National Certificate in Automotive Machanics

UGANDA BUSINESS AND TECHNICAL EXAMINATIONS BOARD
MODULAR ASSESSMENT GUIDE
PROGRAMME: NATIONAL CERTIFICATE IN AUTOMOTIVE MECHANICS (NCAM)
JANUARY 2022
PREAMBLE
The modular assessment is aimed at testing trainees on the basic and fundamental knowledge and skills
of automotive service, maintenance and repair while putting emphasis on core requirements of a well-
trained automotive mechanic required by world of work. The assessment is in line with the
requirements stipulated in the automotive curriculum of the National Curriculum Development Centre.
Furthermore, the assessment stresses the major elements of a Health and Safety Management System
which will help trainees to exhibit improved OHSE awareness and understand the best safety practices
while at work.
The assessment will concentrate on the completed module to verify whether the trainee has acquired
all the necessary competences of the module and to test whether the training outcome has been
achieved.
The competences to be assessed are clearly defined for each module covered within the time allocated.
The modules assessed per package in this course are in the manner that will help the trainee exhibit
particular skills to be used to execute various tasks of the respective time of study.
The modular assessment stipulates that each module should be fully assessed with all the necessary
technology, mathematics, technical drawing science and calculations. This means that the sub -
modules in module like; mathematics, technical drawing science and calculations have been identified
to fall under particular modules to help the trainee apply them to the given module at a particular study
time.
As stipulated by the NCDC curriculum for National Certificate in Automotive Mechanics, if
implemented, this assessment should produce Automotive Mechanics who are able do the following:
1. Exhibit improved OHSE awareness.
2. Fabricate components and machine parts
3. Service and maintain engines in good working conditions.
4. Install, repair and maintain the electrical/ electronic system in a vehicle
5. Prepare reports, budgets, and operation plans
6. Promote and ensure safety of workers and plant
7. Initiate and manage small Business Enterprises.
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SUMMARY OCCUPATIONS, MODULES AND SUB-MODULES
OCCUPATION MODULE SUB-MODULE

1. Occupational Occupational Health a. Safety Responsibilities
Health and Safety and Safety b. Application of HSE
Officer/Guide Awareness c. Employee involvement
d. Hazards Identification and Control
e. Safety beyond work zones
f. Accidents Prevention and investigation
2. Auto-Fabricator Automotive Fitting a. Measuring and marking out
and Fitter and Fabrication b. Fitting and holding tools
Mechanic c. Heat Treatment of metals
d. Joining Materials and Forging
e. Temporary Joining of materials
f. Permanent Joining of materials (Welding, Electric arc welding,
gas welding, soldering and brazing)
g. Forging
3. Engine and its Engine and its a. General Engine Diagnosis
systems Systems b. Cylinder Head and Valve Train Diagnosis and Repair
maintenance, Maintenance, c. Wedge tools and setting Torque application
service and repair Service and Repair d. The Cam
mechanic e. Engine Block Diagnosis and Repair
f. Determination of Engine capacity
g. Conversion of basic units
h. Mensuration
i. Inspecting Engine revolutions (speed)
j. Inspecting cylinder bore wear
k. Determining TDC and BDC for an internal combustion engine
l. Orthographic and isometric projection
m. Using Assembly drawings to dismantle and assemble engine
and its components
n. D. Cooling and lubrication Systems Diagnosis and Repair
o. Viscosity of lubrication oil (both use and new oil)
p. Temperature and Heat
q. E. Fuel, Ignition, Intake and Exhaust
r. Systems Inspection and Service
s. Properties of gases
t. Integration
4. Manual Drive Manual a. Clutch Diagnosis and Repair
Train Transmission , Drive b. Frictional torque transmitted by clutches
Maintenance, Train and Axles c. Transmission Diagnosis and Repair
Service And d. Transaxle (Transfer Gear box) Gear box Diagnosis and Repair
Repair Mechanic e. Drive Shaft/Half-Shaft and Universal
f. Joint/Constant Velocity (CV) Joint
g. Diagnosis and Repair (Front and Rear
h. Wheel Drive)
i. Drive Axle Diagnosis and Repair
j. Ring and Pinion Gears
k. Differential Case/Carrier Assembly
l. Limited Slip/Locking Differential
m. Axle Shafts and Housing
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n. Four-Wheel Drive/All-Wheel Drive
o. Component Diagnosis and Repair
p. Ratios, proportions and percentages in gear mesh analysis
q. Gearbox ratio, Rear Axle ratio, Overall gear ratio and
Efficiency of the drive train
r. Involute Gear construction
5. Automatic Automatic a. General Transmission/Transaxle Diagnosis
Transmission and Transmission and b. Mechanical/Hydraulic Systems
Transaxle Trans-Axle c. Electronic Systems
Maintenance, d. In-Vehicle Transmission/Transaxle
Service and e. Maintenance and Repair
Repair Mechanic f. Off-Vehicle Transmission/Transaxle Repair
g. Removal and Installation
h. Disassembly and Assembly
i. Friction and Reaction Units
j. Using Assembly drawings to dismantle and assemble
Transmission and its components
6. Suspension and Suspension and a) Steering Systems Diagnosis and Repair
Steering Steering b) Forces on vehicles
Maintenance, c) Steering system calculations
Service and d) Steering angles
Repair Mechanic e) Suspension Systems Diagnosis and Repair
f) Application of Simple Harmonic Motion in the Suspension
system analysis
7. Brakes Service 1. Brakes System a) Hydraulic, Power Assist, and Parking

and Repair b) Brake Systems Diagnosis and Repair
Mechanic c) Inspection of retardation/ braking force
d) Drum Brake Diagnosis and Repair
e) Friction
f) Disc Brake Diagnosis and Repair
g) E. Electronic Brake Control Systems: Antilock
h) Brake System (ABS), Traction Control
i) System (TCS), and Electronic Stability
j) Control System (ESC) Diagnosis and Repair
k) Service Air Brakes
l) Pneumatic braking system inspection
m) Service Auxiliary Brakes (The auxiliary braking systems that
improve the safety on the road and provides savings on the
service brakes)
8. Wheels & Tyres Wheels and tyres a) Wheel Alignment Diagnosis, Adjustment, and Repair
Service And b) Wheel and Tyre Diagnosis and service
Alignment c) Specifications and recommendations for tyres
Maintenance
Mechanic
9. Auto Electrical Auto Electrical / a) General Electrical/Electronic System diagnosis
Mechanic Electronic Systems b) Battery and Starting System diagnosis and repair
c) Charging System diagnosis and repair
d) Lighting Systems diagnosis and repair
e) Instrument Cluster and Driver Information Systems diagnosis
and repair
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f) Body Electrical Systems diagnosis and repair
10. Automotive Air Vehicle Interior a) Heating, Ventilation, A/C (HVAC) and
Conditioning Heating And Air b) Engine Cooling System Service, diagnosis, and repair
Maintenance, Conditioning c) Refrigeration System Component diagnosis and repair
Service and d) Operating Systems and related controls diagnosis and repair
Repair Mechanic
11. Engine Diagnosis Automotive Engine a) Engine General Diagnosis
Mechanic Diagnosis b) Ignition System diagnosis and repair
c) Fuel, Air Induction and Exhaust Systems
d) diagnosis and repair
e) Emission Control Systems Diagnosis and repair
f) Positive Crankcase Ventilation
g) Exhaust Gas Recirculation
h) Secondary Air Injection (AIR) and
i) Catalytic Converter
j) Evaporative Emissions Controls
k) Computerized Engine Controls Diagnosis and Repair
12. Light Vehicle Light Vehicle Diesel a) General Diagnosis
Diesel Engines Engines b) Cylinder Head and Valve Train
Service and c) Engine Block Diagnosis and Repair
Repair Mechanic d) Lubrication and Cooling Systems
e) Diagnosis and Repair
f) Air Induction and Exhaust Systems
g) Diagnosis and Repair
h) Fuel System Diagnosis and Repair
13. Vehicle Body Vehicle Body Repair a) Preparation
Repair and Spray and Spray b) Outer Body Panel Repairs, Replacements, and Adjustments
Mechanic c) Metal Finishing and Body Filling
d) Glass and Hardware
e) Welding, Cutting, and Removal
f) Plastic Repair
g) Surface Preparation
h) Spray Gun Operation and Related Equipment
i) Paint Mixing, Matching, and Applying
j) Solving Paint application problems during the application
process
k) Finish Defects, Causes, and Cures
14. Diesel Fuel Diesel Fuel Injection a) Prepare to diagnose and repair diesel fuel injection system
Injection Systems Systems b) Diagnose diesel fuel injection system
Repair Mechanic c) Fuel System Diagnosis and Repair
d) Complete work processes
Other Support Modules

1. Trade Calculations
2. Communication and computer skills
3. Entrepreneurship skills
4. Kiswahili
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MODULE DETAILS
Module 1: OCCUPATIONAL HEALTH AND SAFETY AWARENESS
Total contact hours: 34
Training Outcome: By the end of this module, the Trainee should be able to ensure health and safety
in the workshop and beyond work zones.
SUB-MODULES DUTIES/ TASKS COMPETENCES
a) The need for Health and a) Organisation and layout a) Observes Workshop regulations, precautions
safety of and hazards in the work processes;
b) Safety Responsibilities workshops/Automobile b) Proper illumination maintained in the w/shop
c) Application of HSE garages during operations
d) Employee involvement b) Properly handle c) Proper ways of lifting of heavy loads in the
e) Hazards Identification hazardous fluids(e.g. workshop
and Control acid, A/c gases, radiator d) Proper securing of ladders, jacks, vehicle
f) Safety beyond work high temperature water, stands etc.
zones brake fluid, oils, powders e) First aid in the workshop, factories and at sites.
g) Accidents Prevention among others) f) observes Work ethics and integrity
and investigation c) Deal with hazards and g) ensures Self-consciousness at work and
incidents like fire, electric beyond work zones observed during
shocks, fumes and gases operations
d) Proper usage of workshop h) engages in Team work for complex/multiple
tools. i.e. using tools for workshop tasks
tasks they are designed i) cleans, organizes the workshop and ensures
for.(for instance pressure path ways are open as a means of escape
gauges, Multimeter, route in case of accidents.
manual/hand tools and j) maintains personal Safety and hygiene at
machines) work, in everyday decisions and beyond
e) Use fire extinguishers and work zones.
other fire fighters a) Proper use tyre inflation cages
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Module 2: AUTOMOTIVE FITTING AND FABRICATION
Training Outcome: By the end of this module, the Trainee should be able to fit and fabricate
automotive component attachments
SUB-MODULE DUTIES/TASKS COMPETENCE
Measuring and marking a) Take measurement in various a) Read, convert and interpret
out units measurements of various units.
b) Test for accuracy and proper b) Selects and uses recommended
fitting/ mating of part as required. measuring tools to takes required
c) Mark-out parts during c) Understands various standard
disassembly, measuring measurement units and coverts units
correctly
d) Selects and uses recommended
marking-out tools for marking out.
e) Takes measurements
Fitting and holding tools a) Selection fitting and holding a) Identifies fitting and holding tools and
tools for specific purposes selects them according their use during
b) Proper use of various fitting and repair and fabrication.
holding tools to accomplish b) Interprets working drawings.
specific tasks c) Performs structural repair on vehicles
c) Care for fitting and holding tools d) Fabricates simple vehicle components.
e) Observes OSHE while using fitting and
holding tools.
Heat Treatment of metals Tempering, Hardening, Normalising, The leaner heat treats metallic components
Surface hardening and Annealing of the vehicle according to the required
metals application
Joining Materials and 1. Temporary Joining of 1. Uses the rivet gun the correctly to Joins
Forging materials parts firmly.
a) Riveting 2. Fastens parts together with a bolt and
b) Rebating nut.
c) Joining parts with bolts and nuts 3. Applies adhesive correctly to join parts.
d) Adhesive bonding 4. Is able to lock and unlock parts with
e) Use of locking devices various locking devices
f) Health, safety 5. Selects and applies suitable welding
methods and techniques to join parts.
2. Permanent Joining of 6. Aligns and fits parts
materials 7. Applies the various forging methods
(Welding, Electric arc welding, gas and technique to shape metals
welding, soldering and brazing) 8. Adjust welding current to requirements
a) Identify the suitable 9. Set gas flame at gas torch to
soldering/welding method for a requirements
specific joint. 10. Use of applicable welding technique for
b) Prepare part for welding in a given joint
accordance with joint 11. Self-health, safety and care of welding,
specification soldering and brazing equipment.
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c) Select suitable welding
material/filler rod and flux for a
specific joint
d) Joins materials with soldering,
brazing, gas and electric
welding.
e) Service, and replace exhaust
manifold, exhaust pipes, oxygen
sensors, air/fuel ratio sensors,
mufflers, catalytic converters,
resonators, tailpipes, and heat
shields.
f) Test for exhaust system
restriction or leaks; determine
needed action.
g) Inspect, test, clean and repair or
replace turbocharger or
supercharger and system
components.
h) Repair and weld exhaust pipe
gas leakages
Self-health, safety and care of forging
3. Forging equipment.
a) Perform cold forging
b) Selects suitable forging tools for
a particular forging task.
c) Lighting the hearth
d) Perform hot forging at a
recommended temperature to
shape metals.
e)
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Module 3: ENGINE AND ITS SYSTEMS MAINTENANCE, SERVICE AND REPAIR
Training Outcome: By the end of the module the trainee should be able to maintain, service
and repair an engine and its systems
General Engine a) Verify customer concern and/or road test a) describes the basic construction and
Diagnosis vehicle; determine needed action. principle of operation of 2 stroke
b) Determine if no-cranking, cranks but will cycle and 4stroke cycle Internal
not start, or hard starting condition is an Combustion (IC) engine.
engine mechanical problem, or is caused b) inspects engine components for
by another vehicle subsystem. damage/distortion and takes
c) Inspect engine assembly for fuel, oil, necessary action
coolant and other leaks; determine needed c) dismantles/ disassembles and
action. reassemble engine components in a
d) Isolate engine noises and vibrations; recommended sequential procedure
determine needed action. d) diagnose engine faults such as loss of
e) Perform engine manifold vacuum or power, wear, noise, leaks from oil,
pressure tests; determine needed action. coolant and fuel and determine the
f) Perform cylinder power balance tests; necessary action for repair
determine needed action. e) carries out routine engine
g) Perform cylinder compression tests; maintenance/service
determine needed action. f) Diagnose the cause of excessive oil
h) Perform cylinder leakage/leak-down tests; consumption, coolant consumption,
determine needed action. unusual engine exhaust color and
i) Research system operation using technical odor; determine needed action.
information to determine service
procedures and specifications.
Cylinder Head a) Remove cylinder heads, disassemble, a) dismantles the cylinder head and
and Valve Train clean, and prepare for inspection. inspects it for any damages
Diagnosis and b) Visually inspect cylinder heads for cracks, b) tests and inspects cylinder head
Repair warpage, corrosion, leakage, and the components for wear.
condition of passages; determine needed c) services cylinder head and its
repairs. components
c) Inspect and repair damaged threads where d) performs valve adjustment and
allowed; install core and gallery plugs. timing according to manufacturer’s
d) Inspect, test, and verify valve springs for specification
squareness, pressure, and free height
comparison; replace as needed.
e) Inspect valve spring retainers, rotators,
valve locks, and valve lock grooves.
f) Replace valve stem seals.
g) Inspect valve guides for wear; check valve
stem-to-guide clearance; determine needed
repairs.
h) Inspect valves and valve seats; determine
needed repairs.
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i) Check valve spring installed (assembled)
height and valve stem height; determine
needed repairs.
j) Inspect pushrods, rocker arms, rocker arm
pivots, and rocker arm shafts for wear,
bending, cracks, looseness, and blocked oil
passages; repair or replace as required.
k) Inspect hydraulic or mechanical lifters/lash
adjusters; replace as needed.
l) Adjust valves on engines with mechanical
or hydraulic lifters.
m) Inspect camshaft drive gear train
components (includes gear, chain and belt
systems); repair or replace as needed.
n) Inspect and measure camshaft journals and
lobes; measure camshaft lift; determine
needed repairs.
o) Inspect and measure camshaft bore for
wear, damage, out-of-round, and
alignment; determine needed repairs.
p) Inspect valve timing; time camshaft(s) to
crankshaft.
q) Inspect cylinder head mating surface
condition and finish, reassemble and install
gasket(s) and cylinder head(s);
replace/torque bolts according to
manufacturers’ procedures.
r) Inspect overhead camshaft variable valve
timing components; repair or replace as
needed.
s) Inspect variable valve lift components;
repair or replace as needed.
Wedge tools and a) Identifying the classes of levers in relation a) Differentiates between the classes of
setting Torque to engine dismantling tools belong levers
application (spanners, hammers, screw drivers among b) Computes and sets various torques
others) on a torque wrench
b) Computes the torque applied to a spanner
to loosen or tighten a cylinder head bolt or
nut given the length of a spanner
c) Setting various torques on a torque wrench
a) Construct the displacement diagram and a) construct the different forms of cams
The Cam cam profile of a cam with flat follower for and cam profiles
one complete revolution of the cam b) inspects the cam for any
b) Inspecting valve opening and closure (proper irregularities or wear by observing
seating and sealing) its profile
Engine Block a) Remove and disassemble engine block; a) dismantles the engine block
Diagnosis and clean, identify selective parts, mark b) inspects entire engine block for wear
Repair location and orientation, and prepare and measures ovality and tapper of
components for inspection and reassembly. bores and engine blocks flatness
b) Visually inspect engine block for cracks, c) measures and inspects journal
corrosion, the condition of passages, core bearings for wear.
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and gallery plug hole condition, surface d) grind and reface engine block as
warpage, and surface finish and condition; specified by manufacturer
inspect piston oil cooling nozzle/jets for
damage, proper alignment and restrictions;
determine needed action.
c) Inspect and repair damaged threads where
allowed; install core and gallery plugs.
d) Clean and inspect cylinder walls; measure
cylinder bore; determine needed action.
e) Inspect crankshaft for endplay, journal
damage, keyway damage, visual surface
cracks, thrust flange and sealing surface
condition; check oil passage condition;
measure journal wear; check crankshaft
reluctor ring/tone wheel (where
applicable); determine needed action.
f) Inspect main bearing wear patterns; inspect
and measure main bearing bores and cap
alignment; mark caps for location and
direction; clean and inspect crankshaft
girdle (bed plate/ladder) where applicable.
g) Install main bearings and crankshaft; check
bearing clearances and endplay; inspect,
replace and torque bolts according to
manufacturer's procedures.
h) Inspect camshaft bearings for excessive
wear and alignment; replace bearings if
necessary; install camshaft, timing chain
and gears; check endplay.
i) Inspect auxiliary (balance, intermediate,
idler, counterbalance or silencer) shaft(s),
drive(s)/gear(s), chain(s), and support
bearings for damage and wear; time
balance shaft to crankshaft; determine
needed action.
j) Inspect, measure, service or replace pistons
and piston/wrist pins; identify piston and
bearing wear patterns caused by
connecting rod alignment concerns;
k) Inspect connecting rods and bearings for
damage, bore condition, and pin fit; mark
caps for location and direction; determine
needed action.
l) Inspect, measure, and install or replace
piston rings; assemble piston and
connecting rod; install piston/rod
assembly; check bearing clearance and
side-play; install connecting rod bearings;
inspect, replace and torque fasteners
according to manufacturer's procedures.
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m) Inspect, reinstall or replace crankshaft
vibration damper/harmonic balancer.
n) Inspect crankshaft flange and flywheel
mating surfaces; inspect and replace
crankshaft pilot bearing/bushing (if
applicable); inspect flywheel/flex-plate and
flywheel ring gear for cracks and wear
(includes dual-mass flywheel); measure
flywheel run-out; determine needed action.
o) Inspect and replace pans and covers.
p) Assemble the engine using gaskets, seals,
formed-in-place (tube-applied) sealants,
and thread sealers according to
manufacturers’ specifications; reinstall
engine; prime lubrication system as
needed.
q) Inspect in-block camshaft variable valve
timing components; repair or replace as
needed.
r) Inspect cylinder deactivation system;
Determination a) Measure the cylinder bore and stroke measures cylinder bore and stroke and
of Engine b) Compute the clearance and swept volume uses these to compute engine capacity
capacity for each cylinder and compression ratio for a given engine
c) Compute the engine capacity
Conversion of a) Metric conversion of SI Units performs elementary conversion and
basic units b) Fractions( L.C.M and H.C.M) and manipulation of SI units
decimals
Mensuration Calculation of area, perimeter, volume and determines engine capacity
total surface area
Inspecting a) Compute the force applied on the piston a) determines the force applied to the
Engine during the power/ expansion stroke for a piston during the power stoke
revolutions given gas pressure b) determines the engine rpm
(speed) b) Hence compute the force exerted by the
connecting rod to rotate the crankshaft
c) Compute the speed of the crankshaft which
is the engine speed.
Inspecting a) Measure the ovality and taper of the
cylinder bore cylinder
wear b) Determine the piston and ring size to fit the
rebored cylinder
c) Rebore the cylinder to the available
standard piston size.
Determining a) Applying the principles of loci construct a) Constructs the crank slider
TDC and BDC the loci of a point on a connecting rod of a mechanism and determines the
for an internal trunk slider(piston) mechanism on length of the stroke
Combustion complete rev of the crank shaft b) Determines the strokes made by the
engine b) Determine the top dead and bottom dead piston per crankshaft revolution.
centres
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c) Measure the stroke of the piston/slider for
one complete rev of the crank shaft
Orthographic a) Draw to a given scale the engine
and isometric component in: a) Constructs the isometric, oblique
projection i. Isometric projection. and orthographic projection of
ii. Oblique projection engine parts
b) Draw in the engine components in: b) Interprets working/ production
i. First angle orthographic projection drawings
ii. Third angle orthographic projection
Using Assembly a) Interpret the drawings by the manufacturer relates and assembles engine parts as
drawings to b) Relate and assemble or dismantle parts as specified by manufacturer’s production
dismantle and instructed by the manufacturers Assembly drawings
assemble engine drawing.
and its
components
Cooling and a) Diagnose engine lubrication system The Trainee:
lubrication problems; perform oil pressure tests; 1.describes the constructional details of
Systems perform engine oil dye test; determine the air and water cooling system
Diagnosis and needed action. 2.identifies the causes of engine
Repair b) Disassemble and inspect oil pump overcooling and performs the
(includes gears, rotors, housing, pick-up necessary action
assembly and variable displacement 3.replaces the water pump tensions fan
components); measure oil pump clearance; belts, flushes/cleans the radiator
inspect pressure relief devices, control 4.repairs the radiator leaks provides
systems, and pump drive (includes preventive maintenance to the cooling
belt/chain drive); determine needed action. system
c) Inspect, flush, and test internal and
external engine oil coolers; determine
needed action.
d) Change engine oil and filter(s) using
proper type, viscosity, and rating per
manufacturer's specifications.
e) Perform cooling system pressure tests;
perform coolant dye test; determine needed
action.
f) Inspect and test radiator, heater core,
pressure cap, and coolant recovery system;
replace as required.
g) Inspect, reinstall or replace, and adjust
drive belt(s), tensioner(s), and pulleys.
h) Inspect and replace engine cooling system
and heater system hoses, pipes, fittings and
valves.
i) Inspect, test, reinstall or replace
thermostat, coolant by-pass, and thermostat
housing (including electronically
controlled thermostats).
j) Inspect and replace water pump(s)
(including electrical water pumps).
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k) Inspect and test coolant; drain, flush, and
refill cooling system with recommended
coolant; bleed air as required.
l) Inspect and test fan (both electrical and
mechanical), fan clutch, fan shroud, air
dams, and cooling fan electrical circuits;
repair or replace as required.
m) Verify proper operation of engine related
warning indicators.
Viscosity of a) Explain the properties of lubricating oil a) checks viscosity of engine oil and
lubrication oil b) Check the viscosity of used oil in the takes action as required
(both use and engine prior to change b) Selects correct lubrication oil in
new oil) c) For new engine oil read and interprete the accordance to manufacturer’s
S.A.E number before using it for engine specification
service.
d) Compare with the manufacturer’s
recommended oil viscosity before use
a) Explain the process by which heat
Temperature flows through liquids, solids and gases. inspects the engine temperature and
and Heat b) Describe the changes of state that occur takes necessary action
in an engine cooling system.
c) Explain the ways by which heat is
dissipation from an engine cooling
system
d) Inspect and write down the temperature
at which a thermostat opens and closes
e) Compute the amount of heat dissipated
to the cooling water at the
commencement of circulation
Fuel, Ignition, a) Inspect, clean or replace fuel injection a) describes the constructional details
Intake and system components (including gasoline of the air and water cooling system
Exhaust direct injection/GDI), intake manifold, and b) identifies the causes of engine
Systems gaskets. overcooling and performs the
Inspection and b) Inspect, service or replace air filters, filter necessary action
Service housings, and intake ductwork. c) replaces the water pump
c) Inspect turbocharger/supercharger systems; d) Tensions fan belts
determine needed action. e) flushes/cleans the radiator
d) Test engine cranking system; determine f) repairs the radiator leaks
needed repairs. g) provides preventive maintenance to
e) Inspect and test positive crankcase the cooling system
ventilation (PCV) system components;
replace as
f) Locate and inspect Exhaust manifolds,
Gaskets, Brackets, Clamps, Hangers &
Flanges, Heat Shields & Insulators
g) Exhaust pipes & tubing, Catalytic
converter, Oxygen sensors,
Mufflers/silencer, Exhaust pipe,
connection joints, exhaust mountings and
hanger brackets
h) Diagonise faults of:
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i) excessive loud noises while driving
ii) engine misfires
iii) gasoline odors
iv) decrease in acceleration or power
v) decrease in fuel efficiency
vi) vibrations
Properties of a) Absolute temperature and pressure a) applies the science of properties of

gases b) Apply Boyle’s and Charles’ law during gases to engine cycles
compression and expansion (power) b) draws the P-V graphs for the internal
strokes. combustion engine for both CI and
c) Determine Compression ratio of engine SI
d) Determine Specific heat of gases during
combustion
e) Describe Adiabatic and isothermal
expansion and compression in engine cycles
Integration Determine the work done which is the area determine the horse power of a given
under the P-V graph engine
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Module 4: MANUAL TRANSMISSION, DRIVE TRAIN AND AXLES
and repair Automotive - Manual Transmission, Drive Train and Axles.
SUB-MODULE DUTIES/TASKS COMPETENCES
Clutch Diagnosis a) Diagnose clutch noise, binding, slippage, a) identifies the various types of
and Repair pulsation, chatter, pedal feel/effort, and manual transmission system
release problems; determine needed b) tests the manual transmission
repairs. system for normal operation
b) Inspect, adjust, and replace clutch pedal and recommends accordingly
linkage, brackets, bushings, pivots, c) diagnoses the manual
springs, and electrical switches. transmission system faults and
c) Inspect, adjust, replace, and bleed takes decisions.
hydraulic clutch slave/release cylinder, d) maintains and repairs the
master cylinder, lines, and hoses; clean manual transmission system as
and flush hydraulic system; refill with required.
proper fluid. e) assembles and aligns manual
d) Inspect, adjust, and replace release transmission parts as specified
(throw-out) bearing, bearing retainer, by the manufacturer
lever, and pivot. f) ensures health, safety and
e) Inspect and replace clutch disc and security when working on
pressure plate assembly; inspect input manual transmission systems.
shaft pilot and splines.
f) Inspect pilot bearing/bushing inner and
outer bores; inspect and replace pilot
bearing/bushing.
g) Inspect and measure flywheel and ring
gear; inspect dual-mass flywheel where
required; repair or replace as necessary.
h) Inspect engine block, clutch (bell)
housing, transmission case mating
surfaces, and alignment dowels; inspect
engine core plugs, rear main engine seal,
and other sources of fluid contamination;
determine needed repairs.
i) Measure flywheel surface run-out and
crankshaft end play; determine needed
repairs.
j) Inspect, replace, and align powertrain
mounts.
Frictional torque a) Count the number of springs and measure
transmitted by the force that can be transmitted by each
clutches b) Count the number of frictional faces
c) Measure the mean radius of clutch plate(s)
from the centre.
d) Compute the torque transmitted by the
clutch
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Transmission a) Diagnose transmission noise, difficult
Diagnosis and shifting, gear clash, jumping out of gear,
Repair fluid condition and type, and fluid leakage
problems; determine needed repairs.
b) Inspect, adjust, lubricate and replace
transmission external shift assemblies,
linkages, brackets, bushings/grommets,
cables, pivots, and levers.
c) Inspect and replace transmission gaskets,
sealants, seals, and fasteners; inspect
sealing surfaces.
d) Remove and replace transmission; inspect
transmission mounts.
e) Disassemble and clean transmission
components; reassemble transmission.
f) Inspect, repair, and/or replace
transmission shift cover and internal shift
forks, bushings, bearings, levers, shafts,
sleeves, detent mechanisms, interlocks,
and springs.
g) Inspect and replace input (clutch) shaft,
bearings, and retainers.
h) Inspect and replace output (main) shaft,
gears, thrust washers, bearings, and
retainers/ snap rings; measure clearance
and end play.
i) Inspect and replace synchronizer hub,
sleeve, keys (inserts), springs, and
blocking (synchronizing)
rings/mechanisms; measure blocking ring
clearance.
j) Inspect and replace countershaft, counter
(cluster) gear, bearings, thrust washers,
and retainers/snap rings.
k) Inspect and replace reverse idler gear,
shaft, bearings/bushings, thrust washers,
l) Measure and adjust bearing preload or end
play (shim/spacer selection procedure).
m) Inspect, repair, and replace extension
housing and transmission case mating
surfaces, bores, dowels, bushings, and
vents.
n) Inspect and replace transmission
components related to speedometer
operation.
o) Inspect, test, and replace transmission
sensors, actuators, and switches.
p) Inspect lubrication systems.
q) Check fluid level; refill with
recommended fluid.
Page 17 of 63
Transaxle (Transfer a) Diagnose transaxle noise, difficult
Gear box) Gear shifting, gear clash, jumping out of gear,
box Diagnosis and fluid condition and type, and fluid leakage
Repair problems; determine needed repairs.
b) Inspect, adjust, lubricate and replace
transaxle external shift assemblies,
linkages, brackets, bushings/grommets,
cables, pivots, and levers.
c) Inspect and replace transaxle gaskets,
sealants, seals, and fasteners; inspect
sealing surfaces.
d) Remove and replace transaxle; inspect,
replace, and align transaxle mounts and
e) Sub-frame/cradle assembly
f) Disassemble and clean transaxle
components; reassemble transaxle.
g) Inspect, repair, and/or replace transaxle
shift cover and internal shift forks, levers,
bushings, shafts, sleeves, detent
mechanisms, interlocks, and springs.
h) Inspect and replace input (clutch) shaft
and output (main) shaft, gears, thrust
washers, bearings, and retainers/snap
rings
i) Inspect and replace synchronizer hub,
sleeve, keys (inserts), springs, and
blocking (synchronizing) rings; measure
blocking ring clearance.
j) Inspect and replace reverse idler gear,
shaft, bearings/bushings, thrust washers,
k) Inspect, repair, and/or replace transaxle
case mating surfaces, bores, dowels,
bushings, bearings, and vents.
l) Inspect and replace transaxle components
related to speedometer operation.
m) Inspect, test, and replace transaxle
sensors, actuators, and switches.
n) Diagnose differential assembly noise and
wear; determine needed repairs.
o) Remove and replace differential final
drive assembly.
p) Inspect, measure, adjust and replace
differential pinion (spider) gears, shaft,
side gears, thrust washers, side bearings,
and case/carrier.
q) Diagnose limited slip differential noise,
slippage, and chatter problems; determine
needed repairs.
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r) Measure and adjust shaft and differential
bearing preload and end play (shim/spacer
selection procedure)
s) Inspect lubrication systems
t) Check fluid level; refill with proper fluid
Drive Shaft/Half- a) Diagnose drive/half shaft and
Shaft and universal/CV joint noise and vibration
Universal Joint/ problems; determine needed repairs.
Constant Velocity b) Inspect, service, and replace shafts, yokes,
(CV) Joint boots, and universal/CV joints; verify
Diagnosis and proper phasing.
Repair (Front and c) Inspect, service, and replace center
Rear Wheel Drive) support and intermediate shaft bearings.
d) Check and correct drive/propeller shaft
balance.
e) Measure drive shaft run-out.
f) Measure and adjust drive shaft working
angles.
g) Diagnose, inspect, service, and replace
wheel bearings, seals, and hubs.
Drive Axle
Diagnosis and 1. Ring and Pinion Gears
Repair
a) Diagnose noise, vibration, and fluid
leakage problems; determine needed
repairs.
b) Inspect and replace companion flange,
yoke, and pinion seal; measure companion
flange run-out.
c) Measure ring gear run-out; determine
needed repairs.
d) Inspect and replace ring and pinion gear
set, collapsible spacers/sleeves, shims, and
bearings.
e) Measure and adjust drive pinion depth.
f) Measure and adjust drive pinion bearing
preload (collapsible spacer sleeve or shim
type).
g) Measure and adjust differential (side)
bearing preload, and ring and pinion
backlash (threaded adjuster or shim type).
h) Perform ring and pinion tooth contact
pattern checks; determine needed
adjustments.
2. Differential Case/Carrier Assembly
a) Diagnose differential assembly noise and

vibration problems; determine needed
repairs.
b) Remove and replace differential assembly.
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c) Inspect, measure, adjust and replace
differential pinion (spider) gears, shaft,
side gears, thrust washers, side bearings,
and case/carrier.
d) Measure differential case/carrier run-out;
3. Limited Slip/Locking Differential
a) Diagnose limited slip differential noise,

slippage, and chatter problems; determine
needed repairs.
b) Inspect, drain, and refill with proper
lubricant.
c) Inspect, adjust, repair or replace limited
slip or locking assembly components.
4. Axle Shafts and Housing
a) Diagnose rear axle shaft noise, vibration,

and fluid leakage problems; determine
needed repairs.
b) Inspect and replace rear axle shaft wheel
studs.
c) Remove, inspect, adjust, and/or replace
rear axle shafts, splines, seals, bearings,
and retainers.
d) Measure rear axle flange run-out and shaft
end play; determine needed repairs.
e) Inspect axle housing and vent.
Four-Wheel Drive
/Full-Wheel Drive a) Diagnose drive assembly noise, vibration,
Component leakage and steering problems; determine
Diagnosis and needed repairs.
Repair b) Inspect, adjust, and repair transfer case
manual shifting mechanisms, bushings,
mounts, levers, and brackets.
c) Remove and replace transfer case.
d) Disassemble transfer case; clean and
inspect internal transfer case components;
e) Reassemble transfer case.
f) Check transfer case fluid level; drain and
refill with proper fluid.
g) Inspect, service, and replace
drive/propeller shaft and universal/CV
joints.
h) Inspect, service, and replace drive axle
universal/CV joints and drive/half-shafts.
i) Inspect, service, and replace wheel
bearings, seals, and hubs.
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j) Check transfer case and axle seals and all
vents.
k) Diagnose drive system actuation and
engagement concerns; repair or replace
components as necessary (including:
viscous, hydraulic, magnetic, mechanical,
vacuum, and electrical/electronic).
l) Inspect tyres for condition and matching
circumference; verify proper size for
vehicle application.
Ratios, proportions Compute, Simplify ratios and calculate determines the gear ratios of
and percentages in percentages simple and compound gears using
gear mesh analysis the knowledge of ratios and
proportions.
Gearbox ratio, Rear Perform the necessary calculations for gears a) Compute the gearbox ratio for
Axle ratio, Overall in mesh each gear (both forward and
gear ratio and reverse gears)
Efficiency of the b) Compute the rear axle ratio
drive train c) Compute the overall gear ratio
d) Compute the mechanical
advantage and velocity ratio of
the drive
Involute Gear Construct the involute gear. a) Computes gear data from
construction given data
b) applies the various
geometrical techniques to
construct the involute gear.
Module 5: AUTOMATIC TRANSMISSION /TRANS-AXLE

and repair Automotive - Automatic Transmission /Transaxle.
General 1. Mechanical/Hydraulic Systems a) identifies the various types
Transmission of automatic transmission
/Transaxle a) Road test the vehicle to verify system
Diagnosis mechanical/hydraulic system problems based on b) identifies the systems and
driver’s concern; research vehicle service history; parts of the automatic
determine necessary action. transmission
b) Diagnose noise, vibration, harshness, and shift c) identifies Automatic
quality problems; determine necessary action. Transmission Fluid (ATF)
c) Diagnose fluid loss, type, level, and condition according to
problems; determine necessary action. manufacturer’s
d) Perform pressure tests; determine necessary specification
action. d) maintains and services the
e) Diagnose torque converter stator/one-way clutch automatic transmission
failure; determine necessary action. system
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f) Perform torque converter clutch (lock-up e) diagnoses automatic
converter) mechanical/hydraulic system tests; transmission system faults
determine necessary action. and take decisions on what
to do.
2. Electronic Systems f) Differentiate between
engine performance, or
a) Road test the vehicle to verify electronic system other vehicle systems, and
problems based on driver’s concern; search transmission/ transaxle
vehicle service history; determine necessary related problems
action. g) dismantles the automatic
b) Diagnose pressure concerns on transmissions transmission system.
equipped with electronic pressure control; h) maintains and repairs the
determine necessary action. automatic transmission
c) Perform torque converter clutch (lock up system as required.
converter) electronic system tests; determine i) assembles the automatic
necessary action. transmission system parts
d) Diagnose electronic transmission control systems correctly ensures health,
using appropriate test equipment, service safety and security.
information, technical service bulletins, and j) performs a stall test on the
schematics; diagnose problems in transmission system
electrical/electronic circuits (including data
communications); determine necessary action.
e) Verify proper operation of charging system;
check battery, connections, and power/ground
circuits.
f) Differentiate between engine performance, or
other vehicle systems, and transmission/ transaxle
related problems; determine necessary action.
g) Diagnose shift quality concerns resulting from
problems in the electronic transmission control
system; determine necessary action.
In-Vehicle a) Inspect, adjust, and replace manual valve shift
Transmission/Tran linkage and transmission range sensor/ switch
saxle Maintenance (inhibitor/neutral safety switch).
and Repair b) Inspect and replace external seals and gaskets.
c) Inspect and replace driveshaft yoke, drive axle
joints, bushings, and seals.
d) Check condition and operation of engine cooling
system; inspect transmission cooler, lines and
fittings.
e) Inspect valve body mating surfaces, bores, valves,
springs, sleeves, retainers, brackets, check balls,
screens, spacer plates, and gaskets; replace as
necessary.
f) Torque valve body fasteners to specification using
the proper sequence.
g) Inspect accumulator and servo bores, pistons,
seals, pins/pin bores, springs, and retainers; repair
or replace as necessary.
h) Inspect, test, adjust, repair, or replace
electrical/electronic components and circuits
Page 22 of 63
including control modules, solenoids, sensors,
relays, terminals, connectors, switches, and
harnesses; inspect, test, and verify control module
inputs, outputs, and data communications.
i) Inspect, replace, and/or align power train mounts.
j) Replace fluid and filter(s); verify proper fluid
level and type (for transmissions with, or without,
a dipstick).
Off-Vehicle
Transmission/Tran 1. Removal and Installation
saxle Repair
a) Remove and install transmission/transaxle;
inspect engine core plugs, rear crankshaft seal,
transmission dowel pins, dowel pin holes, and
mating surfaces.
b) Inspect converter flex (drive) plate, converter
attaching bolts, converter pilot, crankshaft pilot
bore, converter pump drive surfaces.
c) Install torque converter and establish correct
converter-to-pump engagement; inspect converter
free movement for pilot engagement during
transmission installation.
d) Inspect, test, flush or replace transmission fluid
cooler.
e) Inspect brackets, wiring harnesses, fuel lines, heat
shields, inspection covers, vents, cooler lines, and
related components for proper routing and
installation.
f) Perform module or component coding and/or
programming (including adaptive learning reset);
road test to confirm proper operation.
2. Disassembly and Assembly
a) Disassemble, clean, and inspect transmission

case, sub-assemblies, mating surfaces, and thread
condition.
b) Inspect and measure fluid pump components;
replace as necessary.
c) Check bearing preload; inspect, measure, and
adjust as needed.
d) Check end play; inspect, measure, and adjust as
needed.
e) Inspect shafts; replace as necessary.
f) Inspect fluid delivery circuit, including seal rings,
ring grooves, sealing surface areas, feed pipes,
orifices, and encapsulated check valves (balls).
g) Inspect and/or measure bushings, thrust washers,
and bearings; replace as necessary.
h) Inspect and measure components of the planetary
gear assembly; replace as necessary.
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i) Inspect case bores, passages, bushings, vents,
mating surfaces, and dowel pins; repair or replace
as necessary.
j) Inspect valve body mating surfaces, bores, valves,
solenoids, springs, sleeves, retainers, brackets,
check balls, screens, spacer plates, and gaskets;
replace as necessary.
k) Inspect transmission/transaxle drive chains,
sprockets, belts, pulleys/sheaves, gears, bearings,
and bushings; replace as necessary.
l) Inspect and measure transaxle final drive
components; repair, replace and/or adjust as
necessary.
m) Assemble after repair.
3. Friction and Reaction Units
a) Inspect components of the hydraulic clutch pack

assembly; replace as necessary.
b) Measure clutch pack clearance; adjust as
necessary.
c) Air test the operation of clutch and servo
assemblies.
d) Inspect components of one way clutch
assemblies; replace as necessary.
e) Inspect bands and drums (housings/ cylinders);
replace and/or adjust as necessary.
Using Assembly a) Interpret the drawings given by the manufacturer
drawings to manual.
dismantle and b) Relate and assemble or dismantle parts as
assemble instructed by the manufacturers Assembly
Transmission and drawing.
its components c) Construct a sectional view on a given cutting
plane for the assembly
Page 24 of 63
Module 6: SUSPENSION AND STEERING
and repair Vehicle Steering and Suspension systems

Steering Systems 1. Steering Columns a) adjusts and sets the
Diagnosis and various steering geometry
Repair a) Diagnose steering column noises and angles in relation to
steering effort concerns (including manual Ackermann’s principle as
and electronic tilt and telescoping recommended by the
mechanisms); determine needed action. manufacturer
b) Inspect and replace steering column, b) diagnoses steering and
steering shaft U‑joint(s), flexible suspension systems faults
coupling(s), collapsible columns, and takes necessary
intermediate shafts, and steering wheels decisions.
(including steering wheels and columns c) differentiates between
equipped with airbags and/or other steering steering and suspension
wheel/column mounted controls, sensors, system faults.
and components). d) performs wheel alignment
c) Disable, enable, and properly handle airbag according to the
system components during vehicle service manufacturer’s
following manufacturers’ procedures. specifications.
d) Diagnose, inspect, adjust, repair or replace e) maintains services and
components (including motors, sensors, repairs the steering and
switches, actuators, harnesses, and control suspension system as
units) of steering column-mounted, required.
electronically controlled, hydraulically f) ensures health, safety and
and/or electrically assisted steering security when working on
systems; initialize systems as required. the steering and
suspension system.
2. Steering Units
a) Diagnose steering gear (non‑rack and

pinion type) noises, binding, vibration,
b) Free-play, steering effort, steering pull
(lead), and leakage concerns; determine
needed action.
c) Diagnose rack and pinion steering gear
noises, binding, vibration, free-play,
steering effort, steering pull (lead), and
leakage concerns; determine needed action.
d) Inspect power steering fluid level and
condition; determine fluid type and adjust
fluid level in accordance with vehicle
manufacturers’ recommendations.
Page 25 of 63
e) Inspect, adjust, align, and replace power
steering pump belt(s), tensioners, and
pulleys.
f) Diagnose power steering pump noises,
vibration, and fluid leakage; determine
needed action.
g) Remove and replace power steering pump;
inspect pump mounting and attaching
brackets; remove and replace power
steering pump pulley; transfer related
components.
h) Perform power steering system pressure
and flow tests; determine needed action.
i) Inspect and replace power steering hoses,
fittings, O‑rings, coolers, and filters.
j) Inspect steering gear (non-rack and pinion
type) seals and gaskets; remove and replace
steering gear.
k) Remove and replace rack and pinion
steering gear; inspect mounting services;
inspect and replace mounting bushings and
brackets.
l) Adjust steering gear (non‑rack and pinion
type) worm bearing preload and sector lash.
m) Adjust rack and pinion steering gear.
n) Inspect and replace rack and pinion steering
gear bellows/boots.
o) Flush, fill, and bleed power steering
system.
p) Diagnose, inspect, repair or replace
components of variable‑assist and/or
variable ratio steering systems.
q) Diagnose, inspect, adjust, repair or replace
components (including motors, sensors,
switches, actuators, harnesses, and control
units) of rack-mounted, electronically
controlled, hydraulically and/or electrically
assisted steering systems; initialize systems
as required.
3. Steering Linkage
a) Inspect and adjust (where applicable) front

and rear steering linkage geometry.
b) Inspect and replace pitman arm.
c) Inspect and replace center link (relay
rod/drag link/intermediate rod).
d) Inspect, adjust (where applicable), and
replace idler arm and mountings.
e) Inspect, replace, and adjust tie rods, tie rod
sleeves/adjusters, clamps, and tie rod ends.
Page 26 of 63
f) Inspect and replace steering linkage
damper(s).
Forces on vehicles a) Determine the maximum velocity during analyses overturning and
cornering. skidding speeds for a given
b) Determine overturning and skidding speeds track radius and vehicle
for a given steering radius. dimesions.
Steering system a) Measure the diameter of the steering wheel
calculations b) Count the number of turns of a steering
wheel used to move a drop from lock to
lock.
c) Compute the steering box gear ratio.
d) Compute the torque applied to the steering
wheel for a given effort/force by the driver
e) Compute the efficiency of the steering
system.
f) Hence suggest ways of reducing the
driver’s effort on the steering wheel using
the above analyses.
Steering angles Compute the cornering angles for a given computes the cornering
vehicle steering geometry angles for a given
Ackermann’s layout
Suspension Systems 1. Front Suspensions
Diagnosis and
Repair a) Diagnose front suspension system noises,
handling, ride height and ride quality
concerns; determine needed action.
b) Inspect and replace upper and lower control
arms, bushings, hardware, and shafts.
c) Inspect and replace rebound and jounce
bumpers/bump stops.
d) Inspect, adjust, and replace track bar, strut
rods/radius arms, and related mounts/
bushings.
e) Inspect and replace upper and lower ball
joints.
f) Inspect solid front axle assembly for
damage and misalignment.
g) Inspect and replace front steering
knuckle/spindle assemblies and steering
arms.
h) Inspect and replace front suspension system
coil springs and spring insulators
(silencers).
i) Inspect and replace front strut(s), strut
bearing(s) and strut mount(s).
j) Inspect, replace, and adjust front
suspension system torsion bars and mounts.
k) Inspect and replace front stabilizer bar
(sway bar), bushings, brackets, and links.
l) Inspect and replace shock absorbers,
mounts, and bushings.
Page 27 of 63
m) Diagnose, service and/or replace front
wheel bearings and/or hub assemblies.
n) Diagnose, inspect, adjust, repair or replace
components (including sensors, switches,
actuators, harnesses, and control units) of
electrically/hydraulically/pneumatically
controlled suspension systems (including
primary and supplemental suspension and
ride control systems); initialize as needed.
o) Inspect and repair front sub-
frame/cradle/cross-member mountings,
bushings, brackets, and bolts.
2. Rear Suspensions
a) Diagnose rear suspension system noises,

handling, ride height and ride quality
concerns; determine needed action.
b) Inspect and replace rear suspension system
coil springs and spring insulators
(silencers).
c) Inspect and replace rear suspension system
lateral links/arms (track bars), control
(trailing) arms, stabilizer bars (sway bars),
bushings, and mounts.
d) Inspect and replace rear suspension system
leaf spring(s), leaf spring insulators
(silencers), shackles, brackets, bushings,
center pins/bolts, U-bolts, and mounts.
e) Inspect and replace rear rebound and jounce
bumpers/bump stops.
f) Inspect and replace rear strut and/or upper
strut mount.
g) Inspect non‑independent rear axle
assembly for damage and misalignment.
h) Inspect and replace rear ball joints and tie
rod/toe link assemblies.
i) Inspect and replace rear knuckle/spindle
assembly.
j) Inspect and replace shock absorbers,
mounts, and bushings.
k) Diagnose, service, and/or replace rear
wheel bearings and/or hub assemblies.
l) Diagnose, inspect, adjust, repair or replace
components (including sensors, switches,
actuators, harnesses, and control units) of
electrically/hydraulically/pneumatically
controlled suspension systems (including
primary and supplemental suspension and
ride control systems).
Page 28 of 63
m) Inspect and repair rear sub-
frame/cradle/cross-member mountings,
bushings, brackets and bolts.
Application of a) Explain the conditions for a system to
Simple Harmonic execute simple harmonic motion
Motion in the b) Demonstrate how periodic motion is
Suspension system applied to the suspension system.
analysis c) Compute the amplitude of a coil and leaf
spring for a given vehicle weight and
deflection by a hump or road surface
irregularity
d) Explain damped oscillations in the
suspension system as applied to SHM
Module 7: BRAKE SYSTEMS

and repair Vehicle Brake systems.
SUB-MODULES DUTIES /TASKS COMPETENCES
Hydraulic, Power Assist, and 1. Master Cylinder a) inspects and tests brakes
Parking for normal operation and
Brake Systems Diagnosis and a) Diagnose poor stopping, dragging, comes up with necessary
Repair high or low pedal, and hard or spongy decisions
pedal caused by the master cylinder; b) diagonises braking system
determine needed repairs. faults and takes necessary
b) Measure and adjust master cylinder action
pushrod length. c) carries out the necessary
c) Check master cylinder for failures by replacement of faulty
pressing brake pedal; determine components of the braking
needed repairs. system
d) Diagnose the cause of master cylinder d) performs the necessary
external fluid leakage. brake adjustments and
e) Remove and replace master cylinder; bleeding.
bench bleed and install master e) ensures health, safety and
cylinder; verify master cylinder security when working on
function. the braking system.
f) Inspects the brake drum,
2. Lines and Hoses pads, shoes and discs for
wear and takes necessary
a) Diagnose poor stopping, pulling or action.
dragging caused by problems in the
lines and hoses; determine needed
repairs.
b) Inspect brake lines and fittings for
leaks, dents, kinks, rust, cracks or
wear;
c) inspect for loose fittings and supports;
Page 29 of 63
d) Inspect flexible brake hoses for leaks,
kinks, cracks, bulging, wear or
corrosion;
e) inspect for loose fittings and supports;
f) Replace brake lines, hoses, fittings
and supports; fabricate brake lines
using proper material and flaring
procedures (double flare and ISO
types).
g) Inspect brake lines and hoses for
proper routing and support.
3. Valves and Switches
a) Diagnose poor stopping, pulling or

dragging caused by problems in the
hydraulic system valve(s); determine
needed repairs.
b) Inspect, test and replace metering,
proportioning, pressure differential
and combination valves.
c) Inspect, test, replace and adjust load
or height sensing‑type proportioning
valve(s).
d) Inspect, test and replace brake system
warning lights, indicators, switches,
sensors and circuits; test, adjust and
repair or replace brake stop
light/brake pedal position switch
sensor, lamps and related circuits.
4. Bleeding, Flushing and Leak

Testing
a) Diagnose poor stopping, pulling,

dragging or incorrect pedal travel
caused by problems in the brake
fluid; determined needed repairs.
b) Bleed and/or flush hydraulic system
using manual, pressure, vacuum or
gravity method(s).
c) Pressure test brake hydraulic system.
d) Select, handle, store and install proper
brake fluids (including silicone
fluids). Fill master cylinder to proper
level.
5. Power Assist Units
Page 30 of 63
a) Inspect and test brake pedal linkage
for binding, looseness and
adjustment; determine needed repairs.
b) Test pedal free travel with and
without engine running to check
power booster operation.
c) Check vacuum supply (manifold or
auxiliary pump) to vacuum-type
power booster.
d) Diagnose vacuum-type power booster
unit for vacuum leaks and proper
operation; inspect the check valve for
proper operation; repair, adjust or
replace parts as necessary.
e) Diagnose hydro-boost system for
leaks and proper operation; repair or
replace parts as necessary; refill and
bleed system following
manufacturers’ specifications.
f) Diagnose electronic brake
servo/brake simulator system for
proper operation; determine needed
repairs.
6. ► Parking Brake
a) Diagnose parking brake system

operation (including electronic
parking brakes); inspect cables and
parts for wear, rust and corrosion;
clean or replace parts as necessary;
lubricate assembly.
b) Adjust parking brake assembly; check
operation.
c) Test the parking brake indicator light,
switch and wiring.
d) Retract integral and/or electronic
parking brake caliper piston(s)
according to manufacturers’
specifications.
e) Adjust calipers with integrated
parking brakes according to
manufacturers’ recommendations.
Inspection of retardation/ a) Measure the diameter of the wheels checks the braking force and
braking force and master cylinder pistons. adjusts the free-play.
b) Compute the braking force on the
drum or disc for a given driver’s
effort applied on the brake pedal
Drum Brake Diagnosis and a) Diagnose poor stopping, pulling,
Repair dragging or incorrect pedal travel
Page 31 of 63
caused by drum brake hydraulic
b) Diagnose poor stopping, noise,
pulling, grabbing, dragging, pedal
pulsation or incorrect pedal travel
caused by drum brake mechanical
c) Remove, clean, inspect and measure
brake drums; follow manufacturers’
recommendations in determining
need to machine or replace.
d) Machine drums according to
manufacturers’ procedures and
specifications.
e) Using proper safety procedures,
remove, clean and inspect mechanical
brake components, such as:
shoes/linings, springs, pins,
self‑adjusters, levers, clips, brake
backing (support) plates and other
related brake hardware; determine
needed repairs.
f) Lubricate brake shoe support pads on
backing (support) plate, self‑adjuster
mechanisms and other brake
hardware.
g) Inspect wheel cylinder(s) for leakage,
operation and mounting; remove and
replace wheel cylinder(s); bleed
system.
h) Following manufacturers’
specifications, install brake shoes and
related hardware.
i) Pre-adjust brake shoes and parking
brake before installing brake drums or
drum/hub assemblies and wheel
bearings.
j) Reinstall wheel, torque lug nuts, and
make final checks and adjustments.
k) Diagnose wheel bearing noises and
repairs.
l) Remove, clean, inspect, repack wheel
bearings or replace wheel bearings
and races; replace seals; replace hub
and bearing assemblies; adjust
wheel/hub bearings according to
Friction a) Explain the importance of friction in explains the importance of
brakes friction in brakes.
Page 32 of 63
b) Compute the frictional force given the
coefficient of friction between the pad
and disc or drum and shoe lining.
c) Determine the braking efficiency of a
vehicle using its stopping distances
and other parameters.
Disc Brake Diagnosis and a) Diagnose poor stopping, pulling,
Repair dragging or incorrect pedal travel
caused by disc brake hydraulic
b) Diagnose poor stopping, noise,
pulling, grabbing, dragging, pedal
pulsation or incorrect pedal travel
caused by disc brake mechanical
c) Retract brake caliper piston(s)
according to manufacturers’
recommendations.
d) Remove caliper assembly from
mountings; inspect for leaks and
damage to caliper housing.
e) Clean and inspect caliper mountings,
slides/pins and threads for wear and
damage.
f) Remove, clean and inspect pads and
retaining hardware; determine needed
repairs, adjustments and
replacements.
g) Clean caliper assembly; inspect
external parts for wear, rust, scoring
and damage; replace any damaged or
worn parts; determine the need to
repair or replace caliper assembly.
h) Clean, inspect and measure rotor with
a dial indicator and a micrometer;
follow manufacturers’
recommendations in determining the
need to index, machine or replace the
rotor.
i) Remove and replace rotor.
j) Machine rotor, using on-car or off-car
method, according to manufacturers’
procedures and specifications.
k) Install pads, calipers and related
attaching hardware; lubricate
components following manufacturers’
procedures and specifications; bleed
system and inspect for leaks.
l) Reinstall wheel, torque lug nuts, and
make final checks and adjustments.
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m) Road test vehicle and burnish/break-
in pads according to manufacturer’s
recommendations.
n) Diagnose wheel bearing noises and
repairs.
o) Remove, clean, inspect, repack wheel
bearings or replace wheel bearings
and races; replace seals; replace hub
and bearing assemblies; adjust
wheel/hub bearings according to
p) Distinguish between brake
component vibration and tyre/wheel
vibration; determine needed repairs.
Electronic Brake Control a) Follow manufacturers’ service and
Systems: Antilock Brake safety precautions when inspecting,
System (ABS), Traction testing and servicing electronic brake
Control System (TCS), and control system hydraulic, electrical,
Electronic Stability Control and mechanical components.
System (ESC) Diagnosis and b) Diagnose increased stopping distance,
Repair wheel lock-up, false activation, pedal
feel, pedal travel, pedal pulsation and
noise concerns associated with the
electronic brake control system;
c) Observe electronic brake control
system indicator/light(s) at start-up
and during road test; determine if
further diagnosis is needed.
d) Diagnose electronic brake control
system, electronic control(s),
components and circuits (with or
without DTCs) using on-board
diagnosis and/or recommended test
equipment such as: scan tool, digital
multimeter (DMM), digital storage
oscilloscope (DSO); determine
needed repairs.
e) Bleed and/or flush the electronic
brake control hydraulic system
following manufacturers’ procedures.
f) Remove and install electronic brake
control system components following
manufacturers’ procedures and
specifications; perform module set-
up/initialization.
g) Test, diagnose and service electronic
brake control system sensors (speed,
yaw, steering angle, brake pedal
position, etc.) and circuits following
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manufacturers’ recommended
procedures (includes output signal,
resistance, amperage, shorts to
voltage/ground and frequency data.).
h) Diagnose electronic brake control
system braking concerns caused by
vehicle modifications (wheel/tyre
size, curb height, final drive ratio,
etc.) and other vehicle mechanical
and electrical/electronic
modifications (communication,
security, radio, etc.).
i) Repair wiring harness and connectors
following manufacturers’ procedures.
j) Diagnose brake problems resulting
from failures of interrelated systems
(for example: electronic stability
control, antilock brake, traction
control, collision avoidance/
mitigation).
k) Clear diagnostic trouble codes
(DTCs) and verify the repair.
Service Air Brakes a) Carry out service on
i. Compressor:
ii. Reservoirs:
iii. Brake chambers:
iv. Brake shoes and drums or brake
rotors and pads:
v. primary and secondary circuits.
vi. drain out the wet tank.
b) Inspect any rubber boots and seals for
ABS connecters and also inspect for
any signs of wear.
c) Confirm that the push rods and slack
adjusters are properly operating,
because these are essential to
maintaining the adjustment of the
brake shoes in relation to the drum.
d) Inspect the push rod actuation from
the brake chambers, particularly any
broken or weak springs.
e) Inspect the parking brakes for leaks in
each chamber, or damaged
components.
Pneumatic braking system a) Determine the pressure of air in a carries out pressure checks and
inspection reservoir given its specification or by reads pressures gauges in the
a pressure gauge entire pneumatic braking
b) Compute the force applied to an air system
brake actuator and unloader valve.
Service Auxiliary Brakes a) Maintain Auxiliary Brake/ Retarders
i. Hydraulic Retarders
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(The auxiliary braking ii. Exhaust brake/ Retarders
systems that improve the iii. Eddy current Retarders
safety on the road and b) Carry out Inspection checks on
provides savings on the i. Air Clearance
service brakes ii. Axis Seal
iii. Output Shaft Seal
iv. Fastening Bolts
v. electrical appliances wire
connections
c) Check and fastening the ground wire
Module 8: WHEELS AND TYRES

and repair Wheels and Tyres
Wheel Alignment a) Diagnose vehicle wander, drift, pull, a) Inspects vehicle wheels
Diagnosis, Adjustment, hard steering, bump steer, memory and tyres and decides
and Repair steer, torque steer, and steering return action needed
concerns; determine needed action. b) Diagonises tyre
b) Measure vehicle ride height; determine problems and takes
needed action. necessary action
c) Measure front and rear wheel camber; c) Performs the necessary
determine needed action. balancing and alignment
d) Adjust front and/or rear wheel camber of wheels in accordance
on suspension systems with a camber manufacturers’
adjustment. specifications.
e) Measure caster; determine needed d) Comes with documented
action. recommendations for
f) Adjust caster on suspension systems vehicle
with a caster adjustment. owners/customers on
g) Measure and adjust front wheel toe. tyre life
h) Center the steering wheel.
i) Measure toe‑out‑on‑turns (turning
radius/angle); determine needed
action.
j) Measure SAI/KPI (steering axis
inclination/king pin inclination);
k) Measure included angle; determine
needed action.
l) Measure rear wheel toe; determine
needed action.
m) Measure thrust angle; determine
needed action.
n) Measure wheelbase setback/offset;
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o) Check front and/or rear sub-
frame/cradle/cross-member alignment;
p) Perform electronic control module
calibration/recalibration; perform
initialization or relearn procedure as
required.
q) Diagnose wheel alignment problems
caused by damaged component
mounting locations; determine needed
action.
Wheel and Tyre a) Diagnose tyre wear patterns;
Diagnosis and service determine needed action.
b) Inspect tyre condition, size, and
application (load and speed ratings).
c) Measure and adjust tyre air pressure.
d) Diagnose wheel/tyre vibration,
shimmy, and noise concerns;
e) Rotate tyres/wheels and torque
fasteners according to manufacturers’
recommendations.
f) Diagnose problems with radial and
lateral run-out of wheel assembly;
measure wheel, tyre, axle flange, and
hub run-out (radial and lateral);
i) Diagnose tyre pull (lead)
problems; determine needed
action.
ii) Dismount and mount tyre on
wheel.
iii) Balance wheel and tyre assembly.
g) Test and diagnose indirect/direct tyre
pressure monitoring systems (TPMS);
determine needed action; perform
system initialization/relearn as
required.
Specifications and a) Check the all the tyres for pressure
recommendations for balance
tyres b) Set the tyre pressure to the
manufacturer’s recommendation.
c) For a given tyre surface area,
determine the volume of air it can hold
at a specified manufacturer’s pressure.
d) Show that a smaller tyre holds air at a
higher pressure than a bigger one.
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Module 9: AUTO-ELECTRICAL / ELECTRONIC SYSTEMS
and repair Automotive Electrical/Electronic systems.
General a) Check voltages and voltage drops in a) trouble shoots electrical and
Electrical/Electronic electrical/electronic circuits; interpret readings and electronic component in the
System Diagnosis determine needed repairs. automobile. For instance;
b) Check current flow in electrical/electronic fuses, sensors, alternator,
circuits; interpret readings and determine needed battery, switches, flushers,
repairs. relays ignition coils, starter
c) Check continuity and resistances in motor among others
electrical/electronic circuits and components; b) measures current, voltage and
interpret readings and determine needed repairs. resistance in automobile
d) Check electronic circuit waveforms; interpret electronic/ electronic circuits
readings and determine needed repairs. in comparison with
e) Use scan tool data, bidirectional controls, and/or manufacturers specifications
diagnostic trouble codes (DTCs) to diagnose and takes necessary action
electronic systems; interpret readings and c) tests for open, short circuit,
determine necessary action. ground and proper function of
f) Find shorts, grounds, opens, and resistance electrical and electronic
problems in electrical/electronic circuits; components in automobile
determine needed repairs. circuits.
g) Measure and diagnose the cause(s) of abnormal d) interpretes readings and wave
key-off battery drain (parasitic draw); determine form display of various
needed repairs. automotive circuits and
h) Inspect, test, and replace fusible links, circuit systems; comes up with
breakers, fuses, diodes, and current limiting correct decision on
devices. rectification if required
i) Read and interpret electrical schematic diagrams e) tests automobile batteries,
and symbols. maintains and service them as
j) Research applicable vehicle and service required.
information, such as vehicle service history, f) starts vehicle and interpretes
service precautions, technical service bulletins, displays on automobile
and service campaigns/recalls. dashboard for both
k) Diagnose failures in the data bus communications computerised and non-
network; determine needed repairs. computerised automobiles;
l) Remove and replace control modules; program, takes necessary action if
reprogram, code, initialize, and/or configure as required.
needed.
Battery and Starting a) Perform battery state-of-charge test; determine
System needed service.
Diagnosis and Repair b) Perform battery tests (load and capacitance);
determine needed service.
c) 3. Follow manufacturer’s procedure to restore (or
maintain if applicable) electronic memory
functions.
d) Perform battery charge in accordance with
manufacturer’s recommendations.
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e) Inspect, clean, repair and/or replace battery(ies),
battery cables, connectors, clamps, hold-downs,
trays, and vent tubes.
f) Jump-start a vehicle using jumper cables, a
booster battery or auxiliary power supply.
g) Perform starter current draw test; determine
needed repairs.
h) Perform starter circuit voltage drop tests;
i) Inspect, test, repair and/or replace starter, relays,
solenoids, modules, switches, connectors, and
wires of starter circuits.
j) Differentiate between electrical and engine
mechanical problems that cause a slow crank, no-
crank, extended cranking, or a cranking noise
condition.
Charging System a) Diagnose charging system problems that cause a
Diagnosis and Repair no-charge, a low charge, or an overcharge
condition; determine needed repairs.
b) Inspect, reinstall and/or replace pulleys, tensioners
and drive belts; adjust belts and check alignment.
c) Perform charging system voltage output test;
d) Perform charging system current output test;
e) Inspect and test generator (alternator) control
components including sensors,
regulators, and modules; determine needed repairs.
f) Perform charging circuit voltage drop tests;
g) Inspect, test, repair and/or replace connectors,
terminals, and wires of charging system circuits.
h) Remove, inspect, and replace generator
(alternator).
Lighting Systems a) Diagnose the cause of brighter than normal,
Diagnosis and Repair intermittent, dim, and continuous or no operation
of exterior lighting; determine needed repairs.
b) Inspect, replace, aim and/or level headlight
assemblies and auxiliary light assemblies (fog
lights/driving lights), including high-intensity
discharge (HID) and LED systems.
c) Inspect, test, repair and/or replace switches, relays,
bulbs, LEDs, sockets, connectors, terminals, wires,
and control modules of exterior lighting.
d) Diagnose the cause of turn signal and/or hazard
light system malfunctions; determine needed
repairs.
e) Inspect, test, repair and/or replace switches, flasher
units, bulbs, sockets, connectors, terminals, wires,
and control modules of turn signal and hazard light
circuits.
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f) Diagnose the cause of intermittent, dim,
continuous or no operation of interior
lighting circuits (such as: courtesy, dome, map,
vanity, glove box, cargo, trunk, hood, instrument,
and accent lighting); determine needed repairs.
g) Inspect, test, repair and/or replace switches, relays,
bulbs, sockets, connectors, terminals, wires, and
control modules of interior lighting circuits (such
as: courtesy, dome, map, vanity, glove box, cargo,
trunk, hood, instrument, and accent lighting).
h) Inspect, test, repair and/or replace trailer wiring
harness, relays, connectors, and control modules
(including brake control).
Instrument Cluster a) Diagnose the cause of intermittent, dim, no lights,
and Driver continuous operation, or no brightness control of
Information instrument lighting circuits; determine needed
Systems Diagnosis repairs.
and Repair b) Inspect, test, repair and/or replace switches, relays,
bulbs, LEDs, sockets, connectors, terminals, wires,
and control modules of instrument lighting
circuits.
c) Diagnose the cause of high, low, intermittent, or
no readings on electronic instrument cluster
gauges; determine needed repairs.
d) Diagnose the cause of constant, intermittent, or no
operation of warning lights, indicator lights,
audible warning devices, and other driver
information systems; determine needed repairs.
e) Inspect, test, repair and/or replace bulbs, sockets,
connectors, terminals, switches, relays, sensors,
timers, wires, gauges, sending units, electronic
components, and control modules of electronic
instrument clusters and driver information system
circuits.
Body Electrical a) Diagnose operation of comfort and convenience
Systems Diagnosis accessories and related circuits (such as: power
and Repair windows, power seats, adjustable pedal height,
power locks, trunk locks, remote start, moon roof,
sunroof, sun shade, keyless entry, voice activation,
phone pairing technology, wireless connectivity,
steering wheel controls, camera systems, park
assist, cruise control, and automated exterior
lighting); determine needed repairs.
b) Inspect, test, repair and/or replace components,
connectors, terminals, and wiring of comfort and
convenience accessories.
c) Diagnose operation of heated and cooled
accessories and related circuits (such as:
heated/cooled seats, heated steering wheel, heated
mirror, heated glass, and heated/ cooled cup
holders); determine needed repairs.
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d) Inspect, test, repair and/or replace components,
connectors, terminals, and wiring of heated and
cooled accessories.
e) Diagnose operation of security/anti-theft systems
and related circuits (such as: theft deterrent, door
locks, keyless entry, remote start, and starter/fuel
disable); determine needed repairs.
f) Inspect, test, repair and/or replace components,
connectors, terminals, and wiring of security/anti-
theft systems.
g) Diagnose operation of entertainment/ infotainment
and related circuits (such as: radio, DVD,
navigation, amplifiers, speakers, antennas, and
voice-activated accessories); determine needed
repairs.
h) Inspect, test, repair and/or replace components,
connectors, terminals, and wiring of
entertainment/infotainment systems.
i) Diagnose operation of safety systems and related
circuits (such as: supplemental restraint systems,
wipers, washers, horn, speed control, collision
avoidance, telematics, heads-up display, park
assist, and camera systems); determine needed
repairs.
j) Inspect, test, repair and/or replace components,
connectors, terminals, and wiring of safety
systems.
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Module 10: VEHICLE INTERIOR HEATING AND AIR CONDITIONING
and repair Automotive Air Conditioning systems.
SUB-MODULE DUTIES/ TASKS COMPETENCES
Heating, Ventilation, A/C a) Identify system type and conduct performance a) Describes the layout
(HVAC) and Engine Cooling test on the A/C system; determine needed of the Vehicle Air
System Service, Diagnosis, and repairs. conditioning (AC)
Repair b) Diagnose A/C system problems indicated by Heating and
system pressures and/or temperature readings; ventilation.
determine needed repairs. b) Troubleshoots Air
c) Diagnose A/C system problems indicated by conditioning system
sight, sound, smell, and touch procedures; faults and causes
determine needed repairs. c) Carries out servicing
d) Leak test A/C system; determine needed of the Vehicle Air
repairs. conditioning (AC)
e) Identify A/C system refrigerant and existing Heating and
charge amount; recover refrigerant. ventilation
f) Evacuate A/C system. d) Repairs faulty Air
g) Inspect A/C system components for condition’s
contamination; determine needed repairs. components
h) Charge A/C system with refrigerant. e) Performs charging
i) Identify A/C system lubricant type and and discharging the
capacity; replenish lubricant if necessary. Air conditioning
j) Inspect and replace passenger compartment Refrigerant
(cabin air, pollen) filter. f) Detects AC system
k) Disarm and enable the airbag system for leakages
vehicle service following manufacturers’ g) Observes the safety
recommended procedures. precautions
l) Read diagnostic trouble codes (DTCs) and
interpret scan tool data stream.
m) Read and interpret technical literature (service
publications, bulletins, recalls, and
information including wiring schematics).
n) Use a scan tool, Digital Multimeter (DMM),
or digital storage oscilloscope (DSO) to test
HVAC system sensors, actuators, circuits, and
control modules; determine needed repairs.
o) Verify proper operation of certified
equipment.
p) Recycle or properly dispose of refrigerant.
q) Label and store refrigerant.
r) Test refrigerant cylinders for non-condensable
gases; identify refrigerant.
s) Identify the procedures and equipment
necessary to service, diagnose, and repair A/C
systems in hybrid/electric vehicles.
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t) Diagnose the cause of temperature control
problems in the heater/ventilation system;
u) Diagnose window fogging problems;
v) Perform engine cooling system tests (flow,
pressure, electrolysis, concentration, and
contamination); determine needed repairs.
w) Inspect and replace engine coolant hoses and
pipes.
x) Inspect, test, and replace radiator, pressure
cap, coolant recovery system, and water pump.
y) Inspect, test, and replace thermostat,
thermostat by pass, and housing.
z) Identify, inspect, recover coolant; flush and
refill system with proper coolant; bleed system
as necessary.
aa) Inspect, test, and replace fan (both electrical
and mechanical), fan clutch, fan belts, fan
shroud, and air dams.
bb) Inspect, test, and replace heater coolant
control valve (manual, vacuum, and electrical
types), and auxiliary coolant pump.
cc) Inspect, flush, and replace heater core.
Refrigeration System Component 1. Compressor and Clutch
Diagnosis and Repair a) Diagnose A/C system problems that cause the
protection devices (pressure, thermal,
b) and electronic controls) to interrupt system
operation; determine needed repairs.
c) Inspect, test, and replace A/C system
pressure, thermal, and electronic protection
devices.
d) Inspect, adjust, and replace A/C compressor
drive belts, pulleys, and tensioners.
e) Inspect, test, service, and replace A/C
compressor clutch components or assembly.
f) Identify required lubricant type; inspect and
correct level in A/C compressor.
g) Inspect, test, service or replace A/C
compressor, mounting, and fasteners.
2. Evaporator, Condenser, and Related

Components
a) Inspect, repair, or replace A/C system

mufflers, hoses, lines, filters, fittings, and
seals.
b) Inspect A/C condenser for proper air flow.
c) Inspect, test, and clean or replace A/C system
condenser; check mountings and air seals.
Page 43 of 63
d) Inspect and replace receiver/drier,
accumulator/drier, or desiccant.
e) Inspect, test, and replace expansion valve(s).
f) Inspect and replace orifice tube(s).
g) Inspect A/C evaporator for proper air flow.
h) Inspect, test, clean, or replace evaporator(s).
i) Inspect, clean and repair evaporator housing,
and water drain.
j) Inspect, test, and replace evaporator
pressure/temperature control systems and
devices.
k) Identify, inspect, and replace A/C system
service valves and valve caps.
l) Inspect and replace A/C system high pressure
relief device.
3. Electrical
a) Diagnose the cause of failures in the electrical

control system of heating, ventilating, and A/C
(HVAC) systems; determine needed repairs.
b) Inspect, test, repair, and replace HVAC heater
blower motors, blower motor speed controls,
resistors, switches, relays/modules, wiring,
and protection devices.
c) Inspect, test, repair, and replace A/C
compressor clutch coil, relay/ modules,
wiring, sensors, switches, diodes, and
protection devices.
d) Inspect, test, repair, and replace A/C-related
powertrain control systems and components.
e) Inspect, test, repair, and replace load sensitive
A/C compressor cut-off systems.
f) Inspect, test, repair, and replace engine
cooling/condenser fan motors, relays/modules,
switches, sensors, wiring, and protection
devices.
g) Inspect, test, adjust, repair and replace climate
control system electric actuator motors, relays/
modules, switches, sensors, wiring, and
protection devices (including dual/multi-zone
systems).
h) Inspect, test, service, or replace HVAC panel
assemblies.
4. ► Vacuum/Mechanical
a) Diagnose the cause of failures of the heating,

ventilating, and A/C (HVAC) vacuum and
mechanical control systems; determine
needed repairs.
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b) Inspect, test, service, or replace HVAC
control panel assemblies.
c) Inspect, test, adjust, and replace HVAC
control cables and linkages.
d) Inspect, test, and replace HVAC vacuum
system actuators (diaphragms/motors),
hoses, reservoir, check valve, and restrictors.
e) Inspect, test, adjust, repair, or replace HVAC
ducts, doors, and outlets (including
dual/multi-zone systems).
Operating Systems and Related 1. Automatic and Semi-Automatic Heating,
Controls Ventilating, and A/C Systems
Diagnosis and Repair a) Diagnose temperature control system
problems; determine needed repairs
(including dual/multi-zone systems).
b) Diagnose blower system problems;
determine needed repairs (including
dual/multi-zone systems).
c) Diagnose air distribution system
problems; determine needed repairs
(including dual/ multi-zone systems).
d) Diagnose compressor clutch control
system; determine needed repairs.
e) Inspect, test, or replace climate and
blower control sensors.
f) Inspect, test, and replace door actuator(s).
g) Inspect, test, and replace heater coolant
control valve and controls.
h) Inspect, test, and replace electric and
vacuum motors, solenoids, and switches.
i) Inspect, test, or replace Automatic
Temperature Control (ATC) control panel
and/or climate control computer/module;
program, code, or initialize as required.
j) Check and adjust calibration of Automatic
Temperature Control (ATC) system.
k) Diagnose data communication issues,
including diagnostic trouble codes (DTCs)
that affect climate control system
operation.
Page 45 of 63
Module 11: AUTOMOTIVE ENGINE DIAGNOSIS
TRAINING OUTCOME: By the end of the module the trainee should be able to perform
Engine Trouble-shooting and Diagnosis.
Engine Diagnosis a) Verify driver’s complaint, perform visual a) Describes the Engine
Mechanic inspection, and/or road test vehicle; determine Management systems and
needed action. Diagnosis procedures.
b) Research applicable vehicle and service b) Uses Diagnosis Scan tools (OBD)
information, such as engine management system on Engine systems
operation, vehicle service history, service c) Troubleshoots Engine system to
precautions, technical service bulletins, and identify faults
service campaigns/recalls. d) Performs tests and take readings
c) Diagnose noises and/or vibration problems e) Interprets Diagnosis Trouble
related to engine performance; determine codes (DTC)
needed action. f) Clears diagnostic trouble codes
d) Diagnose the cause of unusual exhaust color, (DTCs),
odor, and sound; determine needed action. g) Run all OBD II monitors, and
e) Perform engine manifold vacuum or pressure verify the repairs
tests; determine needed action. h) Observes the safety precautions
f) Perform cylinder power balance test; determine
needed action.
g) Perform cylinder cranking, relative, and running
compression tests; interpret test results;
h) Perform cylinder leakage/leak-down test;
i) Diagnose engine mechanical, electrical,
electronic, fuel, and ignition problems with an
oscilloscope, engine analyzer, and/or scan tool;
j) Prepare and inspect vehicle for HC, CO, NOx,
CO2, and O2 exhaust gas analysis; perform test
and interpret exhaust gas readings.
k) Verify valve adjustment on engines with
mechanical or hydraulic lifters.
l) Verify camshaft timing; verify operation of
camshaft timing components, including engines
equipped with variable valve timing; determine
needed action.
m) Diagnose emissions or drivability problems
caused by oil related issues, such as incorrect
pressure, poor quality, incorrect level, or
incorrect type used for the application.
n) Verify engine operating temperature, check
coolant level and condition, perform cooling
system pressure test; determine needed action.
o) Inspect and test mechanically/ hydraulically/
electronically operated fans, fan clutch, fan
Page 46 of 63
shroud/ducting, and fan control devices;
p) Read and interpret electrical schematic
diagrams and symbols.
q) Test and diagnose emissions or drivability
problems caused by battery condition,
connections, or excessive key-off battery drain;
r) Perform starter current draw test; determine
needed action.
s) Perform starter and charging circuit voltage
drop tests; determine needed action.
t) Test and diagnose engine performance problems
resulting from charging system failures;
u) Inspect, adjust, and replace alternator
(generator) drive belts, pulleys, clutches,
tensioners and/or fans.
v) Inspect, test, and repair or replace system
components, connectors and wires in the starter
and charging control circuits.
Ignition System a) Diagnose ignition system related problems such
Diagnosis and as no-starting, hard starting, engine misfire,
Repair poor drivability, spark knock, power loss, poor
mileage, and emissions problems; determine
root cause; determine needed action.
b) Interpret ignition system related diagnostic
trouble codes (DTCs); determine needed action.
c) Inspect, test, repair, or replace ignition primary
circuit wiring and components.
d) Inspect, test, service, repair or replace ignition
system secondary circuit wiring and
components.
e) Inspect, test, and replace ignition coil(s).
f) Inspect, test, and replace ignition system
sensors; adjust as necessary.
g) Inspect, test, and/or replace ignition control
module (ICM) and/or powertrain/engine control
module (PCM/ECM); reprogram/initialize as
needed.
Fuel, Air Induction a) Diagnose fuel system related problems,
and Exhaust Systems including hot or cold no-starting, hard starting,
Diagnosis and poor drivability, incorrect idle speed, poor idle,
Repair flooding, hesitation, surging, engine misfire,
power loss, stalling, poor mileage, and
emissions problems; determine root cause;
b) Interpret fuel or induction system related
diagnostic trouble codes (DTCs); analyze fuel
trim and other scan tool data; determine needed
action.
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c) Inspect fuel tank, filler neck, and gas cap;
inspect and replace fuel lines, fittings, and
hoses; determine needed action.
d) Inspect, test, and replace fuel pump(s) and/or
fuel pump assembly; inspect, service, and
replace fuel filters.
e) Inspect and test fuel pump control circuits and
components; determine needed action.
f) Inspect, test, and repair or replace fuel pressure
regulation system and components of fuel
injection systems; check fuel for contaminants
and quality; perform fuel pressure/ volume test.
g) Inspect, test, service and/or replace throttle
assembly; make related adjustments and/or
perform initialization or relearn procedure as
required.
h) Inspect, test, clean, and replace fuel injectors
and fuel rails.
i) Inspect, service, and repair or replace air
filtration system components.
j) Inspect throttle assembly, air induction system,
intake manifold and gaskets for air/vacuum
leaks, restrictions and/or unmetered air.
k) Remove, clean, inspect, test, and repair or
replace fuel system vacuum and electrical
components and connections.
l) Inspect, service, and replace exhaust manifold,
exhaust pipes, oxygen sensors, air/fuel ratio
sensors, mufflers, catalytic converters,
resonators, tailpipes, and heat shields.
m) Test for exhaust system restriction or leaks;
n) Inspect, test, clean and repair or replace
turbocharger or supercharger and system
components.
Emission Control 1. Positive Crankcase Ventilation
Systems Diagnosis a) Test and diagnose emissions or drivability
and Repair problems caused by positive crankcase
ventilation (PCV) system.
b) Inspect, service, and replace positive crankcase
ventilation (PCV) filter/breather cap, valve, oil
separator tubes, orifice/metering device, and
hoses.
2. Exhaust Gas Recirculation

a) Test and diagnose drivability problems caused
by the exhaust gas recirculation (EGR) system.
b) Interpret exhaust gas recirculation (EGR)
related scan tool data and diagnostic trouble
codes (DTCs); determine needed action.
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c) Inspect, test, service, and replace components of
the EGR system, including EGR valve, tubing,
passages, vacuum/pressure controls, filters,
hoses, electrical/electronic sensors, controls,
solenoids and wiring of exhaust gas
recirculation (EGR) systems.
3. Secondary Air Injection (AIR) and Catalytic

Converter
a) Test and diagnose emissions or drivability
problems caused by the secondary air injection
or catalytic converter systems.
b) Interpret secondary air injection system related
scan tool data and diagnostic trouble codes
(DTCs); determine needed action.
c) Inspect, test, service, and replace mechanical
components and electrical/electronic
components and circuits of secondary air
injection systems.
d) Inspect catalytic converter. Interpret catalytic
converter related diagnostic trouble codes
(DTCs); analyze related scan tool data to
determine root cause of DTCs; determine
needed action.
4. Evaporative Emissions Controls

a) Test and diagnose emissions or drivability
problems caused by the evaporative emissions
control (EVAP) system.
b) Interpret evaporative emissions-related scan
tool data and diagnostic trouble codes (DTCs);
c) Inspect, test, and replace canister, lines/hoses,
filters, mechanical and electrical components of
the evaporative emissions control (EVAP)
system.
Computerized a) Retrieve and record diagnostic trouble codes
Engine Controls (DTCs), OBD II monitor status and freeze
Diagnosis frame data.
and Repair b) Diagnose the causes of emissions or drivability
problems with stored or active diagnostic
trouble codes (DTCs).
c) Diagnose the causes of emissions or drivability
problems without diagnostic trouble codes
(DTCs).
d) Use a scan tool, digital multimeter (DMM), or
digital storage oscilloscope (DSO) to inspect or
test computerized engine control system
sensors, actuators, circuits, and
powertrain/engine control module (PCM/ECM);
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e) Measure and interpret voltage, voltage drop,
amperage, and resistance using digital
multimeter (DMM) readings.
f) Test, remove, inspect, clean, service, and repair
or replace power and ground distribution
circuits and connections.
g) Inspect, test, and/or replace the
powertrain/engine control module (PCM/ECM);
reprogram/initialize as needed.
h) Diagnose drivability and emissions problems
resulting from failures of interrelated systems
(for example: cruise control, security
alarms/theft deterrent, torque management,
traction controls, A/C, non-OEM installed
accessories).
i) Clear diagnostic trouble codes (DTCs), run all
OBD II monitors, and verify the repair.
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Module 12: LIGHT VEHICLE DIESEL ENGINES
Training Outcome: By the end of the module the trainee should be able to service, repair and
Maintain Light Vehicle Diesel Engines.

General Diagnosis a) Verify the complaint, and road/dyno-test vehicle; a) Describes the Diesel
review driver/customer concerns/ expectations and Engine layout of main
vehicle service history (if available); determine parts and systems.
further diagnosis. b) Performs Diesel Engine
b) Record vehicle identification number (VIN). Maintenance overhaul
Identify engine model, calibration and serial and assembling
numbers to research applicable vehicle and service c) Troubleshoots Diesel
information, service precautions, and technical Engine and its systems to
service bulletins; determine needed actions. identify faults
c) Perform scan tool check and visual inspection for d) Carries out service and
physical damage and missing, modified, or tampered repairs on Diesel engine
components; determine needed actions. systems.
d) Check and record electronic diagnostic codes, freeze e) Uses repair tools and
frame and/or operational data; monitor scan tool equipment for diesel
data; determine further diagnosis. engines
e) Clear diagnostic trouble codes (DTCs) and verify f) Observes the safety
the repair. precautions
f) Inspect engine assembly and compartment for fuel,
oil, coolant, exhaust, or other leaks; determine
needed repairs.
g) Inspect engine compartment wiring harness,
connectors, seals, and locks; check for proper
routing and condition; determine needed repairs.
h) Listen for and isolate engine noises; determine
needed repairs.
i) Isolate and diagnose engine related vibration
problems; determine needed actions.
j) Check engine exhaust for abnormal odor and/or
smoke color and volume; determine further
diagnosis.
k) Check fuel for contamination, quantity, quality, and
consumption; determine needed actions.
l) Perform crankcase pressure test; determine further
diagnosis.
m) Diagnose surging, rough operation, misfiring, low
power, slow deceleration, slow acceleration, and
shutdown problems; determine needed actions.
n) Check cooling system for freeze point, level,
contamination, condition, temperature, pressure,
circulation, and fan operation; determine needed
repairs.
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o) Check lubrication system for contamination, oil
level, temperature, pressure, filtration, and oil
consumption; take oil sample and obtain oil analysis
if needed; determine needed repairs.
p) Diagnose no-cranking, cranks but fails to start, hard
starting, and starts but does not continue to run
problems; determine needed actions.
q) Diagnose engine problems caused by battery
condition, connections, or excessive key-off battery
drain; determine needed repairs.
r) Diagnose engine problems resulting from an
electrical undercharge, overcharge, or a no-charge
condition; determine needed action.
Cylinder Head and a) Remove, inspect, disassemble, and clean cylinder
Valve Train head assembly(s).
b) Inspect threaded holes, studs, and bolts for
serviceability; service/replace as needed.
c) Measure cylinder head thickness, and check mating
surfaces for flatness, corrosion,
d) warpage and surface finish; inspect for
cracks/damage; check condition of passages;
e) inspect core and gallery plugs; determine
serviceability and needed repairs.
f) Inspect valves, guides, seats, springs, retainers,
rotators, locks and seals; determine serviceability
and needed repairs.
g) Inspect and/or replace injector sleeves, glow plug
sleeves, and seals; pressure test to verify repair (if
applicable); measure injector tip, nozzle, or pre-
chamber protrusion where specified by
manufacturer.
h) Inspect, and/or replace valve bridges (crossheads)
and guides; adjust bridges
i) (crossheads) if applicable.
j) Reassemble, check, and determine required cylinder
head gasket thickness; install cylinder head
assembly and gasket as specified by the
manufacturer.
k) Inspect pushrods, rocker arms, rocker arm shafts,
electronic components, wiring harness, seals;
repair/replace as needed.
l) Inspect, install, and adjust cam followers, lash
adjusters and retainers; adjust valve clearance if
applicable.
m) Inspect, measure, and replace/reinstall overhead
camshaft and bearings; measure and adjust endplay.
n) Inspect and time drive gear train components
(includes gear, chain, and belt systems).
Engine Block a) Remove, inspect, service, and install pans, covers,
Diagnosis and Repair ventilation systems, gaskets, seals, and wear rings.
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b) Disassemble, clean and inspect engine block for
cracks; check mating surfaces and related
components for damage or warpage and surface
finish; check deck height; check condition of
passages, core, and gallery plugs; inspect threaded
holes, studs, dowel pins and bolts for serviceability;
service/replace as needed.
c) Inspect and measure cylinder walls for wear and
damage; determine needed service.
d) Inspect in-block camshaft bearings for wear and
damage; replace as needed.
e) Inspect, measure, and replace/reinstall in-block
camshaft; measure and correct end play; inspect,
replace/reinstall, and adjust cam followers (if
applicable).
f) Clean and inspect crankshaft and journals for
surface finish, cracks, and damage; check condition
of oil passages; check passage plugs; measure
journal diameters; check mounting surfaces;
determine needed service.
g) Determine the proper select-fit components such as
pistons, connecting rod and main bearings.
h) Inspect and replace main bearings; check cap fit and
bearing clearances; check and correct crankshaft end
play.
i) Inspect, replace, verify, and adjust the drive gear
train components (includes gear, chain, and belt
systems).
j) Inspect, measure, or replace pistons, pins, and
retainers.
k) Measure piston-to-cylinder wall clearance.
l) Identify piston, connecting rod bearing, and main
bearing wear patterns that indicate connecting rod
and crankshaft alignment or bearing bore problems;
check bearing bore and bushing condition;
m) Check ring-to-groove fit and end gaps; install rings
on pistons; assemble pistons and connecting rods
and install in block; check piston height/protrusion;
check liner height/protrusion (if applicable); replace
rod bearings and check clearances; check condition,
position, and clearance of piston cooling jets
(nozzles).
n) Inspect crankshaft vibration damper; determine
needed repairs.
o) Inspect flywheel/flex-plate and/or dual-mass
flywheel (including ring gear) and mounting
surfaces for cracks, wear, and run-out; determine
needed repairs.
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Lubrication and a) Verify base engine oil pressure and check operation
Cooling Systems of pressure sensor/switch and pressure gauge; verify
Diagnosis and Repair engine oil temperature and check operation of
temperature sensor.
b) Inspect, measure, repair/replace oil pump, housing,
drives, pipes, and screens; check drive gear
clearance.
c) Inspect, repair/replace oil pressure regulator
assembly including: housing, bore, spring, regulator
valve(s), oil filter by-pass valve(s), and anti-drain
back valve.
d) Inspect, clean, test, and reinstall/replace oil cooler,
by-pass valve, lines, and hoses.
e) Inspect turbocharger lubrication and cooling
systems; repair/replace as needed.
f) Change engine oil and filters using proper type,
viscosity, and rating per manufacturer specifications.
g) Inspect and reinstall/replace pulleys, tensioners, and
drive belts; adjust drive belts and check alignment.
h) Verify coolant temperature; check operation of
temperature and level sensors, switches, and
temperature gauge.
i) Inspect and replace thermostat(s), by-pass (es),
housing(s), and seal(s).
j) Flush and refill cooling system; following
manufacturer’s specification, add proper coolant
type; bleed air from system.
k) Inspect and replace water pump(s), housing(s),
hoses, and idler pulley(s) or drive gear.
l) Inspect radiator(s), pressure cap(s), and tank(s);
pressure test cooling system and radiator cap(s);
m) Inspect and repair/replace cooling fan, fan hub, fan
clutch, controls, and shroud(s).
Air Induction and a) Inspect and service/replace air induction piping, air
Exhaust Systems cleaner, and element; determine needed actions.
Diagnosis and Repair b) Perform intake manifold pressure tests; inspect, test,
clean, and/or replace charge air cooler and piping
system; determine needed actions.
c) Inspect test, and replace turbocharger(s) (including
variable ratio/geometry VGT), pneumatic, hydraulic,
vacuum, and electronic controls and actuators;
inspect, test, and replace waste-gate and waste-gate
controls.
d) Inspect, test, and replace intake manifold(s), variable
intake manifold(s), gaskets, actuators, temperature
and pressure sensors, and connections.
e) Perform exhaust back pressure and temperature
tests; determine needed actions.
f) Inspect and repair/replace exhaust manifold(s),
gaskets, piping, mufflers, and mounting hardware.
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g) Inspect, test, and repair/replace preheater/inlet air
heater and/or glow plug system and controls.
h) Inspect, test, and replace exhaust after treatment
system components and controls, including diesel
oxidation catalyst (DOC), selective catalyst
reduction (SCR), diesel exhaust fluid (DEF), diesel
particulate filter (DPF); check regeneration system
operation.
i) Inspect, test, service, and replace EGR system
components including EGR valve(s), EGR cooler
by-pass valve(s), EGR cooler(s), piping, electronic
sensors, actuators, controls, and wiring.
j) Inspect, test, and replace airflow control (throttle)
valve(s) and controls.
k) Inspect, test, and replace crankcase ventilation
system components, including sensors, filters,
valves, and piping.
Fuel System Diagnosis a) Inspect, clean, test, and repair/replace fuel system
and Repair tanks, vents, caps, mounts, valves, single/dual
supply and return lines, and fittings.
b) Inspect, clean, test, and repair/replace fuel transfer
and/or supply pump, sensors, strainers, fuel/water
separators/indicators, filters, heaters, coolers, ECM
cooling plates (if applicable), and mounting
hardware.
c) Check fuel system for air; determine needed repairs;
prime and bleed fuel system; check and
repair/replace primer pump.
d) Inspect, test, and repair/replace low fuel pressure
regulator supply and return systems, including low
pressure switches.
e) Inspect and reinstall/replace high-pressure injection
lines, fittings, transfer tubes, seals, and mounting
hardware.
f) Inspect, adjust, and repair/replace electronic throttle
and PTO control devices, circuits, and sensors.
g) Perform on-engine inspections, tests, and replace
high pressure common rail fuel system components
and electronic controls.
h) Perform on-engine inspections and tests; replace
hydraulic electronic unit injector(s) (HEUI)
components and electronic controls.
i) Perform on-engine inspections and tests; replace
pump-line-nozzle fuel system (PLN-E) components
and electronic controls.
j) Perform on-engine inspections and tests; replace
electronic unit injector(s) (EUI) components and
electronic controls.
k) Inspect and replace electrical connector terminals,
pins, harnesses, seals, and locks.
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l) Connect diagnostic scan tool to vehicle/engine;
access, verify and update software calibration
settings, injector calibration codes; perform control
module re-learn procedures as needed.
m) Use a diagnostic scan tool to inspect and test
electronic engine control system, sensors, actuators,
electronic control modules, and circuits; determine
further diagnosis.
n) Measure and interpret voltage, voltage drop,
amperage, and resistance readings using a digital
multimeter (DMM) or appropriate test equipment.
o) Diagnose engine problems resulting from failures of
interrelated systems (for example: cruise control,
security alarms/theft deterrent, transmission
controls, exhaust after treatment systems, electronic
stability control, or non-OEM installed accessories).
Module 13: VEHICLE BODY REPAIR AND SPRAY

Training Outcome: By the end of the module the trainee should be able to perform vehicle
body repair and spray.

Preparation a) Review damage report and replacement parts for a) Describes the
accuracy. Inspect for prior damage and repairs. Inspect for Vehicle Body parts
proper systems operation. layout.
b) Identify potential health, safety, and environmental b) Carries out
concerns associated with vehicle components and inspection of vehicle
systems, i.e. ABS, air bags (SRS), refrigerants, hybrid body panel parts
electric vehicles, coolants, etc. c) Identifies damages
c) Research and determine repair plan, procedures, and on vehicle body
methods of overall repairs in accordance with the vehicle panel parts
manufacturer’s specifications and accepted industry d) Carries out repairs
procedures (including calibration/initialization of on damaged vehicle
advanced vehicle systems). body parts.
d) Position vehicle to perform repairs; lift, raise, or support if e) Uses vehicle Body
necessary. and spray repair
e) Remove damaged or undamaged interior and exterior trim tools
and moldings/claddings as necessary; document missing f) Observes the safety
or broken one-time use parts/fasteners/components, store precautions
removed parts/fasteners/components.
f) Remove and store undamaged, non-structural body panels
and components and mechanical/electrical components
that may interfere with or be damaged during the repair
process.
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g) Check for malfunction indicator lamp (MIL) illumination;
scan all computer systems and retrieve codes and settings;
identify battery disconnect procedures.
h) Protect panels and parts adjacent to repair area to prevent
damage during repair.
i) Remove dirt, grease, wax, and other contaminants from
areas to be repaired.
j) Remove pinstripes, emblems and decals
(transfers/overlays and other paint protection accessories);
remove adhesives if necessary.
k) Remove corrosion protection, under-coatings, sealers, and
other protective coatings as necessary to perform repairs.
l) Remove repairable plastics and other parts for off-vehicle
repair.
m) Identify safety considerations: Personal Protection
Equipment (PPE), shock hazards, fumes, safety data sheet
(SDS), etc. before beginning any repair operation.
Outer Body Panel a) Determine the extent of the direct (Primary) and indirect
Repairs, Replacements, (Secondary) damage and the direction of impact; plan the
and Adjustments methods and order of repair.
b) Remove and replace bolted, riveted, adhesive/ bonded,
and welded panels or panel assemblies.
c) Identify the body panel substrate (high-strength steel,
aluminum, magnesium, composite, etc.), determine the
extent of damage for reparability or replacement.
d) Remove, reinstall or replace, and adjust/align hood, hood
supports, hood hinges, and hood latch/lock.
e) Remove, reinstall or replace, and adjust/align deck lid, lid
hinges, supports, and lid latch/lock.
f) Remove, reinstall or replace and adjust/align doors,
tailgates, hatches, supports,
g) Lift-gates, latch/lock assemblies, handles, and hinges.
h) Remove, reinstall or replace, and adjust/align bumpers,
brackets, reinforcements, guards, absorbers, isolators, and
mounting hardware.
i) Remove, reinstall or replace and adjust/align front
fenders; check and adjust gaps and clearances.
j) Remove, reinstall or replace and adjust/align exterior
lighting and mounting panels.
k) Check outer body panel function, adjust as necessary for
proper operation.
l) Restore contours of a damaged panel to a surface
condition suitable for metal finishing or body filling.
m) Weld cracked or torn metal body panels.
n) Apply protective coatings to restore corrosion protection.
o) Remove damaged body panels; replace panels using a
weld, weld-bond, adhesively-bonded, rivet, rivet-bond, or
other fastening procedures.
p) Repair door frame, repair or replace door skins; inspect
intrusion beams.
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q) Restore seam sealers, mastic, sound deadeners, and foam
fillers.
r) Diagnose and repair water leaks, dust leaks, wind noise,
squeaks, rattles, and vibrations.
s) Install interior and exterior trim, pinstripes, emblems,
decals (transfers/overlays, vapor barriers), and protective
film.
t) Scan computer systems and verify proper system
operation following outer body panel repair, replacement
or adjustment.
Metal Finishing and a) Remove paint and other coatings from the damaged area
Body Filling of a body panel.
b) Heat-shrink stretched panel areas to proper contour.
c) Cold-shrink stretched panel areas to proper contour
d) Metal-finish the damaged area of a body panel to
eliminate surface irregularities.
e) Prepare surface for application of body filler material.
f) Mix, apply and shape body filler material.
g) Sand cured body filler material to contour.
Glass and Hardware a) Inspect, adjust, remove and/or replace moveable,
electrically-heated, stationary, mechanically-fastened,
bonded, and hinged glass.
b) Inspect, adjust, repair, or replace window regulators, run
channels, power mechanisms, and related controls. Reset
automatic features and clear stored codes if necessary.
c) Inspect, adjust, repair, remove or replace power glass roof
panels and related controls.
d) Reset automatic features and clear stored codes if
necessary.
e) Inspect, adjust, repair, remove, or replace removable,
manually-operated glass roof panels and hardware.
f) Diagnose and repair water leaks, dust leaks, wind noises;
rattles, and vibrations; inspect, repair, or replace weather
stripping.
g) Inspect, adjust, and install convertible or retractable roof
and related mechanisms.
h) Reset automatic features and clear stored codes if
necessary.
i) Scan computer systems and verify proper system
operation following stationary glass removal or
replacement.
Welding, Cutting, and a) Identify weldable and non-weldable materials used in
Removal vehicle construction.
b) Identify the considerations for cutting, removing, and
welding various types of steels, aluminum and other
metals.
c) Determine the correct welding process to be used in
specific welding situations: [compression/inverter/squeeze
type resistance spot (STRSW), GTAW (TIG), GMAW
(MIG), MIG-brazing]; determine settings, electrode, wire
Page 58 of 63
type, diameter, gas and bonding material to be used in
specific welding processes.
d) Adjust the welding equipment for proper operation.
e) Perform test welds. Visually inspect, perform destructive
test, and make adjustments as necessary.
f) Determine proper work clamp (ground) location.
g) Use the proper gun-to-joint angle, distance, speed, and
direction of gun travel for welds being made in all
positions.
h) Select proper STRSW arm set, electrode type and
diameter, and settings based on the location and material
to be welded.
i) Protect vehicle components (adjacent components, hybrid
components, computers and other electronic modules)
from possible damage caused by welding and cutting.
j) Clean or prepare the metal to be welded; ensure proper
weld joint fit-up; apply weld through primer if required.
k) Select and prepare the correct joint type (butt, lap, etc.) for
the repair.
l) Identify and perform the correct type of weld (continuous,
stitch, tack, plug, spot, slot, etc.) for each specific welding
operation.
m) Identify the causes of weld defects; perform required
equipment maintenance and/or make necessary
adjustments.
Plastic Repair a) Identify the types of plastic(s) or composite(s); determine
reparability.
b) Identify the proper plastic or composite repair/cleaning
procedures; clean and prepare the surfaces of plastic or
composite parts for repair.
c) Repair plastic parts by welding or using adhesive repair
materials; repair composite parts using adhesive repair
materials; use reinforcing materials as required.
d) Reshape plastic parts.
e) Perform single or two-sided repairs in plastic or
composite panels.
f) Replace bonded plastic or composite body panels;
straighten or align mounting locations.
g) Replace mechanically fastened plastic or composite body
panels; straighten or align mounting locations if
necessary; torque fasteners to specifications. ■
Surface Preparation a) Identify and remove surface corrosion.
b) Remove dirt, road grime, wax, adhesive residue, mold
release agents, tree sap, markings or other contaminants
from the area to be refinished and any adjacent vehicle
surfaces.
c) Inspect and identify substrate, substrate condition, type of
finish, film thickness and surface condition; develop a
plan for refinishing.
d) Remove paint finish.
e) Sand areas to be refinished.
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f) Featheredge areas to be refinished.
g) Identify type of substrate and apply suitable treatment or
undercoat.
h) Mask and protect areas that will not be refinished.
i) Mix and apply primer-surfacer.
j) Apply finishing filler to minor surface imperfections.
k) Block sand area to which primer-surfacer and/or finishing
filler have been applied.
l) Remove dust residue from area to be refinished.
m) Clean area to be refinished using proper cleaning solution.
n) Remove, with a tack cloth, any dust or lint particles from
the area to be refinished.
o) Apply primer-sealer and/or adhesion promoter.
p) Remove imperfections from primer-sealer.
q) Prepare the adjacent areas for blending.
r) Apply stone-chip resistant coating.
s) Apply corrosion resistant coatings to repaired areas.
t) Remove and apply decals, transfers, tapes, pinstripes
(painted and/or taped).
u) Take appropriate measures to eliminate static electricity
v) Prepare surfaces for seam sealer application; evaluate the
application of seam sealers prior to refinishing.
w) Identify pin holing; determine the cause(s) and correct the
condition.
Spray Gun Operation a) Inspect, clean, adjust, maintain, and determine condition
and Related Equipment of spray guns and adequacy of related equipment (air
hoses, regulator, air-lines, air source, filtration unit and
spray environment).
b) Adjust spray gun, air pressure, fluid, and pattern control
valves.
c) Select correct spray gun, needle, fluid tip, and air cap for
material being sprayed.
d) Force-dry sprayed materials (bake, infrared, UV lamps,
airflow, etc.).
Paint Mixing, a) Determine the color, code, and type of finish on the
Matching, and vehicle.
Applying b) Identify paint color formula and the use of mixing
equipment and materials.
c) Mix and strain refinish material.
d) Use appropriate spray gun technique (arc, angle, distance,
speed, and spray pattern overlap) for the finish being
applied.
e) Apply selected product on test panel or let-down panel.
f) Check color match; adjust as necessary.
g) Apply single-stage topcoat for panel refinishing.
h) Apply basecoat or multi-stage (mica, pearl, etc.) coats for
spot, panel, blending, and overall refinishing.
i) Apply clear-coat.
j) Refinish interior and exterior trim components.
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Solving Paint a) Identify dirt or other foreign objects in the refinished
application problems surface; determine the source(s), and correct the
during the application condition.
process b) Identify a dry spray appearance in the refinished surface;
determine the cause(s), and correct the condition.
c) Identify the presence of fish-eyes (crater like appearance);
d) Identify lifting (surface distortion or wrinkling) of the
refinished surface; determine the cause(s), and correct the
condition.
e) Identify mottling or streaking in metallic, mica, and effect
paint finishes; determine the cause(s), and correct the
condition.
f) Identify excessive or lack of texture (orange peel);
g) Identify an overspray condition; determine the cause(s),
and correct the condition.
h) Identify sags and runs; determine the cause(s), and correct
the condition.
i) Identify color mismatch, due to application variables;
j) Identify tape tracking/marking; determine the cause(s),
and correct the condition.
k) Identify poor hiding/lack of coverage; determine the
cause(s) and correct the condition
Finish Defects, Causes, a) Identify delamination (poor adhesion, peeling); determine
and Cures the cause(s) and correct the condition.
b) Identify finish cracking (crow’s feet or line-checking,
micro-checking, etc.); determine the cause(s) and correct
the condition.
c) Identify sags and runs in the refinished surface; determine
the cause(s) and correct the condition.
d) Identify blistering in the finished surface; determine the
cause(s) and correct the
Module 14: DIESEL FUEL INJECTION SYSTEMS

Total contact hours:100
TRAINING OUTCOME: By the end of the module the trainee should be able to perform
Diesel Fuel Injection Systems Repair.
Prepare to diagnose a) Determine Job requirements from workplace a) Describes the Diesel fuel
and repair diesel fuel instructions injection systems layout.
injection system b) Interpret the available Diagnostic information b) Carries out Diagnostic
c) Analyse Diagnostic options and those most appropriate tests of Diesel fuel
to the circumstances injection systems
d) Identify and manage Hazards and risks associated with c) Performs Diesel pumps
the work and Injector nozzle tests
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e) Select Diagnostic tools, equipment and check for d) Interprets service and
serviceability Repair manuals for
Diesel fuel injection
systems.
e) Uses Diesel fuel
injection systems
service and repair tools
f) Observes the safety
precautions
Diagnose diesel fuel a) Checked, adjust and rectify as required according to
injection system manufacturer specifications
b) Carry out Diagnostic tests are according to
manufacturer specifications, workplace procedures, and
environmental and safety requirements
c) Identify Faults from diagnostic test results and
determine causes of faults
d) Carry out necessary adjustments and repairs.
e) Inspect, clean, test, and repair/replace fuel system
tanks, vents, caps, mounts, valves, single/dual supply
and return lines, and fittings.
f) Inspect, clean, test, and repair/replace fuel transfer
and/or supply pump, sensors, strainers, fuel/water
separators/indicators, filters, heaters, coolers, ECM
cooling plates (if applicable), and mounting hardware.
g) Check fuel system for air; determine needed repairs;
prime and bleed fuel system; check and repair/replace
primer pump.
h) Inspect, test, and repair/replace low fuel pressure
regulator supply and return systems, including low
pressure switches.
i) Inspect and reinstall/replace high-pressure injection
lines, fittings, transfer tubes, seals, and mounting
hardware.
j) Inspect, adjust, and repair/replace electronic throttle
and PTO control devices, circuits, and sensors.
k) Perform on-engine inspections, tests, and replace high
pressure common rail fuel system components and
l) Perform on-engine inspections and tests; replace
hydraulic electronic unit injector(s) (HEUI)
components and electronic controls.
m) Perform on-engine inspections and tests; replace pump-
line-nozzle fuel system (PLN-E) components and
n) Perform on-engine inspections and tests; replace
electronic unit injector(s) (EUI) components and
o) Inspect and replace electrical connector terminals, pins,
harnesses, seals, and locks.
p) Connect diagnostic scan tool to vehicle/engine; access,
verify and update software calibration settings, injector
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calibration codes; perform control module re-learn
procedures as needed.
q) Use a diagnostic scan tool to inspect and test electronic
engine control system, sensors, actuators, electronic
control modules, and circuits; determine further
diagnosis.
r) Measure and interpret voltage, voltage drop, amperage,
and resistance readings using a digital multimeter
(DMM) or appropriate test equipment.
s) Diagnose engine problems resulting from failures of
interrelated systems (for example: cruise control,
security alarms/theft deterrent, transmission controls,
exhaust after treatment systems, electronic stability
control, or non-OEM installed accessories).
Fuel System Diagnosis a) Interpret Repair manual information
and Repair b) Select Repair tools, equipment and materials. check
according to manufacturer procedures
c) Perform phasing and calibration of Injection pumps.
d) Perform Injector nozzle pressure tests on a Test-bench.
e) Repair and replace faulty components and adjustments.
f) Confirm test results conforms with the provided
specifications
Complete work a) Ensure Final inspection is made and system is ready for
processes use
b) Cleaned Work area is, waste and non-recyclable
materials are disposed of, and recyclable material is
collected
c) Tools and equipment are checked and stored according
to workplace procedures
d) Workplace documentation is processed according to
workplace procedures.
Page 63 of 63

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UGANDA BUSINESS AND TECHNICAL EXAMINATIONS BOARD

MODULAR ASSESSMENT GUIDE

PROGRAMME: NATIONAL CERTIFICATE IN AUTOMOTIVE MECHANICS (NCAM)

OCCUPATION MODULE SUB-MODULE

7. Brakes Service 1. Brakes System a) Hydraulic, Power Assist, and Parking

Other Support Modules

Properties of a) Absolute temperature and pressure a) applies the science of properties of

2. Differential Case/Carrier Assembly

a) Diagnose differential assembly noise and

3. Limited Slip/Locking Differential

a) Diagnose limited slip differential noise,

4. Axle Shafts and Housing

a) Diagnose rear axle shaft noise, vibration,

Module 5: AUTOMATIC TRANSMISSION /TRANS-AXLE

2. Disassembly and Assembly

a) Disassemble, clean, and inspect transmission

3. Friction and Reaction Units

a) Inspect components of the hydraulic clutch pack

SUB-MODULE DUTIES/TASKS COMPETENCE

a) Diagnose steering gear (non‑rack and

a) Inspect and adjust (where applicable) front

a) Diagnose rear suspension system noises,

Module 7: BRAKE SYSTEMS

a) Diagnose poor stopping, pulling or

4. Bleeding, Flushing and Leak

a) Diagnose poor stopping, pulling,

5. Power Assist Units

a) Diagnose parking brake system

Module 8: WHEELS AND TYRES

2. Evaporator, Condenser, and Related

a) Inspect, repair, or replace A/C system

a) Diagnose the cause of failures in the electrical

a) Diagnose the cause of failures of the heating,

2. Exhaust Gas Recirculation

3. Secondary Air Injection (AIR) and Catalytic

4. Evaporative Emissions Controls

SUB-MODULE DUTIES/ TASKS COMPETENCES

Module 13: VEHICLE BODY REPAIR AND SPRAY

SUB-MODULE DUTIES/ TASKS COMPETENCES

Module 14: DIESEL FUEL INJECTION SYSTEMS

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