prinCiples ofligHt VeHiCleteCHnology

A LWAY S L E A R N I NG

HEINEMANNWork-Based Learning

Level 3

Diploma

2

Authored by Graham Stoakes and moulded around the 2010 specification, these resources are designed to continue seamlessly from levels 1 and 2 and pave your learners’ way to successful careers in the automotive industry.

introduCtion

We’Ve made eValuation easy for you WitH tHis resourCe guidestep 1: Take a look at the sample material* in this guide

showing our new level 3 resources and see how they will work for you and your candidates

step 2: If you are ready to order, visit www.pearsonfe.co.uk/Level3LightVehicle

step 3: If you still want to know more, the why not set up a visit from one of our sales consultants? See the back cover for details.

* All the materials in this resource guide are draft samples and are subject to final correction before publication.

Candidate Handbook:l Designed specifically for your level 3 learners to provide an accessible, relevant and professional handbook that helps candidates progress in their career.

l Helps learners focus on diagnostics and rectifying faults as a progression from level 2.

l Covers the latest technology within the industry which not only provides the knowledge and skills to pass the qualification, but is highly relevant to the workplace.

l Problem-solving features help put theory into practice and better prepare candidates for the world of work.

l Highlights employability skills in a range of focused case studies.

Contents:CHapter 1 Introduction to light vehicle technology / diagnosis and rectification

CHapter 2 Diagnosis and rectification of light vehicle chassis system faults

CHapter 3 Diagnosis and rectification of light vehicle engine faults

CHapter 4 Diagnosis and rectification of light vehicle auxiliary electrical faults

CHapter 5 Diagnosis and rectification of light vehicle transmission and driveline faults

CHapter 6 Identifying and agreeing motor vehicle customer service needs

index

3

Candidate Handbook

Candidate Handbook

candidate handbook 4

Level 2 NVQ/SVQ Diploma Brickwork 3rd editionLevel 3 Light Vehicle Technology

60

To diagnose hydraulic system pressure faults, you must � t a power-assisted steering pressure gauge in series with the pump, then run the engine at different speeds and under different operating conditions. The gauge is similar in operation to an engine oil pressure gauge, but it has a manually operated valve that is able to control the � ow of � uid in the system. In this way, you can check � ow and pressure and compare them with the manufacturer’s speci� cations.

∑ By connecting the gauge with the valve in the open position, you can check supply pressure when the steering is at full lock.

∑ By connecting the gauge with the valve in the open position, you can check supply pressure when the engine is operating in its normal rev range (1000 to 3000 rpm) with the steering in the straight ahead position.

∑ By connecting the gauge with the valve in the closed position, you can check the maximum supply pressure available from the pump.

Steer by wire

Some manufacturers are experimenting with a system of steer by wire. In this set up,

the steering wheel is replaced with a joystick that can control not only steering but also

acceleration and braking. The main drawbacks of this system are the dif� culty in making it

failsafe and the reluctance of drivers to give up control of the steering wheel.

NEW TECH

In series – incorporated

as part of the circuit.

Key term

Figure 2.43 Using a gauge to check steering hydraulic pressures

Do not run the hydraulic pump for more than � ve seconds with the valve on the pressure

gauge in the closed position, as this may cause the pump to overheat and can cause damage.

Power-assisted hydraulic � uid pressures can reach around 80 bar (1160psi) so you must take

care when working on these systems.

Safe working

Examine a vehicle in your

workshop and identify the main

component parts of a hydraulic

power-assisted steering system.

Action

DRAFTTechnology evolves quickly in the engineering world and our NEW TECH sections keep learners up to date on the latest developments.

Safe working sections provide learners with health and safety best practice so injuries can be avoided.

Sample taken from Level 3 Light Vehicle Technology Candidate Handbook.

Candidate Handbook

candidate handbook 5

2 Diagnosis & rectifi cation of light vehicle chassis system faults

61

Table 2.7 Typical operating pressures that may be found during hydraulic testing

Pressure gauge valve open Pressure gauge valve closed

Symptom and possible fault

Engine speed 1000 rpm

Engine speed 3000 rpm

Engine speed 1000 rpm, steering turned to full lock

Engine run (maximum 5 seconds)

40 bar 35 bar 80 bar 80 bar Correct operation

25 bar 25 bar 80 bar 80 bar Power assistance too lowFlow control valve stuck open/faulty

40 bar 35 bar 60 bar 80 bar Power assistance too lowFaulty control valve or hydraulic piston

40 bar 35 bar 60 bar 60 bar Power assistance too lowWorn pump

65 bar 65 bar 80 bar 80 bar Power assistance too highFlow control valve stuck closed/faulty

Noise and bleedingNoise from a hydraulic power-assisted steering system may be caused by:

∑ loose drive belt ∑ air in the hydraulic system, known as cavitation ∑ pump bearing wear.

If air has entered the system, it can be bled by topping up the � uid reservoir with the correct grade of power steering � uid and turning the steering from lock to lock with the engine running. This will help � uid to fully circulate through the steering system and air to escape once it has reached the reservoir.

Speed sensitive solenoid diagnosisTo diagnose the correct operation of the speed sensitive system, you need to connect an oscilloscope to the speed sensor input at the power steering ECU. (You can � nd out how to connect and use an oscilloscope in Chapter 4, pages 184–185.).

With the vehicle in motion, you should see a wave form with a frequency proportional to vehicle speed on the screen of the oscilloscope. This signal may be analogue (see Figure 2.44) or digital (see Figure 2.45). If you don’t see this wave form, check the sensor and wiring.

If the input to the ECU is correct, you should then connect the oscilloscope to the output for the power steering solenoid. At slow speed, you should see a duty cycle or pulse width modulation (PWM) on the screen of the oscilloscope that reduces as vehicle speed increases.

Cavitation – the creation of

bubbles in a hydraulic � uid.

Key term

Volts

Time

Time

Volts

Figure 2.44 Analogue speed signal

Figure 2.45 Digital speed signal

Key term features define difficult and important concepts to aid understanding throughout the book.

DRAFT

Sample taken from Level 3 Light Vehicle Technology Candidate Handbook.

Candidate Handbook

candidate handbook 6

Level 2 NVQ/SVQ Diploma Brickwork 3rd editionLevel 3 Light Vehicle Technology

62

If the output signal is correct, then you should check the wiring and solenoid for correct function and operation.

If the input to the electronic control unit is correct but the output is missing or incorrect, you should suspect a fault with the ECU.

Electro-hydraulic power-assisted steeringAn alternative to the engine-driven hydraulic pump used in power-assisted steering is for the pump to be driven using an electric motor. The electric motor, pump and � uid reservoir can then be mounted in a position away from the engine and activated when required. Sensors mounted on the steering column are able to measure the amount of turning effort applied to the steering system by the driver and send this information along with a signal from the vehicle’s speed sensor to the steering electronic control unit (ECU). The ECU is then able to operate the electric motor to turn the pump and supply a pressure to the piston in the steering rack which is proportional to vehicle speed and the steering effort applied.

The advantages of this type of system are:

∑ Fewer loads are placed on the engine during operation, so fuel economy and engine emissions are improved.

∑ The pump and reservoir can now be mounted anywhere away from the engine, which increases the scope for vehicle design.

∑ If the engine stalls/cuts out, power assistance can be maintained. ∑ The pump can be controlled by a switch to provide even greater

assistance when parking.

50% Duty cycle

75% Duty cycle

75% 75%

25% 25%

Figure 2.46 Duty cycle wave form

Fluid reservoir

Electro hydraulic pump

Pinion

Pinion

Valve rotor

Valve sleeve

Feed oil radial groove

Power cylinder left

Power cylinder right

Piston

Rack housing

Rack Tie rod

Figure 2.47 Electro-hydraulic power steering

Electronic power-assisted steering (EPS)Many modern vehicles use electric motors to drive steering mechanisms and provide power assistance instead of hydraulics. A reversible direct current electric motor can be connected to the steering rack or column

Clear and concise explanation of technical level 3 concepts assist understanding.

DRAFT

Sample taken from Level 3 Light Vehicle Technology Candidate Handbook.

High-quality illustrations throughout help learners visualise technical concepts and automotive systems.

Candidate Handbook

candidate handbook 7

2 Diagnosis & rectifi cation of light vehicle chassis system faults

63

depending on manufacturer design. As the driver applies effort at the steering wheel, movement and turning effort are registered by a torque sensor mounted on the steering column. The information provided by this sensor, as well as other inputs such as vehicle speed are then sent to the steering electronic control unit (ECU). The ECU is then able to operate the electric motor in the desired direction with a force controlled by duty cycle with a force that is proportional to vehicle speed and steering effort applied.

The advantages of this system are:

∑ The motor is only operated when the steering is turned – this reduces loads, improves fuel economy and reduces engine emissions.

∑ The motor and control system is very compact and can be used unobtrusively, even on small cars.

∑ Assistance can be easily varied to provide greater help when parking. ∑ Less maintenance is needed as there is no � uid system or leaks. ∑ If combined with a vehicle radar system, it can be used to provide a

self-parking function.

To diagnose faults with electronic power-assisted steering systems, you can often use a scan tool to retrieve diagnostic trouble codes (DTCs),

Steering wheel

Steering column

Ball joints

Pinion housing

Electric motor

Rubber gaiters

Track rod ends

Track rods

Universal joint

Pinion

Steering rack

Figure 2.48 Electronic power-assisted steering

Investigate vehicles in your

workshop and state if they use:

• hydraulic power-assisted

steering

• electro-hydraulic power-

assisted steering

• electronic power-assisted

steering.

ActionSelf-parking cars

Parallel parking is a slow speed manoeuvre that many drivers � nd dif� cult. As a response

to consumer demand, car manufacturers are starting to design and sell self-parking cars.

Advantages of self-parking cars include:

• Choosing a parking space is not restricted by the driver’s skill at parallel parking.

• A self-parking car can often fi t into smaller spaces than most drivers can manage on

their own, which allows the same number of cars to take up fewer spaces.

• Parking takes less time, which helps to keep traffi c moving.

• Minor damage created by parking is reduced.

Many systems operate with the driver controlling vehicle speed and direction with the

normal driving controls. They have sensors distributed around the front and rear bumpers of

the car, which act as both transmitters and receivers. These sensors send out signals, which

bounce off objects around the car and refl ect back to them. The car’s ECU then uses the

amount of time that it takes those signals to return to calculate the location of the objects.

The electronic power-assisted steering then manoeuvres the car into the parking space.

Manufacturers are now designing vehicles that are completely autonomous and will

control the drive as well as the steering. This means that the driver simply has to select

an appropriate parking spot and position the vehicle close to the space. Having pressed a

button, the car can then park completely by itself.

NEW TECH

Action features provide tasks to contextualise what has been learnt and demonstrate understanding of concepts.

DRAFT

Sample taken from Level 3 Light Vehicle Technology Candidate Handbook.

8

training resourCe disk l Save valuable time with an array of tools to help plan effectively, including suggested schemes of work, lesson plans and PowerPoints.

l Matched to the Candidate Handbook so you can teach level 3 diagnostic skills and knowledge in an engaging and interactive way that maximises success.

l Customise your training - all printable materials are editable, so you can ensure the materials are right for your learners.

training resourCe disk

training resourCe disk

Training resource Disk 9

Chapter 6 Identifying and agreeing motor vehicle customer service needs

Assignment 1 Customer care

© Pearson Education Ltd 2012. Copying permitted for purchasing institution only. This material is not copyright free. 1

Candidate name Date

Assignment brief: 1 Create a script that could be used to greet customers face to face when they arrive

at the garage for the first time and which finds out their service or repair needs. 2 Create a script that could be used to greet customers over the phone when they

contact the garage for the first time and which finds out their service or repair needs. Attach your scripts to this cover sheet.

3 Conduct a role-play activity with another learner where your script can be assessed by one of your peers and constructive feedback given.

Peer assessment and feedback

Peer assessor Date

General comment about the assignment:

Assessment criteria

Did the candidate? Yes/No

Use customer service methods appropriate for a face-to-face greeting.

Use customer service methods appropriate for a telephone greeting.

Fully establish the service or repair needs during the role-play activity.

Assessment for learning

Peer assessor Please give a brief description of how this assignment could have been improved (this could be about technical content or the general approach to the assignment submission).

Assignments allow learners to put what they have learnt into practice and apply their knowledge at the end of each chapter.

Customer service skills can be vital in a garage setting and our customer care chapter aims to equip learners with these skills.

DRAFT

Sample taken from Level 3 Light Vehicle Technology Training Resource Disk.

training resourCe disk

Training resource Disk 10

Chapter 6 Identifying and agreeing motor vehicle customer service needs

Assignment answers

© Pearson Education Ltd 2012. Copying permitted for purchasing institution only. This material is not copyright free. 1

Assignment introduction The assignments provided in this chapter are designed to offer tasks which support and extend classroom learning. Every opportunity should be taken to allow learners to peer and self-assess the work, promoting assessment for learning and reducing tutor marking, while allowing for formative assessment to take place.

Assignment 1 Customer care Learners produce/create a customer greeting script and then undertake a role-play activity to judge its effectiveness. Peers check that the assignment/role-play contains the following information: 1 Customer service methods appropriate to a face-to-face greeting 2 Customer service methods appropriate to a telephone greeting 3 Fully establish the service or repair needs Peers give constructive feedback on technical content, spelling, punctuation, grammar and layout.

Assignment 2 Manufacturer data Learners research manufacturer communication and feedback by using email requests for information. Learners produce individual answers. Learners self-assess the effectiveness of the activity and describe how different forms of written communication could be used in a business situation.

Assignment 3 Common faults Learners research vehicle faults using the Internet and diagnostic questioning sheets designed in Chapters 2, 3, 4 or 5. Learners produce individual answers. Peer/group assessors check the effectiveness of the activity.

Assignment 4 Garage services Learners research local garage products and services and complete a table for three different garages. Learners produce individual answers. Learners self-assess the effectiveness of the activity.

Each assignment comes with answers so you can make sure your learners are on track.

DRAFT

Sample taken from Level 3 Light Vehicle Technology Training Resource Disk.

training resourCe disk

Training resource Disk 111

© P

earson Education Ltd 2012. C

opying permitted for purchasing institution only. This m

aterial is not copyright free.

Chapter 6

Identifying and agreeing motor vehicle custom

er service needs

Lesson plan – Session 1.5 Chapter 6: Identifying and agreeing motor vehicle customer service needs Aims: ● Describe legislation relating to customer service in the automotive industry. SB = Student Book Assignment AS = Activity sheet PP = Presentation IA = Interactive activity IQ = Interactive quiz DT = Decision tree R = Research NS = Non-supervised individual study time This is a 180-minute lesson.

Learning outcomes ● All learners will list different types of customer legislation

● Most learners will design an advertisement which helps explain the Trade Descriptions Act

● Some learners will suggest reasons that might cause infringement of the Data Protection Act

Timing/ content Tutor activity Learner activity Resources Individualised

activity/differentiation

Key/Functional skills, Every child matters, Health and safety

5 minutes Lesson prelims

Take the register. Explain class rules and go through the lesson prelims. Monitor timekeeping.

Listen. Comply with classroom rules and health and safety.

Register Pens/pencils Whiteboard/flip chart

English – speaking and listening Staying safe Ask learners to put bags, coats, etc. out of the way so that they do not create a trip hazard.

10 minutes Recap

Recap with an overview of the subjects covered on the organisational terms and conditions for vehicle acceptance, and ask learners general questions to reinforce learning.

Refer to sections of SB pp.329–330 Answer questions related to last session (customer service).

SB pp.329–330 Learner notebooks Handouts

Use directed questioning so that all learners are involved. Use a probing questioning style that allows for differentiation by outcome.

English – reading and understanding English – speaking and listening

Time-saving lesson plans are fully editable and give you the flexibility to teach in your own style.

DRAFT

Sample taken from Level 3 Light Vehicle Technology Training Resource Disk.

training resourCe disk

Training resource Disk 12

Highly illustrated PowerPoint presentations for each chapter come with tutor notes and further guidance.

DRAFT

Sample taken from Level 3 Light Vehicle Technology Training Resource Disk.

13

next steps

next steps

next steps

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