Table Of ContentAUTOMOTIVE
SERVICES 26
TL
152
A94
1991 STUDENT
RKBOOK
/dlberia
EDUCATION
S
Ex
LIBRIS
UNIVERSITATI
ALBERT/ENSIS
Automotive Services 26
Student Workbook
Grade 11
INTERIM -1991
ALBERTA EDUCATION CATALOGUING IN PUBLICATION DATA
Alberta. Alberta Education.
Automotiveservices26 studentworkbook.
:
ISBN 1-55006-209-3
1. Automotives-- Maintenance and repair--
Studyand teaching --Alberta.
I. Integrated Occupational Program. II. Title.
TL152.A333 1991 629.287
Copyright 1991, the Crown in Right of Alberta, as represented by the Minister of
Education. Alberta Education, 11160 JasperAvenue, Edmonton, Alberta, T5K 0L2. All
rights reserved.
The materials contained in this Student Workbook have been derived from
numerous sources and are designed to provide specific support to selected areas
of the curriculum. Every effort has been made both to provide proper
acknowledgement of the original source and to comply with copyright
regulations. If cases are identified where this has not been done, it would be
appreciated if Alberta Education could be notified to enable appropriate
corrective actionto betaken.
UNIVERSITY LIBRARY
UNIVERSITY OF ALBERTA
ACKNOWLEDGEMENTS
Alberta Education acknowledges with appreciation the contributions of the following individuals
and schooljurisdictionstothe developmentand validation ofthisdocument:
ASSISTANTDIRECTOR: A. A. (Scotty) Day
INTEGRATED OCCUPATIONALPROGRAM MANAGER: Michael Alpern
PROGRAM MANAGER, OCCUPATIONALCOMPONENT: Michael Alpern
PROGRAM DEVELOPMENTOFFICER: Paul McNair
CURRICULAR CONSULTANT: DarleneGamier
INTEGRATED OCCUPATIONALPROGRAM PROJECTTEAM
Gary Bertrand
JeanneCooper
Lorraine Crawford
Marilyn Dyck
Selwyn Jacob
Jan Marvin
Kathy McCabe
Linda Snow
INTEGRATED OCCUPATIONALPROGRAM REVIEWCOMMITTEE:
StuartAdams CountyofStrathcona No. 20
PatBoon-Anderson Lac La BicheSchool Division No. 51
Christopher Harrison Alberta Vocational College, Edmonton
Ed (Edwin) Holt Conference ofAlberta School Superintendents
Wayne Nixon Alberta Career Developmentand Employment
Hugh Sanders Alberta Education
William Smolak Countyof Minbum No. 27
Carol Steen LethbridgeSchool DistrictNo. 51
DougTarney WetaskiwinSchool DistrictNo. 264
EDITING: Elizabeth McCardle
DESKTOPPUBLISHING: Jan Cruickshank
LinGray
Tania Pander
Cheryl Stoochnoff
SECRETARIES: Rita Flint
MarcieWhitecotton-Carroll
Jacquie Reinprecht
ILLUSTRATORS: JenniferAnnesley
Kelvin Ogden
DwightAbbott
GraphicConnections
In addition, Alberta Education acknowledges, with appreciation, the contributions of educators and
representativesofbusinessand industry inthedevelopmentofthisdocument.
i
4
TABLE OF CONTENTS
PAGE
INTRODUCTION
1
SAFETY 6
VEHICLE PARTS 9
SHOP PROCEDURES 12
Inventories 12
Product Identification 15
AutomotiveSuppliers 16
Shop References 20
EquipmentCareand Maintenance 24
TOOLSAND FASTENERS 29
HandTools 29
MeasuringTools 32
Fasteners 46
CLEANING VEHICLES 48
AUTOMOTIVE ENGINES 52
The Four-Stroke Cycle 52
Engine SupportSystems 57
AUTOMOTIVE FUELSYSTEMS 62
System Components 62
Fuel Filters 66
Carburetors 76
AUTOMOTIVETIRES 100
Construction 100
SizeCodes 103
Wear Diagnosis 106
Inflation 110
Tire Rotation 113
AUTOMOTIVE BRAKES 117
Drum Brakes 118
DiscBrakes 137
AUTOMOTIVETESTING 140
CompressionTests 142
VacuumTests 149
Cooling System PressureTests 153
Oil PressureTests 158
TABLE OF CONTENTS (continued)
PAGE
COMMON REPLACEMENTSERVICES 162
Changing Engine Oil and Oil Filter 162
Replacing Cooling System Hoses 170
Replacing Fan Belts 175
Replacing AutomotiveBatteries 178
Replacing Headlights 181
Replacing LightBulbs .... 185
ReplacingWindshield Wiper Blades 188
WELDING 191
OxyacetyleneWelding Equipment 193
OxyacetyleneSafety 197
GasWeldingTerms ............................................................... 200
Types ofFlames 201
BrazeWelding .... ........................................................... 208
Fusion Welding ......................... ................................. 218
FlameCutting .......................................... ..................... 227
WORKSTANDARDSAND MANAGEMENT 235
GLOSSARY 236
APPENDICES
1. AutomotiveServices 26Profile ................................................. 237
2. MajorComponent Removal'and Replacement Chart 239
3. WorkStandardsand Management Monthly Evaluation Chart 240
4. Job Sheet Evaluation Chart 241
COPYRIGHTACKNOWLEDGEMENTS 244
JOB SHEETS
PAGE
1. CollectingAutomotiveJobAdvertisements 4
2. IdentifyingVehicleParts 10
3. Takingan Inventory 13
4. Identifying LocalAutomotiveSuppliers 18
5. Using Shop Manuals 22
6. Maintaining Equipment 26
7. Measuring with Calipers 34
8. Measuring with Micrometers 45
9. Detailing aVehicle 50
10. Identifying EngineComponents 54
11. Identifying EngineSupportSystem Components 60
12. Tracing theFuel System 64
13. Locating Fuel Filters 67
14. Changing an In-Line Fuel Filter 70
15. Changing a Screw-on Fuel Filter 72
16. Changing an In-CarburetorFuel Filter 74
17. Adjusting Curb IdleSpeed 83
18. Adjusting Fast Idle Speed 86
19. Adjusting Idle MixtureScrews 88
20. Investigating ModernCarburetorAdjustment 90
21. Adjusting a Modern Carburetor 92
22. Adjusting anAutomaticChoke 93
23. Investigating CarburetorOverhaul 95
24. Disassembling and Reassembling a SimpleCarburetor 97
25. AdjustingTire Inflation Ill
26. Performing aTire Rotation 114
27. Removing and Replacing BrakeShoes on a Simple Drum Brake Unit 122
28. Removing and Replacing BrakeShoeson a BendixBrake Unit 125
29. Removing and Replacing BrakeShoeson a Delco Morraine Brake Unit 129
30. Adjusting RearDrum Brakes 132
31. Bleeding the Brake HydraulicSystem 134
32. Removing and Replacing aSetofDiscPads 138
v
JOB SHEETS (continued)
PAGE
33. Takinga CompressionTest 146
34. Performing aVacuumTest .... 151
35. PressureTesting a Cooling System 154
36. Performing an Oil PressureTest 159
37. Changing the Engine Oil and Filter ................................... 164
38. Replacing an UpperRadiatorHose .......................................... 171
39. Replacing a Fan Belt 176
40. Replacing a Battery ............................................................ 179
41. Replacing a Headlight 182
42. Replacing a Signal LightBulb ............................................... 186
43. ReplacingWindshieldWiperBlades ............................................. 190
44. Setting UpandTesting an Oxyacetylene Unit 202
45. Lighting, Adjusting and Shutting Down aTorch ................................... 205
46. BrazeWelding a ButtJoint 210
47. BrazeWelding a LapJoint ...................................................... 214
48. Practising HeatControl 219
49. Welding a FusionJoint 222
50. Welding with a Filler Rod 225
51. Practising FlameCutting 232
Use Appendix 4: Job Sheet Evaluation Chart to monitor your own performance and have your
teacher/supervisorand a classmateevaluateyourperformanceeachtime you complete ajob.
VI
