DAIHATSU Technician >> Basic Service Operations

Basic Service Operations Service Task Way of Thinking

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Service Task Way of Thinking

It's important to understand how teamwork among service department staff is essential to
deliver quality service that results in customer satisfaction, retention and stable profits.
By carrying out service and repairs at competitive prices by skilled technicians, customer
trust can be achieved.
By understanding each others job roles, the service advisor, controller/foreman,
technician leader and technician work as a team to deliver No.1 customer satisfaction.

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Basic Service Operations Service Task Way of Thinking

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Basic operations in the
Basic Service Operations
service workshop

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Basic operations in the service workshop

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Service advisor
A • Listen to customer's service requirements and record service
Type/Date/Time/Estimate.
• Reconfirm the appointment one day before.
B • Arrange appointments and advise the controller & parts dept.
• Arrange work schedule for the following day with controller/foreman & parts dept.

Controller/Foreman
C • Arrange work schedule with service advisor & parts dept.

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Basic operations in the
Basic Service Operations service workshop

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Basic operations in the service workshop

Service advisor
A • Greet the customer on arrival.
• Explain the job to the customer especially time required and costs.
• Get customer's approval for the work.
B • Fill in repair order, writing customer's request.
• Check service history.
C • Do vehicle walk-around check.
D • Transfer the repair order to the controller/foreman for dispatch to technician.

Controller/Foreman
E • Perform diagnosis according to the request of service advisor/customer. (if necessary)

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Basic operations in the service workshop

Controller/Foreman
A • Based on the time and skill level required to complete the job, the controller/foreman
allocates the job.

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Basic operations in the
Basic Service Operations service workshop

Technician
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Technician leader

Basic operations in the service workshop

Technician
A • Receive/Check repair order.
• Receive the ordered parts that are necessary for work.
B • Do the job in the allowed time.
C • Confirm completion of job to the technician leader.

Technician leader
D • Carry out more technically difficult jobs and provide supervision or support to
technician.

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service workshop

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Basic operations in the service workshop

Technician leader
A • Perform final inspection.
B • Confirm completion of job to the controller/foreman.

Controller/Foreman
C • Confirm completion of job to the service advisor.

For job stoppage/delay

D • Determine the most efficient way to handle delay and tell service advisor promptly.

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service workshop

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Basic operations in the service workshop

Service advisor
A • Prepare replaced parts to show to the customer.
• Prepare invoicing for all costs.
B • Check that the vehicle is clean, quality checked and the seat cover, floor mats,
steering wheel cover, fender covers and front cover removed.
C • Phone customer to confirm that vehicle is ready for delivery.
• Explain the job to the customer.
{ Confirm job was successfully completed.
{ Show the replaced parts to the customer.
{ Explain the work done and the benefits.
{ Provide detailed invoice showing; parts, labor and lubricant cost.
Controller/Foreman
D • Provide technical explanation or advice when required by service advisor/customer.

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service workshop

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Basic operations in the service workshop

Service advisor
A • Confirm that the customer was totally satisfied with the work done.
• Re-confirm when the next maintenance service is due.

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Basic operations in the
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service workshop

Technician leader
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Basic operations in the service workshop

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service workshop

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 DAIHATSU Technician >> Basic Service Operations

Service Manuals

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Service Manuals
As automobiles evolve, new systems and features are incorporated in the
new models. Thus, it is becoming increasingly difficult for technicians to
service the highly complex vehicles by relying on their experience alone.
To inform the service personnel around the world of the proper service
procedures and new technologies, DMC (DAIHATSU MOTOR CO., LTD.)
publishes CD types manuals.
It is include Technical information, Service manual, Wiring diagrams etc.

Owner's Manuals
Written for the owners of Daihatsu vehicles, these manuals provide them
with important information for ensuring the proper operation of their
vehicles.
They are published for every model and are given to the owners of the
vehicles.

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 DAIHATSU Technician >> Basic Service Operations

Genuine Parts

Features of Daihatsu Genuine Parts

Daihatsu Genuine Parts fit perfectly because they are new parts that are
identical to the parts that are used on the vehicle.
These parts undergo the strictest quality inspections to ensure high quality
and long service life.
HINT:
All Daihatsu Genuine Parts come in packages marked with the
“DAIHATSU GENUINE PARTS" logo.

1:Basic Part Number

The first 5 digits comprise the Basic Part Number, which represents the
general group of the respective part.
For example, a part number that starts with 81110 represents a part of a
headlight.
2: Design Number
The next 5 digits are used for classifying the type of engine or vehicle.

3: (-00)
The next 2 digits, which are included only when needed, are used for
classifying colors and sizes.

Basic part number

Design number
(-00)

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 DAIHATSU Technician >> Basic Service Operations

Daihatsu Parts Numbers

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Daihatsu Parts Numbers

To correctly identify the components of all vehicles, a part number that

consists of 10 or 12 digits of alphanumeric characters is assigned to every
part.
The details of the part numbers are given in the PARTS CATALOG
GUIDE*.
* Published by Toyota's service parts administration division.
1: Basic part number
2: Design number
3: Classification or color code.

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 DAIHATSU Technician >> Basic Service Operations

Daihatsu Parts Catalog

Although part numbers are assigned to all parts, they are not necessarily
indicated on the parts themselves. All part numbers can be looked up in
the parts catalogs.
The parts catalogs come in the following three types. Refer to PARTS
CATALOG GUIDE* for the proper method for using the catalogs.
* Published by Toyota's service parts administration division.
Microfiche Parts Catalog
Paper Parts Catalog
Electronic Parts Catalog (CD-ROM)

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Searching Parts Numbers

Manufacturer's plate (except for
Location of Manufacture’s EU and Algerian specifications)
plate
1
2
3
4
5
6

(for EU and Algerian specifications) Certification regulation plate

8
(for GCC specifications)
7

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Information used for searching Parts Catalogs

To look up a telephone number in a telephone directory, you will need to
know beforehand the name of the person or the address for the number
you are seeking.
Similarly, to look up a part number in a Parts Catalog, you will need to
have some pieces of information about the vehicle.
For example:
1: Manufacture’s name
2: Model code (Type)
The model code is differentiated by the engine, model, body type, and the
vehicle's basic specifications. A model code consists of alphanumeric
characters.
3. Chassis number
Frame Number
The Frame Number, which identifies the vehicle, is punched on the body
or the frame.
A frame number contains the basic model code and a serial number.

4: Engine
The engine type and total displacement are identified on the nameplate.
Vehicles with the same model designation do not necessarily come with
the same type of engine or total piston displacement.
5: Body color code
The exterior color of the vehicle is also represented by a code.
The color code is indispensable for ordering the paint for the body color 17
 DAIHATSU Technician >> Basic Service Operations

Searching Parts Numbers

Searching Parts Numbers

Numbers indicated on the vehicle

Frame number or VIN (Vehicle Identification Number) is punched on the
engine compartment or chassis, etc. in addition to the nameplate. Refer to
the Service Manuals because the punched locations vary with the vehicle
types.
1: VIN
2: Name plate

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Vehicle Specification

The vehicle specifications, which consist of vehicle size, performance, and

other pieces of information, are included in the product brochure and NCF
(New Car Features) manuals, etc.
Service technicians should be acquainted with all the items of the vehicle
specifications.

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 DAIHATSU Technician >> Basic Service Operations

Vehicle Specification

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Major dimensions include these items as in the diagram

Major Dimensions
1: Overall width
This is the maximum width of the vehicle, excluding the outside door
mirrors.
2: Interior width
This is the maximum distance in the center of the interior between the
right and left doors.
3: Overall height
This is the maximum height of the vehicle in an empty state, excluding the
antenna.
4: Tread
This is the distance between the center of the right and left tires.
5: Interior length
This is the distance between the instrument panel near the center of the
vehicle interior and the rear seat back.
6: Approach angle
This is the angle that is formed by the road surface and a hypothetical line
(drawn between the bottom of the front end of the vehicle and the ground
contact surface of the front tire).
7: Ground clearance
This is the distance from the ground surface to the lowest portion of the
vehicle in the gross vehicle weight condition.
8: Interior height 20
 DAIHATSU Technician >> Basic Service Operations

Vehicle Specification

Vehicle weights
- Vehicle weight
- Gross vehicle weight
- Front axle weight
- Front axle gross weight
- Rear axle weight
- Rear axle gross weight

Vehicle weights
•Vehicle weight
This is the weight of the vehicle that includes the standard items that are
necessary for the operation of the vehicle such as fuel, coolant, oil, spare
tire, and on-board tools. Luggage and occupants are excluded.
•Gross vehicle weight
This is the weight of the vehicle to which the weight of the riding capacity
and the weight of the designed maximum loading capacity have been
added.
•Front axle weight
This is the weight of the vehicle that is applied to the front axle.
•Front axle gross weight
This is the part of the gross vehicle weight that is applied to the front axle.
•Rear axle weight
This is the weight of the vehicle that is applied to the rear axle
•Rear axle gross weight
This is the part of the gross vehicle weight that is applied to the rear axle.

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Vehicle Specification

1. Maximum speed

1. Maximum speed
This represents the vehicle's driving performance. The maximum speed is
measured with the gross vehicle weight on a windless, flat, paved road.
The measurement is indicated in km/h (mph) units.

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Vehicle Specification

2. Fuel consumption rate

2. Fuel consumption rate

This represents the volume of fuel that the engine consumes when the
vehicle travels a given distance.
There are two methods for calculating the fuel consumption rate:

1: Volume of fuel consumed while traveling a given distance

(L/100km)

2: Distance traveled while consuming a given volume of fuel (km/L)

HINT:
The fuel consumption rate varies considerably depending on the driving
conditions at the time of measurement (e.g. weather, engine condition,
road gradient, etc).

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Vehicle Specification

3. Hill climbing ability

3. Hill climbing ability

This is the maximum grade that the vehicle can climb with the gross
vehicle weight.
A: Distance of horizontal travel
B: Ascending height
Theta : Maximum grade

Theta = B / A
Example:
Where height (B = 20m), and distance (A = 100m),
20/100 = 0.2 is the maximum grade.

HINT:
The vehicle may not be able to actually climb to the maximum grade if the
tires and the road surface lack the proper amount of friction resistance.

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Vehicle Specification

4. Minimum turning radius

4. Minimum turning radius

This is the radius that is drawn between the center of the rotation of the
vehicle and the center of the tire of the outermost wheel (or the outermost
side of the body), when the vehicle is turned slowly on a paved road by
turning the steering wheel all the way to the right or left.
1: Minimum turning radius (tire)
2: Minimum turning radius (body)

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Vehicle Specification

Engine

Bore and stroke

Engines are classified into three types depending on their cylinder bore
and piston stroke ratio:
1. Long-stroke engine
An engine in which the piston stroke is greater than the cylinder bore.
2. Square engine
An engine in which the cylinder bore and the piston stroke are the same
size.
3. Short-stroke engine
An engine in which the piston stroke is smaller than the cylinder bore.
1: Bore
2: Stroke
3: TDC (Top-Dead-Center)
The position of the piston in the cylinder when it is at the highest point.
4: BDC (Bottom-Dead-Center)
The position of the piston in the cylinder when it is at the lowest point.

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Vehicle Specification

Total piston displacement

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Total piston displacement

The piston displacement (or simply "displacement") in the cylinder is
determined by the bore and stroke. The total piston displacement is
obtained by multiplying the piston displacement of a cylinder by the
number of cylinders.
Generally , the greater the total piston displacement, the greater the
engine's power output.
1: Bore
2: Stroke
3: TDC (Top-Dead-Center)
4: BDC (Bottom-Dead-Center)
(2/5)

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Vehicle Specification

Compression ratio

Compression ratio
This is the ratio in which the air-fuel mixture is compressed by the piston.
Generally, the compression ratio of gasoline engines is between 8 and 11,
and of diesel engines is between 16 and 24.
Compression ratio = (V1+V2)/V1
V1: Combustion chamber volume
V2: Cylinder volume
(Piston displacement)
1: TDC (Top-Dead-Center)
2: BDC (Bottom-Dead-Center)

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Vehicle Specification

Engine torque

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Engine torque
The engine torque represents the power that rotates the crankshaft.
It is represented with N·m, which is calculated as follows:

T=Nxm

T = Torque
N = Force
m = Distance
HINT:
N (Newton) is a unit of mass, and its relationship to kgf is as follows:
1 N = 0.11355 kgf
1 kgf = 9.80665 N

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Vehicle Specification

Engine power output

Engine power output

The engine power output is the amount of power that is produced within a
given time. Although kW is the international unit, the units of HP and PS
are also used.
The power output is the result of the engine speed multiplied by torque.
Because the axial torque decreases due to decrease the intake efficiency
that occurs at high speeds, the power output peaks at a certain level. This
peak is called the maximum power output.
HINT:
The following values describe the relationship between kW to HP and PS.
1 kW = 1.3596 PS
(1 PS = 0.7355 kW)
1 kW = 1.3410 HP
(1 HP = 0.74571 kW)

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Vehicle Specification

Engine Performance Curve

Engine Performance Curve

This curve, which renders the performance of the engine into a graphical
form, shows how the torque or the power output represented by the
vertical axis changes in accordance with the engine speed represented by
the horizontal axis.
The value that represents the power output of the engine
•There is no direct correspondence among the values of these standards.
Gross power output
This value is obtained from the engine unit.
Net power output
This value is obtained from an engine that is actually installed on a
vehicle.
The measured net power output is approximately 10 to 15 percent smaller
than the gross power output.
REFERENCE:
•Driving performance curve

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Vehicle Specification

The value that represents the power output of the engine

The value that represents the power output of the engine

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Vehicle Specification

Driving performance curve

Driving performance curve

This curve renders the performance of the vehicle equipped with the
engine into a graphical form. It allows these three connections to be
interrupted:
1: The engine speed and the vehicle speed
The connection between the engine speed and the vehicle speed at each
gear position.
2: The driving power and the vehicle speed
The connection between the driving power at each gear position and
vehicle speed while the accelerator is fully applied.
3: The driving resistance and the vehicle speed
The connection between the vehicle speed on a slope and the driving
resistance while the slope is 0 through 60%.

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DAIHATSU Technician >> Basic Service Operations

Question-1

Mark each of the following answers True or False:

No. Question True or false

1 If a technician working on a vehicle discovers that it needs True False

additional work, he/she should perform all additional work at
his/her discretion.

2 Generally, technicians receive a repair order from a True False

controller/foreman.

3 After maintenance and repair work is completed, the technician True False
must contact the customer for an after-service follow-up.

4 Technicians perform maintenance and repair work on vehicles True False

after thoroughly understanding the basic workflow in the
workshop.

5 Generally, a technician leader performs the final inspection of the True False
vehicles after they have been serviced.

Refer to page

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DAIHATSU Technician >> Basic Service Operations

Question-2

Match the following job descriptions with the

corresponding employees in the word group below.
Refer to
No. Question
page

1 Handles general customer needs in a reception capacity.

2 Assigns jobs to the technicians, monitors their workmanship, and

tracks their progress.

3 Performs maintenance and repair work and a final inspection upon

completion.

4 Performs maintenance and repair work.

a Controller/Foreman 1 a b c d
b Technician 2 a b c d
c Technician Leader 3 a b c d
d Service Advisor 4 a b c d

Click answer

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DAIHATSU Technician >> Basic Service Operations

Question-3

Mark each of the following statements True or

False:
No Refer to
Question True or False
. page

The Owner's Manual contains information on new True False

1
vehicles and describes new mechanisms.

The total piston displacement is obtained by multiplying True False

2 the displacement of the combustion chamber by the
number of cylinders.

Engine torque is a value that represents the force that True False
3
rotates the crankshaft.

The total piston displacement of the engine is obtained True False

4 by multiplying the displacement of a cylinder by the
number of cylinders.

The first 5 digits of a Daihatsu part number represent True False

5
the production period.

Click to answer

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DAIHATSU Technician >> Basic Service Operations

Question-4

Which one of the following statements is true

about the nameplate of a vehicle?
1. The nameplate of a vehicle indicates a performance curve.
2. The nameplate of a vehicle indicates a repair manual and a wiring diagram manual.
3. The nameplate of a vehicle indicates the model code and frame number.
4. The nameplate of a vehicle indicates the name of the user.

Click to answer

Refer to page

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DAIHATSU Technician >> Basic Service Operations

Question-5

Which one of the following statements is true

about the nameplate of a vehicle?
1. Which one of the following statements is true about the wheelbase?
2. The wheelbase is the length from the front most to the rearmost end of the vehicle.
3. The wheelbase is the distance from the ground to the lowest portion of the vehicle.
The wheelbase is the distance between the center of the front wheel and the center of the
4.
rear wheel.

Click to answer

Refer to page

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DAIHATSU Technician >> Basic Service Operations

Question-6

From the word group indicated below, select the

words that correspond to numbers 1 through 5.

a) Tread b) Overall height c) Ground clearance

d) Overall length e) Overall width f) Approach angle

1 2 3
a b c d e f a b c d e f a b c d e f

4 5
a b c d e f a b c d e f

Click alphabet in column to answer

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DAIHATSU Technician >> Basic Service Operations

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DAIHATSU Technician >> Basic Service Operations

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DAIHATSU Technician >> Basic Service Operations

Close

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 DAIHATSU Technician >> Basic Service Operations

Vehicle Specification

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Major dimensions include these items as in the diagram

Major Dimensions
1: Overall width
This is the maximum width of the vehicle, excluding the outside door
mirrors.
2: Interior width
This is the maximum distance in the center of the interior between the
right and left doors.
3: Overall height
This is the maximum height of the vehicle in an empty state, excluding the
antenna.
4: Tread
This is the distance between the center of the right and left tires.
5: Interior length
This is the distance between the instrument panel near the center of the
vehicle interior and the rear seat back.
6: Approach angle
This is the angle that is formed by the road surface and a hypothetical line
(drawn between the bottom of the front end of the vehicle and the ground
contact surface of the front tire).
7: Ground clearance
This is the distance from the ground surface to the lowest portion of the
vehicle in the gross vehicle weight condition.
8: Interior height 20