EBS18 – Precision Measurements Automobile Technical Training

EBS18 – Precision Measurements

page 1 of 16 © 2019 American Honda Motor Co., Inc - All rights reserved. ver_6_ ETR3244 | 02.2019

Automobile Technical Training

Course Overview:This course will familiarize you with the feeler gauge, digital micrometer, digital caliper and digital electronic indicator. These basic precision measurement tools will aid you in making precise measurements, to determine the serviceability of components.

Course Requirements:1. Demonstrate the proper usage of a feeler gauge to determine if a

component is within the service specification. 2. Demonstrate the proper usage of a digital micrometer to determine if a

component is within the service specification. 3. Demonstrate the proper usage of a digital caliper to determine if a

component is within specification. 4. Demonstrate the proper usage of a digital electronic indicator to

determine if a component is within specification.




1. How do you inspect the feeler gauge for excessive wear? ________________________________________________________________________________________ ________________________________________________________________________________________

2. What should you do if the feeler gauge is kinked/wrinkled or shows signs of corrosion? ________________________________________________________________________________________

3. Is it acceptable to stack two feeler gauge blades together to match the recommended clearance specifications? ________________________________________________________________________________________

4. List at least three examples of clearances that would be measured with feeler gauges ________________________________________________________________________________________

5. What is meant by; “Pull straight from the gap to avoid extra friction from the pinch caused by an angular pull”? ________________________________________________________________________________________

NOTE: See your Instructor for an explanation if you are not sure

Feeler Gauge Knowledge CheckNOTE: If you need help with questions 1-5 please review the self studies in Online University, any Tech2Tech videos on proper valve clearance, and

Job Aids attached to the end of this module.




Skill Check PointDo not proceed until you have consulted with your instructor.Instructor’s initials: _____________

Course Requirement 1a: Feeler Gauge When using a feeler gauge, the amount of drag (resistance) you feel as you slide the blade in and out is very subjective. To find a good reference drag

(resistance), use a 0-25mm micrometer and zero it to the blade of your choice. Using the friction drive on the micrometer, close it on the blade. Do not clamp down on it. Now slide the blade in and out to get the feel of zero clearance on the blade. If you will be checking the gap on lubricated items, check the feel with a lubricated blade, otherwise check the drag dry.

Course Requirement 1b: Feeler Gauge Using your assigned laptop, access the Service Information and locate recommended valve clearance specification for the assigned vehicle.

Intake _________________________________________________Exhaust ___________________________________________________

Examine the provided training center feeler gauge set. What size feeler gauge would you use?Intake _________________________________________________Exhaust ___________________________________________________

Share your feeler gauge selection with your instructor

Instructor’s RecommendationsIntake _________________________________________________Exhaust ___________________________________________________




NOTE: Valve clearance adjustment will be covered in more detail in the training center module ENS44. The above exercise was only designed to provide familiarity with the proper feeler gauge feel and drag.

Inspect valve clearance on the #1 cylinder on the provided training center engine.

Is the clearance correct, too small or too large? _________________________________________________________________________

If the clearance is not correct, please see your Instructor.

Course Requirement 1c: Feeler Gauge Using your assigned laptop, access the Service Information and locate the recommended A/C compressor

clutch clearance for the supplied training center A/C compressor.

Record the specification range here: ____________________________________________

Using the provided feeler gauge set, measure the A/C compressor clutch clearance

Is Compressor Clutch Clearance within Service Limit?

Yes No

If the clearance is not within, please see your Instructor.

NOTE: Compressor clutch inspection and replacement is covered in more detail in Service Bulletin #12-072 and in multiple Tech2Tech segments, which can be found in Tech2Tech archives under the keyword “Compressor”




Micrometer Knowledge CheckNOTE: If you need help with questions 1-5 please review the self studies in Online University, the micrometer user manual, and Job Aids attached to

the end of this module.1. How should the micrometer be stored? _____________________________________________________________________________________________

2. When should the micrometers measuring points (Anvil and Spindle) be cleaned? ____________________________________________________________

3. What is the correct way to clean them? _____________________________________________________________________________________________

4. When should you check the micrometer for correct calibration? __________________________________________________________________________

5. How do you zero out micrometer before use? ________________________________________________________________________________________ ____________________________________________________________________________________________________________________________

6. What are the various size standards used for? ________________________________________________________________________________________

Anvil Spindle LCD Display

Quick driveFriction drive

Spindle lock

NOTE: Be sure to leave a gap between the spindle and anvil when storing the micrometer in its case.




Course Requirement 2a: Micrometer Using a laptop, access the Service Information and locate the length specifications for the main shaft

6th gear distance collar for the training center assigned vehicle.

Record the standard measurement range here ____________________________________

Record your measurement here: _______________________________________________

Is the length within the standard?

Yes No

Course Requirement 2b: Micrometer Locate the training center provided bag of A/C compressor shims.

Measure and record shim thicknesses below:Shim A ___________________ Shim B ___________________Shim C ___________________ Shim D ___________________

Course Requirement 2c: Micrometer Using a Laptop, access the Service Information and locate piston pin specification for the training

center assigned vehicleStandard (New): _______________________________________________________________Service limit: __________________________________________________________________

Measure the provided piston pin and record your finding: _______________________________ Can this piston pin be reused?

Yes No




Digital Caliper Knowledge CheckNOTE: If you need help with questions 1-8 please review self studies in Online University, the digital caliper user manual, and the attached Job Aids.1. Why is it best to store the digital caliper in its storage case? _____________________________________________________________________________

____________________________________________________________________________________________________________________________2. What is the proper way to clean the measuring surfaces of the external jaws of the digital caliper? _______________________________________________

____________________________________________________________________________________________________________________________3. How do you zero out the digital caliper? _____________________________________________________________________________________________

4. Why is it critical to use the “Thumbroll” to move the caliper jaws when taking measurements? ___________________________________________________ ____________________________________________________________________________________________________________________________

5. What does it mean, if the ABS icon is showing in the digital display?_______________________________________________________________________ ____________________________________________________________________________________________________________________________

Course Requirement 3a: Digital Caliper Using a laptop, access the Service Information and locate the cylinder head height specification for your

assigned cylinder head.

Record the standard (New) specification here: ____________________________________________________________________________

Measure the provided cylinder head and record your measurement here: ____________________________________________________________________________

Skill Check PointDo not proceed until you have demonstrated how to zero out the digital caliper to your instructor. Instructor’s initials: _____________




Course Requirement 3b: Digital Caliper For detailed instructions on how to measure depth, refer to the Job Aid D (Digital Calipers) attached to the end of this module. Measure the depth of all the cylinder head valve cover bolt holes in training center provided cylinder head Record your measurements here:

Deepest measurement __________________________________________________________________________________________________________

Shallowest measurement ________________________________________________________________________________________________________

NOTE: This will be a required measurement during thread repair and Time-Sert installation.




Digital Indicator Knowledge CheckNOTE: If you need help with questions 1-8 please review self studies in Online University, the digital indicator user manual, and the attached Job Aids.1. How should the digital indicator be stored? __________________________________________________________________________________________2. How should you align the Indicator in relationship to the expected movement before taking measurements? _______________________________________

____________________________________________________________________________________________________________________________3. How much should you preload the indicator before zeroing it out? ________________________________________________________________________

____________________________________________________________________________________________________________________________4. How do you zero out the digital indicator? ___________________________________________________________________________________________5. The Digital Indicator can display multiple icons. Please explain their meaning?

________________________________________________________________

________________________________________________________________

______________________________________________________________




Course Requirement 4a: Digital Indicator Using a provided laptop, access the Service Information and locate the Service Limit for Camshaft runout for the assign camshaft .

Record the Service Limit here: ____________________________________________________________________________________________________

Using V-blocks on a precision surface block, support the end journals of the camshaft.

Measure the camshaft runout at the center journal using a digital indicator.

Record your measurements here: _________________________________________________________________________________________________

What should you do if the camshaft is not within specifications? __________________________________________________________________________

Note: Avoid axial movement of the camshaft as you are rotating it, this

could cause false readings.

ROTATE ONLY. DO NOT MOVE LEFT OR RIGHT!




Evaluation:To receive credit for this module you will be asked to demonstrate some or all of the tasks listed under skill checks on page 1 and 2 of this module.

EvaluationIf you are ready to demonstrate the skills in this module and receive credit, see your instructor.Instructor’s initials: _____________

Course Requirement 4b: Digital Indicator Using a provided laptop, access Service Information and locate the service limit for wheel bearing end play

Record the service limit here: _____________________________________________________

What must be done before taking the measurement to ensure accuracy? ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________

Set up the Digital Indicator and measure wheel bearing end play.

Record Your measurements here __________________________________________________

Is the measured wheel bearing end play more than service limit?

Yes No

NOTE: Measure the bearing end play while moving the brake disc inward and outward.




Introduction to Digital Measuring Tools Job Aid A

Digital Indicator = Distance amplifying instrumentUsed to measure movement distance

Best usage = Measuring rotational differenceMeasuring end play movement(Accurate to 100th of a millimeter, 0.01)

Digital Caliper = Internal, External and Depth dimensions instrumentUsed to measure length, thickness, width and depth.

Best usage = Measure length, width, thickness or depth where extreme accuracy is not needed (Accurate to 100th of a millimeter, 0.01)

Digital Micrometer = known as a micrometer screw gauge, Used to accurately measure the outside of an itemUsed to measure external sizes of precisely machined components

Best usage = Measuring Crankshaft and camshaft dimensionsMeasuring Piston sizes(The spindle is a very accurately machined screw that will measure to the 1000th of a millimeter, 0.001, a 1000th of a millimeter is a Micron)

Precautions:Although a top quality product, certain precautions are required for any electronic instrument:

● Avoid exposure to all liquids and excessive humidity.

● Avoid exposure to electromagnetic fields. ● Do not expose the instrument direct sunlight. ● Do not attempt to disassemble the indicator

Battery ReplacementPull out the battery cover and battery, remove the old battery, place the new battery with the positive pole “+” facing the battery cover and insert the battery cover with the battery positive pole “+” facing upwards.

Cleaning ● Clean the indicator with a soft cloth. ● Do Not use any type of solvent. ● Do Not immerse the indicator in liquid

For additional information of advanced features on any of these tools, refer to the operation manual.




Job Aid B

Checking the FeelWhen using a feeler gauge, the amount of drag you feel as you slide the blade in and out is very subjective. To find a good reference drag, use a 0-25mm micrometer and screw in the spindle on to the blade. Do not clamp down on it. Allow the micrometer’s friction drive to provide the proper amount of pressure. Now slide the blade in and out to get the feel of zero clearance. If you are checking the gap on a lubricated item, check the feel with a lubricated blade, otherwise check drag dry.Note: Blade markings are not always correct, this is why it is recommended to measure the blade before using. Don’t rely on the stamping for the correct size.

Feeler Gauge = Tool made of different thickness steel that is flexible, used to measure gap widths

Dry Check

Blade Marking’s Blade Condition

SAE and Metric

Check for wear, deformation and rust

Lubricated Check

Conventional Blade Double Conventional Blade

Long Blade Go-No-Go Blades

Blade Line Up

Improper Blade Line Up

Make sure blade is flat between surfaces

Not sitting flat between surfaces

Not sitting straight between surfaces

Twisted between surfaces

Angled blade used for proper line up




Job Aid CIntroduction to the Digital Dial Indicator

The “ABS” mode is for advanced programing (Not used in our applications)

Digital scale reads the first + -, .025 in or first + -, .25 mm

To turn ON, briefly press the “Zero/On“ button

To Turn OFF, Depress “Zero/On” button for 2 seconds

Units can be changed from “Inches” to “Millimeters”, by pressing the “Unit” Button

The “TOL” mode is used with the ABS mode to set tolerance ranges. (Not used in our applications)

The “MIN” button will allow you to record the highest reading.

Maximum mode is indicated by the “upper limit” symbol

Minimum mode is indicated by the “lower limit” symbol

1. Turn on your indicator. Press the “MIN” button once. These two icons appear.

2. Measure your item, the highest reading will stay on the screen.

3. Press the “MIN” Button again, these icons will appear and the reading will go to Zero.

4. Press the “MIN” button again and your reading will reappear.

5. Press the “MIN” button again and this will reset the meter to Zero.

Range mode is indicated by both the upper limit and lower limit symbols and the memory mode symbol




Job Aid DIntroduction to the Digital CaliperDigital Caliper – used to measure length, width, thickness and depth with accuracy of 100th of a millimeter (0.01mm)

Locking Screw

Thumbroll

Measurement

Beam Depth Measurement

RodExternal

Jaws

Internal Jaws

uy

x

v

w

1. Turn the caliper on by pressing the “On/Zero” button. It will turn off automatically after five minutes of inactivity. 2. Make sure the “Locking Screw” is unlocked, (turn counter-clockwise). Zero the caliper by using the “Thumbroll” to GENTLY close the external jaws. When

the jaws are together, push the “ON/ZERO” button (again) to set the digital readout to zero with the jaws closed. Failure to do so will result in an incorrect measurement.

3. Use the Thumbroll to gently move the caliper jaws apart. Place the object to be measured between the open jaws and, using the Thumbroll, roll the movable jaw till it lightly touches the object you are attempting to measure. If you wish, the jaws can be locked in place using the locking screw to retain the measurement for reference.

4. Read the thickness of the object directly from the readout. Measurements can be taken in either millimeters or inches simply by pressing the “in/mm” button above the readout screen.

5. ABS icon should not be displayed during basic measurements. If you see ABS displayed in the digital readout, gently close the jaws using the “Thumbroll” and press the ABS button

6. Internal measurements can be taken by placing the internal jaws inside the object to be measured and completing step 3 above.7. Depth measurements of a hole or component can by made by seating the base end of the “Beam” on the lip (edge) of an object and using the Thumbroll to

extend the “Depth Measurement Rod” till it contacts the bottom of the hole or a flat reference surface.

Precautions: ● Avoid exposure to all liquids ● Avoid exposure to

electromagnetic fields ● Do not expose the

instrument to direct sunlight ● Do not attempt to

disassemble the caliper




Job Aid EIntroduction to the Digital Micro-meter

Anvil Spindle DisplayFriction Drive

Quick Drive

ABS/INC*** Unit Key

On/Off***Set

Precautions: ● Do not subject the instrument to blows or knocks. ● Do not drop it or apply excessive force. ● Do not disassemble the instrument. ● Do not press the keys with a pointed object. ● Do not use or store instrument under direct sunlight, or in

an excessively hot or cold area. ● Do not use the instrument near strong magnetic fields and

high voltages. ● Use a soft cloth or a cotton swab that is dry to clean the

instrument. Alcohol may be used. ● Wipe the measuring faces of the instrument before using it.

● ON/OFF...SET key: Power switch. Datum set. ABS/INC...UNIT key: Absolute & relative measuring. Metric/inch conversion.

● Operation: Two ways of pressing the keys are used in the following illustrations: (1) Press and release; (2) Press and hold (2 sec. or more).

● ON/OFF...SET key: Press and release: Power on/off. Press and hold (2sec. or more): Datum setting for absolute measurement. Origin of metric is 0, 25, 50, 75mm...275mm. Origin of inch is 0, 1, 2, 3 ...11. Sets datum automatically after battery reset.

● ABS/INC...UNIT key: Press and release: Absolute and relative measuring mode conversion; INC sign displayed on LCD in relative measuring mode. No sign displayed on LCD in absolute measuring mode. Press and hold (2 sec. or more): Metric/inch conversion; in sign displayed on LCD for inch, otherwise mm

● Friction Drive: To ensure reliable and accurate measurements, the micrometer incorporates a slipping clutch mechanism called friction drive. It applies constant measuring force to the spindle and prevents over-tightening.

● Quick Drive: Increases the speed at which the spindle rotates, so the space between the anvil and the spindle is reduced faster.

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EBS18 – Precision Measurements Automobile Technical Training