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MOTOR VEHICLE SERVICE AND MAINTENANCE TECHNICIAN (LIGHT VEHICLE) ON-PROGRAMME TASKS TRAINING MANUAL
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CONTENTS
WELCOME TO THE CITY & GUILDS TRAINING MANUAL
5
TASK MAPPING TO APPRENTICESHIP STANDARD
8
BEHAVIOURS
11
ON-PROGRAMME TASKS: TOWARDS GATEWAY 1
25
Tools and equipment
26
Progress tracking
27
1 Safe lifting: Wheels and torque wrench
31
2 Vehicle lift/under-body service
33
3 Brakes inspection
35
4 Under-bonnet service
37
5 Diesel, under-bonnet service
39
6 Workshop hand skills
41
7 Electrical/electronic components
43
8 Circuit board meter checks
45
9 EOBD vehicle diagnostic computer
47
10 MET, trims, clips, lamp and plastics
49
11 Remove and change tyre
51
End of Gateway 1
53
ON-PROGRAMME TASKS: TOWARDS GATEWAY 2
55
Tools and equipment
56
Progress tracking
57
1 Serpentine belt
61
2 Timing belt CI engine (diesel)
63
3 Timing belt SI engine (petrol)
65
4 Engine dismantle and rebuild
67
5 Gearbox removal and clutch inspection
69
6 Suspension arm removal
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7 Steering arms and joints
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8 Brake calliper removal and bleed
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9 Alternator removal
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10 Starter motor removal
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11 Exhaust system removal/air filter
81
12 Lighting rear lamp
83
13 Lighting front headlamp
85
14 Wiper assembly
87
15 Engine testing
89
16 Vehicle interface test readings
91
End of Gateway 2
93
ON-PROGRAMME TASKS: TOWARDS GATEWAY 3
95
Tools and equipment
96
Progress tracking
97
1 Turbo charger
101
2 Engine sensors
103
3 Fuel pump and injection
105
4 Diesel fuel injection
107
5 Emission control and test
109
6 Clutch – dual mass
111
7 Suspension and sensors
113
8 Brakes and electronics
115
9 Engine mechanical diagnostics
117
10 Gearbox inspection diagnostics
119
11 Final drive and inspection
121
12 Starter and charge
123
13 Climate control (air con)
125
14 Hybrid safe working
127
Gateway 3 declaration form
129
COMPLETED EXAMPLE
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Brakes inspection
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WELCOME TO THE CITY & GUILDS TRAINING MANUAL
USING THIS MANUAL Welcome to the City & Guilds Training Manual. The tasks in this manual are provided to support the apprentice’s progression during the on-programme phase of the Automotive Retail Motor Vehicle Service and Maintenance Technician (Light Vehicle) Apprenticeship. It provides recommended tasks that lead up to each of the Apprenticeship Gateways, prior to the End Point Assessment. This training manual does not contain the Gateway assessments. In some cases the components or systems given in the task may be slightly different within training facilities, and in such cases the tasks need to be slightly adapted to suit particular vehicles types and components. Many of the activities are repeated over a number of tasks in order to offer the apprentice the opportunity to develop their skills and behaviours. Similarly, where an apprentice has not performed well in the execution of a task, the task may be repeated. Although many of the tasks are standalone, some of them are designed to integrate into one combined task, providing the apprentice with an opportunity to stretch themselves further. This also reduces material costs.
APPRENTICE INFORMATION When working on these tasks the apprentice will need to ensure that they complete all documentation as neatly and legibly as possible to support their literacy and numeracy development. This can be completed either on paper or in an electronic format. Start date and name must be entered on each task and the trainer/mentor needs to confirm completion by signing and dating the work record. Failure to comply with health and safety workplace policies will result in early termination of the task and renegotiation with the trainer/mentor. The apprentice must show the trainer/mentor, at stages throughout these tasks, any test reading and where data has come from to support their final reports. They must complete all mandatory areas. Tasks can be completed more than once where necessary to support apprentice practical skills and confidence. An example of a completed task is shown at the back end of this manual. Overview of the Apprenticeship journey
Group 5: Intermediate diagnosis and repair
Group 6: Complex diagnosis and repair
End assessment
Group 4: Simple diagnosis and repair
Gateway 3
Group 3: Routine service and inspections
Gateway 2
Group 2: Induction and foundation skills
Gateway 1
Group 1: Soft skills and behaviours
Group 7: Complete systems understanding and repair major components Year 1
Year 2
Year 3
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MATHS AND ENGLISH Employers who recruit candidates without English and Maths at GCSE Grade C (or Functional Skills Level 2) or above must ensure that the candidate achieves this standard before the apprentice is submitted for the end assessment.
F-GAS 7543-01 Level 3 Award in Basic Mobile Air Conditioning Unit 001: Handling refrigerants This unit is mandatory and will allow apprentices to gain a licence to handle F-Gas refrigerants in compliance with the minimum requirements of Regulation (EC) 307/2008. Apprentices will be assessed via a practical assessment and oral questioning.
TRAINER/MENTOR INFORMATION The skills tasks are to support the apprentice through the on-programme skills training, in preparing for each assessment Gateway and for their End Point Assessment. Tools, equipment and procedures: All tools, equipment and relevant workshop procedures must be used in line with current vehicle automotive workshop practices. Vehicles: The vehicles/components must be current products aligned to the latest technologies. Where specially designed training and assessment rigs are used they should replicate that of real components or vehicle sub-assemblies. Electrical and electronic component tests: Where some tasks require just vehicle engine/ components; these need not be attached to the vehicle. Time scales: Although time scales are not stated in the tasks, the apprentice should ultimately achieve the industry standard. Health and safety: All apprentices must wear the correct PPE and work to correct workshop risk assessment procedures. Failure to comply will result in early termination of tasks.
BEHAVIOURS An important part of the on-programme training is the necessary soft skills and behaviours that the apprentice must demonstrate. Some of these may naturally occur in preparing for, completing or reflecting on specific tasks contained in this manual. Recommended opportunities to demonstrate specific soft skills and behaviours are sign-posted within each task although other behaviours may be drawn-out depending on the structure of the task and on the individual apprentice. It is important that opportunities for the apprentice to demonstrate the necessary behaviours are available throughout the full duration of the Apprenticeship, along with opportunities to review and reflect on how their behaviour can develop over time and through experience. An appropriate workplace trainer or mentor should regularly review behaviours with the apprentice including constructive feedback on how to build on existing strengths and how to improve on areas of development. These behavioural evaluations should be captured on recording forms owned by the apprentice but available for review when necessary. An example template has been provided on page 11 which can be used. 6
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GATEWAYS 1–3 At Gateway 1 and 2, the apprentice will need to successfully complete this training manual, pass a practical skills test, a multiple-choice knowledge test and have confirmation that they are sufficiently demonstrating workplace behaviours at the required standard before they are able to continue onto the next phase of the on-programme training. At Gateway 3, the trainer and workplace mentor will need to deem that the apprentice is ready for their End Point Assessment. Trainers and mentors should ensure they are familiar with the relevant Gateway requirements and assessment documentation.
STAGES OF THE APPRENTICESHIP JOURNEY ON-PROGRAMME – TRAINING TOWARDS GATEWAY 1 The apprentice completes the on-programme tasks alongside an on-going review of their workplace soft skills and behaviours.
GATEWAY 1 The apprentice successfully completes • training manual tasks up to Gateway 1 • a multiple-choice knowledge test graded pass or distinction • a practical skills test graded pass only • a formal review of their workplace behaviours with a rating of either achieved or distinction.
ON-PROGRAMME – TRAINING TOWARDS GATEWAY 2 The apprentice completes the on-programme tasks alongside an on-going review of their workplace soft skills and behaviours.
GATEWAY 2 The apprentice successfully completes • training manual tasks up to Gateway 2 • a multiple-choice knowledge test graded pass or distinction • a practical skills test graded pass only • a formal review of their workplace behaviours with a rating of either achieved or distinction.
ON-PROGRAMME – TRAINING TOWARDS GATEWAY 3 The apprentice completes the on-programme tasks alongside an on-going review of their workplace soft skills and behaviours.
GATEWAY 3 The trainer/mentor and employer review the training manual, the results from the Gateway 1 and 2 assessments, the behavioural evidence and confirm that the apprentice is ready for the End Point Assessment.
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8 Group 1: Soft Skills and Behaviours
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Brakes inspection
Under-bonnet service
Diesel, under-bonnet service 1.1 1.2 1.3 1.4 2.1 2.2 2.3
Workshop hand skills
Electrical/electronic components
Circuit board meter checks
EOBD vehicle diagnostic computer
3
4
5
6
7
8
9
3.1 3.2 3.1 3.2 3.4
1.1 1.2 1.3 1.4 2.1 2.2 2.3
1.1 1.2 1.3 1.4 2.1 2.2 2.3
1.1 1.2 1.3 1.4 2.1 2.2 2.3
1.1 1.2 1.3 1.4 2.1 2.2 2.3
1.1 1.2 1.3 1.4 2.1 2.2 2.3
10 MET, trims, clips, lamp and plastics
11 Tyre change, repair puncture and balance
12 Assessment hand skills
13 Assessment service
3.1 3.2 3.3
3.1 3.2 3.3 3.4
3.1 3.4
3.1 3.2
3.1 3.2
1.1 1.2 1.3 1.4 2.1 2.2 2.3
1.1 1.2 1.3 1.4 2.1 2.2 2.3
3.1
3.1 3.3
3.1 3.3
3.1 3.3
1.1 1.2 1.3 1.4 2.1 2.2 2.3
1.1 1.2 1.3 1.4 2.1 2.2 2.3
1.1 1.2 1.3 1.4 2.1 2.2 2.3
Vehicle lift/under-body service
2
3.1 3.3
Safe lifting: Wheels and torque wrench
1
1.1 1.2 1.3 1.4 2.1 2.2 2.3
Group 3: Routine Services and Inspections
3.1
Group 2: Induction and Foundation Skills
1.1 1.2 1.3 1.4 2.1 2.2 2.3
Gateway 1 training and assessment
This supports the competence linked to the knowledge requirements.
Task cross reference to unit grouping.
4.4
Group 4: Simple Diagnosis and Repair
Group 5: Intermediate Diagnosis and Repair
Group 6: Complex Diagnosis and Repair
all
all
all
all
all
all
all
all
all
all
all
all
all
Group 7: Complete systems understanding and major repair
TASK MAPPING TO THE APPRENTICESHIP STANDARD
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BEHAVIOURS
(CONTINUED)
Positive working relationships The standard
Maintain positive working relationships even though the other person may be very different from myself.
What a distinction would look like
Encourage others to be involved, recognise those that are slow to contribute or are being excluded and take steps to bring them into the team.
Apprentice’s personal reflection on how this behaviour could be demonstrated
Trainer/mentor feedback
Score Receiving and managing tasks The standard
Accept the tasks I am given and quickly recognise whether I have the ability to complete them and seek help appropriately.
What a distinction would look like
Recognise the strengths and weaknesses in myself and others and allocate tasks to those who are best able to complete them.
Apprentice’s personal reflection on how this behaviour could be demonstrated
Trainer/mentor feedback
Score
12
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ON-PROGRAMME: TRAINING TOWARDS GATEWAY 1
ON-PROGRAMME TASKS: TOWARDS GATEWAY 1
TASK GROUPINGS GROUP 1: SOFT SKILLS AND BEHAVIOURS GROUP 2: INTRODUCTION AND FOUNDATION SKILLS GROUP 3: ROUTINE SERVICE AND INSPECTIONS
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ON-PROGRAMME: TRAINING TOWARDS GATEWAY 1
TOOLS AND EQUIPMENT
The following is an example of the necessary resources, tools and equipment needed to support the practical skills for Gateway 1. Garage tool box/kits: spanner, sockets, screwdriver, hammer
Allen keys
Torque wrenches – selection of sizes
Spline and Torx sockets
Coolant pressure test equipment
Pullers
Computer diagnostic interface
Press
Ammeter (multi-meter) and a separate amp clamp
Air line
Voltmeter (multi-meter)
Tyre fitting
Ohm meter (multi-meter)
Wheel balancing
Headlamp alignment
Brake bleed equipment
Typical garage ¼, ½, ¾ socket sets
Measuring equipment – micrometer, ruler, vernier, DTI
Impact drivers – air, electric
Vehicle protection – wing, seat, steering and floor
Lifting equipment – vehicle ramps, jacks and stands
Consumables – nuts, washers, bolts, wire terminals
Lifting equipment – transmission
Gasket paper, gaskets
Hand lamps – safe voltages required
Grease, oils, sprays, sealants
Electrical circuit boards equipment
Antifreeze
Drill, drill bits
Data source for vehicle information
Files, punches, general metal workshop tools
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ON-PROGRAMME: TRAINING TOWARDS GATEWAY 1
PROGRESS TRACKING
7
(CONTINUED)
Electrical/electronic components
Feedback where necessary
Mentor/Trainer signature
8
Date of completion
Circuit board meter checks
Feedback where necessary
Mentor/Trainer signature
9
Date of completion
EOBD vehicle diagnostic computer
Feedback where necessary
Mentor/Trainer signature
Date of completion
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ON-PROGRAMME: TRAINING TOWARDS GATEWAY 1
TASK 1 SAFE LIFTING: WHEELS AND TORQUE WRENCH
Apprentice name
Task start date
Lift a vehicle to remove two wheels and refit following correct workshop procedures. Two apprentices working together. You must work safely in an automotive workshop, following correct health and safety requirements. You must wear the correct personal protective equipment (PPE). Data and equipment to be used: Apprentice to complete before starting. Mentor/Trainer to tick if used correctly.
✓
Trolley jack – state SWL: Axle stands – state SWL: Torque wrench – state range and figure used: Power wrench – state type: Behaviours sign-posting: The following behaviours are relevant to this task but this is not an exhaustive list. • • • •
Work with others to achieve target Maintain positive working relationships Accept the task to quickly recognise abilities and seek help appropriately Demonstrate honesty with the team
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ON-PROGRAMME: TRAINING TOWARDS GATEWAY 1
TASK 1 (CONTINUED) SAFE LIFTING: WHEELS AND TORQUE WRENCH
Apprentice report: Provide an overview of the task to include the following criteria. Use sketches to support if necessary. 1 2 3
Where the trolley jack and axle stands were placed. Risks associated with the task. Correct use of torque wrench and settings.
Mentor/Trainer feedback
32
Mentor/Trainer signature
Date
Apprentice signature
Date
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ON-PROGRAMME: TRAINING TOWARDS GATEWAY 1
TASK 2 VEHICLE LIFT/UNDER-BODY SERVICE
Apprentice name
Task start date
Use vehicle lift, check a vehicle’s under-body service items, plus oil and filter change and follow correct workshop procedures. Two apprentices working together. You must work safely in an automotive workshop, following correct health and safety requirements. You must wear the correct personal protective equipment (PPE). Data and equipment to be used: Apprentice to complete before starting. Mentor/Trainer to tick if used correctly.
✓
Ramp – state SWL and type: Engine oil type and amount: Oil drainer used: Oil sealing device on sump plug: Behaviours sign-posting: The following behaviours are relevant to this task but this is not an exhaustive list. • • • •
Carry out task with consideration to others Seek support from colleagues where needed Report any difficulties which may arise in time Feed back to others appropriately with relevant evidence
Mandatory tasks to complete:
✓
Oil and filter Transmission oil levels Suspension springs and damper Exhaust and mountings Fuel lines Brake pipes Suspension control arms and bushes Fluid leaks: brakes, oils and coolants Steering joints Drive line faults and issues Protective underseal and corrosion General under-body damage Completed and checked
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ON-PROGRAMME: TRAINING TOWARDS GATEWAY 1
TASK 2 (CONTINUED) VEHICLE LIFT/UNDER-BODY SERVICE
Apprentice report: Provide an overview of the task to include the following criteria. Use sketches to support if necessary. 1 2 3 4
Safe working with vehicle lifts. Risks associated with old engine oil and its disposal. Oil and filter change procedure. Report on mandatory checks.
Mentor/Trainer feedback
34
Mentor/Trainer signature
Date
Apprentice signature
Date
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COMPLETED EXAMPLE TASK 3 (CONTINUED) BRAKES INSPECTION Apprentice report: Provide an overview of the task to include the following criteria. Use sketches to support if necessary. 1 2 3 4 5
Type of brake system. Risks associated with task. Tools used to measure wear. Report on findings. Reasons why brake pedal must be pumped after reassembly.
Completed a Landrover front brake pad and rotor disc change. This involved safely lifting the vehicle to a working height on a two post ramp of SWL 2.5tonne. I wore PPE (boots, overalls, goggles and face mask, also barrier cream). I had to ensure the dust did not go into the atmosphere and used correct brake cleaning fluid. I removed the front wheels and stored them safely with the wheel nuts. I then removed the brake calliper bolts and clipped the callipers safely to the suspension with cable ties. I removed the pads and disposed of them in the correct waste area to support recycling. I used a DTI to measure the disc run-out, which was 0.3mm and needed replacement. When the task was reassembled the calliper bolts were torqued correctly, callipers cleaned and all signs of corrosion removed. Torque wrench wound back to relieve spring. Wheel nut torque to correct figure of 140Nm Brake pedal pumped to allow pads to contact discs, otherwise a long pedal travel could cause an accident, and fluid levels checked.
Mentor/Trainer feedback
Good work and safe working practices, good communication skills observed, documentation completed correctly and legible. All task elements to a very good standard. Well done.
Mentor/Trainer signature
M J Clayton Apprentice signature
Tommy Atkins 132
Date
28/10/2016 Date
28/10/16
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9301 MOTOR VEHICLE SERVICE AND MAINTENANCE TECHNICIAN (LIGHT VEHICLE) ON-PROGRAMME TASKS TRAINING MANUAL This training manual provides apprentices with a range of practical tasks to apply their knowledge and skills in preparation for assessment. The manual is designed to support formative learning, by allowing the apprentice to track their progress and record evidence. This training manual is also available on Learning Assistant, City & Guilds’ e-portfolio solution.
THIS MANUAL INCLUDES: • Tasks mapped to the three Apprenticeship Gateways • Tasks to support reflective learning and evidence literacy, numeracy and behavioural competencies • Integrated tasks to provide ‘stretch’ learning • Checklists for each task, where assessors can provide feedback.
THE AUTHOR Marshall Clayton is Deputy Director of Automotive & Engineering Technologies at Deeside College.
ISBN 978-0-85193-375-7
125005982 TL9301
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