AUTOMOTIVE MECHANICS

Level-I
Based on Curriculum March 2022, TTLM Version 1

Module Title: - Applying Automotive Mechanical System

Fundamentals
Module code: EIS AUM1 M05 0322
Nominal duration: 80Hour

Prepared by: Ministry of Labor and Skill

September 2022
Addis Ababa, Ethiopia
Table of Content
Acknowledgment………………………………………………………………………...…3
Introduction to the Module .................................................................................................... 5

Unit one: Identify system fundamentals .................................................................................... 6

1.1 Basic terminologies of automotive mechanical systems ................................................. 7
1.2 Functions and principles of operation ....................................................................... 8
1.3 Identifying sources of information for mechanical system ........................................... 12
Self-Check -1 ....................................................................................................................... 18

Unit Two: Identify operation of system/component ............................................................... 19

2.1 Automotive mechanical systems and components ........................................................ 20
2.2 Identifying safety hazards ............................................................................................. 32
Self-Check -2 ....................................................................................................................... 35
Operation sheet 2.1 .............................................................................................................. 37
Operation sheet 2.2 .............................................................................................................. 38
Operation sheet 2.3 .............................................................................................................. 39
Operation sheet 2.4 .............................................................................................................. 40
Operation sheet 2.5 .............................................................................................................. 41
LAP test 1 ............................................................................................................................ 42

Unit Three: Locate system or component on vehicle .............................................................. 43

3.1 Tracing suitable automotive systems and components ........................................... 44
3.2 Confirming location of systems or components ............................................................ 46
Self-Check -3 ....................................................................................................................... 47

Unit Four: Apply system fundamentals ................................................................................... 48

4.1 Examining subassembly components ............................................................................ 49
4.2 Identifying common faults ...................................................................................... 50
Self-Check -4 ....................................................................................................................... 62
Operation sheet 4.1 .............................................................................................................. 64
LAP test 2 ............................................................................................................................ 65
Reference ............................................................................................................................. 66

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Acknowledgment

Ministry of Labor and Skills wish to extend thanks and appreciation to the many
representatives of TVET instructors and respective industry experts who donated their time and
expertise to the development of this Teaching, Training and Learning Materials (TTLM).

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Acronym
OS================== Occupational Standard
LAP test============== Learning Activity Performance test
RWD================ Rear Wheel Drive
CV joints=============Constant Velocity joint
ECU=================Electronic Control unit
IC==================Internal combustion
EC==================External Combustion
FFWD ===============Front engine, Front wheel drive
FRWD ===============Front engine, Rear wheel drive
RR WD===============Rear engine, Rear wheel drive
MR WD===============Mishap engine, Rear wheel drive
SST =================Special service tools
CGM=================Crank gear mechanism
VGM =================Valve gear mechanism
4WD =================four wheel drive

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 Introduction to the Module

In Automotive Mechanic filed; the knowledge, skill and attitude required to demonstrate basic
knowledge and awareness of automotive terminology, terms and principles as they apply to
vehicle systems, components and technologies found in modern motor vehicles and also remove
and re-install non difficult system components.
This module is designed to meet the industry requirement under the Automotive Mechanic
occupational standard, particularly for the unit of competency: Apply Automotive Mechanical
System Fundamentals.

This module covers the units:

 Identifying system fundamentals
 Identifying operation of system or component
 Locate system or component on vehicle
 Apply system fundamentals
Learning Objective of the Module
 Identify system fundamentals
 Identify operation of system or component
 Locate system or component on vehicle
 Apply system fundamentals
Module Instruction
For effective use this modules trainees are expected to follow the following module instruction:
1. Read the information written in each unit
2. Accomplish the Self-checks at the end of each unit
3. Perform Operation Sheets which were provided at the end of units
4. Do the “LAP test” giver at the end of each unit and
5. Read the identified reference book for Examples and exercise

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 Unit one: Identify system fundamentals
This unit is developed to provide you the necessary information regarding the following content
coverage and topics:
 Basic terminologies of automotive mechanical systems
 Identifying Functions and principles of operation
 Identifying sources of information for mechanical system
This unit will also assist you to attain the learning outcomes stated in the cover page.
Specifically, upon completion of this learning guide, you will be able to:
 Identify Basic terminologies of automotive mechanical systems
 Identify Functions and principles of operation
 Identify sources of information for mechanical system

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 1.1 Basic terminologies of automotive mechanical systems

IC Engine Terminologies

Figure 1.1 Engine Terminologies

Basic Definitions used in engine terminology:
Bore: The inner diameter of the cylinder is called a bore.
Stroke: Stroke is the length of the piston moves from the bottom of the cylinder to the top of the
cylinder is known as a stroke.
Clearance Volume: The clearance volume is the space between the top of a cylinder and the top
dead center.
Top Dead Centre: The top dead center point is the end point of the piston which moves in the
cylinder at the time of combustion process.
Bottom Dead Centre: When the piston moves in down wards after the combustion process,
bottom dead center is the bottom point that piston travels and raises again for combustion
process.
Total volume of the cylinder: Total volume of the cylinder is calculated when the piston is at
bottom dead center.
Swept Volume; This is the volume swept by the piston when reciprocating in between the top
dead center and the bottom dead center.
Compression ratio: It is the ratio of total volume to the clearance volume.
Mean Effective Pressure: Mean effective pressure is the ratio of the engine work to the volume
of the cylinder.

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 1.2Functions and principles of operation

A. Operate Engine systems

Introduction the engine is the vehicle's main source of power. The engine uses fuel and burns it
to produce mechanical power. The heat produced by the combustion is used to create pressure
which is then used to drive a mechanical device.
The engine is the heart of the automobile. It converts fuel into the energy that powers the
automobile. To operate, it requires clean air for the fuel, water for cooling, electricity (which it
generates) for igniting the fuel, and oil for lubrication. Engine system means the engine, the
emission control system and the communication interface (hardware and messages) between the
engine system electronic control unit(s) (ECU) and any other powertrain or vehicle control unit;
The engine consists fixed cylinder of and a moving piston. The expanding combustion gases
push the piston, which in turn rotates the crankshaft. Ultimately, through a system of gears in the
powertrain, this motion drives the vehicle's wheels
Principle of engine operation
1. Two-Stroke Cycle Engines – these are engine where the cycle is completed in two (2) strokes
of the piston. This means that the piston has to move two
times to complete the cycle.
Figure 1.2 Two-Stroke Cycle

2. Four-Stroke Engines - these are engines where the cycle is completed in four (4)
strokes of the piston. This means that the piston has to move four (4) times to complete the cycle.

Figure 1.3 Four-Stroke Engines

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 Stroke Movement of Position of the Valve Purpose

the Piston Intake Valve Exhaust Valve

Intake Going Down Open Close  Sucked air/fuel mixture into the
cylinder
Compression Going Up Close Close  Compressed the air/fuel mixture
to increase its temperature
Power Going Down Close Close  Combustion takes place
Exhaust Going Up Close Open  Burned gases pushed out from
the engine cylinder

B. Operate Transmissions and drive trains systems

Definition Of Transmission System :- The mechanism that transmits the power developed by the
engine of automobile to the engine to the driving wheels is called the Transmission system (or
power train).It is composed of Clutch , The gear box, Propeller shaft ,Universal joints ,Rear axle
Wheel Tires Requirements Of Transmission System Provide means of connection and
disconnection of engine with rest of Clutch, The gear box ,Propeller shaft, Universal joints ,
Rear axle Wheel ,Tires.
There are two types of transmissions in use—
 Manual transmission
 Automatic transmission
Manual transmission, the driver selects all gears manually using both a movable gear selector
and a driver-operated clutch. This type of transmission is also known as a "stick shift" or a
"standard" transmission.
Automatic transmission that uses a torque converter, planetary gear set and clutches or bands to
shift through a vehicle's forward gears automatically. Some automatics allow the driver a limited
amount of manual control over the vehicle (aside from choosing a forward, reverse or neutral
mode) -- for example allowing the driver to control upshifts and downshifts by utilizing buttons
or paddles on the steering wheel or the gear selector. Common names for such transmissions are
"shift able automatic," "Tiptronic" and "autostick."

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 Figure 1.4 Manual and Automatic transition

Drive trains
The drivetrain (also called driveline) is the sum of components which are delivering the engine
power to the wheels. For example, on a rear-wheel drive (RWD) vehicle, the drivetrain consists
of: clutch (or torque converter), gearbox (manual or automatic), propeller shaft, differential and
drive shafts.
The efficiency of the drivetrain has a significant impact on the overall efficiency of the vehicle.
The higher the efficiency of the drivetrain, the lower the fuel consumption of the vehicle (also
lower CO2).

Figure 1.5 Transmissions and drive trains systems

C. Steering system
To improve driving comfort, most modern automobiles have wide low pressure tires which
increase the tire to road contact area. As a result of this, more steering efforts is required.
Steering effort can be decreased by increasing the gear ratio of steering gear. However, this will
cause a larger rotary motion of the steering wheel when the vehicle is turning, making sharp
turns impossible.

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 Figure1.6 steering system
operation

In all power steering systems hydraulic pressure is provided by a pump mounted near the front of
the engine. It is driven by a v-belt from the camshaft pulley. The pump is connected to the
control valve by means of two hoses. One hose delivers the hydraulic fluid to the control valve.
The second hose returns the fluid to the reservoir.
D. Suspension system
Function of suspension system
The suspension system on a vehicle is between the frame and the road. The suspension system's
primary function is to maximize the overall performance of a vehicle as it cruises down the road.
The suspension system also helps to absorb bumps in the road and provide a safe and
comfortable ride
Principles of Suspension System
The principles of the suspension system are due to springing action of motor vehicles.
1. Supporting the weight of vehicle.
2. Absorbing satisfactorily larger and smaller road impacts with the help of a single springing
device.
3. The reduction of rolling or pitching of the body to a minimum design and attachment of
springs.

Figure 1.7 Principles of Suspension System

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E. Brake system
The function Break system
Brake system is to stop or slow down the moving motor vehicle or prevent it from moving when
in stationary position. All the braking systems use the force of friction for their operation.
Friction opposes the relative motion of the bodies that are in contact with each other is to stop
the vehicle within the smallest possible distance and hence this is done by converting the kinetic
energy of the vehicle into the heat energy which is dissipated into the atmosphere.
Enabled the vehicle to stop
Brake system enables the vehicle to stop and lowdown.
Braking force takes place when the driver applies pressure and
continuous application to the brakes will enable the vehicle to stop.
The following are the methods of stopping the rotational
movement of the tires :
(a) Foot brakes Figure 1.8 Foot brakes

Foot brakes are used to control the speed and stop the vehicle.
Generally, disc brakes are used in the front wheels and
disc or drum brakes are used in the rear wheels.
(b) Parking brakes
Parking brakes or handbrakes are mainly used when the car
Figure 1.9 Parking brakes
is parked. The mechanical brake system locks the rear wheels.
(c) Engine brake
Engine brake used the retarding effect of
engine when the vehicle is in gear and throttle Valve is closed.
Figure 1.10 engine brakes

Figure 1.11 Engine brake

1.3 Identifying sources of information for mechanical system

Sources of information
Information can come from virtually anywhere; personal experiences, books, articles, expert
opinions, encyclopedias, the web. The type of information needed will change depending on its
application .individuals generate information on daily basis as they go about their work. In
academic institution, staff and students consult various source of information. The choice of the
source to consult is usually determined by the type of information sought.

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In general there are three types of sources of information; primary, secondary and tertiary.it is
important to understand these types and to know what type is appropriate for your coursework
prior to searching for information.
Primary sources
They are the original documents of an event or discovery such as results of research, experiments
or surveys, interviews, letters, diaries, legal documents, and scientific journals articles. Primary
sources are also records of events as they are first described.
Primary source are the first formal appearance of results in print or electronic formats example of
primary source are: eyewitness account, journalistic report, financial report, government
document, archeological and biological evidence, court records, ephemerals (posters, handbills),
literary manuscript and minutes of meetings etc.
Secondary sources
Are offer an analysis or is statement of an event or discovery described in primary sources. They
interrupt, explain or summarize primary sources. Some secondary sources are used to persuade
the reader. Secondary sources may be considered less objectives .Example of secondary source
include dictionaries, encyclopedias, textbooks, articles and editorials
Tertiary sources
Definition: tertiary sources consist of information which is a distillation and collection of
primary and secondary source generally, tertiary sources are not considered to be acceptable
material on which to base academic research. Tertiary sources are usually not credited to a
particular author. They are intended only to provide an overview of what the topic includes its
basic terminology, and often references for further reading. Some reference materials and
textbooks are considered tertiary sources when their chief purpose is to list, summarized or
simply repackage ideas or other information. Tertiary source include
Work which list primary and secondary resources in a specific subject area
Work which index, organized and compile citations to, and show secondary and sometimes
primary source can be used
Material in which the information from secondary sources has been “digested” reformatted and
condensed, to put into a convenient, easy to read form
Source which are once removed in time from secondary sources

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Difference between primary, secondary and tertiary sources of information
Timing of the event recorded Rhetorical aim of the written item

1.3.1 Vehicle workshop manuals

Every technician knows the appropriate type of manuals and their uses as per job requirements.
There are different types of manuals according to their use as job requirements. These are
Manufacturer’s specification manual
Manufacturer’s service manual or sometimes it's called a shop manuals, are written by the
automotive manufacturer for the technicians in their dealership. A shop manual covers one
model and one year of a vehicle in great detail, sometimes it is printed in a number of volumes.
Shop manuals are the best source of detailed service information for specific car.
Shop manuals / service manuals are necessary to obtain the desired specification for specific job.
It also provides drawings and photograph to show where and how to perform a certain procedure
in a particular car you are working on. Special tools or instrument are listed and shown when
they are required. Precautions were given to prevent injury and damage to the parts.

Fig1.12 Typical Cover of a Service Manual

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The shop manuals contain three basic types of information. First, there is diagnostic or
troubleshooting information. Second, they contain a step-by-step repair procedure. Third, there a
specification charts.
Diagnosing or troubleshooting information
Probably the most valuable type of service information comes from the troubleshooting or
diagnosing guides. These are designed to help the technician save time in identifying and solving
problems.
PROCEDURE INFROMATION
Procedure information gives the steps to follow in doing a repair job. The procedures are usually
numbered in a step-by-step order.

SPEFICIFICATION
Specifications are included as part of the service manual. Specifications are technical data,
numbers, clearances and measurements used to diagnose and adjust automobile components.
Specifications can be referred to as specs. They are usually considered precise measurements
under standard conditions. Examples of specifications include valve clearances, spark plug gaps,
tire pressure, number of quarts of oil, ignition timing and size of engine.
Owner's manual
An owner’s manual or an operator’s manual is a booklet that comes with a new car. This manual
usually explains how to operate the automobile’s control and accessories. In addition the owner’s
manual provides a great deal of technical information that can be useful to the technician.
An owner's manual (also called an instruction manual or a user guide) is an
instructional book that is supplied with almost all technologically advanced consumer products
such as vehicles, home appliances and computer peripherals. Information contained in the
owner's manual typically includes:
Repair Manual
A repair manual is most often used by the technician at independent repair shops. This manual is
called an aftermarket because it is published by independent publisher and not by the car
manufacturer. Like the shop manual. This contains information on troubleshooting,
specifications and step-by-step repair procedures. The main difference is that they cover many
different car models and years instead of just one. Because they are covering more models and
years, they typically cover topics in less detail.

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Maintenance Procedure Manual
Procedure information gives the step by step to follow in doing a repair job. The
procedures are usually numbered in a step-by-step order.
Periodic maintenance Manual
Performing inspection
Block diagrams, flow charts , maintenance schedules Changing brake parts, Set back
maintenance indicator, changing drive belt, Oil and Filter changes, Battery maintenance, wheels
Tires, windshield wipers
Structure manual

Structure manual

Manufacturer
Owner’s manual Repair manual
service
manual

 Diagnosing
 Safety instructions  general
information
 Assembly information
 Procedure instructions  engine
 Installation  transmission
information
instructions  electrical
 Specification  Setup instructions

Figure 1.13 structure of manual

1.3.2 Automotive texts and technical articles

We have been providing translations to clients in the automotive industry since 1983. Currently,
we translate around 9 million words of automotive copy a year. We offer you high quality,
flexible delivery and a virtually 100% deadline guarantee. We can help you with:
 Service manuals
 Handbooks
 Software translation
 Technology marketing

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  Technical documents
 Magazine technical articles
The objective for CODE Magazine’s technical articles (“How-To Articles”) is to teach the reader
how to use a certain technology, product, or technique. The author first sets the stage by
introducing the scenario to make sure the reader understands what the article is all about and
what the pre-conditions are. The author then methodically walks the reader through using the
technology, technique, or product. The article focuses on how to do certain things. Articles do
not focus on things that do not work. It may at times be beneficial to warn the reader of certain
pitfalls and explain how to avoid them, but overall, CODE articles take a positive approach and
focus on how to make things happen.

1.3.3 Written instructions automotive

Document workplace procedures
All workplaces use documents to record their business activities. Some documents need to be
completed as part of government acts or regulations, while others are developed to ensure the
efficient delivery of services and products to customers.
It is important to know which workplace documents, records and forms you will be expected to
complete as part of your job.
Click on these headings to learn more about different kinds of workplace documents, forms and
procedures, logs, diaries and basic hand-written or typed reports. It may also include entry of
information into computer-based documents and forms.

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 Self-Check -1 Written Test

Directions: Answer all the questions listed below. Examples may be necessary to aid some
explanations/answers.
1. - What is meant by TDC
A. The extreme top position up
B. Bottom dead center
C. The extreme Bottom position
D. A &C
2. One of the following statement is true about Classification of modern automobiles
A. Source of energy
B. Engine construction
C. Application
D. All
3. Which vehicle has no propeller shaft that pro vides spacious interiors and comfortable ride
A. Front engine, Front wheel drive (FF)
B. Front engine, Rear wheel drive (FR)
C. Rear engine, Rear wheel drive (RR)
D. Mishap engine, Rear wheel drive (MR)
4. . Is the vehicle's main source of power?
A. Transmission
B. Engine
C. steering system
D. suspension system
5. Which of the following is primarily needed to perform vehicle maintenance
a. Manual
b. Procedure
c. Safety
d. Specification
Answer all the questions listed below. Use the Answer sheet provided in the next page:
1. What are primary, secondary and tertiary source of information?
2. List 4 primary, secondary and tertiary sources of information?
3. Write the main Functions of mechanical systems? Score = ___________

Rating: ____________
Answer Sheet
Name: _________________________ Date: _______________
1. _______________________________________________________________
2. _______________________________________________________________
3. _______________________________________________________________

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 Unit Two: Identify operation of system/component
This unit is developed to provide you the necessary information regarding the following content
coverage and topics:
 Identifying Automotive mechanical systems and components
 Identifying safety hazards
This unit will also assist you to attain the learning outcomes stated in the cover page.
Specifically, upon completion of this learning guide, you will be able to:
 Identify Automotive mechanical systems and components
 Identify safety hazards

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2.1 Automotive mechanical systems and components

2.1.1 Engine systems

Figure 2.1 IC engine

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Main Components of IC Engines

Figure 2.2 crank gear mechanism

Figure 2.3 valve gear mechanism

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 a. Intake system
The intake system is responsible for delivering oxygen, which is necessary for combustion. An
intake system generally comprises an air filter, a throttle, and passageways for air to reach the
cylinders themselves. There are several main types of intake systems.
Air cleaner: -Which cleans & filters the air before interring the combustion chamber of an
engine
Superchargers: -it increases the air pressure into the engine so that more fuel can be burnt &
the engine output increases
Intake manifold: -is required to deliver into the cylinder either a mixture of fuel & air From the
carburetor or only from the air Cleaner.

b. Fuel system components Figure 2.4 Intake system

The purpose of the fuel supply system for a petrol engine is to store, transfer and filter the petrol
required by the float chamber of a carburetor
Fuel system: -which includes the fuel tank, fuel line, fuel filter, fuel pump, carburetor and
combustion chamber.
Carburetor: - it is a device to mix air with fuel in the proper ratio for the purpose of combustion
Petrol is the fuel used in the gasoline engine.
Fuel tank is used as a reservoir & for the reason of safety it is placed at the rear of the car, to
prevent it from fire hazards. There is a small filter which is placed in the tank at the end of the
line. (Two filter is called strainer)
Which is used to filtered out large particle out of the fuel
The fuel line which allow fuel to reach to the pump & to the carburetor

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The full filter is used to filtered out dust particle out of the fuel generally it is located b/n the
pump & carburetor, in some model it may be b/n the fuel tank & fuel pump.
Fuel pump: - Which feeds the fuel from the tank to the carburetor through the filter.

Figure 2.5 gasoline Fuel system components

Diesel Fuel System

Diesel fuel is drawn from the fuel tank through the
sedimentor/ water separator and fuel filter by the feed
pump, which is incorporated in the front of the injection
pump. The feed pump not only supplies fuel to the
injection pump, but also circulates fuel to lubricate the
moving parts of the pump. The single pump plunger
meters and distributes the fuel (under pressure) through the
nozzle to the combustion chamber, and does so in the
correct combustion order.
Fuel tank: - It is a reservoir of fuel which is made of sheet
metal of sufficient capacity
Fuel Line: - which allow fuel to reach to the pump & to the
injector nozzle
Fuel Filter Feed pump It maintains the fuel pressure in the
system at a sufficient high level to circulate the fuel Figure 2.6 diesel Fuel system components
Injection Pump the pump supplies fuel to the injectors according to the firing order at the
constant stroke correct time in the cycle.
Nozzle: - A single unit used to meter, atomize & inject the required amount of fuel into the
combustion chamber of the cylinder

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 c. Ignition system
The purpose of the ignition system
The purpose of the ignition system is to produce the high voltage surges required to ignite the
compressed air fuel mixture in the engine combustion chamber at the proper instant under all
speed and load conditions. The ignition system is supplied a 12 volt or less battery voltage or
charging system voltage and increases to 50,000 to 30000 volts required to create a spark across
the spark plug electrodes in the combustion chamber.
Operation of the contact point ignition system
When the ignition key is turned on, the primary circuit is completed and current flows through
the coil causing magnetic field collapses creating a short pulse of high voltage in the secondary
coil the high voltage flows through the distributor cap and rotor to the spark plug in the cylinders
that is ready to fire.
Ignition coil: -is used to step up the battery voltage to 20000 & above
High tension cable: - It connect the secondary voltage the step up voltage to the distributor &
spark plug
Distributor: --It distributed the high voltage to each spark plug & time the spark
Spark plug: -Convert the electrical volt/current to spark by making the high voltage jumped
between to gap

Figure 2.7 ignition system

components

d. Cooling system
The engine cooling system keeps the engine maintains its normal operating temperature.
Types of Cooling System
The engine cooling system keeps the engine maintains its normal operating temperature.
Direct Cooling System – engines with this type of cooling system are also called air-cold
engines. During operation, air is drawn by a blower leading to air metal fins or shrouds are the
cylinders through air ducts.

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 Indirect Cooling System– engines with this type of cooling system are also called water-
cooled engines.

Figure 2.8 cooling system components

Which include the radiator, lower house; water pump, water jacket, thermostat, upper hose and
radiator also fan.
Water Pump: -Is a centrifugal type pump, it increases the flow rate of the water
Fan It draws fresh air through the radiator and thus increases the efficiency of the radiator in
cooling hot water
Radiator: -The purpose of the radiator is to cool down the water received from the engine, it has
three main parts: - upper tank, Lower tank and Tubes
Thermostat:-It is a kind of check valve which opens & closes with the effect of temperature The
normal operating temperature of an engine is 80-900c.
Water Jacket: -It provided a way for the coolant to circulate & take off the heat from the engine
component.
e. Lubrication System
The engine uses a combination pressure/splash lubrication system, delivering oil under pressure
to crankshaft, connecting rod and main bearing surfaces. Other component areas are splash
lubricated. A high-efficiency greater oil pump maintains high oil flow and oil pressure, even at
low speeds and high operating temperatures. A pressure relief valve limits maximum pressure of
system. Oil pan must be removed to service oil\ pickup and oil pump.

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 Components of Engine Lubrication System:

Figure 2.9 lubrication system components

f. Starting system
The purpose of the cranking system
The automotive cranking motor circuit includes the storage battery, the starter switch, the cables
to connect the motors and switch, to the battery, and the ground return circuit. The starter motor
is a low voltage direct current motor, which converts electrical energy from the storage battery in
to mechanical energy. When circuit between the starting motor and the battery is completed by
the cranking switch it cranks the engine at speed sufficient to cause the starting of the engine at
speeds sufficient to cause starting of the engine.
Battery: -provide electrical power to the starter motor
Switch: -it controls the starter circuit
Starter Motor: -It converts the electrical energy to mechanical energy & rotates the crank shaft
with a minimum cranking speed
Ring gear at fly wheel: -it takes the starter motor torque to the engine crank shaft

Figure 2.10 starting system components

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 g. Charging system
This includes the battery, ignition switch and alternator (generator) regulator. It is the system
which supply electricity to the electrical load & charge the battery after the engine is started
Battery: -It is the primary sources of electricity to the vehicle
Switch: -Which operate the circuit of the charging system
Alternator: - Which convert the mechanical energy of the engine to electrical energy
Regulator: - It makes the output of the alternator not mover than 12v.

h. Exhaust system Figure 2.11charging system components

Exhaust system: - The exhaust system collects exhaust gases from the engine & expels them
out. It consists of: -
Exhaust Manifold The exhaust manifold is made of cast iron and is bolted over the exhaust
ports of the engine, usually alongside the intake manifold pipe. It provides heat to the intake
manifold. This heat further vaporizes the fuel in the intake manifold.
Exhaust Pipe The exhaust pipe is a long pipe leading from the exhaust manifold to the muffler.
Catalytic converter It is discussed under exhaust gas treatment.
Muffler The exhaust gas emerges in a pulsating flow and therefore causes marked vibration in
the exhaust pipes and mufflers (silencers).
Resonator It is used to further muffle the noise of the exhaust gases. It is also called secondary
muffler.
Tail Pipe The tail pipe is a pipe that carries the exhaust gases from the muffler to the rear of the
vehicle. This pipe may be a separate unit or an integral part of the muffler when the muffler is
located near the rear of the vehicle.
Turbo Charger: - Is an exhaust gas driven turbine which drives a centrifugal compressor wheel

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 Figure 2.12 exhaust system components

Figure 2.13 turbo

charger

2.2.2 Transmissions and drive trains

The drivetrain includes the transmission, the driveshaft, the axles, and the wheels. Simply put, it
works in conjunction with the engine to move the wheels. The drivetrain system is an essential
component of a vehicle and the transmission is an integral part of the drivetrain.
There are four different types of drivetrains:
 All-wheel drive
 Four-wheel drive
 Front-wheel drive
 Rear-wheel drive.

Figure 2.14 All-wheel drive

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 FFWD RRWD 4WD (four wheel drive),

4WD truck under floor engine, bus 6WD, truck

Parts and Components of drivetrains Figure 2.15 different drive line operation

The driveshaft also referred to as the drive shaft, propeller shaft, or prop shaft—is the first
driveline component.
Differential(s). The differential is the driveline component that transmits torque to the wheels.
 Axle shafts.
 U-joints.
 CV joints. Figure 2.16 Drive trains

2.2.3 Steering system

Types of a steering system
There are two main types of steering gears used for most modern vehicles:
1. The rack and pinion steering gear and
2. The recirculating ball steering gear.

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Rack and pinion steering:- uses a gear-set to convert the circular motion of the steering wheel
into the linear motion required to turn the wheels. It also provides a gear reduction, so turning the
wheels is easier.

Figure 2.17 Rack and pinion steering

2.2.4 Suspension system
The primary functions of the suspension system include maximizing the contact between the
tires and the road surface, providing steering stability and good handling, evenly supporting the
weight of the vehicle (including the frame, engine, and body), and ensuring the comfort of
passengers by absorbing and dampening
Components of Suspension System

Figure 2. 18 Suspension system

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2.2.5 Brake system
Types of Break system
 The drum brake
 Disc brakes
Advantages of drum brakes over disc brakes
 Since the force is applied to the brake shoe at one end and the shoe is pivoted at the other, the
resulting high leverage represents an internal increase in application force. Further more
 Lining friction generates a torque, which presses the leading brake shoe more firmly against
the drum wall and therefore boosts, the braking action. On the trailing shoe however, the
friction created at the rotating drum has the opposite effect, that is to say it reduces shoe
contact pressure.
 It is protected against dirt to a large extent since the drum brake is housed inside the dished
area of the road wheel
 It is an easy matter to install a mechanically operated parking brake
Disadvantage

 Relining work takes longer than on the disc brake

 It is more difficult to provide any form of automatic compensation
 There is a problem of in the disposal of lining dust
 There is heat dissipation problem. Drum brakes suffer badly from fading, that is to say
a drop in braking effect when the brake overheats, for instance during a long period of
continuous braking. At the same time, the drum expands much more rapidly than the
brake shoe with its lining, so that the lining curvature is too severe to make full contact
with the drum surface.

Figure 2.19 Types of Break system

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 2.2 Identifying safety hazards

2.2.1 Electricity and water

Electrical safety is a system of organizational measures and technical means to prevent harmful
and dangerous effects on workers from electric current, electric arc, electromagnetic field and
static electricity Avoid water at all times when working with electricity. Never touch or try
repairing any electrical equipment or circuits with wet hands. It increases the conductivity of the
electric current.
Electric shock safety
 Turn off power at the main breaker.
 Call an ambulance.
 Don't touch the victim until you are certain there is no live electricity. (Never
move someone if they are touching a power line or other high-voltage current.)
 If the victim is not breathing, begin mouth-to-mouth.
 If the victim has no pulse, begin CPR
Electrical Tool Safety
1. Do not use power equipment or tools on which you have not been trained.
2. Keep power cords away from the path of vacuum cleaners, floor polishers and grinders.
3. Do not carry plugged in equipment or tools with your finger on the switch.
4. Do not carry equipment or tools by the cord.
5. Disconnect the tool from the outlet by pulling on the plug, not the cord.
6. Turn the tool off before plugging or unplugging it.
7. Do not leave tools that are "On" unattended.
8. Do not handle or operate electrical tools when your hands are wet or when you are
standing on wet floors.
9. Turn off electrical tools and disconnect the power source from the outlet before
attempting repairs or service work. Tag the tool "Out of Service".
10. Do not drive over, drag, step on or place objects on a cord
Electricity and Water: A Dangerous Combination
Electricity would travel through the water and through you to the ground. This is why it's so
important to keep all electrical appliances away from water, and to make sure your hands are dry
and you are not standing in water when you touch anything electrical

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Depending on the job task to be performed, PPE for the electric power industry generally
includes safety glasses, face shields, hard hats, safety shoes, insulating (rubber) gloves with
leather protectors, insulating sleeves, and flame-resistant (FR) clothing.
10 Tips – How to avoid getting shocked when working with electricity at home?
1. Never mix water and electricity. ...
2. Pay attention to what your appliances are telling you. ...
3. Install Ground Fault Circuit Interrupters (GFCI). ...
4. Make sure you're using the right size circuit breakers and fuses. ...
5. Protect kids with outlet covers
2.2.2 Toxic substances
There are generally four types of toxic entities; chemical, biological, physical and radiation.
Scale is the main scale used to measure toxicity
Here are some examples of natural toxic chemicals:
 Mercury.
 Snake venom.
 Caffeine in coffee, tea, kola and cocoa.
 Arsenic.
 Ricin from castor beans.
 Petroleum.
 Hydrogen sulfide.
 Chlorine gas.
2.2.3 Spillages or damaged equipment.
A manufacturing or design defect in the equipment can increase the risk of an accident. Workers
who have been injured by a piece of defective equipment may have another source of
compensation. They may be able to name the manufacturer or distributor of the equipment in a
third party lawsuit.
Faulty equipment is any type of mechanical or electronic equipment that is dangerous or unsafe
to use. This usually refers to equipment used in the workforce for producing or manufacturing
products. Faulty equipment is responsible for several types of on the job injuries each year
Identifying faulty portable electrical tools and equipment
 a competent person regularly electrically testing and inspecting tools, extension leads and
portable electrical equipment — inspection tags should be fitted;
 recording inspection details in an equipment register;
 tagging out and removing all faulty equipment for repair or disposal; and

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Faulty equipment Harm can be caused when exposed to 'live parts' or through conducting objects
or materials. Faulty or overloaded equipment can lead to fires which can cause damage, injuries
and loss of life.
2.2.4 Flammable materials and fire hazards
Flammable liquids and fire risk. Petrol and other fuels, as well as many common products like
solvents, thinners, cleaners, adhesives, paints, waxes and polishes, are highly flammable and
there's a high risk of fire and/or explosion if there is a source of ignition nearby.
Flammable and combustible liquids are liquids that can burn Under the Workplace Hazardous
Materials Information System (WHMIS) 1988, flammable liquids have a flashpoint below
37.8°C (100°F)
Keep in mind:
 Do not attempt to lift by bending forward. Bend your hips and knees to squat down to
your load, keep it close to your body, and straighten your legs to lift.
 Never lift a heavy object above shoulder level.
 Avoid turning or twisting your body while lifting or holding a heavy object
Check out these safe lifting and handling tips, recommended by the Health and Safety Executive.
 Think before you lift
 Keep the load close to the waist
 Adopt a stable position
 Ensure a good hold on the load
 Don't bend your back when lifting
 Don't bend the back any further while lifting
 Don't twist when you lift.
Spillages
In industrial production, spillages is a loss of production output due to production of series
defective or an acceptable product which must be rejected
The following steps should be taken during spill cleanup.
 Prevent the spread of dusts and vapors. ...
 Neutralize acids and bases, if possible. ...
 Control the spread of the liquid. ...
 Absorb the liquid. ...
 Collect and contain the cleanup residues. ...
 Dispose of the wastes. ...
 Decontaminate the area and affected equipment

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 Self-Check -2 Written Test

Directions: Answer all the questions listed below. Examples may be necessary to aid some
explanations/answers.
Instruction I choose the correct Answer Questions
1. Mechanic A says that “Adding a turbocharger is one way to increase output power of
diesel engines.”
Mechanic B says that “Adding a turbocharger is one way to decries output power of diesel
engines.” which mechanic is correct?
A. Mechanic A only
B. Mechanic B only
C. Mechanic A nor Mechanic B
D. All
2. Measures the amount of oil in the engine sump by what.
A, Dipstick B, Oil Gallery C, Pressure Gauge D, oil filter
3. Viscosity of oil is expressed by
A, engine oil B, viscosity C, number D, all
4. Witch statement is true about air cleaner?
a. To reduce noise c. it captures moisture
b. To control the flow of fuel d. it act as a flame arrestor
5. Witch statement is false about cooling system?
a. To reduce engine temperature c. to prevent engine overheating
b. To control the flow of oil d. effective combustion
6. __________ it increases the air pressure into the engine so that more fuel can be burnt & the
engine output increases
A. Supercharger B .Turbocharger C. Air cleaner D. None
7. One of the following components is not Flammable liquids and fire risk
A. Petrol B. solvents C. paints D. All E. none
8. Which type of toxic entities
A. Chemical B. biological C. Physical D. Radiation E. All
9. Which system is maximizing the contact between the tires and the road surface, providing
steering stability and good handling other
a. Brake system B. steering system C. Suspension system D. Engine system

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10. Which part is exhaust gas treatment?
a. Catalytic converter B. Turbo Charger C. Exhaust Manifold D. All
11. It converts the electrical energy to mechanical energy & rotates the crank shaft with a
minimum cranking speed
A. Starter Motor B. Battery C. Alternator D. Turbo Charger D. All
12. What is the possible fault of Brake Warning Light On

B. A It could also be a faulty sensor or electrical fault

B. Fill up the brake fluid reservoir,

C. check for leaks, normal brake pedal operation

D.ALL

Answer all the questions listed below. Use the Answer sheet provided in the next page:
1. Write mechanical systems /component?
2. What are Toxic substances?
3. List Flammable materials and fire hazards?

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 Operation sheet 2.1

Operation title: check Engine operation systems

Instruction:
 make Safe working area
 Properly operated tools and equipment
 Appropriate working cloths fit with the body
Purpose: Ensure a correct inspection to operate the condition of engine.
Required tools and equipment: Work area, wrench, hammer, screw driver
Consumable Materials: Safety poster, first aid kit, waste bin, engine fluid kerosene
Precautions:
 Wearing proper clothes, eye glass, glove
 Make working area hazard free
 Read and interpret manual which guide you how to use tools and equipment
Procedures:
1. Before road-testing the car, check the tires for specified inflation pressure and for
abnormal wear.
2. Check for proper operation of the instruments-panel warning lights, gauges, and
information displays.
3. Note any unusual noise, vibrations or hardness heard or felt during the road test.
4. Check the headlights and horns to make sure they work. Check all other lights.
Replace burned-out bulbs. Check headlights aim, if necessary.
5.Visual inspection should always be your first step in checking the charging system. Check for
proper electrolyte level and state of charge. When fully charged,
6. Check the battery terminals and cables. The terminals should be free of corrosion and the
cable connections tight.
7. Check the Fuses and Fusible Link • Check the Fuses for Continuity.
8. Check Engine Coolant Level At Radiator Reservoir
9.Check Engine Coolant Quality
10. Check Engine Oil Quality
11. Check Engine Oil Level
12. Check Oil Pressure
13. Start Engine And Check For Oil Leaks
14. Check for belt separation, cracks, fraying, or glazing. If necessary, replace the drive belt.
15. Check the drive belt tension using the proper tension gauge, Nippondenso BTG-20
16. Check the wiring and connections. Replace any damaged wires, tighten any loose
connections.
17. Check for abnormal noises. Squealing may indicate drive belt or bearing problems.
Defective diodes can produce a whine or hissing noise because of a pulsating magnetic field
and vibration.
18. CHECK THE WARNING LAMP CIRCUIT • with the engine warm and all accessories off,
turn the ignition to ON. The warning lamp should light.
19. With the engine started and the ignition in RUN, the warning lamp should be off.
20. If the lamp does not operate as specified, check the bulb and check the lamp circuit.
Quality criteria: operate all activates without any damage and according to specifications

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 Operation sheet 2.2

Operation title: check Transmissions and drive trains operation systems

Instruction:
 make Safe working area
 Properly operated tools and equipment
 Appropriate working cloths fit with the body
Purpose: Ensure a correct inspection to operate the condition of transmission and drive trans.
Required tools and equipment: Work area, wrench, hammer, screw driver
Consumable Materials: Safety poster, first aid kit, waste bin, brake and steering fluid kerosene
Precautions:
 Wearing proper clothes, eye glass, glove
 Make working area hazard free
 Read and interpret manual which guide you how to use tools and equipment
Procedures:
1.Before road-testing the car, check the tires for specified inflation pressure and for
abnormal wear.
2.Check for proper operation of the instruments-panel warning lights, gauges, and
information displays.
3. Check the CV joints for noise and smooth operation. If a CV-joint boot is torn, check for
grit in the grease and for joint wear.
4. Check the operation of the clutch and manual transmission or transaxle. Note the shift
timing and shift quality in a vehicle with an automatic transmission or transaxle.
Note any unusual noise, vibrations or hardness heard or felt during the road test.
5. Check lever Hard to shift or will not shift
6. Check clutch pedal height
7. Check Clutch pedal free play
8. Check For air in clutch line
9. Check clutch line
10. Check clutch Master cylinder
11. Check TRANSMISSION OIL there is linkage or not
12. Check the oil level. Automatic transmission oil has large thermal expansion characteristic
13. Check differential OIL there is linkage or not
14. Check whether each actual gear conditions are synchronized with each shift positions on the
shift lever, or not. (To prevent miss shift, needs to refer manual.)
15. Check the engine to starts only with the shift position “P” and “N”, or not

Quality criteria: operate all activates without any damage and according to specifications

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 Operation sheet 2.3

Operation title: check Steering operation systems

Instruction:
 make Safe working area
 Properly operated tools and equipment
 Appropriate working cloths fit with the body
Purpose: Ensure a correct inspection to operate the condition of steering systems.
Required tools and equipment: Work area, wrench, hammer, screw driver
Consumable Materials: Safety poster, first aid kit, waste bin, steering fluid kerosene
Precautions:
 Wearing proper clothes, eye glass, glove
 Make working area hazard free
 Read and interpret manual which guide you how to use tools and equipment
Procedures:
1. Check the steering system for ease and smoothness of operation.
2. Check for excessive play in the steering system.
3. Note any unusual noise, vibrations or hardness heard or felt during the road test.
4. Check the power steering fluid level.
5. Check the hoses and lines around the power steering pump for possible leaks.
6. Lift the front end of the car with a jack. Check the seals of the rack and pinion for leaks. If
you have an older car, you may have a recirculating ball unit to check instead.
7. Check for loose belts.
ROAD TEST
After adjusting the front axle, suspension, steering and/or front wheel alignment, carry out the
following road test to check the result of the adjustment.
1. STRAIGHT- AHEAD DRIVING
 The steering wheel must be at the correct position during straight- ahead driving
 When driving on a flat road, the vehicle should run straight ahead without pulling to the
left or right.
 Excessive steering shimmy or flutter should occur.
2. TURNING
 The steering wheel should turn easily in either direction, and should return quickly and
smoothly to the neutral position when released.
3. BRAKING
 The steering wheel should not pull to either side when the vehicle is braked on a flat,
smooth road.
4. CHECKING FOR ABNORMAL NOISE
 No abnormal noise must be heard during test. Also the steering and suspension
components must not come into contact with chassis or body when the steering wheel is
fully rotated.
Quality criteria: operate all activates without any damage and according to specifications

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 Operation sheet 2.4
Operation title: check Suspension operation systems
Instruction:

 make Safe working area

 Properly operated tools and equipment
 Appropriate working cloths fit with the body
Purpose: Ensure a correct inspection to operate the condition of suspension systems.

Required tools and equipment: Work area, wrench, hammer, screw driver
Consumable Materials: Safety poster, first aid kit, waste bin, kerosene
Precautions:
 Wearing proper clothes, eye glass, glove
 Make working area hazard free
 Read and interpret manual which guide you how to use tools and equipment
Procedures:
1. Before road-testing the car, check the tires for specified inflation pressure and for
abnormal wear. Abnormal wear would mean suspension trouble and the need for wheel
alignment.
2. Check for proper operation of the instruments-panel warning lights, gauges, and
information displays.
3. Check the suspension system for looseness, excessive play and wear.
4. Check the front-suspension ball joints for excessive wear.
5. Check for loose wheel bearings at the non-driving wheels. Adjust the wheel bearings if
necessary.
6.Note any unusual noise, vibrations or hardness heard or felt during the road test.
7. Inspecting your shocks for leaks, cracks or other damage;
8.Looking for vehicle bounce, nose dives, squats or rolls;
9.Spinning the tires manually to see if there is any wobble, imbalance or uneven tire wear;
10. Checking for leakage from any of the steering components;
11. Ensuring the tension in the power steering pump belt is correct;
12. Bouncing the car to see if your shocks or struts are functioning correctly.

Quality criteria: operate all activates without any damage and according to specifications

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 Operation sheet 2.5

Operation title: check Brake operation systems

Instruction:

 make Safe working area

 Properly operated tools and equipment
 Appropriate working cloths fit with the body
Purpose: Ensure a correct inspection to operate the condition of brake systems.

Required tools and equipment: Work area, wrench, hammer, screw driver
Consumable Materials: Safety poster, first aid kit, waste bin, brake fluid kerosene
Precautions:
 Wearing proper clothes, eye glass, glove
 Make working area hazard free
 Read and interpret manual which guide you how to use tools and equipment
Procedures:
1. Check for Proper Operation of the Instruments-Panel Warning Lights, Gauges, and
Information Displays.
2. Check The Brakes For Even And Adequate Braking.
3. Note Any Unusual Noise, Vibrations Or Hardness Heard Or Felt During The Road Test.
4. Check Brake Fluid
5. Brake Noise.
6. Vibration
7. Abnormal Pad Wear.
8. Check Pedal Height
9. If Necessary, Adjust Pedal Height
10. Check Pedal Free play
11. Check That Parking Brake Lever Travel
12. If Necessary, Adjust Parking Brake Lever Travel

Quality criteria: operate all activates without any damage and according to specifications

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 LAP test 1 Performance test

Name…………………………………………… ID………………………… Date…….

Time started: ________________________ Time finished: ________________

Instructions: Given necessary templates, tools and materials you are required to
perform the following tasks within 6 hour. The project is expected from
each student to do it.

Task 1: Trace suitable automotive systems and components

Task 2: Identify automotive systems and components
Task 3: Identify principles of operation

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 Unit Three: Locate system or component on vehicle
This unit to provide you the necessary information regarding the following content coverage
and topics:
 Tracing suitable automotive systems and components
 Confirming location of systems or components
This guide will also assist you to attain the learning outcomes stated in the cover page.
Specifically, upon completion of this learning guide, you will be able to:
 Trace suitable automotive systems and components
 Confirm location of systems or components

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 3.1Tracing suitable automotive systems and components

a. Engine system
An Engine is a mechanical device used to convert heat energy into mechanical energy. And is
usually called a Heat Engine.
1 - Distributor
2 - Valve cover
3 - High tension cables
4 - Tappet
5 - Air cleaner
6 - Timing pulley
7 - Camshaft
8 - Water pump
9 - Timing belt
10 - Connecting rod
11 Crankshaft pulley
12 - Oil sump 13 - Strainer
14 – Crankshaft 15 - Engine block
16 – piston 17 - exhaust manifold
18– Valve 19 - Cylinder head
Figure 3.1 location of engine components
b. The Drivetrain and the Transmission
The drivetrain and the transmission are actually two very different concepts. The main function
of the transmission is similar to the chain on a bicycle: it keeps the engine turning in time with
the wheels, regardless of what gear the vehicle is in. The drivetrain represents everything that is
behind the transmission involved in propelling the vehicle. The main function of the drivetrain is
basically to convey power from the vehicle’s engine, through the transmission to the drive
wheels on the vehicle to control the amount of torque. “Torque” is turning or twisting force.

Figure 3.2 Drivetrain and the Transmission components

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 c. Steering System
In front wheels can be turned to left and right by steering system so that the vehicle can be
steered. The steering wheel is placed in front of driver. It is mechanically linked to the wheels
to provide the steering control. The primary function of the steering system is to provide
angular motion to front wheels so that vehicle can negotiate a turn. It also provides directional
stability to vehicle when the vehicle moves ahead in straight line.

Figure 3.3
location of
steering
system
components

d. Suspension System
A suspension system also maintains the stability of the vehicle in pitching or rolling when
vehicle is in motion. It supports the body on the axles and maintains the proper geometrical
relationship between the body and wheels.

e. Brake system Figure 3.4 location of Suspension System components

Brakes are used to slow down or stop the vehicle. Hydraulic brakes are generally used in
automobiles, where brakes are applied by pressure on a fluid. Mechanical brakes are also used in
some vehicles. These brakes are operated by means of leavers, linkages, pedals, cams, etc. Hand
brake or parking brake is known usually mechanical brake. These are used for parking the
vehicles on sloppy surfaces and also in case of emergency.

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 Figure 3.5 location
of brake System
components

3.2 Confirming location of systems or components

Figure 3.6 location of mechanical System components

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 Self-Check -3 Written Test

Directions: Answer all the questions listed below. Examples may be necessary to aid some
explanations/answers.

Answer all the questions listed below. Use the Answer sheet provided in the next page:
1. How to Locate mechanical system or component on vehicle

Score = ___________
Answer Sheet
Rating: ____________

Name: _________________________ Date: _______________

1. __________________________________________________________________
_________________________________________________________________
2. __________________________________________________________________
_________________________________________________________________
______________________________________________________________________
______________________________________________________________________
_________

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 Unit Four: Apply system fundamentals

This learning guide is developed to provide you the necessary information regarding the
following content coverage and topics:
 Examining subassembly components
 Identifying common faults
This guide will also assist you to attain the learning outcomes stated in the cover page.
Specifically, upon completion of this learning guide, you will be able to:
 Examine subassembly components
 Identify common faults

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 4.1 Examining subassembly components
a. Air conditioning
Air conditioning is divided into industrial air-conditioning
and comfort air-conditioning. The controlled atmosphere,
which gives maximum comfort to the human beings, is
known as comfort air-conditioning.
b. Airbag
The goal of an airbag is to slow the passenger's forward motion as evenly as possible in a
Figure 4.1 Air conditioning System component
fraction of a second.
Turbocharger and Supercharger
The turbocharger and supercharger are devices that force air into the
cylinders creating a pressure that is greater than the atmospheric
pressure in order to increase engine output.
Generally, the engine output is determined by the amount of the air-fuel
mixture, burned over a specified period of time, and becomes greater as
the amount of the air-fuel mixture increases. Figure 4.2 Air bag System

That means in order to increase the engine output, either the engine displacement or engine speed
must be increased.

Figure 4.3 turbocharger and supercharger Figure 4.4 Alarm system

c. Audio system
Sound systems are available in a wide variety of models. The complexity of the system varies
significantly from the basic AM radio to more complex stereo systems that include an AM/FM
radio receiver, a stereo amplifier, compact disc (CD) player, cassette player, equalizer, several
speakers, and a power antenna system.

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 d. Radio
High frequency, electromagnetic radio waves propagate through the air at the speed of light.

Figure 4.5 radio waves

Figure 4.6 Speakers Figure 4.7 'Active' type
e. Speakers
antenna
The low-frequency AC signals generated by the output stage of the entertainment system must be
converted into acoustic sound-waves at frequencies appropriate for the human ear (in the 20 Hz
to 20 kHz range). This task is performed by the speaker system.
f. Mobile telephone
Phone integration in the vehicle many vehicles are now offered with phone hands-free operation
built in (via Bluetooth). The driver can easily answer and end mobile phone calls as they drive. It
is not necessary to touch the handheld mobile phone once it is paired with the car. As a phone
call is answered, the system conveniently mutes the car’s audio system.

4.2Identifying common faults

4.2.1 Failure to achieve ignition and power

The ignition relay is one of the most important electronic relays found on modern vehicles. It is
usually located in the fuse and relay panel beneath the hood, and is responsible for providing
power to the vehicle’s ignition system, and some of the fuel system’s components. When the key
is turned to the on position the relay is switched on and power is directed to the vehicle’s ignition
and fuel system components, notably the fuel pump and ignition coils. When the relay fails or
has an issue it can cause major problems with the operation of the vehicle. Usually a bad or
failing ignition relay will produce a few symptoms that can notify the driver of a potential issue.

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  Car suddenly stalls while operating
One of the most common symptoms of a failed ignition relay is a car that suddenly stalls while
operating. If the ignition relay shorts, burns out, or otherwise fails while the engine is operating it
will cut off power to the fuel pump and ignition system. This will cause the vehicle to
immediately stall due to fuel and spark being cut off. In some instances of a faulty relay the
vehicle will be able to restart once the relay cools off, only to stall out once again after the relay
overheats.
 Car not starting
Another symptom of a faulty ignition relay is a no power condition. If the relay fails it will cut
off power to fuel pump and ignition system, which will result in a no power, and therefore no
start condition. You may find that turning the key may power on the accessories, and may even
crank the engine, however the vehicle will not start due to there not being any power directed to
the fuel and ignition system. Similar symptoms can also be caused by a wide variety of other
issues, so a proper diagnosis is recommended in order to make certain what the issue is.
 Dead battery
A dead battery is another symptom of a faulty ignition relay. If the relay has an internal short it
may keep power fed to the ignition and fuel system, even when ignition cylinder is in another
position, or the key is removed. This will cause the fuel pump and ignition components to remain
powered on, drawing current, at all times, which will eventually lead to a dead battery. Aside
from draining the battery this may also cause accelerated wear on the components, notably the
fuel pump, due to having them powered on, but not operating.
 Burned relay
In certain instances it may be possible for the relay to overheat to the point of burning up and
melting. Apart from cutting off power to the vehicle’s ignition relay and causing performance
issues, a burned relay may melt onto the fuse panel. This may make it difficult to remove, and in
some instances can even lead to the replacement of the entire fuse box.
While servicing the ignition relay is not generally considered routine maintenance, it can
sometimes fail and cause major issues for the vehicle. If you suspect that your ignition relay may
be having an issue, have the vehicle inspected by a professional technician, such as one from
Your Mechanic, to determine if the relay should be replaced.

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 4.2.2 Failure to achieve fuel flow

Fuel system related problems, can be difficult to solve. Figure 4.8 Failure of fuel flow

Consequently, anything that might affect the flow and pressure of the fuel system; is going to
result in poorer performance.
Above all, the biggest cause of any fuel system problems is dirt.
So, the weak link in the fuel system is usually, the fuel filter. In other words, the very purpose of
this usually small part is to; prevent any contaminants from getting into the fuel.
The big thing to note is that most of the failure warning signs; are the same for most fuel system
problems:
 Hesitating Engine
 Stalling
 Not Starting
 Hard Starting
 Different Performance at Different Speeds
 Engine Misfiring
 Engine Sputters at High Speeds
 Loss of Power When the Vehicle Is Under Load
 Surging

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The three most common causes of fuel pump failure include:
Fuel contamination: Fuel is jeopardized from corrosion, debris and moisture, which can all
bring visible contaminants into the tank.
Clogged strainers/filters: The aforementioned contaminants eventually clog critical components
including strainers, filters and the fuel pump itself. This blockage ultimately impairs the flow of
fuel, which may affect the vehicle during acceleration, among other long-term impairments.
Electrical issues: Electrical faults are also significant contributors to fuel pump failures. The
most common electrical issues are rusted connectors, loose connectors, or melted wiring and
connectors. To help identify issues of poor electrical connections, a high quality digital
volt/ohm/meter should be used to test for voltage drops and continuity.

4.2.3 Excessive exhaust smoke or noise

What does excessive exhaust smoke mean?
If your car is emitting a lot of exhaust smoke there's a solid chance that the vehicle has suffered
some sort of engine issue. If a vehicle's engine is not properly cared for, meaning it is denied
scheduled maintenance such as oil changes and cooling system flushes, it will eventually bite the
dust earlier than one that does have these services completed. Depending on the color of the
smoke coming out of the tailpipe you can generally tell what kind of problem the motor is
suffering from. It is necessary to have your car looked at by an auto mechanic as when you first
notice an increase in the amount of colored exhaust in order to avoid more extensive engine
trouble. These are the most common colors of exhaust smoke and the trouble that they may be a
sign of.

Figure 4.9 Excessive exhaust smoke or noise

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  Blue Exhaust
An oil leak that causes oil to be burnt up in the combustion chamber will result in blue exhaust
smoke. This needs to be taken care of immediately because if the motor becomes starved of oil it
will not be lubricated properly and it will likely result in massive engine damage.
 White Exhaust
If your car is creating white clouds of exhaust smoke there is likely cooling system trouble. The
white smoke is produced by coolant burning up in the engine. This can occur if there's an
internal coolant leak within the motor. Cooling system problems may cause additional problems
for the motor, including blown head gaskets or burnt piston rings. If the issue is not dealt with in
a quick manner you may find your car in need of extensive and expensive engine repair on your
hands.
 Black Exhaust
A vehicle that produces excessive black smoke is likely burning too much gasoline. There are a
number of issues that can cause this, which include:
Leaking fuel injector(s) - Leaking fuel injectors can drip extra fuel into the combustion chamber.
Stuck fuel pump relay - This is a rare problem but if the relay for the fuel pump is stuck in the
"on" position it may feed extra amounts of gas to the engine.
Clogged air filter - Another less common problem is a clogged air filter. If the air filter is
clogged the engine will not be able to produce the right air/fuel mixture and the car's computer
system will compensate by burning extra gas.
4.2.4 Unusual engine noises or vibrations
There are several common causes of engine vibration in a car, and they all result in shaking and
noises that can be quite alarming and sometimes scary. However, if you know what some of the
most frequent caused of engine vibration are, you can not only avoid too much stress and worry,
you can know how to explain the problem and symptoms to a car mechanic when the time comes
to correct the problem. So, here is a list of some of the most common reasons your car's engine
might shake or vibrate.
 Worn Out Spark Plugs
In many vehicles a common cause of engine vibration is worn out or faulty sparkplugs. Worn out
or dirty sparkplugs will cause the car's engine to misfire or not properly fire on each and every
cylinder. When this occurs, it is commonly referred to as the engine missing or not firing on all

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cylinders. This can usually be corrected by installing new sparkplugs or correcting other spark or
compression-related issues.
 Loose or Disconnected Hoses
Loose or disconnected hoses can also be a common cause of many types of engine vibration. A
loose or disconnected air hose or vacuum hose can cause quite a bit of violent shaking and
vibration in your car's engine. To correct the problem, simply look for any loose or disconnected
hoses and reattach them and replace them as needed.
 Broken Motor Mounts
If the vehicle shakes violently or the engine vibrates excessively when stopped at a red light or
when parked with the engine on, this may be a good indicator that the motor mounts or
transmission mounts on the vehicle are damaged or broken. A good way to tell if this is the
problem is to simply put the car in neutral and see if the vibration or shaking decreases a bit.
 Faulty or Poorly Adjusted Fuel Intake System
Another common problem that causes engine vibration and nasty shaking is a poorly adjusted
fuel intake system. Sometimes, idling problems that cause engine vibration may be as simple as
adjusting the idle on a carburetor or cleaning components in the fuel intake system so that fuel
passes through the engine more easily creating cleaner and more efficient combustion your car's
engine.
 Faulty Timing Belt
Problems with your vehicle's timing belt, or other belt driven accessories, are another common
cause of engine vibrations in vehicles. Timing belts and other belts that are loose or damaged
will cause components controlled by belts such as fans and other parts to not rotate or turn a
consistent speeds which will result in strange sounds and vibrations from your car's engine. To
avoid these types of problems, you should frequently inspect all of the belts in your vehicle to
make sure that they are free from cracks and ribbing and also make sure that the belts are tight
and operating as they should.
4.2.5 Excessive play or vibration through steering
 Free play in the tie rods:
Tie rod ends, as the name suggests, are found on the ends of the steering rack and 'tie' the rack to
the steering knuckle or hub carrier. Any free play in these affects the tracking and is generally
displayed as uneven wear on the outside edge of the tyres. Poor tracking will also cause the
vehicle to wander/drift to one side while driving or braking.

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  Free play in the steering rack: Figure 4.10 Free play in the tie rods
The majority of light vehicles use rack and pinion steering. The steering rack is essentially a
straight bar with splines at the ends. These splines engage with similar splines on the pinion and
allow the steering to function when the wheel is turned. Steering racks are fairly tough and
generally little goes wrong with them. If anything the bushings on either side of the rack tend to
fail and it is these that allow for play in the steering.

Figure 4.11 Free play in the steering rack:

 Free play in the ball joints:
To respond to driver inputs and turn the wheels, ball joints allow the suspension to move up and
down while allowing the steering knuckle to pivot. Worn out ball joints affect the camber of the
wheels and result in the poor response to driver input as well as a tendency for the car to pull to
one side.

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  Wheels that are Unbalanced Figure 4.12: Free play in the ball joints
Even if the wheels are just minimally unbalanced, they will cause your steering wheel to
excessively vibrate, and even on your entire vehicle. If you have a new car with a lightweight
suspension system, your vehicle might be susceptible to this problem.
 Bearings that are Not in Good Condition
The hub bearings are essential in letting your wheels rotate correctly. Moreover, they are
important in supporting the car’s weight. When they are not lubricated properly, they eventually
become damaged or broken. Weak bearings cause the steering wheel to shake when you turn the
car to any direction. Typically, bad bearings trigger a noise coming from your wheels. You can
remove them to check for damage. In most cases, you only must clean and properly lubricate
them to fix the issue. On the other hand, when they are badly worn or broken, you’d have to
replace them.
 Your Wheels are Misaligned
One of the most common reasons why your steering wheel is shaking is because of misaligned
wheels. Over time, when you drive on roads with bad conditions, your wheels get misaligned.
You can easily determine if this is the cause of your shaky steering wheel. Simply check the
tread on the tires and look for uneven wear. If the inside has completely worn down while the
outside has almost full tread, then it is likely that your wheels are misaligned. Also, if you notice
that your car guides itself to the sides even when your steering wheel is centered and straight, it
means that you have misaligned wheels. Make sure you consult a professional mechanic to get
this fixed right away.
 Problems with your Brakes
When your steering wheel vibrates whenever you slow down, then it is possible that the problem
lies with your brakes. Shaky steering wheels are caused by loose connections, bad brake discs,

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worn brake pads, or worn shocks. In most cases, you will notice vibration on your steering wheel
when you turn, accelerate, or maintain a particular speed. Brake issues are easier to identify
because even before you start to notice your steering wheel shaking, you will feel that there’s
something wrong when you apply pressure to your brakes.
4.2.6 Loss of coolant
Coolant loss can be hard to diagnose sometimes
Coolant loss may indicate a poorly maintained cooling system, a system fault, or even a change
in driving patterns. For example, a coolant leak could have any of these causes:
1. Overfilling the cooling system
2. A faulty radiator cap
3. A worn-out radiator hose
4. A leak that only occurs under certain operating conditions
5. An undiagnosed cracked engine block or cylinder head, or a blown gasket
6. Towing heavy loads
 Bad Radiator Cap

Figure 4.13: Bad Radiator Cap

A bad radiator cap may not seal properly, which could lead to coolant leaking past the seals and
evaporating. Look for steam near the radiator cap, and also check the overflow reservoir if your
overflow reservoir is pressurized.
 Blown Head Gasket

The head gasket sits between the cylinder head and the engine block. Its job is to keep
combustion gases in the combustion chamber and coolant in the water jackets.
When a leak forms in the head gasket, it is possible for coolant to leak into the combustion
chamber and burn off, exiting the exhaust. When you have an internal head gasket leak, you are

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unlikely to notice any coolant leaking onto the ground. Common symptoms are overheating
and white smoke coming from the exhaust.

Figure 4.14: Blown Head Gasket

 Blown Intake Manifold Gasket

Figure 4.15: Blown Intake Manifold

Gasket

Some intake manifolds have water jackets. If these intake manifold water jackets were to leak
into the intake, coolant would be sucked into the combustion chamber. The resulting symptoms
would resemble a blown head gasket.
 Leaking Turbo Seal

Figure 4.16: Leaking Seal

Most turbos are cooled using engine coolant. If a turbo seal allows coolant to leak into the turbo,
you will lose this coolant out the exhaust.

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  Evaporation

Why Is My Coolant Evaporating?

The water in your coolant can only evaporate when the system isn’t perfectly sealed. The source
of the leak can be tricky to find since it happens so slowly.
As long as the coolant loss is very slow (a few drops every month), this is often no immediate
cause for concern. Keep an eye on things to make sure the leak doesn’t get worse. If you start to
see coolant on the ground, it’s time for a proper repair.

Figure 4.17: Coolant Evaporating

4.2.7 Slow response or excessive pedal travel when braking System or

component fluid or gas leakage

Acceleration tends to get the most attention when it comes to cars, but great performance is
about more than going fast. It's also about stopping quickly.
When you have a brake problem, bringing your car to a full stop can take more effort than it
should. Spongy brakes—also described as squishy or mushy brakes—can cause big trouble if not
addressed right away with a brake inspection and service. Find out what could be causing such a
change in braking performance and how we can help solve it.
 Air in the Brake Lines

Air in the brake lines is one of the most common causes of spongy brakes. Braking systems rely
on evenly distributed hydraulic pressure to bring vehicles to a halt. Air in any of these lines can
throw off this balance of pressure. Poor pressure can result in more time, distance, and/or effort
to stop. In other words: a soft brake pedal. Air in the brake lines could be due to a leak or low
brake fluid.

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  Brake Line Damage

What can damage a brake line and cause a leak? Rust, for one. Rust from road salt and moisture
can cause brake lines to become brittle, leak, and break. Damage from a car crash can also cause
brake lines to bend and collapse, weakening them and making them more susceptible to
problems down the road.
 Old or Low Brake Fluid

And how about low brake fluid? Time might be the key suspect here. Brake fluid converts the
energy you apply to the brake pedal into the force required to bring your car to a stop. Just as
your brake pads wear thin over time, so can your brake fluid. If you can’t remember when you
last had a brake service, then you might have low brake fluid simply because it’s being used by
your braking system. Or, the low fluid could be due to a leak. Either way, it’s time to schedule a
brake inspection!
 Cylinder Wear

The master cylinder plays an important role in distributing the hydraulic pressure mentioned in
#1. It pushes the brake fluid where it needs to be to help bring your car to a stop. Over time, seals
within the cylinder can break or leak. If you have to press the brake pedal all the way to the floor
to bring your vehicle to a stop, this might be why. The braking system simply isn’t working as
efficiently as it used to.
 Damaged Disc Brake Caliper

Braking creates a great deal of heat. That heat can damage your car’s disc brake calipers over
time. How can you spot disc brake caliper damage? On top of spongy brakes, you may notice
that your car pulls to one side or the other when stopping. You might also hear a squeaky or
squealing sound when braking.

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 Self-Check -4 Written Test

Name…………………………………………… ID………………………… Date…….

Test I say true or false

1.___________ mechanical faults are bearing fault, rotor damage, air gap eccentricity and shaft
bending.
2.___________ Suspension issues can be difficult to diagnose
Test II Choose the best alternative
1. What is the possible fault Hard Pedal
A. Servo inoperative B. Seized calliper pistons C. Faulty Master Cylinder D.ALL
2. Black exhaust gas released from diesel engine is the indication of
a. Lean mixture
b. Oil inter in the composition chamber
c. Over rich mixture
d. Worn piston ring
3. Why failures of Slow response or excessive pedal travel when braking System or
component fluid or gas leakage
a. Air in the Brake Lines
b. plugged canister purge vacuum hose
c. Brake Line Damage
d. Old or Low Brake Fluid
e. All
4. Which statement is false about failures of Loss of coolant
a. Overfilling the cooling system
b. A faulty radiator cap
c. A worn-out radiator hose
d. All
e. none
5. White Exhaust gas released from engine is the indication of
a. coolant burning up in the engine
b. Oil inter in the composition chamber
c. Over rich mixture
d. All

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6. The Unusual engine noises or vibrations is
a. Worn Out Spark Plugs
b. Loose or Disconnected Hoses
c. Broken Motor Mounts
d. All
e. none
7. Blue Exhaust gas released from engine is the indication of
a. coolant burning up in the engine
b. Oil inter in the composition chamber
c. Over rich mixture
d. All
8. common Failure to achieve ignition and power is called
a. ignition relay
b. dead battery
c. ignition coils
d. All
Test III Directions: Answer all the questions listed below. Examples may be necessary to aid
some explanations/answers.

1. Write mechanical systems common faults?

2. Write at list 5 subassembly components?

Answer Sheet Score = ___________

Rating: ____________
Name: _________________________ Date: _______________
1._______________________________________________________________________
________________________________________________________________________
________________________________________________________________________
_______________________________________________

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 Operation sheet 4.1

Operation title: check mechanical systems common faults

Engine Testing Instruments (sample)

The most common instruments used for engine diagnosis and tune-up are: -
 Test lump (bulb): - to adjust ignition timing statically.
 Tachometer: - to indicates the engine speed in revolutions per minute (rpm).
 Cylinder compression tester: - to measure the compression pressure.
 Cylinder leakage tester: - to find places of compression pressure leakage.
 Dwell angle tester: - to measure and correct the dwell angle.
 Ignition timing light: - to adjust ignition timing dynamically.
 Oscilloscope: - to examine the condition of the primary and secondary ignition circuits.
 Exhaust-gas analyzer: - to measure the concentration of exhaust gases (CO, HC,).
 Vacuum gauge: - to check manifold vacuum.
 Engine analyzer: - to measure various engine parameters on a single unit.
Tune-up procedures
Step I
1. Know the system.
2. Ask the driver or the owner of the car for the problem.
3. Get hold of the Repair Manual.
4. Inspect the Engine (fuel, engine oil, coolant, battery, wirings, drive belts, valve
clearance, etc.).
5. Run the Engine.
Step II
6. List the possible causes or troubles.
Inspect the starting system
Common engine troubles
Inspect the intake system
 Engine does not crank.
Inspect the fuel system
 Engine cranks but does not start. Inspect the ignition system
 Engine runs but misses. Inspect the lubrication system
 Engine Lacks power, acceleration,… Inspect the cooling system
 Engine consumes more fuel. Inspect the exhaust system
 Engine consumes more oil. Inspect the charging system
 Engine overheats. Check cylinder compression
 Engine backfires. Check cylinder leakage
 Engine emission high. Check engine balance
Check manifold vacuum

Quality criteria: operate all activates without any damage and according to specifications

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 LAP test 2 Performance test

Name…………………………………………… ID………………………… Date…….

Time started: ________________________ Time finished: ________________

Instructions: Given necessary templates, tools and materials you are required to perform the
following tasks within 6 hour. The project is expected from each student to do it.

Task 1: Locate of mechanic systems or components

Task 2: Identify mechanical systems common faults

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 Reference
1. Introduction to Automotive Technology Third Edition 7/2010
Vehicle Service Manual Third Edition 7/2010
2. https://www.autoandbrakerepair.com/blog/fuel-system-common-problems.php
3. 2.https://www.uesystems.com/5-ways-poor-lubrication-can-cause-problems/
4. https://www.yourmechanic.com/article/how-to-diagnose-a-cooling-system-problem-by-
tyler-kirkland
5. https://www.teamryanautomotive.com/strategy-based-diagnostics
6. https://www.autoandbrakerepair.com/blog/fuel-system-common-problems.php
7. https://www.uesystems.com/5-ways-poor-lubrication-can-cause-problems/
8. https://www.yourmechanic.com/article/how-to-diagnose-a-cooling-system-problem-by-
tyler-kirkland
9. https://www.autotrader.co.uk/content/advice/what-is-a-pre-delivery-inspection

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 Participants of this Module (training material) preparation
No Name Qualification Field of Study Organization/ Mobile E-mail
(Level) Institution number
1 Fasil Ebabu A Automotive Technology Debark/PTC 0918209786 [email protected]
2 Abebe Mola A Automotive Technology Hawassa P/ T/ College 0913160533 [email protected]
3 Biniyam bayeh B Motor vehicle Major Meneral 0922258639 [email protected]
engineering Mulugeta Buli/ PTC
4 Zeyneba mengistu A Automotive Technology w/ro sheen /PTC 0912891142 [email protected]
5 Seid denbi B Automotive Technology Assosa/PTC 0915890277 Seiddenbiali25@gmail