Dip_Automotive_Tech._NSQF-6

Diploma in Automotive Technology
GOVERNMENT OF INDIA
MINISTRY OF SKILL DEVELOPMENT & ENTREPRENEURSHIP
DIRECTORATE GENERAL OF TRAINING
COMPETENCY BASED CURRICULUM
Advance Diploma
AUTOMOTIVE TECHNOLOGY
Sector - Automotive
Advance Diploma
AUTOMOTIVE TECHNOLOGY
(Designed in 2019)
Version: 1.0
NSQF LEVEL – 6
Qualification Code: DGT/5002
Developed By
Ministry of Skill Development and Entrepreneurship

Directorate General of Training
CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE
EN-81, Sector-V, Salt Lake City,
Kolkata – 700 091
ACKNOWLEDGEMENT
The DGT sincerely acknowledges contributions of the Industries, Trade Experts, Domain
Expertsand all others who contributed in preparation &vetting the curriculum. Special
acknowledgement is expended by DGT to the following expert members who had contributed
immensely in this curriculum.
Sl. Name & Designation Organization Remarks

No. Sh/Mr./Ms.
Industry/Academic Representative:
1. P. Thangapazham, AGM HR Training, Daimler, Chennai Member
S.Venkatakrishnan, Dy.Mgr Maruti Suzuki India Ltd, Chennai Member
2.
(VSITP )
Murugesan.P., DGM – TVS Training & Services Ltd, Chennai Member
3.
Training
M.Arulmozhivarman, LansonToyaota, Chennai Member
4.
Technical Manager
5. V. Krishanshankar, DGM Training Ashok Leyland, Chennai Member
Atul Chandekar, Divisional Ashok Leyland, Chennai Member
6.
Manager, Service Training
R. Jayaprasad, Automobile GTTI-Coimbatore Member
7.
Instructor
Dr.R.Subramanian, Prof and Department of Automobile Member
8.
Head Engineering, IRTT,Erode.
9. M.Veerasamy, GM, Service CARS India Ltd Member
10. N.Arunkumar, Asst. Manager Ashok Leyland, Chennai Member
R.Durai Raj, Asst. Manager LansonToyaota, Chennai Member
11.
DCTC
Ramaiah, Senior Manager, Airport Authority of India, Chennai Member
12.
Retd.
D.Viswanathan, Senior LansonToyaota, Chennai Member
13.
Manager
Shri Dr.K.Annamali, HOD, Dept Auto Engg, M.I.T, Anna Member
14.
University, Chennai.
DGT/MSDE Representative
Dinesh Kumar Nijhawan, CFI, DGT/MSDE, New Delhi Chairman
15.
Director
16. R. Senthilkumar, Director ATI Chennai Member
M.K.Parial, Joint Director of DGT/MSDE, New Delhi Member
17.
Trg
18. Sandeep Kosaraju, Young DGT/MSDE, New Delhi Member
Professional
Madhu Nair, Executive NIMI, Chennai Member
19.
Director I/C
C.Chandrasekar, CTI, Chennai Member
20. Principal/Joint Director of
Training
K.Srininvasa Rao, Joint NIMI, Chennai Member
21.
Director of Trg,
S.Mathivanan, Joint Director ATI Chennai Member
22.
of Training
Dr.M.Jayaprakasan, Deputy ATI Chennai Member
23.
Director of Training
B.Ravi, Deputy Director of ATI Chennai Member
24.
Training
C.Yuvaraj, Deputy Director of Section I/C Automotive, ATI Chennai Member
25.
Training
R.RajeshKanna, Training ATI Chennai Member
26.
Officer- Automotive
Ramesh Kumar, Training CTI Chennai Member
27.
Officer
CONTENTS
S No. Topics Page No.

1 Course Information 1-5
2 Training System 6-10
3 Job Role 11
4 General Information 12
5 NSQF Level Compliance 13
6. Learning Outcome 14-16
7. Learning Outcome with Assessment Criteria 17-29
8. Syllabus – Professional Skill, Professional Knowledge 30-108
9. Syllabus – Employability Skill 109-113
10. Annexure I - List of Trade Tools & Equipment 114-166
11. Annexure II - Format for Internal Assessment 167
Diploma in Automotive Technolog
1. COURSE INFORMATION
Introduction:
The Ministry of Skill Development and Entrepreneurship is an apex organization for the
development and coordination of the vocational training in our country. The Ministry conducts the
vocational training programmes through the Craftsmen Training Scheme (CTS), Apprenticeship
Training Scheme (ATS), Modular Employable Scheme (MES) under the Skill Development Initiative
(SDI) Scheme, and Craftsmen Instructor Training Scheme (CITS) to cater the needs of different
segments of the Labour market. The National Council for Vocational Training (NCVT) acts as a
central agency to advise Government of India in framing the training policy and coordinating
vocational training throughout India. The day-to-day administration of the ITIs rests with the State
Governments/ Union Territories.
Issues Related to Vocational Training:
Key workforce related issues observed from demand perspective have typically been the
following:
 Low employability due to technical incompetency.
 Lack of employee attitude/inclination for career in engineering.
 Skill gap arises when the education and training system is not responsive to the changing
needs of the industry requirements.
To address theseissues, Ministry has set up Mentor Councils to focus on courses under
NCVT in various sectors with representation from different stakeholders viz., industries, innovative
entrepreneurs, academic/professional institutions, and champion ITIs for each of the sectors. The
Mentor Council for each sector reviews curriculum, course duration, and assessment/evaluation
systems for the sector on a continuous basis and make recommendations.
Skill Diploma Initiative:
In addition to that, the Ministry has planned to start Skill Diploma courses to cater
the need of demand raised on a comprehensive workforce requirement, under NCVT gamut. The
proposed skill diploma holders will be trained more on practical competencies (70% Practical &
30% Theory) rather than more of theoretical knowledge offered in polytechnic/Diploma colleges.
5
Benefits:
Industry Advantage:
The Ministry of skill Development & Entrepreneurship will provide a pool of automotive
engineering technician personnel at shop floor supervisor cum welder level, trained to
international bench mark for industry. This will also enable industry to take challenges in the
Fabrication product development and manufacturing.
Career for Automotive Engineering Professionals:
The Diploma offers opportunity for upward career progression for the NCVT-NTC
certificate holders. There is enormous scope to obtain national and overseas appointment for
Diploma holders starting from the ground level to Automobile engineer.
Course Particulars:
In this Diploma in Automotive Technology, the trainee is trained on Five Core modules
each of 320 hours duration in first year. Each Core module contains professional skill &
professional knowledge. In addition to this, the trainee is entrusted with the project work and
extracurricular activities to build up confidence. In second year, there are three electives where
trainee has to select any of two elective modules, each module containing 320 hours duration
with total duration of 640 hours. The trainee will be trained in Industry for 800 hours (as a part of
on-the-job training). There will be a common subject for all Diploma courses on Employability
Skills which will be for 160 hours in second year. The module wise course coverage is categorized
as below: -
Core Module 1 (Automotive Engineering - Basics): This subject will focus on trainees toreview the
concept of workshop safety, Engineering Drawing, Engineering measurements, Fits and tolerances,
strength of material, fluid power engineering, Theoretical Engine cycle, Manufacturing concepts
and Industrial Engg, Basics of Electrical and Electronics, Vehicle Nomenclature and customer
relationship, this will prepare trainees to apply the basics in servicing of vehicles
Core Module 2 (Automotive Electrical and Electronic System - Diagnosis & Repair):This course
will prepare the trainees to enhancement skill level in fast pace of technological change impact in
Auto Electrical and Electronic system, the development of hybrid and alternative –fuel cars is just
one example, the use of isolation meters and scan tools, leads the trainees in diagnostic skills
through troubleshooting and service of ignition, Starter motor, Alternator and battery,so
electronics is a vital part of the training for automotive technicians. Telematics, which is an
increasingly important automotive technology, is covered in considerable detail (including the

theory of GPS navigation systems).
Core Module 3 (Automotive Engines-Diagnosis & Repair (MPFI & CRDI)): On completion of this
module, trainees should be able to equip with diagnostic & repair skills in automotive engines. It
details the construction, operation, diagnosis, service, and repair of engine (MPFI and CRDI),
diagnosis on four-valve-per-cylinder engines, camshaft timing, variable valve timing, and high-
performance engines, including, Superchargers, Turbochargers, hybrid engines and high-
performance components, finally this course prepares trainees to service today’s vehicles.
Core Module 4 (Automotive Transmission Diagnosis & Repair): Automotive axle and transmission
subject will prepare the trainees with diagnostic & repair skills in Power train module of automatic
transmissions, manual transmissions, clutch, drive line and drive axle construction and operation
including dual clutch systems, various limited-slip differential designs, six-speed transmissions,
continuously variable transmissions (CVT), drivelines for front-wheel drive (FWD) and four-wheel
drive (4WD) vehicles
Core Module 5 (Automotive Vehicle Controls- Brake, Suspension and Steering Diagnosis &
Repair): This Module will make the trainees conversant with concept, techniques and practices in
automotive vehicle dynamics and safety. The course will cover the brake system controls.
Performing hands-on service and repair tasks, diagnosis and service suspension and steering
systems on today's cars, including: run-flat tires, shock absorber mountings, electronic power and
four-wheel steering systems, and new wheel alignment procedures.
Elective Module 1 (Automotive Air Conditioning and Climate Control System: Diagnosis and
Repair): This subject will prepare the trainees in practical and legislative aspects of vehicle climate
control systems. Provide professional skill of current A/C systems, refrigerants and the new
possible replacement systems like CO2, and includes unrivalled coverage of electronic and
electrical control.
Elective Module 2 (Auto body Repair and Refinishing): Auto body repair and refinishing, is an
exciting skill area to apply with millions of vehicles on the road today, there is a strong demand for
well-trained collision repair technicians. With today’s high-tech vehicles and varied construction
methods and repair techniques, competent collision repair takes well-trained, knowledgeable
professionals. This course will prepare the trainees repairing a collision-damaged vehicle and
estimation, major body/frame repairs, vehicle frame damage measurement and repair, details
refinishing and how to prep and paint the vehicle.
Elective Module 3 (Automotive Two-Wheeler – Diagnosis and repair): This subject will prepare a
trainee to take carrier in two-wheeler manufacturing company “fit to work” in the assembly line
directly. By the end of the program the trainee s equipped with hands on practical skills, basic
theoretical knowledge. This course will develop trainee’s capability of performing sequential jobs
independently. The content of the subject covers today basic two-wheeler technology to
advanced one as ECM and sensor system
Project work /Working Model (Emphasis should be on Teamwork: Knowing the power of synergy/
collaboration), Work to be assigned in a group (Group of at least 4 trainees) from the starting of
the diploma programme. The group should demonstrate Planning, Execution, Contribution and
application of Learning. They need to submit Project report
On the Job Training: In this module the trainees will be working/training in the Industry for 800
hours. They work as apprentices/Personnel.
Employability Skills: This module is common for all Diploma courses and the total period is 160
hours. In this module the trainees will improve
 English literacy such as Pronunciation, functional grammar, reading, writing, speaking
and spoken English
 Learn communication skills, listening skills, motivational training, Facing interviews
and behavioural skills.
 Understand concepts of Entrepreneurship, Project preparation and marketing
analysis, Institutions support and Investment Procurement.
 Understand on productivity, its benefits, affecting factors, comparison with developed
countries, personal finance management.
 Understand Safety, Health and Environment Education - Safety & Health, Occupational
Hazards, Accident & safety, First Aid, Basic Provisions, Ecosystem, Pollution, Energy
Conservation, Global warming, Ground Water, Environment.
 Understand benefits guaranteed under various acts- Factories Act, Apprenticeship Act,
Employees State Insurance Act (ESI), Payment of Wages Act, Employees Provident
Fund Act, The Workmen's compensation Act.
 Understand Quality Tools: Quality Consciousness, Quality Circles, Quality Management
System, Housekeeping.
Diploma in Automotive Technolog
2. TRAINING SYSTEM
2.1 GENERAL
Directorate General of Training (DGT) under Ministry of Skill Development &
Entrepreneurship offers a range of Vocational Training courses catering to the need of different
sectors of economy/ Labour market. The Vocational Training Programmes are delivered under
aegis of National Council of Vocational Education & Training (NCVET). Craftsman Training Scheme
(CTS) and Apprenticeship Training Scheme (ATS) are two pioneer programmes of NCVET for
propagating vocational training. Recently DGT has started Technical Diplomas for different
streams and primarily implemented at DGT field institutes such as NSTIs, FTIs and AHI and planned
to expand to State Directorates in future.
Automotive Technology course is very much essential in the current scenario due to a lot
of demand in Automobile Sector. The course is for two years duration. In the first year there are
five core modules each module is credit base and employable. Each module is of 320 hours and is
very much independent. In second year, the trainee will be taking two elective modules out of
three electives each of 320 hours and will be doing on the job training in Industry for 800 hours. In
addition, the trainees will pick up employability skills for 160 hours. After passing out the training
programme, the trainee will be awarded Technical Diploma by NCVT which has worldwide
recognition.
Candidates need broadly to demonstrate that they are able to:

 Read and interpret technical parameters/ documents, plan and organize work processes,
identify necessary materials and tools;
 Perform task with due consideration to safety rules, accident prevention regulations and
environmental protection stipulations;
 Apply professional skill, knowledge & employability skills while performing jobs.
 Document the technical parameters related to the task undertaken.
6
2.2 CAREER PROGRESSION PATHWAYS

 Can pursue higher technical education like BE/B. Tech.
 On successful completion of this course, the candidates shall be gainfully employed in the
following industries:
o Automobile and allied industries
o In public sector industries and private industries in India & abroad.
 Can start theirown enterprise on concerned trade.
2.3 COURSE STRUCTURE
Table below depicts the distribution of training hours across various course elements during a
period of two years: -
S No. Module Course Element Notional Training Hours

Professional Skill (Trade Practical) 1120
1
For five Core Modules Professional Knowledge (Trade
480
Theory)
Professional Skill (Trade Practical) 448
For two Elective
2 Professional Knowledge (Trade
Module 192
Theory)
3 Employability Skills 160
4 On the job training 800
Total 3200 *
Project Work for each Module (40 Hours x 7 Modules)
5 Note: For Elective modules in second year work included in 280
the Instructional hours.
6 Revision (80 Hours x 7 Modules) 560
Theory & Practical Examination of 7 Modules + Employability
7 120
Skills + On the Job Training
Grand Total 4160
*Core Components (3200 Hrs): -

Name Teaching Hours Total
Hours
Core Subjects (All Compulsory) Practical Theory
1 Automotive Engineering Basics 224 96 1600
2 Automotive Electrical & Electronic Systems - Diagnosis 224 96
&Repair
3 Automotive Engine - Diagnosis &Repair 224 96
4 Automotive Transmission Diagnosis &Repair 224 96
5 Automotive Controls - Brake, Suspension and Steering 224 96
Diagnosis &Repair
Elective Subjects (any two)
6 Automotive Air Conditioning and Climate Control System 224 96 640
Diagnosis and Repair
7 Automotive Body repair & Refinishing 224 96
9 Automotive Two &Three-Wheeler – Diagnosis and repair 224 96
Industrial Training
10 On the Job Training 800 800
Common Subjects
11 Employability Skills 160 160
Total Hours of Training 3200
Note : 1. The trainee must complete all the 5 core modules

2. The trainee must select any of two elective courses from the given three elective options
2.4 ASSESSMENT & CERTIFICATION

The trainee will be tested for his skill, knowledge and attitude during the period of course at each
module and at the end of the training programme as notified by Govt of India from time to time.
a) The Internal assessment during the period of training will be done by Formative
assessment method by testing for assessment criteria listed against learning outcomes.
The training institute have to maintain individual trainee portfolio as detailed in
assessment guideline. The marks of internal assessment will be as per the template
(Annexure – I).
b) The final assessment will be in the form of summative assessment method. The All India
Trade Test for awarding Technical Diploma will be conducted by NCVT as per guideline of
Govt of India. The pattern and marking structure is being notified by govt of India from
time to time. The learning outcome and assessment criteria will be basis for setting
question papers for final assessment. The examiner during final examination will also
check individual trainee’s profile as detailed in assessment guideline before giving marks
for practical examination.
2.4.1 PASS REGULATION

The minimum pass percent for Practical is 60% & minimum pass percent for Theory subjects 40%.
2.4.2 ASSESSMENT GUIDELINE

Appropriate arrangements should be made to ensure that there will be no artificial barriers to
assessment. The nature of special needs should be taken into account while undertaking
assessment. Due consideration should be given while assessing for team work,
avoidance/reduction of scrap/wastage and disposal of scarp/wastage as per procedure, behavioral
attitude, sensitivity to environment and regularity in training. The sensitivity towards OSHE and
self-learning attitude are to be considered while assessing competency.
Assessment will be evidence based comprising the following:

 Job carried out in labs/workshop
 Record book/ daily diary
 Answer sheet of assessment
 Viva-voce
 Progress chart
 Attendance and punctuality
 Assignment
 Project work
Evidences of internal assessments are to be preserved until forthcoming semester examination for
audit and verification by examination body. The following marking pattern to be adopted while
assessing:
Performance Level Evidence

(a) Weightage in the range of 60 -75% to be allotted during assessment
For performance in this grade, the candidate  Demonstration of good skill in the use of
with occasional guidance and showing due hand tools, machine tools and workshop
regard for safety procedures and practices, has equipment
produced work which demonstrates  Below 70% tolerance dimension achieved
attainment of an acceptable standard of while undertaking different work with
craftsmanship. those demanded by the component/job.
 A fairly good level of neatness and
consistency in the finish
 Occasional support in completing the
project/job.
(b)Weightage in the range of above 75% - 90% to be allotted during assessment
 Good skill levels in the use of hand tools,
machine tools and workshop equipment
For this grade, the candidate, with little
 70-80% tolerance dimension achieved
guidance and showing due regard for safety
while undertaking different work with
procedures and practices, has produced work
those demanded by the component/job.
which demonstrates attainment of a
 A good level of neatness and consistency
reasonable standard of craftsmanship.
in the finish
 Little support in completing the
project/job
(c) Weightage in the range of above 90% to be allotted during assessment
 High skill levels in the use of hand tools,
For performance in this grade, the candidate, machine tools and workshop equipment
with minimal or no support in organization and  Above 80% tolerance dimension achieved
execution and with due regard for safety while undertaking different work with
procedures and practices, has produced work those demanded by the component/job.
which demonstrates attainment of a high  A high level of neatness and consistency
standard of craftsmanship. in the finish.
 Minimal or no support in completing the
project.
3. JOB ROLE
Brief description of Job roles:
Automotive Engineering Technician sets up and operates equipment to test automobile

parts and accessories according to standard procedures to discover design and fabrication faults.
Studies drawings, sketches, specifications set, and installs units such as assemblies, gears,
universal joints in testing equipment and machines and connects wiring, tubing, couplings and
power sources using hand tools. Operates test equipment and machines to determine factors such
as stress, strain, pressure, flow of fuel, oil and air, wear and usability of installed units under
conditions of heat, cold, high speeds and load. Conducts investigations into experimental tests in
development of new automotive equipment and accessories to secure more economical operating
basis and lowering manufacturing cost. Supervises assembly and repair work, effects necessary
modifications and replacements of parts and checks completed assembly for efficiency of
performances. Studies in detail costs involved and seeks lighter and stronger metal parts in auto.
May specialize in testing or repairs of particular type of auto equipment and accessories.
ReferenceNCO-2015:
i) 3115.0201 – Automotive Engineering Technician/ Testing Manager

4. GENERAL INFORMATION
Name of the Course Diploma in Automotive Technology
NCO – 2015 3115.0201 – Automotive Engineering Technician/ Testing Manager

NSQF Level Level 6
2 Years (5 Core Modules of 320 hours each, Two Elective Modules of
Duration
320 hours each, On-the-job training of 800 hours and Employability
Skills of 160 hours)
10th class + NTC/NAC(Mechanic Motor Vehicle, Mechanic Diesel,
Mechanic Tractor, Mechanic Motor Cycle, Mechanic Auto Electrical &
Entry Qualification
Electronics, Mechanic Auto Body Repair, Mechanic Auto Body
Painting)
Unit Strength (No. Of
20
Student)
Space Norms 800 sq. m.
Power Norms 40 KW
Instructor’s Qualification for
Automotive Technology Degree in Automobile/ Mechanical Engineering from recognized
Engineering College/ university with one-year experience in the
relevant field.
OR
Diploma in Automobile/ Mechanical Engineering from recognized
board of technical education with two-year experience in the relevant
field.
OR
NTC/NAC passed in the Trade of “Mechanic Motor Vehicle” with
three years post qualification experience in the relevant field.
Desirable: Preference will be given to a candidate with CIC (Craft

Instructor Certificate) in Mechanic Motor Vehicle trade.
(iv) Employability Skill MBA OR BBA with two years’ experience OR Graduate in Sociology/
Social Welfare/ Economics with Two years’ experience OR Graduate/
Diploma with Two years’ experience and trained in Employability
Skills from DGET institutes.
AND
Must have studied English/ Communication Skills and Basic Computer
at 12th / Diploma level and above.
OR
Existing Social Studies Instructors duly trained in Employability Skills
from DGET institutes
5. NSQF LEVEL COMPLIANCE
NSQF level for Diploma in Automotive Technology: Level 6
As per notification issued by Govt. of India dated- 27.12.2013 on National Skill Qualification
Framework total 10 (Ten) Levels are defined.
Each level of the NSQF is associated with a set of descriptors made up of five outcome
statements, which describe in general terms, the minimum knowledge, skills and attributes that a
learner needs to acquire in order to be certified for that level.
Each level of the NSQF is described by a statement of learning outcomes in five domains,
known as level descriptors. These five domains are:
a. Process
b. Professional Knowledge
c. Professional Skill
d. Core Skill
e. Responsibility
The Broad Learning outcome of Diploma in Automotive Technology mostly matches with
the Level descriptor at Level- 6.
The NSQF level-6 descriptor is given below:
Process Professional Professional

Level Core Skill Responsibility
Required Knowledge Skill
Level 6 Demands wide Factual and A range of Reasonably Responsibility for
range of theoretical cognitive and good in own work and
specialized knowledge in practical skills mathematical learning and full
technical skill, broad contexts required to calculation, responsibility for
clarity of within a field of generate understanding other`s works
knowledge and work or study. solutions to of social, and learning.
practice in broad specific problems political and
range of activity in a field of work reasonably good
involving standard or study. in data
nonstandard collecting
practices. organizing
information and
logical
communication.
6. LEARNING OUTCOME
Learning outcomes are a reflection of total competencies of a trainee and assessment

will be carried out as per the assessment criteria.
4.1 GENERIC LEARNING OUTCOME

1. Recognize and comply with safe working practices, environment regulation and
housekeeping.
2. Explain the concept in productivity, quality tools and labour welfare legislation and apply
such in day-to-day work to improve productivity & quality.
3. Explain energy conservation, global warming and pollution and contribute in day-to-day
work by optimally using available resources.
4. Explain personal finance, entrepreneurship and manage/organize related task in day-to-
day work for personal & social growth.
5. Plan and organize the work related to the occupation.
6. Apply problem solving skills and supervise team.
4.2 SPECIFIC LEARNING OUTCOME

CORE MODULE 1: AUTOMOTIVE ENGINEERING BASICS:
1. Identify and choose safe working practices, environment regulations and housekeeping.
2. Select and make use of various precision measuring instruments, determine the dimension
of components and record the data.
3. Interpret specifications, different engineering drawing and apply for different application in
the field of work.
4. Organize and carry out various metal testing methods, determine the values and compare
with the standards.
5. Identify and explain the hydraulic and pneumatic components in the workshop and
vehicles.
6. Organize and measure various engine parameters (torque, BHP, BMEP, IHP etc.).
7. Organize and carry out joining of metals using different methods and test for defects.
8. Check and interpret vehicle specification data and VIN and prepare a job card.
9. Plan and perform various basic tests related with auto electrical and electronics and
interpret the values obtained by comparing with the standards.
CORE MODULE 2: AUTOMOTIVE ELECTRICAL AND ELECTRONIC SYSTEM – DIAGNOSIS & REPAIR:
10. Plan and perform the trouble shooting, diagnosis of automotive electrical system,
determine and solve the problems and justify the results.
11. Plan and perform the trouble shooting, diagnosis of automotive electronics and
communication system, determine and solve the problems and justify the results.
12. Demonstrate troubleshoot and Diagnosis of vehicle safety system.
13. Plan and organize the trouble shooting, diagnosis of automotive electrical accessories,
determine and solve the problems and justify the results.
CORE MODULE 3: AUTOMOTIVE ENGINE – DIAGNOSIS AND REPAIR:
14. Plan and organize the troubleshooting and diagnosis of intake and exhaust system.
15. Plan and organize the troubleshooting and diagnosis of power plant (Engine: Construction,
Petrol and Diesel).
16. Plan and perform the trouble shooting, diagnosis of automotive electronics and
communication system, determine and solve the problems and justify the results.
17. Plan and organize the troubleshooting and diagnosis of cooling and lubricating system.
18. Formulate and perform the troubleshooting and diagnosis of Electric and Electronic related
to power plant MPFI and CRDI.
CORE MODULE 4: AUTOMOTIVE TRANSMISSION – DIAGNOSIS AND REPAIR:
19. Plan and organize to find the faults and Diagnosis of manual Transmission system and
suggest appropriate measure for manual transmission, transaxle, differential and final
drive.
20. Examine/interpret the faults in Diagnosis of automatic Transmission system and suggest
appropriate measure for automatic Gear boxes.
CORE MODULE 5: AUTOMOTIVE CONTROLS BRAKE, SUSPENSION AND STEERING DIAGNOSIS

AND REPAIR:
21. Plan and organize to find the faults and Diagnosis of vehicle controls (conventional) and
suggest appropriate measure for brake, suspension and steering system.
22. Examine/interpret the faults in Diagnosis of vehicle control system (advanced) and suggest
appropriate measure for antilock brake and power steering.
23. Evaluate driving performance of trainees.
ELECTIVE MODULE 1: AUTOMOTIVE AIR CONDITIONING AND CLIMATE CONTROL SYSTEM-

DIAGNOSIS AND REPAIR:
24. Demonstrate Diagnosis of automotive air conditioning and climate control system.
25. Plan and organize the troubleshooting and diagnosis of automotive air conditioning and
climate control system components.
ELECTIVE MODULE 2: AUTOMOTIVE BODY REPAIR AND REFINISHING:
26. Organize and analyse the misalignment of the body due to an accident, estimate the
amount of repair to be carried out and propose for repairing of vehicle body.
27. Plan and organize to carry out the body alignment work and perform the welding
processes to make the body perfect for riding.
28. Plan and organize to carry out the body painting work and perform the finishing work.
ELECTIVE MODULE 3: AUTOMOTIVE TWO &THREE-WHEELER- DIAGNOSIS AND REPAIR:
29. Plan and organize to carry out maintenance and overhauling of different types of engines
in two and three wheelers, determine its functionality and its performance.
30. Plan and organize to carry out maintenance and overhauling of different types of
transmission in two and three wheelers, determine its functionality and its performance.
31. Plan and organize to find the faults and Diagnosis of vehicle controls and suggest
appropriate measure for brake, suspension and steering system.
32. Plan and organize to find the faults and Diagnosis of vehicle electrical and electronics and
suggest appropriate measure for its functionality.
7. LEARNING OUTCOME WITH ASSESSMENT CRITERIA
GENERIC LEARNIG OUTCOME

Learning Outcome Assessment criteria
1 Recognize & comply with 1.1 Follow and maintain procedures to achieve a safe working
safe working practices, environment in line with occupational health and safety
environment regulation regulations and requirements.
and housekeeping. 1.2 Recognize and report all unsafe situations according to site
policy.
1.3 Identify and take necessary precautions on fire and safety
hazards and report according to site policy and procedures.
1.4 Identify, handle and store/ dispose of
dangerous/unsalvageable goods and substances according to
site policy and procedures following safety regulations and
requirements.
1.5 Identify and observe site policies and procedures in regard to
illness or accident.
1.6 Identify safety alarms accurately.
1.7 Report competent of authority in the event of accident or
sickness of any staff and record accident details correctly
according to accident/injury procedures.
1.8 Identify basic first aid and use them under different
circumstances.
1.9 Identify different fire extinguisher and use the same as per
requirement.
1.10 Identify environmental pollution & contribute to avoidance of
same.
1.11 Take opportunities to use energy and materials in an
environmentally friendly manner.
1.12 Avoid waste and dispose waste as per procedure.
1.13 Recognize different components of 5S and apply the same in
the working environment.
2 Explain the concept in 2.1 Explain the concept of productivity and quality tools and apply
productivity, quality tools during execution of job.
and labour welfare 2.2 Understand the basic concept of labour welfare legislation and
legislation and apply such adhere to responsibilities and remain sensitive towards such
in day-to-day work to laws.
improve productivity &
quality. 2.3 Knows benefits guaranteed under various acts.
3 Explain energy 3.1 Explain the concept of energy conservation, global warming,
conservation, global pollution and utilize the available resources optimally &
warming, pollution and remain sensitive to avoid environment pollution.
contribute in day-to-day
work by optimally using 3.2 Dispose waste following standard procedure.
available resources.
4 Explain personnel finance, 4.1 Explain personnel finance and entrepreneurship.

entrepreneurship and 4.2 Explain role of various schemes and institutes for self-
manage/ organize related employment i.e. DIC, SIDA, SISI, NSIC, SIDO, Idea for financing/
task in day-to-day work for non-financing support agencies to familiarize with the policies/
personal & societal growth. programmes, procedure & the available scheme.
4.3 Prepare Project report to become an entrepreneur for
submission to financial institutions.
5 Plan and organize the work 5.1 Communicate effectively with others and plan project tasks.
related to the occupation. 5.2 Assign roles and responsibilities of the co-trainees for
execution of the task effectively and monitor the same.
6 Apply Problem solving 6.1 Ability to understand a problem by breaking it down into
skills and supervise team. smaller parts.
6.2 Identify the key issues, implications and identifying solutions.
6.3 Apply knowledge from many different areas to solving a task.
6.4 Motivate and supervise team for achieving the required goal.
SPECIFIC LEARNIG OUTCOME

MODULE 1: AUTOMOTIVE ENGINEERING BASICS
Sl.
Learning Outcome Assessment Criteria
No.
1 Identify and choose safe 1.1 Follow and maintain procedures to achieve a safe working
working practices, environment in line with occupational health and safety
environment regulations regulations and requirements.
and housekeeping. 1.2 Recognize and report all unsafe situations according to the
site policy.
1.3 Identify and take necessary precautions on fire and safety
hazards and report according to site policy and procedures.
1.4 Identify and observe site policies and procedures in regard to
illness or accident.
1.5 Identify personal protective equipment (PPE) and use the
same as per related working environment.
1.6 Identify basic first aid and use them under different
circumstances.
1.7 Identify different fire extinguisher and use the same as per
requirement.
1.8 Identify vehicles with safety equipment and follow safety rules
to carry out work on them.
2 Select and make use of 2.1 Select appropriate precision measuring instruments such as
various precision measuring Vernier calliper, micrometre, dial bore gauge, dial test
instruments, determine the indicator etc.
dimension of components 2.2 Ascertain the functionality and correctness of the instrument.
and record the data. 2.3 Measure various dimension of the components and record
data to analyse with the given drawing/measurement.
3 Interpret specifications, 3.1 Read and interpret the information on drawing and apply in
different engineering executing practical work.
drawing and apply for 3.2 Read and analyse the specification to ascertain the material
different application in the requirement, tools and machining/assembly/maintenance
field of work. parameters.
3.3 Draw the free hand sketch of work shop layout and various
components of engine.
4 Organize and carry out 4.1 Explain the concept of basic science related to the field of
various metal testing strength of material.
methods, determine the 4.2 Plan and prepare as per procedure and safety methods of
values and compare with metal testing equipment.
the standards. 4.3 Carry out the testing of metals and record the values.
4.4 Calculate and find out the results to determine the strength of
materials.
5 Identify and explain the 5.1 Explain the concepts of basic science related to the field of
hydraulic and pneumatic fluid power
components in the 5.2 Trace out the hydraulic circuit in work shop equipment and
workshop and vehicles.
vehicles
5.3 Identify the components of pneumatic circuit in the vehicles
6 Organize and measure 6.1 Explain the basic calculation and science related with the
various engine parameters speed and engine terminologies.
(torque, BHP, BMEP,IHP 6.2 Plan and prepare as per procedure and safety methods of
etc.)
engine testing equipment.
6.3 Carry out the testing of engine and record the values.
6.4 Calculate and find out the results to determine the
performance of the engine.
6.5 Draw the heat balance sheet determine the performance of
the engine.
7 Organize and carry out 7.1 Determine the principles, process of different welding process
joining of metals using applicable in automobile industry.
different methods and test 7.2 Select the appropriate machine to carry out the metal joining
for defects.
process.
7.3 Select the type and size of the consumables to carry out the
metal joining process.
7.4 Set and process the metal joining as per the drawing.
7.5 Clean the work piece and inspect it for and type of defect.
8 Checkand interpret vehicle 8.1 Identify different types of vehicle.

specification data and VIN 8.2 Identify the different vehicle specification data and
and prepare a job card. information.
8.3 Coordinate with the customer to know about the problems
and prepare the job card.
9 Plan and perform various 9.1 Ascertain and select tools and materials for the job and make
basic tests related with auto this available for use in a timely manner.
electrical and electronics 9.2 Set the multimeter to carry out electrical measurement
and interpret the values
parameters.
obtained by comparing with
9.3 Perform electrical measurements with different parameters in
the standards. various vehicle circuits and record the results.

9.4 Perform voltage drop tests and suggest the condition of the
electrical wiring.
9.5 Carry out testing of various electronic components and
suggest for its functionality.
9.6 Identify the engine electronic problems by combination meter
and suggest for remedies.
MODULE 2: AUTOMOTIVE ELECTRICAL AND ELECTRONIC SYSTEM – DIAGNOSIS&REPAIR

Sl.
No.
1 Plan and perform the 1.1 Plan and execute dismantling & assembling of electrical
trouble shooting, diagnosis system components.
of automotive electrical 1.2 Inspect and test auto electrical System components and
system, determine and determine the correctness of each component.
solve the problems and 1.3 Check and propose possible optimization and compare their
justify the results cost effectiveness.
1.4 Contribute to continuous improvement of work process in the
related area.
2 Plan and perform the 2.1 Plan and execute removing and refitting the automobile
trouble shooting, diagnosis electronics and communication system components.
of automotive electronics 2.2 Inspect the auto electronics and communication System
and communication system, components and determine the correctness of each
determine and solve the component.
problems and justify the 2.3 Check and propose possible optimization and compare their
results. cost effectiveness.
2.4 Contribute to continuous improvement of work process in
the related area.
3 Demonstrate troubleshoot 3.1 Identity causes of malfunctions and errors of vehicle safety
and Diagnosis of vehicle system
safety system. 3.2 Evaluate the possibility of the rectification of such
malfunction and errors
3.3 Conduct appropriate and target oriented discussion within
the team
3.4 Carryout or arrange for repair
3.5 Ensure or improve the functionality of the system by controlling
and monitoring different parameters of various vehicle safety
systems.
3.6 Use protective and safety equipment.
4 Plan and organize the 4.1 Plan and execute dismantling & assembling of automobile
trouble shooting, diagnosis electrical accessories.
of automotive electrical 4.2 Inspect and test the auto electrical accessories and determine
accessories, determine and the correctness of each component.
solve the problems and 4.3 Check and propose possible optimization and compare their
justify the results. cost effectiveness.
related area.
MODULE 3: AUTOMOTIVE ENGINE – DIAGNOSIS AND REPAIR

Sl.
No.
1 Plan and organize the 1.1 Plan and execute dismantling & assembling of intake and
troubleshooting and exhaust system components.
diagnosis of intake and 1.2 Inspect the intake and exhaust system components and
exhaust system. determine its proper functionality.
1.3 Check and propose possible optimization and compare their
cost effectiveness.
related area.
2 Plan and organize the 2.1 Plan and execute dismantling & assembling of Engine from
troubleshooting and vehicle along with other accessories.
diagnosis of power plant 2.2 Test engine for its correctness and justify the results.
(Engine: Construction, 2.3 Measure the engine components, compare the values with
Petrol, Diesel) standards and determine its functionality
cost effectiveness.
related area.
2.6 Test Engine Performance.
2.7 Monitor Evaluated and document work result.
3 Plan and perform the 3.1 Plan and execute removing and refitting the auxiliary emission
trouble shooting, diagnosis control device components.
of automotive emission 3.2 Inspect the auxiliary emission control device components and
control system, determine
determine the correctness of each component.
and solve the problems and
justify the results. 3.3 Check and propose possible optimization and compare their
cost effectiveness.
related area.
3.5 Monitor emission of vehicle and execute different operation
to obtain optimum pollution as per emission norms.
4 Plan and organize the 4.1 Plan and execute dismantling & assembling of cooling and
troubleshooting and lubrication system components.
diagnosis of cooling and 4.2 Inspect and test the cooling and lubrication system
lubricating system. components and determine its proper functionality.
cost effectiveness.
related area.
5 Formulate and perform the 5.1 Plan and execute dismantling & assembling of MPFI and CRDI
troubleshooting and system components.
diagnosis of Electric and 5.2 Rectify the defects following the vehicle manufacture
standard procedure
Electronic related to power
5.3 Select and use testing methods that comply with the
plant MPFI and CRDI
manufacturer’s requirements
cost effectiveness
5.5 Test Performance of serviced units for functionality.
MODULE 4: AUTOMOTIVE TRANSMISSION – DIAGNOSIS AND REPAIR

Sl.
No.
1 Plan and organize to find 1.1 Plan and carry out dismantling and assembling of vehicle
the faults and Diagnosis of Transmission system units, adhering to the specifications and
manual Transmission tolerances for the vehicle and following:
system and suggest a. The manufacturer’s approved overhauling methods
appropriate measure for b. Standard/ non-standard repair methods
manual transmission, c. health and safety requirements.
transaxle, differential and d. workplace procedures.
final drive. 1.2 Check the proper functional sequence.
cost effectiveness.
related area.
1.5 Monitor evaluates and document work result.
2 Examine/interpret the 2.1 Plan and execute overhauling of vehicle automatic

faults in Diagnosis of Transmission system units, adhering to the specifications and
automatic Transmission tolerances for the vehicle and following:
system and suggest A. The manufacturer’s approved overhauling methods
appropriate measure for B. Standard/ nonstandard repair methods
automatic Gear boxes. C. health and safety requirements.
D. workplace procedures.
2.2 Assemble sub-assemblies and components in a manner
appropriate to the location and their functionality.
2.3 Check the proper functional sequence.
cost effectiveness.
related area.
MODULE 5: AUTOMOTIVE CONTROLS BRAKE, SUSPENSION AND STEERING DIAGNOSIS AND REPAIR
Sl.
No.
the faults and Diagnosis of control system units (conventional), adhering to the
vehicle controls specifications and tolerances for the vehicle and following:
(conventional) and suggest a. The manufacturer’s approved overhauling methods
appropriate measure for b. Standard/ non-standard repair methods
brake, suspension and c. health and safety requirements.
steering system. d. workplace procedures.
cost effectiveness.
related area.
2 Examine/interpret the 2.1 Plan and execute overhauling of vehicle control system units
faults in Diagnosis of (advanced), adhering to the specifications and tolerances for
vehicle control system the vehicle and following:
A. The manufacturer’s approved overhauling methods
(advanced) and suggest
B. Standard/ non-standard repair methods
appropriate measure for C. health and safety requirements.
antilock brake and power D. workplace procedures.
steering.
2.2 Assemble sub-assemblies and components in a manner
appropriate to the location and their functionality.
cost effectiveness.
related area.
3 Evaluate driving 3.1 Practice Initial freeway Driving & assess the same.
performance of trainees. 3.2 Check Pre – Driving parameters
3.3 Practice Driving on Various road as per rule & evaluate the
same.
Elective 1: AUTOMOTIVE AIR CONDITIONING AND CLIMATE CONTROL SYSTEM- DIAGNOSIS AND
REPAIR
Sl.
No.
1 Demonstrate Diagnosis of 1.1 Identity causes of malfunctions and errors of vehicle air
automotive air conditioning conditioning system.
and climate control system. 1.2 Evaluate the possibility of the rectification of such malfunction
and errors of vehicle Air conditioning system.
1.3 Conduct appropriate and target oriented discussion within the
team.
1.4 Carryout or arrange for repair.
1.5 Ensure or improve the functionality of the system by
controlling and monitoring different parameters of vehicle Air
conditioning system.
1.6 Use protective and safety equipment.
2 Plan and organize the 2.1 Plan and execute dismantling & assembling of air conditioning
troubleshooting and and climate control system components.
diagnosis of automotive air 2.2 Inspect and test the air conditioning and climate control
system components and determine its proper functionality.
conditioning and climate
control system
cost effectiveness.
components. 2.4 Contribute to continuous improvement of work process in the
related area.
Elective 2: AUTOMOTIVE BODY REPAIR AND REFINISHING

Sl.
No.
1 Organize and analyze the 1.1 Plan and execute to find out the damages of the vehicle and
misalignment of the body prepare document to record the reports.
due to an accident, 1.2 Estimate the amount of expenditure to repair the body
estimate the amount of damages.
repair to be carried out and 1.3 Carry out the repair work and assess the work for its proper
propose for repairing of finishing
vehicle body.
2 Plan and organize to carry 2.1 Plan and execute body alignment work and welding processes.
out the body alignment 2.2 Inspect the vehicle body to determine its proper correctness.
work and perform the 2.3 Check and propose possible optimization and compare their
welding processes to make cost effectiveness.
the body perfect for riding. 2.4 Contribute to continuous improvement of work process in the
related area.
3 Plan and organize to carry 3.1 Plan and execute body painting work and finishing processes.
out the body painting work 3.2 Inspect the vehicle body to determine its proper perfectness.
and perform the finishing 3.3 Check and propose possible optimization and compare their
work. cost effectiveness.
related area.
Elective 3: AUTOMOTIVE TWO &THREE WHEELER- DIAGNOSIS AND REPAIR

Sl.
No.
1 Plan and organize to carry 1.1 Plan and execute dismantling and assembling of engine
out maintenance and components and evaluate the condition of the components.
overhauling of different 1.2 Determine the functionality of engine components by
types of engines in two and measuring the components and compare with the standards.
three wheelers, determine 1.3 Check and propose possible optimization and compare their
its functionality and its cost effectiveness.
performance. 1.4 Contribute to continuous improvement of work process in the
related area.
2 Plan and organize to carry 2.1 Plan and execute dismantling and assembling of transmission
out maintenance and components and evaluate the condition of the components.
overhauling of different 2.2 Determine the functionality of components by measuring the
types of transmission in transmission components and compare with the standards.
two and three wheelers, 2.3 Check and propose possible optimization and compare their
determine its functionality cost effectiveness.
and its performance 2.4 Contribute to continuous improvement of work process in the
related area.
the faults and Diagnosis of control system units (conventional), adhering to the
vehicle controls and specifications and tolerances for the vehicle.
suggest appropriate
measure for brake,
cost effectiveness.
suspension and steering 3.4 Contribute to continuous improvement of work process in the
system. related area.
4 Plan and organize to find 4.1 Plan and carry out removing, refitting and servicing of vehicle
the faults and Diagnosis of electrical and electronics system components, test and
vehicle electrical and compare with the standards to decide its correctness.
electronics and suggest
appropriate measure for its
cost effectiveness.
functionality. 4.4 Contribute to continuous improvement of work process in the
related area.

8. SYLLABUS
Syllabus for Diploma in “Automotive Technology”
Core Module 1 : Automotive Engineering Basics: 320 Hrs

Professional Skills Professional Knowledge
Hour (Trade Practical) (Trade Theory)
Learning outcome
No. (224 Hrs.) (96 Hrs.)
(with indicative Hours)
1-19 Identify and  Familiar with the institute and Careers in the automotive field
choose safe the other activities of DGT.  Opportunities in the
working practices, Skills on Work Safety in the automotive field, Training
environment Shop and certification, Job
regulations and  Makeuse of fire extinguishers prospects in the automotive
house keeping  Carryout Safety Features and technology field, Common
Emergency Procedures in the methods used to pay
Shop. automotive technicians, facts
 Identify Vehicles about working as an
EquippedWith a automotive technician
supplemental Restraint Safety
System (SRS) and Antilock  Protecting yourself and
Brake System (ABS). others in the Shop, use of
PPEEquipments. Basic first
aid ,use of fire extinguishers
20-43 Select and make Skills on Engineering Measurement
use of various Measurement  Description, care & use of -
precision  Measure Cam height, Micrometers- Outside and
measuring Camshaft Journal dia, depth micrometer,
instruments, crankshaft journal dia, Valve Micrometer adjustments,
determine the stem dia, piston diameter, Vernier calipers, Telescope
dimension of and piston pin dia with gauges, Dial bore gauges,
components and outside Micrometers Dial indicators, straightedge,
record the data  Measure the height of the feeler gauge, thread pitch
rotor of an oil pump from the gauge, vacuum gauge, tire
surface of the housing or any pressure gauge.
other auto component
measurement with depth
micrometer.
 Measure valve spring free
length use of verniercaliper
 Measure cylinder bore for
taper and out-of-round with

Dial bore gauges.
44-66 Interpret Skills on Engineering Drawing Engineering drawing
specifications,  Read and interpret detailed  Refreshing on dimension-
different and assembly (exploded view orthographic-isometric-
engineering of ) drawings of Air intake sectional views- welding and
drawing and apply system components machining symbols-Bill of
for different  Free hand sketching Drawing materials- Blue –print
application in the of I C engine and their parts. drawing practices
field of work  Engine layouts - Layout of an  Limits, Fits & Tolerances: -
automobile workshop Definition of limits, fits &
tolerances with examples
used in auto components
Organize and carry Skills on Strength of Materials Strength of materials
67-87 out various metal  Carryout tensile testing and  Simple stress & strain-
testing methods, calculate required parameter Hooke’s law – Tensile and
determine the  Measure the coil spring compressive stress- strain
values and tension test of different load. energy- lateral and liner
compare with the Compare the stiffness value strain-Poisson’s ratio-factor
standards with standard value of given of safety, riveted and welded
vehicle service manual joints- beams-torsion-
 Measure the connecting rod bending moment concepts
bend and twist measurement  A force of 600N is applied to
using connecting rod a piston which has a cross-
alignment tester and sectional area at the crown
Compare the bend and twist of 0.01m2, Calculate the
value with standard value of pressure that this force
given vehicle service manual creates in the gas in the
 Perform Torsion testing and cylinder
calculate required parameter  A front suspension spring of
 Perform Fatigue testing and a certain vehicle is
calculate required parameter compressed by 30mm when
it carries a load of 240 N.
Calculate the spring stiffness
(rate).
 A connecting rod has a cross-
sectional area of 200mm2
and it carries a compressive
force of 2.4 tonnes. Calculate
the compressive stress in the
connecting rod.
 Determine the strain energy
stored in a valve spring that
is compressed by 15mm
under a load of 750 N.

88- Identify and Skills on Fluid Power Fluid power
119 explain the  Tracing of hydraulic circuit on  Definition of Pascal law,
hydraulic and hydraulic jack pressure, Force, viscosity.
pneumatic  Tracing of hydraulic circuit in Description, symbols and
components in the hydraulic power steering application in automobile of
workshop and  Tracing of hydraulic circuit in Gear pump-Internal &
vehicles Brake circuit External, single acting,
 Identification of components double acting & Double
in Air brake systems. ended cylinder; Directional
control valves-2/2, 3/2, 4/2,
4/3 way valve, Pressure
relief valve, Non return
valve, Flow control valve
used in automobile.
Pneumatic Symbols,
Description and function of
air Reciprocating
Compressor. Function of Air
service unit (FRL-Filter,
Regulator & Lubricator).
Organize and Skills on Ratio and Proportion, Ratio, proportion and
120- measure various Percentages percentage
168 engine parameters  Measure the engine speed  Basics of Raito and
(torque, BHP, and wheel speed at different proportion, percentage
BMEP,IHP etc.) gear and find the gear ratios calculations- Aspect ratio of
 Measure piston dia and stoke tyres, Gear ratios – gearbox,
length, determine swept calculation for Valve opening
volume and a clearance area, Wheel revolutions and
volume of Engine distance travelled
 Measure the vehicle speed  Calculate compression ratio
and wheel speed and find the of an engine that has a
speed reduction percentage swept volume of 450cm3
 Find the slip angle using slip and a clearance volume of
tester. 50cm3.
Skills on IC Engine power  An engine that develops
 Determine of the engine’s 120kW is tuned to raise the
effective torque (Te), at full power output to 145 kW.
and partial load conditions. Calculate the percentage
Using Dynamometer increase in power
 Determine of the engine’s  A poppet valve with a
break mean effective diameter of 40mm has a lift
pressure (BMEP) at full and of 15 mm. Calculate the area
partial load conditions. Using through which air or mixture
Dynamometer can pass on its way to the

 Determine of the power (Pe) engine cylinder.
and break specific fuel  The rolling diameter of a
consumption (bsfc) large tyre for a commercial
Characteristics at full and vehicle is 943.5 mm. How
partial load conditions. Using many metres will the vehicle
Dynamometer move when the wheel and
tyre rotate 10 times?
 Determination of the engine’s IC engine
heat balance i.e. heat for  Brake power, Horsepower,
power (Qe), heat rejected to Indicated power, Mean
cooling (Qwater), heat effective
rejected to exhaust (Qexh)  Pressure, Cylinder
and heat rejected to overall pressurevs. crank angle,
friction (Qfriction). Mechanicalefficiency of an
engine, Volumetric
Skills on Theoretical engine efficiency, Brake mean
cycles effective pressure, Thermal
 Determine of the engine’s efficiency, Indicated
volumetric efficiency (ηv) and thermalefficiency, Brake
relative air/fuel ratio (λ) at full thermalefficiency petrol vs.
and partial load conditions. diesel
Using Engine dynamometer.  A certain engine develops a
torque of 120Nm while
running at a speed of 3000
rev/min. Calculate the brake
power.
 A 4-cylinder, 4-stroke engine

develops an indicated mean
effective pressure of 8 bar
at2800 rev/min.
 The cross-sectional area of
thecylinder bore is 0.01m2
and the length of the stroke
is 150 mm. Calculate the
indicated power of the
engine in kW.
 Certain engine develops a
brake power of 120kW at a
speed of 3000 rev/min.
 At this speed, the indicated
power is 140 kW. Calculate
the mechanical efficiency of
the engine at this speed.

 A 4-cylinder 4-stroke petrol
engine with a bore diameter
of 100mm and a stroke of
110mm has a volumetric
efficiency of 74% at an
engine speed of 4000
rev/min.
 Determine the actual volume
of air at STP that flows into
the engine in 1 minute.
 During a 10-minute
Dynamometer test on a
petrol engine, the engine
develops a brake power of
45kW and uses 3 kg of
petrol. The petrol has a
calorific value of 43 MJ/kg.
Calculate the brake thermal
efficiency.
 During a dynamometer test,
a certain 4-cylinder, 4-stroke
diesel engine develops an
indicated mean effective
pressure of 8.5 bar at a
speed 2000 rev/min.
 The engine has a bore of
93mm and a stroke of 91
mm.
 The test runs for 5 minutes
during which time 0.8 kg of
fuel are used.
 The calorific value of the fuel
is 43 MJ/kg. Calculate the
indicated thermal efficiency.
Engine cycles
 Charles &Boyel’s law-Otto-
diesel cycle- constant
pressure- constant volume,
isothermal, Carnot cycle,
Adiabatic and polytrophic
process, calorimeter- Heat
balance sheet of engines
 Free hand sketching of Otto
cycle, Diesel cycle.

 Calculate:the indicated
thermal efficiency;the air
standard efficiency;the
relative efficiency.
 For a test engine used
indicated power 50 kW, fuel
used per hour = 15 kg.
Calorific value of the fuel
=43MJ/kg. Engine
compression ratio = 8:1
 Calculate the air standard
efficiency a certain diesel
engine has a compression
ratio of14:1. The fuelling
factor ρ=1.78.
169- organize and carry Skills on Manufacturing Manufacturing concepts and
195 out joining of concepts and Industrial Engg industrial engineering)
metals using  Perform straight beads and  Casting defects- Welding
different methods Butt, Lap & T joints Manual defects-soldering and
and test for Metal Arc Welding. brazing Latent heat- EOQ-
defects  Setting of Gas welding flames, Inventory system, Heat
carryout a straight beads and Treatment process-
joints Oxy – Acetylene Annealing, Normalizing,
welding Hardening and tempering.
 Case hardening, Nitriding,
Induction hardening and
Flame Hardening process
used in auto components
with examples.
196- check and Skills on Vehicle Nomenclature Vehicle nomenclature
220 interpret vehicle  Look for vehicle information  Knowledge on Vehicle
specification data Number from the vehicle and variants, Technical
and VIN and classify the data based on Specification, Vehicle
prepare a job card information obtained. Dimension, Identification of
vehicle information
Skills on Customer relationship Number (VIN). Use of
 Prepare a sample work order Vehicle service information,
using computerized
information.
Customer relationship
 Proper customer relation
procedures, Preparing a
vehicle before and after
service, familiar with the

functions andComponents
of a work order.
 Use the three Cs (concern,
cause, and correction) to
diagnose the
vehicleproblem.
221- Plan and perform Skills on Basic Electrical Basic electrical
320 various basic tests  Perform joining wires using  Review of Electrical,
related with auto soldering Iron. Principles, OHM's Law-
electrical and  Construction of simple Power, Voltage, Current,
electronics and electrical circuits. resistance Calculations,
interpret the  Measure of current, voltage Serious and Parallel circuit
values obtained by and resistance using digital calculation, Use of
comparing with multimeter. multimeters
the standards  Perform continuity test for  Fuses & circuit breakers: -
fuses, jumper wires, fusible Ballast resistor, stripping
links, and circuit breakers. wire insulation, cable colour
 Verify the correlation codes and sizes, Resistors in
between conductor length Series circuits, Parallel
and cross section. circuits and Series-parallel
 Diagnose series, parallel, circuits, Capacitors and its
series-parallel circuits using applications, use of service
Ohm’s law. manual wiring diagram for
 Check electrical circuit with a troubleshooting Capacitors
test lamp. in series and parallel.
 Perform voltage drop test in Basic electronics
circuits using multicentre.  Basic electronics:
Description of
Skills on Basic electronics Semiconductors, Solid state
 Test power and signal devices- Diodes,
connectors for continuity Transistors, Thyristors, Uni
 Test different type of Diodes Junction Transistors ( UJT),
 Carryout NPN & PNP Metal Oxide Field Effect
Transistors for its Transistors ( MOSFETs),
functionality Logic gates-OR, AND & NOT
 Construct and test simple and Logic gates using
logic circuits OR, AND & NOT switches.
and Logic gates using Dash board
switches.  Study of various
Skills on Instrumentation panel gauges/instrument on a
 Diagnosis for combination dash board of a vehicle-
meter warning light and take Speedometer, Tachometer,
corrective action. Odometer and Fuel gauge,
and Indicators such as

gearshift position, Seat belt
warning light, Parking-
brake-engagement warning
light and an Engine-
malfunction light.
Project Work/ Industrial Visit
Revision
Core Module 2 :Automotive Electrical and Electronics System - Diagnosis & Repair:320 hrs
Hour Learning outcome (Trade Practical) (Trade Theory)
No. Reference (224 Hrs) (96 Hrs)
1-72 Plan and perform Skills on Ignition system - Ignition system
the trouble petrol  Ignition principles , Spark
shooting,  Carryout ignition spark test plug components, Inductive
diagnosis of  Perform spark plug removal system operation, Induction
automotive and installation wiring, Hall effect sensors,
electrical system,  Inspect spark plug for air gap Optical type sensors
determine and  Inspect ignition coil  Distributor less ignition
solve the assembly and ignition timing systems, Insulated coils,
problems and and compare with reference Distributor less ignition
justify the results value system timing.
skills on Starting System -petrol Starting system
/diesel  Purpose of starting system,
 Remove starter motor from Description of charging
vehicle and performance circuit, operation of
test for pull in test, Hold in alternators, regulator unit.
test, pinion return test, No-  Description of starter motor
load performance test. circuit, Constructional
 Carryout starter motor details of starter motor
disassembly and reassembly solenoid switches.
 Perform Solenoid test for
hold in coil open circuit, Starting system diagnosis
Armature Test-Ground test,  Common troubles and
open circuit test, pull-in coil remedy in starter circuit.
open circuit test, field coil Charging system
test, Inspection of brush  The purpose of Charging

length wear as per service system, Alternator
manual. principles, Rotor circuit,
Skills on Diagnosis for Starting Voltage regulation, System
System -petrol /diesel operating voltage, High
 Diagnostic for starter motor voltage charging systems,
does not run or run slowly Rotor, Stator, Alternator
 Diagnostic for starter motor end frames, Slip ring &
runs but fails to crank engine brush assembly, Rectifier
 Diagnostic for starter motor assembly, Alternator
abnormal noise cooling fan.
Charging system diagnosis
Skills on charging system  Causes and remedy for
petrol/diesel charging system.
 Perform Generator test for
No load check, load check Battery
 perform battery removal  Battery construction,
and installation Electrolyte, Charge and
 perform Generator drive discharge processes,
belt tension inspection and Technical battery figures
adjustment and terms, Different battery
 perform Generator drive types, Maintenance-free
belt removal and installation batteries, Installation
 perform Generator removal positions of batteries in
and installation vehicle, procedure for safe
 Carryout Generator handling of batteries.
disassembly and disassembly  Concept and working
 Inspect Generator for rotor, principle of Electric
slip ring diameter, bearing, Vehicles, hybrid electric
stator, brush, exposed brush vehicle (HEV), Fuel cell–
length, rectifier, regulator. powered vehicles
Skills on diagnosis for Charging
system
 Troubleshooting for charge
light does not light with
ignition ON and engine off
 Troubleshooting for charge
light does not go out with
engine running
 troubleshooting for
undercharged battery and
overcharged battery
 Troubleshooting for
generator noise
Skills on Battery
 Perform Battery testing
 Perform Battery recharging
 Carryout Boost starting
73- Plan and perform Skills on Engine Control Module Engine control module
180 the trouble (ECM)  Electronic control unit
shooting,  Carryout removal and (ECU) - EFI system ECU,
diagnosis of installation of Engine Control Electronic control unit
automotive Module (ECM) (follow the settings, Engine speed
electronics and Exercise of procedure for limiting, Malfunction
communication registration of ignition key) indicator lamp.
system, determine  Register for ECM Sensors
and solve the replacement procedure  Description of EFI sensors-
problems and  Register for Fuel Injector Intake Temperature sensor,
justify the results Diesel vehicle Mass airflow sensor,
 Carryout Air-fuel ratio date Manifold absolute pressure
initialization for Diesel sensor, Air vortex sensor,
vehicle Fuel system sensor, Throttle
 Inspect Electric throttle body position sensor, Exhaust gas
assembly On-Vehicle oxygen sensor, Crank angle
Skills on testing of sensors sensor, Hall effect voltage
 inspect Accelerator Pedal sensor
position sensor On-Vehicle Communication system
 Carryout removal, inspection  Principle of multiplexing,
and installation of different classes of
Accelerator Pedal assembly communications, principle
with Accelerator Pedal of operation of the
position sensor. Controller Area Network
 Inspect Manifold Absolute (CAN) bus system, principle
sensor (MAP) and compare of operation of the, LIN Bus
its reference value with system Media Oriented
service manual. System Transport (MOST)
 Carryout removal, inspection data bus using fiber optics.
and installation of Engine
Coolant Temperature (ECT)
sensor.
 Inspect On-Vehicle for Air
fuel ratio (A/F) sensor,
Heated Oxygen sensor
(HO2S).
 Carryout removal and
installation of Air fuel ratio
(A/F) sensor, Heated Oxygen
sensor (HO2S).
 Inspect On-Vehicle for

Camshaft Position sensor
(CMP) performance.
installation of Camshaft
Position sensor (CMP).
Crankshaft Position sensor
(CKP) performance.
installation of Crankshaft
Position sensor (CKP).
Vehicle speed sensor (VSS)
performance.
installation of Vehicle speed
sensor (VSS).
 Inspect On-Vehicle for knock
sensor performance.
installation of Knock sensor
 Inspect On-Vehicle for Mass
Air flow (MAF) sensor and
Intake Air temperature (IAT)
sensor.
installation of Mass Air flow
(MAF) sensor and Intake Air
temperature (IAT) sensor.
installation of Boost
pressure sensor.
 Inspect fuel pump relay,
starting motor control relay,
main relay and fuel heater
relay.
installation of Glow plug
control module.
Skills on Communication
Network system
 Diagnosis of CAN
COMMUNICATION system
symptoms.And
troubleshooting for last
communication.
 Trouble tracing in LIN, MOST
BUS circuit.
 Diagnose a body control
module and module
communication errors.
181- Demonstrate Skills on Air bag system Air bag
239 troubleshoot and  Perform Air bag diagnosis  Description of the different
Diagnosis of using "on-board diagnostic types of air bag system
vehicle safety system". sensors.
system  check for Air bag warning  Description of normal
light operation of the air bag
 Diagnosis for "AIR BAG" system warning light.
Warning light comes ON  Procedure for disabling and
steady and take corrective enabling air bag system
action.  Function of the side-impact
 Diagnosis for "AIR BAG" air bags and the locations of
Warning light does not come the modules and sensors
ON take corrective action.
 Perform repair and
inspection after accident as
per procedure.
 Perform disabling air bag
system.
 Perform enabling air bag
system.
 Carryout removal, inspection
and installation of Forward
impact sensor.
240- Plan and organize Skills on Horn system Horn
290 the trouble  Carryout removal, inspection  Working principle of Horn
shooting, and installation of Horn. and horn switch.
diagnosis of Skills on Wiper/Washers Wiper
automotive  Diagnosis for wiper not  Description of Wiper, wiper
electrical working and take corrective motor, Types of windshield
accessories, action. wiper systems.
determine and  Diagnosis for washer not Glass/windows /mirror
solve the working and take corrective  Description and working
problems and action. principle of power window,
justify the results  Carryout removal, inspection power mirror, and power
and installation of Wiper door lock.
tank and washer pump.

and installation of
Windshield wiper.
 Inspect windshield wiper
motor operation.
 carryout removal, inspection
and installation of rear wiper
 Inspect rear wiper motor
operation.
and installation of wiper and
washer switch.
Skills on Glass/windows /mirror

 Diagnosis for rear end door
window defogger does not
operate and take corrective
action.
 Diagnosis for all power
windows do not operate and
take corrective action.
 Diagnosis for only one power
window do not operate and
 Diagnosis for abnormal noise
in power window do not
action.
 Diagnosis for power window
does not moves smoothly
and take corrective action.
 Inspect for rear end door
window defogger switch,
relay and defogger wire.
 Repair rear end door
window defogger wire.
 Inspect for power window
main switch.
291- Demonstrate Skills on power door lock power door lock system
320 troubleshoot and system symptom diagnosis  Causes and remedy for
Diagnosis of  Diagnosis for all doors door lock system.
vehicle safety cannot be locked /unlocked keyless entry system
system. by all of switches and take  Principle of keyless entry

corrective action. system and its advantages.
 Diagnosis for all doors
cannot be locked /unlocked
by only power door lock
switch and take corrective
action.
 Diagnosis for all door cannot
be locked /unlocked by only
key cylinder switch and take
corrective action.
 Diagnosis for only one door
cannot be locked/unlocked
Skills on keyless entry system
symptom diagnosis
 Diagnosis for all door cannot
be locked /unlocked by only
keyless entry transmitter
 Diagnosis for interior light
does not light when doors
are unlocked by keyless
entry transmitter and take
corrective action.
 Diagnosis for hazard warning
lights do not light when
doors are locked/unlocked
by keyless entry transmitter
 Diagnosis for transmitter
code cannot be programmed
to ECM and take corrective
action.
Revision
Core Module 3 :Automotive Engines System-Diagnosis & Repair :320 hrs

HOUR Learning outcome (Trade Practical) (Trade Theory)
No. Reference (224 Hrs) (96 Hrs)
1-22 Plan and organize Skills on Intake system Intake system
the  Check air cleaner filter  Engine Shop safety,
troubleshooting condition, clean and Replace Principals of service station
and diagnosis of if excessive dirty filter as per setup, Description and
intake and reference to service manual. function of Air cleaners,
exhaust system.  Carryout Removal, Different type air cleaner,
inspection and installation of Description of Intake
Air cleaner assembly(follow manifolds and material.
the procedure of Removal of Handling of related tools-
Battery, MAP sensor, EVAP use of Air blow gun,
canister purge valve) application of special tools
 Carryout Electric throttle required for the Engine &.
body assembly removal,  If air cleaner element
inspection and becomes clogged,
Installation(follow the Cleaning/Replacement
procedure of cooling system interval
draining, Removal and  What is an idle mixture, if
installation of air cleaner idle mixture is wrong,
assembly) inspection /Adjustment
 Carryout removal, interval
inspection, and installation  Torques specification chart
of intake manifold with new for various maintenance
gasket. (follow the activities. coolant and Gasket
procedure of Removal and specification
installation of throttle
body, MAP sensor)
23- Plan and organize skills on Cylinder Head Cover Cylinder Head Cover Assembly
130 the Assembly  Description and
troubleshooting  Perform Removal, inspection Constructional feature of
and diagnosis of and installation of cylinder Cylinder head, Importance of
power plant head cover and tighten as Cylinder head design, Type
(Engine: per order and torque of combustion chambers,
Construction, specification(follow the Effect on size of Intake &
Petrol, Diesel) procedure of Removal and exhaust passages, Head
installation of air cleaner gaskets and water tight
assembly, ignition coil sealant specification.
assembly While installing Engine Camshaft
Install new spark plug hole  Description and function of
gasket, cylinder head cover camshaft, procedure for
gasket, apply water tight Inspection and measuring
sealant as per service parameter as per manual,
manual) Description of drives,
Skills on Engine Camshaft Description of Overhead
Assembly camshaft, importance of
 Perform camshaft and Cam lobes.
tappet removal as per  Use of Micrometer, dial
service manual procedure gauge, gauging plastic,
with special tool applicable cylinder bore gauge.
to Engine Engine disassembly and
manufacture.(follow the reassembly
procedure of Removal and  Procedure for dismantling of
installation of cylinder head engine from a vehicle.
cover)  Engine assembly procedure
 Carryout camshaft and with aid of special tools and
tappet inspection and gauges used for engine
reference with service assembling.
manual specification to take petrol Engine performance
decision on replacement, as  Procedure to be followed
camshaft height, camshaft while carryout compression
run out, camshaft journal and Engine vacuum test
wear, camshaft journal Timing chain cover Description
clearance, camshaft journal and function of the fly wheel
diameter, camshaft journal and vibration damper. Crank
housing bore, camshaft case & oil pump, gears timing
housing thrust clearance, mark, Chain sprockets, chain
wear of tappet, measure tensioner etc. Function of clutch
cylinder head to tappet & coupling units attached to
clearance, tappet outside flywheel.
diameter and cylinder head  What is a timing belt,
tappet bore Importance of changing
Skills on Engine disassembly timing belt(Timing chain is
and reassemblyPerform Engine not replaced periodically.), If
assembly removal and timing belt breaks,
installation as per service Replacement interval.
manual procedure. Engine Valve and Cylinder head

 Carryout valves and cylinder Assembly
head disassembly and  Valves & Valve Trains-
reassembly. Description and Function of
 Measure valve stem Engine Valves, different
diameter, valve guide bore types,
and valve stem-to guide  Type of valve operating
clearance and compare with mechanism, Valve- timing
service manual specification. diagram, valve and cylinder
 Measure valve stem end components inclusive DOHC
deflection limit, valve (Double overhead valve
protrusion length, valve camshaft, concept of
head radial run out, seating Variable valve timing.
head contact width.  Use of special tool as valve
 Inspect EGR passage, venturi guide remover, valve lifter,
plug. What is valve clearance,
 Inspect cylinder head for Excessive valve clearance,
distortion head surface on Insufficient valve clearance,
piston side, intake and Inspection/Adjustment
exhaust manifold side and interval.
cylinder head bolt. Piston
 Inspect valve spring and  Description & functions of
measure valve spring free different types of pistons,
length, valve spring preload, piston rings and piston pins.
valve spring squareness.  Recommended clearances
for the rings and its necessity
Skills on piston assembly precautions while fitting
 Perform piston, piston ring, rings, Compression ratio, use
connecting rod and cylinder of special tools piston ring
removal inspection and compressor.
installation(follow the connecting rod Description&
Exercise of removal and function of connecting rod,
installation of Engine importance of big- end split
Assembly, cylinder head) obliquely, piston pins and
 Carryout Perform piston, locking methods of piston pins.
piston ring, connecting rod crankshaft Assembly
and cylinder disassembly Description and function of
and reassembly Crank shaft, Firing order of the
 Inspect cylinder and engine, Inspection and
measure cylinder bore measuring parameter as per
diameter, cylinder taper and manual
out-of-round and compare CRDI Diesel Engine Intercooler
with service manual ref componentsDescription and
values function of Electronic Diesel
 Inspect piston and measure control systems, Common Rail

piston diameter, piston Diesel Injection (CRDI) system
clearance, ring groove  Description & function of
clearance and compare with exhauster, Super charger,
service manual ref values Intercoolers
 Inspect piston ring and
measure piston ring end gap
and take decision if replace
is necessary.
 Inspect piston pins and
connecting rods and
measure piston pin
clearance in connecting road
small end, piston pin
clearance in piston, small
end bore, piston pin
diameter and piston bore.
Skills on connecting rod
Assembly
 Inspect for connecting rod
alignment, connecting rod
bolt deformation and
measure connection rod big-
end side clearance.
 Inspect crank pin and
connecting rod bearing and
measure crank pin diameter,
crank pin taper and out-of-
round.
 Inspect connecting rod
bearing and measure
connecting rod bearing
clearance and select suitable
bearing as per manual.
 Perform removal, inspection
and installation of Main
bearing, crankshaft and
cylinder block and maintain
tightening torque as per
service manual specification.
Skills on crankshaft
AssemblyInspect crankshaft and
measure crankshaft run out,
crankshaft thrust play,

crankshaft out-of-round and
taper.
 Inspect main bearing and
measure main bearing
clearance and selection of
main bearing as per
specification.
 Inspect cylinder block and
measure for cylinder block
flatness.
Skills on CRDI Diesel Engine

Intercooler components
 Perform removal and
Installation of Intercooler
(follow the Exercise of
Removal and installation of
Front bumper).
 Carryout vacuum pump
removal and installation.
(Follow the Exercise of
Removal and installation of
Air cleaner assay).
 Inspect vacuum pressure
and compare with vacuum
pressure specification.
Skills on petrol Engine

performance Check
compression pressure on all
cylinders and verify with the
standard compression pressure
as per service manual.
 Perform Engine vacuum
check and verify with
Vacuum specification.
 Inspect oil level, oil quality
and oil leaks if any.
 Remove and replacement of
oil pressure switch.
 Inspect oil pressure and
compare with oil pressure
specification as stated in
manual.
 Check valve clearance as per
specification if not and
adjust it to desired
specification.
Skills on Timing chain cover
Carryout timing chain cover
removal, inspection and
installation, check oil seal and
replace if necessary (Follow the
procedure of removal &
installation of Engine assembly
from vehicle, water pump, oil
pan, Oil pump strainer, oil
pump).
 Perform flywheel removal
inspection and installation.
 Perform timing chain and
chain tensioner removal,
inspection, and installation.
Skills on Engine Valve and
Cylinder head Assembly
 Carryout valve and cylinder
head removal, inspection
and installation (Follow the
procedure of removal &
installation of Engine
assembly, oil pan, Oil pump
strainer, cylinder head cover,
timing chain cover, timing
chain, camshaft and tappet,
exhaust manifold, Fuel
injector, oil pump).
131- Plan and perform Skills on EGR Valve and EGR EGR Valve and EGR cooler
153 the trouble cooler componentsPerform EGR components Types of emissions:
shooting, Valve and EGR cooler removal Description of Evaporation
diagnosis of and installation(follow the emission control, Catalytic
automotive Exercise of Removal and conversion, Crankcase emission
emission control installation of Glow plug, cooling control, Exhaust gas
system, determine system draining, ECM, Cowl Top recirculation (EGR) valve.
and solve the Garnish components) turbocharger Assembly
problems and Skills on Crankcase ventilation Description & function of turbo
justify the results system components charger, variable turbo charger
Carryout Oil separator and crank mechanism.
case ventilation cover removal,

inspection and
installation(follow the Exercise
of Removal and installation of
ECM, Cowl Top Garnish
components,
Generator/Alternator).
Skills on turbocharger Assembly
 Carryout turbocharger
installation ((follow the
Exercise of Removal and
installation of Air cleaner
assembly, intercooler,
Exhaust manifold
components, glow plug, oil
cooler, exhaust muffler, Air
fuel ratio sensor, catalytic
convertor)
 Inspect turbocharger for
abnormal noise and
excessive run out and
measure stroke of boost
control valve.
154- Plan and organize Skills on Engine Lubrication Lubrication system
199 the system Function of lubrication system,
troubleshooting Check oil level in pan if oil level Viscosity and its grade as per
and diagnosis of is low add oil up to full level SAE,
cooling and mark on oil level gauge.  Importance of engine oil
lubricating  Inspect oil Quality if is change,Engine oil roles,
system. discolored or deteriorated, Replacement interval, Types
change it, Ref service of engine oil.
manual (follow the Exercise  Procedure for strainer
of Engine oil change and replacement, engine oil filter
filter change). roles, if the engine oil filter is
 Check for oil leak if any. not replaced, Replacement
 Check oil pressure and interval.
reference with service  Procedure for Engine oil and
manual specification (Ref the filter change, use of special
exercise of removal and tool as oil filter wrench, oil
installation front Bumper level gauge.
components).  Different type of Oil pump &
 Use of special tools as oil Oil filters, importance of Oil
pressure gauge. pressure relief valve, Spurt
 Change the Engine oil and holes & galleries, Oil

filter. indicators, Oil cooler.
 Inspect oil pressure sensor Cooling System
switch on-vehicle. Description of Engine Cooling
 Carryout oil pan & oil pump systems, block diagram of
strainer removal and coolant circulation routing,
installation and follow the Vehicle coolant properties and
torque tightening value as recommended change of
per service manual (Ref interval, If coolant leaks out,
Exercise of Removal and Different type of cooling
installation of Exhaust systems, Basic cooling system
system components, oil components- Radiator, Coolant
filter). hoses, Water pump, Cooling
 Carry out oil pump system thermostat, Cooling
disassembly and reassembly. fans, Temperature indicators,
 Inspect oil pump for oil seal, Radiator pressure cap, Recovery
relief valve and measure system, Thermo-switch.
radial clearance between  Purpose of drive belt, If drive
rotor and case for oil pump, belt is damaged, Inspection
side clearance for oil pump interval.
inner rotor, rotor plate  Use of pressure tester gauge
clearance, relief valve spring  Procedure for cooling system
free length and load as per Flush and refill.
service manual.
Skills on Engine Cooling System
 Check coolant level if
coolant level is low add  Use of Scan Tool
specified coolant up to FULL
mark level.
 Inspect drive belt for
tension, cracks, cuts,
deformation, wear, if any
defect found replace the
belt.
 Inspect Engine cooling
system and cleaning and ref
with service manual
specification of cooling
system and radiator cap
holding pressure.
 Perform cooling system
draining.
 Perform cooling system
Flush and refill.
 Carryout cooling water

pipes/Hoses removal and
installation.
 Carryout thermostat
removal and
installation(follow the
exercise for cooling system
draining, ECT sensor removal
cooling system Flush and
refill)
 Inspect thermostat
temperature at which
valvebegin to open, become
fully open and thermostat
valve lift.
 Inspect Radiator cooling fan
assembly on-vehicle.
 Check for radiator for
leakage or damage,
straighten bent fins, if any
 Carryout Radiator Removal
and installation(follow the
exercise of follow the
exercise for cooling system
draining, ECT sensor removal
cooling system Flush and
refill)
 Carryout Radiator cooling
fan assembly removal and
installation. (follow the
exercise Radiator Removal
and installation)
 Perform water pump
installation and follow the
torque tightening value as
per service manual.
 Inspect Radiator cooling fan
low speed control system
check.
 Radiator cooling fan high
speed control system check.
200- Formulate and Skills on CRDI Engine CRDI Engine performance

277 perform the performance  Procedure for carryout
troubleshooting  Glow plug removal and compression pressure.
and diagnosis of installation CRDI Engine Disassembly and
Electric and  Glow plug control module reassembly
Electronic related removal and installation.  Procedure for dismantling of
to power plant  Check compression pressure diesel engine from a vehicle.
MPFI and CRDI on all four cylinders and Fuel system -MPFI
verify with the standard  Basic EFI principles block
compression pressure as per diagram of fuel delivery
service manual. system, Routing, Air supply,
 Common rail removal and Air volume, Multi-point
installation. injection systems
 check timing between (MPI/MPFI), Simultaneous
camshafts and crankshafts injection, efficient
Skills on CRDI Engine combustion.
Disassembly and reassembly Fuel pump and fuel tank assay
 Description and function of
Skills on Fuel system -MPFI Fuel pumps, Fuel filters,
 Inspect fuel pressure and Tanks & lines, Fuel lines, Fuel
compare with service rail, Fuel pressure regulator,
manual (use of Fuel pressure Injectors, Tachometric relay,
gauge). Thermotime switch, EFI
 Inspect for fuel cut sensors, Potentiometer,
operation for MPFI (use of Auxiliary air valves, Idle
stethoscope). speed control devices,
 Check for fuel efficiency Inertia sensors.
norms against the  What is a fuel tank cap,
recommendation of the Importance of inspecting the
manufacturer fuel tank cap, Inspection
 Perform fuel pressure relief. interval.
 Check for fuel leakage if any.
 Carryout fuel pipe removal CRDI fuel Injector system
and installation (follow the  Description and function of
exercise of fuel pressure Diesel fuel injection, fuel
relief). characteristics, concept of
 Inspect fuel injector on- Quiet diesel technology &
vehicle (use of stethoscope). Clean diesel technology.
 Check resistance of fuel
injector ref with service

manual specification.
 Carryout fuel injector
installation (follow the
exercise of fuel pressure
relief, removal and
installation of air cleaner
assembly.
 Inspect fuel injector for
injected fuel volume and
fuel leakage and compare
with the reference value
(follow the exercise of fuel
pressure relief, use of special
tool and scan tool).
Skills on fuel pump and fuel
tank assay
 Inspect fuel filler cap.
 Perform Fuel tank removal,
inspection and Installation
pressure relief, removal and
installation of Exhaust pipe
and muffler, use of hand
operated pump).
 Inspect fuel tank for leaks,
deterioration and damage.
 Perform fuel tank purging
procedure.
 Inspect fuel pump on-
vehicle.
 Carryout fuel pump
assembly removal and
installation (follow the
exercise of Fuel tank
Installation).
 Inspect fuel pump assembly
for damage, dirt and
contamination.
 Check fuel level sensor
resistance and reference
with service manual
specification.
 Perform fuel filter removal
and installation.
Skills on Fuel system CRDI
 Perform fuel pressure relief
on-vehicle (use of scan tool).
 Check for fuel leakage.
 perform water draining of
fuel filter
 Perform air bleeding of fuel
system.
 Carryout high-pressure pipe
removal and installation
pressure relief on-vehicle,
removal and installation of
intercooler, use of special
tool for tightening as per
torque specification).
Skills on CRDI fuel Injector
system
 Perform fuel injector
removal and installation as
per service manual
procedure (follow the
exercise of high-pressure
pipe removal and
installation)
 Carryout common rail
removal and installation
pressure relief on-vehicle,
high-pressure pipe removal
and installation)
 Carryout high pressurepump
installation. (follow the
exercise of fuel pressure
relief on-vehicle, removal
and installation of air cleaner
assembly, vacuum pump,
high-pressure pipe removal
and installation)
 Perform fuel temperature
sensor removal and

installation.
 Inspect fuel temperature
sensor and fuel filter water
detection sensor and
compare with service
manual specification.
278- Plan and organize Skills on Exhaust system Exhaust system
301 the  Check Exhaust system as  Description and function of
troubleshooting periodic maintenance for Exhaust manifold, Exhaust
and diagnosis of rubber mountings, leakage, pipe, Extractors, Mufflers-
intake and dent, loose connection, Reactive, absorptive,
exhaust system. ground clearance Combination., Catalytic
 Carryout Exhaust Manifold converters
removal, inspection and  Procedure for Manifold
installation for MPFI (follow fitment, sensors location,
the exercise of removal of diagnosis procedure for
A/F sensor, O2 sensor) turbo charger noise.
 Perform Exhaust pipe and  What is a charcoal canister,
muffler removal, inspection Importance of inspection of
and installation charcoal canister, Inspection
 Carryout Exhaust Manifold interval.
installation for CRDI. (follow
the procedure of cooling
system draining, Removal
and installation of air
cleaner assembly,
turbocharger).
 Carryout catalytic converter
removal inspection and
installation
302- Plan and perform Skills on Aux Emission control Aux Emission control devices
311 the trouble devices  Description of Evaporation
shooting,  Inspect EVAP canister purge emission control
diagnosis of system using scan tool. (EVAP),What is a PCV valve,,
automotive  Inspect EVAP canister purge Importance of inspection of
emission control valve and measure its PCV valve, Inspection
system, determine resistance value with service interval.
and solve the manual.
problems and  Inspect EVAP Canister for
justify the results vacuum passage.
 Insect PCV valve and hose.
312- Plan and organize Skills on Engine diagnosis Engine diagnosis

320 the  Diagnosis for Engine • Causes and remedy for
troubleshooting overheating and take Engine diagnosis for 1) Engine
and diagnosis of corrective action. overheating (2) Unusual noise
power plant  Diagnosis for Unusual noise from engine (3) Engine not
(Engine: from engine and take cranking (4) engine crank but
Construction, corrective action. not start (5) Excessive engine oil
Petrol, Diesel)  Diagnosis for Engine not consumption (6) Excessive
cranking and take corrective engine vibration (oil mix with
action. coolant) (7) low fuel mileage (8)
 Diagnosis for engine crank Poor pickup (9) excessive smoke
but not start and take from exhaust( 10) excessive
corrective action. white smoke (11) Low oil
 Diagnosis for Excessive pressure (12) poor engine
engine vibration (oil mix running (13) Engine stops
with coolant) and take immediately after starting (14)
corrective action. Engine noise (15) Engine misfire
 Diagnosis for poor fuel
mileage and take corrective
action.
 Diagnosis for Poor pickup
 Diagnosis for excessive
smoke from exhaust and
 Diagnosis for excessive white
smoke and take corrective
action.
 Diagnosis for Low oil
pressure and take corrective
action.
 Diagnosis for Engine stops
immediately after starting
 Diagnosis for Engine misfire
after starting and take
corrective action.
 Error code analysis and
corrective action.
Project work/Industrial visit
Revision
Core Module 4 :Automotive Transmission Diagnosis & Repair (320 hrs)

Learning
HOUR (Trade Practical) (Trade Theory)
outcome
No. (224 Hrs) (96 Hrs)
Reference
1-148 Plan and organize Skills on Clutch Assembly Clutch Assembly
to find the faults  Check for clutch pedal height • Clutch principles, Single-
and Diagnosis of and compare with the desired plate clutches, Multi-plate
manual specification as per service clutches, Dual mass flywheels,
Transmission manual. Operating mechanisms, Clutch
system and  Check for clutch pedal free cable replacement condition
suggest travel and compare with the Clutch hydraulic type
appropriate desired specification as per • Principle of Hydraulic
measure for service manual. clutch type, Description of
manual  Adjust clutch cable as per Pressure plate, Driven/ center
transmission, desired specification as per plate, Throw-out bearing.
transaxle, service manual. Clutch diagnosis
differential and  Carryout removal, inspection • Causes and remedy for
final drive. and installation of clutch clutch system 1. Clutch vibrates,
cable. 2. clutch fail to disengage,
 Inspect clutch cable and 3.clutch noisy 4. Clutch slippage
replace if damaged. 5. Clutch chatter 6. Pedal is hard
 Carry out removal, inspection to operate. 7. Spongy clutch
and installation of clutch pedal pedal
assembly.( follow the exercise Manual transaxle unit
• Description of Transaxle
of removal, inspection and designs, Gearbox operation,

installation of clutch cable). Baulk-ring synchromesh unit,
 Carryout removal, inspection Transaxle synchromesh unit.
and installation of clutch cover Gearbox assembly
and clutch disc. (follow the • Gearbox layout &
exercise of manual transaxle operation- Gearbox layouts
unit dismounting and Transmission Diagnosis
remounting). • Causes and remedy for
 Inspect clutch disc for rivet transmission system
head depth and ref with
service manual specification.
 Inspect clutch cover for
diaphragm spring damage or
wear and inspect pressure
plate for heat spots and
replace if any damage.
and installation of clutch
release system.
 Check clutch release bearing
for smooth operation.
 Check clutch release shaft and
its pin for bend and damage
and replace if necessary.
Skills on clutch hydraulic type
and installation of clutch pedal
position switch.
 Inspect CPP switch resistance
and compare with reference
value.
 Inspect clutch pedal height
and adjust it the desired
range.
 Inspect clutch cylinder push
rod play and adjust it the
desired range.
 Inspect clutch pedal free travel
and adjust it the desired range
clutch fluid level.
 Inspect clutch fluid level.
(follow the exercise of brake
fluid level inspection).
 Carryout air bleeding of clutch
system.
 Carry out removal, inspection
and installation of clutch fluid
pipe.
master cylinder (follow the
exercise of removal,
inspection and installation of
clutch fluid pipe).
operating cylinder. (follow the
exercise of manual transaxle
unit dismounting and
remounting)
 Inspect clutch operating
cylinder for clutch fluid
leakage, spring damage and
bearing for smooth operation,
if not working replace the
clutch operating cylinder.
Skills on diagnosis for Clutch

 Diagnosis for clutch vibration
 Diagnosis for clutch fail to
disengage and take corrective
action.
 Diagnosis for noisy clutch and
 Diagnosis for clutch slipping
and take corrective action
 Diagnosis for Clutch chatter
 Diagnosis for Pedal is hard to
action.
 Diagnosis for Spongy clutch
pedal and take corrective
action.
Skills on Manual transaxle unit
 Carryout manual transaxle
unit dismounting and
remounting (follow the

exercise of removal and
installation of Engine
Assembly, front drive shaft,
starting motor ).
and installation of gear shift
and select shaft assembly.
 Carryout disassembly and
reassembly of gear shift and
select shaft.
Skills on Gearbox
assemblyCarryout gear box
disassembly and reassembly as
per procedure.
 Carryout input shaft and
counter shaft assembly
disassembly and reassembly
as per procedure.
 Carryout differential
as per procedure and check
for gear thrust play.
Skills on transmission Diagnosis
 Diagnosis for Gears slipping
out of mesh and take
corrective action.
 Diagnosis for Gears Hard
shifting take corrective action.
 Diagnosis for Gear noise and
149- Examine/interpret Skills on Inspection and Testing Auto transmission
265 the faults in on Auto transmission  Automatic Transmissions-,
Diagnosis of  Perform inspection, testing, Torque converter principles,
automatic and diagnosis procedures on drive plate, Converter
Transmission automatic transmissions / operation, Torque
system and transaxles. multiplication, Fluid flow,
suggest  Perform visual inspection. Heat exchanger, Lock-up
appropriate  Inspect fluid level and converters. Different type of
measure for condition. hybrid power train, Alternate
automatic Gear  Interpret road test results. fuel power train -Electrical
boxes.  Perform on board diagnostics car;
and analyse data Service and repair of Automatic
 Access applicable service transmission /transaxle
information / technical service  Layout & operation for

bulletins. P,R,N&D (1st & 2nd) Selector
 Adjust linkage. positions, Planetary gear set,
 Interpret hydraulic pressure High range power flow, Low
test results. range power flow Servos &
 Carryout power flow trouble. clutches-Rear servo, Front
 Perform shift evaluation. servo, One way clutch, Multi-
 Carryout symptom based plate front clutch, Clutch
diagnosis of transmission / pack, Rear clutch.
component failures Automatic transmission /
 Diagnosis for specific transaxle electronic controls.
component failure and causes  Description of Electronic
Skills on service and repair of control Unit, Fully
Automatictransmission/transaxle hydraulically controlled
 Carryout disassembly transmission, Electronic shift
sequence. programs, Manual selection.
 Perform air test. Diagnosis of automatic
 Perform required transmission / transaxle
measurements. electronic controls
 Inspect and adjust to the  Description of Continuously
manufacturers specific variable transmission (C.V.T.)-
corrections. Drive or reverse, The steel
 Disassemble transmission / belt, Secondary pulley shaft
transaxle. Drive shaft /Axle
 Inspect components  Basic layouts Front-wheel
 Trace power flow through drive layout, Rear-wheel
unit. drive layout, Four-wheel
drive layout, All-wheel drive
 Disassemble and inspect sub
layout, 4WD v/s AWD Front-
components.
wheel drive, Front-wheel
 Re-assemble and verify correct
drive shafts, Front-wheel final
function.
drives, Front-wheel
 Change automatic
differentials
transmission fluid and filters.
 Description of Four-wheel
 Perform flushing of
drive shafts, Four-wheel final
assemblies.
drive, Four-wheel drive
Skills on automatic transmission /
transfer case, Freewheeling
transaxle electronic controls.
hubs, Four-wheel drive
 Inspect power train control
differentials
units (PCU).
 Description of Rear-wheel
 Inspect input devices (sensors)
final drives, Rear-wheel drive
speed, position, pressure,
differentials, Limited slip
temperature.
differentials.
 Inspect output devices Drive shaft /Axle
(solenoids, relays) pressure,  Trouble shooting causes and

shift, torque converter clutch remedy for 1. Excessive
controls (TCC). vibration at low gear or
 Inspect data lines / certain speed, 2. premature
communications. wear 3. Slip joint spline
 Carryout on board diagnostics. wear/tube broken.
 Shaft support on
Skills on interpret results of bearing/rubber insulator
functional and diagnostic tests on wear or fracture.
automatic transmission /  Trouble shooting causes and
transaxle electronic controls remedy for Differential: 1.
 Perform component testing. Pion and crown alignment
 Carryout scan tool utilization. with proper clearance 2.
 Perform performance testing. Humming noise.
 Test pressure controls.
 Test shift controls.
Skills on Drive shaft /Axle
 Carryout front drive shaft
assembly on-vehicle
inspection for.
 Boots for breakage leaks, tear
 Boots bands for loose, crack
 Drive shaft for crack or
damage.
 Check differential side joint for
smooth rotation.
 If any damage the same may
be replaced.
and installation of front drive
shaft assembly.
 carryout front drive shaft
as per service manual
procedure
and installation of Front wheel
hub, steering knuckle and
wheel bearing.( follow the
exercise of removal and
installation of Brake disc )
and installation of Rear wheel
bearing.
Skills on diagnosis for Drive shaft

/Axle
 Diagnosis for Excessive
vibration at low gear or certain
speed and take corrective
action.
 Diagnosis for premature wear
 Diagnosis for Slip joint spline
wear/tube broken and take
corrective action.
 Diagnosis for shaft support on
bearing/rubber insulator wear
or fracture and take corrective
action.
 Diagnosis for Pion and crown
alignment with proper
clearance and take corrective
action.
 Diagnosis for Humming noise
Project work / Industrial visit
Revision

Core Module 5 :Automotive Vehicle Controls- Brake, Suspension and Steering - Diagnosis &Repair
(320 hrs)
Hour Learning (Trade Practical) (Trade Theory)
No. outcome (224 Hrs) (96 Hrs)
1-95 Plan and organize Skills on Brake system Brake system
to find the faults Principles of braking, Brake lines,
 Inspect brake fluid level, brake
and Diagnosis of Brake fluid, air Bleeding.
fluid level switch and change
vehicle controls
the brake fluid if required.
(conventional) Brake pedal assembly
 Carryout air bleeding of brake
and suggest system. Description of Brake pedal, Brake
appropriate Skills on brake pedal light switch.
measure for assemblyCarryout removal,
brake, suspension inspection and installation of Brake master cylinder assembly
and steering brake pedal assembly.
 Description of Master
system. cylinder, Divided systems.
 Check for brake pedal free
height and adjust it to the
Front Brake components
desired standard as per
service manual.  Description of Power booster
 Inspect excessive brake pedal or brake unit, Hydraulic brake
travel and adjust it to the booster, Electro hydraulic
desired specification. braking (EHB), Applying
 Carryout removal, inspection brakes, Brake force,
and installation of brake light Description of Brake pad,
switch and adjust it if required Regenerative braking.
Skills on brake master cylinder  Disc brake system, Disc brake
assembly operation, Disc brake rotors,
Disc brake pads, Disc brake
 Carryout removal, inspection calipers, proportioning valves,
and installation of brake hose Proportioning valve operation,
and pipe. Brake friction materials.
 Check brake hose for deplete,
crack, and damage if any
defect found replace it. Rear Brake
 Check brake pipe for crack,
dent and corrosion if any Description of Drum brake
defect found replace it. system, Drum brake operation,
 Carryout removal, inspection Brake linings & shoes,
and installation of Master
cylinder assembly.  Principles of ABS braking, ABS

 Carryout removal, inspection master cylinder, Hydraulic
and installation of Master control unit.
cylinder reservoir.
 Inspect master cylinder Wheel cylinder Assembly
assembly for No-load Description of Wheel cylinders,
inspection and Air tightness Back plate.
inspection (use of special
tools).
 Check for brake booster Parking brake
function.
Brake type - principles, Air brakes,
Skills on Brake Booster Exhaust brakes, Electric brakes,
Parking brakes, Engine brakes,
 Check for Air tightness,
Regenerative braking.
operation, Air tightness under
loaded condition.
Skills on Front Brake components
 Inspect front brake pad lining

thickness of outside and inside
pads and refer with service
manual specification and
replace if worn out
and installation of front brake
pad.(follow the exercise of
wheel)
disc.(follow the exercise of
removal installation of front
brake pad).
 Inspect front brake disc
deflection (use of special
tools), front brake disc
thickness, front brake pad
lining thickness and compare
with service manual value.
caliper.

assembly of front brake
caliper.
 Check for piston seal.
 Inspect for caliper body and
carrier for deformation crack,
rust and damage, if defective
replace.
 Check cylinder boot for brake
fluid leak.
 Inspect caliper slide pin for its
smooth movement in thrust
direction.
Skills on Rear Brake
 Inspect rear brake shoe lining

thickness on-vehicle and
compared with specified value
if less replace all brake shoe
and installation of rear brake
drum.(follow the exercise of
rear wheel bearing, wheel
with tire, parking brake
adjustment)
 Inspect brake drum for crake,
wear and damage if any defect
found replace brake drum
 Measure brake drum inner
diameter and compare with
ref value specified in service
manual
 Inspect brake shoe lining for
hardening, wear, peel-off and
oil.
 Measure thickness of brake
shoe lining thickness diameter
and compare with ref value
specified in service manual
 Inspect ABS Sensor ring for
damage if any.
and installation of rear brake

shoe.(follow the exercise of
installation of rear brake
drum, wheel with tire, parking
brake adjustment)
 Check for rear brake shoe
adjuster and shoe lever for
wear and damage if any.
Skills on wheel cylinder Assembly

for wear, cracks, corrosion,
fluid leakage, if any defect
found replace wheel cylinder,
and installation of wheel
cylinder. (Follow the exercise
of removal, inspection and
installation of rear brake shoe,
air bleeding of brake system,
parking brake adjustment).
and installation of brake back
plate. (Follow the exercise of
installation of wheel cylinder,
air bleeding of brake system,
parking brake adjustment).
Skills on Parking brake
 Carryout parking brake

inspection for operation, rear
wheel locking, parking brake
stroke and adjust it.
and installation of parking
brake cable.( follow the
rear brake shoe, consol box
components)
and installation of parking
brake lever. (follow the

inspection and installation
consol box components).
 Inspect parking brake switch
for function.
96- Examine/interpret Skills on ABS Systems ABS Systems
131 the faults in
 Diagnostic and repair in • Description of Wheel
Diagnosis of
Antilock Brake System circuit. speed sensors, ABS with EBD
vehicle control
 Diagnostic and repair in electronic control unit. Read ABS
system Electronic Stability Program and ESP circuit diagram
(advanced) and (ESP) system circuit.
suggest ABS symptom diagnosis
appropriate Skills on ABS symptom diagnosis
measure for • Use of Scan Tool, study
antilock brake  Diagnosis for ABS warning (DTC) Diagnostic Trouble Code
light turns ON after engine
and power
start and take corrective Diagnosis for braking stability
steering. action.
 Diagnosis for ABS warning • Causes and remedy for
light does not turns on for 2 Braking system
sec after ignition switch has
turned ON and take corrective
action.
 Diagnosis for ABS warning
light flashes and take
corrective action.
 Diagnosis for EBD warning
light lights after engine start
 Diagnosis for EBD warning
light does not turns on for 2
sec after ignition switch has
turned ON and take corrective
action.
Skills on diagnosis for braking

stability (20 hrs)
 Diagnosis for less braking force
 Diagnosis for brakepull and
 Diagnosis for excessive pedal

travel and take corrective
action.
 Diagnosis for brake locked and
take corrective action
 Diagnosis for brake warning
light lights after engine start
light turn on when brake is
applied and take corrective
action.
light fails to turn on when
parking brake is applied and
132- Plan and organize Skills on Suspension system Suspension system
242 to find the faults  Check suspension frame and  Principles of suspension,
and Diagnosis of arm for deformation, crack Types of suspension-
vehicle controls and damage. Suspension systems,
 Check front& rear shock Description, function and
(conventional)
absorber for oil leakage, advantages of non-
and suggest deformation, damage if any independent suspension
appropriate and play and tightening. Independent suspension, Rear
measure for  Check front& rear Coil spring independent suspension,
brake, suspension crack and damage if any and Rear-wheel drive independent
and steering play and tightening. suspension, electronically
system.  Check bushes for crack and controlled air suspension
damage. (ECAS), Adaptive air
 Check suspension arm joint for suspension operation.
play and suspension arm joint  Description and function of
dust cover for crack. Coil springs, Leaf springs,
Torsion bars, Rubber springs.
Wheel alignment
 Basic principles of wheel
alignment, wheel base, wheel
Skills on wheel alignment track, king pin inclination,
Caster, Camber, Scrub radius,
 Carryout front wheel Toe-in & toe out, Toe-out on
alignment inspection with a turns, Turning radius, Thrust
diagnostic equipment, angle &centerlines
interpret and take corrective
action and adjust to desired Strut Assembly

specification
 Perform Toe-Inspection and  principle of Mc person Strut
adjustment of toe angle. suspension, Short/long arm
 Inspect camber caster and suspension, Torsion bar
kingpin inclination angle. suspension Rear suspension
 Inspect steering angle and types & components-Rigid
adjust it to the desired axle leaf spring suspension,
specification. Rigid axle coil spring
suspension, Independent type
suspension, Rigid non-drive
Skills on strut Assembly suspension
Shock absorber
 Carryout front strut Assembly
removal, inspection for strut  Description and function of
for oil leakage, damage. Hydraulic shock absorbers,
 Inspect coil spring seat for Gas-pressurized shock
cracks and distortion, inspect absorbers, Load-adjustable
rebound stopper, strut shock absorbers, Manual
bearing, strut dust cover, and adjustable-rate shock
strut support for wear, cracks absorbers, Electronic
and distortion. If any adjustable-rate shock
abnormality replace with new absorbers, Automatic load-
one, and installation. adjustable shock absorbers
 Carryout strut assembly and Wheel balancing and tyre
disassembly and reassemble. rotation
(Use of special tool).
 Carryout removal, inspection • Wheel types & sizes, Rim
and installation of suspension sizes & designations, Types of
arm (follow the Exercises of wheels, Tyres, Tyre pressure
removal and installation front monitoring systems, Run flat
bumper components, removal tyres, Space-saver tyres, Tyre
and installation of wheel).
rotation. Descriptions Tire wear
 Check suspension arm for
damage, inspect bush for Patterns and causes
wear, damage, check joint
Diagnosis for suspension system
cover for crake and damage, if
any abnormal replace. • Causes and remedy for
 Perform suspension arm bush suspension system
disassembly and assembly
(Use of special tool). Steering system
 Perform suspension arm dust
cover disassembly and  Description and function of
assembly. Steering systems, Principles of
 Carryout rear wheel alignment steering, Rack-and-pinion

inspection and adjust to steering system, Recirculation
desired specification. ball & nut steering system,
Four-wheel steering systems,
collapsible steering system.
Skills on shock absorber Procedure for centering
contact coil cable Assembly.
 Carryout rear shock absorber  Description and function of
removal, inspection for shock Steering columns.
absorber upper bush for wear,
crack and damage, oil leakage
if any defect found replace it.
and installation.
 Carryout rear coil spring and
spring seat removal,
inspection.
 Check for rear coil spring for
crack, damage, check spring
seat for crack and damage, if
defect found replace it and
installation.
Skills on wheel balancing and tyre

rotation
 Carryout wheel with tyre

removal, inspection – check
wheel disc for dent, crack and
distortion, check tyre for
uneven or excessive wear and
damage and installation as per
manual.
 Perform wheel balancing.
 Carryout tyre rotation.
Skills on Diagnosis for suspension

system
 Diagnosis for vehicle pulls and
 Diagnosis for abnormal or
excessive wear and take
corrective action.
 Diagnosis for wheel tramp and

 Diagnosis for shimmy, shake
or vibration and take
corrective action.
 Diagnosis for abnormal noise,
front end and take corrective
action.
 Diagnosis for Body leans in
corners and take corrective
action.
 Diagnosis for cupped tyres and
Skills on steering system

 Check steering column
capsules, steering column
length and compare with
service manual specified value
and if out of specification
replace it.
and installation of steering
wheel assembly (follow the
exercise of disabling Air bag
system, removal and
installation of driver Air bag
module, Enabling Air bag
system) (use of special tool)
contact coil Cable assembly
(follow the exercise of
installation of steering wheel
assembly.
 Carryout centering contact coil
cable Assembly
 Carry out removal, inspection-
check for steering column for
operation and damage, and
installation of steering column
as per procedure (follow the

steering wheel assembly,
contact coil cable, immobilizer
control module.
and installation of ignition
switch cylinder. (follow the
exercise of disabling air bag
system, immobilizer control
module, enabling air bag
system, registration of the
ignition key).
lock/ ignition switch assembly.
(follow the exercise of removal
column, registration of the
ignition key).
lower shaft.
243- Examine/interpret Skills on power assisted steering Power assisted steering
278 the faults in
 Check steering wheel play and  Power Assisted steering,
Diagnosis of
steering force compare with Steering process, Flow-control
vehicle control
desired value. valve, Electric power assisted
system  Carryout removal, inspection steering, Basic electric power
(advanced) and and installation of tie-rod end. steering operation, Procedure
suggest (follow the exercise of removal for inspection of steering
appropriate and installation of wheel with wheel play and steering force,
measure for tyre, front wheel alignment). Description of Rack-and-
brake  Carry out removal, inspection
pinion gearbox, Helix, Variable
antilock
– check boot for tear , if any ratio steering, Worm gearbox.
and power
damage replace it, and
steering. installation of steering gear Diagnosis for steering
case assembly (follow the
exercise of removal and  Causes and remedy for
installation of front steering system and use of
suspension frame). scan tool for power steering
 Carry out removal, inspection and study of DTC code related
and installation of tie-rod / to power steering.
rack boot (follow the exercise
of removal and installation of
steering gear case assembly).

 Carryout removal, inspection –
check rack plunger for wear or
damage, check rack plunger
spring for deterioration and
installation of steering rack
plunger. (follow the exercise
of removal and installation of
steering gear case assembly).
Skills on diagnosis for steering

 Diagnosis for hard steering
 Diagnosis for rack and pinion
noise and take corrective
action.
 Diagnosis for too much plays
in steering and takes
corrective action.
 Diagnosis for hard steering
279- Evaluate driving Skills on Driving Driving
313 performance of
 Obtaining LLR License.  Instruction to Driving exercise
trainees.
 Driving exercise – orientation. - orientation , limit braking,
 Driving exercise - limit braking. brake in a turn, lane change,
 Driving exercise - lane change. Wet skid pad, Low pressure
 Driving exercise - brake in a evaluation.
turn.
 Driving exercise - Graphing the
USG.
 Driving exercise - Avoidance
maneuver.
 Driving exercise - Wet skid
pad.
 Driving exercise - Baseline
path.
 Driving exercise - Path
variation.
 Driving exercise - Low pressure
evaluation.
 Driving exercise - Lapping in
comparison vehicle.
Project work / Industrial visit:
Revision

Elective Subject 1 :Automotive Air Conditioning and Climate Control System: Diagnosis and Repair (320
hrs)
Learning outcome (224 Hrs) (96 Hrs)
No.
1-16 Demonstrate Diagnosis Skills on A/C performance A/C principles
of automotive air
 Inspect A/C system  Air-conditioning principles,
conditioning and
performance and compare Air-conditioning capacity, A/C
climate control system.
with the desired value flow block diagram
17- Plan and organize the Skills on Diagnosis for A/C system Diagnosis for A/C system
146 troubleshooting and
 Diagnosis on High pressure • Causes and Remedy for
diagnosis of automotive
Gauge. A/C system
air conditioning and
 Diagnosis for pressure is
climate control system higher than acceptable range
components. in "H" area and take corrective
action.
 Diagnosis for pressure is lower
than acceptable range in "I"
area and take corrective
action.
 Diagnosis Low pressure Gauge.
higher than acceptable range
in "J" area and take corrective
action.
higher than acceptable range
in "K" area and take corrective
action.
 Diagnosis for abnormal
pressure and take corrective
action.
 Diagnosis for blower motor
does not operate and take
corrective section.
 Diagnosis for Air outlet port
does not change even if air
flow selector is changed and
take corrective section

 Diagnosis for Air intake door
does not change even if intake
mode is changed and take
corrective section.
 Diagnosis for warm air does
not come out and take
corrective section
 Diagnosis for No cool air
comes out or A/c compressor
does not operate and take
corrective section.
 Diagnosis for No cool air
comes out or radiator Cooling
fan motor does not operate
 Diagnosis for insufficient
cooling and take corrective
action.
 Diagnosis for cool air comes
out only at high speed and
from compressor and take
corrective action.
from Magnetic clutch and take
corrective action.
from condenser assembly and
from A/c Evaporator and take
corrective action.
from Blower motor and take
corrective action.
 Carryout Inspection of HVAC
control unit and its circuit
 Carryout A/C system
inspection at ECM.
147- Demonstrate Diagnosis Skills on Refrigerant Charge A/C Air intake actuator
260 of automotive air
 Follow the local Govt • Description of Air intake
conditioning and regulation working with control actuator

climate control system. refrigerator systems.
 Perform refrigerant charge as • Description of Pressure
per procedure. switches, Heating elements,
 Check A/C system for pressure procedure for adjust compressor
leaks. drive belt tension
 Check A/C system for
refrigerant leaks. A/C Compressor
Skills on Radiator • Description and working

 Carryout removal, inspection principle of Air-conditioning
and installation of Radiator compressors function of Fixed
cooling fan. orifice, Control devices,
Temperature monitoring
Skills on Condenser Assy thermostat.

and installation of condenser
assembly.
and installation of HVAC unit
and installation of blower
motor.
and installation of blower
motor resistor.
Skills on evaporator Assy

and installation of evaporator
temperature sensor.
and installation of expansion
valve.
Skills on HVAC sensors

and installation of HVAC
control unit.
 Inspect for blower speed
selector.
 Inspect for A/C refrigerant
pressure sensor and its circuit.

and installation of A/C
Refrigerant pressure sensor.
Skills on A/C Air intake actuator

and installation of Air intake
control actuator.
and installation of centre, side,
passenger side ventilation
louver.
 Inspect for A/c switch, HVAC
system relay.
 Inspect and adjust compressor
drive belt tension.
Skills on A/C Compressor

and installation of Compressor
drive belt.
and installation of Compressor
assembly.
and installation of Magnetic
clutch.
and installation of relief valve.
Revision
Elective Subject 2 :Auto body Repair and Refinishing (320 hrs)


Learning outcome
No. (224 Hrs) (96 Hrs)
1-28 Organize and analyze Skills on Vehicle Information Vehicle body
the misalignment of  Detect of different type body,
chassis.  Description of vehicle Body
the body due to an
 Detect the location of parts and Chassis.
accident, estimate the
and panels.  Definition of body shop,
amount of repair to be classification of body shop-
 Perform to extract vehicle
carried out and Independent body shop,
data and measurement details
propose for repairing from computer-based service dealership body shop,
of vehicle body. information, service manuals, specialty body shop and
refinishing guides, vehicle repair order
dimension manual. color  Study of Service Information,
matching guides, parts basic steps to refinishing
interchange guides. material.
 Utilize color matching guides.  Vehicle paint code, study of
 Utilize of parts interchange service symbols, diagnosis
guide. charts, wiring diagram.
Skills on Accident Report Body collision

 Inspect Damage vehicle and  Definition of collision,
accident report Preparation.impact of collision and
 Detect the location of collision repair
damaged parts and panels. measurement.
 Preparation of repair
 Perform Parts replacement
list. estimate information by
using an estimating guide
 Preparation of repair estimate
book.
information by using an
 Description of estimate,
estimating 6 hrs)guide book.
Direct repair programs,
Estimate time factor, work
orders, Using Estimate
Guides, Part prices, Labor
costs, Job overlap, and
included operation.
29- Plan and organize to Skills on Measuring of Body and Measuring of Body and Frame
176 carry out the body Frame Damage Damage
alignment work and
 Measure dimension of upper  Measurement of Body
perform the welding
body, front body, body side Dimensions, Gauge
processes to make the
panel, rear body using trame Measuring System, Tram
body perfect for gauge. Gauges, Digital Tram
riding.  Measure Damage Using Gauge Gauges,Centering gauges

measuring system.  Gauge measuring system-
 Perform on analyzing damage- frame gauge, upper body
Length damage, Width dimensioning, measurement
damage, Height damage. of the front body,
 Repair for front-end damage, measurement of the body
rear damage, side damage, sag side panel, measurement of
damage, twist damage, the rear body, digital tram
diamond damage, gauges, dimensional
straightening strut, tower references, the centre panel,
damage, stress relieving, zero planes, diagnosing
straightening strut tower damage, measuring Vehicle
damage, stress relieving with Impact and Its Effects on a
heat, stress concentrators. vehicle, Visually Determining
 Perform anchoring the vehicle the Extent of Impact
using pulling clamps and Damage.
chains and with the aid of  Realignment basics-vehicle
Frame Straightening anchoring and pulling,
Equipment. pulling direction, single-pull
 Perform computerized method, multiple-pull
measuring system. Method, visualizing front-
end Collisions, rear-end
Skills on Compressor Air System collisions, side collision,
rollover damage, angled
 Carryout Overhauling of Air
impacts.
Compressor.
 Unibody/Frame
 Monitoring and servicing of
Straightening Equipment, in-
Units associated with
floor straightening
compressor.
equipment-anchor-pot
system and the modular rail
Skills on Welding System
frame system. portable body
 Carryout MIG, Spot, Tack
and frame pullers, rack
welding technique on auto
(floor) straightening
body panels.
systems, bench straightening
 Carryout Gas welding on
systems, anchoring the
joining of sheet metals.
vehicle using pulling clamps
 Carryout Soldering and Brazing and chains, other
on joining of cut bumper or straightening accessories-
any auto components. restraint bar , door aligner,
 Perform on Plasma Cutting on engine holder, portable
damaged body panel. hydraulic rams, strut plate,
straightening and realigning
Skills on Refinishing System techniques-sequence for a
 Carryout on hand sanding total structure realignment
block to prepare smooth procedure

surface for repair. • Computerized measuring
 Prepare surface area and systems, procedure for planning
apply filler on damaged area. the pull, making pulls-single-pull
 Carryout painting on body setup, multiple-pull setups,
panel with aid of grits ,
executing a pulling sequence,
masking tapes, refinishing
materials-Paint binders, purpose of over pulling.
solvents, additives, sealants,
Compressor Air System
 Repair of scratches on body
panel. • Basic requirement of
 Prepare rust free surface and Compressor System, Types of
corrosion treatment of interior
Compressor, Air and Fluid
& exterior surface for paint
process. Control System, Study of Hose,
Connectors, Adaptors,
Skills on Door Repairs
• Piping arrangement for
 Straighten damage on a door
body shop, color coding for
using a hammer and dolly pry
out a fender to allow for different pipe lines.
hammer straightening using
Welding System
long spoon toremove small
dents in hard-to-reach areas • Common Auto body
using Pry picks.
welding technique, Auto body
 Pull out minor damage using
MIG welding principals and
dent puller.
 Remove dents in steel Panels characteristics, Spot welding
using a spot weld dent puller. techniques, Oxyacetylene
 Remove door and detect the welding, Soldering and Brazing
door assembly parts. procedure, Advantages of
different welding methods
Skills on Hood • Plasma cutting and
operating procedure
 Remove Hood and adjustment
to hinge, latch, height Body Refinishing System
adjustment and refixing.
 Description of Body fillers,
Skills on Fender filler ingredients, types,
 Remove fender adjustment properties, mixing of filler,
and repair, install surface preparation, Rubbing
 Service Grille, trunk lid repair and polishing compound.
and trunk bed service  Refinishing Materials,
Description and types of
Sealer, Primer and Topcoat

Skills on Windshield Paints. Abrasives, grit, grit
 Remove and refit, rubber rating, grit types, wet and
gasket service, apply adhesive dry sanding.
using sealer gun.  Description of Corrosion,
anticorrosion material, basic
Skills on Repair of Plastic Parts surface preparation,
 Repair minor cracks and cuts treatment, exposed joints,
using adhesives and bonding interior and exterior surface.
techniques.
 Reshape plastic parts by heat
technique.
177- Plan and organize to Skills on Paint Mixing Automotive paint
256 carry out the body
 Carryout Paint Mixing.  Topcoat Paints, content of
painting work and
 Practice on measure viscosity paints, curing, flash point,
perform the finishing
of paint mix using ford cup. accelerator, catalyst,
work. adhesion promotor.
Skills on Spray Gun Application  Different ways to mix paint
 Adjust spray knobs, spray or other materials paint
pattern, Gun Stroke, maintain mixing sticks, viscometer, or
Gun Speed, Triggering, Gun viscosity cup, effect on
direction and Spray overlap. finish- material temperature,
 Carryout Spray Pattern film thickness, Automobile
Painting Process.
 Top Heavy or Bottom Heavy.
 Heavy to Right or Left
Spray Gun Application
 Heavy at Center
 Split pattern  Description of Spray Gun
 Carryout spray Gun repairing and its parts, Atomization,
for Sags, runs, leaks, air leaks. High volume low pressure
 Perform Paint Spray Booth gun, Types of air spray gun
maintenance. and their paint feed method.
Skills on Repairing of Paint Advantages and
Surface for work disadvantages of spray gun.
 Spray gun setup- Air Supply,
 Check Paint Thickness. Adjustments, Distance,
 Remove paint using Chemical Adjustment Knobs, Testing
stripping, Media blasting. Spray Pattern, effect of spray
 Perform colour evaluations gun stroke, gun speed,
using sunlight & colour triggering, direction, spray
corrected light bulb. overlap, Description of Paint
 Perform matching Basic Paint booth, types and working
Colors. procedure, Usage of
 Carryout Spraying Metallic Respirators.

Colours. Repairing of Paint Surface for
 Repair with a multistage mica work
or pearl finish.
 Matching Custom paint using  Importance of surface
Spectrophotometer or preparation, Evaluate
electronic colour Analyzer, Surface Condition, Checking
Computerized Paint mix. Paint Thickness, Paint
Removal method
 Functions of paint, OEM
paint finishes procedures,
different between OEM and
refinish painting types of
paint for topcoat refinishing,
properties of paint used for
refinishing. Topcoats, Prime
coats, Pre-painting
Preparations, Applying Prime
coats, Basic Spray Coats
Basecoat/Clear coat Repairs,
Applying Single Stage Paints,
Panel Repairs, Overall
Refinishing, Removal of
Masking
 Introduction, Color Theory,
Lighting-colour evaluations
using sunlight & colour
corrected light bulb,
dimensions of colour-
Value—lightness or
darkness,Hue—color, cast,
or tint, Chroma—saturation,
richness, intensity, or
muddiness, standard colour
chips, variance colour chips,
Matching Basic Paint Colors-
use of colour test panel,
spray-out test panel
procedure
 Spraying Metallic Colours-
Wet Coats of Metallic
Colour, Dry Coats of Metallic
Colour.
 Spectrophotometer or
electronic colour Analyzer,

Computerized Paint
Matching Custom painting.
 Repairing Paint Problems-
problems in wet paint,
removing foreign matter in
wet paint, wet sanding
between coats, Causes,
prevention and correcting of
- paint colour mismatch,
orange peel, runs and sags,
sand scratch swelling, bull’s-
eye featheredge ,
featheredge splitting, water
spotting, chemical spotting,
curing or drying failure, paint
fish-eyes, blushing, bleeding,
prime coat show-through,
blistering, solvent popping,
paint cracking, line checking,
crazing, micro checking,
lifting, paint wrinkling,
mottling, pin holing, peeling,
chalking, paint colour fade,
dulled finish, debris in the
finish, rust under the finish.
Project Work/ Industrial Visit:
Revision
Elective Subject 3 :Automotive Two Wheeler – Diagnosis and repair(320 hrs)


Learning outcome
No. (224 Hrs) (96 Hrs)
1-54 Plan and organize to Skills on Body panels Body panels
carry out  Safety precaution for
 Carryout front fender removal handling tools.
maintenance and
overhauling of
and installation.  Description of Motor cycle
 Carryout seat removal and body panels and their parts.
different types of installation.
engines in two and  Carryout shroud removal and Troubleshooting of Exhaust
three wheelers, installation. system
determine its  Carryout removal and  Causes and remedy for
functionality and its installation body cover/ Tail Exhaust system.
performance. cover.
 Carryout removal and On two wheeler Maintenance
installation of fuel tank cover. system
 Carryout removal and  Description of different type
installation of Head Light of maintenance and its
assembly. schedule.
 Carryout removal and  Measuring/ inspection
installation of rear inner parameter as per manual.
fender.
 Carryout removal and Engine Diagnosis
installation of drive chain  Causes and remedy for
cover. Engine trouble.
installation of exhaust
pipe/muffler.
Skills on troubleshooting of
Exhaust system
 Excessive exhaust noise
 Poor performance
Skills on two-wheeler
Maintenance system
 Inspect throttle operation

performance.
 Measure the throttle grip free
play at the grip flange, If the
free play is out of specification
adjust the throttle.

installation of air cleaner,
Replace the element if it is
excessively dirty or damaged.
 Check the crankcase breather
hose for deterioration, damage
or leakage.
and installation of spark plug.
 inspect spark plug, Clean the
spark, Measure the spark gap,
If necessary, adjust the gap as
per specification
 Inspect, Check each valve
clearance and adjust inlet and
exhaust valve clearance as per
specification.
 inspect Engine oil level and
replace, if required as per
manual
 check the engine idle speed &
adjust it as per manual, If is
necessary
 inspect drive chain slack &
adjust it as per specification, If
is necessary,
 perform cleaning, Lubrication
and inspection of drive chain
 Inspect the drive and driven
sprocket teeth for wear or
damage, replace them if
necessary.
 carryout removal and
installation of drive chain
 Check the brake pads for wear.
 Check the front and rear brake
fluid level, and ensure that the
brake fluid level is between the
limit.
 Inspect break and brake pedal
height and adjust it as per
specification, If is necessary.
 Adjust the headlight beam
 Measure the clutch lever free

play and adjust it as per
specification, If is necessary.
 Check the side stand springs
for damage or loss of tension.
 Check the action of the forks
by operating the front brake
and compressing the front
suspension several times.
 Check the action of the rear
shock absorbers by
compressing them several
times.
 Measure the tread depth at
the center of the tires. Replace
the tires when the tread depth
reaches the limit.
 Check that the handlebar
moves freely from side to side.
Skills on Engine Diagnosis

 Engine cranks but won’t start (
No MIL blinking).
 Engine cranks but won’t start
(No fuel pump operation
sound when turning the
ignition ON).
 Engine stalls, hard to start,
rough idling.
 Backfiring or misfiring during
acceleration.
 Poor performance (drivability)
and poor fuel economy.
 Engine idle speed is below
specifications.
 Engine idle speed is above
specifications.
55- Plan and organize to Skills on Sensor inspection Sensors

101 find the faults and  Check EOT (Engine Oil  Description of different type
Diagnosis of vehicle Temperature) sensor of sensors and Testing
electrical and  check TP (Throttle position) procedure used in motor
sensor vehicle.
electronics and
 Check IAT (Intake Air
suggest appropriate
Temperature) sensor. Ignition system
measure for its
 Check fuel injector.
functionality.  Check O2 (Oxygen)sensor  Causes and remedy for
malfunction. ignition system trouble.
 Check Bank angle sensor.
 Carryout Removal, inspection On service of Ignition system
and installation of ECM.
 Description of Ignition
system and its components.
Skills on Diagnosis of
Ignitionsystem. Diagnosis for Electric Starter
 Trouble shoot for No initial system
voltage with the ignition
switch turned ON  Causes for remedy for
 Trouble shoot for Initial Starter system trouble.
voltage is normal, but it drops
by 2 – 4 V while cranking the Serviceof Electric Starter
engine. system
 Trouble shoot for Initial
voltage is normal but there is  Description of Starter motor
no peak voltage while cranking function and its assembly
the engine. components.
 Trouble shoot for Initial  Inspection procedure for
voltage is normal but peak testing of starter motor.
voltage is lower than the
standard value.
 Troubleshoot for Initial and
peak voltages are normal but
no spark jumps.
Skills on service of Ignition system

 Check Ignition coil primary
Peak voltage, record and
compare it with the specified
value.
 Check CKP (crankshaft
position) sensor peak voltage.
installation of Ignition coil.

 Check ignition timing.
Skills on diagnosis for Electric

Starter system
 Trouble shoot for Starter
motor does not turn
motor turns only when the
transmission is in neutral.
motor turns only when the
transmission is in any gear
with the side stand retracted
and clutch lever pulled in
 Troubleshoot for Starter motor
turns slowly.
 Troubleshoot for Starter motor
turns, but engine does not
turn.
 Trouble shoot for Starter relay
switch "Clicks", but engine
does not turn over.
skills on service of Electric Starter

system

and installation of starter
motor.
 Perform disassembly and
reassembly of starter motor.
 Check the oil seal of the front
cover for deterioration or
damage, and needle bearing
for wear or damage.
 Clean the metallic debris off
between commutator bars.
 Replace the armature with a
new one if necessary.
 Check for continuity between
pair of commutator bars

each commutator bar and the
armature shaft
the insulated brush and cable
terminal
the insulated brush and rear
cover.
and installation starter relay.
 Inspect starter ground line
circuit.
 Inspect starter power line
circuit.
102- Plan and organize to Skill on fuel system Fuel system

173 carry out
 Perform fuel pressure test, If • Description of Fuel
maintenance and
the fuel pressure is out of system and its components,
overhauling of
specified, inspect the
different types of following: • Description of working
engines in two and Fuel line principle of air cleaner, fuel
three wheelers, injector and EVAP system
Fuel pump unit
determine its
functionality and its Fuel filter andconfirm to Diagnosis for lubrication system
performance the desired specification
• Causes and remedy for
 Perform fuel flow inspection
and confirm to the desired lubrication system trouble
specification
Service of lubrication system
installation of fuel tank. • Need of lubrication
system and its components
installation of fuel filter/Fuel
pump unit. Diagnosis for cylinder head and
 Carryout removal and valves
installation of Air Cleaner
housing. • Causes and remedy for
 Carryout removal and cylinder head and valve trouble
installation of fuel injector
 Carryout removal, inspection Service of cylinder head and
and installation of EVAP purge
control solenoid valve. valves

and installation of EVAP • Procedure for carrying
Canister. out compression test
• Description of cylinder
skill on Diagnosis for lubrication head and its assembly
system components
 Diagnosis for Engine oil level • Measuring/ inspection

too low. parameter of cylinder head and
 Diagnosis Oil contamination. valve as per manual
skill on service of lubrication on diagnosis for Engine

system cylinder/piston
 carryout removal, inspection • Causes and remedy for

and installation of oil pump engine cylinder /piston trouble
 perform disassembly,
inspection and assembly of oil Service of cylinder/piston
pump
 Inspect the following parts for • Description of cylinder
damage, abnormal wear, and piston and its assembly
deformation or burning. components
Oil pump driven gear
• Measuring/ inspection
Oil pump shaft
parameter of cylinder and
Lock pin
piston as per manual
Inner rotor
Outer rotor
Oil pump body
 Measure the oil pump
clearances according to
Lubrication system
specifications, If any of the
measurement is out of the
service limit; replace the oil
pump as an assembly.
 Perform removal and
installation of Oil pump drive
Gear.
 Clean Engine oil centrifugal
filter.
Skills on diagnosis for cylinder

head and valves
 Diagnosis for Compression too
low, hard starting or poor
performance at low speed.
high, overheating or knocking.
 Diagnosis for Excessive smoke.
 Diagnosis for Excessive noise.
 Diagnosis for Rough idle.
Skills on service of cylinder head

and valves
 Perform cylinder compression

test.
and installation of
camshaft/Rocker arm.
and installation of cylinder
head.
 Inspect the following parts for
damage, abnormal wear,
deformation, burning or clogs
in oil passages.
Cylinder head
Valve spring
Valves
Valve guides and Measure
each part and clearance
according to cylinder
head/valve specifications,
Replace any part if it is out
of service limit.
 Perform valve guide
replacement.
 Inspect valve seat/refacing.
and installation of cam chain
tensioner.
Skills on diagnosis for Engine

cylinder/piston

low, hard starting or poor
performance at low speed.
high, overheating or knocking.
 Diagnosis for Excessive smoke.
 Diagnosis for Abnormal noise.
Skills on service of cylinder/piston

and installation of the cylinder
and piston with the engine
installed in the frame.
 Replacement of the cylinder
stud bolts if required.
scratch, damage, abnormal
wear, deformation, burning or
clogs in oil passages.
Cylinder
Piston
Piston rings
Piston pin
 Connecting rod small end and
measure each part and
calculate the clearance
according to cylinder/piston
specifications and replace any
part if it is out of service limit.
174- Plan and organize to Skills on diagnosis for clutch and diagnosis for clutch and
195 carry out gearshift linkage gearshift linkage
maintenance and
 diagnosis for Clutch slips when  Causes and remedy for
overhauling of
accelerating clutch and gearshift trouble
different types of
 diagnosis for Motorcycle
transmission in two creeps on service of the clutch and
and three wheelers,  diagnosis for Hard to shift gearshift linkage
determine its  diagnosis for Transmission
functionality and its jumps out of gear • Function of clutch and its
performance  diagnosis for Gearshift pedal assembly components

will not return
Skills on service of the clutch and • Measuring/ inspection
gearshift linkage parameter of clutch as per
manual
and installation of right
crankcase cover can be
serviced with the engine
installed on the frame.
 carryout replacement of
crankshaft bearing
and installation of clutch.
 carryout manual clutch
disassembly and disassembly
wear and deformation.
Replace if necessary
Clutch lifter bearing
Clutch springs
Clutch center
Clutch discs/plates
Clutch outer
Clutch outer guide
Main shaft
Centrifugal filter rotor
Primary drive gear and
measure each part
according to
clutch/Gearshift linkage
specification, replace any
part if it is out of service
limit
 Replace the clutch springs as a
set.
 Replace the clutch discs and
plates as a set.

and installation of gearshift
linkage.
Replace if necessary.
Gearshift spindle
Gearshift arm spring
Gearshift arm
Gearshift spindle oil seal
and measure each part
according to
clutch/Gearshift linkage
limit
196- Plan and organize to Skills on service of Alternator/ service of Alternator/ Starter
208 find the faults and Starter clutch clutch
Diagnosis of vehicle
 Carryoutremoval, inspection  Description of Alternator
electrical and
and installation of Left and starter clutch
electronics and
crankcase cover.  Measuring/ inspection
suggest appropriate  Carryout removal, inspection parameter of Alternator and
measure for its and installation of stator. starter clutch as per manual
functionality.  Carryout removal, inspection
and installation of flywheel.
assembly of starter clutch.
Starter driven gear
Rollers, springs and starter
clutch outer
Starter reduction gear and
shaft
Starter driven gear needle
bearing and measure each

part according to
Alternator/starter clutch
limit
209- Plan and organize to Skills on diagnosis for Diagnosis for
244 carry out crankcase/transmission crankcase/transmission
maintenance and /crankshaft system /crankshaft system
overhauling of
 Diagnosis for gear Hard to shift  Causes and remedy
different types of
 Diagnosis for Transmission transmission trouble.
transmission in two
jumps out of gear
and three wheelers,  Diagnosis for Excessive noise service of crankcase/crankshaft
determine its system
functionality and its
performance Skills on service of  Description of crankshaft
crankcase/crankshaft system and connection rod , timing
sprocket.
 Carryout separation of  Measuring/ inspection
Crankcase from the motor parameter for crankshaft as
cycle per manual.
and installation of crankshaft servicing of transmission
 Inspect the following parts for system
wear and deformation.  Description of working
Replace if necessary. principle of transmission
– Connecting rod system and its assembly
components.
– Timing sprocket and measure  Measuring/ inspection
each part according to parameter for transmission
crankcase/crankshaft/transmission system as per manual.
balancer specification replace any
part if it is out of service limit servicing of Engine
 Measure the side clearance by  Procedure for removal and

inserting the feeler gauge installation of engine.
between the crankshaft and
connecting rod big end
compare with the specified
value
 Measure the crankshaft -
connecting rod big end radial

clearance and compare with
the specified value
 Measure the crankshaft run
out using a dial gauge at
specified location as per
service manual and compare
with the specified value
 Replace the crankshaft if the
outer race does not turn
smoothly, quietly, or if inner
race fits loosely.
 Replace crankshaft bearing
Skills on servicing of transmission
system

and installation of
transmission system
Transmission gears
Transmission bushings
Transmission bearings
Shift drum/journal
Shift forks
Shift fork shaft
Main shaft
Countershaft
Gear shift spindle journal
Oil passages and measure
each part according to
transmission specification
replace any part if it is out
of service limit
 Replace transmission bearing.
Skills on servicing of Engine

and installation of Engine.
245- Plan and organize to Skills on diagnosis for Front Diagnosis for Front wheel/
274 find the faults and wheel/ Suspension /steering Suspension /steering
 Diagnosis for Hard steering  Causes and remedy for front
controls and suggest
 Diagnosis for Steers to one wheel / suspension trouble
appropriate measure
side or does not track straight
for brake, suspension  Diagnosis for Front wheel Servicing of Front wheel/
and steering system. wobbles Suspension /steering
 Diagnosis for Front wheel turns
hard  Description of different type
 Diagnosis for Soft suspension of suspension.
 Diagnosisfor Hard suspension  Measuring / inspection
 Diagnosis for Suspension noisy parameter for front wheel /
suspension.
Skills on servicing of Front wheel/
Suspension /steering Diagnosisfor Rear wheel/
Suspension /steering
and installation of Front wheel  causes and remedy for rear
 Inspect the following parts for wheel / suspension trouble
damage, abnormal wear, Servicing of Rear wheel/
deformation, looseness, Suspension /steering
smoothly operation or bend.
 Measuring / inspection
Front axle
parameter for rear wheel /
Wheel rim suspension.
Wheel bearing
 Carryout removal, inspection Diagnosis for Brake system
and installation of fork
 Causes and remedy for
 Perform disassembly,
brake system trouble.
inspection and assembly of
fork unit
Service of Brake system
damage, abnormal wear, bend,  Description of brake system
deformation and scoring. and its assembly
Fork pipe components.
Outer tube  Measuring/inspection of
parameter for brake system
Slide bushing as per manual.
Guide bushing
Back up ring
 Remove and install Handle
bar
installation of steering stem
Skills on diagnosis for Rear
wheel/ Suspension /steering
 Diagnosis for Steers to one

side or does not track straight
 Diagnosis for Rear wheel
wobbling
 Diagnosis for Wheel hard to
turn
 Diagnosis for Soft suspension
 Diagnosis for Stiff suspension
 Diagnosis for Rear suspension
noisy
Skills on servicing of Rear wheel/

Suspension /steering
and installation of rear wheel
damage, abnormal
wear,deformation, looseness,
smoothly operation or bend.
Rear axle
Wheel rim
Tire
Wheel and driven flange
bearings
carryout removal,
inspection and installation
shock absorber
 Visually inspect the shock
absorber for wear or damage.
 Check the following:
Damper rod for bend or
damage
Damper unit for
deformation or oil leaks
Bushings for wear or
damage
Rubber bumper for wear or
damage
 Replace the shock absorber as
an assembly if necessary.
Skills on diagnosis for Brake

system
 Diagnosis for Brake lever/pedal
soft or spongy
 Diagnosis for Brake lever/pedal
hard
 Diagnosis for Brake drags
Skills on service of Brake system

 Perform brake fluid filling and
Air bleeding.
and installation front brake
pad and rear brake pad.
 Visually inspect the brake discs
for damage or crack.
 Measure the brake disc
according to brake system
specification and replace if
necessary.
 Perform removal, inspection &
installation of Front and rear
Master cylinder.
scoring, scratches,
deterioration or damage.
master cylinder
master piston
piston cups
and installation of Front and

rear Brake calliper
scoring, scratches or damage.
calliper cylinders
calliper pistons
and installation of Brake pedal.
275- Plan and organize to Skills on diagnosis for Battery Diagnosis for Battery
296 find the faults and  Battery is damaged or weak.
• Causes and remedy for
Battery trouble
electrical and Skills on service of Battery
electronics and  Perform removal, inspection Service of Battery
suggest appropriate and installation of Battery.
measure for its  Measure the battery voltage. • Importance of Charging
 Carryout current Leakage test. system and its components
functionality.
installation of Electrical Lighting system
Regulator/Rectifier system.
 Inspect Regulator/Rectifier • Read circuit diagram for
system. different lighting system
Skillson Electrical Lighting system
 Replace head light bulb.

 Replace turn signal light bulb.
 Replace brake and tail light
bulb.
 Replace license light bulb.
 Replace Horn.
installation of Combination
meter.
installation of fuel level sensor.
 Inspect fuel level sensor
resistance & Replace the fuel
level sensor if it is out of
specification.
and installation of ignition
switch.
 Replace right and left
handlebar switch.
 Replace brake light switch.
 Inspect turn signal relay.
Revision
9.SYLLABUS – EMPLOYABILITY SKILL

1. Leadership Skills
Duration: 20 Hrs.
Interact with people and convince Leadership - Define leadership, types of leadership, leadership
them. Traits, Functions of leadership, styles of leadership. Resolving
Individual differences among people.
Assess risk and take the initiative. Risk Analysis tools; estimate the risks that you could face in
your role. In turn, this helps you manage these risks and
minimize their impact on your plans. Break-even point
analysis.
Risk Value = Probability of Event x Cost of Event.
Think differently with the innovative Success stories / Best Practices – Inspection, inspect Demo
mindset. displacement. Innovation has become one of the most
popular buzz words of the Digital Age. Re-evaluate the true
meaning of a concept than when it is being touted by
individuals and companies around the world. Spark
innovation, maximize productivity, and increase profitability
as a result of implementing the Big Five behaviors.
Handle the pressure. Stress management - Define Management, Type of stress
Management, How to improve stress in workplace, Team
leader in workplace.
Ability to gather the client’s Manage relationships with client who may be confused with
requirement. the services requirements.
Build healthy client relationships and use customer centric
approach.
2. Entrepreneurship Skills
Duration: 20 Hrs.
Identifying opportunities not obvious to
Self Employment as a Career path - Define Entrepreneurship,
others. Strategy of entrepreneurship, Market Research.
Implementation of self Employment in workplace Ps, Mange
self employment in workplace.
Quality consciousness – its relevance.
Study of Competitive Advantage Model. PEST factors for
Assessing the competitive advantage of
external changes and implement VRIO resources for getting
ideas.
an edge over the competitors.
Identifying customer or client Ensure that environmental conditions are suitable for the
requirements. client and the services to be carried. Deal with clients lacking
the technical background to solve the problem on their own.
Determining the commercial viability of
Immediate or temporary solutions to resolve delays.
ideas.
Demonstrating sensitivities (political, 5 Strategies of handling sensitive issues (political,

commercial, environmental, cultural, and commercial, environmental, cultural, and so on) at workplace
so on). –
1. Define the issues, 2. Develop Policies Adhering to
Company Goals, 3. Communicate Policies, 4. Hold People
Accountable and 5. Continue to Evolve.
Define marketing, Tools of marketing, 7 Ps define market
Identifying opportunities for setting up strategy, important of market strategy, use of strategy in
business. trade theory (Labour Market Information).
3. Organizational Skills
Duration: 20 Hrs.
Training & Managerial responsibilities Introduction &
Project deadlines. discussion on managerial responsibilities.
Basic quality Concept & 5’S

Work under pressure and tight
Colour Dynamics
deadlines.
Organize the workload to meet with the Follow the organization’s policies and procedures for working
timelines. with colleagues.
Time management - Workplace time Management, maintain

Time management, Benefits of Time Management in
Prioritize the tasks.
workplace, Time management schedule.
4. Creative Abilities
Duration: 30 Hrs.
Boosting Morale - Boosting ethics & Development work
environment, ethics theory, Development of work
Visualize a business idea end-to-end
environment & training process, knowledge of presentation
&self motivation.
Five Dimensions to conceptualize your idea to make it a

successful innovation. When conceptualizing an idea, it is
essential to ask questions like what is the problem that the idea
solves, who is the consumer for the idea, does the idea solve the
Conceptualize an idea consumer’s problems and how will the solution be delivered to the
consumer. It is very important to direct the thinking to specific
dimensions and search answers to certain questions that help in
evolving the idea from the initial thought through the various
stages of innovation.
The single most effective way to come up with a business idea

is to solve a problem. Next step, you bring the idea to life.
Whether it's code, carpentry, or culinary, a project is a
created idea. When the project is nearly complete and it's
Transform notions into business ideas
time to begin putting the project into the hands of real
people. Once your project is perfected through testing, it's
time to come up with a way to make money from it. Growth -
Get the word out about the thing.
5. Strong digital Skills

Duration : 20 Hrs.
Write memos and e-mail to customers, co-workers, and
Write strong and effective emails for
vendors to provide them with work updates and to request
communication.
appropriate information.
Use digital tools like laptops, palmtops, Operate all types of digital tools like laptops, palmtops,
mobiles, fax machines, printers, mobiles, fax machines, printers, projectors, conferencing tools
projectors, conferencing tools effectively.
effectively.
Attributes that feature in the emergence of novel
technologies are: (i) radical novelty, (ii) relatively fast growth,
Strong understanding of emerging (iii) coherence, (iv) prominent impact, and (v) uncertainty and
technologies. ambiguity. The framework for operationalizing emerging
technologies is then elaborated on the basis of the proposed
attributes.
Understanding and adhering to the Information security

aspects of the organization based on ISP.
Information Security Policy (ISP) is a set of rules enacted by an
Good understanding of information
organization to ensure that all users or networks of the IT
security aspects.
structure within the organization’s domain abide by the
prescriptions regarding the security of data stored digitally
within the boundaries the organization stretches its authority.
Create or convert textual contents into graphical

Convert textual content into graphs,
representation, charts, diagrams and flow charts. Learn to
images, charts, diagrams and flow
make graphs and charts in MS excel. Use of digital camera and
charts.
other imaging tools. Use of MS-Powerpoint for developing
diagrams and flowcharts.
6. Self-Management
Duration: 20 Hrs.
Having a personal vision and goals Decision making pertaining to the concerned area of work.
Decision making process.
Identifying the strengths - SWOT Analysis. Define Swot

Being able to evaluate and monitor analysis, Important of swot analysis, characteristics of swot
his/her own performance analysis, Example of swot analysis related with Trade
development in detail
Apply, analyze, and evaluate the information gathered from

Having knowledge and confidence in
observation, experience, reasoning, or communication, as a
your own ideas and vision
guide to thought and action.
Use of multi-model strategies of articulation such as audio

Articulating your own ideas and vision
visual tools, kinaesthetic learning tools, etc.
7 thoughts on taking responsibility at workplace-

 1. There is always a price to pay. 2. Build your self-esteem.3.
Taking responsibility Give yourself the permission to work as you want.4. Taking
actions 5. Understand the limits of your responsibility. 6.
Don't forget to take responsibility in everyday worklife. 7. Aim
to be your best self.
7. Plan and organize the work related to the occupation
Duration: 20Hrs.
Use documents, drawings and recognize
Prepare and organize service feedback files/documents.
hazards in the work site.
The best way is to plan for workplace/ assembly location is to think
Plan workplace/ assembly location with
of any emergency situation before it happens. Think clearly and
due consideration to the operational
logically in a crisis, so it is important to do so in advance with due
stipulation. consideration of the operational stipulation.
Question-answer session to be conducted appropriately in
Communicate effectively with others
order to understand the nature of the problem and make a
and plan project tasks.
diagnosis of the task.
Guidelines for delegating roles and responsibilities to co-
trainees:
1. Identify key opportunities for delegation, 2. Establish a
Assign roles and responsibilities of the
clear set of objectives for each task, 3. Play to your
co-trainees for execution of the task
coworker's strengths, 4. Construct a timeline, 5. Use follow-
effectively and monitor the same.
up tasks to keep your workers on point, 6. Establish authority
and respect, 7. Use a feedback loop to make future
delegation easier.
8. Effective communication (written and verbal)
Duration: 10 Hrs.
Interact with stakeholders, whether it is Communication process & elements of communication.
internal in an organization or external
with partners or clients, is fraught with Maintain clear communication with colleagues (by all means
opportunities for misunderstanding. including face-to-face, telephonic as well as written). Pass on

information to stakeholders in line with organizational
requirements both through verbal as well as non-verbal
means. Principles of effective communication, body language,
handling nervousness/ discomfort and dealing with barriers.
Different Types of Communication Aids: Projected/ Non

Projected using different types of board in a class room
session. Black board, White board, Flannel board, Magnetic
Prepare and give formal presentations
board etc.
and informal presentations during
Application, use & maintenance of OHP, Digital Camera, LCD
meetings.
projector and Smart board. Preparation of slides in MS-
PowerPoint and presentation of the slides.
Handle FAQ session during meetings.
9. Emotional intelligence
Duration : 10 Hrs.
Work well, interact successfully with Work with colleagues to integrate work. Work in ways that
others. show respect for colleagues.
Getting it right from the very beginning, you’ll most likely see
things flourish. Spending ample time collecting information,
Work with clients.
allow client to share their knowledge and participate in the
project.
Connect with people from different Adopt a flexible attitude, learn about the culture beforehand,
cultural backgrounds. expect differences, understand hierarchies, be upfront about
difficulties in communication, be respectful & tolerant and be
patient.
ANNEXURE-I
LIST OF TOOLS & EQUIPMENT

for batch size of 20 trainees
Sl.
Name of the Tools and Equipment with specification Quantity
No.
A. TRAINEES TOOL KIT per 4 Trainees FOR 20 TRAINEES +1 INSTRUCTOR
1. Allen Key- set of 12 pieces (2mm to 14mm) Hexagonal key, complete set. (5+1)
2. Adjustable spanner( pipe wrench of 350 mm) nominal size. 6
3. Caliper inside -150 mm Spring type, high grade steel made with Hardened tips 6
4. Calipers outside- 150 mm spring type, high grade steel made With Hardened 6
tips
5. Center Punch 10 mm. Dia. x 120 mm. Carbon steel, With 90º point angle 6
6. Dividers- 150 mm Spring type, Mild steel made With Hardened tips 6
7. Electrician Screw Drivermin dia of 5 mm and blade length of 250 mm length, 6
the blade of screw driver provided with insulting sleeve.
8. Hammer ball peen mass of 500 g with wooden handle of a length of 300 mm 6
9. Hands file 20 cm. Second cut flat 6
10. Philips Screw Driver set of 5 pieces (100 mm to 300 mm) 6

11. Pliers combination 20 cm. 6
12. Safety glasses 6
13. Screw driver 20cm.X 9mm. Blade 6
14. Screw driver 30 cm. X 9 mm. Blade 6
15. Scriber 15 cm with hardened steel tips 6
16. Spanner D.E. set of 12 pieces (6mm to 32mm) 6
17. Spanner, ring set of 12 metric sizes 6 to 32 mm. 6
18. Spanners socket with speed handle, T-bar, ratchet and universal upto 32 mm 6
set of 28 pieces with box
19. Steel rule 30 cm inch and metric 6
20. Utility KnifeThree position, retractable blade, overall adjustable length 150mm 6
with plastic handle.
21. Wire cutter and stripper 6
22. Steel tool box , five section cantilever with lock and key (folding type) 6
400x200x150 mm
B. Tools Instruments and General Shop outfits
23. Air bag deployment Tool kit suitable for all vehicles 1
24. AC alternator slip ring puller 1

25. Adjustable spanner (pipe wrench 350 mm) 2
110
26. Air blow gun with standard accessories suitable for Blowing off chips, drying, 1
painting (part cleaning), operating medium through compressed air, with
nozzle size of 3 mm.
27. Air impact wrench with standard accessories of Square drive of 1/2", 4
working torque range of forward 70- 380 Nm, in reverse max torque of 620
Nm, Min hose size of 10mm @ 6 bar, Impact wrench of Nominal Size of
metric sockets form M6 to M30
28. Air operated oil waste aspirator mounted with 80 litre tank 1
29. Allen Key- set of 12 pieces (2mm to 14mm) Hexagonal key, complete set. 4
30. Star Allen Key Set Wrench 9 PCS Silver Tone Metal TORX /Star Allen Key Set 2
with Hole from T10-T50
31. Alternator regulator testerapplicable to different brand of vehicle 1
32. Ammeter Analog type portable 300 A/60 A DC with external shunt with 4
probe Fitted in Box
33. Angle plate adjustable 250x150x175 1
34. Anvil 50 Kgs with Stand 1
35. Battery –charger of Input Volt-230A.C. ,50 Cycle, Current up to 200 Amps, 2
Battery charging requirements in different voltages like 12V, 24V, 48V, 120V
DC Output volt-24 D.C.
36. Battery load tester suitable for Variable load capability to 1000 Amps and 1
Tests 2000CCA
37. Battery Terminal puller&battery terminal brush 1
38. Ball joint end pullerSuitable for on many domestic and import front wheel 1
drive vehicles
39. Belt Tensioner gauge 1
40. Brake bleeder and vacuum pump kit 1
41. Brake fluid tester to tests and indicates on LEDs in terms of percent of water 1
in the brake fluid.
42. Caliper inside -15 cm Spring type, high grade steel made With Hardened tips 4
43. Calipers outside- 15 cm spring type, high grade steel made With Hardened 4
tips
44. Chisel 100 mm flat Octagonal stock, 60 deg cutting angle. 4
45. Chisels cross cut 200 mm X 6mm Octagonal stock 4
46. Circlip pliers Expanding and Circlip pliers -External bent size of 150 mm 4
contracting type 15cm and and Internal circlip pliers of size 200 mm
20cm each each, with hardened tips. (4 in a set)
47. Clamps C- 100mm x 70 With suitable handle 2
48. Clamps C- 150mm x 80 With suitable handle 2
49. Clamps C -200mm x 90 With suitable handle 2
50. Cleaning tray 45x30 cm. 4
51. Coil spring compressor for suspension spring designed to quickly and easily 1
compress suspension Mac Pherson Strut Springs.
52. Compression and vacuum pump hand operated with suction cup 1
111
53. Compression testing gauge suitable for diesel Engine. Gauge should be shock 2
protected, with dual calibration of 0-1000 psi, 0-70 bar, standard glow plug
adapter, injector adapter suitable for Maruthi, Tata, Hyundai, Nissan and
Ford etc.,
54. Electronic Continuity Tester to determine if an electrical path can be 6
established between two points that is if an electrical circuit can be made
55. Coolant reverse flushing gunSuits most radiator and heater hoses 1
56. Coolant Flushing Machinepumps that operate on 12 V DC power 1
inputandshould have 2 separate containers for fresh and used coolant
57. Cooling system testerSuitable for the pressure testing of cooling systems and 1
radiator caps up to 35psi with all adapter set
58. Creeper 2
59. Connecting rod alignment fixture suitable for checking the twist and bend in 1
the connecting rods of all types of reciprocating engines, with precision dial
indicators for accuracy.
60. Cylinder bore gauge capacity 20 to 160 mm 4
61. Cylinder liner- Dry & wet liner, press fit & slide fit liner of any brand of LMV 1 each
or HMV for demonstration.
62. DC Ohmmeter 0 to 300 Ohms, mid scales at 20 Ohms 2
63. Depth micrometer -0-25mm Analog type, Least count 0.01mm, with all 4
accessories in a box
64. Dial gauge type 1 Gr. A (complete with clamping devices and with magnetic 4
stand)
65. Demonstration Board of different type of piston supplied of any brand of 1set
OEM produce as Dome, Bowl, Flat and Flat Top Piston with Valve Relief.
66. Dividers- 15 cm Spring type, Mild steel made With Hardened tips 4
67. Drain plug spannerincludes a magnetic handle to keep steel drain plugs from 2
dropping while removing and with 8 different common drain plug size sockets
(13, 14, 15, 6, 17, 18, 19, 24mm) to fit nearly all vehicles.
68. Drift punch copper of nominal size of 150mm 4
69. Drill Twist -(assorted) (Consumables) HSS made straight shank, 0.5mm step 4
70. Electric Soldering Iron 230 V 60 watts; 230 V 25 watts 2 each
71. Electric testing screw driver- With neon bulb indicator, flat tip. 4
72. Engineer’s square of blade length 150 mm, Grade-A and Type 1.that is, with 4
stock
73. Engineers stethoscope 1
74. Executive Auto Electrical tool kit - Min 8 pcs 1
75. Feeler gauges of set No. 4 (20 blades) length 100 mm metric 4
76. File flat 20 cm bastard 4
77. File, half round 20 cm second cut 4
78. File, Square 20 cm second cut 4
79. File, Square 30 cm round 4
80. File, triangular 15 cm second cut 4
112
81. Files assorted sizes and types including safe edge file (20 Nos) 2 set
82. Flat File 25 cm second cut 4
83. Flat File 35 cm bastard 4
84. Flywheel lock toolLocks flywheel in place when removing harmonic balancer 2
85. Garage stand of Capacity from 3000 kg, Max extendable Height upto 500 mm 4
86. Gloves for Welding (Leather and Asbestos) 5 sets
87. Glow plug tester . 2
88. Granite surface plate 1600 x 1000 with stand and cover 1
89. Grease gun of lever type with spring-loaded follower and nominal capacity 2
100 cm3
90. Grease Gun bucket type heavy duty trolley type 10 kg capacity 1
91. Growler 2
92. Hacksaw frame adjustable 20-30 cm 10
93. Hammer Ball Peen 0.75 Kg 4
94. Hammer Chipping 0.25 Kg 5
95. Hammer copper 1 Kg with handle 4
96. Hammer Rubber mallet, of nominal size 400 mm, Type A, having hardness 90 4
Shore A
97. Hammer PlasticMaterial: Toughened Nylon Hammersize of 45 mm ; 250gm, 4
handle
98. Hammer sludge 10kg 1
99. Hand operated crimping tool (i) for crimping up to 4mm and (ii) for crimping 2
up to 10mm
100. Hand reamers -adjustable 10.5 to 11.25 mm, 11.25 to 12.75 mm, 12.75 to 1 sets
14.25 mm and 14.25 to 15.75 mm HSS complete set with handle.
101. Hand Shear Universal 250mm 2
102. Hand Vice - Nominal size of 100 mm 2
103. Hose clamp remover set -tightening 1
hose clamps with diameters of 18 mm to 54 mm
104. Hot Air blow gun, Power input : 1600 w, Working Temperature : 300 - 500 °C 1
Airflow - 240 - 450 l/min
105. Hollow Punch set of seven pieces 6mm to 15mm 2 sets each
106. Impact screw Driver - Screw type, Output drive 1/4" , 2

Clutch type Impact (Double Rocking Dog)
107. Injector – Multi hole type, Pintle type 4 each
108. Insulated Screw driver 20 cm x 9mm blade 4
109. Insulated Screw driver 30 cm x 9mm blade 4
110. LED test lamp portable 2
111. Left cut snips 250mm 4
112. Magnet pickup with camera 1
113. Magneto spanner set with 8 spanners 1 set
113
114. Magnifying glass 75mm 2

115. Marking out table 90X60X90 cm. 1
116. Multimeter digital 5
117. Multi-point fuel injection pump of any brand of LMV (New) vehicle, full size 2
unit along with the special tool required for Disassembly and reassembly
118. Non contact and contact type tachometer, digital, upto 99,999 RPM range 1
119. Non contactinfra red pyrometer -40 dig’s to 1000 deg c 1
120. Oil can 0.5/0.25 liter capacity 4
121. Oil filter wrenchto Remove all oil filters from 2-1/2 to 4 in diameter. 2
Use with 1/2 square drive tool.
122. Oil pressure testerwithQuick release coupling adapters, Large easy to read 1
dual scale gauge 0 – 150 psi
123. Outside micrometer 0 to 25 mm analog type, 0.01mm least count 4
124. Outside micrometer 25 to 50 mm, Analog type,Least count 0.01mm 4
125. Outside micrometer 50 to 75mmAnalogtype,Least count 0.01mm 1
126. ` Outside micrometer 75 to 100 mm Analog type,Least count 0.01mm, 1
127. Fuel Injection Nozzle of Petrol 4
128. Philips Screw Driver set of 5 pieces (100 mm to 300 mm) 2
129. Pipe cutting tool -Roller type with flare cut off groove, fold away reamer and 2
spare cutting wheel under reamer, max size upto 28mm.
130. Pipe flaring tool 2
131. Piston clearance feeler gaugeSet Includes 25 Blades - 12-Inches Long 1
Designed for Long Reach Applications
132. Piston ring compressor ,Strong Spring Steel, Fits Size: 2-1/8" to 7" (53mm - 2
175mm)
133. Piston Ring expander and remover having the feature of Anti-corrosive, Sharp 2
edges of sizes of 40-100 mm
134. Piston Ring groove cleaner. 2
135. Pliers combination 20 cm. 2
136. Pliers flat nose 15 cm 2
137. Pliers round nose 15 cm 2
138. Pliers side cutting 15 cm 2
139. Pole screw driver unit for starter
140. Portable electric drill Machine - Single phase, Max: drill size Dia: 12mm with 1
chuck key, Insulated handles and accessories, with suitable length of
electrical wire. Max: speed between 1800 and 2200rpm.
141. Portable hand grinding machineRated power input : 750 W 1
No-load speed :11000rpm
142. Prick Punch 15 cm 4
143. Punch Letter 4mm (Number) 2 set
144. Right cut snips 250mm 2
145. Rivet sets snap and Dolly combined 3mm, 4mm, 6mm 2
146. Scraper flat 25 cm 2
114
147. Scraper half round 25 cm 2

148. Scraper Triangular 25cm 2
149. Scriber 15 cm 2
150. Scriber with scribing black universal 2
151. Spanner D.E. set of 12 pieces (6mm to 32mm) 4
152. Spanner T. flocks made high grade Chrome - Vanadium steel Size (mm) 2-12 2
mm
153. Spanner, adjustable 15cm. 2
154. Spanner, ring set of 12 metric sizes 6 to 32 mm. 4
155. Spanners socket with speed handle, T-bar, ratchet and universal upto 32 mm 2
set of 28 pieces with box
156. Spark lighter- For igniting gas welding torch 2
157. Spring tension gauge 0-4.5 kg 1
158. Spark plug spanner 10mm, 14mm, 18mmSize 2 no each
159. Steel measuring tape -10 meter in a case Steel engraved 4
160. Steel rule -15 cm, inch and metric Stainless Steel made with Engraved 4
readings.
161. Steel rule -30 cm, inch and metric Stainless Steel made with Engraved 4
readings.
162. Straight edge of Hardened steel, Finished & ground on both sides and edges 2
of size 600 mm.
163. Straight edge of Hardened steel, Finished & ground on both sides and edges 2
of size 1500 mm
164. Stud Extractor Sets6 Piece Sizes: No. 1, 2, 3, 4, 5 and 6. 2 sets

165. Stud remover with socket handle6; 8; 10; 12 mm with socket 1
166. Surface gauge with dial test indicator plunger type i.e. 0.01 mm and magnetic 4
base
167. Taps and Dies complete sets BSF, BSW 1 set
168. Taps and wrenches – metric complete set up to M12 with die stock 2 sets
169. Telescope gauge 4
170. Telescopic Transmission Jack 1/2 ton 1
171. Electric Digital Water Temperature Gauge Sensor Motor Car Thermometer 0- 2
100 deg c
172. Tester sparking plug ‘NEON’ Type 1
173. Thermometer 0-200 range 2
174. Thread pitch gauge metric, BSW , BSF 2
175. Timing lighter 2
176. Toe-in, toe-out gauge 1set
177. Torque wrenches 5-35 Nm, 12-68 Nm & 50-225 Nm 1 each
178. Torx screw driver set 2set
179. Tread wear indicator 2
115
180. Tube valve key inserter 2

181. Tubeless tyre repair kit
182. Tyre pressure gauge with holding nipple 2
183. Universal puller for removing pulleys, bearings 1
184. 'V’ Block having a feature of precise V -shaped groove cast iron material of 2
size 75 x 38 x 38 mm pair with clamps
185. Vacuum gauge to read 0 to 760 mm of Hg. 2
186. 3mm to 13mm, 4 Piece Small Hole Gage Set 4
187. Universal valve guide remover, Mechanical type 2
188. C Type Valve Lifter 1
189. Valve spring compressor universal. 1
190. Vernier Caliper, Measures both in mm & inches, Hardened stainless steel 4
construction, Least Count: 0.02 mm, 0.001” ; Range 0-153mm (0-6")
191. A vice grip plier, Type 2 (curved jaw), Nominal size 250 mm. 2
192. Volt meter 50V/DC 6
193. Work bench 250 x 120 x 60 cm with 4 vices 12cm Jaw with steel structure 4
194. Vacuum Cleaner – Wet and Dry type 1
195. Wheel choke 4
196. Wheel Spanner 4
197. Wire Gauge (metric) 2
198. 4 Point relays, 12V 2
199. 5 Point relays, 12V 2
C. General Installation/ Machineries
200. AC Gas Leak Electronic detector & UV Leak detector for CFC, HFC refrigerants 1
201. ABS (Antilock brake 1
systemTrainer)trainerisabletodemonstrateABShydraulicandelectricalsystemo
peration,
aswellasprovidetheabilitytosimulatechangesinroadconditionsthatimpactABSo
peration, ESP functions and fault simulation board
202. Working model of Air Brake Assembly model using actual components and 1
motorized to show operation
203. Air bag simulator working model 1
204. Air conditioned CRDI Vehicle in running condition -LMV 3
205. Air conditioned MPFI Vehicle in running condition -LMV 3
206. Alternator assembly of any brand of LMV/HMV 12 Volt 40 amp along with 2 each
special tools if any for Disassembly and reassembly
207. Hand operated Arbor presses is ideally utilized for inserting and removing 1
bushes, bearing and allied purposes. Capacity- 2 Ton, Heavy cast Iron Body
208. Anti theft device demonstration board shows the car safety devices 1
operation
209. Auto Electrical test bench able to test alternator, starter and vacuum pump. 1
116
Electrically and battery operated. Able to test alternator with different loads
210. Nitrogen Tyre Inflator 1
211. Automatic sequential six gear transmission gear box any brand of car for 1
fitted with frame along with special tools.
212. Auto transmission trainer is equipped with a four speed automatic 1
transmission and consists of the control unit and a gear substitute panel. The
sensor /Actuator signal connections are reliably run to the back.
213. Automatic Tire Changer Machine 1
214. Automotive exhaust 5 gas analyzer& Diesel Smoke Meter 1
215. Bench lever shears 250mm Blade x 3mm Capacity 1
216. Car test lane with roller brake tester, suspension tester, side slip tester, head 1
light tester
217. Chain Pulley Block-3 ton capacity with tripod stand(Engine Crane) 1
218. Constant Mesh Gear box with stand and CVT Gear box with stand for 1 each
Dismantling and assembly.
219. Mock layout of a motor car –electrical system working model. 1
220. Cut section working model of automatic transmission Gear box (DSG) 1
221. Cut section working model of centrifugal clutch assembly. 1
222. Cut section working model of Diaphragm clutch assembly. 1
223. Cut section working model of Single plate clutch assembly. 1
224. Cut section models of shock absorber 1
225. Cut section of cross ply and radial tyre 1
226. Computer for Autotronicsi7 configuration 10
227. Demonstration Board (made of acrylic or wood) of Ignition System for 1
automobile 4 wheelers made out of
1) Switches
2) Ignition coil
3) Distributor
4) Four spark plugs
5)Battery for power source and necessary wiring connections having the
feature of start functioning by putting on the switch as well as by rotating the
distributor. Further, sequential sparks in the spark plugs can be
demonstrated in these boards.
228. Demonstration Board of MPFI System Working Model which is made out of 1
original used parts such as petrol injector, inlet manifolds, throttle body,
distributor, ECU, canister purge valve, carbon canister, fuel tank module,
supporting sensors such as lambda sensor, engine speed sensor, cam
position sensor etc. MPFI working system can be demonstrated by with aid of
battery.
229. AC Service Machine (car) suitable for servicing of Ac unit of a car system for 1
Recovery, Vacuum, Recharging, Recycle of refrigerant R 134 A with Auto
and Manual Mode.
117
230. Diesel Engine – CRDI - 4 stroke Engine with swiveling stand along with special 3 (1each)
tools for Dismantling and assembling – 4 cylinder, 6 cylinder, V6 cylinder
231. Diesel engine ( Running condition ) Stationary type with all accessories like 1
cooling, lubrication, fuel systems and electronics , turbo charger
232. Discrete Component Trainer / Basic Electronics Trainer 1
233. Disk brake with caliper assembly working model 1
234. Drilling machine bench to drill up to 12mm dia along with accessories 1
235. Driving Simulator 1
236. Distributor –Duel advance type, reluctance type 2 ( 1 each)
237. Drum brake assembly of any HMV 1
238. Front axle drive with transfer case gearbox, RzeeppaUV Joint fitted with 1
stand for Dismantling and assembly
239. Educational Software’s for E- Learning Automotive subject 4 license
240. Full floating axle, semi floating and three Quarter floating axle fitted in a 3 (1 each)
stand for dismantling and assembly
241. Four stroke petrol engine with CNG setup-working condition 1
242. Functional working model of clutches –coil spring and diaphragm type. 1Each
243. Functional/experiment model of different type of sensors. 1
244. D.E. Pedestal Grinding machine with 300mm diameter wheels rough and 1
smooth with twist drill grinding attachment. Motor 1HP 1Phase, 230V
50Hz.
245. Hand operated Hydraulic press 5ton capacity. 1
246. Hydraulic jack HI-LIFT type -3 ton capacity, and 5 Ton capacity 1each
247. Hydraulic trolley jack 5 ton capacity 1

248. Injector testing set (Hand tester) for diesel injectors 1
249. Lifting jack screw type 3 ton, 5ton & 20 Ton capacity 1 each
250. MPFI petrol engine with swiveling stand along with special tools for 3
dismantling and assembling- 4 cylinder, 6 cylinder and v6 cylinder (1 each)
251. Multi Scan Tool with oscilloscope 1
252. Oscilloscope 60MHz 1
253. Radiator cut section-cross flow 1
254. Radiator cut section-down flow 1
255. Pneumatic rivet gun with standard accessories 2
256. Semi-automatic hydraulic car wash system (under chassis automatic car wash 1
system)
257. Spring tension tester 1
258. Starter motor axial type, pre-engagement type & co-axial type for testing 1 (each)
and dismantling and Assembly
259. Steering assembly - 1.Rack& pinion, 2.Worm & roller 3. Recirculating ball, 1 each
4.Power steering
260. Synchronous Gear box with stand for Dismantling and assembly. 1
118
261. Tin smiths bench folder 600 x 1.6mm 1

262. Transfer case with stand for Dismantling and assembly. 1
263. Trolley type portable air compressor single cylinder with 45 liters capacity Air 1
tank, along with accessories & with working pressure 6.5 kg/sq cm.
264. Tube/ tyre vulcanizing machine semi automatic 1
265. Turbocharger cut sectional view on stand 1
266. Two post car lift – capacity 4000 kg 1
267. Ultrasonic Injection cleaning equipment 1
268. Vacuum assisted hydraulics brake assembly with vacuum booster working 1
model
269. Vehicle Mutiplex network trainer –CAN BUS, LIN BUS,& MOST BUS trainer 1
along with accessories & Analysis software
270. Wiper motor assembly 1
271. Working Model of power windows 1
272. Working model of torque converter 1
273. Welding plant Oxy-Acetylene complete ( high pressure) 1
274. Welding Transformer ( 150-300 Amps) 1
275. Working Condition of Diesel Engine – CRDI - 4 stroke Engine Assembly with 1
fault simulation board
276. Working Condition of Petrol MPFI Engine Assembly with fault simulation 1
board
277. Wheel alignment Machine –computerised 3D with four post lift 1
278. Wheel balancing machine 1
279. Engine Dynamometer 1
D. List of consumable:
280. Automatic Transmission oils As required
281. Battery- SMF As required
282. Brake fluids As required
283. Chalk, Prussian blue. As required
284. Chemical compound for fasteners As required
285. Diesel As required
286. Different type gasket material As required
287. Different type of oil seal As required
288. Drill Twist (assorted) As required
289. Emery paper - 36–60 grit, 80–120 As required
290. Engine coolant As required
291. Engine oil As required
292. Gear oils As required
119
293. Gloves for Welding (Leather and Asbestos) 5 sets

294. Hacksaw blade (consumable) As required
295. Hand rubber gloves tested for 5000 V 5 pair
296. Holders, lamp teakwood boards, plug sockets, solders, flux wires and cables As required
batteries round consumable blocks and other consumables as required
297. Hydrometer 4
298. Lapping abrasives As required
299. Leather Apron 5
300. Petrol As required
301. Power steering oil As required
302. Radiator Coolants As required
303. Safety goggles As required
304. Steel wire Brush 50mmx150mm 5
305. Electronic component such as Diodes, transistors, capacitors, resistors, As required
relays, solenoids, ICs, PCB, Breadboards, SCR, potentiometers as required
306. AC gas As required
120
ANNEXURE-II
FORMAT FOR INTERNAL ASSESSMENT
Name & Address of the Assessor: Year of Enrollment:
Name & Address of ITI (Govt./Pvt.): Date of Assessment:
Name & Address of the Industry: Assessment location: Industry / ITI
Trade Name: Examination: Duration of the Trade/course:
Learning Outcome:
Maximum Marks (Total 100 Marks) 15 5 10 5 10 10 5 10 15 15
Total Internal Assessment

Application of Knowledge&
Ability to Read & Interpret
Quality in Workmanship
Catalogues/Datasheets
Punctuality& Discipline
Attitude towards work

Communicationand
Workplace Hygiene
Interpersonal Skills
Result (Y/N)
Ability to work in team
Usage of PPE
Marks
S No.
Manuals/
andleadership skills
Father's /Mother’s
Skills
VIVA
Candidate Name
Name
121

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Diploma in Automotive Technology

COMPETENCY BASED CURRICULUM

Qualification Code: DGT/5002

Ministry of Skill Development and Entrepreneurship

Sl. Name & Designation Organization Remarks

S No. Topics Page No.

Issues Related to Vocational Training:

Skill Diploma Initiative:

Career for Automotive Engineering Professionals:

increasingly important automotive technology, is covered in considerable detail (including the

Candidates need broadly to demonstrate that they are able to:

2.2 CAREER PROGRESSION PATHWAYS

 Can start theirown enterprise on concerned trade.

2.3 COURSE STRUCTURE

S No. Module Course Element Notional Training Hours

*Core Components (3200 Hrs): -

Note : 1. The trainee must complete all the 5 core modules

2.4 ASSESSMENT & CERTIFICATION

2.4.1 PASS REGULATION

2.4.2 ASSESSMENT GUIDELINE

Assessment will be evidence based comprising the following:

Performance Level Evidence

Brief description of Job roles:

Automotive Engineering Technician sets up and operates equipment to test automobile

i) 3115.0201 – Automotive Engineering Technician/ Testing Manager

Name of the Course Diploma in Automotive Technology

NCO – 2015 3115.0201 – Automotive Engineering Technician/ Testing Manager

Desirable: Preference will be given to a candidate with CIC (Craft

5. NSQF LEVEL COMPLIANCE

NSQF level for Diploma in Automotive Technology: Level 6

The NSQF level-6 descriptor is given below:

Process Professional Professional

Learning outcomes are a reflection of total competencies of a trainee and assessment

4.1 GENERIC LEARNING OUTCOME

4.2 SPECIFIC LEARNING OUTCOME

CORE MODULE 3: AUTOMOTIVE ENGINE – DIAGNOSIS AND REPAIR:

CORE MODULE 4: AUTOMOTIVE TRANSMISSION – DIAGNOSIS AND REPAIR:

CORE MODULE 5: AUTOMOTIVE CONTROLS BRAKE, SUSPENSION AND STEERING DIAGNOSIS

ELECTIVE MODULE 1: AUTOMOTIVE AIR CONDITIONING AND CLIMATE CONTROL SYSTEM-

ELECTIVE MODULE 2: AUTOMOTIVE BODY REPAIR AND REFINISHING:

ELECTIVE MODULE 3: AUTOMOTIVE TWO &THREE-WHEELER- DIAGNOSIS AND REPAIR:

7. LEARNING OUTCOME WITH ASSESSMENT CRITERIA

GENERIC LEARNIG OUTCOME

4 Explain personnel finance, 4.1 Explain personnel finance and entrepreneurship.

SPECIFIC LEARNIG OUTCOME

8 Checkand interpret vehicle 8.1 Identify different types of vehicle.

the standards. various vehicle circuits and record the results.

MODULE 2: AUTOMOTIVE ELECTRICAL AND ELECTRONIC SYSTEM – DIAGNOSIS&REPAIR

MODULE 3: AUTOMOTIVE ENGINE – DIAGNOSIS AND REPAIR

MODULE 4: AUTOMOTIVE TRANSMISSION – DIAGNOSIS AND REPAIR

2 Examine/interpret the 2.1 Plan and execute overhauling of vehicle automatic

Elective 2: AUTOMOTIVE BODY REPAIR AND REFINISHING

Elective 3: AUTOMOTIVE TWO &THREE WHEELER- DIAGNOSIS AND REPAIR

4.5 Monitor evaluates and document work result.

Syllabus for Diploma in “Automotive Technology”

Core Module 1 : Automotive Engineering Basics: 320 Hrs

taper and out-of-round with

under a load of 750 N.

Dynamometer can pass on its way to the

 A 4-cylinder, 4-stroke engine