TASK b STEERING and SUSPENSION1

Test Project Automobile Technology
Task B – Steering and Suspension
TP33_10VN_actual
Submitted by
Name
Member Country

TP33_10VN_actual

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: All Members


Skill 33 - Automobile Technology
Competitor Instructions - Automobile Technology
Competitor Name

Country Code

Task
B

Instructions to Competitor
Task

Steering and Suspension

Familiarization Time

15 minutes

Task Duration

3 hours

Total Breaks

15 minutes
Marking Summary
Section

Possible
Mark
1.80

1.

Health, Safety and House keeping

2.

Remove and Replace one side Lower Control Arm

2.20

3.

Remove one side Front Strut Assembly

1.10

4.

Replace Front Strut Assembly

1.20

5.

Install one side Front Strut Assembly

1.30

6.

Wheel Alignment

6.30

7.

Print out Results

0.20

8.

Wheel balancing on one Wheel

1.30

9

Using M-MDS to check faults stored

0.60

Task Total

10TH ASC October 2014, Hanoi Vietnam

16.00


Skill 33 - Automobile Technology
You are required to
- Observe occupational health & safety standards
- Only ask necessary questions
- Not speak to the public while competing
- Comply with Experts instructions
- Ensure Name on all forms
- Use appropriate tools and procedures
- Complete all instructions on the next page
Remark: Vehicle/Model: Mazda2 1.5 A/T , 2014 Model Year
Competitor Name

Country Code

Task
B

You are required to:
1.

Use safe working procedures at all times.

2.

Ensure that the steering and suspension systems are in a safety condition.

3.

Remove and replace the lower control arm as instructed by the judge.

4.

Remove one side of the front strut as instructed by the judge.

5.

Remove and replace the Strut with the service tools provided.

6.

Perform a four wheel alignment. Print out the readings before and after.

7.

Perform tire changing on one extra spare wheel as instructed by the judge.

8.

Perform wheel balancing on one extra spare wheel as instructed by the judge.

9.

Perform check on the EPS Control Module (Electric Power Steering) with
M-MDS (Mazda-Modular Diagnostic System).

10TH ASC October 2014, Hanoi Vietnam


Skill 33 - Automobile Technology
Form 5 - Automobile Technology
Competitor Name

Country Code

Task

Marking Scale

B

Steering & Suspension

Marking Summary
Possible
Mark

Section
1.

Health, Safety and House keeping

1.80

2.

Remove and Replace one side Lower Control Arm

2.20

3.

Remove one side Front Strut Assembly

1.10

4.

Replace Front Strut Assembly

1.20

5.

Install one side Front Strut Assembly

1.30

6.

Wheel Alignment

6.30

7.

Print out Results

0.20

8.

Wheel balancing on one Wheel

1.30

9

Using M-MDS to check faults stored

0.60

Task Total

Actual
Mark

16.00

Time Keeping
Familiarization

Competition

Breaks

Start

Start

Start

Stop

Stop

Stop

Experts Signatures
1

2

10TH ASC October 2014, Hanoi Vietnam

3

4


Skill 33 - Automobile Technology

Competitor Name

1.
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14
1.15
1.16
1.17
1.18

Country Code

Health, Safety and House

Keeping
Check all equipment
Understand all instructions
Use workshop manual
Apply logical working procedure
Proper tools handling
Ramp, lowered onto stops
Jacks, pads used
Jacks, pads positioned correctly
Parking brake applied to maximum
Choke tires
Use fender covers
Use seat covers
Use steering wheel cover
Use floor mats
Checking when lift-up/down the
lifter up the working area
Clean
Clean up tools and equipment
Clean up the test models
Sub - Total

Yes

No

0.10
0.10
0.10
0.10

0.10
0.10
0.10
0.10
0.10
0.10
0.10
0.10
0.10
0.10
0.10
0.10
0.10
0.10

0
0

1.80

0

Yes

No

0.10

0

2.2 Remove the wheel

0.20

0

2.3 Loosen Flange Bolt & nut
Remove the Lower Ball Joint from
2.4
lower arm
Remove All Lower Arm Mounting
2.5
Bolt

0.20

0

0.20

0

0.30

0

2.6 Replace Lower Control Arm

0.30

0

2.7 Install All Lower Arm Mounting Bolt
Install the Lower Ball Joint from
2.8
lower arm
Install and Tighten Flange Bolt &
2.9
nut
Sub - Total

0.30

0

0.30

0

0.30

0

2.20

0

10TH ASC October 2014, Hanoi Vietnam

Marking Scale

B

Steering & Suspension

Actual

Comments

Actual

Remark

0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

Remove and Replace one side

Lower Control Arm
2.1 Vehicle proper secured
2.

Task

One side


Skill 33 - Automobile Technology

Competitor Name

3.
3.1
3.2

Country Code

Remove one side Front Strut
Assembly
Remove wheel sensor Harness clip
Remove brake hose bracket

Yes

No

0.10
0.20

0
0

3.3

Remove Front strut assembly & Self Locking
nut

0.20

0

3.4
3.5

Loosen Flange nuts
Remove Front strut assembly

0.30
0.30

0
0

Sub – Total

1.10

0

4.

Replace Front Strut Assembly

Yes

No

4.1

Remove coil spring from Front Strut

0.40

0

4.2

Replace the strut

0.10

0

4.3

Install the coil spring

0.40

0

4.4

Tighten Strut nut to torque

0.30

Sub – Total

1.20

Marking Scale

B

Steering & Suspension

Actual

Remark

Actual

Remark

Actual

Remark

0

5.

Install one side Front Strut Assembly

Yes

No

5.1

Install Front Strut Assembly into vehicle

0.20

0

5.2

Install Flange Nuts

0.30

0

5.3

Tighten Front strut assembly Bolt & Self

Locking nut

0.30

0

5.4

Install wheel sensor Harness clip

0.10

0

5.5

Install brake hose bracket

0.10

0

5.6

Re-fit wheel and tighten to torque

0.30

0

Sub – Total

1.30

0

10TH ASC October 2014, Hanoi Vietnam

Task


Skill 33 - Automobile Technology

6.

Wheel Alignment

6.1

Check tire pressures and correct it if
necessary
Check wheel bearings
Check joints
Remove one side tie-rod end
Install one side tie-rod end
Check lower ball joints unloaded
Check vehicle level
Set program
Mount Wheel Clamps correctly
Handle Sensors with care

Mount Sensors correctly
Perform all wheels “run-out”
compensation
Position turntable correctly
Apply hand brake
Set turntable to zero
Position Rear Wheels Slip Plate
Bounce car
Remove turntable pins
Set levelling sensor to centre position
Use brake pedal depressor
Check Caster Angle
Check KPI Angle
Centre Steering Wheel Straight ahead
position
Print out wheel alignment results
Lock steering wheel
Perform Front Toe adjustment
Tighten Front Tie-rod end lock nut
Check steering wheel in centre position
Check Camber from print out
Check Caster from print out
Correct front Toe
Tighten tie rod lock nut
Check steering wheel position
Second print out (after adjustment)
Remove all sensors
Reset program

6.2

6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
6.13
6.14
6.15
6.16
6.17
6.18
6.19
6.20
6.21
6.22
6.23
6.24
6.25
6.26
6.27
6.28
6.29
6.30
6.31
6.32

6.33
6.34
6.35
6.36

6.37 Car lowered to ground
Remove brake pedal depressor and
6.38
tools
Total:

10TH ASC October 2014, Hanoi Vietnam

Yes

No

0.20

0

0.20
0.20
0.10
0.10
0.20
0.20
0.30
0.20
0.20

0.20

0
0

0.20

0

0.20
0.10
0.20
0.20
0.10
0.20
0.20
0.20
0.20
0.20

0
0
0
0
0
0
0
0
0
0

0.10

0

0.10
0.10
0.20
0.20
0.10
0.10
0.10
0.40
0.20
0.10
0.10
0.10
0.10

0
0
0
0
0
0
0
0
0
0
0

0
0

0.10

0

0.10

0

6.30

0

0
0
0
0
0
0

Actual

Remark


Skill 33 - Automobile Technology
Competitor Name

Country Code

7.

Print Out Results

Yes

No

7.1

Print out result before Wheel Alignment

0.10

0

7.2

Print out result after Wheel Alignment

0.10

0

0.20

0

Sub - Total

8.

Wheel balancing on one Wheel

Yes

No

8.1

Mount the wheel on balancing machine
correctly

0.10

0

8.2

Set rim distance correctly

0.20

0

8.3

Set rim width correctly

0.20

0

8.4

Set rim diameter correctly

0.20

0

8.5

First balancing attempt

0.30*

8.6

Second balancing attempt

0.20*

8.7

Remove the tire from the balancing
machine

0.10

0

8.8

Return all tools

0.10

0

8.9

Care of equipment

0.10

0

Sub - Total

1.30

0

9.

Using M-MDS to check faults stored

Yes

No

9.1

Connect M-MDS to OBD

0.10

0

9.2

Switch ignition on

0.10

0

9.3

Perform quick test to check for fault
stored

0.10

0

9.4

Clear all fault memories

0.10

0

9.5

Switch off ignition

0.10

0

9.6

Disconnect M-MDS

0.10

0

0.60

0

Sub - Total

10TH ASC October 2014, Hanoi Vietnam

Task

Marking
Scale

B

Steering & Suspension

Actual

Remark

Actual

Remark

*Choose one applicable

0

Actual

Remark