Republic of the Philippines

Commission on Higher Education

LIBON COMMUNITY COLLEGE
LIBON, ALBAY
AY 2020- 2021
First Semester

Course: AT 111 – Introduction to Automotive Technology

Module No.: 3 Module Title: Measuring Systems and Measuring

Tools
Instructor: Jeffrey Segarra Nicomedes

Name of Student:

Year & Section: AT I – A/B

Schedule:
 HOW TO USE THIS MODULE

Welcome to the Module of Automotive Technology. This module contains training materials and
activities for you to complete.

The unit of competency “Measuring Systems and Measuring Tools” contains the knowledge, skills
and attitudes required for a BTVED Automotive Technology course.

You are required to go through a series of learning activities in order to complete each of the learning
outcomes of the module. In each learning outcome there are Information Sheets, Job Sheets, Operation
Sheets and Activity Sheets. Follow these activities on your own and answer the Self- Check at the end of
each learning activity.

If you have questions, don’t hesitate to ask your Instructor for assistance.

Recognition of Prior Learning (RPL)

You may already have some or most of the knowledge and skills covered in this module because you
have:
 been working for some time
 already completed training in this area.

Inside this module you will find the activities for you to complete followed by relevant information sheets for
each learning outcome. Each learning outcome may have more than one learning activity.

This module is prepared to help you achieve the required competency, in receiving and relaying
information. This will be the source of information that will enable you to acquire the knowledge and skills in
performing shop maintenance independently at your own pace or with minimum supervision or help from your
teacher.
Module 3: MEASURING SYSTEMS AND MEASURING TOOLS TOOLS

CONTENTS OF ThIS UNIT

Unit objective

Lesson plans

 Lesson 1: Specialty Tools

 Information outline

 Assignment sheet

AS1-L1-UV: Specialty Tool Uses

 Lesson 2: Fasteners

 Information outline

 Assignment sheet

 AS1-L2-UV: Common Vehicle Fasteners

Lesson 3: Measuring Tools

 Information outline

 Assignment sheet

 AS1-L3-UV: Use and Care of Measuring Tools

Unit Test
MODULE OBJECTIvE

After completing this unit, students should be able to identify the types and uses of specialty
tools, fasteners, and precision measuring tools. Students will demonstrate mastery of the material
by completing the assignment sheets and achieving a score of on the Unit Test.

SPECIFIC OBJECTIvES

After completing the lessons in this unit, students should be able to:

Lesson 1

 Identify the types and uses of specialty tools.

 Complete the assignment sheet on specialty tool uses (AS1-L1-UV).

Lesson 2

 Identify common fasteners used on vehicles.

 Identify tools and methods for cutting threads, repairing damaged threads, and removing
broken bolts.

Complete the assignment sheet on common vehicle fasteners (AS1-L2-UV).

Lesson 3

 Identify the types and uses of measuring tools.

 Identify the procedures for the use and care of measuring tools.

 Complete the assignment sheet on the use and care of measuring tools (AS1-L3-UV).
 INFORMATION SHEET 1-1

LESSON 1: SPECIALTy TOOLS

Types and uses of specialty tools

Special cutting tools

Hacksaws cut metal parts to size or shape and remove damaged

fasteners.

The hacksaw cuts on the forward stroke only and is lifted

on the return stroke.

Hacksaws are sized according to blade length. When installing the blade, point the teeth away
from the handle and tightly secure the blade.

CAUTION: Always wear safety glasses and heavy gloves when using a hacksaw. The blade can
break. In addition, be sure to firmly secure the object being sawed.

Tubing cutters cut without bending, kinking, or scarring the

tubing.

The cutter is placed on a piece of tubing and tightened as it is rotated.

Tubing cutters vary in size according to the diameter of the tube they are designed to cut.
A hand reamer smooth or enlarges holes. Both straight and tapered reamers are used. Straight
reamers may be either fixed in size or adjustable through a specific cutting range.

Files smooth or shape metal. Files are designed in various shapes for different tasks and have
different teeth designs for fine or rough work.

CAUTION: Use a handle on the file to prevent hand injury. Never hammer on or use a file as a
pry bar. Files are brittle and can shatter with dangerous results.

CAUTION: Always wear safety goggles and heavy gloves when working with a file.
Electrical system tools

The digital multimeter (DMM) checks the condition of electrical system components.

This test device is a voltmeter, ohmmeter, and ammeter all in one.

A DMM has two leads, one black and one red. One end of the lead is plugged into the
DMM. The other end is a probe.

A scan tool is used to diagnose electrical problems. The tool is connected to the vehicle’s
data link connector (DLC) to retrieve diagnostic trouble codes (DTCs) and engine sensor
information that are generated by the vehicle’s on-board diagnostics system.
An oscilloscope, or scope, is a voltmeter that displays voltage in relation to time, showing voltage
vertically and time horizontally. Its connections are similar to a DMM.

It produces a line on a cathode ray tube (CRT) or liquid crystal display (LCD) when connected to
circuit voltage.

A circuit problem can be found by comparing the line “pattern” to a known good pattern.

The continuity light checks power in various circuits. One end of the light is grounded and the
other end is pressed into the electrical device.

NOTE: The continuity light should never be used to check the

power supply of electronic components.

A timing light determines if the ignition system is delivering electric charge to the spark plugs at
the correct time.
The remote starter switch allows the technician to use the starter to crank the engine without
actually being in the vehicle.

Battery specialty tools

A cable puller removes the cable from the battery terminal

without breaking the cable or battery posts.

Terminal and post cleaners clean the posts and terminal ends.

A battery lifting tool and carrying strap lifts and transports the battery safely.
Lubrication specialty tools

A transmission funnel is a funnel with a long, small, flexible neck that is ideal for adding
transmission fluid.

An oil filter removing tool is a wrench or socket adapter that fits around an oil filter to remove it.

A grease gun forces grease into fittings. Pressure is created by hand action on the gun’s lever.

Miscellaneous specialty tools

A blowgun uses compressed air to clean or dry various items in the shop.
The C-clamp is a holding device that is commonly used to compress the calipers on floating caliper
disc brake systems.

A puller set functions to remove objects (e.g., gears, bearings) that are pressed onto a shaft, pull
objects (e.g., retainers, oil seals) from various openings, and remove shafts (e.g., pinion shafts,
transmission shafts ) from another object.

Pressure gauges test the air and fluid pressure in various components such as the tires, oil pump,
and fuel pump.

Vacuum gauges check the condition of the engine and various vacuum-operated components.
Gauges compare the pressure in a component to atmospheric pressure at sea level.
 SELF – CHECK No. 1

Directions: Answer the following questions by writing all responses on this sheet.

1. List the function of the following special cutting tools.

 Hacksaw
 Tubing cutter
 Hand reamer
 File

2. List the use of each electrical system tool below.

 DMM
 Scan tool
 Oscilloscope
 Continuity light
 Timing light
 Remote starter switch

3. List the function of the following tools for battery work.

 Cable puller
 Terminal and post cleaner
 Battery lifting tool and carrying strap
 Describe the use of each lubrication tool listed below.
 Transmission funnel
 Oil filter removing tool
 Grease gun

4. List the function of the following specialty tools below.

 Blowgun
 C-clamp
 Puller set
 Pressure gauges
 Vacuum gauges
 INFORMATION SHEET No. 2

LESSON 2: FASTENErS

Common vehicle fasteners

NOTE: Vehicles use many types of fasteners to hold various components together and
technicians need to be familiar with each type. Some of the more common types of threaded
fasteners include nuts and bolts, washers, screws, and studs. Other common fasteners include
snap rings, rivets, and adhesives.

NOTE: American automobile manufacturers have largely switched to the metric system of sizing
fasteners and threads.

Nuts and bolts in the U.S. Customary System (USCS)

Bolt diameters come in increments of 1/16 in, starting with ¼ in. The measurement is the
overall diameter of the bolt threads.

NOTE: It is easiest to measure the unthreaded or shank portion of the bolt.

The length of a bolt is its effective length measured from under the head to the end of the
threads. Bolt lengths usually come in 1/4-in increments, starting from 1/2 in. The longest bolts
normally used in the field are 6 in.

Thread type is either fine or coarse. Do not thread fine-threaded bolts into coarse threads
or vice versa.

NOTE: Nuts are very difficult to measure for diameter, so it is usually best to trial fit the nut onto
a bolt and then measure the bolt.
Thread size is determined by measuring the number of threads per inch. A thread gauge, available
in both metric and USCS, can be used to determine the thread size of bolts.

The strength of a bolt is important. A bolt that is not strong enough can break. The strength
or hardness of a bolt is determined by counting the points or slashes on the head of the bolt.

CAUTION: Never substitute a bolt with one of less strength. A lower strength bolt may break and
cause injury and system failure.

Grade 1 or 2 bolts have no points and are unsuitable for automobile assembly due to their
unknown and possibly low strength.

Grade 5, or 3-point, bolts have three points on the head. These bolts are the most common
in automobile assembly.

Grade 8, or 6-point, bolts have six points on the head. These bolts are expensive but very
strong and are used in high-stress conditions. Examples of grade 8 bolts include harmonic
balancer bolts, flywheel bolts, and steering linkage bolts. Never substitute a lower grade bolt for
a grade 8.

Right-hand thread nuts and bolts are the most common and turn clockwise to tighten. Left-
hand thread nuts and bolts also are available that turn the opposite way. Left-hand nuts and bolts
have notches cut at the corners of the hex head or the letter “L” stamped on them.
NOTE: Very old automobiles (built before 1960), Chrysler products up until the early 1970s, and
Ford vans up through the mid 1980s have left-hand thread wheel lugs only on the driver’s side.

Nuts and bolts in the metric system

The diameter of a metric bolt or nut is measured in the same way as in the USCS; however,
the diameter of a metric bolt is expressed in millimeters.

The bolt is measured for its effective length from under the head to the end of the threads.

Thread size in the metric system is determined by measuring the distance from the crest of one
thread in millimeters to the crest of the next thread.

Metric bolt strength is indicated by a number stamped on the bolt head. This number is
called the property class. Examples of property class numbers include 4.6, 4.8, 5.8, 8.8, 9.8, and
10.9. The higher the number, the stronger the bolt.

CAUTION: Never substitute a bolt with one of less strength. A lower strength bolt may break and
cause injury and system failure.

Washers are frequently used with threaded fasteners.

They fit onto a bolt or screw between the surface being fastened and the nut, or under the
bolt or screw head.

They have two main functions.

Improve the fastening ability by increasing the area that is clamped

Prevent the bolt or nut from damaging the part surface

Many sizes and types of screws are used to fasten automotive parts. Two of the more
common types are the following:

Machine screws are used in threaded holes to clamp small parts together.

Self-tapping screws (also called sheet metal screws) have hard, tapering threads that make their
own threads when driven into a surface.

Studs have threads on each end and no head. Some studs have threads throughout their length.

Fastening with studs is accomplished by threading one end of the stud into a part, placing another
part over the stud, and fastening the other end of the stud with a nut.

Studs are useful for achieving accurate alignment of parts.

Snap rings (also called retaining rings) are used to hold components such as shafts, bearings,
and gears in place.

Internal snap rings fit in a groove inside an opening and external snap rings fit in a groove on the
outside of a part.

Snap-ring pliers are required for installing and removing snap rings.
A rivet is a nonthreaded metal pin with a head on one end. Rivets are available in different designs
and are typically made of copper, steel, or aluminum.

Rivets are used to fasten parts that are not usually taken apart.

Parts are joined together with a rivet by putting the rivet through a hole in the parts and hammering
the headless end with a ball peen hammer or hammer and rivet set until the end is rounded.

Rivets are removed by cutting off the head with a chisel and driving out the pin with a punch.

Various types of adhesives, or glues, are used to bond parts together. Parts that may be glued
include trim, moldings, and various plastic and rubber parts.

CAUTION: When using adhesives, it is important to follow the manufacturer’s specifications

because some adhesives are toxic, flammable, and harmful if inhaled.

Cutting threads, repairing damaged threads, and removing broken bolts

Using a tap to cut threads into a hole

Types of taps

The taper tap is the most commonly used tap because the taper allows easy starting. It cannot
cut threads to the bottom of a blind hole, a hole that does not go completely through the metal.

The plug tap cuts threads part of the way to the bottom of
a blind hole.

A bottoming tap cuts threads all the way to the bottom of a blind hole but cannot start the cutting
process. A taper tap must be used before the bottoming tap.
The machine screw tap cuts the small-diameter threads of numbered screw sizes.

The sequence for cutting threads with a tap is shown below.

General procedure for using a tap

CAUTION: Before drilling a hole to cut threads, choose the correct drill bit size for the thread size.
Failure to use the correct drill bit size can result in a broken tap or inadequate thread depth.

First apply a thread cutting oil.

Start the handle with the tap straight and then make a half turn.
After each partial turn, back the tap off until the metal chips begin to break loose.

Repeat this process until all of the needed threads are cut. Add oil as needed during the process.

Using a die to cut threads onto a rod

A special die stock holds the die for the cutting process.

Dies are selected in the same manner as taps, but the die can be improperly placed in the die
stock. The die should be positioned in the die stock so that the tapered end engages the rod first.

General procedure for using a die

1. First apply a thread cutting oil.

2. Put the tapered side of the die on the rod.

3. Start the die stock with the die straight and then make a
4. half turn.

5. After each partial turn, back the die off until the metal chips begin to break loose.

6. Repeat this process until all of the needed threads are cut. Add oil as needed during the
process.

7. Procedures for repairing damaged or stripped threads

8. Chasing threads involves using a standard tap or die to run through existing threads of the
same size. The purpose of this procedure is to correct small imperfections that interfere
with the threading of the nut or bolt.
NOTE: Use a thread cutting oil during this procedure.

When threads in a hole are so severely damaged that they cannot be adequately repaired by
chasing, a helicoil can be installed to restore the threads back to their original sizes. The basic
steps for this procedure are as follows:

Completely drill out the old, damaged threads with a drill

bit supplied in the helicoil kit.

Tap with a special tap from the kit.

With a special handle, screw in an insert that looks like a spring or coil. The inside of this coil is
the same as the original thread of the hole.

A thread insert can also be used to repair damaged threads. The insert is almost identical to the
helicoil but is somewhat larger. It is retained in place by driving down four pins around the insert.

Thread repair cement can be used on low-torque applications. The cement is applied to the bolt,
and the bolt is then placed back into the damaged hole. New threads are molded as the glue-like
substance hardens.

Procedures for removing a bolt that is broken off in a threaded hole because of overtightening

1. A screw extractor can be used to remove bolts. The screw extractor has flutes or grooves
that spiral in a counterclockwise direction.

2. Drill a hole in the center of the broken bolt.

3. Insert a screw extractor in the hole.

4. Use the tap handle to rotate the extractor and bolt counterclockwise and remove them as
a unit from the bolt hole.

5. Remove a bolt that is not bound to the threaded hole.

6. Drive a sharp punch into the center of the bolt.

7. Use pliers to retrieve the bolt.

NOTE: Breakage due to the wrong thread design, a cross-threaded bolt, or a bolt that is bottomed
out in the hole can make removal difficult. Drill out the bolt and retap the hole. Use the correct bolt
and start it into the hole with the fingers
SELF-CHECK No. 2

Directions — Answer the following questions by writing all responses on this

sheet.

1. Match the fastener with its name by placing the appropriate number in
the blank. All the illustrations will not be used.

A. External 1. 2.
snap ring

B. Machine
screw
3. 4.
C. Metric bolt

D. Plain Flat
Washer

E. Rivet 5. 6.
F. Self-
tapping
screw
7. 8.
G. Stud

9. 10.

W
 2. Answer the following questions about USCS and metric bolts.

 How is the thread size determined for USCS and metric bolts?

 How is bolt strength indicated for USCS and metric bolts?

3. Match the description at the right with the fastener on the left. All the descriptions will not be used.

A.Adhesive Makes its own threads when driven into a surface

B.Internal snap ring Prevents nut from damaging the part surface

C.Self-tapping Bonds two surfaces together

screw
Useful for achieving accurate alignment of parts
D. Stud
Fits in a groove inside an opening
E. Washer
Fits in a groove outside of a part

During installation, headless end is hammered until rounded

4. What is the function of a tap?

5. What is the function of a die?
 INFORMATION SHEET No. 3

LESSON 3: MEASUrING TOOLS

Types and uses of common measuring tools

NOTE: Some vehicle components, particularly in the engine and transmission, contain precision
machined parts that require precise measurements for inspection or replacement.

The outside micrometer is used when an outside measurement must be accurate to .001 in or
less. Parts requiring these measurements include crankshafts, pistons, valves, and camshafts.

The inside micrometer is used when a measurement of the diameter of a hole must be accurate
to less than .001 in. Examples of such holes are cylinder bores and main bearing bores.

The depth micrometer makes precise depth measurements of holes or cavities. For example, it
can be used to measure the distance from the center of the crankshaft to the top of the engine
block (deck height) and the distance from the top of the piston to the top of the engine block (piston
deck clearance).
The dial indicator tool measures thrust, back-and-forth movement, and runout (side-to-side play).
These measurements are made on valves, crankshafts, and flywheels. The dial indicator can also
measure the backlash or movement between gear teeth.

A feeler gauge measures air gaps and clearance between moving parts and has numerous flat
leaves of different specific thicknesses.

A dial caliper is used for inside, outside, and depth measurements. One application is measuring
bolts and small machined parts.

Plastigage is a tiny strip of clay-like material that measures clearances such as between engine
bearings and their journals and main bearings and connecting rod bearings. The strips are color
coded according to the clearance range.

Procedures for the use and care of measuring tools

CAUTION: The proper care and use of precision measuring tools are critical to the accuracy and
long life of the tool. An incorrect measurement can result in expensive component failure.
Use an outside micrometer.

Before using an outside micrometer, become familiar with its parts. See the illustration below.

1. Read the outside micrometer.

NOTE: The outside micrometer does not readily display the measurement. Some addition is
required in order to arrive at the micrometer reading. The technician must develop a feel for the
outside micrometer in order to achieve accurate results.

2. Place the object to be measured between the anvil and spindle and turn the thimble until
the object is lightly contacted by the anvil and spindle. Lock the spindle and remove the
micrometer from the object.

3. Read the number indicated on the micrometer sleeve (upper scale). Each number
represents one tenth (.100) of an inch.

4. Add 25 thousandths (.025) of an inch for each additional

5. line showing on the sleeve (lower scale) past the number.

6. Add the number of thousandths (.001) of an inch indicated on the thimble.

7. Add the number of inches of the minimum dimension that the micrometer can read 0 in
through 5 in.

8. Reading an inside micrometer and depth micrometer is similar to reading an outside

micrometer. Be sure to add the correct figure for the minimum measurement.
Use the dial indicator.

1. Securely attach the dial indicator so it will not move and give inaccurate readings. The dial
indicator is positioned with a clamp-on base or with a magnetic base.

2. Position the plunger against the part being measured.

3. Rotate the indicator until the needle is on zero. If making a thrust measurement, the shaft
or gear that is to be measured must first be pried one way.

4. Rotate the part for runout measurements or pry the gear or shaft for thrust measurements,
and note the reading in thousandths of an inch on the dial.

5. Use the feeler gauge.

6. Select a sample leaf and make a trial fit between the two surfaces.

NOTE: The thickness of the leaf is printed on the leaf.

7. If the leaf is too loose or too tight, try another leaf.

8. When there is a slight, smooth drag as the feeler gauge is removed, the correct leaf has
been found. The size printed on the feeler gauge is the clearance.

9. After use, put a little oil on the leaves to prevent rust.

Use a dial caliper.

NOTE: A dial caliper is accurate to approximately + or - 0.002 in. When more precision is required,
use a micrometer.

1. Before using a dial caliper, become familiar with its parts. See the illustration below.

2. Adjust the dial caliper with the roll knob until the jaws lightly contact the work.

3. Read the measurement on the linear scale and add the reading on the dial.

Use Plastigage.

1. Select a small piece of Plastigage material.

2. Place the Plastigage material on the crankshaft journal. The Plastigage piece must span
the full width of the journal and be centered with the bearing cap.
3. Install the bearing cap and tighten to the proper torque.

4. Remove the bearing cap and inspect the Plastigage. It should appear somewhat smashed.
Compare the width to the paper gauge on the Plastigage package.

5. Care of measuring tools

6. Adjust precision measuring tools carefully. For example, only very slight pressure is
needed to tighten the thimble on a micrometer. Overtightening can destroy the adjustment.

7. Do not attempt to adjust measuring tools with the lock on.

8. Always store measuring tools in their case or in a safe place to protect them from damage,
grease, dirt, and moisture.

9. Check the calibration of precision measuring tools frequently. Consult the manufacturer’s
instructions for the proper procedure.
SELF-CHECK No. 3

Directions — Answer the following questions by writing all responses on this

sheet.

1. Match the use at the right with the measuring tool at the left. All the
uses will not be used.

A. Dial indicator Used for precise outside measurement of parts

B. Feeler gauge Used for inside, outside, and depth measurements

C. Inside micrometer Measures part movement

D. Outside Measures how deep a hole or cavity is

micrometer
Measures air gaps and clearance between moving parts
E. Depth
micrometer Measures diameter of a hole

2.List the basic steps in using a dial indicator.

3. Give the correct micrometer reading for each example below. The micrometer shown measures
from 0 in to 1 in.

4.When using precision measuring tools, how should they be handled?

5.How should precision measuring tools be stored?