Automotive Technician Training Guide

978 Pages·2011·38.87 MB·English

by  Tom Denton

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.
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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
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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.
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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.
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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

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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
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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
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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
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