Curriculum - Repair & overhauling of Engine System ( Petrol ...

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COMPETENCY-BASED CURRICULUM

FOR THE MODULE OF

REPAIR AND OVERHAULING OF ENGINE SYSTEM

(PETROL & DIESEL)

UNDER

SKILL DEVELOPMENT INITIATIVE (SDI) SCHEME

Based on

MODULAR EMPLOYABLE SKILLS (MES)

Government of India

Ministry of Skill Development and Entrepreneurship

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CONTENTS

Sl. No.

Topics Page No.

1. Introduction 2. General Information & Course Structure 3. Job Roles and Reference NOS & NCO 4. NSQF Level Compliance 5. General Training Plan, Examination & Pass Regulation 6. Learning Outcomes

6.1 Generic Outcomes 6.2 Specific Outcomes

7. Assessable Outcomes with Assessment Criteria 8. Syllabus Content with Time Structure

8.1 Syllabus Content for Professional Skill & Knowledge 8.2 Syllabus Content for Soft & Entrepreneurship Skills

9. Infrastructure 10. Assessment Standard

10.1Assessment Guideline 10.2 External Assessments

11. Annexure-I: List of Tools &Equipment 12. Annexure- II: List of Tools &Equipment for Soft &

Entrepreneurship

13. Annexure-III: Guidelines for Instructors and Paper Setters 14. List of Trade Committee Members

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1. INTRODUCTION

The Ministry of Skill Development and Entrepreneurship is an apex organization for the development and coordination of the vocational training including vocational training for women in our country. The Ministry conducts the training programmes through the Craftsmen Training Scheme (CTS), Apprenticeship Training Scheme (ATS), Skill Development Initiative (SDI) Scheme based on Modular Employable Skills (MES), and Craftsmen Instructor Training Scheme (CITS) to cater to 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.

A majority of Indian workforce does not possess marketable skills which is an obstacle in getting decent employment and improving their economic condition. A large number of school drop outs do not have access to skill development for improving their employability. The higher entry requirements and long duration of courses under the formal training system are some of the obstacles for a person of low educational attainment to acquire employable skills.

The Ministry is implementing the Skill Development Initiative (SDI) Scheme based

on Modular Employable Skills (MES) to provide vocational training to early school leavers and existing workers especially in the unorganized sector to develop skilled manpower for the industry. Training is provided by registered Vocational Training Providers (VTPs) under the Government, Private Sector, and Industrial establishments located all over the country. Testing of skills acquired informally by an individual are directly tested on pre-determined parameters through independent Assessing Bodies. Nationally as well as internationally recognized NCVT certificate is issued to every successful individual.

The key features of the Modular Employable Skills (MES) are:

Short-term training programmes designed in consultation with the Industry.

Identification of “minimum skills set” sufficient to get employment.

Flexible training delivery mechanism (part time, weekend, or full time).

Different levels of programmes (Foundation level to advanced level).

Opportunity for lifelong learning.

The training under MES would benefit different target groups like workers seeking certification of their skills acquired informally, workers seeking skill up gradation, and early school dropouts and unemployed. Central Government facilitates and promotes the training while registered Vocational Training Providers (VTP) under the Govt. and Private Sector

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provide the training. Testing of skills is done by independent Assessing Bodies to ensure impartiality.

The National Skills Qualification Framework (NSQF), published in the Gazette of Government of India on 27th December, 2013, is a national framework that aims to integrate general and vocational streams of education and training. The main thrust of the NSQF is to focus on competency-based qualifications. The National Skill Development Agency (NSDA) under the Ministry is responsible for the implementation of the Framework, by bringing together the key stakeholders through the National Skill Qualifications Committee (NSQC).

The competency-based framework organizes qualifications into ten levels, with the entry level being 1, and the highest level being 10. Each level of the NSQF is described by a statement of learning outcomes in five domains, known as level descriptors. These five domains are (1) Process, (2) Professional knowledge, (3) Professional skill, (4) Core skill, and (5) Responsibility. The paradigm shift from learning focused on inputs to an outcome/competency-based education would help in the Recognition of Prior Learning (RPL), and simultaneously enable the alignment of the Indian qualifications with international ones. Government funding is expected to be on a preferential basis for NSQF compliant courses. The NSQF notification provides a Qualification Register, which is the official national database of all qualifications aligned to NSQF levels. Through this Register, learners can expect access to all NSQF compliant qualifications.

The Ministry has set up Mentor Councils to focus on courses under NCVT in various sectors with representation from thought leaders among different stakeholders viz., industries, innovative entrepreneurs who have proved to be game-changers, academic/professional institutions, and champion ITIs for each of the sectors. The Mentor Council for each sector reviews curricula, admission criteria, course duration, and requirement of trainers and assessment/evaluation systems for the sector on a continuous basis and make recommendations regarding the same. Sector-wise Core Groups are formed to plan and prepare the documentation for the competency-based curricula for the courses under each sector.

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2. GENERAL INFORMATION AND COURSE STRUCTURE 1 Qualification REPAIR AND OVERHAULING OF

ENGINE SYSTEM (PETROL & DIESEL) 2 MES Code No. AUR 708 3 NSQF Level Level-3 4 Duration of Modular Training 600 hrs. 5 Entry Qualification Minimum 5th Std.+ Basic Automotive

Servicing 4 wheelers (AUR 702)+ Driver cum Mechanic (AUR703)

6 Trainees per unit 20 Distribution of training on Hourly basis:

Sl. No.

Broad Practical components to be covered Duration (in Hrs)

1 Practice Health & Safety, Interaction with health centre and fire service station to provide demo on First aid and fire safety. Practice in joining wire using soldering iron, construction of simple electrical circuit. Practice continuity test for fuses jumper wires, fusible link, circuit breakers, check electrical circuit with a test lamp perform voltage drop test in circuits using multimeter, measure current flow using multimeter /ammeter. Engine repair: Dismantle complete engine and their components ,Check / test – compression pressure, cylinder head & block warpage, valve leak, lubricating oil pressure, bearing (oil) clearance, measure bore & take decision for further action, ring end gap & side clearance, fuel pressure regulator in MPFI engine, inlet manifold vacuum, cam & crank shaft bend & valve timing, service inlet and exhaust manifolds, remove, clean, check & overhaul engine sub assemblies / components, remove, clean, check & overhaul electrical components, dismantle, clean, assemble and check injectors. Engine Inspection and reconditioning: Fault Diagnosis using engine scanner, find the fault on the given engine and rectify the defect. FIP WORK: Wash / Clean FIP and Injectors, check the FIP on calibration bench and assess the condition, dismantle FIP using special tools, clean and inspect Parts of each components, replace defective components, assemble FIP using special tools, calibrate FIP using calibration test bench, test the Injectors using Injector

600

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Tester, replace defective nozzles using special tools, assemble injectors and test

2 *Training on Soft & Entrepreneurship Skill module has been completed during training on module AUR 701.

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Total 600

*Note: Any candidate completed training for 100 hrs. Soft &Entrepreneurship skills under MES in any module need not to repeat the same.

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3. JOB ROLES BRIEF DESCRIPTION OF JOB ROLES

This course is meant for the candidates who shall be aspire to become Engine Mechanic and able to perform engine repair and FIP repair works in 4 wheelers (petrol & Diesel). NOS & QP/NCO MAPPING

AUR 708 REPAIR AND OVERHAULING OF ENGINE SYSTEM (PETROL & DIESEL)

ASC/ Q 1401 Automotive Service Technician L3

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4. NSQF LEVEL COMPLIANCE The Broad Learning outcomes of REPAIR AND OVERHAULING OF ENGINE SYSTEM (PETROL & DIESEL) trade under MES matches with the Level descriptor at Level- 3. . The NSQF level-3 descriptor is given below:

LEVEL Process

required Professional knowledge

Professional skill

Core skill Responsibility

Level 3 Person may carry out a job which may require limited range of activities routine and predictable

Basic facts, process and principle applied in the trade of employment

recall and demonstrate practical skill, routine and repetitive in narrow range of application

Communication written and oral, with minimum required clarity, skill to basic Arithmetic and algebraic principles, personal banking, basic understanding of social and natural environment

Under close supervision Some Responsibility for own work within defined limit.

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5. GENERAL TRAINING PLAN, ASSESSMENT & CERTIFICATE

General Training Plan The knowledge and skill components as stated in the section for ‘learning outcomes’ are to be imparted in accordance with the instructions in respect of the content and time structure. Assessment The competency assessment for the Modular Employable Skills under the SDI scheme is being done by the assessor of the independent Assessing Bodies (AB) which is not involved in training delivery, to ensure an impartial assessment. The assessment process through Assessing Bodies aims to test and certify the competency of the persons who seek certification of their skills acquired informally or the persons who have been trained at the registered VTPs. In the assessment process, identification of competency, ways to measure the competency and deciding on the type of evidence that has to be collected are the responsibility of the Assessing Bodies whereas administering the assessment and collecting the evidence and reporting the results are the responsibility of the assessors.

Candidates are to demonstrate that they are able to: 1. Plan and organize work processes, identify necessary materials and tools; 2. Perform task with due consideration to safety rules, accident prevention

regulations and environmental protection stipulations; 3. Apply professional knowledge and soft skills& entrepreneurship while performing

the task. 4. Check the job for accuracy, identify and rectify errors in job.

The details of the assessment standard are as per section-13.

Pass regulation: Minimum passing marks for Practical is 60% Minimum pass marks for theory is 40%

Certificate Successful persons will be awarded certificates issued by National Council for Vocational Training (NCVT).

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6. LEARNING OUTCOMES

The following are minimum broad learning outcomes after completion of the REPAIR AND OVERHAULING OF ENGINE SYSTEM (PETROL & DIESEL) course of 600 hrs duration:

6.1. SPECIFIC OUTCOMES

1. Apply safe working practices, environment regulation and safe disposal of hazardous products in an automotive work shop.

2. Use different types of conventional and special tools, hardware, fasteners and work shop equipment in the work shop.

3. Use electrical measuring instrument, diagnostic equipment and tools to carry out testing of series and parallel circuits.

4. State the working principle of MPFI and CRDI Engine system 5. To Identify the different type of sensors used in MPFI and CRDI System 6. Dismantle and assemble of engine components of MPFI and CRDI System and

check for performance 7. State the importance of variable valve timing 8. Identify parts of cooling and lubrication system of engine and execute required

servicing 9. To state the Working principle, Different types & application of starter motor,

alternator 10. State the working principle of Turbocharger. 11. Understand the constructional features and working principles of intake and exhaust

systems of vehicle and related troubleshooting. 12. Use of scan tool for troubleshooting of Engine system 13. State the Working Principle of Fuel Injection Pump (FIP) 14. Identify and check the functionality of FIP components .

NOTE: Learning outcomes are reflection of total competencies of a trainee. Each learning outcome may include multiple assessment components. However assessment will be carried out as per assessable outcome and assessment criteria.

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7. ASSESSABLE OUTCOMES WITH ASSESSMENT CRITERIA

Note: 1. The training shall be conducted as per the syllabus. 2. The trainee shall demonstrate the competencies which are defined below in assessable

outcome and assessment criteria. 3. All the assessable outcomes are to be tested during formative assessment, observations,

and viva-voce. 4. Assessable outcome of Soft skills & entrepreneurship shall be tested separately and also

be applied in Theory and Practical examinations. 5. These assessable outcomes and assessment criteria will serve as a set of guidelines for

Trainers and Assessors.

Specific assessable outcomes: ASSESSABLE OUTCOMES

ASSESSMENT CRITERIA

1. Recognize & comply safe working practices, environment aspect and housekeeping.

1.1 Follow and maintain procedures to achieve a safe working environment in line with occupational health and safety regulations and requirements and according to site policy. 1.2 Identify and take necessary precautions on fire and safety hazards and report according to site policy and procedures. 1.3 Report supervisor/ Competent of authority in the event of accident or sickness of any staff and record accident details correctly according to site accident/injury procedures. 1.4 Identify Personal Productive Equipment (PPE) and use the same as per related working environment. 1.5 Identify basic first aid and use them under different circumstances. 1.6 Take opportunities to use energy and materials in an environmentally friendly manner 1.7 Avoid waste and dispose waste as per procedure

1.8 Recognize different components of 5S and apply the same in the working environment.

2. Understand and practice soft skills, working with Computer and communicate with required clarity.

2.1 Recognize & practice soft skills in day to day work. 2.2 Conduct appropriate discussions with within the team and report to higher authority. 2.3 Present facts and circumstances and use appropriate terminology related to work. 2.4 Conduct written communication.

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5.0 Apply safe working practices in an automotive work shop.

5.1 Follow and maintain procedures to achieve a safe working environment in line with occupational health and safety regulations and requirements and according to site policy. 5.2 Recognize and report all unsafe situations according to site policy. 5.3 Identify and take necessary precautions on fire and safety hazards and report according to site policy and procedures. 5.4 Identify, handle and store/dispose off dangerous goods and substances according to site policy and procedures following safety regulations and requirements. 5.5 Identify and observe site policies and procedures in regard to illness or accident. 5.6 Identify safety alarms accurately. 5.7 Report supervisor/competent of authority in the event of accidents or sickness of any staff and record accident details correctly according to site accident/injury procedures. 5.8 Identify and observe site evacuation procedures according to site policy. 5.9 Identify personal protective equipment (PPE) and use the same as per related working environment. 5.10 Identify basic first aid and use them under different circumstances. 5.11 Identify different fire extinguishers and use the same as per requirement.

2.5 Use computers and access internet for day to day activity 3. Demonstrate knowledge of concept and principles of basic arithmetic calculation, co-ordinate system and apply knowledge of specific area to perform practical operations.

3.1 Apply basic arithmetic calculations for arriving dimensional parameters as per drawing. 3.2Use co-ordinate system for part programming.

4. Explain time management, entrepreneurship and manage/organize related task in day to day work for personal & social growth.

4.1 Ascertain appropriate time for the assigned task. 4.2 Execute the assigned task within time frame. 4.3 Manage own work within specified time. 4.4 Explain importance & factors affect the development

Of entrepreneurship. 4.5 Identify service providers for developing

entrepreneur/business establishment.

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6.0 Comply environment regulations and housekeeping in the work shop.

6.1 Identify environmental pollution and contribute to the avoidance of instances of environmental pollution. 6.2 Carryout maintenance and cleaning of work shop and lifting equipment. 6.3 Take opportunities to use energy and materials in an environmentally friendly manner. 6.4 Avoid waste and dispose waste as per procedure. 6.5 Recognize different components of 5S and apply the same in the working environment.

7.0 Construct electrical circuits and test its parameters by using electrical measuring instruments.

7.1 Plan and organize the work for basic electrical operations.

7.2 Select the tools, instruments and materials required to do the job. 7.3 Comply with safety rules when performing the basic electrical operations. 7.4 Perform electrical wire joints, form electrical circuits and test basic electrical parameters as per the circuit drawings and operating procedures.

8.0 Perform basic electrical testing in a vehicle.

8.1 Plan and organize the work for auto electrical component testing. 8.2 Tracing the auto electrical components in a vehicle.

8.3 Test continuity and voltage drop in the electrical circuits.

8.4 Operate the electrical components in a vehicle and test lamps.

9.0. Identify and check functionality of Dashboard Gauges & engine performance on petrol and Diesel engine

9.1 Ascertain and select tools and materials for the job and make this available for use in a timely manner. 9.2 Plan work in compliance with standard safety norms.

9.3 Demonstrate possible solutions and agree tasks within the team. 9.4 Identify different gauges fitted on the dashboard and check for proper functioning. 95 Perform daily checks before starting the engine.

9.6 Start the engine and allow it to warm up.

9.7 Identify the problem in functionality of particular Gauge fitted on dashboard and record the reading and compare it with standard reading.

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9.8 Repair / Replace the defective gauges as per standard operating practice. 9.9 Check for proper functionality

9.10 Stop the engine.

10.0. Overhaul the Petrol Engine

10.1 Ascertain and select tools and materials for the job and make this available for use in a timely manner.

10.2 Plan work in compliance with standard safety norms.

10.3 Remove a petrol engine from the vehicle as per vehicle manufacturer std. Procedure 10.4 Dismantle the petrol engine as per sequence

10.5 Overhaul the cylinder head assembly and check for warpage, 10.6 Overhaul the piston and connecting rod assembly and check for ring end gap & side clearance 10.7 Check the cylinder bore wear

10.8 Check and compare measurements as per standard specification. 10.9 Assemble the petrol engine as per sequence

10.10Check and adjust valve clearances as per procedure and recommended specification of engine manufacturer

11. Carryout repairs in the fuel feed system



11.3 Remove the fuel tank from vehicle

11.4 Servicing the fuel tank & fuel pipe lines

11.5 Servicing of fuel pipes

11.6 Overhaul the different types of fuel pump

11.7 Overhaul the different types of carburettor and make adjustments 11.8 Replace the air cleaner, fuel filter and charcoal canister

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12. Identify the various components of MPFI petrol engine

12.1 Identify the MPFI components by its name

12.2 Locate the MPFI Components in the given engine

13. Check functionality of MPFI Components



13.3 Test the MPFI fuel pump

13.4 Test the MPFI fuel Injector

13.5 Test the Idle Air control valve

13.6 Test the MPFI fuel pressure regulator

15. Identify and check functionality of various sensors installed in engine, Gauges and instruments on dashboard



14.3 Identify and locate the sensors fitted in the given MPFI engine 14.4 Start the engine and check the function of Mal Indication Lamp (MIL) ,Oil pressure warning light, charge indication light, Temperature warning light/gauge, Seat belt warning light, ABS warning light, Parking light, fuel level gauge 14.5 Repair / Replace the defective gauges as per standard operating practice. 14.6 Test the various sensors fitted on the given engine using multi meter/scan tool

15. Find the trouble in electronic circuit and rectify using scan tool

15.1 Connect the scan tool to the Data link connector of given engine 15.2 Read the Error code

15.3 Test the reference voltage and continuity of the circuit as per vehicle wiring circuit 15.4 Repair/Replace the defective part or wiring

15.5 Erase the error memory

15.6 Start and check the engine

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16. Diagnose and Troubleshoot Petrol Engines



16.3 Carryout the diagnostic procedure by reviewing engine technical workshop manual, following the standard diagnostic procedure for. Engine cranks but Not Starting. 16.4 Engine hard to start

16.5 High Fuel Consumption

17.6 Engine misfiring

17.Troubleshoot the Charging System

17.1 Check Charging system for proper functioning as per manufacturer guidelines 17.2 Check alternator for proper functioning

17.3 Remove alternator from the vehicle.

17.4 Overhaul and check alternator for proper function.

17.5 Refit Alternator to the vehicle and check for functioning

18. Troubleshoot the Starting System

18.1 Check starting system for proper functioning as per manufacturer guidelines 18.2 Check starter for proper functioning

18.3 Remove starter from the vehicle.

18.4 Overhaul and check starter for proper function.

18.5 Refit starter to the vehicle and check for functioning

19. Overhauling of Diesel Engine

19.1 Ascertain and select tools and materials for the job and make this available for use in a timely manner. 19.2 Drain coolant and lubricants from the engine and Remove Accessories of engine 19.3 Service cylinder head assembly.

19.4 Service Oil Sump and Oil Pump

19.5 Service Piston and connecting Rod Assembly

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19.6 Service Flywheel , Crank shaft, camshaft and its Bearings and gear 19.7 Service cylinder block.

19.8 Check and adjust valve clearances as per procedure and recommended specification 19.9 Refit all the accessories.

19.10 Refill all the required coolant and lubricants as per standard specification. 19.11 Start the engine and observe reading of dashboard gauges and record Engine Performance

20. Servicing of Cooling and Lubrication system

20.1 Check Engine Coolant & Reverse flush the cooling system using flushing solution. 20.2 Service Radiator and radiator cap

20.3 Check Radiator hoses for crack and replace if necessary.

20.4 Test Thermostat valve for proper functioning and replace if necessary. 20.5 Check water pump for serviceability and replace if faulty.

20.6 Check Fan/Alternator Belt for proper tension.

20.7 Check and replace Engine Oil and oil filter

20.8 check and Service Oil Cooler & pressure relief valve

21. Service Intake and Exhaust System

21.1 Ascertain and select tools and materials for the job and make this available for use in a timely manner. 21.2 Service/Replace Air Cleaner

21.3 Overhaul Air Compressor & Exhauster Assembly

21.4 Service Turbocharger/Supercharger

21.5 Service Intercooler

21.6 Check Exhaust Leakages and Rubber Mounting of Exhaust System 21.7 Service Exhaust manifold and catalytic converter

21.8 Check and Replace Resonator/Muffler

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22. Service Diesel Fuel System

22.1 Check leakages in fuel line.

22.2 Service Fuel Tank

22.3 Replace Fuel Filter & Feed pump

22.4 Set Fuel Injection Pump Timing as per manufacturer specification 22.5 Service Fuel Injectors as per manufacturers guidelines and Bleed the Fuel System to vent out any air trapped. 22.6 Start the Engine and check for proper functioning.

22.4 Check starter for proper functioning

22.5 Service starter.

23. Diagnose and Troubleshoot Diesel Engines

Carryout the diagnostic procedure by reviewing engine technical workshop manual, following the standard diagnostic procedure for.

a) Engine Not Starting. b) High Fuel Consumption c) Engine Overheating d) Low Power Generation e) Excessive Oil Consumption f) Low/High Engine Oil Pressure g) Abnormal Engine Noise.

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8. SYLLABUS CONTENT WITH TIME STRUCTURE

8.1 FOR THE MODULE OF REPAIR AND OVERHAULING OF ENGINE SYSTEM (PETROL & DIESEL) (Module Code No. AUR 708)

Duration: 600 hrs.

Detailed Syllabus:

Practical Competencies Underpinning Knowledge(Theory)

SAFETY: Practice Health & Safety – familiarize, select, use, maintain & store – tools, equipments, consumables & clothing safely Interaction with health centre and fire service station to provide demo on First aid and fire safety, use of fire extinguishers Measurement practice on engine components by use of different measuring instruments

Safe disposal of toxic dust, safe handling and periodic testing of lifting equipment, Authorization of moving and road test vehicles, Environment control of running indoor engines, Electrical safety Definition & Importance of Quality Control, Quality Assurance, Quality circle. Familiarization of workshop manual. Study of measuring instruments.

ELECTRICAL BASIC: Practice in joining wire using soldering iron. Construction of simple electrical circuit. Measurement of current, voltage and resistance using digital multimeter. Practice continuity test for fuses jumper wires, fusible link, circuit breakers Check electrical circuit with a test lamp perform voltage drop test in circuits using multimeter. Measure current flow using multimeter/ammeter.

Ohm’s Law Series & Parallel resistances circuits Working principle, types & application of capacitors & transistors, Wiring colour-code, reading of engine electrical systems circuits Conductor and insulator. Voltmeter, ammeter, ohmmeter, multimeter,

ENGINE REPAIR WORK Select proper materials for gaskets and packing Select Locking devices and find their applications Identify differences between Petrol & diesel Engines.

Lubrication & cooling systems Layout in Carburettor engine – starting, ignition, charging, fuel supply systems Layout in MPFI engine –air induction, starting, ignition & fuel supply systems Sensors used in the MPFI Engine and its function

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Identify differences between carburettor engine & MPFI Engines. Identification of sensors used in theMPFI & CRDI Engine Remove broken studs Remove engine from vehicle Drain engine oil and coolant Water wash engine / decrease Dismantle complete engine and their components Check / test – compression pressure, cylinder head & block warpage, valve leak, lubricating oil pressure, bearing (oil) clearance, measure bore & take decision for further action, ring end gap & side clearance, fuel pressure regulator in MPFI engine, inlet manifold vacuum, cam & crank shaft bend & valve timing Service inlet and exhaust manifolds Remove, clean, check & overhaul engine sub assemblies / components Remove, clean, check & overhaul electrical components Dismantle, clean, assemble and check injectors

Layout in diesel engine –fuel supply systems Direct injection, Indirect injection, common rail direct injection(CRDI) Systems Sensors used in the CRDI Engine and its function Different valve operating mechanisms-Vaiable valve timing technology& Valve timing diagram Procedure for handling & reading – Torque wrenches &multimeter Procedure for removing engines from the vehicle Working principle, Different types & application of - starter motor, alternator, carburettor, FIPs, Injectors, filters, fuel pumps, liners, pistons, piston rings, valves, valve drives, bearings used on engines, MPFI system components Procedure for – dismantling, checking, assembling & testing of starter motor & cooling fan motor Procedure for – dismantling, checking, assembling & testing of alternator Turbocharger function,Types and its working.

ENGINE INSPECTION & RECONDITION Measure the bore and take the decision Replace – liner, valve guide, piston wrings Do valve lapping & valve grinding Overhaul piston and connecting rod assembly Assemble the engine, Fill up oil & coolant after preparing in correct proportion Start the engine and set idle rpm Fault Diagnosis using engine scanner Find the fault on the given engine and rectify the defect

Procedure for checking/testing – compression pressure, cylinder head & block warpage, valve leak, lubricating oil pressure, bearing (oil) clearance, bore measurement, ring end gap & side clearance, fuel pressure regulator in MPFI engine, inlet manifold vacuum, cam & crank shaft bend & valve timing Procedure for – dismantling, checking, assembling & testing of petrol engines Procedure for – dismantling, checking, assembling & testing of diesel engines Latest emission norms

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Controls available to meet the norms & their working principle. Brief description about onboard diagnostic system(OBD)

FIP WORK Wash / Clean FIP and Injectors Check the FIP on calibration bench and assess the condition Dismantle FIP using special tools Clean and inspect Parts of each components Replace defective components Assemble FIP using special tools Calibrate FIP using calibration test bench Test the Injectors using Injector Tester Replace defective nozzles using special tools Assemble injectors and test

Fuel supply layouts in diesel engines Nomenclature of different types of fuel injection pumps Working principle of FIP Components of an FIP and detailed functioning of each one of them Differences between different types of fuel injection pumps Working principle of Injection Timers and Governors Brief on the FIP Test rig & calibration charts Procedure for phasing & calibration of an FIP Purpose, types, construction & operation of Injectors and nozzles Procedure for testing the Injectors as per specification

9. INFRASTRUCTURE 1. Instructors’ Qualification Degree in Automobile/ Mechanical Engg. With

one year relevant experience OR Diploma in Automobile/ Mechanical Engg. With two years relevant experience OR NTC/NAC in Automobile trade group with three years of relevant experience

2. Desirable qualification Craftsmen Instructor Certificate(CIC) in Fitter trade 3. Space Norms 210 sq. m - (a) Class Room: 30 Sq. meter @ 1.5 sq.

meter per trainee (b) Workshop: 120 sq. meter + 60 sq. meter (parking area)

4. Power Norms 6 KW - (a) Class Room: 1 KW (b) Workshop: 5 KW

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5.Tools, Equipment & General Machinery

(As per Annexure I)

10. ASSESSMENT STANDARD

10.1ASSESSMENT 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 the assessment. Due consideration shall be given while assessing for teamwork, avoidance/reduction of scrap/wastage and disposal of scarp/wastage as per procedure, behavioral attitude, sensitive to environment and regularity in training. The sensitivity towards OSHE and self-learning attitude shall be considered while assessing competency. Assessment will be evidence based comprising the following: 1) Job carried out in labs/workshop 2) Record book/ daily diary 3) Answer sheet for assessment 4) Viva-voce 5) Progress Chart 6) Attendance and punctuality 7) Assignment 8) Project work Evidence of internal assessment should be preserved for an appropriate period of time for audit and verification by examination body. The following marking pattern to be adopted while assessing: a) Weightage in the range of 60-75% to be allotted during assessment under following performance level:

For performance in this grade, the candidate with occasional guidance and showing due regard for safety procedures and practices, has produced work that demonstrates attainment of an acceptable standard of craftsmanship. In this work there is evidence of:

Demonstration of good skill in the use of hand tools, machine tools, and workshop equipment

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Below 70% tolerance dimension achieved while undertaking different work with 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 above75%- 90% to be allotted during assessment under following performance level:

For this grade, the candidate, with little guidance and showing due regard for safety procedures and practices, has produced work that demonstrates attainment of a reasonable standard of craftsmanship. In this work there is evidence of:

Good skill levels in the use of hand tools, machine tools, and workshop equipment

70-80% tolerance dimension achieved while undertaking different work with those demanded by the component/job.

A good level of neatness and consistency in the finish

Little support in completing the project/job c) Weightage in the range of above 90% to be allotted during assessment under following performance level:

For performance in this grade, the candidate, with minimal or no support in organization and execution and with due regard for safety procedures and practices, has produced work which demonstrates attainment of a high standard of craftsmanship. In this work there is evidence of:

High skill levels in the use of hand tools, machine tools, and workshop equipment

Above 80% tolerance dimension achieved while undertaking different work with those demanded by the component/job.

A high level of neatness and consistency in the finish.

Minimal or no support in completing the project. 10.2. EXTERNAL ASSESSMENTS NO.

ASSESSABLE OUTCOMES ASSESSMENT MARKS

1. Recognize & comply safe working practices, environment regulation and housekeeping.

2. Recognize & comply safe working practices, environment regulation and housekeeping.

3. Demonstrate knowledge of concept and principles of basic arithmetic calculation and apply knowledge of specific area to perform practical operations.

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4. Explain time management, entrepreneurship and manage/organize related task in day to day work for personal & societal growth

SPECIFIC Total of External assessment

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Annexure - I

11. List of Tools & Equipment for module for a batch :

Sl. No. Name of Tool/Equipment

Quantity (nos)

Sl. No

Name of Tool/Equipment

Quantity (nos)

TRAINEES KIT

1. Steel Rule 15 cm inch and metric

5 nos 19 Oil can 0.5 litre cap 5 nos

2. Steel Rule 30 cm inch and metric

5 nos 20 Pliers combination 15 cm 5 nos

3. Steel measuring tape 10 meter in a case

5 nos. 21 Wire cutter and stripper 5 nos.

4. Hammer ball peen 0.75 kg 5 nos. 22 Inspection lamp with guard and wandering lead of 10 ft (consumable)

5 nos

5. Socket Spanners with handle, T bar & ratchet

5 sets 23 Horses and wheel chokes 5 nos

6 Mallets (wooden/plastic/copper)

5 nos 24 Scriber 15 cm with scribing block universal

5 nos

7. Screw driver 20 cm. x 9 mm blade

5 nos. 25 Hacksaw frame adjustable for 30 cm blade

5 nos

8. Screw driver 30 cm x 9 mm blade

5 nos 26 Hand vice 37mm 5 nos

9. Philips Screw Driver Type set of 5 pieces 100 mm to 300 mm

5 sets 27 Feeler gauge 20 blades (metric)

5 nos.

10. Spanner D E set of 12 pieces (6 to 32 mm)

5 sets 28 Steel tool box with lock & key (folding type) size 400x200x150mm.

5 nos.

11. Ring spanner set of 12 pieces 6 to 32mm

5 sets 29 Cleaning Tray 45 x 30 cm. 5 nos

12. Centre punch Dia.10 mm x 100 mm

5 nos. 30 Allen Key set of 12 pieces (2 mm to 14 mm)

5 sets

13. Prick punch 15cm 5 nos 31 File card/cleaner 5 nos. 14. Chisel cold flat 20 mm 5 nos 32 Scriber 15cm 5 nos. 15. Chisel cross cut 200mm x

6mm 5 nos 33 Safety glasses for grinding 5 nos.

16. Hand files 20 cm. Second 5 nos 34 Stud extractor ezy out 5 sets

26

cut types 17. Hand files 20 cm. Second

cut half round 5 nos 35 Hand file 30 cm. bastard 5 nos

18. Hand file 20 cm. Smooth triangular

5 nos 36 Hand file 30 cm. round bastard

5 nos

Sl. No Name of Tool/Equipment

Quantity (nos)

Sl. No Name of Tool/Equipment Quantity (nos)

GENERAL TOOLS EQUIPMENTS AND MACHINERIES 1 Circlip plier 15cm

expanding type 1 no 58 Grease gun 2 nos.

2 Spanner, adjustable 20 cm.

1 no 59 Sheet metal gauge 1 no.

3 Torque wrench 5 - 35 Nm, 12 - 68 Nm, 50 – 225 Nm.

1 set 60 Crow bar 1no

4 Plier round nose 15cm 2 nos 61 Battery charger 12V- 36 V

1 no

5 Pipe wrench 350mm 1 no. 62 Tachometer - to read upto10000 rpm

1 no

6 Vice grip pliers 2 nos 63 Screw jack one tone, capacity double lift

7 Circlip pliers Expanding and contracting type 15 cm and 20 cm each

1 each 64 C clamp 100mm, 150mm, 200mm

2 each

8 Screw pitch gauge 1 no 65 Battery 12 V (consumable 2 yrs span)

2 nos

9 Fire bucket (4 nos.) with stand

As required

66 Hydrometer 2 nos

10 Hollow punch set of seven pieces 6 to 15 mm

1 set 67 Portable electric drill 6 mm

1 no

11 Letter punch 4mm 1 set 68 Pullers screw powered 2 mm with bearing puller attachment

1 no

12 Battery tester 1 no 69 Fire Extinguisher As required

13 Angle plate adjustable 250 x 150 x 175

1 no. 70 Nitrogen inflator with Tyre Pressure gauge

1 no

14 Injector test bench along with a set of special tools for repairing different

1 no. 71 Trolly type portable air compressor single cylinder with 45 liters

1 no

27

types injectors capacity air tank, along with accessories & with working pressure 6.5 kg/sq cm

15 Different types of gaskets(consumable)

As required

72 Straight edge gauge 1 no

16 Different types of oil seal(consumable)

As required

73 Fuel feed pump 1 no

17 Marking material (consumable)

As required

74 Drift punch copper 15cm 1 no

18 “V‟ Block 75 x 38 mm pair with Clamps

2 nos 75 Drilling machinebench to drill up to 12mm dia along with accessories

1 no

19 Drill Twist ( assorted ) As required

76 Grinding machine (general purpose) D E pedestal with 300mm dia wheels rough and smooth

1 no

20 Tap and tap wrenches UNC UNF and metric

2 sets 77 Hacksaw blade (consumable)

As required

21 Set of stock and dies-UNC, UNF and metric

2 sets 78 Snip straight and bent 200mm

2 nos each

22 Surface plate 60cm x 60cm

1 no. 79 Arbor press 1 ton 1 no

23 Hand reamers adjustable 10.5 to 11.25mm, 11.25 to 12.75mm, 12.75 to 14.25mm, 14.25 to 15.75mm

2 sets 80 Triple leg grip puller with bearings attachment screw/hydraulic Powered max. Spread 80, 160, 250, 450 mm

1 no.

24 Work bench each 250 x 120x60 with 4 bench vices 12 cm jaw

1 no. 81 Air impact wrench 1 no.

25 Air ratchet 1 no 82 Air chisel 1no. 26 Air blow gun 1 no. 83 Tubular spanner 6mm to

22mm set of 8 pieces 1 set

27 C. V. Joint units of 3 different types

4 sets 84 Tube valve insert key 2 nos

28 Two post lifter 3 ton capacity

1 no. 85 Circlip plier 15cm contracting type

1 no

29 Surface gauge with dial test indicator plunger type

1 no 86 Bearing puller screw powered/ hydraulic

1 no

28

0.01mm powered with attachments Max spread 80, 200 and 300mm

30 Plier side cutting 15cm 1 no 87 Chain and pulley block 3000 kg. Capacity electric type

1 no.

31 Plier flat nose 15cm 1 no 88 Hydraulic jack with trolley capacity 3 Ton

1 no

32 Telescopic gauge 89 Internal Micrometer 5mm to 30mm

1 no

33 Outside Micrometer 0 to 25mm

1 no 90 Depth micrometer 0 to 25mm

1 no


1 no 91 Thread Micrometer 0 to 25mm

1 no


1 no 92 VernierCaliper 200mm 1 no


1 no 93 Dial vernier calliper 300mm

1 no

37 Dial gauge type 1 Gr. A(complete with clamping devices and stand)

1 no 94 Vernier depth gauge 0 – 150mm

1 no

38 Surface gauge with dial test indicator plunger type 0.01mm

1 no 95 Vernier height gauge 500mm

2 nos

39 Cylinder bore gauge capacity 20 to 160mm

1 no 96 Engineers Stethoscope 4 nos

40 Vacuum gauge to read0 to 760mm of Hg

1 no 97 Distributors 2 nos

41 Spanner for spark plugs 14 mm

1 no 98 Carburettor (two different types)

1 each

42 Valve spring compressor 1 no 99 Different types of Injectors

1 each

43 Tool valve grinding, suction type(consumable tool)

1 no 100 Valve seat cutting tools complete with guides and pilot bar (all angles) in a box

1 set

44 Engine management system’s sensors and actuators

1 set 101 Compression testing gauge to read 0 to 115 kg/sq cm

1 no

29

45 Valve key inserter 1 no 102 Piston ring filer 1 no 46 Screw jack 1 ton capacity

double lift 1 no 103 Stud remover 1 no

47 Piston ring compressor &ring expander

1 no 104 DMM auto range 1 no

48 Pliers water pump 250mm long

1 no 105 Injectors. of diesel engines

1 no

49 Petrol injector 1 no 106 Petrol fuel pump of MPFI system

1 no

50 Piston ring compressors 1 no 107 Valve spring lifter 1 no 51 Fuel injection pump one

with pneumatic governor, one with RQ governor and one with RSV governor

1 no 108 Triple leg grip puller with bearing attachment screw/hydraulic powered max. Spread 80, 160, 50 450mm

1 no

52 Petrol engine (4 strokes, Multi Cylinder) of different makes in running condition. (3nos. with MPFI System & 1 Nos. with Carburettor)

4 no 109 Diesel engine (4 stroke, Multi Cylinder) of different makes in running condition (CRDI engine(Vehicle type) -01No,Staionary engine-01 No, Truck engine-01 No)

1 no Each

53 Cut model of 4 stroke petrol engine on stand

1 no 110 Nipple forming tool to form nipple on high pressure pipe lines 6.8 and 10 mm dia

1 no

54 Cut model of 4 stroke diesel engine on stand

1 no 111 Injector testing set (hand operated)

1 no

55 Engine cranker with 12V and 24 V Ac to DC Power supply system

1 no 112 Injector dismantling jig with mounting bench

1 no.

56 Engine scanner 1 no 113 Injector holders 1 no 57 Different types of Fuel

Injection Pumps 1 each 114 FIP test Bench along with

a set of special tools for repairing & Testing different types of FIPs

1 no.

115 Steel Almirah 6ʼ Height 4 no

30

ANNEXURE-III

12. GUIDELINES FOR INSTRUCTORS AND ASSESSORS 1. Due care to be taken for proper & inclusive delivery among the batch. Some of the following method of delivery may be adopted:

A) LECTURE B) LESSON C) DEMONSTRATION D) PRACTICE E) GROUP DISCUSSION F) DISCUSSION WITH PEER GROUP

3. Maximum utilization of latest form of training viz., audio visual aids, integration of IT, etc. May be adopted. 4. The total hours to be devoted against each topic may be decided with due diligence to safety & with prioritizing transfer of required skills. 5. Assessment may be based on following instructions:-

Sl. No.

Question on different aspect Weightage in %age

1 Knowledge 15 2 Understanding 15 3 Practical Execution 70

1. Due weightage to be given to all the topics under the syllabus while assessing.

LIST OF TRADE COMMITTEE MEMBERS Sl. No.

Name S/Shri

Designation Organization Mentor Council Designation

1. A. Ramesh Professor IIT Chennai Chairman 2. TC Saravanabava DDG(AT) DGE&T, HQ, New Delhi Mentor 3. K Srinivasa Rao JDT CSTARI, Kolkata Team Leader 4. Yuvaraj C DDT ATI, Chennai Member 5 V.Krishna Shankar GM Ashok Leyland Member 6 G.Sathiskumar Senior Mgr Ashok Leyland Member 7 Dr.Abhjit KR Consultant NATRIP Member

31

Mandal 8 M.Sivaraman Consultant Delphi TVS Member 9 Mohan Kumar Manager TAFE, Chennai Member 10 Kanchi

Purushotham, Manager Quality Prabha Engineers, Hosur Member

11 Sunil Bagwe, Paint shop Head Prabha Engineers, Hosur Member 12 G.M.Cholanrajan Sr.Manager-

Technical Training

Lanson Toyota, Chennai-107 Member

13 Sunil Kumar S.R, Assistant Manager

Toyota Kirloskar Motor Pvt Ltd Karnataka, 562 109

Member

14 Shri S.Arul Selvan Asst Professor Dept Auto Engg, M.I.T, Anna University, Chennai.

Member

15 Shri S. Jayaraj, Asst Professor Dept Auto Engg, M.I.T, Anna University, Chennai.

Member

16 Shri R. Lakshmanan Training Mgr Bosch Ltd, Bangalore Member 17 Shri V.Vadivelan Consultant NATRIP, Global Automotive

Research centre, Chennai Member

18 Shri B. Gridharan Managing Director

Visa Diesel Service, Chennai Member

19 Shri VKR. Vadivelan

President Two Wheeler workshop owners Association, Chennai

Member

20 P. Marveldass, DDT (Electronics)

ATI, Chennai Member

21 Swamy S.M ,. Senior Officer, Training Dept

Toyota Kirloskar Motor Pvt Ltd Karnataka, 562 109

Member

22 Shri Suresh Babu Service Manager, Body & Paint shop

ABT Maruti, Chennai-32 Member

23 M. Veerasamy Works Manager Vishnu Cars Pvt Ltd, Chennai-43

Member

24 P.Senthil Kumar, Service Manager DSC Motor Pvt Ltd., Chennai-15

Member

25 Shri T.Selvan, Manager Body shop

DSC Motor Pvt Ltd., Chennai-15

Member

26 G Venkatesh ADT ATI(V), Hyderabad Member 27 SP Rewaskar ADT ATI(V), Hyderabad Member 28 N Ramesh kumar TO CTI, Chennai Member

32

29 R Rajeshkanna TO ATI, Chennai Member 30.

Akhilesh Pandey TO ATI, Mumbai Member

31 TN Rudra TO ATI, Howrah Member 32 A. Duraichamy Assistant

Training Officer (ATO)

Govt ITI Coimbatore Member

33 Gurcharan Singh, ADT ATI, Ludhiana Member 34 O.R. Arjun Mohan, AE Agricultural Engg. Dept,

Chennai Member

35 R.Murugesan, AE Agricultural Engg. Dept, Chennai

Member

36 K.Thaniyarasu ATO Govt ITI Trichy Member 37 W. Nirmal Kumar

Israel ATO Govt ITI Trichy Member

38.

N. Duraimurugan ATO Govt ITI Guindy Member

39.

K. Ravindranath ATO Govt. ITI, Ambattur Member

40.

K. Veerappan ATO Govt. ITI, Nagapattinam Member

41 V.Palanikumar ATO Govt ITI, Pudukottai. Member 42 H.S.Kalra Principal Govt ITI Chandigarh Member 43 B Ramarao ATO Govt ITI, Vizag , AP Member 44 Suresh Naik ATO Govt ITI, Mangalore ,

Karnataka Member

45 ND Zaware Principal ITI, Pimpri-Chinchwad Member 46 RM Gotmare TO ITI, Gowandi, Maharastra Member 47 Pranjit Das, DDT Govt ITI Assam Member 48 M. Madaswamy Principal Ramco, ITC, Rajapalayam,

TN Member

49 Damachadramouli Agricultural Er SFMT & TI Hyderabd Member 50 V. Gopalakrishnan Training Officer, Co-ordinator, NIMI,

Chennai.

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