Automotive Mechanics Level-I: Periodic Service

• Automotive mechanics Level-I curriculum, version 1 was released in March 2022
• Perform Periodic Service, has a module code of EIS AUM1 M08 0322 and a nominal duration of 60 Hours

Module units covered

• Preparing for work
• Selecting lubricants/coolants
• Applying lubricants/coolant
• Service and Maintenance activities
• Housekeeping activities

Module Instructions

• Read the information in each unit
• Accomplish the Self-checks at the end of each unit
• Perform Operation Sheets provided at the end of units
• Do the "test" given at the end of each unit
• Read the identified reference book for Examples and exercise

Unit 1: Prepare for work

• Introduction to service and maintenance work plan
• Performing inspection
• Selecting source of information

Service and maintenance work plan (Work plan)

• Scope of Services (SOS) or Scope of Work (SOW) describes tasks or services and specific deliverables needed
• SOS is the first section of the SSA (service scope activity) and may be provided in writing or determined by you
• Periodic services prevent problems; technicians perform them in dealerships, independent shops, or specialty shops

Documentation and equipment

• Equipment and documents to be returned with the vehicle include spare keys (original if delivered)
• Original documentation: vehicle's registration, traffic insurance, warranty booklet, and instruction manual
• Stamped service history documents prove required periodic maintenance was completed
• Periodic maintenance (PM) items and service intervals are in the Owner's Manual

Owner's Manual

• Supplement or Warranty Booklet stipulates maintenance schedule
• Factors: model, age, country of use, or how vehicle is used
• Maintenance operation symbols: T (Tighten to torque), R (Replace), I, A, L

Repair guides and service plans

• Repair guides written for every vehicle entering the shop may be called work orders (WO)
• Work Orders contain information about the customer, the vehicle, the customer's concern or request, an estimate of costs, and time for services
• Work Orders are legal documents for payroll and record-keeping, protecting the shop and customer
• Work Orders contain customer information and vehicle identification
• The service history of the vehicle will be recorded, and include the customer's complaint
• The preliminary diagnosis of the problem will be in a work order
• An estimate of the costs will be included in a work order containing the time the services should be completed, the actual services performed with their cost, and the parts replaced during the services
• Recommendations will be included in a work order for future services, and standard/special tools will be listed
• Work Orders will include Technical information, Procedures and devices for measuring and testing
• A replacement vehicle should be returned: in full, complete condition and with a fuel level same as when delivered and on the specified date
• Drivers are held responsible for transition and any traffic fines imposed to the vehicle

Workplace Health and Safety (WHS)

• Workplace health and safety protects the health, safety, and welfare of all persons impacted by work activities in the workplace
• WHS is the term to describe the laws and processes that help protect employees from death and injury while at work
• Workplace health and safety offers guidelines for lifting, hazardous chemicals, and protective equipment and limits work hours (preventing fatigue/stress)

Safety Precautions examples

• Do not operate the engine for long without proper exhaust ventilation to prevent producing carbon monoxide
• Apply wheel chocks before jacking up the vehicle
• Support the vehicle with safety stands at designated points before working on it
• When removing heavy components, maintain balance and avoid hitting adjacent parts
• Before repair, turn off the ignition and disconnect the ground cable from the battery

Pre-inspection Work

• Before inspection, floor mats and covers must be used to protect from dirt or scratches

• Driver's seat must be protected with a seat cover, floor mats, and steering wheel cover

• The engine hood should be opened by pulling the engine hood release lever, and fender covers placed

• A front cover is required for front covers, with wheel chocks against the wheels

• Clean all disassembled parts in designated liquid or solvent prior to inspection or assembly

• Use approved bonding agent, sealants, or equivalents when needed

• Replace oil seals, gaskets, packing, O-rings, locking washers, cotter pins, self-locking nuts then discard

• Use only the lubricants specified in the applicable section

• Be careful not to touch the terminals of electrical components which utilize microcomputers

• Static electrical charges may damage internal electronic components

• When disconnecting vacuum hose or air hose, attach tag to indicate the proper connection

• Use proper tools and recommended essential tools for safety and efficient service repair

• Certain repairs on fuel, oil, water, vacuum or exhaust systems require certain lines to be checked

• Dispose of drained oil or used solvent for cleaning parts correctly

Inspection

• Inspection is to check various vehicle systems and areas
• Exact systems and subsystems inspected vary and are part of the vehicle registration process
• Automobile dealers may complete a safety inspection on used vehicles before they are sold and report outcomes to the customer

Diagnosis symptoms

• The engine won't crank with a possible cause of a dead battery -- Action needed: Check battery state-of-charge and replace fusible link and clean and tighten any loose connections
• Faulty iginition switch -- Action needed: Check and replace switch operation
• Engine cranks too slowly due to a weak battery -- Action needed: Charge battery as needed and clean and tighten any loose or corroded connections

Vehicle inspection points

• Check to see if the car leans or tilts in any direction from side to side or from front to back
• Check the lights for operation with the ignition switch in the "ON" position -- Clearance, License Plate, Taillights, instrument panel, indicators, and warning lights including brake, oil pressure, and engine

Braking systems

• Braking stops the vehicle by converting kinetic energy to heat energy and heat energy is created in the brakes by friction via moving and non-moving surfaces at each wheel to generate heat
• Disc and drum brakes are common
• Engine braking increases road safety

Factors effecting braking

• Number of wheels braking
• Weight of vehicle
• Type of friction material
• Surface area of friction material
• Size or discs or drums
• Tire traction
• Road surface
• Load transfer
• Incline or decline of road. (gravity)
• Engine braking
• Pressure applied

Braking systems

• Service brakes: the primary braking system using a pedal connected to a hydraulic system
• Parking brakes: mechanically applied by a lever or pedal

Maintenance

• General maintenance includes checking those items during routine vehicle use which can be performed by the owners themselves
• Outside the Vehicle: Maintenance items listed here should be performed from time to time, based on the item
• Inside the Vehicle: Maintenance items to be checked regularly during periodic maintenance

Under vehicle hood

• Check fluid levels: windshield washer, engine coolant, engine oil, brake and clutch fluids and battery
• Make sure the brake and clutch fluid levels are between the "MAX" and "MIN" lines on the reservoir
• Check the fluid level in each cell, the level should be between the "MAX" and "MIN" lines

Instrumentation

• Instruments are typically arranged on the instrument panel in front of the driver's seat

• Displayed via meter and light

• Speedometer: Indicates vehicle speed, odometer (distance traveled), and trip meter (can reset to 0 )

• Tachometer: Indicates engine speed in revolutions per minute (rpm)

• Voltmeter: Indicates battery voltage or alternator output

• Oil pressure gauge will indicate engine oil pressure

• Fuel gauge indicates fuel level in the fuel tank

• Water (Engine coolant temperature gauge) Indicates engine coolant temperature

Additional Inspection areas

• Brake Fluid Level: check for leaks if fluid level is extremely low

• Brake Lines and Cables: Check brake fluid lines and parking brake cables for attachment, leaks, chafing, abrasions, deterioration, etc

• Brake Fluid: Drain the brake fluid from each air bleeder valve to refill

• Tires should have at least 1/16 of tread remaining, if less, replace them

• Tires have "tread wear indicators" molded into them; if the bar shows, the tire is worn beyond limits

• Check the tires for bulges, nails, tears, and other damage, if present, replace

• Follow the Maintenance Schedule Suggested in Your Vehicle's Owner's Manual

• Perform essential maintenance tasks. These include oil changes, tire rotations, replacing transmission fluid etc

Manual types

• Not as detailed as factory manuals
• A set includes data an all American cars produced for several years
• More economical to purchase than factory manuals

Battery basics

• Check for cracks in the battery case and for broken terminals. Electrolyte leakage indicate replace

• Check for cracked or broken cables or connections

• Check for corrosion on terminals and dirt or acid on the case top; if heavy, use a wire brush clean the terminals and case top with a mixture of water and baking soda or ammonia

• Check for a loose battery hold-down and loose cable connections and tighten as needed

• Check the level of electrolyte, the proper level is 1/2" above the separators, add distilled water, and charge the battery

• Check for cloudy or discolored electrolyte caused by overcharging or vibration, could cause high self-discharge, correct the problem and replace the battery

• Check the condition of plates and separators and if light, severe undercharging is indicatorm correct it

• Check the tension and condition of the alternator drive belt: If loose, tighten; if frayed or glazed, replace

• Books with repair details are Service (Shop) Manuals -- Includes manufacturer's manuals, specialized manuals and general repair manuals

Shop Safety

• Inspect equipment and tools before and after work
• Refer to service manual or ask for advice from instructors or superiors
• Do not perform any operations if proper safety cannot be ensured
• Practice sifting, sorting, sweeping, cleaning, and self-discipline
• Keep workplace clean and orderly
• Basic shop safety sign

Electrical Safety

• Risk: short-circuit in electrical equipment and machinery may cause fire therefore take precautions

• Do not go near broken or dangling Electrical wires

• Never touch any electrical equipment with wet hands

• When disconnecting a plug, pull on the plug itself

• Do not route an electrical cord through wet or oil soaked areas, through heated surfaces, or around sharp corners

• Report such matters to the instructor after switching off the switch

• Report any blown fuse to the instructor, do not attempt to repair or replace it

• Always use lift safety lock

Shop Computer Usage

• Computerized management systems facilitate shop. The information is input on the computer's keyboard where software helps in estimates
• Saves information for many purposes: schedule reminders, bookkeeping, vehicle/owner history, and tracking employee productivity
• Notes can be added, which is used to remind of commitments to customers and special information or events during the customer's visit
• Computer can recall information such as license number, the vehicle's identification number, or the owner's name

Checking drive belt

• To check the belt, processes must be carried out when the engine is off using a belt gauge and wrench
• Check it for cracking, edge wear and splitting
• Check also for any missing ribs and whether the belt is contaminated or loose
• Use the belt gauge on a serpentine belt and should be checked with hand and gauge

Unit 2: Select lubricants/coolants

• Types/Classification of Lubricants
• Cause and Effects of Gear Oil Dilution
• Maintenance schedule
• Identifying lubricants/coolants

Lubricants

• Lubrication controls friction
• Lubricants are either a fluid or solid substance, the most common forms are lube oil and grease
• Type of lubricant depends on the application (automobile, industrial, marine)
• Lubricants’ roles reduce friction, transfer heat, prevent corrosion, protect against wear, carry away contaminants, transmit power, and act as a seal
• Types: Engine Oil and Gear Oil

Engine Oil

• Common automotive lubricant; consists of base oils enhanced with anti-wear additives, detergents, dispersants, and viscosity index improvers
• It reduces friction and wear on moving parts and also cleans the engine from sludge and varnish and neutralizes acids from fuel and oxidation

Gear oil

• Generally used for transmissions, transfer cases, and differentials in automobiles, trucks, and other machinery
• Usually has a high viscosity and extreme pressure (EP) additives to cope with the sliding action of hypoid bevel gears and combat wear

Greases

• Prevent wear and tear in the suspension and steering joints and vary in viscosity
• Anti-wear and extreme pressure additives can be added to formulate greases for specific applications

Brake fluids

• Used to maintain and improve performance of brake systems
• Not oils: made from ethylene glycols and anticorrosion additives to withstand temperatures
• Four types: DOT 3, DOT 4, DOT 5, and DOT 5.1, specification defined by SAE
• Now locates the power-steering pump, the level of power-steering fluid is checked with the engine off, also using a dipstick and fill as necessary
• Service manual checkes fluid type before adding fluid

Hydraulic Oil

• Any system that requires force activation from one point to another (power-steering system example in a vehicle)
• Made from base oils and additive package to combat wear and corrosion

Automatic transmission fluids (ATFs) requirements

• Lubricate the gears in the gearbox
• Fill the torque converter (or ‘automatic clutch')
• Convey power from the engine to the gearbox
• Act as hydraulic medium by conveying signals from the valves in the control unit
• Ensure smooth but rapid take-up of power between the friction faces of the oil-immersed clutches/brakes
• Remove frictional heat and cool the whole transmission unit

Oil dilution

• Describes the increase in oil level in engine due to fuel entry (diesel or petrol)
• The effect is intensified by driving short distances, especially in cold outside temperatures, avoid these scenarios

Petrol in oil

• Motor oil smells like petrol
• There is a good chance that your gasoline engine has an oil dilution if the oil level is too high and a fuel smell can be detected
• Fuel settles during cold starts and enters oil via the piston ring and cannot be burned

Diesel in oil

• Can occur in diesel vehicles, the reason is the post-injection of diesel to clean the diesel particle filters: cannot be emitted
• The first indication of oil dilution is to measure the oil level so take an oil sample from the vehicle in order to determine in the laboratory whether there is an increased amount of fuel in the oil
• If there is fuel in the oil it affects viscosity, which results in too much fuel in the oil then leads to a lack of lubrication

Additional oil dilution factors and reasons

• Defective thermostat in the radiator: Replace contaminated oil, shorting the change interval to, for example, one year
• Note when inspecting: amount of minimum oils and fluids to determine starting the engine or operating the wipers

Maintenance schedules for the car owner/ driver

• Can help in early diagnosis of problems that can cause breakdowns
• Check fluid reservoirs: engine compartment, oils, coolant, and brake fluid
• Use the dipstick to check the engine oil level
• Use the level gauge to check washer fluid level
• Note that the purpose of oil and fluid inspection is to determine if there is a minimum amoun

Lubricant & Coolant

• Lubricants create a thin layer between 2 machines which keeps them cool and saves machine parts from rust
• Coolants help cool down the job and the cutting tool, gives long life to cutting tools, creates jobs and makes for easy cutting and smooth running of m/c

Unit 3: Apply lubricants/coolant

• Safe procedure and using PPE (personal protective equipment)
• Using correct tools and equipment
• Draining and re-filling
• Dispose of used lubricants

Safety procedures and PPE

• Automobile industry dangers include chemicals, batteries, engines, and electric items
• Workers can have burns, cuts, or other serious injuries

PPE examples

• Face Guard (polycarbonate face protection) -- Anti-fog, chemical-resistant, scratch-resistant
• Protective Suits
• Lightweight, breathable and protects from chemicals
• Gloves protect from heat and chemical objects
• Always wear protective gloves to avoid electric arcs and thermal discharge

Tools

• Maintenance professionals commonly use hand tools due to easy to use and not needing power versus more complex power tools
• Screwdrivers: Tigthen or remove screws
• Hammers: Drive or remove nails
• Crescent wrenches: tigthen or remove nuts and bolts with hexagonal heads
• Hand saws: Cut materials such as wood, metal and plastic
• Wire and cable strippers: remove the rubber coating from the outside of electrical wires
• Multimeters: measure voltage, resistance and current to test electrical circuits
• Crimpers: to join wires, connectors and other electrical components
• Strap Wrench: turning pipe or cylinders without marring the surface of the work

Draining and re-filling oil

• Remove filter and loosen the bolt to drain. Allow oil to drain from housing and O-ring seal to be exposed and install a new seal
• Tighten finger tight
• Torque 25 Nm
• Fill the engine
• Start engine and check for leaks and then dispose

Waste Oil Disposal

• Used oil is any oil refined from crude or synthetic that has been used and is contaminated by physical and chemical impurities

• Must be handled as hazardous if contaminated

• Use the waste oil container and make sure all oils are removed from the equipment to maintain equipment

• Label the container only for waste oil and use proper volume for the system

• Have spill containment protocol

• Give short answers

• Why is it to employ the right tool

• List the safety rules when the service vehicle

Changing engine oil

• Start the engine and allow to run for 10 minutes
• Loosen the bolt and filter to allow engine oil to drain.
• Expose Make sure that the O-ring seal is exposed, allow 10 min for engine oil to drain anf install new seal
• Tighten the component finger tight first
• Torque to: 25 Nm
• Fill the engine with oil and clean and start the engine and check for leaks
• Then finally change brake fluid

Unit four: Carry-out service and Maintenance activities

• Identifying Systems/subsystems
• Following service rules standards and regulations
• Performing Inspection and replace components

Vehicle Battery

• The battery is the main source of electrical energy for the vehicle and check regularly

Charging System

• A charging system output test measures the max current the alternator can produce at a specified voltage or maximum load, do this when voltage or current is suspected
• Testers, such as a load tester, VAT tester, or ammeter, may be used
• Prevent Damage
• V-belts and V-ribbed (serpentine) belts drive water pumps, power steering pumps, air-conditioning compressors, generators, and emission control pumps

Engine Oil

• A clean or refined Crude Oil
• Crude oil must be refined meet industry standards.
• Has: Can flow easily providing lubrication, Reduces friction and wear
• Prevents formation of rust and parts cleaned.

Additional systems

• Chassis Lubrication is becoming less common due to modern procedure with technology
• Cooling System is visually inspect hoses
• Wiper Blade is the arms
• Windshield Washer is add and level needed for the washers
• Tire inflation is to specifications check it is important

Checks

• At Least Monthly do exterior lights and hazard warning flashers
• Least twice a year to balance lights to do that to test tires
• Lubrication, weather strips etc

Service rules

• Maintenance standards establish criteria for performing maintenance tasks including cleaning, repairs, parts, etc for reducing risks
• Companies establish internal standard operating procedures (SOPs) to ensure smooth maintenance and operations while also ensuring workplace rules

Standard operating procedures importance

• Organizations have to implement SOPs, most high-volume companies this helps manage issues in long terms including costs so must be considered

The Benefits of Maintenance

• Standardize contracts and keep workers health safe
• Harmonize what is know
• Standards prevent quality down

Wipers

• Keeping the windshield is excellent or there are durability

Unit Five: Carry-out service and Maintenance activities

• Storing Tools, equipment and materials are properly

• Keeping workplace

• Tools should stay in a dry, clean area and keep it away from extreme humidity and temperature

• Storing it helps with long time use, increase of value proper organizing also improves access

Organization

• Keeping all the tools organized may seem like a minor detail and benefits by
• Durability by avoid dust by saving money
• Increase in speed of tool use with the accessibility of being finding tools
• Maximizing Space: store primary at arms levels