MINISTRY OF EDUCATION

TECHNICAL COLLEGE OF FIJI

NATIONAL CERTIFICATE IN AUTOMOTIVE

MECHANIC (LEVEL 2)

UNIT CODE: AU00011

UNIT NAME: DESCRIBE MOTOR VEHICLE SAFE
MOTORING REQUIREMENTS AND THE GENERAL
LOCATION OF SYSTEMS AND LOCATION.
TRIMESTER 1 – LEVEL 1

LECTURER : MR MONIL KUMAR

To own/buy a vehicle you need to know
Vehicle Information/Details
– Make - name of company that produce e.g.
Toyota, Daihatsu, Suzuki, and Mitsubishi.
– Model- eg A.E.100, AE102.G102, and many
more.
– Year of Registration.eg1991, 2000, 2004.
– Registration Number,AT534,BR466,DQ416
ET327, LT 3484 , LM 345
– Vehicle Identification Number VIN.
– Color –grey, blue, lime green, etc.
LOCATION OF A REGISTRATION NUMBER
 DISTINGUISHING FEATURES
• 1.5 L petrol engine/ diesel engine
• Number of doors 2, 4, 5 etc
• Types of tyres , 165/65r14 etc
• Type of windows either electric or manual
operated
• Type of locking system either central locking
system or manually locking system
• Type of brake system, abs, disc and drum
brake
• Type of steering system, power steering,
manual steering system.
• Type of drive, front wheel drive, rear wheel drive
• Type of transmission, automatic or manual
transmission.
• Type of body shape
 ROADWORTHINESS
• is preparing your vehicle to its best condition
and performance physically
VEHICLE REGISTRATION
ROAD FUND LICENCED/WARRANT OF
FITNESS
• This is the car tax which covers either 6month
or one year. The tax plate issued upon
payment, and be displayed on the car
windscreen.
 WARRANT OF FITNESS

A compulsory test to ensure that motor vehicles

meet required safety standards.
‘my car is booked for a warrant of fitness
tomorrow’
• A document certifying that a vehicle has
passed the warrant of fitness test.
• ‘the car was not to be driven again until it had
a current warrant of fitness’
CURRENT WARRANT OF FITNESS
VALID THIRD PARTY INSURANCE
PUBLIC TRANSPORTATION\RECORD BOOK.
A CURRENT DRIVING LICENSE
 DRIVING LICENSE
• A LEARNERS DRIVERS have a provisional license
and must display L-Plates. A qualified driver must
accompany him. A full license may be obtained
on demand once the driver passed his driving
test.
• His detailed will be filled in a form such as name,
age, address, physical health etc. If the driver
commits a driving offence the license may be
endorsed if three or more endorsement are made
the license will be withdrawn.
 SAFETY CHECK BEFORE DRIVING A VEHICLE
• Check that the vehicle is sitting square and not
leaning to one side.
• The hazard lights are working.
• Check that the driver’s mirrors
• Check the wheels are in good condition
• correctly inflated tyres should have sufficient tread
• Is the exhaust secure?
• Check the fuel tank cap
• and check that all required lights, reflectors and
markings are fitted, clean and in good condition.
• number plates
• Check the door and mirrors
• Check the windscreen washer reservoir cap
• check the engine fluid levels.
• any signs of fluid leaks such as oil or coolant.
• Check the wipers
• Check that valid tax, or VIN
• the seat and steering wheel
• Check that all instruments, gauges and warning
devices
• Check the foot brake and parking brake
 VEHICLE REGISTRATION
Renew Your Vehicle Registration
• Vehicle registration should be valid in order
for you to drive on the road. If you are caught
driving a vehicle with expired registration,
your vehicle can be seized and you will have to
pay a hefty penalty.
• Vehicle registration should be renewed before
the expiry date. Below are the procedures on
how you can renew your vehicle registration:
 VEHICLE REGISTRATION
Pre – requisites (Prior Condition before
Application)
• 1.If your vehicle registration is expired, you
will need to get a permit to drive first.
• 2.Pay all your convicted TIN’s.

Checklists (What to bring)

• 1.Renew your 3rd Party insurance and carry
with you when at the counter.
 VEHICLE REGISTRATION
Fees
1.0 Inspection Fees (Private) $​​13.74
1.2 Inspection Fees ( PSV) $​26.07

2.0 Issuance of Inspection certificate (Private) $​13.74

2.1 Issuance of Inspection certificate (PSV) $​26.07

3 .0 Annual Registration ranging from $​43.60 - $​328.41

depending on the size of engine

4.0 Road User Levy ranging from $​3.79 - $​109.00

depending on the size of engine

5.0 Arrears Fees (Accumulated if your vehicle is expired)

ROAD CODE
ROAD SIGNS
VEHICLE COMPONENTS AND SYSTEM
LAYOUTS
Engine
Engine Block
• cylinders are bored in the cylinder
block.
• block is the largest single part of the
engine
• contains passages for the engine
coolant called water jackets
• also contains oil galleries.
Cylinder Head
Cylinder Head
• The Inlet and Exhaust Valves open and close
to:

• Let air and fuel in to the cylinders (inlet valves)

• Let exhaust gasses out of the cylinders
(Exhaust valves)
• Seal the combustion chamber during the
compression and power strokes.
Cylinder Bore
• The cylinder block is initially cast with sand
cores occupying the cylinder spaces. After the
sand cores have been removed, the rough holes
are machined with a single-point cutting tool
attached radially at the end of a rotating bar.
The removal of the unwanted metal in the hole
is commonly known as boring the cylinder to
size. Thus the finished cylindrical hole is
known as the cylinder bore, and its internal
diameter simply as the bore or bore size.
Crankshaft
Crankshaft
• The crankshaft rotates in the lower
part of the cylinder block.
• It turns on plain bearing shells.
Camshaft & Valve Train
 Camshaft & Valve Train
• The inlet and exhaust valves are opened by the
camshaft, which is driven from the crankshaft by
gears, chains or a toothed belt.
• The camshaft rotates at half the speed of the
crankshaft. Note the camshaft gear is twice the
size of the crankshaft gear.
• On some engines the camshaft is located in the
cylinder block and is driven by a chain and
sprockets.
• Some engines have overhead camshafts that are
located on top of the cylinder head and are usually
driven by a toothed belt.
 External Components Of An Engine

1. Fan 2.Viscous Coupling 3. Water Pump 4.Spark Plug 5.Timing-belt Cover 6.Spark Plug Connector
7. Throttle Body 8. Intake Manifold 9. Rocker Cover 10. Spark Plug Cables 11. Distributor 12. Cylinder Head
13. Exhaust Manifold 14. Exhaust Pipe 15. Cylinder Block 16. Crankcase 17. Oil Pan 18. Oil Filter 19. Oil
10-33
Pressure Switch 20. Timing Belt
Crankcase
• This is a cast rigid structure which supports
and houses the crankshaft and bearings. It is
usually cast as a mono-construction with the
cylinder block.
Sump
• This is a pressed-steel or cast-aluminum-alloy
container which encloses the bottom of the
crank-case and provides a reservoir for the
engine's lubricant
Piston
• This is a pressure-tight cylindrical plunger
which is subjected to the expanding gas
pressure. Its function is to convert the gas
pressure from combustion into a concentrated
driving thrust along the connecting-rod. It
must therefore also act as a guide for the
small-end of the connecting-rod
Piston Rings
• These are circular rings which seal the gaps
made between the piston and the cylinder,
their object being to prevent gas escaping and
to control the amount of lubricant which is
allowed to reach the top of the cylinder.
Gudgeon-pin
• This pin transfers the thrust from the piston to
the connecting-rod small-end while permitting
the rod to rock to and fro as the crankshaft
rotates.

Connecting-rod
• This acts as both a strut and a tie link-rod. It
transmits the linear pressure impulses acting
on the piston to the crankshaft big-end journal,
where they are converted into turning-effort.
Valves
• These engine parts allow for fuel and air to
enter the combustion chamber and later let the
exhaust They remain sealed during the
combustion process and only open when
required.

Connecting Rod
• The connecting rod connects the piston to the
crankshaft. As the piston moves up and down due to
the controlled explosions, it causes the connecting
rod to move. This then cause the crankshaft to move
as well as it is connected to the connecting rod, in a
circular motion due to the configuration of the
piston, connecting rod and crankshaft.
 CHASSIS FRAME AND BODY

• Chassis is a French term and was initially used

to denote the frame parts or Basic Structure of the
vehicle. It is the back bone of the vehicle. A vehicle
with out body is called Chassis. The components
of the vehicle like Power plant, Transmission
System, Axles, Wheels and Tyres, Suspension,
Controlling Systems like Braking, Steering etc.,
and also electrical system parts are mounted on
the Chassis frame. It is the main mounting for all
the components including the body. So it is also
called as Carrying Unit.
CHASSIS AND ITS MAIN COMPONENTS
1. Frame: it is made up of long two members called
side members riveted together with the help of number
of cross members.
2. Engine or Power plant: It provides the source of
power
3. Clutch: It connects and disconnects the power from
the engine fly wheel to the transmission system.
4. Gear Box
5. U Joint
6. Propeller Shaft
7. Differential
 FUNCTIONS OF THE CHASSIS
FRAME
1. To carry load of the passengers or goods
carried in the body.
2. To support the load of the body, engine, gear
box etc.,
3. To withstand the forces caused due to the
sudden braking or acceleration
4. To withstand the stresses caused due to the
bad road condition.
5. To withstand centrifugal force while cornering
 TYPES OF CHASSIS FRAMES

There are three types of frames

1. Conventional frame
2. Integral frame
3. Semi-integral frame
 Conventional frame

• It has two long side members and 5 to 6

cross members joined together with the help
of rivets and bolts.
• The frame sections are used generally.

a. Channel Section - Good resistance to

bending
b. Tabular Section - Good resistance to Torsion
c. Box Section - Good resistance to both
bending and Torsion
 Integral Frame

• This frame is used now a days in most of

the cars. There is no frame and all the
assembly units are attached to the body.
All the functions of the frame carried out
by the body itself. Due to elimination of
long frame it is cheaper and due to less
weight most economical also. Only
disadvantage is repairing is difficult.
 Semi - Integral Frame
• In some vehicles half frame is fixed in the
front end on which engine gear box and front
suspension is mounted. It has the advantage
when the vehicle is met with accident the
front frame can be taken easily to replace the
damaged chassis frame.
• This type of frame is used in FIAT cars and
some of the European and American cars.
 DRIVE TRAIN SYSTEMS
The drive train transfers turning force from
the engine crankshaft to the drive wheels.
Drive train configurations vary, depending on
vehicle design. The drive train parts commonly
found on a front engine, rear-wheel-drive
vehicle include the clutch, transmission, drive
shaft, and rear axle assembly. The drive train
parts used on most front-engine, front-wheel-
drive vehicles include the clutch, transaxle,
and drive axles.
DRIVE TRAIN SYSTEMS
DRIVE TRAIN SYSTEMS
REAR AXLE ASSEMBLY
The rear axle assembly contains a differential and two axles. The
differential is a set of gears and shafts that transmits power from the
drive shaft to the axles. The axles are steel shafts that connect the
differential and drive wheels.
TRANSAXLE
The transaxle consists of a transmission and a differential in a single
housing. Although a few rear-wheel drive vehicles are equipped with
transaxles, they are most commonly used with front-wheel-drive
vehicles,
FRONT DRIVE AXLES
The front drive axles connect the transaxle differential to the hubs and
wheels of the vehicle. These axles are equipped with constant-velocity
joints, which allow the front wheels to be turned to the left or right and
to move up and down.
TRANSMISSION
The transmission uses various gear combinations, or ratios, to
multiply engine speed and torque to accommodate driving
conditions. Low gear ratios allow the vehicle to accelerate
quickly. High gear ratios permit lower engine speed, providing
good gas mileage.
A manual transmission lets the driver change gear ratios to
better accommodate driving conditions. An automatic
transmission, on the other hand, does not have to be shifted
by the driver. It uses an internal hydraulic system and, in most
cases, electronic controls to shift gears. The input shaft of an
automatic transmission is connected to the engine crankshaft
through a torque converter (fluid coupling) instead of a
clutch.
DRIVE SHAFT
The drive shaft, or propeller shaft, transfers
power from the transmission to the rear
axle assembly. It is a hollow metal tube with
two or more universal (swivel) joints. The
universal joints allow the
rear suspension to move up and down
without damaging the drive shaft.
 AXLE SHAFT
An Axle Shaft is the part of an axle assembly
that is turned by the side gear of the differential
and transfers the power either directly to the
wheel or to the wheel hub that the wheel is
bolted to, depending on the style of axle.
 CARRIER
Sometimes referred to as a Differential Case
or Ring Gear Carrier. This unit transfers the
motion from the ring gear to the axle shafts.
 PINION GEAR
• The pinion gear is the drive gear that turns
the ring gear
 RING GEAR
• The ring gear, transfers power from the
• drive pinion gear to the differential case.
Both the ring gear
• and the case are machined to fit together
tightly
 SPIDER GEARS
• The spider gears are made of hardened steel and
are held in place by a steel shaft called the pinion
shaft. The pinion shaft passes through the
differential case and the center of the spider
gears. It is attached to the case with a bolt.
Spider gears are also called pinion gears.
• Spider gears mesh with side gears, which are
also made of hardened steel. When the ring gear
and differential case turn, the spider and side
gears also turn. Power flow is through the case,
into the spider gears, and on into the side gears.
The side gears are splined to the drive axles.
 SUSPENSION, STEERING, AND BRAKE
SYSTEMS
The suspension, steering, and brake
systems are the movable parts of the
chassis. They bolt or anchor to the frame
and provide important functions that will
be explained in the following sections.
 SUSPENSION SYSTEM
The suspension system allows the vehicle’s
wheels and tires to move up and down
with little effect on body movement. This
makes the vehicle’s ride smooth and safe.
The suspension system also prevents
excessive body lean when turning corners
quickly.
SUSPENSION SYSTEM
 SUSPENSION SYSTEM

SUSPENSION SYSTEM COMPONENTS

CONTROL ARM
is a movable lever that fastens the steering
knuckle to the vehicle frame or body
CONTROL ARM BUSHING
a sleeve, which allows the control arm to move up
and down on the frame
STRUT ROD
prevents the control arm from swinging to the front or
rear of the vehicle
BALL JOINTS
a swivel joint that allows the control arm and
steering knuckle to move up and down, as well as
side to side
SHOCK ABSORBER
keeps the suspension from continuing to bounce
after spring compression and extension
STABILIZER BAR
(limits body roll of the vehicle during cornering)
SPRING (supports the weight of the vehicle;
permits the control arm and wheel to move up
and down
 STEERING SYSTEM
The steering system allows the driver to
control vehicle direction by turning the
wheels right or left. It uses a series of
gears, swivel joints, and rods to do this.
Rack-and-pinion steering system

29-67
Steering arrangement for an independent
suspension

29-68
Steering linkage with a pitman arm
and an idler arm

29-69
Steering system for a van with
forward controls

29-70
 Front-axle assembly and steering
arrangement for a four-wheel-drive
vehicle

29-71
 BRAKE SYSTEM
A braking system consists of two main sections.
These are the brake assemblies at the wheels and
the hydraulic system that applies the brakes.
The system includes the service (foot) brakes for
use when the vehicle is being driven, and a parking
brake, usually hand operated, which is applied
when the vehicle is parked. Some systems have
disc brakes at all four wheels, some have disc
brakes at the front and drum brakes at the rear,
others have drum brakes at all four wheels.
BRAKE SYSTEM
BRAKE SYSTEM
 BRAKE SYSTEM
BRAKE PEDAL
The brake pedal acts as a lever to increase the force
applied to the brake pedal pad, by the driver.
POWER BOOSTER
The power booster assists the driver by reducing the
amount of effort that has to be applied to the brake pedal
during braking
BRAKE LIGHT SWITCH
The function of the stop or brake light switch is to
indicate to people driving behind us that our vehicle
is slowing or stopping.
HYDRAULIC BRAKE BOOSTER
The hydraulic brake booster uses hydraulic pressure
generated by the power steering pump rather than
engine vacuum to provide the power assistance required.
BRAKE LINES
Brake lines carry brake fluid from the master cylinder to
the brakes. For most of their length they are steel, and
attached to the body with clips or brackets to prevent
damage from vibration. They are much the same on all
brake systems.
BRAKE FLUID

• Brake fluid is a special purpose high-

boiling point fluid. It transmits the
hydraulic pressure generated by the
master cylinder to the brake units.
MASTER CYLINDER
• The single-piston master cylinder
transforms the applied pedal force into
an hydraulic pressure which is
transmitted simultaneously to all four
wheels.
 TYPES OF BRAKES
• Disc brake
 FUEL SYSTEM
The fuel system must provide the correct mixture of air and fuel for
efficient combustion (burning). This system must add the right amount
of fuel to the air entering the cylinders. This ensures that a very
volatile (burnable) mixture enters the combustion chambers. The fuel
system must also alter the air-fuel ratio (percentage of air and fuel)
with changes in operating conditions (engine temperature, speed,
load, and other variables).
There are three basic types of automotive fuel systems: gasoline
injection systems, diesel injection systems, and carburetor systems.
GASOLINE INJECTION SYSTEM
Modern gasoline injection systems use a control module, sensors, and
electrically operated fuel injectors (fuel valves) to meter fuel into the
engine. This is the most common type of fuel system on gasoline, or
spark ignition, engines.
An electric fuel pump forces fuel from the fuel tank to the engine. The
control module, reacting to electrical data it receives from the sensors,
opens the injectors for the correct amount of time. Fuel sprays from
the open injectors, mixing with the air entering the combustion
chambers.
A throttle valve controls airflow, engine speed, and engine power.
When the throttle valve is open for more engine power output, the
computer holds the injectors open longer, allowing more fuel to spray
out. When the throttle valve is closed, the computer opens the
injectors for only a short period of time, reducing power output. The
throttle valve (air valve) is connected to the accelerator pedal. When
the pedal is pressed, the throttle valve opens to increase engine power
output.
DIESEL INJECTION SYSTEM
A diesel fuel system is primarily a mechanical system that forces diesel
fuel (not gasoline) directly into the combustion chambers. Unlike the
gasoline engine, the diesel engine does not use spark plugs to ignite
the air-fuel mixture. Instead, it uses the extremely high
pressure produced during the compression stroke to heat the air in the
combustion chamber. The air is squeezed until it is hot enough to ignite
the fuel. When the mechanical pump sprays the diesel fuel into a
combustion chamber, the hot air in the chamber causes the fuel to
begin to burn. The burning fuel expands and forces the piston down on
the power stroke. Electronic devices are commonly used to monitor
and help control the operation of today’s diesel injection systems.
CARBURETOR FUEL SYSTEM
The carburettor fuel system uses engine vacuum (suction) to draw fuel
into the engine. The amount of airflow through the carburettor
determines the amount of fuel used. This automatically maintains the
correct air fuel ratio. Either a mechanical or an electric fuel pump
draws fuel out of the tank and delivers it to the carburettor. The
engine’s intake strokes form a vacuum inside the intake manifold and
carburettor. This causes gasoline to be drawn from the carburettor and
into the air entering the engine.
GASOLINE INJECTION SYSTEM
DIESEL INJECTION SYSTEM
CARBURETOR FUEL SYSTEM
 ELECTRICAL SYSTEM
The vehicle’s electrical system consists of several
subsystems (smaller circuits): ignition system,
starting system, charging system, and lighting
system. Each subsystem is designed to perform a
specific function, such as “fire” the spark plugs to
ignite the engine’s fuel mixture, rotate the
crankshaft to start the
Technical College of Fiji, Nabua Campus.
Lecturer Mr Jai Chand