LESSON

INTRODUCTION TO
1 AUTOMOTIVE
9 HOURS

 This module explains how we are truly living in a "world of wheels." Every day, millions of people
depend on their cars, trucks, vans, and sport-utility vehicles as their primary means of transportation.
As a result, economic experts predict a strong demand for skilled automobile technicians and related
professionals for the foreseeable future. You have chosen to study an area of employment that pays
well and will require thousands of new graduates yearly.


At the end of this lesson, you are expected to:

a. discuss automotive hand tools, materials and equipments;
b. explain safety shop practices;
c. identify different engine classification;
d. determine the steps in detailing the exterior and interior body of an automobile; and
e. give insights on some of the opportunities in the automotive field, the importance of training and how
automotive technicians and training programs are certified..

ACTIVITY #1: My dream…

For each of us dreams of owning a car not just an ordinary one but something which we will appreciate and
really proud of.
If you are to choose your future car, which one will you pick from the available models and explain why?
Attached a picture of that dream car of yours, cut out from newspapers, magazines, catalogues, posters and
flyers and paste it on your notebook.
______________________________________________________________________________________
__________________________________________________________________________________

 In the activity you had, you were able to express your thoughts on about your dream car. It
encourages and inspires creative expression and imagination in students – some amazing ideas are
born from dreams!
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History
You must have heard the word Automobile. Meaning of an automobile can be auto car, motor car or car. It is
a wheeled motor vehicle used for transporting goods or passengers, which also carries its own engine or
motor. The word automobile comes from the Ancient Greek word αὐτός (autós, "self") and the Latin mobilis
("movable"); therefore automobile means a vehicle that moves itself. The alternative name car is believed to
originate from the Latin word carrus or carrum ("wheeled vehicle"), or the Middle English word carre ("cart")
(from Old North French). These words in turn are said to have originated from the Gaulish word karros (a
Gallic Chariot).
 Relevant Knowledge
The Wheel is considered as one of the most important mechanical inventions of all time. The wheel has
been used by man since the beginning of civilization. Most primitive technologies since the invention of
the wheel have been based on its principles. The invention of the Wheel was perhaps in the late
Neolithic age. It is likely that it happened along with other technological advances that gave rise to the
early Bronze Age.
4500 BC: Invention of the potter's wheel, Chalcolithic (Ubaid period)
4500–3300 BC: Chalcolithic, earliest wheeled vehicles, domestication of the horse
3300–2200 BC: Early Bronze Age
2200–1550 BC: Middle Bronze Age, invention of the spoked wheel and the Chariot
 Invention of Wheel
Since the industrial revolution, the Wheel has been a basic element of nearly every machine
constructed by mankind. While the exact time and place of the invention of the wheel has been disputed
but its beginnings can be seen across ancient civilizations. History tells us that WHEEL was most likely
invented in Mesopotamia (modern day Iraq) around 3500 BC. This means that the Wheel is about 5,500
years old !
The first use of the wheel for transportation was in Mesopotamian chariots in 3200 BC. There are
many references to wheeled chariots in Indian mythology also dating to around 3,000 BC. It is
interesting to note that wheels may have been used in industrial or manufacturing applications before
they were used on vehicles.

I. AUTOMOTIVE HAND TOOLS, MATERIALS AND EQUIPMENT

To gain more knowledge about the tools, you must know its basic functions so that you will be able to
identify its use.
A. CLEANING TOOLS
1. Scraper is a flat thin sheet of metal with wooden or plastic handle. It is used to scrape hard to
remove dirt or stubborn grime or plastic sticker.
2. Steel/Wire brush are thin strips of metal inserted in a wooden or plastic stock. It is used to
remove rust, hard to remove dirt and grime with sweeping action.
3. Utility rag is a fibrous cloth used in cleaning and wiping dirt and dust.

B. BENDING/HOLDING/TWISTING/CRIMPING TOOLS
1. Pliers are generally used as all-around tools. They have the capability for bending, crimping,
cutting, holding, stripping and twisting. They are available in various shapes and sizes.
Generally, pliers used for electrical job are insulated, whereas those for mechanical work are
not insulated but sometimes equipped with rubber for gripping. Pliers are not used as
substitute for wrenches.
 Side cutting pliers are tools having a broad, flat, and rough jaw. They have a pair of
nipper-like blades used for cutting and bending wires.
 Combination pliers are equipped with adjustable opening by means of a slip joint. It is
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 used for gripping object because of its inner notch and also used for cutting and
bending small wires.
 Long nose pliers have a needle-nose ends used for holding or picking small object. They
have a razor-like blade on its jaw for stripping, cutting and bending wires.
 Stripping and crimping pliers have two-half round edges used to strip electrical wire and
a crimping nose to fold and lock wire connector.
 Vise grip or locking jaw pliers are specially designed pliers used for holding work pieces
together. They have a variety of uses such as inserting a fastener, holding bolts while
tightening or loosening the nut and removing rounded head bolts and nuts.
 Machinist pliers have adjustable and cutting jaws with tooth-edged nose used for holding,
bending and cutting wires.

2. Bench vise is a device for holding and bending pieces of metal. It consists of one fixed and
one movable jaw operated by a clamping action of the screw.

C. CUTTING TOOLS
1. Chisel is a hand tool essentially used for cutting bolts, nuts and rivets. It comes in different types
and sizes. A flat cold chisel is used for general cutting. Special chisels like a diamond point are
used for cutting sharp-bottomed groove and a round-end chisel for cutting oil grooves.

2. Electric Drill is a tool for boring holes. It is made of either carbon steel which requires frequent
sharpening or high speed steel which requires less sharpening. Electric drill is designed for slow
and high speed drilling. It can be hand operated for slow drilling or electrically operated portable or
heavy duty machine for high speed drilling with replaceable drill attachment at the end. Drills come
in various diameter sizes. Electric drill can also be used as a portable grinding machine by
attaching a handy grinder on its end.

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 3. File is a hard steel tool used for smoothening metal. It comes in various shapes such as flat,
round, half-round, and triangular. It also comes in different fine-to-coarse cutting edges. A single
cut file has a single series of cutting edges parallel to each other whereas a double-cut file has two
sets of cutting edges that cross at an angle.

4. Hacksaw is an excellent tool for cutting bolts, tubing and light to fairly thick metal. It has a light
frame handle with blade connected to both ends of the frame. Depending on the type of work to be
cut, a hacksaw blade tooth per inch (TPI) determines the extent of metal to be cut. It comes in 14,
18, 24, 32 teeth per inch. The lower the number, the lesser the number of TPI and the greater it’s
cutting ability. A special hacksaw such as whole saw is used when boring thin and large diameter
sheet of metal. It is electrically operated by an electric drill.

D. DRIVING TOOLS
1. Hammers are generally used for driving or striking work. It comes in various sizes, weights, and
kinds .
 Ball peen hammer is basically used by machinists as in automotive applications. It has a
weighty ball-shaped metal at the end of the handle with flat surface on one side for striking a
chisel or appropriate work and a rounded shaped for riveting or penning.
 The brass or plastic-tipped hammers are used for striking soft and delicate part such as
aluminium or plastic to avoid danger of breaking or marring the surface.

2. Puncher is a tool made of steel. It is used to cut or drive out a bolt or lock needle pin out of a
hole. Starting punch is a punch with tapered portion used for initially starting a pin or rivet removal.
After initially starting the pin, the drift punch or pin punch is used to complete the job of removing
the pin. A hole punch is used in cutting a paper gasket in making holes.

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E. LOOSENING AND TIGHTENING TOOLS
1. Wrenches are tools for loosening and tightening of bolts and nuts. It comes in different forms
and number in Metric or in English sizes.
1.1 Allen wrench is used in a type of screw bolt with a hexagonal hole on the head.
1.2 Box end wrench is an enclosed end tool used for moderate application for loosening and
tightening bolts and nuts.
1.3 Combination wrench is a tool with an open-end on one side and box-end on the
opposite side. It has the same size on both ends and used in loosening and tightening bolts
and nuts.
1.4 Oil filter wrench is circular-shaped steel with internal tooth and handle. It is inserted to
the oil filter body, tightened as it is turned for removal.
1.5 Open end wrench is a tool with open end used for light application in loosening and
tightening bolts and nuts.
1.6 Socket wrench is a tubular-like tool with an enclosed end used for heavy application for
loosening and tightening bolts and nuts.
1.7 Spark plug wrench is a socket-like wrench intended for removing and installing spark
plugs.
1.8 Tire wrench is a cross-like or sometimes L-shaped piece of round bar used to remove the
wheels of the vehicle.

2. Screwdriver is a piece of long metal rod made of hardened steel and tempered at the tip. It is
used to loosen and tighten screws. It usually comes in different sizes and forms of tips.
 An Allen screwdriver has hexagonal sides at the tip and used for hexagonal slot head of
the screws.
 A flat screw driver has flat tip at the end and used in a single groove screws.
 A Philips screw driver has cross-like tip at the end and used in a cross groove head of
the screws. Depending on the kind of application used, a screwdriver can be of special
types such as stubby screwdriver that has a short shank and handle. It is used for tight
space where a typical screwdriver cannot be used.
 An offset screwdriver has a shank bent in opposite direction several distance just before
the end of the tip. It is used to loosen and tightened screws in difficult areas

F. MARKING TOOLS
1. Center punch is a tool made of hardened steel with conical tip point on its end. It is about 3 to 4
in. long in length and used for marking the material before drilling. It is also used for marking two
parts so that after removing, it can be easily replaced by aligning the marks together.
2. Scriber is a thin steel rod with pointed tip on its end. It is used for marking fine lines on metal for
layout work.

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 3. Pencil is a thin strip of graphite enclosed in a wooden case and used for making drawings and
marking lines.

G. MEASURING TOOLS
1. Torque wrench is a special service tool for measuring the twisting force applied when tightening
bolts and nuts.
2. Steel rule is a measuring strip of steel available in various lengths in metric and English system.
It is available in 12, 24, 36 and 48 inches size. It is used in linear measurement of short length or
height.
3. Caliper is a tool used in measuring the diameter of a circular work. The Inside caliper is used in
measuring the inside diameter whereas the outside caliper is used in measuring the outside
diameter of an object. The caliper is adjustable. The Vernier caliper is a good example that is
capable to measure both the inside and outside diameter of an object with accuracy. It can also
measure the thickness and thinness in thousandths of an inch.
4. Metal tape measure is a push and pull, long strip of thin sheet of metal with corresponding
increments in millimeter and inches graduation. It is used for measuring stock and can be bought in
different sizes of length.
5. Feeler gauge is a thin strip of metal with different thickness used to measure or set gap and
clearance between parts of mechanism.

EQUIPMENT, TOOLS, SUPPLIES and CHEMICALS

 Powerful vacuum - is a device that uses an air pump to create a partial vacuum to suck up dust and dirt,
usually from floors, and optionally from other surfaces as well.
 Heated soil - spray the surface with hot water to quickly break down dirt, grease and grime, and extract it
immediately. The process leaves fabric or carpet free of soapy residue. It eliminates the stains, dirt, grime
and odours that soap, sprays and other cleaning products can’t come close to removing. It also called
steam cleaners or carpet extractor.
 Vapor steamer - uses steam to quickly dry, clean, and sanitize inanimate surfaces. Often the process is
effective enough to disinfect or even sterilize the surfaces.
 Interior dryer – it removes moisture from the interior part of a vehicle

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 Power tools
 Shampooer tool – used for scrubbing carpets, floor mats and seats in automobiles. (air or electric)

Tools
 Nylon scrub brushes - a brush with short stiff bristles for heavy cleaning
 Parts cleaning brush - removes dirt and grease from motors, machinery and metal parts.
 Detail brushes – used for interior dusting and cleaning.
 Detail tool brushes – use for cleaning hard to reach areas.
 Razor blade scraper – used to strip vinyl decals, pin stripes, and dealer stickers. Remove tar, sap,
bugs, adhesive, road paint and chewing gum from interiors.

Supplies
 Microfiber towels – is a pliable material made of soft micro-fiber cloth or non-oily, lint-free soft cloth or
cotton fabric used for cleaning, drying and wiping car body surface. (one for glass, one for chemicals)
 Q-tips – used for cleaning HVAC(heating, ventilation, and air conditioning) vents
 Scrubby pads - used for cleaning carpets, fabric, rubber, leather, tile, and convertible tops.
 Dressing applicator pads – used for applying polishes and waxes on rubber and vinyl.
 Floor mats - Protect your carpeting from dirt, sand, mud, leaves, grit and grime that is tracked in from the
outside every time you enter or exit the vehicle. (either plastic or coated-paper)
 Seat covers - protect your seats from dirt, grime and deterioration from everyday use.
 Loose Items bags – a flexible container with an opening at one end.
 Plastic or metal razors - used to strip vinyl decals, pin stripes, and dealer stickers. Remove tar, sap, bugs,
adhesive, road paint and chewing gum from interiors.

Chemicals
 Stain removers for all types of stains ¡V use to remove all types of grease, oil, sludge and grime from cars,
trucks, SUV’s motorcycles and even RV’s.
 Extractors shampoo – a no-foam shampoo
 Carpet shampoo – foaming type
 All Purpose cleaner – a low pH alkaline cleaner for leather, vinyl, plastic
 Glass cleaner – removes smudges and spots on the glass.
 Water-based dressing - restores shine and luster to vinyl, plastic, leather and rubber surfaces inside and
outside your vehicle.
 Leather conditioner - leaves a silky smooth, dry-to-the-touch feel while restoring the fresh, natural leather
smell.
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 Fabric protector – to protect fabrics, upholstery and carpet against spills, stains, and dirt.
 Fragrance – a pleasant or sweet odour placed inside the car.
 Biological odor eliminator - contains a neutralizing agent to completely eliminate odors and replace them
with our fresh and clean scent.
 Keep in mind that you do not absolutely need every piece of equipment, such as a vapor steamer,
but they do aid in getting a more effective and faster cleaning. Neither do you need an ozone
generator, but it is very effective in eliminating odors.

The following are some of the information you need to know about the safety requirements of hand tools:
1. Technical data. This will give information about the manufacturer’s specifications of the tools produced.
The size, weight, production code number, and the brand are usually marked on the body of the item.

2. User’s manual. It tells where, when and how the tools are to be used. It also gives information on the
limitation of tools if subjected to constant use. In this manual, users are given warning on the possible
injury one may get if used incorrectly. It also gives detailed information on how tools are maintained and
stored. If tools need to be assembled, the manual gives a step-by-step instruction on how to do the task.

3. Physical requirements. Physical requirements of tools have bearing on how they are manufactured.
Their good quality must be:
a. Tensile strength. Tools must be light but durable so that excessive force in using them is not
necessary. In this manner, strain on hands and shoulders are reduced. A tool must be strong and
reliable to stand the stress of constant use. Tooth edge of hacksaw and chisel must be tempered
and so with a screw driver.
b. Powerful. Tools must not be heavy on the hand side rather than on the end portion of the
driving force, as in a hammer. They must be considerably long to give a powerful twisting force as
in a wrench and screw or a heavy blow when using hammer. This reduces muscular effort and
efficiency of work is achieved.
c. User- friendly. Tools must be easy and comfortable to use. They must be hand-fit and oval or
cylindrically shaped. A square-shaped handle creates discomfort on palms because of the edge
area.
d. Safe tools must have gripping surface on their handles to assure holding power and avoid slip
that may lead to injury. Stopper must also be on pointed and sharp-bladed/edged tools. Driving
tools must be provided with appropriate length of grip.
e. Functionally accurate. Tools are especially made to measure like torque wrench. Vernier
caliper and feeler gauge must be technically and functionally accurate. They must give correct
reading of division and sub-division of their fractional value or scale. Inaccurate reading gives
wrong data or information and may result in severe damage to parts.

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 II. SAFETY SHOP PRACTICES
A. Plan and prepare for the tasks to be undertaken
Planning is part and parcel of achieving a successful task. Your ability to plan will enable you to attain your
purpose. Many successful automotive entrepreneurs have realized their success through proper and careful
planning. Likewise, aside from planning, you should also give importance to preparation. Good preparation will
boost your confidence because it means that you are ready to do the task because you have sufficient knowledge
about it. The following are some factors to be considered when you plan and prepare for the tasks:
1. PLACE. See to it that the place for doing the task is conducive to work, well ventilated, clean, and has
good lighting. A space provided for freedom to move is important. A place chosen will give you an idea on what
task is to be done.

2. MATERIALS. Be sure that aside from tools and equipment, necessary materials and fixtures to be used
such as bench work and manual of specifications must be available and ready for use.

3. WASTE DISPOSAL. Used parts or compound substance such as oil, grease and used chemical bottles
must be disposed in proper storage bin or container. Non disposal of used chemical substance invites hazard to
environment and poses danger to health.

4. TOOLS/EQUIPMENT. Tools and equipment must match with the task to be done. You should be careful
enough to choose tools and equipment that are worthy of use. They must be in good condition so that it can be
easily utilized without damaging the parts.

5. SAFETY. Always prioritize safety. Remember that accident is not an excusable incident. It can be
avoided. Always remember the motto “Safety first”.

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 6. SERVICE PROCEDURE/TASK. Identify what task to perform before identifying materials and tools to
use. The service procedure/task to employ will tell you the corresponding tools and materials needed. Appropriate
tools to use with the task will enhance your ability to provide a competitive and efficient service.

The following service procedure/tasks will help you identify and select tools required when performing a job.
SERVICE PROCEDURE/ TASKS TOOLS NEEDED
 Adjusting
Cutting tools
 Checking
Loosening and tightening tools
 Inspecting Measuring tools
 Measuring
Loosening and tightening tools
 Assembling
Marking tools
 Installing Measuring tools
 Cleaning Cleaning tools
Cleaning tools
 Disassembling
Loosening and tightening tools
 Removing Marking tools
Cleaning tools
 Reconditioning Loosening and tightening tools
 Repairing Marking tools
Measuring tools
Loosening and tightening tools
 Testing
Measuring tools

B. PERSONAL SAFETY
Whenever safety is the issue, safety of oneself usually comes to mind. It is a basic instinct for human being
to protect himself.
Safety in the workshop is not only confined to the use of tools, materials and equipment. To some degree,
in workshop, personal safety must come first before anything else. You can replace broken tools with new one. Buy
new materials and operate new equipment but you cannot buy new body as replacement if something happens to
it.
Personal safety involves habits, values, and awareness. Having these virtues will shy you away from injury
and harm.
To be more specific, personal safety can be classified in different manners.
1. Upper body protection. These include safety glass for eye protection called goggles. This is used when
grinding metal or when reconditioning tools. Welding goggles are also used when joining metals so that eyes are
protected from flying debris. Transparent goggles are useful when working under chassis. Eyes are protected from
dust and small particles that may get into the eyes and cause irritation. The head should be protected with head
gear like bonnet or cap. This head gear protects head and hair from dust, accumulated dirt, falling object and
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harmful chemical especially when working underneath the vehicle. The nose and face should be protected with
face mask or respirator so that harmful fumes from exhaust gas and chemicals may not get into the lungs.

2. Middle body protection. These include apron that protects the body from dirt and sudden spill of
substance like oil. High grade rubber gloves protect the hands from paint, solvent and electrical shock. Leather
gloves protect the hands from hot surface like newly welded metal to avoid abrasion. Hand cream is also useful to
protect hands from dryness.

3. Lower body protection. These include safety shoes to protect the feet from slipping and risk from heavy
falling object.

4. Whole body protection. The use of coveralls or jumpsuit is a good protection against flying debris,
chemical spill, paint, solvent and abrasion.

C. General shop safety rules

A. During the course of working in the shop, an automotive technician moves from one area of the shop to
another, moving parts and equipment around the shop and performing varied tasks. It is important that the
shop floor be free of hazards that could cause technicians to slip or trip.
B. In a wide variety of shop tasks, waste materials are produced that can cause dangerous situations
unless the waste materials are disposed of or stored properly.
C. Always be sure that shop exits are well-marked with an “EXIT” sign and are clear of obstructions.
D. For personal safety and to help keep the shop free of hazards, always comply with the following safety
rules.
1. Work quietly and focus solely on the job at hand.
2. Do not leave creepers laying on the floor. Always stand them against the wall, wheels outward, when
not in use.
3. Do not indulge in horseplay in the shop. Immature and improper behavior in the shop can cause
serious accidents.

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 4. Before performing a task, consider the relevant safety precautions related to the task and formulate a
prevention plan for each hazard.
5. Always wear protective clothing and equipment in any situation where it is necessary.
6. Wear protective eyewear at all times in the shop area.
NOTE: The law requires that protective eyewear be available and worn in career and technical
education courses where there is a reasonable probability of injury.
7. Do not wear rings, bracelets, watches, or necklaces when working around moving machinery or
electrical equipment.
a. Jewelry can catch in moving machinery with serious consequences.
• A necklace can become entangled in running machinery, which could pull the technician into the
machinery and cause great bodily harm.
• If a ring or bracelet becomes entangled or caught, it could result in a severed finger or serious
injury to the head or neck.
b. If a ring or bracelet should accidentally create a short circuit of a vehicle battery, the metal of the
ring or bracelet could become white-hot in an instant, causing a serious burn.
8. Do not put sharp objects into the pockets of work clothes. They could cause personal injury or
damage to a vehicle’s interior.
9. Keep hands free from oil and grease.
10. Wipe up grease and other spills from the shop floor immediately or at least put an oil-absorbing
compound over them.
11. When cleaning up flammable liquids, always dispose of the rags in a metal container with a tight-
fitting lid.
12. Do not look in the direction of another person who is welding.
13. Do not run a vehicle engine inside a closed garage unless the vehicle exhaust is hooked up to
exhaust ventilation equipment. A deadly amount of carbon monoxide, which is present in the
exhaust, can collect in a very short time.
14. Do not smoke in the shop, except in an area designated for smoking.
15. When pumping a flammable liquid from a large container into a small one, be sure to first attach a
ground wire between both containers.
16. Always be alert for hazardous situations in the shop. Promptly correct them, if possible, and inform
the instructor of the situation.
17. If road testing a vehicle, always use seat belts, even if only going a short distance.
18. Disconnect the battery as appropriate. This eliminates hazards from shorts that could occur during
repair procedures.
CAUTION: The vehicle manufacturer’s recommendations must be followed for disconnecting
batteries. Some on board vehicle computer systems can be damaged if the battery is
incorrectly disconnected.
19. When parts are removed from a vehicle, they should be stored away from the work area (on a
bench or, if large parts, against a wall).
20. Asbestos particles can cause cancer. Asbestos is found in brake shoes and clutches. Therefore,
wear a particle mask when doing any cleaning work on brake or clutch parts. Do not use compressed
air to clean brake or clutch parts.
21. Do not let the leads on testing equipment fall into the fan of a vehicle while the engine is running.
Electric fan motors can turn on even with the ignition off.
22. Do not play with fire extinguishers. Use fire extinguishers only to extinguish fires.
23. Always read the labels on chemicals and materials and follow the instructions.

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