Car Operation & Maintenance - Philippe Boursin
Contents
1. no exception From the time that a car drives in for service until the time that the bill for service is paid there is paperwork to be done Actually paperwork begins well before the car arrives Let s see how it works 1 The Parts Department The parts department has to have on hand ail fast moving parts that might be needed to service cars These parts include spark plugs fan belts anti freeze engine oil brake fluid distributor contact points ignition coils gaskets and screws and bolts Ail these parts and supplies have to be ordered by the parts manager The parts manager writes out orders for the things needed to stock the department The parts manager also has to keep a record or inventory of the parts in stock That way more parts or supplies can be ordered when the inventory runs low Ail this record keeping and ordering is paperwork 2 The Service Department The phone rings and the service manager or an assistant answers Someone has car trouble The caller wants to bring a car in for service The service manager consults the work schedule often called the dispatch sheet and tells the caller that the department can handle the car at ten the next morning The service manager notes this down on the schedule When the car arrives the next morning it is met by the service manager or a service order writer who is usually called a service writer or a service advisor The driver explains the problem The service writer writes the cust2. KE VALVE CYLINDER HEAD SPARK PLUG Fig 3 2 Cylindre head from a V 8 engine showing the valves for one cylindre removed Chevrolet Motor Division of General Motor Corporation 3 Machining Sometimes you have to remove metal from a part Using a machine to remove metal is called machining Suppose you find valve trouble This could require machining or grinding the valves and valve seats Or you might find that the engine cylinders require machining Special machines are required to do these jobs 4 Installing New Parts You might find that some parts are so worn that they must be thrown away Then new parts must be installed in their place For example engine bearings sometimes wear out and new ones must be installed in place of the old ones Even new parts may require machining to make them fit 5 Reassembling After a repair you may have to put some parts back together This is called reassembly You put the parts back together to make a complete assembly 6 Adjusting As an automobile is operated parts formally wear This requires adjustments from time to time Also adjustments may be required after a service job For example after grinding the valves you put everything back together Then you measure the valve action If it is not right adjustments must be made 3 2 Specifications You will hear the word specifications or specs quite often if your shopwork The specs give you the right measurements for the cars you w
3. Name Business amp Technician Education Council LPo N J Cugnot level A 93 Neuilly Marne Car Operati ar a ii Car Operation amp Maintenance Maintenance option Light Vehicle SHOPWORK and SHOP MANUALS 3 1 The six steps in automotive service Servicing Jobs vary from simple to difficult But no job requires more than six steps These are 1 Measuring 2 Disassembling 3 Machining 4 Installing new or serviced parts 5 Reassembling 6 Adjusting Some jobs require fewer steps Let s look at these six basic steps They are performed by using hand tools measuring tools and power tools Tools and their uses are described in following chapters Note There is a difference between reinstall and replace When you reinstall a part or component you are putting back the same part or component that you removed But when you replace a part or component you have discarded the old part or component and are install a new one These are the definitions used in the automotive service business and in this book 1 Measuring Before you can work on a car you must find out what is wrong with it You often begin by measuring Fig 3 1 Linear measurements are the most common kind of measurement They are measurements you take in a straight line For example you might measure an opening or a diameter Using the familiar United States Customary System USCS you take measurements in inches or fractions of an inch Using the metric system you ta
4. ke measurements in millimeters centimeters or meters Ail imported and many domestic vehicles are measured with the metric system Chapter 4 describes the USC and metric systems There are other ways to measure Sometimes the measuring is done by listening as when you listen to a running engine When you check the oil in an engine you measure its level in the crankcase You use test instruments to measure battery conditions When you check engine vacuum or compression you measure engine performance The results of your measurements tell you what sort of job you have to do F gt Fig 3 1 Measuring the diameter of an engine cylinder with a steel rule ATW Lyc e polyvalent Section professionnelle N J CUGNOT NEUILLY Marne l Name Business amp Technician Education Council LPo N J Cugnot level A 93 Neuilly Marne Car Operati ar a ii Car Operation amp Maintenance Maintenance option Light Vehicle 2 Disassembling Sometimes the measurements show that there is trouble You then have to disassemble or take apart the component to get at the trouble Suppose your measurements show that the valves are not doing their job You then have to take some parts of the engine off to get to the valves and repair them Fig 3 2 Disassembly is also called tear down For example you disassemble or tear down an engine However you do it carefully part by part iin BOLT gt SPRINGS EXHAUST VALVE m INTA
5. lk to replace means to 3 1 a put back a part that was removed b discard the old part and install a new one c reassemble a component d readjust a part that has been replaced 4 Tools used in the shop include 3 1 a hand tools and powers tools b measuring tools and cutting tools c hand tools and cutting tools d all of the above 5 Fiat rate is 3 4 a the rate in dollars required to do a job b the speed with which you can do a job when working flat out c the time it normally takes to do a service job d all of the above Lyc e polyvalent Section professionnelle N J CUGNOT NEUILLY Marne 6
6. nual Introduction Maintenance Lubrication Chart General Data Engine Tuning Data Engine Workshop Manual Phe ase Ped ES RATS px qudm Lacus Engine Local and territorial requirements lpnitian System Cooling Spuer Fuel System Fue System Evaparative Lows Clutch Gearhax nerdrive Gearbox All Synchromesh Overdrive Type L H Automatic Cerarbox Propeller Shaft Rear Axle and Rear Suspension Three quartes lloating Type Rear Axle and Rear Suspension Sami foating Type Steering Gear a z T Steering Gear Energy Absorbing Column Front Suspension Hydraulic Damper Braking Syriam Braking System Tandem Master Cylinder Electrical System Electrical System Local and Territorial Requirements a Wiring Diagrams Wheels and Tyres Body Local and Territorial Requirements Service Toms Recommended Lubricants Lyc e polyvalent Section professionnelle N J CUGNOT NEUILLY Marne P Boursin LPo N J Cugnot 93 Neuilly Marne SECTION NO 6 6AI GAZ GAT 6B 6c 6C3 6CS 6D 6E1 6EZ 6H 4 End of Manual Leyland Cars Service Ceres Dafesd O84 2PUO0 Engle Name Business amp Technician Education Council LPo N J Cugnot level A 93 Neuilly Marne Car Operati ar a Car Operation amp Maintenance Maintenance option Light Vehicle 3 6 Paperwork You cannot run any kind of business without paperwork and the automotive service business is
7. omer complaint on the repair order together with labor instructions and notes to the mechanic The repair order accompanies the car as it is dispatched or sent to the mechanic assigned to do the service job The mechanic follows the labor instructions on the repair order doing whatever is necessary to repair the car If new parts are needed the mechanic gets them from the parts department To get parts from some parts departments the mechanic presents the mechanic s copy of the repair order to the parts counter attendant The attendant issues the parts and writes the price of each part on the repair order When the job is completed the service writer or service manager writes on the repair order the flat rate time or the time taken by the mechanic to do the job To pick up the car the customer pays the price of the parts plus the price of the mechanic s labor charge and any taxes required by haw 3 Billing Everything is added up on the service order to get the total cost of the repair If the job is to be paid for in cash the driver pays the bill when taking delivery of the car If credit has been established the car owner is sent a bill which should be paid after 50 many days Even here the paperwork does not end When the payment comes in it has to be credited against the car owner s account And if the car owner 1s show to pay letters have to go out asking for payment If the car owner refuses to pay it may be necessary to take legal ac
8. ork on The car manufacturer sets the specs You find the specs 1f the manufacturer s shop manual These specs include valve setting ignition timing piston clearances piston ring clearances and hundreds of other measurements These terms are explained if later chapters Lyc e polyvalent Section professionnelle N J CUGNOT NEUILLY Marne 2 Name Business amp Technician Education Council LPo N J Cugnot level A 93 Neuilly Marne Car Operati ar a ii Car Operation amp Maintenance Maintenance option Light Vehicle 3 3 Manufacturer s service manuals Each year every car manufacturer issues a service manual covering the cars manufactured that year Fig 3 3 Each manual covers all service procedures provides the specs names the tools needed and explains how to do all service jobs on the car models produced that year fp legs a uu 77 7 E gt f Fig 3 3 Manufacturers service manuals supply detailed servicing information on their latest models ATW You should take a careful look at any manufacturer s service manual you get your hands on Note how it is arranged in groups or sections Figure 3 4 shows the section index for a recent Chevrolet service manual Each section is further divided into descriptions of specific components These explain how to fond and repair troubles with those components and list the special tools required to service them Get acquainted with car manufacturers service manuals You will be u
9. s and tool and service equipment manufacturers publish manuals on how to install their parts or use their equipment These publications can be very helpful Lyc e polyvalent Section professionnelle N J CUGNOT NEUILLY Marne j Business amp Technician Education Council Car Operation and Maintenance TABLE OF CONTENTS SECTION NAMIE GENERAL INFORMATION General Information Md4aintenance and Lubrication HEATING AND ATR CONDITIONING level A SECTION NO A B Heating and Ventilation 1A Aur Conditioning 1B Air Conditioning Compressor 1c FRAME AND BUMPERS Frame and Body Mounts ZA Burpers 2B Sheet Metal 2C STERING SUSPENSION WHEELS AND TIRES Diagnosis 3 Front End Aligzenent 3A Manual Steering Gear AH1 Power Steering Rack amp Pinion and Pump AB2 steering Wheels and Columns AB3 Font Suspensi n ac Rear Suspension AD Wheels and Tires AE BRAKES Car Operation amp Maintenance option Light Vehicle SECTION NAME ENGINE Diagnosis L4 Engine V6 Engine Diesel Engine Engine Cooling Engine Fuel EZSE Carburettor Diesel Fuel Injection Engine Electrical Emission Control Systems EFI Electronic Fuel Injection Engine Exhaust Vacuum Purmgs TRANSAXLE Automatic Manual Clutch Drive Axle CHASSIS ELECTRICAL Electrical Troubleshooting Chassis Electrical Instrument Panel and Gages ACCESSORIES METRIC INFORMATION BODY Fig 3 4 Section index tram a recent Chevrolet service ma
10. sing them when you work in the shop Practice using these manuals Look up Engine Transmission and 50 on in a manual Note how each section is divided into specific service jobs 3 4 Flat rate Two ways that automotive mechanics are paid are by fixed income and by flat rate or piecework With a fixed income the mechanic is paid so much per hour or per week When the pay is by flat rate the mechanic earns so much per job Fiat rate tells the number of hours and minutes it normally takes to do a service job Car makers and independent companies print flat rate manuals These are also called time labor standards They list every service job and the amount of time it takes to do the job For example one flat rate manual says that it takes 10 hours to install new piston rings in a certain engine If the labour charge is 3000 per hour the total labour charge for the job is 30000 Many shops divide the labour charge with the mechanic With the right tools the mechanic can often do service jobs in less than the flat rate time Suppose a mechanic does a 10 hour job in 8 hours for example The mechanic would still get paid for 10 hours even though the job actually took less time 3 5 Other useful publications Many automotive service magazines are published They contain information on servicing cars and articles on specific service jobs They often have tips on how to make hard jobs a little easier Testing equipment manufacturers parts maker
11. tion All this is paperwork 4 Other Paperwork The owner or manager of an automotive service business also keeps books of various kinds These include periodic P amp L profit and loss statements employee records general inventories and local state and federal tax records You now have a brief review of the paperwork involved in the automotive service business Whatever type of job you take in the business will involve some paperwork You will learn exactly how to handle your paperwork when you go out into the shop Automotive Mechanics Crosse Angolan Gregg Division McGraw Hill Book Company 1984 source http philippe boursin perso sfr fr europe dnl01 htm Lyc e polyvalent Section professionnelle N J CUGNOT NEUILLY Marne 5 Name Business amp Technician Education Council LPo N J Cugnot level A 93 Neuilly Marne Car Operati ar a Car Operation amp Maintenance Maintenance option Light Vehicle Review Questions Select the one correct best or most probable answer to each question You can find the answers in the section indicated at the end of each question 1 The six steps in automotive service include 3 1 a measuring and disassembling b machining and installing new parts c reassembling and adjusting d all of the above 2 To reinstall means to 3 1 a repair a disassembled part b put back a component or part you have removed c reassemble a component d remove and replace a part 3 In shop ta
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