| Chapter | Description | DurationHours | DurationMinutes |
| Intoduction | Ice breaking session General safety rules to be followed in the workshop / garage Importance of auto technician - 4 wheeler Job opportunities for an auto technician Visit to a auto workshop and introduce different tools and equipments | 2 | 0 |
| Importance of Safety | Importance of Safety and general Precautions to be observed in the shop fire Extinguishers used for different types of fire – Storing and Handling of Inflammable Materials Elementary first aid. | 4 | 0 |
| Mathematics – brush up | Basic arithmetic – mathematical operators Basic algebra – solving simple equations Use of decimal numbers, indices and surds Basic geometry – points, lines, angles,triangle,square, rectangle, polygon | 4 | 0 |
| Introduction to commonly used hand tools | Hammers, screw drivers, spanners – single ended, double ended, ring spanners, pliers, files, torque wrenches, allen key set,taps and dies, precision measuring instruments, tachometer and any other equipment as required – specification and application | 8 | 0 |
| Precision measuring instruments | Vernier caliper Micrometer screw gauge Feeler gauges Any other | 8 | 0 |
| Overview of 5s principle | What is 5s? Advantages of 5s Implementation of 5s Practice 5s | 4 | 0 |
| Automotive industry overview | Auto industry overview Automobile industry segmentation Major players in the auto industry Job opportunities Role of a service technician | 6 | 0 |
| Test / discussion / revision | Test / discussion / revision | 2 | 0 |
| Introduction to automobiles | Introduction to automobiles | 10 | 0 |
| Diesel engine | Function of an engine Classification of engines Working principle of four stroke engine and diesel engine Difference between petrol and diesel engine | 4 | 0 |
| Diesel engine | Engine details –cylinder materials cylinder arrangements cylinder liners and their advantages cylinder heads, description, function, care and maintenance – Location combustion chamber in cylinder heads and also heater plugs and post and valve arrangements. | 4 | 0 |
| Diesel engine | Valves, valve operations-Mechanismparts, and function of each valve timing diagram-camshaft and timing gears-types of drives used in engines chain tension and its importance cylinder head and manifold construction and function-water jackets passages. | 4 | 0 |
| Automotive lubrication and cooling system | Friction-its meaning and importance, methods to reduce friction in engines use of lubricants-oil for diesel engine lubrication – properties of lubricants. | 6 | 0 |
| Diesel engine | Engine assembly procedure need for cleanliness and special tools and gauges used for engine assembling, practice-periods of decarburizing and overhauling engine-interms of hours of run or mileage – running in procedure of overhauled engines. | 4 | 0 |
| Cylinder | Cylinder liners-construction and purpose – material used and finish provided – types of liners in use-method used to fir the same in cylinder bore, advantages of wet and dry liners wearpattern and allowable wear cylinder wear and its causes. | 4 | 0 |
| Compressor | Description and operation of air compressor and exhauster attached to transport vehicle engines- common troubles and maintenance of both their specific application for the brakes of the vehicle. | 4 | 0 |
| Internal and External Engine Components | Description of internal and external engines different types of IC Engines parts of all IC Engine 4stroke OTTO cycle engine- 2 stroke petrol engine- | 4 | 0 |
| Friction | Friction-its meaning and importance, methods to reduce friction in engines use of lubricants-oil for diesel engine lubrication – properties of lubricants. | 4 | 0 |
| Brief Description of engine components | Brief Description of engine components-their location and function – cooling and lubrication system-parts and layout of the system-fuel supply system-layout of parts in system and function of each part ignition system in a petrol engine system layout and parts of ignition system and functions of each part working of the system importance of firing order and Adv. retard mechanism. | 4 | 0 |
| Fuel System | Fuel feed system in diesels Air injection and airless injection. System their general description and lay out importance of water separators constructional details of water separators. | 2 | 0 |
| Fuel System | Fuel filters types and constructionaldetails reasons for using no. of filters sequence of replacement of filter elements importance of Diesel fuel cleanliness types of diesel fuel HUS and LSD Description of O.F> valves and their functions. | 2 | 0 |
| Fuel System | Constructional details of fuel injection pumps, feed pumps and governors explanation of function and operation. | 2 | 0 |
| Fuel injection Nozzles | Fuel injection Nozzles description and operation-of each type spray angles and orifices and their characteristicsinjector tester-construction and function types of tests and their purpose-Effects of incorrect setting of nozzles on engine performance. | 4 | 0 |
| Maintenance of Diesel Engine | Importance of periodical maintenance and upkeep of shop equipments preventive maintenance to avoid sudden and major failure-preparing maintenance charts for machineries and follow up. | 4 | 0 |
| BASIC ELECTRICAL | Simple electrical circuit series and parallel circuits identification of alternating –current and direct current meters-insulators and conductors-types of resistance – ohm’s law and its application- common electrical terms and symbols – primary and secondary cells-lead acid battery descriptionconstruction – common troubles and remedy. | 10 | 0 |
| Electric Circuits | Description of electrical circuits – ignition system and the components – purpose of induction coil, condenser, spark plugs – common troubles in ignition circuit and remedy. | 4 | 0 |
| Charging Circuits | Description of charging circuit – operation of dynamo and regulator Unit-Ignition warning lamp- troubles and remedy in charging system. | 4 | 0 |
| Starter Motor | Description of starter motor circuitsconstructional details of starter motorsolenoid switches –common troubles and remedy in starter circuits. | 4 | 0 |
| Practical Exercise | Description of Safety Equipment Their use Safety Rules to be observed in an Automobile Repair shop. | 10 | 0 |
| Practical Exercise | Demonstration of the use of Fitter’s hand tools Marking off with steel Rule, Calipers, scriber, dividers, dot and Centre punch Chipping in marked lines in a given piece sharpening of chisels, Centre punch and Dot punch to correct Angles. | 10 | 0 |
| Practical Exercise | Practice on starting and stopping of diesel engines use of speed center in determining the engine speed running of engine on load checking temperature fuel and oil compression testing of cylinders. | 4 | 0 |
| Practical Exercise | Maintenance checks-daily weekly, monthly for deferent types of engines writing up of inspection schedules Maintenance of log sheets-details of maintenance. | 4 | 0 |
| Practical Exercise | Remove,rockers,arm,assembly manifoldsand cylinder head – removing valves and its parts, cleaning and decarburizing, checking valve seats and valve guide, reconditioning valves seats and prefacing valves – lapping valves on its seats – testing leaks of valve seats for leakage – inspection of cylinder head and manifold surfaces for warping and cracks. | 4 | 0 |
| Practical Exercise | Dismantle rocker arm assembly clean and check shaft-bushes, posts and rocker arm for wear and Cracks and reassemble. Check valve springs, tappets, pushrods, tappet screws and valve stem cap. Reassembling valve parts in sequence refit cylinder head and manifold and rock arm assembly, adjustable valve clearances, starting engine after decarburizing. | 6 | 0 |
| Practical Exercise | Removing piston and connecting rod from engine – examine –piston ring lands for wear examine piston skirt for cracks and distortions, clear oil holes –check connecting rod for bend and twist and parent bore for taper, ovality, and gudgeon pin bushes for wear check elongation of cap fixing bolts. | 8 | 0 |
| Practical Exercise | Removing crankshaft and camshaft from engine-checking oil retainer and trust surface for wear-measure crank shaft journal for wear-checking flywheel and mounting flanges, spigot, bearing-check vibration damper for defects – check cam shaft for bend and crank. | 6 | 0 |
| Practical Exercise | Checking cylinder blocks surface – measure cylinder bore for taper and ovalitycheck main bearing parent bore for taper and ovality clean oil pipe line- check main bearing cap bolt holes check cam shaft, bearing and tappet bore – rescale water passages and examine welsch plugs check cylinder head for warping. | 6 | 0 |
| Practical Exercise | Overhauling oil pump, oil filters oil coolers air cleaners and air filters, check and adjust oil pressure relief values – changing oil in the sump, repairs to oil flow pipelines and unions. | 8 | 0 |
| Practical Exercise | Reassemble al parts of engine in correct sequence and torque al bolts and nuts as per maker’s recommendation for engines. | 6 | 0 |
| Practical Exercise | Reassemble all parts of engine in correct sequence, torque all bolts and nuts as per markers, recommendations for the engine- Fit accessories and start, and run the engine on stands. | 4 | 0 |
| Practical Exercise | Removing cylinder liners from scarp cylinder block, practice in measuring and refitting new liners as per maker’s recommendations precautions while fitting new liners. | 4 | 0 |
| Practical Exercise | Removing radiator and water pump from engine, cleaning and reverse flushing radiator, testing thermostat and refitting on engine-overhauling-water pump-refittingadjusting cooling system of the engine. | 10 | 0 |
| Practical Exercise | Removing radiator and water pump from engines, cleaning and reverse flushing radiator, testing thermostat and refitting on engine- overhauling – water pump-refittingadjusting fan belt tension and connecting water pump with radiator with hoses and flushing cooling system of the engine. | 10 | 0 |
| Practical Exercise | Dismantling air compressor and exhauster – cleaning all parts- measuring wear in the cylinder and blades- reassembling all parts and fitting them in the engine. | 10 | 0 |
| Practical Exercise | Trouble shooting in cooling and lubrication system/engine checking up and connecting oil and water leaks – changing defective packing and gaskets testing radiator leaks and testing functioning of thermostat. | 10 | 0 |
| Practical Exercise | Diagnosis of engine faults like smoky, exhaust, overheating, heavy vibrationmissing cylinders, exhaust noise, hunting characteristics of engine and erratic or irregular idling. | 10 | 0 |
| Practical Exercise | Diagnosis of reasons for starting difficulty in a diesel engine and rectifying the faults. | 10 | 0 |
| Practical Exercise | Cleaning fuel tanks checking leaks in the fuel lines soldering and repairing pipe line and unions brazing nipples to high pressure line studying the fuel feed system in diesel engines draining of water separators. | 10 | 0 |
| Practical Exercise | Practice in joining wires and soldering – firming simple electrical circuits – measuring of current, voltage and resistance – cleaning and topping up of a lead acid battery - Testing battery with hydrometercell tester connecting battery to charger. | 10 | 0 |
| Practical Exercise | Studying electrical circuits in the engine assembly checking loose, open and short circuit in ignition circuits – cleaning and testing of distributor’s assembly checking and setting ignition timings. | 10 | 0 |
| Practical Exercise | Removing dynamo from vehicle dismantling, cleaning checking for defects, assembling and testing for motoring action of dynamo and fitting to vehicles. | 10 | 0 |
| Practical Exercise | Removing starter Motor vehicle and overhauling the starter motor- testing of starter motor. | 10 | 0 |
| Subject Specific Soft Skills | Soft skill related to Mechanic Diesel like do not compromise on safety, gloves, equipments, cleaning engine and other parts, crankshoft, soldering, checking cylinder, overhauling various parts, etc,. | 20 | 0 |
| Soft Skills - General Module | * Introduction * Basics of Grammar * Communication Skills * Learn Continuously * Behavior and Attitude * Discipline and Punctuality * Honesty and Transparency * Respect for Rules and Regulations * Time management * Team Work * Relationship Building * Ethics and values * Safety Conscious and Safe Working Practices * Concern for Quality * Customer Service * Environment and waste disposal | 20 | 0 |