Diagnose and rectify heavy goods and public service vehicle combustion engine and component faults

This standard is about diagnosing and rectifying faults occurring in heavy goods and public service vehicle combustion engine mechanical, electrical, hydraulic/pneumatic and fluid systems.

P2.1 technical data

P2.2 diagnostic test procedures

P3 prepare the vehicle, vehicle systems and work area for safe working procedures as appropriate to the vehicle and environment 

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

P5 use diagnostic methods which are relevant to the symptoms presented

P6 collect sufficient diagnostic information in a systematic way to enable an accurate diagnosis of engine system faults

P7 identify and record any system deviation from manufacturer’s tolerances 

P8 ensure your assessment of dismantled sub-assemblies, units and components identifies their condition and suitability for repair or replacement

P9 promptly inform the relevant person(s) where repairs are uneconomic or unsatisfactory to perform 

P10 use the equipment required, correctly and safely throughout all rectification activities

P11 carry out all rectification activities following:

P11.1 manufacturers' instructions

P11.2 industry recognised repair methods

P11.3 your workplace procedures

P11.4 health, safety and environmental requirements

P12 work in a way which minimises the risk of:

P12.1 damage to other vehicle systems, units and components

P12.2 contact with leakages and hazardous substances

P12.3 damage to your working environment

P12.4 injury to self and others

P13 ensure all repaired and replaced units and components conform to the vehicle operating specification and any legal requirements

P14 adjust units and components correctly to ensure that they operate to meet system requirements, when necessary

P15 promptly record and report any additional faults you notice during the course of work 

P16 use testing methods which are suitable for assessing the performance of the rectified system 

P17 ensure the rectified combustion engine system performs to the vehicle operating specification and any legal requirements prior to return to the customer/driver

P18 ensure your records are accurate, complete and passed to the relevant person(s) within the agreed timescales in the format required

P19 complete all system diagnostic activities within the agreed timescale

P20 promptly report any anticipated delays in completion to the relevant person(s)

K1.1 health and safety

K1.2 the environment (including waste disposal)

K1.3 appropriate personal and vehicle protective equipment

K2 the implications on an Operators Licence of not carrying out repairs and inspections correctly

K3 legal requirements relating to the vehicle (including road safety requirements and European Emissions Standards )

K4 your workplace procedures for

K4.1 recording diagnostic and rectification activities

K4.2 the referral of problems

K4.3 reporting delays to the completion of work

K5 the importance of working to industry recognised diagnostic and rectification procedures and processes and obtaining the correct information for diagnostic and rectification activities to proceed

K6 the importance of recording diagnostic and rectification information

K7 the importance of working to agreed timescales and keeping others informed of progress

K8 the relationship between time, costs and productivity

K9 the importance of promptly reporting anticipated delays to the relevant person(s) 

Electrical and electronic principles

K10 electrical and electronic principles associated with engine systems, including types of sensors and actuators, their application and operation

K11 how electrical and electronic engine systems operate, including electrical component function, electrical inputs, outputs, voltages and oscilloscope patterns, digital and fibre optics principles

K12 the interaction between electrical, electronic and mechanical components with vehicle engine systems

K13 how engine electrical systems interlink and interact, including multiplexing

K14 electrical symbols, units and terms

K15 electrical safety procedures

K16 the hazards associated with working on or near high voltage electrical vehicle components

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Use of diagnostic and rectification equipment

K17 how to prepare and check the accuracy of diagnostic testing *equipment

K18 how to use diagnostic and rectification equipment for combustion engine mechanical, electrical, electronic, hydraulic/pneumatic and fluid systems (including any emissions controls); specialist engine repair tools and general workshop equipment

Combustion engine electrical faults, their diagnosis and rectification

K19 how combustion engine mechanical, electrical, electronic, hydraulic/pneumatic and fluid systems are constructed, operate, dismantled and reassembled

K20 how combustion engine mechanical, electrical, electronic, hydraulic/pneumatic and fluid systems are dismantled, reassembled and adjusted to manufacturers’ specifications

K21 the types and causes of combustion engine mechanical, electrical, electronic, hydraulic/pneumatic and fluid system, unit and component faults and failures

K22 combustion engine mechanical, electrical, electronic, hydraulic/pneumatic and fluid unit and component replacement procedures, the circumstances which will necessitate replacement and other possible courses of action

K23 how to find, interpret and use sources of information on combustion engine electrical and electronic operating specifications, diagnostic test procedures, repair procedures and legal requirements

K24 vehicle operating specifications for limits, fits and tolerances relating to combustion engine mechanical, electrical, electronic, hydraulic/pneumatic and fluid systems for the types of vehicle on which you work

K25 how to select the most appropriate diagnostic testing method for the symptoms presented

K26 how to carry out systematic diagnostic testing of combustion engine mechanical, electrical, electronic, hydraulic/pneumatic and fluid systems using a prescribed process or format and diagnostic methods *

K27 how to assess the condition of mechanical, electrical, electronic, hydraulic/pneumatic and fluid units and components

K28 how to interpret test results and vehicle data in order to identify the location and cause of vehicle system *faults

K29 how to carry out rectification activities in order to correct faults in the combustion engine mechanical, electrical, electronic, hydraulic/pneumatic and fluid systems

K30 the relationship between test methodology and the faults repaired – the use of appropriate testing methods

K31 how to make cost effective recommendations for rectification

K32 the importance of inspecting the vehicle following any repairs

1.1. the combustion engine mechanical system
1.2. the combustion engine electrical and electronic systems
1.3. the combustion engine hydraulic/pneumatic and fluid systems

2. Diagnostic methods are:

2.1. sensory
2.2. measurement
2.3. functional testing
2.4. electrical and electronic systems testing

3. Diagnostic testing is defined as:

3.1. verify the fault
3.2. collect further information
3.3. evaluate the evidence
3.4. carry out further tests in a logical sequence
3.5. rectify the problem
3.6. check all systems

4. Equipment is:

4.1. diagnostic and rectification equipment for combustion engine mechanical systems
4.2. diagnostic and rectification equipment for combustion engine electrical systems
4.3. diagnostic and rectification equipment for combustion engine hydraulic/pneumatic and fluid systems
4.4. specialist repair tools
4.5. general workshop equipment

5. Rectification activities are:

5.1. dismantling
5.2. replacement of units and components
5.3. adjustment of units and components
5.4. repairs to wiring and connectors
5.5. re-programming vehicle systems
5.6. reassembly
5.7. functional testing