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Automotive Service

See Note in Table of Contents

2015Florida

Regional ContestTable of Contents

Automotive Service__________________________________________________________________________

School Facilitator Packet --------------------------------------------------------- 3-5

Site and Materials Requirement

Judge’s Packet --------------------------------------------------------------- 6-75

Scoring Directions and Contest

Including Written Test and Key

Grievance Form -------------------------------------------------------------------- 10

Answer Key for Written Test ---------------------------------------------------- 72

Contestant Packet ----------------------------------------------------------------- 76-99

Complete Contest Including Written Test and Answer Sheet

School Instructor Packet --------------------------------------------------------- 100-101

Tools and Equipment Needed by Contestant

Information on Contest

NOTE:

Make copies of pages 31 thru 51 for Station #4 Engine Performance

Florida Regional Contest of 103


Host SchoolFacilitator

Packet



Materials supplied by host school:

Station #1 – General Automotive SkillsCurrent vehicles (2). One with service manual the other with Labor Guide.

Station #2 – Measuremento Small 4 cylinder engine (lower unit)o Feeler guage seto Set of Micrometerso Vernier calipero Plastic guageo Compression tester (not required but nice to have) just adds funo Leak down tester (not required but nice to have)o Dial guageo Bench with viseo Reference material (Shop Manual)o

Station #3 – Electricalo 500 ohm resistoro 1500 ohm resistoro Variable resistoro Starter and specification on starter usingo Volt-Ohmmeter (supply several types, if possible, to accommodate various student

familiarity) o Batteryo Two different wattage light bulbs wired in series to make an electrical circuit for voltage

drop testo Scratch Paper

Station #4 – Engine Performance

The day before the contest:o Print contestant answer sheets a different color for each station.o Print several copies of the Electrical Wiring Diagram (in color if possible) and tape to

tableo Print several copies of the Terminals of ECM.

o Obtain and label the following Components “A” through “D” and make them visible to the contestants. The components must only have the letter A, B, C, or D on them so as NOT to name the component. The contestant should be instructed NOT to pick up or test these components..

Component “A” 4 wire Oxygen sensor Component “B” Fuel Injector (top feed type, i.e. fuel rail on top, manifold

on the bottom) Component “C” Gas cap (from vehicle 1996 or newer) Component “D” EGR Valve (prefer vacuum diaphragm type)



Station #5 – Brakes Anti-Lock brake assembly on or off the vehicle tag. Brake Master Dissemble and part tag. Brakes shoe to drum gauge. Micrometer Drum micrometer gauge. Steel rulers Brake rotor to measure for parallelism (on or off vehicle) if possible has a bad rotor. Measure the rotor, record on judge’s sheet. Have factory specifications for the rotor you are using. Measure the brake drums, record answer on judge’s sheet Have factory specifications for drums. Measure the brake shoes, record your answer on the judge’s sheet. Have factory specifications for brake shoes.

Station 6. – Air Conditioning Vehicle with A/C A/C manifold gauges Thermometer Coolant Hydrometer Coolant Heater valve Thermostatic

Station 7. – Manual Transmission Equipment: 2 Honda Manual Transmissions Hand Tools: 2 Micrometers

2 Vernier Calipers2 Feeler Gauges

Contest Set-up

This is a 8-station contest.

Station #8 is the written test Stations #1 thru #7 will be at benches/work areas

Provided by Regional Coordinator:

Judges - copy of contest, answer sheet for written test, and scoring sheets. Contestants - all contest documents (Written Test and Practical task sheet(s).

Supplied by the Contestant:

Pen or Pencil All safety equipment for the job (i.e. goggles, safety shoes, etc), One page computer generated resume.

Observers: Provide area for observers.



Judges Packet



Project InformationSkill Performance

The contest will include a series of workstations. Workstations consist of a vehicle and/or simulators, components and service publications.

Contest Guidelines

A variety of vehicles sold in the United States will be used in the contest. This will include both domestic and imported vehicles.

Some or all of the high school work stations may be different than the college/postsecondary work stations.

Safety, quality, ability to follow instructions and procedures, accuracy (in comparison with factory specifications), workmanship, and other skills representative of the trades identified by industry leaders will be judged.

A total of eight to 15 stations will be assigned. Each station must be broken down into specific task criteria and separate steps based on the task. For example:

Station No. 1 Wire test and repair segments Identify faulty circuit = x points Repair condition = x points Assemble/retest = x points Resistor board tests = x points Compare values to specs = x points Workmanship = x points Safety practices = x points

The points allowed for each station will be assigned by the national technical committee and will be based on the difficulty of each assigned task.

Time limits will be assigned for each task, but no bonus points will be awarded for early completion.



JUDGES GENERAL INSTRUCTIONS - REGIONAL and STATE SkillsUSASkill and Leadership Contests

Thank you for giving your time and talent to evaluate our students. Your evaluation of their performance will assist them in their drive to become successful in their chosen occupation.

l. Please remember that the contestants are students with job entry level skills. Please judge them accordingly.

2. Allow time to orient all contestants prior to the contest. Have students draw for a demonstration time. (Post the times)

3. Make sure that each student has an I.D. badge with their contestant number showing. Don't ask student their names or school they are from. Use the contestant list provided to you, to check off the students present. Do not assign contestant I.D.’s to any student that is not on the list. Immediately contact the Regional Coordinator.

4. If a student arrives late, IF POSSIBLE, allow them to start the contest. They will not be allowed extra time unless the Regional Coordinator gives the OK.

5. There are to be no Cell phones in the contest area.

6. If contestants need assistance in bringing equipment into room, 1 person can help them but in no case can any other person assist them in setting up.

7. Select or appoint a head judge who will oversee the contest and be responsible for tallying and certifying the contest rules.

8. Select a judge to keep time and notify the contestant of the time remaining.

9. You are to judge every contestant.

10. Familiarize yourself with the score sheet. The point ranges shown are possible points andyou should give the number of points you feel are deserved. Remember to judge on the basisof entry level skills.

11. Do NOT discuss your scoring with anyone. This includes other judges, contestants, or advisors. Results should be kept confidential. Do not discuss who #l, 2, 3 should be - use the tallies from the score sheets as given. Only the head judge deducts timing, clothing, and Resume penalties.

12. DO NOT allow contestants to talk to ANYONE except other judges. Contestants should not leave the contest or holding area for any reason. No advisors or teachers will be allowed to speak with contestants or to be in the contest or holding area EVER. If there is a problem with advisors, contact the regional coordinator or state director at once.

13. Be consistent in your judging

14. THERE ARE NO TIES when awarding 1st, 2nd, and 3rd place. Remember if contestants have an equal score, the judges must refer to the score obtained on the SkillsUSA knowledge



test to break the tie. It is not necessary to select a medal winner if no contestant scores 70% or higher of the possible points for the contest.

15. Judges are not to alter or change the contests or score sheets. All written materials; score sheets, judge’s sheets, written tests, etc., should be placed in a large manila envelope and turned in to the contest coordinator at the conclusion of the contest.

16. There are no uniform or clothing requirements for the regional contests. However, safety items including safety glasses, hard hats, work shoes, etc., will be mandatory as required. Cosmetology contestants must wear the proper clinical shoes - no high heels allowed.

17. If any problems arise, notify the regional coordinator or the state director.

18. If one contestant discovers an error in the contest or any other problem that needs a judges’ help, it should be shared with all contestants.

19. No judge or facilitator may disqualify ANY contestant without the expressed permission of the regional coordinator or state director.

20. Resumes shall be collected at orientation, a fifty point deduction of the total contestant score shall be made if the contestant fails to provide a one page resume.

NOTE:

If a contestant feels that a rule violation occurred during the contest, the contestant may file a grievance. The grievance form may be obtained from the head contest judge and must be returned to same. The head judge must accept the grievance and must make a ruling on the grievance.

If the head judge cannot rectify the grievance to the satisfaction of the contestant, then and only then may the contestant ask that the grievance be presented to the official grievance committee for consideration.

All grievances must start with the head judge of each contest while the contest is in progress. Time missed while making a grievance report to the judge will be given to the contestant to complete his/her contest without penalty.No grievances will be filed after the contests are concluded.

Final interpretations of all contest rules will be made by the Florida State Director or the Regional Coordinator at the regional contests.



FLORIDA SkillsUSAGRIEVANCE FORM

Grievances:

A Grievances will be accepted for a Rule Violation only Procedure for filing a Grievance:

1. Only contestants may file grievances. No Advisors or Spectators . 2. Grievances must be filed DURING the Contest with the LEAD (Head) Judge prior to the

ending of the Contest. The Contestant ONLY must file grievances!! The Contestant may only file a Grievance based on a rule infraction, which impacts ONLY the Contestant.

Final interpretations of all contest rules will be made by the Florida State Director or the Regional Coordinator at the regional contests.

Contestant Number: _____ Contest being grieved: __________________

Describe the Rule Violation: _____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Contestant Signature: ______________________________

Advisor Signature: ________________________________

Lead Judge Signature: _____________________________

Resolution by Grievance Committee: _________________

Committee Chair Signature: ________________________Date: _________




Station #1 – General Automotive SkillsCurrent vehicles (2). One with service manual the other with Labor Guide.

Station #2 – Measuremento Small 4 cylinder engine (lower unit)o Feeler gauge seto Set of Micrometerso Vernier calipero Plastic gaugeo Compression tester (not required but nice to have) just adds funo Leak down tester (not required but nice to have)o Dial gaugeo Bench with viseo Reference material (Shop Manual)o

Station #3 – Electricalo 500 ohm resistoro 1500 ohm resistoro Variable resistoro Starter and specification on starter usingo Volt-Ohmmeter (supply several types, if possible, to accommodate various student

familiarity) o Batteryo Two different wattage light bulbs wired in series to make an electrical circuit for voltage

drop testo Scratch Paper


The day before the contest:o Print contestant answer sheets a different color for each station.o Print several copies of the Electrical Wiring Diagram (in color if possible) and tape to

tableo Print several copies of the Terminals of ECM.

o Obtain and label the following Components “A” through “D” and make them visible to the contestants. The components must only have the letter A, B, C, or D on them so as NOT to name the component. The contestant should be instructed NOT to pick up or test these components..

Component “A” 4 wire Oxygen sensor Component “B” Fuel Injector (top feed type, i.e. fuel rail on top, manifold

on the bottom) Component “C” Gas cap (from vehicle 1996 or newer) Component “D” EGR Valve (prefer vacuum diaphragm type)



Station #5 – Brakes Anti-Lock brake assembly on or off the vehicle tag. Brake Master Dissemble and part tag. Brakes shoe to drum gauge. Micrometer Drum micrometer gauge. Steel rulers Brake rotor to measure for parallelism (on or off vehicle) if possible has a bad rotor. Measure the rotor, record on judge’s sheet. Have factory specifications for the rotor you are using. Measure the brake drums, record answer on judge’s sheet Have factory specifications for drums. Measure the brake shoes, record your answer on the judge’s sheet. Have factory specifications for brake shoes.

Station 6. – Air Conditioning Vehicle with A/C A/C manifold gauges Thermometer Coolant Hydrometer Coolant Heater valve Thermostatic

Station 7. – Manual Transmission Equipment: 2 Honda Manual Transmissions Hand Tools: 2 Micrometers

3 Vernier Calipers3 Feeler Gauges

Contest Set-up

This is a 8-station contest.

Station #8 is the written test Stations #1 thru #7 will be at benches/work areas

Provided by Regional Coordinator:

Judges - copy of contest, answer sheet for written test, and scoring sheets. Contestants - all contest documents (Written Test and Practical task sheet(s).

Supplied by the Contestant:

Pen or Pencil All safety equipment for the job (i.e. goggles, safety shoes, etc), One page computer generated resume.

Observers: Provide area for observers.AT THE START OF THE CONTEST:



Check off students present, by verifying their contestant number against your sheet. Have students draw for a rotation position. Collect Resume’s from students. All students will be given time to familiarize their selves with the schools tools and

equipment.

TASK:

This is a station contest. Written Test on general knowledge7 work stations including written test (i.e. general, brakes, engine performance, A/C, etc)

Refer to page 7 for conducting the Skills Performance and Contest Guidelines and page 14 for the contest directions.



Practical ProblemDirections for conduction contest

All stations run the same length of time (15 minutes). The head judge (or a designated timer) will start each round. Contestants will rotate stations (based on a predetermined drawing) in regular time intervals.

Upon completion of the station, collect the response sheet. Award only the point value indicated on the form. Do not give partial credit in any area. Make sure the contestant’s number is on the form.

At the end of each station cycle the judge should grade the answer sheet, total the score and then wait for someone to pick up the scored answer sheet. Do not let the contestant see the graded sheet. If any questions come up as far as grading contact the head judge.

Contestants will record all answers on the answer sheet provided.

Station 1. – General Skills

General Automotive Skills

Station 2. - Measurement

Competitors will be required to measure connecting rod end play using the appropriate measuring tool; measure the bore of a cylinder at X and Y axes in six places again using appropriate tools. Finally, take piston to bore measurement at the right place in the cylinder block.

Competitors will wear safety glasses Scoring criteria is included on score sheet, award points only as directed. Judges must become familiar with the instruction sheet, the work sheet, the score

sheet and the reference materials. Judges must watch the competitor closely to check proper use of tools

Station 3. – Electrical

Arrange all items on bench for questions.

Question 1, 2, and 3 the contestant will measure the resistance of the resistors. Questions 4, 5, 6, and, the contestant will identify the electrical symbols. Questions 8,9,10, and 11, the contestant will perform continuity, short, and open or ground

tests on the starter. Question 16 the contestant will calculate the voltage using ohms law.



Station 4. - Engine Performance

Obtain and label the following Components “A” through “D” and make them visible to the contestants.

The components must only have the letter A, B C or D on them so as to NOT to name the component.

The contestants should be instructed NOT to pick up or test these components.

o Component “A” 4 wire Oxygen sensor o Component “B” Fuel Injectoro Component “C” Gas capo Component “D” EGR Valve

Station 5. – Brakes

Anti-Lock brake assembly on or off the vehicle tag. Brake Master Dissemble and part tag. Brakes shoe to drum gauge. Micrometer Drum micrometer gauge. Steel rulers Brake rotor to measure for parallelism (on or off vehicle) if possible has a bad rotor. Measure the rotor, record on judge’s sheet. Have factory specifications for the rotor you are using. Measure the brake drums, record answer on judge’s sheet Have factory specifications for drums. Measure the brake shoes, record your answer on the judge’s sheet. Have factory specifications for brake shoes.

Station 6. – Air Conditioning

o Vehicle with A/Co A/C manifold gaugeso Thermometero Coolant Hydrometero Coolanto Heater valveo Thermostatic

Station 7. – Manual Transmission Inspectiono Honda Manual Transmissions

Station 8. – Written Testo The test is to be administered in a room separate from the holding room. It can be done in

the shop at a bench or desk.



Station #1 (part 1)General Automotive Skills – Contestant Worksheet

Using the service manual supplied and the information givenBelow, answer the following questions.

1998 Chevrolet 5-10 Pickup4.31V-6

1. Spark Plug Gap

2. Firing Order

3. Valve Spring Free Length

4. Rod Side Clearance

S. Balance Shaft Retainer Bolt

Using the labor guide, labor calculation chart and informationgiven below, answer the following questions

1988 Chrysler Lebanon

Engine: 3.0 liter with air conditioning

6. Determine the flat rate time allowed to renew the water pump.

(don't give factory time)

7. A repair facility charges of $60.00 per hour. The technician isallowed 2.3 hours to renew a compressor shaft seal.

What is the total Labor charge?

8. A heater core costs $96.00. Determine the cost when a seven

Percent sales tax is added.

9. Measure the diameter of this bolt. (cap screw)

10. Measure the threads per Inch using the thread pitch gauge.

Contestant # __________



Station #1 (part 2) General Automotive Skills – Contestant Worksheet

11. Determine the tensile strength (grade) of this bolt (cap screw)Using the oil container supplied, answer the following questions.

Using the 011 container supplied, answer the following questions.

12. Determine the viscosity rating of this 011.

13. Determine the API rating of this oil.

14. What does SAE mean

Conversion

15. Convert 3/64 inch to millimeters _mm

16. S.9S3mm to inches _in.

17. Convert" inch to thousands - 18. Convert.75O thousands of an inch to

inches _in.

19. 10 foot-pounds to - Newton meters _Nm

20. 10 Newton meters to - Foot pounds _ft-Ib

Total Score (150)




Station #1 (part 1) General Automotive Skills – Judges Answer Key


Vehicle _____________________Engine _______________________

1. Spark Plug Gap 6

2. Firing Order 6

3. Valve Spring Free Length 6

4. Rod Side Clearance 6

5. Balance Shaft Retainer Bolt 6


Vehicle _____________________

Engine _______________________

6. Determine the flat rate time allowed to renew the water pump. 8

(don't give factory time)

7. A repair facility charges of $60.00 per hour. The technician is 8allowed 2.3 hours to renew a compressor shaft seal.

What is the total Labor charge?

8. A heater core costs $96.00. Determine the cost when a seven 8

Percent sales tax is added.

9. Measure the diameter of this bolt. (cap screw) 8

10. Measure the threads per Inch using the thread pitch gauge. 8



Station #1 (part 2) General Automotive Skills – Judges Answer Key

11. Determine the tensile strength (grade) of this bolt (cap screw) 8Using the oil container supplied, answer the following questions.


12. Determine the viscosity rating of this 011. 8

13. Determine the API rating of this oil. 8

14. What does SAE mean 8

Conversion

15. Convert 3/64 inch to millimeters _mm 8

16. S.9S3mm to inches _in. 8

17. Convert" inch to thousands - 8

18. Convert.75O thousands of an inch to inches _in. 8

19. 10 foot-pounds to - Newton meters _Nm 8

20. 10 Newton meters to - Foot pounds _ft-Ib 8

Total Score 150



Station #2 Measurement – Contestant Worksheet

Perform the following on the engine and components provided.

Points Awarded

1. Measure and record the connecting rod end play .002” ______ ______

2. Record the connecting rod specifications service limit ______ ______

3. Measure and record the cylinder bore on #1 cylinderX 1________ 2__________ 3_________ ______Y 1________ 2__________ 3_________ ______

4. Record the cylinder bore specification service limit ______ ______

5. Measure and record piston diameter. ______ ______

6. Record piston diameter specifications service limit. ______ ______

7. Measure and record piston-to-block clearance on #4cylinder .002” ______ ______

8. Record piston-to-block specification service limit. ______ ______

9. Measure and record ring-to-land clearance .002”. ______ ______

10. Record ring-to-land specification service limit. ______ ______

11. Safety procedures followed? ______ ______

TOTAL POINTS (150) ______




Station #2 Measurement – Judges Answer Key


Points Awarded

1. Measure and record the connecting rod end play .002” ______ ___10__

2. Record the connecting rod specifications service limit ______ ___10__

3. Measure and record the cylinder bore on #1 cylinderX 1________ 2__________ 3_________ ___30__Y 1________ 2__________ 3_________ ___30__10 point per answer possible of 30 points x or y axis

4. Record the cylinder bore specification service limit ______ ___5__

5. Measure and record piston diameter. ______ ___10__

6. Record piston diameter specifications service limit. ______ ___5__

7. Measure and record piston-to-block clearance on #4cylinder .002” ______ ___10__

8. Record piston-to-block specification service limit. ______ ___5__

9. Measure and record ring-to-land clearance .002”. ______ ___10__

10. Record ring-to-land specification service limit. ______ ___5__

11. Safety procedures followed? ______ __ 20__

TOTAL POINTS AWARDED ___150_



Station #3 (part1)Electrical – Contestant Worksheet

1. Identify the type of circuit: switch to ground_____ load to ground_____

2. If the current flow at point 1 is 2 amps, predict the current flow at: point 3?_____ point 4?_____ point 5?_____ ______ 3. Write the principle that explains your answer: ___________________________________________________ ___________________________________________________ ______

4. Predict the voltage at point 5: _______ ______ 5. Write the principle that explains your answer: ___________________________________________________ ___________________________________________________ ______

Identify the following symbols;

6. ______

7. ______

8. ______

9. ______

Set the DMM to the scale to measure 12v DC.

With the switch OFF, measure the voltage drop between the following points.10. points 2&3______ points 4&5______ ______

With the switch ON, measure the voltage drop between the following points. 11. points 1&2______ points 2&3______

Points 3&4______ points 4&5______ ______




Station #3 (part 2)Electrical – Contestant Worksheet

When working with Ohm’s Law or electrical circuits:12. E is the symbol for _______________

I is the symbol for________________

R is the symbol for________________ ______ 13. With steady voltage, if the resistance in a circuit increases, Current flow will ________________ ______

14. Ohm’s Law states that Voltage = ________________________

15. If the voltage at point 3 is 8 volts with the switch ON, what does that indicate? Circle your choice.

(a) The circuit is normal. (b) Open after point 3. (c) Circuit is good up to point 3. (d) Resistance before point 3. ______

16. If the voltage at point 4 is 6 volts with the switch ON, What does that indicate? Circle your choice. (a) The circuit is normal. (b) Circuit is open at point 5. (c) Switch is open. (d) Resistance at points 4 and 5. _______

Set the DMM to measure resistance. Set the Trouble Box to position “A” and measure resistance. Repeat for positions “B” “C” and “D”.

17. (A) ___________ (B) ____________

(C) ___________ (D) ____________ _______

Using Ohms Law, find the amperage for the following circuit.

18. Amperage _______ _______ Resistance 1.66 Voltage 12.5





Station #3 (part 1) Electrical – Judges Answer Key

1. Identify the type of circuit: switch to ground_____ load to ground_____ 6

2. If the current flow at point 1 is 2 amps, predict the current flow at: point 3?_____ point 4?_____ point 5?_____ __ 9___ 3. Write the principle that explains your answer: ___________________________________________________ ___________________________________________________ ___15___

4. Predict the voltage at point 5: _______ ___3___ 5. Write the principle that explains your answer: ___________________________________________________ ___________________________________________________ ___15___


6. __5___

7. ___5___

8. __5___

9. __5___


With the switch OFF, measure the voltage drop between the following points.10. points 2&3______ points 4&5______ ___10___


Points 3&4______ points 4&5______ ___16___



Station #3 (part 2) Electrical – Judges Answer Key



R is the symbol for________________ ___18___ 13. With steady voltage, if the resistance in a circuit increases, Current flow will ________________ ___5__

14. Ohm’s Law states that Voltage = ________________________ ___5__


(a) The circuit is normal. (b) Open after point 3. (c) Circuit is good up to point 3. (d) Resistance before point 3. __5____

16. If the voltage at point 4 is 6 volts with the switch ON, What does that indicate? Circle your choice. (a) The circuit is normal. (b) Circuit is open at point 5. (c) Switch is open. (d) Resistance at points 4 and 5. ___5___


17. (A) ___________ (B) ____________

(C) ___________ (D) ____________ __16___


18. Amperage _______ ___7___ Resistance 1.66 Voltage 12.5




Station #4 (page 1)Engine Performance – Contestant Worksheet

Directions: The judges will tell you when to begin. Record your answers on the answer sheet provided. There are 17 questions for a possible 100 points. Use the Electrical Wiring Diagram and the Terminals of the ECM reference as needed to answer the questions. For questions 10 to 16 FOUR components labeled “A” through “D” are available for you at a nearby table (do not touch these items). For all DVOM readings (except when directed otherwise) the dial is on DC VOLTS, the BLACK LEAD is grounded, and the RED LEAD is at the point mentioned.

1. After replacing a coolant temperature sensor you notice that the scanner information indicates that a permanent DTC is recorded. When the engine is running the Check Engine light is off. What would be your next move and why?

Use the answer sheet to record your answer

2. With the Key on, Engine off, and the fuel injector connected, what should be the voltage reading at the YELLOW wire at the number THREE fuel injector?


3. If the crankshaft rotates 4 complete revolutions, how many Cam Shaft Position Sensor signals does the ECM receive?





4. Terminal 53 on the ECM Connector”C24” normally toggles from 0 volts to 5 volts. What condition (driver action) causes the voltage to go to 5 volts?


5. With the vehicle running, .3 volts is recorded at terminal 5 of the Fuel Pump connector. How might this effect Fuel Trim?


6. Based on the scanner data below (figure #1) and the information provided what part needs replacing? In figures #2 & 3 the data is recorded after the sensor is disconnected.


Figure #1




Question 6 Continued

Figure #2

Figure #3




7. What type of current (AC or DC) would you find what terminals 121 and 122 of ECM connector C24 while the vehicle is running?


8. The customer states that the Check Engine light is on and that the brake pedal is very hard to push. You note that a DTC PO171 (system too lean bank 1), you clear the code, and it does not immediately come back. Based on the scanner data below and the customer’s concern, what would you inspect or suspect as the problem?


Figure #1

9. Which two parts might set a DTC P0303? A bad VSV purge solenoid, a bad fuel injector, an open Air Fuel Ratio, a bad ignition coil, or a bad camshaft timing control valve.


10. Use the electrical wiring diagram as a reference for this question. Component “A” is designated B1S2. A DTC P0037 HO2S Heater Control Circuit Low (Bank 1 Sensor 2) was set. Using an ohmmeter the resistance of wires (terminals 1 & 2) of Component “A” and get an “OL” reading? What do you need to do to repair the vehicle.





11. Component “A” is designated B1S2. Where is it located on the vehicle?Use the answer sheet to record your answer

12. If the TOP “O” ring is split on component “B” what will leak?Use the answer sheet to record your answer

13. If the BOTTOM “O” component “B” ring is split what will leak?Use the answer sheet to record your answer

14. Component “C” is part of the _____________ emission system of the Vehicle?Use the answer sheet to record your answer

15. If component “D” is stuck closed what harmful exhaust emission will increase?Use the answer sheet to record your answer

16. If component “D” is stuck open what will be the biggest complaint?Use the answer sheet to record your answer

17. What FIVE gasses does a 5 gas emission analyzer measure?Use the answer sheet to record your answer

1. Oxygen2. _______________3. _______________4. _______________5. _______________



StatFlorida Regional Contest of 103


Station #4 (page 6)Engine Performance – Contestant Answer Sheet

1 5

2 5

3 5

4 5

5 5

6 5

7 5

8 5

9 5

10 5

11 5

12 5

13 5

14 5

15 5

16 5

17A 5

17B 5

17C 5

17D 5

TOTAL POINTS 100

Contestant # __________Florida Regional Contest

of 103


Station #4Engine Performance – Judges Answer Key

1The vehicle needs to be driven or an equivalent statement. Explanation: A specific drive cycle and/or a combination of drive cycles is needed. The permanent code will erase itself if the repair is confirmed and the original problem that set the code is corrected.

5

2 Source voltage, B+ or 12 volts etc. 5

3Six (three signals per two crankshaft revolutions) Explanation: Vehicles with variable valve timing need more than one signal per camshaft revolution. This is shown in the scope pattern of the cam sensor in the terminals of the ECM reference.

5

4 Turning the steering wheel 5

5 Since there is high resistance in the fuel pump circuit the fuel pump may not attain the proper pressure causing the FUEL TRIM to be POSITIVE 5

6 Mass Sir Flow Meter (the intake air temperature sensor is built into the MAF). The student must figure this out by the wiring diagram. Intake air Temperature sensor is NOT acceptable 5

7 AC or Alternating Current 5

8

The brake booster or the brake booster vacuum hose/source or a broken break booster check valve, etc. Explanation: There is a large vacuum leak indicated by the 203 Short Term Fuel Trim. Since the brake pedal is hard (it uses engine vacuum for power assisted brakes) the obvious next step is to inspect the condition of the brake booster vacuum hose.

5

9 A bad fuel injector a bad ignition coil Explanation: P0303 is a cylinder misfire code for cylinder #3. Only these 2 parts on the list will cause a misfire of only one cylinder. 5

10 Replace the Component “A” or replace B1S2 HO2S Explanation: The heater in the sensor is open so it set the P0037 code. 5

11 Behind the Catalytic Convertor (implied screwed into the exhaust pipe) 5

12 Fuel 5

13 Vacuum (air) 5

14 EVAP or Evaporative 5

15 NOx or Nitrogen Oxides or Oxides of Nitrogen (Nitrous oxide is NOT acceptable) 5

16 Vehicle stalls, poor or no idle, (large vacuum leak) 5

17A 17A to 17D any order is acceptable HC (Hydrocarbons) 5

17B NOx or Nitrogen Oxides or Oxides of Nitrogen (Nitrous oxide is NOT acceptable) 5

17C CO (Carbon Monoxide) 5

17D CO2 (Carbon Dioxide) 5

TOTAL POINTS 100



Station #5Brakes – Contestant Worksheet

1. Identify the components on the bench:

A. ______________________ _____ (8)

B. ______________________ _____ (8)

C. ______________________ _____ (8)

D. ______________________ _____ (8)

2. Measure the rotor for parallelism and record your findings:

A. ______________________ E. _________________________ _____ (8)_____(8)

B. ______________________ F. _________________________ _____ (8)_____(8)

C. _______________________ G. _________________________ _____ (8)_____(8)

D. _______________________ H. _________________________ _____ (8)_____(8)

3. With your findings from question #2, what is the thickness variation,

_______________? Is it within Specifications? Yes_____ No _____ _____ (8)

4. What part of the Disc Brake Caliper causes the piston to move backward

after the brakes are released?

_____________________________________ _____ (8)

5. Check the brake drum inside diameter with inside micrometer or brake

drum micrometer and compare to specifications.

________________________________________ _____ (18)

6. Measure the thickness of the brake shoes lining and compare to

________________________________________ _____ (12)

7. With the answer to question#6, are these brakes within specifications?

Yes _____ No _____ _____ (8)

Total Points (150) ______




Station #5Brakes – Judges Answer Key


E. ___ABS assembly______ _____ (8)

F. ___Secondary seal on the primary piston of master cylinder__ _____ (8)

G. ___Combination valve___ _____ (8)

H. ___Brakes shoe to drum guage _____ (8)


A. ______________________ E. _________________________ _____ (8)_____(8)

B. ______________________ F. _________________________ _____ (8)_____(8)

C. _______________________ G. _________________________ _____ (8)_____(8)

D. _______________________ H. _________________________ _____ (8)_____(8)





_____________________________________ _____ (8)



________________________________________ _____ (18)


________________________________________ _____ (12)


Yes _____ No _____ _____ (8)




Station #6Air Conditioning – Station Set-up

For question #3: The answer is for some model vehicles, it will be different depending on thevehicle you are using, so change the answer on the judges sheet to matchthe vehicle you are using.

For Questions #4,5, & 6: On the vehicle or your choice, install the air conditioning gauges. These can be a problem and can cause bad readings.

Bugs: Install a restriction in the line before the evaporatorRestrict the air flow over the condenserSlightly open both valves on gauges causing low pressure, high and low

Depend on the bug you are doing when you answer for the judges sheet.

For question #7: Label heater valve and thermostat.



Station #6Air Conditioning – Contestant Worksheet

1. On the vehicle, locate and name the component that changes high gas into high liquid and by doing this operation what is removed from the refrigerant? Location ___________________ Component ______________ Removed from ____________ (16 x 3) 32 ______

2. The air conditioning system is divided into two sections high and low. Which two components of the air conditioning divide the system into high and low pressure and what is the state of the refrigerant in both com[opponents? High Component _______________ Refrigerant state ______________ 14 ______ Low Component _______________ Refrigerant state ______________ 14 ______

3. On the vehicle, locate and name the component that removes the latent heat From interior.

Location _______________ Component ____________________ 14 ______

Start the vehicle up and run a performance check (questions 4-6) on the Air Conditioning system.

4. Record your findings on the high side _____________ and record Your findings on the low side ___________. 14 ______

5. Measure and record the temperature at the center dash vent ________ 7 ______

6. With the information from question 4 & 5 does this vehicle pass the performance test according to the manufacture? Yes ______ No _______ 7 ______

Complete this section with the materials supplied on the work bench.

7. Identify the components on the work bench and record your answers below.

1. ___________________ 2. ______________________ 14 ______

8. The heater valve is open and closed by what means. Record your answer below.

_________________________________________ 16 ______

Possible Points (150) ______




Station #6Air Conditioning – Judges Answer Key

1. On the vehicle, locate and name the component that changes high gas into high liquid and by doing this operation what is removed from the refrigerant?

Location _in front of radiator______

Component _condenser______ Removed from _heat______ (16 x 3) 32 ______

2. The air conditioning system is divided into two sections high and low. Which two components of the air conditioning divide the system into high and low pressure and what is the state of the refrigerant in both com[opponents? Component _compressor____ Refrigerant state _high/low gas_____ 14 ______ Component _expansion valve Refrigerant state _high/low liquid___ 14 ______


Location _right side of dash__ Component _evaporator________ 14 ______







1. ___________________ 2. ______________________ 14 ______


_vacuum or cable or electrical motor_____________ 16 ______




Station #7Manual Transmission Inspection

Judges Information

Preparation Sheet

Equipment: 2 Honda Manual Transmissions

Hand Tools: 2 Micrometers4 Vernier Calipers4 Feeler Gauges

Additional operations, comments, safety concerns and specific instructions.

Competitor will be required to use different types of measurement tools, proper care should be demonstrated by competitor. Make sure the tools are calibrated prior to the contest.

Competitor must wear safety glasses when working at the bench but can remove to read shop manual.

Scoring criteria is included on score sheet, award points only as directed.

Judge must become familiar with instruction sheet, work sheet, and score sheet and reference materials.

Judge must complete the Judge Reference Sheet prior to the contest.

* Judges Notes: Return the station back to original condition before the next contestant arrives.*



Station #7 (Page 1)Manual Transmission – Contestant Worksheet

Operation #1:

A. Locate the transmission serial number on the transmission. List the letters and numbers (from the transmission number) that designate the transmission type: (2) _______________________________.

B. List the model year that corresponds to these letters which

were taken from the vehicle identification number. (2) J.________ (2) K________ (2) L.________

C. On transmissions with cable operated shifters one caution is always brought out in the service manual. What is it? (2) ___________________

_______________________________________________________________________

D. What one universal tool is suggested for transmission removal in every procedure? (2) ___________________

_______________________________________________________________________

E. If you forget to do this step before you pull the transmission, you may regret it when you remove the transmission housing. What is it? (2) ___________________

_______________________________________________________________________




Operation #2:

A. How would you identify a “B” style transmission? (2) ______________________

B. What type of oil does the “B” style transmission use? (2) ______________________

C. What measurements, if any, must be taken before removing the transmission shafts from the case?

(4) A. ________ Your reading ___________ Limit _________

(4) B. ________ Your reading ___________ Limit _________

D. What must be done to the screws on the bearing retainer plates after they are reinstalled? (2) ______________________

________________________________________________________________________

Operation #3:

A. Record your synchro-to-gear clearances: (1) 1st __________,

(1) 2nd __________,

(1) 3rd __________,

(1) 4th __________,

(1) 5th __________

B. Service Limit: (2) ___________________

C. Are all the synchro-to-gear clearances acceptable? (3) ___________________




Operation #4:

A. What safety precautions must be observed when removing the shift rod? (2) _____________________

_______________________________________________________________________

B. Measure the differential pinion gear backlash? (2) _____________________.

C. Is your measurement within service limits? (2) _____________________

Operation #5

A. As the clutch friction disc wears, clutch pedal free play (2) _____________________.

B. As the clutch friction disc wears, clutch pedal effort (2) _____________________.

C. Excessive pedal effort can be caused by the throw out bearing not sliding freely on its shaft.

(2) True _______ False _______

Total Points for Transmission (50) _________



Station #7 (Page 1)Manual Transmission – Judges Answer Key

Operation #1:

F. Locate the transmission serial number on the transmission. List the letters and numbers (from the transmission number) that designate the transmission type: (2) _______________________________.

G. List the model year that corresponds to these letters which


H. On transmissions with cable operated shifters one caution is always brought out in the service manual. What is it? (2) ___________________

_______________________________________________________________________

I. What one universal tool is suggested for transmission removal in every procedure? (2) ___________________

_______________________________________________________________________

J. If you forget to do this step before you pull the transmission, you may regret it when you remove the transmission housing. What is it? (2) ___________________

_______________________________________________________________________




Operation #2:

E. How would you identify a “B” style transmission? (2) ______________________

F. What type of oil does the “B” style transmission use? (2) ______________________

G. What measurements, if any, must be taken before removing the transmission shafts from the case?



H. What must be done to the screws on the bearing retainer plates after they are reinstalled? (2) ______________________

________________________________________________________________________

Operation #3:

D. Record your synchro-to-gear clearances: (1) 1st __________,

(1) 2nd __________,

(1) 3rd __________,

(1) 4th __________,

(1) 5th __________

E. Service Limit: (2) ___________________

F. Are all the synchro-to-gear clearances acceptable? (3) ___________________




Operation #4:

D. What safety precautions must be observed when removing the shift rod? (2) _____________________

_______________________________________________________________________

E. Measure the differential pinion gear backlash? (2) _____________________.

F. Is your measurement within service limits? (2) _____________________

Operation #5


D. As the clutch friction disc wears, clutch pedal effort (2) _____________________.

E. Excessive pedal effort can be caused by the throw out bearing not sliding freely on its shaft.

(2) True _______ False _______




Station #8Written Test

DO NOT write in this test. Mark your answers on the sheet provided

Multiple ChoiceIdentify the letter of the choice that best completes the statement or answers the question.

1. In which type of logic gate must both inputs be “on” to produce an output voltage?a. NOT c. ANDb. NAND d. OR

2. Which of the following is not a maintenance operation that you would perform on a manual transmission?a. Change lubricant c. Adjust shift linkageb. Adjust clutch d. Adjust bands

3. A timing belt. gears, or a chain drives the engine’s camshaft at ____the rotation speed of the crankshaft.a. One-fourth c. Three-fourthsb. One-half d. Twice

4. Each of the following is a type of supercharger, except...a. Rotor c. Reciprocatingb. Centrifugal d. Vane

5. A suspension system element sometimes used to prevent side-by-side axle movement when cornering is called a(n) ______.a. Track rod c. Sway barb. Strut rod d. Control arm

6. In a starting headlight testy, the lights stay bright, but the engine does not crank. What does this indicate?a. A shorted starting motor c. A weak or discharged batteryb. An opening in the starting circuit d. A blown fusible link

7. The relationship of tire height to its width is called its ___________.a. Aspect ration c. Width percentageb. Sidewall/tread ration d. Cross-sectional mass

8. The ____ is a heavy wheel mounted on a rubber ring and keypad to the crankshaft snout.a. Dynamic turner c. Harmonic Balanceb. Oscillation damper d. Vibration snubber

9. If warp age of a block deck exceeds _____, the block must be surface-milled or replaced.a. 0.03 to 0.05 in. c. 0.0003 to 0.0005 in.b. 0.003 to 0.005 in. d. 0.00003 to 0.00005 in.



10. In a cam-in-block engine, the part of the valve train riding directly on the cam is the _____.a. Rocker arm c. Push rodb. Valve lifter d. Plunger

11. All of the following are active sensors except...a. Mass airflow sensor c. Oxygen sensorb. Knock sensor d. Crankshaft sensor

12. The insulating elements positioned between battery plates are known as ____.a. Insert plates c. Insulating gridsb. Separators d. Partitions

13. Technician A says that security systems can usually be worked on without referring to the manufacturer’s technical literature. Technician B says that systems vary so much that using a schematic and technical literature on the specific system is a necessary. Who is right?a. A only c. Both A & Bb. B only d. Neither A nor B

14. The _____ is the component of an air conditioning system that transfers heat from the refrigerant to the outside air.a. Compressor c. Condenserb. Evaporator d. Accumulator

15. The turn signal flasher consists of _____.a. A bimetal strip and heating elementb. A trigger wheel and sensorc. A make/break contact and trembler switchd. A stepping relay

16. A small line of conductive material than can short coil voltage to ground or th the wrong distributor terminal lug is called a(n) ______.a. Shorting track c. Low-resistance channelb. Carbide path d. Carbon trace

17. Which of the following is not one of the safety rules that apply when working with gasoline?a. Always use approved containers for storageb. Soak up and spills with oil treatmentc. Keep any source of hear away from the fuel systemd. Disconnect the vehicle’s battery before starting work

18. The piston is mounted to the rod by the _____.a. Cylinder bolt c. Wrist pinb. Piston Skirt d. Cam lobe

19. The temperature of the exhaust manifold at each exhaust poet can be checked with ____.a. A digital pyrometer c. A sling psychrometerb. An analog heat sensor d. A digital temperature guage



20. Resignation will cause _____ in the engine.a. Ping c. Detonation Knockb. Dieseling d. Spark Knock

21. The signals from an FM radio transmitter have a range of approximately ___ miles.a. 25 c. 50b. 35 d. 65

22. What is the most common cause of freeze plug failure that allows a coolant leak to develop?a. Metal fatigue c. Engine vibrationb. Rusting d. Overheating

23. The amount of space between the teeth of meshing gears to permit heat expansion is referred to as ____.a. Backlash c. Run outb. Preload d. Play

24. To reduce radio static a(n) ____ called a noise suppressor is often used.a. Resistor c. Transformerb. Chip d. Capacitor

25. Which of the following is not part of a simple battery cell?a. Electrolyte d. Neutral Plateb. Negative plate e. Positive platec. Container

26. How many ASE tests must be passed to qualify for Certified Master Automotive Techniciam atatus?a. 3 c. 8b. 5 d. 16

27. Which of the binary numbers below is equal to 6 in the decimal system of notation?a. 0111 c. 0110b. 1110 d. 1111

28. Which basic element of electricity is also described as “electrical pressure?”a. Current c. Resistanceb. Capacitance d. Voltage

29. Which of the following is not a function of the lubrication system?a. Removing contaminants from inside engineb. Reducing friction and wear between moving partsc. Cutting power loss; increasing fuel economyd. Maintaining smooth power flow through drive train

30. A cylinder bore must be precisely measured. Technician A says that the proper measuring tool for this job is a telescoping guage. Technician B says an inside micrometer should be used. Who is right?a. A only c. Both A 7 Bb. B only d. Neither A nor B



31. Which of the following statements about inline diesel injection pumps is not correct?a. There is one pumping plunger for each cylinderb. Plungers are operated by tappets that transfer motion from a camshaftc. Fuel from the inline pump is routed to the distributer pump where it is further

pressurized and distributed to the injectorsd. Rotating control sleeves regulate pump output

32. An electric engine fan is controlled by _____.a. The timing belt c. A thermostatic switchb. An engine speed sensor d. A pressure sensor

33. A process called magnafluxing is used to detect cracks in _____ parts.a. Steel c. Cast ironb. Aluminum d. Composite

34. Technician A says that the shift points of an automatic transmission are determined by the engine rpm. Technician B says that the shift points of an automatic transmission are determined by the engine load. Who is correct?a. A only c. Both A & Bb. B only d. Neither A nor B

35. Which of the following is not a function of a diesel injection pump?a. Meters the correct amount of fuel to each injectorb. Times the injection of fuel to meet speed and load of the enginec. Provides a means of shutting off the engined. Controls the airflow into the engine

36. The tool used to measure small clearances or gaps between parts is called __________.a. Veriner caliper c. Rulerb. Feeler guage d. Hole guage

37. The most common type of windshield washer pump in new cars is a(n) _________ pump.a. Centrifugal c. Rotaryb. Reciprocating d. Diaphragm

38. Technician A says that the ideal, chemically correct fuel mixture is 14parts air to 1 part fuel. Technician B says that 15 parts air to 1 part fuel is the right mixture. Who is correct?a. A only c. Both A & Bb. B only d. Neither A nor B

39. The starter pinion gear engages the _____ to “crank” the enginea. Harmonic Balancer c. Flywheel gearb. Cam gear d. Crankshaft pulley

40. Voltage in the secondary circuit of an ignition system is typically ____ volts.a. 6 c. 15,000b. 12 d. 30,000



41. If the cold light does not flash when checking an electronic fuel injector’s feed circuit, the cause of the problem may be all of the following except _____.a. An open in the wiring c. A faulty injectorb. A bad connection d. A control module problem

42. Which of the following is the least likely place to find the ignition control module of an electronic ignition system?a. Inside the distributer c. Behind the harmonic balancerb. Under the vehicle dash d. on the side of the distributer

43. An automotive ______is a group of related parts that perform a specific job.a. System c. Componentb. Sequence d. Process

44. Power for tools used in the automotive shop in provided by _____.a. Compressed air d. Only a & cb. Hydraulics e. All of the abovec. Electricity

45. Abnormal wear patterns can identify tire problems. Which pattern indicates that the tire was consistently underinflated?a. Wear along outer treat area c. Wear along one edgeb. Wear along the centerline d. Feathering of tread rubber

46. Cylinder _____, or deglazing is normally a part of cylinder block service. a. Grinding c. Boringb. Honing d. Filing

47. A cold-start injector is activated by a(n) _____.a. Control relay c. Oxygen sensorb. Thermo-time switch d. Timing circuit

48. When rebuilding a diesel injector, special ____ cleaning tools must be used to remove carbon deposits without damaging parts.a. Steel c. Fiberglass-reinforcedb. Nylon d. Brass

49. Technician A says that an air bag module should be placed on a workbench with the bag and trim cover facing up. Technician B says that it is safer to place the module with the bag facing down. Who is right?a. A only c. Both A & Bb. B only d. Neither A nor B

50. Ina typical gasoline powered automotive engine, how many piston strokes make up a complets cycle?a. 1 c. 3b. 2 d. 4

End of Written Test. Turn in this test and your answer sheet to the judge.



Answer Sheet

1. _____

2. _____

3. _____

4. _____

5. _____

6. _____

7. _____

8. _____

9. _____

10. _____

11. _____

12. _____

13. _____

14. _____

15. _____

16. _____

17. _____

18. _____

19. _____

20. _____

21. _____

22. _____

23. _____

24. _____

25. _____

26. _____

27. _____

28. _____

29. _____

30. _____

31. _____

32. _____

33. _____

34. _____

35. _____

36. _____

37. _____

38. _____

39. _____

40. _____

41. _____

42. _____

43. _____

44. _____

45. _____

46. _____

47. _____

48. _____

49. _____

50. _____




Judges KEY - Written Test 1.

1. __C___

2. __D___

3. __B___

4. __C___

5. __A___

6. __B___

7. __A___

8. __C___

9. __B___

10. __B___

11. __A___

12. __B___

13. __B___

14. __C___

15. __A___

16. __D___

17. __B___

18. __C___

19. __A___

20. __A___

21. __B___

22. __B___

23. __A___

24. __D___

25. __D___

26. __C___

27. __C___

28. __D___

29. __D___

30. __B___

31. __C___

32. __C___

33. __C___

34. __C___

35. __D___

36. __B___

37. __C___

38. __D___

39. __C___

40. __D___

41. __C___

42. __C___

43. __A___

44. __E___

45. __A___

46. __B___

47. __B___

48. __D___

49. __A___

50. __D___



ITEMS EVALUATED Possible Points

CONTESTANT NUMBER

Station #1 – General Automotive Knowledge

150

Station #2 - Measurement 150

Station #3 - Electrical 150


100

Station #5 - Brakes 150

Station #6 – A/C 150

Station #7 – Manual Transmission

50

Station #8 - Written Test 100

Sub Total (1000)

OSHA, Job Site Safety (Clothing & Tool Use) Penalty range from -1 to disqualification . If proper student does not have the proper safety equipment they will be disqualifiedResume (0 or -50)Clothing Penalty (up to -50)

Total (1000 POSSIBLE)



TALLY SHEET

Please place all judges’ total scores on this sheet. Add the judge’s scores to determine the placement of each student.

Remember you might have secondary (high school) and Post-Secondary (those that have graduated from high school) in the contest. The way to determine is look at their I.D. badge.

If you have both groups you will have winners in each group

Judge Contestant number

#1#2#3#4#5

Total

Place

Judge Contestant number

#1#2#3#4#5

Total

Place



Secondary

3rd Place __________________________________

2nd Place _________________________________

1st Place __________________________________

Post Secondary

3rd Place __________________________________

2nd Place _________________________________

1st Place __________________________________



ContestantPacket



Directions: Have you drawn for your rotation? Have you given your Resume to the judge? Do you have your safety equipment and a pencil/pen? Make sure your contestant number is showing and make sure to put your number on

your work. This is to prevent confusion in judging. If you have a question, let the head judge know before the start of the contest.

You will be scored on the following Criteria.

ITEMS EVALUATED Possible Points

Station #1 – General Automotive Knowledge 150Station #2 - Measurement 150Station #3 - Electrical 150Station #4 – Engine Performance 100Station #5 - Brakes 150Station #6 – A/C 150Station #7 – Manual Transmission 100Station #8 - Written Test 50

Total Possible Points 1000

--------Think Safety--------1. Upon completion and the judges give you the OK, you can leave the area.

*****Remember Safety is always a priority*****



Station #1 (part 1)General Automotive Skills – Contestant Worksheet


Vehicle ________________ Engine Size_________________

1. Spark Plug Gap

2. Firing Order

3. Valve Spring Free Length

4. Rod Side Clearance

S. Balance Shaft Retainer Bolt


Vehicle _________________ Engine _______________ liter with air conditioning

6. Determine the flat rate time allowed to renew the water pump.(don't give factory time)

7.A repair facility charges of $60.00 per hour. The technician isallowed 2.3 hours to renew a compressor shaft seal.What is the total Labor charge?

8. A heater core costs $96.00. Determine the cost when a sevenPercent sales tax is added.

9. Measure the diameter of this bolt. (cap screw)

10. Measure the threads per Inch using the thread pitch gauge.




Station #1 (part 2) General Automotive Skills – Contestant Worksheet

11. Determine the tensile strength (grade) of this bolt (cap screw)Using the oil container supplied, answer the following questions.


12. Determine the viscosity rating of this 011.

13. Determine the API rating of this oil.

14. What does SAE mean

Conversion

15. Convert 3/64 inch to millimeters _mm

16. S.9S3mm to inches _in.

17. Convert" inch to thousands -18. Convert.75O thousands of an inch to

inches _in.

19. 10 foot-pounds to - Newton meters _Nm

20. 10 Newton meters to - Foot pounds _ft-Ib

Total Score (150)




Station #2 Measurement – Contestant Worksheet


Points Awarded

1. Measure and record the connecting rod end play .002” ______ ______

2. Record the connecting rod specifications service limit ______ ______

3. Measure and record the cylinder bore on #1 cylinderX 1________ 2__________ 3_________ ______Y 1________ 2__________ 3_________ ______

4. Record the cylinder bore specification service limit ______ ______

5. Measure and record piston diameter. ______ ______

6. Record piston diameter specifications service limit. ______ ______

7. Measure and record piston-to-block clearance on #4cylinder .002” ______ ______

8. Record piston-to-block specification service limit. ______ ______

9. Measure and record ring-to-land clearance .002”. ______ ______

10. Record ring-to-land specification service limit. ______ ______

11. Safety procedures followed? ______ ______





Station #3 (part1)Electrical – Contestant Worksheet

1. Identify the type of circuit: switch to ground_____ load to ground_____

2. If the current flow at point 1 is 2 amps, predict the current flow at: point 3?_____ point 4?_____ point 5?_____ ______ 3. Write the principle that explains your answer: ___________________________________________________ ___________________________________________________ ______

4. Predict the voltage at point 5: _______ ______ 5. Write the principle that explains your answer: ___________________________________________________ ___________________________________________________ ______


6.

7.

8.

9.


With the switch OFF, measure the voltage drop between the following points.10. points 2&3______ points 4&5______ ______


Points 3&4______ points 4&5______ ______




Station #3 (part 2)Electrical – Contestant Worksheet



R is the symbol for________________ ______ 13. With steady voltage, if the resistance in a circuit increases, Current flow will ________________ ______

14. Ohm’s Law states that Voltage = ________________________


(a) The circuit is normal. (b) Open after point 3. (c) Circuit is good up to point 3. (d) Resistance before point 3. ______

16. If the voltage at point 4 is 6 volts with the switch ON, What does that indicate? Circle your choice. (a) The circuit is normal. (b) Circuit is open at point 5. (c) Switch is open. (d) Resistance at points 4 and 5. _______


17. (A) ___________ (B) ____________

(C) ___________ (D) ____________ _______


18. Amperage _______ _______ Resistance 1.66 Voltage 12.5






Directions: The judges will tell you when to begin. Record your answers on the answer sheet provided. There are 17 questions for a possible 100 points. Use the Electrical Wiring Diagram and the Terminals of the ECM reference as needed to answer the questions. For questions 10 to 16 FOUR components labeled “A” through “D” are available for you at a nearby table (do not touch these items). For all DVOM readings (except when directed otherwise) the dial is on DC VOLTS, the BLACK LEAD is grounded, and the RED LEAD is at the point mentioned.

1. After replacing a coolant temperature sensor you notice that the scanner information indicates that a permanent DTC is recorded. When the engine is running the Check Engine light is off. What would be your next move and why?


2. With the Key on, Engine off, and the fuel injector connected, what should be the voltage reading at the YELLOW wire at the number THREE fuel injector?


3. If the crankshaft rotates 4 complete revolutions, how many Cam Shaft Position Sensor signals does the ECM receive?





4. Terminal 53 on the ECM Connector”C24” normally toggles from 0 volts to 5 volts. What condition (driver action) causes the voltage to go to 5 volts?


5. With the vehicle running, .3 volts is recorded at terminal 5 of the Fuel Pump connector. How might this effect Fuel Trim?


6. Based on the scanner data below (figure #1) and the information provided what part needs replacing? In figures #2 & 3 the data is recorded after the sensor is disconnected.


Figure #1




Question 6 Continued

Figure #2

Figure #3




7. What type of current (AC or DC) would you find what terminals 121 and 122 of ECM connector C24 while the vehicle is running?


8. The customer states that the Check Engine light is on and that the brake pedal is very hard to push. You note that a DTC PO171 (system too lean bank 1), you clear the code, and it does not immediately come back. Based on the scanner data below and the customer’s concern, what would you inspect or suspect as the problem?


Figure #1

9. Which two parts might set a DTC P0303? A bad VSV purge solenoid, a bad fuel injector, an open Air Fuel Ratio, a bad ignition coil, or a bad camshaft timing control valve.


10. Use the electrical wiring diagram as a reference for this question. Component “A” is designated B1S2. A DTC P0037 HO2S Heater Control Circuit Low (Bank 1 Sensor 2) was set. Using an ohmmeter the resistance of wires (terminals 1 & 2) of Component “A” and get an “OL” reading? What do you need to do to repair the vehicle.





11. Component “A” is designated B1S2. Where is it located on the vehicle?Use the answer sheet to record your answer

12. If the TOP “O” ring is split on component “B” what will leak?Use the answer sheet to record your answer

13. If the BOTTOM “O” component “B” ring is split what will leak?Use the answer sheet to record your answer

14. Component “C” is part of the _____________ emission system of the Vehicle?Use the answer sheet to record your answer

15. If component “D” is stuck closed what harmful exhaust emission will increase?Use the answer sheet to record your answer

16. If component “D” is stuck open what will be the biggest complaint?Use the answer sheet to record your answer

17. What FIVE gasses does a 5 gas emission analyzer measure?Use the answer sheet to record your answer

1. Oxygen2. _______________3. _______________4. _______________5. _______________



Station #4 (page 6)Engine Performance – Contestant Answer Sheet

1 5

2 5

3 5

4 5

5 5

6 5

7 5

8 5

9 5

10 5

11 5

12 5

13 5

14 5

15 5

16 5

17A 5

17B 5

17C 5

17D 5

TOTAL POINTS 100




Station #5Brakes – Contestant Worksheet


I. ______________________ _____ (8)

J. ______________________ _____ (8)

K. ______________________ _____ (8)

L. ______________________ _____ (8)


A. ______________________ E. _________________________ _____ (8)_____(8)

B. ______________________ F. _________________________ _____ (8)_____(8)

C. _______________________ G. _________________________ _____ (8)_____(8)

D. _______________________ H. _________________________ _____ (8)_____(8)





_____________________________________ _____ (8)



________________________________________ _____ (18)


________________________________________ _____ (12)


Yes _____ No _____ _____ (8)





Station #6Air Conditioning – Contestant Worksheet

1. On the vehicle, locate and name the component that changes high gas into high liquid and by doing this operation what is removed from the refrigerant? Location ___________________ Component ______________ Removed from ____________ (16 x 3) 32 ______

2. The air conditioning system is divided into two sections high and low. Which two components of the air conditioning divide the system into high and low pressure and what is the state of the refrigerant in both com[opponents? High Component _______________ Refrigerant state ______________ 14 ______ Low Component _______________ Refrigerant state ______________ 14 ______


Location _______________ Component ____________________ 14 ______







1. ___________________ 2. ______________________ 14 ______


_________________________________________ 16 ______






Operation #1:

K. Locate the transmission serial number on the transmission. List the letters and numbers (from the transmission number) that designate the transmission type: (2) _______________________________.

L. List the model year that corresponds to these letters which


M. On transmissions with cable operated shifters one caution is always brought out in the service manual. What is it? (2) ___________________

_______________________________________________________________________

N. What one universal tool is suggested for transmission removal in every procedure? (2) ___________________

_______________________________________________________________________

O. If you forget to do this step before you pull the transmission, you may regret it when you remove the transmission housing. What is it? (2) ___________________

_______________________________________________________________________




Operation #2:

I. How would you identify a “B” style transmission? (2) ______________________

J. What type of oil does the “B” style transmission use? (2) ______________________

K. What measurements, if any, must be taken before removing the transmission shafts from the case?



L. What must be done to the screws on the bearing retainer plates after they are reinstalled? (2) ______________________

________________________________________________________________________

Operation #3:

G. Record your synchro-to-gear clearances: (1) 1st __________,

(1) 2nd __________,

(1) 3rd __________,

(1) 4th __________,

(1) 5th __________

H. Service Limit: (2) ___________________

I. Are all the synchro-to-gear clearances acceptable? (3) ___________________




Operation #4:

G. What safety precautions must be observed when removing the shift rod? (2) _____________________

_______________________________________________________________________

H. Measure the differential pinion gear backlash? (2) _____________________.

I. Is your measurement within service limits? (2) _____________________

Operation #5


F. As the clutch friction disc wears, clutch pedal effort (2) _____________________.

G. Excessive pedal effort can be caused by the throw out bearing not sliding freely on its shaft.

(2) True _______ False _______




Station #8Written Test

Multiple ChoiceIdentify the letter of the choice that best completes the statement or answers the question.

1. In which type of logic gate must both inputs be “on” to produce an output voltage?a. NOT c. ANDb. NAND d. OR

2. Which of the following is not a maintenance operation that you would perform on a manual transmission?a. Change lubricant c. Adjust shift linkageb. Adjust clutch d. Adjust bands

3. A timing belt. gears, or a chain drives the engine’s camshaft at ____the rotation speed of the crankshaft.a. One-fourth c. Three-fourthsb. One-half d. Twice

4. Each of the following is a type of supercharger, except...a. Rotor c. Reciprocatingb. Centrifugal d. Vane

5. A suspension system element sometimes used to prevent side-by-side axle movement when cornering is called a(n) ______.a. Track rod c. Sway barb. Strut rod d. Control arm

6. In a starting headlight testy, the lights stay bright, but the engine does not crank. What does this indicate?a. A shorted starting motor c. A weak or discharged batteryb. An opening in the starting circuit d. A blown fusible link

7. The relationship of tire height to its width is called its ___________.a. Aspect ration c. Width percentageb. Sidewall/tread ration d. Cross-sectional mass

8. The ____ is a heavy wheel mounted on a rubber ring and keypad to the crankshaft snout.a. Dynamic turner c. Harmonic Balanceb. Oscillation damper d. Vibration snubber

9. If warp age of a block deck exceeds _____, the block must be surface-milled or replaced.a. 0.03 to 0.05 in. c. 0.0003 to 0.0005 in.b. 0.003 to 0.005 in. d. 0.00003 to 0.00005 in.

10. In a cam-in-block engine, the part of the valve train riding directly on the cam is the _____.a. Rocker arm c. Push rod



b. Valve lifter d. Plunger

11. All of the following are active sensors except...a. Mass airflow sensor c. Oxygen sensorb. Knock sensor d. Crankshaft sensor

12. The insulating elements positioned between battery plates are known as ____.a. Insert plates c. Insulating gridsb. Separators d. Partitions

13. Technician A says that security systems can usually be worked on without referring to the manufacturer’s technical literature. Technician B says that systems vary so much that using a schematic and technical literature on the specific system is a necessary. Who is right?a. A only c. Both A & Bb. B only d. Neither A nor B

14. The _____ is the component of an air conditioning system that transfers heat from the refrigerant to the outside air.a. Compressor c. Condenserb. Evaporator d. Accumulator

15. The turn signal flasher consists of _____.a. A bimetal strip and heating elementb. A trigger wheel and sensorc. A make/break contact and trembler switchd. A stepping relay

16. A small line of conductive material than can short coil voltage to ground or th the wrong distributor terminal lug is called a(n) ______.a. Shorting track c. Low-resistance channelb. Carbide path d. Carbon trace

17. Which of the following is not one of the safety rules that apply when working with gasoline?a. Always use approved containers for storageb. Soak up and spills with oil treatmentc. Keep any source of hear away from the fuel systemd. Disconnect the vehicle’s battery before starting work

18. The piston is mounted to the rod by the _____.a. Cylinder bolt c. Wrist pinb. Piston Skirt d. Cam lobe

19. The temperature of the exhaust manifold at each exhaust poet can be checked with ____.a. A digital pyrometer c. A sling psychrometerb. An analog heat sensor d. A digital temperature guage

20. Resignation will cause _____ in the engine.a. Ping c. Detonation Knock



b. Dieseling d. Spark Knock

21. The signals from an FM radio transmitter have a range of approximately ___ miles.a. 25 c. 50b. 35 d. 65

22. What is the most common cause of freeze plug failure that allows a coolant leak to develop?a. Metal fatigue c. Engine vibrationb. Rusting d. Overheating

23. The amount of space between the teeth of meshing gears to permit heat expansion is referred to as ____.a. Backlash c. Run outb. Preload d. Play

24. To reduce radio static a(n) ____ called a noise suppressor is often used.a. Resistor c. Transformerb. Chip d. Capacitor

25. Which of the following is not part of a simple battery cell?a. Electrolyte d. Neutral Plateb. Negative plate e. Positive platec. Container

26. How many ASE tests must be passed to qualify for Certified Master Automotive Techniciam atatus?a. 3 c. 8b. 5 d. 16

27. Which of the binary numbers below is equal to 6 in the decimal system of notation?a. 0111 c. 0110b. 1110 d. 1111

28. Which basic element of electricity is also described as “electrical pressure?”a. Current c. Resistanceb. Capacitance d. Voltage

29. Which of the following is not a function of the lubrication system?a. Removing contaminants from inside engineb. Reducing friction and wear between moving partsc. Cutting power loss; increasing fuel economyd. Maintaining smooth power flow through drive train

30. A cylinder bore must be precisely measured. Technician A says that the proper measuring tool for this job is a telescoping guage. Technician B says an inside micrometer should be used. Who is right?a. A only c. Both A 7 Bb. B only d. Neither A nor B

31. Which of the following statements about inline diesel injection pumps is not correct?a. There is one pumping plunger for each cylinder



b. Plungers are operated by tappets that transfer motion from a camshaftc. Fuel from the inline pump is routed to the distributer pump where it is further

pressurized and distributed to the injectorsd. Rotating control sleeves regulate pump output

32. An electric engine fan is controlled by _____.a. The timing belt c. A thermostatic switchb. An engine speed sensor d. A pressure sensor

33. A process called magnafluxing is used to detect cracks in _____ parts.a. Steel c. Cast ironb. Aluminum d. Composite

34. Technician A says that the shift points of an automatic transmission are determined by the engine rpm. Technician B says that the shift points of an automatic transmission are determined by the engine load. Who is correct?a. A only c. Both A & Bb. B only d. Neither A nor B

35. Which of the following is not a function of a diesel injection pump?a. Meters the correct amount of fuel to each injectorb. Times the injection of fuel to meet speed and load of the enginec. Provides a means of shutting off the engined. Controls the airflow into the engine

36. The tool used to measure small clearances or gaps between parts is called __________.a. Veriner caliper c. Rulerb. Feeler guage d. Hole guage

37. The most common type of windshield washer pump in new cars is a(n) _________ pump.a. Centrifugal c. Rotaryb. Reciprocating d. Diaphragm

38. Technician A says that the ideal, chemically correct fuel mixture is 14parts air to 1 part fuel. Technician B says that 15 parts air to 1 part fuel is the right mixture. Who is correct?a. A only c. Both A & Bb. B only d. Neither A nor B

39. The starter pinion gear engages the _____ to “crank” the enginea. Harmonic Balancer c. Flywheel gearb. Cam gear d. Crankshaft pulley

40. Voltage in the secondary circuit of an ignition system is typically ____ volts.a. 6 c. 15,000b. 12 d. 30,000

41. If the cold light does not flash when checking an electronic fuel injector’s feed circuit, the cause of the problem may be all of the following except _____.a. An open in the wiring c. A faulty injector



b. A bad connection d. A control module problem

42. Which of the following is the least likely place to find the ignition control module of an electronic ignition system?a. Inside the distributer c. Behind the harmonic balancerb. Under the vehicle dash d. on the side of the distributer

43. An automotive ______is a group of related parts that perform a specific job.a. System c. Componentb. Sequence d. Process

44. Power for tools used in the automotive shop in provided by _____.a. Compressed air d. Only a & cb. Hydraulics e. All of the abovec. Electricity

45. Abnormal wear patterns can identify tire problems. Which pattern indicates that the tire was consistently underinflated?a. Wear along outer treat area c. Wear along one edgeb. Wear along the centerline d. Feathering of tread rubber

46. Cylinder _____, or deglazing is normally a part of cylinder block service. a. Grinding c. Boringb. Honing d. Filing

47. A cold-start injector is activated by a(n) _____.a. Control relay c. Oxygen sensorb. Thermo-time switch d. Timing circuit

48. When rebuilding a diesel injector, special ____ cleaning tools must be used to remove carbon deposits without damaging parts.a. Steel c. Fiberglass-reinforcedb. Nylon d. Brass

49. Technician A says that an air bag module should be placed on a workbench with the bag and trim cover facing up. Technician B says that it is safer to place the module with the bag facing down. Who is right?a. A only c. Both A & Bb. B only d. Neither A nor B

50. Ina typical gasoline powered automotive engine, how many piston strokes make up a complets cycle?a. 1 c. 3b. 2 d. 4

End of Written Test. Turn in this test and your answer sheet to the judge.



Answer Sheet

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InstructorsPacket




Station #1 – General Automotive SkillsCurrent vehicle and service and labor manual

Station #2 – Measurement Small 4 cylinder engine (lower unit) Feeler guage set Set of Micrometers Vernier caliper Plastic guage Compression tester (not required but nice to have) just adds fun Leak down tester (not required but nice to have) Dial guage Bench with vise Reference material (Shop Manual)

Station #3 – Electrical Electrical Parts Scratch Paper

Station #4 – Engine Performance Obtain and label Components The components must only have a letter on them so as to NOT to name the

component.

Station #5 – BrakesVehicle with drum and disc brakes or stand along components and tools for job.

Station #6. – Air ConditioningVehicle with A/C and tools to test the system

Station #7. – Manual Transmissiono Manual Transmissions on bench

Contest Set-up

This is a 8-station contest. 1. Station #8 is the written test2. Stations #1 thru #7 will be at benches/workareas

Provided by Regional Coordinator1. Judges - copy of contest, answer sheet for written test, and scoring sheets.2. Contestants - all contest documents (Written Test and Practical task sheet(s).

Supplied by the Contestant:1. Pen or Pencil2. All safety equipment for the job (i.e. goggles, safety shoes, etc), 3. One page computer generated resume.


s · web viewlikely place to find the ignition control module of an electronic ignition...

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