Class of 14/15 Pass Out - Thursday 11th June 2015

A momentous day was reached today, with the Class of 14/15 taking their final exams and completing their City & Guilds Diploma, Level 3 Advanced Motor Vehicle Diagnostics Course. Very much a day of mixed emotions for myself, on the one hand happy having completed a 3 year programme of hard study and examination, yet on the other, saying farewell to a group of fellow students and Tutors with whom I have been in the presence of for the past 3 years.

The experience has most definitely been the re-making of me, and I would thoroughly endorse it to anyone who may be considering re-training, or wishing to gain additional knowledge and confidence as a result of it.  I continue to work for my current employer, however having now undergone this experience, I remain focussed upon attaining some form of employment within the field of Education, in whatever form that it may reveal itself.  Focussed and buzzing I remain - Thank you One and all very much indeed.

The Garage - Friday 5th June 2015

New Blue 2 Post Ramp to increase lift capacity

Not much in the way of automotive maintenance today due to garage re-furbishment work. I have been away for the past week visiting family for half term, and I was most surprised to return and find an additional 2 poster in the Main Workshop.  Clever bit of space management!

After initially assisting Dave refit a front bumper and grill to a Jeep Cherokee, I was required to sit inside the vehicle to operate the throttle and bleed the cooling sytem - Due to the width of the vehicle, an access issue became apparant and a slim volunteer was therefore required!  With the Jeep satisfactorarily road tested it was then down to paint stripping, scraping, brushing and mopping in readiness for a new coat of paint.

Dan on the Mop

We were assisted by a favourable breeze which assisted with the floor drying process, and then it was down to a bit of trigonometry in marking out the bays ready to be painted.

Andy "Pythagoras"
Kirby at work

After confirming satisfactory alignment and tolerances, it was time to mark out the bays with masking tape.

Anyone for
Badminton?

With all three 2 Post Bays marked out it was time to bring out the roller and pole, and a tin of very red paint!  Extremely smart!

Bay 1 nearly done

You missed a bit Dan!

Professionally timed "Photo-bomb"
by Jim! Outstanding agility and
ability!

Bay 2 was almost complete when the big hand was on 12 and the little one was on 4, whereupon I was required to be elsewhere. Due to the imminent cessation of College Studies next Thursday (final exam), I will be putting in some additional hours at the garage as;

a. I would otherwise go off the boil and lose focus, and;

b. I enjoy being there!  Great crew and experiences forevermore - thanks guys,  See you all on Monday and Happy Friday!

Task No 13 - Vehicle Inspection - Tuesday 19 May 2015

Plan

Undertake inspection and test of 4 Post Ramp prior to vehicle loading.  Load vehicle and undertake inspection as per current regulations and criteria and report findings.

Task Requirements

• Inspection & Report
• Emissions Test
• Tyre Tread Depths
• Foot Brake Performance
• Hand Brake Performance
• Complete Knowledge Questions
• Complete Blogger
• Report to Assessor with Analysis and Diagnosis
• Account for all tools and equipment.
• Clean and Tidy Work Area.

Analysis

The inspection was performed following the provided check sheet, and the following observations recorded:

Wipers/Washers 

OSF Jet blocked - Washers do not provide enough liquid to clear screen in conjunction with wipers (6.1.3)

Doors

OSR Door does not open from inside (6.5.5)

Registration Plates

Vehicle Registration Plates absent from front and rear of Vehicle (6.8.1 a)

Headlamp Aim

Headlamp Setting 1 %

Headlamp Aim of the NSF was too high (1.6.1)

High Beam Pattern

Steering

OSF Track Rod Loose (including split gaiters) (2.2.c)

Brakes

Imbalance was noted to NSR handbrake.

Diagnosis

Due to the faults identified above, a pass certificate can not be issued for this vehicle, until the faults have been rectified, and a further test subsequently conducted.

Task No 11 - Faults in Steering System

Plan

Task Commenced:  Tue 5th May 15.

Gather all tools and equipment and retrieve vehicle information for entry onto Job Card.  Conduct an inspection and test of the 4 post ramp prior to vehicle loading.  Crack front wheel nuts and raise front of vehicle on beam jack.  Remove front road wheels and track rod ends and report. Reinstate track rod ends and road wheels, lower beam jack and torque road wheels to manufacturer's specification.  Undertake 4 wheel alignment using Hawkeye Aligner.

Task Requirements

• Remove and Re-fit Track Rod Ends.
• Undertake 4 Wheel Alignment.
• Complete Knowledge Questions.
• Complete Blog.
• Report to Assessor with Analysis & Diagnosis.
• Account for all tools and equipment & tidy work area.

Analysis - Track Rod Ends

Track rods and ends were disengaged from steering knuckle.  Track rod ends were wound off whilst counting the number of turns respectively. 

NSF Turns: 17

OSF Turns: 16

Rubber boots to both ends were badly split and both stems displayed excessive levels of play.

Split Boot

Diagnosis

Due to the extent of splitting to the respective boots, the excessive levels of stem play and the unknown amount of time of exposure to the elements and debris, I would recommend ordering 2 new track rod ends, rather than just replacing the boots.  There was also an inbalance in the number of turns of the track rod ends noted at removal.  In such circumstances it is recommended that the amounts of turns are added together and then halved and evened accordingly.  16+17= 33.  Round down to 32 and divide by 2 = 16 turns back on for both track rod ends.  The vehicle should now also undergo a wheel alignment accordingly.

The Garage - Friday 15th May 2015

1991 VW Transporter

Today I was assigned an electrical fault (lighting) task on a 1991 VW Transporter/Camper Van.  The vehicle has been at the garage for about 3 weeks, as the fault has proved very elusive to all who have attempted, and priority work loading has since prevented further progress.  This was my second attempt, as the first involved checking all the fuses and relays and the replacement of the left hand "Main Beam/Dip" column stalk, which was originally thought to be the cause of the fault.  There was originally evidence of a broken contact on the original component, however upon its re-assembly the fault of "no main beam/dip" remained.





Due to the level of work being undertaken inside, I was required to undertake the task outside in the bright and warm sunshine (ah well)! This also brought to the front of my mind the probable pining for the vehicle by the customer for the imminent Summer months, which spurred me on to solve the issue this time around!

Column Shroud
Removed

Having first removed the steering column shroud, I then 
proceeded to remove the horn switch to expose the steering wheel securing nut.  With the nut removed I was able to remove the steering wheel and expose the first of the 2 column stalks.  This was the component that was replaced last time around, and as far as any previous disassembly had gone.  Andy had instructed me to remove both stalks this time, and be particulalry vigilant in observing any broken or corroded wires and contacts in the process.

2nd Stalk exposed

Steering Wheel
Removed

Contact at 6 Oclock
originally damaged

Electrical Connector
Examined & Removed

It was at this stage I noticed that a connector on the 2nd stalk was only partially connected, which I duly noted on my Job Card for bringing to the attention of Andy at de-brief.  With all connections fully removed I was then able to remove the 2nd stalk, leaving the steering column stripped as far as the job required.

Partially engaged
connector

2nd Stalk Removed

Stripped Column

I then reported my findings to Andy who instructed me to re-assemble the components without attaching the steering wheel, ensuring all connectors were fully engaged, and then call him again to undertake another test of functions.

Happy Friday!
Which way to
Zone 2 please!

With all carefully completed Jim came out and observed a test of functions - which I am pleased to report was an outstanding success!!  With fault recorded as loose connector, it was then just a case of re-attaching the steering wheel with a high torque setting (ensuring that the road wheels were as straight as possible), and then reconnecting, inserting and testing the horn switch (which I did several times with a big smile)!  I was then requested to bring the vehicle to the front of the Workshop in order for it to undergo an MOT re-test and a subsequent front wheel allignment.  This was unfortunately the time that I was required to depart for my evening location, however it was a very satisfying and busy day which I enjoyed thoroughly!

Visit to Oulton Park - Tuesday 12th May 2015

Had a fantastic day out today with the College, and the Sun came out too! We visited Oulton Park Race Circuit, which was a most welcomed break from our previous years studies.  We arrived at College at 9 am (mostly) ready to be counted and then awaited the arrival of our transport, which was scheduled for departure at 10 am.  With all heads counted and the minibus present, we were duly escorted off to Oulton Park Race Circuit under the supervision of Kev "the college stig" Rogers (as he was affectionately named), even though the minibus was speed limited.  There was suggestion on the way that Kev should take the College Chariot onto the circuit for a bit of "drifting", however I am pleased to report that eventuallity did not manifest itself!

Level 3 Crew
De-bused

This was another first for me, even though I spent most of my school years living a stone's throw away from Thruxton!  The days' attraction was road cars on a track day, and there were some outstanding examples of performance tuned and balanced vehicles taking part (one in particular made my day, and one in particular made Wendy's)!  After a quick comfort break and a caffiene shot at the cafe (ouch), we set off to find a good vantage point to capture some photographs of the cars being put through their paces.

My reactions were nowhere quick enough to capture any detailed photographs of the cars in action, however we were granted exclusive access to the pits at the circuit stand down, and managed to catch up with the crews and have a closer look at the cars, which was awesome!  I

Austin

eventually caught up with my favourite, which caught me completely by humoured surprise in performance testing, as it was the very last car I expected to see cutting along at a "very" respectable pace with the others.  I have a great video on my phone which I will treasure for evermore, and as soon as I find a way of getting the video on my phone compatible with Blogger, it will be included!

E-Type Jaguar

There was one other car that caught my attention, and that was an E-Type Jaguar.  Absolutely "mint" condition also, and how the heck those drivers have the kahoonas to drive them at such a pace without fear of giving them a "ding" is beyond my comprehension!

E-Type Engine!

After chatting with the crews' of a few more of the other cars it was unfortunately "time up" for us all, and back to the bus we all duly headed for the short journey back to college.  Big thanks to Kevin for his guidance and driving, and also to Carl Roberts for making the event possible in the first place - very much appreciated, and thanks again!

Faults in Starter/Charger Systems - Task No 11 - Tuesday 28 April 2015

Plan

Gather all tools and equipment required and retrieve vehicle information for entry onto Job Card.

Task Requirements

• Obtain Battery Charge Level
• Obtain Battery Voltage Starter Cranking
• Ascertain Maximum Regulated Voltage
• Ascertain Alternator Current Output on load
• Establish Starter Motor Current Cranking
• Establish Volt Drop Alternator Circuit
• Establish Volt Drop Starter Circuit
• Capture Images of Task Progress
• Report to Assessor with Analysis & Diagnosis
• Complete Blogger
• Account for all Tools and Equipment and tidy work area

Preliminary Vehicle Checks

Healthy Battery

Battery voltage was checked using a Voltmeter, which returned a healthy reading of 12.62 Volts (12.6 V minimum).  All other engine bay fluid levels were also checked and ascertained to be maintained at a satisfactory level for operation.

Starter Cranking

Analysis Starter/Charger Circuits

Battery Voltage (Starter Cranking).  Coil was disconnected and engine was cranked whilst measuring Battery Voltage with a Voltmeter. Reading returned was 11.54 Volts (Minimum 10 V Recommended).

Alternator Maximum Regulated Voltage.  Coil was reconnected and engine started whilst measuring Battery Voltage with a Voltmeter. Reading returned was 14.27 Volts (Recommended 13.8 V to 14.4 V).

Alternator Output Current.  With the engine running, this was measured using an Amps Clamp placed around the Alternator Output Lead.  Reading returned was 54.1 Amps.

Starter Motor Current on Cranking.  With the Coil disconnected, this was measured using an Amps Clamp placed around the Starter Motor Output Lead.  My photographic device was not quick enough to capture the initial reading, however the reading was confirmed visually at 153 Amps.

Volt Drop Alternator
Insulated Circuit

Volt Drop Starter
Circuit Earth Return

Volt Drop Alternator Circuit.  This was measured using a Voltmeter.  Volt Drop on the Insulated circuit was recorded at 0.44 Volts and at 0.78 Volts on the Earth Return (0.5 Volts maximum - See Diagnosis).

Volt Drop Starter Circuit.   This was measured using a Voltmeter.  Volt Drop on the Insulated Circuit was recorded at 0.05 Volts and at 0.2 Volts on the Earth Return (0.5 Volts maximum).

Diagnosis

Volt Drop Alternator
Earth Return upon
Rectification

Voltage Drop on the Alternator Earth Return was recorded at 0.78 Volts, exceeding the maximum 0.5 Volts permissible.  Further examination revealed a loose Earth connection causing high resistance.  The connector was re-secured and a further test undertaken accordingly.  Subsequent testing resulted in obtaining a reading of 0.18 Volts.  All other readings indicated a healthy Charging and Starting electrical system.

Well done.

I have had a look at the last few posts on this Blog and have highlighted in red some of the literacy mistakes/grammatical errors you have made. I would like now for you to correct these mistakes but leave them in red so that I can see what has been changed and to support you further with your literacy I suggest you go back through all of your posts and see if you can spot any mistakes.

As expected there are very few mistakes but I managed to find more than three which gets me off the hook (and I promise I did not sabotage it).

Web Conference - Tuesday 21st April 2015

Coleg Cambria was recently short listed for an award for the Innovative Use of Technology and Myself and a Level 1 Student, representing Motor Vehicle, were invited to be present at the College's bid presentation.  The bid was presented live to Cardiff from the Web Conference Suite using some impressive hi-tech wizardry.  We were accompanied by Carl Black and Charlie Jones and met up with a few others from different parts of the College in the Conference Suite ready to "go live".

I was most impressed by the facility, but more so from the brief insight into how much time, finance and effort is invested into creating a positive learning environment for the Students and Tutors alike, all of which happens completely behind the screens.  The names of the presenters I cannot recall, however I can say they were thorough and professional, clearly showing how much work had already been done to get this far in the selection process, and how impassioned they were in their field of employment.

I was to give a brief statement regarding the use of Blogger in complimenting and enhancing my studies, followed by Carl Black as lead Tutor on the subject.  Carl Roberts was away leading an exchange visit to Bremen in Germany, which was unfortunate but unavoidable, as he has been the Tutor to take up the lead using this facility, inspiring us to use it to its fullest potential.  I was a bit of a techniphobe regarding technology prior to commencing Level 3, however It didn't take me long to see the potential in what he envisaged and I have since thrown myself right in - almost to the point of being addicted to blogging (however I'm sure there's a 0800 helpline somewhere)!  It is a fantastic facility which not only acts as a learning process reinforcement tool, but is mightily flexible in multiple other uses, such as for also including a CV for viewing electronically by prospective employers.  I can only support and endorse it to all others.

The Level 1 Motor Vehicle Student (name?) then gave his view on the use of Pro-Portal, seconded by Charlie Jones, prior to the meeting moving to the other gathered crew, and then out to Northop who were also present via Web Cam.  I think the judges were impressed with what they saw and heard and I sincerely hope the College wins the award for which they clearly deserve.  Results will not be known until the end of May 2015 so positive thoughts always!  Great experience to be involved with -  Diolch!

Exhaust Emissions & Control (SI) - Task No 3 - Tuesday 21st April 2015

Plan

Gather all tools and equipment required and retrieve vehicle information for entry onto Job Card.

Task Requirements

• Establish Lambda Operating Voltages
• Establish correct functioning of Sensor
• Record Fault Codes
• Provide Graphs/Drawings of Performance Patterns
• Record Emissions at Tail Pipe
• Establish Fuel Injector Duration at Idle
• Complete Knowledge Questions
• Complete Blog
• Account for all Tools and Equipment and tidy work area
• Report to Assessor with Analysis and Diagnosis

Preliminary Vehicle Checks

Healthy Battery

Battery voltage was checked using a Voltmeter and returned a healthy reading of 12.82 Volts.  All other engine bay fluid levels were also checked and ascertained to be maintained at a satisfactory level for operation.

Analysis Fault Codes

Initial Search Results

Autel Diagnostics scanner was connected to vehicle ECU via the DLC and interrogated for DTCs accordingly.  Initial search was cleared and then a fresh search undertaken, which returned ""No DTCs Found".

System Pass

Sensor Location

4 Wire Zirconia Sensor Connector

Analysis Lambda Sensor Voltages

Manufacturer's Data suggests that expected operating voltages to be within the range of 0.2 Volts - 0.8 Volts (Lean to Rich).  The Sensor under examination is a 4 Wire Zirconia Pre-Cat O2 Sensor.  There are 2 White wires which are for the Heater Element, a Black wire for the Signal and a Grey wire for the Signal Earth Return.  All wiring and connections appeared to be integrally sound.  A Picoscope was then connected as per the on-board package instructions and then the engine started and allowed to reach operating temperature at idle RPM.

Diagnosis

Expected Pattern of correct Sensor operation

Pattern Retrieved (at Idle RPM)

Sensor Switching

The image returned was not as expected and initially suggested a faulty sensor.  However upon applying the throttle, the pattern performed correctly, moving between rich and lean accordingly.  








In order to test the heating element, the engine was turned off and the sensor disconnected. An Ohmeter was then used to probe the 2 white wires (Heater Element), which returned a reading of Infinity and confirmed a faulty sensor. Recommend R&R new Sensor and then confirm procedure with an emissions test accordingly.

Monday 27th April 2015

Analysis Injector Duration

A Picoscope was connected as per the on board package instructions and a test conducted to ascertain injector duration performance under a variety of throttle operating conditions.  Manufacturer's data suggests a pattern be retrieved within the parameters as displayed below:

Expected Pattern at Idle

Diagnosis Injector Duration

Images were captured at start up, throttling and idle, all of which met the expected parameters:

Start Up

Throttling

At Idle RPM (Measured)

Voltage peaked at 54.33 Volts (between 50-60 Volts recommended) and had a duration of 3.168 ms, indicating satisfactory performance.

Analysis Emissions Test

Manufacturer's Emissions Data

Manufacturer's Data was retrieved regarding permissible emissions and were listed as follows:

Oil Temp: 80 Degrees C
CO (idle): 0.5% Max
HC (idle): 100ppm
CO2 (idle): 14.5 - 16%
O2 (idle): 0.1 - 0.5 %

Emissions Results

Diagnosis Emissions Test

The vehicle failed to meet the minimum standards with an excessively high CO & HC content recorded.  Idle RPM appears higher than it should be, and it is recommended that the Throttle Potentiometer be checked, and the test re-initiated accordingly.