Automotive Restructure Proposal

1

Automotive Restructure Proposal

Table of Contents Pg.

1. Safety Course—OSHA Safety Training 2

2. Introduction to Automotive Technology—G1 ASE 3

3. Engine Repair—A1 ASE & AERA Certifications 5

4. Automatic Transmissions—A2 ASE 7

5. Manual Transmissions—A3 ASE 9

6. Brake Systems—A4 ASE & State Brake License 11

7. Steering and Suspension—A5 ASE 12

8. Electrical—A6 ASE & State Lamp License 13

9. Advanced Electrical—A6 & L3 ASE 14

10. Heating and Air Conditioning—A7 ASE & MAC 16

11. Engine Performance—A8 ASE 19

12. Advanced Engine Performance—L1 ASE 21

13. Light Duty Diesel—A9 & L2 22

14. Smog Inspector Training—Level 1 & Level 2 23

15. Automotive Management—C1 ASE 25

2

Safety Course (OSHA safety training)

This should be an online training course required for all automotive students.

1. General Shop Safety Training

a. Safety Training should include specific safety training for:

i. AT1

ii. AT2

iii. IT3

iv. IT4

2. Online SP2 training

a. Mechanical Pollution Prevention

b. Mechanical Safety

3

Introduction to Automotive Technology (G1)

Safety—General safety

A. The Auto Shop and Safety

B. S/P 2 Online Safety Modules and Tests

General overview of automotive

C. The Automobile

1. Brief overview of all systems and major components

D. Basic Hand Tools & Power tools

E. Automotive Measurement and Math

1. Precision measuring tools and micrometers

2. Lab assignment using: straight edge, feeler gauge, T gauge, micrometer, and dial

indicator

F. Fasteners, Gaskets, Seals, and Sealants

1. Metric and standard fasteners and bolt ID

2. Thread repair

3. Brief discussion of gaskets and seals along with general repair techniques

4. Discussion of different sealants (silicone, Loctite, and other adhesives)

G. Vehicle Maintenance

1. Oil service and other maintenance inspections

2. Lab assignment to R&R timing belt

H. Bureau of Automotive Repair “Write It Right” Guideline

1. HW assignment and class discussion of invoices. Lab assignment for filling out invoices

I. Tire, Wheel, and Wheel Bearing Fundamentals

1. Tire purpose, function and part ID. Lab to mount and dismount tires, Lab to rotate and

balance tires. Demonstration of tire repair and diagnosis. Discussion of Tire pressure

monitoring systems

J. Suspension System Technology

1. Purpose function and parts ID. Lab assignment for checking suspension for worn parts

K. Steering System Technology

1. Purpose function and parts ID. Lab assignment for checking steering for worn parts

2. ****weak on power steering systems***

L. Brake System Technology

1. Purpose function and parts ID. Brake inspection lab component. Demonstration of brake

job and repacking wheel bearings.

2. *** Discussion is very brief could defiantly be more in-depth for brake class.***

M. Engine Fundamentals

1. Purpose function and parts ID. Lab component for hooking up and reading manifold

vacuum. Demonstration of compression test and leak down test.

N. Cooling System Technology

1. Purpose function and parts ID. Students inspect cooling systems for leaks in lab

2. ***Not thorough enough to equip students for modern diagnosis of cooling system

malfunctions.

O. Electrical Principals and Ohm’s Law

1. Basic ohms law and meter usage. Students build and measure series and parallel circuits

for voltage, voltage drop, and amperage in the lab. Use a sub-harness to check for

resistance, open circuits, and shorts. Pretty thorough on ohms law.

4

P. 12-Volt and HV Battery Technology & Starter

1. Purpose function and parts ID. Basic battery construction and demonstration of testing.

Demonstration of starting system diagnosis and some reading and using wiring

diagrams.

2. *** Improvements could be made in diagnosing starting systems with Vat 40 this is

demonstrated but there is no hands on component to this.***

Q. Charging System Fundamentals

1. Purpose function and parts ID. Basic alternator construction and demonstration of

testing. Demonstration of charging system diagnosis and some reading and using wiring

diagrams.

2. *** Improvements could be made in diagnosing charging systems with Vat 40 this is

demonstrated but there is no hands on component to this.***

R. Ignition System Technology

1. Purpose function and parts ID. Basic maintenance level information. *** I do not go

much into the details of the various ignition system designs or supporting sensors for

the timing of the ignition spark. In this class I do not have students check ignition timing

because I do not have a running engine for them to check timing on.

S. Gasoline Injection Fundamentals

1. Purpose function and parts ID. Very fundamental in this area. Maintenance level

information.

T. Emission Control Systems Technology

1. Purpose function and parts ID. Consumer level information and general info. No

diagnosis or testing is covered in this class.

5

Engine Repair A (A1)

Safety, Engine Construction, Diagnosis, Disassembly and Inspection

A. Chapter 2 - Engine Shop Safety

1. Shop Health and Safety, cleanliness, Fire Prevention, Tool and Equipment Safety, Lifting

Equipment, Hazardous Materials.

2. Online Safety Modules and Tests

3. Bakersfield College Engine Lab Safety presentation and Test

B. Chapter 1 - Engine Construction and Operation

1. Two and Four Stroke Theory, Engine Classification, Engine Design, Firing Order,

Cooling, Spark and Compression Ignition.

C. Chapter 3 - Diagnosing Engine Problems

1. Oil Consumption and Leaks, Fuel Mixture Issues, Compression Loss, Engine Noises,

Lubricating Problems, Cooling Problems, Electrical Problems.

D. Chapter 4 - Engine Disassembly & Inspection

1. Engine Removal and Disassembly, Engine Identification, Service Information

E. Chapter 5 - Cleaning the Engine

1. Cleaning Procedures, Cleaning Equipment, Cleaning Chemicals

F. Chapter 6 - Measuring

1. Units of Measurement, Measuring Tools, Measuring Procedures

2. Micrometer Quiz

The Breathing System

G. Chapter 7 - Cylinder Head: Parts and Service

1. Disassembly, Cleaning and Inspection, Crack Repair, Valve Guide Repair, Resurfacing

H. Chapter 8 - Cylinder Head: Springs, Valves and Valve Seats

1. Valve Refacing, Valve Seat Repair, Springs, Pushrods, Rocker Arms, Head Assembly

I. Chapter 9 - Camshafts, Lifters, Timing Belts and Chains

1. Valve Lifters, Hydraulic Lifter Operation, Valve Lash, Cam Drives, Timing Devices

Engine Repair B (A1)

Cylinder Block Assembly

A. Chapter 11 - Cylinder Block: Inspection and Service

1. Engine Block Design and Inspection, Cylinder Boring and Honing, Cylinder Sleeves,

Lifter Bores, Deck Resurfacing.

B. Chapter 12 - Crankshaft, Bearings and Engine Balancing

1. Crankshaft Design, End Thrust, Crank Inspection, Crank Bearings, Engine Balancing

C. Chapter 13 - Pistons, Rings and Connecting Rods

1. Piston Design, Ring Materials and Design, Connecting Rod Design, Materials, Inspection

and Machining

D. Chapter 14 - Lubrication

1. Engine Oil Licensing and Certification, Oil Pumps and Filters, Crankcase Ventilation,

Emission Control Devises

E. Chapter 15 - Cooling System

1. Cooling System Circulation, Water Pumps, Drive Belts, Radiators, Thermostats, Hoses,

Ethylene Glycol Coolant

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Engine Repair and Reassembly

F. Chapter 16 - Engine Hardware: Fasteners, Thread Repair and Gaskets

1. Bolt Stretch, Torque and Friction, Drill Bits, Taps and Dies, Gaskets and Seals, Adhesive

G. Chapter 10 - Engine Power Development:

1. Manifolds, Turbochargers, Superchargers, Camshaft Profiles, Engine Displacement,

Torque and Horsepower, Engine Performance Measurement

H. Chapter 17 - Reassembly and Starting

1. Engine Assembly and Installation, Engine Starting and Initial Break-in, Final Inspection,

Warranty Coverage and Issues

Engine Repair C (A1)

A. Disassembly of complete Engine

1. Initial Diagnosis

2. Order of disassembly procedure

B. Cleaning & Inspection of Individual Components

1. Cleaning equipment, chemicals and procedure

2. Measurement & inspection of components

C. Cylinder Head

1. Valve Repair

2. Valve Guide Repair

3. Valve Seat Repair

4. Cylinder Head Resurfacing

5. Reassemble Procedures

Lab:

D. Engine Disassembly

E. Cleaning & Inspection of Components

F. Cylinder Head

1. Inspection

2. Valve Repair

3. Valve Guide Repair

4. Valve Seat Repair

5. Resurfacing

6. Reassembly

Engine Repair D (A1)

A. Personal and industrial safety

B. Environmental hazards in the automotive workplace

C. Consumer protection regulations

D. Personal work ethics

E. Fuel system and emission controls

F. Engine operating principals

G. Engine air/fuel requirements

H. Fuel delivery systems

I. Electronic engine control systems

J. Supercharging and turbocharging systems

K. Variable, flex and bi-fuel systems

L. Emissions, five gas theory and emission inspection programs

M. Diagnosis and repair of common fuel and emission system problems

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Automatic Transmissions and Transaxles (A2)

A. Automatic transmissions and transaxles: Basic theory and concepts

1. Drive train layout

a. Rear-wheel drive train components

b. Front-wheel drive train components

c. Power flow through the transmission and transaxle

2. Transmission basic construction and components

3. Transmission design variations: Chrysler Ford General Motors Nissan and Toyota

4. Internal construction and components basic power flow

5. Hydraulic operation: concepts and applied theory

6. Frictional members and theory of operation

7. Torque converters and oil Pumps

a. Purpose basic designs theory of operation

b. Torque multiplication theory

c. Lockup systems and design

8. Gear assemblies and shafts

a. Planetary gears

1. Theory of operation

2. Power flow reverse gear reduction and overdrive concepts

b. Final drives and differentials

c. Four wheel drive variations

d. Drive chains

e. 4-wheel drive transfer concepts

9. Reaction and friction units

a. Basic purpose and function

b. Frictional characteristics concepts and related purpose

c. Brake bands servos and accumulators

d. One-way clutches and brakes

e. Multiple-friction disc clutch and brake assemblies

10. Transmission oil coolers

11. Electrical and electronic controls

a. Electro-mechanical theory and concepts

b. On-board diagnostics

c. System testing

12. Hybrid vehicle drive train basic layout and concepts

B. General transmission and transaxle diagnosis

1. Acquiring maintenance service and repair information

a. Electronic and hard-copy sources

b. Factory vs. aftermarket technical information

c. Vehicle Identification Number (VIN)

d. Vehicle certification labels and calibration decals

e. Vehicle service history service precautions

f. Technical Service Bulletins (TSB’s)

2. Transmission and transaxle maintenance

a. Basic transmission service: visual inspection fluid and filter replacement

b. Basic adjustments: throttle valve (TV) linkages or cables; manual shift linkages

or cables transmission range sensor; gear select indicator

c. Electronic mechanical hydraulic and vacuum control systems

3. Transmission/transaxle basic diagnostics and trouble analysis

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a. Engine condition and operation and its effect on transmission operation

b. Transmission and transaxle fluid leaks usage level and condition concerns

c. Pressure test

d. Stall test

e. Lock-up converter system tests

f. Noise vibration harshness (NVH) concerns

C. In-vehicle transmission and transaxle service and repair

1. Seals and gaskets

2. Extension housing bushings and seals

3. Transmission fluid cooler lines and fittings

4. Speedometer drive gear driven gear vehicle speed sensor (VSS) and retainers

5. Governor assembly

6. Electronic transmission control systems

7. Alignment of power train mounts

D. Off-vehicle transmission and transaxle repair

1. Torque converters

2. Transmission/transaxle disassembly cleaning measurements analysis reassembly

3. Valve bodies

4. Internal passages and bores

a. Servo bore piston seals pin spring and retainers

b. Accumulator bore piston seals spring and retainers

5. Oil pump and converter

a. Converter flex plate attaching parts pilot pump drive and seal contact areas

b. Torque converter end-play and interference stator clutch

c. Oil pump assembly and components

6. Gear train shafts bushings and case

a. End-play or preload

b. Thrust washers and bearings

c. Oil delivery seal rings ring grooves and sealing surface areas

d. Bushings

e. Planetary gear assembly

1. Sun ring planetary gears

2. Carrier assembly

3. Thrust washers

f. Case bores passages vents bushings and mating surfaces

g. Transaxle drive link chains sprockets gears bearings and bushings

h. Transaxle final drive and differential components

i. Parking pawl shaft spring and retainer

7. Reaction and friction units and members

a. Bands and drums

b. Clutch drum piston check-balls springs retainers seals

c. Roller and sprag clutch races rollers sprags springs cages and retainers

d. Clutch pack

1. Friction disks and steel disks

2. Clutch pack clearance

3. Air test of clutch and servo assemblies

9

Manual Transmissions and Drivetrains (A3)

A. General Drive Train concepts overview

1. Drive Train layout

a. Rear-wheel drive train components

b. Front-wheel drive train components

2. Mounting and insulating methods

B. General Drive Train Diagnosis

1. Applicable vehicle and service Information

2. Vehicle service history service precautions and Technical Service

C. Bulletins (TSB’s)

1. Vehicle and major component identification numbers (VIN vehicle certification labels

calibration decals)

2. Fluid usage level and condition concerns

3. Noise vibration and harshness concerns

D. Clutch Diagnosis and Repair

1. Characteristics and theory of friction

2. Clutch system components and operation

a. Flywheel and ring gear

b. Pressure plate assembly

c. Clutch disk

d. Release (throw-out) bearing

e. Pilot bearing or bushing

f. Clutch pedal linkage cables automatic adjuster mechanisms brackets bushings

pivots and springs

g. Hydraulic system slave and master cylinders lines and hoses

E. Transmission/transaxle Diagnosis and Repair

1. Manual Transmission/Transaxle

a. Power flow through the transmission/transaxle

b. Gear reduction and overdrive theory

c. Synchronizers

d. Bearings

e. Shift mechanisms

f. Endplay or preload (shim or spacer selection procedure) on

transmission/transaxle shafts

1. Synchronizer hub sleeve keys (inserts) springs and blocking rings

2. Speedometer drive gear driven gear vehicle speed sensor (VSS) retainers

3. Transaxle final drive pinion gears (spiders) shaft side gears side bearings

thrust washers and case assembly

4. Lubrication devices (oil pump or slingers)

g. External components

1. Shift cover forks levers grommets shafts sleeves detent mechanism

interlocks and springs

2. Transmission/transaxle sensors and switches

3. Transmission/transaxle case extension housing case mating surfaces

bores bushings and vents

4. Shift linkages brackets bushings cables pivots and levers

5. Powertrain mounts.

6. Gaskets seals and sealants

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F. Driveshaft and Half Shaft Universal and Constant-Velocity (CV) Joint Diagnosis and Repair

1. Constant-velocity (CV) joint noise and vibration concerns

2. Universal joint noise and vibration concerns

3. Front wheel drive (FWD) front wheel bearing

4. Shafts yokes boots and CV joints

5. Shaft center support bearings

6. Shaft balance shaft runout driveline angles

7. Shaft balance shaft runout driveline angles

8. Companion flange and pinion seal

G. Drive Axle Diagnosis and Repair

1. Drive Shafts and Universal Joints

2. Drive shaft construction placement and operation

3. Universal joints (U-joints)

4. Differentials / final drives

a. Construction purpose power flow

b. Gear reduction

c. Differential action

H. Four-wheel Drive/All-Wheel Drive Component Diagnosis and Repair

1. System layout construction

2. Power flow

3. 4-wheel drive shift control

4. Locking axles

5. Transfer case construction and operation

6. Electronic controls

7. Operation shift controls

8. Electronic controls

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Brake Systems (A4)

A. General Brake System Diagnosis

1. Basic principles and theory

a. Hydraulics principles: Pascal's Law

b. Principles of friction: Kinetic theory

2. Overview of system components

3. Applicable vehicle and service information

4. Vehicle Identification Number (VIN) decals

5. Measurement math concepts

6. Conversion principles: SAE and metric

B. Hydraulic System Diagnosis and Repair

1. Overview of system parts and components

2. Master cylinder operation and brake pedal height

3. Symptoms of hydraulic malfunctions

4. System leaks: Internal and external

5. Brake lines and hoses

6. Combination valves and Proportioning valves

7. Warning lights

C. Drum Brakes Diagnosis and Repair

1. Overview: System components

2. Backing plate assembly and related components

3. Friction materials and brake shoes

4. Parking brake

5. Symptoms of component failures

6. Brake drums and micrometer measurement

D. Disc Brakes Diagnosis and Repair

1. Overview: System components

2. Caliper assembly

3. Friction materials and brake pads

4. Hardware

5. Rotor designs

6. Integrated parking brake

7. Symptoms of component failures

8. Brake rotors and micrometer measurement

E. Power Assist Units Diagnosis and Repair

1. Positive and negative air pressure theory and concepts

2. Power booster and Hydro-booster

F. Miscellaneous (Wheel Bearings Parking Brakes electrical Etc. Diagnosis and Repair)

1. Wheel bearing types service and repair

2. Wheel shimmy and vibration issues

3. Parking brake cable types service and repair

4. Stop light operation circuitry diagnostics and repair

G. Electronic Brake Traction and Stability Control Systems Diagnosis and Repair

1. Body Control Module (BCM) system control and communication

2. PC-based diagnostics

3. Flash codes

4. Speed sensor testing

5. Traction control integration

6. System pressure testing

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Steering and Suspension (A5)

A. Technical service and repair information

1. Acquiring vehicle service and repair information online hard-copy

2. Vehicle service history service precautions and Technical Service Bulletins (TSB’s)


calibration decals)

B. Steering systems concepts diagnosis and repair

1. Supplemental Restraint Systems (SRS)

2. Steering wheel SRS coil

3. Power-steering (P/S) systems

4. Rack-and-pinion bearing sector lash

5. Tie rod ends

6. Collapsible steering columns

7. P/S pumps and P/S fluids correct application and maintenance

8. Computer-controlled electronic steering

C. Suspension systems concepts diagnosis and repair

1. Control arms short- and long-arm designs

2. Strut assemblies

3. Suspension bushings noise and wear diagnostics

4. Ball joint inspection and replacement

5. Stabilizer bars and bushings

6. Torsion bar inspection and replacement

7. Ride-height control

8. Stability control

D. Wheel alignment: Measuring evaluating and adjusting the following angles and readings

1. Basic camber caster toe angles toe-out on turns

2. Steering Axis Inclination (SAI) reading

3. Included Angle (IA) readings

4. Scrub radius, Thrust angle, Ride height and Steering center

E. Wheels and tires

1. Design theory and concepts

2. Tire wear patterns

3. Acquiring correct tire air pressure information

4. Evaluating tire noise vibration harshness (NVH) issues

5. Rotation directional tire precautions

6. Tire removal repair replacement and installation precautions

7. Tire/wheel balance

F. Technical service and repair information

1. Acquiring vehicle service and repair information online hard-copy

2. Vehicle service history service precautions and Technical Service Bulletins (TSB’s)


calibration decals)

G. Steering systems concepts diagnosis and repair

1. Supplemental Restraint Systems (SRS)

2. Steering wheel SRS coil

3. Power-steering (P/S) systems

4. Rack-and-pinion bearing sector lash

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Electrical/Electronic Systems: Introductory (A6)

A. General Electrical System theory and concepts.

1. Electrical basics: Electron theory ohm’s law magnetic induction concepts.

2. Wiring diagrams and Electrical circuits.

3. Voltages and voltage drops in electrical/electronic circuits.

4. Current flow in electrical/electronic circuits and components.

5. Shorts grounds opens and high resistance problems in electrical/electronic.

6. Parasitic current draw.

7. Circuit protective devices.

8. Circuit components: Switches connectors insulators conductors.

9. Units of measure and conversion processes used in electricity and electronics.

B. Battery theory and science

1. Battery state-of-charge.

2. Battery capacity (load high-rate discharge).

3. Electronic memory concepts.

4. Slow/ vs. fast battery charge concepts.

5. Battery cables connectors clamps and hold-downs.

6. Theory and accepted practices of applying auxiliary vehicle electrical power sources.

C. Starting System

1. Concepts of magnetism induction and torque.

2. Starter current draw and circuit voltage drop.

3. Relays solenoids and magnetic induction theory.

D. Charging System concepts and theory of operation.

1. Electro-mechanical theory and concepts.

2. AC / DC theory and diode rectification concepts.

3. Concepts and analysis of undercharge no-charge or an overcharge condition.

4. Voltage regulation.

E. Lighting Systems power flow concepts

1. Headlights taillights and stoplights.

2. Clearance and auxiliary lighting.

3. Turn signal or hazard light operation.

4. Module control of daytime running lights.

5. Voltage drop and lighting systems functionality.

F. Driver Information Systems theory and operation

1. Concepts and causes of intermittent high low or no gauge readings.

2. Circuit voltage regulators (limiters).

3. Gauges and gauge sending units.

4. Printed circuit board concepts.

5. Constant intermittent or no warning light and driver information system operation.

6. Intermittent high low or no readings on electronic digital instrument clusters.

7. Sensors sending units connectors and wires of electronic digital instrument circuits.

G. Horn and Wiper/Washer.

1. Circuitry layout and structure.

2. Electrical concepts and theories associated with these circuits.

H. Accessories analysis and diagnostics

1. Slow intermittent or no operation of motor-driven accessory circuits.

2. Poor intermittent or no electric door and hatch/trunk lock operation.

3. Unregulated intermittent or no operation of cruise control systems.

4. Supplemental restraint system warning light staying on or flashing. Safety procedures to

prevent accidental deployment.

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Advanced Electrical/Electronic Systems (A6 & L3)

A. Review of electrical fundamentals and basic test equipment

1. Current flow in electrical circuits

2. AC vs. DC voltage concepts

3. Insulators vs. conductors

4. Ohm’s law to figure voltage current and resistance values.

5. Voltage values and voltage drop concepts

6. Circuit protection: Fusible links circuit breakers and fuses

7. Switches connectors wire types and sizes

8. Electrical sensors

9. Electrical malfunctions: Shorts grounds opens and high resistance issues

10. Key-off battery parasitic drain

11. Diagnosis of electrical circuits using fused jumper wires

12. Voltmeters Ammeters Ohmmeters

13. Test lights multimeters logic probes

B. Electrical circuit analysis

1. Series circuits

2. Parallel circuits

3. Series-parallel circuits

4. Circuits that perform work

5. Control circuits

6. Circuit diagnostics

C. Advanced electronics fundamentals

1. Analog vs. digital circuits

2. Concepts of Kirchhoff’s law

3. Solid state principles

D. Electronic control devices:

1. Electronic Control Units (ECU)

2. Body Control Modules (BCM)

3. Inputs vs. outputs

4. Actuators

E. Advanced circuitry: Concepts and principles

1. Integrated circuits

2. Multiplex circuits

3. Controller Area Network (CAN) concepts

4. Local Area Network (LAN) circuits

5. Binary Unit System (BUS) concepts

6. Other advanced on-board circuits

a. Supplemental Restraint System (SRS)

b. Timer-controlled circuits

c. Duty cycle and pulse width

F. Hybrid Technology

1. Basic layout and concepts

2. battery system

3. internal combustion engine (ICE)

4. drive system

5. power electronics

6. Hybrid supporting systems.

7. Diagnostic strategies and pinpoint tests

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G. Advanced diagnostic equipment:

1. The Digital Storage Oscilloscope (DSO)

a. DSO slope switch and trigger

b. Reading and interpreting a DSO pattern

c. Pulsing DC voltage signal and frequency

d. Using a current probe with a DSO

e. Analyzing the DSO multiple-trace function

2. Scan tools: Factory and aftermarket

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Heating and Air Conditioning (A7)

A. Unit 1: Introduction and Shop Safety

1. Historical development of air conditioning

2. Domestic refrigeration

3. Mobile air conditioning

4. The service technician

B. Unit 2: Body Comfort

1. The body produces heat

2. The body rejects heat

3. Conditions that affect body comfort (temperature, humidity, & air movement)

C. Unit 3: Matter

1. The structure of matter

2. Arrangement and movement of molecules

D. Unit 4: Heat

1. Sensible heat

2. Measurement of heat

3. Latent heat

4. Specific heat

5. Cold – the absence of heat

6. Thermometers – temperature conversion

E. Unit 5: Pressure

1. Atmospheric pressure

2. Temperature and pressure

F. Unit 6: Principles of Refrigeration

1. Air conditioning

2. The mechanical refrigeration system

3. Ton of refrigeration

G. Unit 7: Refrigerant and Refrigeration Oil

1. Temperature and pressure relationship of R-12,R-134A and compatible alternatives

2. Handling refrigerant

3. Special safety precautions

4. Refrigeration oil

5. Compatibility

6. Servicing tips

H. Unit 8: The Refrigeration Circuit

1. Receiver/Drier

2. Thermostatic expansion valve

3. Evaporator

4. Compressor

5. Condenser

6. Hoses

7. Operation

I. Unit 9: Moisture and Moisture Removal

1. Moisture removal

2. Triple evacuation method.

J. Unit 10: Service Valves

1. Schrader valve

2. Hand shutoff valve

K. Unit 11: Manifold and Gauge Ser

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1. Manifold

2. Low-side gauge

3. High-side gauge

4. Gauge calibration and scales

5. Hoses

6. The third gauge

L. Unit 12: Leak Detectors

1. Halide leak detector principles of operation maintenance

2. Leak detection using a soap solution

3. Leak detection using dye

4. Electronic leak detectors

M. Unit 13: Compressors

1. Function

2. Design

1. crankshaft

2. axial plate

3. Reciprocating or piston-type compressors

4. York Vane rotary compressor

5. Diagnosing problems and making repairs

N. Unit 14: The Receiver/Dehydrator

1. Receiver/Dehydrator Components

1. the desiccant

2. the filter

3. the pickup tube

4. the strainer

5. the sight glass

2. How the receiver dehydrator functions

3. Installation and servicing

4. Accumulator

O. Unit 15: The Thermostatic Expansion Valve

1. Operation of the thermostatic expansion valve

1. remove bulb

2. throttling action

3. modulating action

4. controlling action

5. superheat

2. The thermostatic expansion valve as a control device

3. Equalizers

4. Fixed orifice tube

5. Valves – In – Receiver

6. Combination valve

P. Unit 16: Electrical Circuits

1. Fuses and circuit breakers

2. Master control

3. Thermostat

4. Bellows-type thermostat

5. Bimetallic

6. Blower Motor

7. Electromagnetic clutch

8. Pressure cutoff switch

9. Compressor discharge pressure switch

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10. Coolant temperature warning system

Q. Unit 17: Vacuum Circuits

1. Vacuum-Operated devices

2. Vacuum source

1. reserve tank

2. check vale

3. Restrictor

4. Vacuum system diagrams

R. Unit 18: Pressure Controls

1. Suction pressure regulators

2. Evaporator pressure regulators

3. Pilot-operated evaporator pressure regulator

4. Evaporator temperature regulator

5. Pilot-operated valve

6. Valves – in – receiver

7. Combination valve

S. Unit 19: Automatic Temperature Controls

1. Electropneumatic Temperature Control

1. sensors

2. Amplifier

1. transducer

2. power servo

3. Electrothermo-Hydraulic Pneumatic Temp. Control

1. sensors and power element

2. temperature door

3. program vacuum switch

4. ambient compensator

5. aspirator and bimetal sensor

T. Unit 20: Control Devices

1. Heater control

2. Refrigerant pressure controls

3. Mode doors

4. Vacuum motors

5. Blower control

6. Time-delay relay

7. Electrovacuum relay

8. Ambient switch

9. Thermostatic vacuum valve

10. Check valves and relays

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Engine Performance (A8)

A. Review: Electrical fundamentals and basic test equipment.

1. Current flow in electrical circuits.

2. AC vs. DC voltage concepts.

3. Ohm’s law: Computing voltage current and resistance values.

4. Electro-mechanical concepts.

5. AC / DC theory and diode rectification concepts.

6. Voltage values and voltage drop concepts.

7. Electrical malfunctions: Shorts grounds opens and high resistance issues.

8. Key-off battery parasitic drain.

9. Basic diagnostics used on engine management circuits.

10. Voltmeters Ammeters Ohmmeters.

11. Test lights multimeters logic probes.

B. Review: Theory and concepts of engine operation.

1. Basic engine construction and operation.

2. Combustion theory and concepts.

C. Review: diagnostics of engine mechanical condition.

1. Vacuum Gauge, Cylinder compression, Cylinder leakage.

2. Cylinder power balance tests.

3. Exhaust back pressure testing.

D. Computer control of engine management systems.

1. Fundamentals of control modules.

2. Basic functions.

3. Input sensors.

a. Engine coolant temperature.

b. Intake air temperature.

c. Manifold pressure.

d. Barometric pressure.

e. Throttle position.

f. Oxygen.

g. Mass air flow sensors.

4. Output actuators.

E. Basic ignition system concepts.

1. Science of combustion: Igniting the air-fuel mixture.

2. Concepts of magnetic induction: High secondary voltage for the spark plugs.

3. Timing the spark.

4. Analysis of ignition waveform.

F. Engine fuels and combustion

1. Gasoline

a. Science of petroleum processing.

b. Ratings and additives.

c. Testing fuel for contaminants and quality.

d. Combustion concepts and theory.

2. Other fuels

a. Diesel bio-diesel.

b. Ethanol methanol.

c. E85 mixed fuels.

G. Basic electronic fuel-injection concepts.

1. Throttle body style.

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2. Port fuel injection.

3. Science of air / fuel ratio and stoichiometric concepts.

4. Controlling the air/fuel mixture.

5. Idle air controls.

H. Controlling excessive exhaust and other fuel-related emissions.

1. Science of smog.

a. Ozone from sunlight NOX and VOC’s.

b. Equipment and other contributors to smog.

2. Mechanical emission control devices: Theory and concepts of operation.

a. PCV (Positive Crankcase Ventilation).

b. Air injection.

c. Evaporative Emission Control System (EVAP). d. Exhaust gas recirculating

system (EGR)

d. Catalytic converters.

3. Science of electronics to control exhaust and other emissions.

a. On-board Diagnostics (OBD) I and OBD II systems overview.

b. Diagnostics task management.

c. Monitors and enabling criteria On-board Diagnostics (OBD) I and OBD II

systems overview

I. Engine performance diagnosis and testing.

1. Retrieval and interpretation of service and repair information.

2. Identification and interpretation of engine performance concerns.

3. Retrieval of on board diagnostic (OBD) I and OBD II codes.

4. Diagnosis using scan tools to analyze diagnostic trouble codes (DTC’s).

5. Inspection and testing of ignition system pick-up sensor or trigger devices.

6. Retrieval and recording of stored OBD II trouble codes and data.

7. Analysis of inspection and testing results of inputs to body control module (BCM) and

Power train module.

8. Analysis of emissions vs. driveability.

9. Power train control module (PCM) system analysis using a graphing multimeter (GMM)

a digital storage oscilloscope (DSO).

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Advanced Engine Performance (L1)

A. General Engine Diagnosis.

1. Completing a Repair Order.

2. Technical service bulletins and scan tool data.

3. Types of technical service bulletin.

4. Electronic retrieval systems.

5. Symptom-based diagnosis.

6. Driveability concerns.

7. No start hard to start.

8. Poor fuel economy.

9. Advanced starting and charging systems diagnosis.

10. Battery tests.

11. Pinpoint voltage current and resistance tests

B. Computerized Engine Controls Diagnosis and Repair

1. Advanced computer sensor diagnosis

2. Pinpoint testing of ECT IAT MAP TPS O2 POST O2 MAF VSS and WSS sensors

3. Advanced computerized diagnosis

4. Circuit diagnosis and service

5. Diagnostic trouble code retrieval.

6. How diagnostic trouble codes (DTC’s) are set.

7. Methods for clearing DTC’s.

8. Advanced scan tool testing

C. Advanced ignition system diagnosis and repair

1. Pinpoint testing of primary and secondary circuit systems and components.

2. Pinpoint testing of ignition system related sensors

3. Current ramping of ignition system primary circuit

D. Fuel Air induction and Exhaust System Diagnosis and Repair.

1. Fuel delivery systems.

2. Pinpoint electronic component tests.

3. Idle air control diagnosis and service.

4. Advanced electronic fuel injection diagnosis and service.

5. Engine fuels and driveability diagnosis.

6. Rich or lean exhaust.

7. Excessive CO HC or Nox emissions.

E. Emissions Control Systems Diagnosis and Repair.

1. Advanced emission control device diagnosis and service.

2. PCV AIR EVAP EGR and catalytic converter.

3. Advanced five-gas exhaust analysis.

4. Hydrocarbons carbon monoxide carbon dioxide oxygen oxides of nitrogen

F. Engine Related Service

1. Engine condition diagnosis.

a. Relative Compression Testing

b. Pressure Transducer Testing

2. General Engine Diagnosis.

3. Troubleshooting fundamentals.

4. The 8-step diagnostic procedure.

5. Trouble shooting computerized engines.

6. Typical non-computer problems.

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Light Duty Diesel (A9 and L2)

A. Introduction, Syllabus, S/P2 and Safety training

B. Foundational diesel engine theory

C. Engine mechanical diagnosis and repair including cooling system failures/inspection and each

aspects affect on engine performance and emission controls.

D. Ford Powerstroke 6.0L, High Pressure Oil System

E. Ford Powerstroke 6.4L and 6.7L High Pressure Fuel System

F. Ford Powerstroke Oil and Fuel Control Issues; Glow plug issues

G. Ford Powerstroke Variable Geometry Turbo and EGR Diagnosis

H. Ford Powerstroke Exhaust Aftertreatment Systems

I. Ford Factory Scan Tool Functionality: Unique functions of factory scan tools utilized in

diagnosing diesel drivability problems.

J. Cummings 5.9L and 6.7L Common Rail Injection Systems

K. Cummings 6.7L Variable Nozzle Injection

L. Cummings 5.9L and 6.7L Fuel system and Common Rail Injection Systems Diagnosis

M. Cummings 5.9L and 6.7L Turbo Systems and EGR Diagnosis

N. Cummings 5.9L and 6.7L Exhaust Aftertreatment Systems

O. Dodge Factory Scan Tool Functionality: Unique functions of factory scan tools utilized in


P. Duramax Common Rail Fuel Injection Operation

Q. Duramax Injection System Diagnosis

R. Duramax Turbo Systems Diagnosis

S. Duramax EGR, and Glow Plug Diagnosis

T. Duramax Exhaust Aftertreatment System Diagnosis

U. Chevrolet Factory Scan Tool Functionality: Unique functions of factory scan tools utilized in


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Smog Inspector Training (Level 1 and Level 2)

The Level 1 (L1) Engine and Emission Control training is intended to provide students with

fundamental knowledge of engine and emission control theory, design, and operation. Students who

successfully complete this training will have met the first step of the Bureau of Automotive Repair’s

(BAR) training requirements for inexperienced or minimally experienced candidates for the Smog Check

Inspectors license.

The Level 2 (L2) Smog Check Training is Intended to provide students with the knowledge,

skills, and abilities needed to perform Smog Check inspections. Students who successfully complete this

training will have met the BAR training requirements to qualify to take the Smog Check Inspector state

licensing examination. Prior to enrolling in this course candidates must have passed the L1 training or met

the other BAR specified criteria.

Level 1

Upon successful completion of this training, students shall, at a minimum, be able to:

1. Describe engine theory, design, and operation for both gasoline and diesel vehicles.

2. Demonstrate their knowledge, skills and abilities in identifying engine systems, parts and

components.

3. Describe emission control systems theory, design and operation for both gasoline and diesel

vehicles.

4. Demonstrate their knowledge, skills and abilities in identifying emission control systems on

various vehicle designs.

5. Demonstrate their knowledge, skills and abilities in checking ignition timing on various vehicle

designs.

6. Demonstrate their knowledge, skills and abilities in checking the operation of exhaust gas

recirculation systems on various system designs.

7. Demonstrate their knowledge, skills and abilities in checking monitor readiness on vehicles

equipped with second generation on-board diagnostics systems (OBDII).

Level 2

Upon successful completion of this training, students shall, at a minimum, be able to:

1. Describe and demonstrate personal, shop, equipment, and vehicle safety practices.

2. Describe the laws, regulations, and procedures associated with consumer authorization of

inspections and the overall administration of the Smog Check Program.

3. Describe the standards of practice expected of Smog Check Inspectors.

4. Demonstrate ability to calibrate an emission inspection system.

5. Demonstrate their knowledge, skills and abilities in performing Smog Check emission tests on


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6. Demonstrate their knowledge, skills and abilities in performing Smog Check visual inspections on


7. Describe and demonstrate they have the knowledge, skills and abilities to perform smog check

functional tests on various vehicle designs

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Automotive Management (Service Consultant C1 )

A. Automotive Industry Scan (2 weeks)

B. State Auto Regulations – Bureau of Automotive Affairs (2 weeks)

C. Safety Practices and OSHA Compliance (1 week)

D. Effective Interpersonal Communication (1 week)

E. Team Building and Participation (1 week)

F. Ethics in the Workplace (1 week)

G. Customer Service (1week)

H. Telephone Skills (1 week)

I. Sales Skills (1 week)

J. Job 1: Service Writer/Service Advisor (1 week)

K. Job 2: Parts Sales and Service/Counterperson (1 week)

L. Job 3: Warranty Specialist/Clerk (1 week)

M. Job 4: DMV Title Clerk (1 week)

Documents

Automotive Restructure Proposal