DRV COMMON UC4 - NEW Final

TABLE OF CONTENTS
How to Use This Competency-Based Learning Material.............................2
List of Competencies.................................................................................3
Qualification Title, Unit of Competency, Module Title,

Module Descriptor,Nominal Duration,
Summary of Learning Outcomes, and Assessment Criteria.......................6
Learning Outcome #1 Identify and Access Manual/ Specifications...............7
Learning Experiences................................................................................8
 Information Sheet 4.1-1...................................................................9

 Self Check 4.1-1..............................................................................14
 Answer Key 4.1-1.............................................................................15
Learning Outcome #2 Interpret Manuals...................................................16

 Self Check 4.2-1..............................................................................23
 Answer Key 4.2-1.............................................................................24
Learning Outcome #3 Apply Information In Manual..................................25

 Self Check 4.3-1..............................................................................42
 Answer Key 4.3-1.............................................................................43
Learning Outcome #4 Store Manuals........................................................44

 Self Check 4.4-1..............................................................................48
 Answer Key 4.4-1.............................................................................49
Glossary....................................................................................................50
Date Prepared: Document No.

DRIVING NC II
June 2022 Issued by:
READING, Developed by: TESDA PTC-
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SPECIFICATION AND Revision #00
MANUALS
HOW TO USE THIS COMPETENCY BASED LEARNING
MATERIALS
WELCOME!
This module read, interpret and apply specifications & manuals
contains information sheets, task sheet, and job sheet on reading,
interpreting manuals it also includes on how to use manuals.
Read and understand information sheet and answer self-check and

compare your answer with the answer key. Information sheet will help you
to understand with all the information about the unit of competency read,
interpret and apply specifications & manuals.
Perform the task sheet and job sheet until you can do the task and
the job based on the performance criteria checklist. After completing this
module and you are competent with this unit of competency you can
proceed to the next competency.
This module involves the skills and knowledge and attitudes required
to read, interpret and apply specifications & manuals . It also includes the action
to implement the vehicle manufacturer’s specifications for routine checks
and maintenance and that the vehicle is operational to the requirements of
both the workplace.
Recognition of Prior Learning (RPL)
You may already have some of the knowledge and skills covered in
this module because you have:
o been working for some time
o Already have completed training in this area.
If you can demonstrate to your teacher that you are competent in a

particular skill or skills, talk to him/her about having them formally
recognized so you don’t have to do the same training again. If you have a
qualification or Certificate of Competency from previous trainings show it to
your teacher. If the skills you acquired are still current and relevant to this
module, they may become part of the evidence you can present for RPL. If
you are not sure about the currency of your skills, discuss it with your
teacher.

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After completing this module ask your teacher to assess your
competency. Result of your assessment will be recorded in your competency
profile. All the learning activities are designed for you to complete at your
own pace.
Inside this module you will find the activities for you to complete
followed by relevant information sheets for each learning outcome. Each
learning outcome may have more than one learning activity.

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DRIVING NC II
COMPETENCY-BASED LEARNING MATERIALS
List of Competencies
No. Unit of Competency Module Title Code

BASIC
1 Participate in Participating in 400311210

workplace workplace
communication communication
2 Work in Team environment Working in team 400311211

environment
3 Solve/address general workplace Solving/addressing general 400311212
problems workplace problems
4 Develop career and life decisions Developing career and life 400311213
decisions
5 Contribute to Contributing to 400311214
workplace innovation workplace
innovation
6 Present relevant information Presenting relevant 400311215
information
7 Practice occupational safety Practicing occupational 400311216
and health policies and safety and health
procedures policies and
procedures
8 Exercise efficient and Exercising efficient 400311217
effective sustainable and effective
practices in the workplace sustainable
practices in the
workplace
9 Practice entrepreneurial Practicing 400311218
skills in the workplace entrepreneurial
skills in the
workplace
COMMON
Apply appropriate sealant Applying
adhesive appropriate ALT723201
1.
sealant adhesive
Move and position the Moving and
vehicle positioning the ALT723202
2.
vehicle

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Perform Mensuration and Performing
calculation Mensuration and ALT311202
3.
calculation
Read, Interpret and Reading,
Apply Specifications and Interpreting and
Manuals Applying ALT723203
4.
Specifications
and Manuals
Use and apply Using and
lubricant/coolant applying ALT723204
5.
lubricant/coolant
Perform shop Performing shop
ALT723205
6. maintenance maintenance
CORE
Carry Out Minor Carrying Out Minor
Vehicle Maintenance Vehicle Maintenance ALT723348
1.
and Servicing and Servicing
Drive Light Vehicle Driving Light Vehicle ALT832302

2.
Obeying and
Obey and Observe
Observing Traffic
Traffic Rules and ALT832303
3. Rules and
Regulations
Regulations
Implementing and
Implement and
Coordinating
Coordinate Accident- ALT832304
4. Accident-Emergency
Emergency Procedures
Procedures

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MANUALS
QUALIFICATION TITLE: DRIVING NC II
UNIT OF COMPETENCY: READ, INTERPRET AND APPLY
SPECIFICATIONS AND MANUALS
MODULE TITLE : READING, INTERPRETING AND APPLYING
SPECIFICATIONS AND MANUALS
MODULE DISCRIPTOR:
This module deals with identifying, interpreting and applying service
specification manuals, maintenance procedures manuals, and
periodic maintenance manual.
NOMINAL DURATION: 2 HOURS
SUMMARY OF LEARNING OUTCOME:

At the end of this module you MUST be able to:
1. Identify and access manual/specifications
2. Interpret manuals
3. Apply information in manual
4. Store manuals
ASSESSMENT CRITERIA:
 Appropriate manuals are identified and accessed as per job
requirements.
 Version and date of manual are checked to ensure correct
specification and procedure are identified.
 Relevant sections, chapters of manuals/specifications are located in
relation to the work to be conducted
 Information and procedure in the manual are interpreted in
accordance with industry practices
 Manual is interpreted according to job requirements
 Work steps are correctly identified in accordance with manufacturer
specification
 Manual data are applied according to the given task
 All correct sequencing and adjustments are interpreted in accordance
with information contained on the manual or specifications
 Manual or specification are stored appropriately to ensure prevention
of damage, ready access and updating of information when required
in accordance with company requirements
Assessment Method:

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1. Demonstration 3. Oral Questioning
2. Written Test
LEARNING OUTCOME #1:
Identify and Access Manual/Specification
CONTENTS:
 Types of manuals used in automotive & driving industry
Assessment Criteria
1. Appropriate manuals are identified and accessed as per job
requirements.
2. Version and date of manual are checked to ensure correct
specification and procedure are identified.
CONDITIONS:
Students/trainees must be provided with the following:
1. Supplies and materials:
- manufacturing specifications
- repair manual
- maintenance manual
- periodic maintenance manual
2. Instructional materials
- reference books
- professional emergency
- learning guides
- modules
- CD’s, VHS tapes, transparencies
METHODOLOGIES:
 Lecture
 Demonstration
 Self-paced
 Distance learning
ASSESSMENT METHODS:
 Written test
 Project method
 Interview with Oral Questioning

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Learning Experiences
Learning Outcome No.1:
IDENTIFY AND ACCESS MANUAL SPECIFICATIONS

Learning Activities Special Instructions
 Read Information Sheet 4.1-1 Read and understand the
“Types of manuals used in information sheet provided and
automotive & driving industry” browse to internet for more sample
guide. Check yourself by answering
 Answer Self-Check 4.1-1 the self-check and by performing
the task sheet. You must complete
Compare answer with Answer Key all the requirements before
4.1-1 proceeding to the next activity.

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Information Sheet 4.1-1
Types of Manuals Used In Automotive & Driving Industry
Learning Objectives:
After reading this INFORMATION SHEET, YOU MUST be able to:
1. Identify the types of manuals used in automotive and driving
lesson
Introduction
Manuals are defined as a guidebook that tells you how to operate

something or to do something. An example is the book that comes from your
vehicle that tells you how to drive and to use it.
Manuals are the plural form of manual, which is a book of

instructions, especially for operating a machine or learning a subject. It can
as well be defined as a thing operated or done by hand, rather than by
electronic means.
These are the types of manuals used in automotive.
 An owner's manual (also called an instruction manual) is an

instructional book or bookletthat is supplied with almost all
technologically advanced consumer products such asvehicles, home
appliances and computer peripherals.

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 Service/Repair manuals explain how to carry out routine
maintenance, restoration and servicing of cars and motorcycles, and
are aimed primarily at the Do-it-yourself
MANUFACTURE’S SERVICE MANUAL
Manufacturer’s service manual or sometimes it’s called a shop

manuals, are written by the automotive manufacturer for the technicians in
their dealership. A shop manual covers one model and one year of a vehicle
in great detail, sometimes it is printed in a number of volumes. Shop
manuals are the best source of detailed service information for specific car.
Shop manuals / service manuals are necessary to obtain the desired

specification for specific job. It also provides drawings and photograph to
show where and how to perform a certain procedure in a particular car you
are working on. Special tools or instrument are listed and shown when they
are required. Precautions were given to prevent injury and damage to the
parts.
Automobile manufacturers publish a service manuals or set of

manuals for each model and year of their cars. These manuals provide the
best and most complete information for their cars. Although the manuals
from different manufacturer vary in presentations and arrangement of
topics, all service manuals are easy to use after you become familiar with
their organizations.
Shop manuals are divided into a number of sections, each covering a

different aspect of the vehicle. The beginning sections commonly provide a
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vehicle identification and basic maintenance information. The remaining
sections deal with each different vehicle system. And each section has an
index indicating more specific areas of information
Typical Cover of a Service Manual

DIAGNOSING OR TROUBLESHOOTING INFORMATION
Probably the most valuable type of service information comes from the
troubleshooting or diagnosing guides. These are designed to help the
technician save time in identifying and solving problems.
PROCEDURE INFORMATION

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Procedure information gives the steps to follow in doing a repair job.
The procedures are usually numbered in a step-by-step order.

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SPECIFICATION
Specifications are included as part of the service manual.
Specifications are technical data, numbers, clearances and measurements
used to diagnose and adjust automobile components. Specifications can be
referred to as specs. They are usually considered precise measurements
under standard conditions. Examples of specifications include valve
clearances, spark plug gaps, tire pressure, number of quarts of oil, ignition
timing and size of engine.
TYPES OF SPECIFICATIONS
General Engine Specification – This specification identify the size and

style of the engine. They include cubic inch displacement, engine codes, fuel
system settings, bore and stroke, horsepower, torque, compression ratio,
and normal oil pressure.
Tune-Up specifications – This specification helps identify adjustments

necessary for tune-up on the vehicle. This includes spark plug gap, firing
order, degrees of ignition timings, fuel system settings and fuel pump
pressure.
Capacity Specifications –This specification include identifying the capacity of

different fluids on the vehicle. This includes cooling capacity, number of
quarts of oil, fuel tank size, transmission transaxle capacity, and rear axle
capacity.
Overhaul and Maintenance Specifications – This specifications is used to aid

technician in servicing the vehicle. This include distributor advance at
different speeds, valve seat angles, valve stem clearance, piston
measurements, ring end gaps, bearing clearances, shaft end play and many
more. This specification help the technician determine how much wear has
occurred. The mechanic is then able to decide whether or not to replace the
component in question. Usually maximum or minimum clearances are given
for this purpose.
Operational Specification – This specification tell how the vehicle is to

operate, what type of oil to use, and so on. Some of them are found in the
owner’s manual. Other specification includes tire inflation, type of gasoline
to use, tire size and general information for the operator of the vehicle.
Torque Specification – It is important to torque each bolt or nut correctly

when replacing or installing a component on the automobile. Torque
specifications are used for this purpose. This torque specification should be
used in place of any standard bolt and nut torque specification.

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AFTERMARKET REPAIR MANUAL
An aftermarket repair manual is most often used by the technician at

independent repair shops. This manual is called an aftermarket because it
is published by independent publisher and not by the car manufacturer.
Like the shop manual. This contains information on troubleshooting,
specifications and step-by-step repair procedures. The main difference is
that they cover many different car models and years instead of just one.
Because they are covering more models and years, they typically cover
topics in less detail

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VIN (Vehicle Identification Number)
The official vehicle identification number is needed to identify the exact

type of vehicle being worked on. The VIN is also used for title and
registration purposes. It is normally stamped on a metal tab that is fastened
to the instrument panel close to the wind shield. Each manufacturer has
assigned a VIN to each vehicle manufactured. Each VIN number represents
different data. The following information can be determined be reading the
VIN number.
 The country by which the vehicle was manufactured or the world
manufacturer
 The corporation and division
 Model or series of the vehicle
 Model year
 Body style
 Check digit
 Engine type
 Factory or plant code
 Vehicle serial number

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SELF CHECK 4.1-1
Essay:
Instructions: Explain each of the following:

1. Service manual
2. Service procedures
3. Operators manual
4. Specification
5. General engine specification
6. Tune-Up specification
7. Capacity specification
8. Overhaul and maintenance specification
9. Operational specification
10. Torque specification

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ANSWER KEY 4.1-1
Essay:
Direction: Explain the following terms used.
1. Service manual- designed and written to help service technician in
servicing vehicle
2. Service procedures- this aid the technician to speed up the work and
make his job easier and safer
3. Operators manual-a booklet provided with a new car that describes
the car features, maintenance and specifications
4. Specification- these are technical data, numbers, clearances and
measurement used to diagnose and adjust automobile components
5. General engine specification- this specification identify the size and
style of the engine, also includes the engine displacement, engine
codes fuel systems settings, etc.
6. Tune-Up specification- this specifications identifies the necessary
adjustment for vehicle tune-up
7. Capacity specification- this specifications determines the capacities of
different fluids used in the vehicle
8. Overhaul and maintenance specification-
9. Operational specification- this specification tells how to operate the
vehicle, what type of oil to use and so on…
10. Torque specification- used to identify the correct torque of each
bolt and nut during replacing or installing an automotive component

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LEARNING OUTCOME #2: Interpret Manuals
CONTENTS:
 Identification of symbols used in manuals
Assessment Criteria
1. Relevant sections, chapters of manuals/specifications are located in
relation to the work to be conducted
2. Information and procedure in the manual are interpreted in
accordance with industry practices
CONDITIONS:
1. Supplies and materials:
- manufacturing specifications
- repair manual
- maintenance manual
- reference books
- professional emergency
- learning guides
- modules
METHODOLOGIES:
 Lecture
 Demonstration
 Self-paced
ASSESSMENT METHODS:
 Written test
 Project method
 Interview with Oral Questioning

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Learning Outcome No.2
INTERPRET MANUALS
 Read Information Sheet 4.2-1 Read and understand the
“Identification of symbols usedinformation sheet provided and
in manuals” browse to internet for more sample
Checking self-check using Answer
all the requirements before
Key 4.2-1
proceeding to the next activity.

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Identification of Symbols Used In Manuals
1. Identify the symbols use in driving and automotive manuals
Introduction
SYMBOL AND IDENTIFICATION MANUAL
This manual contains Symbol and Vehicle Identification Number (VIN)

information for all major domestic and foreign makes.
Retain these pages as a reference when using the Symbol and Identification
Manual.
Brake Warning Indicators, U.S. and

Canada (r)
Engine Coolant Temperature Indicator

Symbols
Engine Oil Level or Oil Pressure

Warning Light Symbol
Engine Oil Sensor and Level Indicators
Charging System Warning Light

Symbols

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Master Warning Light
SRS Air Bag Indicator Symbols
Side Airbag Off Indicator
Security and/or
Immobilizer Symbols
Drivetrain or Powertrain Trouble

Lights
Electronic Shift Malfunction
Transmission Warning Indicator Symbol
Transmission Temperature Warning
Power Steering Trouble Light
Parking Brake Indicators

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Low Brake Fluid Indicator Symbol
Antilock Brake System

Trouble Lights
Low Brake Pad Warning Light
Electronically Controlled Brake System Symbol
Electric Park Brake Fault Indicator
Automatic Shift Lock (ASL) Indicator Symbol
Tire Pressure Monitoring System

Lights
Check Engine Light

Symbols
Check Engine Electrical Indicator
Reduced Engine Power Indicator

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Engine Fault Indicator
Lambda (Oxygen) Sensor Indicator Symbol
Check Gas Cap Indicator Symbol
Message Indicator Symbol
Owner Manual Indicator Symbol
Catalytic Converter Warning Symbol
Low Coolant Lights, more
More Low Coolant Lights
Electronic Throttle Control Indicator Symbol
Service Reminder Indicators

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Clogged Air Filter Indicator
Seat Belt Reminder Indicator Symbol
Wiring diagrams use symbols (see below) to identify various circuit

components. Individual circuits are usually numbered, and the wires in the
circuits are color-coded to make identification easier. When there is a two-
color code for a wire, it means the wire is one color and there is a colored
stripe of a different color on that same wire.

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SELF CHECK 4.2-1
Matching type:
1. Electronic Throttle Control Indicator 6. Tire Pressure Monitoring System
Symbol Lights
2. More Low Coolant Lights 7. Seat Belt Reminder Indicator Symbol
3. Service Reminder Indicators 8. Antilock Brake System Trouble Lights
4. Reduced Engine Power Indicator 9. Clogged Air Filter Indicator
5. Check Engine Light Symbols 10. Engine Fault Indicator

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A.
B.
C.
D.
E.
F.
G.
H.
I.
J.

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ANSWER KEY 4.2-1
Matching type:
1. D
2. E
3. C
4. F
5. H
6. I
7. B
8. J
9. A
10. G

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LEARNING OUTCOME #3: Apply Information in Manual
CONTENTS:
 Applying and accessing information in manual
Assessment Criteria
1. Manual is interpreted according to job requirements
2. Work steps are correctly identified in accordance with manufacturer
specification
3. Manual data are applied according to the given task
4. All correct sequencing and adjustments are interpreted in accordance
with information contained on the manual or specifications.
CONDITIONS:
1. Supplies and materials
- Manufacturer’s specifications
- repair manual
- maintenance procedure manual
- reference books
- learning guides
- modules
METHODOLOGIES:
 Lecture
 Demonstration
 Self-paced
ASSESSMENT METHODS:
 Written/oral examinations
 Project method
 Interview

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Learning Outcome No. 3

Applying Information in Manual
 Read Task Sheet 4.3-1 “Applying Read and understand the
and Accessing Information in information sheet provided and
Manual” browse to internet for more sample
Compare answers with Answer
all the requirements before
Key 4.3-1

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Applying and Accessing Information in Manuals
1. Understand the information in manuals
Introduction
After discussing to you the different service information used by the

technicians, the following pages will show you the examples of each services
information presented on the first Learning Outcomes. Be able to study the
examples given and at the end of this LO you are going to perform the
different activities related to the different service information presented.
DIAGNOSING OR TROUBLESHOOTING INFORMATION

One type of troubleshooting guide is the diagnosis chart. The first part
list the possible problem, then it is divided into three areas: condition, cause
and the correction.
Improper procedure used Check with the customer to

determine if proper starting
Engine cranks normally
procedure is used, as out lined
- will not start in the owner’s manual
Choke valve not operating Check the choke valve and/or

properly linkage as necessary. Replace
parts if defective. If caused by
foreign material and gum, clean
with suitable non-oil-base
solvent
No fuel in carburetor
 Perform fuel pump flow test

 Inspect fuel inlet filter. If
plugged, replace
 If fuel is ok, remove air horn
and check for a bind in the
float mechanism.

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Turn ignition off
Disconnect connector from
controller asm
With an ohmmeter probe between
connector cavity pins “F” (circuit 38)
and “H” (circuit 399)
Measure the resistance
Does resistance
measure between 20-30
ohms?
N Ye
o s
Disconnect the servo Turn ignition off

electrical connector from the Disconnect connector from
servo. With an ohmmeter controller asm.
Disconnect connector from servo
probe between pins “B”
asm.
(circuit 399) and “D” With an ohmmeter probe between
(circuit398) on the servo controller connector cavity Pin “C”
assembly. (Not (circuit 430) and grd.
theconnector) Measure the resistance of the wire
Does resistance
measure between 20-30
ohms?
Doesresistance measure
(infinity)?
No Ye Continuity No
s Continuity
Replac Check circuits 399 & 398 Find short to grd. and Leave ohmmeter
e (Pin “H” of controller to Pin “B” of servo) repair (circuit 403) connected as is.
servo (Pin “F” of controller to Pin “D” of servo) for opens in Use jumper wire and
wires and/or connectors. connect cavity “A” of servo
Repair connector to know good
ground.
Measure resistance
Does resistance measure

0 ohms?
N Y
es
o
Remove jumper wire Find open in circuit 403
With ohmmeter probe (Pin “C” of controller to
between controller Pin “A”of servo)
connector cavityPin “K”
(circuit 402) and grd.
Repair or Replace
asrequired
Continuity No
Continuity
Find short to grd. and Leave ohmmeter
repair (circuit402 connected as is
Use jumper wire and
connect Cavity “E” of
servo connector to
known goodground.
Measure resistance
Does resistance Turn ignition off

measure 0 ohms? Disconnect connector from
servo
With an ohmmeter probe
connector cavity Pin “C” Repair or Replace
Ye N (circuit 150) to know good asRequired
s o ground
Measure the resistance
A
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The “road map” type of troubleshooting chart is shown on the page 14.
With this of chart the technician follows a set of procedures. First, select the
troubleshooting chart for the appropriate problem. The technician begins
the reading at the top of the chart, then follows the lines on chart
downward. Depending on the results of each steps, two or more possible
courses of action may be presented. The two different procedures follow the
first step. If you answer “NO” , you directed to perform another test. If you
answer “YES”, you are directed to proceed to another steps. The directions
on this type of chart should be followed exactly, without skipping any steps.
PROCEDURE INFROMATION
Procedure information gives the step by step to follow in doing a repair
job. The procedures are usually numbered in a step-by-step order. Below is
an example of step-by-step procedure to follow in replacing a cylinder head.
CYLINDER HEAD
Replace
1. Raise and support front of vehicle, then drain cooling system and disconnect
exhaust pipe from manifold.
2. Lower vehicle and remove oil dipstick tube and air cleaner.
3. Disconnect wire connectors and vacuum hoses from carburetor or TBI unit.
4. Remove EGR valve base plate from intake manifold, if applicable.
5. Disconnect heater hose from intake manifold, then remove AIR system
discharge tube attaching bolt from intake manifold.
6. Remove ignition coil lower attaching bolt, then disconnect wiring from coil.
7. Disconnect all wiring from cylinder head and intake manifold, then remove
engine upper support attaching bolt from engine strut.
8. Remove A/C compressor and position aside with refrigerant lines attached.
9. Remove alternator drive belt, then remove AIR pump bracket bolt from
engine block, if equipped.
10.Disconnect throttle and throttle valve cables from throttle lever and intake
manifold.
11.Disconnect upper radiator hose from cylinder head then disconnect AIR hose
from tube assembly, if equipped.
12. Remove rocker arm cover, and then remove rocker arms and push rod.
13.Remove cylinder head attaching bolts then lift cylinder head and intake and
exhaust manifold as an assembly from cylinder block.
14.Reverse procedure to install. Coat heads and threads of cylinder bolts with
suitable sealing compound, then install bolts finger tight. Tighten cylinder
head bolts in proper sequence.

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SPEFICIFICATION
Specifications are technical data, numbers, clearances and
measurements used to diagnose and adjust automobile components.
Specifications can be referred to as specs. They are usually considered
precise measurements under standard conditions.
TYPES OF SPECIFICATIONS
General Engine Specification

This specification identifies the size and style of the engine. They
include cubic inch displacement, engine codes, fuel system settings, bore
and stroke, horsepower, torque, compression ratio, and normal oil pressure.
SPECIFICATIONS
Year Engine Fuel Bore & Compression Net Brake Maximum Normal Oil
System Stroke Ratio H.P@ RPM Torque Pressure
CID/Liter VIN code
1
2 Psi.
4.3L/V6-262 Z TBI 4.00X3.48 9.3 145@4200 225@2000 3

5.0L/V8-305 E TBI 3.74X3.48 9.3 170@4000 255@2400 3
1989
5.0L/V8-307 Y 4Bbl. 3.800X3.385 8.0 140@3200 255@2000 30 4
4.3L/V6262 Z TBI 4.00X3.48 9.3 145@4200 225@2000 3
5.0L/V8-305 E TBI 3.74X3.48 9.3 170@4000 255@2400 3
1990 5.0L/V8-307 Y 4Bbl. 3.800X3.385 8.0 140@3200 255@2000 30 4
5.7L/V8-350 7 TBI 4.00X3.48 9.3 175@4200 295@2000 3
5.0L/V8-305 E TBI 3.74X3.48 9.3 170@4000 255@2400 3
1991 5.7L/V8-350 7 TBI 4.00X3.48 9.8 185@3800 300@2400 3
4.3L/V6-262 Z TBI 4.00X3.48 9.3 145@4200 225@2000 3
5.0L/V8-305 E TBI 3.74X3.48 9.3 170@4000 255@2400 3
1992 5.7L/V8-350 7 TBI 4.00X3.48 9.8 185@3800 300@2400 3
General Engine specifications
Gives information about the engine type to help technician identify the exact type of engine in a vehicle.(Courtesy of Motor
Publication, Auto Repair Manual)

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1
- the eight digit of the VIN denotes engine code
2
– rating are net, as installed in the vehicle
3
4 - minimum with engine hot, 6 psi@1000 RPM; 18psi.@2000 RPM; 24
psi.@4000 RPM
- minimum with engine hot @ 1500 RPM
TBI – Throttle Body Fuel Injection

4Bbl– 4 barrel carburetor
Tune-Up specifications
This specification helps identify adjustments necessary for tune-up on
the vehicle.
TUNE UP SPECIFICATIONS
Ignition Timing Fuel
Pump
Year & Spark Plug Firing Degrees Mark Fig Curb Idle Fast Idle Pressure
Engine/ VIN Gap Order 2 BT DC 3 Speed 4 Speed 5 Psl
Code 1
1989
5 6 6 7
4.3L/V8-262/Z .035 E TDC B 9-13
5
5 6 6 7
5.0L/V8-305/E .035 A 6 B 9-13
5
12 6 9 11
5.0L/V8-307/Y .060 C 20 D 550D
1
5 6 6 7
5.7L/V8-350/7 .035 A 6 B 2 9-13
5
2
1990
5 6 6
4.3L/V8-262/Z .035 E TDC B 9-13 7
5
6 6
5.0L/V8-305/E .035 A 6 5 B 9-13 7
12 5
6 9 11
5.0L/V8-307/Y .060 C 20 D 550D
1
5 6 6 7
5.7L/V8-350/7 .035 A 6 B 2 9-13
5
2
1991
8 6 6
5.0L/V8-305/E .035 A TDC B 9-13 7
5
6 6 7
5.7L/V8-350/7 .035 A 10 B 9-13
5
1992
5 6 6 7
4.3L/V8-262/Z .035 E TDC B 9-13
5
8 6 6 7
5.0L/V8-305/E .035 A TDC B 9-13
5
10 6 6 7
5.7L/V8-350/7 .035 A B 9-13
5
Tune-Up specification used by the service technician to tune-up the vehicle. (Courtesy of Motor Publication, Auto
Repair Manual)

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2 -the eight digit of the VIN denotes engine code
1
-before removing wires from the distributor cap, determine location of No. 1
3 wire in a cap as distributor position may have been altered from that
show at the end of this chart.
- BTDC: Before Top Dead Center
4
- D: Drive. When adjusting idle speed set parking brake and block drive
5
wheels
-Disconnect set timing by-pass connector (tan/black wire) when adjusting
ignition timing. The timing by-pass connector breaks out of the engine
compartment. After completing adjustment, reconnect set timing connector.
6 With engine off, clear trouble code from ECM memory by removing battery
voltage to the ECM for 30 seconds.
- Idle speed is controlled by IAC (Idle Air Control) or ILC (Idle Load
7
5
Compensator)
- Wrap shop towel around fuel hose to steel line connection in engine
compartment to prevent fuel spillage. Disconnect hose from steel line and
8 install suitable fuel pressure gauge between hose and line. Ensure gauge
connections are tight, then start engine and check fuel pressure readings.
- Disconnect EST bypass electrical connector when checking ignition timing.
The bypass connector is located on the AIR control valve tube. After
9 completing adjustment, reconnect EST bypass electrical connector.
1
2 -On low step on fast idle cam
2
10 -Computer controlled, no adjustment
11
-Mechanical fuel pump pressure, 5.5-6.5 psi, electric pump
12
- At 11000 RPM with jumper wire connected between ALCL connector
terminals
A&B. ALCL is located under the instrument panel to the right of the steering
column.
After completing adjustment, disconnect jumper wire from between
terminals A&B. With engine off, clear trouble code from Electronic Control
Module (ECM) by removing battery voltage from ECM for 30 seconds.
Capacity Specifications
This specification includes identifying the capacity of different fluids
on the vehicle. This includes cooling capacity, number of quarts of oil, fuel
tank size, transmission transaxle capacity, and rear axle capacity.

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COOLING SYSTEM & CAPACITY DATA
Cooling Radiator Cap Thermo. Fuel Tank Engine Transmission Oil

Capacity, Qts Relief Opening Qts. Refill Qts.
Engine & VIN Code pressure, Psi. Temp. Man. Auto. Rear
Trans. Trans. Axle Oil
Pts Qts.  Pts.
1989-90
3.8L/V6-232 (4) 11.6 16 197 18.8 4 - 12.3  
3.8L/V6-232 SC (C, 12 16 197 18.8 4 6.3  12.3  

R)
5.0L/V8-302 (F) 14.1 16 197 18 4  - 12.3  
1991
3.8L/V6-232 (4) 11.8 16 196 19 4.5  - 12.3  3.1
3.8L/V6-232 SC 11.8 16 197 19 4.5  6.3  12.3  3.4
(C,R)
5.0L/V8-302 (F)  14.4 16 192 18 4  - 12.3  3.8
5.0L/V8-302 HO (T) 14.1 16 195 19 4  - 12.3  3.4

1992
3.8L/V6-232 (4, C, 12.5 16 197 18 4.5  6.3 12.3  3.1
R)
4.6L/V8-281 (F) 13.6 14-18 195 20 5.0 - 12.3  3.8
5.0L/V8-302 HO (T) 14.1 14-18 192-197 18 4.0  - 12.3  3.35
 - Approximate, make final oz. of friction modifier is located at left hand bottom
check with dipstick. meeting Ford Motor Co. of oil pan
specification
Add 1 qt. with filter change. Conventional axle, 4 pts.
 - EST-M2C118-A Models w/  -
Use Mercon type transmission 8.8 inch ring gear, Traction-Lok axle, 3.75 pts.
 - fluid. Plus 4 oz. of friction modifier
conventional axle, 3.5 pts;
traction-lok axle, 3.75 pts, meeting Ford Motor Co.
Conventional axle, 3 pts. specification
plus 4 oz. of friction modifier
 - Traction modifier meeting meeting Ford Motor Co. EST-M2C118-A.
 - Ford specification EST-M2C118-A.
Add ½ qt. with filter change.
Motor Co. specification  - Equipped with dual sump oil  -
pan. Remove both drain Crown Victoria & Grand
EST-M2C118-A. plugs to fully drain oil. One  - Marquis.
Models w/ 7.5 inch ring gear, drain plug is located at front  - Cougar & Thunderbird
conventional axle, 3 pts.; of oil pan. Second drain plug
- On Super Charged Engines,
Traction-Lok axle, 2.75 pts, 3.50 pts
plus 4

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Overhaul and Maintenance Specifications
This specification used to aid technician in servicing the vehicle.
PISTONS, PINS, & RINGS
Engine Year Piston Piston Piston Pin Pin to Piston End Ring Piston Ring Side
Liter/ CID Diameter Clearanc Diameter Piston Clearance
(Std.) e Clearance Gap 
Comp. Oil Comp. Oil
1.3L/4-80.8 1989- 2.793-2.794 .006 .7864-.7866 .0-.0010 .006 .008 .001-.00 -
91 3
1.6L/4-97 1991 3.0690- .0010-.0026 .7869-.7871 .0004-.0012 .008 .0012-.00 .0012-.00
3.0698 26 26
1.8L/4-112 1991 3.2659- .0015-.0020 .7869-.7871 .0002-.0005 .006-.01 .008 .0012-.00 -

3.2667 2 28
1.9L/4-116 1989-  .0016-.0024 .8119-.8124 .0003-.0005 .010 .016 -

91
2.2L/4-133 1989- 3.3836- .0014-.0030 .8651-.8654 -- .001-.00 -
91 3.3844 3
2.3L/4-140 1989-  .0030-.0038 .9118-.9124 .0003-.0005 .010 .015 .002-.00 -
 91 4
2.3L/4-140 1989-  .0012-.0022 .9119-.9124 .0002-.0005 .008 .015 .002-.00 -
 91 4
2.5L/4-153 1989-  .0013-.0021 .9119-.9124 .0002-.0005 .008 .015 .002-.00 -
91 4
2.9L/V6-177 1989- .0011-.0019 .9446-.9450 .0003-.0006 .015 .015 .0020-.00 -
91 33
3.0L/V6-182 1989-  .0014-.0022 .9119-.9124 .0002-.0005 .010 .010 .0012-.00 -

91 31
3.0L/V6-182 1989- 3.5023- .0012-.0020 .8267-.8271 .00004 .012 .008 .0024-.00

91 3.5035 59
3.8L/V6-232 1989-  .9119-.9124 .015 .0016-.00 -

90 34
3.8L/V6-232 1991  .9119-.9124 .0002-.0005 .010 .015 .0016-.00 -

34
4.6L/V8-281 1991 .0008-.0018 .8659-.8661 .0002-.0039 .009 .010

5.0L/V8-302 1989-   .9119-.9124 .0002-.0004 .010 .015 .002-.00 -
91 4
5.8L/V8-351 1989- .0018-.0026 .9119-.9124 .0003-0005 .010 .015 .002-.00 -
91 4

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 - Minimum  - Except V8-302 HO engine, - EFI, .0014-.0032 inch;
coded red, 3.9989-3.9995 SC, .0035-.0040 inch
 - Coded red, 3.224-3.225 inch; inch; coded blue, 4.0001-
coded blue, 3.225-3.226 inch 4.0007 inch; coded yellow, - EFI, .0002-.0005 inch;
4.0013-4.0019 inch. V8-302 SC, .0003-.0006 inch
 - Overhead cam (OHC) engine
HO engine, coded red,
 - Coded red, 3.7764-3.7770 inch; 3.9972-3.9980 inch; coded - First ring, .011 inch; second
coded blue, 3.7776-3.7782 inch. blue, 3.9984-3.9992 inch; ring, .009 inch
coded yellow, 3.9996-4.0004
 - High swirl combustion (HSC) inch. - EFI, .0014-.0032 inch;
engine SC, .0040-.0045 inch
First ring, .0015-.0032 inch;
 - Coded red, 3.6783-3.6789 inch; - second ring, .0015-.0035 inch
coded blue, 3.6795-3.6801 inch;
coded yellow, 3.6807-3.6811 Coded red, 3.6605-3.6615 - Coded red, 3.5498-3.5503 inch;
inch. inch. coded blue, 3.5503-3.5509
- inch; coded yellow, 3.5509-
 - Coded red, 3.5024-3.5031 inch; - First ring, .008 inch; second - 3.5514 inch
coded blue, 3.5035-3.5041 inch; ring, .006 inch
First ring. .002-.004 inch;
coded yellow, 3.5045-3.5051 second ring, .001-.003 inch.
inch. Turbo, .006 inch; non-
 - - - Maximum .0006 inch
Coded red, 3.8095-3.8101 inch; turbo, .012 inch
 - coded blue, 3.8107-3.8113 inch; - Super High output (SHO) - Coded red, 3.9978-3.9984 inch;
coded yellow, 3.8119-3.8125 engine. coded blue, 3.9990-3.9996
inch. inch; coded yellow, 4.0002-
- First ring, .0008-.0024 inch; 4.0008 inch.
Except V8-302 HO second ring, .0006-.0022 inch
engine, .0014 to .0022 inch; V8-
302 HO engine, .0030-.0038
inch.

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Operational Specification
This specification tell how the vehicle is to operate,.
BREAK – IN SPEED LIMIT MPH (KM/H)
1st 2nd 3rd 4th 5th
Manual
Transaxl
e 4- Speed 0 to 22 12 to 37 20 to 55 25 to 75
(0 to 35) (20 to (30 to 90) (40 to 120)
60)
0 to 22 10 to 37 15 to 53 22 to 68 28 to 80
5- Speed (0 to 35) (25 to (25 to 85) (36 to 110) (45 to 130)
85)
“1” Low “2” Low “D” Drive
Automatic Transaxle
0 to 30 (0 to 50) 0 to 53 (0 to 85) 0 to 75 (0 to 120)
Operational specifications showing the break-in speed limit for operating the
vehicle. (Courtesy of Nissan Motor Corporation in USA)
Torque Specification
Is important to torque each bolt or nut correctly when replacing or installing a
component on the automobile. Torque specifications are used for this purpose. This
torque specification should be used in place of any standard bolt and nut torque
specification.

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Engine Tightening Specifications
Torque specifications are for clean & lightly lubricated threads only. Dry or dirty threads increase friction which
prevents accurate measurement of tightness.
Spark Cylinder Intake Exhaust Rocker Rocker Connecting Main Flywheel Vibration
Plugs Head Manifold Manifol Arm Arm Rod Cap Bearing To Damper
Engine Ft.Lbs Bolts Ft.Lbs. d Shaft Cover Bolts Cap Bolts Crankshaft Or Pulley
MODEL/ . Ft.Lbs. Ft.Lbs. Bracket Ft.Lbs. Ft.Lbs. Ft.Lbs. Ft.Lbs. Ft.Lbs.
V.I.N. Ft.Lbs.
4-150/U 27 85  23 23 19  28  33 80  90 
4-151/B 11 92 37 37 20  7 30 65 66 160
4-151/B 11 92 26 37 20  7 30 65 66 162
6-258/C 11 85 23 23 19  28  33 65 105 80 
6-258/C 11 85  23 23 19  28  33 80 105 80
 - In Lbs.  - Rocker Arm Cap Screw  - Torque bolts to 50 Ft. Lbs.,
 - Coat under side of cylinder head  - Lubricate bolt threads lightly before then tighten boltsan bolt
heads & threads with a suitable additional 60 degree sealing compound
Owner’s Manual
An owner’s manual or an operator’s manual is a booklet that comes with a

new car. This manual usually explains how to operate the automobile’s control and
accessories.
In an owner’s manual a vehicle maintenance procedure is provided so that
the owner will know when to get needed service.
Automobile’s control and accessories.

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Maintenance procedure
Service at the Miles x1,000 15 30 45 60 75 90 105 120

indicated
Km x 1,000 24 48 72 96 120 144 168 192
mileage or time
whichever months 12 24 36 48 60 72 84 96 Note
comes first
Replace engine oil Replace every 7,500 miles or 12 months Capacity 5.0L
Replace engine oil filter        

Check engine oil & coolant Check oil and coolant at each fuel stop Check for
leaks
Replace air cleaner element    

Inspect valve clearance  In .15-0.1mm
Ex .17-.2mm
measure
when cold
Replace spark plug  Gap 1.0-

1.1mm
Replace fuel filter  

Inspect idle speed  800+/-rpm
(MT)
780+/-rpm
(AT)
Replace engine coolant    Capacity

12.0L
Replace transmission fluid  Manual Trans.

MTF 2.65L
Auto. Trans
ATF 2.9L
Inspect front & rear brakes         Check brake

thickness and
movement.
Check caliper
for leakage
Replace brake fluid (including ABS)   DOT3 brake

fluid. Check
that fluid is
between
upper & lower
marks in
reservoir
Check parking brake adjustment Engage 10 to

14 notches
Rotate tires (check inflation & condition at Rotation

method
least once per month
Rotation every 7,500 miles shown I
owner’s
manual

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VIN (Vehicle Identification Number)
1G1AB68CXDY 123456
NATION OF ORIGIN
PLANT SEQUENTIAL NUMBER
1.USA
2.CANADA BODY TYPES
CODE ASSEMBLY PLANT
MANUFACTURER
MODEL YEAR
GENERAL MOTORS
D 1983 A LAKEWOOD
MAKE AND TYPE E 1984 B BALTIMORE
1. CHEVROLET C SOUTH GATE

F 1985
2. GM OF CANADA D DORAVILLE
G 1986
E LINDEN
RESTRAINT SYSTEM H 1987
G FRAMINGHAM
A. NON PASSIVE J 1988
B. PASSIVE RESTRAINT/AUTOMATIC BELTS H FLINT (BUICK)
C. PASSIVE RESTRAINT/INFLATABLE J JANESVILLE
RESTRAINT
K LEEDS
L VAN NUYS
CARLINE/SERIES M LANSING
CODE SERIES N NORWOOD

CHECK DIGIT
P PONTIAC MOTOR
“B” MODELS L IMPALA R ARLINGTON
N CAPRICE CLASSIC S ST. LOUIS
Z MONTE CARLO T TARRYTOWN

“G” MODELS W MALIBU CLASSIC
W EL CAMINO
“A” MODELS W CELEBRITY

“X” MODELS H CITATION
P CAMARO SPORT COUPE
“F” MODELS S CAMARO BERLINETTA
D CAVALIER
“J” MODELS E CAVALIER (TYPE 10)
C CAVALIER CADET
B CHEVETTE
“T” MODELS J CHEVETTE SCOOTER
“V” MODELS Y CORVETTE

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Instruction: After understanding the different service information, you are
given an option to perform from different activities given. As trainee inform
your trainer which activity you have chosen for this learning outcome no. 2.
Suggested activities:
1. Find a simple road-type troubleshooting guide and be able to interpret

it.
2. Find a service procedure of one simple task and be able to perform it
actually under the monitoring/ supervision of your trainer
3. Find and interpret one Vehicle Identification Number
4. Find examples of different types of specification
ENGINE TYPE AND MAKE
MODEL
CODE PRODUCER TYPE USAGE RPO
A BUICK 3.8 L V6 2BBL BG LD5

B CHEVROLET 2.0 L L4 2BBL J LR9
C CHEVROLET 1.6 L L4 2BBL T L17
D CHEVROLET 1.8 L L4 DIESEL T LJ5
F PONTIAC 2.5 L L4 2BBL F LO8
H
L
N
P
R
S

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SELF CHECK 4.3-1
Essay:
Directions: Answer the following briefly.
1. What are the different information you can find from vehicle’s
identification number? Give at least five.
2. What are the three things given in a diagnostic guide?
3. What is the importance of a vehicle maintenance procedure
4. 1G1AB68CXDY123456 Determine the meaning every
underlined item.

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ANSWER KEY 4.3-1
Essay:
1.
 The country by which the vehicle was manufactured or the world
manufacturer
 The corporation and division
 Model or series of the vehicle
 Model year
 Body style
 Check digit
 Engine type
 Factory or plant code
 Vehicle serial number
2.
 Problems
 Possible cause
 Correction or remedy
3. vehicle maintenance procedure is provided so that the owner will know

when to get needed service.
4.
 1- nation of origin
 G- manufacturer
 1- make and type
 A- restrain system
 B- carline series
 68- body types
 C- engine type and make
 X- check digit
 D- model
 Y- body types
 123456- plant sequential number

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LEARNING OUTCOME #4: Store Manuals
CONTENTS:
 Store manuals appropriately
Assessment Criteria
1. Manual or specification is stored appropriately to ensure prevention of
damage, ready access and updating of information when required in
accordance with company requirements.
CONDITIONS:
 All manuals/catalogues relative to Automotive
 Job order, requisitions
 Actual vehicle or simulator
METHODOLOGIES:
 Lecture
 Demonstration
 Self-paced
ASSESSMENT METHODS:
 Written test
 Interview with oral questioning

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MANUALS
Learning Outcome No. 4

Store Manuals
 Read Task Sheet 4.4-1 “Store Read and understand the
manuals appropriately” information sheet provided and
browse to internet for more sample
 Answer Self-Check 4.4-1 guide. Check yourself by answering
the self-check and by performing
Compare answers with Answer the task sheet. You must complete
Key 4.4-1 all the requirements before

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Storing Manuals Appropriately
1. Arrange manuals properly
Introduction
Don’t you just love all those user guides, manuals and warranties that
seem to come with every electrical item you purchase? Whether it’s a fridge,
TV or child’s toy, there is nearly always an instruction manual of some sort!
Most of us want to keep this information – so what’s the best way to

organise them?
1. In a Folder. A friend of mine does this and it works really well for
her. She has a number of folders for different items (e.g. kitchen,
lounge/living, and children) and largish plastic sleeves which she slots the
information in. These folders live on shelves in her office, ready for easy
access.
2. In a Filing Cabinet. This is not my favourite option. My feeling is

that if you have a filing cabinet it should be working hard to store all your
reference files. But if you like to store your manuals in it that’s fine – just
make sure it doesn’t end up looking like a chaotic pile of papers that are
hard to make sense of!

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3. In a Storage Tub. This is my favourite solution for organising user
guides, manuals and warranties. It’s so easy – and one I use myself. I have
a plastic box that fits the largest manual size you can get (usually A4 size)
which is labelled and lives in my laundry (close to the living areas of our
home). If we buy something the receipt and guide gets put in – and we know
exactly where they are if we need them.
These three options will keep your user guides, manuals and
warranties in some sort of order. Of course at some stage you’ll need to go
through and cull items you no longer have – but that’s another blog post!

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SELF CHECK 4.4-1
Enumeration:
Instruction: Enumerate the following question.
1. Enumerate the 3 option that you can arrange your manual

properly.

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ANSWER KEY 4.4-1
Enumeration:
1. In a folder
Filing in the cabinet
Storage tub

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GLOSSARY
Manuals - are defined as a guidebook that tells you how to operate

something or to do something. An example is the book that
comes from your vehicle that tells you how to drive and to
use it.
General Engine Specification– This specification identify the size and style
of the engine. They include cubic inch displacement, engine
codes, fuel system settings, bore and stroke, horsepower,
torque, compression ratio, and normal oil pressure.
Aftermarket - repair manual is most often used by the technician at

independent repair shops. This manual is called an aftermarket
because it is published by independent publisher and not by the
car manufacturer. Like the shop manual.
Service/Repair manuals -explain how to carry out routine maintenance,

restoration and servicing of cars and motorcycles, and are
aimed primarily at the Do-it-yourself
VIN – Vehicle Identification Number

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MANUALS

DRV COMMON UC4 - NEW Final

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TABLE OF CONTENTS

How to Use This Competency-Based Learning Material.............................2

Qualification Title, Unit of Competency, Module Title,

Learning Outcome #1 Identify and Access Manual/ Specifications...............7

 Information Sheet 4.1-1...................................................................9

Learning Outcome #2 Interpret Manuals...................................................16

 Information Sheet 4.2-1...................................................................18

Learning Outcome #3 Apply Information In Manual..................................25

 Information Sheet 4.3-1...................................................................27

Learning Outcome #4 Store Manuals........................................................44

 Information Sheet 4.4-1...................................................................46

Date Prepared: Document No.

Read and understand information sheet and answer self-check and

Recognition of Prior Learning (RPL)

If you can demonstrate to your teacher that you are competent in a

Date Prepared: Document No.

Date Prepared: Document No.

No. Unit of Competency Module Title Code

1 Participate in Participating in 400311210

2 Work in Team environment Working in team 400311211

Date Prepared: Document No.

Drive Light Vehicle Driving Light Vehicle ALT832302

Date Prepared: Document No.

NOMINAL DURATION: 2 HOURS

SUMMARY OF LEARNING OUTCOME:

Date Prepared: Document No.

Date Prepared: Document No.

IDENTIFY AND ACCESS MANUAL SPECIFICATIONS

Date Prepared: Document No.

Manuals are defined as a guidebook that tells you how to operate

Manuals are the plural form of manual, which is a book of

These are the types of manuals used in automotive.

 An owner's manual (also called an instruction manual) is an

Date Prepared: Document No.

MANUFACTURE’S SERVICE MANUAL

Manufacturer’s service manual or sometimes it’s called a shop

Shop manuals / service manuals are necessary to obtain the desired

Automobile manufacturers publish a service manuals or set of

Shop manuals are divided into a number of sections, each covering a

Typical Cover of a Service Manual

Date Prepared: Document No.

Date Prepared: Document No.

General Engine Specification – This specification identify the size and

Tune-Up specifications – This specification helps identify adjustments

Capacity Specifications –This specification include identifying the capacity of

Overhaul and Maintenance Specifications – This specifications is used to aid

Operational Specification – This specification tell how the vehicle is to

Torque Specification – It is important to torque each bolt or nut correctly

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An aftermarket repair manual is most often used by the technician at

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The official vehicle identification number is needed to identify the exact

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Instructions: Explain each of the following:

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Learning Outcome No.2

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