Ats 4
Ats 4
Ats 4
Department of Education
0
TABLE OF CONTENTS
Page
Introduction……………………………………………………………. ii
1
HOW TO USE THIS COMPETENCY-BASED LEARNING MATERIAL
You may already have some or most of the knowledge and skills covered in
this learner’s guide because you have:
0 Been working for some time
1 Already completed training in this area.
Inside this learner’s guide you will find the activities for you to
complete and at the back are the relevant operation sheets for each learning
outcome. Each learning outcome may have more than one learning
activities.
2
Course Title : AUTOMOTIVE SERVICING
Introduction
3
TECHNICAL TERMS
4
Program/Course: Automotive Servicing NC I
ASSESSMENT CRITERIA
Resources
1
LEARNING EXPERIENCES/ACTIVITIES
2
OPERATION SHEET NO.1
Condition
Tools
5888 A set of open wrench
5889 Set of special service tool
Equipment
23 Engine
24 Injection system mock-up
25 TV monitor with VCD/LCD
26 Vehicle
3
23 Assemble the O rings to the timing gear case.
4
0 Diesel Timing Marks
signifying numbers
Condition:
Tools
Equipment
0 Engine
1 Injection system mock-up
2 TV monitor with VCD/LCD
5
0 Vehicle
Procedure in installing of Injection pump, timing gear to engine
vintage type vehicle.
Loosen the four nuts attaching the pump to the mounting flange
plate and align the center timing mark on the pump flange with
the pointer on the plate. Tighten the four nuts.
Be sure that the O-ring is in place on the forward face of the pump
mounting flange.
Push the pump forward into the case. Rotate it away from the
crankcase to align the attachment holes.
Install the governor housing timing port plug and proceed with the
pump installation by reversing the remainder of the removal
procedure. Do not connect the no. 1 injecting pipe, fuel control
rod or the batteries.
Bleed the air from the fuel filter and the injection pump by
removing the air bleeder screws.
6
OPERATION SHEET NO.3
Condition:
0 CD
1 Bond paper
2 Board marker
3 White board
Tools
Equipment
0 Engine
1 Injection system mock-up
2 TV monitor with VCD/LCD
3 Vehicle
1 Disconnect the batteries and the fuel shut off rod at the stop lever.
3 Remove the forward oil filler cap on the rocker cover and check the
no. 1 cylinder valves for looseness. If they are loose, you are at
TDC.
7
0 Turn the crankshaft in the normal direction of engine operation in
small steps. Stop when fuel begins to flow from the delivery valve
holder. Injection begins at this point. The control lever must be in
the idle position.
1 Read the injection timing point from the scale on the back of the
crankshaft damper. If the timing is correct, the timing mark should
be at the value shown on the Vehicle Emission Control Information
label on the rocker cover +- 2 degrees.
Fig.1
Fig. 2
8
OPERATION SHEET NO.4
Condition:
Tools
Equipment
Engine
Injection system mock-up
TV monitor with VCD/LCD
Vehicle
9
Installation of front plate
Install the gasket and front plate by aligning the holes with the
locating dowels on the cylinder body using 3 bolts.
Note: Apply a thin coat of liquid gasket evenly to both faces of
the gasket before installation.
Installation of camshaft
Apply engine oil to the camshaft journals and cams,
then install the camshaft on the cylinder body.
10
Installation of camshaft gear bolt
6.1 Install the plain washer with its chamfered side out, then
install the bolt.
0 Do not over tighten pump drive gear nut. The replacement pump
shaft should be aligned in position to eliminate the need to set
pump-to-engine timing for this is not the final torque for the drive
gear.
1 Do not steam-clean the injection pump while the engine is running.
(The temperature difference may cause serious damage to the
pump.
2 When using a timing pin, do not forget to remove it before turning
the engine over; otherwise the injection pump will be damaged.
3 Be careful of mounting the injection pump to engine, dropping it by
accident would damage the body parts of the pump.
4 Do not apply heavy rotational force on pump after gear back lash is
removed as this may preload the pump and effect pump-to-engine
timing.
5 Be sure that the area is clean.
11
ASSESSMENT PERFORMANCE
Workmanship/Performance
Points
12
Program/Course: Automotive Servicing NC I
ASSESSEMENT CRITERIA
Resources
13
LEARNING EXPERIENCES/ACTIVITIES
14
OPERATION SHEET No. 5
Condition:
Diesel fuel
Rags
Container
Tools
Equipment
After the injection pump is timed to the engine and its mounting
bolts are torque to specifications connect the low-pressure fuel
line, the injection lines, the throttle, and the shut off control to
the injection pump.
Bleed the air from the filters, fuel lines, and the injection pump to
prevent lock of lubrication to the pump elements and possible
damage to the closely fitted parts.
To bleed the system, first check the level of the fuel tank. If it is
below the injection pump, fill the tank.
15
Open the shut off value, the primary filter, the secondary filter, and
the injection-pump vent screws. Allow fuel and air to flow from
the vents until the fuel is free of air bubbles. Then tighten the
vent screws in sequence, one after the other.
Condition:
Tools
16
Equipment
17
OPERATION SHEET No. 7
Condition:
Diesel fuel
Rags
Container
Tools
Equipment
18
Procedure in bleeding the Fuel System shut off engine.
Loosen the fuel filter petcock or valve and operate the priming pump
on the feed pump. If the filter is filled with fuel, fuel containing air
bubbles will be discharged from the petcock or valve. Continue
pumping until the discharge fuel contains no more air bubbles.
Then tighten the fuel valve or petcock securely.
Loosen the air bleeder screw at the top of the injection pump and
operate the priming pump. Continue pumping until all air is bled
from the fuel in the pump reservoir. Then close air bleeder screw
securely.
19
OPERATION SHEET No. 8 under LO2
Condition:
Diesel fuel
Rags
Container
Tools
Equipment
Bleed the air from fuel filter. Loosen the air bleed screw at the top
of the fuel filter expel in the fuel flowing from the filter.
Bleed the air from the fuel return pipe installed on the fuel injector,
and bleed the air by operation the manual handle of the lift
pump. (If there is more than one injector, bleed the one at the
end of the line).
Bleeding the air from the fuel line – (line from the filter to the
injector pump). Loosen the air venting screw at the injection
pump and operate the manual handle of the lift pump until all
the air bubbles are out.
20
Bleed the air from the fuel injector. Loosen the nipple on the fuel
injector side, set the throttle to half and the decompression lever
to the decompression position and crank engine. When no more
bubbles appear in the fuel flowing from the end of the injection
pipe, re-tighten the nipple.
Fig.1 shows the part and the diesel fuel line connection
0 If your bleed the system by using the hand priming pump, do not
forget to lock it. If the pump is not locked, there will be no transfer-
pump pressure because fuel will circulate within the transfer
pump.
1 Since the presence of air in the fuel system anywhere between the
fuel tank and the injector will cause a no start of erratic running
condition. Always bleed the air when the system if disassembled,
filter changed or run out of fuel.
2 Air entrapped in the fuel system can cause inadequate fuel
injection, poor operation, and hard starting. Whenever the fuel
system is serviced, it should be bled of entrapped air in the proper
sequence.
3 Be sure that every fittings of the Diesel fuel line are all air tight in
order to prevent atmospheric air pressure enters the line loose
fittings.
4 Be sure that each fuel line is installed onto the same pump outlet
port position from which it was removed value holders from
injection pump delivery valve holders from turning when installing
the lines onto the pump.
21
ASSESSMENT PERFORMANCE
Workmanship/Performance Points
-Threetotwominutes-------------- 20
6 minutes or more - - - - - - - - - - - - - - - - - 10
100
22
Program/Course: Automotive Servicing NC I
ASSESSMENT CRITERIA
Resources
23
OPERATION SHEET No. 9
Condition:
Ball pen
Bond paper
watch
Tools
Equipment
Disconnect the wire from the fuel shutoff solenoid terminal of the
injector pump. This prevents delivery of fuel during the test.
24
Disconnect glow-plug wires and remove glow plugs
Check all cylinders on the same way. Get the reading of every
cylinder.
Note:
Clean the injector bore or sleeve with the recommended tool,
but make certain that no carbon remains in the combustion
space.
25
b. Be sure the crankcase is at the proper level, the battery is
properly charged and with a good effective starter that
produces high efficiency in cranking the engine.
EXAMPLES
126 ÷ .7 = 180
180 – 126 = 54
54÷.3=180
180 x 1.0 =
275 ÷ .7 = 393
393 – 275 = 118
118 ÷ .3 = 393
393 x 1.0 = 393
140 ÷ .75 = 187
187 – 140 = 47
47 ÷ .25 = 187
1.0 x 140 = 140
105 ÷ .75 = 140
140 – 105 = 35
35 ÷ .25 = 140
1.0 x 140 = 140
27
CHART OF COMPRESSION PRESSURES THAT RANGES MINIMUM AND
MAXIMUM WILL BE THE BASES OF TECHNICIAN RECOMMENDATION.
Maximum
Minimum PSI Maximum PSI Minimum PSI
PSI
135 ......... .101 192 ..........144
136 ......... .102 193 ..........145
139 ......... .104 196 ..........147
140 ......... .105 197 ..........148
143 .......... 107 200. .........150
144 ......... .108 201 ..........151
147 ......... .110 204 ..........153
148 ......... .111 205. .........154
151 ......... .113 208 .........156
152 ......... .114 209. .........157
153 ......... .115 211 .........158
156 ......... .117 213 ..........160
157 ......... .118 216. .........162
160 ......... .120 217 ..........163
161 ......... .121 220 ..........165
164 ......... .123 221 ..........166
165 ......... .124 224 ..........168
168 ......... .126 225 ..........169
169 ......... .127 228. ..........171
172 ......... .129 229 ..........172
175 ......... .131 232 ..........174
176 ......... .132 233. .........175
177 ......... .133 236. .........177
180 ......... .135 237. .........178
181 ......... .136 240 ..........180
184 ......... .138 241 ..........181
187 ......... .140 244. .........183
188 ..........141245..........184
189..........142 248 ..........186
249 ..........187
28
ASSESSMENT PERFORMANCE
Workmanship/Performance Points
25 to 40 minutes - - - - - - - - - - - - - - - - - - 35
41 to 59 minutes - - - - - - - - - - - - - - - - - - 25
1 hour – up - - - - - - - - - - - - - - - - - - - - - - 15
None - - - - - - - - - - - - - - - - - - - - - - - - - - 15
None - - - - - - - - - - - - - - - - - - - - - - - - - - 10
100
29
ACKNOWLEDGMENT
Technology Teachers:
Jonathan O. Diaz
TVE-Automotive-Technology Coordinator
Teacher III
Robert S. Domingo
Teacher I
Lino A. Olit
Teacher I
30
Community Vocational High School
Arpil P. Medrano
Teacher I
ACADEMIC WRITERS:
Araceli T. Bondoc
Romhel C. Odtohan
Teacher I (ENGLISH)
Teacher I (SCIENCE)
Helen U. Divina
Teacher I (SCIENCE)
Belen P. Caldez
31
Division of City Schools, Manila
Teacher I (MATH)
JOHN DIEGO
LINO OLIT
ROMEO IBLOGUIN
NELSON SENEDO
32
REFERENCES
Manuals:
ISUZU WORKSHOP MANUAL C240 MODEL DIESEL ENGINE BY
ISUZE MOTORS LIMITED TOKYO, JAPAN.
SERVICE TRAINING MANUAL OF MITSUBISHI 4D56 DIESEL
ENGINE. BY OVERSEAS SERVICE DEPARTMENT MITSUBISHI
MOTOR CORPORATION.
Internets
http://dodgeram.info/tsb/recalls/605.htm
http://www.autozone.com/az/cds/en_us/0900823d/80/16/f3
/57/0900823d8016f357/repairInfoPages.htm#hd1-1-2
http://www.valvoline.com/carcare/articleviewer.asp?pg=ccr200
60201d2&cccid=2&scccid=5
http://www.tpub.com/content/construction/14264/css/14264
_105.htm
33
Republic of the Philippines
Department of Education
PUBLIC TECHNICAL-
VOCATIONAL
0
TABLE OF CONTENTS
Page
How to Use this Module ………………………………………….. i
Introduction……………………………………………………………. Ii
Technical Terms …………………………………………………….. iii
1
HOW TO USE THIS MODULE
Welcome to the Module “Performing Gas Engine Tune Up”. This module
contains training materials and activities for you to complete.
The unit of competency “Perform Gas Engine Tune Up” contains the
knowledge, skills and attitudes required for Automotive Servicing NC 1
course required to obtain the National Certificate (NC) level & II.
You are required to go through a series of learning activities in order to
complete each of the learning outcomes of the module. In each learning
outcome there are Information Sheets,, Operation Sheets and Activity
Sheets. Do these activities on your own and answer the Self-Check at the end
of each learning activity.
If you have questions, don’t hesitate to ask your teacher for assistance.
You have already some basic knowledge and skills covered in this module
because you have been working for some time; and already completed training
in this area.
If you can demonstrate competence to your teacher in a particular skill, talk to
your teacher so you don’t have to undergo the same training again. If you have a
qualification or Certificate of Competency from previous trainings show it to
him/her. If the skills you acquired are consistent with and relevant to this
module, they become part of the evidence. You can present these for RPL. If you
are not sure about your competence skills, discuss this with your teacher.
After completing this module, ask your teacher to assess your competence.
Result of your assessment will be recorded in your competency profile. All the
learning activities are designed for you to complete at your own pace.
In this module, you will find the activities for you to complete and relevant
information sheets for each learning outcome. Each learning outcome may
have more than one learning activity.
This module is prepared to help you achieve the required competency, in
receiving and relaying information. This will be the source of information that
will enable you to acquire the knowledge and skills in Arabic Language and
Values Education independently at your own pace with minimum supervision
from your teacher.
i
Program/Course AUTOMOTIVE SERVICING
INTRODUCTION:
ii
Technical Terms
iii
Magnetism An energy form resulting Jack stands Support devices used to
from atoms aligning within certain hold the vehicle off the floor after it
materials, giving the materials the has been raised by the floor jack.
ability to attract other metals. Lamp A device that produces light as
a result of current flow through a
Ohm Unit of measure for resistance.
filament. The filament is enclosed
One ohm is the resistance of the
within a glass envelope and is a
conductor such that a constant
type of resistance wire that is
current of one ampere in it
generally made from tungsten.
produces a voltage of one volt
between its ends. Series-parallel circuit A circuit that
have some loads in series and
Ohmmeter A test meter used to
some in parallel.
measure resistance and continuity
in a circuit. Short An electrical fault that allows
for electrical current to bypass its
Ohm's law Defines the relationship
normal path.
between current, voltage and
resistance. Solenoid An electromagnetic device
Open circuit A term used to indicate that uses movement of a plunger to
exert a pulling or holding force.
that current flow is stopped. By
opening the circuit, the path for Splice The joining of single wire ends
electron flow is broken. or the joining of two or more
Overload Excess current flow in a electrical conductors at a single
circuit. point.
Parallel circuit A circuit that State of charge The condition of a
provides two or more paths for battery's electrolyte and plate
electricity to flow. materials at any given time.
Relay A device that uses low current Valve clearance The measured gap
to control a high current circuit. between the end of the valve stem
Low current is used to energize the and the rocker arm, cam lobe or
electromagnetic coil, while high follower that activates the valve.
current is able to pass over the Voltage The difference or potential
relay contacts. that indicates an excess of
electrons at the end of the circuit
Resistance Opposition to current
flow. the farthest from the electromotive
force. It is the electrical pressure
that causes electrons to move
through a circuit. One volt is the
amount of pressure required to
move one amp of current through
one ohm of resistance.
iv
Program/Course : Automotive Servicing NC I
ASSESSMENT CRITERIA:
REFERENCE:
VHS/CD
LEARNING EXPERIENCES/ACTIVITIES
2. Perform, check and adjust valve See your teacher for guidance
clearance. Complete the task
1
INFORMATION SHEET No. 1
Piston engine operates on either the two-stroke cycle or the four stroke
cycle. Automotive engines are four-stroke cycle engine. Every fourth piston
stroke is a power stroke, there is power in every two full crankshaft
revolution (720 degrees).
A. ENGINE OPERATION
The complete cycle of events in the cylinder requires four piston strokes.
These are intake, compression, power and exhaust.
2
CYCLE – means a series of events that repeat themselves. ( see Fig. 17)
COMPRESSION STOKE both valve are closed, the upward moving piston
compresses the air-fuel mixture into a smaller space,
between the top of the piston and cylinder head. This
space is called the Combustion Chamber.
3
EXHAUST STROKE as the piston approaches BDC on the power-stroke
the exhaust valve opens. After passing through BDC,
the pistons moves up again. The burned gases escape
through the open exhaust port while the intake valve
remains closed.
B. VALVE ACTION
In many engines, each cylinder has two valves. One intake valve, the
other is an exhaust valve, some engines have more than two valves; these are
multi-valve engines. They have three, four, five, or six valves for cylinder.
Value train is the series of parts that open and close the valves. The
action starts at the camshaft. The crankshaft drives the camshaft through
gears, sprockets and chain or sprockets and a toothed timing belt, most
camshaft have a cam for each valve in the engine. Each cam is a round collar
with a highest spot or lobe. When the rotating cam brings the cam lobe down
against the top of the bucket tappet, the lobe pushes the tappet down and this
compresses the spring and pushes the value down off its seat. The valve opens
4
as the cam continues to rotate while the lobe moves away from the tappet. The
spring pushes the tappet until the valve seats.
5
INFORMATION SHEET 2
TOPIC 1
Quick and accurate diagnosis and service of the engine require the use
of various test instruments and gauges. These will show if the battery,
starting, starting, charging, fuel, and emissions systems are operating
properly. They would also indicate the mechanical condition of the engine.
6
In electronic ignition systems, the ECM
controls dwell. It is not adjustable. The
dwellmeter is used to check the duty
cycle of the mixture-control solenoid in a
feedback carburetor.
7
Engine Vacuum Gauge The engine
vacuum gauge measures intake-
manifold vacuum. The intake-
manifold vacuum changes with
the load on engine defects. The
way the vacuum varies from
normal indicates what could be
wrong inside the engine. Before
making the test, check if all
vacuum hoses are properly
connected and not leaking. Make a
backpressure test if a restricted
exhaust system is indicated.
8
Exhaust Gas Analyzer The exhaust
gas analyzer measures the amount
of various gases in the exhaust.
There are two main types:
0 Two-gas analyzer that
measures HC and CO.
1 Four-gas analyzer that
measures HC, CO, O2 and CO2
Note: An exhaust gas analyzer can also be used to check for exhaust-gas
leakage into the cooling system. Figure 11 shows the exhaust-gas
analyzer being used to locate fuel or fuel-vapor leaks.
9
Four-Gas Analysis Combustion at
the stoichiometric ratio of 14.7:1
provides maximum conversion
efficiency. This results in
minimum tail pipe emissions of
HC and CO. Figure 12 shows the
relationship among the four gases Figure 8. Suggested test
measured by the four-gas specifications for testing exhaust
analyzer. Each gas and its emissions.
readings are described below.
1
0
Cylinder-Balance Test The cylinder –
balance test determines if each
cylinder in a running engine
produces the same amount of
power. Disabling a cylinder should
cause a change in engine speed.
The change should be about the
same for all cylinders.
Connect a tachometer to the
engine. Then disable the cylinder.
This is done by shorting the spark
plug or disconnecting each fuel
injector in a port-injected engine.
Note the tach reading. Repeat the
test on each cylinder. All cylinders Figure 10. All cylinders are
are contributing the same amount
contributing to the same amount
of power if the rpm drops are the
of power if the tachometer shows
same. Weaker cylinders show less
that all rpm drops are the same as
of rpm change. Shorting or
each cylinder is disabled. (Sun
disabling a dead cylinder causes
Electric Corporation)
no change in rpm.
1
1
Engine Analyzer An engine analyzer
combines several testers, meters
and gauges into a single piece of
portable shop equipment. When
connected to the vehicle, the
analyzer provides quick and
accurate testing and diagnosis of
various engine and vehicle
systems. Most shop engine
analyzers include an oscilloscope.
It displays voltage patterns of the
ignition system and electronic fuel
injectors. Some computerized
analyzers include a second screen.
This displays information needed
by the technician, such as steps in
a test procedure or the test results.
The analyzer may have a printer to
provide a written report.
12
SELF-CHECK No. 2
Multiple-Choice Test
Select the correct answer to each question. Write the letter in your
test notebook.
3.The cylinder leakage tester applies air pressure to the cylinder with
the piston
0 TDC with both valves closed
1 BDC with both valves closed
2 the starting compression stroke
3 TDC with both valves open
1
3
OPERATION SHEET No.1
Intake - .008"
Exhaust - .014"
14
Procedures in adjusting valve tappet
clearance:
15
Use two thin wrenches when
adjusting valve clearance. Use
the lower wrench to hold the
tappet and the upper wrench to
raise or lower the tappet
adjusting screw. When the valve Fig. 7. Adjusting valve tappet clearance
lash is properly adjusted, the
appropriate feeler gauge should
pass between the tappet and its
corresponding valve stem with
a slight drag
Note: Follow/refer to
Manufacturer’s
Specification Manual.
6. Crank the engine one-half
revolution at a time and check
the clearance of each valve;
adjust if necessary. Do this on
each set of cylinder valves in
succession according to the
firing order of the engine, which
is 1-3-4-2.
Note: Locate the firing order of
Engine.
Fig. 8. Checking the valve clearances.
Install new gasket and install valve
tappet cover. Be sure the valve
cover has an oil- tight seal with
the crankcase.
Note: Use the appropriate
sealant, gasket and
ensure the correct
bolt tight
Fig. 9. New gaskets.
8. Replace the spark plug, spark plug wire and coil wire.
1
6
PERFORMANCE CRITERIA
SCORING RUBRICS
17
QUALIFICATION : Automotive Servicing NC I
ASSESSMENT CRITERIA:
REFERENCES:
6. VHS/CD
Communication Module
1
8
LEARNING EXPERIENCES / ACTIVITIES
1
9
Operation Sheet No. 1
Sand paper
Rag
New set of spark plug
Procedures
Walk around to the front of the car, reach under the hood, look for the latch
and squeeze it. Open the hood.
Find the spark plugs, located in a row
along one side of the engine (on an
in-line four-cylinder engine) and
attached to thick wires, called spark
plug wires. Cars with V-shaped
engines (which can have four, six or
eight cylinders) have spark plugs
and spark plug wires on both sides
of the engine.
20
Warning:
Change one spark plug at a time,
putting the wire back on after you're
done. If you pull all the wires off at
once, you may put them back on the
wrong spark plugs; this changes the
firing order, and your car will run
badly or not at all. If you must take
all the wires off at once, label them
with white correction fluid or with
masking tape and a marker.
5. Pull off one spark plug wire attached Fig. 2 show the removal of high
to the plug. There is a little rubber tension cable
boot at the plug end of the wire; pull
on this part. Pulling higher up on the
wire can damage the spark plug wire
and cause it to separate; repair or
replace if necessary.
21
Installing spark plugs
An over-torque spark plug can suffer from severe stress to the Metal
Shell which in turn can distort the spark plug's inner gas seals or even cause a
hairline fracture to the spark plug's insulator...in either case, heat transfer can
again be slow and the above mentioned conditions can occur or it might lose
either the outside and inside thread of the plug hole.
Steps:
Hand-tighten each spark plug in place. If you feel any resistance, stop and
start over to prevent cross-threading.
Tighten the plugs with a socket wrench until snug. Do not over tighten.
Replace the spark plug wires. Usually, you will hear a soft pop when the
plug wire snaps onto the plug.
Start the engine. Listen. If the engine runs roughly or doesn't start, make
sure the wires are pushed all the way onto the new plugs.
22
OPERATION SHEET No. 2
Procedure:
Find the chart listing the proper "gap" for your plugs in your car's repair
manual. The spark plug gap may also be on the sticker on the inside of the
car's hood. The parts store can provide you with this specification as well
or read the basics below.
Note: Spark plug gap specifications are listed in inches and/or millimeters.
The gapper will have inches on one side and millimeters on the other. This is
shown in every blade of the feller gauge.
Since the gap size has a direct affect on the spark plug's tip temperature and
on the voltage necessary to ionize (light) the air/fuel mixture, careful attention
is required. While it is a popular misconception that plugs are pre-gapped
from the factory, the fact remains that the gap must be adjusted for the
vehicle that the spark plug is intended for. Those with modified engines must
remember that a modified engine with higher compression or forced induction
will typically require a smaller gap setting (to ensure ignitability in these
denser air/fuel mixtures). As a rule, the more power you are making, the
smaller the gap you will need.
2
3
A spark plug's voltage requirement is directly proportionate to the gap size.
The larger the gap, the more voltage is needed to bridge the gap. Most
experienced tuners know that opening gaps up to present a larger spark to the
air/fuel mixture maximizes burn efficiency. It is for this reason that most
racers add high power ignition systems. The added power allows them to open
the gap yet still provide a strong spark.
Proper gapping of the spark plug is necessary to get maximum spark energy,
lowest RFI release as well as what is best for the longevity of the secondary
ignition components (coil, cap, rotor, wires, plugs).
When checking plug gaps, the correct way is to use ONLY wire gauges,
though many of us are using the slider style gapping tools. These flat
or feeler gauge style gauges do not accurately measure true width of
spark plug gap.
When increasing the gap size for our high performance applications utilizing
advanced ignition systems such as Mallory, Accel, Jacobs, Crane and Holley
... it is important never to go more than plus or minus .008". This is to
maintain parallel surfaces between ground and the center electrodes.
Something many people do not know is that with Higher Compression ratios
and Superchargers as well as Nitrous, in many cases smaller spark plug
gaps must be used as well as the use of a much hotter ignition system (see
above). These higher cylinder pressures require more energy to jump the
spark plug gap.
The rule of thumb on plug gaps is to open them up in .002" increments at a
time. When the car (race vehicle) begins to lose power or slow down then go
back .001-.002" and this in most cases is the optimum gap.
Remembering that the Ignition Unit, plug brand as well as heat range,
cap and/or rotor styles and in many cases fuel type or brand will change
the optimum spark plug gap settings.
24
PERFORMANCE CRITERIA
SCORING RUBRICS
2
5
Program/Course : Automotive Servicing NC I
ASSESSMENT CRITERIA:
REFERENCES:
7. VHS/CD
Communication Module
2
6
LEARNING EXPERIENCES
Tools
Equipment
2
7
Procedure
Rest the vehicle for 24 hours to let any remaining fuel pressure bleed off.
2
8
Use the 3/8" ratchet and 10mm
socket remove the support bolt
for the left half of the air cleaner
housing. Remove the temperature
sensor connector by pushing and
holding down the metal clip and
gently pulling the connector off
the back of the air cleaner
housing.
2
9
Disconnect the electrical
connector to the mass air flow
sensor by turning the plastic
locking ring and then gently
pulling the connector off of
the mass air flow sensor.
3
0
Now that the air cleaner housing is
out of the way there is plenty of
room in which to work. You'll
need a good supply of rags and a
small can to catch the gas that
will inevitably come out of the
filter. Remove the connection
near the rear of the car first. Used
a 19mm open wrench on the filter
side nut to hold the filter steady
and a 19mm flare wrench on the
fuel line nut to break the
connection.
3
1
The fuel line support bracket is
freed up by loosening a 10mm
bolt in the right rear wheel
well that screw into the six-
sided plastic nut on the
support bracket.
All that remain is to put everything back together again pretty much in
the reverse order you took it all apart. The order was:
Reattach the fuel line support bracket (note: remember the offset plastic
washer!).
Insert new fuel filter and attach to the forward 17mm fuel line nut. Be careful
to get the filter oriented the proper direction. There should be an arrow on
the fuel filter itself (should point to the rear of the car) and the nut
arrangement between the fuel lines and filter are in one direction.
Secure the fuel filter hose clamp. Mark the mileage and date on the filter for
future reference.
Attach the rubber hose to the lower left corner of the air cleaner housing.
Set the air cleaner housing to the two lower rubber support mounts and work
the mass air flow sensor into the back of the air cleaner housing being
cognizant of the sealing gasket.
3
2
Rotate the mass air flow sensor to the rear of the car to re-engage the
bayonet lock between the air flow sensor and the air cleaner housing.
Secure the 10mm support bolt on the upper left half of the air cleaner
housing.
Tighten the mass air flow sensor hose clamp with the 8" #2 Phillips
screwdrivers. Use your right hand to hold the clamp in place while using
a screwdriver in your left hand to tighten the hose clamp.
Reattach the mass air flow sensor connector and the air cleaner housing
temperature sensor connector.
Replace the air filter, the air cleaner housing cover and the "snorkel tube."
Finally, start the car and check for leaks. It will probably take a couple
tries before the car will start up.
3
3
PERFORMANCE CRITERIA
SCORING RUBRICS
Tools
Equipment
Air compressor
Running condition vehicle/ Engine mock up
Procedure:
3
4
Changing the air filter should be part of any major tune-up, but if you drive
on dirt roads or in other dusty conditions, you will need to replace it more
frequently. On most cars, this is a fairly simple procedure. You should change
your car's air filter every 15,000 miles.
3
5
Clean the area with a vacuum cleaner or seal the top of the carburetor. This will
keep debris out of the carburetor as you continue to clean the housing.
Warning: Avoid using the wrong size air filter. Your engine will run
less efficiently.
Note: Reusable air filters cost more than disposable filters, but if cared
for correctly, they can last for over 50,000 miles.
Another good way to make your air filter last is to actually use a vacuum
cleaner. Simply take the filter out and with the small attachments from the
vacuum, suck out the dust and dirt. Good as new and it will make your
filter last a littler longer.
3
6
PERFORMANCE CRITERIA
SCORING RUBRICS
ASSESSMENT CRITERIA:
REFERENCE:
3
7
Toyota Training Manual
by: Toyota
8. VHS/CD
Communication Module
MATERIALS
New set of breaker points
New condenser
Grease
Chalk
TOOLS
Screw drivers: flat and phillip
Dwell –tach
Timing light
Wrench 10mm
Feeler gauge
Vehicle service manual
EQUIPMENT
Running condition vehicle
38
Procedure
Contact points should be replaced every 10,000 miles. It's good practice to
replace the condenser at the same time. When you replace the points, you then
must check and, if necessary, re-set the timing to specification.
39
Remove the condenser. The
condenser is that little metal can
inside or outside of the
distributor. There is one screw
that holds the condenser on
itself, and there is another which
holds the black plastic plug to the
distributor body. Both of these
screws are readily accessible, so
remove them and the little metal
plug clip, and then remove the
condenser and plug from the
distributor. Fig. 4 shows the condenser
4
0
PERFORMANCE CRITERIA
SCORING RUBRICS
ASSESSMENT CRITERIA:
REFERENCE:
4
1
Toyota Training Manual
by: Toyota
9. VHS/CD
Communication Module
42
Information Sheet
4
3
OPERATION SHEET
MATERIALS
TOOLS
EQUIPMENT
Procedure
Connect the dwell meter as per its manufacturer's instructions: Generally one
of two leads is connected to the positive terminal of the battery and the
other lead to the negative terminal of the coil.
4) Restart the engine and re-measure Top view of distributor (cap removed)
dwell angle. Repeat 1-3 until dwell showing contact breaker points.
angle is correct.
44
SETTING IGNITION TIMING
Set the timing by connecting the light (inductive or direct) and then mark
the correct timing position on the crank pulley or damper.
Note: Connect the power lead to the + terminal on the battery or the + side
of the coil and the other wire to ground.
Follow your engine manual and make an easy-to-read mark with White-Out
(liquid paper) or chalk.
Disconnect the vacuum line from the distributor and stick a pencil or nail
into it to prevent a vacuum leak.
Start the engine and get it running about 500-600 rpm to prevent any action
from the centrifugal advance mechanism (if there is one) and then slowly
rotate the distributor until the timing mark lines up with its pointer.
Tighten the hold-down on the distributor. If the engine won't run slowly
enough back off on the accelerator linkage at the carburetor. If the
engine runs too slow increase the idle speed.
Check the timing again and then put the light away.
4
5
PERFORMANCE CRITERIA
SCORING RUBRICS
Total 100%
4
6
QUALIFICATION : Automotive Servicing NC I
ASSESSMENT CRITERIA:
REFERENCES:
VHS/CD
Communication Module
4
7
LEARNING EXPERIENCES / ACTIVITIES
MATERIALS
Gasoline
TOOLS
Vehicle service manual
Screwdrivers flat and Philip
Carburetor synchronizer
Wrench 10mm
EQUIPMENT
Running condition vehicle
48
Procedures
4
9
PERFORMANCE CRITERIA
SCORING RUBRICS
ASSESSMENT CRITERIA:
REFERENCES:
by: Toyota
Communication Module
5
0
LEARNING EXPERIENCES/ACTIVITIES
INFORMATION SHEET
Ignition Timing is also called spark timing, refers to how early or late
the spark plug fires in relation to position of the engine pistons. Ignition timing
must vary with engine speed, load and temperature.
TIMING ADVANCE
It occurs when the spark plugs fired sooner on the engine’s
compression stokes. The timing is set several degrees before TDC. More timing
advance is needed at higher engine speeds to give combustion enough time to
develop pressure on the power stroke.
51
TIMING RETARD
It occurs when the spark plugs fire later on the compression strokes. It
is the opposite of timing advance; spark retard is needed at lower engine
speeds and under high load conditions. Timing retard prevents the fuel from
burning too much on the compression stroke, causing a spark knock or plug.
5
2
Vacuum Delay Valve – a vacuum delay valve restricts the flow of air to
slow down the vacuum action on a vacuum device. Note how the delay valve
has a small orifice (opening) for vacuum. It also has a check valve that allows
flow in only one direction. The vacuum delay valve keeps the vacuum advance
from working too quickly, preventing possible knock or ping. The check valve
allows free release of vacuum from the diaphragm when returning to the retard
position.
53
would assure that the engine attained high fuel economy on the highway.
Since computer system vary, refer to a service manual for more information.
The manual will detail the operation of the specific system.
Base Timing
Is the ignition timing without computers controlled advance. To make the
engine run on base timing, you might have to disconnect a wire near the
distributor or use a scanner to trigger computer retard.
Check the timing with the engine at normal operating temperature and
idling at the specified speed, in setting ignition timing follow the procedures.
Gasoline
Tools:
Timing light
Wrench No. 12mm
Equipment:
5
4
Procedure:
NOTE:
Keep your hands and the timing-light leads away from the fan and drive
belts. Never stand in line with the fan. A blade might fly off and strike you.
55
Self Check No. 3
SCORING RUBRICS
100% Total
5
6
QUALIFICATION : Automotive Servicing NC I
ASSESSMENT CRITERIA:
REFERENCES:
VHS/CD
Communication Module
5
7
LEARNING EXPERIENCES / ACTIVITIES
MATERIALS:
Gasoline
TOOLS
Vehicle service manual
Basic hand tool set
Compression gauge
Safety gauge
EQUIPMENT
Running condition vehicle
Procedure
The cylinder compression tester measures the ability of the cylinders to hold
compression while the starting motor cranks the engine. The compression
tester is a pressure gauge that measures the amount of pressure or
compression, built-up in the cylinder during the compression stroke. How
well a cylinder holds compression is an indication of the condition of the
piston, piston rings, cylinder wall, valves and head gasket.
58
Connect a pressure gauge to the
cylinder port as shown.
Turn the engine with the starter until the pressure gauge registers no
further rise in pressure.
59
Information Sheet
Note: Never perform a wet compression test on a diesel engine. The heat of
a compression could ignite the oil and damage the compression
tester. Also, since the oil is not compressible, it could fill the
combustion chamber and create a hydrostatic lock. This prevents
the crankshaft from turning and may damage the engine.
6
0
ANSWER KEY
No. 1
B
C
A
C
D
No. 2
No. 3
piston rings
20 psi above
compression tester
6
1
ACKNOWLEDGMENT
Technology Teachers:
LINO OLIT
Calapan, Community V.H.S.
ROBERT S. DOMINGO
A.F.G.Bernardino Memorial Trade School-Lias, Marilao, Bulacan
JOHN DIEGO
Isabela SAT
GEORGE CALLANTA
Don A. Roces, Sr. Science Technology High School-Quezon City
ROMEO IBLOGUIN
E.Rodriguez V.H.S.
NELSON SENEDO
Tagum National High School
Contextual Teacher:
BELEN L. TADO
Tagum National High School
Facilitator:
Beatrice A. Adriano
E. Rodriguez Vocational HS
Encoder
Rowena S. Fonacier
6
2
REFERENCES AND FURTHER READING:
6
3
Republic of the Philippines
Department of Education
PUBLIC TECHNICAL-VOCATIONAL
HIGH SCHOOLS
PUBLIC TECHNICAL-VOCATIONAL
1
The unit of competency “Perform Underchassis Preventive Maintenance”
contains the knowledge, skills and attitudes required for Automotive Servicing. This
is one of the common modules for National Certificate level I (NC I).
If you have questions, please don’t hesitate to ask your teacher for assistance.
Your facilitator will always be available to assist you during the training.
You may already have some or most of the knowledge and skills covered in this
module because you have:
been working for some time
already completed training in this area.
If you can demonstrate to your trainer that you are competent in a particular skill
or skills, talk to him/her about having them formally recognized so you don’t have to
do the same training again. If you have a qualification or Certificate of Competency
from previous trainings show it to your trainer. If the skills you acquired are still
current and relevant to this module, they may become part of the evidence you can
present for RPL. If you are not sure about the currency of your skills, discuss this
with your trainer.
After completing this module ask your trainer to assess your competency. Result
of your assessment will be recorded in your competency profile. All the learning
activities are designed for you to complete at your own pace.
Inside this module you will find the activities for you to complete and at the back
are the relevant information sheets for each learning outcome. Each learning
outcome may have more than one learning activities.
At the end of this module is a Learner’s Diary. Use this diary to record important
dates, jobs undertaken and other workplace events that will assist you in providing
further details to your trainer or an assessor. A Record of Achievement is provided
for you by your trainer to accomplish once you complete the module.
1
This module was prepared to help you achieve the required competency, in
performing underchassis preventive maintenance independently at your own pace
with minimum supervision from your facilitator.
Talk to your trainer and agree on how you will both organize the training of this
unit. Read through the learning guide carefully. It is divided into sections which
cover all the skills and knowledge you need to successfully complete this module.
Work through all the information and complete the activities in each section and
complete the self-check. Suggested references are included to supplement the
materials provided in this module.
Most probably your trainer will also be your supervisor or manager. He/she is
there to support you and show you the correct way to do things. Ask for help.
Your trainer will tell you about the important things you need to consider when
you are completing activities and it is important that you listen and take notes.
Talk to more experienced work mates and ask for their guidance.
Use the self-check questions at the end of each section to test your own progress.
When you are ready, ask your trainer to watch you perform the activities outlined
in the learning guide.
As you work through the activities, ask for written feedback of your progress from
your trainer. After completing each element, ask your trainer to mark on the
report that you are ready for assessment.
When you have completed this module (or several modules) and feel confident that
you have had sufficient practice your trainer will arrange an appointment with you
to asses you. The result of your assessment will be recorded in your Competency
Achievement Record.
Before you perform the manual exercises, read the information/operation sheet
and answer the self-check provided to confirm to your self and to your teacher
that you are equipped with knowledge necessary to perform the skill portion of the
particular learning outcomes.
Upon completion of this module ask your teacher, to assess you. You will be given
a certificate of completion as proof that you met the standard requirements
(knowledge and skills) for this module. The assessment could be made in different
methods, as prescribed in the competency standards.
2
QUALIFICATION : AUTOMOTIVE SERVICING NC I
UNIT OF COMPETENCY : PERFORM UNDERCHASSIS PREVENTIVE
MAINTENANCE
MODULE TITLE : PERFORMING UNDERCHASSIS PREVENTIVE
MAINTENANCE
INTRODUCTION:
LEARNING OUTCOMES:
1
Qualification Automotive Servicing NCI
Reference
1. Automotive brake system (shop manual) pp. 53-74
Eichhorn, Lane
1
Are you ready to perform this activity?
2
INFORMATION SHEET No. 1
AUTOMOTIVE CLUTCH
The clutch is located between the engine and the transmission. To engage
and disengage the power transmission from the engine by pedal
operation during gear shifting. The clutch gradually transmit power from
the engine to the drive wheels in order to start the automobile smoothly,
and smoothly change the transmission gears according to the condition
under which the vehicle is traveling.
FLYWHEEL
It is necessary that the clutch disc transmit power smoothly and once it is
engaged, it transmit power continuously without slipping. The clutch disc
must be built in such a way that, when the power is disconnected, this
can be done accurately as well as quickly.
The clutch disc consists of the facing, which is a friction material (usually
it is made of asbestos) riveted onto both side of the disc circumference
and a hub in the center, which receives the input shaft of the
transmission.
Since the clutch cover assembly is fitted to the flywheel of the engine
and rotates integrally with the engine, it must be well-balanced for good
rotation. In addition, it must have good capacity to radiate heat from the
engaged clutch.
Clutch covers are divided in two types depending on the type of springs
used for pushing the pressure plates against the clutch disc: those
having a diaphragm and those with coil springs.
While the diaphragm spring type clutch cover is used frequently today,
the coil spring type clutch cover is also used in some heavy duty
commercial vehicles.
4
Fig. 4 shows the pressure plate assembly
B. TYPES OF CLUTCH
There are two types of CLUTCH, distinguished by the way they are
operated: the hydraulically operated clutch and the mechanically
operated clutch using a cable linkage.
5
HYDRAULIC OPERATED CLUTCH
CLUTCH OPERATION
Disengaging the clutch ( pushing down the clutch pedal down) moves the
pressure plate away from the friction disc. Releasing the clutch pedal
engages the clutch. Spring force clamps the friction disc between the
pressure plate and the flywheel. Then the friction disc and transmission
input shaft turn with the flywheel.
When the driver depresses the clutch pedal, linkage to the clutch fork
causes it to pivot. The fork pushes against the release bearing or throw
out bearing. This forces the release bearing inward against release
fingers or lever in the pressure plate assembly. These pivot pushes the
pressure plate away from the friction
7
Fig. 8 shows the clutch engage
P5MASTER CYLINDER
Fig. 9 shows the parts and the cutaway view of master cylinder
Conditions:
Tools
Rags
Procedure:
Things Needed:
Brake Fluids
Step1
Determine whether your car has a hydraulic clutch.
Step2
Turn the engine off and open the hood.
9
Step3
Step 4
Check the fluid level. The reservoir is usually clear with a small
round rubber cap on the top; it should be filled to the top.
Step 5
Step 6
Replace the cap.
SELF-CHECK LO1-1
What are the types of fluids that have a clear to amber color and are
hygroscopic? _____________________ .
In the master cylinder, the primary piston is the piston that is:
(Choose the correct answer.)
0 directly operated by the pushrod
1 nearest the front-end of the car
2 hydraulically operated by the secondary piston
3 needed only on vehicles with drum brakes
11
Parts of master cylinder that force the piston to return to its released
position faster than fluid can flow back to the master cylinder is called
______________________..
CHECKLIST LO1
OK R A C D T Re Specif
(Repla (Adjus (Clean (Disas (Tight (Repai y
Check
ce) t) ) sembl en) r)
e)
1. Clutch line for
leakage
2. Clutch line for
cracks
3. Clutch line for
twists
4. Clutch line for
bends
5. Clutch line for
loose
connections
6. Clutch line for
restriction
ASSESSMENT CRITERIA:
Brake fluid level is checked and maintained between the minimum
and maximum
Brake lines or hoses are checked and freed from twist and bends
Brake pedal free play is specified
Brake operation is checked and tested as per SOP.
12
Hydraulic fluid is used/changed without spillage and at the
specified level
Brake pedal height/free-play is checked and adjusted
Hydraulic brake system is bled in accordance with brake standards
Emergency brake function is checked
1. Points for adjustment of emergency brake are identified.
Resources
Automotive Mechanics, 10th edition
By: Crouse/ Anglin
Manufacturer’s Manual
Toyota Corporation
Complete: Self-Check #2
Self-Check #2
Refer to Model Answer #2 for the correct answer
on self-check. Model Answer #2
TYPES OF BRAKES
In automobile it has two types of brakes; These are service brakes and
the parking brakes.
SERVICE BRAKES
This type of brakes usually operated by a foot pedal, which slow or stop
the moving vehicle. Most automotive service brakes are hydraulically
brakes. They operate hydraulically by pressure applied through a liquid.
The service or foundation brakes on many medium and heavy-duty
trucks and buses are operated by air pressure these are air brakes.
When the brakes are applied by pushing down on the brake pedal,
a fluid flows through tubes or brake lines to the brake mechanisms at
the wheels. The brake mechanisms apply force on rotating parts so the
wheels are slowed or stopped.
BRAKE ACTION
The service braking system includes two basic parts. These are
the master cylinder and the drum and disc wheel-brake mechanisms.
The master cylinder is a reciprocating-piston pump. It pressurizes the
hydraulic system when the driver depresses the brake pedal. This
converts the mechanical force from the brake pedal into hydraulic force
that applies the brakes at the wheels.
NOTE: Flow of brake fluid to the calipers at the front and to the
wheel cylinder at the rear when the brakes are applied.
OPERATING MECHANISM
1. Master Cylinder
The master cylinder converts the motion of the brake pedal into
hydraulic pressure. It consists of the reservoir tank, which contains
the brake fluid, as well as the piston and cylinder, which generate
the hydraulic pressure.
15
Fig. 3 shows the parts of master cylinder
2. Brake Booster
The force with which the driver steps on the brake pedal would
not be enough to cause the brakes to operate to stop the vehicle
quickly. The brake booster therefore multiplies the driver’s pedal
effort so that a large braking force is created.
The brake booster may be an integral part of the master cylinder
of fitted separately from it. The integrated type is used with
passenger cars and light-duty trucks.
The brake booster consists mainly of the booster body, booster
piston, diaphragm, reaction mechanism and control valve
mechanism.
16
The booster body is divided into the front (constant pressure
chamber) rear (variable pressure chamber) sections, separated from
each other by a diaphragm and booster piston.
The vehicle is broken by friction between the tire and the road.
The friction increases in proportion to the load.
Since the engine is usually in the front of the vehicle, the front is
heavier than the rear. When the vehicle is broken, the center of
gravity of the vehicle shifts forward due to inertia, and even a
greater load is applied to the front.
For this reason, a device is needed that causes more braking
force to be applied to the front wheels than to the rear wheels.
Such a device is called a “proportioning valve” or simply a P
valve. It automatically reduces the hydraulic pressure to the
rear wheel cylinders so that it is less than that to the front, so
less braking force is applied to the rear wheels
17
DRUM BRAKES
The drum brake has a metal brake drum that encloses the brake assembly
at each wheel. Two curved brakes shoes expand outward to slow or stop
the drum which rotates with the wheel. The brake assembly attaches to a
steering knuckle, axle housing or strut-spindle assembly.
18
NOTE:
The construction and operation of front drum brakes are the same as
rear drum brakes. Most vehicles have rear wheel parking brakes.
Backing Plate
The backing plate is pressed steel plate, bolted to the rear axle
housing or rear axle carrier. Since the brake shoes are fitted to the
backing plate, all of the braking force acts on the backing plate.
IMPORTANT
WHEEL CYLINDER
When the driver depresses the brake pedal, brake fluid flows from a
pressure chamber in the master cylinder through brake lines to the wheel
cylinder. It converts the hydraulic pressure from the master cylinder into
mechanical movement. The wheel cylinder has two pistons, with seals or
cups and a spring in between. As the pressure increases, the pistons
overcome the brake-shoe return springs and push the shoe outward into
contact with the drum.
19
Fig. 8 shows the construction of wheel cylinder
20
Brake Drum
The brake drum is generally made of gray cast iron and has a
cross-section such as shown below. It is positioned very close to the brake
shoe without actually touching it and rotates with the wheel.
As the lining is pushed against the inner surface of the drum
when the brake is applied, friction heat can reach as high as 200 0C
(3920F) to 3000 (5720F).
Disc Brake
Fig. 11 shows the brake pad Fig . 12 shows the flow of fluid in fixed
caliper type
21
Fig. 13 shows the flow of fluid in floating caliper type
Disc Rotor
Generally, the disc rotor is made of gray cast iron, and is either
solid ventilated.
The solid type disc rotor consists of a pair of hollow discs to
ensure good cooling, both to prevent fading and to ensure longer pad life.
2. Brake Pad
Fixed caliper type (double pistons) Floating caliper type (single pistons)
The fixed caliper is provided with the pair of pistons. Braking force is
obtained when the pads are pushed hydraulically by the piston against
both ends of the disc rotor.
23
Floating caliper type, the piston is located in one side of the caliper
only.
Fig. 16 shows the floating caliper type Fig. 17 shows the fixed caliper
type
The floating type calipers are further grouped into the following kinds:
F type
FS type
Full-floating type AD type
PD type
Fig. 18 shows the full floating caliper Fig. 19 shows the different
types of rotor
24
PARKING BRAKE
Parking brakes are mainly used for parking the vehicle. Passenger cars
and small commercial vehicles have rear wheel type parking brakes
that shares the brake drums of the service brakes or exclusive parking
brake that are connected to the rear wheels.
Large commercial vehicles use center brake type parking brakes that are
fitted between the propeller shaft and the transmission.
Figure
Fig. 20 shows the parking break lever Fig. 21 shows the parking lever
type with travel
adjusting blot
Fig. 22 shows the two types of parking Fig. 23 shows the parts of the
parking brake brake
25
OPERATING MECHANISM
The operating mechanism is basically the same in both the rear
wheel type parking brake and the center brake type parking brake. The
parking brake lever is located near the driver’s seat. Pulling the parking
brake lever operates the brakes via a cable connected to the lever.
The parking brake lever is provided with ratchet to maintain the
lever at the position to which it was set. Some parking levers have
adjusting screw near the brake lever so the amount of brake lever
travel can be easily adjusted.
The parking brake cable transmits the lever movement to the brake
drum sub-assembly. In the case of the rear wheel parking brake, there is
an equalizer in the middle of the cable to equally divide the lever
operating force to both wheels.
26
Fig. 24 shows the pedal height
1 Loosen the lock nut 3 of the stop light switch and screw out the
stop light switch in few turns.
2 Loosen the lock nut 4 of the push rod 5 and adjust the pedal
height by turning the push rod.
3 Screw in the stop light switch until its pedal stopper lightly
contacts the cushion, and then tighten the lock nut.
IMPORTANT!
Be careful that the pedal stopper of the switch is not touching
the pedal cushion too strongly or the pedal height may be
insufficient.
27
brake booster by pumping the brake pedal until the pedal reserve
distance does not change even with the pedal pressure
IMPORTANT!
If vacuum remains in the booster, the correct free-play cannot be
checked.
(b) Lightly push the brake pedal with your finger until it meets
resistance and measure the pedal stroke.
REFERENCE
The shoe clearance is adjusted differently depending on
the vehicle model and brake type. REFER TO
APPROPRIATE REPAIR MANUAL.
28
Some hydraulic systems require vacuum bleeding. Check your
vehicles service manual for the procedure.
Fill the master cylinder reservoir with clean brake fluid. Check the
fluid level often during bleeding procedure; do not let the reservoir
fall below half full.
2 Crack open the front brake line connection again, purging air
from the cylinder.
29
Fig. 26 Bleeding the Brake System
Proceed to the appropriate wheel first and follow the set sequence
according to the Wheel Bleed Sequence.
Place a transparent tube over the bleeder valve and then allow the
tube to hang down into a transparent container, figure 5. Ensure
the end of the tube is submerged in clean brake fluid.
Crack open the bleeder valve, purging air from cylinder. Retighten
the bleeder screw and slowly release pedal.
Wait 15 seconds and then repeat the preceding bleed steps. Repeat
these steps until all the air is bled from the system.
30
OPERATION SHEET No. 4
Checking Leaks
When external leaks occur, the system loses brake fluid. External
31
leaks are caused by cracks or brakes in master cylinder reservoirs, loose
system connections, damaged seals, or leaking brake lines or hoses.
When the clutch pedal is depressed, hydraulic fluid flows from the
clutch master cylinder to the servo. The fluid pushes the servo piston out
of the cylinder. This moves the release bearing against the fingers of the
clutch plate and disengages the clutch
32
Fig. 27 shows the brake line mounting on the diagonally split
brake system
Brake lines are made of steel. Because they are under the floor
pan, they are wrapped with wire armor to protect them from flying debris.
The ends are flared in either a double flare or an ISO flare. The flare
provides maximum protection against leakage. A short flexible brake hose
or flex hose connects the steel brake lines to the wheel cylinders or
calipers.
CHECKLIST LO2
OK R A C D T Re Specif
(Repla (Adjus (Clean (Disas (Tight (Repai y
Check
ce) t) ) sembl en) r)
e)
1. Brake line for
leakage
2. Brake line for
cracks
3. Brake line for
twists
4. Brake line for
bends
5. Brake line for
loose connections
7. Bleed brake
system
SELF-CHECK LO1
1. What are the two types of leaks in the hydraulic brake system?
33
In a hydraulic system, what causes corrosion or deposits to form in
the bore, resulting in the wear of the cylinder bore or its parts?
SELF-CHECK No. 2
________________________________________________________.
ASSESSMENT CRITERIA:
1. Clutch fluid level and lines are checked
34
Clutch line is checked for cracks, twists, bends, loose and restricted
lines.
Low levels of fluid in master cylinder is refilled to maximum level
Resources
SELF-CHECK LO2-1
36
The diaphragm under the master cylinder cover prevents
___________________________________________ in the
hydraulic system.
Resources :
1. Automotive Transmission-Principles (CD)
37
LEARNING EXPERIENCES / ACTIVITIES
Self-Check #4
38
INFORMATION SHEET
39
Fig. 1 differential component parts
40
41
Fig. 2 a disassembled five speed manual transmission with the
major parts
Fig. 4 power flow through a limited slip differential when making a turn
42
GEAR LUBRICANTS
In the gearbox, the moving metal parts must not touch each other. They
must be continuously separated by a thin film of lubricant to prevent
excessive wear and premature failure.
As gear teeth mesh, there is a sliding or wiping action between the contact
faces. This action produces friction and heat. Without lubrication, the
gears would wear quickly and fail. However, lubrication provides a fluid
film between contact faces. This prevents metal-to-metal contact.
Therefore, all gearboxes have some type of lubricant or gear oil on them.
Gear oil has five jobs to do. These are:
The typical gear oil is a straight mineral oil (refined crude oil) with the
required additives in it. Today, some oils are made from synthetic oil.
Regardless of type, gear oils for use in most cars and light trucks has a
classification SAE 75W, 75W-80, 80W-90, 85W-90, 90, or 140.
43
ATF is also used as the factory fill in some manual transmissions built by
Crysler. If excessive gear rattle is heard in idle or during acceleration in
direct drive or in overdrive gear. ATF may be drained out and the
transmission filled with multipurpose gear oil, such as SAE 85W-90.
Some manual transaxles are also filled with ATF.
To prevent the lubricant from leaking out, the gearbox has an oiltight
case. Seals are used around each cover and shaft. In addition, seals are
provided around the input shafts and the output shafts. The clutch shaft
on many transmissions does not have a separate seal. Instead, an oil
slinger is used to throw back any oil that reaches it. Other designs have a
passage in the clutch-shaft-bearing retainer that returns to the case any
oil passing through the bearing.
SELF-CHECK
Enumerate the types of gear that most cars and light trucks use?
44
LEARNING EXPERIENCES / ACTIVITIES
Oil that is too thick (high viscosity) flows too slowly to engine parts,
especially when the engine and oil are cold. This also causes rapid engine
wear. The engine runs with insufficient oil when first starting. Also, in
cold weather, a high-viscosity oil may be so thick that it prevents normal
45
cranking and starting. A single-viscosity oil (defined below) gets thick
when cold and thin when hot.
46
LUBRICANT CHECK
Lubricant should be level with, or not more than 1/2 inch below the fill
hole. Add the proper grade lubricant as needed using a filler pump.
Manual transmission/transaxle lubricants in use today include single
and multiple viscosity gear oils, engine oils, and automatic transmission
fluid. Always refer to the service manual to determine the correct
lubricant and viscosity range for the vehicle and operation conditions.
47
Fig. 3 shows the drain and filler plug
LUBRICANT REPLACEMENT
VISUAL INSPECTION
Check for lubricant leaks at all gaskets and seals. The transmission rear
seal at the driveline is particularly prone to leakage.
Check the case body for signs of porosity that show up as leakage or see
page of lubricant
48
Push up and down on the unit. Watch the transmission mounts to see if
the rubber separates from the metal plate. If the case moves up, but
not down, the mounts require replacement.
Move the clutch and shift linkages around and check for loose or missing
components. Cable linkages should have no kinks or sharp bends,
and all movement should be smooth.
Please do not attempt this if you do not have the proper equipment and if
you are not confident of your abilities I can accept no responsibility of
you damage your car or hurt yourself.
Basic Steps:
raise one side of the car
49
replace panel
lower car
automobile jack
drain pan
Follow the directions for jacking the car and removing the engine
access panel as described in the oil change instructions.
50
Fig. 5 proper jacking of vehicle
This shows the view looking forward, with the rear support point just under the cross
member that encloses the fuel tank. The gear box is barely visible in the top left of
the picture.Drain the Transmission Gear Oil
51
Fig. 6 shows the drain plug
Locate the drain plug. It is a large hex headed bolt, 24mm, that is at the
lowest point on the transmission casing. You can see the two half
shafts that drive the rear wheels as well as the twin cables that run to
the shift mechanism.
Loosen and remove the fill plug, 17mm (see location below). This will
allow air into the casing as the oil drains out the bottom.
(I loosened the fill plug thinking it will let enough air in during the
draining process. Do not make the mistake of removing the fill plug
while draining. The oil will suddenly come out in a rush. Ask me how I
know! What a mess!)
52
Replace the drain plug and torque to 29 ft-lbs. It is the one with the big
head. The filler and the drain are threaded the same. Do not mix them up
when replacing them.
Carefully note the position of the filler. It is not the bolt holding
the bracket on. It is horizontal and is near the split in the casing.
The filler and the drain are threaded the same. Do not mix them up
when replacing them.
Fill the gearbox with new fluid. This is easily done using a cheap oil
pump specifically for this task. Continue to pump the new fluid into the
hole until you have pumped about two quarts. Then proceed slowly until
the fluid reaches the level of the hole. A small amount will drip out at
which time you should replace the fill bolt.
You can now replace the access panel and lower the car back onto its
wheels as described in the oil change instructions.
SELF-CHECK
1. What is transmission?
2. Identify the component parts of transmission.
53
Give the types of gear oil.
Resources :
1. Automotive Training Manual (step 2) pp 2-16
Mazda
54
LEARNING EXPERIENCES / ACTIVITIES
4. Self-check #6
5. Model Answer #6
Two basic principles are used in all hydraulic power steering systems: (1)
Liquids can be compressed very little, (2) Pressure applied to a liquid
makes it act equally in all directions, so liquids can be used to transmit a
force.
56
Fig. 2 principal components of hydraulic power steering system
57
Interconnecting hoses and a means of driving the pump are also needed.
A V-belt (or belts) is the usual pump drive, and all components are
interconnected to form an oil circuit. Circulation of the oil is continuous
when the engine is running.
Basically, the pump supplies hydraulic fluid under pressure to the control
valve, which directs the fluid to the right or left side of the power cylinder
piston, depending upon the direction of turn being made. The power
cylinder, when actuated by this applied pressure, reduces the amount of
effort required at the steering wheel. Arrangement of the principal
components differs according to installation requirements. Some of these
are shown in the following illustrations.
In the so-called linkage type, the second valve and power cylinder may be
separate parts and mounted separately in the linkage, (a) or they may be
in a single unit known as an in-line unit (b).
In the semi-integral type the control valve is assembled on the steering
gear, and the power cylinder is mounted in the linkage. In the integral
type, the control valve and power cylinders are an integral part of the
steering-gear assembly.
Rack-and-pinion type
The oil pump's control valve structure and operation are basically the
same as the ballnut type, except that the steering gear and power cylinder
coupling are as shown below.
58
Fig. 3 parts of rack-and-pinion type
59
Fig. 4 shows the typical power steering pump
60
FLUID LEAKS - Clean the suspected area, then cycle the wheel from lock
to lock several times. Fluid leakage will not only cause abnormal noises,
but may result in unequal and abnormal steering efforts. If no sign of
leakage are apparent, repeat the wheel cycling process and inspection
several more times. Consult the appropriate section of the service
manual for detailed information about the action necessary to correct
any leaks.
Where two diameters of hose are used on the pressure side, the larger
diameter or pressure hose is at the pump end. It acts as a reservoir and
as an accumulator absorbing pulsations, The smaller diameter or return
hose reduces the effects of kickback from the gear itself. By restricting
fluid flow, it also maintains constant back pressure on the pump, which
reduces pump noise. If the hose is of one diameter, the gearbox is
performing the damping functions internally.
61
Because of working fluid temperature and adjacent engine temperatures,
these hose must be able to withstand temperatures up to 300oF. Due to
various weather conditions, they must also tolerate sub-zero
temperatures as well. Hose material is specifically formulated to resist
breakdown or deterioration due to oil or temperature conditions.
62
Fig. 7 parts of rack-and-pinion power steering system
63
OPERATION SHEET No. 1
Introduction
Checking power steering fluid on most cars is easy, though not all cars
have it: if you can parallel park with one hand and eat an ice cream
cone with the other, then you have power steering.
Tips & Warnings:
Check the fluid level and the power steering belt if you hear a
squeal when you turn the wheel all the way to one side.
Power steering fluid does not get "used up" - other than a leak,
there's no reason that the fluid should be low. Fill the reservoir to
the proper level and check frequently if you find it low. If it
continues to be low, check for leaks and go see your mechanic. An
empty power steering pump can be damaged very quickly and is
costly to replace.
PROCEDURE
Step1
Find the hood release, usually located beneath the dash. Pull.
Step2
Walk around the front of the car. Find the hood latch. The hood latch
is usually located at the front edge of the hood. Depress the latch.
While depressing the latch, lift and open the hood.
Step3
64
Fig. 8 locate the belt of power steering pump
Locate the belts. The power steering pump is driven by a pulley and a
belt and has a clear plastic or metal (usually round) reservoir on top if it.
The power steering cap will often say "power steering."
Step4
Check the fluid level either by looking at the side of the reservoir (if you
have the clear plastic type) or by unscrewing the cap (for the metal type).
Some reservoirs may have a small dipstick attached to the cap. Typically,
you have a choice between checking the fluid warm or cold, and there
will be corresponding "Hot" and "Cold" levels.
65
Step5
Add fluid if necessary. Use only the proper type of power steering fluid for
your car. Check the owner's manual and the bottle. Some cars require
power steering fluid specifically for your make of car.
SELF-CHECK
66
Step to replace fluid level
0 open and drain steering fluid
1 tighten and close power steering drain plug
2 pull-out the power steering pump
3 install power steering pump
Resources :
1. Automotive Technology (manual) pp. 79-81
67
LEARNING EXPERIENCES / ACTIVITIES
68
INFORMATION SHEET
69
DISASSEMBLED VIEW (1)
70
DISASSEMBLED VIEW (2)
71
HYDRAULIC SYSTEM
Functions of the Hydraulic System
Fluid Pressure
Piston
Clutch Patches
Plates
Fluid Pressure
Function
Planetary gear set with clutch engaged. One set of clutch plates is splined
to the sun-gear drum. The other set is fixed to the planet-pinion carrier.
When fluid pressure from the pump acts on the apply side of the clutch
piston (as shown), the clutch plates are forced together. This locks the
sun gear to the planet carrier and the planetary gear set rotates as a
single unit.
NORMAL MAINTENANCE
FLUID CHECKS
A check of the fluid level, color and conditions should be made at every
change of engine oil. To check the fluid level, drive the vehicle for 15
minutes or until the engine and transmission are at normal operating
temperature. Park the vehicle on level ground and firmly apply the
parking brake. Let the engine idle. Place the transmission selector lever in
park (or NEUTRAL, if specified by the manufacturer).
Clean any dirt from around the dipstick cap. Pull out the dipstick, wipe it,
reinsert it, and pull it out again. Note the fluid level on the dipstick.
Touch the fluid on the end of the dipstick to get an indication of fluid
temperature. If the fluid feels cool, the fluid level should be on the low
side of the dipstick. If the fluid level feels warm or hot, (too hot to hold),
the dipstick level should be on the high side.
73
CHECKING FLUID COLOR
74
As the towel absorbs the fluid, examine the stain for specks or particles.
This indicates solid material in the fluid. If the stain spreads and is red or
light brown in color, the fluid probably is good. If the stain is dark and
remains small, the fluid is oxidized and should be changed. Oxidized
fluid has combined with oxygen in the air and no longer has its original
properties.
75
OPERATION SHEET No.
CHECKING FLUID LEVEL IN AUTOMATIC TRANSMISSION
Instructions
With some cars the engine should not be running while you check
the fluid, so be sure to consult your owner's manual.
ATF doesn't get used up, so if it's low, that indicates a leak. Don't
ignore leaks or drive around with low ATF since it can lead to
expensive transmission repairs.
SELF-CHECK
Resources :
76
NISSAN DIESEL ENGINE Repair manual
(model PD and PDT)
77
After performing the first activity, you can now do
the second activity.
1.1 proper use of personal protective equipment Change from vapor to liquid.
(PPE)
1.2 hazards in bleeding air tank.
78
The air brake system consists of three sub-systems; the air supply
system, the air delivery system, and the parking/emergency air brake
system. The components making up the brake system of each vehicle
may differ, but all systems operate in basically the same manner.
All models use a vertically split brake system. If a failure occurs in the
front brake system, the rear brake system will continue to operate
and give reduced stopping capability until the air supply is depleted.
In the event of a failure in the rear system, the relay valve modulates
application of the rear spring brake units and the front brakes continue to
function.
The air reservoirs are equipped with manual drain valves and/or an
automatic moisture ejector valve which can be drained for the removal of
moisture from the air brake system.
PARKING/EMERGENCY SYSTEM
The parking brake system is composed of a parking brake control valve, a
relay or double check valve (tractors), quick release valves and spring
brake chambers. The spring brake chambers use a powerful spring to
mechanically apply the brakes when air pressure is not available
(provided the brakes are properly adjusted).
Air pressure releases the spring brake chamber when the vehicle is
moving. The air pressure is delivered to the spring chamber by a relay
valve or a double check valve which is controlled by an air pressure signal
from the control valve on the instrument panel. The relay valve or double
check valve also functions to prevent the application of the spring brakes
and service brakes at the same time thus preventing brake system
damage.
Air pressure from the reservoir to the reservoir port of the governor forces
the piston to overcome the resistance of the pressure setting spring. (The
piston and the inlet and exhaust valve move up when reservoir air
pressure reaches the governor cut-out setting.) The exhaust steam seats
on the inlet and exhaust valve thus opening the inlet passage. Reservoir
air pressure then flows by the open inlet valve, through the passage in the
piston and out the unloader port to the compressor unloading
mechanism.
As air pressure in the reservoir drops to the governor cut-in setting, the
force exerted by air pressure on the piston will be reduced so that the
pressure spring will move the piston downward. The inlet valve will close
and the exhaust valve will open. With the exhaust valve open, air in the
80
unloader line will escape through the exhaust stem and out the exhaust
port.
SAFETY VALVE
The Safety Valve protects the air
brake system against excessive air
pressure build up. The safety valve
consists of a spring loaded ball valve
subjected to reservoir pressure
which will permit air to exhaust the
reservoir pressure to the atmosphere
if reservoir pressure rises above the
valve pressure setting which is
determined by the force of the spring. A safety valve setting of 1034 kPa
(150 psi) is used and is not adjustable.
Should system pressure rise to approximately 1034 kPa (150 psi) air
pressure would force the ball vent off its seat and allow reservoir pressure
to vent to the atmosphere through the exhaust port in the spring cage.
When reservoir pressure decreases sufficiently, the spring force will seat the
ball check valve, sealing off reservoir pressure. This occurs at 930 kPa (135
psi) for the 1034 kPa (150 psi) setting. It is important to note that the desired
pressure setting of the safety valve is determined by the governor cut-out
pressure. The opening and closing pressures of the safety valve should
always be in excess of the governor cut-out pressure setting. The pressure
setting is stamped on the lower wrench flat of the valve.
Normally, the safety valve remains inoperative and only functions when
reservoir pressure rises above the setting of the valve. Constant 'popping
off' or exhausting of the safety valve can be caused by a faulty safety
valve, governor compressor unloader mechanism, or a combination of any
of the preceding items.
AUTOMATIC MOISTURE
EJECTOR
VALVE (Typical)
The Automatic Moisture
Ejector Valve (Fig. 4) expels
moisture and contaminants
from the air system reservoir.
81
It operates automatically from ascending and descending reservoir
pressures and
requires no control from other sources. The automatic moisture ejector
valve may be drained manually by depressing the stem wire located in the
exhaust port.
The elector valve has a die cast aluminum body and cover, and is
mounted in the bottom or lower end port of the air system reservoir.
Automatic Moisture Ejector Valve
With no air pressure in the system, the inlet and exhaust valves are
closed. Upon charging the air system, a slight pressure opens the inlet
valve which permits air and contaminants to collect in the sump. The
inlet valve remains op
The length of time the exhaust valve remains open and the amount of
moisture and contaminants ejected depends upon the sump pressure and
the reservoir pressure drop that occurs each time air is used from the
system.
To drain the valve manually, use a tool to move the wire in the exhaust
port upward and hold it in until draining is completed to 0 kPa (0 psi).
AIR GAUGE
Air Brake systems are dual circuit type which provides an emergency
brake system, primary or secondary service circuit, should a failure occur
in any part of the brake system. The air gauge provides a direct reading of
each service system's air pressure.
82
PRESSURE PROTECTION VALVE -- PR-3
The pressure protection valve is a normally closed, pressure control valve
which can be referred to as a non-exhausting sequence valve. An example
would be in an air brake system to protect on reservoir or reservoir
system from another, by Closing automatically at a preset pressure
should a reservoir system failure occur. The valves can also be used to
delay filling of auxiliary reservoirs to ensure a quick build-up of brake
system pressure. Air entering the supply port is initially prevented from
flowing out the delivery port by the inlet valve which is held closed by the
pressure regulating spring above the piston.
When sufficient air pressure builds beneath the piston to overcome the
setting of the regulating spring, the piston will move, causing the inlet
valve to unseat (open), and allow air to flow out the delivery port. As long
as air pressure at the supply port and beneath the piston remains above
the specified closing pressure, the inlet valve will remain open.
The single check valve is located in the air line from the supply tank to
83
each reservoir. It allows air to flow in
one direction only and prevents the flow
of air in the reverse direction. Air flow in
the normal direction moves the check
valve disc from its seat (Fig. 6), and the
flow is unobstructed. Flow in the
reverse direction is prevented by the
seating of the disc, which is caused by a
drop in the up-stream all pressure and
assisted by the spring.
Relay
Piston
Return Spring
modulating valve R-
The front brakes are supplied directly from the foot control valve.
84
RELAY VALVE TYPE R-6
The brake chamber assembly consists of two separate air chambers, each
with its own diaphragm and push rod. The service brake chamber applies
the brake by air pressure and releases it by spring pressure when air is
exhausted. The parking or emergency brake is applied by spring pressure
and is released by air pressure.
Diaphragms should be replaced every 80,000 km (50,000 miles) or every
12 months. Compressed air, admitted to the brake chamber, enters the
chamber behind a dLm3hraoPa which forces the push plate and push rod
outward. On cam-type air brakes, the outward movement of the push rod
rotates the slack adjuster which rotates the
brake camshaft and cam, forcing the shoes
against the drum. Air pressure delivered to
the air chambers (delivered through the inlet
port) acts on the diaphragm, thus moving
the push rod and plate. The amount of force
coming from the chamber is equal to the air
pressure multiplied by the effective area of
the diaphragm.
This force is proportional to the air pressure
delivered to the chambers.
WARNING: The very strong spring in these units is highly compressed and
can cause
serious, even fatal, injury if the spring is released without control. Do not
remove chamber clamp before the spring is caged. Install release tool in
spring plate and tighten down to cage the spring.
Manual Release
The spring pressure can be wound-
off, by a threaded bolt on each
spring chamber, to allow the
vehicle to be moved in an
emergency, when there is a system
failure or low air pressure, or to
dismantle the brakes for repair.
When the parking brake is 'OFF'
the service brake part of the
actuator will operate normally for
service brake application.
CAUTION: The only braking available with the system in this condition
is by the park brake control. Use only to move the vehicle to safety.
87
DOUBLE CHECK VALVE
Double Check Valves are used in an air
brake system to direct a flow of air into a
common line from either of two sources,
whichever is at the higher pressure. They
may be used for directing air flow for
specific functions or to select the higher
pressure of either of two sources of air as
a supply source.
It is used with the tractor hand control
valve to allow either foot brake control or
hand brake control valve applications of
the trailer brakes.
The double check valve operates as
follows: air under pressure enters either
end of the double check valve (supply
port). The moving shuttle responds to the
pressure and seals the opposite port,
assuming it is at a lower pressure level
than the other. The air flow continues out
the delivery port of the double check
valve.
Trailer brake system. When the control valve is in the manual position air
supply to the trailer system is cut off. When the control valve is placed
in the automatic position air supply to the trailer system is shut off
should there be a sudden drop in air pressure on the trailer side of the
primer mover or tractor protection manifold, as with a trailer
breakaway.
89
Assessment Criteria: 1. Tire inspected for unwanted solid object.
Tire inspected for wear and deformities in accordance
with manual.
Cause of abnormal tire wear determined.
Tire pressure check in accordance with manufacturer’s
specification.
Resources :
1. Automotive Mechanics 1oth edition, pp. 749-753
Crouse-Anglin;
90
You've encountered problems while
inspecting/bleeding air tank, haven't you?
Self-Check 8
91
After performing the first activity, you are now
going to inspect tire for wear and deformities in
accordance with manufacturer's manual.
Read: Resource on causes of tire wear and The Automotive Drive Trains
deformities. and Chassis Unit, Felizardo
Y Francisco, pp. 118-121
Perform correct procedures in inspecting tire for
wear and deformities considering proper use of
personal protective equipment, proper handling
of tools and equipment.
Modern Technical Physics,
In inspecting tire, determine causes of abnormal Arthur Bieser, pp. 382-388
tire wear. Matter and Chemistry, pp.
3.1 Read: 106-107
0 ideal gas flow
1 polymers
92
INFORMATION SHEET No. 1 Checking Tire and Tire Pressure
Purpose of Tires
93
make turns without skidding.
Types of Tires
There are two types of tires and tubeless. Tube tires have an inner tube
inside the tire. This is a round rubber container that holds the air which
supports the vehicle. Both the tube and tire mount on the wheel rim. The
tire valve is part of the tube and protrudes through the rim. Compressed
air is forced through the valve to inflate the tube. The air pressure in the
tube then causes the tire to hold its shape. Tubes are used in some truck
and motorcycle tires. Tubes are seldom used in passenger and light-duty
vehicles. Most automotive vehicles use tubeless tires. The tire mounts on
an airtight rim so air is retained between the flange and the tire bead.
Tire Construction
The tire casings for tube and tubeless tires are made in the same way.
Layers of cord or plies are shaped on a form and impregnated with
rubber. The tire sidewall and treads are then applied. They are vulcanized
in place to form the tire. To vulcanize means to heat the rubber under
pressure. This molds the tire into desired form.
The number of cord layers or plies varies. Passenger-car tires have 2, 4, or
6 plies. Heavy-duty truck and bus tires may have up to 14 plies. Tires for
heavy-duty service, such as earth-moving machinery, may have up to 32
plies.
All tires do not have the same shape or profile. The aspect ratio or profile
ratio differs. This is the ratio of a tire's section height to section width.
Three aspect ratios are 80, 70, and 60. The lower the number, the wider
the tire appears. A 60-series tire is only 60 percent high as it is wide.
All new cars and most light-duty vehicles have radial tires. The radial-tire
sidewall is more flexible than the bias-ply. Therefore, the radial tire tread
wraps around the edge of the tire to compensate for the flexible sidewall.
The result is that the radial tread does not hell up as much when the
vehicle rounds a curve. This keeps more of the tread on the road and
reduces the tendency of the tire to skid.
The radial tire provides better fuel economy than a bias-ply tire. This is
because the radial has less rolling resistance and less engine power is
required to roll the tire. The radial also wears more slowly. It has less heat
buildup and the tread does not squirm as the tire meets the road.
94
Some bias-ply tires are belted. These tires are bias-ply tires to
which stabilizer belts have been added under the tread.
Tire Tread
Tire tread is part of the tire that meets
the road. It has a raised pattern
molded into it. There are many
designs, depending on the intended
use of the tire. Many passenger
vehicles use mud-and-snow tires.
These can be identified by M+S or
M&S molded into the sidewall. They
provide quiet running with good traction in mud and snow.
Mud and snow tires are used on four-wheel-drive pickup trucks. Its tread
pattern is deeper and wider or "more aggressive" than normal tread
designs. This provides better mud-and-snow traction with acceptable
wear on paved surfaces. The tread compound is also designed to resist
tearing and chunking.
The treads shown are symmetric and nondirectional. "Nondirectional"
means the tire can run equally well in either direction. The tire can be
installed with either sidewall facing out. The tire must be installed for
forward rotation in the direction of an arrow on the sidewall.
Directional and asymmetric sports car tread are used as the rear of the
Chevrolet Corvette. "Asymmetric" means the inside half of the tread is not the
same as the outside half. The tire is installed on the side of the car marked
on the sidewall, and with the specified direction of forward rotation. This tire
provides better braking and handling characteristics than a comparable
symmetric, nondirectional tire. Different size tires are used at the front and
rear of the Corvette. As a result, each tire is position specific. It can run only
in a specified wheel-position on the car. Other tires are classified as snow
tires, studded tires, and off-road tires. Snow tires have large rubber cleats
that cut through snow to improve traction. 95
Studded tires have steel studs that stick out above the tread. These
improve traction on ice and snow. However, many states regulate or ban
studded tires because of possible damage to the road surface. A variety of
off-road tires are available. These often have tread patterns
using knobs or cleats. Off-road tires usually make noise and wear
prematurely when driven on the highway.
96
Some tires use two different
compounds in the tread. Con
compound is softer than the other
for improved traction. In general,
the softer the compound, the
better the traction. The harder the
compound, the longer the tread
life.
Tire Valve
Air is put into the tire or tube
trough a spring-loaded tire valve
or Schrader valve. On tube tires,
the valve is on the inner tube and
sticks out through a hole in the
rim. Tubeless tires use a separate
tire valve mounted in a hole in the
rim.
Spring force and air pressure hold
the tire valve in its normally-
closed position. A cap is usually
threaded over the valve stem end
to protect it from dirt. The cap
also keeps guard against air
leaks. Some tire valves have a
non-movable valve core. The core
is three-pronged white plastic. A
special deflator is required to let
air out of the tube.
Tire pressure
The amount of air pressure in the
tire depends on the type of tire
and how it is used. Passenger-car
tires are inflated from about 22 to
36 psi (152 to 248 kPa).
Heavyduty tires for trucks and
buses may be inflated to 100 psi
(690 kPa). The maximum inflation
pressure is marked on the tire
sidewall. A tire placard or tire
information label lists the
97
recommended inflation pressure for each tire. This label is usually located
on a door edge or door jamb, or inside the glovebox door. The label also
lists maximum load and tire size (including spare). Running the tires at
the specified pressure helps provide better vehicle handling while avoiding
premature tire wear. Underinflated tires wear on the outsides of the tread.
Also, the tires flex excessively which produces extra heat and more rapid
wear. Overinflation causes the center of the tread to wear. The tire cannot
flex normally and this puts stress on the sidewalls and plies.
TIRE INSPECTION
Cautions for Servicing
Tires
Several cautions must be
followed to avoid personal
injury and to prevent
damage to the wheel and
tire.
Matching tire and wheel
width. Do not try to
install a narrow tire with
a high-aspect ratio on a
wide rim. For example, a
tire with an 80 aspect
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ratio must not be installed on a wide rim that requires a 60 tire.
Matching tire and wheel diameter. Do not try to mount a 16-inch tire
on a 16.5-inch wheel, or a 15-inch tire on a 15.5-inch wheel. The
result could be a deadly explosion when inflating the tire. Check the
rim size. It may be stamped near the center of the wheel disc.
Mixing tires. All tires on a vehicle should be the same size, construction
(radial or non-radial), and speed rating unless otherwise specified by
the vehicle manufacturer. If two radials and two non-radials are on the
vehicle, put the radials on the rear. Snow tires should be installed in
pairs on the drive axle (either front or rear), or on all four wheels.
Never put non-radial (bias or belted-bias) snow tires on the rear if
radials are on the front. Match tire sizes and construction on four-
wheel drive vehicles. Tires affect vehicle stability and handling. Mixing
tires may cause handling problems.
Protecting your eyes Wear eye protection (safety glasses, safety goggles, or
a face shield) when demounting and mounting tires. When deflating a
tire, avoid the air stream from the tire valve. The air comes out at high
speed and can blow dirt or debris into your eyes.
Tire Inspection
The purpose of inspecting tires is to determine if they are safe for further
use. When defects or improper wear patterns are found, inform the driver.
Recommend the services that will correct the cause of the abnormal wear.
Tires have tread-wear indicators or wear bars. These are filled-in sections
of the tread grooves that will show when the tread has worn down to
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1/16 inch (1.6 mm). A tire with a wear bar showing is worn out and
should be replaced. Too little tread remains for continued safe driving. A
tread-depth gauge can be inserted into the tread grooves to measure tread
depth of at least 1/32 inch (0.8 mm) in any two adjacent grooves at any
location on the tire.
Check for bulges in the sidewalls. Bulges mean plies have separated and
the tire could fail at any time. Tires with separated or broken plies should
be replaced.
Examine the sidewalls and tread area of each tire in turn. Check for
cuts, tears, and lumps, bulges, separation of the tread, and
exposure of the ply or cord. Check that the tire bead is correctly
seated on the wheel rim, that the valve is sound and properly
seated, and that the wheel is not distorted or damaged.
Check that the tires are of the correct size for the vehicle, that they are
of the same size and type on each axle, and that the pressures are
correct.
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Check the tire tread depth. The legal minimum at the time of writing is
1.6mm over at least three-quarters of the tread width. Abnormal
wear may indicate incorrect front wheel alignment.
SELF-CHECK
Technician A says the lower the aspect ratio the wider the tire appears. Technician
B says aspect ratio is the ratio of the tires section height to section width.
Who is right?
0 A only
1 B only
2 both A and B
3 d. neither A nor B
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All the following are true about radial tires except-
0 all plies run parallel to each other
1 there is less squirm than with bias-ply tires
2 a belt steel mesh or other material is applied over the plies
3 a radial tire has greater rolling resistance than bias plies
Recommend inflation pressures for the front and rear tires on the car are listed in the-
0 VECI label
1 tire information label
2 VIN number
3 sidewall markings
If two radials and two non-radials are on the vehicle, the radials should be-
0 on the front c. removed from the vehicle
1 on the rear d. inflated to a higher pressure
Assessment Criteria: 1. Body bolts and nuts inspected for tightness and
damage.
Cross member bolts and nuts checked for tightness.
Transmission mounting bolts and nuts checked.
Propeller shaft bolts and nuts checked for tightness
and damage.
Leaf spring shackle center bolts and nuts checked for
tightness and damage.
Resources :
1. Automotive Mechanics 10th ed; Crouse- pp. 58-69
Anglin; pp. 38-47
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LEARNING EXPERIENCES / ACTIVITIES
4. Self Check 9
Screw Threads
A fastener that has a spiral ridge, or screw thread, on its surface is a
threaded fastener. This includes bolts, screws, studs, and nuts.
Bolts and screws are lengths of rod with a head on one end and threads
on the other. A stud looks like a headless bolt with threads on one or both
ends. Bolts, screws. And studs have external (outside) threads, Nuts and
threaded (or tapped) holes have internal (inside) threads.
Screws, bolts, studs, nuts, and tapped (threaded) holes are manufactured
with either US customary (USC) or metric screw threads. They are not
interchangeable. A USC screw will not fit a metric tapped hole.
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And a metric screw will not fit a USC tapped hole. Some cars have metric
fasteners.
Others have USC fasteners. Some have both. To work on a variety of cars,
you need new fasteners of both types available. In addition, your tools
must include both USC and metric sockets and wrenches.
When you are doing a service job, you must use the correct screw, bolt,
or nut. A 1/4-inch screw can have 20, 28, or 32 threads per inch. You
cannot use a 20-thread (coarse) screw in a 28-thread (fine) hole.
METRIC SCREW THREADS
Metric bolts, screws, and threads are measured in millimeters. Thread
pitch is the distance between individual threads. A pitch may run from
1 to 2 mm as the diameter of the threads increases. A bolt with a basic
thread diameter of 6 mm has a pitch of 1 mm. A bolt with a thread
diameter of 16 mm has a pitch of 1 mm.
104
The table shows typical applications for bolts or screws of different
strength. The minimum tensile strength is the pull in pounds that a
round rod with a cross section of 1 square inch can stand before it
break apart. Higher-strength bolts and screws are more expensive. They
are used only where the
added strength is needed.
Nuts
The hex nut is the most common in the automotive shop. The slotted
hex and the castle nut are used with a cotter pin
Thread Pitch
½ inch
Grade Bolt
Marking Diameter
Collage -13 per
inch
Fine
Extra Pitch
105
OPERATION SHEET No. 1
Checking Underchassis
106
Shock Depress each corner of the vehicle in
absorbers turn, then release it. The vehicle
should rise and then settle in its
normal position. If the vehicle
continues to rise and fall, the shock
absorber is defective.
A shock absorber which has seized will
also cause the vehicle to fail.
SELF-CHECK
Select the one correct, best, or most probable answer to each question.
You can find the answer in the section indicated at the end of each
question.
Technician A says the more lines there are on the head of a USC bolt,
the stronger the bolt. Technician B says the higher the number of
the head of a metric bolt, the stronger the bolt. Who is right?
0 A only
1 B only
2 both A and B
3 neither A nor B
107
Bolts that are tightened by measuring how much head is turned
are:
0 prevailing-torque fasteners
1 torque-to-yield fasteners
2 used with a cotter pin
3 self-tapping setscrews
108
ANSWER KEY LO1-1
Brake fluid
a. DOT 3
0 DOT 4
c. DOT 5
DOT 4
DOT 5
a. DOT 3 b.
DOT 4
Letter a
Return springs
10.
locking
primary piston assembly
secondary seal
secondary piston
primary seal
spring retainer
spring
cylinder body
proportioner with O' ring
quick take-up valve
grommet
fluid level switch
reservoir
diaphragm
reservoir cover
2 moisture or dirt
109
b. vacuum brake booster
0 release button
1 parking brake lever
2 parking brake cable
3 rear drum brake
4 service brake pedal
5 brake light switch
6 front disc brake
7 master cylinder
8 dual proportioning valve
9 brake lines
110
ANSWER KEY No. 3
An assembly of gears that provides the different gear ratios as well as neutral
and reverse, through which engine power is transmitted to the final drive to
rotate the drive wheel.
2.
111
ANSWER KEY
Chemical additives
b. SAE 75W
0 75W-80
1 80W-90
2 85W-90
0 A
1 A
2 A
3 A
4 C
112
Parts of an Automatic Transmission
Pull out the dipstick, wipe it, reinsert it, and pull it out again. If fluid feels cool, the
fluid level should be on the low side of the dipstick. If fluid feels warm or hot
(too hot to hold) the dipstick level should be on the high side.
Fluid level will vary under normal operating conditions as much as ¾ inch (19
mm) from cold to hot.
113
B
114
REFERENCES AND FURTHER READING
115
ACKNOWLEDGMENT
Technology Teacher:
Jonathan O. Diaz
TVE-Automotive-Technology Coordinator
San Pedro Relocation Center National High School
Langgam, San Pedro, Laguna
Robert S. Domingo
Teacher I
AFG Bernardino Memorial Trade School
Lias, Marilao, Bulacan
Lino A. Olit
Teacher I
Community Vocational High School
Masipit, Calapan City, Oriental Mindoro
Arpil P. Medrano
Teacher I
Tanza National Trade School
Paradahan I, Tanza, Cavite
George C. Callanta
Don Alejandro Roces, Sr. Science-Technology High
School Quezon City
116
John Diego
Isabela School of Arts and Trades
Isabela
Robert Domingo
AFG Bernardino Malolos Trade School
Malolos, Bulacan
Lino Olit
Calapan Community Vocational HS
Calapan Mindoro
Romeo Ibloguin
E. Rodriguez Vocational HS
Sta. Mesa, Manila
Nelson Señedo
Tagum National High School
Tagum, Davao del Norte
ACADEMIC WRITERS:
Araceli T. Bondoc
Head Teacher III (ENGLISH)
A.J. Villegas Vocational High School
Division of City Schools, Manila
Romhel C. Odtohan
Teacher I (ENGLISH)
AFG Bernardino Memorial Trade School
Lias, Marilao, Bulacan
Helen U. Divina
Teacher I (SCIENCE)
General Mariano Alvarez Technical High School
Poblacion V, GMA, Cavite
117
Belen P. Caldez
Head Teacher VI (MATH)
E. Quirino High School
Division of City Schools, Manila
English:
Belen Tado
Facilitators:
Encoder:
Rowena S. Fonacier
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