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AUTOMOBILE

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AUTOMOBILE
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.
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