SCHOOLS OF AUTOMOTIVE TECHNOLOGY 3/2010 AUTOMOTIVE TECHNOLOGY II

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1 I. COUSE DESCRIPTION SCHOOLS OF AUTOMOTIVE TECHNOLOGY 3/2010 AUTOMOTIVE TECHNOLOGY II This course will provide a sound educational building foundation for the students with a strong interest in the automotive industry. They will describe the trade requirements and will give direction into the automotive employment opportunities. The students will demonstrate competency written and performance activities in shop operation procedures and shop safety rules. The students will identify, select, operate and maintain the hand tools of the automotive trade. They will identify, operate, maintain and store the equipment used on various automotive shops such as: hydraulic jacks, safety stands, vehicle lifts, tire mounting and dismounting machines, tire/wheel balancing machines, battery charger, battery testers, bench grinder, bench vise, parts washing machine, and grease lubricating guns. The students will be able to set a vehicle lift in order to raise a vehicle safely. The students will raise a vehicle using a hydraulic jack safely and will place safety stands under a vehicle correctly to prevent any injury to themselves or cause any damage to the car and equipment. The students will perform routine scheduled maintenance services to the vehicle such as: change engine oil and filter; lubricate moving parts as required by the manufacturer. The students will inspect and refill all fluids found in a vehicle. The students will be able to search information for diagnosis and repair using industry-based information including computerized multimedia based material. The A-5 ASE brake section will enable the students to identify components, clean inspect and repair brake systems. The A-1 ASE engine repair section will enable the students to identify components, clean, machine and remove and replace components found in today s engines. Passaic County Technical Institute s automotive program is a National Automotive Technicians Educational Foundation (NATEF) Certified program, which offers students instruction in the four basic areas of automotive technology. This program provides students with industry-based standards in Engine Performance, Brakes, Electrical/Electronics as well as in Steering and Suspension. The task-based curriculum teaches industry standards so that the student can have a smooth transition to the work environment. Students enter this in the first year by applying both to our School of Automotive Technology. This exploratory year enables students to participate in our NATEF certified Auto Collision Repair and our Automotive Technology Program. The half-year course is designed to have student explore all possibilities of the automotive industry. Automotive Technology I provides entry-level tasks that can accent either program. The program begins with a comprehensive safety program that is reinforced every year. The students will identify, select, operate, and maintain equipment used in various automotive shops such as: hydraulic jacks, safety stands, car lifts, tire mounting and dismounting machines, battery chargers and testers as well as hand tools associated with the industry. Students will perform routine maintenance schedules, which involve fluid inspections, replacement, adjustments and lubrication.

2 Second year students have selected Automotive Technology as a major, These students can demonstrate written and performance driven competencies. Building upon skills from the previous year they will participate in a safety program as well as a shop maintenance program. Major areas of concentration are ASE task area A-1 (Engine Repair) and A-5 (Brake Systems). Engine repair gives the student basic knowledge and the correct operation of the power plant of today s modern vehicles. This becomes the foundation of all the levels to come. Brakes systems are an overview, which will enable students to identify, clean, inspect and repair brake components. Level Three begins with an advanced review of levels II & I and also improve the work habits and learning skill of the students. ASE Task Areas are A-4 (Steering and Suspension) an A-6 (Electrical / Electronics-phase 1). A-4 teaches the basic components, inspection, repair and adjustments of today s complex steering and suspension systems. A-6 phase-1 is electrical theory, battery, charging system and starting system inspection and repair. Completing levels I, II, & III prepares the student with enough employable skills that makes them eligible for the Automotive Youth Education System (AYES). AYES is an industry-based program that sponsors a junior in High School as an apprentice for the summer. Ayes students generally become part of the School to Work program at PCTI so that students can finish their senior year by going to academic class in the morning and working in the afternoon. Basically earning while learning. Level IV begins with an advanced review of, Auto I, II, & III. ASE task areas are A-6 phase II and A-8 (Engine Performance). Phase II presents Accessory diagnosis, driver information systems, safety device systems and interpreting wiring diagrams. A-8 Engine Performance includes general engine diagnosis, computerized engine controls, and emission control devices. The Automotive Technology curriculum is task based so that upon successful completion of the program students have learned and demonstrated employable skills. II. COURSE OBJECTIVES / OUTLINE LEVEL II (300 Hours) Safety Tools and Equipment Careers Communication Vehicle Maintenance Service Publication Vehicle Preparation Engine Repair Brakes NATEF Exit Exam Preparation Upon successful completion of the requirements of this course, the student will be able to: A. Apply orientation procedures and shop rules.(1.3.2, , 6.9.8) B. Develop proper attitudes concerning safety in the automotive shop and practice safety rules. (2.1.4) C. Properly use shop hand tools, power tools and specialized equipment appropriate for this level of instruction. (1.3.2, )

3 D. Apply service and diagnostic procedures using all types of conventional automotive fasteners.(1.6.3, 2.2.2) E. Acquire an understanding of how to utilize and locate information found in automotive service manuals, including CD-ROM based information such as ALLDATA. (1.6.3, 4.5.5, 5.2.3) F. Acquire an understanding of how to properly fill out an automotive repair order. (3.5.10) G. Perform all types of lubrications on automobiles including the proper identification of each type. (2.5.11) H. Diagnose and service various types of wheel and tires found on domestic and foreign vehicles. (1.6.3, ) I. Indicate a basic understanding of test equipment including, battery, charging system tester, digital volt ohmmeter, and a test light. (4.5.5) J. Diagnose and service different types of cooling systems including identification and functions of each component.(1.6.3, ) K. Describe and explain basic fuel injection theory.(3.4.22) L. Identify and make service repairs on various types of exhaust systems. (2.5.11, 6.1.2) M. Describe and explain basic engine theory. (3.4.22) N. Diagnose and service domestic and foreign engines.(1.6.3, ) O. Acquire an understanding of how to read and use a micrometer. (4.5.5) P. Describe and explain the brake system theory.(3.4.22, 6.5.4) Q. Diagnose and service various types of brakes found on today s vehicles.(1.6.3, ) LEVEL II TASK LIST I. ENGINE REPAIR A. General Engine Diagnosis; Removal and Reinstallation (R & R) 1. Verify and interpret engine concern; determine necessary action. P-1 2. Inspect engine assembly for fuel, oil, coolant, and other leaks; determine necessary action. I. ENGINE REPAIR B. Cylinder Head and Valve Train Diagnosis and Repair 1. Remove cylinder head(s); visually inspect cylinder head(s) for cracks; check gasket surface areas for warpage and leakage; check passage condition. 2. Install cylinder heads and gaskets; tighten according to manufacturer s specifications and procedures. 3. Inspect and test valve springs for squareness, pressure, and free height comparison; replace as needed. 4. Inspect valve spring retainers, locks, and valve grooves. 5. Replace valve stem seals.

4 6. Inspect valve guides for wear; check valve guide height and stem-to-guide clearance; recondition or replace as needed. 7. Resurface valves; perform necessary action. 8. Resurface valve seats; perform necessary action. 9. Check valve face-to-seat contact and valve seat concentricity (runout); service seats and valves as needed. 10. Check valve spring assembled height and valve stem height; service valve and spring assemblies as needed. 11. Inspect pushrods, rocker arms, rocker arm pivots and shafts for wear, bending, cracks, looseness, and blocked oil passages (orifices); perform necessary action. 12. Inspect hydraulic or mechanical lifters; replace as needed. 13. Adjust valves (mechanical or hydraulic lifters). P Inspect camshaft drives (including gear wear and backlash, sprocket and chain wear); replace as necessary. 15. Inspect and replace timing belt(s), overhead camdrive sprockets, and tensioners; check belt tension; adjust as necessary. P Inspect camshaft for runout, journal wear and lobe wear. 17. Inspect and measure camshaft bearings for wear, damage, out-of-round, and alignment; determine necessary action. 18. Verify camshaft(s) timing according to manufacturer s specifications and procedure. P-1 I. ENGINE REPAIR C. Engine Block Assembly Diagnosis and Repair 1. Inspect and replace pans, covers, gaskets, and seals. 2. Inspect engine block for visible cracks, passage condition, core and gallery plug condition, and surface warpage; determine necessary action. 3. Inspect internal and external threads; restore as needed (includes installing thread inserts). P-1 4. Remove cylinder wall ridges. 5. Inspect and measure cylinder walls for damage and wear; determine necessary action. 6. Deglaze and clean cylinder walls. P-1 7. Inspect and measure camshaft bearings for wear, damage, out-of-round, and alignment; determine necessary action. 8. Inspect crankshaft for surface cracks and journal damage; check oil passage condition; measure journal wear; determine necessary action. 9. Inspect and measure main and connecting rod bearings for damage, clearance, and end play; determine necessary action (includes the proper selection of bearings). 10. Identify piston and bearing wear patterns that indicate connecting rod alignment and main bearing bore problems; inspect rod alignment and bearing bore condition. 11. Inspect, measure, and service pistons and pins; determine necessary action.

5 12. Inspect, measure, and install piston rings. 13. Inspect, repair or replace crankshaft vibration damper (harmonic balancer). 14. Reassemble engine components using correct gaskets and sealants. 15. Inspect auxiliary (balance, intermediate, idler, counterbalance or silencer) shaft(s); inspect shaft(s) and support bearings for damage and wear; determine necessary action; reinstall and time. III. EVALUATION Students are evaluated using the following criteria: 1. Attendance 2. Class participation 3. Periodic tests and quizzes 4. Lab projects 5. Notebook 6. Completion of ASE task skills for each area 7. Special projects, reports, oral presentations IV. Textbooks, Instructional Materials & Software Modern Automotive Technology Automotive Technology AYES Automotive Curriculum Automotive Software Brakes Steering and Suspension Electrical/Electronics Engine Performance James E. Duffy, The Goodheart -Willcox Company, Inc., Tinley Park, Illinois; 2009 Jack Erjavec, Rene Green, Delmar Publishers, Albany, N.Y.; 2000 Cord Communications, Inc, Waco, Texas, Automotive Youth Education Systems, Troy, Michigan, 1999 CDX ON-LINE Software Jones and Bartlett Publishers 40 Tall Pine Drive Sudbury, MA, USA ALLDATA ALLDATA, 2009 Multimedia ON-LINE Based Service Manuals

6 V. INSTRUCTIONAL STRATEGIES Various teaching methods are utilized in the Schools of Automotive Technology course. The instructors will use meaning exercises such as prepared worksheets and exercises from textbooks, ATECH workbooks, AYES curriculum, and AYES vehicle work orders. Teacher examples of work ethics and habits, cooperative learning and teacher evaluation, will also be implemented. Finally, the use of auto-related video material, overhead projector, test/diagnostic equipment and vehicle components would supplement and enhance classroom instruction. VI. Automotive Technology Level II Scope and Sequence A-5 Automotive Brakes Name Week Beginning Skill Set Record Sheets Week Ending Directions: Evaluate the student by checking the appropriate number or letter to indicate the degree of competency. The rating for each task should reflect employability readiness A5 rather than the grades given in class. B. Drum Brake Diagnosis and Repair Rating Scale: 3 Mastered- can work independently wit no supervision 2 Requires Supervision- can perform job completely with limited supervision 1 Not Mastered- requires instruction and close supervision N No Exposure- no experience or knowledge in this area A5 A. Hydraulic System Diagnosis and Repair 1. Measure and adjust pedal pushrod length and pedal height. 2. Check master cylinder for internal and external leaks and proper operation; determine needed repairs. 3. Remove, bench bleed, and replace master cylinder. P-1 4. Diagnose poor stopping, pulling or dragging caused by problems in the hydraulic system; determine needed repairs. 5. Inspect brake lines and fittings for leaks, dents, kinks, rust, cracks or wear; tighten loose fittings and supports. 6. Inspect flexible brake hoses for leaks, kinks, cracks, bulging or wear; tighten loose fittings and supports. 7. Fabricate and install brake lines (double flare and ISO types); replace hoses, fittings, and supports as needed. P-1 8. Select, handle, store, and install brake fluids to proper level. 9. Inspect, test, and replace metering hold-off), proportioning (balance), pressure differential, and combination valves. 10. Inspect, test, replace, and adjust height (load) sensing proportioning valve.

7 11. Inspect, test, and replace components of brake waning light systems. P Bleed (manual, pressure, vacuum or surge) brake systems; flush hydraulic system. A 5 B. Drum Brake Diagnosis and Repair P-1 1. Diagnose poor stopping, noise, pulling, grabbing, dragging or pedal pulsation problems; determine needed repairs. P-1 2. Remove, clean (using proper safety procedures), inspect, and measure brake drums; service or replace as needed. 3. Mount brake drum on lathe; machine braking surface. 4. Remove, clean, and inspect brake shoes, springs, pins, clips, levers, adjusters/self-adjusters, other related brake hardware and backing support plates; lubricate and reassemble. 5. Remove and reinstall wheel cylinders. 6. Pre-adjust brake shoes and parking brake before installing brake drums or drum/hub assemblies and wheel bearings. P-1 7. Reinstall wheel, torque lug nuts, and make final checks and adjustments. A 5 C.0Disk Brake Diagnosis and Repair P-1 1. Diagnose poor stopping, noise, pulling, grabbing, dragging or pedal pulsation caused problems; determine needed repairs. 2. Remove caliper assembly from mountings; clean and inspect for leaks and damage to caliper housing. 3. Clean and inspect caliper mounting and slides for wear and damage. 4. Remove, clean, and inspect pads and retaining hardware; determine needed service. 5. Disassemble and clean caliper assembly; inspect parts for wear, rust, scoring, and damage; replace seal, boot, and damaged or worn parts. 6. Reassemble, lubricate, and reinstall caliper, pads, and related hardware. P-1 7. Clean, inspect, and measure rotor with a dial indicator and a micrometer; follow manufacturer s recommendations in determining need to machine or replace. 8. Refinish rotor according to manufacturer s recommendations.

8 9. Adjust caliper with integrated parking brake system. P Fill master cylinder with recommended fluid and seat pads; inspect caliper for leaks. P Reinstall wheel, torque lug nuts, and make final checks and adjustments. 12. Remove and replace rotor. A 5 D. Power Assist Unit Diagnosis and Repair 1. Test pedal travel with and without engine running; check power assist operation. 2. Check vacuum supply (manifold or auxiliary pump) to vacuum-type power booster. 3. Inspect the vacuum-type power booster unit for vacuum leaks; inspect the check valve for proper operation; repair or replace parts as needed. A 5 E. Miscellaneous (Wheel Bearings, Parking Brakes, Electrical, Etc.) Diagnosis and Repair P-1 1. Diagnose wheel bearing noises, wheel shimmy, and vibration problems; determine needed repairs. P-1 2. Remove, clean, inspect, repack, and reinstall wheel bearings and replace seals; reinstall hub and adjust wheel bearings. 3. Check parking brake cables and components for wear, rusting, binding, and corrosion; clean, lubricate, and replace as needed. P-1 4. Check parking brake operation; adjust as needed. 5. Check operation of parking brake indicator light system. P-1 6. Check operation of brake stop light system; adjust and service as needed. P-1 7. Replace wheel bearing and race. A5 F. Anti-Lock Brake System 1. Inspect, test, and service anti-lock brake system (ABS) hydraulic, electrical, and mechanical components. 2. Diagnose poor stopping, wheel lock-up, abnormal pedal feel or pulsation, and noise problems caused by the anti-lock brake system (ABS); determine needed repairs.

9 3. Observe anti-lock brake system )ABS) warning light(s) at startup; determine if further diagnosis is needed. 4. Diagnose anti-lock brake system (ABS) electronic control(s) and components using self-diagnosis and/or recommended test equipment; determine needed repairs. 5. Depressurize high pressure components of the antilock brake system (ABS) following manufacturer s recommended safety procedures. 6. Fill the anti-lock brake systems (ABS) master cylinder with recommended fluid following manufacturer s procedures; inspect system for leaks. 7. Bleed the anti-lock brake system s (ABS) front and rear hydraulic circuits following manufacturer s procedures. 8. Perform a fluid pressure (hydraulic boost) diagnosis on the high pressure anti-lock brake system (ABS); determine needed repairs. 9. Remove and install anti-lock brake systems (ABS) electrical/electronic/hydraulic components following manufacturer s procedures and specification. 10. Service, test, and adjust anti-lock brake system (ABS) speed sensors following manufacturer s recommended procedures. 11. Diagnose anti-lock brake system (ABS) braking problems caused by vehicle modifications (tire size, curb height, final drive ratio, etc.).

10 PASSAIC COUNTY TECHNICAL INSTITUTE SCHOOL OF AUTOMOTIVE TECHNOLOGY STUDENT PROFICIENCIES AUTOMOTIVE TECHNOLOGY II Course Overview This course provides the Automotive Technology II students with a Comprehensive program that includes the preparation of the automobile for various types of repairs, as it would be required in the automobile industry. Proficiencies- Upon successful completion of the requirements of this course, the student will be able to: A. Apply orientation procedures and shop rules. B. Develop proper attitudes concerning safety in the automotive shop and practice safety rules. C. Properly use shop hand tools, power tools and specialized equipment appropriate for this level of instruction. D. Apply service and diagnostic procedures using all types of conventional automotive fasteners. E. Acquire an understanding of how to utilize and locate information found in automotive service manuals, including On-line based information such as ALLDATA and Identifix F. Acquire an understanding of how to properly fill out an automotive repair order. G. Perform all types of lubrications on automobiles including the proper identification of each type. H. Diagnose and service various types of wheel and tires found on domestic and foreign vehicles. I. Indicate a basic understanding of test equipment including, battery, charging system tester, digital volt ohmmeter, and a test light. J. Diagnose and service different types of cooling systems including identification and functions of each component. K. Describe and explain basic fuel injection theory. L. Identify and make service repairs on various types of exhaust systems. M. Describe and explain basic engine theory. N. Diagnose and service domestic and foreign engines. O. Acquire an understanding of how to read and use a micrometer. P. Describe and explain the brake system theory. Q. Diagnose and service various types of brakes found on today s vehicles.

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