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prinCiples ofligHt VeHiCleteCHnology
A LWAY S L E A R N I NG
HEINEMANNWork-Based Learning
Level 3
Diploma
2
Authored by Graham Stoakes and moulded around the 2010 specification, these resources are designed to continue seamlessly from levels 1 and 2 and pave your learners’ way to successful careers in the automotive industry.
introduCtion
We’Ve made eValuation easy for you WitH tHis resourCe guidestep 1: Take a look at the sample material* in this guide
showing our new level 3 resources and see how they will work for you and your candidates
step 2: If you are ready to order, visit www.pearsonfe.co.uk/Level3LightVehicle
step 3: If you still want to know more, the why not set up a visit from one of our sales consultants? See the back cover for details.
* All the materials in this resource guide are draft samples and are subject to final correction before publication.
Candidate Handbook:l Designed specifically for your level 3 learners to provide an accessible, relevant and professional handbook that helps candidates progress in their career.
l Helps learners focus on diagnostics and rectifying faults as a progression from level 2.
l Covers the latest technology within the industry which not only provides the knowledge and skills to pass the qualification, but is highly relevant to the workplace.
l Problem-solving features help put theory into practice and better prepare candidates for the world of work.
l Highlights employability skills in a range of focused case studies.
Contents:CHapter 1 Introduction to light vehicle technology / diagnosis and rectification
CHapter 2 Diagnosis and rectification of light vehicle chassis system faults
CHapter 3 Diagnosis and rectification of light vehicle engine faults
CHapter 4 Diagnosis and rectification of light vehicle auxiliary electrical faults
CHapter 5 Diagnosis and rectification of light vehicle transmission and driveline faults
CHapter 6 Identifying and agreeing motor vehicle customer service needs
index
3
Candidate Handbook
Candidate Handbook
candidate handbook 4
Level 2 NVQ/SVQ Diploma Brickwork 3rd editionLevel 3 Light Vehicle Technology
60
To diagnose hydraulic system pressure faults, you must � t a power-assisted steering pressure gauge in series with the pump, then run the engine at different speeds and under different operating conditions. The gauge is similar in operation to an engine oil pressure gauge, but it has a manually operated valve that is able to control the � ow of � uid in the system. In this way, you can check � ow and pressure and compare them with the manufacturer’s speci� cations.
∑ By connecting the gauge with the valve in the open position, you can check supply pressure when the steering is at full lock.
∑ By connecting the gauge with the valve in the open position, you can check supply pressure when the engine is operating in its normal rev range (1000 to 3000 rpm) with the steering in the straight ahead position.
∑ By connecting the gauge with the valve in the closed position, you can check the maximum supply pressure available from the pump.
Steer by wire
Some manufacturers are experimenting with a system of steer by wire. In this set up,
the steering wheel is replaced with a joystick that can control not only steering but also
acceleration and braking. The main drawbacks of this system are the dif� culty in making it
failsafe and the reluctance of drivers to give up control of the steering wheel.
NEW TECH
In series – incorporated
as part of the circuit.
Key term
Figure 2.43 Using a gauge to check steering hydraulic pressures
Do not run the hydraulic pump for more than � ve seconds with the valve on the pressure
gauge in the closed position, as this may cause the pump to overheat and can cause damage.
Power-assisted hydraulic � uid pressures can reach around 80 bar (1160psi) so you must take
care when working on these systems.
Safe working
Examine a vehicle in your
workshop and identify the main
component parts of a hydraulic
power-assisted steering system.
Action
DRAFTTechnology evolves quickly in the engineering world and our NEW TECH sections keep learners up to date on the latest developments.
Safe working sections provide learners with health and safety best practice so injuries can be avoided.
Sample taken from Level 3 Light Vehicle Technology Candidate Handbook.
Candidate Handbook
candidate handbook 5
2 Diagnosis & rectifi cation of light vehicle chassis system faults
61
Table 2.7 Typical operating pressures that may be found during hydraulic testing
Pressure gauge valve open Pressure gauge valve closed
Symptom and possible fault
Engine speed 1000 rpm
Engine speed 3000 rpm
Engine speed 1000 rpm, steering turned to full lock
Engine run (maximum 5 seconds)
40 bar 35 bar 80 bar 80 bar Correct operation
25 bar 25 bar 80 bar 80 bar Power assistance too lowFlow control valve stuck open/faulty
40 bar 35 bar 60 bar 80 bar Power assistance too lowFaulty control valve or hydraulic piston
40 bar 35 bar 60 bar 60 bar Power assistance too lowWorn pump
65 bar 65 bar 80 bar 80 bar Power assistance too highFlow control valve stuck closed/faulty
Noise and bleedingNoise from a hydraulic power-assisted steering system may be caused by:
∑ loose drive belt ∑ air in the hydraulic system, known as cavitation ∑ pump bearing wear.
If air has entered the system, it can be bled by topping up the � uid reservoir with the correct grade of power steering � uid and turning the steering from lock to lock with the engine running. This will help � uid to fully circulate through the steering system and air to escape once it has reached the reservoir.
Speed sensitive solenoid diagnosisTo diagnose the correct operation of the speed sensitive system, you need to connect an oscilloscope to the speed sensor input at the power steering ECU. (You can � nd out how to connect and use an oscilloscope in Chapter 4, pages 184–185.).
With the vehicle in motion, you should see a wave form with a frequency proportional to vehicle speed on the screen of the oscilloscope. This signal may be analogue (see Figure 2.44) or digital (see Figure 2.45). If you don’t see this wave form, check the sensor and wiring.
If the input to the ECU is correct, you should then connect the oscilloscope to the output for the power steering solenoid. At slow speed, you should see a duty cycle or pulse width modulation (PWM) on the screen of the oscilloscope that reduces as vehicle speed increases.
Cavitation – the creation of
bubbles in a hydraulic � uid.
Key term
Volts
Time
Time
Volts
Figure 2.44 Analogue speed signal
Figure 2.45 Digital speed signal
Key term features define difficult and important concepts to aid understanding throughout the book.
DRAFT
Sample taken from Level 3 Light Vehicle Technology Candidate Handbook.
Candidate Handbook
candidate handbook 6
Level 2 NVQ/SVQ Diploma Brickwork 3rd editionLevel 3 Light Vehicle Technology
62
If the output signal is correct, then you should check the wiring and solenoid for correct function and operation.
If the input to the electronic control unit is correct but the output is missing or incorrect, you should suspect a fault with the ECU.
Electro-hydraulic power-assisted steeringAn alternative to the engine-driven hydraulic pump used in power-assisted steering is for the pump to be driven using an electric motor. The electric motor, pump and � uid reservoir can then be mounted in a position away from the engine and activated when required. Sensors mounted on the steering column are able to measure the amount of turning effort applied to the steering system by the driver and send this information along with a signal from the vehicle’s speed sensor to the steering electronic control unit (ECU). The ECU is then able to operate the electric motor to turn the pump and supply a pressure to the piston in the steering rack which is proportional to vehicle speed and the steering effort applied.
The advantages of this type of system are:
∑ Fewer loads are placed on the engine during operation, so fuel economy and engine emissions are improved.
∑ The pump and reservoir can now be mounted anywhere away from the engine, which increases the scope for vehicle design.
∑ If the engine stalls/cuts out, power assistance can be maintained. ∑ The pump can be controlled by a switch to provide even greater
assistance when parking.
50% Duty cycle
75% Duty cycle
75% 75%
25% 25%
Figure 2.46 Duty cycle wave form
Fluid reservoir
Electro hydraulic pump
Pinion
Pinion
Valve rotor
Valve sleeve
Feed oil radial groove
Power cylinder left
Power cylinder right
Piston
Rack housing
Rack Tie rod
Figure 2.47 Electro-hydraulic power steering
Electronic power-assisted steering (EPS)Many modern vehicles use electric motors to drive steering mechanisms and provide power assistance instead of hydraulics. A reversible direct current electric motor can be connected to the steering rack or column
Clear and concise explanation of technical level 3 concepts assist understanding.
DRAFT
Sample taken from Level 3 Light Vehicle Technology Candidate Handbook.
High-quality illustrations throughout help learners visualise technical concepts and automotive systems.
Candidate Handbook
candidate handbook 7
2 Diagnosis & rectifi cation of light vehicle chassis system faults
63
depending on manufacturer design. As the driver applies effort at the steering wheel, movement and turning effort are registered by a torque sensor mounted on the steering column. The information provided by this sensor, as well as other inputs such as vehicle speed are then sent to the steering electronic control unit (ECU). The ECU is then able to operate the electric motor in the desired direction with a force controlled by duty cycle with a force that is proportional to vehicle speed and steering effort applied.
The advantages of this system are:
∑ The motor is only operated when the steering is turned – this reduces loads, improves fuel economy and reduces engine emissions.
∑ The motor and control system is very compact and can be used unobtrusively, even on small cars.
∑ Assistance can be easily varied to provide greater help when parking. ∑ Less maintenance is needed as there is no � uid system or leaks. ∑ If combined with a vehicle radar system, it can be used to provide a
self-parking function.
To diagnose faults with electronic power-assisted steering systems, you can often use a scan tool to retrieve diagnostic trouble codes (DTCs),
Steering wheel
Steering column
Ball joints
Pinion housing
Electric motor
Rubber gaiters
Track rod ends
Track rods
Universal joint
Pinion
Steering rack
Figure 2.48 Electronic power-assisted steering
Investigate vehicles in your
workshop and state if they use:
• hydraulic power-assisted
steering
• electro-hydraulic power-
assisted steering
• electronic power-assisted
steering.
ActionSelf-parking cars
Parallel parking is a slow speed manoeuvre that many drivers � nd dif� cult. As a response
to consumer demand, car manufacturers are starting to design and sell self-parking cars.
Advantages of self-parking cars include:
• Choosing a parking space is not restricted by the driver’s skill at parallel parking.
• A self-parking car can often fi t into smaller spaces than most drivers can manage on
their own, which allows the same number of cars to take up fewer spaces.
• Parking takes less time, which helps to keep traffi c moving.
• Minor damage created by parking is reduced.
Many systems operate with the driver controlling vehicle speed and direction with the
normal driving controls. They have sensors distributed around the front and rear bumpers of
the car, which act as both transmitters and receivers. These sensors send out signals, which
bounce off objects around the car and refl ect back to them. The car’s ECU then uses the
amount of time that it takes those signals to return to calculate the location of the objects.
The electronic power-assisted steering then manoeuvres the car into the parking space.
Manufacturers are now designing vehicles that are completely autonomous and will
control the drive as well as the steering. This means that the driver simply has to select
an appropriate parking spot and position the vehicle close to the space. Having pressed a
button, the car can then park completely by itself.
NEW TECH
Action features provide tasks to contextualise what has been learnt and demonstrate understanding of concepts.
DRAFT
Sample taken from Level 3 Light Vehicle Technology Candidate Handbook.
8
training resourCe disk l Save valuable time with an array of tools to help plan effectively, including suggested schemes of work, lesson plans and PowerPoints.
l Matched to the Candidate Handbook so you can teach level 3 diagnostic skills and knowledge in an engaging and interactive way that maximises success.
l Customise your training - all printable materials are editable, so you can ensure the materials are right for your learners.
training resourCe disk
training resourCe disk
Training resource Disk 9
Chapter 6 Identifying and agreeing motor vehicle customer service needs
Assignment 1 Customer care
© Pearson Education Ltd 2012. Copying permitted for purchasing institution only. This material is not copyright free. 1
Candidate name Date
Assignment brief: 1 Create a script that could be used to greet customers face to face when they arrive
at the garage for the first time and which finds out their service or repair needs. 2 Create a script that could be used to greet customers over the phone when they
contact the garage for the first time and which finds out their service or repair needs. Attach your scripts to this cover sheet.
3 Conduct a role-play activity with another learner where your script can be assessed by one of your peers and constructive feedback given.
Peer assessment and feedback
Peer assessor Date
General comment about the assignment:
Assessment criteria
Did the candidate? Yes/No
Use customer service methods appropriate for a face-to-face greeting.
Use customer service methods appropriate for a telephone greeting.
Fully establish the service or repair needs during the role-play activity.
Assessment for learning
Peer assessor Please give a brief description of how this assignment could have been improved (this could be about technical content or the general approach to the assignment submission).
Assignments allow learners to put what they have learnt into practice and apply their knowledge at the end of each chapter.
Customer service skills can be vital in a garage setting and our customer care chapter aims to equip learners with these skills.
DRAFT
Sample taken from Level 3 Light Vehicle Technology Training Resource Disk.
training resourCe disk
Training resource Disk 10
Chapter 6 Identifying and agreeing motor vehicle customer service needs
Assignment answers
© Pearson Education Ltd 2012. Copying permitted for purchasing institution only. This material is not copyright free. 1
Assignment introduction The assignments provided in this chapter are designed to offer tasks which support and extend classroom learning. Every opportunity should be taken to allow learners to peer and self-assess the work, promoting assessment for learning and reducing tutor marking, while allowing for formative assessment to take place.
Assignment 1 Customer care Learners produce/create a customer greeting script and then undertake a role-play activity to judge its effectiveness. Peers check that the assignment/role-play contains the following information: 1 Customer service methods appropriate to a face-to-face greeting 2 Customer service methods appropriate to a telephone greeting 3 Fully establish the service or repair needs Peers give constructive feedback on technical content, spelling, punctuation, grammar and layout.
Assignment 2 Manufacturer data Learners research manufacturer communication and feedback by using email requests for information. Learners produce individual answers. Learners self-assess the effectiveness of the activity and describe how different forms of written communication could be used in a business situation.
Assignment 3 Common faults Learners research vehicle faults using the Internet and diagnostic questioning sheets designed in Chapters 2, 3, 4 or 5. Learners produce individual answers. Peer/group assessors check the effectiveness of the activity.
Assignment 4 Garage services Learners research local garage products and services and complete a table for three different garages. Learners produce individual answers. Learners self-assess the effectiveness of the activity.
Each assignment comes with answers so you can make sure your learners are on track.
DRAFT
Sample taken from Level 3 Light Vehicle Technology Training Resource Disk.
training resourCe disk
Training resource Disk 111
© P
earson Education Ltd 2012. C
opying permitted for purchasing institution only. This m
aterial is not copyright free.
Chapter 6
Identifying and agreeing motor vehicle custom
er service needs
Lesson plan – Session 1.5 Chapter 6: Identifying and agreeing motor vehicle customer service needs Aims: ● Describe legislation relating to customer service in the automotive industry. SB = Student Book Assignment AS = Activity sheet PP = Presentation IA = Interactive activity IQ = Interactive quiz DT = Decision tree R = Research NS = Non-supervised individual study time This is a 180-minute lesson.
Learning outcomes ● All learners will list different types of customer legislation
● Most learners will design an advertisement which helps explain the Trade Descriptions Act
● Some learners will suggest reasons that might cause infringement of the Data Protection Act
Timing/ content Tutor activity Learner activity Resources Individualised
activity/differentiation
Key/Functional skills, Every child matters, Health and safety
5 minutes Lesson prelims
Take the register. Explain class rules and go through the lesson prelims. Monitor timekeeping.
Listen. Comply with classroom rules and health and safety.
Register Pens/pencils Whiteboard/flip chart
English – speaking and listening Staying safe Ask learners to put bags, coats, etc. out of the way so that they do not create a trip hazard.
10 minutes Recap
Recap with an overview of the subjects covered on the organisational terms and conditions for vehicle acceptance, and ask learners general questions to reinforce learning.
Refer to sections of SB pp.329–330 Answer questions related to last session (customer service).
SB pp.329–330 Learner notebooks Handouts
Use directed questioning so that all learners are involved. Use a probing questioning style that allows for differentiation by outcome.
English – reading and understanding English – speaking and listening
Time-saving lesson plans are fully editable and give you the flexibility to teach in your own style.
DRAFT
Sample taken from Level 3 Light Vehicle Technology Training Resource Disk.
training resourCe disk
Training resource Disk 12
Highly illustrated PowerPoint presentations for each chapter come with tutor notes and further guidance.
DRAFT
Sample taken from Level 3 Light Vehicle Technology Training Resource Disk.
13
next steps
next steps
next steps
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