P-115-123

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 02 DUTY: SERVICE CARBURATION SYSTEM

TASK NO: 02.02 TASK: CHECK AIR AND FUEL FILTERS

LEVEL: L1 PERFORMANCE STANDARD
CHECK AIR AND FUEL FILTERS GIVEN SER
PERFORMANCE MEETS MANUFACTURER’S

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

1. Determine the condition of air filter. Knowledge of :

(Replace if necessary) 1.1 Design and function of air filter

Ability to :
1.1 Remove air filter
1.2 Check air filter
1.3 Clean air filter
1.4 Install air filter

2. Determine the condition of fuel Knowledge of :
filter. (Replace if necessary) 2.1 Design and function of fuel filte

2

M

RVICE MANUAL USING HAND TOOLS SO THAT THE ENGINE
S STANDARD

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

1. Service manual
2. Hand tools
3. Air filter
4. Fuel filter

er

8

SUB-TASK / STEP ENABLING RE
3. Check engine performance (Knowledge, Skill,

Ability to :
2.1 Remove fuel filter
2.2 Check fuel filter
2.3 Install fuel filter

Safety :
2.1 Keep away from spark or fire

Knowledge of :
3.1 Engine performance criteria

Ability to :
3.1 Check engine performance
3.2 Visual check for fuel leak at fue

Safety :
3.1 Handle with care

2

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

el filter joint

9

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 02 DUTY: SERVICE CARBURATION SYSTEM

TASK NO: 02.03 TASK: REPLACE FUEL PUMP

LEVEL: L1 PERFORMANCE STANDARD
REPLACE FUEL PUMP GIVEN SERVICE MA
FUNCTION ACCORDING TO MANUFACTUR

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

1. Remove fuel hoses connected to Knowledge of :
the fuel pump 1.1 Fuel system layout or diagram
1.2 Type of fuel hose

Ability to :
1.1 Disconnect fuel hose from fuel

Safety :
1.1 Keep away from spark or fire
1.2 Remove negative battery termin

2. Remove fuel pump from the engine Knowledge of :
2.1 Types and construction of fuel p

3

M

ANUAL USING HAND TOOLS, FUEL PUMP SO THAT THE FUEL SYSTEM WILL
RER’S STANDARD

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

1. Service manual
2. Hand tools
3. Fuel pump

pump

nal
pump

0

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

2.2 Operation of fuel pump

Ability to :
2.1 Remove fuel pump
2.2 Check function of fuel pump

Safety :
2.1 Keep away from spark or fire

3. Install new fuel pump to the engine Knowledge of :

and connect the hoses 3.1 Operation of fuel pump

Ability to :
3.1 Test fuel pump
3.2 Fix fuel pump correctly to the e

4. Start engine and check engine Knowledge of :
performance 4.1 Engine performance criteria

3

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

engine
1

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

Ability to :
4.1 Check engine performance
4.2 Visual inspection of fuel leak at
4.3 Connect battery terminal

Safety :
4.1 Handle with care

3

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

t fuel pump

2

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 02 DUTY: SERVICE CARBURATION SYSTEM

TASK NO: 02.04 TASK: TUNE UP CARBURETOR

LEVEL: L1 PERFORMANCE STANDARD
TUNE UP CARBURETOR GIVEN SERVICE M
MEET THE MANUFACTURER’S STANDARD

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

1. Calibrate exhaust gas analyzer Knowledge of :
1.1 Exhaust gas analyzer

Ability to :
1.1 Handle exhaust gas analyzer
1.2 Connect gas analyzer probe to

connection

Safety :
1.1 Ensure the exhaust gas analyze

3

M

MANUAL USING HAND TOOLS SO THAT AIR FUEL MIXTURE IS TUNE TO

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

the exhaust pipe and other 1. Service manual
2. Hand tools
3. Exhaust gas analyzer (4-gas)
4. Tachometer

er is connected properly

3

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

2. Adjust air fuel mixture Knowledge of :
2.1 Basic carburetor tune up
2.2 Exhaust gas analyser

Ability to :
2.1 Adjust idling speed
2.2 Read gas value for carbon mon

exhaust gas analyzer
2.3 Adjust air/fuel mixture
2.4 Use tachometer

3. Disconnect probe and exhaust gas Knowledge of :
analyzer 3.1 Exhaust gas analyzer
3.2 Engine performance criteria

Ability to :
3.1 Remove exhaust gas analyzer
3.2 Check engine performance

Attitude :
3.1 Maintain good house keeping

3

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

noxide (CO) and hydrocarbon (HC) at

from engine

4

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 02 DUTY: SERVICE CARBURATION SYSTEM

TASK NO: 02.05 TASK: REPLACE FUEL TANK

LEVEL: L2 PERFORMANCE STANDARD
REPLACE FUEL TANK GIVEN SERVICE MAN
ACCORDING TO MANUFACTURER'S STAND

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

1. Disconnect fuel pipe/line Knowledge of :
2. Remove fuel tank 1.1 Fuel system layout
1.2 Fuel tank construction and func

Ability to :
1.1 Identify component of fuel syste
1.2 Drain fuel from fuel tank
1.3 Use hand tools/container/funnel

Safety :
1.1 Keep away from fire or spark

Knowledge of :
2.1 Fuel system layout

3

M

NUAL USING HAND TOOLS SO THAT THE FUEL TANK CAN BE INSTALLED
DARD

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

ction 1. Service manual
em 2. Hand tools
3. Petrol
4. Container
5. Funnel
6. Vehicle

5

SUB-TASK / STEP ENABLING RE
3. Install new fuel tank (Knowledge, Skill, A
4. Check engine performance
Ability to :
2.1 Remove fuel tank securing bolt

Safety :
2.1 Handle with care

Knowledge of :
3.1 Fuel system layout

Ability to :
3.1 Connect fuel lines/pipe to the ta
3.2 Tighten securing bolts for fuel ta
3.3 Tighten fuel lines/pipe clips

Safety :
3.1 Handle with care

Knowledge of :
4.1 Fuel system layout

3

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS
ts

ank
ank

6

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

Ability to :
4.1 Tighten fuel tank drain plug
4.2 Refill fuel into the tank
4.3 Check fuel leakage

Attitude :
4.1 Maintain good house keeping

3

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

7

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 02 DUTY: SERVICE CARBURATION SYSTEM

TASK NO: 02.06 TASK: OVERHAUL CARBURETOR

LEVEL: L2 PERFORMANCE STANDARD
OVERHAUL CARBURETOR GIVEN SERVICE
ACCORDING TO THE MANUFACTURER’S S

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

1. Remove carburetor from intake Knowledge of :
manifold 1.1 Layout of fuel system
1.2 Function of carburetor

Ability to :
1.1 Identify location of carburetor
1.2 Remove air cleaner and housin
1.3 Remove fuel line/wire connecto

Safety :
1.1 Remove battery terminal

3

M

E MANUAL USING HAND TOOLS SO THAT THE CARBURETOR FUNCTION
STANDARD

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

ng from carburetor 1. Service manual
or/cable from carburetor 2. Hand tools
3. Petrol
4. Tray
5. Carburetor repair kit
6. Exhaust gas analyzer
7. Tachometer
8. Carburetor Services special tool
9. Straight edge

8

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

2. Dismantle and clean carburetor Knowledge of :
2.1 Construction and operation of c
2.2 Function of carburetor circuit

Ability to :
2.1 Remove mounting bolts
2.2 Clean carburetor components a

Safety :
2.1 Keep away from fire or spark

3. Assemble carburetor components Knowledge of :
and kits 3.1 Construction and operation of t

Ability to :
3.1 Replace parts according to con
3.2 Measure and adjust float level
3.3 Fix carburetor components

4. Check intake manifold surface Knowledge of :
4.1 Straight edge

3

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS
carburetor

and kits

the carburetor
ndition

9

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

Ability to :
4.1 Clean surface of intake manifold
4.2 Measure surface of intake manif

5. Install carburetor to intake manifold Knowledge of :
5.1 Fuel system layout

6. Check engine performance Ability to :
5.1 Fix carburetor insulator and gas
5.2 Tighten carburetor mounting bo
5.3 Fix fuel hose/cable/wire connec

Safety :
5.1 Handle with care

Knowledge of :
6.1 Engine performance criteria
6.2 Exhaust gas analyzer
6.3 Exhaust gas and air/fuel mixtur

Ability to :
6.1 Check fuel leakage
6.2 Tune up carburetor to specifica
6.3 Use exhaust gas analyzer

Attitude :
6.1 Use fender cover
6.2 Good housekeeping

4

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

d
fold for carburetor position

sket
olts
ctor

re

ation

0

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 03 DUTY: SERVICE DIESEL FUEL SYSTEM

TASK NO: 01 TASK: CHECK DIESEL FUEL SYSTEM FO

LEVEL: L1 PERFORMANCE STANDARD
CHECK THE DIESEL FUEL SYSTEM FOR PR
FILTER WRENCH ETC, SO THAT THE SYST

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

1. Determine fuel system layout Knowledge of :
2. Check fuel feed (lift) pump 1.1 Fuel system layout
1.2 Basic diesel engine operation

Ability to :
1.1 Locate diesel fuel system comp

Safety :
1.1 Perform task in a well ventilated

Knowledge of :
2.1 Operation of lift pump
2.2 Location of lift pump

Ability to
2.1 Operation fuel feed pump

4

OR PROPER FUNCTIONING

ROPER FUNCTIONING GIVEN SERVICE MANUAL USING HAND TOOLS,
TEM FUNCTION ACCORDING TO THE MANUFACTURER’S SPECIFICATIONS

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

1. Hand tools
2. Service manual
3. Filter wrench
4. Diesel tray
5. Service special tools (SST)

ponent
area

1

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

3. Check hoses and pipes for leaks Knowledge of :
3.1 Function of hoses and pipes

Ability to :
3.1 Distinguish low pressure and hi
3.2 Check and rectify leaks

4. Check fuel injection pipe (FIP) Knowledge of :
linkages or proper connections 4.1 Function and operation of fuel i
4.2 Type of fuel injection pipe (FIP)
5. Check fuel filter for clog
Ability to :
4.1 Check loose linkages
4.2 Use correct hand tools

Safety :
4.1 Use only flaring tools service sp

Knowledge of :
5.1 Design and function of fuel filte

4

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

igh pressure pipes

injection pipe (FIP)
)

pecial tools (SST)
er

2

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

Ability to :
5.1 Check fuel filter
5.2 Remove fuel filter
5.3 Install fuel filter
5.4 Bleed diesel fuel system

Safety :
5.1 Keep away from spark or fire

4

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

3

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 03 DUTY: SERVICE DIESEL FUEL SYSTEM

TASK NO: 02 TASK: CHANGE DIESEL FUEL FILTER

LEVEL: L1 PERFORMANCE STANDARD
CHANGE DIESEL FUEL FILTER GIVEN NEW
ARE SECURELY INSTALLED ACCORDING T

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

1.Locate the primary and secondary Knowledge of :
fuel filter 1.1 Filter construction and function

Ability to :
1.1 Identify the primary and second

2. Remove the fuel filter Knowledge of :
2.1 Type of filter

Ability to :
2.1 Remove fuel filter mounting bol

4

W FILTER USING HAND TOOLS AND FILTER WRENCH, SO THAT THE FILTER
TO SPECIFICATION

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

1. Filter wrench
2. Hand tools
3. Diesel tray
4. Diesel fuel filter

dary filter

lts

4

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

Safety / attitude :
2.1 Good housekeeping

3. Check the new filter Knowledge of :
3.1 Part number of the diesel fuel fi

Ability to :
3.1 Identify the correct fuel filter

4. Install the new filter and tighten to Knowledge of :
proper torque 4.1 Diesel fuel system

Ability to :
4.1 Use torque wrench

Safety :
4.1 Do not over tighten

5. Bleed the fuel system Knowledge of :
5.1 Bleeding procedure of the diese
5.2 Purpose of bleeding diesel fuel

Ability to :
5.1 Prime fuel feed pump
5.2 Identify bleeding screws
5.3 Carry out bleeding according to

4

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

ilter

el fuel system
system

o procedure

5

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

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

4

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

6

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 03 DUTY: SERVICE DIESEL FUEL SYSTEM

TASK NO: 03 TASK: TEST DIESEL FUEL INJECTORS

LEVEL: L1 PERFORMANCE STANDARD
TEST DIESEL FUEL INJECTORS GIVEN SER
AND NOZZLE CLEANING KIT ETC, SO THAT
SPECIFICATIONS.

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

1. Remove the fuel injectors from the Knowledge of :
engine 1.1 Type and construction of injecto
1.2 Function of injector

Ability to :
1.1 Unscrew the injectors from eng

2. Mount the fuel injector to the diesel Knowledge of :

injector tester 2.1 The functions of injector tester

Ability to :
2.1 Install the injector to injector tes
2.2 Operate the injector tester

4

RVICE MANUAL USING THE HAND TOOLS, NOZZLE TESTING EQUIPMENT
T THE INJECTORS ARE FUNCTIONING ACCORDING TO MANUFACTURER’S

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

ors 1. Hand tools
2. Nozzle testing equipment
gine 3. Test oil/Filtered diesel
4. Nozzle cleaning kit
5. Diagram of correct spray pattern
6 Diesel tachometer
7 Service manual

ster

7

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

3. Determine the spray pattern and Safety :
pressure 2.1 Handle with care

Knowledge of :
3.1 Type of spray pattern
3.2 Specification of injector pressur

Ability to :
3.1 Operate injector tester
3.2 Read fuel gauge

Safety :
3.1 Keep hand away from nozzle w

4. Service fuel injector Knowledge of :
4.1 Construction of injector

Ability to :
4.1 Dismantle injectors
4.2 Clean injector
4.3 Adjust injector

Safety :
4.1 Handle with care

5. Install the injectors to the engine Knowledge of :
5.1 Layout of diesel fuel system
5.2 Function of injector

4

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

re

while testing

8

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A
6. Start engine and adjust idling
speed Ability to
5.1 Install the fuel injector
5.2 Connect high pressure line
5.3 bleed fuel system

Knowledge of :
6.1 Air intake system
6.2 Principle of diesel engine

Ability to :
6.1 Adjust idling speed
6.2 Use diesel tachometer

4

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

9

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 03 DUTY: SERVICE DIESEL FUEL SYSTEM

TASK NO: 04 TASK: TIME DIESEL FUEL INJECTION PU

LEVEL: L2 PERFORMANCE STANDARD
TIME DIESEL FUEL INJECTION PUMP TO EN
TIMING TOOLS, SWAN NECK ETC, SO THAT
ACCORDING TO MANUFACTURER’S SPECI

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

1. Select special timing tools Knowledge of :
2. Set injection timing 1.1 Type of fuel injection pump (FIP
1.2 Special timing tools

Ability to :
1.1 Use special timing tools

Knowledge of :
2.1 Type and construction of engine
2.2 Basic diesel engine operation

5

UMP TO ENGINE

NGINE GIVEN THE SERVICE MANUAL USING HAND TOOLS, SPECIAL
T THE FUEL INJECTION PUMP IS CORRECTLY TIMED TO THE ENGINE
IFICATION

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

1. Special timing tools
P) 2. Swan neck

3. hand tools
4. Service manual

0

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

Ability to :
2.1 Mount service special tools (SST
2.2 Set timing alignment

3. Install fuel injection pump (FIP) to Knowledge of :

engine 3.1 Injection timing

3.2 Timing of engine and fuel injectio

Ability to :
3.1 Locate install and time fuel inject

Attitude :
3.1 Tighten mounting bolt

4. Perform spill port timing Knowledge of :
4.1 Injection pump timing
4.2 Spill port timing procedures

Ability to :
4.1 Perform spill port timing
4.2 Use swan neck

Safety :
4.1 Adhere to all safety and proper w
4.2 Maintain good house keeping

5

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

T)

on pump (FIP)
tion pump (FIP) to the engine

working procedure
1

SUB-TASK / STEP ENABLING RE
5. Start engine and adjust timing (Knowledge, Skill,

Knowledge of :
5.1 Bleeding technique
5.2 Injection pump timing

Ability to :
5.1 Bleed fuel system and start engin
5.2 Check timing by using tachomete
5.3 Adjust idling speed

Safety :
5.1 Maintain good house keeping
5.2 Observe safety while adjusting in

5

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

ne
er

njection pump timing

2