ITI's which provides courses for Mechanic Repair & Maintenance of Light Vehicles

Sem. I

Sr. No.

Subjects of Study

Trade Practical

Trade Theory

1

Familiarization with institute, Importance of the trade Machinery used in Trade. Types of work done by the students in the Institute-shop floor of the Institute.

Introduction to Central Outer Vehicle Acts & Rules. General introduction to the course-duration of the course & course content.

2

Description of safety equipment their use safety rules to be observed in an Automobiles repair shop.

Importance of safety & general precautions to be observed in the shop, fire extinguishers used for different types of fire storing & handling of Inflammable materials elementary first aid.

3

General servicing of vehicles washing, cleaning, oiling, greasing and lubrication of vehicle.

General description of motor vehicles major assemblies description location and function.

4

Inspection of under carriage of vehicle. Tightening all loose bolts & nuts-use of hydraulic jacks hoist and horses used in the shop selecting materials for packing cutting packing’s and gaskets practice in use of locking devices.

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5

Removing wheels from vehicle, dismantling tyres and tubes checking puncture assembling inflating to correct pressure.

Description of wheels and tyres types selection of tyres, ply rating, inflation pressure and carrying capacity, storage of tyres.

6

Inspection the frame checking alignment of frame servicing of spring replacing new bushes in shackle pins changing hushes in shock absorbers-cleaning & lubrication of wheel bearings, adjusting wheel bearings

Frames-description and function common troubles conventional suspension system

7

Removing kingpins and bushes replacing new bushes & plus after removing bushes & lubrication of king pin bushes in the front, independent suspension system.

Description of different types of Independent suspension system special features in each system maintenance and lubrication of front suspension system.

8

Inspection and overhaul front & rear suspension rear springs, coil spring torsion bars, check up main axle for alignment.

The front axle description & functions types of steering knuckles arrangement of steering knuckle joint general layout of steering linkages.

9

Inspect and adjust steering linkages, after replacement of worn parts alignment of steering wheels with respect to front wheel, check and correct toe-in

Description of different types of steering boxes

10

Inspect and overhaul steering boxes adjusting steering gear backlash, and end play check and adjust toe-in, camber angles checking king-pin angle & caster angle with special gauges.

Description of Ackerman’s angle, caster, camber toe-in and toe-out on turns, purpose and effects of these angles.

11

Adjusting brake pedal play dismantling wheel break assembly cleaning and inspecting adjusting brake shoes for proper clearances, bleeding hydraulic brakes & Disk brakes.

Arrangement of brakes in cars and trucks-description of hand brakes, its purposes layout of mechanical and hydraulic breaking system in cars.

12

Removing master cylinder, dismantling cleaning and inspection of parts assembling and testing bleeding the braking system after cleaning the pipelines.

Master cylinders common troubles & remedy. Engine Exhaust brakes. T.B. Valves used in light vehicles.

13

Dismantling wheel brake assembly removing old lining & fitting new lining on the brake shoe removing, cleaning of brake drums inspecting wheel cylinders & brake drums-fitting new cups and brake hosepipes

Brake lining types of uses relining the brake shoes precautions to be observed wheel cylinders description function and types brake fluids.

14

Trouble tracing in braking system of a vehicle adjusting brakes and balancing all four wheel brakes, precautions to be observed while testing brakes points to be remember while preparing the vehicle for brake certificate.

Brake testing efficiency of brakes braking distance, weight transference during braking a vehicle common trouble in brakes & their remedies.

15

Adjusting clutch pedal play removing gear box and clutch assembly from vehicle. Dismantling clutch assembly, cleaning inspecting parts.

Layout of transmission system description of single plate clutch different types of clutches used in vehicle.

16

Removing & fitting of new pilot bearing, removing & fitting of ring gear in fly wheel relining a clutch plate.

Clutch linings types materials used bonded & riveted lining clutch plate.

17

Assembling of pressure plate adjusting the fingers checking run out of fly wheel and aligning clutch assembly with flywheel.

Fluid coupling description operation & advantage of using fluid coupling common troubles and remedy.

18

Dismantling a synchromesh gear box, cleaning, inspecting parts replacing worn out defective parts assembling & testing for correct performance identifying noises from gear boxes and rectifying.

Synchromesh gear box advantages description, operation in different gear positions common trouble and remedy types of synchromesh gearboxes their special features.

19

Dismantling cleaning and assembling of gear shift mechanism changing oil in gear box studying gear ratios in the gear box.

Lubrication of gearbox constant mesh gearbox description and advantages.

20

Removing open type propeller shaft from vehicle, removing universal joints cleaning replacing worn out parts, re-assembling & refitting to vehicle-special precautions while removing torque tube drive shaft.

Universal joints and propeller shaft-open and closed type propellers shaft types of universal joints, care and maintenance.

Project Work

Sem. II

Trade Practical

Trade Theory

1

Removing rear axle assembly from vehicle, dismantling, cleaning, inspecting parts for wear and damage, cutting packing’s/gaskets- removing tail pinion and bearings cleaning and inspection of oil-seals and bearings.

Description & functions of final drive assembly crown wheel and tail pinion hypoid gear and its lubrication descriptions of differential and its principle of operation.

2

Checking tooth contact in crown land pinion and adjusting back-lash assembling the rear axle assembly on vehicles and testing.

Description and function of differential gears types tooth contact and back lash, preloading adjustment.

3

Trouble shooting in the transmission system of vehicle detecting noises from clutch, gear box, universal joints and rear axle assembly dismantling transfer case from vehicle, cleaning, inspecting replacing worn parts, reassembling & fitting to vehicle.

Description & purpose of optional fittings such as transfer case free wheel power take off common troubles in these unit and their remedy care and maintenance.

4

Dismantling of unserviceable engine cleaning studying the parts in the engine and reassembling the engine practice in the use of correct tools and right procedure.

Description of internal and external combustion engineers, different types of I.C. engines. Important working parts in the engine, the 4-stroke cycle of operation.

5

Dismantling an unserviceable engine, cleaning of parts in the engine, measuring of cylinder bore

Two-stroke cycle operation difference between 4 stroke & 2 stroke cycle engines.

6

Checking compression pressure in a running engine dismantling the cylinder head from the engine, decarbonising the cylinder head, removing the valves cleaning re assembling and adjusting tappets.

Description & function of cylinder block cylinder head cylinder liners reconditioning of cylinder heads.

7

Removing pistons and connecting rods from engine, dismantling, cleaning, inspecting, checking clearances installing rings and pistons pins.

Description & functions of different types of pistons, piston rings and piston pins common troubles and remedy.

8

Removing connecting rod assembly, cleaning & checking bearing clearances, replacing bearing shells, setting correct clearances.

Description & functions of connecting rod.

9

Assembling crankshaft, main bearings, connecting rods and piston assembly in the engine, fitting cylinder head and starting the engine.

Firing order of the different types engine and crank shaft balancing description of the fly wheel and its function crank case and oil sump.

10

Checking cooling system for overheating cleaning radiators, dismantling, cleaning, assembling and testing water pump, reverse flushing the system.

Engine cooling methods air & water-cooling radiators, pump, thermostats and fan, their description, function care.

11

Studying the lubrication oil flow system in engine, overhauling oil filters, oil pump and setting the pressure release valve for correct oil pressure maintenance and repairs in the lubrication system in engine.

Need for lubrication of engine parts-friction lubrication oil and its properties, lubrication system types full flow and by pass flow system, components in lubrication system oil filters and pumps, types their special features and uses.

12

Simple repairs in fuel feed system overhauling of petrol pump, carburetors, fuel filters & air cleaners.

Fuel feed system in motor vehicles description and layout of the system description, operation, maintenance of fuel pump & fuel injector’s filters and carburetors.

13

Repairs to solex and S.U. carburetors adjusting float level and slow speed adjustments studying the flow circuit in carburetors.

Types of carburettors special features advantages different adjustments & their purposes.

14

Practice in engine up in a vehicle-testing vacuum and compression of engine, adjusting tappets setting, ignition timing & adjusting carburetors for slow speeds by using of tachometer.

Explanation of engine tunes up job-description of compressions & vacuum testing description of ignition timing setting and slow speed adjustment.

15

Practice in joining wires and soldering forming simple electrical circuits measuring of current, voltage & resistance cleaning and topping up of a lead acid battery testing battery with hydrometer-cell tester, connecting battery to charge.

Simple electrical circuit, series & parallel, circuits identification of alternating current and direct/current meters insulators conductors types of resistance.

16

Studying electrical circuit in the engine assembly checking loose open and short circuits cleaning and testing spark plugs.

Description of electrical circuits-ignition system and the components purpose of induction coil, condenser, spark plugs common troubles in ignition circuit & remedy.

17

Removing dynamo alternators from vehicle, dismantling cleaning, checking for defects, assembling and testing for motoring action of dynamo & fitting to vehicles.

Description of charging circuit operation of dynamo alternatives regulator unit ignition warning lamp troubles and remedy in charging system.

18

Removing starter motor from vehicle and overhauling the starter motor testing of starter motor.

Description of starter motor circuit constructional details of starter motor solenoid switches, common troubles and remedy in starter circuit.

19

Practice on unserviceable diesel engine-removing jammed nuts, broken studs and reconditioning damaged threaded holes-removing cylinder head connecting rods, and pistons cleaning, inspecting and refitting them.

History & Development of compression ignition engines classification of C.I. Engine Advantages and dis- advantages over petrol engines, constructional details of single and multi cylinder engines.

20

Practice in starting & stopping of vehicle engines, general maintenance of engines-checking oil, fuel, water levels and accessories of diesel engines.

The four stroke and two stroke diesels- Engineuni-flow and loop scavenging constant volume cycles the diesel cycle, indicator diagrams.

21

Bleeding fuel lines for air locks repairing fuel leaks in the pipe lines and unions cleaning of oil and air filters in diesel engines.

Fuel used in diesel engines, specification of diesel fuels, importance of clean fuel, Air fuel ratio, general layout of the fuel feed system in diesel engines.

22

Cleaning and servicing of primary fuel filters and pressure stage filters, removing feed pump dismantling cleaning, reassembling, re-fitting and testing the feed pump.

Types of CRDI system fuel injection systems air injection & airless injection fuel feed pumps description, operation-common troubles and remedy.

23

Dismantling an unserviceable fuel injection pump, cleaning inspecting, studying parts and reassembling. Removing F.I. pumps from running engine changing oil in fitting back to engine, testing the governor & setting injection timing.

Fuel injection pumps description & operation types adjustments in the pumps phasing and calibration of pumps checking and fixing injection-timing governors types their description and operation starting and adjusting slow speed.

34

Testing injectors for missing on the vehicle removing dismantling, cleaning, inspecting replacing defective parts reassembling the injectors and testing them. Demonstrating retrofitting of vehicles CNG & LPG system Euro II, III, IV.

Injector nozzles types description, operation testing of injector’s special features of pintle nozzles. Emission standard, Catalyzing  converter, noise pollution, Battery operated vehicle, Hy-bride vehicle.