5.7L RESTRAINT MANUAL BELTS WITH DRV / PASS INFLATABLE RESTRAINTS FIGURE 3-89 Deciphering the VIN is often necessary to determine the model year, engine size, body style, and other aspects of the vehicle.

33 Chapter 3 Shop Orientation 75 VIN number FIGURE 3-90 The VIN is required to be located in the dash area of the driver s A pillar. One of the reasons that the VIN is placed in so many different places on the vehicle is to help prevent the sale of parts removed from a stolen vehicle. The VIN provides a way to track down parts that have been removed from a stolen vehicle and resold. OTHER VEHICLE ID TAGS The VIN is just one of many different types of identification tags found on modern cars and trucks. There may be six or seven different types of tags or decals located throughout the vehicle, each for a different purpose. Knowing what these tags are for and their common locations can save you a lot of time when you need to track down certain pieces of information about a vehicle. Vehicle Emissions Control Information (VECI) Decal. Located under the hood of each vehicle is the emissions decal. Examples are shown in Figure 3-91 and Figure This decal contains such information as the emission year for which the vehicle is certified, installed emission control devices, FIGURE 3-92 This VECI shows it is for a hybrid electric vehicle (HEV). and what emission standards the vehicle meets. Other information on the decal may include spark plug gap, valve lash settings, and a vacuum schematic. This decal may also tell how to adjust the idle and ignition timing on older vehicles. If the door decal containing the production date is missing from the vehicle, refer to the VECI since it will show for which model year the vehicle is certified. Door Decals. The stickers located on the door jambs can contain a wealth of information, though each manufacturer will supply different details on one or more decals on one or more door jambs. An example of a door decal is shown in Figure Typically, the door decal will contain the vehicle production date and gross vehicle weight, and may contain information about wheelbase, transmission and differential identification, and paint codes. The tire information decal has information about tire size, wheel size, and the recommended inflation pressures. This sticker may also list any optional tire sizes for that vehicle. An example of a tire decal is FIGURE 3-91 The vehicle emission control information (VECI) decal is located under the hood and contains information specific to the engine and emission control devices installed in the vehicle. FIGURE 3-93 This door decal contains information about the transmission and final drive axle. Copyright 201 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the ebook and/or echapter(s).

34 76 Chapter 3 Shop Orientation FIGURE 3-94 Tire decals show the tire and wheel size for the vehicle, the recommended tire pressure, and spare tire information. FIGURE 3-95 An example of a paint code sticker. shown in Figure The tire information may also be located on a glove box door, console door, fuel door or with the spare tire. Paint and trim code stickers may also be located on the door jamb. An example of a paint code sticker is shown in Figure Calibration and Production Decals. Some manufacturers have calibration decals on the engine or transmission. An engine calibration sticker is shown in Figure This decal provides specific information about emissions system devices and calibrations. A production tag is often used on the engine and transmission or transaxle, as shown in Figure This sticker can indicate when the transmission was assembled, at which plant and shift, and gear ranges. FIGURE 3-97 An example of a transmission ID tag. SPO Tags. Vehicles produced by General Motors have a Service Parts Organization (SPO), shown in Figure This tag contains information about all of the options with which the vehicle is equipped, such as interior styles and colors, radio options, and many others. As you can see, however, the tag contains a lot of three-digit codes, which unless you know exactly which one you are looking for, mean nothing. Fortunately, these codes can be deciphered by using the proper service information, from Internet sources, and by a GM parts department. Other vehicle manufacturers use a similar system for tracking the options installed on the vehicle. FIGURE 3-96 The calibration decal has information about the engine and emission control system. FIGURE 3-98 An example of a General Motors Service Parts Organization (SPO) decal. This contains information about installed options and colors used in the vehicle. Copyright 201 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the ebook and/or echapter(s).

35 Chapter 3 Shop Orientation 77 FIGURE 3-99 An example of the numerous decals found under the hood. Accessing Identification Labels under the Hood. Because of the number and varying locations of labels throughout a vehicle, it is worth noting how to access some of these labels. VECI and engine calibration tags are located under the hood in the engine compartment, shown in Figure Also under the hood are decals with information about the air conditioning system, cooling system, accessory belt routing, and possibly others. To get to these labels, you must first open the hood. Locate the interior hood release mechanism, examples of which are shown in Figure and Figure This releases the primary hood latch, shown in Figure Once the interior FIGURE The hood release may be attached to the lower dash trim. FIGURE A typical hood release lever on the left (driver s) side kick panel. FIGURE The hood latch has the secondary hood release. Locate the release lever to fully open the hood. Copyright 201 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the ebook and/or echapter(s).

36 78 Chapter 3 Shop Orientation FIGURE This portion of the hood latch is attached to the hood. Watch out to avoid hitting your head on the latch. FIGURE The hood latch has a primary and secondary release. The cable from the passenger compartment release operates the primary. The secondary is released from under the hood or around the grill area. release is pulled, the hood should pop up slightly, allowing access to the secondary release. This release, shown in Figure and Figure 3-104, is used to prevent the hood from accidently flying open if the driver pulls the primary release by accident while driving. The secondary release lever may be located under the hood in the center, or left or right of center, or may be tucked into or behind the grill. The locations and operation of the secondary release vary greatly among makes and models of vehicles. Once the secondary latch is released, raise the hood. Many vehicles have a hood prop, shown in Figure 3-105, that must be set into a slot in the hood. Other vehicles use either gas-charged hood supports, similar to shock absorbers, to keep the hood raised or a set of springs FIGURE Many vehicles have a simple prop rod to hold the hood open. Locate the recess or hole in the hood for the prop rod. Do not forget to remove and secure the prop rod before trying to close the hood. Figure Before getting under the hood, make sure that it is securely supported on the hood prop or that the struts tend to lose their ability to keep the hood up over time, resulting in a situation where the hood can suddenly drop. Service Orders A service order or repair order (RO) is a contract between the customer and the shop. It contains pertinent customer information, vehicle information, and a record of services and repairs. A service order is also a legal document, designed for both the shop and the customer. CUSTOMER RECORDS One of the main purposes of the service order is to maintain customer records. This database contains customers contact information and the service histories for their vehicles. Many shops also use this database to send Copyright 201 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the ebook and/or echapter(s).

37 Chapter 3 Shop Orientation The method of approving additional repairs or services. 6. The customer s signature and receipt of an estimate. FIGURE A hood may be supported by gas-charged shocks, called lifts or struts. Before working under the hood supported by these shocks, make sure the hood will remain up. Old, worn out shocks allow the hood to drop, sometimes slowly, sometimes fast. reminders to their customers when certain services are due, such as engine oil changes. Components of a Service Order. When a vehicle is in for service, a service order should be completed. An example of a service order is shown in Figure A service order allows the shop to provide a written estimate and to document what services are performed. It should contain the following information: 1. Customer name, address, and contact information. Include cell phone numbers and addresses as needed to ensure your ability to contact the customer easily. 2. Vehicle information, such as the year, make, model, license number, and VIN. 3. A complete and accurate description of the complaint(s), if applicable. 4. A description of the services, repairs, or diagnostic procedures to be performed and their costs. Many states have laws requiring the shop to provide an estimate for work if the expected cost is over a certain amount, such as $25. The repair order should include adequate space for the documentation of communication with the customer about estimates and delivery times. Most shops now use a computerized repair order system. This allows for easy storage and retrieval of customer records without the necessity of storing large amounts of paper records. Electronic repair order generation also allows for maintaining a customer database, useful for quickly finding customer information, past repair histories, and comments and recommendations made during previous visits. An example is shown in Figure Computerized repair orders also allow for more precise job dispatching to the technicians. While some shops may send repair orders out to the next available technician, many shops select what a technician will receive based on his or her abilities. Doing this ensures that the most qualified technicians receive the work, increasing productivity and customer satisfaction. Once a technician receives the work order, notes regarding diagnosis, needed parts and labor, and other recommendations can be entered or written on the paper copy and sent back to the service advisor. The service advisor will then cost-out the order and contact the customer. Accurate and complete documentation of diagnostic steps, test results, and recommendations are critical. Technician and shop income can be reduced by incomplete documentation. Some states allow for a slight amount of difference between a repair estimate and the final cost; this difference is typically 10 percent or less of the total bill. If the expected cost of repairs does change due to unforeseen problems, the customer needs to be notified and given a revised estimate. Technician Records. The service order also provides a method of determining how much technicians are paid. This is because many shops pay their technicians a commission, often based on how much labor is produced or in some cases, the total amount of parts and labor sales. Regardless of which method is used, if a technician s pay is based on a commission, it is important for the technician to correctly document all the work he or she performed. When you are completing a service order, the technician or the service advisor fills in part and labor codes, shown

38 80 Chapter 3 Shop Orientation Customer Information JACK S SHOP REPAIR 1234 TODAY S Some Street DATE ORDER Company Sometown, AA (456) DATE / / MAKE SURE YOU HAVE Name ALL OF THE Vehicle Information Address CUSTOMER S CONTACT INFORMATION!! Year: Make: YOU MUST HAVE COMPLETE City Model: AND ACCURATE INFORMATION State Zip code Color: IN ORDER TO PROPERLY Home: ( ) VIN: REPAIR THE VEHICLE! Work: ( ) Engine: Cell: ( ) License Number: ST Other: ( ) Odometer reading: Description of Service Repair Estimate Total Parts: Total Labor: THIS IS ONE OF THE MOST Other charges: IN MOST STATES, YOUR Initial estimate: ESTIMATE MUST BE IMPORTANT SPACES YOU Estimate given by: FINAL NEED TO FILL IN! Date BILL. TAKE Time YOUR TIME AND GIVE AS EXPLAIN WHAT THE CUSTOMER Phone: ACCURATE AN ESTIMATE WANTS AND/OR WHY THE VEHICLE In person AS YOU CAN! HAS BEEN BROUGHT INTO THE SHOP. Additional authorized amount: WITHIN 10% OF THE Revised estimate: Authorization given by: Date Time Phone: Services Time Price Totals R&R Right Front Strut Date completed / / R&R Air Filter Tech EACH SERVICE PERFORMED STANDARD TIME FOR EACH SERVICE Part # Description Qty. Price Ext.Price JE8538 Strut assembly RE4949 Air filter XX3344z Shop supplies THIS INFORMATION NEEDS TO BE COMPLETE FOR ACCURATE BILLING AND FOR INVENTORY MAINTENANCE. HOURLY LABOR RATE MULTIPLIED BY TIME Services Parts Shop supplies Sub total WHAT THE Tax CUSTOMER PAYS 6% Total $ FIGURE A repair order is a legal contract between the shop and the customer. All relevant information should be included on the RO.

39 Chapter 3 Shop Orientation 81 FIGURE An example of an electronic RO. in Figure These codes identify the parts used and labor operations for the vehicle. These codes are important, especially when performing warranty repairs, so that both the technician and the shop are properly reimbursed. Legal Issues. Because the service order is a legal document, a type of contract between the customer and FIGURE Part numbers listed on an RO. the shop, there is usually some type of legal disclaimer that the customer signs. An example of this may state that once the customer agrees to the estimate and authorizes the shop to begin repairs, labor charges will be incurred if the customer halts the repair before completion. Another example is that customers have the right to keep their old parts. If there is a core charge on a part, the customers must pay the core charge to obtain the old part. SUMMARY Automotive training programs are an excellent way in which to begin a career in the auto repair industry. Most programs use both classroom and lab environments to teach the necessary skills to the students. Because of this, many labs operate in very similar ways to real auto repair shops. This allows students to get experience as they would in the real world but also presents certain dangers if safety and correct behaviors are disregarded. Working in the auto lab exposes students to many types of tools, from basic hand tools to expensive diagnostic and specialty equipment. Because of this, students need to fully understand a piece of equipment s proper operation before attempting to use the equipment. This helps to prevent damage to equipment and injury to the student. REVIEW QUESTIONS 1. Every vehicle has a unique that contains information about where and when the vehicle was made. 2. wrenches have a box end and an open end. 3. A hammer contains lead shot or a similar material to reduce rebound. 4. A set is often used to correct damaged threads. 5. The VECI or often contains information about spark plug gap and valve lash adjustment. 6. Which of the following is not a safety precaution when using an above ground lift? a. Recheck the pad contact after raising the vehicle. b. Ensure the area under the vehicle is clear before lowering. c. Read and understand the operating instructions of the lift before use. d. Raise to the desired height and begin to work.