Job Role-AUTOMOTIVE SREVICE TECHNICIAN-2

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Binayak Sahoo

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Course Name : Job Role-AUTOMOTIVE SREVICE TECHNICIAN-2

Code(Credit) : ABC01(1-4-1)

Course Objectives

I. To perform skill automotive work in diagnostic, repairing and maintaining of mechanical and electrical system work on 4-wheeler vehicle and follow preventive maintenance duty of technical task relative to assign work reasonability.
II. Apply safe working practice in an automotive workshop.
III. Demonstrate knowledge of concept and principle of basic arithmetic, calculation and apply knowledge of specific area to perform practical operation.

Learning Outcomes

I. Assist the technician in identifying & diagnosis of the operational fault responsible for the root cause of the vehicle trouble.
II. Assist in taking necessary action post the root caused analysis to repair the vehicle.
III. Carry out the routine and scheduled maintenance.
IV. Carry out other maintenance activity on the vehicle which are not a part of schedule maintenance.
V. Carry out minor service and repair in the vehicle (Including mechanical and electrical aggregates).
VI. Plan and organise work requirement including various activities deliverable or work output required in the given time.
VII. Maintain set quality standard.
VIII. Use resource in the responsible manner (both equipment/material and manpower).
IX. Interact and communicate with colleague effectively including member of the own group as well other group.

Course Syllabus

Module 1:Safety.

Importance of safety during work.
Personal safety, vehicle or Component safety and environmental safety.

Module 2: Anatomy of 4-wheeler vehicle.

Introduction.
Segmentation of 4-wheeler vehicle.
Automobile 4-wheeler vehicle safety technology.

Practice: -Understanding of air bag safety standard.

Practice: -Demonstration of different companies model vehicle.

Module 3: Overview construction of 4-wheeler.

Introduction.
Component identification.

Variable valve technology.

Practice: - Peripheral part identification.

Practice: - Demonstration of body structure.

Practice: - Understanding of different companies VVT technology.

Module 4: Overview of SI & CI engine.

Introduction.
Diesel engine (CI).

Petrol engine (SI).

Engine component identification.
Classification of the engine.
Specification of the engine.

Petrol vs Diesel engine.
Basic engine terminology.

Practice: - Understanding of diesel engine system.

Practice: - Understanding of petrol engine.

Practice: - Engine component identification.

Practice: - Demonstration of engine position as per the drive system of the vehicle.

Practice: - Understanding of V-type engine configuration.

Module 5: System of the engine.

Air intake and exhaust system.
Fuel system.

Cooling system.

Lubricating system.

Practice: - Understanding of Turbocharger and supercharger.

Practice: -Understanding and dismantle the common rail direct injection system CRDI.

Practice: -Fuel injection pump FIP advancement.

Practice: -Visualization and understanding of oil line gallery.

Practice: -Understanding of thermostat valve operating function.

Module 6: Measurement of engine internal component and special tools identification.

Introduction.
Identification of engine special tools and measuring tools.

Step procedure to measurement of component,

Practice: -Overview and brief idea about the engine special tools and measuring tools.

Practice: -Standard procedure to take measurement as per the respective service manual.

Practice: -Engine block deck measurement.

Practice: -Replacement of engine oversize head gasket with measurement.

Project -Phase 1.

Measure engine components.

(Piston, Crankshaft, connecting rod, gudgen pin, camshaft, rocker arm, push rod, valve guide, block deck test, engine cylinder, oil clearance between main journal bearing and crank throw shaft, valve adjustment, crankshaft endplay) etc.

Module 7: Overhauling of diesel and petrol engine.

Standard overhauling procedure.
Dismantle and recondition the dead engine.

Oversize spare parts replacement.

Piston cylinder rod assembly.

Practice: -Engine dismantling procedure.

Practice: -Engine assembling procedure.

Practice: -Valve adjustment practice.

Practice: -Understanding of flywheel, intake and exhaust valve position during valve adjustment.

Practice: -Replacement of engine head gasket.

Project -Phase 2.

Dismantle and assemble the Hyundai 4-cylinder 1400cc engine.

Dismantle and assemble theEicher 3-cykinder diesel engine as per the respective manual.

Module 8: Electrical and electronic system.

Introduction.
Basics of automobile electrical component.

ISO symbols (International standardization for organization).

Introduction of electronic control unit ECU.
Basic circuit diagram of starting and charging system.

Practice-identification of electrical components (Fuse, relay, Battery, Relay, Fuse, Diode, Resister, Capacitor, Switch, Transistor, Solenoid, Harness connector, Sensors.

Practice-Interpretation and understanding of ISO symbol and circuit diagram.

Practice-ECU connector pin configuration.

Practice: -Use of multimeter, Thermometer.

Project -Phase 3.

Diagnose battery to starter motor supply.

Module 9: Braking and steering system.

Introduction.
Function and principle of braking and steering system.

Types of braking system.

Types of steering system.
Various components of steering system.
Anti-lock braking system ABS.

Practice: -Component identification of braking system.

Practice: -component identification of steering system.

Practice: -Dismantling and assembling of drum and disk brake.

Practice: -Dismantling and assembling recirculating ball bearing system.

Practice: -Demonstration of all types of breaking system.

Module 10: Chassis configuration suspension system.

Structure of chassis.
Anatomy of 4WD & 2WD chassis.

Function and working principle of suspension system.

Types of suspension system.

Practice: -Measurement of chassis.

Practice: -Demonstration of chassis structure as per the 4WD & 2WD vehicle.

Module 11:Overview construction of transmission system, clutch and propeller shaft.

Introduction.
Function and working principle of transmission system, clutch and propeller shaft.

Types of transmission system.

Types of clutch.

Practice: - Component identification and understanding of transmission, clutch and propeller shaft.

Practice: - Dismantle and assemble the synchronous mesh gear box.

Practice: - Dismantling procedure of multi-plate clutch.

Practice: - Understanding of propeller shaft position (front & Rear base).

Module 12: Wheel &tyre and axle configuration.

Introduction.
Wheel balancing.

Tyre specification.

Function of front and rear axle.
Function and working principle of differential.

Practice: -Component identification wheel hub and hub reduction axle.

Practice: -Demonstration of power transmission from engine to wheel.

Practice: -Dismantle and assemble procedure of differential.

Module 13: Interval scheduled maintenance.

Need of maintenance.
Introduction of changeable item or parts.

Practice: -Interpretation of maintenance chart.

Practice: -Inspection of the vehicle.

Practice: -Standard service maintenance with respect to the different companies model.

Practice: -Preparation of service report.

Project -Phase 4.

By following the service program, inspect the vehicle and short out the problem caused along with service report.

Project:

Measure engine components.

Dismantle and assemble the Hyundai 4-cylinder 1400cc engine.

Dismantle and assemble the Eicher 3-cykinder diesel engine as per the respective manual.

Diagnose battery to starter motor supply.

By following the service program, inspect the vehicle and short out the problem caused along with service report.

Project:

Measure engine components.

Dismantle and assemble the Hyundai 4-cylinder 1400cc engine.

Dismantle and assemble the Eicher 3-cykinder diesel engine as per the respective manual.

Diagnose battery to starter motor supply.

By following the service program, inspect the vehicle and short out the problem caused along with service report.

Session Plan

Session 1

LECTURE – Safety and job role model.

DEMO – Personal safety, Machine or Component safety and environmental safety.

Video tutorial-1. https://youtu.be/pUtYm0Ja0Ng

Video tutorial-2. https://youtu.be/_gmnTKq86OA

Session 14

Practice: -Engine dismantling procedure.

Practice: -Engine assembling procedure.

Practice: -Valve adjustment practice.

Video tutorial-1. https://youtu.be/OyklvRhzwKk

Video tutorial-2. https://youtu.be/mxMTPegt5D4

Session 13

LECTURE – Overhauling of diesel and petrol engine.

DEMO – Demonstration of workshop overhauling practice.

Video tutorial-1. https://youtu.be/fSHDyisbYZ8

Session 12

Practice: -Engine block deck measurement.

Practice: -Replacement of engine oversize head gasket with measurement.

Video tutorial-1. https://youtu.be/235BvFJw3Hc

Video tutorial-2. https://youtu.be/NhNAS1dHtGY

Session 11

Practice: -Overview and brief idea about the engine special tools and measuring tools.

Practice: -Standard procedure to take measurement as per the respective service manual.

Video tutorial-1. https://youtu.be/vkPlzmalvN4

https://youtu.be/StBc56ZifMs

Video tutorial-2. https://youtu.be/wFytmRTEo04

Session 10

LECTURE –Measurement of engine internal component and special tools identification.

DEMO – Understanding of all engine internal components.

Video tutorial-1. https://youtu.be/Mxv8Kv9iCwI

https://youtu.be/UubnxErZNsw

https://youtu.be/JrGeSt0Ks5g

Session 9

Practice: -Fuel injection pump FIP advancement.

Practice: -Visualization and understanding of oil line gallery.

Video tutorial-1. https://youtu.be/JSymXTP8HTg

Video tutorial-2. https://youtu.be/RcEDc9HraIU

Session 8

Practice: - Understanding of Turbocharger and supercharger.

Practice: -Understanding of thermostat valve operating function.

Practice: -Understanding and dismantle the common rail direct injection system CRDI.

Video tutorial-1. https://youtu.be/lrCwmpjR77U

Video tutorial-2 . https://youtu.be/_HclvBmwWgQ

Session 7

LECTURE – System of the engine.

DEMO –Brief idea about air intake and exhaust system, fuel system, lubricating system and cooling system.

Video tutorial-1. https://youtu.be/lWQQZCZf5H8 (intake and exhaust system)

https://youtu.be/mmmcj53TNic(lubrication system)

https://youtu.be/V7inC4lOpGs (cooling system)

https://youtu.be/3EwVHyKfNH0 (fuel system)

Session 6

Practice: - Understanding of diesel engine system.

Practice: - Understanding of petrol engine.

Practice: - Engine component identification.

Practice: - Demonstration of engine position as per the drive system of the vehicle.

Practice: - Understanding of V-type engine configuration.

Video tutorial-1. https://youtu.be/XVdZj2EDmhM

Session 5

LECTURE – Overview of SI & CI engine.

DEMO – Basic engine terminology of diesel and petrol engine.

Video tutorial-1. https://youtu.be/rlK7JIAz9WY

Session 4

Practice: - Peripheral part identification.

Practice: - Demonstration of body structure.

Practice: - Understanding of different companies VVT technology.

Video tutorial-1. https://youtu.be/ZuJMtW3xeNQ

Video tutorial-2. https://youtu.be/51WYFsr9zNQ

Session 3

LECTURE – Overview construction of 4-wheeler.

DEMO – Demonstration of all automotiveComponent identification.

Video tutorial-1. https://youtu.be/ralw-IZAaf0

Session 2

LECTURE –Segmentation of 4-wheeler vehicle.

DEMO –Demonstration of different companies model vehicle along with safety technology.

Practice - Understanding of air bag safety standard.

Video tutorial-1. https://youtu.be/gTnhRiMQSME

Session 15

Practice: -Understanding of flywheel, intake and exhaust valve position during valve adjustment.

Practice: -Replacement of engine head gasket.

Video tutorial-1. https://youtu.be/h2VhzUv61b8

Video tutorial-2. https://youtu.be/YL9QjN7AcW8

Session 16

LECTURE – Electrical and electronic system.

DEMO –Basics of automobile electrical component.

Video tutorial-1. https://youtu.be/KOLBGKMo3zQ

Session 17

Session – 17. (P-6HRS)

Practice- identification of electrical components (Fuse, relay, Battery, Relay, Fuse, Diode, Resister, Capacitor, Switch, Transistor, Solenoid, Harness connector, Sensors.

Practice-Interpretation and understanding of ISO symbol and circuit diagram.

Video tutorial-1. https://youtu.be/n9renPKEtUc

Video tutorial-2. https://youtu.be/BbmocfETTFo

Video tutorial-3. https://youtu.be/Kzm1XNl7okc