JOB REPORT

SAMPLE

Trainees: George; Tamil, Khaled

Trainer: J. Jabour
Date: 27. 01. 2010
Specification:
Type and make: Opel Omega
Year of manufacturing: 1999
Code: EBF
Chassis no.: 111111.
KW: 80
Injection
system: Motronic M 1.5.4.
Ignition system: M 1.5.4.
Km reading: 98000
Engine cc: 2 ltr
Spark plug type: Ne 134
Engine oil quality:SAE 20/40
Capacities:
Engine oil: 5.5 ltr. w. filter
Fuel tank: 60 ltr
Coolant system: 5.6ltr
Transmission: Autom.
Tire pressure front: 2.2
Rear: 2.0
Description of scenario or customer complaint: Module: 3
The customer complaints about poor engine performance and high fuel consumption.

General steps
Questions to
customer
concerning
details about
complaint

Visual inspection

Test, diagnose,
measure, access,
trace fault
test drive if
necessary

Work steps for tests, fault finding, repairs of

components and systems
Ask questions who begin with:When What Where
(and other problem related once)
When - does the problem occur at full load
Where - is the problem at engine, different engine
noise
What - are the effects high fuel consumption
Result: The trouble started when the timing belt was
changed in another workshop, wrong timing is
suspected
Any abnormalities: leakages, smell, excessive heat,
unusual noise, loose connections, change of colour

Fault out reading, test drive, check ignition timing

compare set values and actual values

Component or system
Test results

Ignition point 10 o out of

position at 2500 rpm

Tester, tools and

facilities required

Engine system
tester, scanner
stroboscope

Set value Act. Value

30o

20 o

BTDC

BTDC

Print out results

for customer
inspection

General steps
Prepare
Diagnose result
and fault
description

Work steps for tests, fault finding, repairs, of

components and systems

Timing belt fitted in wrong position, about one tooth

out

List requirements Spare parts and other items:

Timing belt, valve cover gasket, tensioner roll

Calculation of
required time
Calculation of
costs
Repair

Control quality
of work,
final inspection
Ensure
cleanliness
Handing over
procedure

Tester tools and

facilities required

Estimate time for the planning, preparation,

execution, control, test drive etc.
Estimation: 2 hours 30 min
Estimated costs; hour rate given
Spare parts, labour hours X hour rate, VAT,
1. Disconnect negative battery terminal
2. Turn engine to TDC ignition point, engage 4. gear
and handbrake
3. Remove valve and timing belt cover
4. Mark turning direction on belt
5. Open belt tensioner
6. Remove belt,
7. Check timing marks on crankshaft and camshaft
8. Fit new or same belt, apply correct tension
9. Turn engine 2 turns
10.Check timing and belt tension
11. Replace covers and battery terminal
12.Start engine, test drive and check performance
Bolts and nuts tight, cable connections back in place,
all systems function, test drive
Steering wheel, seat belt and seats, gear lever,
handles, body
Explain to customer: costs, necessity of repairs,
condition of car, future repairs and cooperation
show old parts for inspection by the customer
Remarks:

Result
Performance: Good:

Fair:

Poor:

Spare part list

Separate paper
Timing belt
tension check
tool,
General tools

Basic tools

Old damaged
parts