Chapter One: Introduction

1.1 Introduction
This is a study of the use of service manuals in the workshop, and its importance. It also shows how the use of service manuals could affect the business, the vehicle, and the mechanic in the workshops and the problem that those who aren’t using the manuals. This chapter is a prelude of the background, the purpose, the objectives, and the focus of the study. It state the issue of the study related to the field of automotive, the aim, the reasons, and the focal point of the study.

1.2 Background of Study
The main task of automotive industries is to offer quick and quality of service for transportation of goods and passengers. The main measure toward servicing vehicle is to use the workshop manual while undergo repairs and maintenance on vehicle. The good design of a service manual is to help in providing procedures for repairs work, vehicle maintenance. My motivation for researching the use of workshop manual in service center is based on the following: Expensive and sometimes inefficient service centres. The study of automotive technology has taught me that by following the precaution, diagrams and procedures in the workshop manual can help save life from risk that may not be visible while working on some parts of the vehicle, and save time in finishing the repair job which the salary is based on (Flat Rate).


1. customers have to return for a couple of times to fix the car.  To predict which part of vehicle needs to be replaced due to excessive wear. the vehicle breaks down completely because of not following the specification in the manual while doing some adjustment to the components of the vehicle. and how to work safely.    To explore the procedures in the workshop manual. To compare the quality of repairs between using the manual and not using it. For most of the time. heavy equipment and office etc. Organizational structures and service procedures 2 .) is necessary while performing vehicle maintenance.3 Statement of Problem In Petaling Jaya. 1. most of the non-dealership service centres don’t use the service manual while servicing the vehicle.1. fire and rotating object. which would have been a waste of time and money. how to keep the work done fast. This could result in further damage to other components of the vehicle which might be expensive to repair.4 Purpose of Study  To determine what (tools. To investigate how to give a better service. And in some rare cases.5 Objective of Study The prime objective of this study is to provide an awareness to use the service manuals that gives:    Physical layout of the vehicle parts and component to refer to Precaution of danger in certain contact with chemical.

6 Focus of Study The spotlight of this study is to create a competitive service center that is capable of handling difficult task smoothly with particular reference to the service centers.7 Conclusion Service manuals are a fundamental part of every service center wishing to provide quality service to vehicle. along the busiest street and close to each other. All participants are located in the suburban area of Petaling Jaya. and also to balance the whole mechanic body so that there won’t be any severe vibration which could cause the parts to fell off its attachment.1. Following procedure on the manual is to ensure that we can reassemble it back the way it was without missing a part. Safety precautions are provided to allow the technician to realize the danger and to be prepared of it in case of an emergency. 1. 3 .

Repair manuals in 1965 were relatively small.[1] Service manuals explain how to carry out maintenance. it is a good idea to consult the service manuals for any helpful hints and precautions that will make the task easier. and was about only 5000 pages comparing to today’s which about 1. or information store on compact disc. It describes. identify the types of manuals.1 Introduction The purpose of literature is to provide the background to and justification for the research undertaken. networks and on the internet. clarify and integrate the content of the study of services manuals. and to put my work into perspectives. [1] 4 . evaluate.6 billion of pages and still continuing to grow. 2. restoration and servicing cars. computer hard drives. Before working on any make of vehicle for the first time.2 Service Manuals Many procedures had to be learned to successfully service and repair automobiles.Chapter Two: Literature Review 2. summaries. the literature review will provide information about service manuals. Through this chapter. Service information for only one make of today’s make of vehicle is usually consists of more than one manual.

often including warnings against doing things that no intelligent person would consider doing. for when the product does not work as expected. for productions that need to be installed in a home or workplace. for microprocessor controlled products such as VCRs.Information contained in the Service Manual typically includes:  Safety instructions.     Maintenance instructions. for products that arrive in pieces for easier shipping. [4] 5 . for devices that keep track of time or which maintain user accessible state.  Programming instructions. for liability reasons these can be extensive. Setup instructions. Service locations.  Product technical specifications. for when the product requires repair by a factory authorized technician. programmable calculators. Installation instructions. for example with respect to safety or electromagnetic interference. and synthesizers. Troubleshooting instructions.    Assembly instructions. Regulatory code compliance information.

and depending on the answer will branch off in two or more directions. It will ask a question. Repair Manuals contain specification charts for the amount of torque required for a bolt.2. [1] 6 .1 Manufacturers’ Service Manuals Service information contained in this shop manuals are usually:    Diagnostic or troubleshooting information Step by step repair information Specification charts Repair manuals will have a diagnostic tree that goes in a logical progression. The last box in the tree will have the problem and how to correct it. Repair Manuals offer step by step guidance throughout the entire repair with the help of diagrams and technical charts to make even the most difficult repair seem effortless.3.3 Types of Service Manuals       Manufacturers’ Service Manuals Generic Service Manuals Lubrication Service Manuals Owners’ Workshop Manuals Electronic Service Information Interchange Manuals [1] 2. and accompanied by diagram to help visualize which bolt it is referring to. usually yes or no.

Each first page of the sections is an index of service operations that can be used to locate a particular service procedure. and valves. and wheel lug torque specifications. lubrication diagrams and specification. Many manuals have separate sections for different component repair and a few pages of each page contain specifications for tune-up. 7 .2. engine alignment. There are two types of generic manuals:   Manuals for mechanical repairs Fuel/emission/ignition/air-conditioning manuals Comprehensive generic repair manuals include section for each makes of car arranged in alphabetical order by maker and is located in the front of the manual. and preventative maintenance intervals. electrical.3.2 Generic Service Manuals Generic service manuals which deal with all makes of either foreign or domestic cars are produced by several companies. [1] 2. vehicle lift points. The capacities section includes cooling and air-conditioning system capacities. engine tightening. wheel alignment.3.3 Lubrication Service Manuals Lubrication service manuals have all of the most used specification. It is arranged in three basic sections:    Lubrication and maintenance information Capacities Under hood Service Information The Lubrication and maintenance section includes lube and maintenance instruction. cooling system air bleed locations wheel and tire specifications.

Subscriptions to computerized information library like: AllData and Mitchell On Demand are available. The information is easy to access from selection on the screen.6 Interchange Manuals Salvage yards use an interchange manual that lists parts that interchange from one vehicle to another. and fuel system. [1] 2. specifications for engine tune-up. [1] 2.3.3. diagrams. It contains all essential information of that vehicle for repair. cover several years of one model of car. information can be stored in CDs or DVDs that are updated quarterly. On single-user systems. service and maintenance. mechanical. electrical.5 Electronic Service Information The predominant storage system for service information has to be the computer. and read off directly from the screen or printed by computer printer and taken to the service bay or workbench.4 Owners’ Workshop Manuals Owners’ workshop manuals often sold by parts stores. [1] 2. and is available for both domestic and imported vehicles [1] 8 .3.The under hood service information section includes under hood service instructions. It is updated with new material each year. and belt tensions.

we can help save fuel economy and prevent certain damage to the vehicle components that require periodic checks. If the same is ignored or delayed with time. Get the right service manual for that vehicle. your vehicle maybe in trouble. [3] 2. 4.5 How to Use a Service Manual 1. Manuals are specific to the make. engine oil level check. e. Consult the Table of Contents to determine which section contains the information you desire. you could save up money spent on fuel and repairs that can be prevented if the vehicle is serviced according to the manual.[3] The timely detailed maintenance must be followed as per schedule to keep the vehicle running flawlessly without any troubles. and diagram which help to locate all the vehicle parts. Consult the following table for description of symbols that maybe used on the vehicle or throughout this service manual. Follow the step by step instructions to begin repair/service/maintain the vehicle. [1] 9 .g. [2]  Cheap – With periodic maintenance.2. 3. 2. model and year.4 Importance of Service Manuals  Quality of work – By following the basic maintenance checks in the manuals.

6 Conclusion There are so many types of service manuals. more than one type of manual is needed in the workshop to get the information. I find that it is much better to use manuals obtain from internet services like AllData. 10 . Sometimes service center might provide a number of services. because it’s cheaper and information could be attain easily. for example: Lubrication service. if the service center handles different kinds of vehicle in a high volume.2. each with a specific usage for different types of service centers.

What are the advantages of using this method? Answer: This method is useful as it helps to prevent bias in gathering and presenting research data. The advantages and disadvantages as well as the reliability of this instrument were also part of the objectives. and also establish very specific research problem and terms. In order to answer these research goals. the researcher also made use of secondary resources in the form of published articles and literatures to support the survey results. Data gathered from this research instrument were then computed for interpretation. Specifically.1 Introduction This research is to systematically solve the problem of this research by using scientific method to collect data.2.1 Questionnaire What method is being used? Answer: Quantitative method. and interpret the data using diagrams and words.2 Methods of Research This research was conducted in order to determine whether personality questionnaire play a significant role in the servicing vehicle using manuals. Why is this method being used? Answer: Because it is able to show the objectives of my study clearly in the way it is meant for. 3. 11 . Along with primary data.Chapter Three: Research Methodology 3. a total of 4 respondents from 3 service centre within Petaling Jaya were selected. Selected participants answered a survey questionnaire. 3. Various steps are adopted in the research along with the logic behind them. the researcher opted to obtain the view of human resource employees in line with this topic.

The duration of time taken to answer the question. The questionnaire was divided into two main sections: a profile and the survey proper.3. particularly on its usability and reliability of the service manuals as a selection and appraisal tool.1 Questionnaire How many questions are there in the survey? Answer: There are 5 question in total used.3 Instrumentation The survey questionnaire was used as the main data-gathering instrument for this study. along with a few subjective. The profile contains socio-demographic characteristics of the respondents such as age. How is the answer being laid out? Answer: It is in an ABCD multiple choice formats. civil status. The questionnaire proper section also contains questions that identify the advantages and disadvantages of using service manuals in the service department. Answer: The estimated time taken would be around 5 to 10 minutes. The survey proper explored the perceptions of employees on personality questionnaire. 12 . gender. What is the question about? Answer: the question is about the usage of service manuals in the participant’s workshop. the number of years they had served the company as well as their assigned job position. 3.3.

3. This deductive approach to research considers a potential cause of something and hopes to verify its effect. 13 . 47300.3.) Specialize in servicing Mitsubishi lorry.5 Methodology The method used in collecting data is quantitative. The quantitative research looks at the general case of this research and moves toward the specific. Jalan Ss 2/72. Petaling Jaya. Jalan 19/1Â Seksyen 19.  Perodua Service Center (Lot 11. Petaling Jaya.5. Selangor) Specialize in servicing Perodua vehicles. 3.1 Questionnaire How’s the method being carried out? Answer: Survey questions are printed onto papers and distributed to the participants to answer. where tons of vehicles are always passing by this suburban area.) Specialize in all makes of vehicle servicing. All of the participant can be located near Rothmans Roundabout. Statistical model is constructed based on the data collected from the survey and interpreted in the form of numbers and statistics. Selangor. Petaling Jaya. Selangor.4 Target Group The participants are:  Autodoc Sdn. when the service centers have just open. 46300. When did the surveys being carried out? Answer: The surveys are carried out in a Saturday morning. How long is it to collect the surveys? Answer: Around an hour. Jalan 19/1Â Seksyen 19. Bhd (67.  Camic Auto Service Center (Lot13. 46300.

3. The survey is then collected back. and the data based on the answer which is answered by the personal of the service centers is then interpreted. The questionnaires are given to three service centers to answer the questions. 14 .6 Conclusion Survey questionnaire has been used to collect data from this research in order to find out whether Service Manuals is being used by technicians to undergo some work on the vehicle he or she is servicing.

the specific charts are the main reasons for the technicians in the workshop to inspect the components of the vehicle which they are servicing. Bhd Based on the data from the histogram. And that the advantage in using the manual is a smoother task. 15 . the data collected is then show in the form of histogram. of Technician using the Service Manuals 15 5 0 Perodua Service Center Camic Auto Service Center Autodoc Sdn. According to the supervisor from Perodua. Bhd is the only one who doesn’t use the manual.1 Introduction As research on the use of service centres have been made. According to the senior technician from Camic. some of the technicians in the workshop rely on the procedure in the manual to undertake repairs of heavy vehicles (Mitsubishi lorry). Perodua service center and Camic Auto service center are using service manuals during vehicle inspection. Discussion is then made based on that histogram to evaluate the data and to explain the reason. Autodoc Sdn.Chapter Four: Results and Discussions 4. 4. diagnose and repair jobs.2 Results of Findings 25 20 Service Manuals No. of Technicians 10 No.

According to Autodoc. Certain danger of chemical that could cost them a life time of suffers. the reasons for the use of service manuals are different from service center to another. 4. This is because most of the vehicle they service is based on experiences that the technicians have. And that certain bolt should be tightened according to the procedure to ensure that it is sealed properly.which is very difficult to do.3 Conclusions In conclusion. and that they don’t rely on manual to perform repairs. for example: brake fluid. 16 . there is no manual in the shop. And the manual has helped them save time to perform difficult task that might take even several days to have the job done. and that they are no well aware of the importance of the information in the service manuals.

the entire previous chapter is being summarize and further recommendation of study is also reckoned. 17 . On the final chapter.Chapter Five: Conclusions 5. the goal and where the research had taken place. On the second chapter. the first chapter is used to familiarize with the main idea of the research. all the data collected from the research was being formulated and analyzed.1 Introduction In order to find out the importance of service manuals in a workshop. it shows the written materials from other author from various sources that is related to the topic of this research. where specifically did it take place. the conclusion of the research is written. and which method was used to collect the data. Results of this research are also presented in this chapter. it shows how the walkthrough of this research. a research has been undergone and a report has been formulated to show the results of that research. On the third chapter. On the fourth chapter. In this report. the reasons.

handing over the survey questionnaire to one of the employee to acquire information about the usage of service manuals in their workshop. so that technicians would know about the advantages of manuals and continue to recommend its uses to others. By visiting the target groups. which will help to build a better automotive industry in Malaysia. This is because the skill and knowledge taught by teachers in college should include the use of manuals. the information collected differs from one another and is shown in the graph above (chapter 4). by first building the foundation. Education is the foundation of all types of industry. model and year.2 Summary This research of service manuals in the workshop is to understand the importance about using the manuals while doing certain work on vehicles. To look for new and better ways to enhance one of the Malaysia largest industries. but they are all design to make sure that the vehicle is working in tip top condition.3 Recommendation To further this study. 5. 18 . there should be a research on the education of auto repairing in this country to improve the services in this industry. Overall.5. most of them use the manuals to refer to information written before they repair a vehicle. Although there are many types of manual and each differs from the vehicle makes.

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