CRT 3020 - Mechanical & Electrical Comp

MECHANICAL AND ELECTRICAL COMPONENTS

A. Safety Precautions

1. Select and use proper personal safety equipment; take necessary precautions with hazardous operations and materials in accordance with federal, state, and local regulations. HP-I
2. Locate OEM procedures to identify materials and composition of the vehicle being repaired (mild steel, high strength steel, ultra-high strength steel, aluminum, etc.)
3. Locate procedures and precautions that may apply to the vehicle being repaired. HP-I
4.  Identify vehicle system precaution and/or inspections to include but not limited to supplemental restraint system (SRS), advanced driver assistance systems (ADAS) hybrid/electric/alternative fuel vehicles, locations and recommended procedures before inspecting or replacing components. HP-I
5. Perform vehicle clean-up; complete quality control using a checklist on operations performed. HP-I
    

B. Suspension and Steering

1. Perform visual inspection and measuring checks to identify steering and suspension collision damage. HP-G
2. Identify one-time use fasteners. HP-I
3. Clean, inspect, and prepare reusable fasteners. HP-I
4. Remove, replace, inspect or adjust power steering pump, pulleys, belts, hoses, fittings and pump mounts. HP-G
5. Remove and replace power steering gear (non-rack and pinion type).   HP-G
6. Inspect, remove, and replace power rack and pinion steering gear and related components. HP-G
7. Inspect and replace parallelogram steering linkage components. HP-G
8. Inspect, remove and replace upper and lower control arms and related components. HP-G
9. Inspect, remove and replace steering knuckle/spindle/hub assemblies (including bearings, races, seals, etc.). HP-G
10. Inspect, remove and replace front suspension system coil springs and spring insulators (silencers). HP-G
11.  Inspect, remove, replace, and adjust suspension system torsion bars, and mounts. HP-G
12. Inspect, remove and replace stabilizer bar bushings, brackets, and links. HP-G
13. Inspect, remove and replace MacPherson strut or assembly, upper bearing, and mount. HP-G
14. Inspect, remove, and replace rear suspension system transverse links, control arms, stabilizer bars, bushings, and mounts. HP-G
15. Inspect, remove, and replace suspension system leaf spring(s) and related components. HP-G
16.  Inspect axle assembly for damage and misalignment. HP-G
17. Inspect, remove and replace shock absorbers. HP-G
18. Diagnose, inspect, adjust, repair or replace active suspension systems and associated lines and fittings. HP-G
19. Measure vehicle ride height and wheel base; according to manufacturer specifications. HP-I
20. Inspect, remove, replace, and align front and rear frame (cradles/sub frame).  HP-G
21. Diagnose and inspect steering wheel, steering column, and components.  HP-G
22. Verify proper operation of steering systems including electronically controlled, hydraulic and electronically assisted steering systems. HP-G
23. Diagnose front and rear suspension system noises and body sway problems; determine necessary action. HP-G
24. Diagnose vehicle wandering, pulling, hard steering, bump steer, memory steering, torque steering, and steering return problems; determine necessary action. HP-G
25. Demonstrate an understanding of wheel, suspension, and steering alignments (caster, camber, toe, SAI etc.). HP-G
26. Inspect tires; identify tire wear patterns direction of rotation and location; check tire size, tire pressure monitoring system (TPM) and adjust air pressure. HP-I
27. Diagnose wheel/tire vibration, shimmy, tire pull (lead), wheel hop problems; determine needed repairs. HP-G
28. Measure wheel, tire, axle, and hub runout; determine needed repairs.  HP-I
29. Reinstall wheels and torque lug nuts. HP-I
30. Perform initialization or calibration procedures following suspension and/or steering system repairs. HP-G
31. Perform a tire pressure monitoring system (TPMS) recalibration. HP-G
32. Lift the vehicle for inspections, service, and repair by properly raising and supporting the vehicle. HP-G

C. Brakes

1. Inspect brake lines, hoses, and fittings for damage or wear; tighten fittings and supports; replace brake lines (double flare and ISO types). HP-G
2. Replace hoses, fittings, seals, and supports. HP-G
3. Identify, handle, store, and fill with appropriate brake fluids. HP-G
4. Bleed (manual, pressure, or vacuum) hydraulic brake system. HP-G
5. Pressure test brake hydraulic system; determine necessary action. HP-G
6. Adjust brake shoes or pads; remove and reinstall brake drums or drum/hub assemblies. HP-G
7. Remove, clean and inspect caliper and rotor assembly and mountings for wear and damage; reinstall. HP-I
8. Inspect parking brake system operation; repair or adjust as necessary; verify operation. HP-G
9. Identify the proper procedures for handling brake dust. HP-G
10. Check for bent or damaged brake system components. HP-G
11. Demonstrate an understanding of various types of advanced braking systems (ABS, electronic parking brake, hydraulic, electronic, traction and stability control). HP-G

D. Drive Train

1. Remove, replace, and adjust shift or clutch linkage as required. HP-G
2.  Remove and replace electronic sensors, wires, and connectors. HP-G
3. Remove and reinstall powertrain assembly; inspect, replace, and align powertrain mounts. HP-G
4. Remove and replace drive axle assembly. HP-G
5. Inspect, remove and replace half shafts and axle constant velocity (CV) joints. HP-G
6.  Inspect, remove and replace drive shafts and universal joints. HP-G
7. Demonstrate an understanding of safe handling procedures associated with high voltage powertrain components. HP-G

E. Cooling Systems

1. Check engine cooling and heater system hoses and belts; determine necessary action. HP-I
2. Inspect, test, remove, and replace radiator, pressure cap, coolant system components, 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 regulations. HP-I
4. Remove, inspect and replace fan (both electrical and mechanical), fan sensors, fan pulley, fan clutch, and fan shroud; check operation. HP-G
5. Inspect, remove, and replace auxiliary oil/fluid coolers; check oil levels. HP-G
6. Demonstrate an understanding of hybrid/electric cooling systems. HP-G

F. Heating and Air Conditioning

1. Identify and comply with environmental regulations 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-I
4. Recover, label and recycle refrigerant from an A/C system. HP-G
5. Select refrigerant, evacuate, and recharge A/C system. HP-G
6. Select oil type and install correct amount in A/C system. HP-G
7. Inspect, adjust, and replace A/C compressor drive belts; check pulley alignment. HP-G
8. Remove and replace A/C compressor; inspect, repair or replace A/C    compressor mount. HP-G
9. Inspect, repair or replace A/C system mufflers, hoses, lines, fittings, orifice tube, expansion valve, and seals. HP-G
10. Inspect, test, and replace A/C system condenser and mounts. HP-G
11. Inspect and replace receiver/drier or accumulator/drier. HP-G
12. Inspect and repair A/C component wiring. HP-G
13.  Demonstrate an understanding of safe handling procedures associated with high voltage A/C compressors and wiring. HP-G
14. Inspect and protect open A/C system components from contaminants during repairs. HP-G

G. Electrical

1. Demonstrate an understanding of Ohm’s Law.  HP-I
2. Check for available voltage, voltage drop and current, and resistance in electrical wiring circuits and components with a DMM (digital multimeter). HP-I
3. Repair wiring and connectors. HP-G
4. Inspect, test, and replace fusible links, circuit breakers, and fuses. HP-I
5. Perform battery state-of-charge test and slow/fast battery charge. HP-I 
6. Inspect, clean, repair or replace battery, battery cables, connectors and clamps. HP-I
7. Dispose recycle batteries according to local, state, and federal requirements. HP-G
8. Identify programmable electrical/electronic components and check for malfunction indicator lamp (MIL) and fault codes; record data for reprogramming before disconnecting battery. HP-I
9. Inspect alignment, adjust, remove and replace alternator (generator), drive belts, pulleys, and fans. HP-I
10. Check operation and aim headlamp assemblies and fog/driving lamps; determine needed repairs. HP-G
11. Inspect, test, and repair or replace switches, relays, bulbs, sockets, connectors, and ground wires of interior and exterior light circuits. HP-I
12. Remove and replace horn(s); check operation. HP-I
13. Check operation of wiper/washer systems; determine needed repairs.  HP-I
14. Check operation of power side and tailgate window; determine needed repairs. HP-I
15. Check operation of motorized sliding doors, lift gates, tailgates, running boards, etc.; determine needed repairs. HP-G
16. Inspect, remove and replace power seat, motors, linkages, cables, etc.  HP-G
17. Inspect, remove and replace components of electric door and hatch/trunk lock. HP-G
18. Inspect, remove and replace components of keyless lock/unlock devices and alarm systems. HP-G
19. Inspect, remove and replace components of electrical sunroof and convertible/retractable hard top. HP-G
20. Check operation of electrically heated mirrors, windshields, back lights, panels, etc.; determine needed repairs. HP-I
21. Demonstrate self-grounding procedures (anti-static) for handling electronic components. HP-I
22. Check for module communication errors using a scan tool. HP-G
23.  Use wiring diagrams, component location, and diagnostic flow charts during diagnosis of electrical circuit problems. HP-G
24. Identify safe disabling techniques of high voltage systems on hybrid/electric vehicles. HP-G
25. Identify potential safety and materials handling concerns associated with high voltage hybrid/electric vehicle battery systems. HP-G
     

H. Restraint System

1. Inspect, remove, and replace seatbelt and shoulder harness assembly and components. HP-G
2. Inspect restraint system mounting areas for damage; repair as needed.  HP-G
3. Inspect the operation of the seatbelt system. HP-I
4. Disable and enable Supplemental Restraint System (SRS). HP-G
5. Inspect, protect, remove and replace Supplemental Restraint Systems (SRS) sensors and wiring; ensure sensor orientation. HP-G
6. Verify that Supplemental Restraint System (SRS) is operational. HP-I
7.  Inspect, remove, replace and dispose of deployed and non-deployed airbag(s) and pretensioners. HP-G
8. Use Diagnostic Trouble Codes (DTC) to diagnose and repair the Supplemental Restraint System (SRS). HP-G
9. Demonstrate an understanding of advanced restraint and occupant classification systems (OCS). HP-G
10. Identify components of Supplemental Restraint Systems (SRS) HP-I

I. 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/DEF tank, tank filter, cap, filler hose, pump/sending unit and inertia switch; inspect and replace fuel lines and hoses. HP-G
3. Inspect, remove and replace engine components of air intake components. HP-G
4. Inspect, remove and replace canister, filter, vent, and purge lines of fuel vapor (EVAP) control systems. HP-G