kskv Fuel System Repair

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December Edition 2013

MINISTRY OF EDUCATION, MALAYSIA

VOCATIONAL COLLEGE STANDARD CURRICULLUM

COURSE INFORMATION

COURSE NAME

CODE NAME

:

:

FUEL SYSTEM REPAIR

GMA 302

LEVEL : 2 SEMESTER 3

CREDIT UNIT : 3.0

CONTACT HOUR : FACE TO FACE : 5.0 HOURS/WEEK (1T+4!

NON FACE TO FACE :

COURSE T"E : VOCATIONAL

RE#RE$UISITE : #

CORE RE$UISITE : #

Last Edited 10-13Nov 2013

Module Page 1/34 Document Page 1




COURSE OUTCOMES

At the end of the course, the students should be able to:

• Ser!ice fuel in"ector

• #roubleshoot fuel s$stem %roblems

• O!erhaul fuel in"ection %um%

• Carr$ out installin& en&ine assembl$

• Re%air distributor unit

COURSE DESCRITION

This unit identifies the competence required to service fuel injector using hand tool set, cleanin& 'it, tor(ue )rench, in"ector tester, ser!ice

manual and shims so that fuel injector service manual obtained, fuel injector unit removed, fuel injector parts dismantled, fuel injector partscleaned, fuel injector parts assembled, fuel injector unit tested, fuel injector unit installed and engine performance tested in accordance with

manufacturer’s specification.

This unit identifies the competence required to troubleshoot fuel s$stem %roblems usin& customer com%laint form, hand tool set, fuel faultfindin& chart, fuel s$stem ser!ice manual, chec' sheet, ne) s%are %arts so that fuel s$stem ser!ice manual obtained, fuel s$stem %roblemschec'ed, fuel s$stem %roblems rectified, rectified fuel s$stem %roblems tested and troubleshootin& chec'list recorded in accordance )ithstandard o%eratin& %rocedure*

This unit identifies the competence required to overhaul fuel injection pump using hand tool set, calibration machine, fuel injection pump service

manual, calibration pump service manual, puller and special tools so that fuel injection pump service manual obtained, fuel injection pump

removed, fuel injection pump components dismantled, fuel injection pump components checked, fuel injection pump components assembled, bench test executed and fuel injection pump installed in accordance with manufacturer’s specification.

This unit identifies the competence required to carry out installing engine assembly using hand tools set, h$draulic "ac', deter&ent, en&ine






manual, ra&s, )heel sto%%er and lifting equipment so that job order obtained, engine assembly installed and external attachment connected in

accordance with engine’s specification.

This unit identifies the competence required to repair distributor unit using hand tools set, distributor unit service manual, new contact breaker

point, test lamp, service checklist and log book so that distributor unit service manual obtained, distributor assembly removed, distributor

components dismantled, distributor components checked, distributor components assembled, distributor assembly installed and engine performance tested in accordance with manufacturer’s specification






CONTENT AND LEARNING STANDARDS

PROGRAM : AGRICULTURAL MECHANI%ATION

COURSE NAME : FUEL SYSTEM REPAIR

CODE NAME : GMA 302

COMETENC" : 1

CONTENTSTANDARD

performanceH&'

LEARNING STANDARDperformance , condiion

ERFORMANCE CRITERIAperformance,condiion, !andard

1 ervice fuel

injector

1*1 !btain fuel in"ector Ser!icemanual

1.1.1 "etermine source of fuel injector service manual according to

manufacturer specification.

1.1.# $cquire fuel injector service manual according to


1.1.% &nterpret fuel injector service manual according to


1*2 'emove fuel in"ector unit 1.#.1 &dentify t$%e of fuel in"ectors according to manufacturer

specification.

1.#.# (xplain basic o%eration of fuel in"ector unit according to







CONTENTSTANDARD

performanceH&'



1.#.% &dentify t$%e of hand tools according to manufacturer

specification.

1.#.) (xplain techni(ues of remo!in& fuel in"ector unit according to


1.#.* "etermine t$%es of fuel in"ector according to manufacturer

specification.

1.#.+ "etermine basic o%eration of fuel in"ector unit according tomanufacturer specification.

1.#. -hoose t$%e of hand tools according to manufacturer

specification.

1.#. $pply remo!in& fuel in"ector unit techni(ue according to


1.#./ "isconnect batter$ terminal before e+ecutin& an$ )or's

related to fuel s$stem according to manufacturer

specification.

1*3 "ismantle fuel in"ector %arts 1.%.1 &dentify t$%e of fuel in"ector %arts according to manufacturerspecification.

1.%.# (xplain techni(ues of dismantlin& fuel in"ector %arts

according to manufacturer specification.






CONTENTSTANDARD

performanceH&'



1.%.% 0ist methods of disassemble fuel in"ector %arts according to


1.%.) (xplain meticulous )hen remo!in& in"ector nole accordin&

to manufacturer specification.

1.%.* "etermine t$%e of fuel in"ector %arts according to


1.%.+ $pply dismantlin& fuel in"ector %arts techni(ue according tomanufacturer specification.

1.%. "isassemble fuel in"ector %arts according to manufacturerspecification.

1*- -lean fuel in"ector %arts 1.).1 &dentify t$%es of sol!ent according to manufacturer

specification.

1.).# (xplain functions of sol!ent according to manufacturer

specification.

1.).% (xplain techni(ues of cleanin& fuel in"ector %art according to


1.).) praying fuel in"ector %arts )ith %ressure air according to







CONTENTSTANDARD

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1.).* -hoose t$%es of sol!ent according to manufacturer

specification.

1.).+ oak fuel in"ector %arts )ith sol!ent according to


1.). pray fuel in"ector %arts )ith %ressure air according to


1.). $pply cleanin& fuel in"ector %arts techni(ue according tomanufacturer specification.

1*. $ssemble fuel in"ector %arts 1.*.1 (xplain function of fuel in"ector %arts according tomanufacturer specification.

1.*.# (xplain %rocedures of assemblin& fuel in"ector %arts


1.*.% 0ist methods of reassemble fuel in"ector %arts according to


1.*.) "etermine function of fuel in"ector %arts according to


1.*.* $pply assemblin& fuel in"ector %arts %rocedure according to


1.*.+ "etermine reassemble fuel in"ector %arts according to






CONTENTSTANDARD

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1*/ &nstall fuel in"ector unit 1.+.1 (xplain function of fuel injector unit according to


1.+.# (xplain techniques of installing fuel injector unit according


1.+.% 0ist methods of reinstalling fuel injector units according to


1.+.) "etermine function of fuel injector unit according to


1.+.* $pply assembling fuel injector unit technique according to


1.+.+ $pply method of reinstalling fuel injector units according to


1* Test en&ine %erformance 1..1 (xplain engine starting procedure according to manufacturer

specification.

1..# (xplain leakage inspection procedure according to



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CONTENTSTANDARD

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1..% (xplain engine idling 'evolution per inute 2'34


1..) 0ist methods of testing engine performance according to


1..* (xplain updating log book according to manufacturerspecification.

1..+ $pply engine starting procedure according to manufacturer

specification.

1.. &nspect engine leakage according to manufacturer

specification.

1.. Tune engine idling 'evolution per inute 2'34 according


1../ $pply testing engine performance method according tomanufacturer specification.

1..15 6pdate log book according to manufacturer specification.


Module Page !/34 Document Page !







CODE NAME : GMA 302

COMETENC" : 2

CONTENTSTANDARD

performanceH&'



#Troubleshoot fuel

system problems

2*1 !btain fuel s$stem ser!icemanual

#.1.1 &dentify sources of fuel system service manual according to


#.1.# (xplain procedures of acquiring fuel system service manual


#.1.% &dentify fuel system service manual according to


#.1.) "etermine source of fuel system service manual according tomanufacturer specification.

#.1.* $cquire fuel system service manual according to


#.1.+ &nterpret fuel system service manual according to







CONTENTSTANDARD

performanceH&'



2*2 -heck fuel s$stem %roblems #.#.1 (xplain procedures of guessing possible root cause according


#.#.# (xplain root cause of fuel system fault according to


#.#.% (xplain fuel system analy7er equipment according to


#.#.) (xplain procedures of testing engine performance according


#.#.* 8ollow procedure of guest possible root cause according to


#.#.+ "etermine root cause of fuel system fault according to


#.#. -hange fuel system defect parts according to manufacturer

specification.

#.#. 8ollow procedure of testing engine performance according to







CONTENTSTANDARD

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2*3 'ectify fuel s$stem %roblems #.%.1 &dentify types of fuel system problems according to


#.%.# (xplain techniques of engine rectification according to


#.%.% (xplain engine rectification procedures according to


#.%.) (xplain techniques special tool handling according to


#.%.* "etermine type of fuel system problem according tomanufacturer specification.

#.%.+ $pply technique of engine rectification according to


#.%. 8ollow engine rectification procedure according to


#.%. $pply technique of handling special tool according to


2*- Test rectified fuel s$stem #.).1 &dentify fuel system requirements according to manufacturerspecification.






CONTENTSTANDARD

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#.).# 0ist methods of fuel system testing according to


#.).% 0ist procedures of fuel system testing according to


#.).) (xplain technique of handling testing tool according to


#.).* "etermine fuel system testing requirements according to


#.).+ $pply method of fuel system testing according tomanufacturer specification.

#.). 8ollow procedure of fuel system testing according to


#.). $pply technique of handling testing tool according to


2*. 'ecord troubleshootin& chec'list #.*.1 &dentify types of troubleshooting checklist according to


#.*.# (xplain technique of fill in troubleshooting checklistaccording to manufacturer specification.






CONTENTSTANDARD

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#.*.% &dentify types of troubleshooting service checklist according


#.*.) (xplain procedures of recording troubleshooting checklist


#.*.* (xplain filing of troubleshooting checklist according to


#.*.+ (xplain compiling troubleshooting checklist record method


#.*. "etermine types of troubleshooting checklist according tomanufacturer specification.

#.*. 8ollow technique of filling troubleshooting checklist


#.*./ 8ill in troubleshooting checklist according to manufacturer

specification.

#.*.15 "etermine types of service checklist according to


#.*.11 &dentify file troubleshooting checklist record according tomanufacturer specification.






CONTENTSTANDARD

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#.*.1# $pply compiling troubleshooting checklist record method










CODE NAME : GMA 302

COMETENC" : 3

CONTENTSTANDARD

performanceH&'



% !verhaul fuel

injection pump

3*1 !btain fuel in"ection %um% ser!icemanual

%.1.1 &dentify source of fuel injector service manual according to


%.1.# (xplain procedures of acquiring fuel injector service manual


%.1.% &dentify fuel injector service manual according to


%.1.) "etermine source of fuel injector service manual according tomanufacturer specification.

%.1.* $cquire fuel injector service manual according to


%.1.+ &nterpret fuel injector service manual according to







CONTENTSTANDARD

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3*2 'emove fuel in"ection %um% %.#.1 &dentify type of hand tools according to manufacturer

specification.

%.#.# (xplain operation of fuel injection pump assembly according


%.#.% &dentify type of high pressure pipes according to


%.#.) 0ist methods of removing fuel injection pump according to


%.#.* -hoose hand tools according to manufacturer specification.

%.#.+ "etermine operation of fuel injection pump assembly


%.#. 6ninstall high pressure pipes connection according tomanufacturer specification.

%.#. $pply removing fuel injection pump method according to


3*3 "ismantle fuel in"ection %um% %.%.1 &dentify fuel injection pump components according to






CONTENTSTANDARD

performanceH&'



com%onents manufacturer specification.

%.%.# (xplain operation of pump governor according tomanufacturer specification.

%.%.% &dentify fuel injection pump according to manufacturer

specification.

%.%.) (xplain methods of dismantling fuel injection pump


%.%.* (xplain soaking fuel injection pump components with

solvent according to manufacturer specification.

%.%.+ (xplain techniques of disassemble pump camshaft according


%.%. ethod moving out lifter according to manufacturer

specification.

%.%. "etermine fuel injection pump components according to


%.%./ "isassemble pump governor according to manufacturer

specification.

%.%.15 "isassemble injector plunger according to manufacturer

specification.






CONTENTSTANDARD

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%.%.11 ove out lifter according to manufacturer specification.

%.%.1# "isassemble pump camshaft according to manufacturer

specification.

%.%.1% $pply method of dismantling fuel injection pump accordingto manufacturer specification.

%.%.1) oak fuel injection pump components with solvent according


3*- -heck fuel in"ection %um%com%onents

%.).1 &dentify type of fuel injection pump components defect


%.).# (xplain methods of checking fuel injection pump

components from wear and tear according to manufacturer

specification.

%.).% (xplain techniques of changing defect parts according to


%.).) &nspect fuel injection pump components defect according to



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CONTENTSTANDARD

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%.).* $pply checking fuel injection pump components from wear

and tear method according to manufacturer specification.

%.).+ -hange defect parts according to manufacturer specification.

3*. $ssemble fuel in"ection %um%com%onents

%.*.1 &dentify types of housing bearing according to manufacturer

specification.

%.*.# &dentify type’s camshaft and fly weight according to


%.*.% 0ist setting lifter unit’s procedure according to manufacturer

specification.

%.*.) (xplain tighten plunger and bushing method according to


%.*.* (xplain reinstalling pump governor technique according to


%.*.+ (xplain methods of assembling fuel injection pump

component according to manufacturer specification.

%.*. -hange housing bearing according to manufacturerspecification.

%.*. 3lace camshaft and fly weight in position according to






CONTENTSTANDARD

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%.*./ 3lace lifter units according to manufacturer specification.

%.*.15 Tighten plunger and bushing to required torque according to


%.*.11 'einstall pump governor according to manufacturer

specification.

%.*.1# $pply method of assembling fuel injection pump component


3*/ (xecute bench test %.+.1 (xplain fuel injection pump bench test procedure according


%.+.# (xplain fuel injection pump calibration method according to


%.+.% &dentify calibration service manual according to manufacturer

specification.

%.+.) (xplain justification of bench test result according tomanufacturer specification.

%.+.* (xplain procedure of fuel injection pump bench test






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%.+.+ (xplain connecting gauges at oil line and fuel line according


%.+. 8ix pump assembly on bench test according to manufacturer

specification.

%.+. -onnect gauges at oil line and fuel line according to


%.+./ $pply method of pump calibration according to manufacturer

specification.

%.+.15 -ompare data with calibration service manual according to


%.+.11 9ustify bench test result according to manufacturer

specification.

%.+.1# 8ollow procedure of fuel injection pump bench test according


3* &nstall fuel in"ection %um% %..1 &dentify types of special tools according to manufacturer

specification.






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%..# (xplain methods of &nstalling fuel injection pump assembly


%..% (xplain techniques of reinstall high pressure pipes

connection according to manufacturer specification.

%..) (xplain bleeding air from fuel system according tomanufacturer specification.

%..* (xplain updating log book according to manufacturer

specification.

%..+ -hoose hand tools according to manufacturer specification.

%.. $pply installing fuel injection pump assembly method


%.. 'einstall high pressure pipes connection according to


%../ :leed air from system according to manufacturer

specification.

%..15 6pdate log book according to manufacturer specification.














CODE NAME : GMA 302

COMETENC" : 4

CONTENTSTANDARD

performanceH&'



) -arry out

installing engine

assembly

-*1* !btain "ob order ).1.1. &dentify type of job order according to manufacturer

specification.

).1.#. (xplain sourcing of job order form according to manufacturer

specification.

).1.%. (xplain procedure to acquire job order according to


).1.). "etermine type of job order according to manufacturerspecification.

).1.*. &dentify source job order form according to manufacturer

specification.

).1.+. $pply procedure to acquire job order according to







CONTENTSTANDARD

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-*2* &nstall en&ine assembl$ ).#.1. (xplain function of lifting equipment according to


).#.#. (xplain function of hydraulic jack according to manufacturer

specification.

).#.%. &nstalling engine assembly procedure according to


).#.). 6se lifting equipment according to manufacturer

specification.

).#.*. 6se hydraulic jack according to manufacturer specification.

).#.+. $pply installing engine assembly procedure according to


-*3* -onnect e+ternal attachment ).%.1. &dentify type of external attachment according to


).%.#. (xplain connecting external attachment procedure according


).%.%. "etermine type of external attachment according to






CONTENTSTANDARD

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).%.). $pply connecting external attachment procedure according to





CODE NAME : GMA 302

COMETENC" : 5

CONTENTSTANDARD

performanceH&'



* 'epair

distributor unit

.*1 !btain Distributor Unit Ser!iceanual

*.1.1 &dentify source of distributor unit service manual according


*.1.# (xplain procedure of acquiring distributor unit servicemanual according to manufacturer specification.

*.1.% (xplain distributor unit service manual according to








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specification.

*.#.+ "etermine function of distributor unit according to


*.#. "isconnect high tension cable according to manufacturer

specification.

*.#. 6ninstall distributor assembly from engine according to


*.#./ $pply removing distributor assembly procedure according to


*.#.15 "isconnect battery terminal before executing any works

related to removing electrical instruments according to


.*3 "ismantle Distributor Com%onents *.%.1 (xplain distributor %arts and com%onents according to


*.%.# (xplain function of contact brea'er %oint according to


*.%.% (xplain %rocedure of dismantlin& distributor %arts and

com%onents according to manufacturer specification.


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CONTENTSTANDARD

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*.%.) ove out distributor ca% according to manufacturer

specification.

*.%.* 3ick out contact brea'er %oint according to manufacturer

specification.

*.%.+ "isassemble distributor %arts and com%onents according to


.*- -heck Distributor Com%onents *.).1 &dentify t$%es of distributor com%onents defects according tomanufacturer specification.

*.).# (xplain ins%ection of distributor com%onents defects

%rocedure according to manufacturer specification.

*.).% "etermine t$%es of distributor com%onents defects according


*.).) &nspect distributor com%onents defects according to


*.).* $pply chec'in& distributor com%onents defect %rocedure

according to manufacturer specification

.*. $ssemble Distributor Com%onents *.*.1 &dentify distributor %arts and com%onents according to






CONTENTSTANDARD

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*.*.# (xplain function of contact brea'er %oint according to


*.*.% (xplain dismantlin& distributor %arts and com%onents


*.*.) "etermine reassemble distributor %arts and com%onents


*.*.* -hange ne) contact brea'er %oint to locatio according to


*.*.+ -hange ne) distributor oil seal according to manufacturerspecification.

*.*. $pply assemblin& distributor %arts and com%onents


.*/ &nstall Distributor Assembl$

*.+.1 &dentify i&nition timin& dia&ram according to manufacturer

specification.

*.+.# (xplain ad!ance and retard timin& mechanism according to


*.+.% (xplain settin& contact brea'er %oint &a% according to







CONTENTSTANDARD

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*.+.) &nstalling mo!e out distributor ca% according to manufacturer

specification.

*.+.* "istributor assembl$ %rocedure according to manufacturerspecification.

*.+.+ "etermine dia&ram of i&nition s$stem according to


*.+. &nterpret i&nition timin& dia&ram according to manufacturerspecification.

*.+. et com%ression stro'e for number one c$linder according to


*.+./ $djust ad!ance and retard timin& mechanism according to


*.+.15 et contact brea'er %oint &a% according to manufacturer

specification.

*.+.11 $pply installin& distributor assembl$ %rocedure according to


.* Test En&ine erformance *..1 &dentify en&ine startin& %rocedure according to manufacturer specification.

*..# (xplain testin& en&ine %erformance techni(ue according to







CONTENTSTANDARD

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*..% (xplain en&ine idlin& Re!olution %er inute R4 accordingto manufacturer specification.

*..) (xplain u%datin& lo& boo' according to manufacturer

specification.

*..* $pply en&ine startin& %rocedure according to manufacturer

specification.

*..+ $pply testin& en&ine %erformance techni(ue according tomanufacturer specification.

*.. Tune en&ine idlin& Re!olution er inuteR4 according to


*.. 6pdate lo& boo' according to manufacturer specification.

*../ eticulous )hen fillin& ser!ice chec'list form according to


*..15 ;eep )or' areas clean, uncluttered and free of s%ills




Documents

kskv Fuel System Repair