Automotive Technology Mr. Lacivita

Automotive Technology Mr. Lacivita

A GENERAL PLAN FOR PROBLEM SOLVING Creating an Plan Can Help You Solve Any Problem! A. Understand the problem 1. Check the facts. a. What do you know? b. What do you need to find? 2. Organize the information a. Draw a picture b. Make a list c. Make a chart d. Rewrite the problem in your own words B. Develop a plan (research) 1. Draw a diagram 2. Make a model 3. Find a pattern 4. Solve a simpler problem of the same type 5. Use a known formula 6. Use an equation 7. Guess and check C. Carry out the plan D. Check the results 1. Did I carry out the plan correctly? a. Did I make any mistakes in my calculations? b. Do the numbers and the units make sense? c. Can I make an estimate of the calculations? d. Is the calculated answer close to my estimate? 2. Did the plan work? a. Is the answer reasonable for the question? 3. Does it answer the question? a. Check the results b. What if the problem is not solved?

Introductory Personal Survey Name: Date: School and grade: Home address: Home phone number: Father s name & cell phone number: Mother s name & cell phone number: Father s occupation: Mother s occupation: What are your career interests and goals? What activates do you participate in at your home school? What activities do you participate in outside of school? What do you consider the best car ever made? Why?

If you could own any car built today, what would it be? Why? Who is your favorite NASCAR driver? What were the last three (3) movies you saw? What is your favorite movie? Who are your favorite musicians? What is the last song you downloaded from the Internet? What is your favorite video game? What is your favorite web site? What were the last three (3) books you read? What newspaper(s) or magazine(s) do you read? What do you consider your strengths as a student? What do you need to improve to become a better student?

What type of automotive or mechanical experience have you had? What would you like to get out of this class (other than an "A")? What is your biggest complaint about school? What is your biggest complaint about society? What is your biggest complaint? Have you considered attending college or some other type of post-secondary education after graduating high school? Why? Why not?

Automotive Technology Safety Rules Safety glasses must always be worn while in the shop/lab area No Exceptions, No Excuses! A face shield must be worn when using a grinder of any type. Safety glasses MUST also be worn under the face shield. A dust mask must be used under dusty conditions. Use the right tool. Do not force small tools to do the job of a heavy-duty tool. Maintain tools with care. Keep tools sharp, well adjusted and clean. Be sure handles are securely fastened. All tools must be returned to the proper tool bin at the end of the session. Keep all guards in place and in working order. Keep children out of work area. All visitors should be kept at a safe distance. If they enter the lab, they must wear safety glasses. Keep work area clean and organized. Keep benches clear and tools off of the floor. Store idle tools. When not in use, tools should be stored out of the way. Disconnect all power tools when not in use. Wear proper apparel. Loose clothing can get caught in moving parts. No hanging jewelry is allowed in the shop area. Secure all work by using a clamp or vice. Do not force a tool to do a job it was not designed to do. Do not over reach, keep proper footing and balance. Pull on wrenches, do not push. If you must push on a wrench, use the base of your palm and keep your hand open. Always hold sharp and pointed tools away from your body to avoid possible injury. Ground all power equipment. Have plenty of light and ventilation. Benches must be well-lit and exhaust fumes out of the shop. Classroom and lab must be cleaned at the end of each session. No students are allowed to operate any shop equipment that is powered by electric, air or hydraulic power without first receiving safety instructions from the instructor. No student will use a damaged or broken tool. Any tool that is damaged or broken must be turned into the instructor.

USING A TORQUE WRENCH TO USE A TORQUE WRENCH PROPERLY, FOLLOW THESE BASIC RULES: 1. Keep a steady pull on the wrench. For accuracy, do NOT use short, jerky pull motions. 2. Clean and lightly oil the fasteners threads, bolt shaft and underside of bolt head. 3. When possible, avoid using swivel (universal) joints. 4. When reading a beam type torque wrench, look straight down at the scale. Viewing from an angle can give a false reading. 5. A general torque value chart should only be used when manufactures specs are NOT available. 6. When manufacturers torque patters are not available, use a general crisscross order for tightening fasteners. 7. Pull only on handle of torque wrench. DO NOT allow beam of a beam type torque wrench to touch anything. 8. Tighten bolts and nuts in four steps: to one-half torque, then to three-quarters, and then to full torque and then to full torque again. 9. Retorque when required. On some assemblies C especially on cylinder heads, intake manifolds and exhaust manifolds C the bolts may have to be retightened after operation and heating. TORQUE WRENCH THEORY ONE FOOT-POUND EQUALS ONE POUND OF PULL ON A ONE-FOOT-LONG LEVER ARM

Standard Bolt Identification and Torque Chart The torque specifications listed below are approximate guidelines only and may vary depending on conditions when used such as amount and type of lubricant. Grade of bolt Minimum Tensile Strength Markings On Head US Standard Bolt Diameter SAE 1 & 2 64,000 P.S.I. SAE STANDARD / FOOT POUNDS SAE SAE SAE 5 6 8 105,000 132,000 150,000 P.S.I. P.S.I. P.S.I. Foot Pounds Size Of Socket Or Wrench Opening U.S. Regular Bolt Head Nut 1/4 5 7 10 10.5 3/8 7/16 5/16 9 14 19 22 2 9/16 3/8 15 25 34 37 9/16 5/8 7/16 24 40 55 60 5/8 3/4 1/2 37 60 85 92 3/4 13/16 9/16 53 88 120 132 7/8 7/8 5/8 74 120 167 180 15/16 1 3/4 120 200 280 296 1 1/8 1 1/8 FLEX BAR OR BEAM TYPE TORQUE

Metric Bolt Identification and Torque Chart The torque specifications listed below are approximate guidelines only and may vary depending on conditions when used such as amount and type of lubricant METRIC Grade of bolt 5D 8G 10K 12K Minimum Tensile Strength 71,160 P.S.I. 113,800 P.S.I. 142,000 P.S.I. 170,600 P.S.I. Grade Markings On Head 5D 8G 10K 12K Metric Bolt US Foot Pounds Diameter Decimal Equivalent Size Of Socket Or Wrench Opening Metric Bolt Head 6mm.2362 5 6 8 10 10mm 8mm.3150 10 16 22 27 14mm 10mm.3937 19 31 40 49 17mm 12mm.4720 34 54 70 86 19mm 14mm.5512 55 89 117 137 22mm 16mm.6299 83 132 175 208 24mm 18mm.709 111 182 236 283 27mm 22mm.8661 182 284 394 464 32mm DIAL INDICATOR TORQUE WRENCH A VERY ACCURATE TYPE OF TORQUE WRENCH 9

Decimal Conversion Chart Customary Measuring System 10

Math Worksheet Decimals 1. The odometer reading was 68 432.6 kilometers before a trip and 69 561.5 after the trip. What was the distance of the trip? 2. Five quarts of oil and an oil filter cost $10.35. However, with a coupon, these items may be purchased for $3.43 less. What is the final cost of the oil and filter? 3. A cylinder measures 3.1256 inches at the top and 3.1197 inches at the bottom. How much taper does the cylinder have? 4. A turbine shaft has 1.7-mm endplay. Specifications call for only 0.6 mm. What size selective thrust washer (spacer) must be used to bring turbine shaft endplay within specified limits? 5. Differential ring-gear backlash is specified at 0.006 inch and is measured at 0.035 inch. What is the difference between the specified backlash and the measured backlash? 6. A valve guide bore measures 0.0453 inch and the valve stem measures 0.0426 inch. What is the valve stem clearance? 7. The maximum diameter of a brake drum is listed as 11.090 inches. The brake drum measures 11.063 inches. After machining 0.022 inch from the drum to remove score marks you must determine if the drum is still usable. (a) What does the drum now measure? (b) Can it be reused? 8. A new piston has a diameter of 3.625 inches. This is 0.0143 larger than a worn piston. What is the size of the worn piston? 9. A vehicle gets 34.6 mpg of fuel. How far can a vehicle travel on 17.5 gallons of fuel? 11

Math Worksheet Division 1. An automobile was driven 368 miles and used 16 gallons of fuel. How many miles per gallon is this? 2. The labor charge for 6 hours of work was $102. How much is the labor rate in dollars per hour? 3. Six piston rings sets cost $84. How much did each set cost? 4. A manufacturer has purchased 255,486 head bolts that are to be used for engine assembly. Each engine uses 14 head bolts. How many engines can be assembled from the supply of head bolts? 5. A driver has just traveled 350 miles in 7 hours. What was the average speed? 6. An automobile traveled 935 km and used 55 liters of fuel. How many kilometers was the auto able to travel on each liter? 7. A driver has just purchased four new tires for$468. How much did each tire cost? 8. A manufacturer has purchased 56,500 feet of window weather-stripping. Each car requires 32 feet of weather-stripping. How many cars can be outfitted with windows using this supply of weatherstripping? 9. An empty pickup truck weighs 3760 pounds. It loads a cargo of 15 identical boxes. With the boxes, the truck now weighs 5605 pounds. How much does each box weigh? 10. A manufacturer purchased 393,924 identical bolts. Each engine assembly uses 8 of these bolts and each transmission needs 9 bolts. How many engine and transmission combinations can be assembled using this supply of bolts? 12

1. Gasoline should only be stored in: a. glass bottles that have lids b. approved, sealed safety containers c. old paint cans d. all of the above Basic Measurements Worksheet 2. Automobile batteries can explode. If false, why? a. T b. F 3. Smoking is permitted in an automobile repair shop. If false, why? a. T b. F 4. Which can cause an electric shock: a. missing ground prong on the cord b. using an electric drill around water c. exposed wires on an extension cord d. all of the above 5. Adequate lighting in an automobile repair shop can increase working safety. If false, why? a. T b. F 6. Using the 10-Decimal Conversion Chart, find the equivalent measurements. a. 1/16 of an inch = inches mm b. 11/32 of an inch = inches mm c..29688 inches = fraction mm d..93750 inches = fraction mm e. 14.684 mm= fraction inches f. 7.938 mm= fraction inches 13

7. Using the chart, put the amount of angle rotation in degrees: a. b. c. C B A d. e. D E 8. Using the metric temperature chart: a. Water freezes at degrees F, Degrees C b. Water boils at degrees F, Degrees C c. Normal body temperature degrees F, Degrees C 9. Using Bolt Identification and Torque Charts, determine the proper setting for each fastener: a. The torque of a SAE Grade 1, 1/4 inch diameter bolt is ft. lbs. b. The torque of a SAE Grade 6, 9/16 inch diameter bolt is ft. lbs. c. The torque of a SAE Grade 8, 3/4 inch diameter bolt is ft. lbs. d. The torque of a Metric 8G, 6mm diameter bolt is ft. lbs. e. The torque of a Metric10K, 14mm diameter bolt is ft. lbs. 10. You should torque bolts/fasteners in three (3) steps. If false why? a. T b. F 14

Torquing Bolts Worksheet When assembled, a bolts and nuts (fasteners) are a simple machine that exerts powerful clamping forces on parts. It is very important bolts and nuts are torqued (tightened) properly. If a bolt or nut is OVERTIGHTENED: The bolt or nut threads will stretch and break and will fail. If a bolt or nut is UNDERTIGHTENED: A bolt or nut could work loose due to vibration and fail. Part movement could also shear a fastener, causing a gasket to leak or the possibility of a FATAL ACCIDENT! Use the information and follow the instructions at the bottom of pages titled Bolt Identification and Torque Chart Example: If the final torque on a bolt is 100 lb.ft, the torque settings would be as follows: Step 1, 50 lb.ft; Step 2, 75 lb.ft Step 3, 100 lb.ft Step 4, 100 lb.ft Fill in the correct information for the specifications given below If the final torque spec of a bolt is 40 lb.ft, what are the settings for: If the final torque spec of bolt is 60 lb.ft., what are the settings for: If the final torque spec of bolt is 90 lb.ft., what are the settings for: If the final torque spec of bolt is 125 lb.ft., what are the settings for: If the final torque spec of bolt is 180 lb.ft., what are the settings for: Step 1 Step 2 Step 3 Step 4 15

How to Read a Conventional Micrometer Micrometers divide an inch into one-thousand parts. The barrel has a scale divided into 40 equal spaces of 0.025 each. The movable part, called the thimble, is divided into 25 equal parts of 0.001 each. One full rotation moves it one full space on the barrel. To read a micrometer: Examples Barrel reading: 0.025 reading: Thimble reading: Micrometer Reading: Barrel reading: 0.025 reading: Thimble reading: Micrometer Reading: 16

Micrometer Worksheet 17

Precision Measurements Task Measureme nt 1 Properly identify a 0" to 1" and 1 to 2 outside micrometer. 2 Measure the diameter of Bolt # 1 using a 0" to 1" outside micrometer. 3 Measure the diameter of Bolt # 2 using a 0" to 1" outside micrometer. 4 Measure the diameter of Bolt # 3 using a 0" to 1" outside micrometer. 5 Measure the diameter of Bolt # 4 using a 0" to 1" outside micrometer. 6 Measure the diameter of Bolt # 5 using a 0" to 1" outside micrometer. 7 Measure a strand of your hair using a 0" to 1" outside micrometer. 8 Measure a piece of paper using a 0" to 1" outside micrometer. 9 Measure the thickness of the padlock shackle using the veneer calibers. 10 Measure the thickness of the padlock shackle using a 0" to 1" outside micrometer. 11 Measure the diameter a brake drum using the fractional scale on the drum gauge. 12 Measure the diameter a brake drum using the metric scale on the drum gauge. Convert to fractions. 13 Measure the thickness of a brake rotor using an outside micrometer. 14 Measure the thickness of a brake rotor using an outside micrometer. 15 Measure the diameter of freeze plug #1using the veneer calibers. 16 Measure the diameter of freeze plug #1using a micrometer. 17 Measure the diameter of freeze plug #2 using the calibers. 18 Measure the diameter of freeze plug #2 using a micrometer. 19 Measure the air gap of a spark plug using a feeler gauge. 20 Measure the air gap of a spark plug using a feeler gauge. 18

Student Survey You may use information from various sources such as newspapers, employers (either visit or by phone), instructors, home school, public or classroom library to answer the following questions related to your present course of study. You must find and describe job opportunities associated with the class you are now in. Example: In Auto Technology, you need to describe jobs associated with the automotive industry. Occupation1: 1. Describe job and job duties: 2. What are the current and future career opportunities of this position? 3. Wages: 4. Hours: 5. Educational requirements: 6. Physical demands required to perform this job: Occupation 2: 1. Describe job and job duties: 2. What are the current and future career opportunities of this position? 3. Wages: 4. Hours: 5. Educational requirements: 6. Physical demands required to perform this job: 19

Occupation3: 1. Describe job and job duties: 2. What are the current and future career opportunities of this position? 3. Wages: 4. Hours: 5. Educational requirements: 6. Physical demands required to perform this job: Occupation 4: 1. Describe job and job duties: 2. What are the current and future career opportunities of this position? 3. Wages: 4. Hours: 5. Educational requirements: 6. Physical demands required to perform this job: 20

Career Objective Survey DIRECTIONS: Write a paper on your interest and achievement in a specific career. This paper is to be typed and double-spaced. All grammar, spelling, punctuation and content will be evaluated. The following questions must be answered in the composition. Any information from your research, experience and interests that are important should also be included. 1. What is your career goal and why are you pursuing this area? 2. What abilities or aptitudes are needed for this career? 3. What further training does this job require, if any? (Further technical training, community college, 4-year college, certification, etc.?) 4. Describe working conditions and physical surroundings? 5. What is the job outlook in this area? 6. Are your personality and interests in line with career? Please briefly explain. 21

Cluster Experience Journal Directions: Think about what you have experienced in the classroom and lab this week and answer the following questions: 1. What are some of the safety rules in this lab? 2. What skills did you learn this week? 3. What skills did you enjoy doing? Why? What skills didn t you enjoy doing? Why? 4. What grade would you give yourself this week? Why? 5. What grade do you think your instructor will give you? Why? 6. Would you consider taking this class/lab? Why? 22