6. (Continued) Z = Italy U = Romania K = Korea 5 = United States Y = Sweden T = Czechoslovakia J = Japan 4 = United States X = Russia S = England 9 = Brazil 3 = Mexico W = Germany R = Taiwan 8 = Argentina 2 = Canada V = France L = China 6 = Australia 1 = United States

8. (Continued) 6 = 2006/2036 W = 1998/2028 L = 1990/2020 C = 1982/2012 7 = 2007/2037 X = 1999/2029 M = 1991/2021 D = 1983/2013 8 = 2008/2038 Y = 2000/2030 N = 1992/2022 E = 1984/2014 9 = 2009/2039 1 = 2001/2031 P = 1993/2023 F = 1985/2015 2 = 2002/2032 R = 1994/2024 G = 1986/2016 3 = 2003/2033 S = 1995/2025 H = 1987/2017 5 = 2005/2035 V = 1997/2027 K = 1989/2019 B = 1981/2011 4 = 2004/2034 T = 1996/2026 J = 1988/2018 A = 1980/2010

9. Figure 1-1 Typical vehicle identification number (VIN) as viewed through the windshield.

13. Figure 1-2 The vehicle emission control information (VECI) stick is placed under the hood.

15. Figure 1-3 A typical calibration code sticker on the case of a controller. The information on this sticker is often needed when ordering parts or a replacement controller.

17. Figure 1-4 Engine block identification can be either cast or stamped or both.

22. Figure 1-5 A factory service manual contains all specifications and procedures for a particular vehicle or model in one or more volumes.

23. Figure 1-6 Electronic service information is available from aftermarket sources such as All-Data and Mitchell-On-Demand as well as on websites hosted by the vehicle manufacturer.

24. Figure 1-7 Technical service bulletins are issued by vehicle manufacturers when a fault occurs that affects many vehicles with the same problem.

28. Figure 1-8 The dimensions of a typical bolt showing where sizes are measured. The crest is the same as the major diameter.

29. Figure 1-9 Thread pitch gauge used to measure the pitch of the thread. This bolt is 1/2-in. diameter with 13 threads to the inch (1/2-13).

30. Figure 1-10 Bolts and screws have many different heads which determine what tool must be used.

31. Figure 1-11 The American National System is one method of sizing fasteners.

33. Figure 1-12 The metric system specifies fasteners by diameter, length, and pitch.

35. Figure 1-13 Stronger threads are created by cold-rolling a heat-treated bolt blank instead of cutting the threads using a die.

38. Figure 1-14 Metrick bolt (cap screw) grade markings and approximate tensile strength.

40. Figure 1-15 Types of lock nuts. On the left, a nylon ring; in the center, a distorted shape; and on the right, a castle for use with a cotter key.

41. Figure 1-16 Various types of nuts (top) and washers (bottom) serve different purposes and all are used to secure bolts or cap screws.

44. Figure 1-17 A typical 110-volt electric soldering gun.

45. Figure 1-18 A typical 110-volt electric soldering pencil.

47. Figure 1-19 Many different types of screw heads have been used over the years in a variety of applications.

48. Figure 1-20 Combination wrench. The openings are the same size at both ends. Notice the angle of the open end to permit use in close spaces.

49. Figure 1-21 Three different qualities of open-end wrenches. The cheap wrench on the left is made from weaker steel and is thicker and less accurate machined than the standard in the center. The wrench on the right is of professional quality (and price).

50. Figure 1-22 Flare-nut wrench; also known as a line wrench, fitting wrench, or tube-nut wrench. This style of wrench is designed to grasp most of the flats of a six-sided (hex) tubing fitting to provide the most grip without damage to the fitting.

51. Figure 1-23 Box-end wrench;recommended to loosen or tighten a bolt or nut where a socket will not fit. A box-end wrench has a different size at each end and is better to use than an open-end wrench because it touches the bolt or nut around the entire head instead of at just two places.

52. Figure 1-24 Open-end wrench. Each end has a different-sized opening and is recommended for general usage. Do not attempt to loosen or tighten bolts or nuts from or to full torque with an open-end wrench because it could round the flats of the fastener.

53. Figure 1-25 Adjustable wrench. The size (12 inches) is the length of the wrench, not how far the jaws open!

54. Figure 1-26 A flat-blade (or straight-blade) screwdriver (on the left) is specified by the length of the screwdriver and width of the blade. The width of the blade should match the width of the screw slot of the fastener. A Phillips-head screw-driver (on the right) is specified by the length of the handle and the size of the point at the tip. A #1 is a sharp point, a #2 is most common (as shown), and a #3 Phillips is blunt and is only used for larger sizes of Phillips-head fasteners.

55. Figure 1-27 Assortment of pliers. Slip-joint pliers (far left) are often confused with water pump pliers (second from left).

56. Figure 1-28 A ball-peen hammer (top) is purchased according to weight (usually in ounces) of the head of the hammer. At bottom is a soft-faced (plastic) hammer. Always use a hammer that is softer than the material being driven. Use a block of wood or similar material between a steel hammer and steel or iron engine parts to prevent damage to the engine parts.

57. Figure 1-29 Typical drive handles for sockets.

58. Figure 1-30 Various socket extensions. The universal joint (U-joint) in the center (bottom) is useful for gaining access in tight areas.

59. Figure 1-31 Socket drive adapters. These adapters permit the use of a 3/8-inch ratchet with 1/2-inch drive sockets, or other combinations as the various adapters permit. Adapters should not be used where a larger tool used with excessive force could break or damage a smaller-sized socket.

60. Figure 1-32 A 6-point socket fits the head of the bolt or nut on all sides. A 12-point socket can round off the head of a bolt or nut if a lot of force is applied.

61. Figure 1-33 Standard 12-point short socket (left), universal joint socket (center), and deep-well socket (right). Both the universal and deep well are 6-point sockets.

62. Figure 1-34 Various punches on the left and a chisel on the right.

63. Figure 1-35 Using a die to cut threads on a rod.

64. Figure 1-36 Dies are used to make threads on the outside of round stock. Taps are used to make threads inside holes. A thread chaser is used to clean threads without removing metal.

65. Figure 1-37 Starting a tap in a drilled hole. The hole diameter should be matched exactly to the tap size for proper thread clearance. The proper drill size to use is called the tap drill size.

72. Figure 1-38 (a) A beginning technician can start with some simple basic hand tools. (b) An experienced, serious technician often spends several thousand dollars a year for tools such as those found in this large (and expensive) tool box. A

73. Figure 1-38 (a) A beginning technician can start with some simple basic hand tools. (b) An experienced, serious technician often spends several thousand dollars a year for tools such as those found in this large (and expensive) tool box. B

74. Figure 1-39 An inexpensive muffin tin can be used to keep small parts separated.

75. Figure 1-40 A good fluorescent trouble light is essential. A fluorescent light operates cooler than an incandescent light and does not pose a fire hazard as when gasoline is accidentally dropped on an unprotected incandescent bulb used in some trouble lights.

76. Figure 1-41 Synthetic wintergreen oil can be used as a penetrating oil to loosen rusted bolts or nuts.

77. Figure 1-42 A typical 1/2-inch drive air impact wrench.

78. Figure 1-43 This air impact wrench features a variable torque setting using a rotary knob; the direction of rotation can be changed by pressing the buttons at the bottom.

79. Figure 1-44 A typical battery-powered 3/8-inch drive impact wrench.

80. Figure 1-45 A black impact socket. Always use impact-type sockets whenever using an impact wrench to avoid the possibility of shattering the socket, which can cause personal injury.

81. Figure 1-46 An air ratchet is a very useful tool that allows fast removal and installation of fasteners, especially in areas that are difficult to reach or do not have room enough to move a hand ratchet wrench.

82. Figure 1-47 This typical die grinder surface preparation kit includes the air-operated die grinder as well as a variety of sanding disks for smoothing surfaces or removing rust.

83. Figure 1-48 A typical pedestal grinder with a wire wheel on the left side and a stone wheel on the right side. Even though this machine is equipped with guards, safety glasses or a face shield should always be worn whenever working using a grinder or wire wheel.

84. Figure 1-49 Protective gloves such as these vinyl gloves are available in several sizes. Select the size that allows the gloves to fit snugly. Vinyl gloves last a long time and often can be worn all day to help protect your hands from dirt and possible hazardous materials.

91. Figure 1-50 Safety glasses should be worn at all times when working on or around any vehicle or servicing any component.

92. Figure 1-51 Steel-toed shoes are a worthwhile investment to help prevent foot injury due to falling objects. Even these well-worn shoes can protect the feet of this service technician.

93. Figure 1-52 One version of a bump cap is this padded plastic insert that is worn inside a regular cloth cap.

94. Figure 1-53 Remove all jewelry before performing service work on any vehicle.

95. Figure 1-54 Always connect an exhaust hose to the tailpipe of the engine of a vehicle to be run inside a building.

96. Figure 1-55 (continued) (a) A crude but effective method is to use locking pliers on the chrome-plated shaft of a hood strut. Locking pliers should only be used on defective struts because the jaws of the pliers can damage the strut shaft. (b) A commercially available hood clamp. This tool uses a bright orange tag to help remind the technician to remove the clamp before attempting to close the hood. The hood could be bent if force is used to close the hood with the clamp in place. A

97. Figure 1-56 All oily shop cloths should be stored in a metal container equipped with a lid to help prevent spontaneous combustion.

103. Figure 1-57 Most newer vehicles have a triangle symbol indicating the recommended hoisting lift points.

104. Figure 1-58 (a) Tall safety stands can be used to provide additional support for a vehicle while on a hoist. (b) A block of wood should be used to avoid the possibility of doing damage to components supported by the stand. A

105. Figure 1-58 (continued) (a) Tall safety stands can be used to provide additional support for a vehicle while on a hoist. (b) A block of wood should be used to avoid the possibility of doing damage to components supported by the stand. B

106. Figure 1-59 This vehicle fell from the hoist because the pads were not set correctly. No one was hurt, but the vehicle was a total loss.

107. Figure 1-60 (a) An assortment of hoist pad adapters that are often necessary to safely hoist many pickup trucks, vans, and sport utility vehicles. (b) A view from underneath a Chevrolet pickup truck showing how the pad extensions are used to attach the hoist lifting pad to contact the frame. A

108. Figure 1-60 (continued) (a) An assortment of hoist pad adapters that are often necessary to safely hoist many pickup trucks, vans, and sport utility vehicles. (b) A view from underneath a Chevrolet pickup truck showing how the pad extensions are used to attach the hoist lifting pad to contact the frame.

109. Figure 1-61 (a) In this photo the pad arm is just contacting the rocker panel of the vehicle. (b) This photo shows what can occur if the technician places the pad too far inward underneath the vehicle. The arm of the hoist has dented in the rocker panel. A

110. Figure 1-61 (continued) (a) In this photo the pad arm is just contacting the rocker panel of the vehicle. (b) This photo shows what can occur if the technician places the pad too far inward underneath the vehicle. The arm of the hoist has dented in the rocker panel.

112. Figure 1-62 (a) A typical 3-ton (6000-pound) capacity hydraulic floor jack. (b) Whenever a vehicle is raised off of the ground, a safety stand should be placed under the frame, axle, or body to support the weight of the vehicle. A

113. Figure 1-62 (continued) (a) A typical 3-ton (6000-pound) capacity hydraulic floor jack. (b) Whenever a vehicle is raised off of the ground, a safety stand should be placed under the frame, axle, or body to support the weight of the vehicle. B

115. Figure 1-63 Drive-on type ramps. The wheel on the ground level must be chocked (blocked) to prevent accidental movement down the ramp.

119. Figure 1-64 Jumping cable usage guide.

121. Figure 1-65 The air pressure going to the nozzle should be reduced to 30 psi or less.

126. Figure 1-66 A typical fire extinguisher designed to be used on type A, B, or C fires.

127. Figure 1-67 A CO 2 fire extinguisher being used on a fire set in an open steel drum during a demonstration at a fire department training center.

129. Figure 1-68 A treated wool blanket is kept in this easy-to-open wall-mounted holder and should be placed in a centralized location in the shop.

136. Figure 1-69 A first-aid box should be centrally located in the shop and kept stocked with the recommended supplies.

137. Figure 1-70 A typical eye wash station. Often a thorough flushing of the eyes with water is the best treatment in the event of eye contamination.

138. Figure 1-71 An area that has been blocked off to help keep visitors from the dangerous work area.

148. Figure 1-72 A warning label on a Honda hybrid warns that a person can be killed due to the high-voltage circuits under the cover.

149. Figure 1-73 The high-voltage shut off switch on a Ford Escape hybrid. The switch is located under the carpet at the rear of the vehicle.

150. Figure 1-74 The shut-off switch on a GM parallel hybrid truck is green because this system uses 42 volts instead of higher, and possible fatal, voltages used in other hybrid vehicles.