Student Reference

Automotive
Technology
Curriculum
Automotive
Technology
Curriculum
Module 1: Introduction to
Automotive Technology
Module 1: Introduction to
70-1801-S
2006 Edition
Student
Reference

INTRODUCTION TO AUTOMOTIVE TECHNOLOGY
Module 1: Introduction to Automotive Technology
Student Reference
ProducedbytheInstructionalMaterialsLaboratory
1400RockQuarryCenter
UniversityofMissouri-Columbia
Columbia,MO65211
(800)669-2465
2006Edition
Catalogno.70-1801-S
2006.TheCuratorsoftheUniversityofMissouri.
AllRightsReserved.
Technical
Consultants:
KenEstes
RobinFerguson
SteveReese
Project
Coordinator:
EricaKassel
Editor:
JanisLevsen
Graphic
Artists:
ChrisBenedict
JacquelineCraig
AUTOMOTIVE TECHNOLOGY
ACKNOWLEDGMENTS
The2006revisionofIntroduction to Automotive Technologyrepresentsthe
InstructionalMaterialsLaboratoryscommitmenttothecontinualimprovement
oftheAutomotiveTechnologyCurriculum.Introduction to Automotive Technology
is the frst in the nine-module series. The other modules are as follows:
Module2 Electrical Systems
Module3 Engine Performance, Section 1: Ignition Systems
Module3 Engine Performance, Section 2: Fuel and Exhaust Systems
Module3 Engine Performance, Section 3: Emission Control Systems
Module4 Engine Repair
Module5 Steering and Suspension Systems
Module6 Brakes
Module7 Manual Drive Train and Axles
Module8 Automatic Transmissions and Transaxles
Module9 Heating and Air Conditioning
AllmodulesarebasedontheNationalAutomotiveTechniciansEducation
Foundation(NATEF)tasklist.ForyearstheNationalInstituteforAutomotive
ServiceExcellence(ASE)hassettheprofessionalstandardsforautomotive
technicians.AstrongNATEForientationmakestheninecurriculumguidesan
effective tool for preparing students to enter the technologically advanced feld of
automotivetechnology.
IML gratefully acknowledges the important contribution of the advisory
committee:
RogerDonovan,IllinoisCentralCollege,EastPeoria,IL
KenEstes,GrandRiverTechnicalSchool,Chillicothe,MO
RobinFerguson,KirksvilleVocationalTechnicalSchool,Kirksville,MO
SamJeanrenaud,LeesSummit,MO
KeithKendrick,JohnA.LoganCollege,Carterville,IL
Steve Reese, Lewis and Clark Vocational Technical School, St. Charles, MO
Ron Tuetken, Lewis and Clark Community College, Godfrey, IL
JohnWalker,HannibalAreaVocationalTechnicalSchool,Hannibal,MO
RodneyWolken,EldonCareerCenter,Eldon,MO
v
v
TABLE OF CONTENTS
Introduction ................................................................................................................ i
TitlePage............................................................................................... i
Acknowledgments.............................................................................iii
Components.......................................................................................vii
References.........................................................................................viii
Unit I Careers in the Automotive Field ..................................................S 1
Lesson1:TheAutomotiveTechnologyCareer.......................... S5
Unit II Safety ...............................................................................................S 11

Lesson1:ProtectingYourselfandOthersintheShop............ S15
Lesson2:ShopSafetyFeaturesandEmergency
Procedures...................................................................................... S35
Lesson3:RaisingandSupportingVehiclesSafely.................. S41
Lesson4:FederalandStateHazardousMaterial
Regulations..................................................................................... S49
Unit III Chemicals and Their Use ............................................................S 59
Lesson1:Solvents,Soaps,andCleaningSolutions................. S63
Lesson2:LubricantsandSpecialtyChemicals......................... S71
Lesson3:Gases,AsbestosDust,andBatteryAcid.................. S79
Unit IV Basic Hand Tools ..........................................................................S 85
Lesson1:TypesofWrenches...................................................... S89
Lesson 2: Types of Screwdrivers and Pliers.............................. S97
Lesson3:TypesofHammers,Punches,andChisels............. S103
v
Unit V Specialty Tools, Fasteners, and Measuring Tools ................S 107
Lesson1:SpecialtyTools........................................................... S111
Lesson2:Fasteners..................................................................... S119
Lesson3:MeasuringTools........................................................ S129
Unit VI Power Tools and Shop Equipment ..........................................S 135
Lesson 1: Power Tools................................................................ S139
Lesson2:ShopEquipment........................................................ S151
Unit VII Vehicle Information ...................................................................S 161
Lesson1:ServiceInformationandVehicle
Identifcation................................................................................. S165
Unit VIII Customer Service ........................................................................S 169

Lesson1:CustomerService,WorkOrders,and
VehiclePreparation..................................................................... S173
v
COMPONENTS
I. Objectives Eachunitisbasedonobjectivesthatstatethemeasurable
unit and specifc behavioral or performance objectives that the student is
expectedtoachieve.Becausetheobjectivesoftheunitprovidedirection
fortheteaching-learningprocess,theteacherandstudentneedacommon
understandingoftheintentoftheobjectives.
II. Information Sheets Presentedinoutlineformat,theinformationsheets
provide content essential for meeting the cognitive (knowledge) objectives
intheunit.Thestudentshouldstudytheinformationsheetsbeforeany
classdiscussionorcompletionoftheassignmentsheets.Thecorresponding
StudentReferencepagenumbersappearintheuppercornerofthe
InstructorGuide.
III. Assignment Sheets The assignment sheets allow the student to respond
to cognitive questions in writing.
IV. Job Sheets Thejobsheetsaredesignedtoguidethestudentthrough
variouskeytasksandprovideameansfortheinstructortoevaluatea
studentsperformanceofthetask.
V. Unit Tests The unit tests evaluate the students knowledge of the
material.
VI. Student Workbook and Student Test Packet Tracking Sheets These
provide the instructor with an effective way to track student progress on
theassignmentsheets,jobsheets,andunittests.
v
rEFErENCES
Alliance of Automobile Manufacturers. www.autoalliance.org.
AqueousPartsCleaning.Best Environmental Practices for Auto Repair,
November1999.EnvironmentalProtectionAgency.
Automotive Lift Institute. www.autolift.org
Battery Safety. National Ag Safety Database (NASD). www.cdc.gov/nasd.
Chrysler. www.chrysler.com.
Dodge. www.dodge.com.
Duffy,JamesE.ModernAutomotiveTechnology.TinleyPark,IL:The
Goodheart-WillcoxCompany,Inc.,2000.
FloorCleanup.Best Environmental Practices for Auto Repair,November1999.
EnvironmentalProtectionAgency.
Ford Motor Company. www.ford.com.
General Motors. www.gm.com.
NationalAutomotiveTechniciansEducationFoundation(NATEF).
www.natef.org.
National Institute for Automotive Service Excellence (ASE). www.asecert.org.
Occupational Outlook Handbook, 200607 Edition.UnitedStatesDepartmentof
Labor. Bureau of Labor Statistics. www.bls.gov/oco.
Screw Drive Systems. Sizes.com. www.sizes.com.
Sunkin,Ed.TrendsandTraitsofTodaysTechnicians:The2001Professional
AutomotiveTechniciansSurvey.Underhood Service,March2001.
Tobolt,WilliamK,LarryJohnson,andW.ScottGauthier.Automotive
Encyclopedia.TinleyPark,IL:TheGoodheart-WillcoxCompany,Inc.,2000.
UnitedStatesDepartmentofLabor,OccupationalSafetyandHealth
Administration. www.osha.gov.
United States Environmental Protection Agency. www.epa.gov.
IntroductIon to AutomotIve technology
S
UNIT I: careers IN The aUTomoTIve fIeld
coNTeNTs of ThIs UNIT
I. Unitobjective
II. Lessonplan
A. Lesson1:TheAutomotiveTechnologyCareer
1. Informationoutline
2. AssignmentSheet
a. AS1-L1-UI:AutomotiveTechnologyField
III. UnitITest
AutomotIve technology
s
S
Aftercompletingthisunit,studentswillbeabletoidentifysomeofthe
opportunities in the automotive feld and various facts about the automotive
technologycareer.Studentswilldemonstratemasteryofthematerialby
completingtheassignmentsheetandachievingascoreof_____ontheUnitI
Test.
sPecIfIc oBJecTIves
Aftercompletingthelessoninthisunit,studentsshouldbeableto:
Lesson 1
I. Identify some of the opportunities in the automotive feld.
II. Identifytheimportanceoftrainingandhowautomotivetechniciansand
training programs are certifed.
III. Identify job prospects in the automotive technology feld.
IV. Identifycommonmethodsusedtopayautomotivetechnicians.
V. Identifyotherfactsaboutworkingasanautomotivetechnician.
VI. Complete the assignment sheet on the automotive technology feld
(AS1-L1-UI).
s
S
lessoN 1: The aUTomoTIve TechNology career
I. Opportunities in the automotive feld
A. AccordingtostatisticsfromtheU.S.DepartmentofLabor,over
800,000peopleintheUnitedStatesareemployedasautomotive
servicetechniciansandmechanics.
1. Mostareemployedinthefollowingbusinesses:
a. Automotiverepairandmaintenanceshops
b. Automobiledealers
c. Retailersandwholesalersofautomotiveparts,accessories,
andsupplies
2. Othersworkinthefollowingbusinessesororganizations:
a. Gasstations
b. Homeandautomotivesupplystores
c. Automotiveequipmentrentalandleasingcompanies
d. Federal,state,andlocalgovernments
3. Over16%owntheirowntheirownbusiness.
B. Manyjobopportunitiesareavailablethatrelatedirectlyandindirectly
to the automotive technology feld.
S
1. Opportunitiesdirectlyrelatedtoautomotivetechnology
a. Automotivetechnician
b. Automotivetechniciansapprentice
c. Repairshopsupervisor
d. Exhaustandemissionstechnician
e. Tune-uptechnician
f. Servicewriter
g. Mechanicalunitrepairer
h. Technicianinautomotivemanufacturingplants
i. Airconditioningtechnician
j. Enginetechnician
k. Teacherortrainer
NOTE: Manygraduatesofautomotivetechnology
programsqualifytopursueacareerasateacherortrainer
withlittleornoextratrainingrequiredforanentry-level
position.
l. Dieseltechnician
m. Businspector
n. Tractortechnician
o. Partssalvager
2. Opportunitiesindirectlyrelatedtoautomotivetechnology
a. Farmequipmenttechnician
b. Aircrafttechnician
c. Offceequipmentservicetechnician/servicerepresentative
d. Machinistapprentice
S
e. Airconditioningandheatingserviceapprentice
f. Industrialmachinemaintenancetechnician
g. Smallenginetechnician
h. Marineequipmenttechnician
i. Motorcycletechnician
II. Training and certifcation

A. Repairingandmaintainingtodayssophisticatedvehiclesrequires
knowledgeinmanydiversesystemsandtechnologicallyadvanced
areas.
1. Thedaysofgettingajobbasedonperformingautomotive
repairasahobbyortinkeringinthegaragearegone.
2. Mostjobopportunitiesrequireformaltraininginautomotive
technologyinhighschoolorapostsecondaryschoolorcollege.
B. Certifyingorganizations
1. AsstatedontheirWebsite,theNationalInstitutefor
Automotive Service Excellence (ASE) is a nonproft organization
thataimstoimprovethequalityofvehiclerepairandservice
through the testing and certifcation of repair and service
professionals.
a. Automotive technicians can be certifed in one or more of
theeightareasbelow.
Brakes
Electrical/electrical systems
Engineperformance
Suspensionandsteering
Automatictransmissionandtransaxle
Enginerepair
Heatingandairconditioning
s
Manualdrivetrainandaxles
b. To be certifed, technicians must have at least 2 years of
experienceandpassanASEwrittenexamination.They
mustretaketheexamevery5yearstomaintaintheir
certifcation.
2. TheNationalAutomotiveTechniciansEducationFoundation
(NATEF),anarmofASE,reviewstrainingprogramstoensure
theyaremeetingASEstandardsandstayingup-to-datewith
thecontinuouslychangingautomotivetechnologyandrepair
methods.
a. Trainingprogramsrequestthereviewprocessona
voluntarybasis.Ifaprogrampassesthereview,NATEF
recommends it to ASE for certifcation. Programs must be
reviewed again every 5 years to be recertifed.
b. InASEsautomobilespecialty,trainingprogramscanbe
certifed in the eight areas listed in 1a.
C. To stay current with changes and advancements in the feld,

automotivetechnicianswillneedtoattendtrainingclasses
throughouttheircareers.Techniciansmayreceivetrainingattheir
workplaceormayneedtoattendclassesatatechnicalschoolor
college.
S
III. Job prospects in the automotive technology feld
A. Prospectsareverygoodforindividualswithtrainingandskillsin
diagnosis,problemsolving,electronics,andmathematics.Knowledge
inelectronicshasbecomecrucialbecausemostvehicleconcerns
involveworkingwithoranalyzingtheelectricalsystem.Accordingto
theAllianceofAutomobileManufacturers,electronicsnowcontrol
morethan86%ofallsystemsinatypicalvehicle.
B. Manyemployersintheindustryhavereportedthatthereisashortage
of automotive technicians and they have diffculty hiring individuals
witheducationandexperienceintheareasdesired.
C. AccordingtotheOccupational Outlook Handbook,publishedbytheU.S.
DepartmentofLabor,jobopportunitiesforautomotivetechnicians
areexpectedtoincrease9%to17%throughtheyear2014.The
growthwillbeduetotheincreasednumberofvehiclesontheroad
andthelossoftechniciansbecauseofretirementoradvancementto
specializedpositions.
D. Workforautomotivetechniciansisgenerallysteadythroughout
theyearandnotverysensitivetochangesineconomicconditions.
Therefore,layoffsarenotabigconcern.
IV. Commonmethodsusedtopayautomotivetechnicians
A. HourlyThetechnicianispaidforthetimeheorsheputsin.
B. SalaryAsalaryisasetamountofmoney,usually40hoursperweek,
regardlessofthevolumeofworkperformed.
C. FlatrateThetechnicianispaidhisorherhourlywagemultiplied
by the time listed for a specifc job in a factory fat-rate manual or
anaftermarketlabortimeguide.Theseguidesaresometimescalled
partsandlaborestimatingguides.Techniciansrefertotheseasbook
hours. The technician is paid this fat rate regardless of the time
spentonajob.
D. Hourlyplusapercentageoflaborandparts
V. Otherfactsaboutworkingasanautomotivetechnician
A. Automotivetechniciansusemanydifferenttoolsandequipment,
includingthoseinthefollowinglist.Techniciansusuallypurchase
theirownhandtools,whereastheshopprovidesthemoreexpensive
powertoolsandequipment.
s 10
1. Commonhandtools
2. Powertools
3. Machinetools
4. Weldingandoxyfuelcuttingequipment
5. Liftsandjacks
6. Computerstoperformadministrativetasksandaccessservice
information
7. Computerizeddiagnosticequipment
8. Measuringtools
9. Testinstruments
10. Otherspecialtytools,dependingontheautomotivetechnology
area
B. Someshopsareunionized,whichmeansthattechniciansemployed
therearesubjecttounionrulesregardingpayandotherissues.For
example,thetechnicianmayberequiredtoworkfor2yearsasan
apprenticebeforeadvancingtothejourneylevel.Theunionalso
functionstohelpemployeesnegotiatewiththeiremployersregarding
salariesandworkingconditions.
s 11
UNIT II: safeTy
I. Unitobjective
II. Lessonplans
A. Lesson1:ProtectingYourselfandOthersintheShop
2. Assignmentsheet
a. AS1-L1-UII:WorkSafetyintheShop
3. Jobsheet
a. JS1-L1-UII:IdentifyVehiclesEquippedWitha
SupplementalRestraintSystem(SRS)andAntilockBrake
System(ABS)
B. Lesson2:ShopSafetyFeaturesandEmergencyProcedures
2. Assignmentsheets
a. AS1-L2-UII:SafetyFeaturesandEmergencyProceduresin
theShop
b. AS2-L2-UII:ShopSafetyInspectionChecklist
C. Lesson3:RaisingandSupportingVehiclesSafely
2. Assignmentsheet
a. AS1-L3-UII:LiftandSupportVehicles
3. Jobsheet
a. JS1-L3-UII:LiftaVehicle
S 2
D. Lesson4:FederalandStateHazardousMaterialRegulations
2. Assignmentsheet
a. AS1-L4-UII:HazardousMaterialRegulations
III. UnitIITest
s 13
UNIT II: safeTy
UNIT oBJecTIve
Aftercompletingthisunit,studentsshouldbeabletoidentifyvarioussafety
rulesforpersonalsafetyintheshop,liftingandsupportingavehicle,and
workingwithhazardousmaterials.Theyshouldalsobeabletoidentifysafety
featuresandemergencyproceduresintheshop.Studentswilldemonstrate
masteryofthematerialbycompletingtheassignmentsheets,successfully
performing specifc tasks on the job sheets, and achieving a score of _____ on the
UnitIITest.
sPecIfIc oBJecTIves
Aftercompletingthelessonsinthisunit,studentsshouldbeableto:
Lesson 1
I. Identifywhoisresponsibleforsafetyintheshop.
II. Identifyfederalagenciesandguidelinesforsafepractices.
III. Identifygeneralshopsafetyrules.
IV. Identifygeneralsafetyrulesforhandlingtoolsandequipment.
V. Identifyrulesforelectricweldingsafety.
VI. Identifyrulesforoxyacetyleneweldingandcuttingsafety.
VII. Identifyrulesforliftingheavyobjectssafely.
VIII. Identifythepersonalprotectiveclothingandequipmentthatisusedinthe
shop.
IX. Identifytheimportanceofpropergroomingandhygiene.
X. Identifyrulesforusinghazardousmaterialssafely.
XI. Identifysafetyprecautionsforsupplementalrestraintsystems(SRSs)and
antilockbrakesystems(ABSs).
XII. Completetheassignmentsheetonworksafetyintheshop
(AS1-L1-UII).
S 4
XIII. Demonstratetheabilityto:
A. Identifyvehiclesequippedwithasupplementalrestraintsystemand
antilockbrakesystem(ABS)(JS1-L1-UII).
Lesson 2
I. Identifythesafetyfeaturesandequipmentintheshop.
II. Identifytheimportanceofmaintainingcleanlinessandorderintheshop.
III. Identifyemergencyproceduresusedintheshop.
IV. Completetheassignmentsheetonsafetyfeaturesandemergency
proceduresintheshop(AS1-L2-UII).
V. Completetheassignmentsheetonashopsafetyinspectionchecklist
(AS2-L2-UII).
Lesson 3
I. Identify terms and defnitions associated with lifting vehicles.
II. Identifycommonliftingdevices.
III. Identifycommonsupportdevices.
IV. Identifyprinciplesofliftingandsupportingvehicles.
V. Completetheassignmentsheetonliftingandsupportingvehicles
(AS1-L3-UII).
VI. Demonstratetheabilityto:
A. Liftavehicle(JS1-L3-UII).
Lesson 4
I. IdentifytherequirementsinOSHAshazardousmaterialregulations.
II. IdentifytherequirementsintheEPAshazardousmaterialregulations.
III. Completetheassignmentsheetonhazardousmaterialregulations
(AS1-L4-UII).
s 15
UNIT II: safeTy
lessoN 1: ProTecTINg yoUrself aNd oThers IN The shoP
I. Responsibilityforsafety
A. Safetyintheautomotiveshopistheresponsibilityofeveryone.
Safetymeansprotectingyourselfandothersfrominjuryatalltimes.
Workingintheshoprequirestheuseofalargevarietyoftools,
materials,andequipmentthatcaninjuretheworkerandothersinthe
shopifnotproperlyhandled.
B. Safetyintheshopincludestheitemslistedbelow.
1. Followingfederalguidelinesforsafepractices
2. Keepingtheshopfreeofhazards
3. Usingprotectiveclothingandequipment
4. Handlingandusingmaterialscontainingpotentiallyharmful
chemicalscorrectly
5. Usinghandtools,powertools,andequipmentcorrectly
6. Followingweldingsafetyrules
II. Federalguidelinesforsafepractices
A. Twofederalagenciesissueguidelinesandoverseesafetyinthe
workplace.
1. OSHA(OccupationalSafetyandHealthAdministration)issues
guidelinesconcerningsafetyfortheworker.
2. TheEPA(EnvironmentalProtectionAgency)issuesguidelines
concerningsafetyfortheenvironment.
B. OSHAguidelinesandEPAguidelines
1. EachschoolwillhaveacopyofOSHAandEPAguidelinesthat
mustbefollowed.DuetothechangingnatureofOSHAand
EPAguidelines,theinstructorwillgoovercurrentguidelines
withstudents.AllstudentsarerequiredtofollowOSHAand
EPAguidelines.
S 6
2. OSHAguidelinesconcernthecorrectlabelingofhazardous
componentsofequipment,thecorrectstorageofequipment
andmaterials,theuseofprotectiveclothingandequipment,
theplacementofwarningandsafetysigns,andgeneralsafety
practices.
3. EPAguidelinesconcernproperhandling,storage,anddisposal
ofhazardousmaterials.Theycoveranymaterialsthatmay
behazardousifreleasedintotheenvironment,includingthe
environmentoftheshop.
4. SeeLesson4formoreinformationabouttheseagencies.

III. Generalshopsafetyrules
A. Duringthecourseofworkingintheshop,anautomotivetechnician
movesfromoneareaoftheshoptoanother,movingpartsand
equipmentaroundtheshopandperformingvariedtasks.Itis
important that the shop foor be free of hazards that could cause
technicianstosliportrip.
B. Inawidevarietyofshoptasks,wastematerialsareproducedthatcan
causedangeroussituationsunlessthewastematerialsaredisposedof
orstoredproperly.
C. Alwaysbesurethatshopexitsarewell-markedwithanEXITsign
andareclearofobstructions.
D. Forpersonalsafetyandtohelpkeeptheshopfreeofhazards,always
complywiththefollowingsafetyrules.
1. Workquietlyandfocussolelyonthejobathand.
2. Do not leave creepers laying on the foor. Always stand them
againstthewall,wheelsoutward,whennotinuse.
3. Donotindulgeinhorseplayintheshop.Immatureand
improperbehaviorintheshopcancauseseriousaccidents.
4. Beforeperformingatask,considertherelevantsafety
precautionsrelatedtothetaskandformulateapreventionplan
foreachhazard.
5. Alwayswearprotectiveclothingandequipmentinanysituation
whereitisnecessary.
s 17
6. Wearprotectiveeyewearatalltimesintheshoparea.
NOTE:Thelawrequiresthatprotectiveeyewearbeavailable
andwornincareerandtechnicaleducationcourseswherethere
isareasonableprobabilityofinjury.
7. Donotwearrings,bracelets,watches,ornecklaceswhen
workingaroundmovingmachineryorelectricalequipment.
a. Jewelrycancatchinmovingmachinerywithserious
consequences.
Anecklacecanbecomeentangledinrunning
machinery,whichcouldpullthetechnicianintothe
machineryandcausegreatbodilyharm.
Ifaringorbraceletbecomesentangledorcaught,it
could result in a severed fnger or serious injury to
theheadorneck.
b. Ifaringorbraceletshouldaccidentallycreateashort
circuitofavehiclebattery,themetaloftheringorbracelet
couldbecomewhite-hotinaninstant,causingaserious
burn.
8. Donotputsharpobjectsintothepocketsofworkclothes.They
couldcausepersonalinjuryordamagetoavehiclesinterior.
9. Keephandsfreefromoilandgrease.
10. Wipe up grease and other spills from the shop foor
immediately,oratleastputanoil-absorbingcompoundover
them.
11. When cleaning up fammable liquids, always dispose of the rags
in a metal container with a tight-ftting lid.
S 8
12. Donotlookinthedirectionofanotherpersonwhoiswelding.
13. Donotrunavehicleengineinsideaclosedgarageunlessthe
vehicleexhaustishookeduptoexhaustventilationequipment.
Adeadlyamountofcarbonmonoxide,whichispresentinthe
exhaust,cancollectinaveryshorttime.
14. Donotsmokeintheshop,exceptinanareadesignatedfor
smoking.
15. When pumping a fammable liquid from a large container into
a small one, be sure to frst attach a ground wire between both
containers.
16. Alwaysbealertforhazardoussituationsintheshop.Promptly
correctthem,ifpossible,andinformtheinstructorofthe
situation.
17. Ifroadtestingavehicle,alwaysuseseatbelts,evenifonlygoing
ashortdistance.
18. Disconnectthebatteryasappropriate.Thiseliminateshazards
fromshortsthatcouldoccurduringrepairprocedures.
CAUTION: The vehicle manufacturers recommendations
must be followed for disconnecting batteries. Some onboard
vehicle computer systems can be damaged if the battery is
incorrectly disconnected.
19. Whenpartsareremovedfromavehicle,theyshouldbestored
awayfromtheworkarea(onabenchor,iflargeparts,againsta
wall).
s 19
20. Asbestosparticlescancausecancer.Asbestosisfoundinbrake
shoesandclutches.Therefore,wearaparticlemaskwhen
doinganycleaningworkonbrakeorclutchparts.Donotuse
compressedairtocleanbrakeorclutchparts.
21. Donotlettheleadsontestingequipmentfallintothefanofa
vehiclewhiletheengineisrunning.Electricfanmotorscanturn
onevenwiththeignitionoff.
22. Do not play with fre extinguishers. Use fre extinguishers only
to extinguish fres.
23. Alwaysreadthelabelsonchemicalsandmaterialsandfollow
theinstructions.
IV. Generalsafetyrulesforhandlingtoolsandequipment
A. Donotoperateanypieceofequipmentunlesstrainedintheuseofthe
equipment.
B. Evenifinstructedintheuseofapieceofequipment,donotuseit
unless given specifc permission by the instructor.
C. Selectthetoolorpieceofequipmentthatwillhandlethejobinthe
safest and most effcient manner. Use tools or equipment only as
recommendedbythemanufacturer.
D. Beforeusingatoolorpieceofequipment,inspectitfordefects,
missingorimproperlyadjustedsafetyguards,andanyothermissing
ormalfunctioningparts.
E. Maintainandstoretoolsandequipmentproperly.Developaregular
maintenancescheduleforshopequipment.Discard,repair,orreplace
worntoolsbecauseworntoolscanbeasafetyhazardandadversely
affectworkquality.
F. Donotusecompressedairtoblowdirtfromclothesanddonotpoint
acompressed-airhoseatanotherperson.
G. Whenusingcompressedairforcleaningobjectsintheshop,theair
pressuremustnotbemorethan30poundspersquareinch(psi).
H. Keeptools,especiallytoolhandles,freefromoilandgrease.
I. Beforeusingatool,checkthehandletomakesureitissecure.For
example,ahammerwithaloosehandleisunsafebecausethehead
may fy off during use.
S 20
J. Whenoperatingelectrictools,usetheproperprecautionstoavoid
electricshock.
K. Beforeinspectingormakingadjustmentstopneumaticorelectric
tools,alwaysdisconnectthemfromtheairorpowersupply.
V. Electricweldingsafety
A. Protectionfromelectricshock
1. Makesurethewelderisinstalledandhookedupproperly.
2. Donotuseequipmentthatisdamagedordefective,suchasan
electrodeholderwithdamagedinsulation.
3. Donotputtheelectrodeholderinwatertocoolit.
4. Do not use water to extinguish an electrical fre or any fre near
thewelder.
5. Keeptheworkarea,equipment,andclothingdrywhenusing
electricweldersbecauseevenaslightamountofmoisturecan
conductenoughelectricitytocauseasevereshock.
B. Protection from burns and fre
1. Make sure the work area is as fre resistant as possible.
2. Donotdragweldingcablesorhosesthroughdirtoroil,anddo
notpullonacabletoforceitoveranobstruction.
3. Takeprecautionswhenhandlinghotworkpieces.Usetongsor
pliers,nothands,topickuphotmetal.
4. Radiationfromaweldingarcisstrongenoughtosunburnor
sometimesblisterbareskiniftheexposureisintenseorforan
extendedperiod,sothearms,legs,andtorsoshouldbecovered
with durable, fame-resistant clothing.
5. Keeptheworkareacleanandfreeoftrash,grease,oil,andother
fammable materials.
6. Keep a fre extinguisher, frst-aid kit, and safety equipment
withineasyreach.
7. Donotdrapeanelectricweldingcableoveranytypeofgas
cylinder,anddonotstrikeanarconagascylinder.
s 1
C. Protectionfromarcrays
1. Aweldingarcproducesultravioletandinfraredradiationthat
canseverelyburneyesthatareunprotectedwithapropershade
ofprotectivelens.
NOTE: A welding hood or helmet protects the head from fying
sparksandtheshadedlensprotectstheeyes.
2. Makesureallothersintheweldingareaarewearingeye
protectionaswell.
3. Whenusingawelder,enclosetheweldingareatoprotectothers
fromthedangersofarcrays.
D. Protectionfromtoxicfumesandvapors
1. Manyweldingactivitiesproducetoxicfumesandvaporsthat
arehazardoustobreathe,andeveryworkstationshouldbe
equippedwithaventilationorexhaustsystemcapableofsafely
removingdangerousandirritatingsmokeandcontaminants.
CAUTION: Always position the head to the side of rising
fumes.
2. In confned areas where the hazard of toxic fumes is increased,
aweldershouldwearanair-suppliedrespiratororaself-
contained breathing apparatus, not a flter-type mask that
cannotcompensateforoxygendisplacement.
3. Cleanthemetalbeforewelding.Cleaningthemetalhelps
removeanychemicalthatmightmixwiththefumesproduced
bywelding.
VI. Oxyacetyleneweldingandcuttingsafety
A. Protection from burns (from heat or light rays), fre, and explosions
1. Donotallowoilorgreasetocomeincontactwithoxygenunder
pressure.
S 22
NOTE: Nolubricationoftheapparatusisnecessary.
2. Donotuseoxygenasasubstituteforcompressedair.
3. Beforestartingtoweldorcut,makecertainthereisno
fammable material nearby.
4. Alwayswearweldinggogglesandheavygloveswhenworking
withalightedtorch.
5. Wearweldinggogglesandprotectiveclothingthatblocks
harmful light from the acetylene fame.
6. Whenusingawelder,enclosetheweldingareatoprotectothers
from the dangers of acetylene fames.
7. Donotusematchesforlightingacetylenetorches.Aspark
lighter,heldatanangle,shouldbeusedtolightatorch.
8. Do not relight oxyacetylene fames on a hot work section in a
small confned space.
CAUTION: Acetylene gas gathers in one spot.
9. Donotuseacetyleneatapressureabove15psi.
CAUTION: Using acetylene at a pressure above 15 psi may
result in hand burns.
10. Useparticularcautionwhenweldingorcuttingindustyordirty
locations.
CAUTION: Dust can explode.
B. Protectionfromtoxicfumesandvapors
1. Manyweldingorcuttingactivitiesproducetoxicfumesand
vaporsthatarehazardoustobreathe,andeveryworkstation
shouldbeequippedwithaventilationorexhaustsystem
capableofsafelyremovingdangerousandirritatingsmokeand
contaminants.
CAUTION: Always position the head to the side of rising
fumes.
s 3
2. In confned areas where the hazard of toxic fumes is increased,
aweldershouldwearanair-suppliedrespiratororaself-
contained breathing apparatus, not a flter-type mask that
cannotcompensateforoxygendisplacement.
CAUTION: Argon is much heavier than air and quickly
displaces oxygen, so be especially careful using the MIG
process in a confned area, even though the area appears to
have adequate ventilation.

3. Cleanthemetalbeforeweldingorcutting.Cleaningthemetal
helpsremoveanychemicalthatmightmixwiththefumes
producedbytheprocess.
4. Someofthematerialsthatgiveoffespeciallytoxicfumesare
brass,bronze,galvanizedmaterials,ironorsteelcoatedwith
lead,orpaintcontaininglead.
C. Safehandlingofgascylinders
CAUTION: The acetylene and oxygen cylinders are highly
pressurized and may explode if not handled properly.
1. Oxygenandacetylenecylindersmustbestoredinaventilated
areaandmustbekeptseparate.Allowatleast20ftbetween
oxygencylindersandacetylenecylinders.
2. Allgascylindersmustbesecuredinboththestorageareaand
onthewheeledcartwithasafetychainorapprovedlashing.
3. Theprotectivecapsmustbeinplaceanytimethecylindersare
notinuse.
4. Donotmovethecylinderswithoutprotectivecapsinplace.
5. Donotdroporknockcylindersaround.
6. Donottamperwithsafetydevicesormarkingsonacylinder.
7. Donotuseahammerorwrenchtoopenacylindervalve.
8. Do not move a cylinder unless confdent in handling it.
S 24
9. Alwaysmoveagascylinderbyusingahandtruckwithasafety
chainorbytiltingitslightlyandrollingitonitsbottomedge
withonehandontheprotectivecap.
CAUTION: Do not tilt the cylinder too far over center; it may
cause the cylinder to drop.
VII. Liftingsafety
A. Thetechnicianwillencountermanysituationsinwhichheavyobjects
must be lifted from the foor. Back injuries are common if lifting is
notdoneproperly.
B. Alternativestoliftingheavyobjects
1. Avoidlifting,ifpossible.
2. Moveheavyobjectsbypushing,pulling,rolling,orsliding.
3. Usehoists,jacks,carts,andwheeltruckswhenpossible.
C. Toavoidinjurywhenliftingaheavyobject,useamechanicaldevice
orgettheassistanceofanotherperson.
s 5
D. Stepsofproceduretoliftanobject
CAUTION: Do not lift in an area where the foor is wet or greasy.
1. Spreadthefeetslightly,untilcomfortable,withonefootslightly
aheadoftheotherandalongsideoftheobject.
2. Bendtheknees,kneel,orsquat;donotbendtheback.
3. Useblockingunderobjectstogetahandhold.
4. Getagoodgripanduseglovesiftheobjecthassharporjagged
surfaces.
5. Liftwiththeleg,arm,andshouldermuscles,straighteningthe
legsandcomingtoastandingposition.
6. Shiftthefeettoturn;donottwist.
7. Lowertheloadbybendingtheknees,keepingthebackstraight
and using leg and arm muscles, and keep fngers and toes clear
ofobjects.
8. Use blocking to keep from pinching the fngers when setting the
objectdown.
VIII.Personalprotectiveclothingandequipment
CAUTION: Personal protective clothing and equipment should not be
considered the frst line of defense against injury but rather as backup
protection.
S 26
A. Wearprotectiveeyewearatalltimesintheshoparea.
NOTE:Thelawrequiresthatprotectiveeyewearbeavailableand
wornincareerandtechnicaleducationcourseswherethereisa
reasonableprobabilityofinjury.
1. Specialsplash-resistantgogglesarewornwhenthereisa
potentialchemicalhazard.
2. Whenwelding,aweldinghoodorhelmetmustbewornto
protect the head from fying sparks and protect the eyes from
burns.
3. Tintedgogglesmayberequiredifweldingisbeingperformed
closetotheworkarea.Consulttheinstructorforthe
appropriatetintedgogglesfortheweldingoperation.
4. Properglassesandwiremeshgogglesorplasticspectacles
withsideshieldsarerequiredinimpacthazardareas,suchas
grindingareas.
5. Everyperson,includingvisitors,mustwearindustrial-quality
protectiveeyewearatalltimesintheshoparea.
s 7
B. Wear a full face shield in situations where sharp fying objects could
injuretheface.
C. Respiratoryprotectionissometimesnecessary.Respiratorydevices
consistofameshthatcoversthenoseandmouth.Weararespiratory
maskwhendoingtasksthatcancreatedust.
D. Noiseintheshopcancausehearingdamage,dependingonthelevel
andduration.Wearingearplugsandearmuffshelpsprotecttheears
fromnoisecreatedbyequipmentsuchaspneumatictools,grinders,
andengines.
E. Adequatefootwearshouldbewornintheshoparea.Feetcaneasily
becrushed,cut,orpuncturedifnotproperlyprotected.
1. Footwearshouldhaveleatherorrubberoil-resistantsoles.
2. Footwearshouldprovideafullleatherorstrongfabriccoverfor
theentirefootuptotheankles.
NOTE: Footwearwithsteel-reinforcedtoesprovidesevenmore
protection.
3. High-topleatherbootsarerecommendedforwelding
operations.
S 28
F. Protectiveclothingforthebodyandhandsreducesthehazardof
injuryandprotectsstreetclothing.
1. Glovesandhandleathersareimportantpiecesofprotective
clothing.Differenttasksrequiredifferentmaterials(e.g.,rubber
glovesarewornwhenhandlingcausticchemicalsandheavy
leathergloveswithgauntletsarewornwhenwelding).
CAUTION: If operating machinery and wearing gloves, the
gloves may become entangled in the moving parts.
2. Apronsareusedtoprotectfromsparks,hotmetalsplashes,
andsplashingliquids.Thematerialshouldbesuitableforthe
intendeduse.
CAUTION: Never wear loose aprons around revolving or
reciprocating machinery.
3. Coverallsprotectthebody.Overalls,avariationofcoveralls,do
nothavesleeves.Fire-resistantcoverallsmadeofcottonorwool
arerecommendedforweldingoperations.
4. Shopcoatsprovideprotectionagainstdirtandgreasethat
soilstreetclothing.Thesealsooffersomeprotectionagainst
chemicalsandhotsubstances.
IX. Theimportanceofpropergroomingandhygiene
A. Longhaircanbecomecaughtinmovingmachinery,whichcanresult
inaportionofscalpbeinglostorpulledintothemachinery.Keep
longhairoutofmachinerybypinningituporwearingacap.
B. Jewelryshouldnotbewornintheshop.SeesectionIIIinthislesson
for the specifc hazards related to jewelry.
C. Havinggreasyhandscancauseslippagewhenworkingwithhand
tools.Greasealsosoilsinteriorsandpaint.
D. Havinggreaseonworkshoescanspreadgreaseacrosstheshop
foor, which increases the risk of slipping and falling. Dirty, greasy
coveralls/overalls and shoes can ruin vehicle interiors.
E. Having brake fuid and other chemicals on the hands could allow
accidentaltransfertopaintedsurfacesandcauseexpensiverepairs.
s 9
F. Protective eyewear that is dirty and scratched is diffcult to see
through.Protectiveeyewearshouldbekeptclean.Donotplacethe
lenses down on the foor or table. The soft, plastic coating can easily
bescratched.
X. Hazardousmaterialssafety
A. Fivegeneralsafetyrules
CAUTION: Consult the instructor before using an unfamiliar
product.
1. Followthemanufacturersrecommendations.Refertomaterial
safetydatasheets(MSDSs).SeeLesson4forinformationabout
MSDSs.
2. Carefullyreadtheproductlabelforcorrectusesandhazards.
3. Becarefultopreventspills,damagetothevehicle,orunsafe
situations/conditions.
4. Properlystorechemicalsandusedrags.
5. Usechemicalsonlyfortheirintendedpurposes.
B. Hazardousmaterialsincludethefollowing:
NOTE: Thefollowinglistincludessomeofthemorecommon
chemicalsfoundintheshopandisnotmeanttobeall-inclusive.See
UnitIIIforthesafetyprecautionsandusesofthesechemicals.
1. SolventsandacidsPart-washingsolvents,chokeand
carburetorcleaner,brakecleaner,gasketremover,
digestive-typecarburetorcleaner,andvehiclebatteryacid
2. LubricantsRust-penetratingoil,siliconelubricant,liquid
graphite, motor oil, automatic transmission fuid, power
steering fuid, gear lube, hydraulic fuids, various greases, and
specialtyadditives(e.g.,oiltreatmentandgastreatment)
3. GasesanddustGasesinengineexhaust,vaporsfrom
gasoline,refrigerantgas,andasbestosdustfrombrakeand
clutchlinings
S 0
C. Safety from skin damage and fre
1. Manychemicalsintheshopposeahazardtotheskinandeyes.
Followthesafetyprecautionsontheproductlabel.
2. Keepelectricaldevices,sparks,andanyhotmaterialawayfrom
fammable chemicals.
D. Safetyfromtoxicfumes
CAUTION: Breathing toxic fumes can cause dizziness, nausea,
headaches, unconsciousness, and can even lead to death.
1. Acommonsourceoftoxicfumesintheshopistheexhaustfrom
arunningengine.Eachtimeavehiclesengineisruninthe
shop,exhaustventilationequipmentshouldbeattachedtothe
vehicletoproperlyventthecarbonmonoxide,apoisonousgas
emittedintheexhaust.
CAUTION: Be sure to use approved exhaust ventilation
equipment when operating a vehicle in an enclosed area.
2. Wheneverfumesorvaporsarepresent,besuretoturnonthe
shopsventilationsystemassoonaspossibletoremovethem.
s 31
3. Usebreathingprotection,suchasarespirator,whenworking
withanymaterialsorchemicalsthatcouldbehazardousif
inhaled.
XI. Safetyprecautionsforsupplementalrestraintsystems(SRSs)and
antilockbrakesystems(ABSs)
NOTE:Techniciansneedtobeawareofspecialsafetyconsiderations
whenworkingonoraroundthesesystems.
A. SRSorairbagsystem
1. Firstappearinginafew1985-modelvehicles,airbagsystems
arestandardequipmentonmostvehiclesontheroadtoday.A
ruling by the National Highway Traffc Safety Administration
requiredallnewpassengercarstohavedualairbags(oneon
thedriverssideandoneonthepassengersside)by1998and
allnewlighttruckstohavedualairbagsby1999.
2. The SRS is designed to infate when a vehicle collides head-
onwithanobjectataspeedofmorethan14mph.Duringthe
collision,thedriverandpassengerimpacttheairbagrather
thanthesteeringcolumnordashboard.
3. Inadditiontodriver-sideandpassenger-sideairbags,some
vehiclesmaybeequippedwithside-impact,window,andrear-
seatairbags.
4. Airbagsarerelativelynewdevices.Newsafetyissues
regardingairbagsarecontinuallybeingrecognizedand
studied.
5. Airbagsmustbeusedwithseatbelts,shoulderharnesses,and
theproperheadreststoprovidemaximumprotection.
S 2
NOTE:Itisimportantforeveryoneintheautomotiveindustry,
includingautomotivetechnicians,toexplaintothepublic
thattheSRSalonedoesnotprovidemaximumprotectionina
collision.
6. Beforeworkingnearavehiclesairbags,besuretheyare
disabled.
CAUTION: The force of an air bag can break bones and cause
other serious injuries.
7. Evenifanairbaghasbeendisabled,theairbagmaydeployif
thediagnosticmodulesreservepowerhasnotbeendepleted.
CAUTION: The diagnostic module keeps the air bag
activated for some time after the negative battery cable has
been disconnected. Wait until the diagnostic modules reserve
power has depleted before working on or around the SRS.
The time can vary from a few seconds to over 30 minutes.
B. ABS
1. AnABShelpsthedrivermaintaincontrolofthevehiclewhen
braking.Ifthewheelslockduringbraking,thevehiclemay
slideoutofcontrol.Theantilocksystempreventsthebrakes
frombeingappliedhardenoughtolockthewheels.
2. Evenwhentheantilocksystemclosesdown,normal
power-assistedbrakingremains.Awarninglightlocatedinthe
instrumentpanelindicatesproblems.
3. Listedbelowaregeneralprecautionstoobservewhenservicing
theABS.
CAUTION: Failure to observe these precautions may result in
personal injury and damage to the ABS.
a. Followtheserviceinformationcarefully.Usetheproper
serviceinformationforthevehicle.Usingthewrong
sequenceofservicesteps,skippingsteps,orusingthe
wronginformationleadstounnecessaryreplacementof
parts.
b. Some brake parts contain asbestos fbers that can become
airborneasdustduringbrakeservice.Followthelatest
federalprocedureswhenworkingwithasbestos.
s 33
CAUTION: Asbestos is a cancer-causing substance. Do
not breathe asbestos dust or allow it to escape into the
air.
c. ManycomponentsofanABSarenotserviceable;replace
themasanassembly.DisassemblinganABScomponent
thatisnotdesignedtobeservicedmaycausepersonal
injuryorsystemmalfunction.
d. Thereisnoonebleedingprocedurethatappliestoall
ABSs.Proceduresvarygreatlyfromsystemtosystem.
TobleedavehiclewithanABS,usethemanufacturers
specifc bleeding method for the vehicle being serviced.
e. Ifusingelectricarcweldingequipmentonavehiclewith
anABS,disconnectthebatteryandpowertraincontrol
module(PCM).
f. AnABSoperatesatveryhighpressures.Always
depressurizetheaccumulatorbeforeservicingtheABS.
g. Toprotectthecontrolmodule,neverdisconnectorconnect
anyABSconnectorwhiletheignitionswitchison.
h. PortionsofanABSoperateatverylowsystemvoltages;
therefore,neveruseaconventional12-volttestlight
toprobecircuits.Aconventional12-volttestlightcan
damagetheantilockcomponents.Alwaysuseahigh-
impedancedigitalmultimeter(DMM)toprobethecircuits.
i. WhenworkingwithwiringonanABS,nevertouchthe
electricalconnectionsorpinsorallowthemtocontactthe
brake fuid. This kind of contact damages the PCM.
j. Beforetestdrivingavehiclewithabrakeproblem,test
thebrakesatalowspeedtobesurethatthecarstops
normally.
C. ProceduresforidentifyingvehiclesequippedwithanSRSandABS
1. On some vehicles, the vehicle identifcation number (VIN)
indicatesthatthevehicleisequippedwithanSRSandABS.
Checkthemanufacturersserviceinformationtodeterminewhat
digitsindicatethatthevehicleisequippedwithanSRSandABS.
S 4
2. Theschematicsmayalsocomewithvariouswarningsthatthe
vehicleisequippedwithanSRSandABS.
3. Somevehicleshaveamarkonthesteeringwheelcoverto
indicateanSRS.
S
UNIT II: safeTy
lessoN : shoP safeTy feaTUres aNd emergeNcy
ProcedUres
I. Observethefollowingguidelinesaboutsafetyfeaturesandequipmentina
shop.
A. Walkaroundtheshoptobecomefamiliarwiththevariousareas(e.g.,
work bays, management offces, parts department, customer waiting
area) and the traffc fow of vehicles coming in and out of the shop.
B. Notethelocationofshopexits,whichshouldbewell-markedwithan
EXITsign.Keeptheareaaroundtheexitsfreeofobstructions.
C. Befamiliarwiththeshopsevacuationroutesandproceduresincase
of fre or other emergencies.
D. Note the location of specifc work areas, such as those for welding,
painting,andgrinding,whichshouldbeclearlymarked.
E. Knowthelocationandhowtooperatetheeyewashstation,whichis
used to fush the eyes in case of a chemical splash.
F. Know where the frst-aid supplies are kept and be familiar with the
suppliesavailableandhowtousethem.
G. Locatethetelephonesthatcanbeusedforemergenciesandwhere
emergencynumbersareposted.
H. Notethelocationofstoragecontainersforhazardouswastesand
materials.
I. Know the location of the shops fre blanket. Every shop must have
a 100% wool fre blanket. The fre blanket can be wrapped tightly
around a person who is on fre to smother the fames.
1. Avoid using a fre blanket on a burning person wearing
syntheticclothing.Doingsocancauseseriousskindamage.
Usewatertoextinguishburningsyntheticclothing.
2. Workcoverallsandshopclothingshouldbemadeofcotton.
CAUTION: Do not allow a person on fre to run.
s 3
J. Know where the fre alarm is and how to activate it at the frst sign of
a fre that has any possibility of getting out of control.
K. Know where fre extinguishers are located and how to use them. It
is critical to be familiar with how the fre extinguishers in the shop
operate to be prepared if a fre should start.
1. Types of fre extinguishers
a. ClassAPlainwater
b. ClassBCMaybecarbondioxide,ordinarydrychemical,
orhalon
c. ClassABCMultipurposedrychemical
d. ClassDDrypowder
2. Classes of fres and the appropriate extinguisher for each
a. Class A fres include burning paper, wood, rubber, cloth,
andothermaterialscommonlyfoundinclassroomsand
offces. These fres may be effectively handled with either
a dry-chemical or water fre extinguisher.
S
b. Class B fres include burning liquids, gases, grease, and
oil. Use only dry-chemical fre extinguishers. Water fre
extinguisherscausetheburningliquidtospread.
c. Class C fres are electrical fres. Use only a Class C fre
extinguisherthatcontainsdrychemicalsandcarbon
dioxide. Water or foam-type fre extinguishers can
electrocutepeopleinthearea.
d. Class D fres include burning metals, such as magnesium
or sodium. Use only Class D fre extinguishers that
contain the appropriate dry powder and are identifed by
a5-pointstarwiththeletterDprintedwithinthestar.
NOTE: Most shops use multiple-class fre extinguishers
that can be used on Class A, B, and C fres.
3. Universal symbols for fre extinguishers
4. General procedure for using a fre extinguisher
CAUTION: Do not operate a fre extinguisher if not trained
to do so, if the fames are large or progress beyond their initial
stage, or if the fre becomes too hot or smoky. If there is any
doubt about being able to extinguish the fre, evacuate the
building immediately.
CAUTION: Before attempting to put out a fre with a fre
extinguisher, be sure to identify a safe evacuation route.
NOTE: Theinstructorwilldemonstratetheproperoperation
of the fre protection equipment available in the shop. Most
fre extinguishers operate using the P.A.S.S. method, which is
includedbelow.
a. PullPullthepin,ring,clip,etc.fromtheextinguishers
handle.Thisactionwillbreakthetamperseal.
s 3
b. AimAimtheextinguishernozzleatthebaseofthe
fames.
c. SqueezeSqueezetheextinguisherhandletoreleasethe
contents.
d. SweepSweepfromsidetosideatthebaseofthe
fames, discharging the extinguishing agent until the fre
isout.
II. Theimportanceofmaintainingcleanlinessandorderintheshop
A. Acleanshopenvironmentreducesthehazardsofslippingand
soilingclothing.Italsoprotectsvehiclesfromgreaseorpaint
damage.
B. Anorderlyshopwithclearpathwaysallowsemployeeseasyaccess
to exits. Regulations from the EPA and local fre codes empower the
local fre marshal to insist on an orderly, uncluttered, and safe shop
area.
C. Keeptools,equipment,andsuppliesorganizedtoallowgreater
effciency. Store tools, equipment, and supplies in their proper place
whennotinuse.
D. Acleanandorderlyshopisthemarkofcompetentprofessionalsand
promotesbusinessgrowth.
III. Emergencyprocedures
A. Ifsomeoneisinjuredintheshop,notifytheinstructoratonce.
S
B. Do not give frst aid to a victim unless trained to do so. However, if
properly trained, do not hesitate to give frst aid.
C. Ifsomeonecomesintocontactwithelectricalcurrentandreceives
animmobilizingshock,donottrytomovehimorherifthecurrent
isstillonandthepersonisstillincontactwithit.Shutoffthemain
circuit to the shop. Electrical current will fow through whoever
touchesthepersonbeingshocked.Notifytheinstructoratonce.
D. General fre emergency procedure
NOTE: Specifc procedures for dealing with fre emergencies vary. It
is important to know the specifc procedures for your shop.
1. If a person is on fre, immediately wrap the person in a fre
blanket to smother the fames.
2. For other fres, turn on the fre alarm.
3. Notifytheinstructorassoonaspossible.Theinstructorwill
decide whether or not to attempt to extinguish the fre or to wait
foremergencypersonnel.
4. Turnoffanymachinesandpowerintheeventofanalarmif
timeorcircumstancesallow.
5. Followbuildingevacuationproceduresasrequired.
s 0
S 4
UNIT II: safeTy
lessoN 3: raIsINg aNd sUPPorTINg vehIcles safely
I. Terms and defnitions
A. Jack A device, such as a hydraulic foor jack, that raises the front,
rear,orsideofavehicleofftheground.
B. Lift Apieceofhydraulicequipmentusedtoliftthewholevehicle
offtheground.
C. Lifting Usingadevicetoraiseavehicleoffthegroundforthe
purposeofinspection,service,orrepair.
D. Safety stands Lightweightframesusedtosupportavehicleafter
beingliftedbyajack.
E. Torque box areas Thefourcornersofthepassengercompartment
regardlessofwhetherthevehicleactuallyhastorqueboxes.
F. Torque boxes Locatedineachcornerofthepassenger
compartmentanddesignedtominimizedamagetothecompartment
inacollision.
G. Wheel blocks or wheel chocks Blocksthatareplacedononeor
morewheelsbeforeliftingtokeepthevehiclefromrolling.
II. Commonliftingdevices
A. Inordertoinspectorrepairavehicle,itisfrequentlynecessarytoget
thevehicleoffthegroundtoprovideaccesstotheunderside.
B. Awidevarietyofequipmentisavailableforliftingvehicles,suchas
lifts and hydraulic foor jacks. Most equipment is hydraulic, but there
arealsopneumaticlifts.
s
C. Hydrauliclift
1. Functions hydraulically to raise the whole vehicle off the foor
2. Allowsforinspectionunderthevehicle
3. Allowsrepairstobedoneatamorecomfortableheightforthe
technician
4. Safety
a. Refertoserviceinformationforpositioningthevehicleon
theliftandfollowallsafetyprecautionsforoperatingthe
lift.
b. Beforeliftingthevehicle,checkforproperclearanceonall
sidesofthevehicleintheliftareasothatthevehicledoes
nothitotherobjects.
c. Donotliftvehicleswithpassengersinsideorwiththe
doors,hood,orluggagelidopen.
d. Besurethattheliftslockingmechanismisinthelocked
positionbeforewalkingunderthelift.
e. Befamiliarwithsafetylockreleasemechanismsforsafe
loweringofvehicles.
S 4
D. Hydraulic foor jack
1. Usesmechanicalforce,withtheoperatorusingalevertopump
upthejack
2. Ismountedonfourwheelsforportability
3. Usedofteninraisingthefront,rear,orsideofavehiclefor
placementonsafetystands
4. Safety
a. Ensurethevehiclebeingliftedisonalevel,solidsurface.
b. Alwaysbesurethereleasevalveiscompletelyclosed
beforeattemptingtoliftavehicle.
c. Refer to service information to fnd the correct lift point on
thevehicletopositionthesaddleofthejack.
d. Nevercrawlunderavehiclehelduponlybyajack,either
hydraulicorpneumatic.Alwaysusesafetystandsto
supportthevehicle.
e. Besurethattheload-capacityratingforthesafetystandsis
suffcient to safely support the vehicle.
f. Afterpositioningthesafetystandsunderthevehicle,shake
thebodyofthevehicletomakesureitisstable.
g. After raising a vehicle with a foor jack, be sure the handle
ofthejackispointedstraightup.
h. Donotoperatehydraulicjacksiftheyareleakingbecause
theymayfail.
s
i. Donotliftvehicleswithpassengersinsideorwiththe
j. Makesureeveryoneinthevicinityisstandingwellaway
fromaraisedvehiclebeforeopeningthereleasevalveto
lowerit.Whenloweringavehicle,thereleasemechanism
shouldbeopenedalittleatatime,andthenclosed,to
lowerthevehiclealittleatatime.
CAUTION: If the release mechanism is opened all the
way, it will drop the vehicle to the foor instantly. This
may cause injury to the operator and others in the area as
well as damage to vehicle.
III. Commonsupportdevices
A. Safetystands
1. Sturdymetaldevicesthatsupportthevehicleafterbeinglifted
byajack
2. Availableindifferentheightsandloadcapacities
3. Placedundersecurepointsonthevehiclesuchastheframeand
axlehousing
NOTE: Refertoserviceinformationandthemanufacturers
instructionsforthecorrectpointstoplacesafetystands.
S 4
B. Wheelblocks,alsoknownaswheelchocks
1. Wedge-shapedblocksusedasasafetymeasure,inadditionto
safetystands,tokeepthevehiclefromrollingafterbeinglifted
2. Usedbeforeliftingthevehiclewithajack
3. Placedinthefrontandrearofawheelthatwillremainonthe
groundafterlifting
IV. Principlesofliftingandsupportingvehicles
A. Each vehicle has specifc lifting points. Consult current service
informationortheownersmanualforeachmodeltodetermine
properliftingpoints.
CAUTION: Identifcation of proper lifting points is extremely
important. Damage caused by improper lifting can be severe.
Common sense, along with an understanding of vehicle
construction and vehicle supporting techniques, must be used in
each repair instance.
B. Thepurposeofraisingthevehicleistogetthevehiclehighenoughin
theairtosafelyinspect,service,orrepairtheunderside.
C. Beforeliftingavehicle,checkboththevehicleandequipment
manufacturersrecommendations.
D. Ingettingthevehicleofftheground,therearetwoseparatepointsto
beconsideredasfollows:
1. Properliftingmethods
s
2. Propersupportingmethods
E. Liftandsupportpoints
NOTE: Thecorrectliftandsupportpointsdependonthemodelof
thevehicleandthetypeofliftequipmentbeingused.Refertoservice
informationandthemanufacturersinstructions.
1. Torqueboxareasaregenerallyacceptableliftpoints.
a. Theseareasaredesignedtoabsorbtwisting(torque)force
causedbyacollisionandroutedamageawayfromthe
passengercompartment.
b. Thefourtorqueboxareasarelocatedatthecornersofthe
passengersection.
c. Evenifthevehicledoesnothaveactualtorqueboxes,the
fourcornersofthepassengercompartmentarereferredto
astorqueboxareas.
d. Torqueboxareasaregenerallythestrongestareasofthe
vehicleforliftingandsupporting.
S 4
2. Thepinchweldareaoftherockerpanel,whichisthefactoryweld
that fuses the bottom fange of the outer rocker panel to the inner
rockerpanel,isastrongsupportareaonunibodyvehicles.
s
S 4
UNIT II: safeTy
lessoN : federal aNd sTaTe hazardoUs maTerIal
regUlaTIoNs
I. OccupationalSafetyandHealthAdministration(OSHA)regulations
A. OSHAisafederalorganizationthatsetsandenforceswork
environmentstandardstoprotectthehealthandsafetyofthe
individualworker.Anyemployerorinstitutionthatdoesnotadhere
toOSHAstandardsissubjecttoprosecution.
1. Ifemployeesprovidetheirowneyeandfaceprotective
equipment,OSHArequiresthattheemployermakesurethe
equipment meets specifc safety standards.
2. OSHArequirestheemployertoprovideaventilationsystem,
masks,andanyothersuchdevicesneededtoprovidereasonable
protectionagainstharmfuldusts,fogs,fumes,mists,gases,
smokes,sprays,andvapors.
3. OSHA requires that fammable liquids like gasoline and solvents
thatarepackagedorkeptinsmallcontainersbestoredinan
approvedmetalcabinetinquantitiesoflessthan60gal.
NOTE:Themetalcabinetsmustbeapprovedbythe
UnderwritersLaboratoriesInc.(UL).
4. OSHArequiresthatpotentiallyhazardouschemicalsstoredon
sitebeclearlylabeled.Safetytrainingforemployeesshould
addressthecorrectproceduresforchemicalhandling,storage,
anddisposal.
5. OSHArequiresthatemployersprovideadequateearprotection
forallworkersexposedtonoiselevelsdeemedharmful.
B. TheHazardousCommunicationStandardorRight-to-Knowlaw
informsemployeesaboutthehazardoussubstancesthatareavailable
intheirshop.
1. RequirementsoftheRight-to-Knowlaw
a. A specifc person or group is responsible for the operation
ofthecompanysRight-to-Knowprogram.
s 50
b. Allhazardoussubstancesandharmfulphysicalagents
must be identifed.
c. Awrittenprogramdescribestrainingactivities,chemical
identities,andwastedisposal.
d. Allcontainersofhazardoussubstancemustbelabeled
withthenecessaryhealthandsafetyinformation.
e. Employersmustobtainwritteninformationoneach
hazardoussubstanceandprovidethemtoemployeesin
theformofmaterialsafetydatasheets(MSDS).
f. AllemployeesmustbetrainedinthedetailsoftheRight-
to-Knowrequirements.
C. OSHAusescertainbasiccharacteristicstodeterminewhichmaterials
areincludedonitshazardoussubstancelist.
1. Ahazardousmaterialisanysubstancethatcouldcauseinjuryor
deathtopeopleorcoulddamageandpolluteland,air,orwater.
2. Tobeconsideredhazardousasubstancemustbeeithertoxic,
fammable, corrosive, reactive, or come into contact with the
skin.
a. Toxicisthetermusedtodescribeamaterialthatcan
causeillnessordeathafterbeinginhaledorcominginto
contactwiththeskin.OSHAandtheEnvironmental
ProtectionAgency(EPA)haveliststhatincludehundreds
ofdifferenttoxicchemicals.
b. Flammableisusedforanignitablesubstancethatcan
easily catch fre or any material that has a fash point below
200F.
c. Corrosiveisusedforasubstancestrongenoughto
dissolvemetal,burnskin,orcauseeyedamage.Acidsand
basesareexamplesofcorrosivematerials.
d. Reactiveisusedforamaterialthatcanbecomeunstable,
burn,explode,orgiveofftoxicvaporsifmixedwithair,
water,heat,orothermaterials.
S
D. Employeetrainingisrequired.
1. Employersarerequiredtotrainthefollowingpeople.
a. Workerswhoareroutinelyexposedtohazardous
chemicalsorhazardouswaste.
b. Workerswhohandlepackagescontaininghazardous
materials.
c. Anyonethatcouldbeexposedtohazardousmaterialsina
foreseeableemergencyorcouldbeinvolvedifanaccident
occurs.
d. Newemployeesthatmeettheaboveexamplesmust
betrainedbeforetheybeginworkwheretheycouldbe
exposedtohazardousmaterials.
e. Offce workers that only encounter hazardous chemicals in
isolatedcasesdonotrequiretraining.
2. Thefollowingmustbeincludedinthetraining.
a. Employeesmustbetrainedtorecognizehazardous
materialsandhowtogatherinformationaboutthose
hazardousmaterials.
b. Employeesmustbetrainedinthebasicwaystoprotect
themselvesfromharmfulexposure.
c. Employeesmustbetrainedintheproperuseoflevelsand
MSDSmaterials.
d. Employeesmustbetrainedinwhattodoinanemergency
andhowtouseequipment.
e. Employersmusteducateemployeesonthedetailsofthe
Right-to-Knowprogram.
3. FederalregulationsdonotincludeannualRight-to-Know
training,butmanystatesnowrequiresafetytrainingbe
repeatedonanannualbasis.
E. Employershavecertainresponsibilities.
1. Theremustbeatleastonepersonappointedtoadministerthe
Right-to-Knowprogram.
s 5
2. Hazardous materials in the workplace must be identifed and
listed.
3. AnMSDSmustbeobtainedandkeptforeachhazardous
chemicalonsite.
4. Awrittenplanmustbedevelopedthatoutlinesthe
requirementsoftheRight-to-Knowprogram.
5. Employeesmustbetrainedtounderstandthephysicaland
healthhazardsofthechemicals.
6. Theinformationoncontainerlabelsmustbeexplainedand
maintained.
7. Workersmustbeshownhowtoprotectthemselvesfrom
chemicalhazards.
8. Theremustbeinstructionsonwhattodoinanemergencyand
howtouseprotectiveequipment.
F. Employeeshavecertainresponsibilities.
1. TheymustknowwheretheMSDSsarekept.
2. TheymustknowhowtoreadlabelsandMSDSinformationand
howtofollowthemanufacturersinstructionsandwarnings.
3. Theymustknowhowtoobtaininformationandaskquestions.
4. Theymustknowtheproperproceduresfordealingwith
hazardousmaterials.
5. Theymustknowtheproperproceduresfordealingwithan
emergencythatinvolveshazardousmaterials.
G. MSDSrequirementsincludethefollowing:
1. PerOSHArequirements,chemicalmanufacturersandmaterial
importersmustobtainordevelopanMSDSforeachhazardous
materialtheyproduceorimport.AsampleMSDSappearsafter
thenextpage.
2. EmployersmusthaveanMSDSintheworkplaceforeach
hazardousmaterialtheyuse.
3. EachMSDSmustbeinEnglish.
S
NOTE: Theemployermaymaintaincopiesinotherlanguages.
4. Chemicalmanufacturersandimporterscanuseanyformfora
MSDSaslongasitisincompliancewithOSHAstandardsand
contains the specifc following information.
a. Thename,commonname,andcommonnameofany
chemicalsusedinthemix
b. Thephysicalandchemicalcharacteristics
c. Physical hazards including the potential for fre, explosion,
andreactivity
d. Healthhazardsincludingthesignsandsymptomsof
exposureandanymedicalconditionsthataregenerally
recognizedasbeingaggravatedbyexposure
e. Primaryroutesofentryonthebody,suchasinhalation
andskinabsorption
f. TheOSHA-permissibleexposurelimit,theAmerican
ConferenceofGovernmentalIndustrialHygienists
(ACGIH)thresholdlimit,andanyotherexposurelimits
thatareusedorrecommended
g. WhetherornotthechemicalislistedbyOSHAandthe
NationalToxicologyProgram(NTP)annualreporton
carcinogensorisconsideredtobeapotentialcarcinogen
intheInternationalAgencyforResearchonCancer(IARC)
monographs
h. Anyapplicableprecautionsforsafehandlingandusethat
areknown
i. Anyapplicablecontrolmeasuresthatareknown
j. Emergency and frst aid procedures
k. DateofpreparationoftheMSDSorthedateofthelast
changetotheMSDS
l. Name,address,andtelephonenumberofthechemical
manufacturer,importer,oremployerthatpreparedthe
MSDS
5. Each manufacturer will have specifc information about how to
readanMSDS.
s 5
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II. EPAregulations
A. TheEPAisafederalagencythatwritesandenforcesregulations
onhazardouswasteandisresponsibleforhowthehealthofthe
populationisaffectedbytheenvironment.
B. Federal laws defne three categories of hazardous waste generators.
1. AConditionallyExemptSmallQuantityGeneratorgenerates
100kgorlessofhazardouswastepermonthandneverstores
morethan1,000kgatthebusiness.
2. ASmallQuantityGeneratorgeneratesbetween100kgand1,000
kgofhazardouswastepermonth.Theamountofhazardous
wastestoredonsitemustneverexceeds6,000kg.
NOTE: The typical shop is classifed by the EPA as a Small
QuantityGenerator.
3. ALargeQuantityGeneratorgenerates1,000kgormoreper
monthofhazardouswaste.Thistypeofgeneratordoesnothave
ahazardouswastestoragelimitbutcannotstorewasteonsite
formorethan90days.
C. Allcategoriesofgeneratorsaresubjecttothefollowingrequirements.
1. Ageneratormustdeterminewhichmaterialsarehazardous.
2. AgeneratormustobtainanEPAIDnumber.
3. Ageneratormustprepareandstorehazardouswasteas
requiredbylaw.
4. Ageneratormustshipwastesfortreatmentanddisposalonlyto
companieswithproperEPAIDnumbers.
5. Ageneratormustfollowtheproperhazardouswastestorage
rulesfortanksanddrums.
a. Drums must be marked with the date the waste was frst
placedinthedrum.
b. Thecorrectlabelsmustbeused.
c. Theremustbeasecurestorageareatoprevent
unauthorizedaccess.
s 5
d. Outdoorstoragemustbeshadedfromsunlightifthe
wastesareignitable.
e. The foor in the outdoor storage area must be curbed and
impermeabletocatchandcontainleaksofthewaste.
6. Ageneratormustkeepmanifestsforatleast3years.Exception
reports are fled if a waste shipment is lost.
7. Thefacilitymustbeoperatedtominimizeaccidentsandbe
equippedwithinternalandexternalcommunicationequipment.
Local authorities, fre, police, and emergency medical must be
familiarwiththelayout,entranceroutes,accessroutes,andthe
listofwastesatthefacilityandrelatedlocations.
NOTE: Anyrefusalbythelocalauthoritiestorespondshould
bedocumented.
8. Ageneratormustinspectwastecontainersonaweeklybasis.
Containersmustbekeptclosedbetweenuse.Ifthefacilityis
everclosed,allwastemustberemoved.
D. Additionalrequirementsforcategory2and3generatorsareas
follows:
1. Anemergencycoordinatormustbedesignatedforthesite.This
personisoncall24hoursadaytorespondtoanyemergency.
2. Thenameandphonenumberoftheemergencycoordinator,the
location of the fre extinguishers, the location of the spill control
equipment, and the fre department phone number must be
postedbythetelephone.
3. Thegeneratormustensureanddocumentthatemployeeshave
beentrainedinemergencyoperationsandcommunications
systems.
4. Theemergencycoordinatormustrespondtoanyemergencyand
followtheemergencyresponseplan.
E. Hazardouswastesmustbestoredproperly.
1. Whenwastesaregenerated,alabeliscreatedwiththestartdate,
facilityaddress,EPAIDnumber,thewordsHazardousWaste,
wasteinformation,andshippinginformation.
S
2. Awarningstickermayalsobenecessary.Somewasteshave
morethanonehazardandrequireawarninglabelforeach
hazard.
3. Containermanagementrequiresthatalogmustbekeptto
recordweeklyinspectionsofdrumsduringstorage.Drum
inspectionsrequirethedateandinitialsoftheinspector.See
SectionII,C,5forotherrequirements.
F. EPAregulationsrelatedtothestorageofhazardouswastesinclude
thefollowing:
1. Thedifferenttypesofhazardouswastescannotbemixed.
2. Storagecontainersmustbeinsoundconditionandhavethe
properdesignandcharacteristicsforthetypeofmaterial.
3. Containersmustbeclearlymarkedandstoredawayfromthe
shoparea.TheEPAandDepartmentofTransportation(DOT)
require specifc labels to indicate various types of wastes.
G. EPAregulationsrelatedtothehandlingofhazardouswastesinclude
thefollowing:
1. Employeesmustbetrainedintheproperuseanddisposalof
hazardouswastes.
2. Signsandchartsidentifyinganddescribingthehazardous
materialsmustbedisplayedintheshop.
a. Emergencyproceduresfordealingwithhazardouswaste
accidentsmustbedisplayedintheshop.
b. Thephonenumbersoftheemergencycoordinator,
fre department, police, health center, and the national
responsecentermustbepostedbythetelephone.
3. Theshopareamustbeunclutteredandexitseasilyaccessible.
The local fre marshal determines if the shop is meeting these
requirements.
4. The shop operator must have on fle precise information on the
chemicalscontainedineachproductintheshop.Theoperator
should also have on fle frst aid procedures relating to exposure
tothesechemicals.
s 5
H. EPAregulationsrelatedtothedisposalofhazardouswastesinclude
thefollowing:
1. Hazardouswastesmustbecollectedbyanapprovedwaste
hauler.
2. Ashoprepresentativemustcompleteawastemanifesteachtime
awastehaulerpicksuphazardousmaterial.Thehaulercannot
acceptwastewithoutthecorrectforms.
NOTE:Anexceptiontothisruleinvolvestheuseofsolvents
thatwillberecycledbythewastehauler.Inthiscase,the
paperworkishandledbythehauler.
3. Theshopmustobtainatwelve-digitcodenumberfromtheEPA.
ThisnumberregisterstheshopasaSmallQuantityGenerator.
Awastehaulermusthavethiscode.
4. Eachtypeofwastemustbeinasuitablepackageorcontainer
and identifed with a code name as specifed by the DOT.
5. FailuretoobserveEPAregulationsresultsincriminalliabilityto
theshoporwastehauler.
I. Chemicalsorproductsthataredesignatedashazardouswastecan
change.Thefollowingaretwowaysamaterialisjudgedhazardous
andsubjecttoEPAregulations.
1. The EPA has a published list of specifc chemicals deemed to be
hazardoustohealthandtheenvironment.
2. If an operator believes a material is fammable or corrosive, will
reactchemicallywithothermaterials,orwillreleasehazardous
materials,thematerialcanbedeemedhazardous.
J. Thefollowingarewaysinwhichashopcanreducetheproductionof
hazardouswasteandthecostofdisposingofit.
1. Encouragetheconservativeuseofsolventstoreducewaste
disposalcostsaswellasthereplacementcostsofsolvent.
2. Useheatersthatburnoil,whichsavesonheatingbillsaswellas
wastedisposalcosts.
3. Shipthehazardouswastedirectlytoarecyclingplantthatwill
pickthewasteupatnochargeandusuallynotrequireawaste
manifest.
S
UNIT III: chemIcals aNd TheIr Use
I. Unitobjective
II. Lessonplans
A. Lesson1:Solvents,Soaps,andCleaningSolutions
2. AssignmentSheet
a. AS1-L1-UIII:SolventsandSoaps
B. Lesson2:LubricantsandSpecialtyChemicals
2. AssignmentSheet
a. AS1-L2-UIII:LubricantsandSpecialtyChemicals
C. Lesson3:Gases,AsbestosDust,andBatteryAcid
2. AssignmentSheet
a. AS1-L3-UIII:Gases,Dust,andAcid
III. UnitIIITest
s 0
S 6
UNIT oBJecTIve
Aftercompletingthisunit,studentswillbeabletoidentifycommonchemicals
usedintheshop,theirpurpose,andhowtousethemsafely.Thestudentswill
demonstratemasteryofthematerialbycompletingtheassignmentsheetsand
achievingascoreof_____ontheUnitIIITest.
sPecIfIc oBJecTIves
Lesson 1
I. Describe the fve general rules for using automotive chemicals.
II. Identifythetypesandusesofsolvents.
III. Identifythetypesandusesofsoapsandcleaningsolutions.
IV. Completetheassignmentsheetonsolventsandsoaps(AS1-L1-UIII).
Lesson 2
I. Identifythetypesandusesofoils.
II. Identifythetypesandusesofgreases.
III. Identifythetypesandusesofspecialtyadditives.
IV. Identifythetypesandusesofspecialtychemicals.
V. Completetheassignmentsheetonlubricantsandspecialtychemicals
(AS1-L2-UIII).
Lesson 3
I. Identifygasesandthehazardstheypresent.
II. Identifythehazardsofasbestosdust.
III. Identifythehazardsofbatteryacid.
IV. Completetheassignmentsheetongases,dust,andacid(AS1-L3-UIII).
s
S 6
lessoN 1: solveNTs, soaPs, aNd cleaNINg solUTIoNs
I. Fivegeneralrulesforusingchemicals
CAUTION: Consult the instructor before using an unfamiliar product.
A. Followthemanufacturersrecommendations.
B. Carefullyreadtheproductlabelforcorrectusesandhazards.
C. Work to prevent spills, damage to the vehicle, or unsafe situations/
conditions.
D. Properlystorechemicalsandusedrags.
E. Usechemicalsonlyfortheintendedpurposes.
II. Typesandusesofsolvents
A. Parts-washingsolvent(petroleumbased)
1. Thistypeofsolventdissolvesoil,grease,andvarnishfrom
enginecomponentsandotherpartsofthevehicle.Itisusually
dispensed in a parts-washing tank that flters and recycles the
solvent.
2. Thissolventcontainsvolatileorganiccompounds(VOCs)that
giveofftoxicvaporsandmustbemanagedasahazardous
waste. Parts-washing solvent is not as fammable as some other
solvents, but can burn and does present a fre hazard.

a. Keepelectricaldevices,sparks,andanyhotmaterialaway
fromtheparts-washingtank.
b. Thesolventtankshouldbeequippedwithasafetylink,
whichwillmeltshouldthesolventignite.Whenthe
safetylinkmelts,thelidonthewashertankwillcloseand
smother the fre.
c. Parts-washingsolventpresentsahazardtotheeyesand
skin,especiallywhenthesolventisfresh.Breathing
solventvaporsisalsoahealthrisk.Wearpersonal
protectiveequipment(PPE)whenworkingwiththe
solvent.
s
CAUTION: Some technicians may have a severe allergic
reaction to the parts-washing solvent.
3. Petroleum-basedparts-washingsolventcanmeltsomeshoe
rubberandshouldneverbesplashedorpouredontheshop
foor. If a solvent spill is not immediately wiped up from the
foor, it can cause people to slip and fall.
4. Neverputunitssuchaselectricmotorsinthesolventtank.Such
unitsmaysustaininsulationdamage;theymayalsobehardto
dryontheinside.
5. Toextendtheusablelifeofthesolventandtopreventclogging
thetank,removemostofthegrease,gasketmaterial,anddirt
frompartsbeforewashing.Neverpourotherliquidsintothe
solventtank.
B. Parts-washingsolvent(aqueousbased)
1. Thistypeofsolventisusedforthesamepurposesasthe
petroleum-based solvents, but it is typically nonfammable and
containslessthan5%VOCs.Besideswater,theingredientsin
aqueous-basedsolventsgenerallyincludeadetergent,corrosive
substance,oralkalineagentandarustinhibitor.
2. Ratherthandissolvinggreaseandsolidswithchemicals,
aqueoussolventsuseheat,agitation,anddetergentstoclean
automotiveparts.
3. Specialcleaningequipmentisrequiredthatheatstheaqueous
solventandspraysitwithgreatforce.
a. Spraycabinets,whicharetotallyenclosed,arebestfor
cleaningheavilysoiledpartsoralargenumberofparts.
b. Sink-topunitsareusedformorelightlysoiledpartsor
fewerparts.
4. The life of the solvent can be prolonged by using flters,
maintainingthesolventsconcentration,andskimminggrease
fromthesolution.
5. Aqueoussolventmaybecomehazardouswastethroughuse.
Wastedisposalprofessionalsmustanalyzethesolutionto
determinehowtodisposeofitsafely.
S 6
C. Chokeandthrottlebodycleanerisanaerosolproductthatismore
aggressivethanparts-washingsolventinthecleaningofoil,grease,
andvarnishfromcarburetorcomponentsandothersmallprecision-
machinedparts.Itisapetroleum-basedproduct.
1. Choke and throttle body cleaner is extremely fammable and
presents a dangerous fre hazard. Never spray the cleaner on
hot engine parts or around sparks or fre.
2. Thecleanercandamagepaint.Donotspraythecleanernearthe
bodyofthevehicleorotherpaintedcomponents.
3. Thecleanercandamageeyesandirritateskin.Breathingits
vaporsisalsohazardous.AlwayswearPPE.Spraythecleaner
awayfromthebodysothatvaporsarenotinhaledandthe
cleanerdoesnotcontacttheskin.
4. Observethesafetywarningsonthecleanercan.Donotexpose
thecleanercantoheatunderanycircumstancesbecauseheat
willcausethecleanercantoexplode.
D. Brakecleanerisanaerosolproductthatisextremelyeffectivein
removinggreaseandoilfrombrakedrums,rotors,andengine
fywheels.
1. Brake cleaner is extremely fammable and presents a severe fre
hazardbecausethecleanerissprayedfromanaerosolcan.
2. Brakecleanercandamagepaint.Donotspraythecleanernear
thebodyofthevehicleorotherpaintedcomponents.
3. Brakecleanercandamageeyesandirritateskin.Breathingits
4. Observethesafetywarningsonthecleanercan.Donotstore
brakecleanerinahotarea.Donotexposethecantoheatunder
anycircumstancesbecauseheatwillcausethecleanercanto
explode.
E. Gasketremoverisanaerosolproductthatloosensgasketmaterialthat
maybetightlystucktoenginecomponentswithsealersorglue.
1. Gasket remover is extremely fammable and presents a serious
fre hazard because the gasket cleaner is sprayed from an aerosol
can.
s
2. Gasketremovercandamagepaint.Donotspraytheremover
nearthebodyofthevehicleorotherpaintedcomponents.
3. Gasketremovercandamageeyesandirritateskin.Breathingits
4. Observethesafetywarningsonthegasketremovercan.Donot
storegasketremoverinahotarea.Donotexposethecanto
heatunderanycircumstancesbecauseheatwillcausethegasket
removercantoexplode.
F. Digestive-typecarburetorcleanerisanaggressivechemicalagentthat
isusuallystoredina1-or5-galloncontainer.Thechemicaldissolves
organicmaterial,leavingonlycleanmetalthatisthenrinsedwith
water.
1. Digestive-typecarburetorcleanerreactsvigorouslywithorganic
material.Itpresentsseverehazardstotheeyesandskin.
AlwayswearPPE.
2. Donotsplashdigestive-typecarburetorcleaner.
CAUTION: Digestive-type carburetor cleaner will quickly
burn skin that it contacts, so fush afficted areas immediately
with water.
3. Tocleanparts,gentlysubmergethebasketofpartsintothecan.
When the solvent has fnished cleaning, carry the basket with lid
inplacetothesink.Thebasketofcleanpartsshouldbeplaced
inthesinkandthepartsrinsedinagentlestreamofwater.
4. Anyspillsmustbecleanedupimmediately.Ragsortowelsused
inthecleanupshouldbediscarded.
5. Becausedigestive-typecleanerreactswithorganicandsome
nonorganicsubstances,useitonlyonmetallicparts.
a. Parts made of rubber, fber, or plastic may be ruined by
digestive-typecarburetorcleaner.Thecleanermayeven
removeanodizedcoatingsalongwithpaintandvarnish.
b. Neveruseanyofthesechemicalsforpurposesotherthan
thoselistedontheproductcanorcontainer.
S 6
6. Tokeepfumesandevaporationtoaminimum,adda1-inlayer
ofwaterontopofthecleanerandcoverthecanwithalid.
7. Digestive-typecarburetorcleanerisanexpensivechemical
andshouldbeusedonlytocleansmall,precisioncomponents.
Largercomponentscanbecleanedwithothersolvents.
G. Safetywarningaboutgasoline
1. Donotusegasolineasasolvent.Gasolineisintendedforuseas
afuelnotasacleanerforautomotiveparts.
CAUTION: Never use gasoline or other chemicals for
purposes other than those listed on the product can or
container. Consult with the instructor before using any
solvent or chemical.
2. Gasolinefumescancausesimilarhealthproblemsascleaning
solventsandcontributetohydrocarbonemissions.Thefumes
are also extremely fammable and, if ignited, can cause severe
burnsordeath.

3. Prolongedexposuretoliquidgasolinehasbeenshowntocause
cancerinlaboratoryanimals.

4. Gasolineadditivescanleaveharmfuldepositsonimportant
enginecomponents.
III. Typesandusesofsoapsandcleaningsolutions
A. Soapsandcleaningsolutionsarewater-solubleagentsusedfor
cleaningdirtandgrease.
B. Liquiddetergent,ordishwashingliquid,isamilddetergentthatis
convenienttouse.Liquiddetergentissuitableforwashingengine
blocksafterhoningorglazebreaking.
C. Glass cleaner and windshield washer fuid are available in aerosol,
pumpspray,orliquidform.Thebestresultsareobtainedwhenglass
cleanerisusedwithpapertowelsratherthanshoptowels.Shop
towelsalmostalwaysretaingreaseandleavelint.
CAUTION: When flling the windshield washer fuid reservoir in
the winter time, read the label on the solution to see if it contains
the necessary antifreeze. Freezing can result in a cracked reservoir
tank due to expansion.
s
D. Handsoapsthataretypicallyusedcontainanabrasivetohelpclean
ground-ingrease.Thesesoapscancauserawnessorcrackingofthe
skin.
CAUTION: Never use abrasive hand soaps on vehicle fnishes or
plastics because scratches can occur.
E. Hand-cleaningcreamsaremoreeffectivethanordinaryhandsoaps
ongreaseanddirt.Hand-cleaningcreamsarealsoavailablewith
abrasivesfortoughcleaningjobs.Thesecanbeusedinconjunction
withhandsoaps.
F. Hand-protectingcreamsthatareappliedbeforeworkareeffectivein
preventingdirtandgreasefromstainingthehandsandarms.Useof
ordinaryhandsoapwillremovethehand-protectingcream.

G. Cleaning methods for shop foors should be as dry as possible to help
preventwaterpollution.
1. AccordingtoEPAguidelines,shopworkersshouldkeep
the shop foor as dry as possible to minimize the amount of
wastewaterthatisgenerated.
2. Ways to keep the foor dry and clean include the following:
a. Keep spills off the foor by using dedicated containers for
substanceslikeusedoilandantifreeze.
b. Cleanupspillsimmediatelytopreventworkersfrom
slippinginthesubstanceandtrackingittootherareas.
c. Useragstocleanupsmallspillsanddisposeofthesoiled
ragsproperly.
d. Useabsorbentpadsormopstocleanlargespillsandwring
thesubstancefromthepadsormopsintoadedicated
containerforrecyclingordisposal.
e. Use foor sweep (granules that absorb liquids) only when
cleaninguphazardouswastespillssuchasgasolineor
solvents.
f. Sweep the foor with a broom every day to prevent the
buildupofdirtandcontaminants.
S 6
g. Do not hose down the foor with water or dump mop
waterbecausethecontaminantswillgointothestorm
drainorsewer,causingpollution.
h. Usewater,amop,andamilddetergentonlyifnecessary
afterthespillhasbeenremoved.Checkwithlocal
authoritiesfortheproperdisposalprocedure.
H. Examplesofspecialtycleaningagents
1. Spotremover
2. Bugandtarremover
3. Velourupholsterycleaner
4. Carpetcleaner
5. Vinylcleanerandconditioner
6. Batterycleaner
7. Wirewheelcleaner
8. Whitesidewallcleaner
s 70
S
lessoN : lUBrIcaNTs aNd sPecIalTy chemIcals
I. Typesandusesofoils
A. Oilisapetroleum-basedorsyntheticproductthatlubricatespartsor
acts as a hydraulic fuid. When using oil, follow the safety precautions
below.
CAUTION: Wear personal protective equipment (PPE) when
working with oils.
1. All types of oils can represent a signifcant fre hazard.
Spontaneous combustion, fre initiated without fame, can and
doesoccurwithragssoakedinanytypeofoil.Oilmustbe
stored in a designated area away from heat, fame, or sparks.
a. Oilyragsmustbestoredinametalsafetycontainerwith
anairtightlidbuiltforthispurpose.
b. Oilcanigniteatanytemperatureabove0when
mixedwithpureoxygen.Oilmustneverbeappliedto
oxyacetyleneweldingequipment.
c. Immediatelyuseordiscardbottlesandcansthatare
leakingoil.
2. If oil is dripped or spilled on the shop foor, clean it immediately
topreventslipping.
a. Wipeupsmallspillsordripswithatowel.
b. Largerspillsmayneedtobeabsorbedwithsawdustoroil
absorbentgranulesandthensweptupanddiscarded.If
necessary,scrubremainingslicknesswithsoapandwater.
c. Drainpanshelptopreventoilspills.
3. Avoidprolongedcontactwithoils.
a. Short-termcontactcancauseirritation,chapping,or
dryingoftheskin.
b. Long-termcontactcancauseavarietyofskindiseasesthat
includescancer.
s 7
B. Lightorpenetratingoilsareaerosolproductsthatincluderust-
penetratingoil,siliconelubricant,liquidgraphite,andbeltdressing.
1. Lightoilsareusedtolubricateprecisionpartsbecausethe
lubricantgetsintotightclearancesanddoesnotattractasmuch
dustanddirtasheavieroils.
2. Becausetheycandissolvesomerust,rust-penetratingoilsare
usedtoaidintheremovalofrustyboltsandfasteners.
3. Liquidgraphitedriestoaslick,blackcoatingthatdoesnot
attractanydustordirt.Thismakesitdesirableforcomponents
withtinymovingparts,suchaslocks.
4. Beltdressingissprayedondrivebeltstopreventslippageand
quietbeltsthatdryoutandgetnoisy.
CAUTION: Aerosol cans are pressurized. The can must not be
punctured or crushed, even when empty. The can should not be
stored near heat or sparks. Never spray these products towards the
body.
C. Standard and heavy oils are motor oil, automatic transmission fuid,
power steering fuid, and gear lube.
1. Motor oils are used in vehicle engines and classifed by viscosity
orweight(e.g.,10W-30)andatwo-lettergrade(e.g.,SJandSL).
a. Refertothemanufacturersrecommendationforthe
correct viscosity and service classifcation for the vehicle
beingserviced.
b. Refertothevehicleserviceinformationfortheproper
intervalforchangingthemotoroil.
2. Automatic transmission fuid (ATF) is available in three main
types:TypeF,DexronII,andDexronIII.
a. ATFisusedinallautomatictransmissionsandsome
manual-shift,front-wheel-drivetransaxles.
b. Somevehiclemanufacturersrecommendusingonly
their products that include specifc additives. Refer to the
manufacturersrecommendationwhenselectingandusing
ATF.
S
3. Power steering fuid is similar to ATF. Refer to the
manufacturersrecommendationwhenselectingandusing
power steering fuid.
4. GearlubeisthickerthanmotoroilorATFandprovidessuperior
lubricationbetweenthelargeandhighlystressedgearsof
manualgearboxesanddifferentials.
D. Hydraulic fuids include hydraulic jack oil and brake fuid.
1. Hydraulicjackoilisusedinshopequipmentthathasa
hydrauliccylinder,suchasjacks,enginehoists,liftracks,and
forklifts.
CAUTION: Do not add hydraulic jack oil to shop equipment
without the permission and supervision of the instructor.
2. Brake fuid is added to the master cylinder reservoir and clutch
mastercylinderinahydraulicclutchsystem.
a. In America, brake fuids must be rated at least DOT-3
(Department of Transportation Specifcation #3).
b. Using the incorrect brake fuid can result in brake fade, the
deteriorationofrubberseals,orcompletebrakefailure.
3. Most hydraulic fuids, especially brake fuid, attack and dissolve
paint.
NOTE: If you suspect that brake fuid has contacted a painted
surface,immediatelywashthatsurfacewithsoapandwater.
a. Cover fenders when adding brake fuid.
b. Thoroughlywashhandsimmediatelyaftercontactwith
brake fuid.
4. Hydraulic fuids, especially brake fuid, must be capped tightly
to prevent dirt and moisture from contaminating the fuid.
a. Smallamountsofmoisturecanturntosteamwhenbrake
fuid becomes hot during brake application. The steam
reducestheeffectivenessofthebrakes.
b. Hydraulic fuids must be stored in a designated area away
from heat, fame, or sparks.
s 7
c. Neversubstituteothertypesofoilforhydraulicoil.
Nonhydraulicoilmayharmrubbersealsorfailunderthe
heatgeneratedbythebrakesystem.
II. Typesandusesofgreases
A. Greaseisusedwhenalubricantmuststayonpartsforalongperiod
oftimeandendurehighpressure.Whenworkingwithgrease,follow
thesafetyprecautionsbelow.
CAUTION: Wear PPE when working with greases.
1. Greasyragsarealsosubjecttospontaneouscombustion.Greasy
ragsmustbestoredinametalsafetycontainerwithanairtight
lidbuiltforthispurpose.
2. Greaseproductsmustbestoredinadesignatedareaawayfrom
heat, fame, or sparks. Wipe up grease spills and clean the area
immediatelywithsoapandwater.
3. Avoidprolongedcontactwithgreases.

a. Short-termcontactcancauseskinirritation,chapping,or
dryingoftheskin.
b. Long-termcontactcancauseavarietyofskindiseasesthat
includescancer.
B. Multipurposegreaseissuitableforlubricatingsuchitemsassteering
linkagecomponentsandwheelbearings.
1. Multipurposegreasecanalsobeusedasanassemblygluewhen
packingbearingsintoamanual-shifttransmission.

2. Readtheinformationonthelubricationlabelbeforeusing
multipurposegreasetobesurethatitisrecommendedforthe
plannedapplication.
C. Wheelbearinggreaseissuitableforsteeringlinkagecomponentsas
wellaswheelbearings.Ifpackingwheelbearingsinadiscbrakeor
highheatapplication,useanextreme-pressure(EP)wheelbearing
greasecompatiblewiththediscbrakes.
D. Brakegreaseisappliedinsmallamountstothebackingplateon
vehiclesequippedwithdrumbrakes.
S
E. Camlubricantissometimesincludedwithanewcamshaft.The
lubricantcanhelpwithbreakinginthecamshaft.
F. Whitelithiumgreaseisageneral-purposelubricantavailableinatube
oraerosolcan.Usesofwhitelithiumgreaseincludehoodhinges,
doorhinges,cables,linkage,andshopequipmentmaintenance.
G. Sticklubricantsareusedondoorstrikersbecausetheydonotstain
clothes.
H. Somelight-coloredgreases,suchaswhitelithiumgrease,arenot
compatiblewithATFandshouldnotbeusedasanassemblyglueor
asaprelubeforinternaltransmissionparts.
CAUTION: If noncompatible grease is used during automatic
transmission assembly, components in the valve body of the
transmission can become stuck, resulting in shifting problems.
I. Dielectricgrease,availableinatube,isusedtosealelectrical
connectionstopreventvoltageleakageandkeepoutdirt,corrosion,
andmoisture.
J. Brakesystemsiliconecompoundisagreaselikelubricantthatcomes
inatube.Itisusedtolubricatesliders,rubberparts,orplasticparts
onbrakesystems.
III. Typesandusesofspecialtyadditives
A. Specialtyadditivesincludeoiltreatment,gastreatment,transmission
conditioner,andstartingether.Refertothecontainerlabelforhazard
warningsandhandlingprocedures.
CAUTION: Wear PPE when working with specialty additives.
B. Oiltreatmentsareusedtoraisemotoroilviscosityortofreesticking
valvesorlifters.Raisingthemotoroilviscositycanextendenginelife
byincreasingoilpressure.
NOTE:Addingtoomuchoiltreatmentcanresultinpoorlubricating
propertiesoroilthatexceedstheproperviscosity,especiallyincold
weather.
C. Gastreatmentisusedtohelpreducemoistureingasolineand
eliminatebuildupofcarbon,gum,andvarnishinfuellines.Gas
treatmentusuallycontainsalcohol.Excessiveamountsofmethanol
candestroyrubbercarburetororfuelsystemcomponentsanddamage
theliningofthefueltank.
s 7
D. Transmission conditioner is added to automatic transmission fuid to
prolong the life of the fuid and improve the shifting performance of
worntransmissions.
E. Startingetherissometimesusedtostartanengineinextremecold.
Thedirectionsforusingstartingethermustbefollowedcarefully.
CAUTION: Starting ether is extremely fammable and can create an
explosion if the engine backfres.
IV. Typesandusesofspecialtychemicals
CAUTION: Wear PPE when working with specialty chemicals.
A. Thetwotypesofsealersarehardeningandnonhardening.
1. Hardeningsealersformahardsealbetweencomponents.
They are used to seal permanent assemblies and to fll gaps in
irregularsurfaces.
2. Nonhardeningsealersremainpliable.Theyareusedinareas
thatareexposedtovibration,expansion,andcontraction.
a. Roomtemperaturevulcanizingsealer(RTV),typically
availableinatube,isaspecialrubberthatsetsupatroom
temperatureandformsasealbetweencomponents.RTVis
used instead of a rubber or fber gasket. It is aerobic, which
meansitcureswhenexposedtoair.
NOTE: SomeRTVscannotbeusedonenginesinvehicles
equippedwithcomponentssuchasoxygensensorsor
automatictransmissions.
b. Gasketsealers,appliedwithabrushorfromatube,helpto
ensureagoodsealbetweengasketsandirregularsurfaces.
Thesesealersareanaerobic,whichmeanstheywillcure
onlyintheabsenceofair.
c. Threadsealantisusedtosealthreadsandboltsthatare
exposedtoliquids,usuallyeitherlubricatingoilorcoolant.
B. Lockingandantiseizecompounds
1. Lockingcompoundspreventafastenerfromlooseningbyacting
asalockwasher.Lockingcompoundshavevariousstrengths
thatrangefromwrenchremovaltopermanentlybonded.
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2. Antiseizecompoundspreventthreadedfastenersfrombecoming
permanentlybondedtoanothercomponentandareused
whenthefastenerismadeofadifferenttypeofmetalfromthe
componenttowhichitisattached.
D. Twocommonadhesivesareweatherstripandgasketadhesiveand
rearviewmirroradhesive.
1. Weatherstripandgasketadhesiveisusedtogluegasketsto
metalandweatherstripstothevehiclesdoorsandtrunk.
2. Rearviewmirroradhesiveisusedtoglueinsiderearview
mirrorstothewindshield.
s 7
S
lessoN 3: gases, asBesTos dUsT, aNd BaTTery acId
I. Gasesandthehazardstheypresent
NOTE: Gasesincludethoseemittedfromengineexhaust,vaporsresulting
fromevaporatingfuel,andgasesstoredinpressurizedcontainers.
A. Internal-combustiongasolineenginesemitavarietyofgases.Carbon
dioxide(CO
2
),watervapor,andsulfurdioxide(SO
2
)presentfew,if
any,healthrisks.Gasesintheexhaustthatpresentthemostserious
healthrisksarecarbonmonoxide(CO),hydrocarbons(HCs),and
oxidesofnitrogen(NOx).
1. COresultsfromincompletecombustionoffuelandairinthe
engine.
a. Wheninhaled,itdisplacesoxygeninthebloodthatcauses
asphyxiationanddeath.COhasnonoticeableodor,which
makesitparticularlydangerous.
b. ToavoidCOpoisoning,exhaustfumesmustalwaysbe
ventilatedtotheoutside.Consulttheinstructorforthe
properuseofexhaustventilationequipment.
2. HCscontainhydrogenandcarbon.Rawunburnedgasolineisa
HC.ExhaustgascontainssmallamountsofHCs.
a. ExcessivelevelsofHCscausesnausea,vomiting,and
possiblyevencancer.
s 0
b. ToavoidinhalingHCs,exhaustfumesmustalwaysbe
ventilatedtotheoutside.Consulttheinstructorforthe
properuseofexhaustventilationequipment.
3. NOxareproducedduringhighcombustiontemperatures.
NOxhasapungentodorandmustbeventilatedtotheoutside.
Consulttheinstructorfortheproperuseofexhaustventilation
equipment.
B. Fuel vapors, such as gasoline vapors, are extremely fammable and
toxic.Gasolinevaporscanbereleasedfromthefueltankorother
storage tanks and the engine carburetor. To avoid the risks of fre and
explosionoffuelvapors,thefollowingstepsmustbetaken.
1. Gasolinedestroysmanytypesofcontainersandmustbestored
inUnderwritersLaboratory(UL)approvedcontainers.These
containersmustthenbestoredinametalsafetycabinetaway
fromsparksandheat.
CAUTION: Never leave gasoline cans open or uncapped in

the shop area. Fumes can collect and explode.
2. Avoidgasolinespills.Wipeupspillsimmediately.Disconnect
andplugthefuellines.Drainorsiphonthefueltankbefore
removingfromthevehicle.
3. Anemptyfueltankisdangerousbecauseofgasolinefumes.
Neverattempttoweldafueltank.Thismustbedoneonlyby
experiencedprofessionals.
S 8
4. Sparksandheatmustbekeptawayfromenginecarburetors.
Evenemptycarburetorsmaycontaingasolineresidueand
fumes.Nevermakeelectricalgroundconnectionstothe
carburetor.
5. Consulttheinstructorfortheproperdisposalprocedurein
theshop.Neverpourgasolinedownasinkorintothesewer.
Doingsoisaseriousviolationoffederalregulations.
C. Gasesfromthevehiclesbattery
1. Batteriesproducehydrogengasthatcancollectatthetopofthe
battery. The gas can explode if exposed to a spark or fame.
2. Keep sparks and fames away from the battery.
a. Inspectthebatteryindaylight,notwithalamp.
b. Donotwearjewelrythatcouldcontactthebatteryand
createaspark.
c. Do not smoke or have open fames around the battery.
d. Connectbatterycablesproperlyandusetoolscarefully
aroundthebatterytopreventsparks.
D. Storedgases
1. Propaneishydrocarbongasthatisusuallystoredinmetal
containersunderpressure.
a. Propaneisusedintorchesduringsomecarburetor
adjustments,vacuumleakdetection,andcatalytic
convertertests.
b. Propanetanksmustbestoredawayfromheatandsparks.
Thetankmustneverbepunctured.Neverdiscarda
propanetankthatstillcontainspressure.
s
2. Acetyleneisasynthetichydrocarbongascommonlyusedforthe
cuttingandweldingofmetal.
a. Acetylene gas is extremely fammable and chemically
unstable.Acetylene,inconjunctionwithoxygen,presents
graveandunusualhazards.
b. Onlyexperiencedtechnicians,whohavehadextensive
safetytraining,shoulduseanoxyacetylenetorchset.
c. Oilpresentsthemostprominentdangerbecauseitcan
createanexplosioninthepresenceofpureoxygen.
CAUTION: Never allow oil to contact any part of an
oxyacetylene torch set or use oxygen or acetylene as
compressed air.
E. R-12,orFreon,isarefrigerantgasusedinairconditioningsystems
priorto1995.Since1995,theenvironmentallysafeR-134ahasbeen
used.
1. Refrigerantshouldnotbedirectlyinhaledorexposedtoopen
fame. Refrigerant is stored under pressure and creates extreme
coldwhenreleased.
2. Blindnesscanresultifrefrigerantcontactstheeyes.
S 8
3. Theareashouldbewellventilatedandpersonalprotective
equipment(PPE)mustbeworn.
4. Neverallowarefrigerantcontainertobepuncturedorstored
nearheat.
II. Thehazardsofasbestosdust
CAUTION: Asbestos dust from brake linings and clutch discs is a
hazardous material that requires special precautions.
A. Untilrecentlynearlyallbrakeandclutchliningscontainedasbestos,
amaterialthatcanwithstandextremelyhightemperatures.Asbestos
dusthasbeenshowntocauselungcancer,eveninminutequantities.
Forthisreason,specialcaremustbeexercisedduringbrakeandclutch
work.
CAUTION: Some imported brake products may still contain
asbestos.
1. Neverusecompressedairtoblowoutbrakesorclutches.
2. Wearadustmaskandusetheproperdustevacuationsystem
whenworkingonbrakesystems.
3. Alloldbrakeliningsandclutchdiscsmustbereturnedtoa
tight-sealingbox.Neverleavethesepartslyingaroundthe
shop.
s
III. Thehazardsofbatteryacid
A. Vehiclebatteriescontainbatteryacid,alsocalledelectrolyte,whichis
asolutionof40%sulfuricacidand60%distilledwater.Sulfuricacid,
madefromsulfurdioxide,isahighlycorrosiveacid.
B. Observethefollowingsafetyprecautionswhencleaningandhandling
abattery.
1. WearPPE(goggles,faceshield,apron,andgloves)when
inspecting,cleaning,orhandlingabattery.
CAUTION: Do not allow battery acid to contact the skin or
eyes because it causes serious burns and damage. The acid
will burn holes in clothing as well.
2. If battery acid contacts the skin, fush the area immediately with
plentyofwater.
3. If battery acid contacts the eyes, fush the eyes with water
immediatelyfor30minutesandseekmedicalattention.
4. Avoidrubbingtheeyesorunprotectedskinwhileworkingwith
abatterytopreventcontactwiththeacid.
5. Washhandsimmediatelyafterworkingwithabattery.
6. Ifacidspillsintheshop,neutralizetheacidwithamixtureof
bakingsodaandwater,wipeupthespill,andrinsethearea
with clear water. If acid gets on clothing, fush the clothing with
thebakingsodaandwatermixture.
S 8
UNIT Iv: BasIc haNd Tools
I. Unitobjective
II. Lessonplans
A. Lesson1:TypesofWrenches
2. AssignmentSheet

a. AS1-L1-UIV:Wrenches
B. Lesson2:TypesofScrewdriversandPliers
2. AssignmentSheet

a. AS1-L2-UIV:ScrewdriversandPliers
C. Lesson3:TypesofHammers,Punches,andChisels
2. AssignmentSheet

a. AS1-L3-UIV:Hammers,Punches,andChisels
III. UnitIVTest
s
S 8
UNIT oBJecTIve
Aftercompletingthisunit,studentsshouldbeabletoidentifybasichandtools
andtheiruses.Studentswilldemonstratemasteryofthematerialbycompleting
theassignmentsheetsandachievingascoreof_____ontheUnitIVTest.
sPecIfIc oBJecTIves
Lesson 1
I. IdentifythedifferencesbetweenmetricandUSCSwrenches.
II. Identifythetypesandusesofcommonwrenches.
III. Identifythetypesandusesofsocketwrenches.
IV. Identifythetypesandusesofotherwrenches.
V. Completetheassignmentsheetonwrenches(AS1-L1-UIV).
Lesson 2
I. Identifythetypesandusesofscrewdrivers.
II. Identifythetypesandusesofpliers.
III. Completetheassignmentsheetonscrewdriversandpliers(AS1-L2-UIV).
Lesson 3
I. Identifythetypesandusesofhammers.
II. Identifythetypesandusesofpunchesandchisels.
III. Completetheassignmentsheetonhammers,punches,andchisels
(AS1-L3-UIV).
s
S 8
lessoN 1: TyPes of WreNches
I. MetricandU.S.CustomarySystem(USCS)wrenches
A. AlltechniciansshouldhaveasetofbothmetricandUSCS(alsocalled
SAE)wrenchesforlooseningandtighteningboltsandnuts.
1. Metricwrenchesaresizedperthemeasurementinmillimeters
(mm)ofthejawopening,fromfacetoface.Thejawsizeis
actuallyalittlelargerthantheboltornutofthesamesizeto
allow the jaw to ft around the bolt or nut.
2. USCSwrenchesaresizedperthemeasurementinfractionsof
aninchofthejawopening,fromfacetoface.Thejawsizeis
actuallyalittlelargerthantheboltornutofthesamesizeto
allow the jaw to ft around the bolt or nut.
B. MetricandUSCSwrenchesarenotinterchangeable.Forexample,if
removing a 14-mm nut, a 9/16-in wrench is close in size but is not the
proper size to effectively remove the nut. The 9/16-in wrench may
slipandroundoffthesidesofthenut.A14-mmwrenchshouldbe
used.
II. Commonwrenches
A. Theopen-endwrenchturnsnutsandboltsthathavealreadybeen
loosened.Iftoomuchtorqueorturningactionisapplied,itcan
roundoffthecornersofnutsorbolts.Theendsofthewrenchareset
ata15angletoreducethedistancethewrenchismovedtogripthe
nextsideofthehexhead.
s 90
B. Theboxwrenchcompletelyencirclesthenutorbolttogripallthe
corners,whichallowsconsiderablymoretorquetobeappliedwithout
strippingthenutorbolt.Thiswrenchisparticularlyusefulfor
looseningtightboltsandnuts.Moretimeisrequiredtoturnloose
boltswiththeboxwrench.
C. Thecombination-endwrenchisacombinationopen-endandbox
wrench.Itisafavoriteoftechniciansbecauseofitsmultipleuses.
D. A tubing wrench, or fare nut wrench, has ends with a portion of one
sidecutawaysothatthewrenchmaybeslippedoverasteelline.
Eachendpartiallyencirclesthehexheadofanutorbolt.Steelline
fttings are usually brass and require this type of wrench to loosen a
tight ftting without causing damage.
NOTE:Inadditiontothetubingwrench,anopen-endwrenchisused
to frmly hold the ftting while attaching it to the steel line. Do not
allowthesteellinetobecometwisted.
E. Maintenance
1. Wrenchesshouldbekeptfreeofdirtandgreaseandstoredina
dryplacetopreventrust.
2. Wrencheswithdistortedjawsshouldbediscarded.
F. Safety
1. Alwaysusethepropersizewrench.Donotusemetricwrenches
onUSCSboltsorviceversa.
2. Donotuseawrenchasahammerorprybar.
III. Socketwrenches
A. Thiswrenchissonamedbecauseithasacylindricalsocket(inthesize
of the bolt) that fts down over the bolt, much like a box-end wrench.
S
B. Thesocketwrenchisthepreferredtoolofmosttechnicianswhenthey
workwithnutsandbolts.Socketwrenchescanbeusedinplacesthat
areinaccessibletocommonwrenchesandarefasteratremovingbolts.
C. Thetwobasicpartsofasocketwrencharethesocketandbaror
handle.
1. SocketscomeinmetricandUSCSsizesandaresizedaccording
to the size of the bolt head they ft and the size of the bar they
take.Theyareavailableinfourpointtypes:4point,8point,6
point,and12point,withthe6-pointand12-pointsocketsbeing
themostcommonlyused.

a. Ashallow12-pointsocketisusedforturninghexagonal
boltheadsintightplacesbecauseitofferstwiceasmany
startingpositions.
b. Ashallow6-pointsocketisusedforturninghexagonal
boltheadsbecauseitoffersbettergripandlesschanceof
roundingofftheboltheadwhenexcesstorqueisused.
c. Adeep-well12-pointsocketisusedtoturnnutswhena
boltorstudprotrudesthroughthenutenoughtoprohibit
theuseoftheshallowsocket.
d. Adeep-well6-pointsocketisusedinthesamesituationas
describedabove.Itisparticularlyusefulwhenthereisa
riskofroundingofftightnuts.
e. Swivelsockets,oruniversalsockets,haveauniversaljoint
builtintothesocketdriveendthatallowsboltsandnuts
tobeturnedwhenitisnotpossibletogetstraightontothe
head.
s 9
f. Impactsocketsaredesignedtowithstandthegreattorque
andimpactdeliveredbyairimpacttools.Animpact
sockethasthickerconstructionthanastandardsocket.
CAUTION: Do not use standard sockets on air impact

guns because the socket may shatter.
2. Barsandhandlesareusedtoturnthesockets.Thedriveendis
square and available in 1/4-in, 3/8-in, 1/2-in, and 3/4-in sizes.

NOTE: The 3/4-in size is used for large, heavy-duty bolts
that are found in trucks. The 1/2-in size is used on large
automotive bolts. The 3/8-in size is the most commonly used by
technicians. For very small work, the 1/4-in size is used because
ofitscompactness.
a. Thebreakerbarisasturdyhandlethatisusedwhengreat
torqueisrequiredtoloosenboltsandnuts.Theendofthe
breakerbarcanswingtoallowclearance.
NOTE: Thelengthofthehandleonthebreakerbar
providessuperiorleveragefortightnutsandbolts.
b. Theratchetisthemostcommonlyusedhandleforturning
sockets.Byrotatingbackandforth,theratchetturnsnuts
andboltsinareasoflimitedaccesswithoutbeingremoved
aftereachpartialturn.
Theratchetisnotintendedforuseunderextreme
torquebecausetheteethontheratchetmechanism
maystrip.

Someratchetshaveheadsthatswivel,whichallows
clearancewhileturning.

S
c. Extensionbarsaidinreachingrecessedboltsandnuts
byextendingtheratchetdriveend.Commonextension
lengthsinclude3in,6in,and12in.Manyotherlengths
arealsoavailable.
d. SpeedhandlesandT-handlesareoccasionallyusedto
speedassembly.Oneadvantageofthesehandlesisthey
donotplacesidestressontheextensionandsocket.These
handles are not used for the fnal tightening.
e. Atorquewrenchisaspecialhandlethatindicatesthe
amountoftwistingforce(torque)thatisbeingappliedin
tighteningabolt.
Thiswrenchisnecessarywhenthetorqueofbolts
must meet manufacturers specifcations.
Somemodelshaveascaleordialtoindicatetorque.
Othersclickorreleasemomentarilywhenthepreset
torqueisreached.
Mostrecently,electronicversionsareavailablethat
haveeasilyprogrammableandaccessibletorque
settingsandindicatetorquebyvibrating,producing
anaudiblesignal,andprovidingadigitaldisplay.
NOTE: Specifcations for the torque of bolts are extremely
important.Iftoomuchtorqueisapplied,thesurfaces
being joined or the bolt/nut will be damaged. If too little
torqueisapplied,theboltmayworkloose.
s 9
D. Occasionally,thetechnicianmustuseasocketadapteronasocketto
easeboltremoval.
NOTE:Thetorquecapacityofthesocketandratchetmustbe
consideredsothatthetoolisnotdamagedorbroken.
1. Asizeadapterallowsthetechniciantouseadifferentdrivesize
socketontheratchetortorquewrench.
NOTE:Caremustbeexercisedwhenadaptinglargebreaker
barsdowntosmallerdrivesocketsbecausethetorquecapacity
ofthesmallsocketmaybeexceeded.
2. Auniversaladapteroperatesbestwhenasockethaslimited
accessthatpreventstheratchetandextensionfromengaging
straightontothesocket.Theseadapterscannotwithstandgreat
amountsoftorque.
E. Maintenance
1. Socketsandhandlesshouldbekeptfreeofdirtandgreaseand
storedinadryplacetoavoidrust.
2. Ratchethandlescanbecomewornandshouldbereconditioned
iftheratchetstartstoslip.
F. Safety
1. Ratchethandlescanturnbothcounterclockwiseandclockwise
and the lever that switches the direction should be frmly and
fullyplacedintoitsproperposition.
2. Donotusearatchethandleasahammerorprybar.
3. Theexactsizesocketmustalwaysbeused.Damagedsockets
shouldbediscarded,becausetheycanslipoffabolt.
S
a. Whenusingasocketonadamagedbolthead,be
especiallycarefulsothewrenchdoesnotslipoffandcause
aninjurytotheknuckleorhand.
b. Alwaysbesurethesocketiscompletelyoverthebolthead.
If the bolt head is so damaged that the socket cannot ft
completelyoverthehead,useanothermethodofremoval.
IV. Otherwrenches
A. AnAllenwrenchisusedonhexheadfasteners,whichcontaina
cavitywithsixsides.Atorxwrenchisusedontorxbolts,which
containacavityofsixroundedpoints.Thisdesignreducestheriskof
strippingordisengagingthethreadsofsmallfasteners.
B. Anadjustablewrenchhasascrewthatallowsthejawtoadjustto
differentsizes.Undernormalcircumstances,techniciansdonotuse
anadjustablewrenchforturningnutsandbolts.
1. Ithasthedisadvantageofnotgrippingassolidlyasbox-end
wrenches,andunlessproperlyadjustedandingoodcondition,
maynotgripassolidlyasopen-endwrenches.
2. Anadjustablewrenchmaybeusedifthetechniciandoesnot
haveimmediateaccesstotheproperwrenchandiftorque
requirementsarenottoohigh.
C. Standardwrenchescannotbeusedonpipesbecauseoftheround
shapeofpipes.Thepipewrenchhasteeththatdiginasthewrench
turnsthepipe.Theriskofscarringthepipecanbereducedby
placingaleatherstrapbetweenthepipeandthewrenchteeth.
s 9
S
lessoN : TyPes of screWdrIvers aNd PlIers
I. Screwdrivers
A. Thestandardscrewdriverhasastraightbladeforturningscrewswith
aslotthatisthesamewidthandlengthasthescrewdriverblade.
CAUTION: The standard screwdriver is not intended for use as a

pry bar, chisel, or gasket scraper. These misuses of the screwdriver
can damage the tool and injure the technician.
B. The Phillips screwdriver fts the crossed slot of a Phillips screw. One
advantagethisscrewdriverhasoverthestandardoneiswhenitis
insertedintheslot,itisself-centering.
1. Phillips screwdrivers are available in various tip sizes (e.g., #0,

#1, #2, #3, #4) with the lower number being the smallest.
2. Atechnicianshouldnotattempttouseastandardscrewdriver
toturnaPhillipsscrew.
3. AgooddealofpressuremustbeappliedwhenusingaPhillips
screwdriverorthetipmaydisengagetheslot,damagingthe
screworthetool.
4. IftheslotofaPhillipsscrewisstripped,itwillhavetobedrilled
out.
s 9
C. ThePozidrivscrewdriverissimilartothePhillipsinthatitisusedon
across-slottedscrew.However,thePozidrivscrewdriverandscrew
headhavefouradditionalpointsofcontact.
1. MoretorquecanbeappliedwiththePozidrivscrewdriver
becausethebladewillnotslipoutofthescrewheadaseasilyas
thePhillipsscrewdriverwill.
2. Although not recommended because of improper ft, a Phillips
screwdriverwillturnaPozidrivscrew.APozidrivscrewdriver,
however,willnotturnaPhillipsscrew.
D. Thetorxscrewdriverhasa6-pointtipthatisusedontorx-head
screws.
E. Nutdrivershaveahandleandshaftlikeascrewdriverbuthavea
socketattheendoftheshaftthatisnotremovable.Becausenut
driverscanbeoperatedwithgreaterspeedthansocketwrenches,they
areidealforlooseningandtighteningthesmallnutsandboltsfound
onvehicles.
F. Maintenance
1. Keepscrewdriversfreeofdirtandgreaseandstorethemina
dryplacetopreventrust.
2. Keeptheheadsingoodcondition,freefromnicks.
G. Safety
1. Therightsizescrewdrivershouldbeusedforeachjob.
a. Thescrewdrivershouldbetherightlengthforaccessto
leverage.
S
b. Theheadofthescrewdrivershouldmatchtheheadofthe
screw(bothtypeandsizeofthescrew).
2. Donottrytouseanothertool,suchaslockingpliers,tograbthe
handleofthescrewdriverandgetmoreleverage.Ifitcannotbe
turnedbyhand,anothertoolisneeded.
3. Usescrewdriverswithinsulatedhandlestopreventelectric
shock.
4. Donotuseascrewdriverasapunchorchisel.
II. Pliers
A. Standardslip-jointpliersareoneofthemostcommontypesofpliers
usedbytechnicians.Thesegripirregularpartsandholdworkduring
drilling.
B. Lockingpliersareverysimilartostandardslip-jointpliers.By
turningaknobandthenclampingthehandlesinplace,thelocking
pliersholdworksecurely.
CAUTION: When clamping or removing locking pliers, keep a
proper grip on the handles. The handles snap together and snap
apart with considerable force.
C. Adjustable-jointpliershavealongslotwithawidevarietyof
adjustmentpositions.Theoffsetjawsoftheadjustable-jointpliers
offerareachadvantage.
s 100
D. Long-nosepliers,orneedle-nosepliers,areusefulforgrippingtiny
pinsandpartsduringtheserviceofcarburetorsandothersmall
assemblies.
E. Diagonal-cuttingpliersareusedtocutelectricalwireandtapeaswell
asavarietyofothermaterial.Diagonal-cuttingpliersarewell-suited
forremovingcotterpinsonfront-endcomponents.
CAUTION: Do not use on live electrical circuits.

CAUTION: Do not cut spring steel with diagonal-cutting pliers
because the pliers will be nicked and ruined.
F. Snap-ringplierscomeinmanystylesandtypes.Snap-ringpliersare
requiredforspreadingorcompressingspringysnapringsfoundin
transmissions.Snap-ringpliersareavailablethatcanremoveinternal
snaprings,externalsnaprings,orboth.
G. Maintenance
1. Pliersshouldbekeptfreeofdirtandgreaseandstoredinadry
placetopreventrust.
2. Ifthejawsofthepliersareheldbyascrew,thescrewshouldbe
keptsnug.
S 0
H. Safety
1. Whenworkingnearelectricalequipment,useplierswith
insulatedhandles.
2. Donotusepliersasahammer.
3. Donothammeronthehandles.
s 10
S 0
lessoN 3: TyPes of hammers, PUNches, aNd chIsels
CAUTION: Wear protective eyewear at all times when using a hammer,
punch, or chisel to protect the eyes from fying metal chips. Never strike one
hammer with another, because hammer heads are very brittle and metal chips
can fy off.
I. Hammers
A. Theballpeenhammeristhemostcommonhammerusedfordriving
punches and chisels. It has a domed head on one side and a fat head
ontheother.
B. Ahand-heldsledgehammercanbeusedwhenagreatdealofdriving
powerisrequired.
C. Asoft-facedhammercanbeusedtoavoiddamagetotheworkbeing
driven.Theheadcanbemadeofbrass,bronze,rubber,orrawhideas
thesematerialsdominimaldamagetoironandsteelcomponents.
D. Aplastic-tiphammerisusedwhenlightdrivingpowerisneededand
abrasshammercouldcausedamage.
CAUTION: Do not use this hammer to drive punches and chisels.

It will destroy the plastic tip.
s 10
E. Arubbermalletisusefulforinstallingwheelcovers.Alwaysstrike
thewheelcoverevenlyaroundtheperimeter.
F. Maintenance
1. Hammersshouldbekeptfreeofdirtandgrease,withthefaces
smoothandfreeofallforeignmatter.
2. Hammersshouldbestoredinadryplacetopreventrust.
G. Safety
1. Always be sure the head is secured frmly on the handle.
2. Besurethehandleisingoodcondition.
3. Strike a fat-surfaced hammer fat against the object being
struck,notatanangle.
II. Punchesandchisels
A. Punches
1. Ataperorstartingpunchisthemostcommonlyusedpunch.
Thispunchisdesignedtodriveoutrivetsaftertheheadshave
beenremoved.Itisalsousedtopunchoutstraightandtapered
pins.
2. Apinpunchisusedwhenasmallrollpinmustbedriven
throughahole.
3. Thecenterpunchisusedtomakeasmalldimpleinmetalprior
todrilling.Thismarkhelpsensurethattheholewillbedrilled
intheproperplaceandthatthedrillbitwillnotmove.
S 0
4. Abrassorbronzepunchisusedwheninanareawhere
fammable liquid or gasoline is present. This ensures that no
sparkswillbecreated.
B. Chisels
1. Thestandardcoldchiselisusedtocutandremovemetal.The
endofthechiselshouldbegroundtoasharppointona60
angle.
2. Differentchiselshapesareavailableforparticularjobs.The
shapesincludetheroundnose,diamondpoint,andhalfround.
Thesechiselsareusedtocutorchipmetal.
C. Maintenanceforpunchesandchisels
1. Whentheheadofthepunchorchiselmushrooms,the
mushroomingmustbegroundoffwithagrindingwheel.
2. Whenthecuttingedgeofthepunchorchiselbecomesdulland
chipped,itmustbesharpenedwithagrindingwheel.
3. Afteracertainamountofmaintenancewiththegrindingwheel,
thepunchorchiselbecomestooshortortheedgebecomestoo
blunt.Whenthishappens,itshouldbediscarded.
4. Punchesandchiselsshouldbekeptfreeofdirtandgreaseand
shouldbestoredinadryplacetopreventrust.
D. Safetyforpunchesandchisels
1. Alwayswearheavyglovesandsafetyglasseswhenworking
withpunchesandchisels.
s 10
2. Grinddownamushroomedheadimmediately.The
mushroomed metal may fy off and cause injury. Also, the
hammerslipsoffofamushroomedheadmoreeasily.
3. Punchesshouldbetappedgentlyratherthanwithbrute
force.Usuallyseverallighthitsontheheadworkbetterforall
purposesthanaheavyhit.
4. Useachiselholdertominimizetheriskofmissingthechiseland
hittingahand.
S 0
UNIT v: sPecIalTy Tools, fasTeNers, aNd measUrINg Tools
I. Unitobjective
II. Lessonplans
A. Lesson1:SpecialtyTools
2. Assignmentsheet

a. AS1-L1-UV:SpecialtyToolUses
B. Lesson2:Fasteners
2. Assignmentsheet
a. AS1-L2-UV:CommonVehicleFasteners
C. Lesson3:MeasuringTools
2. Assignmentsheet
a. AS1-L3-UV:UseandCareofMeasuringTools
III. UnitVTest
s 10
S 0
UNIT oBJecTIve
Aftercompletingthisunit,studentsshouldbeabletoidentifythetypesand
usesofspecialtytools,fasteners,andprecisionmeasuringtools.Studentswill
demonstratemasteryofthematerialbycompletingtheassignmentsheetsand
achievingascoreof_____ontheUnitVTest.
sPecIfIc oBJecTIves
Lesson 1
I. Identifythetypesandusesofspecialtytools.
II. Completetheassignmentsheetonspecialtytooluses(AS1-L1-UV).
Lesson 2
I. Identifycommonfastenersusedonvehicles.
II. Identifytoolsandmethodsforcuttingthreads,repairingdamagedthreads,
andremovingbrokenbolts.
III. Completetheassignmentsheetoncommonvehiclefasteners
(AS1-L2-UV).
Lesson 3
I. Identifythetypesandusesofmeasuringtools.
II. Identifytheproceduresfortheuseandcareofmeasuringtools.
III. Completetheassignmentsheetontheuseandcareofmeasuringtools
(AS1-L3-UV).
s 110
S
lessoN 1: sPecIalTy Tools
I. Typesandusesofspecialtytools
A. Specialcuttingtools
1. Hacksawscutmetalpartstosizeorshapeandremovedamaged
fasteners.
a. Thehacksawcutsontheforwardstrokeonlyandislifted
onthereturnstroke.
b. Hacksawsaresizedaccordingtobladelength.When
installingtheblade,pointtheteethawayfromthehandle
andtightlysecuretheblade.
CAUTION: Always wear safety glasses and heavy
gloves when using a hacksaw. The blade can break. In
addition, be sure to frmly secure the object being sawed.
2. Tubingcutterscutwithoutbending,kinking,orscarringthe
tubing.
a. Thecutterisplacedonapieceoftubingandtightenedasit
isrotated.
b. Tubingcuttersvaryinsizeaccordingtothediameterofthe
tubetheyaredesignedtocut.
s 11
3. Ahandreamersmoothsorenlargesholes.Bothstraightand
tapered reamers are used. Straight reamers may be either fxed
in size or adjustable through a specifc cutting range.
4. Filessmoothorshapemetal.Filesaredesignedinvarious
shapesfordifferenttasksandhavedifferentteethdesignsfor
fne or rough work.
CAUTION: Use a handle on the fle to prevent hand injury.

Never hammer on or use a fle as a pry bar. Files are brittle
and can shatter with dangerous results.
CAUTION: Always wear safety goggles and heavy gloves
when working with a fle.
S
B. Electricalsystemtools
1. Thedigitalmultimeter(DMM)checkstheconditionofelectrical
systemcomponents.
a. Thistestdeviceisavoltmeter,ohmmeter,andammeterall
inone.
b. ADMMhastwoleads,oneblackandonered.Oneend
oftheleadispluggedintotheDMM.Theotherendisa
probe.
2. Ascantoolisusedtodiagnoseelectricalproblems.Thetoolis
connectedtothevehiclesdatalinkconnector(DLC)toretrieve
diagnostictroublecodes(DTCs)andenginesensorinformation
thataregeneratedbythevehicleson-boarddiagnosticssystem.
s 11
3. Anoscilloscope,orscope,isavoltmeterthatdisplaysvoltage
inrelationtotime,showingvoltageverticallyandtime
horizontally.ItsconnectionsaresimilartoaDMM.
a. Itproducesalineonacathoderaytube(CRT)orliquid
crystaldisplay(LCD)whenconnectedtocircuitvoltage.
b. Acircuitproblemcanbefoundbycomparingtheline
patterntoaknowngoodpattern.
4. Thecontinuitylightcheckspowerinvariouscircuits.Oneend
ofthelightisgroundedandtheotherendispressedintothe
electricaldevice.
NOTE: Thecontinuitylightshouldneverbeusedtocheckthe
powersupplyofelectroniccomponents.
5. Atiminglightdeterminesiftheignitionsystemisdelivering
electricchargetothesparkplugsatthecorrecttime.
S
6. Theremotestarterswitchallowsthetechniciantousethestarter
tocranktheenginewithoutactuallybeinginthevehicle.
C. Batteryspecialtytools
1. Acablepullerremovesthecablefromthebatteryterminal
withoutbreakingthecableorbatteryposts.
2. Terminalandpostcleanerscleanthepostsandterminalends.
3. Abatteryliftingtoolandcarryingstrapliftsandtransportsthe
batterysafely.
s 11
D. Lubricationspecialtytools
1. A transmission funnel is a funnel with a long, small, fexible
neck that is ideal for adding transmission fuid.
2. An oil flter removing tool is a wrench or socket adapter that fts
around an oil flter to remove it.
3. A grease gun forces grease into fttings. Pressure is created by
handactiononthegunslever.
E. Miscellaneousspecialtytools
1. Ablowgunusescompressedairtocleanordryvariousitemsin
theshop.
S
2. TheC-clampisaholdingdevicethatiscommonlyusedto
compress the calipers on foating caliper disc brake systems.
3. Apullersetfunctionstoremoveobjects(e.g.,gears,bearings)
thatarepressedontoashaft,pullobjects(e.g.,retainers,oil
seals)fromvariousopenings,andremoveshafts(e.g.,pinion
shafts,transmissionshafts)fromanotherobject.
4. Pressure gauges test the air and fuid pressure in various
componentssuchasthetires,oilpump,andfuelpump.
5. Vacuumgaugeschecktheconditionoftheengineandvarious
vacuum-operatedcomponents.Gaugescomparethepressure
inacomponenttoatmosphericpressureatsealevel.
s 11
S
lessoN : fasTeNers
I. Commonvehiclefasteners
NOTE:Vehiclesusemanytypesoffastenerstoholdvariouscomponents
togetherandtechniciansneedtobefamiliarwitheachtype.Someofthe
morecommontypesofthreadedfastenersincludenutsandbolts,washers,
screws,andstuds.Othercommonfastenersincludesnaprings,rivets,and
adhesives.
NOTE: Americanautomobilemanufacturershavelargelyswitchedtothe
metricsystemofsizingfastenersandthreads.
A. NutsandboltsintheU.S.CustomarySystem(USCS)
1. Bolt diameters come in increments of 1/16 in, starting with 1/4
in.Themeasurementistheoveralldiameteroftheboltthreads.
NOTE: Itiseasiesttomeasuretheunthreadedorshankportion
ofthebolt.
2. Thelengthofaboltisitseffectivelengthmeasuredfromunder
theheadtotheendofthethreads.Boltlengthsusuallycome
in 1/4-in increments, starting from 1/2 in. The longest bolts
normally used in the feld are 6 in.
3. Thread type is either fne or coarse. Do not thread
fne-threaded bolts into coarse threads or vice versa.
NOTE: Nuts are very diffcult to measure for diameter, so it is
usually best to trial ft the nut onto a bolt and then measure the
bolt.
s 10
4. Threadsizeisdeterminedbymeasuringthenumberofthreads
perinch.Athreadgauge,availableinbothmetricandUSCS,
canbeusedtodeterminethethreadsizeofbolts.
5. Thestrengthofaboltisimportant.Aboltthatisnotstrong
enoughcanbreak.Thestrengthorhardnessofaboltis
determinedbycountingthepointsorslashesontheheadofthe
bolt.
CAUTION: Never substitute a bolt with one of less strength.
A lower strength bolt may break and cause injury and system
failure.
a. Grade1or2boltshavenopointsandareunsuitablefor
automobileassemblyduetotheirunknownandpossibly
lowstrength.
b. Grade5,or3-point,boltshavethreepointsonthehead.
Theseboltsarethemostcommoninautomobileassembly.
c. Grade8,or6-point,boltshavesixpointsonthehead.
Theseboltsareexpensivebutverystrongandareusedin
high-stressconditions.Examplesofgrade8boltsinclude
harmonic balancer bolts, fywheel bolts, and steering
linkagebolts.Neversubstitutealowergradeboltfora
grade8.
6. Right-handthreadnutsandboltsarethemostcommonandturn
clockwisetotighten.Left-handthreadnutsandboltsalsoare
availablethatturntheoppositeway.Left-handnutsandbolts
havenotchescutatthecornersofthehexheadortheletterL
stampedonthem.
S 2
NOTE: Veryoldautomobiles(builtbefore1960),Chrysler
productsupuntiltheearly1970s,andFordvansupthroughthe
mid1980shaveleft-handthreadwheellugsonlyonthedrivers
side.
B. Nutsandboltsinthemetricsystem
1. Thediameterofametricboltornutismeasuredinthesame
wayasintheUSCS;however,thediameterofametricboltis
expressedinmillimeters.
2. Theboltismeasuredforitseffectivelengthfromunderthehead
totheendofthethreads.
3. Threadsizeinthemetricsystemisdeterminedbymeasuringthe
distancefromthecrestofonethreadinmillimeterstothecrest
ofthenextthread.

4. Metricboltstrengthisindicatedbyanumberstampedonthe
bolthead.Thisnumberiscalledthepropertyclass.Examples
ofpropertyclassnumbersinclude4.6,4.8,5.8,8.8,9.8,and10.9.
Thehigherthenumber,thestrongerthebolt.
CAUTION: Never substitute a bolt with one of less strength.
A lower strength bolt may break and cause injury and system
failure.
C. Washersarefrequentlyusedwiththreadedfasteners.
1. They ft onto a bolt or screw between the surface being fastened
andthenut,orundertheboltorscrewhead.
2. Theyhavetwomainfunctions.
a. Improvethefasteningabilitybyincreasingtheareathatis
clamped
Automotive technology
S 122
b. Preventtheboltornutfromdamagingthepartsurface
D. Manysizesandtypesofscrewsareusedtofastenautomotiveparts.
Twoofthemorecommontypesarethefollowing:
1. Machinescrewsareusedinthreadedholestoclampsmallparts
together.
2. Self-tappingscrews(alsocalledsheetmetalscrews)havehard,
taperingthreadsthatmaketheirownthreadswhendriveninto
asurface.
E. Studshavethreadsoneachendandnohead.Somestudshave
threadsthroughouttheirlength.
1. Fasteningwithstudsisaccomplishedbythreadingoneend
ofthestudintoapart,placinganotherpartoverthestud,and
fasteningtheotherendofthestudwithanut.
2. Studsareusefulforachievingaccuratealignmentofparts.
F. Snaprings(alsocalledretainingrings)areusedtoholdcomponents
suchasshafts,bearings,andgearsinplace.
1. Internalsnapringsftinagrooveinsideanopeningandexternal
snapringsftinagrooveontheoutsideofapart.
2. Snap-ringpliersarerequiredforinstallingandremovingsnap
rings.
introduction to Automotive technology
S 123
G. Arivetisanonthreadedmetalpinwithaheadononeend.Rivetsare
availableindifferentdesignsandaretypicallymadeofcopper,steel,
oraluminum.
1. Rivetsareusedtofastenpartsthatarenotusuallytakenapart.
2. Partsarejoinedtogetherwitharivetbyputtingtherivet
throughaholeinthepartsandhammeringtheheadlessend
withaballpeenhammerorhammerandrivetsetuntiltheend
isrounded.
3. Rivetsareremovedbycuttingofftheheadwithachiseland
drivingoutthepinwithapunch.
H. Varioustypesofadhesives,orglues,areusedtobondpartstogether.
Partsthatmaybegluedincludetrim,moldings,andvariousplastic
andrubberparts.
CAUTION: When using adhesives, it is important to follow the
manufacturers specifcations because some adhesives are toxic,
fammable, and harmful if inhaled.
II. Cuttingthreads,repairingdamagedthreads,andremovingbrokenbolts
A. Usingataptocutthreadsintoahole
1. Typesoftaps
a. Thetapertapisthemostcommonlyusedtapbecausethe
taperallowseasystarting.Itcannotcutthreadstothe
bottomofablindhole,aholethatdoesnotgocompletely
throughthemetal.
b. Theplugtapcutsthreadspartofthewaytothebottomof
ablindhole.
c. Abottomingtapcutsthreadsallthewaytothebottomofa
blindholebutcannotstartthecuttingprocess.Atapertap
mustbeusedbeforethebottomingtap.
S 124
d. Themachinescrewtapcutsthesmall-diameterthreadsof
numberedscrewsizes.
2. Thesequenceforcuttingthreadswithatapisshownbelow.
3. Generalprocedureforusingatap
CAUTION: Before drilling a hole to cut threads, choose the
correct drill bit size for the thread size. Failure to use the
correct drill bit size can result in a broken tap or inadequate
thread depth.
a. Firstapplyathreadcuttingoil.
b. Startthehandlewiththetapstraightandthenmakeahalf
turn.
S 125
c. Aftereachpartialturn,backthetapoffuntilthemetal
chipsbegintobreakloose.
d. Repeatthisprocessuntilalloftheneededthreadsarecut.
Addoilasneededduringtheprocess.
B. Usingadietocutthreadsontoarod
1. Aspecialdiestockholdsthedieforthecuttingprocess.
2. Diesareselectedinthesamemannerastaps,butthediecanbe
improperlyplacedinthediestock.Thedieshouldbepositioned
inthediestocksothatthetaperedendengagestherodfrst.
3. Generalprocedureforusingadie
a. Firstapplyathreadcuttingoil.
b. Putthetaperedsideofthedieontherod.
c. Startthediestockwiththediestraightandthenmakea
halfturn.
d. Aftereachpartialturn,backthedieoffuntilthemetal
chipsbegintobreakloose.
e. Repeatthisprocessuntilalloftheneededthreadsarecut.
Addoilasneededduringtheprocess.
C. Proceduresforrepairingdamagedorstrippedthreads
1. Chasingthreadsinvolvesusingastandardtapordietorun
throughexistingthreadsofthesamesize.Thepurposeofthis
procedureistocorrectsmallimperfectionsthatinterferewiththe
threadingofthenutorbolt.
S 126
NOTE:Useathreadcuttingoilduringthisprocedure.
2. Whenthreadsinaholearesoseverelydamagedthattheycannot
beadequatelyrepairedbychasing,ahelicoilcanbeinstalledto
restorethethreadsbacktotheiroriginalsizes.Thebasicsteps
forthisprocedureareasfollows:
a. Completelydrillouttheold,damagedthreadswithadrill
bitsuppliedinthehelicoilkit.

b. Tapwithaspecialtapfromthekit.
c. Withaspecialhandle,screwinaninsertthatlookslike
aspringorcoil.Theinsideofthiscoilisthesameasthe
originalthreadofthehole.
3. Athreadinsertcanalsobeusedtorepairdamagedthreads.The
insertisalmostidenticaltothehelicoilbutissomewhatlarger.It
isretainedinplacebydrivingdownfourpinsaroundtheinsert.
4. Threadrepaircementcanbeusedonlow-torqueapplications.
Thecementisappliedtothebolt,andtheboltisthenplaced
backintothedamagedhole.Newthreadsaremoldedasthe
glue-likesubstancehardens.
D. Proceduresforremovingaboltthatisbrokenoffinathreadedhole
becauseofovertightening
1. Ascrewextractorcanbeusedtoremovebolts.Thescrew
extractorhasfutesorgroovesthatspiralinacounterclockwise
direction.

a. Drillaholeinthecenterofthebrokenbolt.
b. Insertascrewextractorinthehole.
c. Usethetaphandletorotatetheextractorandbolt
counterclockwiseandremovethemasaunitfromthebolt
hole.
2. Removeaboltthatisnotboundtothethreadedhole.
a. Driveasharppunchintothecenterofthebolt.
b. Useplierstoretrievethebolt.
S 127
NOTE: Breakageduetothewrongthreaddesign,
across-threadedbolt,oraboltthatisbottomedoutinthe
holecanmakeremovaldiffcult.Drillouttheboltand
retapthehole.Usethecorrectboltandstartitintothehole
withthefngers.
S 128
S 2
lessoN 3: measUrINg Tools
I. Typesandusesofcommonmeasuringtools
NOTE: Somevehiclecomponents,particularlyintheengineand
transmission,containprecisionmachinedpartsthatrequireprecise
measurementsforinspectionorreplacement.
A. Theoutsidemicrometerisusedwhenanoutsidemeasurementmust
beaccurateto.001inorless.Partsrequiringthesemeasurements
includecrankshafts,pistons,valves,andcamshafts.
B. Theinsidemicrometerisusedwhenameasurementofthediameter
ofaholemustbeaccuratetolessthan.001in.Examplesofsuchholes
arecylinderboresandmainbearingbores.
C. Thedepthmicrometermakesprecisedepthmeasurementsofholesor
cavities.Forexample,itcanbeusedtomeasurethedistancefromthe
centerofthecrankshafttothetopoftheengineblock(deckheight)
andthedistancefromthetopofthepistontothetopoftheengine
block(pistondeckclearance).
s 130
D. Thedialindicatortoolmeasuresthrust,back-and-forthmovement,
andrunout(side-to-sideplay).Thesemeasurementsaremade
on valves, crankshafts, and fywheels. The dial indicator can also
measurethebacklashormovementbetweengearteeth.
E. Afeelergaugemeasuresairgapsandclearancebetweenmoving
parts and has numerous fat leaves of different specifc thicknesses.
F. Adialcaliperisusedforinside,outside,anddepthmeasurements.
Oneapplicationismeasuringboltsandsmallmachinedparts.
G. Plastigageisatinystripofclay-likematerialthatmeasuresclearances
suchasbetweenenginebearingsandtheirjournalsandmainbearings
andconnectingrodbearings.Thestripsarecolorcodedaccordingto
theclearancerange.
II. Proceduresfortheuseandcareofmeasuringtools
CAUTION: The proper care and use of precision measuring tools
are critical to the accuracy and long life of the tool. An incorrect
measurement can result in expensive component failure.
S
A. Useanoutsidemicrometer.
1. Beforeusinganoutsidemicrometer,becomefamiliarwithits
parts.Seetheillustrationbelow.
2. Readtheoutsidemicrometer.
NOTE:Theoutsidemicrometerdoesnotreadilydisplaythe
measurement.Someadditionisrequiredinordertoarriveat
themicrometerreading.Thetechnicianmustdevelopafeelfor
theoutsidemicrometerinordertoachieveaccurateresults.
a. Placetheobjecttobemeasuredbetweentheanviland
spindleandturnthethimbleuntiltheobjectislightly
contactedbytheanvilandspindle.Lockthespindleand
removethemicrometerfromtheobject.
b. Readthenumberindicatedonthemicrometersleeve
(upperscale).Eachnumberrepresentsonetenth(.100)of
aninch.
c. Add25thousandths(.025)ofaninchforeachadditional
lineshowingonthesleeve(lowerscale)pastthenumber.
d. Addthenumberofthousandths(.001)ofaninchindicated
onthethimble.
e. Addthenumberofinchesoftheminimumdimensionthat
themicrometercanread0inthrough5in.
B. Readinganinsidemicrometeranddepthmicrometerissimilarto
reading an outside micrometer. Be sure to add the correct fgure for
theminimummeasurement.
s 13
C. Usethedialindicator.
1. Securelyattachthedialindicatorsoitwillnotmoveandgive
inaccuratereadings.Thedialindicatorispositionedwitha
clamp-onbaseorwithamagneticbase.
2. Positiontheplungeragainstthepartbeingmeasured.
3. Rotatetheindicatoruntiltheneedleisonzero.Ifmakinga
thrustmeasurement,theshaftorgearthatistobemeasured
must frst be pried one way.
4. Rotatethepartforrunoutmeasurementsorprythegearorshaft
forthrustmeasurements,andnotethereadinginthousandthsof
aninchonthedial.
D. Usethefeelergauge.
1. Select a sample leaf and make a trial ft between the two
surfaces.
NOTE: Thethicknessoftheleafisprintedontheleaf.
2. Iftheleafistoolooseortootight,tryanotherleaf.
3. Whenthereisaslight,smoothdragasthefeelergaugeis
removed,thecorrectleafhasbeenfound.Thesizeprintedon
thefeelergaugeistheclearance.
4. Afteruse,putalittleoilontheleavestopreventrust.
E. Useadialcaliper.
NOTE: Adialcaliperisaccuratetoapproximately+or-0.002in.
Whenmoreprecisionisrequired,useamicrometer.
S
1. Beforeusingadialcaliper,becomefamiliarwithitsparts.See
theillustrationbelow.
2. Adjustthedialcaliperwiththerollknobuntilthejawslightly
contactthework.
3. Readthemeasurementonthelinearscaleandaddthereading
onthedial.
F. UsePlastigage.
1. SelectasmallpieceofPlastigagematerial.
2. PlacethePlastigagematerialonthecrankshaftjournal.The
Plastigagepiecemustspanthefullwidthofthejournalandbe
centeredwiththebearingcap.
3. Installthebearingcapandtightentothepropertorque.
4. RemovethebearingcapandinspectthePlastigage.Itshould
appearsomewhatsmashed.Comparethewidthtothepaper
gaugeonthePlastigagepackage.
G. Careofmeasuringtools
1. Adjustprecisionmeasuringtoolscarefully.Forexample,
onlyveryslightpressureisneededtotightenthethimbleona
micrometer.Overtighteningcandestroytheadjustment.
2. Donotattempttoadjustmeasuringtoolswiththelockon.
3. Alwaysstoremeasuringtoolsintheircaseorinasafeplaceto
protectthemfromdamage,grease,dirt,andmoisture.
s 13
4. Checkthecalibrationofprecisionmeasuringtoolsfrequently.
Consultthemanufacturersinstructionsfortheproper
procedure.
S
UNIT vI: PoWer Tools aNd shoP eqUIPmeNT
I. Unitobjective
II. Lessonplans
A. Lesson1:PowerTools
2. Assignmentsheet
a. AS1-L1-UVI:PowerToolsandTheirUses
B. Lesson2:ShopEquipment
2. Assignmentsheet
a. AS1-L2-UVI:ShopEquipmentUse
III. UnitVITest
s 13
S
UNIT oBJecTIve
Aftercompletingthisunit,studentsshouldbeabletoidentifycharacteristics
and the proper use of power tools and equipment used in the automotive feld.
Studentswilldemonstratemasterybycompletingtheassignmentsheetsand
achievingascoreof____ontheUnitVITest.
sPecIfIc oBJecTIves
Lesson 1
I. Identifytheprinciplesofusingvarioustypesofpowertools.
II. Identifythecharacteristicsandsafeuseofpowerdrills.
III. Identifythecharacteristicsandsafeuseofpowerwrenches.
IV. Identifythecharacteristicsofmiscellaneouspowertools.
V. Completetheassignmentsheetonpowertoolsandtheiruses
(AS1-L1-UVI).
Lesson 2
I. Identifythecharacteristicsandsafeuseofelectricalequipment.
II. Identifythecharacteristicsandsafeuseofpneumaticequipment.
III. Identifythecharacteristicsandsafeuseofhydraulicequipment.
IV. Completetheassignmentsheetonshopequipmentuse(AS1-L2-UVI).
s 13
S
lessoN 1: PoWer Tools
I. Principlesofusingpowertools
A. Electrictools
NOTE:Electrichandtoolsarestillinuseinshops,butsomehave
beenreplacedbypneumatic(air-operated)equipment,whichis
usuallylighter.
1. Electrictoolsaredrivenbyanelectricmotor.
2. Usingelectricalequipmentisamatterofcommonsenseand
usinggoodsafetypractices.
3. Safety
a. Aswithanyelectricaldevices,beawareofthedangersof
electricshock.
b. Donotstandonwetgroundorawetsurfacewhen
operatinganelectrictool.
c. Alwayscheckthatthepowercordwillnotbedamagedby
theoperationoftheequipmentanddonotrunoverpower
cordswithanyheavyobject.
d. Alwayscheckthatthepowercordisnotfrayedorworn.
e. Allelectrictoolsmusthaveathree-prongedplugunless
thetoolisdoubleinsulated.Double-insulatedtoolscannot
shorttotheoutsidecaseandrequireonlyatwo-prong
plug.
f. Donoteliminatethegroundterminalofathree-prong
plugbyusinganadapterorclippingtheterminal.
s 10
g. Donotputcordsinwateroracrossmovingmachinery.
h. Wrapupcordscarefullyafteruseandstorethemproperly.
i. Keephandsandclothingawayfromthemovingpartsof
electricalequipment.
j. Wheninspectingormakingadjustmentstoelectrictools,
alwaysdisconnectthemfromthepowersupply.
4. Maintenance
a. Checktheservicemanualfortheequipmentbeingused.
b. Electricalequipmentshouldbekeptfreeofdirtandgrease
andshouldbestoredinanareathatisdryandfreeofdust.
B. Pneumatictools
1. Pneumatictoolsarepoweredbycompressedair.
2. Pneumatictoolshaveadvantagesoverelectrictools.They
arelighterand,unlikeelectrictools,arenotdamagedby
overloadingorstalling.
3. Althoughtherearedangersassociatedwithcompressedair,the
dangersarenotasgreatasthoseassociatedwithelectricity.
4. Safety
a. Operateairtoolsonlyfortheirintendedpurpose.
b. Airimpactguns,airhammers,andairdrillscancreate
fying metal chips that are dangerous to the eyes. Wear
protectiveeyewearatalltimeswhenworkingwithor
aroundairtools.
CAUTION: Wear personal protective equipment (PPE)
when fying metal chips are possible.
c. Pneumatictoolsproduceagreatdealofpower.Usingan
improperattachmentorplacingtheattachmentonthetool
incorrectlycanresultinbreakage.Useonlyimpactsockets
onairimpactguns.
S 4
d. Waterandoilcanaccumulateinaircompressors.These
shouldbedraineddaily.Itispossibleforcompressedair
tocarryinfectionevenwithdailydraining.
CAUTION: Do not play with compressed air blowguns
or hoses. The high-pressure air stream on the skin can
cause severe infection, require the amputation of a limb,
and cause death.
e. Pneumatictoolscreateagreatdealofnoise.Wearear
plugs,earmuffs,orothertypesofearprotection.
f. Donotlookintotheair-outletvalveornozzleonanypiece
ofair-poweredequipment.
g. Donotgrabthemovableportionofanair-poweredtool
withthehandwhenitishookeduptotheairline.
h. Wheninspectingormakingadjustmentstopneumatic
tools,alwaysdisconnectthemfromtheairsupply.
5. Maintenanceofpneumaticequipment
a. Beforeanynewairtoolisused,threeorfoursquirtsof
fushing oil should be applied to the air inlet to fush any
dirtormoisturefromtherotorandtolubricatethemoving
parts. Do not use fushing oil around an open famethe
fushing oil is fammable.
b. Oilpneumatictoolsregularlyaccordingtomanufacturer
recommendations.
c. Pneumaticequipmentshouldbekeptfreeofdirtand
greaseandshouldbestoredinanareathatisdryandfree
ofdust.
d. Careshouldbetakenthatnoforeignmatterentersthe
nippleopeningofthecouplingsonpneumaticequipment.
6. Basicdesignsofpneumatictools
a. RotaryTheairdrivesarotor(turbine)thatspinsashaft
andprovidesthepower.
b. ReciprocatingTheairdrivesapistonthatisforcedback
andforthbythecompressedair.
s 1
NOTE: Theexceptionstotheabovetwokindsare
blowgunsandpaint-sprayingequipment,whichusea
directstreamofair.
7. Pneumaticcouplings
a. Pneumaticequipmentisconnectedtoairsupply
equipmentthroughquickcouplers.
b. Thequickcouplerisontheendoftheairsupplyhoseand
connectsintoanippleontheequipment.
c. Onsometools,themanufacturerrecommendsattachinga
shortleaderhosetothetoolandinstallingthenippleatthe
endoftheleaderhose.
d. Thequickcoupleroperatesbypullingbackacollaronthe
coupler,whichallowsthenippletobeinsertedintothe
coupler.Whenthecollarisreleased,itlocksthenipple
intothecoupler.
C. Cordlesstools
1. Thesetoolsuseabatterycellasthepowersupply,insteadof
electricityfromawalloutlet.
2. Theyareconvenientinshopsduetoportabilityandtheabsence
ofpowercords;however,frequentrechargingisnecessary.
3. Safety
a. Alwaysdisconnectacordlesstoolfromitsbatterybefore
inspectingitandmakingadjustmentstoit.
b. Use only the battery specifed by the manufacturer for the
toolbeingused.
c. Alwaysstorebatterypackssafelysothatnometalcan
comeincontactwiththeterminals.Contactingthe
terminal can short-circuit the battery and cause sparks, fre,
orburns.
S 4
D. Hydraulictools
NOTE: Most hydraulic tools ft in the category of shop equipment,
whichisdiscussedinthenextlesson.
1. Hydraulic tools use pressurized fuid within a cylinder to create
greatpressure.
2. The fuid is hydraulic fuid, a petroleum product that is much
likeoil.
3. Thehydraulicpressurewithinthetooliscreatedbyairpressure
orthemanualpumpingofahandle.
4. Commonhydraulictoolsandequipmentusedintheshop
includejacks,lifts,hoists,andpresses.
5. Safety
a. Beforeoperatingahydraulictool,inspectitspartstomake
surenonearedamagedordeteriorated.
b. Keephydraulichosesawayfrompotentialdamagesuch
asgrease,oil,sharpobjects,andhotsurfaces.
c. Beforeusingahydraulictool,consultthemanufacturers
informationtobesureitisappropriateforthetaskand
thatthetaskwillnotexceedthetoolsloadlimit.
d. Checkhydraulictoolsfrequentlyforleaks.Leakscan
causethetooltofail,withdangerousresults.
6. Maintenance
a. Checktheservicemanualforthetoolbeingused.
b. Inspecttoolcomponentsandreportanydamage,leaks,or
deteriorationtotheinstructor.
s 1
II. Powerdrills
A. Electricdrillscanbeusedinterchangeablywithpneumaticdrills.
B. Drillsareusedwithdrillbitstodrillholesorwithspecialattachments
toremoverustorgasketmaterial.
C. Electricdrillsuseanelectricmotortodriveachuck,adevicethat
holdsthedrillbitinplaceandalignsitproperly.Pneumatictoolsuse
arotor,whichdrivesthechuck.
D. Achuckkeyisusedtoloosenandtightenthechuck.Drillsarealso
availablewithkeylesschucks.
E. Thesizeofthedrillisdeterminedbythemaximumdiameterofthe
drill bit shaft that the chuck holds. For example, a 1/4-in drill holds a
drill bit with a shaft diameter no larger than 1/4 in. The most popular
sizes are 1/4 in, 3/8 in, and 1/2 in.
S 4
F. Drillbits
1. Drillbitscomeinvarioussizesandlengthsandare
interchangeablebetweenelectricandpneumaticdrills.When
lookingforaparticularsizeofdrillbit,useadrillgauge.
2. Drillbitsaremadeofhigh-gradesteeland,ifusedproperly,
theyseldomneedsharpening.
3. Drillbitsaresizedaccordingtothesizeofholetheydrill.Do
notusemetricdrillsinplaceofUnitedStatesCustomarySystem
(USCS)drillsorviceversa.Ifa12-mmholeisrequired,usea
12-mmbit.
G. Safetyforpowerdrills
1. Makesurethebitistightlyseatedinthechuck,securingitby
turningthechuckkeyineachhole.Besuretoremovethechuck
keybeforestartingthedrill.
2. Make sure the work is frmly secured before starting to drill.
3. Keep a frm grip on the drill and be ready to shut it off if it jams.
Drillsoftenjamjustastheyareabouttopenetratewhattheyare
cutting.
4. Ifanelectricdrilljams,turnthedrilloffandpullitbackout,
thenstartitandcontinuetodrillthehole.Thesameprocedure
shouldbeperformedforrestartingapneumaticdrill.Such
jammingmaydamageanelectricdrill.
5. Removethebitfromthedrillwhentheworkiscompleted.
III. Powerwrenches
A. Impactwrenches
s 1
1. Thesetoolscanbeeitherpneumaticorelectricandareusedto
driveimpactsocketstoloosenortightennutsandbolts.
2. Theyusesocketsthatarespeciallymadetohavegreater
strengththanstandardsockets.
3. Thewheeltorquesocket,alsocalledtorquestick,isatypeof
socketcommonlyusedwithimpactwrenches.
a. Torquesticksarelong-shaftedsocketsthatworkin
combinationwithanimpactwrenchtoinstalllugnutson
wheels.
b. They are designed to fex when the proper torque is
reached,helpingtopreventthedamagethatcanresult
fromovertorquing.
c. Thesticksarecolorcodedpersocketdiameterandtorque
limit.
CAUTION: Torque sticks are designed for tightening
lug nuts, not loosening them; using torque sticks to
loosen lug nuts will damage the sticks.
4. Usingimpactwrenches
a. Abuilt-inregulatorallowsforadjustmentsinspeedand
torque.However,donotrelyontheregulatortoadjustthe
amountoftorqueaccurately.Finaltighteningshouldbe
donewithatorquewrench.
b. Holdthewrenchwithaslightforwardpressureonthebolt
ornut.
c. Soakrustyboltsandnutswithpenetratingoilbeforeusing
animpactwrenchtoloosenthem.
d. Aswitchcanchangetheimpactwrenchfrom
counterclockwisetoclockwiseoperation.
S 4
B. Airratchet
1. Isasmallerversionoftheimpactwrenchandusuallyusesa
1/4-in or 3/8-in drive lug
2. Deliverslessforcethantheimpactwrenchandstandardsockets
maybeusedwithit
3. Hasaswitchtochangeitfromclockwisetocounterclockwise
rotation
NOTE: Anairratchetshouldbeusedonlytosnugabolt.A
conventionalratchetortorquewrenchshouldbeusedto
completethetighteningofabolt.
C. Airchisel(airhammer)
1. Usesreciprocatingmotiontoproviderapidimpactforce,much
likearapidseriesofshorthammerblows
2. Attachmentsavailableincludecutters,chisels,andpunches
3. Oftenusedtobreakweldsloose,cutrivets,punchholes,and
shearsheetmetal

D. Safetyforpowerwrenches
1. AlwayswearPPEwhenusingpowerwrenches.
2. Whenoperatinganimpactwrench,onlyusesocketsthatare
madeforimpactwrenches.Ifastandardsocketisused,itmay
break or be damaged and fy off of the tool.
s 1
3. Be sure that the chisel in the air chisel is frmly secured and that
thecuttingedgeissharp.
IV. Miscellaneouspowertools
A. Heatguns
1. Heatgunsarehand-heldheatersthatuseforcedairpassing
throughheatedcoils.
2. Theyareusedinvariousrepairprocedurestosoften,loosen,and
thaw vehicle components. Specifc uses include softening vinyl;
loosening sleeves/trim and adhesives; thawing frozen locks,
wipers,andweatherstrips;andheatingdecalsforeasyremoval.
B. Tireburnishingtool
1. Thetireburnishingtoolisusedfortirerepair.
2. Thewheelmakestherubberontheinsideofthetirerough.This
preparestherubberfortheapplicationofatirepatch.
S 4
C. Minidiegrinder
1. Aminidiegrinderisusedforcuttingmetal;removinggasket
material;andcleaningbrakerotors,backingplates,andpad
mounts.
2. Thegrinderillustratedhasaheadangledat90foreasyaccess
andhandling.
D. Blowguns
1. Ablowgunisapneumaticattachmentthatdirectsasmall,
powerfulstreamofair.
2. Ablowgunisusedtocleananddrysurfacestobepaintedand
tocleandustfromshopequipment.
CAUTION: Only blowguns that have an approved pressure
limiter should be used in the shop. A proper blowgun
attachment limits the maximum pressure to 30 pounds per
square inch (psi).
s 150
s 151
lessoN : shoP eqUIPmeNT
NOTE: Thetermshopequipmentreferstolargeorexpensivepiecesof
equipmentortools,whicharegenerallyprovidedbytheshopowner.
I. Electricalequipment
A. Shopsequippedtomounttireshaveawheelbalancer.
1. Manyshopsnowusecomputerizedwheelbalancers.Wheel
balancersareusedtoequallydistributeweightaroundthe
wheelscenterline.
2. Safety
a. Consulttheinstructorbeforeusingthewheelbalancer.
b. Aswithanyelectricaldevices,beawareofthedangersof
electricshock.
c. Donotstandonwetgroundorawetsurfacewhen
operatingelectricalequipment.
d. Ensuretheguardsareinplacebeforeoperatingthewheel
balancer.Beawareoftherotatingmassthatcouldcause
injuryifcontactismade.
S 2
B. Abenchgrinderisacommonpieceofshopequipment.
1. Abenchgrinderisgenerallyusedtomaintaintoolsthathave
becomedullandtogrindsharpedgesfrommetalpieces.
2. Thegrinderismountedtoabenchandispoweredbyanelectric
motor.
3. Inadditiontothegrindingwheel,thegrindercanbeusedwitha
wirewheelthatcleansrustanddirtoffparts.
4. Safety
electricshock.
b. Alwayswearsafetyglassesandaparticlemaskwhen
workingwithabenchgrinder.Weararespirator,as
needed,forgrindingcertainmaterials.
c. Besurethatclothing,hair,andothercombustiblesinthe
areaareprotectedfromthesparksgivenoffbythegrinder.
d. Thebenchgrindershouldhaveatoolrestplatforminfront
ofeachabrasivewheel,inadditiontoawheelguardand
aneyeshield.
e. Donotputexcessivepressureonthewheelbecauseit
couldbreakapart.Donotusewheelsthatarebrokenor
worn.
f. Followthebenchgrindermanufacturers
recommendationsforremovingandreplacinggrinding
wheels.Donotovertightenthespindlenut.
g. Whengrindingsmallparts,neverholdthepartsbyhand.
Thepartscanbeveryhotandeasilypropelledthrough
theairbythewheel.Usestandardslip-jointplierstohold
smallparts.
s 153
h. Abrasive wheels are designed for specifc types of metals.
Donotgrindaluminumongrindingwheelsdesignedfor
steel.Aluminumchipswillclogthewheelssurface.

C. Someshopshaveadrillpressfordrillingholesinmetalparts.
1. Maintenance
a. Inspectbitsregularly.Sharpbitscutbetterandareless
likelytobreak.
b. Oilthebitasneededtopreventbinding.
2. Safety
electricshock.
b. Afullfaceshieldandprotectiveeyewearshouldbeworn.
c. Partsdrilledbythepressmustbesecurelyheldbyavise
orstandardslip-jointpliers.Thispreventstheworkfrom
spinningoutofcontrolandcuttinghands.
d. Whenusingthedrillpress,donotwearlooseclothingor
jewelry.Donotallowlonghairtohangfreely.
D. Avarietyofelectricaltestandserviceequipmentcanbefoundinthe
shop.Eachpieceofequipmenthasitsuniquesafetyconsiderations.
Consulttheinstructorbeforeusinganewpieceofequipment.
S 4
E. Generalmaintenanceguidelinesforelectricalequipment
1. Checktheservicemanualfortheequipmentbeingused.
2. Electricalequipmentshouldbekeptfreeofdirtandgreaseand
shouldbestoredinanareathatisdryandfreeofdust.
II. Pneumaticequipmentcanbepermanentlyattachedtotheshopair
compressorortemporarilyattachedtothecompressorbyrubberhoses.
A. Anaircompressorprovidesthecompressedairneededtooperate
pneumatichandtoolsandequipmentintheshop.
1. Compressorsareusuallyoperatedbyanelectricmotorandare
composedofthefollowingthreemainparts.
a. Motor
b. Compressor
c. Storagetank
2. Themotordrivesacompressorthattakesintheairaroundit,
compressesitintoasmallervolume(thusincreasingpressure),
andthenstoresthecompressedairinalargestoragetank.
3. Maintenance
a. Checktheoileachweekandmaintaintheoilattheproper
level.
b. Drainwaterfromthetankandchecktheair-safetyvalve
eachday.
c. Changetheoil,checkthebeltconditionandtension,
andcleantheair-intakebreatherpermanufacturers
recommendations.
s 155
4. Safety
a. Alwaysdisconnectanaircompressorfromthepower
beforeinspectingormakingadjustmentstoit.
b. Beforeoperatinganaircompressor,inspectitspartsto
makesurenonearedamaged.
c. Makesuretheelectricaloutletfortheaircompressoris
properlygrounded.
d. Waterandoilcanaccumulateinaircompressors.These
shouldbedraineddaily.Itispossibleforcompressedair
tocarryinfectionevenwithdailydraining.
CAUTION: Do not play with compressed air blowguns
or hoses. The high-pressure air stream on the skin can
cause severe infection, require the amputation of a limb,
and cause death.
e. Airhosesshouldnotberunoverwithvehiclesor
equipmentandshouldnotbeusedtopulltoolsacrossthe
shop foor.
f. Airhosesshouldbekeptfreeofgreaseandoilandneatly
coiledforstorageattheendoftheworkday.
B. Thetiremachineusesgreatforcetomanipulatetires.
1. Itsusesincluderemovingandreinstallingthetireontothe
wheel and infating the tire to the proper pressure.
S 6
2. Safety
a. Thetiremachineisoneofthemostdangerouspiecesof
shopequipment.Donotusethetiremachinewithout
propertraining.
b. Trucktiresthatusethesplitrimtypeofmountingare
very dangerous. These must be infated in a special cage.
Consulttheinstructorbeforeattemptingtomountatruck
tireoranytypeoftire.
c. Wearprotectiveeyewearwhenworkingwithatire
machine.
C. Apneumaticjackcanraiseavehiclebythebumperoraxle.
1. Specialinstructionisrequiredtouseapneumaticjack.
2. Thevehiclemustbeloweredontosafetystandsbeforea
techniciancanworkunderavehiclesupportedbyajack.
3. Safety
a. Neverworkunderavehiclesupportedonlybyajack.
b. Consulttheinstructorandrepairmanualwhenplacing
safetystandsfortheproperlocationsofthestands.
c. Besurethattheload-capacityratingforthesafetystandsis
suffcient to safely support the vehicle.
d. Donotliftvehicleswithpassengersinsideorwiththe
s 157
D. Generalmaintenanceguidelinesforpneumaticequipment
1. Consultthemaintenanceinstructionsprovidedbythe
equipmentmanufacturer.
2. Keepthepieceofequipmentfreeofdirtandgreaseandstoreit
inanareathatisdryandfreeofdust.
3. Careshouldbetakenthatnoforeignmatterentersthenipple
openingofthecouplingsonpneumaticequipment.
III. Hydraulicequipmentdevelopspressureasaresultoftheclosingofavalve
andthepumpingofahandleorasaresultofacombinationofairpressure
over hydraulic fuid.
A. The hydraulic foor jack has a cylinder that raises the front, rear, or
sideofavehiclebypumpingahandle.
1. A foor jack is mounted on four wheels for portability.
2. Itshouldonlybeusedafterthoroughinstruction.Thevehicle
mustalsobesupportedbysafetystands.
3. RefertoUnitII,Lesson3forsafetyguidelines.
S 8
B. Aliftraisestheentirevehicleofftheground.
1. Most lifts use air pressure to pressurize hydraulic fuid, which is

thenpumpedintooneormorelargecylinders.
2. RefertoUnitII,Lesson3forsafetyguidelines.
C. Ahydraulicpressisfoundinmostshops.Itusesapowerfulpushing
forcetopressbearingsandgearsontoandoffofshafts.
1. Pullingahandleonthepressraisesorlowersaram.Theram
pressesthepartagainstatable.
2. Safety
a. Consulttheinstructorfortheprocedureforproperly
settingupandusingthehydraulicpress.
b. Wearpersonalprotectiveequipment(PPE)whileusinga
hydraulicpress.
s 159
D. Theenginehoist,orportableenginecrane,isusedtoraiseheavy
enginesandtransmissions.Afterturningavalve,ahandleispumped
toraisethehoist.
1. Ahoistissimplyahydraulicjackthatisdesignedforattaching
ontothetopofanobjectandpullingitupward,insteadof
gettingunderneathofanobjectandpushingitupward.
2. Theenginehoistisnotintendedtosupportanenginewhileit
isbeingserviced.Theengineshouldbemountedonanengine
standduringservice.
3. Safety
a. Consulttheinstructorbeforeusingtheenginehoist.
b. Standclearofanyobjectbeingraisedincasethehoistfails
ortopples,ortheobjectbeingliftedcomesloose.
c. Whenmovinganobjectthatissuspendedfromthecrane,
movethecraneveryslowly.
S 60
d. Donotworkonanyobjectwhileitissuspendedfromthe
crane. Lower it to a workbench or the foor (or into an
enginestandforamotor).
E. Generalmaintenanceguidelinesforhydraulicequipment
1. Consultthemaintenanceinstructionsprovidedbythe
equipmentmanufacturer.
2. Inspectequipmentcomponentsandreportanydamage,leaks,or
deteriorationtotheinstructor.
S 6
UNIT vII: vehIcle INformaTIoN
I. Unitobjective
II. Lessonplan
A. Lesson 1: Service Information and Vehicle Identifcation
2. Assignmentsheet
a. AS1-L1-UVII: Vehicle Information and Identifcation
III. UnitVIITest
aUTomoTIve TechNology
s 1
S 6
UNIT oBJecTIve
Aftercompletingthisunit,studentsshouldbeabletoidentifythedifferenttypes
of service information and vehicle identifcation. Students will demonstrate
masteryofthematerialbycompletingtheassignmentsheetandachievinga
scoreof_____ontheUnitVIITest.
sPecIfIc oBJecTIves
Lesson 1
I. Identifythedifferentsourcesandformatsofvehicleserviceinformation.
II. Identifyguidelinesforusingamanufacturersserviceinformation.
III. Identifythecommonlocationsofvehiclecodesandhowtoreadthecodes.
IV. Complete the assignment sheet on vehicle information and identifcation
(AS1-L1-UVII).
s 1
S 6
lessoN 1: servIce INformaTIoN aNd vehIcle IdeNTIfIcaTIoN
I. Vehicleserviceinformation
A. Sources
NOTE: Vehicleshavebecomesotechnologicallyadvancedthat
serviceinformationisusedoneveryjob.Thisinformationcontains
diagnosis procedures, specifcations, and service procedures.
Techniciansmustknowhowtolocateandusetheinformationthatis
available.
1. Vehiclemanufacturerspublishserviceinformationforeach
modelyearofthevehiclestheymanufacture.
a. Thisserviceinformationisthemostcomprehensiveand
the best source of information for a specifc vehicle.
b. It includes vehicle specifcations, diagnostic and repair
procedures,partsdiagrams,andspecialtoolsrequired.
c. Becausemanytechnicalchangesoccuraftertheservice
informationispublished,manufacturersprovidetechnical
servicebulletins(TSBs)toupdatetheinformation.The
informationintheTSBsalsoappearsinthenexteditionof
theserviceinformation.
2. Professionalgeneralservicemanualsareusedbyindependent
repairshopsbecauseonemanualcancontaininformationfor
manydomesticorforeigncarsproducedoverseveralyears.
Thesebookssummarizethemostimportantinformationanddo
not include all the specifcs.
3. Aftermarketspecialtymanualsareoftensoldatbookstoresand
maycoveronemodelofvehicleproducedoverseveralyears.
Thesemanualsarewrittenforindividualswithandwithout
experienceintheautomotiverepairprofessionandarepopular
withthedo-it-yourselfindividual.
4. Anownersmanual,preparedbythevehiclemanufacturer,is
providedtothepurchaserofthevehicleandisusuallystoredin
theglovecompartment.Itincludesbasicinformationaboutthe
locationandfunctionofvehicleaccessories,startingthevehicle,
andmaintainingthevehicle.
s 1
5. Sites on the Internet are available to fnd information that a shop
maynothaveinitslibrary,suchasmoreup-to-dateinformation,
recallinformation,orinformationaboutahard-to-diagnose
repairissue.
B. Formats
1. Besidesprintedmanuals,serviceinformationisavailableforuse
oncomputerharddrives,networks,andCD-ROMs.
2. Usingcomputerizedinformationratherthanprintedmaterials
savesspace.Inaddition,accessingtheinformationona
computeriseasierandsavestime.
II. Usingthemanufacturersserviceinformation
A. Getfamiliarwiththecomponentsoftheserviceinformationandhow
they are organized. Doing so will help in fnding information quickly.
1. Thegeneralinformationsectionincludesvehicleinformation
such as identifcation (e.g., reading the vehicle identifcation
number(VIN)togetdataaboutthevehicle),basicmaintenance,
andlubrication.
2. Therepairsections,whichcovereachsystemofthevehicle,have
detailedproceduresfordiagnosing,inspecting,testing,and
repairingthesystems.Thesesectionsalsoincludethefollowing
features:
a. Illustrationsofexplodedviewsofpartsorstepsinthe
procedure
b. Diagramsshowingthelayoutofhosesorcircuits
c. Diagnosticortroubleshootingchartsforsystematically
fnding the source of a problem
S 6
B. Beforeperformingaprocedure,readitthroughoncetogetan
understandingandoverviewofwhatisrequired.
C. Becarefultodoallstepsinaprocedureandperformtheminthe
correctorder.Missingstepsorperformingthemoutofordermay
causeunsuccessfulresults.
III. Locatingandreadingthevehiclecodes
A. In the early 1980s, the National Highway Traffc Safety
Administrationbeganrequiringvehiclemanufacturerstoidentify
eachvehiclemadeforhighwayusewithaVIN.
1. AvehiclesVINisacodewith17characters(lettersand
numbers) that is permanently affxed to the vehicle.
2. TheVINistypicallyfoundinseverallocationsonavehicle.
Someofthemorecommonlocationsarelistedbelow.
a. Dashboardnearthelowerpartofthewindshieldonthe
driversside
b. Certifcation label on the drivers door frame
c. Enginecompartment
3. The VIN uniquely identifes a vehicle and provides a great deal
ofinformationaboutthevehiclesoriginandfeatures.Seethe
sampleVINbelowforabreakdownofthecode.
s 1
4. For help in reading the VIN for a specifc vehicle, check the
generalserviceinformationsectionoftheserviceinformationfor
thatvehicle.
B. An engine serial number and identifcation number or code is
generallystampedontheengineblock.
1. Theexactlocationofthesenumbersdependsonthe
manufacturer.
2. Engine codes provide technicians with specifcations for the
vehiclesengine,suchasthehorsepowerratingandwhetherthe
enginewasdesignedforamanualorautomatictransmission.
S 6
UNIT vIII: cUsTomer servIce
I. Unitobjective
II. Lessonplan
A. Lesson1:CustomerService,WorkOrders,andVehiclePreparation
2. Assignmentsheet
a. AS1-L1-UVIII:CustomerService,WorkOrders,and
VehiclePreparation
3. Jobsheets
a. JS1-L1-UVIII:CompleteaWorkOrderWithConcern,
Cause,andCorrection
b. JS2-L1-UVIII:PerformaGeneralDiagnosis
III. UnitVIIITest
s 170
S
UNIT oBJecTIve
Aftercompletingthisunit,studentsshouldbeabletoidentifyprinciplesofgood
customerservice,componentsandfunctionsofworkorders,andhowtoprepare
avehiclebeforeandafterservice.Studentswilldemonstratemasteryofthe
material by completing the assignment sheets, successfully performing specifc
tasksinthejobsheet,andachievingascoreof_____ontheUnitVIIITest.
sPecIfIc oBJecTIves
Lesson 1
I. Identifypropercustomerrelationprocedures.
II. Identifytheproceduresforpreparingavehiclebeforeandafterservice.
III. Identifythefunctionsandcomponentsofaworkorder.
IV. IdentifythethreeCsandhowtousethemtodiagnoseavehicleproblem.
V. Completetheassignmentsheetoncustomerservice,workorders,and
vehiclepreparation(AS1-L1-UVIII).
VI. Demonstratetheabilityto:
A. Completeaworkorderwithconcern,cause,andcorrection
(JS1-L1-UVIII).
B. Performageneraldiagnosis(JS2-L1-UVIII).
s 17
S
lessoN 1: cUsTomer servIce, Work orders, aNd vehIcle
PreParaTIoN
I. Propercustomerrelationprocedures
NOTE: Studies have shown that more people are fred for their inability to
getalongwithothersthanforalackoftechnicalexpertise.Thebehaviorof
the technician and other workers can jeopardize the fnancial stability of the
shop.
NOTE: Theamountanddegreeofcustomercontactrequiredinan
automotivetechnicianpositionwillvarydependingonshoporganization
andpolicy.
A. Allemployeesintheshopshouldgreetthecustomerwhen
appropriateandactinafriendly,courteousmanner.Refertothe
customerbyusingMr.orMs.andthepersonssurname.
B. Listencarefullyandpatiently.Afterthecustomerhasexplained
theproblem,askquestionsthatmayhelpinthediagnosis.People
communicateatdifferentpacesandindifferentstyles.
NOTE: Thecustomerislikelytobeupsetthatthevehicleheorshe
dependsonisunavailableandthattherepairmaybeexpensive.
C. Itisimportanttoverifythecomplaint.Somecustomersunknowingly
giveafalsediagnosis.
D. Givethecustomeranestimate.Acustomerwilllikelybeveryupset
ifpresentedwithalargerepairthatwasnotexpected.Obtainthe
customersphonenumberandcallthecustomerbeforebeginningthe
repairs.
E. Lookforpotentialproblemsotherthanthosedescribedby
thecustomer.Explainanynewproblemstothecustomerina
professionalmanner.

NOTE: In most shops, the service manager/writer usually has the
responsibilityofcallingthecustomer.
F. Performtherepairinaprofessionalmanner.Rememberthatthe
customerispayingforarepair.Theoutcomeofthejobperformed
makesastatementtothecustomerandemployeraboutthe
techniciansskillsandprofessionalism.
s 17
G. Verifytherepair.Oneofthemostcommoncomplaintsofvehicle
ownersisthattheypaidtohavearepairperformedonlytoexperience
thesameproblemaftertherepairwastohavebeenmade.
II. Preparingavehiclebeforeandafterservice
A. Anotherimportantpartofcustomerserviceismakingsureeach
customersvehiclestayscleanandfreeofdamageduringitstimein
theshop.
1. Placefendercoversonthefenders,frontgrille,andotherareas
asneededtoprotectthevehiclefromgrease,scratches,and
dents.
2. Use foor protectors to ensure dirt and grease from technicians
shoesdonotsoilthecarpet.
3. Useseatcoverstoensurethatdirtyorgreasyhandsandclothing
donotsoiltheseats.
4. Coverthesteeringwheelwithasteeringwheelcovertoprotect
it from greasy hands and fngerprints.
B. Afterservice,followtheshopspolicyonpreparingthevehicleto
returnittothecustomer.
1. Someshopsmayrequirethatallprotectivecoversareremoved,
whereas others may want covers such as the foor protectors left
in.
2. Ensurethatthecustomersvehicleisascleanaswhenheorshe
droppeditoff.Cleanoffanydirtorgreasethatmayhavegotten
onthevehiclesexteriororinterior.
III. Theautomotivetechnicianshouldbefamiliarwiththefunctionsand
componentsofaworkorder.
NOTE:Asampleworkorderappearsinthissection.
A. Theworkorderservesseveralfunctions.
1. Itemizestherepairsbylistingthecostofpartsandlabor
2. Canbeusedtoauthorizetherepair
3. Hasthenecessaryinformationonhowtocontacttheownerand
servesasdocumentationforfuturereference
S
4. Mayalsospecifylimitedwarrantiesandliabilitiesoftheshop
5. Mayserveasareferenceforrecentservicehistoryforwarranty
orlegalpurposes
B. Aworkordertypicallyhasthefollowingcomponents.
1. Customername,address,andphonenumber(homeorwork
withextensionnumber)
2. Date
3. Invoicenumber
4. Year, make, model, vehicle identifcation number (VIN), and
mileageofthevehicle
5. Name/initials of the service writer and technician
6. Customerauthorizationsignaturetoallowrepairs
7. Descriptionofcustomerconcern
8. Vehicleservicehistoryinformation
9. Relatedtechnicalservicebulletins(TSB)
10. Techniciansnotesthatincludesdiagnosticprocedures
performed,theresultsofdiagnosis,andanyimportant
observationsorremarks
11. Componentorsystemdefectresponsiblefortheconcern
12. Serviceperformedtosuccessfullycorrecttheconcern
13. Laborproceduresandcostsbasedonthepartsandlabor
estimationguides
14. Outsidelaborproceduresandcoststhatincludeifashopsenta
particularpartouttoanothershopforrepairs
15. Listingofeachpartthatincludesname,description,andcost
16. Salestax,whichisusuallycalculatedonpartsonly
17. Total that represents the fnal price that the customer will pay
forallchargesrelatedtotherepair
s 17
Smiths Automotive Repair
CustomersName: Tom Steffensmeier Date:3/24/2006 Invoice #: 5463874093
Address:601 N. Ann St., Macon, MO 63552 Phone:(660) 442-1577
Year/Make: 2000 Ford Model: Taurus VIN:1FAFP538BYA145471 Mileage:67, 349
ServiceWriter: F. Smith Technician:F. Smith
CustomerAuthorizationSignature:Tom Steffensmeier
CustomerConcern:Front brakes are making grinding noise

VehicleServiceHistoryInformation:Routine maintenance performed 12/14/05

RelatedTechnicalServiceBulletins:

DiagnosticProceduresPerformed:Inspected front brakes and rotors and rear drums

Cause:Worn brake pads

Correction:Replaced front brake pads, machined front rotors, and adjusted rear drums

Labor Procedures and Costs Estimated Actual
Brake Repair 85.00 70.00
Drum Repair 10.00 10.00
Outside Labor Procedures and Costs
Total Labor Costs 95.00 80.00
Parts Costs
Quantity Part # Description
1 1U2-5680 Kit Brk Friction 49.95 49.95
Total Parts Costs 49.95 49.95
Labor Total 95.00 80.00
Parts Total 49.95 49.95
Sales Tax 11.16 10.01
GRAND TOTAL $156.11 $139.96

S
C. Workordersmaybehandwrittenorpreparedbyenteringcodesina
computerterminalandthenprinted.
D. Dependingonthepart,thefollowinginformationmayberequired
fororderingrepairparts.
1. Make,model,andmodelyear(foundonthedriverssidedoor
jamb)ofthevehicle
2. VIN
3. Engineinformationthatincludesenginesize,incubicinchesor
liters,thenumberofcylinders,andthetypeoffuelsystem
4. Wheelbase
5. Numberofdoors

IV. UsethethreeCs(concern,cause,andcorrection)todiagnosethevehicle
problem.
A. Identify the concern. If possible, ask the owner/driver the following
questions.
1. Underwhatconditionsdoestheproblemoccur?
2. Arethereunusualsounds?
3. Howlonghastheproblemexisted?Isitgettingworse?
B. Testdrivethevehicleundertheconditionsthattheproblemhas
beenobserved.
CAUTION: Always obtain instructors approval before conducting
a road test. Conduct the road test in an area with little or no traffc.
Never exceed the legal speed limit during the road test. Always
wear safety belts. An assistant should record all observations made
during the road test. Do not attempt to drive and record results at
the same time.
C. Isolatethecauseoftheproblem.
1. Locate and interpret vehicle and major component identifcation
numbers.
a. VIN
s 17
b. Vehicle certifcation labels
c. Calibrationdecals
2. Researchapplicablevehicleandserviceinformation.
a. Applicablecomponentsandtheiroperation
b. Vehicleservicehistory
c. Serviceprecautions
d. Technicalservicebulletins
3. Performavisualinspectionoftheapplicablesystem.
a. Lookfordamagedorbrokencomponents.
b. Lookforwornormisalignedcomponents.
c. Check fuid levels.
d. Inspectrelatedelectricalsensors,corrector,controls,and
wiring.
4. Testthesystemsandcomponentsthatcouldcausetheproblem.
Eliminategoodcomponentsuntilthecauseisfound.
D. Determinethenecessaryactionandcorrecttheproblem.

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