P-115-123

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

Ability to :
2.1 Test the emission control device
2.2 Use multi meter
2.3 Read electronic fuel injection (EF
2.4 Use exhaust gas analyzer

Safety :
2.1 Handle with care

3. Start engine check exhaust gases Knowledge of :
4. Check engine performance 3.1 Lambda closed loop control syst

Ability to :
3.1 Check the four gases hydrocarbo
and oxygen

Safety :
3.1 Handle with care

Knowledge of :
4.1 Testing engine performance

Ability to :
4,1 Perform road test
4.2 Detect engine fault

Safety :
4.1 Possess a valid driving license
4.2 Use seat belt

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

es
FI) wiring system

tem
on, carbon monoxide, carbon dioxide

128

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 07 DUTY: REPAIR CLUTCH SYSTEM
TASK NO:
LEVEL: 01 TASK: CHECK CONDITION OF CLUTCH S

L1 PERFORMANCE STANDARD
CHECK CONDITION OF CLUTCH SYSTEM G
SYSTEM IS OPERATING SATISFACTORILY

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

1. Determine type of clutch system Knowledge of :
1.1 Function of clutch system (mech

Ability to :
1.1 Differentiate types of clutch syste

2. Check clutch pedal free play Knowledge of :
2.1 Clutch pedal free play
2.2 Clutch judder, noise and slip

Ability to :
2.1 Measure clutch pedal free play
2.2 Test clutch judder

SYSTEM

GIVEN SERVICE MANUAL USING HAND TOOLS ETC, SO THAT THE CLUTCH

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

hanically and hydraulically operated) 1. Hand tools
em 2. Service manual
3. Clutch fluid of suitable grade
4. Fender cover

129

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

2.3 Identify clutch noise
2.4 Determine clutch slip
2.5 Adjust pedal free play

Safety :
2.1 Handle with care

Attitude :
2.1 Good house keeping
2.2 Use fender cover

3. Check condition of clutch cable Knowledge of :
3.1 Clutch cable function
3.2 Cable locking device

Ability to :
3.1 Identify faulty clutch cable
3.2 Adjust cable locking device

Safety :
3.1 Handle with care

Attitude :
3.1 Good house keeping
3.2 Use fender cover

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

130

SUB-TASK / STEP ENABLING RE
4. Check hydraulic clutch system (Knowledge, Skill, A

Knowledge of :
4.1 Correct fluid level
4.2 Right type of fluid
4.3 Causes of spongy clutch

Ability to :
4.1 Identify leakage
4.2 Bleed clutch system

Safety :
4.1
Handle with care

Attitude :
4.1 Good house keeping
4.2 Use fender cover

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

131

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 07 DUTY: REPAIR CLUTCH SYSTEM
TASK NO:
LEVEL: 02 TASK: REPLACE CLUTCH CABLE

L2 PERFORMANCE STANDARD
REPLACE CLUTCH CABLE GIVEN SERVICE
FITTED PROPERLY.

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

1. Determine the location and position Knowledge of :

of clutch cable 1.1 Mechanical clutch system’s func

Ability to :
1.1 Locate clutch cable

2. Renew clutch cable Knowledge of :
2.1 Type of clutch cable

Ability to :
2.1 Release clutch adjuster unit
2.2 Remove/install clutch cable scur
2.3 Adjust pedal free play

Safety :
2.1 Ensure floor area is oil free
2.2. Use fender cover

E MANUAL USING HAND TOOLS ETC, SO THAT THE CLUTCH CABLE IS

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

ction 1. Hand tools
2. Service manual
3. Clutch cable
4. Fender cover

rrying pin

132

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 07 DUTY: REPAIR CLUTCH SYSTEM

TASK NO: 03 TASK: BLEED CLUTCH HYDRAULIC SYS

LEVEL: L2 PERFORMANCE STANDARD
BLEED CLUTCH HYDRAULIC SYSTEM GIVE
CLUTCH HYDRAULIC SYSTEM IS OPERATIN

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

1. Preparation of vehicle Knowledge of :
1.1 Proper vehicle functioning

Ability to :
1.1 Park vehicle on level ground
1.2 Jack both front wheels

Safety :
1.1 Use vehicle stand
1.2 Use vehicle stoppers

Attitude :
1.1 Use fender cover
1.2 Good housekeeping

STEM

EN SERVICE MANUAL USING BLEEDING EQUIPMENT SO THAT THE
NG SATISFACTORILY

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

1. Hand tools
2. Service manual
3. Bleeding equipment
4. Vehicle stand
5. Wheel stopper
6. Clutch fluid of suitable grade
7. Floor jack
8. Fender cover
9. Seat cover

133

SUB-TASK / STEP ENABLING RE
2. Hydraulic clutch bleeding (Knowledge, Skill, A

Knowledge of :
2.1 Function and layout hydraulic clu
2.2 Bleeding procedures
2.3 Topping up hydraulic fluid

Ability to :
2.1 Use bleeding equipment
2.2 Loosen bleeding nipple at the sla
2.3 Bleed according to service manu
2.4 Identify spongy clutch
2.5 Test clutch for proper functioning

Safety :
2.1 Use vehicle stands
2.2 Use wheel stoppers
2.3 Avoid spilling of hydraulic fluid

Attitude :
2.1 Good house keeping
2.2 Use fender cover
2.3 Use seat cover

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

utch system

ave cylinder/master pump
ual
g

134

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 07 DUTY: REPAIR CLUTCH SYSTEM
TASK NO:
LEVEL: 04 TASK: OVERHAUL CLUTCH MASTER PU

L2 PERFORMANCE STANDARD
OVERHAUL CLUTCH MASTER PUMP/SLAVE
BLEEDING EQUIPMENT AND REPAIR KITS
OPERATING SATISFACTORILY

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

1. Preparation of vehicle Knowledge of :
1.1 Proper vehicle positioning

Ability to :
1.1 Park vehicle on level ground
1.2 Jack both front wheels

Safety :
1.1 Use vehicle stands
1.2 Use wheel stoppers

Attitude ;
1.1 Use fender cover
1.2 Good housekeeping

UMP/SLAVE CYLINDER

E CYLINDER GIVEN SERVICE MANUAL USING PROPER HAND TOOLS,
ETC SO THAT THE CLUTCH MASTER PUMP/SLAVE CYLINDER IS

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

1. Hand tools
2. Service manual
3. Bleeding equipment
4. Vehicle stand
5. Wheel stopper
6. Replacement parts
7. Clutch fluid of suitable grade
8. Floor jack
9. Fender cover

135

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

2. Service clutch master pump and Knowledge of :
clutch slave cylinder 2.1 Master pump and slave cylinder
2.2 Service procedures

Ability to :
2.1 Remove master pump and slave
2.2 Disassemble master pump and s
2.3 Clean and fix new seal to pistons
2.4 Reassemble master pump and s
2.5 Fix master pump and slave cylin

Safety :
2.1 Handle hydraulic fluid with care

Attitude :
2.1 Use seat cover
2.2 Use fender cover
2.3 Good house keeping

3. Bleed hydraulic clutch system Knowledge of :
3.1 Bleeding procedures
3.2 Topping up hydraulic fluid

Ability to :
3.1 Use bleeding equipment
3.2 Loosen bleeding nipple at the sla

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

construction

e cylinder
slave cylinder
s
slave cylinder
nder

ave cylinder/master pump
136

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

3.3 Bleed according to service manu
3.4 Identify spongy clutch
3.5 Test clutch for proper functioning

Safety :
3.1 Use vehicle stand
3.2 Use wheel stopper
3.3 Use fender cover
3.4 Handle with care

Attitude :
3.1 Good house keeping

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

ual
g

137

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 07 DUTY: REPAIR CLUTCH SYSTEM

TASK NO: 05 TASK: REPLACE CLUTCH PRESSURE PL

LEVEL: L2 PERFORMANCE STANDARD
REPLACE CLUTCH PRESSURE PLATE, DIS
SO THAT THE CLUTCH ASSEMBLY FUNCTI

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

1. Preparation of vehicle Knowledge of :
1.1 Proper vehicle positioning

Ability to :
1.1 Park vehicle on level ground
1.2 Jack up vehicle/hoist vehicle

Safety :
1.1 Use vehicle stand
1.2 Use wheel stopper

Attitude :
1.1 Use seat cover
1.2 Use fender cover
1.3 Good housekeeping

LATE, DISC AND BEARING

SC AND BEARING GIVEN SERVICE MANUAL USING SPECIAL TOOLS ETC.
IONS SATISFACTORILY

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

1. Hand tools
2. Service manual
3. Special tools
4. Floor jack/ hoist
5. Vehicle stand
6. Transmission support
7. Wheel stopper
8. Clutch pressure plate
9. Clutch disc
10. Clutch bearing
11. Clutch fluid of suitable grade

138

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

2. Remove transmission from vehicle Knowledge of :
2.1 Clutch assembly function
2.2 Clutch system layout
2.3 Transmission layout

Ability to :
2.1 Remove transmission

Safety / attitude :
2.1 Vehicle stand
2.2 Use transmission support
2.3 Use seat cover
2.4 Use fender cover
2.5Good housekeeping

3. Install clutch assembly Knowledge of :
3.1 Clutch assembly construction an
3.2 Clutch system layout
3.3 Transmission layout

Ability to :
3.1 Remove/install clutch assembly
3.2 Determine condition of clutch ass
3.3 Install transmission
3.4 Test clutch for proper functioning
3.5 Adjust clutch pedal free play

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

nd function
sembly
g

139

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

Safety :
3.1 Use vehicle stand
3.2 Use transmission support

Attitude :
3.1 Use seat cover
3.2 Use fender cover
3.3 Good house keeping

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

140

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 08 DUTY: REPAIR MANUAL DRIVE TRAIN
TASK NO:
LEVEL: 01 TASK: CHECK TRANSAXLE

L1 PERFORMANCE STANDARD
CHECK TRANSAXLE GIVEN THE SERVIC
OPERATES SATISFACTORILY

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

1. Hoist up vehicle Knowledge of :
2. Inspect oil leak 1.1 Jacking points

Ability to :
1.1 Operate hoist

Safety :
1.1 Place hoist at proper height

Knowledge of :
2.1 Possible oil leak locations

Ability to :
2.1 Locate source of leakage

Safety / attitude :
2.1 Good house keeping

CE MANUAL USING THE VEHICLE HOIST SO THAT THE TRANSAXLE

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

1. Service manual
2. Complete hand tools
3. Vehicle hoist
4. Transmission oil of grade
5. Seat cover
6. Fender cover

141

SUB-TASK / STEP ENABLING RE
3. Check gear shift pattern (Knowledge, Skill, A

4. Check oil level Knowledge of :
3.1 Gear shift mechanism
5. Top up oil (if necessary)
Ability to :
3.1 Evaluate smooth gear shift

Safety :
3.1 Use seat cover

Knowledge of :
4.1 Proper grade of gear oil

Ability to :
4.1 Determine maximum/minimum le

Safety / attitude :
4.1 Avoid spill oil on floor
4.2 Use fender cover

Knowledge of :
5.1 Proper grade of grade oil

Ability to :
5.1 Determine quantity of oil required

Safety / attitude :
5.1 Good housekeeping
5.2 Use fender cover

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

evel
d
142

SUB-TASK / STEP ENABLING RE
6. Check conditions of drive shaft (Knowledge, Skill, A
rubber boots
Knowledge of :
7. Report defect 6.1 Drive shaft assembly and layout

Ability to :
6.1 Identify faulty parts

Safety/Attitude :
6.1 Cleanliness and systematic

Knowledge of :
7.1 Part serviceability

Ability to :
7.1 Make oral and written report

Safety/Attitude :
7.1 Good housekeeping

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

143

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 08 DUTY: REPAIR MANUAL DRIVE TRAIN
TASK NO:
LEVEL: 02 TASK: CHECK TRANSMISSION

L1 PERFORMANCE STANDARD
CHECK TRANSMISSION GIVEN SERVICE M
THE TRANSMISSION OPERATES SATISFAC

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

1. Hoist up vehicle Knowledge of :
1.1 Proper jacking spots
2. Conduct physical check on
transmission for damages Ability to :
1.1 Operate hoist

Safety :
1.1 Raise hoist at proper height

Knowledge of :
2.1 Function of transmission

Ability to :
2.1 Locate damages

MANUAL USING VEHICLE HOIST AND APPROPRIATE HAND TOOLS SO THAT
CTORILY

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

1. Service manual
2. Hoists
3. Hand tools
4. Transmission oil of suitable grade

144

SUB-TASK / STEP ENABLING RE
3. Check for oil leak (Knowledge, Skill, A

4. Top up transmission oil Safety / attitude :
(if necessary) 2.1 Good house keeping

5. Check for smooth gear shift Knowledge of :
3.1 Possible oil leak locations

Ability to :
3.1 Locate source of leakage

Safety / attitude :
3.1 Good house keeping

Knowledge of :
4.1 Transmission oil grade

Ability to :
4.1 Choose proper grade of oil
4.2 Filling transmission oil

Safety/Attitude :
4.1 Good house keeping

Knowledge of :
5.1 Gear shifting characteristics

Ability to :
5.1 Evaluate smooth shifting pattern

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

n
145

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

Safety/Attitude :
5.1 Good house keeping

6. Check condition of propeller shaft Knowledge of :
and U-joints 6.1 Propeller shaft assembly/function

Ability to :
6.1 Locate defects

7. Report any defects Knowledge of :
7.1 Parts serviceability

Ability to :
7.1 Make oral and written report
7.2 Rectify the defects

Safety/Attitude :
7.1 Good house keeping

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

n

146

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 08 DUTY: REPAIR MANUAL DRIVE TRAIN

TASK NO: 03 TASK: CHECK REAR AXLE

LEVEL: L1 PERFORMANCE STANDARD
CHECK REAR AXLE GIVEN SERVICE MAN
REAR AXLE OPERATES SATISFACTORILY

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

1. Hoist up vehicle Knowledge of :
1.1 Proper jacking procedure
2. Conduct physical check on rear
axle for damages Ability to :
1.1 Operate hoist safely

Safety/Attitude :
1.1 Raise hoist to suitable height

Knowledge of :
2.1 Rear axle construction

Ability to :
2.1 Identify defects

Safety / attitude :
2.1 Good house keeping

NUAL, USING VEHICLE HOIST AND APPROPRIATE HAND TOOLS SO THAT

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

1. Service manual
2. Hoist
3. Hand tools
4. Rear axle oil of proper grade

147

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

3. Check for oil leaks Knowledge of :
3.1 Possible oil leak locations

Ability to :
3.1 Locate source of leakage

Safety / attitude :
3.1 Good house keeping

4. Top up rear axle oil (if necessary) Knowledge of :
4.1 Suitable oil grade

Ability to :
4.1 Choose correct grade of oil

Safety / attitude :
4.1 Good house keeping

5. Report any defects Knowledge of :
5.1 Parts serviceability

Ability to :
5.1 Make oral and written report

Safety/Attitude :
5.1 Good house keeping

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

148

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 08 DUTY: REPAIR MANUAL DRIVE TRAIN
TASK NO:
LEVEL: 04 TASK: OVERHAUL TRANSMISSION

L2 PERFORMANCE STANDARD
OVERHAUL TRANSMISSION GIVEN WORK
FUNCTION ACCORDING TO MANUFACTUR

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

1. Determine the type of transmission Knowledge of :
1.1 Transmission function and opera

Ability to :
1.1 Identify type of transmission

2. Mount transmission on overhaul Knowledge of :
stand 2.1 Overhauling procedure

Ability to :
2.1 Secure transmission on stand

Safety/Attitude :
2.1 Handle with care

KSHOP MANUAL USING SPECIFIC HAND TOOLS SO THAT TRANSMISSION
RER’S SPECIFICATION

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

ation 1. Workshop manual
2. Overhaul stand
3. Hand tools
4. Service special tools
5. Cleaning materials
6. Gasket set
7. Replacement parts
8. Transmission oil of suitable grade

149

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

3. Select required tools and service Knowledge of :
special tools 3.1 Service special tools application

Ability to :
3.1 Choose precisely tools required

Safety/Attitude :
3.1 Handle with care

4. Drain transmission oil Knowledge of :
4.1 Procedure of draining oil

Ability to :
4.1 Drain oil

Safety / attitude :
4.1 Good housekeeping

5. Dismantle the transmission Knowledge of :
5.1 Gear assembly and shifting mec
5.2 Various gear engagement

Ability to :
5.1 Identify parts and assembly
5.2 Dismantle the transmission acco

Safety/Attitude :
5.1 Avoid mixing of parts
5.2 Good housekeeping

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

and usage

chanism
ording to procedure

150

SUB-TASK / STEP ENABLING RE
6. Clean all parts (Knowledge, Skill, A

7. Check parts for serviceability Knowledge of :
6.1 Solvent used for cleaning
8. Assemble all parts
Ability to :
6.1 Clean parts thoroughly

Safety/Attitude :
6.1 Handle with care

Knowledge of :
7.1 Parts serviceability

Ability to ;
7.1 Determine serviceability of parts

Safety/Attitude :
7.1 Good housekeeping

Knowledge of :
8.1 Transmission part assembly

Ability to :
8.1 Install parts accordingly

Safety :
8.1 Handle parts with care

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

151

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

9. Check for proper gear shift and Knowledge of :
smooth engagement 9.1 Gear function and engagement

Ability to :
9.1 Evaluate smoothness of gear sh

Safety :
9.1 Use seat cover
9.2 Handle with care

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

hift and engagement

152