automotive technician training practical worksheets level 2 pdf

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AutomotiveTechnician
Training:
PracticalWorksheetsLevel2
Automotivepracticalworksheetsforstudentsat
Level2
ThisLevel2studentworksheetsbookcontainstasksthathelpyoudevelop
practicalskillsandprepareyouforassessment.Thetasksalsoreinforcethe
automotivetheorythatyouwilllearnonlineandintheclassroom.Each
worksheetcoversindividualtopicsinastep-by-stepmanner,detailinghowto
carryoutallthemostimportanttaskscontainedwithinthesyllabus.
Alongsideeachoftheseworksheetsisajobcardthatcanbefilledinandused
asevidencetowardsyourqualification.
EndorsedbytheInstituteoftheMotorIndustryforalltheirLevel2
automotivecourses.
Step-by-stepguidestothepracticaltasksrequiredforallLevel2
qualifications.
Jobsheetsforstudentstocompleteandfeedbacksheetsforassessorsto
complete.
TomDentonistheleadingUKautomotiveauthorwithateachingcareer
spanninglecturertoheadofautomotiveengineeringinalargecollege.His
rangeofautomotivetextbookspublishedsince1995arebestsellersandledto
hisauthoringoftheAutomotiveTechnicianTrainingmultimediasystemthat

isincommonuseintheUK,USAandseveralothercountries.Tomnowworks
astheeLearningDevelopmentManagerfortheInstituteoftheMotorIndustry
(IMI).

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AutomotiveTechnician
Training
PracticalWorksheetsLevel2
TomDenton

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Firstpublished2015
byRoutledge
2ParkSquare,MiltonPark,Abingdon,OxonOX144RN
andbyRoutledge
711ThirdAvenue,NewYork,NY10017
RoutledgeisanimprintoftheTaylor&FrancisGroup,aninformabusiness
©2015TomDenton
TherightofTomDentontobeidentifiedasauthorofthisworkhasbeenassertedbyhiminaccordance
withsections77and78oftheCopyright,DesignsandPatentsAct1988.
Allrightsreserved.Thepurchaseofthiscopyrightedmaterialconferstherightonthepurchasing
institutiontophotocopypageswhichbearthecopyrightlineatthebottomofthepage.Nootherpartsof
thisbookmaybereprintedorreproducedorutilisedinanyformorbyanyelectronic,mechanical,or
othermeans,nowknownorhereafterinvented,includingphotocopyingandrecording,orinany
informationstorageorretrievalsystem,withoutpermissioninwritingfromthepublishers.
Trademarknotice:Productorcorporatenamesmaybetrademarksorregisteredtrademarks,andareused

onlyforidentificationandexplanationwithoutintenttoinfringe.
BritishLibraryCataloguing-in-PublicationData
AcataloguerecordforthisbookisavailablefromtheBritishLibrary
LibraryofCongressCataloginginPublicationData
Acatalogrecordforthisbookhasbeenrequested
ISBN:978-1-138-85237-2(pbk)
ISBN:978-1-315-72351-8(ebk)
TypesetinUniversby
ServisFilmsettingLtd,Stockport,Cheshire

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Contents
PracticalWorksheets–Level2
Engines
Chassis
Transmission
Electrical

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PracticalWorksheets–Level2
Introduction
Thepurposeofthisworksheetsbookistoprovidearangeofpractical
activitiesthatwillenableyoutodevelopyourabilitiesasatechnician.The
tasksarealignedwithrecognizedvocationalqualifications.However,thereare
farmoretaskswithinthisworkbookthanarerequiredbytheawardingbody
fortheachievementofaVocationallyRecognizedQualification–becausethe

moreyoupractise,themoreskillsyouwilldevelop.
TheworksheetsarepresentedasthreeseparatebooksatLevel1,Level2and
Level3tofollowtherecognizedqualifications.Withineachlevelthereare
tasksforthemajorautomotiveareas:Engines,Chassis,Transmissionand
Electrical.Thetasksrangefromcomponentidentificationtoremovalandrefit
atLevel1and2,anddiagnosisofcomplexsystemfaultsatLevel3.
Ablankjobcardandassessorreportareprovidedwitheachworksheet.This
shouldbecopiedandthenfilledinalongsidethetaskyouarecompleting,
includingallrelevantdetailsregardingthevehicle,thefaultandthe
rectificationprocedurewhereappropriate.Youshouldwritedowna
descriptionoftheworkthatyoudidtocompletethetaskincludingany
technicaldatathatyousourced,anydifficultiesthatyouencounteredandhow
youovercamethem.Ifyouhadanyhealthandsafetyissuestoaddress,i.e.
disposalofwastematerialsorclearingupspillages,thiswillhelpdemonstrate
yourcompetence.Bycompletingjobcardsthoroughlyatthisstageofyour
careerasatechnician,youwillbewellpreparedforthetimewhenyouare
requiredtocompletejobcardsintheworkplace.Thiscanbeveryimportant,
forexample,ifawarrantyjobcardisnotaccuratethenthemanufacturerwill
notpayfortheclaim.Anexampleofacompletedjobcardisshownonpage7.
Forteacher/lecturers,thisworkbookmorethancoverstherequirementsfor
VocationalQualifications.Usingthefollowingtrackingdocumentyoucan
noteprogressandalsocross-referencethehighlightedworksheetsthatdirectly
relatetotheawardingbodyrequiredpracticaltasks.

Tracking

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Importantnotesaboutpracticalwork

Safety
Workingonvehiclesisperfectlysafeaslongasyoufollowproperprocedures.
Foralloftheworksheetsinthisbookyoumusttherefore:
Complywithpersonalandenvironmentalsafetypracticesassociated
withclothing;eyeprotection;handtools;powerequipment;proper
ventilation;andthehandling,storage,anddisposalof
chemicals/materialsinaccordancewithallappropriatesafetyand
environmentalregulations.
Therearesomespecificrecommendationsbelowbutyoushouldalsoreferto
theothertextbooksoronlineresourcesforadditionalinformation.
Personalprotectiveequipment(PPE),suchassafetyclothing,isvery
importanttoprotectyourself.Somepeoplethinkitcleverortoughnottouse
protection.Theyareverysadandwilldieorbeinjuredlongbeforeyou!Some
thingsareobvious,suchaswhenholdingahotorsharpexhaustyouwould
likelybeburntorcut!Otherthingssuchasbreathinginbrakedust,orworking
inanoisyarea,donotproduceimmediatelynoticeableeffectsbutcouldaffect
youlaterinlife.

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Eyeprotectionandglovesinuse

Fortunatelytheriskstoworkersarenowquitewellunderstoodandwecan
protectourselvesbeforeitistoolate.Inthefollowingtable,Ihavelisteda
numberofitemsclassedasPPE(personalprotectiveequipment)togetherwith
suggesteduses.Youwillseethattheuseofmostitemsisplaincommonsense.
Equipment Notes

Suggestedorexampleswhereused

Ear
defenders

Mustmeetappropriatestandards

Whenworkinginnoisyareasorifusinganair
chisel

Facemask

Forindividualpersonaluseonly

Dustyconditions.Whencleaningbrakesorif
preparingbodywork

High
visibility
clothing

Fluorescentcolourssuchasyellowor
orange

Workingintrafficsuchaswhenonabreakdown

Leather
apron

Shouldbereplacedifitisholedorworn
thin

Whenweldingorworkingwithveryhotitems

Leather
gloves

Shouldbereplacedwhentheybecome
holedorwornthin

Whenweldingorworkingwithveryhotitemsand
alsoifhandlingsharpmetalwork

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Lifejacket

Mustmeetcurrentstandards

Usewhenattendingvehiclebreakdownsonferries!

Overalls

Shouldbekeptcleanandbeflameproofif
usedforwelding

Theseshouldbewornatalltimestoprotectyour
clothesandskin.Ifyougettoohotjustwearshorts
andaT-shirtunderneath

Rubberor
plastic
apron

Replaceifholed

Useifyoudoalotofworkwithbatteryacidor
withstrongsolvents

Rubberor
plastic
gloves

Replaceifholed

Glovesmustalwaysbeusedwhenusing
degreasingequipment

Safety
shoesor
boots

Strongtoecapsarerecommended

Workinginanyworkshopwithheavyequipment

Safety
goggles

Keepthelensescleanandprevent

scratches

Alwaysusegoggleswhengrindingorwhenany
riskofeyecontamination.Cheapplasticgoggles
aremucheasiertocomebythanneweyes

Safety
helmet

Mustbetocurrentstandards

Undervehicleworkinsomecases

Welding
gogglesor
welding
mask

Checkthegogglesaresuitableforthetype Youshouldwearweldinggogglesoruseamask
ofwelding.GasweldinggogglesareNOT evenifyouareonlyassistingbyholding
goodenoughwhenarcwelding
something

Also,aswellasyourownprotectionyoushouldalwaysuseaprotectionkit
forthevehicle:floormats,wingcoversandseatcoversforexample.

Toolsandequipment
Tocarryoutanyworkyouwillneedastandardtoolkitandinsomecases
additional‘special’toolswillberequired.Makesureyouhaveaccesstoall
necessaryequipmentbeforestartingwork.Afewexamplesarementioned

belowbutyoushouldalsorefertotheothertextbooksoronlineresourcesfor
additionalinformation.
Usinghandtoolsissomethingyouwilllearnbyexperience,butanimportant
firststepistounderstandthepurposeofthecommontypes.Thissection
thereforestartsbylistingsomeofthemorepopulartools,withexamplesof
theiruse,andendswithsomegeneraladviceandinstructions.

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Toolkit

Practiseuntilyouunderstandtheuseandpurposeofthefollowingtoolswhen
workingonvehicles.
Handtool

Exampleusesand/ornotes

Adjustable
spanner
(wrench)

Anidealstandbytoolandusefulforholdingoneendofanutandbolt.

Open-ended
spanner

Usefornutsandboltswhereaccessislimitedoraringspannercan’tbeused.

Ringspanner

Thebesttoolforholdinghexagonboltsornuts.Iffittedcorrectlyitwillnotslipand
damagebothyouandthebolthead.

Torquewrench

Essentialforcorrecttighteningoffixings.Thewrenchcanbesetinmostcasesto‘click’
whentherequiredtorquehasbeenreached.Manyfittersthinkitisclevernottousea
torquewrench.Goodtechniciansrealizethebenefits.

Socketwrench

Oftencontainaratchettomakeoperationfareasier.

Hexagonsocket
spanner

Socketsareidealformanyjobswhereaspannercan’tbeused.Inmanycasesasocketis
quickerandeasierthanaspanner.Extensionsandswiveljointsarealsoavailabletohelp
reachthatawkwardbolt.

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Airwrench

Theseareoftenreferredtoaswheelguns.Air-driventoolsaregreatforspeedingupyour
workbutitiseasytodamagecomponentsbecauseanairwrenchisverypowerful.Only
special,extrastrong,high-qualitysocketsshouldbeused.

Blade
(engineer’s)
screwdriver

Simplecommonscrewheads.Usethecorrectsize!

Pozidrive,
Philipsand
crosshead
screwdrivers

BettergripispossibleparticularlywiththePozidrivebutlearnnottoconfusethetwovery
similartypes.Thewrongtypewillslipanddamagewilloccur.

Torx®

SimilartoahexagontoollikeanAllenkeybutwithfurtherflutescutintheside.Itcan
transmitgoodtorque.

Specialpurpose
wrenches

Manydifferenttypesareavailable.Asanexamplemolegripsareveryusefultoolsasthey
holdlikepliersbutcanlockinposition.

Pliers

Theseareusedforgrippingandpullingorbending.Theyareavailableinawidevarietyof
sizes.Theserangefromsnipenose,forelectricalwork,toengineerspliersforlargerjobs
suchasfittingsplitpins.

Levers

Usedtoapplyaverylargeforcetoasmallarea.Ifyourememberthisyouwillrealizehow,
ifincorrectlyapplied,itiseasytodamageacomponent.

Hammer

Anybodycanhitsomethingwithahammer,butexactlyhowhardandwhereisagreat
skilltolearn!

Generaladviceandinstructionsfortheuseofhandtools(takenfrom
informationprovidedbySnap-on):
Onlyuseatoolforitsintendedpurpose
Alwaysusethecorrectsizetoolforthejobyouaredoing
Pullaspannerorwrenchratherthanpushingwheneverpossible
Donotuseafileorsimilarwithoutahandle
Keepalltoolscleanandreplacetheminasuitableboxorcabinet
Donotuseascrewdriverasaprybar
Lookafteryourtoolsandtheywilllookafteryou!

Information
Beforestartingworkyoushouldalwaysmakesureyouhavethecorrect

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informationtohand.Thiscanbeintheformofaworkshopmanualora
computer-basedsource.
Theworksheetsinthisbookareageneralguidesomakesurethe

correctinformation,proceduresanddatafortheparticularvehicleyou
areworkingonareavailablebeforeyoustartwork.

Autodataonlineinformation

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Jobcard:example

Assessorreport:example

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Engines
Worksheet1:Routinevehiclemaintenance
inspections/service
Procedure
Generalvisualinspection–listenforabnormalnoises.
Visual/oillevelandcondition.Replaceoilandfilteratspecifiedintervals.
Visual/inspectionsforoilleakage.
Visual/inspectionofexhaustsmoke–atidlespeedatmid-enginespeed(3000
rpm)onoverrunduringroadtest.
Engineoilpressuretest–checkwarninglightoperates(attachapressure
gaugeandadapterandtachometer)–pressureatidlespeed–stabilized
pressure–stabilizedpressureenginerpm.
Crankcaseventilationsystem–checkconditionofhoses(visualandremove
hosesandvalves)–orificetoinletmanifoldclear–aircleanercondition–
controlvalvecondition.

Checkcoolantlevelandspecificgravity.
Checkbrakeoperationandpad/disccondition–recordthickness.
Checktyretreaddepths.
Torquewheelnuts–includetorquefiguresandcalibrationdateoftorque
wrench.
Additionalitems–seemanufacturer’sschedule.

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Jobcard

Assessorreport

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Worksheet2:Vehicleinspections
Procedure
Generalvisualinspection–listenforabnormalnoises.
Checkbrakeoperationandpad/disccondition–recordthickness.
Checktyretreaddepths.
Torquewheelnuts–includetorquefiguresandcalibrationdateoftorque
wrench.
Additionalitems–seemanufacturer’sscheduledependingupontypeof
inspection–pre-andpost-work,pre-deliveryinspection(PDI),prepurchaseinspection(PPI),preMOT,visualhealthcheck(VHC)orpost
repair.

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Jobcard

Assessorreport

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Worksheet3:Adjustvalveclearances(OHV)
Procedure
Runengineandlistenforabnormalnoisesfromtopofengine.Checkfor
misfire/cylinderbalance.Disconnectbatteryearth/groundcable.Remove
rockercover.
Measurewithfeelergaugesallvalveclearancesatthe‘back-of-the-cam’
(heel)position.Checkmanufacturer’srecommendedprocedurefor
positioningtheengine,e.g.ruleofnineorvalvesrockingmethod.
Adjusteachvalveusingaspecialtoolorwrenchandscrewdriveras
appropriate.Notethatinletandexhaustsettingsmayvary.
Refitallandrunenginetocheckfornoiseormisfire.

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Jobcard

Assessorreport

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Worksheet4:Inspectcamshaftlobes,journalsand
bearings,auxiliaryshafts,bearingsanddrive
Procedure
Striptoaccessthecamshaft.Checktheendfloatbeforeremoving.
Removecamshaftandvisuallyinspectforconditionofbearingjournalsand
camlobes.Inspectretaining/thrustplateforwear.
Inspectbearingsintheengineblockorhead.Lookforwear,scoring,pitting,
orotherdeterioration.
Laythecamshaftinoiledpapersupportsinveeblocksonasurfacetable.
Assembleadialtestindicator(DTI)toabaseandzerooncentrejournal.
Rotateshaftandobservevariationinneedlepositiontoindicateifthe
shaftisbent.
Measureandrecordcamliftonalllobes.Comparewithmanufacturer’sdata.
Measurecamjournalswithexternalmicrometerandrecordresults.Measure
forovality.Measureinternaldimensionsofbearingsandrecord.Compare
readingswithmanufacturer’sdataforsizeandweartolerances.
Reassembleshaftandothercomponents.Runengineandlistenforabnormal
noises.

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Theinspectionofauxiliaryshaftsisasimilarprocedure.

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Jobcard

Assessorreport

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Worksheet5:Removeandreinstallengine(RWD)
withouttransmission
Procedure
Obtaincrane,slingandliftingeyeswithaSWLinexcessofengineweight.
Disconnectbatteryearth/groundcable.Fitliftingeyestoengineasper
manufacturer’sinstructions.Labelanddisconnectallelectricalcablesto
engineincludingenginegroundcable.Labelanddisconnectallvacuum
pipestoengine.Removeairintakeductingandaircleaner,blankoffopen
pipes.
Depressurize,labelanddisconnectfuellinestoengine,blankoffpipes.Label
anddisconnectthrottle/chokeandothercontrolcables.Disconnect
exhaustdownpipeatmanifoldflange.Remove,ifnecessary,thestarter
motorandclutchoperatingmechanism(cableorhydraulic).Slackenall
clutchhousingboltsandremoveallbuttwo,oneeitherside.Slackenand
remove,ifsafetodoso,theenginemountingnutsfromtheundersideof
vehicle.
Whenallundersideworkiscompleted,drainthecoolantandremoveradiator
andallhoses.Whenairconditioningisfitted,donotdisconnect
refrigerantpipes/hosesbeforeremovingrefrigerant(specialisttask).If

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