Technica Service Training Goba Fundamentas Curricuum Training TF1010016S Shop Practices Student Information FCS-13202-REF CG7972/S en 12/2001
Copyright 2001 Ford Motor Company
Introduction Preface Goba fundamentas training overview The goa of the Goba Fundamentas Training is to provide students with a common knowedge base of the theory and operation of automotive systems and components. The Goba Fundamentas Training Curricuum (FCS-13203-REF) consists of nine sef-study books. A brief isting of the topics covered in each of the sef-study books appears beow. Shop Practices (FCS-13202-REF) expains how to prepare for work and describes procedures for ifting materias and vehices, handing substances safey, and performing potentiay hazardous activities (such as weding). Understanding hazard abes, using protective equipment, the importance of environmenta poicy, and using technica resources are aso covered. Brake Systems (FCS-13201-REF) describes the function and operation of drum brakes, disc brakes, master cyinder and brake ines, power-assist brakes, and anti-ock braking systems. Steering and Suspension Systems (FCS-13196-REF) describes the function and operation of the powerassisted steering system, tires and whees, the suspension system, and steering aignment. Cimate Contro (FCS-13198-REF) expains the theories behind cimate contro systems, such as heat transfer and the reationship of temperature to pressure. The sef-study aso describes the function and operation of the refrigeration systems, the air distribution system, the ventiation system, and the eectrica contro system. Eectrica Systems (FCS-13197-REF) expains the theories reated to eectricity, incuding the characteristics of eectricity and basic circuits. The sef-study aso describes the function and operation of common automotive eectrica and eectronic devices. Manua Transmission and Drivetrain (FCS-13199-REF) expains the theory and operation of gears. The sef-study aso describes the function and operation of the drivetrain, the cutch, manua transmissions and transaxes, the driveshaft, the rear axe and differentia, the transfer case, and the 4x4 system. Automatic Transmissions (FCS-13200-REF) expains the function and operation of the transmission and transaxe, the mechanica system, the hydrauic contro system, the eectronic contro system, and the transaxe fina drive. The sef-study aso describes the theory behind automatic transmissions incuding mechanica powerfow and eectro-hydrauic operation. Engine Operation (FCS-13195-REF) expains the four-stroke process and the function and operation of the engine bock assemby and the vave train. Aso described are the ubrication system, the intake air system, the exhaust system, and the cooing system. Diese engine function and operation are covered aso. Engine Performance (FCS-13194-REF) expains the combustion process and the resuting emissions. The sef-study book aso describes the function and operation of the powertrain contro system, the fue injection system, the ignition system, emissions contro devices, the forced induction systems, and diese engine fue injection. Read Engine Operation before competing Engine Performance. To order curricuum or individua sef-study books, contact Hem Inc. To Free: 1-800-782-4356 (8:00 am 6:00 pm EST) Mai: 14310 Hamiton Ave., Highand Park, MI 48203 USA Internet: www.heminc.com (24 hours a day, 7 days a week) Service Training 1
Contents Introduction Introduction... 1 Preface... 1 Goba fundamentas training overview... 1 Contents... 2 Lesson 1 Genera guideines... 4 Overview... 4 Introduction... 4 Genera... 5 Objectives... 5 Hazards... 6 Hazards and accidents... 6 Prevention... 7 Prevention... 7 Protection... 8 Protection... 8 Keeping a cean shop... 8 Dressing appropriatey... 9 Shop toos... 10 Using hand toos... 10 Using compressed air... 10 Behavior... 11 Behaving appropriatey... 11 Handing materias... 12 Methods for ifting materias... 12 Lesson 2 Handing hazardous materias... 14 Genera... 14 Objective... 14 Substances... 15 Handing substances... 15 Refrigerant... 18 Handing air conditioning refrigerant... 18 Fues... 19 Handing fues... 19 Sovents and greases... 20 Handing sovents... 20 Handing ubricants and greases... 20 Handing chorinated fuorocarbons (CFC)... 21 Dusts... 22 Handing Viton... 22 Handing dusts... 22 Handing asbestos... 23 Handing fiber insuation... 23 2 Service Training
Introduction Contents Antifreeze... 24 Handing antifreeze... 24 Acids and akais... 25 Handing acids and akais... 25 Handing battery acids...25 Handing brake fuid... 25 Handing corrosion protection materias... 25 Handing paints... 25 Adhesives and seaers... 26 Handing adhesives and seaers... 26 Handing foams... 27 Lesson 3 Performing hazardous procedures... 28 Genera... 28 Objectives... 28 Weding... 29 Performing potentiay hazardous activities... 29 Weding... 29 Eectrica... 30 Sodering... 30 Eectrica work... 30 Symbos... 31 Hazard symbos... 31 Protective equipment... 34 Poicies... 36 Environmenta poicies...36 Lesson 4 Resources... 37 Genera... 37 Objective... 37 At a gance... 38 Technica resources... 38 Diagrams... 39 Wiring diagrams... 39 Manuas... 42 Workshop manuas... 42 Hotine... 46 Technica service hotine... 46 Service Training 3
Overview Lesson 1 Genera guideines Introduction Proper work preparation is essentia to perform work tasks and create a safe working environment. Toos and safety equipment are necessary to perform and compete many aspects of automotive shop work. Persona safety must remain paramount to every technician. Practicing proper work preparation prevents accidents from occurring to yoursef or to those around you. 4 Service Training
Lesson 1 Genera guideines Genera Objectives Upon competion of this esson, you wi be abe to: Describe potentia hazards and accidents that can occur in the workpace and how to prevent them. Describe proper ifting methods. Service Training 5
Hazards Lesson 1 Genera guideines Hazards and accidents A vehice workshop is potentiay a dangerous environment. For this reason it is important that you be famiiar with some of the common accidents that can occur in a workshop and what causes them. A of the accidents isted beow can, and do, happen in workshops: ACCIDENTS Cuts and skin abrasion Impact injuries Heart attack Back strains Poisoning Asphyxia Lung damage Burns Chemica burns Frost bite Skin irritation Eye damage Ear damage Eectric shock POSSIBLE CAUSES Defective or misused hand toos Being caught in machinery Heavy objects faing from above Faing over things eft ying around, or on sippery substances Air bags depoying incorrecty inside vehices Partices of hard substances from grinding work fying into eyes Exposion, CNG or LPG Air forced into the boodstream by compressed air machine Hand ifting Chemicas (for exampe: air conditioning refrigerant, exhaust fumes, fues, sovents, minera ois, paints, adhesives and seaers) entering bood through ungs, stomach or skin Carbon monoxide (contained in exhaust fumes) Dusts and powders, especiay asbestos dust Fires (compressed gases), moten meta, hot spashes Strong acids and akais corrosive substances Contact with air conditioning refrigerant Contact with fiber insuation, brake fuids, gasoine, sovents, minera oi High eve of UV radiation (arc weding) High eve of noise The human body cosing an eectrica circuit Heath and safety responsibiities As an empoyee you have three genera heath and safety responsibiities: 1. Take reasonabe care for your own heath and safety and that of others who may be affected by what you do (or fai to do). 2. Cooperate with your empoyer on heath and safety. 3. Don t interfere with or misuse anything provided for your heath, safety or wefare. 6Service Training
Lesson 1 Genera guideines Prevention Prevention Prevention means anticipating in order to stop dangerous events from happening. Once started, a dangerous event can get out of contro quicky, so the safe thing is not to et it start. Most dangerous events can be prevented if you: stay aware of what is happening around you. do not rush. avoid distraction. think ahead. use machinery and chemicas according to the instructions. never take short cuts on safety. Service Training 7
Protection Lesson 1 Genera guideines Protection Protection means guarding against the bad effects of an event which you can t prevent. When prevention fais, protection takes over in preserving your safety. Protection is necessary when a particuar hazard can t be prevented. For exampe, you can t prevent an air chise from making noise, therefore you have to protect yoursef against the noise by wearing ear muffs. Protection is aso needed to cover competey unpredictabe hazards. For exampe, you can t be absoutey sure that nothing hits your head whie working under a car (even if you took preventive actions), so it is safer to wear a safety hat. Most importanty, remember that nothing is too much troube when it comes to your safety! Use both prevention and protection to reduce risk. Keeping a cean shop Many accidents are caused by untidiness. Injuries caused by tripping, faing or sipping on things eft ying around are a too common in an untidy work area. It is our responsibiity to protect ourseves, and feow workers, by ensuring that a equipment, components and vehices are kept in a safe pace and in proper condition. Features of a cean workshop incude: Foor is cean and not sippery. Fire escape routes are not bocked. Easy access to a equipment without having to cimb over items not being used. Too storage is safe and easiy reached. Power outets such as eectricity and compressed air are ceary abeed and reguary checked. Extension cabes or hoses are put away after use or are suspended from the roof. Adequate ighting for the work to be undertaken. Good air quaity to maintain a comfortabe working environment. Fixed equipment or pant is maintained and in a safe condition. A personne working in the area have been trained to use the equipment and are aware of safety procedures. 8 Service Training
Lesson 1 Genera guideines Protection Dressing appropriatey Safety at work often begins before you arrive. When you eave home for work, are you propery equipped? Think about the type of cothing suitabe for the task ahead. Remember safety is your responsibiity, too. Here are some things to avoid: Here is a ist of things you shoud do: Remove jewery. Wear the approved type of work wear, overas, etc. Loose cuffs Wear safety footwear with toe crush preventers. Neckaces Tie up ong hair. Braceets Use the correct eye/hand/ear protection where Fared trousers necessary. Fashion shoes Do not rush into preparations for work. Give yoursef enough time to be safe. Tight skirts Loose ties Long hair Watches Rings Laces undone Rags hanging out of pockets Service Training 9
Shop toos Lesson 1 Genera guideines Using hand toos Many cuts and abrasions are caused by defective or misused hand toos. Keep toos in a cean condition. Never use a too you know to be defective. Most hand toos require some force to be appied by the operator such as puing, pushing or twisting aways ensure you have stabe footing. Make sure that your hand wi not be trapped if the too shoud sip or give way. Using compressed air In many workshops a compressed air suppy provides a convenient source of power to drive toos. It is safe if used correcty but misuse can be very dangerous, causing serious injury or death. Do not use compressed air to: bow fiings or swarf off a work bench. Aways use the correct size too for the job. remove dust from your cothing. Protect the edges of sharp toos when not in use. give someone a shock as a joke. Do not use a too with a oose hande. Do not use toos for inappropriate jobs. Do not use a punch or chise with a mushroomed head. Aways use a vise to hod oose items when using screwdrivers or knives. Never use cracked sockets. Never extend a too to gain extra everage. cean out partiay seaed objects such as ight units. remove dust from brake units. Remember, compressed air is not a toy. The pressure in a typica workshop may be over 700 kpa (100 psi or 6.9 bar). This is more than enough to force air through cothing and into the boodstream, which may cause death. Fooing around with an air ine may seem ike fun, but it can have tragic consequences. Never use power toos to drive hand use sockets. Do not eave toos under the hood use a too tabe. Remember Look after your toos and they wi ook after you. 10 Service Training
Lesson 1 Genera guideines Behavior Behaving appropriatey Many peope suffer serious injury through fooing around at work. Accidents happen when you are distracted, or through ack of concentration. You owe it to yoursef and your coeagues to act responsiby at a times in the workpace. When in the workpace: Wak, do not run. Do not wear persona stereos or wakmans. Be aware of what is happening around you. Drive carefuy. Operate machinery safey. Never cut corners on safety. If you are unsure about whether you are fit for work, consut your supervisor or medica adviser. Never work when unfit due to acoho or drugs; you are putting yoursef and others at risk. Service Training 11
Handing materias Lesson 1 Genera guideines Methods for ifting materias It is necessary to ift toos, items, and materias whie working in the shop. It is important to adhere to proper safe ifting procedures. Manua ifting It is part of everyday ife to ift objects from the foor or workbench. The method used when ifting is important to hep reduce the risk of back injury. The key eements: Do not try to ift too much weight. 20 kg is a safe imit for one person. 3 1 2 When ifting from the foor keep the feet sighty apart, knees bent, and back straight. Your eg musces shoud provide the power to raise the oad. Do not jerk objects. When carrying a oad, keep it cose to your body. SHO001-A/VF Method for proper ifting 1 Object not more than 20 kg hed cose to body 2 Back straight 3 Knees bent 12 Service Training
Lesson 1 Genera guideines Handing materias Lifts and cranes For objects of more than 20 kg it is recommended to use a ifting device such as a mobie crane, or jack. Specific training shoud be given for each piece of equipment, but there are severa rues which are common sense. Never exceed the safe working oad (SWL) of the equipment you are using. Aways support vehices with axe stands before working underneath them. There is aways a danger when oads are ifted or suspended. Never work under an unsupported, suspended or raised oad such as a suspended engine. Aways ensure that ifting equipment such as jacks, hoists, axe stands, sings, etc. are adequate and suitabe for the job, in good condition and reguary maintained. Never improvise ifting tacke. Service Training 13
Genera Lesson 2 Handing hazardous materias Objective Upon competion of this esson, you wi be abe to: Expain the various methods of safey handing hazardous materias. 14 Service Training
Lesson 2 Handing hazardous materias Substances Handing substances Chemica materias don ts For heath and safety reasons it is necessary to hande substances safey using the appropriate equipment. Mishanding substances can resut in heath and environmenta hazards. Handing chemicas The production and maintenance of motor vehices invoves the use of some potentiay hazardous substances. This is a brief guide to some of the materias which might be encountered during work on a vehice. Chemica materias such as sovents, seaers, adhesives, paints, resin foams, battery acids, antifreeze, brake fuids, fues, ois and grease shoud aways be used with caution and stored and handed with care. They may be toxic, harmfu, corrosive, an irritant, highy fammabe or give rise to hazardous fumes and dusts. The effects of excessive exposure to chemicas may be immediate or deayed, briefy experienced or permanent, cumuative, ife threatening, or may reduce ife expectancy. Do not mix chemica materias except under the manufacturer s instructions; some chemicas can form other toxic or harmfu chemicas, give off toxic or harmfu fumes or become exposive when mixed together. Do not spray chemica materias, particuary those based on sovents, in confined spaces, such as when peope are inside a vehice. Do not appy heat or fame to chemica materias except under the manufacturer s instructions. Some materias are highy fammabe and some may reease toxic or harmfu fumes. Do not eave containers open. Fumes given off can buid up to toxic, harmfu or exposive concentrations. Some fumes are heavier than air and accumuate in confined areas, pits, etc. Do not transfer chemica materias to unabeed containers. Do not cean hands or cothing with chemicas. Chemicas, particuary sovents and fues, dry the skin and may cause irritation eading to dermatitis or be absorbed through the skin in toxic or harmfu quantities. Do not use emptied containers for other materias except when they have been ceaned under supervised conditions. Do not sniff or sme chemica materias. Brief exposure to high concentrations of fumes can be toxic or harmfu. Service Training 15
Substances Lesson 2 Handing hazardous materias Handing substances (continued) Chemica materias do s Do carefuy read and observe hazard and Do wash before job breaks, before eating, precaution warnings given on materia containers smoking, drinking or using the toiet faciities (abes) and in any accompanying eafets, posters when handing chemica materias. or other instructions. Materia heath and safety data sheets can be obtained from manufacturers. Do keep work areas cean, uncuttered and free of spis. Do remove chemica materias from the skin and cothing as soon as practicabe after soiing. Change heaviy soied cothing and have it Do store chemica materias according to nationa and oca reguations. ceaned. Do keep chemica materias out of reach of Do organize work practices and protective cothing chidren. to avoid soiing of the skin and eyes; breathing vapors, aerosos, dusts or fumes; inadequate container abeing; fire and exposion hazards. 16Service Training
Lesson 2 Handing hazardous materias Substances Handing exhaust fumes Exhaust fumes contain asphyxiating, harmfu and toxic chemicas and partices such as carbon oxides, nitrogen oxides, adehydes, ead and aromatic hydrocarbons. Engines shoud be run ony under conditions of adequate exhaust extraction or genera ventiation and not in confined spaces. 1 2 With gasoine engines, there may not be adequate warning of odor or irritation before toxic or harmfu effects arise. These may be immediate or deayed. SHO002-A/VF With diese engines, soot, discomfort and irritation usuay give adequate warning of hazardous fume concentrations. Exhaust fume extraction 1 Roof-mounted extraction fan 2 Exhaust fume extraction hose attached to outet of vehice Service Training 17
Refrigerant Lesson 2 Handing hazardous materias Handing air conditioning refrigerant Air conditioning refrigerant is highy fammabe and combustibe. Aways observe no smoking poicies. Any skin contact may resut in frostbite. Instructions given by the manufacturer must be foowed. Avoid naked ights, wear suitabe protective goves and gogges. If refrigerant comes into contact with the skin or eyes, rinse the affected areas with water immediatey. Eyes shoud aso be rinsed with an appropriate irrigation soution and shoud not be rubbed. Seek medica assistance if necessary. Loca reguations may require that technicians be certified to repair or hande air conditioning refrigerant. Air conditioning fuid do not s Do not expose refrigerant bottes to sunight or heat. When fiing, foow manufacturer s recommendations. Do not expose refrigerant bottes to frost. Do not drop refrigerant bottes. Do not vent refrigerant to the atmosphere under any circumstances. Do not mix refrigerants (R12 and R134A). 18 Service Training
Lesson 2 Handing hazardous materias Fues Handing fues Avoid skin contact with fue. Shoud contact occur, wash the affected skin with soap and water. Fue is highy fammabe. Aways observe no smoking signs. Swaowing fue can resut in mouth and throat irritation and absorption from the stomach can resut in drowsiness and unconsciousness. Sma amounts can be fata to chidren. Aspiration of iquid into the ungs through vomiting, for exampe, is a very serious hazard. Observe strict fire safety precautions when storing and handing fammabe materias or sovents, particuary near eectrica equipment or weding processes. Before using eectrica or weding equipment, ensure that there is no fire hazard present. Have a suitabe fire extinguisher avaiabe when using weding or heating equipment. Gasoine dries the skin and can cause irritation and dermatitis on proonged or repeated contact. Liquid gasoine in the eye causes severe irritation. Gasoine may contain appreciabe quantities of benzene, which is toxic upon inhaation, and the concentration of gasoine vapors must be kept very ow. High concentrations cause eye, nose and throat irritation, nausea, headache, depression and symptoms of drunkenness. Very high concentrations resut in rapid oss of consciousness. Long term exposure to high concentrations can cause cancer. Service Training 19
Sovents and greases Handing sovents Lesson 2 Handing hazardous materias Handing ubricants and greases Sovents incude acetone, white spirit, touene, xyene, and trichoroethane. Sovents are primariy used in ceaning and dewaxing materias, paints, pastics, resins, thinners, etc. Some may be highy fammabe. Skin contact degreases the skin and may resut in irritation and dermatitis foowing repeated or proonged contact. Some sovents can be absorbed through the skin in toxic or harmfu quantities. Spashes in the eye may cause severe irritation and coud ead to oss of vision. Brief exposure to high concentrations of vapors or mists causes eye and throat irritation, drowsiness, dizziness, headaches and, in the worst circumstances, unconsciousness. Repeated or proonged exposure to excessive but ower concentrations of vapors or mists, for which there might not be adequate warning indications, can cause more serious toxic or harmfu effects. Avoid a proonged and repeated contact with minera ois. A ubricants and greases may be irritating to the eyes and skin. Proonged and repeated contact with minera oi can resut in the remova of natura fats from the skin, eading to dryness, irritation and dermatitis. Used engine oi precautions In addition, used engine oi contains potentiay harmfu contaminants which may cause skin cancer. Adequate means of skin protection and washing faciities must be provided. Do not empoy used engine ois as ubricants or for any appication where appreciabe skin contact is ikey to occur. Dispose of used oi and used fiters through authorized waste disposa sites, or to the waste oi recamation trade. If in doubt, contact the reevant oca authority for advice on disposa faciities. It is iega to pour used oi onto the ground, down sewers or drains, or into water courses. If oi finds its way into a river, the effects can be devastating to fish and other creatures. If the river provides fresh water for human consumption, the suppy may be contaminated for a considerabe time. One iter (0.26 gaon) of oi can contaminate five miion iters (1,320,000 gaons) of water! 20 Service Training
Lesson 2 Handing hazardous materias Sovents and greases Heath protection precautions Handing chorinated fuorocarbons (CFC) Avoid proonged and repeated contact with ois, particuary used engine ois. Wear protective cothing, incuding impervious goves when practicabe. Do not put oiy rags into pockets. Avoid oi-contaminated cothes, particuary underpants and footwear. First aid treatment shoud be obtained immediatey for open cuts and wounds. Use barrier creams, appying them before each work period, to hep the remova of oi from the skin. Wash with soap and water to ensure a oi is removed (skin ceansers and nai brushes hep). Preparations containing anoin repace the natura skin ois which have been removed. There is concern in the scientific community that CFCs and Haons are depeting the upper ozone ayer, which fiters out harmfu utravioet radiation. Decreased fitration of utravioet radiation may resut in increases in skin cancer, cataracts and immune system suppression in humans, as we as decreased productivity of crops and aquatic systems. CFCs are used primariy as refrigerants (R12) in vehice air conditioning systems and as aeroso propeants. Haons are used as fire extinguishers. Automotive manufacturers support wordwide eimination of CFC usage and its use is being phased out as acceptabe substitutes are commerciay avaiabe. Do not use gasoine, kerosene, diese fue, thinners or sovents for ceaning skin. If skin disorders deveop, obtain medica advice without deay. Where practica, degrease components prior to handing. Where there is a risk of eye contact, eye protection such as chemica gogges or face shieds shoud be worn. In addition, an eye wash faciity shoud be provided. Service Training 21
Dusts Handing Viton Lesson 2 Handing hazardous materias Handing dusts Some components fitted to vehices have O-rings, seas or gaskets which contain a materia known as Viton. Viton is a fuoroeastomer, a synthetic rubber type which contains fuorine. It is commony used for O-rings, gaskets and seas of a types. Athough Viton is the most we known fuoroeastomer, there are others, incuding Fuore and Tecmofon. When used under design conditions, fuoroeastomers are perfecty safe. If, however, they are exposed to temperatures in excess of 400 C (752 F), the materia does not burn, but decomposes, and one of the products formed is hydrofuoric acid. Powder, dusts or couds may be irritating, harmfu or toxic. Avoid breathing dusts from powdery chemica materias or those arising from dry abrasion operations. Wear respiratory protection if ventiation is inadequate. Fine dusts of combustibe materia are present an exposion hazard. Avoid exposive imits and sources of ignition. Do not use compressed air to remove dust from surfaces or fabrics. Inquiries shoud be made to determine whether Viton or any other fuoroeastomer has been used in the affected O-ring, sea or gasket. If they are of natura rubber or nitrie there is no hazard. If in doubt, be cautious and assume that the materia may be Viton or any fuoroeastomer. If Viton or any other fuoroeastomer has been used, the affected area shoud be decontaminated before the start of work. Disposabe heavy duty pastic goves shoud be worn at a times, and the affected area washed down using wire woo and a imewater (cacium hydroxide) soution to neutraize the acid before disposing of the decomposed Viton residue and fina ceaning of the area. After use, the pastic goves shoud be discarded carefuy and safey. 22 Service Training
Lesson 2 Handing hazardous materias Dusts Handing asbestos Breathing asbestos dust may cause ung damage or, in some cases, cancer. Asbestos is used in brake and cutch inings, transmission brake bands and gaskets. Most origina production and repacement items today, however, are asbestos-free. 1 2 3 The use of drum ceaning units, vacuum ceaning or damp wiping is preferred. Asbestos dust waste shoud be dampened, paced in a seaed container and marked to ensure safe disposa. If any cutting or driing is attempted on materias containing asbestos, the item shoud be dampened and ony hand toos or ow speed power toos used. Handing fiber insuation Fiber insuation is used in noise and sound insuation. The fibrous nature of surfaces and cut edges can cause skin irritation. This is usuay a physica and not a chemica effect. Precautions shoud be taken to avoid excessive skin contact through carefu organization of work practices and the use of goves. SHO004-A/VF Asbestos handing equipment 1 Brake ceaning hood which contains integrated goves and vacuum hose 2 Vacuum pump powered by eectrica suppy 3 Fiter/trap assemby Service Training 23
Antifreeze Lesson 2 Handing hazardous materias Handing antifreeze Antifreeze is highy fammabe and combustibe. Antifreeze is used in vehice cooing systems, brake air pressure systems, and screenwash soutions. Vapors may be given off from cooant (antifreeze) when heated. Avoid breathing these vapors. Antifreeze may be absorbed through the skin in toxic or harmfu quantities. Antifreeze, if swaowed, can be fata and medica attention shoud be sought immediatey. Antifreeze must not be used in any cooing or industria water system which is connected or inked to genera food preparation or drinking water suppies. 24 Service Training
Lesson 2 Handing hazardous materias Acids and akais Handing acids and akais Acids and akais incude caustic soda or sufuric acid and are used in batteries and ceaning materias. Acids and akais are irritating and corrosive to the skin, eyes, nose and throat and can cause burns and destroy ordinary protective cothing. You shoud avoid spashes to the skin, eyes and cothing. Wear a suitabe protective impervious apron, goves and gogges. Do not breathe mists. Ensure that eyewash bottes, shower and soap are readiy avaiabe for spashing accidents. Eye Hazard signs shoud aso be dispayed where appropriate. Handing battery acids Gases reeased during battery charging are exposive. Never use naked fames or aow sparks near charging or recenty charged batteries. Aways ensure adequate ventiation. Aways foow oca reguations and poicies when charging or handing batteries. Handing brake fuid Handing corrosion protection materias Corrosion protection materias are varied, and the manufacturer s instructions shoud be foowed. They may contain sovents, resins, petroeum products, etc. They are usuay highy fammabe and any no smoking poicies shoud be observed. Skin and eye contact shoud be avoided. They shoud ony be sprayed in conditions of adequate ventiation and not in confined spaces. Handing paints Paints can contain harmfu or toxic pigments, dryers and other components as we as sovents. The manufacturer s instructions shoud be foowed. Any spraying shoud preferaby be carried out in exhausted ventiated booths removing vapor and spray mists from the breathing zone. Individuas working in booths shoud wear appropriate respiratory protection. Those doing sma scae repair work in the open workshop shoud wear air-fed respirators. Spashes to the skin and eyes are sighty irritating. Avoid skin and eye contact. Vapor inhaation hazards do not arise at ambient temperatures because of the very ow vapor pressure. Service Training 25
Adhesives and seaers Handing adhesives and seaers Lesson 2 Handing hazardous materias Anaerobic and cyanoacryate (super-gues) Adhesives and seaers shoud generay be stored in no smoking areas. Ceaniness and tidiness in use shoud be observed, for exampe: disposabe paper covering benches; adhesives and seaers shoud be dispensed from appicators where possibe; containers, incuding secondary containers, shoud be abeed appropriatey. Water-based adhesives/seaers Water-based adhesives and seaers that are based on poymer emusions and rubber atexes may contain sma amounts of voatie, toxic and harmfu chemicas. Skin and eye contact shoud be avoided and adequate ventiation provided during use. Isocyanate (poyurethane) adhesives/seaers Individuas suffering from asthma or respiratory aergies shoud not work with or near these materias as sensitivity reactions can occur. Many acryic adhesives are irritating, sensitizing or harmfu to the skin and the respiratory tract. Some are eye irritants. Skin and eye contact shoud be avoided and the manufacturer s instructions foowed. Cyanoacryate adhesives (super-gues) must not contact the skin or eyes. If skin or eye tissue is bonded, cover with a cean moist pad and seek immediate medica attention. Do not attempt to pu tissue apart. Use in we ventiated areas, as vapors can cause irritation to the nose and eyes. Resin-based adhesives and seaers Resin-based adhesives and seaers incude epoxide and formadehyde resin-based adhesives and seaers. Mixing shoud be carried out in we ventiated areas, as harmfu or toxic voatie chemicas may be reeased. Overexposure to isocyanate adhesives and seaers is irritating to the eyes and respiratory system. Excessive concentrations may produce effects on the nervous system, incuding drowsiness. In extreme cases, oss of consciousness may resut. Long term exposure to vapor concentrations may resut in adverse heath effects. Proonged contact with the skin may have a defatting effect which may ead to skin irritation and, in some cases, dermatitis. 26Service Training
Lesson 2 Handing hazardous materias Adhesives and seaers Handing foams Foams are used for sound and noise insuation. Cured foams are used in seat and trim cushioning. Cured components are irritating and may be harmfu to the skin and eyes. Individuas with chronic respiratory diseases, asthma, bronchia medica probems, or histories of aergic diseases shoud not work with or near uncured materias. Aways wear goves and gogges. Skin contact with uncured resins and hardeners can resut in irritation, dermatitis, and absorption of toxic or harmfu chemicas through the skin. Spashes can damage the eyes. Any spraying shoud preferaby be carried out in exhaust ventiated booths, removing vapors and spray dropets from the breathing zone. Hot met adhesives Vapors and spray mists must not be inhaed. These materias must be appied with adequate ventiation and respiratory protection. Do not remove the respirator immediatey after spraying. Wait unti the vapors/mists have ceared. Burning of the uncured components and the cured foams can generate toxic and harmfu fumes. Smoking, naked fames or the use of eectrica equipment during foaming operations before vapors/ mists have ceared shoud not be aowed. Any heat cutting of cured foams or partiay cured foams shoud be conducted with extraction ventiation. Passive restraint systems Foow manufacturer s recommendations when handing passive restraint system components. In the soid state, hot met adhesives are safe. In the moten state they may cause burns, and heath hazards may arise from the inhaation of toxic fumes. Use appropriate protective cothing and a thermostatcontroed heater with a therma cut-out and adequate extraction. The components, vapors or spray mists can cause direct irritation, sensitivity reactions and may be toxic or harmfu. Service Training 27
Genera Lesson 3 Performing hazardous procedures Objectives Upon competion of this esson, you wi be abe to: Expain how to correcty perform potentiay hazardous activities. Expain the purpose of hazard abes. Expain the purpose of the environmenta poicy. 28 Service Training
Lesson 3 Performing hazardous procedures Weding Performing potentiay hazardous activities In order to accompish certain repair tasks, it may be necessary to perform potentiay hazardous activities. Proper safety equipment must be used when performing potentiay hazardous activities. Weding Weding processes incude resistance weding (spot weding), arc weding and gas weding. Resistance weding Resistance weding may cause partices of moten meta to be emitted at a high veocity, and the eyes and skin must be protected. Arc weding Arc weding emits a high eve of utravioet radiation which may cause arc-eye and skin burns to the operator and to peope nearby. Gas-shieded weding processes are particuary hazardous in this respect. Persona protection must be worn, and screens must be used to shied other peope. Contact ens wearers are advised to revert to ordinary spectaces when arc weding as the arc spectrum is beieved to emit microwaves which dry out the fuid between the ens and the eye. This may resut in bindness when the ens is removed from the eye. Meta spatter may aso occur and appropriate eye and skin protection is necessary. The heat of the weding arc produces fumes and gases from the metas being weded, the rods and any appied coatings or contamination on the surfaces being worked on. These gases and fumes may be toxic and inhaation shoud be avoided. The use of extraction ventiation to remove the fumes from the working area may be necessary, particuary in cases where the genera ventiation is poor, or where considerabe weding work is anticipated. In extreme cases or confined spaces where adequate ventiation cannot be provided, air-fed respirators may be necessary. Oxy-acetyene torches may be used for weding and cutting, and specia care must be taken to prevent the risk of fire and exposion. The weding process produces meta spatter and eye and skin protection is necessary. The fame is bright, and eye protection shoud be used. But the utravioet emission is much ess than from arc weding, and ighter fiters may be used. The weding process itsef produces few toxic fumes, but such fumes and gases may be produced from coatings on the work, particuary during cutting away of damaged body parts. Inhaation of the fumes shoud be avoided. In brazing, toxic fumes may be produced from the metas in the brazing rod, and a severe hazard may arise if brazing rods containing cadmium are used. If rods containing cadmium are used, particuar care must be taken to avoid inhaation of fumes and expert advice may be required. Specia precautions must be taken before any weding or cutting takes pace on vesses which have contained combustibe materias (for exampe, boiing or steaming out of fue tanks). Service Training 29
Eectrica Sodering Lesson 3 Performing hazardous procedures Eectrica work Soders are mixtures of metas with the meting point of the mixture beow that of the constituent metas (normay ead and tin). Soder appication does not normay produce toxic fumes, provided a gas/air fame is used. Oxy-acetyene fames shoud not be used, as they are much hotter and wi cause ead fumes to be produced. To prevent eectric shock when working on automotive eectrica systems, aways check a wires, cabes and connectors for cuts, corrosion or scrapes in the insuation. Due to the risk of eectric shock, when working with automotive eectrica equipment aways refer to the appropriate workshop manua for the vehice that you are working on. Fumes may be produced by the appication of a fame to surfaces coated with grease, etc. Inhaation of these fumes shoud be avoided. Remova of excess soder shoud be undertaken with care to ensure that fine ead dust is not produced, which can have toxic effects if inhaed. Respiratory protection may be necessary. Soder spiage and fiings shoud be coected and removed prompty to prevent genera air contamination by ead. High standards of persona hygiene are necessary to avoid ingestion of ead or inhaation of soder dust from cothing. 30 Service Training
Lesson 3 Performing hazardous procedures Symbos Hazard symbo Decas showing warning symbos can be found on various vehice components, fuid containers, workshop areas, and on most hazardous areas or materias. These symbos are warnings which must be carefuy foowed. Interpreting some basic warning symbos Components or assembies dispaying either version of the safety aert symbo indicates a potentia injury hazard. SHO005-B/VF Safety aert symbo aternate versions An open book symbo means to consut the reevant section of the owner handbook before touching or attempting adjustments of any kind. SHO019-A/VF Owner handbook reference symbo Service Training 31
Symbos Lesson 3 Performing hazardous procedures Hazard symbos (continued) Vehices and repacement parts which contain asbestos are identified by this symbo. SHO006-A/VF Asbestos warning symbo Components or assembies dispaying the warning triange with the eectrified arrow and open book symbo give warning of inherent high votages. Never touch these with the engine running or the ignition switched on. SHO020-A/VF High votage symbo 32 Service Training
Lesson 3 Performing hazardous procedures Symbos Components or assembies dispaying this symbo give warning that the component contains a corrosive substance. SHO007-A/VF Corrosive substance symbo Vehices dispaying the prohibition symbo (red circe and sash) with ighted match symbo caution against the use of naked ights or fames within the immediate vicinity, due to the presence of highy fammabe or exposive iquids or vapors. SHO008-B/VF Fire hazard symbo Vehices dispaying this symbo (normay in conjunction with the above symbo) warn of the presence of potentiay exposive matter within the immediate vicinity. SHO009-A/VF Exposive hazard symbo Service Training 33
Symbos Lesson 3 Performing hazardous procedures Protective equipment Whatever you need to do your job safey can be obtained. A you have to do is wear it or use it correcty. In some regions, you are egay obiged to do so. Head protection Head protection is advisabe when working under a vehice on a ramp. Head protection prevents injury from faing toos or objects. SHO010-B/VF Head protection symbo Eye protection Eye protection is advisabe when working in an area with fying sparks or dust from grinding/driing operations. SHO011-B/VF Eye protection symbo Ear protection Use of ear protection is advisabe when working in a noisy environment. If you have to shout to be heard by someone standing three meters away, it may be too noisy for unprotected ears. SHO012-B/VF Ear protection symbo 34 Service Training
Lesson 3 Performing hazardous procedures Symbos Hand protection Use the correct type of gove to prevent cuts or burns when handing materias which are sharp, hot, cod or chemica substances. SHO013-B/VF Hand protection symbo Foot protection Footwear shoud be practica for the type of work being undertaken. The soes shoud be non-sip and the toes shoud be protected by an anti-crush cap. SHO014-B/VF Foot protection symbo Respiratory protection Some work creates dust or invoves the use of materias giving off fumes. The correct type of face mask shoud be used to prevent the dust or fumes from being inhaed. SHO015-B/VF Respiratory protection symbo Service Training 35
Poicies Lesson 3 Performing hazardous procedures Environmenta poicies Automobies are designed to have minima impact on the environment. The vehice itsef must be fue efficient, abe to operate within the specified imits for emission of poutants, and abe to deiver driving satisfaction to the user. Consideration is not ony given to specific assemby or production sites, but aso to the externa environment. The community and surrounding andscape are important parts of the faciity in any operation. Strategies to minimize impact on environment It is important that automobie manufacturing operations, products, and services accompish their functions in a manner that provides responsibiity for protection of heath and for the care of our environment. A products, services, processes and faciities are panned and operated to avoid or minimize the production of waste. Any waste which is produced shoud have the minimum impact on heath and environment. Standards to meet and exceed ega requirements Heath and environment shoud be considered in every business decision. Potentia effects on heath and environment as we as future egisation must be a part of the panning process. Shared responsibiity The protection of heath and environment is the responsibiity of everyone. A empoyees have to carry out their own assignments within the genera poicy outine. The adoption of aws and good practice is in the company s interest. Everyone concerned must be kept informed as new ideas or information is made avaiabe. To prevent the waste of resources manufacturers have, severa initiatives have been taken where savings are produced by cutting out waste and at the same time heping to stop poution. These initiatives incude reducing waste water and energy waste. 36Service Training
Lesson 4 Resources Genera Objective Upon competion of this esson, you wi be abe to: Expain the purpose of using technica resources. Service Training 37
At a gance Lesson 4 Resources Technica resources Technica resources provide the technician with the information about vehices and vehice systems. Technica resources assist in the diagnosis and competion of the repair process. 38 Service Training
Lesson 4 Resources Diagrams Wiring diagrams Wiring diagrams are avaiabe to technicians for assistance in diagnosis and repair of automotive eectrica systems. Wiring diagrams provide the foowing: Fuse and reay information Power distribution In genera, wiring diagrams are presented in the foowing format: Components that work together are shown together. A components used in a specific system are shown in one diagram. Fuse detais Ground distribution Component ocation charts Circuit breakers, fuses, etc., are shown at the top of the page. A wires, connectors, components, and spices are shown in the fow of current to ground. Component ocation views Ground is shown at the bottom of the page. Connector views Wiring diagrams are provided in severa different formats, depending on manufacturer: Workshop manua If a component is used in severa systems, it is shown in severa paces. Schematic pages contain references to fu-view iustrations and description notes for various components. On-ine (internet) If the power suppy or ground connection is Microfiche represented by a dashed ine, the fu representation can be found in one of the foowing CD-Rom sections: Power distribution Fuse detais Ground distribution Service Training 39
Diagrams Lesson 4 Resources Wiring diagrams (continued) O1 Battery 30 N278 Ignition switch 0 1 2 3 0)Off 1)Acc 1 C456 2)Run 3)Start P93 G1 Battery Junction Box (BJB) 30 F9 20A V33 Diode 30-RH10 2.5 RD 3 1 15-RH9 2.5 GN/BU C1008 K13 Power hod reay 4 5 2 S117 30 91-DA4 F12 15A C1008.75 BK/GN S118 G1 15-RH6 1 GN/BU 30-RH6 1 RD 1 3 C1007 K4 Fue pump reay 2 5 4 C1007 not used 15-RP3 1 GN/OG 91-RH5.75 BK/BU 7 C80 15-RP3 1 GN/OG S118 2 C933 N61 Inertia Fue Shutoff G1 (IFS) switch 2 1 1 C933 1)Norma 2)Post impact 15S-RE31 1 GN/OG 9 C731 A195 Fue pump driver modue 2 10 3 1 7 C731 31-RE31 1 BK 31-RG2 1 BK 15-RE16.75 GN/BK 15S-RG2 1 GN/OG 31S-RE32.75 BK/WH S81 1 5 C732 1 A31 Fue tank unit 1)Fue pump 54 40 C415 A147 Powertrain Contro Modue (PCM) G54 SHO017-A/VF Sampe wiring diagram 40 Service Training
Lesson 4 Resources Diagrams A B C D E F 5 C91 Y134 C900 Y134 C900 5 4 4 12A522 3 N75 C692 12A522 N75 C692 3 2 9H589 CVH C92 9H589 C90 ZETEC E 2 1 VFE700025118 A B C D E F 1 Engine compartment, RH side, rear 12A522................................. C 4 12A522.................................. F 3 9H589.................................. A 2 9H589.................................. D 2 C90.................................... D 2 C91.................................... A 5 C92.................................... C 2 C692................................... C 3 C692.................................... F 3 C900................................... C 5 C900.................................... F 5 N75.. A/C compressor cycing switch....... C 3 N75.. A/C compressor cycing switch........ F 3 Y134. EVAP canister purge vave........... C 5 Y134. EVAP canister purge vave............ F 5 SHO018-A/VF Sampe of component ocation information Location indexes are usuay provided to hep ocate the foowing items: Components Spices Connectors Grounds Service Training 41
Manuas Lesson 4 Resources Workshop manuas The workshop manua is a step-by-step guide that may be avaiabe in print form, CD-Rom, DVD or microfiche, that assists the technician in performing the foowing activities to service customers vehices and components: Diagnosis and testing Remova and instaation Disassemby and assemby Ceaning and inspection Adjustments Specifications Specia service toos/equipment Individua components genera procedures and description and operation 42 Service Training
Lesson 4 Resources Manuas REMOVAL AND INSTALLATION (Continued) 3. Remove the top two starter motor bots. 4. Raise and support the vehice. For additiona information, refer to Section 100-02. 5. NOTE: A protective cap is instaed over the B-termina and must be repaced after servicing the starter motor and soenoid assemby. Disconnect the (A) S-termina wire, and the (B) B-termina nut and cabe from the starter motor. 6. Remove the ower starter motor bot and remove the starter motor and soenoid assemby. Sampe of component remova procedures Service Training 43
Manuas Lesson 4 Resources Workshop manuas (continued) The foowing section provides a typica exampe of how a workshop manua can be used to assist in diagnosing and repairing a vehice: 1. Review the repair order received with the vehice. 2. Obtain the vehice workshop manua. 3. Go to the Tabe of Contents at the beginning of the manua. 4. Seect the appropriate group based on the symptom. 6. Conduct the Inspection and Verification procedures: If inspection reveas concern, service as required. If inspection does not revea concern, proceed with next step. 7. Determine symptom of concern and go to the Symptom Chart. 8. If the Symptom Chart directs it, go to the Pinpoint Tests. 5. From the Group Tabe of Contents choose the appropriate section. 44 Service Training
Lesson 4 Resources Manuas Diagnostic and testing manuas Diagnostic and testing manuas cover vehice system diagnosis, testing procedures, component iustrations, technica iustrations, and detais of specia toos and equipment that may be used. Some manuas may be divided into subsections such as: 5. Locate the suspected category from the index at the beginning of each subsection. 6. Locate the specific diagnosis and testing page by using the subsection index. Genera information Chassis Powertrain Eectrica Body and paint 7. Conduct an inspection and verification. The visua inspection charts hep identify system components. 8. If inspection reveas a concern, service as required. If inspection does not revea a concern, proceed to the symptom chart. This eads the diagnosis from condition, to possibe sources, to action. 1. Use the information about the vehice driveabiity or emission concern, from the service write-up, to verify/recreate the symptom. 2. Diagnosis and testing manuas can be consuted to aid in diagnosis. 3. Locate the diagnosis and testing manua voume for your vehice from the workshop s reference area. 9. Go to pinpoint test if directed from the symptom chart. Pinpoint tests are used to identify the source of an eectrica concern in a ogica, step-by-step manner. 10. Go to component test if directed from a pinpoint test. Component tests are used to test a compete component, as opposed to a portion of a component or wiring. 4. Locate the subsection number in the Tabe of Contents. Service Training 45