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Automotive Technician Training Guide PDF

978 Pages·2011·38.87 MB·English
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AUTOMOTIVE TECHNICIAN TRAINING – © TOM DENTON LEVEL 1 Automotive Technician Training (ATT) Copyright © ATT Training Ltd. – Tom Denton, BA, FIMI, MIRTE, MSAE, Cert Ed Online editions may also be available for this title. Please visit www.atttraining.com for more information. All rights reserved by the author. No part of this publication can be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior permission of the publishers and/or authors. This publication does not form part of any photocopying licence agreement. 1 AUTOMOTIVE TECHNICIAN TRAINING – © TOM DENTON ACKNOWLEDGEMENTS Over the years many people have helped in the production of my books. I am therefore very grateful to the following companies who provided information and/or permission to reproduce photographs and/or diagrams: AA Photo Library Mazda Unipart Group AC Delco McLaren Electronic Valeo Alpine Audio Systems Systems Vauxhall ATT Training (UK and Mercedes Cars UK VDO Instruments USA) Mitsubishi Cars UK Volvo Media Autologic Data NGK Plugs Volkswagen cars Systems Nissan Cars UK Wikimedia BMW UK Most Corporation ZF Servomatic Bosch Gmbh Peugeot UK Bosch Media Philips C&K Components PicoTech Citroën UK Pioneer Radio Clarion Car Audio Porsche Cars UK Delphi Media Robert Bosch GmbH. Eberspaecher Robert Bosch UK Fluke Instruments UK Rover Cars Ford Motor Company Saab Cars UK Ford Media Saab Media FreeScale Electronics Scandmec General Motors SMSC GenRad Snap-on Tools Hella UK Sofanou (France) Honda Cars UK Sun Electric UK Hyundai UK Tesla Motors Jaguar Cars Thrust SSC Land Kavlico Speed Team Loctite T&M Auto-Electrical 2 AUTOMOTIVE TECHNICIAN TRAINING – © TOM DENTON Lucas UK Toyota Cars UK LucasVarity Tracker UK If I have used any information, or mentioned a company name that is not listed here, please accept my apologies and let me know so it can be rectified as soon as possible. 3 AUTOMOTIVE TECHNICIAN TRAINING – © TOM DENTON HOW TO USE THIS BOOK Introduction This book is for use with the ‘Automotive Technician Training’ blended eLearning material. The text and images are the same on screen and in this book – most importantly, the images on screen are much larger and often animated. Diagrams Most of the diagrams in this book have numbered (or similar) labels. Use the computer material to find out what the labels should say and then write them in to the book. In some cases there will be a blank space where the diagram from the screen should be drawn in. Notes Use this book as a workbook, make notes, add bullet points, underline things, make sketches and highlight important points. This is your book, so use it in whatever way works for you! Online In most cases you will probably access the computer based materials through a college or training centre. However, the learning screens, questions, worksheets, activities (and more!) are also available at: www.atttraining.com. Structure The main part of this textbook is set out as four units (engines, chassis, electrical and transmission), which are then divided into chapters that cover major areas of the vehicle; brakes and steering for example. The structure of the computer based material may be in a slightly different order but it is easy to find what you need. 4 AUTOMOTIVE TECHNICIAN TRAINING – © TOM DENTON Worksheets Practical worksheets, for use under supervision in the workshop, are included in a separate book as a PDF or printing. These match all the tasks outlined in this book as well as covering more practical activities. Symbols A number of symbols are used as a reminder that you should complete different tasks:  Check the computer for animations or videos ()  Complete self-assessment questions  Draw a diagram in this space  Look back over the previous section and write out a list of the key bullet points  Worksheets to match the practical tasks in this textbook are in the support book 5 AUTOMOTIVE TECHNICIAN TRAINING – © TOM DENTON CONTENTS Acknowledgements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 How to Use this Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 G e n e r a l I n t r o d u . .c.t. .i.o. .n. . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8 Vehicle Layouts and Introduction ........................... 18 Health and Safety on Vehicles .............................. 35 Maintenance, Regulations and Information ................. 49 Reasons for Maintenance and Inspections ................................. 49 Information Sources, Recording and Regulations ..................... 52 Workshop Bench Skills ....................................... 54 Introduction ..................................................................................... 54 Fitting and Machining ..................................................................... 54 Filing ................................................................................................... 56 Drilling................................................................................................ 57 Cutting ............................................................................................... 58 Thread Cutting ................................................................................. 60 Joining ................................................................................................ 63 Nuts And Bolts ................................................................................. 65 Adhesives .......................................................................................... 68 6 AUTOMOTIVE TECHNICIAN TRAINING – © TOM DENTON Soldering ........................................................................................... 71 Brazing ............................................................................................... 72 Welding .............................................................................................. 72 Shrinking ........................................................................................... 75 Riveting .............................................................................................. 77 Gaskets .............................................................................................. 78 Sealants ............................................................................................. 80 Oil Seals ............................................................................................ 81 Valeting ....................................................... 84 Overview, equipment and safety .................................................. 84 Exterior cleaning ............................................................................. 89 Interior cleaning ............................................................................ 100 The Motor Trade ............................................ 103 Introduction ................................................................................... 103 Types of MV companies ................................................................ 105 Company Structure ....................................................................... 107 Role of a franchised dealer ......................................................... 108 Reception and booking systems .................................................. 108 Parts department .......................................................................... 110 7 AUTOMOTIVE TECHNICIAN TRAINING – © TOM DENTON Estimating Costs and Times ........................................................ 112 Job Cards and Systems ................................................................ 113 Invoicing .......................................................................................... 114 Computerised Workshop System ............................................... 116 Warranties ...................................................................................... 124 Background Studies .......................................... 126 Introduction ................................................................................... 126 Science............................................................................................. 131 Electricity ....................................................................................... 140 Materials ......................................................................................... 152 Mechanical Machines .................................................................... 155 Maths ............................................................................................... 159 Drawings .......................................................................................... 162 Safety and General Units . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 67 Contribute to Workplace Good Housekeeping .............. 167 Legal Requirements ....................................................................... 167 General Housekeeping ................................................................... 170 Equipment Maintenance ................................................................ 175 Ensure Your Own Actions Reduce Risks to Health and Safety ........................................................ 179 8

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