Test Project Automobile Technology

Task A - Steering, Suspension & Brake Systems

TP33 _ RSC_ 2017_ 25%

Submitted by: All Coaches/Judges

Member Region: NCR

TP33_ RSC 2016_pre_NCR

 Skill 33 - Automobile Technology

COMPETITOR INSTRUCTION

Competitor Name Country Code Task

Instructions to Competitor

Task Brake, Suspension and Steering Systems

Familiarization Time 15 minutes

Task Duration 3 hours
Total Breaks 15 minutes

MARKING SUMMARY

Possible
Section
Mark
1 Health, Safety and House keeping 4.30
2. Remove / replace Front Strut Assembly 3.00
3. Install Front Strut Assembly 2.50
4. Front Brake Calliper & Disc Brake Measurement 2.40
5. Perform the necessary Wheel Alignment Adjustment 4.50
6. Replace Brake Master Cylinder Assembly 2.40
7. Overhaul front Calliper and check the conditions of all Brake Pads 3.40
8. Hydraulic Brake System Air Bleeding 2.50
Total 25.00

You are required to:

- Observe occupational health & safety standards
- Only ask necessary questions
- Not speak to the public while competing
- Comply with Experts instructions
- Ensure Name on all forms
- Use appropriate tools and procedures
- Complete all instructions on the next page

Remark: Vehicle/Model: Toyota Corolla Model Year 94 - 97

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 Skill 33 - Automobile Technology

COMPETITOR INSTRUCTION

Competitor Name Country Code Task

1. Use safe working procedures at all times.

Ensure that the steering, suspension and brake systems are in a safety
2.
condition.

3. Service front LHS and RHS brake assembly.

Remove and replace Front Strut Assembly with the service tools provided as
4.
instructed by the judge.

5. Remove and replace side tie-rod end with service tools provided.

Perform the wheel alignment adjustment.

6.
Print out and interpret the readings.

7. Replace Brake Master Cylinder Assembly.

7. Overhaul front calliper and check condition of all brake pads.

8. Perform hydraulic Brake System Air Bleeding (using vacuum bleeder).

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 Skill 33 - Automobile Technology

COMPETITOR REPORT SHEET

Competitor Name Country Code Task Report Form

Steering, Suspension
A
& Brake Systems

Brakes System Report Sheet

Front Brake Disc RHS - Measurement

Measured Reading Status Condition

Items
Specification Actual OK Not OK

Disc Std
Round-Out

Max

Disc
Std
Thickness

Min

Brake Pads
Thickness Inner

Outer

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 Skill 33 - Automobile Technology

COMPETITOR REPORT SHEET

Competitor Name Country Code Task Report Form

Steering, Suspension
A
& Brake Systems

Front Brake Disc LHS - Measurement

Measured Reading Status Condition

Items
Specification Actual OK Not OK

Disc Std
Round-Out

Max

n
Disc
Std
Thickness

Min

Brake Pads
Thickness Inner

Outer

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 Skill 33 - Automobile Technology

FORM 5 – MARKING SUMMARY FORM

Competitor Name Country Code Task Marking Scale

Steering, Suspension &

A Brake Systems

MARKING SUMMARY

Possible Actual
Section
Mark Mark
1. Health, Safety and House keeping 4.30
2. Remove / replace Front Strut Assembly 3.00
3. Install Front Strut Assembly 2.50
4. Front Brake Calliper & Disc Brake Measurement 2.40
5. Perform the necessary Wheel Alignment Adjustment 4.50
6. Replace Brake Master Cylinder Assembly 2.40
Overhaul front Calliper and check the conditions of all Brake
7. 3.40
Pads
8. Hydraulic Brake System Air Bleeding 2.50

Task Total 25.00

Time Keeping

Familiarization Competition Breaks

Start Start Start

Stop Stop Stop

Experts Signatures

1 2 3 4

Judge Judge Judge Chief Judge

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 Skill 33 - Automobile Technology

Competitor Name Country Code Task Marking Scheme

Steering, Suspension &

A Brake Systems

MARKING FORM

Health, Safety & 5S House

1. Yes No Actual Comments
Keeping
1.01 Check & prepare all equipment 0.10 0
1.02 Use workshop manual 0.10 0
1.03 Apply logical working procedure 0.10 0
1.04 Check engine oil level 0.10 0
1.05 Check coolant level 0.10 0
1.06 Ramp lowered on stops 0.10 0
1.07 Jacks, pads used 0.10 0 Positioned correctly
1.08 Parking Brake applied to maximum 0.10 0
1.09 Chock tires 0.10 0 Min 2 pcs @ front & rear
1.10 Use fender covers 0.10 0
1.11 Use seat covers 0.10 0
1.12 Use steering wheel cover 0.10 0
1.13 Use gear shift lever cover 0.10 0
1.14 Use floor mats 0.10 0
1.15 Did not wear any metal objects 0.20 0 Wrist watch, bangle etc
During engine starting /
1.16 Voice out to alert others 0.20 0 operating hoist up / down
Use of safety goggle during brake
1.17 0.50 0
bleeding activity
1.18 Proper tools handling 0.50 0 Not dropped >2 x
1.19 Precision tools not dropped 0.50 0
No brake fluid spilled over on any part
1.20 0.50 0
of vehicle body
1.21 Wipe out all initial markings made 0.10 0
1.22 Clean up tools and equipment 0.10 0 * Marks ONLY be awarded when
the task is completed
1.23 Clean up the test models & work area 0.10 0
1.24 Close front engine hood 0.10 0
1.25 Hand over vehicle key to judge 0.10 0

Sub-Total 4.30 0

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 Skill 33 - Automobile Technology

Competitor Name Country Code Task Marking Scale

Steering, Suspension &

A Brake Systems

MARKING FORM

Remove / Replace Front Strut

2. Yes No Actual Remark
Assembly
2.01 Brief judge on the task activity 0.10 0

2.02 Loosen wheel nuts before lifting up 0.10 0

2.03 Raise vehicle to suitable height 0.10 0

2.04 Mark the wheel position/location 0.10 0

2.05 Remove and mark all wheels 0.10 0
2.06 Remove brake hose bracket 0.10 0
Remove Front RHS Strut Assembly &
2.07 0.10 0
Self Locking Nut
2.08 Loosen Flange Nuts 0.10 0
2.09 Remove Strut Assembly (on bench) 0.10 0

2.10 Remove coil spring from Strut (on bench) 0.10 0

- Front coil spring 0.20 0
- Lower Spring ,
0.20 0
Insulator Verbal Inspection report
Verbal - Front s/absorber assembly 0.20 0
Inspection
2.11 - Rubber Spring ,
Report 0.20 0
Bumper
- Absorber Lock Nut 0.20 0
- Dust Seal 0.20 0
Check condition of the Front Strut (on
2.12 0.20 0 Demonstrate procedure
bench)
2.13 Replace the Strut Assembly (on bench) 0.10 0
Reassemble all Components correctly (on
2.14 0.20 0
bench)
Update judge on critical assembling
2.15 0.20 0
points with manual (on bench)
to secure the strut assy.to its
2.16 Temporary tighten the Lock Nut 0.10 0 position

Sub - Total 3.00 0

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 Skill 33 - Automobile Technology

Competitor Name Country Code Task Marking Scale

Steering, Suspension &
A Brake Systems

MARKING FORM

Install one side Front Strut

3. Yes No Actual Remark
Assembly
Install Front Strut Assembly to the vehicle
3.01 0.50 0
and torque nut to specification
3.02 Install & tighten the 3 Flange Nuts 0.40 0
Tighten Front Strut Assembly and torque
3.03 0.50 0
to specifications
3.04 Torque the stabilizer link nut 0.50 0
3.05 Install Wheel Sensor Harness Clip 0.30 0
3.06 Install Brake Hose Bracket 0.30 0

Sub - Total 2.50 0

Front Brake Calliper & Disc -

4. Yes No Actual Comments
Brake Assembly
4.01 Update judge on the task activity 0.10 0 What he planned to do
Temporarily relocate front caliper
4.02 0.10 0 Hook caliper on spring area
assembly via metal hook
Torque all 5 wheel nuts correctly (RHS
4.03 0.10 0 Using correct SST
and LHS)
4.04 Mount brake hose to strut assembly 0.30 0 DTI pointer set accurately
Check run-out of front brake disc (RHS Refer R/M on process
4.05 0.50 0
and LHS)
Measure thickness of brake disc (RHS Indicate 1-5 markings
4.06 0.50 0
and LHS)
Measure thickness of brake pads (RHS
4.07 0.20 0
and LHS)
Install the caliper & torque (RHS and
4.08 0.10 0
LHS)
Re-installed brake pads correctly (RHS
4.09 0.10 0
and LHS)
4.10 Accurate data on report sheet 0.20 0
Fix back all wheels to the initially
4.11 0.10 0
marked position
Tighten the wheel nut to
4.12 0.10 0
recommended specification
Sub - Total 2.40 0

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 Skill 33 - Automobile Technology

Competitor Name Country Code Task Marking Scale

Steering, Suspension &

B Brake Systems

MARKING FORM

Perform the necessary Wheel

5. Yes No Actual Remark
Alignment Adjustment
5.01 Update judge on the task activity 0.10 0
Check tire pressures and correct if
5.02 0.20 0
necessary
Check conditions of wheel bearings (RHS
5.03 0.10 0
and LHS)
5.04 Check joints (RHS and LHS) 0.10 0
5.05 Remove / replace tie-rod end (RHS and 0.10 0
LHS)
Check lower ball joints unloaded (RHS
5.06 0.10 0
and LHS)
5.07 Check vehicle level 0.10 0
5.08 Check wheel base 0.10 0
5.09 Set program on computer alignment 0.10 0
5.10 Mount Wheel Clamps correctly 0.10 0
5.11 Handle Sensors with care 0.30 0
5.12 Mount Sensors correctly 0.10 0
Perform all wheels “run-out”
5.13 0.10 0
compensation
5.14 Position turntable correctly 0.10 0
5.15 Apply parking brake (hand brake) 0.10 0
5.16 Set the turn table to zero 0.10 0
5.17 Position Rear Wheels Slip Plate 0.10 0
5.18 Bounce the car 0.10 0
5.19 Remove the turn table pins 0.10 0
5.20 Set levelling sensor to centre position 0.10 0
5.21 Use brake pedal depressor 0.10 0
5.22 Check Caster Angle 0.10 0
5.23 Check KPI/SAI Angle Ball Joint 0.10 0 Steering Axis Inclination
Centre Steering Wheel Straight ahead
5.24 0.20 0
position
5.25 Lock steering wheel 0.10 0
5.26 Interpret Camber Angle on screen 0.20 0
5.27 Interpret Caster Angle on screen 0.20 0
5.28 Interpret Toe Angle on screen 0.20 0

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 Skill 33 - Automobile Technology

Competitor Name Country Code Task Marking Scale

Steering, Suspension &

B Brake Systems

MARKING FORM

Perform the necessary Wheel

5. Yes No Actual Remark
Alignment Adjustment
5.29 Correct Front Toe Adjustment 0.30 0

5.30 Tighten Tie-rod end lock nut 0.10 0

5.31 Check steering wheel position 0.10 0

5.32 Print out (after adjustment) 0.10 0

5.33 Remove all sensors 0.10 0

5.34 Reset program 0.10 0

5.35 Car lowered to ground 0.10 0

5.36 Remove brake pedal depressor and tools 0.10 0

Sub - Total 4.50 0

Replace Brake Master Cylinder

6. Yes No Actual Remark
Assembly
Recover the brake fluid from the master
6.01 0.4 0 Via the brake bleeder unit assy.
cylinder reservoir
Pumped brake pedal several times to
6.02 0.40 0
remove vacuum from the brake booster
Remove / replace the Brake Master
6.03 0.60 0
Cylinder Assembly
Bleed the brake hydraulic system once
6.04 0.50 0
again
Confirm the status of the brake hydraulic
6.05 0.50 0
system
Sub - Total 2.40 0

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 Skill 33 - Automobile Technology

Competitor Name Country Code Task Marking Scale

Steering, Suspension &

B Brake Systems

MARKING FORM

Overhaul Rear Calliper and

7. check the conditions of all Yes No Actual Comments
Brake Pads
7.01 Update judge on the task activity 0.10 0 What he planned to do

Remove front calliper assembly (left

7.02 0.10 0 Remove rear brake pads
and right side)
Disassemble rear caliper assembly (left
7.03 0.10 0
and right side)

- Caliper piston 0.10 0

- Dust cover 0.10 0

Verbal
Inspect & verify conditions of the
7.04 Inspection - Rubber seal 0.10 0 caliper components
Report
- Caliper bracket 0.10 0

- Sliding mechanism 0.10 0

Reassemble the caliper assembly (left
7.05 0.50 0 Ensure proper marking
and right side)
Update judge on critical assembling
7.06 0.30 0 Refer R/Manual
points with manual
Measure thickness of brake pads (left
7.07 0.30 0
and right side)
Measure thickness of brake disc (left
7.08 0.30 0
and right side)
Re-install brake pads correctly (left and
7.09 0.40 0
right side)
Install caliper and tighten to torque
7.10 0.40 0
(left and right side)
7.11 Accurate info on report sheet 0.40 0

Sub-Total 3.40 0

Hydraulic Brake System

8. Yes No Actual Comments
Bleeding
8.01 Update judge on the task activity 0.40 0 What he planned to do

8.02 Install brake fluid dispenser unit 0.50 0

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 Skill 33 - Automobile Technology

Competitor Name Country Code Task Marking Scale

Steering, Suspension &

B Brake Systems

MARKING FORM

Hydraulic Brake System

8. Yes No Actual Comments
Bleeding
Correct (X) method/procedure
8.03 Perform brake bleeding correctly 0.60 0 (use vacuum bleeder)
8.04 Check functions of brake system 0.60 0
8.05 Update judge on the status 0.40 0 What he planned to do

Sub Total 2.50 0

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