REDESIGNED MODULES FOR THE SECTOR OF AUTOMOBILE UNDER MODULAR EMPLOYABLE SKILLS (MES) Redesigned in - 2014 By Government of India Directorate General of Employment & Training Ministry of Labour & Employment (DGE&T) GENERAL INFORMATION FOR ADVANCED CAR REPAIR Name of Sector AUTOMOBILE Name of Module Automotive Service and Repair advance level 1 MES Code AUR 813 Competency as per N C O Code Duration of Course Entry Qualification 1000 Hrs of Minimum 10th Std Pass., 18 years of Age Trainee + AUR 710 Unit size (No. of Trainees) 20 Power Norms 6 KW - (a) Class Room: 1 KW (b) Workshop: 5 KW Space Norms(Workshop (a) Class Room: 30 Sq. meter @ 1.5 sq. meter per trainee (b) Workshop: OEM authorized service Workshop and Class Room) Job Profile Service Mechanic Objective 1.Produce Service Mechanic for automotive workshop by pinning with following Employability skills: (i)Skill to carry out disassembly assembly and repair of Chassis transmission and HVAC systems 1.Diagnosis, repair and maintenance of Chassis transmission and HVAC systems. Terminal competency Instructor Qualification Desirable Qualification Degree in Automobile/ Mechanical Engg. With one year relevant experience OR Diploma in Automobile/ Mechanical Engg. With two year relevant experience OR NTC/NAC in Automobile trade group with three years of relevant experience Craft Instructor Certificate(CIC) Course Contents for Module -3 Advanced Car Repair (AUR206B) Practical Competencies Underpinning Knowledge(Theory) Units & Definition of force, work, power, torque & pressure. Power flow from engine to wheels Description of single plate clutch. Functions of different parts of the clutch assembly. Clutch linings material. Power flow in clutch plate. Clutch operating manual& hydraulic Clutch faults Type of gears and application-advantages disadvantages-gear ratio Types of gear box Working principle of synchromesh gear boxes Gear selection mechanism Lubrication of transmission system Gear box faults Check and correct the steering geometry with instruments Types of bearings, maintenance, their characteristics & application Remove and refit steering boxes from vehicle Working principle velocity joints Working principle of differential CHASSIS SYSTEM Identify different parts of chassis Identify different equipments Remove gear box from vehicle, dismantle, check, rectify, fill lubricating oil & assemble Align gear selector fork Remove CV Joint, lubricate & refit & Function of Clutch, Various Type of Clutch release mechanism Remove clutch plate from vehicle, check for defects & rectify/replace & refit Clutch play Adjustment procedure tools Dismantle, Remove rear axle assembly dismantle of crown wheel, pinion and bearings, clean parts. Check tooth contact in the crown and pinion and adjust backlash & Assemble rear axle assembly mechanisms- of their and constant Check and top-up oil in steering box. Faults in differential, C.V.Joints & drive shafts Check and adjusting steering wheel play and backlash. Function of Steering system Overhaul hydraulic power assisted steering system – pump, control valve & cylinder. Rack & Pinion Steering System Hydraulic Power Steering System Electronic Power Steering System Repair Electronic power steering system Overhauling and inspection of shackle, leaf spring, front and rear suspension. Wheel Alignment - Camber, Caster & Toe-in , Toe adjustment Front & Rear Wheels Function of Suspension System Components of Suspension Overhauling and inspection of front and rear suspension. Types of Suspension Systems Removing, inspection and assembling of shock absorber and strut assy and other suspension parts. Inspection of Suspension System Noise vibration and harshness (NVH) Basics Lubricating a suspension system. Cycle Identifying and Troubleshooting of NVH problems in vehicles Frequency (Hertz) Amplitude Free Vibration Forced Vibration System Heating Ventilation Air Conditioning Natural Frequency (HVAC) Resonance Identification of Air conditioning components, Performance test on Damping A/c unit, Road test procedure for identifying Checking Charged state of NVH related problems refrigerant, Inspecting & adjusting an engine drive belt, Replacing an engine drive belt. Heating Ventilation Air Conditioning Checking a heating system, (HVAC) Compressor rotation test, air Gap check, AC System Layout & Components Refrigerant recovery –evacuating explanation –charging of A/c system. Location of various AC Replenishing compressor oil level. components in vehicle Auto AC HVAC Troubleshooting, diagnosis Diagnosis & Repair of AC system and repair for Recharging AC refrigent using No cooling or warm air, recovery machine Cool air comes out only Compressor oil (Lubricant), intermittently, property and quantity. AC system performance Insufficient cooling, inspection Abnormal noise from compressor, Heating Ventilation Air Conditioning (HVAC) legislation, Magnetic clutch, condenser, Vehicle heating, ventilation & evaporator, Blower motor. cooling systems, Basic air Diagnosis test for AC conditioning principles, AirPerformance conditioning capacity, Airconditioning refrigerant, Humidity High and low pressure test Description and function of Fixed orifice, Control devices, Thermostatic expansion valve system, Thermal expansion valves, Air-conditioning compressors, Condensers & evaporators, Receiver drier, Lines & hoses, thermostat, Refrigerants, Pressure switches, Heating elements Air-conditioning ECU, Ambient air temperature sensor, Automatic climate control sensors, Evaporator temperature sensor, Blower speed control, Ventilation systems.