COMPETENCY BASED LEARNING MATERIAL

Sector: AUTOMOTIVE / LAND TRANSPORT

Qualification: Driving NC II

Unit of Competency : Read, Interpret and Apply Specifications and Manuals

Module Title: Reading, Interpreting and Applying Specifications and Manuals

Technical Education and Skills Development Authority

NORTHERN MINDANAO SCHOOL OF FISHERIES
Matabao,Buenavista, Agusan del Norte

AUTOMOTIVE/LAND TRANSPORT
INDUSTRY SECTOR
 NATIONAL CERTIFICATE LEVEL 2
QUALIFICATION LEVEL

COMPETENCY-BASED LEARNING MATERIALS

No. Basic Competencies Module Title Code

1. Participate in Workplace Participating in Workplace 500311101

Communication Communication

2. Work in Team Environment Working in Team Environment 500311102

Practice Career Professionalism Practicing Career Professionalism
3. 500311103
Practice Occupational Health and Practicing Occupational Health 500311104
4.
Safety Procedures and Safety Procedures

No. Common Competencies Module Title Code

1. Apply Appropriate Applying Appropriate ALT723201

Sealant/Adhesive Sealant/Adhesive

2. Move and Position Vehicle Moving and Positioning Vehicle ALT723202

Perform Mensuration and Performing Mensuration and ALT311202
3.
Calculation Calculation
Read, Interpret and Apply Reading, Interpreting and ALT723203
4.
Specifications and Manual Applying Specifications and
Manual
Use and Apply Lubricant/Coolant Using and Applying Lubricants/ ALT723204
5.
Coolants

6. Perform Shop Maintenance Perform Shop Maintenance ALT723205

No. Core Competencies Module Title Code

1. Carry Out Minor Vehicle Carrying Out Minor Vehicle ALT723348

Maintenance and Servicing Maintenance and Servicing

2. Drive Light Vehicle Driving Light Vehicle ALT832302

3. Obey and Observe Traffic Rules Obeying and Observe Traffic ALT832303
and Regulation Rules and Regulation

4. Implement and Coordinate Implementing and Coordinate ALT832304

Accident-Emergency Procedures Accident-Emergency Procedures
HOW TO USE THIS COMPETENCY-BASED LEANING MODULE

Welcome to the module: “READING, INTERPRETING, AND APPLYING

SPECIFICATION AND MANUALS”. This module contains training materials and activities
for you to complete.
The unit of competency, READ, INTERPRETE AND APPLY SPECIFICATION
AND MANUALS contains the knowledge, skills and attitudes required for an Automotive
Servicing course. This is one of the common module for National Certificate level I (NC II)

You are required to go through a series of learning activities, n order to complete

each learning outcome there are information sheets, operation sheet and job sheet.
Reference materials for further reading to help you better understand and required
activities on you own and answer the self-check at the end of each learning outcome. Get
the answer form your instructor and check your work honestly. If you have question,
please don’t hesitate to ask the facilitator for assistance.

RECOGNITION OF PRIOR LEARNING

You may already have some or most of the knowledge and skills covered in this
module because you have:

 Been working for sometime

 Already completed training in this area

If you can demonstrate to your trainer that you are competent in particular skill or
skills, talk to him/her about having them formally recognized so you won’t have to do the
same training again. If you have qualifications or certificates of competency are still
relevant of this module, they may become part of evidence you can present you RPL. If
you are not sure about the currency of your skills, discuss it with you trainer.

After completing with this module ask your trainer to assess your competency.
Result of your assessment will be recorded in your competency profile. All the learning
activities are designed for you to complete at your own pace.
Inside this module you will find the activities for you to complete and at the back are
the relevant information sheets for each learning outcome. Each learning outcome may
have more than one learning activities.

At the end of this module is a Learner’s Diary. Use this diary to record important
dates, jobs undertaken and other workplace events that will assist you in providing further
details to your trainer or an assessor. A Record of Achievement is provided for you by
your trainer to accomplish once you complete the module.
 This learning material was prepared to help you achieve the required competency
in working team environment. This will be the source of information for you to acquire the
knowledge and skills in this particular trade independently and at your own pace with
minimum supervision or help from your instructor
In doing these activities to complete the requirements of this module, please be guided by
the following:

 Talk to your trainer and agree on how you will both organize the training under this
module. Read through module carefully. It is divided into sections which cover all
skills and knowledge you need to successfully complete.

 Work through all information and complete the activities in each section. Read
information sheets and complete the self-check provided in this module.

 Most probably your trainer will also be your supervisor or manager. He/she is there
to support you and show you the correct way to do things. Ask for help.

 Your trainer will tell you about the important things you need to consider when you
are completing the activities and it is important that you listen to take notes.
 You will be given plenty of opportunities to ask question and practice on the job.
Make sure you practice your new skills during the regular work shifts. This way you
will improve both your speed and memory and also your confidence.

 Talk to more experienced work mates and ask their guidance.

 Use self-check question at the end of each section to test your own progress.

 As you work through the activities, ask for written feedback on your progress. Your
trainer keeps feedback/ pre-assessment reports for this reason. When you have
completed this learning material and feel confident that you have the sufficient
knowledge to assess you. The results of the assessment will be recorded in your
competency achievement record.

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 MODULE CONTENT

QUALIFICATION : Driving
Unit of Competency: Read, Interpret and Apply Specification and Manuals
Module Title: Reading, Interpreting and Applying Specification and Manuals

INTRODUCTION:
This unit deals with identifying, interpreting, and applying service specification
manuals, maintenance procedure manuals and periodic maintenance manual
NOMINAL DURATION: 3 hrs.
LEARNING OUTCOMES
After completing this module, you should be able to:
1. Identify and access manual/specification
2. Interpret manuals
3. Apply information in manual
4. Store Manuals

ASSESSMENT CRITERIA:
 Appropriate manuals are identified and accessed as per job requirements.
 Version and date of manual is checked to ensure correct specification and
procedure are identified.
 Relevant sections, chapters of manuals/specifications are located in relation to
the work to be conducted
 Information and procedures in the manual are interpreted in accordance to the
industry practices.
 Manual is interpreted according to job requirements
 Work steps are correctly identified in accordance with the manufacturer
specification
 Manual data is applied according to the given task
 All correct sequencing and adjustment are interpreted in accordance with the
information contained on the manual or specification
 Manual or specifications are stored appropriately to ensure prevention of
damage, ready access and updating of information when required in
accordance with the company requirements.

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LEARNING OUTCOME #1 Identify and access manual/specification

CONTENTS:
1. Identifying appropriate manual
2. Procedure /techniques in interpreting data and specifications.
3. Knowledge and techniques in accessing data and specifications as per job
requirements.
4. Types of manuals used in automotive industry
5. Identification of symbols used in the manuals

ASSESSMENT CRITERIA:
The learning outcome stated above is attained if you can demonstrate
the following:
 Appropriate manuals are identified and accessed as per job requirements.
 Version and date of manual is checked to ensure correct specification and
procedure are identified.

CONDITIONS: Students /trainees must be provided with the following:

1. Supplies/materials
- manufacturing specifications
- repair manual
- maintenance manual
- periodic maintenance manual
2. Instructional materials
- reference books
- professional emergency
- learning guides
- modules,
CDs, VHS tapes, transparencies
METHODOLOGY:
1. Lecture/demonstration
2. Dualized
3. Distance learning
ASSESSMENT METHODS:Written /oral examinations
1. Direct observation
2. Project method
Interview

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 LEARNING EXPERIENCES

1. LEARNING OUTCOME NO. 1: Identify and access manual/specification

Learning Activities Special Instruction

Read: Information Sheet 4.1-1  If you have some problem on the

Identify and access manual and specification content of the information sheet,
don’t hesitate to approach your
facilitator.
Answer Self Check No. . 4.1-1  If you feel that you are now
knowledgeable on the content of the
Identify and access manual and specification
information sheet, you can now
answer self-check provided in the
module.
Compare your answer to the key. If
you got 100% correct answer on
the self-check . 4.1-1
 Identify and access manual and
specification
 you can now move to the next
information sheet. If not review the
information sheet and go over the
self-check again.

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 INFORMATION SHEET 4.1-1
Identify and access manual and specification

Introduction:
This unit deals with identifying, interpreting, and applying service specification
manuals, maintenance procedure manuals and periodic maintenance manual
All over the years, the vehicles you will be working on as a technician become more
and more complicated. In years past, a mechanic or a technician could keep all the repair
information they needed in their head. Now, those days were gone. One of the important
tools as a technician must have is the correct, up-to-date service information for the car
you are working on. A technician must learn to read and understand service information.
This module will present the different types of service information used by the technician.

MANUFACTURE’S SERVICE MANUAL

Manufacturer’s service manual or sometimes its called a shop manuals, are written
by the automotive manufacturer for the technicians in their dealership. A shop manual
covers one model and one year of a vehicle in great detail, sometimes it is printed in a
number of volumes. Shop manuals are the best source of detailed service information for
specific car.

Shop manuals / service manuals are necessary to obtain the desired specification
for specific job. It also provide drawings and photograph to show where and how to
perform a certain procedure in a particular car you are working on. Special tools or
instrument are listed and shown when they are required. Precautions were given to
prevent injury and damage to the parts.

Automobile manufacturers publish a service manuals or set of manuals for each

model and year of their cars. These manuals provide the best and most complete
information for their cars. Although the manuals from different manufacturer vary in
presentations and arrangement of topics, all service manuals are easy to use after you
become familiar with their organizations.

Shop manuals are divided into a number of sections, each covering a different
aspect of the vehicle. The beginning sections commonly provide a vehicle identification
and basic maintenance information. The remaining sections deals with each different
vehicle system. And each section has an index indicating more specific areas of
information

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 Typical Cover of A Service Manual

Table of Contents

The shop manuals contain three basis types of information. First, there is
diagnostic or troubleshooting information. Second, they contain a step-by-step repair
procedure. Third, there a specification charts.
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DIAGNOSING OR TROUBLESHOOTING INFORMATION

Probably the most valuable type of service information comes from the
troubleshooting or diagnosing guides. These are designed to help the technician save
time in identifying and solving problems.

PROCEDURE INFROMATION

Procedure information gives the steps to follow in doing a repair job. The
procedures are usually numbered in a step-by-step order.

SPEFICIFICATION

Specifications are included as part of the service manual. Specifications are

technical data, numbers, clearances and measurements used to diagnose and adjust
automobile components. Specifications can be referred to as specs. They are usually
considered precise measurements under standard conditions. Examples of specifications
include valve clearances, spark plug gaps, tire pressure, number of quarts of oil, ignition
timing and size of engine.

TYPES OF SPECIFICATIONS
General Engine Specification – This specification identify the size and style of the engine.
They include cubic inch displacement, engine codes, fuel system settings, bore and
stroke, horsepower, torque, compression ratio, and normal oil pressure.

Tune-Up specifications – This specification helps identify adjustments necessary for tune-
up on the vehicle. This includes spark plug gap, firing order, degrees of ignition timings,
fuel system settings and fuel pump pressure.

Capacity Specifications –This specification include to identify the capacity of different

fluids on the vehicle. This includes cooling capacity, number of quarts of oil, fuel tank size,
transmission transaxle capacity, and rear axle capacity.
Overhaul and Maintenance Specifications – This specification used to aid technician in
servicing the vehicle. This include distributor advance at different speeds, valve seat
angles, valve stem clearance, piston measurements, ring end gaps, bearing clearances,
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shaft end play and many more. This specification help the technician determine how much
wear has occurred. The mechanic is then able to decide whether or not to replace the
component in question. Usually maximum or minimum clearances are given for this
purpose.

Operational Specification – This specification tell how the vehicle is to operate, what type
of oil to use, and so on. Some of them are found in the owner’s manual. Other
specification includes tire inflation, type of gasoline to use, tire size and general
information for the operator of the vehicle.

Torque Specification – It is important to torque each bolt or nut correctly when replacing
or installing a component on the automobile. Torque specifications are used for this
purpose. This torque specification should be used in place of any standard bolt and nut
torque specification.
OWNERS MANUAL
An owner’s manual or an operator’s manual is a booklet that comes with a new car.
This manual usually explains how to operate the automobile’s control and accessories. In
addition the owner’s manual provides a great deal of technical information that can be
useful to the technician.

In an owner’s manual a vehicle maintenance procedure is provided so that the

owner will know when to get needed service.

A cover and a table of contents of a typical owner’s manual

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AFTERMARKET REPAIR MANUAL

An aftermarket repair manual is most often used by the technician at independent

repair shops. This manual is called an aftermarket because it is published by independent
publisher and not by the car manufacturer. Like the shop manual. This contains
information on troubleshooting, specifications and step-by-step repair procedures. The
main difference is that they cover many different car models and years instead of just one.
Because they are covering more models and years, they typically cover topics in less
detail

(Vehicle Identification Number)

The official vehicle identification number is needed to identify the exact type of vehicle
being worked on. The VIN is also used for title and registration purposes. It is normally
stamped on a metal tab that is fastened to the instrument panel close to the wind shield.
Each manufacturer has assigned a VIN to each vehicle manufactured. Each VIN number
represents different data. The following information can be determined be reading the VIN
number.

 The country by which the vehicle was manufactured or the world manufacturer
 The corporation and division
 Model or series of the vehicle
 Model year
 Body style
 Check digit
 Engine type
 Factory or plant code
 Vehicle serial number

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 SELF CHECK 4.1-1
Direction: Explain the following terms used.
1. Service manual
2. Service procedures
3. Operators manual
4. Specification
5. General engine specification
6. Tune-Up specification
7. Capacity specification
8. Overhaul and maintenance specification
9. Operational specification
10. Torque specification

Multiple Choice: Select the best answer:

1. Which of the following information is not included in a service manual?
a. specification
b. sales and promotion
c. disassembly procedures
d. detailed theoretical information
e. vehicle colors and styling
2. Which of the following information is usually shown as measurement, clearances and
numbers?
a. Procedure Information
b. Troubleshooting information
c. specification information
d. overhaul procedures
e. special tool
3. Specification that include spark plug gap, ignition timing and carburetor adjustment
are called?
a. Tune-up specification
b. Capacity specification
c. Overhaul and maintenance specification
d. Procedure specification
e. None of the above
4. Specification that show bearing clearance, and ring gaps are called?
a. Tune-up specification
b. General engine specification
c. Capacity specification
d. Overhaul and maintenance specification
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 e. Troubleshooting specification
5. Torque specification are identified as:
a. Torque on nuts and bolts
b. Engine torque at certain speeds
c. Torque applied to the crankshaft during operation
d. Torque applied to the generator
e. Torque applied on turns
6. Technician A says that plug gaps, clearances and torque on bolts cannot be
found in a service manual. Technician B says overhaul procedures in the sales
literature. Who is right?
a. A only
b. B only
c. Both A and B
d. Neither A or B
7. Technician A says that diagnosis information can be found in the service
manuals. Technician B says that diagnosis information can be found only in
literature obtained from the manufacturer. Who is right?
a. A only
b. B only
c. Both A and B
d. Neither A or B
8. Technician A says that the VIN does not include any information about the
engine in the vehicle. Technician B says that the VIN does not include the
vehicle serial number. Who is right?
a. A only
b. B only
c. Both A and B
d. Neither A or B

9. When looking for the VIN on the vehicle, technician A says it ca be found on the
dashboard on the driver’s side. Technician B says it can be found in the owner’s
manual. Who is right?
a. A only
b. B only
c. Both A and B
d. Neither A or B

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 ANSWER KEY 4.1-1
Direction: Explain the following terms used.
1. Service manual- designed and written to help service technician in servicing
vehicle
2. Service procedures- this aid the technician to speed up the work and make his job
easier and safer
3. Operators manual-a booklet provided with a new car that describes the car
features, maintenance and specifications
4. Specification- these are technical data, numbers, clearances and measurement
used to diagnose and adjust automobile components
5. General engine specification- this specifications identifies the size and style of the
engine, also includes the engine displacement, engine codes fuel systems settings,
etc..
6. Tune-Up specification- this specifications identifies the necessary adjustment for
vehicle tune-up
7. Capacity specification- this specifications determines the capacities of different
fluids used in the vehicle
8. Overhaul and maintenance specification-
9. Operational specification- this specifications tells how to operate the vehicle, what
type of oil to use and so on…
10. Torque specification- used to identify the correct torque of each bolt and nut during
replacing or installing an automotive component

Multiple Choice: Select the best answer:

1. B
2. C
3. A
4. D
5. A
6. D
7. A
8. D
9. A

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LEARNING OUTCOME # 2 Interpreting Manuals
CONTENTS:
 Identifying appropriate manual
 Procedure /techniques in interpreting data and specifications.
 Knowledge and techniques in accessing data and specifications as per job
requirements.
 Types of manuals used in automotive industry
 Identification of symbols used in the manuals
ASSESSMENT CRITERIA:
The learning outcome stated above is attained if you can demonstrate
the following:
 Relevant sections, chapters of manuals/specifications are located
in relation to the work t be conducted
 Information and procedures in the manual are interpreted in
accordance to the industry practices.
CONDITIONS: Students /trainees must be provided with the following:

2. Supplies/materials
- manufacturing specifications
- repair manual
- maintenance manual
- periodic maintenance manual
3. Instructional materials
- reference books
- professional emergency
- learning guides
- modules,
CDs, VHS tapes, transparencies
METHODOLOGY:
4. Lecture/demonstration
5. Dualized
6. Distance learning
ASSESSMENT METHODS:Written /oral examinations
3. Direct observation
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 4. Project method
5. Interview

LEARNING EXPERIENCES

LEARNING OUTCOME NO. 2: Interpreting Manuals

Learning Activities Special Instruction

Read: Information Sheet 4.2-1 diagnosing or  If you have some problem on the
troubleshooting information content of the information sheet,
don’t hesitate to approach your
facilitator.
 If you feel that you are now
Answer Self Check No. . 4.2-1 diagnosing or knowledgeable on the content of the
troubleshooting information information sheet, you can now
answer self-check provided in the
module.
Compare your answer to the key. If you
got 100% correct answer on the self-
check . 4.2-1 diagnosing or troubleshooting
information
 you can now move to the next
information sheet. If not review the
information sheet and go over the
self-check again.

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 INFORMATION SHEET 4.2-1
DIAGNOSING OR TROUBLESHOOTING INFORMATION

After discussing to you the different service information used by the technicians, the
following pages will show you the examples of each service information presented on the
first Learning Outcomes. Be able to study the examples given and at the end of this LO
you are going to perform the different activities related to the different service information
presented.
DIAGNOSING OR TROUBLESHOOTING INFORMATION
One type of troubleshooting guide is the diagnosis chart. The first part list the
possible problem, then it is divided into three areas: condition, cause and the correction.

FUEL SYSTEM DIAGNOSIS

The following diagnostic procedures are for fuel system problems and their effect on vehicle performance.
Other systems of the vehicle can also cause similar problems and should be checked when listed on the
chart. The problem areas described are:
1. Engines cranks normally. Will not start
2. Engines starts and stalls.
3. Engine starts hard.
4. Engine idles abnormally and/ or stalls
5. Inconsistent engine idle speeds
6. Engine diesels (after run) when shut off.
7. Engines hesitates on acceleration
8. Engine less than normal power at low speeds
9. Engine has less than normal power on heavy acceleration or at high speed.
10. Engine surges
11. Poor gas mileage
CONDITION POSSIBLE CAUSE CORRECTION

Engine cranks normally Improper procedure used Check with the customer to determine if
proper starting procedure is used, as out lined
- will not start
in the owner’s manual
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 Check the choke valve and/or linkage as
necessary. Replace parts if defective. If
Choke valve not operating
Turn ignition off caused by foreign material and gum, clean
properly Disconnect connectorwith
from suitable non-oil-base solvent
controller asm
With an ohmmeter probe  Perform fuel pump flow test
between connector cavity
pins “F” (circuit 38)and “H”
Inspect fuel inlet filter. If plugged, replace
No fuel in carburetor (circuit 399)  If fuel is ok, remove air horn and check for
Measure the resistance a bind in the float mechanism.

Does resistance
measure between
20-30 ohms?

No Yes

Disconnect the servo Turn ignition off

electrical connector from Disconnect connector from
the servo. With an controller asm.
ohmmeter probe between Disconnect connector from
pins “B” (circuit 399) and servo asm.
“D” (circuit 398) on the With an ohmmeter probe
servo assembly. (Not the between controller connector
connector) cavity Pin “C” (circuit 430)
and grd.
Measure the resistance of the
Does resistance wire
measure between 20-
30 ohms?
Does resistance measure
 (infinity)?

No Yes Continuity No Continuity

Replace Check circuits 399 & 398 Find short to grd. and Leave ohmmeter
servo repair (circuit 403) connected as is.
(Pin “H” of controller to Pin “B” of servo) Use jumper wire and
(Pin “F” of controller to Pin “D” of servo) for connect cavity “A”
opens in wires and/or connectors. of servo connector
to know good
Repair ground.
Does resistance Measure resistance
measure 0 ohms?

No Yes

Remove jumper wire Find open in circuit

With ohmmeter probe 403 (Pin “C” of
between controller controller to Pin “A” of
connector cavity servo)
Pin “K” (circuit 402)
and grd.
Repair or
Replace as
Continuity No Continuity required

Find short to grd. and Leave ohmmeter

repair (circuit 402 connected as is
Use jumper wire and
connect Cavity “E”
of servo connector
to known good
ground.
Measure resistance Document No.
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Disconnect connector from measure 0 Page 17
Disconnect connector of 60
Read,
servo Interpret and ohms? from servo
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With an ohmmeter probe With an ohmmeter Repair or
connector cavity Pin “C”
Specifications and Yes No
Revision probe
# 00connector Replace as
(circuit 150) to know good cavity Pin “C” (circuit Required
groundManuals 150) to know good
Measure the resistance ground
Measure the resistance
A
 The “road map” type of troubleshooting chart is shown on the page 14. With this of
chart the technician follows a set of procedures. First, select the troubleshooting chart for
the appropriate problem. The technician begins the reading at the top of the chart, then
follows the lines on chart downward. Depending on the results of each steps, two or more
possible courses of action may be presented. The two different procedures follow the first
step. If you answer “NO” , you directed to perform another test. If you answer “YES”, you
are directed to proceed to another steps. The directions on this type of chart should be
followed exactly, without skipping any steps.

PROCEDURE INFROMATION
Procedure information gives the step by step to follow in doing a repair job. The
procedures are usually numbered in a step-by-step order. Below is an example of step-by-
step procedure to follow in replacing a cylinder head .

CYLINDER HEAD
Replace

1. Raise and support front of vehicle, then drain cooling system and disconnect exhaust pipe
from manifold.
2. Lower vehicle and remove oil dipstick tube and air cleaner.
3. Disconnect wire connectors and vacuum hoses from carburetor or TBI unit.
4. Remove EGR valve base plate from intake manifold, if applicable.
5. Disconnect heater hose from intake manifold, then remove AIR system discharge tube
attaching bolt from intake manifold.
6. Remove ignition coil lower attaching bolt, then disconnect wiring from coil.
7. Disconnect all wiring from cylinder head and intake manifold, then remove engine upper
support attaching bolt from engine strut.
8. Remove A/C compressor and position aside with refrigerant lines attached.
9. Remove alternator drive belt, then remove AIR pump bracket bolt from engine block, if
equipped.
10. Disconnect throttle and throttle valve cables from throttle lever and intake manifold.

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 11. Disconnect upper radiator hose from cylinder head then disconnect AIR hose from tube
assembly, if equipped.
12. Remove rocker arm cover, and then remove rocker arms and push rod.
13. Remove cylinder head attaching bolts then lift cylinder head and intake and exhaust
manifold as an assembly from cylinder block.
14. Reverse procedure to install. Coat heads and threads of cylinder bolts with suitable sealing
compound, then install bolts finger tight. Tighten cylinder head bolts in proper sequence.
SPEFICIFICATION
Specifications are technical data, numbers, clearances and measurements used to
diagnose and adjust automobile components. Specifications can be referred to as
specs. They are usually considered precise measurements under standard conditions.
TYPES OF SPECIFICATIONS
General Engine Specification
This specification identify the size and style of the engine. They include cubic inch
displacement, engine codes, fuel system settings, bore and stroke, horsepower, torque,
compression ratio, and normal oil pressure.
SPECIFICATIONS

Year Engine Fuel Bore & Compression Net Brake Maximum Normal Oil
System Stroke Ratio H.P@ RPM 2 Torque Pressure
CID/Liter VIN code Psi.
1

4.3L/V6-262 Z TBI 4.00X3.48 9.3 145@4200 225@2000 3

1989
5.0L/V8-305 E TBI 3.74X3.48 9.3 170@4000 255@2400 3

5.0L/V8-307 Y 4Bbl. 3.800X3.38 8.0 140@3200 255@2000 30 4

5

4.3L/V6262 Z TBI 4.00X3.48 9.3 145@4200 225@2000 3

5.0L/V8-305 E TBI 3.74X3.48 9.3 170@4000 255@2400 3

1990
5.0L/V8-307 Y 4Bbl. 3.800X3.38 8.0 140@3200 255@2000 30 4
5

5.7L/V8-350 7 TBI 4.00X3.48 9.3 175@4200 295@2000 3

5.0L/V8-305 E TBI 3.74X3.48 9.3 170@4000 255@2400 3

1991
5.7L/V8-350 7 TBI 4.00X3.48 9.8 185@3800 300@2400 3

4.3L/V6-262 Z TBI 4.00X3.48 9.3 145@4200 225@2000 3

5.0L/V8-305 E TBI 3.74X3.48 9.3 170@4000 255@2400 3

1992
5.7L/V8-350 7 TBI 4.00X3.48 9.8 185@3800 300@2400 3

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 General Engine specifications

Gives information about the engine type to help technician identify the exact type of engine in a vehicle. (Courtesy of Motor
Publication, Auto Repair Manual)

1
- the eight digit of the VIN denotes engine code

2
– rating are net, as installed in the vehicle

3
- minimum with engine hot, 6 psi@1000 RPM; 18psi.@2000 RPM; 24 psi.@4000 RPM

4
- minimum with engine hot @ 1500 RPM

TBI – Throttle Body Fuel Injection

4Bbl– 4 barrel carburetor

Tune-Up specifications
This specification helps identify adjustments necessary for tune-up on the vehicle.

TUNE UP SPECIFICATIONS

Ignition Timing Fuel

Pump
Year & Spark Plug Mark Fig Curb Idle Fast Idle Pressure
Engine/ VIN Gap Firing 2 Degrees 3 Speed 4 Speed 5
Order BT DC Psl
Code 1

1989 5 6 6 7
5
4.3L/V8-262/Z .035 E TDC B 9-13
5 6 6 7
5
5.0L/V8-305/E .035 A 6 B 9-13
12 6 9 11
1
5.0L/V8-307/Y .060 C 20 D 550D 2
5 6 6 7
2 5
5.7L/V8-350/7 .035 A 6 B 9-13

1990
5 6 6 7
5
4.3L/V8-262/Z .035 E TDC B 9-13
5 6 6 7
5
5.0L/V8-305/E .035 A 6 12 B 9-13
6 9 11
1
5.0L/V8-307/Y .060 C 20 D 550D 2
5 6 6 7
2 5
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 5.7L/V8-350/7 .035 A 6 B 9-13

1991
6 6 7
8 5
5.0L/V8-305/E .035 A TDC B 9-13
6 6 7
10 5
5.7L/V8-350/7 .035 A B 9-13

1992
5 6 6 7
5
4.3L/V8-262/Z .035 E TDC B 9-13
6 6 7
8 5
5.0L/V8-305/E .035 A TDC B 9-13
10 6 6 7
5
5.7L/V8-350/7 .035 A B 9-13

Tune-Up specification used by the service technician to tune-up the vehicle. (Courtesy of Motor Publication, Auto Repair
Manual)

1
-the eight digit of the VIN denotes engine code
2 -before removing wires from the distributor cap, determine location of No. 1 wire in a cap as distributor position may
have been altered from that show at the end of this chart.
3
- BTDC: Before Top Dead Center
4 - D: Drive. When adjusting idle speed set parking brake and block drive wheels
5
-Disconnect set timing by-pass connector (tan/black wire) when adjusting ignition timing. The timing by-pass connector
breaks out of the engine compartment. After completing adjustment, reconnect set timing connector. With engine off,
clear trouble code from ECM memory by removing battery voltage to the ECM for 30 seconds.

6 - Idle speed is controlled by IAC (Idle Air Control) or ILC (Idle Load Compensator)
7
- Wrap shop towel around fuel hose to steel line connection in engine compartment to prevent fuel spillage. Disconnect
5
hose from steel line and install suitable fuel pressure gauge between hose and line. Ensure gauge connections are tight,
then start engine and check fuel pressure readings.
- Disconnect EST bypass electrical connector when checking ignition timing. The bypass connector is located on the AIR
8
control valve tube. After completing adjustment, reconnect EST bypass electrical connector.
-On low step on fast idle cam
9
1 -Computer controlled, no adjustment
10
2
11
2 -Mechanical fuel pump pressure, 5.5-6.5 psi, electric pump
12
- At 11000 RPM with jumper wire connected between ALCL connector terminals
A&B. ALCL is located under the instrument panel to the right of the steering column.
After completing adjustment, disconnect jumper wire from between terminals A&B. With engine off, clear trouble code
from Electronic Control Module (ECM) by removing battery voltage from ECM for 30 seconds.

Capacity Specifications
This specification include to identify the capacity of different fluids on the vehicle.
This includes cooling capacity, number of quarts of oil, fuel tank size, transmission
transaxle capacity, and rear axle capacity.

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 COOLING SYSTEM & CAPACITY DATA

Cooling Radiator Cap Thermo. Fuel Tank Engine Transmission Oil

Capacity, Qts Relief Opening Qts. Refill Qts.
Engine & VIN Code pressure, Psi. Temp. Man. Auto. Rear
Trans. Trans. Axle Oil
Pts Qts.  Pts.

1989-90

3.8L/V6-232 (4) 11.6 16 197 18.8 4 - 12.3  

3.8L/V6-232 SC (C, 12 16 197 18.8 4 6.3  12.3  

R)

5.0L/V8-302 (F) 14.1 16 197 18 4 - 12.3  

1991

3.8L/V6-232 (4) 11.8 16 196 19 4.5  - 12.3  3.1

3.8L/V6-232 SC 11.8 16 197 19 4.5  6.3  12.3  3.4

(C,R)

5.0L/V8-302 (F)  14.4 16 192 18 4 - 12.3  3.8

5.0L/V8-302 HO (T) 14.1 16 195 19 4 - 12.3  3.4



1992

3.8L/V6-232 (4, C, 12.5 16 197 18 4.5  6.3 12.3  3.1

R)

4.6L/V8-281 (F) 13.6 14-18 195 20 5.0 - 12.3  3.8

5.0L/V8-302 HO (T) 14.1 14-18 192-197 18 4.0  - 12.3  3.35

 - Approximate, make final check oz. of friction modifier meeting is located at left hand bottom of
with dipstick. Ford Motor Co. specification oil pan
Add 1 qt. with filter change. EST-M2C118-A Models w/ 8.8 Conventional axle, 4 pts.
 - inch ring gear, conventional  -
Use Mercon type transmission axle, 3.5 pts; traction-lok axle, Traction-Lok axle, 3.75 pts.
 - fluid. Plus 4 oz. of friction modifier
3.75 pts, plus 4 oz. of friction
modifier meeting Ford Motor meeting Ford Motor Co.
Conventional axle, 3 pts. specification
Co. specification EST-M2C118-
 - Traction modifier meeting Ford A. EST-M2C118-A.
 - Motor Co. specification
 - Equipped with dual sump oil Add ½ qt. with filter change.
EST-M2C118-A.  -
pan. Remove both drain plugs Crown Victoria & Grand
to fully drain oil. One drain plug  - Marquis.
Models w/ 7.5 inch ring gear, is located at front of oil pan.
conventional axle, 3 pts.; Second drain plug  - Cougar & Thunderbird
Traction-Lok axle, 2.75 pts, plus - On Super Charged Engines,
4 3.50 pts

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Overhaul and Maintenance Specifications
This specification used to aid technician in servicing the vehicle.
PISTONS, PINS, & RINGS
Engine Year Piston Piston Piston Pin Pin to Piston End Ring Piston Ring Side
Liter/ CID Diameter Clearance Diameter Piston Clearance
(Std.) Clearance Gap 

Comp. Oil Comp. Oil

1.3L/4-80.8 1989- 2.793-2.794 .006 .7864-.7866 .0-.0010 .006 .008 .001-.00 -

91 3

1.6L/4-97 1991 3.0690- .0010-.0026 .7869-.7871 .0004-.0012 .008 .0012-.00 .0012-.00

3.0698 26 26

1.8L/4-112 1991 3.2659- .0015-.0020 .7869-.7871 .0002-.0005 .006-.01 .008 .0012-.00 -

3.2667 2 28

1.9L/4-116 1989-  .0016-.0024 .8119-.8124 .0003-.0005 .010 .016 -

91

2.2L/4-133 1989- 3.3836- .0014-.0030 .8651-.8654 -- .001-.00 -

91 3.3844 3

2.3L/4-140 1989-  .0030-.0038 .9118-.9124 .0003-.0005 .010 .015 .002-.00 -

 91 4

2.3L/4-140 1989-  .0012-.0022 .9119-.9124 .0002-.0005 .008 .015 .002-.00 -

 91 4

2.5L/4-153 1989-  .0013-.0021 .9119-.9124 .0002-.0005 .008 .015 .002-.00 -

91 4

2.9L/V6-177 1989- .0011-.0019 .9446-.9450 .0003-.0006 .015 .015 .0020-.00 -

91 33

3.0L/V6-182 1989-  .0014-.0022 .9119-.9124 .0002-.0005 .010 .010 .0012-.00 -

91 31

3.0L/V6-182 1989- 3.5023- .0012-.0020 .8267-.8271 .00004 .012 .008 .0024-.00

91 3.5035 59

3.8L/V6-232 1989-  .9119-.9124 .015 .0016-.00 -

90 34

3.8L/V6-232 1991  .9119-.9124 .0002-.0005 .010 .015 .0016-.00 -

34

4.6L/V8-281 1991 .0008-.0018 .8659-.8661 .0002-.0039 .009 .010

5.0L/V8-302 1989-   .9119-.9124 .0002-.0004 .010 .015 .002-.00 -

91 4

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5.8L/V8-351 1989- .0018-.0026 .9119-.9124 .0003-0005 .010 .015 .002-.00 -
91 4

 - Minimum  - Except V8-302 HO engine, - EFI, .0014-.0032 inch;

coded red, 3.9989-3.9995 inch; SC, .0035-.0040 inch
 - Coded red, 3.224-3.225 inch; coded blue, 4.0001-4.0007 inch;
coded blue, 3.225-3.226 inch coded yellow, 4.0013-4.0019 - EFI, .0002-.0005 inch;
inch. V8-302 HO engine, coded SC, .0003-.0006 inch
red, 3.9972-3.9980 inch; coded
 - Overhead cam (OHC) engine blue, 3.9984-3.9992 inch; coded
yellow, 3.9996-4.0004 inch.
 - Coded red, 3.7764-3.7770 inch; - First ring, .011 inch; second
coded blue, 3.7776-3.7782 inch. First ring, .0015-.0032 inch; ring, .009 inch
second ring, .0015-.0035 inch
 - High swirl combustion (HSC) Coded red, 3.6605-3.6615 inch. - EFI, .0014-.0032 inch;
engine SC, .0040-.0045 inch
First ring, .008 inch; second ring,
.006 inch
 - Coded red, 3.6783-3.6789 inch; -
coded blue, 3.6795-3.6801 inch;
coded yellow, 3.6807-3.6811 inch. - Coded red, 3.5498-3.5503 inch;
Turbo, .006 inch; non-turbo, .012
coded blue, 3.5503-3.5509 inch;
inch
- coded yellow, 3.5509-3.5514 inch
First ring. .002-.004 inch; second
 - Coded red, 3.5024-3.5031 inch; - - ring, .001-.003 inch.
coded blue, 3.5035-3.5041 inch;
coded yellow, 3.5045-3.5051 inch.
 - Coded red, 3.8095-3.8101 inch; - - Maximum .0006 inch
coded blue, 3.8107-3.8113 inch; - Coded red, 3.9978-3.9984 inch;
 - coded yellow, 3.8119-3.8125 inch. - Super High output (SHO) coded blue, 3.9990-3.9996 inch;
engine. coded yellow, 4.0002-4.0008 inch.
Except V8-302 HO engine, .0014
to .0022 inch; V8-302 HO
engine, .0030-.0038 inch. - First ring, .0008-.0024 inch;
second ring, .0006-.0022 inch

Operational Specification
This specification tell how the vehicle is to operate,.

BREAK – IN SPEED LIMIT MPH (KM/H)

1st 2nd 3rd 4th 5th

Manual
Transaxle
4- Speed 0 to 22 12 t o 37 20 to 55 25 to 75

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 (0 to 35) (20 to (30 to 90) (40 to 120)
60)

0 to 22 10 to 37 15 to 53 22 to 68 28 to 80
5- Speed (0 to 35) (25 to (25 to 85) (36 to 110) (45 to 130)
85)

“1” Low “2” Low “D” Drive

Automatic Transaxle

0 to 30 (0 to 50) 0 to 53 (0 to 85) 0 to 75 (0 to 120)

Operational specification showing the break-in speed limit for operating the vehicle.
(Courtesy of Nissan Motor Corporation in USA)
Torque Specification
Is important to torque each bolt or nut correctly when replacing or installing a
component on the automobile. Torque specifications are used for this purpose. This
torque specification should be used in place of any standard bolt and nut torque
specification.

Engine Tightening Specifications

Torque specifications are for clean & lightly lubricated threads only. Dry or dirty threads increase friction
which
prevents accurate measurement of tightness.
Spark Cylinder Intake Exhaust Rocker Rocker Connecting Main Flywheel Vibration
Plugs Head Manifold Manifold Arm Arm Rod Cap Bearing To Damper
Engine Ft. Bolts Ft. Ft. Lbs Ft. Lbs. Shaft Cover Bolts Ft. Cap Bolts Crankshaft Or Pulley
MODEL/ Lbs. Lbs. Bracket Ft. Lbs. Ft. Lbs. Ft. Lbs. Ft. Lbs.
V.I.N. Ft. Lbs. Lbs.

4-150/U 27 85  23 23 19  28  33 80  90 

4-151/B 11 92 37 37 20  7 30 65 66 160

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 4-151/B 11 92 26 37 20  7 30 65 66 162

6-258/C 11 85 23 23 19  28  33 65 105 80 

6-258/C 11 85  23 23 19  28  33 80 105 80

 - In Lbs.  - Rocker Arm Cap Screw  - Torque bolts to 50 Ft. Lbs.,

 - Coat under side of cylinder head  - Lubricate bolt threads lightly before then tighten bolts an
bolt heads & threads with a suitable assembly additional 60 degrees
sealing compound

Owner’s Manual An owner’s manual or an operator’s manual is a booklet that

comes with a new car. This manual usually explains how to operate the automobile’s control and
accessories.
In an owner’s manual a vehicle maintenance procedure is provided so that the
owner will know when to get needed service.
Automobile’s control and accessories.

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 Maintenance procedure
Servi service at Miles x1,000 15 30 45 60 75 90 105 120
the indicated Km x 1,000 24 48 72 96 120 144 168 192
mileage or time Note
whichever comes months 12 24 36 48 60 72 84 96
first
Replace engine oil Replace every 7,500 miles or 12 months Capacity
5.0L
Replace engine oil filter        
Check engine oil & coolant Check oil and coolant at each fuel stop Check for
leaks
Replace air cleaner element    
Inspect valve clearance  In .15-
0.1mm
Ex .17-.2mm
measure
when cold
Replace spark plug  Gap 1.0-
1.1mm
Replace fuel filter  
Inspect idle speed  800+/-rpm
(MT)
780+/-rpm
(AT)
Replace engine coolant    Capacity
12.0L
Replace transmission fluid  Manual
Trans. MTF
2.65L
Auto. Trans
ATF 2.9L
Inspect front & rear brakes         Check brake
thickness
and
movement.
Check
caliper for
leakage
Replace brake fluid (including ABS)   DOT3 brake
fluid. Check
that fluid is
between
upper &
lower marks
in reservoir
Check parking brake adjustment Engage 10
to 14
notches
Rotate tires (check inflation & condition at Rotation
least once per month Rotation every 7,500 miles method
shown I
owner’s
manual

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 VIN (Vehicle Identification Number)
1G1AB68C XDY 123456

NATION OF ORIGIN PLANT SEQUENTIAL NUMBER

1. USA
BODY TYPES
2. CANADA
CODE ASSEMBLY PLANT

MANUFACTURER MODEL YEAR

D 1983 A LAKEWOOD

E 1984 B BALTIMORE
MAKE AND TYPE
C SOUTH GATE
1. CHEVROLET F 1985
2. GM OF D DORAVILLE
G 1986
E LINDEN
H 1987
RESTRAINT SYSTEM G FRAMINGHAM
J 1988
H FLINT (BUICK)

A. NON PASSIVE J JANESVILLE

B. PASSIVE RESTRAINT/AUTOMATIC K LEEDS
BELTS
L VAN NUYS

CARLINE/SERIES M LANSING

CODE SERIES N NORWOOD

--------------------- P PONTIAC MOTOR
---------------------
“B” L IMPALA R ARLINGTON
MODELS
N CAPRICE CLASSIC S ST. LOUIS
T TARRY TOWN
Z MONTE CARLO
“G” W MALIBU CLASSIC
MODELS ENGINE TYPE AND MAKE
W EL CAMINO

“A” W CELEBRITY MODEL

MODELS
CODE PRODUCER TYPE USAGE
RPO
“X” H CITATION
MODELS
A BUICK 3.8 L V6 2BBL BG LD5
B CHEVROLET 2.0 L L4 2BBL J LR9
C CHEVROLET 1.6 L L4 2BBL T L17
D CHEVROLET 1.8 L L4 DIESEL T LJ5
F PONTIAC 2.5 L L4 2BBL F LO8
H
L
N
P
R

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Instruction: After understanding the different service information, you are given an option
to perform from different activities given. As trainee inform your trainer which activity you
have chosen for this learning outcome no. 2.

Suggested activities:

1. Find a simple road-type troubleshooting guide and be able to interpret it.

2. Find a service procedure of one simple task and be able to perform it actually under
the monitoring/ supervision of your trainer
3. Find and interpret one Vehicle Identification Number
4. Find examples of different types of specification

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 SELF CHECK 4.2-1
Directions: Answer the following briefly.

Questions:

1. What are the different information you can find from vehicle’s identification
number? Give at least five.
2. What are the three things given in a diagnostic guide?
3. What is the importance of a vehicle maintenance procedure
4. 1 G 1 A B 68 C X D Y 123456 Determine the meaning every
underlined item.

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 ANSWER KEY 4.2-1
Answers:
1.
 The country by which the vehicle was manufactured or the world manufacturer
 The corporation and division
 Model or series of the vehicle
 Model year
 Body style
 Check digit
 Engine type
 Factory or plant code
 Vehicle serial number
2.
 Problems
 Possible cause
 Correction or remedy
3. vehicle maintenance procedure is provided so that the owner will know when to get
needed service.

 1- nation of origin
 G- manufacturer
 1- make and type
 A- restrain system
 B- carline series
 68- body types
 C- engine type and make
 X- check digit
 D- model
 Y- body types

 123456- plant sequential number

LEARNING OUTCOME #3 Applying information in the manual.

CONTENTS:
 Identifying appropriate manual
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  Procedure /techniques in interpreting data and specifications.
 Knowledge and techniques in accessing data and specifications as per job
requirements.
 Types of manuals used in automotive industry
 Identification of symbols used in the manuals
 Identification of units of measurement and unit cover
ASSESSMENT CRITERIA:
The learning outcome stated above is attained if you can demonstrate
the following:
 Manuals is interpreted according to job requirements work steps are correctly
identified in accordance with the manufacturer specification
 Manual data is applied according to the given task
 All correct sequencing and adjustment are interpreted in accordance to the
industry practice

CONDITIONS: Students /trainees must be provided with the following:

3. Supplies/materials
- manufacturing specifications
- repair manual
- maintenance manual
- periodic maintenance manual
4. Instructional materials
- reference books
- professional emergency
- learning guides
- modules,
CDs, VHS tapes, transparencies
METHODOLOGY:
1. Lecture/demonstration
2. Dualized
3. Distance learning
ASSESSMENT METHODS:Written /oral examinations
1. Direct observation
2. Project method/Interview

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 LEARNING EXPERIENCES

LEARNING OUTCOME NO. 3: Applying information in the manual

Learning Activities Special Instruction

Read: Information Sheet 4.3-1  If you have some problem on the

procedures for finding specification content of the information sheet,
don’t hesitate to approach your
Answer Self Check No. . 4.3-1 facilitator.
procedures for finding specification  If you feel that you are now
knowledgeable on the content of the
information sheet, you can now
answer self-check provided in the
module.
Compare your answer to the key. If you
got 100% correct answer on the self-
check . 4.3-1
procedures for finding specification
 you can now move to the next
information sheet. If not review the
information sheet and go over the
self-check again.

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 INFORMATION SHEET 4.3-1
PROCEDURES FOR FINDING SPECIFICATION

Learning Objective: After reading this information sheet you must be able to follow
the general procedure when locating the information.
The following are the general procedure when locating information:
1. Identify the type, model and year.

2. Locate the VIN on the vehicle for reference

3. Select the appropriate year of the service manual

4. Refer to the first table of contents in the manual on the inside cover and page
number that covers the type of vehicle.

5. Turn to that page and read the index of service operation

6. Look for the engine rebuilding specifications page number and turn to that page.

7. Engine rebuilding specifications are shown in various tables.

8. Often these specifications will be listed according to the size and configuration of
the engine. If you are unsure of this information, use the VIN to identify the size and
configuration. VIN information can be found by referring to the first table of
contents.

9. Also pay close attention to the footnotes identified by the numbers such as
1,2,3,4,5. These footnotes give valuable information to the service technician
concerning specific engine styles.

* The next page will show you the table of contents and a number section of the service
manual. Following the procedure given and familiarizing the table of contents will help you
locate the informations you are looking easier and faster.

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 SECTION
TABLE OF CONTENTS NUMBER

GENERAL INFO. AND LUBE

General Information OA
Maintenance and Lubrication OB

HEATING AND AIR COND.

Heating and Vent. (nonA/C) 1A
Air Conditioning System 1B
V-5 A/C Compressor Overhaul 1D3

BUMPERS AND FRONT BODY

PANELS
Bumpers (See 10-4)
Fr. End Body Panels (See 10-
5)

STEERING, SUSPENSION,
TIRES, AND WHEELS
Diagnosis
3
Wheel Alignment
3A
Power Steering Gear & Pump
3B1
Front Suspension
3C
Rear Suspension
3D
Tires and Wheels
3E
Steering Col. On-Vehicle
3F
Service
3F1
Steering Col.-Std. Unit Repair
3F2
Steering col.-Tilt, Unit Repair

DRIVE AXLES
Drive Axles 4D

BRAKES
General Info.-Diagnosis and
On- Car Service
5
Compact Master Cylinder
5A1
Disc Brake Caliper
5B2
Drum Brake – Anchor Plate
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 Power Brake Booster 5C2
Assembly
5D2

ENGINES
General Information 6
2.0 Liter I-4 Engine 6A1
3.1 Liter V6 Engine 6A3
Cooling System 6B
Fuel System 6C
Engine Electrical – General 6D
Battery 6D1
Cranking System 6D2
Charging System 6D3
Ignition System 6D4
Engine Wiring 6D5
Driveability & Emissions – Gen 6E
Driiveability & Emissions – TBI 6E2
Driveability & Emissions – PFI 6E3
Exhaust System 6F

SECTION
TABLE OF CONTENTS NUMBER

TRANSAXLE
Auto. Transaxle On-Car 7A
Serv.
3T40
Auto. Trans. – Hydraulic
HD
Diagnosis

3T40
Auto. Trans.-Unit Repair
7B
Man. Trans. On-Car Service
7B1
5-Sp. 5TM40 Man. Trans.
Unit
7B2
Repair
5-Sp. Isuzu Man. Trans.
Unit 7C
Repair

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 Clutch

CHASSIS ELECTRICAL
INSTRUMENT PANEL, AND
WIPER/WASHER
Electrical Diagnosis
8A
Lighting and Horns
8B
Instrument panel and
Console 8C
Windshield Wiper/Washer 8E5

ACCESSORIES
Audio System 9A
Cruise Control 9B
Engine Block Heater 9C

BODY SERVICE
General Body Service 10-1
Stationary Glass 10-2
Underbody 10-3
Bumpers 10-4
Body Front End 10-5
Doors 10-6
Rear Quarters 10-7
Body Rear End 10-8
Roof & Convertible Top 10-9
Seats 10-10
Safely Belts 10-11
Body Wiring 10-12
Unibody Collision Repair 11-1
Welded Panel Replacement 11-2

INDEX
Alphabetical Index
 The table of contents directs you to the major systems and components areas in the service manual

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How to use a Shop Manual

1. Select he appropriate manual for he vehicle being serviced.

2. Use the table of contents to locate the section that applies to the work being
done.

3. Use the index at the front of that section to locate the required information.

4. Carefully read the information and study the applicable illustrations and diagrams.

5. Follow all the required steps and procedures give for that service information.

6. Adhere to all the given specifications and perform all measurements and
adjustment procedure with accuracy and precision.

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 Self check 4.3-1
1. Enumerate the general procedure when locating information..
2. Enumerate the procedure on How to use the shop manual.

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 ANSWER KEY 4.3-1

T
1. The general procedure when locating information
 Identify the type, model and year.

 Locate the VIN on the vehicle for reference

 Select the appropriate year of the service manual

 Refer to the first table of contents in the manual on the inside cover and page number that
covers the type of vehicle.

 Turn to that page and read the index of service operation

 Look for the engine rebuilding specifications page number and turn to that page.

 Engine rebuilding specifications are shown in various tables.

 Often these specifications will be listed according to the size and configuration of the
engine. If you are unsure of this information, use the VIN to identify the size and
configuration. VIN information can be found by referring to the first table of contents.

 Also pay close attention to the footnotes identified by the numbers such as 1,2,3,4,5. These
footnotes give valuable information to the service technician concerning specific engine
styles.
2. How to use a Shop Manual
 Select he appropriate manual for he vehicle being serviced.
 Use the table of contents to locate the section that applies to the work being done.
 Use the index at the front of that section to locate the required information.
 Carefully read the information and study the applicable illustrations and diagrams.
 Follow all the required steps and procedures give for that service information.
 Adhere to all the given specifications and perform all measurements and adjustment
procedure with accuracy and precision

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 ACTIVITY SHEET 4.3-1

ENGINE TUNE-UP SPECIFICATION( Gasoline Engine)

Direction: fill-up the Engine Tune-Up worksheet below. Refer to the service manual
available on you workshop.
Engine Model :__________________________ Body Model: _____________________
Name: _________________________________ Date: ___________________________

ITEM SPECIFICATION

Battery
 Voltage
 Specific gravity
 Post clamp
 Electrolyte level
Compression Pressure
Std.
Limit
At _______ rpm
Valve Clearance
In.
Ex.
Ignition system
 Spark plug gap
 HTC resistance
 Contact point gap
 Damping spring gap
 Condenser capacity
 Primary coil
 Secondary coil
 External resistor
 Dwell angle
 Dwell angle variation
 Ignition timing
 Firing order
 Governor advance
 Vacuum advance
Cooling System
 Coolant level
 Coolant capacity
 Valve opening pressure Std: Limit
 Quality check
 Drive belt tension/Fan alternator New

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 LEARNING OUTCOME #4 Store manuals.
CONTENTS:
 Identifying appropriate manual
 Procedure /techniques in interpreting data and specifications.
 Knowledge and techniques in accessing data and specifications as per job
requirements.
 Types of manuals used in automotive industry
 Identification of symbols used in the manuals
 Identification of units of measurement and unit conver
ASSESSMENT CRITERIA:
Manuals or specifications are stored appropriately to ensure prevention of
damage, ready to access and updating of information when required in
accordance with the company requirements

CONDITIONS: Students /trainees must be provided with the following:

1. Supplies/materials
- manufacturing specifications
- repair manual
- maintenance manual
- periodic maintenance manual
2. Instructional materials
- reference books
- professional emergency
- learning guides
- modules,
CDs, VHS tapes, transparencies
METHODOLOGY:
1. Lecture/demonstration
2. Dualized
3. Distance learning
ASSESSMENT METHODS:Written /oral examinations
1. Direct observation
2. Project method
3. Interview
LEARNING EXPERIENCES

LEARNING OUTCOME NO. 4: Store manuals

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 Learning Activities Special Instruction

Read: Information Sheet 4.4-1  If you have some problem on the

Store manuals content of the information sheet,
don’t hesitate to approach your
. facilitator.
 If you feel that you are now
knowledgeable on the content of the
information sheet, you can now
answer self-check provided in the
module.

Answer Self Check No. 4.4-1 Compare your answer to the Answer
key4.4-1
Store manuals
Store manuals
.
.
 If you got 100% correct answer on the
Perform, Activity sheet 4.4-1 self-check, you can now move to the
Maintain learning resource area next information sheet. If not review
the information sheet and go over the
self-check again.
Evaluate your own work using the
performance criteria /procedural
checklist SHEET 4.4-1
Maintain learning resource area
.

INFORMATION SHEET 4.4-1

Store manuals

Learning Objectives: After reading this information sheet you must be able to store maual properly.

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 Your book/manual collection will find its environmental utopia in a darkened room with a
stable thermostat set to 16ºC - 18ºC, with a relative humidity of around 50-60%. Sunlight is a
natural enemy of books, and even a small amount will fade and warp a book over time. Cover any
windows with heavy curtains. The room should be dry, but not excessively arid like the attic. A
total lack of moisture is as detrimental as an excessive amount of moisture. Paper and book
binding deteriorate under either extreme. So, a commercial humidifier might be a wise option for
those preserving special or expensive collections.

Books/manuals should be shelved in an upright position (vertically). Larger books/manuals,

however, should be stored on their sides (horizontally) to a prevent page/binding separation which
can occur as a result of the weight of the book itself. Also, be sure to leave a bit of space behind
your shelved books/manuals, for air circulation.

Vertically stored books/manuals should be shelved tight enough to prevent leaning, which
leads to warping. Do not shelve your books so tightly that you are forced to rip at the binding to
retrieve a book from your unit. Books like to be comfortably shelved.

Books/Manuals properly stored

ACTIVITY SHEET 4.4-1

Maintain learning resource area
Directions: As trainee part of your responsibility is to maintain your learning resource area tidy and
clean. All books and manuals must be properly in place for easy access and prevention of

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damages. Check your learning resource area and be able to store all the arrange all the books
and manuals.

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EVIDENCE PLAN

Competency Standard Automotive Servicing

Unit of Competency Read, Interpret and Apply Specification and Manual

Ways in which evidence will be collected:

Question/ Interview
(tick the column)

Demonstration
The evidence must show that the candidate…

 *Identify and access appropriate manuals as

per job requirement
 Check version and date of manual to ensure
correct specification and procedures are
identified
 Locate relevant sections, chapters of
manuals/specification in relation to the work
to be conducted
 *Interpret information and procedure from the
manual in accordance to the industry
practices
 *Interpret manual according to the job
requirement
 Correctly identify work steps in accordance
with the manufacturer specification
 *Apply manual data according to the given
task
 Interpret all correct sequencing and
adjustment in accordance with the
information contained on the manual or
specification
 *Store manual appropriately to ensure
prevention of damage, ready to access and
updating of information when required in
accordance with the company requirement
Note: * Critical aspect of competency

Prepared by: Instructor I Date:

Checked by Date:

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Observation Checklist
Qualification Level NC I
Candidate Name:
Assessor’s Name:
Assessment Center:
Unit of Competency: Read, Interpret and Apply Specification and Manual
Competency Standard: Automotive Servicing
Date of Assessment:
Time of Assessment:
Instruction for Demonstration:
Materials and Equipment:
Manuals/ catalogues relative to Automotive, job order, requisition, actual vehicle
Observation: To show if evidence is
During the demonstration of skills did the candidate: demonstrated
YES No N/A
 *Identified and accessed appropriate manuals as per
job requirement
 Checked version and date of manual to ensure
correct specification and procedures are identified
 Locate relevant sections, chapters of
manuals/specification in relation to the work to be
conducted
 *Interpreted information and procedure from the
manual in accordance to the industry practices
 *Interpreted manual according to the job requirement
 Correctly identified work steps in accordance with
the manufacturer specification
 *Applied manual data according to the given task
 Interpreted all correct sequencing and adjustment in
accordance with the information contained on the
manual or specification
 *Stored manual appropriately to ensure prevention of
damage, ready to access and updating of
information when required in accordance with the
company requirement
The candidate’s demonstration was:

Satisfactory Unsatisfactory

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Questioning / Interview

Candidate Name:

Assessment Center:

Unit of Competency: Read, Interpret and Apply Specification and Manual

Competency Standard: Automotive Servicing

Satisfactory
response
Questions:

The candidate should answer the following question: YES NO

1. What are the different service informations used in the
automotive industry?
2. What are the information can we get at the VIN?

3. Give the difference of a diagnostic flowchart and

diagnostic guide?
4. What are the different types of specification?

5. What is a service manual?

6. What is an owner’s manual?

The candidate underpinning knowledge was:

Satisfactory  Not satisfactory 

Feedback to candidate:

The candidate’s overall performance was:

Satisfactory  Not satisfactory 

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 PERFORMANCE TEST

Learner’s Name: Date:

Unit of Competency: Test Attempt
Read, Interpret and Apply Specification and Manual 1st 2nd 3rd
Direction: Overall Evaluation
Level Performance Levels
Call instructor, ask your instructor to Achieved
assess your performance in the 4- Can perform this skills without
following critical task and supervision and with iniative and
performance criteria below. adaptability to problem situation
3- Can perform this skills
satisfactorily without assistance
You will be rated based on overall or supervision
evaluation on the right side. 2- Can perform this skills
satisfactorily but requires some
assistance or supervision
1-can perform parts of this skill
satisfactorily but requires
considerable assistance and
supervision
Instructor will initial level achieved
Performance Standards
For acceptable achievements, all items should receive a YES NO N/A
“YES” or “N/A” response
 *Identify and access appropriate manuals as per job
requirement
 Check version and date of manual to ensure correct
specification and procedures are identified
 Locate relevant sections, chapters of
manuals/specification in relation to the work to be
conducted
 *Interpret information and procedure from the manual in
accordance to the industry practices
 *Interpret manual according to the job requirement
 Correctly identify work steps in accordance with the
manufacturer specification
 *Apply manual data according to the given task
 Interpret all correct sequencing and adjustment in
accordance with the information contained on the
manual or specification
 *Store manual appropriately to ensure prevention of
damage, ready to access and updating of information
when required in accordance with the company
requirement
GLOSSARY OF TERMS

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Assessment the process of gathering and judging evidence in order to decide whether a
person has achieved a standard of competency or competence objective.
Automatic transmission a transmission in which gear ratios are changed automatically instead
of by hand or in a manual transmission.
Brake an energy conversion device used to slow, stop or hold a vehicle or
mechanism.
Clutch a coupling that connect and disconnect a shaft from its drive while the drive
mechanism is running.
Coolant the liquid mixture of about 50 percent antifreeze and 50 percent water used to
carry heat out of the engine.
Drive Line an assembly of one or more driveshafts, universal joints that forms the driving
connections.
Engine a machine that converts heat energy into mechanical energy.
Fuel any combustible substance.
Fuse a device that opens an electric current when excessive current flows, to protect
equipment in the circuit
Learning module a segment of a given body of skill for which a measurable learning objective
can be identified. The term is also used to describe a self-contained booklet
covering a specific item of skill or knowledge. (Vocational Training: Glossary
of Selected Terms, ILO)
Overdrive transmission gearing that causes the output shaft to overdrive or turn faster
than input shaft.
Speedometer a device on display in the instrument panel that shows the driver how fast the
vehicle is moving.
Trainer a person who directs the practices of skills towards immediate improvement in
some task.
Training a systematic process of the development of competencies required by an
individual to perform adequately in a given job or task.
technical training program for the purpose of acquiring and developing job-related skills (RA 7796 –
TESD Act of 1994)
Trainers/trainors - persons who provide training, to trainees aimed at developing the latter’s
capacities for imparting attitude, knowledge, skills and behavior patterns
required for specific jobs, tasks, occupations or group of related occupations
(RA 7796 – TESD Act of 1994)

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 - persons who direct the practice of skills towards immediate improvement in
some task (RA 7796 – TESD Act of 1994)
Training a process of the development of skills, related knowledge, attitudes and
behavior patterns required for the adequate performance of a given task or job.
Training center an establishment specialized in training people for skilled occupations, usually
comprised of classrooms and training workshops. Training centers generally exist outside the formal
education system and can be either privately or government funded. (Vocational Training: Glossary
of Selected Terms, ILO

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