CURRICULUM of COMPETENCY UNIT (CoCU)

Sub Sector AFTER SALES

Job Area AUTOMOTIVE AFTER SALES SERVICE
Competency Unit Title ENGINE COOLING SYSTEM RECTIFICATION WORKS
The outcome of this competency is to provide high standard rectification on engine cooling system components to
ensure efficiency of the cooling system. Upon completion of this competency unit, trainees will be able to: -
 Carry out engine drive belt and tensioner replacement
 Conduct cooling system pressure test
 Carry out radiator pressure cap replacement
 Inspect engine cooling system’s components condition
Learning Outcome
 Carry out engine cooling system’s thermostat replacement
 Flush cooling system
 Replace radiator
 Replace engine cooling system’s electric fan motor
 Replace engine water pump
 Replace engine water jacket core plug
Training Credit
Competency Unit ID TP-300-2:2013-C02 Level 2
Duration
60 Hours
Hours
Attitude / Safety / Training Delivery
Work Activities Related Knowledge Related Skills Assessment Criteria
Environmental Hours Mode
1. Carry out engine i. Types of job order 1 hour Lecture i. Job order
drive belt and such as: - interpreted
tensioner  Work sheet / job ii. Service advisor /
replacement card job controller
ii. Function of job consulted
order iii. Tools and
iii. Tools and equipment
equipment such as: selected
 Mechanic hand iv. Belt condition
tools set checked
 Flare nut v. Belt tension
wrenches checked
iv. Types of cooling vi. Tensioner tension

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 Attitude / Safety / Training Delivery
Work Activities Related Knowledge Related Skills Assessment Criteria
Environmental Hours Mode
system checked
v. Layout of drive belt vii. Tensioner belt
and tensioner for bearing checked
cooling system viii. Engine drive belt
vi. Procedures of replaced
testing and ix. Tensioner bearing
checking drive belt replaced
and tensioner
vii. Procedures of
replacing and
tensioning drive belt

i. Interpret job order 5 hours Demonstration

ii. Consult service &
advisor / job Observation
controller
iii. Select tools and
equipment
iv. Plan repair activity
v. Check belt condition
vi. Check belt tension
vii. Check tensioner
tension
viii. Check tensioner belt
bearing
ix. Replace engine drive
belt
x. Replace tensioner
bearing

Attitude:
i. Systematic in
organising work
activities

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 Attitude / Safety / Training Delivery
Work Activities Related Knowledge Related Skills Assessment Criteria
Environmental Hours Mode
Safety:
i. Adhere to safety
precaution in
carrying out
engine drive belt
and tensioner
replacement
ii. Ensure correct
tension of belt

2. Conduct cooling i. Principles of cooling 1 hour Lecture i. Pressure tester

system pressure system attached to the
test ii. Procedures of radiator
testing cooling ii. Cooling system
system pressure pressure test
iii. Cooling system performed
pressure test such iii. Pressure test
as: - result interpreted
 Radiator
 Radiator cap

i. Attach pressure tester 5 hours Demonstration

to the radiator &
ii. Perform cooling Observation
system pressure test
iii. Interpret pressure test
result Attitude:
i. Always use
extreme caution
when conducting
cooling system
pressure test
ii. Always follow
vehicle
manufacturer’s

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 Attitude / Safety / Training Delivery
Work Activities Related Knowledge Related Skills Assessment Criteria
Environmental Hours Mode
warnings, cautions
and service
procedures

Safety:
i. Follow pressure
test safety
procedure
ii. Ensure engine is
cool before
opening radiator
cap
iii. Cautions when
opening radiator
cap while
temperature of the
engine is high

3. Carry out radiator i. Function of radiator 1 hour Lecture i. Cap seal

pressure cap and radiator cap deterioriation
replacement ii. Procedure or checked
removing and ii. Return spring
replacing radiator condition checked
cap iii. Release valve
checked
i. Check cap seal 5 hours Demonstration iv. Radiator cap
deterioriation & tested using
ii. Check return spring Observation pressure tester
condition v. Radiator cap
iii. Check release valve replaced
iv. Test radiator cap using
pressure tester
v. Replace radiator cap
Attitude:
i. Always use

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 Attitude / Safety / Training Delivery
Work Activities Related Knowledge Related Skills Assessment Criteria
Environmental Hours Mode
extreme caution
when carrying out
radiator pressure
cap replacement
ii. Always follow
vehicle
manufacturer’s
warnings,
cautions and
service
procedures

Safety:
i. Ensure engine is
cool before
opening radiator
cap
ii. Cautions when
opening radiator
cap while
temperature of the
engine is high

4. Inspect engine i. Types of cooling 1 hour Lecture i. Radiator coolant

cooling system’s system checked
components ii. Layout of cooling ii. Radiator cap
condition system condition checked
iii. Procedures of iii. Cooling system
checking cooling hoses checked
system components iv. Hose clip
iv. Components of condition checked
cooling system v. Water pump
such as: checked for
 Water pump leakage
 Radiator vi. Radiator condition

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 Attitude / Safety / Training Delivery
Work Activities Related Knowledge Related Skills Assessment Criteria
Environmental Hours Mode
 Belting checked
 Fan blade vii. Radiator fan
 Fan motor/ blade condition
pulley checked
 Thermostat viii. Radiator fan
 Radiator cap mechanical /
 Water electrical type
temperature checked
sender unit ix. Fan belt
v. Functions of cooling (mechanical type)
system components checked
x. Water
i. Check radiator 5 hours Demonstration temperature
coolant & sender unit /
ii. Check radiator cap Observation sensor condition
condition checked
iii. Check cooling
system hoses
iv. Check hose clip
condition
v. Check water pump
for leakage
vi. Check radiator
condition
vii. Check radiator fan
blade condition
viii. Check radiator fan
mechanical /
electrical type
ix. Check fan belt
(mechanical type)
x. Check water
temperature sender
unit / sensor
condition

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 Attitude / Safety / Training Delivery
Work Activities Related Knowledge Related Skills Assessment Criteria
Environmental Hours Mode
Attitude:
i. Always use
extreme caution
when inspecting
engine cooling
system’s
components
condition
ii. Always follow
vehicle
manufacturer’s
warnings,
cautions and
service
procedures

Safety:
i. Ensure engine is
cool before
opening radiator
cap

5. Carry out engine i. Function of 1 hour Lecture i. Radiator upper

cooling system’s thermostat hose & clip
thermostat ii. Types of thermostat dismantled
replacement iii. Construction of ii. Thermostat
thermostat housing removed
iv. Procedure of testing iii. Thermostat
thermostat removed from
v. Engine cooling engine
system’s thermostat iv. Thermostat tested
location according to
vi. Procedure of service manual
removing and v. Thermostat
replacing replaced

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 Attitude / Safety / Training Delivery
Work Activities Related Knowledge Related Skills Assessment Criteria
Environmental Hours Mode
thermostat vi. Thermostat gasket
/ ‘O’ ring replaced
i. Dismantle radiator 5 hours Demonstration vii. Thermostat
upper hose & clip & installed to the
ii. Remove thermostat Observation engine
housing
iii. Remove thermostat
from engine
iv. Test thermostat
according to service
manual
v. Replace thermostat
vi. Replace thermostat
gasket / ‘O’ ring
vii. Install thermostat to
the engine
Attitude:
i. Always use
extreme caution
when carrying out
engine cooling
system’s
thermostat
replacement
ii. Always follow
vehicle
manufacturer’s
warnings,
cautions and
service
procedures

Safety:
i. Careful when
handling hot water

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 Attitude / Safety / Training Delivery
Work Activities Related Knowledge Related Skills Assessment Criteria
Environmental Hours Mode
ii. Ensure engine is
cool before
opening radiator
cap

6. Flush cooling i. Types of coolant 1 hour Lecture i. Radiator cap

system ii. Types of cooling removed
system flushing ii. Radiator coolant
treatment drained
iii. Procedure of iii. Drain plug
flushing cooling tightened
system iv. Cooling system
iv. Used coolant flushing performed
recovery and
storage

i. Remove radiator cap 5 hours Demonstration

ii. Drain radiator coolant &
iii. Tighten drain plug Observation
iv. Perform cooling
system flushing

Attitude:
i. Always use
extreme caution
when flushing
cooling system
ii. Always follow
vehicle
manufacturer’s
warnings,
cautions and
service
procedures

65
 Attitude / Safety / Training Delivery
Work Activities Related Knowledge Related Skills Assessment Criteria
Environmental Hours Mode
Safety:
i. Ensure engine is
cool before
opening the
radiator cap
ii. Careful when
opening the
radiator cap after
flushing

7. Replace radiator i. Function of radiator 1 hour Lecture i. Radiator cap

and radiator cap opened
ii. Procedure of ii. Radiator coolant
replacing radiator drained
and radiator cap iii. Radiator assembly
and mounting
i. Open radiator cap 5 hours Demonstration removed
ii. Drain radiator coolant & iv. Radiator assembly
iii. Remove radiator Observation and mounting
assembly and replaced
mounting v. Radiator assembly
iv. Replace radiator and mounting
assembly and installed
mounting
v. Install radiator
assembly and
mounting
Attitude:
i. Always use
extreme caution
when replacing
radiator
ii. Always follow
vehicle
manufacturer’s

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 Attitude / Safety / Training Delivery
Work Activities Related Knowledge Related Skills Assessment Criteria
Environmental Hours Mode
warnings,
cautions and
service
procedures

8. Replace engine i. Function of radiator 1 hour Lecture i. Electric fan motor

cooling system’s cooling fan removed
electric fan motor assembly ii. Electric fan motor
ii. Components of replaced
radiator cooling fan iii. Electrical fan
assembly motor installed
iii. Procedure of
checking and
replacing radiator
cooling fan
assembly
components

i. Remove electric fan 5 hours Demonstration

motor &
ii. Replace electric fan Observation
motor
iii. Install electrical fan
motor
Attitude:
i. Always use
extreme caution
when replacing
engine cooling
system’s electric
fan motor
ii. Always follow
vehicle
manufacturer’s
warnings,

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 Attitude / Safety / Training Delivery
Work Activities Related Knowledge Related Skills Assessment Criteria
Environmental Hours Mode
cautions and
service
procedures

9. Replace engine i. Function of water 1 hour Lecture i. Beltings removed

water pump pump ii. Front pulleys
ii. Types of water removed
pump iii. Timing belt cover
iii. Beltings removed
components such iv. Timing belt
as: - marking set
 Alternator i. Timing belt
 Air-conditioning removed
compressor ii. Water pump
 Power steering assembly removed
iv. Front pulleys iii. Water pump
components such assembly replaced
as: iv. Water pump
 Crankshaft gasket and sealant
 Water pump applied
v. Procedure of v. Water pump
checking and assembly installed
replacing water vi. Timing belt
pump installed and
adjusted according
i. Remove beltings 5 hours Demonstration to service manual
ii. Remove front pulleys & vii. Timing belt cover
iii. Remove timing belt Observation installed
cover viii. Front pulleys
iv. Set timing belt installed
marking ix. Beltings installed
v. Remove timing belt and adjusted
vi. Remove water pump
assembly
vii. Replace water pump

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 Attitude / Safety / Training Delivery
Work Activities Related Knowledge Related Skills Assessment Criteria
Environmental Hours Mode
assembly
viii. Apply water pump
gasket and sealant
ix. Install water pump
assembly
x. Install and adjust
timing belt according
to service manual
xi. Install timing belt
cover
xii. Install front pulleys
xiii. Install and adjust
beltings
Attitude:
i. Always use
extreme caution
when replacing
engine water
pump
ii. Always follow
vehicle
manufacturer’s
warnings,
cautions and
service
procedures

10. Replace engine i. Layout of engine 1 hour Lecture i. Water jacket core
water jacket core block cooling plug removed
plug system ii. Water jacket core
ii. Function of engine plug replaced
water jacket iii. Water jacket core
iii. Function of engine plug sealant
water jacket core applied
iv. Procedure of iv. Leakage checked

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 Attitude / Safety / Training Delivery
Work Activities Related Knowledge Related Skills Assessment Criteria
Environmental Hours Mode
checking and
replacing engine
water jacket core

i. Remove water jacket 5 hours Demonstration

core plug &
ii. Replace water jacket Observation
core plug
iii. Apply water jacket
core plug sealant
iv. Check for leakage
Attitude:
i. Always use
extreme caution
when replacing
engine water
jacket core plug
ii. Always follow
vehicle
manufacturer’s
warnings,
cautions and
service
procedures

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Employability Skills

Core Abilities Social Skills

01.07 Utilize database applications to locate and process information 1. Communication skills
01.11 Apply thinking skills and creativity 2. Conceptual skills
02.11 Convey information and ideas to people
3. Interpersonal skills
03.15 Liaise to achieve identified outcomes
03.16 Identify and assess client/customer needs 4. Learning skills
5. Leadership skills
6. Multitasking and prioritizing
7. Self-discipline
8. Teamwork

Tools, Equipment and Materials (TEM)

ITEMS RATIO (TEM : Trainees)

1. Motor vehicle 1:5

2. Radiator pressure tester 1:5
3. Hand tools set 1:5
4. Personal Protective Equipment (PPE) 1:1
5. Combination pliers 1:5
6. Coolant As required
7. Sealant gasket As required
8. Radiator flushing equipment 1:10
9. Water hose As required
10. Engine cooling system spare parts (fan motor, thermostat, water As required
jacket core plug, belting, water pump)
11. Used coolant container As required

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References

REFERENCES

1. Anthony E.Schwaller (2004), Total Automotive Technology 4th Edition, Delmar Learning, ISBN: 1-4018-2476-5
2. Ed May (2003), Automotive Mechanic Vol 2, 7th Edition, Mc Graw-Hill Australia ISBN: 0074712969
3. S Srinivasan (2001), Automotive Engines, Tata McGraw-Hill Education, ISBN 0070402655, 9780070402652
4. Victor Hillier, Peter Coombes (2004), Fundamentals of Motor Vehicle Technology, Nelson Thornes, ISBN 0748780823, 9780748780822
5. Jeff Hartman (2004), How to une and odify ngine anagement ystems, MotorBooks International, ISBN 0760315825, 9780760315828
6. Greg Banish (2007), Engine Management: Advanced Tuning, CarTech Inc, ISBN 1932494421, 9781932494426

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