Curriculum for

Automobile Mechanic
(1 Year)
 Contents

Overall objectives of the course…………………………………………. 3

Competencies gained after completion of the course.……….. 3
Job opportunities available immediately and in the future……. 3
Entry level…………………………………………………………… 4
Grade………………………………………………………..………. 4
Overview about the program……………………………………………… 5
Automobile Mechanic curriculum contents……………………….…….. 7
Module 1: Automotive Workshop Basics ……………………… 7
Module 2: Diagnosing and Servicing the Engine …………….. 9
Module 3: Service of Power Train ……………………………… 13
Module 4: Servicing Chassis Systems………………………… 15
Module 5: Servicing Automotive Electrical ………………..….. 17
Module 6: Application of Related Studies …………………..… 18
Assessment………………………………………………………………… 20
Module 1: Automotive Workshop Basics ……………………… 20
Module 2: Diagnosing and Servicing the Engine …………….. 22
Module 3: Service of Power Train ……………………………… 26
Module 4: Servicing Chassis Systems………………………… 28
Module 5: Servicing Automotive Electrical ………………..…. 29
Module 6: Application of Related Studies ………………..…… 30
Supportive notes………………………………………………………….. 32
Assessment context……………………………………………… 32
Critical aspects……………………………………………………. 32
Assessment condition……………………………………………. 33
Special notes………………………………………………………. 34
Resources required………………………………………………... 34

2
 Overall Objectives of the Course
(i) The learner will be able to work as a semi skilled worker.
(ii) Fulfill the job requirements for an employer.
(iii) Facilitate new entrants to learn and enter the labor market.
(iv) Improve the workmanship of existing workers.

Competencies Gained after Completion of Course

To apply safety precautions.

Select use and handle auto motive, hand tools, workshop tools, safely and efficiently.
Identify and use automotive fasteners.
Tune up the car.
Diagnose and service the engine.
Diagnose and service of fuel (Petrol, Diesel, E.F.I., and C.N.G.), lubricating, cooling, ignition, emission and exhaust systems.
Diagnose and service the power train components as clutch, transmission, drive shaft, differential and axles.
Diagnose and service the suspension, steering and brake systems.
Replace battery, self starter and alternator.
Do minor repair work of car wiring such as replacing fuses, bulbs and horns etc.
Recheck the work done.

Job Opportunities Available Immediately and in the Future

Pass out may be employed in following sectors.

Car Workshops
Car Dealerships
Heavy Duty Workshops
Private fleets and garages
Government departments
Assembly plants
Generator workshops
Spare parts stores.
Self Business.
3
Learners can also progress to get admission in a 2 year course aimed at producing skilled workers i.e. Head Technician and Forman.

Entry Level

(i) Minimum Middle

(ii) Preferably Matric

Grading

Theory: Pass marks 40%

Practical: Pass marks 60%
Fail 0 – 59%
Average 60 – 78%
Good 79 – 92%
V. Good 93 – 100%

4
 Overview about the program – Curriculum for Automobile Mechanic

Module Title and Aim Learning Units Theory Workplace

hours hours
Module 1: Automotive Workshop
Apply:
Basics
1.1 Safety Precautions
1.2 Measuring tools
Aim: 1.3 Fasteners, sealants and cleaning liquids. 22 72
1.4 Automotive hand tools
Behave as a good automotive
1.5 Workshop tools
technician, use the tools, fasteners
1.6 Behave safely in workshop
safely and efficiently.

Service the:
Module 2: Diagnosing and Servicing 2.1 Engine
the Engine
2.2 Fuel Systems
2.3 Lubrication Systems 115 602
Aim:
2.4 Cooling Systems
Perform maintenance, diagnosis and
service work on engine efficiently. 2.5 Ignition Systems
2.6 Exhaust Systems.

Service the:
Module 3: Service of Power Trains
3.1 Clutch Systems
3.2 Transmission and Transaxles
Aim: 40 204
3.3 Propeller Shaft.
Diagnose and service the power train
3.4 Differentials
components amicably.
3.5 Axles

Module 4: Servicing Chassis Service the:

69 272
Systems 4.1 Suspension Systems

5
 4.2 Steering Systems
Aim: 4.3 Brake Systems
Diagnose and repair the chassis
systems efficiently.

Module 5: Basic Electrical Systems Maintenance and service of the:

5.1 Battery
Aim: 5.2 Self Starter 20 70
Perform basic electrical tasks required 5.3 Charging Systems
for an engine technician 5.4 Electrical Components

Module 6: Application of Related

Studies

Aim: 6.1 Solve mathematical problems

54 60
1. Apply simple mathematical rules 6.2 Sketch out technical drawing(Basic / related.
important in the workshop
2. Explain construction and function of
components of various automotive
systems
TOTAL HOURS 320 1280

6
 Auto Mechanic Curriculum Contents (Teaching and Learning Guide)
Module 1 Title: Automotive Workshop Basics
Objective of the Module: Behave as a good automotive technician, use the tools, fasteners safely and efficiently.
Duration: 94 hours Theory: 22 hours Practice: 72 hours

Learning Unit Learning Outcomes Learning Elements Duration Materials/ Tools Learning
Required Place
- Describe personal safety
To adopt safety measures, Tools and machine safety Fire extinguishers Class room
1.1 Apply the safety Vehicle
personally, for the tools, job - Job safety 6 Hrs and Institute
precautions
and environment - Environment safety workshop
- Demonstrate proper use of the fire extinguishers

Explain:
- Measure units of mass, volume, length and time in Steel foot rule
Imperial/Metric System Vernier Caliper
To measure precisely and to - Measure units in metric system Micrometer Measuring
1.2 Measuring - Identify and use with: 20 Hrs
compare with standard size Dial Gauge Lab
• Steel rules V – Blocks
• Vernier Caliper Required Tools
• Micrometer
• Dial Gauge

- Define fastener and its types

- Identify auto motive fasteners and locking devices Various Types of
1.3 Use of - Use of Circlips Fasteners Class room
To identify and use fasteners
Fasteners and - Select and use of sealants 14 Hrs Torque Wrench and Institute
and sealants
Sealants. - Explain purpose and materials of Gaskets Gaskets workshop
- Identify Gaskets and “O” rings Sealants
- Removing of broken studs/bolts

- Identify and use fitting tools

 Screw Drivers General
1.4 Use of Hand Select use and handle the  Spanners Institute
39 Hrs Mechanic Tool
Tools hand tools properly  Socket Set workshop
Kit
 Allen Key
 Adjustable Wrench

7
  Torque Wrench
- Identify and use striking tools
 Hammers
 Punches
- Identify and use pliers
- Identify and use pullers
 Removing and refitting of bearings
- Identify and use cutting tools
 Hack saws
 Chisels
 Shears
 Files
 Drills
 Reamers
 Taps and dies
- Pipe cutting, bending and flaring
- Identify and use general workshop tools for cleaning,
lubrication etc.

- Identify and use the Bench Vise

- Identify and use the electric tools
 Drill Machine
Identify and use the  Bench Grinder Class room
1.5 Use of Workshop Tools
workshop equipment  Air Compressor 9 Hrs and Institute
workshop tools as in Column 3
efficiently and safely workshop
 Jacks and Lifts
 Arbor and Hydraulic Press
 Washer Tanks

1.6 Behave
- Behave professionally
professionally Behave professionally in the
- Display good attitude with colleagues and customers 6 Hrs Class room
in automotive workshop
- Display good attitude to the work at hand
workshop

8
Module 2 Title: Diagnosing and Servicing the Engine
Objective of the Module: Perform maintenance, diagnosis and service work on engine efficiently)
Duration: 717 hours Theory: 115 hours Practice: 602 hours

Learning Unit Learning Outcomes Learning Elements Duration Materials Required Learning
Place
Explain:
General mechanics tool kit
- Engine and its types Lifting equipment
- 4 stroke petrol engine working. Torque wrench
- 2 stroke petrol engine working Bench Vice
- Working of diesel engine. Valve seat cutter/Lapping Class Room
- Spark Ignition Engine Stick and institute
- Describe construction and function of: Micrometer workshop
 Cylinder heads Vernier calipers
- Learner will be able to  Valve mechanisms Pullers of different size
explain the working of an  Cylinder blocks
2.1 Diagnose and engine. Straight edge.
 Piston, piston rings and pins Valve spring compressor
Service - Identify Engine  Connecting rod and big end bearings 282 Hrs
Engine components Valve spring tester
 Crank shaft and main journal bearings
- Dismantle, check and Cotton Waste
 Fly wheels
assemble engine. - Remove the engine from the car Kerosene oil
- Dismantle the engine Compression gauge/tester
- Inspect and check the engine parts Cleaning equipment
Hydraulic press Auto mobile
- Engine timing (valve and ignition) workshop
- Assemble the engine Engine oil and grease
- Adjusting tappet clearance Diesel and petrol fuel
- Fit the engine in the car Metal pans for cleaning
- Start the engine
tray.
- Perform Compression test
- Describe the purpose of a fuel system
- Describe Air fuel ratios General mechanic tools kit
Learner will be able to - Describe construction, function and Lifting equipment
Fuel pressure gauge Class room /
identify, service and repair operation of fuel systems
2.2 Diagnose and Torque wrench Institutional
the fuel systems:  Fuel tank
Service Fuel 283 Hrs Oscilloscope multi meter workshop and
 Fuel pumps
Systems - Carburetor E.F.I. auto mobile
 Fuel and air filters Computer lead box
- C.N.G. workshop
 Thermostatic air cleaner diagnosis systems and
- Diesel fuel injection
 Carburetor circuits and attachments interface box
 Fuel gauges Tachometer

9
  Replacing fuel pumps and checking Cleaning equipment
pressure and capacity Test lamp
 Replace air and fuel filters Bench vice
- Carburetor service Scan tools
 Dismantle, check and assemble the Exhaust gas analyzer
carburetor Special tools as per
 Setting float level manufacturer’s
 Setting idle speed & mixture recommendations
 Diagnose fuel system troubles Compressed air
 Describe E.F.I. systems (T.B.I. & P.F.I)
- Explain the function of:
 E.C.M/ E.C.U
 Sensors (throttle, MAP, Coolant, O2,
Crank position sensor etc.)
 Actuators
 Malfunction indicator light
 Checking E.F.I. Systems
 Checking and cleaning fuel injectors
 Relieving fuel line pressure
 Re-setting inertia switch
 Testing fuel pressure regulator
 On board diagnostics
 Retrieve the trouble codes
 Using scan tool
 Checking sensors
 Diagnosing E.C.M.
- Explain the construction and function of
C.N.G. supply systems
- Adjust the mixture
- Explain the construction and function of
diesel injection systems components
- List the types of combustion chambers
- Replace the diesel filter
- Bleeding diesel fuel injection system
- Adjust the fuel injector pressure
- Set the injection timing
- Trouble shoot the diesel fuel system
- Explain purpose and working of super, turbo
charger and inter cooler

2.3 Diagnose and - Explain the purpose, construction and General mechanic tool kit Class room /
Trainee will be able to 16 Hrs
service the working of an engine lubricating systems Oil filter wrench Institutional
diagnose and repair the
lubricating - Chang oil and filters Sealant workshop and

10
 systems lubricating system - Service oil pumps Lifting equipment auto mobile
- Checking oil pressure Scarper workshop
- Diagnose Troubles Oil funnel
Recommended oil
Waste oil drum

- Explain the purpose, construction and

working of engine cooling systems General mechanic tool kit
- Describe the function of radiator cap
2.4 Diagnose and Multi meter
Trainee will be able to - Check/ test radiator cap Class room /
Service of Radiator cap tester
diagnose and repair the - Test the thermostat valve 26 Hrs Institutional
Cooling Temperature gauge
cooling system - Adjust the fan belt workshop
Systems Hoses
- Replace the water pump
- Replace the hose pipe Clamps
- Diagnose for problems

- Explain the purpose, construction and Test lamp

operation of ignition systems (battery, Engine analyzer
ignition switch, blast resistance, ignition coil, Dwell / tacho meter
distributor and spark plugs) Condenser Tester
- Explain spark plugs types Spark plug deep socket
- Testing spark set
- Replace C.B. Point Insulation tester
- Test ignition coil General mechanic tool kit
- Service of spark plugs Timing light
- Setting of ignition timing Plug cleaner and tester
- Use ignition timing light Hand vacuum pump Class room /
2.5 Diagnose and
Trainee will be able to - Use dwell angle tester Soldering iron Institutional
Service of
diagnose and service the - Diagnose for problems 75 Hrs workshop and
Ignition SPARES
ignition system - Explain pick up coil ignition, high energy auto mobile
systems
ignition, hall effect switch, optical photodiode Condensers workshop
distributor, multiple coil distributor less C.B. Points
ignition, crank and cam position sensor, High tension cables
direct multiple coil ignition, direct capacitor Spark plugs
and discharge ignition.
- Triggering test INSTRUCTIONAL DATA
- Retrieve ignition system troubles Manufacturer’s manuals
- Test with a breakout box Equipment operational
- Check air gap of pick up coil ignition manuals
- Test pick up coil, hall effect switch Drawings
- Check ignition module Circuit diagrams

11
 - Introduction of emission control systems
- Explain positive crank case ventilation
2.6 Service and (P.C.V), evaporative control emission, Class room /
diagnose the Trainee will be able to exhaust gas recirculation, and Catalytic Institutional
emission diagnose and repair the converters. 15 Hrs General mechanic tool kit workshop and
control P.C.V. system - Service of P.C.V. systems auto mobile
systems - Service thermostatic air cleaner workshop
- Explain safety precautions of catalytic
converter
Class room /
2.7 Service of Trainee will be able to - Explain the purpose and construction of Institutional
Exhaust diagnose and replace the exhaust systems 20 Hrs General mechanic tool kit workshop and
system Exhaust system parts - Service exhaust systems auto mobile
workshop

12
Module 3 Title: Service of Power Train
Objective of the Module: Diagnose and service the power train components amicably
Duration: 244 hours Theory: 40 hours Practice: 204 hours

Learning Unit Learning Learning Elements Duration Materials Required Learning Place
Outcomes
Mechanic’s tool kit
- Explain the purpose, construction and Clutch aligning tool
operation of a clutch Emery paper
- Explain the types of clutch Grease
3.1 Diagnose and Trainee will be able - Explain the clutch linkages Class room /
Clutch plate
Service the to diagnose and - Remove, check and reinstall the clutch Institutional workshop
59 Hrs Pressure plate
Clutch service the clutch assembly and auto mobile
Systems system - Clutch master cylinder service and Thrust bearing workshop
bleeding. Clutch cable
- Adjust clutch pedal free play Brake oil
- Trouble shooting. Steel rule
Fly wheel
Explain:
- Define gear ratio
Trainee will be able - Purpose, construction and function of 4
3.2 Diagnose and speed synchromesh gearbox / transaxle Mechanic’s tool kit Class room /
to diagnose and
service of - Introduction to automatic gears Transmission oil Institutional workshop
repair the 88 Hrs
Transmission - Remove input shaft, output shaft assembly Pan for dismantling and auto mobile
transmission &
and transaxle and countershaft Transmission/Transaxle workshop
transaxle system
- Checking and inspection of parts
- Reassembly
- Trouble shooting

Explain:
- The purpose of a propeller shaft Mechanics tool kit
- Construction and function of universal joint Class room /
Trainee will be able Jacks and stands
3.3 Service the and slip joints Institutional workshop
to check & service 29 Hrs Dial indicator with
drive line and auto mobile
the drive line - Remove, check and install a propeller shaft magnetic stand workshop
- Trouble shooting V-Block

13
 Describe:
Mechanic’s tool kit
- The purpose, function and construction of Shims, Bearing
differential and axles (rear and front) Differential oil
3.4 Diagnose & Trainee will be able - Remove, dismantle, check and assemble Boot & boot-clips Class room /
service the to check & service the differential Grease (silicon base) Institutional workshop
68 Hrs
differential and differential and axle - Adjust back lash Sealant & Gaskets and auto mobile
axle assembly assembly - Remove, check and refit front drive axle Cleaning liquids workshop
- Refit front drive axle Oil seals
- Adjust wheel bearings Jack & stands
Rags
- Trouble shooting

14
Module 4 Title: Servicing Chassis Systems
Objective of the Module: Diagnose and repair of chassis systems efficiently
Duration: 341 hours Theory: 69 hours Practice: 272 hours

Learning Unit Learning Learning Elements Duration Materials Required Learning

Outcomes Place
- Explain the purpose of suspension
systems Mechanics tool kit Class room /
4.1 Diagnose and Trainee will be able - Explain the types of suspension Institutional
Garage Jacks
Service the to diagnose and system workshop
46 Hrs Trolley Jack
suspension service the - Check and replace shock and auto
system suspension systems absorbers/refill Coil spring compressor mobile
- Remove and refit leaf springs Safety stands workshop
- Remove and refit of Mc-Pherson struts

- Explain:
- The purpose, construction and types of
steering systems (Mechanical &
Power)
- The steering linkages
- Explain wheel balance and steering Mechanics tool kit Class room /
4.2 Diagnose and Trainee will be able geometry Garage Jacks Institutional
Service the to diagnose and - Service steering gear boxes workshop
175 Hrs Safety stands
steering service the steering - Adjust steering wheel free plate and auto
systems systems - Check and replace the tie rods Wheel balancing machine mobile
- Wheel balance Wheel alignment equipment workshop
- Check Toe in camber, caster, steering
axis inclination (S.A.I) toe-in & toe-out
on turn
- Adjust angles
- Trouble shooting

- Explain the purpose of brakes Mechanics tool kit

- Describe the construction, function & Class room /
Trainee will be able Vehicle Lifting Jacks & Safety stands Institutional
4.3 Diagnose and types of brakes
to diagnose and - Explain the function of parking brakes MATERIALS workshop
Service the 120 Hrs
service the brake - Replace and adjust the brake shoes and auto
brake system Brake oil
systems - Check and replace the disc pads mobile
- Check the brake servo unit Grease workshop
- Service the master cylinders Repair kits (Master and wheel

15
- Service the wheel cylinder cylinder)
- Bleeding the brakes Brake pads
- Adjust parking brakes Brake shoes
- Trouble shooting Brake hoses and pipes
Vinyl tube and container
Emery paper

16
Module 5 Title: Servicing Automotive Electrical Components
Objective of the Module: Perform important electrical tasks required for an engine technician
Duration: 90 hours Theory: 20 hours Practice: 70 hours

Learning Unit Learning Learning Elements Duration Materials Required Learning

Outcomes Place
- Describe conductor and insulator Auto wire
- Explain ampere, volt, and resistance Thimble
- Explain series and parallel circuits Thimble plier
- Explain magnet and magnetism Ampere meter, volt meter,
- Explain the purpose and function of Multi meter
Battery Bulbs and holders
Self starter Class room /
5.1 Maintenance of Trainee will be able to Soldering iron, paste and
Alternator Institutional
the automotive perform maintenance wire
- Connect resistances in series and 90 Hrs workshop and
electrical of the automotive Hydrometer
parallel circuits auto mobile
components electrical components. Battery charger
- Use volt meter and ampere meter workshop
Distilled water
- Use of ohm meter
Insulation tapes
- Perform battery maintenance
- Cranking motor wiring circuit Lamp tester
- Remove and reinstall battery, Battery clamps
alternator and self-starter Battery service kit
- Replace fuses and bulbs Mechanic tool kit

17
Module 6 Title: Application of Related Studies (Technical Maths & Drawing)
Objective of the Module: 1.Apply simple mathematical rules important in workshop
2.Explain construction and function of components of various automotive systems
Duration: 114 hours Theory: 54 hours Practice: 60 hours

Learning Unit Learning Outcomes Learning Elements Duration Materials Learning

Required Place
Calculate
- Addition
Trainee will be able to - Subtraction Technical
6.1 Mathematics
solve mathematical - Multiplication 40 Hrs Mathematics Class Room
problems - Division Book
- Fractions
- Decimals
- Percentage

- Define types of lines, dimensions and lettering

- Define three views
- Define full section and half section
Complete the sketch/block/circuit diagram of the
following:
- 4 stroke engine operation
- 2 stroke engine operation
Trainee will be able to - Lubrication flow
identify and sketch out the - Coolant circulation
6.2 Technical Technical
construction and function 74 Hrs Class Room
drawing - Working of fuel pumps Drawing Book
of components of
Automotive systems. - Working of carburetors (Idle/High speed circuit)
- Battery coil ignition (Circuit diagram)
- Electronic ignition (Circuit diagram)
- Clutch function (Engage and disengage position)
- 4 speed synchromesh transmission (Power flow
in different gears)
- Differential function on turn
- Brake Master cylinder working (Tendum, single)
- Brake shoe assembly

18
- Steering linkages (Label the diagram)
- Wheel alignment angles (Sketch)
- Series and parallel circuits (complete the circuit)
- Cranking motor circuit (complete the circuit)
- Charging circuit (complete the circuit)

19
 Assessment
Module 1: Automotive Workshop Basics

Learning Theory Workplace Recommended formative assessment Recommended Scheduled

Units hours hours Methodology Dates
- Describe personal safety
Observation
1.1 Apply safety Tools and machine safety
3 3 - Job safety Oral Questions
precautions
- Environment safety
- Demonstrate proper use of the fire extinguishers
Explain:
- Measure units of mass, volume, length and time in Question Paper
Imperial/Metric System Measuring Job
- Measure units in metric system
1.2 Measuring 5 15
- Identify and use with:
• Steel rules
• Vernier Caliper
• Micrometer
• Dial Gauge
- Define fastener and its types
Oral questions
1.3 Use of - Identify auto motive fasteners
Checking the Job
Fasteners, - Use of Circlips Oral Questions
Sealants 4 10 - Select and use of sealants Checking Measurement
and - Explain purpose and materials of Gaskets Fitting
Gaskets
- Identify Gaskets and “O” rings Use
- Removing of broken studs/bolts
- Identify and use fitting tools
 Screw Drivers
 Spanners
Questioning
 Socket Set
1.4 Use of Hand  Allen Key Demonstration
5 34
Tools  Adjustable Wrench
 Torque Wrench
- Identify and use striking tools
 Hammers
 Punches

20
 - Identify and use pliers
- Identify and use pullers
 Removing and refitting of bearings
- Identify and use cutting tools
 Hack saws
 Chisels
 Shears
 Files
 Drills
 Reamers
 Taps and dies
- Pipe cutting, bending and flaring
- Identify and use general workshop tools for
cleaning, lubrication etc.
- Identify and use the Bench Vise
Question & Demonstration
- Identify and use the electric tools
 Drill Machine
1.5 Use of
 Bench Grinder
workshop 3 6
tools  Air Compressor
 Jacks and Lifts
 Arbor and Hydraulic Press
 Washer Tanks

1.6 Behave in - Behave professionally

Oral questions
automotive 2 4 - Display good attitude with colleagues and
workshop customers
- Display good attitude to the work at hand

21
Module 2: Diagnosing and Servicing the Engine

Learning Theory Workplace Recommended formative assessment Recommended Scheduled

Units hours hours Methodology Dates
Explain:
- Engine and its types Questions & Answers
- 4 stroke petrol engine working.
- 2 stroke petrol engine working
- Working of diesel engine.
- Spark Ignition Engine
- Describe construction and function of:
 Cylinder heads
 Valve mechanisms
2.1 Diagnose  Cylinder blocks
and  Piston, piston rings and pins
40 242  Connecting rod and big end bearings
Service the
Engine  Crank shaft and main journal bearings
 Fly wheels
- Remove the engine from the car Continues Checking of
- Dismantle the engine Job
- Inspect and check the engine parts
- Engine timing (valve and ignition)
- Assemble the engine
- Adjusting tappet clearance
- Fit the engine in the car
- Start the engine Checking
- Perform Compression test

- Describe the purpose of a fuel system Questions & Answers

- Describe Air fuel ratios Written / Oral
- Describe construction, function and operation of fuel
systems
2.2 Diagnose  Fuel tank
and  Fuel pumps
Service 40 243  Fuel and air filters
Fuel  Thermostatic air cleaner
Systems  Carburetor circuits and attachments
 Fuel gauges
 Replacing fuel pumps and checking pressure and
capacity
Checking the method of
 Replace air and fuel filters

22
 - Carburetor service work
 Dismantle, check and assemble the carburetor
 Setting float level
 Setting idle speed & mixture
 Diagnose fuel system troubles
 Describe E.F.I. systems (T.B.I. & P.F.I)
- Explain the function of:
 E.C.M.
Questions & Answers
 Sensors (throttle, MAP, Coolant, O2, Crank position
Written / Oral
sensor etc.)
 Actuators
 Malfunction indicator light
 Checking E.F.I. Systems
 Checking and cleaning fuel injectors
 Relieving fuel line pressure Checking the job
 Re-setting inertia switch
 Testing fuel pressure regulator
 On board diagnostics
 Retrieve the trouble codes
 Using scan tool
 Checking sensors
 Diagnosing E.C.M.
- Explain the construction and function of C.N.G. supply Questions and answers
systems
- Adjust the mixture Checking the job
- Explain the construction and function of diesel injection Question and answers
systems components
- List the types of combustion chambers
- Replace the diesel filter Checking the job
- Bleeding diesel fuel injection system
- Adjust the fuel injector pressure
- Set the injection timing
- Trouble shoot the diesel fuel system
- Explain purpose and working of super, turbo charger and Question and answers
inter cooler

- Explain the purpose, construction and working of an Question and answer

2.3 Diagnose
engine lubricating systems
and
- Change of oil and filters Checking the job
service the 3 13
- Service oil pumps
lubricating
- Checking oil pressure
systems
- Diagnose Troubles

23
 - Explain the purpose, construction and working of engine Questions and answers
cooling systems
2.4 Diagnose
- Describe the function of radiator cap Checking the job
and
- Test the thermostat
Service of 5 21
- Adjust the fan belt
Cooling
- Replace the water pump
Systems
- Replace the hose pipe
- Diagnose for problems

- Explain the purpose, construction and operation of Question and answers

ignition systems (battery, ignition switch, blast resistance,
ignition coil, distributor and spark plugs)
- Explain spark plugs types
- Testing spark
- Replace C.B. Point
- Test ignition coil
- Service of spark plugs
- Setting of ignition timing
2.5 Diagnose - Use ignition timing light Checking the job
and - Use dwell angle tester
Service of 15 60 - Diagnose for problems
Ignition - Explain pick up coil ignition, high energy ignition, hall
systems effect switch, optical photodiode distributor, multiple coil
distributor less ignition, crank and cam position sensor,
direct multiple coil ignition, direct capacitor and discharge
ignition.
- Triggering test
- Retrieve ignition system troubles
- Test with a breakout box
- Check air gap of pick up coil ignition
- Test pick up coil, hall effect switch
- Check ignition module

- Explain the purpose of Emission control systems Question and answers

2.6 Service and
- Explain positive crank case ventilation (P.C.V),
diagnose
evaporative control emission, exhaust gas recirculation,
the
5 10 and Catalytic converters.
emission
- Service of P.C.V. systems
control
- Service thermostatic air cleaner
systems
- Explain safety precautions of catalytic converter Checking the job

2.7 Service of 7 13 - Explain the purpose and construction of exhaust systems Question and Answer

24
Exhaust - Service exhaust systems
system

25
Module 3: Service of Power Train

Learning Units Theory Workplace Recommended formative assessment Recommended Scheduled

hours hours Methodology Dates
- Explain the purpose, construction and operation of a Questions and answers
clutch
3.1 Diagnose and - Explain the types of clutch
Service the - Explain the clutch linkages
9 50
Clutch - Remove, check and reinstall the clutch assembly Checking the job
Systems - Clutch master cylinder service and bleeding.
- Adjust clutch pedal free play
- Trouble shooting.
Explain: Questions and answers
- Define gear ratio
- Purpose, construction and function of 4 speed
3.2 Diagnose and synchromesh gearbox / transaxle
service of - Introduction to automatic gears
13 75 Checking the job
Transmission - Remove input shaft, output shaft assembly and
and transaxle countershaft
- Checking and inspection of parts
- Reassembly
- Trouble shooting

Explain: Questions and answers

- The purpose of a propeller shaft
- Construction and function of universal joint and slip
3.3 Service the joints
5 24 - Remove, check and install a propeller shaft Checking the job
drive line
- Trouble shooting
Questions and answers

Describe: Questions and answers

3.4 Diagnose &
service the 13 55 - The purpose, function and construction of differential
differential and axles (rear and front)
and axle - Remove, dismantle, check and assemble the Checking the job

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assembly differential
- Adjust back lash
- Remove, check and refit front drive axles,
- Adjust wheel bearings
- Trouble shooting
Questions and answers

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Module 4: Servicing Chassis Systems

Learning Theory Workplace Recommended formative assessment Recommended Scheduled

Units hours hours Methodology Dates
Questions and answers
4.1 Diagnose - Explain the purpose of suspension systems
and - Explain the types of suspension system
Service the 9 37 - Check and replace shock absorbers/refill
suspensio - Remove and refit leaf springs Checking the job
n system - Remove and refit of Mc-Pherson struts

- Explain: Questions and answers

- The purpose, construction and types of steering
systems (Mechanical & Power)
- The steering linkages
4.2 Diagnose - Explain wheel balance and steering geometry
and - Service steering gear boxes
Service the 40 135 - Adjust steering wheel free plate Checking the job
steering - Check and replace the tie rods
systems - Wheel balance
- Check Toe in camber, caster, steering axis inclination
(S.A.I) toe-in & toe-out on turn
- Adjust angles
- Trouble shooting

- Explain the purpose of brakes Questions and answers

- Explain the construction, function & types of brakes
- Replace and adjust the brake shoes
4.3 Diagnose
- Check and replace the disc pads
and
- Check the brake servo unit
Service the 20 100
- Service the master cylinders Checking the job
brake
- Service the wheel cylinder
system
- Bleeding the brakes
- Adjust parking brakes
- Trouble shooting

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Module 5: Servicing Automotive Electrical

Learning Units Theory Workplace Recommended formative assessment Recommended Scheduled

hours Hours Methodology Dates
- Explain conductor and insulator Questions and answers
- Explain ampere, volt, and resistance
- Explain series and parallel circuits
- Explain magnet and magnetism
- Explain the purpose and function of
Battery
Self starter
5.1 Maintenance of
the automotive Alternator
20 70 - Connect resistances in series and parallel
electrical Checking the job
components circuits
- Use volt meter and ampere meter
- Use of ohm meter
- Perform battery maintenance
- Cranking motor wiring circuit
- Remove and reinstall battery, alternator and
self-starter
- Replace fuses and bulbs

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Module 6: Application of Related Studies

Learning Theory Workplace Recommended formative assessment Recommended Scheduled

Units hours hours Methodology Dates

Calculate
- Addition
- Subtraction
7.1 Mathematics
40 - - Multiplication
Questions and answers
- Division
- Fractions
- Decimals
- Percentage

- Define types of lines, dimensions and lettering

- Define three views
- Define full section and half section
Complete the sketch/block/circuit diagram of the following:
- 4 stroke engine operation
- 2 stroke engine operation
- Lubrication flow
- Coolant circulation Sketching the drawings
- Working of fuel pumps
7.2 Technical
14 60 - Working of carburetors (Idle/High speed circuit)
drawing
- Battery coil ignition (Circuit diagram)
- Electronic ignition (Circuit diagram)
- Clutch function (Engage and disengage position)
- 4 speed synchromesh transmission (Power flow in
different gears)
- Differential function
- Brake Master cylinder working (Tendum, single)
- Brake shoe assembly
- Steering linkages (Label the diagram)
- Wheel alignment angles (Sketch)

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- Series and parallel circuits (complete the circuit)
- Cranking motor circuit (complete the circuit)
- Charging circuit (complete the circuit)

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 Supportive notes
Assessment Context

These learning units may be assessed on the job, off the job or a combination of on and off the job demonstrated by an individual
working alone. In some areas continuous assessment may be required to gauge the competency.
Assessment of the practical skills must take place only after a period of supervised practice and repetitive experience. If work place
conditions are not available, assessment is simulated and that the work place conditions are acceptable.
The prescribed outcome must be achieved without direct supervision.
Competency should be assessed within the context of the qualification being sought.

Critical Aspects

Assessment must confirm that the candidate is able to:

1: Apply the health and safety legislations while working.

2: Use fire extinguishers.
3: Read measurements with measuring tools.
4: Identify and use the automotive fasteners.
5: Select, handle and use hand tools, workshop tools safely and properly.
6: Check the compression pressure of engine and diagnose the faults.
7: Diagnose problems in different fuel systems and make the necessary adjustment.
8: Set the valve and ignition timing.
9: Diagnose and service the lubricating, cooling, ignition systems.
10: Service the clutch and adjust the free play.
11: Remove, dismantle, check, assemble and refit the transmission.
12: Adjust the back lash of differential.
13: Replace the axle bearing.
14: Accuracy of adjustments.
15: Replace the suspension systems components.
16: Carry out the wheel balancing.
17: Carry out the wheel alignment.
18: Service of various mechanical steering gear boxes.
19: Service of power steering.

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20: Adjust the brake system.
21: Bleed the brake system.
22: Connect the battery.
23: Wiring up the cranking motor circuit.
24: Identify and connect the charging system connections.
25: Drive the car amicably in forward and reverse speeds in the ground.
26: Apply the mathematical rules in routine work.
27: Identify and demonstrate the drawings.

Assessment Condition

The candidate will have access to:

- All tools, equipment, materials and documentation required.

The candidates will be permitted to refer the following documents.

- Relevant workplace procedures.
- Relevant product and manufacturing specifications.
- Relevant drawings, manuals, codes, standards and reference material.

The Candidate will be required to:

- Orally or by other methods of communication, answer, questions put forward by the assessor.
- Identify superiors who can be approached for the collection of competency evidence where appropriate.
- Present evidence of credit for any off job training related course.

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Special Notes

During assessment the individual will:

Demonstrate safe working practices all the times.
Communicate information about processes, events or tasks being under taken to ensure a safe and efficient working environment.
Take the responsibility for the quality of his/her own work.
Plan tasks in all situations and review tasks requirements as appropriate.
Perform all tasks in accordance with standard operating procedures.
Perform all tasks to specifications.
Use accepted engineering techniques, practices, processes and work place procedures.
Items requiring specialize repair will be sent to appropriate specialists.

The tasks involved will be completed within reasonable time frames relating to typical work place activities. The resources required for
assessment include tools, equipment and machines listed within these learning units. The completed product should comply with the respective
industrial standards.

Resources required

Materials, tools, equipment and machines are listed within the learning units.

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