B5 Mechanical and Electrical Components

  • Suspension and Steering
  • Electrical
  • Brakes
  • Heating and Air Conditioning
  • Engine Cooling Systems
  • Drive Train
  • Fuel, Intake, and Exhaust Systems
  • Restraint Systems

Mechanical and Electrical Components

A. Suspension and Steering (11 questions)

1. Identify and replace one-time use suspension fasteners.

2. Inspect, diagnose, and replace rack and pinion steering gear, inner tie rod ends, and bellows boots.

3. Inspect, diagnose, remove, and replace power steering pump, pulley, belts, hoses, fittings, and pump mounts. Identify fluid type specific to the vehicle; perform bleeding procedure if required.

4. Inspect and diagnose manual and power steering gear (non-rack and pinion types) noises, binding, uneven turning effort, looseness, hard steering and lubricant leakage problems; determine needed repairs.

5. Inspect and diagnose manual and power rack and pinion steering gear mount

bushings, brackets, noises, vibration, looseness, hard steering, and lubricant leakage problems; ensure proper mounting position.

6. Inspect, diagnose, and repair steering linkage geometry (attitude/parallelism).

7. Inspect and diagnose sector shaft; inspect and replace pitman arm.

8. Inspect, diagnose, and replace relay rod (center link/intermediate rod/drag link).

9. Inspect, diagnose, remove and replace idler arms and mounting locations; determine needed actions.

10. Inspect, diagnose, remove, and replace tie rod sleeves, clamps, and tie rod ends.

11. Inspect, diagnose, remove, and replace steering linkage damper.

12. Inspect, diagnose, remove, and replace upper and lower control arms, strut rods, and bushings.

13. Inspect, diagnose, remove, and replace upper and lower ball joints.

14. Inspect, diagnose, remove, and replace steering knuckle/spindle/hub and bearing assemblies.

15. Inspect, diagnose, remove, and replace coil springs and spring insulators (silencers).

16. Inspect, diagnose, replace, and/or adjust front suspension torsion bars; inspect mounts.

17. Inspect, diagnose, and replace strut cartridge or assembly, upper bearing, and mount.

18. Inspect, diagnose, remove, and replace rear suspension transverse links, control arms, bushings, and mounts.

19. Inspect, diagnose, remove, and replace rear suspension leaf spring(s), leaf spring insulators (silencers), shackles, brackets, bushings, and mounts.

20. Inspect and diagnose front and/or rear axle assemblies for damage and misalignment; remove, repair, or replace as required.

21. Inspect, diagnose, and replace shock absorbers, load-leveling devices, air springs, and associated lines, fittings, and components.

22. Inspect and diagnose, adjust, or replace components (including sensors, switches, actuators, and control units) of electronically-controlled suspension and steering systems (including electronically controlled hydraulic and electronically assisted steering systems).

23. Measure vehicle ride height; determine needed repairs.

24. Inspect, remove, replace, and align front and rear subframes (including engine cradles and axle carriers).

25. Inspect and diagnose steering column damage, looseness, and binding problems (including positioning mechanisms), inspect mounting locations; determine needed actions.

26. Inspect, diagnose, and replace steering shaft U-joint(s), flexible coupling(s), collapsible columns, and steering wheels.

27. Diagnose vehicle noise, vibration and harshness (NVH) problems (including suspension, tire, and driveline); determine needed action.

28. Diagnose vehicle wandering, pulling, hard steering, bump steering, memory steering, torque steering, and steering return problems; determine needed repairs.

29. Measure front and rear wheel camber; determine needed repairs or adjustments.

30. Measure caster; determine needed repairs or adjustments.

31. Measure front and rear wheel toe; determine needed repairs or adjustments.

32. Identify toe-out-on-turns (turning radius) and related problems; determine needed repairs.

33. Identify SAI (steering axis inclination), included angle, and scrub radius related problems; determine needed repairs.

34. Identify thrust angle related problems; determine needed repairs or adjustments.

35. Measure wheel setback and wheel base; determine needed actions.

36. Perform pre-alignment inspection; identify tire wear patterns and check air pressure; determine needed actions.

37. Inspect wheels, tires and pressure monitor sensors (TPM) for damage; balance tires; determine needed repairs.

38. Inspect and diagnose wheel, hub, and axle bearing for damage; determine needed action.

39. Inspect and diagnose front and rear stabilizer systems (anti-sway bar); determine needed repairs.

40. Perform initialization or calibration procedures following suspension and/or steering system repairs.

41. Verify effectiveness of suspension and steering repairs.

B. Electrical (10 questions)

1. Measure voltage in electrical wiring circuits with a DMM (digital multimeter); determine repair procedure.

2. Measure continuity and resistance in electrical wiring circuits and components with a DMM (digital multimeter); determine repair procedure.

3. Check electrical circuits, wiring, connectors, terminals, sockets, and routing; determine needed action.

4. Inspect, test, and replace fusible links, circuit breakers, and fuses.

5. Inspect, test, and replace relays.

6. Inspect, test, repair and/or replace electrical circuit switches.

7. Inspect, test, and replace electrical motors.

8. Inspect, test, clean, charge, and replace battery, battery cables, connectors, and clamps.

9. Identify programmable electrical/electronic components and modules; determine needed repairs.

10. Inspect, test, remove, and replace alternator/generator, drive belts, pulleys, tensioners, and fans; inspect and adjust alignment.

11. Align/aim headlamps and fog/driving lamps.

12. Inspect, test, adjust, and repair or replace components of exterior lighting systems; verify system operation.

13. Inspect, test, and repair or replace components of interior lighting systems; verify system operation.

14. Inspect, test, repair or replace horn system components; verify system operation.

15. Inspect, test, repair or replace components of wiper/washer systems; verify operation.

16. Inspect, test, repair or replace components of power window systems; verify operation.

17. Inspect, test, repair or replace components of power seats, heated/cooled seats; verify operation.

18. Inspect, test, repair or replace components of electrical, mechanical door and hatch/trunk locks; verify operation.

19. Inspect, test, repair or replace components of power sliding doors and power liftgates; verify system operation.

20. Inspect, test, repair or replace components of keyless lock/unlock devices and security systems; verify system operation.

21. Inspect, test, repair or replace electrical and mechanical components of sunroofs or convertible/retractable tops; verify system operation.

22. Inspect, test, repair or replace electrically heated mirrors, windshields, and back glass; verify operation.

23. Inspect, test, repair or replace electrical antennas; verify operation.

24. Inspect, test, repair or replace electrical interior and exterior mirrors; verify operation.

25. Retrieve diagnostic trouble codes (DTCs); verify malfunction indicator lamp (MIL) status; determine needed repairs.

26. Identify personal safety precautions, safe battery handling, and high voltage system diagnostic and repair considerations associated with hybrid/electric vehicles.

27. Inspect, test and diagnose operation of advanced driver assistance systems (such as: collision avoidance, active cruise control, back-up camera/sensors, lane departure, park assist).

28. Perform initialization, calibration or synchronization procedures following body control systems repair.

C. Brakes (4 questions)

1. Inspect brake lines, hoses and fittings for leaks, dents, kinks, rust, cracks or wear; tighten fittings and supports; replace brake lines (double flare and ISO types), hoses, fittings, seals, and supports.

2. Inspect/test brake fluid; determine proper fluid type for application.

3. Bleed (manual, pressure, vacuum, or surge) and/or flush hydraulic brake system; verify system operation.

4. Inspect, remove, and replace disc brake rotors or drums; adjust as needed.

5. Inspect and replace wheel studs and fasteners. Reinstall wheels and torque fasteners.

6. Inspect brake caliper mounts and slides for wear and damage; determine needed repairs.

7. Inspect parking brake system operation; repair or adjust as necessary; verify operation.

8. Identify, test, and replace ABS wheel speed sensor components.

9. Depressurize ABS hydraulic system.

10. Identify, repair or replace traction control and electronic stability control components; verify operation.

D. Heating and Air Conditioning (5 questions)

1. Recover, recycle and recharge A/C system; identify refrigerant and oil type, determine oil and refrigerant capacities; leak test and check high and low side gauge readings to verify system operation.

2. Inspect, adjust, and replace A/C compressor drive belts; check pulley tensioner alignment and clutch operation.

3. Inspect, remove, and replace A/C compressor clutch and mountings.

4. Inspect, repair or replace A/C system mufflers, hoses, lines, fittings, pressure switches, valves, and seals.

5. Verify A/C condenser air flow and cooling fan operation.

6. Inspect, test, and replace A/C system condenser, mountings, seals, and deflectors.

7. Remove and replace receiver/drier or accumulator/drier.

8. Remove and replace evaporator; inspect evaporator housing and water drain.

9. Inspect, test, repair or replace heating, ventilating, and A/C system, electrical/vacuum and mechanical controls.

10. Inspect, test, clean, and repair or replace heating, ventilating, and A/C ducts, housing(s), doors, hoses, filters, and outlets.

11. Inspect, repair or replace heating system hoses, lines, fittings, seals and components; verify operation.

12. Perform initialization, calibration, or synchronization procedures following A/C system repairs if required.

E. Engine Cooling Systems (4 questions)

1. Inspect, test, remove, and replace radiator, mounts, pressure cap, coolant recovery system, hoses, and water pump.

2. Remove and replace thermostat, by-pass, and housing.

3. Recover, flush, bleed, and refill system with proper coolant, verify protection level.

4. Inspect, remove, and replace electrical/mechanical cooling fan components; verify operation.

5. Inspect, remove, and replace auxiliary oil/fluid coolers and components.

F. Drive Train (5 questions)

1. Inspect, remove, and replace powertrain assembly and components; inspect, replace, and align powertrain mounts, subframes, and engine cradles.

2. Inspect, remove, and replace electronic components, wires, terminals, and connectors.

3. Inspect, remove, replace, and adjust electrical, mechanical or hydraulic shift/throttle and clutch components.

4. Inspect, remove, and replace front and/or rear drive axle assembly.

5. Inspect, remove, and replace half shafts and constant velocity (CV) joints and components.

6. Inspect, remove, and replace drive shafts and universal joints.

7. Inspect, remove, and replace transaxles, transmissions, and transfer cases.

G. Fuel, Intake and Exhaust Systems (3 questions)

1. Inspect, remove, and replace exhaust manifold, exhaust pipes, mufflers, converters, sensors, resonators, tail pipes, heat shields, and components.

2. Inspect, remove, and replace fuel tank, straps, fuel pump, fuel tank filter, rollover valve, fuel cap, fuel filler hose, fuel filler-to-body seal, and inertia switch; inspect and replace fuel lines and hoses; check fuel for contaminants.

3. Inspect, remove, and replace intake manifold, air cleaner, turbocharger, intercooler, hoses, and sensors.

4. Inspect, remove, and replace canister, filter, sensors, vent, and purge lines of fuel vapor control systems; ensure proper routing.

H. Restraint Systems (8 questions)

1. Inspect, remove, and replace seatbelt and shoulder harness assembly and components; verify operation.

2. Inspect restraint system mounting areas for damage; repair or replace as needed.

Research applicable vehicle service information to determine if components are reusable.

3. Deactivate, inspect, replace, and reactivate supplemental restraint system (SRS) and components; verify system operation readiness.

4. Inspect, remove, replace, and dispose of deployed and non-deployed airbag(s) and pretensioners; store airbag(s) during vehicle service.

5. Use diagnostic trouble codes (DTCs) to diagnose and repair the Supplemental Restraint System (SRS), including occupant classification systems (OCS).

6. Perform initialization, calibration, or synchronization procedures following restraint system repairs.