2008 Automotive Technology Final

WORLDSKILLS SINGAPORE 2008
AUTOMOTIVE TECHNOLOGY
FINAL
Project Overview
Each competitor is required to carry out fault diagnosis and rectification,
maintenance and repairing of car's systems and components independently
within the duration specified for the each task.
II
Project Description
You are required to complete 7 tasks within the time specified. The tasks are
as follows :
Task
Duration
Engine Mechanical
3 hrs
Body Electrics
3 hrs
Engine Management
3 hrs
Diesel Fuel Systems
3 hrs
Braking Systems
3 hrs
Automatic Transmission
3 hrs
Steering and Suspension
3 hrs
TOTAL
III
21 hrs
Tools and Material List

A tool and material list is given for each task.
IV
Instructions to Candidates
1
You are required to read and follow the specific instructions stated in
each task.
You are required to write your NRIC No on each page of the Report
Form.
You are required to complete the Report Form for Task 1 to 7 and
submit to the examiner after you have completed the assignment.
Answers in the Report Form must be written either in blue or black ink
pen.
Service manuals for the make of cars or units will be provided to you.
Measurements should be taken using the measuring instruments or

equipment provided.
You are required to adopt safe practices throughout the competition.
Assessment Criteria
Task
Weighting
Engine Mechanical
14
Body Electrics
14
Engine Management
15
Diesel Fuel Systems
14
Braking Systems
15
Automatic Transmission
14
Steering & Suspension
14
TOTAL
100
Oct 2008
WorldSkills Singapore 2008
WORLDSKILLS SINGAPORE 2008 FINAL

Task No 1: Engine Mechanical

Time allocated: 3 hours
Familiarisation time: 15 mins
Specific Instructions to Candidates

1
You are provided with the following equipment, tools and materials:
1.1
One Engine Model: Toyota 4A-FE (for stripping & assessment)
1.2
One Engine Model: Toyota 4A-FE (able to crank and perform

compression test)
1.3
Compression gauge
1.4
Timing belt deflection tool
1.5
Common hand tools
1.6
Spark plug wrench
1.7
Straight edge for cylinder head
1.8
Feeler gauge
1.9
Torque wrenches (small and medium range)
1.10
Surface table
1.11
V-blocks for camshaft (one pair)
1.12
Dial gauge with magnetic stand
1.13
Cylinder bore gauge
1.14
Air gun
1.15
Engine on stand
1.16
Piston ring expander
1.17
Piston ring compressor
1.18
Service manual
1.19
Cylinder ridge reamer
1.20
Work bench
1.21
Small hole gauge (for cylinder valve guide bushings)
1.22
Valve seat cutter
1.23
Pneumatic valve lap
1.24
Lapping paste
1.25
Cylinder head supports
1.26
Rubber hose for connecting rod bolts
1.27
Oil container
1.28
Plastigage
1.29
New engine oil (whether necessary or not)
1.30
Lint free clothes for cleaning
1.31
Valve spring compressor
1.32
Spare parts: Complete engine overhaul repair kit and a set of cylinder
head bolts
1.33
External micrometer : 0 mm to 25 mm
1.34
1.35
1.36
Vernier calliper
1.37
Engineering blue
Clients Problems:
The engine has low power output and high fuel consumption.
An engine overhaul is recommended to rectify the faults.
You are required to:

3.1
Remove the timing belt and tensioner;
3.2
Remove rocker arm assembly and camshaft;
3.3
Remove cylinder head and gasket;
3.4
Remove oil pan;
3.5
Remove No. ( 1 )* piston assembly;
3.6
Perform the necessary measurements and complete the Report

Forms;
3.7
Make recommendations for the components that are being inspected

and measured;
3.8
Change the valve stem (inlet and exhaust) oil seals for No ( 1 )*
cylinder;
3.9
Reassemble all components to the engine block; and
3.10
Conduct engine compression test. **
* The judge will inform you which number to remove/measure/change.

** A stand-by running engine is arranged for the engine compression test.

REPORT FORM
1 of 4
Competitor NRIC : ___________________________
Task No 1 : Engine Mechanical
S/No
Skills Category :Automotive Technology
Performance/
Condition of
Components (Tick)
Items
Good
1
Cylinder Head
Measured Value (max)
1.1 Warpage
_________mm
Standard Value
________mm
Valve Assembly
Measured Value (max)
2.1 Valve stem to guide

Clearance (Inlet no-1)
Standard Value
_________mm
_________mm
2.2 Valve stem to guide

_________mm
Clearance (Exhaust no-1)
_________mm
Recommendation:
_______________________________________________
_____________________________________________________
_____________________________________________________
Bad

REPORT FORM
2 of 4
Competitor NRIC : ___________________________

S/No

Performance/
Condition of
Components (Tick)
Good
Bad
Items
No. ( 1 ) Piston and Connecting Rod Assembly

Measured Value(max)
Standard
Value
3.1 No ( 1 ) compression
ring clearance
_ ______ mm
_________ mm
3.2 No ( 2 ) compression
ring end gap
________ mm
_________ mm
________ mm
_________ mm
_________ mm
_________ mm
3.3 Oil ring (side rail)

end gap
3.4 Piston no ( 1 ) to
cylinder clearance
Cylinder Bore
Measured Value(max)
Standard
Value
4.1 # (1 )Cylinder bore
(Taper)
Note : Measure at middle
4.2 # (1)Cylinder bore
(Ovality)
Note : Measure at middle
________ mm
________ mm
________ mm
_________ mm
Recommendation:
_____________________________________________________
_____________________________________________________

REPORT FORM
3 of 4
Competitor NRIC : ___________________________
S/No

Performance/
Condition
of Components
(Tick)
Good
Bad
Items
Camshaft
Measured Value(max)
Standard
Value
5.1 Camshaft runout
_________ mm
_________ mm
5.2 Cam lobes height

- Intake (No-1)
_________mm
__________mm
Exhaust (No-1)
_________mm
__________mm
_________mm
__________mm
5.4 Camshaft oil

clearance
_________mm
__________mm
5.5 Camshaft thrust

clearance
_________mm
5.3 Camshaft journals

Diameter
- Exhaust (No-1)
__________mm
Recommendation:
_____________________________________________________
_____________________________________________________
_____________________________________________________
10

REPORT FORM
4 of 4
Competitor NRIC : ___________________________
S/No

Performance/
Condition
of Components
(Tick)
Good
Bad
Items
Conduct Engine Compression Test

Measured Value
Standard Value
6.1 No-1 cylinder
__________ psi ____________ psi
6.2 No-2 cylinder
__________ psi ____________ psi
6.3 No-3 cylinder
__________ psi ____________ psi
6.4 No-4 cylinder
__________ psi ____________ psi
Recommendation:
_____________________________________________________
_____________________________________________________
_____________________________________________________
--- END ---
11

Task No 2: Body Electrics
Time allocated : 3 hours
Familiarisation time : 15 mins

1
You are provided with the following equipment, tools and materials :
1.1
Car Model : Toyota Crown LX- 10 / 12
1.2
Common hand tools
1.3
Electrical multi-tester (Voltmeter/Ammeter/Ohmmeter functions)
1.4
Hydrometer
1.5
Test lamp (3.4W & 21W)
1.6
Test leads
1.7
Lead acid battery (12V)
1.8
Belt tension gauge
1.9
Wires and connectors
1.10
Cloths for cleaning
1.11
Service manuals
1.12
Wiring diagrams
1.13
Spare parts for defective components
1.14
Torque wrench (0 to 50 Nm)
1.15
Electrical water heater with thermostat control
12
The owner of a Toyota Crown vehicle gave the following feedback :

2.1
He had been experiencing difficulty starting on his diesel vehicle in the

morning for the past few days and usually the vehicle would be all right
after the morning start. However, this morning he was not able to crank
the engine at all.
2.2
The LHS power mirror was not functioning properly.
2.3
The rear windscreen defogger system was not functioning during rainy
day.
2.4
The vehicle interior room light was not working.
2.5
Sometime the water gauge was at cold level even when the vehicle
was fully warmed-up. Therefore, he has requested that the
temperature gauge system to be checked.
2.6
The RHS power window was not working since yesterday, so he has
requested for a check on this unit.
You are required to :

3.1
Check and rectify the Difficult Cold Starting fault/s of this diesel
vehicle.
3.2
Check and rectify the LHS Power Mirror system fault/s.
3.3
Check and rectify rear Windscreen Defogger system fault/s.
3.4
Check and rectify Interior Room Light system fault/s.
3.5
Check and rectify Combination Meter (Water Gauge) operation

fault/s.
3.6
Check and report RHS Power Window system fault/s.

( Do Not Repair )
3.7
Complete the Report Form(s).
13

REPORT FORM
1 of 7
Competitor NRIC : ___________________________
Task No 2 : Body Electric
PART 2A: Preparation work
Please make sure that customer vehicle has been taken care of and this include :
The cleanliness of the vehicle driver seat interior.
The protection of your customers vehicle body paint work.
(ie.both front fenders).
The pre and post job organizational work.
Observe safety at work at all times.
Observe proper usage of tools and equipment during work.
PART 2B: Use the appropriate measuring instruments provided to diagnose

and locate the faulty components that needed to be replaced or
rectified.
1.
The difficult cold starting fault/s is/are :

(Tick) Condition of Component
: Good (G) or Bad (B)
A) List 2 basic regular physical conditions of the battery that you should
check to ensure the general up keep and maintenance of the battery :
I.
) of the battery
II.
) of the battery
14
B) Carry out the hydrometer test on any 3 battery cell compartments in the
battery :
I.
Specific gravity reading of the first cell
: ___________________.
II.
Specific gravity reading of the third cell : ___________________.
III.
Specific gravity reading of the fifth cell
: ___________________.
Condition of battery
)G
)B
C) Glow plug switch functionality test :

I.
Write down the approximate lighted up time in ______________ second.

Condition of switch
: (
)G
)B
D) Glow plug relay functionality test :

I.
Continuity test on terminal
: (
and
II.
Continuity test on terminal
: (
and (
Condition of switch
: (
)G
)B
E) Glow plug unit functionality test for ALL :

Resistor inspection, please fill in the approximate ohm values:
I.
First
: ___________ ohm
:(
)G
)B
II.
Second
: ___________ ohm
:(
)G
)B
III.
Third
: ___________ ohm
:(
)G
)B
IV.
Fourth
: ___________ ohm
:(
)G
)B
F) State the item/s being repaired or replaced :

I.
__________________________________________
II.
__________________________________________
III.
__________________________________________
G) Remarks :
__________________________________________________
____________________________________________________
15
2.
The power mirror control system fault/s is/are :

A)
Power mirror fuse:

I. Fill in the junction block fuse rating
: (
) Amp
II. Visual inspection plus continuity tested condition : (
B)
)G
)B
LHS power mirror switch functionality test :

Fill in the continuity test on (LEFT SIDE MIRROR) ;
Pin position up
:(
)&(
):(
)&(
Pin position down : (
)&(
):(
)&(
Pin position right : (
)&(
):(
)&(
Pin position left
)&(
):(
)&(
:(
Condition of mirror switch
C)
:(
)G
)B
LHS mirror unit functionality test :

i
Mirror turns to the RIGHT with terminal: (
) connected to battery
negative
and (
) on battery positive terminal.
ii Mirror turns DOWN with terminal: (

(
) on battery positive terminal.
Condition of mirror motor
:(
) connected to battery negative and
)G
)B
D) Please state the item/s being repaired or replaced :

I. _____________________________________________
II. _____________________________________________
III. _____________________________________________
E) Remarks : _________________________________________________
___________________________________________________________
___________________________________________________________
16
3.
The rear windscreen defogger system is/are :

A) Defogger fuse inspection :
B)
I.
Fill in the defogger fuse rating
:(
) Amp.
II.
Visual condition inspection
:(
)G
) B.
Defogger timer switch functionality test :

Electrical supply test (with test bulb)
I.
State the terminal position: (
) plus (
) on battery positive and
) on negative terminal.
(
II.
State the timer switch timing in minutes (

out.
Condition of the timer switch
:(
) before the test bulb go
)G
)B
C) Defogger relay functionality test :

Relay terminal test
I.
Continuity test on terminal position: (
)& (
II.
Continuity test on terminal position: (

terminal 1 & 2.
)&(
Condition of relay
D)
:(
)G
).
), with B+ between
)B
I.
Visual inspection of the defogger wire network : (
)G
II.
Voltage inspection on the defogger wire network and write down the
measurements as :
Defogger wire functionality test :

(
)B
i. Lower section
:(
) Volt (approximate voltage)
ii. Middle section
:(
iii. Upper section
:(
Overall condition of defogger unit
17
:(
)G
)B
E) State the item/s being repaired or replaced :

I.
_____________________________________________
II.
_____________________________________________
III.
_____________________________________________
F) Remarks: ________________________________________________
___________________________________________________________
4.
The interior room light system fault/s is/are :

A) Room light fuse :

Fill in the junction block DOME fuse rating : (
ii Visual condition inspection
) Amp
: (
)G
)B
B) Room light assembly continuity inspection :

i
With room light switch in ON position, there is continuity between terminal

(
) and unit body ground : ( Yes / No ) (please circle one)
ii With room light switch in DOOR position, there is continuity between terminal
(
) and (
) : ( Yes / No ) (please circle one)
Condition of room light assembly
:(
)G
)B
C) State the item/s being repaired or replaced:

I.
_____________________________________________
II.
_____________________________________________
III.
_____________________________________________
D) Remarks: _______________________________________________
___________________________________________________________
___________________________________________________________
18
5.
The combination meter (water gauge) operation fault/s is/are:

A) Water Receiver gauge inspection test:

a. Fill in the resistance test results on:
i. Test terminal position: (
resistance.
)&(
) with (
) approx.
ii. Test terminal position: (

resistance.
)&(
) with (
) approx.
iii. Test terminal position: (

resistance.
)&(
) with (
) approx.
Condition of water receiver gauge
:(
)G
)B
B) Sender gauge unit test:

a.
Measure the resistance between the terminal and gauge body:

i.
At 50 deg. C : (
) approx. resistance.
ii.
At 120 deg. C : (
) approx. resistance.
Condition of sender gauge
C)
:(
)G
)B
Assuming that the circuit plate is in good serviceable condition, locate &
repair the fault/s.
D) State the item/s being repaired or replaced:

I. _____________________________________________
II. _____________________________________________
III. _____________________________________________
E) Remarks: _______________________________________________
___________________________________________________________
___________________________________________________________
19
6.
The RHS power window system fault/s is/are:

(Do not repair the fault/s)
A)
Power window master switch inspection:

I.
Driver switch continuity inspection test :

With UP position, please fill in the terminal position (
plus (
)&(
)
)&(
With OFF position, please fill in the terminal position (

(
)
), (
) and
With DOWN position, please fill in the terminal position (
) & (
)
plus (
)&(
Condition of master switch
B)
:(
)G
)B
Power window motor inspection test :

a. Right hand side (RHS) :
i.
For motor to turns clockwise battery :

Positive (+) terminal must be connected to terminal
ii.
:(
Negative ( ) terminal must be connected to terminal : (
Reverse the polarity, inspect the motor turning :

___________________.
Condition of power window motor : (
C)
D)
)G
)B
Please state the faulty/s item/s ( But do not repair )

I.
_____________________________________________
ii
_____________________________________________
iii
_____________________________________________
Remarks :
_________________________________________________
_________________________________________________
--END---
20

Task No 3: Engine Management
1
2.
You are provided with the following equipment, tools and materials :
1.1
Engine Model : Hyundai Elantra 1.3 SOHC MY 1998

Fuel System : Electronic fuel injection
1.2
Common hand tools
1.3
Digital multimeter
1.4
Engine analyser SM 450 or SM500
1.5
4 gas analyser
1.6
Hand-held vacuum pump
1.7
Service manual
Clients Problems :
2.1.
The engine could not start.
2.2.
Under load, engine has low output and high fuel consumption.

3.1
Diagnose the problem(s) using the necessary test equipment (eg

multimeter, analyser) and make the necessary repairs, replacing parts,
if necessary;
3.2
Check the exhaust emission;
3.3
Make the necessary adjustments as specified in the workshop manual,

in order to reduce the exhaust emissions to the required specifications;
3.4
Observe the health and safety rules; and
3.5
21

REPORT FORM
1 of 4
Competitor NRIC : ___________________________
Task No 3 : Engine Management

Technology
S/No
Skills Category : Automotive
Performance/
Condition of
Components (Tick)
Items
Good
1
Ignition system
HT Cables
Resistance
Cylinder No 1
__________
Cylinder No 2
__________
Cylinder No 3
__________
Cylinder No 4
__________
Intake Air Temperature Sensor (engine warm)

Sensor
Resistance
Standard
Resistance
_______
_______
Coolant Temperature Sensor
Temperature
Sensor
Resistance
Engine warm
______
Standard
Resistance
______
22
Bad

REPORT FORM
2 of 4
Competitor's NRIC : ___________________________

Technology
S/No
Skills Category :Automotive
Performance/
Condition of
Components (Tick)
Good
Bad
Items
Fuel Injector Inspection

Resistance
Supply voltage
Injector No 1
__________
________ V
Injector No 2
__________
________ V
Injector No 3
__________
________ V
Injector No 4
__________
________ V
Oscilloscope Test ( Any cylinder )

Firing voltage peak (idle speed )
Firing voltage peak waste
______ KV
______ KV
Burn voltage
______ KV
Burn duration
______ ms
23

REPORT FORM
3 of 4

Technology
S/No
Performance/
Condition of
Components (Tick)
Good
Bad
Items
Injector Duration Test

(Duration in milliseconds)
Injector No (
) _________ idle speed

_________ 2000 rpm
_________ snap acceleration
_________ deceleration
Exhaust Emission Test

At Idling Speed
CO concentration
________ %
CO2 concentration
________ %
O2 concentration
________ %
HC concentration
________ ppm
24

REPORT FORM
4 of 4
Competitor NRIC : ___________________________

Technology
S/No
Skills Category : Automotive
Performance/
Condition of
Components (Tick)
Good
Bad
Items
Power Balance Test
Best-performing
Cylinder
_____________ %
Worse-performing
Cylinder
____________ %
Condition of engine :
--- END ---
25

Task No 4 : Diesel Fuel Systems

1 You are provided with the following equipment, tools and materials:
1.1
Opel Combo 1.7 Van
1.2
GM Tech2 Diagnostic Scanner
1.3
GM Technical Information System
1.4
Toxr Wrench (Hexican)
1.5
Digital Multimeter
1.6
Common Hand Tools
1.7
Fender Cover/Seat Cover
1.8
Torque Wrench (Maximum 70Nm)
1.9
Floor Jack/Safety Stand
1.10
Fuel Pressure Gauge
26
2 Clients Complaints :
2.1
The check engine light has turned on.
2.2
The vehicle could not start and when it started it stalled.
2.3
There was no response from the accelerator pedal.
3 You are required to:

3.1
Diagnose the problems, rectify them and get the vehicle started
3.2
On completion of repair, confirm the vehicle is in good condition by

scanning through the operating parameters and fill n the Report Form.
3.3
Observe safe working procedures at all times.
4 Safety Instructions:
4.1
Remember that you are working on a high pressure system (up to 2000
bar is present at the high pressure system connections).
4.2
Before carrying our any operation on the high pressure system, ensure
that the lines are not pressurised.
4.3
Lines must not be opened or released when the engine is running.
4.4
Before opening the high pressure fuel system, disconnect the battery and
ensure that the high pressure fuel system has depressurized.
4.5
Always check for leaks after opening the high pressure system.
4.6
Utmost cleanliness must be ensured when working on fuel injection

system.
4.7
All fuel lines must be tightened to the specific torque.
27

REPORT FORM
1 of 5
Competitor NRIC : ___________________________
S/N
Items
Preparation
Measurements
Nominal
General Condition of Engine (Visual)
Battery Condition
Engine Coolant Level
Engine Oil Level
Fuel Level
Others
28
Actual
Performance/Conditions
of Components
Good
Bad

REPORT FORM
2 of 5
Competitor NRIC : ___________________________
S/N
Items
Measurements
Engine Cannot Start
Nominal
Battery Voltage
2
3
Fuel Rail Pressure

Diagnostic Trouble Code (DTC) If Present
3.1
3.2
Actual
of Components
Good
Bad
3.3
3.4
3.5
3.6
4
Harness Terminal Measurement

DTC
Task
Measurements
Measured
Terminals
Nominal
29
Actual
of Components
Good
Bad

REPORT FORM
3 of 5
Competitor NRIC : ___________________________
S/N
Items
Measurements
Engine Check Light On
Nominal
Engine Check Light Status

2.1
2.2
Actual
of Components
Good
Bad
2.3
2.4
2.5
2.6

DTC
Task
Measurements
Measured
Terminals
Nominal
30
Actual
of Components
Good
Bad

REPORT FORM
4 of 5
Competitor NRIC : ___________________________
S/N
Items
Measurements
Accelerator Has No Response
Nominal
Responsiveness of Accelerator
Pedal
Engine Check Light Status

3.1
3.2
Actual
of Components
Good
Bad
3.3
3.4
3.5
3.6
4

DTC
Task
Measurements
Measured
Terminals
Nominal
31
Actual
of Components
Good
Bad

REPORT FORM
5 of 5
Competitor NRIC : ___________________________

S/N
Items
Measurements
Nominal
S/N
8
Acceleration Pedal Position

Sensor 1
1.1 Pedal not actuated
1.2 Pedal to wide open throttle
Sensor 2
1.3 Pedal not actuated
1.4 Pedal to wide open throttle
Engine Started
2.1 Idle speed (rpm)
0.9~1.1v
3.6~4.3v
0.4~0.6v
1.8~2.2v
800-1000
Coolant Temperature
3.1 At idle (Degrees C)
80-110
Fuel Temperature
10-60
Intake Air Temperature

10-50
Mass Airflow Temperature

6.1 At idle (Kg/h)
25-40
Boost Pressure (KPa)

7.1 At idle
7.2 At 3520
90-110
130-160
Items
Common Rail Pressure (MPa)
8.1 At Idle
Actual
of Components
Good
Bad
Measurements
20-35
--- END ---
32
of Components

Task No 5: Braking Systems

1
1.1
Car Model: Nissan Sunny N16 (A/T) 2005
1.2
Disc brake service tool
1.1
Flare nut torque wrench
1.1
Handbrake adjusting tool
1.1
Digital Multimeter
1.1
Wire harness for testing
1.1
Brake fluid
1.1
Hoist
1.1
Fender cover / seat cover / steering wheel cover / Paper Floor Mat
1.1
Safety stand / floor jack
1.1
Common hand tools
1.1
Torque wrench
1.1
Electronic Service manuals (ESM)
1.1
Micrometer
1.1
Vernier caliper
1.1
Transparent tube and container
1.1
Rubber grease
1.1
Sucker / syringe
33
Clients Problem:
The owner of a Nissan Sunny has problems on his/her car braking control
system.
2.1
Brake judder and noisy whenever he / she applied brake.
2.2
Owner feel the brake control system seem jammed and vehicle lost of
power.
2.3
The Anti-Lock Brake System (ABS) warning light stays On and ABS
does not operate.
2.4
Hand brake warning light stays On at all time.
You are required to:

3.1
Rectify / repair all faulty components according to manufacturers

specifications;
3.2
Carry out self diagnosis test on anti-lock braking system using the
Consult II to;
3.3
Complete the Report Form(s); and
3.4
Report to the examiner upon completion.
34

REPORT FORM
1 of 2

Task No 5 : Braking Systems
S/No
Performance/
Condition of
Components (Tick)
Good
Bad
Items
Brake Booster condition
Brake pad / shoe thickness

Measured Value
Standard Value
2.1 Front right hand
_________mm
________mm
2.2 Front left hand
_________mm
_________mm
2.3 Rear right hand
_________mm
_________mm
2.4 Rear left hand
_________mm
_________mm
Brake Pedal Height adjustment

3.1
Brake Pedal Height
_____________mm.
3.2
Pedal Freeplay
______________mm
3.3 Brake Booster check valve condition

4
Maximum disc run out position
4.1 Front right hand
Measured Value
_________ mm
Standard value
_________ mm
4.2 Front left hand
_________ mm
_________ mm
Hand brake
Setting
_________clicks
35

REPORT FORM
2 of 2
Competitor NRIC : ___________________________
Task No 5 : Braking Systems
S/No

Performance/
Condition of
Components (Tick)
Good
Bad
Items
ABS Components/system test

Diagnosis items detected
Answers 6.1 _________________________________
6.2 __________________________________
Wheel sensors
6.3 Front left wheel sensor resistance
6.4 Front right wheel sensor resistance
6.5 Rear left wheel sensor resistance
6.6 Rear right wheel sensor resistance
6.7 ABS ground circuit check
--- END ---
36

REPORT FORM (1 of 2)
Competitor's NRIC : _________________
Task No : Anti-lock Brake System
S/No
Performance/Condition
of Components (Tick)
Good
Bad
Items
Brake Booster condition
Brake pad / shoe thickness

Measure Value Standard Value
2.1 Front right hand _________mm ________mm
2.2 Front left hand
_________mm _________mm
2.3 Rear right hand
_________mm _________mm
2.4 Rear left hand
_________mm _________mm
Brake Pedal Height adjustment

3.1
Brake Pedal Height
_____________mm.
3.2
Pedal Freeplay
______________mm
3.3 Brake Booster check valve condition

4
Maximum disc run out position

Measure Value
4.1 Front right hand _________ mm
Standard value
_________ mm
4.2 Front left hand
_________ mm
_________ mm
Hand brake
Setting
_________clicks

REPORT FORM (2 of 2)
Competitor's NRIC : _______________
S/No
6
Good
Bad
Items
ABS Components/system test
Diagnosis items detected
Answer:6.1 _________________________________
6.2 __________________________________
Wheel sensors
6.3 Front left wheel sensor resistance
_____
6.4 Front right wheel sensor resistance
____
6.5 Rear left wheel sensor resistance
____
6.6 Rear right wheel sensor resistance
____
6.7 ABS ground circuit check
--- END ---

Task No 6: Automatic Transmissions

1
1.1
Car Model : Mercedes-Benz E-Class equipped with automatic

transmission 722.6
1.2
Mercedes-Benz automatic transmission 722.6 dismantled components
1.3
Star diagnosis
1.4
Service manuals
1.5
Mercedes-Benz automatic transmission special tool
1.6
Digital multi-meter
1.7
Depth gauge (range 0 100, graduation 0.05mm)
1.8
Micrometer (range 0 25mm)
1.9
Straightedge (length: at least 300mm)
1.10
Common hand tools
1.11
Wheel choke
1.12
Hydraulic press
1.13
Fender cover
1.14
Calculator
1.15
Hoist
1.16
Rags/ Lint-free cleaning papers
Clients Complaints:
2.1
There is sharp jerk when gear lever is shifted from positions P to R

and D.
2.2
Vehicle has no power and it seems like the transmission is not upshifting normally while driving.
2.3
A Mercedes-Benz automatic transmission 722.6 has been diagnosed

and confirmed that overhauling is needed. The dismantled
components require further inspection.

Part A : OntheCar Inspection
3.2
Check and recommend the parts that need to be ordered and to rectify
the vehicle jerk problem.
3.3
Check and recommend the parts that need to be ordered and to rectify
the transmission gear shifting problem.
Part B : OfftheCar Inspection

3.4
Identify the transmission clutches and brakes, and to install the

operating components in working order.
3.5
Disassemble and assemble Clutch K1 for inspection of external and

internal discs condition. Check the condition of K1 piston seal ring as
well as to check and adjust the K1 clearance.

REPORT FORM
1 of 4
Competitor NRIC : ___________________________
Task No 6 : Automatic Transmissions
Skills Category : Automotive Technology
Good
Bad
Items
S/No
Part A : On-the-Car Inspection

1
Automatic Transmission Fluid Check
1.1 ATF level (Before top-up) :
1.2 ATF condition :
Recommendation:
__________________________
__________________________
2
Star Diagnosis Check

2.1
2.2 Fault code (after erase):
Recommendation:
__________________________
__________________________

REPORT FORM
2 of 4
Competitor NRIC : ___________________________

S/No
Good
Bad
Items
2.3 Actual values / actuations :
Recommendation:
__________________________
__________________________
Electrical / Electronic Component & Wiring Check

3.1 Shift solenoid valve conditions :
3.1.1 Specified resistance value
________
3.1.2 Measured value

1-2/4-5 Shift solenoid valve
resistance
________
2-3 Shift solenoid valve

resistance
________
3-4 Shift solenoid valve

resistance
________
3.2 Terminal resistance value :

Between 1-2/4-5 and 2-3 shift
solenoid valve
________
Between 1-2/4-5 and 3-4 shift

solenoid valve
________
Between 2-3 and 3-4 shift

solenoid valve
________
Recommendation :
__________________________
__________________________

REPORT FORM
3 of 4
Competitor NRIC : ___________________________

Technology
Good
Bad
Items
S/No
3.3 Starter lockout contact conditions :

3.3.1 Specified resistance value
At position
________
At position
________
3.4. Wiring conditions :

Recommendation:
__________________________
__________________________

REPORT FORM
4 of 4
Competitor NRIC : ___________________________
Part B : Off-the-Car Inspection

4
Clutch K1
4.1 Condition of external disc
4.1.1 External disc 1
4.2 Condition of internal disc
4.2.1 Internal disc 1
4.3 Condition of seal ring
4.4 K1 Clearance
Measured Value
Standard Value
_______ mm
_______ mm
-- END --
10

Task No 7: Steering & Suspension

1
1.1
Car Model : Toyota Vios NCP42
1.17
Common hand tools
1.3
Scissors hoist
1.4
Wheel alignment lLift (4-posts)
1.5
Wheel alignment machine - 4 wheel/8-toe alignment type
1.6
Wheel balancer machine
1.7
Tie rod end remover, SST No: 09628-62011/ coil spring compressor
SST No: 09727-30021 (00010, 00021, 00031)
1.8
Tyre pressure gauge
1.9
Tyre tread depth gauge
1.10
Tyre balancing weights (adhesive type, assorted weights)
1.11
Front suspension strut Left & Right
1.12
Tie rod end ball-joint Left & Right
1.13
Service manual
1.14
Belt tension gauge
1.15
Power steering fluid ATF Dextron II or III
1.16
Torque wrench set (range from 29 Nm to 103 Nm)
11
Clients Problems :
A client complains that the ride is very bouncy and the steering wobbles at
about 80 km/h. In addition, it is observed that the tyre wear is uneven.

Diagnose the problem(s) using the necessary test equipment and make the
necessary repairs. You should replace worn parts where necessary.
3.1
Remove and check condition of one* front suspension strut assembly
3.2.
Remove coil spring
3.3.
Inspect steering knuckle
3.4.
Inspect operation of shock absorber
3.5.
Reassemble the front suspension strut
3.6
Remove and inspect both front tie rod end ball joints;
3.7.
Inspect both lower control arm ball joints for excessive looseness;
3.8.
Refit right tie rod end;
3.9.
Refit front strut;
3.10.
Check tyre pressure and tread depth;
3.11.
Check front wheel bearing for looseness
3.12.
Balance both front wheels;
3.13.
Prepare vehicle for wheel alignment check;
3.12
Perform 4-wheel alignment and make adjustments where necessary;
3.13
Print readings before and after adjustment;
3.14
Observe the health and safety rules; and
3.15.
* The judge will inform you which side to remove.
12

REPORT FORM
1 of 2
Competitor NRIC : ___________________________
Task No 7 : Steering & Suspension
Perform the following inspection:
S/No
Yes
No
Items
Steering System
Fluid level Condition OK ?
Leak at steering gearbox ?
Leak at Steering Pump ?
Suspension System
Tie rod ball-joint - Condition OK ?
Front absorber - Condition OK ?
Steering and tyres

Tyre tread depth (worst case) Acceptable ?
Perform the following measurements and record their readings in the table
below;
Tyre
pressure
L.F:
R.F. :
L.R. :
R.R.:
L.F:
R.F. :
L.R. :
R.R.:
(Kpa)
Tyre tread
depth
(mm)
13

REPORT FORM
2 of 2
Competitor NRIC : ___________________________
Task No 7 : Steering & Suspension
Perform the following inspection :
Wheel Alignment
First Reading (before adjustment)
Left front camber
________
Right front camber
________
Left front caster
________
Right front caster
________
Front wheel toe (total)
Front wheel toe-out-on-turns - OK ?
Left rear camber
________
Right rear camber
________
Rear toe (total)
________
________
-- END ---
14

2008 Automotive Technology Final

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WORLDSKILLS SINGAPORE 2008

Diesel Fuel Systems

Steering and Suspension

Tools and Material List

Measurements should be taken using the measuring instruments or

You are required to adopt safe practices throughout the competition.

Diesel Fuel Systems

Steering & Suspension

WORLDSKILLS SINGAPORE 2008 FINAL

Task No 1: Engine Mechanical

Specific Instructions to Candidates

One Engine Model: Toyota 4A-FE (for stripping & assessment)

One Engine Model: Toyota 4A-FE (able to crank and perform

Timing belt deflection tool

Common hand tools

Spark plug wrench

Straight edge for cylinder head

Torque wrenches (small and medium range)

V-blocks for camshaft (one pair)

Dial gauge with magnetic stand

Cylinder bore gauge

Piston ring expander

Piston ring compressor

Cylinder ridge reamer

Small hole gauge (for cylinder valve guide bushings)

Valve seat cutter

Pneumatic valve lap

Cylinder head supports

Rubber hose for connecting rod bolts

New engine oil (whether necessary or not)

Lint free clothes for cleaning

Valve spring compressor

External micrometer : 75 mm to 100 mm

You are required to:

Remove the timing belt and tensioner;

Remove rocker arm assembly and camshaft;

Remove cylinder head and gasket;

Remove oil pan;

Remove No. ( 1 )* piston assembly;

Perform the necessary measurements and complete the Report

Make recommendations for the components that are being inspected

Reassemble all components to the engine block; and

Conduct engine compression test. **

* The judge will inform you which number to remove/measure/change.

WORLDSKILLS SINGAPORE 2008 FINAL

Competitor NRIC : ___________________________

Task No 1 : Engine Mechanical

Skills Category :Automotive Technology

2.1 Valve stem to guide

2.2 Valve stem to guide

WORLDSKILLS SINGAPORE 2008 FINAL

Competitor NRIC : ___________________________

Skills Category :Automotive Technology

No. ( 1 ) Piston and Connecting Rod Assembly

3.3 Oil ring (side rail)

WORLDSKILLS SINGAPORE 2008 FINAL

Competitor NRIC : ___________________________

Task No 1 : Engine Mechanical

Skills Category :Automotive Technology

5.2 Cam lobes height

5.4 Camshaft oil

5.5 Camshaft thrust

5.3 Camshaft journals

WORLDSKILLS SINGAPORE 2008 FINAL

psi __ psi

psi __ psi

psi __ psi

psi __ psi