ITI's which provides courses for Mechanic (Motor Vehicle)

Sem. I

Sr. No.

Subjects of Study

Trade Practical

Trade Theory

1

Familiarisation with institute, Job opportunities in the automobile sector, Machinery used in Trade. Types of work done by the students in the shop floor

Admission & introduction to the trade

2

Practical related to Safety and Health, Importance of maintenance and cleanliness of Workshop.

Occupational Safety & Health 

3

Practice using all marking aids, like steel rule with spring calipers, dividers, scriber, punches, Chisel etc.,

Hand & Power Tools

4

Measuring practice on Cam height, Camshaft Journal dia, crankshaft journal dia, Valve stem dia, piston diameter, and piston pin dia with outside Micrometers

Systems of measurement, Description, care & use of - Micrometers

5

Practice on General cleaning, checking and use of nut, bolts, & studs etc.,

Fasteners, Cutting tools, Limits, Fits & Tolerances

6

Practice on Marking and Drilling clear and Blind Holes, Sharpening of Twist Drills Safety precautions to be observed while using a drilling machine.

Drilling machine, Taps and Dies

7

Practice on making Rectangular Tray. Pipe bending, Fitting nipples unions in pipes. Soldering and Brazing of Pipes.

Sheet metal - State the various common metal Sheets used in Sheet Metal shop Sheet metal operations - Shearing, bending, Drawing, Squeezing

8

Practice in joining wires using soldering Iron, Construction of simple electrical circuits, Measuring of current, voltage and resistance using digital multimeter, practice continuity test for fuses, jumper wires, fusible links, circuit breakers

Basic electricity, Electricity principles, Ground connections, Ohm's law, Voltage, Current, Resistance, Power, Energy. Voltmeter, ammeter, Ohmmeter Mulitmeter, Conductors & insulators, Wires, Shielding, Length vs. resistance, Resistor ratings. 

9

Diagnose series, parallel, series parallel circuits using Ohm’s law, Check electrical circuit with a test lamp, perform voltage drop test in circuits using multimeter, measure current flow using multimeter /ammeter, use of service manual wiring diagram for troubleshooting.

Fuses & circuit breakers, Ballast resistor, Stripping wire insulation, cable colour codes and sizes, Resistors in Series circuits , Parallel circuits and Series-parallel circuits, Electrostatic effects, Capacitors and its applications, Capacitors in series and parallel.

10

Cleaning and topping up of a lead Acid battery, Testing battery with hydrometer, Connecting battery to a charger for battery charging, Inspecting & testing a battery after charging, Measure and Diagnose the cause(s) of excessive Key-off battery drain (parasitic draw) and do corrective action.

Description of Chemical effects, Batteries & cells, Lead acid batteries & Stay Maintenance Free (SMF) batteries, Magnetic effects, Heating effects, Thermo-electric energy, Thermisters, Thermo couples, Electrochemical energy, Photovoltaic energy, Piezo-electric energy, Electromagnetic induction, Relays, Solenoids, Primary & Secondary windings, Transformers, stator and rotor coils.

11

Identify and test power and signal connectors for continuity, Identify and test different type of Diodes, NPN & PNP Transistors for its functionality,

Basic electronics: Description of Semi conductors, Solid state devices- Diodes, Transistors, Thyristors, Uni Junction Transistors (UJT), Metal Oxide Field Effect Transistors (MOSFETs), Logic gates-OR, AND & NOT andLogic gates using switches.

12

Practice to make straight beads and Butt, Lap & T joints Manual Metal Arc Welding.

Introduction to welding and Heat Treatment

13

Practice on Liquid penetrates testing method and Magnetic particle testing method.

Non-destructive Testing Methods- Importance of Non-Destructive Testing In Automotive Industry, Definition of NDT, Liquid penetrate and Magnetic particle testing method – Portable Yoke method

14

Identification of different type of Vehicle. Demonstration of vehicle specification data; Identification of vehicle information Number (VIN).

Auto Industry - History, leading manufacturers, development in automobile industry, trends, new product.

Sem. II

Trade Practical

Trade Theory

1

Identification of parts in a diesel engine of LMV/ HMV Practice on starting and stopping of diesel engines.

Introduction to Engine

2

Overhauling of cylinder head assembly, Use of service manual for clearance and other parameters, Practice on removing rocker arm assembly manifolds

Diesel Engine Components, Valves & Valve Trains,

3

Overhauling of crankshaft, Use of service manual for clearance and other parameters

Description and function of Crank shaft, camshaft, Engine bearings- classification and location – materials used & composition of bearing materials- Shell bearing and their advantages

4

Checking of flywheel and mounting flanges, spigot, bearing. Check vibration damper for defects, Practice on removing cam shaft from engine block, Check for bend & twist of camshaft.

Description and function of the fly wheel and vibration damper. Crank case & oil pump, gears timing mark, Chain sprockets, chain tensioner etc.

5

Cleaning and Checking of cylinder blocks Surface for any crack, flatness, Measure cylinder bore for taper & ovality, clean oil gallery passage and oil pipe line, Bore

Description of Cylinder block, Cylinder block construction, and Different type of Cylinder sleeves (liner).

6

Reassemble all parts of engine in correct Sequence and torque all bolts and nuts as per workshop manual of the engine.

Engine assembly procedure with aid of special tools and gauges used for engine assembling.

7

Practice on Checking &Top up coolant, Draining & refilling coolant, Checking / replacing a coolant hose, Testing cooling system pressure, Practice on Removing & replacing radiator/ thermostat.

Need for Cooling systems, Basic cooling system components, Need for lubrication system

8

Practice on Dismantling air compressor and exhauster and cleaning all parts – measuring wear in the cylinder, reassembling all parts and fitting them in the engine. 

Intake & exhaust systems, Intake system components, Exhaust system components

9

Practice on removing & Cleaning fuel tanks, checking leaks in the fuel lines, soldering & repairing pipe lines and Unions, brazing nipples to high pressure line studying the fuel feed system in diesel engines, draining of water separators.

Diesel Fuel Systems, Diesel fuel system components, Electronic Diesel control-

10

Practice on Start engine adjust idling speed and damping device in pneumatic governor and venture control unit checking Performance of engine with off load adjusting timings.

Marine & Stationary Engine

11

Monitoring emissions procedures by use of Engine gas analyser or Diesel smoke meter

Emission Control:- Vehicle emissions Standards - Euro and Bhart II, III, IV, V Sources of emission, Combustion, Combustion chamber design.

12

Practice on removing alternator from vehicle dismantling, cleaning checking for defects, assembling and testing for motoring action of alternator & fitting to vehicles. 

Description .of charging circuit operation of alternators, regulator unit, ignition warning lamp- troubles and remedy in charging system

13

Practice on troubleshooting in LMV/HMV for Engine Not starting –Mechanical & Electrical causes, High fuel consumption, Engine overheating, Low Power Generation, Excessive oil consumption, Low/High Engine Oil Pressure, Engine Noise.

Troubleshooting : Causes and remedy for Engine Not starting – Mechanical & Electrical causes, High fuel consumption, Engine overheating, Low Power Generation, Excessive oil consumption, Low/High Engine Oil Pressure, Engine Noise. 

Sem. III

Trade Practical

Trade Theory

1

Identification of different major components of Heavy vehicle and their function & placement study of different make lorry/bus/tractor in Institute with different dealers or organizations.

Introduction: Study of different major components & assemblies of heavy vehicle, and different make (indigenous). Name plate-constructional differences and their merits. leading manufacturers in Heavy vehicle Industry

2

Practice on adjusting clutch pedal play removing gearbox and clutch assembly from Light & Heavy Vehicle. Dismantling clutch assembly, cleaning inspecting parts.

Clutches & Manual Transmissions, Clutch components, Manual transmissions, Gearbox layout & operation

3

Practice on Removing open type propeller shaft from vehicle, Practice on removing universal joints, cleaning replacing worn out parts, re-assembling & refitting to vehicle

Final Drive & Drive Shafts, Rear-wheel drive, Four-wheel drive, All-wheel drive.

4

Identification of Automatic transmission components Checking automatic transmission fluid, Changing transmission fluid & filter

Automatic Transmissions, Planetary gearing, Electronic control transmission, Hydraulic system & controls, Valve types & functions, Pressure regulation, continuously variable transmission (C.V.T.)

5

Following practical to be Practiced On Light & Heavy Vehicle. Practice on removing the drop arm, Check and adjust the turning angle, align the drop arm and steering wheel with the front wheel.

Steering Systems, Steering boxes & columns, Steering arms & components, Wheel alignment fundamentals,

6

Following practical to be Practiced On Light & Heavy Vehicle Practice on visual Inspection of chassis frame for crack, bent and twists.

Suspension Systems:- Principles of suspension, Suspension force, Unsprung weight, Wheel unit location, Dampening.

7

Practice on removing wheels from light & Heavy vehicle, dismantling tyres and tubes checking puncture.

Wheels & Tyres-Wheel types & sizes Wheels, Rim sizes & designations, Types of wheels; Tyre types & characteristics

8

Practice on Adjusting brake pedal play, Overhauling and inspection of tandem master cylinder assembly, Overhauling and inspection of front and rear brake assembly, overhauling and inspection of wheel cylinder assembly

Braking Systems, Brake type, Braking system components, Drum brakes & component, Disc brakes & components, Antilock braking system & components,

9

Trouble shooting Practice with Heavy vehicle for Engine Not starting – Mechanical & Electrical causes, High fuel consumption, Engine overheating, Low Power Generation, Excessive oil consumption, Low/High Engine Oil Pressure, Engine Noise.

Study of Motor Vehicle act Rules & Regulation-Laws governing to use of motor vehicle & vehicle transport, Licensing of drivers & conductors, Registration of vehicle, Traffic rules, Signals & controls, Accidents, Causes & analysis.

Sem. IV

Trade Practical

Trade Theory

1

Identification of petrol Engine components. Practice on starting and stopping of petrol engines. Observe and report the reading of Tachometer, Odometer, temp and Fuel gauge under ideal and on load condition.

Petrol Engine Basics: 4-stroke spark-ignition engines, Spark-ignition engine components, Intake & exhaust systems, Intake system components, Gasoline Fuel Systems

2

Simple repairs in fuel feed system – overhauling of fuel pump, carburetors, fuel Filters and air cleaners. Repair to a car carburetors – adjusting float level and slow speed adjustments

Carburetor operation-Carburation, Carburetor systems, Metering jets, Accelerating, Carburetor barrels, Carbureted system components

3

Practice on Cleaning fuel tank, checking for leaks in Fuel tank. Identification of various components of MPFI system. Testing of MPFI components and replacement if necessary. Check delivery from fuel Pump. Replacing a fuel filter. 

Introduction to Electronic fuel injection (EFI) fuel supply system , Basic EFI principles, Air supply, Air volume, Multi-point injection systems (MPI/MPFI), Simultaneous injection, Efficient combustion EFI fuel supply system components.

4

Identification of Electronic control Unit. Set up for testing, Testing of Electronic Control Circuit.

Introduction to EFI Engine Management - EFI operation Modes of EFI, Electronic fuel injection, Idle speed control systems, Feedback & looping, Cold start systems, Air measurement, Air-flow monitoring, Variable intake manifold system, Electrical functions, EFI wiring diagram Electronic control unit (ECU)

5

Diagnosis- Possible causes and remedy for Engine cranks, but will not or hard to start, Poor fuel economy or engine performance

Ignition principles and Faraday’s laws,

Primary and secondary winding of transformer, Ignition components,  Spark plugs, Spark plug components, Vacuum & centrifugal units, Plug firing voltage, Induction.

6

Checking a charging system for the cause of undercharge, No charge, and over charge conditions. Removing & replacing an alternator, Inspection of rotor for ground, open circuit – field coil resistance, slip ring surface, Fan, bearing.

Charging system- The purpose of Charging system, charging system components, charging system circuit, Alternator principles, Alternating current, Alternator components, Rectification, Phase winding connections, Rotor circuit, Voltage regulation, System operating voltage

7

Removing starter motor from vehicle, and Performance test for pull-in test, Hold-in test, pinion (plunger) return test, No-load performance test.

Starting system- purpose of starting system, Staring system components, Starter motor principles, study of starter control circuits

8

9

Trace the light circuit - test bulbs, align head lamps, Aiming headlights. Changing a headlight bulb, Checking of a head light switch and to replace if faulty

Lighting system, Lamps/light bulbs, Lamp/light bulb information, LED lighting, Headlights-description of standard sealed beam, halogen sealed beam, composite and High intensity discharge (HID) headlights.

10

Identification of Air conditioning components, Performance test on A/c unit, Checking Charged state of refrigerant, Inspecting & adjusting an engine drive belt, Replacing an engine drive belt.

Heating Ventilation Air Conditioning (HVAC) legislation, Vehicle heating, ventilation & cooling systems, Basic air-conditioning principles, Air-conditioning capacity, Air-conditioning refrigerant, Humidity Description and function of Fixed orifice, Control devices, Thermostatic expansion valve system, Thermal expansion valves, Air-conditioning compressors

11

Trouble shooting and remedy for Horn- No horn operation, poor sound quality, horn sounds continuously and to replace the horn if faulty

Accessories: Horn circuit, wiper circuit, power window components and circuit. Power door lock circuit, automatic door lock circuit, remote keyless entry system circuit, antitheft system, immobilizer system. Navigation system, Car radio and cassette player, car videos

12

Driving Practice. Practice in straight driving on wide roads. Driving through lanes and curves. Practice in reversing. Practice overtaking another vehicle. Practice in driving through sand and wet surfaces. Practice in parking and Diagonal parking. 

Locating vehicle information, Obtaining & interpreting scan tool data, Using a repair manual, Using a shop manual, Using an owner's manual, Using a labor guide, Using a parts program, Using a service information program

Project Work