LEARNING MODULE

TVET PROGRAM TITLE: Automotive Engine service (Level II)

MODULE TITLE: Service Diesel Fuel Injection System
MODULE CODE: AUM AES2 03 1110

NOMINAL DURATION: 160 Hours

MODULE DESCRIPTION:
This unit covers the knowledge, attitudes and skills required to service diesel fuel
injection systems and components in an automotive retail, service and/or repair context
procedures.
LEARNING OUTCOMES:
1. Prepare for work
2. Service fuel system and components
3. Prepare engine for normal operation

MODULE CONTENTS:
Introduction
 Nature and scope of work requirement
 To working with diesel engine
 To service procedures and techniques
 To diesel vehicle service procedures
 Safety

 Personal Protective Equipment

 OHS regulation
 Housekeeping
A. Drawing and Reading
 Read and sketch diesel fuel system Diagram and Drawing
 Interpretation of Manuals and guidelines
 Read and trussing diesel fuel system
B. Communication
 Automotive diesel fuel system /components terminologies
 Prepare Technical report
 Interpret and prepare work/job order
 Work effectively with others (Manage People performance and relationship)
  Use of communication devices
C. Codes and Regulations
 Collect, organize and understand legal and technical information related to diese
fuel systems
 Ethiopian Pollution control standard and policy
 Vehicle Industry regulation
 Workplace procedure regulation (OH&S)
D. Materials: uses and specifications
 Handling and storage of workshop manuals (service, operation, maintenance &
etc.)
 Automotive diesel fuel system materials uses and specifications
E. Trade Theories System
 Identifying and confirming nature and scope of the work requirements.
 Making workstation ready and safe for servicing works.
 Selecting and preparing Methods appropriate to the circumstances in
accordance with standard operating procedures
 Accessing and interpreting correct information from manufacturer
specifications
 Completing diesel fuel injection system components service without
causing damage to the component or system
- Fuel tank
- Fuel line
- Fuel filter(primary and secondary)
- Feed pump and injection pump
- Injection pump(inline and distributor type)
- Injection nozzle
 Servicing diesel fuel system components
 making adjustments during the service in accordance with manufacturer
specifications
 Testing engine and fuel system for correct operation
 Preparing fuel system for normal operation
 Completing service schedule documentation
 Making final inspection to ensure safety features are in place
 cleaning equipment/engine for use or storage in accordance with workplace
standards
 Processing job card in accordance with workplace procedures
F. Tools and equipment - use and maintenance
 Hand and Power Tools
 Calibration and pressure testing equipment.
 exhaust gas analyser
 vacuum gauge
 pressure gauge
 tachometer

LEARNING STRATEGIES:
 Lecture-discussion
 Group work
 Demonstration
 Observation
 Project work
 Simulation
ASSESSMENT METHODS:
 Oral questioning
 Written test
 Practical test
 Demonstration
 Project work
ASSESSMENT CRITERIA:
LO 1. Prepare for work
1.1 Nature and scope of the work requirements are identified and confirmed.
1.2 Procedures and information such as workshop manuals, specifications and
tooling and equipment are acquired.
1.3 Workstation is made ready and safe for servicing works.
1.4 Methods appropriate to the circumstances are selected and prepared in
accordance with standard operating procedures.
1.5 Resources requirements including support equipment for diesel fuel injection
system servicing are identified and prepared.
1.6 Technical requirements for works are sourced and support equipment identified
and prepared
1.7 OHS and warnings in relation to working with engine are observed throughout the
work operation.
LO 2 Service fuel system and components
2.1 Correct information is accessed and interpreted from manufacturer specifications.
2.2 Service of diesel fuel injection system is carried out in accordance with
manufacturer specifications.
2.3 Diesel fuel injection system components service is completed without causing
damage to the component or system.
2.4 Adjustments made during the service are in accordance with manufacturer
specifications.
2.5 Engine and fuel system are tested for correct operation
LO3 Prepare engine for normal operation
3.1 Service schedule documentation is completed.
3.2 Final inspection is made to ensure protective guards, safety features and cowlings
are in place.
3.3 Final inspection is made to ensure conformance to workplace standards and
expectations.
3.4 Equipment/engine is cleaned for use or storage in accordance with workplace
standards.
3.5 Job card is processed in accordance with workplace procedures.

Annex: Resource Requirements

AUM AES2 03 1110 Service Diesel Fuel Injection System

Item Recommended Ratio
Category/Item Description/ Specifications Quantity
No. (Item: Trainee)
A. Learning Materials
To be prepared by the
1. TTLM 25 1:1
Trainer
Marketing management 3 1:10
Introduction to management 3 1:10
Strength of materials 3 1:10
Ethics and public service
3 1:10
delivery
Risk management 1 1:25
Cost accounting 3 1:10
2. Books
Business management 3 1:10
Automotive vehicle
3 1:10
management
Industrial management 3 1:10
Commercial law 3 1:10
Administrative law 3 1:10
Performance management 3 1:10
Ethiopian Tax & Regulations 1 1:25
Patent & Property Right Law 1 1:25
3. Manuals
Vehicle industry regulation 5 1:5
Policies and guide lines 3 1:10
B. Learning Facilities & Infrastructure
1. Lecture Room 6x8m 2
2. Computer Room 6x8m 1
3. LCD Projector/screen 1-lecture, 1- computer room 2
4. Reading Room 6x8m 1
 5. Whiteboard, portable 2 x 3m with stand 4
Broadband/Wireless internet
6. Internet Service 1
service
Desktop-trainee 25, Trainer-
7. Desktop computer + Tables & Chairs 30 1:1
5
8. Laptop Trainer 5
9. Printer, Heavy 1
10. Printer, color HP, Laser jet 1
11. Photocopier 1
12., Scanner 3 in 1 1
13. Trainers office 4x5m 1
14. Toilet and washing room 2x3m 2
15. Locker room 3x5m 1
16. Metal cabinet/locker Sheet metal 1.5x0.5x0.5m 25 1:1
C. Consumable Materials
1. Diesel fuel
2. rag
3. soap
D Tools and equipment
Safety shoes, Working
clothes, hand gloves, safety 25 in each
1. Personal protective device 1:1
goggle clear, apron, item
respirator, ear plug
Safety shoes, Working
clothes, hand gloves, safety 5 in each
2. Personal protective device 1:1
goggle clear, apron, item
respirator, ear plug
Gasoline, electronically
controlled Engine
3. Live Vehicle 2
management, Automatic
Trans, Body Management
Diesel CRDI, Manual &
4. Live Vehicle Automatic, electronic 2
controlled
Gasoline engine/Electric
5. Hybrid vehicle, Toyota Prius 1
motor drive
Safety shoes, Working
clothes, hand gloves, safety 25 in each
6. Personal protective device 1:1
goggle clear, apron, item
respirator, ear plug
Safety shoes, Working
clothes, hand gloves, safety 5 in each
7. Personal protective device 1:1
goggle clear, apron, item
respirator, ear plug
Gasoline, electronically
controlled Engine
8. Live Vehicle 2
management, Automatic
Trans, Body Management
Diesel CRDI, Manual &
9. Live Vehicle Automatic, electronic 2
controlled
Gasoline engine/Electric
10. Hybrid vehicle, Toyota Prius 1
motor drive
Safety shoes, Working 25 in each
11. Personal protective device 1:1
clothes, hand gloves, safety item
 goggle clear, apron,
respirator, ear plug
Safety shoes, Working
clothes, hand gloves, safety 5 in each
12. Personal protective device 1:1
goggle clear, apron, item
respirator, ear plug
Gasoline, electronically
controlled Engine
13. Live Vehicle 2
management, Automatic
Trans, Body Management
Diesel CRDI, Manual &
14. Live Vehicle Automatic, electronic 2
controlled
Gasoline engine/Electric
15. Hybrid vehicle, Toyota Prius 1
motor drive
16. Screw Driver, set 7 pcs per set 25 1:1
17. Open end wrench set 6mm-32mm 5 1:5
18. Box end wrench set 6mm-32mm 5 1:5
19. Combination wrench set 6mm-32mm 5 1:5
20. Socket wrench set 6mm-32mm 5 1:5
21. Socket wrench set 36mm – 80mm 2 1:10
22 Deep socket wrench set 6mm-32mm 2 1:10
23. Deep socket wrench set 36mm-80mm 1
24. Torque wrench set , 3 pcs/set 300, 200, 100 ft-lb 3
25. Adjustable Wrench 12 inches 5 1:5
26. Screw Driver, set 7 pcs per set 25 1:1
27. Open end wrench set 6mm-32mm 5 1:5
28. Box end wrench set 6mm-32mm 5 1:5
29. Combination wrench set 6mm-32mm 5 1:5
30. Socket wrench set 6mm-32mm 5 1:5
31. Socket wrench set 36mm – 80mm 2 1:10
32. Deep socket wrench set 6mm-32mm 2 1:10
33. Deep socket wrench set 36mm-80mm 1