Automotive Technician Training: Practical Worksheets Level 2 Automotive practical worksheets for students at Level 2 This Level 2 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 2 automotive courses. Step-by-step guides to the practical tasks required for all Level 2 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 2 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: 978-1-138-85237-2 (pbk) ISBN: 978-1-315-72351-8 (ebk) Typeset in Univers by Servis Filmsetting Ltd, Stockport, Cheshire Contents Practical Worksheets – Level 2 Engines Chassis Transmission Electrical Practical Worksheets – Level 2 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 work book 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.
Equipment Notes Suggested or examples where used Ear Must meet appropriate standards When working in noisy areas or if using an air defenders chisel Face mask For individual personal use only Dusty conditions. When cleaning brakes or if preparing bodywork High Fluorescent colours such as yellow or Working in traffic such as when on a breakdown visibility orange clothing Leather Should be replaced if it is holed or worn When welding or working with very hot items apron thin Leather Should be replaced when they become When welding or working with very hot items and gloves holed or worn thin also if handling sharp metalwork Life jacket Must meet current standards Use when attending vehicle breakdowns on ferries! Overalls Should be kept clean and be flame proof if These should be worn at all times to protect your used for welding clothes and skin. If you get too hot just wear shorts and a T-shirt underneath Rubber or Replace if holed Use if you do a lot of work with battery acid or plastic with strong solvents apron Rubber or Replace if holed Gloves must always be used when using plastic degreasing equipment gloves Safety Strong toe caps are recommended Working in any workshop with heavy equipment shoes or boots Safety Keep the lenses clean and prevent Always use goggles when grinding or when any goggles scratches risk of eye contamination. Cheap plastic goggles are much easier to come by than new eyes Safety Must be to current standards Under vehicle work in some cases helmet Welding Check the goggles are suitable for the You should wear welding goggles or use a mask goggles or type of welding.
Gas welding goggles are even if you are only assisting by holding welding NOT good enough when arc welding something mask 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. Hand tool Example uses and/or notes Adjustable An ideal stand by tool and useful for holding one end of a nut and bolt.
spanner (wrench) Open-ended Use for nuts and bolts where access is limited or a ring spanner can’t be used. spanner Ring spanner The best tool for holding hexagon bolts or nuts. If fitted correctly it will not slip and damage both you and the bolt head. Torque wrench Essential for correct tightening of fixings.
The wrench can be set in most cases to ‘click’ when the required torque has been reached. Many fitters think it is clever not to use a torque wrench. Good technicians realize the benefits. Socket wrench Often contain a ratchet to make operation far easier.
Hexagon socket Sockets are ideal for many jobs where a spanner can’t be used. In many cases a socket is spanner quicker and easier than a spanner. Extensions and swivel joints are also available to help reach that awkward bolt. Air wrench These are often referred to as wheel guns.
Air-driven tools are great for speeding up your work but it is easy to damage components because an air wrench is very powerful. Only special, extra strong, high-quality sockets should be used. Blade Simple common screw heads. Use the correct size! (engineer’s) screwdriver Pozidrive, Better grip is possible particularly with the Pozidrive but learn not to confuse the two very Philips and similar types.
The wrong type will slip and damage will occur. crosshead screwdrivers Torx® Similar to a hexagon tool like an Allen key but with further flutes cut in the side. It can transmit good torque. Special purpose Many different types are available.
As an example mole grips are very useful tools as they wrenches hold like pliers but can lock in position. Pliers These are used for gripping and pulling or bending. They are available in a wide variety of sizes. These range from snipe nose, for electrical work, to engineers pliers for larger jobs such as fitting split pins.
Levers Used to apply a very large force to a small area. If you remember this you will realize how, if incorrectly applied, it is easy to damage a component. Hammer Anybody can hit something with a hammer, but exactly how hard and where is a great skill to learn! 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.