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971550-50165000 Automotive Service See Note in Table of Contents2015FloridaRegional ContestTable of ContentsSchool Facilitator Packet --------------------------------------------------------- 3-5Site and Materials RequirementJudge’s Packet --------------------------------------------------------------- 6-75Scoring Directions and ContestIncluding Written Test and KeyGrievance Form -------------------------------------------------------------------- 10Answer Key for Written Test ---------------------------------------------------- 72Contestant Packet -----------------------------------------------------------------76-99Complete Contest Including Written Test and Answer SheetSchool Instructor Packet ---------------------------------------------------------100-101Tools and Equipment Needed by ContestantInformation on ContestNOTE:Make copies of pages 31 thru 51 for Station #4 Engine PerformanceHost SchoolFacilitatorPacketMaterials supplied by host school: Station #1 – General Automotive SkillsCurrent vehicles (2). One with service manual the other with Labor Guide.Station #2 – MeasurementSmall 4 cylinder engine (lower unit)Feeler guage setSet of MicrometersVernier caliperPlastic guageCompression tester (not required but nice to have) just adds funLeak down tester (not required but nice to have)Dial guageBench with viseReference material (Shop Manual)Station #3 – Electrical500 ohm resistor1500 ohm resistorVariable resistorStarter and specification on starter usingVolt-Ohmmeter (supply several types, if possible, to accommodate various student familiarity) BatteryTwo different wattage light bulbs wired in series to make an electrical circuit for voltage drop testScratch PaperStation #4 – Engine PerformanceThe day before the contest:Print contestant answer sheets a different color for each station.Print several copies of the Electrical Wiring Diagram (in color if possible) and tape to tablePrint several copies of the Terminals of ECM.Obtain and label the following Components “A” through “D” and make them visible to the contestants. The components must only have the letter A, B, C, or D on them so as NOT to name the component. The contestant should be instructed NOT to pick up or test these components..Component “A”4 wire Oxygen sensor Component “B”Fuel Injector (top feed type, i.e. fuel rail on top, manifold on the bottom)Component “C”Gas cap (from vehicle 1996 or newer)Component “D”EGR Valve (prefer vacuum diaphragm type)Station #5 – BrakesAnti-Lock brake assembly on or off the vehicle tag. Brake Master Dissemble and part tag.Brakes shoe to drum gauge.MicrometerDrum micrometer gauge.Steel rulersBrake rotor to measure for parallelism (on or off vehicle) if possible has a bad rotor.Measure the rotor, record on judge’s sheet.Have factory specifications for the rotor you are using.Measure the brake drums, record answer on judge’s sheetHave factory specifications for drums.Measure the brake shoes, record your answer on the judge’s sheet.Have factory specifications for brake shoes.Station 6. – Air ConditioningVehicle with A/CA/C manifold gaugesThermometerCoolant HydrometerCoolantHeater valveThermostaticStation 7. – Manual TransmissionEquipment:2Honda Manual TransmissionsHand Tools:2MicrometersVernier CalipersFeeler GaugesContest Set-upThis is a 8-station contest. Station #8 is the written testStations #1 thru #7 will be at benches/work areasProvided by Regional Coordinator:Judges - copy of contest, answer sheet for written test, and scoring sheets.Contestants - all contest documents (Written Test and Practical task sheet(s).Supplied by the Contestant:Pen or PencilAll safety equipment for the job (i.e. goggles, safety shoes, etc), One page computer generated resume.Observers:Provide area for observers.Judges PacketProject InformationSkill PerformanceThe contest will include a series of workstations. Workstations consist of a vehicle and/or simulators, components and service publications.Contest GuidelinesA variety of vehicles sold in the United States will be used in the contest. This will include both domestic and imported vehicles.Some or all of the high school work stations may be different than the college/postsecondary work stations.Safety, quality, ability to follow instructions and procedures, accuracy (in comparison with factory specifications), workmanship, and other skills representative of the trades identified by industry leaders will be judged.A total of eight to 15 stations will be assigned. Each station must be broken down into specific task criteria and separate steps based on the task. For example:Station No. 1 Wire test and repair segmentsIdentify faulty circuit = x pointsRepair condition = x pointsAssemble/retest = x pointsResistor board tests = x pointsCompare values to specs = x pointsWorkmanship = x pointsSafety practices = x pointsThe points allowed for each station will be assigned by the national technical committee and will be based on the difficulty of each assigned task.Time limits will be assigned for each task, but no bonus points will be awarded for early completion.JUDGES GENERAL INSTRUCTIONS - REGIONAL and STATE SkillsUSASkill and Leadership ContestsThank you for giving your time and talent to evaluate our students. Your evaluation of their performance will assist them in their drive to become successful in their chosen occupation. l. Please remember that the contestants are students with job entry level skills. Please judge them accordingly.2.Allow time to orient all contestants prior to the contest. Have students draw for a demonstration time. (Post the times)3.Make sure that each student has an I.D. badge with their contestant number showing. Don't ask student their names or school they are from. Use the contestant list provided to you, to check off the students present. Do not assign contestant I.D.’s to any student that is not on the list. Immediately contact the Regional Coordinator.4.If a student arrives late, IF POSSIBLE, allow them to start the contest. They will not be allowed extra time unless the Regional Coordinator gives the OK.5.There are to be no Cell phones in the contest area. 6. If contestants need assistance in bringing equipment into room, 1 person can help them but in no case can any other person assist them in setting up. 7. Select or appoint a head judge who will oversee the contest and be responsible for tallying and certifying the contest rules.8.Select a judge to keep time and notify the contestant of the time remaining.9.You are to judge every contestant. 10. Familiarize yourself with the score sheet. The point ranges shown are possible points andyou should give the number of points you feel are deserved. Remember to judge on the basisof entry level skills.11.Do NOT discuss your scoring with anyone. This includes other judges, contestants, or advisors. Results should be kept confidential. Do not discuss who #l, 2, 3 should be - use the tallies from the score sheets as given. Only the head judge deducts timing, clothing, and Resume penalties.12.DO NOT allow contestants to talk to ANYONE except other judges. Contestants should not leave the contest or holding area for any reason. No advisors or teachers will be allowed to speak with contestants or to be in the contest or holding area EVER. If there is a problem with advisors, contact the regional coordinator or state director at once.13.Be consistent in your judging14.THERE ARE NO TIES when awarding 1st, 2nd, and 3rd place. Remember if contestants have an equal score, the judges must refer to the score obtained on the SkillsUSA knowledge test to break the tie. It is not necessary to select a medal winner if no contestant scores 70% or higher of the possible points for the contest.15.Judges are not to alter or change the contests or score sheets. All written materials; score sheets, judge’s sheets, written tests, etc., should be placed in a large manila envelope and turned in to the contest coordinator at the conclusion of the contest.16.There are no uniform or clothing requirements for the regional contests. However, safety items including safety glasses, hard hats, work shoes, etc., will be mandatory as required. Cosmetology contestants must wear the proper clinical shoes - no high heels allowed.17. If any problems arise, notify the regional coordinator or the state director.18. If one contestant discovers an error in the contest or any other problem that needs a judges’ help, it should be shared with all contestants.19.No judge or facilitator may disqualify ANY contestant without the expressed permission of the regional coordinator or state director.20. Resumes shall be collected at orientation, a fifty point deduction of the total contestant score shall be made if the contestant fails to provide a one page resume.NOTE:If a contestant feels that a rule violation occurred during the contest, the contestant may file a grievance. The grievance form may be obtained from the head contest judge and must be returned to same. The head judge must accept the grievance and must make a ruling on the grievance. If the head judge cannot rectify the grievance to the satisfaction of the contestant, then and only then may the contestant ask that the grievance be presented to the official grievance committee for consideration.All grievances must start with the head judge of each contest while the contest is in progress. Time missed while making a grievance report to the judge will be given to the contestant to complete his/her contest without penalty.No grievances will be filed after the contests are concluded.Final interpretations of all contest rules will be made by the Florida State Director or the Regional Coordinator at the regional contests. FLORIDA SkillsUSAGRIEVANCE FORMGrievances:A Grievances will be accepted for a Rule Violation only?Procedure for filing a Grievance:1.Only contestants may file grievances. No Advisors or Spectators.?2.Grievances must be filed DURING the Contest with the LEAD (Head) Judge prior to the ending of the Contest. The Contestant ONLY must file grievances!! The Contestant may only file a Grievance based on a rule infraction, which impacts ONLY the Contestant.Final interpretations of all contest rules will be made by the Florida State Director or the Regional Coordinator at the regional contests. Contestant Number: _____Contest being grieved: __________________Describe the Rule Violation: _____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Contestant Signature: ______________________________Advisor Signature: ________________________________Lead Judge Signature: _____________________________Resolution by Grievance Committee: _________________Committee Chair Signature: ________________________Date: _________Materials supplied by host school: Station #1 – General Automotive SkillsCurrent vehicles (2). One with service manual the other with Labor Guide.Station #2 – MeasurementSmall 4 cylinder engine (lower unit)Feeler gauge setSet of MicrometersVernier caliperPlastic gaugeCompression tester (not required but nice to have) just adds funLeak down tester (not required but nice to have)Dial gaugeBench with viseReference material (Shop Manual)Station #3 – Electrical500 ohm resistor1500 ohm resistorVariable resistorStarter and specification on starter usingVolt-Ohmmeter (supply several types, if possible, to accommodate various student familiarity) BatteryTwo different wattage light bulbs wired in series to make an electrical circuit for voltage drop testScratch PaperStation #4 – Engine PerformanceThe day before the contest:Print contestant answer sheets a different color for each station.Print several copies of the Electrical Wiring Diagram (in color if possible) and tape to tablePrint several copies of the Terminals of ECM.Obtain and label the following Components “A” through “D” and make them visible to the contestants. The components must only have the letter A, B, C, or D on them so as NOT to name the component. The contestant should be instructed NOT to pick up or test these components..Component “A”4 wire Oxygen sensor Component “B”Fuel Injector (top feed type, i.e. fuel rail on top, manifold on the bottom)Component “C”Gas cap (from vehicle 1996 or newer)Component “D”EGR Valve (prefer vacuum diaphragm type)Station #5 – BrakesAnti-Lock brake assembly on or off the vehicle tag. Brake Master Dissemble and part tag.Brakes shoe to drum gauge.MicrometerDrum micrometer gauge.Steel rulersBrake rotor to measure for parallelism (on or off vehicle) if possible has a bad rotor.Measure the rotor, record on judge’s sheet.Have factory specifications for the rotor you are using.Measure the brake drums, record answer on judge’s sheetHave factory specifications for drums.Measure the brake shoes, record your answer on the judge’s sheet.Have factory specifications for brake shoes.Station 6. – Air ConditioningVehicle with A/CA/C manifold gaugesThermometerCoolant HydrometerCoolantHeater valveThermostaticStation 7. – Manual TransmissionEquipment:2Honda Manual TransmissionsHand Tools:2MicrometersVernier CalipersFeeler GaugesContest Set-upThis is a 8-station contest. Station #8 is the written testStations #1 thru #7 will be at benches/work areasProvided by Regional Coordinator:Judges - copy of contest, answer sheet for written test, and scoring sheets.Contestants - all contest documents (Written Test and Practical task sheet(s).Supplied by the Contestant:Pen or PencilAll safety equipment for the job (i.e. goggles, safety shoes, etc), One page computer generated resume.Observers:Provide area for observers.AT THE START OF THE CONTEST:Check off students present, by verifying their contestant number against your sheet.Have students draw for a rotation position.Collect Resume’s from students.All students will be given time to familiarize their selves with the schools tools and equipment.TASK:This is a station contest. Written Test on general knowledge7 work stations including written test (i.e. general, brakes, engine performance, A/C, etc)Refer to page 7 for conducting the Skills Performance and Contest Guidelines and page 14 for the contest directions.Practical ProblemDirections for conduction contestAll stations run the same length of time (15 minutes). The head judge (or a designated timer) will start each round. Contestants will rotate stations (based on a predetermined drawing) in regular time intervals. Upon completion of the station, collect the response sheet. Award only the point value indicated on the form. Do not give partial credit in any area. Make sure the contestant’s number is on the form.At the end of each station cycle the judge should grade the answer sheet, total the score and then wait for someone to pick up the scored answer sheet. Do not let the contestant see the graded sheet. If any questions come up as far as grading contact the head judge. Contestants will record all answers on the answer sheet provided.Station 1. – General SkillsGeneral Automotive SkillsStation 2. - MeasurementCompetitors will be required to measure connecting rod end play using the appropriate measuring tool; measure the bore of a cylinder at X and Y axes in six places again using appropriate tools. Finally, take piston to bore measurement at the right place in the cylinder block. Competitors will wear safety glassesScoring criteria is included on score sheet, award points only as directed.Judges must become familiar with the instruction sheet, the work sheet, the score sheet and the reference materials.Judges must watch the competitor closely to check proper use of toolsStation 3. – Electrical Arrange all items on bench for questions.Question 1, 2, and 3 the contestant will measure the resistance of the resistors. Questions 4, 5, 6, and, the contestant will identify the electrical symbols. Questions 8,9,10, and 11, the contestant will perform continuity, short, and open or ground tests on the starter. Question 16 the contestant will calculate the voltage using ohms law.Station 4. - Engine PerformanceObtain and label the following Components “A” through “D” and make them visible to the contestants. The components must only have the letter A, B C or D on them so as to NOT to name the component. The contestants should be instructed NOT to pick up or test these ponent “A”4 wire Oxygen sensor Component “B”Fuel InjectorComponent “C”Gas capComponent “D”EGR ValveStation 5. – BrakesAnti-Lock brake assembly on or off the vehicle tag. Brake Master Dissemble and part tag.Brakes shoe to drum gauge.MicrometerDrum micrometer gauge.Steel rulersBrake rotor to measure for parallelism (on or off vehicle) if possible has a bad rotor.Measure the rotor, record on judge’s sheet.Have factory specifications for the rotor you are using.Measure the brake drums, record answer on judge’s sheetHave factory specifications for drums.Measure the brake shoes, record your answer on the judge’s sheet.Have factory specifications for brake shoes.Station 6. – Air ConditioningVehicle with A/CA/C manifold gaugesThermometerCoolant HydrometerCoolantHeater valveThermostaticStation 7. – Manual Transmission InspectionHonda Manual TransmissionsStation 8. – Written TestThe test is to be administered in a room separate from the holding room. It can be done in the shop at a bench or desk. Station #1(part 1)General Automotive Skills – Contestant WorksheetUsing the service manual supplied and the information given Below, answer the following questions. 1998 Chevrolet 5-10 Pickup 4.31V-6 1.Spark Plug Gap 2.Firing Order 3.Valve Spring Free Length 4.Rod Side Clearance S.Balance Shaft Retainer Bolt Using the labor guide, labor calculation chart and information given below, answer the following questions 1988 Chrysler Lebanon Engine: 3.0 liter with air conditioning 6.Determine the flat rate time allowed to renew the water pump. (don't give factory time) 7.A repair facility charges of $60.00 per hour. The technician is allowed 2.3 hours to renew a compressor shaft seal. What is the total Labor charge? 8.A heater core costs $96.00. Determine the cost when a seven Percent sales tax is added. 9.Measure the diameter of this bolt. (cap screw) 10.Measure the threads per Inch using the thread pitch gauge.Contestant # __________Station #1(part 2) General Automotive Skills – Contestant Worksheet11.Determine the tensile strength (grade) of this bolt (cap screw) Using the oil container supplied, answer the following questions. Using the 011 container supplied, answer the following questions. 12.Determine the viscosity rating of this 011. 13.Determine the API rating of this oil. 14.What does SAE mean Conversion 15.Convert 3/64 inch to millimeters_mm 16.S.9S3mm to inches_in. 17.Convert" inch to thousands- 18.Convert.75O thousands of an inch to inches_in. 19.10 foot-pounds to - Newton meters_Nm 20.10 Newton meters to - Foot pounds_ft-Ib Total Score (150)Contestant # __________Station #1(part 1) General Automotive Skills – Judges Answer KeyUsing the service manual supplied and the information given Below, answer the following questions. Vehicle _____________________ Engine _______________________ 1.Spark Plug Gap6 2.Firing Order6 3.Valve Spring Free Length6 4.Rod Side Clearance6 5.Balance Shaft Retainer Bolt6 Using the labor guide, labor calculation chart and information given below, answer the following questions Vehicle _____________________ Engine _______________________ 6.Determine the flat rate time allowed to renew the water pump.8 (don't give factory time) 7.A repair facility charges of $60.00 per hour. The technician is8 allowed 2.3 hours to renew a compressor shaft seal. What is the total Labor charge? 8.A heater core costs $96.00. Determine the cost when a seven8 Percent sales tax is added. 9.Measure the diameter of this bolt. (cap screw)8 10.Measure the threads per Inch using the thread pitch gauge.8Station #1(part 2) General Automotive Skills – Judges Answer Key11.Determine the tensile strength (grade) of this bolt (cap screw)8 Using the oil container supplied, answer the following questions. Using the 011 container supplied, answer the following questions. 12.Determine the viscosity rating of this 011.8 13.Determine the API rating of this oil.8 14.What does SAE mean8 Conversion 15.Convert 3/64 inch to millimeters_mm8 16.S.9S3mm to inches_in.8 17.Convert" inch to thousands-8 18.Convert.75O thousands of an inch to inches_in.8 19.10 foot-pounds to - Newton meters_Nm8 20.10 Newton meters to - Foot pounds_ft-Ib8 Total Score150Station #2 Measurement – Contestant WorksheetPerform the following on the engine and components provided.Points Awarded1. Measure and record the connecting rod end play ? .002”____________2. Record the connecting rod specifications service limit ____________3. Measure and record the cylinder bore on #1 cylinderX1________2__________3_______________Y1________2__________3_______________4. Record the cylinder bore specification service limit ____________5. Measure and record piston diameter. ____________6. Record piston diameter specifications service limit. ____________7. Measure and record piston-to-block clearance on #4cylinder ? .002” ____________8. Record piston-to-block specification service limit. ____________9. Measure and record ring-to-land clearance ? .002”. ____________10. Record ring-to-land specification service limit. ____________11. Safety procedures followed? ____________TOTAL POINTS (150)______Contestant # __________Station #2 Measurement – Judges Answer KeyPerform the following on the engine and components provided.Points Awarded1. Measure and record the connecting rod end play ? .002”_________10__2. Record the connecting rod specifications service limit _________10__3. Measure and record the cylinder bore on #1 cylinderX1________2__________3____________30__Y1________2__________3____________30__10 point per answer possible of 30 points x or y axis4. Record the cylinder bore specification service limit _________5__5. Measure and record piston diameter. _________10__6. Record piston diameter specifications service limit. _________5__7. Measure and record piston-to-block clearance on #4cylinder ? .002” _________10__8. Record piston-to-block specification service limit. _________5__9. Measure and record ring-to-land clearance ? .002”. _________10__10. Record ring-to-land specification service limit. _________5__11. Safety procedures followed? ________ 20__TOTAL POINTS AWARDED___150_Station #3(part1)Electrical – Contestant Worksheet1. Identify the type of circuit: switch to ground_____ load to ground_____ 2. If the current flow at point 1 is 2 amps, predict the current flow at: point 3?_____ point 4?_____ point 5?_____ ______ 3. Write the principle that explains your answer: ___________________________________________________ ___________________________________________________ ______ 4. Predict the voltage at point 5: _______ ______ 5. Write the principle that explains your answer: ___________________________________________________ ___________________________________________________ ______ Identify the following symbols;6. ______ 7. ______ 8. ______ 9. ______ Set the DMM to the scale to measure 12v DC.With the switch OFF, measure the voltage drop between the following points.10. points 2&3______ points 4&5______ ______ With the switch ON, measure the voltage drop between the following points. 11. points 1&2______ points 2&3______ Points 3&4______ points 4&5______ ______ Contestant # __________Station #3(part 2)Electrical – Contestant WorksheetWhen working with Ohm’s Law or electrical circuits:12. E is the symbol for _______________ I is the symbol for________________ R is the symbol for________________ ______ 13. With steady voltage, if the resistance in a circuit increases, Current flow will ________________ ______ 14. Ohm’s Law states that Voltage = ________________________ 15. If the voltage at point 3 is 8 volts with the switch ON, what does that indicate? Circle your choice. (a) The circuit is normal. (b) Open after point 3. (c) Circuit is good up to point 3. (d) Resistance before point 3. ______ 16. If the voltage at point 4 is 6 volts with the switch ON, What does that indicate? Circle your choice. (a) The circuit is normal. (b) Circuit is open at point 5. (c) Switch is open. (d) Resistance at points 4 and 5. _______ Set the DMM to measure resistance. Set the Trouble Box to position “A” and measure resistance. Repeat for positions “B” “C” and “D”.17. (A) ___________ (B) ____________ (C) ___________ (D) ____________ _______ Using Ohms Law, find the amperage for the following circuit.18. Amperage _______ _______ Resistance 1.66 Voltage 12.5 TOTAL POINTS (150) ______ Contestant # __________Station #3(part 1) Electrical – Judges Answer Key1. Identify the type of circuit: switch to ground_____ load to ground_____ 6 2. If the current flow at point 1 is 2 amps, predict the current flow at: point 3?_____ point 4?_____ point 5?_____ __ 9___ 3. Write the principle that explains your answer: ___________________________________________________ ___________________________________________________ ___15___ 4. Predict the voltage at point 5: _______ ___3___ 5. Write the principle that explains your answer: ___________________________________________________ ___________________________________________________ ___15___ Identify the following symbols;6. __5___ 7. ___5___ 8. __5___ 9. __5___ Set the DMM to the scale to measure 12v DC.With the switch OFF, measure the voltage drop between the following points.10. points 2&3______ points 4&5______ ___10___ With the switch ON, measure the voltage drop between the following points. 11. points 1&2______ points 2&3______ Points 3&4______ points 4&5______ ___16___ Station #3(part 2) Electrical – Judges Answer KeyWhen working with Ohm’s Law or electrical circuits:12. E is the symbol for _______________ I is the symbol for________________ R is the symbol for________________ ___18___ 13. With steady voltage, if the resistance in a circuit increases, Current flow will ________________ ___5__ 14. Ohm’s Law states that Voltage = ________________________ ___5__ 15. If the voltage at point 3 is 8 volts with the switch ON, what does that indicate? Circle your choice. (a) The circuit is normal. (b) Open after point 3. (c) Circuit is good up to point 3. (d) Resistance before point 3. __5____ 16. If the voltage at point 4 is 6 volts with the switch ON, What does that indicate? Circle your choice. (a) The circuit is normal. (b) Circuit is open at point 5. (c) Switch is open. (d) Resistance at points 4 and 5. ___5___ Set the DMM to measure resistance. Set the Trouble Box to position “A” and measure resistance. Repeat for positions “B” “C” and “D”.17. (A) ___________ (B) ____________ (C) ___________ (D) ____________ __16___ Using Ohms Law, find the amperage for the following circuit.18. Amperage _______ ___7___ Resistance 1.66 Voltage 12.5 TOTAL POINTS (150) ______ Station #4(page 1)Engine Performance – Contestant WorksheetDirections: The judges will tell you when to begin. Record your answers on the answer sheet provided. There are 17 questions for a possible 100 points. Use the Electrical Wiring Diagram and the Terminals of the ECM reference as needed to answer the questions. For questions 10 to 16 FOUR components labeled “A” through “D” are available for you at a nearby table (do not touch these items). For all DVOM readings (except when directed otherwise) the dial is on DC VOLTS, the BLACK LEAD is grounded, and the RED LEAD is at the point mentioned.After replacing a coolant temperature sensor you notice that the scanner information indicates that a permanent DTC is recorded. When the engine is running the Check Engine light is off. What would be your next move and why? Use the answer sheet to record your answerWith the Key on, Engine off, and the fuel injector connected, what should be the voltage reading at the YELLOW wire at the number THREE fuel injector? Use the answer sheet to record your answer If the crankshaft rotates 4 complete revolutions, how many Cam Shaft Position Sensor signals does the ECM receive? Use the answer sheet to record your answer Station #4(page 2)Engine Performance – Contestant WorksheetTerminal 53 on the ECM Connector”C24” normally toggles from 0 volts to 5 volts. What condition (driver action) causes the voltage to go to 5 volts? Use the answer sheet to record your answerWith the vehicle running, .3 volts is recorded at terminal 5 of the Fuel Pump connector. How might this effect Fuel Trim?Use the answer sheet to record your answer Based on the scanner data below (figure #1) and the information provided what part needs replacing? In figures #2 & 3 the data is recorded after the sensor is disconnected. Use the answer sheet to record your answer Figure #1Station #4(page 3)Engine Performance – Contestant WorksheetQuestion 6 ContinuedFigure #2Figure #3Station #4(page 4)Engine Performance – Contestant WorksheetWhat type of current (AC or DC) would you find what terminals 121 and 122 of ECM connector C24 while the vehicle is running? Use the answer sheet to record your answer The customer states that the Check Engine light is on and that the brake pedal is very hard to push. You note that a DTC PO171 (system too lean bank 1), you clear the code, and it does not immediately come back. Based on the scanner data below and the customer’s concern, what would you inspect or suspect as the problem? Use the answer sheet to record your answer Figure #1Which two parts might set a DTC P0303? A bad VSV purge solenoid, a bad fuel injector, an open Air Fuel Ratio, a bad ignition coil, or a bad camshaft timing control valve.Use the answer sheet to record your answer Use the electrical wiring diagram as a reference for this question. Component “A” is designated B1S2. A DTC P0037 HO2S Heater Control Circuit Low (Bank 1 Sensor 2) was set. Using an ohmmeter the resistance of wires (terminals 1 & 2) of Component “A” and get an “OL” reading? What do you need to do to repair the vehicle. Use the answer sheet to record your answer Station #4(page 5)Engine Performance – Contestant WorksheetComponent “A” is designated B1S2. Where is it located on the vehicle?Use the answer sheet to record your answer If the TOP “O” ring is split on component “B” what will leak?Use the answer sheet to record your answer If the BOTTOM “O” component “B” ring is split what will leak?Use the answer sheet to record your answer Component “C” is part of the _____________ emission system of the Vehicle?Use the answer sheet to record your answer If component “D” is stuck closed what harmful exhaust emission will increase?Use the answer sheet to record your answer If component “D” is stuck open what will be the biggest complaint?Use the answer sheet to record your answer What FIVE gasses does a 5 gas emission analyzer measure?Use the answer sheet to record your answer 1. Oxygen2. _______________3. _______________4. _______________5. _______________StatStation #4(page 6)Engine Performance – Contestant Answer Sheet15253545556575859510511512513514515516517A517B517C517D5TOTAL POINTS100Contestant # __________Station #4Engine Performance – Judges Answer Key1The vehicle needs to be driven or an equivalent statement. Explanation: A specific drive cycle and/or a combination of drive cycles is needed. The permanent code will erase itself if the repair is confirmed and the original problem that set the code is corrected.52Source voltage, B+ or 12 volts etc.53Six (three signals per two crankshaft revolutions) Explanation: Vehicles with variable valve timing need more than one signal per camshaft revolution. This is shown in the scope pattern of the cam sensor in the terminals of the ECM reference. 54Turning the steering wheel55Since there is high resistance in the fuel pump circuit the fuel pump may not attain the proper pressure causing the FUEL TRIM to be POSITIVE56Mass Sir Flow Meter (the intake air temperature sensor is built into the MAF). The student must figure this out by the wiring diagram. Intake air Temperature sensor is NOT acceptable57AC or Alternating Current58The brake booster or the brake booster vacuum hose/source or a broken break booster check valve, etc. Explanation: There is a large vacuum leak indicated by the 203 Short Term Fuel Trim. Since the brake pedal is hard (it uses engine vacuum for power assisted brakes) the obvious next step is to inspect the condition of the brake booster vacuum hose. 59A bad fuel injector a bad ignition coil Explanation: P0303 is a cylinder misfire code for cylinder #3. Only these 2 parts on the list will cause a misfire of only one cylinder. 510Replace the Component “A” or replace B1S2 HO2S Explanation: The heater in the sensor is open so it set the P0037 code.511Behind the Catalytic Convertor (implied screwed into the exhaust pipe)512Fuel513Vacuum (air)514EVAP or Evaporative515NOx or Nitrogen Oxides or Oxides of Nitrogen (Nitrous oxide is NOT acceptable)516Vehicle stalls, poor or no idle, (large vacuum leak)517A17A to 17D any order is acceptable HC (Hydrocarbons)517BNOx or Nitrogen Oxides or Oxides of Nitrogen (Nitrous oxide is NOT acceptable)517CCO (Carbon Monoxide)517DCO2 (Carbon Dioxide)5TOTAL POINTS100Station #5Brakes – Contestant WorksheetIdentify the components on the bench:______________________ _____(8)___________________________(8)___________________________(8)___________________________(8)Measure the rotor for parallelism and record your findings:A. ______________________E. ______________________________ (8)_____(8)B. ______________________F. ______________________________ (8)_____(8)C. _______________________G. ______________________________ (8)_____(8)D. _______________________H. ______________________________ (8)_____(8)With your findings from question #2, what is the thickness variation,_______________? Is it within Specifications? Yes_____No __________(8)What part of the Disc Brake Caliper causes the piston to move backward after the brakes are released? __________________________________________(8)Check the brake drum inside diameter with inside micrometer or brakedrum micrometer and compare to specifications._____________________________________________ (18)Measure the thickness of the brake shoes lining and compare to _____________________________________________ (12)With the answer to question#6, are these brakes within specifications? Yes _____No __________ (8)Total Points (150)______Contestant # __________Station #5Brakes – Judges Answer KeyIdentify the components on the bench:___ABS assembly______ _____(8)___Secondary seal on the primary piston of master cylinder_______(8)___Combination valve________(8)___Brakes shoe to drum guage_____(8)Measure the rotor for parallelism and record your findings:A. ______________________E. ______________________________ (8)_____(8)B. ______________________F. ______________________________ (8)_____(8)C. _______________________G. ______________________________ (8)_____(8)D. _______________________H. ______________________________ (8)_____(8)With your findings from question #2, what is the thickness variation,_______________? Is it within Specifications? Yes_____No __________(8)What part of the Disc Brake Caliper causes the piston to move backward after the brakes are released? __________________________________________(8)Check the brake drum inside diameter with inside micrometer or brakedrum micrometer and compare to specifications._____________________________________________ (18)Measure the thickness of the brake shoes lining and compare to _____________________________________________ (12)With the answer to question#6, are these brakes within specifications? Yes _____No __________ (8)Total Points (150)______Station #6Air Conditioning – Station Set-upFor question #3:The answer is for some model vehicles, it will be different depending on thevehicle you are using, so change the answer on the judges sheet to matchthe vehicle you are using.For Questions #4,5, & 6:On the vehicle or your choice, install the air conditioning gauges. These can be a problem and can cause bad readings. Bugs:Install a restriction in the line before the evaporatorRestrict the air flow over the condenserSlightly open both valves on gauges causing low pressure, high and lowDepend on the bug you are doing when you answer for the judges sheet.For question #7:Label heater valve and thermostat. Station #6Air Conditioning – Contestant Worksheet1. On the vehicle, locate and name the component that changes high gas into high liquid and by doing this operation what is removed from the refrigerant? Location ___________________ Component ______________ Removed from ____________(16 x 3) 32______2. The air conditioning system is divided into two sections high and low. Which two components of the air conditioning divide the system into high and low pressure and what is the state of the refrigerant in both com[opponents? High Component _______________Refrigerant state ______________14______ Low Component _______________Refrigerant state ______________14______3. On the vehicle, locate and name the component that removes the latent heat From interior.Location _______________Component ____________________ 14______Start the vehicle up and run a performance check (questions 4-6) on the Air Conditioning system.4. Record your findings on the high side _____________ and record Your findings on the low side ___________.14______5. Measure and record the temperature at the center dash vent ________ 7______6. With the information from question 4 & 5 does this vehicle pass the per- formance test according to the manufacture? Yes ______ No _______ 7______Complete this section with the materials supplied on the work bench.7. Identify the components on the work bench and record your answers below. 1. ___________________2. ______________________14______8. The heater valve is open and closed by what means. Record your answer below. _________________________________________16______Possible Points (150)______Contestant # __________Station #6Air Conditioning – Judges Answer Key1. On the vehicle, locate and name the component that changes high gas into high liquid and by doing this operation what is removed from the refrigerant? Location _in front of radiator______ Component _condenser______ Removed from _heat______ (16 x 3) 32______2. The air conditioning system is divided into two sections high and low. Which two components of the air conditioning divide the system into high and low pressure and what is the state of the refrigerant in both com[opponents? Component _compressor____Refrigerant state _high/low gas_____14______ Component _expansion valveRefrigerant state _high/low liquid___14______3. On the vehicle, locate and name the component that removes the latent heat From interior.Location _right side of dash__ Component _evaporator________ 14______Start the vehicle up and run a performance check (questions 4-6) on the Air Conditioning system.4. Record your findings on the high side _____________ and record Your findings on the low side ___________.14______5. Measure and record the temperature at the center dash vent ________ 7______6. With the information from question 4 & 5 does this vehicle pass the per- formance test according to the manufacture? Yes ______ No _______ 7______Complete this section with the materials supplied on the work bench.7. Identify the components on the work bench and record your answers below. 1. ___________________2. ______________________14______8. The heater valve is open and closed by what means. Record your answer below. _vacuum or cable or electrical motor_____________16______Possible Points (150)______Station #7Manual Transmission InspectionJudges Information Preparation SheetEquipment:2 Honda Manual TransmissionsHand Tools:2MicrometersVernier CalipersFeeler GaugesAdditional operations, comments, safety concerns and specific petitor will be required to use different types of measurement tools, proper care should be demonstrated by competitor. Make sure the tools are calibrated prior to the petitor must wear safety glasses when working at the bench but can remove to read shop manual.Scoring criteria is included on score sheet, award points only as directed.Judge must become familiar with instruction sheet, work sheet, and score sheet and reference materials.Judge must complete the Judge Reference Sheet prior to the contest.* Judges Notes:Return the station back to original condition before the next contestant arrives.*Station #7 (Page 1)Manual Transmission – Contestant Worksheet Operation #1:Locate the transmission serial number on the transmission. List the letters and numbers (from the transmission number) that designate the transmission type: (2) _______________________________. List the model year that corresponds to these letters which were taken from the vehicle identification number. (2) J.________ (2)K________ (2)L.________On transmissions with cable operated shifters one caution is always brought out in the service manual. What is it?(2) __________________________________________________________________________________________What one universal tool is suggested for transmission removal in every procedure?(2) __________________________________________________________________________________________If you forget to do this step before you pull the transmission, you may regret it when you remove the transmission housing. What is it? (2) __________________________________________________________________________________________Station #7 (Page 2)Manual Transmission – Contestant Worksheet Operation #2:How would you identify a “B” style transmission?(2)______________________What type of oil does the “B” style transmission use?(2)______________________What measurements, if any, must be taken before removing the transmission shafts from the case?(4)A. ________Your reading ___________Limit _________(4)B. ________Your reading ___________ Limit _________What must be done to the screws on the bearing retainer plates after they are reinstalled? (2)______________________________________________________________________________________________Operation #3:Record your synchro-to-gear clearances: (1)1st __________, (1)2nd __________, (1)3rd __________, (1)4th __________, (1)5th __________Service Limit: (2)___________________Are all the synchro-to-gear clearances acceptable? (3)___________________Station #7 (Page 3)Manual Transmission – Contestant Worksheet Operation #4:What safety precautions must be observed when removing the shift rod? (2)____________________________________________________________________________________________Measure the differential pinion gear backlash? (2)_____________________. Is your measurement within service limits? (2)_____________________Operation #5A. As the clutch friction disc wears, clutch pedal free play(2)_____________________.As the clutch friction disc wears, clutch pedal effort (2)_____________________.Excessive pedal effort can be caused by the throw out bearing not sliding freely on its shaft. (2)True _______False _______Total Points for Transmission(50) _________Station #7 (Page 1)Manual Transmission – Judges Answer Key Operation #1:Locate the transmission serial number on the transmission. List the letters and numbers (from the transmission number) that designate the transmission type: (2) _______________________________. List the model year that corresponds to these letters which were taken from the vehicle identification number. (2) J.________ (2)K________ (2)L.________On transmissions with cable operated shifters one caution is always brought out in the service manual. What is it?(2) __________________________________________________________________________________________What one universal tool is suggested for transmission removal in every procedure?(2) __________________________________________________________________________________________If you forget to do this step before you pull the transmission, you may regret it when you remove the transmission housing. What is it? (2) __________________________________________________________________________________________Station #7 (Page 2)Manual Transmission – Judges Answer KeyOperation #2:How would you identify a “B” style transmission?(2)______________________What type of oil does the “B” style transmission use?(2)______________________What measurements, if any, must be taken before removing the transmission shafts from the case?(4)A. ________Your reading ___________Limit _________(4)B. ________Your reading ___________ Limit _________What must be done to the screws on the bearing retainer plates after they are reinstalled? (2)______________________________________________________________________________________________Operation #3:Record your synchro-to-gear clearances: (1)1st __________, (1)2nd __________, (1)3rd __________, (1)4th __________, (1)5th __________Service Limit: (2)___________________Are all the synchro-to-gear clearances acceptable? (3)___________________Station #7 (Page 3)Manual Transmission – Judges Answer KeyOperation #4:What safety precautions must be observed when removing the shift rod? (2)____________________________________________________________________________________________Measure the differential pinion gear backlash? (2)_____________________. Is your measurement within service limits? (2)_____________________Operation #5A. As the clutch friction disc wears, clutch pedal free play(2)_____________________.As the clutch friction disc wears, clutch pedal effort (2)_____________________.Excessive pedal effort can be caused by the throw out bearing not sliding freely on its shaft. (2)True _______False _______Total Points for Transmission(50) _________Station #8Written TestDO NOT write in this test. Mark your answers on the sheet providedMultiple ChoiceIdentify the letter of the choice that best completes the statement or answers the question.1.In which type of logic gate must both inputs be “on” to produce an output voltage?a.NOTc.ANDb.NANDd.OR2.Which of the following is not a maintenance operation that you would perform on a manual transmission?a.Change lubricantc.Adjust shift linkageb.Adjust clutchd.Adjust bands3.A timing belt. gears, or a chain drives the engine’s camshaft at ____the rotation speed of the crankshaft.a.One-fourthc.Three-fourthsb.One-halfd.Twice4.Each of the following is a type of supercharger, except...a.Rotorc.Reciprocatingb.Centrifugald.Vane5.A suspension system element sometimes used to prevent side-by-side axle movement when cornering is called a(n) ______.a.Track rodc.Sway barb.Strut rodd.Control arm6.In a starting headlight testy, the lights stay bright, but the engine does not crank. What does this indicate?a.A shorted starting motorc.A weak or discharged batteryb.An opening in the starting circuitd.A blown fusible link7.The relationship of tire height to its width is called its ___________.a.Aspect rationc.Width percentageb.Sidewall/tread rationd.Cross-sectional mass8.The ____ is a heavy wheel mounted on a rubber ring and keypad to the crankshaft snout.a.Dynamic turnerc.Harmonic Balanceb.Oscillation damperd.Vibration snubber9.If warp age of a block deck exceeds _____, the block must be surface-milled or replaced.a.0.03 to 0.05 in.c.0.0003 to 0.0005 in.b.0.003 to 0.005 in.d.0.00003 to 0.00005 in.10.In a cam-in-block engine, the part of the valve train riding directly on the cam is the _____.a.Rocker armc.Push rodb.Valve lifterd.Plunger11. All of the following are active sensors except...a.Mass airflow sensorc.Oxygen sensorb.Knock sensord.Crankshaft sensor12.The insulating elements positioned between battery plates are known as ____.a.Insert platesc.Insulating gridsb.Separatorsd.Partitions13.Technician A says that security systems can usually be worked on without referring to the manufacturer’s technical literature. Technician B says that systems vary so much that using a schematic and technical literature on the specific system is a necessary. Who is right?a.A onlyc.Both A & Bb.B onlyd.Neither A nor B14.The _____ is the component of an air conditioning system that transfers heat from the refrigerant to the outside air.pressorc.Condenserb.Evaporatord.Accumulator15.The turn signal flasher consists of _____.a.A bimetal strip and heating elementb.A trigger wheel and sensorc.A make/break contact and trembler switchd.A stepping relay16.A small line of conductive material than can short coil voltage to ground or th the wrong distributor terminal lug is called a(n) ______.a.Shorting trackc.Low-resistance channelb.Carbide pathd.Carbon trace17.Which of the following is not one of the safety rules that apply when working with gasoline?a.Always use approved containers for storageb.Soak up and spills with oil treatmentc.Keep any source of hear away from the fuel systemd.Disconnect the vehicle’s battery before starting work18.The piston is mounted to the rod by the _____.a.Cylinder boltc.Wrist pinb.Piston Skirtd.Cam lobe19.The temperature of the exhaust manifold at each exhaust poet can be checked with ____.a.A digital pyrometerc.A sling psychrometerb.An analog heat sensord.A digital temperature guage20.Resignation will cause _____ in the engine.a.Pingc.Detonation Knockb.Dieselingd.Spark Knock21.The signals from an FM radio transmitter have a range of approximately ___ miles.a.25c.50b.35d.6522.What is the most common cause of freeze plug failure that allows a coolant leak to develop?a.Metal fatiguec.Engine vibrationb.Rustingd.Overheating23.The amount of space between the teeth of meshing gears to permit heat expansion is referred to as ____.a.Backlashc.Run outb.Preloadd.Play24.To reduce radio static a(n) ____ called a noise suppressor is often used.a.Resistorc.Transformerb.Chipd.Capacitor25.Which of the following is not part of a simple battery cell?a.Electrolyted.Neutral Plateb.Negative platee.Positive platec.Container26.How many ASE tests must be passed to qualify for Certified Master Automotive Techniciam atatus?a.3c.8b.5d.1627.Which of the binary numbers below is equal to 6 in the decimal system of notation?a.0111c.0110b.1110d.111128.Which basic element of electricity is also described as “electrical pressure?”a.Currentc.Resistanceb.Capacitanced.Voltage29.Which of the following is not a function of the lubrication system?a.Removing contaminants from inside engineb.Reducing friction and wear between moving partsc.Cutting power loss; increasing fuel economyd.Maintaining smooth power flow through drive train30.A cylinder bore must be precisely measured. Technician A says that the proper measuring tool for this job is a telescoping guage. Technician B says an inside micrometer should be used. Who is right?a.A onlyc.Both A 7 Bb.B onlyd.Neither A nor B 31.Which of the following statements about inline diesel injection pumps is not correct?a.There is one pumping plunger for each cylinderb.Plungers are operated by tappets that transfer motion from a camshaftc.Fuel from the inline pump is routed to the distributer pump where it is further pressurized and distributed to the injectorsd.Rotating control sleeves regulate pump output32.An electric engine fan is controlled by _____.a.The timing beltc.A thermostatic switchb.An engine speed sensord.A pressure sensor33.A process called magnafluxing is used to detect cracks in _____ parts.a.Steelc.Cast ironb.posite34.Technician A says that the shift points of an automatic transmission are determined by the engine rpm. Technician B says that the shift points of an automatic transmission are determined by the engine load. Who is correct?a.A onlyc.Both A & Bb.B onlyd.Neither A nor B35.Which of the following is not a function of a diesel injection pump?a.Meters the correct amount of fuel to each injectorb.Times the injection of fuel to meet speed and load of the enginec.Provides a means of shutting off the engined.Controls the airflow into the engine36.The tool used to measure small clearances or gaps between parts is called __________.a.Veriner caliperc.Rulerb.Feeler guaged.Hole guage37.The most common type of windshield washer pump in new cars is a(n) _________ pump.a.Centrifugalc.Rotaryb.Reciprocatingd.Diaphragm38.Technician A says that the ideal, chemically correct fuel mixture is 14parts air to 1 part fuel. Technician B says that 15 parts air to 1 part fuel is the right mixture. Who is correct?a.A onlyc.Both A & Bb.B only d.Neither A nor B39.The starter pinion gear engages the _____ to “crank” the enginea.Harmonic Balancerc.Flywheel gearb.Cam geard.Crankshaft pulley40.Voltage in the secondary circuit of an ignition system is typically ____ volts.a.6c.15,000b.12d.30,00041.If the cold light does not flash when checking an electronic fuel injector’s feed circuit, the cause of the problem may be all of the following except _____.a.An open in the wiringc.A faulty injectorb.A bad connectiond.A control module problem42.Which of the following is the least likely place to find the ignition control module of an electronic ignition system?a.Inside the distributerc.Behind the harmonic balancerb.Under the vehicle dashd.on the side of the distributer43.An automotive ______is a group of related parts that perform a specific job.a.ponentb.Sequenced.Process44.Power for tools used in the automotive shop in provided by _____.pressed aird.Only a & cb.Hydraulicse.All of the abovec.Electricity45.Abnormal wear patterns can identify tire problems. Which pattern indicates that the tire was consistently underinflated?a.Wear along outer treat areac.Wear along one edgeb.Wear along the centerlined.Feathering of tread rubber46.Cylinder _____, or deglazing is normally a part of cylinder block service. a.Grindingc.Boringb.Honingd.Filing47.A cold-start injector is activated by a(n) _____.a.Control relayc.Oxygen sensorb.Thermo-time switchd.Timing circuit48.When rebuilding a diesel injector, special ____ cleaning tools must be used to remove carbon deposits without damaging parts.a.Steelc.Fiberglass-reinforcedb.Nylond.Brass49.Technician A says that an air bag module should be placed on a workbench with the bag and trim cover facing up. Technician B says that it is safer to place the module with the bag facing down. Who is right?a.A onlyc.Both A & Bb.B onlyd.Neither A nor B50.Ina typical gasoline powered automotive engine, how many piston strokes make up a complets cycle?a.1c.3b.2d.4End of Written Test.Turn in this test and your answer sheet to the judge.Answer Sheet__________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Contestant # __________Judges KEY - Written Test __C_____D_____B_____C_____A_____B_____A_____C_____B_____B_____A_____B_____B_____C_____A_____D_____B_____C_____A_____A_____B_____B_____A_____D_____D_____C_____C_____D_____D_____B_____C_____C_____C_____C_____D_____B_____C_____D_____C_____D_____C_____C_____A_____E_____A_____B_____B_____D_____A_____D___ITEMS EVALUATEDPossible PointsCONTESTANT NUMBERStation #1 – General Automotive Knowledge150Station #2 - Measurement150 Station #3 - Electrical150 Station #4 – Engine Performance100Station #5 - Brakes150Station #6 – A/C150 Station #7 – Manual Transmission50Station #8 - Written Test100Sub Total (1000)OSHA, Job Site Safety (Clothing & Tool Use) Penalty range from -1 to disqualification. If proper student does not have the proper safety equipment they will be disqualifiedResume (0 or -50)Clothing Penalty (up to -50)Total (1000 POSSIBLE) TALLY SHEET Please place all judges’ total scores on this sheet. Add the judge’s scores to determine the placement of each student.Remember you might have secondary (high school) and Post-Secondary (those that have graduated from high school) in the contest. The way to determine is look at their I.D. badge. If you have both groups you will have winners in each groupJudgeContestant number#1#2#3#4#5TotalPlace JudgeContestant number#1#2#3#4#5TotalPlaceSecondary3rd Place __________________________________2nd Place _________________________________1st Place __________________________________Post Secondary3rd Place __________________________________2nd Place _________________________________1st Place __________________________________ContestantPacketDirections:Have you drawn for your rotation?Have you given your Resume to the judge?Do you have your safety equipment and a pencil/pen?Make sure your contestant number is showing and make sure to put your number on your work. This is to prevent confusion in judging.If you have a question, let the head judge know before the start of the contest. You will be scored on the following Criteria.ITEMS EVALUATEDPossible PointsStation #1 – General Automotive Knowledge150Station #2 - Measurement150Station #3 - Electrical150Station #4 – Engine Performance100Station #5 - Brakes150Station #6 – A/C150Station #7 – Manual Transmission100Station #8 - Written Test50 Total Possible Points 1000--------Think Safety--------Upon completion and the judges give you the OK, you can leave the area. *****Remember Safety is always a priority*****Station #1(part 1)General Automotive Skills – Contestant WorksheetUsing the service manual supplied and the information givenBelow, answer the following questions.Vehicle ________________ Engine Size_________________1.Spark Plug Gap2.Firing Order3.Valve Spring Free Length4.Rod Side ClearanceS.Balance Shaft Retainer BoltUsing the labor guide, labor calculation chart and informationgiven below, answer the following questionsVehicle _________________ Engine _______________ liter with air conditioning6.Determine the flat rate time allowed to renew the water pump.(don't give factory time)7.A repair facility charges of $60.00 per hour. The technician isallowed 2.3 hours to renew a compressor shaft seal.What is the total Labor charge?8.A heater core costs $96.00. Determine the cost when a sevenPercent sales tax is added.9.Measure the diameter of this bolt. (cap screw)10.Measure the threads per Inch using the thread pitch gauge.Contestant # __________Station #1(part 2) General Automotive Skills – Contestant Worksheet11.Determine the tensile strength (grade) of this bolt (cap screw)Using the oil container supplied, answer the following questions.Using the 011 container supplied, answer the following questions.12.Determine the viscosity rating of this 011.13.Determine the API rating of this oil.14.What does SAE meanConversion15.Convert 3/64 inch to millimeters_mm16.S.9S3mm to inches_in.17.Convert" inch to thousands-18.Convert.75O thousands of an inch to inches_in.19.10 foot-pounds to - Newton meters_Nm20.10 Newton meters to - Foot pounds_ft-Ib Total Score (150) Contestant # __________Station #2 Measurement – Contestant WorksheetPerform the following on the engine and components provided.Points Awarded1. Measure and record the connecting rod end play ? .002”____________2. Record the connecting rod specifications service limit ____________3. Measure and record the cylinder bore on #1 cylinderX1________2__________3_______________Y1________2__________3_______________4. Record the cylinder bore specification service limit ____________5. Measure and record piston diameter. ____________6. Record piston diameter specifications service limit. ____________7. Measure and record piston-to-block clearance on #4cylinder ? .002” ____________8. Record piston-to-block specification service limit. ____________9. Measure and record ring-to-land clearance ? .002”. ____________10. Record ring-to-land specification service limit. ____________11. Safety procedures followed? ____________TOTAL POINTS (150)______Contestant # __________Station #3(part1)Electrical – Contestant Worksheet1. Identify the type of circuit: switch to ground_____ load to ground_____ 2. If the current flow at point 1 is 2 amps, predict the current flow at: point 3?_____ point 4?_____ point 5?_____ ______ 3. Write the principle that explains your answer: ___________________________________________________ ___________________________________________________ ______ 4. Predict the voltage at point 5: _______ ______ 5. Write the principle that explains your answer: ___________________________________________________ ___________________________________________________ ______ Identify the following symbols;6. 7. 8. 9. Set the DMM to the scale to measure 12v DC.With the switch OFF, measure the voltage drop between the following points.10. points 2&3______ points 4&5______ ______ With the switch ON, measure the voltage drop between the following points. 11. points 1&2______ points 2&3______ Points 3&4______ points 4&5______ ______ Contestant # __________Station #3(part 2)Electrical – Contestant WorksheetWhen working with Ohm’s Law or electrical circuits:12. E is the symbol for _______________ I is the symbol for________________ R is the symbol for________________ ______ 13. With steady voltage, if the resistance in a circuit increases, Current flow will ________________ ______ 14. Ohm’s Law states that Voltage = ________________________ 15. If the voltage at point 3 is 8 volts with the switch ON, what does that indicate? Circle your choice. (a) The circuit is normal. (b) Open after point 3. (c) Circuit is good up to point 3. (d) Resistance before point 3. ______ 16. If the voltage at point 4 is 6 volts with the switch ON, What does that indicate? Circle your choice. (a) The circuit is normal. (b) Circuit is open at point 5. (c) Switch is open. (d) Resistance at points 4 and 5. _______ Set the DMM to measure resistance. Set the Trouble Box to position “A” and measure resistance. Repeat for positions “B” “C” and “D”.17. (A) ___________ (B) ____________ (C) ___________ (D) ____________ _______ Using Ohms Law, find the amperage for the following circuit.18. Amperage _______ _______ Resistance 1.66 Voltage 12.5 TOTAL POINTS (150) ______ Contestant # __________Station #4(page 1)Engine Performance – Contestant WorksheetDirections: The judges will tell you when to begin. Record your answers on the answer sheet provided. There are 17 questions for a possible 100 points. Use the Electrical Wiring Diagram and the Terminals of the ECM reference as needed to answer the questions. For questions 10 to 16 FOUR components labeled “A” through “D” are available for you at a nearby table (do not touch these items). For all DVOM readings (except when directed otherwise) the dial is on DC VOLTS, the BLACK LEAD is grounded, and the RED LEAD is at the point mentioned.After replacing a coolant temperature sensor you notice that the scanner information indicates that a permanent DTC is recorded. When the engine is running the Check Engine light is off. What would be your next move and why? Use the answer sheet to record your answerWith the Key on, Engine off, and the fuel injector connected, what should be the voltage reading at the YELLOW wire at the number THREE fuel injector? Use the answer sheet to record your answer If the crankshaft rotates 4 complete revolutions, how many Cam Shaft Position Sensor signals does the ECM receive? Use the answer sheet to record your answer Station #4(page 2)Engine Performance – Contestant WorksheetTerminal 53 on the ECM Connector”C24” normally toggles from 0 volts to 5 volts. What condition (driver action) causes the voltage to go to 5 volts? Use the answer sheet to record your answerWith the vehicle running, .3 volts is recorded at terminal 5 of the Fuel Pump connector. How might this effect Fuel Trim?Use the answer sheet to record your answer Based on the scanner data below (figure #1) and the information provided what part needs replacing? In figures #2 & 3 the data is recorded after the sensor is disconnected. Use the answer sheet to record your answer Figure #1Station #4(page 3)Engine Performance – Contestant WorksheetQuestion 6 ContinuedFigure #2Figure #3Station #4(page 4)Engine Performance – Contestant WorksheetWhat type of current (AC or DC) would you find what terminals 121 and 122 of ECM connector C24 while the vehicle is running? Use the answer sheet to record your answer The customer states that the Check Engine light is on and that the brake pedal is very hard to push. You note that a DTC PO171 (system too lean bank 1), you clear the code, and it does not immediately come back. Based on the scanner data below and the customer’s concern, what would you inspect or suspect as the problem? Use the answer sheet to record your answer Figure #1Which two parts might set a DTC P0303? A bad VSV purge solenoid, a bad fuel injector, an open Air Fuel Ratio, a bad ignition coil, or a bad camshaft timing control valve.Use the answer sheet to record your answer Use the electrical wiring diagram as a reference for this question. Component “A” is designated B1S2. A DTC P0037 HO2S Heater Control Circuit Low (Bank 1 Sensor 2) was set. Using an ohmmeter the resistance of wires (terminals 1 & 2) of Component “A” and get an “OL” reading? What do you need to do to repair the vehicle. Use the answer sheet to record your answer Station #4(page 5)Engine Performance – Contestant WorksheetComponent “A” is designated B1S2. Where is it located on the vehicle?Use the answer sheet to record your answer If the TOP “O” ring is split on component “B” what will leak?Use the answer sheet to record your answer If the BOTTOM “O” component “B” ring is split what will leak?Use the answer sheet to record your answer Component “C” is part of the _____________ emission system of the Vehicle?Use the answer sheet to record your answer If component “D” is stuck closed what harmful exhaust emission will increase?Use the answer sheet to record your answer If component “D” is stuck open what will be the biggest complaint?Use the answer sheet to record your answer What FIVE gasses does a 5 gas emission analyzer measure?Use the answer sheet to record your answer 1. Oxygen2. _______________3. _______________4. _______________5. _______________Station #4(page 6)Engine Performance – Contestant Answer Sheet15253545556575859510511512513514515516517A517B517C517D5TOTAL POINTS100Contestant # __________Station #5Brakes – Contestant WorksheetIdentify the components on the bench:______________________ _____(8)___________________________(8)___________________________(8)___________________________(8)Measure the rotor for parallelism and record your findings:A. ______________________E. ______________________________ (8)_____(8)B. ______________________F. ______________________________ (8)_____(8)C. _______________________G. ______________________________ (8)_____(8)D. _______________________H. ______________________________ (8)_____(8)With your findings from question #2, what is the thickness variation,_______________? Is it within Specifications? Yes_____No __________(8)What part of the Disc Brake Caliper causes the piston to move backward after the brakes are released? __________________________________________(8)Check the brake drum inside diameter with inside micrometer or brakedrum micrometer and compare to specifications._____________________________________________ (18)Measure the thickness of the brake shoes lining and compare to _____________________________________________ (12)With the answer to question#6, are these brakes within specifications? Yes _____No __________ (8)Total Points (150)______Contestant # __________Station #6Air Conditioning – Contestant Worksheet1. On the vehicle, locate and name the component that changes high gas into high liquid and by doing this operation what is removed from the refrigerant? Location ___________________ Component ______________ Removed from ____________(16 x 3) 32______2. The air conditioning system is divided into two sections high and low. Which two components of the air conditioning divide the system into high and low pressure and what is the state of the refrigerant in both com[opponents? High Component _______________Refrigerant state ______________14______ Low Component _______________Refrigerant state ______________14______3. On the vehicle, locate and name the component that removes the latent heat From interior.Location _______________Component ____________________ 14______Start the vehicle up and run a performance check (questions 4-6) on the Air Conditioning system.4. Record your findings on the high side _____________ and record Your findings on the low side ___________.14______5. Measure and record the temperature at the center dash vent ________ 7______6. With the information from question 4 & 5 does this vehicle pass the per- formance test according to the manufacture? Yes ______ No _______ 7______Complete this section with the materials supplied on the work bench.7. Identify the components on the work bench and record your answers below. 1. ___________________2. ______________________14______8. The heater valve is open and closed by what means. Record your answer below. _________________________________________16______Possible Points (150)______Contestant # __________Station #7 (Page 1)Manual Transmission – Contestant Worksheet Operation #1:Locate the transmission serial number on the transmission. List the letters and numbers (from the transmission number) that designate the transmission type: (2) _______________________________. List the model year that corresponds to these letters which were taken from the vehicle identification number. (2) J.________ (2)K________ (2)L.________On transmissions with cable operated shifters one caution is always brought out in the service manual. What is it?(2) __________________________________________________________________________________________What one universal tool is suggested for transmission removal in every procedure?(2) __________________________________________________________________________________________If you forget to do this step before you pull the transmission, you may regret it when you remove the transmission housing. What is it? (2) __________________________________________________________________________________________Station #7 (Page 2)Manual Transmission – Contestant Worksheet Operation #2:How would you identify a “B” style transmission?(2)______________________What type of oil does the “B” style transmission use?(2)______________________What measurements, if any, must be taken before removing the transmission shafts from the case?(4)A. ________Your reading ___________Limit _________(4)B. ________Your reading ___________ Limit _________What must be done to the screws on the bearing retainer plates after they are reinstalled? (2)______________________________________________________________________________________________Operation #3:Record your synchro-to-gear clearances: (1)1st __________, (1)2nd __________, (1)3rd __________, (1)4th __________, (1)5th __________Service Limit: (2)___________________Are all the synchro-to-gear clearances acceptable? (3)___________________Station #7 (Page 3)Manual Transmission – Contestant Worksheet Operation #4:What safety precautions must be observed when removing the shift rod? (2)____________________________________________________________________________________________Measure the differential pinion gear backlash? (2)_____________________. Is your measurement within service limits? (2)_____________________Operation #5A. As the clutch friction disc wears, clutch pedal free play(2)_____________________.As the clutch friction disc wears, clutch pedal effort (2)_____________________.Excessive pedal effort can be caused by the throw out bearing not sliding freely on its shaft. (2)True _______False _______Total Points for Transmission(50) _________Station #8Written TestMultiple ChoiceIdentify the letter of the choice that best completes the statement or answers the question.1.In which type of logic gate must both inputs be “on” to produce an output voltage?a.NOTc.ANDb.NANDd.OR2.Which of the following is not a maintenance operation that you would perform on a manual transmission?a.Change lubricantc.Adjust shift linkageb.Adjust clutchd.Adjust bands3.A timing belt. gears, or a chain drives the engine’s camshaft at ____the rotation speed of the crankshaft.a.One-fourthc.Three-fourthsb.One-halfd.Twice4.Each of the following is a type of supercharger, except...a.Rotorc.Reciprocatingb.Centrifugald.Vane5.A suspension system element sometimes used to prevent side-by-side axle movement when cornering is called a(n) ______.a.Track rodc.Sway barb.Strut rodd.Control arm6.In a starting headlight testy, the lights stay bright, but the engine does not crank. What does this indicate?a.A shorted starting motorc.A weak or discharged batteryb.An opening in the starting circuitd.A blown fusible link7.The relationship of tire height to its width is called its ___________.a.Aspect rationc.Width percentageb.Sidewall/tread rationd.Cross-sectional mass8.The ____ is a heavy wheel mounted on a rubber ring and keypad to the crankshaft snout.a.Dynamic turnerc.Harmonic Balanceb.Oscillation damperd.Vibration snubber9.If warp age of a block deck exceeds _____, the block must be surface-milled or replaced.a.0.03 to 0.05 in.c.0.0003 to 0.0005 in.b.0.003 to 0.005 in.d.0.00003 to 0.00005 in.10.In a cam-in-block engine, the part of the valve train riding directly on the cam is the _____.a.Rocker armc.Push rodb.Valve lifterd.Plunger11. All of the following are active sensors except...a.Mass airflow sensorc.Oxygen sensorb.Knock sensord.Crankshaft sensor12.The insulating elements positioned between battery plates are known as ____.a.Insert platesc.Insulating gridsb.Separatorsd.Partitions13.Technician A says that security systems can usually be worked on without referring to the manufacturer’s technical literature. Technician B says that systems vary so much that using a schematic and technical literature on the specific system is a necessary. Who is right?a.A onlyc.Both A & Bb.B onlyd.Neither A nor B14.The _____ is the component of an air conditioning system that transfers heat from the refrigerant to the outside air.pressorc.Condenserb.Evaporatord.Accumulator15.The turn signal flasher consists of _____.a.A bimetal strip and heating elementb.A trigger wheel and sensorc.A make/break contact and trembler switchd.A stepping relay16.A small line of conductive material than can short coil voltage to ground or th the wrong distributor terminal lug is called a(n) ______.a.Shorting trackc.Low-resistance channelb.Carbide pathd.Carbon trace17.Which of the following is not one of the safety rules that apply when working with gasoline?a.Always use approved containers for storageb.Soak up and spills with oil treatmentc.Keep any source of hear away from the fuel systemd.Disconnect the vehicle’s battery before starting work18.The piston is mounted to the rod by the _____.a.Cylinder boltc.Wrist pinb.Piston Skirtd.Cam lobe19.The temperature of the exhaust manifold at each exhaust poet can be checked with ____.a.A digital pyrometerc.A sling psychrometerb.An analog heat sensord.A digital temperature guage20.Resignation will cause _____ in the engine.a.Pingc.Detonation Knockb.Dieselingd.Spark Knock21.The signals from an FM radio transmitter have a range of approximately ___ miles.a.25c.50b.35d.6522.What is the most common cause of freeze plug failure that allows a coolant leak to develop?a.Metal fatiguec.Engine vibrationb.Rustingd.Overheating23.The amount of space between the teeth of meshing gears to permit heat expansion is referred to as ____.a.Backlashc.Run outb.Preloadd.Play24.To reduce radio static a(n) ____ called a noise suppressor is often used.a.Resistorc.Transformerb.Chipd.Capacitor25.Which of the following is not part of a simple battery cell?a.Electrolyted.Neutral Plateb.Negative platee.Positive platec.Container26.How many ASE tests must be passed to qualify for Certified Master Automotive Techniciam atatus?a.3c.8b.5d.1627.Which of the binary numbers below is equal to 6 in the decimal system of notation?a.0111c.0110b.1110d.111128.Which basic element of electricity is also described as “electrical pressure?”a.Currentc.Resistanceb.Capacitanced.Voltage29.Which of the following is not a function of the lubrication system?a.Removing contaminants from inside engineb.Reducing friction and wear between moving partsc.Cutting power loss; increasing fuel economyd.Maintaining smooth power flow through drive train30.A cylinder bore must be precisely measured. Technician A says that the proper measuring tool for this job is a telescoping guage. Technician B says an inside micrometer should be used. Who is right?a.A onlyc.Both A 7 Bb.B onlyd.Neither A nor B 31.Which of the following statements about inline diesel injection pumps is not correct?a.There is one pumping plunger for each cylinderb.Plungers are operated by tappets that transfer motion from a camshaftc.Fuel from the inline pump is routed to the distributer pump where it is further pressurized and distributed to the injectorsd.Rotating control sleeves regulate pump output32.An electric engine fan is controlled by _____.a.The timing beltc.A thermostatic switchb.An engine speed sensord.A pressure sensor33.A process called magnafluxing is used to detect cracks in _____ parts.a.Steelc.Cast ironb.posite34.Technician A says that the shift points of an automatic transmission are determined by the engine rpm. Technician B says that the shift points of an automatic transmission are determined by the engine load. Who is correct?a.A onlyc.Both A & Bb.B onlyd.Neither A nor B35.Which of the following is not a function of a diesel injection pump?a.Meters the correct amount of fuel to each injectorb.Times the injection of fuel to meet speed and load of the enginec.Provides a means of shutting off the engined.Controls the airflow into the engine36.The tool used to measure small clearances or gaps between parts is called __________.a.Veriner caliperc.Rulerb.Feeler guaged.Hole guage37.The most common type of windshield washer pump in new cars is a(n) _________ pump.a.Centrifugalc.Rotaryb.Reciprocatingd.Diaphragm38.Technician A says that the ideal, chemically correct fuel mixture is 14parts air to 1 part fuel. Technician B says that 15 parts air to 1 part fuel is the right mixture. Who is correct?a.A onlyc.Both A & Bb.B only d.Neither A nor B39.The starter pinion gear engages the _____ to “crank” the enginea.Harmonic Balancerc.Flywheel gearb.Cam geard.Crankshaft pulley40.Voltage in the secondary circuit of an ignition system is typically ____ volts.a.6c.15,000b.12d.30,00041.If the cold light does not flash when checking an electronic fuel injector’s feed circuit, the cause of the problem may be all of the following except _____.a.An open in the wiringc.A faulty injectorb.A bad connectiond.A control module problem42.Which of the following is the least likely place to find the ignition control module of an electronic ignition system?a.Inside the distributerc.Behind the harmonic balancerb.Under the vehicle dashd.on the side of the distributer43.An automotive ______is a group of related parts that perform a specific job.a.ponentb.Sequenced.Process44.Power for tools used in the automotive shop in provided by _____.pressed aird.Only a & cb.Hydraulicse.All of the abovec.Electricity45.Abnormal wear patterns can identify tire problems. Which pattern indicates that the tire was consistently underinflated?a.Wear along outer treat areac.Wear along one edgeb.Wear along the centerlined.Feathering of tread rubber46.Cylinder _____, or deglazing is normally a part of cylinder block service. a.Grindingc.Boringb.Honingd.Filing47.A cold-start injector is activated by a(n) _____.a.Control relayc.Oxygen sensorb.Thermo-time switchd.Timing circuit48.When rebuilding a diesel injector, special ____ cleaning tools must be used to remove carbon deposits without damaging parts.a.Steelc.Fiberglass-reinforcedb.Nylond.Brass49.Technician A says that an air bag module should be placed on a workbench with the bag and trim cover facing up. Technician B says that it is safer to place the module with the bag facing down. Who is right?a.A onlyc.Both A & Bb.B onlyd.Neither A nor B50.Ina typical gasoline powered automotive engine, how many piston strokes make up a complets cycle?a.1c.3b.2d.4End of Written Test.Turn in this test and your answer sheet to the judge.Answer Sheet__________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Contestant # __________ InstructorsPacketMaterials supplied by host school: Station #1 – General Automotive SkillsCurrent vehicle and service and labor manual Station #2 – MeasurementSmall 4 cylinder engine (lower unit)Feeler guage setSet of MicrometersVernier caliperPlastic guageCompression tester (not required but nice to have) just adds funLeak down tester (not required but nice to have)Dial guageBench with viseReference material (Shop Manual)Station #3 – ElectricalElectrical PartsScratch PaperStation #4 – Engine PerformanceObtain and label Components The components must only have a letter on them so as to NOT to name the component.Station #5 – BrakesVehicle with drum and disc brakes or stand along components and tools for job. Station #6. – Air ConditioningVehicle with A/C and tools to test the systemStation #7. – Manual TransmissionManual Transmissions on benchContest Set-upThis is a 8-station contest. Station #8 is the written testStations #1 thru #7 will be at benches/workareasProvided by Regional CoordinatorJudges - copy of contest, answer sheet for written test, and scoring sheets.Contestants - all contest documents (Written Test and Practical task sheet(s).Supplied by the Contestant:Pen or PencilAll safety equipment for the job (i.e. goggles, safety shoes, etc), One page computer generated resume. ................
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