1. T-DAP MAP 32
WPP

2. Agenda Toyota General Information Fire Safety Vehicle Dimensions
Nameplates
VIN
Fire Safety
Vehicle Dimensions
Tools & Measurement

3. Toyota Nameplates Found on cowl panel Information
Model
Engine type
VIN/Frame number
Body colour
Trim code
Transmission code
Axle code
Plant name code
Since 1989 – replaced with door certification label

4. VIN Breakdown
All VIN numbers (Vehicle Identification Numbers) have been 17 digits (alpha-numeric) since 1981
JT2BA02E3T
What do all the positions mean?

5. VIN Breakdown What year is it? 1980 started with “A”
2010 will start with “A” again

6. Fire Safety
Types of Fire Extinguishers
Classes

7. Vehicle Dimensions

8. Tools & Safety
Hand Tools
SSTs
Measuring Tools

9. Vernier Calipers
Is considered a precision measuring tool as it can provide information to hundredths of millimeters and thousandths of inches
“Vernier” means small moveable scale that runs parallel to a fixed scale

10. Vernier Calipers

11. Vernier Calipers

12. Vernier Calipers

13. Vernier Calipers
Proper use

14. Vernier Calipers
Proper use

15. Vernier Calipers
Proper use

16. Vernier Calipers
Proper use

17. Vernier Calipers

18. Vernier Calipers

19. Vernier Calipers

20. Vernier Calipers

21. Vernier Calipers
applet

22. Micrometers
Two types
Inside and outside micrometers
Used to measure inner and outer diameters respectively
Precision vs. verniers

23. Micrometers
Construction

24. Micrometers

25. Micrometers How does it work?
As the thimble turns on it’s threads, if the pitch of the thread is 1mm, for each revolution of the thimble, the spindle moves 1 mm
Therefore, the markings on the thimble are divisions of 1mm.
What do the markings on the outer sleeve represent?

26. Micrometers Zeroing/calibration Dealing with rotating parts
Must make sure, for accuracy sake that micrometers are calibrated
Clean surfaces
Use ratchet stopper! (I mean properly use)
Use calibration block (usually comes with mic)
Use lock clamp
Line up zero with index line

27. Micrometers
Zeroing!

28. Micrometers Reading micrometers
Make sure micrometer is type you want e.g. imperial/metric
Take note of micrometer size e.g mm, mm, mm, 0-1 inch,3-4 inch
Use ratchet end slowly to fit mic to object
Close lock clamp

29. Micrometers Reading micrometers
From the scale above the index line, note the number of whole units
Note the number of partial units below the index line
From the index line, note the reading on the thimble
Add together to get reading

30. Micrometers

31. Micrometers

32. Micrometers

33. Micrometers

34. Micrometers

35. Micrometers

36. Micrometers

37. Ten-thousandths?
Some micrometers have another vernier style scale to measure to the ten-thousandths of an inch

38. Ten-thousandths?

39. PMI Care Proper use and care Always wipe tool clean Always zero
Ensure tool in good working condition
Ensure surfaces are clean and dry *
Never force tool
When storing – clean & dry, use WD-40
Store open – let air circulate
Never touch tips

40. Inside Micrometers
Reads same way as micrometer (same scales, lines etc.)
More difficult to use
Make sure you know starting length!
Open mic until touches and make sure you are on true plane
Position correctly

41. Inside Micrometers

42. Inside Micrometers

43. Depth Micrometers
Reads same way as micrometer (same scales, lines etc.)
Used for determining depth
Can add/remove rods

44. Depth Micrometers

45. Telescoping Gauges
Used for measuring bore diameters and other clearances
Also called “snap gauges”
Available in small (small bore gauges) up to 6”

46. Telescoping Gauges Consists of two telescoping spring-loaded plungers
A handle
Lock screw
* Small bore gauges are slightly different

47. Telescoping Gauges To use: Compress plungers
Lightly tighten lock screw
Install into bore
Loosen lock screw; plungers expand
tighten lock screw
Measure with micrometer or other proper measuring instrument

48. Telescoping Gauges

49. Telescoping Gauges

50. Telescoping Gauges Do not:
Open lock screw and allow plungers to open all the way unobstructed
Over tighten the lock screw
Treat the same as a PMI

51. Dial indicators Used for measuring movement
Runout, parallelism, flatness etc.
Consists of a body with outer ring
Body has connection for mounting
Stem and spindle (tips)
Pointer and revolution counter

52. Dial indicators

53. Dial indicators Magnetic Stand Vice grips and flexible stand
Rigid clamp stand

54. Dial indicators

55. Dial indicators

56. Dial indicators
Important to make sure spindle is at 90° to the item being measured
Adjust zero point
May count above and below zero line
Use “V” blocks for measuring shaft runout (cam/crank etc.)

57. Dial indicators

58. Dial indicators

59. Dial indicators

60. Cylinder Gauge Used to measure bore diameters with greater accuracy
Works similar to inside micrometer but with dial gauge and spring loaded measuring point

61. Cylinder Gauge

62. Cylinder Gauge
Care must be taken to accurately calibrate tool with washers and rods
How to measure
Measure work with vernier to select correct washer and rod
Set micrometer to decided length and place cylinder gauge in micrometer. Zero gauge. Gauge is now exact to micrometer reading.
Place tool in work. Move tool to find lowest point. This gives accurate and centered reading

63. Cylinder Gauge

64. Cylinder Gauge

65. Feeler Gauges
Thin strip of metal or plastic of known and closely controlled thickness
Usually come in a set where desired thickness can be pivoted out to use
Uses
Piston ring end gap, clearances, endplay, spark plug gap

66. Feeler Gauges

67. Feeler Gauges
Special gauges made from plastic and brass for use on magnetic parts eg. Crank/speed sensors
Special round-wire gauge for spark plug

68. Straightedge
A precise machined bar, totally flat and straight used to check flat surfaces
Cylinder head, block
Used with feeler gauge to determine warpage

69. Straightedge

70. Torque Definition: “A turning or twisting force”
Torque is a twisting force equal to the distance from the pivot point, times the force applied
Expressed in N-m (newton-metres) or lb-ft (pound feet)
Note: Newtons are sometimes replaced by kilograms or kg giving kg-m. * Watch because 1 N = 9.8kg

71. Torque Q: What is a torque wrench?
A: It makes sure that big, burly mechanics and those of slighter builds agree on when a bolt is “tight.”
Based on Hooke’s Law that simply states, “the extension of a spring (or other stretch object) is directly proportional to the force acting on it”

72. Torque

73. Torque
Calibrated scale measures beams bend

74. Torque

75. Torque 4 types of torque wrenches in various ranges
Beam (like previous slides) – old, not highly accurate
Click type – most common – wrench emits audible “click” when desired torque reached
Dial type – has a “dial indicator” style gauge that points to the amount of torque exerted on the wrench (some have light/buzzer)
Digital – displays torque digitally (may have light/buzzer)

76. Torque wrench - beam

77. Torque wrench - clicker

78. Torque wrench - clicker

79. Torque wrench - clicker

80. Torque wrench - dial

81. Torque wrench - dial

82. Torque wrench – use for accurate readings
Specs – make sure you find PROPER specs
Mentally divide reading by 3
Hold torque wrench at 90° to fastener
Tighten to 1/3 torque
Tighten to 2/3 torque
Tighten to torque value -10
Tighten to torque value
Recheck torque

83. Torque wrench – Do’s Use at 90° to fastener Grip properly at handle
In vertical applications, push down not pull up
Use good sockets
Use smooth motion
Zero torque and release tension after use

84. Torque wrench – Don’ts “jerk” the torque wrench
Continue after torque setting achieved
Use a torque wrench for loosening fasteners
Use cheater bars – torque values distorted

85. Torque wrench - cautions
Avoid use of torque wrench at limits
accuracy

86. Torque wrench - calibration
Torque wrenches can go out of calibration
Responsibility of tool owner to calibrate
Usually based on use not just time

87. Torque wrench - adapters
Adding adapters to a torque wrench will change torque value
Demo
Using socket extensions – 6”

88. Torque wrench
Adding adapters to a torque wrench will change torque value
Demo
Using socket extensions – 6”