NATIONAL CERTIFICATE IN MOTOR VEHICLE MECHANICS – 346/25/CR/MO

MINISTRY OF HIGHER AND TERTIARY EDUCATION, INNOVATION, SCIENCE AND CODE

TECHNOLOGY DEVELOPMENT
SKILLS PROFICIENCY SCHEDULE

INDUSTRY TRADE/ OCCUPATION CLASS/ LEVEL

AUTOMOTIVE MOTO VEHICLE MECHANICS NC
DUTY A: SAFTEY, HEALTH, ENVIROMENT, AND QUALITY MAINTAINANCE 5
Pre-requisites: Approval Date: Review Date:
TASK STEPS PROFICIENCY RELATED WORKPLACE
INDICATORS KNOWLEDGE ESSENTIAL
SKILLS
A1: Observe  Carry out risk assessment  Risk assessment report  Factories Act o Communication
personal  Put on appropriate personal produced and o Coordination
safety and protective gear.  Warning signs observed Regulations o Firefighting
health and  Interpret safety warning  Personal protective gear  SHEQ Equipment
demonstrate signs worn. standards handling
First Aid  Use safety regulation rules  Correct tool used for job  First Aid
Procedure  Use correct tool for the right and properly handled  Fire Fighting
job  Accident register  Computer
 Handle tools and equipment maintained. Literacy
appropriately  Personal safety ensured.
 Maintain accident report  Victim removed from
register danger
 Ensure personal safety.  Assistance from nearby
 Call for nearby assistance. obtained.
 Remove victim from danger  Appropriate first aid
following laid down rendered.
procedure.
NATIONAL CERTIFICATE IN MOTOR VEHICLE MECHANICS 346/25/CR/0
 Introduce yourself to the
victim.
 State your intention to the
victim
 Assess victim condition
 Communicate with victim
(where necessary)
 Render appropriate first aid
action as required
 Call for medical assistance
 Document incident

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 NATIONAL CERTIFICATE IN MOTOR VEHICLE MECHANICS 346/25/CR/0
A2: Maintain  Put on appropriate PPE.  Appropriate PPE worn
safe working  Barricade the working area.  Barricades installed
conditions  Practice safe working  Safety precautions
and perform environment observed.
housekeeping  Place tools and equipment in  Tools and equipment well
appropriate positions. placed.
 Tidy up the places as per  Appropriate tools used
procedure for right job.
 Segregate the waste  Tolls and equipment
 Dispose waste following laid checklist availed
down procedure  Waste management
 Store tools and equipment disposal procedures
as per standard. observed.
 Clean working area  Clean working area
 Clear gang ways of obstacles  Gang ways free of
 Separate waste materials obstacles
according to class  Classified waste
 Sweep floors regularly materials
 Clean tools and equipment  Clean floors
after use  Clean stored tools and
 Store tools and equipment equipment
according to rules and
regulations
A3: Comply  Identify potential  List/ register of potential
with environmental aspects environmental aspects
environmental  Adhere to relevant statutory  Spillage free environment
management instruments  Lower waste material
systems  Dispose waste in line with  Clean environment
local authority regulations  Colour coded bins
 Prevent unnecessary
spillages to the environment

199
 NATIONAL CERTIFICATE IN MOTOR VEHICLE MECHANICS 346/25/CR/0
 Implement Reduce recycle
and reuse practices
A4:  Mobilise SHEQ awareness  SHEQ campaign
Participate in campaigning material materials availed
SHEQ  Attend SHEQ briefing  Attendance
awareness meeting register/Minutes
campaign and  Identify potential hazards  Hazards Register
maintain  Induct new personnel on  Loss incidences
organizational SHEQ issues  Proper Personal
standards  Adhere to SHEQ rules and Protection Equipment
regulations (PPE)
 Enforce SHEQ rules and  List/register of relevant
regulations quality standards
 Identify relevant quality produced
standards  Quality checks
 Perform quality checks conducted in accordance
 Adhere to standard to set procedures
operating procedures  Operational checklist
 Maintain product quality  Quality products

TOOLS AND EQUIPMENT NECESSARY TO COMPLETE THIS DUTY:

 First aid kit.
 Safety signs and symbols.
 Awareness campaigns material.

HEALTH, SAFETY AND ENVIRONMENTAL ISSUES RELATED TO THIS DUTY:

 Personal protective gear
 Use of proper insulated tools
 Use of calibrated instruments incompliance to ISO standards
 Free gang ways at the worksite
 Floors free of slippery conditions
 Safety insignia post at all relevant areas.

200
NATIONAL CERTIFICATE IN MOTOR VEHICLE MECHANICS 346/25/CR/0

SPECIFIC WORKER TRAITS REQUIRED COMPLETING THIS DUTY:

 Team work
 Sober minded
 Communication
 Honest
 Punctual
Target orientated.

201
 NATIONAL CERTIFICATE IN MOTOR VEHICLE MECHANICS – 346/25/CR/MO
MINISTRY OF HIGHER AND TERTIARY EDUCATION, INNOVATION, CODE
SCIENCE AND TECHNOLOGY DEVELOPMENT SKILLS
PROFICIENCY SCHEDULE

INDUSTRY:A UTOMOTIVE TRADE/OCCUPATION: CLASS/LEVEL:NC

MOTOR MECHANICS

DUTY A: OVERERHAUL TRANSMISSION SYSTEM 15

Pre-requisit Approval Date: Review Date:
es: ‘O’ LEVEL
TASK STEPS  PROFICIENCY RELATEDKNOWLEDGE WORKPLACEESSENTIAL
INDICATORS SKILLS
B 1:Replace  Select suitable tools  Suitable tools and  Safety precautions o Communication
clutch  Fit fender covers, seat equipment selected  Safe handling, care and o Reading and writing
assembly and covers, floor mats and  Fenders covered use of tools and o Driving
clutch steering cover  Battery earth terminal equipment o Organizing
booster/ air  Disconnect battery disconnected  Component o Planning
pack  Disconnect gear  All electrical connectors  identification o Analytical
shift/ lever are disconnected  Drawings and sketch o Numeracy
 Disconnect air pipes  All electrical connectors readings
and hydraulic pipes re-connected according  Storage and care of
 Remove clutch air to manufacturer’s components
pack mounting specifications  Lubrication system
bolts/booster  Push-rod adjusted to service and maintenance
 Withdraw clutch air specifications procedures
pack /booster  Dismantling of  Operation of hydraulic
 Fit new clutch air components done systems, types,
pack/booster according to set
 Raise vehicle procedures
 NATIONAL CERCTIlFeIaCnA,TiEnsIpNeMctOaTnOdRrVeEplHaIcCeLE MECHANBICoSlts34ti6g/h2t5e/nCedR/t0o
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ReCmonovneecptroppueslhlerrod to clutch  Clutch system cleared
shpaefdtal of air and adjusted
FiMt toauilnptieccl eutpclhugmaster accordingly
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 Road test
B3. Replace  Select suitable tools  Suitable tools and
clutch cable  Cover fenders equipment selected
 Choke wheels  Fenders covered
 Disconnect battery  Battery earth terminal
 Disconnect cable from disconnected
clutch fork, bell housing  Correct size cable fitted
bracket and clutch pedal and adjusted accordingly
 Remove rubber glommet  Bracket tightened to
 Withdraw cable specifications
 Connect new clutch cable to
clutch pedal, fork and
bracket
 Fit rubber glommet
 Tighten new clutch cable
mounting brackets
 Check operation and adjust

203
  R e m o v e ge ar b ox e-Sgl3a4z6e/d25/CaRp/p0lication and rating
NATIONAL C ER TI F IC A T E IN M O TOR V EHICFLlEywMhEeCeHl iAsNdIC
mounting, housing and checked specifications
bolts and gearbox  Pressure plate is  Material science
 Remove clutch measured for finger  Vehicle electrics
assembly height operation, application and
 Inspect flywheel, circuit components
thrust bearing,  Pneumatics
clutch fork and  Motion and principles of
gearbox mounting forces
 Fit new clutch
assembly and thrust
bearing
 Fit gearbox and
support
 Fit cross member
and propeller shaft
 Connect gearbox
linkages,
speedometer cable
and electrical
connections
 Fill up transmission
oil
 Fit starter motor and
slave cylinder
 Lower vehicle
 Connect gear
lever/shift and
battery
 Start vehicle
 Check operation

204
 NATIONAL CERTIFICATE IN MOTOR VEHICLE MECHANICS 346/25/CR/0
 Road test

B2. Repair  Select suitable tools  Suitable tools and

clutch master  Cover fenders equipment selected
and slave  Choke wheels  Fenders covered
cylinders  Disconnect fluid  No brake fluid spilled
pipes on paint
 Remove clutch  Battery earth terminal
master cylinder disconnected
mounting bolts  Pistons checked for
 Disconnect pushrod scores
from clutch pedal  Seals checked for
 Withdraw clutch scores and
master cylinder functionality
 Remove reservoir  Cylinder bore checked
 Remove pushrod for scoring
from clutch master
 cylinder
 Remove piston

205
 TOOLS AND EQUIPMENT NECESSARY TO COMPLETE THIS DUTY:
Torque wrench, Feeler gauge, Pliers set, Filter remover, Hammer set,
Grease gun, Multi–meter Dial gauge Files Spanners

HEALTH, SAFETY AND ENVIRONMENTAL ISSUES RELATED TO THIS DUTY:

Personal protective clothing (PPE) worn all the time

 ean components
 Fit new bearing

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constant platCeosver fenders equipment selected
velocity  ConRneemctovberawkheefelusid pipes  Fenders covered
joints andLopoasrekn-boru ak teer ccaobnlsetsant  Vehicle to be secured on
 Fit vderlu om citsya(n Cd .Vd)rsuem c uri n g nut chassis stands if using
 R a i
r eta in er s s e vehicle and remove  jack
 Mou wnhteewlsh eels  Wheel pads removed
 FilRdeimfeorveentbiraalkoeil pads wear  Gear box oil drained
 Lowin erd ivceahto icrleconnectors brake  Inner CV joint removed
 Roacdaltiepsetr, ABS sensor from gearbox
eleRcetmsouviteadbalemtpoeorls/ shock
B8. Replace  S  Sui tab leritvoeolsshaanftdaesqsuemipbmlyent
 D
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hub  Choke wheels
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 Rem Vo
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boltDrain gearbox oil  I ns pec t ecw
 F i
t n omcpon
on steanntst velocity
 RemRoevmeofvlaeningenemroCuVntjionin g t from   Repjolain cetsdteofedcrtiivvee shaft comFpitodnreinvetsshaft assembly
to
boltgsearbox  Fit gneeawrbhouxb reduction gear
 WitChlderaanwdwrihveeslhhauftbafslasn
emgebly
 Fit S alildceom
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 CleDaniswmhaenetllehaunbd inspect drive
206
 CompoDnreinvetssfhitatfetdaisnsembly
reversifnitgteodrdtoergearbox

 Bolts tightened to
 manufBacotlutsretirg’shtsepneecdifitcoations
 manufacturer’s

  specifications
 Mount steering knuckle
shock absorber / damper
Workplace safety rules adhered to always
Environmental regulations
Proper use of tools and equipment

207
 NATIONAL CERTIFICATE IN MOTOR VEHICLE MECHANICS 346/25/CR/0
 Mount brake caliper, ABS
sensor and electrical
connectors
 Fill up gear oil
 Mount wheels
 Lower vehicle
 Tighten outer CV securing
nut
 Check operation
 Road test
B5. Replace  Select suitable tools  Suitable tools and equipment
propeller  Cover fenders selected
shaft, centre  Choke wheels  Fenders covered
bearing and  Raise vehicle  Bolts tightened to
universal  Drain gearbox oil manufacturer’s
joints  Indent match marks on  specifications
flanges  Match marks aligned on
 Remove propeller shaft reassembling
mounting bolts from final
drive flange
 Remove centre bearing
mounting bolts
 Withdraw propeller shaft
assembly
 Dismantle universal
joints(UJs) and fit new
 Slide propeller assembly into
gearbox
 Secure centre bearing

208
NATIONAL CERTIFICATE IN MOTOR VEHICLE MECHANICS 346/25/CR/0
 Mount propeller shaft
mounting bolts and nuts to
final drive flange
 Tighten centre bearing bolts
and nuts
 Fill gearbox oil
 Lower vehicle
 Road test

First aid

SPECIFIC WORKER TRAITS REQUIRED IN COMPLETING THIS DUTY:

Honesty Punctual Team worker Physically fit

Dedicated Sober minded Competent Tolerant
Focused

209
 NATIONAL CERTIFICATE IN MOTOR VEHICLE MECHANICS 346/25/CR/0
B6. Replace  Select suitable tools  Suitable tools and equipment
final drive  Cover fenders selected
unit/third  Loosen rear axle wheel nuts  Fenders covered
differential and raise vehicle  Components disassembled
lock unit and  Remove wheels, drum following repair manual
differential retainers and drum procedures
gears  Disconnect electrical  Faulty components replaced
connections  Bolts tightened to
 Replace differential lock unit manufacturer’s
 Remove crown wheel  specifications using torque
assembly wrench
 Dismantle differential unit
 Clean differential unit
 Inspect components
 Replace defective
components
MINISTRY OF HIGHER AND TERTIARY EDUCATION, INNOVATION, SCIENCE CODE
AND TECHNOLOGY DEVELOPMENT
SKILLS PROFICIENCY SCHEDULE

INDUSTRY:AUTOMOTIVE TRADE/OCCUPATION:MOTOR MECHANICS CLASS/LEVEL:NC

(to include diesel & tractor)

DUTY C: ENGINE OVERHAUL 15

Pre-requisites: ORDINARY LEVEL Approval Date: Review Date:
TASK STEPS PROFICIENCY RELATED WORKPLACE
INDICATORS KNOWLEDGE ESSENTIAL SKILLS

210
 Assemble differential unit 
Fit crown wheel  differentials
Adjust final drive unit
Connect electrical
NATIONA L CERcToIFnIn
CeAcTtE
orIsN MOTOR VEHICL E MECHANICS 346/25/CR/0
 Fit axle shafts
 Connect brake fluid pipes
and park-brake cables
 Fit wheel drums and
retainers
 Mount wheels
 Fill differential oil
 Lower vehicle
 Road test

C1;Remove  Select suitable tools  tools and equipment  Automotive o Communication

engine  Choke wheels selected Technology o Reading and
 Disconnect battery  Wheels choked  Safety precautions o writing
 Remove covers  Battery earth terminal  Safe handling, care o Estimations
 Drain engine oil disconnected and use of tools and o Driving
 Drain coolant  All electrical connectors  equipment o Organizing
 Remove radiator hoses are safely disconnected  Component o Planning
 Remove radiator  Engine oil and water  identification o Analytical
 Disconnect all electrical drained in containers  Drawings and o Numeracy
connections  All pipes to be blocked sketch readings
 Remove starter motor  Lifting position  Storage and care of
 Remove hydraulic pipes identified as stated in components
 Remove pneumatic pipes service manual  Material science
 Disconnect all  Engine removed within  Vehicle electrics
accessories specified time operation,

211
 NATIONAL CERTIFICATE IN MOTOR VEHICLE MECHANICS 346/25/CR/0
B7. Replace  Select suitable tools  Suitable tools and equipment
half shafts,  Cover fenders selected
bearing and  Loosen rear axle wheel nuts  Fenders covered
wheel studs and raise vehicle  Components removed
 Remove wheels, drum  according to manufacturer
retainers and drum  specifications
 Disconnect electrical  Stud holes inspected
connections, ABS sensor,  Components fitted according
brake fluid pipes and to manufacturer
parking brake cables  specifications
 Drain differential oil  Bolts tightened to
 Withdraw axle half-shafts manufacturer’s
 Remove wheel bearing  specifications
retainer
 Press out wheel bearing from
axle shaft
 Remove wheel studs
 inspect stud hole
 Replace defective axle shaft
and fit new studs
 Put lifting tackle in application and
position circuit components
 Connect hoist
 Remove engine mounting
bolts
 Detach engine from
other components
 Lift engine out
 Place engine on work-
bench or stands

212
 NATIONAL CERTIFICATE IN MOTOR VEHICLE MECHANICS 346/25/CR/0
C2.  Select suitable tools  Suitable tools and
Dismantle  Remove clutch equipment selected
engine assembly/torque  Engine disassembled
converter, flywheel following
and housing manufacturer’s
 Remove hydraulic specifications
pumps and  Visual inspection
carried out on all
Remove the components
following:  Crankshaft journals are
o tappet cover measured
o high pressure  Cylinder head warp-age
pipes and is checked
injector pump  Oil sump is checked for
o rocker shaft dents
assembly and  Worn out components
pushrods ordered.
o cylinder head
o timing cover
o sump
o oil strainer and
pump
o e crankshaft
balance
weights
o big end caps
o pistons
o idler gears
o camshaft and
cam-followers
o back-plate

213
 NATIONAL CERTIFICATE IN MOTOR VEHICLE MECHANICS 346/25/CR/0
o crank-shaft

 Clean and dry all

components
 Visually inspect all
components
 Smear crankshaft,
camshaft and
cylinder bore with oil
 Measure components
to check for wear
 Order replacement
parts
C3. Repair  Select suitable tools  Suitable tools and
engine  Clean and dry engine equipment used
block  Crankshaft tunnel run
 Oil cylinders out checked
 Fit new engine bearings  Correct size main
and crankshaft bearings
 Check end float  fitted
 Verify piston ring working  Bearing crush /nip
gap checked
 Fit piston and connecting  Oil clearances
rod into cylinder block measured on big end
 Fit oil pump, oil strainer, bearings
sump and back plate  Crankshaft end-float
 Fit timing gears, idler checked
gears and injector pump  necessary adjustments
 Fit cylinder head gasket made
and cylinder head

214
 NATIONAL CERTIFICATE IN MOTOR VEHICLE MECHANICS 346/25/CR/0
 Fit push rods and rocker  Pistons and
shafts connecting rods
 Carry out valve timing correctly assembled
 Adjust valve clearances  Piston ring working
 Fit high pressure pipes gap measured
and tappet cover  Cylinder head and
 Fill engine with oil cylinder head gasket
 Fit flywheel, clutch and fitted according to laid
pressure plate down
 Mount engine on  procedure
dynamometer  Bolts tightened to
 Fit starter motor specified torque.
 Connect water hoses and  Valve timing done to
all electrical connectors specifications.
 Start engine
 Check oil pressure, oil
leaks and water leaks
 Load engine and check
load appreciation
 Run in engine and re-
torque
 Remove engine from
dynamometer
C4. Fit  Select suitable tools  -Suitable tools and
engine  Cover vehicle fenders equipment selected

215
NATIONAL CERTIFICATE IN MOTOR VEHICLE MECHANICS 346/25/CR/0
 Fit lifting chains onto  -Vehicle fenders
engine covered
 Lift and fit engine onto  Engine mountings
vehicle replaced
 Fit engine to gearbox  Lifting chains fitted to
 secure bell housing bolts lifting lugs.
 Fit engine mountings  -All bolts tightened to
 Fit radiator and hoses specified torque
 Fit alternator, starter
motor and electrical
connections
 Fit all accessories and
attachments
 Run in engine


TOOLS AND EQUIPMENT NECESSARY TO COMPLETE THIS DUTY:

Plug spanner, Allen key Spanner Torque wrench, Feeler Pliers
set, set, gauge,
set,
Filter remover, Hammer Grease Multi -meter, Micrometer
set, gun,
Vernier caliper V- block

HEALTH, SAFETY AND ENVIRONMENTAL ISSUES RELATED TO THIS DUTY:

 Personal protective clothing(PPE),
 Workplace safety rules,
 Environmental regulations
 Proper use of tools and equipment
 First aid kit
SPECIFIC WORKER TRAITS REQUIRED TO COMPLETE THIS DUTY:

216
 NATIONAL CERTIFICATE IN MOTOR VEHICLE MECHANICS 346/25/CR/0
Honesty Punctual Team worker
Physically fit Dedicated Competent
Focused Tolerant
MINISTRY OF HIGHER AND TERTIARY EDUCATION, INNOVATION, SCIENCE AND CODE
TECHNOLOGY DEVELOPMENT
SKILLS PROFICIENCY SCHEDULE

INDUSTRY:AUTOMOTIVE TRADE/OCCUPATION:MOTOR MECHANICS CLASS/LEVEL:NC

(to include diesel & tractor)

DUTY D: OVERHAUL STEERING SYSTEM 10

Pre-requisites: ORDINARY Approval Date: Review Date:
LEVEL
TASK STEPS PROFICIENCY RELATED WORKPLACE
INDICATORS KNOWLEDGE ESSENTIAL
SKILLS

217
 NATIONAL CERTIFICATE IN MOTOR VEHICLE MECHANICS 346/25/CR/0
D1:Perform  Select suitable tools  Appropriate tools  Steering geometry o Communication
wheel  Fit fender, steering, seat and equipment used  Component o Reading and writing
alignment and steering wheel  Fenders covered  identification o Computers
covers  Gauges set to  Drawings and sketch o Estimations
 Calibrate gauges manufacturer’s readings o Measurements
 Inspect suspension specifications  Storage and care of o Driving
system components  Tyres inflated to components o Organizing
 Replace defective specifications  Lubrication system o Planning
components  Readings compared service and o Analytical
 Inspect tyres with manufacturer’s maintenance o Numeracy
 Replace defective tyres specifications procedures
 Inflate tyres to required  Correct adjustments  Operation of
specifications done hydraulic systems,
 Park vehicle in straight types, application
ahead position
 Jack vehicle and place
on turn tables
 Mount gauges or
projectors on vehicle
 Note reading on gauges
or projectors
 Compare readings with
manufacturer’s
specifications
 Adjust geometrical
angles to specifications
 Centralize steering wheel
 Jack vehicle and remove
turn tables

218
 NATIONAL CERTIFICATE IN MOTOR VEHICLE MECHANICS 346/25/CR/0
D2. Repair  Select tools and  Appropriate tools and
stub axle, equipment selected
ball joints and secure  Components removed
 Remove wheels and  according to
caliper assembly manufacturer
 Remove hub nut and specifications
hub  Worn components
 Remove tie-rod end ball replaced
joint and lower ball  Hub nut and wheels
joint tightened to
 Disconnect electrical manufacturer’s
connections specifications
 Remove damper  Bearing grease used to
mounting bolts pack new bearings
 Replace tie-rod ends  Bearings pre-loaded to
and ball joints specifications
 Grease new hub
bearings and fit into
hub
 Fit hub to stub axle
 Pre-load bearings
 Fit back caliper
assembly and mount
wheels

219
 NATIONAL CERTIFICATE IN MOTOR VEHICLE MECHANICS 346/25/CR/0
D3.  Select suitable tools  Appropriate tools and
Replace  Fit fender covers, seat equipment selected
steering covers and floor mats  Fenders covered
column  Steer wheels to straight  Wheels choked
and ahead  Components removed
coupling  choke wheels  according to
 Remove steering wheel manufacturer manual
nut, column retainers,  Components fitted
column, coupling bolts  Bolts and nuts
and coupling tightened to
 Withdraw steering manufacturer’s
column specifications using
 Centralize steering torque wrench
wheel  Steering wheel aligned
 Fit steering coupling,
column and retainers,
steering wheel and
securing nut
 Remove chokes
D4.  Select suitable tools  Suitable tools and
Replace  Fit fender covers, seat equipment used
steering covers, floor mats and  Fenders covered
drop arm steering cover  Drop arm disconnected
 Choke wheels  New drop arm fitted
 Disconnect drop arm  Bolts tightened to
from drag link and manufacturer’s
steering box. specifications
 Remove drop arm
securing nut and drop
arm

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NATIONAL CERTIFICATE IN MOTOR VEHICLE MECHANICS 346/25/CR/0
 Centralize steering
gearbox
 Fit new drop arm and
torque nuts to
specifications

TOOLS AND EQUIPMENT NECESSARY TO COMPLETE THIS DUTY:

Plug spanner Allen key set Spanner set Torque wrench
Feeler gauge Pliers set Filter remover Hammer set Grease gun Multi -
meter HEALTH, SAFETY AND ENVIRONMENTAL ISSUES RELATED TO THIS DUTY:
Proper use of tools
Personal protective clothing (PPE)
Workplace safety rules
Environmental regulations
First aid

SPECIFIC WORKER TRAITS REQUIRED TO COMPLETE THIS DUTY:

 Honesty
 Punctual
 Team worker
 Physicallyfit
 Dedicated
 Focused

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 Competent
 Tolerant

TOOLS AND EQUIPMENT NECESSARY TO COMPLETE THIS DUTY:

 Plug spanner
 Allen key set
 Spanner set
 Torque wrench
 Feeler gauge
 Pliers set
 Filter remover
 Hammer set
 Grease gun
 Multi -meter

HEALTH, SAFETY AND ENVIRONMENTAL ISSUES RELATED TO THIS DUTY:

 Proper use of tools

 Personal protective clothing (PPE)

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 Workplace safety rules
 Environmental regulations
 First aid

SPECIFIC WORKER TRAITS REQUIRED TO COMPLETE THIS DUTY:

 Honesty
 Punctual
MINISTRY OF HIGHER AND TERTIARY EDUCATION,INNOVATION, SCIENCE AND CODE
TECHNOLOGY DEVELOPMENT
SKILLS PROFICIENCY SCHEDULE

INDUSTRY: AUTOMOTIVE TRADE/OCCUPATION: MOTOR VEHICLE CLASS/LEVEL: NC

MECHANICS
(to include diesel & tractor)
DUTY E: CARRY OUT SERVICE 5
Pre-requisites: ORDINARY LEVEL Approval Date: Review Date:
TASK STEPS PROFICIENCY INDICATORS WORKPLACE
RELATED ESSENTIAL
KNOWLEDGE SKILLS
E1: Change  Place vehicle on level  Suitable tools and equipment  Knowledge of o Communication
engine oil and ground used oil o Reading and writing
oil filter  Block wheels  Fenders covered  viscosity o Computers
 Start engine  Wheels blocked  Engine o Estimations
 Switch off engine  Oil filled to specifications performance o Measurements
 Remove drain plug  Oil leaks identified  Workshop o Driving
 Drain oil into container health and
 Replace drain plug  safety

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 Fill engine oil to  Operation of
specifications hydraulic
 Start the engine systems, types,
 check for leaks application
E2: Carry out  Check battery  Safety procedures adhered to
basic electric  Check hooter  Suitable tools and equipment
checks  Check indicators are selected
 Check headlights  Battery condition noted
 Check wipers  Hooter functionality checked
 Check reverse lights  Indicators functionality
 Check gauges checked
 Check interior fan  Headlights condition recorded
 Check warning lights  Wipers’ condition checked
 Gauges operation checked
according to manual
E3: Replace  Loosen attaching bolts  Safety procedures are
fan and  Remove fan belt and adhered to
radiator and fan  Suitable tools and equipment
sump  Fit fan and fan belt are selected
 Tension fan belt  Fan removed
 Check engine  Fan belt tensioned according
temperature to manufacturer’s
 Remove radiator cap specifications
 Drain coolant  Bolts torqued to
 Remove hoses and manufacturers specifications
cowling  Radiator cap removed
 Remove radiator  Coolant drained
 Fit radiator  Cowling removed
 Fit cowling and hoses  Radiator removed
 Fill in coolant
 Fit radiator cap

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 Start the engine  Radiator, hoses and cowling
 Check for leaks fitted according to
 Check engine manufacturer’s guidelines
temperature  Radiator hoses checked for
 Drain oil leaks
 Remove sump bolts and  Oil drained
sump  Sump removed according to
 Fit new sump gasket the manual
 Fit sump  Sump fitted according to
 Fill oil manufacturer’s specifications
 Run engine  Sump checked for leaks
 Check oil leaks  Oil filled according to manual
E4:  Clean grease nipples  Grease nipples cleaned
Lubricate  Fill grease gun  Grease gun filled
joints (ball  Grease joints  Joints greased
joints, cv  Remove bearings  Safety procedures adhered to
joints,  Clean bearings  Suitable tools and equipment
universal  Inspect bearings are selected
joints,  Repack bearings with  Repacking grease procedure
propeller shaft) grease followed
and bearings  Re-fit bearings  Bearings refitted
 Pre-load bearings  Bearings pre-loaded according
to manufacturer specifications

 Team worker
 Physically fit
 Dedicated
 Sober minded

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 Focused
 Competent
 Tolerant

MINISTRY OF HIGHER AND TERTIARY EDUCATION, INNOVATION,

SCIENCE AND TECHNOLOGY DEVELOPMENT SKILLS PROFICIENCY
SCHEDULE

INDUSTRY:AUTOMOTIVE TRADE/OCCUPATION: MOTOR MECHANICS CLASS/LEVEL: NC

(to include diesel & tractor)

DUTY F: PERFORM ENGINE TUNE UP 10

Pre-requisites: ORDINARY LEVEL Approval Date: Review Date:
TASK STEPS PROFICIENCY INDICATORS RELATED
KNOWLEDGE WORKPLACE
ESSENTIAL
SKILLS

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F1  Start engine to warm  Spark plug area blown  Knowledge of oil Communication
Conduct  Stop engine  Spark plug removed properties Drawing
compression  Blow spark plug area  Coil isolated  Engine performance Reading and writing
test  Remove spark plug, heater  Compression tester  Basic electrics Computers
plug or injector mounted  Workshop health and Estimations
 Isolate coil  Engine cranked  safety Measurements
 Mount compression tester  Accelerator full depressed  Fuel economy Driving
 Crank engine  Dry test reading noted
 Depress accelerator fully  Compression tester
 Record dry test reading for disconnected
each cylinder  West test reading noted
 Disconnect compression  Compression is compared
tester to manufacturer
 Squirt oil into each cylinder specifications
 Mount compression tester
 Crank engine
 Record wet test reading for
each cylinder
 Compare results
F2: Overhaul  Disconnect battery  Safety procedures adhered
Carburettor  Remove air cleaner housing to
and replace  Disconnect accelerator  Visual inspection of
fuel filter cable and other components carried out
attachments  Overhauling procedure
 Remove carburettor followed
mounting bolts

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 Remove carburettor  Idling speed adjusted
 Cover manifold hole according to
 Strip carburettor manufacturers’
 Clean and inspect specifications
components  Workbench is clean and
 Replace defective dust free
components  Stipulated cleaning
 Re assemble carburettor solvents are used
 Adjust float level  Battery connected
 Fit back carburettor  Bolts torqued to
 Reconnect accelerator cable manufacturers
and other attachments specifications
 Fit air cleaner housing
 Change air cleaner element  Safety procedures adhered
 Reconnect battery to
 Start engine  Suitable tools and
 Adjust idling speed equipment are selected
 Adjust air fuel mixture  System is bled until it is
 Release fuel pressure bubble free
 Loosen hose clamps  Diesel leaks are eliminated
 Remove fuel filters
 Fit new filter
 Tighten hose clamps
 Bleed air if diesel engine
 Reconnect battery
 Start engine
 Check for leaks
 Carry out road test
F3: Secure  Disconnect battery  Battery terminals
manifolds  Check engine temperature disconnected

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 Tighten bolts  Engine temperature noted
 Re connect battery  Bolts torque to
 Start engine manufacturers
 Check for leaks specifications
 Battery terminals
connected
 Leaks noted

F4: Replace  Switch off engine  Engine switched off

high tension  Check number one position  Direction of rotation
cables and on distributor cap identified
spark plugs  Check direction of rotation  High tension cables
 Remove high tension removed
cables  High tension cables fitted
 Fit high tension cables  Misfiring checked
 Start engine  Safety procedures
 Check for misfiring adhered to
 Check engine temperature  High tension cables
 Blow spark plug area disconnected
 Remove high tension  Specified spark plugs are
cables fitted
 Remove spark plug  High tension cables fitted
 Fit new spark plugs in accordance to firing
 Fit high tension cables order
 Start engine  Misfiring checked
 Check for misfiring

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F5  Check engine temperature  Battery terminals
Overhaul  Disconnect battery disconnected
distributor  Remove distributor cap  Engine firing order
 Turn engine to mark identified
number one  Distributor removed
 firing  Distributor dismantled
 Disconnect cable to  Distributor is assembled
distributor according to
 Remove distributor manufacturer’s
mounting bolt  specifications
 Remove distributor  Damaged or defected
 Strip distributor components are replaced
 Clean components
 Inspect components
 Replace worn out parts
 Re assemble distributor
 Carry out bench test
 Fit distributor
 Reconnect cable to distributor
 Adjust ignition timing
 Tighten distributor mounting
bolt
 Fit distributor cap
 Reconnect battery
 Start engine

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F6: Replace  Disconnect battery  Safety procedures
ignition coil  Disconnect cables to coil adhered to
 Remove mounting bolts  Mounting bolts removed
 Remove coil  Ignition coil is assessed
 Fit new coil for tracking
 Tighten mounting bolts  Cables connected to coils
 Connect cables to coil  Battery terminals
 Connect battery connected
 Start engine  Tracking recorded
 Check for tracking
F7: Replace  Switch off engine  Fuel pressure regulator
fuel pressure  Disconnect battery removed according to
regulator  Release fuel pressure manufacturer’s standards
 Loosen hose clamps  New fuel pressure
 Remove regulator mounting regulator fitted according
bolts to
 Remove regulator  manufacturer’s
 Fit new regulator specifications
 Tighten hose clamps  Bolts tightened to
 Start engine specifications
F8: Service  Switch off engine  Safety procedures adhered
sedimentor  Disconnect hoses to
 Remove sedimentor from  Suitable tools and
housing equipment are selected
 Clean housing and  System is bled until
components system is bubble free
 Assemble sedimentor  Leaks checked for
 Fit sedimentor housing
 Connect hoses
 bleed the fuel system

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 start engine
 check for leaks

TOOLS AND EQUIPMENT NECESSARY TO COMPLETE THIS DUTY:

 Plug spanner
 Allen key set
 Spanner set
 Torque wrench
 Feeler gauge
 Pliers set
 Filter remover
 Hammer set
 Grease gun
 Multi -meter

HEALTH, SAFETY AND ENVIRONMENTAL ISSUES RELATED TO THIS DUTY:

 Personal protective clothing (PPE)

 Workplace safety rules
 Environmental regulations

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NATIONAL CERTIFICATE IN MOTOR VEHICLE MECHANICS 346/25/CR/0
 Proper use, storage and handling of tools
 First aid

SPECIFIC WORKER TRAITS REQUIRED TO COMPLETE THIS DUTY:

 Honesty
 Punctual
 Team worker
 Physically fit
 Dedicated
 Sober minded
 Focused
 Competent
 Tolerant

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 NATIONAL CERTIFICATE IN MOTOR VEHICLE MECHANICS 346/25/CR/0
MINISTRY OF HIGHER AND TERTIARY EDUCATION, INNOVATION, CODE
SCIENCE AND TECHNOLOGY DEVELOPMENT SKILLS PROFICIENCY
SCHEDULE

INDUSTRY:AUTOMOTIVE TRADE/OCCUPATION:MOTOR MECHANICS CLASS/LEVEL: NC

(to include diesel & tractor)

DUTYG: OVERHAUL SUSPENSION 10

Pre-requisites: CLASS Approval Date: Review Date:
TASK STEPS PROFICIENCY INDICATORS RELATED
KNOWLEDGE WORKPLACE
ESSENTIAL
SKILLS
G1: Replace  Choke wheels and put  Safety procedures are  Workshop health o Communication
suspension fender covers adhered to and Drawing
bushes  Jack and put vehicle on  Hub assembly  safety o Reading and
stands disconnected  Component writing
 Remove wheels  Upper and lower arm  identification o Computers
 Disconnect hub assembly removed.  Drawings and sketch o Estimations
from upper and lower  Components inspected readings o Measurements
control arms  Bushes removed from  Storage and care of o Driving
 Secure ball joints control arm components o Organizing
 Remove upper and lower  Bushes fitted according to  Lubrication system o Planning
control arm manufacturer’s service and o Analytical
 inspect components specifications or manual maintenance o Numeracy
 Remove bushes from  Defective components are procedures
control arms  identified  Operation of
 Fit new bushes on control hydraulic systems,
arms and grease types, application

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 Fit upper and lower control  Geometrical angles  Different types of
arms and connect ball adjusted to manufacturers suspensions
joints specifications  Properties of metals
 Fit wheels and remove  Specified grease used
stands  Steering wheel centralized
 Align wheels

G2:Replace  Select appropriate tools

leaf spring  Choke wheels  Suitable tools and
 Remove park brake cable equipment are selected
from spring  Spring removed according
 Loosen ‘u’ bolts to manual
 Jack vehicle and put on  New spring fitted
stands according to
 Remove ’u’ bolts and manufacturer’s manual
shackle hanger  Bolts tightened to
 Remove spring manufactures
 Inspect components specifications
 Fit new spring, ’u’ bolts’,
shackle hanger
 Connect park brake cable
 Jack vehicle and remove
stands

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 NATIONAL CERTIFICATE IN MOTOR VEHICLE MECHANICS 346/25/CR/0
G3  Select appropriate tools  Safety procedures are
Replace coil  Choke wheels adhered to
spring  Cover fenders  Wheels chocked
 Jack front of vehicle and  Fenders covered
support on safety stands  Vehicle supported on
 Remove wheels safety stands
 Disconnect shock absorber  Wheels removed
from stub axle  Shock absorber
disconnected from stab
axle
 Coil sprig aligned on pads

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NATIONAL CERTIFICATE IN MOTOR VEHICLE MECHANICS 346/25/CR/0
 Remove brake fluid pipe  Coil spring height
mounting bracket from measured
shock strut
 Remove shock pad and  Brake fluid pipes
withdraw shock absorber secured

spring
 Remove shock pad
 retaining nut
 Remove coil spring and
inspect
 Clamp new spring
 and fit shock absorber and
pad
 retaining nut
 Unclamp spring
 Fit shock pad
 connect shock absorber on
stab axle
 Secure brake fluid pipe to
shock absorber
 Fit wheels
 Jack and remove stands
 Test vehicle

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 NATIONAL CERTIFICATE IN MOTOR VEHICLE MECHANICS 346/25/CR/0
 Select appropriate tools  Safety procedures are
G4: Replace  Choke wheels adhered to
suspension  Jack vehicle and support on  Suitable tools and
air bag safety stands equipment are selected
 Remove air pipes  Airbags removed
 Remove air bag mounting according to manual
nuts and withdraw air bag  Airbag fitted according to
 Fit new airbag manual
 Fit air pipes  System air pressure
 Jack vehicle and remove checked to manufacturers
stands  specifications
 Start vehicle and check
pressure

G5: Replace  Select appropriate tools  Safety procedures are

shock  Choke wheels adhered to
absorber  Remove upper and  Suitable tools and
 lower locknuts, retainers equipment are selected
and bushes  Locknuts, retainers
 Inspect components and bushes removed
 Fit new shock absorber  Components are
 Fit upper and lower, inspected
retainers bushes and
locknuts  Shock absorber primed
 Test vehicle  before fitting

 Match marks are

observed

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 NATIONAL CERTIFICATE IN MOTOR VEHICLE MECHANICS 346/25/CR/0
G6: Replace  Select appropriate tools
axle  Choke wheels  Suitable tools and
 Loosen ‘u’ bolts equipment are selected
 Jack vehicle and put on
stands
 Remove wheels  Brakes adjusted to
 drums ,brake cables manufacturers
 Support axle beam, brake specifications
pipes and remove shock
absorbers  Braking efficiency
tested

 Remove ‘u’ bolts  Park brake adjusted

 Lower axle according to
 Remove propeller manufacturer’s
 shaft  specifications
 Fit new axle
 Fit ‘u’ bolts, shock
absorbers, brake pipes,
drums and wheels
 Fit propeller shaft
 Jack vehicle and remove
stands
 Start engine, bleed and
adjust brakes
 Rest brakes

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 NATIONAL CERTIFICATE IN MOTOR VEHICLE MECHANICS 346/25/CR/0
G7: Replace  Select appropriate tools  Safety procedures are
torsion bar,  Choke wheels adhered to
control arm  Cover fenders  Suitable tools and
and stabilizer  Jack front of vehicle and equipment are selected
bar put on stands
 Remove torsion bar anchor  Defective components
bolt, anchor swivel and are
torque  identified
 plate mounting bolt  Geometrical angles
 Remove lower arm adjusted to
 spindle ,washer and nut manufacturers
from lower control arm  specifications
 Remove torsion bar
 Remove stabilizer bar from
control arm
 Remove control arm
 Clean components
 Inspect components
 Fit new control arm and
camber plates
 Fit new stabilizer bar
 Connect ball joints
 Fit new torsion bar
 Jack vehicle and remove
stands
 Align wheels
 Test vehicle

TOOLS AND EQUIPMENT NECESSARY TO COMPLETE THIS DUTY:

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NATIONAL CERTIFICATE IN MOTOR VEHICLE MECHANICS 346/25/CR/0
 Plug spanner
 Allen key set
 Spanner set
 Torque wrench
 Feeler gauge
 Pliers set
 Filter remover
 Hammer set
 Grease gun
 Multi -meter
 Trolley jack
 Bottle jack
 Stands

HEALTH, SAFETY AND ENVIRONMENTAL ISSUES RELATED TO THIS DUTY:

 Proper use, storage and handling of tools

 Personal protective clothing (PPE)
 Workplace safety rules
 Environmental regulations
 First aid

SPECIFIC WORKER TRAITS REQUIRED TO COMPLETE THIS DUTY:

 Honesty
 Punctual
 Team worker
 Physically fit
 Competent
 Focused
 Tolerant
 Dedicated

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 Sober minded

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 NATIONAL CERTIFICATE IN MOTOR VEHICLE MECHANICS – 346/25/CR/MO

MINISTRY OF HIGHER AND TERTIARY EDUCATION, INNOVATION, CODE

SCIENCE AND TECHNOLOGY DEVELOPMENT SKILLS PROFICIENCY
SCHEDULE

INDUSTRY: AUTOMOTIVE TRADE/OCCUPATION:MOTOR MECHANICS CLASS/LEVEL:NC

(to include diesel & tractor)

DUTYH: OVERHAUL GEARBOX 10

Pre-requisites: ORDINARY LEVEL Approval Date: Review Date:
TASK STEPS PROFICIENCY INDICATORS RELATED
KNOWLEDGE WORKPLACE
ESSENTIAL
SKILLS
H1  Select appropriate tools  Safety procedures are  Knowledge of metal o Communication
Strip  Clean gearbox adhered properties o Drawing
gearbox  Put gearbox on stands  to  Knowledge of o Reading and
 Remove bell housing  Suitable tools and  safety and health writing
 Remove selector detents equipment are selected  regulations o Computers
 Remove front bearing retainer  Gearbox dismantled  Knowledge of o Estimations
 Remove transmission casing according to manual  different gearbox o Measurements
 bolts  Dismantled components operation o Driving
 Remove input shaft  cleaned  Ability to interpret
 Remove transmission shift  Defective components are diagrams
cover control retainer  identified  Knowledge of oil
 Remove restrict pins properties and
 NATIONAL CERTIFICATE IN MOTOR VEHICLE MECHANICS 346/25/CR/0
 Remove speedometer drive  function
gear  Knowledge of
 Remove shift and selector workshop
lever detent machinery and
 Remove shift fork shaft s  tools
 Remove front output shaft
snap ring, gears and
synchronizers
 Remove idler gear shaft
stopper
 Remove reverse idler gear
shaft
 Remove rear bearing retainer
 Remove counter gear/ lay
shaft
 Remove output shaft from
intermediate plate
 Clean and inspect
components
H2:Replace  Select appropriate tools
gearbox  Clean gearbox  Suitable tools and
input shaft  Put gearbox on stands equipment are selected
bearing  Remove bell housing  Dismantled components
 Remove selector fork detents are cleaned
 Remove front bearing retainer  Defective components are
 Remove snap ring from input  identified
 shaft  Assembling of components
 Remove input shaft bearing done according to manual
 Clean components
 Fit new bearing

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 Fit snap ring  Bolts tightened to
 Fit input shaft to output shaft manufactures
 Fit lay shaft and input shaft specifications
snap rings  Operation checked
 Fit bearing retainer and
gasket
 Fit bell housing
 Fit selector detents
 Check operation
H3:Replace  Select appropriate tools
reverse  Choke wheels  Suitable tools and
switch  Disconnect electrical equipment are selected
connections  Electrical connections
 Remove reverse switch disconnected
 Fit new reverse switch  Reverse switch removed
 Connect electrical according to manual
connections  New reverse switch fitted
 Check operation according to manufacturer
 Remove cover fenders and guidelines.
wheel chokes

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 NATIONAL CERTIFICATE IN MOTOR VEHICLE MECHANICS 346/25/CR/0
H4  Select appropriate tools
Replace  Park vehicle on level ground  Suitable tools and
speedometer  Choke wheels equipment are selected
drive gear  Disconnect mechanical or  Speedometer drive gear
electrical cable from removed according to
speedometer drive gear manual
 Remove speedometer drive 
gear  Speedometer drive gear
 Fit new speedometer drive fitted according to manual
gear  Wheel chockers removed.
 Connect mechanical or
electrical cable to
speedometer drive gear
 Remove wheel chokes
 Test for operation

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 NATIONAL CERTIFICATE IN MOTOR VEHICLE MECHANICS 346/25/CR/0
H5  Select appropriate tools  Safety procedures are
Replace  Choke wheels adhered
gearbox oil  Cover fenders  to
cooler  Disconnect radiator hoses  Suitable tools and
 Disconnect fan electrical equipment are selected
connections  Radiator, radiator hoses,
 Remove fan assembly from and automatic
 radiator transmission fluid pipes
 Disconnect automatic are tested for leaks
transmission fluid pipes from  Bolts tightened to
radiator manufactures
 Remove radiator specifications
 Fit new radiator  Oil topped up to specified
 Connect automatic levels.
transmission  Electrical components
 fluid pipes connected
 Fit fan assembly
 Connect radiator hoses
 Fill radiator with water
 Top up automatic
transmission
 fluid
 Remove fender covers and
wheel chokes
 Start engine and test for
operation
H6  Select appropriate tools  Safety procedures are
Replace  Remove speedometer drive adhered
transfer gear  to
chain  Remove transfer indicator  Dismantled components are
switch cleaned

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NATIONAL CERTIFICATE IN MOTOR VEHICLE MECHANICS 346/25/CR/0
 Remove shift gear head  Defective components are
 Remove front retainer cover  identified
 Remove upper cover and oil  Assembling of components
deflector done according to manual
 Remove front and rear  Components assessed
companion flange  according to specifications
 Remove extension housing
 Remove speedometer drive
gear
 Separate front case and rear
case
 Remove selector fork
 Remove front drive fork, fork
shaft and detents
 Remove high and low fork ,
fork shaft and stopper
 Remove rear output shaft,
driver sprocket and chain
 Fit driver sprocket ,new chain,
and rear output shaft
 Fit high and low fork shaft,
fork and stopper
 Fit front drive shaft, fork and
selector detents
 Fit front case to rear case
 Fit speedometer drive gear

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 Fit extension housing
 Fit rear and front companion
flange
 Fit oil deflector and upper
cover
 Fit front retainer cover
 Fit shift gear head
mechanism
 Fit transfer indicator switch
 Fit speedometer drive gear
and cable
 Start vehicle and test for
operation

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H7  Select suitable tools  Appropriate tools and
Disassemble  Clean work bench equipment selected and
automatic  Clean transaxle properly used
transaxle  Drain automatic  Safety precautions adhered
transmission to
 fluid  Working area is dust free
 Mount gearbox on cradle  Parts dismantled according
 Remove input turbine sensor to manufacturer’s
 Remove oil pressure switch specifications
 Remove transaxle range  Parts arranged in order of
switch dismantling
 Remove vehicle speed sensor  Recommended cleaning
 Remove connector pipe solvents use
 Remove oil pan  Cleaned parts dried with
 Disconnect solenoid valve compressed air
connector
 Remove the ground and
transaxle fluid temperature
sensor
 Remove oil strainer
 Remove control valve body
 Remove the coupler
component
 Remove accumulator
component, manual shaft,
park
rod lever component and band

pump
 Remove torque converter
housing

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 Remove forward clutch
component
 Remove differential unit
 Remove secondary gear and
output gear
 Remove actuator plate and
support actuator
 Remove park pawl
 Remove end cover
 Remove ‘o’ ring from
transaxle case
 Remove band strut
 Remove brake bands
 Remove clutch component
 Remove snap ring
 Remove rear planetary gear
component
 Remove front sun gear
 Remove forward clutch hub
 Remove front internal gear
and one way clutch
 Remove locknut
 Remove primary gear
 Remove bearing
 Remove funnel
 Remove oil pipe
 Clean and inspect
components

TOOLS AND EQUIPMENT NECESSARY TO COMPLETE THIS DUTY:

 Plug spanner

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 Allen key set
 Spanner set
 Torque wrench
 Feeler gauge
 Pliers set
 Hammer set
 Grease gun
 Multi -meter
 Bearing puller
 Hole punchers
 Oil pump
 Pin punch
 Center punch

HEALTH, SAFETY AND ENVIRONMENTAL ISSUES RELATED TO THIS DUTY:

 Personal protective clothing (PPE)

 Workplace safety rules
 Environmental regulations
 Proper use, storage and handling of tools
 First aid

SPECIFIC WORKER TRAITS REQUIRED TO COMPLETE THIS DUTY:

 Honesty  Tolerant
 Punctual
 Team worker
 Physically fit
 Dedicated
 Sober minded
 Focused
 Competent

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MINISTRY OF HIGHER AND TERTIARY EDUCATION, CODE
INNOVATION, SCIENCE AND TECHNOLOGY DEVELOPMENT
SKILLS PROFICIENCY SCHEDULE

INDUSTRY: AUTOMOTIVE TRADE/OCCUPATION:MOTOR MECHA NIC CLASS/LEVEL: NC

AUT ( to include diesel and tractor) S

DUTY I: OVERHAUL BRAKING SYSTEMS 10 10

Pre- O LEVEL Approval Date: Review D ate:
requisites:
TASK STEPS PROFICIENCY INDICATORS RELATED WORKPLACE
KNOWLEDGE ESSENTIAL SKILLS
I1:Replace  Select appropriate tools  Suitable tools and  Material
brake and equipment equipment selected  Vehicle b o Communication
booster  Choke wheels  Fenders covered system o Drawing
 Disconnect battery  Battery earth terminal  Vehicle o Reading and writing
 Detach master cylinder disconnected  science o Computers
 Disconnect vacuum pipe  Push-rod adjusted to raking o Estimations
 Disconnect pedal specifications models o Measurements
connections  Bolts tightened to o Organizing
 Remove mounting bolts manufacturer’s o Planning
 Mount new booster specifications o Analytical
 Connect pedal connections o Numeracy
 Connect vacuum pipe

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 Mount master cylinder
 Connect battery
 Start engine
 Test booster operation

I.2:Overhau  Select appropriate tools  Battery negative terminal

l brake and equipment disconnected
master  Choke wheels  Vehicle fenders covered
cylinder  Disconnect battery  Work-bench is cleaned
 Cover vehicle fenders,  and free of dust
steering wheel, floor and  Correct use of tools done
gear knob  Master cylinder
 Disconnect electrical dismantled according to
connections and pipes on manufacturer’s
master cylinder specifications
 Remove master cylinder  Visual inspection carried
 Empty brake fluid to check for scoring and
 Dismantle master wear in bore
cylinder  Defective parts are
 Inspect and replace  identified
defective components  Correct replacement
 Reassemble master parts fitted
cylinder  Master cylinder assembled
 Bench test master according to
cylinder manufacturer’s
 Fit master cylinder, pipes specifications
and electrical  Safety precautions to be
connections observed when
 Fill up master cylinder disconnecting electrical
and bleed system connections

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 Connect battery  Brake fluid
 Remove wheel chokes, handling
covers from gear knob, precautions observed
steering wheel and
fenders  Appropriate type of
 Road test vehicle fluid is used

 Pedal travel and

clearance measured

 Hydraulic system to be
 rid of air after bleeding

 Water used to clean

brake components

I.3: Replace  Select appropriate tools  Suitable tools and

Anti-lock and equipment equipment selected
Braking  Choke wheels  Fenders covered
system  Disconnect battery  Battery earth terminal
(ABS) o Cover vehicle connected
fenders  Safety precautions
 Disconnect electrical observed
connection and fluid  Specified ABS unit fitted
pipes  Brake fluid system bled
 Remove mounting bolts  Reservoir filled with
specified brakefluid
Fit fluid pipes  ABS unit tested
o Fill reservoir
o Connect electrical
connections and
battery

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 Start vehicle
 Test ABS operation
 Remove fender covers
and wheel chokes

I.4:Replace  Select appropriate tools  Suitable tools and

brake discs and equipment equipment selected
and pads  Loosen wheel nuts  Fenders covered
 Jack vehicle  Brake disc replaced
 Fit stands  New brake pads fitted
 Remove wheels  Wheel bearings
 Remove electrical inspected
connections, brake  Wheel bearings greased
caliper and caliper  Electrical
bracket connections
 Remove wheel hub where connected
integral and disc  Bearings pre-loaded
 Fit new disc to
 Clean and inspect wheel manufacturer’s
bearings specifications
 Grease wheel bearings  Bolts tightened to
and fit manufacturer’s
 Fit hub and pre-load specifications using a
bearings torque wrench
 Fit caliper bracket, new  Wheels tightened
brake pads and brake to
caliper manufacturer’s
 Fit electrical connections specifications
 Check for operation
 Fit wheels and torque
 Lower vehicle
 Road test vehicle

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I.5:Overhaul brake  Select appropriate tools  Suitable tools and

caliper and equipment equipment selected
 Loosen wheel nuts  Fenders covered
 Jack vehicle  Safety precautions
 Place vehicle on stands observed
 Remove wheels and  Faulty components
electrical connections
 Remove flexible hose/pipe, components replaced
mounting bolts, caliper and  Assembling done in
pads reverse order
 Dismantle caliper  Brake pipes connected
 Clean and Inspect  Hydraulic system bled
components
 Replace defective parts
 Assemble caliper
 Fit caliper and pads
 Fit brake pipe and
electrical connections
 Fill reservoir
 Bleed brakes
 Check operation
 Fit wheels
 Lower vehicle
 Road test vehicle

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I.6:Replace brake  Select appropriate tools Correct use of tools
drum, shoe and equipment
assembly and  Loosen wheel nuts
wheel cylinder
 Jack vehicle  Vehicle secured on
 Place vehicle on stands  chassis stands
 Remove wheels  Wheel cylinder mounted
 Release park brake  All bolts are tightened to
 Remove drum retainers specified torque
and drum  Defective parts replaced
 Remove shoe return  Shoes adjuster and
springs, adjuster  retainer fitted back
mechanism, shoe retainers  Park brake cable fitted
and shoes  Shoes adjusted
 Disconnect park brake  Brake fluid bled
cable  Brake operation tested
 Remove wheel cylinder
mounting bolts
 Dismantle wheel cylinder
 Clean and inspect
components
 Replace defective
components
 Assemble wheel cylinder
and fit wheel cylinder
 Connect park brake cable
to new shoes
 Fit shoe retainers, adjuster
mechanism, shoe return
springs and shoes
 Adjust shoes

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 Fit new drum and drum
retainers
 Check operation
 Fit wheels
 Lower vehicle
 Road test vehicle

I.7:Replace load  Select appropriate tools  Appropriate tools

sensing valve and equipment  selected
 Jack and put vehicle on  Vehicle secured on
stands  chassis stands
 Disconnect brake fluid  Correct type of brake
pipes  fluid used
 Remove mounting bolts  Brakes bled
 Fit new load sensing valve  All pipes connected
 Connect brake pipes without stripping threads
 Fill reservoir with brake  Load sensing valve
fluid connected according to
 Bleed brakes manufacturer’s
 Check operation specifications
 Road test vehicle  All bolts are tightened to
specified torque
I.8:Replace  Select appropriate tools  Appropriate quantities
retarder and equipment selected.
 Choke wheels  Loosening sequence
 Disconnect electrical observed
connections  Components assembled
 Remove mounting brackets in reverse order
 Remove mounting bolts
 Remove retarder

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 Fit new retarder and  Retarder operation
gaskets checked
 Fit brackets
 Connect electrical
connections
 Start vehicle
 Check retarder operation

I.9:Repair  Disconnect battery  Battery earth terminal

compressor  Disconnect water, oil and disconnected
air pipes  Loosening sequence
 Remove mounting bolts observed
 Remove compressor  Brakes end play checked
 Clean compressor  Operation of brakes
 Disassemble compressor ascertained
 Clean components  Recommended cleaning
 Inspect components  solvents used
 Replace defective  Air and oil leaks checked
components
 Assemble compressor
 Mount compressor
 Connect water and oil
pipes
 Connect battery and start
engine
 Connect air pipes
 Test for operation

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I10:Overhaul 
spring applied Disconnect oil pipe
hydraulic released  Clean component after
brakes plugging
(S.A.H.R)  oil port
 Loosen securing bolts  Battery earth terminal
disconnected
 Take out brake assembly
 Danger warning on
cover
 spring noted
 Take out separator and
friction plates  Loosening sequence
observed
 Take out piston
 Order of friction discs and
 Clean and inspect
separator plates noted
 Thickness of friction discs
defective components
and separator plates
 Change piston seals
 Refit all components and fit measured against
 specifications
back cover
 Piston thickness
 Test brakes
measured
 Brakes end play checked
 Releasing of brakes
ascertained
I.11:Replace brake  Select appropriate tools  Use of correct tools
foot valve and equipment  Danger warning on
 Disconnect air pipes  spring noted
 Disconnect electrical  Loosening sequence
connections observed
 Remove mounting bolts  Brakes end play checked
 Withdraw foot valve  Releasing of brakes
 Connect air pipes ascertained

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 Connect electrical
connections
 Check pressure
 Test for operation

I.12:Replace slack  Block wheels

adjuster  Start engine  Battery earth terminal
 Check pressure disconnected
 Switch off engine  Pressure released
 Disconnect slack adjuster  Slack adjuster removed
from push-rod  Components fitted back in
 Remove slack adjuster reverse order
retaining  Brake adjusted to
 circlip  specifications
 Withdraw the slack  Brake tested
adjuster
 Fit slack adjuster retaining
circlip
 Connect slack adjuster to
push rod
 Adjust brakes
 Test brakes

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I.13:Replace brake  Block wheels  Use of correct tools
chamber  Start engine  Battery earth terminal
 Release handbook disconnected
 Switch off engine  Loosening sequence
 Cage brake chamber observed
 Disconnect slack adjuster  Brakes end play checked
from push-rod  Releasing of brakes
 Remove mounting bolts ascertained
and nuts  Slack adjuster
 Withdraw brake chamber disconnected
 Mount new brake chamber  New brake
 Connect air pipes chamber
 Start engine  fitted
 Check pressure  Airpipe connected
 Switch off engine  Operation noted
 Check operation
 Connect slack adjuster to
push rod
 Adjust brakes
 Road test vehicle

I.14:Replace brake  Disconnect electrical  Battery earth terminal

pneumatic connections disconnected
governor  Disconnect air pipes  Danger warning on spring
 Remove mounting bolts noted
 Loosening sequence
observed

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 Remove brake pneumatic  Releasing of brakes
governor ascertained
 Fit new pneumatic  Air pipes checked for leaks
governor  Pneumatic governor fitted
 Connect air pipes  Electrical connections fitted
 Connect electrical back
 Operation noted
 Check pressure
 Check operation

I.15:Replace quick  Disconnect air pipes  Brakes end play checked

release valve  Remove mounting bolts  Releasing of brakes
 Remove quick release valve ascertained
 Fit new quick release valve  Mounting bolts secured
 Connect air pipes  Release valve fitted
 Start engine  Air pipes connected
 Check pressure  Engine started
 Check operation  Pressure checked

I.16:Replace ‘S’  Choke wheels  Battery earth terminal

cam shaft  Loosen wheel nuts disconnected
 Jack vehicle and put on  Loosening sequence
stands observed
 Remove wheels  Bushes and seals inspected
 Remove wheel drum  New ‘S’ cam fitted
 Remove shoe assembly  Slack adjuster reconnected
 Disconnect slack adjuster  Brakes adjusted
from push rod  Operation tested

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 Remove slack adjuster  Vehicle road test record
retaining documented.
 circlip
 Withdraw slack adjuster
 Withdraw ‘S’ camshaft
 inspect bushes and seals
 Replace defective
components
 Grease bushes
 Fit new ‘s’ camshaft
 Fit shoe assembly
 Fit slack adjuster and
retaining
 circlip
 Connect slack adjuster to
push-rod
 Fit wheel drum
 Adjust brakes
 Test operation
 Fit wheels
 Jack vehicle and remove
stands
 Remove wheel chokes
 Road test vehicle

I 17:Replace  Select appropriate tools and  Apppropriate tools

vacuum pump equipment  selected
 Choke wheels  Battery earth terminal
 Disconnect battery disconnected
 Disconnect vacuum hoses

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 Remove mounting bolts  Releasing of brakes
 Withdraw vacuum pump ascertained
 Fit new vacuum pump  Mounting bolts removed
 Connect vacuum hoses  Vacuum pump removed
 Connect battery  New Vacuum pump
 start engine  fitted
 Check operation  Battery connected
 Road test vehicle  Operation checked
 Vehicle test results noted.

TOOLS AND EQUIPMENT NECESSARY TO COMPLETE THIS DUTY:

Dynamometer Repair manual Jacks and axle stands work-bench

Heavy duty spanners, sockets, screw-drivers and hammers

Torque wrench Valve adjustment set Oil ring remover Allen keys
Oil drainer Scrappers, files, centre punches,
Stocks and dies, hacksaws, chisels Overhead crane and Injector tester
lifts
Parts catalog Standard tool Hydraulic press/ puller
box
Dial indicator gauge Fire extinguisher

Steam cleaner measuring instruments

HEALTH, SAFETY AND ENVIRONMENTAL ISSUES RELATED TO THIS DUTY:

 Brake fluid corrodes paint so it should never be spilled
 Utilize Personal protective clothing (PPE)
 Workplace safety rules

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 Environmental protection agency regulations and occupational safety and health administration
 Proper use of tools
 First aid
 Understand common safety hazards in automotive repair business
 Hazardous material and waste control
 Types of fires, fire extinguishers and operating procedures
SPECIFIC WORKER TRAITS REQUIRED TO COMPLETE THIS DUTY:
Honesty Punctual Team worker Physically fit Sober minded Dedicated Competent Tolerant Focused

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MINISTRY OF HIGHER AND TERTIARY EDUCATION,INNOVATION, SCIENCE AND CODE

TECHNOLOGY DEVELOPMENT
SKILLS PROFICIENCY SCHEDULE

INDUSTRY: AUTOMOTIVE TRADE/OCCUPATION: MOTOR VEHICLE CLASS/LEVEL: NC

MECHANICS
(to include diesel & tractor)
DUTY J: CARRY OUT FITTING AND MACHINING PROCESSES 5
Pre-requisites: ORDINARY LEVEL Approval Date: Review Date:
TASK STEPS PROFICIENCY INDICATORS WORKPLACE
RELATED ESSENTIAL
KNOWLEDGE SKILLS

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Perform  Wear protective clothing  Health and safety procedures o Communication
Cutting, Filing  Select correct tools adhered to o Drawing
and drilling  Perform cutting using a  Suitable tools and equipment o Reading and writing
hacksaw a selected o Computers
 Perform filing  Workpiece cut o Estimations
 Perform drilling  Filing carried out correctly o Measurements
 Drilling carried out o Organizing
 Project produced o Planning
o Analytical
Numeracy
J1: Perform  Disconnect battery  Health and safety procedures
arch welding terminal adhered to
 Select amperage  Suitable tools and equipment
 Select rods are selected
 Clean surfaces  Amperage selected to size of
 Attach machine earth welding rods and thickness of
 Wear protective clothing material
 Tack components  Components are joined
 Weld components
 Clean weld

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J2  Clean surfaces  Safety procedures adhered to
Perform gas  Open gas bottles  Suitable tools and equipment
welding  Adjust working are selected
pressure  Acetylene and oxygen gas
 Open acetylene gas operated according to laid
 Light acetylene gas  down procedures
 Introduce oxygen  Surfaces are joined
 Adjust flame
 Wear protective clothing
 Select rods
 Weld surfaces
 Switch off acetylene
 Switch off oxygen
 Close gas bottles

J3 Perform  Clean surfaces  Suitable tools and equipment

brazing  Open gas bottles are selected
 Adjust working  Acetylene and oxygen gas
pressure operated according to laid
 Open acetylene gas  down procedures
 Light acetylene gas  Surfaces are joined
 Introduce oxygen
 Adjust flame
 Select rods
 Heat surfaces
 Heat rod
 Dip in flux
 Braze components
 Switch off acetylene
 Switch off oxygen
 Close gas bottles

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