P-115-123

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

6. Install alternator to the engine Ability to :
7. Test voltage and current output 5.1 Fix the components at the correc
5.2 Assemble alternator

Knowledge of :
6.1 Location of alternator in the engi
6.2 Type of belt

Ability to :
6.1 Fix alternator at correct position
6.2 Adjust alternator belt tension

Knowledge of :
7.1 Ohm’s law
7.2 Alternator operation

Ability to :
7.1 Perform alternator output test

Safety :
7.1 Caution on polarity
7.2 Handle with care

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

ct position

ine

78

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 04 DUTY: SERVICE VEHICLE ELECTRICAL S
TASK NO:
LEVEL: 10 TASK: CHECK DASH BOARD INSTRUME

L2 PERFORMANCE STANDARD
CHECK DASH BOARD INSTRUMENT GIVEN
THE GAUGES AND INDICATOR LAMPS FUN

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

1. Obtain wiring circuit diagram of Knowledge of :
vehicle 1.1 Wiring diagram system

2. Identify wiring sockets and Ability to :
connectors 1.1 Read wiring diagram

Knowledge of :
2.1 Type of socket connector
2.2 Wire colour coding and sizes

Ability to :
2.1 Disconnect connector
2.2 Read wiring diagram

SYSTEM
ENTS

N WIRING BLUE PRINT OF VEHICLE USING A MULTI METER, ETC SO THAT
NCTION CORRECTLY

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

1. Multi meter
2. Wiring blue print of vehicle
3. Hand tools
4. Service manual

79

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

3. Remove meter panel from dash Knowledge of :
board 3.1 Layout of meter panel/instrumen
3.2 Symbol of meter panel/instrumen

Ability to :
3.1 Disconnect the connector from m
3.2 Disassemble meter panel from d

Safety :
3.1 Handle with care

4. Check gauges and indicators for Knowledge of :
proper functioning (replace if 4.1 Layout of meter panel/instrumen
necessary)
Ability to :
4.1 Use multi meter
4.2 Identify connection and continuit
4.3 Test gauges at meter panel

5. Install meter panel to dash board Knowledge of :
5.1 Layout of meter panel/instrumen

Ability to :
5.1 Fix meter panel at correct positio
5.2 Connect connector to panel mete

Safety :
5.1 Handle with care

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

nt cluster
nt cluster
meter panel
dash board

nt cluster
ty at meter panel

nt cluster
on to dash board
er/instrument cluster

80

OCCUPATION: MOTOR VEHICLE TECHNICIAN

DUTY NO. 04 DUTY: SERVICE ELECTRICAL SYSTEM
TASK NO:
LEVEL: 11 TASK: CHECK POWER WINDOWS

L3 PERFORMANCE STANDARD
CHECK POWER WINDOWS GIVEN SERVICE
WINDOWS FUNCTION PROPERLY ACCORD

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

1. Check wiring circuit for : Knowledge of :
- Solenoid motor 1.1 Basic electricity/ Electromagnetic
- Switches 1.2 Function of solenoid motor and r
- Relays 1.3 Layout of power windows wiring
- Linkage
Ability to :
2. Check continuity of each 1.1 Use multi meter
components 1.2 Read wiring diagram
1.3 Identify and locate of power wind
1.4 Test voltage in wiring circuit

Safety / attitude :
1.1 Handle with care

Knowledge of :
2.1 Ohm’s law
2.2 Multi switch function
2.3 Fuse type and function

E MANUAL USING MULTI METER, HAND TOOLS ETC SO THAT POWER
DING MANUFACTURER’S SPECIFICATION

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

c Force 1. Hand tools
relays 2. Service manual
diagram 3. Multi meter

dow parts

81

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

Ability to :
2.1 Use multi meter
2.2 Test multi switch/switches/fuse
2.3 Remove multi switch/switches

Safety / attitude :
2.1 Handle with care

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

82

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 05 DUTY: PERFORM ENGINE REPAIR
TASK NO:
LEVEL: 01 TASK: SERVICE COOLING SYSTEM

L1 PERFORMANCE STANDARD
SERVICE COOLING SYSTEM GIVEN SERVIC
THAT THE OPERATION MEET THE REQUIR

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

1. Identify the component location Knowledge of :
1.1 Cooling system layout

Ability to :
1.1 Locate each individual compone

Safety :
1.1 Handle with care

2. Check leakage of the system with Knowledge of :
radiator pressure tester 2.1 The function of radiator pressure
2.2 Cooling system

Ability to :
2.1 Use radiator pressure tester
2.2 Interpret test result

CE MANUAL USING RADIATOR PRESSURE TESTER, HAND TOOLS ETC SO
REMENT OF MANUFACTURER’S SPECIFICATION

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

1. Hand tools
2. Service manual
3. Radiator pressure tester
4. Radiator hoses
ent

e tester

83

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

Safety :
2.1 Follow manufacturer’s specificat
system

Attitude :
2.1 Good house keeping
2.2 Use fender cover

3. Conduct visual inspection on hoses Knowledge of :

( replace if necessary) 3.1 Cooling system layout

Ability to :
3.1 Identify faulty hoses
3.2 Replace new hoses

Safety :
3.1 Beware of hot hoses

Attitude :
3.1 Good house keeping
3.2 Use fender cover

4. Check thermostat for proper Knowledge of :
functioning 4.1 Function of thermostat
4.2 Engine working temperature

Ability to:
4.1 Carry out testing on thermostat
4.2 Read thermometer

Safety :
4.1 Handle with care

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

tion when pressurizing the cooling

84

SUB-TASK / STEP ENABLING RE
5. Check water pump (replace if (Knowledge, Skill, A
necessary)
Attitude :
6. Flush radiator 4.1 Good house keeping

Knowledge of :
5.1 Function of water pump

Ability to :
5.1 Identify faulty water pump
5.2 Replace water pump
5.3 Check and adjust fan belt

Safety :
5.1 Handle with care

Attitude :
5.1 Use fender cover
5.2 Good house keeping

Knowledge of :
6.1 Function of radiator

Ability to :
6.1 Remove radiator from vehicle

Safety :
6.1 Do not open the cap of hot radia
6.2 Release system pressure before

Attitude :
6.1 Use fender cover
6.2 Good house keeping

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

ator
e removing radiator cap

85

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 05 DUTY: PERFORM ENGINE REPAIR
TASK NO:
LEVEL: 02 TASK: SERVICE LUBRICATING SYSTEM

L1 PERFORMANCE STANDARD
SERVICE LUBRICATING SYSTEM GIVEN SE
METER SO THAT THE ENGINE LUBRICATIN
SPECIFICATION

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

1. Determine the layout of lubricating Knowledge of :

system components 1.1 Function of lubricating system an

Ability to :
1.1 Identify system and components

Attitude :
1.1 Use fender cover

ERVICE MANUAL USING HAND TOOLS PRESSURE GAUGE, AND MULTI
NG SYSTEM OPERATE ACCORDING TO THE MANUFACTURER’S

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

nd components 1. Hand tools
s layout 2. Oil pressure gauge
3. Service manual
4. Multi meter
5. Fender cover

86

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

2. Check lubricating oil for leakage Knowledge of :
while engine running 2.1 Function of lubricating system

Ability to :
2.1 Identify oil leakage

Safety / attitude :
2.1 Good house keeping
2.2 Use fender cover

3. Check the pressure of lubricating Knowledge of :
system 3.1 Function of lubricating system

Ability to :
3.1 Read oil pressure gauge/oil warn

Safety / attitude :
3.1 Good house keeping
3.2 Use fender cover

4. Replace oil pressure switch Knowledge of :
4.1 Procedure of testing oil pressure

Ability to :
4.1 Use and read multi meter

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

ning light
e switch

87

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

Safety / attitude :
4.1 Good house keeping
4.2 Use fender cover

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

88

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 05 DUTY: PERFORM ENGINE REPAIR
TASK NO:
LEVEL: 03 TASK: DETERMINE ENGINE CONDITION

L1 PERFORMANCE STANDARD
DETERMINE ENGINE CONDITION GIVEN SE
CONDITION IS WITHIN MANUFACTURER'S

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

1. Determine type/model of engine Knowledge of :
1.1 Principle of engine operation
2. Warm up engine to its working 1.2 Types of engines
temperature
Ability to :
1.1 Identify types of engine

Knowledge of :
2.1 Engine operating temperature

Ability to :
2.1 Read temperature gauge

Safety :
2.1 Prevent engine from over heating

N

ERVICE MANUAL USING COMPRESSION GAUGE SO THAT ENGINE
SPECIFICATION

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

1. Hand tools
2. Compression tester
3. Multi meter
4. Service manual
5. Fender cover
6. Seat cover

ng
89

SUB-TASK / STEP ENABLING RE
3. Carry out the compression test (Knowledge, Skill, A

Attitude :
2.1 Use fender cover
2.2 Use seat cover

Knowledge of :
3.1 Procedure of testing
3.2 Dry and wet test procedure

Ability to :
3.1 Use compression tester
3.2 Carry out compression test
3.3 Analyse test result

Safety :
3.1 Handle equipment with care
3.2 Follow proper procedure during t

Attitude :
3.1 Good house keeping
3.2 Use fender cover

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

testing

90

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 05 DUTY: PERFORM ENGINE REPAIR

TASK NO: 04 TASK: CARRY OUT TOP OVERHAUL

LEVEL: L1 PERFORMANCE STANDARD
CARRY OUT TOP OVERHAUL GIVEN SERVI
PERFORMANCE MEETS MANUFACTURER’S

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

1. Determine type/model engine Knowledge of :
2. Drain water and engine oil 1.1 Principle of engine operation
1.2 Types of engine

Ability to :
1.1 Identify types of engines

Safety :
1.1 Good house keeping

Knowledge of :
2.1 Location of drain plug

Ability to :
2.1 Use correct size of tools

ICE MANUAL USING CORRECT TOOLS AND EQUIPMENT SO THAT ENGINE
S SPECIFICATION

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

1. Hand tools
2. Service manual
3. Torque wrench
4. Dial gauge
5. Internal and external micrometer
6. Straight edge
7. Feeler gauge
8. Exhaust gas analyser
9. Timing light
10. Tachometer
11. Valve grinding paste
12. Valve grinding stick
13. Taps and die
14. File
15. Fender cover

91

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

3. Remove hindering components Safety :
- damaged thread 2.1 Ensure engine is completely coo
- broken studs 2.2 Prevent oil spill
- cracked bracket
Attitude :
2.1 Good house keeping
2.2 Handle with care
2.3 Use fender cover

Knowledge of :
3.1 Components to be removed
3.2 Procedure of removing hindering
3.3 Thread, tap and die and filing

Ability to :
3.1 Use correct tools
3.2 Use tap and die
3.3 Hacksaw and file

Safety / attitude :
3.1 Good house keeping
3.2 Handle with care
3.3 Use fender cover

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS
oled down

g components

92

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

4. Remove rocker mechanism Knowledge of :
4.1 Layout of rocker mechanism

Ability to :
4.1 Remove rocker mechanism acco

Safety / attitude :
4.1 Good house keeping
4.2 Handle with care

5. Remove cylinder head from engine Knowledge of :
5.1 Removing procedure of cylinder
5.2 Dismantling cylinder head compo
5.3 Cleaning cylinder head compone

Ability to :
5.1 Loosen cylinder head bolts acco
5.2 Check cylinder head surface for
5.3 Check camshaft for wear full out
5.4 Check valve stem and valve guid
5.5 Do valve lapping correctly

Safety / attitude :
5.1 Good house keeping
5.2 Handle with care

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

ording to service manual

head
onents
ents
ording to procedure
war page
t end float
de for wear

93

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

6. Install cylinder head to engine Knowledge of :
6.1 Installing procedure

Ability to :
6.1 Use torque wrench
6.2 Tighten cylinder head according

Safety / attitude :
6.1 Good house keeping
6.2 Handle with care
6.3 Use fender cover

7. Install rocker mechanism assembly Knowledge of :
7.1 Assembling rocker mechanism

Ability to :
7.1 Set valve timing and install timin
7.2 Adjust valve clearance

Safety / attitude :
7.1 Good house keeping
7.2 Handle with care
7.3 Use fender cover

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

to torque and sequence

ng belt
94

SUB-TASK / STEP ENABLING RE
8. Fill in coolant and engine oil (Knowledge, Skill, A

Knowledge of :
8.1 Correct grade of oil and suitable

Ability to :
8.1 Fill up correct quantity of oil and

Safety / attitude :
8.1 Good house keeping
8.2 Handle with care
8.3 Use fender cover

9. Run the engine and check for Knowledge of :
leakage 9.1 Possible oil and coolant leakage

Ability to :
9.1 Check leakage

Attitude :
9.1 Good house keeping
9.2 Handle with care
9.3 Use fender cover

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS
coolant
coolant

e area

95

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

10. Tune up engine to specification Knowledge of :
10.1 Procedure of engine tuning

Ability to :
10.1 Use engine tuning equipment
10.2 Operate exhaust analyser, timin

Safety / attitude :
10.1 Good house keeping
10.2 Handle with care
10.3 Use fender cover

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

ng light and tachometer

96

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 05 DUTY: PERFORM ENGINE REPAIR
TASK NO:
LEVEL: 05 TASK: CARRY OUT ENGINE OVERHAUL

L2 PERFORMANCE STANDARD
PERFORM ENGINE OVERHAUL GIVEN SER
MECHANICAL CONDITION OF THE ENGINE

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

1. Determine type/model of engine Knowledge of :
1.1 Principle of engine operation

Ability to :
1.1 Identify types of engines

Safety / attitude :
1.1 Disconnect negative battery term

2. Drain water and engine oil Knowledge of :
2.1 Location of drain plug

Ability to :
2.1 Use correct tools

RVICE MANUAL USING HAND TOOLS, EQUIPMENT ETC SO THAT
E CAN BE RESTORED TO THE MANUFACTURER’S SPECIFICATION

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

minal 1. Hand tools
2. Torque wrench
3. Plastic gauge
4. Measuring instrument such as :

- Vernier caliper
- Micrometer
- Connecting rod jig
- Feeler gauge
- Ring expender
- Ring compressor
- Bore gauge
5. Service manual
6. Exhaust gas analyser
7. Tachometer
8. Surface plate
9. Vee block
10. Dial gauge indicator
11. Fender cover

97

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

Safety / attitude :
2.1 Good house keeping
2.2 Handle with care
2.3 Use fender cover

3. Remove hindering components Knowledge of :
- damaged thread 3.1 Components to be removed
- broken stud 3.2 Correct procedure of removing
- cracked bracket
Ability to :
3.1 Use correct tools

Safety / attitude :
3.1 Good house keeping
3.2 Handle with care
3.3 Use fender cover

4. Remove engine from the vehicle Knowledge of :
4.1 Layout of the engine

Ability to :
4.1 Operate engine hoist

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

98

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

Safety :
4.1 Ensure engine is properly secure
4.2 Handle engine with care

Attitude :
4.1 Good house keeping
4.2 Use fender cover

5. Remove rocker mechanism Knowledge of :
5.1 Rocker mechanism layout
5.2 The procedure of removing timin

Ability to :
5.1 Disassemble rocker assembly ac

Safety :
5.1 Handle components with care

Attitude :
5.1 Good house keeping

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

ed to hoist when lifting

ng chain/timing belt
ccording to service manual

99

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

6. Remove cylinder head from engine Knowledge of :
6.1 Cylinder head construction

Ability to :
6.1 Loosen cylinder head bolts acco

Safety :
6.1 Handle components with care
6.2 Ensure floor area is oil free

Attitude :
6.1 Good house keeping

7. Remove crank case and oil sump Knowledge of :
7.1 Function and operation of oil pum

Ability to :
7.1 Check crank shaft for wear, tape
7.2 Check crank shaft end float
7.3 Check oil pump for wear
7.4 Analyse condition of parts
7.5 Determine components
7.6 Use measuring instruments and

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

ording to sequence

mp and crankshaft
er and ovulate

torque wrench

100

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

Safety / attitude :
7.1 Good house keeping
7.2 Handle with care

8. Remove and check engine block Knowledge of :
8.1 Function and operation of the en

Ability to :
8.1 Use hand tools, measuring instru
8.2 Check cylinder bore for wear, tap
8.3 Check connecting rod for bent an
8.4 Check piston/piston rings for wea
8.5Check piston ring gap and side c

Safety / attitude :
8.1 Good housekeeping

9. Assemble crankcase and oil sump Knowledge of :
9.1 Function and construction of eng

Ability to :
9.1 Assemble engine according to pr
9.2 Identify parts for serviceability

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

ngine block components
uments and torque wrench
per and ovality
nd twist
ar
learances

gine
procedure

101

SUB-TASK / STEP ENABLING RE
10. Install cylinder head (Knowledge, Skill, A

11. Install rocker mechanism Safety / attitude :
9.1 Handle with care

Knowledge of :
10.1 Cylinder head tightening torque

Ability to :
10.1 Fix valves assembly to cylinder
10.2 Install cylinder head to the engi
10.3 Tighten cylinder head according

Safety / attitude :
10.1 Handle with care

Knowledge of :
11.1 Layout of rocker mechanism an

Ability to :
11.1 Set valve timing and fix timing b
11.2 Adjust valve clearances

Safety / attitude :
11.1 Handle with care

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

e and sequence
r head
ine block
g to sequence and torque

nd valve assembly
belt

102