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Cos Modul 3 Engine Repair
Cos Modul 3 Engine Repair
Module Objectives:
Carry out petrol engine repair using car service manual, hand tools set, special tools, measuring tools, timing light, tachometer, valve grinding
paste, valve grinding stick, compression gauge, oil filter wrench, oil funnel, lubrication oil, oil filter opener, waste oil receiver, top set gasket, radiator,
pressure tester, thermometer, personal protection equipment, oil filter, air filter, hose, radiator pressure cap, water coolant and multimeter so that
engine compression test conducted, cylinder head assembly removed, engine cylinder head assembly examined, cylinder head assembly installed,
oil pressure relief valve, radiator unit, thermostat functioning, water pump functioning and cooling fan functioning checked, cooling system pressure
test conducted, engine air filter and ignition timing checked, and lubrication system pressure test conducted in accordance with manufacturer’s
specification.
Module Content
Task No
03.03 Determine engine condition
03.02 Rectify engine lubricating system
03.01 Rectify engine cooling system
03.04 Carry out engine top overhaul
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DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE
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20
DELIVERY ASSESSMENT
STEPS KNOWLEDGE PERFORMANCE HRS
MODE MODE
1.1 Determine type of engine 9 Demonstration and Inspect cylinder head
Internal combustion Observation - Bend
External - Cracks
combustion - Surface (flatness)
2 stroke Inspect cylinder head
4 stroke components
Rotary - Valve mechanism
1.2 Determine construction of - Hydraulic lifter
engine - Rocker
1.3 Determine engine mechanism
cylinder head assembly - Cam shaft bearing
component such as Measure cylinder
Cylinder head head components
Valve Inspect for oil
Bucket tappet leakage
Cam shaft Inspect oil pressure
Rocker arm relief valve
Valve spring Inspect oil pressure
Rocker finger relief valve
Rocker cover Change oil pressure
1.4 Test engine compression switch
Dry test Inspect for water
Wet test leakage
Running test Inspect condition of
1.5 Interpret compression radiator hoses
test result Inspect condition of
Refer engine radiator pressure cap
specification Inspect condition of
expansion tank
Attitude/Safety:
Handle compression gauge
with care
21
DELIVERY ASSESSMENT
STEPS KNOWLEDGE PERFORMANCE HRS
MODE MODE
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DELIVERY ASSESSMENT
STEPS KNOWLEDGE PERFORMANCE HRS
MODE MODE
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DELIVERY ASSESSMENT
STEPS KNOWLEDGE PERFORMANCE HRS
MODE MODE
Attitude/Safety:
Patient when lapping valve
Meticulous when measure
cylinder head components
24
DELIVERY ASSESSMENT
STEPS KNOWLEDGE PERFORMANCE HRS
MODE MODE
Attitude/Safety:
Meticulous when adjust
valve clearance
25
DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE
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DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE
5.3 Inspect for oil leakage
5.4 Apply procedure to
change oil pressure
switch
Test oil pressure
switch
Remove oil pressure
switch
Replace oil pressure
switch
Fix and tighten oil
pressure switch
according to
specifications
Attitude/Safety:
Avoid spilling oil on floor
Handle oil pressure
gauge with care
27
DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE
6.4 Function of cooling system
components such as
Water pump
Thermostat
Radiator
Radiator fan
Radiator hose
Radiator cap
Expansion tank
Belt
Temperature sensor
Temperature gauge
Water jacket
6.5 Types of radiator
Down flow
Cross flow
6.6 Construction of radiator
Radiator core assembly
Inlet/outlet pipe
Inlet/outlet tank
Gasket
Filler neck
6.7 Checking radiator unit
method
6.8 Types of coolant
Anti freeze
Anti corrosion
6.9 Purpose of flushing
radiator
6.10Techniques to flush
radiator
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DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE
6.1 Determine location of 4 Demonstration and
cooling system Observation
components
6.2 Inspect for water leakage
6.3 Inspect condition of
radiator hoses
6.4 Inspect condition of
radiator pressure cap
6.5 Inspect condition of
expansion tank
6.6 Inspect radiator
assembly condition
Upper tank
Lower tank
Core
Fin
6.7 Flush radiator
Attitude/Safety:
Meticulous when handling
hot water
Wear PPE
7. Check thermostat 7.1 Function, operation and 1 Lecture
functioning types of thermostat
Single stage
Two stage
7.2 Thermostat opening
specifications
7.3 Procedures to remove
thermostat
7.4 Method to test thermostat
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DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE
Attitude/Safety:
Meticulous when
handling hot water
30
DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE
8.1 Determine type of water 12 Demonstration and
pump Observation
8.2 Detach water pump
8.3 Inspect water pump from
noise
8.4 Make water pump gasket
8.5 Install water pump
8.6 Refill water coolant
8.7 Test water pump from
leakage
Attitude/Safety:
Meticulous when
installing water pump
9. Check cooling fan 9.1 Types of cooling fan 2 Lecture
functioning Manual fan
Electric fan
9.2 Construction of cooling fan
Fan motor
Fan blade
9.3 Procedure to remove
cooling fan
9.4 Method to check cooling
fan functioning 9.1 Determine type of 2 Demonstration and
cooling fan Observation
9.2 Detach cooling fan
9.3 Test cooling fan
functioning
9.4 Fix cooling fan
Attitude/Safety:
Keep hands away from
moving fan
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DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE
8.1 Determine type of water 12 Demonstration and
pump Observation
8.2 Detach water pump
8.3 Inspect water pump from
noise
8.4 Make water pump gasket
8.5 Install water pump
8.6 Refill water coolant
8.7 Test water pump from
leakage
Attitude/Safety:
Meticulous when
installing water pump
DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE
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DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE
8.1 Determine type of water 12 Demonstration and
pump Observation
8.2 Detach water pump
8.3 Inspect water pump from
noise
8.4 Make water pump gasket
8.5 Install water pump
8.6 Refill water coolant
8.7 Test water pump from
leakage
Attitude/Safety:
Meticulous when
installing water pump
10. Conduct cooling 10.1 Purpose of cooling system 1 Lecture
system pressure pressure test
test 10.2 Procedures of testing
cooling system pressure
10.3 Types of cooling system
pressure tester
10.4 Operation of cooling
system pressure tester
10.5 Cooling system pressure
specifications
Attitude/Safety:
Meticulous when
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DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE
8.1 Determine type of water 12 Demonstration and
pump Observation
8.2 Detach water pump
8.3 Inspect water pump from
noise
8.4 Make water pump gasket
8.5 Install water pump
8.6 Refill water coolant
8.7 Test water pump from
leakage
Attitude/Safety:
Meticulous when
installing water pump
11. Check engine air 11.1 Purpose of engine air filter 1 Lecture
filter 11.2 Types of engine air filter
Paper element
Oil bath
11.3 Operation of engine air
filter
11.4 Procedures of cleaning air
filter
11.5 Method of checking
engine air filter
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DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE
11.1 Detach engine air filter 3 Demonstration and
11.2 Clean engine air filter Observation
11.3 Fix engine air filter
Attitude/Safety:
Meticulous when cleaning
air filter
Wear dust mask
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DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE
12.8 Inspect engine from
abnormal noise
Knocking
Humming
Pinking
12.9 Adjust ignition timing
12.10 Tune up engine idling
speed
Attitude/Safety:
Connect positive battery
first
Attitude/Safety:
Meticulous when
installing oil pressure test
gauge
36
DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE
Core Abilities
37
Selected References and Audio Visual Materials
REFERENCES AUDIO VISUAL MATERIALS
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20. Waste oil receiver 1:5
21. Top set gasket 1:5
21. Radiator pressure tester 1:5
22. Thermometer 1:5
23. Personal protection equipment 1:1
24. Oil filter 1:5
25. Air filter 1:5
26. Hose 1:5
27. Radiator pressure cap 1:5
28. Water coolant As required
29. Multimeter 1:5
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