LV02 Foundation Skills

Foundation Skills LV02
LV02 Foundation Skills - Copyright © Automotive Skills 2003 Ltd. All rights reserved.
Introduction
On completion of this module you will be expected to
effectively:
• Identify and use common hand tools
• Describe the principles of measurement
• Identify and use measuring equipment
• Describe the principles of electricity and electrical
circuits
• Identify and use electrical measuring equipment
• Identify locking and securing devices
• Identify materials used in vehicle construction
• Describe the different types of inspection
LV02 Foundation SKills - Copyright © Automotive Skills 2003 Ltd. All rights reserved.
Hand Tools
Spanners
Spanners
Ring
Open jaw
Brake pipe
Correct Use
Ratchets
Sockets
Impact Sockets – Air Tool Safe
Universal Joint
Air Tools
Speed Brace
Crows Foot
Hexagon Bit Socket (Allen Key)
Multi – Spline Bit Socket (12 Spline)
Torx Bit Socket (6 Spline)
Hexagon and Spline Bit Set
Torx Bit Set
Spanner Priority
First choice last choice
Adjustable Spanner
Torque Wrench
Torque Wrench Use
One click only!
Torque Wrench
50 Nm
Torque Meter
Pliers
Long Nose Pliers
Grips
Circlip Pliers
Files
File Profiles
Flat triangle Round
Flat Square
Files
Body Heel
Tang
Safe Use
Correct Use
Correct Use
Hacksaw
Centre Punch
Centre Punch
Do Not Strangle The Hammer!
Drill Bit
Drill Bit
Tap and Die Set
Taps Die stock
Tap stock Dies

Die
Taps
Tap Use
Tap Use
Keep the tap

straight
Will result in a
drunken thread
Die Use
Die Use
Keep the Die

straight
Will result in a
drunken thread
Screw Pitch Gauge
Screw Threads
Easy-Outs
Useful for sheared

bolt/stud removal
Special Service Tools
Special Service Tools
Progress check 1
1) What is the correct name for this

tool?
Multi-spline socket
2) Put the following tools in the correct order of preferred use:

Open jaw spanner, socket, adjustable spanner, ring spanner
1) Socket
2) Ring spanner
3) Open jaw
4) Adjustable
3) What is the correct name for a tool that is designed to cut

internal threads?
Tap
Progress check 1
4) What is the difference between a high impact socket and a

normal socket?
High impact sockets have been designed withstand high
levels of stress.
They have been strengthened for use on air tools.
5) After you have used a ‘torque wrench’ how should the wrench be
stored?
All tension should be removed from the torque wrench and returned
to its original box.
Measurement
Length
The S.I. (Système Internationale) unit of length is the metre.
This unit of length is too large for the majority of automotive applications, so the
metre is split down into smaller parts:
One metre is divided into 100 equal parts and each is called a centimetre
Each centimetre is split down into 10 equal parts and each is called a millimetre.
Each millimetre is split down into 100 equal parts and each is referred to
decimally:
0.01mm (1 hundredth of a millimetre)
Each 0.01mm can be split down further into 10 equal parts and therefore each is
expressed:
0.001mm (1 thousandth of a millimetre)
Length
1 metre
1 hu
ndr
edth
1 cm 1 te
nt h
1 mm 1 hu
ndr
edth
0.01mm
nth
1 te
0.001mm
1 hundreth
of millimetre
1 thousanth
Of millimetre
Area and Volume
r
Height
Width
Height
Length Length
Width
Exercise
9cm
10cm
Pressure
Pressure is a force acting over an area
I’m soaked up
to my waist!
Pressure Large
small
force force
Very large surface area

Tiny surface area
Pressure
Pressure Gauges
Progress check 2
1. How many millimetres are there in a metre?

One thousand
2. How many p.s.i. is 20 kPa?
3 p.s.i
3. What is the study of pressure in liquids referred to as?

Hydraulics
4. What is the volume of the regular shape pictured below?
800 cm³ (cc)

80mm
100mm
10cm
Progress check 2
5. What is the unit of force?

Newtons
Measuring Equipment
External Micrometer 0 – 25 mm
External Micrometer 0 – 150 mm
Interchangeable
anvils Distance
pieces
C spanner
Principle of the Micrometer
0.5mm
1 turn
Zeroing
Zeroed
Zeroing 25 – 50 mm Range
Measurement
0.01mm
0.04mm
0.05mm
0.09mm
0.1mm
0.15mm
0.4mm
0.49mm
0.5mm
0.75mm
0.99mm
1.01mm
3.56mm
Vernier Calliper
Vernier Calliper
Vernier Calliper
Zeroed
Measurement
0.1mm Whole millimetres
0.02mm
Measurement
1.02mm
Measurement
10.02mm
Measurement
10.56mm
Measurement
6.74mm
Dial Gauge
Dial Gauge
Dial Gauge
0.01mm
0.05mm
0.09mm
0.1mm
0.5mm
0.6mm
2.41mm
Dial Gauge
Feeler Blades
0.006 Inches
(6 thou)
0.152mm
Feeler Blades
Progress check 3
1. In the diagram to the right what is part ‘A’ called?
Spindle
2. What dimension is the micrometer to the right

displaying?
0.75mm
3. What does DTI stand for? Dial Test Indicator
Principles of Electricity
Types of Electricity
Static electricity
Dynamic electricity
Static Electricity
Electrostatic induction
When a charged body is placed near a conductor with an insulator

in between, this conductor will be charged as well.
insulator
Static Electricity
__
_ _ _
_
___
Static Electricity
Lightning strikes upwards!!
Electricity - Current
Current is measured in amperes (amps)

Conductor
,s
1 amp of electrical current is equal to;

625,000,000,000,000,000 electrons flowing in a conductor per second!
Current
1 amp is said to be the

amount of current flowing in
a circuit if that circuit has a
resistance of 1 ohm and 1
volt of electrical pressure
has been applied
Electricity - Voltage
High pressure
+ ve
- ve
Low pressure
Voltage
1 volt is said to be the

amount of electrical
pressure present if it brings
about a current flow of 1
amp in a circuit that has a
resistance of 1 ohm
Electricity - Resistance
Resistance reduces current flow
Resistance is measured in ohms ()

Resistance
Water
The higher the resistance, the less current that will flow
Resistance
1 ohm is said to be the

amount of electrical
resistance present if 1 amp
of current flows in a circuit
when 1 volt of electrical
pressure is applied to that
circuit
Resistance
Less current flow means

Resistor less work done and
therefore the bulb is dimly
illuminated
Electricity
Current = flow of electricity (amps)
Voltage = potential difference (volts)
Resistance = resistance to flow (ohms)
Ohm’s Law
Ohm’s Law states that:
“The current flowing in a circuit is in direct proportion to the voltage

applied, and inversely proportionate to the resistance”
This can be expressed mathematically in the following way:
I = current - V = voltage - R = resistance
Ohm’s Law Triangle
Ohm’s Law - Questions
V = 24
I=?
(Ω) R=4
V = 12
I=3
(Ω)R = ?
V=?
I=4
(Ω)R = 2.5
Ohm’s Law - Questions
4 amps
? ohms
12 volts
Electrical Power
Electrical power is measured in “watts”
W
W
I =
I V
V
Note. 1 horsepower is equal to 746 watts

1.34 HP is equal to 1KW
Electrical Power - Questions
W = 10
I=2
V=?
W
W=? I V
I=?
V = 24
(Ω)R = 6
Progress check 4
1. Which unit do we use to describe electrical pressure?

The volt
2. If we increase the resistance of a circuit for a given applied

voltage, what will happen to the amount of current that will
flow?
It will decrease
3. If a circuit has a resistance of 12 ohms and 2 amps of

current is flowing, what is the voltage applied?
24 v
4. Complete the Ohms Law triangles below
V W
I ?R I? V
Electrical Measurement
Equipment
Digital Multimeter
Selector
Hold / AUTORANGE
volts, ohms
And diodes
10A port
300mA port Common
Digital Multimeter
~ __
V ----
V
__ __
---- ----
A 300mV

~
A
Unit Multipliers
One amp is equal to one thousand milliamps which is written as:
1 A = 1000mA
One amp is equal to one million micro amps and is written as:
1A = 1,000,000 µA
One thousand amps is equal to one Kilo amp which is written as:
1000A = 1KA
One million amps is equal to one Mega amp and is written as:
1,000,000A = 1MA
All other electrical units use the same multipliers such as 1mV, 1M
Analogue Multimeter
Analogue Multimeter
12v 13.3v
10v
30v full deflection
Voltmeter – Checking Voltage -12
- vv
12 v 12 v 12 v
0v
0v
0v
A voltmeter displays the
12 v difference in voltage
between where you put the
red probe and where you
put the black probe
Ohmmeter – Resistance Checks
14.4
Remember:
• Always switch the
0.00
O/L
circuit OFF first
• Always disconnect the

component from the
remainder of the circuit
Close switch
Ammeter – Checking Current Flow
0.83A
Remember:
always fit an ammeter
in series with the circuit
Never connect an ammeter across a resistance; a good

ammeter has zero internal resistance
Progress check 5
__
1. What does the following symbol mean? ----
V
Volts DC
2. How many mV in a volt?
One thousand
3. How is a voltmeter fitted to a circuit?
In parallel
Progress check 5
4. When using an ohmmeter what precautions should you take

before testing the circuit?
No current is following in the circuit
5. Draw a series circuit containing 3 bulbs, a battery, and a switch
Types of Circuit
Series Circuits
Parallel Circuits
Series Parallel Circuits
Progress check 6
1. What type of circuit is this?
Series parallel
Wiring Diagrams
Symbols – Japanese Manufacturers
= B4 Relay = Fusible Link
= Analogue = Capacitor
Speed
Sensor
= Variable = Wires
Resistor Crossing
= Ignition Coil = Transistor

NPN
= Horn = Short Pin

(Junction Block Connector)
= Battery = Resistor
= Circuit = Lamp
Breaker
= M4 Relay = Analogue
Meter
= Distributor = Double
IIA Throw
Switch
= Diode = Cigarette
Lighter
= Tapped = Zener
Resistor Diode
= Ground = Splice
Joint
= Ignition = Speaker
Switch
= Switch ON = Twin
Filament
Bulb
= Motor = Wiper Park

Switch
= Fuse = Digital Fuel

Gauge
= LED = Thermistor
= Switch OFF = Transistor

PNP
= Double = Solenoid
Throw Relay
= Splice Joint
Japanese Wiring Diagram
Symbols – European Manufacturers
Resistor
Ground
Variable resistor
Adjustable resistor
Common ground
Fuse
Fuse
Chassis ground
Circuit breaker
Cell Capacitor
Switch closed Variable capacitor
Switch open
Male connector
Two way switch
Female connector
Push switch
Lamp NPN transistor
Speaker PNP transistor
Inductor
Magnetic core Diode

inductor
Transformer Zener diode
European Wiring Diagram
Engine
Management
Fuse F16 Fuse F6 Fuse F4 Fuse F13
ECM
30 amp 10 / 7.5 10 amp 15 amp
amp
Battery
Tacho -
Heater if fitted
control
solenoid
4 2 5 12 1
Heater
M
motor
9
Heater Control ECM
Air
M recirculation
module Recirculation “on” indica tor
Temperature con trol

Heater con trol
panel
Heater motor resistor illumination
Recirculation
Recirculation switch
switch
illumination
3 6
Heater Control Assembly
Heater motor
4 3 2 1 Heater con trol speed switch
speeds
Locking and Securing
Devices
Fasteners
Screw Hex screw
Bolt
Coach bolt
Self tapping
Countersunk screw
Dimensions
Strength
Fasteners
Nut Flanged nut Nylock nut
Castellated nut Wing nut Shear nut
Fasteners
Flat washer
Penny washer
Spring washer
Fasteners
Woodruff key
Clevis pin
Copper Rivets
Copper rivet
Chemical Thread Locking
Loctite 577
Medium strength
Loctite 2701
High strength
Progress check 7
1. What type of nut is this?
Nylock
2. What is this locking device called?
Clevis pin (cotter pin in the USA)
3. What is a tab washer for?
Provides a means of securely locking a flat headed bolt
Progress check 7
4. When can a split pin be re-used?
Never
Inspection and
Other Fault-Finding
Techniques
Building the Big Picture
ECT TPS
MAP
VOLTS ECM EARTH
INJ IDLE
IGN
Build the puzzle until one of the pieces is missing or doesn't fit
Charging into Diagnosis
Charging into diagnosis can lead to wasted time, frustration

and misdiagnosis
Keeping Things Simple
I can’t
understand how
this light bulb
works so it must
be the ECM at
fault
It’s easy to over complicate diagnosis, start with

simple checks and easy to access components
Interrogating the Customer!
General open questions

1. Why has the customer brought the vehicle in?
2. When does the fault occur?
3. What system does the fault generally appear
in?
4. Where does the fault occur (bumpy road etc.)?
5. Does it only happen to a specific driver?
6. How can you get the fault to occur (vehicle/
driving conditions)?
The customer normally has first hand knowledge of the fault. Asking the
customer the right types of questions can save time before proceeding with
unnecessary diagnostic routines.
Asking the Customer - Example Questionnaire
Vehicle
details
Vehicle
symptoms
Vehicle
conditions
Instrument
warning lamp
Visual Inspection
Aural Inspection
Road Test
Progress check 8
1. Identify four different methods of diagnostic inspection
(the first is given):
A. Visual
B. ____________?
Aural
C. ____________?
Questioning
D. ____________?
Road test
2. What does ‘aural’ mean?
Listening/hearing
3. What does the term guarantee refer to?
A set period of time when all repairs/parts are covered by

either a manufacturer, supplier, or dealership against faulty
workmanship
Published by Automotive Skills
201 Great Portland Street, London W1W 5AB
Tel: 020 7436 6373, Fax: 020 7436 5108
www.automotive-skills.org.uk
Automotive Skills wishes to thank the Sector Skills Development

Agency (SSDA) and the Learning and Skills Council (LSC) for
supporting the development of this Technical Certificate Learning
Material. It was produced in association with PROAUTO Ltd.
No part of this learning material may be produced, reproduced, stored

in any retrieval system or transmitted in any form or by any means,
electronic, photocopying, recording or otherwise without the prior
written permission of Automotive Skills.
Copyright © Automotive Skills 2003. All rights reserved.

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Foundation Skills LV02

First choice last choice

One click only!

Tap stock Dies

Keep the tap

Keep the Die

Useful for sheared

1) What is the correct name for this

2) Put the following tools in the correct order of preferred use:

3) What is the correct name for a tool that is designed to cut

4) What is the difference between a high impact socket and a

They have been strengthened for use on air tools.

0.01mm (1 hundredth of a millimetre)

Very large surface area

1. How many millimetres are there in a metre?

3. What is the study of pressure in liquids referred to as?

800 cm³ (cc)

5. What is the unit of force?

1. In the diagram to the right what is part ‘A’ called?

2. What dimension is the micrometer to the right

3. What does DTI stand for? Dial Test Indicator

When a charged body is placed near a conductor with an insulator

Current is measured in amperes (amps)

1 amp of electrical current is equal to;

1 amp is said to be the

1 volt is said to be the

Resistance is measured in ohms ()

1 ohm is said to be the

Less current flow means

Current = flow of electricity (amps)

Voltage = potential difference (volts)

Resistance = resistance to flow (ohms)

Ohm’s Law states that:

“The current flowing in a circuit is in direct proportion to the voltage

This can be expressed mathematically in the following way:

I = current - V = voltage - R = resistance

Electrical power is measured in “watts”

Note. 1 horsepower is equal to 746 watts

1. Which unit do we use to describe electrical pressure?

2. If we increase the resistance of a circuit for a given applied

3. If a circuit has a resistance of 12 ohms and 2 amps of

4. Complete the Ohms Law triangles below

30v full deflection

• Always disconnect the

Never connect an ammeter across a resistance; a good

2. How many mV in a volt?

3. How is a voltmeter fitted to a circuit?

4. When using an ohmmeter what precautions should you take

No current is following in the circuit

5. Draw a series circuit containing 3 bulbs, a battery, and a switch

= B4 Relay = Fusible Link

= Ignition Coil = Transistor

= Horn = Short Pin

= Motor = Wiper Park

= Fuse = Digital Fuel

= Switch OFF = Transistor

Switch closed Variable capacitor

Two way switch

Lamp NPN transistor

Speaker PNP transistor

Magnetic core Diode

Transformer Zener diode

Temperature con trol

Nut Flanged nut Nylock nut