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CAREERS IN THE
AUTOMOTIVE INDUSTRY
CHAPTER OVERVIEW
This chapter examines the automotive industry today and points out the changes that are
occurring. Professional service provided by a properly trained technician is critical because
of the technology used in todays vehicles. A detailed description is given of what it takes
to be a professional technician. Descriptions of career opportunities, job classifications,
and ASE certification requirements are provided.

CHAPTER OBJECTIVES
Describe the reasons why todays automotive industry is considered a global
industry.
Explain how computer technology has changed the way vehicles are built and
serviced.
Explain why the need for qualified automotive technicians is increasing.
Describe the major types of businesses that employ automotive technicians.
List some of the many job opportunities available to people with a background in
automotive technology.
Describe the different ways a student can gain work experience while attending
classes.
Describe the requirements for ASE certification as an automotive technician and as
a master auto technician.

INSTRUCTIONAL OUTLINE WITH TEACHING HINTS


I. Servicing Todays Vehicles
A. The Importance of Automotive Technicians
B. The Need for Quality Service
C. The Need for Ongoing Service
1. Warranties
2. Increased Vehicle Age
Hint: Discuss the need for repairs as cars become older and what
opportunities this need presents to a qualified technician.

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II.

III.

IV.

V.

D. Career Opportunities
1. Dealerships
2. Independent Service Shops
3. Franchise Repair Shop
4. Store-Associated Shops
5. Fleet Service and Maintenance
Hint: Discuss career opportunities in all areas of automotive service.
Job Classifications
A. Service Technician
B. Shop Foreman
C. Service Adviser
D. Parts Counterperson
E. Parts Manager
Hint: Discuss the various automotive shop positions and how they each
relate to the technicians.
Related Career Opportunities
A. Parts Distribution
B. Marketing and Sales
C. Other Opportunities
Training for a Career in Automotive Service
A. Student Work Experience
1. Job Shadowing Program
2. Mentoring Program
3. Cooperative Education
4. Apprenticeship Program
5. Part-Time Employment
6. Postgraduate Education
B. Canadas Automotive Apprenticeship Program
1. Red Seal Program
C The Need for Continuous Learning
ASE Certification
Hint: Introduce the various programs in your area that are available to students.

ANSWERS TO TEXTBOOK REVIEW QUESTIONS


1. Electronics are widely used because they allow for rapid response to changes in operating conditions; they are inexpensive, lightweight, and very reliable.
2. To become a successful automotive technician you must be able to master and keep
up with the latest technologies, and you must possess the skills to work well with
people.
3. There are a variety of types of businesses that employ automotive technicians.
a. Dealerships provide repair and maintenance on vehicles while they are under warranty and beyond. They offer the technician good technical support, special diagnostic equipment, an opportunity to specialize, and ongoing training. A disadvantage
could be becoming limited to one or two particular model lines.
b. Independent repair shops service all types of vehicles, sometimes specializing in
certain areas of repair, or in either import or domestic vehicles. This type of shop may
present constant service and diagnostic challenges to the technician, providing an
opportunity to gain a well rounded technical background. Disadvantages may include

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Careers in the Automotive Industry

4.

5.
6.
7.
8.
9.

10.
11.
12.
13.
14.

15.

having less sophisticated diagnostic equipment to work with and less dealership sponsored training.
c. Store-associated shops provide certain specialized services such as brakes, exhaust
systems, and wheel and tire repair. An advantage to the technician is the ability to specialize in one area and product. A disadvantage is not becoming as well rounded in
other areas of automotive service.
d. Specialty service shops provide repairs in specialized repair areas such as engine
rebuilding, transmission/transaxle overhauling, brake, exhaust, emissions, or electrical systems. Technicians can become very skilled in the specialized area, but they can
also limit themselves.
e. Fleet service and maintenance shops provide service and maintenance for a fleet
of company-owned vehicles. Their technicians can become very familiar with a wide
range of vehicles over an extended period of time.
There are many ways that you can gain work experience while you are a student. They
include:
a. job shadowing
b. mentoring
c. cooperative education
d. apprenticeship
e. part-time employment
True. Apprenticeships have prescribed tasks that must be completed.
b. While a vehicle is still under warranty, repairs are usually performed in dealership
service departments.
c. Specialty shops perform work on one or more automotive systems.
d. The service advisor prepares cost estimates.
d. Neither technician is correct. After technicians pass a particular certification exam
they have completed the voluntary exam requirement for certification in that test area,
but they must still complete the work experience requirement before certification is
complete. ASE certification questions are written in several formats such as Technician A and Technician B, Most Likely, Least Likely, and questions with the word
except. Because neither technician is correct, d is the best answer.
d. A successful technician must possess each of the skills listed.
b. Two years of work experience are required to complete ASE certification. Two years
of formal training count as one of the two required years of hands-on experience.
b. Master automotive technicians are certified in all eight ASE areas.
a. Batteries and other automotive parts have prorated warranties.
c. Aftermarket parts stores that sell to both the general public and to service shops
are referred to as jobbers. Warehouse distributors do not generally sell to the general public, and mass merchandisers selling automotive products are retail outlets.
d. Technical training and support is supplied by original equipment manufacturers
(OEMs), aftermarket parts manufacturers, jobbers, tool and equipment suppliers, and
others.

ANSWERS TO TECH MANUAL REVIEW QUESTIONS


1. Hydraulics, electronics, pneumatics, and mechanical
2. Doing the job right the first time leads to success and self-confidence and to customer
confidence.
3. PM is performing services on a scheduled basis to prevent problems, not repair them.

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4. Warehouse distributors sell and supply parts to part wholesalers commonly known as
jobbers. Jobbers sell and service automotive shops and do-it-yourselfers.
5. Some specialty shops are franchised shops. Explanations will vary.
6. Perform diagnosis, act professionally, be honest, and receive updated training
7. The Red Seal program is the highest achievement for a technician certification.
8. Diagnosis, system knowledge, and experience
9. Technician, parts counterperson, service advisor, equipment sales or service, and
instructor
10. Answers will vary.

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2
WORKPLACE SKILLS

CHAPTER OVERVIEW
This chapter describes the workplace skills needed to successfully obtain a job and how
to keep it. Among the topics discussed are the preparation of a resume and cover letter,
and how to prepare for a job interview. The basis for good workplace skills is respect. You
must not only have respect for yourself, but also for your employer, your fellow employees, and your customers.

CHAPTER OBJECTIVES
Develop a personal employment plan.
Seek and apply for employment.
Prepare a resume and cover letter.
Prepare for an employment interview.
Accept employment.
Understand how automotive technicians are compensated.
Understand the proper relationship between an employer and an employee.
Explain the key elements of on-the-job communications.
Be able to use critical thinking and problem-solving skills.
Explain how you should look and act to be regarded as a professional.
Explain how fellow workers and customers should be treated.
Describe the information that should be included on a repair order.
Explain how repair costs can be estimated.

INSTRUCTIONAL OUTLINE WITH TEACHING HINTS


I. Seeking and Applying for Employment
A. Employment plan
B. References
C. Identifying Job Possibilities
D. Preparing Your Resume
E. Preparing Your Cover Letter
F. Contacting Potential Employers

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II.

III.

IV.

V.

VI.
VII.

VIII.

G. Applications
H. The Interview
I. After the Interview
Hint: Show examples of good and poorly completed resumes, cover letters,
and applications. Have the students apply for a mock job opening. Block out
the names and have the class look at the applications, cover letters, and
resumes and vote on which the applicant would most likely get hired.
Accepting Employment
A. Compensation
1. Flat Rate
Working as an Automotive Technician
A. Employer-Employee Relationships
1. Instruction and Supervision
2. Clean, Safe Place to Work
3. Wages
4. Fringe Benefits
5. Opportunity and Fair Treatment
6. Regular Attendance
7. Following Directions
8. Responsibility
9. Productivity
10. Loyalty
Hint: Invite a shop foreman or service manager to speak to the students
about what characteristics are most valued in employees.
Communications
A. Nonverbal Communication
Hint: Have a student demonstrate various nonverbal communications and let
the class decide what is being communicated.
Solving Problems and Critical Thinking
A. Diagnosis
Hint: Provide several puzzles or riddles to allow the students to test their
critical thinking skills.
Professionalism
A. Coping with Change
Interpersonal Relationships
A. Customer Relations
Hint: Invite a receptionist or a similar professional to talk to the students
about telephone etiquette and customer relations.
Repair Orders
A. Guidelines for Estimating Repair Costs
Hint: Show examples of properly and improperly completed work orders.

ANSWERS TO TEXTBOOK REVIEW QUESTIONS


1. c. Deciding to replace components using a process of elimination until the problem
is repaired is not part of an accurate diagnosis
2. Your employment plan should include your specific job goals and a plan to reach them.
You should list your interests, skills, and attitudes that match the job you are seeking.
Include both your short-term and long-term goals along with a prioritized list of potential employers.

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3. Flat rate means that each technician is paid according to the amount of work produced. Each job has a flat rate time, and the technician is paid for that amount of time
regardless of how long it takes to complete the task. The flat rate system rewards the
most productive technicians, while providing for more accurate repair estimates.
4. Your cover letter should include three paragraphs. The first should describe your
interest in working for this employer and the position you are seeking. The second
paragraph is used to sell yourself, and the third is used as a closing by thanking the
employer and requesting an interview.
5. True. A repair order protects the rights of both the shop and the customer.
6. b. Do not list all of the jobs you have ever had. List and emphasize only the things
that relate to the job you are seeking.
7. c. A responsible person does not attempt to avoid the consequences of his mistakes
or share the blame with others.
8. False. The best way to quit a job is to write a letter of resignation and present it personally to the employer.
9. False. The application should be filled out completely. Answer every question. Write
N/A if a question does not apply to you.
10. c. Never answer questions with a simple yes or no.
11. c. A good employee should be reliable, responsible, and loyal. Being sociable can be
a good characteristic, but should not interfere with productivity.
12. a. After an interview you should reflect on what took place in order to do better next
time. A letter of thanks should be sent to the employer within three days after the
interview, not within two weeks as stated by Applicant B.
13. c. You should not only look at people while they are speaking to you, but also listen
carefully and try to fully comprehend the message.
14. b. Try to fully comprehend messages by asking questions and gathering details. Folding your arms is a nonverbal communication indicating rejection of the message.
15. a. Soft skills are personal skills that are part of your personality and are used while
relating to other people. Enjoyment of solving puzzles or problems is a technical skill
rather than a personal skill.

ANSWERS TO TECH MANUAL REVIEW QUESTIONS


1. It is the blueprint of career goals for the next 6 months, 5 years, and 10 years,
respectively.
2. The cover letter describes your job-ready skills and how they apply to the position you
are seeking.
3. As the successful candidate for a position, your job offer will include hours of work
and starting hourly or monthly salary depending on the company.
4. The automotive technician is compensated by an hourly wage, flat-rate hourly wage,
or monthly salary.
5. a. provide a clean, safe, and harassment-free work environment
b. pay for services rendered
c. provide fringe benefits as agreed
d. provide an opportunity for career advancement
6. a. arrive for work on time
b. have regular attendance
c. give an honest days work
d. be responsible for their actions

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7. Descriptions of the following elements of good communication will vary:


a. speaking
b. listening
c. reading
d. writing
8. The difference between verbal and nonverbal communication is that verbal communication involves speaking, listening, reading, and writing. Whereas, nonverbal communication is demonstrated by voice tone, body expression, and body positioning.
9. a. written authorization for the vehicle repairs
b. legal agreement to pay for the work performed
10. a. flat-rate labor time for the task
b. part(s) cost
c. shop supplies
d. state and federal taxes

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3
WORKING SAFELY
IN THE SHOP
CHAPTER OVERVIEW
This chapter discusses shop safety in detail. The topics range from clothing and eye protection to handling tools, vehicle handling in the shop, and handling hazardous waste. The
instructor might want to refer to this chapter for review when discussing safety issues in
later chapters.

CHAPTER OBJECTIVES
Understand the importance of safety and accident prevention in an automotive shop.
Explain the basic principles of personal safety, including protective eye wear,
clothing, gloves, shoes, and hearing protection.
Explain the procedures and precautions for safely using tools and equipment.
Explain the precautions that need to be followed to safely raise a vehicle on a lift.
Explain what should be done to maintain a safe working area in a shop, including
running the engines of vehicles in the shop and venting the exhaust gases.
Describe the purpose of the laws concerning hazardous wastes and materials,
including the right-to-know laws.
Describe your rights, as an employee and/or student, to have a safe place to work.

INSTRUCTIONAL OUTLINE WITH TEACHING HINTS


I. Personal Safety
A. Personal Safety Precautions
1. Eye Protection
2. Clothing
3. Hair and Jewelry
4. Shoes
5. Gloves
6. Disease Prevention
7. Ear Protection
8. Respiratory Protection
9. Lifting and Carrying

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II.

III.

IV.

V.

B. Professional Behavior
Hint: Invite the students to tell about persons they are acquainted with who
have had work-related injuries.
Tool and Equipment Safety
A. Hand Tool Safety
B. Power Tool Safety
C. Compressed Air Equipment Safety
D. Lift Safety
E. Jack and Jack Stand Safety
F. Chain Hoist and Crane Safety
G. Cleaning Equipment Safety
1. Chemical Cleaning
2. Thermal Cleaning
3. Abrasive Cleaning
H. Vehicle Operation
Hint: Show the students various items of equipment in the shop and explain
the safety concerns related to each.
Work Area Safety
A. Fire Extinguishers
Hint: Show where the fire extinguishers are located and tell how they should
be operated.
Manufacturers Warnings and Government Regulations
A. Chemical Hazards
B. Hazardous Wastes
C. Physical Hazards
D. Ergonomic Hazards
E. OSHA
F. Right-To-Know Law
Hazardous Materials
Hint: Show the MSDS sheets and the substances they apply to in your work area.
A. Guidelines for Handling Shop Wastes
1. 0.1
2. Oil Filters
3. Batteries
4. Metal Residue from Machining
5. Refrigerants
6. Solvents
7. Containers
8. Other Solids
9. Liquid Recycling
10. Shop Towels/Rags
11. Hiring a Hauler
12. Waste Storage
Hint: Show the students where in their work areas these items are to be
disposed of.
B. Asbestos

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11

ANSWERS TO TEXTBOOK REVIEW QUESTIONS


1. Used oil filters should be drained for at least 24 hours, then crushed and recycled.
2. Up-to-date phone numbers for doctors, hospitals, and the fire and police departments
should be clearly posted next to the phone.
3. Some shops have posted areas where safety glasses are required; for example, there
may be a red line painted on the floor with a sign warning that safety glasses are
required beyond the red line. Any time a person is working around risks such as
vapors, dust, metal shavings, or liquids that may cause eye injuries, safety glasses
should be worn.
4. A class B fire extinguisher should be used to smother the fire. Apply a blanketing,
flame-interrupting covering over the entire flaming liquid surface.
5. The Code of Federal Regulations contains a complete list of hazardous wastes.
6. d. All of these statements are true.
7. d. All of the statements are true.
8. c. Shoes worn in the shop should have nonslip soles, and steel-toed safety shoes are
recommended.
9. a. Engine coolant should be collected and recycled. Transmission fluid, brake fluid,
and solvents containing chlorinated hydrocarbons should be stored and recycled or
disposed of separately.
10. c. Further cleaning to remove residue is necessary following thermal cleaning.
11. b. Right-to-know laws concern hazards associated with chemicals used in the
workplace.
12. d. All of the above.
13. d. When a material reacts violently with water, or other materials, it is said to have
high reactivity.
14. c. Water is not recommended for extinguishing liquid fires; a class B fire extinguisher
should be used.
15. d. Do not leave power tools running unattended or overload equipment.
16. The proper procedure for using a fire extinguisher is the PASS system:
P, pull the pin
A, aim at the base of the fire
S, squeeze the handle
S, sweep the entire width of the fire with the contents of the extinguisher
17. c. Long hair should be tied back or tucked under a cap.
18. d. Do not use compressed air for cleaning.
19. d. All of the above
20. d. All of the above

ADDITIONAL TEACHING HINTS


Show the students the equipment they will be working with and describe the safety
concerns for each item. Point out areas where personal equipment such as
protective eyewear and hearing protection is required.
Show the students the MSDS manual and show a sample of each substance they
will be using. Describe the safe handling and disposal procedures for each.

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Show where the emergency phone numbers are located and describe accident
reporting procedures.
Walk through the lab with each student listing safety concerns they find such as
tripping hazards, spills, and so on. Compare their lists and lead a discussion of each
persons responsibility to maintain a safe work area.

ANSWERS TO TECH MANUAL REVIEW QUESTIONS


1. Many shop safety items will be covered by the instructor, including:
a. wear eye protection
b. no horseplay
c. wear proper clothing
d. use tools and equipment properly
e. proper care of long hair
2. The tires should be blocked, the car should be in PARK or NEUTRAL with the parking
brake set, and there should be an exhaust vent system hose connected to the vehicle.
3. a. solvents
b. paint
c. gas
d. lubricants
e. fluids
f. cleaners
4. a. recycle
b. have material picked up by a licensed disposal company
5. Material name, compounds found in the material, safety precautions, degree of danger of material, disposal procedures, health precautions, procedures, procedures to
follow if there is contact with the skin or if it is swallowed
6. b
7. b
8. False
9. False
10. False

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4
AUTOMOTIVE SYSTEMS AND
PREVENTIVE MAINTENANCE
CHAPTER OVERVIEW
This chapter discusses significant automotive features and design revolution. The latest,
most progressive changes are emphasized. The basic automobile systems covered in later
chapters are introduced.

CHAPTER OBJECTIVES
Explain the major events that have influenced the development of the automobile
during the last 35 years.
Explain the difference between unitized and body-over-frame vehicles.
Describe the manufacturing process used in a modern automated automobile
assembly plant.
List the basic systems that make up an automobile and name their major
components and functions.
Explain the importance of preventive maintenance, and list six examples of typical
preventive maintenance.

INSTRUCTIONAL OUTLINE WITH TEACHING HINTS


I. Historical Background
II. Modern Power Plants
III. Design Evolution
A. Unitized Construction
B. Body-Over-Frame Construction
IV. Body Shapes
A. Sedan
B. Convertible
C. Liftback or Hatchback
D. Station Wagon
E. Pickups
F. Vans
G. Sport Utility Vehicles (SUVs)

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V. Technological Advances
A. Computers
B. Hybrids
C. Fuel Cells
VI. The Basic Engine
A. Cylinder Block
B. Cylinder Head
1. Combustion Chamber
2. Ports
C. Piston
D. Connecting Rods and Crankshaft
E. Valve Train
F. Manifolds
1. Intake manifold
2. Exhaust Manifold
VII. Engine Systems
A. Lubrication System
1. Oil Pan
2. Oil Pump
B. Cooling System
1. Water Pump
2. Water Jackets
3. Radiator
4. Pressure Cap
5. Thermostat
C. Fuel and Air System
D. Emission Control System
1. Positive Crankcase Ventilation (PCV) System
2. Evaporative Emission Control System
3. Exhaust Gas Recirculation (EGR) System
4. Catalytic Converter
5. Air Injection System
E. Exhaust System
VIII. Electrical and Electronic Systems
A. Ignition System
B. Starting and Charging Systems
C. Electronic Engine Controls
D. On-Board Diagnostics
IX. Drivetrain
A. Clutch
B. Manual Transmission
C. Automatic Transmission
D. Driveline
E. Differential
F. Driving Axles
G. Transaxle
H. Four-Wheel-Drive System
X. Running Gear
A. Suspension System
1. Springs

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15

2. Torsion Bars
3. Shock Absorbers
B. Steering System
C. Brakes
D. Wheels and Tires
XI. Vehicle Identification
Hint: Display a sample VIN. Show and explain which characters are needed by
the technician to identify the vehicle.
XII. Preventive Maintenance
Hint: Show or give examples of vehicles with very high mileage whose owners
have practiced good maintenance.
A. Typical PM Services
1. Engine Oil
2. Cooling System
3. Drive Belts
4. Battery
5. Transmission Fluid
6. Power-Steering Fluid
7. Brake Fluid
8. Windshield Washer Fluid
9. Windshield Wipers
10. Tires
B. Additional PM Checks

ANSWERS TO TEXTBOOK REVIEW QUESTIONS


1. The Corporate Average Fuel Economy (CAFE) standards require a certain fuel economy average for all vehicles produced by a manufacturer.
2. The vehicle identification number (VIN) consists of 17 characters and numbers that
contain the following information: country where the vehicle was manufactured, manufacturer, manufacturing division, body style, vehicle model, engine type, model year,
and production sequence number.
3. Internal combustion means that the fuel is burned inside the engine to produce energy.
4. In addition to the battery, a charging system should include a generator, voltage regulator, charge indicator light or gauge, and the necessary wiring.
5. When refueling you should check the engine oil, the windshield washer fluid level,
and the tire inflation.
6. c. The EPA is a government agency.
7. c. Automatic transmissions use torque converters instead of clutches.
8. c. Both technicians are correct. Follow manufacturers recommendations and also
take vehicle usage and driving conditions into consideration.
9. d. Combustion is a process, not a stroke; it is part of the power stroke.
10. b. The catalytic converter reduces HC, CO, and NOx emissions. The purpose of the
PCV system is to reduce emissions of HC, not CO.
11. c. Both gasoline and diesel engines are internal combustion engines.
12. d. The valve train opens and closes the intake and exhaust ports of each cylinder.
13. a. Liquid-cooled engines maintain a constant operating temperature.
14. b. The battery has sufficient power to crank the engine; therefore, the no-spark condition is most likely caused by a faulty ignition system.

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15. b. The exhaust gas recirculation (EGR) system introduces exhaust gasses into the
intake manifold in order to reduce NOx emissions.
16. c. An alternator is an AC generator, so both technicians are correct.
17. d. Neither technician is correct. Transaxles are most commonly used to drive the
front wheels of FWD vehicles.
18. a. The differential is part of the drivetrain.
19. c. The engine oil level should be checked most frequently.
20. c. Both technicians are correct. Tires have tread wear indicator bars, and a tread
depth gauge is used to check tire tread wear.

TECH MANUAL
The following procedure is included in Chapter 4 of the Tech Manual:
1. Basic preventive maintenance inspection.

ANSWERS TO TECH MANUAL REVIEW QUESTIONS


1. EPA and NTSA, among the many others to be covered by the instructor
2. In the owners manual or on the decal or placard glued to the doorjamb
3. An air/fuel mixture is ignited in a sealed cylinder. There is a drastic increase in pressure
in the cylinder due to the combustion of the air/fuel mixture. This pressure pushes
down on the cylinders piston. The pressure or force moving the piston downward is
used to power the vehicle.
4. The suspension system helps the driver maintain control of the vehicle while it is traveling on a bumpy road.
5. Preventive maintenance is the proper care of a vehicle on a regular basis to prevent
premature component failure.
6. Corporate Average Fuel Economy (CAFE)
7. c
8. c
9. False
10. False

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5
HAND TOOLS AND
SHOP EQUIPMENT
CHAPTER OVERVIEW
This chapter presents some of the more commonly used hand and power tools with which
every technician must be familiar. Because units of measurement play such an important
part in tool selection and in diagnosing automotive problems, this chapter begins with a
presentation of measuring systems. Prior to the discussion on tools, there is a discussion
on another topic that relates very much to measuring systemsfasteners.

CHAPTER OBJECTIVES
List the basic units of measurement for length, volume, and mass in the two
measuring systems.
Describe the different types of fasteners used in the automotive industry.
List the various mechanical measuring tools used in the automotive shop.
Describe the proper procedure for measuring with a micrometer.
List some of the hand tools used in auto repair.
List the common types of shop equipment and state their purpose.
Describe the use of common pneumatic, electrical, and hydraulic power tools found
in the automotive service department.
Describe the different sources for service information that are available to the
technician.

INSTRUCTIONAL OUTLINE WITH TEACHING HINTS


I. Measuring Systems
A. Linear
B. Square
C. Volume
D. Weight
E. Temperature
F. Pressure
G. Torque
Hint: Compare measuring systems. Show how to make conversions.
Emphasize becoming familiar with the metric system.

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II. Fasteners
A. Bolt Identification
B. Tightening Bolts
C. Washers
D. Thread Lubricants and Sealants
E. Screw Pitch Gauge
F. Taps and Dies
G. Threaded Inserts
1. Spark Plug Thread Repair
Hint: Show examples of SAE and metric bolt and nut classifications and
how to correctly identify them. Compare grade strengths and discuss the
differences in torque and holding power. Show an example of a bolt with
stretched threads.
III. Measuring Tools
A. Machinists Rule
B. Vernier Caliper
C. Dial Caliper
D. Micrometers
1. Reading a Metric Outside Micrometer
2. Using an Outside Micrometer
3. Reading an Inside Micrometer
4. Reading a Depth Micrometer
E. Telescoping Gauge
F. Small Hole Gauge
G. Feeler Gauge
H. Straightedge
I. Dial Indicator
IV. Hand Tools
A. Wrenches
1. Open-End Wrench
2. Box-End Wrench
3. Combination Wrench
4. Flare Nut (Line) Wrenches
5. Allen Wrench
6. Adjustable-End Wrench
B. Sockets and Ratchets
1. Special Sockets
2. Extensions
3. Socket Adapters
C. Torque Wrenches
D. Screwdrivers
1. Standard Tip
2. Phillips
3. Pozidriv
4. Reed and Prince
E. Impact Screwdriver
F. Pliers
1. Combination
2. Adjustable
3. Locking (vise grips)

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Hand Tools and Shop Equipment

V.

VI.

VII.

VIII.

19

4. Diagonal Cutting
5. Snap or Lock Ring
6. Retaining Ring
G. Hammers
H. Chisels and Punches
I. Removers
1. Extractors
J. Hacksaws
K. Files
L. Gear and Bearing Puller
1. Bushing and Seal Puller and Drivers
M. Trouble Light
Shop Equipment
A. Bench Vises
B. Bench Grinder
C. Presses
D. Grease Guns
Power Tools
A. Impact Wrench
B. Air Ratchet
C. Air Drill
D. Blowgun
Jacks and Lifts
A. Floor Jack
B. Lift
C. Portable Crane
D. Engine Stands/Benches
Service Information
A. Auto Manufacturers Service Manuals
B. General and Specialty Repair Manuals
C. Finding Information in Service Manuals
D. Aftermarket Suppliers Guides and Catalogs
E. Lubrication Guides
F. Owners Manuals
G. Flat-Rate Manuals
H. Computer-Based Information
I. Hotline Services
J. iATN

ANSWERS TO TEXTBOOK REVIEW QUESTIONS


1. A micrometer should be checked weekly and also right after you drop it.
2. Use a dial indicator for such things as measuring valve lift, crankshaft endplay, flywheel
or brake rotor runout, gear backlash, or crankshaft journal concentricity.
3. The size of a wrench is determined by the distance between its jaws measured in
inches or millimeters. This size will be slightly larger than the indicated size so that it
will fit around a nut or bolt.
4. True. Service manual information is usually also made available by certain manufacturers on CDs, DVDs, or via the Internet.

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Chapter 5

5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

16.
17.

18.
19.
20.

Service bulletins are used to update service information throughout the year.
b. A box-end wrench is not likely to slip off a bolt or a nut.
c. Both technicians are right.
d. Neither technician is right. A tap is used to cut internal threads, and a die is used
to cut external threads.
c. A Pozidriv screwdriver is similar to a Phillips, but flatter and blunter.
b. Needle nose pliers are best for grasping small parts.
c. Both technicians are correct. Punches may be used for both purposes.
d. An extractor is used to remove broken bolts.
b. Parts with a press fit should not have any relative motion between them.
a. Use a blowgun to blow off parts during cleaning, but never direct it toward a
person.
a. Flare nut wrenches are used for brake line and tubing fittings. Open-end wrenches do not have as many points of contact as a flare nut wrench, and therefore would
not provide as positive a grip on the fitting.
c. Both technicians are right. A dial caliper may be used for inside, outside, and depth
measurements.
d. Neither technician is right. A machinist rule is marked in 1/8 (3.18 mm), 1/16
(1.59 mm), 1/32 (.79 mm), or 1/64 (.40 mm), increments. Most micrometers are
designed to measure objects with 0.001 (one-thousandth) of an inch accuracy. To measure an object with an accuracy of one ten-thousandth of an inch, a special micrometer is needed.
c. Both technicians are correct. Floor jacks may be either hand operated, hydraulic
powered, or use compressed air.
d. Neither technician is correct. Metric and SAE wrenches are not interchangeable.
a. Impact sockets and adapters should be used with an air impact wrench.

TECH MANUAL
The following procedures are included in Chapter 5 of the Tech Manual:
1.
2.
3.
4.
5.
6.
7.

Repairing and/or replacing damaged threads.


Cutting with a chisel.
Proper use of a vehicle hoist.
Proper use of a hydraulic floor jack.
Proper use of a stationary grinder.
Proper use of a service manual.
Proper use of electronic media.

ADDITIONAL TEACHING HINTS


Discuss the power tools provided in the shop and the safety rules for each tool.
Demonstrate as many tools in Chapter 5 as practical.
Have students sort and identify bolts and other fasteners by grade, thread pitch,
and type.
Demonstrate and review shop manual usage. If computer-based service manuals are
available, show how to access information.

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Hand Tools and Shop Equipment

21

ANSWERS TO TECH MANUAL REVIEW QUESTIONS


1. A better grip on the head of a bolt or nut is possible with a box-end wrench.
2. a. Hands can be cut by the sharp edges of a mushroomed chisel.
b. The mushroomed edges of a chisel can break off and fly into your eyes when the
chisel is struck with a hammer.
3. Hand tools
4. The exact procedure for a particular vehicle may differ from that used for other vehicles. Failure to follow the correct procedure can lead to frustration, wasted time, and
poor repairs.
5. Although this situation should be avoided, if necessary the block should be placed
between the saddle of the lift and the lifting point on the vehicle.
6. b
7. b
8. c
9. d
10. dial indicator
11. False
12. 6-point
13. Check the service manual.
14. A tap is used for cutting internal threads, and a die is used for cutting external threads.
15. Combination, water pump, needle nose, channel lock, slip joint, and vise grip

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6
DIAGNOSTIC EQUIPMENT
AND SPECIAL TOOLS
CHAPTER OVERVIEW
This chapter describes the diagnostic equipment and special tools used by technicians to
diagnose and service various automotive systems. Diagnostic equipment is used to test the
performance of a system, and special tools designed for a particular purpose are used to
make the necessary repairs.

CHAPTER OBJECTIVES
Describe the various diagnostic tools used to check an engine and its related
systems.
Describe the common tools used to service an engine and its related systems.
Describe the various diagnostic tools used to check electrical and electronic
systems.
Describe the common tools used to service electrical and electronic systems.
Describe the various diagnostic tools used to check a vehicles drivetrain.
Describe the common tools used to service a vehicles drivetrain.
Describe the various diagnostic tools used to check a vehicles running gear for
wear and damage.
Describe the common tools used to service a vehicles running gear.
Describe the various diagnostic tools used to check a vehicles heating and airconditioning system.
Describe the common tools used to service a vehicles heating and air-conditioning
system.

INSTRUCTIONAL OUTLINE WITH TEACHING HINTS


I. Engine Repair Tools
A. Compression Testers
B. Cylinder Leakage Tester
C. Oil Pressure Gauge
D. Stethoscope

22

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Diagnostic Equipment and Special Tools

E. Transaxle Removal and Installation Equipment


F. Ridge Reamer
G. Ring Compressor
H. Ring Expander
I. Ring Groove Cleaner
J. Dial Bore Indicator
K. Cylinder Deglazer
L. Cylinder Hone
M. Cam Bearing Driver Set
N. V-Blocks
O. Valve and Valve Seat Resurfacing Equipment
P. Valve Guide Repair Tools
Q. Valve Spring Compressor
R. Valve Spring Tester
S. Torque Angle Gauge
T. Oil Priming Tool
U. Cooling System Pressure Tester
V. Coolant Hydrometer
W. Coolant Recovery and Recycle System
II. Electrical/Electronic System Tools
A. Computer Memory Saver
B. Circuit Tester
C. Voltmeter
D. Ohmmeter
E. Ammeter
F. Volt/Ampere Tester
G. Multimeters
H. Lab Scopes
I. Battery Hydrometer
J. Wire and Terminal Repair Tools
K. Headlight Aimers
III. Engine Performance Tools
A. Scan Tools
B. Engine Analyzers
C. Fuel Pressure Gauge
D. Injector Balance Tester
E. Injector Circuit Test Light
F. Fuel Injector Cleaners
G. Fuel Line Tools
H. Pinch-Off Pliers
I. Vacuum Gauge
J. Vacuum Pump
K. Vacuum Leak Detector
L. Tachometer
M. Timing Light
N. Spark Tester
O. Logic Probes
P. Sensor Tools
Q. Static Strap

23

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Chapter 6

IV.

V.

VI.

VII.

R. Pyrometers
S. Spark Plug Sockets
T. Exhaust Analyzers
Transmission and Driveline Tools
A. Transaxle Removal and Installation Equipment
B. Transmission/Transaxle Holding Fixtures
C. Transmission Jack
D. Axle Pullers
E. Special Tool Sets
F. Clutch Alignment Tool
G. Clutch Pilot Bearing/Bushing Puller/Installer
H. Universal Joint Tools
I. Drive Shaft Angle Gauge
J. Hydraulic Pressure Gauge Set
Suspension and Steering Tools
A. Tire Tread Depth Gauge
B. Power-Steering Pressure Gauge
C. Control Arm Bushing Tools
D. Tie-Rod End and Ball Joint Puller
E. Front Bearing Hub Tool
F. Pitman Arm Puller
G. Tie-Rod Sleeve-Adjusting Tool
H. Steering Column Special Tool Set
I. Shock Absorber Tools
J. Spring/Strut Compressor Tool
K. Power-Steering Pump Pulley Special Tool Set
L. Brake Pedal Depressor
M. Wheel Alignment EquipmentFour Wheel
N. Tire Changer
O. Wheel BalancerElectronic Type
P. Wheel Weight Pliers
Brake System Tools
A. Cleaning Equipment and Containment Systems
B. Hold-down Spring and Return Spring Tools
C. Boot Drivers, Rings, and Pliers
D. Caliper Piston Removal Tools
E. Drum Brake Adjusting Tools
F. Brake Cylinder Hones
G. Tubing Tools
H. Brake Disc Micrometer
I. Drum Micrometer
J. Brake Shoe Adjusting Gauge (Calipers)
K. Brake Lathes
L. Bleeder Screw Wrenches
M. Pressure Bleeders
Heating and Air-Conditioning Tools
A. Manifold Gauge Set
B. Service Port Adapter Set

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Diagnostic Equipment and Special Tools

C.
D.
E.
F.
G.
H.
I.
J.

25

Electronic Leak Detector


Fluorescent Leak Tracer
Refrigerant Identifier
Refrigerant Charging Station
Refrigerant Recovery and Recycling System
Thermometer
Compressor Tools
Hose and Fitting Tools

ANSWERS TO TEXTBOOK REVIEW QUESTIONS


1. There are two types of test lights. The first is sometimes called a circuit tester and is
used to check for the presence of voltage in a circuit. A ground clip is attached to a
suitable ground, and the tester lights when the probe is touched to a portion of the
circuit having sufficient voltage present. The second is sometimes referred to as a selfpowered test light or continuity tester. It has an internal battery and is used to check
unpowered portions of a circuit for continuity. When the ground clip is attached to
the negative side of the circuit and the probe is attached to the positive side, the tester
will light when there is continuity in the circuit.
2. False. Knurling is used to decrease the inside diameter of the guide.
3. The two types of compression gauges are push-in and screw-in.
4. A vacuum gauge is used to test engine manifold vacuum.
5. d. Ideally, we would like to see very low amounts of O2 in the exhaust stream.
6. a. A brake disc micrometer has pointed anvils and is read the same way as other
micrometers. A brake drum micrometer, however, has two moveable arms and a dial
indicator, and is read differently than other micrometers.
7. c. Both technicians are correct. A pyrometer and a thermometer both measure
temperature.
8. True. A lab scope displays voltage over a period of time.
9. c. Both technicians are correct. Connect a voltmeter across the portion of the circuit
being tested with the red lead on the most positive side of the circuit.
10. c. Both technicians are correct. A digital volt/ohmmeter may be used to test either
voltage or resistance.
11. c. Both technicians are correct.
12. a. Separate gauge sets are required to service vehicles with different refrigerants.
13. True.
14. b. Lower than normal oil pressure can be caused by excessive engine bearing clearances.
15. d. All of these conditions may be revealed by fuel pressure readings.
16. d. Neither A nor B. An ultrasonic leak detector is normally used to locate vacuum
leaks.
17. b. Sulfated and plugged fuel injectors are usually the result of the sulfur content in gasoline and inconsistent detergent levels, and may be cleaned with fuel injector cleaners.
18. c. Most engine analyzers contain a scan tool along with their other diagnostic tools.
19. a. Little or no pressure drop can indicate a plugged or faulty injector. An excessive
pressure drop indicates an overly rich condition.
20. c. An inductive pickup makes it easier to measure current in a circuit.

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Chapter 6

TECH MANUAL
The following procedures are included in Chapter 6 of the Tech Manual:
1.
2.
3.
4.
5.
6.

Checking the pressure in a cooling system.


Understanding DMM controls.
Identifying special drivetrain tools.
Dismounting and mounting a tire from a wheel.
Measuring brake rotor thickness.
Checking the clearance (air gap) of an air-conditioning compressors clutch.

ADDITIONAL TEACHING HINTS


Demonstrate DMM voltage, amps, and ohm tests on various car circuits.
Demonstrate how to observe ignition timing with a timing light and how timing
affects engine operation.
Demonstrate how to connect and adjust a labscope.
Demonstrate on a two- or four-gas exhaust analyzer how the gases change if a
cylinder is disabled.
Discuss details of how to hook up an engine analyzer to a vehicle.

ANSWERS TO TECH MANUAL REVIEW QUESTIONS


1. When electrons are able to flow along a path between two points, an electrical circuit
is formed. An electrical circuit is considered complete when there is a path that connects the positive and negative terminals of the electrical power source.
2. Voltage is the electrical pressure that causes the movement of electricity, whereas current is the movement of electricity.
3. c
4. a
5. True
6. False
7. a
8. False
9. b
10. c

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7
BASIC THEORIES AND MATH

CHAPTER OVERVIEW
This chapter introduces many of the principles taught in other courses in order to help the
student become more employable and successful as a technician. These principles are covered again in greater detail according to the topic. A thorough understanding of this chapter is recommended to prepare the student for further instruction.

CHAPTER OBJECTIVES
Describe how all matter exists.
Explain what energy is and how energy is converted.
Calculate the volume of a cylinder.
Explain the forces that influence the design and operation of an automobile.
Describe and apply Newtons laws of motion to an automobile.
Define friction and describe how it can be minimized.
Describe the various types of simple machines.
Explain the difference between torque and horsepower.
Differentiate between a vibration and a sound.
Explain Pascals law and give an example of how it applies to an automobile.
Explain the behavior of gases.
Explain how heat affects matter.
Describe what is meant by the chemical properties of a substance.
Explain the difference between oxidation and reduction.
Describe the origin and practical applications of electromagnetism.

INSTRUCTIONAL OUTLINE WITH TEACHING HINTS


I. Matter
A. Atoms and Molecules
1. Elements
2. Protons
3. Neutrons
4. Electrons
5. Compounds

27

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Chapter 7

II.

III.

IV.

V.
VI.

VII.

B. States of Matter
1. Absorption and Adsorption
Energy
A. Kinetic and Potential Energy
1. Chemical Energy
2. Electrical Energy
3. Mechanical Energy
4. Thermal Energy
5. Radiant Energy
6. Nuclear Energy
Hint: Give examples of the various forms of energy.
B. Energy Conversion
1. Chemical to Thermal Energy
2. Chemical to Electrical Energy
3. Electrical to Mechanical Energy
4. Thermal to Mechanical Energy
5. Mechanical to Electrical Energy
6. Electrical to Radiant Energy
Hint: Give examples of energy conversions in an automobile.
C. Mass and Weight
1. Mass
2. Weight
D. Size
Volume
A. Ratios
B. Proportions
Force
A. Automotive Forces
1. Balanced and Unbalanced Force
2. Turning Forces
B. Forces on Tires and Wheels
C. Centrifugal/Centripetal Forces
D. Wheel and Tire Balance
E. Pressure
Time
Motion
A. Rates
B. Newtons Laws of Motion
C. Friction
1. Lubrication
2. Rollers
D. Air Resistance
1. Aerodynamics
Work
A. Simple Machines
1. Inclined Plane
2. Pulleys
3. Levers
4. Gears

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Basic Theories and Math

VIII.

IX.
X.

XI.

XII.

XIII.

5. Wheels and Axles


Hint: Have the class think of examples in which the simple machines
listed here may be found in a typical automobile.
B. Torque
1. Torque Multiplication
C. Power
D. Horsepower
Hint: Discuss the difference between torque and horsepower.
Waves and Oscillations
A. Vibrations
B. Sound
1. Speakers
C. Noise
Light
A. Photo Cells
Liquids
A. Laws of Hydraulics
B. Mechanical Advantage with Hydraulics
Hint: Have the class list all of the systems in an automobile that use
hydraulics.
Gases
A. Behavior of Gases
B. Air Pressure
1. Vacuum
Heat
A. Heat Transfer
1. Convection
2. Conduction
3. Radiation
B. The Effects of Temperature Change
1. Expansion
2. Contraction
C. Controlling Heat
Chemical Properties
A. Specific Gravity
B. Chemical Reactions
C. Catalysts and Inhibitors
D. Acids/Bases
1. pH
E. Reduction and Oxidation
F. Metallurgy
1. Hardening
2. Carburizing
3. Heat Treating
4. Tempering
G. Solids under Tension
1. Tensile Strength
H. Electrochemistry
1. Electrolysis
2. Electrolyte

29

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Chapter 7

XIV. Electricity and Electromagnetism


A. Electricity
B. Magnets
C. Electromagnetism
D. Producing Electrical Energy
E. Radio Waves
Hint: Have the class list the systems in an automobile that would function
without electricity and magnetism.

ANSWERS TO TEXTBOOK REVIEW QUESTIONS


1. Newtons first law of motion is referred to as inertia. It means that an object at rest
tends to remain at rest, and an object in motion tends to remain in motion unless some
force acts on it. For example, when a car is parked on a level street, it remains stationary unless it is driven or pushed.
2. Newtons second law states that when a force acts on an object, the motion of the
object will change. The change in motion is proportional to the amount of force applied
and the mass of the object. For example, a truck has greater mass than an automobile, so it requires a larger engine to provide the force needed to drive it.
3. There are six different forms of energy: chemical, electrical, mechanical, thermal,
radiant, and nuclear.
4. Types of energy conversion commonly used in automobiles are chemical-to-thermal
energy (as in the combustion of the fuel); chemical-to-electrical energy (as in the battery); electrical-to-mechanical energy (as in the starter); thermal-to-mechanical energy (as in an internal combustion engine); mechanical-to-electrical energy (as in an
alternator or AC generator); and electrical-to-radiant energy (as in lighting).
5. A rotating, tilted wheel will move in the direction of the tilt because the side of the
wheel opposite the direction of the tilt has a larger diameter and circumference, causing it to travel a greater distance in one revolution. This difference in distance traveled pushes the wheel in the direction of the tilt.
6. The effects of static and dynamic balance will be the absence or reduction of vibration. Static imbalance can result in a condition referred to as tramp, and a dynamic
imbalance can result in a wobble or shimmy.
7. According to Charles law, the volume of a mass of gas depends on its temperature.
The higher the temperature; the greater the volume.
8. The nucleus of an atom contains protons and neutrons.
9. Work is calculated by multiplying the applied force by the distance the object moved.
10. Energy may be defined as the ability to do work.
11. When one object is moved across the surface of another object, the resistance to
motion is called friction.
12. Weight is the measurement of the earths gravitational pull on an object.
13. Torque is a force that does work with a turning (or rotating) action.
14. Engines are mounted in a vehicle using flexible mounts to reduce the transfer of
vibrations.
15. Vacuum is defined as the absence of atmospheric pressure.
16. d. Neither technician is correct. Stored energy is called potential energy, and energy
that is released to do work is called kinetic energy.
17. c. Both technicians are correct. Friction occurs in liquids, solids, and gases, and converts kinetic energy into heat.

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Basic Theories and Math

31

18. d. Neither technician is correct. Mass is the amount of matter in an object. Weight is
measured in pounds or kilograms.
19. d. If a 50-pound object is moved 10 feet, 500 ft.-lb of work are produced.
20. a. Thermal energy is heat; light is not one of the six forms of available energy.

TECH MANUAL
The following procedures are included in Chapter 7 of the Tech Manual:
1.
2.
3.
4.

Measuring engine bore and stroke and calculating displacement.


Identifying the proper lubricants.
Calculating overall gear ratios.
Applying Pascals Law.

ADDITIONAL TEACHING HINTS


Using principles learned in the classroom, have the students calculate the
displacement of a single cylinder and then the total displacement of several sizes of
sample engines.
Conduct a tour of the shop and have students list where energy conversions occur
in the shop equipment and vehicles found there. Compare lists and lead a
discussion of the different forms of energy and their usefulness to us.

ANSWERS TO TECH MANUAL REVIEW QUESTIONS


1. a. solid
b. liquid
c. gas
2. Heating or freezing
3. Energy os defined as the ability to do work. Since all matter consists of atoms and
molecules that are in constant motion, all matter has energy. Energy conversion occurs
when one form of energy is changed to another form. Since energy is not always in
the desired form, it must be converted to a form we can use. Three examples of energy conversion are chemical to thermal, electrical to mechanical, and mechanical to
electrical.
4. When a force acts on an object, the motion of the object will change.
5. Two positive effects of friction are vehicle braking and electrical regeneration; the two
negative aspects of friction are heat generation between mechanical moving parts and
air friction (air drag) during vehicle movement.
6. Use of bearings and lubrication
7. Intensity or strength of the vibration
8. Properties observable during a chemical reaction
9. Oxidation is a chemical reaction in which the bare surface of the metal substance combines with the oxygen of the air.
10. Electromagnetic induction happens under the following conditions. Electricity is passed
through a conductor. Magnetic lines of force present around the conductor are cut by
a second conductor in a closed circuit. The result of electromagnetic induction is
electricity.

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