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The Official ASE Study Guide

ASE Medium/Heavy Truck Tests

ASE_MedHeavyTruck_2010.indd 1 11/25/09 10:39:21 AM

Table of Contents

Overview ................................................................................................ 3–7

Medium/Heavy Truck Tests .................................................................. 8–61 • GasolineEngines(TestT1) .............................................................8 • DieselEngines(TestT2) ...............................................................17 • DriveTrain(TestT3) ....................................................................24 • Brakes(TestT4) ............................................................................30 • SuspensionandSteering(TestT5) ................................................36

• Electrical/ElectronicSystems(TestT6) ........................................42 • Heating,Ventilation,andAirConditioning

(HVAC)Systems(TestT7) ...........................................................48 • PreventiveMaintenanceInspection(PMI)(TestT8) ....................54

Industry Training ............................................................................... 62–65

ASE MEdiuM/HEAvy Truck TESTS


ASE MEdiuM/HEAvy Truck STudy GuidE PAGE 3

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IntroductionTheOfficial ASE Study Guide for the Medium/Heavy Truck TestsisintendedtohelptechniciansstudyfortheASEcertificationtests.Thespecificmaterialabouteachtest,includedinthebookletisausefultoolforreviewingthetechnicalknowledgethatiscoveredintheMedium/Heavy Truck tests.Afterperforming athoroughreview,itshouldbeeasiertoselectadditionalreferencematerialthatwillassistyouwiththetestpreparationneeds. ASEvoluntarycertificationisameansbywhichtechnicianscanprovetheirabilitiestothemselves,totheiremployers,andtotheircustomers.BypassingASEtestsyouwillearnthemostvaluablecredentialavailabletotrucktechni-cians.Becausethetestsaretough,you’llhavethesatisfactionofprovingtoyourselfthatyouareamongtheeliteinyourprofession.What’smore,thesecredentialsarerecognizedthroughoutthenation. Certifiedtechnicianspromotecustomertrustandimprovetheimageof theindustry.Andtrustandprofessionalismarethefirststepstoabetter,moreprosperousbusiness. ASEencouragesyoutotakethetestsandtojointheprovenproswhowearTheASEBlueSealofExcellence.®

How Do I Become Certified?TherearecurrentlyeighttestsintheMedium/HeavyTruckTechniciancertifica-tionseries.Class4throughClass8trucksarecovered.MediumdutyClass4–6is14,001to26,000lbs.grossvehicleweight(GVW).HeavydutyClass7–8is26,001andabovegrossvehicleweight(GVW). Ifyoupassoneormoretestsandhaveatleasttwoyearsofrelevanthands-onworkexperience,youwillbecomecertifiedasanASEMedium/HeavyTruckTechnician.IfyoupasstheDieselEnginesTest(T2)andtestsT3,T4,T5,T6,andT7youwillearnthecertificateofMasterMedium/HeavyTruckTechnician. IfyouarecurrentlycertifiedinDieselEngines(A9,H2,S2,orT2) andElectrical/ElectronicSystems(A6,H6,S6,orT6),youareeligibletotaketheL2ElectronicDieselEngineDiagnosisSpecialisttest.


PAGE 4 ASE MEdiuM/HEAvy Truck STudy GuidE

Ifyoufailatest,youmaytakeitagainduringanyscheduledtest administrationinwhichitisoffered.Andremember,youaretheonlyonewhowillreceiveyourtestsscores;resultswillnotbegivenoverthephonenorwilltheybereleasedtoanyonewithoutyourwrittenpermission.

Medium/Heavy Truck TestsASEtestsandcertifiestechniciansinthefollowingtruckareas:• GasolineEngines(TestT1)• DieselEngines(TestT2)• DriveTrain(TestT3)• Brakes(TestT4)• SuspensionandSteering(TestT5)• Electrical/ElectronicSystems(TestT6)• Heating,Ventilation,andAirConditioning(HVAC)Systems(TestT7)• PreventiveMaintenanceInspection(PMI)(TestT8)

ASEalsoofferscertificationinAutomobile,TruckEquipment,TransitBus,SchoolBus,CollisionRepair/Refinish,EngineMachinist,PartsSpecialist,andAdvancedLevelspecialties. ForfullinformationonASEtestingaswellasdownloadableStudy Guides,Registration Booklets,andmore,visitwww.ase.com.YoumayalsorequestRegistration BookletsbymailingthecouponlocatedonthebackcoverofthisbookletorbycallingASEat703-669-6600,ext.400.

Who Writes the Questions?Thequestions,writtenbyserviceindustryexpertsfamiliarwithallaspectsofmedium/heavytruckrepair,areentirelyjob-related.Theyaredesignedtotesttheskillsthatyouneedtoknowinservicingtrucks;theoreticalknowledge isnotcovered. EachquestionhasitsrootsinanASE“item-writing”workshopwhereservicerepresentativesfrommedium/heavytruckmanufacturers,aftermarketpartsandequipmentmanufacturers,workingtechniciansandtechnicaleduca-torsgettogetherinaworkshopsettingtoshareideasandtranslatethemintotestquestions.Eachtestquestionwrittenbytheseexpertsmustsurvivereviewbyallmembersofthegroup.Thequestionsarewrittentodealwithpracticalproblemsofdiagnosisandrepairexperiencedbytechniciansintheirday-to-daywork.

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Fromthere,allquestionsarepre-testedandquality-checkedonanationalsampleoftechnicians.ThosequestionsthatmeetASEstandardsofqualityandaccuracyareincludedinthetests;the“rejects”aresentbacktothedrawingboardordiscardedaltogether. Eachcertificationtestismadeupofbetween40and55multiple-choicequestions.Thetestingsessionsare4hoursand15minutes,allowingplenty oftimetocompleteseveraltests.Note: Eachtestcouldcontainuptofifteenadditionalquestionsthatareincludedforstatisticalresearchpurposesonly.Youranswerstothesequestionswillnotaffectyourscore,butsinceyoudonotknowwhichonestheyare,youshouldanswerallquestionsinthetest.Thefive-yearRecertificationTestwillcoverthesamecontentareasasthoselistedabove.However,thenumberofquestionsineachcontentareaoftheRecertificationTestwillbereducedbyaboutone-half.

How Do I Prepare for the ASE Tests?Becomefamiliarwithtestcontentandquestionformat:TheTestSpecificationsforeachofthetestscoveredinthisbookletcontainasummarydescriptionofthecontentcoveredbyeachtest.TheListsdescribetheactualworkperformedbytechniciansineachspecialtyarea.Together,theseforma“blueprint”forwritingandassemblingtheASEtests. Pleasenotethateachquestiononthetestiskeyedorlinkedtoaparticularorsetoftasksinthelist.Therefore,areviewofthelists,withaneyetojudgingwhetheryouknowhowtoperformeachlisted,willprovidevaluableinformationtoprepareforthetests. Therearefivetypesofmultiple-choicequestionsonthetests,eachofwhichisincludedinthesamplequestionsinthisbooklet.Notethedifferentinstructionsforsomequestions. Besuretoreadeachquestioncarefully,(twice,ifnecessary)sothatyouunderstandexactlywhatisbeingasked.Each question tests a specific diagnostic or repair problem and has only one best answer. Tosummarize,wesuggestthefollowingstepstobetakentoprepareforthetests: Step 1. Studythecontentlistforeachtestyouwillattempt. Step 2. Carefullyreadthelistforeacharea. Step 3. Go over the sample questions to become familiar with each questiontype.This is very important. Step4. Reviewsteps1through3above,andidentifytheskillareaswhere youneedadditionalstudy.




Types of Knowledge Measured by the TestsThetypesofknowledgeandskillsyouwillneedtoknowtopassthetestsareasfollows:• Basic technical knowledge:Testsyourknowledgeofwhatisinasystemandhowthesystemworks,andwhataretheproperproceduresand/orprecautionstobefollowedinmakingrepairsandadjustments.

• Service or repair knowledge and skill:Testsyourunderstandingandabilitytoapplygenerallyacceptedrepairproceduresandprecautionsinassembly,disassembly,andreconditioningoperations;andinmakingmajorinspectionsandadjustments.Alsotestsabilitytouseshopmanualsandprecisiontoolsofthetrade.

• Testing and diagnostic knowledge and skill:Testsyourabilitytorecognizeproblemsandtousegenerallyavailablemeasurementandtestingequipmenttomakeadiagnosis.Alsotestsyourabilitytotracetheeffectsofaparticularconditionandfindthecauseofaparticularsetofsymptoms.

Ifyouareanexperiencedandcompetenttechnician,acarefulreviewofthisbooklet,andadditionalbrush-uponthoseareasinwhichyouareweakest,isallyoushouldneedtopasstheASEtests.

Before The TestsTrytobewellrestedforthetestssoyouwillbealertandefficient.Havethreeorfoursharpenedsoft-lead(#2)pencilsandaneraserwithyou;pencilswillnotbefurnishedatthetestcenter.Ifyouwishtopaceyourself,bringawatch,sincesometestingroomsmaynothaveclocks.Finally,besuretobringalongyourtestcenteradmissionticketandsomeformofidentification.

At the Test CenterWhenyoureachthetestcenter,waitintheassignedareauntiltheproctorbeginsthetestadministration.Heorshewillinstructyouinfillingouttheanswerfolderandwilltellyoutheamountoftimeallottedforeachtest. Oncethetesthasbegun,keeptrackoftime.Donotspendtoolongonanyonequestion.Ifaquestionisdifficult,marktheanswerthatyouthinkiscor-rectandputacheckbyitinthetestbook.Thengoontothenextquestion.Ifyoufinishbeforetheallottedtime,youmaygobacktothequestionsthatyouchecked. It is to your advantage to answer every question. Do not leave any answers blank. Your score will be based on the number of correct answers that you give.




Test Content and Sample QuestionsThefollowingmaterialisdesignedtohelptechniciansprepareforASEcertifica-tiontests. EachofthesectionsbeginswiththeTestSpecifications,whichlistthemaincategoriescoveredonthatparticulartestandthenumberoftestquestionsandpercentageofthetestdevotedtoeachtopic. TheListdescribestheworkactivitiesatechnicianshouldbeabletoperformineachtechnicalareacoveredonthattest.Thislistwasdevelopedbyworkingtechniciansandtechnicalexpertsfromacrossthecountryandwillprovideavalu-ablechecklistofwhattostudyforthetest. Itshouldbenotedthatthenumberofquestionsineachcontentareamaynotequalthenumberoftaskslisted.Someofthetasksarecomplexandbroadinscopeandmaybecoveredbyseveralquestions.Othertasksaresimpleandnarrowinscopeandonequestionmaycoverseveraltasks.Themainobjectiveinlistingthetasksistodescribeaccuratelywhatisdoneonthejob,nottomakeeachcorrespondtoaparticulartestquestion. Samplequestionsfollow.Althoughthesesamequestionswillnotappearonactualtests,theyareinthesameformatasactualtestquestions.Allfivetypesofmultiple-choicequestionsusedontheASEtestsarerepresentedhere.Notethedifferentinstructionsforsomequestions.




Content Questions Percentage Area in Test of Test A. General Engine Diagnosis 14 28% B. Cylinder Head and Valve Train Diagnosis and Repair 4 8% C. Engine Block Diagnosis and Repair 4 8% D. Lubrication and Cooling Systems Diagnosis and Repair 3 6% E. Ignition System Diagnosis and Repair 6 12% F. Fuel, Air Induction, and Exhaust Systems Diagnosis and Repair 6 12% G. Emissions Control Systems Diagnosis and Repair 5 10% H. Computerized Engine Controls Diagnosis and Repair 8 16%

Total 50 100%

TEST SpEcificATiOnSGASOlinE EnGinES (TEST T1)

A. General Diagnosis (14 questions) 1. Verifythecomplaintand/orroadtestvehicle;reviewdriver/customerinterviewand

pastmaintenancedocuments(ifavailable);determinefurtherdiagnosis. 2. Researchapplicablevehicleandserviceinformation,suchasenginemanagement

systemoperation,vehicleservicehistory,serviceprecautions,technicalservice bulletins,andservicecampaigns/recalls.

3. Inspectengineassemblyforfuel,oil,coolant,andotherleaks;determineneeded action.

4. Diagnosenoisesand/orvibrationproblemsrelatedtoengineperformance;determineneededaction.

5. Diagnosethecauseofunusualexhaustcolor,odor,andsound;determineneeded action.

6. Performenginemanifoldvacuumorpressuretests;determineneededaction. 7. Performcylinderpowerbalancetest;determineneededaction. 8. Performcylindercompressiontest;determineneededaction. 9. Performcylinderleakage/leak-downtest;determineneededaction.



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10.Diagnoseenginemechanical,electrical,electronic,fuel,andignitionproblemswithanoscilloscope,engineanalyzer,digitalmultimeter(DMM),and/orscantool;determineneededaction.

11. Inspectenginecompartmentwiringharness,connectors,seals,locks,vacuumhoses;checkforproperroutingandcondition;determineneededrepairs.

12. Observeandinterpretinstrumentpanelgaugereadings.13. Readandinterpretelectricalschematicdiagramsandsymbols.14. Testanddiagnoseemissionsordriveabilityproblemscausedbybatterycondition,

connections,orexcessivekey-offbatterydrain;determineneededrepairs.15. Performstartercurrentdrawtest;determineneededaction.16. Performstarterandchargingcircuitvoltagedroptests;determineneededaction.17. Inspect,test,andrepairorreplacecomponents,connectors,andwiresinthestarter

andchargingcontrolcircuits.18. Differentiatebetweenelectricalandmechanicalproblemsthatcauseaslowcrank,no

crank,extendedcranking,oracrankingnoisecondition.19. Testanddiagnoseengineperformanceproblemsresultingfromanundercharge,over-

charge,orano-chargecondition;determineneededaction.20. Inspect,adjust,andreplacealternator(generator)drivebelts,pulleys,tensioners,and

fans.

B. Cylinder Head and Valve Train Diagnosis and Repair (4 questions) 1. Remove,inspect,disassemble,andcleancylinderheadassembly(s). 2. Inspectthreadedholes,studs,andboltsforserviceability;service/replaceasneeded. 3. Measurecylinderheadthickness;checkmatingsurfacesforwarpageandsurface

finish;inspectforcracks/damage;checkconditionofpassages;inspectcoreand galleryplugs;determineserviceabilityandneededrepairs.

4. Inspectvalves,guides,seats,springs,retainers,locks,andseals;determineservice-abilityandneededrepairs.

5. Reassemble,check,andinstallcylinderheadassembly(s)andgasket(s)asspecifiedbythemanufacturer.

6. Inspectpushrods,rockerarms,rockerarmshafts,electronicwiringharness,andbrackets;repair/replaceasneeded.

7. Inspect,install,andadjustvalveliftersandretainers;adjustvalveclearance. 8. Inspect,measure,andreplace/reinstalloverheadcamshaftandbearings;measure

andadjustendplay.

C. Engine Block Diagnosis and Repair (4 questions) 1. Remove,inspect,service,andinstallpans,covers,ventilationsystems,gaskets,seals,

andwearsleeves. 2. Disassemble,cleanandinspectengineblockforcracks;checkmatingsurfacesand

relatedcomponentsfordamageorwarpageandsurfacefinish;checkdeckheight;checkconditionofpassages,core,andgalleryplugs;inspectthreadedholes,studs,dowelpinsandboltsforserviceability;service/replaceasneeded.

3. Inspectandmeasurecylinderwallsforwearanddamage;determineserviceabilityandneededrepairs.

4. Inspectin-blockcamshaftbearingsforwearanddamage;replaceasneeded.



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5. Inspect,measure,andreplace/reinstallin-blockcamshaft;measure/andcorrectendplay;inspect,replace/reinstall,andadjustvalvelifters.

6. Cleanandinspectcrankshaftandjournalsforsurfacecracksanddamage;checkconditionofoilpassages;checkpassageplugs;measurejournaldiameters;checkmountingsurfaces;determineneededrepairs.

7. Diagnosepiston,connectingrodbearing,andmainbearingwearpatternsthatindicateconnectingrodandcrankshaftalignmentorbearingboreproblems;checkbearingboreandbushingcondition;determineneededrepairs.

8. Determinetheproperselect-fitcomponentssuchaspistons,connectingrods,andmainbearings.

9. Inspectandreplacemainbearings;checkcapfitandbearingclearances;checkandcorrectcrankshaftendplay.

10. Removeand/orreplacethetimingchainandgears;ensurecorrecttiming.11. Inspect,measure,orreplacepistons,pins,andretainers.12. Measurepiston-to-cylinderwallclearance.13. Checkring-to-groovefitandendgaps;installringsonpistons.Assemblepistonsand

connectingrodsandinstallinblock;installrodbearingsandcheckclearances.14. Inspectand/orreplacecrankshaftvibrationdamper.15. Inspectflywheel/flexplate(includingringgear)andmountingsurfacesforcracks,

wear,andrunout;determineneededrepairs.

D. Lubrication and Cooling Systems Diagnosis and Repair (3 questions) 1. Diagnoseenginelubricationsystemproblems;performoilpressuretests;determine

neededrepairs. 2. Disassembleandinspectoilpump(includesgears,rotors,housing,andpick-upas-

sembly);measureoilpumpclearance;inspectpressurereliefdevicesandpumpdrive;determineneededrepairs.

3. Inspect,clean,test,reinstall/replaceoilcooler,by-passvalve,linesandhoses. 4. Changeengineoilandfilter(s);addpropertype,viscosity,andratingofoil. 5. Inspectandreinstall/replacepulleys,tensioners,anddrivebelts;adjustdrivebeltsand

checkalignment. 6. Diagnoseenginecoolingsystemtemperatureandpressureproblems;determine

neededrepairs. 7. Inspect,test,andreplacethermostat,coolantby-pass,andthermostathousing,seals,

hoses,andfittings. 8. Inspectandtestcoolant;drain,flush,andrefillcoolingsystemwithrecommended

coolant;bleedairfromcoolingsystemasrequired. 9. Inspectandreplacewaterpump,housing,andhoses.10. Inspectandreplaceradiator,pressurecap,expansiontank,andcoolantrecovery

system.11. Inspect,test,andrepair/replacefan(bothelectricalandmechanical),fanclutch,fan

shroud,airdams,andcoolingfanelectricalcircuits.12. Verifyproperoperationofenginerelatedgaugesandwarningindicators;determine

neededrepairs.



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E. Ignition System Diagnosis and Repair (6 questions) 1. Diagnoseignitionsystemrelatedproblemssuchasno-starting,hardstarting,engine

misfire,poordriveability,sparkknock,powerloss,reducedfueleconomy,and emissionsproblems;determinerootcause;determineneededrepairs.

2. Interpretignitionsystemrelateddiagnostictroublecodes(DTCs);determineneededrepairs.

3. Inspect,test,repair,orreplaceignitionprimarycircuitwiringandcomponents. 4. Inspect,test,repair,orreplaceignitionsystemsecondarycircuitwiringand

components. 5. Inspect,test,andreplaceignitioncoil(s). 6. Inspect,test,andreplaceignitionsystemsensors;adjustasnecessary. 7. Inspect,test,and/orreplaceignitioncontrolmodule(ICM)/powertrain/engine

controlmodule(PCM/ECM);reprogramasneeded.

F. Fuel, Air Induction, and Exhaust Systems Diagnosis and Repair (6 questions) 1. Diagnosefuelsystemrelatedproblemssuchasno-starting,hardstarting,poordrive-

ability,incorrectidlespeed,pooridle,flooding,hesitation,surging,enginemisfire,powerloss,stalling,reducedfueleconomy,andemissionsproblems;determinerootcause;determineneededrepairs.

2. Interpretfuelorinductionsystemrelateddiagnostictroublecodes(DTCs);analyzefueltrimandotherscantooldata;determineneededrepairs.

3. Inspectfueltank,fillerneck,andfuelcap;inspectandreplacefuellines,fittings,andhoses;checkfuelforcontaminantsandquality.

4. Inspect,test,andreplacefuelpump(s)and/orfuelpumpassembly;inspect,service,andreplacefuelfilters.

5. Inspectandtestelectricfuelpumpcontrolcircuitsandcomponents;determineneededrepairs.

6. Inspect,test,andrepairorreplacefuelpressureregulationsystemandcomponentsoffuelinjectionsystems;performfuelpressure/volumetest.

7. Inspect,remove,serviceorreplacethrottlebodyassemblyandcontrols,includingelectronicthrottleactuatorcontrol(TAC)systems;makerelatedadjustments.

8. Inspect,test,clean,andreplacefuelinjectorsandfuelrails. 9. Inspect,service,andrepairorreplaceairfiltrationsystemcomponents.10. Inspectairinductionsystem,intakemanifold,andgasketsforair/vacuumleaks.11. Remove,clean,inspect,test,andrepairorreplacefuelsystemvacuumandelectrical

componentsandconnections.12. Inspect,service,andreplaceexhaustmanifold,gaskets,exhaustpipes,oxygen

sensors,mufflers,catalyticconverters,resonators,tailpipes,andheatshields.13. Testforexhaustsystemrestrictionorleaks;determineneededrepair.



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G. Emissions Control Systems Diagnosis And Repair (5 questions) 1. Testanddiagnoseemissionsordriveabilityproblemscausedbypositivecrankcase

ventilation(PCV)system. 2. Inspect,service,andreplacepositivecrankcaseventilation(PCV)filter,valve,tubes,

orifice/meteringdevice,andhoses. 3. Testanddiagnosedriveabilityproblemscausedbytheexhaustgasrecirculation

(EGR)system. 4. Interpretexhaustgasrecirculation(EGR)relatedscantooldataanddiagnostictrouble

codes(DTCs);determineneededrepairs. 5. Inspect,test,service,andreplacecomponentsoftheexhaustgasrecirculation(EGR)

system,includingEGRvalve,tubing,passages,vacuum/pressurecontrols,filters,hoses,electrical/electronicsensors,controls,solenoids,andwiringofEGRsystems.

6. Testanddiagnoseemissionsordriveabilityproblemscausedbythesecondaryairinjectionorcatalyticconvertersystems.

7. Interpretsecondaryairinjectionsystemrelatedscantooldataanddiagnostictroublecodes(DTCs);determineneededrepairs.

8. Inspect,test,service,andreplacemechanicalcomponentsandelectrical/ electronically-operatedcomponentsandcircuitsofsecondaryairinjectionsystem.

9. Inspectcatalyticconverter.Interpretcatalyticconverterrelateddiagnostictroublecodes(DTCs);analyzerelatedscantooldatatodeterminerootcauseofDTCs; determineneededrepairs.

10. Testanddiagnoseemissionsordriveabilityproblemscausedbytheevaporativeemis-sionscontrolsystem.

11. Interpretevaporativeemissions-relatedscantooldataanddiagnostictroublecodes(DTCs);determineneededrepairs.

12. Inspect,test,andreplacecanister,lines,hoses,mechanical,andelectricalcomponentsoftheevaporativeemissionscontrolsystem.

H. Computerized Engine Controls Diagnosis And Repair (8 questions) 1. ResearchOBDIIsystemoperationtodeterminetheenablecriteriaforsettingand

clearingdiagnostictroublecodes(DTCs)andmalfunctionindicatorlamp(MIL)operation.Performappropriatedrivecycletodeterminesystemconditionandverifyrepaireffectiveness.

2. InterpretOBDIIscantooldatastream,diagnostictroublecodes(DTCs),freezeframedata,systemmonitors,monitorreadinessindicators,andtripanddrivecycleinformation.

3. Readandinterprettechnicalliterature(servicepublicationsandinformationincludingwiringschematics).

4. Diagnosethecausesofemissionsordriveabilityproblemswithstoredoractivediag-nostictroublecodes(DTCs).

5. Diagnosethecausesofemissionsordriveabilityproblemswithoutdiagnostictroublecodes(DTCs).

6. Useascantool,digitalmultimeter(DMM),ordigitalstorageoscilloscope(DSO)toinspectortestcomputerizedenginecontrolsystemsensors,actuators,circuits,andpowertrain/enginecontrolmodule(PCM/ECM);determineneededrepairs.



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7. Measureandinterpretvoltage,voltagedrop,amperage,andresistanceusingdigitalmultimeter(DMM)readings.

8. Test,remove,inspect,clean,service,andrepairorreplacepowerandgrounddistribu-tioncircuitsandconnections.

9. Removeandreplacethepowertrain/enginecontrolmodule(PCM/ECM);reprogramasneeded.

10. Diagnosedriveabilityandemissionsproblemsresultingfromfailuresofinterrelatedsystems(forexample:cruisecontrol,securityalarms/theftdeterrent,torquecontrols,tractioncontrols,torquemanagement,A/C,and/ornon-OEMinstalledaccessories).

11. Cleardiagnostictroublecodes(DTCs),runallOBDIImonitors,andverifytherepair.



SAMplE QuESTiOnSGASOlinE EnGinES (TEST T1)

QuESTiOnS:

1. TechnicianAsaysthatthecompressiontestreadingsshownabovecouldbecausedbyablowncylinderheadgasket. TechnicianBsaysthatthecompressiontestreadingsshownabovecouldbecausedbywrongvalvetiming. Whoisright?

*(A)Aonly (C)BothAandB (B)Bonly (D)NeitherAnorB

2. TechnicianAsaysthatpartXshownaboveisusedtoimprovevalvespringrotation. TechnicianBsaysthatpartXshownaboveisusedtocorrectinstalledspringheight. Whoisright?

(A)Aonly (C)BothAandB *(B)Bonly (D)NeitherAnorB

COMPRESSION SPECS 140 PSI

130

140

15

15

140

140

130

135



3. Anengineisusingtoomuchoil.TechnicianAsaysthatwornvalveguidescouldbethecause. TechnicianBsaysthattaperedcylinderwallscouldbethecause. Whoisright?

(A)Aonly *(C)BothAandB (B)Bonly (D)NeitherAnorB

4. Whileperformingacylinderleakagetestonanengine,thetechnicianseesairbubblesintheupperradiatortank. TechnicianAsaysthatacrackedheadcouldbethecause. TechnicianBsaysthatacrackedblockcouldbethecause. Whoisright?


5. TechnicianAsaysthatmainbearingoilclearancecanbecheckedwithplasti-gage. TechnicianBsaysthatmainbearingoilclearancecanbecheckedwithafeelergauge. Whoisright?


6. Thetechnicianfindsnosparkandnoinjectorpulsesonavehiclethatwillnotstart.Themostlikelycauseisafailed:

(A)massairflowsensor(MAF). *(B)crankshaftpositionsensor(CKP). (C)throttlepositionsensor(TPS). (D)fuelpumpmodule(FP).

7. Anenginewithanelectronicfuelinjection(EFI)systemhashighfuelpressureatidle.Whichofthesecouldbethecause?

*(A)Lowmanifoldvacuum (B)Aleakingfuelpumpcheckvalve (C)Apluggedfuelinjector (D)Highmanifoldvacuum

T1 SAMplE QuESTiOnS (cOnTinuEd)



8. Whichofthesecancauseacatalyticconvertertooverheat? (A)Abrokenairpumpdrivebelt (B)Apluggedcanisterpurgevacuumhose (C)Afailedexhaustgasrecirculation(EGR)valve *(D)Adisconnectedsparkplugwire

Question 9 is not like the ones above. IthasthewordEXCEPT.LookforthechoicethatcouldNOTcausethe

describedsituation.Readtheentirequestioncarefullybeforechoosingyouranswer.

9. Enginedetonation(knock)couldbecausedbyanyoftheseEXCEPT: (A)aleanairfuelmixture. *(B)retardedignitiontiming. (C)excesscarboninthecombustionchambers. (D)astuck-closedexhaustgasrecirculation(EGR)valve.




Content Questions Percentage Area in Test of Test A. General Engine Diagnosis 11 20% B. Cylinder Head and Valve Train 4 7% Diagnosis and Repair C. Engine Block Diagnosis and Repair 5 9% D. Lubrication and Cooling Systems Diagnosis and Repair 6 11% E. Air Induction and Exhaust Systems Diagnosis and Repair 6 11% F. Fuel System Diagnosis and Repair 16 29% G. Starting and Charging System Diagnosis and Repair 4 7% H. Engine Brakes 3 5%

Total 55 100%

TEST SpEcificATiOnS And TASk liSTdiESEl EnGinES (TEST T2)

A. General Engine Diagnosis (11 questions) 1. Verifythecomplaint,androad/dynotestvehicle;reviewdriver/customerinterview

andpastmaintenancedocuments(ifavailable);determinefurtherdiagnosis. 2. Identifyenginemodelandserialnumbertoresearchapplicablevehicleandservice

information,serviceprecautions,andtechnicalservicebulletins;determineneededactions.

3. Inspectengineassemblyandcompartmentforfuel,oil,coolant,exhaust,orotherleaks;determineneededrepairs.

4. Inspectenginecompartmentwiringharness,connectors,seals,andlocks;checkforproperroutingandcondition;determineneededrepairs.

5. Isolateanddiagnoseenginenoises;determineneededrepairs. 6. Checkengineexhaustforodor,smokecolor,anddensity;determineneededrepairs. 7. Performfuelsupplyandreturnsystemtests;checkfuelforcontamination,quality,

andconsumption;determineneededrepairs. 8. Performairintakesystemrestrictionandleakagetests;determineneededrepairs. 9. Performintakemanifoldpressuretests;determineneededrepairs.10. Performexhaustbackpressureandtemperaturetests;determineneededrepairs.11. Performcrankcasepressuretest;determineneededrepairs.12. Diagnosenocranking,cranksbutfailstostart,hardstarting,andstartsbutdoesnot

continuetorunproblems;determineneededrepairs.



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13. Diagnosesurging,roughoperation,misfiring,lowpower,slowdeceleration,slowacceleration,andshutdownproblems;determineneededrepairs.

14. Isolateanddiagnoseenginerelatedvibrationproblems;determineneededrepairs.15. Checkcoolingsystemforfreezepoint,level,contamination,coolanttype,

temperature,pressure,circulation,conditionerconcentration,filtration,andfan operation;determineneededrepairs.

16. Checklubricationsystemforcontamination,oillevel,temperature,pressure, filtration,andoilconsumption;interpretoilanalysisinformation;determineneededrepairs.

17. Checkandrecordelectronicdiagnosticcodesandtrip/operationaldata;monitor electronicdata;verifycustomerprogrammableparameters;clearcodes;determinefurtherdiagnosis.

18. Performvisualinspectionforphysicaldamageandmissing,modified,ortamperedcomponents;determineneededrepairs.

B. Cylinder Head and Valve Train Diagnosis and Repair (4 questions) 1. Remove,inspect,disassemble,andcleancylinderheadassembly(s). 2. Inspectthreadedholes,studs,andboltsforserviceability;service/replaceasneeded. 3. Measurecylinderheadthickness,andcheckmatingsurfacesforwarpageandsurface

finish;inspectforcracks/damage;checkconditionofpassages;inspectcoreand galleryplugs;determineserviceabilityandneededrepairs.

4. Inspectvalves,guides,seats,springs,retainers,rotators,locksandseals;determineserviceabilityandneededrepairs.

5. Inspectand/orreplaceinjectorsleevesandseals;pressuretesttoverifyrepair (ifapplicable);measureinjectortipornozzleprotrusionwherespecifiedby manufacturer.

6. Inspect,and/orreplacevalvebridges(crossheads)andguides;adjustbridges (crossheads)ifapplicable.

7. Cleancomponents;reassemble,check,andinstallcylinderheadassembly. 8. Inspectpushrods,rockerarms,rockerarmshafts,electronicwiringharness,and

bracketsforwear,bending,cracks,looseness,andblockedoilpassages;repair/ replaceasneeded.

9. Inspect,install,andadjustcamfollowersandretainers.10. Adjustvalveclearanceandinjectorsettings.11. Inspect,measure,andreplace/reinstalloverheadcamshaftandbearings;measure

andadjustendplayandbacklash.

C. Engine Block Diagnosis and Repair (5 questions) 1. Remove,inspect,service,andinstallpans,covers,ventilationsystems,gaskets,seals,

andwearrings. 2. Disassemble,cleanandinspectengineblockforcracks;checkmatingsurfacesand

relatedcomponentsfordamageorwarpageandsurfacefinish;checkdeckheight;checkconditionofpassages,core,andgalleryplugs;inspectthreadedholes,studs,dowelpinsandboltsforserviceability;service/replaceasneeded.

3. Inspectcylindersleevecounterboreandlowerbore;checkboredistortion;determineneededservice.



4. Inspectandmeasurecylinderwallsorlinersforwearanddamage;determineneededservice.

5. Replace/reinstallcylinderlinersandseals;checkandadjustlinerheight/protrusion. 6. Inspectin-blockcamshaftbearingsforwearanddamage;replaceasneeded. 7. Inspect,measure,andreplace/reinstallin-blockcamshaft;measure/adjustendplay;

inspect,replace/reinstall,andadjustcamfollowers(ifapplicable). 8. Cleanandinspectcrankshaftandjournalsforsurfacecracksanddamage;check

conditionofoilpassages;checkpassageplugs;measurejournaldiameters;checkmountingsurfaces;determineneededservice.

9. Inspectandreplacemainbearings;checkcapfitandbearingclearances;checkandcorrectcrankshaftendplay.

10. Inspect,reinstall,andtimethedrivegeartrain.(Includescheckingenginepositionandspeedindicatorcomponents,gearwear,andbacklashofcrankshaft,camshaft,auxiliary,drive,andidlergears;serviceshafts,bushings,andbearings.)

11. Clean,inspect,measure,orreplacepistons,pins,andretainers.12. Measurepiston-to-cylinderwallclearance.13. Checkring-to-groovefitandendgaps;installringsonpistons.14. Identifypiston,connectingrodbearing,andmainbearingwearpatternsthatindicate

connectingrodandcrankshaftalignmentorbearingboreproblems;checkbearingboreandbushingcondition;determineneededrepairs.

15. Assemblepistonsandconnectingrodsandinstallinblock;checkpistonheight/ protrusion;replacerodbearingsandcheckclearances;checkcondition,position, andclearanceofpistoncoolingjets(nozzles).

16. Inspectandmeasurecrankshaftvibrationdamper;replaceasneeded.17. Inspect,install,andalignflywheelhousing.18. Inspectflywheel/flexplate(includingringgear)andmountingsurfacesforcracks,

wear,andrunout;determineneededrepairs.

D. Lubrication and Cooling Systems Diagnosis and Repair (6 questions) 1. Verifyengineoilpressureandcheckoperationofpressuresensor/switchandpressure

gauge;verifyengineoiltemperatureandcheckoperationoftemperaturesensor. 2. Inspect,measure,andrepair/replaceoilpump,housing,drives,pipes,andscreens;

adjustdrivegearclearanceifapplicable. 3. Inspectandrepair/replaceoilpressureregulatorvalve(s),andby-passvalve(s). 4. Inspect,clean,test,andreinstall/replaceoilcooler,by-passvalve,oilthermostat;lines

andhoses. 5. Inspectturbochargerlubricationandcoolingsystems;repair/replaceasneeded. 6. Changeengineoilandfilters;addpropertypeofoil. 7. Inspectandreinstall/replacepulleys,tensionersanddrivebelts;adjustdrivebeltsand

checkalignment. 8. Verifycoolanttemperatureandcheckoperationoftemperatureandlevelsensors/

switch,andtemperaturegauge. 9. Inspectandreplacethermostat(s),by-passes,housing(s),andseals.10. Flushandrefillcoolingsystem;bleedairfromsystem;recovercoolant.11. Inspectandrepair/replacecoolantconditioner/filter,valves,lines,andfittings.12. Inspectandrepair/replacewaterpump,housing,hoses,andidlerpulleyordrivegear.




13. Inspectradiator,pressurecap,andtank(s);determineneededservice.14. Inspectandrepair/replacefanhub,fan,fanclutch,fancontrols,fanthermostat,and

fanshroud.15. Pressuretestcoolingsystemandradiatorcap;determineneededrepairs.

E. Air Induction and Exhaust Systems Diagnosis and Repair (6 questions) 1. Inspectandservice/replaceairinductionpiping,aircleaner,andelement;check

forairrestriction. 2. Inspect,test,andreplaceturbocharger(s)(includingvariableratio/geometryVGT),

pneumatic,hydraulic,andelectroniccontrolsandactuators;inspect,test,andreplacewastegateandwastegatecontrols.

3. Inspectandrepair/replaceintakemanifold,gaskets,temperatureandpressuresensors,andconnections.

4. Inspect,test,clean,replacechargeaircoolerandpipingsystem. 5. Inspectandrepair/replaceexhaustmanifold,gaskets,piping,mufflers,exhaustafter

treatmentdevices,(includingthree-wayandoxidationcatalystanddieselparticulatefiltersDPF)andmountinghardware.

6. Inspect,test,andrepair/replacepreheater/inletairheater,orglowplugsystemandcontrols.

7. Inspect,test,andreplaceexhaustaftertreatmentregenerationsystemandcontrols. 8. Inspect,test,service,andreplaceexhaustgasrecirculation(EGR)systemcompo-

nents;includingEGRvalve,cooler,piping,filter,sensors,controls,andwiring.

F. Fuel System Diagnosis and Repair (16 questions) 1. Inspect,test,andrepair/replacefuelsystemtanks,vents,capsmounts,valves,

single/dualsupplyandreturnlines,andfittings. 2. Inspect,clean,test,andrepair/replacefueltransfer(supply)pump,pumpdrives,

strainers,fuel/waterseparators/indicators,filters,heaters,coolers,ECMcoolingplates,andmountinghardware.(Protectfuelsystemcomponentsfrom contamination),

3. Checkfuelsystemforair;determineneededrepairs;primeandbleedfuelsystem;check,repair/replaceprimerpump.

4. Inspect,test,andrepair/replacelow-pressureregulatorsystems(checkvalves, pressureregulatorvalvesandrestrictivefittings).

5. Inspectandreinstall/replacehigh-pressureinjectionlines,fittings,seals,and mountinghardware.(Protecthigh-pressureinjectioncomponentsfrom contamination).

6. Inspect,adjust,andrepair/replaceelectronicthrottleandPTOcontroldevices, circuits,andsensors.

7. Performon-engineinspections,tests,andadjustmentsonhydraulicelectronicunitinjectors(HEUI)andelectroniccontrols(railpressurecontrol).

8. Performon-engineinspections,testsandadjustmentsonelectronicunitinjectors(EUI)andelectroniccontrols.

9. Performon-engineinspectionsandtests,onhigh-pressurecommonrailfuelsystemsandelectroniccontrols.

10. Inspect,test,andreplaceengineprotectionandautomaticstop/restartsystem components.




11. Inspectandreplaceelectricalconnectorterminals,pins,harnesses,seals,andlocks.12. Connectdiagnostictooltovehicle/engine;accessandverifyprogrammable

parameters;changeifapplicable.13. Useadiagnostictool(hand-heldorPCbased)toinspectandtestelectronicengine

controlsystem,sensors,actuators,electroniccontrolmodules(ECMs),andcircuits;determinefurtherdiagnosis.

14. Measureandinterpretvoltage,voltagedrop,amperage,andresistancereadingsusingadigitalmultimeter(DMM)orappropriatetestequipment.

G. Starting and Charging System Diagnosis and Repair (4 questions) 1. Performbatterystate-of-chargeandloadorcapacitancetests;determineneeded

service. 2. Chargebatteryusingsloworfastchargemethod,asappropriate. 3. Startavehicleusingjumpercablesoraboosterbattery. 4. Inspect,clean,andrepair/replacebatteries,batterycables,andterminalconnections. 5. Inspect,test,andreinstall/replacestarterrelays,safetyswitch(s),andsolenoids. 6. Performalternatorvoltageandamperageoutputtests;determineneededrepairs. 7. Performstarterandchargingcircuitvoltagedroptests;determineneededrepairs.

H. Engine Brakes (3 questions) 1. Inspect,test,andadjustenginecompressionandexhaustbrakes. 2. Inspect,test,adjust,andrepair/replaceenginecompressionandexhaustbrakecontrol

circuits,switches,andsolenoids. 3. Inspectandrepair/replaceenginecompressionandexhaustbrakehousing(s),valves,

seals,springs,lines,andfittings.




SAMplE QuESTiOnSdiESEl EnGinES (TEST T2)

QuESTiOnS:1. Whenadieselengineisoperatedunderaload,coolantcontinuallycomesout

oftheradiatoroverflowandtherearebubblesintheradiator.Whichoftheseisthemostlikelycause?

(A)Toomuchcoolantinthecoolingsystem (B)Acloggedradiator (C)Astuck-openthermostat *(D)Compressionleakageintothecoolingsystem 2. Adieselenginehasexcessiveblacksmokewhenstartedinthemorning.

Whichofthesecouldbethecause? *(A)Abadfuelinjectionnozzle (B)Arestrictedfuelfilter (C)Ablockedfueltankvent (D)Aleakingfuelreturnline

3. Whichofthesecancauseano-startconditiononaHEUIengine? (A)Highfuelpressure *(B)Lowinjectioncontrolpressure (C)Highboostpressure (D)Lowboostpressure

4. Adieselengineishardtostart,butrunsgoodafterithasbeenprimedandrunforafewminutes.Themostlikelycauseisa:

(A)leakinginjectorline. (B)leakingfuelreturnline. (C)pluggedfueltankvent. *(D)badtransferpumpcheckvalve.

5. Adieselenginewithwetlinershasbeenrunningtoohot,andthereiscoolantinthecrankcase.Themostlikelycauseis:

(A)acrackedblock (B)crackedliners *(C)leakinglinerseals. (D)aleakinginjectorseal.



6. Dieselenginecylinderlinerprotrusion(height)canbeadjustedbyselecting thecorrectsize:

(A)cylinderliner. (B)headgasket. *(C)linershim. (D)firering.

7. AdieselenginewithEUIhasamisfireandthecheckenginelightisON.FaultcodeS4FMI5“cylinder4currentbelownormal”isactive.Thiscouldbecausedbya:

(A)failedenginepositionsensor. (B)sticking#4injectionplunger. *(C)broken#4injectionwireterminal. (D)stickingthrottlepositionsensor.

8. Thecauseofaloggedfaultcodeinanelectronicdieselenginehasjustbeenrepaired. TechnicianAsaysthatthecodesshouldbeclearedbeforereleasingthevehicle. TechnicianBsaysthatthecustomer’spasswordshouldberesetbefore releasingthevehicle.

Whoisright? *(A)Aonly (C)BothAandB (B)Bonly (D)NeitherAnorB

9. Adieselenginehaslowpowerandlowturbochargerboostpressureisfound.TechnicianAsaysthataleakingexhaustmanifoldcouldbethecause. TechnicianBsaysthatapluggedturbochargeroilreturnlinecouldbethecause. Whoisright?





Content Questions Percentage Area in Test of Test A. Clutch Diagnosis and Repair 11 28% B. Transmission Diagnosis and Repair 13 33% C. Driveshaft and Universal Joint Diagnosis and Repair 7 18% D. Drive Axle Diagnosis and Repair 9 23%

Total 40 100%

TEST SpEcificATiOnS And liSTdrivE TrAin (TEST T3)

A. Clutch Diagnosis and Repair (11 questions) 1. Diagnoseclutchnoise,binding,slippage,pulsation,vibration,grabbing,andchatter

problems;determinecauseoffailureandneededrepairs. 2. Inspect,adjust,repair,orreplaceclutchlinkage,cables,levers,brackets,bushings,

pivots,springs,andclutchsafetyswitch(includespushandpulltypeassemblies);checkpedalheightandtravel.

3. Inspect,adjust,repair,orreplacehydraulicclutchslaveandmastercylinders,lines,andhoses;bleedsystem.

4. Inspect,orremoveandinstallrelease(throwout)bearing,sleeve,bushings,springs,housing,levers,releasefork,forkpads,forkrollers,shafts,andseals;measureandadjustrelease(throwout)bearingposition.

5. Inspect,orremoveandinstallsingle-discclutchpressureplateandclutchdisc; adjustfreeplayandreleasebearingposition.

6. Inspect,orremoveandinstalltwo-plateclutchpressureplate,clutchdisc, intermediateplate;determineproperclutchtorquerating;adjustfreeplayand releasebearingposition.

7. Inspectandreplaceclutchbrakeassembly;inspectandreplaceinputshaftandbear-ingretainer.

8. Inspect,orremoveandinstallself-adjusting/continuous-adjustingclutchassembly;performinitialand/orresetadjustmentprocedure.

9. Inspectandreplacepilotbearing.10. Inspectflywheelmountingareaoncrankshaft,rearmainoilseal,andmeasure

crankshaftendplay;determineneededrepairs.11. Inspectflywheel,starterringgear,andmeasureflywheelfaceandpilotborerunout;

determineneededrepairs.12. Inspectflywheelhousing(s)totransmissionhousing/enginematingsurface(s)and

measureflywheelhousingfaceandborerunout;determineneededrepairs.



T3 liST (cOnTinuEd)

B. Transmission Diagnosis and Repair (13 questions) 1. Determinethecauseoftransmissioncomponentfailure,bothbeforeandduring

disassemblyprocedures. 2. Diagnosetransmissionvibration/noise,shifting,lockup,slipping/jumping

out-of-gear,andoverheatingproblems;determineneededrepairs. 3. Inspect,adjust,repair,orreplacetransmissionremoteshiftlinkages,cables,brackets,

bushings,pivots,andlevers. 4. Inspect,testoperation,adjust,repair,orreplaceairshiftcontrols,lines,hoses,valves,

regulators,filters,andcylinderassemblies. 5. Inspect,testoperation,adjust,repair,orreplaceelectronicshiftcontrols,shift,range

andsplittersolenoids,shiftmotors,indicators,speedandrangesensors,electronic/transmissioncontrolunits(ECU/TCU),neutral/ingearandreverseswitches,and wiringharnesses.

6. Inspect,testoperation,repair,orreplaceelectronicshiftselectors(in-cabcontrols),airandelectricalswitches,displaysandindicators,wiringharnesses,andairlines.

7. Useappropriatediagnostictoolsandsoftware,procedures,andserviceinforma-tion/flowchartstodiagnoseautomatedmechanicaltransmissionproblems;checkandrecorddiagnosticcodes,clearcodes,interpretdigitalmultimeter(DMM)readings,determineneededrepairs.

8. Diagnoseautomatedmechanicaltransmissionproblemscausedbydatalink/bus interfaceswithrelatedelectroniccontrolsystems.

9. Removeandreplacetransmission;inspectandreplacetransmissionmounts, insulators,andmountingbolts.

10. Inspectforleakageandreplacetransmissioncoverplates,gaskets,sealants,seals,vents,andcapbolts;inspectsealsurfaces.

11. Checktransmissionfluidlevel,andcondition;determineneededservice,andaddpropertypeoflubricant.

12. Inspect,adjust,andreplacetransmissionshiftlever,cover,rails,forks,levers, bushings,sleeves,detents,interlocks,springs,andlockbolts.

13. Inspectandreplaceinputshaft,gear,spacers,bearings,retainers,andslingers.14. Inspectmainshaft,gears,slidingclutches,washers,spacers,bushings,bearings,aux-

iliarydrivegear/assembly,retainers/snaprings,andkeys;determineneededrepairs.15. Inspectcountershafts,gears,bearings,timingretainer/snaprings,andkeys;check

bearingpreload/endplay;verifymultiplecountershaftgeartiming;determineneededrepairs.

16. Inspectoutputshaft,gears,washers,spacers,bearings,retainers/snaprings,andkeys;determineneededrepairs.

17. Inspectreverseidlershaft(s),gear(s),bushings,bearings,thrustwashers,and retainers/snaprings;checkreverseidlergearendplay;determineneededrepairs.

18. Inspectsynchronizerhub,sleeve,keys/inserts,springs,blockingrings,synchronizerplates,blockerpins,andslidingclutches;determineneededrepairs.

19. Inspecttransmissioncasesincludingmatingsurfaces,bores,bushings,pins,studs,vents,andmagneticplugs;determineneededrepairs.

20. Inspect,service,orreplacetransmissionlubricationsystemcomponents,pumps,troughs,collectors,slingers,coolers,filters,andlinesandhoses.

21. Inspect,test,replace,andadjustelectronicspeedometerdrivecomponents.



T3 liST (cOnTinuEd)

22. Inspect,adjust,service,repair,orreplacepowertake-offassembliesandcontrols.23. Inspectandtestoperationofbackuplight,neutralstart,andwarningdevicecircuits

andswitches;determineneededrepairs.24. Inspectandtesttransmissiontemperaturesendingunit/sensorandgauge;determine

neededrepairs.25. Inspect,adjust,repair,orreplacetransfercaseassembliesandcontrols.

C. Driveshaft and Universal Joint Diagnosis and Repair (7 questions) 1. Diagnosedriveshaftanduniversaljointnoise,vibration,andrunoutproblems;deter-

minecauseoffailureandneededrepairs. 2. Inspect,service,orreplacedriveshaft,slipjoints/yokes,yokes,driveflanges,

universaljoints,driveshaftbootsandseals,andretaininghardware;properly phase/timeyokes.

3. Inspectandreplacedriveshaftcentersupportbearingsandmounts. 4. Measureandadjustvehiclerideheight;measureandadjustdrivelineslopesand

angles(vehicleloadedandunloaded),includingPTOdriveshafts. 5. Useappropriatedrivelineanalysissoftwaretodiagnosedrivelineproblems. 6. Diagnosedrivelineretarderproblems;determineneededrepairs.

D. Drive Axle Diagnosis and Repair (9 questions) 1. Diagnosedriveaxleunitnoiseandoverheatingproblems;determineneededrepairs. 2. Checkandrepairfluidleaks;inspectandreplacedriveaxlehousingcoverplates,

gaskets,sealants,vents,magneticplugs,andseals. 3. Checkdriveaxlefluidlevel,andcondition;determineneededservice,addproper

typeoflubricantusingcorrectfillprocedure. 4. Removeandreplacedifferentialcarrierassembly. 5. Inspectandreplacedifferentialcaseassemblyincludingspider/piniongears,cross

shaft,sidegears,thrustwashers,casehalves,andbearings. 6. Inspectandreplacecomponentsoflockingdifferentialcaseassembly. 7. Measureringgearbacklashandrunout;determineneededrepairs. 8. Inspectringanddrivepiniongears,spacers,shims,sleeves,bearingcages,and

bearings;determineneededrepairs. 9. Checkringandpiniongeartoothcontactpattern;interpretpatternand

determineneededrepairs.10. Inspectandreplacepowerdivider(inter-axledifferential)assembly.11. Inspect,adjust,repair,orreplaceairoperatedpowerdivider(inter-axledifferential)

lockoutassemblyincludingdiaphragms,seals,springs,yokes,pins,lines,hoses, fittings,andcontrols.

12. Inspectandmeasuredriveaxlehousingmatingsurfacesandalignment;determineneededrepairs.

13. Inspect,service,orreplacedriveaxlelubricationsystemcomponents,pump,troughs,collectors,slingers,tubes,andfilters.

14. Inspectandreplacedriveaxleshafts.15. Removeandreplacewheelassembly;checkdriveaxlewheel/hubsealandaxleflange

gasketforleaks;determineneededrepairs.



T3 liST (cOnTinuEd)

16. Diagnosedriveaxlewheelbearingnoisesanddamage;determineneededrepairs.17. Clean,inspect,lubricate,andreplacewheelbearingsandraces/cups;replaceseals

andwearrings;adjustdriveaxlewheelbearings(includingoneandtwonuttypes) tomanufacturers’specifications.

18. Inspectandtestdriveaxletemperaturesendingunit/sensorandgauge;determineneededrepairs.

19. Check,adjust,and/orreplacewheelspeedsensor(s).20. Inspectorreplaceextendedservice(sealed,close-tolerance,andunitized)

bearingassemblies;performinitialinstallationprocedurestomanufacturers’ specifications.



SAMplE QuESTiOnSdrivE TrAin (TEST T3)

QuESTiOnS:

1. Whatoperationisbeingperformed inthesetupshownabove?

(A)Adjustingtoothcontact *(B)Checkingringgearrunout (C)Checkingringgearbacklash (D)Settingdifferentialbearingpreload

2. Atruckdoesnotmoveinanygear. TechnicianAsaysthatabrokenshifterforkcouldbethecause. TechnicianBsaysthatabrokenoutputshaftcouldbethecause. Whoisright?


3. Theshiftleverona13-speedtransmissionishardtomove. Whichoftheseisthemostlikelycause?

(A)Bentshiftrails *(B)Galledslidingclutchgears (C)Worndetentsprings (D)Toomuchmainshaftgearendplay

4. Theairpressureregulatorforatransmissionisbeingchecked. TechnicianAsaysthatthetractorairpressureshouldbeatmaximumsystempressure. TechnicianBsaysthattheregulatorairfiltershouldbecleanedandthesystemrecheckediftheairpressurereadingisbelownormal. Whoisright?


ROTATE RING GEAR



5. Thedriverofatrucksaysthatagrindingnoisecanbeheardwhentheclutchpedalisdepressed.Whichoftheseisthemostlikelycause?

(A)Toolittleclutchpedalfreeplay *(B)Awornclutchrelease(throwout)bearing (C)Alowtransmissionlubricantlevel (D)Awornclutchpressureplate

6. Atwo-platepull-typeclutchengagesOK,butthetransmissiongrindswhengoingintofirstgearfromneutral. TechnicianAsaysthatawornclutchbrakecouldbethecause. TechnicianBsaysthattoolittlefreeplaycouldbethecause. Whoisright?


7. Whichofthesecouldbethecauseofadriveshaftvibrationonatruck thathasjusthadaU-jointreplaced?

*(A)Thedriveshaftisout-of-phase (B)TheU-jointwasinstalledbackwards (C)TheU-jointwasnotlubricated (D)Thereisdirtonthedriveshaft

8. Atruckwithasinglerearaxlehastoomuchrearaxlenoiseonlywhenthetruckispulling.Whichoftheseisthemostlikelycause?

(A)Wornaxleshaftbearings (B)Wornwheelbearings (C)Worndifferentialpinion(spider)gears *(D)Wornringandpiniongears


ROTATE RING GEAR



Content Questions Percentage Area in Test of Test A. Air Brakes Diagnosis and Repair 28 56% 1. Air Supply and Service Systems (14) 2. Mechanical/Foundation (10) 3. Parking Brakes (4) B. Hydraulic Brakes Diagnosis and Repair 14 28% 1. Hydraulic System (6) 2. Mechanical System (5) 3. Power Assist Units and Miscellaneous (3) C. Air and Hydraulic Antilock Brake Systems (ABS), Automatic traction Control (ATC), and Electronic Stability Control Systems 5 10% D. Wheel Bearings Diagnosis and Repair 3 6%

Total 50 100%

TEST SpEcificATiOnS And liST BrAkES (TEST T4)

A. Air Brakes Diagnosis and Repair (28 questions)

1. Air Supply and Service Systems (14 questions) 1. Diagnosepoorstopping,prematurewear,brakenoise,airleaks,pulling,grabbing,

ordraggingproblemscausedbysupplyandservicesystemcomponents;determineneededrepairs.

2. Checkairsystembuild-uptime;determineneededrepairs. 3. Drainairreservoirtanks;checkforoil,water,andforeignmaterial;determineneeded

repairs. 4. Inspect,adjust,align,andreplacecompressordrivebeltsandpulleys. 5. Inspectandreplacecompressordrivegearandcoupling. 6. Inspect,repair,orreplaceaircompressor,oilsupply,waterlines,hoses,fittingsand

mountingbrackets. 7. Inspect,test,adjust,andreplacesystempressurecontrols(governor/reliefvalve),

unloaderassembly,lines,hoses,andfittings. 8. Inspect,repair,orreplaceairsystemlines,hoses,fittings,andcouplings;checkfor

properrouting. 9. Inspect,test,clean,andreplaceairtankrelief(pop-off)valves,one-way(single)

checkvalves,draincocks,automaticdrain(spitter)valves,heaters,wiring,and connectors.



T4 liST (cOnTinuEd)

10. Inspect,test,clean,repair,orreplaceairdriersystems,filters,valves,heaters,wiring,andconnectors.

11. Inspect,test,repair,orreplacebrakeapplication(foot)valve,fittings,andmounts;checkpedaloperation.

12. Inspect,test,andreplacetwo-way(double)checkvalvesandanti-compoundingvalves.

13. Inspect,test,repair,orreplacestopandparkingbrakelightcircuitswitches,wiring,andconnectors.

14. Inspect,test,repair,orreplacehandbrake(trailer)controlvalve,lines,hoses, fittings,andmountings.

15. Inspect,test,andreplacebrakerelayvalves.16. Inspect,test,andreplacequickreleasevalves.17. Inspect,test,andreplacetractorprotectionvalve.18. Inspect,test,andreplaceinversion/emergency(spring)brakecontrolvalve(s).19. Inspect,test,andreplacelowpressurewarningdevices.20. Inspect,test,repairorreplaceairpressuregauges,in-cablines,hoses,fittings,and

pressuresensors(transducers).21. Determineifairbrakesystemproblemiscausedbytractorortrailersupplyorservice

systemcomponents.22. Verifythecomplaintandroadtestvehicle;reviewdriver/customerinterviewand

pastmaintenancedocuments(ifavailable);determinefurtherdiagnosis.

2. Mechanical/Foundation (10 questions) 1. Diagnosepoorstopping,prematurewear,brakenoise,pulling,grabbing,ordragging

problemscausedbyfoundationbrakecomponents;determineneededrepairs. 2. Inspect,test,repair,orreplaceservicebrakechambers,diaphragm,clamp,return

spring,pushrod,clevis,andmountingbrackets. 3. Inspect,service,orreplacemanualandautomaticslackadjusters. 4. InspectandreplaceS-cambrakerollers,bushings,camshafts,seals,spacers,retain-

ers,brakespiders,shields,anchorpins,andsprings. 5. Inspect,clean,rebuildorreplace,andadjustairdiscbrakecaliperassemblies. 6. Inspectandreplacebrakeshoes,orpads;determineneededrepair. 7. Inspectandreplacebrakedrumsorrotorsasneeded.

3. Parking Brakes (4 questions) 1. Inspectandtestparking(spring)brakechamberoperation;replaceparking(spring)

brakechamber;disposeofremovedchambersinaccordancewithlocalregulations. 2. Inspect,test,andreplaceparking(spring)brakecheckvalves,lines,hoses,and

fittings. 3. Inspect,test,andreplaceparking(spring)brakeapplicationandreleasevalve. 4. Manuallyrelease(cage)andreset(uncage)parking(spring)brakes.



T4 liST (cOnTinuEd)

B. Hydraulic Brakes Diagnosis and Repair (14 questions)

1. Hydraulic System (6 questions) 1. Diagnosepoorstopping,brakenoise,prematurewear,pulling,grabbing,

dragging,orpedalfeelproblemscausedbyhydraulicsystemcomponents;determineneededrepairs.

2. Pressuretesthydraulicsystemandinspectforleaks. 3. Checkandadjustbrakepedalpushrodlength. 4. Inspect,test,andreplacemastercylinder. 5. Inspectandreplacebrakelines,flexiblehoses,andfittings. 6. Inspect,test,andreplacemetering(hold-off),loadsensing/proportioning,

proportioning,andcombinationvalves. 7. Inspect,test,repair,orreplacebrakepressuredifferentialvalveandwarninglight

circuitswitch,bulbs,wiring,andconnectors. 8. Inspectandreplacewheelcylinders. 9. Inspect,clean,andreplacediscbrakecaliperassemblies.10. Inspect/testbrakefluid;bleedand/orflushsystem;determineproperfluidtypefor

application.11. Inspect,test,repair,orreplacehydraulically-controlledparkingbrakecomponents,

systems,andwarningdevices.

2. Mechanical System (5 questions) 1. Diagnosepoorstopping,brakenoise,prematurewear,pulling,grabbing,dragging,

orpedalfeelproblemscausedbydiscanddrumbrakemechanicalcomponents; determineneededrepairs.

2. Inspect,resurface,orreplacebrakedrumsorrotors. 3. Inspect,adjust,andreplacedrumbrakeshoes,mountinghardware,adjuster

mechanisms,andbackingplates. 4. Inspect,service,andreplacediscbrakepads,hardware,andmounts. 5. Inspect,adjust,repair,orreplacedrivelineparkingbrakedrums,rotors,shoes,

mountinghardware,andadjusters;burnish/seatreplacementshoesasrequired. 6. Inspect,adjust,repair,orreplacedrivelineparkingbrakeapplicationsystempedal,

cables,linkage,levers,pivots,andsprings.

3. Power Assist Units and Miscellaneous (3 questions) 1. Diagnosepoorstoppingcomplaintscausedbybrakeassist(booster)system

problems;determineneededrepairs. 2. Inspect,test,repair,orreplacepowerbrakeassist(booster),hoses,controlvalves

andfilters;determineproperfluidtypeforapplication. 3. Test,adjust,andreplacebrakestoplightswitch,bulbs,wiring,andconnectors.



T4 liST (cOnTinuEd)

C. Air and Hydraulic Antilock Brake Systems (ABS), Automatic Traction Control (ATC), and Electronic Stability Control Systems (5 questions) 1. Observeantilockbrakesystem(ABS)warninglightoperation;determineiffurther

diagnosisisneeded;(includesdashmountedtrailerABSwarninglight). 2. Diagnoseantilockbrakesystem(ABS)electroniccontrol(s)andcomponentsusing

self-diagnosisand/orspecifiedtestequipment(scantool,PCbasedsoftware); determineneededrepairs.

3. Diagnosewheellock-upcausedbyfailureoftheantilockbrakesystem(ABS); determineneededrepairs.

4. Inspect,test,andreplaceantilockbrakesystem(ABS)air,hydraulic,electrical, andmechanicalcomponents.

5. Diagnoseautomatictractioncontrol(ATC)electroniccontrol(s)andcomponentsusingself-diagnosisand/orspecifiedtestequipment(scantool,PCbasedsoftware);determineneededrepairs.

6. Diagnoseelectronicstabilitycontrolsystemsandcomponentsusingself-diagnosisand/orspecifiedtestequipment(scantool,PCbasedsoftware);determineneededrepairs.

D. Wheel Bearings Diagnosis and Repair (3 questions) l. Removeandreplaceaxlewheelassembly. 2. Clean,inspect,lubricate,andreplacewheelbearingsandraces/cups;replaceseals

andsealwearrings. 3. Adjuststeeringanddriveaxlewheelbearings(includingoneandtwonuttypes)

tomanufacturers’specifications. 4. Inspectorreplaceextendedservice(sealed,close-tolerance,andunitized)

bearingassemblies;performinitialinstallationprocedurestomanufacturers’ specifications.



SAMplE QuESTiOnSBrAkES (TEST T4)

QuESTiOnS:

1. Theparkingbrakesfailtoapplyonatruckwithairbrakes. TechnicianAsaysthatlowairpressureinthespringbrakechambercouldbethecause. TechnicianBsaysthatarupturedspringbrakediaphragmcouldbethecause.Whoisright?

(A)Aonly (C)BothAandB (B)Bonly *(D)NeitherAnorB

2. Atruckhasanunevenbrakingproblem.Whichofthesecouldbethecause? (A)Abindingtreadle(foot)valve (B)Lowbrakelineairpressure *(C)Abadbrakedrum (D)Abadgovernor

3. Aservicebrakeonatruckwithanairbrakesystemreleasestooslowly. TechnicianAsaysthatlowairpressurecouldbethecause. TechnicianBsaysthatakinkedairlinecouldbethecause. Whoisright?


4. Aservicebrakechamberleakswhenthebrakesareapplied.Whichofthesecouldbethecause?

(A)Excessivepushrodtravel *(B)Abadchamberdiaphragm (C)Abrokenchamberreturnspring (D)Amisalignedpushrod



5. Allthewheelsonatruckwithairbrakeslockupwhenasmallamountofpres-sureisappliedtothetreadle(foot)valve.Whichofthesecouldbethecause?

*(A)Theapplicationvalveisbad. (B)Thelimitingvalveisleaking. (C)Thecompressorregulatorissettoohigh. (D)Thebrakesareadjustedtoohigh. 6. Whenanairreservoirtankisdrained,thereisanexcessiveamountofmoisture.

Thiscouldbecausedbya: (A)crackedaircompressorbracket. (B)cloggedaircompressorintake. (C)failedonewaycheckvalve. *(D)failedairdryerpurgevalve. 7. Allthebrakesdragonatruckwithhydraulicbrakes.Whichofthesecouldbe

thecause? (A)Airinthehydraulicsystem (B)Toohighvacuumsupplytothepowerbrakebooster (C)Aleakingsecondarycupinthemastercylinder *(D)Nobrakepedalfreetravel

Questions 8 and 9 are not like the ones above. EachofthesehasthewordEXCEPT.Foreachquestion,lookforthechoice

thatcouldNOT causethedescribedsituation.Readtheentirequestion carefullybeforechoosingyouranswer.

8. Atruckwithhydraulicbrakespullstoonesidewhenthebrakesareapplied.AnyofthesecouldbethecauseEXCEPT a:

(A)stickingwheelcylinderpiston. (B)greasecontaminatedbrakelining. (C)crimpedhydraulicline. *(D)pluggedcompensatingport. 9. Thedriverofatruckwithairbrakessaysithaspoorstoppingpower.

AnyofthesecouldbethecauseEXCEPT: *(A)thequickreleasevalveexhaustportisplugged. (B)theairpressureistoolow. (C)theapplicationlineisrestricted. (D)thebrakesareoutofadjustment.




Content Questions Percentage Area in Test of Test A. Steering System Diagnosis and Repair 12 24.0% 1. Steering Column (3) 2. Steering Units (6) 3. Steering Linkage (3) B. Suspension System Diagnosis and Repair 13 26.0% C. Wheel Alignment Diagnosis, Adjustment, and Repair 13 26.0% D. Wheels and Tires Diagnosis and Repair 9 18.0% E. Frame Service and Repair 3 6.0%

Total 50* 100%

TEST SpEcificATiOnS And liSTSuSpEnSiOn And STEErinG (TEST T5)

A. Steering System Diagnosis and Repair (12 Questions)

1. Steering Column (3 Questions) 1. Diagnosefixedanddriveradjustablesteeringcolumnandshaftnoise,looseness,and

bindingproblems;determineneededrepairs. 2. InspectandreplacesteeringshaftU-joint(s),slipjoints,bearings,bushings,andseals;

phaseshaftU-joints. 3. Checkandadjustcabmountingandrideheight. 4. Removethesteeringwheel(includessteeringwheelsequippedwithelectrical/

electroniccontrolsandcomponents);installandcenterthesteeringwheel.

2. Steering Units (6 Questions) 1. Diagnosepowersteeringsystemnoise,steeringbinding,darting/oversteer,reduced

wheelcut,steeringwheelkick,pulling,non-recovery,turningeffort,looseness,hardsteering,overheating,fluidleakage,andfluidaerationproblems;determineneededrepairs.

2. Determinerecommendedtypeofpowersteeringfluid;checklevelandcondition;determineneededservice.

3. Flushandrefillpowersteeringsystem;purgeairfromsystem. 4. Performpowersteeringsystempressure,temperature,andflowtests;determine

neededrepairs. 5. Inspect,service,orreplacepowersteeringreservoirincludingfilter,seals,and

gaskets.



T5 liST (cOnTinuEd)

6. Inspectandreinstall/replacepowersteeringpumpdrivebelts,pulleysandtensioners;adjustdrivebeltsandcheckalignment.

7. Inspectorreplacepowersteeringpumpdrivegearandcoupling. 8. Inspect,adjust,orreplacepowersteeringpump,mountings,andbrackets. 9. Inspectandreplacepowersteeringsystemcooler,lines,hoses,clamps/mountings,

andfittings.10. Inspect,adjust,orreplacelinkage-assisttypepowersteeringcylinderorgear

(dualsystem).11. Inspect,adjust,repair,orreplaceintegraltypepowersteeringgear.12. Adjustmanualandautomaticsteeringgearpoppet/reliefvalves.

3. Steering Linkage (3 Questions) 1. Inspect,align,andreplacepitmanarm. 2. Inspect,adjust,orreplacedraglink(relayrod)andtierodends(ballandadjustable

sockettype). 3. Inspectandreplacesteeringarms. 4. Inspectorreplaceclampsandretainersoncrosstube/relayrod/centerlink/tierod;

positionasneeded. 5. Checkandadjustwheelstops.

B. Suspension System Diagnosis and Repair (13 Questions) 1. Inspectandreplacefrontaxlebeamandmountinghardware. 2. Inspect,service,adjust,orreplacekingpin,bushings,locks,bearings,seals,and

covers. 3. Inspectandreplaceshockabsorbers,bushings,brackets,andmounts. 4. Inspect,repair,orreplace(leafandparabolic)springs,centerbolts,clips,spring

eyeboltsandbushings,shackles,slippers,insulators,brackets,andmounts. 5. Inspect,adjust,orreplacetorquearms,bushings,andmounts. 6. Inspect,adjust,orreplaceaxlealigningdevicessuchasradiusrods,transversetorque

rods/trackbars,stabilizerbars,andrelatedbushings,mounts,shims,andcams. 7. Inspectorreplacewalkingbeams,center(cross)tube,bushings,mounts,loadpads,

brackets,caps,andmountinghardware. 8. Inspect,test,adjust,repair,orreplaceairsuspensionpressureregulatorandheight

controlvalves,linkages,lines,hoses,andfittings. 9. Inspect,test,repair,orreplaceairsuspensionsprings(bags),mountingplates,

mainsupportbeams/springs,suspensionarms(radius/torque,andtransversetorque),andbushings.

10. Measurevehiclerideheight;determineneededadjustmentsorrepairs.11. Verifyanddiagnosevehiclesuspensioncomplaints.12. TorqueU-boltstomanufacturers’specifications.13. Checkaxleloaddistributionproblemsonrearsuspensions;checkaxleseatplaning

anglesandpinionangles.



T5 liST (cOnTinuEd)

C. Wheel Alignment Diagnosis, Adjustment, and Repair (13 Questions) 1. Diagnosevehiclewandering,darting,pulling,shimmy,andsteeringeffortproblems;

determineneededadjustmentsandrepairs. 2. CheckcamberandKPI(kingpininclination);determineneededrepairs. 3. Checkandadjustcaster. 4. Checkandadjusttoe. 5. Checkrearaxle(s)alignment(thrustline/centerline)andtracking(lateraloffset,

parallelism);adjustordetermineneededrepairs. 6. Checkturning/Ackermanangle(toe-out-on-turns)andmaximumturningradius

(wheelcut);determineneededrepairs.

D. Wheels and Tires Diagnosis and Repair (9 Questions) 1. Diagnosetirewearpatterns;determineneededrepairs. 2. Diagnosewheelendvibration,shimmy,pounding,hop(tramp)problems;

determineneededrepairs. 3. Inspectandreplacewheels,spacers,rims,sideflanges,lockingrings,rimclamps,

studs,andnuts. 4. Measurewheelandtireradialandlateralrunout;determineneededrepairsor

adjustments. 5. Inspecttires;checkandadjustairpressuretotiremanufacturers’specifications. 6. Performstaticbalanceofwheelandtireassembly. 7. Performdynamicbalanceofwheelandtireassembly. 8. Measuretirediameterandmatchtiresonaxles. 9. Removeandreplacesteeringand/ordriveaxlewheelassembly.10. Clean,inspect,lubricate,andreplacewheelbearingsandraces/cups;replaceseals

andwearrings;adjuststeeringanddriveaxlewheelbearings(includingoneand twonuttypes)tomanufacturers’specifications.

11. Inspectorreplaceextendedservice(sealed,closetolerance,andunitized)bearingassemblies;performinitialinstallationprocedurestomanufacturers’specifications.

E. Frame Service and Repair (3 Questions) 1. Inspect,adjust,service,repair,orreplacefifthwheel,pivotpins,bushings,locking

jawmechanisms,andmountingbolts. 2. Inspect,adjust,service,repair,orreplaceslidingfifthwheel,tracks,stops,locking

systems,aircylinders,springs,lines,hoses,andcontrols. 3. Inspectframeandframemembersforcracks,breaks,distortion,elongatedholes,

looseness,anddamage;determineneededrepairs. 4. Inspect,install,orrepairframehangers,brackets,andcrossmembersinaccordance

withmanufacturers’recommendedprocedures. 5. Inspect,install,repairorreplacepintlehooksanddrawbars.



SAMplE QuESTiOnSSuSpEnSiOn And STEErinG (TEST T5)

QuESTiOnS:

1. Whichofthesecouldcausethefronttiresofatrucktoshowafeatherededgewearpattern?

*(A)Anincorrecttoesetting (B)Anincorrectcambersetting (C)Anincorrectcastersetting (D)Incorrecttirepressures 2. Thedriveaxlesonatruckwithawalkingbeamsuspensionareoutofalign-

ment. TechnicianAsaysthatincorrectlengthtorquerodscouldbethecause. TechnicianBsaysthatwornwalkingbeambushingscouldbethecause. Whoisright?

(A)Aonly (C)BothAandB *(B)Bonly (D)NeitherAnorB 3. Thedriverofatruckthathasjusthaditsfrontspringsandhangersreplaced

saysthatitishardtokeepinastraightaheadposition. TechnicianAsaysthatthiscouldbecausedbyinstallingthecastershimsbackwards. TechnicianBsaysthatthiscouldbecausedbyinstallingforwardspring hangerswhicharetooshort. Whoisright?

*(A)Aonly (C)BothAandB (B)Bonly (D)NeitherAnorB 4. Thedriverofatrucksaysthatitishardtosteerandthesteeringreturnispoor.

TechnicianAsaysthattightkingpinscouldbethecause. TechnicianBsaysthattoomuchtoe-incouldbethecause. Whoisright?




5. Ruststreakscomingfromaroundthestudholesofadiscwheelcouldbecausedby:

(A)anoverloadedconditon. (B)overtorquedlug/capnuts. *(C)Anoutofbalancecondition. (D)Looselug/capnuts. 6. Atruckhasahistoryofspringsbreakingatthecenterboltholes.

TechnicianAsaysthatlooseU-boltscouldbethecause. TechnicianBsaysthatloosespringshacklescouldbethecause. Whoisright?

*(A)Aonly (C)BothAandB (B)Bonly (D)NeitherAnorB 7. Aconstantbuzzingnoisecomesfromthepowersteeringpump.

TechnicianAsaysthecausecouldbeairinthesystem. TechnicianBsaysthecausecouldbethatthereliefvalveisstuckinthe openposition. Whoisright?





8. Thetandemrearaxleairsuspensionrideheightrisesabovenormalasthe vehicleisunloaded.Whichofthesecouldbethecause?

(A)Akinkedairspring(bag)supplyline (B)Aleakingheightcontrolvalve *(C)Apluggedheightcontrolvalveexhaustport (D)Aleakingpressureprotectionvalve Question 9 is not like the ones above. IthasthewordEXCEPT.Forthisquestion,lookforthechoicethatcould

NOT causethedescribedsituation.Readthequestioncarefullybefore choosingyouranswer.

9. Alloftheseshouldbecheckedbeforealigningthefrontwheelsonatruck EXCEPT:

(A)tirepressure. (B)rideheight. (C)wheelbearingadjustment. *(D)tirebalance.




Content Questions Percentage Area in Test of Test A. General Electrical Diagnosis 14 28% B. Battery Diagnosis and Repair 4 8% C. Starting System Diagnosis and Repair 7 14% D. Charging System Diagnosis and Repair 7 14% E. Lighting Systems Diagnosis and Repair 6 12% 1. Headlights, Parking, Clearance, Tail, Cab and Dash Lights (3) 2. Stoplights, Turn Signals, Hazard Light, and Backup Lights (3) F. Gauges and Warning Devices Diagnosis 4 8% and Repair G. Related Systems 8 12%

Total 50 100%

TEST SpEcificATiOnS And liSTElEcTricAl/ElEcTrOnic SySTEMS (TEST T6)

A. General Electrical Systems Diagnosis (14 questions) 1. Checkcontinuityinelectrical/electroniccircuitsusingappropriatetestequipment. 2. Checkappliedvoltages,circuitvoltages,andvoltagedropsinelectrical/electronic

circuitsusingdigitalmultimeter(DMM),orappropriatetestequipment. 3. Checkcurrentflowinelectrical/electroniccircuitsandcomponentsusingadigital

multimeter(DMM),clamp-onammeter,orappropriatetestequipment. 4. Checkresistanceinelectrical/electroniccircuitsandcomponentsusingadigital

multimeter(DMM),orappropriatetestequipment. 5. Findshorts,grounds,andopensinelectrical/electroniccircuits. 6. Diagnosekey-offbatterydrainproblems. 7. Inspect,test,andreplacefusiblelinks,circuitbreakers,andfuses. 8. Inspectandtestspikesuppressionsdiodes/resistorsandcapacitors. 9. Inspectandtestrelaysandsolenoids.10. Readandinterpretelectricalschematicdiagramsandsymbols.11. Diagnosefailuresinthedatacommunicationsbusnetwork;determineneededrepairs.

B. Battery Diagnosis and Repair (4 questions) 1. Performbatterytests(loadandcapacitance);determineneededservice. 2. Determinebatterystateofchargebymeasuringterminalpostvoltageusingadigital

multimeter(DMM). 3. Inspect,clean,service,orreplacebatteryandterminalconnections.



T6 liST (cOnTinuEd)

4. Inspect,clean,repairandreplacebatteryboxes,mounts,andholddowns. 5. Chargebatteryusingsloworfastchargemethodasappropriate. 6. Jumpstartavehicleusingjumpercablesandaboosterbatteryorappropriate

auxiliarypowersupply. 7. Diagnoselowvoltagedisconnect(LVD)systems;determineneededrepairs.

C. Starting System Diagnosis and Repair (7 questions) 1. Performstartingcircuitvoltagedroptests;determineneededrepairs. 2. Inspect,test,andreplacecomponentsandwiresinthestartercontrolcircuit. 3. Inspect,test,andreplacestarterrelaysandsolenoids/switches. 4. Removeandreplacestarter;inspectflywheelringgearorflexplate. 5. Inspect,clean,repair,andreplacebatterycablesandconnectorsinthecrankingcircuit. 6. Differentiatebetweenelectricalandmechanicalproblemsthatcauseaslowcrank,

nocrank,extendedcranking,oracrankingnoisecondition. 7. Test/monitorbatteryvoltageduringcranking.Determineneededrepairs

D. Charging System Diagnosis and Repair (7 questions) 1. Diagnosedashmountedchargemetersand/orindicatorlightsthatshowanocharge,

lowcharge,oroverchargecondition;determineneededrepairs. 2. Diagnosethecauseofnocharge,lowcharge,oroverchargeconditions;determine

neededrepairs(includesremotesensealternators) 3. Inspect,adjust,andreplacealternatordrivebelts/gears,pulleys,fans,mounting

brackets,andtensioners. 4. Performchargingsystemoutputtests;determineneededrepairs. 5. Performchargingcircuitvoltagedroptests;determineneededrepairs. 6. Removeandreplacealternator. 7. Inspect,repair,orreplaceconnectorsandwiresinthechargingcircuit.

E. Lighting Systems Diagnosis and Repair (6 questions)

1. Headlights, Daytime Running Lights, Parking, Clearance, Tail, Cab, and Dash Lights (3 questions) 1. Diagnosethecauseofbrighterthannormal,intermittent,dim,ornoheadlightand

daytimerunninglight(DRL)operation. 2. Test,aimandreplaceheadlights. 3. Test,repair,andreplaceheadlightanddimmerswitches,wires,connectors,terminals,

sockets,relays,andcontrolcomponents. 4. Inspect,test,repair,orreplaceswitches,bulbs,sockets,connectors,terminals,relays,

wires,andlight-emittingdiodes(LEDs)oflightingcircuitsontrucksandtrailers. 5. Inspect,test,repair,orreplacedashlightcircuitswitches,bulbs,LEDs,sockets,

connectors,terminals,wires,andprintedcircuits. 6. Inspect,test,repair,orreplaceinteriorcablightcircuitswitches,bulbs,LEDs,

sockets,connectors,terminals,orwires.

2. Stoplights, Turn Signals, Hazard Lights and Backup Lights (3 questions) 1. Inspect,test,adjust,repair,orreplacestoplightcircuitswitches,bulbs,LEDs,sockets,

connectors,terminals,relays,andwires. 2. Diagnosethecauseofturnsignalandhazardflasherlightmalfunctions;determine

neededrepairs.



T6 liST (cOnTinuEd)

3. Inspect,test,repair,orreplaceturnsignalandhazardcircuitflashers,switches,bulbs,LEDs,sockets,connectors,terminals,relays,andwires.

4. Inspect,test,adjust,repair,orreplacebackuplightandwarningdevices,circuitswitches,bulbs,LEDs,sockets,connectors,terminals,andwires.

5. Inspectandtesttrailerlightcordconnectorandcable;determineneededrepairs.

F. Gauges and Warning Devices Diagnosis and Repair (4 questions) 1. Diagnosethecauseofintermittent,high,low,ornogaugereadings;determineneeded

repairs.(Doesnotincludechargeindicators.) 2. Diagnosethecauseofdatabusdrivengaugemalfunctions;determineneededrepairs. 3. Inspect,test,adjust,repair,orreplacegaugecircuitsendingunits,sensors,gauges,

connectors,terminals,andwires. 4. Inspect,test,repair,orreplacewarningdevices(lightsandaudible)circuitsending

units,sensors,bulbs,audiblecomponent,socketsconnectors,terminals,wires,andprintedcircuits/controlmodules.

5. Inspect,test,andreplaceelectronicinstrumentationsystems;verifypropercalibrationforvehicleapplication.

G. Related Systems (8 questions) 1. Diagnosethecauseofconstant,intermittent,ornohornoperation. 2. Inspect,test,repair,orreplacehorncircuitrelays,horns,switches,connectors,

terminals,andwires. 3. Diagnosethecauseofconstant,intermittent,ornowiperoperation;diagnosethe

causeofwiperspeedcontroland/orparkproblems. 4. Inspect,test,repair,orreplacewipermotor,resistors,parkswitch,relays,switches,

connectors,terminals,andwires. 5. Inspectandreplacewipermotortransmissionmechanicallinkage,arms,andblades. 6. Inspect,test,repair,orreplacewindshieldwashermotororpump/relayassembly,

switches,connectors,terminals,andwires. 7. Inspect,test,repair,orreplacesideviewmirrormotors,heatercircuitgrids,relays,

switches,connectors,terminals,andwires. 8. Inspect,test,repair,orreplaceheaterandA/Celectricalcomponentsincluding:

A/Cclutches,motors,resistors,relays,switches,controls,connectors,terminals, andwires.

9. Inspect,test,repair,orreplacecigarettelighterand/orauxiliarypoweroutletcase,integralfuse,connectors,terminals,andwires.

10. Diagnosethecauseofslow,intermittent,ornopowerwindowoperation.11. Inspect,test,repair,andreplacemotors,switches,relays,connectors,terminals,

andwiresofpowerwindowcircuits.12. Diagnoseinverter/shorepowersystems;determineneededrepairs.13. Diagnosethecauseofpoor,intermittent,ornooperationofelectricdoorlocks.14. Inspect,test,repair,andreplaceswitches,relays,controllers,actuators/solenoids,

connectors,terminals,andwiresofelectricdoorlockcircuits.15. Inspect,testrepairandreplacecruisecontrolelectricalcomponents.16. Inspect,test,repair,andreplaceenginecoolingfanelectricalcontrolcomponents.17. Diagnosefailuresinthedatacommunicationsbusnetwork;determineneeded

repairs.



SAMplE QuESTiOnSElEcTricAl/ElEcTrOnic SySTEMS (TEST T6)

QuESTiOnS:

1. Inthechargingsystemshownabove,themeterreadingwillshow: (A)chargingoutputvoltage. (B)regulatoroperatingvoltage. *(C)chargingcircuitvoltagedrop. (D)ignitionswitchvoltagedrop.

2. Atruck’scabheaterblowermotoroperatesatlowspeedonly.Whichoftheseisthemostlikelycause?

(A)Anopenblowerswitchground *(B)Abadblowerswitch (C)Abindingblowercage (D)Ashorttopowerattheblowermotor

ALTERNATOR

BATTERY

BATTERY TERMINAL

IGNITION TERMINAL

VOLTMETER

IGNITION SWITCH




3. Thehornsinthecircuitshownaboveonlyblowwhenajumperwireiscon-nectedbetweenterminals30and87ofthehornrelay. TechnicianAsaysthatafailedhornrelaycouldbethecause. TechnicianBsaysthatashorttogroundinthecircuitbetweenthehornrelayandthehornbuttoncouldbethecause. Whoisright?


4. Atruck’sbatterydischargesaftersittingovernight. TechnicianAsaysthatabadalternatorcouldbethecause. TechnicianBsaysthatabadstartercouldbethecause. Whoisright?


5. Adrivercomplainsthatthetrailermarkerlightsaredimatnightwhilebraking.Whichoftheseisthemostlikelycause?

(A)Lowbatteryvoltage (B)Oneburnedoutbrakelightbulb *(C)Apoorgroundinthetrailerlightcord (D)Toomuchgreaseonthe5thwheel



6. Bothheadlightsonavehiclearediminhighbeamandnormalinlowbeam.TechnicianAsaysthatapoorheadlightgroundcouldbethecause. TechnicianBsaysthatashortedheadlightswitchcouldbethecause. Whoisright?

(A)Aonly (C)BothAandB (B)Bonly *(D)NeitherAnorB


7. Thevoltagereadingsshownaboveweretakenwhilecrankingtheengine.Whichoftheseisindicatedbythereadings?

(A)Battery#2hasresistanceinthegroundcable. *(B)Battery#2isweakerthanbattery#1. (C)Battery#1islowonelectrolyte. (D)Battery#2shouldbereplaced.



TEST SpEcificATiOnS And TASk liST HEATinG, vEnTilATiOn, And Air cOndiTiOninG (HvAc) SySTEMS (TEST T7)

Content Questions Percentage Area in Test of Test A. HVAC Systems Diagnosis, Service, and Repair 6 15% B. A/C System and Component Diagnosis, Service, and Repair 16 40% 1. A/C System – General (6) 2. Compressor and Clutch (5) 3. Evaporator, Condenser, and Related Components (5) C. Heating and Engine Cooling Systems Diagnosis, Service, and Repair 6 15% D. Operating Systems and Related Controls Diagnosis and Repair 8 20% 1. Electrical (5) 2. Air/Vacuum/Mechanical (2) 3. Constant/Automatic Temperature Control (1) E. Refrigerant Recovery, Recycling, Handling,andRetrofit 4 10%

Total 40 100%

A. HVAC Systems Diagnosis, Service, and Repair (6 questions) 1. Verifythecomplaint,roadtestthevehicle,reviewdriver/customerinterviewand

pastmaintenancedocuments(ifavailable);determinefurtherdiagnosis. 2. VerifytheneedofserviceorrepairofHVACsystemsbasedonunusualoperating

noises;determineappropriateaction. 3. VerifytheneedofserviceorrepairofHVACsystemsbasedonunusualvisual,

smell,andtouchconditions;determineappropriateaction. 4. Identifysystemtypeandcomponents(cyclingclutchorificetube-CCOT,expansion

valve,typeofrefrigerant)andconductperformancetest(s)onHVACsystems; determineappropriateaction.



T7 liST (cOnTinuEd)

B. A/C System and Component Diagnosis, Service, and Repair (16 questions)

1. A/C System. General (6 questions) 1. DiagnosethecauseoftemperaturecontrolproblemsintheA/Csystem;determine

neededrepairs. 2. Identifyrefrigeranttypeandcheckforcontamination;determineappropriateaction. 3. DiagnoseA/Csystemproblemsindicatedbypressuregaugereadingsandsightglass/

moistureindicatorconditions(whereapplicable);determineneededservice orrepairs.

4. DiagnoseA/Csystemproblemsindicatedbyunusualoperatingnoise,visual, smell,andtouchprocedures;determineneededrepairs.

5. PerformA/Csystemleaktest;determineneededrepairs. 6. EvacuateA/Csystemusingappropriateequipment. 7. InternallycleancontaminatedA/Csystemcomponentsandhoses. 8. ChargeA/Csystemwithcorrecttypeandquantityofrefrigerant. 9. Identifylubricanttypeneededforsystemapplication.

2. Compressor and Clutch (5 questions) 1. DiagnoseA/Csystemproblemsthatcauseprotectiondevices(pressure,thermal,and

electronic)tointerruptsystemoperation;determineneededrepairs. 2. Inspect,test,andreplaceA/Csystempressure,thermal,andelectronicprotection

devices. 3. InspectandreplaceA/Ccompressordrivebelts,pulleys,idlers,andtensioners;

adjustdrivebeltsandcheckalignment. 4. Inspect,test,service,andreplaceA/Ccompressorclutchcomponentsorassembly. 5. InspectandcorrectA/Ccompressorlubricantlevel. 6. Inspect,test,andreplaceA/Ccompressor. 7. Inspect,repair,orreplaceA/Ccompressormountingsandhardware.

3. Evaporator, Condenser, and Related Components (5 questions) 1. Correctsystemlubricantlevelwhenreplacingtheevaporator,condenser,

receiver/drieroraccumulator/drier,andhoses. 2. Inspect,repair,orreplaceA/Csystemhoses,lines,filters,fittings,andseals. 3. InspectA/Ccondenserforproperairflow. 4. Inspect,test,andreplaceA/Csystemcondenserandmountings. 5. Inspectandreplacereceiver/drieroraccumulator/drier. 6. Inspect,test,andreplacecab/sleeperrefrigerantsolenoid,expansionvalve(s),

thermostaticswitch(thermistor);andcheckplacementofthermalbulb (capillarytube).

7. Inspectandreplaceorificetube. 8. Inspect,test,andreplacecab/sleeperevaporatorcore. 9. Inspect,clean,andrepairevaporatorhousingandwaterdrain;inspectand

service/replaceevaporatorairfilter.10. Identify,inspect,andreplaceA/Csystemserviceports/valves(gaugeconnections).11. DiagnosesystemfailuresresultinginrefrigerantlossfromtheA/Csystemhigh

pressurereliefdevice.



T7 liST (cOnTinuEd)

C. Heating and Engine Cooling Systems Diagnosis, Service, and Repair (6 questions) 1. DiagnosethecauseofoutletairtemperaturecontrolproblemsintheHVACsystem;

determineneededrepairs. 2. Diagnosewindowfoggingproblems;determineneededrepairs. 3. Performenginecoolingsystemtestsforleaks,protectionlevel,contamination,

coolantlevel,temperature,coolanttype,andconditionerconcentration;determineneededrepairs.

4. Inspectandreplaceenginecoolingandheatingsystemhoses,lines,fittings,andclamps.

5. Inspectandtestradiator,pressurecap,andcoolantrecoverysystem(surgetank);determineneededrepairs.

6. Inspectwaterpumpanddrivesystem;determineneededrepairs. 7. Inspectandtestthermostats,by-passes,housings,andseals;determinedneeded

repairs. 8. Flushandrefillcoolingsystem;bleedairfromsystem. 9. Inspect,test,andrepairorreplacefan,fanhub,fanclutch,fancontrols,fan

thermostat,andfanshroud.10. Inspect,test,andreplaceheatingsystemcoolantcontrolvalve(s)andmanual

shut-offvalves.11. Inspect,flush,andreplaceheatercore.

D. Operating Systems and Related Controls Diagnosis and Repair (8 questions)

1. Electrical (5 questions) 1. DiagnosethecauseoffailuresinHVACelectricalcontrolsystems;determine

neededrepairs. 2. Inspect,test,repair,andreplaceA/Cheaterblowermotors,resistors,switches,relays,

modules,wiring,andprotectiondevices. 3. Inspect,test,repair,andreplaceA/Ccompressorclutchrelays,modules,wiring,

sensors,switches,diodes,andprotectiondevices. 4. InspectandtestA/C-relatedelectronicenginecontrolsystems;determineneeded

repairs. 5. Inspect,test,repair,andreplaceenginecooling/condenserfanmotors,relays,

modules,switches,sensors,wiring,andprotectiondevices. 6. Inspect,test,repair,andreplaceelectricactuatormotors,relays/modules,switches,

sensors,wiring,andprotectiondevices. 7. Inspect,test,repair,orreplaceHVACsystemelectricalcontrolpanelassemblies.

2. Air/Vacuum/Mechanical (2 questions) 1. DiagnosethecauseoffailuresinHVACair,vacuum,andmechanicalswitchesand

controls;determineneededrepairs. 2. Inspect,test,repair,orreplaceHVACsystemair/vacuum/mechanicalcontrolpanel

assemblies. 3. Inspect,test,adjust,orreplaceHVACsystemair/vacuum/mechanicalcontrolcables

andlinkages. 4. Inspect,test,andreplaceHVACsystemvacuumpumps,actuators(diaphragms/

motors)andhoses.



T7 liST (cOnTinuEd)

5. Identify,inspect,test,andreplaceHVACsystemvacuumreservoir(s),check valve(s),andrestrictors.

6. Inspect,test,adjust,repair,orreplaceHVACsystemducts,doors,andoutlets.

3. Constant/Automatic Temperature Control (1 question) 1. Diagnoseconstant/automatictemperaturecontrolsystemproblems;determineneeded

repairs. 2. Inspect,test,andreplaceclimatecontroltemperaturesensors. 3. Inspect,test,repair,andreplacetemperatureblenddoor/powerservosystem. 4. Inspect,test,adjustorreplaceheaterwatervalveandcontrols. 5. Inspect,test,andreplaceelectric,air,andvacuummotors,solenoids,andswitches. 6. Inspect,testandreplaceconstant/automatictemperaturecontrolpanels. 7. Inspect,test,andreplaceconstant/automatictemperaturecontrolmicroprocessor

(climatecontrolcomputer/programmer).

E. Refrigerant Recovery, Recycling, Handling, and Retrofit (4 questions)Note:Tasks1through5shouldbeaccomplishedinaccordancewithpublishedEPAand

appropriateSAE“J”standardsforR-12,R-134a,andEPAapprovedrefrigerant blends.

1. Maintainandverifycorrectoperationofcertifiedequipment. 2. IdentifyandrecoverA/Csystemrefrigerant. 3. Recyclerefrigerant. 4. Handle,labelandstorerefrigerant. 5. Testrecycledrefrigerantfornon-condensablegases. 6. RetrofitA/Csystemsfollowingindustry/manufacturers’acceptedproceduresand

federal/locallaws.



SAMplE QuESTiOnS HEATinG, vEnTilATiOn, And Air cOndiTiOninG (HvAc) SySTEMS (TEST T7)

QuESTiOnS:

1. Atruck’sA/Csystemdoesnotcoolproperlyduetoanicingevaporator problem. TechnicianAsaysthatastuck-closedcyclingswitchcouldbethecause. TechnicianBsaysthatarefrigerantoverchargecouldbethecause. Whoisright?

*(A)Aonly (C)BothAandB (B)Bonly (D)NeitherAnorB 2. ThesleeperA/Cunitisnotcooling.Asystemcheckshowsallpressuresare

normal.Whichoftheseisthemostlikelycause? (A)Apluggedreceiverdrier (B)Astuck-openexpansionvalve (C)Ashortedhighpressureswitch *(D)Astuck-closedrefrigerantsolenoidvalve

3. AnA/Csystemhasalowdischargepressure.whichofthesecouldbe thecause?

*(A)Aleakingcompressorseal (B)Arestrictedrefrigerantflowinthecondenser (C)Arestricedairflowoverthecondenser (D)Acompressorclutchthatwillnotengage

4. Duringreplacement,itisnoticedthatthetubesontheinletandoutletof aheatercoreareruptured.Themostlikelycauseis:

(A)alowcoolantlevel. (B)airinthecoolingsystem. *(C)incorrectcoolantprotection. (D)abadheatercontrolvalve.



5. Noairisflowingfromatruck’sHVACducts. TechnicianAsaysthatafailedblowermotorcouldbethecause. TechnicianBsaysthatastuckrecirculationairdoorcouldbethecause. Whoisright?


6. Arecovery/recyclemachinehasbeenusedtorecycleavehicle’srefrigerant.Themoistureindicatoronthemachineshowsthatmoistureispresent. Themostlikelycauseisa:

(A)fullrefrigerantstoragetank. (B)faultyairpurgevalve. *(C)saturatedfilter/drier. (D)faultystoragetankpressureswitch. Question 7 is not like the ones above. IthasthewordEXCEPT.Forthisquestion,lookforthechoicethatcould

NOT causethedescribedsituation.Readtheentirequestioncarefullybeforechoosingyouranswer.

7. Atruck’sA/Csystemhasjustbeenrepairedandfilledwiththeproperamountofrefrigerant.Thesystemblowscool,butnotcoldair.Thehigh-sidepressureis250psi,andthelow-sidepressureis50psi.AnyofthesecouldbethecauseEXCEPT:

(A)thecoolingfanisinoperative. *(B)apartiallyrestrictedexpansionvalve. (C)asystemoverchargedwithoil. (D)amissingradiatorfanshroud.




Content Questions Percentage Area in Test of Test A. Engine Systems 10 20% B. Cab and Hood 5 10% C. Electrical/Electronics 10 20% D. Frame and Chassis 22 44% 1. Brakes (10) 2. Drivetrain (4) 3. Steering, Tires, and Wheels (4) 4. Suspension, Frame, and 5th Wheel (4) E. Road/Operational Test 3 6%

Total 50 100%

TEST SpEcificATiOnS And liST prEvEnTivE MAinTEnAncE And inSpEcTiOn (pMi) (TEST T8)

A. Engine Systems (10 questions) 1. Reviewpastmaintenance/repairdocuments,drivervehicleconditionreports,and

brake/tirewearreport.Checkandrecordelectronicdiagnosticcodesandtrip/opera-tionaldata.Clearcodesanddata.

2. Checkengineoperation(includingunusualnoises,vibration,andexcessiveexhaustsmoke);recordidlerpm,governedrpm,andPTOrpm(ifapplicable).

3. Inspectvibrationdamper. 4. Inspectconditionofbelt(s),tensioner(s),andpulley(s);checkandadjustbelttension. 5. Checkengineforoil,coolant,air,andfuelleaks(EngineOffandEngineRunning). 6. Inspectenginemountsforloosenessanddeterioration. 7. Checkengineoillevelandcondition;checkdipsticksealandfillcapseal. 8. Checkenginecompartmentwiring,harnesses,connectors,andsealsfordamage,

mounting,andproperrouting. 9. Checkfueltanks,vents,mountings,lines,caps,andseals;checkanti-siphondevice

(ifapplicable).10. Inspectwaterseparator/fuelheater;drainwaterfromseparator;replacefuelfilter(s);

primeandbleedfuelsystem.11. Inspectcrankcaseventilationsystem.12. Checkexhaustsystemmountingsforloosenessanddamage.13. Checkengineexhaustsystemforleaks,excessivenoise,properrouting,andmissing

ordamagedcomponents(heatshieldsandguards).14. Checkairinductionsystempiping,chargeaircooler,hoses,clamps,mountings,

properrouting,andindicators;checkforairrestrictionsandleaks.



T8 liST (cOnTinuEd)

15. Inspectturbocharger(s)fornoise,oilandexhaustleaks;checkmountingsand connections;checkwastegate,variablegeometryturbocharger(VGT),linkages, andhoses.

16. Serviceorreplaceairfilter(s)asneeded.17. Inspectdieselemissioncontrolsystems,includingexhaustgasrecirculation(EGR),

exhaustgasrecirculation(EGR)cooler,dieselparticulatefilter(DPF),and/orcata-lyticconverter.

18. Checkfanclutch/huboperation,bearingconditionandnoise(includingviscous/ thermostatic,air,andelectricfantypes);inspectfanassemblyandshroudformissinganddamagedcomponents.

19. Inspectradiator(includingairflowrestriction,missing/corrodedfins,leaks,and damage)andmountings.

20. Pressuretestcoolingsystemandradiatorcap.21. Inspectcoolanthosesandclampsforleaks,damage,andproperrouting.22. Inspectcoolantrecoverysystem.23. Identifycoolanttype;checkcoolantforcontamination,supplementalcoolant

additives(SCAs),andprotectionlevel(freezepoint).24. Servicecoolantfilter/conditioner.25. Drainandrefillcoolingsystem;bleedairfromsystem;recovercoolant.26. Inspectwaterpumpforleaksandbearingplay.27. Changeengineoilandfilters;visuallycheckoilforcoolantorfuelcontamination;

inspectandcleanmagneticdrainplugs.28. Takeanengineoilsample.

B. Cab and Hood (5 questions) 1. Inspectkeyconditionandcheckoperationofignitionswitch. 2. Checkoperationofindicatorlights,warninglightsand/oralarms. 3. Checkoperationofinstruments/gaugesandpanellighting. 4. Checkoperationofelectronicpowertakeoff(PTO)andengineidlespeedcontrols

(ifapplicable). 5. Checkoperationofdefroster,heater,ventilation,andA/C(HVAC)controls. 6. Checkoperationofallaccessories. 7. Usediagnostictooloron-boarddiagnosticsystemtoreadcurrentandhistoric

diagnostictroublecodesfromelectronicmodules(includingengine,transmission,brake,supplementalrestraint,tractioncontrolandbodycontrolsystems).

8. Checkoperationofelectricandairhorns. 9. Checkconditionofsafetyequipment,includingflares,sparefuses,reflective

triangles,fireextinguisher,andallrequireddecals.10. Inspectseatbelts,seattethers,andsleeperrestraints.11.Checksupplementalrestraintsystem(SRS)forproperwarninglightoperationand

diagnostictroublecodes(ifapplicable).12. Inspectwiperbladesandarms.13. Checkwiperandwasheroperation.14. Checkforallrequiredvehiclepermits,registration,decals,andinspectionpapers.15. Inspectwindshieldglassforcracks,chips,clarity,discoloration/glazing,orother

damage;checksunvisoroperation.



T8 liST (cOnTinuEd)

16. Checkseatcondition,operation,mounting,andsuspensioncomponents.17. Checkdoorglassandwindowoperation.18. Inspectstepsandgrabhandles.19. Inspectmirrormountings,brackets,glass,heaters,andmotors.20. Inspectandrecordallobservedphysicaldamage.21. Lubricateallcabandhoodgreasefittings.22. Inspectandlubricatedoorandhoodhinges,latches,strikers,lockcylinders,linkages,

andcables.23. Inspectcabmountings,hinges,latches,linkages;serviceasneeded.24. Inspecttiltcabhydraulicpump,lines,andcylindersforleakage;inspecttiltcabsafety

devices;serviceasneeded.25. Checkaccelerator,clutch,andbrakepedaloperationandcondition.26. Checkcabrideheight;inspectcabairsuspensionsprings,mounts,hoses,valves,

shockabsorbers,andfittingsforleaksanddamage.27. Inspectfrontbumper,fairings,andmounts.28. InspectA/Ccondenserandlinesforconditionandvisibleleaks;checkmountings.29. InspectA/Ccompressorandlinesforconditionandvisibleleaks;checkclutch;check

mountings.30. CheckA/Csystemconditionandoperation.31. CheckHVACairinletfiltersandducts;serviceasneeded.32Checkauxiliarypowerunit(APU)operationandmounting;inspectfordamage,leaks,

andbelttension.

C. Electrical/Electronics (10 questions) 1. Inspectbatterybox(es),cover(s),andmountings. 2. Inspectbatteryholddowns,connections,cables,andcablerouting;serviceasneeded. 3. Checkandrecordbatterystateofcharge(opencircuitvoltage)andcondition. 4. Performbatterytest(loadandcapacitance). 5. Inspectstarter,mounting,connections,cables,andcablerouting. 6. Engagestarter;checkforunusualnoises,starterdrag,andstartingdifficulty. 7. Inspectalternator,mounting,wiring,andwiringrouting. 8. Performalternatorcurrentoutputtest. 9. Performalternatorvoltageoutputtest.10. Checkoperationofinteriorlights;serviceasneeded.11. Checkallexteriorlights,lenses,andreflectors;checkheadlightalignment;service

asneeded.12. Inspectandtesttrailerpowercordconnector,cable,andholder;serviceasneeded.

D. Frame and Chassis (22 questions)

1. Brakes (10 questions) 1. Checkairparkingbrakeoperation. 2. Checkandrecordairgovernorcut-inandcut-outsettings(psi). 3. Serviceairdrierasneeded.Checkairdrierpurgevalveoperationandairdrierheater,

ifequipped. 4. Checkairsystemforleaks(brakesreleased). 5. Checkairsystemforleaks(brakesapplied). 6. Drainairtanks;testone-wayanddouble-checkvalves.



T8 liST (cOnTinuEd)

7. Checklowairpressurewarningdevices. 8. Checkspringbrakeinversion/emergency(spring)brakecontrolvalve,ifequipped. 9. Checktractorprotectionvalve,ifequipped.10. Testairpressurebuild-uptime.11. Checkconditionandoperationofhandbrake(trailer)controlvalve,ifequipped.12. Performantilockbrakesystem(ABS)operationalsystemself-test.Performautomatic

tractioncontrol(ATC)operationalsystemself-test,ifequipped.13. Inspectcouplingairlines,holders,andgladhands.14. Checkbrakechambersandairlinesforsecuremountings,damage,andmissing

cagingplugs.15. Inspectandrecordfrontandrearbrakelining/padconditionandthickness.16. Inspectconditionoffrontandrearbrakedrums/rotors.17. Checkoperationandadjustmentoffrontandrearbrakeautomaticslackadjusters.18. CheckS-camshaftandbushingcondition.19. Lubricateallairbrakecomponentgreasefittings.20. Checkmastercylinderforleaksanddamage;checkfluidlevelandcondition.21. Inspecthydraulicbrakelines,fittings,flexiblehoses,andvalvesforleaksand

damage.22. Checkhydraulicparkingbrakeoperation;inspectparkingbrakeapplicationand

holdingdevices.23. Checkoperationofhydraulicsystem;pedaltravel,pedaleffort,andpedalfeel(drift).24. Inspectcalipersand/orwheelcylindersforleaksanddamage.25. Inspectpowerbrakebooster(s),hoses,andcontrolvalves.26. Checkand/oradjusthydraulicdrumbrakes.27. Checkoperationofhydraulicassistback-upsystemandwarningdevices.

2. Drivetrain (4 questions) 1. Checkoperationofrelease/throwoutbearingandclutchbrake. 2. Checkclutchlinkage/cableandleversforloosenessorbinding;lubricaterelease/

throwoutbearingasrequired. 3. Checkclutchmastercylinderfluidlevel;checkclutchmastercylinder,slavecylinder,

lines,andhosesforleaksanddamage. 4. Checkand/oradjustclutch. 5. Checktransmissionand/ortransfercasehousing,fasteners,seals,filter,cooler,and

coolerlinesforcracks,leaks,andproperrouting,ifequipped. 6. Checktransmissionwiring,connectors,seals,andharnessesfordamageandproper

routing. 7. Inspecttransmissionbreather,serviceasneeded. 8. Inspecttransmissionmountsforloosenessanddeterioration. 9. Checktransmissionoil/fluidlevelandcondition.10. InspectU-joints,yokes,driveshafts,andcenterbearingsforlooseness,damage,and

properphasing.11. Inspectaxlehousing(s)forcracksandleaks.12. Inspectaxlebreather(s);serviceasneeded.13. Lubricatealldrivetraingreasefittings.14. Checkdriveaxle(s)oillevel.15. Changedriveaxle(s)oilandfilter;checkandcleanmagneticplugs.



T8 liST (cOnTinuEd)

16. Checkpowertakeoff(PTO)unitoperationandmounting;checkPTOU-joints anddriveshaftforlooseness,damage,andproperphasing,ifequipped.

17. Changetransmissionoil/fluidandfilters;checkandcleanmagneticplugs.18. Taketransmissionoilsample.19. Takedriveaxle(s)oilsample.

3. Steering, Tires, and Wheels (4 questions) 1. Checksteeringwheelandcolumnoperationforfreeplayandbinding. 2. Checkpowersteeringpumpandhosesforleaksandmounting;checkfluidlevel

andcondition. 3. Changepowersteeringfluidandfilter. 4. Inspectsteeringgear(s)orrack-and-pinionforleaksandmounting. 5. InspectsteeringshaftsandU-jointsconditionandforproperphasing;inspectpinch

bolts,splines,Pitmanarm-to-steeringsectorshaft,draglink,tierodends,crosstube,andwheelstops.

6. Checkkingpinandthrustbearingwear. 7. Checkfrontandrearwheelbearings/hubassembliesforloosenessandnoise,

includingextendedservice(sealed,closetolerance,andunitized)assemblies. 8. Checkoillevelandconditioninallnon-driveaxlehubs;checkforleaks. 9. Adjustwheelbearingsasneeded(includingoneandtwonuttypes)inaccordance

withmanufacturer’sspecifications.10. Inspecttiresforirregularwearpatternsandpropermountingofdirectionaltires.11. Inspecttiresforcuts,cracks,bulges,andsidewalldamage.12. Inspectvalvecapsandstems.13. Measureandrecordtiretreaddepth;probeforimbeddeddebris.14. Checkandrecordtireairpressure;adjustasneeded.15. Checkforlooselugsand/orslippedwheels;checkmountinghardwarecondition;

serviceasneeded.16. Retorquelugs/nutsinaccordancewithmanufacturers’specifications.17. Inspectwheelsandspacersforcracksordamage.18. Checktirematching(diameterandtread)ondualtireinstallations.19. Lubricateallsteeringgreasefittings.

4. Suspension, Frame, and 5th Wheel (4 questions) 1. Inspectfrontandrearsuspensioncomponents(springs,hangers,shackles,spring

U-bolts,insulators,radiusrods,torquerods,loadpads,walkingbeams,and equalizers);checkU-bolttorqueinaccordancewithmanufacturers’specifications.

2. Inspectshockabsorbersforleaksandmounting. 3. Inspectairsuspensioncomponents(airsprings/bags,mounts,arms,hoses,valves,

linkage,andfittings)forleaksanddamage;checksuspensionrideheight. 4. Inspectoperationoftag/pusheraxleandcomponentsformountinganddamage. 5. Lubricateallsuspensiongreasefittings. 6. Checktandemaxlespacing. 7. Inspectfifthwheelmount,bolts,slider,airlines,locks,pivotpins,bushings,and

stops. 8. Testoperationoffifthwheellockingdevice;adjustasneeded. 9. Checkmudflaps,brackets,andreflectivedevices.10. Checkpintlehookassembly,mountingbolts,andlocks.



T8 liST (cOnTinuEd)

11. Cleanandinspectfifthwheelplateforcracksanddamage;lubricatefifthwheel plateandallgreasefittings.

12. Inspectframeandframemembersforcracksanddamage.13. Inspectbodyattachinghardware.14. Inspectcargoramps.Inspectliftgates,cylinders,controls,hoses,wiring,andwarning

decals;checkfluidlevel,serviceasneeded.15. Inspectrear(ICC/DOT)impactguard.

E. Road/Operational Test (3 questions) 1. Checkoperationofclutchandgearshift. 2. Checkoperationofallinstruments,gauges,andlights. 3. Checksteeringwheelforplay,binding,andcentering. 4. Checkoperationofautomaticorautomatedmechanicaltransmission. 5. Checkroadspeedlimiter. 6. Checkcruisecontrol. 7. Observeexhaustforexcessivesmoke. 8. Testservicebrakes. 9. Verifyengine/exhaustbrakeorretarderoperation.10. Checkoperationofbackupwarningdevices.



SAMplE QuESTiOnS prEvEnTivE MAinTEnAncE inSpEcTiOn (pMi) (TEST T8)

QuESTiOnS:

1. WhichoftheseistheminimumtiretreaddepthpermittedbyfederalDOTstandardsonallsteeraxletiresontrucks,tractors,orbuses?

(A)1/32in. (B)2/32in. *(C)4/32in. (D)5/32in.2. TechnicianAsaysthatthelowairbrakepressurewarninglampshouldbelit

whenthesupplysystempressureisbelow60psi. TechnicianBsaysthattheparkingbrakesshouldautomaticallyapplywhenthesupplysystemairpressurefallsbelow45psi. Whoisright?

(A)Aonly *(C)BothAandB (B)Bonly (D)NeitherAnorB 3. Thedriverofatractor/trailerreportsthattheengine’sfanhitstheshroudwhen

acceleratingunderaload.Themostlikelycauseis: (A)overspeedingtheengine. (B)impropervehicleshifting. (C)excessivefanbladeflexing. *(D)alooseenginemount.

4. Adriveaxlelubricantisamilkycolor.Themostlikelycauseis: (A)metalcontamination. (B)mixinglubricanttypes. (C)gasketsealercontamination. *(D)watercontamination.




5. ThePMinspectornoticesthat part“X”ismissing.Thiscouldcause:

*(A)fluidcontamination. (B)lossofstaticpressure. (C)excessivepedaleffort. (D)brakewarninglampillumination. 6. Whenpressuretestingacoolingsystem,

thetechnicianshouldapply: (A)5poundsofpressurewiththe

enginerunning. *(B)theamountofpressurelisted

ontheradiatorcap. (C)pressurenottoexceedthedangerzone

onthepressuregauge. (D)5poundsmorepressurethanlistedontheradiatorcap. 7. Whenperformingabatteryloadtestonamultiplebatteryvehicle: (A)connecttheloadtestclampstoanypositivebatterypostandground. (B)disconnectthegroundcable(s)fromtheframe. (C)connecttheloadtestampsclamparoundanegativevehiclebatterycable. *(D)disconnectthebatteriesfromeachother. Question 8 is not like the ones above. IthasthewordEXCEPT.Forthisquestion,lookforthechoicethatcould

NOT causethedescribedsituation.Readtheentirequestioncarefullybeforechoosingyouranswer.

8. AzeroreadingonanairrestrictiondashgaugecouldbecausedbyalloftheseEXCEPT:

(A)abadrestrictiongauge. *(B)apluggedairfilter. (C)anopeningintheintakesystem. (D)atornairfilter.



Thefollowingsourcesofinformationprovidecomprehensivelistingsoftrainingresourcesavailabletoworkingtechnicians:

Delmar Cengage LearningP.O.Box6904Florence,KY410221-800-487-8488www.autoed.cengage.comwww.cengage.com/delmar

Motor Age Training for Certification131WestFirstStreetDuluth,MN55802800-240-1968www.motorage.com

In Canada

Thomson Learning Nelson Canada1120BirchmountRoadScarborough,OntarioM1K5G41-800-268-222E-mail:[email protected]

MD PublicationsUndercarDigest,JulyIssueTransmissionDigest,SeptemberIssueP.O.Box2210Springfield,MO658011-800-274-7890

Motor Source GuideHearstBusinessPublishing,Inc.645StewartAve.GardenCity,NY11530www.motor.com

Fleet Equipment, April IssueP.O.Box7605Mt.Prospect,IL60056-7605www.truklink.com

induSTry TrAininG

Recursos de Educación en EspañolParaobteneraccesoalalistadeproveedoresdeeducación,ómaterialeseducativosenEspañoldiríjaseawww.ase.com;unavesallí,entreenlasección“Español”yprosigaalárea“ListadeEducadoresyMaterialesDidácticos.”

Spanish Language Training ResourcesForalistingoftrainingproviderswhooffertraining,ortrainingmaterialsinSpanishgotowww.ase.com;oncethere,enterthe“ServiceProfessionals”areaandclickon“SpanishLanguageTrainingResources.”

CASE: ASE Certification for Training Providers of Continuing Automotive Service Education. Visit www.natef.org/case/case_certified.cfm for periodic updates to this list. TheNationalInstituteforAutomotiveServiceExcellence(ASE)anditseducationalfoundation,theNationalAutomotiveTechniciansEducationFoundation(NATEF),offeravoluntarycertificationprogramforinstitutionsandorganizationsprovidingcontinuingautomotiveserviceeducation.ASEseekstoimprovethequalityofcontinuingautomotiveeducationandhelpautomotivetechniciansidentifyappropriatetrainingsourcesandactivitiesbyevaluatingandcertifyingprovidersofcontinuingautomotiveserviceeducationagainstCASEStandards. TheCASEprogramdiffersfromASE’sexistingentry-leveltrainingprogramcertificationinthatitaddressesthetrainingprovider’sprocessofdevelopinganddeliveringtrainingasopposedtoprescribingspecificprogramcontent.Elementsoforganization,structureandmethodswhichappeartocontributesignificantlytothedevelopmentanddeliveryofhighqualityautomotiveserviceeducation,havebeenidentifiedandincorporatedintotheCASEStandards. ThefollowingtrainingprovidershaveachievedCASEcertification.Pleasenotethat*indicatesaproprietaryprogramunavailabletoalltechnicians.



induSTry TrAininG

3M Industrial and Transportation Business Services Training and Development3MCenterBuilding225-1N-01St.Paul,MN55144651-737-0141www.3m.com/automotive

ACDelco Service Training6200GrandPointDr.,MC#2-316GrandBlanc,MI48439800-825-5886prompt1www.acdelcotechconnect.com

Affinia Under Vehicle GroupTechnicalServicesDepartment4400PrimeParkwayMcHenry,IL60050815-363-9000–askfortechnicalwww.raybestos.com

AKZO NOBEL Coatings Inc., Car Refinishes5555SpaldingDr.Norcross,GA30092770-242-5760www.akzonobelcarrefinishes.net

American Automobile Association, Inc.1000AAADr.Heathrow,FL32746407-444-7169or407-444-8041AllanStanley,[email protected],[email protected]

*American Honda Automobile Service Training1919TorranceBlvd.Torrance,CA90501310-783-3557www.honda.com

Automotive Spray Equipment Technologies (ASET)3703WestParkwayBlvd.SaltLakeCity,UT84120801-964-6646www.asetusa.com

ATech Training, Inc12290ChandlerDr.POBox297Walton,KY41094859-485-7229ext.109www.atechtraining.com

BASF Automotive Refinish Division26701TelegraphRd.Southfield,MI48034248-304-5200www.basfrefinish.com

BP Global Fuels Technology150W.WarrenvilleRd.800BuildingNaperville,IL60563312-729-4212www.fuelcertification.com

Chief Automotive Systems996IndustrialDr.Madison,IN47250800-445-9262www.chiefautomotive.com

CARQUEST Technical Institute4401AtlanticAve.Raliegh,NC27604919-573-3000www.CARQUEST.com/CTI

Collision Management Services Inc.2040RLordBaltimoreDr.Baltimore,MD21244410-944-3383www.ineedcms.com/Training.html

Delphi Integrated Service Solutions5820DelphiDr.Troy,MI48098800-545-2220 CustomerSupportwww.delphi-iss.com

DuPont Performance Coatings500EagleviewBlvd.Exton,PA19341610-458-6323www.pc.dupont.com



induSTry TrAininG

EAST Training Inc.4404SylonBlvd.Hainesport,NJ08036609-267-2223www.easttraining.com

Federal Mogul Technical Education Centers 6565WellsAve.St.Louis,MO63133314-977-0684www.federal-mogul.com

Fox Valley Technical College1825N.BluemoundDr.Appleton,WI54912920-993-5163www.fvtc.edu/public

*General Motors Service Technical College30501VanDykeAve.,M/C480-204-100Warren,MI48090586-947-9704www.gmstc.com

Hunter Engineering11250HunterDr.Bridgeton,MO63044314-731-0000www.hunter.com

I-CAR (Inter-Industry Conference on Auto Collision Repair)5125TrilliumBlvd.HoffmanEstates,IL60192800-422-7872www.i-car.com

Iwata Medea3703WestParkwayBlvd.WestValleyCity,UT87120801-964-6646www.asetusa.com

Jiffy Lube International700Milam,Room24038PNTHouston,TX77002713-546-3957www.jiffylube.com

Kent Automotive6200OakTreeBlvd.,#350Independence,OH44131216-642-5973www.kent-automotive.com

Lawson State Community College11009thAve.,SWBessemer,AL35022205-929-3521www.lawsonstate.edu

Lew Kinney & AssociatesOn-siteWeldingTrainingandCertificationsPOBox511,184StateRoute314Centerburg,OH43011740-625-6342

*Lexus, A Division of Toyota Motor Sales, Inc., U.S.A.19001S.WesternAve.Torrance,CA90509TechnicalTraining310-468-4958www.lexus.com

Martin Senour Automotive Finishes7019HighgroveRd.BurrRidge,IL60527630-887-7516www.martinsenour-autopaint.com

Megatech Corporation525WoburnSt.,Suite3Tewksbury,MA01876800-767-6342(US)978-937-9600(Int’l)www.megatechcorp.com

Melior, Inc.200CahabaParkCircleWest,Suite250Birmingham,AL35242205-298-8300www.melioronline.com

National Automotive Parts Association (NAPA)2999Circle75Pkwy.Atlanta,GA30339800-292-NIAT(6428)www.niat-training.com



induSTry TrAininG

* This program is proprietary and therefore not available to all technicians.

National Appraisal Institute10150CanogaAveChatsworth,CA91311818-775-1370www.nainstitute.com

Nationwide Training Organization9243ColumbusPikeLewisCenter,OH43035614-840-7169www.nationwide.com

*Navistar, Inc.3033WayneTerraceFortWayne,IN46806260-461-1951www.navistar.com

*Nissan North America, Inc.CustomerLoyaltyandTrainingP.O.Box685001Franklin,TN37068615-725-8319www.nissantechinfo.com

*Penske Truck LeasingRoute10PheasantRd.,POBox563Reading,PA19607610-775-6479www.gopenske.com

PPG Industries19699ProgressDr.Strongsville,OH44149440-572-6784www.ppg.com

Raytheon Professional Services L.L.C.1919TechnologyDr.Troy,MI48083248-837-6777www.rps.com

Saint Gobain Abrasives1NewBondSt.Worcester,MA01606508-795-2774www.nortonautomotive.comwww.aa.carborundumabrasives.com

SEM Products, Inc.1685OverviewDr.RockHill,SC29730803-207-8231www.semproducts.com

Sherwin-Williams Automotive Finishes Corp. 7019HighgroveRd.BurrRidge,IL60527630-887-7516www.sherwin-automotive.com

Solera, Inc.P.O.Box151376AltamonteSprings,FL32715858-724-1600www.training.audatex.us

Specialty Products Company4045SpecialtyPlaceLongmont,CO80504303-772-2103www.spcalignment.com

Technical Training, Inc. (TTi)2750ProductDr.RochesterHills,MI48309248-853-5550or800-837-5222www.ttinao.com

*Toyota Motor Sales, USA, Inc.19001S.WesternAve.Torrance,CA90509-2991310-468-7171www.toyota.com

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