For every task in Mechanical and Electrical Components, the following safety
requirement must be strictly enforced:
Comply with personal and environmental safety practices associated with clothing;
respiratory protection; eye protection; hand tools; power equipment; proper
ventilation; and the handling, storage, and disposal of chemicals/materials in
accordance with local, state, and federal safety and environmental regulations.
| III. MECHANICAL AND ELECTRICAL COMPONENTS |
|
A. Suspension and Steering |
|
| 1. |
Identify suspension system fasteners that should not be reused. |
HP-G |
| 2. |
Inspect and replace rack and pinion steering gear, tie rod ends, and bellows boots. |
HP-G |
| 3. |
Inspect alignment, adjust tension, and replace power steering pump belts. |
HP-G |
| 4. |
Remove and replace power steering pump, pulleys; inspect pump mounts. |
HP-G |
| 5. |
Inspect and replace power steering hoses and fittings. |
HP-G |
| 6. |
Remove and replace power steering gear (non-rack and pinion type). |
HP-G |
| 7. |
Remove and replace power rack and pinion steering gear; inspect and replace
mounting bushings and brackets; ensure proper mounting location. |
HP-G |
| 8. |
Inspect and adjust (where applicable) steering linkage geometry
(attitude/parallelism). |
HP-G |
| 9. |
Inspect and replace pitman arm. |
HP-G |
| 10. |
Inspect and replace relay (center link/intermediate) rod. |
HP-G |
| 11. |
Inspect, remove and replace idler arm and mountings. |
HP-G |
| 12. |
Inspect, remove and replace tie rod sleeves, clamps, and tie rod ends. |
HP-G |
| 13. |
Inspect, remove and replace steering linkage damper. |
HP-G |
| 14. |
Inspect, remove and replace upper and lower control arms. |
HP-G |
| 15. |
Inspect, remove and replace upper and lower control arm bushings, shafts and
rebound bumpers. |
HP-G |
| 16. |
Inspect, remove and replace upper and lower ball joints. |
HP-G |
| 17. |
Inspect, remove and replace steering knuckle/spindle/hub assemblies (including
bearings, races, seals, etc.). |
HP-G |
| 18. |
Inspect, remove and replace front suspension system coil springs and spring
insulators (silencers). |
HP-G |
| 19. |
Inspect, remove, replace, and adjust suspension system torsion bars, and inspect
mounts. |
HP-G |
| 20. |
Inspect, remove and replace stabilizer bar bushings, brackets, and links. |
HP-G |
| 21. |
Inspect, remove and replace MacPherson strut cartridge or assembly, upper
bearing, and mount. |
HP-G |
| 22. |
Inspect, remove, and replace rear suspension system transverse links, control
arms, stabilizer bars, bushings, and mounts. |
HP-G |
| 23. |
Inspect, remove, and replace suspension system leaf spring(s), leaf spring
insulators (silencers), shackles, brackets, bushings, and mounts. |
HP-G |
| 24. |
Inspect axle assembly for damage and misalignment. |
HP-G |
| 25. |
Inspect, remove and replace shock absorbers. |
HP-G |
| 26. |
Inspect, remove and replace air shock absorbers, load-leveling devices, air
springs, and associated lines and fittings. |
HP-G |
| 27. |
Diagnose, inspect, adjust, repair or replace components of electronically
controlled suspension systems. |
HP-G |
| 28. |
Measure vehicle ride height; determine needed repairs. |
HP-I |
| 29. |
Inspect, remove, replace, and align front and rear frame (cradles/stub). |
HP-G |
| 30. |
Diagnose steering column damage, looseness, and binding problems (including
tilt mechanisms); determine needed repairs. |
HP-G |
| 31. |
Inspect, remove and replace steering shaft U-joint(s), flexible coupling(s),
collapsible columns, and steering wheels. |
HP-G |
| 32. |
Diagnose manual and power steering gear (non-rack and pinion type) noises,
binding, uneven turning effort, looseness, hard steering, and fluid leakage
problems; determine needed repairs. |
HP-G |
| 33. |
Diagnose power rack and pinion steering gear noises, vibration, looseness, hard
steering, and fluid leakage problems, ensure proper mounting location;
determine needed repairs. |
HP-G |
| 34. |
Diagnose non-MacPherson front and rear suspension system noises and body
sway problems; determine needed repairs. |
HP-G |
| 35. |
Diagnose MacPherson strut suspension system noises and body sway problems;
determine needed repairs. |
HP-G |
| 36. |
Diagnose vehicle wandering, pulling, hard steering, bump steer, memory
steering, torque steering, and steering return problems; determine needed
repairs. |
HP-G |
| 37. |
Adjust front and rear wheel camber on suspension systems with camber
adjustments. |
HP-I |
| 38. |
Check front and rear wheel camber on adjustable and non-adjustable suspension
systems; determine needed repairs. |
HP-I |
| 39. |
Adjust caster on suspension systems with caster adjustments. |
HP-I |
| 40. |
Check caster on adjustable and non-adjustable suspension systems; determine
needed repairs. |
HP-I |
| 41. |
Check and adjust wheel toe; determine needed adjustment or repair. |
HP-I |
| 42. |
Center steering wheel. |
HP-I |
| 43. |
Identify toe-out-on-turns (turning radius) related problems; determine needed
repairs. |
HP-I |
| 44. |
Identify SAI (steering axis inclination)/KPI (king pin inclination) related
problems; determine needed repairs. |
HP-I |
| 45. |
Identify thrust angle related problems; determine needed repairs. |
HP-I |
| 46. |
Check for front wheel setback; determine needed repairs. |
HP-I |
| 47. |
Diagnose tire wear patterns; determine needed repairs. |
HP-I |
| 48. |
Inspect tires, identify direction of rotation, and location; check and adjust air
pressure. |
HP-I |
| 49. |
Diagnose wheel/tire vibration, shimmy, and tramp (wheel hop) problems;
determine needed repairs. |
HP-G |
| 50. |
Measure wheel, tire, axle, and hub runout; determine needed repairs. |
HP-I |
| 51. |
Diagnose tire pull (lead) problems; determine corrective actions. |
HP-G |
| 52. |
Reinstall wheels and torque lug nuts according to manufacturer's specifications. |
HP-I |
| III. MECHANICAL AND ELECTRICAL COMPONENTS |
|
B. Electrical |
|
| 1. |
Check voltages in electrical wiring circuits with a DMM (digital multimeter). |
HP-I |
| 2. |
Check continuity and resistance in electrical wiring circuits and components
with a DMM (digital multimeter). |
HP-I |
| 3. |
Repair electrical circuits, wiring, and connectors according to manufacturer's
specifications. |
HP-I |
| 4. |
Inspect, test, and replace fusible links, circuit breakers, and fuses. |
HP-I |
| 5. |
Perform battery state-of-charge test; determine needed service. |
HP-I |
| 6. |
Inspect, clean, and replace battery. |
HP-I |
| 7. |
Dispose of batteries and battery acid according to local, state, and federal
requirements. |
HP-G |
| 8. |
Perform slow/fast battery charge in accordance with manufacturer's
recommendations. |
HP-I |
| 9. |
Identify programmable electrical/electronic components; record data for
reprogramming before disconnecting battery. |
HP-G |
| 10. |
Inspect, clean, and repair or replace battery cables, connectors, and clamps. |
HP-I |
| 11. |
Inspect alignment, adjust, and replace generator (alternator) drive belts, pulleys,
and fans. |
HP-I |
| 12. |
Remove and replace generator (alternator). |
HP-G |
| 13. |
Check operation of exterior lighting; determine needed repairs. |
HP-I |
| 14. |
Aim headlamp assemblies and fog/driving lamps; determine needed repairs. |
HP-I |
| 15. |
Check operation of retractable headlamp assembly. |
HP-G |
| 16. |
Remove and replace motors, switches, relays, connectors, and wires of
retractable headlamp assembly circuits. |
HP-G |
| 17. |
Inspect, test, and repair or replace switches, relays, bulbs, sockets, connectors,
and wires of all interior and exterior light circuits. |
HP-I |
| 18. |
Remove and replace horn(s); check operation. |
HP-G |
| 19. |
Check operation of windshield wiper/washer system. |
HP-I |
| 20. |
Check operation of power side windows and power tailgate window. |
HP-I |
| 21. |
Inspect, remove and replace power seat, motors, linkages, cables, etc. |
HP-G |
| 22. |
Inspect, remove and replace components of electric door and hatch/trunk lock. |
HP-G |
| 23. |
Inspect, remove and replace components of keyless lock/unlock devices and
alarm systems. |
HP-G |
| 24. |
Inspect, remove and replace components of electrical sunroof and convertible
top. |
HP-G |
| 25. |
Check operation of electrically heated mirrors, windshields, back lights, panels,
etc.; repair as necessary. |
HP-I |
| 26. |
Inspect, remove and replace components of power antenna circuits. |
HP-I |
| 27. |
Demonstrate the proper self-grounding procedures for handling electrical
components. |
HP-I |
| III. MECHANICAL AND ELECTRICAL COMPONENTS |
|
C. Brakes |
|
| 1. |
Inspect brake lines and fittings for leaks, dents, kinks, rust, cracks or wear;
tighten loose fittings and supports; replace brake lines (double flare and ISO
types), hoses, fittings, and supports. |
HP-G |
| 2. |
Inspect flexible brake hoses for leaks, kinks, cracks, bulging or wear; remove
and replace hoses; tighten loose fittings and supports. |
HP-G |
| 3. |
Identify, handle, store, and install appropriate brake fluids; dispose of in
accordance with federal, state, and local regulations. |
HP-G |
| 4. |
Bleed (manual, pressure, vacuum or surge) hydraulic brake system in
accordance with manufacturer's procedures. |
HP-I |
| 5. |
Pressure test brake hydraulic system; determine needed repair. |
HP-G |
| 6. |
Adjust brake shoes; remove and reinstall brake drums or drum/hub assemblies
and wheel bearings. |
HP-G |
| 7. |
Reinstall wheel and torque lug nuts according to manufacturer's specifications. |
HP-I |
| 8. |
Remove and reinstall caliper assembly. |
HP-I |
| 9. |
Clean and inspect caliper mountings for wear and damage. |
HP-I |
| 10. |
Check parking brake system operation. |
HP-I |
| 11. |
Identify and replace ABS wheel speed sensor components according to
manufacturer's specifications. |
HP-G |
| 12. |
Depressurize ABS hydraulic system according to manufacturer's procedures. |
HP-G |
| 13. |
Identify the proper procedures for handling brake dust. |
HP-G |
| 14. |
Check for bent or damaged brake system components. |
HP-G |
| III. MECHANICAL AND ELECTRICAL COMPONENTS |
|
D. Heating and Air Conditioning |
|
| 1. |
Identify and comply with environmental concerns relating to refrigerants and
coolants. |
HP-G |
| 2. |
Maintain and verify correct operation of certified refrigerant recovery and
recharging equipment. |
HP-G |
| 3. |
Locate and identify A/C system service ports. |
HP-G |
| 4. |
Identify and recover refrigerant from A/C system. |
HP-G |
| 5. |
Recycle refrigerant in accordance with EPA regulations. |
HP-G |
| 6. |
Identify, label and store refrigerant. |
HP-G |
| 7. |
Test recycled refrigerant for non-condensable gases. |
HP-G |
| 8. |
Evacuate A/C system; check for leaks. |
HP-G |
| 9. |
Recharge A/C system with refrigerant; perform leak test. |
HP-G |
| 10. |
Identify oil type and maintain correct amount in A/C system according to
manufacturer's specifications. |
HP-G |
| 11. |
Inspect, adjust, and replace A/C compressor drive belts; check pulley alignment. |
HP-G |
| 12. |
Remove and replace A/C compressor; inspect, repair or replace A/C compressor
mount. |
HP-G |
| 13. |
Inspect, repair or replace A/C system mufflers, hoses, lines, fittings, and seals. |
HP-G |
| 14. |
Inspect A/C condenser for damage or restrictions. |
HP-G |
| 15. |
Inspect, test, and replace A/C system condenser and mounts. |
HP-G |
| 16. |
Inspect and replace receiver/drier or accumulator/drier. |
HP-G |
| 17. |
Inspect and repair A/C component wiring. |
HP-G |
| III. MECHANICAL AND ELECTRICAL COMPONENTS |
|
E. Cooling Systems |
|
| 1. |
Inspect and replace engine cooling and heater system hoses and belts. |
HP-G |
| 2. |
Inspect, test, remove, and replace radiator, pressure cap, coolant recovery
system, and water pump. |
HP-G |
| 3. |
Recover, refill, and bleed system with proper coolant and check level of
protection; leak test system and dispose of materials in accordance with EPA
specifications. |
HP-I |
| 4. |
Remove and replace fan (both electrical and mechanical), fan pulley, fan clutch,
and fan shroud. |
HP-G |
| 5. |
Inspect, remove, and replace auxiliary oil/fluid coolers; check oil levels. |
HP-G |
| 6. |
Inspect, remove, and replace electric fan sensors; check operation. |
HP-G |
| III. MECHANICAL AND ELECTRICAL COMPONENTS |
|
F. Drive Train |
|
| 1. |
Remove, replace, and adjust shift or clutch linkage as required. |
HP-G |
| 2. |
Remove, replace, and adjust cables or linkages for throttle valve (TV),
kickdown, and accelerator pedal. |
HP-G |
| 3. |
Remove and replace electronic sensors, wires, and connectors. |
HP-G |
| 4. |
Remove and replace powertrain assembly; inspect, replace, and align powertrain
mounts. |
HP-G |
| 5. |
Remove and replace drive axle assembly. |
HP-G |
| 6. |
Inspect, remove and replace half shafts and axle constant velocity (CV) joints. |
HP-G |
| 7. |
Inspect, remove, and replace drive shafts and universal joints. |
HP-G |
| III. MECHANICAL AND ELECTRICAL COMPONENTS |
|
G. Fuel, Intake and Exhaust Systems |
|
| 1. |
Inspect, remove and replace exhaust pipes, mufflers, converters, resonators, tail
pipes, and heat shields. |
HP-G |
| 2. |
Inspect, remove and replace fuel tank, fuel tank filter, fuel cap, fuel filler hose,
and inertia switch; inspect and replace fuel lines and hoses; check fuel for
contaminants. |
HP-G |
| 3. |
Inspect, remove and replace engine components of air intake systems. |
HP-G |
| 4. |
Inspect, remove and replace canister, filter, vent, and purge lines of fuel vapor
(EVAP) control systems. |
HP-G |
| III. MECHANICAL AND ELECTRICAL COMPONENTS |
|
H. Restraint Systems |
|
|
1. Active Restraint Systems |
|
| 1. |
Inspect, remove, and replace seatbelt and shoulder harness assembly and
components in accordance with manufacturer's specifications/procedures. |
HP-G |
| 2. |
Inspect restraint system mounting areas for damage; repair in accordance with
manufacturer's specifications/procedures. |
HP-G |
| 3. |
Verify proper operation of seatbelt in accordance with manufacturer's
specifications/procedures. |
HP-G |
|
2. Passive Restraint Systems |
|
| 1. |
Inspect, remove, and replace seatbelt and shoulder harness assembly and
components in accordance with manufacturer's specifications/procedures. |
HP-I |
| 2. |
Inspect restraint system mounting areas for damage in accordance with
manufacturer's specifications/procedures. |
HP-G |
| 3. |
Verify proper operation of seatbelt in accordance with manufacturer's
specifications/procedures. |
HP-G |
| 4. |
Inspect, remove and replace track and drive assembly, lap retractor, torso
retractor, inboard buckle-lap retractor, tensioners and knee bolster (blocker) in
accordance with manufacturer's specifications/procedures. |
HP-G |
|
3. Supplemental Restraint Systems (SRS) |
|
| 1. |
Disarm SRS in accordance with manufacturer's specifications/procedures. |
HP-I |
| 2. |
Inspect, remove and replace sensors and wiring in accordance with
manufacturer's specifications/procedures; ensure sensor orientation. |
HP-G |
| 3. |
Inspect, remove, replace, and dispose of deployed SRS modules in accordance
with manufacturer's specifications/procedures. |
HP-G |
| 4. |
Verify that SRS is operational. |
HP-I |
| 5. |
Inspect, remove, replace, and dispose of non-deployed SRS in accordance with
manufacturer's specifications/procedures. |
HP-G |
| 6. |
Diagnose and repair SRS using fault codes and test equipment. |
HP-G |
