AUTOMOTIVE WORKSHOP PRACTICE 3 MECHANICAL ENGINEERING DEPARTMENT LAB SHEET DJA40052 POLITEKNIK KUCHING SARAWAK
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 i LAB SHEET DJA40052 AUTOMOTIVE WORKSHOP PRACTICE 3 Ts. SHAIFUL HAZMIR SHAIFUDDIN PENERBIT JABATAN KEJURUTERAAN MEKANIKAL POLITEKNIK KUCHING SARAWAK 2023
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 ii Authors Ts. SHAIFUL HAZMIR BIN SHAIFUDDIN ABU HARFIZ BIN HASSAN ASHRAF AZZAM BIN ZULKIFLI AMIN Ts. AHMAD SAPUAN BIN HASAN AHMAD FAIRUZ BIN MOHAMAD HERMAN NORDIADI BIN ABD WAHAB AZLAN BIN ADAM ZIKRI BIN ZAKARIA MOHD FITRI BIN SAFE'I MOHD SARHAN BIN OTHMAN MOHAMAD SHUKRI BIN MUDA MOHD NOR HAKIM BIN AB WAHAB AZRUL NIZAM BIN AZHAR MOHD FATHI BIN RAMLI NOR HAFIZA BINTI ISMAIL POLITEKNIK KUCHING SARAWAK MINISTRY OF HIGHER EDUCATION KM22, JALAN MATANG, 93050 KUCHING, SARAWAK. Phone No. : (082) 845596/7/8 Fax No. : (082) 845023 E-mail : [email protected] Website : http://www.poliku.edu.my/ Copyright © 2023 Politeknik Kuching Sarawak eISBN: 978-629-7638-00-3 All rights reserved. No parts of this publication may be copied, stored in form or by any means, electronic, mechanical, photocopying and recording or otherwise or by any means for reproduced without the prior permission of Politeknik Kuching Sarawak. Published by: Politeknik Kuching Sarawak Ministry Of Higher Education
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 iii PREFACE Head of Mechanical Engineering Department Assalamualaikum warahmatullahi wabarakatuh and greetings. Thanks be to Allah SWT because with His permission, Lab Sheet AUTOMOTIVE WORKSHOP PRACTICE 3 (DJA 40052) has been successfully published. This Lab Sheet is another effort of the Mechanical Engineering Department to strengthen the quality of studies and improve the quality of Teaching and Learning (PDP). Department of Mechanical Engineering, Polytechnic Kuching Sarawak is on a mission to empower TVET in producing holistic, entrepreneurial and innovative graduates to meet the needs of the industry. A study environment that promotes the development of excellent TVET centres must always be supported to produce competent, innovative and virtuous people. This can also meet national and international needs that are always concerned about the quality of study programs. Therefore, it is hoped that this publication of Lab Sheet AUTOMOTIVE WORKSHOP PRACTICE 3 (DJA 40052) will be able to be used as a guide and reference by all students studying in Diploma in Mechanical Engineering (Automotive). Finally, I would like to express my infinite appreciation and gratitude to all parties involved in the successful publication of this Lab Sheet AUTOMOTIVE WORKSHOP PRACTICE 3 (DJA 40052). Hopefully this Lab Sheet will be able to help Politeknik Kuching Sarawak efforts in driving student excellence. DASIMA BT NEN@SHAHINAN KETUA JABATAN JABATAN KEJURUTERAAN MEKANIKAL
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 iv SYNOPSIS AUTOMOTIVE WORKSHOP PRACTICE 3 (DJA40052) provides basic automotive related skills which focus on follow troubleshooting and servicing of Natural Gas Vehicle (NGV), Diesel Common Rail System, Hybrid Car System, Antilock Brake System (ABS), Electronic Stability Program (ESP), air conditioning system, Continuously Variable Transmission (CVT), and Supplemental Restraint System (SRS) by using OBD II and inspection and testing of actuators. This lab sheet was developed for student to proceed troubleshooting method of automotive systems, follow skill for servicing automotive systems, demonstrate awareness of social responsibility and safety procedures in the workshop according to the workshop safety regulations to create a secured environment in an organization while doing practical work, apply appropriate techniques, resources, and modern engineering and IT tools to well-defined engineering problems, with an awareness of the limitations and demonstrate knowledge of the societal, health, safety, legal and cultural issues and the consequent responsibilities relevant to engineering technician practice and solutions to well-defined engineering problems.
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 v LAB SHEET EDITING AND DEVELOPMENT BACKGROUND Ts. Shaiful Hazmir Bin Shaifuddin is a former lecturer at Kolej Komuniti Sungai Petani for the Servis Kenderaan Ringan (SKR) course and currently serves at Politeknik Kuching Sarawak in Department of Mechanical Engineering. Education background: Bachelor's Degree in Mechanical-Automotive Engineering (Honours) from the International Islamic University of Malaysia (UIAM) and Master's in the field of Technical and Vocational Education at University Pendidikan Sultan Idris (UPSI). PROVIDED TOGETHER: EN. ABU HARFIZ BIN HASSAN EN. ASHRAF AZZAM BIN ZULKIFLI AMIN Ts. AHMAD SAPUAN BIN HASAN EN. AHMAD FAIRUZ BIN MOHAMAD EN. HERMAN NORDIADI BIN ABD WAHAB EN. AZLAN BIN ADAM EN. ZIKRI BIN ZAKARIA EN. MOHD FITRI BIN SAFE'I Ts. MOHD SARHAN BIN OTHMAN EN. MOHAMAD SHUKRI BIN MUDA EN. MOHD NOR HAKIM BIN AB WAHAB EN. AZRUL NIZAM BIN AZHAR EN. MOHD FATHI BIN RAMLI PN. NOR HAFIZA BINTI ISMAIL
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 vi CONTENT PREFACE iii SYNOPSIS iv LAB SHEET EDITING AND DEVELOPMENT BACKGROUND v Safety Health Environment and Welfare 1 Practical Task 1 safety, health environment and welfare 3 Natural Gas Vehicle (NGV) 12 Engine (natural Gas Vehicle, NGV) 13 Demonstrate Natural Gas Vehicle (NGV) Servicing 13 Natural Gas Vehicle Troubleshooting 18 Gas Consumption 18 Engine Overheating 18 Power Loss 19 Engine Rough Idling 19 Inspect NGV (Leakage Test) 20 Inspect NGV (Cooling System) 20 Inspect NGV (Fuel System) 21 Diesel Common Rail 22 Diesel Common Rail troubleshooting and servicing 23 Hybrid System 28 Troubleshooting and service of hybrid system 29 Antilock Brake System (ABS) 37 Antilock brake system diagnosis and servicing 38 Electronic Stability Program (ESP) 48 Electronic stability program (ESP) diagnosis and servicing 49 Car Air conditioning System 63 Demonstrate air conditioning system diagnosis and servicing 64 Continuously Variable Transmission (CVT) 79 Continuously Variable Transmission (CVT) diagnosis and servicing 80 Supplemental Restraint System (SRS) 87 Supplemental Restraint System (SRS) diagnosis and servicing 88
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 1 SAFETY HEALTH ENVIRONMENT AND WELFARE
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 2 1.0 Safety, Health, Environment and Welfare 1.1 Explain Safety, Health, Environment and Welfare in Workshop Practice a. OSHA b. NIOSH c. DOSH 1.2 Follow Safety Procedure, Health, Environment and Welfare in Workshop Practice a. Personnel b. Equipment and maintenance c. Workplace d. Emergency procedures in case of accident e. Procedures in case of accident f. Hazardous storage and disposal procedures Assessment: Practical Task (A) PREPARED BY: Ts. SHAIFUL HAZMIR BIN SHAIFUDDIN PN. NOR HAFIZA BINTI ISMAIL
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 3 TASK 1 : SAFETY, HEALTH ENVIRONMENT AND WELFARE TITLE : 1.1 IDENTIFY SAFETY, HEALTH, ENVIRONMENT AND WELFARE IN WORKSHOP PRACTICE 1.2 OBSERVE SAFETY, HEALTH AND ENVIRONMENT IN WORKSHOP PRACTICE 1.0 Experiment outcome At the end of the lab session students should be able: i) To identify safety, health and environment practice in workshop ii) To implement safety, health and environment in workshop practice 2.0 Theory OSHA (Occupational, Safety and Health Act) - With the Occupational Safety and Health Act of 1970, Congress created the Occupational Safety and Health Administration (OSHA) to assure safe and healthful working conditions for working men and women by setting and enforcing standards and by providing training, outreach, education and assistance. NIOSH (National Institute of Occupational, Safety and Health) - NIOSH was established to help ensure safe and healthful working conditions by providing research, information, education, and training in the field of occupational safety and health. NIOSH provides national and world leadership to prevent work-related illness, injury, disability, and death by gathering information, conducting scientific research, and translating the knowledge gained into products and services.
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 4 TASK 1 : SAFETY, HEALTH ENVIRONMENT AND WELFARE TITLE : 1.1 IDENTIFY SAFETY, HEALTH, ENVIRONMENT AND WELFARE IN WORKSHOP PRACTICE 1.2 OBSERVE SAFETY, HEALTH AND ENVIRONMENT IN WORKSHOP PRACTICE DOSH (Department of Occupational, Safety and Health) - The Department of Occupational Safety and Health (DOSH) is a department under the Ministry of Human Resources. This department is responsible for ensuring the safety, health and welfare of people at work as well as protecting other people from the safety and health hazards arising from the activities sectors which include: a) Manufacturing b) Mining and Quarrying c) Construction d) Hotels and Restaurant e) Agriculture, Forestry and Fishing f) Transport, Storage and Communication g) Public Services and Statutory Authorities h) Utilities - Gas, Electricity, Water and Sanitary Service i) Finance, Insurance, Real Estate and Business Services j) Wholesale and Retail Trades - As a government agency, the department is responsible for the administration and enforcement of legislations related to occupational safety and health of the country, with a vision of becoming an organisation which leads the nation in creating a safe and healthy work culture that contributes towards enhancing the quality of working life.
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 5 TASK 1 : SAFETY, HEALTH ENVIRONMENT AND WELFARE TITLE : 1.1 IDENTIFY SAFETY, HEALTH, ENVIRONMENT AND WELFARE IN WORKSHOP PRACTICE 1.2 OBSERVE SAFETY, HEALTH AND ENVIRONMENT IN WORKSHOP PRACTICE Personnel safety, health and welfare i) Employer’s duties Under Section 8 of the Act the employer has a duty to ensure the employees’ safety, health and welfare at work as far as is reasonably practicable. In order to prevent workplace injuries and ill health the employer is required, among other things to: • Provide and maintain a safe workplace which uses safe plant and equipment • Prevent risks from use of any article or substance and from exposure to physical agents, noise and vibration. • Prevent any improper conduct or behaviour likely to put the safety, health and welfare of employees at risk. • Provide instruction and training to employees on health and safety. • Provide protective clothing and equipment to employees. • Appointing a competent person as the organization’s Safety Officer ii) Employees’ duties The duties of employees while at work are set out in Section 13 of the Act. These include the following: • To take reasonable care to protect the health and safety of themselves and of other people in the workplace. • Not to engage in improper behaviour that will endanger themselves or others. • Not to be under the influence of drink or drugs in the workplace • To undergo any reasonable medical or other assessment if requested to do so by the employer. • To report any defects in the place of work or equipment which might be a danger to health and safety.
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 6 TASK 1 : SAFETY, HEALTH ENVIRONMENT AND WELFARE TITLE : 1.1 IDENTIFY SAFETY, HEALTH, ENVIRONMENT AND WELFARE IN WORKSHOP PRACTICE 1.2 OBSERVE SAFETY, HEALTH AND ENVIRONMENT IN WORKSHOP PRACTICE Workplace and equipment safety, health and welfare The Workplace (Health, Safety & Welfare) Regulations 1992 cover any premises or part of premises (excluding domestic premises) which are made available to any person as a place of work. They cover a wide range of basic health, safety and welfare issues. Employers have a general duty under section 2 of the Health and Safety at Work Act 1974 to ensure, so far as is reasonably practicable, the health, safety and welfare of their employees at work. Health requirement that need to be consider such as temperature, ventilation, lighting, cleanliness, workstation, seating, waste and etc. Maintenance of the workplace, certain equipment, devices and systems in efficient working order also are crucial requirements in assuring safety. Follow emergency procedures in case of accident. Every workplace should have plans to deal with emergencies. The plans that are needed will depend on the types of emergencies that might happen. Emergencies can include: • Fire • chemical spill • explosion • bomb threat • flooding
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 7 TASK 1 : SAFETY, HEALTH ENVIRONMENT AND WELFARE TITLE : 1.1 IDENTIFY SAFETY, HEALTH, ENVIRONMENT AND WELFARE IN WORKSHOP PRACTICE 1.2 OBSERVE SAFETY, HEALTH AND ENVIRONMENT IN WORKSHOP PRACTICE Follow safety procedures in case of accident In most cases these emergencies will mean the workplace has to be evacuated. Most organisations will have some sort of evacuation plan, especially if the public access the building. You are likely to find evacuation plans displayed somewhere highly visible, such as a bulletin board, or as a sign on the wall. These plans should describe: • How you are alerted of an evacuation, e.g., alarm or announcement. • How to evacuate the building e.g., not using lifts, how to find your nearest exit. • Where to evacuate to, and who to report to so they know you are out of the building. Follow hazardous storage and disposal procedures A hazard is anything that might cause harm to a person in the workplace. Everyone in a workplace has as a role to play in identifying hazards. Some examples of hazards are: • Noise • Infectious diseases • Dangerous chemicals or harmful substances • Mechanical equipment • Electricity • Working at heights • Bullying and harassment • Manual handling (lifting, moving). • An accident or near miss is reported. • An inspection identifies a problem • A hazard is reported by someone at the workplace.
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 8 TASK 1: SAFETY, HEALTH ENVIRONMENT AND WELFARE TITLE : 1.1 IDENTIFY SAFETY, HEALTH, ENVIRONMENT AND WELFARE IN WORKSHOP PRACTICE 1.2 OBSERVE SAFETY, HEALTH AND ENVIRONMENT IN WORKSHOP PRACTICE 3.0 Apparatus/Equipment i. Pen/Pencil ii. Paper 4.0 Safety Precautions i. Safety boots ii. Safety jacket 5.0 Procedures i. Create a group of 4 to 6 students. ii. Observe entire workshop area and try to spot any item that can contribute to hazard. iii. Illustrate the item using picture or by sketching. iv. Write what might happen if the hazard is not fixed. v. After a hazard has been identified, an assessment should be done to rate the risk involved. A risk is an estimate of how likely a hazard is to cause harm. Describe how you asses the level or rate of risk. vi. Introduce controls to eliminate or reduce the identified risk to health and safety. vii. When a risk control measure is decided on, and action is taken to put it into place, there is still more to be done. Suggest an action to make sure that risk control measure is implemented.
MECHANICAL ENGINEERING DEPARTMENPOLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACT TASK 1: SAFETY, HEALTH ENVIRONMENT AND WE TITLE : 1.1 IDENTIFY SAFETY, HEALTH, ENVIRONWORKSHOP PRACTICE 1.2 OBSERVE SAFETY, HEALTH AND ENVPRACTICE 6.0 Results/Data No Illustration of item How it can contribute to hhazard 1 2 3
NT TICE 3 9 ELFARE MENT AND WELFARE IN VIRONMENT IN WORKSHOP Type of Introduce to Further action to hazard & Rate eliminate or assure implementation of risk reduce the risk
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 10 TASK 1: SAFETY, HEALTH ENVIRONMENT AND WELFARE TITLE : 1.1 IDENTIFY SAFETY, HEALTH, ENVIRONMENT AND WELFARE IN WORKSHOP PRACTICE 1.2 OBSERVE SAFETY, HEALTH AND ENVIRONMENT IN WORKSHOP PRACTICE 7.0 Discussion i. Please identify type of hazards. ii. Several topics as given below have been briefly discussed in theoretical segment. Please briefly explain how you relate the discovery item in result as hazard based on those topics: a) Personnel safety, health and welfare. b) Workplace and equipment safety, health and welfare. c) Follow emergency procedures in case of accident. d) Follow safety procedures in case of accident. e) Follow hazardous storage and disposal procedures iii. Please explain how you rate the risk given in the table above. iv. Risk management system start from HIRARC. Give definition of HIRARC. 8.0 Conclusion and Recommendation Your conclusion should be related to your practical and theoretical understanding on the related topic. 9.0 References i. Arduniwati A., Fairulnizar R. & Fakharuldin I.(……..) C1043 Keselamatan dan Kesihatan Pekerjaan I, Modul Politeknik Kementerian Pendidikan Malaysia ii. “Health and safety at work”. This article was cited from http://www.citizensinformation.html on 5th July 2012. iii. “Workplace health, safety and welfare”. This article was cited in http://www.gosport.gov.uk on 5th July 2012
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 11 TASK 1: SAFETY, HEALTH ENVIRONMENT AND WELFARE TITLE : 1.1 IDENTIFY SAFETY, HEALTH, ENVIRONMENT AND WELFARE IN WORKSHOP PRACTICE 1.2 OBSERVE SAFETY, HEALTH AND ENVIRONMENT IN WORKSHOP PRACTICE 10.0 Questions Related i. What is the definition of Occupational, Safety and Health? ii. What are behaviors that can contribute to accident in workplace? iii. What are the responsibilities of employee and employer in ensuring safety at workplace? iv. What is the objective of Occupational, Safety and Health Act?
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 12 NATURAL GAS VEHICLE (NGV)
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 13 1.0 ENGINE (Natural Gas Vehicle, NGV) 1.1 Demonstrate Natural Gas Vehicle (NGV) Servicing. a. Conduct NGV troubleshooting. i. High gas consumption. ii. Engine overheating. iii. Jerking at low and high speed. iv. Engine power loss. v. Engine rough idling. b. Inspect NGV electrical components. c. Leakage test. i. Cooling system ii. Fuel system d. NGV regulator overhaul. e. Tune engine according to specification. Assessment: Practical Task (A) PREPARED BY: EN. ASHRAF AZZAM BIN ZULKIFLI AMIN Ts. AHMAD SAPUAN BIN HASAN
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 14 Title: Natural Gas Vehicle (NGV) Session: Lecturer: Date: Assessment: Practical Task (Psychomotor-1) & (Affective-1) PT-P1&A1 INTRODUCTION NGV System Layout OBJECTIVES 1. To identify all components and understand the function of NGV 2. To inspect NGV electrical components 3. To perform NGV troubleshooting THEORY Explain in details the components and how it works of the Natural Gas Vehicle (NGV)system PROBLEM STATEMENT Justify all problems regarding to NGV systems
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 15 EQUIPMENTS List down all tools and equipment during inspection, troubleshooting and servicing PROCEDURES 1. Inspect all NGV components 2. Dismantle and assemble NGV regulator 3. Perform NGV solenoid tester CHECKING & TESTING From the problem statement and after servicing the components identify the checking and testing method on the system. DISCUSSION 1. What is the function of Regulator? 2. Describe the function of selector switch? 3. Explain why engine oil can be extending mileage when using NGV? 4. Explain why the government encourage users to use NGV system? CONCLUSION Conclude the result from the job / service. REFERENCES List down all references involved.
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 16 PLO5: Apply appropriate techniques, resources, and modern engineering and IT tools to well defined engineering problems, with an awareness of limitations CLO2: Follow skill for servicing automotive systems (P3) CRITERION SUBCRITERION ASSESSMENT LEVEL SCORE 2 4 6 8 10 Not participate Participation was Did the machining Used time well. Excellent Used ① at all. minimal OR student was not but did not appear very interested. Stayed focused on the machining time well in workshop and PART A Display very interested in Focus was lost on most of the time. focused attention Servicing Participation participating. several occasions. on the machining. skills (P3) Able to assemble Able to assemble Able to assemble ② Unable to assemble Able to assemble correct tools with correct tools with moderate accurate tools with little assistance accurate tools without assistance Tool correct tools. major assistance. assistance. according to the according to the assembly criteria criteria (P3) ③ Display appropriate Unable to use the appropriate tool usage according to Use some appropriate tool usage according to SOP Selecting and using appropriate tool usage according to SOP Best use of the tool usage according to SOP Excellent use of the tool usage according to SOP tools usage SOP (P3) Student needs Student was Student was able Student was able Student was able ④ Organize task assistance all the time. unable to complete task without major to complete the task with moderate assistance. to complete the task with little to complete the task without assistance. (P3) assistance. assistance. Do not follow to Do not follow too Follow to some of Follow the work Maintains and ⑤ the work procedure and the work procedure but can the work procedures and procedure and can use the right follow the work procedure and Follow Work unable to select select the can choose the technique for the mastering the right Procedure the appropriate Appropriate right technique for work. technique for the (P3) technique for technique for the the work work. the work. work. TOTAL Title : Natural Gas Vehicle (NGV) Session: Lecturer : Date: NAME REG. NUMBER MARKS TOTAL (100 %) CLO2: Practical Task – Affective (60%) Part A1 Part A2 Part A3 Part A4 Part A5 Part B1 Part B2 Part B3 Part B4 Part B5 1. 2. 3. 4.
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 17 CRITERION SUBCRITERI ON COMPETENCY LEVEL SCORE 2 4 6 8 10 PART B Specific Task Servicing Skills ① Remove NGV Regulator (P3) Insufficient evidence to determine grade The student demonstrated limited knowledge and skill in the process The student demonstrated partial knowledge and skill in the process The student demonstrated substantial knowledge and skill in the process The student demonstrated extensive knowledge and skill in the process The student demonstrated limited knowledge and skill in the process The student demonstrated partial knowledge and skill in the process The student demonstrated substantial knowledge and skill in the process The student demonstrated extensive knowledge and skill in the process ② Dismantle NGV Regulator (P3) Insufficient evidence to determine grade (NGV Servicing) ③ Assemble NGV Regulator (P3) Insufficient evidence to determine grade The student demonstrated limited knowledge and skill in the process The student demonstrated partial knowledge and skill in the process The student demonstrated substantial knowledge and skill in the process The student demonstrated extensive knowledge and skill in the process ④ Perform inspection leak test (P3) Insufficient evidence to determine grade The student demonstrated limited knowledge and skill in the process The student demonstrated partial knowledge and skill in the process The student demonstrated substantial knowledge and skill in the process The student demonstrated extensive knowledge and skill in the process ⑤ Perform NGV solenoid tester Insufficient evidence to determine grade The student demonstrated limited knowledge and skill in the process The student demonstrated partial knowledge and skill in the process The student demonstrated substantial knowledge and skill in the process The student demonstrated extensive knowledge and skill in the process TOTAL
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 18 1.2 Natural Gas Vehicle Troubleshooting Natural gas vehicles can experience a variety of issues. Here are some common troubleshooting steps: 1. Check the fuel system for leaks or blockages 2. Verify the ignition system is functioning properly 3. Inspect the spark plugs and replace if necessary 4. Check the air filter and replace if dirty. 5. Ensure the fuel pressure is within specifications. 6. Verify the exhaust system is not restricted. 7. Check the vehicle's computer for any error codes or diagnostic information If these steps do not resolve the issue, it may be necessary to seek the assistance of a certified technician. Gas Consumption The gas consumption of a natural gas vehicle varies depending on factors such as the vehicle model, driving conditions, and driving habits. However, on average, a natural gas vehicle can travel approximately 1.5 to 2 times the distance of a similar gasoline-powered vehicle on the same amount of fuel. Engine Overheating Overheating in a natural gas vehicle engine could be caused by several factors such as a malfunctioning thermostat, low coolant levels, a faulty water pump, or a clogged radiator. It's important to have a professional mechanic diagnose and fix the issue to prevent further damage to the engine.
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 19 Power Loss Power loss in natural gas vehicles can be caused by a variety of factors such as low fuel pressure, clogged fuel filters, malfunctioning injectors, or issues with the ignition system. It is recommended to have the vehicle diagnosed by a qualified mechanic to determine the exact cause of the power loss. Engine Rough Idling Rough idling in a natural gas vehicle engine could be caused by a variety of issues, such as a malfunctioning fuel injection system, a dirty air filter or throttle body, or a problem with the ignition system. It's best to have a qualified mechanic diagnose and repair the issue to ensure your vehicle is running smoothly and efficiently.
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 20 Inspect NGV (Leakage Test) 1. Never use an open flame to search for a leak 2. Keep any possible ignition sources away from the CNG system and fueling areas. 3. Leak test: a. Start with using leak test detector b. Use a solution to look for bubbling or foaming at point of leak. Wait for 10 minutes. c. The leak may appear form or bubbles d. Depressurize system completely before performing maintenance or repair. Inspect NGV (Cooling System) 1. Ensure the engine has cooled down before starting any work on the cooling system. 2. Open the hood and visually inspect the cooling system components, including hoses, radiator, and electric fan. 3. Look for any visible leaks, damaged hoses, or loose connections. 4. Wait until the engine is cool before opening the radiator cap. 5. Place a rag over the radiator cap to catch any steam that might escape. 6. Slowly twist the cap counter clockwise to release pressure. Push down and twist further to remove it. 7. Check the coolant level inside the radiator. It should be near the top of the radiator neck. If low, add coolant following the manufacturer's recommendations. 8. Check the coolant level in the reservoir and adjust it as needed. 9. Inspect the colour and condition of the coolant. Replace it if it appears dirty or discoloured. 10. Turn on the ignition (without starting the engine) and observe if the electric fan comes on. If the engine is warm, the fan should activate when the coolant temperature rises. 11. Locate the fan relay in the fuse box. Using a multimeter set to the appropriate setting, check if the relay is receiving power and sending power to the fan when it should be activated. 12. Inspect the temperature sensor's wiring and connections. Make sure they are secure and free from damage. 13. Check the fan motor's electrical connections and wiring for any issues. If the fan is not working, visually inspect the fan blades for damage or obstruction. 14. Use the radiator pressure test to identify the source of the leak problem.
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 21 Inspect NGV (Fuel System) Figure 2: NGV selector switch wiring diagram 1. Make sure you're in a well-ventilated area and there are no open flames or potential ignition sources nearby. 2. Check the exterior of the NGV for any visible signs of damage, leaks, or corrosion. Look for rust, dents, or any abnormalities in the fuel tank and fuel lines. 3. Inspect the NGV's tank for any signs of damage or corrosion. Look for rust spots, dents, or cracks. If the tank is mounted externally, ensure that it is securely fastened. 4. Check all fuel lines and connections for leaks, cracks, or loose fittings. The fittings should be tight, and there should be no signs of gas escaping. 5. Check for any wear or damage to the rubber hoses and metal pipes. 6. Ensure that the pressure relief valve is in place, not damaged, and functions correctly. 7. Check the pressure gauge to make sure it's within the recommended pressure range during operation. 8. Inspect any additional components such as regulators, filters, and valves. 9. Set the switch selector to ‘NGV’ mode with ignition ‘ON’. 10. Check the indicator light ‘ON’ and listen to simultaneous clicking sound at gas solenoid and primer solenoid.
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 22 DIESEL COMMON RAIL
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 23 Diesel Common Rail 2.2 Follow Diesel Common Rail troubleshooting and servicing. a. Engine control system components. i. Sensors ii. ECU iii. Actuators b. Troubleshooting test using diagnostic tool and repair of. i. Sensors ii. Actuators c. Vehicle inspection. i. Injection identification code registration procedure. ii. Procedure for small injection quantity. iii. Procedure for supply pump correction. iv. Procedure for idling. Assessment: Report PREPARED BY: EN. AZLAN BIN ADAM EN. ZIKRI BIN ZAKARIA
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 24 Title: Common Rail System Session: Lecturer: Date: Assessment: Report 1 INTRODUCTION* (Students needs to explain suitable introduction for the topics) Common Rail System Layout OBJECTIVES 1. To identify all components and understand the function of common rail system 2. To inspect common rail components 3. To perform common rail troubleshooting THEORY* Students is COMPULSORY to explain in details the components and how it works of the common rail system PROBLEM STATEMENT* Justify all problems regarding to common rail systems
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 25 EQUIPMENTS* List down all tools and equipment during inspection, troubleshooting and servicing PROCEDURES* 1.Troubleshooting test using diagnostic tool (Students needs to explain in details by using diagnostic tool to troubleshoot common rail system) CHECKING & TESTING* From the problem statement and after servicing the components identify the checking and testing method on the system. DISCUSSION* 1. What is the function of filter? 2. Describe the function of pressure limiter valve? 3. Explain what is split injection? 4. Explain how common rail injectors works? CONCLUSION* Conclude the result from the job / service. REFERENCES List down all references involved. *In report, student need to answer all the questions for marks to be given
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 26 Title : Session: Lecturer : Date: NAME: REG. NUMBER TOTAL MARK (100%) 1. 2. 3. 4. 5. 6. 7. 8. CLO1 Proceeds troubleshooting method of automotive systems PLO5 Apply appropriate techniques, resources, and modern engineering and IT tools to well defined engineering problems, with an awareness and limitations CRITERION SUBCRITERION ASSESSMENT LEVEL SCORE 0 1 2 3 4 (DOMAIN TAXONOMY) (P2) Introduction Introduction (Identify-P1) Introduction identified is not related to the work and study. Introduction identified is only few related to the work and study. Gives very little information. Introduction identified is related to the work and study with little information. Introduction identified is related to the work and study with much information - more like a summary. Introduction identified is related to the work and study. Present a brief lead-in to the report Objective (Identify-P1) Purposed of the work is not identified Purposed of the work is identified but not clear and not complete Purposed of the work is identified but not complete Purpose of the work is identified and complete Purpose of the work are complete, clearly stated and identified Theory (Explain – P2) Theory explain is not related to the work and study. Theory explain is only few related to the work and study. Gives very little information. Theory explain is related to the work and study. Gives very little information. Theory explain is related to the work and study. Gives too much information - more like a summary. Theory explain is related to the work and study. Present a brief lead-in to the report Work Procedure Problem statement (RecognizeP2) Not recognized any problem statement Recognized some problem statement Recognized all the problem statement Recognized all the problem statement with little clarification Clearly recognized all the problem statement with clarification Equipment (Choose-P1) Not list of equipment/ material chose Few equipment/ materials chose are listed but not complete Most of the equipment/ material chose are included and listed. All necessary equipment/ material chose are included and listed. All necessary equipment/ material chose are included and listed in detail. Tool usage (Explains-P2) Not explained any tool usage and the function. Clearly explained most of the tool usage but not complete Clearly explained the tool use and their functions but not complete Clearly explained all tool use and their functions Clearly and completely explained all tool use and their functions Work Procedure (Explains-P2) Work procedures are not explained. Work procedures are not explained in clear steps with Work procedures are explained in clear steps but not numbered All work procedures are explained in clear steps and All work procedures are explained in clear steps and
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 27 major missing steps with some missing steps each step are numbered. each step are numbered and in complete sentences. Techniques (Identify-P1) Not identified the appropriate techniques to conduct the work. Identified only some of the appropriate techniques to conduct the work. Identified the appropriate techniques to conduct the work but not clear. Identified the appropriate techniques to conduct the work. Identified the best techniques to conduct the work. Discussion Checking and Testing (Explain-P2) No checking and testing of the result/service is explained Checking and testing of the result/service is explained but not comparing with the theories. Explained checking and testing of the results/service with the theories but not in details and not clear Explained checking and testing of the results/service clearly and compare with the theories and the objectives Explained in detail and discussing checking and testing of the results/service clearly and compare with the theories and the objectives Discussion (Respond-P2) Unable to responded to questions and relate the knowledge learned after conducting the work Able to respond to some question but unable to relate the knowledge learned after conducting the work Able to respond to question and relate some of the knowledge learned after conducting the work. Able to respond to question and relate the knowledge learned after conducting the work. Excellently able to respond to question and relate the knowledge learned after conducting the work. Conclusion (Comprehend-P2) No conclusion is comprehended at all Conclusions are not comprehended in relation to the studies. Conclusions are comprehended in relation to the studies but not clearly. Conclusions are comprehended slightly in relation to the studies. Conclusions are completely comprehended in relation to the studies. Reference (Set-P2) Not set any citations Little set of citations A partial set of citations A substantial set of citations A thorough set of citations (PART A, 70%) TOTAL /48
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 28 HYBRID SYSTEM
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 29 Hybrid system 2.3 Follow troubleshooting and service of hybrid system. a. Standard operating procedure for servicing hybrid car i. Safety procedure. ii.Tool and equipment b. The hybrid energy storage system i.Install battery ii. Remove battery. c. The main components of hybrid system i. DC converter/inverter ii. prime mover iii. Electric motor iv. Transmission System d. The problems of hybrid systems i. Diagnose hybrid system with scan tool. ii. Trouble shooting hybrid system. Assessment: Report PREPARED BY: EN. AZRUL NIZAM BIN AZHAR PN. NOR HAFIZA BINTI ISMAIL
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 30 REPORT : (Vehicle Diagnosis) TITLE : Perform Hybrid Car Service 1.0 Experiment outcome At the end of the session students should be able: 1. To perform hybrid car battery removal and installation. 2.0 Theory Hybrid vehicles combine the convenience of a gas-powered engine with the efficiency of a battery-powered electric car. The electric motor is powered by a battery, which is charged through regenerative braking and by the gas engine, plus some models allow for plug-in charging. The battery pack is separate from the 12-volt auxiliary or starting battery, and it contains higher capacity and higher voltage. Figure 1 : Hybrid car
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 31 3.0 Apparatus/Equipment a) Insulated rubber gloves. b) Eye protection. c) Insulated socket and ratchet set. d) Non-conductive wrenches and screwdrivers. e) Trim tools. f) Spill response kit for electrolyte. 4.0 Safety Precautions i. Use all cleaning solutions with care. Report all necessary repairs. ii. Disconnect the battery and discharge any capacitors before starting work on the machine. iii. Do not work on any machine that is supported only by lift jacks or a hoist. Always use blocks or jack stands to support the machine before performing any service of disassembly. iv. Make sure that the work area around the machine is safe and be aware of any hazardous conditions that may exist. If an engine is started inside an enclosure, make sure that the engine’s exhaust is properly vented. v. Always use tools that are in good working condition. Ensure that you understand the proper use of the tools before performing any service work. vi. Replace all fasteners with the same part number. Do not use a lesser quality fastener if replacements are necessary. vii. Secure all loose items such as lunch boxes, tools, and other items that are not a part of the equipment. viii. Do not damage wiring during the removal operations. Wiring should be reinstalled so that the wiring is not damaged. Wiring should also be installed so that the wiring will not be damaged during normal operation of the equipment. Do not connect wiring to a line that may contain fluid. ix. Tighten connections to the correct torque. x. Never operate an engine in an enclosed area. The work area must be properly ventilated to remove hazardous carbon non-oxide gases from the work area or other areas of the building. xi. Work in a space with ample room for maneuvering around the engine and application.
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 32 xii. Do not have an open flame or smoke near flammable liquids. xiii. Do not refuel an engine while it is operating. Allow the engine to adequately cool before refueling. xiv. Do not operate an engine if gas has spilled. Move the engine away from the spill and avoid creating any ignition until the gas has evaporated. xv. Be familiar with engine shutoff procedures for quick response in an emergency. xvi. Never leave an operating engine unattended. xvii. Avoid contact with hot engine parts such as the muffler. cylinder head, or cooling fins. xviii. Keep feet, hands, and clothes away from moving engine and equipment components. Perform service and maintenance procedures with the engine not operating if possible. xix. Always have an approved fire extinguisher near the work area. 5.0 Procedures STEPS FIGURES 1. Disconnect the 12-volt battery With the car parked and the ignition off, disconnect the 12-volt battery’s negative cable. If it remains energized, there can be an inadvertent activation in the electrical system that causes problems later.
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 33 2. Remove the battery hybrid disconnect Hybrid vehicles are designed with a master disconnect that cuts power to the car from the battery pack. Check your owner’s manual for its location in your car, then remove it. Keep the disconnect in a safe place because you’ll need to reuse it with the new hybrid battery. 3. Remove seat back Fold down second row seat backs and remove the 4 x 14 mm bolts. Move seat backs out of the way. 4. Remove plastic cover Pop-up plastic trim covering the hybrid battery after removing the one 10mm bolt holding it down.
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 34 5. HV leads Remove the metal cover on the passenger side of the battery to expose HV leads. Use the orange disconnect plug to remove the orange pin lock. Take off the two 10mm nuts securing the HV leads. 6. Disconnecting connectors Next disconnect all 3 of the electrical connectors on the back side of the battery. Loosen the plastic clips securing the wiring to the top of the fan and battery. 7. Remove the six 12 mm bolts securing the battery to the frame of the car.
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 35 8. The battery is now loose and ready to be removed from the vehicle. While standing over the battery, shift it a few inches towards the passenger side to allow enough clearance to pick the driver’s side up and swing it out the hatchback. 9. Remove the crossbar from the bottom of the battery and re-install it on the new battery. Follow these same steps in reverse to install the replacement battery 6.0 Discussion You are required to find information about the hybrid vehicle system as below: i. The hybrid vehicle system. ii. Types of components, functions and operation of hybrid vehicle systems below. • DC converter. • Prime mover. • Electric motor. • Transmission system. iii. Risks, dangers, and safety measures when maintaining hybrid vehicles.
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 36 7.0 Conclusion and Recommendation Your conclusion should be related to your practical and theoretical understanding on the related topic. 8.0 References 9.0 Question related 1. Discuss how to diagnose hybrid system using scan tools. 2. Give FIVE (5) common hybrid car problems.
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 37 Antilock Brake System (ABS)
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 38 3.0 CHASSIS Antilock Brake System (ABS) 3.1 Follow Antilock Brake System diagnosis and servicing. a. Retrieve fault code using On Board Diagnostic tool (OBD) b. Service, inspection and repair of anti-lock braking system. c. Check of anti-lock brake system problems. d. Strategy-based troubleshooting and repair. Assessment: Practical Task (P) PREPARED BY: EN. AHMAD FAIRUZ BIN MOHAMAD EN. HERMAN NORDIADI BIN ABD WAHAB
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 39 1.0 Experiment outcome At the end of the session students should be able: a. Retrieve fault code using On Board Diagnostic tool (OBD) b. Service, inspection and repair of anti-lock braking system. c. Check of anti-lock brake system problems. d. Strategy-based troubleshooting and repair. 2.0 Theory The ABS electrically control the brake fluid pressure to each wheel to prevent the wheel from locking during braking on slippery road surfaces, thereby enabling the driver to maintain the directional control. If the ABS become inoperative, a fail-safe system is activated to ensure same level of braking performance as with a conventional brake system. In that case, the warning light comes on to indicate that the ABS is malfunctioning. The ABS is a 4-sensor, 4-channel system. The front wheel system is an independent control design, while the rear wheel system is a select-low control design. Vehicles with Sports ABS have an additional function which independently controls the rear wheels according to the value sent from the lateral G sensor.
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 40 3.0 Apparatus/Equipment i) Vehicle with ABS system ii) Multimeter iii) Scan Tools iv) Battery v) Suitable hand tools 4.0 Safety Precautions i. Always make sure that you wear the appropriate personal protection equipment before starting the job. It is very easy to hurt yourself even when the most exhaustive protection measures are taken. ii. Always ensure that your work area/environment is as safe as you can make it. Do not use damaged, broken or worn out workshop equipment. iii. Always follow any manufacturer's personal safety instructions to prevent damage to the vehicle you are servicing. iv. Make sure that you understand and observe all legislative and personal safety procedures when carrying out the following tasks. 5.0 Procedures FIGURE PROSEDURES Scan tools check 1. Turn the ignition switch OFF. 2. Connector the scan tool to the 16P data link connector located the driver’s side kick panel. 3. Turn the ignition switch ON. 4. Check for diagnostic trouble using the scan tool 5. After completion trouble of the repair or correction of the problem, erase the stored fault codes the clear key on the scantool. 6. Disconnect the scan tool from the 16P data link connector.
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 41 Bleeding of brake system 1. Remove the reservoir cap and fill the brake reservoir with brake fluid. 2. Connect a clear plastic tube to the wheel cylinder bleeder plug and insert the other end of the tube into a halffilled clear plastic bottle. 3. Connect the scan tool to the data link connector located underneath the dash panel 4. Select and operate according to the instructions on the scan tool screen Select and operate according to the instructions on the scan tool screen. 1. Select vehicle name. 2. Select Anti-Lock Brake system. 3. Select air bleeding mode. 4. Press "YES" to operate motor pump and solenoid valve. 5. Wait 120 second before operating the air bleeding (If not, you may damage the motor) Press "YES" to operate motor pump and solenoid valve. Wait 120 second before operating the air bleeding (If not, you may damage the motor)
MECHANICAL ENGINEERING DEPARTMENT POLITEKNIK KUCHING SARAWAK DJA40052 – AUTOMOTIVE WORKSHOP PRACTICE 3 42 Perform the air bleeding Pump the brake pedal several times, and then loosen the bleeder screw until fluid starts to run out without bubbles. Then close the bleeder screw. Repeat step until there are no more bubbles in the fluid for each wheel Tighten the bleeder screw