ROBERTO T.

AQUENDE
REGISTERED MECHANICAL ENGINEER

TRAINERS METHODOLOGY CERTIFICATE I

NATIONAL TVET TRAINER CERTIFICATE LEVEL I IN

AUTOMOTIVE SERVICING NC II
AUTOMOTIVE MECHANICSTENTH EDITION
BY ANGLIN AND CROUSE
AUTOMOTIVE SERVICING NC I &
II TRAINING
 AUTOMOTIVE SERVICING NC I
BASIC COMPETENCIES
Received and respond to workplace communication
Work with others
Demonstrate work values
Practice basic housekeeping procedures
COMMON COMPETENTCIES
Validate vehicle specification
Move and position vehicle
Utilize automotive tools
Perform mensuration and calculation
Utilize workshop facilities and equipment
Prepare servicing parts and consumables
Prepare vehicle for servicing and releasing
AUTOMOTIVE SERVICING NC II
BASIC COMPETENCIES
Participate in workplace communication
Work in team environment
Practice career professionalism
Practice occupation health and safety procedures
COMMON COMPETENTCIES
Apply appropriate sealant /adhesive.
Move and position vehicle
Perform mensuration and calculation
Read, interpret and apply specifications and manuals
Use and apply lubricants/ coolants
Perform shop maintenance
Perform job estimates
Interpret/draw technical drawing
Practice shop safety procedures
Inspect technical quality of work
Maintain quality systems
Provide work skill instructions
Identify and select original automotive parts and products
AUTOMOTIVE SERVICING NC I
CORE COMPETENCIES
Perform pre-delivery inspection
Perform periodic maintenance of automotive
engine
Perform periodic maintenance of drive train
Perform periodic maintenance of brake system
Perform periodic maintenance of suspension
system
Perform periodic maintenance of steering system
AUTOMOTIVE SERVICING NC II
CORE COMPETENCIES
Service automotive battery
Service ignition system
Test and repair wiring /lighting system
Service starting system
Service charging system
Service engine mechanical system
Service clutch system
Service differential and front axle
Service steering system
Service brake system
Service suspension system
Perform under chassis preventive maintenance
Overhaul manual transmission
AUTOMOTIVE MECHANICS
Introduction to the automobile
Defining the automobile
Self –propelled vehicle or motor /automotive vehicle that travels by
land, such as cars, buses and trucks.
History
Automobile were existing since more than 100 years earlier, invented in Germany by Karl
Benz 1885, intended for personal transportation only and later it is use for commercial /
business transportation. Then followed by several inventor like Charles and Frank 1893, in
USA, by Henry Ford in USA in 1895.

Major Components of an Automobile (7 Basic Parts and System)

1. Engine – a machine that converts heat energy into mechanical energy. It
produces power to move the vehicle through burning of fuel inside cylinders or
combustion chambers. Internal Combustion Engine
2. Power train –mechanism that carry power from the
engine crankshaft to the drive wheels; it includes the clutch
assembly, transmission, drive shaft, differential, and axles.
3. Suspension system – automotive system that carry vehicle weight,
stabilizes steering system, maintains wheel traction and absorbs the
shock of the tires and wheels meeting bumps and holes in the road.
Includes springs, shock absorbers, and related parts between the wheels
and vehicle body or frame.
4. Steering system – mechanism that enables the driver to
control the direction of vehicle travel.
5. Braking system – the system which is used to slow and
stop the vehicle.
6. Electrical system – provides electricity for cranking the
engine, charging the battery, and powering the lights and
other electrical equipment.
7. Body – provides enclosures or compartments for the
engine, for safety and comfort of passengers and
luggage or cargoes.
Mounting of an engine
• Longitudinal mounting

• Transverse mounting
Identifying the Drive Wheels
 Rear Wheel Drive – RWD
 Front Wheel Drive – FWD
 Four Wheel Drive (4WD ) - using transfer case
/two speed auxiliary transmission
• All-Wheel Drive (AWD) – no transfer case
 ENGINE – THE SOURCE OF POWER

 Internal Combustion Engine – Power is produced by

burning a mixture of air and fuel inside cylinder in
the engine.
 Types of Internal Combustion Engine

 Piston Type
1.Spark- ignition engine (gas/LPG) – an engine
operating on Otto cycle is called spark-ignition
engine. In which the fuel is ignited by the heat
from an electric spark as it jumps the gap at the
end of the spark plug.
 
2. Compression-ignition engine (diesel)
– an engine operating on diesel cycle is
called compression-ignition engine. In
which the fuel is injected into the
cylinder, where the heat of compression
ignites it.
 Rotary – an engine, such as a gas turbine or a wankel, in
which the power is delivered to a spinning rotor.
1. Turbine – a rotary engine in which the burning air- fuel mixture spins a
power turbine that is geared to the car wheels.
2. Wankel – a rotary engine, usually with two three lobe rotors,
that turns eccentrically in an oval chamber to produce power.
FOUR STAGES OF 4 STROKE PISTON TYPE ENGINE
GASOLINE ENGINE ( 8:1)
FOUR STAGES OF 4 STROKE PISTON TYPE ENGINE
DIESEL ENGINE ( 22:1)
 Note:
 Valves open & close thru valve train. It is the series of parts which includes the
camshaft & drives (gears, sprockets and chain, or sprockets and toothed timing belt)
that open and close the valves by transferring cam-lobe movement to the valves.
 TDC – Top dead center – the upper limit of piston can travel.
 BDC – Bottom dead center – the lower limit of piston can
travel
 Compression ratio – the volume of the cylinder and
combustion chamber when the piston is at BDC, divided by
the volume when the piston is at TDC. The measure of how
much air or air fuel mixture is compressed during
compression stroke.
 Combustion chamber – the space between the TDC and the
cylinder head in which the fuel is burned.
 
Engine Support System
 Fuel system – delivers air-fuel mixture (for
gasoline engine) or fuel only (for diesel) to the
combustion chambers or cylinders of an engine.
Consist of the fuel tank and lines, gauge, fuel
pump, fuel filter, carburetor or fuel injection
system, and intake manifold.
 
Engine Support System ( gasoline engine )
 Fuel system
 
DIESEL ENGINE FUEL SYSTEM
 Types of Fuel system (gasoline engine)
a.Carburetor – device which mixes fuel with air and supplies
the combustible mixture to the intake manifold.
Types of carburetor
1.Fixed Venturi carburetor
2. Variable Venturi carburetor
3. Two-Barrel carburetor
4. Four -Barrel carburetor
Basic parts of carburetor
1. Air horn
2. Float bowl
3. Throttle body
Internal System of carburetor
1. Float system - control the fuel level in the float bowl thru
needle valve, as the float rises the flow of fuel decreases until
it shut off when needle valve seats. When the float falls as
fuel level go low, needle valve will open for fuel flow.
2. Idle system - supplies air-fuel mixture during closed-throttle operation
3. Main metering system – takes over idle system to supply air-fuel
mixture when throttle valve is open past the low speed port or transfer
port until venturi vacuum grows stronger when air flow become faster
as the throttle valve opening becomes wider.
4. Power system – at wide open throttle it enriches the fuel supply if
necessary for more engine power. It is operated mechanically or by
intake manifold vacuum or mixture control solenoid (electronic
controlled carburetor).
a)Mechanically –operated power system – uses metering rod and a
metering-rod jet attached to the throttle linkage.
b.)Vacuum – operated power system – uses metering rod and jet
operated by intake manifold vacuum. A spring loaded vacuum
diaphragm linked to metering rod, at WOT, in the intake manifold a
little vacuum will occur, this will give more fuel flows. Sometimes it
uses power piston instead of diaphragm.

c.) Combination of mechanical and vacuum.

5. Accelerator Pump System – supplies needed fuel during quick
acceleration to avoid hesitation, stalling and backfiring. Operated by pump
plunger and duration spring or pump diaphragm. Pump Diaphragm is
connected to throttle linkages, when the throttle opens, it pushes
diaphragm into fuel-filled chamber forcing fuel out of the pump jet, and this
is similar to the operation of pump plunger.
6. Choke system – needed during cold start or starting to
enrich fuel for Gas Engine.
Types of choke:
 

a.Mechanically operated choke – uses a pull knob to

open and close the choke.
b. Semi- automatic choke with automatic return- uses coolant temperature to
activate thermostat.

c. Automatic choke – automatically closes or opens choke

through exhaust manifold temperature (thermostatic
spring) and intake manifold vacuum.
d. Thermostat in manifold (exhaust and intake )
e. Coolant operated choke –uses
coolant temperature to activate
thermostat.
f. Vacuum diaphragm /piston – when vacuum is applied,
it pull off choke to close position.
g. Electric choke – uses heater to quickly heat thermostatic spring as
engine starts to run. Heater can be put on by oil pressure switch to
ensure engine is running before heating starts.
7. Air Bleed / Air Vent / Anti-siphon Passages – all carburetor fuel-
metering systems except the accelerator pump system have small air
passages. They allow air to enter or bleed into the system to help
premix and vaporize the fuel. It also prevent siphoning of fuel from
the float bowl when vacuum develops during the engine is off,
vacuum occurs as engine cools off this air vent neutralizes it.
 MIXTURE HEATING DEVICES
•Thermostatic air cleaner. This system heats the intake air during cold engine
operation using thermostatic spring attached to air bleed valve connected to
vacuum motor which opens and closes control damper. During cold operation,
air flows through hot-air pipe, when engine is warm air enters through snorkel
tube.
 Early Fuel Evaporation System (EFE). Uses a vacuum motor
instead of thermostatic spring to control the heat-control valve.
Vacuum motor is connected to thermal vacuum switch, when engine
is cold it admits vacuum to operate vacuum motor.
 Electric Intake – Manifold Heater –When engine is cold heater
relay closes to activate heater, as it get warm it disconnects to
stop heating.
 
 External carburetor devices
1.Idle /cut-off solenoid – completely closed the fuel-air
supply when ignition is off
 
 .
2 Electric speedup solenoid – increase engine idle when
A/C activates
3. Throttle return check or dash pot – it slowly close
throttle valve when accelerator pedal is release, to avoid
richness of fuel (no need if with idle solenoid)
4. Idle speed-control motor (ISC) – Idle speed-motor control by
ECM which maintains proper idle speed if load condition change.
5. Electric switches
a.Kick down switch – downshift transmission when gas
pedal is floored
b. Cutout switch – cutout switch of A/C compressor when at wide
open throttle or at high RPM to avoid high pressure in A/C
compressor.
6. Throttle position sensor (TPS) –
reports throttle position to ECM for
proper air fuel ratio for optimum engine
performance.
 ELECTRONIC CONTROLLED CARBURETOR

Similar to Electronic Fuel Injection systems, the major

difference is that the ECM sends pulses to a carburettor
Mixture-control Solenoid instead of to fuel injector.
 b. Fuel Injection (FI) System – delivers fuel
under pressure into the combustion chamber or
MIXTURE-CONTROL
into the intake manifold.
SOLENOID – replaces vacuum
or mechanically operated power
system.
 Types of Fuel Injection
1. Throttle Body Injection ( TBI) - for gasoline engine
2. Port Fuel Injection (PFI) – for gasoline engine
3. Direct /Combustion Chamber Fuel Injection – for diesel / gas
engine
 Types of Fuel Injector
1. Solenoid-operated fuel injector
2. Mechanical fuel injector
Forced Induction – Forcing additional
air or air –fuel mixture into the
cylinders to improve volumetric
efficiency for more engine power.
 
Absolute pressure = Pressure gauge
reading + Atmospheric pressure

Forced induction can be

provided by:

a) Supercharger – Air pump or blower

driven mechanically by a belt or chain
from the engine crankshaft ( its speed
is two or three times faster than engine
speed )
 Types of Supercharger

1. Roots Supercharger
 
2. Scroll or spiral Supercharger
Magnetic clutch controlled
by ECM – reduces loss of
power or drag especially
during light load.
Boost control valve or By-
pass valve – Also reduce
power loss. Either be vacuum
controlled or operated by
throttle linkage. Recirculates
boost pressure to get fuel
economy and improves
performance.
b) Turbocharger –Centrifugal air pump or compressor driven / spin by the engine exhaust gas that
passes thru its turbine. RPM may reach up to 120,000 or higher.
To limit or prevent over boost pressure it needs Wastegate.
Wastegate is controlled by:
• Pneumatic (activates when preset maximum pressure is attained )

• ECM (pressure sensor & solenoid valve / actuator)

Intercooler - This is a charge - air cooler which looks like radiator. Cools air to
increase its density to get higher compression without detonation caused by
overheating.
Electronic detonation control system – includes detonation sensor and knock
sensor which report to ECM to retard its spark timing.
Turbo lag – Delay of power felt when gas pedal is depressed.
To minimize turbo lag:
1. Uses lighter compressor and turbine wheels.
2. Use bi-turbo or twin turbo
3. Variable geometry turbocharging – Varies the angle at which the exhaust gases hit the turbine
blades or vanes. No wastegate is needed
Types:
a) Variable-nozzle turbocharger (VNT)
b) Variable – area turbocharger
 Ignition system ( not applicable for diesel
engine) – provides electrical sparks inside combustion
chamber
Types of ignition system
a. Distributor type Cam & Contact point with vacuum and
mechanical advance
b. Electronic ignition
1. Distributor type with mechanical centrifugal and vacuum advance – reluctor, electronic
control module & pick up coil
2. Distributor type with electronic spark advance –
Electronic engine control system ECM & sensors input
3. Distributorless type with multiple ignition coil
4. Distributorless type with direct capacitor discharge ignition for each spark plug
•Lubricating system – keeps all internal moving parts coated with thin
layer of oil so they move easily , prevents premature wear , helps cool and
cleans the engine.
Cooling system – removes excess heat of an engine leaving just enough heat to maintain
its normal operating temperature. (2200 C+) 1/3
Types:
a. Water –cooled- Radiator, coolant, water pump, water jacket, thermostat, fan, expansion
tank, temperature gauge
b. Air-cooled – cooling fins
Exhaust system – reduces noise, heat and  Emission control system
carries burned gases safely away from
 Air Pollution ; HC, CO, NOx
passenger compartment.
1. Positive crankcase ventilation(PCV) )
2. Air injection
3. Exhaust gas recirculation (EGR) 4. Charcoal Canister
5. Catalytic converter
6. ENGINE ELECTRONIC CONTROL
Oxygen sensor Mass Air Flow Sensor ( MAF)
6. Mass Air flow, and Air Temperature sensors
6. Manifold Air Pressure and Throttle Position sensors
6. ECM/ECU : Sensors-Mass Air flow, Manifold Air Pressure, Throttle
Position, Oxygen, Crank /Cam shaft. Actuators- EFI, IACV, EGRV, etc.
CLASSIFICATION OF INTERNAL COMBUSTION ENGINE
1. Number of cylinders
 3 cylinder
CLASSIFICATION OF INTERNAL COMBUSTION ENGINE
1. Number of cylinders
 4 cylinder
CLASSIFICATION OF INTERNAL COMBUSTION ENGINE
1. Number of cylinders
 6 cylinder
CLASSIFICATION OF INTERNAL COMBUSTION ENGINE
1. Number of cylinders
 8 cylinder
2. Arrangement of cylinders
3. Arrangement of valves / camshafts and valve train
 L-head  I-head
3. Arrangement of valves / camshafts and valve train
 Overhead valve (OHV) • Overhead camshaft - SOHC, DOHC
3. Arrangement of valves / camshafts and valve train
 Camshaft drive – timing gears, sprockets and timing chain or
sprockets and toothed timing belt
3. Arrangement of valves / camshafts and valve train
4. Number of valve per cylinder – two valve,
four valve, multi valve.
5.Engine rotation, cylinder numbering and firing order
 Clockwise rotation facing timing marks or front of an engine
6. By cooling
 Liquid cooled  Air-cooled
7. By cycle
• Two stroke  Four stroke
8. By fuel
 Gas , LPG, Alcogas  Diesel
9. Method of ignition
Gasoline Engine – By electrical sparks Diesel Engine – By heat of compression
10. Reciprocating and rotary

POWER TRAIN – Transmit power from engine to car wheel

 CLUTCH – Engage and disengage power transmission from engine to car wheels so as to allow
cranking, shift to various gear ratio or reverse. Also provides smooth engagement to lessen the shock of
gears, shaft, etc.
 Clutch assembly includes flywheel, friction disc and pressure plate
II) POWER TRAIN
 Typical Types of clutch – diaphragm spring, coil spring (both can be single or
double disc)
Coil Spring Clutch
 Clutch linkages – mechanical ( cable or rod ) , hydraulic ( can be electronically
controlled clutch /automatic clutch thru sensors and ECM once shift lever is move by the
driver )
 
 MANUAL TRANSMISSIONS AND TRANSAXLE – Provide needed torque
in various driving conditions / loads, can be shifted to reverse and neutral.

MANUAL TRANSMISSION
MANUAL TRANSAXLE GEAR SHIFTING
 Synchronizer
Assembly
 Types of transmission /transaxle – manual and automatic
MANUAL TRANSMISSION AUTOMATIC TRANSMISSION
 Gear shift lever – Floor mounted , Steering column mounted

FLOOR MOUNTED COLUMN MOUNTED

 Gear shift linkage – external ( cable / rod ) , internal

ROD LINKAGE CABLE LINKAGE

 Sensors and switches – TCS (transmission control spark), Back up light
switch , speedometer drive, vehicle speed sensor (VSS), neutral safety switch
 

TCS SWITCH
 Driveshafts, universal joints, slip joints, drive axles, CV joints, differential,
transfer case
SUSPENSION SYSTEM – Support weight of the vehicle, cushion bumps and
holes in the road, maintain traction and wheel alignment.
 Components are shock absorbers (gas, hydraulic ,spring assisted, adjustable,
air shock absorber), springs (leaf, coil, torsion bar, air spring)
FRONT WHEEL SUSPENSION
FRONT WHEEL SUSPENSION
REAR WHEEL SUSPENSION
IV) STEERING SYSTEM – Allows the driver to control the direction of the
vehicle travel.
 Kinds of steering
1. Manual Steering
2. Power Steering
a. Hydraulic Pump –Assisted Power Steering
 
b. Electric Motor-assisted Power Steering
•Rack and pinion steering gear
 Recirculating Ball Gear Worm and roller steering gear

 Steering ratio – The number of degrees that the steering wheel must be turned to pivot
the front wheels one degree.
 Wheel alignment
Caster – Tilting of the steering axis forward or backward to provide
directional steering stability. Rearward tilt provides positive caster.
Camber - The tilt of the top of the wheel from the vertical; when the tilt is
outward, the camber is positive.
Steering axis inclination – The inward tilt of the steering axis from the
vertical as viewed from the front of the vehicle.
Toe – The amount or degrees by which the front wheel points inward ( toe-in)
or outward (toe-out)
Suspension height
 Improper tire wear
V) BRAKING SYSTEM
Two kinds of brake
1. Service Brake
2. Parking brake
 
Typical Brake System
Dual Brake system
a) Front –rear split b.)Diagonal /Triangle Split
Two types of self-adjust drum brake
1.One shot
2.Incremental
Self-adjust brake can be activated when
parking brake is applied or braking during
reverse travel.
Types of Disc brakes
1.Fixed caliper disc brake – Having two / four piston caliper
on both sides, attached to steering knuckle or stationary
part of vehicle. Only pistons and pads move when brake is
applied
2.Floating caliper – Usually one / two pistons at inboard side,
caliper moves or floats in one or two guide pins.
3.Sliding caliper – Similar to floating caliper. Its caliper
moves slightly on machined surfaces on steering knuckle
adapter, no guide pins.
Disc brakes are self-adjust
ABS – Antilock Braking System - Prevents
wheel lock-up and tire skidding during hard
braking.
Brake lining materials:
1.Asbestos - hazardous material
2.Fiberglass / Semi-metallic material
Parking Brakes
Types of parking brakes
1. Integral parking brakes
a)Rear drum brake
b)Rear Disc Brake
2. Independent parking brake
a)Drum type parking brake
b)Transmission mounted parking brake
Brake system valves:
1. Pressure-differential valve – turns on brake
warning light when either sides losses pressure
2. Hold-off valve or metering valve – prevents
front disc brakes from applying until rear brake
starts to apply.
Note : If all are drum brakes or disc brakes,
no need
3. Proportioning valve – Works similar
to ABS
4. Combination valve – All of the
above valves are put together in single
assembly
 
 
 
VI) ELECTRICAL SYSTEM
Introduction to Electricity
• Current is a flow of electron in conductor like water flowing in a pipeline (ampere)
• It has two electrical charges for DC, negative and positive
• Like charges repel, unlike charges attract
• Difference in potentials (shortage of electron) – causes electron to flow from negative to positive terminal.
• Can be measured by ammeter and voltmeter
• Current flowing through a conductor / wire creates a magnetic field around the wire. Its strength proportionately increases / decreases with
the amount of current flowing through.
• Conductors allow current to flow, Insulators prevent current from flowing
• Short circuit – current flows to wrong direction.
• Conductor resistance: the bigger wire diameter has lesser resistance than smaller wire diameter and usually a hotter wire has a higher
resistance. Although some conductor used in thermistor decreases resistance when it gets hotter.
• OHM law. Current = Voltage / Resistance: Power law , Wattage = Voltage X Current
• Automotive electrical system is a One –wire system which uses body ground as return circuit.
• Electromagnetism – a coil of wire wound on a tube and connected to a battery becomes a magnet. One end becomes the North Pole and
other end is South Pole.
• Battery
• Starting Motor
• Charging system -Alternator
• Ignition system
1. Cam & contact point ignition
2. Electronic ignition
• Lights & other electrical equipment
 
 
 
 
Introduction to Electronic
• Electronic is pertaining to electrons, it includes any devices operated by electrons.
• Semiconductors – under some conditions, it can be either a conductor or an insulator
• Diode – It acts as a one way check valve for electricity.
• Transistor – can act as switch, stop current flow, or it can act as an amplifier.
ECM (Electronic Control Module) – It receive signals, process them, make decisions and then send commands that control other devices. Also called as
ECU (Electronic Control Unit). EEC (Electronic Engine Control), it usually controls the fuel and ignition systems.
Basic parts of control system
a. Sensors –the input devices
b. Actuators –the output devices
c. Decision maker – the driver, mechanical governor & electronic processor
Two main parts of ECM:
1. Microprocessor – Control processing unit
2. Memory – Stores data, specifications, formulas and information.
Two Types of Memory in ECM
a. ROM (Read Only Memory)- the stored information can be read by microprocessor but cannot be change.
PROM (Programmable Read Only Memory) is a removable memory chip that can be reprogrammed by another program or computer.
b. RAM – can be read, change or write new information into it.
1. Volatile memory – stores information temporarily, as long as the battery power is available. Disconnecting the battery erases all the stored data.
2. Nonvolatile memory – Disconnecting the battery does not affect stored data.
Two types of memory chip
1. Look up tables – contain data about the car or conditions that are permanently stored on chip.
2. Keep Alive Memory (KAM) – is a volatile memory. Stored data like trouble codes. May also make changes in how the vehicle is operating. Once data
is lost by disconnecting the battery, it can retrieve needed data from look up tables and restart to relearn all information stored previously. It has always
small current flowing even the key is off, it is key-off current drain.
VII) BODY – Comfort and safety of passengers and cargoes
Types of body
1. Body and frame – separate body and frame like trucks
2. Unibody – body panel and short stub frame or engine cradle are welded together
3. Space frame – made of steel stampings welded together, panels (plastic, aluminum, fiberglass) are fasten to space
frame.
Aerodynamic / streamlining – minimize air resistance / drag
Low coefficient of drag is more fuel efficient
 
VIII) FEDERAL LEGISLATION
Automotive Air Pollution – HC, CO, NOx, (H20 , CO2)
1. Emission control devices
Automotive Safety
Federal Motor Vehicle Safety Standards (FMVSS)
1. Crash avoidance (such as high mounted rear stoplight)
2. Occupant protection ( such as padded dash and locking seat backs
3. Post-crash protection (such as roll bars and air bags that deploy instantly after a crash begins).
Automotive Fuel Economy
IX) AUTOMOTIVE SERVICE
• Predelivery service
• Warranty
• Recall
• Limited warranty
• As is Basis – no warranty
Automotive Service Procedure
1. Inspection – Is there something wrong?
2. Diagnosis – What is wrong? What caused the problem?
3. Repair – repair both the problem and its cause
4. Quality check – perform step 1 again. If the proper repair has been made, the original problem no longer exists.
6 Steps in an Automotive Repair Job
1. Measuring ( USC- United States Customary / Metric system )
• Bore gauge
• Feeler gauge
• Wire gauge
• Micrometer
• Inside micrometer
• Outside micrometer
• Vernier Caliper
• Depth gauge
• Pressure gauge
• Vacuum gauge
• Multitester (VOM)
• Cylinder compression /vacuum tester
2. Disassembling
3. Machining
4. Installing new, rebuilt, or serviced parts
5. Reassembling
6. Adjusting
Vehicle Identification Number ( VIN )
Located at driver instrument panel near windshield , readable outside the vehicle or in the hood cover of the car / engine compartment.
Vehicle Emission Control Information (VECI )
Can be located in engine compartment
AUTOMOTIVE FASTENERS
Fasteners include bolts, screws, nuts, studs, rivets, snap rings and cotter pins (USC/Metric)
USC THREAD DESIGNATION
1. THREAD SERIES – Coarse, fine and extra fine
2. THREAD CLASS – Class 1 (loosest fit) , Class 2 (tighter fit ), Class 3 ( very close fit)
3. UNC / NC –Coarse, UNF / NF – Fine, UNEF / NEF – Extra-fine. A –External thread, B –tapped
holes
4. Example ¼-20 UNC-2A X 4 is ¼ inch diameter, coarse thread with 20 TPI, the thread external, class
2 thread

DIAGNOSIS AND SERVICES

Fuel Injected Fuel System
Major causes of trouble
1. Fuel pumps wear out
2. Pressure regulator go bad
3. Fuel injectors get dirty
4. Sensors fail
5. Wiring connectors get loose, cut and corrosion

Safety Precaution
1. Wear eye protection
2. Provide class B fire extinguisher near at work area.
3. Relieve fuel line pressure with shop towel to soak squirting fuel.
Procedure in troubleshooting
1. Check leaks of fuel, air and vacuum
2. Check fuel injectors
a) TBI
• Remove air cleaner, observe fuel spray while idling engine.
• Disconnect wire connector and attach injector test light then crank the engine and observe if light is flashing.
b) PFI
• While engine idling feel vibration on top of each injector, or use stethoscope or large screw driver to listen to clicking sounds produce
by operative injectors.
• Disconnect wiring connector of injector one by one while engine is idling, observe if there is changes in idling as it should be.
3. Relieve fuel line pressure
• Thru Schrader valve with covered towel, if no Schrader valve do either of the following:
• Remove fuel tank cap, and disconnect negative cable from battery terminal, loosen fittings on fuel filter to release pressure.
• Remove fuel pump fuse, run the engine until it stalls, then crank the engine five seconds to relieve the pressure.
CAUSES INOPERATIVE FUEL PUMP
1. Defective (Low fuel pressure , incorrect fuel volume delivery, incorrect pressure regulator)
2. Blown fuse
3. Open / short circuit inertia switch.
To reset inertia switch:
• Turn ignition key-off
• Check fuel leakage
• If no leaks, press reset button on top of the switch
• Turn ignition key on for few seconds then to off. Re check leak if none. If okay, start the engine.