CHAPTER ONE: INTRODUCTION

1.1 Definition of Terms: 
• Vehicle  Servicing:­    is  a  method  of  keeping  the  vehicle  in  a 
condition  of  safety,  reliability,  good  performance,  low  fuel 
consumption and low emission level.
• Depending on the type of troubles, servicing may be classified 
as tune­up and overhauling.
• Tune­up:­ is a process of replacing, correcting or adjusting the 
troubles or problems of a vehicle.
• Overhauling:­  If  the    troubles  are  mostly  related  to  the 
internal  component  parts  eg.  Worn  out  cylinder,  piston,  burn 
valves, synchronizer etc. 
− It  should  be  disassembled,  inspected,  the  defective  part 
have to be repaired or replaced and reassembled. This type 
of servicing is called overhauling.
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• Symptom :- is the effect of a fault noticed by the driver, user or
technician
• Fault:- The root cause of a symptom/problem
• Troubleshooting:- is a process of gathering information that should help
you narrow the source of the problem down to a particular system and
solving it. In computerized vehicle systems appropriate scan tool is
used to retrieve the trouble codes precisely.
• Diagnostics:- is the process of tracing a fault by means of its symptoms,
applying knowledge and analyzing test results
− is a method of finding out the troubles within a vehicle by visual
examination, by the sound produced, by the smoke of the exhaust
and/or with the help of instruments.
• Logical procedure:- A step by step method used to ensure nothing is
missed
• Vehicle Performance Testing :- is a type of test performed on a
vehicle to determine the brake torque, brake power and the amount of
fuel consumed by the engine and other vehicle parts.
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 1.2 Common Sense Safety Rules
• To be a professional and to prevent accidents follow these simple
rules:
– Think what you are doing at all the times.
– Always wear the appropriate PPE when working on vehicles
– Keep your tools and equipment clean.
– Do not leave tools and parts on the floor. Make a habit of putting them
on a workbench or work stand.
– Do not play around in the shop (Avoid horseplay)
– Clean up any spilled fuel, oil or grease immediately to prevent yourself
or others from slipping on the floor.
– Never point a compressed air gun at other person.
– Always use safety stand to support a car after lifting.
– Always set the parking brake of the vehicle you are working on when
the engine is running.
– Never run an engine in a closed unventilated shop.
– Do
February, 2018not put sharp objects into your
Vehicle Performance pocket.
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 1.3 Proper Use of Equipment

 When working with any equipment:

• Equipment should never be used for purposes other than those they
are designed for.
• Check it before you use it! If it is unsafe, put a sign on it warning
others not to use it.
• It should be cleaned after finishing a job, checked item by item,
and stored in the tool box.
• It should be properly maintained and periodically inspected for
unsafe conditions.
• Remove dirt and oil from special service tools (SST), testers, gages
etc., and put them away neatly in the correct places.
• Electrical, hydraulic and compressed air equipment can cause
serious injury if incorrectly used.

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 1.4 WORK AREA SAFETY
• The floor of your work area and bench tops should be kept clean, dry, and
orderly.
• Any oil, coolant, or grease on the floor can make it slippery. Slips can
result in serious injuries.
• Make sure the work areas around machines are large enough to safely
operate the machine.
• Keep an up dated list of emergency telephone numbers clearly posted
next to the telephone. These numbers should include a doctor, hospital,
and fire and police departments.
• The work area should have a first-aid kit for treating minor injuries and
eye flushing kits readily available. You should know where these items
are kept.
• Turn on the ventilation fans any time fumes are present or use exhaust
hose if a vehicle is running in the shop.
• Keep tools in good condition by using them properly and storing them
properly.
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 1.5 FIRE PREVENTION
• In the case of fire you should know:
 The  location  of  the  fire  extinguishers  and  fire  alarms  in 
the shop 
 The different types of fire and fire extinguishers.
 How to use fire extinguishers
• If no fire extinguisher is available, a blanket or a fender cover 
can be used to smother the flames. Care must be taken when 
doing so, because the heat of the fire may still burn you and 
blanket you are attempting to use.
 If the fire is too great call the local fire department. 
 The  use  of  wrong  fire  extinguisher  will  not  pull  out  the  fire 
and under some conditions may cause to increase the fire.

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 FIRE PREVENTION (CONT.…)
• All workers should cooperate in putting out fires. To do this, they
should know where the fire extinguishers are located and how to
use them.
• Rags socked with gasoline and oil may sometimes ignite by
spontaneous ignition that they should be disposed of in a metal
container fitted with a cover.
• Never use open flames or create sparks in the vicinity of batteries
being changed, as they give off explosive gas which could ignites.
• Never bring fuel or cleaning solvents into the workshop except
when necessary, and use a special container that can be sealed.
• Do not start the engines of a vehicles with leaks in the fuel system
until repairs have been completed.
• DO NOT SMOKE except in authorized areas.

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 Fire rules
Pull the Fire Alarm
 Call emergency number
 Assist anyone in danger
Never Fight a Fire if you don't know what is burning.
 If you don't know what is burning, you don't know what type of
extinguisher to use. Even if you have an ABC extinguisher, there
may be something in the fire which is going to explode or produce
highly toxic smoke.

Never fight a fire if your instinct tell you not to.

If you are uncomfortable with the situation for any reason, just let
the fire department do their job.

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 Never Fight a fire if you don't have adequate or appropriate
equipment
If you don't have the correct type or large enough extinguisher, it is
best not to try to fight the fire.
Never fight a fire if you might inhale toxic smoke
If the fire is producing large amounts of smoke that you would have to
breathe in order to fight it, it is best not to try.
The final rule is to always position yourself with an exit or means
of escape at your back before you attempt to use an extinguisher to put
out a fire.
In case the extinguisher malfunctions, or something unexpected
happens, you need to be able to get out quickly, and you don't want to
become trapped. Just remember, always keep an exit at your back.
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 1.6 MAINTENANCE TUNE-UP
• A tune-up that includes the checking, adjusting, and replacement of
items recommended by the manufacturer is referred as maintenance
tune-up.
 Maintenance tune-up should be done on a regular basis to ensure that:
– Engine or vehicle will perform well &
– To extend the life of the engine or vehicle.
• Most of the time maintenance tune-up is performed due to wearing of
parts.
 Besides the replacement of wearing parts, maintenance tune up also
includes:
 The replacement of dirty oils
 The replacement of an oil filter
 The replacement of air and fuel filter
 The replacement of ignition system parts
 The replacement and maintenance of emission controls
 Adjustment of faulty parts

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 1.7 DIAGNOSTICS TUNE-UP
 Diagnostic tune­up should be performed when a problem exists 
or a car does not run right. 
 So  in  diagnostic  tune­up  the  entire  vehicle  is  analyzed  and 
tested to identify the system that is failing, then that system is 
tested again to identify the part or parts that have failed.
 A  diagnostics  tune­up  includes  checking,  adjusting  and 
replacement of items like: 
 Checking the charging, starting and fuel systems
 Adjusting the timing, carburetor and choke
 Checking PCV valve and road testing the car
 Checking power train systems
 Therefore diagnostic tune up helps us to find the root cause of 
the  vehicle  performance  using  logical  and  systematic 
approach. 
 Typical tune-up:- includes the checking, adjusting, and replacement
of items of already identified
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trouble of specific system or parts.
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 1.8 ENGINE DIAGNOSTICS
 Engine diagnosis :- is a method of finding out the troubles within an engine by
visual examination, by the sound produced, by the smoke of the exhaust and/or
with the help of instruments.
 Engine diagnostics requires an understanding of the fundamentals and systematic
approach to determine what the problem is.
 The engine is responsible for:
 Sealing the cylinders
 Compressing the air fuel mixtures
 Conversion of power produced in the engine cylinders to move the vehicle
 Produces the signals for precise operation of the other systems.
• To determine the condition of the engine and its parts, there are diagnostic
techniques (tests )that should be conducted. These are:
– Compression test
– Cylinder leakage test
– Cylinder power balance test
– Oil pressure test
– Engine smoke test
– Engine noise test
– Vacuum test
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