Automotive Measuring Tools
Automotive Measuring Tools
Automotive Measuring Tools
Page 8 Calipers
Page 9 Micrometers
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STANDARD AURTTA003
RELEVANT VOCABULARY
It is recommended that you are familiar with the following words and their definitions
to help your understanding of the material contained in this workbook.
Tensioned: To tighten
Coarse: Rough
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MEASURING TOOLS
Various kinds of measuring tools are used in automotive workshops and their main
purpose is to enable safe, accurate and speedy measurement of work. To achieve this
Start Reading you must select the most appropriate tools and know how to use them correctly.
2. Carry out regular tool maintenance to maximise the service life and to ensure
ongoing accuracy of the tool.
3. Read the tool manufacturer’s operating instructions. Tools can vary from
Correct tool manufacturer to manufacturer.
for the job
4. To reduce down time in searching for tools always return the tools to their correct
position on the shadow board or in their container.
5. Ensure that tools are kept clean and free from grease or oil. This will prevent the
grease or oil from being transferred to the customer’s vehicle and will also assist
the technician to maintain a firm grip of the tool.
6. Ensure that the tool is correctly calibrated before use. A faulty measuring tool will
provide inaccurate readings which could prove to be expensive if relied upon.
Tag faulty 7. Tools that are faulty, damaged or in need of calibration should be removed from
tools service, tagged and reported to the workshop supervisor.
8. Only use tools for their intended purpose. Measuring tools are precision
instruments that have been designed for specific purposes. Using them outside
specifications may cause damage, premature wear or give unreliable results.
9. Always double check measurements. Refer to conversion charts for imperial and
metric measurements.
Very Important
Safety Points Safety when using measuring tools
Some measuring tools have sharp edges so take care to avoid cuts.
Never carry tools in pockets or throw tools to colleagues.
Only use tools for their intended purpose.
Steel measuring tools are conductive so avoid using near live wires or
sources of heat.
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VERNIER CALIPERS
The Vernier calipers are a hand held tool that allow an object to be measured in
inches/mm to the second decimal place.
Vernier calipers measure inside, outside and depth measurements. Verniers are made
from stress relieved stainless steel and have precisely ground measuring surfaces to give
an accurate reading on the scale. The scale is precisely etched onto the caliper bar and a
standard set of Vernier calipers measure from zero millimetres to 152 millimetres.
The three main applications of a Vernier scale are to measure outside diameters, inside
diameters and depth.
Step 2
Using the Vernier scale (bottom row)
locate the first point at which the
Vernier scale is in alignment with the
main scale. Vernier scale
Step 3
Add the readings together.
A thumb lock is used to clamp the caliper sliding bars to enable the user to inspect
closely when measuring in awkward places. Calipers are also available with a dial
indicator gauge. It is recommended that eye protection be worn when operating a
Vernier caliper.
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Correct use of Vernier calipers
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Reading the Vernier scale
Example One
The main scale reading = 71.00 millimetres
10mm divisions
0.02mm divisions
Example Two
The main scale reading = 11.00 millimetres
Total = 11.24 mm
Take Note * Storage and handling of Vernier calipers
Handle calipers carefully. Avoid dropping or bumping. Calipers are
precision tools and any damage will affect the accuracy of readings taken.
After use, the calipers should be cleaned and dried thoroughly. Wipe the
sliding surfaces and measuring faces. If lubrication is required apply oil
lightly to each part of the caliper.
Check the slider moves free and smoothly. Adjust the set screw as required.
Store calipers in their container. Do not expose to direct sunlight
Ensure top pivot is secure and thread not damaged
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Digital Calipers
Digital calipers can also be used to take internal, external and depth measurements.
They provide accurate measurements and can be switched between imperial and metric.
A zero function allows for display to be reset at any point along the slide.
Internal Locking screw
Depth measure
Calipers
Calipers can be used for measuring distances and scribing parallel lines, arcs and
circles. The main types of calipers used in automotive workshops include:
Internal calipers
Internal calipers are used for measuring inside diameters.
Inside
The measuring points of the internal calipers point away
diameters
from each other.
External caliper
Outside External calipers are used for measuring outside
diameters diameters.
The measuring points of the external calipers point
towards each other.
Can be used to compare the sizes of two parts.
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Take Note * Storage and handling of calipers
Handle calipers carefully. Avoid dropping or bumping. Calipers are
precision tools and any damage will affect the accuracy of readings taken.
After use the calipers should be cleaned and dried thoroughly.
Store calipers in their container
Never store calipers with loose tools.
MICROMETERS
Micrometers are precision made tools designed to measure inside, outside, and depth
measurements to 0.01 mm. They are mainly used to determine the serviceability of
components and are generally used on engine components such as:
Apply the thimble locking mechanism and remove the work to allow a close inspection
Centralise the of the measuring scale.
Work
The first reading is taken from the lower scale
of the sleeve. Read the whole millimetre
figure.
The next reading is taking from the scale on the thimble (this scale is measured in
0.01mm graduations).
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Outside Micrometer Reading
The lower scale on the sleeve indicates the distance in whole millimetres.
The upper scale on the sleeve indicates the distance in 0.5mm graduations.
The upper and lower scales are read from left to right.
The thimble scale indicates the distance in 0.01mm graduations and is read from
bottom to top.
Example One:
47
11
11
All lines =
0.01mm
Example Two:
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The inside micrometer is a precision tool
designed to measure the inside diameter of an
object.
Remove the inside micrometer to allow a close inspection of the measuring scale.
2. The lower scale on the sleeve indicates the distance in 0.5mm graduations. The
upper and lower scales are read from left to right.
3. The thimble scale indicates the distance in 0.01 millimetre graduations and is read
from bottom to top.
Example One:
3
2
11
Example Two:
DEPTH MICROMETERS
Depth micrometer is a precision tool used to measure the depth of a hole or a step.
4
Reading a Depth Micrometer
Adjust the ratchet until the anvil reaches the bottom of the
Right to Left hole or step.
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The upper scale on the sleeve indicates the distance in whole millimetres.
1. The lower scale indicates the distance in 0.5 millimetre graduations.
The upper and lower scales are read from right to left.
2. The thimble scale indicates the distance in 0.01 millimetre graduations as in read
from top to bottom.
Example One:
Example Two:
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Take Note * Storage and handling of Micrometers
Handle micrometers carefully. Avoid dropping or bumping. Micrometers
are precision tools and any damage will affect the accuracy of readings
taken.
Before use wipe off any dust from the spindle, anvil and measuring faces.
Allow the micrometer some time to adjust to room temperature.
After use, the calipers should be cleaned and dried thoroughly. Wipe the
sliding surfaces and measuring faces. If lubrication is required apply oil
lightly to each part of the caliper.
Check the slider moves free and smoothly. Adjust the set screw as required.
Store calipers in their container. Do not expose to direct sunlight
Ensure top pivot is secure and thread not damaged
STEEL RULES
A standard steel rule is 30 cm long and is precision machined from steel with two
straight edges with a metric and imperial measuring scale. It is used for general purpose
measuring of components and metal measuring, scribing, marking and aligning.
General
Measuring
It is important that the steel rule is perfectly flat and straight with straight edges.
Flush with 1. Position the steel rule straight across and flush with the surface to be measured.
surface The rule should be held at an angle of 90° to the surface of the work and at 90°
to both edges of the work.
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STRAIGHT EDGES
A standard straight edge is approximately one metre long. It is constructed from
Determine precision machined steel and has two straight edges and a measuring scale on one edge.
Warpage The straight edge is used with a feeler gauge to determine warp in cylinder heads,
engine blocks and manifolds.
Take Note * Storage and handling of steel rules and straight edges
Handle rules and edges carefully. Avoid dropping or bumping. Remember
these are precision tools and any damage will affect the accuracy of readings
taken.
Rules and edges must never be exposed to an electrical supply.
After use, rules and edges should be cleaned and dried thoroughly.
Steel rules should be stored in their protective plastic covering provided by
the manufacturer when not in use.
Store rules and edges their protective cover and hang on a shadow board.
Never store rules or edges with loose tools.
MEASURING TAPES
Retractable measuring tapes are used in the automotive industry for a variety of
measuring activities such as measuring panels, suspension heights, lamp positions and
wheel base dimensions. Measuring tape scales can be metric, imperial or a both.
Measuring tape sizes range from 2m to 10m. After use measuring tapes should be wiped
with a clean rag to remove oil and grease and then stored in a tool box.
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SQUARES
Squares are commonly used in panelbeating, fabrication and engineering workshops for
measuring work where specific angles are required. Squares that may be used include:
Engineer’s square
Combination square
T-square
Bevel protractor
ENGINEER’S SQUARE
An engineer’s square is a precision tool made of carbon steel and
Datum lines is used for measuring and checking angles of 90°, for marking out
lines at right angles to the datum line and for squaring two pieces
of work.
Blade
The engineer’s square consists of two straight edges (marking
blade, stock rest) joined together at an angle of 90°. It is important
that the engineer’s square is regularly calibrated.
Stock
1. Before using the engineer’s square ensure that the work surface is clean and free
of burrs.
2. Position the edge of the stock rest firmly against the work surface.
3. Move the stock rest until the marking blade is flat onto the surface of the work.
Stock rest
4. Evidence of clearance between the work surface and the marking blade indicates
that the work surface is warped.
5. To square two pieces of work, position the stock rest flat on one surface and
align the marking blade with the side of the second work piece. To ensure the
accuracy of alignment reposition the engineer’s square 90° from the initial
position and recheck.
An engineer’s square should be handled and stored in the same manner as a steel rule.
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COMBINATION SQUARES
A combination square is a hand held tool that is precision made and is designed as a
multipurpose measure and level. It has a 30cm steel rule blade with metric and imperial
Multipurpose measurements, a groove through the centre of the blade and a spirit level attachment
Measure and that travels along the groove.
Level
The spirit level attachment has a precision machined surface that runs at 90 degrees to
the steel rule blade and a thumb screw to lock the spirit level attachment to the steel rule
blade. A combination square can be used to measure:
Distance
Depths
Levels
Inside right angles
Outside right angles
45 degree angles
Construction
1. 12 inch steel rule.
2. Sliding frame.
3. 90 degree face to the rule.
4. 45 degree face to the rule.
5. Spirit level bubble.
6. Sliding frame lock nut.
7. Sliding frame groove in the centre of the
steel rule.
8. Hanging hole for storage.
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T-SQUARES
The T-square is a good option when looking to draw and cut
in a straight line.
Most T-squares have a hole towards the end of the blade for hanging the tool up.
After use wipe the blade and stock with a clean rag and hang on a shadow board or store
in its original container.
BEVEL PROTRACTORS
A bevel protractor is a graduated circular protractor
with one pivoted arm used for measuring or marking
off angles. Sometimes Vernier scales are attached to
give more precise readings.
The bevel protractor consists of a base, a graduated dial and a blade which is connected
to a swivel plate (with Vernier scale) by a thumb nut and clamp.
The base is placed on the bottom side of the angle to be measured while the blade is
placed on the opposite side. To measure the angle adjust the nut to release the blade and
protractor which allows the protractor to be moved along the blade to fit an angle. When
the edges of the base and blade are parallel, a small mark on the swivel plate coincides
with the zero line on the graduated dial.
Since the spaces, both on the main scale and the Vernier scale, are numbered both to the
right and to the left from zero, any angle can be measured.
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SPIRIT LEVELS
A spirit level is an instrument designed to indicate whether a surface is
horizontal or vertical. Used in the motor industry to check and calibrate
workshop equipment.
The level has a machined true edge and contains a sealed glass tube
partially filled with alcohol or other liquid, containing an air bubble
whose position reveals whether a surface is perfectly level.
The spirit levels edge should be free of nicks, dents and warpage in order to provide the
most accurate reading when flat against an object. Make sure that the vials are not
damaged. If broken, replace the entire level rather than just the vial. Longer levels
typically have a hole on the end so they can be stored on a shadow board. Wipe with a
clean rag after use.
CALIBRATION
Measuring tools should be calibrated on a regular basis to ensure that they are
measuring accurately. Usually a known measured standard device is used to test the
accuracy of the tools. Measuring tools will lose some accuracy over time due to wear or
tear, or may suffer immediate loss due to sudden electrical or mechanical impact.
During the calibration process the tool may be reset to its factory settings.
SECTION OVERVIEW
All measuring tools should be handled with care, well-maintained and stored in the
original containers.
Calibration checks are required to ensure the measuring tools are accurate.
The tool must be operated in accordance with manufacturer’s specifications.
It may be necessary to wear protective clothing when using measuring equipment.
Read manufacturer’s guidelines for advice.
Faulty tools must be tagged and reported to the workshop supervisor.
Tools must only be used for their intended purposes.
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REVIEW QUESTIONS
Thimble ____________
Reading ____________
Thimble ____________
Reading ____________
Thimble ____________
Reading ____________
Thimble ____________
Reading ____________
Reading
____________________
Reading ____________________
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Q2 List 5 general rules to be considered when using measuring tools:
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Q4 Name the tool that is designed for measuring the inside diameter of an object.
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Q6 Name the tool that is designed for measuring the depth of a hole.
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Q7 Provide an automotive use for a straight edge.
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Q10 Why is it important to remove moisture from measuring tools before storing?
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Q12 How can a spirit level help to determine whether a surface is flat?
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ELEMENTS AND PERFORMANCE CRITERIA – UNIT AURTTA003
ELEMENT NAME
1.3 Potential hazards and risks associated with the task are identified and reported to
workplace supervisor
1.4 Measuring devices are selected to meet job requirements, and checked for
serviceability and calibration according to manufacturer specifications and workplace
procedures
ELEMENT NAME
2.1 Measuring devices are maintained and stored according to manufacturer specifications
and workplace procedures
2.2 Faulty devices are tagged and reported according to workplace procedures as required
ELEMENT NAME
3.1 Final inspection is made to ensure work meets task instructions and workplace
standards
3.2 Work area is cleaned, waste and non-recyclable materials are disposed of, and
recyclable material is collected and stored
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