Vehicle Brake System

Jabatan Pembangunan Kemahiran
Kementerian Sumber Manusia, Malaysia
STANDARD KEMAHIRAN PEKERJAAN KEBANGSAAN

(NATIONAL OCCUPATIONAL SKILLS STANDARD)
G452-002-2:2018
LIGHT VEHICLE-REPAIR SERVICE

PERKHIDMATAN PEMBAIKAN- KENDERAAN
RINGAN
LEVEL 2
Copyright © DSD 2018
Department of Skills Development (DSD)

Federal Government Administrative Centre
62530 PUTRAJAYA, MALAYSIA
NATIONAL OCCUPATIONAL SKILLS STANDARD
PERKHIDMATAN PEMBAIKAN- KENDERAAN RINGAN
LEVEL 2
All rights reserved.

No part of this publication may be produced, stored in data base, retrieval system, or in any
form by any means, electronic, mechanical, photocopying, recording or otherwise without
prior written permission from Department of Skills Development (DSD).
TABLE OF CONTENTS
Abbreviation....................................................................................................................................i
Glossary..........................................................................................................................................ii
Acknowledgement.........................................................................................................................iv
STANDARD PRACTICE.............................................................................................................1
1. Introduction..........................................................................................................................2
1.1. Occupation Overview...................................................................................................2
1.2. Rationale of NOSS Development.................................................................................4
1.3. Rationale of Occupational Structure and Occupational Area Structure................5
1.4. Regulatory / Statutory Body Requirements Related to Occupation........................6
1.5. Occupational Pre-Requisite.........................................................................................6
1.6. General Training Pre-Requisite For Malaysian Skills Certification System..........6
2. Occupational Structure (OS)..............................................................................................7
3. Occupational Area Structure (OAS)..................................................................................7
4. Definition of Competency Levels........................................................................................8
5. Award of Certificate............................................................................................................9
6. Occupational Competencies................................................................................................9
7. Work Conditions..................................................................................................................9
8. Employment Prospects......................................................................................................10
9. Up Skilling Opportunities..................................................................................................10
10. Organisation Reference for Sources of Additional Information...................................11
11. Standard Technical Evaluation Committee....................................................................13
12. Standard Development Committee..................................................................................14
STANDARD CONTENT.............................................................................................................15
13. Competency Profile Chart (CPC).....................................................................................16
14. Competency Profile (CP)...................................................................................................18
CURRICULUM OF COMPETENCY UNIT............................................................................36
15. Curriculum of Competency Unit......................................................................................36
15.1. Vehicle Workshop Housekeeping............................................................................37
15.2. Vehicle Engine Service..............................................................................................53
15.3. Vehicle Engine Overhauling.....................................................................................60
15.4. Brake System Service................................................................................................67
15.5. Engine Cooling System Replacement......................................................................72
15.6. Rear / Front Axle Rectification................................................................................77
15.7. Exhaust System Rectification...................................................................................82
15.8. Vehicle Electrical & Electronic System Service.....................................................86
15.9. Vehicle Steering, Suspension and Wheel System Service......................................94
15.10.Vehicle Heated Ventilation Air Conditioning (HVAC) System Rectification . 101
15.11. Automatic Transmission / Transaxle Unit Overhauling...................................107
15.12. Manual Transmission / Transaxle Unit Overhauling........................................112
15.13. Transfer Case Overhauling..................................................................................118
15.14. Vehicle Carburettor Service.................................................................................123
16. Delivery Mode...................................................................................................................128
17. Tools, Equipment and Materials (TEM)........................................................................129
18. Competency Weightage...................................................................................................132
Sample Calculation for Summary of Training Hours..................................................135
G452-002-
Abbreviation
1. 3R Reduce, Reuse, and Recycle.
2. DOE Department of Environment.
3. CoCU Curriculum Of Competency Unit.
4. CP Competence Profile.
5. CPC Competence Profile Chart.
6. CU Competency Unit.
7. DSD Department Of Skills Development.
8. DOSH Department of Occupational Safety and Health.
9. HVAC Heating, Ventilation, and Air Conditioning .
10. JPJ JabatanPengangkutan Jalan.
11. MAI Malaysia Automotive Institute.
12. NOSS National Occupational Skill Standard.
13. MOT Ministry of Transport.
14. OAS Occupational Area Structure.
15. OEM Original Equipment Manufacturer.
16. OSHA Occupational Safety and Health Act.
17. OS Occupational Structure.
18. PPE Personal Protective Equipment.
19. RTA Road Transportation Act.
20. SDC Standard Development Committee.
21. SKM Sijil Kemahiran Malaysia.
22. SP Standard Practice
23. SOP Standard Operating Procedure.
24. TEM Tools, Equipment and Materials.

25. HSE Health Safety & Environment
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G452-002-
Glossary
1. Diagnostic. The definition of diagnostic is something related to the identification of a problem or

disease.
2. Inspection. An inspection is, most generally, an organized examination or formal evaluation

exercise. In engineering activities inspection involves the measurements, tests, and
gauges applied to certain characteristics in regard to an object or activity. The results
are usually compared to specified requirements and standards for determining
whether the item or activity is in line with these targets, often with a Standard
Inspection Procedure in place to ensure consistent checking. Inspections are usually
non-destructive.
3. Job Order. A work order or job order is an order received by an organization from a customer or
client, or an order created internally within the organization. A work order may be for
products or services.
4. Maintenance Maintenance, repair and operations (MRO) or maintenance, repair, and overhaul
Repair, And involves fixing any sort of mechanical, plumbing or electrical device should it
Overhaul. become out of order or broken (known as repair, unscheduled, or casualty
maintenance). It also includes performing routine actions which keep the device in
working order (known as scheduled maintenance) or prevent trouble from arising
(preventive maintenance).
MRO may be defined as, "All actions which have the objective of retaining or
restoring an item in or to a state in which it can perform its required function. The
actions include the combination of all technical and corresponding administrative,
managerial, and supervision actions." MRO operations can be categorised by whether
the product remains the property of the customer, i.e. a service is being offered, or
whether the product is bought by the reprocessing organisation and sold to any
customer wishing to make the purchase. In the former case it may be a back shop
operation within a larger organization or smaller operation. The former of these
represents a closed loop supply chain and usually has the scope of maintenance,
repair or overhaul of the product. The latter of the categorisations is an open loop
supply chain and is typified by refurbishment and remanufacture. The main
characteristic of the closed loop system is that the demand for a product is matched
with the supply of a used product. Neglecting asset write-offs and exceptional
activities the total population of the product between the customer and the service
provider remains constant.
5. Service. A Service is a set of actions or solutions that are put in place or are performed to
provide a repeatable and consistent set of outcomes, deliverables, and performance
for people, organizations, and systems that represent consumers or beneficiaries of
such results
6. Workshop Workshop manuals are a series of practical repair manuals and service manuals,
Manual. which are the same essential industry standard documents orsoftwares as used by the
dealerships around the world, covering repairs, service schedules, maintenance,
wiring diagrams and diagnostics.
i
G452-002-
7. Light Vehicle Also known as passenger vehicle that doesnot have more than 9 seats, is a
classification of a vehicle that weight not more than 3,500kg. Van, small pickup
truck, passenger car, saloon, hatchback or aeroback, station wagon, coupe,
convertible, and multipurpose vehicle are consider light vehicle.
8. 5S 5S is a workplace organization method that uses a list of five Japanese words: seiri,
seiton, seiso, seiketsu, and shitsuke. These have been translated as "Sort", "Set In
Order", "Shine", "Standardize" and "Sustain". The method describes how to organize
a work space for efficiency and effectiveness by identifying and storing the items
used, maintaining the area and items, and sustaining the new order. The decision-
making process usually comes from a dialogue about standardization, which builds
understanding among employees of how they should do the work.
i
G452-002-
Acknowledgement
The Director General of DSD would like to extend his gratitude to the organisations and
individuals who have been involved in developing this Standard including:
i. National Skills Development Council (NSDC)

ii. Standard Technical Committee (STC)
iii. Standard Technical Evaluation Committee (STEC)
iv. Standard Development Committee (SDC)
v. Facilitator
vi. Secretariat
vii. Related Organisation
i
G452-002-
STANDARD PRACTICE
NATIONAL OCCUPATIONAL SKILLS STANDARD (NOSS) FOR:
LEVEL 2
1
G452-002-
1. Introduction
1.1. Occupation Overview
With the predicted skilled labour shortage, and continual retirement of experienced
technicians within the next few years, interest in training and skills upgrading in the
automotive-repair sector has continued to increase. In addition, technology continues to
change and training programs must keep pace with the changing technology. Not only
have vehicle engines moved into the area of electronics and computerization, but the
peripheral automotive industries, such as glass and parts, have also seen vast changes in
the technical aspects of the automotive trades. One of the main purposes of this review is
to provide a thorough review of existing training contents, and the creation of new
programs (if necessary), that the training materials and curriculum match the needs of
today technicians and employers.
We believe that a resourceful and productive career with a prosperous and sustainable
future is built on a foundation of solid early development. Basic skills and knowledge in
the earliest years lays the groundwork for a lifetime of solid knowledge. When
developing skills are strengthened by positive early experiences, knowledgeable
technicians are more likely to grow into competent technicians. The automotive repair
and maintenance industry comprises of companies of automotive mechatronic, tyre
service, automotive service, Heating Ventilation Air Conditioning (HVAC), accessories,
Hybrid system, NGV system, and power train maintenance that provide repair and
maintenance services for light vehicles. The occupational function of work and services
includes the repair and/or replacement of parts, rust-proofing, oil change, lubrication, tire
changes and car washes. The demand of automotive repair and maintenance services
largely depends on the average car usage and the number of cars on the road. They are
also required to perform diagnostic test & evaluation for the vehicle performance, repair
& maintenance, after service, warranty and maintain inventory of automotive parts
related to a holistic vehicle maintenance and repair occupation or employment
The vehicle maintenance and repair industry value chain enters into the system
diagnostic, testing, and comprehensive rectification of vehicle performance which allows
a mechanic to determine the root cause of a problem in the vehicle. The profession may
be required to evaluate the next course of action, such as the type of repair that needs to
be performed to solve the problem for all vehicle maintenance service which includes
electric and hybrid vehicles, body work, wheel servicing, and infotainment. Hence, the
fundamental of the profession should begin with the service and repair of damaged parts
of the vehicle, perform maintenance services to prevent any future damages and others
holistic or completed services to ensure the vehicles on-road safety and security.
With the increasing numbers of vehicles year by year, based on Figure 1 below, it shows
that a lot of vehicles do require maintenance and repair services. Hence, vast numbers of
expertise are required to maintain and repair for light vehicles. It is considered as a
specialist skill to maintain the said work in the vehicle maintenance and repair industry
2
G452-002-2:2018
Negeri 2013 2014 2015 2016 2017

Perlis 3,627.00 6,266.00 5,709.00 3,936.00 3,090.00
Kedah 60,915.00 55,969.00 50,130.00 40,283.00 35,875.00
Pulau Pinang 92,863.00 91,505.00 56,515.00 47,108.00 39,582.00
Perak 82,438.00 71,812.00 47,496.00 41,292.00 30,632.00
Selangor 101,757.00 118,698.00 99,777.00 76,231.00 59,725.00
Wilayah Persekutuan 356,897.00 293,622.00 168,453.00 115,409.00 100,418.00
Negeri Sembilan 30,384.00 31,260.00 26,543.00 19,472.00 15,509.00
Melaka 29,761.00 30,267.00 23,598.00 17,803.00 0
Johor 161,963.00 143,029.00 93,235.00 75,888.00 58,982.00
Pahang 44,904.00 37,411.00 29,373.00 23,971.00 19,526.00
Terengganu 30,252.00 25,272.00 17,836.00 15,566.00 15,135.00
Kelantan 41,951.00 40,436.00 27,880.00 17,461.00 10,764.00
Sabah 74,124.00 73,355.00 49,605.00 37,096.00 33,115.00
Sarawak 90,838.00 91,028.00 63,162.00 41,750.00 39,071.00
Portal RakanNiaga 0 172,006.00 441,448.00 528,769.00 648,206.00
Total 1,202,674.00 1,109,930.00 759,312.00 573,266.00 461,424.00
Figure 1: Total Registration of Motor Vehicle in Malaysia By State For Year 2013-
2017
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1.2. Rationale of NOSS Development
Previously there is level 1 for the mechanic maintenance. Following the demand of the
market and the industry, the level 1 have been embedded into level 2. The purpose of
this NOSS is to provide learners, education and training providers and employers with
the standards and the range of learning required to work effectively in the aftermarket
making use of automotive repair and maintenance skills and to meet the challenges of
the automotive industry and related environments. The primary skill recognised in this
qualification is the ability to apply the theory behind repair and maintenance in
performing general servicing of vehicles; where this capability requires an understanding
of basic repair and maintenance theory, names and functions of fluids and lubricants,
automotive components and how to read and interpret workshop manuals and workshop
procedures.
The NOSS review and development work also reviewed the current mechanic NOSS,
Vehicle mechanic (TP-300-2), together with the related industry and occupation at their
career and advancement, i.e. automotive mechatronic, tyre service, automotive service,
Heating Ventilation Air Conditioning (HVAC), accessory, Hybrid system, NGV system,
and power train maintenance whereby the occupation is enhanced in the new proposed
NOSS Level 2. This NOSS document provides a structured set of activities that enables
a person who aspires to achieve competencies in the education and training sector.
Standard Practice and Standard Content are part of NOSS document. The job area being
developed is based on the outcome of Occupational Area Analysis (OAA). This
document covers the competency standard of Light Vehicle-Repair Service (Level 2).
Standard Practice is a document showing the career path of any particular professionals
or practitioner. Standard Content is a part of NOSS document and is developed with
Training Manual and Internship Manual to complete the whole NOSS
This NOSS is developed with the following objectives:

a) To enhance awareness and knowledge on vehicle services and repair for
workshops
b) To recommend good practice to be used by local aftermarket services and
repair workshops to perform relevant activities
c) To adhere to the National Automotive Policy (NAP) 2014 Strategic Thrust of
safety, security and environment through the regulated and standardisation of
light vehicle workshop service and repair activities.
d) Malaysia is part of the United Nation Environment (UNE) committee and
already created programs and standards to make sure that all the players in
light vehicle services and repair adhered to the current standards and
regulations such as MS 2697:2018 Motor vehicle aftermarket - Repair, reuse,
recycle and remanufacture (4R) for parts and components - Code of practice
&MS 2696:2018 Motor vehicle aftermarket - Service and spare parts (2S) -
Code of practice.
4
G452-002-
1.3. Rationale of Occupational Structure and Occupational Area Structure
Previously there is level 1 for the mechanic maintenance, following the demand of the
market and the industry, the level 1 have been embedded in level 2 for training purposes.
Level 1 still existed in the Occupational Structure and Occupational Area Structure and
the person that finish the training of this skill shall either start in level 1 or level 2
depends on the market and the industry demand.
In NAP 2014, there are 6 roadmaps, one of it is the Malaysia Automotive Human Capital
(MAHR) Roadmap which focuses on;
a) Detailing the on-going development of human capital in the automotive
industry at all levels from 2014 to 2020 to realize the target set in the
National Automotive Policy (NAP) 2014.
b) Improving the quality of existing Human Capital Development (HCD)
programmes at all levels.
c) Outlining the implementation plan to create specialized automotive industry
talents in critical areas for example hybrid components and engines
transmissions.
d) Training competent workforces with various skills and ready for process
automation to reduce dependency on unskilled foreign workers and help
create skilled local workforces with high incomes.
The roadmap is centred on assessment and gap analysis of the Human Capital
Development (HCD) requirement by the automotive industry. Thrust areas were
identified and implementation plans were put forward.
Figure 2: assessment and gap analysis
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G452-002-
1.4. Regulatory / Statutory Body Requirements Related to Occupation
I. Consumer Protection Act 1999, Workshop Information Disclosure Regulations

2002, Ministry of Domestic Trade and Consumer Affairs (KPDNHEP).
II. Environmental Quality (Refrigerant Management) Regulations 1999 and

Environmental Quality (Refrigerant Management) (Amendment) Regulations 2004
under the Environmental Quality Act 1974, Department of Environment (DOE).
III. Ministry of Urban Wellbeing, Housing and Local Government (KPKT), act 171
and act 133.
IV. MS 2696:2018 Motor vehicle aftermarket - Service and spare parts (2S) - Code of
practice. This standard prescribes industry best practices for aftermarket service
providers activities including the responsibility with regards to the requirements of
4M (Man, Method, Machine and Material).
1.5. Occupational Pre-Requisite
Generally the light vehicle-repair service technician may work with minimum
supervision individually or in a team complied with Occupational Safety and Health
(OSHA) requirement and Environmental Quality Act and its Regulations.
1.6. General Training Pre-Requisite For Malaysian Skills Certification System
 No certification and experience required
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G452-002-
2. Occupational Structure (OS)
Section (G) Wholesale And Retail Trade, Repair Of Motor Vehicles And
Motorcycles
Group (452) Maintenance And Repair Of Motor Vehicles
Area Passenger Vehicle Maintenance & Service
Level 5 Service / Operation Manager
Level 4 Service / Operation Executive
Level 3 Passenger Vehicle Maintenance & Service Diagnostic Technician
Level 2 Motor Vehicle Maintenance & Service Senior Technician
Level 1 Motor Vehicle Repair And Maintenance Technician
Figure 3: Occupational Structure
3. Occupational Area Structure (OAS)
Section (G) Wholesale And Retail Trade, Repair Of Motor Vehicles And
Motorcycles
Group (452) Maintenance And Repair Of Motor Vehicles
Area Passenger Vehicle Maintenance & Service
Level 5 After Sales – Service Management
Level 4 After Sales - Service Operation
Level 3 Light Vehicle -Diagnose Service
Level 2 Light Vehicle-Repair Service
Level 1 Embedded Into L2
Figure 4: Occupational Area Structure
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G452-002-
4. Definition of Competency Levels
The NOSS is developed for various occupational areas. Below is a guideline of each NOSS
Level as defined by the Department of Skills Development, Ministry of Human Resources,
Malaysia.
Level 1: Competent in performing a range of varied work activities, most of which are
routine and predictable.
Level 2: Competent in performing a significant range of varied work activities,

performed in a variety of contexts. Some of the activities are non-routine and
required individual responsibility and autonomy.
Level 3: Competent in performing a broad range of varied work activities, performed in a

variety of contexts, most of which are complex and non-routine. There is
considerable responsibility and autonomy and control or guidance of others is
often required.
Level 4: Competent in performing a broad range of complex technical or professional

work activities performed in a wide variety of contexts and with a substantial
degree of personal responsibility and autonomy. Responsibility for the work of
others and allocation of resources is often present.
Level 5: Competent in applying a significant range of fundamental principles and

complex techniques across a wide and often unpredictable variety of contexts.
Very substantial personal autonomy and often significant responsibility for the
work of others and for the allocation of substantial resources features strongly,
as do personal accountabilities for analysis, diagnosis, planning, execution and
evaluation.
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G452-002-
5. Award of Certificate
The Director General may award, to any person upon conforming to the Standards the
following skills qualifications as stipulated under the National Skills Development Act 2006
(Act 652):
5.1. Malaysian Skills Certificate (MSC)

5.2. Statements of Achievement
6. Occupational Competencies
Light Vehicle-Repair Service (Level 2) personnel is competent in performing the following

core competencies:
6.1 Vehicle Workshop Housekeeping

6.2 Vehicle Engine Service
6.3 Vehicle Engine Overhauling
6.4 Vehicle Brake System Service
6.5 Engine Cooling System Replacement
6.6 Rear / Front Axle Rectification
6.7 Exhaust System Rectification
6.8 Vehicle Electrical & Electronic System Service
6.9 Vehicle Steering, Suspension and Wheel System Service
6.10 Vehicle Heated Ventilation Air Conditioning (HVAC) System Rectification
6.11 Automatic Transmission / Transaxle Unit Overhauling
6.12 Manual Transmission / Transaxle Unit Overhauling
Optionally, the Light Vehicle-Repair Service (Level 2) is competent in performing the

following elective competency:-
6.13 Transfer Case Overhauling

6.14 Vehicle Carburettor Service
7. Work Conditions
Generally workers will work under similar operating hours of the organisation/company.
He/she may involve in outside normal working hours or work during weekends. The
technician also must be comply with Department of Environmental (DOE) regulation
regarding waste storage, waste handling and waste disposal. Also an understanding and
compliance of 5S.
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8. Employment Prospects
The knowledge and skills gained by the motor vehicle maintenance & Service in handling
people and the ability to work independently would be advantageous for employment in
other related service industries.
8.1 Other related occupations with respect to employment opportunities are:

 Service advisor
8.2 Other related industries with respect to employment opportunities are:

 Motor vehicle workshop
 Motor vehicle service centre
9. Up Skilling Opportunities
Based on the Occupational area structure, the person that is competent in level 2 can go to the
Light Vehicle-Diagnose Service level 3.
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G452-002-
10. Organisation Reference for Sources of Additional Information
The following organisations can be referred as sources of additional information which can
assist in defining the documents contents.
10.1 Ministry of International Trade and Industry

(MITI) No. 7, Menara MITI,
Jalan Sultan Haji Ahmad Shah,
50480 Kuala Lumpur, Malaysia.
Tel: 603 8000 8000
Fax: 03-6202 3446
Email: webmiti@miti.gov.my
10.2 Malaysia Automotive Institute (MAI),

Ministry of International Trade and Industry (MITI)
Block 2280, Jalan Usahawan 2, Cyber 6
63000 Cyberjaya, Selangor, MALAYSIA
Tel: 603 8318 7742
Fax: 603 8318 7743
Email: autoaftermarket@mai.org.my
10.3 Ministry of Transport (MOT)

No. 26, Jalan Tun Hussein, Presint 4,
62100 W.P. Putrajaya, Malaysia.
Tel: 603-8000 8000
Fax: 603-8888 0158
Email: aduan@mot.gov.my
10.4 JabatanPengangkutan Jalan (JPJ),

Ministry of Transport Malaysia (MOT)
Aras 3-5, No. 26,
Jalan Tun Hussien, Presint 4,
Pusat Pentadbiran Kerajaan Persekutuan,
62100 WP Putrajaya, Malaysia
+6038000 8000
www.jpj.gov.my
aduantrafik@jpj.gov.my
10.5 Ministry of Energy, Science, Technology, Environment & Climate

Change (MESTECC)
Level 1-7, Block C4 & C5, Complex C,
Federal Government Administration,
62662, Putrajaya, MALAYSIA
Tel: (603) 8885 8000
enquiry@mestecc.gov.my
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10.6 Department of Environment (DOE),

Ministry of Energy, Science, Technology, Environment & Climate Change
(MESTECC)
Block 4G3, Aras1-4, Podium 2, 3, 25,
Persiaran Perdana,
62574 Putrajaya, MALAYSIA.
Tel: (603) 8871 2000
www.nre.gov.my
Email: aduan_k@doe.gov.my
10.7 Ministry of Domestic Trade and Consumer Affairs (KPDNHEP)

No. 13, Persiaran Perdana,
Presint 2,62623 Putrajaya, Malaysia
Tel: 603-80008000
Fax: 603-88825762
Email: e-aduan.kpdnkk.gov.my
10.8 PUSPAKOM Sdn. Bhd. (285985-U),

Level 3 & 4, Wisma DRB-HICOM,
No 2, Jalan Usahawan U1/8, Seksyen U1,
40150 Shah Alam,Selangor, Malaysia
+603 2052 7474
www.puspakom.com.my
customerservice@puspakom.com.my
10.9 Malaysian Automotive Association (MAA)

F-1-47, Block F, Jalan PJU 1A/3
Taipan Damansara 2, Parcel 1
Ara Damansara, 47301 Petaling Jaya
Selangor Darul Ehsan
Tel: 6 03 7843 9947
Fax: 6 03 7843 0847
Email: secretariat@maa.org.my
10.10 Federation of Motor & Credit Company Association of

Malaysia 85A, Jalan Jejaka 2, Taman Maluri,
Off Jalan Cheras, 55100 Kuala Lumpur
Tel: 603-9200 6880
Fax: 603-9200 7208
10.11 PersatuanInsuran Am Malaysia (PIAM)

3rd Floor Wisma PIAM 150 Jalan Tun Sambanthan,
Kuala Lumpur, 50470, Kuala Lumpur
Tel: 03-2274 7399
Fax: 03-2274 5910
Email: pic@piam.org.my
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11. Standard Technical Evaluation Committee
NO NAME POSITION&ORGANISATION
Assistant Manager of After Market
1. Selveraj Subramaniam
PERODUA
Head of Trainer
2. Mohd Razif Bin Mustaffa
PERODUA
Head of Trainer
3. Steven Chua
TCTECH
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11. Standard Development Committee
LEVEL 2
NO NAME POSITION&ORGANISATION
Head Trainer
1. Hock Swee Lim
Bermaz Auto
Vehicle Examiner
2. Mohd Syazwan Bin Solah Malaysian Institute Of Road Safety
Research (MIROS)
Senior Engineer & Assistant Director
3. Mahamad Rashid Bin Ibrahim
Jabatan Pengankutan Jalan (JPJ)
Trainer
4. Tengku Hazif Tengku Mansor
Proton Holding Sdn Bhd
General Manager
5. Zulkeffli Bin Saad
Auto Svs Academy
Head Mechanics & General Manager
6. Mohammed Rais Bin Sayuti
G Autotech Services
7. Megat Mohd Hamirul
Next Assyst Auto Care
8. Azahree Bin Kamarudin
Ai Kz Auto Workshop
Operation Manager
9. Azieman Zuhaidee B. Othman
G Tuned Motor Sport
Technical Manager
10. Zaidi Bin Pandak
Britcars Automobile SdnBhd
FACILITATOR
1. Mohd Firdaaus Mohd Munir Malaysia Automotive Institute (MAI)
2. Siti Maisarah Mohd Pisal Malaysia Automotive Institute (MAI)
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STANDARD CONTENT
LEVEL 2
15
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13. Competency Profile Chart (CPC)
SECTION (G) WHOLESALE AND RETAIL TRADE; REPAIR OF MOTOR VEHICLES AND MOTORCYCLES
GROUP (452) MAINTENANCE AND REPAIR OF MOTOR VEHICLES
AREA LIGHT VEHICLE MAINTENANCE & SERVICE
NOSS TITLE LIGHT VEHICLE-REPAIR SERVICE
NOSS LEVEL TWO (2) NOSS CODE G452-002-2:2018
COMPETENCY UNIT
VEHICLE VEHICLE BRAKE

CORE VEHICLE ENGINE VEHICLE ENGINE
WORKSHOP SYSTEM SERVICE
COMPETENCY SERVICE OVERHAULING
HOUSEKEEPING
G452-002-2:2018-CU01 G452-002-2:2018-CU02 G452-002-2:2018-CU03 G452-002-2:2018-CU04
VEHICLE
ENGINE COOLING
REAR / FRONT AXLE EXHAUST SYSTEM ELECTRICAL &
SYSTEM
RECTIFICATION RECTIFICATION ELECTRONIC
REPLACEMENT
SYSTEM SERVICE
G452-002-2:2018-CU05 G452-002-2:2018-CU06 G452-002-2:2018-CU07 G452-002-2:2018-CU08
VEHICLE HEATED
VEHICLE STEERING, AUTOMATIC MANUAL
VENTILATION AIR
SUSPENSION AND TRANSMISSION / TRANSMISSION /
CONDITIONING
WHEEL SYSTEM TRANSAXLE UNIT TRANSAXLE UNIT
(HVAC) SYSTEM
SERVICE OVERHAULING OVERHAULING
RECTIFICATION
G452-002-2:2018-CU09 G452-002-2:2018-CU10 G452-002-2:2018-CU11 G452-002-2:2018-CU12
16
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VEHICLE
ELECTIVE TRANSFER CASE
CARBURETTOR
COMPETENCY OVERHAULING
SERVICE
G452-002-2:2018-EU01 G452-002-2:2018-EU02
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14. Competency Profile (CP)
SECTION (G)Wholesale And Retail Trade; Repair Of Motor Vehicles And Motorcycles
GROUP (452)Maintenance And Repair Of Motor Vehicles
AREA Light Vehicle Maintenance & Service
NOSS TITLE Light Vehicle-Repair Service
NOSS LEVEL Two (2) NOSS CODE G452-002-2:2018
CU TITLE & CU
CU DESCRIPTOR WORK ACTIVITIES PERFORMANCE CRITERIA
CODE
1. Vehicle Vehicle Workshop Housekeeping is the 1. Identify workshop 1.1 Workshop housekeeping instructions is
Workshop essential role of vehicle maintenance housekeeping obtained for sorting housekeeping
Housekeeping shops hygiene, safety and security requirements. activities schedule.
conformant to enable services are 1.2 Type of housekeeping area is
G452-002- rendered at worthiness condition. It is determined for identifying workplace
2:2018-CU01 to utilize all resources for safeguarding housekeeping requirement.
vehicle maintenance shops to be at 1.3 Type of tools, equipment and materials
optimum comfort, at the same time are determined for desirable
complying with the legislative housekeeping activities preparation.
compliances. The importance of this 2. Prepare workshop 2.1 Signage for work procedures are
competency unit is the ability to apply housekeeping setup. arranged to allow risks mitigation.
the standards procedures and measures 2.2 Safety equipment are arranged for work
to avoid injuries of people working in safety.
automotive workshops, creating and 2.3 Standard Operating Procedure (SOP)
maintaining work safes expectations, for workshop housekeeping is adhered
and the principles to address health and to complying with standards working
safety problems in automotive procedures.
workshops for enabling worthiness 2.4 Maintenance schedule for workshop
operation. housekeeping activities are listed for
work arrangement.
The competency includes to identify 3. Perform workshop 3.1 Workshop safety practices are carried
workshop housekeeping requirements, housekeeping activities. out for workplace housekeeping.
prepare workshop housekeeping setup, 3.2 Workshop tools maintenance activities
perform workshop housekeeping are carried out to enable safe
activities, check workshop functionality and application.
housekeeping conformance, and 3.3 Workshops equipment housekeeping
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prepare workshop periodic report. and re-allocation are carried out for
worthiness operation.
The outcome of this competency is to 3.4 Housekeeping compliances for
perform essential roles of vehicle legislative condition are checked to
workshops layout organization meet workplace standards.
structure, hygiene, safety and security 4. Check workshop 4.1 Workshop activities are being assessed
conformant to enable services are housekeeping for determining housekeeping
rendered at worthiness condition. It is conformance. performance.
to utilize all resources for safeguarding 4.2 Workshop activities checklist is
vehicle workshops are at optimum compiled for documenting
comfort complying with the legislative housekeeping outcome.
compliances. 4.3 Tools, equipment & materials
placement condition are checked for
assessing worthiness operation.
5. Prepare workshop periodic 5.1 Housekeeping information and remarks
report. are compiled for administrative
function.
5.2 Activities summary is reported to
supervisor/ manager.
5.3 Housekeeping compliance is
documented for standards verification.
2. Vehicle Engine Vehicle Engine Service is an essential 1. Change lubrication oil & 1.1 Job order obtained and interpreted.
Service role for vehicle maintenance to ensure oil filter. 1.2 Tools, equipment and parts confirmed
that oil levels are sufficiently topped up according to job requirement.
G452-002- to avoid major faulty repair. The 1.3 Oil filter replaced in accordance with
2:2018-CU02 importance of this competency unit is the workshop manual.
to exchange the engine oil, replace the 1.4 Lubricant refilled out to meet the
oil filter and change minor components vehicle requirement according to the
of the engine. workshop manual.
1.5 Lubrication leakage is checked to
The competency includes to change ensure worthiness of lubrication
lubrication oil & oil filter, change services.
engine drive belt and tensioner, inspect 1.6 Next service indicator updated and
exhaust systems components condition, presented.
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change air filter, change fuel filter and 1.7 Lubrication oil & oil filter replacement
change spark plugs. checklist updated in accordance with
the workshop manual.
The outcome of this competency is to
be able to service the engine vehicle
2.1 Job order obtained and interpreted.
regularly or periodically to avoid major 2. Change engine drive belt
and tensioner. 2.2 Tools, equipment and parts confirmed
faulty after long mileage and ensuring
according to job requirement.
vehicle are at optimum condition after
2.3 Engine drive belt and tensioner
lubrication service complying with
checked according to service manual.
vehicle lubrication manual & practice.
replaced in accordance with the
workshop manual.
replacement checklist updated in
accordance with the workshop manual.
3. Inspect exhaust system 3.1 Job order obtained and interpreted.
components condition. 3.2 Tools, equipment and parts confirmed
3.3 Exhaust system components condition
are checked for leakages in accordance
with the workshop manual.
3.4 Exhaust system components condition
inspection checklist updated in
4. Change air filter. 4.1 Air filter condition is checked in
4.2 Air filter replaced in accordance with
4.3 Air filter replacement checklist updated
in accordance with the workshop
manual.
5. Change fuel filter. 5.1 Fuel filter condition are checked in
5.2 Fuel filter replaced in accordance with
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5.3 Fuel filter replacement checklist
updated in accordance with the
workshop manual.
6. Change spark plugs. 6.1 Spark plugs condition are checked in
6.2 Spark plugs replaced in accordance
6.3 Spark plug gap adjusted in accordance
6.4 Spark plugs replacement checklist
updated in accordance with the
workshop manual.
3. Vehicle Engine Vehicle Engine Overhauling is a scope 1. Conduct engine 1.1 Job order obtained and interpreted.
Overhauling of competency to examine and restore compression test. 1.2 Tools, equipment and parts confirmed
the diesel / petrol engine components to according to job requirement.
G452-002- meet manufacturers specifications and 1.3 Engine compression tests are completed
2:2018-CU03 tolerances during overhaul. Proper in accordance with the workshop
dimensions and tolerances must be met manual.
to obtain proper performance and 1.4 Engine compression test reports
maximum engine life. The importance prepared.
of this competency unit is about the 1.5 Engine compression test reports
engine which has been removed, compared to the manufacturers
disassembled (torn down), cleaned, specifications.
inspected, and replace parts as 1.6 Engine overhaul recommendation is
necessary and tested using workshop prepared in accordance with the
manual approved procedures. The workshop manual.
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procedure generally involves honing, 2. Conduct engine cylinder 2.1 Engine cylinder leakage test using
new piston rings, bearings, gaskets, oil leakages test. diagnostic tool are completed in
seals. accordance with the workshop manual.
2.2 Engine cylinder leakage test reports
The competency includes to conduct compared to the manufacturers
engine compression test, conduct specifications.
engine cylinder leakages test, remove 2.3 Engine overhaul recommendation is
engine from vehicle, perform engine prepared and printed in accordance
overhaul, reinstall engine onto vehicle with the workshop manual.
and conduct engine test. 3. Remove engine from 3.1 Vehicle operation fluids and lubricant
vehicle. are drained out in accordance with the
The outcome of this competency is to workshop manual.
make sure no abnormal knocking 3.2 Refrigerant gases are recovered in
sound, no visible and possible leaking accordance with the workshop manual.
from the engine and free from defect to 3.3 Engine auxiliary components and
ensure the engine functions in full attachments are removed in accordance
optimal performance also defect free. with the workshop manual.
3.4 Crane-out the engine from vehicle in
4. Perform engine overhaul. 4.1 Engine external components are
removed in accordance with workshop
manual.
4.2 Engine internal components are
removed and strip down in accordance
with workshop manual.
4.3 Engine parts and components are
cleaned-up in accordance with
workshop manual.
4.4 Engine parts and components are
inspected in accordance with the
workshop manual.
4.5 Engine part and components wear and
tear are measured in accordance with
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4.6 Machine shop work is prepared
according with the workshop manual
are coordinated.
4.7 Worn or damaged parts and
components changed in accordance
4.8 External and internal engine
components reassembled.
5. Reinstall engine onto 5.1 Vehicle operation fluids and lubricants
vehicle. are refilled.
5.2 Refrigerant gases are refilled.
5.3 Engine auxiliary components and
attachments are fitted.
5.4 Engine is craned-in onto vehicle in
accordance with the OEM
specification.
6. Conduct engine test. 6.1 Leakages are checked in accordance
with the service manual.
6.2 Abnormal noises are checked through
audio inspection in accordance with the
workshop manual.
6.3 On Board Diagnostic (OBD) test is
performed in accordance with the
workshop manual.
6.4 Vehicle test drive is carried out to
determine the engine performance in
6.5 Final control test on the overall vehicle
performance is performed in
accordance with the OEM
specification.
6.6 Engine test report is prepared in
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4. Vehicle Brake Vehicle Brake System Service is a 1. Inspect brake system 1.1 Job order obtained and interpreted.
System Service scope of competency to restore drum condition. 1.2 Tools, equipment and parts confirmed
brake system or disc brake system in according to job requirement.
G452-002- order to slow or stops the wheels and 1.3 Brake leakages condition is checked in
2:2018-CU04 the vehicle. Importance of this accordance with hydraulic brake system
competency unit is that the person can condition inspection procedure.
perform service on the brake system of 1.4 Water vapour contamination level of
the vehicle. the brake fluid is checked according
The competency includes to inspect 1.5 Inspection brake system condition
brake system condition, change brake checklist is prepared in accordance with
system and change parking brake the workshop manual.
system components. 2. Change brake system 2.1 Brake system components replaced in
components. accordance with workshop manual.
The outcome of this competency is to 2.2 Brake system components replacement
make sure the continuous of the brake checklist prepared in accordance with
functions, free of any fluid leakages, the workshop manual.
and to ensure the safeness of the driver. 3. Change parking brake 3.1 Parking brake components condition
system components. checked in accordance with the
workshop manual.
3.2 Parking brake components replaced in
3.3 Vehicle brake system service report is
prepared in accordance with the
workshop manual.
5. Engine Engine Cooling System Replacement is 1. Conduct cooling system 1.1 Job order obtained and interpreted.
Cooling a scope of competency to examine and pressure test. 1.2 Tools, equipment and parts confirmed
System replace faulty engine cooling system according to job requirement.
Replacement and prevent engine from over-heating. 1.3 Cooling system pressure test completed
Importance of this competency unit is in accordance with the workshop
G452-002- that the person can perform faulty parts manual.
2:2018-CU05 replacement for the engine cooling 1.4 Pressure test result acquired.
system. 2. Conduct cooling system 2.1 Noise, vibration & harshness (NVH)
parts functionality test. abnormalities confirmed by cooling
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This competency includes conduct system components functionality test.
cooling system pressure test, conduct 2.2 Cooling system components
cooling system parts functionality test functionality test status checklist
and change cooling system parts updated.
3. Change cooling system 3.1 Cooling system parts replaced in
The outcome of this competency is to parts. accordance with workshop manual.
provide smooth engine cooling 3.2 Cooling system parts functionality
functions, free of noise and defects, confirmed in accordance with
maintain the temperature of the engine workshop manual.
and to ensure efficiency of the cooling 3.3 Engine cooling system replacement
system. report prepared in accordance with
workshop manual.
6. Rear / Front Rear / Front Axle Unit Rectification is 1. Inspect rear / front axle 1.1 Job order obtained and interpreted.
Axle a scope of competency to restore final- condition. 1.2 Tools, equipment and parts confirmed
Rectification drive gears in order to reduce the speed according to job requirement.
of the axle shafts while increasing the 1.3 Rear / front axle leakages are visually
G452-002- torque applied to them and axle checked according to the workshop
2:2018-CU06 differential unit to allow different rates manual.
of wheel rotation on curves. Importance 1.4 Rear / front axle abnormal noise and
of this competency unit is that the vibration confirmed to determine the
person can perform rectification work possibility worn out condition.
on the rear / front axle of the vehicle. 2. Dismantle rear / front axle 2.1 Wheels are removed from the rear /
differential unit. front axle differential unit in
The competency includes inspect rear / accordance with the workshop manual.
front axle condition, dismantle rear / 2.2 Differential gear oil drained in
front axle differential unit and change accordance with removing rear axle
rear / front axle differential components differential unit requirement.
& parts. 2.3 Drive shaft removed from vehicle in
accordance with workshop manual.
The outcome of this competency is to 2.4 Rear / front axle differential unit
provide free of leakages, other defects attachment parts removed in
and smooth performance of the rear / accordance with the workshop manual.
front axle. 3. Change rear / front axle 3.1 Rear / front axle differential unit
differential components & dismantled in accordance with
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parts. workshop manual.
3.2 Rear / front axle differential unit parts
& components replaced in accordance
with workshop manual.
3.3 Rear / front axle differential unit
assembled in accordance with the
workshop manual.
3.4 Rear / front axle differential unit
installed into rear / front axle in
3.5 Wheel installed to the vehicle in
3.6 Pre-delivery inspection test is
performed in accordance with
workshop manual.
3.7 Rear / front axle rectification report is
workshop manual.
7. Exhaust Exhaust System Rectification is a scope 1. Inspect exhaust system 1.1 Job order obtained and interpreted.
System of competency to ensure the exhaust components condition. 1.2 Tools, equipment and parts confirmed
Rectification gases discharged away from the engine according to job requirement.
into the air and muffle the noise of the 1.3 Exhaust System Components Condition
G452-002- exhaust. Importance of this competency checked in accordance with the
2:2018-CU07 unit is that the person can perform workshop manual.
rectification work on exhaust system of 1.4 Exhaust System Components Condition
the vehicle. status checklist prepared in accordance
The competency includes to inspect 2. Change exhaust system 2.1 Exhaust system components replaced in
exhaust system components condition, components. accordance with workshop manual.
change exhaust system components, 2.2 Exhaust system components
and test exhaust system performance. replacement checklist status prepared.
3. Conduct exhaust system 3.1 Exhaust system components replaced in
The outcome of this competency is to components performance accordance with workshop manual.
provide free of leakages, noise & test. 3.2 Exhaust system components
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vibration, good cosmetic value & replacement checklist status prepared.
performance of engine exhaust system 3.3 Exhaust system rectification report
and also to make sure safer prepared in accordance with the
environment. workshop manual.
8. Vehicle Vehicle Electrical & Electronic System 1. Inspect electrical & 1.1 Job order obtained and interpreted.
Electrical & Service is a scope of competency to electronic system parts & 1.2 Tools, equipment and parts confirmed
Electronic restore electrical and electronic system, components functionality. according to job requirement.
System Service producing electricity and delivering 1.3 Electrical & electronic system parts &
electric energy from these sources on components functionality checked in
G452-002- demand to any other electrical accordance with the workshop manual.
2:2018-CU08 components in the vehicle. Importance 1.4 Inspection technical report prepared
of this competency unit is that the and submitted in accordance with
person can perform service and workshop manual.
replacement of parts on the electrical & 2. Change electrical & 2.1 Electrical& electronic system parts &
electronic system of the vehicle. electronic system parts & components replaced in accordance
components. with workshop manual.
The competency includes the inspection 2.2 Electrical& electronic system parts &
of electrical & electronic components components performance test
functionality, change electrical & performed in accordance with
electronic system parts & components, workshop manual.
inspect chassis electrical system and 2.3 Electrical & electronic system parts &
change vehicle chassis electrical system components replacement report
components. prepared in accordance with the
workshop manual.
The outcome of this competency is to 3. Inspect chassis electrical 3.1 Electrical & electronic system parts &
provide clear engine ignition, system. components functionality checked in
combustion of the engine and a smooth accordance with the workshop manual.
fuel injection operation. 3.2 Inspection technical report prepared
and submitted in accordance with
workshop manual.
4. Change chassis electrical 4.1 Chassis electrical system components
system components. replaced in accordance with workshop
manual.
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4.2 Chassis electrical system components
performance test performed in
4.3 Chassis electrical system components
replacement report prepared in
9. Vehicle Vehicle Steering, Suspension and 1. Inspect steering, 1.1 Job order obtained and interpreted.
Steering, Wheel System Service is a scope of suspension and wheel 1.2 Tools, equipment and parts confirmed
Suspension competency to ensure steering, wheel system functionality. according to job requirement.
and Wheel and suspension system are responsible 1.3 Steering, suspension and wheel system
System Service for providing optimal ride comfort and functionality checked in accordance
handling performance. Importance of with the workshop manual.
G452-002- this competency unit is that the person 1.4 Inspection steering, suspension and
2:2018-CU09 can perform service and replacement of wheel system functionality technical
parts & components on the steering, report prepared and submitted in
suspension and wheel system of the accordance with workshop manual.
vehicle. 2. Change steering system 2.1 Steering system replaced in accordance
parts. with workshop manual.
The competency includes to inspect 2.2 Steering system performance test
steering, suspension and wheel system performed in accordance with
functionality, change steering system workshop manual.
parts, replace suspension system parts 2.3 Steering system replacement report
and change vehicle tyres and rims. prepared in accordance with the
The outcome of this competency is to workshop manual.
provide free leakages, vibration and 3. Change suspension system 3.1 Suspension system parts replaced in
stiff defect, smooth performance and parts. accordance with workshop manual.
operational of vehicle steering & 3.2 Suspension system parts performance
wheels, free stiff, noise defect and test performed in accordance with
safety ensure for suspension. workshop manual.
3.3 Suspension system parts replacement
report prepared in accordance with the
workshop manual.
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4. Change vehicle tyres and 4.1 Tyres and rims replaced in accordance
rims with workshop manual.
4.2 Tyres and rims performance test
performed in accordance with
workshop manual.
4.3 Tyres and rims replacement report
workshop manual.
10. Vehicle Heated Vehicle Heated Ventilation Air 1. Inspect heated ventilation 1.1 Job order obtained and interpreted.
Ventilation Air Conditioning (HVAC) System air conditioning (HVAC) 1.2 Tools, equipment and parts confirmed
Conditioning Rectification is a competency to restore system condition. according to job requirement.
(HVAC) damaged or faulty air conditioning 1.3 Heated ventilation air conditioning
System system components back to its original (HVAC) system functionality checked
Rectification function. Importance of this in accordance with the workshop
competency unit is that the person can manual.
G452-002- perform rectification work and parts 1.4 Heated ventilation air conditioning
2:2018-CU10 replacement on the heated ventilation (HVAC) system functionality
air conditioning (HVAC)system of the inspection technical report prepared
vehicle. and submitted in accordance with
workshop manual.
The competency includes inspect 2. Change heated ventilation 2.1 Air filter replaced in accordance with
heated ventilation air conditioning air conditioning (HVAC) the workshop manual.
(HVAC) system condition, change system parts and 2.2 Condenser fan unit replaced in
heated ventilation air conditioning components. accordance with the workshop manual.
(HVAC) system parts and components 2.3 Heated ventilation air conditioning
and conduct heated ventilation air (HVAC) refrigerant recharged in
conditioning (HVAC) system accordance with the workshop manual.
performance test. 2.4 Blower motor replaced in accordance
The outcome of this competency is to 2.5 Perform blower motor switch &
ensure free leakages, free defect and control resistor replacement.
temperature accuracy for cooling effect. 2.6 Heated ventilation air conditioning
(HVAC) system parts and components
replacements prepared and submitted
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in accordance with workshop manual.
3. Conduct heated ventilation 3.1 Leakages checked in accordance with

air conditioning (HVAC) the workshop manual.
system performance test. 3.2 Noise, vibration and harshness (NVH)
checked in accordance with the
workshop manual.
3.3 Abnormal defect checklist prepared in
accordance with the workshop
manual.
11. Automatic Automatic Transmission / Transaxle 1. Conduct automatic 1.1 Job order obtained and interpreted.
Transmission / Unit Overhauling is a scope of transmission / transaxle 1.2 Tools, equipment and parts confirmed
Transaxle Unit competency to restore automatic unit functional test. according to job requirement.
Overhauling transmission / transaxle unit providing 1.3 Vehicle test is carried out to determine
torque needed to move the vehicle Automatic Transmission / Transaxle
G452-002- under a variety of road and load Unit functionality in accordance with
2:2018-CU11 condition. The importance of this the workshop manual.
competency unit is about the automatic 1.4 Automatic transmission / transaxle unit
transmission / transaxle unit which to shifting condition is checked in
be removed, disassembled (torn down), accordance with workshop manual.
cleaned, inspected, and replace parts as 1.5 Functional test report is prepared in
necessary and tested using workshop accordance with workshop manual.
manual approved procedures. The 2. Remove automatic 2.1 Automatic transaxle/transmission fluid
procedure generally involves honing, transmission / transaxle (ATF) drained in accordance with
new parts, bearings, gaskets, oil seals. from vehicle. workshop manual.
2.2 Automatic transmission / transaxle
The competency includes to conduct attachments detached in accordance
automatic transmission / transaxle unit with workshop manual.
functional test, remove automatic 2.3 Torque converter removed from the
transmission / transaxle from vehicle, vehicle in accordance with workshop
perform automatic transmission / manual.
transaxle overhauling and install 2.4 Automatic transmission / transaxle
automatic transmission / transaxle into mount onto the overhaul stand in
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vehicle. 3. Perform automatic 3.1 Automatic transmission / transaxle
transmission / transaxle internal components dismantled in
The outcome of this competency is to overhauling. accordance with workshop manual.
ensure the smoothness of the 3.2 Automatic transmission / transaxle
transmission / transaxle unit shifting components parts condition inspected
time, the quality of the shifting and free in accordance with workshop manual.
defect and malfunctions in accordance 3.3 Automatic transmission / transaxle
with OEM specifications. components parts replaced in
3.4 Automatic transmission / transaxle unit
reassembled in accordance with
workshop manual.
4. Install automatic 4.1 Automatic transmission / transaxle
transmission / transaxle attachments reattached in accordance
into vehicle. with workshop manual.
4.2 Torque converter installed to the
automatic transmission / transaxle unit.
4.3 Automatic transmission / transaxle unit
installed in accordance with workshop
manual.
4.4 Automatic Transmission / Transaxle
Fluid (ATF) refilled in accordance with
workshop manual.
4.5 Automatic transmission / transaxle
functionality test performed in
12. Manual Manual Transmission / Transaxle 1. Conduct manual 1.1 Job order obtained and interpreted.
Transmission / Unit Overhauling is a scope of transmission / transaxle 1.2 Tools, equipment and parts confirmed
Transaxle Unit competency to restore manual unit functional test. according to job requirement.
Overhauling Transmission / Transaxle providing 1.3 Vehicle test is carried out to determine
torque needed to move the vehicle Manual Transmission / Transaxle Unit
G452-002- under a variety of road and load functionality in accordance with the
2:2018-CU12 condition. The importance of this workshop manual.
competency unit is about the manual 1.4 Manual transmission / transaxle unit
shifting condition is checked in
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transmission / transaxle unit which to accordance with workshop manual.
be removed, disassembled (torn down), 1.5 Functional test report is prepared in
cleaned, inspected, and replace parts as accordance with workshop manual.
necessary and tested using workshop 2. Remove manual 2.1 Manual transaxle/transmission fluid
manual approved procedures. The transmission / transaxle (MTF) drained in accordance with
procedure generally involves honing, from vehicle. workshop manual.
new parts, bearings, gaskets, oil seals. 2.2 Manual transmission / transaxle
attachments detached in accordance
The competency includes to conduct with workshop manual.
manual transmission / transaxle unit 2.3 Manual transmission / transaxle mount
functional test, remove manual on the overhaul stand in accordance
transmission / transaxle from vehicle, with workshop manual.
perform clutch system overhaul, 3. Perform clutch system 3.1 Clutch system functionality test
perform manual transmission / overhaul. performed in accordance with
transaxle overhauling and install workshop manual.
manual transmission / transaxle into 3.2 Clutch system assembly dissembled in
vehicle accordance with workshop manual.
3.3 Clutch system parts & components
The outcome of this competency is to replaced in accordance with workshop
ensure the smoothness of the manual.
transmission unit shifting time, the 3.4 Clutch system assembly assembled in
quality of the shifting and free defect accordance with workshop manual.
and malfunctions in accordance with 4. Perform manual 4.1 Manual transmission / transaxle internal
OEM specifications. transmission / transaxle components dismantled in accordance
overhauling. with workshop manual.
4.2 Manual transmission / transaxle
components parts condition inspected
in accordance with workshop manual.
components parts replaced in
4.4 Manual transmission / transaxle unit
workshop manual.
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5. Install manual 5.1 Manual transmission / transaxle
transmission / transaxle attachments reattached in accordance
into vehicle. with workshop manual.
5.2 Manual transmission / transaxle unit
installed in accordance with workshop
manual.
5.3 Manual Transmission / Transaxle Fluid
(MTF) refilled in accordance with
workshop manual.
functionality test performed in
13. Transfer Case Transfer Case Overhauling is a scope of 1. Conduct transfer case unit 1.1 Job order obtained and interpreted.
Overhauling competency to ensure transfer case to functional test. 1.2 Tools, equipment and parts confirmed
provide power-flow to front and rear according to job requirement.
G452-002- axle. The importance of this 1.3 Vehicle test is carry out to determine
2:2018-EU01 competency unit is about the transfer transfer case unit functionality in
case which to be removed, accordance with the workshop manual.
disassembled (torn down), cleaned, 1.4 Transfer case unit shifting condition is
inspected, and replace parts as checked in accordance with workshop
necessary and tested using workshop manual.
manual approved procedures. The 1.5 Transfer case functional test report is
procedure generally involves honing, prepared in accordance with workshop
new parts, bearings, gaskets, oil seals. manual.
2. Remove transfer case unit 2.1 Transfer case gear oil drained in
The competency includes conduct from vehicle. accordance with workshop manual.
transfer case unit functional test, 2.2 Transfer case attachments detached in
remove transfer case unit from vehicle, accordance with workshop manual.
perform transfer case unit overhauling 2.3 Transfer case mount on the overhaul
and install transfer case unit into stand in accordance with workshop
vehicle. manual.
3. Perform transfer case unit 3.1 Transfer case unit internal components
The outcome of this competency is to overhauling. dismantled in accordance with
ensure the smoothness of the gear workshop manual.
3.2 Transfer case unit components parts
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engage, the quality of the shifting and condition inspected in accordance with
free defect and malfunctions in workshop manual.
accordance with OEM specifications. 3.3 Transfer case unit components parts
replaced in accordance with workshop
manual.
3.4 Transfer case unit reassembled in
4. Install transfer case unit 4.1 Transfer case unit attachments
into vehicle. reattached in accordance with workshop
manual.
4.2 Transfer case unit installed in
4.3 Transfer case unit gear oil refilled in
4.4 Transfer case unit functionality test
performed in accordance with the
workshop manual.
14. Vehicle Vehicle Carburettor Service is a scope 1. Inspect carburettor 1.1 Job order obtained and interpreted.
Carburettor of competency to rectify faulty functionality. 1.2 Tools, equipment and parts confirmed
Service carburettor system in accordance according to job requirement.
with manufactures workshop manual. 1.3 Carburettor leakages condition is
G452-002- visually checked in accordance with
2:2018-EU02 The competency includes inspect inspection procedure.
carburettor functionality, overhaul 1.4 Carburettor idling speed performance is
carburettor and perform carburettor checked in accordance to workshop
tuning. manual.
The outcome of this competency is to 1.5 Carburettor acceleration performance is
ensure the smoothness of the engine, checked in accordance with workshop
optimum performance and free defect manual.
and malfunctions in accordance with 2. Overhaul carburettor. 2.1 Job order obtained and interpreted.
OEM specifications. 2.2 Tools, equipment and parts confirmed
2.3 Carburettor attachments are removed in
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2.4 Carburettor is removed from the intake
manifold in accordance with the
workshop manual.
2.5 Carburettor components are dismantled
in accordance with the workshop
manual.
2.6 Carburettor components worn out or
damage conditions are determined in
2.7 Carburettor components are cleaned in
accordance with service requirement.
2.8 Carburettor components are changed in
2.9 Carburettor components are
workshop manual.
2.10 Carburettor is mounted to intake
manifold in accordance with the
workshop manual.
2.11 Carburettor attachments are
workshop manual.
3. Perform carburettor 3.1 Carburettor idling tuning test is
tuning. performed in accordance with service
manual.
3.2 Carburettor acceleration tuning test is
performed in accordance with service
manual.
3.3 Carburettor choke tuning test is
performed in accordance with service
manual.
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CURRICULUM OF COMPETENCY UNIT
LEVEL 2
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15. Curriculum of Competency Unit

15.1. Vehicle Workshop Housekeeping
AREA Passenger Vehicle Maintenance & Service
COMPETENCY UNIT TITLE Vehicle Workshop Housekeeping
LEARNING OUTCOMES The outcome of this competency unit is able to perform essential roles of vehicle
workshops layout organization structure, hygiene, safety and security conformant to enable
services are rendered at worthiness condition. It is to utilize all resources for safeguarding
vehicle workshops are at optimum comfort complying with the legislative compliances.
Upon completion of this competency unit, trainees shall be able to:

1. Identify workshop housekeeping requirements.
2. Prepare workshop housekeeping setup.
3. Perform workshop housekeeping activities.
4. Check workshop housekeeping conformance.
5. Prepare workshop periodic report.
TRAINING PRE-REQUISITE (SPECIFIC) N/A
CU CODE G452-002-2:2018-CU01 NOSS LEVEL Two (2)
WORK RELATED RELATED SKILLS ATTITUDE/ SAFETY/ ASSESSMENT CRITERIA

ACTIVITIES KNOWLEDGE ENVIRONMENT
1. Identify 1.1 Workshop 1.1 Assess workshop ATTITUDE: 1.1 Workshop safe working
workshop housekeeping housekeeping  Accurate in condition are achieved
housekeeping administrative instructions. determining workshop following the workshop
requirements. functions such as: 1.2 Determine types of housekeeping manual.
 Schedule workshop requirement and 1.2 Types of workshop
housekeeping housekeeping condition. housekeeping requirements
work requirements. and compliances are listed.
 Adhoc housekeeping 1.3 Determine workshop 1.3 Workshop area cleanliness
work cleaning area. requirement are identified.
 Reporting hierarchy 1.4 Determine SAFETY: 1.4 Workshop tools, equipment
and priority
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 Supervision and housekeeping  Practice integrity in and materials housekeeping
administrative workshop tools, determining workshop condition are identified.
functions equipment and housekeeping 1.5 Workshop housekeeping
 Source of materials. compliances. supporting resources and
information 1.5 Determine workshop  Comply CHRA utilization are obtained.
 Risks mitigation housekeeping (Chemical Health Risk 1.6 Workshop housekeeping
 First aids kit supporting resources. Assessment). schedule and working
1.2 Types of workshop 1.6 Determine workshop  Use relevant PPE standards are listed.
housekeeping housekeeping (Personal Protective 1.7 Workshop housekeeping
activities and schedule. Equipment). legislative and in-house
requirements such 1.7 Determine workshop  Interpret MSDS conditions are listed.
as: housekeeping (Material Safety Data
 Oil spillage compliances. Sheet).
condition
 Tools, equipment, ENVIRONMENT:
and materials re-  Practice waste
allocation management
 Consumables and concept in making
dangerous goods printed documents.
maintenance
 Waste materials
discharge and
disposal
 Electrical installation
1.3 Workshop area
cleaning standards
such as:
 Workshop cleaning
requirement
 Types of
workplace area
cleaning
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activities
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 Tools, equipment
and materials
cleaning
 Cleaning liability
and responsibility
person-in-charge
1.4 Workshop tools,
equipment and
materials
housekeeping such
as:
 Area safety
requirement
 Workplace
housekeeping
arrangement
 Workshop
housekeeping
compliances
 Housekeeping
liability and
responsibility
person-in-charge
1.5 Workshop
housekeeping tools
and equipment
such as:
 Cleaning apparatus
 Safety tools
and materials
1.6 Workshop
housekeeping
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schedule such as:
 Internal &
external
housekeeper
 Area of work
 Responsible person-
in-charge
 Supervision
hierarchy
1.7 Workshop
housekeeping
compliances such as:
 Legislative condition
 In-house
requirement
 Electrical safety
regulation
1.8 Workshop
housekeeping
supporting
resources
 Type
 Function
2. Prepare 2.1 Workshop signage for 2.1 Determine workshop ATTITUDE: 2.1 Workshop warning and safety
workshop work procedures such signage.  Ethics and discipline in signage work procedures are
housekeeping as: 2.2 Select workshop risks arranging workshop selected.
setup.  Safety signage mitigation method. housekeeping tools, 2.2 Workshop risks mitigation for
 Working precaution 2.3 Sort out workshop equipment and hazardous control are
aids safety equipment. materials. arranged.
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 Housekeeping 2.4 Determine workshop 2.3 Workshop safety equipment
service charter housekeeping SOP. SAFETY: and materials are arranged.
2.2 Workshop risks 2.5 Setup workshop  Practice integrity in 2.4 Workshop housekeeping SOP
mitigation such housekeeping arranging workshop and legislative compliances
as: materials. warning and safety are listed.
 Fire protection 2.6 Arrange workshop signage. 2.5 Workshop housekeeping
aids such as fire housekeeping tools & materials and resources are
extinguisher, fire equipment. ENVIRONMENT: arranged.
fighting hose  Practice waste 2.6 Workshop housekeeping tools
 Waste handling management & equipment are arranged.
and service charter concept in making
 Injuries and printed documents.
supporting
aids
 Workplace directory
 Electrical protection
and alarm
2.3 Workshop safety
equipment such
as:
 Health and safety
toolbox
 Lifting equipment
 Warning signs
 Workplace
protecting
tools,
equipment and
materials
2.4 Workshop
housekeeping
SOP such as:
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 Work safe
expectation
 Workshop operation
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compliance
 Administrative
policies and
procedures
 Preventive and
corrective
manual
 Tag out/loch out
system of workshop
tools, equipment and
materials
 Storage and racking
of resources/parts
2.5 Workshop
housekeeping
materials such as:
 Spillage and
cleaning
resources
 Used materials,
debris and
disposal containers
 Hazardous
substances clearance
materials
2.6 Workshop
housekeeping tools &
equipment
 Stairs and ladders
 Floor map
and storage
layout
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 First aids provisions

and tools
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3. Perform 3.1 Workshop 3.1 Access workshop ATTITUDE: 3.1 Workshop housekeeping
workshop housekeeping housekeeping  Responsible in schedule and working
housekeeping schedule and working schedule. performing condition are listed.
activities. condition such as: 3.2 Clean workshop area. workshop 3.2 Workshop area cleaning
 Servicing and 3.3 Housekeep workshop housekeeping condition and requirement are
mechanical tools, equipment & activities. carried out.
repair workplace materials. 3.3 Housekeep workshop tools,
housekeeping 3.4 Dispose workshop SAFETY: equipment & materials
activities waste materials.  Careful and avoid housekeeping activities are
 Vehicle bodies, 3.5 Arrange workshop procedure facilities carried out.
painting and housekeeping support. malfunction. 3.4 Workshop waste materials
storage 3.6 Check workshop handling are carried out.
requirements resources safety, ENVIRONMENT: 3.5 Workshop housekeeping
 Electrical installation security and validity.  Consider energy support.
debris, waste and 3.7 Check workshop saving when sourcing 3.6 Workshop resources
removal activities housekeeping the procedure safety, security and validity
 Preventive, conformant. facilities. are arranged.
and corrective 3.7 Workshop housekeeping
housekeeping conformant are adhered.
activities
3.2 Workshop area
requirement and
condition such
as:
 Lubricant, spillages,
and waste cleaning
 Properties and
hazards handling
 Utilization and
storage of
consumables
3.3 Working condition for
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housekeep workshop
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tools, equipment &
materials such as:
 Application and
utilization of work
materials
 Accessibility and
store work tools,
equipment and
materials
 Compliance to the
Department of
Safety and Health
(DOSH)
requirements
3.4 Workshop waste
materials handling
such as:
 Types of oil & fluid
disposal such as
Engine oil, Brake
fluid,
Gasoline/Diesel/Avi
ation fuel,
Antifreeze,
Transmission fluid,
Hydraulic fluid,
Degreasers, Part
cleaning solvents,
Power steering fluid
 Waste disposal &
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procedures
 Waste hazardous
3.5 Workshop
housekeeping support
such as:
 Safety and injuries
supporting aids such
as first aids, fire
combating tools,
inspection and
troubleshooting tools
 Hazard early
warning
 Storage and traffic
support such as
warning signs, slips
& trips preventing
aids
 Housekeeping,
safety zones and
compliances
condition such as
warning cones or
warning triangles,
flashing light on
service vehicle,
mechanic/tyre fitter
wears a high-
visibility
vest/clothing
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3.6 Workshop resources
safety, security and
validity such as:
 Storages validity
 Workplace waste,
safety and security
procedures
 Workplace
standards of
ventilation, lighting,
fluid, fume
extraction, access,
egress and ingress
3.7 Workshop
housekeeping
conformant such as:
 Environment
compliances
 Workplace safety
and security
compliances
 Workman Health
Safety
&Environment
(HSE)
compliances
 Workplace operation
legislative
compliances
 In-house Health
Safety &
Environment (HSE)
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compliances
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4 Check 4.1 Workshop safety 4.1 Inspect workshop ATTITUDE: 4.1 Workshop safety condition
workshop condition such safety condition.  Accurate meticulous in and requirement are identified.
housekeeping as: 4.2 Inspect workshop analysing workshop 4.2 Workshop security condition
conformance.  Workshop traffic security condition. housekeeping and requirement are identified.
such as customers 4.3 Inspect workshop compliances. 4.3 Workshop tools, equipment
drop off area tools, equipment and and materials housekeeping
safety, pedestrian materials SAFETY: condition and conformant are
and parking bay housekeeping  Practice integrity in listed.
safety condition. making finding on 4.4 Workshop housekeeping
 Workplace safety 4.4 Confirm workshop safety and security activities performance and
such as avoiding housekeeping practices in workshop. compliances are listed.
spills/wet patches, activities performance.  Comply CHRA 4.5 Workshop housekeeping
available of 4.5 Confirm workshop (Chemical Health Risk activities conformant
absorbent to housekeeping Assessment). and outcome are listed.
avoid slippery activities compliances.  Use relevant PPE 4.6 Workshop housekeeping
 Tripping hazards 4.6 Inspect workshop (Personal protective support and arrangement are
in floor surfaces housekeeping support equipment). arranged.
are clear and clean and arrangement.  Interpret MSDS
 Retractable reels, (Material Safety Data
power and Sheet).
pneumatic outlets
are located close
to the safe area ENVIRONMENT:
4.2 Workshop security  Practice energy saving
condition such as: in using application
 Hazardous tools.
substances are
clear and clean
 Avoiding the
exposure to harmful
chemicals or other
risks
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 Place available
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warning cones or
warning triangles,
flashing light on
service vehicle,
mechanic/tyre fitter
wears a high-
visibility
vest/clothing
4.3 Workshop tools,
equipment and
materials
housekeeping
condition such as:
 Availability of
lifting aids for
lift/manage heavy
objects
 Handling aids and
on-site equipment
availability
 Work area, lighting
and visibility
 Hydraulic jacks
and trolley jacks
housekeeping
 Forklifts and lifting
equipment upkeep in
safe place
 Storage system with
proper warning
signs
4.4 Workshop
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housekeeping
activities performance
such as:
 Fix risks or zero-
down the injuries
 Disposal of
prohibited items
 Safety and security
hazards monitoring
 Legislative and
operational
procedures
adherence
4.5 Workshop
housekeeping
activities compliance
 Fire
department
compliances
 DOSH compliances
 Local authority
operational
compliances
 Environment
compliances
4.6 Workshop
housekeeping support
and arrangement
 External or
outsource
housekeeping
providers
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 Availability of
safety, security and
hygiene maintenance
materials
 Advance signage
and first aids
5 Prepare 5.1 Workshop 5.1 Compile workshop ATTITUDE: 5.1 Workshop housekeeping
workshop housekeeping housekeeping  Practice integrity and checklist and
periodic checklist and checklist and ethics in arranging information checklist
report. information such information. housekeeping reports. updated.
as: 5.2 Draft up workshop 5.2 Workshop housekeeping
 Types of checklist housekeeping SAFETY: summary draft prepared.
for workshop summary.  Get client response and 5.3 Workshop housekeeping
safety hygiene, 5.3 Report to superior certifying client outcome compiled.
safety and security workshop feedback and 5.4 Workshop housekeeping
assessment housekeeping information. database documented.
 Workshop outcome.  Comply CHRA
housekeeping 5.4 Documents workshop (Chemical Health Risk
policy and housekeeping Assessment).
procedures database.  Use relevant PPE
 Incident (Personal protective
and equipment).
occurrence  Interpret MSDS
remarks (Material Safety Data
5.2 Workshop Sheet).
housekeeping
analysis and summary ENVIRONMENT:
such as:  Practice Reduce,
 Frequency of Reuse, Recycle (3R)
housekeeping concept in producing
and service
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 Administrative
terms and
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condition clients analysis
 Reporting finding.
hierarchy
and priority
5.3 Workshop
housekeeping outcome
such as:
 Workshop
housekeeping
database
 Housekeeping
activities
records and log
 Housekeeping
administrator
commentary
Employability Skills
Core Abilities
 Please refer NCS- Core Abilities latest edition.
Social Values & Social Skills

 Please refer Handbook on Social Skills and Social Values in Technical Education and Vocational Training.
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References for Learning Material Development
1 Tony Candela, Automotive Wiring and Electrical Systems (Workbench Series), Publisher:CarTech (April 2, 2009), ISBN-
10: 1932494871, ISBN-13: 978-1932494877
2 Tony Candela, Automotive Electrical Performance Projects (S-A Design Projects), August 24, 2011, Publisher:CarTech (August
24, 2011), ISBN-10: 1934709557, ISBN-13: 978-1934709559
3 Matt Joseph , Automotive Bodywork & Rust Repair Paperback – October 5, 2009, Publisher:CarTech (October 5, 2009), ISBN-
10: 1932494979, ISBN-13: 978-1932494976
4 Ed May (2003), Automotive Mechanic Vol 2, 7th Edition, Mc Graw-Hill Australia ISBN: 0074712969
5 S Srinivasan (2001), Automotive Engines, Tata McGraw-Hill Education, ISBN 0070402655, 9780070402652
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15.2. Vehicle Engine Service
SECTION (G) Wholesale And Retail Trade; Repair Of Motor Vehicles And Motorcycles
GROUP (452) Maintenance And Repair Of Motor Vehicles
COMPETENCY UNIT TITLE Vehicle Engine Service
LEARNING 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.

1 Change lubrication oil & oil filter.
2 Change engine drive belt and tensioner.
3 Inspect exhaust system components condition.
4 Change air filter.
5 Change fuel filter.
6 Change spark plugs.
TRAINING PRE-REQUISITE N/A

1. Change 1.1 Fundamental of 1.1 Receive job order. ATTITUDE: 1.1 Job order are obtained,
lubrication oil job order 1.2 Prepare tools,  Adhere to workplace presented and explained.
& oil filter.  Function material and safety practises. 1.2 Tools, material and working
 Types working area.  Follow safety signage. area readied and confirmed.
 Format 1.3 Drain out all  Skilful in using tools. 1.3 Lubrication oil draining
 Information lubrication oil. process confirmed.
1.2 Schedule maintenance 1.4 Remove oil filter. SAFETY: 1.4 Oil filter
service Booklet. 1.5 Install new oil filter.  Practice integrity in replacement
1.3 lubrication oil & oil 1.6 Replace drain plug determining workshop performed.
filter change tools gasket. housekeeping
1.5 Drain plug gasket
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 Special Set Tools 1.7 Tighten drain plug. compliances. replacement confirmed.
 Common Tools 1.8 Fill in new 1.6 Drain plug tightened to
 Usage lubrication oil. ENVIRONMENT: specific torque using torque
 Function 1.9 Check oil level.  Adhere to wrench.
1.4 Function of lubrication 1.10 Check oil leakage. Environment quality 1.7 New lubrication oil poured
system. 1.11 Observe oil pressure act and regulations. through filler cap.
1.5 Fundamental level indicator. 1.8 Oil level verified.
of lubricants 1.12 Record/ reset next 1.9 Oil leakage checked while
 Type service interval engine are running.
 Usage sticker. 1.10 Oil pressure indicator
 Function checked accordance to light
on/ off.
 Viscosity
1.11 Next service interval sticker
 Classification
updated and placed on the
1.6 Fundamental of vehicle windshield.
oil filter
 Type
 Usage
 Function
1.7 Lubrication oil & oil
filter change process.
2. Change 2.1 Fundamental of 2.1 Receive job order. ATTITUDE: 2.1 Job order are obtained,
engine drive job order 2.2 Prepare tools, material  Adhere to workplace presented and explained.
belt and  Function and working area. safety practises. 2.2 Tools, material and working
tensioner.  Types 2.3 Change engine drive  Follow safety signage. area readied and confirmed.
 Format belt.  Skilful in using tools. 2.3 Belt condition checked.
 Information 2.4 Change tensioner 2.4 Belt tension checked.
2.2 Tools and equipment: bearing. SAFETY: 2.5 Tensioner tension checked.
 Special set tools 2.5 Prepare technical  Practice integrity in 2.6 Tensioner belt bearing
 Common tools report. determining workshop checked.
2.3 Fundamental of housekeeping 2.7 New engine drive belt
replacement
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confirmed.
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engine drive belt compliances. 2.8 Tensioner bearing
 Usage replacement
 Function ENVIRONMENT: confirmed.
 Layout  Adhere to 2.9 Engine drive belt and
 Type of defect Environment quality tensioner replacement
2.4 Procedures of act and regulations. technical report updated and
replacing and printed.
tensioning drive belt.
2.5 Testing and
checking drive belt
and tensioner
procedure.
2.6 Preparing engine drive
belt and tensioner
replacement technical
report procedure.
3. Inspect 3.1 Fundamental of 3.1 Receive job order ATTITUDE: 3.1 Job order are obtained,
exhaust job order 3.2 Prepare tools, material  Systematic in presented and explained.
system  Function and working area. organizing work 3.2 Tools, material and working
components  Types 3.3 Check exhaust activities. area readied and confirmed.
condition.  Format manifold gasket  Follow safety signage. 3.3 Exhaust manifold gasket
 Information leakage. leakage confirmed and
3.2 Exhaust system 3.4 Check resonator SAFETY: ascertained.
components inspection (flexible) exhaust  Adhere to safety 3.4 Resonator (flexible) exhaust
tools pipe. precaution in pipe condition confirmed and
 Special Set Tools 3.5 Check catalytic inspecting exhaust ascertained.
 Common Tools converter condition. system components 3.5 Catalytic converter condition
 Usage 3.6 Check exhaust muffler condition. confirmed and ascertained.
condition. 3.6 Exhaust muffler condition
 Function
3.7 Prepare inspection confirmed and ascertained.
3.3 Fundamental
report. 3.7 Exhaust system components
of exhaust
ENVIRONMENT: inspection report updated and
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system
components
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 Type  Adhere to printed.
 Usage Environment Quality
 Function Act 1973 and the
 Noise, Vibration, regulation under the
Harshness (NVH) act.
3.4 Exhaust system
components inspect
procedure.
3.5 Exhaust system
components inspection
report procedure.
4 Change air 4.1 Fundamental of 4.1 Receive job order. ATTITUDE: 4.1 Job order are obtained,
filter. job order 4.2 Prepare tools, material  Systematic in presented and explained.
 Function and working area. organizing work 4.2 Tools, material and working
 Types 4.3 Remove air filter. activities. area readied and confirmed.
 Format 4.4 Replace air filter. 4.3 Faulty air filter removed
 Information 4.5 Prepare technical SAFETY: from vehicle confirmed and
4.2 Fundamental of air report.  Adhere to safety ascertained.
filter components precaution in carrying 4.4 Air filter condition are
 Type out air filter ascertained and confirmed.
 Usage replacement. 4.5 Air filter unit cleaned using
 Function air duster.
ENVIRONMENT: 4.6 New air filter replacement
 Type of defect
 Practice Reduce, confirmed.
4.3 Air filter
Reuse, Recycle (3R). 4.7 Air filter replacement
components
technical report updated.
replacement tools
 Special Set Tools
 Common Tools
 Usage
 Function
4.4 Air filter replacement
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procedure.
4.5 Air filter replacement
technical report
procedure.
5 Change fuel 5.1 Fundamental of 5.1 Receive job order. ATTITUDE: 5.1 Job order are obtained,
filter. job order 5.2 Prepare tools, material  Always use extreme presented and explained.
 Function and working area. caution when carrying 5.2 Tools, material and working
 Types 5.3 Remove fuel filter out fuel filter area readied and confirmed.
 Format hose. replacement. 5.3 Faulty fuel filter hose removed
 Information 5.4 Replace fuel filter.  Always follow vehicle from vehicle confirmed.
5.2 Fuel filter 5.5 Attach fuel filter hose. manufacturers 5.4 New fuel filter installed.
replacement tools 5.6 Check for fuel filter warnings, cautions 5.5 Fuel filter hose inserted
 Special Set Tools leakage. and service according to service manual.
 Common Tools 5.7 Prepare technical procedures. 5.6 Fuel filter leaking condition
report. detected and ascertained.
 Usage
SAFETY: 5.7 Fuel filter replacement
 Function
 Careful when handling technical report updated and
5.3 Fundamental of fuel
flammable liquid. printed.
filter
 Type  Avoid working near
 Usage heat source.
 Function  Do not spill fuel the
floor.
 Type of defect
5.4 Fuel filter
ENVIRONMENT:
replacement
 Practice Reduce,
procedure.
Reuse, Recycle (3R).
5.5 Fuel filter
report procedure.
6 Change spark 6.1 Fundamental of 6.1 Receive job order. ATTITUDE: 6.1 Job order are obtained,
plugs. job order 6.2 Prepare tools, material  Systematic in presented and explained.
 Function and working area. organising work 6.2 Tools, material and working
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 Types 6.3 Remove ignition activities. area readied and confirmed.
 Format system attachments. 6.3 Ignition system attachments
 Information 6.4 Unfasten spark plug SAFETY: removing process ascertained
6.2 Spark plugs from cylinder head.  Adhere to safety and confirmed.
replacement tools 6.5 Clean spark plug precaution in changing 6.4 Faulty spark plug removed
 Special set tools seat threads on spark plugs according to service
 Common tools cylinder head. replacement. manual.
 Usage 6.6 Replace spark plug. 6.5 Spark plug seat threads on
 Function 6.7 Attach ignition system ENVIRONMENT: cylinder head cleaned from
attachments.  Practice Reduce, dirt and grim.
6.3 Fundamental of spark
6.8 Crank vehicle engine. Reuse, Recycle(3R). 6.6 New spark plug
plugs
6.9 Prepare technical installed confirmed.
 Type
report. 6.7 Ignition system attachments
 Usage
installed to vehicle confirmed.
 Function 6.8 Spark plugs replacement
 Type of defect technical report updated and
6.4 Spark plugs printed.
replacement
procedure.
6.5 Spark plugs
report procedure.
Core Abilities

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10: 1932494871, ISBN-13: 978-1932494877
24, 2011), ISBN-10: 1934709557, ISBN-13: 978-1934709559
5 MS 827:2002. Spark Plugs for Internal Combustion Engines (First Revision).
6 MS ISO 4548-1:2005. Methods Of Test For Full-Flow Lubricating Oil Filters For Internal Combustion Engines - Part 1:
Differential Pressure/Flow Characteristics (ISO 4548-1:1997, IDT).
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15.3. Vehicle Engine Overhauling
COMPETENCY UNIT TITLE Vehicle Engine Overhauling
LEARNING OUTCOMES The person who is competent in this CU shall be able to make sure no abnormal knocking sound, no
visible and possible leaking from the engine and free from defect to ensure the engine functions in full
optimal performance also defect free.

1 Conduct engine compression test.
2 Conduct engine cylinder leakages test.
3 Remove engine from vehicle.
4 Perform engine overhaul.
5 Reinstall engine onto vehicle.
6 Conduct engine test.

1. Conduct 1.1 Fundamental of 1.1 Receive job order. ATTITUDE: 1.1 Job orders are obtained,
engine job order 1.2 Prepare tools, material  Systematic in presented and explained.
compression  Function and working area. organising work 1.2 Tools, material and working
test.  Types 1.3 Perform engine activities. area readied and confirmed.
 Format compression test.  Using appropriate 1.3 Engine compression test is
 Information 1.4 Record engine tools. completed following the
1.2 Engine compression compression test  Handle tools with procedure.
test tools result. care. 1.4 Engine compression test result
 Type 1.5 Perform analysis on are recorded and printed.
 Usage test result. 1.5 Analysis on engine
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 Function 1.6 Prepare engine SAFETY: compression test checklist are
1.3 Fundamental of engine overhaul  Adhere to safety identified and confirmed.
compression test recommendation precaution in 1.6 Engine overhaul
 Type of engine checklist. conducting engine recommendation checklist are
 Engine components compression test. prepared and presented.
 Usage  Adhere to company
 Function safety and policy.
 Type of defect  Use relevant
1.4 Engine compression Personal Protective
test procedure. Equipment (PPE).
 Occupational safety &
health act.
ENVIRONMENT:
 Practice Reuse,
Recycle and
Reduce (3R).
 Environment Quality
act.
2. Conduct 2.1 Fundamental of 2.1 Receive job order. ATTITUDE: 2.1 Job orders are obtained,
engine job order 2.2 Prepare tools, material  Systematic in presented and explained.
cylinder  Function and working area. organising work 2.2 Tools, material and working
leakages test.  Types 2.3 Perform engine activities. area readied and confirmed.
 Format cylinder leakages test. 2.3 Engine cylinder leakages test
 Information 2.4 Record engine SAFETY: completed following the
2.2 Engine cylinder cylinder leakages test  Adhere to safety procedure.
leakages test tools result. precaution in 2.4 Engine cylinder leakages test
 Type 2.5 Perform analysis on conducting engine result are recorded and
 Usage test result. cylinder leakage printed.
2.6 Prepare engine test. 2.5 Analysis on engine cylinder
 Function
overhaul  Adhere to company leakages test checklist are
safety and policy.
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2.3 Fundamental of engine recommendation  Use relevant identified and confirmed.
cylinder leakages test checklist. Personal Protective 2.6 Engine overhaul
 Type of engine Equipment (PPE). recommendation checklist are
 Usage  Follow occupational prepared and presented.
 Function safety & health act.
 Type of defect
2.4 Engine cylinder ENVIRONMENT:
leakages test  Practice Reuse,
procedure. Recycle and
Reduce (3R).
 Environment Quality
act.
3. Remove 3.1 Overhaul 3.1 Interpret overhaul ATTITUDE: 3.1 Workplace for removing
engine from recommendation recommendation  Systematic in engine is prepared.
vehicle. checklist checklist. organising work 3.2 Power cable from battery
 Type 3.2 Setup workplace for activities. terminals is visually
 Usage removing engine. disconnected.
3.2 Engine removal tools 3.3 Disconnect power SAFETY: 3.3 Operation fluids and
 Type cable from battery  Adhere to safety lubricant are drained empty.
 Usage terminals. precaution in 3.4 Used operation fluids and
 Function 3.4 Drain operation fluids removing engine lubricant are disposed into
3.3 Fundamental of engine and lubricant. from vehicle. disposable container.
 Type of engine 3.5 Recover refrigerant.  Adhere to company 3.5 Refrigerant recovered empty
 Engine components 3.6 Detach engine safety and policy. without leakages and dispose
auxiliary components  Use relevant into disposable container.
 Usage
and attachments. Personal Protective 3.6 Engine auxiliary components
 Function
3.7 Lift-out vehicle engine Equipment (PPE). and attachments visually
3.4 Engine
from vehicle.  Follow occupational detached.
removal
3.8 Mount engine on safety & health act. 3.7 Vehicle engine lift-out safely
procedure
engine stand. from vehicle using hoist and
safety harness.
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ENVIRONMENT: 3.8 Vehicle Engine mounted and
 Practice Reuse, secured on engine stand.
Recycle and
Reduce (3R).
 Follow Environment
Quality act.
4. Perform 4.1 Engine overhaul 4.1 Remove engine ATTITUDE: 4.1 Engine external components
engine tools and external components.  Systematic in are visually dismantled.
overhaul. materials 4.2 Remove internal organising work 4.2 Engine internal components
 Type components. activities. are visually dismantled.
 Usage 4.3 Strip down the 4.3 Engine parts and components
 Function internal components. SAFETY: are cleaned from grease and
4.2 Fundamental 4.4 Clean engine parts  Adhere to safety grimes.
of engine and components. precaution in 4.4 Engine parts and components
 Petrol 4.5 Inspect engine parts performing are inspected visually.
 Diesel and components. engine overhaul. 4.5 Engine part and components
4.3 Fundamental of 4.6 Measure engine part  Adhere to company wear and tear condition are
engine and components safety and policy. ascertained and confirmed.
components wear and tear  Use relevant 4.6 Components for machine shop
 Function condition. Personal Protective work are readied, delivered
 Usage 4.7 Prepare components Equipment (PPE). and received.
for machine shop  Follow occupational 4.7 New parts and components are
 Type of defect
work. safety & health act. replaced.
4.4 Engine external
4.8 Check engine parts 4.8 External and internal engine
components such
and components ENVIRONMENT: components are reassembled
as:
received.  Practice Reuse, in accordance with workshop
 Cylinder head cover
4.9 Change worn or Recycle and manual.
 Exhaust manifold damaged parts and
 Compressor Reduce (3R).
components.  Follow Environment
4.5 Engine internal 4.10 Reassemble external
components such Quality act.
and internal engine
as:
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 Engine block
 Crankshaft
 Camshaft
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4.6 Engine components.
schematic
diagram.
4.7 Engine parts
cleaning procedure.
4.8 Engine part
measuring
procedures.
4.9 Machine shop
working
procedure.
4.10 Parts & components
changing
procedure.
4.11 Engine components
reassembling
procedure.
5. Reinstall 5.1 Engine reinstalling 5.1 Crane-in the engine ATTITUDE: 5.1 Engine craned-in onto vehicle
engine onto procedure. onto vehicle.  Systematic in are confirmed.
vehicle. 5.2 Attaching auxiliary 5.2 Fit engine auxiliary organising work 5.2 Engine auxiliary components
components components and activities. and attachments are visually
procedure. attachments. fitted.
5.3 Vehicle operation 5.3 Refill vehicle SAFETY: 5.3 Vehicle operation fluids,
fluids, lubricant and operation fluids and  Adhere to safety lubricant full level and
refrigerants lubricant. precaution in refrigerant full level are
 Types 5.4 Recharge refrigerant. reinstalling engine confirmed.
 Functions 5.5 Reconnect electrical onto vehicle. 5.4 Power cable to battery
5.4 Recharge power source.  Adhere to company terminals visually
refrigerant 5.6 Prepare technical safety and policy. reconnected.
procedure. report.  Follow Occupational 5.5Engine reinstall technical
5.5 Recharge vehicle safety & health act. report updated and printed.
operation fluids and
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lubricant procedure. ENVIRONMENT:

5.6 Reconnecting power  Practice Reuse,
electrical power
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source procedure. Recycle and Reduce
5.7 Engine reinstall (3R).
technical report  Follow Environment
procedure. Quality act.
6. Conduct 6.1 Type of 6.1 Check leakages of the ATTITUDE: 6.1 Oil leakages, free from
engine test. engine engine.  Systematic in grease are confirmed.
malfunctions 6.2 Check noise, vibration organising work 6.2 Leakages of the engine are
 Electrical and harshness (NVH). activities. visually checked.
 Mechanical 6.3 Carry out OBD (On 6.3 Engine is free from knocking
6.2 Type of leakages: Board Diagnostic) SAFETY: and screeching sound check
 Source test.  Adhere to safety list are completed.
- Cylinder head 6.4 Prepare vehicle for precaution in 6.4 Absent of noise from engine is
- Crank case test drive. conducting engine test. explained.
- Air-Cond 6.5 Prepare engine  Adhere to company 6.5 OBD test are performed with
pipes/hoses test report. safety and policy. diagnostic tools.
 Cause  Follow Occupational 6.6 Test drive vehicle performed
- Miss-aligned safety & health act. by driving the vehicle.
gasket 6.7 Final control test on the
- Fastening ENVIRONMENT: overall vehicle performance
manner  Practice Reuse, checklist are completed.
- Incompatible Recycle and 6.8 Engine test report are
materials Reduce (3R). produced and presented.
6.3 Types of NVH  Follow Environment
 Sources Quality act.
- Miss-aligned
cam and
crank shaft
- Engine
mounting
 Causes
- Fastening
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manner
- Incompatible
materials
 Type of noises
- Grinding
- Knocking
- Humming
- Sizzling
6.4 Engine test procedure.
6.5 Preparing engine test
report procedure.
Core Abilities
 Please refer Handbook on Social Skills and Social Values in Technical Education and Vocational
Training. References for Learning Material Development
1 Automotive Mechanics / Willian H. Crouse and Donald L. Anglin 10 th ed. ISBN0-02-800943-6
10: 1932494871, ISBN-13: 978-1932494877
24, 2011), ISBN-10: 1934709557, ISBN-13: 978-1934709559
77
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15.4. Vehicle Brake System Service
COMPETENCY UNIT TITLE Vehicle Brake System Service
LEARNING OUTCOMES The person who is competent in this CU shall be able to make sure the continuous of the brake functions,
free of any fluid leakages, and to ensure the safeness of the driver.

1. Inspect Brake System Condition.
2. Change brake system.
3. Change parking brake system components.

1. Inspect brake 1.1 Fundamental of 1.1 Receive job order. ATTITUDE: 1.1 Job order are obtained,
system job order 1.2 Prepare tools, material  Systematic in presented and explained.
condition.  Function and working area. organising work 1.2 Hydraulic brake system tools
 Types 1.3 Check condition of activities. and equipment are prepared.
 Format brake leakages. 1.3 Condition of the brake
 Information 1.4 Check water vapour SAFETY: leakages are visually checked.
1.2 Function of hydraulic contamination level of  Adhere to safety 1.4 Water vapour contamination
brake system. the brake fluid. precaution in level ascertained and
1.3 Hydraulic brake 1.5 Check brake fluid inspecting brake confirmed.
system repair level switch. system. 1.5 Brake fluid viscosity and
tools 1.6 Check brake pedal  Adhere to company discoloration condition
 Type of tools free-play. safety and policy. visually checked.
(such as common 1.7 Update brake system  Follow Occupational 1.6 Brake fluid level switch is
tools and special condition inspection safety & health act. visually checked.
tools)
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 Functions of tools
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1.4 Hydraulic status checklist. 1.7 Brake pedal free-play are
brake system ENVIRONMENT: checked and pressed.
layout.  Practice Reuse, 1.8 Brake system condition
1.5 Hydraulic brake Recycle and inspection status checklist are
system functionality Reduce (3R). completed and printed.
test procedure.  Follow Environment
1.6 Water vapour Quality act.
contamination
condition
 Discoloration
 Viscosity
1.7 Brake fluid level
switch functionality.
1.8 Free-play checking
procedure.
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2. Change brake 2.1 Fundamental of 2.1 Remove brake system ATTITUDE: 2.1 Brake system parts
system. Pascal law. parts from vehicle.  Systematic in removed and sorted safely
2.2 Type and functions of 2.2 Replace disc brake organising work from the vehicle.
brake system parts. activities. 2.2 New disc brake parts indicated
 Disc Brake 2.3 Replace drum brake  Handling brake fluid by part numbers replaced in
 Drum Brake parts. with care. compliance with the workshop
 Brake Fluids 2.4 Update brake system manual.
2.3 Drum brake replacement status SAFETY: 2.3 New drum brake parts
system parts checklist.  Adhere to safety indicated by part numbers
 Brake booster precaution in changing replaced in compliance with
 Master cylinder brake system the workshop manual.
 Proportioning valve components service. 2.4 Brake system replacement
 Brake  Adhere to company status checklist are updated
line/hoses/pipes safety and policy. and printed.
 Wheel cylinder  Follow occupational
 Brake Shoes safety & health act
 Brake Drum  Avoid brake fluid
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2.4 Disc brake spillage.
system parts
 Brake Booster ENVIRONMENT:
 master cylinder  Practice Reuse,
 Proportioning valve Recycle and
 Brake Reduce (3R).
line/hoses/pipes  Follow Practice
 brake callipers Environment Quality
 Brake pads act.
 Disc Rotor
2.5 Brake system
replacing procedure.
 Replace vehicle
disc brake pads
 Overhaul vehicle
brake calliper.
 Replace vehicle
brake disc
 Replace vehicle
drum brake
shoes.
drum brake
wheel cylinder
brake master
cylinder.
 Replace vehicle
brake booster.
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3. Change 3.1 Parking brake 3.1 Check parking brake ATTITUDE: 3.1 Parking brake cable is visually
parking brake functionality checking functionality.  Systematic in checked.
system procedure. 3.2 Release parking brake organising work 3.2 Condition parking brake cable
components. 3.2 Type and functions of cable adjustment. activities. components confirmed.
parking brake system. 3.3 Remove parking brake 3.3 Condition Parking brake
3.3 Fundamental of cable assembly. SAFETY: cable is confirmed.
parking brake 3.4 Replace parking brake  Adhere to safety 3.4 Releasing parking brake cable
system such as:- cable assembly. precaution in changing adjustment is confirmed.
 Schematic diagram 3.5 Install parking brake parking brake system 3.5 Parking brake cable assembly
 Components of cable assembly. components service. is removed from the vehicle.
parking brake 3.6 Carryout parking  Adhere to company 3.6 New parking brake cable
3.4 Parking brake brake final test. safety and policy. indicated by part numbers
removing and 3.7 Update Parking Brake  Follow Occupational isreplaced in compliance with
replacing procedure. system replacement safety & health act. the workshop manual.
status checklist. 3.7 Parking brake cable assembly
ENVIRONMENT: is installed onto vehicle.
 Practice Reuse, 3.8 Parking brake stop light and
Recycle and Reduce third light indicator check list
(3R). are performed.
Environment Quality 3.9 Parking brake system
act. replacement status checklist
are completed and printed.
Core Abilities

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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.
3 BOSCH, Automotive Handbook, Published by Bosch in 1996, ISBN 1-56091-918-3.
4 Ellis Johnson, Tires and Handling, Published by SAE in 1996, ISBN 1-56091-752-0.
5 Rudolf Limpert, Brake and Design Safety, Published by SAE in 1999, ISBN 1-56091-915-9.
6 MS ISO 6311:2003. Methods Of Test For Automotive Friction Materials (Brake Lining, Disc Pads And Bonded Shoe) : Part 5 :
Internal Shear Strength Of Lining Material Â– Test Procedure(ISO 6311:1980, IDT).
7 MS ISO 3996:2005. Road Vehicles - Brake Hose Assemblies For Hydraulic Braking Systems Used With Non-Petroleum-Base
Brake Fluid (ISO 3996:1995, IDT)
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15.5. Engine Cooling System Replacement
COMPETENCY UNIT TITLE Engine Cooling System Replacement
LEARNING OUTCOMES The person who is competent in this CU shall be able to provide smooth of the engine cooling functions,
free of noise and defects, maintain the temperature of the engine and to ensure efficiency of the cooling
system.

1. Conduct cooling system pressure test.
2. Conduct cooling system parts functionality test.
3. Change cooling system parts.

1. Conduct 1.1 Fundamental of 1.1 Receive job order. ATTITUDE: 1.1 Job order are obtained,
cooling job order 1.2 Identify tools,  Always use extreme presented and explained.
system  Function equipment and caution when 1.2 Tools, equipment and
pressure test.  Types materials. conducting cooling materials for conducting
 Format 1.3 Prepare tools, material system pressure test. cooling system pressure test
 Information and working area.  Always follow vehicle are acquired and prepared in
1.2 Fundamentals of 1.4 Carry out cooling manufacturers working place.
cooling system. system pressure test. warnings, cautions 1.3 Cooling system pressure test
1.3 Procedures of cooling 1.5 Update pressure test and service performed.
system pressure test. result status. procedures. 1.4 Pressure test result status
 Follow safety signage. checklist are completed and
printed.
SAFETY:
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 Follow pressure
test safety
procedure.
 Ensure engine cool
before opening
radiator cap.
 Cautions when
opening radiator cap
while temperature of
the engine is high.
ENVIRONMENT:
Quality act.
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2. Conduct 2.1 Types of cooling 2.1 Identify tools, ATTITUDE: 2.1 Tools, equipment and
cooling system. equipment and  Always use extreme materials for cooling system
system parts 2.2 Layout of cooling materials. caution when components functionality test
functionality system. 2.2 Prepare tools, material inspecting engine are acquired and prepared in
test. 2.3 Procedures of and working area. cooling systems working place.
checking cooling 2.3 Conduct cooling components condition. 2.2 Cooling system components
system parts. system components  Always follow vehicle functionality test are identified
2.4 Components of functionality test for manufacturers and confirmed for Noise,
cooling system Noise, vibration & warnings, cautions vibration & harshness (NVH).
such as: harshness (NVH). and service 2.3 Cooling system components
 Water pump 2.4 Update cooling system procedures. functionality test status
 Radiator components  Follow safety signage. checklist are completed and
 Belting functionality test printed.
 Fan blade status checklist. SAFETY:
 Fan motor/ pulley  Ensure engine is
 Thermostat cool before opening
 Radiator cap radiator cap.
 Water temperature
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sender unit
2.5 Functions of cooling ENVIRONMENT:
system components.  Follow Environment
2.6 NVH Sources: Quality act.
 Miss-aligned
cam and crank
shaft
 Engine mounting
2.7 Problem and
causes NVH:
 Fastening manner
 Incompatible
materials
2.8 Type of
noises created:
 Grinding
 Knocking
 Humming
 Sizzling
3. Change 3.1 Removing and 3.1 Identify tools, ATTITUDE: 3.1 Tools, equipment and
cooling replacing cooling equipment and  Systematic in materials for cooling system
system parts. system materials. organising work parts replacement are acquired
components 3.2 Prepare tools, material activities. and prepared in working place.
procedure. and working area. 3.2 New cooling system parts is
3.2 New Cooling 3.3 Replace new cooling SAFETY: installed in compliance with
system part: system parts.  Adhere to safety the workshop manual.
 part numbers 3.4 Conduct cooling precaution in changing 3.3 Cooling system performance
3.3 Types of system performance cooling system test are performed and
coolant test. components. ascertained.
following OEM. 3.5 Update cooling system  Adhere to company 3.4 Cooling system parts
3.4 Types and functions of rectification checklist. safety and policy. replacement status checklist
cooling system parts  Follow Occupational are completed and printed.
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 Pressure cap
 radiator
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 radiator hoses safety & health act
 radiator fan ENVIRONMENT:
 water pump  Practice Reuse,
 thermostat Recycle and
 cooling Reduce (3R).
system sensors  Follow Environment
 expansion tank Quality act
3.5 Cooling system
performance such as :
 Leakages
 Temperature rising
 Functionality of
the components
(thermostat,
fan, temperature
sensor, radiator
cap)
3.6 Engine cooling
system replacement
procedure:
 Replace
engine
radiator
pressure cap.
 Replace
engine
radiator
hose.
 Replace
engine
radiator
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assembly.
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 Replace
engine
thermostat.
 Replace
radiator
electrical
cooling fan
assembly.
Core Abilities


4 Eric Chowanietz, Automobile Electronics, Published by SAE in 1995, ISBN 0-7506-1878-7.
5 Tom Denton, Automotive Electric and Electronic system fourth edition, ISBN 978-0-08-096942-8.
92
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15.6. Rear / Front Axle Rectification
COMPETENCY UNIT TITLE Rear / Front Axle Rectification
LEARNING OUTCOMES The person who is competent in this CU shall be able to provide free of leakages, other defects and
smooth performance of the rear / front axle.

1. Inspect rear / front axle condition.
2. Dismantle rear / front axle differential unit.
3. Change rear / front axle differential components & parts.

1. Inspect rear / 1.1 Fundamental of 1.1 Receive job order. ATTITUDE: 1.1 Job order are obtained,
front axle job order 1.2 Setup tools, equipment  Systematic in presented and explained.
condition.  Function and parts. organising work 1.2 Tools, equipment and parts
 Types 1.3 Check rear / front axle activities. prepared at working area.
 Format leakages. 1.3 Rear / front axle leakages
 Information 1.4 Check rear / front axle SAFETY: ascertained and confirmed.
1.2 Tools, equipment and abnormal noise.  Adhere to safety 1.4 Rear / front axle abnormal
parts such as : 1.5 Check rear / front axle precaution in noise detection performed.
 Machine hand abnormal vibration. conducting rear / 1.5 Rear / front axle abnormal
tools set 1.6 Prepare rear / front front axle condition vibration detection performed.
 Common tools axle condition inspection. 1.6 Rear / front axle condition
 Special tools checklist / report.  Adhere to company checklist are completed and
safety and policy. printed.
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 Workshop manual  Follow Occupational
1.3 Types and functions of safety & health act.
rear and front axle:
1.4 Rear and front axle ENVIRONMENT:
unit schematic  Practice Reuse,
diagram. Recycle and
1.5 Type of possible Reduce (3R).
leakage:  Follow Environment
 Source (such as Quality act.
differential unit, drain
plug gasket, drive
shaft boot, oil seal)
 Cause (such as wear
and tear,
misalignment,
accident)
1.6 NVH Sources:
 Bearing damage
 Worn out gears
1.7 Problem and causes
NVH:
 Fastening manner
 Incompatible
materials
1.8 Type of noises created
by NVH
 Grinding
 Humming
1.9 Rear / front axle
condition inspection
procedure.
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2. Dismantle rear 2.1 Removing wheel 2.1 Remove wheel from ATTITUDE: 2.1 Wheel safely removed from
/ front axle from the front axle the front axle.  Systematic in the front axle and safely put
differential procedure. 2.2 Drain-out gear oil. organising work onto wheel rack / holder.
unit. 2.2 Drain differential 2.3 Remove drive shaft & activities. 2.2 Gear oil safely drain-out into
gear oil procedure CV (Constant disposable container.
2.3 Removing front axle Velocity) joint for rear SAFETY: 2.3 Rear axle drive shaft safely
components axle.  Adhere to safety removed from vehicle.
procedure: 2.4 Remove transaxle unit precaution in 2.4 Rear axle constant velocity
 Drive shaft from engine for rear conducting rear / (CV) joint safely removed
 CV (Constant axle. front axle from vehicle.
Velocity) joint 2.5 Remove propeller differential unit 2.5 Front axle propeller shaft
2.4 Removing rear axle shaft and half shaft for dismantling. safely removed from vehicle.
components front axle.  Adhere to company 2.1 Front axle half shaft safely
procedure: 2.6 Remove differential safety and policy. removed from vehicle.
 Propeller shaft unit from transaxle. 2.6 Differential unit safely
 Half shaft  Follow Occupational
safety & health act removed from vehicle.
2.5 Remove
differential unit
procedure. ENVIRONMENT:
 Practice Reuse,
Recycle and
Reduce (3R).
Quality act.
3. Change rear / 3.1 Rear / Front Axle 3.1 Dismantle rear axleATTITUDE: 3.1 Rear / Front axle
front axle differential unit differential unit.  Systematic in differential unit dismantled
differential components. 3.2 Check crown wheel organising work by components.
components &  Type & pinion worn out activities. 3.2 Crown wheel & Pinion
parts.  Function condition. worn out condition
3.2 Rear axle 3.3 Change crown wheel SAFETY: physically and visually
differential unit gear set & pinion  Adhere to safety checked.
dismantle procedure. wheel set. precaution in 3.3 New crown & pinion
3.3 Rear axle differential 3.4 Change pinion oil conducting axle wheel installed.
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3.4 Gasket worn out condition
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unit components seal differential unit faulty physically and visually
replacement and 3.5 Replace gasket. / worn out checked.
measurement 3.6 Check bearing worn components parts 3.5 New gasket installed.
procedures. out condition. replacing. 3.6 Bearing worn out condition
3.4 Front axle 3.7 Replace bearing.  Adhere to company physically and visually
differential unit 3.8 Adjust rear axle safety and policy. checked.
dismantle procedure. components parts  Follow Occupational 3.7 New bearing installed.
3.5 Front axle clearance / free play. safety & health act. 3.8 Rear / Front axle components
differential unit 3.9 Assemble rear axle parts clearance / free play
components differential unit ENVIRONMENT: adjustment ascertained and
replacement and components.  Practice Reuse, confirmed.
measurement 3.10 Replace drive shaft Recycle and 3.9 Rear / Front axle
procedures. oil seal. Reduce (3R). differential unit components
3.11 Install rear axle  Follow Environment assembly process
differential unit into Quality act. ascertained and confirmed.
rear axle. 3.10 Drive Shaft oil seal
3.12 Install rear wheels. worn out condition
3.13 Carryout Pre- physically and visually
delivery inspection checked.
test. 3.11 New drive shaft oil seal
installed.
3.12 Rear / Front wheels safely
installed in compliance with
3.13 Pre-delivery inspection
test are performed in
compliance with the workshop
manual.
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Core Abilities


4 Thomas D. Gillespie, Fundamentals of Vehicle Dynamics, Published by SAE in 1999, ISBN 1-56091-199-9.
98
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15.7. Exhaust System Rectification
COMPETENCY UNIT TITLE Exhaust System Rectification
LEARNING OUTCOMES The person who is competent in this CU shall be able to provide free of leakages, noise & vibration,
good cosmetic value & performance of engine exhaust system and also to make sure safer environment.

1. Inspect exhaust system components condition.
2. Change exhaust system components.
3. Conduct exhaust system components performance test.

1. Inspect 1.1 Fundamental of 1.1 Received job order. ATTITUDE: 1.1 Job Order received and
exhaust job order 1.2 Prepare tools, material  Systematic in explained and understood.
system  Function and working area. organising work 1.2 Tools, equipment and parts
components  Types 1.3 Check exhaust silencer activities. setup at the working area.
condition.  Format worn out condition. 1.3 Exhaust silencer worn out
 Information 1.4 Check manifold and SAFETY: condition confirmed.
1.2 Emission specification gasket leakages.  Adhere to safety 1.4 Manifold gasket leakages
1.3 Tools, equipment, 1.5 Check resonator precaution in condition confirmed.
parts and condition. conducting exhaust 1.5 Abnormal vibration of
materials: 1.6 Check exhaust pipe systems components resonator condition
 Emission tester condition. usability condition confirmed.
 Power tool 1.7 Update inspection inspection. 1.6 Exhaust pipe corrosion and
 Special tool result checklist.  Adhere to company worn out condition confirmed.
1.8 Prepare replacement safety and policy. 1.7 Oxygen sensors measurement
 Testing equipment
recorded.
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 Exhaust checklist.  Follow Occupational 1.8 Catalytic convertor worn out
components safety & health act. and corroded condition
1.4 Exhaust system checked.
schematic diagram. ENVIRONMENT: 1.9 Inspection result and
1.5 Exhaust system  Practice Reuse, replacement checklist are
components such as Recycle and printed and presented.
: Reduce (3R).
 Types  Follow Environment
 Functions Quality act.
1.6 Types of Exhaust
Components defect :
 Leakages
 Corrosion
 Noise, vibration &
harshness (NVH)
1.7 Exhaust system
inspection procedure.
2. Change 2.1 Type and functions 2.1 Replace defect exhaust ATTITUDE: 2.1 New exhaust silencer installed
exhaust of exhaust system manifold unit and  Systematic in in compliance with the
system components. gasket. organising work workshop manual.
components. 2.2 Exhaust silencer 2.2 Change defect activities. 2.2 New gasket installed in
changing catalytic convertor compliance with the workshop
procedure. and gasket. SAFETY: manual.
2.3 Gasket changing 2.3 Change defect flexible  Adhere to safety 2.3 New tail pipe installed in
procedure. joint. precaution in compliance with the workshop
2.4 Resonator changing 2.4 Change defect exhaust conducting exhaust manual.
procedure. pipe and gasket. system components 2.4 New exhaust pipe installed in
2.5 Tail pipe changing 2.5 Change defect oxygen replacing. compliance with the workshop
procedure. sensors.  Adhere to company manual.
2.6 Exhaust pipe 2.6 Change defect exhaust safety and policy. 2.5 New catalytic convertor
changing procedure. silencer.  Occupational safety installed in compliance with
2.7 Mounting rubber 2.7 Change defect & health act. the workshop manual.
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changing
procedure.
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2.8 Oxygen sensors mounting rubber. ENVIRONMENT: 2.6 Tail pipe, exhaust pipe and
changing 2.8 Prepare technical  Practice Reuse, catalytic convertor firmly
procedure. report. Recycle and connected together.
2.9 Catalytic convertor Reduce (3R). 2.7 New mounting rubber
changing  Follow Environment installed in compliance with
procedure. Quality act. the workshop manual.
2.10 Flexible joint 2.8 New oxygen sensors installed
changing procedure. in compliance with the
workshop manual.
2.9 New flexible joint installed in
compliance with the workshop
manual.
3. Conduct 3.1 Exhaust silencer 3.1 Start engine in idle ATTITUDE: 3.1 Engine start up confirmed.
exhaust performance mode.  Systematic in 3.2 Exhaust silencer free of
system test procedure. 3.2 Carry out exhaust organising work abnormal noise are confirmed.
components 3.2 Resonator gas leakages test. activities. 3.3 Resonator free of abnormal
performance performance 3.3 Carry out NVH test. vibration confirmed.
test. test procedure. 3.4 Carry out emission SAFETY: 3.4 Tail pipe, exhaust pipe and
3.3 Tail pipe, exhaust pipe test.  Adhere to safety catalytic convertor
and catalytic 3.5 Prepare technical precaution in cosmetically fitted.
convertor connecting report. conducting exhaust 3.5 Flexible joint vibration check
& fitting procedure. system performance list completed.
3.4 Complete combustion test. 3.6 Physically check for exhaust
procedure.  Adhere to company gas leakages.
3.5 Flexible joint vibration safety and policy. 3.7 Exhaust system are confirmed
procedure.  Follow Occupational free of noise, vibration &
safety & health act. harshness (NVH).
3.8 Exhaust system
performance checklist are
printed and presented.
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ENVIRONMENT:
 Practice Reuse,
Recycle and
Reduce (3R).
Quality act.
Core Abilities

4 Lenz, Cozzarini, Emissions and Air Quality, Published by SAE in 1999, ISBN 0-7680-0248-6.
6 Michael Plint, Anthony Martyr, Engine Testing Theory and Practice, Published by SAE in 1999, ISBN 0-7680-0314-8
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15.8. Vehicle Electrical & Electronic System Service
COMPETENCY UNIT TITLE Vehicle Electrical & Electronic System Service
LEARNING OUTCOMES The person who is competent in this CU shall be able to provide clear engine ignition, combustion of the
engine and a smooth fuel injection operation and chassis.

1. Inspect electrical & electronic system parts & components functionality.
2. Change electrical & electronic system parts & components.
3. Inspect chassis electrical system.
4. Change chassis electrical system components.

1. Inspect 1.1 Fundamental of 1.1 Received job order. ATTITUDE: 1.1 Job order are obtained,
electrical & job order 1.2 Prepare parts, tools,  Ensure components presented and explained.
electronic  Function equipment and according to 1.2 Part, tools, equipment and
system parts manufacturer
 Types materials in working materials are obtained and
& components
 Format area. specification. readied in working area.
functionality.
 Information 1.3 Inspect vehicle battery  Handle tools and 1.3 Vehicle battery condition
1.2 Fundamentals of condition. equipment with care. confirmed and ascertained.
common tools & 1.4 Inspect fuses, relays  Ensure safe 1.4 Fuses, relays and wiring
special tools for and wiring harness workplace. harness functionality tested
inspection functionality. and condition confirmed.
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 Function 1.5 Inspect electrical & SAFETY: 1.5 Electrical & electronic
 Usage electronic  Safety components functionality
 Type components. work condition confirmed and
1.3 Introduction to basic 1.6 Inspect body procedure. ascertained.
circuit theory. electrical system  Wear appropriate PPE. 1.6 Body electrical system
1.4 Fundamental functionality. functionality condition
of vehicle 1.7 Prepare inspection ENVIRONMENT: confirmed and ascertained.
technical report.  Practice Reduce, 1.7 Inspection technical report
battery
Reuse, Recycle (3R). printed and presented.
 Type
 Function
 Usage
 Inspection
procedure
 Safety
 Handling
 Type of defect
 Dispose process
1.5 Fundamentals of
starting system
 Type
 Function
 Usage
 Inspection
procedure
 Safety
 Type of defect
 Handling
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 Dispose process
1.6 Fundamentals of
charging system
 Type
 Function
 Usage
 Inspection
procedure
 Safety
 Type of defect
1.7 Fundamentals of body
electrical system
 Type
 Function
 Usage
 Inspection
procedure
 Safety
 Type of defect
1.8 Fundamentals of
instrument panel
system
 Type
 Function
 Usage
 Inspection
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procedure
 Safety
 Type of defect
1.9 Fundamentals of fuses,
relays and wiring
harness system
 Type
 Function
 Usage
 Inspection
procedure
 Safety
 Type of defect
1.10 Technical report
 Type
 Function
 Method of writing
report
2. Change 2.1 Fundamentals of 2.1 Receive technical ATTITUDE: 2.1 Inspection technical report
electrical & tools, equipment and report.  Handle equipment interpreted and understood.
electronic materials for system 2.2 Prepare parts, tools, with care. 2.2 Parts, tools, equipment and
system parts equipment and  Ensure safe materials for system parts &
parts & components
& materials in working workplace. components replacement are
components. replacement area. acquired and prepared in
 Comply standard
 Type 2.3 Replace vehicle workshop working place.
 Function battery. manual. 2.3 New battery installed onto
 Usage 2.4 Replace fuses, relays vehicle.
and wiring harness SAFETY: 2.4 New fuses, relays and wiring
 Safety work
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2.2 Electrical & electronic system. procedure harness are replaced and
system parts & 2.5 Replace starting  Wear appropriate installed onto the vehicle.
components system parts & PPE. 2.5 New starting system parts &
components. components are replaced and
replacement
2.6 Replace charging ENVIRONMENT: installed onto vehicle.
procedure system parts & 2.6 New charging system parts
 Practice Reduce,
 Starting system components. Reuse, Recycle (3R). & components are
 Charging system 2.7 Replace body replaced and installed onto
 Body electrical system vehicle.
electrical parts & components. 2.7 New body electrical system
2.8 Replace instrument parts & components are
system
panel system parts & replaced and installed onto
 Instrument components. vehicle.
panel system 2.9 Replace fuel 2.8 New instrument panel
 Battery system injection system system parts & components
 Fuses, relays and parts & components. are replaced and installed
wiring harness 2.10 Conduct onto vehicle.
performance test 2.9 New fuel injection system
system
2.11 Prepare technical parts & components are
 Fuel report. replaced and installed onto
injection vehicle.
system 2.10 Electrical & electronic
 Vehicle battery system parts & components
 Vehicle alternator performance test are
conducted and confirmed.
2.3 Electrical & electronic
system parts & system parts & components
components replacement technical report
performance test are printed and presented.
procedure.
system parts &
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components
replacement report
109
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writing :
 Type of report
 Content /
information
 Submission
procedure
chassis job order 3.2 Prepare parts, tools,  Systematic in presented and explained.
electrical  Function equipment and organising work 3.2 Customer complaints based on
system.  Types materials in working activities. the initial report by inspecting
 Format area in working area. the systems physical condition
 Information 3.3 Check vehicle SAFETY: verified and understood.
3.2 Tools, equipment, instrumentation panel.  Adhere to safety 3.3 Suitable work space, common
materials and parts: 3.4 Check vehicle chassis precaution in and special tools set up.
 Usage electrical system fuses conducting vehicle 3.4 Vehicle instrumentation panel
 Functions and relay chassis electrical tell-tale condition confirmed.
 Types functionality. system inspection. 3.5 Vehicles chassis electrical
3.5 Inspect vehicles  Adhere to system fuses and relay
3.3 Fundamentals of
lighting system company safety functionality confirmed.
chassis
components and policy. 3.6 Vehicles lighting system
electrical
functionality.  Follow components functionality
system:
3.6 Check vehicle horn Occupational confirmed.
 Vehicle electrical
functionality. safety & 3.7 Vehicles horn functionality
circuit guideline
3.7 Check wiper motor health act. condition confirmed.
3.4 Vehicle chassis
functionality. 3.8 Wiper motor functionality
electrical system
3.8 Check motor operated ENVIRONMENT: condition confirmed.
inspection procedure.
rear view window  Practice 3.9 Motor operated rear view
3.5 Inspection report
functionality. Reuse, Recycle window functionality
writing:
3.9 Prepare technical and Reduce condition confirmed.
 Format such as
report. (3R). 3.10Inspection report
computerised or
 Follow produced and presented.
manual
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Environment
111
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 Content / information quality act.
 Submission
procedure
4. Change 4.1 Fundamentals of 4.1 Replace vehicle ATTITUDE: 4.1 New vehicle chassis
chassis chassis chassis electrical  Systematic in electrical system fuses and
electrical electrical system fuses and organising work relay installed.
system system: relay. activities. 4.2 New vehicle lighting
components.  Vehicle electrical 4.2 Replace vehicle system components
circuit guideline lighting system SAFETY: installed.
4.2 Vehicle chassis components.  Adhere to safety 4.3 New vehicle horn installed.
electrical 4.3 Replace vehicle horn. precaution in 4.4 New wiper motor installed.
system 4.4 Replace wiper motor. conducting 4.5 New motor operated rear view
components 4.5 Replace motor vehicles chassis window installed.
replacement operated rear view electrical 4.6 Vehicle chassis electrical
procedure. window. system system components
4.3 Replacement 4.6 Prepare technical components performance test are
report writing: report. replacement. conducted and confirmed.
 Format such as  Adhere to 4.7 Vehicle chassis electrical
computerised or company safety system components
manual and policy. replacement report updated
 Content /  Follow and presented.
information Occupational
 Submission safety &
procedure health act.
ENVIRONMENT:
 Practice
Reuse, Recycle
and Reduce
(3R).
 Follow
Environment
112
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quality act.
113
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Core Abilities


7 MS 1827: PART 2:2005. Road Vehicles - Ignition Systems: Part 2: Electrical Performance And Function Test Methods (ISO 6518-
2:1995 And Its Technical Corrigendum 1:1997, MOD).
8 MS ISO 8092-1:2005. Road Vehicles - Connections For On-Board Electrical Wiring Harnesses - Part 1: Tabs For Single-
Pole Connections - Dimensions And Specific Requirements (ISO 8092-1:1996, IDT).
9 MS ISO 8092-4:2009. Road Vehicles - Connections For On-Board Electrical Wiring Harnesses - Part 4: Pins For Single- And Multi-
Pole Connections - Dimensions And Specific Requirements (ISO 8092-4:1997, IDT).
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15.9. Vehicle Steering, Suspension and Wheel System Service
COMPETENCY UNIT TITLE Vehicle Steering, Suspension and Wheel System Service
LEARNING OUTCOMES The person who is competent in this cu shall be able to provide free leakages, vibration and stiff defect,
smooth performance and operational of vehicle steering and wheels, free stiff, noise defect and safety
ensure for suspension.

1. Inspect steering, suspension and wheel system functionality.
2. Change steering system parts.
3. Change suspension system parts.
4. Change vehicle tyres and rims.

steering, job order 1.2 Prepare parts, tools,  Systematic in presented and explained.
suspension  Function equipment and organising work 1.2 Part, tools, equipment and
and wheel  Types materials in working activities. materials for functionality
system  Format area. inspection are obtained and
functionality.  Information 1.3 Inspect steering & SAFETY: readied in working area.
1.2 Fundamentals of suspension abnormal  Adhere to safety 1.3 Steering & suspension
tools, equipment and noises. precaution in abnormal noises sources
materials for steering 1.4 Inspect steering & conducting identified and confirmed.
& suspension system suspension stiffness steering & 1.4 Steering & suspension
functionality condition. suspension system stiffness condition sources
inspection: 1.5 Check suspension functionality identified.
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 Function system leakages. inspections. 1.5 Suspension system
 Usage 1.6 Check steering wheel  Adhere to leakages sources identified.
free play condition. company safety 1.6 Steering wheel free play
 Type
1.7 Check steering & and policy. condition performed and
1.3 Steering system suspension abnormal confirmed.
 Follow
abnormalities such vibration. 1.7 Steering & suspension
Occupational
as: 1.8 Prepare steering & abnormal vibration sources
safety &
 Noises suspension system health act. identified.
 Leakages functionality technical 1.8 Steering & suspension system
 Stiffness report. ENVIRONMENT: functionality technical report
 Other defects  Practice updated and printed.
1.4 E-power steering Reuse, Recycle
(EPS) system and Reduce
abnormalities such (3R).
as:  Follow
 Noises Environment
 Stiffness Quality act.
 Other defects
1.5 Suspension system
abnormalities such
as:
 Noises
 Leakages
 Stiffness
 Other defect
1.6 Steering wheel
free play
procedure.
1.7 Steering &
suspension system
functionality
inspection report
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writing :
 Type of report
 Content /
information
117
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 Submission
procedure
2. Change 2.1 Fundamentals of 2.1 Prepare parts, tools, ATTITUDE: 2.1 Part, tools, equipment and
steering tools, equipment and equipment and  Systematic in materials for steering parts
system parts. materials for steering materials in working organising work replacement are obtained
parts replacement : area. activities. and readied in working
 Function 2.2 Disassemble steering area.
 Usage system parts. SAFETY: 2.2 Steering parts and
2.3 Replace defect  Adhere to safety components dissembled
 Type
steering wheel. precaution in and safely organised.
2.2 Fundamentals of 2.4 Replace defect 2.3 New steering wheel
conducting
steering such as steering column. installed and secured onto
steering system
: 2.5 Replace defect the vehicle.
service.
 System steering rack. 2.4 New steering column
 Adhere to
schematic 2.6 Reassemble steering installed and secured onto
company safety
diagram system parts & the vehicle.
and policy.
 Principle of components. 2.5 New steering rack installed
 Follow
operation 2.7 Reinstall steering and secured onto the
Occupational
 System electric system into vehicle. vehicle.
safety & health
diagram 2.8 Prepare steering 2.6 Steering system parts &
act.
2.3 Steering parts system parts components reassembled
and components: replacement technical following the workshop
ENVIRONMENT:
 Type report. manual.
 Practice
 Function Reuse, Recycle 2.7 Steering system reinstalled
 Usage and Reduce to vehicle.
 Code number (3R). 2.8 Steering system parts
2.4 Steering  Follow replacement technical
system Environment report updated and printed.
disassembling Quality act.
procedure.
2.5 Steering system parts
and components
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checking functionality
procedure.
119
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2.6 Steering system
components replacing
procedure.
2.7 Steering
system
reassembling
procedure.
2.8 Steering system
reinstalling
procedure.
2.9 Steering system
parts replacement
report writing :
 Type of report
 Content /
information
 Submission
procedure
suspension tools, equipment and equipment and  Systematic in materials for suspension
system parts materials for steering materials in working organising work parts replacement are
parts replacement : area. activities. obtained and readied in
 Function 3.2 Disassemble working area.
 Usage suspension parts. SAFETY: 3.2 Suspension parts and
3.3 Replace defect  Adhere to safety components dissembled and
 Type
suspension wheel. precaution in safely organised.
3.2 Fundamentals of 3.4 Replace defect 3.3 New suspension wheel
conducting
suspension such as : suspension column. installed and secured onto
suspension system
 System 3.5 Replace defect the vehicle.
service.
schematic suspension rack. 3.4 New suspension column
 Adhere to
diagram 3.6 Reassemble installed and secured onto
company safety
 Principle of suspension system and policy. the vehicle.
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operation parts & components.  Follow 3.5 New suspension rack

 System electric
121
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diagram 3.7 Reinstall suspension Occupational installed and secured onto
3.3 Suspension parts and system into vehicle. safety & health the vehicle.
components: 3.8 Prepare suspension act. 3.6 Suspension system parts &
 Type system parts components reassembled
 Function replacement technical ENVIRONMENT: following the workshop
 Usage report.  Practice manual.
 Code number Reuse, Recycle 3.7 Suspension system
3.4 Suspension system and Reduce reinstalled to
disassembling (3R). vehicle.
procedure.  Follow 3.9 Steering system parts &
3.5 Suspension system Environment components replacement
parts and components Quality act. technical report updated and
checking functionality printed.
procedure.
components replacing
procedure.
reassembling
procedure.
reinstalling
procedure.
parts replacement
report writing :
 Type of report
 Content /
information
 Submission
procedure
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4. Change 4.1 Fundamentals of 4.1 Select tools, ATTITUDE: 4.1 Part, tools, equipment and
vehicle tyres tools, equipment and equipment and parts.  Systematic in materials for suspension
and rims materials for steering 4.2 Remove the vehicle organising work parts replacement are
parts replacement : wheel. activities. obtained and readied in
 Function 4.3 Replace vehicle tyres. working area.
 Usage 4.4 Replace vehicle rim. SAFETY: 4.2 Wheel dismounted from
 Type 4.5 Carry out wheel  Adhere to safety vehicle with air pressure
4.2 Fundamentals of tyre: balancing. precaution in released.
 Function 4.6 Install the wheel. conducting inspect 4.3 Tyres and rim are
4.7 Carry out wheel tyres and rims separated.
 Usage
alignment. condition inspections. 4.4 Tyre direction indication
 Type  Adhere to company
4.8 Prepare vehicle for are confirmed.
 Size safety and policy.
road test. 4.5 New tyre, tube, rim and
 Production date  Follow Occupational
4.9 Prepare vehicle tyres valve are fitted onto
 Material and rims parts safety & health act. wheels.
 Speed index replacement technical 4.6 Tyre are inflated and
 Tyre rating report. ENVIRONMENT:
air pressure confirmed.
 Load index  Practice Reuse, 4.7 Air leakage ascertained thru
 Leakages Recycle and
water submerging process.
4.3 Wheel removing Reduce (3R).
4.8 Wheel balancing indicator
from vehicle  Follow Environment
specification are confirmed.
procedure. Quality act.
4.9 Wheel mounted to vehicle.
4.4 Tyre removing from 4.10 Wheel alignment result are
rim procedure. confirmed.
4.5 Tyre valve installing 4.11 Vehicle are readied in the
procedure.
testing area.
4.6 Tyre installing on
4.12 Vehicles wheel
the rim procedure.
4.7 Rim changing
procedure. report updated and printed.
4.8 Vehicle tyres and rims
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parts replacement
report writing :
 Type of report
 Content /
information
 Submission
procedure
Core Abilities


5 Ellis Johnson, Tires and Handling, Published by SAE in 1996, ISBN 1-56091-752-0.
124
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15.10. Vehicle Heated Ventilation Air Conditioning (HVAC) System Rectification
COMPETENCY UNIT TITLE Vehicle Heated Ventilation Air Conditioning (HVAC) System Rectification
LEARNING OUTCOMES The person who is competent in this CU shall be able to ensure free leakages, free defect and
temperature accuracy for cooling effect.

1. Inspect heated ventilation air conditioning (HVAC) system condition.
2. Change heated ventilation air conditioning (HVAC) system parts and components.
3. Conduct heated ventilation air conditioning (HVAC) system performance test.

1. Inspect heated 1.1 Fundamental of 1.1 Received job order. ATTITUDE: 1.1 Job order obtained from
ventilation air job order 1.2 Prepare parts, tools,
 Systematic in superior are interpreted and
conditioning  Function equipment and organising work understand.
(HVAC)  Types materials in working activities. 1.2 Part, tools, equipment and
system  Format area. materials for functionality
condition.  Information 1.3 Check leakage. SAFETY: inspection are obtained and
1.2 Fundamentals of 1.4 Check cooling  Adhere to safety readied in working area.
tools, equipment and effect of the heated precaution in 1.3 Heated Ventilation Air
materials for heated ventilation air conducting heated Conditioning (HVAC)
ventilation air conditioning ventilation air system leakage are
conditioning (HVAC) (HVAC) system. conditioning (HVAC) confirmed and ascertained.
system condition: 1.5 Check abnormal system inspection. 1.4 Cooling effect of heated
 Function noise.  Adhere to company ventilation air conditioning
 Usage 1.6 Check air-condition safety and policy. (HVAC) system physically
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 Type condensers fan unit  Follow Occupational confirmed and ascertained.
1.3 Fundamentals of functionality. safety & health act. 1.5 Heated ventilation air
heated ventilation air 1.7 Check refrigerant conditioning (HVAC)
conditioning (HVAC) gas adequacy. ENVIRONMENT: abnormal noise and
system such as : 1.8 Check blower motor  Practice Reuse, harshness confirmed and
 Functionality functionality. Recycle and ascertained.
 Usability 1.9 Check blower motor Reduce (3R). 1.6 Heated ventilation air
 Schematic switch functionality.  Follow Environment conditioning (HVAC)
diagram 1.10 Check blower motor Quality act. condenser fan unit
 Parts & control resistor. functionality condition
components 1.11 Prepare heated confirmed and ascertained.
 Flange ventilation air 1.7 Refrigerant Gas adequacy
related parts conditioning condition confirmed and
(attachments) (HVAC)system ascertained.
1.4 Heated ventilation air condition inspection 1.8 Blower motor functionality
conditioning technical report. condition confirmed and
(HVAC)system ascertained.
condition check 1.9 Blower motor switch turn on
procedure: and off functionality
 Leakage performed, confirmed and
 Cooling effect ascertained.
1.10 Blower motor control
 Noise
resistor functionality
1.5 Check usability
performed, confirmed and
components condition
ascertained.
procedure such as:
1.11 Heated ventilation air
 Micro filter
conditioning (HVAC)
element
inspection technical report
 Condensers updated and printed.
fan unit
 Blower motor
126
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 Switch & resistor
1.6 Check refrigerant gas
adequacy procedure.
1.7 Inspection report
writing:
 Format such as
computerised or
manual
 Content /
information
 Submission
procedure
heated heated ventilation air equipment and  Systematic in materials for heated
ventilation air conditioning (HVAC) materials in working organising work ventilation air conditioning
conditioning system parts and area. activities. (HVAC)system parts and
(HVAC) components 2.2 Perform defect air components replacements are
system parts  Micro filter filter replacement. SAFETY: obtained and readied in
and element blockage 2.3 Perform defect  Adhere to safety working area.
components. / air filter condenser fan precaution in 2.2 New heated ventilation air
 Condenser fan unit replacement conducting heated conditioning (HVAC) air filter
 Blower motor unit 2.4 Recharge heated ventilation air replacement completed.
 Blower motor ventilation air conditioning (HVAC) 2.3 New heated ventilation air
switch & conditioning (HVAC) system inspection. conditioning (HVAC)
control resistor refrigerant.  Adhere to company condenser fan unit
unit 2.5 Perform defect blower safety and policy. replacement completed.
2.2 HVAC parts operation motor replacement.  Follow Occupational 2.4 Refrigerant fully recharge
such as: 2.6 Perform defect blower safety & health act. and adequacy confirmed and
 Compressor motor switch & completed.
 Condenser control resistor 2.5 New heated ventilation air
 Receiver replacement. conditioning (HVAC) blower
2.3 Micro filter element
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removal procedure. 2.7 Prepare heated motor replacement completed.
2.4 Condenser fan unit ventilation air ENVIRONMENT: 2.6 New heated ventilation air
removal conditioning (HVAC)  Practice Reuse, conditioning (HVAC) blower
procedure. system parts and Recycle and motor switch & control
2.5 Refrigerant measuring components Reduce (3R). resistor replacement
procedure. replacements technical  Follow Environment completed.
2.6 Heated ventilation air report. Quality act. 2.7 Heated ventilation air
conditioning (HVAC) conditioning (HVAC) system
recovery & flushing parts and components
procedure. replacements technical report
2.7 Air-condition updated and printed.
refrigerant
recharge procedure.
2.8 Blower motor unit
removal
procedure.
2.9 Blower motor
switch & control
resistor removal
procedure.
2.10 Replacements
report writing:
 Format such as
computerised or
manual
 Content /
information
 Submission
procedure
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3. Conduct 3.1 Heated ventilation air 3.1 Switch on heated ATTITUDE: 3.1 Air-Conditioner switch
heated conditioning (HVAC) ventilation air  Systematic in turned on.
ventilation air temperature conditioning (HVAC) organising work 3.2 Leakages, noise, vibration and
conditioning performance test. system. activities. harshness inspection
(HVAC) 3.2 Abnormal defects 3.2 Check abnormal completed.
129
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system  Leakage defect. 3.3 Noise, vibration and
performance  Cooling effect 3.3 Carry out heated SAFETY: harshness checklist are
test.  Noise ventilation air  Adhere to safety updated.
 Not function conditioning (HVAC) precaution in 3.4 Abnormal defect checklist
 Noise, Vibration system performance conducting heated completed.
and Harshness test. ventilation air 3.5 Heated ventilation air
(NVH) condition 3.4 Prepare heated conditioning (HVAC) conditioning (HVAC) system
3.3 Heated ventilation air ventilation air system performance performance test technical
conditioning conditioning (HVAC) test. report updated and printed.
(HVAC)system system performance  Adhere to company
performance test test technical report. safety and policy.
report writing :  Follow Occupational
 Format such as safety & health act.
computerised or
manual ENVIRONMENT:
 Content /  Reuse, Recycle and
information Reduce (3R).
 Submission  Follow Environment
procedure Quality act.
130
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Core Abilities

1 Quansheng Zhang (Author) ShengboEben Li (Author) Kun Deng (Author). Automotive Air Conditioning: Optimization, Control and
Diagnosis 1st ed. ISBN-13: 978-3319335896. Springer; 1st ed. 2016 edition (August 11, 2016).
2 Graham Stoakes (Author). Principles of Light Vehicle Air Conditioning. ISBN-10: 0992949246.
3 Anon (Author). Air Conditioning Manual. ISBN-10: 1785213598. J H Haynes & Co Ltd (June 27, 2016).
4 Chris Johanson (Author). Auto Heating and Air Conditioning. ISBN-10: 1619607638. Goodheart-Shallcox; 4 edition (September
12, 2014)
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15.11. Automatic Transmission / Transaxle Unit Overhauling
COMPETENCY UNIT TITLE Automatic Transmission / Transaxle Unit Overhauling
LEARNING OUTCOMES The person who is competent in this CU shall be able to ensure the smoothness of the transmission /
transaxle unit shifting time, the quality of the shifting and free defect and malfunctions in accordance
with OEM specifications.

1. Conduct automatic transmission / transaxle unit functional test.
2. Remove automatic transmission / transaxle from vehicle.
3. Perform automatic transmission / transaxle overhauling.
4. Install automatic transmission / transaxle into vehicle.

1. Conduct 1.1 Fundamental of 1.1 Received job order. ATTITUDE: 1.1 Job order are obtained,
automatic job order 1.2 Carry out vehicle  Systematic in presented and explained.
transmission /  Function test drive. organising work 1.2 Vehicle automatic
transaxle unit  Types 1.3 Carry out automatic activities. transmission / transaxle
functional  Format transmission / shifting condition by
test.  Information transaxle functionality SAFETY: performing vehicle test
1.2 Fundamental of condition test.  Adhere to safety identified and ascertained.
Automatic 1.4 Prepare functional precaution in 1.3 Automatic transmission /
Transmission / test technical report. conducting manual transaxle functionality
transaxle such as: transmission / condition checklist completed.
 Functions transaxle unit 1.4 Functional test technical report
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 Parts & functional test. updated and printed.
components  Adhere to company
 schematic diagram safety and policy.
 usability  Follow Occupational
conditions safety & health act.
1.3 Automatic
Transmission / ENVIRONMENT:
transaxle functionality  Practice Reuse,
condition test Recycle and
procedure Reduce (3R).
1.4 Functional test  Follow Environment
technical report Quality act.
writing:
 Format such as
computerised or
manual
 Content /
information
 Submission
procedure
2. Remove 2.1 Fundamentals of tools, 2.1 Prepare parts, tools, ATTITUDE: 2.1 Part, tools, equipment and
automatic equipment and equipment and  Systematic in materials for functionality
transmission / materials for automatic materials in working organising work inspection are obtained and
transaxle from transmission / area. activities. readied in working area.
vehicle. 2.2 Drain out automatic 2.2 Automatic
transaxle overhaul:
transmission / transaxle/transmission fluid
 Function transaxle fluid (ATF). SAFETY: (ATF) draining process
 Usage 2.3 Detach automatic  Adhere to safety performed and confirmed.
 Type transmission / precaution in 2.3 Used automatic transmission /
2.2 Drain ATF Transaxle attachments. conducting remove transaxle fluid (ATF) fully
(automatic 2.4 Remove torque automatic drain out into disposable
transmission fluid) converter. transmission/ transaxle container.
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procedure.
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2.3 Type of automatic 2.5 Mount automatic from vehicle. 2.4 Automatic transmission /
transmission transmission /  Adhere to company transaxle attachments safely
attachment such Transaxle on the safety and policy. detached.
as: overhaul stand. 2.5 Torque converter is removed
 Follow Occupational
 Cables from the vehicle.
safety & health act. 2.6 Automatic transmission /
 Propeller shaft
 U-joint transaxle secured on the
ENVIRONMENT: overhaul stand using hoist and
 Bracket & mounting
 Practice Reuse, safety harness.
2.4 Automatic
Recycle and Reduce
transmission
(3R).
attachment
detaching procedure
Quality act.
such as:
 Linkage cable
disconnected
 Indicator switch
harness disconnected
2.5 Fundamental of torque
converter such as :
 Functions
 Parts and components
 Schematic diagrams
2.6 Torque converter
removing
procedure
2.7 Automatic
transmission /
transaxle mount on the
overhaul stand
procedure.
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3. Perform 3.1 Internal components 3.1 Dismantle automatic ATTITUDE: 3.1 All automatic transmission /
automatic dismantling procedure. transmission /  Systematic in transaxle internal components
transmission / 3.2 Automatic transaxle internal organising work dismantling process performed
transaxle transmission/ components. activities. and confirmed.
Transaxle components 3.2 Determine 3.2 Automatic transmission /
overhauling. usability condition automatic transaxle components parts
transmission /
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such as: transaxle components SAFETY: condition checklist performed.
 Worn out parts condition.  Adhere to safety 3.3 New automatic transmission /
 Defective & 3.3 Replace defect precaution in transaxle components parts
damaged components automatic / transaxle replacement performed and
conducting automatic
 Leakages transmission confirmed.
3.3 Components changing components parts. transmission/ transaxle 3.4 Automatic transmission /
procedure. 3.4 Reassemble automatic overhauling. transaxle unit reassembling
3.4 Automatic / transaxle  Adhere to company process performed and
transmission / transmission unit. safety and policy. confirmed.
Transaxle unit  Follow Occupational
reassembling safety & health act.
procedure.
ENVIRONMENT:
 Practice Reuse,
Recycle and
Reduce (3R).
Quality act.
4. Install 4.1 Install attachments to 4.1 Reattach automatic ATTITUDE: 4.1 Automatic transmission /
automatic the automatic transmission /  Systematic in transaxle attachments
transmission / transmission / transaxle attachments. organising work reattached to engine
transaxle into transaxle unit 4.2 Detach automatic activities. confirmed.
procedure. transmission / 4.2 Automatic transmission /
vehicle.
4.2 Torque converter transaxle unit from the transaxle unit lifted from the
installing overhaul stand. SAFETY: overhaul stand by safety hoist
procedure. 4.3 Install torque  Adhere to safety and harness.
4.3 Automatic converter to the precaution in 4.3 Torque converter installation
transmission / automatic transmission conducting install to automatic transmission /
transaxle unit / transaxle unit. automatic transaxle unit performed and
installing 4.4 Install automatic transmission/ transaxle confirmed.
procedure. transmission / into vehicle. 4.4 Automatic transmission /
4.4 Refill Automatic transaxle unit onto the transaxle unit installation onto
engine.  Adhere to company engine performed and
Transmission Fluid
(ATF) procedure. 4.5 Refill automatic safety and policy. confirmed.
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4.5 Automatic
transmission /
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transaxle functionality transmission/transaxle Follow Occupational 4.5 Automatic Transmission /
test procedure. fluid (ATF). safety & health act. Transaxle Fluid (ATF) refilled
4.6 Automatic 4.6 Test Automatic fully.
transmission / transmission / ENVIRONMENT: 4.6 Automatic transmission /
transaxle unit transaxle functionality. transaxle functionality
overhauling technical 4.7 Prepare automatic  Practice Reuse, checklist are updated and
report writing : transmission / Recycle and confirmed.
 Format such as transaxle unit Reduce (3R). 4.7 Automatic transmission /
computerised or overhauling technical  Follow Environment transaxle unit overhauling
manual report. Quality act. technical report updated and
printed.
 Content /
information
 Submission
procedure
Core Abilities


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15.12. Manual Transmission / Transaxle Unit Overhauling
COMPETENCY UNIT TITLE Manual Transmission / Transaxle Unit Overhauling
LEARNING OUTCOMES The person who is competent in this CU shall be able to ensure the smoothness of the transmission unit
shifting time, the quality of the shifting and free defect and malfunctions in accordance with OEM
specifications.

1. Conduct manual transmission / transaxle unit functional test.
2. Remove manual transmission / transaxle from vehicle.
3. Perform clutch system overhaul.
4. Perform manual transmission / transaxle overhauling.
5. Install manual transmission / transaxle into vehicle.

1. Conduct 1.1 Fundamental of 1.1 Received job order. ATTITUDE: 1.1 Job order are obtained,
manual job order 1.2 Carry out manual  Systematic in presented and explained.
transmission /  Function transmission / organising work 1.2 Manual transmission /
transaxle unit  Types transaxle functionality activities. transaxle functionality
functional  Format condition test. condition checklist completed.
test.  Information 1.3 Prepare functional test SAFETY: 1.3 Functional test technical report
1.2 Fundamental of report.  Adhere to safety updated and printed.
Manual Transmission / precaution in
transaxle such as: conducting manual
 Functions transmission /
 Parts & transaxle unit
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components functional test.
 schematic diagram  Adhere to company
 usability safety and policy.
conditions  Follow Occupational
1.3 Manual Transmission / safety & health act.
transaxle functionality
condition test ENVIRONMENT:
procedure.  Practice Reuse,
1.4 Functional test report Recycle and
writing: Reduce (3R).
 Format such as  Follow Environment
computerised or Quality act.
manual
 Content /
information
 Submission
procedure
2. Remove 2.1 Fundamentals of 2.1 Prepare parts, tools, ATTITUDE: 2.1 Part, tools, equipment and
manual tools, equipment and equipment and  Systematic in materials for functionality
transmission / materials for manual materials in working organising work inspection are obtained and
transaxle from transmission / area. activities. readied in working area.
vehicle. transaxle overhaul: 2.2 Drain out manual 2.2 Manual transmission /
 Function transmission / transaxle fluid (MTF) draining
transaxle fluid (MTF). SAFETY: process performed and
 Usage  Adhere to safety
 Type 2.3 Detach Manual confirmed.
transmission precaution in 2.3 Used manual transmission /
2.2 Drain Manual conducting remove
attachments. transaxle fluid (MTF) are
Transmission /
2.4 Mount Manual manual transmission/ disposed into disposable
transaxle Fluid
Transmission / transaxle from vehicle. container.
(MTF) procedure.
transaxle on the  Adhere to company 2.4 Manual transmission /
2.3 Type of manual
overhaul stand. safety and policy. transaxle attachments
transmission /
 Follow Occupational detached.
transaxle attachment
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such as: safety & health act. 2.5 Manual transmission /
 Cables transaxle safely lift-out from
 Propeller shaft ENVIRONMENT: vehicle using hoist and safety
 U-joint  Practice Reuse, harness.
2.6 Manual transmission /
 Bracket & Recycle and
transaxle secured on the
mounting Reduce (3R). overhaul stand using hoist and
2.4 Manual transmission /  Follow Environment safety harness.
transaxle attachment Quality act.
detaching procedure
such as:
 Linkage cable
disconnected
 Indicator
switch harness
disconnected
2.5 Manual transmission
mount on the overhaul
stand procedure.
3. Perform 3.1 Fundamentals of 3.1 Prepare parts, tools, ATTITUDE: 3.1 Part, tools, equipment and
clutch system tools, equipment and equipment and  Systematic in materials for clutch system
overhaul. materials for clutch materials in working organising work overhaul are obtained and
system overhaul: area. activities. readied in working area.
 Function 3.2 Perform clutch system 3.2 Clutch system inspection
 Usage inspection. SAFETY: checklist are updated and
 Type 3.3 Disassemble clutch  Adhere to safety confirmed.
3.2 Fundamentals of system assembly. precaution in 3.3 Clutch system assembly are
clutch system 3.4 Replace defect clutch conducting clutch dissembled and organised
 Schematic diagram system parts & system overhaul. following workshop manual.
 Functions components.  Adhere to company 3.4 New clutch system parts &
 Types of linking 3.5 Assemble clutch safety and policy. components replacement
system system assembly.  Follow Occupational performed and confirmed.
(hydraulic 3.5 Clutch system assembly
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and cable) safety & health act. assembling process performed
 Type of possible and confirmed.
leakage ENVIRONMENT:
 Clutch external  Practice Reuse,
parts & components Recycle and
 Clutch external Reduce (3R).
parts & components  Follow Environment
 Clutch bleeding Quality act.
procedure
 Transmission /
transaxle mating
casing inspection
and replacement
procedure.
4. Perform 4.1 Internal components 4.1 Dismantle manual ATTITUDE: 4.1 All manual transmission /
manual dismantling procedure transmission /  Systematic in transaxle internal components
transmission / 4.2 Manual transmission / transaxle internal organising work dismantling process
transaxle transaxle components components. activities. performed and confirmed.
usability condition 4.2 Determine manual 4.2 Manual transmission /
overhauling. such as: transmission / transaxle components parts
transaxle components SAFETY: condition checklist performed.
 Worn out
 Defective parts condition.  Adhere to safety 4.3 New Manual transmission /
& damaged 4.3 Replace manual precaution in transaxle components parts
transmission / conducting manual replacement performed and
components
transaxle components transmission / confirmed.
 Leakages parts. 4.4 Manual transmission /
4.3 Components changing transaxle overhauling.
4.4 Reassemble manual  Adhere to company transaxle unit reassembling
procedure according transmission / process confirmed.
to OEM requirement transaxle unit. safety and policy.
4.4 Manual transmission /  Follow Occupational
transaxle unit safety & health act.
reassembling
procedure ENVIRONMENT:
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 Practice Reuse,
Recycle and
Reduce (3R).
Quality act.
5. Install manual 5.1 Install attachments to 5.1 Reattach manual ATTITUDE: 5.1 Manual transmission /
transmission / the manual transmission /  Systematic in transaxle attachments
transaxle into transmission / transaxle attachments. organising work reattached to engine
vehicle. transaxle unit 5.2 Detach manual confirmed.
activities.
procedure. transmission / 5.2 Manual transmission /
5.2 Manual transmission / transaxle unit from the transaxle unit lifted from the
transaxle detach from overhaul stand. SAFETY: overhaul stand by safety hoist
the overhaul stand 5.3 Install manual  Adhere to safety and harness.
procedure. transmission / precaution in 5.3 Manual transmission /
5.3 Torque converter transaxle unit onto the conducting manual transaxle unit installation onto
installing to the engine. transmission into engine performed and
manual transmission / 5.4 Refill manual vehicle installation. confirmed.
transaxle unit transmission /  Adhere to company 5.4 Manual Transmission /
procedure. transaxle fluid (MFT) Transaxle Fluid (ATF) refilled
5.4 Manual transmission / fluid. safety and policy. fully.
transaxle unit 5.5 Test manual  Follow Occupational 5.5 Manual transmission /
installing onto the transmission / safety & health act. transaxle functionality
engine procedure. transaxle checklist are updated and
5.5 Refill manual functionality. ENVIRONMENT: confirmed.
transmission / 5.6 Prepare manual  Practice Reuse, 5.6 Manual transmission /
transaxle fluid transmission / Recycle and transaxle unit overhauling
(MTF) procedure. transaxle unit Reduce (3R). technical report updated and
5.6 Manual transmission / overhauling report. printed.
transaxle functionality  Follow Environment
test procedure. Quality act.
5.7 Manual transmission /
transaxle unit
overhauling report
writing :
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 Format such as
computerised or
manual
 Content /
information
Core Abilities


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15.13. Transfer Case Overhauling
COMPETENCY UNIT TITLE Transfer Case Overhauling
LEARNING OUTCOMES The person who is competent in this CU shall be to ensure the smoothness of the gear engage, the quality
of the shifting and free defect and malfunctions in accordance with OEM specifications.

1. Conduct transfer case unit functional test.
2. Remove transfer case unit from vehicle.
3. Perform transfer case unit overhauling.
4. Install transfer case unit into vehicle.
CU CODE G452-002-2:2018-EU01 NOSS LEVEL Two (2)

1. Conduct 1.1 Fundamental of 1.1 Received job order. ATTITUDE: 1.1 Job order obtained and
transfer case job order 1.2 Carry out transfer case  Systematic in interpreted and understand.
unit functional  Function functionality condition organising work 1.2 Transfer case functionality
test.  Types test. activities. condition checklist completed.
 Format 1.3 Prepare functional 1.3 Functional test report
 Information test report. SAFETY: produced and presented.
1.2 Fundamental of  Adhere to safety
transfer case such precaution in
as: conducting manual
 Functions transmission /
 Parts & transaxle unit
components functional test.
 Schematic diagram  Adhere to company
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 Usability safety and policy.
conditions  Follow Occupational
1.3 Transfer case safety & health act.
functionality
condition test ENVIRONMENT:
procedure  Practice Reuse,
1.4 Functional test report Recycle and
writing: Reduce (3R).
 Format such as  Follow Environment
computerised or Quality act.
manual
 Content /
information
 Submission
procedure
2. Remove 2.1 Fundamentals of 2.1 Prepare parts, tools, ATTITUDE: 2.1 Part, tools, equipment and
transfer case tools, equipment and equipment and  Systematic in materials for functionality
unit from materials for transfer materials in working organising work inspection obtained and
vehicle. case unit overhaul: area. activities. readied in working area.
 Function 2.2 Drain out gear oil. 2.2 Gear oil fully drain out into
 Usage 2.3 Detach manual disposable container.
transmission SAFETY:
 Type  Adhere to safety 2.3 Transfer case cables, propeller
attachments. shaft, u-joint, bracket and
2.2 Drain gear oil precaution in
2.4 Mount transfer case mounting detached checklist
procedure conducting remove
unit on the overhaul
2.3 Type of transfer are updated.
stand. transfer case unit from
case unit attachment 2.4 Transfer case mount on the
such as: vehicle. overhaul stand using hoist
 Cables  Adhere to company and safety harness.
 Propeller shaft safety and policy.
 U-joint  Follow Occupational
safety & health act.
 Bracket &
mounting
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2.4 Transfer case unit ENVIRONMENT:
attachment detaching  Practice reuse, recycle
procedure such as: and reduce (3R).
 Linkage cable  Follow Environment
disconnected quality act.
 Indicator
switch harness
disconnected
2.5 Transfer case unit on
the overhaul stand
procedure.
3. Perform 3.1 Internal components 3.1 Dismantle transfer ATTITUDE: 3.1 Transfer case internal
transfer case dismantling case internal  Systematic in components dismantled
unit procedure. components. organising work accordingly one by
overhauling. 3.2 Transfer case 3.2 Determine transfer activities. one.
components usability case components parts 3.2 Transfer case components
condition such as: worn, defective and SAFETY: parts condition checklist
 Worn out damaged condition.  Adhere to safety performed.
 Defective 3.3 Replace transfer case precaution in 3.3 Transfer case components
& damaged components parts. conducting transfer parts replace checklist
components 3.4 Reassemble transfer case overhauling. performed.
 Leakages case components.  Adhere to company 3.4 Transfer case unit safely
3.3 Transfer case 3.5 Refill gear oil. safety and policy. reassembled.
components changing 3.6 Test transfer case  Follow Occupational 3.5 Gear oil fully replenished
procedure. functionality. 3.6 Transfer case unit
safety & health act.
3.7 Transfer case unit functionality test checklist are
3.4 Transfer case updated and confirmed.
unit reassembling overhauling report. ENVIRONMENT: 3.7 Transfer case unit overhauling
procedure.  Practice Reuse, report produced and presented.
3.5 Refill gear oil Recycle and Reduce
procedure. (3R).
3.6 Transfer case
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functionality  Follow Environment
test procedure quality act.
3.7 Transfer case unit
overhauling report
writing :
 Format such as
computerised or
manual
 Content /
information
4. Install transfer 4.1 Transfer case 4.1 Reattach transfer case ATTITUDE: 4.1 Transfer Case unit
case unit into unit detach from unit attachments.  Systematic in attachments reattach checklist
vehicle. the overhaul 4.2 Detach transfer case organising work performed.
stand procedure. unit from the overhaul activities. 4.2 Transfer Case unit lifted from
4.2 Transfer case unit stand. the overhaul stand by safety
installing to the 4.3 Install transfer case hoist and harness.
manual transmission / unit onto the engine. SAFETY: 4.3 Transfer Case unit installed
transaxle unit 4.4 Refill gear oil.  Adhere to safety onto the engine and safely
procedure. 4.5 Test transfer case unit. precaution in secured.
4.3 Transfer case unit 4.6 Prepare transfer case conducting manual 4.4 Transfer Case unit gear oil
installing onto the unit overhauling transmission into replenished
engine procedure. report. vehicle installation. 4.5 Transfer Case unit
4.4 Refill gear oil  Adhere to company functionality checklist are
procedure. updated and confirmed.
safety and policy.
4.5 Transfer case 4.6 Transfer Case unit
unit functionality  Follow Occupational overhauling report prepared
test procedure. safety & health act. and presented.
4.6 Transfer case unit
overhauling report ENVIRONMENT:
writing :  Practice Reuse,
 Format such as Recycle and
computerised or Reduce (3R).
manual
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 Content /  Follow Environment
information Quality act.
Core Abilities


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15.14. Vehicle Carburettor Service
COMPETENCY UNIT TITLE Vehicle Carburettor Service
LEARNING OUTCOMES The person who is competent in this CU shall be able to ensure the smoothness of the engine, optimum
performance and free defect and malfunctions in accordance with OEM specifications.

1. Inspect carburettor functionality.
2. Overhaul carburettor.
3. Perform carburettor tuning.
CU CODE G452-002-2:2018-EU02 NOSS LEVEL Two (2)

carburettor job order 1.2 Prepare parts, tools,  Systematic in presented and explained.
functionality.  Function equipment and organising work 1.2 Part, tools, equipment and
 Types materials in working activities. materials for functionality
 Format area. inspection are obtained and
 Information 1.3 Check carburettor SAFETY: readied in working area.
1.2 Fundamentals of leakages condition.  Adhere to safety 1.3 Carburettor leakages condition
tools, equipment and 1.4 Check carburettor precaution in visually checked.
materials for idling speed. conducting 1.4 Carburettor idling speed
carburettor 1.5 Check carburettor carburettor characteristic determined.
functionality acceleration functionality 1.5 Carburettor acceleration
inspection: performance. inspection. performance checklist
 Function  Adhere to performed.
 Usage company safety
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1.3 Type Fundamentals of and policy.
carburettor such as :-  Follow
 Functionality Occupational
 Usability safety &
 7 stage of health act.
carburettor
 Schematic ENVIRONMENT:
Diagram  Practice
 Parts & Reuse, Recycle
components and Reduce
 Flange related (3R).
parts (attachments)  Follow
1.4 Type of possible Environment
leakage Quality act.
 Source (such
as petrol part,
oil ring,
gasket )
 cause (such
as wear and
tear,
misalignment,
accident)
1.5 Carburettor idling
speed checking
procedure such as :-
 Components
checking (fuel
hose, fuel pump
assembly, gasket)
 Functions
(auto choke,
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air-
conditioner
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actuator, vacuum
hose)
1.6 Carburettor
acceleration
performance checking
procedure.
2. Overhaul 2.1 Fundamentals of 2.1 Prepare parts, tools, ATTITUDE: 2.1 Part, tools, equipment and
carburettor. tools, equipment and equipment and  Systematic in materials for functionality
materials for materials in working organising work inspection obtained and
carburettor service: area. activities. readied in working area.
 Function 2.2 Remove carburettor 2.2 Carburettor cables, brackets
 Usage attachments. SAFETY: and mounting removed.
2.1 Carburettor attachment 2.3 Remove carburettor  Adhere to safety 2.3 Carburettor is removed from
dismantling procedure. from the intake precaution in intake manifold and put on
2.2 Carburettor removing manifold. conducting overhaul stand.
from the intake 2.4 Dismantle carburettor carburettor 2.4 Carburettor components
manifold procedure. components. overhaul. dismantled following OEM
2.3 Carburettor 2.5 Determine carburettor manual.
components  Adhere to
dismantling components worn out company safety 2.5 Carburettor components worn
procedure. or damage conditions and policy. out or damage conditions
2.4 Carburettor 2.6 Clean carburettor  Follow characteristic determined.
components usability components. Occupational 2.6 Carburettor components
condition such as: 2.7 Change carburettor safety & cleaned from grime and dirt.
 Worn out components. health act. 2.7 Carburettor components
 Defective & 2.8 Reassemble changing checklist performed.
damaged carburettor ENVIRONMENT: 2.8 Carburettor components
components components.  Practice replacing checklist performed.
 Leakages 2.9 Mount carburettor to Reuse, Recycle 2.9 Carburettor hoist into intake
2.5 Carburettor intake manifold. and Reduce manifold and secured.
components cleaning 2.10 Reassemble (3R). 2.10 Carburettor attachments
procedure. carburettor  Follow reassembling checklist
2.6 Carburettor Environment
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components changing attachments. Quality act. performed.
procedure.
2.7 Carburettor
components
reassembling
procedure.
2.8 Mount carburettor to
the intake manifold.
2.9 Carburettor attachment
reassembling
procedure.
3. Perform 3.1 Carburettor 3.1 Carry out Carburettor ATTITUDE: 3.1 Carburettor idling tuning
carburettor fundamental idling tuning testing.  Systematic in testing checklist performed.
tuning. test procedure 3.2 Carry out Carburettor organising work 3.2 Carburettor acceleration
such: acceleration tuning activities. tuning test checklist
 Idling test test. performed.
 Tuning test 3.3 Carry out Carburettor 3.3 Carburettor choke tuning test
choke tuning test. SAFETY: checklist performed.
3.2 Acceleration testing  Adhere to safety
procedure. 3.4 Prepare Data 3.4 Data technical inspection
3.3 Choke testing Technical Inspection precaution in (DTI) sheet checklist
procedure. (DTI) sheet. conducting completed.
3.4 Data Technical 3.5 Test transfer case carburettor 3.5 Vehicle carburettor
Inspection (DTI) functionality. overhaul. functionality test checklist are
preparing procedure. 3.6 Vehicle carburettor  Adhere to updated and confirmed.
3.5 Transfer case service report. company safety 3.6 Vehicle carburettor service
functionality and policy. report produced and presented.
test procedure.  Follow
3.6 Vehicle carburettor Occupational
service report writing
safety &
:
health act.
 Format such as
computerised or
manual
 Content /
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information
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ENVIRONMENT:
 Practice Reuse,
Recycle and
Reduce (3R).
 Follow
Environment
Quality act.
Core Abilities


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16. Delivery Mode
The following are the recommended training delivery modes:-
KNOWLEDGE SKILL
 Lecture  Demonstration
 Group discussion  Simulation
 E-learning, self-paced  Project
 E-learning, facilitate  Scenario based training (SBT)
 Case study or Problem based learning (PBL)  Role play
 Self-paced learning, non-electronic  Coaching
 One-on-one tutorial  Observation
 Shop talk  Mentoring
 Seminar
Skills training and skills assessment of trainees should be implemented in accordance with TEM requirements and actual situation.
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17. Tools, Equipment and Materials (TEM)

LEVEL 2
CU CU CODE COMPETENCY UNIT TITLE

No.
CU1 G452-002-2:2018-CU01 Vehicle Workshop Housekeeping
CU2 G452-002-2:2018-CU02 Vehicle Engine Service
CU3 G452-002-2:2018-CU03 Vehicle Engine Overhauling
CU4 G452-002-2:2018-CU04 Vehicle Brake System Service
CU5 G452-002-2:2018-CU05 Engine Cooling System Replacement
CU6 G452-002-2:2018-CU06 Rear / Front Axle Rectification
CU7 G452-002-2:2018-CU07 Exhaust System Rectification
CU8 G452-002-2:2018-CU08 Vehicle Electrical & Electronic System Service
CU9 G452-002-2:2018-CU09 Vehicle Steering, Suspension and Wheel System Service
CU10 G452-002-2:2018-CU10 Vehicle Heated Ventilation Air Conditioning (HVAC) System Rectification
CU11 G452-002-2:2018-CU11 Automatic Transmission / Transaxle Unit Overhauling
CU12 G452-002-2:2018-CU12 Manual Transmission / Transaxle Unit Overhauling
E01 G452-002-2:2018-EU01 Transfer Case Overhauling
E02 G452-002-2:2018-EU02 Vehicle Carburettor Service
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* Items listed refer to TEMs minimum requirement for skills delivery only.
Bil ITEM* RATIO (TEM : Trainees or AR = As Required)

CU1 CU2 CU3 CU4 CU5 CU6 CU7 CU8 CU9 CU10 CU11 CU12 E01 E02
A. Tools
1 Job order sample 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5
Customer handling
2 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5
sample.
Chronology of
3 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5
event sample.
Warranty term &
4 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5
condition sample
5 Sample of parts 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5
6 Floor jack 1:25 1:25 1:25 1:25 1:25 1:25 1:25 1:25 1:25 1:25 1:25 1:25 1:25
7 Safety stand 1:25 1:25 1:25 1:25 1:25 1:25 1:25 1:25 1:25 1:25 1:25 1:25 1:25
8 Test light 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5
9 Multimeters 1:5 1:5 1:5
10 Ohmmeter 1:5 1:5
11 Oscilloscopes 1:25 1:25
12 Belt tension gauge 1:25 1:25 1:25 1:25 1:25
Vacuum pump &
13 1:25 1:25 1:25 1:25 1:25
gauge
Recovery/recycling
14 1:25 1:25 1:25 1:25 1:25
machine
15 Evacuation pumps 1:25 1:25 1:25 1:25 1:25
16 Pressure tester 1:25 1:25 1:25 1:25 1:5
17 Service manual 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5
18 Workshop manual 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5
19 Sample report 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1
20 Sample checklist 1:25 1:25 1:25 1:25 1:25 1:25 1:25 1:25 1:25 1:25 1:25 1:25 1:25
160
G452-002-
21 Automatic vehicle 1:25 1:25 1:25 1:25 1:25 1:25 1:25 1:25 1:25 1:25 1:25 1:25 1:25
22 Manual vehicle 1:25 1:25 1:25 1:25 1:25 1:25 1:25 1:25 1:25 1:25 1:25 1:25 1:25
Special automotive
23 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5
tools set
General
24 automotive tools 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5 1:5
set
Sample of
workshop
25 1:1
housekeeping
manual
Workshop
housekeeping
26 1:5
tools, equipment
and materials
27 Stationary 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1
HVAC manifolds
28 1:25
gauge
29 Ventilation hoses 1:25
B. Equipment
Personnel
1 Protective 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1
Equipment (PPE)
Computer
2 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1
peripheral
C. Materials
1 Soap solution 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1
2 Test strips 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1
Safety and security
3 protecting 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1
materials
161
G452-002-
18. Competency Weightage
The following table shows the percentage of training priorities based on consensus made by the Standard Development Committee
(SDC).
LEVEL 2
COMPETENCY
CU COMPETENCY UNIT WORK ACTIVITIES
WORK ACTIVITIES
CODE UNIT TITLE WEIGHTAGE
WEIGHTAGE
Identify workshop housekeeping requirements 21%
G452- Prepare workshop housekeeping setup 21%
Vehicle
002-
Workshop 6% Perform workshop housekeeping activities 21%
2:2018-
Housekeeping Check workshop housekeeping conformance 21%
CU01
Prepare workshop periodic report 16%
Change Lubrication Oil & Oil Filter. 20%
G452- Change Engine Drive Belt and Tensioner. 20%
002- Vehicle Engine Inspect Exhaust System Components Condition 20%
6%
2:2018- Service Change Air Filter. 10%
CU02 Change Fuel Filter. 20%
Change Spark Plugs. 10%
Conduct Engine Compression Test. 15%
G452- Conduct Engine Cylinder Leakages Test. 15%
002- Vehicle Engine Remove Engine From Vehicle. 15%
10%
2:2018- Overhauling Perform Engine Overhaul. 25%
CU03 Reinstall Engine Onto Vehicle. 15%
Conduct Engine Test. 15%
162
G452-002-
G452- Inspect Brake System Condition 20%

002- Vehicle Brake Change Brake System Components 40%
8%
2:2018- System Service
CU04 Change Parking Brake System Components 40%
G452- Conduct Cooling System Pressure Test 20%
Engine Cooling
002- Conduct Cooling System Parts Functionality Test 40%
System 8%
2:2018-
Replacement Change Cooling System Parts. 40%
CU05
G452- Inspect Rear / Front Axle Condition 20%
Rear / Front
002- Dismantle Rear / Front Axle Differential Unit 40%
Axle 8%
2:2018- Change Rear / Front Axle Differential Components &
Rectification 40%
CU06 Parts.
G452- Inspect Exhaust System Components Condition 20%
002- Exhaust System Change Exhaust System Components 40%
8%
2:2018- rectification Conduct Exhaust System Components Performance
CU07 40%
Test
Inspect Electrical & Electronic System Parts &
20%
G452- Vehicle Components Functionality.
002- Electrical & Change Electrical & Electronic System Parts &
10% 30%
2:2018- Electronic Components.
CU08 System Service Inspect Chassis Electrical System. 30%
Change Chassis Electrical System Components. 20%
Vehicle Inspect Steering, Suspension And Wheel System
G452- 10%
Steering, Functionality.
002- Change Steering System Parts 30%
Suspension and 10%
2:2018-
Wheel System Change Suspension System Parts. 30%
CU09
Service Change Vehicle Tyres And Rims 30%
G452- Vehicle Heated Inspect Heated Ventilation Air Conditioning (HVAC)
20%
002- Ventilation Air System Condition.
8%
2:2018- Conditioning Change Heated Ventilation Air Conditioning (HVAC)
40%
CU10 (HVAC) System System Parts and Components.
163
G452-002-
Rectification Conduct Heated Ventilation Air Conditioning (HVAC)

40%
System Performance Test.
Conduct Automatic Transmission / transaxle Unit
10%
Functional Test.
G452- Automatic Remove Automatic Transmission / Transaxle from
30%
002- Transmission / Vehicle.
8%
2:2018- Transaxle Unit Perform Automatic Transmission / Transaxle
30%
CU11 Overhauling Overhauling.
Install Automatic Transmission / Transaxle into
30%
Vehicle.
Conduct Manual Transmission / transaxle Unit
10%
Functional Test.
G452- Manual Remove Manual Transmission / Transaxle from
25%
002- Transmission / Vehicle.
10% Perform Clutch System Overhaul. 20%
2:2018- Transaxle Unit
CU12 Overhauling Perform Manual Transmission / Transaxle
25%
Overhauling.
Install Manual Transmission / Transaxle into Vehicle. 20%
TOTAL PERCENTAGE (CORE COMPETENCY) 100%
G452- Conduct Transfer Case Unit Functional Test. 10%
002- Transfer Case Remove Transfer Case Unit From Vehicle. 30%
10%
2:2018- Overhauling Perform Transfer Case Unit Overhauling. 30%
EU01 Install transfer case unit into Vehicle. 30%
G452- Inspect Carburettor Functionality 20%
Vehicle
002- Overhaul Carburettor 40%
Carburettor 10%
2:2018-
Service Perform Carburettor Tuning 40%
EU02
TOTAL PERCENTAGE (ELECTIVE COMPETENCY) 100%
CORE ABILITY 80
164
G452-002-
18 (a) Sample Calculation for Summary of Training Hours
The following table shows the nominal training hours based on recommendations made by the Standard Development Committee
(SDC). For purpose of Malaysian Skills Certification through accredited centre training, the program duration is subject to Malaysian
Skills Certification System.
LEVEL 2
WORK ACTIVITY
TRAINING DURATION TRAINING
CU COMPETENCY SKILLS
WORK ACTIVITY (HOURS) DURATION
CODE UNIT TITLE CREDIT
(HOURS)
KNOWLEDGE SKILLS
Identify workshop housekeeping requirements 8 16
G452- Prepare workshop housekeeping setup 8 16
Vehicle
002-
Workshop Perform workshop housekeeping activities 8 16 108 11
2:2018-
Housekeeping Check workshop housekeeping conformance 8 16
CU01
Prepare workshop periodic report 4 8
Change Lubrication Oil & Oil Filter. 9 28
G452- Change Engine Drive Belt and Tensioner. 5 10
002- Vehicle Engine Inspect Exhaust System Components Condition. 3 7
104 11
2:2018- Service Change Air Filter. 5 9
CU02 Change Fuel Filter. 5 9
Change Spark Plugs. 5 9
Conduct Engine Compression Test 5 14
G452- Conduct Engine Cylinder Leakages Test 5 14
002- Vehicle Engine Remove Engine From Vehicle 5 15 118 12
2:2018- Overhauling
CU03 Perform Engine Overhaul 5 15
Reinstall Engine Onto Vehicle 5 15
165
G452-002-
Conduct Engine Test 5 15

G452- Inspect Brake System Condition 3 7
002- Vehicle Brake Change Brake System Components 3 7 30 3
2:2018- System Service
CU04 Change Parking Brake System Components 3 7
G452- Conduct Cooling System Pressure Test 3 7
Engine Cooling
002- Conduct Cooling System Parts Functionality Test 3 6
System 28 3
2:2018-
Replacement Change Cooling System Parts 3 6
CU05
G452- Inspect Rear / Front Axle Condition 3 7
002- Rear / Front Axle Dismantle Rear / Front Axle Differential Unit 3 8
32 4
2:2018- Rectification Change Rear / Front Axle Differential Components &
CU06 3 8
Parts.
G452- Inspect Exhaust System Components Condition 3 7
002- Exhaust System Change Exhaust System Components 3 8 32 4
2:2018- rectification
CU07 Conduct Exhaust System Components Performance Test 3 8
Inspect Electrical & Electronic System Parts &
8 24
G452- Components Functionality.
Vehicle Change Electrical & Electronic System Parts &
002- 14 32
Electrical & Components. 143 15
2:2018-
Electronic Inspect Chassis Electrical System. 12 40
CU08
System Service
Change Chassis Electrical System Components. 3 10
Inspect Steering, Suspension And Wheel System
G452- Vehicle Steering, 3 8
Functionality
002- Suspension and Change Steering System Parts 3 10 50 5
2:2018- Wheel System
Change Suspension System Parts 3 10
CU09 Service
Change Vehicle Tyres And Rims 3 10
G452- Vehicle Heated Inspect Heated Ventilation Air Conditioning (HVAC)
3 10
002- Ventilation Air System Condition
38 4
2:2018- Conditioning Change Heated Ventilation Air Conditioning (HVAC)
3 10
CU10 (HVAC) System System Parts and Components
166
G452-002-
Rectification Conduct Heated Ventilation Air Conditioning (HVAC)

3 9
System Performance Test
Conduct Automatic Transmission / transaxle Unit
3 15
Functional Test
G452- Automatic Remove Automatic Transmission / Transaxle from
002- Transmission / 3 10
Vehicle 57 7
2:2018- Transaxle Unit Perform Automatic Transmission / Transaxle
CU11 Overhauling 3 10
Overhauling
Install Automatic Transmission / Transaxle into Vehicle 3 10
Conduct Manual Transmission / transaxle Unit Functional
3 15
G452- Manual Test
002- Transmission / Remove Manual Transmission / Transaxle from Vehicle 3 10
Perform Clutch System Overhaul 3 10 70 7
2:2018- Transaxle Unit
CU12 Overhauling Perform Manual Transmission / Transaxle Overhauling 3 10
Install Manual Transmission / Transaxle into Vehicle 3 10
TOTAL HOURS (Core Competencies) 216 594 810
G452- Conduct Transfer Case Unit Functional Test 2 4
002- Transfer Case Remove Transfer Case Unit From Vehicle 2 4
34 4
2:2018- Overhauling Perform Transfer Case Unit Overhauling 3 8
EU01 Install Transfer Case Unit Into Vehicle 3 8
G452- Inspect Carburettor Functionality 3 6
Vehicle
002- Overhaul Carburettor 3 6
Carburettor 27 3
2:2018-
Service Perform Carburettor Tuning 3 6
EU02
TOTAL HOURS (Electives Competencies) 19 42 61
TOTAL HOURS OF COMPETENCY UNIT 871
CORE ABILITY 80
The sample calculations performed are based on table in section 18 for delivery of level 2 training program at 871 hours excluding
delivery of core abilities.
167

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Jabatan Pembangunan Kemahiran

Kementerian Sumber Manusia, Malaysia

STANDARD KEMAHIRAN PEKERJAAN KEBANGSAAN

LIGHT VEHICLE-REPAIR SERVICE

Department of Skills Development (DSD)

NATIONAL OCCUPATIONAL SKILLS STANDARD

LIGHT VEHICLE-REPAIR SERVICE

PERKHIDMATAN PEMBAIKAN- KENDERAAN RINGAN

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1. 3R Reduce, Reuse, and Recycle.

2. DOE Department of Environment.

3. CoCU Curriculum Of Competency Unit.

5. CPC Competence Profile Chart.

7. DSD Department Of Skills Development.

8. DOSH Department of Occupational Safety and Health.

9. HVAC Heating, Ventilation, and Air Conditioning .

10. JPJ JabatanPengangkutan Jalan.

11. MAI Malaysia Automotive Institute.

12. NOSS National Occupational Skill Standard.

13. MOT Ministry of Transport.

14. OAS Occupational Area Structure.

15. OEM Original Equipment Manufacturer.

16. OSHA Occupational Safety and Health Act.

17. OS Occupational Structure.

18. PPE Personal Protective Equipment.

19. RTA Road Transportation Act.

20. SDC Standard Development Committee.

21. SKM Sijil Kemahiran Malaysia.

22. SP Standard Practice

23. SOP Standard Operating Procedure.

24. TEM Tools, Equipment and Materials.

1. Diagnostic. The definition of diagnostic is something related to the identification of a problem or

2. Inspection. An inspection is, most generally, an organized examination or formal evaluation

i. National Skills Development Council (NSDC)

NATIONAL OCCUPATIONAL SKILLS STANDARD (NOSS) FOR:

LIGHT VEHICLE-REPAIR SERVICE

1.1. Occupation Overview

Negeri 2013 2014 2015 2016 2017

1.2. Rationale of NOSS Development

This NOSS is developed with the following objectives:

1.3. Rationale of Occupational Structure and Occupational Area Structure

Figure 2: assessment and gap analysis

1.4. Regulatory / Statutory Body Requirements Related to Occupation

I. Consumer Protection Act 1999, Workshop Information Disclosure Regulations

II. Environmental Quality (Refrigerant Management) Regulations 1999 and

1.5. Occupational Pre-Requisite

1.6. General Training Pre-Requisite For Malaysian Skills Certification System

 No certification and experience required

2. Occupational Structure (OS)

Figure 3: Occupational Structure

3. Occupational Area Structure (OAS)

Figure 4: Occupational Area Structure

4. Definition of Competency Levels

Level 2: Competent in performing a significant range of varied work activities,

Level 3: Competent in performing a broad range of varied work activities, performed in a

Level 4: Competent in performing a broad range of complex technical or professional

Level 5: Competent in applying a significant range of fundamental principles and

5.1. Malaysian Skills Certificate (MSC)

Light Vehicle-Repair Service (Level 2) personnel is competent in performing the following

6.1 Vehicle Workshop Housekeeping

Optionally, the Light Vehicle-Repair Service (Level 2) is competent in performing the

6.13 Transfer Case Overhauling

8.1 Other related occupations with respect to employment opportunities are: