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Duration:469 HoursQ U A L I F I C A T I O N : E B E TAUTOMOTIVE SERVICING NC IITRAINING MODULEDays:59 DaysPARTNERSHIPCOMPETENCYGROWTHOPPORTUNITYPurok 2, San Jose, Malaybalay City, BukidnonTESDA Accredited Training Partner0926 198 4835glt.tesda.ebet2026@gmail.com
basic competenciesA U T O M O T I V E S E R V I C I N G N C I I
Module Descriptor This module covers the knowledge, skills, and attitudes required to receive, interpret, and respond to workplace communication in an automotive service center. It includes following routine spoken messages, interpreting written notices, understanding job orders and service requests, participating in workplace meetings, completing workplace documents, and reporting work progress according to company procedures and Occupational Safety and Health (OSH) requirements. Upon completion of this module, trainees will be able to communicate effectively with supervisors, co-workers, and customers while performing automotive servicing tasks in accordance with workplace standards. RECEIVE AND RESPOND TO WORKPLACE COMMUNICATION Learning Objectives Upon completion of this module, the trainee should be able to: 1.Explain the importance of workplace communication. 2.Follow routine spoken instructions accurately. 3.Interpret job orders, service requests, and written notices. 4.Participate effectively in toolbox meetings and workplace briefings. 5.Complete workplace forms and reports accurately. 6.Report work progress and task completion following company procedures. 7.Demonstrate professional communication in an automotive service center. 8.Observe workplace communication protocols and safety requirements.
IMPORTANCE OF WORKPLACE COMMUNICATION What is Workplace Communication? Workplace communication refers to the exchange of information, instructions, and feedback among employees, supervisors, customers, and management. Importance Prevents misunderstandings Improves productivity Enhances teamwork Promotes safety Improves customer satisfaction Example A technician receives instructions to replace the engine oil and inspect the air filter. Proper communication ensures the correct task is completed without errors. TYPES OF WORKPLACE COMMUNICATION Verbal Communication Communication through spoken words. Examples: Toolbox meetings Supervisor instructions Safety briefings Written Communication Communication through documents. Examples: Job orders Service requests Maintenance schedules Safety notices Non-Verbal Communication Communication through actions or gestures. Examples: Hand signals Safety symbols Warning signs
Purpose of Job Orders A job order provides information regarding: Customer concerns Required repairs Vehicle information Assigned technician Sample Job Order Information Vehicle: Toyota Vios Complaint: Engine oil due for replacement Assigned Technician: Juan Dela Cruz FOLLOWING ROUTINE SPOKEN MESSAGES Guidelines 1.Listen carefully. 2.Maintain eye contact. 3.Avoid interruptions. 4.Ask questions when instructions are unclear. 5.Repeat important instructions for confirmation. Example Supervisor: "Check the brake fluid level and inspect the brake pads before lunch.” Technician: "Sir, I will check the brake fluid level and inspect the brake pads before lunch.” INTERPRETING JOB ORDERS AND SERVICE REQUESTS Importance Ensures correct work is performed Avoids unnecessary repairs Improves customer satisfaction WORKPLACE NOTICES AND SAFETY SIGNAGES Common Workplace Notices Safety reminders Work schedules Maintenance advisories Company memoranda Common Safety Signs Danger Sign Indicates immediate hazard. Warning Sign Indicates potential hazard. Mandatory Sign Indicates required action. Prohibition Sign Indicates prohibited action.
REPORTING WORK PROGRESS AND TASK COMPLETIONExample "Engine oil replacement completed. Air filter inspected and found serviceable." WORKPLACE COMMUNICATION PROTOCOLS Information Included in Reports Task and time completed Materials used Problems encountered Recommendations Communication Chain Technician Team Leader Shop Supervisor Service Manager Example A completed maintenance checklist confirms that all inspection points were checked before vehicle release. Rules Follow the proper chain of communication. Report problems immediately. Maintain professionalism. Respect confidentiality. Good Communication Practices Be clear and concise. Use professional language. Listen actively. Provide accurate information. Common Documents Job Orders Service Reports Maintenance Checklists Vehicle Inspection Forms Workplace Logbooks Importance of Reporting Reporting allows supervisors to: Monitor work progress Allocate resources Ensure quality of work Importance Provides work history Supports quality assurance Serves as legal documentation Improves accountability
ACTIVITY SHEET #1 Title Listening and Following Instructions Objective Demonstrate the ability to receive and follow verbal instructions accurately. Instructions 1.Listen to instructions given by the trainer. 2.Write down key points. 3.Perform the assigned task. 4.Report completion to the trainer. Evaluation Performance will be assessed based on accuracy and completeness. ACTIVITY SHEET #2 Title Job Order Interpretation Objective Interpret job orders and service requests correctly. Instructions 1.Review the provided job order. 2.Identify customer concerns. 3.Determine required servicing activities. 4.Present findings to the class. Evaluation Assessment will focus on interpretation’s accuracy. ACTIVITY SHEET #3 Title Workplace Communication Role Play Objective Practice professional workplace communication. Evaluation Assessment will focus on communication effectiveness and professionalism. Instructions Form groups of three. Assign roles: Supervisor Technician Customer Simulate a workplace communication scenario. Demonstrate proper reporting and feedback procedures
JOB SHEET Title Receiving and Responding to Workplace Communication Objective Demonstrate the ability to receive verbal instructions, interpret workplace documents, perform assigned tasks, and report work completion according to workplace procedures. Materials and Equipment Job Order Form Service Request Form Maintenance Checklist Workplace Logbook Pen and Paper Personal Protective Equipment (PPE) Sample Safety Notices Manufacturer's Service Manual Procedure 1.Wear appropriate PPE. 2.Attend the toolbox meeting. 3.Receive verbal instructions from the supervisor. 4.Clarify instructions when necessary. 5.Obtain and review the assigned job order. 6.Read and interpret workplace notices and schedules. 7.Perform the assigned workplace activity. 8.Accomplish required workplace forms. 9.Report work progress to the supervisor. 10.Submit completed documentation. 11.Receive feedback from the trainer.
Trainee Name: Date: Performance Criteria Yes No Listened attentively to verbal instructions ☐ ☐ Clarified unclear instructions appropriately ☐ ☐ Participated actively in toolbox meetings ☐ ☐ Interpreted job orders correctly ☐ ☐ Read and followed written notices accurately ☐ ☐ Performed assigned duties according to instructions ☐ ☐ Completed workplace forms correctly ☐ ☐ Reported work progress accurately ☐ ☐ Demonstrated effective communication with co-workers ☐ ☐ Followed workplace communication protocols ☐ ☐ Observed safety requirements ☐ ☐ Demonstrated professionalism and positive attitude ☐ ☐ PERFORMANCE/OBSERVATION CHECKLIST
WORK WITH OTHERS Module Descriptor This module covers the knowledge, skills, and attitudes required to develop effective workplace relationships and contribute to work group activities in an automotive service center. It includes communicating effectively with supervisors and co-workers, participating in team activities, demonstrating professionalism and work ethics, assisting team members, resolving workplace issues appropriately, and contributing to organizational goals while observing workplace policies and safety requirements. Learning Objectives Upon completion of this module, the trainee should be able to: LO1. Develop Effective Workplace Relationships 1.Communicate effectively with supervisors and co-workers. 2.Demonstrate respect and professionalism in workplace interactions. 3.Follow workplace communication protocols and organizational structure. 4.Maintain positive workplace relationships. LO2. Contribute to Work Group Activities 1.Participate actively in team activities and discussions. 2.Assist team members in accomplishing assigned tasks. 3.Contribute ideas and information to improve work processes. 4.Support workplace safety, quality, and housekeeping activities.
DEVELOP EFFECTIVE WORKPLACE RELATIONSHIPS What is Workplace Relationship? A workplace relationship refers to the interaction and professional association between employees, supervisors, customers, and management personnel. Importance Good workplace relationships: Improve teamwork Increase productivity Reduce conflicts Improve morale Promote safety Enhance customer satisfaction Example A technician informs another technician about a loose brake hose discovered during inspection. Because of effective communication, the problem is corrected immediately, preventing vehicle failure. WORKPLACE ORGANIZATIONAL STRUCTURE Typical Automotive Service Center Structure Service Manager Shop Supervisor Lead Technician Automotive Technician Utility Personnel Why Organizational Structure is Important Clarifies authority Defines responsibilities Improves communication flow Prevents misunderstandings Example A trainee should report technical concerns to the Lead Technician instead of directly approaching upper management.
Example A technician reports an accidental scratch on a vehicle instead of hiding the damage. E F F E C R T I V E W O R K P L A C E C O M M U N I C A T I O N Communication Methods 1. Verbal Communication Examples: Toolbox meetings Safety briefings Team discussions 2. Written Communication Examples: Job orders Work schedules Memoranda 3. Electronic Communication Examples: Messaging apps Email notifications PROFESSIONAL BEHAVIOR AND WORKPLACE ETHICS Workplace Professionalism Professional employees: Arrive on time Wear proper uniform Observe safety rules Respect co-workers Accept responsibility Workplace Ethics Ethics refers to moral principles that guide behavior. Examples: Honesty Integrity Accountability Respect Fairness Characteristics of Effective Communication Clear Accurate Respectful Timely Profesional
ROLES AND RESPONSIBILITIES IN A TEAM Team Member Responsibilities Perform assigned duties Support team goals Share information Assist co-workers Follow workplace procedures CONFLICT RESOLUTION IN THE WORKPLACE Common Causes of Conflict Miscommunication Unclear responsibilities Personal differences Work pressure Team Leader Responsibilities Coordinate activities Assign tasks Monitor progress Ensure safety compliance PARTICIPATION IN QUALITY AND HOUSEKEEPING ACTIVITIES Example Two technicians disagree about work assignments. The supervisor clarifies responsibilities and resolves the misunderstanding Conflict Resolution Steps 1.Identify the issue. 2.Listen to all parties. 3.Discuss solutions. 4.Agree on corrective action. 5.Follow up. Quality Activities Examples Vehicle inspection Service verification Documentation review Housekeeping Activities Examples: Tool organization Waste segregation Work area cleaning Importance Improves efficiency Prevents accidents Enhances service quality
ACTIVITY SHEET #1 Title Practicing Effective Workplace Communication Objective Demonstrate proper communication with supervisors and co-workers. Materials Workplace scenarios Job orders Communication logbook Procedure 1.Read the assigned workplace scenario. 2.Discuss the situation with group members. 3.Practice communicating the information clearly. 4.Present your response to the trainer. 5.Receive feedback and recommendations. Evaluation Performance will be assessed based on effectivity of communication and resolution. ACTIVITY SHEET #2 Title Team-Based Vehicle Servicing Activity Objective Demonstrate teamwork during automotive servicing operations. Materials Service vehicle Job order Hand tools PPE Procedure 1.Form a team of four members. 2.Assign individual responsibilities. 3.Complete the assigned servicing activity. 4.Coordinate tasks with team members. 5.Observe workplace safety procedures. 6.Submit accomplishment report. Evaluation Assessment will focus on team coordination.
JOB SHEET Title Working Effectively with Others During Automotive Servicing Operations Objective Demonstrate the ability to establish workplace relationships and contribute to work group activities while performing automotive servicing tasks. Materials and Equipment Actual service vehicle Job Order Service Request Form Toolbox Meeting Attendance Sheet Communication Logbook Standard Operating Procedures (SOPs) PPE Automotive Hand Tools Housekeeping Checklist Procedure 1.Attend toolbox meeting and receive instructions. 2.Coordinate assigned tasks with team members. 3.Communicate work requirements clearly. 4.Assist co-workers when necessary. 5.Share relevant information regarding servicing activities. 6.Participate in workplace housekeeping activities. 7.Observe safety procedures at all times. 8.Report work progress to the team leader. 9.Complete assigned tasks collaboratively. 10.Participate in post-work evaluation and feedback session.
Trainee Name: Date: Performance Criteria Yes No Attended toolbox meeting and workplace briefing ☐ ☐ Communicated effectively with supervisors and co-workers ☐ ☐ Demonstrated respect and professionalism ☐ ☐ Followed workplace communication protocols ☐ ☐ Worked cooperatively with team members ☐ ☐ Assisted co-workers when needed ☐ ☐ Shared relevant work information accurately ☐ ☐ Participated actively in team discussions ☐ ☐ Contributed to workplace housekeeping activities ☐ ☐ Observed safety procedures consistently ☐ ☐ Demonstrated positive work attitude ☐ ☐ Helped achieve team objectives ☐ ☐ PERFORMANCE/OBSERVATION CHECKLIST
DEMONSTRATE WORK VALUES Module Descriptor This module covers the knowledge, skills, and attitudes required to demonstrate positive work values in an automotive service center. It includes understanding the purpose of work, applying workplace values and ethics, dealing with ethical problems, and maintaining integrity of conduct in the workplace. The module emphasizes professionalism, responsibility, honesty, discipline, teamwork, customer service, and compliance with company policies and Occupational Safety and Health (OSH) standards. Learning Objectives Upon completion of this module, the trainee should be able to: LO1. Define the Purpose of Work 1.Explain the importance of work in personal and professional development. 2.Identify the benefits of productive work. 3.Recognize the role of employees in achieving organizational goals. LO2. Apply Work Values and Ethics 1.Demonstrate professionalism and positive work attitudes. 2.Observe workplace rules and company policies. 3.Apply ethical standards in workplace activities. LO3. Deal with Ethical Problems 1.Identify workplace ethical issues and concerns. 2.Apply appropriate decision-making processes. 3.Resolve ethical situations responsibly. LO4. Maintain Integrity of Conduct in the Workplace 1.Demonstrate honesty, accountability, and responsibility. 2.Protect company property and customer information. 3.Maintain professional conduct at all times.
MEANING AND PURPOSE OF WORK What is Work? Work refers to productive activities performed to accomplish tasks, provide services, and contribute to organizational objectives. Importance of Work Provides income Develops competencies Supports family needs Builds self-confidence Contributes to society Example An automotive technician performs vehicle maintenance services to ensure customer safety while earning a living and developing expertise. THE EMPLOYEE'S ROLE IN ORGANIZATIONAL SUCCESS Employee Responsibilities Perform assigned duties efficiently Follow company policies Maintain quality standards Observe workplace safety Support organizational goals Example A technician who performs accurate inspections helps improve customer satisfaction and company reputation. WORK VALUES IN AUTOMOTIVE SERVICING Important Work Values Responsibility Completing assigned tasks correctly and on time. Discipline Following workplace rules and procedures consistently. Respect Treating supervisors, co-workers, and customers professionally. Commitment Performing work to the best of one's ability. Teamwork Cooperating with others to achieve common goals. Integrity Being honest and having strong moral principles.
WORKPLACE ETHICS Definition Workplace ethics are moral principles that guide behavior and decision- making. Ethical Practices Honesty Fairness Integrity Accountability Professionalism Unethical Practices Falsifying reports Misusing company property Dishonesty Neglecting safety procedures Misrepresenting completed work PROFESSIONAL WORKPLACE BEHAVIOR Characteristics of Professional Employees Punctual Courteous Respectful Reliable Safety-conscious Example Greeting customers politely and explaining service findings professionally. Professional Conduct Proper grooming Wearing PPE Following workplace rules Communicating respectfully UNDERSTANDING ETHICAL PROBLEMS Ethical Problems in Automotive Servicing Examples: Reporting false inspection findings Charging customers for unnecessary repairs Using company tools for personal gain Concealing mistakes Effects Loss of customer trust Safety risks Legal liabilities Damage to company reputation
ETHICAL DECISION- MAKING PROCESS Steps: 1.Identify the issue. 2.Gather facts. 3.Evaluate alternatives. 4.Consider consequences. 5.Make the ethical decision. 6.Take appropriate action. Example A technician accidentally damages a vehicle component and immediately reports the incident to the supervisor. RESOLVING WORKPLACE ETHICAL ISSUES Guidelines: 1.Remain objective. 2.Follow company policies. 3.Seek supervisor guidance. 4.Document incidents. 5.Focus on facts. Example A technician reports observed safety violations through proper reporting channels. INTEGRITY IN THE WORKPLACE Definition Integrity means consistently doing what is right even when no one is watching. Characteristics Honesty Accountability Trustworthiness Responsibility Example A technician returns excess spare parts instead of keeping them.
PROTECTING COMPANY PROPERTY AND RESOURCES Company Property Includes Tools Equipment Vehicles Facilities Documents Employee Responsibilities Proper use Proper storage Prevent misuse Report damages CONFIDENTIALITY AND CUSTOMER TRUST Confidential Information Customer records Vehicle history Company reports Financial information Guidelines Share information only with authorized personnel. Protect customer privacy. Secure workplace records. Example Do not disclose customer information to unauthorized persons.
ACTIVITY SHEET #1 Title Evaluating Workplace Values Objective Identify and apply appropriate work values in workplace situations. Materials Workplace scenarios Activity worksheet Procedure 1.Read the assigned scenario. 2.Identify work values demonstrated. 3.Discuss findings with group members. 4.Present answers to the class. Evaluation Performance will be assessed based on the values presented of the group. ACTIVITY SHEET #2 Title Ethical Case Study Analysis Objective Analyze workplace ethical situations and recommend appropriate actions. Materials Case Study Document Activity worksheet Procedure 1.Read assigned case study. 2.Identify ethical concerns. 3.Recommend corrective actions. 4.Present findings. 5.Participate in group discussion. Evaluation Performance will be assessed based on the ethical dilemmas identified.
JOB SHEET Title Demonstrating Work Values During Automotive Servicing Operations Objective Demonstrate workplace values, ethics, professionalism, and integrity while performing assigned automotive servicing activities. Materials and Equipment Employee Handbook Company Code of Conduct SOP Manual Job Orders Attendance Records PPE Workplace Ethics Case Studies Performance Evaluation Form Service Vehicle Automotive Tools and Equipment Procedure 1.Attend workplace orientation and briefing. 2.Review company policies and code of conduct. 3.Wear appropriate PPE and report on time. 4.Perform assigned servicing tasks responsibly. 5.Demonstrate professionalism when dealing with customers and co-workers. 6.Follow workplace rules and safety procedures. 7.Report work accomplishments honestly. 8.Handle tools, equipment, and materials properly. 9.Maintain confidentiality of workplace information. 10.Participate in evaluation and feedback sessions.
Trainee Name: Date: Performance Criteria Yes No Reported to work on time ☐ ☐ Demonstrated responsibility in assigned tasks ☐ ☐ Followed company rules and workplace procedures ☐ ☐ Observed safety requirements consistently ☐ ☐ Demonstrated honesty in reporting work performed ☐ ☐ Showed respect toward supervisors and co-workers ☐ ☐ Demonstrated professionalism during workplace interactions ☐ ☐ Participated actively in workplace activities ☐ ☐ Protected company tools and property ☐ ☐ Maintained confidentiality of information ☐ ☐ Applied ethical decision-making appropriately ☐ ☐ Demonstrated integrity and accountability throughout activities ☐ ☐ PERFORMANCE/OBSERVATION CHECKLIST
PRACTICE BASIC HOUSEKEEPING PROCEDURES Module Descriptor This module covers the knowledge, skills, and attitudes required to maintain cleanliness, orderliness, safety, and efficiency in an automotive service center. It includes sorting and removing unnecessary items, arranging and organizing tools and materials, maintaining work areas, tools, and equipment, following standardized work procedures, and performing housekeeping activities proactively. The module emphasizes the application of 5S principles, Occupational Safety and Health (OSH) requirements, environmental awareness, and workplace discipline. Learning Objectives LO1. Sort and Remove Unnecessary Items 1.Identify necessary and unnecessary workplace items. 2.Apply proper sorting procedures. 3.Remove and dispose of unnecessary materials safely. LO2. Arrange Items 1.Organize tools, equipment, and materials systematically. 2.Apply labeling and storage procedures. 3.Maintain accessibility and workplace order. LO3. Maintain Work Area, Tools, and Equipment Perform routine cleaning and inspection activities. Maintain serviceability of tools and equipment. Observe workplace safety and cleanliness standards. LO4. Follow Standardized Work Process and Procedures Follow housekeeping SOPs and 5S guidelines. Comply with safety and environmental requirements. Participate in workplace inspections and audits. LO5. Perform Work Spontaneously Demonstrate initiative in maintaining workplace orderliness. Correct housekeeping deficiencies without supervision. Promote a culture of cleanliness and discipline. Upon completion of this module, the trainee should be able to:
INTRODUCTION TO 5S HOUSEKEEPING What is 5S? 5S is a workplace organization system developed to improve efficiency, productivity, and safety. SORTING WORKPLACE ITEMS Necessary Items: Items required for daily operations. Examples: Hand tools Measuring instruments Service manuals PPE The 5s Principles 1.Sort (Seiri) 2.Set in Order (Seiton) 3.Shine (Seiso) 4.Standardize (Seiketsu) 5.Sustain (Shitsuke) Benefits of 5S Cleaner workplace Improved productivity Reduced accidents Better equipment care Improved morale Example Removing broken parts, empty containers, and obsolete materials from the service bay. Unnecessary Items: Items no longer needed. Examples: Scrap materials Damaged containers Obsolete documents Defective parts Red Tag System A method used to identify unnecessary items for removal. ORGANIZING TOOLS AND MATERIALS Purpose of Organization Easy retrieval Reduced downtime Improved safety Better inventory control Storage Principles Frequently used items should be accessible. Heavy items should be stored safely. Hazardous materials must be properly labeled.
LABELING AND STORAGE SYSTEMS Common Labeling Methods Color coding Tool shadow boards Storage labels Inventory tags Example A wrench set is stored in a labeled toolbox compartment according to size. WORKPLACE CLEANING PROCEDURES Cleaning Activities Sweep floors Wipe work benches Remove oil spills Empty waste bins Clean equipment surfaces Importance Prevents accidents Improves efficiency Maintains professional image TOOL AND EQUIPMENT MAINTENANCE Maintenance Activities Inspection Cleaning Lubrication Calibration Proper storage Reporting Defects Defective tools should be tagged and reported immediately. HOUSEKEEPING SOPS 4.1 Purpose Housekeeping SOPs ensure consistent and safe workplace practices. Common SOP Requirements Daily cleaning schedule Tool accountability Waste segregation Equipment inspection
DEMONSTRATING INITIATIVE What is Initiative? Initiative means performing necessary tasks without waiting for instructions. Example Cleaning a spill immediately. Returning tools after use. Correcting misplaced materials. Reporting unsafe conditions. OCCUPATIONAL SAFETY AND HEALTH REQUIREMENTS 4.2 Safety Practices Wear PPE Follow safety signages Report hazards immediately Maintain emergency access routes Example Cleaning oil spills immediately to prevent slips and falls. SUSTAINING GOOD HOUSEKEEPING PRACTICES Methods Conduct regular inspections. Participate in housekeeping audits. Follow workplace standards daily. Encourage co-workers to observe 5S. Method Benefits Increased productivity Better safety performance Improved workplace discipline
ACTIVITY SHEET #1 Title Workplace Sorting Activity Objective Apply proper sorting procedures in the work area. Materials Red tags Inspection checklist Sample tools and materials Procedure 1.Inspect the assigned work area. 2.Identify necessary and unnecessary items. 3.Tag unnecessary items. 4.Prepare a disposal or relocation list. 5.Submit findings to the trainer. ACTIVITY SHEET #2 Title Tool Organization Activity Objective Organize workplace tools and materials properly. Procedure 1.Inspect tool storage areas. 2.Arrange tools according to SOPs. 3.Label storage locations. 4.Verify accessibility and safety. 5.Present completed work to the trainer. ACTIVITY SHEET #3 Title Work Area Cleaning and Inspection Objective Maintain cleanliness and safety of workstations. Procedure 1.Inspect the assigned area. 2.Clean the workstation. 3.Inspect tools and equipment. 4.Report defects. 5.Complete housekeeping checklist.
JOB SHEET Title Performing Basic Housekeeping Procedures in an Automotive Service Center Objective Demonstrate proper housekeeping procedures using 5S principles while maintaining workplace cleanliness, safety, and organization. Materials and Equipment Housekeeping Checklist Cleaning Materials Broom and Dustpan Waste Segregation Bins Red Tags Tool Storage Cabinet Labels and Tags PPE Inspection Forms SOP Manual Procedure 1.Wear appropriate PPE. 2.Inspect the assigned work area. 3.Sort and remove unnecessary items. 4.Tag unnecessary materials using red tags. 5.Organize and label tools and equipment. 6.Clean workstations, floors, and equipment. 7.Inspect tools and report defects. 8.Segregate and dispose of waste properly. 9.Complete housekeeping checklist. 10.Participate in housekeeping audit. 11.Submit report to the trainer.
Trainee Name: Date: Performance Criteria Yes No Sorted necessary and unnecessary items correctly ☐ ☐ Removed unnecessary items from the work area ☐ ☐ Organized tools and equipment properly ☐ ☐ Applied labeling and storage procedures correctly ☐ ☐ Cleaned workstations and equipment thoroughly ☐ ☐ Followed housekeeping SOPs consistently ☐ ☐ Segregated waste materials properly ☐ ☐ Reported defective tools and equipment ☐ ☐ Observed OSH requirements and safety procedures ☐ ☐ Demonstrated initiative in maintaining cleanliness ☐ ☐ Participated actively in housekeeping inspections ☐ ☐ Maintained workplace orderliness throughout the activity ☐ ☐ PERFORMANCE/OBSERVATION CHECKLIST
COMMON competenciesA U T O M O T I V E S E R V I C I N G N C I I
DEMONSTRATE WORK VALUES Module Descriptor This module covers the knowledge, skills, and attitudes required to validate vehicle specifications in an automotive service center. It includes identifying vehicle body types, determining engine types, checking vehicle specifications, and completing vehicle specification validation activities. The module emphasizes the proper use of vehicle identification systems, manufacturer's technical references, inspection procedures, documentation practices, and Occupational Safety and Health (OSH) requirements. Upon completion of this module, trainees will be able to accurately identify and verify vehicle information required for automotive servicing and maintenance operations. Learning Objectives LO3. Check Vehicle Specifications 1.Locate and interpret VIN and vehicle information plates. 2.Verify vehicle specifications using manufacturer references. 3.Compare actual vehicle information with technical records. LO4. Complete Validation of Vehicle Specification 1.Accomplish vehicle validation forms accurately. 2.Report findings and discrepancies. 3.Maintain proper documentation procedures. LO1. Check Body Type of the Vehicle 1.Identify different vehicle body classifications. 2.Determine vehicle body type through inspection. 3.Record body type information correctly. LO2. Check Vehicle Engine Type 1.Locate engine identification markings. 2.Determine engine type and configuration. 3.Verify engine information using technical references. Upon completion of this module, the trainee should be able to:
INTRODUCTION TO VEHICLE CLASSIFICATION What is Vehicle Classification? Vehicle classification refers to grouping vehicles according to their design, purpose, and construction. Importance Assists in selecting proper service procedures. Ensures correct parts identification. Supports accurate maintenance planning. COMMON VEHICLE BODY TYPES Sedan A passenger vehicle with four doors and a separate trunk compartment. Example: Toyota Vios, Honda City Hatchback A passenger vehicle with a rear door that opens upward. Example: Toyota Wigo, Suzuki Celerio SUV (Sport Utility Vehicle) A larger passenger vehicle designed for both on- road and off-road use. Example: Toyota Fortuner, Mitsubishi Montero Sport Pickup Truck A vehicle with an enclosed cabin and open cargo bed. Example: Isuzu D-Max, Toyota Hilux Van A vehicle designed for passenger or cargo transport. Example: Toyota HiAce Utility Vehicle Used for commercial and transport operations.
Inspection Procedures Observe overall vehicle design. Identify number of doors. Check cargo area configuration. Verify information using vehicle documentation. Example A vehicle with four doors and a separate luggage compartment is classified as a sedan. IDENTIFYING VEHICLE BODY TYPES TYPES OF AUTOMOTIVE ENGINES Gasoline Engine Uses gasoline as fuel and spark ignition for combustion. Diesel Engine Uses diesel fuel and compression ignition. Hybrid Engine Combines internal combustion engine and electric motor. Electric Vehicle (EV) Motor Uses electric power without an internal combustion engine. ENGINE CONFIGURATION Inline Engine Cylinders arranged in a straight line. V-Type Engine Cylinders arranged in a V configuration. Horizontally Opposed Engine Cylinders arranged opposite each other. LOCATING ENGINE IDENTIFICATION INFORMATION Engine Number Usually stamped on the engine block. Engine Identification Plate Contains engine model and specifications. Importance Parts identification Service planning Warranty verification
VEHICLE IDENTIFICATION NUMBER (VIN) What is VIN? VIN stands for Vehicle Identification Number. It is a unique 17-character code assigned to every vehicle. Functions Vehicle identification Registration Warranty tracking Service history VEHICLE INFORMATION PLATE Information Found Manufacturer Model Engine displacement Gross vehicle weight Tire specifications Example JTDKB20U983456789 Information Found Common Locations Driver-side door jamb Engine compartment Dashboard area MANUFACTURER'S SERVICE MANUALS Purpose Manufacturer's service manuals provide: Vehicle specifications Service procedures Torque values Maintenance requirements Importance Ensures accurate servicing and inspection.
VEHICLE VALIDATION DOCUMENTATION Documents Used Inspection Checklists Validation Forms Service Records Vehicle Registration Documents Importance Provides accurate service information. Supports repair planning. Maintains vehicle history records. REPORTING FINDINGS AND DISCREPANCIES Common Discrepancies Incorrect VIN records Engine replacement not documented Mismatched specifications Missing information plates Reporting Procedure Record findings. Inform supervisor. Complete documentation. Submit report.
ACTIVITY SHEET #1 Title Vehicle Body Type Identification Objective Identify and classify vehicle body types accurately. Materials Actual vehicles Vehicle inspection checklist Vehicle reference guide Procedure 1.Inspect assigned vehicles. 2.Identify body type. 3.Record findings. 4.Verify answers with references. 5.Submit completed checklist. ACTIVITY SHEET #2 Title Engine Identification Activity Objective Identify vehicle engine type and engine information. Procedure 1.Locate engine identification markings. 2.Record engine number. 3.Determine engine type. 4.Verify information using manuals. 5.Complete inspection form. ACTIVITY SHEET #3 Title Vehicle Specification Verification Objective Verify vehicle specifications using references. Procedure 1.Locate VIN and vehicle information plate. 2.Record vehicle details. 3.Consult service manuals. 4.Compare specifications. 5.Complete validation form.
JOB SHEET Title Validating Vehicle Specifications Objective Demonstrate the ability to identify vehicle body type, determine engine type, verify vehicle specifications, and complete vehicle validation documentation. Materials and Equipment Actual Vehicle Vehicle Registration Documents Manufacturer's Service Manual Vehicle Specification Guide VIN Reference Chart Validation Form Inspection Checklist PPE Flashlight Writing Materials Procedure 1.Wear appropriate PPE. 2.Inspect the vehicle exterior. 3.Identify and record vehicle body type. 4.Locate VIN and vehicle information plate. 5.Record vehicle identification details. 6.Locate engine identification markings. 7.Determine engine type and specifications. 8.Verify information using service manuals. 9.Compare actual vehicle information with records. 10.Record findings on validation forms. 11.Report discrepancies to the supervisor. 12.Submit completed documentation.
Trainee Name: Date: Performance Criteria Yes No Wore appropriate PPE before inspection ☐ ☐ Identified vehicle body type correctly ☐ ☐ Located VIN successfully ☐ ☐ Located vehicle information plate correctly ☐ ☐ Recorded vehicle information accurately ☐ ☐ Identified engine type correctly ☐ ☐ Verified specifications using references ☐ ☐ Compared actual and documented information accurately ☐ ☐ Identified discrepancies correctly ☐ ☐ Completed validation forms accurately ☐ ☐ Reported findings properly ☐ ☐ Followed workplace safety procedures throughout the activity ☐ ☐ PERFORMANCE/OBSERVATION CHECKLIST
This module covers the knowledge, skills, and attitudes required to safely prepare, move, position, park, and secure vehicles within an automotive service center. It includes conducting pre-operation inspections, identifying vehicle controls and instruments, operating vehicles safely, positioning vehicles in service bays and workstations, applying parking procedures, and observing Occupational Safety and Health (OSH) standards. The module emphasizes workplace safety, vehicle protection, and compliance with standard operating procedures. Upon completion of this module, trainees will be able to move and position vehicles safely and accurately for inspection, servicing, maintenance, and repair operations. MOVE AND POSITION VEHICLE Module Descriptor Upon completion of this module, the trainee should be able to: LO1. Prepare Vehicle for Operation 1.Conduct pre-operation inspection. 2.Identify vehicle controls and instruments. 3.Verify vehicle readiness for movement. LO2. Position Vehicle 1.Move vehicles safely within the workshop. 2.Position vehicles accurately in designated work areas. 3.Observe workshop traffic and safety procedures. LO3. Park and Stop the Vehicle 1.Apply correct parking procedures. 2.Secure vehicles using safety devices. 3.Prepare vehicles for servicing activities. Learning Objectives
IMPORTANCE OF VEHICLE PREPARATION Why Prepare a Vehicle Before Movement? Vehicle preparation ensures that the vehicle is safe to operate and prevents accidents, injuries, and property damage. Example Before moving a vehicle into a service bay, the technician checks the brakes, steering, mirrors, and surroundings. Benefits Ensures vehicle safety Prevents equipment damage Protects personnel Improves efficiency PRE-OPERATION VEHICLE INSPECTION Importance A pre-operation inspection helps identify hazards before vehicle movement. Exterior Inspection Tire condition Tire pressure Fluid leaks Body damage Obstructions around the vehicle Interior Inspection Steering wheel condition Brake pedal operation Parking brake Instrument panel Mirrors VEHICLE CONTROLS AND INSTRUMENTS Primary Controls Steering Wheel Accelerator Pedal Brake Pedal Clutch Pedal (Manual Transmission) Gear Selector Secondary Controls Lights Windshield Wipers Horn Hazard Lights Dashboard Instruments Speedometer Fuel Gauge Temperature Gauge Warning Indicators Importance A technician verifies that no warning lights are illuminated before moving the vehicle.
OCCUPATIONAL SAFETY AND HEALTH (OSH) BREQUIREMENTS Example A technician uses a spotter when reversing a vehicle into a service bay. Safety Rules Wear appropriate PPE. Inspect surroundings before movement. Follow traffic signs and markings. Use spotters when visibility is limited. Observe workshop speed limits. SAFE VEHICLE MOVEMENT PROCEDURES Before Moving Check surroundings. Fasten seat belt. Start engine properly. Confirm gear position. Example A vehicle is moved slowly toward the designated service bay while observing pedestrian traffic. During Movement 1.Drive slowly. 2.Maintain awareness. 3.Follow workshop traffic routes. 4.Observe safety signages. POSITIONING VEHICLES IN SERVICE BAYS Objectives Provide safe access for servicing. Prevent damage to vehicles and equipment. Improve work efficiency. Positioning Guidelines 1.Align vehicle properly. 2.Maintain clearance from equipment. 3.Center vehicle on service lifts.
Safety Precautions Verify lift capacity. Position lift arms correctly. Ensure vehicle balance. Follow manufacturer's instructions. VEHICLE LIFTS AND HOISTS Importance Vehicle lifts provide safe access to undercarriage components. Example Improper positioning on a lift may cause vehicle instability and accidents. WORKSHOP TRAFFIC MANAGEMENT Traffic Control Devices Safety cones Directional signs Floor markings Warning signs Benefits 1.Prevents collisions 2.Improves workflow 3.Enhances workplace safety WORKSHOP TRAFFIC MANAGEMENT Steps 1.Bring vehicle to a complete stop. 2.Shift transmission appropriately. 3.Apply parking brake. 4.Turn off engine. 5.Remove ignition key when required. Importance 1.Prevents unintended vehicle movement. 2.Protects workers and equipment.
PREPARING VEHICLES FOR SERVICING Procedures 1.Secure vehicle properly. 2.Install wheel chocks. 3.Verify parking brake engagement. 4.Prepare service documents. 5.Notify assigned technician. Importance Ensures safety before maintenance activities begin. VEHICLE SECURING DEVICES Wheel Chocks Prevent wheel movement. Safety Cones Warn personnel of vehicle presence. Parking Brake Provides vehicle restraint.
ACTIVITY SHEET #1 Title Conducting a Pre-Operation Vehicle Inspection Objective Perform a complete pre-operation vehicle inspection. Materials Vehicle inspection checklist Actual vehicle PPE Procedure 1.Wear PPE. 2.Inspect vehicle exterior. 3.Inspect vehicle interior. 4.Check controls and instruments. 5.Record findings. 6.Submit inspection report. ACTIVITY SHEET #2 Title Vehicle Positioning Exercise Objective Move and position a vehicle accurately in a service bay. Materials Training vehicle Service bay Safety cones PPE Procedure 1.Perform pre-operation inspection. 2.Move vehicle according to instructions. 3.Align vehicle with the service bay. 4.Position vehicle accurately. 5.Await trainer evaluation. ACTIVITY SHEET #3 Title Vehicle Parking and Securing Activity Objective Demonstrate proper parking and securing procedures. Procedure 1.Move vehicle to designated area. 2.Park vehicle safely. 3.Apply parking brake. 4.Install wheel chocks. 5.Place safety cones if required. 6.Verify vehicle security.
JOB SHEET Title Moving and Positioning a Vehicle for Servicing Objective Demonstrate the ability to prepare, move, position, park, and secure a vehicle safely in accordance with workplace procedures and safety standards. Materials and Equipment Training Vehicle (Manual or Automatic) Vehicle Inspection Checklist Service Bay Vehicle Lift or Hoist Wheel Chocks Safety Cones SOP Manual PPE Vehicle Operator's Manual Workshop Traffic Signages Procedure 1.Wear appropriate PPE. 2.Conduct pre-operation inspection. 3.Identify vehicle controls and instruments. 4.Check surroundings before movement. 5.Start vehicle following manufacturer procedures. 6.Move vehicle safely to the designated location. 7.Position vehicle accurately in the service bay or lift area. 8.Align vehicle according to servicing requirements. 9.Bring vehicle to a complete stop. 10.Apply parking brake. 11.Shift transmission to appropriate gear or park position. 12.Install wheel chocks and safety devices. 13.Turn off engine and secure vehicle. 14.Complete inspection documentation.
Trainee Name: Date: Performance Criteria Yes No Wore appropriate PPE before operation ☐ ☐ Conducted pre-operation inspection correctly ☐ ☐ Identified vehicle controls and instruments accurately ☐ ☐ Checked surroundings before moving vehicle ☐ ☐ Operated vehicle safely and smoothly ☐ ☐ Observed workshop traffic rules and signages ☐ ☐ Positioned vehicle accurately in designated area ☐ ☐ Aligned vehicle properly for servicing ☐ ☐ Applied correct parking procedures ☐ ☐ Used wheel chocks and safety devices properly ☐ ☐ Secured vehicle before servicing activities ☐ ☐ Followed OSH requirements throughout the activity ☐ ☐ PERFORMANCE/OBSERVATION CHECKLIST
UTILIZE AUTOMOTIVE TOOLS Module Descriptor This module covers the knowledge, skills, and attitudes required to prepare, use, and maintain automotive tools in an automotive service center. It includes identifying and selecting appropriate tools, inspecting tools for serviceability, operating hand tools, power tools, and special service tools (SST), observing Occupational Safety and Health (OSH) requirements, and performing tool maintenance and storage procedures. The module emphasizes safe work practices, tool accountability, equipment care, and compliance with manufacturer specifications and workplace procedures. Learning Objectives Upon completion of this module, the trainee should be able to: LO1. Prepare Automotive Tools Identify automotive tools and their functions. Select appropriate tools for specific servicing tasks. Inspect tools for serviceability and safety. LO2. Use Automotive Tools Operate automotive tools correctly and safely. Apply proper tool handling techniques. Perform servicing activities using appropriate tools. LO3. Maintain Automotive Tools Clean and inspect tools after use. Store tools properly. Report and document defective tools.
INTRODUCTION TO AUTOMOTIVE TOOLS What are Automotive Tools? Automotive tools are devices used to perform inspection, maintenance, repair, assembly, and servicing operations on motor vehicles. Example Using a torque wrench instead of an ordinary wrench ensures that bolts are tightened according to manufacturer specifications. Importance Improve work efficiency Ensure service accuracy Reduce technician effort Prevent vehicle damage Improve workplace safety CLASSIFICATION OF AUTOMOTIVE TOOLS Combination Wrench Has fixed open and box ends for precise turning. 1. Hand Tools - tools operated manually to tighten or loosen nuts and bolts Socket Wrench Has a ratcheting handle with interchangeable sockets for faster work. Screwdriver To turn screws in or out of materials. Pliers To grip, hold, bend, or cut wires and other materials. Hammer To drive nails and break or shape materials.
Impact Wrench For drilling holes and driving screws. 2. Power Tools - Tools powered by electricity or compressed air. Impact Wrench For quickly tightening or loosening nuts and bolts. Angle Grinder For cutting, grinding, and polishing materials. Air Ratchet For quickly tightening or loosening bolts and nuts. Bearing Puller 3. Special Service Tools (SST) - Tools designed for specific servicing operations. Valve Spring Compressor Oil Filter Wrench Ball Joint Separator Micrometer Measures the small dimensions precisely. 4. Measuring Tools - Tools used to obtain accurate measurements. Vernier Caliper Measures the inside, outside, and depth dimensions. Feeler Gauge Measures small gaps and clearances. Dial Indicator Measures the small movements and the variations. Steel Rule Used for basic linear measurements. Torque Wrench For precise bolt tightening.
TOOL SELECTION PROCEDURES Example A 12 mm combination wrench should be used on a 12 mm fastener to prevent damage. Effects of Improper Tool Selection Damaged fasteners Tool breakage Personal injury Poor work quality Increased repair costs Factors to Consider Nature of work Manufacturer recommendations Size requirements Safety considerations TOOL INSPECTION AND SAFETY CHECKS Importance Inspection prevents accidents and equipment failure. Inspection Items Cracks Excessive wear Loose handles Damaged insulation Missing parts Example A cracked socket may shatter during use and cause injury. PROPER USE OF HAND TOOLS Guidelines Use the correct tool. Maintain proper grip. Pull wrenches whenever possible. Avoid excessive force. Follow manufacturer instructions. Example Use a box-end wrench rather than pliers when loosening bolts.
PROPER USE OF POWER TOOLS Common Hazards Flying debris Electric shock Noise exposure Entanglement Safety Precautions Inspect cords and hoses. Wear PPE. Secure workpieces. Follow operating procedures. Disconnect power when not in use. PROPER USE OF SPECIAL SERVICE TOOLS Benefits Increased accuracy Reduced component damage Faster servicing operations Purpose SSTs are designed for specialized automotive servicing operations. Example A bearing puller safely removes bearings without damaging shafts. OCCUPATIONAL SAFETY AN HEALTH (OSH) IN TOOL USAGE Safe Work Practices Maintain clean work area. Use tools only for intended purposes. Follow lockout/tagout procedures where applicable. PPE Requirements Safety goggles Gloves Safety shoes Hearing protection CLEANING AUTOMOTIVE TOOLS Cleaning Procedures Remove dirt and grease. Wipe tools dry. Apply rust preventive if necessary. Importance Extends tool life Prevents corrosion Improves performance Maintains safety
TOOL STORAGE PROCEDURES Benefits Easy retrieval Better inventory control Reduced loss and damage Storage Methods Toolboxes Storage cabinets Shadow boards Tool racks REPORTING DEFECTIVE TOOLS Reporting Procedure Tag defective tool. Remove from service. Inform supervisor. Record in maintenance log. Indicators of Defects Cracks Excessive wear Loose components Damaged insulation TOOL MAINTENANCE RECORDS Common Records Inspection checklist Tool inventory log Maintenance report Purpose Monitor tool condition Schedule repairs Maintain accountability
ACTIVITY SHEET #1 Title Tool Identification and Selection Activity Objective Identify and select appropriate automotive tools. Materials Automotive tool set Tool identification worksheet Manufacturer's service manual Procedure 1.Inspect available tools. 2.Identify each tool. 3.State its function. 4.Match tools with assigned servicing tasks. 5.Submit completed worksheet. ACTIVITY SHEET #2 Title Performing Automotive Servicing Using Proper Tools Objective Demonstrate proper operation of automotive tools. Materials Actual vehicle Hand tools Power tools SSTs PPE Procedure 1.Review assigned servicing task. 2.Select appropriate tools. 3.Inspect tools before use. 4.Perform servicing activity. 5.Observe safety requirements. 6.Return tools after completion. ACTIVITY SHEET #3 Title Tool Inspection and Maintenance Activity Procedure 1.Collect used tools. 2.Inspect for defects. 3.Clean tools properly. 4.Record inspection findings. 5.Store tools in designated locations. Objective Perform proper cleaning, inspection, and storage of automotive tools. Materials 1.Automotive tools 2.Inspection checklist 3.Cleaning materials 4.Tool storage cabinet
JOB SHEET Title Preparing, Using, and Maintaining Automotive Tools Objective Demonstrate proper preparation, utilization, maintenance, and storage of automotive tools according to workplace procedures and safety requirements. Materials and Equipment Automotive Hand Tool Set Power Tools Special Service Tools (SST) Measuring Tools Torque Wrench Tool Inspection Checklist Tool Maintenance Logbook Cleaning Materials PPE Service Manual Actual Vehicle Procedure 1.Wear appropriate PPE. 2.Review assigned servicing task. 3.Select appropriate tools based on service requirements. 4.Inspect tools for serviceability and safety. 5.Prepare work area and materials. 6.Perform assigned servicing activity using proper tools. 7.Follow OSH requirements during tool operation. 8.Clean tools after use. 9.Inspect tools for damage or defects. 10.Record findings in maintenance logbook. 11.Store tools properly in designated storage areas. 12.Report defective tools to the supervisor.
Trainee Name: Date: Performance Criteria Yes No Wore appropriate PPE before starting work ☐ ☐ Selected appropriate tools for assigned task ☐ ☐ Inspected tools before use ☐ ☐ Identified defective tools correctly ☐ ☐ Operated hand tools safely and correctly ☐ ☐ Operated power tools safely and correctly ☐ ☐ Used special service tools properly ☐ ☐ Followed manufacturer's instructions and SOPs ☐ ☐ Observed OSH requirements throughout the activity ☐ ☐ Cleaned tools after use ☐ ☐ Stored tools properly in designated locations ☐ ☐ Completed maintenance and inspection records accurately ☐ ☐ PERFORMANCE/OBSERVATION CHECKLIST
This module covers the knowledge, skills, and attitudes required to select measuring instruments, perform measurements and calculations, and maintain measuring instruments used in automotive servicing. It includes the application of measurement principles, unit conversion, interpretation of specifications, calculation of dimensions and tolerances, and proper care of measuring devices. The module emphasizes accuracy, precision, workplace safety, and compliance with manufacturer's specifications and standard operating procedures. PERFORM MENSURATION AND CALCULATION Module Descriptor Upon completion of this module, the trainee should be able to: LO1. Select Measuring Instruments 1.Identify measuring instruments used in automotive servicing. 2.Select appropriate measuring instruments for specific tasks. 3.Inspect measuring instruments before use. LO2. Carry Out Measurements and Calculations 1.Measure automotive parts and components accurately. 2.Perform mathematical calculations related to automotive servicing. 3.Convert units of measurement correctly. 4.Record and interpret measurement results. LO3. Maintain Measuring Instruments 1.Clean and inspect measuring instruments after use. 2.Store instruments properly. 3.Report damaged or defective measuring instruments. Learning Objectives
Micrometer Measures the small dimensions precisely. Vernier Caliper Measures the inside, outside, and depth dimensions. Feeler Gauge Measures small gaps and clearances. Dial Indicator Measures the small movements and the variations. Steel Rule Used for basic linear measurements. Torque Wrench For precise bolt tightening. What is Measurement? Measurement is the process of determining the size, quantity, dimension, capacity, or amount of an object using standard units. Example Measuring brake disc thickness to determine whether replacement is required. IMPORTANCE OF MEASUREMENT IN AUTOMOTIVE SERVICING Importance Ensures accurate repairs Maintains vehicle performance Prevents premature wear Supports quality workmanship TYPES OF MEASURING INSTRUMENTS SELECTING APPROPRIATE MEASURING INSTRUMENTS Factors to Consider Type of measurement required Accuracy needed Component specifications Manufacturer requirements Bolt Tightening Brake Disc Thickness Valve Clearance Shaft Diameter Torque Wrench Vernier Caliper Feeler Gauge Micrometer
Inspection Points Cleanliness Calibration status Physical condition Accuracy of readings Metric System (Common Units) Quantity Unit Length Millimeter (mm) Mass Kilogram (kg) Volume Liter (L) Force Newton (N) Torque Newton-meter (N·m) English System Length Inch (in) Mass Pound (lb) Volume Gallon (gal) INSPECTION OF MEASURING INSTRUMENTS Importance Ensures measurement reliability and accuracy. BASIC UNITS OF MEASUREMENT Reading a Vernier Caliper 1.Read the main scale. 2.Read the vernier scale. 3.Add both readings. READING MEASURING INSTRUMENTS Reading a Micrometer 1.Read sleeve scale. 2.Read thimble scale. 3.Combine readings. Importance Accurate reading prevents servicing errors.
Common Calculations Clearance Outer Dimension − Inner Dimension Volume Length × Width × Height Fuel Consumption Distance ÷ Fuel Used Compression Ratio Used in engine performance calculations. AUTOMOTIVE CALCULATIONS Unit Conversion 1 inch 25.4 mm 1 foot 304.8 mm 1 liter 1000 mL 1 kilogram 2.205 lb RECORDING AND INTERPRETING MEASUREMENTS Guidelines Record measurements accurately. Use correct units. Compare results with specifications. Report discrepancies immediately. Example Measured Valve Clearance = 0.35 mm Specification = 0.25–0.30 mm Result: Requires adjustment.
CARE AND MAINTENANCE OF MEASURING INSTRUMENTS Maintenance Procedures Clean after use Protect from moisture Store properly Avoid dropping instruments Importance Preserves accuracy Extends service life Prevents measurement errors CALIBRATION OF MEASURING INSTRUMENTS What is Calibration? Calibration is the process of verifying measurement accuracy against established standards. Example A micrometer is checked against a calibration standard before use. Importance Ensures reliable measurements Maintains quality standards STORAGE AND REPORTING PROCEDURES Proper Storage Store in protective cases. Keep in dry locations. Protect from dust and impacts. Reporting Defects 1.Inspect instrument. 2.Tag defective equipment. 3.Inform supervisor. 4.Complete maintenance records.
ACTIVITY SHEET #1 Title Identification and Selection of Measuring Instruments Objective Identify and select measuring instruments according to servicing requirements. Materials Measuring instruments Identification worksheet Service manual Procedure 1.Examine available measuring instruments. 2.Identify each instrument. 3.State its function. 4.Match instruments with servicing tasks. 5.Submit completed worksheet. ACTIVITY SHEET #2 Title Measurement and Calculation Exercise Objective Perform measurements and automotive calculations accurately. Materials Vernier caliper Micrometer Feeler gauge Automotive components Calculator Procedure 1.Measure assigned components. 2.Record measurements. 3.Perform required calculations. 4.Compare results with specifications. 5.Submit completed worksheet. ACTIVITY SHEET #3 Title Unit Conversion Workshop Procedure 1.Solve assigned conversion exercises. 2.Verify answers. 3.Present results to the trainer. 4.Discuss computation procedures. Objective Convert measurements using standard conversion procedures.
JOB SHEET Title Measuring and Calculating Automotive Component Specifications Objective Demonstrate the ability to select measuring instruments, perform measurements and calculations, interpret results, and maintain measuring instruments according to workplace procedures. Materials and Equipment Vernier Caliper Micrometer Feeler Gauge Steel Rule Dial Indicator Torque Wrench Calculator Manufacturer's Service Manual Automotive Components Measurement Worksheet Cleaning Materials PPE Procedure 1.Wear appropriate PPE. 2.Review assigned measurement task. 3.Select the appropriate measuring instrument. 4.Inspect the instrument before use. 5.Measure the assigned automotive component. 6.Record measurements accurately. 7.Perform required calculations. 8.Compare results with manufacturer specifications. 9.Interpret findings and determine serviceability. 10.Clean measuring instruments after use. 11.Store measuring instruments properly. 12.Report defective instruments if found.
Trainee Name: Date: Performance Criteria Yes No Wore appropriate PPE before activity ☐ ☐ Selected appropriate measuring instruments correctly ☐ ☐ Inspected measuring instruments before use ☐ ☐ Used measuring instruments properly ☐ ☐ Obtained accurate measurements ☐ ☐ Performed calculations correctly ☐ ☐ Applied unit conversion procedures accurately ☐ ☐ Recorded measurements correctly ☐ ☐ Compared measurements with specifications properly ☐ ☐ Interpreted measurement results accurately ☐ ☐ Cleaned and maintained measuring instruments after use ☐ ☐ Stored measuring instruments properly ☐ ☐ PERFORMANCE/OBSERVATION CHECKLIST
Module Descriptor This module covers the knowledge, skills, and attitudes required to utilize automotive workshop facilities and equipment safely and efficiently. It includes performing pre-operation activities, operating workshop facilities and equipment, and conducting post-operation activities. The module emphasizes proper equipment inspection, safe operating procedures, preventive maintenance, workplace housekeeping, and Occupational Safety and Health (OSH) compliance. RECEIVE AND RESPOND TO WORKPLACE COMMUNICATION Learning Objectives Upon completion of this module, the trainee should be able to: LO1. Perform Pre-Operation Activities Identify workshop facilities and equipment. Conduct pre-operation inspection. Prepare equipment for operation. LO2. Use Facilities and Equipment Operate workshop facilities and equipment safely. Monitor equipment performance during operation. Apply safety procedures while performing servicing activities. LO3. Conduct Post-Operation Activities Shut down equipment properly. Perform cleaning and housekeeping activities. Complete equipment maintenance and usage records.
INTRODUCTION TO WORKSHOP FACILITIES AND EQUIPMENT What are Workshop Facilities and Equipment? Workshop facilities and equipment are tools, machines, workstations, and support systems used to perform automotive servicing and repair operations. Example Vehicle lifts Hydraulic jacks Air compressors Battery chargers Tire changers Benefits Improve productivity Enhance service quality Ensure workplace safety Support efficient vehicle servicing TYPES OF AUTOMOTIVE WORKSHOP EQUIPMENT Vehicle Lifts and Hoists Used for raising vehicles to provide access to underbody components. Hydraulic Jacks and Jack Stands Used for lifting and supporting vehicles during servicing. Air Compressors Provides compressed air to strongly power and efficiently operate pneumatic tools. Battery Chargers and Testers Used for battery charging and testing operations. Tire Changers and Wheel Balancers Used during tire mounting and wheel balancing procedures. Welding Equipment Used for fabrication and repair work where applicable.
PRE-OPERATIONAL INSPECTION PROCEDURES Equipment Condition Damaged parts Loose components Fluid leaks Electrical defects Safety Devices Emergency stop switches Safety locks Guards and shields Warning labels Importance Pre-operation inspections help prevent accidents and equipment failure. EQUIPMENT PREPARATION PROCEDURES Steps 1.Review operating manual. 2.Conduct visual inspection. 3.Verify safety devices. 4.Prepare work area. 5.Wear required PPE. 6.Obtain supervisor authorization if necessary. Example Before using a vehicle lift, inspect lift arms, locking mechanisms, and hydraulic systems. SAFE OPERATION OF WORKSHOP EQUIPMENT General Safety Rules Follow SOPs. Read equipment manuals. Wear appropriate PPE. Use equipment only for intended purposes. Report unsafe conditions immediately. Benefits Prevents accidents Protects equipment Improves work quality
OPERATING VEHICLE LIFTS AND HOISTS Procedures 1.Position vehicle correctly. 2.Verify lift capacity. 3.Place lift arms properly. 4.Raise vehicle slowly. 5.Engage safety locks. 6.Inspect vehicle stability. Safety Reminder Never work under a vehicle unless safety locks are engaged. OPERATING PNEUMATIC AND ELECTRICAL EQUIPMENT Pneumatic Equipment Example: Air impact wrench Air ratchet Tire inflator Electrical Equipment Examples: Battery charger Wheel balancer Diagnostic equipment Safety Equipment Example: Inspect cords and hoses. Avoid water exposure. Disconnect power before maintenance. MONITORING EQUIPMENT PERFORMANCE Indicators of Problems Unusual noises Excessive vibration Fluid leakage Electrical overheating Abnormal operation Reporting Procedure Stop operation if unsafe. Inform supervisor. Record findings. Tag equipment if necessary.
OCCUPATIONAL SAFETY AND HEALTH (OSH) REQUIREMENTS Required PPE Safety shoes Gloves Safety goggles Face shield Hearing protection Workplace Safety Practices Keep work areas clean. Follow safety signage. Observe emergency procedures. EQUIPMENT SHUTDOWN PROCEDURES Procedures 1.Turn off equipment. 2.Disconnect power if required. 3.Release stored energy. 4.Inspect equipment condition. Importance Proper shutdown prevents equipment damage and workplace accidents. CLEANING AND HOUSEKEEPING PROCEDURES Activities Remove dirt and debris. Clean equipment surfaces. Organize tools and accessories. Dispose of waste properly. Benefits Maintains equipment condition. Improves workplace safety. Supports 5S implementation.
EQUIPMENT MAINTENANCE RECORDS Common Records Inspection checklist Usage logbook Maintenance report Repair request form Importance Supports preventive maintenance. Tracks equipment performance. Improves accountability. REPORTING EQUIPMENT DEFECTS Procedure Identify defect. Stop operation if necessary. Tag defective equipment. Notify supervisor. Record findings.
ACTIVITY SHEET #1 Title Workshop Equipment Inspection Activity Objective Conduct a pre-operational inspection of workshop facilities and equipment. Materials Inspection checklist Workshop equipment PPE Procedure 1.Wear PPE. 2.Select assigned equipment. 3.Conduct visual inspection. 4.Check safety devices. 5.Record findings. 6.Submit inspection report. ACTIVITY SHEET #2 Title Operating Workshop Equipment Objective Operate workshop facilities and equipment safely according to SOPs. Materials Vehicle lift Air compressor Battery charger PPE Procedure 1.Conduct pre-operation inspection. 2.Prepare equipment. 3.Operate equipment according to instructions. 4.Monitor operation. 5.Shut down equipment properly. ACTIVITY SHEET #3 Title Equipment Safety Observation Exercise Procedure 1.Observe assigned equipment. 2.Identify safety hazards. 3.Recommend corrective actions. 4.Present findings to the trainer. Objective Identify safety hazards associated with workshop equipment.
JOB SHEET Title Utilizing Automotive Workshop Facilities and Equipment Objective Demonstrate the ability to inspect, operate, monitor, and maintain automotive workshop facilities and equipment according to workplace procedures and safety standards. Materials and Equipment Vehicle Lift or Hoist Hydraulic Jack and Jack Stands Air Compressor Pneumatic Tools Battery Charger and Tester Tire Changer and Wheel Balancer Equipment Inspection Checklist Maintenance Logbook SOP Manual PPE Actual Vehicle Procedure 1.Wear appropriate PPE. 2.Review equipment operating procedures. 3.Conduct pre-operational inspection. 4.Verify safety devices and controls. 5.Prepare equipment for operation. 6.Operate assigned workshop equipment. 7.Observe safety procedures during operation. 8.Monitor equipment performance. 9.Report abnormal conditions immediately. 10.Shut down equipment properly. 11.Clean equipment and work area. 12.Complete inspection and maintenance records. 13.Store accessories and materials properly.
Trainee Name: Date: Performance Criteria Yes No Wore appropriate PPE before operation ☐ ☐ Conducted pre-operational inspection correctly ☐ ☐ Identified equipment controls and safety devices ☐ ☐ Prepared equipment according to SOPs ☐ ☐ Operated equipment safely and correctly ☐ ☐ Followed manufacturer's instructions ☐ ☐ Applied OSH requirements during operation ☐ ☐ Monitored equipment performance properly ☐ ☐ Reported abnormal equipment conditions ☐ ☐ Performed proper shutdown procedures ☐ ☐ Cleaned equipment and work area after use ☐ ☐ Completed maintenance and usage records accurately ☐ ☐ PERFORMANCE/OBSERVATION CHECKLIST
This module covers the knowledge, skills, and attitudes required to identify, retrieve, withdraw, and manage automotive servicing parts and consumables in accordance with workplace procedures and manufacturer specifications. It includes interpreting parts catalogs and service manuals, accomplishing requisition documents, verifying parts and consumables, maintaining inventory records, and observing proper handling, storage, safety, and environmental practices. The module also emphasizes accuracy in documentation, accountability in inventory control, and compliance with Occupational Safety and Health (OSH) requirements. Module Descriptor PREPARE SERVICING PARTS AND CONSUMABLES Learning Objectives Upon completion of this module, the trainee should be able to: LO1. Identify Parts and Consumables Identify automotive parts and consumables based on servicing requirements. Read and interpret parts catalogs, stock cards, and service manuals. Verify parts specifications, descriptions, and applications. LO2. Retrieve and Withdraw Parts and Consumables Accomplish parts requisition and withdrawal forms correctly. Retrieve and withdraw the correct parts and consumables from storage areas. Verify part numbers, quantities, and conditions before issuance. LO3. Complete Work Process Record issued, utilized, and returned parts and consumables accurately. Follow workplace procedures for waste disposal and environmental management. Complete required documentation and inventory records.
INTRODUCTION TO AUTOMOTIVE PARTS AND CONSUMABLES What are Automotive Parts? Automotive parts are components installed in a vehicle to perform specific mechanical, electrical, or structural functions. Example Oil Filter Air Filter Spark Plug Brake Pad Drive Belt Fuel Filter Importance Prevents installation errors Ensures service quality Reduces downtime Improves customer satisfaction What are Automotive Consumables? Consumables are materials that are used up during servicing operations and require periodic replacement. Example Engine Oil Brake Fluid Coolant Grease Cleaning Solvents READING PARTS CATALOGS AND SERVICE MANUALS Purpose of Parts Catalogs Parts catalogs provide detailed information about vehicle components, including: Part numbers Descriptions Applications Exploded diagrams Importance of Service Manuals Service manuals help technicians determine: Correct replacement parts Service specifications Installation procedures Example Part Number: 90915-YZZE1 Description: Oil Filter Vehicle Application: Toyota Gasoline Engine
IDENTIFYING PARTS ACCORDING TO SPECIFICATIONS Verification Procedures Check part number Check dimensions OEM vs Replacement Parts PARTS REQUISITION PROCEDURES Purpose To ensure proper authorization and control of inventory. Required Information Job Order Number Vehicle Information Part Description RETRIEVING AND VERIFYING PARTS Retrieval Procedures Review requisition form. Locate required item. Verify stock information. Check quantity and condition. Prepare items for issuance. Verification Checklist ✓ Correct Part Number ✓ Correct Quantity ✓ Correct Specification ✓ Good Condition OEM Parts Manufactured according to manufacturer standards. Replacement Parts Produced by third-party manufacturers and designed to meet equivalent specifications. Verify compatibility Compare with manufacturer's specifications SAFE HANDLING AND STORAGE OF CONSUMABLES Quantity Technician's Name Supervisor Approval Handling Requirements Wear appropriate PPE. Follow SDS/MSDS instructions. Avoid contamination. Prevent spills and leaks. Example Engine Oil Brake Fluid Coolant Transmission Fluid Storage Requirements Proper labeling Proper ventilation Designated storage areas Temperature control when required
Importance Inventory control Accountability Cost monitoring RECORDING ISSUED AND RETURNED ITEMS Documents Used Stock Cards Withdrawal Slips Requisition Forms Inventory Records Recording Requirements Date issued Item description Quantity issued Quantity returned Person responsible WASTE DISPOSAL AND ENVIRONMENTAL PROCEDURES Common Automotive Wastes Used oil Used filters Coolants Damaged parts Contaminated materials Disposal Procedures Segregate waste properly. Follow environmental regulations. Use designated disposal containers. Complete disposal records. Importance Environmental protection Workplace safety Regulatory compliance WORKPLACE DOCUMENTATION AND REPORTING Common Reports Inventory Utilization Report Withdrawal Report Return Slip Damage Report Waste Disposal Log Reporting Procedures Complete required documents. Verify entries. Submit reports to supervisor. Update inventory records.
ACTIVITY SHEET #1 Title Parts and Consumables Identification Objective Identify automotive parts and consumables correctly according to service requirements. Materials Automotive parts and consumables Parts catalog/service manual Inspection checklist PPE Procedure 1.Inspect assigned parts and consumables. 2.Identify item names and functions. 3.Verify part numbers using catalogs. 4.Record findings. 5.Submit accomplished worksheet. ACTIVITY SHEET #2 Title Parts Retrieval and Verification Exercise Objective Retrieve and verify automotive parts and consumables following workplace procedures. Materials Automotive parts and consumables Requisition form Parts catalog/service manual Storage bins/racks PPE Procedure 1.Review assigned requisition form. 2.Locate required parts. 3.Verify specifications and quantity. 4.Inspect item condition. 5.Prepare items for issuance. ACTIVITY SHEET #3 Title Inventory Recording and Documentation Activity Procedure 1.Record issued items. 2.Document returned materials. 3.Update inventory records. 4.Prepare utilization report. 5.Submit documents for verification. Objective Accurately complete inventory records and workplace documentation.
JOB SHEET Title Preparing Servicing Parts and Consumables for Automotive Servicing Objective Demonstrate the ability to identify, retrieve, verify, document, and manage servicing parts and consumables according to workplace procedures and manufacturer specifications. Materials and Equipment Automotive Parts Catalog Manufacturer's Service Manual Parts Requisition Form Withdrawal Slip Stock Cards Inventory Records Automotive Parts and Components Automotive Consumables PPE Storage Shelves and Bins Procedure 1.Review job order requirements. 2.Identify required parts and consumables. 3.Verify specifications using references. 4.Accomplish requisition forms. 5.Retrieve required items. 6.Verify quantity and condition. 7.Prepare items for servicing operations. 8.Record issuance and utilization. 9.Return unused items. 10.Dispose of waste materials properly. 11.Complete inventory and workplace records.
Trainee Name: Date: Performance Criteria Yes No Identified parts correctly ☐ ☐ Identified consumables correctly ☐ ☐ Interpreted parts catalogs accurately ☐ ☐ Verified specifications correctly ☐ ☐ Accomplished requisition forms properly ☐ ☐ Retrieved correct parts and consumables ☐ ☐ Verified quantity and condition of items ☐ ☐ Applied proper handling and storage procedures ☐ ☐ Recorded issued and returned items accurately ☐ ☐ Followed waste disposal procedures ☐ ☐ Completed workplace documentation correctly ☐ ☐ Observed OSH requirements throughout the activity ☐ ☐ PERFORMANCE/OBSERVATION CHECKLIST
At the end of this module, the trainee will be able to: LO1. Receive Vehicle 1.Verify vehicle information, customer concerns, and service requirements. 2.Conduct initial vehicle inspection and documentation. 3.Accomplish vehicle reception forms and job orders accurately. LO2. Prepare Vehicle for Servicing 1.Protect vehicle surfaces and interior components from damage. 2.Position and secure vehicles safely in designated work areas. 3.Prepare vehicles according to workplace servicing procedures. LO3. Prepare Vehicle for Releasing Conduct post-service inspection and quality checks. Prepare and clean the vehicle for customer release. Complete service documentation and participate in vehicle turnover procedures. PREPARE VEHICLE FOR SERVICING AND RELEASING Module Descriptor This module covers the knowledge, skills, and attitudes required to receive vehicles, prepare vehicles for servicing, and prepare vehicles for release in accordance with workplace procedures, customer service standards, and quality requirements. It includes vehicle reception, initial inspection, documentation, vehicle protection, work area preparation, post-service inspection, vehicle cleaning, completion of service records, and customer turnover procedures. Learning Objectives
VEHICLE RECEPTION PROCEDURES Overview Vehicle reception is the first step in the servicing process. Proper vehicle reception ensures that customer concerns and service requirements are clearly identified before work begins. Information to Verify Vehicle make and model Plate number Odometer reading Customer information Service request Reception Activities Welcome the customer professionally. Verify vehicle information. Determine customer concerns. Review service requirements. Open a job order. Importance Assist understanding Ensures accuracy Improves customer satisfaction INITIAL VEHICLE INSPECTION Overview An initial inspection will document the condition of the vehicle before servicing. Exterior Condition Dents & scratches Broken lights Damaged mirrors Interior Condition Seat condition Dashboard condition Accessories Vehicle Operation Warning indicators Fuel level Battery condition Importance Protects both the customer and the service center by documenting initial vehicle condition. JOB ORDERS AND SERVICE DOCUMENTATION Definition A Job Order (JO) serves as the official authorization to perform servicing activities. Contents of a Job Order Customer details Vehicle information Requested services Inspection findings Technician assignment Importance Tracks servicing activities Supports billing procedures Provides service history
VEHICLE PROTECTION PROCEDURES Overview Protective materials are installed to prevent vehicle damage during servicing. Common Protective Devices Seat covers Steering wheel covers Fender covers Floor mats Benefits Maintains vehicle cleanliness Prevents scratches and stains Improves customer confidence POSITIONING AND SECURING VEHICLES Procedures Move vehicle to designated work area. Engage parking brake. Place wheel chocks when necessary. Turn off engine. Secure vehicle properly. Safety Considerations Follow workshop traffic rules. Observe safety signages. Maintain clear work areas. PREPARING VEHICLES FOR SERVICING OPERATIONS Overview Preparation ensures that technicians can perform servicing safely and efficiently. Activities Verify service requirements. Prepare tools and equipment. Install protective covers. Position vehicle correctly. Ensure safe working conditions. Importance Proper preparation reduces delays and prevents workplace accidents.
POST-SERVICE INSPECTION PROCEDURES Overview A post-service inspection verifies that all required work has been completed correctly. Inspection Areas Completed repairs Fluid levels Vehicle cleanlines Importance Ensures service quality and customer satisfaction. VEHICLE CLEANING AND QUALITY CONTROL Overview Before release, the vehicle should be cleaned and inspected according to company standards. Cleaning Activities Remove protective covers. Clean work areas affected by servicing. Wipe vehicle surfaces. Remove dirt and debris. Quality Control Checks Verify completed work. Check for leaks. Confirm proper operation. VEHICLE RELEASE AND CUSTOMER TURNOVER PROCEDURES Overview Vehicle release is the final stage of the service process. Release Activities Review completed work. Explain services performed. Present service records. Obtain customer acknowledgment. Documents Required Job Order Service Report Vehicle Release Form Quality Inspection Report Importance Provides clear communication and ensures customer satisfaction. Safety systems Warning indicators
ACTIVITY SHEET #1 Title Vehicle Reception and Inspection Activity Objective Receive and inspect a vehicle according to workplace procedures. Materials Automotive parts and consumables Parts catalogue/service manual Vehicle inspection checklist Job card/work order Basic inspection tools PPE Procedure 1.Verify vehicle information. 2.Interview customer regarding service concerns. 3.Conduct vehicle inspection. 4.Record findings. 5.Accomplish job order and inspection checklist. ACTIVITY SHEET #2 Title Vehicle Preparation for Servicing Objective Prepare a vehicle for servicing following standard operating procedures. Materials Automotive parts and consumables Requisition form Parts catalogue/service manual Storage bins/racks Job card/work order Vehicle protection covers PPE Procedure 1.Install protective covers. 2.Move vehicle to assigned service bay. 3.Secure vehicle properly. 4.Prepare required servicing area. 5.Verify readiness for servicing. ACTIVITY SHEET #3 Title Vehicle Release and Documentation Activity Procedure 1.Conduct final inspection. 2.Verify completed work. 3.Clean vehicle. 4.Complete release documents. 5.Conduct customer turnover simulation. Objective Prepare the serviced vehicle for release and complete documentation.
JOB SHEET Title Preparing a Vehicle for Servicing and Releasing Objective Demonstrate the ability to receive, inspect, prepare, document, and release a vehicle according to workplace procedures and customer service standards. Materials and Equipment Actual Vehicle Job Order Form Vehicle Inspection Checklist Vehicle Release Form Service Record Forms Seat Covers Steering Wheel Covers Fender Covers Floor Mats Cleaning Materials PPE Standard Operating Procedures (SOPs) Procedure 1.Receive the vehicle and verify customer concerns. 2.Record vehicle information. 3.Conduct initial inspection. 4.Accomplish job order and inspection forms. 5.Install protective covers. 6.Move vehicle to service bay. 7.Secure vehicle properly. 8.Verify completion of servicing activities. 9.Conduct post-service inspection. 10.Clean vehicle and remove protective covers. 11.Complete service and release documents. 12.Conduct customer turnover and explain completed work. 13.Obtain required approvals and signatures.
Trainee Name: Date: Performance Criteria Yes No Verified customer concerns and service requirements ☐ ☐ Recorded vehicle information accurately ☐ ☐ Conducted initial vehicle inspection properly ☐ ☐ Accomplished job order and inspection forms correctly ☐ ☐ Installed protective covers properly ☐ ☐ Positioned vehicle safely in service area ☐ ☐ Secured vehicle according to safety procedures ☐ ☐ Conducted post-service inspection correctly ☐ ☐ Verified completion of required servicing work ☐ ☐ Cleaned and prepared vehicle for release ☐ ☐ Completed service and release documents accurately ☐ ☐ Demonstrated proper customer turnover procedures ☐ ☐ Observed workplace safety and OSH requirements ☐ ☐ PERFORMANCE/OBSERVATION CHECKLIST
CORE competenciesA U T O M O T I V E S E R V I C I N G N C I I
PERFORM PRE-DELIVERY INSPECTION Module Descriptor This module covers the knowledge, skills, and attitudes required to effectively perform pre-delivery inspection (PDI) on vehicles before turnover, release, or customer delivery. It includes preparing the vehicle, tools, equipment, and documentation for inspection; conducting thorough physical and functional inspections of vehicle systems, components, and safety features; identifying, assessing, and documenting defects or irregularities; verifying that necessary corrective actions have been properly completed; and ensuring the vehicle meets required quality, safety, and operational standards. It also covers the accurate completion of inspection reports, checklists, quality control records, and other required documentation to support proper vehicle release and customer satisfaction. Learning Objectives At the end of this module, the trainee will be able to: LO1. Prepare for Pre-Delivery Inspection 1.Review vehicle documents, inspection checklists, and manufacturer requirements. 2.Prepare tools, equipment, and materials needed for inspection. 3.Observe safety procedures prior to inspection activities. LO2. Perform Physical and Functional Inspection 1.Conduct systematic inspection of vehicle components and systems. 2.Perform functional testing of vehicle controls, accessories, and operating systems. 3.Identify and document defects, discrepancies, and missing components. LO3. Complete Work Processes 1.Accomplish inspection reports and quality control records accurately. 2.Verify completion of corrective actions. 3.Prepare the vehicle for turnover or customer release.
INTRODUCTION TO PRE- DELIVERY INSPECTION (PDI) What is Pre-Delivery Inspection? Pre-Delivery Inspection (PDI) is the final inspection performed on a vehicle before it is released to the customer. It ensures that the vehicle meets manufacturer specifications, safety standards, and quality requirements. Objectives of PDI Verify vehicle condition Ensure safety and reliability Detect defects before release Improve customer satisfaction Importance A properly conducted PDI minimizes customer complaints and ensures that the vehicle is delivered in excellent condition. REQUIRED DOCUMENTS AND INSPECTION CHECKLISTS Documents Used During PDI Job Order Vehicle Delivery Checklist PDI Checklist Service Records Quality Control Forms Typical Checklist Sections Exterior Interior Engine Compartment Under Chassis Electrical Systems Importance of Inspection Checklists Inspection checklists help ensure that all vehicle systems and components are inspected systematically. PREPARATION OF TOOLS, EQUIPMENT, AND WORK AREA Tools and Equipment Commonly Used Flashlight Tire Pressure Gauge Multimeter Scan Tool Inspection Mirror Hand Tools Preparation Activities Review inspection requirements. Gather required tools and equipment. Prepare inspection forms. Wear appropriate PPE. Ensure work area safety.
PHYSICAL INSPECTION OF VEHICLE COMPONENTS Exterior Inspection Check the following: Paint condition Body panels Windshield and windows Mirrors Lights and lenses Interior Inspection Inspect: Seats Dashboard Seat belts Controls and switches Floor coverings Engine Compartment Inspection Check: Fluid levels Battery condition FUNCTIONAL INSPECTION OF VEHICLE SYSTEMS Electrical System Headlights Signal lights Horn Wipers Instrument panel Engine Operation Engine starting Idling performance Warning indicators Brake and Steering Systems Brake pedal operation Steering wheel response Parking brake function Importance Functional inspection verifies that all systems operate according to specifications. Hoses and belts Wiring connections IDENTIFYING AND REPORTING DEFECTS Common Defects Loose components Fluid leaks Damaged parts Missing accessories Malfunctioning systems Reporting Procedure Record findings. Identify affected components. Inform supervisor. Recommend corrective actions. Importance Early defect identification prevents vehicle release with unresolved issues.
ACCOMPLISHING INSPECTION REPORTS Purpose of Inspection Reports Inspection reports provide documentation of vehicle condition and inspection results. Information Recorded Vehicle information Inspection results Defects identified Corrective actions required Importance Ensures traceability and quality control. VERIFICATION OF CORRECTIVE ACTIONS Verification Activities Reinspect corrected items. Confirm compliance with specifications. Validate repair completion. Update inspection records. Importance Ensures all defects are resolved before release. VEHICLE TURNOVER AND RELEASE Procedures Final Activities Review inspection documents. Confirm completion of repairs. Verify vehicle cleanliness. Obtain approvals and signatures. Verification Activities Requirements for Release No unresolved defects Complete documentation Passed quality control inspection.
ACTIVITY SHEET #1 Title Preparation for Pre-Delivery Inspection Objective Prepare the workplace, vehicle documents, tools, and equipment required for pre-delivery inspection. Materials Vehicle records/documents PDI checklist Job card/work order Parts catalogue/service manual Required inspection tools Vehicle protection covers PPE Procedure 1.Review assigned vehicle records. 2.Secure inspection forms. 3.Gather required tools and equipment. 4.Inspect PPE. 5.Prepare the inspection area. ACTIVITY SHEET #2 Title Conducting Physical and Functional Vehicle Inspection Objective Perform physical and functional inspection of a vehicle using a standard PDI checklist. Materials PDI checklist Job card/work order Parts catalogue/service manual Basic diagnostic/inspection tools Functional testing equipment Vehicle protection covers PPE Procedure 1.Inspect vehicle exterior. 2.Inspect vehicle interior. 3.Inspect engine compartment. 4.Conduct functional testing. 5.Record inspection findings. ACTIVITY SHEET #3 Title Completion of PDI Documentation and Vehicle Release Procedure 1.Review inspection findings. 2.Verify corrective actions. 3.Accomplish quality control records. 4.Secure approvals. 5.Prepare vehicle for release. Objective Complete inspection reports and verify readiness for vehicle release.
JOB SHEET Title Performing a Pre-Delivery Inspection (PDI) Objective Demonstrate the ability to prepare for, conduct, document, and complete a pre-delivery inspection according to workplace procedures and manufacturer standards. Materials and Equipment Vehicle for Inspection PDI Checklist Job Order Service Records Manufacturer's Service Manual Flashlight Tire Pressure Gauge Multimeter Inspection Mirror Diagnostic Scanner (if available) Hand Tools PPE Quality Control Forms Procedure 1.Wear required PPE. 2.Review vehicle documents and inspection checklist. 3.Prepare tools and equipment. 4.Conduct exterior inspection. 5.Conduct interior inspection. 6.Inspect engine compartment. 7.Inspect under chassis components. 8.Perform functional tests of vehicle systems. 9.Record defects and discrepancies. 10.Accomplish inspection report. 11.Verify corrective actions. 12.Complete quality control records. 13.Prepare vehicle for release.
Trainee Name: Date: Performance Criteria Yes No Reviewed vehicle documents and inspection checklist ☐ ☐ Prepared tools and equipment correctly ☐ ☐ Wore appropriate PPE ☐ ☐ Conducted exterior inspection systematically ☐ ☐ Conducted interior inspection properly ☐ ☐ Inspected engine compartment accurately ☐ ☐ Performed functional testing correctly ☐ ☐ Identified defects and discrepancies accurately ☐ ☐ Recorded findings completely and accurately ☐ ☐ Verified corrective actions properly ☐ ☐ Completed inspection and quality control forms correctly ☐ ☐ Prepared vehicle for release according to standards ☐ ☐ Observed workplace safety and OSH requirements ☐ ☐ PERFORMANCE/OBSERVATION CHECKLIST
This module covers the knowledge, skills, and attitudes required to perform periodic engine maintenance according to manufacturer specifications and workplace procedures. It includes engine inspection, routine maintenance, proper use of tools and equipment, and completion of required documentation, with emphasis on safety, environmental protection, and quality workmanship. Upon completion, trainees will be able to maintain and service automotive engines for reliable performance and longer service life. PERFORM PERIODIC MAINTENANCE OF AUTOMOTIVE ENGINE Module Descriptor At the end of this module, the trainee will be able to: LO1. Prepare for Inspection and Service Engine 1.Review maintenance schedules, job orders, and service manuals. 2.Prepare tools, equipment, parts, and consumables. 3.Observe safety and environmental requirements before servicing. LO2. Inspect Engine 1.Conduct visual and operational inspection of engine systems and components. 2.Identify engine maintenance requirements. 3.Record inspection findings according to workplace procedures. LO3. Service Engine 1.Perform engine oil change, filter replacement, and fluid servicing. 2.Carry out routine engine maintenance procedures according to manufacturer specifications. 3.Observe proper safety and environmental practices during servicing LO4. Complete Work Processes Accomplish maintenance records and service documentation. Verify service completion and vehicle condition. Perform housekeeping and waste disposal procedures. Learning Objectives
INTRODUCTION TO PERIODIC ENGINE MAINTENANCE What is Periodic Maintenance? Periodic maintenance consists of regularly scheduled inspections and servicing activities performed to maintain engine performance and prevent premature failures. Objectives Maintain engine efficiency Prevent breakdowns Extend engine life Ensure vehicle reliability Common Maintenance Activities Engine oil replacement Oil filter replacement Air filter inspection Coolant inspection Belt inspection MAINTENANCE SCHEDULES AND SERVICE MANUALS Maintenance Schedule A maintenance schedule specifies when inspections and servicing should be performed. Sources of Maintenance Information Manufacturer's Service Manual Maintenance Schedule Booklet Importance Following maintenance schedules helps prevent costly repairs and unexpected breakdowns. PREPARING TOOLS, EQUIPMENT, PARTS, AND CONSUMABLES Tools and Equipment Socket Wrench Set Oil Filter Wrench Consumables Engine Oil Oil Filter Coolant Cleaning Materials Safety Preparation Wear PPE. Prepare work area. Review servicing procedures. Drain Pan Funnel Torque Wrench Job Order Service Records
VISUAL INSPECTION OF ENGINE COMPONENTS Components to Inspect Engine oil level Coolant level Drive belts Hoses Battery connections Air filter Purpose To identify wear, leaks, damage, and maintenance requirements. CHECKING ENGINE FLUIDS Engine Oil Check: Oil level Oil condition Contamination Coolant Check: Coolant level Reservoir condition Leaks Importance Proper fluid levels help maintain engine performance and prevent overheating. IDENTIFYING ENGINE MAINTENANCE REQUIREMENTS Common Findings Dirty air filter Low engine oil Coolant leaks Cracked belts Damaged hoses Reporting Procedures 1.Record findings. 2.Inform supervisor. 3.Recommend corrective action.
ENGINE OIL AND OIL FILTER REPLACEMENT Basic Procedures Drain used oil. Remove old oil filter. Install new oil filter. Refill engine oil. Check for leaks. Safety Reminder Dispose of used oil according to environmental regulations. Importance Engine oil lubricates moving engine parts and reduces wear. AIR FILTER AND COOLING SYSTEM MAINTENANCE Air Filter Maintenance Inspect filter condition. Clean or replace as required. Cooling System Maintenance Check coolant level. Inspect radiator hoses. Check for leaks. Importance Proper airflow and cooling improve engine efficiency. SAFETY AND ENVIRONMENTAL PROCEDURES Safety Requirements Wear PPE. Follow SOPs. Use proper lifting techniques. Avoid hot engine components. Environmental Procedures Proper disposal of used oil. Segregation of waste materials. Prevention of fluid spills..
ACCOMPLISHING MAINTENANCE RECORDS Documents Used Maintenance Checklist Job Order Service Report Inspection Form Importance Accurate documentation provides service history and supports quality control. VERIFICATION OF COMPLETED WORK Verification Activities Check fluid levels. Verify filter installation. Inspect for leaks. Confirm service completion. Importance Ensures vehicle readiness and service quality. HOUSEKEEPING AND WASTE MANAGEMENT Housekeeping Activities Clean tools and equipment. Organize work area. Return unused materials. Waste Disposal Used engine oil Oil filters Cleaning materials
ACTIVITY SHEET #1 Title Preparation for Engine Maintenance Objective Prepare the tools, equipment, parts, and documents required for engine maintenance. Procedure 1.Review job order. 2.Review service manual. 3.Gather tools and equipment. 4.Prepare parts and consumables. 5.Wear required PPE. ACTIVITY SHEET #2 Title Engine Inspection Activity Objective Inspect engine components and determine maintenance requirements. Procedure 1.Perform visual inspection. 2.Check fluid levels. 3.Inspect belts and hoses. 4.Record observations. 5.Submit inspection report. ACTIVITY SHEET #3 ACTIVITY SHEET #4 Title Performing Engine Maintenance Procedures Objective Perform routine engine maintenance according to workplace and manufacturer requirements. Procedure 1.Perform oil change. 2.Replace oil filter. 3.Check coolant condition. 4.Inspect air filter. 5.Verify service completion. Title Completing Engine Maintenance Documentation Objective Complete service records and workplace documentation accurately. Procedure 1.Review completed work. 2.Complete checklist. 3.Record replaced parts. 4.Complete service report. 5.Submit to supervisor.
JOB SHEET Title Performing Periodic Maintenance of Automotive Engine Objective Demonstrate the ability to inspect, service, and document periodic maintenance activities on an automotive engine according to manufacturer specifications and workplace procedures. Materials and Equipment Vehicle with Engine Manufacturer's Service Manual Job Order Maintenance Checklist Engine Oil Oil Filter Air Filter Coolant Oil Drain Pan Oil Filter Wrench Socket Set Torque Wrench Funnel Cleaning Materials PPE Procedure 1.Review maintenance schedule and job order. 2.Prepare tools, equipment, and consumables. 3.Wear PPE. 4.Conduct engine inspection. 5.Check oil and coolant levels. 6.Inspect belts, hoses, and filters. 7.Drain engine oil. 8.Replace oil filter. 9.Refill engine oil according to specifications. 10.Check for leaks. 11.Verify service completion. 12.Clean work area and tools. 13.Accomplish maintenance records and reports.
Trainee Name: Date: Performance Criteria Yes No Reviewed maintenance schedule and service manual ☐ ☐ Prepared tools, equipment, and consumables properly ☐ ☐ Wore appropriate PPE ☐ ☐ Conducted engine inspection correctly ☐ ☐ Checked fluid levels accurately ☐ ☐ Inspected belts, hoses, and filters properly ☐ ☐ Performed oil change according to specifications ☐ ☐ Replaced oil filter correctly ☐ ☐ Applied safety and environmental procedures ☐ ☐ Verified service completion properly ☐ ☐ Completed documentation accurately ☐ ☐ Performed housekeeping and waste disposal procedures ☐ ☐ PERFORMANCE/OBSERVATION CHECKLIST
PERFORM PERIODIC MAINTENANCE OF DRIVE TRAIN Module Descriptor This module covers the knowledge, skills, and attitudes required to perform periodic maintenance of automotive drive train systems. It includes preparing for drive train servicing, conducting inspection and maintenance activities on drive train components, and performing post-service activities. The module emphasizes proper maintenance procedures, adherence to manufacturer specifications, workplace safety, environmental compliance, and accurate documentation. Upon completion of this module, trainees will be able to inspect, service, lubricate, and maintain drive train systems to ensure efficient power transmission, vehicle reliability, and optimum performance. Learning Objectives At the end of this module, the trainee will be able to: LO1. Perform Pre-Service Preparations Review job orders, maintenance schedules, and service manuals. Prepare tools, equipment, lubricants, and consumables. Observe workplace safety requirements before servicing. LO2. Conduct Periodic Maintenance of Drive Trains Inspect drive train components and identify maintenance requirements. Check and replenish transmission and driveline lubricants. Perform routine maintenance procedures according to manufacturer specifications. LO3. Perform Post-Service Activities Conduct post-service inspection and verification. Complete maintenance reports and documentation. Perform housekeeping and waste disposal procedures.
INTRODUCTION TO DRIVE TRAIN SYSTEMS What is a Drive Train? The drive train is the group of components that transmit engine power to the vehicle wheels. Major Drive Train Components Clutch (Manual Transmission) Transmission Assembly Propeller Shaft Universal Joints Differential Axle Shafts Final Drive Components Importance Proper maintenance ensures: Smooth power transmission Reduced component wear Improved fuel efficiency Longer service life MAINTENANCE SCHEDULES AND SERVICE MANUALS What is a Maintenance Schedule? The maintenance schedule specifies inspection and service intervals recommended by the manufacturer. Sources of Information Service Manuals Maintenance Schedules Job Orders Service Bulletins Importance Following maintenance schedules helps prevent premature drive train failures and costly repairs. PREPARATION OF TOOLS, EQUIPMENT, AND CONSUMABLES Common Tools and Equipment Socket Wrench Set Torque Wrench Hydraulic Jack Safety Preparation Wear PPE. Secure vehicle properly. Grease Cleaning Materials Vehicle Lift Drain Pan Grease Gun Consumables Transmission Fluid Grease Cleaning Materials Gear Oil
INSPECTION OF DRIVE TRAIN COMPONENTS Components to Inspect Transmission Housing Propeller Shaft Universal Joints Differential Housing Axle Shafts Boots and Seals Inspection Areas Damaged components Excessive wear Fluid leaks Loose fasteners Importance Regular inspection helps identify defects before major failures occur. CHECKING AND REPLACING DRIVE TRAIN LUBRICANTS Types of Lubricants Transmission Fluid Gear Oil Grease Inspection Procedures Check lubricant level. Inspect lubricant condition. Check for contamination. Replace lubricant when necessary. Importance Lubricants reduce friction, wear, and overheating of drive train components. ROUTINE MAINTENANCE PROCEDURES Common Maintenance Activities Checking transmission fluid Lubricating universal joints Inspecting differential assembly Tightening mounting bolts Inspecting seals and boots Safety Precautions Follow SOPs. Use proper lifting equipment. Prevent lubricant spills.
POST-SERVICE INSPECTION PROCEDURES Inspection Activities Verify fluid levels. Check for leaks. Confirm component security. Verify completion of maintenance tasks. Importance Ensures quality and safety of completed work. DOCUMENTATION AND MAINTENANCE RECORDS Common Documents Maintenance Checklist Inspection Report Service Record Job Order Importance Provides maintenance history Supports quality control Ensures accountability HOUSEKEEPING AND ENVIRONMENTAL PROCEDURES Housekeeping Activities Clean tools and equipment. Organize workplace. Return unused materials. Waste Management Dispose of used lubricants properly. Segregate waste materials. Follow environmental regulations. Importance Promotes safety and environmental protection.
ACTIVITY SHEET #1 Title Preparation for Drive Train Maintenance Objective Prepare tools, equipment, consumables, and workplace requirements for drive train servicing. Materials Vehicle records/documents Job card/work order Parts catalogue/service manual Required tools and equipment Consumables Vehicle protection covers PPE Procedure 1.Review job order and service manual. 2.Gather required tools and materials. 3.Inspect tools and equipment. 4.Wear required PPE. 5.Prepare service area. ACTIVITY SHEET #2 Title Drive Train Inspection and Maintenance Activity Objective Inspect and perform routine maintenance on drive train components. Materials Job card/work order Parts catalogue/service manual Inspection/diagnostic tools Lubricants and consumables Functional testing equipment Vehicle protection covers PPE Procedure 1.Raise vehicle safely. 2.Inspect drive train components. 3.Check lubricant levels. 4.Lubricate applicable components. 5.Record maintenance findings. ACTIVITY SHEET #3 Title Completion of Drive Train Service Documentation Procedure 1.Conduct final inspection. 2.Verify service completion. 3.Complete maintenance forms. 4.Clean workplace. 5.Submit documentation. Objective Complete service records and verify maintenance.
JOB SHEET Title Performing Periodic Maintenance of Drive Train Objective Demonstrate the ability to inspect, lubricate, maintain, and document periodic maintenance activities on automotive drive train systems according to manufacturer specifications and workplace procedures. Materials and Equipment Vehicle with Drive Train System Manufacturer's Service Manual Maintenance Checklist Job Order Vehicle Lift or Hydraulic Jack Socket Wrench Set Torque Wrench Grease Gun Drain Pan Transmission Fluid Gear Oil Grease Cleaning Materials PPE Procedure 1.Review maintenance schedule and job order. 2.Prepare tools, equipment, and consumables. 3.Wear PPE. 4.Raise and secure vehicle safely. 5.Inspect drive train components. 6.Check transmission fluid condition and level. 7.Inspect universal joints, propeller shaft, and differential. 8.Lubricate applicable components. 9.Verify completion of maintenance activities. 10.Conduct post-service inspection. 11.Clean tools and work area. 12.Complete maintenance records and reports.
Trainee Name: Date: Performance Criteria Yes No Reviewed maintenance schedule and service manual ☐ ☐ Prepared tools, equipment, and consumables correctly ☐ ☐ Wore appropriate PPE ☐ ☐ Conducted drive train inspection properly ☐ ☐ Identified maintenance requirements accurately ☐ ☐ Checked lubricant levels correctly ☐ ☐ Performed lubrication procedures properly ☐ ☐ Followed workplace safety procedures ☐ ☐ Observed environmental requirements ☐ ☐ Conducted post-service inspection correctly ☐ ☐ Completed documentation accurately ☐ ☐ Performed housekeeping and waste disposal procedures ☐ ☐ PERFORMANCE/OBSERVATION CHECKLIST
PERFORM PERIODIC MAINTENANCE OF BRAKE SYSTEM Module Descriptor This module covers the knowledge, skills, and attitudes required to perform periodic maintenance of automotive brake systems. It includes preparation for brake system maintenance, inspection and servicing of brake system components, and completion of post-maintenance activities and documentation. The module emphasizes adherence to manufacturer specifications, workplace procedures, safety standards, and environmental regulations. Upon completion of this module, trainees will be able to inspect, clean, adjust, maintain, and evaluate brake system components to ensure safe and efficient vehicle operation. Learning Objectives At the end of this module, the trainee will be able to: LO1. Prepare for Periodic Maintenance of Brake System Review maintenance schedules, job orders, and service manuals. Prepare tools, equipment, brake fluids, and consumables. Observe safety and environmental requirements before servicing. LO2. Carry-Out Periodic Maintenance Procedures Inspect brake system components and identify maintenance requirements. Check brake fluid level and condition. Clean, inspect, and adjust brake components according to manufacturer specifications. LO3. Complete Periodic Maintenance Procedure Conduct operational checks and verify brake system performance. Complete maintenance records and service documentation. Perform housekeeping and waste disposal procedures.
INTRODUCTION TO AUTOMOTIVE BRAKE SYSTEMS What is a Brake System? The brake system is a vehicle safety system designed to slow down or stop vehicle movement through friction and hydraulic force. Major Brake System Components Brake Pedal Master Cylinder Brake Fluid Reservoir Brake Lines and Hoses Disc Brakes Drum Brakes Brake Pads and Shoes Importance Regular maintenance ensures safe braking performance and prevents brake failure. MAINTENANCE SCHEDULES AND SERVICE REFERENCES Sources of Maintenance Information Manufacturer's Service Manual Maintenance Schedule Job Order Technical Service Bulletins Maintenance Intervals Brake inspections are performed at specified mileage or service intervals depending on manufacturer recommendations. Importance Following service schedules helps maintain braking efficiency and vehicle safety. PREPARATION OF TOOLS, EQUIPMENT, AND CONSUMABLES Common Tools and Equipment Socket Wrench Set Brake Spring Tools Consumables Brake Fluid Brake Cleaner Cleaning Cloths Safety Requirements Wear PPE. Secure vehicle properly. Follow workshop safety procedures. Brake Adjustment Tools Brake Inspection Tools Hydraulic Jack Jack Stands
INSPECTION OF BRAKE SYSTEM COMPONENTS Components to Inspect Brake Pads Brake Shoes Brake Disc Rotor Brake Drum Brake Lines Brake Hoses Master Cylinder Importance Regular inspection prevents brake system failure and ensures road safety. Inspection Areas Wear Damage Leaks Corrosion Loose Components Functions of Brake Fluid Brake fluid transmits hydraulic pressure from the brake pedal to the brake assemblies. BRAKE FLUID INSPECTION AND MAINTENANCE Inspection Procedures 1.Check fluid level. 2.Inspect fluid condition. 3.Check for contamination. 4.Refill if necessary. Common Brake Fluid Problems Low fluid level Moisture contamination Fluid leakage CLEANING AND ADJUSTING BRAKE COMPONENTS Cleaning Procedures Remove dirt and debris. Use approved brake cleaner. Inspect cleaned components. Adjustment Procedures Adjust brake shoes if applicable. Check parking brake adjustment. Verify proper brake clearance. Safety Reminder Avoid inhaling brake dust and always use approved cleaning materials.
OPERATIONAL TESTING OF BRAKE SYSTEMS Operational Checks Brake Pedal Travel Brake Response Parking Brake Function Brake Warning Indicators Importance Operational testing confirms proper brake system performance after servicing. DOCUMENTATION AND MAINTENANCE RECORDS Documents Used Maintenance Checklist Brake Inspection Report Service Record Job Order Importance Accurate documentation provides maintenance history and supports quality assurance. HOUSEKEEPING AND ENVIRONMENTAL PROCEDURES Housekeeping Activities Clean tools and equipment. Return tools to storage. Clean service area. Waste Disposal Procedures Dispose of used brake fluid properly. Segregate contaminated materials. Follow environmental regulations. Importance Promotes workplace safety and environmental protection.
ACTIVITY SHEET #1 Title Preparation for Brake System Maintenance Objective Prepare tools, equipment, consumables, and workplace requirements for brake system maintenance. Materials Vehicle records/documents Job card/work order Parts catalogue/service manual Required tools and equipment Brake consumables Vehicle protection covers PPE Procedure 1.Review maintenance schedule. 2.Review service manual. 3.Gather tools and consumables. 4.Wear PPE. 5.Secure vehicle for servicing. ACTIVITY SHEET #2 Title Brake System Inspection and Maintenance Activity Objective Inspect and perform routine maintenance procedures on automotive brake systems. Materials Job card/work order Parts catalogue/service manual Inspection/diagnostic tools Brake fluid and consumables Functional testing equipment Vehicle protection covers PPE Procedure 1.Secure vehicle. 2.Inspect brake components. 3.Check brake fluid. 4.Clean and adjust components. 5.Record findings. ACTIVITY SHEET #3 Title Completion of Brake Maintenance Documentation Procedure 1.Perform final brake inspection. 2.Verify brake operation. 3.Complete records. 4.Clean workplace. 5.Submit reports. Objective Complete service records and verify brake maintenance.
JOB SHEET Title Performing Periodic Maintenance of Brake System Objective Demonstrate the ability to inspect, clean, adjust, service, and document periodic maintenance activities on automotive brake systems according to manufacturer specifications and workplace procedures. Materials and Equipment Vehicle with Brake System Manufacturer's Service Manual Job Order Maintenance Checklist Hydraulic Jack Jack Stands Socket Wrench Set Brake Inspection Tools Brake Adjustment Tools Brake Cleaner Brake Fluid Cleaning Materials PPE Procedure 1.Review maintenance schedule and service manual. 2.Prepare tools, equipment, and consumables. 3.Wear PPE. 4.Raise and secure vehicle. 5.Inspect brake components. 6.Check brake fluid condition and level. 7.Clean brake assemblies. 8.Adjust brake components if necessary. 9.Conduct operational testing. 10.Verify completion of maintenance activities. 11.Clean work area and tools. 12.Complete maintenance records and reports.
Trainee Name: Date: Performance Criteria Yes No Reviewed maintenance schedule and service manual ☐ ☐ Prepared tools, equipment, and consumables correctly ☐ ☐ Wore appropriate PPE ☐ ☐ Conducted brake system inspection properly ☐ ☐ Identified brake system defects accurately ☐ ☐ Checked brake fluid level and condition correctly ☐ ☐ Cleaned brake components properly ☐ ☐ Adjusted brake components according to specifications ☐ ☐ Conducted operational brake testing correctly ☐ ☐ Followed workplace safety procedures ☐ ☐ Completed maintenance documentation accurately ☐ ☐ Performed housekeeping and waste disposal procedures ☐ ☐ PERFORMANCE/OBSERVATION CHECKLIST
PERFORM PERIODIC MAINTENANCE OF SUSPENSION SYSTEM Module Descriptor This module covers the knowledge, skills, and attitudes required to perform periodic maintenance of automotive suspension systems. It includes preparation for maintenance activities, inspection and servicing of suspension system components, and completion of maintenance work processes. The module emphasizes proper inspection techniques, adherence to manufacturer specifications, workplace safety, environmental compliance, and accurate documentation. Upon completion of this module, trainees will be able to inspect, lubricate, maintain, and evaluate suspension system components to ensure vehicle stability, ride comfort, handling performance, and road safety. Learning Objectives At the end of this module, the trainee will be able to: LO1. Perform Pre-Periodic Maintenance of Suspension System Review maintenance schedules, job orders, and service manuals. Prepare tools, equipment, replacement parts, and consumables. Observe safety requirements before servicing activities. LO2. Perform Periodic Maintenance of Suspension System Inspect suspension system components and identify defects. Check shock absorbers, springs, bushings, ball joints, and linkages. Lubricate and maintain applicable suspension components. LO3. Perform Work to Completion Conduct operational and visual inspections after servicing. Complete maintenance records and service reports. Perform housekeeping and waste disposal procedures.
INTRODUCTION TO SUSPENSION SYSTEMS What is a Suspension System? The suspension system supports the vehicle's weight, absorbs road shocks, and maintains tire contact with the road surface. Major Suspension Components Shock Absorbers Struts Coil Springs Leaf Springs Ball Joints Control Arms Bushings Stabilizer Bars Importance Proper maintenance improves ride comfort, steering control, tire life, and vehicle safety. MAINTENANCE SCHEDULES AND SERVICE REFERENCES Maintenance Requirements Periodic inspection helps identify worn or damaged suspension components before they affect vehicle performance. Sources of Information Manufacturer's Service Manuals Maintenance Schedules Job Orders Technical Service Bulletins Importance Following recommended maintenance intervals prevents costly repairs and unsafe driving conditions. PREPARATION OF TOOLS, EQUIPMENT, AND CONSUMABLES Common Tools and Equipment Socket Wrench Set Pry Bar Consumables Grease Cleaning Materials Replacement Bushings Cotter Pins Torque Wrench Hydraulic Jack Jack Stands Vehicle Lift Safety Precautions Wear PPE. Secure vehicle properly. Use lifting equipment correctly. Follow workplace safety procedures.
INSPECTION OF SUSPENSION COMPONENTS Components to Inspect Shock Absorbers Struts Coil Springs Bushings Control Arms Stabilizer Links Importance Routine inspection helps identify defects that affect ride quality and safety. Inspection Areas Cracks Wear Leaks Looseness Physical Damage INSPECTION OF BALL JOINTS AND SUSPENSION LINKAGES Ball Joint Inspection Check for: Excessive play Damage Loose mounting Suspension Linkages Inspect: Tie Rod Connections Stabilizer Links Mounting Brackets Importance Defective joints and linkages may cause steering instability and uneven tire wear. LUBRICATION AND MAINTENANCE PROCEDURES Maintenance Activities Lubricate serviceable joints. Tighten loose fasteners. Inspect rubber components. Replace damaged cotter pins. Safety Reminder Always follow manufacturer specifications when servicing suspension components
OPERATIONAL AND VISUAL INSPECTION Operational Checks Vehicle Ride Height Suspension Movement Noise During Operation Vehicle Stability Importance Verifies service quality and vehicle safety. Visual Checks Component Condition Fastener Security Fluid Leaks (if applicable) DOCUMENTATION AND SERVICE RECORDS Documents Used Maintenance Checklist Inspection Report Service Record Job Order Importance Provides maintenance history and supports quality assurance activities. HOUSEKEEPING AND ENVIRONMENTAL PROCEDURES Housekeeping Activities Clean tools and equipment. Return tools to storage. Organize workplace. Waste Disposal Procedures Segregate waste materials. Dispose of damaged components properly. Follow environmental regulations. Importance Maintains a safe, clean, and productive workplace.
ACTIVITY SHEET #1 Title Preparation for Suspension System Maintenance Objective Prepare tools, equipment, consumables, and workplace requirements for suspension system maintenance. Materials Service manual Job card Inspection tools PPE Procedure 1.Review job order and maintenance schedule. 2.Gather tools and equipment. 3.Prepare consumables and replacement parts. 4.Wear PPE. 5.Secure vehicle for inspection. ACTIVITY SHEET #2 Title Suspension System Inspection and Maintenance Activity Objective Inspect and perform routine maintenance on automotive suspension system components. Materials Service manual Inspection tools Lubricants/consumables PPE Procedure 1.Raise and secure vehicle. 2.Inspect suspension components. 3.Check ball joints and bushings. 4.Lubricate applicable components. 5.Record maintenance findings. ACTIVITY SHEET #3 Title Completion of Suspension System Maintenance Documentation Procedure 1.Conduct final inspection. 2.Verify maintenance completion. 3.Accomplish service records. 4.Clean work area. 5.Submit completed reports. Objective Complete records and verify suspension maintenance.
JOB SHEET Title Performing Periodic Maintenance of Suspension System Objective Demonstrate the ability to inspect, lubricate, maintain, and document periodic maintenance activities on automotive suspension systems according to manufacturer specifications and workplace procedures. Materials and Equipment Vehicle with Suspension System Manufacturer's Service Manual Maintenance Checklist Job Order Vehicle Lift or Hydraulic Jack Jack Stands Socket Wrench Set Torque Wrench Pry Bar Grease Gun Lubricants and Grease Cleaning Materials Suspension Inspection Tools PPE Procedure 1.Review maintenance schedule and service manual. 2.Prepare tools, equipment, and consumables. 3.Wear PPE. 4.Raise and secure vehicle. 5.Inspect shock absorbers and springs. 6.Inspect bushings, ball joints, and suspension linkages. 7.Lubricate applicable suspension components. 8.Tighten loose fasteners according to specifications. 9.Conduct operational and visual inspections. 10.Verify completion of maintenance activities. 11.Clean work area and tools. 12.Complete maintenance records and reports.
Trainee Name: Date: Performance Criteria Yes No Reviewed maintenance schedule and service manual ☐ ☐ Prepared tools, equipment, and consumables correctly ☐ ☐ Wore appropriate PPE ☐ ☐ Conducted suspension system inspection properly ☐ ☐ Identified suspension component defects accurately ☐ ☐ Inspected shock absorbers and springs correctly ☐ ☐ Inspected ball joints and bushings properly ☐ ☐ Performed lubrication procedures correctly ☐ ☐ Conducted operational and visual inspections properly ☐ ☐ Followed workplace safety procedures ☐ ☐ Completed maintenance documentation accurately ☐ ☐ Performed housekeeping and waste disposal procedures ☐ ☐ PERFORMANCE/OBSERVATION CHECKLIST
PERFORM PERIODIC MAINTENANCE OF STEERING SYSTEM Module Descriptor This module covers the knowledge, skills, and attitudes required to perform periodic maintenance of automotive steering systems. It includes preparation for maintenance activities, inspection and servicing of steering system components, and completion of maintenance work processes. The module emphasizes proper inspection techniques, adherence to manufacturer specifications, workplace safety, environmental compliance, and accurate documentation. Upon completion of this module, trainees will be able to inspect, lubricate, maintain, and evaluate steering system components to ensure safe vehicle operation, steering responsiveness, directional stability, and driving comfort. Learning Objectives At the end of this module, the trainee will be able to: LO1. Perform Pre-Periodic Maintenance of Steering System Review schedules, job orders, and manuals. Prepare tools, parts, and consumables. Follow workplace safety requirements. LO2. Perform Periodic Maintenance of Steering System Inspect steering components. Check steering and power steering components. Perform maintenance per specifications. LO3. Perform Work to Completion Conduct final inspections. Complete maintenance records. Clean workplace and dispose of waste.
INTRODUCTION TO AUTOMOTIVE STEERING SYSTEMS What is a Steering System? The steering system allows the driver to control the direction of vehicle movement safely and accurately. Major Steering Components Steering Wheel Steering Column Steering Gear Box / Rack and Pinion Tie Rod Ends Pitman Arm Idler Arm Steering Linkages Power Steering Pump (if equipped) Importance Proper maintenance ensures: Accurate steering control Improved vehicle stability Reduced tire wear Safe vehicle operation MAINTENANCE SCHEDULES AND SERVICE REFERENCES Sources of Maintenance Information Manufacturer's Service Manuals Maintenance Schedules Job Orders Technical Service Bulletins Importance Periodic inspection helps detect steering problems before they become major safety hazards. PREPARATION OF TOOLS, EQUIPMENT, AND CONSUMABLES Common Tools and Equipment Socket Wrench Set Torque Wrench Pry Bar Hydraulic Jack Jack Stands Steering Inspection Tools Consumables Power Steering Fluid Lubricants Cleaning Materials Safety Precautions Wear PPE. Secure vehicle properly. Use lifting devices correctly. Follow workplace safety procedures.
INSPECTION OF STEERING COMPONENTS Components to Inspect Steering Wheel Steering Column Steering Gear Assembly Tie Rod Ends Steering Linkages Steering Boots Importance Periodic inspection helps detect steering problems before they become major safety hazards. Inspection Areas Wear Damage Looseness Corrosion Fluid Leaks CHECKING STEERING WHEEL FREE PLAY AND LINKAGES Steering Wheel Free Play Free play refers to steering wheel movement before the wheels begin to turn. Inspection Procedure Measure free play according to manufacturer specifications. Check steering response. Inspect linkage connections. Common Problems Excessive free play Loose tie rod ends Worn steering components POWER STEERING SYSTEM MAINTENANCE Components to Check Power Steering Fluid Reservoir Power Steering Pump Hoses and Connections Steering Rack Maintenance Procedures Check fluid level. Inspect fluid condition. Check for leaks. Replenish fluid when necessary Importance Proper maintenance ensures smooth steering operation and prevents component damage.
OPERATIONAL AND VISUAL INSPECTION Operational Checks Steering Response Ease of Steering Operation Steering Wheel Alignment Unusual Noise or Vibration Importance Confirms proper steering system operation after servicing. Visual Checks Fluid Leaks Component Security Hose Condition Fastener Tightness DOCUMENTATION AND SERVICE RECORDS Documents Used Maintenance Checklist Steering Inspection Report Service Record Job Order Importance Accurate records provide maintenance history and support quality assurance. HOUSEKEEPING AND ENVIRONMENTAL PROCEDURES Housekeeping Activities Clean tools and equipment. Return tools to proper storage. Organize work area. Waste Disposal Procedures Dispose of used power steering fluid properly. Segregate waste materials. Follow environmental regulations. Importance Maintains workplace safety and environmental compliance.
ACTIVITY SHEET #1 Title Preparation for Steering System Maintenance Objective Prepare tools, equipment, consumables, and workplace requirements for steering system maintenance. Materials Job card/work order Service manual Required tools PPE Procedure 1.Review job order and maintenance schedule. 2.Gather required tools and equipment. 3.Prepare lubricants and consumables. 4.Wear PPE. 5.Secure vehicle for servicing. ACTIVITY SHEET #2 Title Steering System Inspection and Maintenance Activity Objective Inspect and perform routine maintenance procedures on automotive steering systems. Materials Job card/work order Service manual Inspection tools Lubricants/consumables PPE Procedure 1.Raise and secure vehicle. 2.Inspect steering components. 3.Check steering wheel free play. 4.Inspect tie rods and linkages. 5.Check power steering fluid level and condition. 6.Record inspection findings. ACTIVITY SHEET #3 Title Completion of Steering System Maintenance Documentation Procedure 1.Conduct final inspection. 2.Verify steering performance. 3.Complete maintenance reports. 4.Clean work area and tools. 5.Submit documentation. Objective Complete records and verify steering maintenance.
JOB SHEET Title Performing Periodic Maintenance of Steering System Objective Demonstrate the ability to inspect, service, maintain, and document periodic maintenance activities on automotive steering systems according to manufacturer specifications and workplace procedures. Materials and Equipment Vehicle with Steering System Manufacturer's Service Manual Maintenance Checklist Job Order Vehicle Lift or Hydraulic Jack Jack Stands Socket Wrench Set Torque Wrench Steering Inspection Tools Power Steering Fluid Lubricants Cleaning Materials PPE Procedure 1.Review maintenance schedule and service manual. 2.Prepare tools, equipment, and consumables. 3.Wear PPE. 4.Raise and secure vehicle safely. 5.Inspect steering wheel, steering gear, and steering linkages. 6.Check steering wheel free play. 7.Inspect tie rods and steering joints. 8.Check power steering fluid level and condition. 9.Replenish fluid if necessary. 10.Conduct operational steering checks. 11.Verify completion of maintenance activities. 12.Clean work area and tools. 13.Complete maintenance records and reports.
Trainee Name: Date: Performance Criteria Yes No Reviewed maintenance schedule and service manual ☐ ☐ Prepared tools, equipment, and consumables correctly ☐ ☐ Wore appropriate PPE ☐ ☐ Conducted steering system inspection properly ☐ ☐ Identified steering system defects accurately ☐ ☐ Checked steering wheel free play correctly ☐ ☐ Inspected tie rods and steering linkages properly ☐ ☐ Checked power steering fluid level and condition correctly ☐ ☐ Conducted operational steering checks properly ☐ ☐ Followed workplace safety procedures ☐ ☐ Completed maintenance documentation accurately ☐ ☐ Performed housekeeping and waste disposal procedures ☐ ☐ PERFORMANCE/OBSERVATION CHECKLIST