Automotive Technician Training: Practical Worksheets Level 1 Automotive practical worksheets for students at Level 1 This Level 1 student worksheets book contains tasks that help you develop practical skills and prepare you for assessment. The tasks also reinforce the automotive theory that you will learn online and in the classroom. Each worksheet covers individual topics in a step-by-step manner, detailing how to carry out all the most important tasks contained within the syllabus. Alongside each of these worksheets is a job card that can be filled in and used as evidence towards your qualification.
Endorsed by the Institute of the Motor Industry for all their Level 1 automotive courses. Step-by-step guides to the practical tasks required for all Level 1 qualifications. Job sheets for students to complete and feedback sheets for assessors to complete. Tom Denton is the leading UK automotive author with a teaching career spanning lecturer to head of automotive engineering in a large college.
His range of automotive textbooks published since 1995 are bestsellers and led to his authoring of the Automotive Technician Training multimedia system that is in common use in the UK, USA and several other countries. Tom now works as the eLearning Development Manager for the Institute of the Motor Industry (IMI). Automotive Technician Training Practical Worksheets Level 1 Tom Denton First published 2015 by Routledge 2 Park Square, Milton Park, Abingdon, Oxon OX14 4RN and by Routledge 711 Third Avenue, New York, NY 10017 Routledge is an imprint of the Taylor & Francis Group, an informa business © 2015 Tom Denton The right of Tom Denton to be identified as author of this work has been asserted by him in accordance with sections 77 and 78 of the Copyright, Designs and Patents Act 1988. All rights reserved.
The purchase of this copyrighted material confers the right on the purchasing institution to photocopy pages which bear the copyright line at the bottom of the page. No other parts of this book may be reprinted or reproduced or utilised in any form or by any electronic, mechanical, or other means, now known or hereafter invented, including photocopying and recording, or in any information storage or retrieval system, without permission in writing from the publishers. Trademark notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation without intent to infringe. British Library Cataloguing-in-Publication Data A catalogue record for this book is available from the British Library Library of Congress Cataloging in Publication Data A catalog record for this book has been requested ISBN: 978-1-138-85236-5 (pbk) ISBN: 978-1-315-72353-2 (ebk) Typeset in Univers by Servis Filmsetting Ltd, Stockport, Cheshire Contents Practical Worksheets – Level 1 Engines Chassis Transmission Electrical Practical Worksheets – Level 1 Introduction The purpose of this worksheets book is to provide a range of practical activities that will enable you to develop your abilities as a technician.
The tasks are aligned with recognized vocational qualifications. However, there are far more tasks within this workbook than are required by the awarding body for the achievement of a Vocationally Recognized Qualification – because the more you practise, the more skills you will develop. The worksheets are presented as three separate books at Level 1, Level 2 and Level 3 to follow the recognized qualifications. Within each level there are tasks for the major automotive areas: Engines, Chassis, Transmission and Electrical.
The tasks range from component identification to removal and refit at Level 1 and 2, and diagnosis of complex system faults at Level 3. A blank job card and assessor report are provided with each worksheet. This should be copied and then filled in alongside the task you are completing, including all relevant details regarding the vehicle, the fault and the rectification procedure where appropriate. You should write down a description of the work that you did to complete the task including any technical data that you sourced, any difficulties that you encountered and how you overcame them.
If you had any health and safety issues to address, i. disposal of waste materials or clearing up spillages, this will help demonstrate your competence. By completing job cards thoroughly at this stage of your career as a technician, you will be well prepared for the time when you are required to complete job cards in the workplace. This can be very important, for example, if a warranty job card is not accurate then the manufacturer will not pay for the claim.
An example of a completed job card is shown on page 7. For teacher/lecturers, this workbook more than covers the requirements for Vocational Qualifications. Using the following tracking document you can note progress and also cross-reference the highlighted worksheets that directly relate to the awarding body required practical tasks. Tracking Important notes about practical work Safety Working on vehicles is perfectly safe as long as you follow proper procedures.
For all of the worksheets in this book you must therefore: Comply with personal and environmental safety practices associated with clothing; eye protection; hand tools; power equipment; proper ventilation; and the handling, storage, and disposal of chemicals/materials in accordance with all appropriate safety and environmental regulations. There are some specific recommendations below but you should also refer to the other textbooks or online resources for additional information. Personal protective equipment (PPE), such as safety clothing, is very important to protect yourself. Some people think it clever or tough not to use protection.
They are very sad and will die or be injured long before you! Some things are obvious, such as when holding a hot or sharp exhaust you would likely be burnt or cut! Other things such as breathing in brake dust, or working in a noisy area, do not produce immediately noticeable effects but could affect you later in life. Eye protection and gloves in use Fortunately the risks to workers are now quite well understood and we can protect ourselves before it is too late. In the following table, I have listed a number of items classed as PPE (personal protective equipment) together with suggested uses. You will see that the use of most items is plain common sense.
Also, as well as your own protection you should always use a protection kit for the vehicle: floor mats, wing covers and seat covers for example. Tools and equipment To carry out any work you will need a standard toolkit and in some cases additional ‘special’ tools will be required. Make sure you have access to all necessary equipment before starting work. A few examples are mentioned below but you should also refer to the other textbooks or online resources for additional information.
Using hand tools is something you will learn by experience, but an important first step is to understand the purpose of the common types. This section therefore starts by listing some of the more popular tools, with examples of their use, and ends with some general advice and instructions. Toolkit Practise until you understand the use and purpose of the following tools when working on vehicles. General advice and instructions for the use of hand tools (taken from information provided by Snap-on): Only use a tool for its intended purpose Always use the correct size tool for the job you are doing Pull a spanner or wrench rather than pushing whenever possible Do not use a file or similar without a handle Keep all tools clean and replace them in a suitable box or cabinet Do not use a screwdriver as a pry bar Look after your tools and they will look after you! Information Before starting work you should always make sure you have the correct information to hand.
This can be in the form of a workshop manual or a computer-based source. The worksheets in this book are a general guide so make sure the correct information, procedures and data for the particular vehicle you are working on are available before you start work. Autodata online information Job card: example Assessor report: example Engines Worksheet 1: Routine vehicle maintenance inspections/service Procedure General visual inspection – listen for abnormal noises. Visual/oil level and condition.
Replace oil and filter at specified intervals. Visual/inspections for oil leakage. Visual/inspection of exhaust smoke – at idle speed at mid-engine speed (3000 rpm) on overrun during road test. Engine oil pressure test – check warning light operates (attach a pressure gauge and adapter and tachometer) – pressure at idle speed – stabilized pressure – stabilized pressure engine rpm.
Crankcase ventilation system – check condition of hoses (visual and remove hoses and valves) – orifice to inlet manifold clear – air cleaner condition – control valve condition. Check coolant level and specific gravity. Check brake operation and pad/disc condition – record thickness. Check tyre tread depths.
Torque wheel nuts – include torque figures and calibration date of torque wrench. Additional items – see manufacturer’s schedule. Job card Assessor report Worksheet 2: Perform visual and aural checks on running engine Procedure Lift bonnet – general impression – check oil and coolant levels. Start engine from cold and carry out checks as engine warms up.
Check cooling system operation as engine warms up. Check top hose remains cool until engine is hot and then top hose should suddenly heat up as the thermostat opens. Electric fan operation follows when the engine temperature rises higher – keep hands clear of fan. Check fast idle speed (engine cold) and idle speed (engine hot).
Look at the colour of the exhaust smoke, blip throttle and watch for changes. Increase engine speed to about 3000 rpm and hold for 20–30 seconds – watch exhaust smoke. Release throttle to allow engine to idle – watch exhaust smoke on deceleration. Look for oil leaks and oil flow from areas of leakage.
Look at engine security when blipping throttle – look for excessive movement. Listen for exhaust knocking on body/chassis. Listen for abnormal noises – belt slipping squeal, scream/squeal from loose or leaking exhaust manifold or flange. Listen for engine mechanical sounds – light knocking/tapping from valve gear or pistons … Heavy knocking from crankshaft big end bearings … Rumble from crankshaft main bearings … Job card Assessor report Worksheet 3: Inspect chain drive mechanisms Procedure Strip to access chain drive mechanism.
Look for general condition, tension, lubrication and damage to covers. Check chain tension and condition of chain self-tensioner device. Check chain wear or stretch and ‘fit’ on the sprockets. Turn engine to align the timing marks and remove the chain and sprockets.
Check chain wear by observing the bend when the chain is held on its side. Check all rollers for tightness or seizure. Check the condition of the teeth on the sprockets. Check sprocket to hub location and securing holes and devices.
Reassemble chain and sprockets keeping the timing marks aligned. Refit and set tensioner. Turn engine at least two full revolutions and recheck timing and chain tension. When engine is running listen for abnormal noises and correct operation of the engine.
Job card Assessor report Worksheet 4: Remove and replace air cleaners, carburettors, inlet manifolds and early fuel evaporation system components Procedure Disconnect the battery earth lead. Undo the air cleaner and ducting securing screws/clips. Lift off air cleaner and ducting. Label and disconnect the throttle, choke and electrical cables to the carburettor and the early fuel evaporation heater grid.
Disconnect and cap or plug the fuel feed and return pipes/hoses. Undo the carburettor to inlet manifold securing nuts and remove. Lift off the carburettor from the inlet manifold. Inspect all gaskets and the heat insulation block or the early fuel evaporative heater grid plate.
Label and disconnect the vacuum connections on the inlet manifold. For water- heated inlet manifolds, drain the cooling system and disconnect the coolant pipes/hoses on the inlet manifold. Undo the inlet manifold to cylinder head nuts/bolts and remove. Lift off the manifold.
Inspect the gaskets for signs of leakage. Cleaning all mating faces – cylinder head, manifold, carburettor and heat shield and check for true (flatness).