assessment criteria for - institute of the motor industry

01-09-2011 / Version 4

Assessment Criteria

for

IMI QUALIFICATION

IMI Level 3 Extended Diploma in

Motorsport Vehicle Maintenance

and Repair

I.D: 600/2760/5

To be used in conjunction with Learner Guidance, Candidate

Assessment Summary, and Assessments

For assessor use only: Assessor Verifier Guidance

CENTRE INFORMATION

Please be aware that any legislation referred to in this qualification may be subject to amendment/s

during the life of this qualification. Therefore IMI Approved Centres must ensure they are aware of and

comply with any amendments, e.g. to health and safety legislation and employment practices.

Please be aware that vehicle technologies referred to in this qualification reflect current practice, but may

be subject to amendment/s, updates and replacements during the life of this qualification. Therefore IMI

Approved Centres must ensure they are aware of the latest developments and emerging technologies to

ensure the currency of this qualification.

Please note: the relevance of the information contained in the unit content will vary depending upon the

vehicle types being worked upon. The unit content is for guidance only and is not meant to be prescriptive.

© 2015 IMI

All rights reserved. No part of this publication may be reproduced, stored in retrieval system, or transmitted, in any

form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written

permission of IMI

Requests should be made in writing and addressed to:

Institute of the Motor Industry (IMI)

Fanshaws, Brickendon, Hertford SG13 8PQ

MS ED L3 Motorsport Assessment Criteria

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CONTACT SHEET

Learner Name:

Learner Registration No:

Learner Address:

Learner Tel No:

Learner Email:

Employer Contact:

Employer Name & Address:

Employer Tel No:

Please complete as appropriate:

Witness Name: Witness Name:

Witness Job Title: Witness Job Title:

Witness Signature: Witness Signature:

Witness Name: Witness Name:

Witness Job Title: Witness Job Title:

Witness Signature: Witness Signature:

Assessor Name: Assessor Name:

Assessor Signature: Assessor Signature:

Assessor Name:

Assessor Signature:

Internal Verifier Name: Internal Verifier Name:

Internal Verifier Signature: Internal Verifier Signature:


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IMI Level 3 Extended Diploma in Motorsport Vehicle

Maintenance and Repair

In order to achieve the qualification, learners must achieve a total of 90 credits from the following groups:

Group A: 18 Credits from the Mandatory Generic Units.

Group B: 37 Credits from the Mandatory Motorsport Units

Group C: A minimum of 14 credits from the Optional Units

Group D: A minimum of 21 credits from the Applied Units

Group E: No credits are required from the Additional Units but may be taken if desired

Average GLH approx: 648 hours (however if Generic units completed as part of Level 2, this reduces to

483 hours.)

TQT = 895

Note: Assessments

The assessments for this qualification combine various assessment styles/methodologies in order to suit

the units contained within it.

The table below clarifies what IMI assessments are available for each unit, and whether these

assessments are mandatory (M) or optional (O) for the selected unit.

The key below details the style of assessment/s:

P = Practical Assessments

T = On-line tests (Please note that every knowledge unit has an online test and the test number is the

same as the ‘set ref’.)

W = Written Assessments

Or = Oral Assessments

A = Assignments

Full guidance for each type of assessment is available in the IMI Assessor and Verifier Guidance document

for the Level 2 and Level 3 Extended Diplomas in Motorsport Vehicle Maintenance and Repair (QCF)

(September 2011).

Mandatory Generic Units – Group A

Set Ref: Unit Ref: Unit Title GLH Unit

Level

Credit

Value

Assessments

P T W Or

MS0102

MS0102K

Knowledge of Health, Safety and Good

Housekeeping in the Motorsport Environment

(F/503/3616)

30 2 3 - M O -

MS0102S Skills in Health, Safety and Good Housekeeping

in the Motorsport Environment (F/503/3826) 30 2 4 M - - -

MS3 MS3K Knowledge of Motorsport Event Regulations

(Y/503/3623) 20 2 2 - M O -

MS4

MS4K

Knowledge of Materials, Fabrication, Tools and

Measuring Devices used in the Motorsport

Environment (T/503/3824)

40 2 4 - M O -

MS4S

Skills in Materials, Fabrication, Tools and

Measuring Devices used in the Motorsport

Environment (A/503/3825)

45 2 5 M - - -

TOTAL AVAILABLE 165 18


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Mandatory Motorsport Units – Group B

Set ref: Unit Ref: Unit Title GLH Unit

Level

Credit

Value

Assessments

P T W Or

MS58

MS58K Knowledge of Setting up Motorsport Vehicles

(F/503/3762) 40 3 5 - M M -

MS58S Skills in Setting up Motorsport Vehicles

(R/503/3765) 51 3 6 M - - -

MS57

MS57K Knowledge of Inspecting a Motorsport Vehicle

During Competition (Y/503/3640) 28 2 4 - M O -

MS57S Skills in Inspecting a Motorsport Vehicle During

Competition (M/503/3644) 30 2 4 M - - -

MS60 MS60K

Knowledge of Diagnosing and Rectifying

Motorsport Engine and Ancillary Components

(Y/503/3766)

44 3 6 - M M -

MS61 MS61K

Knowledge of Diagnosis and Rectification of

Motorsport Transmission and Driveline Faults

(D/503/3767)

29 3 4 - M M -

MS62

MS62K Knowledge of Diagnosis and Rectification of

Motorsport Chassis System faults (H/503/3768) 28 3 4 - M M -

MS62S Skills in Diagnosing and Rectifying Motorsport

Chassis System Faults (K/503/3769) 30 3 4 M - - -

TOTAL AVAILABLE 280 37

Optional Units – Group C (Note: There are no IMI Set Assessments for the Optional Units.)


Level Credit

Assessments

P T W Or

MS60 MS60S Skills in Diagnosing and Rectifying Motorsport

Engine and Ancillary Components (D/503/3770) 38 3 5 - - - -

MS61 MS61S Skills in Diagnosing and Rectifying Motorsport

Transmission and Driveline Faults (K/503/3822) 30 3 4 - - - -

MS68

MS68K Knowledge of Removing, Fitting and Trimming

Bodywork to Motorsport Vehicles (F/503/3776) 28 3 4 - - - -

MS68S Skills in Removing, Fitting and Trimming

Bodywork to Motorsport Vehicles (A/503/3761) 30 3 4 - - - -

MS69

MS69K

Knowledge of Diagnosing and Rectifying

Electrical/Electronic Equipment Faults on

Motorsport Vehicles (L/503/3778)

18 3 3 - - - -

MS69S

Skills in Diagnosing and Rectifying

Electrical/Electronic Equipment Faults on

Motorsport Vehicles (H/503/3821)

19 3 3 - - - -

MS74

MS74K

Knowledge of Joining Motorsport Vehicle

Components using a Fusion and non fusion

Processes (K/503/3786)

56 3 7 - - - -

MS74S

Skills in Joining Motorsport Vehicle Components

using a Fusion and Non Fusion Processes

(T/503/3788)

52 3 6 - - - -

MS72

MS72K

Knowledge of Marking Out, Cutting, Shaping and

Forming Sheet and Tube Materials to Fabricate

Motorsport Components (A/503/3789)

34 3 4 - - - -

MS72S

Skills in Marking Out, Cutting, Shaping and

Forming Sheet and Tube Materials to Fabricate

Motorsport Components (M/503/3790)

49 3 6 - - - -


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Optional Units – Group C (cont)


Level Credit

Assessments

P T W Or

MS78

MS78K

Knowledge of Inspecting Motorsport Components

by Penetrant Flaw Detection Techniques

(T/503/3791)

29 3 4 - - - -

MS78S

Skills in Inspecting Motorsport Components by

Penetrant Flaw Detection Techniques

(A/503/3792)

20 3 2 - - - -

MS89

MS89K

Knowledge of Constructing, Installing and Testing

Cable forms and Looms in Motorsport Vehicles

(H/503/3818)

46 3 6 - - - -

MS89S

Skills in Constructing, Installing, Testing Cable

Forms and Looms in Motorsport Vehicles

(F/503/3812)

49 3 6 - - - -

MS90

MS90K

Knowledge of Installing, Setting Up and Testing

Electrical/Electronic Engine/Transmission

Control Units to Motorsport Vehicles

(A/503/3811)

53 3 6 - - - -

MS90S

Skills in Installing, Setting Up and Testing

Electrical/Electronic Engine/Transmission

Control Units to Motorsport Vehicles

(F/503/3809)

67 3 8 - - - -

MS91

MS91K


Visual Display, Computer and Data Acquisition

Systems to Motorsport Vehicles (M/503/3806)

60 3 7 - - - -

MS91S

Skills in Installing, Setting Up and Testing Visual

Display, Computer and Data Acquisition Systems

to Motorsport Vehicles (H/503/3804)

62 3 7 - - - -

MS92

MS92K


Communication Systems to Motorsport Vehicles

(A/503/3839)

55 3 6 - - - -

MS92S

Skills in Installing, Setting up and Testing

Communication Systems to Motorsport Vehicles

(J/503/3844)

38 3 5 - - - -

MS94

MS94K Knowledge of Modifying Motorsport Vehicle

Electrical/Electronic Systems (R/503/3846) 28 3 4 - - - -

MS94S Skills in Modifying Motorsport Vehicle

Electrical/Electronic Systems (H/503/3849) 30 3 4 - - - -

MS101

MS101K Knowledge of Stripping and Rebuilding Engines

for Motorsport Vehicles (Y/503/3850) 40 3 5 - - - -

MS101S Skills in Stripping and Rebuilding Engines for

Motorsport Vehicles (D/503/3851) 53 3 7 - - - -

MS103

MS103K Knowledge of Testing Engines for Motorsport

Vehicles (Fixed Dynamometer) (H/503/3852) 48 3 6 - - - -

MS103S Skills in Testing Engines for Motorsport Vehicles

(Fixed Dynamometer) (K/503/3853) 44 3 5 - - - -

MS105

MS105K Knowledge of Dressing Engines for Motorsport

Vehicles (M/503/3854) 29 3 4 - - - -

MS105S Skills Dressing Engines for Motorsport Vehicles

(T/503/3855) 20 3 2 - - - -

MS106

MS106K Knowledge of Inspecting Motorsport Components

by Magnetic Particle Testing (A/503/3856) 28 3 4 - - - -

MS106S Skills in Inspecting Motorsport Components by

Magnetic Particle Testing (F/503/3857) 30 3 4 - - - -

TOTAL AVAILABLE


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Optional Applied Units – Group D

Unit Ref: Unit Title GLH Unit

Level

Credit

Value

Assessments

T A

EE3 EE3 - Vehicle Electrical and Electronics 3 (D/503/1288) 36 3 7 M M

ICT3 ICT3 - Information Communication and Technology for

Vehicle Repair 3 (J/503/1303) 36 3 7 M M

M3 M3 - Vehicle Mathematics (D/503/1307) 36 3 7 M M

S3 S3 - Vehicle Science (D/503/1310) 36 3 7 M M

TOTAL AVAILABLE

Additional Units – Group E


Level Credit

Assessments

P T W Or

EP2 EP2 Electrically Propelled Vehicle Hazard

Management (A/502/7734) 12 2 2 - M - M

EP3 EP3 Routine Maintenance and Repair Activities on

Electrically Propelled Vehicles (M/502/7732) 16 2 3 M M - -

EP4 EP4 Electrically Propelled Vehicle System Repair and

Replacement (F502/7735) 20 3 4 M M - -

VF02

VF02K

Knowledge of Inspection, Repair and

Replacement of High Performance Light Vehicle

Tyres (T/601/6032)

24 2 3 - M O -

VF02S

Skills in Inspection, Repair and Replacement of

High Performance Light Vehicle Tyres

(K/601/6092)

36 2 4 M - - -

VF04

VF04K Knowledge of Inspection, Repair and

Replacement of Motorcycle Tyres (R/601/6040) 24 2 3 - M O -

VF04S Skills in Inspection, Repair and Replacement

Motorcycle Tyres (T/601/6094) 36 2 4 M - - -

RR03

RR03K Knowledge of Assessing and Securing the

Roadside Situation (A/601/7408) 47 2 6 - M O -

RR03S Skills in Assessing and Securing the Roadside

Situation (F/601/7409) 50 2 5 M - - -

L121 L121 Introduction to Low Carbon Technologies in the

Automotive Industry (Y/602/0011) 20 1 3 - - M -

TOTAL AVAILABLE


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UNIT REF:

MS0102K

UNIT TITLE: KNOWLEDGE OF HEALTH, SAFETY AND GOOD HOUSEKEEPING

IN THE MOTORSPORT ENVIRONMENT

Level: 2 Route: Knowledge Credit Value: 3 GLH: 30

Mapping: This unit is mapped to the SEMTA Unit 01

Rationale: This unit enables the learner to develop an understanding of good housekeeping, using recourses

economically, duties and health and safety legislation in the motorsport environment. It will provide an appreciation of

significant risks in the motorsport environment and how to identify and deal with them. Once completed the learner

will be able to identify hazards and evaluate and reduce risk.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Understand the correct personal and vehicle

protective equipment to be used within the

motorsport environment

1.1. Explain the importance of wearing the types of

PPE required for a range repair activities

1.2. Identify vehicle protective equipment for a range

of repair activities

1.3. Describe vehicle and personal safety

considerations when working at an event

2. Understand effective housekeeping practices in the


2.1. Describe why the motorsport environment should

be properly cleaned and maintained.

2.2. Describe requirements and systems that may be

put in place to ensure a clean motorsport

environment.

2.3. Describe how to minimise waste when using

utilities and consumables

2.4. State the procedures and precautions necessary

when cleaning and maintaining a Motorsport

environment.

2.5. Describe the selection and use of cleaning

equipment when dealing with general cleaning,

spillages and leaks in the motorsport

environment.

2.6. Describe procedures for correct disposal of waste

materials from an motorsport environment

2.7. Describe procedures for starting and ending the

working day which ensure effective housekeeping

practices are followed


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3. Understand key health and safety requirements

relevant to the motorsport environment

3.1. Describe the general legal duties of employers

and employees required by current health and

safety legislation

3.2. Describe key, current health and safety

requirements relating to the motorsport

environment.

3.3. Describe why workplace policies and procedures

relating to health and safety are important

4. Understand about hazards and potential risks

relevant to the motorsport environment

4.1. Identify key hazards and risks in an motorsport

environment

4.2. Describe policies and procedures for reporting

hazards, risks, health and safety matters in the

motorsport environment.

4.3. State precautions and procedures that need to be

taken when working with vehicles, associated

materials, tools and equipment.

4.4. Identify fire extinguishers in common use and

which types of fire they should be used on

4.5. Identify key warning signs and their characteristics

that are found in a Motorsport environment.

4.6. State the meaning of common product warning

labels used in a motorsport environment.

5. Understand personal responsibilities 5.1. Explain the importance of personal conduct in

maintaining the health and safety of the

individual and others

5.2. Explain the importance of personal presentation

in maintaining health safety and welfare


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Content:

Economic use of resources

a. Consumable materials e.g. grease, oils, split pins, locking and fastening devices etc.

Requirement to maintain work area effectively

a. Cleaning tools and equipment to maximise workplace efficiency.

b. Requirement to carry out the housekeeping activities safely and in a way that minimises inconvenience to

customers and staff.

c. Risks involved when using solvents and detergents.

d. Advantages of good housekeeping.

Spillages, leaks and waste materials

a. Relevance of safe systems of work to the storage and disposal of waste materials.

b. Requirement to store and dispose of waste, used materials and debris correctly.

c. Safe disposal of special / hazardous waste materials.

d. Advantages of recycling waste materials.

e. Dealing with spillages and leaks

Basic legislative requirements

a. Provision and Use of Work Equipment Regulations 1992.

b. Power Presses Regulations 1992.

c. Pressure Systems and Transportable Gas Containers Regulations 1989.

d. Electricity at Work Regulations 1989.

e. Noise at Work Regulations 1989.

f. Manual Handling Operations Regulations 1992.

g. Health and Safety (Display Screen Equipment) Regulations 1992.

h. Abrasive Wheel Regulations.

i. Safe Working Loads.

j. Working at Height Regulations (date)

Routine maintenance of the workplace

a. Trainee’s personal responsibilities and limits of their authority with regard to work equipment.

b. Risk assessment of the workplace activities and work equipment.

c. Workplace person responsible for training and maintenance of workplace equipment.

d. When and why safety equipment must be used.

e. Location of safety equipment.

f. Particular hazards associated with their work area and equipment.

g. Prohibited areas.

h. Plant and machinery that trainees must not use or operate.

i. Why and how faults on unsafe equipment should be reported.

j. Storing tools, equipment and products safely and appropriately.

k. Using the correct PPE.

l. Following manufacturer’s recommendations.

m. Location of routine maintenance information e.g. electrical safety check log.

Legislation relevant to Health and Safety

a. HASAWA

b. COSHH

c. EPA

d. Manual Handling Operations Regulations 1992

e. PPE Regulations 1992


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Content: Contd

General regulations to include an awareness of:

a Health and Safety (Display Screen Equipment) Regulations 1992

b Health and Safety (First Aid) Regulations 1981

c Health and Safety (Safety Signs and Signals) Regulations 1996

d Health and Safety (Consultation with Employees) Regulations 1996

e Employers Liability (Compulsory Insurance) Act 1969 and Regulations 1998

f Confined Spaces Regulations 1997

g Noise at Work Regulations 1989

h Electricity at Work Regulations 1989

i Electricity (Safety) Regulations 1994

j Fire Precautions Act 1971

k Reporting of Injuries, Diseases and Dangerous Occurrences Regulations 1985

l Pressure Systems Safety Regulations 2000

m Waste Management 1991

n Dangerous Substances and Explosive Atmospheres Regulations (DSEAR) 2002

o Control of Asbestos at Work Regulations 2002

Legislative duties:

a. The purpose of a Health and Safety Policy.

b. The relevance of the Health and Safety Executive.

c. The relevance of an initial induction to Health and Safety requirements at your workplace.

d. General employee responsibilities under the HASAWA and the consequences of non-compliance.

e. General employer responsibilities under the HASAWA and the consequences of non-compliance.

f. The limits of authority with regard to Health and Safety within a personal job role.

g. Workplace procedure to be followed to report Health and Safety matters.

Precautions to be taken when working with vehicles, workshop materials, tools and equipment including electrical

safety, pneumatics and hydraulics

a. Accessing and interpreting safety information

b. Seeking advice when needed

c. Seeking assistance when required

d. Reporting of unsafe equipment

e. Storing tools, equipment and products safely and appropriately

f. Using the correct PPE

g. Following manufacturers recommendations

h. Following application procedures e.g. hazardous substances

I. The correct selection and use of extraction equipment

PPE to include:

a. Typical maintenance procedures for PPE equipment to include:

i. typical maintenance log

ii. cleaning procedures

iii. filter maintenance

iv. variation in glove types

v. air quality checks

b Choice and fitting procedures for masks and air breathing equipment.

c. Typical workplace processes which would require the use of PPE to include:

i. welding

ii. sanding and grinding

iii. filling

iv. panel removal and replacement

v. drilling

vi. cutting

vii. chiselling

viii. removal of broken glass

ix. removal of rubber seals from fire damaged vehicles

x. removal of hypodermic needles

xi. servicing activities

xii. roadside recovery

d. Unserviceable PPE.


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Content: Contd

e. PPE required for a range Motorsport repair activities. To include appropriate protection of:

i. eyes

ii. ears

iii. head

iv. skin

v. feet

vi. hands

vii. lungs

Fire and extinguishers

a. Classification of fire types

b. Using a fire extinguisher effectively.

c. Types of Extinguishers

i. foam

ii. dry powder

iii. CO2

iv. water

v. fire blanket

Action to be taken in the event of a fire to include:

a. The procedure as:

i. raise the alarm

ii. fight fire only if appropriate

iii. evacuate building

iv. call for assistance

Product warning labels to include:

a. Reasons for placing warning labels on containers.

b. Warning labels in common use, to include:

i. toxic

ii. corrosive

iii. poisonous

iv. harmful

v. irritant

vi. flammable

vii. explosive

Warning signs and notices

a. Colours used for warning signs:

i. red

ii. blue

iii. green

b Shapes and meaning of warning signs:

i. round

ii. triangular

iii. square

c. The meaning of prohibitive warning signs in common use.

d. The meaning of mandatory warning signs in common use.

e. The meaning of warning notices in common use.

f. General design of safe place warning signs.


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Content: contd

Hazards and risks to include:

a. The difference between a risk and a hazard.

b. Potential risks resulting from:

i. the use and maintenance of machinery or equipment

ii. the use of materials or substances

iii. accidental breakages and spillages

iv. unsafe behaviour

v. working practices that do not conform to laid down policies

vi. environmental factors

vii. personal presentation

viii. unauthorised personal, customers, contractors etc entering your work premises

ix. working by the roadside

x. vehicle recovery

c. The employee’s responsibilities in identifying and reporting risks within their working environment.

d. The method of reporting risks that are outside your limits of authority.

e. Potential causes of:

i. fire

ii. explosion

iii. noise

iv. harmful fumes

v. slips

vi. trips

vii. falling objects

viii. accidents whilst dealing with broken down vehicles

Personal responsibilities

a. The purpose of workplace policies and procedures on:

i. the use of safe working methods and equipment

ii. the safe use of hazardous substances

iii. smoking, eating , drinking and drugs

iv. emergency procedures

v. personal appearance

b. The importance of personal appearance in the control of health and safety.

Action to be taken in the event of colleagues suffering accidents

a. The typical sequence of events following the discovery of an accident such as:

i. make the area safe

ii.remove hazards if appropriate i.e. switch off power

iii. administer minor first aid

iv. take appropriate action to re-assure the injured party

v. raise the alarm

vi. get help

vii. report on the accident

b. Typical examples of first aid which can be administered by persons at the scene of an accident:

i. check for consciousness

ii.stem bleeding

iii. keep the injured person’s airways free

iv. place in the recovery position if injured person is unconscious

v. issue plasters for minor cuts

vi. action to prevent shock i.e. keep the injured party warm

vii. administer water for minor burns or chemical injuries

viii. wash eyes with water to remove dust or ingress of chemicals (battery acid)

ix. need to seek professional help for serious injuries

c. Examples of bad practice which may result in further injury such as:

i. moving the injured party

ii.removing foreign objects from wounds or eyes

iii. inducing vomiting

iv. straightening deformed limbs


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UNIT REF:

MS0102S

UNIT TITLE: SKILLS IN HEALTH, SAFETY AND GOOD HOUSEKEEPING IN THE

MOTORSPORT ENVIRONMENT

Level: 2 Route: Skills Credit Value: 4 GLH: 30

Mapping: This unit is mapped to SEMTA unit 01

Rationale: This unit will enable the learner to develop the skills required to carry out area cleaning, clearing away,

dealing with spillages, disposal of waste and debris. The learner will also be able to Identify hazards and risks in the

motorsport environment and complying with relevant legislation and good practice and work safely at all times within

the motorsport environment, both as an individual and with others.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Be able to use correct personal and vehicle

protection within the motorsport environment

1.1. Select and use personal protective equipment

throughout activities. To include appropriate

protection of:

a. eyes

b. ears

c. head

d. skin

e. feet

f. hands

g. lungs

1.2. Select and use vehicle protective equipment

throughout all activities

2. Be able to carry out effective housekeeping practices

in the motorsport environment

2.1. Select and use cleaning equipment which is of the

right type and suitable for the task

2.2. Use utilities and appropriate consumables,

avoiding waste

2.3. Use materials and equipment to carry out cleaning

and maintenance duties in allocated work areas,

following Motorsport work environment policies,

schedules and manufacturers instructions

2.4. Perform housekeeping activities safely and in a

way which minimizes inconvenience to customers

and staff

2.5. Keep the work area clean and free from debris

and waste materials

2.6. Keep tools and equipment fit for purpose by

regular cleaning and keeping tidy

2.7. Dispose of used cleaning agents, waste materials

and debris to comply with legal and workplace

requirements


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3. Be able to recognise and deal with dangers in order

to work safely within the motorsport workplace

3.1. Name and locate the responsible persons for

health and safety in their relevant workplace

3.2. Identify and report working practices and hazards

which could be harmful to themselves or others

3.3. Carry out safe working practices whilst working

with equipment, materials and products in the


3.4. Rectify health and safety risks encountered at

work, within the scope and capability of their job

role

4. Be able to conduct themselves responsibly 4.1. Show personal conduct in the workplace which

does not endanger the health and safety of

themselves or others

4.2. Display suitable personal presentation at work

which ensures the health and safety of

themselves and others at work

EVIDENCE REQUIREMENTS

1. You must produce evidence of use of personal and

vehicle protection, cleaning the work environment and

disposal of waste on 2 separate occasions.

2. You must produce evidence of identifying risks which

may result from at least 2 of the items listed below:

the use and maintenance of machinery or equipment

the use of materials or substances

working practices which do not conform to laid down

policies

unsafe behaviour

accidental breakages and spillages

environmental factors

3. You must produce evidence of identifying risks.

4. You must produce evidence of following at least 2 of the

workplace policies listed below:

the use of safe working methods and equipment

the safe use of hazardous substances

smoking, eating, drinking and drugs

what to do in the event of an emergency

personal presentation


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UNIT REF: MS3K UNIT TITLE: KNOWLEDGE OF MOTORSPORT EVENT REGULATIONS


Mapping:

Rationale: This unit enables the learner to develop an understanding of the rules and regulations surrounding race

meetings and how to keep safe with colleagues in the motorsport work environment.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Understand the structure, roles and responsibilities at

motorsport racing events

1.1. Identify the purpose of the different sections/areas of a

motorsport race meeting

1.2. Identify organisational structures and lines of communication

within the motorsport event work environment

1.3. Describe levels of responsibility within specific jobroles in a

Motorsport team

1.4. Identify definitions and categories of meetings

1.5. State the role of the scrutineer

1.6. State the terms of reference and duties of the Officials

2. Understand key rules and regulations relating to motorsport

at racing events

2.1. Identify racing eligibility including licences and capacity of

motorsport vehicles

2.2. Describe any special clothing requirements for different roles

at a motorsport event

2.3. Identify fire extinguishers and requirements at a motorsport

event

2.4. Describe the restriction that apply to the movement of

vehicles at a motorsport event

2.5. Identify who has access to the track

2.6. Identify flags and flag signals used at a race meeting

including lights

2.7. Describe the regulations applying to practice

2.8. State the rules and regulations that apply to the working area

and vehicle preparation

2.9. State the behaviour that is required during an event

2.10. State typical penalties that can be imposed by the officials

2.11. Describe the definition of the pit lane or service area, and pit

lane or service area procedures

2.12. Describe event start procedures


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UNIT REF: MS4K

UNIT TITLE: KNOWLEDGE OF MATERIALS, FABRICATION, TOOLS AND

MEASURING DEVICES USED IN THE MOTORSPORT

ENVIRONMENT


Mapping: This unit is mapped to SEMTA units 57, 58, 59 & 60

Rationale: This unit enables the learner to develop an understanding of the correct selection, care and use of key

hand tools and measuring devices for modification, fabrication and repair in the motorsport environment and the

correct application of motorsport engineering fabrication and fitting principles

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Understand how to select, use and care for hand

tools and measuring devices in the motorsport

environment

1.1. Identify and explain the use of common types of

hand tools used for fabricating and fitting in the


1.2. Identify and explain the use of common measuring

devices used for fabrication and preparation in the


1.3. Describe, within the scope of their responsibilities,

how to select, prepare and maintain hand tools,

measuring devices and PPE used for fabrication

and preparation in the motorsport environment

1.4. State the limitations of common hand tools and

measuring devices used for fabricating and

preparation in the motorsport workplace

1.5. Explain how common hand tools and measuring

devices used for fabricating, repair and fitting in the

motorsport environment should be stored and

maintained

1.6. Identify common electrical measuring tools used in

the preparation of motorsport vehicles and

components

1.7. Explain the preparation and safe and correct use of

common electrical tools when measuring voltage,

current and resistance

2. Understand how to prepare and use common

workshop equipment

2.1. Describe the preparation and safe use of workshop

equipment

2.2. Explain the term: safe working load


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3. Understand how to select materials when

fabricating, modifying and preparing vehicles and

fitting components

3.1. Describe the properties, application and limitations

of ferrous and non-ferrous metals, including their

safe use.

3.2. Describe the properties, application and limitations

of common non-metallic materials, including their

safe use

3.3. Define common terms relating to the properties of

materials

4. Understand how to apply automotive engineering,

fabrication and fitting principles when preparing

motorsport vehicles and components

4.1. Describe how to tap threads, file, cut and drill

plastics and metals when preparing motorsport

vehicles

4.2. Describe how to measure, mark out, shape and join

materials when fabricating

4.3. Describe the selection and fitting procedures of the

following:

a. gaskets and seals

b. sealants and adhesives

c. fittings and fasteners

d. electrical circuit components

4.4. Identify locking, fastening, fixing, and securing

devices

4.5. State the importance of correct operating

specifications for limits, fits and tolerances in the


Content:

1. The specific safety precautions to be followed when working in a fabrication environment and when carrying out

joining activities using fabricated components (general workshop and site safety, appropriate personal protective

equipment, accident procedure; statutory regulations, risk assessment procedures and COSHH regulations)

2. The personal protective clothing and equipment to be worn when carrying out the joining activities (leather gloves,

eye protection, safety helmets, etc)

3. The hazards associated with the joining operations (such as handling sheet/fabricated components, using hot

metal, handling and using sealants and cleaning agents, dangerous or badly maintained tools and equipment),

and how they can be minimised

4. Mechanical properties and use examples of materials to illustrate these properties

a. State the definitions of the following mechanical properties:

i. ductility

ii. malleability

iii. hardness

iv. toughness

v. elasticity

vi. plasticity

vii. weld ability

viii. conductivity

ix. insulation

b. Give examples of materials and components exhibiting the above properties.

c. Describe ways in which the above properties can be changed temporarily or permanently to include:

i. heating

ii. alloying

iii. cold working

iv. heat treatments


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Content:

5. Define and distinguish between classes of materials

a. Define classes of materials as:

i. metals

ii. non metals

iii. synthetic

iv. natural

b. Classify metals into:

i. ferrous

ii. non ferrous

iii. pure metals

iv. alloys

6. Factors which affect the selection of listed materials

a. Identify the range of selection factors which determine the use of materials to include:

i. material costs

ii. suitability for use

iii. form of supply

iv. joining characteristics

v. strength

vi. material properties

vii. corrosion resistance

viii. melting point

b. Compare the factors effecting the use of:

i. pure metals

ii. alloys

iii. plastics

7. Listed materials used in repair or construction

a. Identify the types and properties of steels used in construction and repair to include:

i. low carbon steels

ii. medium carbon steels

iii. high carbon steels

iv. cast irons

v. alloy steels

vi. UHSS

b. Describe the properties of common non ferrous metals used in construction and repair to include:

i. aluminium

ii. zinc

iii. lead

iv. tin

v. copper

c. Compare and identify listed non-metals used in repair or construction to include:

i. plastics

ii. glass

iii. fabrics

iv. leather

v. rubber

d. Define the terms:

i. thermo plastic

ii. thermo setting plastics

e. Identify the uses and properties of materials used for interior furnishings such as:

i. rubber

ii. fabric

iii. leather

iv. glass

f. Give examples of common plastics used in repair and construction including:

i. ABS

ii.polyethylene

iii. polypropylene

iv. polyester

v. acrylic

vi. glass reinforced plastic


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Content:

8. Pure metals and alloys and list common alloys in motor vehicles

a. Explain the basic structure of metals in terms of simple grain structure to include:

i. single type grains

ii. mixtures

b. Explain the term alloy in terms of:

i. grain structure

ii. properties

iii. advantages of using alloys

iv. comparisons with pure metals

c. State the constituents and general properties of the following alloys:

i. solder

ii. stainless steel

iii. low carbon steel

iv. brass

v. bronze

vi. aluminium alloys including duralumin

9. Ways in which the properties of metals can be changed temporarily or permanently

a. Explain the advantages of changing the material properties temporarily

b. Explain the effects of changing the material properties permanently

c. State the advantages of changing materials properties

d. State that material properties can be changed by:

i. heat treatment

ii. cold working

iii. alloying

10. How to obtain the necessary drawings and joining procedure specifications

11. The use of manufacturers’ specifications for the types of fasteners used

12. The various joining processes that are used, and the tools and equipment required

13. The preparations to be carried out on the materials/components prior to joining them (such as materials to

be degreased, dry and clean, with holes and flanges de-burred)

14. How to set up and align the joints prior to fixing, and the tools and methods that

can be used (such as clamps, temporary fixings, jacking and supporting devices)

15. How to produce a secure joint

16. The range of bolts and screwed fasteners that are to be used; why it is important to use the correct type of

washer; sequence of tightening bolts on flanged joints; and the tools and equipment used to ensure they

are tightened to the required torque

17. Checks to be carried out on the tools and equipment prior to use to ensure that they are in a safe and

usable condition (such as condition of plugs and leads on power tools, condition of striking faces on

hammers)

18. Equipment setting, operating and care procedures; why equipment and tools need to be correctly set up and

in good condition

19. The importance of using the tools only for the purpose intended; the care that is required when using the

equipment and tools; the proper way of preserving and storing tools and equipment between operations


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UNIT REF: MS4S UNIT TITLE: SKILLS IN MATERIALS, FABRICATION, TOOLS AND MEASURING

DEVICES USED IN THE MOTORSPORT ENVIRONMENT


Mapping: This unit is mapped to SEMTA 56, 57, 58, 59 & 60

Rationale: This unit helps the learner to develop the skills required for the correct selection, care and use of key hand

tools and measuring devices for modification, fabrication and repair in the motorsport environment. The correct

preparation and use of common work equipment. The correct selection and fabrication of materials used when

modifying and repairing and the correct application of engineering fabrication and fitting principle

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Be able to select, maintain and use

and hand tools and measuring devices

in the motorsport environment

1.1. Select, maintain and use suitable hand tools safely when

fabricating and fitting in the motorsport workplace

1.2. Select, maintain and use suitable measuring devices safely when

fabricating and fitting in the motorsport environment

1.3. Select, maintain and use suitable PPE for fabrication, repair and

fitting in the motorsport environment.

1.4. Select, maintain and use suitable electrical measuring tools

safely when repairing vehicles and components

2. Be able to prepare and use common

workshop equipment

2.1. Use suitably maintained workshop equipment safely

2.2. Use correct interpretation of ‘safe working load’ on lifting and

supporting equipment.

2.3. Report any faulty or damaged tools and equipment to the relevant

persons clearly and promptly.

2.4. Store work tools and equipment in a safe manner that permits

ease of access and identification for use.

3. Be able to select materials when

fabricating, modifying and repairing

vehicles and fitting components

3.1. Select and use appropriate materials whilst constructing, fitting,

modifying or repairing vehicles and components.


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4. Be able to apply motorsport

engineering, fabrication and fitting

principles when modifying and

repairing vehicles and components

4.1. Use correct procedures when:

a. filing,

b. tapping threads

c. cutting plastics and metals

d. drilling plastics and metals.

e. fitting

4.2. Use appropriate techniques when fabricating, repairing and

modifying vehicles and components

4.3. Select and use:

a. gaskets

b. seals

c. sealants

d. fittings and fasteners

4.4. Apply modification and repair techniques to motorsport electrical

circuits

4.5. Select and use locking, fixing and fastening devices


1. You must produce evidence of undertaking basic routine

checks of hand tools, measuring devices and workshop

equipment covering all of those listed below:

electrical

mechanical

pneumatic

hydraulic

2. You must produce evidence of fabricating at least 1 item

from suitable materials to known tolerances, which

includes the following processes

filing

tapping threads

cutting

drilling

joining

3. You must be observed by your assessor carrying out

routine checks and during stages of fabrication


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UNIT REF: MS58K UNIT TITLE: KNOWLEDGE OF SETTING UP MOTORSPORT VEHICLES


Mapping: Mapping: The unit has links with the SEMTA National Occupational Standards in Automotive Engineering

Suite 3, particularly unit 58

Rationale: This unit enables the learner to develop an understanding of the knowledge they need to set up a

motorsport vehicle prior to a competition, in a recognised sequence and to a high standard.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Understand how to set up a

motorsport vehicle prior to

competition

1.1. Explain the procedures for obtaining the information required during

the setting up of motorsport vehicles

1.2. Explain the set-up methods and techniques used to meet the

team’s requirements, and the importance of adhering to these

procedures

1.3. Explain the need for set-up adjustments when setting up a

motorsport vehicle for a competition

1.4. Describe how the set-up adjustments are to be made

1.5. Identify the quality control procedures to be followed during the set-

up activities

1.6. Explain the various tests and checks to be carried out on

completion of the set-up activities

1.7. Describe set-up problems (such as inability to set to correct

specification)

Content:

Please note: the relevance of the information below will vary depending upon the vehicle types being worked

upon. It is for guidance only and is not meant to be prescriptive.

Set-up activities

1. obtain and use the appropriate documentation (such as job instructions, company and/or manufacturer’s

specification, set-up information and documentation, quality control documentation)

2. adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment

and other relevant safety regulations and procedures to realise a safe system of work

3. ensure that any appropriate environmental conditions can be met

4. ensure that the work area is suitably prepared for the set-up to take place

5. obtain approval to carry out the set-up activities

6. position and secure the vehicle, using the correct equipment

7. provide safe access and working arrangements for the set-up area

8. ensure that correct personal protective equipment is worn for the task being undertaken

9. ensure that any required consumables are available

10. dispose of waste items in a safe and environmentally acceptable manner

11. leave the work area in a safe and appropriate condition and free from foreign objects


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Content:

Appropriate methods and techniques to set up a motorsport vehicle:

1. selecting and preparing an appropriate flat area for setting up the vehicle

2. determining the appropriate amount of ballast required for the vehicle (where appropriate)

3. using the correct equipment for jacking the vehicle when making adjustments

4. setting, aligning and adjusting motorsport vehicle components

5. making mechanical connections

6. tightening fastenings to the required torque

7. removing all bodywork, fairings, covers and hatches, and storing them correctly

8. ensuring that the motorsport vehicle is supported on the appropriate stands/supports prior to being

worked on

9. obtaining all the required tools and equipment for carrying out a motorsport vehicle set-up, and checking

that they are in a safe and usable condition

10. ensuring that the setting-up activity is carried out in the correct sequence

Tools used during the set-up activities:

1. pressure gauges

2. toe-in equipment

3. corner weight scales

4. castor gauges

5. angle gauges

6. camber gauges

7. data calibration devices

8. bump steer gauges

9. ride height measuring tools

10. levelling devices

11. Ackerman plates

Motorsport vehicle set-up adjustments:

1. measure and adjust ride heights

2. measure and adjust bump steer

3. check and adjust cambers

4. check and adjust castor

5. check and adjust damper packer clearances

6. check and adjust toe-in

7. check and adjust corner weights

8. calculate total vehicle weight

9. wing settings

10. change road springs

11. adjust drive chain tension

12. change sprocket ratio

13. check operation/calibration of data sensors

14. check and adjust damper settings

15. check and adjust track or wheelbase

16. check and adjust anti-dive or squat

Vehicle regulation checks

1. overall track width

2. wheelbase

3. front wing dimensions

4. rear wing dimensions

5. operation of lighting systems

6. bumper overhangs

7. ground clearance

8. minimum weight

Compliance of motorsport vehicles

1. race associations (such as FIA, MSA)

2. BS, ISO or BSEN standards and procedures

3. vehicle manufacturer’s specification

4. customer standards and requirements

5. team/company standards and procedures

6. specific vehicle requirements


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Content:

Passing of relevant information regarding the setting-up of the vehicle

1. driver

2. team manager

3. chief mechanic

4. No1 mechanic

5. other appropriate person


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UNIT REF: MS58S UNIT TITLE: SKILLS IN SETTING UP MOTORSPORT VEHICLES




Rationale: This unit enables the learner to develop an understanding of the skills they need to set up a motorsport

vehicle prior to a competition, in a recognised sequence and to a high standard.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Be able to work safely when setting up

a motorsport vehicle

1.1. Use suitable personal protective equipment when setting up

motorsport vehicles

1.2. Work in a way which minimises the risk of damage or injury to the

vehicle, people and the environment

2. Be able to use relevant information to

carry out the task

2.1. Select suitable sources of technical information to support the

setting up of motorsport vehicles

2.2. Use sufficient information in a systematic way to carry out the

required work

3. Be able to use appropriate tools and

equipment

3.1. Select the appropriate tools and equipment necessary for setting

up motorsport vehicles

3.2. Ensure that equipment has been calibrated to meet

manufacturers’ requirements

3.3. Use the equipment required, correctly and safely throughout all

motorsport setting up activities

4. Be able to carry out motorsport setting

up activities

4.1. Use setting up methods that are relevant to the type of

competition

4.2. Evaluate the dismantled sub-assemblies for condition and

suitability for setting up accurately

4.3. Carry out all setting up activities following:

a teams instructions

b recognised researched methods

c health and safety requirements

4.4. Ensure all repaired or replacement components and units conform

to the vehicle operating specification

4.5. Adjust components and units correctly to ensure that they operate

to meet system requirements

4.6. Use testing methods that are suitable for assessing the

performance of the system rectified

4.7. Ensure the rectified motorsport system performs to the vehicle

operating specification

5. Be able to record information and

make suitable recommendations

5.1. Produce work records that are accurate, complete and passed to

the relevant person(s) promptly in the format required

5.3. Record and report any additional faults noticed during the course

of their work promptly in the format required


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1. You must be observed by your assessor successfully

carrying out the setting up of 1 motorsport vehicle prior to

the competition

Observation Ref:


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UNIT REF: MS57K UNIT TITLE: KNOWLEDGE OF INSPECTING A MOTORSPORT VEHICLE

DURING COMPETITION


Mapping: The unit has links with the SEMTA National Occupational Standards in Automotive Engineering Suite 3,

particularly unit 57

Rationale: This unit enables the learner to develop an understanding of carrying out a range of inspections on

motorsport vehicles using a variety of prescribed testing and inspection methods

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Understand how to carry out

inspections on motorsport vehicles

using prescribed methods

1.1. Explain the difference between the various prescribed motorsport

vehicles inspection methods to include:

a. pre-competition

b. post-competition

c. during competition

1.2. Identify the different systems to be inspected when using the

prescribed inspection methods

1.3. Identify the procedures involved in carry out the systematic

inspection of the prescribed inspection methods on motorsport

vehicles

1.4. Explain how to record and complete the inspection results in the

format required

1.5. Identify the recommendations that can be made based on results of

the motorsport vehicle inspections

1.6. Explain the implications of failing to carry out motorsport vehicle

inspections activities correctly

1.7. Explain the procedure for reporting damage to motorsport vehicle

components

1.8. State the tools and equipment used in inspection activities, and their

calibration/care and control procedures

1.9. Explain the need to control and account for all tools and equipment

used during the inspection activities at an event or competition


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Content:



1. Vehicle Inspections

a. using a torque wrench to spanner-check wheel nuts, bolts and other critical fastenings

b. ensuring that fuel tanks are filled to their correct capacity

c. checking that suitable tyres are fitted, that they are free from damage and are at the correct cold

pressures

d. checking for correct oil pressure prior to engine warm-up

e. checking engine temperatures and pressures during warm-up

f. pressurising the cooling system after initial start-up

g. testing that the throttle operation reaches 100% opening

h. checking that power steering fluid levels are correct and free from leaks

i. checking that hydraulic brake and clutch fluids are at the correct levels, and that the brake balance is set

j. inflating damper bump canisters, using the appropriate gases

k. checking that clutch operating clearance is correct, and that gear selection is satisfactory through all

gears

l. testing that electrical systems are operating correctly

m. checking spherical bearings and wheel bearings for play

n. checking that all bodywork, fairings, wings, covers and hatches are correctly secured

o. checking that the driver is fitted correctly into the seat, and that seat belts are securely fastened

p. ensuring that the fire extinguisher bottle is full and the system is armed

q. ensuring that wheels are correctly torqued, and locking mechanisms are in place

r. ensuring that the driver has the appropriate vehicle information prior to entering the vehicle or

competition (such as amount of fuel, type of tyres and pressures, track conditions, vehicle geometry

changes, brake balance, brake condition)

s. cleaning the bodywork, fairings, windscreen and other relevant areas of the vehicle

t. checking that the work area/vehicle track access lane is free from tools, equipment and foreign objects

2. Completion of documentation to include:

i. inspection records

ii. job cards

iii. vehicle records

3. Make recommendations based on results of vehicle inspections to:

i. driver/rider

ii. team manager

iii. chief mechanic

iv. No1 mechanic

v. other appropriate person


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UNIT REF: MS57S UNIT TITLE: SKILLS IN INSPECTING A MOTORSPORT VEHICLE DURING

COMPETITION




Rationale: This unit allows the learner to develop skills to carry out a range of motorsport vehicle inspections on

vehicles using a variety of prescribed testing and inspection methods.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Be able to work safely when carrying

out motorsport vehicle inspections

using prescribed methods

1.1. Use suitable personal protective equipment and vehicle coverings

throughout all motorsport vehicle inspection activities




carry out the task

2.1 Select suitable sources of technical information to support

motorsport vehicle inspection activities including:

a. vehicle technical data

b. inspection procedures

c. legal requirement

2.2 Use technical information to support motorsport vehicle

inspection activities

3 Be able to use appropriate tools and

equipment

3.1. Select the appropriate tools and equipment necessary for

carrying out a range of inspections on motorsport vehicle

systems


manufacturers’ and legal requirements

3.3 Use the correct tools and equipment in the way specified by

manufacturers when carrying out a range of inspections on

motorsport vehicle systems

4. Be able to carry out motorsport

vehicle inspections using prescribed

methods

4.1. Plan the inspection activities before they are started

4.2. Carry out motorsport vehicle inspections using prescribed

methods, adhering to the correct specifications and tolerances

for the vehicle and following health and safety requirements

4.3. Ensure that inspected motorsport vehicle conforms to the vehicle

operating specification and any legal requirements

4.4. Use suitable testing methods to evaluate the performance of the

inspected systems

5 Be able to record information and







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1. You must be observed by your assessor carrying out at

least 1 inspection from the following: Observation Ref:

Pre-competition inspection

Post-competition inspection

During race inspection


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UNIT REF: MS60K UNIT TITLE: KNOWLEDGE OF DIAGNOSING AND RECTIFYING MOTORSPORT

ENGINES AND ANCILLARY COMPONENTS



Suite 3, particularly unit 60, 66and 67

Rationale: This unit enables the learner to develop an understanding of diagnosis and rectification of engine

mechanical, electrical, hydraulic and fluid systems. It also covers the evaluation and performance of motorsport

engine systems.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Understand how the motorsport

engine systems operate

1.1. Explain the construction and operation of motorsport engine

systems to include:

a. SI fuel systems

b. CI fuel systems

c. ignition systems

d. engine management

e. valve mechanisms

f. pressure charged induction systems

g. exhaust emission reduction systems

h. ventilation and cooling

1.2. Explain the interaction between electrical, electronic and

mechanical components within motorsport engine systems

1.3. Explain how electrical systems interlink and interact, including

multiplexing and fibre optics

1.4. Compare motorsport engine system components and assemblies

against alternatives to identify differences in construction and

operation

1.5. Identify the engineering principles that are related to motorsport

engine systems

a. volumetric efficiency

b. flame travel, pre ignition and detonation

c. fuel properties

d. composition of carbon fuels

e. combustion process

f. exhaust emissions

2. Understand how to diagnose and

rectify faults in motorsport engine

systems

2.1. Describe how to analyse symptoms and causes of faults found in

motorsport engine systems to include:

a. engine mechanical components

b. ignition systems

c. fuel systems

d. engine management system

e. pressure charged induction systems

f. ventilation and cooling

2.2. Explain systematic diagnostic techniques used in identifying engine

system faults

2.3. Explain how to examine, measure and make suitable adjustments

to the components.

2.4. Explain how to carry out the diagnosis and rectification activities in

order to correct the faults in the motorsport engine systems


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2.5. Explain how to select, prepare and use diagnostic and rectification

equipment for motorsport engine systems

2.6. Explain how to evaluate and interpret test results found in

diagnosing motorsport engine system faults against vehicle

manufacturer specifications and settings

2.7. Explain how to evaluate the operation of components and systems

following diagnosis and repair to confirm system performance

Content:



Single and Multi-Point Petrol Injection Systems

a. The operation and construction of single and multi-point injection systems including:

i. types of air flow sensor

ii. fuel supply system

iii. fuel pump

iv. filter

v. fuel regulator

vi. injectors

vii. sequential injection

viii. continuous injection

ix. semi-continuous injection

x. electronic control unit (ECU)

xi. injector pulse width

xii. sensors

b. The operation of each system under various operating conditions including:

i. cold starting

ii. warm up

iii. hot starting

iv. acceleration

v. deceleration

vi. cruising

vii. full load

c. Engine speed limiting and knock sensing.

Engine Management

a. The function and purpose of engine management systems.

b. The difference between analogue, digital, programmable and non-programmable systems.

c. Open loop and closed loop control, types of input and output devices.

d. The function and operation of digital components and systems.

e. The operation of engine management systems under various conditions.

Valve Mechanisms

a. The reasons for variable valve timing and multi-valve arrangements and the effect on performance.

b. Layout of multi-valve arrangements, components, operation and drive arrangements.

c. Construction features and operation of variable valve timing engines and electronic control.


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Content:

Pressure Charged Induction Systems

a. The meaning of volumetric efficiency; explain the effect of volumetric efficiency on engine performance,

torque and power.

b. The methods used to improve volumetric efficiency:

i. variable valve timing

ii. turbo-charging

iii. supercharging

iv. intercoolers

c. The operation of turbo-chargers and the purpose of:

i. turbo-charging

ii. supercharging

iii. intercoolers

iv. waste gates

v. exhaust gas recirculation

d. Advantages and disadvantages of pressure charging induction systems.

Terms Associated with Combustion

a. Flame travel, pre-ignition and detonation.

b. Fuel properties:

i. octane rating

ii. flash point

iii. fire point

iv. volatility

v. composition of petrol and diesel fuels

vi. hydro-carbon content

c. Composition of carbon fuels (petrol and diesel):

i. % hydrogen and carbon

ii. composition of air

iii. % oxygen

iv. % nitrogen

d. Combustion process for spark ignition and compression ignition engines:

i. air fuel ratio

ii. lambda ratio

iii. stoichiometric ratio

e. The by-products of combustion for different engine conditions and fuel mixtures:

i. CO

ii. CO2

iii. O

iv. N

v. H2O

vi. NOx

f. Describe the legal requirements for exhaust emissions;

i. MOT requirements

ii. EURO 3

iii. 4 & 5 regulations

Assessment, Repair and Restoration of Mechanical Engine Components

a. How engine mechanical components are assessed and measured for wear and serviceability:

i. cylinder bores

ii. cylinder heads

iii. crankshaft journals

iv. valve faces

v. valve guides

vi. valve seats

vii. camshafts

b. The methods used for the repair and restoration of engine components.


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Content:

Symptoms and Faults in Engine Mechanical Systems and Components

a. Symptoms and faults related to:

i. worn cylinders

ii. cylinder liners

iii. pistons

iv. piston rings

v. crankshaft

vi. camshaft

vii. bearings

viii. cylinder head and gasket

ix. valves

x. valve seats and valve guides

xi. cambelts

xii. lubrication system and components

xiii. oil pump

xiv. relief valve

xv. filter

xvi. turbo-charger

xvii supercharger

Diagnosis of Faults in Engine Mechanical Systems and Components

a. Interpret information for:

i. diagnostic tests

ii. manufacturer’s vehicle and equipment specifications

iii. use of equipment

iv. testing procedures

v. test plans

vi. legal requirements

b. The preparation of tools and equipment for use in diagnostic testing and assessment.

c. Systematic assessment, testing and inspection of engine components and systems including:

i. mechanical system & component condition

ii. engine balance

iii. power balance

iv. performance and operation

v. wear

vi. run out

vii. alignment

d. Use of appropriate tools and equipment including:

i. compression gauges

ii. leakage testers

iii. cylinder balance tester

iv. pressure gauges

v. micrometers

vi. vernier gauges

e. Evaluate and interpret test results from diagnostic testing.

f. Compare test result and values with vehicle manufacturer’s specifications and settings.

g. The procedures for dismantling, components and systems and the use of appropriate equipment and

procedures.

h. Assess, examine and measure components including:

i. settings

ii. values

iii. condition

iv. wear and performance of components and systems

i. Probable faults

i. malfunctions

ii. incorrect settings

iii. wear

j. Rectification or replacement procedures.

k. Evaluate operation of components and systems following diagnosis and repair to confirm system

performance.


37

01-09-11V4


38

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Content:

Faults and Symptoms in Ignition Systems

a. Ignition system failure or malfunctions including:

i. no spark

ii. misfiring

iii. backfiring

iv. cold or hot starting problems

v. poor performance

vi. pre-ignition

vii. detonation

viii. exhaust emission levels

ix. fuel consumption

x. low power

xi. unstable idle speed

Faults and Symptoms in Electronic Petrol and Diesel Injection Systems

a. Petrol and diesel injection system failures or malfunctions including:

i. cold or hot starting problems

ii. poor performance

iii. exhaust emissions

iv. high fuel consumption

v. erratic running

vi. low power

vii. unstable idle speed

Faults and Symptoms in Engine Management Systems

a. Engine management system failure or malfunctions including:

i. misfiring

ii. backfiring

iii. cold or hot starting problems

iv. poor performance

v. pre-ignition

vi. detonation

vii. exhaust emission levels

viii. fuel consumption

ix. low power

x. unstable idle speed

Diagnosis of Faults in Electronic Ignition, Petrol and Diesel Injection and Engine Management Systems

a. Locate and interpret information for:

i. diagnostic tests

ii. manufacturer’s vehicle and equipment specifications



v. test plans

vi. fault codes

vii. legal requirements

b. The preparation of tools and equipment for use in diagnostic testing and assessment.

c. Conduct systematic assessment, testing of engine systems including:

i. component condition and performance

ii. component settings

iii. component values

iv. electrical and electronic values

v. system performance and operation

vi. use of appropriate tools and equipment including gauges

vii. multi-meter

viii. breakout box

ix. oscilloscope

x. diagnostic tester

xi. manufacturer’s dedicated equipment

xii. exhaust gas analyser

xiii. fuel flow meter

xiv. pressure gauges


39

01-09-11V4

Content:

d. Evaluate and interpret test results from diagnostic testing.

e. Compare test result, values and fault codes with vehicle manufacturer’s specifications and settings.

f. The procedures for dismantling, components and systems using appropriate equipment.

g. Assess, examine and measure components including:

i. settings

ii. input and output values

iii. voltages

iv. current consumption

v. resistance

vi. output patterns with oscilloscope

vii. condition

viii. wear and performance of components and systems

h. Identify probable faults and indications of:

i. faults

ii. malfunctions

iii. incorrect settings

iv. wear

v. values

vi. inputs and outputs

vii. fault codes

i. Rectification or replacement procedures.

j. Evaluation and the operation of components and systems following diagnosis and repair to confirm system

performance.


40

01-09-11V4

UNIT REF: MS61K UNIT TITLE: KNOWLEDGE OF DIAGNOSIS AND RECTIFICATION OF

MOTORSPORT TRANSMISSION AND DRIVELINE FAULTS



particularly unit 61 and 67

Rationale: This unit enables the learner to develop an understanding of diagnosis and rectification of motorsport

gearboxes, hubs and bearings, driveline shafts, clutches, differentials and final drive units. It also covers the

evaluation of performance of the systems

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Understand how the motorsport transmission

and driveline systems operate

1.1. Explain the construction and operation of motorsport

transmission and driveline systems


mechanical components within motorsport transmission

and driveline systems

1.3. Explain how electrical systems interlink and interact,

including multiplexing

1.4. Compare motorsport transmission and driveline system

components and assemblies against alternatives to identify

differences in construction and operation

1.5. Identify the engineering principles that are related to

motorsport transmission and driveline systems

a friction

b torque transmission

c materials

d fluids & energy

e potential & kinetic energy

2. Understand how to diagnose and rectify

faults in motorsport transmission and

driveline systems

2.1. Explain the symptoms and causes of faults found in

motorsport transmission and driveline systems

2.2. Explain systematic diagnostic techniques used in identifying

transmission and driveline system faults

2.3. Explain how to examine, measure and make suitable

adjustments components

2.4. Explain how to carry out the rectification activities in order to

correct the faults in motorsport transmission and driveline

systems

2.5. Explain how to select, prepare and use diagnostic and

rectification equipment for motorsport transmission and

driveline systems


diagnosing motorsport transmission and driveline system

faults against vehicle manufacturer specifications and

settings

2.7. Explain how to evaluate the operation of components and

systems following diagnosis and repair to confirm system

performance


41

01-09-11V4

Content:

Please note: the relevance of the information below will vary depending upon the vehicle types being worked upon. It

is for guidance only and is not meant to be prescriptive.

Electrical and electronic principles related to motorsport transmission systems

a. The operation of electrical and electronic systems and components related to motorsport transmission systems

including:

i. ECU

ii. sensors and actuators

iii. electrical inputs & outputs

iv. voltages

v. oscilloscope patterns

vi. digital and fibre optic principles

b. The interaction between the electrical/electronic system, hydraulic system and mechanical components of the

transmission systems.

c. Electronic and electrical safety procedures.

The operation motorsport clutches and fluid couplings

a. The construction and operation of friction clutches (coil spring, diaphragm) including single and twin clutch

designs.

b. The construction and operation of fluid couplings including:

i. fluid flywheel

ii. torque converter (torque multiplication, efficiency)

iii. benefits of fluid couplings

iv. benefits of toque converter over fluid flywheel

The operation of motorsport transmissions and driveline systems

a. The construction and operation of manual gearboxes:

i. 4, 5 & 6 speed gearboxes

ii. gear arrangements

iii. shaft and bearing arrangements

iv. synchromesh devices

v. interlock mechanisms

vi. linkages

vii. overdrive

viii. lubrication

b. The construction and operation of automatic gearboxes including hydraulic and electronic control systems:

operations of epicyclic gears (sun, planet, annulus and carrier), method for achieving different gear ratios using

epicyclic gearing; hydraulic control systems, components and operation; electronic control system, components

and operation.

c. The construction and operation of continuously variable transmissions (CVT) and the benefits of this type of

gearbox design.

d. The construction and operation of the sequential manual gearbox (SMG).

e. The construction and operation of final drive systems including:

i. conventional crown wheel and pinion

ii. differential gears

iii. limited slip differential

f. The construction and operation of motorsport 4 wheel drive systems including third differential and differential

locks.

g. The operation of motorsport traction control systems and launch control.

h. The construction and operation of motorsport hub arrangements.

i. The construction and operation of:

i. drive shafts

ii. prop shafts including flexible joints and couplings

iii. universal joints

iv. constant velocity joints

v. sliding joints


42

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Content:

Symptoms and faults in motorsport transmissions and drive-line systems

a. Clutch and coupling faults:

i. abnormal noises

ii. vibrations

iii. fluid leaks

iv. slip

v. judder

vi. grab

vii. failure to release

b. Gearbox faults:

i. abnormal noises

ii. vibrations

iii. loss of drive

iv. difficulty engaging or disengaging gears

v. automatic gear box types

vi. abnormal noises

vii. vibrations

viii. loss of drive

ix. failure to engage gear

x. failure to disengage gear

xi. leaks

xii. failure to operate

xiii. incorrect shift patterns

xiv. electrical and electronic faults

c. Final drive faults:

i. abnormal noises

ii. vibrations

iii. loss of drive

iv. oil leaks

v. failure to operate

vi. electrical and electronic faults

d. Drive-lines and couplings:

i. abnormal noises

ii. vibrations

iii. loss of drive

Faults in motorsport transmission systems

a. Interpret information for diagnostic tests, vehicle and equipment specifications, and use of equipment,

testing procedures, test plans, fault codes and legal requirements.

b. How to prepare equipment for use in diagnostic testing.

c. How to conduct systematic testing and inspection of transmission system, mechanical, hydraulic, electrical

and electronic systems using appropriate tools and equipment including, mullet-meters, oscilloscope and

pressure gauges.

d. How to carry out workshop based and road testing of vehicle and transmission system.

e. Evaluate and interpret test results from diagnostic and/or road testing.


g. How to dismantle, components and systems using appropriate equipment and procedures.

h. Assess, examine and evaluate the operation, settings, values, condition and performance of components

and systems.

i. Probable faults, malfunctions and incorrect settings.


k. Operation of systems following diagnosis and repair to confirm operation and performance.

Measurements on components to include:

a. Settings

b. Input and output values

c. Voltages

d. Current consumption

e. Resistance

f. Output patterns with oscilloscope

g. Pressures

h. Condition

i. Wear and performance


43

01-09-11V4

UNIT REF: MS62K UNIT TITLE: KNOWLEDGE OF DIAGNOSIS AND RECTIFICATION OF

MOTORSPORT CHASSIS SYSTEM FAULTS



particularly units 62, 63, 64 & 67

Rationale: This unit enables the learner to develop an understanding of diagnosis and rectification of braking steering

and suspension systems. It also covers motorsport chassis systems and the evaluation of their performance.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Understand how the motorsport

chassis systems operate

1.1. Explain the construction and operation of motorsport chassis

systems to include:

a. electronic braking

b. front and rear wheel geometry

c. four wheel steer

d. hydraulic power steering

e. electronic power steering

f. self levelling suspension

g. ride control system


mechanical components within motorsport chassis systems

1.3. Explain how motorsport chassis electrical systems interlink and

interact, including multiplexing

1.4. Compare motorsport chassis system components and assemblies

against alternatives to identify differences in construction and

operation

1.5. Identify the engineering principles that are related to motorsport

chassis systems

a. inertia force, mass and acceleration

b. laws of friction

c. static’s (springs and torsion bars)

d. hydraulic machines


rectify faults in motorsport chassis

systems

2.1. Explain symptoms and causes of faults found in motorsport

chassis systems


chassis system faults


to the components

2.4. Explain how to carry out the diagnosis and rectification activities in

order to correct the faults in the motorsport chassis systems


equipment for motorsport chassis systems


diagnosing motorsport chassis system faults against vehicle





44

01-09-11V4

Content:



Electrical and electronic principles of light vehicle chassis systems

a. The operation of electrical and electronic systems and components related to light vehicle chassis systems

including:

i. ECU

ii. sensors and actuators

iii. electrical inputs

iv. voltages

v. oscilloscope patterns

vi. digital and fibre optic principles

b. The interaction between the electrical/electronic system and mechanical components of chassis systems.

c. Electronic and electrical safety procedures.

Operation of electronic ABS and EBD braking systems

a. Layout of:

i. ABS and EBD braking systems

ii. anti-lock braking

iii. anti-skid control systems

iv. warning systems

b. Operation of:

i. hydraulic and electronic control units

ii. wheel speed sensors

iii. load sensors

iv. hoses

v. cables and connectors

c. Advantage of ABS and EBD braking systems over conventional braking systems.

d. The relationship and interaction of ABS braking with and other vehicle systems – traction control.

Steering geometry for advanced light vehicle applications

a. Non-steered wheel geometry settings.

b. Front/rear wheel geometry:

i. castor

ii. camber

iii. kingpin or swivel pin inclination

iv. negative offset

v. wheel alignment (tracking)

vi. toe in and toe out

vii. toe out on turns and steered wheel geometry

viii. Ackerman principle

ix. slip angles

x. self-aligning torque

xi. oversteer and understeer

xii. neutral steer

c. The operation and layout of rear and four wheel steering.

d. The construction and operation of power assisted steering systems:

i. hydraulic system

ii. power cylinders

iii. drive belts and pumps

iv. hydraulic valve (rotary, spool and flapper type)

e. The operation of:

i. electronic power steering systems (EPS)

ii. electrical and electronic components

Components and operation of self-levelling suspension

a. The components, construction and operation of a self-leveling suspension system.

b. The operation of self -leveling suspension system under various conditions:

i. self-energising

ii. pump operated self-levelling suspension


45

01-09-11V4

Content:

Operation of fitting ride-controlled systems.

a. The reasons for fitting ride controlled systems.

b. The operation of driver controlled and ride controlled systems.

Symptoms and faults in braking systems

a. Symptoms and faults associated with conventional braking systems, ABS, and EBD systems:

i. mechanical

ii. hydraulic

iii. electrical and electronic systems

iv. fluid leaks

v. warning light operation

vi. poor brake efficiency

vii. wheel locking under braking

Diagnosis and faults in braking systems


i. diagnostic tests

ii. vehicle and equipment specifications



v. test plans

vi. fault codes


b. Prepare equipment for use in diagnostic testing.

c. Conduct systematic testing and inspection of:

i. braking system

ii. ABS

iii. EBD

iv. mechanical

v. hydraulic

vi. electrical and electronic systems

d. Using appropriate tools and equipment including:

i. multi-meters

ii. oscilloscope

iii. pressure gauges




h. Assess, examine and evaluate the operation, settings, values, condition and performance of components

and systems.

i. Probable faults, malfunctions, incorrect settings.



Symptoms and faults associated with steering systems

a. Symptoms and faults associated with steering systems:

i. mechanical

ii. hydraulic

iii. electrical and electronic

iv. steering boxes (rack and pinion, worm and re-circulating ball)

v. steering arms and linkages

vi. steering joints and bushes

vii. idler gears

viii. bearings

ix. steering columns (collapsible and absorbing)

x. power steering system


46

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Content:

Diagnosis and faults in steering systems


i. diagnostic tests




v. test plans

vi. fault codes



c. Conduct systematic testing and inspection of:

i. steering systems

ii. mechanical

iii. hydraulic

iv. electrical and electronic systems

v. power steering system


i. multi-meters

ii. oscilloscope


iv. wheel alignment equipment

v. steering geometry equipment




h. Assess, examine and evaluate the:

i. operation

ii. settings

iii. values

iv. condition and performance of components and systems

i. Probable faults, malfunctions, and incorrect settings.



Symptoms and faults associated with suspension systems

a. Symptoms and faults associated with suspension systems:

i. mechanical

ii. hydraulic

iii. electrical and electronic

iv. conventional

v. self-levelling and ride controlled suspension systems

vi. ride height ( unequal and low)

vii. wear

viii. noises under operation

ix. fluid leakage

x. excessive travel

xi. excessive tyre wear

Diagnosis and faults in suspension systems


i. diagnostic tests




v. test plans

vi. fault codes



47

01-09-11V4

Content:


c. How to conduct systematic testing and inspection of:

i. suspension systems

ii. mechanical

iii. hydraulic

iv. electrical and electronic systems

v. conventional

vi. self-levelling and ride controlled suspension systems


i. multi-meters

ii. oscilloscope


iv. alignment equipment

v. geometry equipment

d. Evaluate and interpret test results from diagnostic testing.

e. Compare test result and values with vehicle manufacturer’s specifications and settings.

f. How to dismantle, components and systems using appropriate equipment and procedures.

g. Assess, examine and evaluate the operation, settings, values, condition and performance of components and

systems.

h. Probable faults, malfunctions and incorrect settings.

i. Rectification or replacement procedures.

j. Operation of systems following diagnosis and repair to confirm operation and performance.


48

01-09-11V4

UNIT REF: MS62S UNIT TITLE: SKILLS IN DIAGNOSING AND RECTIFYING MOTORSPORT

CHASSIS SYSTEM FAULTS



particularly units 62, 63, 64 & 67

Rationale: This unit allows the learner to develop skills to diagnose and rectify motorsport braking steering and

suspension systems faults. It also covers the evaluation of performance of the replaced or repaired units and systems.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA


out motorsport chassis diagnostic

and rectification activities


when using motorsport diagnostic methods and carrying out

rectification activities




carry out the task

2.1. Select suitable sources of technical information to support

motorsport diagnostic and rectification activities including:

a vehicle technical data

b diagnostic test procedures

2.2. Use sufficient diagnostic information in a systematic way to enable

an accurate diagnosis of motorsport chassis system faults


equipment


diagnostic and rectification activities




motorsport chassis diagnostic and rectification activities


chassis diagnosis, rectification and

test activities

4.1. Use diagnostic methods that are relevant to the symptoms

presented

4.2. Evaluate your assessment of dismantled sub-assemblies and

identify their condition and suitability for repair or replacement

accurately

4.3. Carry out all diagnostic and rectification activities following:

a manufacturers’ instructions

b recognised researched repair methods



to the vehicle operating specification and any legal requirements





4.7. Ensure the rectified motorsport chassis system performs to the

vehicle operating specification and any legal requirements


49

01-09-11V4

5. Be able to record information and make

suitable recommendations

5.1. Produce work records that are accurate, complete and passed to the

relevant person(s) promptly in the format required

5.2. Make suitable and justifiable recommendations for cost effective repairs

5.3. Record and report any additional faults noticed during the course of their

work promptly in the format required


1. You must be observed by your assessor carrying out the

diagnosis and rectification of 1 fault occurring in each

system listed. The fault should involve a 2 or more step

diagnostic activity. The evidence must include

demonstration of skill in at least 1 of each: -

mechanical, electrical / electronic or hydraulic units or

components.

Observation Ref:

Steering systems

Suspension systems

Braking systems


50

01-09-11V4


ENGINE AND ANCILLARY COMPONENTS



Suite 3, particularly unit 60 and 67

Rationale: This unit allows the learner to develop skills to diagnose and rectify motorsport engine mechanical,

electrical, hydraulic and fluid systems faults. It also covers the evaluation of performance of the replaced or repaired

units and systems.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA


out motorsport engine diagnostic and








carry out the task




b. diagnostic test procedures


an accurate diagnosis of motorsport engine system faults


equipment




manufacturers’ requirements


motorsport engine diagnostic and rectification activities

4. Be able to carry out motorsport engine

diagnosis, rectification and test

activities


presented


identify their condition and suitability for repair or replacement

accurately






to the vehicle operating specification





4.7. Ensure the rectified motorsport engine system performs to the

vehicle operating specification


51

01-09-11V4





5.2. Make suitable and justifiable recommendations for cost effective

repairs





diagnosis and rectification of faults occurring in 3 out of

the 5 engine systems listed. The faults should involve a 2

or more step diagnostic activity.

Observation Ref:

engine mechanical components

engine management system

pressure charged induction systems

exhaust emission reduction systems

heating, ventilation and cooling


52

01-09-11V4


TRANSMISSION AND DRIVELINE FAULTS



particularly unit 61 and 67

Rationale: This unit allows the learner to develop skills in diagnosing and rectifying motorsport gearboxes, hubs

bearings, driveline shafts, clutches, differentials and final drive unit faults. It also covers the evaluation of

performance of the replaced or repaired units and systems.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA


out motorsport transmission and

driveline diagnostic and rectification

activities




1.2. Work in a way, which minimises the risk of damage or injury to the

vehicle, people or environment.


carry out the task



a vehicle technical data

b diagnostic test procedures


an accurate diagnosis of motorsport transmission and driveline

system faults


equipment





3.3 Use the equipment required, correctly and safely throughout all

motorsport transmission and driveline diagnostic and rectification

activities


transmission and driveline diagnosis,

rectification and test activities


presented

4.2. Evaluate dismantled sub-assemblies for their condition and

suitability for repair or replacement






to the vehicle operating specification and any legal requirements





4.7. Ensure the motorsport transmission and driveline system rectified

performs to the vehicle operating specification and any legal

requirements


53

01-09-11V4





5.2. Make suitable and justifiable recommendations for cost effective

repairs





diagnosis and rectification of faults occurring in 2 of the

systems listed. The fault should involve a 2 or more step

diagnostic activity. The evidence must include

demonstration of skill in at least 2 of the following: -

mechanical, electrical / electronic and hydraulic units or

components.

Observation Ref:

clutch

gearbox

drive line (shafts, couplings, hubs and bearings)

final drive


54

01-09-11V4

UNIT REF: MS68K UNIT TITLE: KNOWLEDGE OF REMOVING, FITTING AND TRIMMING

BODYWORK TO MOTORSPORT VEHICLES




Rationale: This unit enables the learner to develop an understanding of carrying out a range of removal and fitting of

bodywork components and non-permanently fixed motorsport body panels. It also covers the evaluation of the

operation of the components when fitted

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Understand how to carry out

removal and fitting of motorsport

bodywork components

1.1. Identify the procedures involved in carry out the systematic removal

and fitting of motorsport bodywork components to the standard

required

1.2. Identify the procedures involved in working with supplementary

safety systems when fitting motorsport bodywork components

1.3. Identify the procedures involved in working with gas discharge

headlamp systems when fitting basic motorsport bodywork

components

1.4. Explain the methods and procedures for storing removed

motorsport bodywork components

1.5. Identify the different types of fastenings and fixings used when

removing and fitting motorsport bodywork components

1.6. Explain the reasons for the use of different types of fastenings and

fixings used in motorsport bodywork components

1.7. Explain the procedures, methods and reasons for ensuring correct

alignment of motorsport bodywork components

1.8. Identify the quality checks that can be used to ensure correct

alignment and operation of motorsport bodywork components

1.9. Identify correct conformity of vehicle systems against motorsport

specification and legal requirements on completion

1.10. Explain the procedure for reporting cosmetic damage to

motorsport bodywork components and units


55

01-09-11V4

Content:



Body work components to be removed and replaced

a. floor pans

b. door assemblies

c. bonnet assemblies

d. internal trim

e. fairings

f. seat assemblies

g. front wings

h. ducts

i. rear wings

j. side pods

k. splitters

l. engine inlets

m. radiator inlets

n. boot lid assemblies

o. engine covers

p. other trim

Describe procedures to prevent damage to the vehicle, components and contents when removing, storing and

refitting bodywork components

a. The methods that can be used to protect undamaged items to ensure they are removed and refitted without

causing unnecessary damage:

i. bumpers

ii. headlamp units

iii. road wheels

iv. batteries

v. bonnet and boot trim

vi. interior trim components

vii. exterior trim components

b. The procedures for the correct storage of vehicle contents.

c. The process for the reporting of extra damage and items that may have broken when removed or refitted.

The processes involved when handling batteries

a. The procedure for the removal, storage and refitting of lead acid batteries.

b. The procedure for the disposal of lead acid batteries.

c. Battery checks:

i. electrolyte

ii. discharge

iii. specific gravity

d. The charging process and procedures:

i. trickle charge

ii. normal charge

iii. boost / start

e. The health and safety issues involved when charging (explosive gasses).


56

01-09-11V4

Content:

Types of clips and fixings

a. The following types of clips and identify reasons and limitations for their use:

i. speed

ii. ‘c’

iii. ‘d’

iv. ‘j’ type captive nut

v. ‘r’

vi. ‘u’ type captive nut

vii. cable clip

viii. trim clips

b. The following types of fixings and identify reasons and limitations for their use:

i. pop rivet

ii. plastic rivet

iii. plastic capture nut

iv. nut and bolt

v. shoulder bolt

vi. ‘Nyloc’ type nuts

vii. washers

viii. ‘spring’ type washers

ix. self tapping screws and bolts

x. quick release plastic trim fastenings

xi. trim tapes

xii. adhesives and sealers

The processes involved when carrying out quality checks

a. Items that may have been ‘workshop’ soiled and describe processes for rectifying:

i. door cards

ii. seats

iii. carpets

iv. boot and bonnet trims

b. Methods for checking gaps.

c. The process for checking and aligning headlamps:

i. address handling procedures for halogen bulbs

ii. address handling and health and safety issues relating to xenon bulbs and systems

d. Operational checks and rectification methods to include:

i. lights

ii. washers and wipers

iii. SRS systems (checking not rectification)

iv. charging system (checking not rectification)

v. horn

vi. fluid levels

vii. interior switches

viii. operation of door lock mechanisms


57

01-09-11V4

UNIT REF: MS68S UNIT TITLE: SKILLS IN REMOVING, FITTING AND TRIMMING BODYWORK TO

MOTORSPORT VEHICLES




Rationale: This unit allows the learner to demonstrate they can carry out a range of removal and fitting of mechanical,

electrical and trim (bodywork) components and non-permanently fixed motorsport body panels. It also covers the

evaluation of the operation of the components when fitted

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Be able to work safely when carrying out

removal and fitting of bodywork components

and non-permanently fixed motorsport body

panels

1.1. Use suitable personal protective equipment and

vehicle coverings throughout all motorsport removal

and fitting of bodywork components and non-

permanently fixed motorsport body panels

1.2. Work in a way which minimises the risk of damage or

injury to the vehicle, people and the environment

2. Be able to use relevant information to carry out

the task

2.1. Select suitable sources of technical information to

support motorsport removal and fitting activities

including:


b. removal and fitting procedures

c. legal requirements

2.2. Use technical information to support motorsport

removal and fitting activities

3. Be able to use appropriate tools and equipment

3.1. Select the appropriate tools and equipment necessary

for carrying out removal and fitting of bodywork

components and non-permanently fixed motorsport

body panels



3.3. Use the correct tools and equipment in the way

specified by manufacturers when carrying removal

and fitting of bodywork components and non-


4. Be able to carry out removal and fitting of

bodywork components and non-permanently

fixed motorsport body panels

4.1. Remove and fit basic bodywork components and non-


4.2 Ensure that the removal and fitting of bodywork

components and non-permanently fixed motorsport

body panels conforms to the vehicle operating

specification and any legal requirements

4.3 Ensure no damage occurs to other components when

removal and fitting of bodywork components and non-


4.4 Ensure all components and panels are stored safely

and in the correct location


58

01-09-11V4



5.1. Produce work records that are accurate, complete and

passed to the relevant person(s) promptly in the

format required

5.2. Make suitable and justifiable recommendations for

cost effective repairs

5.3. Record and report any additional faults noticed during

the course of their work promptly in the format

required


1. You must be observed by your assessor removing and

replacing 6 of the 16 units or components from the list

below

Observation Ref:

floor pans

door assemblies

bonnet assemblies

internal trim

fairings

seat assemblies

front wings

ducts

rear wings

side pods

splitters

engine inlets

radiator inlets

boot lid assemblies

engine covers

other trim


59

01-09-11V4

UNIT REF: MS69K

UNIT TITLE: KNOWLEDGE OF DIAGNOSING AND RECTIFYING

ELECTRICAL/ELECTRONIC EQUIPMENT FAULTS ON

MOTORSPORT VEHICLES



Suite 3, particularly unit 67 & 69

Rationale: This unit enables the learner to develop an understanding of diagnosis and rectification of motorsport

electrical systems and their units. It also covers the evaluation of performance of the systems.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Understand vehicle electrical and

electronic principles

1.1. Explain the principles of electrical inputs, outputs, voltages,

oscilloscope patterns, digital and fibre optics

1.2. Explain the principles of sensor inputs, computer processing and

actuator outputs.

1.3. Identify sensor types (passive and active)

1.4. Identify the electrical principles that are related to motorsport

vehicle electrical circuits:

2. Understand how motorsport vehicle

electrical systems operate

2.1. Identify advanced motorsport electrical system components

2.2. Explain the construction and operation of motorsport electrical

systems.


mechanical components within the system defined

2.4. Explain the operation of the electrical and electronic systems for

regenerative braking systems

2.5. Explain how electrical systems interlink and interact, including

multiplexing and fibre optics

2.6. Compare motorsport electrical system components and

assemblies against alternatives to identify differences in

construction and operation


rectify faults in electrical systems

3.1. Explain the symptoms and causes of faults found in motorsport

electrical systems


motorsport electrical system faults


to components

3.4. Explain how to carry out the rectification activities in order to

correct the faults in the motorsport electrical systems


equipment for motorsport electrical systems


diagnosing motorsport electrical system faults against vehicle





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01-09-11V4

Content:



The electrical principles that are related to motorsport vehicle electrical circuits:

a. Ohms law

b. Voltage

c. Power

d. Current (AC and DC)

e. Resistance

f. Magnetism

g. Electromagnetism and electromagnetic induction

h. Digital and fibre optic principles

i. Electrical units and symbols

j. Electrical and electronic terminology

k. Relevant electrical safety

Battery and Charging

a. The construction and operation of vehicle batteries including:

i. low maintenance and maintenance free

ii. lead acid and nickel cadmium types

iii. cells

iv. separators

v. plates

vi. electrolyte

b. The operation of the vehicle charging system:

i. alternator

ii. rotor

iii. stator

iv. slip ring

v. brush assembly

vi. three phase output

vii. diode rectification pack

viii. voltage regulation

ix. phased winding connections

x. cooling fan

xi. alternator drive system

Starting

a. The layout, construction and operation of engine starting systems: inertia and pre-engaged principles.

b. The function and operation of the following components:

i. inertia and pre-engaged starter motor

ii. starter ring gear

iii. pinion

iv. starter solenoid

v. ignition/starter switch

vi. starter relay (if appropriate)

vii. one-way clutch (pre-engaged starter motor)

c. The layout, construction and operation of engine starting systems: inertia and pre-engaged principles.

d. The function and operation of the following components:

viii. inertia and pre-engaged starter motor

ix. starter ring gear

x. pinion

xi. starter solenoid

xii. ignition/starter switch

xiii. starter relay (if appropriate)

xiv. one-way clutch (pre-engaged starter motor)


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Content:

Lighting systems and technology

a. Lighting systems should include:

i. Xenon lighting

ii. gas discharge lighting

iii. ballast system

iv. LED

v. intelligent front lighting

vi. blue lights

vii. complex reflectors

viii. fibre optic

ix. optical patterning

Lighting circuits and the relationship between each circuit

a. Circuits must include:

i. Sidelights including number plate lights and marker lights

ii. dipped beam

iii. main beam

iv. dim/dip

v. indicators and hazard lights

vi. high intensity and fog light

Common faults and testing methods associated with external lighting system

a. Fault diagnosis for:

i. lighting systems failing to operate correctly

ii. switches

iii. relays

iv. bulbs failing to operate

The operating principles of external lighting systems and multiplexing systems

a. To include all external lighting systems and a good knowledge of multiplexing systems.

The different types of electric windows, and mirror systems and components

a. Components should include:

i. window

ii. mirror motors

iii. multi-functional switches

iv. relays

The function of component parts in the electric window and mirror systems

a. Components must include:

i. motors

ii. relays

iii. interfaces

iv. modules

v. switches

The operating principles of electric windows and mirror systems

a. Operating principles of the following:

i. motors

ii. interfaces

iii. switches

iv. modules

Common faults and testing methods associated with electric windows mirror systems


i. electric windows failing to open or close

ii. electric mirrors fail to adjust

iii. slow operation on both systems


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Content:

The different types of screen heating systems and components

a. Systems must include:

i. heated front screens

ii. heated rear screens

iii. heated mirrors

The function and operating principles of components for heated screen and mirror systems


i. front screen elements

ii. mirror elements

iii. time control relays

iv. multifunction relays and switches

Common faults and testing methods associated with heated screen and mirror systems

a. Faults must include:

i. screen elements not operating

ii. timer relays not operating and staying on permanently

The different types of integrated security/warning systems and components

a. Components to include:

i. control units

ii. alarm modules

iii. audible warning units

iv. immobiliser units

v. sensing units

vi. horn

vii. audible warning speakers

The function of component parts in integrated security and warning systems

a. Components to include

i. control units

ii. alarm modules

iii. audible warning units

iv. interior sensing systems

v. immobiliser units

vi. relays

vii. LED’s

viii. horns

The operating principles of integrated security and warning systems

a. Operation of alarm systems and audible warning units.

The relevant legislation relevant to security and warning systems

a. Find and apply all relevant legislation for the fitment and use of security and warning systems.

Common faults and testing methods associated with security and warning systems

a. Components to include:

i. control units

ii. audible warning units

iii. immobiliser units

iv. horns

v. relays

vi. LED’s

vii. wiring

viii. connections and protection devices

ix. removal and refitting procedures

x. using computer diagnostics to identify faults

xi. use of manufacturers diagnostic equipment


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Content:

The different wiper system components


i. wiper motors

ii. washer motors

iii. wiper linkage

iv. multifunction relays

v. headlamp wash/wipe

The function of component wiper and washer components

a. Components and systems must include:

i. wiper motors

ii. intermittent wash wipe relays

iii. parking systems

The operating principles, faults and testing methods of wiper and washer systems

a. Principles, fault diagnosis and testing for:

i. wiper motors failing

ii. damaged linkages

iii. incorrect operation of intermittent and parking systems

iv. earth faults

v. control unit failure

The different heater, cooling system components and air con.

a. Components include:

i. heater motors

ii. speed rheostats,

iii. switches

iv. valves

v. radiator cooling fan motors

vi. relays

vii. air conditioning units

The function of component heater, cooling parts and air conditioning


i. heater motors

ii. rheostats

iii. valves

iv. switches

v. relays

vi. cooling fan motors

vii. air conditioning units

viii. thermostatic switches

The operating principles of heater, cooling systems and air conditioning

a. Principles to include:

i. conduction

ii. convection

iii. radiation

iv. circulation

v. boiling points

vi. states of matter (Gas, liquid, solid)

vii. temperature control

viii. antifreeze mixtures

ix. heat transfer


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Content:

Common faults and testing methods associated with heater, cooling systems and air conditioning


i. heater motor failing to operate on all/one speed

ii. radiator cooling fan not operating

iii. valves

iv. relays

v. switches not operating

vi. electrical related faults on the air conditioning system

The different types of locking system components

a. Door locking actuators, solenoids, deadlocking actuators, anti-theft modules.

The function of component parts in the locking system

a. Solenoids, actuators (electrical and pneumatic), multifunctional relays, anti-theft modules and release systems.

The operating principles of locking systems

a. Doors and cabs

Common faults and testing methods associated with locking systems

a. Door locking actuators, solenoids, connections, wiring, relays, and protection devices/fuses

The different types of Supplementary Restraint and Airbag systems


i. control units

ii. sensors

iii. seat belt pre-tensioner

iv. airbag assemblies

v. wiring systems

vi. warning systems

The function of component parts in the Supplementary Restraint and Airbag systems


i. control units

ii. interfaces

iii. sensors

iv. airbag units

v. pre-tensioner

The operating principles of Supplementary Restraint and Airbag systems

a. Operation of the sensors.

b. Operation of the airbag unit.

c. Operation of the various types of pretension.

d. Safe handling procedures and regulations.

Common faults and testing methods associated Supplementary Restraint and Airbag systems

a. Fault diagnosis for Airbag and SRS faults:

i. fault code identification

ii. wiring faults

iii. component failure

iv. earth problems

v. sensor faults.


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Content:

How to examine, measure and make suitable adjustments to components are:

a. Settings

b. Input and output values

c. Voltages

d. Current consumption

e. Resistance

f. Input and output patterns with oscilloscope (including frequency and duty cycle measurements)

g. Condition

h. Wear and performance

How to select, prepare and use diagnostic and rectification equipment for motorsport electrical systems:

a. Voltmeters

b. Ammeters

c. Ohmmeters

d. Multi-meters

e. Battery testing equipment

f. Dedicated and computer based diagnostic equipment

g. Oscilloscopes


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UNIT REF: MS69S

UNIT TITLE: SKILLS IN DIAGNOSING AND RECTIFYING

ELECTRICAL/ELECTRONIC EQUIPMENT FAULTS ON

MOTORSPORT VEHICLES




Rationale: This unit will help the learner to develop the skills required to demonstrate they can diagnose and rectify

motorsport vehicle electrical system faults. It also covers the evaluation of performance of the replaced or repaired

units and systems.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Be able to work safely when carrying out

motorsport vehicle electrical diagnostic and


1.1. Use suitable personal protective equipment and vehicle

coverings throughout when carrying out electrical diagnostic

and rectification activities

1.2. Work in a way which minimises the risk of damage or injury

to the vehicle, people and the environment

2. Be able to use relevant information to carry

out the task


motorsport vehicle diagnostic and rectification activities

including:


b. diagnostic test procedures

2.2. Use sufficient diagnostic information in a systematic way to

enable an accurate diagnosis of motorsport electrical

system faults


equipment





3.3. Use the equipment required, correctly and safely throughout

all motorsport electrical diagnostic and rectification

activities

4. Be able to carry out motorsport vehicle

electrical diagnosis, rectification and test

activities


presented


identify their condition and suitability for repair or

replacement accurately


a. manufacturers’ instructions

b. recognised researched repair methods

c. health and safety requirements

4.4. Ensure all repaired or replacement components and units

conform to the vehicle operating specification and any legal

requirements

4.5. Adjust components and units correctly to ensure that they

operate to meet system requirements



4.7. Ensure the rectified motorsport electrical system performs to

the vehicle operating specification and any legal

requirement


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passed to the relevant person(s) promptly in the format

required

5.2. Make suitable and justifiable recommendations for cost

effective repairs

5.3. Record and report any additional faults noticed during the

course of their work promptly in the format required


1. You must be observed by an assessor carrying out

diagnosis and rectification activities from 3 different

systems out of the 9 listed below, which covers the

learning outcomes. The fault should involve a 2 or more

step diagnostic activity.

Observation Ref:

lighting systems

starting systems

communication systems

data acquisition system

direct current power supply system

auxiliary power supply system

instrumentation, indication and warning systems

electrical/electronic control system

safety and emergency systems


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UNIT REF: MS74K UNIT TITLE: KNOWLEDGE OF JOINING MOTORSPORT VEHICLE

COMPONENTS USING FUSION AND NON FUSION PROCESSES




Rationale: This unit enables the learner to develop an understanding of different types of fusion and non fusion joining

process

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Understand how to work safely when

carrying out fusion and non fusion process

on vehicles used in motorsport

1.1 Explain and explain the health, safety and legal

requirements relating to the joining of materials using

fusion and non fusion techniques

1.2 Describe the importance of selecting, using and maintaining

the appropriate personal protective equipment when joining

materials using fusion and non fusion techniques to

include:

a. face mask with appropriate eye protection

b. protective flame retardant coveralls

c. protective flame retardant gauntlets

d. steel toe cap boots

e. appropriate vehicle protection

f. appropriate protection for others in the workshop

g. fume mask

1.3 Explain the requirements for protecting the vehicle and

contents from damage before, during and after the joining

of materials by fusion and non fusion techniques

2. Understand how to select, check, use and

maintain appropriate tools and equipment

used in fusion and non fusion process

2.1. Explain the use of all tools and equipment required to join

materials using fusion and non fusion techniques

2.2. Describe, within the scope of their responsibilities, how to

select, prepare and maintain tools and equipment required

to join materials using fusion and non fusion techniques

3. Understand how to carry out fusion and

non fusion joining process on vehicle used

in motorsport

3.1. Explain the importance of correct surface preparation

methods to ensure a good joining process is achieved

3.2. Describe the correct need for alignment/mating of

materials and the best methods used to achieve this in

fusion and non fusion joining

3.3. Explain the joining processes, techniques and joints used

for the joining of materials using fusion and non fusion

joints to include:

a. lap plug

b. lap joint

c. butt joint

d. fillet joint

3.4. Explain the faults and defects that can occur when carrying

out fusion and non fusion joining

3.5. Explain common causes which produce the faults and

defects in fusion and non fusion

3.6. Describe the types of quality control checks that can be

used to ensure correct joining of materials


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3.7. Describe how to inspect and assess fusion and non fusion

joining in accordance to British Standards

3.8. Explain the advantages and disadvantages of fusion and

non fusion joining

3.9. Explain the importance and implications of checking and

carrying out test pieces prior to carrying out the joining

process

Content:



1. The safe working practices and procedures to be observed when working with fusion and non fusion

equipment (general workshop and site safety; appropriate personal protective equipment; fire prevention;

protecting other workers from the effects of the welding arc; safety in enclosed/confined spaces; fume control;

accident procedure; statutory requirements, risk assessment procedures and relevant requirements of

HASAWA, COSHH and Work Equipment Regulations; safe disposal of waste materials)

2. The correct handling and storage of gas cylinders (manual handling and use of cylinder trolley, leak detection

procedures, relevant BCGA codes of practice, cylinder identification, gas pressures, cylinder and equipment

safety features, emergency shutdown procedures)

3. The hazards associated with arc welding (live electrical components; poor earthing; the electric arc; fumes and

gases; gas supply leaks; spatter, hot slag and metal; elevated working; enclosed spaces; slips, trips and falls),

and how they can be minimised

4. The manual MIG, MAG or cored wire arc welding process (basic principles of fusion welding, AC and DC power

sources, ancillary equipment, power ranges, care of equipment)

5. The consumables associated with all fusion and non fusion joining

6. The types of welded joints to be produced (fillet and butt welds, single and multi-run welds, sheet and sections;

welding positions)

7. Setting up and restraining the joint (the use of jigs and fixtures, manipulators and positioners, restraining

devices, tack welding size and spacing in relationship to material thickness)

8. Preparing the welding equipment and checks that need to be made to ensure that it is safe and ready to use

(electrical connections, power return and earthing arrangements; wire feed mechanisms, gas supply, setting

welding parameters, correct joint set-up, cleanliness of materials used; calibration before use; routine care

and maintenance of equipment)

9. The techniques of operating the joining equipment to produce a range of joints in the various joint positions

(fine tuning parameters, correct manipulation of the welding gun, safe closing down of the welding equipment)

10. The importance of complying with job instructions and the joining procedure specification

11. Problems that can occur with the joining activities and how these can be overcome (causes of distortion and

methods of control, effects of welding on materials and sources of weld defects; methods of prevention)

12. The organisational quality systems used and weld standards to be achieved; weld inspection and test

procedures used (including visual and non-destructive tests)

13. Personal approval tests, and their applicability to your work

14. The extent of your own authority and whom you should report to if you have problems that you cannot resolve

15. Reporting lines and procedures, line supervision and technical experts


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UNIT REF: MS74S UNIT TITLE: SKILLS IN JOINING MOTORSPORT VEHICLE COMPONENTS

USING FUSION AND NON FUSION JOINING PROCESSES




Rationale: This unit allows the learner to demonstrate they can carry out different types of fusion and non fusion

joining process

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Be able to work safely when carrying out fusion

or non fusion joining processes on motorsport

vehicles

1.1 Wear suitable personal protective equipment and use

suitable vehicle coverings throughout all fusion and

non fusion joining operations including:

a. face mask with appropriate eye protection

b. protective flame retardant coveralls

c. protective flame retardant gauntlets

d. steel toe cap boots

e. appropriate vehicle protection

f. appropriate protection for others in the workshop

g. fume mask

1.2 Work in a way which minimises the risk of damage or


2. Be able to use relevant information to carry out

the task


support fusion or non fusion joining processes on

vehicle involved in motorsport including:


b. welding procedures


2.2. Interpret technical information to support fusion or non

fusion joining processes on vehicle involved in

motorsport including:


b. welding procedures




for carrying out fusion or non fusion joining processes

on vehicle involved in motorsport

3.2. Check all tools and equipment that are required are in

a safe working condition

3.3 Set up and use the correct tools and equipment in the

way specified by manufacturers when carrying fusion

or non fusion joining processes on vehicle involved in

motorsport

3.4 Clean and store PPE and equipment in the appropriate

manner


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4. Be able to carry out fusion or non fusion joining

processes on vehicle involved in motorsport

4.1. Carry out surface preparation to ensure a good joint is

achieved

4.2. Check for correct alignment/mating and treatment of

flanges to enable a suitable join to be achieved

4.3. Carry out fusion or non fusion joining processes

including:

a. lap plug

b. lap joint

c. butt joint

d. fillet joint

4.4. Carry out fusion or non fusion joining processes

following:

a. manufacturers processes, methods and procedures

b. test procedures and providing test coupons on

equivalent material in accordance with British

Standards

c. recognised researched repair methods

d. health, safety and legal requirements

e. workplace procedures

4.5. Dress the weld area without reducing material

thickness and protect the area to inhibit corrosion

where applicable

4.6. Recognise when the joint is not forming correctly and

what action needs to be taken

4.7. Inspect and assess all fusion or non fusion joining

processes for quality in accordance with British

Standards and manufacturers specification

4.8. Check the integrity of the joint and record the type of

joint achieved on the appropriate paperwork.

4.9. Avoid damaging other components, units, panels and

surfaces on the vehicle and the surrounding work area.

Any damage caused should be correctly reinstated

4.10. Ensure no damage is incurred to other vehicle

systems when fusion or non fusion joining


the course of their work promptly in the format

required

4.12. Work to the specified timescale for the activity



5.1. Identify and report any expected delays in completion

to the relevant person(s) promptly in the format

required.



required.


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You must be observed by your assessor carrying out 2

different fusion processes and 2 different non-fusion

processes from the list below. 3 different types of joint must

be produced for the fusion process 1 type of joint must be

produced for the non fusion process

You must be observed by your assessor joining four of the

following motorsport vehicle components and in two different

positions

Observation Ref:

Fusion Processes

MIG/MAG welding

MMA welding

TIG welding

Oxy-acetylene welding

Non - Fusion Processes

Soldering

Brazing

MIG Brazing

Silver Soldering

Adhesive

Motorsport Vehicle Components

Wishbones

Uprights

Water or oil coolers

Roll cages

Radiator tanks

Chassis components

Swirl pots

Panels

Wings/bodywork

Space frames

Exhaust systems

Jigs and fixtures

Header tanks

Heat exchangers

Pedals

Brackets

Other specific components


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UNIT REF: MS72K

UNIT TITLE: KNOWLEDGE OF MARKING OUT, CUTTING, SHAPING AND

FORMING SHEET AND TUBE MATERIALS TO FABRICATE

MOTORSPORT COMPONENTS



particularly unit 071, 072 & 073

Rationale: This unit enables the learner to develop an understanding of marking out, cutting, shaping and forming

motorsport components

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can:

Mapped to NOS unit

072

1. Understand how to extract and use

information from engineering

drawings in the production of

components used in motorsport

1.1 Extract and use information from engineering drawings and related

specifications

1.2 Interpret first and third angle engineering drawings

1.3 Explain imperial and metric measurement systems

1.4 Identify the tolerance system

1.5 Interpret marking out conventions

2. Understand how to mark out sheet

and tube materials to fabricate


2.1. Identify the procedures involved in marking out motorsport

components for fabrication

2.2. Explain the reasons for the marking out motorsport components

for fabrication

2.3 Identify the quality checks that can be used to ensure correct

marking out of motorsport components

2.4 Describe Things that can go wrong when marking out motorsport-

specific fabricated components, and how these can be avoided

3. Understand how to cut and shape

sheet and tube materials to

fabricate motorsport components

3.1 Describe preparations that they may have to be carry out on the

material prior to cutting it

3.2 Identify the procedures involved in cutting and shaping motorsport

components for fabrication


cutting and shaping of motorsport components

3.4 Describe things that can go wrong when cutting and shaping

motorsport-specific fabricated components, and how these can be

avoided

4. Understand how to form sheet and

tube materials to fabricate


4.1. Identify the procedures involved in forming motorsport components

for fabrication

4.2. Identify the material characteristics and process considerations to

be taken into account when cutting and shaping sheet metal and

tubular sections


forming of the motorsport components

4.4 Describe things that can go wrong when forming motorsport

specific fabricated components, and how these can be avoid


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Content:



1. The specific safety precautions to be taken when working with sheet and tube materials in a motorsport

fabrication environment (such as general workshop safety, appropriate personal protective equipment,

accident procedure; statutory requirements, risk assessment procedures and relevant requirements of

HASAWA, COSHH and Work Equipment Regulations; safe disposal of waste materials)

2. The personal protective clothing and equipment to be worn when carrying out marking out, cutting, shaping

and forming activities (overalls, leather gloves, eye protection, ear protection)

3. The correct methods of moving or lifting sheet metal and tubular sections

4. Safe working practices and procedures to be observed when using manual and power operated tools

5. The hazards associated with marking out, cutting, shaping and forming sheet and tube materials, and with the

tools and equipment used (such as using dangerous or badly maintained tools and equipment, operating

guillotines, and when using hand and bench shears), and how to minimise them and reduce any risks

6. The procedures for obtaining the necessary drawings and specifications, and how to check that they are the

latest issue

7. How to extract and use information from engineering drawings and related specifications (to include symbols

and conventions to appropriate BS, ISO or BSEN standards) in relation to work undertaken

8. How to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece

reference points and system of tolerancing

9. How to interpret the marking-out conventions on the materials to be cut and shaped (such as cutting lines,

centre lines)

10. The tools and techniques available for marking out, cutting, shaping and forming sheet metal (such as tin

snips, bench shears, guillotines, portable power tools, bench drills, saws)

11. Preparations that you may have to carry out on the material prior to cutting it

12. The material characteristics and process considerations to be taken into account when marking out, cutting,

shaping and forming sheet metal and tubular sections

13. The use and care of tools and equipment, including checks that need to be made to ensure that the tools are

fit for purpose (such as tools are sharp and undamaged, plugs and cables are secure and free from damage,

machine guards or safety devices are operating correctly)

14. Setting and adjusting tools and equipment (such as the use of back stops on guillotines)

15. The importance of using tools or equipment only for the purpose intended; the care that is required when

using the tools or equipment; the proper way of preserving tools or equipment between operations

16. Things that can go wrong when marking out, cutting, shaping and forming sheet metal and tubular sections,

and how these can be avoided

17. The importance of using the machine guards and safety protection equipment at all times

18. Inspection techniques that can be applied to check that shape and dimensional accuracy are to specification

and within acceptable limits

19. The extent of your own authority and to whom you should report if you have problems that you cannot resolve


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UNIT REF: MS72S

UNIT TITLE: SKILLS IN MARKING OUT, CUTTING, SHAPING AND FORMING

SHEET AND TUBE MATERIALS TO FABRICATE MOTORSPORT

COMPONENTS




Rationale: This unit allows the learner to demonstrate they can mark out, cut, shape and form component used in

motorsport

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Be able to work safely when marking out, cutting,

shaping and forming materials to produce motorsport

components

1.1. Use suitable personal protective equipment a

throughout all fabricating activities

1.2. Work in a way which minimises the risk of

damage or injury to the vehicle, people and

the environment

2. Be able to use relevant information to carry out the

task

2.1. Select suitable sources of technical

information to support marking out, cutting,

shaping and forming materials to fabricate


2.2. Use technical information to support marking

out, cutting, shaping and forming materials to

fabricate motorsport components


3.1. Select the appropriate tools and equipment

necessary for marking out, cutting, shaping

and forming materials to fabricate motorsport

components

3.2. Ensure that equipment has been calibrated to

meet manufacturers’ and legal requirements

3.3. Use the correct tools and equipment in the

way specified by manufacturers when

marking out, cutting, shaping and forming

materials to fabricate motorsport

components

4. Be able to mark out, cut, shape and form sheet and

tube material to fabricate motorsport components

4.1. Mark out, cut, shape and form sheet and tube

materials to fabricate motorsport

components using appropriate methods

4.2 Ensure that the marking out, cutting, shaping

and forming complies with the specification

4.3 Ensure no damage occurs to other

components

4.4 Ensure all components and are stored safely

and in the correct location


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5. Be able to record information and make suitable

recommendations

5.1. Produce work records that are accurate,

complete and passed to the relevant

person(s) promptly in the format required

5.2. Make suitable and justifiable

recommendations for cost effective repairs

5.3. Record and report any additional faults

noticed during the course of their work

promptly in the format required


You must produce evidence of marking out, cutting, shaping

and forming 2 from the following list. You must produce

evidence of working with 2 different materials. You must

produce evidence of producing 5 of the shapes listed

Evidence Ref:

● wishbones

● uprights

● water or oil coolers

● roll cages

● space frames

● swirl pots

● panels

● wings/bodywork

● header tanks

● radiator tanks

● heat exchangers

● pedals

● brackets

● other specific components

Shapes

swaged holes

external curved contours

round holes

square holes

straight cuts

cut-ins (straight and curved)

notches

complex concave/convex profiles


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UNIT REF: MS78K UNIT TITLE: KNOWLEDGE OF INSPECTING MOTORSPORT COMPONENTS BY

PENETRANT FLAW DETECTION TECHNIQUES




Rationale: This unit allows the learner to demonstrate the knowledge needed to carry out penetrant flaw detection

tests on ferrous or non-ferrous motorsport components, materials or structures and in accordance with approved

procedures.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Understand how to prepare motorsport

vehicle components for inspection by

penetrant flaw detection

1.1. Explain the reasons why some components, materials or

structures need to be tested using non-destructive

testing methods

1.2. Explain how obtain the necessary job instructions,

testing specifications, and how to interpret their

information

1.3. Explain why it is sometimes necessary to use a range of

different non-destructive testing methods

1.4. Identify penetrant flaw detection equipment

1.5. Explain the characteristics of penetrant flaw detection

testing

1.6. Identify the different types of penetrants

1.7. Identify the different types of penetrant removers

1.8. Identify the various types of developers

1.9. Identify the types of lighting that is required with


1.10. Explain the preparations that need to be carried out

before penetrant flaw detection

2. Understand how to inspect motorsport

vehicle components by penetrant flaw

detection

2.1. Identify the procedures to be adopted to obtain the

necessary job instructions

2.2. Explain the techniques to operate the equipment to

produce clear indications of flaws

2.3. Describe how to carry out testing activities

2.4. Identify the types of defect that are detectable using

penetrant flaw detection methods

2.5. Explain how to recognise the defects from the developed

indications

2.6. State the level of defects that are acceptable in the

motor components

2.7. Explain why it is critical that records of penetrant flaw

detection on the products, materials or structures are

accurate, comprehensive and maintained legibly

2.8. Describe quality control systems and standards


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Content:



1. The specific safety precautions to be taken when carrying out penetrant flaw detection activities on

motorsport components, materials or structures

2. The hazards associated with carrying out the penetrant flaw detection activities and with the tools and

equipment used (such as using inflammable materials, toxic and volatile material, use of aerosol containers

and safety in the use of sprays and powders), and how to minimise them and reduce any risks

3. The type(s) of personal protective equipment (PPE) to be used, and how to obtain it

4. The COSHH regulations relating to materials used during the penetrant flaw detection process

5. How to obtain the necessary job instructions, testing specifications, and how to interpret their information

6. The reasons why some components, materials or structures need to be tested using non-destructive testing

methods

7. Why it is sometimes necessary to use a range of different non-destructive testing methods (such as magnetic

particle, penetrant flaw detection, ultrasonic and radiography)

8. The various types of penetrant flaw detection equipment used (such as portable kits and fixed installations;

containers and dispensers for penetrants, removers and developers)

9. The basic concepts of penetrant flaw detection testing (such as the type and characteristics of penetrant

liquids; how the liquids are absorbed by capillary flow into the surface of the product, breaking any

discontinuities/flaws in the products)

10. How to develop indications of the discontinuities/flaws so that they show up clearly

11. The different types of penetrants that are used (such as colour and fluorescent intensity, methods of applying

them and contact time required to be effective)

12. The various types of penetrant removers (such as solvents, water-soluble and oil-soluble emulsifiers)

13. The various types of developers that are used (such as dry powder, powder in aqueous and non-aqueous

carriers, developers in solution), and the contact times required for effective development

14. The type of lighting that is required for the defects to show up clearly

15. The preparations to be carried out on the test area (such as degreasing); the effect of finish, contaminants

and testing temperature on the test results achieved

16. How to carry out the testing activities (such as the application of the penetrant, removal of excess penetrant,

contact time, drying of products, application of developer, conditions for viewing developed indications (such

as ambient light or ultraviolet (UV) light), and cleaning of the products on completion of the testing activities 17. The types of defect that are detectable using penetrant flaw detection methods

18. How to recognise the defects from the developed indications, and how to identify false indication of effects

and their cause

19. The level of defects that are acceptable in the components, materials or structures; influence of the defects

on the service/performance of the components, materials or structures

20. Why it is critical that records of penetrant flaw detection on the products, materials or structures are accurate,

comprehensive and maintained legibly

21. The person that you need to pass the inspection records too


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22. The extent of your own responsibility, and to whom you should report if you have problems that you cannot

resolve


80

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UNIT REF: MS78S UNIT TITLE: SKILLS IN INSPECTING MOTORSPORT COMPONENTS BY

PENETRANT FLAW DETECTION TECHNIQUES




Rationale: This unit allows the learner to demonstrate the skills needed to carry out penetrant flaw detection tests on

ferrous or non-ferrous motorsport components, materials or structures and in accordance with approved procedures.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Be able to work safely when inspecting

motorsport components by penetrant flaw

detection techniques


coverings throughout all activities




out the task


support inspecting motorsport components by


2.2. Use technical information to support inspection activities


equipment


for inspecting motorsport components by penetrant flaw

detection techniques



3.3. Use the correct tools and equipment in the way specified

by manufacturers when inspecting motorsport

components by penetrant flaw detection techniques

4. Be able to carry out inspections of motorsport

components by penetrant flaw detection

techniques

4.1. Inspect motorsport components using appropriate

methods

4.2. Ensure that the inspection complies with the acceptance

criteria

4.3. Identify any defects or variation from the specification

4.4. Ensure all components and are stored safely and in the

correct location





required


effective repairs


the course of their work promptly in the format required


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You must be observed by your assessor carrying out penetrant

flaw detection on one of the following using the correct

procedures and processes:

Observation Ref:

● welded joints

● motorsport mechanical components (such as brake disks,

cylinder heads, drive shafts)

● motorsport/vehicle structures (such as chassis members)

● other specific components or materials


82

01-09-11V4

UNIT REF: MS89K UNIT TITLE: KNOWLEDGE OF CONSTRUCTING, INSTALLING AND TESTING

CABLEFORMS AND LOOMS IN MOTORSPORT VEHICLES




Rationale: This unit allows the learner to demonstrate the knowledge needed to construct, install and tests cableforms

and looms in motorsport vehicles, in accordance with approved procedures.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 2. Understand how to prepare for the

construction and installation of cableforms

and looms in motorsport vehicles

1.1. Explain how to obtain and interpret information required

from drawings and specifications to construct and install

cableforms and looms used in motorsport

1.2. Identify the cableforms or looms to be constructed or

installed for a particular system

1.3. Explain the function of the cableforms within a particular

system

1.4 Describe the different types of cabling

1.5. Explain the different types of electrical components to be

installed

1.5 Describe the types of fastening methods to be used

1.6 Explain the reason for anti-vibration mounting

1.7. Describe how to determine if cableforms are fit for

purpose using British and International standards

1.8. Explain why electrical bonding is critical, and why it must

be both mechanically and electrically secure

1.9. Identify problems with construction and installation of

motorsport vehicle cableforms and wiring looms, and

the importance of informing the appropriate people of

non-conformances

2. Understand how to construct and install

cableforms and looms in motorsport

vehicles

2.1. Describe the methods used to layout the various cables

to produce the required loom

2.2. Explain the methods of harnessing the various cables to

form the loom

2.3. Explain how to correctly align and position cableforms

and looms

2.4. Explain the importance of correct routeing and securing

of cableforms and looms

2.5. Describe the different techniques used to position, align,

support, secure and distribute cabling through the

motorsport vehicle

2.6. Describe how to extract and insert cables through-

bulkhead penetration without causing damage to cables

or components

2.7. Explain the methods and techniques to be used for

soldering and de-soldering, and the importance of

adhering to these procedures


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2.8. Describe the methods and techniques to be used for

crimping and heat-shrinking, and the importance of

adhering to these procedures

2.9. Explain the need to record results using the appropriate

documentation

3. Understand how to test cableforms and

looms in motorsport vehicles

3.1. Describe the types of test equipment to be used, and

their selection for particular types of test

3.2. Explain how to calibrate the test equipment to be used

3.3. Describe how to connect the appropriate test equipment

into the circuits/equipment

3.4 Explain the various testing methods and procedures

3.5 Explain how to recognise defects

3.6. Describe the various fault finding techniques that can be

used if the system fails the test

3.7. Describe how to interpret the test readings obtained,

and the significance of the readings

3.8 Explain how to analyse the test results


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Content:



1. The specific safety practices and procedures that you need to observe when constructing, installing and

testing of cableforms/looms in motorsport vehicles (including any specific legislation, regulations/codes of

practice for the activities, equipment or materials)

2. The health and safety requirements of the work area where you are carrying out the activities, and the

responsibility these requirements place on you

3. The hazards and risks associated with constructing, installing and testing of cableforms/looms in motorsport

vehicles, and with the tools and equipment used, and how to minimise them and reduce any risks

4. The protective equipment that you need to use for both personal protection and protection of the motorsport

vehicle/equipment

5. How to obtain and interpret drawings, circuit and physical layouts, charts, specifications, vehicle manuals,

wiring regulations and other documentation used during the construction, installation and testing process

(including BS, ISO or BSEN schematics, symbols and terminology)

6. How to carry out currency/issue checks on the specifications you are working with

7. The cableforms and looms to be constructed, installed or tested and their function within the particular

system

8. Methods used to correctly layout the various cables to produce the required cableform or loom (such as the

use of jigs and fixtures, pin boards and templates)

9. Methods of harnessing the various cables to form cableforms and looms (such as applying tape, applying

corrugated flexible conduit/coverings, lacing cables and applying cable ties at suitable intervals)

10. The construction and installation techniques to be used, and the importance of adhering to these procedures

11. The different types of cabling (such as multicore cables, single-core cables, screened cables), fittings and

their application

12. How to correctly align and position the cableforms and looms according to their use

13. The importance of correct routeing and securing of cableforms and looms

14. The different types of electrical components to be installed (such as relay panels, control panels, circuit

breakers/fuse panels)

15. The techniques used to position, align, support, secure and distribute the cabling through the vehicle

16. How to extract and insert cables through-bulkhead penetration without causing damage to cables or

components

17. The methods and techniques to be used for soldering and de-soldering, and the importance of adhering to

these procedures

18. The methods and techniques to be used for crimping and heat-shrinking, and the importance of adhering to

these procedures

19. Types of fastening methods to be used such as adhesive, cable ties and mechanical fasteners

20. The use of anti-vibration mountings

21. The importance of ensuring that the completed installation is free from damage and of ensuring that any

exposed components are protected

22. The quality control procedures to be followed during the installation operations

23. How to conduct any necessary checks to ensure that the completed wiring complies with all required

standards

24. The types of test equipment to be used, and their selection for particular types of test

25. How to calibrate the test equipment to be used; or the organisational procedures for ensuring that the test

equipment is maintained and correctly calibrated

26. How to connect the appropriate test equipment into the circuits/equipment (for the measurement of such

things as continuity, voltage checks, power output)

27. The various testing methods and procedures, as recommended in approved electrical codes of practice, and

how to apply them to different operating conditions

28. How to recognise defects (such as under or over performance)

29. The various fault finding techniques that can be used if the system fails the test

30. Displaying/recording test results, and the documentation to be used

31. How to interpret the test readings obtained, and the significance of the readings

32. How to analyse the test results

33. The importance of safe storage of components prior to assembly and installation

34. The importance of ensuring that the completed installation is free from dirt, swarf and foreign object damage,

and of ensuring that any exposed components, looms and wiring are correctly covered/protected


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Content:

35. The procedures for ensuring that you have the correct tools, equipment, components and fasteners for the

activities

36. Why electrical bonding is critical, and why it must be both mechanically and electrically secure

37. The procedure for the safe disposal of waste materials

38. The tools and equipment used in the installation activities, and their calibration/care and control procedures

39. Why tool/equipment control is critical, and what to do if a tool or piece of equipment is unaccounted for on

completion of the activities

40. Problems with construction, installation and testing of motorsport vehicle cableforms and wiring looms, and

the importance of informing the appropriate people of non-conformances

41. The problems that can occur with the electrical wiring installation operations, and how these can be

overcome

42. The recording documentation to be completed for the activities undertaken

43. The extent of your own responsibility and to whom you should report if you have problems that you cannot

resolve


86

01-09-11V4

UNIT REF: MS89S UNIT TITLE: SKILLS IN CONSTRUCTING, INSTALLING AND TESTING

CABLEFORMS AND LOOMS IN MOTORSPORT VEHICLES




Rationale: This unit allows the learner to demonstrate the skills needed to construct, install and test cableforms and

looms in motorsport vehicles, in accordance with approved procedures.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Be able to work safely when constructing,

installing and testing cableforms and looms

in motorsport vehicles






out the task


support the construction, installation and testing of

cableforms and looms in motorsport vehicles

2.2. Use technical information to support construction,

instillation and testing activities


equipment


for the constructing, installing and testing of cableforms

and looms in motorsport vehicles




by manufacturers when constructing, installing and

testing cableforms and looms in motorsport vehicles

4. Be able to construct, install and test

cableforms and looms in motorsport vehicles

4.1. Construct cableforms and looms in motorsport vehicles

4.2. Install cableforms and looms in motorsport vehicles

4.3. Test cableforms and looms in motorsport vehicles

4.4. Ensure that the construction, instillation and testing

complies with the acceptance criteria

4.3. Ensure no damage occurs to other components





required


effective repairs




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01-09-11V4


You must be observed by your assessor constructing one of

the following types of cableforms/looms for the systems listed:

You must be observed by your assessor installing two of the

following types of cableforms/looms for the systems listed:

You must be observed by your assessor using appropriate

equipment to carry out four of the following types of test listed:

Observation Ref:

SYSTEMS

control system

lighting system

communication system

power supply system

charging/starting system

data acquisition system

ignition system

visual display system

safety system

TESTS

onboard diagnostic check

performance of circuit

current check

voltage check

open/short circuit

continuity checks

resistance

other specific tests


88

01-09-11V4

UNIT REF: MS90K

UNIT TITLE: KNOWLEDGE OF INSTALLING, SETTING UP AND TESTING

ELECTRICAL/ELECTRONIC ENGINE/TRANSMISSION

CONTROL UNITS TO MOTORSPORT VEHICLES



particularly unit 090 & 096

Rationale: This unit allows the learner to demonstrate the knowledge needed to install, set up and test

electrical/electronic control units used in motorsport vehicle engine/transmission systems, in accordance with

approved procedures.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Understand how to prepare for installation

of electrical/ electronic

engine/transmission control units in

motorsport vehicles

1.1. Explain how to obtain the necessary job instructions and

how to interpret their information

1.2. Identify motorsport engine/transmission control units

and components to be installed

1.3. Explain the principles of operation of the motorsport

engine/transmission equipment/control units and

circuits being installed, and the purpose of individual

modules/components

1.4. Describe the assembly and installation techniques used,

and the importance of adhering to these procedures

1.5. Explain how to mark out, drill and prepare holes for

mounting and securing the components and cables

including fitting cable protection devices

1.6. Identify types of fastening methods

1.7. Identify the use of anti-vibration mountings

1.8. Identify the different types of cabling

1.9. Explain the applications of different cabling

1.10. Describe the techniques used to terminate electrical

equipment and components

1.11. Explain the importance of applying electrostatic

discharge (ESD) procedures when working on sensitive

equipment or devices


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2. Understand how to install

electrical/electronic engine/transmission

control units in motorsport vehicles

2.1 Explain how to carry out currency/issue checks on the

specifications you are working with

2.2 Describe the techniques used to position, align, adjust

and secure the components to the motorsport vehicle

according to their use

2.3 Describe methods of attaching markers/labels to

components or cables to assist with identification

2.4 Describe how to make adjustments to

components/assemblies to ensure that they function

correctly

2.5 Explain the importance of ensuring that the completed

installation is free from dirt, swarf and foreign object

damage and of ensuring that any exposed components,

looms and wiring are correctly covered/protected

2.6 Explain why electrical bonding is critical, and why it must

be both mechanically and electrically secure

2.7 Describe how to recognise installation defects and the

procedures to correct them

2.8 Identify problems with assembly and installation of

motorsport electronic and electrical systems, and the

importance of informing the appropriate people of non-

conformances

3. Understand how to set up and test

electrical/electronic engine/transmission


3.1 Explain the adjustments/corrections/tuning required to

bring the equipment/system to operational standard

3.2 Describe the types of test equipment to be used, and

their selection for particular types of tests

3.3 Explain how to calibrate the test equipment to be used

3.4 Describe how to connect the appropriate test equipment

into the circuits

3.5 Explain the various testing methods and procedures

3.6 Describe how to recognise defects

3.7 Explain the various fault finding techniques that can be


3.8 Explain how to interpret the test readings obtained, and

the significance of the readings gained

3.9 Describe how to analyse the test results


90

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Content:



1. The specific safety practices and procedures that you need to observe when installing, setting up and testing

motorsport vehicle engine/transmission electrical/electronic equipment (including any specific legislation,

regulations or codes of practice for the activities, equipment or materials being used)

2. The procedures to be carried out before starting work on the installation (such as obtaining permission to

work on the vehicle, obtaining and complying with risk assessments and other health and safety

requirements)

3. The health and safety requirements of the work area where you are carrying out the installation, setting up

and testing activities, and the responsibility these requirements place on you

4. The hazards associated with installing, setting up and testing motorsport vehicle electrical equipment, and

with the tools and equipment used, and how to minimise them and reduce any risks in the work area

5. The personal protective equipment (PPE) that you need to use for both personal protection and protection of

the motorsport vehicle

6. The interpretation of drawings, standards, quality control procedures and specifications used for the

installation, setting up and testing of motorsport engine/transmission control units (including BS, ISO or

BSEN schematics, wiring regulations, symbols and terminology)


8. How to identify motorsport engine/transmission control units and components to be installed

9. The principles of operation of the motorsport engine/transmission equipment/control units and circuits being

installed, and the purpose of individual modules/components

10. The installation, setting up and testing techniques to be used, and the importance of adhering to these

procedures

11. How to mark out, drill and prepare holes for mounting and securing the components and cables including

fitting cable protection devices

12. The techniques used to position, align, adjust and secure the components to the motorsport vehicle


13. Types of fastening methods such as adhesive, cable ties and mechanical fasteners


15. The different types of cabling and their application (such as multi-core cables, single core cables, screened

cables, data/communications cables, fibre optics)

16. The techniques used to terminate electrical equipment and components (such as free plugs and sockets,

crimped cable end fittings, soldered fittings, screwed and clamped connections)

17. The importance of applying electrostatic discharge (ESD) procedures when working on sensitive equipment or

devices

18. Methods of attaching markers/labels to components or cables to assist with identification

19. How to make adjustments to components/assemblies to ensure that they function correctly


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01-09-11V4

Content:

20. Electrical bonding specifications, and their importance

21. The types of test equipment to be used, and their selection for particular types of tests




things as continuity, voltage checks, equipment calibration)






28. How to interpret the test readings obtained, and the significance of the readings gained


30. The quality control procedures to be followed during and after the installation, setting up and testing

operations

31. How to check that tools and equipment are free from damage or defects, and are in a safe and usable

condition

32. The importance of ensuring that the completed installation is free from dirt, swarf and foreign object damage

and of ensuring that any exposed components, looms and wiring are correctly covered/protected.


34. The tools and equipment used in the installation, setting up and testing activities, and their calibration and

care procedures

35. How to recognise installation defects and the procedures to correct them

36. Problems with installation, setting up and testing of motorsport electronic and electrical systems, and the

importance of informing the appropriate people of non-conformances


38. The recording documentation to be completed for the activities undertaken and, where appropriate, the

importance of marking and identifying specific pieces of work in relation to the documentation


resolve


92

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UNIT REF: MS90S

UNIT TITLE: SKILLS IN INSTALLING, SETTING UP AND TESTING

ELECTRICAL/ELECTRONIC ENGINE/TRANSMISSION

CONTROL UNITS TO MOTORSPORT VEHICLES




Rationale: This unit allows the learner to demonstrate the skills needed to install, set up and test electrical/electronic

control units used in motorsport vehicle engine/transmission systems, in accordance with approved procedures.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Be able to work safely when installing,

setting up and testing electrical/

electronic engine/transmission control

units in motorsport vehicles



1.2. Work in a way which minimises the risk of damage or injury

to the vehicle, people and the environment


carry out the task


installing electrical/ electronic engine/transmission


2.2. Use technical information to support instillation activities


equipment


installing, setting up and testing electrical/ electronic

engine/transmission control units in motorsport vehicles




by manufacturers when installing, setting up and testing

electrical/ electronic engine/transmission control units in

motorsport vehicles

4. Be able to install, set up and test

electrical/ electronic engine/transmission


4.1. Install electrical/ electronic engine/transmission control

units in motorsport vehicles

4.2. Set up and test electrical/ electronic engine/transmission


4.3. Ensure that the instillation, set up and test complies with

the acceptance criteria






required


effective repairs




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01-09-11V4


You must be observed by your assessor installing three of the

following engine/transmission control system components

You must be observed by your assessor using appropriate

equipment to carry out four of the following types of test listed:

Observation Ref:

System Components

micro processor controllers

control devices

indication/alarm devices

sensors

detectors

switches

inertial reference unit (IRU’s)

location/positioning system

actuators

cable connectors

safety devices/overload protection devices

other specific electrical/electronic equipment

Tests

standard operational checks

voltage checks

continuity checks

input/output

referencing/calibration checks

resistance

other specific tests


94

01-09-11V4

UNIT REF: MS91K

UNIT TITLE: KNOWLEDGE OF INSTALLING, SETTING UP AND TESTING

VISUAL DISPLAY, COMPUTER AND DATA ACQUISTION

SYSTEMS TO MOTORSPORT VEHICLES



particularly unit 091, 093, 097 & 099

Rationale: This unit allows the learner to demonstrate the knowledge needed to install set up and test visual display,

computer and data acquisition systems to motorsport vehicles, in accordance with approved procedures.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Understand how to install visual display,

computer, and data acquisition systems to

motorsport vehicles

1.1 Explain how to obtain and interpret the necessary job

instructions/information

1.2 Explain how to carry out currency/issue checks on the


1.3. Identify the various motorsport vehicle visual display,

computing and data acquisition units and components

to be installed


visual display, computing and data acquisition system

components and circuits being installed

1.5. Describe the techniques used to position, align, adjust



1.6. Describe methods of attaching markers/labels to



1.8. Identify seals/sealant, adhesives to avoid moisture

ingress, and the precautions that need to be taken with

them


1.10. Explain the importance of correct routing and securing

of motorsport panels, meters, VDUs and computer

systems




1.12. Explain the importance of ensuring that the completed




1.13. Explain why electrical bonding is critical, and why it

must be both mechanically and electrically secure

1.14. Describe how to recognise installation defects and the

procedures to correct them

1.15. Identify problems with assembly and installation of

motorsport vehicle visual display, computing and data

acquisition systems, and the importance of informing

the appropriate people of non-conformances


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96

01-09-11V4

2. Understand how to set up and test visual

display, computer, and data acquisition

systems to motorsport vehicles

2.1. Explain the correct operating procedures of the system

being set up and tested

2.2. Describe how to make adjustments to


correctly

2.3. Explain how to calibrate the test equipment to be used

2.4. Explain how to connect the appropriate test equipment


2.5. Describe the various testing methods and procedures

2.6. Explain how to recognise defects

2.7. Describe the various fault finding techniques that can be


2.8. Explain the reason for displaying/recording test results,

and the documentation to be used

2.9. Explain how to interpret the test readings obtained

2.10. Explain how to analyse the test results

Content:



1. The specific safety practices and procedures that you need to observe when installing motorsport vehicle

visual display, computing and data acquisition equipment (including any specific legislation, regulations or

codes of practice for the activities, equipment or materials being used)



requirements)

3. The health and safety requirements of the work area where you are carrying out the installation activities,

and the responsibility these requirements place on you

4. The hazards associated with installing motorsport vehicle visual display, computing and data acquisition

equipment, and with the tools and equipment used, and how to minimise them and reduce any risks



6. The interpretation of drawings, wiring diagrams, standards, quality control procedures and specifications

used for the installation of motorsport vehicle visual display, computing and data acquisition equipment

(including BS, ISO or BSEN schematics, wiring regulations, symbols and terminology)


8. How to identify the various motorsport vehicle visual display, computing and data acquisition units and

components to be installed

9. The principles of operation of the motorsport vehicle visual display, computing and data acquisition system

components and circuits being installed, and the purpose of individual modules/components

10. The assembly and installation techniques to be used, and the importance of adhering to these procedures



12. The techniques used to position, align, adjust and secure the components to the motorsport vehicle without

damage and according to their use

13. The various mechanical fasteners that will be used and their method of installation (such as open and blind

rivets, threaded fasteners, adhesives and special securing devices)



97

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Content:

15. The use of seals/sealant, adhesives to avoid moisture ingress, and the precautions that need to be taken


cables, data/communications cables, fibre optics)

17. The importance of correct routing and securing of motorsport panels, meters, VDUs and computer systems



19. The importance of applying electrostatic discharge (ESD) procedures when working on sensitive equipment

or devices


21. The tools and equipment used in the installation activities (including the use of cable stripping tools,

crimping tools, soldering irons and torches)

22. How to conduct any necessary checks to ensure the system integrity, functionality, accuracy and quality of

the installation

23. The quality control procedures to be followed during and after the installation operations


condition




27. The tools and equipment used in the installation activities, and their calibration and care procedures


29. Problems with assembly and installation of motorsport vehicle visual display, computing and data acquisition

systems, and the importance of informing the appropriate people of non-conformances

30. The correct operating procedures of the system being set up and tested

31. The adjustments/corrections/tuning required to bring the equipment/system to operational standard

through full range parameters

32. The quality control procedures to be followed during the setting-up and testing operations





things as continuity, voltage checks, signal noise/interference levels, signal strength, power output, exhaust

gas and pressure calibration, temperature and accelerometer calibration, camera alignment and control

position calibration)












resolve


98

01-09-11V4

UNIT REF: MS91S

UNIT TITLE: SKILLS IN INSTALLING, SETTING UP AND TESTING VISUAL

DISPLAY, COMPUTER, AND DATA ACQUISITION SYSTEMS TO

MOTORSPORT VEHICLES



particularly unit 091, 093, 097 & 099

Rationale: This unit allows the learner to demonstrate the skills needed to install, set up and test visual display

computer, and data acquisition systems to motorsport vehicles, in accordance with approved procedures.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA


setting up and testing visual display,

computer and data acquisition systems to

motorsport vehicles






out the task


support installing, setting up and testing visual display

computer and data acquisition systems to motorsport

vehicles

2.2. Use technical information to support instillation, setting

up and testing of visual display, computer and data

acquisition activities


equipment


for installing, setting up and testing of visual display

computer and data acquisition systems





of visual display computer and data acquisition systems

4. Be able to install, set up and test visual

display, computer and data acquisition

systems in motorsport vehicles

4.1. Install visual display computer and data acquisition


4.2. Set up visual display computer and data acquisition


4.3. Test visual display computer and data acquisition


4.4. Ensure that the instillation complies with the acceptance

criteria






required


effective repairs




99

01-09-11V4


You must be observed by your assessor installing, setting up

and testing motorsport vehicle visual display equipment and

computer systems which include one of the following:

You must be observed by your assessor installing, setting up

and testing motorsport vehicle data acquisition systems which

include one of the following:

Observation Ref:

Visual display equipment and computer systems

motorsport vehicle management system

electronic instrumentation systems

driver warning panel systems

computer display systems

vehicle condition display meters

Data acquisition systems

data logging system

transmission data transfer systems

chassis/aero dynamics data transfer system

speed/position data transfer system

audio/visual data transfer systems

engine data transfer systems

test/development data transfer systems

digital data link


100

01-09-11V4

UNIT REF: MS92K UNIT TITLE: KNOWLEDGE OF INSTALLING, SETTING UP AND TESTING

COMMUNICATION SYSTEMS TO MOTORSPORT VEHICLES




Rationale: This unit allows the learner to demonstrate the knowledge needed to install, set up and test communication

systems to motorsport vehicles, in accordance with approved procedures.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Understand how to install communication


1.1. Explain how to obtain and interpret the necessary

instructions and information

1.2. Explain how to carry out currency/issue checks on the


1.3. Identify the various motorsport vehicle communication

equipment units and components to be installed

1.4. Explain principles of operation of the motorsport

communication equipment system components and

circuits being installed




1.6. Describe methods of attaching markers/labels to




1.9. Explain the importance of correct routing and securing of

the motorsport vehicle communication equipment

components








1.12. Explain why electrical bonding is critical, and why it

must be both mechanically and electrically secure


101

01-09-11V4

2. Understand how to set up and test

communication systems to motorsport

vehicles

2.1 Explain the correct operating procedures of the system

being set up and tested

2.2 Describe how to make adjustments to


correctly

2.3 Explain how to calibrate the test equipment to be used

2.4 Explain how to connect the appropriate test equipment


2.5 Describe the various testing methods and procedures

2.6 Explain how to recognise defects

2.7 Describe the various fault finding techniques that can

be used if the system fails the test

2.8 Explain the reason for displaying/recording test results,

and the documentation to be used

2.9 Explain how to interpret the test readings obtained

2.10 Explain how to analyse the test results

Content:



1. The specific safety practices and procedures that you need to observe when installing motorsport vehicle

communication equipment (including any specific legislation, regulations or codes of practice for the

activities, equipment or materials being used)



requirements)

3. The health and safety requirements of the work area where you are carrying out the installation activities, and

the responsibility these requirements place on you

4. The hazards associated with installing motorsport vehicle communication equipment, and with the tools and

equipment used, and how to minimise them and reduce any risks



6. The interpretation of drawings, wiring diagrams, standards, quality control procedures and specifications

used for the installation of motorsport vehicle communication equipment (including BS, ISO or BSEN

schematics, wiring regulations, symbols and terminology)


8. How to identify the various motorsport vehicle communication equipment units and components to be

installed

9. The basic principles of operation of the motorsport vehicle communication system components and circuits

being installed, and the purpose of individual modules/components

10. The assembly and installation techniques to be used, and the importance of adhering to these procedures





13. The various mechanical fasteners that will be used and their method of installation (such as open and blind

rivets, threaded fasteners, adhesives and special securing devices)


15. The use of seals/sealant, adhesives to avoid moisture ingress, and the precautions that need to be taken

16. The different types of cabling and their application (such as multicore cables, single core cables, screened

cables, co-axial and tri-axial cables, data/communications cables, fibre optics)

17. The importance of correct routing and securing of the motorsport vehicle communication equipment

components


102

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103

01-09-11V4

Content:




devices


21. The tools and equipment used in the installation activities (such as the use of cable stripping tools, crimping

tools, soldering irons and torches)

22. How to conduct any necessary checks to ensure the system integrity, functionality, accuracy and quality of the

installation

23. The quality control procedures to be followed during and after the installation operations


condition




27. The tools and equipment used in the installation activities, and their calibration and care procedures


29. Problems with assembly and installation of motorsport vehicle communication systems, and the importance

of informing the appropriate people of non-conformances

30. The correct operating procedures of the system being set-up and tested

31. The components to be set up and tested, and their function within the particular communication system

32. The adjustments/corrections/tuning required to bring the equipment/system to operational standard through

full range parameters

33. The quality control procedures to be followed during the setting up and testing operations

34. Electrical bonding specifications, and their importance





things as continuity, voltage checks, signal noise/interference levels, power output, receiver sensitivity and

distortion checks)




40. The various fault-finding techniques that can be used if the system fails the test








resolve


104

01-09-11V4

UNIT REF: MS92S UNIT TITLE: SKILLS IN INSTALLING, SETTING UP AND TESTING

COMMUNICATION SYSTEMS TO MOTORSPORT VEHICLES




Rationale: This unit allows the learner to demonstrate the skills needed to install, set up and test communication

systems to motorsport vehicles, in accordance with approved procedures.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA


setting up and testing communication







out the task


support installing, setting up and testing of

communication systems to motorsport vehicles

2.2. Use technical information to support instillation, setting

up and testing activities


equipment


for installing, setting up and testing communication






communication systems in motorsport vehicles

4. Be able to install, set up and test

communication systems in motorsport

vehicles

4.1. Install communication systems in motorsport vehicles

4.2. Set up communication systems in motorsport vehicles

4.3. Test communication systems in motorsport vehicles

4.4. Ensure that the instillation complies with the acceptance

criteria






required


effective repairs




105

01-09-11V4


You must be observed by your assessor installing one of the

following types of motorsport vehicle communication systems:

You must be observed by your assessor setting up and testing

one of the following motorsport vehicle communication

systems:

You must be observed by your assessor testing four of the

following motorsport vehicle communication system

components:

Observation Ref:

Communication Systems

VHF radio

HF radio

UHF radio

Intercom

visual recording systems (cameras)

digital data link

global positioning system

event position indicating system

Communication Systems Components

aerials

receiver units

headsets

video units

transmitter units

switches

indicator units

control units

intercom units

plugs and sockets

GPS Units

cables

power supply


106

01-09-11V4

UNIT REF: MS94K UNIT TITLE: KNOWLEDGE OF MODIFYING MOTORSPORT VEHICLE

ELECTRICAL/ELECTRONIC SYSTEMS




Rationale: This unit allows the learner to demonstrate the knowledge needed to modify motorsport vehicle

electrical/electronic systems, in accordance with approved procedures.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Understand how to prepare for modifying

motorsport vehicle electrical/electronic

systems


instructions/information to carry out the modifications

1.2. Identify the various motorsport vehicle

electrical/electronic systems, units and components to

be modified


vehicle electrical/electronic systems, components and

circuits being modified, and the purpose of individual

modules/components

1.4. Identify the components to be used

1.5. Explain the preparations to be undertaken on the

motorsport vehicle electrical/electronic system prior to

modification




1.7. Identify the different types of cable protection, and

reasons for each type

1.8. Identify the various mechanical fasteners that will be

used and their method of installation

1.9. Explain the importance of using the specified fasteners

for the modification, and why you must not use

substitutes

1.10. Explain the use of anti-vibration mountings

1.11. Explain the use of seals/sealant, adhesives to prevent

moisture ingress, and the precautions that need to be

taken

1.12. Identify the different types of cabling and their

application


107

01-09-11V4

2. Understand how to modifying motorsport

vehicle electrical/electronic systems



2.2. Describe the modification, assembly and installation

techniques to be used, and the importance of adhering to

these procedures



without damage and according to their use

2.4. Describe the methods and techniques to be used for

soldering and de-soldering, crimping and heat shrinking,

the assembly of screened and unscreened plugs and

sockets, and the importance of adhering to the

procedures

2.5. Describe the importance of correct routing and securing

of cables and modified electrical/electronic units

2.6. Describe the quality control procedures to be followed

during the modification operations

2.7. Describe the importance of ensuring that the completed


damage, and of ensuring that any exposed components,

looms and wiring are correctly covered/

Content:



1. The specific safety precautions and procedures to be observed whilst carrying out the modifications to

motorsport vehicle electrical/electronic systems, (including any specific legislation, regulations or codes of

practice relating to the activities, equipment or materials being used)

2. The procedures to be carried out before starting work on the modification (such as obtaining permission to


requirements)

3. The health and safety requirements of the work area in which you are carrying out the modification activities,

and the responsibility these requirements place on you

4. The hazards associated with carrying out modifications to motorsport vehicle electrical/electronic systems,

and with the tools and equipment used, and how to minimise them and reduce any risks



6. The interpretation of drawings, wiring diagrams, standards, quality control procedures and specifications used

for the modification of the motorsport vehicle electrical/electronic equipment (including BS, ISO or BSEN

schematics, wiring regulations, symbols and terminology)


8. How to identify the various motorsport vehicle electrical/electronic systems, units and components to be

modified

9. The basic principles of operation of the motorsport vehicle electrical/electronic systems, components and

circuits being modified, and the purpose of individual modules/components

10. How to identify the components to be used; component identification systems (such as codes and component

orientation indicators)

11. Preparations to be undertaken on the motorsport vehicle electrical/electronic system prior to modification


108

01-09-11V4

Content:


devices

13. The modification, assembly and installation techniques to be used, and the importance of adhering to these

procedures





16. The methods and techniques to be used for soldering and de-soldering, crimping and heat shrinking, the

assembly of screened and unscreened plugs and sockets, and the importance of adhering to the procedures

17. The different types of cable protection, and reasons for each type

18. The various mechanical fasteners that will be used and their method of installation (such as rivets, threaded

fasteners, adhesives and special securing devices)

19. The importance of using the specified fasteners for the modification, and why you must not use substitutes

20. The use of anti-vibration mountings.

21. The use of seals/sealant, adhesives to prevent moisture ingress, and the precautions that need to be taken


cables, co-axial and tri-axial cables, data/communications cables, fibre optics)

23. The importance of correct routing and securing of cables and modified electrical/electronic units

24. The quality control procedures to be followed during the modification operations

25. How to conduct any necessary checks to ensure the accuracy and quality of the modification

26. How to recognise defects (such as misalignment, ineffective fasteners, foreign object damage or

contamination)

27. The importance of ensuring that the completed installation is free from dirt, swarf and foreign object damage,

and of ensuring that any exposed components, looms and wiring are correctly covered/

28. The tools and equipment used in the modifying activities, and their calibration and care procedures

29. Why tool/equipment control is critical, and what to do if a tool or piece of equipment is unaccounted for on

completion of the activities

30. The problems that can occur with the modification operations on motorsport vehicles and the importance of

informing the appropriate people of non-conformances




resolve


109

01-09-11V4

UNIT REF: MS94S UNIT TITLE: SKILLS IN MODIFYING MOTORSPORT VEHICLE

ELECTRICAL/ELECTRONIC SYSTEMS




Rationale: This unit allows the learner to demonstrate the skills needed to modify electrical/electronic systems used in

motorsport vehicles, in accordance with approved procedures.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Be able to work safely when modifying

electrical/electronic systems to motorsport

vehicles






out the task


support the modification of electrical/electronic systems

to motorsport vehicles

2.2. Use technical information to support modification

activities


equipment


modifying electrical/electronic systems to motorsport

vehicles




by manufacturers when modifying electrical/electronic


4. Be able to modifying electrical/electronic


4.1. Confirm and agree what modifications are to be carried

out to meet the specification

4.2. Modify electrical/electronic systems in motorsport

vehicles

4.3. Ensure that the modification complies with the

acceptance criteria

4.4. Ensure no damage occurs to other component





required


effective repairs




110

01-09-11V4


You must be observed by your assessor carrying out

modifications to two of the following motorsport vehicle

electrical/electronic systems:

You must be observed by your assessor carrying out four of

the following types of modification:

Observation Ref:

Electrical/electronic systems

power supply

charging/starting

ignition

lighting system

communications

data acquisition

visual display and computer

engine transmission control

safety systems

other electrical/electronic systems (such as fuel

supply, chassis control, active ride)

Types of modification

replacing cables of different size or length

changing or adding components to panels or sub-

assemblies (such as meters/dash instrumentation)

changing position or angle of cable breakout points

making changes to components on end of cable (such

as engine RPM sensor)

making changes to cable termination

changing electrical/electronic units

changing routes of cables

adding new looms

making changes to looms

changing position of electrical units

fitting new electrical systems (such as audio/visual)

removing cables

adding cables

updating software


111

01-09-11V4

UNIT REF: MS101K UNIT TITLE: KNOWLEDGE OF STRIPPING AND REBUILDING ENGINES FOR

MOTORSPORT VEHICLES




Rationale: This unit allows the learner to demonstrate the knowledge needed to strip down, examine and rebuild

motorsport vehicle engines in accordance with approved procedures. The engine to be dismantled and rebuilt will

have been removed from the vehicle, and the activities may take place in a garage/workshop or may have been

returned to the manufacturer.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Understand how to prepare to strip and

rebuild engines for motorsport vehicles

1.1. Explain the reasons for stripping and rebuilding engines

for motorsport vehicles


instructions/information




during the stripping and rebuilding operations

1.5. Explain the importance for obtaining the correct

specification replacement parts, materials and other

consumables necessary for the stripping and rebuilding

1.6. Describe company policy on the repair/replacement of

components during the stripping and rebuilding process

1.7. Explain terminology used in motorsport vehicle engines

and engine modules

1.8. Explain the principles of how the engine functions, its

operating sequence, the working purpose of individual

units/components and how they interact

1.9. Describe the various mechanical fasteners that are used

and their method of removal and replacement

1.10 Describe the various types of electrical connector that are

used, methods of unlocking, orientation indicators and

locating and locking in of the connections

1.11 Identify the tools and equipment used in the overhauling

activities, and how to check that they are in a safe and

usable condition

1.12 Explain the importance of ensuring that all tools are used

correctly and within their permitted operating range


112

01-09-11V4

2. Understand how to strip and rebuild engines

for motorsport vehicles

2.1. Describe the extent to which the equipment is to be

dismantled

2.2. Explain the sequence to be adopted for the

dismantling/reassembling of various types of engine

assemblies

2.3. Explain the techniques used to dismantle the motorsport

vehicle engines without damage to the components or

surrounding structure

2.4. Describe the methods of reassembling the motorsport

vehicle engine using new or previously overhauled

subassemblies

2.5. Explain how to make adjustments to replaced


correctly

2.6. Explain the problems that can occur during the stripping

and rebuilding activity, and how they can be overcome

Content:



1. The specific safety practices and procedures that you need to observe when stripping and rebuilding

motorsport vehicle engines (including any specific legislation, regulations/codes of practice for the activities,

equipment or materials)

2. The health and safety requirements of the area in which the motorsport vehicle engine striping and rebuilding

activity is to take place, and the responsibility these requirements place on you

3. The hazards associated with stripping and rebuilding motorsport vehicle engines (such as such as handling

oils, greases, fuel, stored pressure/force, use of power tools, misuse of tools, using damaged or badly

maintained tools and equipment, not following laid down overhaul procedures, lifting and moving large and

heavy components), and how to minimise them and reduce any risks

4. The importance of wearing protective clothing and other appropriate safety equipment during the stripping

and rebuilding activities

5. How to obtain and interpret drawings, specifications, manufacturers’ manuals, history/maintenance reports,

and other documents needed in the stripping and rebuilding process


7. The quality control procedures to be followed during the stripping and rebuilding operations

8. The importance for obtaining the correct specification replacement parts, materials and other consumables

necessary for the stripping and rebuilding

9. Company policy on the repair/replacement of components during the stripping and rebuilding process

10. Terminology used in motorsport vehicle engines and engine modules

11. The basic principles of how the engine functions, its operating sequence, the working purpose of individual

units/components and how they interact

12. The extent to which the equipment is to be dismantled

13. The sequence to be adopted for the dismantling/reassembling of various types of engine assemblies

14. The techniques used to dismantle the motorsport vehicle engines without damage to the components or

surrounding structure (such as release of energy (pressures/force), draining of fluids, making electrical

disconnections, proof marking components to aid reassembly, removing assemblies requiring pressure/force,

removing mechanical locking and securing mechanisms/devices) and the need to protect the system integrity

by ensuring exposed components are correctly covered/protected)

15. How to lift and move large components and assemblies; the methods and equipment used to transport,

handle and lift the components during the dismantling activities

16. The need to ensure that lifting and handling equipment is within its current certification dates

17. Methods of checking that components are fit for purpose, how to identify defects and wear characteristics,

and the need to replace ‘lifed’ items (such as seals and gaskets)


113

01-09-11V4

Content:

18. The uses of measuring equipment (such as micrometers, Vernier, expansion indicators and other devices)

19. Methods of reassembling the motorsport vehicle engine using new or previously overhauled subassemblies

(such as replacing assemblies requiring pressure/force, ensuring correct orientation and location of

subassemblies, replacing mechanical locking and securing mechanisms/devices, reconnecting pipes and

electrical connectors)

20. How to make adjustments to replaced components/assemblies to ensure that they function correctly (such as

checking alignment, balancing of rotating components such as flywheels and torque converters, setting

working clearance, setting travel, and pre-loading bearings)

21. The various mechanical fasteners that are used and their method of removal and replacement (such as bolts,

nuts, rivets, threaded fasteners, special securing devices)

22. The various types of electrical connector that are used, methods of unlocking, orientation indicators and

locating and locking in of the connections

23. The tools and equipment used in the overhauling activities, and how to check that they are in a safe and

usable condition

24. The importance of ensuring that all tools are used correctly and within their permitted operating range

25. The importance of ensuring all tools, equipment and components are accounted for and returned to their

correct location on completion of the overhaul activities


27. The generation of maintenance documentation and/or reports following the stripping and rebuilding activity

28. The problems that can occur during the stripping and rebuilding activity, and how they can be overcome

29. The extent of your own authority and to whom you should report if you have a problem that you cannot resolve


114

01-09-11V4

UNIT REF: MS101S UNIT TITLE: SKILLS IN STRIPPING AND REBUILDING ENGINES FOR

MOTORSPORT VEHICLES




Rationale: This unit allows the learner to demonstrate the skills needed to strip down, examine and rebuild motorsport

vehicle engines in accordance with approved procedures. The engine to be dismantled and rebuilt will have been

removed from the vehicle, and the activities may take place in a garage/workshop or may have been returned to the

manufacturer.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Be able to work safely when stripping and

rebuilding engines for motorsport vehicles






out the task


support stripping and rebuilding engines for motorsport

vehicles

2.2. Use technical information to support stripping and

rebuilding activities


equipment


stripping and rebuilding motorsport engines




by manufacturers when stripping and rebuilding

motorsport engines

4. Be able to strip and rebuild motorsport

engines

4.1. Strip and rebuild motorsport engines

4.2. Ensure that the rebuild complies with the acceptance

criteria


4.4. Ensure all components and are stored safely and in the

correct location





required


effective repairs




115

01-09-11V4


You must be observed by your assessor carrying out one

engine strip and rebuild to a motorsport engine

You must be observed by your assessor inspecting ten of the

removed components for wear and serviceability using

appropriate instrumentation

You must be observed by your assessor carrying out

inspections and tests during the rebuilding of the engine, to

include eight of the following:

Observation Ref:

Motorsport engine

Removed components:

● cylinder head for flatness, signs of damage and condition

of valve seats and guides

● cylinder bores/liners for size/wear/distortion

● crankshaft bearings and journals for size/wear

● camshaft bearings and cam lobes for size/wear

● pistons for cracks, detonation, scoring, ring grooves for

wear/damage

● connecting rods for little and big end bearing wear, and

freedom from twisting and heat damage

● valves for pitting, cracks and valve stem wear

● flywheel for wear to clutch face and starter ring gear for

damage to teeth

● chain/belt mechanisms for wear to drive teeth

● pumps for damage and excessive movement in bearings

● valve springs for height/tension and signs of damage

● clutch assembly for wear to pressure plate and drive

plate(s), release bearing for wear/damage

● pipes for damage and hoses for cuts, cracks and general

deterioration

● oil galleries for blockages

● crankshafts, flywheels, connecting rods, pistons for

balance

● transfer port alignment

● manifolds for cracks/leakage

● cylinder block for flatness

● power valves/reed valves for wear and damage

Inspections and tests during the rebuilding

● orientation

● alignment

● freedom of movement

● end float (such as crankshaft, camshaft, bearing)

● gear backlash

● cylinder liner protrusion

● checking for system blockages (such as oil and airways)

● timing (such as valve, ignition, fuel injection)

● operating/working clearance (such as valve)

● belt/chain tension

● torque loading of bolts

● visual inspection for completeness and freedom from

damage or foreign objects


116

01-09-11V4

UNIT REF: MS103K UNIT TITLE: KNOWLEDGE OF TESTING ENGINES FOR MOTORSPORT

VEHICLES (FIXED DYNAMOMETER)




Rationale: This unit allows the learner to demonstrate the knowledge to carry out dynamometer tests on engines for

motorsport vehicles, in accordance with approved procedures, and as is appropriate to the engine type

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Understand how to prepare to test engines

for motorsport vehicles using a fixed

dynamometer

1.1. Explain the preparations to be carried out on the engine

prior to starting the engine tests

1.2. Describe how to carry out initial start-up procedures and

checks

1.3. Explain how to access and setup the computer software

required to run the engine tests

1.4. Explain how to obtain the required test schedules and

specifications for the motorsport and engine type being

tested, and how to check their currency and validity

1.5. Describe how to read and interpret the specifications, and

who you can seek assistance from if you have problems or

issues regarding the test schedules or specifications

1.6. Explain the need to apply engine power in incremental

stages, and to check all readings, temperatures and

pressures at each stage

2. Understand how to test engines for

motorsport vehicles using a fixed

dynamometer

2.1. Explain the methods and procedures to be used to carry

out the various engine tests

2.2. Describe how to record the results of each individual test,

and the documentation that must be used

2.3. Describe the procedure to alter or change the test

procedures

2.4. Explain the procedures to be followed if the engine or

system fails to meet the test specification

2.5. Explain how to analyse the test results and make valid

decisions about the acceptability of the engine

2.6. Describe potential problems that can occur with the

testing activities, and how they can be overcome

2.7. Explain things that may cause errors or discrepancies

in/with the test results, and how to avoid them

2.8. Describe environmental controls required relating to the

testing

2.9. Explain why equipment control is critical, and what to do if

a piece of equipment is unaccounted for on completion of

the testing activities

2.10. Identify documentation to be completed at the end of



117

01-09-11V4

Content:



1. The specific safety practices and procedures that you need to observe when testing motorsport engines

(including any specific legislation, regulations/codes of practice required for the activities, equipment or

materials used)

2. The health and safety requirements of the work area in which you are carrying out the activities, and the

responsibility these requirements place on you

3. The safety procedures that must be carried out before tests are started on the engine (such as checking that

the dynamometer safety system is functioning, and that all personnel are clear of the test area)

4. The personal protective clothing and equipment to be worn during the tests

5. The hazards associated with dynamometer testing motorsport engines, and how to minimise them and reduce

any risk (such as code of safe working practices/risk assessment)

6. The preparations to be carried out on the engine prior to starting the engine tests (such as attaching to the

dynamometer, fitting test instrumentation, fitting ancillary equipment, fitting blanking plates, filling engine

with oil, making fuel connections, attaching electrical power and making final electrical checks of all systems)

7. How to carry out initial start-up procedures and checks (to include checking that engine starting and shutdown

systems operate correctly, idle speed is satisfactory, fuel flow is operating correct, oil pressure is to

specification, oil filters, connections, gaskets and seals are free from leaks)

8. How to access and set up the computer software required to run the engine tests

9. How to obtain the required test schedules and specifications for the motorsport and engine type being tested,

and how to check their currency and validity

10. How to read and interpret the specifications, and who you can seek assistance from if you have problems or

issues regarding the test schedules or specifications

11. The methods and procedures to be used to carry out the various engine tests

12. The need to apply engine power in incremental stages, and to check all readings, temperatures and pressures

at each stage

13. How to record the results of each individual test, and the documentation that must be used

14. From whom to seek authorisation if you need to alter or change the test procedures

15. The procedures to be followed if the engine or system fails to meet the test specification

16. How to analyse the test results and make valid decisions about the acceptability of the engine

17. Potential problems that can occur with the testing activities, and how they can be overcome

18. Things that may cause errors or discrepancies in/with the test results, and how to avoid them

19. Any environmental controls required relating to the testing

20. Why equipment control is critical, and what to do if a piece of equipment is unaccounted for on completion of


21. Documentation to be completed at the end of the testing activities


resolve


118

01-09-11V4

UNIT REF: MS103S UNIT TITLE: SKILLS IN TESTING ENGINES FOR MOTORSPORT VEHICLES

(FIXED DYNAMOMETER)




Rationale: This unit allows the learner to demonstrate the skills needed to carry out dynamometer tests on engines for

motorsport vehicles, in accordance with approved procedures, and as is appropriate to the engine type

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Be able to work safely when testing engines

for motorsport vehicles using a fixed

dynamometer






out the task


support testing motorsport engines for vehicles using a

fixed dynamometer

2.2. Use technical information to support testing activities


equipment


testing motorsport engines




by manufacturers when testing motorsport engines

4. Be able to test motorsport engines using a

fixed dynamometer

4.1. Test motorsport engines using a fixed dynamometer

4.2. Ensure that the test complies with the acceptance criteria






required


effective repairs




119

01-09-11V4


You must be observed by your assessor testing one

motorsport engine using a fixed dynamometer

You must be observed by your assessor preparing the engine

for testing and carry out initial start-up checks, to include all of

the following, as applicable to the engine type:

You must be observed by your assessor undertaking engine

tests as listed in the appropriate engine test schedule, to

include all of the following:

You must be observed by your assessor disconnecting the

engine on completion of the testing procedures, to include

carrying out all of the following:

You must be observed by your assessor reviewing and analyse

the results of the test run, using two of the following

Observation Ref:

Motorsport engine

Initial start-up checks

correctly connect the engine to the dynamometer

fit all required engine ancillary equipment (such as

starter motors, slave oil filters, magnetic chip

detectors and strainers)

fit all required environmental equipment (such as

forced air fans, exhaust extraction)

fit blanking plates (where appropriate)

fill the engine with oil

make all required connections to the engine, to

include fuel connections, electrical and

instrumentation

carry out all necessary electrical checks and confirm

that the engine is ready for testing

ensure that all personal are clear of the test facility

and safe working distance procedures are maintained

load and prepare computer software for operation

(where applicable)

check the engine starting system

run the engine and check that the engine shutdown

system operates correctly

carry out idle checks

check that engine oil pressure is satisfactory

check that fuel flow is operating correctly

check all oil filters, connections, gaskets and seals for

signs of leakage


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EVIDENCE REQUIREMENTS continued

You must be observed by your assessor testing one

motorsport engine using a fixed dynamometer

You must be observed by your assessor preparing the engine

for testing and carry out initial start-up checks, to include all of

the following, as applicable to the engine type:

You must be observed by your assessor undertaking engine

tests as listed in the appropriate engine test schedule, to

include all of the following:

You must be observed by your assessor disconnecting the

engine on completion of the testing procedures, to include


You must be observed by your assessor reviewing and analyse

the results of the test run, using two of the following

Observation Ref:

Engine test schedule

initiating the engine test sequence

carrying out running and handling checks

carrying out performance curves

carrying out vibration surveys

checking engine pressures are within specification

checking that engine temperature is within

specification

checking that throttle/high pressure fuel flow

operates smoothly

ensuring that maximum power is achieved

Disconnecting the engine

shutting down computer driver (where appropriate)

checking all oil filters, connections, gaskets and seals

for signs of leakage

removing and checking magnetic chip detectors for

contamination

removing and checking slave filters for contamination

installing engine’s own magnetic chip detectors and

filters

draining all oil and fuel from the engine

removing all blanks and instrumentation fitted

removing engine from dynamometer safely and

correctly

preparing engine for passing to race team/customer

Review and analyse the results

data sheets

calibration records

log cards/history sheet

engine test schedule

fault records


121

01-09-11V4

UNIT REF: MS105K UNIT TITLE: KNOWLEDGE OF DRESSING ENGINES FOR MOTORSPORT

VEHICLES




Rationale: This unit allows the learner to demonstrate the knowledge needed to carry out assembly operations to

dress engines for motorsport vehicles, in accordance with approved procedures.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Understand how to prepare to dress

engines for motorsport vehicles

1.1. Explain the reasons for dressing engines for motorsport

vehicles

1.2. Describe how to Identify the components to be used;

component identification systems

1.3. Describe preparations and inspections to be undertaken

on the components prior to fitting them onto the engine

1.4. Explain the engine dressing/assembly methods and

procedures to be used, and the importance of adhering

to the procedures

1.5. Describe how the components are to be aligned and

positioned prior to securing, and the tools and equipment

that are used

1.6. Identify the various mechanical fasteners that will be

used, and their method of installation 2. Understand how to dress engines for

motorsport vehicles


out the various engine instillations

2.2. Explain the importance of using the specified fasteners

for the assembly, and why they must not use substitutes

2.3. Describe how to complete basic fitting practices, meeting

regulatory and organisational requirements

2.4. Explain how to deal with components or fastening devices

that are incorrectly assembled, damaged or having other

faults

2.5. Describe the application of sealants and adhesives within

the dressing/assembly activities, and the precautions

that must be taken when working with them


during the dressing/assembly operations

2.7. Explain how to conduct any necessary checks to ensure

the accuracy and quality of the dressed engines

2.8. Describe how to detect assembly defects, and what to do

to rectify them


engine is free from dirt, swarf and foreign objects

2.10. Describe things that can go wrong with the engine

dressing activities, and how they can be avoided


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Content:



1. The specific safety precautions to be taken whilst carrying out the dressing of motorsport engines (including

any specific legislation, regulations or codes of practice relating to the activities, equipment or materials)

2. The health and safety requirements of the work area in which you are carrying out the engine dressing

activities, and the responsibility they place on you

3. The hazards associated with the dressing of motorsport engines, and how to minimise them and reduce any

risks

4. COSHH regulations with regard to the substances used in the dressing/assembly process

5. The personal protective equipment (PPE) and clothing to be worn during the dressing/assembly activities

6. The various types of drawing and specification that are used during the engine dressing and assembly

activities

7. How to identify the components to be used; component identification systems (such as codes and component

orientation indicators)

8. Preparations and inspections to be undertaken on the components prior to fitting them onto the engine

9. The engine dressing/assembly methods and procedures to be used, and the importance of adhering to the

procedures

10. How the components are to be aligned and positioned prior to securing, and the tools and equipment that are

used (including jigs and fixtures)

11. The various mechanical fasteners that will be used, and their method of installation (such as threaded

fasteners, special securing devices)

12. The importance of using the specified fasteners for the assembly, and why you must not use substitutes

13. How to complete basic fitting practices, meeting regulatory and organisational requirements (such as torque

tightening, wire locking, fitting wire thread inserts, fitting O-ring seals, fitting lock nuts and tab washers)

14. Dealing with components or fastening devices that are incorrectly assembled, damaged or having other faults

15. The application of sealants and adhesives within the dressing/assembly activities, and the precautions that

must be taken when working with them

16. The quality control procedures to be followed during the dressing/assembly operations

17. How to conduct any necessary checks to ensure the accuracy and quality of the dressed engines

18. How to detect assembly defects, and what to do to rectify them (such as ineffective fasteners, foreign object

damage)

19. How to move large components and assemblies, the methods and equipment used to transport, handle and

lift the components into position, and how to check that the equipment is within its current certification dates

20. How to check that the tools and equipment to be used are correctly calibrated and are in a safe and

serviceable condition

21. The importance of ensuring that all tools are used correctly and within their permitted operating range

22. The importance of ensuring that the completed engine is free from dirt, swarf and foreign objects

23. The importance of ensuring that all tools, equipment and components are accounted for and returned to their

correct location on completion of the engine dressing/assembly activities

24. The things that can go wrong with the engine dressing activities, and how they can be avoided

25. The importance of informing appropriate people of non-conformances


resolve


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UNIT REF: MS105S UNIT TITLE: SKILLS IN DRESSING ENGINES FOR MOTORSPORT VEHICLES




Rationale: This unit allows the learner to demonstrate the skills needed to carry out assembly operations to dress

engines for motorsport vehicles, in accordance with approved procedures.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Be able to work safely when dressing

engines for motorsport vehicles






out the task

2.1. Select suitable sources of technical information to dress

motorsport engines

2.2. Use technical information to support dressing of

motorsport engines


equipment


dressing motorsport engines




by manufacturers when dressing motorsport engines

4. Be able to dress motorsport engines

4.1. Use the appropriate methods and techniques to

assemble the components in their correct positions

4.2. Secure the components using the specified connectors

and securing devices

4.3. Ensure that the engine complies with the acceptance

criteria






required




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01-09-11V4


You must be observed by an assessor carrying out the

dressing of one type of motorsport engine

You must be observed by an assessor using five of the

following assembly methods and techniques:

You must be observed by an assessor carrying out the

dressing of the engine, by fitting ten of the following:

Observation Ref:

Motorsport engine

Assembly methods and techniques

assembly of components by pressure

aligning components

setting working clearances

torque setting of fasteners

securing components using mechanical fasteners and

threaded devices

making connections to electrical components and

harnesses

applying bolt-locking methods (split pins, wire locking,

lock nuts, stiff nuts).

applying sealant/adhesives

drilling and riveting

earth bonding of components

Dressing of the engine

engine mountings

manifolds

pumps (such as fuel, coolant, oil)

coolers (such as air, oil, fuel)

filters (such as fuel, oil, air)

valves (such as solenoid, bleed, pressure)

heat exchangers (such as oil, water)

charging/starting components

clutch assemblies

sensors (such as temperature,

pressure, fire)

electronic control units

electrical harnesses/looms

primary exhaust systems

turbo chargers/super chargers

air intake systems (such as air

boxes and plenums)

fuel pipes

oil pipes

air pipes

brackets

sump pans


125

01-09-11V4

UNIT REF: MS106K UNIT TITLE: KNOWLEDGE OF INSPECTING MOTORSPORT COMPONENTS BY

MAGNETIC PARTICLE TESTING




Rationale: This unit allows the learner to demonstrate the knowledge needed to carry out magnetic particle tests on

ferromagnetic motorsport components, materials or structures, in accordance with approved procedures.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Understand how to prepare to carry out

magnetic particle testing on motorsport

vehicles

1.1. Explain why components, materials or structures require

to be tested using non-destructive testing methods

1.2. Describe the various types of drawing and specification

that are used during the inspection activities

1.3. Explain why it is sometimes necessary to use a range of

different non-destructive testing methods

1.4. Identify the various types of magnetic particle detection

equipment used (to include portable and fixed machines)

1.5. Identify the various components that make up the

equipment

1.6. Explain the concepts of magnetic particle testing

1.7. Explain how to check that the testing equipment is within

current calibration dates

1.8. Describe the types of check that can be carried out on the

equipment

2. Understand how to inspect motorsport

vehicle by magnetic particle testing


out magnetic particle testing

2.2. Identify the different detecting mediums that are used

2.3. Explain the methods of applying and removing different

detecting mediums

2.4. Explain how to set up the equipment parameters for the

testing activities undertaken

2.5. Describe the preparations to be carried out on the

components, materials or structure test area

2.6. Explain the types of defect that are detectable using

magnetic particle detection methods

2.7. Explain defects in the components, materials or

structures from the displayed indications, and how to

identify false indication of defects and their cause

2.8. Explain the level of defects that are acceptable in the

components, materials or structures; the influence of the

defects on the service/performance of the components,

materials or structures


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01-09-11V4

Content:



1. The specific safety precautions to be taken when carrying out magnetic particle inspection activities on

motorsport components, materials or structures

2. The hazards associated with carrying out the magnetic particle inspection activities (such as electrical,

mechanical, toxic and fire), and how to minimise them and reduce any risks

3. The personal protective equipment (PPE) to be used, and how to obtain it

4. The COSHH regulations relating to materials used during the magnetic particle inspection process

5. How to obtain the necessary job instructions and testing specifications, and how to interpret them

6. The reasons why some components, materials or structures require to be tested using non-destructive testing

methods

7. Why it is sometimes necessary to use a range of different non-destructive testing methods (such as magnetic

particle, penetrant flaw detection, ultrasonic and radiography)

8. The various types of magnetic particle detection equipment used (to include portable and fixed machines)

9. The various components that make up the equipment (such as contact prods and heads, rigid and flexible

coils, permanent magnets, electromagnets)

10. The basic concepts of magnetic particle testing (including creating the magnetic field, magnetisation of the

component, the use of a magnetic flux, disruption of the flux by discontinuities/flaws in the components and

imaging of the disruption by the magnetic media)

11. How can you check that the testing equipment is within current calibration dates

12. The types of check that can be carried out on the equipment (such as sensitivity assessment, functional tests,

operation of flux indicators and field strength meters, ammeters and quality of detecting medium)

13. The different detecting mediums that are used (to include inks and powders), the methods of applying them

and their removal on completion

14. How to set up the equipment parameters for the testing activities undertaken (to include selection of

magnetising technique, field strength, direction of current flow, calculation of magnetising current required

and flux density required)

15. The preparations to be carried out on the components, materials or structure test area (such as degreasing,

grinding, filling, polishing and other mechanical operations and where appropriate the application of contrast

aid paint)

16. How to carry out the testing activities (including the application of the magnetic field; application of the

detecting media; viewing conditions required such as ambient light or ultraviolet (UV); identification of the

displayed defects; defect transfer techniques such as magnetic rubber and photographic)

17. The types of defect that are detectable using magnetic particle detection methods

18. How to recognise defects in the components, materials or structures from the displayed indications, and how

to identify false indication of defects and their cause

19. The level of defects that are acceptable in the components, materials or structures; the influence of the

defects on the service/performance of the components, materials or structures

20. The system of quality control within the company and who is responsible for it

21. Why is it critical that records of magnetic particle inspections are accurate, comprehensive and maintained

legibly

22. The person that you need to pass the inspection records to


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01-09-11V4


solve

UNIT REF: MS106S UNIT TITLE: SKILLS IN INSPECTING MOTORSPORT COMPONENTS BY

MAGNETIC PARTICLE TESTING




Rationale: This unit allows the learner to demonstrate the skills needed to carry out magnetic particle tests on

ferromagnetic motorsport components, materials or structures, in accordance with approved procedures.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Be able to work safely when inspecting

motorsport components by magnetic particle

testing






out the task


support magnetic particle testing of motorsport

components

2.2. Use technical information to support magnetic particle

testing of motorsport components


equipment


magnetic particle testing of motorsport components




by manufacturers when magnetic particle testing of


4. Be able to inspect motorsport components

using magnetic particle testing

4.1. Inspect motorsport components using magnetic particle

testing

4.2. Identify any defects or variations from the specification

4.3. Ensure that the inspection complies with the acceptance

criteria






required


effective repairs




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You must be observed by an assessor carrying out magnetic

particle testing on one of the following:

You must be observed by an assessor preparing the

components, materials or structures for testing, to include


You must be observed by an assessor carrying out all of the

following tests in accordance with instructions:

Observation Ref:

Magnetic particle testing

welded joints

motorsport mechanical components (such as brake

disks, cylinder heads, drive shafts)

motorsport/vehicle structures (such as chassis

members)

other specific components or materials

Preparing the components, materials or structures

identifying and marking the test areas

removing any contaminants from the test area (such

as degreasing)

preparing the test surface to the specified finish (such

as grinding or polishing)

Instructions

setting the equipment parameters to the appropriate

levels

magnetising the components

applying the detecting medium (ink or powder)

correctly

using magnetic flux indicators

observing defect indications under correct lighting

conditions (ambient light or ultraviolet (UV)

recording conclusions of observations

demagnetising and cleaning the components on

completion of the test


129

01-09-11V4

UNIT REF: EE3 UNIT TITLE: VEHICLE ELECTRICAL AND ELECTRONIC 3

Level: 3 Route: Credit Value: 7 GLH: 36

Rationale: This unit broadens and develops the aspects covered in the Level 2 extended diploma. The aim is to

provide learners, with a broader understanding of electrical auxiliary systems and further develop their understanding

of electrical and electronic principles. The content will support learners in understanding vehicle chassis and engine

systems that incorporate electrical and electronic components and control circuits. To assist learners learning and

interest the content should be delivered in the context of motor vehicles and be related to the appropriate technical

units

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Understand the principles of electronic circuits 1.1. Explain the principle of electronic components

1.2. Explain digital electronic principles

2. Understand principles of microprocessors 2.1. Explain the principle of a microprocessor

2.2. Explain the basic functions of a microprocessor

2.3. Critically compare electronic sensors

2.4. Critically compare the types of performance maps

used in engine electronic systems

2.5. Explain the use of the oscilloscope (CRO) for

testing electronic systems

3. Understand electrical auxiliary systems 3.1. Explain electric windscreen wiper systems

3.2. Explain direction indicator systems

3.3. Explain electric windows and central door locking

systems

Content:

1.1 The principle of electronic components

a. Explain the structure of atoms: protons, neutrons and electrons.

b. Describe the atomic structure of materials, which are good electrical conductors, and materials, which are

good electrical insulators.

c. Describe the principle of semiconductors.

d. Explain the principle electron flow.

e. Explain the structure and operating principle of electronic components; diodes, Zener diode, light emitting

diode, transistor, phototransistor and thyristor.

1.2 Digital electronic principles

a. Explain the binary number system and the principle of representing denary numbers as binary codes.

b. Explain electronic terms; bits, bytes, kilobyte, megabyte, binary coded decimal, RAM, ROM, EPROM.

c. Compare analogue and digital signals.

d. Explain why the binary system is suited to digital signals.

e. Explain the voltage levels for digital data in vehicle electronic circuits.

f. Explain the principle of A/D and D/A converters.

g. Explain that logic gates process digital signals.

h. Explain the principle of logic gates; AND, OR, NOT, NAND and NOR.

i. Recognise the symbols used for logic gates.

j. Construct truth tables for AND, OR, NOT, NAND and NOR gates.

k. Explain the principle of combinational logic circuits incorporating two logic gates.


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Content:

2.1 The principle of a microprocessor

a. Explain the purpose of using a microprocessor in motor vehicle circuits.

b. State the advantages and disadvantages of using a microprocessor.

c. Identify at least two motor vehicle circuits that include a microprocessor.

d. Describe the three basic elements of a microprocessor; input, process and output.

e. Describe how the three basic elements are applied in a vehicle microprocessor circuit i.e. sensor, A/D

converter and amplifier, digital processor, D/A converter and amplifier and actuator.

f. Distinguish between open loop and closed loop systems.

2.2 The basic functions of a microprocessor

a. Identify the main components of a microprocessor.

b. Explain the basic function of the microprocessor components; CPU, I/O interface, register section, program

counter, memory tables, arithmetic and logic section, A/D and D/A conversion, fetch and execute cycle

2.3 The principle of electronic sensors

a. Identify the main types of sensor used in vehicle electronic circuits e.g. pressure, position, flow and

temperature.

b. Identify the aspects that are sensed in vehicle electronic systems e.g. engine speed, vehicle speed, engine

temperature, ambient temperature, manifold absolute temperature (MAP), air flow, crankshaft angular

position, accelerator position, oxygen in exhaust gas, wheel speed etc.

c. Describe the types of pressure sensor in use and where they are used in vehicle electronic circuits (variable

resistor, variable inductance and variable differential transformer).

d. Describe the types of magnetic and optical sensors in use and where these are used in electronic circuits

(variable reluctance, inductive, Hall effect, reed switch, optical).

e. Describe the types of flow sensor in use and where these are used in vehicle electronic circuits (hot wire, flap

etc)

2.4 The types of performance maps used in engine electronic systems

a. Describe the principle of engine mapping.

b. Describe the type of engine data stored in a map; ignition advance maps (load/speed/advance and

load/temperature/advance), fuel mixture maps (engine speed/manifold pressure/injection time and engine

speed/load/temperature).

c. Describe the basic principle of how these maps are used to influence engine performance.

2.5 The use of the oscilloscope for testing electronic systems

a. Explain the basic principle of a cathode ray oscilloscope (CRO).

b. Recognise the normal patterns for engine and chassis systems; ignition, fuel injection, alternator, ABS

etc.

3.1 Electric windscreen wiper systems

a. Identify the components in electric windscreen wiper systems; motor, linkage, arms and blades.

b. Compare wound and permanent magnet motors.

c. Explain how the wiper motors operate to provide self-parking, two-speed operation and intermittent wipe.

d. Recognise windscreen wiper defects; blade judder, incomplete wipe pattern and wiper screech.

e. Identify causes of wiper defects; worn blades, worn arms, bent arms and weak springs.

3.2 Direction indicator systems

a. Explain the layout and components of direction indicators and hazard warning circuits; fuse, flasher unit,

switch, wiring, indicator lamps and warning lamps.

b. Describe the electrical tests to check the indicator circuit for; blown fuse, defective switch and defective

flasher unit.

3.3 Electric windows and central door locking systems

a. Explain the layout and components of the electric window winding circuit.

b. Describe the operation of electric window winding mechanism and the electrical window winding circuit.

c. Explain the layout and components in an electric door locking circuit.

d. Describe the operation of electric door locking mechanism and the electric door locking circuit.


131

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UNIT REF: ICT3 UNIT TITLE: INFORMATION COMMUNICATION AND TECHNOLOGY FOR

VEHICLE REPAIR 3


Rationale: This unit builds on the Information Communication and Technology unit at level 2. It aims to develop and

broaden further learners understanding of the principles of information technology to an advanced level, to support

their study of other units in the Level 3 extended diploma. To promote interest and understanding the use of

Information Communication and Technology in this unit should be applied to a motor vehicle application. Learners

should use computers to develop their understanding of the principles and gain confidence with applications and ICT

terminology. The unit will provide a progression route to qualifications at level 4

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Be able to use multiple software applications

1.1 Select information sources to enable the collection

of relevant data

1.2 Use multiple software applications to analyse and

present data in a suitable format

2. Be able to professionally present information using

ICT

2.1. Produce and save a new presentation

2.2. Demonstrate the copying and pasting data and

charts into the presentation

2.3. Develop a slide design that clearly presents

information to include; page numbers, text boxes,

header and/or footers, text boxes, bulleted lists

2.4. Demonstrate the making a presentation that is

clear and interesting to include special effects

2.5. Present the information to a known or unknown

audience

3. Be able to produce a report using ICT

3.1. Produce a typed written report

3.2. Produce graphical and/or statistical information

3.3. Apply solutions to an investigation

3.4. Evaluate conclusions and make recommendations

3.5. Analyse and present alternative recommendations


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Content:

1.1 Database application

a. Use information sources to collect information to investigate a solution to a motor vehicle application e.g.

buying and selecting a car within a preset price range.

b. Create and save a new database.

c. Create and save a database table for the information from (a.) with at least 4 different fields e.g. vehicle

make, vehicle model, engine capacity, vehicle dimensions, OTR price. (Ensure the correct field data type is

used for each field).

d. Create a primary key from the inserted fields.

e. Sort the information in the database table in ascending order e.g. engine capacity.

f. Print out the database table.

g. Create and save a form using the database table.

h. Enter additional information into the database using the form.

i. Create and save a single table query.

j. Edit the query by adding and removing criteria.

k. Print out the query.

1.2 Spreadsheet application

This section uses the database information from section 1.1.

a. Create and save a new workbook.

b. Copy the information from the database in section 1 into a worksheet.

c. Rename the worksheet e.g. car table.

d. Apply formatting to the information e.g. cell borders, shading, and font colours.

e. Generate at least three formulas using the table information e.g. sum, sumif, count, if

f. Create a pie chart and a line chart using one or more of the table columns, and insert the pie charts into their

own worksheets.

g. Modify one of the charts to include:

i. font attributes

ii. axes scales

iii. background colours

iv. font orientation e.g. 450

h. Add a header and/or footer to the worksheet.

i. Print out the worksheet.

1.3 Word processing application.

This section uses the spreadsheet information from section 1.2.

a. Create and save a new document.

b. Copy and paste the data (including charts) from the spreadsheet in section 2 into the new document.

c. Produce and save a print screen of the inserted charts in the new document.

d. Create a table and insert the pasted data information into the table.

e. Add a column and a row to the table.

f. Apply formatting to the table e.g. font attributes, borders, shading

g. Sort on one of the table columns in descending order.

h. Insert a formula function into the table e.g. sum, count.

i. Insert a header/and or footer into the document which includes a clip art picture.

j. Insert a clip art picture into the document.

k. Ungroup and modify the clip art picture (Group on completion).

l. Insert a heading using the Word Art function.

m. Print out the document.


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Content:

2.1 Presentation software.

This section uses the information from Learning Outcome 1, section 3 (1.3).

a. Create and save a new presentation.

b. Copy and paste the data and charts from Learning Outcome 1, section 3 into the presentation.

c. Apply a slide design.

d. Use suitable slide layouts to present the information.

e. Apply automatic slide numbering to the slide show.

f. Insert a header and/or footer into the presentation.

g. Insert a text box(s).

h. Insert a bulleted list(s).

i. Insert Clip Art.

j. Add animation effects to each slide.

k. Add transition effects between slides.

l. Rearrange the slide order.

m. Present the information to a known or unknown audience.

3.1 Produce reports.

This section uses the information from Learning Outcomes 1 & 2.

a. Produce a type written report of at least 500 words to show how you compiled the information from each

software application.

b. Produce graphical and/or statistical information to support your findings.

c. Identify any solutions to your investigation.

d. Make recommendations based upon your solution(s).

e. Identify any alternative recommendations.


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UNIT REF: M3 UNIT TITLE: VEHICLE MATHEMATICS 3


Rationale: This unit provides develops the mathematical principles introduced at level 2. It aims to broaden learners

understanding of mathematics to support their study of other units in the Level 3 extended diplomas. The content

also strongly supports the development of the Key Skills Application of Number or Functional Skills Maths. To promote

interest and understanding calculations should be applied to motor vehicle applications wherever possible. Learners

should solve problems in each topic, both with and without the use of calculators, to develop their understanding of

basic principles and gain confidence with mathematical tasks. The unit will provide a progression route to

qualifications at Level 4

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Be able to use advanced mathematical techniques 1.1. Use the advanced functions of the scientific

calculator

1.2. Compare different number systems

1.3. Explain the law of indices

1.4. Explain arithmetical and geometric progression

2. Be able to solve problems involving non right-angled

and complex triangles

2.1. Solve problems using the inverse trigonometric

ratios

2.2. Use trigonometric ratios for angles greater than

90°

2.3. Solve problems using the sine rule

2.4. Solve problems using the cosine rule.

3. Be able to solve simultaneous and quadratic

equations

3.1. Solve simultaneous equations

3.2. Solve quadratic equations

3.3. Construct graphs of quadratic equations

4. Be able to use statistical techniques 4.1. Calculate the mean, median and mode of grouped

frequency distributions

4.2. Construct histograms from data

4.3. Use standard deviation

4.4. Use probability techniques

4.5. Use correlation and regression techniques


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01-09-11V4

Content:

1.1. Use the scientific calculator

a. Identify the keys and main functions of a scientific calculator.

b. Use the scientific calculator’s memory to store, add and recall numeric values.

c. Use the scientific calculator to carryout calculations involving +, -, x, ÷, parentheses (brackets), + and – numbers.

d. Use the scientific calculator to represent and calculate numbers in standard form.

e. Use the scientific calculator for calculating trigonometric functions (sine, cosine and tangent)

f. Use the scientific calculator for calculating the inverse trigonometric functions (Cotangent, Cosecant, Secant).

g. Use the scientific calculator for calculating complex powers and roots.

h. Use the scientific calculator to carryout calculations for the unit’s learning outcomes 1, 2, 3 and 4.

1.2. Explain number systems

a. Compare different number systems e.g. base 10 (decimal), base 2 (binary), base 8 (octal), base 16

(hexadecimal).

b. Explain how decimal numbers are shown as binary coded decimals

c. Convert simple decimal numbers to binary, octal and hexadecimal e.g. convert 56 to binary.

d. Relate the use of binary, octal and hexadecimal numbers to vehicle electronic systems and computers.

1.3. Explain indices

a. Explain the laws of indices e.g. multiplication of powers of the same quantity, division of powers of the same

value, negative indices, fractional indices.

b. Explain that any quantity raised to the power of zero is equal to 1.

c. Describe complex powers and roots e.g. where the power or root is a decimal fraction.

d. Use a scientific calculator to find the value of complex powers e.g. 9.80.5 = 3.1305.

e. Use a scientific calculator to find the value of complex roots e.g. 2.3√64 = 6.0995.

f. Carryout mixed calculations involving complex powers and roots.

1.4. Explain arithmetical and geometric progression

a. Recognise that a set of numbers that are connected by a definite law is called a series or progression.

b. Explain that an arithmetical progression is obtained by adding or subtracting a constant amount to the preceding

term e.g. in the series 1, 4, 7, 10 the number 3 is added to each preceding amount.

c. State the rule for calculating arithmetical progressions; a, a + d, a + 2d where d = the coefficient (difference)

and a is the first number in the series e.g. 9th term is a + 8d

d. Find the ninth term in an arithmetical series e.g. find the 9th term in the series 1, 5, 9 etc (33).

e. Explain that a geometric progression is obtained from the preceding term by multiplying or dividing a constant

amount.

f. State the general expression for a series in geometric progression is a, ar, ar2, ar3 etc. where “a” is the first term

and r is the common ratio.

g. Relate geometric progression to vehicle gearbox ratios.

h. Calculate the gear ratios of a gearbox that has gears arranged in geometric progression e.g. if 1st and 4th gears

are known find the 2nd and 3rd gear ratios.

2.1. Explain the inverse trigonometric ratios

a. State the inverse trigonometric ratios; cotangent cosecant and secant.

b. Use a calculator or tables to identify the cotangent, cosecant and secant of angles.

c. Use trigonometric ratios to solve vehicle related problems e.g. steering angles, crankshaft, connecting rod angles

and piston displacement.

2.2. Find the trigonometric ratios for angles greater than 90°

a. Determine the sine, cosine and tangent for angles greater than 90°.

2.3. Use the sine rule

a. Explain the sine rule i.e. a/Sine A = b/Sine B

b. Explain that the sine rule is used to solve triangles when one side and two angles are known or when two sides

and one angle are known

c. Use the sine rule to solve vehicle related problems e.g. steering angles, crankshaft and connecting rod angles,


2.4. Use the cosine rule.

a. Explain the cosine rule i.e. a2 = b2 + c2 – 2bc cos A etc.

b. Explain that the cosine rule is used to solve triangles when two sides and the angle between them is known or

when three sides are known.

c. Use the cosine rule to solve vehicle related problems e.g. steering angles, crankshaft and connecting rod angles,



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Content:

3.1. Solve simultaneous equations

a. Explain that simultaneous equations contain two unknown quantities (x and y).

b. Recognise that there are two methods that can be used to solve simultaneous equations; by elimination and

by substitution.

c. Solve simultaneous equations using elimination.

d. Solve simultaneous equations using substitution.

3.2. Solve quadratic equations

a. Explain that quadratic equations contain the square of the unknown quantity.

b. Explain that quadratic equations have two solutions or roots.

c. Explain that any quadratic equation can be expressed in the form ax2 + bx + c = 0.

d. State the formula for solving quadratic equations as x = (- b ± √b2 – 4ac) ÷ 2a

e. Use the formula to solve quadratic equations.

3.3. Produce graphs of quadratic equations

a. Recognise that graphs of quadratic equations produce a curve known as a parabola.

b. Using a typical quadratic equations produce a table of y values for specific values of x (e.g. values of y if x is -

6 to +6).

c. Plot graphs of quadratic equations.

d. Identify from the graph the values of x.

4.1. Calculate the mean, median and mode of grouped frequency distributions

a. Use tally charts to sort raw data for simple and grouped frequency distributions.

b. For grouped frequency distributions understand the terms “class width”, “upper class limit”, “lower class

limit” and “class mid-point”.

c. Produce and interpret information in simple and grouped frequency distributions.

d. Identify the range, upper quartile, lower quartile and inter-quartile range of data.

e. Explain the terms “arithmetic mean”, “median” and “mode” and find their values for simple frequency

distributions.

f. Find the mean of a frequency distribution.

g. Find the mean in a grouped frequency distribution using the assumed mean method.

4.2. Produce histograms

a. Explain the difference between a bar chart and a histogram.

b. Explain that in a histogram the width of the bar represents the class width and the height of the bar

represents the frequency.

c. Recognise that the bar height is halved when class width is twice the standard class width etc.

d. Produce histograms of grouped frequency distributions for typical vehicle related data.

e. Identify from the histogram the modal class.

f. Use the histogram to find the mode.

4.3. Use standard deviation

a. Explain that frequency distributions having the same mean can have different dispersions of data e.g. either

concentrated about the mean or widely dispersed.

b. Explain that the degree dispersion in a frequency distribution can be measured using standard deviation.

c. State the formula for calculating the standard deviation.

d. Find the standard deviation of typical vehicle related frequency distributions.

4.4. Use probability techniques

a. Explain the principle of simple probability.

b. Calculate simple probabilities.

c. Explain the basic laws of probability

d. Solve vehicle related problems using probability

4.5. Use correlation and regression techniques

a. Produce scatter graphs of two variables having a likely connection e.g. vehicle mileage and the number of

breakdowns or vehicle mileage and the failure of a component.

b. Describe the type of scatter graphs that would indicate a strong relationship and a poor relationship between

the two variables.

c. Position a “line of best fit” to a scatter graph and use the line to predict values within the range of the plotted

points.

d. Position a regression line to the scatter graph using the three point method e.g. upper average, lower

average, total average points).

e. Use the regression line to predict values within the range of the plotted points and beyond the plotted points

(extrapolation).

f. Explain the risks of predicting values beyond the plotted points e.g. relationship between the variables may

change beyond plotted points – risk of inaccurate predictions


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UNIT REF: S3 UNIT TITLE: VEHICLE SCIENCE 3


Rationale: This unit develops and broadens the aspects of motor vehicle science at level 2. It covers the aspects of

vehicle science that relate to engine and vehicle performance required to support other units in the Level 3

programme. The aim of the unit is to develop learners’ knowledge of advanced vehicle science, to develop their ability

to interpret technical information, enhance their diagnostic skills and improve their understanding of the technical

features found on modern vehicles. To promote interest and assist learning, the content should be delivered in the

context of motor vehicles and be related to the appropriate vehicle technology units where possible. The unit will

provide a progression route to further study at level 4 qualifications

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Be able to solve problems involving engine

performance

1.1. Solve problems involving engine torque, brake

power and specific fuel consumption

1.2. Solve problems involving mean effective pressure

and indicated power

1.3. Solve problems involving engine efficiencies

2. Be able to solve problems involving gas law 2.1. Solve problems using the general gas law equation

2.2. Explain isothermal and adiabatic compression and

expansion of gases

3. Be able to solve problems involving vehicle

performance

3.1. Explain the meaning of tractive effort

3.2. Explain the meaning of tractive resistance

3.3. Solve problems of gradient resistance

3.4. Calculate tractive effort from given data

4. Be able to solve problems involving angular motion 4.1. Explain the meaning of angular motion

4.2. Explain the meaning of centrifugal force

4.3. Evaluate vehicle related problems involving

centrifugal and centripetal force

4.4. Solve problems using equations of anular motion


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Content:

1.1. Engine torque, brake power and specific fuel consumption

a. Describe the principle of how engine torque and power can be measured using an engine dynamometer or

brake.

b. Explain that engine power measured using a dynamometer is known as brake power (Pb) and is measured in

watts (W) or kilowatts (kW).

c. State the formula for calculating engine torque i.e. T = force x radius (brake arm length).

d. State the formula for calculating brake power i.e. Pb = 2 π N T (where N = revs/sec and T = torque (Nm).

e. Solve problems involving engine torque and power.

f. Compare alternative units for measuring engine power; W, kW, and bhp e.g. 1 bhp = 750 watts, 1000 watts

= 1 kW.

g. Explain the principle of measuring brake specific fuel consumption and the reasons this method is used by

engine manufacturers.

h. State the units for specific fuel consumption as litres/kW hour or g/kW hour.

i. Calculate the brake specific fuel consumption of an engine from given data.

j. Recognise the typical performance curves for brake power, torque and specific fuel consumption.

1.2. Mean effective pressure and indicated power

a. Describe the basic principle of producing engine PV diagrams e.g. transducer signal of cylinder pressure

against crankshaft rotation or cylinder volume.

b. Recognise and interpret the typical pressure/volume diagrams (PV) for petrol and diesel engines.

c. Explain how the area of the PV diagram can be determined using the mid-ordinate rule.

d. Explain that the average height of a PV diagram is equal to the indicated mean effective pressure (imep).

e. State the units for the indicated mean effective pressure i.e. kN/m2 or KPa.

f. State the formula for calculating the indicated power i.e. Pi = P L A N (where P is the imep, L is the engine’s

stroke, A is the area of the cylinder and N is number of working strokes per minute.

g. Explain the difference between indicated power (Pi) and brake power (Pb).

h. Solve problems involving indicated mean effective pressure and indicated power.

1.3. Engine efficiencies

a. Explain, in relation to engines, the meaning of mechanical efficiency.

b. Determine the mechanical efficiency of an engine using either Pb ÷ Pi x 100 or bmep ÷ imep x 100.

c. Explain the meaning of brake thermal efficiency i.e. the proportion of heat energy that produces brake

power.

d. Explain the method for formula for calculating the heat energy released by the fuel burnt in the engine’s

cylinders e.g. mass of fuel per second x fuel’s calorific value.

e. Determine the thermal efficiency of an engine using given information i.e. fuel flow per second, calorific

value of fuel and brake power.


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Content:

2.1. General gas law equation

a. Explain the general gas law equation i.e. P1V1/T1 = P2V2/T2.

b. Explain standard temperature and pressure.

c. Convert pressures and temperatures to absolute units.

d. Solve gas law problems involving the general gas law equation.

2.2. Isothermal and adiabatic compression and expansion of gases

a. Describe isothermal and adiabatic compression and expansion of gases.

b. Explain that isothermal compressions and expansions follow Boyle’s law i.e. PV = c.

c. Explain the adiabatic compressions and expansions follow the law PVy = c, where y (gamma) = 1.4

d. Explain that the value of y = cp ÷ cv; the specific heat capacities of the gas at constant pressure and

constant volume.

e. Explain that the compression and expansion of gases in internal combustion engines are close to adiabatic

and follow the rule PVn + c, where n has a value less than 1.4 (usually between 1.25 and 1.36).

f. Solve gas law problems involving the equation PVn + c.

3.1. Tractive effort

a. Explain that tractive effort is the driving force produced at the road wheels that propels the vehicle along the

road.

b. Explain that the tractive effort can be determined using the equation Te = (TxGxE) ÷ R, where T = engine

torque, G = overall gear ratio, E = the transmission efficiency and R = the rolling radius of the road wheels.

c. Determine the tractive effort of vehicles from given data.

3.2. Tractive resistance

a. Explain that tractive resistance is the force that opposes the motion of the vehicle along the road.

b. Explain that the tractive resistance has three components; rolling resistance (Rr), gradient resistance (Rg)

and air resistance (Ra).

c. Explain that rolling resistance is due to transmission friction and the deformation of the tyres, normally

expressed in N/tonne of vehicle mass.

d. Explain that gradient resistance is due to the steepness of the slope or hill which the vehicle is climbing.

e. Explain that gradient resistance can be determined using the equation Rg = (mg) ÷ G, where m = vehicle

mass, g = gravity and G = gradient.

f. Determine the gradient resistance of vehicles for different gradients.

g. Explain that air resistance depends on the vehicle shape, the frontal area and the vehicle speed.

h. Explain how different vehicle shapes have different drag coefficients (Cd) e.g. cars, vans, trucks.

i. Explain that the air resistance (Ra) of vehicles can be determined using the equation Ra = kAV2 where k = a

constant depending on vehicle shape, A = the frontal area and V = vehicle speed.

j. Determine the air resistance of a vehicle from given data.

k. Calculate the total tractive resistance for a vehicle from given data.

4.1. Angular motion

a. Explain that the radian is the unit of angular displacement.

b. Explain that 1 radian equals 57.3° and that there are 2π radians in 1 revolution (360°).

c. Explain that angular velocity is measured in radians per second (rad/s) and denoted by the symbol ω

(omega).

d. Explain that angular acceleration is measured in rad/s2 and is denoted by the symbol α (alpha).

e. Explain the relationship between angular and linear motion i.e. v = ω r.

f. Explain the equations of angular motion.

4.2. Centrifugal force

a. Describe how centrifugal and centripetal force is generated by a rotating mass and when a vehicle is

cornering.

b. Explain how centrifugal force and centripetal force must be equal for the vehicle to maintain a circular path.

c. Explain that centrifugal force and centripetal force = (mv2) ÷ r (or mrω2).

d. Solve vehicle related problems involving centrifugal and centripetal force.


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UNIT REF: EP2 UNIT TITLE: ELECTRICALLY PROPELLED VEHICLE HAZARD MANAGEMENT


Mapping: Based on IMI SSC Electric Vehicle NOS 2011

Rationale: This unit is designed for those people who may encounter accident damaged or broken down electrically

propelled and assisted vehicles, e.g. emergency services and roadside recovery operators. It contains the knowledge

required to work safely around a vehicle that may have had damage to its high and/or low energy electrical system.

Note: This is a knowledge unit only and does not deem someone competent to work on the high energy electrical

system.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Know about the types of electrically propelled

vehicles available

1.1. Describe how to identify electrically propelled

vehicles

1.2. Give examples of the electrically propelled

vehicles that are currently available

1.3. Outline the main differences between hybrid and

electric vehicles

2. Know about electrically propelled vehicle systems

2.1 Give examples of the typical voltages used for a

range of electrically propelled and assisted

vehicles

2.2 Identify the typical location of high energy

electrical cables and components on electrically

propelled vehicles

2.3 Describe how to identify high energy electrical

cabling and associated components

2.4 Compare the differences between alternating and

direct current

3. Understand the hazards surrounding electrically

propelled vehicles

3.1. Describe the basic hazards associated with high

energy electricity

3.2. State the levels of current and voltage that

present a hazard for both alternating and direct

current systems

3.3. Describe the potential hazards that may be

present when an electrically propelled vehicle has

been damaged by fire or impact

3.4. Describe the effects of alternating and direct

current on humans


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4. Know how to reduce the risk of injury when

encountering electrically propelled vehicles

4.1. Describe the methods that vehicle manufacturers

use to provide protection from high energy

electrical cabling and components

4.2. Identify who may be at risk in the event of

electrically propelled vehicle incidents

4.3. Describe how to make an initial assessment of the

extent of vehicle damage and or faults.

4.4. Describe how to take steps to secure the safety of

themselves and others at incident scenes

involving electrically propelled vehicles.

4.5. Describe the precautions that can be taken to

reduce risks by those encountering damaged

electrically propelled vehicles

Content:

a. How to identify electrically propelled vehicles:

i. construction

ii. badging

b. Examples of the electrically propelled vehicles that are currently available

i. hybrid incl. plug in

ii. electric

iii. two wheel moped/scooters

iv. commercial vehicles

v. passenger transport

vi. car

c. The main differences between hybrid and electric vehicles

i. layouts

ii. components

iii. batteries

iv. motors

d. Examples of the typical voltages used for a range of electrically propelled vehicles

i. 100-650V

ECE R100 (relating to vehicle regulations) paragraph 2.14 clearly defines high voltage:

“High Voltage means the classification of an electric component or circuit, if its working voltage is > 60 V and ≤

1500 V DC or > 30 V and ≤ 1000 V AC root mean square (rms).”

NOTE: This is different to definitions in commercial and domestic use which are:

i. Extra Low Voltage<50 V rms AC and <120 V DC

ii. Low Voltage 50-1000 V rms AC and 120-1500 V DC

iii. High Voltage >1000 V rms AC and >1500 V DC

a. The typical location of high energy cables and components on electrically propelled vehicles

i. provide examples from various manufacturers

b. How to identify high energy cabling and associated components

i. colouring

ii. warning symbols

c. Difference between AC and DC voltage:

i. definitions of ac/dc -alternating current/direct current

ii. voltage comparisons

iii. current flow


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Content:

d. The basic hazards associated with high energy electricity

i. electric shock

ii. burns

iii. arc flash

iv. arc blast

v. fire

vi. explosion

vii. chemicals

viii. gases/fumes

e. Levels of current and voltage that may present hazards

i. contact time

ii. AC/DC current and voltage levels

iii. factors affecting resistance to current flow

f. The potential hazards when vehicles are damaged by fire or impact

i. electric shock

ii. burns

iii. arc flash

iv. arc blast

v. fire

vi. explosion

vii. chemicals

viii. gases/fumes

g. The effect of different AC and DC electrical currents passing through human body

i. IEC 60479

ii. IEC 479-2

h. The methods that vehicle manufacturers use to provide protection from high energy cabling and components

i. direct protection- enclosure, insulation, location

ii. indirect protection- fuse, RCD, RCBO,MCB

i. Who may be at risk in the event of electrically propelled vehicle incidents

i. occupants

ii. on-lookers

iii. recovery personnel

iv. emergency services

j. How to make an initial assessment of the extent of vehicle damage and or faults.

i. risk assessment

ii. personal protection

iii. visual inspection

k. How to take steps to secure the safety of themselves and others at incident scenes involving electrically

propelled vehicles.

i. evacuation procedures

ii. site protection

l. The precautions that can be taken to reduce risks by those encountering damaged electrically propelled

vehicles

i. overalls with non conductive fasteners

ii. gloves

iii. protective footwear; rubberised soles; non-metallic protective toe caps

iv. goggles

v. dealing with leakage from battery packs

vi. isolation of high energy electrical system; vehicle shut down procedures

vii. risk assessment


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UNIT REF: EP3 UNIT TITLE: ROUTINE MAINTENANCE AND REPAIR ACTIVITIES ON

ELECTRICALLY PROPELLED VEHICLES


Mapping: Based on IMI SSC Electric Vehicle NOS 2011

Rationale: This unit introduces learners to electrically propelled and assisted vehicle technology including, and in

particular, the safety requirements of working on these types of vehicles, e.g. whilst carrying out servicing, or general

repairs that are not related to the high energy electrical system.

Note: This unit does not prove that someone is competent to work on the high energy electrical system, and assumes

an already good level of electrical understanding. This unit does not cover commercial or domestic electrical

installations.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Know about electrically propelled vehicle system

components and operation

1.1. Identify the components that make up the high

energy electrical drive train system

1.2. Describe the construction and function of battery

modules

1.3. Describe the construction and function of electric

motors

1.4. Describe the construction and function of

associated high energy electrical components

including circuit protection and cabling

1.5. Describe how to identify high energy electrical

cabling and associated components

2. Understand the hazards surrounding electrically

propelled vehicles

2.1 Describe the basic hazards associated with high

energy electricity

2.2 State the levels of current and voltage that

present a hazard for both alternating and direct

current systems

2.3 Describe the potential hazards that may be

present when an electrically propelled vehicle has

been damaged by fire, impact or overcharging

2.4. Describe the effects of alternating and direct

current on humans

3. Know how to reduce the risks to yourself and others

when working on electrically propelled vehicles

3.1. Describe the methods that vehicle manufacturers

use to provide protection from high energy

electrical cabling and components

3.2. State safety precautions to be taken to reduce

risks to self and others before carrying out routine

maintenance and repairs on electrically propelled

vehicles

3.3. Describe the specific personal protective

equipment required to work on electrically

propelled vehicles

3.4. Describe the precautions required prior to working

near high energy electrical components


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4. Know how to safely prepare the vehicle when

carrying out maintenance and routine repair

activities on electrically propelled vehicles

4.1. Identify the possibility of the high energy electrical

system affecting repairs on other vehicle systems

4.2. Describe the procedures required to make safe

the high energy electrical system before carrying

out maintenance and repair activities

4.3. Describe the precautions taken prior to removing

and replacing high energy electrical components

4.4. Describe appropriate methods to re-instate

vehicles after repairs affecting high energy

electrical systems

4.5 Identify additional tools and equipment required to

carry out work on electrically propelled vehicles

4.6. Describe how to connect an external power source

to an electrically propelled vehicle

5. Be able to work safely on an electrically propelled

vehicle

5.1. Use suitable personal protective equipment at all

times whilst working on electrically propelled

vehicles

5.2. Select suitable sources of information to support

the work being carried out

5.3. Carry out the safe isolation of the high energy

electrical system, following the vehicle

manufacturers instructions

5.4. Use the correct methods to safely re-instate the

vehicle following the vehicle manufacturers

instructions

5.5. Use the correct procedures to connect an

alternative power source to an electrically

propelled vehicle

Content:

a. Identification of the components that make up the electrical propulsion system should include:

i. batteries/stack, pod, module.

ii. motors

iii. cabling;

iv. relays/control units

v. charger and charging points

vi. isolators

vii. inverter

viii. battery management interface

ix. ignition/key-on control switch

x. driver display panel

xi. multi-battery server unit

b. The construction and function of battery modules should include:

i. types; lead-acid; sodium-nickel chloride; lithium-ion derivatives; nickel-cadmium (Ni-Cad); nickel-ion (Ni-

Fe); nickel-metal-hydride

ii. capacities; primary/secondary cells; power density; energy density

iii. housings; materials used

iv. reactive materials; positive/ negative potential

v. connections; shape; material; position

vi. charging process; fast/slow charge; higher and lower voltages

vii. location; effects on cooling, ease of maintenance, space, weight transfer; removing and refitting.


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Content:

c. The construction and function of electric motors should include:

i. principle of DC/AC types; permanent magnet; induction, brushed, brushless, single/three phase

ii. connections; screwed; push; integrity; security

iii. power rating/output

iv. housing materials/insulation

v. armatures

vi. windings

vii. principle of regenerative braking

d. The construction and function of associated electrical components should include:

i. cabling; materials; colour coding; routing; insulation; cross-sectional area

ii. circuit protection; fuses; thermal cut outs; insulation

iii. relay/control units; battery management interface; inverter;

iv. distribution units

v. electrical symbols and terminology; circuit protection methods.

vi. circuit theory; interaction between voltage, current, resistance (ohm`s law);power equation to

vii. calculate power dissipated in a circuit

viii. conductors, insulators; earth return, insulated return

e. Examples of the typical voltages used for a range of electrically propelled vehicles

i. e.g 100-650V

ECE R100 (relating to vehicle regulations) paragraph 2.14 clearly defines high voltage:

“High Voltage means the classification of an electric component or circuit, if its working voltage is > 60 V and ≤

1500 V DC or > 30 V and ≤ 1000 V AC root mean square (rms).”

NOTE: This is different to definitions in commercial and domestic use which are:

i. Extra Low Voltage <50 V rms AC and <120 V DC

ii. Low Voltage 50-1000 V rms AC and 120-1500 V DC

iii. High Voltage >1000 V rms AC and >1500 V DC

a. The basic hazards associated with high energy electricity

i. electric shock

ii. burns

iii. arc flash

iv. arc blast

v. fire

vi. explosion

vii. chemicals

viii. gases/fumes

b. The hazards that may be present in the event of an accident or suspected overcharging

i. as above

c. Levels of current and voltage that may present hazards

i. contact time

ii. AC/DC current and voltage levels

iii. factors affecting resistance to current flow

d. The effect of different AC and DC electrical currents passing through the human body.

i. IEC 60479

ii. IEC 479-2

e. Safety precautions to be taken before carrying out any maintenance and repair procedures on high voltage

vehicles should include:

i. overalls with non conductive fasteners

ii. gloves

iii. protective footwear; rubberised soles; non-metallic protective toe caps

iv. goggles

v. precautions when using electrical equipment; differentiating between low/high energy

vi. disposal of waste materials; recycling obligations

vii. dealing with leakage from battery packs

viii. isolation of high energy electrical system; vehicle shut down procedures

ix. risk assessment


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Content:

f. The identification of high energy cabling and associated components should include:

i. using wiring diagrams

ii. wiring colour

iii. wiring size/cross-sectional area

iv. warning signs

v. using voltmeters correctly

g. The precautions required when working with high energy vehicle components:

i. awareness of highly magnetic components and strong magnetic fields

ii. medical conditions that may be affected by high energy or magnetic fields

iii. checking voltage prior to working near or on high energy systems

h. The possibility of the electrically propelled vehicle drive train system affecting repairs on other vehicle systems

should include:

i. connections to other systems

ii. electro-magnetic interference

iii. interlink between low and high energy sources

iv. residual magnetism

i. The procedures required to make safe the high energy vehicle system before carrying out repair activities

should include:

i. identification of isolation switches

ii. preparing vehicle for isolation/shut down

iii. following set procedures

iv. observation of data displays

j. The precautions taken prior to removing and replacing high energy components should include:

i. check system is made safe/isolated/shut down

ii. check voltage prior to starting work

iii. make others aware of work being carried out/warning signs

k. Appropriate methods to re-instate vehicles after repairs affecting high energy vehicle systems could include:

i. re-connection of high energy battery

ii. use of fault code readers

iii. on board displays

l. Additional tools and equipment required to carry out work on electrically propelled vehicles should include

i. hand tools

ii. code readers

iii. specialist tools e.g. manufacturer specific software

iv. electrical meters e.g. voltmeter rated to 1,000 and either CAT. 111 or CAT. 1V

m. How to connect an additional 12 volt power source to an High Voltage vehicle should include:

i. identification of connections

ii. correct connection methods

iii. awareness of current draw capability of vehicle

iv. use of correct cables

v. correct use of PPE

vi. awareness of short circuits and component damage

n. Connect an external power source to an electrically propelled vehicle e.g. to jump start it


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UNIT REF: EP4 UNIT TITLE: ELECTRICALLY PROPELLED VEHICLE SYSTEM REPAIR AND

REPLACEMENT


Mapping: Based on IMI SSC Electric vehicle NOS 2011

Rationale: This unit enables learners to demonstrate, in a practical way, their knowledge of electrically propelled and

assisted vehicle technology and repair procedures. The unit also ensures that the learner is aware of the effect that

eectrically propelled vehicle technology has on other vehicle systems.

Note: This unit only provides the knowledge and skills required to work on non-live high energy electrical components

and associated systems. It does not enable a learner to dismantle ‘live’ components, e.g. battery packs, and assumes

an already good level of electrical understanding. This unit does not cover commercial or domestic electrical

installations.

The unit should also only be undertaken after completion of Unit EP3 Routine Maintenance and Repair Activities on

Electrically Propelled Vehicles.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Be able to work safely on an electrically propelled

vehicle

1.1. Use suitable personal protective equipment

throughout all vehicle inspection activities.

1.2. Work in a way which minimises the risk of damage

to the vehicle and its systems, other people and

their property

2. Be able to use information to carry out the task


support electrically propelled vehicle repair

activities.

2.2. Use suitable sources of technical information to

support electrically propelled vehicle repair

activities.


3.1. Select appropriate tools and equipment to carry

out electrically propelled vehicle repairs

3.2. Ensure that equipment has been calibrated to

meet manufacturers’ requirements.

3.3. Use the tools and equipment in the correct way

4. Know how to carry out repairs on High energy

electrical systems

4.1. Explain the correct procedures required prior to

removing and replacing high energy electrical

system components

4.2. Explain how to isolate and re-connect live high

energy electrical supplies correctly

5. Be able to carry out repairs on High energy

electrical systems

5.1. Make the high energy electrical system safe to

work on prior to carrying out any work

5.2. Use the correct procedures to disconnect and

reconnect an isolated high energy battery pack

5.3. Use the correct procedures to remove and refit

non-live high energy electrical vehicle system

components

5.4. Use appropriate procedures to re-instate the

vehicle and confirm repairs successfully carried

out

5.5. Reset vehicle systems post-repair


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01-09-11V4


recommendations

6.1. Complete records accurately, in the format

required.

6.2. Compare inspection and test results with suitable

data

6.3. Make suitable recommendations based upon the

results of carrying out the replacement activities.

Content:

a. Personal protective equipment should include:

i. non-conductive overalls

ii. gloves

iii. protective non-conductive footwear

iv. goggles

b. Methods to minimise the risk of damage to the vehicle and its systems, other people and their property should

include:

i. vehicle protection

ii. precautions when using electrical equipment

iii. disposal of waste materials

iv. awareness of actions to others e.g. magnetic field effects on pacemakers and intravenous insulin

meters

v. a knowledge of COSHH regulations with regard to hazardous battery chemicals and compounds

vi. correct knowledge of thermal runaway in battery stacks/modules

c. Suitable sources of technical information to support electrically propelled vehicle repair activities should

include:

i. manufacturer data, safety data sheets, workshop manuals

ii. third party data, driver, customer

iii. correct method and technique for gathering information from customers, drivers

iv. paper based

v. electronic

vi. on vehicle data/warnings

d. The use of technical information to support electrically propelled vehicle repair activities should include:

i. wiring diagrams

ii. repair instructions

iii. bulletins

iv. verbal instruction

v. on vehicle data/warning

vi. manufacturer specific data

e. Appropriate tools and equipment to carry out electrically propelled vehicle repairs should include:

i. hand tools

ii. diagnostic code readers

iii. specialist tools

iv. correctly rated electrical multimeters

f. Equipment that may be calibrated to meet manufacturers’ requirements should include:

i. multimeters

ii. torque wrenches

iii. measuring equipment

iv. manufacturers specialist tools

v. current diagnostic updates

g. The correct use of tools and equipment should include:

i. following manufacturer instructions

ii. following workplace procedures

iii. appropriate use of hand tools

iv. appropriate use of electrical tools

v. appropriate use of specialist tools

vi. relevant training on new dedicated equipment


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01-09-11V4

Content:

h. The correct procedures required when removing and replacing electrically propelled vehicle drive train system

vehicle components should include:

i. observation of H & S

ii. correct use of PPE

iii. correct use of tools and equipment

iv. correct use of tools and equipment

v. following repair procedures

vi. following workplace procedures

vii. referral to manufacturer specific information

i. The knowledge of disconnecting high energy supplies correctly should include:

i. batteries

ii. motors

iii. cabling

iv. control units

v. relays

vi. switches

vii. charging system

viii. circuit protection

ix. associated connectors

x. auxiliary system components

j. Make the system safe prior to carrying out repairs should include:

i. isolate/disconnect high energy system following manufacturer’s instructions

ii. test high energy system with correctly rated voltmeter and PPE

iii. allowing discharge time for capacitance in disconnected circuits.

k. High energy components that must be disconnected should include:

i. high energy battery pack/modules

ii. charger

iii. battery management interface

iv. inverter

v. air brake compressor

vi. power steering motor

vii. electric heating / air conditioning

l. Low energy components that must be disconnected should include:

i. control units/fuse boxes

ii. low energy components associated with interior heating

iii. associated cabling

iv. battery

v. switches

vi. lighting

vii. low energy components associated with air conditioning

viii. alarm/immobilizer

ix. central locking

x. electric windows/wipers/washers

xi. central locking

m. Appropriate procedures to confirm repairs successfully carried out should include:

i. on vehicle testing

ii. checking fault codes

iii. voltage/current checks

iv. use of specialist equipment

v. wiring and cable routing integrity

vi. on road testing/drive cycling

n. Demonstrate the correct methods to reset vehicle systems post-repair should include:

i. use of scan tools

ii. on board diagnostics

iii. use of specialist equipment

iv. driver display module

v. instrument information/warning information


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01-09-11V4

Content:

o. Records to be completed accurately, in the format required could include:

i. job cards

ii. warranty records

iii. on line data transfer

iv. workplace internal records as a means of monitoring research and development

p. Comparison of inspection and test results with suitable data could include:

i. wiring diagrams

ii. repair instructions

iii. bulletins

iv. torque settings

v. technical data

vi. research and development data

q. Suitable recommendations based upon the results of carrying out the replacement activities could include:

i. recommendations for further investigation and repairs

ii. recommendations for further replacement

iii. no further action required

iv. recommendations for customer

v. recommendations for improvement in working methods

r. Isolate and re-connect live high energy electrical supplies correctly e.g. batteries, capacitors and motors

s. Reset vehicle systems post-repair e.g. clear fault codes


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UNIT REF: VF02K UNIT TITLE: KNOWLEDGE OF INSPECTION, REPAIR AND REPLACEMENT OF

HIGH PERFORMANCE LIGHT VEHICLE TYRES


Mapping: This unit is mapped to the IMI NOS VF02

Rationale: This unit enables the learner to develop knowledge of inspection, fitting, repairing and maintaining high

performance light vehicle tyres.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Understand high performance light vehicle wheel

and tyre construction, legislation and special

workplace procedures

1.1. Describe the purpose, function and construction of

high performance light vehicle wheels and tyres.

1.2. Describe the types and functions of pressure

monitoring systems

1.3. Describe the current legal requirements for high


1.4. Describe the relevant parts of the British and

European Standard for the repair of high

performance light vehicle tyres

1.5. Give examples of how to deal with specialist waste

materials in their workplace.

2. Understand the tools and equipment used when

working with high performance light vehicle tyres

2.1. Give examples of how to select, prepare, and use

tools and equipment appropriate to working with

high performance light vehicle tyres

2.2. Describe specialist maintenance requirements of

wheel balancing and tyre removal and refitting

machinery

3. Understand the materials used in the repair of

high performance light vehicle tyres

3.1. Describe the types of repair materials available

and when it is permissible for them to be used.

4. Understand how to inspect, remove, repair and

replace high performance light vehicle tyres

4.1. Describe the different types of valve construction

used with high performance light vehicle tyres and

their installation techniques

4.2. Give examples of the meanings of markings used

on standard and high performance light vehicle

tyres and where these can be found.

4.3. Describe the inspection and fault identification

methods and procedures associated with high


4.4. Give examples of the common faults associated

with high performance light vehicle tyres and

wheels.

4.5. Describe high performance light vehicle tyre and

wheel removal, replacement and refitting methods

and procedures.

4.6. Describe the principles of wheel balancing. To

include:

a. static balancing

b. dynamic balancing


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Content:

Tyres are

a Directional tread

b Asymmetric tread

c Composite tread

d High speed ratings (V,W,Y or ZR ratings)

e An aspect ratio of 55% or below

f Run flat capability

Main function of tyres

a. Interaction between tyres, other components and vehicle handling

b. Steering, drive and suspension

c. Passenger comfort

Types of standard and high performance light vehicle wheel and rim construction

a. Light alloy, pressed steel and wire wheels

b. Standard and safety rims (runflat)

c. Asymmetric rims

d. Space saver rims

Markings on standard light vehicle tyres.

a. Speed rating

b. Size Markings

c. Aspect ratio

d. Load handling

e. Ply rating

f. Tread wear indicators

g. EC markings and specialist application markings e.g. ‘M&S’

Inspection and fault identification methods and procedures

a. Inspection:

i. on the rim visual (external)

ii. removed from wheel (internal)

b. Use of tread depth indicators, tyre probes and pressure gauges

c. Information sources including tyre and vehicle manufacturers’ technical data and the importance of accurate

measurements

i. the importance of accurate fault identification

ii. the importance of accurate adjustments

Limits of standard light vehicle tyre wear and serviceability.

a. Tread depth and tyre damage

b. Limitations under BS159 and Construction & Use Regulations

c. Tyre pressure and maintenance requirements

d. Suitability for minor repairs

Common faults associated with standard light vehicle tyres and wheels.

a Excessive tyre wear and abnormal tread wear patterns (centre, outer edges, worn patches)

b Damage to tread or side walls

c Bulging, separation of tread, carcass distortion,

d Impact damage, wheels running out of true, buckled wheels

e Incorrect tyre pressure

f Wrong tyre for vehicle or run flat


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Content: contd

Methods and materials used in the repair of standard light vehicle tyres.

a. Tyre inspection

b. Damage limitation

c. Accurate measurement

d. Repair techniques and methods:

i. preparation of tyre

ii. mechanical and chemical buffing

e. Repair materials:

i. plug patch

ii. patch and filler

iii. solutions and chemicals.

f. Economic use of materials

g. Correct storage of materials (including shelf life)

Principles of interchanging tyres/wheels

a. Over sizing tyre and wheel fitment

b. Longitudinal and diagonal

c. Mixing radial, cross-ply and bias-belted tyres on same axle or different axles

i. lifting and supporting equipment

ii. tyre fitting and removal tools and machinery

iii. hand tools

iv. tyre repair tools

v. measuring equipment

vi. wheel balancing equipment

vii. tyre inflation equipment

Dealing with waste materials including

a Scrapped tyres

b Wheel weights

c Waste repair materials

Removal and fitting methods

To include:

a. Tyre sidewall fitting instructions

b. Vehicle protection

c. Use of hand and impact tools

d. Correct tyre inflation

e. Final inspection

Legal requirements to include:

a Tread depth

b Tyre wall and casing damage

c Tyre pressure

d Mixing of tyre types

e Correct fitting


154

01-09-11V4

UNIT REF: VF02S UNIT TITLE: SKILLS IN INSPECTION, REPAIR AND REPLACEMENT OF HIGH

PERFORMANCE LIGHT VEHICLE TYRES



Rationale: This unit will enable the learner to develop the skills required to inspect, fit, repair and maintain high


LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Be able to work safely when carrying out removal

and replacement activities

1.1 Use suitable personal protective equipment and

vehicle coverings when working on vehicles


or injury to the vehicle, people and the

environment

2. Be able to inspect high performance light vehicle

tyres

2.1. Inspect light vehicle wheels and tyres using

suitable tools, sources of information, and

equipment. To include:

a visual inspection

b measurement of tread depth

c tyre pressures

d balance

3. Be able to repair and replace high performance

light vehicle tyres

3.1. Carry out tyre repair activities within appropriate

timescales, using:

a suitable tools and equipment

b correct repair and replacement techniques

c correct type and size of replacement

components

d correct materials

3.2. Carry out tyre replacement activities within

appropriate timescales

4. Be able to balance wheels and tyres and carry out

final checks on high performance light vehicles

4.1. Carry out wheel balancing to within acceptable

limits

4.2. Carry out final vehicle safety checks in the

workshop, prior to releasing the vehicle to the

customer


recommendations

5.1. Produce work records that are accurate, complete

and passed to the relevant person(s) promptly in

the format required

5.2. Make suitable and justifiable recommendations

for cost effective repairs

5.3. Record and report any additional faults noticed

during the course of their work promptly in the

format required


155

01-09-11V4


1. You must produce evidence of inspecting wheel, tyre and

valve assemblies and the removal and replacement or refitting

of at least 2 of the 5 types of tyre listed below. Those:

with high speed ratings, for example V, W, Y, or Z.(nb

as before in k)

having and aspect ratio of 55% or below

with run flat capability

with directional and asymmetric tread patterns

with composite tread patterns

2. You must produce evidence of repairing at least 1 of the

5 types of tyre listed above.

3. You must produce evidence of balancing a wheel and tyre

assembly to manufacturers’ tolerances.


156

01-09-11V4

UNIT REF: VF04K UNIT TITLE: KNOWLEDGE OF INSPECTION, REPAIR AND REPLACEMENT OF

MOTORCYCLE TYRES



Rationale: This unit enables the learner to develop and knowledge of inspection, fitting, repairing and maintaining

motorcycle, quad bike, tricycle, scooter, moped and sidecar combination wheels and tyres.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Understand motorcycle tyre construction,

legislation and special workplace procedures

1.1. Describe the purpose, function and construction of

motorcycle wheels and tyres

1.2. Describe the current legal requirements for

motorcycle tyres

1.3. Describe the relevant parts of the British and

European Standard for the repair of motorcycle

tyres

1.4. Give examples of how to deal with specialist waste

materials in their workplace

2. Understand the tools and equipment used when

working with motorcycle tyres

2.1. Give examples of how to select, prepare and use

tools and equipment appropriate to working with

motorcycle wheels and tyres

2.2. Describe specialist maintenance requirements of

wheel balancing and tyre removal and refitting

machinery

3. Understand the materials used in the repair of

motorcycle tyres

3.1. Describe the types of repair materials available

and when it may be permissible for them to be

used

4. Understand how to inspect, remove, repair and

replace motorcycle tyres

4.1. Describe the types of valve used in motorcycle

tyres and their removal and installation

techniques

4.2. Give examples of the meanings of markings used

on motorcycle tyres and tubes and where these

can be found.

4.3. Describe the inspection and fault identification

methods and procedures associated with

motorcycle tyres, rims and valves

4.4. Give examples of the common faults associated

with motorcycle tyres, wheels and valves.

4.5. Describe motorcycle wheel, tyre and tube removal

and refitting methods and procedures.

4.6. Describe the principles of wheel balancing. To

include:

a static balancing

b dynamic balancing


157

01-09-11V4

Content:

Note, the term ‘motorcycle’ also refers to: quad bike, tricycle, scooter, moped and sidecar combination tyres.

Describe the purpose, function and construction of motorcycle wheels and construction

a. Tubed

b. Tubeless

c. Radial

d. Bias belted cross ply

e. Two compound technology

f. Directional

g. Spoke wheels

h. Cast wheels

i. Composite wheels

j. Split rims Identify the different types of motorcycle tyre construction

a. Radial

b. Bias and bias belted

c. Tube type

d. Tubeless

e. Tread and sidewall designs (for example, high speed, rotational, off road)

Identify the different types of motorcycle wheel drive arrangements

a. Shaft drive

b. Chain drive

Identify sidewall markings on motorcycle tyres

a. Service description (load and speed markings)

b. Size designations

c. Aspect ratios

d. Construction markings (bias and bias belted, radial, tube type, tubeless)

e. Type approval markings

f. Date of manufacture markings

g. Tread wear indicators

h. Sidewall fitting instructions

i. Special service markings

Inspection and fault identification methods and procedures

a. Inspection:

i. on the rim visual (external)

ii. removed from wheel (internal)

b. Use of tread depth indicators, tyre probes and pressure gauges

c. Information sources including tyre and vehicle manufacturers’ technical data

d. The importance of accurate measurements

e. The importance of accurate fault identification

f. The importance of accurate adjustments

Identify the tools and equipment used to identify faults relating to motorcycle tyres and wheels and confirm them

safe to use

a. Tyre tread depth gauges

b. Tyre probes

c. Bead spreaders

d. Tyre pressure gauges

e. Hand lamps or torches


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Content: contd

Identify the faults relating to motorcycle tyres and wheels

a. Suitable personal protective equipment for conducting Motorcycle tyre and rim inspections

b. Worn tread through normal use

c. Abnormal wear (wheel misalignment, over and under-inflation, incorrect application and adjustment)

d. Carcass damage (lumps and bulges, cuts, exposed cords, run-flat damage, penetrations, chemical damage)

e. Incorrect fitment (load rating, speed rating, size, construction, tread design, sidewall information)

f. Worn or damaged wheels and components (cracks, deformations).

g. Worn, damaged or incorrect wheel fixings and axle

h. Worn or damaged valves

i. Worn, damaged or incorrect tubes

Make recommendations relating to motorcycle tyres and wheels

a. Suitability for fitting

b. Suitability for minor repair

c. Isolate scrapped tyres for correct disposal

d. Isolate scrapped wheel rims and components for correct disposal

e. Consequences of improper disposal of scrap tyres and wheels

Identify the tools and equipment used for the removal and fitting of motorcycle wheels and tyres and confirm

them safe to use

a. Technical information relating to safe lifting points and wheel torque and tyre pressure data.

b. Motorcycle stands.

c. Hand tools and torque wrenches.

d. Bead unseating tools, tyre levers, bead lubricant.

e. Tyre inflation equipment

f. Wheel balancing equipment

Remove and fit motorcycle tyres and wheels

a. Manufacturer and sidewall fitting instructions

b. Protecting the motorcycle during wheel and tyre removal and fitting.

c. Suitable personal protective equipment for motorcycle tyre and wheel removal and fitting.

d. Use and positioning of lifting and supporting devices.

e. Wheel removal and fitting using hand tools

f. Tyre removal and fitting using hand or powered tools

g. Valve replacement for wheel rims.

h. Safe tyre inflation

i. Wheel balancing

j. Wheel alignment

k. Informing relevant persons of anticipated delays.

l. Keeping relevant persons informed of progress

m. The relationship between time and cost

Methods and materials used in the repair of motorcycle tyres

a Repair Materials:

i. rubber only plug patch

ii. rubber only patch and filler material

iii. solutions and chemicals

Identify the tools and equipment used for the minor repair of Motorcycle tyres and inner tubes and confirm them

safe to use

a. Technical information relating to minor repair areas, repair unit application instructions and injury limitations

b. Suitable personal protective equipment for tyre and inner tube repairing.

c. Measuring equipment for determining repairable areas

d. Reamers, buffers and tyre bead spreaders

e. Plug patch applicators, tyre probes, cover scrapers, roller stitchers, pliers and side cutters.

f. Liquid buffing solutions, chemical vulcanising fluids, liner seal solutions and tyre talc (French

Chalk)Combination plug/patches, patch and filler materials, inner tube patches


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01-09-11V4

Content: contd

Carry out minor repairs to motorcycle tyres and inner tubes

a. Internal inspection of tyre for secondary damage.

b. Preparation of the tyre for application of repair materials

c. Preparation of inner tube for application of repair materials

d. Inspection of tyre and tube after repair

e. Inflation of tyre/tube to check for leaks

Main function of tyres

a. Interaction between tyres, other components and handling

b. Steering, drive and suspension

c. Passenger comfort

a Lifting and supporting equipment

b Tyre fitting and removal tools and machinery

c Hand tools

d Tyre repair tools

e Measuring equipment

f Wheel balancing equipment

g Tyre inflation equipment

Dealing with waste materials including:

a. Scrapped tyres

b. Wheel weights

c. Waste repair materials

Legal requirements to include:

a Tread depth

b Tyre wall and casing damage

c Tyre pressure

d Mixing of tyre types

e Correct fitting


160

01-09-11V4

UNIT REF: VF04S UNIT TITLE: SKILLS IN INSPECTION, REPAIR AND REPLACEMENT OF

MOTORCYCLE TYRES



Rationale: This unit will enable the learner to develop the skills required to inspect, fit, repair and maintain motorcycle,

quad bike, tricycle, scooter, moped and sidecar combination tyres.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Be able to work safely when carrying out removal

and replacement activities

1.1. Use suitable personal protective equipment and

vehicle coverings when working on vehicles


or injury to the vehicle, people and the

environment

2. Be able to inspect motorcycle tyres

2.1. Inspect motorcycle wheels and tyres using suitable

tools, sources of information, and equipment. To

include:

a. visual inspection

b. measurement of tread depth

c. tyre pressures

d. balance

3. Be able to repair and replace motorcycle tyres and

tubes

3.1. Remove front and rear wheels from motorcycles to

facilitate tyre removal and refitment

3.2. Carry out tyre repair activities using:

a. suitable tools and equipment

b. correct repair and replacement techniques

c. correct type and size of replacement

components

d. correct materials

3.3. Carry out tyre replacements activities within

appropriate timescales

3.4 Use suitable equipment to align front and rear

wheels following wheel refitment

4. Be able to balance wheels and tyres as part of final

checks on motorcycles

4.1. Carry out wheel balancing to manufacturers’

tolerances

4.2. Carry out final vehicle safety checks in the

workshop, prior to releasing the motorcycle to the

customer


recommendations

5.1. Produce work records that are accurate, complete

and passed to the relevant person(s) promptly in

the format required

5.2. Make suitable and justifiable recommendations

for cost effective repairs

5.3. Record and report any additional faults noticed

during the course of their work promptly in the

format required


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01-09-11V4


1. You must produce evidence of inspecting wheel, tyre and

valve assemblies and the removal and replacement or

refitting motorcycle tyres on at least 2 different

occasions.

2. You must produce evidence of repairing a motorcycle

tyre.

3. You must produce evidence of successfully balancing 1

wheel and tyre assembly to manufacturers’ tolerances,

4. You must produce evidence of carrying out final wheel

and tyre related safety checks on 1 motorcycle.


162

01-09-11V4

UNIT REF: RRO3K UNIT TITLE: KNOWLEDGE IN ASSESSING AND SECURING THE ROADSIDE

SITUATION


Mapping: This unit is mapped to the IMI NOS RR03

Rationale: This unit enables the learner to develop an understanding of securing and making an initial assessment of

the site and vehicle in order to make decisions for further action. Providing information to and seeking guidance from

relevant specialist authorities where hazardous substances or situations may be involved.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Understand about organisational requirements

and procedures

1.1. Describe the range of services and resources

within a typical roadside assistance/recovery

organisation.

1.2. Explain operating, reporting and recording

procedures for a typical roadside

assistance/recovery organisation.

1.3. Explain how to complete records and the

importance of doing so in a roadside assistance/

recovery context

2. Understand the legal requirements and codes of

practice for site protection and recovery

arrangements

2.1. Describe the legal requirements and industry

codes of practice governing site protection and

recovery operations.

2.2. Explain the importance of wearing personal

protective equipment.

3. Understand how to assess and secure a site

3.1. Describe the difference in requirements for

securing and protecting a breakdown site and an

accident site.

3.2. Describe the sources of specialist advice and

guidance.

3.3. Describe how weather conditions affect the

assessment and security of the roadside situation.

3.4. Explain how to approach the scene of an incident.

3.5. Describe the circumstances in which to call for

specialist assistance.

3.6. Describe how to secure and protect incident sites

in line with current industry codes of practice.

3.7. Describe how to take steps to secure the safety of

yourself and others.

3.8. Explain how to use electronic and radio

communication methods.

3.9. Describe how to communicate with customers and

relevant authorities

3.10. Describe how to make an initial assessment of

the extent of vehicle damage and or faults.

3.11. Explain how to identify vehicles carrying

hazardous substances.

3.12. Describe the possible consequences of

inaccurate roadside assessment


163

01-09-11V4

Content

Organisational requirements and procedures

a. The range of services and resources within a typical roadside assistance/recovery organisation. i. roadside assistance-service vans, light, commercial, motorcycle

ii. recovery-light, commercial, motorcycle, breakdown, accident

iii. customer welfare-protection at the scene, welfare facilities at base-toilets, refreshments etc.

b. Operating, reporting and recording procedures for a typical roadside assistance/recovery organisation. i. receiving of work-office, dedicated control centre

ii. distribution of work-types of communication methods

iii. recording of work-database, hand held devices, Job cards

c. How to complete records and the importance of doing so in a roadside assistance/ recovery context

i. risk assessment-generic, specific, dynamic-difference, Importance

ii. electronic records-hand held device job completion, damage reports

iii. manual recording systems-job cards, damage reports

The legal requirements and codes of practice for site protection and recovery arrangements

a. The legal requirements and industry codes of practice governing site protection and recovery operations

i. HASAWA-Employers duties, employees duties, duty of care

ii. PAS 43-Industry guidance document

iii. Sector agreement-Life On The Edge 6, regarded as the code of practice for the recovery sector

b. The importance of wearing personal protective equipment.

i. last resort-In many cases no other way of reducing the risk

ii. personal safety-operator safety paramount, warns other road users

How to assess and secure a site

a. The difference in requirements for securing and protecting a breakdown site and an accident site.

i. the risk assessment-Increased hazards present at an accident scene

ii. services present-police, HATO, other emergency services

iii. casualty occupants-time at scene, shocked from RTC, children and babies

iv. welfare needs-toilet facilities, refreshments, on-going journey arrangements

v. temporary traffic management-beacons, relaxed sign layout(signs and cones carried on the recovery

vehicle), standard sign layout(signs and cones laid out by a third party), road closure

b. The sources of specialist advice and guidance

i. Company procedures and risk assessments

ii. The Life on the Edge series of films

iii. PAS 43

iv. Company management, line manager, control centre, incident manager

v. Police-Officer on scene, control room

vi. Highways Agency-traffic officer on scene, control centre

c. Why weather conditions affect the assessment and security of the roadside situation.

i. visibility-heavy rain, snow, bright sunshine

ii. extreme cold-Increased hazards due to ice, additional clothing required, use of gloves

iii. extreme heat-personal comfort, PPE

iv. high winds-commercial vehicle risks

d. Approaching the scene of an incident

i. flow of traffic-type of road, is there a hard shoulder? Is there a place of safety?

ii. slowing down to park at scene-Warnings, indicators, other means

iii. parking position-in front of casualty, behind casualty

iv. distance to casualty vehicle

v. beacons-are they needed?

vi. personal protective equipment-minimum requirements

vii. exiting the recovery vehicle-safety, checking for traffic, correct dismount

viii. codes of practice (PAS 43)

ix. communication and reporting to relevant people and organisations using appropriate method.


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Content: contd

e. Circumstances in which to call for specialist assistance.

i. injuries to passengers-not known to emergency services, who to call, unlikely event

ii. disabled passengers-cannot get in to the recovery vehicle, specialist vehicle not available

iii. hazardous substances present-Who should be called

f. Securing and protecting incident sites in line with current industry codes of practice

i. ‘fend’ position

ii. recovery vehicle conspicuity

iii. recovery vehicle beacons

iv. relaxed sign layout-cones and signs on the recovery vehicle

v. standard sign layout-cones and signs laid out by a third party ( Police or HA)

vi. road closure

g. How to take steps to secure the safety of yourself and others.

i. personal safety-watching, listening, using a lookout

ii. passengers of casualty vehicles-control of movement, safe waiting areas, type of road

iii. the public-safe working zones, control methods, 3rd party control (i.e. Police)

h. Explain how to use electronic and radio communication methods.

i. types of communication equipment-Radio, Mobile telephone, Mobile Data Terminal, PDA

ii. licence requirements

iii. use of correct language

iv. on route

v. on scene

vi. delays

vii. job completion

viii. assistance needed

ix. at base or waiting area

I. How to communicate with customers and relevant authorities

i. customers-respect, empathy, compassion, firmly

ii. police-officer in charge, recovery requirements

iii. highways agency-traffic officer on scene, recovery requirements

iv. other-other emergency services, EA, Utility managers/workers, Traffic management

j. How to make an initial assessment of the extent of vehicle damage and or faults.

i. breakdown-what is the fault? Is a repair quicker than recovery? Are parts required? Do you have the

correct recovery vehicle? Prestige vehicles, Safety issues

ii. accident-How much damage is there? Does the casualty roll? How many casualties are there? Do you

have the correct recovery vehicle? Are there special requirements by the Police? (Preservation of

mechanical evidence etc)

k. How to identify vehicles carrying hazardous substances.

i. marker plates-types, shapes, colours, numbering system

l. Describe the possible consequences of inaccurate roadside assessment

i. danger to recovery technician

ii. danger to driver/passengers of casualty

iii. danger to others


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UNIT REF: RR03S UNIT TITLE: SKILLS IN ASSESSING AND SECURING THE ROADSIDE

SITUATION


Mapping: This unit is mapped to the IMI NOS RR03

Rationale: This unit will help the learner to develop the skills needed to secure and make an initial assessment of the

site and vehicle in order to make decisions for further action. Provide information to and seek guidance from relevant

specialist authorities where hazardous substances or situations may be involved.

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Be able to secure and protect an incident site

1.1. Carry out roadside assessment and security

activities wearing suitable personal protective

equipment throughout

1.2. Show how to secure and protect an incident site to

comply with legal requirements, current industry

codes of practice, prevailing weather conditions

and the roadside situation

2. Be able to secure the safety of themselves and

others

2.1. Show how to secure the immediate safety of

themselves and the driver and passengers of a

casualty vehicle.

3. Be able to make an initial assessment of a site and

provide information to others

3.1. Carry out their initial assessment of the incident

identifying:

a The existence of any hazardous or

potentially hazardous substances

b Any real or potential fire risks

c The use of beacons

d Relaxed sign layout

e Standard sign layout

f Road closure

g The need for any specialist assistance

3.2. Provide information promptly and clearly to all

relevant authorities and their control centre

covering:

a. The existence of any injured persons

b. The prevailing weather conditions

c. The location and roadside situation

d. The nature of the incident

e. Real and potential hazards

3.3. Show how to seek assistance and guidance

promptly from the relevant authorities when they

believe that hazardous substances are present.

3.4. Carry out an initial assessment of the vehicle to

establish:

a. The nature and extent of damage or

breakdown

b. The feasibility of a roadside repair

3.5. Make justifiable decisions for a course of action

based upon the information gained from their

initial assessment of the situation


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1. You must produce evidence of assessing and securing a

simulated roadside situation, comprising the following

specified situation

1 breakdown off a live carriageway

The evidence should also show how to secure the safety of the driver / passengers of a broken down vehicle


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UNIT REF: L121 UNIT TITLE: INTRODUCTION TO LOW CARBON TECHNOLOGIES IN THE

AUTOMOTIVE INDUSTRY

Level: Level 1 Route:

Credit value: 3

Guided Learning Hours: 20

Rationale: This unit aims to encourage learners to realise how there actions in driving vehicles can impact the

environment and some of the measures vehicle manufacturers are taking to reduce carbon outputs.

LEARNING OUTCOMES

The learner will:

1. Know how their own actions can affect the environment

2. Know the impact that a conventional vehicle has on the environment

3. Know some of the actions vehicle manufacturers are taking to reduce carbon emissions

LEARNING OUTCOMES

The Learner will:

ASSESSMENT CRITERIA

The Learner can: 1. Know how their own actions can affect the

environment

1.1. Give examples of driving styles that harm the

environment

1.2. Give examples how they can reduce carbon emissions

when travelling

2. Know the impact that a conventional vehicle

has on the environment

2.1. Identify the exhaust emissions that a conventional

vehicle produces

2.2 Describe the impact of exhaust emissions on people and

the environment

2.3 State the meaning of ‘carbon footprint’

3. Know some of the actions vehicle

manufacturers are taking to reduce carbon

emissions

3.1. State the common vehicle parts that may be recycled

3.2. Identify the new types of propulsion available in modern

and future vehicles

3.3. State the benefits of alternative fuel types and

propulsion methods for the user and environment

3.4. Describe how bio-fuels can reduce carbon emissions


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Content to include:

1.1 Examples of driving styles that harm the environment are:

a. Excessive acceleration

b. Excessive deceleration

c. Driving at high speed

d. Idling engine whilst stopped

e. Incorrect gear selection

f. Use of auxiliary equipment e.g. air conditioning

1.2 Examples how carbon emissions can be reduced when travelling (in addition to not doing the above):

a. Carefully planned routes

b. Use motor transport less- walk, cycle

c. Car sharing

d. Use public transport

e. More efficient vehicles- lower engine size, alternative fuel vehicles

f. Correctly inflated tyres

g. Properly serviced and maintained vehicles

h. Do not carry excessive loads e.g. empty vehicle boot

i. Keep windows closed to reduce drag

2.1, 2.2 Exhaust emissions that a conventional vehicle produces and harmful effects:

a. Carbon monoxide – colourless, odourless, poisonous to animal life

b. Carbon dioxide – greenhouse gas that contributes to global warming

c. Oxides of Nitrogen – can cause respiratory conditions, smog and acid rain

d. Sulphur dioxide – pollution and acid rain

e. Soot particles – causes respiratory problems and cancers

f. Hydrocarbons - causes respiratory problems, liver damage and cancers

2.3 Carbon footprint relating to a vehicle can be defined as:

a. The amount of greenhouse gases, most commonly carbon dioxide, produced over the life time of a

vehicle. This includes during the manufacture, running and disposal of the vehicle at the end of its

working life.

3.1 The common vehicle parts that may be recycled are:

a. Metals

b. Plastics

c. Oils

d. Other fluids e.g. brake fluid and antifreeze

e. Batteries

f. Refrigerant from air conditioning systems

g. Glass

h. Tyres

3.2, 3.3 New types of propulsion available in modern and future vehicles and benefits:

a. Low emission conventional engine e.g lean burn- improvement on normal engines but not vastly

b. Alternative fuels including LPG and bio-fuel engines- normally uses a mixture of normal fuels and gas, or

fuels produced from vegetable or plant extracts resulting in reduced engine emissions, renewable, and

less processing required than crude oil

c. Hybrid vehicles using a combination of power sources such as conventional engine and electric motors-

resulting in reduced emissions, improved fuel consumption

d. Electric vehicles using solely electric motors to propel the vehicle. Benefits are zero emissions and low

running cost but expensive at present and limited range. Expected to increase in numbers considerably

over the next few years

e. Hydrogen powered vehicles- zero emissions but limited availability and hazardous

3.4 How bio-fuels can reduce carbon emissions:

a. Potential to reduce greenhouse gases because the carbon in the plant matter from which the fuel is

produced comes from the carbon dioxide absorbed by the plants over the course of its life. Unlike fossil

fuels where the carbon has been locked up under ground for millions of years and then released to the

atmosphere as carbon dioxide when burnt during combustion.

b. impact on land being used for growing fuel crops instead of food crops

assessment criteria for - institute of the motor industry

Documents