P-115-123

SUB-TASK / STEP ENABLING RE
3. Adjust steering free play (Knowledge, Skill, A

Knowledge of :
3.1 Steering free play

Ability to :
3.1 Adjust steering free play

Safety/Attitude :
3.1 Use fender cover
3.2 Use seat cover

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

201

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 11 DUTY: REPAIR STEERING SYSTEM
TASK NO:
LEVEL: 02 TASK: REPLACE MANUAL STEERING SY

L1 PERFORMANCE STANDARD
REPLACE MANUAL STEERING SYSTEM CO
STEERING OPERATES SATISFACTORILY

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

1. Remove steering system Knowledge of :
components 1.1 Manual steering’s components fu

2. Clean and inspect components Ability to :
1.1 Dismantle steering components

Safety/Attitude :
1.1 Good housekeeping
1.2 Use fender cover

Knowledge of :
2.1 Steering component wear and te

Ability to :
2.1 Check for serviceability

YSTEM COMPONENTS

OMPONENTS GIVEN SERVICE MANUAL USING SPECIAL TOOLS SO THAT

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

unction and construction 1. Service manual
2. Hand tools
3. Special tools
4. Solvent
5. Replacement parts
6. Grease
7. Fender cover

ear

202

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

Safety / attitude :
2.1 Good housekeeping

3. Replace manual steering system Knowledge of :
component 3.1 Sourcing replacement parts

Ability to :
3.1 Dismantle worn parts from the sy
3.2 Replace new parts to the system

Safety/Attitude :
3.1 Handle with care
3.2 Good housekeeping

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

ystem
m

203

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 11 DUTY: REPAIR STEERING SYSTEM

TASK NO: 03 TASK: CARRY OUT WHEEL ALIGNMENT

LEVEL: L2 PERFORMANCE STANDARD
CARRY OUT WHEEL ALIGNMENT GIVEN SE
STEERING GEOMETRY MEETS MANUFACT

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

1. Park vehicle at alignment pit Knowledge of :
1.1 Alignment equipment application

Ability to :
1.1 Place wheels properly on the tur

Safety / attitude :
1.1 Handle with care

2. Check condition of all wheels, front Knowledge of :

and rear suspension 2.1 Construction of the suspension

Ability to :
2.1 Identify defective wheels
2.2 Identify defective suspension

T

ERVICE MANUAL USING ALIGNMENT EQUIPMENT SO THAT THE
TURER’S SPECIFICATION

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

n 1. Service manual
rn table 2. Alignment data
3. Wheel alignment equipment
4. Hand tools

204

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A
3. Mount alignment attachment
Safety/Attitude :
4. Check and adjust 2.1 Handle with care
- King-pin inclination
- Caster angle Knowledge of :
- Camber angle 3.1 Alignment equipment mounting p
- Toe-in / Toe-out
Ability to :
5. Conduct road test 3.1 Fix alignment attachment

Safety/Attitude :
3.1 Handle with care

Knowledge of :
4.1 Wheel alignment adjustment pro

Ability to :
4.1 Read data from screen/gauge
4.2 Adjust wheel alignment accordin

Safety/Attitude :
4.1 Handle with care
4.2 Use fender cover

Knowledge of :
5.1 Road test procedure

Ability to :
5.1 Evaluate alignment characteristic

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

procedure

ocedure
ng to procedure

cs
205

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

3. Mount steering box on jig Knowledge of :
3.1 Jig/fixture application
4. Disassemble steering box
Ability to :
5. Clean and inspect steering box 3.1 secure steering box to jig fixture
components
Safety :
3.1 Handle with care

Knowledge of :
4.1 Disassembling steering box proc

Ability to :
4.1 Drain oil from steering box
4.2 Dismantle steering box compone

Safety/Attitude :
4.1 Handle with care
4.2 Good housekeeping

Knowledge of :
5.1 Parts serviceability

Ability to :
5.1 Conduct visual check on steering
5.2 Determine steering box compone

Safety/Attitude :
5.1 Handle with care
5.2 Good housekeeping

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

cedure
ent

g box component
ents for serviceability

208

SUB-TASK / STEP ENABLING RE
6. Reassemble Components (Knowledge, Skill, A

7. Mount steering box to vehicle Knowledge of :
6.1 Reassembling procedure

Ability to :
6.1 Fix component to steering box

Safety :
6.1 Handle with care

Knowledge of :
7.1 Installing procedure

Ability to :
7.1 Mount steering box to vehicle
7.2 Connect steering linkages

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

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

209

OCCUPATION: MOTOR VEHICLE MECHANICS

DUTY NO. 11 DUTY: REPAIR STEERING SYSTEM

TASK NO: 05 TASK: SERVICE POWER STEERING SYS

LEVEL: L2 PERFORMANCE STANDARD
SERVICE POWER STEERING SYSTEM GIVE
POWER STEERING OPERATES SATISFACT

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

1. Check power steering fluid and belt Knowledge of :

tension 1.1 Power steering layout

1.2 Power steering component funct

Ability to :
1.1 Ascertain correct belt tension an

Safety :
1.1 Use fender cover
1.2 Handle with care

2. Start engine and turn steering Knowledge of :
wheel 2.1 Power steering system operation

Ability to :
2.1 Evaluate power steering for prop

STEM

EN SERVICE MANUAL USING APPROPRIATE TOOLS, ETC SO THAT THE
TORILY

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

tion and operation 1. service manual
nd fluid level 2. Hand tools
3. Power steering fluid
4. Fender over

n
per function

210

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

Safety/Attitude :
2.1 Handle with care

3. Adjust steering pump belt tension Knowledge of :
and top up steering fluid if necessary 3.1 Belt tension adjustment procedu
3.2 Proper steering fluid level

Ability to :
3.1 Tension the belt correctly

Safety / attitude :
3.1 Handle with care
3.2 Use fender cover

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

ure

211

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 11 DUTY: REPAIR STEERING SYSTEM
TASK NO:
LEVEL: 06 TASK: OVERHAUL POWER STEERING S

L2 PERFORMANCE STANDARD
OVERHAUL POWER STEERING SYSTEM GI
SO THAT THE POWER STEERING SYSTEM

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

1. Drain power steering fluid Knowledge of :
1.1 Draining procedure

Ability to :
1.1 Remove oil drain plug

Safety / attitude :
1.1 Use fender cover
1.2 Use steering cover
1.3 Handle with care

2. Remove power steering box and Knowledge of :
hydraulic pump 2.1 Power steering components layo
2.2 Power steering pump and box co

SYSTEM

IVEN WORKSHOP MANUAL USING HAND TOOLS, PRESSURE GAUGE ETC,
M OPERATES SATISFACTORILY

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

1. Workshop manual
2. Hand tools
3. Replacement parts
4. Pressure gauge
5. Power steering fluid
6. Fender cover
7. Steering cover

out
onstruction, function and operation

212

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

Ability to :
2.1 Disconnect belt and pipe lines

Safety/Attitude :
2.1 Handle with care
2.2 Use fender cover

3. Dismantle power steering box and Knowledge of :
pump assembly 3.1 Steering box and pump function
3.2 Disassembling procedure

Ability to :
3.1 Strip of steering box and pump c

Safety :
3.1 Use flare wrench for pipe lines
3.2 Handle with care

4. Clean and inspect power steering Knowledge of :
box and pump components 4.1 Power steering box pump parts w

Ability to :
4.1 Conduct visual check on power s
4.2 Determine steering box and pum

Safety/Attitude :
4.1 Good housekeeping
4.2 Handle with care

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

and operation
components

wear and tear
steering box and pump components
mp components for serviceability

213

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

5. Reassemble power steering box Knowledge of :
and pump components 5.1 Resembling procedure

Ability to :
5.1 Fix components to the power ste

Safety :
5.1 Handle with care

6. Install power steering box and Knowledge of :
pump to vehicle 6.1 Installing procedure

Ability to :
6.1 Mount the power steering box an
6.2 Connect pipe lines to the power
6.3 Fill the power steering system wi
6.4 Bleed the system

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

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

eering box and pump

nd pump to vehicle
r steering box and pump
with correct type of fluid

214

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 12 DUTY: REPAIR SUSPENSION SYSTEM
TASK NO:
LEVEL: 01 TASK: REPLACE BALL JOINTS

L1 PERFORMANCE STANDARD
REPLACE BALL JOINTS GIVEN THE SERVIC
OPERATE SATISFACTORILY

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

1. Drive car to ramp, or jack up the Knowledge of :
car 1.1 Using ramp and jacks

Ability to :
1.1 Jack up the vehicle

Safety :
1.1 Handle with care

2. Remove and check ball joints Knowledge of :
2.1 Ball joints construction

Ability to :
2.1 Determine the condition of ball jo
2.2 Extract defective ball joints

Safety :
2.1 Ensure vehicle is safely supporte

CE MANUAL USING THE APPROPRIATE TOOLS SO THAT THE BALL JOINTS

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

1. Ramp or floor jack
2. Steering lock-up device
3. Brake pedal press
4. Vehicle stand
5. Service manual
6. Ball joints splitter/remover

oints
ed when removing the ball joints
215

SUB-TASK / STEP ENABLING RE
3. Install ball joints (Knowledge, Skill, A

Knowledge of :
3.1 Ball joints installing procedure

Ability to :
3.1 Fix ball joints
3.2 Tighten to correct torque

Safety :
3.1 Handle with care

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

216

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 12 DUTY: REPAIR SUSPENSION SYSTEM
TASK NO:
LEVEL: 02 TASK: REPLACE SUSPENSION BUSHES

L1 PERFORMANCE STANDARD
REPLACE SUSPENSION BUSHES GIVEN SE
SUSPENSION BUSHES OPERATE SATISFA

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

1. Remove suspension bushes Knowledge of :
1.1 Construction and function of sus
2. Check condition of bushes and 1.2 Removing procedure of suspens
seating
Ability to :
1.1 Dismantle suspension componen
1.2 Use hydraulic press to remove b

Safety :
1.1 Handle with care

Knowledge of :
2.1 Function of bushes
2.2 Wear and tear of bushes

Ability to :
2.1 Inspect bushes for serviceability

S

ERVICE MANUAL USING THE APPROPRIATE TOOLS SO THAT THE
ACTORILY

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

spension components 1. Service manual
sion bushes 2. Hand tools
3. Floor jack/ramp
nt from vehicle 4. Creeper
bushes 5. Reamers
6. Hydraulic press

217

SUB-TASK / STEP ENABLING RE
3. Install suspension bush (Knowledge, Skill, A

Safety :
2.1 Good housekeeping

Knowledge of :
3.1 Installing procedure

Ability to :
3.1 Use hydraulic press to fix the bus

Safety :
3.1 Handle with care

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

shes onto the seating

218

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 12 DUTY: REPAIR SUSPENSION SYSTEM
TASK NO:
LEVEL: 03 TASK: REPLACE SHOCK ABSORBERS/B

L1 PERFORMANCE STANDARD
REPLACE SHOCK ABSORBERS/BUMP STO
THAT SHOCK ABSORBERS AND BUMP STO

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

1. Test shock absorbers on vehicle Knowledge of :
1.1 Shock absorbers types and func
1.2 Shock absorber testing procedur

Ability to :
1.1 Determine serviceability of shock

Safety :
1.1 Handle with care

2. Conduct physical/visual check on Knowledge of :
shock absorber 2.1 Shock absorber function

Ability to :
2.1 Check shock absorber visually

BUMP STOPPERS

OPPERS GIVEN SERVICE MANUAL USING APPROPRIATE TOOLS ETC SO
OPPERS OPERATE SATISFACTORILY

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

ction 1. Service manual
res 2. Complete hand tools
3. Fender cover
k absorber 4. Replacement parts for shock absorber
and bump stoppers

219

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

3. Install shock absorber to vehicle Knowledge of :
3.1 Shock absorber installing proced

Ability to :
3.1 Fix shock absorber to vehicle

Safety :
3.1 Handle with care

4. Determine conditions of bump Knowledge of :
stoppers 4.1 Bump stoppers position and func

Ability to :
4.1 Inspect condition of bump stoppe

5. Remove bump stoppers Knowledge of :
5.1 Bump stoppers removing proced

Ability to :
5.1 Dismantle the bump stoppers

6. Install bump stoppers Knowledge of :
6.1 Bump stoppers installation proce

Ability to :
6.1 Fix bump stoppers correctly

Safety :
6.1 Handle with care

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS
dure

ction
ers for serviceability
dure

edure

220

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 12 DUTY: REPAIR SUSPENSION SYSTEM
TASK NO:
LEVEL: 04 TASK: REMOVE TIRES FROM RIMS

L1 PERFORMANCE STANDARD
REMOVE TYRES FROM RIMS GIVEN OPER
CAN BE REPLACED PROPERLY.

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

1. Loosen wheel nuts and jack up Knowledge of :
vehicle 1.1 Wheel and tyre function

Ability to :
1.1 Use floor jack
1.2 Remove out wheels from vehicle

Safety :
1.1 Ensure vehicle on level ground
1.2 use vehicle stand

2. Conduct visual check on tires and Knowledge of
rims 2.1 Types of rims
2.2 Tire’s function
2.3 Tire’s wear pattern

Ability to :
2.1 Determine tyre and rim condition

RATION MANUAL, USING THE TIRE REMOVAL MACHINE SO THAT TIRES

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

e 1. Operation manual
2. Floor jack
3. Tyre removal machines
4. Tyre removing tools and lubricants
5. New tyres
6. Air compressor
7. Vehicle stand

ns
221

SUB-TASK / STEP ENABLING RE
3. Place wheel on tyre removing (Knowledge, Skill, A
machine
Knowledge of :
4. Mount tyre on to rims 3.1 Tyre removing machine operatio

Ability to :
3.1 Use tyre removing machine
3.2 Remove tire from rim

Safety :
3.1 Ensure tyre is secured
3.2 Handle with care

Knowledge of :
4.1 Tyre mounting procedure
4.2 Inflex tyre to proper pressure

to : Ability
4.1 Fix tyre to the rim

Safety :
4.1 Handle with care

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

on and function

222

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 12 DUTY: REPAIR SUSPENSION SYSTEM

TASK NO: 05 TASK: REMOVE COIL SPRINGS/LEAF SP

LEVEL: L2 PERFORMANCE STANDARD
REMOVE COIL SPRING/ LEAF SPRING GIVE
COIL SPRING/ LEAF SPRING CAN BE REPL

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

1. Remove ball joints and brake Knowledge of :
assembly 1.1 Ball joints layout and brake asse

2. Remove drive shafts Ability to :
1.1 Take out ball joints and brake as

Safety :
1.1 Handle with care
1.2 Use axle stands

Knowledge of :
2.1 Drive shaft’s function

Ability to :
2. Remove drive shaft lock nut

Safety/Attitude :
2.1 Handle with care

PRINGS

EN SERVICE MANUAL USING COIL SPRING COMPRESSOR ETC, SO THAT
LACED PROPERLY

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

embly 1. Service manual
ssembly 2. Floor jack
3. Hand tools
4. Axle stand
5. Coil spring compressor

223

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

3. Remove coil/leaf spring from Knowledge of :
vehicle 3.1 Removing coil/ leaf spring proced

Ability to :
3.1 Separate lower arm assembly or
3.2 Take OFFcoil/leaf spring
3.3 Use coil spring compressor

Safety :
3.1 Ensure vehicle is safely supporte
3.2 Coil spring seats properly in the

4. Install coil/leaf springs to vehicle Knowledge of :
4.1 Installation of coil / leaf spring pr

Ability to :
4.1 Secure coil/leaf spring properly
4.2 Install driveshaft
4.3 Tighten driveshaft lock nut accor
4.4 Install ball joints and brake assem

Safety / attitude :
4.1 Handle with care

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

dure
r the shackles

ed
compressor ends

rocedure

rding to torque
mbly

224

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 12 DUTY: REPAIR SUSPENSION SYSTEM

TASK NO: 06 TASK: SERVICE SUSPENSION COMPON

LEVEL: L2 PERFORMANCE STANDARD
SERVICE SUSPENSION COMPONENTS GIV
THE SUSPENSION SYSTEM OPERATES SA

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

1. Jack up vehicle and place the axle Knowledge of :

stand 1.1 Jacking points

Ability to :
1.1 Identify the correct jacking points
1.2 Place axle stand at proper points

Safety :
1.1 Handle with care

2. Remove all wheels Knowledge of :
2.1 Wheel removing procedure

Ability to :
2.1 Use wheel brace

NENTS

VEN SERVICE MANUAL USING THE APPROPRIATE TOOLS ETC SO THAT
ATISFACTORILY

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

1. Service manual
2. Suspension removal and installation
tools
3. Axle stands
s 4. Floor jack/ ramp
s 5. Replacement parts
6. Brakes fluid
7. Drive shaft grease
8. General purpose grease

225

SUB-TASK / STEP ENABLING RE
3. Remove tie rod assembly (Knowledge, Skill, A
4. Remove the brake assemblies
5. Remove drive shafts Safety / attitude :
2.1 Handle with care

Knowledge of :
3.1 Tie rod layout

Ability to :
3.1 Use tie rod remover

Safety :
3.1 Handle with care

Knowledge of :
4.1 Brake assembly layout

Ability to :
4.1 Use brake hoses removal tools

Safety / attitude :
4.1 Good housekeeping
4.2 Handle with care

Knowledge of :
5.1 Drive shaft layout

Ability to :
5.1 Use drive shaft removal tools

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

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

226

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

6. remove complete front and rear Knowledge of :
suspension components 6.1 Front and rear suspension layou
(Replace parts of components if
necessary) Ability to :
6.1 Use suspension removal tools
6.2 Identify defective parts/ compone
Safety :
6.1 Handle with care

7. Install front and rear suspension Knowledge of :
components 7.1 Installing procedure

Ability to :
7.1 Install tie rod assembly
7.2 install driveshafts
7.3 Install brake assembly

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

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

ut or type

ents

227