Maintenance on faulty electrical tools in an automotive workplace should be

carried out by:

a. Qualified automotive mechanic.
b. Anybody.
c. A qualified automotive electrician.
d. A qualified electrician.
A good technician is a highly skilled and knowledgeable individual in regard
to vehicle repairs and modification. What does a professional technician
demonstrate?
a. The willingness to follow rules, regulations, and policies.
b. The willingness to fulfil the responsibilities of their job.
c. Assuming responsibility and accountability for your decisions and actions.
d. All the answers are correct
A simple reporting procedure will help you obtain important information
about health and safety issues in the workplace, identify problems when they
arise, and address them
a. True
b. False
You must have a process to record all injuries and incidents that occur at the
workplace like? Circle the correct answers
a. What issues to report – e.g. faulty equipment, hazardous spills, housekeeping issues, injuries, near
misses, general safety hazards, suggestions for improving processes etc.
b. How to report them – establish the process, at the very least, of verbally reporting issues to either
supervisors or management. Written reports of issues allow you to track and analyses trends. If possible,
have workers make suggestions about suitable control strategies.
c. Who to report issues to – issues should be reported to supervisors or management? You should
nominate someone to have authority to act upon the safety reports, such as yourself or a supervisor.
d. How are issues resolved – if there is a health and safety issue at the workplace, reasonable
efforts must be made to achieve a timely, final and effective resolution. Involve your workers in
developing an agreed written procedure for issue resolution or follow the default procedure set out
in the Work Health and Safety Regulation 2011.
A good workshop manual will cover different aspects of a vehicle, List 4
sections or chapters relation to vehicle servicing and repairs that covered by a
good workshop manual.
a. Repair Instructions.
b. Wiring diagrams
c. Specifications of torque
d. Filling of Capacities
e. Schedules for services.
Workshop manuals are also known as service manuals or repair manuals.
Many are available on CD or online.
a. True
b. False
Technicians need to be able to access a variety of information in order to
estimate and quote vehicle modifications and repair faults on vehicles. Name 7
most common sources of information you could access to assist to diagnose
and repair faults on vehicles?
a. Workshop manual
b. Vehicle owners hand book
c. Service tune-up guide
d. Standard times guide
e. Product guides
f. On the vehicle
g. Internet
What types of technical information can be found in workshop manuals? Fill
in the missing category and/or Definitions.
Category Definition

The features and construction of a component or a system are often described at the start of
Descriptions
a section as a means of introducing a component

Principles of operation The principles of operation of various components and systems are described – it is
necessary to know how things function before they can be properly serviced, particularly
when diagnosing problems

Maintenance and These are procedures that should be carried out at regular intervals to maintain the vehicle
service in a sound condition

Service adjustments Manuals include descriptions of how adjustments are carried out and when they should be
done

Tune-up procedures
It is the services that should be done periodically to maintain the efficiency of
engine.

These are the detailed descriptions and illustrations of both major and minor repairs. They
Repair operations include methods of dismantling, repairing, installing and adjusting the various components
and systems

Information is provided on special tools and equipment needed to service the

Special tools and particular model of vehicle
equipment

Technical data Technical data is a information that includes specifications, torque settings,
capacities (fuel, oil and coolant), sizes, wear limits, clearances and other
information needed during
servicing or repairs.

Wiring diagrams
The electrical wiring for the various parts of the vehicle shown by wiring diagram. The
color code for the wires and connections includes in the diagram for the all-electrical
components.
Name the 8 main sections of the parts catalogue?
a. Table of contents
b. Use of the catalogue
c. Cross-reference chart /identification for vehicle model
d. Identification number for vehicle (some catalogues only)
e. Clearly labelled illustrations
f. Information regarding warranty or supply
g. Part number index
h. Part name index

Using the table provided showing a section of a Flat Rate manual with
the labor times for the removal and installation of front brakes on a
vehicle, Answer the questions following.

Code W/G Description Time

3252211 00 02/02 Front brake disc rotor (one side) 0.6

(Additional operation)
Per 1 pc
0.1
Disc pad assembly remove and replace
0.1
32552211 89 02/02 Front brake disc(rotor) on vehicle grinding (both side) 1.4
Disc pad assembly replacement.
0.1

32552211 10 01/01 Front brake caliper removal and assembly (one side) 0.8
(Additional operation)
Wheel Assembly remove and install.
0.1
3253140 00 01/01 Brake air bleed
Per 1pc
0.4

3252227 00 01/01 Front brake disc caliper Slide pin remove and replace
Per1 pc
0.5

3252611 89 02/02 Rear brake disc removes and install (one side)
Rear brake caliper assembly remove and install (one side) 0.7

0.2
Rear brake pad assembly remove and install

0.1
 3252123 00 02/02 Rear Brake hose remove and install (one side)
0.8

a. How many minutes or hours does 0.6 in the time column mean? …36 Minutes …
b. If the front brake calipers must be removed to grind the disc how many minutes or hours does it
take to do each side? …132 minutes…
c. How long should it take to remove and replace the rear brake disc on each side and replace the
brake disc and pads remembering that the brake caliper must be removed to remove the
disc…….1 hour.…
d. When removing and replacing the rear brake hose on the left side it should take 48 minutes, but
the brakes need to be bled after replacement. How long should it take to bleed the braking
system? ……96 minutes …
e. To replace both front brake discs and brake pads where the brake caliper does not need to be
removed to access discs or the pads how many hours labor will the customer pay for?......84
Minutes.….
When estimating and quoting labor time for a vehicle modification, which
book should you refer to?
a. Textbook
b. Owner’s manual
c. Flat rate book
d. All the answers are correct

What 4 things should you look at when reading a flat rate book when
estimating and quoting labor time for a vehicle modification?
a. First look the vehicle and its model
b. Check on requirements for the repairs and select the correct operation
c. Read the time specified in the correct column
d. Add any items not specifically mentioned in the explanation of the operation
An estimate or quote presents the prices for parts and labor to a customer.
a. True
b. False

In 15-20 words define the difference between an estimate and a quote?

An estimate doesn't bind legally either of the party and A quote is legally binding documents.
In 20-30 words explain the principles of estimating?
Principles of estimating is all about having accurate knowledge of the direct costs of your resources - that
is your Workplace, Labor, Materials and your Subcontractor prices
Complete the following statement about “Mark-up” on parts using the
following words. Words: Associated, Expenses, Managers, Parts
Mark-ups are needed to cover the EXPENSES that a facility incurs to obtain or pick up part as well as
earn a profit from the sale. In some cases, the mark-up covers PARTS that must be prepaid before
delivery (such as engines) and cost to STORE them in the inventory, the time the parts specialist takes to
look up the parts and order them from a supplier, and the time MANAGERS or owners spend to make
arrangements with parts suppliers. In addition, the mark-ups must cover the work ASSOCIATED with
core returns or the proper disposal of old parts in accordance with local, state, and federal laws.
When estimating and quoting part replacement options for a customer
vehicle, what 3 parts options should you consider?
1. New parts
2. Reconditioned parts
3. Second hand parts
How much GST must be added to the total of the estimate or quote?
1. 5%
2. 10%
3. 15%
4. 20%

In 15-20 words explain the reason to use a specialization workshop instead of

carrying out repairs in general?
Specialization workshop carries out the repair job in less time with lower cost compare to general
workshop
All workshops will need to make use of subcontractors for specialized work.
How would the work to be carried out be listed on the estimate or quote?
Give 2 examples.
1. Having a cylinder head re-machined
2. Having brake drums or brake discs machined
Labor times are divided into 2 categories. What are they?
1. Times studied by the factory and used for warranty claims at new-car dealers.
2. Aftermarket labor times published in books sold to service facilities that are derived from the
factory times.
Referring to the Holden Labor Time Manual, locate the labor time to remove
and replace following components. Log the labor time next to each remove
and replace component. The first and last is completed for you.
20. Component Labor time

Holden VZ V6 Engine & Transmission Assembly 4.3

Holden WL GEN III Alternator Assembly 0.6

Holden VY GEN III Water Pump Assembly 1.3

 Holden VZ Horn & Bracket Assembly (L/H) 0.3

Holden WL V6 1, 3, 5 Exhaust Manifold 1.3

Holden VZ Climate Control Module Assembly .4

Referring to the Holden Labor Time Manual, Place the correct word to the
definition.
Choose from these definitions: Add, Adjust, Major Operations, Overhaul, Removal and
Reinstall, Replace, Straight Time
All operations allocated a labor operation number are classed as major operations.
Major Operations The time allowed indicated is sufficient to do the work described as a single complete
operation,

Additional time allowances which may be required for performing a major operation
Add or supplement a major operation are included in the “Add” section under the
“Operation Description” heading.

The term means to remove a major component or assembly, reinstall this assembly,
Removal and and make all necessary adjustments. Generally, this term is used to designate a major
reinstall operation and normally one or more of the adds listed below the major operation will
be necessary to complete the work.

When this term is used with a major operation, it means to take off a part or assembly
and put back a new part or assembly. This includes remove and reinstall and all
Replace necessary adjustments. When this term is used with an “Add” operation, it does not
include remove and reinstall, but only that work necessary to prepare a new part or
assembly for installation in the vehicle.

When this term is used with a major operation, it means to remove an assembly from
the vehicle, disassemble, clean and inspect all parts, rebuild the assembly with same
or new parts, reinstall the assembly in the vehicle and make all necessary adjustments.
Overhaul When this term is used with an “Add” operation, it does not include remove and
reinstall but only that work necessary to overhaul an assembly once it is removed
from the vehicle.

Adjust To bring the part described to an established standard for fit or performance.

Where the term is indicated in the labor time manual, the actual time taken to
Straight Time perform the repair should be entered on the warranty claim for consideration of
credit.
You must prepare an estimate for all modification, repair, and diagnostic
work and review the charges with the customer before a repair order is
prepared.
a. True
b. False

Before you present the customer with the estimate for a modification, a slight
margin should be added to the price of parts and labour. This will ensure that
costs will cover the charges and hopefully allow the invoice to be less than the
estimate
a. True
b. False

What are the 4 successful customer interactions during the estimate stage?
a. Greeting of the customer
b. TO obtain information from customer
c. Identify concerns from the customer
d. Confirm understanding

When you give an estimate, you should also point out any variations that may
occur and any items excluded from the estimate.
a. True
b. False

Under Vehicle Standards Bulletin (VSB) 14, list 3 of the 5 basic engine
mechanical modifications may be performed without certification,
providing the modifications are carried out in compliance with Australian
Design Rules (ADRs) requirements?
a. Fitting of the replacement, new, used or reconditioned engine
b. Fitting of the manufacturer's optional engine together with any associated components supplied
by the manufacturer for that same model vehicle
c. Fitting or replace mint of original equipment engine and exhaust components
d. Fitting or replacement of original equipment, equivalent or better, components that influence on
engine, performance or emissions (e.g. higher volume oil pump than original)
e. Fitting equivalent engines with an increase of up to 20% of original power.
Under Vehicle Standards Bulletin (VSB) 14, list 3 of the 5 engine mechanical
modifications that may be performed that WILL require certification under
LA codes?
a. Engine firring with greater than 120% of original power and/ or engine mass;
b. Fitting of the performance engines;
c. Fitting engines from non-original equipment sources;
d. Installing a supercharger or turbocharger; and
e. The engine modification and engine components that result in an increase in engine power of
more than 20% and/or affects exhaust emissions

Under Vehicle Standards Bulletin (VSB) 14, substitution or replacement of

engine components such as camshafts, carburetors, engine management
systems, exhaust systems, etc. must not be carried out unless it can be
demonstrated that the vehicle will continue to meet the appropriate gaseous
and noise emission standards.
a. True
b. False

Under Vehicle Standards Bulletin (VSB) 14, list 3 of the 5 basic body
modifications that may be performed WITHOUT certification, providing the
modifications are carried out in compliance with Australian Design Rules
(ADRs) requirements?
a. Bonnet scoops and projections
b. Bonnet Dins and mascots
c. Panel customization and replacement l
d. Modification of Inner mudguard, Glass and surface films.

Under Vehicle Standards Bulletin (VSB) 14, list 3 of the 5 body modifications
that may be performed will require certification under LH codes?
a. Vehicle conversation by removing or modifying the roof, e.g. convertible conversion; Vehicle
conversation by extending or reducing the wheelbase, e.g. stretched limousine;
b. Vehicle construction using at least the chassis or body from a production vehicle, e.
c. g. Holden station wagon body on a Landcruiser chassis
d. vehicle conversation to a different model variant, e.g. station wagon to utility conversion;
e. Tilt-fronts.
Complete the following statement about Vehicle Standards Bulletin (VSB) 14
Electrical System Modifications using the following words.
Words: 600mm, alternator, battery, boxes, conduit, electrical, enclosed, gel cell, grommets,
heat, noise, shielded
Electrical wires in wiring looms must be protected from mechanical damage by wrapping with tape or
enclosing them in CONDUIT or other covering. Looms must be supported on the vehicle at positions no
more than 600mm apart with allowance being made for the relative movement that can occur between the
engine/transmission and the body/chassis.
The replacement engine’s ALTERNATOR output rating and the battery capacity should be compatible
with the vehicle’s ELECTRICAL systems and the replacement engine.
Adequate protection from excessive HEAT should be provided for all electrical harnesses (and other
hose,
rubber and plastic components). All heat and NOISE insulation material as originally fitted should be
retained.
With some engine substitutions the BATTERY has to be relocated to the passenger or luggage
compartment. Unless a special kind of battery (e.g., a sealed GEL CELL) is used in these locations, the
battery must be fully ENCLOSED and the enclosure vented to outside the vehicle. Electrically insulated
enclosures such as sealed marine battery BOXES should be used. The battery must be securely fastened
to the vehicle. Battery cables must be SHIELDED where necessary to prevent damage from grommets
road debris and be secured to the body at a maximum spacing of 600mm. Rubber ROMMETS must be
fitted where cables pass through holes in body panels and chassis sections.