Remove and replace light vehicle combustion engine units and components

​This NOS is about removing and replacing 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 not those replaced as part of normal routine, vehicle maintenance (servicing) activities.

P2.1 vehicle technical data

P2.2 removal and replacement procedures

P2.3 legal requirements 

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

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 recognised repair methods

P5.3 health, safety and environmental requirements

P5.4 your workplace procedures

P6 work in a way which minimises the risk of:

P6.1 damage to other vehicle systems

P6.2 damage to other vehicle components and units

P6.3 contact with leakage

P6.4 contact with hazardous substances

P6.5 damage to your working environment

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

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

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

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

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

P12 complete all removal and replacement activities within the agreed timescale

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

K2.1 health and safety

K2.2 the environment (including waste disposal)

K2.3 appropriate personal and vehicle protective equipment

K3 the importance of documenting removal and replacement information

K4 the importance of working to agreed timescales and keeping others informed progress

K5 the relationship between time and costs

K6 the importance of reporting anticipated delays to the relevant person(s) promptly

Use of technical information

K7 how to find, interpret and use sources of information applicable to units and component removal and replacement within combustion engine systems

K8 the importance of using the correct sources of technical information

K9 the purpose of and how to use identification codes

Electrical principles

K10 vehicle earthing principles and earthing methods 

K11 principles associated with vehicle combustion engine systems, including types of sensors, actuators, their application and operation

K12 types of circuit protection and why these are necessary

K13 electrical safety procedures 

K14 how warning circuits work

K15 electric symbols, units and terms

K16 battery charging

K17 electrical/electronic control system principles

K18 the hazards associated with working on or near high energy electrical vehicle components

Combustion engine system operation and construction *

K19 how *combustion engine systems and their related units and components are constructed, dismantled and reassembled for the classification of vehicle worked upon

K20 how combustion engine systems and their related units and components operate for the classification of vehicle worked upon

Equipment

K21 how to prepare, check and use all the removal and replacement equipment required

Combustion engine unit and component removal and replacement

K22 how to remove and replace engine system mechanical and electrical unit components for the classification of vehicle worked upon

K23 how to select and fit gaskets, sealants, fittings and fasteners

K24 how to test and evaluate the performance of replacement engine units and components and the reassembled system against the vehicle operating specifications and any legal requirements

K25 the relationship between testing methods and the engine units and components replaced – the use of appropriate test methods

K26 the properties of jointing materials and when and where they should be used

K27 the manufacturer's specification for the type and quality of engine units and components to be used

K28 how to work safely avoiding damage to other vehicle systems, components units and contact with leakage and hazardous substances

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. visual

2.2. aural

2.3. functional

2.4. 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 systems

4.4. fuel and ignition systems

4.5. engine electrical systems

4.6. lubrication systems