December Edition 2012

MINISTRY OF EDUCATION, MALAYSIA MODULE INFORMATION

MODULE CODE LEVEL CREDIT UNIT CONTACT HOUR

: : : : :

SUSPENSION SYSTEM 2 MAT 401 2 SEMESTER 4 2.0 FACE TO FACE : 3.0 HOURS / WEEK

NON FACE TO FACE : MODULE STATUS PREREQUISITE CORE REQUISITE : : : VOCATIONAL -

Last Edited Module Page

03 06 Dec 2012 1/10 Document Page 1

December Edition 2012

MODULE OUTCOMES: At the end of the course, the students should be able to:1. Identify Macpherson strut assembly location 2. Remove Macpherson strut assembly 3. Dismantle Macpherson strut assembly 4. Assemble Macpherson strut assembly 5. Install Macpherson strut assembly to vehicle 6. Identify suspension ball joint location 7. Remove suspension ball joint assembly 8. Check suspension ball joint 9. Install suspension ball joint 10. Identify suspension bushes location 11. Remove suspension bushes 12. Check suspension bushes 13. Install suspension bushes 14. Identify suspension control arm location 15. Remove suspension control arm 16. Check suspension control arm 17. Install suspension control arm

MODULE DESCRIPTION Carry out Macpherson strut assembly replacement using service manual, hand tools, Macpherson-strut assembly replacement parts so that Macpherson-strut assembly location identified, removed, dismantled, assembled and installed in accordance with manufacturers service manual Carry out suspension ball joint replacement using service manual, hand tools, special tools, suspension ball joint so that suspension ball joint location identified, removed, check and installed according to manufacturers service manual Carry out suspension bushes replacement using service manual, hand tools, special tools, suspension bushes so that suspension bushes location identified, removed, check and installed in accordance with manufacturers service manual

Last Edited Module Page

03 06 Dec 2012 2/10 Document Page 2

December Edition 2012

CONTENT AND LEARNING STANDARD COURSE MODULE CODE : AUTOMOTIVE TECHNOLOGY : VECHICLE SUSPENSION : MAT 401

KOMPETENSI

KAEDAH PENGAJARAN

PERFORMANCE CRITERIA

KAEDAH PENTAKSIRAN

BAHAN / SUMBER

1.CARRY OUT

1.1 Identify Macpherson strut assembly location

MACPHERSON STRUT ASSEMBLY

REPLACEMENT

1.1.1. Describe type of Macpherson strut assembly in accordance with manufacturers service manual 1.1.2. Explain the purpose of Macpherson strut assembly in accordance with manufacturers service manual 1.1.3. Describe construction of

Memberi penekanan dan penjelasan mengapa keperluan ini perlu dipatuhi. Menyediakan folio/laporan Kuiz dan Ujian

1. Buku rujukan Automotif 2. Kereta proton 3. Tupang McPherson 4. Jek kenderaan 5. Safety stand 6. Bearing grease 7. Pembuka tayar 8. Set sepana 9. Set tools box

Last Edited Module Page

03 06 Dec 2012 3/10 Document Page 3

December Edition 2012

1.2 Remove Macpherson strut assembly

Macpherson strut assembly in accordance with manufacturers service manual 1.1.4. Locate Macpherson strut assembly in accordance with Pengajar menunjuk cara kepada manufacturers murid dan murid kompeten. service manual

1. 1. Buku rujukan Automotif 2. Kereta proton 3. Tupang McPherson 4. Jek kenderaan 5. Safety stand 6. Bearing grease 7. Pembuka tayar 8. Set sepanar 9. Set tools box

Demonstrasi penggunaan dengan kaedah yang betul. Membuat latihan

1.2.1. Detach insulator flange nuts in accordance with manufacturers service manual 1.2.2. Detach steering knuckle from strut assembly in accordance with manufacturers service manual 1.2.3. Detach Macpherson strut assembly in accordance with manufacturers

1.3 Dismantle Macpherson strut assembly

Last Edited Module Page 03 06 Dec 2012 4/10

Document Page

December Edition 2012

service manual 1.2.4. Steering knuckle detaching procedure accordance with manufacturers service manual 1.2.5. Macpherson strut assembly detaching procedure accordance with manufacturers service manual

Pengajar menunjuk cara kepada murid dan murid kompeten. Demonstrasi penggunaan dengan kaedah yang betul Membuat latihan

1.4 Assemble Macpherson strut assembly

1.3.1. Describe Macpherson strut assembly components parts in accordance with workshop service manual 1.3.2. Compress coil spring in accordance with workshop service manual 1.3.3. Detach insulator assembly, upper spring seat, front spring pad, rubber bump, dust cover and spring, from strut in accordance with

Pengajar menunjuk cara kepada murid dan murid kompeten. Demonstrasi penggunaan dengan kaedah yang betul. Membuat latihan

Last Edited Module Page

03 06 Dec 2012 5/10 Document Page 5

December Edition 2012

workshop service manual

1.5 Install Macpherson strut assembly to vehicle

1.4.1. Macpherson strut assembly fixing procedure accordance with workshop service manual 1.4.2. Insulator assembly, spring fitting technique accordance with workshop service manual 1.4.3. Flange nut tightening technique accordance with workshop service manual 1.4.4. Fit insulator assembly, spring. in accordance with manufacturers service manual 1.4.5. Secure Flange nut in accordance with manufacturers service manual

Pengajar menunjuk cara kepada murid dan murid kompeten. Demonstrasi penggunaan dengan kaedah yang betul. Membuat latihan

Last Edited Module Page

03 06 Dec 2012 6/10 Document Page 6

December Edition 2012

1.5.1. Fix Macpherson strut component parts in accordance with manufacturers service manual 1.5.2. Tighten stabiliser link in accordance with manufacturers service manual 1.5.3. Fix steering knuckle in accordance with manufacturers service Manual 1.4.6. Stabiliser link tightening technique accordance with workshop service manual 1.4.7. Steering knuckle fixing technique accordance with workshop service manual

Last Edited Module Page

03 06 Dec 2012 7/10 Document Page 7

December Edition 2012

CONTENT AND LEARNING STANDARD COURSE MODULE CODE : AUTOMOTIVE TECHNOLOGY : VECHICLE SUSPENSION : MAT 401

CONTENT STANDARD

LEARNING STANDARD

PERFORMANCE CRITERIA 2.1.1. Describe types of suspension ball joint in accordance with manufacturers service manual 2.1.2. Explain the purpose of suspension system in accordance with manufacturers service manual 2.1.3. Detach lower arm in accordance with workshop service manual 2.1.4. Locate suspension ball joint in accordance with workshop service manual 2.1.5. Construction of suspension system in accordance with manufacturers service manual
Document Page 8

2.CARRY OUT SUSPENSION BALL JOINT REPLACEMENT

2.1 Identify suspension ball joint location

Last Edited Module Page

03 06 Dec 2012 8/10

December Edition 2012

2.1.6. Location of suspension ball joint in accordance with workshop service manual 2.2.1. Detach suspension ball joint in accordance with manufacturers service manual 2.2.2. Describe types of suspension ball joint in accordance with manufacturers service manual 2.2.3. Detach lower arm in accordance with workshop service manual 2.2.4. Lower arm detaching procedure in accordance with workshop service manual 2.2.5. Suspension ball joint detaching technique in accordance with workshop service manual 2.3.1. Explain function of the suspension ball joint in accordance with manufacturers service manual 2.3.2. Test the condition of suspension ball joint in accordance with manufacturers service manual 2.3.3. Determine suspensions ball joint condition in accordance with manufacturers service manual 2.4.1. Attach suspension ball joint in accordance with manufacturers service manual 2.4.2. Secure suspension ball joint in accordance with manufacturers service manual

2.2 Remove suspension ball joint assembly

2.3 Check suspension ball joint

2.4 Install suspension ball joint

Last Edited Module Page

03 06 Dec 2012 9/10 Document Page 9

December Edition 2012

CONTENT AND LEARNING STANDARD COURSE MODULE CODE : AUTOMOTIVE TECHNOLOGY : VECHICLE SUSPENSION : MAT 401

CONTENT STANDARD

LEARNING STANDARD

PERFORMANCE CRITERIA

3.CARRY OUT SUSPENSION BUSHES REPLACEMENT

3.1 Identify suspension bushes location

3.1.1 3.1.2 3.1.3

Describe type of suspension bushes in accordance with manufacturers service manual Explain the purpose of suspension bushes in accordance with manufacturers service manual Locate suspension bushes in accordance with workshop service manual

Last Edited Module Page

03 06 Dec 2012 10/10 Document Page 10

December Edition 2012

3.2 Remove suspension bushes

3.2.1 3.2.2

Detach suspension components in accordance with workshop service manual Detach suspension bushes in accordance with workshop service manual Describe suspension bushes testing procedure in accordance with manufacturers service manual Determine condition of suspension bushes in accordance with workshop service manual Fix suspension bushes in accordance with manufacturers service manual Secure suspension bushes in accordance with manufacturers service manual Fix suspension components in accordance with manufacturers service manual Suspension bushes attaching procedure in accordance with manufacturers service manual

3.3 Check suspension bushes

3.3.1 3.3.2

3.4 Install suspension bushes

3.4.1 3.4.2

3.4.3 3.4.4

Last Edited Module Page

03 06 Dec 2012 11/10 Document Page 11

December Edition 2012

CONTENT AND LEARNING STANDARD COURSE MODULE CODE : AUTOMOTIVE TECHNOLOGY : VECHICLE SUSPENSION : MAT 401 LEARNING STANDARD PERFORMANCE CRITERIA

CONTENT STANDARD

4.CARRY OUT CONTROL ARM REPLACEMENT

4.1 Identify suspension control arm location

4.1.1 4.1.2 4.1.3

Explain the purpose of control arm in accordance with manufacturers service manual Describe construction of the control arm in accordance with workshop service manual Locate front / rear control arm in accordance with workshop service manual Describe control arm attachment parts in accordance with
Document Page 12

4.2 Remove suspension control

Last Edited Module Page 03 06 Dec 2012 12/10

4.2.1

December Edition 2012

arm 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.2.7

manufacturers service manual Detach control arm attachment parts in accordance with manufacturers service manual Detach control arm from vehicle in accordance with manufacturers service manual Control arm attachment parts in accordance with workshop service manual Control arm attachment parts detaching procedure in accordance with workshop service manual Control arm detaching procedure in accordance with workshop service manual Control arm detaching technique in accordance with workshop service manual Describe function of suspension control arm in accordance with manufacturers service manual Describe suspension control arm testing procedure in accordance with manufacturers service manual Determine condition of suspension control arm in accordance with manufacturers service manual Attach suspension control arm in accordance with manufacturers service manual Secure suspension control arm bolts and nuts in accordance with manufacturers service manual

4.3 Check suspension control arm

4.3.1 4.3.2 4.3.3

4.4 Install suspension control arm

4.4.1 4.4.2

Last Edited Module Page

03 06 Dec 2012 13/10 Document Page 13