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8/3/2009

Eng. Bashar Alzuwayer

Automotive Engines Tech.ME-111

Eng. Bashar Alzuwayer11/10/2009

Lecture’s Topics

• Basic Hand Tools. • Power Tools & Equipments.• Automotive Shop Safety.• Measurements.

Chapters covered: 3, 4, 5.

1Eng. Bashar Alzuwayer

Basic Hand tools

Basic Hand Tools

Tools rule:1- Use quality tools.2- Keep tools organized.3- Keep tools clean.4- Use the right tool for given job.


Wrenches

They are used to remove and install nuts and bolts. Following these rules:

1- Select the right size always.

2- Never hammer standard wrenches, use slug wrench if you have to use hammer.


Types of Wrenches

Wrenches come in two sizes, Metric or ِِِEnglish. There are five types of wrenches:

1.Open End Wrench.2.Box End Wrench.3.Combination Wrench.4.Line Wrench.5.Socket Wrench.


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Open End Wrenches

They have open, split, jaw on each end, the jaws are weak and should not be used for extremely tight nuts and bolts, the jaws will flex or round off the bolt head.


Box End Wrenches

They have completely closed ends to surround the bolt, they will not round off the bolt head easily, they come with 6 points or 12 points. 6 points is stronger and should be used for rusted strong bolts.


Combination Wrenches

• They have box end and open end, it offers two different wrenches on the same piece, usually they both ends have the same size.


Line Wrenches

• Also called tubing, or flare nut wrench.• It has a box end, but with a small opening.• It is used for brake lines, fuel lines and power

steering lines, it prevents soft fittings from damage.


Socket Wrenches

• It is cylindrical shaped, box end tool the fits over the bolt. The other end has squared hole to fit the socket handle on.


Socket Handles


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Screwdrivers

Phillips Head

Standard Head

Reed and Prince Head

Clutch Head

Torx Head


Screwdrivers


Pliers

• Could be used to cut, grip, hold and bend various parts. There are many types of pliers each is used for specific job.


Slip Joint Pliers

• Also called combination pliers.

• The jaws are adjustable to grasp different size parts.


Rib Joint Pliers

• Also called channel lock pliers or water pump pliers.

• It has extra wide jaws to hold heavy parts.


Needle Nose Pliers

• For holding small parts only.

• Do not twist to hard, otherwise you will break the tips.


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Vise Grips Pliers

• Also called locking pliers.• Used to hold two parts

firmly, to free the technician hands.

• Also used to remove damaged bolt head.

• Should never be used on undamaged bolts.


Snap Ring Pliers

• Have sharp and small tips.• Used to remove special

clips called snap rings.


Hammers

• Hammers Rules:1. Select the right size.2. Check hammer head

tightness.3. Use brass, plastic or dead

blow hammers, if the part could be damaged by steel.

4. Use steel hammer if maximum force is needed.

5. Always strike squarely


Ball Peen Hammer

• It is the most used hammer and it is a general purpose hammer.

• It has two faces, a flat face for general striking and a round face for shaping sheet metals.


Sledge Hammer.

• It has a very large and heavy head.

• It is the most powerful hammer used to remove frozen parts.


Brass Hammer

• It has a soft head made of brass.• Usually used to prevent the part from scarring, in

other words, to protect the part from being damaged by the hammer.


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Plastic Hammer

• Used when light striking is needed, to prevent the parts for damage.


Rubber mallet

• It has a head that is made of hard rubber. Not recommended to be used on solid metal parts, since it will bounce and rebound.

• Used on sheet metal or plastic parts.


Chisels and Punches

• Chisels are used for cutting damaged or rusted nuts, bolts and rivet heads.

• Punches are used to make parts for reassembly.


Handling Tools

• Vice, is used for holding parts during cutting, drilling, hammering and pressing operations.

• C- Clamps also used for holding parts on a work surface during drilling, cutting welding, it is a portable holding tool.


Power Tools and equipmetn

Power Tools & Equipment

• Power tools are tool driven by compressed air, electricity, or pressurized liquid. They make the operations easier and quicker.

• Shop equipment are large shop tools such as floor jacks, part cleaning tanks, steam cleaners .. etc.


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Compressed Air System


Compressed Air System

• The system includes the following parts:1. Air compressor unit: it has an electric motor that

compresses air inside the tank to keep the pressure level high.

2. Filter: to remove water from the air.3. Pressure regulator: used to set the pressure exiting

from the unit, usually between 100-150 Psi.4. Lubricator: to lubricate the tools.5. Hoses & Lines: to carry compressed air.


Air Tools

• Air tools use the energy of compressed air for operation, also called pneumatic tools.

• Some air tools:1.Air wrenches.2.Air ratchet.3.Impact Sockets.4.Air Hammer.5.Blowgun.6.Air Drill 32Eng. Bashar Alzuwayer

Air wrenches

• Air wrenches or impact wrenches are used to quickly remove on install threaded fasteners.


Air Ratchet

• It is a special impact wrench designed to work in limited spaces.


Impact Sockets

• Impact sockets are special sockets that should be used with air wrenches or air ratchets.

• Ordinary sockets could be totally damaged if used with air wrenches.


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Air Hammer

• It is useful for driving or cutting operations.• Used for cutting old rusted parts.• It can produce 1000 – 4000 impacts per minute


Blowgun

• Used to clean, dry, wash parts with solvents.


Air Drill

• It is multiuse powerful tool, it performs job too quickly with less effort.

• Could be used to drill, brush, cleaning and filing.


Electric Tools

• There are many electric tools that could be used in automotive shops, some of them:

1.Bench grinder.2.Drills.3.Press Drills.


Bench Grinder

• Could be used for grinding, cleaning and polishing operations.

• It has two wheels, one for grinding and the other one for cleaning and polishing


Drills

• Are used to make holes in plastic or metal parts.• The drill bit should be chosen according to

material the would be drilled.


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Press Drills

• Are large drills, bench mounted. It allows the bit to be pressed against the work piece with increased force.


Hydraulic Tools

• Hydraulic tools use the power of pressurized liquid.

• Some hydraulic tools:1.Floor jack.2.Transmission jack.3.Engine crane (hoist).4.Hydraulic press.


Floor and Trans Jacks


Engine Crane


Hydraulic Press

• Used to remove or install gears, pulleys, bearings, seals and other parts that need high pushing force.


Shop Equipment

Some shop equipment:1.Arbor press.2.Jack stands.3.Engine stands.4.Pullers.


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Arbor Press

• It is the same as hydraulic press but it does not use hydraulic power. Used to install small parts like bearings.


Jack & Engine Stands


Pullers

• Used to remove seals, gears, pulleys, axles and other press fit parts.


Auto shop & safety

Shop Layout

• There are many areas in the auto shop, some of them:

1. Repair Area.2. Tool Room.3. Class Room.4. Locker Room.


Repair Area

• It is any area where repairs are performed, it includes:

1.Shop stall.2.Lift.3.Alignment rack.4.Out side area.


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Tool Room & Class Room

• Tool room is used to store shop tools, small equipment and supplies (nuts, bolts, oil, etc).

• Class room is used for seminars, demonstrations and other training activities.

• Also, any workshop should include a locker or dressing room for technicians.

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Shop Safety

• Every year thousands of technicians are accidently injured or killed on the job, and that is due to their negligence of safety standards.

• Always while working look around and think of safety, look for unsafe work habits, unsafe equipment and other potentials for accidents.


Types of Accidents

• Work shop accidents, could be one of these:


Fires. Chemical burn.

Explosions. Electrical shock.

Asphyxiation. Physical injuries.

Fires

• Some combustible substances ( gasoline, oily rags, paints, thinners).

• General rules:1. Store gasoline in approved & sealed container.2. Disconnect the battery before working.3. Wipe up gasoline spills immediately.4. Keep heat away from gasoline.5. Do not use gasoline as a cleaning solvent.


Explosions

• An explosion is rapid combustion that would create a powerful shock wave that travel through the shop.

• When charging a battery, Hydrogen is produced, which is highly combustible gas with colorless flame.

• Keep heat away from the gasoline tank, since the gasoline tank is vented to the atmosphere.


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Asphyxiation

• Is caused by breathing toxic gases such as the exhaust gas which is extremely toxic gas.

• When operating a vehicle in enclosed area, the tailpipe should be connected to a ventilation system.

• There are many shop substances that are harmful if inhaled, for example brake dust (asbestos).


Chemical Burns

• Solvents (part cleaners), battery acid and other shop substances could cause chemical burns to the skin, you should wear protection gloves.

• Carburetor cleaner is very powerful and can burn your skin in seconds.



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