ZIMBABWE

HIGHER EDUCATION EXAMINATIONS COUNCIL

2024

REGULATIONS AND MODULES FOR THE

NATIONAL FOUNDATION CERTIFICATE

IN

CAR MAINTENANCE
Course Code: 110 /24/CR/M0

Implementation date: January 2025

HERITAGE-BASED EDUCATION 5.0

NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

PREAMBLE
This course is designed to produce a Car Maintenance Assistant with knowledge, skills and
attitudes required to operate in the Automotive and Allied Industries. The course duration is 800
hours. The entry requirement is a minimum of two years secondary education or equivalent. The
course is offered on a full time or part time basis. Assessment is through continuous assessment
and theory examinations. The course will consider gender mainstreaming, sustainable
development, physical challenges, health dispositions and the intersections between race, class
and culture.

CONSULTATIONS YEAR
National Manpower Advisory Council (NAMACO Automotive 2024
Sectoral Committee)
Motor Trade Association of Zimbabwe 2024
Ministry of Primary and Secondary Education 2024
Ministry of Youth, Empowerment and Indigenization 2024
Chaminuka Vocational Training Centre 2024
Marondera Vocational Training Centre 2024

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

PART I COURSE REGULATIONS

1.0 TITLE AND LEVEL OF THE COURSE

National Foundation Certificate in Car Maintenance

2.0 AIM
The aim of the course is to produce a Car Maintenance Assistant with knowledge,
skills and attitudes required to operate in the Automotive and Allied Industries.

3.0 OBJECTIVE
By the end of the course, the student should be able to carry out basic maintenance,
service and repair of motor vehicles, components and units.

4.0 STRUCTURE

MODULE CODE DURATION

(HOURS)

1. Car Maintenance 110/24/M01 800

5.0 DURATION
Course duration is 800 hours

6.0 ENTRY REQUIREMENTS

At least 2 years of secondary school education or equivalent qualification.

7.0 MODE OF STUDY

Full time 800 hours
Part time (Secondary School Students) 800 hours

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 NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

8.0 ASSESSMENT SCHEME

NO MODULE AND WRITTEN EXAMINATION CONTINUOUS WEIGHTING

CODE 40% ASSESSMENT
60%
A minimum of

1. Car Maintenance Paper 1 • 2 Practical 100%

(Theory Paper): 3 hours Assignments
110/24/M01 (30%)

9.0 GRADING

0% to 49% - Fail
50% to 59% - Pass
60% to 79% - Credit
80% to 100% - Distinction

10.0 CONDITIONS OF AWARD

10.1 A candidate should attend at least 85% learning sessions to qualify for examinations.
10.2 A candidate should pass the module to be awarded a National Foundation Certificate in
Car Maintenance.
10.3 Candidate should pass on aggregate provided they score at least 40% in each of
continuous assessment and examinations.
10.4 The aggregate pass mark shall be 50 %.
10.4 Non-submission of coursework marks will result in the candidate being deferred.

11.0 RE – WRITES
11.1 A candidate should pass the continuous assessment to qualify for a re-write.
11.2 Re-writes should conform to current course structure.
11.3 A candidate is given no time limit in which to re-write the failed module.
11.4 There is no aggregation for re-writes.
11.5 All re-writes should pass on performance in the examination and maximum
grading will be a pass.
11.6 If a candidate fails continuous assessment, he/she repeats the module.

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

12.0 EXEMPTIONS
12.1 No Exemptions at this level.

13.0 IRREGULAR PRACTICES

13.1 Cheating in examinations will result in disqualification from the whole course
and all other HEXCO courses. The candidate will be suspended for one year
from the course and all HEXCO courses. After the suspension period, the
candidate will rewrite the module.
13.2 Plagiarism with a similarity index of more than 15% in any of the assessments
will result in automatic disqualification from the module.

14.0 RESOURCES
14.1 Manpower
a. National Certificate in Motor Vehicle Mechanics
b. Skilled Worker class 1 certificate in a Motor Vehicle Mechanics
c. A Teaching/Training qualifications or experience

14.2 Tools, Equipment and Infrastructure

For an institution to successfully implement this course, the following will
need to be in place (also see APPENDIX I for the list of tools and equipment).
a. A classroom to comfortably hold about 12 students, durable quality
desks, chairs, chalkboard/whiteboard, sufficient headroom and ventilation.
b. Workshop
c. Fire fighting appliances.
d. First aid kit and protective wear for each student and the lecturer/instructor.
e. Audio – visual learning Aids such as overhead Projector, colour

T.V and Video Cassette player with access to relevant software.

APPENDIX 1
SECTION 1: HAND TOOLS
ITEM QUANTITY
Tool Box(portable) 5

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

Tool box(wall mounted) 5

Combination spanner set 8mm to 32 mm 5
Ring spanner set 5
Combination pliers 5
Long nose pliers 5
Adjustable wrenches 5
Screw driver set: flared tip and Phillips 5
Scriber 5
Ball pein hammer 5
Plastic hammer 5
Rubber mallet 5
Centre punch 5
Pin punch set 5
Cold chisel 5
Engineer’s file set 5
Socket set: 6mm to 32mm 5
Socket set:36mm to 80mm 5
Torque wrench ½ inch drive ( direct reading) 5
Torque wrench ½ inch drive 5Nm to 35Nm 5
Torque wrench 50Nm to 225Nm 5
Flared – nut spanner set 5
Pipe wrench 5
Vice grip pliers 5
Grip welding clamp (for plates) 1
Wire brush 5
Hacksaw 300mm blade 5
Junior hacksaw 5
File card brush 5
Stud remover set 5
Screw exCar set 5
Engineer’s hammer 5
Hollow punch set 5
Gasket cutter 5
Tin snips - straight 2
Pop riveter set 2
Tyre lever set - trucks 2
Four – way wheel spanner – Car / Trucks 2
Tyre valve tool 2
Brake piston clamp set 2
Cylinder honing tool - portable 1
Circlip pliers: inside and outside 5 of each
Allen key set: 2mm to 19mm 5
Drain plug wrench set 2
Oil filter wrench 2
Valve spring compressor 2
Battery service tool kit 1
Impact screwdriver set 2
Clutch plate aligning tool set 2
Socket set 7/8 to 2 inch AF 5
Socket set 3/8 to 11/4 inch AF 5

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

Socket set ¼ to 7/8 inch AF 5

Ring spanner set ¼ to 11/4 inch AF 5
Combination spanner ser 3/8 to 7/8 inch AF 5
Allen key set 1/16 to ¼ inch AF 5
Sliding hammer set 2
Dividers 5
Crimping tool 2

SECTION 2: MACHINE AND CUTTING TOOLS

ITEM QUANTITY
Bench grinder: Double ended 4
Pedestal grinder: Double ended 2
Drill bit sharpener 5
Pillar drilling machine 13mm 2
Machine vice 4
Engine valve grinder : bench type 1
Engine valve seat grinding kit 1
Twist drill set 1 – 13 mm 5
Die stock set: metric (M3 – M12) 1
Die stock set: Imperial ¼ - ½ inch (BSW, 1 of each type UNF, UNC 1
Thread repair kit metric 1
Thread repair kit metric 1
Thread restorer set (Metric and Imperial) 1 of each type
Cylinder ridge reamer 1
Twist drill set 1/64 to ½ inch 5

SECTION 3: GENERAL WORKSHOP EQUIPMENT

ITEM QUANTITY
Tool cabinets 4
Tool trolleys 4
Work benches: Steel top with storage cabinets 8
Open self units 8
Oil drain pans 8
Axle stands 6 pairs
Compressed air system comprising:
(a)air compressor 500 lit/min 1
(b)air filter with regulator 1
(c)ball valve 1
(d)air hoses, 100m length and 10mm diameters 5
(e) air coupling set 4
(f) air reservoir: 50 litre capacity 1
Waste containers 4
Bench vices 1
Garage creeper 4
Inspection lamp 4
Cable extension reel 4
Arbour press 20kN 1

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

Hydraulic press 600kN 1

Diesel engine stand(with rotating spindle) 2
Exhaust gas exCar fan 1
Electric drill: portable 4
Pneumatic impact wrench ½ drive 2
Impact socket set 2
Inspection set 1
Pit jack 2
Trolley jack 20kN 4
Bottle jack 4
Portable crane 2
Chain hoist 2
chain sling 2
Low loading trolley 4
Brake bleeding unit 1
Optical alignment gauge (e.g. Dunlop type) 1
Tyre testing tank 1
tyre guard 1
Tyre and tube repair kits (cold and vulcanising equipment) 1 of each kit
Battery charger 6 – 12 and 24 volts 2
Soldering irons 60w & 100 w 2
Arc welding set 3
Gas welding and cutting set 4
Gas cylinder trolley 4
Welding table 4
Puller set (for sleeves, flywheels, etc) 2
welders apron 14
welders gloves 14 pairs
Welding helmet 14
Blow lamp (paraffin) 2 spray paint kit
Spray paint kit 1
Parts cleaning tank 1
Wash – basket trolley 4
Cold water high pressure cleaner 1
Heated high pressure cleaner 1
Grease gun: Lever type 4
Lubricating pump: Pneumatic 1
Manual drum pump 2
Drum tap 2
Oil can set 8
Gravity oil drain unit 1
Protective goggles 14
Work gloves 14 pairs
Face mask 5
First aid Kit 5
Emergency stretcher 1
Fire extinguisher 5
Fire hoses 5
Sand buckets 4
Fire blanket 1

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

SECTION 4: MEASURING AND TESTING EQUIPMENT

ITEM QUANTITY
Test light: 6 to 24 volts 10
Injector tester 2
Cylinder compression tester 2
Fuel feed pump gauge 2
Current ammeter 400A 2
Voltmeter 30V 2
Mechanical system Analyser 2
Cooling system Analyser 2
Thermometer 2
Headlamp tester 1
Oil pressure gauge 2
Steel rule 14
Height gauges 4
Vernier callipers 14
Micrometers : inside and outside 25 – 100mm 3 of each
Thread gauges: metric and imperial 2 of each
Cylinder leakage tester 1
Hydrometer 4
Tyre pressure gauges 4
Multi-meter 2
Cylinder bore gauge set 2
Dial gauge with magnetic base 4
Universal surface gauge 4
Surface plate 500 x 600mm 4
Straight edge 1 000mm 4
Combination square set 7
Engineers square 4
Calliper: inside and outside 14 of each
Measuring tape 2 metres 4
Drill grinding gauge 14 of each
Feeler gauge set: metric 10
Feeler gauge set: imperial 10
Spring scale 200g 2
Buzzer (for continuity testing) 2
Hydraulic system test kit 1

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

SECTION 5: CONSUMABLE MATERIALS

ITEM QUANTITY
Solder – less terminal kit 1
Electric cables (various colours) 2 rolls each
Fuses 2 cartons
Hacksaw blades 24 TPI 36 cartons
Emery cloth sheet assortment 4 cartons
Bolts and nut assortment 4 cartons
Flat steel washer assortment (different sizes) 4 boxes of each kind
Spring washer assortment 4 boxes
Split pin assortment 4 boxes
Screw assortment 4 boxes
Gasket sheet assortment (different sizes) 2 rolls of each size
Gasket sealer 4 roller
Pop rivet kit 2 rolls
Masking tape 2 rolls
Insulation tape 50 rolls
Grease nipple assortment 4 boxes
Resin core solder 10 rolls
Gas welding rods 200
Bronze welding rods 200
Bronze welding flux 4 tins
Arc welding rods (various sizes) 200
Battery 12 volts ( heavy duty) 5
Auto – electrical assortment (bulbs, fuses etc) 4 boxes
Engine oil 50 litres
Gearbox oil 20 litres
Brake fluid 10 litres
Differential oil 20 litres
Multi – purpose grease 30 litres
Rubber lubricant 5 litres
Engine oil filters (for available engines) 4 for each
Air filters 4 for each
In – line fuel filters 2 types
Tube and tyre patches 4 packets
Tube and tyre repair adhesives 5 litres
First aid items 4 packets
Degreasing fluid 60 litres
Hand cleaner 10 litres
Heater plugs 1 set per engine
Distilled de – ionised water 5 litres
Battery acid (concentrated sulphuric acid) ½ litres
Mutton cloth 20 rolls
Hydraulic fluid 9 e.g. ( Texamatic) 50 litres
Diesel fuel / Calibration oil 50 litres
High pressure fuel pipes 1 set engine
Paraffin 20 litres
Car ballasting weights ( Rear Axle and Car Front) 1 set

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

SECTION 6: TEACHING AIDS

ITEM QUANTITY
Four stroke engine model ( Desk Model) 2 of each
Two Stroke engine model ( Desk Model) 2 of each
Single disc clutch model 2
Gearbox model 2 of each type
Differential model 2 of each type
Steering mechanism model 2 of each type
Hydraulic dual circuit brake system model 2
Injector pump model 2 of each type
Alternator model 2 of each type
Generator model 2 of each type
Starter model 2 of each type
Battery model 2 of each type
Fuel injection system model 2 of each type
Auto electrical model (Circuit board) 4
Tow truck model 1
Four cylinder in line petrol engine ( 4 stroke) 2
Horizontal opposed piston engine model 1
six cylinder in – line engine model 2
Diesel engine component assortments
valve timing assemblies, chain, belts and gear drive
Injectors pumps in line and rotary (D.P.A) 2 of each type
Four speed gear boxes, sliding, sychro and constant mesh 2 of each type
Five speeds gearbox 2 types
Rear wheel drive Car chassis: complete 1
Suspension dampers: one and two way 10
Steering gearboxes: worm and sector, recirculating ball, rack and pinion and 2 of each type
worm and nut
Vehicle chassis with basic air brake circuitry, mechanical handbrake system and
auto – electric circuitry 1
snub axle with left hand threaded studs and wheel nuts 2
Tyres tubeless, retreads, cross-ply and radial 2 of each type
Tubes 4 sizes
Epicyclic gear set model 2
Hydraulic system model 1
Power take off models/ degreaser 2 tyres
Hand cleaner 210 litres

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 NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

14.3 LIST OF SUGGESTED BOOKS FOR REFERENCE

Coker, A.J (2000) Automotive Electrical Systems 4th Elsevier, New York.
Edition

Denton, T (2013) Automobile Electrical and Electronics Butterworths, London

4th Edition

Erjavec, J & (2014) Automotive Technology: A Systems Delmar Publishers, New York.
Thompson R Approach

Georing, C.E (2004) Engine and Car Power Butterworths, London

Gilles, T (2011) Automotive Service: Inspection, Delmar Publishers, New York.

Maintenance, Repair

Hillier V & (2014) Fundamentals of Motor Vehicle Nelson Thornes, London

Coombs P Technology 5th Edition

Hillier V & (1980) Fundamentals of Heavy Vehicles Hutchinson, London

Pittuck P Technology

Hancock W & (2011) Auto Math Handbook HP1554 Penguin Group, New York.
Lawlor J

Jain S.C & (1985) Farm Car Maintenance and Repair McGraw Hill, New Delhi
Rai C.R
(1985) Science & Calculations for Motor Delmar Publishers, New York.
Marton A.L Vehicle technicians

Nunney M.J (1993) Light & Heavy Vehicle Technology (2nd Hutchison, London
Edition)

Pekison J,& (2005) Math for the Automotive Trade 3rd Delmar Publishers, New York.
deKryger W Edition

Stone, R (1988) Introduction to the internal Combustion Macmillan, London

Engine

Stormo, T (2009) Engine and Car Power Delmar Publishers, New York.

South, D.W & (2004) Delmar’s Automotive Dictionary Delmar Publishers, New York.
Dwiggins, B.H

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

PART II

15. MODULE CONTENT

MODULE TITLE: CAR MAINTENANCE

CODE: 110/24/M01

DURATION: 800 Hours

1.0 AIM

The aim of the module is to develop a Car Maintenance Assistant with knowledge, skills
and attitudes required to operate in the Automotive and Allied Industries.
.

2.0 OBJECTIVES
By the end of the course the student should be able to:
2.1 Demonstrate safe working practices when using hand tools and
workshop equipment to maintain efficiency and reduce the risk of injury
2.2 Perform routine engine maintenance tasks to maximize engine performance and
efficiency
2.3 Troubleshoot common cooling system faults to optimize engine performance
2.4 Perform basic motor vehicle electrical system maintenance for
efficient operation and maintaining optimal performance.
2.5 Carry out basic braking system maintenance to optimize braking
performance and safety
2.6 Perform routine transmission system maintenance for smooth
operation and maintain optimal performance
2.7 Carry out routine maintenance tasks on the steering and
suspension system to maintain ride comfort, vehicle handling
and stability
2.8 Service wheels and tyres to improve stability, traction and overall
performance

3.0 TOPICS
3.1 Safe Working Environment Maintenance

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

3.2 Workshop Tools and Equipment

3.3 Engine Maintenance
3.4 Lubrication System Maintenance
3.5 Cooling System Maintenance
3.6 Ignition System Maintenance
3.7 Fuel System Maintenance
3.8 Transmission System Maintenance
3.9 Final Drive, Differential, Propeller Shafts and Drive Shafts Maintenance
3.10 Braking System Maintenance
3.11 Steering and Suspension System Maintenance
3.12 Wheels and Tyres Maintenance
3.13 Car Frame Service
3.14 Basic Auto-Electrics

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Module Code: 133/24/CR/M01

Module Title: CAR MAINTENANCE

ZNQF Level: NATIONAL FOUNDATION CERTIFICATE

Credits: 80

Duration: 800 Hours

Relationship with Based on Unit Standard : NATIONAL FOUNDATION CERTIFICATE IN CAR

Qualification MAINTENANCE
Standards:
Pre-requisite N/A
modules:
Purpose of Module: This unit will enable an individual assistant to an artesian to analyze and apply skills in
conducting minor repairs and maintenance of light vehicles.
List of Learning LO1: Demonstrate and adhere to safety and healthy practices in the workshop.
Outcomes: LO2: Use appropriate PPE.
LO3: Conduct risk assessment in the workshop
LO4: Participate in safety and health awareness meetings.
Assessment Criteria: 1.1. Demonstrate and adhere to safety and healthy practices in the workshop.
1.2. Use appropriate PPE.
1.3. Conduct risk assessment in the workshop.
1.4. Participate in safety and health awareness meetings.
Content: 1.1 Outline and explain the requirements for workshop safety
1.1.1 State workshop rules.
1.1.2. Discuss the impact of neglecting workshop rules.
1.1.3. Demonstrate first aid techniques.
1.1.4 Illustrate fire extinguisher use.

1.2 Use of Appropriate PPE

1.2.1. Explain what PPE stands for.
1.2.2. State PPE used in the workshop.
1.2.3. Illustrate how each PPE is used.
1.2.4. Demonstrate first aid techniques.

1.3. Conduct risk assessment in the workshop.

• Fire risks
• Trips and falls
• Blocked exits
• Damaged tools and equipment.
• Clutter in the workshop

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1.3. Participate in safety and health awareness meetings.

1.3.1 Raise risk concerns in the meetings.
1.3.2. Discuss safety improvement methods.

Assessment Tasks: 1.Written and/or oral assessment on the skills and knowledge required to carry out
procedures as outlined in the assessment criteria and content above.
2. Labour Act, Chapter 28.01 and National Social Security Authority’s Accident
Prevention Workers Compensation Scheme Notice No 68 of 1990
Conditions/Context 1. Written and/or oral assessment can be conducted in a classroom environment. Oral
of assessment assessment can also be conducted by the assessor during the performance of the
practical assessment by the trainees.
2. The practical assessment will be conducted in the workplace or simulated work
environment in the training institution.
2. Workshop Tools and Equipment

List of Learning LO1: Demonstrate the proper use of hand tools and equipment.
Outcomes: LO2: Identify and classify hand tools according to their jobs.
LO3: Observe the precautions required when using, storing and maintaining
Measuring. testing and lifting equipment.
LO4: Describe measures to be taken before using power tools
Assessment 1.1 State the use of different types of tools
Criteria: 1.2 Illustrate how hand tools are safely stored and maintained
1.3 Identify the use of the correct tool for the correct job
2.1 Distinguish the different types of hand tools according to their uses
2.2 Define the terms used in the classification of tools: measuring, testing, cutting etc.
2.3 Apply safety when using tools
3.1 Implement safety precautions when using, storing and maintaining measuring, testing
and lifting equipment
3.2 Practice safe methods of using tools
3.3 Identify safe practices that reduce damages and injuries.
4.1Observe safety precautions when using power tools
4.2 Discuss the methods used to reduce electric shocks when using power tools
4.3 State the requirements for proper attire regarding safety of electric equipment
Content: 1.1 Carry out procedures and processes in tool handling
1.1.1 Discuss the safe methods of storing and maintaining tools
1.1.2. Apply their skills and knowledge in using measuring tools
1.1.3. Observe the proper use of power tools
2.1.1 Explain the correct use of the different types of hand tools.
2.1.2 Describe how different types of tools are used.
2.1.3 Give the use of the following equipment:
• hoist
• cranes
• jacks

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 NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

• axle stands
• ramps
• air compressors
• steam cleaners
• degreasing equipment
2.1.4 Apply the safe practices in selecting the appropriate tool to use
3.1.1 Explain how tools can be safely used to produce the desired outcome
3.1.2 Describe how neglected safe practices can lead to damages and injuries
3.1.3 State the methods used to safely store sharp cutting tools
4.1.1 List the safety precautions to be observed when using power tools
4.1.2 Check electric equipment for naked wires or burnt insulation
4.1.3 Use proper attire to avoid electrocution
Assessment Tasks: 1. Written and/or oral assessment on the skills and knowledge required to carry out
procedures as outlined in the assessment criteria and content above.
2. Practical assessment on engine overhauls and measuring components based on the
performance criteria of the level 2 standard for a Car Maintenance Assistant on the
unit title Workshop Tools and Equipment.
Conditions/Context 1. Written and/or oral assessment can be conducted in a classroom environment. Oral
of assessment assessment can also be conducted by the assessor during the performance of the
practical assessment by the trainees.
2. The practical assessment will be conducted in the workplace or simulated work
environment in the training institution.
3. Engine Maintenance

List of Learning LO1: Describe the operation of the internal combustion engine.
Outcomes: LO2: Identify engine components.
LO3: Describe the different engine layouts
LO4: Perform valve timing
Assessment Criteria: 1.1 Describe the operation of the internal combustion engine.
1.2 Identify the different components that make up an engine.
1.3 Identify and describe different engine layouts.
1.4 Effectively carry out valve timing
Content: 1.1 Operation of the Internal Combustion Engine.
1.1.1 Explain the four-stroke cycle of an internal combustion engine.
1.1.2. Discuss the two-stroke cycle of an internal combustion engine.
1.1.3. Explain engine terms
• TDC
• BDC
• S.I
• C.I
• OHC
• DOHC
• OHV

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• Stroke
• Bore
1.2. Engine Components and their Functions.
1.2.1 Components in the cylinder header
1.2.2 Components in the cylinder block.
1.2.3 External components attached to the engine.
1.3. Engine layouts:
- In-line
- V- type
- Horizontally opposed pistons.
1.4. Valve timing
1.4.1 Carry out valve timing
1.4.2 List tools needed.
1.4.3 State precautions that must be observed.
• Establish hazards.
• Discuss how one could prevent accidents.
Assessment Tasks: 1. Written and/or oral assessment on the skills and knowledge required to measure and
repair/replace/service components as outlined in the assessment criteria and content
above.
2. Practical assessment on engine overhauls and measuring components based on the
performance criteria of the level 2 standard for a Car Maintenance Assistant on the
unit title Engine Maintenance.
Conditions/Context 1. Written and/or oral assessment can be conducted in a classroom environment. Oral
of assessment can also conducted by the assessor during the performance of the practical
assessment assessment by the trainees.
2. The practical assessment will be conducted in the workshop or simulated work
environment in the training resources requirements:-
• Standard tool box
• Lifting equipment and Hoist equipment
• Powered hand tools
• Workbench
• Mutton cloth
• Detergents
4. Lubrication System Maintenance

List of Learning L01: Identify light motor vehicle lubrication system components.
Outcomes: L02: Describe the three types of friction experienced on vehicle’s lubrication system.
L03: Identify and select different grades of engine and transmission oils.
L04: Carry out the procedure of changing engine oil and filters.
L05: Describe the effects of low oil pressure and high oil pressure.
Assessment Criteria: 1.1 List the components of the lubrication system.
1.2 State the function of the lubrication system components
2.1. List three types of friction and explain the differences.

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2.2. State the functions of lubrication oil.

2.3. Draw a block diagram of the lubrication system.
3.1. Describe the different grades of oils.
3.2. Identify the various types of oil additives.
3.3. State and explain the different grades of transmission oils
4.1. Describe the safety measures to be considered before carrying out the procedure of
changing oil.
4.2. Conduct the procedure of changing engine oil and filters.
5.1. Identify areas on the engine there is a possibility of oil leak.
5.2. Explain the effects of low oil pressure and high oil press on the operation the motor
vehicle.
Content: 1.1.1. Name the components of the lubrication system.
1.1.2. Give the functions of the following lubrication system components;
a) Oil strainer
b) Oil pump
c) Oil filter
d) Oil switch
2.1.1. Describe the three types of friction
2.1.2. Give the functions of the lubricating oil on a motor vehicle.
2.1.3. Neatly draw a block diagram of the lubrication system and label all parts.
3.1.1. Name and describe the following grades of oils;
a) Normal grade
b) Winter grade
c) Multi-grade
3.1.2. List and describe oil additive
a) Anti-rust inhibitor.
b) Anti-corrosion inhibitor
c) Anti-foam agents
d) Detergents agents
e) Oiliness substance
f) Oxygen inhibitor
3.1.3. Differentiate between gearbox and final drive oils.
4.1.1. List the safety precautions that are to be observed before changing engine oil.
4.1.2. Perform the procedure of changing engine oil at recommended intervals.
5.1.1. Possible areas on the engine where oil is likely to leak are as follows;
a) Front seal
b) Rear main seal
c) Sump gasket
d) Tappet / rocker cover
e) Timing cover
5.1.2. Give the effects of low oil pressure and high oil pressure on the operation efficiency
of the motor vehicles.

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Assessment Tasks: 1. Written and/or oral assessment on the skills and knowledge required to maintain the
lubrication system components as outlined in the assessment criteria and content above.
2. Practical assessment on proper use of tools and equipment and maintaining the
lubrication system based on the performance criteria of the level 2 standard for a
Car Maintenance Assistant on the unit title Lubrication System Maintenance.
Conditions/Context 1. Written and/or oral assessment can be conducted in a classroom environment. Oral
of assessment assessment can also conducted by the assessor during the performance of the practical
assessment by the trainees.
2. The practical assessment will be conducted in the workshop or simulated work
environment in the training resources requirements:-
• Standard tool box
• Lifting equipment and Hoist equipment
• Powered hand tools
• Workbench
• Mutton cloth
• Detergents
5. Cooling System Maintenance

List of Learning LO1: Identify methods of Cooling engines

Outcomes: LO2: Check cooling system leaks
LO3: Practice proper Cooling system maintenance
LO4: Adhere to proper Cooling system maintenance
Assessment Criteria: 1.1 State the functions of a Cooling system
1.2 Describe the methods used to cool an engine
1.3 List the components of an air cooled engine
1.4 Give the functions of the following water cooled engine components
• radiator
• fan
• thermostat
• water pump
• water jackets
• pressure cap
• welch/core plugs
• radiator blinds and shutters.
2.1 Demonstrate the proper methods of checking for leaks
2.2 perform system checks using leak testing and pressure testing equipment.
2.3 Apply safety precautions when working on hot engine.
3.1 Demonstrate proper procedures of maintaining the cooling system.
3.2 Check, change coolant at correct intervals
3.3 State the correct method of checking coolant density
4.1 Describe the proper procedure for servicing a Cooling system.
4.2 Discuss the service requirements of a Cooling system.
4.3 State the causes of engine overheating

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Content: 1.1.1 Define Cooling system terms, overheating, undercooling; underheating and
overcooling.
1.1.2 State the function of the cooling system.
1.1.3 Describe the methods of heat transfer, conduction, convection and radiation.
1.1.4 Draw diagrams of the following:
- Wax and bellows thermostat
- Pressure cap
- Thermosyphon system
1.1.5 State components of the cooling system and give their functions.
1.1.6 Explain the operating principle of the engine cooling system.
1.1.7 Distinguish water and air cooled engines
1.1.8 Test thermostat for correct operation
1.1.9 Carry out engine cooling system maintenance
1.1.3 Explain the operation of a pressure cap on expansion and contraction
2.1.1 Explain the functions of leaks testing equipment
2.1.2 Describe how leaks affect the efficiency of a Cooling system
2.13 Perform leak down tests
2.1.4 Check wet liners for leakage
3.1.1 Explain how coolant is change and density check is performed.
3.1.2 State the functions of anti-rust and antifreeze additives.
3.1.3 Describe the methods used to flush the radiator.
4.1.1 Demonstrate the proper methods of opening the radiator pressure cap.
4.1.2 Apply the proper procedure of checking and adjusting fan belt tension.
4.1.3 Explain the effects of: incorrect coolant level in the radiator
: incorrect fan belt tension
Assessment Tasks: 1. Written and/or oral assessment on the skills and knowledge required to inspect and
repair the cooling system and components as outlined in the assessment criteria and
content above.
2. Practical assessment on system maintenance based on the performance criteria
of the level 2 standard for a Car Maintenance Assistant on the unit title Cooling
System Maintenance.
Conditions/Context 1. Written and/or oral assessment can be conducted in a classroom environment. Oral
of assessment can also conducted by the assessor during the performance of the practical
assessment assessment by the trainees.
2. The practical assessment will be conducted in the workshop or simulated work
environment in the training institution.
3. The context of assessment should include the facilities, tools, equipment and materials
listed below:
• Standard tool box
• Torque wrench
• Mutton cloth
• Specifications Manual

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6. Ignition System Maintenance

List of Learning LO1: Identify types of Ignition systems

Outcomes: LO2: Perform ignition system checks and maintenance
LO3: Adhere to proper Ignition system checks and maintenance procedures
Assessment Criteria: 1.1 State the types of Ignition systems
1.2 List ignition system components
1.3 Give functions of ignition system components
2.1 State the procedure for adjusting contact breaker gap
2.2 Illustrate the correct method of carrying out: static ignition timing
: dynamic ignition timing.
2.3 Describe the proper procedure for detecting a misfiring cylinder
3.1 Identify potential risks or hazards associated with ignition HT circuit
3.2 Illustrate the correct method of using dynamic timing lights
3.3 state the safety precautions to taken before working on Ignition HT circuits

Content: 1.1.1 Discuss the methods used to transform battery voltage to a high voltage
1.1.2 Identify the ignition LT and HT circuits
1.1.3 Draw the ignition circuit and label all parts
2.1.1 Explain the operation of an Ignition circuit.
2.1.2 Describe the effects of an incorrect ignition timing
2.1.3 State the precautions that should be taken during servicing the ignition system
3.1.1 list the measures to be taken before removing part of the ignition system
3.1.2 Demonstrate the proper methods of servicing ignition system

Assessment Tasks: 1. Written and/or oral assessment on the skills and knowledge required to inspect and
repair the compression ignition system and components as outlined in the assessment
criteria and content above.
2. Practical assessment on system maintenance based on the performance criteria
of the level 2 standard for a Car Maintenance Assistant on the unit title Ignition
System Maintenance.
Conditions/Context 1. Written and/or oral assessment can be conducted in a classroom environment. Oral
of assessment can also conducted by the assessor during the performance of the practical
assessment assessment by the trainees.
2. The practical assessment will be conducted in the workshop or simulated work
environment in the training institution.
3. The context of assessment should include the facilities, tools, equipment and materials
listed below:
• Standard tool box
• Injector tester
• Torque wrench
• Mutton cloth
• Specifications Manual

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7. Fuel System Maintenance

List of Learning LO1: Identify petrol fuel system components (carburetor and fuel injection systems).
Outcomes: LO2: Describe the functions of the components.
LO3: Check the fuel system for leaks.
LO4: Inspect mechanical lift pump operation.
LO5: Change fuel filters and unblock restricted fuel lines.
LO6: Service motor vehicle fuel system components.
LO7: Identify diesel fuel injection system components
LO8: Perform bleeding of the fuel system.
Assessment Criteria: 1.1 State the functions of a carburetor
1.2 Identify carburetor components and state their functions
1.3 Explain the scientific principles used by a carburetor to atomize the fuel
1.4 Discuss the effects of lean and rich mixtures
2.1 Identify petrol fuel injection system components and their functions
2.2 Give the advantages of a petrol injection system
3.1 Perform fuel filter changes
3.2 Illustrate the method used to check for system leaks and blockages
3.3 Demonstrate the proper procedures of adjusting idling speed
3.1 State the function of the lift pump
3.2 Inspect a fuel lift pump.
3.3 Identify diesel fuel injection system components and their functions
5.1. Define bleeding.
5.2 Discuss situations that give rise to fuel system needing bleeding.
Content: 1.1.1 Functions and operating principles of carburetor and petrol fuel injection components
2.1.1 Draw a line diagram showing the carburetor and fuel injection system.
2.1.2 Advantages of petrol fuel injection system
3.1.1 Discuss how to remedy leaks on a fuel system
3.1.2 Describe the construction of a lift pump.
3.1.3 Explain the operation of a mechanical lift pump.
4.1.1 Describe a procedure for checking for blocked or restricted fuel lines.
4.1.2 Procedure for removing petrol and diesel fuel filters
5.1.1 Describe the process of bleeding a fuel system.
5.1.2 Explain the precautions that must be taken into consideration during bleeding of a fuel
system.
Assessment Tasks: 1. Written and/or oral assessment on the skills and knowledge required to carry out visual
engine fuel system checks, identify major minor components, service the fuel system as
outlined in the assessment criteria and content above.
2. Practical assessment on carry out fuel system maintenance based on the performance
criteria of the level 2 standard for a Car Maintenance Assistant on the unit title Fuel
System Maintenance.

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Conditions/Context 1. Written and/or oral assessment can be conducted in a classroom environment. Oral
Of assessment assessment can also conducted by the assessor during the performance of the practical
assessment by the trainees.
2. The practical assessment will be conducted in the workshop or simulated work
environment in the training institution.
3. The context of assessment should include the facilities, tools, equipment and materials
listed in the training resources requirements:-
• Automotive tool box
• Powered hand tools
• Mutton cloth
• Detergents
• PPC
• Safety stand
8. Transmission System Maintenance

List of Learning LO1: Identify clutch system components.

Outcomes: LO2: Inspect clutch operating/actuating mechanisms.
LO3: Service a hydraulic clutch actuation mechanism.
LO4: Rectify clutch defects and faults.
LO5: Conduct clutch system overhaul.
LO6: Identify gearbox components.
LO7: Demonstrate the correct procedure of removing and replacing a motor vehicle
gearbox.
LO8: Conduct motor vehicle gearbox overhaul.
Assessment Criteria: 1.1. Identify clutch system components.
1.2. Inspect clutch operating/actuating mechanisms.
1.3. Service a hydraulic clutch actuation mechanism.
1.4. Rectify clutch defects and faults.
1.5. Conduct clutch system overhaul.
1.6. Identify gearbox components.
1.7. Demonstrate the correct procedure of removing and replacing a gearbox
1.8. Carry out motor vehicle gearbox overhaul.
Content: 1.1 Clutch System Components.
1.1.1 State functions of the clutch.
1.1.2 Describe clutch lining material properties.
1.1.3 Discuss clutch components functions.
• Pressure plate
• Driven plate
• Release lever
• Thrust bearing
• Release bearing
• Pilot bearing

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1.2. Clutch Operating/Actuating Mechanisms

1.2.1 Discuss methods of clutch actuation.
• Rods
• Cables
• Hydraulic fluid
1.2.2 Advantages and disadvantages of each method stated above.

1.3. Service a hydraulic clutch actuation mechanism.

1.3.1 State reason(s) why adjustment is necessary after fitting a new clutch assembly.

1.4 Rectify clutch defects and faults.

1.4.1 State the clutch faults.
• Judder
• Fierceness
• Slip
• Drag
• Spin
1.4.2 Discuss the causes of each clutch fault.
1.4.3 Describe how one can rectify each fault.

1.5 Conduct clutch system overhaul.

1.5.1 List tools and equipment needed during clutch overhaul.
1.5.2 State precautions to take when overhauling a clutch
1.5.3 Remove and replace a clutch.
1.5.4 Illustrate inspections that should be done during a clutch overhaul.

1.6 Identify gearbox components.

• Gear housing
• Shafts
• Gears
• Bearings
1.7 Demonstrate the correct procedure of removing and replacing a gearbox
1.7.1 List tools and equipment needed to remove and replace a gearbox.
1.7.2 State precautions associated with gearbox removal and replacement.
1.7.3 Remove, inspect and replace gearbox.

1.8 Carry out gearbox overhaul.

1.8.1 State the tool and equipment required for motor vehicle gearbox overhaul.
1.8.2 Discuss the precautions to be observed when conducting gearbox overhaul.
1.8.3 Describe the procedure to be followed when conducting a gearbox overhaul.
1.8.4 Illustrate checks and tests that should be done during a gearbox overhaul.

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Assessment Tasks: 1. Written and/or oral assessment on the skills and knowledge required to remove the
transmission components as outlined in the assessment criteria and content above.
2. Practical assessment on transmission system components removal and repairing based
on the performance criteria of the level 2 standard for a Car Maintenance Assistant
on the unit title Transmission System Maintenance
Conditions/Context 1. Written and/or oral assessment can be conducted in a classroom environment. Oral
of assessment can also conducted by the assessor during the performance of the practical
assessment assessment by the trainees.
2. The practical assessment will be conducted in the workshop or simulated work
environment in the training institution.
3. The context of assessment should include the facilities, tools, equipment and materials
listed below;
• Standard tool box
• Workbench
• Mutton cloth
• Specifications Manual
• Fender covers
9. Final Drive, Differential, Propeller Shafts and Drive Shafts Maintenance

List of Learning LO1: State the components that forms a Final drive
Outcomes: LO2: Explain the need for a differential on the driving axle
LO3: Describe the proper techniques and safety precautions to be followed when
conducting final drive adjustments
LO4: State the functions of a propeller shaft
LO5: Explain the application of drive shafts
LO6: Demonstrate the correct procedure for checking propeller shaft and drive shafts
for wear
Assessment Criteria: 1.1 State functions of a final drive
1.2 Describe the operating principles of a final drive
1.3 Explain the following final drive adjustments, end-float, backlash, pinion height,
bearing preload, tooth contact pattern
2.1 State the purpose of a differential unit
2.2 Describe the special properties of oil used in the differential
2.3 Identify the components that forms a differential
3.1 Describe the noise produced by the differential when:
• the vehicle is moving straight
• the vehicle is negotiating a curve
3.2 Demonstrate the proper procedure for checking final drive oil level
3.3 Illustrate the correct method of changing differential oil
4.1 Identify the parts of a Propeller shaft: universal joints, sliding joints, centre bearing.
4.2 List the types of universal joints
4.3 Give reasons why the alignment of yokes is important when installing the shaft
5.1 Describe the removal and installation of drive Shafts
5.2 Demonstrate the correct procedure for checking universal joints and constant velocity
joints for wear
5.3 Illustrate the method used for lubricating universal joints and constant velocity joints

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Content: 1.1.1 Functions of the final drive

1.1.2 Operating principles of the final drive
1.1.3 Types of final drives
1.1.4 Final drive adjustments
2.1.1 Functions of the differential unit
2.1.2 Name the components of the differential unit.
2.1.3 Operating principles of the differential unit.
3.1.1 Procedures for changing oil and checking oil level
4.1.1 Functions of driveline components.
4.1.2 Types of universal joints
4.1.2 Installation procedures
5.1.1 Demonstrate the correct procedure for checking universal joints and constant
velocity
joints for wear
5.1.2 Illustrate the method used for lubricating universal joints and constant velocity joints

Assessment Tasks: 1. Written and/or oral assessment on the skills and knowledge required to repair and service
the Final Drive, Differential, Propeller Shafts and Drive Shafts as outlined in the
assessment criteria and content above.
2. Practical assessment on brakes assessment, cleaning, inspection and maintenance based
on the performance criteria of the level 2 standard for a Car Maintenance Assistant on
the unit title Final Drive, Differential, Propeller Shafts and Drive Shafts Maintenance.

Conditions/Context 1. Written and/or oral assessment can be conducted in a classroom environment. Oral
Of assessment assessment can also be conducted by the assessor during the performance of the practical
assessment by the trainees.
2. The practical assessment will be conducted in the workshop or simulated work
environment in the training institution.
3. The context of assessment should include the facilities, tools, equipment and materials
listed in the training resources requirements: -
• Standard tool box
• Workbench
• Mutton cloth
• Detergents
• PPC
10. Braking System Maintenance

List of Learning L01: Identity hydraulic braking system components.

Outcomes: L02: Describe the operating principle of the braking system.
L03: Inspect the handbrake system.
L04: Perform brake shoe adjustment.
L05: Describe the properties of hydraulic brake fluid.
L06: Carry out the bleeding procedure of a hydraulic braking system.

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L07: State functions of air brake components.

L08: Draw the line diagram of a basic air brake circuit.
Assessment Criteria: 1.1 List the components of the hydraulic system.
1.2 State the function(s) of the components.
2.1 Draw a basic hydraulic braking system layout.
2.2 Describe the operating of hydraulic braking system.
3.1 List the components of the handbrake system.
3.2 Describe the procedure of adjusting the handbrake system.
4.1 Describe the procedure for adjusting brake shoes
5.1 State the properties of the brake fluid.
5.2 List the advantages and disadvantages of the use of natural rubber kits compared to
synthetic rubber kits.
6.1 Explain the need for absolute cleanliness of all components and fluid when
overhauling a hydraulic system.
6.2 Bleeding the hydraulic brake system.
7.1 Identify the components of an air-brake system.
7.2 Give functions of the air-brake system.
8.1 Draw clearly a line diagram of simple air-brake system and label the components.
Content: 1.1.1 Name the components of motor vehicle hydraulic system.
1.1.2 Give the functions of the following braking system components.
a) Master cylinder
b) Wheel cylinder
c) Brake pipes
d) Drums
2.1.1 Neatly draw a hydraulic braking system layout and label parts.
2.1.2 Describe the operating principle of the hydraulic braking system.
3.1.1 Name the components of the handbrake system.
3.1.2 Explain the reason(s) for handbrake adjustment.
3.1.3 Describe the procedure of adjusting the handbrake system.
4.1.1 Brake adjustment procedure
5.1.1 Describe the following properties of hydraulic fluid;
a) Low freezing point
b) High boiling point
c) Low viscosity
d) Oiliness
e) Compatible
5.1.2 State the advantages and disadvantages of using natural rubber kits compared to
synthetic rubber kits.
6.1.1 Justify the need for absolute cleanliness of a components and fluid when
overhauling the hydraulic brake system.
6.1.2 Describe in logical form the procedure of bleeding the hydraulic brake system.
7.1.1 Name components of the air-brake system which includes;
a) Compressor

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b) Foot valve
c) Reservoir
d) Unloader valve
e) Brake chambers
f) Quick release valve
7.1.2 State the function(s) of the air-brake system components.
8.1.1 Basic air brake system layout.
Assessment Tasks: 1. Written and/or oral assessment on the skills and knowledge required to repair and service
the braking system as outlined in the assessment criteria and content above.
2. Practical assessment on brakes assessment, cleaning, inspection and maintenance based
on the performance criteria of the level 2 standard for a Car Maintenance Assistant on
the unit title Braking System Maintenance.

Conditions/Context 1. Written and/or oral assessment can be conducted in a classroom environment. Oral
Of assessment assessment can also be conducted by the assessor during the performance of the practical
assessment by the trainees.
2. The practical assessment will be conducted in the workshop or simulated work
environment in the training institution.
3. The context of assessment should include the facilities, tools, equipment and materials
listed in the training resources requirements: -
• Standard tool box
• Lifting equipment
• Workbench
• Mutton cloth
• Detergents
• PPC
• Safety stands
• Wheel chokes
11. Suspension and Steering System Maintenance

List of Learning LO1: Identify steering and suspension system components

Outcomes: LO2: Describe the functions of the steering and suspension system components
LO3: Explain suspension and steering system maintenance
Assessment Criteria: 1.1 Name the components that make up a steering system of a motor vehicle.
1.2 List the main components that forms the suspension system of a motor vehicle.
1.3 Draw a steering system layout and label all the parts
2.1 Give the functions of each steering system components: steering wheel, steering
column, steering box, rocker shaft, drop arm, drag link, steering arm, track rod, tie rod
ends, knuckles, stub axles, etc.
2.2 Illustrate functions of suspension system components such as springs, dampers and
stabilizer links, control arms/wishbones
2.3 Demonstrate the need for suspension system on a vehicle
3.1 List tyre wear patterns that reflect faulty steering and suspension systems

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3.2 Describe how steering and suspension system components are checked for wear
3.3 Explain how wheel alignment affects the steering system.
3.4 State steering system and suspension system components that must be checked for
wear before carrying out wheel alignment

Content: 1.1.1 Explain the method used to true rolling motion on curves.
1.1.2 Illustrate with the aid of diagrams the difference between swinging beam and fixed
beam and king pins
1.1.3 Distinguish between independent suspension and rigid beam suspension system
1.1.4 Name the components that serves as suspension units of a vehicle
2.1.1 Explain the functions of a steering system and suspension system
2.1.2 Describe how the steering system and the suspension system are interrelated in
stabilizing a vehicle
2.1.3 Define terms associated with steering system: camber, castor, KPI/SAI, toe etc.
2.1.4 State the effects of overseer and understeer
3.1.1 Name steering system and suspension system components that are most affected by
wear
3.1.2 Explain the meanings of the following steering system faults:
a. end-float
b. backlash.
3.1.3 State the faults caused by lack of lubrication.
Assessment Tasks: 1. Written and/or oral assessment on the skills and knowledge required to carry out
Suspension and Steering system repairs as outlined in the assessment criteria and
content above.
2. Practical assessment on proper use of tools, to maintain suspension and steering
systems following correct procedures based on the performance criteria of the level 2
standard for a Car Maintenance Assistant on the unit title Suspension and Steering
Systems Maintenance.
Conditions/Context 22. Written and/or oral assessment can be conducted in a classroom environment. Oral
of assessment can also be conducted by the assessor during the performance of the
assessment practical assessment by the trainees.
23. The practical assessment will be conducted in the workshop or simulated work
environment in the training institution.
24. The context of assessment should include the facilities, tools, equipment and materials
listed in the training resources requirements: -
• Standard tool box
• Wheel Alignment Machine
• Mutton cloth
• Detergents
• PPC
• Wheel chokes

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12. Wheels and Tyres Maintenance

List of Learning LO1: State the functions of wheels

Outcomes: LO2: Describe the functions of tyres
LO3: Give the advantages of tubeless tyres
Assessment Criteria: 1.1 Explain the functions of the parts of a wheel
1.3 Identify the types of wheels
2.1 State the types of tyre construction
2.2 Describe the functions of the parts of a tyre.
2.3 Identify the meanings of tyre markings
3.1 State the functions of a tyre tube.
3.2 Give materials for tyre tubes

Content: 1.1.1 Illustrate the method used to balance the wheels

1.1.2 List the types of wheel rims
2.1.1 Explain the functions of tyres
2.1.2 State the effects of tyre treads on touring
2.1.3 Demonstrate the proper methods of checking tyres for wear
2.1.4 List tyre faults and their causes
2.1.4 Perform wheel alignment
3.1.1 Describe a tubeless tyre
3.1.2 List the advantages of tubeless tyres
Assessment Tasks: 1. Written and/or oral assessment on the skills and knowledge required to repair wheels and
tyres as outlined in the assessment criteria and content above.
2. Practical assessment on Engine fitting based on the performance criteria of the level 2
standard for a Car Maintenance Assistant on the unit title Wheels and Tyres
Maintenance.
Conditions/Context 1. Written and/or oral assessment can be conducted in a classroom environment. Oral
of assessment assessment can also be conducted by the assessor during the performance of the practical
assessment by the trainees.
2. The practical assessment will be conducted in the workshop or simulated work
environment in the training institution.
3.The context of assessment should include the facilities, tools, equipment and materials
listed below:-
• Standard tool box
• Wheel Alignment Machine
• Wheel Balancing Machine
• Mutton cloth
• Detergents
• PPC
• Wheel chokes

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12. Car Frame Service

List of Learning LO1: Describe the functions of a motor vehicle frame

Outcomes: LO2: Identify types of motor vehicle frames
LO3: Explain methods used to check the frame for straightness
Assessment Criteria: 1.1 State the functions of a motor vehicle frame
1.2 List stresses that must be resisted by a motor vehicle frame
1.3 Identify the main parts of a frame
1.4 Name at least four frame designs.
2.1 List the types frames used on motor vehicles.
2.2 state the types of frame sections
2.3 Explain why the frames need to be reinforced
2.4 give the advantages of the integral frame construction
3.1 State the effects of a misaligned frame on vehicle handling
3.2 Describe how the frame is checked for alignment
3.3 Explain frame check under the following subheadings:
-alignment check
-wheel base check
-plumb line check

Content: 1.1.1 Explain the need for a motor vehicle frame

1.1.2 State the requirements of a motor vehicle frame.
1.1.2 Name the forces that must be resisted by a motor vehicle utility frame
1.1.3 State the methods of carrying out frame alignment checks:
a. alignment checks
b. wheel base check
c. plumb line check
1.1.4 Identify faults that are caused by frame misalignment
2.1.1 Identify engine, gearbox and suspension mounting points.
2.1.2 Locate jacking points
2.1.3 State the functions of crush/crumble zones
3.1.1 Describe the construction details of a motor vehicle frame
3.1.2 State the functions of jacking points and attachment points on a frame
3.1.3 Name major vehicle components that are attached to the frame
3.1.4 Perform frame alignment checks
3.1.5 list the effects a misaligned frame have on suspension and steering

Assessment Tasks: 1. Written and/or oral assessment on the skills and knowledge required to carry out
repairs as outlined in the assessment criteria and content above.
2. Practical assessment on proper use of tools, to maintain Car frames following correct
procedures based on the performance criteria of the level 2 standard for a Car
Maintenance Assistant on the unit title Car Frame Service.

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Conditions/Context 1. Written and/or oral assessment can be conducted in a classroom environment. Oral
of assessment can also be conducted by the assessor during the performance of the practical
assessment assessment by the trainees.
2. The practical assessment will be conducted in the workplace or simulated work
environment in the training institution.
3. The Context of assessment should include the facilities, tools, equipment and materials
listed below:-
• Standard tool box
• Lifting equipment
• Mutton cloth
• Detergents
• Specifications Manual

14. Basic Auto-Electrics

List of Learning LO1:Explain the automotive workshop safety requirements
Outcomes: LO2: Identify components of a basic electrical system.
LO3: Demonstrate skills in care and maintenance of lead acid batteries.
LO4: Identify charging system components
LO5: Explain the functions of the starting system
LO6: Identify components of a basic lighting circuit
LO7: State the composition of solder and flux
LO8: Explain the need for cleanliness of surfaces to be bonded
LO9: Describe the proper techniques and safety precautions to be observed to ensure
strong and reliable joints
Assessment Criteria: 1.1 Describe automotive workshop hazards
1.2 Discuss the potential dangers caused by failing to follow proper automotive workshop
safety precautions
1.3 Adhere to automotive workshop safety requirements.
2.1 Identify components that forms an electrical circuit.
2.2 State the procedure for carrying out fault diagnosis.
3.1 State the functions of a car battery
3.2 Describe the precautions to be followed when removing and connecting a battery
3.3 Identify safe practices which reduces damages and injuries when charging batteries
4.1 Discuss the functions of a charging system
4.2 List the main components that forms the charging system
4.3 Perform charging system checks and maintenance
5.2 Describe the principle of the starting motor
5.3 Perform starting system maintenance
6.1 State the functions of the lighting system
6.2 List the circuits that forms a lighting system
6.3 Discuss the methods used to adjust the headlamps alignment
7.1 Explain the functions of a soldering iron.

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7.2 Illustrate the method used to prepare the work pieces to be bonded
7.3 Give the advantages of this method of joining electrical units
8.1 Discuss the proper techniques and requirements for strong joints
8.2 State the heat ranges of various soldering irons
8.3 Explain how heat ranges are suitable for various applications
3.1 Describe the proper methods of caring for soldering irons
3.2 Demonstrate the need for proper earthing of electric soldering irons and the electric s
shock hazards associated with improper care and use of irons
3.3 Practice safety precautions when using soldering irons

Content: 1.1.1 List the automotive workshop safety precautions to be followed when removing parts
of an electrical system.
1.1.2 Apply safety skills in using measuring and testing equipment.
1.1.3 Perform electrical system checks and maintenance
2.1.1 Describe the functions of the following parts of a circuit
• battery
• feed wires
• switch
• load
• earth/return wire
2.1.2 Define the circuit fault:
• Short circuit
• open circuit
2.1.3 Identify the electrical symbols for electrical components.
2.1.4 Discuss the electrical units of various electrical properties: voltage, resistance, current
and power.
2.1.5 Apply safety skills in testing different electrical circuit properties
3.1.1 Explain the cell action when the battery is charging and discharging.
3.1.2 State the proper procedure for checking electrolyte density.
3.1.3 Describe the composition of the electrolyte.
3.1.4 Apply proper procedures for servicing the battery.
4.1.1 Illustrate the need for an efficient charging system.
4.1.2 State the functions of the charging system components.
4.1.3 Explain the checks that must be conducted on the charging system
4.1.4 Perform charging system checks and maintenance
5.1.1 Identify the components that forms a starting system
5.1.2 Apply safety skills in testing the performance of a starting motor.
5.1.3 Perform starting system checks and maintenance
6.1.1 Explain the functions of:
• headlamps
• park lights
• stop lights

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 NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

• instrument panel lights

• indicator lights
• fog lights
• sport lights
• reverse lights
6.1.2 State the proper procedure for checking lighting system faults
6.1.3 Demonstrate proper servicing and maintenance procedures
6.1.4 Adjust headlamps
7.1.1 Functions and of a soldering iron.
7.1.2 Methods used to prepare the work pieces to be bonded
7.1.3 Advantages of the soldering method of joining electrical units
8.1.1 Proper techniques and requirements for strong joints
8.1.2 State the heat ranges of various soldering irons
8.1.3 Explain how heat ranges are suitable for various applications
9.1.1 Describe the proper methods of caring for soldering irons
9.1.2 Demonstrate the need for proper earthing of electric soldering irons and the electric s
shock hazards associated with improper care and use of irons
9.1.3 Practice safety precautions when using soldering irons

Assessment Tasks: 1. Written and/or oral assessment on the skills and knowledge required to carry out basic
electrical checks on the vehicle as outlined in the assessment criteria and content above.
2. Practical assessment on vehicle electrical checks based on the performance criteria of
the level 2 standard for a Car Maintenance Assistant on the unit title Basic Auto-
Electrics.
1. Written and/or oral assessment can be conducted in a classroom environment. Oral
assessment can also conducted by the assessor during the performance of the practical
assessment by the trainees.
2. The practical assessment will be conducted in the workshop or simulated work
environment in the training institution.
3.The context of assessment should include the facilities, tools, equipment and materials
listed below:
• Standard tool box
• Battery tester
• Workbench
• Mutton cloth
• Detergents
• Specifications Manual

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 NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

TOPIC WEIGHTING
%
1. Safe Working Environment Maintenance 50

2. Workshop Tools and Equipment 50

3. Engine Maintenance 150

4. Lubrication System Maintenance 30

5. Cooling System Maintenance

30
6. Ignition System Maintenance 30

7. Fuel System Maintenance 40

8. Transmission System Maintenance 100

9. Final Drive, Differential, Propeller Shafts and

Drive Shafts Maintenance
10. Braking System Maintenance 50

11. Steering and Suspension System Maintenance 50

12. Wheels and Tyres Maintenance 30

13. Car Frame Service 30

14. Basic Auto Electrics 80

TOTAL 800

Approach to Teaching and Learning:

29. Observation of adult learning principles.
30. Both institution-based and work-based learning to facilitate the integration of theory and
practice.
31. Face-to-face education and learning.
32. Problem-based learning.

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

33. Online/distance education and learning.

34. Blended/hybrid education and learning.
35. Use of social media.
Approach to Assessment:
25. Weighting of practical and theory assessment: 70% theory and 30% practical.
26. Weighting of institution-based and work-based assessment: 50% institution-based
assessment and 50%.
27. Oral assessment to be conducted by a panel of two or more assessors.
28. RPL assessment.
29. Portfolio of evidence.
30. Assessment of work conducted by both individual learners and teams of learners.
Resources:
17. Qualifications and experience of Trainers, Assessors and Moderators
All trainers, assessors and moderators should have undergone ZNQF accredited training
programmes and should have qualifications and experience recognised by the Zimbabwe
National Qualifications Authority (ZNQA).
18. Facilities, Tools, Equipment and Materials
• Theory Classroom (fitted with writing surface- e.g. Whiteboard).
• Protected inspection pit, vehicle ramp or hoist
• Workbenches
• Bench vice
• Fire-fighting appliances and Emergency Exit
• Hand-wash basin
• Lifting equipment Mechanical, Electrical or Pneumatic
• Pedestal drill
• Compressed Air Supply and Appliances
• Electricity supply (safely connected)
• Diesel component testing and adjusting facility (i.e. Diesel laboratory)
• Storage facilities (for Equipment, Spares and Consumables, etc
• Precision Machining Equipment
• Writing surface for trainer
• Motor Mechanic tool box
• Detergents
• PPC
• Safety stands
• Wheel chokes
• Vehicle Specifications Manual
• Precision measuring tools
• Aligning jigs
• Torque wrench
• Filler gauge
• D.T.I
• Oil Pressure Gauge
• Engine Temperature Gauge
• Dynamometer
• Vacuum Gauge
• Scientific Calculator
19. Learning Resources

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 NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

Relevant training manual (learners‟ guide) and facilitators‟ guide

20. Reference Materials (recommended textbooks, recommended readings)

7.0 LIST OF SUGGESTED BOOKS FOR REFERENCE

Coker, A.J (2000) Automotive Electrical Systems 4th Edition Elsevier, New York.

Denton, T (2013) Automobile Electrical and Electronics 4th Butterworths London

Edition

Erjavec, J & (2014) Automotive Technology: A Systems Approach Delmar Publishers, New York.
Thompson R

Georing, C.E (2004) Engine and Car Power Butterworths London

Gilles, T (2011) Automotive Service: Inspection, Delmar Publishers, New York.

Maintenance, Repair

Hillier V & Coombs (2014) Fundamentals of Motor Vehicle Technology Nelson Thornes, London
P 5th Edition

Hillier V & Pittuck P (1980) Fundamentals of Heavy Vehicles Technology Hutchinson London

Hancock W & (2011) Auto Math Handbook HP1554

Lawlor J Penguin Group, New York.

Jain S.C & (1985) Farm Car Maintenance and Repair

Rai C.R McGraw Hill, New Delhi

Marton A.L (1985) Science & Calculations for Motor Vehicle Delmar Publishers, New York.
technicians

Nunney M.J (1993) Light & Heavy Vehicle Technology (2nd Hutchison, London
Edition)

Pekison J,& (2005) Math for the Automotive Trade 3rd Edition Delmar Publishers, New York.
deKryger W

Stone, R (1988) Introduction to the internal Combustion Macmillan, London

Engine

Stormo, T (2009) Engine and Car Power Delmar Publishers, New York.

South, D.W & (2004) Delmar’s Automotive Dictionary Delmar Publishers, New York.
Dwiggins, B.H

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

MINISTRY OF HIGHER AND TERTIARY EDUCATION,

INNOVATION, SCIENCE AND TECHNOLOGY DEVELOPMENT

HIGHER EDUCATION EXAMINATIONS COUNCIL

(HEXCO)

OCCUPATIONAL STANDARD

FOR

CAR MAINTENANCE

SECTOR: AUTOMOTIVE

QUALIFICATION FOR A CAR MAINTENANCE ASSISTANT

QUALIFICATION CODE: TBA

LEVEL: NATIONAL FOUNDATION

CERTIFICATE

DATE OF PROMULGATION: TBA

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

Definition of Terms
Assessment A process of collecting evidence of a learner’s work to measure and
make judgements about the achievement or non-achievement of the
specified National Qualifications Framework standards or
qualifications.

Certification Awarding of approved documentary evidence of a qualification.

Competences Critical relevant knowledge, skills and attitudes a learner requires in

required in order to achieve specified outcomes before assessment.
readiness for
assessment

Credit The value assigned to a unit completed or a value assigned to a unit

standard which reflects the relative time and effort required to
complete the outcomes.

Date of Date when standard and qualification have been approved, registered
promulgation and gazetted.

Duration The minimum notional hours required by a learner to attain all the
competences in a unit standard.

Element The smallest component of a unit with a meaningful outcome.

Generic skills Universal skills which apply to more than one occupation.

Level descriptor A specific indicator of competence level on the ZQF.

Occupation A group of related economically beneficial work activities performed

by a person.

Performance A statement of competence or achievement against which the

criteria attainment of outcomes is measured.

Qualification Formal award of recognition of the achievement of the required

competency and/or capability level of the Zimbabwe Qualifications
Framework as may be determined by the relevant bodies registered
for such purpose by the Authority.

Range statement The context or conditions within which a competence is performed

and assessed that include tools, equipment, materials and duration.

Review Date Date of revision of qualification standard as and when necessary but
not later than three years from date of issue.

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

Sector A section of the economy in which operators produce or provide

similar products or services.

Standard Registered statement of desired education and training outcomes and

their assessment criteria.

Unit The smallest combination of work activities capable of being a

fulltime economically beneficial occupation.

Unit Standard Registered statement(s) of desired education and training outcomes,

their associated assessment criteria together with administrative
information as specified.

ZQF National qualifications framework approved by the minister for

registration of national standards and qualifications.

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 NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

SUMMARY OF STANDARD

UNIT TITLE ELEMENTS CREDITS

CAR 1. Safe Working Environment Maintenance

MAINTENANCE
1.1 Practice and Adhere to Safety, Health and Environment 5
1.2 Use Appropriate PPE/PPC
1.3 Carry out risk assessment
1.4 Participate in safety Awareness Meetings
2. Workshop Tools and Equipment
2.1 Demonstrate proper use and care of hand tools 5
2.2 Identify and demonstrate correct use of workshop tools and equipment
2.3 Identify precautions that should be observed when using, storing and
maintaining measuring and testing equipment
2.4 Demonstrate the proper methods of using power tools
2.5 Adhere to proper methods of handling tools and workshop equipment

3. Engine Maintenance 15
3.1 Identify engine components
3.2 Explain engine operation procedures
3.3 Perform engine overhauls
3.4 Demonstrate valve timing procedures
3.5 Describe the different engine layouts
4. Lubrication System Maintenance
4.1 Practice proper lubrication system maintenance 3
4.2 Adhere to proper system maintenance procedure
4.3 Identify different grades of engine oil
4.4 Check engine oil for correct circulating pressure
4.5 Perform engine oil and filter change
4.6 Check engine oil leaks
5. Cooling System Maintenance
5.1 Practice proper cooling system maintenance 3
5.2 Adhere to proper cooling system maintenance procedure
5.3 Identify methods of cooling engines
5.4 Check cooling system for leaks

6. Ignition System Maintenance

6.1 Perform ignition system checks and maintenance 3
6.2 Adhere to proper system checks and maintenance procedures
6.3 Identify types of ignition systems
6.4 Adhere to safety precautions when working on ignition circuits

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

7. Fuel System Maintenance

7.1 Identify fuel system components (carburettor and fuel injection systems). 4
7.2 Describe the functions of the components.
7.3 Check fuel system for leaks.
7.4 Change fuel filters and unblock restricted fuel lines.
7.5 Inspect mechanical lift pump for operation.
7.6 Service motor vehicle fuel system components.
7.1 Identify diesel fuel injection system components
7.2 Perform bleeding of the fuel system
7.6 Adhere to proper system checks and maintenance procedures

8. Transmission System Maintenance 10

8.1 Identify the clutch system components
8.2 Inspect clutch operating or actuating mechanism
8.3 Service hydraulic clutch actuating mechanism
8.4 Rectify clutch defects or faults
8.5 Carry out clutch system overhaul
8.6 Identify gearbox components
8.7 Demonstrate correct motor vehicle gearbox removal and
replacement procedure
8.8 Carry out Car gearbox overhaul
9. Final Drive, Differential, Propeller Shafts and Drive Shafts Maintenance 5
9.1 Identify the final drive components
9.2 State the functions of a differential
9.3 Demonstrate the procedure for changing the differential oil and checking oil
level
9.4 Illustrate the procedure for checking the correct operation of the final drive
9.5 Identify the application of propeller shafts and drive shafts
9.6 List the propeller shaft components
9.7 State the functions of the universal and constant velocity joints
9.8 Describe the correct procedure for removing a propeller shaft
9.10 Illustrate the operational difference between a propeller shaft and a drive
shaft
10. Braking System Maintenance
10.1 Identify the motor vehicle braking system components. 10
10.2 Describe the operating principle of the motor vehicle hydraulic
braking system.
10.3 Inspect the vehicle's handbrake system.
10.4 Perform brake shoe adjustment and repairs.
10.5 Describe the properties of hydraulic brake fluid.
10.6 Conduct the bleeding procedure of the motor vehicle hydraulic
braking system.
10.7 Describe the basic air brake circuit using a line diagram.
11. Steering and Suspension System Maintenance
11.1 Identify steering and suspension system components 5
11.2 Describe functions of the steering and suspension
systems
11.3 Identify steering and suspension faults

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

12. Wheels and Tyres Maintenance

12.1 Describe motor vehicle tyre markings 3
12.2 Identify types of tyre construction
12.3 State tyre faults and their causes
12.4 List advantages of tubeless tyres
12.5 Demonstrate proper methods of checking tyres for wear
12.6 Apply safety measures when inflating tyres

13. Car Frame Service

13.1 State the functions of a car frame 3
13.2 Identify car-jacking points
13.3 Demonstrate proper procedures for jacking a car
13.4 Describe the functions crumble zones of car
13.5 Explain the method used to check a frame for straightness
13.6 Explain the reasons for reinforcing the frame
13.7 List the types of car frame sections

14. Basic Auto Electrics

14.1 Demonstrate correct safety requirements and first aid procedure 8
relating to electrical shock
14.2 Identify the motor vehicle basic electrical system components
14.3 Demonstrate skills in care and maintenance of lead acid battery
14.4 Use measuring and testing equipment to check and diagnose
electrical circuits faults
14.5 Describe proper procedure for faulty components replacement
TOTAL 80

UNIT

Unit Title: CAR MAINTENANCE

Level of Unit: NATIONAL FOUNDATION CERTIFICATE

Credits: 80

Occupation: CAR MAINTENANCE ASSISTANT

Date of Promulgation: TBA

Review Date: TBA

AIM

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

This unit will enable an individual to successfully carry out maintenance of

components/equipment as per schedule and to specified standards

ELEMENT AND PERFORMANCE CRITERIA

Element 1.1 Practice and Adhere to Safety, Health and Environment

Performance Criteria:

1.1.1 Employees introduced to safety, Health and Environment policies

1.1.2 Safety colour codes are established
1.1.3 Gangways labelled
1.1.4 Storage areas identified
1.1.5 Fire-fighting procedures demonstrated
1.1.6 Tools and lifting equipment usage demonstrated
1.1.7 Handling of Hazardous substances manual produced

Element 1.2 Use Appropriate PPE and PPC

Performance Criteria:
1.2.1 Personnel Protective equipment is used
1.2.2 Personnel Protective clothing worn
1.2.3 Use of PPE and PPC monitored
1.2.4 Organisational Standards and Regulations are enforced

Element 1.3 Carry out Risk Assessment

Performance Criteria:
1.3.1 Housekeeping issues addressed.
1.3.2 Correct work procedure followed.
1.3.3 Equipment register is enforced
1.3.4 Equipment storage procedure is observed/followed
1.3.5 Lock out mechanism is in stored
1.3.6 Hazardous areas barricaded
1.3.7 Hot jobs, working on heights permitted
1.3.8 Incidents reports generated

Element 1.4 Participate in Safety Awareness Meetings

Performance Criteria:

1.4.1 Safety meetings attended to

1.4.2 Meeting pointer are implemented
1.4.3 Safety signs and symbols identified

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

1.4.4 Fire-fighting drills carried out

1.4.5 Fire-fighting equipment identified.
1.4.6 Smoking zones designated
1.4 7 Incidents reports generated

Element 2.1 Workshop Tools and Equipment

Performance Criteria:

2.1.1 Proper use and care of hand tools carried out.

2.1.2 Workshop tools and equipment classified and used appropriately.
2.1.3 Required precautions identified.
2.1.4 Correct methods of using power tools demonstrated.
2.1.5 Proper care, maintenance and storage of hand tools properly practiced.
2.1.6 Proper workshop equipment handling methods adhered to.

Element 3.1 Engine Maintenance

Performance Criteria:

3.1.1 Engine components identified

3.1.2 Engine operation procedures explained
3.1.3 Overhauls performed
3.1.4 Correct procedures demonstrated
3.1.5 Different engine layouts described

Element 4.1 Lubrication System Maintenance

Performance Criteria:

4.1.1 Proper system maintenance practiced

4.1.2 Proper system maintenance procedure adhered to
4.1.3 Oil grades identified
4.1.4 Engine oil pressure checked
4.1.5 Engine oil and filter changed
4.1.6 Oil leaks checked

Element 5.1 Cooling System Maintenance

Performance Criteria:

5.1.1 Proper system maintenance practiced

5.1.2 Proper procedure adhered to
5.1.3 Cooling methods identified
5.1.4 Cooling system checked for leaks

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

Element 6.1 Ignition System Maintenance

Performance Criteria:

6.1.1 System checks performed

6.1.2 Maintenance procedures adhered to
6.1.3 Types of ignition system identified
6.1.4 Safety precautions adhered to

Element 7.1 Fuel System Maintenance

Performance Criteria:

7.1.1 Petrol fuel system components identified.

7.1.2 Fuel system components functions described.
7.1.3 Procedure for checking fuel system leaks carried out.
7.1.4 Fuel filters changed and fuel lines restrictions cleared.
7.1.5 Inspection for operating efficiency of the mechanical lift pump conducted.
7.1.6 Fuel system components servicing procedure properly executed.
7.1.7 Diesel fuel system components identified
7.1.8 System leaks checking procedure conducted
7.1.9 Inspection carried out
7.1.10 System bleeding performed
7.1.11 Proper checks and maintenance procedures adhered to

Element 8.1 Transmission System Maintenance

Performance Criteria:

8.1.1 Clutch components identified

8.1.2 Operating or actuating mechanism described and inspected
8.1.3 Hydraulic actuating mechanism serviced
8.1.4 Faults rectified
8.1.5 Clutch system overhaul carried out
8.1.6 Gearbox components identified
8.1.7 Correct gearbox removal and replacement procedure demonstrated
8.1.8 Gearbox overhaul carried out

Element 9.1 Final Drive, Differential, Propeller Shafts and Drive Shafts
Maintenance

9.1.1 Final drive components identified

9.1.2 Functions of a differential unit

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

9.1.3 Procedure for topping up differential unit and checking oil level described
9.1.4 Method for checking the final drive for correct operation illustrated
9.1.5 Application of propeller shafts and drive shafts identified
9.1.6 Parts of a propeller shaft listed
9.1.7 Functions and universal and constant velocity joints stated
9.1.8 The correct procedure for a propeller shaft removal described
9.1.9 The operational difference between the shafts illustrated

Element 10.1 Braking System Maintenance

Performance Criteria:

9.1.1 Motor vehicle braking system components identified.

9.1.2 Principle of operation of the vehicle's hydraulic braking system described.
9.1.3 Motor vehicle hand brake system inspected.
9.1.4 Brake shoe adjustment procedure conducted.
9.1.5 Hydraulic brake fluid properties described.
9.1.6 Bleeding the motor vehicle braking system performed.
.19.7 Basic air brake circuit described

Element Suspension and Steering System Maintenance

11.1

Performance Criteria:

11.1.1 Suspension and steering system components identified

11.1.2 System functions described
11.1.3 System faults identified rectified

Element Wheels and Tyre Maintenance

12.1

Performance Criteria:

12.1.1 Tyre markings described

12.1.2 General types of construction details described
12.1.3 Tyre faults and their causes stated
12.1.4 Advantages of tubeless tyres listed
12.1.5 Proper methods of checking tyres for wear demonstrated
12.1.5 Safety measures when inflating tyres applied

Element Car Frame Service

13.1

Performance Criteria:

13.1.1 Functions of a car frame stated

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

13.1.2 Car-jacking points identified

13.1.3 Proper procedures for jacking a car demonstrated
13.1.4 Functions of crumble zones of a car described
13.1.5 Methods of checking a frame for straightness explained
13.1.6 Reasons for reinforcing the frame explained
13.1.7 Types of car frame sections listed

Element Basic Auto-Electrics

14.1

Performance Criteria:

14.1.1 Correct safety requirements and first aid procedure demonstrated

14.1.2 Basic electrical system components identified
14.1.3 Skills in care and lead acid battery maintenance demonstrated
14.1.4 Electrical circuits faults diagnosed
14.1.5 Proper procedure for faulty components replacement described

Competencies Required in Readiness for Assessment:

Ability to interpret Statutes, Regulations

Knowledge of Safety, Health and Environmental regulations
Knowledge of Fire-fighting equipment, fire drills and fire prevention
Knowledge of report writing Skills
Fault detection skills
Driving skills (Safety precaution adherence)
Accuracy
Tool handling and care
Service type knowledge
Component knowledge
Fault diagnosis skills
Basic electronics

GENERIC SKILLS / Common Essential Skills:

Analytical
Computer literacy
Leadership
Communication
Drawing
Reading and writing
Estimations
Measurements

RANGE STATEMENT:
Given the appropriate tools and equipment, an individual should be able to determine faults on all
components, dismantle, repair, reassemble and refit components in a specified time according to
set standards and procedures.

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

Tools and equipment

Artisan’s toolbox
Lux meter
Noise level meter
Hydrometer
pH meters
Gas analyser
Thermometer
Camera
Tape measure
Breathlyser
Press fitting machine
Special Service Tools (SST)
Bench vice
Materials
Balancing Special Service Tools
Alignment Special Service Tools

Stationery
PPE
Engine cleaner
Hand cleaner
Grease
Lubricants
Mutton cloth
Soldiering gun
Insulation tape
Silicon sealer
Degreaser
Lock tight
Exhaust sealer
Insulation tape

Duration: 800 Hours

ASSESSMENT AND CERTIFICATION:

In order to gain credits for this unit standard, a candidate must be assessed and demonstrate
competency in all the elements and performance criteria of this unit standard.

Assessment will be conducted by accredited assessors. The results of the assessment will be
submitted to ZIMEQA. A candidate can apply to ZIMEQA for documentary evidence of their
achievements.

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

MINISTRY OF HIGHER AND TERTIARY EDUCATION, CODE

SCIENCE & TECHNOLOGY DEVELOPMENT
SKILLS PROFICIENCY SCHEDULE

INDUSTRY: AUTOMOTIVE ENGINEERING / OCCUPATION: CAR MAINTENANCE ASSISTANT

CLASS/ LEVEL National Foundation Certificate

DUTY A: HEALTH AND SAFETY PRACTICES

▪ Pre-requisites: Approval Date:
Review Date:

TASK STEPS PROFICIENCY INDICATORS RELATED WORKPLACE

KNOWLEDGE ESSENTIAL SKILLS
A1: Observe • Familiarise with ➢ Appropriate PPE is used o Workshop rules - Communication
safety rules workshop rules/ ➢ Safety Regulations o Safe and Health - Tool handling
charts, notices adhered to practices - Planning
warning signs ➢ Practice safe acts o Testing - Reading instructions/
• Wear Personnel ➢ Possible hazards are equipment and manuals/specifications
Protective identified and eliminated procedures
Equipment ➢ Working authority is o Causes of
• Identify possible given accidents
dangers ➢ Manufacturer’s manual o Basic First Aid
knowledge
• Seek working referred to
o Fire- fighting
authority procedures
• Avoid possible o Colour coding of
dangers fire extinguishers
• Refer to o Good house
manufacturer’s keeping
manual

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

o Testing
equipment and
procedures

• Wear PPE • Appropriate PPE is used

A2: Practices • Clear gang ways • Gang ways cleared
safety • Display warning • Warning signs displayed
Procedures signs • Working environment
• Clean working cleaned
environment • Power isolated and DB
• Screen own working and Panel locked
area • Appropriate tools and
• Use appropriate tool equipment
and equipment • Own area screened
• Practice good • Gas cylinders stored in
housekeeping upright position
• Store gas cylinders • Clean working area
in upright position observed
• Store flammable • Flammable material stored
material away from away from welding area
welding area • Defective free equipment
• Use defective free use
equipment
•
A3 : Operate • Wear appropriate ➢ Appropriate PPE is used
fire- fighting PPE ➢ Types of fires and fire
equipment • Classify types of extinguishers classified
fires and ➢ Types of fire extinguisher
extinguishers identified
• Identify appropriate ➢ Fire alarm raised
extinguishers ➢ Safety pin unlocked
➢ Safety collar removed

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

• Raise a fire alarm ➢ Knob struck

• Unlock safety pin ➢ Fire extinguished
• Remove safety ➢ Incident reported
collar where
necessary
• Strike the knob
• Direct jet towards
the base of fire
• Report incident

A.4 Carry out • Appropriate PPE is ➢ Suitable PPE worn

safety drills used ➢ Appropriate drill selected
• Select appropriate ➢ Appropriate tools and
drill equipment selected
• Select appropriate ➢ Safety drill performed
tools and equipment ➢ Safety drill evaluated
• Perform safety drill
• Evaluate safety drill
•
A. 5 Carry out • Appropriate PPE is ➢ Suitable PPE worn
First Aid used ➢ Causes of problem
• Identify need for identified
First Aid ➢ Appropriate First Aid
• Apply appropriate procedure applied
First Aid procedure ➢ Medical help provided
• Call for Medical ➢ Situational report in place
help
• Give situational
report

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

TOOLS AND EQUIPMENT NECESSARY TO COMPLETE THIS DUTY:

Personnel Protective
Equipment First Aid Kit
Fire Fighting Equipment
Brooms
Basic Tool box

HEALTH, SAFETY AND ENVIRONMENTAL ISSUES RELATED TO THIS DUTY:

- First Aid
- Fire Extinguisher
- PPE
- Adherence to environment regulations
- Firefighting equipment
- Display warning signs at all areas
-
SPECIFIC WORKER TRAITS REQUIRED COMPLETING THIS DUTY:
- Sober mind
- Result oriented
- Honest
- Team player
- Neatnes
- Punctuality

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

MINISTRY OF HIGHER AND TERTIARY EDUCATION, CODE

SCIENCE & TECHNOLOGY DEVELOPMENT
SKILLS PROFICIENCY SCHEDULE
INDUSTRY: AUTOMOTIVE ENGINEERING / OCCUPATION: CAR MAINTENANCE

CLASS/ LEVEL National Foundation Certificate

DUTY: B BENCHFITTING
Pre-requisites: Approval Date: Review Date:

TASK STEPS PROFICIENCY RELATED WORKPLACE

INDICATORS KNOWLEDGE ESSENTIAL SKILLS
B1: Identify Hand • Wear appropriate PPE ➢ Appropriate PPE • Workshop - Communication
tools and Equipment • Withdraw tools and worn rules - Planning
equipment from stores ➢ Tools and equipment • Safe and health - Numeracy
• Group tools and equipment withdrawn from practices - Tool and
according to function stores • Use of correct equipment
• Name tools and equipment ➢ Tools and equipment equipment handling
• State function of each tool grouped according to • Engineering - Reading
and equipment function drawing instruction
➢ Tools and equipment • Knowledge of - Calculations
named materials - Interpretation of
➢ Function of each tool • Equipment drawings
and equipment stated operation
• Using
measuring
tools
• Purpose of
coolants and
types

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

B2 Demonstrate • Wear appropriate PPE ➢ Appropriate PPE ➢ Workshop

correct use of hand • Select appropriate tools and worn rules
tools and equipment equipment ➢ Appropriate tools and ➢ Safe and health
• Secure work pieces on vice equipment selected practices
• Illustrate correct stance ➢ Work piece secured ➢ Use of correct
• Perform the correct use of in vice equipment
tool/ equipment ➢ Correct stance ➢ Engineering
• Select trainee to perform the illustrated drawing
process ➢ Correct use of tool ➢ Knowledge of
performed materials
➢ Selected performed ➢ Equipment
the process operation
➢ Using
measuring
tools
Purpose of coolants and
types
B3 : Practice correct • Wear appropriate PPE ➢ Appropriate PPE
benchfitting • Select appropriate tools and worn
techniques equipment ➢ Appropriate tools and
• Apply cutting methods equipment selected
techniques ➢ Cutting methods
• Perform joining methods techniques applied
techniques ➢ Joining methods
• Carry out measuring and techniques performed
marking out techniques ➢ Measuring and
marking out
techniques carried
out.

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

B4 Maintain hand • Wear appropriate PPE ➢ Appropriate PPE

tools and equipment • Check tools and equipment worn
condition after use ➢ Condition of tools
• Clean tools and equipment and equipment
before and after use checked after use
• Oil/ grease tools and ➢ Tools and equipment
equipment where necessary cleaned before and
• Arrange tools and equipment after use.
into respective places ➢ Tools and equipment
oiled/ greased where
necessary
➢ Tools and equipment
arranged into
respective places

TOOLS AND EQUIPMENT NECESSARY TO COMPLETE THIS DUTY:

Scriber Engineer’s hammer Centre punch Pin punch set
Chisels Engineer’s file set Wire brush Hack saw
Twisted drill bit set Welding machine Pillar drilling machine Die stock set
Work bench with vice Tool cabinet Mallet Pop rivet set
Steel rule Goggles Gas cylinders Vernier calipers
Engineer’s square

HEALTH, SAFETY AND ENVIRONMENTAL ISSUES RELATED TO THIS DUTY:

- Adherence to - Floor free of slippery conditions

environment - Fire extinguishers
regulations - PPE
- Free gang way in
workshop
SPECIFIC WORKER TRAITS REQUIRED COMPLETING THIS DUTY:
➢ Team work ➢ Honesty
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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

➢ Result ➢ Punctuality
oriented ➢ Sober
➢ Neatness minded

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

MINISTRY OF HIGHER AND TERTIARY EDUCATION, CODE

SCIENCE & TECHNOLOGY DEVELOPMENT
SKILLS PROFICIENCY SCHEDULE
STRY: AUTOMOTIVE ENGINEERING / OCCUPATION: CAR MAINTENANCE

CLASS/ LEVEL NATIONAL FOUNDATION CERTIFICATE

DUTY C : SERVICING MOTOR VEHICLE

C1 Carry out • Wear appropriate PPE ➢ Appropriate PPE worn • Knowledge of - Diagnostic
visual inspection • Check oil, water, brake ➢ Oil/water/ brake fluid cleaning solvents - Communication
fluid leaks leaks checked • Component - Planning
• Check battery electrolyte ➢ Battery electrolyte level identification - Interpretation of
level checked • Handling of interpretation
• Check battery terminals ➢ Battery terminals for tools - Following instruction i.e
for tightness tightness checked • Testing specification
• Check fan belt/ V-belt for ➢ Fan belt/ V-belt for equipment
slackness tension checked • Types of oils
• Check high tension ➢ High tension cables • Technology
cables for cracks checked for cracks
➢ Brake pads checked for
• Check brake pads for
wear
wear
• Check for tyre condition • Condition of tyres
checked
• Check lighting system
• Lighting system and
and loose connections
loose connections
checked

C2 Change oil • Wear appropriate PPE ➢ Appropriate PPE worn

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

• Select appropriate tools ➢ Appropriate tools and

and equipment equipment selected
• Add engine flush where ➢ Engine flush added
necessary ➢ Engine ran according to
• Run engine according to manufacturer’s
manufacturer’s specifications
specifications ➢ Vehicle positioned on
• Drive vehicle to service service pit and switched
pit and switch off off
• Choke the wheels of the ➢ Vehicle choked
vehicle ➢ Bonnet opened and oil
• Open bonnet and remove filler cap removed
oil filler caps ➢ Sump plug removed and
oil drained
• Remove sump plug and
➢ Sump plug fitted back
drain engine oil into
➢ Oil filter replaced
collecting tray
➢ New oil added
• Replace washer and fit
➢ Oil level checked
back sump plug.
➢ Engine cleaned
• Replace oil filter
➢ Engine ran
• Add new oil ➢ Oil leaks and level
• Check oil level checked
• Clean engine ➢ Test drive carried out
• Run the engine
• Check for oil leaks and
level
• Test drive

C3: Change spark • Wear appropriate PPE ➢ Appropriate PPE worn

plugs • Select appropriate tools ➢ Appropriate tools
• Open bonnet and put selected
fender covers ➢ Bonnet opened and
• Disconnect negative fender covers put

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

battery terminal ➢ Battery negative

• Remove high tension terminal removed
cable from spark plugs ➢ Spark plugs removed
• Remove spark plug ➢ Spark plug gap adjusted
• Check spark plug gap on ➢ New plugs fitted
new plugs ➢ High tension cable fitted
• Adjust gap according to according to firing order
manufacturer’s ➢ Engine started
specifications
• Fit new plugs
• Fit high tension cable
according to firing order
• Start engine
•

C4 Change • Wear appropriate PPE ➢ Appropriate PPE worn

distributor points • Select appropriate tools ➢ Appropriate tools
and condenser • Open bonnet and put selected
fender covers ➢ Bonnet opened and
• Disconnect negative fender covers put
battery terminal ➢ Battery negative
• Remove distributor cap terminal removed
• Check distributor for ➢ Distributor cap removed
cracks ➢ Distributor cap checked
• Clean distributor for cracks
➢ Distributor components
components
cleaned
• Turn engine in the
➢ Piston at TDC
direction of rotation until
➢ Timing marks checked
No. 1 piston is at TDC
➢ Contacts points and
• Check timing marks to condenser removed
verify ➢ Distributor cam lobes
• Remove contact points greased

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

and condenser ➢ New contact points and

• Grease distributor cam condenser fitted
lobes ➢ Contact points adjusted
• Fit new points and according to
condenser specifications
• Adjust contact points gap ➢ Distributor cap fitted
to specifications back
• Fit back distributor cap ➢ Battery terminal
• Connect battery terminal connected
• Start engine and set ➢ Engine started and
idling idling set
C5 Change air • Wear appropriate PPE ➢ Appropriate PPE worn
and fuel filters • Select appropriate tools ➢ Appropriate tools
• Open bonnet and put selected
fender covers ➢ Bonnet opened and
• Remove air filter housing fender covers put
cover ➢ Air filter housing
• Remove air filter element removed
• Clean air filter housing ➢ Air filter housing
• Replace air filter element cleaned
➢ Air filter element
• Secure air filter housing
replaced
cover
➢ Air filter housing cover
• Disconnect fuel lines
secured
• Remove fuel filter ➢ Fuel lines disconnected
• Replace fuel filter ➢ Fuel filter removed
• Connect fuel lines ➢ Fuel filter replaced
• Prime fuel filter(diesel) ➢ Fuel lines connected
• Start engine and check ➢ Fuel primed
for fuel leaks ➢ Engine started and
• checked for fuel leaks
➢

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

C6 Change brake • Wear appropriate PPE ➢ Wear appropriate PPE

pads • Select appropriate tools ➢ Select appropriate tools
and equipment and equipment
• Place vehicle on level ➢ Place vehicle on level
ground ground
• Choke rear wheels ➢ Rear wheels choked
• Loosen front wheel nuts ➢ Front wheel nuts
• Jack up vehicle and loosened
suspend on axle stands ➢ Vehicle suspended
• Remove wheels ➢ Front wheels removed
➢ Bonnet opened and
• Open bonnet and put
fender covers put
fender covers
➢ Brake fluid reservoir cap
• Remove brake fluid
removed
reservoir cap
➢ Brake pads removed
• Loosen brake caliper ➢ Wheel cylinder piston
holder and remove brake compressed
pads ➢ Disc checked for wear
• Compress wheel cylinder and scores
piston ➢ New pads fitted
• Check disc for ➢ Wheel cylinder
wear/scores Piston released
• Fit new pads ➢ Wheels fitted and nuts
• Pump brake pedal to tightened
release wheel cylinder ➢ Axle stands removed
piston ➢ Test drive done
• Fit back wheels
• Jack up vehicle to
remove axle stands
• Remove rear chokes and
choke front wheels
• (Repeat the above
process for rear wheels)

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

C7 Change brake • Wear appropriate PPE ➢ Wear appropriate PPE

shoes • Select appropriate tools ➢ Select appropriate tools
and equipment and equipment
• Place vehicle on level ➢ Place vehicle on level
ground ground
• Disconnect battery ➢ Battery disconnected
• Loosen nuts ➢ Wheel nuts loosened
• Suspend /raise vehicle ➢ Vehicle raised
• Remove rear wheels ➢ Hand brake cable
released
• Release hand brake cable
➢ Brake drums removed
• Remove brake drums
➢ Drums inspected for
• Inspect drum for scores scores
• Disconnect hand brake ➢ Hand brake cable
cable disconnected
• Remove brake shoes ➢ Brake shoes removed
• Clean brake assembly ➢ Drum assembly cleaned
• Replace brake shoes ➢ Brake shoes replaced.
• Connect hand brake cable ➢ Hand brake cable
• Fit back brake drum and connected
wheels ➢ Brake drum and wheels
• Tighten wheel nuts fitted
• Adjust brake shoes to ➢ Wheel nuts tightened
lock the drum ➢ Brake shoes adjusted
• Release brake adjuster ➢ Brake shoe adjuster
slightly to turn the wheel released
one revolution ➢ Vehicle lowered to the
• Lower the vehicle ground
• Test drive the vehicle ➢ Vehicle tes driven

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

C8 Grease moving • Wear appropriate PPE ➢ Wear appropriate

parts • Select appropriate tools PPE
and equipment ➢ Select appropriate
• Place vehicle on service tools and
pit equipment
• Choke road wheels ➢ Vehicle placed on
• Identify the greasing service pit
points ➢ Road wheels
• Grease the moving parts choked
➢ Greasing points
identified
➢ Moving parts
greased

OLS AND EQUIPMENT NECESSARY TO COMPLETE THIS DUTY:

Basic tool Feeler gauge set Hole
Kit Axle Filter wrench punches
stands Trolley and bottle Battery
Fender jacks Tyre lever set testers
covers Pipe Battery
Garage creep wrench charger
Inspection Gasket Grease gun
lamp cutter Lubrication
Car lift inspection Letter gun
pit Brake stamp Computer
bleeding unit Measuring
tools

HEALTH, SAFETY AND ENVIRONMENTAL ISSUES RELATED TO THIS DUTY:

- First Aid kit
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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

- Free gang ways in the workshop

- PPE
- Fire extinguishers
- Display warning signs at all areas
- Adherence to environment regulations

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

SPECIFIC WORKER TRAITS REQUIRED COMPLETING THIS DUTY:

➢ Sober minded
➢ Team work
➢ Honesty
➢ Result oriented
➢ Neatness
➢ Punctuality

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

MINISTRY OF HIGHER AND TERTIARY EDUCATION, CODE

SCIENCE & TECHNOLOGY DEVELOPMENT
SKILLS PROFICIENCY SCHEDULE
INDUSTRY: AUTOMOTIVE ENGINEERING / OCCUPATION: CAR MAINTENANCE

CLASS/ LEVEL NATIONAL FOUNDATION CERTIFICATE

DUTY D: FAULT DIAGNOSIS AND REPAIR

Pre-requisites: Approval Date: Review Date:

TASK STEPS PROFICIENCY RELATED WORKPLACE

INDICATORS KNOWLEDGE ESSENTIAL SKILLS
DI: Diagnose basic • Wear appropriate PPE ➢ Appropriate PPE worn • Bearing and - Reading instruction
electrical faults • Select appropriate tools ➢ Appropriate tools and seal technology - Planning
and equipment equipment selected • Motor - Interpretation of
• Disconnect battery ➢ Battery terminals mechanics circuit diagrams
terminals disconnected Technology - Interpretation of
• Remove battery clamp ➢ Battery clamp holder • Auto electrics result
holder removed technology - Communication
• Remove battery from ➢ Battery removed from • Component
vehicle vehicle identification
• Clean the battery ➢ Battery cleaned • Use of correct
• Check for cracks ➢ Battery checked for equipment to
cracks
• Check electrolyte level- identity faults
➢ Electrolyte level • Causes of faults
top up if necessary
checked
• Charge the battery • Testing
➢ Battery charged
• Carry out load test ➢ Load test carried out
procedures
• Put back battery on ➢ Battery connected back
vehicle the vehicle
• Connect the battery

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

D3 Diagnose • Wear appropriate PPE ➢ Appropriate PPE worn

Electrical Fault - • Select appropriate tools and ➢ Appropriate tools and
Charging equipment equipment selected
Check fan/ V-belt tension ➢ Tension for fan/ V- belt
• Check for loose connections checked
• Check charging voltage ➢ Loose connected checked
• Measure charging current ➢ Charging voltage checked
• Compare results with ➢ Charging current measured
manufacturer’s ➢ Results compared with
specifications manufacturer’s
specifications
Diagnose Basic • Wear appropriate PPE ➢ Appropriate PPE worn
Electrical fault • Select appropriate tools and ➢ Appropriate tools and
(Lighting) equipment equipment selected
• Locate fuse box ➢ Fuse box located
• Check fuse ratings ➢ Fuse rating checked
• Locate switches and relays ➢ Switches and relays located
• Switch on Head lamps, stop ➢ Lighting systems tested
lights, tail lights, reverse ➢ Faulty bulbs replaced
lights and indicator lights ➢ Open and short circuit
checked for
• Replace fault bulbs with
➢ Identified problems rectified
correct ones
• Check for short circuit
• Check for open circuit
• Rectify identified problems
•
Diagnose Basic • Wear appropriate PPE ➢ Appropriate PPE worn
Electrical fault • Select appropriate tools and ➢ Appropriate tools and
(Beam focusing) equipment equipment selected
Using wall • Check lights for ➢ Lights checked for
functionality functionality
• Drive vehicle at least 10 ➢ Vehicle parked 10 m away
from wall

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

metres away from the wall ➢ Tyre pressure checked

• Check tyre pressure ➢ Recommended distance
• Measure distance from floor measured and transferred to
to centre of beam on both wall
lights and transfer to wall ➢ Adjusting screws located
• Locate adjusting screw
Diagnose Basic • Wear appropriate PPE ➢ Appropriate PPE worn
Electrical fault • Select appropriate tools and ➢ Appropriate tools and
(Beam setting using equipment equipment selected
beam setter) • Check lights for ➢ Lights checked for
functionality functionality
• Check tyre pressure ➢ Tyre pressure checked
• Locate adjusting screw ➢ Adjusting screws located
• Place beam setter according ➢ Beam setter placed
to specification according specifications

Diagnose Basic • Wear appropriate PPE ➢ Appropriate PPE worn

Electrical fault • Select appropriate tools and ➢ Appropriate tools and
(Replacement of equipment equipment selected
Electrical • Check for loose connections ➢ Loose connections tightened
component: • Check and test battery ➢ Battery condition
Alternator, Starter condition ascertained
motor, flasher unit • Test components whilst on ➢ Faulty components replaced
etc vehicle ➢
• Disconnect battery
• Remove components from
vehicle
• Bench test the components
• Replace faulty components
•
D2 : Diagnose basic • Wear appropriate PPE ➢ Appropriate PPE worn
mechanical faults • Select appropriate tools and ➢ Appropriate tools and

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

(Engine) equipment equipment selected

• Check for any metallic ➢ Whining and metallic sound
sound checked
• Listen to any whining sound ➢ Misfiring and backfiring
• Check vehicle for misfiring checked
and backfiring ➢ Engine running condition
• Observe running condition observed
of engine

D2 : Diagnose basic • Wear appropriate PPE ➢ Appropriate PPE worn

mechanical faults • Select appropriate tools and ➢ Appropriate tools and
(Lubrication) equipment equipment selected
• Check for oil pressure ➢ Oil pressure checked
• Check for oil level ➢ Oil level checked
• Check for oil viscosity ➢ Oil viscosity checked
• Check for oil pressure ➢ Oil pressure gauge checked
gauge functionality ➢ Oil leaks checked
• Check for oil leaks

D2 : Diagnose basic • Wear appropriate PPE ➢ Appropriate PPE worn

mechanical faults • Select appropriate tools and ➢ Appropriate tools and
(Cooling system) equipment equipment selected
• Check for coolant level ➢ Coolant level checked
• Verify thermostat and ➢ Thermostat and switch
switch operation operation condition
• Check V- belts tension ascertained
• Verify waterpump operation ➢ Correct V- belt tension
• Check radiator condition attained
➢ Water pump operating
• Verify temperature gauge
condition established
operation
➢ Blockage free radiator used
• Inspect the cooling system
➢ Temperature gauge
for leaks
operation condition

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

established
➢ Cooling system inspected
for leaks

D2 : : Diagnose • Wear appropriate PPE ➢ Appropriate PPE worn

basic mechanical • Select appropriate tools ➢ Appropriate tools and
faults (Clutch and equipment equipment selected
system) • Check fluid level ➢ Fluid level checked
• Check pedal free- play ➢ Pedal free-play checked
• Check for system leaks ➢ System leaks checked
• Check operation of ➢ Clutch operation
clutch verified
• Check operation of ➢ Thrust bearing operation
checked
thrust bearing
➢ Pilot bearing operation
• Check operation of pilot
checked
bearing

D2. : Diagnose basic • Wear appropriate PPE ➢ Appropriate PPE worn

mechanical faults • Select appropriate tools ➢ Appropriate tools and
(gear box) and equipment equipment selected
• Check oil level ➢ Oil level checked
• Check gearbox linkages ➢ Gearbox linkages
• Check gearbox checked
mountings ➢ Gearbox mountings
• Check shifting of gears checked
• Check meshing of gears ➢ Shifting of gears
verified
• Check locking of gears
➢ Meshing of gears
• Check gear noise when
checked
shifting
➢ Locking of gears
• Check gear breather for checked
blockages ➢ Gear noise when

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

shifting checked
➢ Gearbox breather
checked for blockages

D2: Diagnose basic • Wear appropriate PPE ➢ Appropriate PPE worn

mechanical faults • Select appropriate tools ➢ Appropriate tools and
(Propeller shaft) and equipment equipment selected
• Check propeller shaft ➢ Propeller shaft yokes are
yokes for alignment checked for alignment
• Check condition of ➢ Condition of centre
centre bearing bearing checked
• Check universal joints ➢ Universal joints checked
for wear for wear
• Check condition of ➢ Condition of propeller
propeller shaft splines shaft splines checked
➢ Propeller shaft checked
• Check propeller shaft
for vibration
for vibration
➢ Propeller shaft greasing
• Check propeller shaft
points checked
greasing points
•
D2: Diagnose basic • Wear appropriate PPE ➢ Appropriate PPE worn
mechanical faults • Select appropriate tools ➢ Appropriate tools and
(Drive shaft) and equipment equipment selected
• Check CV joints for ➢ CV joints checked for
wear wear
• Check condition of CV ➢ Condition of CV dust
dust boots boots checked
• Check for grease in CV ➢ Grease in CV joints
checked

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

joints ➢ Condition of splines

• Check condition of checked
splines ➢ Condition of wheel
• Check condition of bearings checked
wheel bearings ➢ Condition of lock nuts
• Check condition of lock checked
nuts

D2: Diagnose basic • Wear appropriate PPE ➢ Appropriate PPE worn

mechanical faults • Select appropriate tools ➢ Appropriate tools and
(Final Drive) and equipment equipment selected
• Check oil level ➢ Oil levels checked
• Check oil leaks ➢ Oil leaks checked
• Check breather for ➢ Breather checked for
blockages blockages
• Check for mechanical ➢ Mechanical noise
noise checked
• Check condition of half ➢ Condition of half shaft
shaft splines splines checked
➢ Condition of bearings
• Check condition of
checked
bearings
D2: Diagnose basic • Wear appropriate PPE ➢ Appropriate PPE worn
mechanical faults • Select appropriate tools ➢ Appropriate tools and
(Steering and and equipment equipment selected
suspension system) • Check tyre pressure ➢ Tyre pressure checked
• Check condition of ➢ Condition of shuckle
shuckle bushes bushes checked
• Check condition of ball ➢ Condition of ball joints
joints checked
• Check condition of track ➢ Condition of track rod
rod bushes and tie rod bushes and tie rod ends
ends checked

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

• Check condition of ➢ Condition of wheel

wheel bearings bearings checked
• Check steering free-play ➢ Steering free-play
• Check condition of checked
torsion bar ➢ Condition of torsion bar
• Check condition of wish checked
bone bushes ➢ Condition of wish bone
• Check steering box for bushes checked
leaks ➢ Steering box checked
• Check for equal turns for leaks
from left to right ➢ Equal turns from left to
right checked
• Check steering for
➢ Steering checked for
looseness
looseness
• Check condition of
➢ Condition of spring
spring bushes
bushes checked
• Check damper for
➢ Damper checked for
operation
operation
• Check alignment of ➢ Wheel alignment
wheels checked
➢
D2: Diagnose basic • Wear appropriate PPE ➢ Appropriate PPE worn
mechanical faults • Select appropriate tools ➢ Appropriate tools and
(Chassis) and equipment equipment selected
• Inspect for cracks and ➢ Cracks and broken
broken welds on frame welds on frame
• Check for chassis inspected
alignment ➢ Chassis alignment
checked

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

D2: Diagnose basic • Wear appropriate PPE ➢ Appropriate PPE worn

mechanical faults • Select appropriate tools ➢ Appropriate tools and
(Brakes) and equipment equipment selected
• Check level of brake ➢ Level of brake fluid in
fluid in reservoir reservoir checked
• Check condition of ➢ Condition of brake pedal
brake pedal checked
• Check condition of ➢ Condition of master
master cylinder cylinder checked
• Check adjustment of ➢ Hand brake adjusted
hand brake ➢ Brake shoes adjusted
➢ Hydraulic brake system
• Check adjustment of
bled
brake shoes
• Check for air in the
hydraulic brake system

D2: Diagnose basic • Wear appropriate PPE ➢ Appropriate PPE worn

mechanical faults • Select appropriate tools ➢ Appropriate tools and
(Wheel, tyres and and equipment equipment selected
tubes) • Check tyre pressure ➢ Tyre pressure checked
• Check tyre tread ➢ Tyre tread patterns
patterns checked
• Check wheel alignment ➢ Wheel alignment
• Check tie-rod ends for checked
wear ➢ Tie-rod ends checked
• Check suspension for wear
bushes for wear ➢ Suspension bushes
checked for wear
• Check condition
➢ Condition stabilizer bar
stabilizer bar
checked
• Check balance of wheel
➢ Wheel Balanced
statically and
statically and
dynamically
dynamically

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NATIONAL FOUNDATION CERTIFICATE IN CAR MAINTENANCE – 110/24/CR/M0

TOOLS AND EQUIPMENT NECESSARY TO COMPLETE THIS DUTY:

Basic Auto Electrician Lubrication Soldering
tool kit Basic Motor pump Beam iron Grease
Mechanic tool Kit Battery setter gun Oil can
service Kit Pit jack, trolley and bottle
Multimete jack Tyre testing tank
r Feeler Bench vices
gauge Inspection
Tyre pressure gauges lamp Spark
Cylinder leakage tester plug gauge Air
Cylinder bore gauge compressor
tester

HEALTH, SAFETY AND ENVIRONMENTAL ISSUES RELATED TO THIS DUTY:

- Well ventilated workshop
- Defective free equipment
- PPE
- Free gang way
- Floor free of slippery conditions
- Adequate lighting

SPECIFIC WORKER TRAITS REQUIRED COMPLETING THIS DUTY:

➢ Sober minded
➢ Team player
➢ Accuracy
➢ Good communication
➢ Target oriented

27