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1. 11 Do not smoke when working on vehicles 12 Do not smoke or create sparks near flammable materials or liquids 13 Store combustible shop supplies such as paint in a closed steel cabinet 14 Store gasoline in approved safety containers 15 If a gasoline tank is removed from a vehicle do not drag the tank on the shop floor 16 Know the approved fire escape route from your classroom or shop to the outside of the building 17 If a fire occurs do not open doors or windows This action creates extra draft that makes the fire worse 18 Do not put water on a gasoline fire because the water will make the fire worse 19 Call the fire department as soon as a fire begins and then attempt to extinguish the fire 20 If possible stand 6 to 10 feet from the fire and aim the fire extinguisher nozzle at the base of the fire with a sweeping action 21 If a fire produces a great deal of smoke in the room remain close to the floor to obtain oxygen and avoid breathing smoke 22 If the fire is too hot or the smoke makes breathing difficult leave the building 23 Do not reenter a burning building Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reser
2. roomed end When struck with a hammer a piece of the mushroomed metal could break off resulting in severe eye or other injury Do not leave power tools running and unattended Serious burns may be prevented by avoiding contact with hot metal components such as exhaust manifolds other exhaust system components radiators and some air conditioning hoses When lubricant such as engine oil is drained always use caution because the oil could be hot enough to cause burns Before getting under a vehicle be sure the vehicle is placed securely on safety stands Operate all shop equipment including lifts according to the equipment manufacturer s recommended procedure Do not operate equipment unless you are familiar with the correct operating procedure Do not run or engage in horseplay in the shop Obey all state and federal fire safety and environmental regulations Do not stand in front of or behind vehicles Always place fender covers and a seat cover on a customer s vehicle before working on the car Inform the shop foreman of any safety dangers and suggestions for safety improvement 30 Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cen
3. versely if grease spots are found on the upholstery or fenders after service work is completed customers will probably think the shop is very careless not only in car care but also in service work quality Housekeeping CUSTOMER CARE When customers see that you are concerned about their vehicles and that you operate a shop with excellent housekeeping habits they will be impressed and will likely keep returning for service Careful housekeeping habits prevent accidents and increase worker efficiency Good house keeping also helps to impress upon customers that quality work is a priority in this shop Fol low these housekeeping rules 1 Keep aisles and walkways clear of tools equipment and other items Be sure all sewer covers are securely in place 2 3 Keep floor surfaces free of oil grease water and loose material 4 Place proper garbage containers in convenient locations and empty them regularly 5 Make sure that access to fire extinguishers is unobstructed at all times and check fire extinguishers for proper charge at regular intervals 31 Excellent house keeping involves general shop cleanliness proper shop safety equipment in good working condition and the proper maintenance of all shop equipment and tools Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed fr
4. 1 Two systems of measurement in common use are the United States customary USC and international system SI The SI system may be called the metric system In the metric system the units can be divided or multiplied by 10 Personal safety is the responsibility of everyone in the shop When lifting heavy objects always bend your knees rather than your back Many shop accidents are caused by the improper use of hand tools Never operate any type of equipment unless you are familiar with the proper operat ing procedure 8 Never exceed the rated capacity of a hydraulic press hydraulic jack vehicle lift or jack stands 9 When raising a vehicle with a lift or floor jack always be sure the lifting equipment is contacting the vehicle on the manufacturer s recommended lift points 10 After a vehicle is raised on a lift be sure the lift locking mechanism is in place 11 Never operate electric equipment with a frayed cord or without a ground wire 12 Never direct a blast of compressed air against human flesh 13 Always wear eye protection and protective gloves when cleaning parts in any type of cleaning solution 14 Electronic fuel injection EFI systems must be depressurized before connecting a fuel gauge or disconnecting fuel system components 15 On a port fuel injection PFD system the pressure gauge is connected to the Schrader valve on the fuel rail 16 On throttle body injection TBD or carburetor systems the fuel pres
5. Matthew Thouin COPYRIGHT 2006 Thomson Delmar Learning Thomson the Star Logo and Delmar Learning are trademarks used herein under license Printed in the United States of America 12345 XX 07 06 05 For more information contact Thomson Delmar Learning Executive Woods 5 Maxwell Drive PO Box 8007 Clifton Park NY 12065 8007 Or find us on the World Wide Web at www delmarlearning com Mark Schnubel Channel Manager William Lawrensen Marketing Coordinator Mark Pierro Production Director Mary Ellen Black ALL RIGHTS RESERVED No part of this work covered by the copyright hereon may be reproduced in any form or by any means graphic electronic or mechanical including photocopying recording taping Web distribution or information storage and retrieval systems without the written permission of the publisher For permission to use material from the text or product contact us by Tel 800 730 2214 Fax 800 730 2215 www thomsonrights com NOTICE TO THE READER Production Editor Barbara Diaz Art Design Specialist Cheri Plasse Technology Project Manager Kevin Smith Editorial Assistant Andrea Domkowski Library of Congress Cataloging in Publication Data Schnubel Mark Shop manual for advanced engine performance Mark Schnubel p cm Today s technician ISBN 1 4018 7787 7 CM amp SM ISBN 1 4018 7788 5 IML 1 Automobiles Motors Mainte nance and repair
6. terminal melted out of the battery The technician s finger was so badly burned that a surgeon had to cut the ring from his finger and repair the finger This technician forgot to disconnect the negative battery cable before working on the vehicle CASE STUDY 4 A technician had just replaced the engine in a Ford product and she was performing final adjustments such as timing and air fuel mixture In this shop the cars were parked in the work bays at an angle on both sides of the shop With the engine running at fast idle the automatic transmission suddenly slipped into reverse The car went backwards across the shop and collided with a car in one of the electrical repair bays Both vehicles were damaged to a considerable extent Fortunately no personnel were injured This technician forgot to apply the parking brake while working on the vehicle Terms to Know Asbestos dust vacuum cleaner ASE technician certification Shop layout ASE blue seal of excellence ASE Style Review Questions 1 While discussing shop hazards 2 While discussing shop rules Technician A says high pressure air from an air gun Technician A says breathing carbon monoxide may may penetrate the skin cause arthritis Technician B says air in the bloodstream may be fatal Technician B says breathing carbon monoxide may Who is correct cause headaches A A only C Both A and B Who is correct B B only D Neither A nor B A A only C Both A and B
7. to cause burning 4 Keep the shop neat and clean Always pick up tools and parts and do not leave creepers lying on the floor 5 Keep the workbenches clean Do not leave heavy objects such as used parts on the bench after you are finished with them TT Figure 1 3 Paints and combustible material Figure 1 4 Oily rags must be stored in approved containers must be kept in an approved safety airtight containers cabinet Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it General Shop Safety 1 All sewer covers must fit properly and be kept securely in place 13 14 15 16 17 18 19 20 21 22 23 24 Always wear a face shield protective gloves and protective clothing when necessary Gloves should be worn when working with solvents and caustic solutions handling hot metal or grinding metal Various types of protective gloves are available Shop coats and coveralls are the most common types of protective clothing Never direct high pressure air from an air gun against human flesh If this
8. 2 Automobiles Perfor mance I Title Advanced engine performance Il Title III Series TL210 S37 2006 629 25 0288 dc22 2005054908 Publisher does not warrant or guarantee any of the products described herein or perform any independent analysis in connection with any of the product information contained herein Publisher does not assume and expressly disclaims any obligation to obtain and include information other than that provided to it by the manufacturer The reader is expressly warned to consider and adopt all safety precautions that might be indicated by the activities herein and to avoid all potential hazards By following the instructions contained herein the reader willingly assumes all risks in connection with such instructions The publisher makes no representation or warranties of any kind including but not limited to the warranties of fitness for partic ular purpose or merchantability nor are any such representations implied with respect to the material set forth herein and the publisher takes no responsibility with respect to such material The publisher shall not be liable for any special consequential or exemplary damages resulting in whole or part from the readers use of or reliance upon this material Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook an
9. B B only D Neither A nor B 39 Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it While discussing shop rules 8 Technician says breathing asbestos dust may cause heart defects Technician B says oily rags should be stored in uncovered garbage containers Who is correct A A only B B only C Both A and B D Neither A nor B While discussing hazardous waste disposal Technician A says the right to know laws require employers to train employees regarding hazardous waste materials 9 Technician B says the right to know laws do not require employers to keep permanent records regarding hazardous waste materials Who is correct A A only B B only C Both A and B D Neither A nor B While discussing material safety data sheets MSDS Technician A says these sheets explain employers and employees responsibilities regarding hazardous material handling and disposal Technician B says these sheets contain specific information about hazardous materials Who is correct A A only B B only C Both A and
10. B D Neither A nor B While discussing air quality Technician A says a battery gives off hydrogen gas during the charging process Technician B says a battery gives off oxygen gas during the charging process Who is correct A A only B B only C Both A and B D Neither A nor B While discussing air quality Technician A says diesel exhaust contains particulates Technician B says particulate emissions contain oxides of nitrogen Who is correct A A only C Both A and B B B only D Neither A nor B 10 While discussing employer and employee responsibilities Technician A says employers are required to inform their employees about hazardous materials in the shop Technician B says that employers have no obligation to inform their employees about hazardous materials in the shop Who is correct A A only B B only C Both A and B D Neither A nor B While discussing hazardous materials Technician A says a solid that ignites spontaneously is considered a hazardous material Technician B says a liquid with a flash point below 140 F 60 C is considered a hazardous material Who is correct A A only B B only C Both A and B D Neither A nor B While discussing hazardous waste disposal Technician A says hazardous waste materials may be hauled to an approved hazardous waste disposal site or recycled in the shop Technician B says all hazardous waste materials must be hauled to an approved haz
11. MSDS sheets have been met A general right to know compliance proce dure manual must be maintained by employers 15 Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it Personal Safety Personal safety is the responsibility of each technician in the shop Always follow these safety practices 1 Always use the correct tool for the job If the wrong tool is used it may slip and cause hand injury 2 Follow the car manufacturer s recommended service procedures 3 Always wear eye protection such as safety glasses or a face shield Figure 1 14 4 Wear protective gloves when cleaning parts in hot or cold tanks and when handling hot parts such as exhaust manifolds 5 Do not smoke when working on a vehicle A spark from a cigarette or lighter may ignite flammable materials in the work area 6 When working on a running engine keep hands and tools away from rotating parts Remember that electric drive fans may start turning at any time 7 Do not wear loose clothing and keep long hair tied behind your head Loose clothing or long hair
12. Parts washers approved by OSHA must be used to clean the dust from these components Figure 1 24 Brake washer concentrate is mixed with water in these parts washers Figure 1 25 A catch basin with a removable liner is placed under the parts to be washed and the washer sprays the cleaning solution on the parts After the washing operation is completed the liner containing the clean ing solution and asbestos dust is removed sealed and labeled for proper handling and dis posal according to waste disposal laws Even though technicians take every precaution to maintain air quality in the shop some undesirable gases may still get in the air For example exhaust manifolds may get oil on them during an engine overhaul When the engine is started and these manifolds become hot the oil burns off the manifolds and pollutes the shop air with oil smoke Adequate shop ventilation must be provided to take care of this type of air contamination WASHER Figure 1 24 Brake assembly washer for asbestos dust Figure 1 25 Brake washer concentrate 33 Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content a
13. This action may result in lift damage or personal injury An engine lift is used to remove and replace automotive engines A long pivoted arm is mounted on the top of the engine lift Figure 1 18 When the lift handle is pumped hydraulic fluid is forced into a cylinder under the lift arm This action extends the cylinder ram and forces the arm 22 Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it Figure 1 18 Engine lift upward to lift the engine A lifting chain is attached to the lift arm and this chain is bolted securely to the engine Always be sure that these retaining bolts are strong enough to support the engine weight Hydraulic Jack and Jack Stand Safety CAUTION Always make sure the jack stand weight capacity rating exceeds the vehicle weight that is lowered onto the stands WARNING Never lift a vehicle with a floor jack if the weight of the vehicle exceeds the rated capacity of the jack This action may cause the jack to drop suddenly result ing in personal injury or vehicle damage Accidents involving the
14. a healthy workplace atmosphere 4 Employee instruction Employers must provide employees with clear job descriptions and be sure that each worker is aware of his or her obligations 5 Employee supervision Employers should inform their workers regarding the responsi bilities of their immediate supervisors and other management personnel 6 Employee training Employers must make sure that each employee is familiar with the safe operation of all the equipment that they are required to use in their job situation Since automotive technology is changing rapidly employers should provide regular update training for their technicians Under the right to know laws employers are required to inform all employees about hazardous materials in the shop Employees should be familiar with WHMIS which detail the labeling and handling of hazardous waste and the health problems if exposed to hazardous waste Job Responsibilities An automotive technician has specific responsibilities regarding each job performed on a cus tomer s vehicle These job responsibilities include 1 Do every job to the best of your ability There is no place in the automotive service industry for careless workmanship Automotive technicians and students must realize they have a very responsible job During many repair jobs you as a student or techni cian working on a customer s vehicle actually have the customer s life and the safety of the vehicle in your hands For exa
15. and the parts cleaning area must be located so they are easily accessible from all areas of the shop The service manager s office should also be cen trally located All shop personnel should familiarize themselves with the shop layout especially 28 Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it Bay 1 Workbench tools instruments Quick Machining service Bay 2 Bay 3 Bay 4 Bay 5 area area lift i lift o ift lift Parts Fi inguish cleaning Shop ire extinguishers door Eyewash First aid kit fountain First aid kit Service ee Parts Bay 6 Eee Electrical manager Sea dept lift die area tires Bench Figure 1 23 Typical shop layout the location of safety equipment If you know the exact fire extinguisher locations you may get an extinguisher into operation a few seconds faster These few seconds could make the differ ence between a fire that is quickly extinguished and one that gets out o
16. automotive service experts from various areas of automotive service such as automotive instructors service managers automotive man ufacturer s representatives test equipment representatives and certified technicians The test questions are pretested and checked for quality by a national sample of technicians Most ques tions have the Technician A and Technician B format similar to the questions at the end of each chapter in this book ASE regulations demand that each technician must have 2 years of working experience in the automotive service industry prior to taking a certification test or tests However relevant formal training may be substituted for one of the years of working experience Contact ASE for details regarding this substitution Shops that employ ASE certified technicians display an official ASE blue seal of excel lence This blue seal increases the customers awareness of the shop s commitment to quality service and the competency of certified technicians AS CERTIFIED Figure 1 26 ASE certification shoulder patches worn by automotive technicians and master technicians 36 Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cenga
17. gasoline has a force equal to four teen sticks of dynamite It is the expanding vapors from gasoline that are extremely dangerous These vapors are present even in cold temperatures Vapors formed in gasoline tanks on cars are controlled but vapors from a gasoline storage can may escape from the can resulting in a haz ardous situation Therefore gasoline storage containers must be placed in a well ventilated space Approved gasoline storage cans have a flash arresting screen at the outlet Figure 1 2 These screens prevent external ignition sources from igniting the gasoline within the can while the gasoline is being poured Follow these safety precautions regarding gasoline containers 1 Always used approved gasoline containers that are painted red for proper identification 2 Do not fill gasoline containers completely full Always leave the level of gasoline at least 1 inch from the top of the container This action allows expansion of the gasoline at higher temperatures If gasoline containers are completely full the gasoline will expand when the temperature increases This expansion forces gasoline from the can and creates a dangerous spill 3 If gasoline containers must be stored place them in a well ventilated area such as a storage shed Do not store gasoline containers in your home or in the trunk of a vehicle Screen Figure 1 2 An approved gasoline container Copyright 2011 Cengage Learning All Rights Reserve
18. is slowed by drugs or alcohol you may not get your foot out of the way in time resulting in a foot injury When a fire starts in the workplace and you are a few seconds slower putting a fire extin guisher into operation because of alcohol or drug use it could make the difference between extinguishing a fire and having expensive fire damage The improper or excessive use of alcoholic beverages and or drugs may be referred to as substance abuse Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it Electrical Safety 1 Frayed cords on electrical equipment must be replaced or repaired immediately 2 All electrical cords from lights and electrical equipment must have a ground connec tion The ground connector is the round terminal in a three prong electrical plug Do not use a two prong adapter to plug in a three prong electrical cord Three prong electrical outlets should be mandatory in all shops 3 Do not leave electrical equipment running and unattended Gasoline Safety Gasoline is a very explosive liquid One exploding gallon of
19. lift pad upward and lift the vehicle Always be sure that the lift pad is positioned securely under one of the car manufacturer s recommended lift points To release the hydraulic pressure and lower the vehicle the handle or release lever must be turned slowly Do not leave the jack handle where someone can trip over it 20 Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it Figure 1 16 Hydraulic floor jack Lift WARNING Always be sure that the lift arms are securely positioned under the car manufacturer s recommended lift points before raising a vehicle These lift points are shown in the service manual Using improper lift points may cause the vehicle to slip off the lift resulting in vehicle damage or personal injury CAUTION The maximum capacity of the vehicle lift is placed on an identification plate Never lift a vehicle that is heavier than the maximum capacity of the lift A lift is used to raise a vehicle so the technician can work under the vehicle The lift arms must be placed under the car manufacturer s recommended li
20. personnel should be familiar with the follow ing types of fires and fire extinguishers 1 Class A fires are those involving ordinary combustible materials such as paper wood clothing and textiles Multipurpose dry chemical extinguishers are used on these fires 2 Class B fires involve the burning of flammable liquids such as gasoline oil paint sol vents and greases These fires may be extinguished with multipurpose dry chemical extinguishers Fire extinguishers containing halogen or halon may be used to extin guish class B fires The chemicals in this type of extinguisher attach to the hydrogen hydroxide and oxygen molecules to stop the combustion process almost instantly However the resultant gases from the use of halogen type extinguishers are very toxic and harmful to the operator of the extinguisher 3 Class C fires involve the burning of electrical equipment such as wires motors and switches These fires may be extinguished with multipurpose dry chemical extinguishers 4 Class D fires involve the combustion of metal chips turnings and shavings Dry chemical extinguishers are the only type of extinguisher recommended for these fires FEDA A Figure 1 6 Types and sizes of fire extinguishers Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s E
21. tech nicians Honesty creates a feeling of trust between technicians employers and cus tomers Loyalty As an employee you are obliged to act in the best interests of your employer both on and off the job Attitude Employees should maintain a positive attitude at all times As in other profes sions automotive technicians have days when it may be difficult to maintain a positive attitude For example there will be days when the technical problems on a certain vehicle are difficult to solve However developing a negative attitude certainly will not help the situation A positive attitude has a positive effect on the job situation as well as on the customer and employer Responsibility You are responsible for your conduct on the job and your work related obligations These obligations include always maintaining good workmanship and customer relations Attention to details such as always placing fender and seat covers on customer vehicles prior to driving or working on the vehicle greatly improve cus tomer relations Following directions All of us like to do things our way Such action may not be in the best interests of the shop and as an employee you have an obligation to follow the supervisor s directions Punctuality and regular attendance Employees have an obligation to be on time for work and to be regular in attendance on the job It is very difficult for a business to operate successfully if it cannot count on its employees
22. to remove additional content at any time if subsequent rights restrictions require it Figure 1 15 Hydraulic press adjustable steel beam bed is retained to the lower press frame with heavy steel pins A hydraulic cylinder and ram is mounted on the top part of the press with the ram facing downward toward the press bed Figure 1 15 The component being pressed is placed on the press bed with appropriate steel supports A hand operated hydraulic pump is mounted on the side of the press When the handle is pumped hydraulic fluid is forced into the cylinder and the ram is extended against the component on the press bed to complete the pressing operation A pressure gauge on the press indicates the pressure applied from the hand pump to the cylinder The press frame is designed for a certain maximum pressure and this pressure must not be exceeded during hand pump operation Floor Jack CAUTION The maximum lifting capacity of the floor jack is usually written on a jack decal Never lift a vehicle that exceeds the jack lifting capacity This action may cause the jack to break or collapse resulting in vehicle damage or personal injury A floor jack is a portable unit mounted on wheels The lifting pad on the jack is placed under the chassis of the vehicle and the jack handle is operated with a pumping action Figure 1 16 This jack handle operation forces fluid into a hydraulic cylinder in the jack and this cylinder extends to force the jack
23. use of floor jacks and jack stands may be avoided if these safety precau tions are followed 1 Never work under a vehicle unless jack stands are placed securely under the vehicle chassis and the vehicle is resting on these stands Figure 1 19 Figure 1 19 Jack stands 23 Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it 2 Before lifting a vehicle with a floor jack be sure that the jack lift pad is positioned securely under a recommended lift point on the vehicle Lifting the front end of a vehi cle with the jack placed under a radiator support may cause severe damage to the radiator and support 3 Position the jack stands under a strong chassis member such as the frame or axle housing The jack stands must contact the vehicle manufacturer s recommended lift points 4 Since the floor jack is on wheels the vehicle and jack tend to move as the vehicle is lowered from a floor jack onto jack stands Always be sure the jack stands remain under the chassis member during this operation and be sure the jack stands do not tip All
24. 1 Paint and body repair products waste Solvents for parts and equipment cleaning Batteries and battery acid Mild acids used for metal cleaning and preparation Waste oil and engine coolants or antifreeze SS ew MN Air conditioning refrigerants 7 Engine oil filters Never under any circumstances use the following methods to dispose of hazardous waste material 1 Pour hazardous wastes on weeds to kill them 2 Pour hazardous wastes on gravel streets to prevent dust 3 Throw hazardous wastes in a dumpster 4 Dispose of hazardous wastes anywhere but an approved disposal site 5 Pour hazardous wastes down sewers toilets sinks or floor drains The right to know laws state that employees have a right to know when the materials they use at work are hazardous The right to know laws started with the Hazard Communication Stan dard published by OSHA in 1983 This document was originally intended for chemical companies and manufacturers that required employees to handle hazardous materials in their work situation At the present time most states have established their own right to know laws Meanwhile the federal courts have decided to apply these laws to all companies including automotive service shops Under the right to know laws employers have three responsibilities regarding the han dling of hazardous materials by their employees First all employees must be trained about the types of hazardous materials they will encounter in the
25. TODAY S TECHNICIAN Advanced Engine Performance Classroom Manuals ae Mark Schnubel Licensed to iChapters User This is an electronic version of the print textbook Due to electronic rights restrictions some third party content may be suppressed Editorial review has deemed that any suppressed content does not materially affect the overall learning experience The publisher reserves the right to remove content from this title at any time if subsequent rights restrictions require it For valuable information on pricing previous editions changes to current editions and alternate formats please visit www cengage com highered to search by ISBN author title or keyword for materials in your areas of interest Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it THOMSON rr DELMAR LEARNING Today s Technician Advanced Engine Performance Shop Manual Vice President Technology and Trades SBU Dave Garza Editorial Director Sandy Clark Senior Acquisitions Editor David Boelio Developmental Editor
26. Waste Di posal Methods DISPOSE IN ACCORDANCE NTH ALL APPLICABLE FEDERAL STATE AND PE ENMI RONMENTAL REGULATIONS EPA HAZARDOUS WASTE NUMBER D001 IGNITABLE Handling Na REIN ARE BOND AND GROUND CONTAINERS WHEN TRANSFERRING LIQUID KEEP CONTAINER aS Other Precautions USE oe ERAL OR LOCAL EXHAUST VENTILATION TO MEET TLVREQUIREMENTS STONAGE COLOR CODE RED FLAMMABLE Flash Point Method CC Flash Point Text 9F _23C pos Limits 1 Be Erina Limits 77 7 DATE Media USE ALCOHOL FOAM DRY CHEMICAL OR CARBON DIOXIDE WATER MAY BE Fre e Figg Procedures USE NIOSH MSHA APPROVED SCBA amp FULL PROTECTIVE Unusual frees losion Hazard VAP MAY FORM ALONG SURFS TO DIST IGNIT SOURCES amp FLASH BACK CONT W STRON amp G OERS MAY CAUSE FIRE TOX GASES PRDCED MAY INCL CARBON MONOXIDE CARBON DIOXID Material safety data sheets MSDS inform employees about hazardous materials must supply all warning and precautionary information about hazardous materials and this infor mation must be read and understood by the employee before handling the material Thirdly employers are responsible for maintaining permanent files regarding hazardous materials These files must include information on hazardous materials in the shop proof of employee training programs and information about accidents such as spills or leaks of hazardous materials Employers files must also include proof that employees requests for hazardous mate rial information such as
27. action is allowed air may penetrate the skin and enter the bloodstream causing serious health problems or death Always keep air hoses in good condition If an end blows off an air hose the hose may whip around and cause personal injury Use only OSHA approved air gun nozzles Handle all hazardous waste materials according to state and federal regulations These regulations are explained later in this chapter Always place a shop exhaust hose on the tailpipe of a vehicle if the engine is running in the shop and be sure the shop exhaust fan is turned on Keep hands long hair and tools away from rotating parts such as fan blades and belts on running engines Remember that an electric drive fan may start turning at any time When servicing brakes or clutches from manual transmissions always clean asbestos dust from these components with an approved asbestos dust vacuum cleaner Always use the correct tool for the job For example never strike a hardened steel component such as a piston pin with a steel hammer This type of component may shatter and fragments can penetrate eyes or skin Follow the car manufacturer s recommended service procedures 10 11 12 Be sure that the shop has adequate ventilation Make sure the work area has adequate lighting Use trouble lights with steel or plastic cages around the bulb If an unprotected bulb breaks it may ignite flammable materials in the area When servicing a vehicle always ap
28. ade electrical contact from the alternator battery terminal to ground on the alternator housing Even though the alternator battery wire is protected with a fuse link which melted a high current flowed through the wristwatch bracelet This heated the bracelet to a very high temperature and severely burned the technician s arm 38 Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it This technician forgot two safety rules 1 Never wear jewelry such as watches and rings while working in an automotive shop 2 Before performing electrical work on a vehicle disconnect the negative battery cable If the vehicle is equipped with an air bag wait 1 minute after this cable is discon nected CASE STUDY 3 A technician was removing and replacing the starting motor with the solenoid mounted on top of the motor The technician began removing the battery cable from the solenoid and the ring on one of his fingers made contact between the end of the wrench and the engine block The current flow through the ring was so high that the positive battery
29. an testers have the capability to test various computer systems on the vehicle the tester must be programmed for the computer system being tested 37 The scan tester must be connected to the appropriate diagnostic connector on the vehicle 38 A two gas emissions analyzer reads carbon monoxide CO and hydrocarbon HC emission levels 39 A four gas emissions analyzer reads the same emission levels as a two gas analyzer plus oxygen O and carbon dioxide CO The latter two emissions are not affected by the catalytic converter 40 Emissions analyzers require a 15 minute warm up and calibration period when they are turned on 41 An engine analyzer contains a combination of many different automotive testers Shop Layout There are many different types of shops in the automotive service industry including new car dealers independent repair shops specialty shops service stations and fleet shops WARNING Always know the location of all safety equipment in the shop and be familiar with the operation of this equipment The shop layout in any shop is important to maintaining shop efficiency and safety Shop layout includes bays for various types of repairs space for equipment storage and office loca tions Safety equipment such as fire extinguishers first aid kits and eyewash fountains must be in easily accessible locations The location of each piece of safety equipment must be clearly marked Areas such as the parts department
30. ardous waste disposal site Who is correct A A only B B only C Both A and B D Neither A nor B 40 Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it
31. at extremely high speed Under this condition the bearing may be damaged or disintegrate caus ing personal injury 8 All pneumatic tools must be operated according to the tool manufacturer s recom mended operating procedure 9 Follow the equipment manufacturer s recommended maintenance schedule for all compressed air equipment Hydraulic Pressing and Lifting Equipment Hydraulic Press WARNING When operating a hydraulic press always be sure that the components being pressed are properly supported on the press bed with steel supports Improperly supported components may suddenly move or fall resulting in personal injury WARNING When using a hydraulic press never operate the pump handle until the pressure gauge exceeds the maximum pressure rating of the press If this pressure is exceeded some part of the press may suddenly break and cause severe personal injury When two components have a tight precision fit between them a hydraulic press is used to sepa rate these components or press them together The hydraulic press rests on the shop floor and an 19 Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right
32. d May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it 4 When a gasoline container must be transported be sure it is secured against upsets 5 Do not store a partially filled gasoline container for long periods of time because it may give off vapors and produce a potential danger 6 Never leave gasoline containers open except while filling or pouring gasoline from the container 7 Do not prime an engine with gasoline while cranking the engine 8 Never use gasoline as a cleaning agent Housekeeping Safety 1 Keep shop floors clean Always clean shop floors immediately after a spill 2 Store paint and other flammable liquids in a closed steel cabinet Figure 1 3 3 Oily rags must be stored in approved covered garbage containers Figure 1 4 A slow generation of heat occurs from oxidation of oil on these rags Heat may continue to be generated until the ignition temperature is reached The oil and the rags then begin to burn causing a fire This action is called spontaneous combustion However if the oily rags are in an airtight approved container the fire cannot receive enough oxygen
33. d or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it Safety and Shop Practices Upon completion and review of this chapter you should be able to LI Recognize shop hazards and take the necessary steps to avoid personal injury or property damage _J Explain the purposes of the Occupational Safety and Health Act OSHA Ll Identify the necessary steps for personal safety in the automotive shop D Describe the reasons for prohibiting drug and alcohol use in the shop D Explain the steps required to provide electrical safety in the shop D Define the steps required to provide safe handling and storage of gasoline D Describe the necessary housekeeping safety steps D Explain the essential general shop safety practices D Define the steps required to provide fire safety in the shop LI Describe a typical fire extinguisher operating procedure _J Explain four different types of fires and the type of fire extinguisher required for each type of fire D Describe three other pieces of shop safety equipment other than fire extinguishers D Follow proper safety precautions while handling hazardous waste materials D Dispose of hazardous waste materials in accordance with state and federal regulations I Describe t
34. d that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it Bz i ULUL LLII 727 77 ke 104 AT AU AA RRQ ARTE TENTE AAA AA AN NY NN POWERMAS TER Figure 1 20 Parts washer with electromechanical agitator Cold Parts Washer with Agitated Immersion Tank Some parts washers have an agitated immersion chamber under the shelves which provides thorough parts cleaning Folding workshelves provide a large upper cleaning area with a con stant flow of solution from the dispensing hose Figure 1 21 This cold parts washer operates on Degreasol 99R cleaning solution Figure 1 21 Cold parts washer with agitated immersion tank 25 Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it Figure 1 22 Aqueous parts cleaning tank Aqueous Parts Cleaning Tank The aqueous parts cleaning tank uses a water based environmentally friendly cleaning solution such as Greasoff 2 rathe
35. ditorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it TABLE 1 1 FIRE EXTINGUISHER SELECTION Courtesy of General Fire Extinguisher Corporation FIRES OPERATION USE A 7 FOAM GLASS FIRES soLurion oF OK FOR A B ou oreert sreeam ALUMINUM INTO THE BURNING ORDINARY COMBUSTIBLE SULPHATE AND LIQUID ALLOW FOAM TO MATERIALS SUCH AS BICARBONATE E WOOD PAPER TEXTILES NOT FOR C FALL LIGHTLY ON FIRE AND SO FORTH REQUIRES COOLING SUENCHING pe CARBON DIOXIDE DIRECT NOT FOR DISCHARGE AS CLOSE TO B FIRE AS POSSIBLE FIRST AT EDGE OF FLAMES AND GRADUALLY FORWARD AND UPWARD CLASS B FIRES _ GAS UNDER B C FLAMMABLE LIQUIDS PRESSURE GREASES GASOLINE OILS PAINTS AND SO MULTI ORDINARY FORTH PURPOSE BC DRY CHEMICAL DIRECT REQUIRES BLANKETING TYPE TYPE STREAM AT BASE OF OR SMOTHERING DRY A nor FLAMES USE RAPID LEFT CHEMICAL 3K Fi TO RIGHT MOTION TOWARD C or B ok p FLAMES Cl ror CLASS C FIRES ELECTRICAL EQUIPMENT CZ SODA ACID OKFOR A MOTORS SWITCHES AND BICARBONATE SO FORTH OF SODA SOLU SODA ACID DIRECT STREAM REQUIRES A NONCON SUPLURIC AT BASE OF FLAME DUCTING AGENT NOT FOR BC Additional information regarding types of extinguishers for various types of fires is provided in Table 1 1 Eyewa
36. e material Figure 1 12 The shop owner or manager should have a written contract with the hazardous waste hauler Rather than have hazardous waste mate rial hauled to an approved hazardous waste disposal site a shop may choose to recycle the material in the shop Therefore the user must store hazardous waste material properly and safely and be responsible for the transportation of this material until it arrives at an approved hazardous waste disposal site and is processed according to the law pr FiiEADVANCED ADVANTAGE Sad sed Liquid 7 Advance t Recycling Inc Figure 1 12 Hazardous waste hauler 13 The Resource Conservation and Recovery Act RCRA states that hazardous material users are responsible for hazardous materials from the time they become a waste until the proper waste disposal is completed Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it Material safety data sheets MSDS provide extensive information about hazardous materials The RCRA controls the following types of automotive waste
37. e still on the recommended lift points When a vehicle is raised on a lift be sure the safety mechanism is in place to prevent the lift from accidentally dropping Before lowering a vehicle on a lift always make sure there are no objects tools or people under the vehicle Do not rock a vehicle on a lift during a service job When a vehicle is raised on a lift removal of some heavy components may cause vehicle imbalance on the lift Since front wheel drive cars have the engine and transaxle located at the front of the vehicle these cars have most of their weight on the front end Removing a heavy rear end component on these cars may cause the back end of the car to rise off the lift If this action is allowed to happen the vehicle could fall off the lift Do not raise a vehicle on a lift with people in the vehicle When raising pickup trucks and vans on a lift remember these vehicles are higher than a passenger car Be sure there is adequate clearance between the top of the vehi cle and the shop ceiling or components under the ceiling Do not raise a four wheel drive vehicle with a frame contact lift because this may dam age axle joints Do not operate a front wheel drive vehicle that is raised on a frame contact lift This action may damage the front drive axles Engine Lift WARNING An engine lift has a maximum lifting capacity that is usually indicated on a decal Never lift anything heavier than the maximum capacity of the lift
38. ers and employees should be familiar with workplace hazardous mate rials information systems WHIMS Service technicians and students encounter many hazards in an automotive shop When these hazards are known basic shop safety rules and procedures must be followed to avoid personal injury Some of the hazards in an automotive shop are 1 Flammable liquids such as gasoline and paint must be handled and stored properly 2 Flammable materials such as oily rags must be stored properly to avoid a fire hazard 3 Batteries contain a corrosive sulfuric acid solution and produce explosive hydrogen gas while charging 4 Loose sewer and drain covers may cause foot or toe injuries 5 Caustic liquids such as those in hot cleaning tanks are harmful to skin and eyes 6 High pressure air in the shop compressed air system can be very dangerous if it pene trates the skin and enters the bloodstream 7 Frayed cords on electric equipment and lights may result in severe electrical shock 8 Hazardous waste material such as batteries and the caustic cleaning solution from a hot or cold cleaning tank must be handled properly to avoid harmful effects 9 Carbon monoxide CO from vehicle exhaust is poisonous 10 Loose clothing or long hair may become entangled in rotating parts on equipment or vehicles resulting in serious injury 11 Dust and vapors generated during some repair jobs are harmful Asbestos dust gener ated during brake lining s
39. ervice and clutch service is a contributor to lung cancer 12 High noise levels from shop equipment such as an air chisel may be harmful to the ears 13 Oil grease water or parts cleaning solutions on shop floors may cause someone to slip and fall resulting in serious injury Safety in the Automotive Shop Each person in an automotive shop must follow certain basic shop safety rules to remove the danger from shop hazards When all personnel in the automotive shop follow these basic shop safety rules personal injury vehicle damage and property damage may be prevented Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it Hearing protection Safety Respirator CO goggles AX Welding shield Welding A i Gloves gloves Working clothes Figure 1 1 Shop safety equipment including safety goggles respirator welding shield proper work clothes ear protection welding gloves work gloves and safety shoes Personal Protection 1 Always wear safety glasses or a face shield in the shop Figure 1 1 2 Wear ear plugs or c
40. f control causing exten sive damage and personal injury Most shops have specific bays for certain types of work such as electrical repair wheel alignment and tires and machining Figure 1 23 The tools and equipment required for a certain type of work are stored in that specific bay For example the equipment for electrical and electronic service work is stored in the bay allotted to that type of repair When certain bays are allotted to specific types of repair work unnecessary equipment movement is eliminated Each technician has his or her own tools on a portable roll cabinet which is moved to the vehicle being repaired Special tools are provided by the shop and these tools may be located on tool boards attached to the wall Other shops may have a tool room where special tools are located Adequate workbench space must be provided in those bays where bench work is required mi CAUTION Shop rules vehicle operation in the shop and shop housekeeping are serious business Each year a significant number of technicians are injured and vehicles damaged by disregarding shop rules careless vehicle operation and sloppy housekeeping The application of some basic shop rules helps to prevent serious expensive accidents Failure to comply with shop rules may cause personal injury or expensive damage to vehicles and shop facilities It is the responsibility of the employer and all shop employees to make sure that shop rules are understood and fo
41. ffect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it 25 26 27 28 29 30 All shop equipment must have regularly scheduled maintenance and adjustment Some shops have safety lines around equipment always work within these lines when operating equipment Be sure that shop heating equipment is well ventilated Do not run in the shop or engage in horseplay Post emergency phone numbers near the phone These numbers should include a doctor ambulance fire department hospital and police Do not place hydraulic jack handles where someone can trip over them 31 Keep aisles clear of debris Fire Safety 1 Familiarize yourself with the location and operation of all shop fire extinguishers 2 If a fire extinguisher is used report it to management so the extinguisher can be recharged 3 Do not use any type of open flame heater to heat the work area 4 Do not turn the ignition switch on or crank the engine with a gasoline line discon nected 5 Store all combustible materials such as gasoline paint and oily rags in approved safety containers 6 Clean up gasoline oil or grease spills immediately 7 Always wear clean shop clothes Do not wear oil soaked clothes 8 Do not allow sparks and flames near batteries 9 Welding tanks must be securely fastened in an upright position 10 Do not block doors stairways or exits
42. ft points prior to raising a vehicle Twin posts are used on some lifts whereas other lifts have a single post Figure 1 17 Some lifts have an elec tric motor that drives a hydraulic pump to create fluid pressure and force the lift upward Other lifts use air pressure from the shop air supply to force the lift upward If shop air pressure is used for this purpose the air pressure is applied to fluid in the lift cylinder A control lever or switch is placed near the lift The control lever supplies shop air pressure to the lift cylinder and the switch turns on the lift pump motor Always be sure that the safety lock is engaged after the lift is raised When the safety lock is released a release lever is operated slowly to lower the vehicle Figure 1 17 Lifts are used to raise a vehicle 21 A lift may be referred to as a hoist An engine lift may be called a crane or a cherry picker Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it Lift Safety WARNING Do not raise a vehicle on a lift if the vehicle weight exceeds the maxi
43. gage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it Vehicle Operation When driving a customers vehicle certain precautions must be observed to prevent accidents and maintain good customer relations 1 Before driving a vehicle always make sure the brakes are operating and fasten the safety belt 2 Check to be sure there are no people or objects under the car before you start the engine 3 If the vehicle is parked on a lift be sure the lift is fully down and the lift arms or com ponents are not contacting the vehicle chassis 4 Check to see if there are any objects directly in front of or behind the vehicle before driving away 5 Always drive slowly in the shop and watch carefully for personnel and other moving vehicles 6 Make sure the shop door is up high enough so there is plenty of clearance between the top of the vehicle and the door 7 Watch the shop door to be certain that it is not coming down as you attempt to drive under the door 8 If a road test is necessary obey all traffic laws and never drive in a reckless manner 9 Do not squeal tires when accelerating or turning corners If customers observe that service personnel take good care of their cars by driving carefully and installing fender and seat covers the service department image is greatly enhanced in their eyes These procedures impress upon customers that shop personnel respect their cars Con
44. ge Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it The ASE test Advanced Engine Performance Specialist L1 can only be taken by those technicians who are currently certified in Engine Performance A8 The test is designed to identify those technicians who are knowledgeable in the areas of driveability and emissions related diagnostics on automobiles light trucks and SUVs The test is designed to test the tech nician s knowledge of PCM controlled engine and emission control systems as well as the technician s ability to diagnose and repair the causes of emission failures ASE Advanced Engine Performance Specialist Test L1 Content Area Questions in Test Percentage of Test General Powertrain Diagnosis 5 10 Computerized Powertrain Diagnosis 13 26 ncluding OBD ID Ignition System Diagnosis 7 14 Fuel Systems and Air Induction Systems 7 14 Diagnosis Emission Control System Diagnosis 10 20 I M Failure Diagnosis 8 16 Total 50 100 Shop Projects to Enhance the Theories in Chapter 1 of the Classroom Manual 1 Strike the tread of an inflated tire with a rubber hammer What reaction did you find Why did this reaction occur 2 Place some cold water in a graduated heat resistant container supported on a metal stand and record the exact quantity of water Heat the water with a propane torch until it boils and record the exact
45. hapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it HEXANE Name HEXANE N HEXANE gt 97 OSMA PEL 500 PPM ACGIH TLV 50 PPM EPA Rpt Qty 1 LB DOT Rpt Qty 1 LB LD50 LC50 Mixture LD50 ORAL RAT 28 7 KG MG Route Of Entry Inds _ Inhalation YES Skin YES Ingestion YES D One NTP NO OSHA NO Effects of Exposure ACUTE INHALATION AND INA ARE HARMFUL AND MAY BE FATAL INHALATION AND ACER MAY CAUSE HEADACH AUSEA VOMITING DIZZINESS IRRITATION F RESPIRATORY TRACT GASTROINTESTINAL IARITATION AND UNCONSCIOUSNESS CONTACT VERRE EYES MAY CAUSE IRRITATION PROLONGED SKIN MAY RESULT IN DERMATITIS EFTS Reesor And Symptions OF Ove ues rahe HLTH HAZ CHRONIC MAY INCLUDE CENTRAL Medical an ee Cae By Exposure ure RONE DE First Aid En INGE O NOT INDUCE VOMITIN NOT BREATHING GIVE ARTIFICIAL RESPISATION IF BREATHI EYES IMM ED FL SH W PLENTY OF WATER FOR AT LEAST 15 MI ORN ATERIPORIA LEAST 15 MINS WHILE REMOVING CONTAM i ill Release Procedures WEAR NIOSH MSHA SCBA amp FULL PROT CLTHG SHUT OFF NIT SOURCES NO FLAMES N NES IN AREA STOP LEAK IF YOU CAN DO SO W OUT ONM USE WATER SPRAY TO REDUCE VAPS TAKE UP W SAND OR OTHER NON_COMBUST MATL amp PLACE INTO CNTNR FOR ATER eu PDAT Neutralizing Agent NONE SPECIFIED BY MANUFACTUR
46. has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it National Institute for Automotive Service Excellence ASE Certification Automotive Service Excellence ASE has provided voluntary testing and certification of automo tive technicians on a national basis for many years The image of the automotive service industry has been enhanced by the ASE certification program More than 265 000 ASE certified automotive technicians now work in a wide variety of automotive service shops ASE provides certification in these eight areas of automotive repair 1 Engine repair Automatic transmissions transaxles Manual drivetrain and axles Suspension and steering Brakes Electrical systems Heating and air conditioning oN AMR w N Engine performance A technician may take the ASE test and become certified in any or all of the eight areas When a technician passes an ASE test in one of the eight areas an Automotive Technician s shoulder patch is issued by ASE If a technician passes all eight tests he or she receives a Mas ter Technician s shoulder patch Figure 1 26 Retesting at 5 year intervals is required to remain certified The certification test in each of the eight areas contains forty to eighty multiple choice questions The test questions are written by a panel of
47. hree requirements for shop lay out and explain why these requirements are important CHAPTER I Observe all shop rules when working in the shop I Observe all personal safety precautions while working in the automotive shop D Demonstrate proper lifting procedures and precautions I Demonstrate proper vehicle lift operating and safety procedures I Observe all safety precautions when hydraulic tools are used in the automotive shop I Follow the recommended procedure while operating hydraulic tools such as presses floor jacks and vehicle lifts to perform auto motive service tasks L Follow safety precautions regarding the use of power tools I Demonstrate proper safety precautions dur ing the use of compressed air equipment I Follow safety precautions while using clean ing equipment in the automotive shop D Operate vehicles in the shop according to shop driving rules LI Observe all shop housekeeping rules I Follow the necessary procedures to main tain satisfactory shop air quality J Fulfill employee obligations when working in the shop LI Accept job responsibilities for each job completed in the shop I Describe the ASE technician testing and certification process including the eight areas of certification Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppres
48. icle inside the shop without an exhaust hose connected to the tailpipe Vehicle exhaust contains small amounts of carbon monoxide which is a poisonous gas Strong concentrations of carbon monoxide may be fatal for human beings All shop personnel are responsible for air quality in the shop Shop management is responsible for an adequate exhaust system to remove exhaust fumes from the maximum number of vehicles that may be running in the shop at the same time Technicians should never run a vehicle in the shop unless a shop exhaust hose is installed on the tailpipe of the vehicle The exhaust fan must be switched on to remove exhaust fumes If shop heaters or furnaces have restricted chimneys they release carbon monoxide emis sions into the shop air Therefore chimneys should be checked periodically for restriction and proper ventilation Monitors are available to measure the level of carbon monoxide in the shop Some of these monitors read the amount of carbon monoxide present in the shop air and other monitors pro vide an audible alarm if the concentration of carbon monoxide exceeds the danger level Diesel exhaust contains some carbon monoxide but particulates are also present in the exhaust from these engines Particulates are basically small carbon particles which can be harmful to the lungs The sulfuric acid solution in car batteries is a very corrosive poisonous liquid If a battery is charged with a fast charger at a high rate f
49. ing aluminum or aluminum alloy parts in a cleaning solution Some cleaning solutions will damage these components Always follow the cleaning equipment manufacturer s recom mendations Parts Washers with Electromechanical Agitation Some parts washers provide electromechanical agitation of the parts to provide improved clean ing action Figure 1 20 These parts washers may be heated with gas or electricity and various water based hot tank cleaning solutions are available depending on the type of metals being cleaned For example Kleer Flo Greasoff number 1 powdered detergent is available for cleaning iron and steel Nonheated electromechanical parts washers are also available These washers use cold cleaning solutions such as Kleer Flo Degreasol formulas Many cleaning solutions such as Kleer Flo Degreasol 99R contain no ingredients listed as hazardous by the Environmental Protection Agency s RCRA Act This cleaning solution is a blend of sulphur free hydrocarbons wetting agents and detergents Degreasol 99R does not contain aromatic or chlorinated solvents and it conforms to California s Rule 66 for clean air Always use the cleaning solution recommended by the equipment manufacturer 24 Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deeme
50. ing in severe burns Set the parking brake when working on a vehicle If the vehicle has an automatic trans mission place the gear selector in park unless a service procedure requires another selector position When the vehicle is equipped with a manual transmission position the gear selector in neutral with the engine running or reverse with the engine stopped Always connect a shop exhaust hose to the vehicle tailpipe and be sure the shop exhaust fan is running If it is absolutely necessary to operate a vehicle without a shop exhaust pipe connected to the tailpipe open the large shop door to provide adequate ventilation Carbon monoxide in the vehicle exhaust may cause severe headaches and other medical problems High concentrations of carbon monoxide may result in death Keep hands clothing and wrenches away from rotating parts such as cooling fans Remember that electric drive fans may start turning at any time even with the ignition off Always leave the ignition switch off unless a service procedure requires another switch position Do not smoke in the shop If the shop has designated smoking areas smoke only in these areas Store oily rags and other discarded combustibles in regulation covered metal garbage containers Always use a wrench or socket that fits properly on the bolt Do not substitute metric for English wrenches or vice versa Keep tools in good condition For example do not use a punch or chisel with a mush
51. ips that are intended to be sharp should be kept in a sharp condition Sharp tools such as chisels will do the job faster with less effort Power Tool Safety Power tools use electricity shop air or hydraulic pressure as a power source Careless operation of power tools may cause personal injury and vehicle damage Follow these steps for safe power tool operation 1 OM 8 W IN N 10 11 12 13 14 15 16 17 Do not operate power tools with frayed power cords Be sure the power tool cord has a proper ground connection Do not stand on a wet floor while operating an electric power tool Always unplug an electric power tool before servicing the tool Do not leave a power tool running and unattended When using a power tool on small parts do not hold the part in your hand The part must be secured in a bench vise or with locking pliers Do not use a power tool on a job where the maximum capacity of the tool is exceeded Be sure that all power tools are in good condition and always operate these tools according to the tool manufacturer s recommended procedure Make sure all protective shields and guards are in position Maintain proper body balance while using a power tool Always wear safety glasses or a face shield Wear ear protection Follow the equipment manufacturer s recommended maintenance schedule for all shop equipment Never operate a power tool unless you are familiar with the tool man
52. is easily entangled in rotating parts 8 Wear safety shoes or boots 9 Do not wear watches jewelry or rings when working on a vehicle Severe burns occur when jewelry makes contact between an electric terminal and ground 10 Always place a shop exhaust hose on the vehicle tailpipe if the engine is running and be sure the exhaust fan is running Carbon monoxide in the vehicle exhaust is harmful or fatal to the human body 11 Be sure that the shop has adequate ventilation 12 Make sure the work area has adequate lighting 13 Use trouble lights with steel or plastic cages around the bulb If an unprotected bulb breaks it may ignite flammable materials in the area 14 When servicing a vehicle always apply the parking brake and place the transmission in park with an automatic transmission or neutral with a manual transmission 15 Avoid working on a vehicle parked on an incline 16 Never work under a vehicle unless the vehicle chassis is supported securely on safety stands Figure 1 14 Safety glasses 16 Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subse
53. ith the lifting job Follow these steps when lifting or carrying an object 1 If the object is to be carried be sure your path is free from loose parts or tools 2 Position your feet close to the object and position your back reasonably straight for proper balance 3 Your back and elbows should be kept as straight as possible Continue to bend your knees until your hands reach the best lifting location on the object to be lifted 4 Be certain the container is in good condition If a container falls apart during the lifting operation parts may drop out of the container and result in foot injury or part damage 5 Maintain a firm grip on the object and do not attempt to change your grip while lifting is in progress 6 Straighten your legs to lift the object and keep the object close to your body Use leg muscles rather than back muscles 7 If you have to change the direction of travel turn your whole body instead of twisting it 8 Do not bend forward to place an object on a workbench or table Position the object on the front surface of the workbench and slide it back Do not pinch your fingers under the object while setting it on the front of the bench 9 If the object must be placed on the floor or a low surface bend your legs to lower the object Do not bend your back forward because this movement strains back muscles 10 When a heavy object must be placed on the floor locate suitable blocks under the object to prevent jamming yo
54. kits At least one of the shop personnel should have basic first aid training and this person should be in charge of administering first aid and keeping first aid kits filled Hazardous Waste Disposal WARNING To avoid personal injury when handling hazardous waste material always wear proper protective clothing and equipment detailed in the right to know laws This includes respirator equipment Figure 1 11 All recommended procedures must be followed accurately Figure 1 11 Wear recommended safety clothing and equipment when hazardous materials are handled 12 Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it Hazardous waste materials in automotive shops are chemicals or components that the shop no longer needs These materials pose a danger to the environment and people if they are disposed of in ordinary garbage cans or sewers However it should be noted that no material is considered hazardous waste until the shop has finished using it and is ready to dispose of it The Environ mental Protection Agency EPA publishes a
55. licies require the use of eye protection in the shop Some automotive technicians have been blinded in one or both eyes because they did not bother to wear safety glasses All safety glasses must be equipped with safety glass and they should provide some type of side protection Figure 1 8 When selecting a pair of safety glasses they should feel comfortable on your face If they are uncomfortable you may tend to take them off leaving the eyes unprotected A face shield should be worn when handling haz ardous chemicals or when using an electric grinder or buffer Figure 1 9 Side protectors Figure 1 8 Safety glasses with side protection must be Figure 1 9 Face shield worn in the automotive shop 11 Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it Figure 1 10 First aid kit First Aid Kits First aid kits should be clearly identified and conveniently located Figure 1 10 These kits contain such items as bandages and ointment required for minor cuts All shop personnel must be familiar with the location of first aid
56. list of hazardous materials which is included in the Code of Federal Regulations Waste is considered hazardous if it is included on the EPA list of hazardous materials or if it has one or more of the following characteristics 1 Reactive Any material that reacts violently with water or other chemicals is considered hazardous If a material releases cyanide gas when exposed to low pH acid solutions hydrogen sulphide gas or similar gases it is hazardous 2 Corrosive If a material burns the skin or dissolves metals and other materials it is considered hazardous 3 Toxic Materials are hazardous if they leach one or more of eight heavy metals in con centrations greater than 100 times primary drinking water standard 4 Ignitable A liquid is hazardous if it has a flash point below 140 F 60 C and a solid is hazardous if it ignites spontaneously WARNING Hazardous waste disposal laws include serious penalties for anyone responsible for breaking these laws Federal and state laws control the disposal of hazardous waste materials Every shop employee must be familiar with these laws Hazardous waste disposal laws include the Resource Conservation and Recovery Act RCRA This law basically states that hazardous material users are responsible for hazardous materials from the time they become a waste until the proper waste disposal is completed Many automotive shops hire an independent hazardous waste hauler to dispose of hazardous wast
57. llowed until these rules become automatic habits The fol lowing basic shop rules should be followed 1 Always wear safety glasses and other protective equipment that is required by a service procedure For example a special parts washer must be used to avoid breathing asbestos dust into the lungs Asbestos dust is a known cause of lung cancer This dust is encountered in manual transmission clutch facings and brake linings 2 Tie long hair securely behind the head and do not wear loose or torn clothing 29 Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it Carbon monoxide is a poisonous gas and when breathed into the lungs it may cause headaches nausea ringing in the ears tiredness and heart flutter In strong concentrations it causes death 10 11 12 13 14 15 16 17 18 19 20 21 Do not wear rings watches or loose hanging jewelry If jewelry such as a ring metal watch band or chain makes contact between an electrical terminal and ground the jew elry becomes extremely hot result
58. mple if you are doing a brake job and leave the wheel nuts loose on one wheel that wheel may fall off the vehicle at high speed This could result in serious personal injury for the customer and others plus extensive vehicle damage If this type of disaster occurs the individual who worked on the vehicle and the shop may be involved in a very expensive legal action As a student or technician working on customer vehicles you are responsible for the safety of every vehicle that you work on Even when careless work does not create a safety hazard it leads to dissatisfied customers who often take their business to another shop and nobody benefits when that happens 2 Treat customers fairly and honestly on every repair job Do not install parts that are unnecessary to complete the repair job 3 Use published specifications do not guess at adjustments 4 Follow the service procedures in the service manual provided by the vehicle manufac turer or an independent manual publisher 5 When the repair job is completed always be sure the customer s complaint has been corrected 6 Do not be too concerned with work speed when you begin working as an automotive technician Speed comes with experience 35 Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review
59. mum capacity of the lift This action may result in lift damage or sudden lowering of the lift which may result in personal injury WARNING When a vehicle is raised on a lift the vehicle must be raised high enough to allow engagement of the lift locking mechanism If the locking mechanism is not engaged the lift may drop suddenly resulting in personal injury Special precautions and procedures must be followed when a vehicle is raised on a lift Follow these steps for lift safety 1 2 10 11 12 13 Always be sure the lift is completely lowered before driving a vehicle on or off the lift Do not hit or run over lift arms and adapters when driving a vehicle on or off the lift Have a co worker guide you when driving a vehicle onto the lift Do not stand in front of a lift with the car coming towards you Be sure the lift pads on the lift are contacting the car manufacturer s recommended lift points shown in the service manual If the proper lift points are not used components under the vehicle such as brake lines or body parts may be damaged Failure to use the recommended lift points may cause the vehicle to slip off the lift resulting in severe vehicle damage and personal injury Before a vehicle is raised or lowered close the doors hood and trunk lid When a vehicle is lifted a short distance off the floor stop the lift and check the con tact between the hoist lift pads and the vehicle to be sure the lift pads ar
60. o they are lifting on the vehicle manufacturer s specified lift points The technician carefully positioned the front lift post and arms properly but forgot to check the position of the rear tires in the floor depressions The car was raised on the lift and the technician proceeded with the service work Suddenly there was a loud thump and the rear of the car bounced up and down The rear lift arms were positioned against the floor of the trunk rather than on the rear axle and the lift arms punched through the floor of the trunk narrowly missing the fuel tank The technician was extremely fortunate the car did not fall off the lift resulting in severe damage If the rear lift arms had punctured the fuel tank a disastrous fire could have occurred Luckily these events did not happen The technician learned a very important lesson about lift operation Always follow all the recommended procedures in the lift operators manual The trunk floor was repaired at no cost to the customer and fortunately the shop and the vehicle escaped without major damage amp CASE STUDY 2 A technician was removing and replacing the alternator on a General Motors car After installing the replacement alternator and connecting the alternator battery wire the technician proceeded to install the alternator belt The rubber boot was still removed from the alternator battery terminal While installing this belt the technician s wristwatch expansion bracelet m
61. of the jack stand legs must remain in contact with the shop floor 5 When the vehicle is lowered from the floor jack onto jack stands remove the floor jack from under the vehicle Never leave a jack handle sticking out from under a vehi cle Someone may trip over the handle and injure themselves Cleaning Equipment Safety and Environmental Considerations WARNING Some parts cleaners contain caustic solutions To avoid personal injury always wear protective gloves and a face shield when using this equipment All technicians are required to clean parts during their normal work routines Face shields and protective gloves must be worn while operating cleaning equipment In most states environ mental regulations require that the runoff from steam cleaning must be contained in the steam cleaning system This runoff cannot be dumped into the sewer system Since it is expensive to contain this runoff in the steam cleaner system the popularity of steam cleaning has decreased The solution in hot and cold cleaning tanks may be caustic and contact between this solution and skin or eyes must be avoided Parts cleaning often creates a slippery floor and care must be taken when walking in the parts cleaning area The floor in this area should be cleaned fre quently When the caustic cleaning solution in hot or cold cleaning tanks is replaced environ mental regulations require that the old solution be handled as hazardous waste Use caution when plac
62. om the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it Wa SERVICE TIP When you are finished with a tool never set it on the customer s car After using a tool the best place for it is in your tool box or on the workbench Many tools have been lost by leaving them on customers vehicles Keep tools clean and in good condition When not in use store tools in their proper location Place oily rags and other combustibles in properly covered garbage containers son o Make sure that rotating components on equipment and machinery have guards and that all shop equipment has regular service and adjustment schedules 10 Maintain benches and seats in a clean condition 11 Keep parts and materials in their proper location 12 When not in use store creepers in a specific location 13 Make sure that the shop is well lighted and keep all lights in working order 14 Replace frayed electrical cords on lights or equipment 15 Regularly clean walls and windows 16 Keep stairs clean well lighted and free of loose material If these housekeeping rules are followed the shop will be a safer place to work and cus tomers will be impressed with the appearance of the premises Air Quality WARNING Never run the engine in a veh
63. ontent at any time if subsequent rights restrictions require it 3 The application of driving rules in the shop increases safety protects customer vehi cles and shop property and improves the shop image in the eyes of the customer 4 When good housekeeping habits are developed shop safety is improved worker effi ciency is increased and customers are impressed 5 If some basic rules are followed to maintain shop air quality the personal health of shop employees is improved 6 When employers and employees accept and fulfill their obligations personal relation ships and general attitudes are greatly improved shop productivity is increased and customer relations are improved 7 If a technician accepts certain job responsibilities job quality improves and customer satisfaction increases 8 ASE technician certification improves the quality of automotive repair and improves the image of the profession B CASE STUDY 1 A technician raised a vehicle on a lift to perform an oil and filter change including a chassis lubrication on a Grand Marquis This lift was a twin post type with separate front and rear lift posts On this type of lift the rear wheels must be positioned in depressions in the floor to position the rear axle above the rear lift arm Then the front lift post and arms must be moved forward or rearward to position the front lift arm under the front suspension The front lift arms must also be moved inward or outward s
64. or a period of time the battery becomes hot and the sul furic acid solution begins to boil Under this condition the battery may emit a strong sulfuric acid smell and these fumes may be harmful to the lungs If this condition occurs in the shop the battery charger should be turned off or the charger rate should be reduced considerably 32 Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it WARNING When an automotive battery is charged hydrogen gas and oxygen gas escape from the battery If these gases are combined they form water but hydro gen gas by itself is very explosive While a battery is charged sparks flames and other sources of ignition must not be allowed near the battery WARNING Breathing asbestos dust must be avoided because this dust is a known contributor to lung cancer Some automotive clutch facings and brake linings contain asbestos Never use an air hose to blow dirt from these components because this action disperses asbestos dust into the shop where it may be inhaled by technicians and other people in the shop
65. overs if high noise levels are encountered 3 Always wear boots or shoes that provide adequate foot protection Heavy duty work boots or shoes with steel toe caps are best for working in the automotive shop Footwear must protect against heavy falling objects flying sparks and corrosive liq uids Soles on footwear must protect against punctures by sharp objects Runners and street shoes are not recommended in the shop 4 Do not wear watches jewelry or rings when working on a vehicle Severe burns occur when jewelry makes contact between an electrical terminal and ground Jewelry may catch on an object resulting in painful injury 5 Do not wear loose clothing and keep long hair tied behind your head Loose clothing and long hair are easily entangled in rotating parts 6 Wear a respirator to protect your lungs when working in dusty conditions Smoking Alcohol and Drugs in the Shop Do not smoke when working in the shop If the shop has designated smoking areas smoke only in these areas Do not smoke in customers cars A nonsmoker may not appreciate cigarette odor in his or her car A spark from a cigarette or lighter may ignite flammable materials in the work place The use of drugs or alcohol must be avoided while working in the shop Even a small amount of drugs or alcohol affects reaction time In an emergency situation slow reaction time may cause personal injury If a heavy object falls off the work bench and your reaction time
66. ply the parking brake and place the transmission in park with an automatic transmission or neutral with a manual transmission if the engine is running When the engine is stopped place the transmission in park with an automatic transmission or reverse with a manual transmission Avoid working on a vehicle parked on an incline Never work under a vehicle unless the vehicle chassis is supported securely on jack stands When one end of a vehicle is raised place wheel chocks on both sides of the wheels remaining on the floor Be sure that you know the location of shop first aid kits eyewash fountains and fire extinguishers Collect oil fuel brake fluid and other liquids in the proper safety containers Use only approved cleaning fluids and equipment Do not use gasoline to clean parts Obey all state and federal safety fire and hazardous material regulations Always operate equipment according to the equipment manufacturer s recommended procedure Do not operate equipment unless you are familiar with the correct operating procedure Do not leave running equipment unattended Be sure the safety shields are in place on rotating equipment Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially a
67. quantity of water What happened to the water when it was heated 3 Obtain an empty metal 1 gallon container with a tight fitting top Place about 1 pint of water in the container and heat the container until the water is boiling Then install the top securely and allow the container to cool Cooling time may be reduced by placing ice on the container What happened to the container Why did this happen 4 Obtain a vacuum hand pump and a vacuum advance from a distributor Gradually operate the pump and observe the vacuum diaphragm How much vacuum is required to begin moving the vacuum diaphragm How much vacuum is required to move this diaphragm to the fully advanced position What two forces move the diaphragm Guidelines for Following Proper Shop Practices 1 Technicians must be familiar with shop layout especially the location of safety equip ment This knowledge provides a safer more efficient shop 2 Shop rules must be observed by everyone in the shop to provide adequate shop safety personal health protection and vehicle protection 37 Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional c
68. quent rights restrictions require it 17 When one end of a vehicle is raised place wheel chocks on both sides of the wheels remaining on the floor 18 Be sure that you know the location of shop first aid kits and eyewash fountains 19 Familiarize yourself with the location of all shop fire extinguishers 20 Do not use any type of open flame heater to heat the work area 21 Collect oil fuel brake fluid and other liquids in the proper safety containers 22 Use only approved cleaning fluids and equipment Do not use gasoline to clean parts 23 Obey all state and federal safety fire and hazardous material regulations 24 Always operate equipment according to the equipment manufacturer s recommended procedure 25 Do not operate equipment unless you are familiar with the correct operating procedure 26 Do not leave running equipment unattended 27 Do not use electrical equipment including trouble lights with frayed cords 28 Be sure the safety shields are in place on rotating equipment 29 Before operating electric equipment be sure the power cord has a ground connection 30 When working in an area where extreme noise levels are encountered wear ear plugs or covers Lifting and Carrying Many automotive service jobs require heavy lifting You should know your maximum weight lifting ability Do not attempt to lift more than this weight If a heavy part exceeds your weight lifting abil ity have a co worker help w
69. r current draw tests alternator output tests and alternator normal system voltage tests 24 Multimeters read AC volts DC volts milliamperes amperes and ohms on various scales 25 Digital multimeters have higher impedance than analog multimeters 26 Only high impedance digital multimeters should be used to test computer system components such as oxygen O sensors 27 Tach dwellmeters read engine rpm and ignition dwell 28 A piece of reflective tape attached to a rotating component such as the crankshaft pulley provides a signal for a photoelectric tachometer 29 The probe on a magnetic probe type digital tachometer is installed in the magnetic timing receptacle above the crankshaft pulley 30 The control knob on an advance type timing light may be used to check spark advance 31 When a magnetic probe type digital timing meter is used the offset on the tester must be adjusted for the engine being tested 32 Many ignition module testers check the ignition module and primary ignition circuit voltage and current under various engine operating conditions 33 An oscilloscope contains a cathode ray tube CRT which provides a voltage trace of the ignition system voltage much like a very fast reacting voltmeter 34 Scan testers retrieve fault codes from the computer memory and perform many other diagnostic functions 35 The scan tester must be programmed for the vehicle make model year and type of engine 36 Since most sc
70. r than traditional solvents The immersion tank is heated and agitated for effective parts cleaning Figure 1 22 A sparger bar pumps a constant flow of cleaning solution across the surface to push floating oils away and an integral skimmer removes these oils This action prevents floating surface oils from redepositing on cleaned parts Safety Training Exercises After the equipment operation and safety practices are explained by your instructor complete these safety training exercises to demonstrate your understanding of equipment operation and safety procedures 1 Find the lift points on a specific vehicle in the vehicle manufacturer s service manual Under the supervision of your instructor position this vehicle properly on a lift then use the proper lift operating procedures to raise and lower the vehicle on the lift 2 Find the lift points on a specific vehicle in the vehicle manufacturer s service manual Under the supervision of your instructor raise the front and rear suspension of this vehicle with a floor jack and lower the vehicle onto jack stands Raise the vehicle with a floor jack and remove the jack stands and lower the vehicle 3 Find the lift points on a specific vehicle in the vehicle manufacturer s service manual Under the supervision of your instructor position this vehicle properly on a lift and raise the vehicle Follow proper service and safety procedures to remove and replace all four wheels Remove two wheels
71. re they are easily accessible at all times Everyone working in the shop must know how to operate the fire extinguishers There are several different types of fire extinguishers but their operation usually involves these steps HU Oe WON a Get as close as possible to the fire without jeopardizing your safety Grasp the extinguisher firmly and aim the extinguisher at the fire Pull a pin from the extinguisher handle Squeeze the handle to dispense the contents of the extinguisher Direct the fire extinguisher nozzle at the base of the fire and dispense the contents of the extinguisher with a sweeping action back and forth across the fire Most extin guishers discharge their contents in 8 to 25 seconds Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it 6 Always be sure the fire is extinguished 7 Always keep an escape route open behind you so a quick exit is possible if the fire becomes out of control A decal on each fire extinguisher identifies the type of chemical in the extinguisher and provides operating information Figure 1 6 Shop
72. ressure air in the shop compressor and air lines Serious injury or property damage may result from careless operation of compressed air equipment Fol low these steps to improve safety when using compressed air equipment 1 Wear safety glasses or a face shield for all shop tasks including those tasks involving the use of compressed air equipment 2 Wear ear protection when using compressed air equipment 3 Always maintain air hoses and fittings in good condition If an end suddenly blows off an air hose the hose will whip around and this may cause personal injury 4 Do not direct compressed air against the skin This air may penetrate the skin particu larly through small cuts or scratches If air penetrates the skin and enters the blood stream it can be fatal or cause serious health complications Use only air gun nozzles approved by OSHA 5 Do not use an air gun to blow off clothing or hair 6 Do not clean the workbench or floor with compressed air This action may blow very small parts against your skin or into your eye Small parts blown by compressed air may cause vehicle damage For example if the car in the next stall has the air cleaner removed a small part may go into the carburetor or throttle body When the engine is started this part will likely be pulled into the cylinder by engine vacuum and the part will penetrate through the top of a piston 7 Never spin bearings with compressed air because the bearing will rotate
73. sed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it The Occupational Safety and Health Act OSHA regulates working conditions in the United States Shop hazards must be recognized and avoided to prevent personal injury Personal injury vehicle damage and property damage must be avoided by following safety rules regarding personal protection substance abuse electrical safety gasoline safety housekeeping safety fire safety and general shop safety Occupational Safety and Health Act The Occupational Safety and Health Act OSHA was passed by the United States government in 1970 The purposes of this legislation are 1 To assist and encourage the citizens of the United States in their efforts to assure safe and healthful working conditions by providing research information education and training in the field of occupational safety and health 2 To assure safe and healthful working conditions for working men and women by authorizing enforcement of the standards developed under the Act Since approximately 25 percent of workers are exposed to health and safety hazards on the job the OSHA is necessary to monitor control and educate workers regarding health and safety in the workplace Employ
74. sh Fountains Eve injuries may occur in various ways in an automotive shop Some of the common eye acci dents are 1 Thermal burns from excessive heat Irradiation burns from excessive light such as from an arc welder Chemical burns from strong liquids such as battery electrolyte Foreign material in the eye Penetration of the eye by a sharp object Au FWD A blow from a blunt object Wearing safety glasses and observing shop safety rules will prevent most eye accidents If a chemical gets in your eyes it must be washed out immediately to prevent a chemical burn An eyewash fountain is the most effective way to wash the eyes and every shop should be equipped with some eyewash facility Figure 1 7 Be sure you know the location of the eyewash fountain in the shop 10 Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it Figure 1 7 Eyewash fountain Safety Glasses and Face Shields The mandatory use of eye protection with safety glasses or a face shield is one of the most important safety rules in a shop Many shop insurance po
75. sure gauge must be connected in series at the fuel inlet line 17 The injector balance tester is a timing device that opens each injector for a specific length of time 18 During an injector balance test the fuel system pressure drop is recorded when each injector is opened for a specific length of time 19 Injectors are cleaned with a solution of unleaded gasoline and injector cleaner in a pressurized container connected to the Schrader valve on the fuel rail 20 During the injector cleaning procedure the return fuel line must be blocked and the electric fuel pump must be disabled 21 Conventional 12 volt or self powered test lights should not be used to test computer circuits High impedance test lights should be used for this purpose 22 Test lights of any type must not be used to diagnose air bag circuits Only the vehicle manufacturer s recommended tools should be used on these systems NO ur BP WN 27 Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it 23 Volt ampere testers are commonly used to perform battery load tests starte
76. t any time if subsequent rights restrictions require it Employer and Employee Obligations When you begin employment you enter into a business agreement with your employer A business agreement involves an exchange of goods or services that have value Although the automotive technician may not have a written agreement with his or her employer the techni cian exchanges time skills and effort for money paid by the employer Both the employee and the employer have obligations The automotive technician s obligations include the following 1 10 Productivity As an automotive technician you have a responsibility to your employer to make the best possible use of time on the job Each job should be done in a rea sonable length of time Employees are paid for their skills effort and time Quality Each repair job should be a quality job Work should never be done in a careless manner Nothing improves customer relations like quality workmanship Teamwork The shop staff is a team and everyone including technicians and manage ment personnel is a team member You should cooperate with and care about other team members Each member of the team should strive for harmonious relations with fellow workers Cooperative teamwork helps to improve shop efficiency productivity and customer relations Customers may be turned off by bickering between shop personnel Honesty Employers and customers expect and deserve honesty from automotive
77. to be on the job at the appointed time Regulations Automotive technicians should be familiar with all state and federal regu lations such as the OSHA and hazardous waste disposal laws pertaining to their job situation In Canada employees should be familiar with workplace hazardous materi als information systems WHMIS Employer to employee obligations include 1 Wages The employer has a responsibility to inform the employee regarding the exact amount of financial remuneration they will receive and when they will be paid 34 Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it 2 Fringe benefits A detailed description of all fringe benefits should be provided by the employer These benefits may include holiday pay sickness and accident insurance and pension plans 3 Working conditions A clean safe workplace must be provided by the employer The shop must have adequate safety equipment and first aid supplies Employers must be certain that all shop personnel maintain the shop area and equipment to provide ade quate safety and
78. ufacturer s recom mended operating procedure Serious accidents occur from improper operating proce dures Always make sure that the wheels are in good condition and are securely attached on the electric grinder Keep fingers and clothing away from grinding and buffing wheels When grinding or buffing a small part it should be held with a pair of locking pliers Always make sure the sanding or buffing disc is securely attached to the sander pad 18 Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it 18 Special heavy duty sockets must be used on impact wrenches If ordinary sockets are used on an impact wrench they may break and cause serious personal injury 19 Never operate an air chisel unless the tool is securely connected to the chisel with the proper retaining device 20 Never direct a blast of air from an air gun against any part of your body If air penetrates the skin and enters the bloodstream it may cause very serious health problems and even death Compressed Air Equipment Safety The shop air supply contains high p
79. ur fingers under the object 17 Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it Hand Tool Safety Many shop accidents are caused by improper use and care of hand tools These hand tool safety steps must be followed 1 Maintain tools in good condition and keep them clean Worn tools may slip and cause hand injury If a hammer is used with a loose head the head may fly off and cause personal injury or vehicle damage Your hand may slip off a greasy tool and this action may cause some part of your body to hit the vehicle For example your head may hit the vehicle hood Using the wrong tool for the job may cause damage to the tool fastener or your hand if the tool slips If you use a screwdriver for a chisel or pry bar the blade may shatter causing serious personal injury Use sharp pointed tools with caution Always check your pockets before sitting on the vehicle seat A screwdriver punch or chisel in the back pocket may put an expensive tear in the upholstery Do not lean over fenders with sharp tools in your pockets Tool t
80. ves the right to remove additional content at any time if subsequent rights restrictions require it Shop safety equipment must be easily accessible and in good working condition Ground to _ water pipe Screw clamp solvent drum Transfer pump Bond wire Paint or Figure 1 5 Safe procedures for flammable liquid transfer 24 Keep solvent containers covered except when pouring from one container to another 25 When flammable liquids are transferred from bulk storage the bulk container should be grounded to a permanent shop fixture such as a metal pipe During this transfer process the bulk container should be grounded to the portable container Figure 1 5 These ground wires prevent the buildup of a static electric charge which could result in a spark and disastrous explosion Always discard or clean empty solvent containers because fumes in these containers are a fire hazard Familiarize yourself with different types of fires and fire extinguishers and know the type of extinguisher to use on each fire Shop Safety Equipment Fire Extinguishers Fire extinguishers are one of the most important pieces of safety equipment All shop personnel must know the location of the fire extinguishers in the shop If you have to waste time looking for an extinguisher after a fire starts the fire could become out of control before you put the extin guisher into operation Fire extinguishers should be located whe
81. with an electric impact wrench and the other two wheels with an air impact wrench 4 Draw a layout diagram of your automotive shop or shops indicating the major service areas and service equipment and clearly identify the location of all safety equipment 26 Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eChapter s Editorial review has deemed that any suppressed content does not materially affect the overall learning experience Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it CUSTOMER CARE Some automotive service centers have a policy of performing some minor service as an indication of their appreciation to the customer This service may include cleaning all the windows and or vacuuming the floors before the car is returned to the customer Although this service involves more labor costs for the shop it may actually improve profits over a period of time When customers find their windows cleaned and or the floors vacuumed it impresses them with the quality of work you do and the fact that you care about their vehicle They will likely return for service and tell their friends about the quality of service your shop performs Guidelines for Use of Tools Safety Practices and the Use of Test Equipment
82. workplace The employees must be informed about their rights under legislation regarding the handling of hazardous materials All hazardous materials must be properly labeled and information about each hazardous material must be posted on material safety data sheets MSDS which are available from the manufacturer Figure 1 13 In Canada MSDS sheets are called workplace hazardous materials information systems WHMIS Employers have a responsibility to place MSDS sheets where they are easily accessible to all employees The MSDS sheets provide extensive information about the hazardous material such as Chemical name Physical characteristics Protective equipment required for handling Explosion and fire hazards Other incompatible materials QAM Pw nN Health hazards such as signs and symptoms of exposure medical conditions aggra vated by exposure and emergency and first aid procedures 7 Safe handling precautions 8 Spill and leak procedures Secondly the employer has a responsibility to make sure that all hazardous materials are properly labeled The label information must include health fire and reactivity hazards posed by the material and the protective equipment necessary to handle the material The manufacturer 14 Copyright 2011 Cengage Learning All Rights Reserved May not be copied scanned or duplicated in whole or in part Due to electronic rights some third party content may be suppressed from the eBook and or eC

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