CURRICULUM of COMPETENCY UNIT (CoCU)

Sub Sector MACHINERY & LAND TRANSPORTATION

Job Area COMMERCIAL VEHICLE SERVICING AND MAINTENANCE
Competency Unit Title FUEL SYSTEM SERVICING
Common rail system servicing is a set of skills to carry out common rail system servicing that includes knowledge
about various types of common rail components, torque wrench and angle. The person whom is competent in
common rail system servicing works must be able to identify common rail system servicing requirements, execute
Competency Unit Descriptor
common rail system, execute, and check common rail performance and service activities according to
manufacturer’s specification, regulation requirements, vehicle specification, safety requirements and standard
operating procedures (SOP)
Training Credit
Competency Unit ID Level 3 46 Hours
Duration Hours

14
 Attitude / Safety / Training Delivery
Work Activities Related Knowledge Applied Skills Assessment Criteria
Environmental Hours Mode

1. Prepare fuel i. Fuel system operation 2 hours Lecture i. Types of

system servicing ii. Types of common rail common rail
requirements system, such as; component listed
 Common rail out
 Super common rail ii. Common rail
 Common rail with system
piezoelectric injector requirement and
 Etc. procedure collected
iii. Occupational Safety and iii. Common rail
Health (OSHA) Act system tools,
requirement equipment and
iv. Workshop safety material obtained
v. Department of
Environment (DOE)
requirement

i. Determine types of 4 hours Demonstration,

common rail Observation &
Practical

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 Attitude / Safety / Training Delivery
Work Activities Related Knowledge Applied Skills Assessment Criteria
Environmental Hours Mode
ii. Determine types of
common rail component and Attitude:
calibration procedures i. Ensure components
according to
manufacturer
specification

Safety:
i. Wear appropriate
Personal Protective
Equipment (PPE)
ii. Ensure safe
workplace

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 Attitude / Safety / Training Delivery
Work Activities Related Knowledge Applied Skills Assessment Criteria
Environmental Hours Mode

2. Perform common i. Common rail system 3 hours Lecture i. Diagnostic

rail system operation tester operated
servicing ii. Types and function of accordingly
common rail component, such ii. Common rail
as: components
 ECU (Electronic Control dismantled
Unit) correctly
 Electrical pump iii. All equipment
has been examined
 Solenoid injector and identified
iv. All equipment
that is damaged a
 Supply pump
new convertible
v. Services
 Common rail common rail
system operating
 Pressure limiter required to
standard
 Pressure sensor vi. Common rail
system functioning
 Fuel filter as recommended
by manufacturer
 Tank

 EDU (Electronic Driver

Unit)

 Speed sensor

 Throttle
 LP Return Line
 Etc
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 Attitude / Safety / Training Delivery
Work Activities Related Knowledge Applied Skills Assessment Criteria
Environmental Hours Mode

i. Prepare servicing tools, 6 hours Demonstration,

equipment and materials on Observation &
work area Practical
ii. Dismantle common rail
system component
according to manufacturer’s
manual
iii. Check common rail
components faulty
iv. Replace faulty components
according to manufacturer’s
manual
v. Assemble common rail
components according to
manufacturer’s manual
vi. Carry out housekeeping
activities
Attitude:
i. Handle equipment
with care
ii. Comply with
manufacture’s
standard
Safety:
i. Wear appropriate
Personal Protective
Equipment (PPE)
ii. Ensure safe
workplace

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 Attitude / Safety / Training Delivery
Work Activities Related Knowledge Applied Skills Assessment Criteria
Environmental Hours Mode

3. Perform common i. Common rail system 2 hours Lecture i. Common rail

rail system function operation system checked
ability check ii. Common rail system according to
leakage manufacturer’s
iii. Engine noise (Diesel standard
Knock) ii. Common rail
iv. Procedure to check system leakage
common rail system function checked
ability

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 Attitude / Safety / Training Delivery
Work Activities Related Knowledge Applied Skills Assessment Criteria
Environmental Hours Mode
iii. Engine noise
i. Check common rail 4 hours Demonstration, (Diesel knock)
system operation condition Observation & checked
ii. Check common rail Practical i. Common rail
system leakage system
iii. Check engine noise performance
using stethoscope checked against
iv. Check function ability of manufacturer’s
common rail system specification
according to manufacturer’s
standard
Attitude:
i. Handle
equipment with care
ii. Comply
manufacture’s
standard

Safety:
i. Wear appropriate
Personal Protective
Equipment (PPE)
ii. Ensure safe
workplace

4. Report service i. Job card 2 hours Lecture i. Common rail

activities ii. Formats of record system servicing
iii. Report writing skills

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 Attitude / Safety / Training Delivery
Work Activities Related Knowledge Applied Skills Assessment Criteria
Environmental Hours Mode
activities report
i. Determine formats of record 3 hours Demonstration, produced
ii. Write common rail system Observation &
servicing activities report Practical
Attitude:
iii. Meticulous in
recording checklist
iv. Adhere to
deadline
v. Follow ethics in
report writing

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Employability Skills

CORE ABILITIES SOCIAL SKILLS

01.09 Utilise business graphic application to process information 1. Communication skills

3 1. Conceptual skills
01.11 Apply thinking skills and creativity 2. Interpersonal skills
3 3. Multitasking and prioritizing
02.11 Convey information and ideas to people 4. Self-discipline
3 5. Teamwork
03.15 Liase to achieve identified outcomes 6. Leadership
3 7. Learning skill
03.16 Identify and assess client/customer needs
3
04.06 Allocate work
3
04.07 Negotiate acceptance and support for objectives and strategies
3
05.01 Implement project/work plans
3
05.02 Inspect and monitor work done and/or in progress
3

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Tools, Equipment and Materials (TEM)

ITEMS RATIO (TEM : Trainees)

1. Tray 2:5
2. Hand tools 1:1
3. Power tools
1:5
4. Vanier Calliper
5. Torque Wrench 1:1
6. Personal Protective Equipment (PPE) 1:5
7. Diagnostic tool kit 1:1
8. Multi meter 1:5
9. Test bench Flange 1:5
10. Injector puller 1:5
11. Sliding hammer puller
1:5
12. Common rail injector tester
13. Diagnostic tester 1:5
14. Burette kit 1:5
1:5
1:5

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References

REFERENCES

1. John F. Dagel & Robert N. Brady. (1998). Diesel Engine and Fuel System Repair. Michigan: Prentice Hall
2. Mohd Bahaman Mohd Rajuli, International Book Service (1989), Teknologi Automotif, ISBN 967-950-128-0
3. Paul Dempsey, (2008), 4th edition, Troubleshooting and Repair of Diesel Engines
4. Sean Bennet, Ian Andrew Norman, (2011), Heavy Duty Truck Systems
5. David A. Crolla, Butterworth-Heinemann, Burlington, (2009), Automotive Engineering: Powertrain, Chassis System and Vehicle Body
6. David John Leeming, Reg Hertley, Nelson Thornes, (1981), 2nd Edition, Heavy Vehicle Technology

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