Content Outline and Competencies:

I. Engine Repair

A. General

1. Verify operation of the instrument panel engine warning indicators.

2. Inspect engine assembly for fuel, oil, coolant and other leaks; determine necessary action.

B. Lubrication and Cooling Systems

1. Perform cooling system pressure and dye tests to identify leaks; check coolant condition and level; inspect and test radiator, pressure cap, coolant recovery tank, heater core and galley plugs; determine necessary action.

2. Inspect, replace and/or adjust drive belts, tensioners and pulleys; check pulley and belt alignment.

3. Remove, inspect and replace thermostat and gasket/seal.

4. Inspect and test coolant; drain and recover coolant; flush and refill cooling system; use proper fluid type per manufacturer specification; bleed air as required.

5. Perform engine oil and filter change; use proper fluid type per manufacturer specification; reset maintenance reminder as required.

II. Automatic Transmission and Transaxle

A. General

1. Research vehicle service information including fluid type, vehicle service history, service precautions and technical service bulletins.

2. Check fluid level in a transmission or a transaxle equipped with a dip-stick.

3. Check fluid level in a transmission or a transaxle not equipped with a dip-stick.

4. Check transmission fluid condition; check for leaks.

5. Identify drive train components and configuration.

B. In-Vehicle Transmission/Transaxle

1. Inspect, adjust and/or replace external manual valve shift linkage, transmission range sensor/switch and/or park/neutral position switch.

2. Inspect for leakage at external seals, gaskets and bushings.

3. Inspect replace and/or align power train mounts.

4. Drain and replace fluid and filter(s); use proper fluid type per manufacturer specification.

C. Off-Vehicle Transmission and Transaxle

1. Describe the operational characteristics of a continuously variable transmission (CVT).

2. Describe the operational characteristics of a hybrid vehicle drive train.

III. Manual Drivetrain and Axles

A. General

1. Research vehicle service information including fluid type, vehicle service history, service precautions and technical service bulletins.

2. Drain and refill manual transmission/transaxle and final drive unit; use proper fluid type per manufacturer specification.

3. Check fluid condition; check for leaks.

4. Identify manual drive train and axle components and configuration.

5. Describe the operational characteristics of an electronically-controlled manual transmission/transaxle.

B. Clutch

1. Check and adjust clutch master cylinder fluid level; use proper fluid type per manufacturer specification.

2. Check for hydraulic system leaks.

C. Drive Shaft, Half Shafts, Universal and Constant-Velocity (CV) Joints

1. Inspect, remove and/or replace bearings, hubs and seals.

2. Inspect, service and/or replace shafts, yokes, boots and universal/CV joints

3. Inspect locking hubs.

4. Check fir leaks at drive assembly and transfer case seals; check vents check fluid level; use proper fluid type per manufacturer specification.

D. Differential Case Assembly

1. Clean and inspect differential case; check for leaks; inspect housing vent.

2. Check and adjust differential case fluid level; use proper fluid per manufacturer specification.

3. Drain and refill differential housing.

4. Inspect and replace drive axle wheel studs

IV. Suspension and Steering Systems

A. Wheels and Tires

1. Inspect tire condition; identify tire wear patterns; check for correct size, application (load and speed ratings) and adjust air pressure as listed on the tire information placard/label.

2. Rotate tires according to manufacturer’s recommendations including vehicles equipped with tire pressure monitoring systems (TPMS).

3. Dismount, inspect and remount tire on wheel; balance wheel and tire assembly (static and dynamic).

4. Dismount, inspect and remount tire on wheel equipped with tire pressure monitoring system sensor.

5. Inspect tire and wheel assembly for air loss; determine necessary action.

6. Repair tire following manufacturer approved procedure.

B. TPMS (tire pressure monitoring systems)

1. Identify indirect and direct tire pressure monitoring systems (TPMS); calibrate system; verify operation of instrument panel lamps.

2. Demonstrate knowledge of steps required to remove and replace sensors in a tire pressure monitoring system (TPMS), including relearn procedure.

V. Heating and Air Conditioning

A. General

1. Research vehicle service information, including refrigerant/oil type, vehicle service history, service precautions and technical service bulletins.

2. Identify heating, ventilation and air conditioning (HVAC) components and configuration.

B. Refrigeration System Components

1. Inspect and replace A/C compressor drive belts, pulleys and tensioners; visually inspect A/C components for signs of leaks; determine necessary action.

2. Identify hybrid vehicle A/C system electrical circuits and the service/safety precautions.

3. Inspect A/C condenser for airflow restrictions; determine necessary action.

C. Heating, Ventilation and Engine Cooling Systems

1. Inspect engine cooling and heater systems hoses and pipes.

2. Perform necessary action.

D. Operating Systems and Related Controls

1. Inspect A/C-heater ducts, doors, hoses, cabin filters and outlets; determine necessary action.

2. Identify the source of A/C system odors.

VI. Engine Performance

A. Fuel, Air Induction and Exhaust Systems

1. Check diesel exhaust fluid (DEF).

2. Refill DEF.

B. Emissions Control Systems

1. Inspect positive crankcase ventilation (PCV) filter/breather cap, valve, tubes, orifices and hoses.

2. Test and service the positive crankcase ventilation system; perform necessary action.

VII. Required Supplemental Tasks

A. Shop and Personal Safety

1. Identify general shop safety rules and procedures.

2. Utilize safe procedures for handling of tools and equipment.

3. Identify and use proper placement of floor jacks and jack stands.

4. Identify and use proper procedures for safe lift operation.

5. Utilize proper ventilation procedures for working within the lab/shop area.

6. Identify marked safety areas.

7. Identify the location and the types of fire extinguishers and other fire safety equipment; demonstrate knowledge of the procedures for using fire extinguishers and other fire safety equipment.

8. Identify the location and use of eye wash stations.

9. Identify the location of the posted evacuation routes.

10. Comply with the required use of safety glasses, ear protection, gloves and shoes during lab/shop activities.

11. Identify and wear appropriate clothing for lab/shop activities.

12. Secure hair and jewelry for lab/shop activities.

13. Demonstrate awareness of the safety aspects of supplemental restraint systems (SRS), electronic brake control systems and hybrid vehicle high voltage circuits.

14. Demonstrate awareness of the safety aspects of high voltage circuits (such as high intensity discharge (HID) lamps, ignition systems, injection systems, etc.).

15. Locate and demonstrate knowledge of material safety data sheets (MSDS).

B. Tools and Equipment

1. Identify tools and their usage in automotive applications.

2. Identify standard and metric designation.

3. Demonstrate safe handling and use of appropriate tools.

4. Demonstrate proper cleaning, storage and maintenance of tools and equipment.

5. Demonstrate proper use of precision measuring tools (i.e. micrometer, dial-indicator, dial-caliper).

C. Preparing Vehicle for Service

1. Identify information needed and the service requested on a repair order.

2. Identify purpose and demonstrate proper use of fender covers, mats.

3. Demonstrate use of the three C’s (concern, cause and correction).

4. Review vehicle service history.

5. Complete work order to include customer information, vehicle identifying information, customer concern, related service history, cause and correction.

D. Preparing Vehicle for Customer

1. Ensure vehicle is prepared to return to customer per school/company policy (floor mats, steering wheel cover, etc.).

2. Review vehicle paperwork for return of vehicle to customer.

E. Workplace Employability Skills

1. Personal Standards (see Standard 7.9)

a. Reports to work daily on time; able to take directions and motivated to accomplish the task at hand.

b. Dresses appropriately and uses language and manners suitable for the workplace.

c. Maintains appropriate personal hygiene

d. Meets and maintains employment eligibility criteria, such as drug/alcohol-free status, clean driving record, etc.

2. Demonstrates honesty, integrity and reliability

F. Work Habits / Ethic (see Standard 7.10)

1. Complies with workplace policies/laws

2. Contributes to the success of the team, assists others and requests help when needed.

3. Works well with all customers and coworkers.

4. Negotiates solutions to interpersonal and workplace conflicts.

5. Contributes ideas and initiative

6. Follows directions

7. Communicates (written and verbal) effectively with customers and coworkers.

8. Reads and interprets workplace documents; writes clearly and concisely.

9. Analyzes and resolves problems that arise in completing assigned tasks.

10. Organizes and implements a productive plan of work.

11. Uses scientific, technical, engineering and mathematics principles and reasoning to accomplish assigned tasks

12. Identifies and addresses the needs of all customers, providing helpful, courteous and knowledgeable service and advice as needed.

Content Outline and Competencies:

I. Safety Rules
   A. List and discuss personal safety.
   B. List and discuss shop safety.

II. Hand Tools and Equipment Usage
   A.  Perform work on small engine using proper hand tools.
   B.  Perform work on small engine using shop equipment properly.

III. Measuring Engine Parts
   A.  Use and read a micrometer.
   B.  Measure parts using calipers.
   C.  Operate cylinder micrometer and hole gauges.

IV. Small Engine Design
   A.  Identify a two-stroke engine.
   B.  Identify a four-stroke engine.
   C.  Compare vertical and horizontal shaft engines.

V. Ignition, Charging and Starting Systems
   A.  Explain ignition systems.
   B.  Describe engine charging system.
   C.  Define starting systems.

VI. Engine Maintenance
   A.  Explain lubrication and fuel system.
   B.  Describe cooling and governor systems.

VII. Troubleshooting and Overhaul Engines
   A.  Troubleshooting and overhaul one four-stroke engine.
   B.  Troubleshooting and overhaul one two-stroke engine.

VIII. Attitudes and Work Habits
   A. Identify and develop positive attitudes toward tasks and fellow
employees appropriate for the workplace, including giving and accepting
criticism and praise.
   B. Identify and develop productive work habits, including attending to
detail, completing tasks, maintaining the work setting and recording
data.
   C. Identify and develop collaborative/teamwork skills, including
solving problems in groups, building consensus and responding to
supervision.

Competency completion level      50% of grade 
Tests and quizzes                40% of grade 
Participation and work habits    10% of grade 
TOTAL                           100%

Attitude and Work Habits:
Although attendance is important, productive attitudes and work habits
affect morale, efficiency, accuracy and safety in the automotive shop and
will be a factor in determining grades.  In addition, collaboration and
teamwork will be expected and evaluated.

Content Outline and Competencies:

I. Complete Service Work Orders

A. Complete work order to include customer information, vehicle identifying information, customer concern, related service history, cause, and correction. 5.A.1

B. Research applicable vehicle and service information, such as brake system operation, vehicle service history, service precautions, and technical service bulletins. 5.A.3

C. Locate and interpret vehicle and major component identification numbers. 5.A.4

II. Appropriate System Pressure Tests Utilizing Service Specifications

A. Diagnose pressure concerns in the brake system using hydraulic principles (Pascal's Law). 5.B.1

B. Measure brake pedal height, travel, and free play (as applicable); determine necessary action. 5.B.2

C. Check master cylinder for internal/external leaks and proper operation; determine necessary action. 5.B.3

D. Remove, bench bleed, and reinstall master cylinder. 5.B.4

E. Diagnose poor stopping, pulling or dragging concerns caused by malfunctions in the hydraulic system; determine necessary action. 5.B.5

F. Inspect brake lines, flexible hoses, and fittings for leaks, dents, kinks, rust, cracks, bulging or wear; tighten loose fittings and supports; determine necessary action. 5.B.6

G. Replace brake lines, hoses, fittings, and supports. 5.B.7

H. Fabricate brake lines using proper material and flaring procedures (double flare and ISO types). 5.B.8

I. Select, handle, store, and fill brake fluids to proper level. 5.B.9

J. Inspect, test, and/or replace metering (hold-off), proportioning (balance), pressure differential, and combination valves. 5.B.10

K. Inspect, test, and/or replace components of brake warning light system. 5.B.11

L. Bleed and/or flush brake system. 5.B.12

M. Test brake fluid for contamination. 5.B.13

III. Brake System Concerns and Necessary Actions

A. Identify and interpret brake system concern; determine necessary action. 5.A.2

B. Research applicable vehicle and service information, such as brake system operation, vehicle service history, service precautions, and technical service bulletins. 5.A.3

C. Locate and interpret vehicle and major component identification numbers. 5.A.4

IV. Poor Stopping, Pulling or Dragging Concerns Caused by Malfunctions in the Hydraulic System

A. Measure brake pedal height, travel, and free play (as applicable); determine necessary action. 5.B.2

B. Check master cylinder for internal/external leaks and proper operation; determine necessary action. 5.B.3

C. Remove, bench bleed, and reinstall master cylinder. 5.B.4

D. Diagnose poor stopping, pulling or dragging concerns caused by malfunctions in the hydraulic system; determine necessary action. 5.B.5

E. Inspect brake lines, flexible hoses, and fittings for leaks, dents, kinks, rust, cracks, bulging or wear; tighten loose fittings and supports; determine necessary action. 5.B.6

F. Replace brake lines, hoses, fittings, and supports. 5.B.7

G. Fabricate brake lines using proper material and flaring procedures (double flare and ISO types). 5.B.8

H. Select, handle, store and fill brake fluids to proper level. 5.B.9

I. Inspect, test, and/or replace metering (hold-off), proportioning (balance), pressure differential, and combination valves. 5.B.10

J. Inspect, test, and/or replace components of brake warning light system. 5.B.11

V. Inspect, Fabricate and/or Replace Brake Lines and Hoses

A. Inspect brake lines, flexible hoses, and fittings for leaks, dents, kinks, rust, cracks, bulging or wear, tighten loose fittings and supports; determine necessary action. 5.B.6

B. Replace brake lines, hoses, fittings, and supports. 5.B.7

C. Fabricate brake lines using proper material and flaring procedures (double flare and ISO types). 5.B.8

D. Select, handle, store, and fill brake fluids to proper level. 5.B.9

VI. Service Specifications Pertaining to the Removal, Cleaning and Refinishing Procedures on Brake Drums

A. Remove, clean, inspect, and measure brake drums; determine necessary action. 5.C.2

B. Refinish brake drum; measure final drum diameter. 5.C.3

VII. Drum Brake Repair and Replacement Procedures

A. Remove, clean, and inspect brake shoes, springs, pins, clips, levers, adjusters/self-adjusters, other related brake hardware, and backing support plates; lubricate and reassemble. 5.C.4

B. Inspect, and install wheel cylinders. 5.C.5

C. Pre-adjust brake shoes and parking brake; install brake drums or drum/hub assemblies and wheel bearings. 5.C.6

D. Install wheel, torque lug nuts, and make final checks and adjustments. 5.C.7

VIII. Poor Stopping, Noise Vibration, Pulling, Grabbing, Dragging, or Pedal Pulsation Concerns on Disc-Brake Vehicles

A. Diagnose poor stopping, noise, pulling, grabbing, dragging or pulsation concerns; determine necessary action. 5.D.1

B. Remove caliper assembly; inspect for leaks and damage to caliper housing; determine necessary action. 5.D.2

C. Clean and inspect caliper mounting and slides/pins for operation, wear, and damage; determine necessary action. 5.D.3

IX. Disc Brake Repair and Replacement Procedures

A. Remove, inspect, and replace pads and retaining hardware; determine necessary action. 5.D.4

B. Disassemble and clean caliper assembly; inspect parts for wear, rust, scoring, and damage; replace seal, boot, and damaged or worn parts. 5.D.5

C. Reassemble, lubricate, and reinstall caliper, pads, and related hardware; seat pads, and inspect for leaks. 5.D.6

D. Clean, inspect, and measure rotor thickness, lateral runout, and thickness variation; determine necessary action. 5.D.7

E. Remove and reinstall rotor. 5.D.8

F. Check brake pad wear indicator system operation; determine necessary action. 5.D.13

G. Retract caliper piston on an integrated parking brake system. 5.D.11

H. Diagnose wheel bearing noises, wheel shimmy, and vibration concerns; determine necessary action. 5.F.1

X. Remove, Inspect and Replace Bearing and Hub Assemblies

      A. Diagnose wheel bearing noises, wheel shimmy, and vibration concerns; determine          necessary action. 5.F.1

B. Remove, clean, inspect, repack, and install wheel bearings and replace seals; install hub and adjust bearings. 5.F.2

C. Check parking brake cables and components for wear, binding, and corrosion; clean, lubricate, adjust or replace as needed. 5.F.3

D. Check parking brake and indicator light system operation; determine necessary action. 5.F.4

E. Check operation of brake stop light system; determine necessary action. 5.F.5

F. Replace wheel bearing and race. 5.F.6

G. Inspect and replace wheel studs. 5.F.7

H. Remove and reinstall sealed wheel bearing assembly. 5.F.8

Content Outline and Competencies:

I. Brake System Correction

A. Complete work order to include customer information, vehicle identifying information, customer concern, related service history, cause, and correction. 5.A.1

B. Identify and interpret brake system concern; determine necessary action. 5.A.2

C. Research applicable vehicle and service information, such as brake system operation, vehicle service history, service precautions, and technical service bulletins. 5.A.3

D. Locate and interpret vehicle and major component identification numbers. 5.A.4

II. System Pressure Tests Utilizing Service Specifications

A. Diagnose pressure concerns in the brake system using hydraulic principles (Paschal's Law). 5.B.1

B. Measure brake pedal height, travel, and free play (as applicable); determine necessary action. 5.B.2

C. Check master cylinder for internal/external leaks and proper operation; determine necessary action. 5.B.3

D. Remove, bench bleed, and reinstall master cylinder. 5.B.4

E. Diagnose poor stopping, pulling or dragging concerns caused by malfunctions in the hydraulic system; determine necessary action. 5.B.5

F. Inspect brake lines, flexible hoses, and fittings for leaks, dents, kinks, rust, cracks, bulging or wear; tighten loose fittings and supports; determine necessary action. 5.B.6

G. Replace brake lines, hoses, fittings, and supports. 5.B.7

H. Fabricate brake lines using proper material and flaring procedures (double flare and ISO types). 5.B.8

I. Select, handle, store, and fill brake fluids to proper level. 5.B.9

J. Inspect, test, and/or replace metering (hold-off), proportioning (balance), pressure differential, and combination valves. 5.B.10

K. Inspect, test, and/or replace components of brake warning light system. 5.B.11

L. Bleed and/or flush brake system. 5.B.12

M. Test brake fluid for contamination. 5.B.13

III. Poor Stopping, Pulling or Dragging Concerns Caused by Malfunctions in the Hydraulic System

A. Measure brake pedal height, travel, and free play (as applicable); determine necessary action. 5.B.2

B. Check master cylinder for internal/external leaks and proper operation; determine necessary action. 5.B.3

C. Remove, bench bleed, and reinstall master cylinder. 5.B.4

D. Diagnose poor stopping, pulling or dragging concerns caused by malfunctions in the hydraulic system; determine necessary action. 5.B.5

E. Inspect brake lines, flexible hoses, and fittings for leaks, dents, kinks, rust, cracks, bulging or wear; tighten loose fittings and supports; determine necessary action. 5.B.6

F. Replace brake lines, hoses, fittings, and supports. 5.B.7

G. Fabricate brake lines using proper material and flaring procedures (double flare and ISO types). 5.B.8

H. Select, handle, store, and fill brake fluids to proper level. 5.B.9

I. Inspect, test, and/or replace metering (hold-off), proportioning (balance), pressure differential, and combination valves. 5.B.10

J. Inspect, test, and/or replace components of brake warning light system. 5.B.11

IV. Inspect, Fabricate and/or Replace Brake Lines and Hoses

A. Inspect brake lines, flexible hoses, and fittings for leaks, dents, kinks, rust, cracks, bulging or wear; tighten loose fittings and supports; determine necessary action. 5.B.6

B. Replace brake lines, hoses, fittings, and supports. 5.B.7

C. Fabricate brake lines using proper material and flaring procedures (double flare and ISO types). 5.B.8

D. Select, handle, store and fill brake fluids to proper level. 5.B.9

V. Poor Stopping, Noise Vibration, Pulling, Grabbing, Dragging or Pedal Pulsation Concerns

A. Diagnose poor stopping, noise vibration, pulling, grabbing, dragging or pedal pulsation concerns; determine necessary action. 5.C.1

B. Diagnose poor stopping, noise, pulling, grabbing, dragging or pulsation concerns; determine necessary action. 5.D.1

C. Remove caliper assembly; inspect for leaks and damage to caliper housing; determine necessary action. 5.D.2

D. Clean and inspect caliper mounting and slides/pins for operation, wear, and damage; determine necessary action. 5.D.3

VI. Service Specifications Pertaining to the Removal, Cleaning and Refinishing Procedures on Brake Drums

A. Remove, clean, inspect, and measure brake drums; determine necessary action. 5.C.2

B. Refinish brake drum; measure final drum diameter. 5.C.3

VII. Drum Brake Repair and Replacement Procedures

A. Remove, clean, and inspect brake shoes, springs, pins, clips, levers, adjusters/self-adjusters, other related brake hardware, and backing support plates; lubricate and reassemble. 5.C.4

B. Inspect, and install wheel cylinders. 5.C.5

C. Pre-adjust brakes shoes and parking brake; install brake drums or drum/hub assemblies and wheel bearings. 5.C.6

D. Install wheel, torque lug nuts, and make final checks and adjustments. 5.C.7

VIII. Disc Brake Repair and Replacement Procedures

A. Remove, inspect, and replace pads and retaining hardware; determine necessary action. 5.D.4

B. Disassemble and clean caliper assembly; inspect parts for wear, rust, scoring, and damage; replace seal, boot, and damaged or worn parts. 5.D.5

C. Reassemble, lubricate, and reinstall caliper, pads, and related hardware; seat pads, and inspect for leaks. 5.D.6

D. Clean, inspect, and measure rotor thickness, lateral runout, and thickness variation; determine necessary action. 5.D.7

E. Remove and reinstall rotor. 5.D.8

F. Check brake pad wear indicator system operation; determine necessary action. 5.D.13

G. Retract caliper piston on an integrated parking brake system. 5.D.11

IX. Machine Rotor According to Service Specifications

A. Refinish rotor on vehicle; measure final rotor thickness. 5.D.9

B. Refinish rotor off vehicle; measure final rotor thickness. 5.D.10

X. Power Assist Systems

A. Test pedal free travel; check power assist operation. 5.E.1

B. Check vacuum supply to vacuum-type power booster. 5.E.2

C. Inspect the vacuum-type power booster unit for leaks; inspect the check valve for proper operation; determine necessary action. 5.E.3

D. Inspect and test hydraulically assisted power brake system for leaks and proper operation; determine necessary action. 5.E.4

XI. Remove, Inspect and Replace Bearing and Hub Assemblies

      A. Diagnose wheel bearing noises, wheel shimmy, and vibration concerns; determine          necessary action. 5.F.1

B. Remove, clean, inspect, repack, and install wheel bearings and replace seals; install hub and adjust bearings. 5.F.2

C. Check parking brake cables and components for wear, binding, and corrosion; clean, lubricate, adjust or replace as needed. 5.F.3

D. Check parking brake and indicator light system operation; determine necessary action. 5.F.4

E. Check operation of brake stop light system; determine necessary action. 5.F.5

F. Replace wheel bearing and race. 5.F.6

G. Inspect and replace wheel studs. 5.F.7

H. Remove and reinstall sealed wheel bearing assembly. 5.F.8

Content Outline and Competencies:

I. General

A. Research applicable vehicle and service information, vehicle service history, service precautions and technical service bulletins. P-1

B. Identify and interpret suspension and steering system concerns; determine necessary action. P-1

C. Disable and enable supplemental restraint system (SRS). P-1

II. Related Suspension and Steering Service

A. Remove and replace steering wheel; center/time supplemental restraint system (SRS) coil (clock spring). P-1

B. Inspect rack-and-pinion steering gear, inner tie rod ends (sockets) and bellows boots; replace as needed. P-2

C. Diagnose power steering gear (both rack and pinion and non-rack and pinion) binding, uneven turning effort, looseness, hard steering and noise concerns; determine necessary action. P-2

D. Inspect steering shaft universal joint(s), flexible coupling(s), collapsible column, lock cylinder mechanism and steering wheel; perform necessary action. P-2

E. Remove and replace rack-and-pinion steering gear; inspect mounting bushings and brackets. P-2

F. Determine proper power steering fluid type; inspect fluid level and condition. P-1

G. Flush, fill, and bleed power steering system. P-2

H. Inspect for power steering fluid leakage; determine necessary action. P-1

I. Remove, inspect, replace, and adjust power steering pump drive belt. P-1

J. Remove and reinstall power steering pump. P-2

K. Inspect and replace power steering hoses and fittings. P-2

L. Remove and reinstall press fit power steering pump pulley; check pulley and belt alignment. P-2

M. Inspect and replace Pitman arm, relay (center link/intermediate) rod, idler arm and mountings, and steering linkage damper. P-2

N. Inspect, replace and adjust tie rod ends (sockets), tie rod sleeves and clamps. P-1

O. Diagnose short and long arm suspension system noises, body sway and uneven ride height concerns; determine necessary action. P-1

P. Diagnose strut suspension system noises, body sway and uneven ride height concerns; determine necessary action. P-1

Q. Inspect, remove and install upper and lower control arms, bushings and shafts. P-3

R. Inspect and replace rebound and jounce bumpers. P-3

S. Inspect remove and install track bar, strut rods/radius arms, and related mounts and bushings. P-3

T. Inspect remove and install upper and lower ball joints (with or without wear indicators). P-2

U. Inspect, remove and install steering knuckle assemblies. P-3

V. Inspect, remove and install short and long arm suspension system coil springs and spring insulators (silencers). P-3

W. Inspect, remove and install suspension system torsion bars and mounts. P-3

X. Inspect and replace front stabilizer bar (sway bar) bushings, brackets and links. P-3

Y. Inspect remove and install strut cartridge or assembly, strut coil spring, insulators (silencers), and upper strut bearing mount. P-3

Z. Inspect, remove and install upper front strut bearing and mount. P-3

AA. Inspect, remove and install front and rear suspension system lateral links/arms (track bars), strut rods/radius arms, control (trailing) arms, and related mounts and bushings. P-3

BB. Inspect rear suspension system leaf spring(s), spring insulators (silencers), shackles, brackets, bushings, center pins/bolts and mounts. P-1

CC. Inspect, remove and replace shock absorbers; inspect mounts and bushings. P-1

DD. Inspect electric power-assisted steering. P-3

EE. Inspect, test and diagnose components of electronically-controlled steering systems using a scan tool; determine necessary action. P-3

FF. Identify hybrid vehicle power steering system electrical circuits and safety precautions. P-2

GG. Remove, inspect, and service or replace front and rear wheel bearings. P-1

HH. Describe the function of the power steering pressure switch. P-3

III. Wheel Alignment

A. Diagnose vehicle wander, drift, pull, hard steering, bump steer, memory steer, torque steer and steering return concerns; determine necessary action. P-1

B. Perform pre-alignment inspection and measure vehicle ride height; determine necessary action. P-1

C. Prepare vehicle for wheel alignment on alignment machine; perform four-wheel alignment by checking and adjusting front and rear wheel caster, camber and toe as required; center steering wheel. P-1

D. Check toe-out-on-turns (turning radius); determine necessary action. P-2

E. Check SAI (steering axis inclination) and included angle; determine necessary action. P-2

F. Check rear wheel thrust angle; determine necessary action. P-1

G. Check for front wheel setback; determine necessary action. P-2

H. Check front and/or rear cradle (sub frame) alignment; determine necessary action. P-3

I. Reset steering angle sensor. P-2

IV. Wheels and Tires

A. Inspect tire condition; identify tire wear patterns; check for correct size and application (load and speed ratings) and adjust air pressure; determine necessary action. P-1

B. Diagnose wheel/tire vibration, shimmy and noise; determine necessary action. P-2

C. Rotate tires according to manufacturer’s recommendations. P-1

D. Measure wheel, tire, axle flange and hub runout; determine necessary action. P-2

E. Diagnose tire pull problems; determine necessary action. P-2

F. Dismount, inspect and remount tire on wheel; balance wheel and tire assembly (static and dynamic). P-1

G. Dismount, inspect and remount tire on wheel equipped with tire pressure monitoring system sensor. P-2

H. Inspect tire and wheel assembly for air loss; perform necessary action. P-1

I. Repair tire using internal patch. P-1

J. Identify and test tire pressure monitoring systems (indirect and direct) for operation; calibrate system; verify operation of instrument panel lamps. P-2

K. Demonstrate knowledge of steps required to remove and replace sensors in a tire pressure monitoring system. P-1

Content Outline and Competencies:

I. General

A. Research applicable vehicle and service information, vehicle service history, service precautions and technical service bulletins. P-1

B. Inspect steering and suspension components as a prealignment check. P-1

II. Wheel Alignment

A. Diagnose vehicle wander, drift, pull, hard steering, bump steer, memory steer, torque steer, and steering return concerns; determine necessary action. P-1

B. Perform prealignment inspection and measure vehicle ride height; determine necessary action. P-1

C. Prepare vehicle for wheel alignment on alignment machine; perform four-wheel alignment by checking and adjusting front and rear wheel caster, camber and toe as required; center steering wheel. P-1

D. Check toe-out-on-turns (turning radius); determine necessary action. P-2

E. Check SAI (steering axis inclination) and included angle; determine necessary action. P-2

F. Check rear wheel thrust angle; determine necessary action. P-1

G. Check for front wheel setback; determine necessary action. P-2

H. Check front and/or rear cradle (sub frame) alignment; determine necessary action. P-3

I. Reset steering angle sensor. P-2

Content Outline and Competencies:

I. General: Engine Diagnosis; Removal and Re-installation (R & R) 

A. Complete work order to include customer information, vehicle identifying information, customer concern, related service history, cause, and correction. 

B. Research vehicle service information including fluid type, internal engine operation, vehicle service history, service precautions, and technical service bulletins. 

C. Verify operation of the instrument panel engine warning indicators. 

D. Inspect engine assembly for fuel, oil, coolant, and other leaks; determine needed action. 

E. Install engine covers using gaskets, seals, and sealers as required. 

F. Verify engine mechanical timing. 

G. Perform common fastener and thread repair, to include: remove broken bolt, restore internal and external threads, and repair internal threads with thread insert. 

H. Inspect, remove and/or replace engine mounts. 

I. Identify service precautions related to service of the internal combustion engine of a hybrid vehicle. 

II. Cylinder Head and Valve Train Diagnosis and Repair 

A. Remove cylinder head; inspect gasket condition; install cylinder head and gasket; tighten according to manufacturer’s specification and procedure. 

B. Clean and visually inspect a cylinder head for cracks; check gasket surface areas for warpage and surface finish; check passage condition. 

C. Inspect pushrods, rocker arms, rocker arm pivots and shafts for wear, bending, cracks, looseness, and blocked oil passages (orifices); determine needed action. 

D. Adjust valves (mechanical or hydraulic lifters).  

E. Inspect and replace camshaft and drive belt/chain; includes checking drive gear wear and backlash,  end play, sprocket and chain wear, overhead cam drive sprocket(s), drive belt(s), belt tension,  tensioners, camshaft reluctor ring/tone-wheel, and valve timing components; verify correct camshaft timing. 

F. Establish camshaft position sensor indexing.  

G. Inspect valve springs for squareness and free height comparison; determine needed action. 

H. Replace valve stem seals on an assembled engine; inspect valve spring retainers, locks/keepers, and valve lock/keeper grooves; determine needed action. 

I. Inspect valve guides for wear; check valve stem-to-guide clearance; determine needed action. 

J. Inspect valves and valve seats; determine needed action. 

K. Check valve spring assembled height and valve stem height; determine needed action. 

L. Inspect valve lifters; determine needed action. 

M. Inspect and/or measure camshaft for runout, journal wear and lobe wear. 

N. Inspect camshaft bearing surface for wear, damage, out-of-round, and alignment; determine needed action. 

III. Engine Block Assembly Diagnosis and Repair 

A. Remove, inspect, and/or replace crankshaft vibration damper (harmonic balancer).  

B. Disassemble engine block; clean and prepare components for inspection and reassembly. 

C. Inspect engine block for visible cracks, passage condition, core and gallery plug condition, and surface warpage; determine needed action. 

D. Inspect and measure cylinder walls/sleeves for damage, wear, and ridges; determine needed action. 

E. Inspect and measure camshaft bearings for wear, damage, out-of-round, and alignment; determine needed action. 

F. Inspect crankshaft for straightness, journal damage, keyway damage, thrust flange and sealing surface condition, and visual surface cracks; check oil passage condition; measure end play and journal wear; check crankshaft position sensor reluctor ring (where applicable); determine needed action. 

G. Inspect main and connecting rod bearings for damage and wear; determine needed action.  

H. Identify piston and bearing wear patterns that indicate connecting rod alignment and main bearing bore problems; determine needed action. 

I.  Inspect and measure piston skirts and ring lands; determine needed action. 

J. Determine piston-to-bore clearance. 

K. Inspect, measure, and install piston rings. 

L.  Inspect auxiliary shaft(s) (balance, intermediate, idler, counterbalance and/or silencer); inspect shaft(s) and support bearings for damage and wear; determine needed action; reinstall and time. 

M. Assemble engine block.  

IV. Lubrication and Cooling Systems Diagnosis and Repair 

A. Perform cooling system pressure and dye tests to identify leaks; check coolant condition and level; inspect and test radiator, pressure cap, coolant recovery tank, heater core, and galley plugs; determine needed action. 

B. Identify causes of engine overheating. 

C. Inspect, replace, and/or adjust drive belts, tensioners, and pulleys; check pulley and belt alignment. 

D. Inspect and/or test coolant; drain and recover coolant; flush and refill cooling system; use proper fluid type per manufacturer specification; bleed air as required. 

E. Inspect, remove, and replace water pump. 

F. Remove and replace radiator. 

G. Remove, inspect, and replace thermostat and gasket/seal. 

H. Inspect and test fan(s), fan clutch (electrical or mechanical), fan shroud, and air dams; determine needed action. 

I. Perform oil pressure tests; determine needed action. 

J. Perform engine oil and filter change; use proper fluid type per manufacturer specification. 

K.  Inspect auxiliary coolers; determine needed action. 

L. Inspect, test, and replace oil temperature and pressure switches and sensors. 

M.  Inspect oil pump gears or rotors, housing, pressure relief devices, and pump drive; perform needed action. 

Content Outline and Competencies:

I. General Electrical System Diagnosis

A. Complete work order to include customer information, vehicle identifying information, customer concern, related service history, cause, and correction.

B. Research applicable vehicle and service information, such as electrical/electronic system operation, vehicle service history, service precautions, and technical service bulletins.

C. Locate and interpret vehicle and major component identification numbers.

II. The Relationship Between Voltage, Ohms and Amperage

A. Demonstrate knowledge of electrical/electronic series, parallel, and series-parallel circuits using principles of electricity.

B. Demonstrate the proper use of a digital multimeter (DMM) during diagnosis of electrical circuit problems including source voltage, voltage drop, current flow, and resistance.

III. Basic Electrical Circuit Repairs

A. Remove and replace electrical connectors and terminal ends.

B. Perform solder repair of electrical wiring.

IV. Electrical System Faults

A. Identify and interpret electrical/electronic system concern; determine necessary action.

B. Check electrical circuits with a test light; determine necessary action.

C. Check electrical circuits using fused jumper wires; determine necessary action.

D. Inspect and test fusible links, circuit breakers, and fuses; determine necessary action.

E. Inspect and test switches, connectors, relays, solid state devices, and wires of electrical/electronic circuits; perform necessary action.

F. Demonstrate knowledge of the causes and effects from shorts, grounds, opens, and resistance problems in electrical/electronic circuits.

G. Use wiring diagrams during diagnosis of electrical circuit problems.

I. Measure key-off batter drain (parasitic draw).

V. Battery Service

A. Perform battery state-of-charge test; determine necessary action.

B. Conform proper batter capacity for vehicle application; perform batter capacity test; determine necessary action.

C. Maintain or restore electronic memory functions.

D. Inspect and clean battery; fill battery cells; check cables, connectors, clamps, and hold-downs.

E. Perform slow/fast battery charge according to manufacturer’s recommendations.

F. Jump-start a vehicle using jumper cables and a booster battery or auxiliary power supply.

Content Outline and Competencies:

I. Complete Work Order and Check History
   A. Complete work order to include customer information, vehicle
identifying information, customer concern, related service history, cause,
and correction. 8.A.1
   B. Research applicable vehicle and service information, such as engine
management system operation, vehicle service history, service precautions,
and technical service bulletins. 8.A.3
   C. Locate and interpret vehicle and major component identification
numbers. 8.A.4

II. Engine Mechanical Integrity
   A. Identify and interpret engine performance concern; determine
necessary action. 8.A.2
   B. Inspect engine assembly for fuel, oil, coolant, and other leaks;
determine necessary action. 8.A.5
   C. Diagnose abnormal engine noise or vibration concerns; determine
necessary action. 8.A.6
   D. Diagnose abnormal exhaust color, odor, and sound; determine
necessary action. 8.A.7
   E. Perform engine absolute (vacuum/boost) manifold pressure tests;
determine necessary action. 8.A.8
   F. Perform cylinder power balance test; determine necessary action.
8.A.9
   G. Perform cylinder cranking and running compression tests; determine
necessary action. 8.A.10
   H. Perform cylinder leakage test; determine necessary action. 8.A.11
   I. Diagnose engine mechanical, electrical, electronic, fuel, and
ignition concerns; determine necessary action. 8.A.12
   J. Perform cooling system pressure tests; check coolant condition;
inspect and test radiator, pressure cap, coolant recovery tank, and hoses;
perform necessary action. 8.A.15
   K. Verify correct camshaft timing. 8.A.16
   L. Retrieve and record diagnostic trouble codes, OBD monitor status,
and freeze frame data; clear codes when applicable. 8.B.1
   M. Access and use service information to perform step-by-step
diagnosis. 8.B.6
   N. Inspect and test crankshaft and camshaft position sensor(s); perform
necessary action. 8.C.3

III. Fuel System Concerns
   A. Diagnose engine mechanical, electrical, electronic, fuel, and
ignition concerns; determine necessary action. 8.A.12
   B. Access and use service information to perform step-by-step
diagnosis. 8.B.6
   C. Perform active tests of actuators using a scan tool; determine
necessary action. 8.B.8
   D. Diagnose hot or cold no-starting, hard starting, poor driveability,
incorrect idle speed, poor idle, flooding, hesitation, surging, engine
misfire, power loss, stalling, poor mileage, dieseling, and emissions
problems; determine necessary action. 8.D.1
   E. Check fuel for contaminants and quality; determine necessary action.
8.D.2
   F. Inspect and test fuel pumps and pump control systems for pressure,
regulation, and volume; perform necessary action. 8.D.3
   G. Replace fuel filters. 8.D.4
   H. Inspect throttle body, air induction system, intake manifold and
gaskets for vacuum leaks and/or unmetered air. 8.D.5
   I. Inspect and test fuel injectors. 8.D.6
   J. Verify idle control operation. 8.D.7

IV. Ignition System Concerns
   A. Diagnose engine mechanical, electrical, electronic, fuel, and
ignition concerns; determine necessary action. 8.A.12
   B. Retrieve and record diagnostic trouble codes, OBD monitor status,
and freeze frame data; clear codes when applicable. 8.B.1
   C. Access and use service information to perform step-by-step
diagnosis. 8.B.6
   D. Perform active tests of actuators using a scan tool, determine
necessary action. 8.B.8
   E. Diagnose ignition system related problems such as no-starting, hard
starting, engine misfire, poor driveability, spark knock, power loss, poor
mileage, and emissions concerns; determine necessary action. 8.C.1
   F. Inspect and test ignition primary and secondary circuit wiring and
solid state components; test ignition coil(s); perform necessary action.
8.C.2
   G. Inspect and test crankshaft and camshaft position sensor(s); perform
necessary action. 8.C.3
   H. Inspect, test, and/or replace ignition control module,
powertrain/engine control module; reprogram as necessary. 8.C.4

V. Induction System Concerns
   A. Perform engine absolute (vacuum/boost) manifold pressure tests;
determine necessary action. 8.A.8
   B. Retrieve and record diagnostic trouble codes, OBD monitor status,
and freeze frame data; clear codes when applicable. 8.B.1
   C. Access and use service information to perform step-by-step
diagnosis. 8.B.6
   D. Perform active tests of actuators using a scan tool; determine
necessary action. 8.B.8
   E. Diagnose hot or cold no-starting, hard starting, poor driveability,
incorrect idle speed, poor idle, flooding, hesitation, surging, engine
misfire, power loss, stalling, poor mileage, dieseling, and emissions
problems; determine necessary action. 8.D.1
   F. Inspect throttle body, air induction system, intake manifold and
gaskets for vacuum leaks and/or unmetered air. 8.D.5
   G. Verify idle control operation. 8.D.7

VI. Exhaust System Concerns
   A. Diagnose abnormal exhaust color, odor, and sound; determine
necessary action. 8.A.7
   B. Perform engine absolute (vacuum/boost) manifold pressure tests;
determine necessary action. 8.A.8
   C. Retrieve and record diagnostic trouble codes, OBD monitor status,
and freeze frame data; clear codes when applicable. 8.B.1
   D. Diagnose hot or cold no-starting, hard starting, poor driveability,
incorrect idle speed, poor idle, flooding, hesitation, surging, engine
misfire, power loss, stalling, poor mileage, dieseling, and emissions
problems; determine necessary action. 8.D.1

30-60% of grade Competency completion level/Lab Assignments
20-50% of grade Test and quizzes
10-20% of grade Attendance, attitude and work habits
Total 100%

Attitude and Work Habits: Although attendance is important, productive
attitudes and work habits affect morale, efficiency, accuracy and safety
in the automotive shop and will be a factor in determining grades. In
addition, collaboration and teamwork will be expected and evaluated.

Grading Scale:
A = 90-100%
B = 80-89%
C = 70-79%
D = 60-69%
F = Below 60%

Content Outline and Competencies:

I. General: Electrical System Diagnosis

A. Research vehicle service information including vehicle service history, service precautions, and technical service bulletins.

B. Use wiring diagrams during the diagnosis (troubleshooting) of electrical/electronic circuit problems.

C. Inspect and test switches, connectors, relays, solenoid solid state devices, and wires of electrical/electronic circuits; determine necessary action.

D. Repair wiring harness.

II. Starting System Diagnosis and Repair

A. Perform starter current draw tests; determine needed action.

B. Perform starter circuit voltage drop tests; determine needed action.

C. Inspect and test starter relays and solenoids; determine needed action.

D. Remove and install starter in a vehicle.

E. Inspect and test switches, connectors, and wires of starter control circuits; determine needed action.

F. Differentiate between electrical and engine mechanical problems that cause a slow-crank or a no-crank condition.

III. Charging System Diagnosis and Repair

A. Perform charging system output test; determine needed action.

B. Diagnose (troubleshoot) charging system for causes of undercharge, no-charge, or overcharge conditions.

C. Inspect, adjust, and/or replace generator (alternator) drive belts; check pulleys and tensioners for wear; check pulley and belt alignment.

D. Remove, inspect, and/or replace generator (alternator).

E. Perform charging circuit voltage drop tests; determine needed action.

IV.  Lighting Systems Diagnosis and Repair

A. Diagnose (troubleshoot) the causes of brighter-than-normal, intermittent, dim, or no light operation; determine needed action.

B. Inspect interior and exterior lamps and sockets including headlights and auxiliary lights (fog lights/driving lights); replace as needed.

C. Identify system voltage and safety precautions associated with high-intensity discharge headlights.

Content Outline and Competencies:

I. ASE Certification Process

A. List the eight areas needed to be a Master Technician.

B. Explain how to register for ASE tests.

C. Describe the price structure for ASE tests.

D. Describe how test results are obtained.

II. ASE Test Construction

A. Describe the ASE test question format.

B. Analyze the author’s intent for questions.

C. List the different question types used in ASE tests.

D. Describe the level of proficiency ASE test questions address.

III. Automotive System Components

A. Identify key components in automotive systems.

B. Recognize key component names and uses.

IV. Automotive Diagnostic Methods

A. Describe various troubleshooting methods.

B. Apply troubleshooting methods to test questions.

V. Automotive Repair Procedures

A. Describe various repair procedures.

B. Apply repair procedures to test questions.

Content Outline and Competencies:

I. Engine Mechanical Integrity

A. Diagnose engine mechanical, electrical, electronic, fuel, and ignition concerns; determine necessary action. 8.A.12

B. Prepare 4 or 5 gas analyzer; inspect and prepare vehicle for test, and obtain exhaust readings; interpret readings, and determine necessary action. 8.A.13

C. Retrieve and record diagnostic trouble codes, OBD monitor status, and freeze frame data; clear codes when applicable. 8.B.1

D. Diagnose the causes of emissions or driveability concerns with stored or active diagnostic trouble codes; obtain, graph, and interpret scan tool data. 8.B.2

E. Diagnose emissions or driveability concerns without stored diagnostic trouble codes; determine necessary action. 8.B.3

F. Perform active tests of actuators using a scan tool; determine necessary action. 8.B.8

G. Diagnose hot or cold no-starting, hard starting, poor driveability, incorrect idle speed, poor idle, flooding, hesitation, surging, engine misfire, power loss, stalling, poor mileage, dieseling, and emissions problems; determine necessary action. 8.D.1

H. Inspect and test electrical/electronic sensors, controls, and wiring of EGR systems; perform necessary action. 8.E.5

I. Inspect and test electrical/electronically-operated components and circuits of air injection systems; perform necessary action. 8.E.8

II. Ignition System

A. Diagnose engine mechanical, electrical, electronic, fuel, and ignition concerns; determine necessary action. 8.A.12

B. Prepare 4 or 5 gas analyzer; inspect and prepare vehicle for test, and obtain exhaust readings; interpret readings, and determine necessary action. 8.A.13

C. Retrieve and record diagnostic trouble codes, OBD monitor status, and freeze frame data; clear codes when applicable. 8.B.1

D. Diagnose the causes of emissions or driveability concerns with stored or active diagnostic trouble codes; obtain, graph, and interpret scan tool data. 8.B.2

E. Diagnose emissions or driveability concerns without stored diagnostic trouble codes; determine necessary action. 8.B.3

F. Perform active tests of actuators using a scan tool; determine necessary action. 8.B.8

G. Diagnose hot or cold no-starting, hard starting, poor driveability, incorrect idle speed, poor idle, flooding, hesitation, surging, engine misfire, power loss, stalling, poor mileage, dieseling, and emissions problems; determine necessary action. 8.D.1

H. Inspect and test electrical/electronic sensors, controls, and wiring of EGR systems; perform necessary action. 8.E.5

I. Diagnose emissions and driveability concerns caused by the secondary air injection and catalytic converter systems; determine necessary action. 8.E.6

J. Inspect and test mechanical components of secondary air injection systems; perform necessary action. 8.E.7

K. Inspect and test electrical/electronically-operated components and circuits of air injection systems; perform necessary action. 8.E.8

III. Induction and Exhaust System

A. Diagnose engine mechanical, electrical, electronic, fuel, and ignition concerns; determine necessary action. 8.A.12

B. Prepare 4 or 5 gas analyzer; inspect and prepare vehicle for test, and obtain exhaust readings; interpret readings, and determine necessary action. 8.A.13

C. Retrieve and record diagnostic trouble codes, OBD monitor status, and freeze frame data; clear codes when applicable. 8.B.1

D. Diagnose the causes of emissions or driveability concerns with stored or active diagnostic trouble codes; obtain, graph, and interpret scan tool data. 8.B.2

E. Diagnose emissions or driveability concerns without stored diagnostic trouble codes; determine necessary action. 8.B.3

F. Diagnose hot or cold no-starting, hard starting, poor driveability, incorrect idle speed, poor idle, flooding, hesitation, surging, engine misfire, power loss, stalling, poor mileage, dieseling, and emissions problems; determine necessary action. 8.D.1

G. Diagnose oil leaks, emissions, and driveability concerns caused by the positive crankcase ventilation (PCV) system; determine necessary action. 8.E.1

H. Inspect, test, and service positive crankcase ventilation (PCV) filter/breather cap, valve, tubes, orifices, and hoses; perform necessary action. 8.E.2

I. Diagnose emissions and driveability concerns caused by the exhaust gas recirculation (EGR) system; determine action. 8.E.3

J. Inspect, test, service, and replace components of the EGR system, including EGR tubing, exhaust passages, vacuum/pressure controls, filters and hoses; perform necessary action. 8.E.4

K. Inspect and test electrical/electronic sensors, controls, and wiring of EGR systems; perform necessary action. 8.E.5

L. Diagnose emissions and driveability concerns caused by the secondary air injection and catalytic converter systems; determine necessary action. 8.E.6

M. Inspect and test mechanical components of secondary air injection systems; perform necessary action. 8.E.7

N. Inspect and test electrical/electronically-operated components and circuits of air injection systems; perform necessary action. 8.E.8

O. Inspect and test catalytic converter efficiency. 8.E.9

Content Outline and Competencies:

I. General: Drive Train Diagnosis

A. Visually inspect drive train.

B. Identify and interpret drive train concerns; determine needed action.

II. Clutch Diagnosis and Repair

A. Diagnose clutch noise, binding, slippage, pulsation, and chatter; determine needed action.

B. Inspect clutch pedal linkage, cables, automatic adjuster mechanisms, brackets, bushings, pivots, and springs; perform needed action.

C.  Inspect and/or replace clutch pressure plate assembly, clutch disc, release (throw-out) bearing, linkage, and pilot bearing/bushing (as applicable).

D. Bleed clutch hydraulic system.

E. Inspect flywheel and ring gear for wear, cracks, and discoloration; determine needed action.

F. Measure flywheel runout and crankshaft end play; determine needed action.

G. Describe the operation and service of a system that uses a dual mass flywheel.

III. Transmission/Transaxle Diagnosis and Repair

A. Inspect, adjust, lubricate, and/or replace shift linkages, brackets, bushings, cables, pivots, and levers.

B. Diagnose noise concerns through the application of transmission/transaxle powerflow principles.

C. Diagnose hard shifting and jumping out of gear concerns; determine needed action.

D. Diagnose transaxle final drive assembly noise and vibration concerns; determine needed action.

E. Disassemble, inspect clean, and reassemble internal transmission/transaxle components.

IV. Drive Shaft and Half Shaft, Universal and Constant-Velocity (CV) Joint Diagnosis and Repair (Front, Rear, All-wheel, and Four-wheel drive)

A. Diagnose constant-velocity (CV) joint noise and vibration concerns; determine needed action.

B. Diagnose universal joint noise and vibration concerns; perform needed action.

C. Inspect, remove, and/or replace bearings, hubs, and seals.

D. Inspect, service, and/or replace shafts, yokes, boots, and universal/CV joints.

E. Check shaft balance and phasing; measure shaft runout; measure and adjust driveline angles.

V. Drive Axle Diagnosis and Repair

A. Ring and Pinion Gears and Differential Case Assembly

1. Diagnose noise and vibration concerns; determine needed action.

2. Inspect and replace companion flange and/or pinion seal; measure companion flange runout.

3. Inspect ring gear and measure runout; determine needed action.

4. Remove, inspect, reinstall and/or drive pinion and ring gear, spacers, sleeves, and bearings.

5. Measure and adjust drive pinion depth.

6. Measure and adjust drive pinion bearing preload.

7. Measure and adjust side bearing preload and ring and pinion gear total backlash and backlash variation on a differential carrier assembly (threaded cup or shim types).

8. Check ring and pinion tooth contact patterns; perform needed action.

9. Disassemble, inspect, measure, adjust, and/or replace differential pinion gears (spiders), shaft, side gears, side bearings, thrust washers, and case.

10. Reassemble and reinstall differential case assembly; measure runout; determine needed action.

B. Limited Slip Differential

1. Diagnose noise, slippage, and chatter concerns; determine needed action.

2. Measure rotating torque; determine needed action.

C. Drive Axles 

1. Remove and replace drive axle shafts.

2. Inspect and replace drive axle shaft seals, bearings, and retainers.

3. Measure drive axle flange runout and shaft end play; determine needed action.

4. Diagnose drive axle shafts, bearings, and seals for noise, vibration, and fluid leakage concerns; determine needed action.

VII. Four-wheel Drive/All-wheel Drive Component Diagnosis and Repair

A. Inspect, adjust, and repair shifting controls (mechanical, electrical, and vacuum), bushings, mounts, levers, and brackets.

B. Identify concerns related to variations in tire circumference and/or final drive ratios. 

C. Diagnose noise, vibration, and unusual steering concerns; determine needed action.

D. Diagnose, test, adjust, and/or replace electrical/electronic components of four-wheel drive/all-wheel drive systems.

E. Disassemble, service, and reassemble transfer case and components.

Content Outline and Competencies:

I. General: A/C System Diagnosis and Repair

A. Performance test A/C system; identify problems.

B. Identify abnormal operating noises in the A/C system; determine needed action.

C. Identify refrigerant type; select and connect proper gauge set/test equipment; record temperature and pressure readings.

D. Leak test A/C system; determine needed action.

E. Inspect condition of refrigerant oil removed from A/C system; determine needed action.

F. Determine recommended oil and oil capacity for system application.

G. Using a scan tool, observe and record related HVAC data and trouble codes.

II. Refrigeration System Component Diagnosis and Repair

A. Determine need for an additional A/C system filter; perform needed action.

B. Remove and inspect A/C system mufflers, hoses, lines, fittings, O-rings, seals, and service valves; perform needed action.

C. Remove, inspect, and replace receiver/drier or accumulator/drier; determine recommended oil type and quantity.

D. Remove, inspect, and install expansion valve or orifice (expansion) tube.

E. Inspect evaporator housing water drain; perform needed action.

F. Diagnose A/C system conditions that cause the protection devices (pressure, thermal, and/or control module) to interrupt system operation; determine needed action.

G. Determine procedure to remove and reinstall evaporator; determine required oil type and quantity.

H. Remove, inspect, reinstall, and/or replace condenser; determine required oil type and quantity.

III. Heating, Ventilation, and Engine Cooling Systems Diagnosis and Repair

A. Inspect and test heater control valve(s); perform needed action

B. Diagnose temperature control problems in the HVAC system; determine needed action.

C. Determine procedure to remove, inspect, reinstall, and/or replace heater core.

IV. Operating Systems and Related Controls Diagnosis and Repair

A. Inspect and test HVAC system blower motors, resistors, switches, relays, wiring, and protection devices; determine needed action.

B. Diagnose A/C compressor clutch control systems; determine needed action.

C. Diagnose malfunctions in the vacuum, mechanical, and electrical components and controls of the heating, ventilation, and A/C (HVAC) system; determine needed action.

D. Inspect and test HVAC system control panel assembly; determine needed action.

E. Inspect and test HVAC system control cables, motors, and linkages; perform needed action.

F. Check operation of automatic or semi-automatic HVAC control systems; determine needed action.

V. Refrigerant Recovery, Recycling, and Handling

A. Perform correct use and maintenance of refrigerant handling equipment according to equipment manufacturer’s standards.

B. Identify A/C system refrigerant; test for sealants; recover, evacuate, and charge A/C system; add refrigerant oil as required.

C. Recycle, label, and store refrigerant.

Content Outline and Competencies:

I. General: Electrical System Diagnosis

A. Inspect, test, repair, and/or replace components, connectors, terminals, harnesses, and wiring in electrical/electronic systems (including solder repairs); determine needed action.

B. Check electrical/electronic circuit waveforms; interpret readings and determine needed repairs.

C. Repair data bus wiring harness.

II. Instrument Cluster and Driver Information Systems Diagnosis and Repair

A. Inspect and test gauges and gauge sending units for causes of abnormal readings; determine needed action.

B. Diagnose (troubleshoot) the causes of incorrect operation of warning devices and other driver information systems; determine needed action.

III. Body Electrical Systems Diagnosis and Repair

A. Diagnose operation of comfort and convenience accessories and related circuits (such as: power window, power seats, pedal height, power locks, truck locks, remote start, moon roof, sun roof, sun shade, remote keyless entry, voice activation, steering wheel controls, back-up camera, parking assist, cruise control, and auto dimming headlamps); determine needed repairs.

B. Diagnose operation of security/anti-theft systems and related circuits (such as: theft deterrent, door locks, remote keyless entry, remote start, and starter/fuel disable); determine needed repairs.

C. Diagnose operation of entertainment and related circuits (such as: radio, DVD, remote CD changer, navigation, amplifiers, speakers, antennas, and voice-activated accessories); determine needed repairs.

D. Diagnose operation of safety systems and related circuits (such as:  horn, airbags, seat belt pretensioners, occupancy classification, wipers, washers, speed control/collision avoidance, heads-up display, parking assist, and back-up camera); determine needed repairs.

E. Diagnose body electronic systems circuits using a scan tool; check for module communication errors (data communication bus systems); determine needed action.

F. Describe the process for software transfer, software updates, or reprogramming of electronic modules.

Content Outline and Competencies:

I. Fuel System Concerns
   A. Diagnose engine mechanical, electrical, electronic, fuel, and
ignition concerns; determine necessary action. 8.A.12
   B. Prepare 4 or 5 gas analyzer; inspect and prepare vehicle for test,
and obtain exhaust readings; interpret readings, and determine necessary
action. 8.A.13
   C. Retrieve and record diagnostic trouble codes, OBD monitor status,
and freeze frame data; clear codes when applicable. 8.B.1
   D. Diagnose the causes of emissions or driveability concerns with
stored or active diagnostic trouble codes; obtain, graph, and interpret
scan tool data. 8.B.2
   E. Diagnose emissions or driveability concerns without stored
diagnostic trouble codes; determine necessary action. 8.B.3
   F. Check for module communication (including CAN/BUS systems) errors
using a scan tool. 8.B.4
   G. Inspect and test computerized engine control system sensors,
powertrain/engine control module (PCM/ECM), actuators, and circuits using
a graphing multimeter (GMM)/digital storage oscilloscope (DSO); perform
necessary action. 8.B.5
   H. Perform active tests of actuators using a scan tool; determine
necessary action. 8.B.8
   I. Describe the importance of running all OBDII monitors for repair
verification. 8.B.9
   J. Diagnose hot or cold no-starting, hard starting, poor driveability,
incorrect idle speed, poor idle, flooding, hesitation, surging, engine
misfire, power loss, stalling, poor mileage, dieseling, and emissions
problems; determine necessary action. 8.D.1
   K. Diagnose emissions and driveability concerns caused by the
evaporative emissions control system; determine necessary action. 8.E.10
   L. Inspect and test components and hoses of the evaporative emissions
control system; perform necessary action. 8.E.11
   M. Interpret diagnostic trouble codes (DTCs) and scan tool data related
to the emissions control systems; perform necessary action. 8.E.12
   N. Identify hybrid vehicle internal combustion engine service
precautions. 8.F.7

II. Ignition System Concerns
   A. Diagnose engine mechanical, electrical, electronic, fuel, and
ignition concerns; determine necessary action. 8.A.12
   B. Prepare 4 or 5 gas analyzer; inspect and prepare vehicle for test,
and obtain exhaust readings; interpret readings, and determine necessary
action. 8.A.13
   C. Retrieve and record diagnostic trouble codes, OBD monitor status,
and freeze frame data; clear codes when applicable. 8.B.1
   D. Diagnose the causes of emissions or driveability concerns with
stored or active diagnostic trouble codes; obtain, graph, and interpret
scan tool data. 8.B.2
   E. Diagnose emissions or driveability concerns without stored
diagnostic trouble codes; determine necessary action. 8.B.3
   F. Check for module communication (including CAN/BUS systems) errors
using a scan tool. 8.B.4
   G. Inspect and test computerized engine control system sensors,
powertrain/engine control module (PCM/ECM), actuators, and circuits using
a graphing multimeter (GMM)/digital storage oscilloscope (DSO); perform
necessary action. 8.B.5
   H. Perform active tests of actuators using a scan tool; determine
necessary action. 8.B.8
   I. Describe the importance of running all OBDII monitors for repair
verification. 8.B.9
   J. Diagnose hot or cold no-starting, poor driveability, incorrect idle
speed, poor idle, flooding, hesitation, surging, engine misfire, power
loss, stalling, poor mileage, dieseling, and emissions problems; determine
necessary action. 8.D.1
   K. Diagnose emissions and driveability concerns caused by the
evaporative emissions control system; determine necessary action. 8.E.10
   L. Inspect and test components and hoses of the evaporative emissions
control system; perform necessary action. 8.E.11
   M. Interpret diagnostic trouble codes (DTCs) and scan tool data related
to the emissions control systems; perform necessary action. 8.E.12
   N. Identify hybrid vehicle internal combustion engine service
precautions. 8.F.7

III. Induction and Exhaust System Concerns
   A. Diagnose engine mechanical, electrical, electronic, fuel, and
ignition concerns; determine necessary action. 8.A.12
   B. Prepare 4 or 5 gas analyzer; inspect and prepare vehicle for test,
and obtain exhaust readings; interpret readings, and determine necessary
action. 8.A.13
   C. Retrieve and record diagnostic trouble codes, OBD monitor status,
and freeze frame data; clear codes when applicable. 8.B.1
   D. Diagnose the causes of emissions or driveability concerns with
stored or active diagnostic trouble codes; obtain, graph, and interpret
scan tool data. 8.B.2
   E. Diagnose emissions or driveability concerns without stored
diagnostic trouble codes; determine necessary action. 8.B.3
   F. Check for module communication (including CAN/BUS systems) errors
using a scan tool. 8.B.4
   G. Inspect and test computerized engine control system sensors,
powertrain/engine control module (PCM/ECM), actuators, and circuits using
a graphing multimeter (GMM)/digital storage oscilloscope (DSO); perform
necessary action. 8.B.5
   H. Diagnose driveability and emissions problems resulting from
malfunctions of interrelated systems (cruise control, security alarms,
suspension controls, traction controls, A/C, automatic transmissions,
non-OEM-installed accessories, or similar systems); determine necessary
action. 8.B.7
   I. Perform active tests of actuators using a scan tool; determine
necessary action 8.B.8
   J. Describe the importance of running all OBDII monitors for repair
verification. 8.B.9
   K. Diagnose hot or cold no-starting, hard starting, poor driveability,
incorrect idle speed, poor idle, flooding, hesitation, surging, engine
misfire, power loss, stalling, poor mileage, dieseling, and emissions
problems; determine necessary action. 8.D.1
   L. Diagnose emissions and driveability concerns caused by the secondary
air injection and catalytic converter systems; determine necessary action.
8.E.6
   M. Inspect and test mechanical components of secondary air injection
systems; perform necessary action. 8.E.7
   N. Inspect and test electrical/electronically-operated components and
circuits of air injection systems; perform necessary action. 8.E.8
   O. Inspect and test catalytic converter efficiency. 8.E.9
   P. Diagnose emissions and driveability concerns caused by the
evaporative emissions control system; determine necessary action. 8.E.10
   Q. Inspect and test components and hoses of the evaporative emissions
control system; perform necessary action. 8.E.11
   R. Interpret diagnostic trouble codes (DTCs) and scan tool data related
to the emissions control systems; perform necessary action. 8.E.12
   S. Identify hybrid vehicle internal combustion engine service
precautions. 8.F.7 
 

Competency completion level/Lab Assignments 30-60% of grade
Test and quizzes 20-50% of grade
Attendance, attitude and work habits 10-20% of grade
Total 100%

Attitude and Work Habits: Although attendance is important, productive
attitudes and work habits affect morale, efficiency, accuracy and safety
in the automotive shop and will be a factor in determining grades. In
addition, collaboration and teamwork will be expected and evaluated.

Grading Scale:
A = 90-100%
B = 80-89%
C = 70-79%
D = 60-69%
F = Below 60%

Content Outline and Competencies:

I. Diesel Powered Vehicles

A. High Pressure Fuel Injection

1. Identify and explain the purpose and function of high pressure fuel.

2. Identify and describe the methods of fuel metering.

3. Identify and explain the purpose and function of governor controls.

4. Describe and explain injection timing.

5. Define and describe injection rate control.

6. Define and explain fuel atomization.

7. Define and describe fuel distribution.

B. Injection Nozzles

1. Identify and describe principles of injection nozzles.

2. Identify and describe nozzle types, construction and applications.

3. Perform nozzle diagnostics and evaluation.

C. Electronically Controlled Injection Systems

1. Identify and explain the advantages of an electronically controlled system.

2. Identify and classify different injector types.

3. Identify and describe components of high pressure actuation systems.

4. Identify and describe components of the electronic control systems.

D. Common Rail Systems

1. Describe the construction and function of the different types of common rail systems.

2. Describe and explain the operation of the different types of common rail injectors.

3. Identify and describe common rail pressure control components.

E. Emission Controls/Exhaust Treatment Systems

1. Describe the construction, functions, and application of exhaust treatment systems.

2. Identify, describe and explain diesel particulate filter systems and their maintenance.

3. Identify and describe the types, composition, construction and operation of NOx emission-reduction after-treatment systems.

II. Hybrid-Electric Systems

A. Safety and Service Procedures

1. Demonstrate safely de-powering a hybrid electric vehicle (HEV).

2. Demonstrate safely performing a high-voltage disconnect.

3. Describe service issues related to HEV high-voltage systems.

4. Demonstrate correct use of appropriate personal protective equipment (PPE).

5. Explain the hazards of driving, moving, towing and hoisting a HEV.

B. Hybrid-Electric Battery Systems

1. Describe how hybrid-electric battery systems work.

2. List necessary safety precautions for working with batteries.

3. Explain safely recharging the batteries.

4. Explain high-voltage battery types.

C. Electric Motors, Generators and their Controls

1. Describe the operation of DC (direct current) and AC (alternating current) electric motors.

2. Explain how a brushless DC motor works.

3. Discuss the use of electric motors in HEV’s.

4. Describe DC-to-DC converter operation.

5. Discuss DC-to-AC inverter operation.

D. Regenerative Braking Systems

1. Explain how regenerative braking works and the principles involved.

2. Discuss regenerative braking parts and components.

3. Describe service precautions with regenerative brakes.

E. Electric and Plug-In Hybrid Vehicles

1. Identify a plug-in hybrid electric vehicle (PHEV).

2. Explain recharging a high-voltage battery in a PHEV and electric vehicle (EV).

3. Discuss battery capacity and range correlation in an EV.

4. Describe the different chargers used for PHEV or EV vehicles.

Content Outline and Competencies:

I. General: Transmission and Transaxle Diagnosis

A. Identify and interpret transmission/transaxle concerns, differentiate between engine performance and transmission/transaxle concerns; determine needed action.

B. Perform pressure tests (including transmissions/transaxles equipped with electronic pressure control); determine needed action.

C. Diagnose noise and vibration concerns; determine needed action.

D. Perform stall test; determine needed action.

E. Perform lock-up converter system tests; determine needed action.

F. Diagnose transmission/transaxle gear reduction/multiplication concerns using driving, driven, and held member (power flow) principles.

G. Diagnose electronic transmission/transaxle control systems using appropriate test equipment and service information. 

H. Diagnose pressure concerns in a transmission using hydraulic principles (Pascal’s Law).

II. In-Vehicle Transmission/Transaxle Maintenance and Repair

A. Inspect, test, adjust, repair, and/or replace electrical/electronic components and circuits including computers, solenoids, sensors, relays, terminals, connectors, switches, and harnesses. 

B. Demonstrate understanding of the relearn procedure.

III. Off-Vehicle Transmission and Transaxle Repair

A. Inspect, leak test, flush, and/or replace transmission/transaxle oil cooler, lines, and fittings.

B. Disassemble, clean, and inspect transmission/transaxle.

C. Inspect, measure, clean, and replace valve body (includes surfaces, bores, springs, valves, switches, solenoids, sleeves, retainers, brackets, check valves/balls, screens, spacers, and gaskets).

D. Inspect servo and accumulator bores, pistons, seals, pins, springs, and retainers; determine needed action.

E. Assemble transmission/transaxle.

F. Inspect, measure, and reseal oil pump assembly and components.

G. Measure transmission/transaxle end play and/or preload; determine needed action.

H. Inspect, measure, and/or replace thrust washers and bearings.

I. Inspect oil delivery circuits, including seal rings, ring grooves, and sealing surface areas, feed pipes, orifices, and check valves/balls.

J. Inspect bushings; determine needed action.

K. Inspect and measure planetary gear assembly components; determine needed action.

L. Inspect case bores, passages, bushings, vents, and mating surfaces; determine needed action.

M. Diagnose and inspect transaxle drive, link chains, sprockets, gears, bearings, and bushings; perform needed action.

N. Inspect measure, repair, adjust or replace transaxle final drive components.

O. Inspect clutch drum, piston, check-balls, springs, retainers, seals, friction plates, pressure plates, and bands; determine needed action.

P. Measure clutch pack clearance; determine needed action.

Q. Air test operation of clutch and servo assemblies.

R. Inspect one-way clutches, races, rollers, sprags, springs, cages, retainers; determine needed action.

Content Outline and Competencies:

I. Shop safety and tool usage

A. Identify general shop safety rules.

B. Demonstrate shop safety procedures.

C. Demonstrate proper use and storage of tools and equipment.

II. Personal standards and work habits

A. Demonstrate personal integrity standards.

B. Demonstrate Work habits appropriate to the industry.

III. The diagnostic process

A. Create a personal diagnostic routine.

B. Demonstrate a reliable diagnostic process.

IV. Specialized equipment operation

A. Determine necessary tests and equipment for diagnosing the problem.

B. demonstrate the proper operation of specialized equipment.

V. Theory and operation review of vehicle electrical and mechanical systems.

A. Explain theory of vehicle electrical and mechanical systems.

B. Demonstrate the use of theory and operation of vehicle electrical and mechanical systems diagnosis and repair.

VI. Vehicle preparation for service and return to the customer

A. Demonstrate vehicle preparation for service.

B. Demonstrate vehicle preparation for return to the customer.

C. Demonstrate proper paperwork for each vehicle.

Content Outline and Competencies:

I. Introduction to Internship

A. Interpret program requirements.

B. Complete the required forms from the handbook.

C. Discuss the procedures set forth by the Career Program Facilitator.

II. The Job Search Process

A. Find three sources of job information.

B. Identify three job postings in your career program field.

III. Obtaining Employment

A. Write a letter of inquiry.

B. Write a resume.

C. Complete a job application. D. Describe a job interview.

IV. Employer/Employee Relationships

A. Define labor relations.

B. Explain human relations.

C. Write examples of conflict and resolution.

V. Employee Growth and Development

A. Define employment advancement.

B. Examine personal assessment of your job performance.

C. Depict management opportunities in your career area.

VI. Leadership in the Work Place

A. Describe qualities of leadership.

B. Define fellowship.

VII. Dealing with Termination

A. Define termination with cause.

B. Define termination without cause.

C. Describe how to deal with employment termination.

VIII. The Structure of Business and Industry

A. Explain organizational theory.

B. Describe work flow patterns.

IX. Conclusion

A. Summarize your employer evaluation.

B. Write a self evaluation.