AUTOMOTIVE MAINTENANCE PROGRAM OVERVIEW & WORKBOOK
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1 AUTOMOTIVE MAINTENANCE PROGRAM OVERVIEW & WORKBOOK MERIT BADGE UNIVERSITY OVERLAND TRAILS COUNCIL
2 TABLE OF CONTENTS PROGRAM OVERVIEW MERIT BADGE REQUIREMENTS (PRE-REQUISITE REQUIREMENTS IN BOLD RED UNDERLINED ITALICS) WORKBOOK PART ONE (COMPLETE BEFORE ATTENDING MBU) WORKBOOK PART TWO (WILL BE COMPLETED DURING CLASS) ADDITIONAL RESOURCES APPLICATION for MERIT BADGE (MUST HAVE UNIT LEADER SIGNATURE PRIOR TO CLASS) Overland Trails Council, August 2010 Information in this booklet was accurate at the time of publishing. Automotive Maintenance Merit Badge Requirements, Copyrighted Boy Scouts of America
3 AUTOMOTIVE MAINTENANCE PROGRAM OVERVIEW BRING TO CLASS: Old set of clothes. Automotive Maintenance merit badge pamphlet. Automotive Maintenance merit badge workbook, part one & part two. Signed Application for Merit Badge, found at the end of the merit badge workbook. (This will be your only record of work completed on this merit badge.) If your Council requires the official blue card, you must bring one with you to class. PRE-REQUISITES: Complete Part One of the workbook before class (requirement 11 & 12). Complete information on Application for Merit Badge including Scoutmasters signature. CURRICULUM: Requirements 1, 2, 3, 4, 5, 6, 7, 8, 9, & 10 will be completed during class (part two of the workbook). Pre-requisites will also be reviewed during class. CLASS SIZE: 15
4 AUTOMOTIVE MAINTENANCE Automotive Maintenance Merit Badge Requirements, 2008 PRE-REQUISITE REQUIREMENTS ARE PRINTED IN BOLD UNDERLINED RED ITALICS & MUST BE COMPLETED BEFORE CLASS. You will need access to a car or truck and its owner s manual to meet some requirements for this merit badge. 1. Discuss with your counselor the safety equipment, tools, and clothing used while checking or repairing a motor vehicle. Use this equipment, tools, and/or clothing (when needed or called for) in meeting the requirements for this merit badge. 2. General Maintenance, Safety, and Registration. Do the following: a) Review the maintenance chart in the owner s manual. Explain the requirements and time limits. b) Demonstrate how to check the following: 1) Brake fluid 2) Engine oil 3) Coolant 4) Power steering fluid 5) Windshield washer fluid 6) Transmission fluid 7) Battery fluid (if possible) and condition of the battery terminals c) Locate the fuse boxes; determine the size of fuses. Demonstrate the proper replacement of burned-out fuses. d) Demonstrate how to check the condition and tension of belts and hoses. e) Check the lighting in the vehicle, including instrument, warning, and exterior bulbs. f) Locate and check the air filter. g) Explain the purpose, importance, and limitations of safety belts and passive restraints. h) Find out the requirements for the state inspection in your state, including how often a vehicle needs to be inspected. i) Explain the importance of registering a vehicle and find out the annual registration fee for renewing your family car s registration. 3. Dashboard. Do the following: a) Explain the function of the fuel gauge, speedometer, tachometer, oil pressure, and engine temperature gauge. Point each one out on the instrument cluster. b) Explain the symbols that light up on the dashboard and the difference between the yellow and red symbols. Explain each of the indicators on the dashboard, using the owner s manual if necessary.
5 4. Tires. Do the following: a) Explain the difference between tire manufacturer s and vehicle manufacturer s specifications and show where to find them. b) Demonstrate how to check tire pressure and properly inflate a tire. Check the spare tire and make sure it is ready for use. c) Explain why wheel alignment is important to the life of a tire. Explain caster, camber, and toe-in adjustments on wheel alignment. d) Explain the purpose of the lateral-wear bar indicator. e) Explain how to dispose of old tires in accordance with local laws and regulations 5. Engine. Do the following: a) Explain how an internal combustion engine operates. Tell the differences between gasoline and diesel engines. Explain how a gasoline-electric hybrid vehicle is powered. b) Discuss the purpose of engine oil. Explain the API service code, the SAE number, and the viscosity rating. c) Explain where to find the recommended oil type and the amount of oil to be used in the vehicle engine. 6. Cooling System. Do the following: a) Explain the need for coolant in the cooling system. b) Explain how to flush and change the engine coolant in the vehicle, and how to properly dispose of the used coolant. 7. Fuel System. Do the following: a) Explain how the air and fuel systems work together and why it is necessary to have an air filter and fuel filter. b) Explain how a fuel injection system works and how an onboard computer works with the fuel injection system. 8. Ignition and Electrical Systems. Do the following: a) Diagram and explain the parts of the electrical system. b) Explain the cylinder engine sequence. c) Explain the purpose of the spark gap. d) Demonstrate how to change the spark plugs in any internal combustion engine (lawn mower, dirt bike, motorcycle). e) Demonstrate how to safely connect jumper cables to your car battery. 9. Drive Train. Do the following: a) Diagram the drive train and explain the different parts. b) Explain the difference between automatic and standard transmissions. c) Explain the types of automatic transmission fluid. d) Explain the types of lubricants used in a standard transmission and in the differential. e) Explain the difference between front-wheel, rear-wheel, and four-wheel drive. 10. Brake System. Do the following: a) Explain the brake system (including antilock systems) and how it operates. b) Explain the differences between disc and drum systems.
6 c) Demonstrate how to check the condition of a vehicle s brake system. After checking, make recommendations for repairs (if necessary). 11. Do TWO of the following: a) Determine the value of three different vehicles you are interested in purchasing. One must be new and one must be used: the third vehicle can be new or used. For each vehicle, find out the requirements and cost of automobile insurance to include basic liability and options for collision, comprehensive, towing, and rental car. Using the three vehicles you chose and with your merit badge counselor s assistance, complete the operation/maintenance chart provided in the merit badge pamphlet. Use this information to determine the operating cost per mile for each vehicle, and discuss what you learn with your counselor. b) Choose a car cleaner and wax product for a vehicle you want to clean. Explain clearcoat paint and the precautions necessary for care. Clean the vehicle, both inside and out, and wax the exterior. Use a vinyl and rubber protectant (on vinyl tops, rubber door seals, sidewalls, etc.) and explain the importance of this protectant. c) Locate the manufacturer s jack. Use the jack to demonstrate how to engage the jack correctly on the vehicle, then change a tire correctly. d) Perform an oil filter and oil change on a vehicle. Explain how to properly dispose of the used oil and filter. 12. Find out about three career opportunities in the automotive industry. Pick one and find out the education, training, and experience required for this profession. Discuss this with your counselor, and explain why this profession might interest you.
7 AUTOMOTIVE MAINTENANCE WORKBOOK PART ONE, PRE-REQUSITIES Name Unit # Council District Part One of the workbook must be completed before class. Bring the entire workbook (part one and part two) with you to class. Also bring the Application for Merit Badge signed by your scoutmaster (included at the end of the workbook). 11. Do TWO of the following: a) Determine the value of three different vehicles you are interested in purchasing. One must be new and one must be used: the third vehicle can be new or used. For each vehicle, find out the requirements and cost of automobile insurance to include basic liability and options for collision, comprehensive, towing, and rental car. Using the three vehicles you chose and with your merit badge counselor s assistance, complete the operation/maintenance chart provided in the merit badge pamphlet. Use this information to determine the operating cost per mile for each vehicle, and discuss what you learn with your counselor. Operating cost completed: initial: date: To help you complete this requirement the Cost per Mile worksheet, as found in the Automotive Maintenance Merit Badge Pamphlet, has been reproduced at the end of this workbook. Discuss what you have learned with your counselor:
8 AUTOMOTVIE MAINTENANCE WORKBOOK, PART ONE, p.2 Name 11. continued AND/OR b) Choose a car cleaner and wax product for a vehicle you want to clean. Explain clear-coat paint and the precautions necessary for care. Clean the vehicle, both inside and out, and wax the exterior. Use a vinyl and rubber protectant (on vinyl tops, rubber door seals, sidewalls, etc.) and explain the importance of this protectant. Cleaned vehicle: initial: date: Explain clear-coat paint and precautions necessary for care: Explain importance of vinyl and rubber protectants: AND/OR c) Locate the manufacturer s jack. Use the jack to demonstrate how to engage the jack correctly on the vehicle, then change a tire correctly. Locate tire jack, engage jack correctly and changed tire: Changed tire successfully : initial: date: AND/OR d) Perform an oil filter and oil change on a vehicle. Explain how to properly dispose of the used oil and filter. Performed oil filter and oil change: Vehicle: initial: date: Used oil and filter:
9 AUTOMOTVIE MAINTENANCE WORKBOOK, PART ONE, p.3 Name 12. Find out about three career opportunities in the automotive industry. Pick one and find out the education, training, and experience required for this profession. Discuss this with your counselor, and explain why this profession might interest you. Career opportunities in the automotive industry: Pick one career: Career: Education: Training: Experience: Why this profession interest s you:
10 AUTOMOTIVE MAINTENANCE WORKBOOK PART TWO, CLASS CURRICULUM Name Unit # Council District Part Two of the workbook will be completed during class. 1. Discuss with your counselor the safety equipment, tools, and clothing used while checking or repairing a motor vehicle. Use this equipment, tools, and/or clothing (when needed or called for) in meeting the requirements for this merit badge. Safety equipment: Tools: Clothing: 2. General Maintenance, Safety, and Registration. Do the following: a) Review the maintenance chart in the owner s manual. Explain the requirements and time limits. Review the maintenance chart: Explain the requirements and time limits:
11 Name AUTOMOTIVE MAINTENANCE WORKBOOK, PART TWO, p.2 2. continued b) Demonstrate how to check the following: 1) Brake fluid 2) Engine oil 3) Coolant 4) Power steering fluid 5) Windshield washer fluid 6) Transmission fluid 7) Battery fluid (if possible) and condition of the battery terminals Brake fluid Engine oil Coolant Power steering fluid Windshield washer fluid Transmission fluid Battery fluid (if possible) and condition of the battery terminals c) Locate the fuse boxes; determine the size of fuses. Demonstrate the proper replacement of burned-out fuses. Locate fuse box Determine fuse sizes Proper replacement of fuse d) Demonstrate how to check the condition and tension of belts and hoses. Belts Hoses e) Check the lighting in the vehicle, including instrument, warning, and exterior bulbs. Instrument lights Warning lights Exterior bulbs
12 AUTOMOTIVE MAINTENANCE WORKBOOK, PART TWO, p.3 Name 2. continued f) Locate and check the air filter. Air filter g) Explain the purpose, importance, and limitations of safety belts and passive restraints. Purpose and importance of safety belts and passive restraints: Limitations of safety belts and passive restraints: h) Find out the requirements for the state inspection in your state, including how often a vehicle needs to be inspected. State inspection: i) Explain the importance of registering a vehicle and find out the annual registration fee for renewing your family car s registration. Importance of vehicle registration: Renewing your family car s registration fee:
13 Name AUTOMOTIVE MAINTENANCE WORKBOOK, PART TWO, p.4 3. Dashboard. Do the following: a) Explain the function of the fuel gauge, speedometer, tachometer, oil pressure, and engine temperature gauge. Point each one out on the instrument cluster. Explain the function of the following: Fuel gauge Speedometer Tachometer Oil pressures Engine temperature gauge b) Explain the symbols that light up on the dashboard and the difference between the yellow and red symbols. Explain each of the indicators on the dashboard, using the owner s manual if necessary. Dashboard symbols that light up: Difference between the yellow and red symbols:
14 Name AUTOMOTIVE MAINTENANCE WORKBOOK, PART TWO, p.5 4. Tires. Do the following: a) Explain the difference between tire manufacturer s and vehicle manufacturer s specifications and show where to find them. Difference between tire manufacturer s and vehicle manufacturer s specifications: Where to find them: b) Demonstrate how to check tire pressure and properly inflate a tire. Check the spare tire and make sure it is ready for use. Tire pressure Properly inflate a tire Spare tire c) Explain why wheel alignment is important to the life of a tire. Explain caster, camber, and toe-in adjustments on wheel alignment. Importance of wheel alignment: Explain the following wheel alignment adjustments: Caster Camber Toe-in d) Explain the purpose of the lateral-wear bar indicator. Purpose of the lateral-wear bar indicator:
15 AUTOMOTIVE MAINTENANCE WORKBOOK, PART TWO, p.6 Name 4. continued e) Explain how to dispose of old tires in accordance with local laws and regulations How to dispose of old tires 5. Engine. Do the following: a) Explain how an internal combustion engine operates. Tell the differences between gasoline and diesel engines. Explain how a gasoline-electric hybrid vehicle is powered. How an internal combustion engine operates: Differences between gasoline and diesel engines: How a gasoline-electric hybrid vehicle is powered:
16 Name AUTOMOTIVE MAINTENANCE WORKBOOK, PART TWO, p.7 5. continued b) Discuss the purpose of engine oil. Explain the API service code, the SAE number, and the viscosity rating. Purpose of engine oil: Explain the following: API service code SAE number Viscosity rating c) Explain where to find the recommended oil type and the amount of oil to be used in the vehicle engine. Explain where to find the recommended oil type and amount of oil needed: 6. Cooling System. Do the following: a) Explain the need for coolant in the cooling system. Explain the need for coolant: b) Explain how to flush and change the engine coolant in the vehicle, and how to properly dispose of the used coolant. Flush and change engine coolant: Proper disposal of used coolant:
17 Name AUTOMOTIVE MAINTENANCE WORKBOOK, PART TWO, p.8 7. Fuel System. Do the following: a) Explain how the air and fuel systems work together and why it is necessary to have an air filter and fuel filter. Explain how the air and fuel systems work together: Why air and fuel filters are necessary: b) Explain how a fuel injection system works and how an onboard computer works with the fuel injection system. Explain how a fuel injection systems works: How an onboard computer works with the fuel injection system:
18 Name AUTOMOTIVE MAINTENANCE WORKBOOK, PART TWO, p.9 8. Ignition and Electrical Systems. Do the following: a) Diagram and explain the parts of the electrical system. Diagram the electrical system:
19 AUTOMOTIVE MAINTENANCE WORKBOOK, PART TWO, p.10 Name 8. continued b) Explain the cylinder engine sequence. Cylinder engine sequence: c) Explain the purpose of the spark gap. Purpose of the spark gap: d) Demonstrate how to change the spark plugs in any internal combustion engine (lawn mower, dirt bike, motorcycle). Change spark plug e) Demonstrate how to safely connect jumper cables to your car battery. Safely connect jumper cables to car battery
20 AUTOMOTIVE MAINTENANCE WORKBOOK, PART TWO, p.11 Name 9. Drive Train. Do the following: a) Diagram the drive train and explain the different parts. Diagram the drive train: b) Explain the difference between automatic and standard transmissions. Automatic transmissions: Standard transmissions:
21 AUTOMOTIVE MAINTENANCE WORKBOOK, PART TWO, p.12 Name 9. continued c) Explain the types of automatic transmission fluid. Types of automatic transmission fluid: d) Explain the types of lubricants used in a standard transmission and in the differential. Types of lubricants: e) Explain the difference between front-wheel, rear-wheel, and four-wheel drive. Front-wheel drive: Rear-wheel drive: Four-wheel drive:
22 AUTOMOTIVE MAINTENANCE WORKBOOK, PART TWO, p.13 Name 10. Brake System. Do the following: a) Explain the brake system (including antilock systems) and how it operates. Explain the brake system: Antilock systems: b) Explain the differences between disc and drum systems. Disc brake systems: Drum brake systems: c) Demonstrate how to check the condition of a vehicle s brake system. After checking, make recommendations for repairs (if necessary). Brake system
23 ORGANIZATIONS and WEB SITES (Whenever you go online, be sure you have your parent s permission first.) Cars.com Car Talk Edmunds Insurance Institute for Highway Safety Kelley Blue Book NADA Guides National Institute for Automotive Service Excellence SaferCar.gov
24 Calculating Annual Totals to Produce Approximate Cost Per Mile Expenses New car Used car New or used car Operating Costs Cost of gas per 10,000 miles driven (Cost per gallon of gas/miles per gallon x 10,000) Maintenance Oil changes Air, fuel filters Tune-ups Other Tires Rotation and balance Wheel alignment Ownership Costs Insurance (basic liability, collision, comprehensive, towing, rental car) License, registration, taxes Miscellaneous Costs Car washes, cleaning supplies Accessories Total Driving Costs (Add all rows) Divide total driving costs by total miles driven Yearly Cost Per Mile Note: if you will be financing your car, the monthly payment should also be figured in under ownership costs. Automotive Maintenance Merit Badge Pamphlet, Boy Scouts of America, 2009 Printing
25 OVERLAND TRAILS COUNCIL APPLICATION FOR MERIT BADGE MERIT BADGE UNIVERSITY SECTION A S C O U T SCOUT & MERIT BADGE INFORMATION APPLICATION FOR MERIT BADGE MERIT BADGE UNIVERISTY Name: Merit Badge: Automotive Maintenance Address: City: Address: Overland Trails Council State: PO Box 1361 Is a registered Boy Scout, 2808 O Flannagan Varsity Scout, Grand Island, NE Venturer, of No. Phone: Troop, team, crew, ship District: mbucounselor@gmail.com Council: SECTION B WORKBOOK PART ONE (Pre-requisite Requirements) U N I T Requirement No. and letter Date of Approval Counselor Initial Requirement No. and letter Date of Approval Counselor Initial L E A D E R The applicant has personally appeared before me and demonstrated to my satisfaction that he has met all pre-requisite requirements for the above stated merit badge and/or the scout is qualified and is ready to attend his assigned MBU class. Signature of Unit Leader Date SECTION C WORKBOOK PART TWO (Class Curriculum) C O U N S E L O R Requirement No. and letter Date of Approval Counselor Initial Requirement No. and letter Date of Approval Counselor Initial The applicant has personally appeared before me and demonstrated to my satisfaction that he has completed all requirements in SECTION C listed above for the Merit Badge: Automotive Maintenance Name of Counselor: Please Print Signature of Counselor Date
26 SCOUT INSTRUCTIONS Complete SECTION A Attend the merit badge class Sign the Attendance Sheet provided by your merit badge counselor After your merit badge class return this completed Application for Merit Badge to your Unit Leader SCOUTS PLEASE REMEMBER Have your merit badge workbook, the appropriate merit badge pamphlet, and this Application for Merit Badge with you when you attend class If the merit badge pre-requisites are not completed before class, you will not be able to complete the merit badge during this weekend event, you will need to follow up with your Unit s Advancement Chair when you return home PLEASE BE AWARE THAT SOME COUNSELORS WILL NOT ALLOW YOU TO ATTEND THEIR CLASS WITHOUT THE PRE-REQUISITES COMPLETED SOME CLASS CURRICULUMS ARE DEPENDENT ON THE PRE-REQUISITE WORK BEING COMPLETED! UNIT LEADER INSTRUCTIONS Complete SECTION B 1. Date and initial each requirement listed in the table. 2. Sign your name in the space provided at the bottom of the section. After the Scout has returned this completed Application for Merit Badge to you, please forward to your Unit s Advancement Chair UNIT LEADERS PLEASE REMEMBER Please make sure your scout has his merit badge workbook, the appropriate merit badge pamphlet and this Application for Merit Badge with him when he attends class COUNSELOR INSTRUCTIONS Complete SECTION C 1. Date and initial each requirement listed in the table that was completed during class (If a requirement that is listed is not completed, please cross that requirement out) 2. Print and sign your name in the space provided at the bottom of the section COUNSELORS PLEASE REMEMBER Never meet with a Scout alone Merit Badge Requirements must be completed as written; nothing may be added or deleted NOTE TO UNIT ADVANCEMENT CHAIRMAN Before a Scout can receive credit for completing a merit badge, both Sections B and Section C must be signed. 1. Section B should be signed by the Scoutmaster from your Unit or another leader approved by your unit committee. 2. Section C must be signed by the merit badge counselor from the MBU.
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