DCS 1101

Name: A. Junid
Subject: Introduction to Automotive Technology

TOPICS ASSIGNMENT:

Instructions:
1. Student shall research the topics and make his/her own format and presentation.
All the same work submitted shall be marked zero. Submit your assignment in
words format through edmodo.com.
2. No submission of assignment after due date or it will consider zero mark.

Date of Submission: 15/09/2015, Tuesday

1. Identify different Personal Protective Equipment (PPE).

PPE includes:
1) Safety gloves for static equipment, e.g. mounting tyres, welding, etc

2) Respirators for work involving fumes, e.g. painting

3) Hearing/ear protectors

4) Eye protectors, e.g. safety glasses, goggles, face shield

5) Safety shoes, i.e. electrical insulation rated, with steel protector for toes

6) Leather apron for welding work

7) Safety helmet for undercarriage work

2. State the 5S culture and explain their meaning.

5s culture is a work philosophy/methodology based on the following points to help make the
workplace environment easy, quick and safe to work at:

1) Seiri (Sift):
• Group tools/materials by type and frequency of use, e.g. manual tools, power tools,
special tools, common lubricants
• Segregate unwanted material from the workplace

2) Seiton (Sort):
• Sort tools/bits according to size
• Make it easy to find and pick up necessary items

3) Seiso (Sweeping and washing)

• Clean up messes immediately
• Also, try not to dirty work area/equipment in the first place
• Apply cleaning as an inspection method
• Maintenance to minimise machinery and equipment deterioration
• Keep workplace safe and easy to work

4) Seiketsu (Standardize)
• Standardize commonly applied processes, procedures and tools
• This includes classifying commonly used items and removing unnecessary ones
• Maintain housekeeping, neatness and organization at all times

5) Shitsuke (Self Discipline)

• This includes teamwork, consideration, making others feel comfortable & doing good
deeds
• Maintain skills and update them by regular training
• Aim for monthly audits against agreed goals

3. What are the classifications of fire?

Classifications of fires:
1) Class A: Wood, paper, trash, plastic, cloth (nonmetal solids)
2) Class B: Flammable fluid & gas
3) Class C: Electrically energised fire
4) Class D: Metals/metal compounds, e.g. Potassium, Sodium, Aluminium, Magnesium types
4. Differentiate monocoque and body & frame construction.

A true monocoque construction is where vehicle loading and overall impact stresses are
designed to be supported by the vehicle's outer body structure:

Source: http://www.slideshare.net/altairhtcus/speed-and-safety-composite-materials-in-motorsport-dallara-automobili

A body & frame construction is where vehicle loading and overall impact stresses are
designed to be supported by the vehicle's frame/chassis. The vehicle body in this case will
be attached to the frame/chassis:

Source: 1) http://www.primermagazine.com/2013/learn/shop-talk-the-chassis
2) https://en.wikipedia.org/wiki/Body-on-frame

5. What are the different automotive glasses?

Types of automotive glass:

1) Safety glass: Specially annealed glass that breaks into granular pieces. Typically applied
for passenger & rear windows
2) Tempered glass: Glass that sandwiches transparent film (often with some UV blocking),
which can also limit crack propagation. Typically used for front windscreen
3) UV reduction glass: Glass with UV reduction film applied to it
4) Tinted glass: Glass with slight green or bronze tint. Typically applied in gradations at the
top of the front windshield
5) Solar energy absorbing glass: Glass with small amount of metals impregnated, e.g. nickel,
cobalt, iron. The metals block/absorb solar radiation/heat to reduce interior heating
6. State different measuring tools and give their applications.

Examples of measuring tools:

1) Metric ruler:
• For approximate measurements, e.g. to nearest 1mm

2) Thickness gauges, e.g. feeler gauges, plastigauge:

• To measure small gaps/clearances
• May be flat-type or wire-type

3) Vernier caliper:
• To measure internal/external lengths/diameters and depth
• For larger Vernier calipers, accuracy to nearest 0.05mm
• For smaller Vernier calipers, accuracy to nearest 0.02mm

4) Micrometer:
• To measure external length/diameters with accuracy to nearest 0.01mm

5) Dial indicators:
• To measure relative movement/depth/bore
• Includes caliper gauges

6) Temperature indicators:
• To measure temperature, e.g. using infrared detection

7) Pressure gauge:
• To measure pressure, e.g. compression

8) Multimeters:
• Includes ohmmeters and voltmeters
• Measures electrical resistance and voltage
• May be used in conjunction with current clamp to measure current
• May also have temperature measurement (thermopile) function
9) Current clampmeter:
• Measures electrical current

10) Oscilloscope and other electronic measurement devices:

• To measure electrical electrical timing, e.g. distributor timing to spark plugs
• Diagnose/test Electronic Control Units (ECUs)
• Wheel alignment and balancing
Procedure in lifting the vehicle with:

A. 2 post lift

1) Check that vehicle weight does not exceed the lift's rating

2) Check the engine location type to identify centre of gravity location (Gilles 2012, p136)

3) Remove luggage from car and counterbalance vehicle if lift manual indicates so. Position
the vehicle's centre of gravity in line with the 2 lifting posts.

4) Identify vehicle jacking points. Refer to vehicle manuals if unsure. Ensure adaptor/contact
block & jacking point are free from oil/debris and that vehicle weight will be evenly spread.

5) For swing arm type, align the posts' swing arms & pads with the undercarriage jacking
points. For plate type, align the contact blocks with jacking points.

6) For air suspension vehicles, check vehicle manual for suspension setting prior to lifting.

7) Ensure all doors closed. Ensure no parts in the way. Signal to others vehicle about to be
raised. Raise vehicle slightly until tires are about 10-18 cm off the ground.

8) Jounce the vehicle to check for sufficient contact/engagement between pads and vehicle
frame/jacking points

9) Ensure all four pads are bearing a load. If any one pad is free to move or if vehicle
appears unbalanced, lower vehicle & reposition the arm/pads

10) Once lifted to suitable height, engage the lifts safety locking device at each post (Gilles
2012, p137). If the height does not allow the locking device, use 4 supplementary stands

11) Ensure the area under vehicle is free from oil and clutter

12) Take care when performing removal and replacement of heavy parts as the center of
gravity of the vehicle may change.

13) If the operation is to be left unfinished for a period of time, always lower the vehicle.

14) After undercarriage work complete, ensure the lift area is free from tools/material. All
doors should be closed. Alert others nearby before lowering.
15) Before driving off, ensure the lift is all the way down and arms/pads secured safely out of
the way

B. 4 post lift

1) Check that vehicle weight does not exceed the lift's rating

2) a) For frame-contact type, Ensure contact block & jacking point are free from oil/debris.
b) For wheel-contact type, ensure tyre track on respective lifting plate & each tyre chocked

3) Ensure all doors closed. Ensure no parts in the way. Signal to others vehicle about to be
raised.

4) Lift to suitable height. Engage the lift safety locking device at each post (Gilles 2012,
p137). If the height does not allow the locking device, use 4 supplementary stands

5) When using 4-post hoist with rolling-bridge jacks:

i) For air suspension vehicles, check vehicle manual for suspension setting prior to lifting
ii) Raise vehicle only until tyres are about 10-18 cm off the ground.
iii) Jounce the vehicle to check for sufficient contact/engagement between pads and
vehicle frame/jacking points
iv) Ensure all four contact blocks are bearing a load.
6) Ensure the area under vehicle is free from oil and clutter

7) If the operation is to be left unfinished for a period of time, always lower the vehicle.

8) After undercarriage work complete, ensure the lift area is free from tools/material. All
doors should be closed. Alert others nearby before lowering.

9) Before driving off, ensure the lift is all the way down and arms/adaptors/chocks secured
safely out of the way

C. Jack & jack stand

1) Check that vehicle weight does not exceed the jack's rating

2) Ensure handbrake engaged. Chock wheels that are not being lifted
3) Remove luggage from car. Prepare jack stands that are similar in type & height

4) Identify vehicle jacking points & stand resting points. Refer to vehicle manuals if unsure. If
needed, use jack adaptor for off-centre axles.

5) For air suspension vehicles, check vehicle manual for suspension setting prior to lifting.

6) Ensure jack stands are similar & same height. Closed vehicle doors. Ensure jack handle
securely fastened, rotated in correct direction for lifting, and jack point free from oil/debris,

7) If planning to remove tires, untighten each wheel nut prior to lifting.

8) If lifting all 4 wheels using jack, start with jack points at lighter end of vehicle. If jacking
only one end or side, skip to step #13 below

9) If jacking on soft ground, use hard backing, e.g. steel plate for jack & jack stand base.

10) Raise(jack) vehicle to required height. Attach stands and lower vehicle slowly onto them.
Do not enter the area under the vehicle while placing, removing or test-tapping the stands
11) Repeat (8) & (9) for other end of vehicle. For some vehicles with lack of jacking points,
vehicle subframe (rocker panel) may be used with long piece of wood to spread weight:

12) Re-check that car is level & lower vehicle to adjust stands if necessary

13) Tap stands gently with hammer to ensure each stand is touching the car and ground

14) If not in the way, jack may remain as a backup. Else, it may be removed

15) After undercarriage work complete, ensure under-vehicle area is free from items. All
doors should be closed. Indicate to others nearby that lowering will commence

16) Raise the heavier end of the vehicle first and remove jack stands. Then lower that end
(loosen release handle) slowly to the ground. Chock the wheels.

17) Raise the other end of the vehicle and remove jack stands. Then lower that end (loosen
release handle slowly) to the ground. Check parking brake is engaged. Remove chocks.
7. List down 20 different hand tools found in the workshop.

1) Torque wrench
2) Wrenches (open-end fixed/adjustable and box/ring type)
3) Ratchets & adaptors
4) Screwdrivers & Hex-drivers
5) Combination Pliers:

6) Diagonal cutter Pliers

7) Rib-joint pliers
8) Vise-grip plier
9) Hammer (may be used with brass bar)
10) Mallet (soft material type)
11) Hole-punch (Center punch)
12) Files
13) Chisel
14) Hacksaw
15) Pullers & Extractors for bearings, bolts, spark plugs:

16) Jacks
17) Jack stands
18) Universal joint adaptors:

19) Manual drills

20) Scissors and cutters

8. What are the use of automotive fasteners and describe its construction.

Automotive fasteners are devices used to mechanically join or affix two or more objects
together. Examples include:
1) Bolts, nuts:
• These are made from steel, with bolt material gradings depending on tensile & yield
strength needed (Gilles 2012, p73)
• Thread pitch will be based on existing standards (Gilles 2012, p72)
• Shear bolts are designed to shear off upon particular shear strength experienced by
the bolt
• Coach(captive) bolts have a lower head section shaped to grip a shaped hole so that
the bolt remains non-rotating while its nut gets screwed in
• Plastic region bolts are designed to deform slightly upon tightening. This helps
ensure uniform tightening strength, e.g. valve covers to the engine block.
• Nylock nuts have nylon fittings to minimise loosening
• Castle nuts are used with cotter pins and bolt holes to ensure no loosening
• Winged nuts are tightened using the hand only

2) Screws:
• Also typically made of steel
• Screws may be machine type (similar thread type to bolts) or self-tapping
• Screw heads may be +, -, star or hex

3) Washers:
• Washers used to reduce loosening risk and spread bolt head / nut /screw pressure

4) Studs:
• Also made of steel but with threads at both ends

5) Rivets:
• Typically made from copper

6) Ties & Straps:

• These may be nylon or velcro type
• Typically used for wire harness and cable dressing

7) Pins:
• Typically made from steel. Used in conjunction with other fastener devices, e.g.
Castle nuts
8) Rings:
• Also made of steel. Often used to hold rotating mass devices in place
• Examples include E rings, Cylinder rings
 9) Snap fasteners:
• May be either metal alloy or plastic
• Typically used for car interior materials

10) Clips:
• Includes C clips

9. Identify different fuel types and lubricants.

Fuel types:

1) Gasoline: Anti-knocking / ignitability precision is defined by Research Octane Number

(RON)
2) Diesel: Anti-knocking / ignitability precision is defined by Cetane Number. Diesel
also acts as a lubricant

Lubricant types:

1) Engine Oils: Used for petrol and diesel engines. Defined by their viscosity index (Gilles
2012, p144-145)
2) Gear Oils: Applied for transmission, differentials and steering. Also defined by a
viscosity index
3) Greases: Multipurpose: Chassis/suspension/door lubrication
Speciality: Disc brakes
High temperature: Wheel bearings, clutch backing plate
Lithium glycol: Brake system cylinders
Molybdenum glycol: Drive shafts
4) Coolant: Used in radiator systems
5) Brake fluid: May be either dot3 (Gilles 2012, p219) or dot4, depending on boiling point
requirements
6) ATF fluid: Automatic Transmission Fluid. Manufacturer specific for automatic
transmissions
7) CVT fluid: Continuous Variable Transmission fluid. Manufacturer specific for CVTs

Note:
i) There are also suspension fluids, but these are usually not authorised workshop replaceable
ii) Sealants are also used to keep fluids gas-tight within its mechanical operating zone
11. Identify types of automotive service manuals

Types of automotive service manuals:

1) Repair manuals:
• Used for detailed troubleshooting and diagnosis reference
• Includes detail on how to remove components
• Includes detail on removal/reinstallation sequence & component inspection

2) Electrical wiring diagrams:

• Used for detailed reference on electrical systems & logic/wiring
3) Special Service Tools:
• Used for detailed reference on special service tools applied for vehicle maintenance /
overhaul

4) New Car Features:

• Used for updates on new features installed by manufacturer
5) Service Data Sheets (a.k.a. Service Bulletin):
• Used for updates on recommended settings, e.g. belt tension, valve clearances

6) Owner's manual:
• Used by vehicle owner for operations and minor maintenance reference

7) Other supplementary manuals:

a) Repair manuals for bodies:
• For body repair reference
b) Fundamental manuals for painting
• For painting reference

c) HFC134a air conditioning fundamentals & repairs

• For air cond. system maintenance reference

d) Audio component service manual

• For audio system testing/repair reference
e) Flat rate manual
• For reference on recommended pricing for work done

f) Electrical system diagnosis manual

• For electrical system diagnosis and repair reference

g) Training bulletins
• For training updates required
h) Service bulletins
• Updates on service practice / intervals

i) Product updates (a.k.a. recall/callback bulletins)

• Used for reference on product replacements/recalls

---