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KSKV SVM 2017

MINISTRY OF EDUCATION, MALAYSIA

VOCATIONAL COLLEGE STANDARD CURRICULUM

COURSE INFORMATION

PROGRAMME : AUTOMOTIVE TECHNOLOGY

COURSE NAME : ENGINE MAINTANCE

CODE NAME : MTA 2013

LEVEL / SEMESTER : 2 SEMESTER 2

CREDIT UNIT : 3.0

CONTACT HOUR : FACE TO FACE : 6.0 HOURS/WEEK

NON FACE TO FACE :

COURSE TYPE : VOCATIONAL

PREREQUISITE : -

CORE REQUISITE : -

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COURSE OUTCOMES

The person who is competent in this CU shall be to enable vehicle are service regularly or periodically to avoid major faulty after
long mileage and ensuring vehicle are at optimum condition after lubrication service complying with vehicle lubrication manual &
practice. Upon completion of this competency unit, trainees will be able to:
 Change lubrication oil & oil filter
 Confirm lubrication compliance
 Carry out engine drive belt and tensioner replacement
 Conduct cooling system pressure test
 Carry out radiator pressure cap replacement
 Inspect engine cooling system’s components condition
 Carry out engine cooling system’s thermostat replacement
 Inspect exhaust system’s component’s condition
 Change air filter replacement
 Change fuel filter replacement
 Change spark plugs replacement

COURSE DESCRIPTION

Vehicle engine service is an essential role for vehicle maintenance to ensure that oil levels are sufficiently topped up to avoid major
faulty repair. It is to exchange the engine oil, replace the oil filter, lubricate the chassis and all wear points.

The competency includes change lubrication oil & oil filter, confirm lubrication conformance, carry out engine drive belt and tensioner
replacement, conduct cooling system pressure test, carry out radiator pressure cap replacement, inspect engine cooling system’s
components condition, carry out engine cooling system’s thermostat replacement, and inspect exhaust system’s component’s
condition

The outcome of this competency is to able vehicle are service regularly or periodically to avoid major faulty after long mileage and
ensuring vehicle are at optimum condition after lubrication service complying with vehicle lubrication manual & practice.

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CONTENT AND LEARNING STANDARDS

PROGRAM : AUTOMOTIVE TECHNOLOGY

COURSE NAME : ENGINE MAINTANCE ( ENGINE SERVICE )

CODE NAME : MTA 2013

CONTACT HOURS CONTENT LEARNING STANDARD


PERFORMANCE CRITERIA /
(TRAINING STANDARD (RELATED KNOWLEDGE / APPLIED SKILLS /
ASSESSSMENT CRITERIA
DURATION) (WORK ACTIVITIES) ATTITUDE / SAFETY / ENVIROMENTAL)

RELATED KNOWLEDGE ASSESSSMENT CRITERIA


1. CHANGE
3 JAM LUBRICATION 1.1 Function of lubrication system 1.1 Carry out loosing of drain plug for
OIL & OIL 1.2 Classification of lubricants such as: lubricant dispose.
FILTER  American Petroleum Institute (API) 1.2 Carry out draining of old engine oil for
 Society of Automotive Engineers (SAE) new lubricant replacement
 Mineral/Semi/Fully Oil. 1.3 Carry out removing of oil filter for waste
1.3 Types of oil filter oil discharge
1.4 Schedule maintenance service chart. 1.4 Carry out tightening of drain plug
1.5 Type of tool required for lubrication service according to lubrication service
standards
1.5 Carry out installation of new oil filter for
APPLIED SKILLS replacement requirement.
1.6 Carry out refill lubricant to meet
1.1 Interpret schedule maintenance service lubrication standards
chart
1.2 Apply vehicle lubrication procedure
1.3 Drain out lubrication oil
1.4 Remove oil filter
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1.5 Install new oil filter


1.6 Replace drain plug gasket.
1.7 Tighten drain plug
1.8 Refill new lubrication oil

ATTITUDE / SAFETY / ENVIROMENTAL

Attitude:
i. Adhere to workplace safety practises
ii. Follow safety signage

Safety:

i. Practice integrity in determining workshop


housekeeping compliances

Environmental:

i. Adhere to Environmental Quality Act 1973


and the regulation under the act

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CONTACT HOURS CONTENT LEARNING STANDARD


PERFORMANCE CRITERIA /
(TRAINING STANDARD (RELATED KNOWLEDGE / APPLIED SKILLS /
ASSESSSMENT CRITERIA
DURATION) (WORK ACTIVITIES) ATTITUDE / SAFETY / ENVIROMENTAL)

RELATED KNOWLEDGE
ASSESSSMENT CRITERIA
2.1 Next service internal recommended.
2 JAM 2. LUBRICATION 2.2 Measurement of oil level. 2.1 Check lubrication level according to
COMPLIANCE 2.3 Understand warning indicator (oil press) engine specification
light service 2.2 Check lubrication leakage to ensure
worthiness of lubrication services
APPLIED SKILLS 2.3 Perform oil pressure level indictor
observation to confirm standard pressure.
2.1 Check oil level. 2.4 Perform next service indicator recording.
2.2 Check oil leakage.
2.3 Observe oil pressure level indicator.
2.4 Record/ reset next service interval
sticker.

ATTITUDE / SAFETY / ENVIROMENTAL

Attitude:
i. Adhere to workplace safety practices
ii. Follow safety signage
Safety:

i. Practice integrity in determining workshop


housekeeping compliances

Environmental:

i. Adhere to Environmental Quality Act 1973


and the regulation under the act
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CONTACT HOURS CONTENT LEARNING STANDARD PERFORMANCE CRITERIA /


(TRAINING STANDARD (RELATED KNOWLEDGE / APPLIED SKILLS / ASSESSSMENT CRITERIA
DURATION) (WORK ACTIVITIES) ATTITUDE / SAFETY / ENVIROMENTAL)

RELATED KNOWLEDGE ASSESSSMENT CRITERIA

3 JAM 3. ENGINE DRIVE 3.1 Types of job order such as: 3.1 Perform job order interpret and compare
BELT AND  Work sheet / job card with manufacturer specification
TENSIONER 3.2 Function of job order 3.2 Confirm tools, equipment and parts
REPLACEMENT 3.3 Tools and equipment such as: according to job requirement
 Mechanic hand tools set 3.3 Perform repair activity planning according
 Flare nut wrenches to workshop manual
3.4 Types of cooling system 3.4 Check engine drive belt and tensioner
3.5 Layout of drive belt and tensioner for according to service manual
cooling system 3.5 Perform engine drive belt and tensioner
3.6 Procedures of testing and checking drive replacement according to manufacturer’s
belt and tensioner service manual
3.7 Procedures of replacing and tensioning .
drive belt

APPLIED SKILLS

3.1 Interpret job order


3.2 Consult service advisor / job controller
3.3 Select tools and equipment
3.4 Plan repair activity
3.5 Check belt condition
3.6 Check belt tension
3.7 Check tensioner tension
3.8 Check tensioner belt bearing
3.9 Replace engine drive belt
3.10Replace tensioner bearing

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ATTITUDE / SAFETY / ENVIROMENTAL

Attitude:
i. Systematic in organizing work activities
ii. Follow safety signage

Safety:
i. Adhere to safety precaution in carrying out
engine drive belt and tensioner replacement
ii. Ensure correct tension of belt

Environmental:

i. Adhere to Environmental Quality Act 1973


and the regulation under the act

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CONTACT HOURS CONTENT LEARNING STANDARD


PERFORMANCE CRITERIA /
(TRAINING STANDARD (RELATED KNOWLEDGE / APPLIED SKILLS /
ASSESSSMENT CRITERIA
DURATION) (WORK ACTIVITIES) ATTITUDE / SAFETY / ENVIROMENTAL)

RELATED KNOWLEDGE ASSESSSMENT CRITERIA

4 JAM 4. COOLING 4.1 Principles of cooling system 4.1 Perform cooling system pressure
SYSTEM 4.2 Procedures of testing cooling system test preparation according to
PRESSURE TEST pressure workshop manual.
4.3 Cooling system pressure test such as: 4.2 Perform cooling system pressure
 Radiator test according to service manual
 Radiator cap

APPLIED SKILLS

4.1 Attach pressure tester to the radiator


4.2 Perform cooling system pressure test
4.3 Interpret pressure test result

ATTITUDE / SAFETY / ENVIROMENTAL

Attitude:
i. Always use extreme caution when conducting
cooling system pressure test
ii. Always follow vehicle manufacturer’s
warnings, cautions and service procedures
iii. Follow safety signage

Safety:
i. Follow pressure test safety procedure
ii. Ensure engine is cool before opening radiator
cap
iii. Cautions when opening radiator cap while
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temperature of the engine is high

Environmental:

i. Adhere to Environmental Quality Act 1973


and the regulation under the act

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CONTACT HOURS CONTENT LEARNING STANDARD


PERFORMANCE CRITERIA /
(TRAINING STANDARD (RELATED KNOWLEDGE / APPLIED SKILLS /
ASSESSSMENT CRITERIA
DURATION) (WORK ACTIVITIES) ATTITUDE / SAFETY / ENVIROMENTAL)

RELATED KNOWLEDGE ASSESSSMENT CRITERIA

2 JAM 5. RADIATOR 5.1 Function of radiator and radiator cap 5.1 Check radiator cap condition
PRESSURE CAP 5.2 Procedure or removing and replacing according to service manual
REPLACEMENT radiator cap 5.2 Perform radiator cap pressure testing
according to service manual
APPLIED SKILLS 5.3 Perform radiator cap replacement
according to service manual
5.1 Check cap seal deterioration
5.2 Check return spring condition
5.3 Check release valve
5.4 Test radiator cap using pressure tester
5.5 Replace radiator cap

ATTITUDE / SAFETY / ENVIROMENTAL

Attitude:
i. Always use extreme caution when carrying
out radiator pressure cap replacement
ii. Always follow vehicle manufacturer’s
warnings, cautions and service procedures
iii. Follow safety signage

Safety:
i. Ensure engine is cool before opening radiator
cap
ii. Cautions when opening radiator cap while
temperature of the engine is high

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Environmental:

i. Adhere to Environmental Quality Act 1973


and the regulation under the act

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CONTACT HOURS CONTENT LEARNING STANDARD


PERFORMANCE CRITERIA /
(TRAINING STANDARD (RELATED KNOWLEDGE / APPLIED SKILLS /
ASSESSSMENT CRITERIA
DURATION) (WORK ACTIVITIES) ATTITUDE / SAFETY / ENVIROMENTAL)

RELATED KNOWLEDGE ASSESSSMENT CRITERIA

7 JAM 6. ENGINE 6.1 Types of cooling system 6.1 Perform engine cooling system’s
COOLING 6.2 Layout of cooling system components condition inspection
SYSTEM’S 65.3 Procedures of checking cooling system according to service manual
COMPONENTS components 6.2 Determine Engine cooling system’s
CONDITION 6.4 Components of cooling system such as: components functionality
 Water pump
 Radiator
 Belting
 Fan blade
 Fan motor/ pulley
 Thermostat
 Radiator cap
 Water temperature sender unit
6.5 Functions of cooling system
components

APPLIED SKILLS

6.1 Check radiator coolant


6.2 Check radiator cap condition
6.3 Check cooling system hoses
6.4 Check hose clip condition
6.5 Check water pump for leakage
6.6 Check radiator condition
6.7 Check radiator fan blade condition
6.8 Check radiator fan mechanical / electrical
type
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6.9 Check fan belt (mechanical type)


6.10Check water temperature sender unit /
sensor condition

ATTITUDE / SAFETY / ENVIROMENTAL

Attitude:
i. Always use extreme caution when inspecting
engine cooling system’s components
condition
ii. Always follow vehicle manufacturer’s
warnings, cautions and service procedures
iii. Follow safety signage

Safety:
i. Ensure engine is cool before opening radiator
cap

Environmental:

i. Adhere to Environmental Quality Act 1973


and the regulation under the act

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CONTACT HOURS CONTENT LEARNING STANDARD


PERFORMANCE CRITERIA /
(TRAINING STANDARD (RELATED KNOWLEDGE / APPLIED SKILLS /
ASSESSSMENT CRITERIA
DURATION) (WORK ACTIVITIES) ATTITUDE / SAFETY / ENVIROMENTAL)

RELATED KNOWLEDGE ASSESSSMENT CRITERIA

7 JAM 7. ENGINE 7.1 Function of thermostat 7.1 Check engine cooling system’s
COOLING 7.2 Types of thermostat thermostat condition according to
SYSTEM’S 7.3 Construction of thermostat service manual
THERMOSTAT 7.4 Procedure of testing thermostat 7.2 Perform engine cooling system’s
REPLACEMENT 7.5 Engine cooling system’s thermostat thermostat removing and replacement
location according to service manual
7.6 Procedure of removing and replacing
thermostat

APPLIED SKILLS

7.1 Dismantle radiator upper hose & clip


7.2 Remove thermostat housing
7.3 Remove thermostat from engine
7.4 Test thermostat according to service
manual
7.5 Replace thermostat
7.6 Replace thermostat gasket / ‘O’ ring
7.7 Install thermostat to the engine

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ATTITUDE / SAFETY / ENVIROMENTAL

Attitude:
i. Always use extreme caution when carrying
out engine cooling system’s thermostat
replacement
ii. Always follow vehicle manufacturer’s
warnings, cautions and service procedures
iii. Follow safety signage

Safety:
i. Careful when handling hot water
ii. Ensure engine is cool before opening
radiator cap

Environmental:

i. Adhere to Environmental Quality Act 1973


and the regulation under the act

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CONTACT HOURS CONTENT LEARNING STANDARD


PERFORMANCE CRITERIA /
(TRAINING STANDARD (RELATED KNOWLEDGE / APPLIED SKILLS /
ASSESSSMENT CRITERIA
DURATION) (WORK ACTIVITIES) ATTITUDE / SAFETY / ENVIROMENTAL)

RELATED KNOWLEDGE ASSESSSMENT CRITERIA

5 JAM 8. EXHAUST 8.1 Types of job order such as: 8.1 Interpret and compare job order to
SYSTEM’S  Work sheet / job card manufacturer specification
COMPONENT’S 8.2 Function of job order 8.2 Confirm tools, equipment and parts
CONDITION 8.3 Hand tools such as: according to job confirm
 Mechanic hand tools set 8.3 Perform repair activity planning
8.4 Purpose of exhaust muffler According to workshop manual.
8.5 Layout of exhaust system component 8.4 Inspect exhaust system component’s
8.6 Types of exhaust system’s component condition according to service manual
8.5 Perform exhaust system component’s
APPLIED SKILLS functionality confirmation.

8.1 Interpret job order


8.2 Consult service advisor / job controller
8.3 Select exhaust system rectification work
tools, equipment and parts
8.4 Plan repair activity
8.5 Check exhaust system leakage
8.6 Check exhaust manifold gasket leakage
8.7 Check resonator (flexible) exhaust pipe
8.8 Check catalytic converter condition
8.9 Check exhaust muffler condition

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ATTITUDE / SAFETY / ENVIROMENTAL

Attitude:
i. Systematic in organizing work activities
ii. Follow safety signage

Safety:
i. Adhere to safety precaution in inspecting
exhaust system’s component’s condition
ii. Disconnect battery terminal, ECU connector
during welding

Environmental:

Adhere to Environmental Quality Act 1973 and


the regulation under the act

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CONTACT HOURS CONTENT LEARNING STANDARD


PERFORMANCE CRITERIA /
(TRAINING STANDARD (RELATED KNOWLEDGE / APPLIED SKILLS /
ASSESSSMENT CRITERIA
DURATION) (WORK ACTIVITIES) ATTITUDE / SAFETY / ENVIROMENTAL)

RELATED KNOWLEDGE ASSESSSMENT CRITERIA

2 JAM 9. AIR FILTER 9.1 Types of job order such as: 9.1 Perform job order interpretation and
REPLACEMENT  Work sheet / job card compare with manufacturer
9.2 Function of job order specification
9.3 Hand tools such as: 9.2 Perform tools, equipment and parts
 Mechanic hand tools set confirm according to job specification.
9.4 Function of air filter 9.3 Perform repair activity planning
9.5 Types of air filter according to nob specification
9.6 Procedure of replacing air filter 9.4 Removed air filter according to service
manual
APPLIED SKILLS 9.5 Check air filter condition according to
service manual
9.1 Interpret job order 9.6 Perform air filter replacement
9.2 Consult service advisor / job controller according to service manual
9.3 Select tools and equipment
9.4 Plan work activity
9.5 Remove air filter
9.6 Check air filter condition
9.7 Clean air filter unit
9.8 Replace air filter
9.9 Install air filter

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ATTITUDE / SAFETY / ENVIROMENTAL

Attitude:
i. Systematic in organizing work activities

Safety:
i. Adhere to safety precaution in carrying out air
filter replacement

Environmental:
i. Practice 3R (Reduce, Reuse, Recycle)

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CONTACT HOURS CONTENT LEARNING STANDARD


PERFORMANCE CRITERIA /
(TRAINING STANDARD (RELATED KNOWLEDGE / APPLIED SKILLS /
ASSESSSMENT CRITERIA
DURATION) (WORK ACTIVITIES) ATTITUDE / SAFETY / ENVIROMENTAL)

RELATED KNOWLEDGE ASSESSSMENT CRITERIA

2 JAM 10. FUEL FILTER 10.1 Function of fuel filter 10.1 Remove fuel filter and fuel filter
REPLACEMENT 10.2 Fuel filter location hose according to service manual
10.3 Procedure of removing and replacing 10.2 Replace fuel filter and fuel filter
fuel filter hose according to service manual

APPLIED SKILLS

10.1 Remove fuel filter hose


10.2 Remove fuel filter
10.3 Replace fuel filter
10.4 Install fuel filter
10.5 Insert fuel filter hose
10.6 Check for leakage

ATTITUDE / SAFETY / ENVIROMENTAL

Attitude:
i. Always use extreme caution when carrying
out fuel filter replacement
ii. Always follow vehicle manufacturer’s
warnings, cautions and service procedures

Safety:
i. Careful when handling flammable liquid
ii. Avoid working near heat source
iii. Do not spill fuel the floor
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Environmental:
i. Practice 3R (Reduce, Reuse, Recycle)

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CONTACT HOURS CONTENT LEARNING STANDARD


PERFORMANCE CRITERIA /
(TRAINING STANDARD (RELATED KNOWLEDGE / APPLIED SKILLS /
ASSESSSMENT CRITERIA
DURATION) (WORK ACTIVITIES) ATTITUDE / SAFETY / ENVIROMENTAL)

RELATED KNOWLEDGE ASSESSSMENT CRITERIA

2 JAM 11. SPARK PLUGS 11.1 Types and function of spark plug 11.1 Remove sparks plug according to
REPLACEMENT 11.2 Construction of spark plug service manual
11.3 Heat ranges and reach of spark plugs 11.2 Replace sparks plug according to
11.4 Spark plug condition service manual

APPLIED SKILLS

11.1 Detach spark plug


11.2 Adjust spark plug electrode gap
11.3 Clean around the threads before
reinserting the new spark plugs
11.4 Insert new spark plug

ATTITUDE / SAFETY / ENVIROMENTAL

Attitude:
i. Systematic in organising work activities

Safety:
i. Adhere to safety precaution in changing spark
plugs replacement

Environmental:
i. Practice 3R (Reduce, Reuse, Recycle)

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CORE ABILITY

CORE ABILITY

SILA RUJUK LAMPIRAN A : JADUAL PEMETAAN NOSS DAN KSKV

SILA RUJUK LAMPIRAN B : JADUAL PEMETAAN NOSS DAN CORE ABILITY

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Tools, Equipment and Materials (TEM) KSKV SVM 2017

ITEMS RATIO (TEM : Trainees)

1. Engine 1:5
2. Job order sample 1:5
12. Customer handling sample. 1:5
13. Chronology of event sample. 1:5
5. Warranty term & condition sample. 1:5
15. Tools, equipment and parts. 1:5
16. Consumable material/parts guideline and references. 1:5
8. Workplace setup requirement. 1:5
9. Tools setup and arrangement procedure. 1:5
10. Safety and security protecting materials. 1:5
11. Manufacturer SOP sample. 1:5

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References

1. BOSCH Automotive Terminology, Published by SAE in 1998, ISBN 0-7680-0338-5.


2. Jose Luis Leyva, Learn Automotive Terminology in 2015, ISBN 9-781503-225725.
12. BOSCH, Automotive Handbook, Published by Bosch in 1996, ISBN 1-56091-918-12.
13. Lenz, Cozzarini, Emissions and Air Quality, Published by SAE in 1999, ISBN 0-7680-0248-15.
5. Owen Coley, Automotive Fuels Reference Book, Published by SAE in 1995, ISBN 1-56091-589-16.
15. Eric Chowanietz, Automobile Electronics, Published by SAE in 1995, ISBN 0-7506-1878-16.
16. Tom Denton, Automotive Electric and Electronic system fourth edition, ISBN 978-0-08-096942-8.
8. Thomas D. Gillespie, Fundamentals of Vehicle Dynamics, Published by SAE in 1999, ISBN 1-56091-199-9.
9. Michael Plint, Anthony Martyr, Engine Testing Theory and Practice, Published by SAE in 1999, ISBN 0-7680-0314-8
10. Ellis Johnson, Tires and Handling, Published by SAE in 1996, ISBN 1-56091-752-0.
11. Rudolf Limpert, Brake and Design Safety, Published by SAE in 1999, ISBN 1-56091-915-9.

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