Remove and replace heavy goods and public service vehicle combustion engine units and components

This standard is about removing and replacing heavy goods and public service vehicle units and components where dismantling and re-assembly of combustion engine systems is required. It is also about evaluating the performance of replaced units and components. The units and components concerned are those not replaced as part of normal routine, vehicle maintenance (servicing) activities.

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P2.1 vehicle technical data

P2.2 removal and replacement procedures

P2.3 legal requirements

P3 prepare the vehicle, vehicle systems and the work area for safe working procedures 

P4 prepare, check and use all the equipment required following manufacturers' instructions

P5 carry out all removal and replacement activities following;

P5.1 manufacturers' instructions

P5.2 industry recognised repair methods

P5.3 your workplace procedures

P5.4 health, safety and environmental requirements

P6 work in a way which minimises the risk of:

P6.1 damage to other vehicle systems, units and components

P6.2 contact with leakage and hazardous substances

P6.3 damage to your working environment

P6.4 injury to self and others

P7 ensure replaced combustion engine units and components conform to the vehicle operating specification and any legal requirements

P8 promptly record and report any additional faults you notice during the course of your work

P9 use suitable testing methods to evaluate the performance of the reassembled system 

P10 ensure the reassembled system performs to the vehicle operating specification and meets any legal requirements prior to return to the customer/driver

P11 ensure your records are accurate, complete and passed to the relevant person(s) within the agreed timescale in the format required

P12 complete all removal and replacement activities within the agreed timescale

P13 promptly report any anticipated delays in completion to the relevant person(s)

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K3.1 health and safety

K3.2 the environment (including waste disposal)

K3.3 appropriate personal and vehicle protective equipment

K4 your workplace procedures for

K4.1 recording removal and replacement information

K4.2 the referral of problems

K4.3 reporting delays to the completion of work

K5 the importance of recording removal and replacement information

K6 the importance of working to agreed timescales and keeping others informed of progress

K7 the relationship between time and costs

K8 the importance of promptly reporting anticipated delays to the relevant person(s)

Use of technical information

K9 how to find, interpret and use sources of information applicable to unit and component removal and replacement within combustion engine systems

K10 the importance of using the correct sources of technical information

K11 the purpose of and how to use identification codes

Electrical and electronic principles

K12 vehicle earthing principles and methods

K13 electrical and electronic principles associated with vehicle combustion engine systems, including types of sensors, actuators, their application and operation

K14 types of circuit protection and why these are necessary

K15 electrical safety procedures

K16 how warning circuits work

K17 electric symbols, units and terms

K18 battery charging

K19 electrical/electronic control system principles

K20 the hazards associated with working on or near high voltage electrical vehicle components

Combustion engine system operation and construction

K21 how combustion engine systems and their related units and components are constructed, dismantled and reassembled for the types of vehicle on which you work

K22 how combustion engine systems and their related units and components operate for the types of vehicle on which you work

Equipment

K23 how to prepare, check and use all the removal and replacement equipment required

Combustion engine unit and component removal and replacement

K24 how to remove and replace combustion engine system mechanical and electrical units and components for the types of vehicle on which you work

K25 how to select and fit gaskets, sealants, fittings and fasteners

K26 how to test and evaluate the performance of replacement combustion engine units and components and the reassembled system against the vehicle operating specifications and any legal requirements 

K27 the relationship between testing methods and the combustion engine units and components replaced – the use of appropriate test methods

K28 the properties of jointing materials and when and where they should be used

K29 the manufacturer's specification for the type and quality of combustion engine units and components to be used

K30 how to work safely avoiding damage to other vehicle systems, units and components and contact with leakage and hazardous substances

K31 the importance of inspecting the vehicle following any repairs

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1.1. hand tools

1.2. special workshop tools

1.3. general workshop equipment

1.4. electrical testing equipment

2. Testing methods are:

2.1. sensory

2.2. functional

2.3. measurement

3. Units and components are:

3.1. mechanical

3.2. electrical

4. Combustion engine systems are:

4.1. engine mechanical systems

4.2. cooling, heating and ventilation systems

4.3. air supply and exhaust emission systems

4.4. fuel and ignition systems

4.5. engine electrical and electronic systems

4.6. lubrication systems

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3

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31 Mar 2024

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Current

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Original

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IMI

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MRHV02

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Engineering, Heavy Vehicle Service Technician (Automotive), Vehicle Trades, Bus and Coach Mechanic (semi-skilled), Bus and Coach Mechanic, Bus and Coach Mechelec

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5231

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Engine; units; remove; replace; commercial; heavy goods vehicle; public service vehicle; diesel; compression; ignition; combustion; components; bus; coach;

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