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CHAPTER ONE
1. Automotive tools & equipment and OHS

INTRODUCTION
The skills and knowledge that you will gain from this unit of work as you complete each task,
should enable you to use and maintain workplace tools and equipment. An important part of the
automotive repair industry is the type, quality and selection of hand tools and equipment. Hand
tools are classed as those tools that can be held or supported by the operator's hands while they are
being used. Equipment is defined as those devices that are controlled by an operator, but supported
by a floor, building or vehicle. The range of tools and equipment that you will encounter in the
automotive industry is huge. It will be an expectation of your employer that you will know how to
use and maintain all tools and equipment and where necessary tag and remove an unserviceable
item from the workplace, for repair or replacement and report your actions to your supervisor, in
accordance with enterprise requirements. The tools and equipment that you will come in contact
with in an automotive workshop can include the following:
It is the responsibility of the operator and workshop manager to service and maintain all tools and
equipment. Good quality, well maintained tools and equipment will ensure that the job in the
workshop can be completed without delay, and to a high standard. The ability to quickly identify
and select the correct hand tool and/or equipment to complete the job successfully is achieved
through practice. The aim of tool selection is to make ready all the tools needed for the job before
work is commenced. This reduces down time, looking for tools. This unit will provide you with
the underpinning knowledge and skills necessary to display competence in how you use and
maintain a variety of workplace tools and equipment.

1.1 Safety and OHS

1.1.1 Identify automotive workshop safety
Safety: - means protecting our selves and others from injury or any other accidents. These accidents
in the workplace are prevented by the following;
a. Working safely and
b. Follow the right work procedure.
 The ways to learn and understand safety are;
a. Accidental experiences and
b. Safety education.
Accidental experiences: - are experiences which were caused by accidents. But, you can’t afford
to learn safety through experiences. However, being safe can mean the difference between life and
death.
Safety education: - means knowing by learning safety before performing anything. This is a
method which makes us aware of dangerous situations to avoid accidents or injuries.

In general, there are three safety guide lines and called general workshop safety procedures. These
are:-
 Personal safety,
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 Tools and equipment safety and

 Work area safety
Personal safety /personal protection equipment or needs/
Personal safety means protecting ourselves from injury or accidents. How to protect or take care
yourself in the workshop?
 Protecting yourself from injury is by wearing of personal protective equipment (PPE) and
clothing. These are:
 Wearing eye glasses(goggles)
 Wearing ear protection
 Wearing cap head band or hairnet.
 Wearing proper clothing, shoes, and gloves.
Tools and equipment safety: - this is

 Correctly handling of tools and equipment

 Proper use of tools and equipment
When working with any tool and equipment;
 Make sure it is make properly,
 It should be properly maintained
 Check it before you use it.
Work area safety: - that means;
 Keeping the workshop clear of obstruction such as oil, water, and acid, chips of metal wood and wastage
particles in automotive work shop areas.
 A clean and an organized work area such as machines, tools and consumable material.
This is done by implementing workshop activities, such as:

 Regular inspection
 Cleaning of areas
 Disposal of wastes
 Storage of equipment that are not in use.
First aid: - is an immediate care given to person who has been injured or suddenly taken ill. It includes self-
care and home care.

1.1.2 Identifying workshop staff Responsibilities

Workshop:-is the palace of training areas which includes resource of training location such as material,
machineries comfortable work areas to demonstrate/practice, consumable material for training and training
class rom.
Staff:-is the employs of particular organization. In automotive department workshops the staff members
includes such as:-department head, trainer and store man are the staff as one training section.
Responsibilities:-is the opportunity or ability to act independently and take actions.
Workshop staffs responsibly are:-
 Personal equipment usage
 Implement the safety rule on training
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 Identify or categorize hazard materials

 Prepare necessary materials to protect any types of work shop accidents
 Give training before work any types of task in the work shop area on safety
 Give necessary information about rule and regulation to the trainees
 Identify and categorize training section and practical area.
 Cleaning and properly handling of training workshop tools and areas.
 Prepare the necessary safety requirement:-such as first aid, and fire extinguishers & etc
 refer problems outside area of responsibility to appropriate person
1.1.3 General Shop Safety rule

 Safety glasses, cover goggles, or face shields are required when in any shop area, whether
working or not!!
 Shoes must be worn in any shop area. No one wearing sandals will be allowed to enter any shop
area. The minimum footwear must cover the entire foot.
 Do not operate any item of equipment unless you are familiar with its operation and have been
authorized to operate it. If you have any questions regarding the use of equipment, ask the area
supervisor.
 No work may be performed using power tools unless at least two people are in the shop area
and can see each other.
 Avoid excessive use of compressed air to blow dirt or chips from machinery to avoid scattering
chips. Never use compressed air guns to clean clothing, hair, or aim at another person.
 In case of injury, no matter how slight, report it to the shop supervisor.
 Do not attempt to remove foreign objects from the eye or body. Report to the Health Center for
medical treatment. If chemicals get in the eye(s), wash eye(s) for 15 minutes in an open flow of
water before proceeding for medical treatment. In severe cases, notify the Department of Public
Safety.
 Machines must be shut off when cleaning, repairing, or oiling.
 Do not wear ties, loose clothing, jewelry, gloves, etc. around moving or rotating machinery.
Long hair must be tied back or covered to keep it away from moving machinery. Hand
protection in the form of suitable gloves should be used for handling hot objects, glass, or sharp-
edged items.
 Wear appropriate clothing for the job (i.e., do not wear short sleeve shirts or short pants when
welding).
 How do you identify a hazard?
In order to control work place hazards and eliminate or reduce the risk you should take the
following stapes:
1. Identify the hazard by carrying out work place risk assessment
2. determine how employees might be at risk

3. evaluate risk
4. Record and review hazard at least annually or earlier if something changes.

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 The six main categories of hazard are:-

1. Biological. Biological hazard s include viruses, bacteria, insects, animals and etc that can cause
adverse health impact
2. Chemical. Chemical hazards are hazardous substance s that can cause harm. Gases, dusts
,fumes, vapors and liquids
3. Physical-slippery floors, objects in walkways, unsafe, or misused machinery, excessive noise,
poor lighting, fire
4. Safety
5. Ergonomic – poor design of equipment, work station design, (postural) or workflow, manual
handling, repetitive movement.
6. Psychological

1.1.4 Personal safety procedures of PPE

Personal safety means protecting ourselves from injury or accidents. How to protect or take care
yourself in the workshop? Protecting yourself from injury is by wearing of personal protective
equipment (PPE) and clothing. These are:

 Wearing eye glasses(goggles)

 Wearing ear protection
 Wearing cap head band or hairnet.
 Wearing proper clothing, shoes, and gloves.

Fig 1. Safety equipment’s

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Hazards in the work shop

a) Faulty work habits
b) Misuse of equipment
c) Misuse of hand tools
a) Faulty work habits
i) Smoking around fuel and solvents
ii) Incorrect handling of paint, thinners, solvents, flammable liquids etc..
iii) Blocking exits. A block exit could mean serious injury or even death during an
emergency case such as fire.
b) Misuse of equipment

i) Incorrect safety guarding of moving machinery

ii) Misuse of flexible electric cords or worn cords. When used through holes the may
cause fire
iii) Improperly stored composed gas cylinders
iv) Using hand held electric tools improperly grounded
C) Misuse of hand tools
i) Keeping hand tools dirty and in poor conditions
ii) Improper storing of hand tools
iii) Using defective hand tools
iv) Keeping sharp tools in pockets
1.2 Automotive tools & equipment
Tool and equipment safety
An automotive technician must follow to the following shop safety guidelines when using all
tools and equipment.
1. Hand Tool Safety
Careless use of simple hand tools such as wrenches, screwdrivers, and hammers causes many
shop accidents that could be prevented. Keep in mind the following tips when using hand tools:
• Keep all hand tools grease-free. Oily tools can slip out of your hand, causing broken fingers or
at least cut or skinned knuckles.
• Inspect your tools for cracks, broken parts, or other dangerous conditions before you use them.
• Hand tools should only be used for the purpose they were designed for. Use the right tool for
the job.
• Make sure the tool is of professional quality.
• Never use broken or damaged tools.
• When using a wrench, always pull it, not push it, toward you.
• Always use the correct size of wrench.
• Use an adjustable wrench only when it is absolutely necessary; pull the wrench so that the
force of the pull is on the nonadjustable jaw.
• When using an air impact wrench, always use impact sockets.

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• Never use wrenches or sockets that have cracks or breaks.

• Never use a wrench or pliers as a hammer.
• Never use pliers to loosen or tighten a nut; use the correct wrench.
• Always be sure to strike an object with the full face of the hammerhead.
• Always wear safety glasses when using a hammer and/or chisel.
• Never strike two hammer heads together.
• Never use screwdrivers as chisels.
• Do not place sharp tools or other sharp objects into your pockets.
• Always hand a pointed or sharp tool to someone else with the handle toward the person to
whom you are handing the tool.

2. Power Tool Safety

Power tools are operated by an outside power source, such as electricity, compressed air, or hydraulic pressure.
Always respect the tool and its power source. Carelessness can result in serious injury. Also, always wear
safety glasses when using power tools. Never try to use a tool beyond its stated capacity.
2.1 Electrical Tools
When using an electrically powered tool, make sure it is properly grounded. Check the wiring for insulation
cracks, as well as bare wires, before using it. Also, when using electrical power tools never stand on a wet or
damp floor. Before plugging in any electric tool, make sure its switch is in the off position. When you are
finished using the tool, turn it off and unplug it. Never leave a running power tool unattended. When using
power equipment on a small part, never hold the part in your hand. Always mount the part in a bench vise or
use vise grip pliers. When using a bench or floor grinding wheel, check the machine and the grinding wheels
for signs of damage before using them. If the wheels are damaged, they should be replaced before using the
machine. Keep your hands and clothing away from the moving parts. Maintain a balanced stance while using
the machine.

2.2 Pneumatic Tools

Tools that use compressed air are called pneumatic tools. Compressed air is used to inflate tires, apply paint, and
drive tools, such as air ratchets and impact wrenches. Pneumatic tools must always be operated at the pressure
recommended by the manufacturer. Before using a pneumatic tool, check all hoses connections for leaks. Also

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check for airline damage. When using an air nozzle, wear safety glasses and/ or a face shield. Particles of dirt and
pieces of metal, blown by the high-pressure air, can penetrate your skin or get into your eyes. Always hold an air
nozzle or air control device securely when starting or shutting off the compressed air. A loose nozzle can whip
suddenly and cause serious injury. Never point an air nozzle at anyone. Never use compressed air to blow dirt
from your clothes or hair. Never use compressed air to clean the floor or workbench. Never spin bearings with
compressed air. If the bearing is damaged, one of the steel balls or rollers might fly out and cause serious injury.

2.3 Hydraulic tools

A vehicle can be raised off the ground by a hydraulic jack. A handle on the jack is moved up and down to raise
part of a vehicle and a valve is turned to release the hydraulic pressure in the jack to lower the part. At the end
of the jack is a lifting pad. The pad must be positioned under an area of the vehicle’s frame or at one of the
manufacturer’s recommended lift points. Never place the pad under the floor pan or under steering and
suspension components, because they can easily be damaged by the weight of the vehicle. Always position the
jack so that the wheels of the vehicle can roll as the vehicle is being raised.

2.3.1 Hydraulic Jack (Safety stands)

Safety stands, also called jack stands, are supports of various heights that sit on the floor. They are placed
under a sturdy chassis member, such as the frame or axle housing, to support the vehicle. Once the safety
stands are in position, the hydraulic pressure in the jack should be slowly released until the weight of the

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vehicle is on the stands. Like jacks, jack stands also have a capacity rating. Always use a jack stand of the
correct rating. Never move under a vehicle when it is supported by only a hydraulic jack. Rest the vehicle on
the safety stands before moving under the vehicle. The jack should be removed after the jack stands are set in
place. This eliminates a hazard, such as a jack handle sticking out into a walkway. A jack handle that is bumped
or kicked can cause a tripping accident or cause the vehicle to fall.

Hydraulic Crane (Chain Hoist and Crane Safety)

Heavy parts of the automobile, such as engines, are removed by using chain hoists or cranes. Another term for a
chain crane is chain fall. To prevent serious injury, chain hoists and cranes must be properly attached to the parts
being lifted. Always use bolts with enough strength to support the object being lifted. After you have attached the
lifting chain or cable to the part that is being removed, have your instructor check it. Place the chain hoist or crane
directly over the assembly. Then, attach the lifting chain or cable to the hoist.

1.2.1 Hand tools

The word wrench means twist. A wrench is a tool for twisting and/or holding bolt heads or nuts. Nearly all bolt
heads and nuts have six sides; the jaw of a wrench fits around these sides to turn the bolt or nut. All technicians
should have a complete collection of wrenches. This includes both metric and SAE wrenches in a variety of sizes
and styles. The width of the jaw opening determines its size. For example, a 1⁄2-inch wrench has a jaw opening
(from face to face) of 1⁄2 inch. The size is actually slightly larger than its nominal size so the wrench fits around a
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nut or bolt head of equal size. The following is a brief discussion of the types of wrenches used by automotive
technicians.
1. Open-End Wrench: The jaws of the open-end wrench allow the wrench to slide around two sides of a bolt
or nut head where there might be insufficient clearance above or on one side of the nut to accept a box wrench.

2. Box-End Wrench: The end of the box-end wrench is boxed or closed rather than open. The jaws of the wrench
fit completely around a bolt or nut, gripping each point on the fastener. The box-end wrench is not likely to slip off
a nut or bolt. It is safer than an open-end wrench. Box-end wrenches are available as 6 point and 12 point. The 6-
point box end grips the screw more securely than a 12-point box-end wrench can and avoids damage to the bolt head.

3 Combination Wrench: The combination wrench has an open-end jaw on one end and a box-end on the
other. Both ends are the same size. The combination wrench is probably the best choice for the second set. It
can be used with either open-end or box-end wrench sets and can be used as an open-end or box-end wrench.

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4 Sockets and Ratchets: A socket wrench is much safer, faster, and easier to use than any other
wrench. In fact, sometimes it is the only wrench that will work. The basic socket wrench set consists
of a ratchet handle and several barrel-shaped sockets. Sockets are available in 6, 8, or 12 points. A
6-point socket has stronger walls and improved grip on a bolt compared to a normal 12-point socket.
Six-point sockets are mostly used on fasteners that are rusted or rounded. Eight-point sockets are
available to use on square nuts or square-headed bolts. The square hole is the size of the hole and
handle lug (1⁄4 inch, 3⁄8 inch, 1⁄2 inch, and so on) indicates the drive size of the socket wrench.

5. Allen Wrench: Setscrews are used to fasten door handles, instrument panel knobs, engine parts, and even
brake calipers. A set of fractional and metric hex head wrenches, or Allen wrenches, should be in every
technician’s toolbox. An Allen wrench can be L-shaped or can be mounted in a socket driver and used with a
ratchet.

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7. Adjustable-End Wrench: An adjustable-end wrench (commonly called a crescent wrench) has one
fixed jaw and one movable jaw. The wrench opening can be adjusted by rotating a helical adjusting screw
that is mated to teeth in the lower jaw.

 Extensions An extension is commonly used to separate the socket from the ratchet or handle. The
extension moves the handle away from the bolt and makes the use of a ratchet more feasible. Extensions
are available in all common drive sizes and in a variety of lengths.
 Flexible adapters are used with extensions to gain access to bolts that cannot be directly tightened
or loosened. Wobble extensions allow a socket to pivot slightly at the drive connection. This type of
extension provides for a more positive connection to the socket than swivel joints but only allows
approximately 16 degrees of flexibility.

1. Screwdrivers: A screwdriver drives a variety of threaded fasteners used in the automotive industry.
Each fastener requires a specific kind of screwdriver. Screwdrivers are defined by their sizes, their tips, and
the types of fasteners they should be used with. Special screwdrivers.

2.

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3. Phillips Screwdriver: The tip of a Phillips screwdriver has four prongs that fit the four slots in
a Phillips head screw. The four surfaces enclose the screwdriver tip so it is less likely that the
screwdriver will slip out of the fastener.

4. Pliers: are gripping tools used for working with wires, clips, and pins. At a minimum, an auto
technician should own several types: standard pliers for common parts and wires, needle nose for small
parts, and large, adjustable pliers for large items and heavy-duty work.

 Combination pliers are the most common type of pliers and are frequently used in many kinds
of automotive repair. The jaws have both flat and curved surfaces for holding flat or round
objects.
 Needle nose pliers have long, tapered jaws. They are great for holding small parts or for
reaching into tight spots. Many needle nose pliers also have wire-cutting edges and a wire
stripper. Curved needle nose pliers allow you to work on a small object around a corner.
 Locking pliers, or vise grips,are similar to the standard pliers, except they can be tightly
locked around an object. They are extremely useful for holding parts together. They are also
useful for getting a firm grip on a badly rounded fastener that is impossible to turn with a
wrench or socket. Locking pliers come in several sizes and jaw configurations for use in many
auto repair jobs.
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 Diagonal-cutting pliers, or cutters, are used to cut electrical connections, cotter pins, and
wires on a vehicle. Jaws on these pliers have extra-hard cutting edges that are squeezed around
the item to be cut.
5. Hammers
Hammers are identified by the material and weight of the head. There are two groups of hammer
heads: steel and soft faced. The heads of steel-faced hammers are made from high-grade alloy
steel. The steel is deep forged and heat treated to a suitable degree of hardness. Soft-faced hammers
have a surface that yields when it strikes an object. Soft-faced hammers should be used on
machined surfaces and when marring a finish is undesirable.

4.1.1 Power tools

1. Electric hand drill
It is used to drive drill bit so that holes can be drilled. The electric drill has an electric motor that
drives the chuck. The chuck has jaws that can be opened and then closed to grip a drill bit.

Figure: Electric hand drill and chuck key

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A special chuck key is required to operate the jaws. Here are some cautions to observe when using
an electric hand drill.
1. Make sure that the drill is properly grounded.
2. Make sure that the twist drill is sharpened properly and the hole to be drilled is center –
punched.
3. Keep a firm grip on the drill.
4. Keep the drill in the perpendicular direction with the object to be drilled.
5. Use cutting oil to prevent surface hardening and to cool the drill.
2. Electric grinders
The grinder can be either bench – mounted or portable. It may have a grinding wheel and wire
wheel. If it has two grinding wheels, then one wheel is coarse and the other fine.

The grinding wheel is used to grind metal to the proper size and the wire wheel is used to clean parts.

Figure: Grinding wheel

Observe the following cautions when using a grinding wheel.
1. Wear safety goggles at all times when performing any operation with a grinder.
2. Don’t hammer on the wheel or apply excessive force against it.
3. Don’t touch the rotating wheel.

4. Hold the work securely.

5. Stand to one side when starting the grinder. Allow the wheel to reach full rpm before using it.
6. When grinding a tool, do not over heat it. This will get the tool soft and not hold in edge. To
prevent over heating deep the tool in water repeatedly during the grinding operation.

3. Hydraulic tools
The hand jack is compact tool for applying great force for lifting or straightening a bent part. When in use
be sure the jack is properly positioned so that it will not slip causing damage to the part or injury to the
operator. Be sure also that the capacity of the hand jack is enough to lift the part. Their capacity is written
on their side.

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Figure: Hydraulic tools and safety stands

Portable Cranes
Portable cranes are mounted on wheels and allow lifting an engine and other heavy objects and
transporting them to the desired place. When using portable crane, stand clear of the component being
lifted in case the component should slip or the lifting device topple. Never work on a component that is
suspended in the air.
1.2.3 Measuring tools
1. Rules
The simplest tool for measuring linear distances is the steel scale, or rule. It can be marked off in both or
either metric and/or inch.

2. Thickness Gauges
Thickness gauges or “feeler” gauges are strips or blades of metal of various thicknesses. Thickness gauges
are used to measure small distances such as the clearance between two parts. For example, to check the
clearance between the rocker arm and valve stem in an engine.

Figure: Thickness gauges

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3. Micrometers
The micrometer is a precision measuring tool that can measure thickness in hundredths of a millimeter (metric
system) or in thousandths or ten-thousandths of an inch. There are three types, outside micrometers, inside
micrometers and depth micrometers.

A. Outside Micrometers
The standard micrometer is the outside micrometer. The six major parts of a micrometer are anvil, frame,
spindle, thimble and ratchet screw. The outside micrometer is designed to measure the outside diameter of
cylindrical forms and the thickness of materials. Its spindle is attached to the thimble on the inside often, a
ratchet stop is provided. It can measure anything that will fit between the anvil and spindle. Micrometers come
in many different frame sizes. The standard sizes are 0-25mm, 25-50mm, 50-75mm, and 75-100 and so on.

Figure: Parts of outside micrometer Figure: Digital micrometer

Remember to always store micrometers in a clean, dry, safe place.

B. Inside Micrometer
The inside micrometer is used for measuring the distance between two parallel surfaces and for measuring the
inside diameter of cylinders. Inside micrometers come with a micrometer body with a thimble, sleeve, and
ratchet. Within the kit is an assortment of spindle of various lengths to use in holes of different sizes. To use
this instrument, select a spindle that will just accommodate the inside of a cylinder or above when it is threaded
to the thimble and sleeve. Extend the thimble until the spindle touches one side of the cylinder and the thimble
end touches the other. Read the measurement in the same way you read outside micrometer and add to this
reading the size of the spindle.

Figure: Inside micrometer set Figure: Components of inside micrometers

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C. Depth Micrometers
Depth micrometers, as the name implies, measures the depth of an object. There are also dial depth
gauges. These dial depth gauges are useful in checking end play and run out on a large number of parts

Figure: Depth micrometers Figure: Dial depth gauges

4. Dial Indicator
The dial indicator is a gauge that uses a dial face and a needle to register measurements. As the plunger
or arm is moved, the needle rotates on the dial face to indicate the distance in hundredths of a millimeter
or thousandths of an inch. The dial indicator can be used for checking the run-out, out of round and taper
condition of the cylinder walls in an engine, to measure an endplay in shafts or gears, the amount of run
out of a flywheel and numerous other measurements.

Figure: Dial indicator

5. Vernier Caliper
Mostly, the Vernier caliper is more convenient than the mike. The Vernier caliper can take inside,
outside, and depth measurements to within hundredths or thousandths of a millimeter or thousandths of
an inch.

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Figure: Vernier Caliper

6. Telescopic Gauge
Telescopic gauge are measures the inside diameter of a hole or a bore and consists of two spring
loaded telescoping members and a locking handle. In use, the gauge is placed in the hole or bore
with the handle parallel to the sides of the bore. The gauge is moved up and down several times
to center it in the bore. An inner coil spring holds the telescoping members against the sides of
the wall. The handle is then turned to lock the gauge. Upon removal, the distance hole diameter
across telescoping members are measured with a micrometer or caliper.

Figure: Telescopic gauge

7. Plastic gage
Plastic gage is used to determine clearances. It is a plastic thread which flattens when placed between the
journal and bearing. To measure bearing clearance, place a piece of Plastic gage along the width of the bearing

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cap. Install the bearing cap with the Plastic gage between the bearing and the journal and tighten the cap to
the proper torque value.

Figure: Plastic gage

Remove the bearing cap and with the gauge provided, check the width of the flattened plastigage. The
gauge has a number of different width graduations which are marked to indicate bearing clearances in
hundredths of a millimeter or hundredths of an inch.

[Link] Testing Devices

1. Stethoscope
A stethoscope is used to locate the source of engine and other noises. The stethoscope pickup is placed on
the suspected component, and the stethoscope receptacles are placed in the technician’s ears. Some sounds
can be heard easily without using a listening device, but others are impossible to hear unless amplified,
which is what a stethoscope does. It can also help you distinguish between normal and abnormal noise. The
best results, however, are obtained with an electronic listening device.

2. Circuit Tester
Circuit testers are used to check for voltage in an electrical circuit. A circuit tester commonly called a
test-light. Its handle is transparent and contains a light bulb. A probe extends from one end of the handle
and a ground clip and wire from the other end. When the ground clip is attached to a good ground and
the probe touched to a live connector, the bulb in the handle will light up. If the bulb does not light,
voltage is not available at the connector. A self-powered test-light is called a continuity tester. It is used
on open circuits. It looks like a regular test-light but has a small internal battery. When the ground clip

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is attached to one end of the wire or circuit and the probe touched to the other end, the lamp will light if
there is continuity in the circuit.

3. Multi-meters
A multi-meter is a must for diagnosing the individual components of an electrical system. A digital
multi-meter (DMM) can measure volts, ohms, and low current such as direct current (dc) and alternating
current (ac) amperes, diode continuity. DMMs provide great accuracy by measuring volts, ohms, or
amperes in tenths, hundredths, or thousandths of a unit.

4. Lab Scopes
An oscilloscope or lab scope is a visual voltmeter. A lab scope converts electrical signals to a visual
image representing voltage changes over a specific period of time. This information is displayed in the
form of a continuous voltage line called a waveform or trace. With a scope, precise measurement is
possible. A scope displays any change in voltage as it occurs.

5. Hand-Held Engine Analyzer

With the help of powerful functions, MT3500 Hand-held Engine Analyzer supplies serial testing items,
and meets serial testing demands; the following is the function explanation:
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 Dual-track oscilloscope can directly test the signal waveforms and data, AC and DC voltage,
frequency, Pulse- Width and duty cycle.
 There are six testing channels that can test the secondary ignition of the six cylinders at the same time.
 The functions of digital meter.
 Functions of testing components.
 Storage capacity is more than 32Mb.
 Power Supply: 3 pieces of batteries, low consumption design, and AUTO OFF function can
last the life of batteries.
 Document and data management function.
 Function of system setup.
 Direct installation of application.

 ENGINE PERFORMANCE TOOLS

 Scan Tools
A scan tool is a microprocessor designed to communicate with the vehicle’s computer. Connected to the
computer through diagnostic connectors, a scan tool can access diagnostic trouble codes (DTCs), run
tests to check system operations, and monitor the activity of the system. Trouble codes and test results
are displayed on a screen or printed out on the scanner printer. The scan tool is connected to specific
diagnostic connectors on the vehicle. It must be programmed for the model year, make of vehicle, and
type of engine. With OBD-II, the diagnostic connectors (commonly called Data Link Connector or
DLCs) are located in the same place on all vehicles.

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 Engine Analyzer
With an engine analyzer, you can perform tests on the battery, starting system, charging system, primary
and secondary ignition circuits, electronic control systems, fuel system, emissions system, and engine
assembly. The analyzer is connected to these systems by a variety of leads, inductive clamps, probes,
and connectors. The data received from these connections is processed by several computers within the
analyzer. The analyzer may compare the test results to the vehicle manufacturer’s specifications. When
the test series is completed, the analyzer prints a summary report. Many analyzers also provide diagnostic
assistance for the problems indicated by their measurements.

 Fuel Pressure Gauge

A fuel pressure gauge is essential for diagnosing fuel injection systems. These systems rely on very high
fuel pressures, from 35 to 70 psi. A drop in fuel pressure reduces the amount of fuel delivered to the injectors
and results in a lean air-fuel mixture. A fuel pressure gauge is used to check the discharge pressure of fuel
pumps, the regulated pressure of fuel injection systems, and injector pressure drop. This test can identify
faulty pumps, regulators, or injectors and can identify restrictions present in the fuel delivery system.
Restrictions are typically caused by a dirty fuel filter, collapsed hoses, or damaged fuel lines.

 Vacuum Gauge
Measuring intake manifold vacuum is another way to diagnose the condition of an engine. Manifold vacuum
is tested with a vacuum gauge. Vacuum is formed on a piston’s intake stroke. As the piston moves down, it
lowers the pressure of the air in the cylinder if the cylinder is sealed. This lower cylinder pressure is called
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engine vacuum. If there is a leak, atmospheric pressure will force air into the cylinder and the resultant
pressure will not be as low. The reason atmospheric pressure enters is simply that whenever there is a low
and high pressure, the high pressure always moves toward the low pressure. Vacuum is measured in inches
of mercury (in. Hg) and in kilo Pascal’s (kPa).

To measure vacuum, a flexible hose on the vacuum gauge is connected to a source of manifold vacuum,
either on the manifold or at a point below the throttle plates. The test is made with the engine cranking or
running. A good vacuum reading is typically at least 16 [Link] However, a reading of 15 to 20 in. Hg (50
to 65 kPa) is normally acceptable. Since the intake stroke of each cylinder occurs at a different time, the
production of vacuum occurs in pulses. If the amount of vacuum produced by each cylinder is the same,
the vacuum gauge will show a stable reading. If one or more cylinders are producing different amounts of
vacuum, the gauge will show a fluctuating reading.
 Vacuum Pump
There are many vacuum-operated devices and vacuum switches on cars. These devices use engine vacuum
to cause a mechanical action or to switch something on or off. The tool used to test vacuum actuated
components is the vacuum pump. The vacuum pump is also used to locate vacuum leaks by connecting
the vacuum pump to a suspect vacuum hose or component and applying vacuum.

 Tachometer
A tachometer is used to measure engine speed. Like other meters, tachometers are available in analog and
digital types. Digital meters are the most common. Tachometers are connected to the ignition system to
monitor ignition pulses, which are then converted to engine speed by the meter. Several types of inductive
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pickup tachometers that simplify rpm testing are available. An inductive tachometer simply clamps over
the number 1 spark plug wire. The digital display gives the engine rpm, based on the magnetic pulses
created by the secondary voltage in the wire. This type of tachometer is suitable for distributor less ignition
systems.

 Timing Light
Timing light is used to check ignition timing. The timing light is connected to the battery terminals and
has an inductive clamp that fits over the number 1 spark plug wire. While the engine is running, the timing
light emits a beam of light each time the spark plug fires. Many timing lights have a timing advance knob
that may be used to check spark advance. Some timing lights electronically measure timing advance as
the engine rpm is increased and displays it on an LED display.

 Exhaust Analyzers
Exhaust analyzers measure the amount of HC and CO in the exhaust. HC is measured in parts per
million (ppm) or grams per mile (g/mi) and CO is measured as a percent of the total exhaust. In
addition to measuring HC and CO levels, an exhaust analyzer also monitors CO2 and O2 levels.
By measuring NOx, CO2, and O2, in addition to HC and CO, a technician gets a better look at the
engine’s efficiency. There is a desired relationship among the five gases.

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