Automobile CBT

CBT CURRICULUM
FOR
NVQ LEVELS 5 & 6

IN
AUTOMOBILE TECHNOLOGY
(CBT Curriculum Code: G50C001)
Developed by
Technical Education Development Project

Ministry of Youth Affairs & Skills Development
Edited by
University of Vocational Technology

No.100, Kandawala Road,
Ratmalana
Frist Publication -December 2010
COPYRIGHT
All rights reserved. This book, in whole or any part thereof, should not be reproduced, stored in a
retrieval system or transmitted in any form or by any means-electronic, photo copying, recording
or otherwise without the prior permission of Tertiary and Vocational Education
Commission (TVEC)
Copyrights © 2010, TVEC
Published by
Tertiary & Vocational Education Commission

354/2, Nipunatha Piyasa, Elvitigala Mawatha,
Colombo 5, Sri Lanka.
Tel: 0115849291
Fax: 0112555007
E-mail: info@tvec.gov.lk
Web: www.tvec.gov.lk
Funded by
Technical Education Development Project

ADB Loan No. 2197 - SRI (SF)
MINISTRY OF YOUTH AFFAIRS & SKILLS DEVELOPMENT
CBT Curriculum Code: G50C001 Endorsement Date : Revision No.: 0 Revision Date: Page i
29 th June 2011 13 th May 2012
PREFACE
.............................
Hector Hemachandra Dr. Tissa Jinasena Dr.T.A.Piyasiri

Project Director Chairman DirectorGeneral
Technical Education National Apprentice & Tertiary & Vocational
Development Project Industrial Training Authority EducationCommission
CBT Curriculum Code: G50C001 Endorsement Date : Revision No.: 0 Revision Date: Page ii
29 th June 2011 13 th May 2012
CURRICULUM OUTLINE FOR
(Code No. G50C001)
NATIONAL DIPLOMA IN AUTOMOBILE TECHNOLOGY AT NVQ LEVEL 5 & 6
Endorsement date: 29th June 2011 Date for review: 13th May 2012
Curriculum code: G50C001
4. Development Group Developed by - Mr. ......................................, Consultant, Technical

and National Industrial Education Development Project
Training Advisory
Committee : Edited by - University of Vocational Technology
NITAC
 Dr. Victor Mendis, Consultant

 Mr. Devaka Abesekara, Car Mart Ltd.
 Mr. Ananda Mapolagama, Diesel & Motor Engineering Co. Ltd.
 Mr. V.B. Jayasekara, CMT Engineering Service
 Mr. L.K. Peiris, Field Service Manager, David Peiris Motor Co. Ltd.
 Mr. D.L.A. Peiris, District Factory Inspecting Engineers
 Mr. S.U.K. Rubasinghe, TVEC
 Ms. Senani Wewala, University of Vocational Technology
 Mrs. D. C. Wahalatantri, NITAC Registrar, National Apprentice &
Industrial Training Authority (NAITA)
 Mr. W.G. Saman Kumara, National Apprentice & Industrial Training
Authority (NAITA)
 Mr. P.A.C. Punchihewa
CBT Curriculum Code: G50C001 Endorsement Date : Revision No.: 0 Revision Date: Page iii
29 th June 2011 13 th May 2012
CBT CURRICULUM
FOR
NVQ LEVEL 5
List of Modules Code No. Page
SEMESTER 1
Technical Modules
1. Occupational Health and workshop safetyProcedures G50C001M01 1

and Practices
2. Automobile repair /service workshop G50C001M02 3
3. Engineering Drawing G50C001M03 5
4. Applied Electricity G50C001M04 7
5. Applied Electronics G50C001M05 9
6. Engineering Materials G50C001M06 11
7. Hydraulics G50C001M07 13
8. Theory of Machines G50C001M08 15
Employability Modules
1. Manage Workplace Information EMPM 01 17

2. Manage Workplace Communication EMPM 02 19
SEMESTER 2
Technical Modules
1. Pneumatics G50C001M09 21
2. Automobile Engines G50C001M10 23
3. Automobile Engine Systems G50C001M11 26
4. Automobile Electrical and Electronic Equipment G50C001M12 29
and Systems
5. Automobile Drive Chain G50C001M13 31
6. Emission Control, Engine Performance and Drivability G50C001M14 34
7. Automobile chassis and Allied Systems G50C001M15 36
8. Automobile Heating Ventilation and Air Conditioning G50C001M16 40
systems
9. Identify and assess defects and damages to G50C001M22 42
Automobile bodies chassis & finishes
1. Plan work to be performed at workplace EMPM03 38
CBT Curriculum Code: G50C001 Endorsement Date : Revision No.: 0 Revision Date: Page iv
29 th June 2011 13 th May 2012
CBT CURRICULUM
FOR
NVQ LEVEL 6
List of Modules Code No. Page
SEMESTER 1
Technical Modules
1. Estimate preparation for repairs/services G50C001M17 44

2. Vehicle body and Body Finishes G50C001M18 46
3. Plan and Assign Jobs G50C001M19 48
4. Supervise work in-progress G50C001M20 50
5. Perform General Administrative functions of the Workshop G50C001M21 52
1. Problem Solving and decision making EMPM 04 54

2. Team work and Leadership EMPM 05 56
SEMESTER 2
Technical Modules
1. Automobile Advance Electrical and Electronic Equipment G50C001M23 58

and Systems
2. Manage Vehicle Handing over Activities G50C001M24 60
3. Provide Technical workshopInformation/Specifications to G50C001M25 62
staff andother Departments
4. Modify/Alter Vehicle/Vehicle Components G50C001M26 64
5. Manage Assembly Lines/Production line G50C001M27 66
6. Collect, process data and analyze information G50C001M28 68
1. Creation and maintenance of a Learning Culture. EMPM06 70
CBT Curriculum Code: G50C001 Endorsement Date : Revision No.: 0 Revision Date: Page v
29 th June 2011 13 th May 2012
MODULE STRUCTURE
NVQ Level 5
Semester 1
Practicals
Notional Lectures/ /Design/ Self-
Module Code Module Type
hours Tutorials site visits study
G50C001M01 Occupational Health and Workshop C 50 30 10 10

Safety Procedures and Practices
G50C001M02 Automobile Repair/ Service Workshop C 150 75 50 25
G50C001M03 Engineering Drawing C 75 30 40 05
G50C001M04 Applied Electricity C 75 50 15 10
G50C001M05 Applied Electronics C 75 50 15 10
G50C001M06 Engineering Materials C 75 50 15 10
G50C001M07 Hydraulics C 75 50 15 10
G50C001M08 Theory of machines C 100 75 15 10
EMPM01 Manage Workplace Information C 75 60 - 15
EMPM02 Manage Workplace Communication C 75 60 15
Total 825 530 175 120
CBT Curriculum Code: G50C001 Endorsement Date : Revision No.: 0 Revision Date: Page vi
29 th June 2011 13 th May 2012
Semester 2
Practicals
Module Code Module Type Notional Lectures/ /Design/ Self-
hours Tutorials study
site visits
G50C001M09 Pneumatics C 75 50 15 10
G50C001M10 Automobile Engines E 100 75 20 05
G50C001M11 Automobile Engine Systems C 150 120 25 05
G50C001M12 Automobile Electrical and Electronic C 100 75 25 -

Equipment and Systems
G50C001M13 Automobile Drive Chains C 100 75 25 -
G50C001M14 Emission Control, Engine Performance C 75 50 15 10

and Drivability
G50C001M15 Automobile Chassis and Allied C 100 75 20 05

Systems
G50C001M16* Automobile Heating Ventilation and

Air Conditioning System E 100 75 20 05
G50C001M22* Identify and assess defects and E 100 75 20 05

damages to Automobile bodies
chassis & finishes
EMPM03 Plan work to be performed at C 75 60 - 15

workplace
Total 775 580 145 50
* 1. Only one of these elective modules will be offered
2. Institutional training component of these electives are 100 hours.

The remaining 150 hours will be covered through the industrial training.
CBT Curriculum Code: G50C001 Endorsement Date : Revision No.: 0 Revision Date: Page vii
29 th June 2011 13 th May 2012
MODULE STRUCTURE
NVQ Level 6
Semester 1
Practicals
G50C001M17 Estimate preparation for repair/services C 50 20 20 10
G50C001M18 Vehicle body and body finishes C 75 60 10 05
G500001M19 Plan and assign Jobs C 50 30 15 05
G500001M20 Supervise work in- progress C 100 75 15 10
G500001M21 Perform General Administrative C 100 75 15 10

functions of the workshop
EMPM04 Problem Solving and decision making C 75 60 - 15
EMPM05 Team work and Leadership C 75 60 - 15
Total 525 380 75 70
Semester 2
Practicals
G500001M23 Automobile Advance Electrical and C 100 75 20 05

Electronic Equipment and Systems
G500001M24 Manage Vehicle Handover Activities C 50 30 15 05
G500001M25 Provide Technical Workshop C 75 50 20 05

Information /specifications to staff and
other departments
G50C001M26* Modify/Alter vehicle/vehicle components E 175 125 40 05
G50C001M27* Manage Assembly Lines/Production line E 175 125 40 10
G50C001M28 Collect, process data and analyze C 100 50 40 10

information
EMPM06 Creation and maintenance of a learning C 75 50 15 10

culture.
Total 575 380 150 45
* 1. Only one of these elective modules will be offered

2. Institutional training component of these electives are 175 hours.
The remaining 75 hours will be covered through the industrial training.
CBT Curriculum Code: G50C001 Endorsement Date : Revision No.: 0 Revision Date: Page viii
29 th June 2011 13 th May 2012
MAPPING OF COMPETENCY UNITS & CURRICULUM MODULES
NVQ Level 5
Semester 1
Module Code Module Competency Unit/s related
M01 Occupational Health and workshop G50T001U10

safety Procedures & Practices
M02 Automobile repair /serviceworkshop G50T001U02
M03 Engineering Drawing
M04 Applied Electricity G50T001U03
M05 Applied Electronics G50T001U03
M06 Engineering Materials
M07 Hydraulics G50T001U01
M08 Theory of Machines G50T001U01
EMPM01 Manage Workplace Information EMPU01
EMPM02 Manage Workplace Communication EMPU02
Semester 2
M09 Pneumatics G50T001U02
M10 Automobile engines G50T001U13
M11 Automobile engine systems G50T001U01
M12 Automobile electrical and electronic G50T001U03

equipment and systems
M13 Automobile drive chains G50T001U01
M14 Emission control, engine performance G50T001U01

and drivability
M15 Automobile chassis and allied systems G50T001U02
M16 Automobile Heating Ventilation and Air G50T001U11
M22 Identify and assess defects and G50T001U12

damages to Automobile bodies chassis
& finishes
EMPM03 Plan work to be performed at workplace EMPU03
CBT Curriculum Code: G50C001 Endorsement Date : Revision No.: 0 Revision Date: Page ix
29 th June 2011 13 th May 2012
MAPPING OF COMPETENCY UNITS & CURRICULUM MODULES
NVQ Level 6
Semester 1
M17 Estimate preparation for repairs/services G50T001U05
M18 Vehicle body and body finishes G50T001U05
M19 Plan and assign Jobs EMPU03
M20 Supervise work in-progress G50T001U07
M21 Perform generalAdministrative G50T001U09

Functions of the Workshop
EMP04 Problem Solving and decision making EMPU04
EMP05 Team work and Leadership EMPU05
Semester 2
M23 Automobile advance electrical and

electronic equipment and systems G50T001U04
M24 Manage vehicle handing over activities G50T001U08
M25 Provide Technical workshop information/ G50T001U09

specifications to staff and other
departments
M26 Modify/alter vehicle/vehicle components G50T001U15
M27 Mange Assembly lines/ production lines G50T001U14
M28 Collect , process data and analyze EMPU01

information
EMPM06 Creation and maintenance of a learning EMPU06, G50T001U06

culture
CBT Curriculum Code: G50C001 Endorsement Date : Revision No.: 0 Revision Date: Page x
29 th June 2011 13 th May 2012
MODULE DESCRIPTOR
AUTOMOBILE TECHNOLOGY – NVQ LEVEL 5
Module Title Occupational Health and Workshop Safety Procedures and Practices
Module Code G50C001M01
Module Type Compulsory
Related Unit/s G50T001U10
Pre-Requisites Not applicable
Module Aim(s) To enable the students to:

 Create awareness among the workers on occupational health and workshop
safety
 Identify possible impacts on occupational health safety at workplace.
Learning Outcomes The student will be able to:

 Demonstrate & Understanding of occupational health & safety
 Ensure practices applicable to safety precautions & procedures in workshop
 Perform & Ensure c omplianc e of workshop housekeeping with
environmental protection rules and regulations
 Ensure safety of vehicles, customers, staff and tools & equipment
Learning Content /  Definition of occupational health and workshop safety, hazards encountered in
Topics the automotive industry, National and international rules pertaining to
occupational health and workshop safety, safety precautions in respect of
different types of hazards.
 Factors to be considered when arranging training programmes on OH & S.
 Rules and regulations pertaining to renewal and maintenance of safety
equipment. Knowledge on insurances policies
 Rules and regulations laid down by government authorities on work
environment protection as given in the Factories Ordinance
 Hazards caused by work environment pollutions, actions to be taken to
protect environment.
 Types of fire extinguishers appropriate to different kinds of fires. Workshop
accidents and fire prevention methods/procedures, basic first aid
 Workmen’s compensation act
 Handling of chemicals & MSDS
Practical  Arrange programmes on occupational health & workshop safety for workers
 Perform workshop housekeeping
Resources Computer, Printer, Fire extinguishers & fire alarm,

Personnel safety gears, First aid box, First aid mock-ups, Illustrations like
wall charts, safety signs, warning boards, internet facilities etc
Prescribed Texts & Factory Ordinance, workmen’s compensation act, MSDS

/ or References
Teaching/ Learning  Deliver the theoretical content using lectures assisted with multimedia.
Activities  Provide handouts (to supplement lectures) covering the important points
and aspects.
 Conduct group discussions
 Arrange industrial visits for students to gain adequate practical experience
directly related to this module.
 Fire drills
 Role plays and simulations
CBT Curriculum Code: G50C001 Endorsement Date : Revision No.: 0 Revision Date: Page 1
29 th June 2011 13 th May 2012
Assessment and Type Topic / Activity Weighting
Weighting
Continuous One individual 60%
assignment based on
Case studies.
Final assessment 3 hr paper 40%
Duration 50 Hours
29 th June 2011 13 th May 2012
MODULE DESCRIPTOR
Module Title Automobile Repair /Service Workshop
Pre-Requisites -

 handle common tools, power equipment and machinery used in a typical
automobile workshop service & repair

 Awareness of the history and the development of automobiles, automobile
industry and its current and future trends
 Describe the understanding of the various functions of the workshop.
 Demonstrate the correct use of hydraulic jack, shop crane, hydraulic press
and other commonly used tools and equipment.
Learning Content /  Introduction to the Automobile industry, history of automobiles, present and
Topics future trends in Automobile industry
 Types of Jobs in automotive services & repairs
 Shop work and service Information, Finding and using Automotive service
information
 Automotive Shop Safety, Shop Safety Rules, Hazardous Material and
Hazardous Waste
 Measurements & Measuring Tools- Linear, pressure, Vacuum ,temperature
etc;
 Automotive Fasteners, Gaskets, and Sealants, Seals, Thread - Locking
Chemicals
 Hand Tools- Striking, Turning, Gripping and Cutting Tools, Torque Wrench and
Torque - Angle Gauge
 Equipment and power Tools- Electric, pneumatic and Hydraulic Tools
Practical  Identify the lubricants

 Identification of mileages for full/half services
 Carryout a full service
Resources  Equipment available in a standard, automobile repairs & services workshop

which should include:
Measuring instruments, Hand tools, portable power tools, power tools and
equipments
 Personal safety gears
 Gaskets, sealants and fasteners used in automobiles.
 Information sheets on safety
 Lubricants
Prescribed Texts & -

/ or References
29 th June 2011 13 th May 2012
Teaching/ Learning  Use lectures and group discussions to deliver theoretical knowledge
Activities mentioned in the “Learning content”.
 Provide handouts to cover each of the main topics delivered.
 Guide students to refer books and prepare assignments on selected topics.
 Example- History of automobiles and latest trends in the automobile industry.
 Use real objects, models and videos, if available, to support lectures and
group discussions
 Demonstrate the correct use of tools, equipment and machinery related
to the module and get students practice the use of the same under guidance
and instructions. Follow with individual practice sessions
 Use case studies to develop problem solving skills.
 Encourage students
 attend exhibitions of automobile industry
 view relevant television programs
 visit Automobile repair/service workshops and report observations
 Arrange guest lectures on selected topics pertaining to latest technological
developments in automobile industry.

Weighting
Continues assessment -Individualassignment - 50%
tutorials -case studies
Final assessment 3 hr paper-practical viva - 50%

project
Duration 150 Hours
29 th June 2011 13 th May 2012
MODULE DESCRIPTOR
Module Title Engineering Drawing
Related Unit/s -

draw and present engineering information through
engineering drawings drawn as per the standard practices.

 Read and interpret information contained in engineering drawings accurately.
 Draw technical drawings including sectional assembly drawing using first
and third angle projections as per the standard drawing conventions
 Draw engineering drawings using common drafting software
Learning Content /  Drawing standards, conventions, line work and tangency

Topics Types of drawing and layouts, Line work, Ink and pencil drawings, Lettering,
Tangency
 Orthographic Projection
First angle orthographic projection, third angle orthographic projection,
Auxiliary views, true length
 Isometric and oblique pictorial projection
The circle in Isometric projection, irregular curves in isometric projection,
oblique projection.
Applications of loci mechanisms, the involutes, Archimedean spiral, the
epicycloids, the helix, right hand square thread, the ellipse
 Intersections and Development
Intersections between geometrical solids, Fillets, developments, chord
stepping, oblique cone
 Screw threads and fastening system
Screw threads, threads for power transmission, multiple threads, bolts,
nuts and washers
 Dimensioning methods, limits and fits
Dimensioning, chain dimensioning, dimensioning radii, dimensioning curves,
dimensioning diameters, dimensioning tapers, hole basis fits, shaft basis
fits, selection of tolerances,
 Geometrical tolerances symbols, interpretations
 Engineering drawing including section and assemblies
 Sections and sectional views, sections in two parallel planes, successive
sections,
 Computer Aided Drafting (AutoCAD)
Use commonly used software packages for Technical Drawing
Practical Component & assembly drawing

Manually & AutoCAD
Resources Drawing table with drawing boards, Chalk board or white board with facilities to
draw technical drawings, Drawing models, Drawing instruments, Over Head Pro-
jector, Computer, multi-media projector, Computer software for Computer aided
drafting
29 th June 2011 13 th May 2012
Prescribed Texts &
/ or References
Teaching/ Learning  Support lectures with demonstrations and discussions

Activities  Develop and provide handouts to supplement the lectures
 Develop practical exercises to cover each topic
Provide guided practice to carry out the practical already designed
 Organize students to practice individually

Weighting
Continues -Individual 50%
Assessment assignments
Final assessment 3 hr paper 50%
Duration 75 Hours
29 th June 2011 13 th May 2012
MODULE DESCRIPTOR
Module Title Applied Electricity
Pre-Requisites -

 diagnose and rectify electrical faults in automobiles

 Demonstrate the understanding of applications of basic electricity in
automobiles
 Use standard measuring tools and equipment accurately to suit specific
measuring requirements
 Solve electrical problems in automobiles through application of principles of
electricity.
Learning Content /  Magnetic fields, Alternating rotating fields

Topics  Electrical measurements and Basic measuring Instruments
 Power, energy, efficiency and their measurements
 Electrical current and Ohm’s law, DC network Theorems, Electrostatics and
capacitance, Magnetism & Electromagnetism, AC fundamentals, RLC
circuits, Poly phase Circuits
 DC generators/power supplies, DC motors, Speed Control of DC motors,
Stepper Motors, Servo Motors and Motor Drives, Transformers, Induction
motors, Synchronous motors, Alternators
Practical  Measurement of Voltage ,current and power

 Disassembling, diagnosing and assembling various
types of electrical equipments in automobiles.
Resources  Standard laboratory equipment used in Electrical engineering Laboratory,

 Trainer panels to carryout experiments on AC & DC theory and Electrical
Machines.
 Electrical equipments and components used in automobiles and their
models
Prescribed Texts &  IEE regulations

/ or References
Teaching/ Learning  Provide theoretical inputs using student centered teaching /learning
Activities Methodologies.
 Demonstrate and provide facilities to students to carry out the practical
work given above
 Instruct students to prepare reports/complete
coursework in respect of practical assignment
29 th June 2011 13 th May 2012
Weighting
Continues assessment -Practical viva 50%
-Tutorial
-Individual
assignment
Final assessment 3 hrs paper 50%
Duration 75 Hours
29 th June 2011 13 th May 2012
MODULE DESCRIPTOR
Module Title Applied Electronics
Pre-Requisites -

 Diagnose and rectify faults in electronic circuits and components of
automobiles

 Describe the understanding of applications of electronics in automobiles
 Use standard measuring tools and equipment accurately to suit specific
measuring requirements
 Test electronic components and circuits in automobiles to identify defects.
 Diagnose & rectifies problems of electronic circuits in automobiles by
applying knowledge gained
Learning Content /  Semiconductor Electronics

Topics Semiconductor physics as the basis for understanding Electronics devices.
Junction Diodes, Zener diodes, voltage regulators, Optoelectronics Devices,
Analysis of Diodes circuits
 Bipolar junction Transistors
Bipolar transistor physics, Common emitter transistor circuits, Bipolar
transistor switch, Bipolar transistor packages.
 Uni polar transistors, Uni polar transistor physics ,types of unipolar
transistors, Common source circuits,
 Analog signal processing using operational amplifiers.
Amplifiers, Operational amplifiers, comparators, Inverting amplifier, non
inverting amplifier, Differential amplifier, Instrumentation amplifier, integrator,
Converters (Voltage, Current), Summing Amplifier
 Digital circuits
Number systems, digital representations, combinational logic and logic
families, timing diagrams, design of logic systems, Sequential logic,
Application of Flip-Flops, Counters, Encoders, Decoders, Memory devices,
multiplexes and de-multiplexes
 Electronic Sensors
Inductive sensors, Magnetic sensors, Capacitive sensors, Pressure
sensors, Temperature sensors, Photo electric sensors
 Basic Electronic Measuring Instruments
Types and applications, Oscilloscopes, Function
generator, Frequency counter, Logic probes
Practical  Analogue circuits measurements, digital circuits

measurements ,testing of electronic sensors
Resources Standard laboratory equipment used in Electronics engineeringLaboratory,Logic

trainer kit, logic probes,
Analogue trainer kit, Oscilloscope, Simulation software.
Prescribed Texts &

/ or References
29 th June 2011 13 th May 2012
Teaching/ Learning  Provide theoretical inputs using student centered teaching /learning
Activities methodologies.
 Demonstrate how to test electronic components for functionality
and allow students to practice the same in groups or individually
 Conduct practical exercises with respect to each main topic covered in
the module and provide facilities to students to carry out the practical work
under guidance.
 Instruct students to prepare reports/complete coursework for each practical
assignment
 Demonstrate to students the systematic way of trouble shooting electronic
circuits.
 Simulate faults in electronic circuits and get students to rectify the same.

Weighting
continuous assessment -Tutorial 50%
-individual assignment
-practical viva
-Simulate electronic faults
in automobiles
Duration 75 Hours
29 th June 2011 13 th May 2012
MODULE DESCRIPTOR
Module Title Engineering Materials
Related Unit/s -
Pre-Requisites -

 provide knowledge and understanding of properties of engineering materials
used in the automobile industry.

 Describe the understanding of the uses of engineering material in
automobiles with respect to their properties.
 Describe the understanding of the metal shaping process for making parts
of automobiles.
 Describe the understanding of causes for failure of material used in automobiles.
 Describe the understanding of applications of heat treatment process as
applicable to automobile industry.
Learning Content / Introduction

Topics
Importance of Material Technology for mechanical engineering, Properties of
materials, (Physical, Chemical, Mechanical & Manufacturing properties of metals)
Science of materials
grain structure, Polymerization, Formation of thermo & thermosetting plastics,
Molecular structure of plastics, fiber & wood used in automobile application
 Types, properties & Applications of materials

Types, properties & application of ferrous metals (Carbon steels, Alloy steels
& Cast irons), Non ferrous metals (Aluminum alloys, Copper alloys, Lead
alloys & Magnesium alloys), Types of rubber and its applications, Insulating
materials and their applications (Electrical And Thermal), Polymer materials
and their applications
Shaping metals
Principles of mechanical forming, Difference between hot & cold forming,
Effect on metal due to mechanical forming, Work hardening, Principle of
casting, Effect on metal due to casting
 Failure of material Stress, Strain, Young’s modulus, Stress Strain diagram

& important points & zones of the diagram, Failure of metal due to stress,
Corrosion of metal, Galvanic corrosion, Reasons for galvanic corrosion,
How to avoid galvanic corrosion
 Heat Treatment
Thermal equilibrium diagram, Fe/C Thermal equilibrium diagram, Ferrite,
Pearlite, Cementite & Austenite, Process, Change of structure, Change of
properties & Application of heat treatment (Annealing, Sperodizing,
Normalizing, Hardening & Tempering ), Process, Change of properties &
Application of Chemical treatments (Carburizing, Nitriding & Cyaniding)
29 th June 2011 13 th May 2012
Practical Tensile test, Hardness test & Impact test to compare properties of materials.
Heat treatment (tempering hardening etc.)
Resources Testing equipment (Tensile tester, Hardness tester & Impact tester), Avon for
heat treatment with tools to hold the hot specimens, Metallurgical Microscopes,
Specimen cleaning chemical kit, Grinder to smooth the specimens faces, Chalk
board or white board, Over Head Projector with soft wear & Computer with multi-
media projector
Prescribed Texts &

/ or References
Teaching/ Learning Impart theory through lectures. Provide handouts to supplement lectures.
Activities
Conduct group discussions on specific instances of application of metal shaping
processes and heat treatment processes in the automobile industry.
Develop case studies on failures of material used in automobiles use case studies
to develop problem solving skills of students.
Conduct group discussion on corrosion prevention strategies used with respect to

automobiles.
Arrange field visits to show different metal shaping processes in industry Use
Library assignments also as a learning method.

Weighting
Cont. assessment - Individual assignmnet 50%
- tutorial
- viva on practical
conducted
Final assessment - case study 50%

- 3 hrs paper
Duration 75 Hours
29 th June 2011 13 th May 2012
MODULE DESCRIPTOR
Module Title Hydraulics
Pre-Requisites -

 Diagnose and rectify faults of hydraulic and ally abstracted components of
automobiles.

 Describe the understanding of the applications of hydraulics in automobiles.
 Use standard measuring instruments and tools accurately to suit measuring
requirements.
 Diagnose problems related to hydraulic systems/circuits of automobiles
by applying principles of hydraulics.
 Demonstrate the understanding of the functions of different components
of hydraulic circuits.
Learning Content /  Introduction

Topics
Units of Measurements, Properties of fluids, Capillarity of water, Static
head, Kinetic or velocity head, Position, potential or Geodetic head,
Negative vacuum or suction head.
Fluid Pressure and its Measurements

Pressure head, pressure, Pressure recording devices, Piezometer, tube,
Manometers (Simple manometer, Micro Manometer, Differential Manometer
Inverted differential manometer.)
Hydrostatics
Pascal’s Law, Total Pressure, Total pressure on a horizontally immersed
surface
Total pressure on a vertical immersed surface, Center of Pressure
Equilibrium of floating bodies

Archimedes Principle, Conditions of equilibrium of a floating body
Fluid flow concept

Characteristic of flow, Steady and unsteady flow,
Uniform and Non uniform flows, Compressible and Incompressible flow
 Flow through pipes Types of flow in pipes, Loss of head in pipes.
 Basic Hydraulic Circuits Actuators, Control valves & Hydraulic Power Pack
Practical  Refer teaching learning activities

 Use hydraulic trainer panel to simulate various faults.
Resources Hydraulic Training Kit, Components use in hydraulic circuits/systems.
29 th June 2011 13 th May 2012
Prescribed Texts &
/ or References
Teaching/ Learning Deliver the theoretical content using lectures assisted with multimedia. Provide
Activities handouts covering the important points and aspects to supplement lectures.
Conduct group discussions on the applications of hydraulics in automobiles.
(Use hydraulic trainer panel to simulate various faults)

Weighting
continues Assessment - Tutorial 50%
- Individual assignment
- practical viva
Final Assessment - Case study 50 %

- 3 hrs paper
Duration 75 Hours
29 th June 2011 13 th May 2012
MODULE DESCRIPTOR
Module Title Theory of Machines
Pre-Requisites Mathematics, science, & English modules

 Develop knowledge and understanding of the basic principles of mechanics
to facilitate their further learning and fault finding abilities.

 Demonstrate the understanding of basic concepts of mechanics of
machines
 Understand the working principles of different drive systems.
 Use the knowledge and understanding gained to solve practical problems
related to automobiles
Learning Content /  Angular motion.

Topics  Angular motion constant acceleration, applied torque, Moment of inertia,
Radius of gyration, centripetal acceleration and Static balancing.
 Linear and Angular Kinetic energy
 Linear Kinetic Energy, Angular Kinetic energy, Fly wheel and lift system.
 Simple Harmonic motion.
 Relationship & Interrelationship between Restoring force & displacement,
Displacement & time, Velocity & time and Acceleration & displacement.
Circular motion of phasor & circular frequency, simple pendulum and spring
mass system.
 Belt Drive Systems.
 Belt drive formula for flat and V belt, Critical angle of lap, centripetal tension
in belt, Power transmission, Calculating size and number of belts to transmit
power.
 Gear Drive Systems.
 Types of gear & Their application environment, Gear ratio & Speed ratio,
Calculations related to Simple gear train, Idler gear train & Compound
gear train, Lead, Pitch & start of a worm, Calculations related to Worm &
Worm gear system
 Velocity Diagram for Mechanism
 Velocity diagram for four bar chain, Slide crank chain, Combined slider,
Rotation mechanism
Practical  Gear drive systems

 Belt & rope friction
 Second moment of inertia
Resources Training Panels
Prescribed Texts &

/ or References
29 th June 2011 13 th May 2012
Teaching/ Learning Deliver the theoretical content indicated in the content through lectures; always
Activities try to elaborate concepts by taking examples from automobiles.
Develop and distribute handouts to supplement the lectures.
Develop practical assignments/exercises to illustrate the principles of mechanics,

let students to perform the same in groups.
Conduct group discussions about applications of drive systems in automobiles.

Weighting
continuous - Tutorials 50%
assessments - Individual assignments
- practical viva on each
practical
Final assessment Case study 50 %

3 hrs paper
Duration 100 Hours
29 th June 2011 13 th May 2012
MODULE DESCRIPTOR
Module Title Manage workplace information
Module Code EMPM01
Related Unit/s EMPU01
Pre-Requisites None

 Make use of information and information systems to carry out organizational
functions
 Make use of information and information systems to enhance workplace
performance

 Explain the importance of ICT tools in promoting the productivity of the
organization
 Describes the purpose of establishing ICT tools and strategies in enhancing
the performance at workplace
 Apply Information skills to enhance the productivity of the organization
Learning Content /  Identification of documentation requirements

Topics  Selecting and/or collecting required documentation
 Documentation procedures and methods
 Completing /perfecting documentation
 Reading, interpreting and using equipment/system manuals and specifications
 Interpretation of all applicable laws, policies and procedures relevant to enterprise
 Computer and information system usage
 Forecasting Techniques
 Forecasting Software
 Mathematical Modelling
 Data Collection Techniques for Market Research
 The range of analytical techniques appropriate for analysis of information
 The influence of human factors on information analysis
 Conducting and recording of performance evaluations
Resources: Equip- Occupational Tools, Instruments, Equipment, material

ment, Tools & Mate-
 Documents on Company policies and procedures
rials
 Calculator
 Computer
 MIS resources
 Software used for information purposes
 Equipment/system manuals and specifications
 Safety signs
 Safety procedures
 Variety of forms, formats used in the organization
Instructional Tools, Instruments, Equipment, material

 Multimedia projector
 Screen
 Flash cards
 Flip charts
29 th June 2011 13 th May 2012
 Permanent and white board markers
 Overhead projector
 Printer
 Transparencies
 Colour Printer and scanner
 Safety manuals
 Safety illustrations
Prescribed Texts & /

or References
Teaching/Learning  Discuss/ explain and provide essential theoretical inputs.

Activities  Emphasize the importance of a valid information system in promoting
customer relations - make reference to following
- Identification of customer needs.
- Measurement of customer needs and satisfaction.
- Obtaining feedback from customers.
- Recognition and understanding of customer problems and resolution or
timely referral of problem in a manner satisfactory to the customer.
 Application of enterprise policies in satisfying customer needs
 Identifying enterprise Protocols associated with “Customer Services”
 Discuss “Satisfying customer complaints” using information sources available

Weighting
Multiple Choice Test Items/ Knowledge on various 30%
Matching and Completion aspects of information
test items and structured management skills at work
essay type questions place
Oral questioning during Knowledge on various 10%

class room presentations aspects of information
management skills at work
place
Viva voce knowledge on application 10%

of information management
skills
Continuous assessment at Use of ICT Tools, Software 50%

work place applications, application of
information management
skills
Duration 75 Hours
29 th June 2011 13 th May 2012
MODULE DESCRIPTOR
Module Title Manage workplace communication
Module Code EMPM02
Pre-Requisites None
Module Aims To enable the students to:

 Apply communication skills to maintain effective workplace performance
 Adjust to diverse situations at workplace, through effective manipulation of
communication skills

 Identify the essential components of an efficient communication system
 Identify and overcome barriers to effective communication
 Use all channels of communication equally well
 Use common computer applications to collect, analyze and maintain essential
data and information required to perform and enhance day to day activities of
the organisation
 Contributes to the overall growth and productivity development of the
organization
Learning Content /  Basic communication models - (Reference to 2 typical models)

Topics  Principles of effective, interactive communication
 Barriers to effective communication and distortions in the communication
process
 Personal values and communication
 Policies of the organization relevant to information and communication function
 Protocol and Procedures of the organization
 Importance of ICT tools in promoting the efficiency and effectiveness of the
organization
 Common computer applications
 Importance of networking in day to day activities of the organization

ment, Tools & Mate-
rials  Company policies and procedures
 Software used for information/communication purposes
 Safety signs
 Variety of forms, formats used within the organization and for external
communication
 Calculator
 Computer

 Screen
 Flash cards
 Flip charts
 Overhead projectors
29 th June 2011 13 th May 2012
 Transparencies
 Communication models
 Safety manuals

or References
Teaching/Learning  Knowledge to be imparted by providing learner centred activities

Activities  Facilitator may use different teaching methodologies such as brainstorming,
projects, mind mapping, small group activities, illustrated talk, fish ball
technique, demonstrations, when delivering knowledge component of this
module
The following may be discussed in groups of trainees and followed up with Exercises”
& “Role plays”
 Oral communication
 Written communication
The following may be discussed in groups of trainees and followed up with” Exercises”
& “Role plays”
 Constructing sound inductive arguments.
 Reading and comprehending written communications and information
 Using job-related terminology
 Using proper listening techniques

Weighting
Multiple Choice Test Items/ Knowledge of various 30%
Matching and Completion aspects of communication
test items and structured skills at work place
essay type questions
Oral questioning during Knowledge of various 10%

class room presentations aspects of communication
skills at work place

of communication skills
Continuous assessment at Application of 50%

work place communication skills
Duration 75 Hours
29 th June 2011 13 th May 2012
MODULE DESCRIPTOR
Module Title Pneumatics
Module Type -
Pre-Requisites Mathematics, Science & English modules

 Diagnose and rectify faults of pneumatic circuits /systems of automobiles

 Describe the applications of pneumatics in automobiles.
 Describe the functions of different components used in pneumatic circuits.
 Describe the basic pneumatic valves.
 Apply knowledge and understanding of pneumatics to diagnose and rectify
faults of pneumatic systems /components of automobiles.

Topics  Physical quantities and units of pneumatics
 Physical properties and laws of air
 Air and influence of heat and pressure
 Water absorption capacity of air
 Air and the influence of flow speed and pressure
 Compressed air as a working medium
 Pneumatic supply units:
 Compressor, compressed-air reservoir, filter, valves, etc.
 Basic pneumatic circuits
 Pressure and speed control circuits, Sequencing and air logic control
circuit, Electro pneumatic control circuits, and Vacuum circuits.
 Pneumatic components
Pneumatic actuators, Directional control valves, Flow control valves, Quick
exhaust valves,sequencing valves.
Practical Practical using Pneumatic Trainer Panel
Resources Pneumatic Training Panel

or References
Teaching/Learning For each main topic of the content develop handouts to be distributed to
Activities students.
Impart theoretical content through student centered teaching methodologies
Develop case studies on faults of pneumatic systems and use to develop

problem solving skills of students.
Simulate faults using the pneumatic trainer.
29 th June 2011 13 th May 2012
Weighting
Continuous practical viva 50%
assessments tutorials individual
assignment
Final assessments - case study-3 hrs paper 50%
Duration 75 Hours
29 th June 2011 13 th May 2012
MODULE DESCRIPTOR
Module Title Automobile Engines
Pre-Requisites -

 identify types of automobile engines & their functionalities
 identify and rectify faults of Automobile engines

 Demonstrate the understanding of the fundamentals of automobile engines
construction and operation.
 Classify engines and list advantages, disadvantages and practical
applications of different automobile engines.
 Perform measurements on engine performance
 Disassemble and assemble automobile engines.
 Conduct diagnostic tests to identify faults of automobile engines
 Identify faults of automobile engines
 Rectify faults of automobile engines.
 Advice customers on maintenance of automobile engines
Learning Content /  Fundamentals of Engine Operation - Combustion and action in the Engine
Topics Cylinder,
 Basic Engine Construction and operation
 Engine Types and classifications - spark ignition and compression
ignition(diesel) engines, number and arrangement of cylinders
 Firing Order & interval Two- Stroke Cycle and Four stroke-Cycle Engines, Gas-
Turbine
 Engine construction - Cylinder Blocks, Cylinder heads, Manifolds, Crankshaft,
Bearings, Rods, Pistons and Rings, camshaft
 Valves and Valve Trains - Driving and Timing the camshaft, Valve seats
and Valve -Train Components
fix Valve Timing and Variable Valve Timing, valve cooling
Engine service: connecting rods, rod bearings, pistons and piston rings
Crank shafts and cylinder blocks, refinishing cylinders and installing

cylinder
Introduction to systems supporting engine operation , fuel system, ignition

system, lubrication system, cooling system, engine control systems,
starting systems, emission control systems
Engine performance measurements,

compression Ratioand Volumetric Efficiency, engine power and torque,
overall efficiency, power weight ratio, engine mounts positioning, materials
removing & re fixing
29 th June 2011 13 th May 2012
Practical Visual inspections of automobile engines
Performance measurements of automobile engines

Carryout diagnostic tests
Disassembling and assembling engine
Crankshaft and Cylinder block Service, Refinishing
Cylinders and installing cylinder liners

Connecting rod, bearing, piston and ring service
Fault finding of automobile engines
Analyze exhaust gas emissions
Resources Multi meter,

Alternator / starter motor tester,
General hand tools, Oscilloscope
compression tester,
Spark plug tester,

Thermometer,
Stethoscope,
Pressure gauges (fuel, oil, pneumatic)
Vacuum meter,
Tachometer,
Dwell angle tester,
Tapley meter,
On board diagnosis equipment,
Computer Printer,
Exhaust gas analyzer,
Smoke meter,
Jump leads,
Jacks/hoist,
Vehicle Technical specification manual ,

Spare parts Manual, Workshop user manual, Equipment user manual,
Relevant vehicle records
Prescribed Texts &

/ or References
Teaching/ Learning Use lectures and group discussions to deliver theoretical knowledge mentioned
Activities in the “Learning content”.
Provide handouts cover each of the main topics delivered.
Guide students to refer books and prepare assignments on selected topics.

Example- History of automobiles and latest trends in the automobile industry.
Use real objects, models and videos, if available, to support lectures and group
discussions
Demonstrate the correct use of tools, equipment and machinery related to the
module and get students practice the use of the same under guidance and
instructions. Follow it up with individual practice sessions
Use case studies to develop problem solving skills. Encourage students

a) attend exhibitions of automobile industry
b) view relevant television programs/internet/CD
c) visit Automobile repair/service workshops and report observations
d) arrange guest lectures on selected topics pertaining to latest technological
29 th June 2011 13 th May 2012
Weighting
Continuous assessment -tutorials 50%
-individual assignments.
-practical tests
-case studies
Duration 100 Hours
29 th June 2011 13 th May 2012
MODULE DESCRIPTOR
Module Title Automobile Engine Systems
Pre-Requisites Mathematics, science & communication skills modules

 Identify types of different systems of automobiles & their functionalities
 Identify and rectify faults of automobile engine and related systems.

 Describe the understanding of the construction and functions of automobile
engine systems.
 Find & rectify faults of the following automobile engine related systems;
starting system, Ignition system, Lubrication system, Cooling system,
Emission control systems, Engine control systems and fuel systems.
 Diagnose faults, repair & service automobile engine systems.
 Advise customers on correct maintenance of engine systems
Learning Content /  Automobile Engine Fuels - Combustion, Abnormal Combustion, Detonation,

Topics Alcohol, Alcohol - blend, and other fuels
 Engine Fuel and Exhaust Systems- Air intake and mixture distribution
Electronic knock control
 Superchargers, Turbochargers and after cooler
Construction and Operation
Supercharger and Turbocharger Diagnosis and service
 Electronic Fuel Injection Systems , Air/ fuel Ratio and Stoichiometric Ratio,
Injectors, Sensors and Actuators in port and TBI Systems
 Injected fuel systems: Diagnosis and Service, On-Board diagnostics and
retrieving trouble codes, ECM diagnosis and Testing, Cleaning Injectors
and Servicing Fuel Injection Systems
 Carburetors ( Single & Multiple Barrel) and Variable vacuum Carburetors,
Electronically controlled feedback carburetors
 Carbureted fuel Systems: Diagnosis and service - Testingmixture Control
Solenoid, Carburetor adjustments and Service
 Diesel Fuel Injection Systems, Fuel Injection Pumps , Governors, Diesel
injection nozzles and electronic controls
 Engine lubricating systems ,engine oil and indicators
 Lubricating systems, Trouble diagnosis and service
 Engine Cooling Systems , Antifreeze and cooling System Components,
drive belts, Electric fans and indicators
 Cooling System Service ,Cooling system fault diagnosis, Testing and Service
 Engine Service, tightening Cylinder Head, Bolt to specifiedtorque
 Adjusting valve clearance
Practical  Supercharger and Turbocharger diagnosis and service

 Cooling System diagnosis, Testing and Service
 Adjusting cylinder head valve clearance
 Lubricating System, Trouble diagnosis and service
 Carburetor service and adjustments
 Diagnostics and retrieving trouble codes,
 Diagnosis, Testing and Cleaning injectors and servicing fuel- Injection Systems
29 th June 2011 13 th May 2012
Resources  Multi meter,
 Alternator / starter motor tester,
 General hand tools,
 Oscilloscope
 Compression tester,
 Spark plug tester,
 Thermometer,
 Stethoscope,
 Pressure gauges (radiator, fuel, oil, pneumatic)
 Vacuum meter,
 Tachometer,
 Dwell angle tester,
 Tapley meter,
 Trainer panel on engine and systems
 On board diagnosis equipment,
 Computer,
 Printer,
 Jump leads,
 Jacks/hoist
 Documents
Vehicle Technical specification manual ,

Spare parts Manual, Workshop user manual, Equipment user manual,
Relevant vehicle records
Prescribed Texts &

/ or References
Teaching/ Learning Use lectures and group discussions to deliver theoretical

Activities knowledge mentioned in the “Learning content”.
Example - History of automobiles and latest trends in the automobile industry.
discussions
Use case studies to develop problem solving skills.
Encourage students
b) view relevant television programs
c) visit automobile repair & service workshops and report observations.
d) Arrange guest lectures on selected topics pertaining to latest technological

29 th June 2011 13 th May 2012
Weighting
Continuous assessment - tutorials 50%
- assignmentspaper
- practical tests
- tutorials
- Ind. Assignments
Final assessment - 3 hrs paper, 50%

- practical viva,
Duration 150 Hours
29 th June 2011 13 th May 2012
MODULE DESCRIPTOR
Module Title Automobile Electrical and Electronic Equipment and Systems
Pre-Requisites -

 diagnose and rectify faults of automobile electrical and Electronic components
and systems.

 Demonstrate the understanding of the construction and functions of
automobile electrical and electronic systems
 Diagnose and rectify faults of the automobile electrical and electronic
systems.
 Repair/service automobile electrical and electronic systems and system
components. .
 Advise customers on correct maintenance of electrical and electronic
systems and system components.
Learning Content /  Automotive Electric and Electronic Systems , Electrical Circuit Components ,
Topics Symbols and wiring diagrams, Basic electrical diagnosis, Tests and
measurements
 Automotive Battery , Operation , Maintenance and Service, Battery testing,
diagnosis, charging, and replacement
 Starting System, Magnet and electromagnet starting motors,
 Starting system trouble diagnosis, Testing and Service
 Charging System, Alternators and Regulators, Charging system trouble
diagnosis, Testing and service
 Conventional Ignition System, Ignitions system components, Timing and
spark advance, Spark plugs and heat range
 Electronic Ignition Systems ,Pickup Coil, Optical distributors
 Multiple coil and Capacitor, discharge ignition
Ignition system diagnosis and service, Spark Test, Triggering test, and
Oscilloscope Diagnosis, Trouble codes, Component testing and ignition
timing
 Automobile lighting system, lights, safety and signaling, Driver Information
and control devices, Fiber , Optic and computer controlled lighting
Practical  Spark plug test, triggering test, and Oscilloscope diagnosis, Trouble Codes,
Component testing and setting ignition timing.
- Charging system trouble diagnosis, Testing and Service
- Basic electrical diagnosis, Tests and measurements
- Battery testing, diagnosis & charging
- Starting system trouble diagnosis, Testing and service
- Head lamp realignment
Resources  Multi meter,

 Alternator / starter motor tester,
 Oscilloscope
 Compression tester,
29 th June 2011 13 th May 2012
 Spark plug tester,
 Thermometer,
 Stethoscope,
 Pressure gauges (fuel, oil, pneumatic)
 Vacuum meter,
 Tachometer,
 Dwell angle tester,
 Tapley meter,
 Computer,
 Printer,
 Exhaust gas analyzer,
 Jump leads,
 Jacks/hoist,
Documents
 Vehicle technical specification manual
 Spare part manual
 Workshop user manual,
 Equipment user manual
 Relevant vehicle records
Prescribed Texts &

/ or References
Teaching/ Learning Use lectures and group discussions to deliver theoretical knowledge mentioned
Activities in the “Learning content”.
discussions

Encourage students

b) view relevant television programs/internet/CD
d) arrange guest lectures on selected topics pertaining to latest technological

Weighting
Continuous assessment - Tutorials 50%
Ind. Assignments
- practical tests

Practical & Viva
Duration 100 Hours
29 th June 2011 13 th May 2012
MODULE DESCRIPTOR
Module Title Automobile Drive Chains
Pre-Requisites -

 diagnose and rectify faults in automobile drive systems

 Describe the construction and functions of automobile drive systems
 Diagnose and rectify faults of the automobile drive systems
 Repair/service drive systems.
 Advice customers on correct maintenance of drive systems
Learning Content / Automobile Clutches: purpose, functions, clutch

Topics construction, types, Operation, clutch linkage
(linkage types cable, hydraulic, electromagnetic), release bearing, Hydraulic and
electronic controls, Clutch noises, clutch trouble diagnosis (Complains, possible
causes, correction)
Adjustments, inspection and service of clutch parts, Dismantling &
assembling clutch
Manual Transmissions and Transaxles - Purpose, difference between

transmission and transaxle, Gears and Gearing, gear ratio and torque, Gear
shifting, and Shift Linkage (steering column and floor shift levers), switches and
sensors, Manual transmission and transaxle, construction, synchronizer action,
manual transmission operation, Gear lubrication.
Manual transmissions and transaxles: Diagnosis and service -

Transmission and transaxle noise and trouble diagnosis.
Transmission and transaxle inspection and Service, Manual transmission
complains-possible causes and correction. Manual transaxle complains-possible
causes and correction
Drive shafts, Drivelines for front and rear wheel drives, Universal Joints,
Differentials and Drive Axles - Drive Lines, CV joints and Half shafts
Four wheel drive, Transfer cases, and Viscous
Couplings, All wheel drive, Center differential and viscous coupling, Four wheel
drive and Transfer case fault diagnosis and service
Automatic Transmissions and Transaxles, construction and operation, Torque
Converter, types of planetary gears, planetary gear set controls, Hydraulic system
functions, automatic transmission fluid, transmission fluid cooler, hydraulic control
circuits, Electronic control system, electronic shift controls, Continuously Variable
transmission (CVT), triptronic and other Automatic Transmissions
Automatic Transmissions and Transaxles: Diagnosis and Service, Fluid

Checks, noise and Trouble diagnosis
Procedures, Air Pressure Test Electronic shift control diagnosis
Automatic transmission and transaxle service, linkage and band adjustments
Automatic transmission /transaxle overhaul.
29 th June 2011 13 th May 2012
Practical  Fault diagnosis of Hydraulic and Electronic Controls & Clutch ,Adjustments,
repair and Service
 Fluid Check and trouble diagnosis procedures, fluid line pressure test and air
pressure test
 Four wheel drive and transfer case fault diagnosis repair and service
 Manual Transmission and transaxle trouble diagnosis. Transaxle inspection
and Service
 CV joint and half shaft trouble diagnosis, repair and service
 Replace axle bearing and seals
 Service differential assembly
 Service automatic transmission and transaxles
 Maintenance (automatic transmit ion)Fluid check level, colour, condition,

pan inspection
Fluid leak checking
 Automatic transmission and transaxle trouble diagnosis tests mentioned
in the content
Resources Manual and automatic transmission system ,Trainer panel with the functions of
demonstrating the working principle, simulating faults etc, Cut models of trans-
mission system components, models of transmission system components, Two
vehicles having manual and automatic transmission systems, Operational , tech-
nical, repair and service manuals of transmission system and standard set of
equipment available in a automobile repair workshop,
Prescribed Texts & Manufacturers service & repair manuals

/ or References
Teaching/ Learning Use lectures and group discussions to deliver theoretical knowledge mentioned in
Activities the “Learning content”.
Conduct group discussions with the students on the following topics:
Clutch trouble diagnosis Transfer - case trouble diagnosis Rear wheel drive trouble
diagnosis Manual transaxle trouble diagnosis Manual transmission trouble
diagnosis
The discussions/case studies should focus and cover
Probable complains regarding the operation, probable Causesr such and the
checking to be done and the remedial actions to be taken to rectify the trouble
advice to be given to the user( driver) etc. After discussions give assignments to
prepare report on each topic.
Provide handouts to cover each of the main topics delivered.
Guide students to refer books and carry out assignments on selected topics.
Example- History of automobilesand latest trends in the automobile industry.
discussions
Encourage students
b) view relevant television programs, CDs. DVD, Internet
29 th June 2011 13 th May 2012
Weighting
- Individual assign.
- Practical
Final assessment question paper 50%

case studies
Duration 100 Hours
29 th June 2011 13 th May 2012
MODULE DESCRIPTOR
Module Title Emission control, Engine Performance, and Drivability
Pre-Requisites -

 Trouble shoot automobile emission control systems, and carryout engine
performance and drivability tests.

 Describe the construction and functions of automobile emission control
systems, performance of engines.
 Repair/service automobile emission control systems
 Conduct engine performance measurement tests.
 Advise customers on correct maintenance of automobile emission control
systems
 Describe the drivability problems, driver complaints, engine symptoms, engine
noises.
Learning Content /  Automobile air pollution, pollutants emitted by automobiles

Topics Laws related to automobile emissions
 Automotive Emission Control Systems ,Controlling Crankcase Emissions,
controlling evaporative emissions, Testing exhaust gases, using Exhaust
gas analyzers
 Air injection system - service, trouble diagnosis and repair.
 Servicing Emission Control Systems, Positive Crankcase
Ventilation (PCV) systems, Exhaust gas recirculation (EGR) systems,
Oxygen sensor and catalytic converter - trouble diagnosis repair and
service
 Engine Test Equipment-Exhaust Gas Analyzer and exhaust Gas Analysis,
 Diagnostic Computer and Dynamometer
 Engine Performance and drivability diagnosis, complaints and engine
symptoms, Engine noises and other troubles
Definition of Engine tune up, typical tune up procedure,
Aspects of vehicle care
Practical  Service Emission Control Systems

 Engine Tune up
 Air injection systems - trouble diagnosis and service
 Test engine performance
 Test PCV systems
 Service PCV systems
 Test EGR system
 Service EGR system
 Analyze exhaust gas.
 Use engine analyzer to test Voltage patterns of the ignition system, charging
system and electronic fuel injectors etc.
29 th June 2011 13 th May 2012
Resources PCV tester, Air compressor, vacuum gauge, Vacuum pump, EGR valve tester,
Exhaust gas analyzer, Taco meter, Dwell meter, Cylinder compression tester,
Cylinder leakage tester, Engine vacuum gauge, dynamometer, Service bay
diagnostic computer connected to the vehicle manufactures host computer through
internet (Optional), oscilloscope, Analog/Digital Multi meters, and General
mechanics tool, Vehicle models or real vehicles
Trainer panels
Prescribed Texts & SLS regulation

/ or References
Example - History of automobiles and latest trends in the automobile industry.
discussions
Encourage students
a) attend exhibitions related to environmental pollution in automobile industry
b) view relevant television/CD/DVD/Internet programs
c) visit emission test centers, workshops and report observations

Weighting
tutorials 50%
Individual
assignments
practical tests.
3 hrs paper 50%

case studies
Duration 75 Hours
29 th June 2011 13 th May 2012
MODULE DESCRIPTOR
Module Title Automobile Chassis and Allied Systems
Pre-Requisites -

 diagnose and rectify faults of automobile chassis and allied systems

 Demonstrate the understanding of the construction and functions of
automobile Chassis and allied systems
Find faults of the automobile chassis and allied systems
 Repair/service automobile chassis and allied system components
 Advice customers on correct maintenance of automobile chassis and allied
systems and system components
Learning Content /  Automotive Suspension Systems, Macpherson struts, Ball joints and
Topics torsion bars, Electronic ride control and mechanical/hydraulic/pneumatics
suspension systems, dampers and active suspension system
Fault finding, repair & service of above systems.
Dampers(different types of dampers)
 Types of steering Gears, Fault diagnosis repair & service
 Steering geometry ,adjustment & setting according to manufactures manual
 Automotive braking systems Mechanical, hydraulically operated, power
assisted, fault diagnosis, repair and service
 Antilock Braking systems, Traction control (construction & operation
principles) faults diagnosis, repair & service
 Types of Tires and W heels identification with codes, Tire and wheel
Inspection, Service and repair
Practical Faults diagnosis of Braking system repair & service Fault diagnosis of
Traction control system, service &repair
 W heel alignment & balancing
 Fault diagnosis of suspension system repair & service
Resources  Head lamp aligner

 Oscilloscope
 Thermometer,
 Stethoscope,
 Pressure gauges (fuel, oil, pneumatic)
 Vacuum meter,
 Suspension system tester,
 Brake dynamo meter,
 W heel balancer,
 Wheel alignment gauge,
 Chassis and body aligning jigs,
 Brake fluid quality tester,
 Tyre inflator,
 Computer,
29 th June 2011 13 th May 2012
Resources  Printer,
 Jacks/hoist,
Documents
Vehicle technical specification manual
 Spare part manual
 Workshop user manual,
 Equipment user manual
 Relevant vehicle records
Prescribed Texts &

/ or References
Teaching/ Learning Use lectures and group discussions to deliver theoretical

Activities knowledge mentioned in the “Learning content”.

Example- History of automobiles and latest trends in the automobile industry.
discussions
Use case studies to develop problem solving skills. Encourage students

b) view relevant television programs
Arrange guest lectures on selected topics pertaining to latest technological de-

velopments in automobile industry.

Weighting
- Ind. Assignments
- practical tests
Final assessment case studies 50%

paper,
Duration 100 Hours
29 th June 2011 13 th May 2012
MODULE DESCRIPTOR
Module Title Planning and Scheduling Work at Workplace
Module Code EMPM03
Pre-Requisites None
Module Aims To enable the students to:

 Plan and schedule work to be performed at workplace
 Assign work to workers based on assessment of competencies / work
capacities of individual workers/working team
 Predict likely problems / probable changes that would come up in
implementation of planned schedule

 Prepare a work schedule for a given work situation
 Determine work priorities as per predetermined criteria such as goals, targets
and organizational requirements
 Develop a plan (process) to complete work to be done in a given situation
 Assess competencies of individual workers before assigning work
Learning Content /  Goals and Objectives of the organization

Topics  Planning priorities
 Plans related to work and related activities at workplace
 Systems, procedures and processes relevant to the organization
 Quality and continuous improvement processes applied within the
organization
 Company specific performance standards
 Industry/Workplace Codes of Practice /Codes of ethics
 Frontline management roles applicable to team management
 Manufacturer’ s specifications and product specifications
 Standard specifications of commonly used materials
 Simple planning techniques/methods - ( two to three common techniques/
methods)
 Forecasting Techniques /methods
 Time management techniques
 Competency assessment methods

ment, Tools & Mate-  Documents on Company policies and Procedures
rials  Documents on Industry/Workplace
 Codes of Practice /Codes of ethics
 Documents on Manufacturer’ s specifications and product specifications
 Documents on competency based assessments
 Software used for planning/scheduling
 Software applications used in performance appraisal
 Safety signs
 Computer
 Calculator
29 th June 2011 13 th May 2012
 Screen
 Flash cards
 Flip charts
 Permanent markers
 White board markers
 Transparencies
 Safety manuals

or References
Teaching/Learning  Small group activity -1 - Identify work requirements of a drawing office or of a

Activities given project
 Small group activity -2 - Set work priorities as per organisational requirements
goals and targets
 Small group activity -3 -Develop a plan (process) to complete work to be
done at drawing office or in a given project
 Individual activity - Prepare list/s of tools, equipment, material required to
complete the work as indicated in the plan developed in activity -3
 Small group activity -4 Brainstorm in groups to identify,
1) Deficiencies in the plan (Developed in activity -3)
2) Modifications to be made to overcome deficiencies
 Explain and follow up with exercises
Forecasting methods / Techniques, Time management techniques,
Competency assessment methods

Weighting
Matching and Completion aspects of planning of work
test items and structured to be performed at
essay type questions workplace
Oral questioning during Knowledge of various 10%

class room presentations aspects of planning of work
to be performed at
workplace

of planning of work in a
given work situation
Continuous assessment at Use of different approaches 50%

work place and techniques related to
planning of work,
application of skills in
Planning work
Duration 75 Hours
29 th June 2011 13 th May 2012
MODULE DESCRIPTOR
Module Title Automobile Heating Ventilation and Air Conditioning Systems
Module Type Elective
Pre-Requisites -

 Identify and rectify faults of automobile heating ventilation and air
conditioning systems.

 Describe the construction and functions of automobile heating, ventilation
and air conditioning systems.
 Diagnoses of the automobile heating ventilation and air conditioning
systems
 Repair/service automobile heating and air conditioning systems and system
components.
 Advice customers on correct maintenance of automobile heating ventilation
and air conditioning systems and system components.
Learning Content /  Principals of refrigeration , basic refrigeration cycle ,Heat transfer principals
Topics  Purpose of Heating, Ventilation, and Air Conditioning(HVAC)
 Construction and operation of HVAC systems and system components.
Temperature control systems- manual and automatic
Heater and Air- Conditioner Service
 Heater and Air Conditioner diagnosis and repair & service, R-12 and or R-
134a systems
Latest technology and future trends of HVAC systems
 Environmental concerns related to HVAC systems, environmental regulations
Recovery & recycling of refrigerants
Practical  Disassemble and assemble HVAC systems

 Trouble shoot HVAC systems
 Conduct diagnostic tests
 Measure performance of HVAC systems
 Mechanical & electrical component testing
Resources  Belt tensioner & tension gauge

 Coolant system pressure tester
 Refrigerant leak detectors
 Electronics refrigerant identifier
 Electronic leak detector’
 Thermometers
 Vacuum pump
 Compressor
 Service tools
 Refrigerant horse adaptors
 Fins straightner
 Scan tools (on board diagnosis)
 General auto mechanic’s tool kit.
 Manifold gauge set
 Nitrogen cylinder
29 th June 2011 13 th May 2012
Prescribed Texts &
/ or References
Example- History of automobilesand latest trends in the automobile industry.
discussions
Encourage students
b) view relevant television programs, CDs. DVD, Internet

Weighting
Continuous assessment Tutorials ind. 50%
assignments
practical tests.

case studies
Duration 100 Hours
29 th June 2011 13 th May 2012
MODULE DESCRIPTOR
Module Title Identify & assess defects & damage to automobile bodies, chassis & finishes
Pre-Requisites -

 Identify & assess defects & damage to automobile bodies, chassis & finishes

 Interact with customers to determine vehicle faults/ deficiencies with respect
to vehicle bodies. chassis and finishes
 Conduct tests to identify / verify vehicle faults / deficiencies.
 Assess accident damages, Assess the damages to automotive body in
particular and prepare list of materials for repair
 Demonstrate the understanding of the bodies and the construction methods
of vehicle bodies
 Demonstrate the understanding of major repair techniques
 Record identified faults and deficiencies of vehicle and obtain customer approval
/ authorization for necessary action to be
Learning Content /  Equipment of the body shop

Topics  Legal requirements, Insurance procedures
 Automobile Bodies-Basic construction, construction methods, maj or
components, material used and their properties
 Activities involved in Repairs of Damages
 Tinkering
 Shaping metals by hand
 Hammering techniques
 Filling
 Sanding
 Grinding
 Chemical hardening
 Hydraulic Body Jack
 Accident and Damages to Body
 Damage classification & assessment
 Pulling, alignment & repair systems used or major accident damages
 Repair techniques
 Estimation & costing
 Terminology used in automotive finishing
 Paints –basic components, paint types, material used.
 Spray painting equipment operation
 Spray gun –types, construction operation cleaning, handling & maintenance
– spray gun motion study.
 Preparation of vehicle for repainting ,
 Estimation and costing for accident repairs, Automotive Body Finishing
 Finishing & refinishing processes.
 Automotive paints - types - composition,
 Materials used for finishing
 Spray painting, techniques, equipment
 Spray gun, basic construction, maintenance, motion study
29 th June 2011 13 th May 2012
 Sanding and polishing, technique used
 Prepa ra tion of motor vehicle for repainting
 Finishing and refinishing processes
 Rust roofing
 Color Mixing and Matching
Practical To be decided by the lecturer considering the recourses available to achieve learning
outcomes specified
Resources  Personal Protective Gear such as,

- Special air fed breathing apparatus including full-face type mask, or
separate mask (cartridge type)
- Safety goggles
- Earplugs,
- Rubber gloves,
- Safety shoes
- Overalls.
 Test plates
 Micron meter (to check paint film thickness)
 Colour mixing stick
 Sanding blocks
 Measuring tape (30m)
 Pocket tape (3m)
 Mechanic’s tools
 Fender guards
 Centring gauges
 Universal measuring systems
 Alignment measuring systems
Prescribed Texts &  Vehile technical specification/repair manuals

/ or References  Workshop user manual
Teaching/ Learning  Visit to automobile body repair workshop

Activities  Guest Lectures on paints and application of paints, etc.
 Demonstration followed by guided practice for the correct use of tools
 Practical work on shaping, grinding, forming, filling of metals
 Visiting lectures on accidents, assessments, insurance etc.
 Practical exercises on the use of spray gun
 Theoretical Input to be imparted through lectures assisted with multimedia or
other visuals and group discussions
 Role plays and simulations may be used to develop interactive skills related
to customer relations. It is recommended to use problem centered learning
techniques with small groups to help develop problem solving skills

Weighting
Continuous assessment -oral test 50%
-individual assignments
-practical tests
-Role plays
-presentation and
viva on projects
Duration 100 hrs Institutional training

At least One month industrial training is recommended
29 th June 2011 13 th May 2012
MODULE DESCRIPTOR
Module Title Estimate preparation for repairs/ services
Pre-Requisites -

 prepare estimates for repairs/ services of automobiles

 Estimate material quantities
 Estimate material cost for repairs /replacements
 Calculate overheads
 Estimate labour cost based on standard time and previous experience
 Calculate profit margin
 Prepare supplementary estimate for any additional repairs / replacements
 State pre conditions of the estimate
 Obtain customer’s approval for prepared estimate
Learning Content /  Labour codes and relevant labour unit rates, calculation of quantity of
Topics materials required for particular job/ work
 Calculation of labour cost based on labour time or standard, previous standards
if applicable
 Calculation of quantities of material/ components/ spares requirements and
cost of material to be included in the estimate
 Describe material requirements according to the work to be carried out
indicating the job number or standard.
Costing for merchandise
 Guidance to identify special spares and cost of special items
 Calculation of air/sea cargo or other means of transport cost
Calculation of taxes, overheads and profit.
 Definition of preconditions.
Routine maintenance.
Legal provisions and other limitations for accident repairs
Practical Calculation of overhead costs

Estimation of labour cost
Estimation of material cost
 Preparation of estimates for repairs / services of automobiles
Estimation of machine cost
Resources  Calculator
 Computer
 Printer,
 examples of prepared estimates
 standard formats used in preparing estimates
 Guidelines for preparation of estimates.
Prescribed Texts &

/ or References
29 th June 2011 13 th May 2012
Teaching/ Learning  Discuss with students the various cost components that need to be
Activities included in an estimate.
 Give samples of estimates prepared for reference.
 Show standard formats of cost estimates.
 Discuss about the legal aspects related to estimates.
 Discuss special aspects that have to be considered in preparing estimate
for accident repairs which involve insurance claims.
 Use role plays to train students the competency of obtaining customers
approval for estimates.
 Obtain services of assessors of accidents, insurance
companies to deliver guest lectures on estimate preparation for accident
repairs.
 Use case studies to elicit deficiencies in estimates.
 Let students prepare estimates for dummy activities.

Weighting
Continuous assessment practical exercises 50%
simulations/role plays
Duration 50 hrs
29 th June 2011 13 th May 2012
MODULE DESCRIPTOR
Module Title Vehicle Body and Body Finishes
Pre-Requisites -

 identify and rectify defects, damages and faults of automobile bodies and
body finishes

 Demonstrate the competence of adherence to the health and safety
practices applicable to automotive body shop
 Demonstrate the understanding of the bodies and the construction methods
of vehicle bodies
 Use hand and power tools required in the body repair work
 Demonstrate the understanding of major repair techniques
 Demonstrate the craft techniques used to repair of minor accident damages
in vehicle bodies
 Assess accident damages, Assess the damages to automotive body in
particular and prepare list of materials for repair
Learning Content /  Vehicle Body Shop

Topics  General layout with specific designated areas
 Lighting and ventilation
 Equipment of the body shop
 Legal requirements
 Automobile Bodies
 Basic construction, construction methods, major components
 Material used and their properties
 Activities involved in Repairs of Damages
 Tinkering (forming by hand)
 Shaping metals by hand
 Hammering techniques
 Filling
 Sanding
 Grinding
 Chemical hardening
 Glow(gas) welding
 Spot welding
 Hydraulic Body Jack
 Constructions
 Applications
 Maintenance
 Accident and Damages to Body
 Classification of damages
 Assessment of damages
 Repair techniques used for major damages
 Estimation and costing for accident repairs,
Automotive Body Finishing
29 th June 2011 13 th May 2012
 Automotive paints - types - composition,
 Materials used for finishing
 Spray painting, techniques, equipment
 Spray gun, basic construction, maintenance, motion study
 Spray painting defects
 Sanding and polishing, technique used
 Preparation of Motor Vehicle for Repainting
 Finishing and refinishing processes
 Rust roofing
 Color Mixing and Matching
Practical Job involving tinkering & repair
Resources Personal protective gear such as

full-face type safety goggles,Special air fed breathing apparatus including mask, or
separate mask (cartridge type) and Earplugs, Rubber gloves, Safety shoes, Overalls.
Prescribed Texts &

/ or References
Teaching/ Learning  Visit to automobile body repair workshop

Activities  Guest Lectures on paints and application of paints, etc.
 Demonstration followed by guided practice for the correct use of tools
 Practical work on shaping, grinding, forming, filling of metals
 Visiting lectures on accidents, assessments, insurance etc.
 Practical exercises on the use of spray gun
 Theoretical Input to be imparted through lectures assisted with multimedia
or other visuals and group discussions
 Role plays and simulations may be used to develop interactive skills. It is
recommended to use problem centered learning techniques with small
groups to help develop problem solving skills

Weighting
Continuous assessment -oral test 50%
-individual assignments
-practical tests
-Role plays
-presentation and
viva on projects
Duration 75 hrs
29 th June 2011 13 th May 2012
MODULE DESCRIPTOR
Module Title Plan and Assign Jobs
Related Unit/s EMPUO3
Pre-Requisites -

 Plan automobile repair/ service /modification work.
 Assign different activities to different workers base on their abilities and
expertise.

 Prepare job card
 Prepare vehicle inventory
 Identify resources needed for the job
 Assign jobs to workers
 Provide assistance and other requirements
Learning Content /  Formats and contents of job cards

Topics  Definition of inventory, information to be included in inventory, types of
formats used for inventories,
 Gathering information from customers.
 Gathering information from other departments (availability of parts materials
etc.).
 Special short forms/ abbreviations/ symbols/ codes used in filling job cards
and vehicle inventory.
 Planning resources required for repairs/ replacements.
 Factors to be considered when assigning jobs to workers and support
staff /services
 Preparation of material requisition notes.
 Identification of human resources.
Practical  Prepare job card / work order

 Prepare vehicle inventory
 Identify resources needed for the job
 Assign jobs to workers
 Preparation of requisition
Resources  Stationary items

 Computer
 Printer
 Different formats of job cards
 Different formats of inventory used in Automobile industry
 Competency Assessment forms
 Resource planning formats
 Maintain manual of the vehicle
Prescribed Texts &

/ or References
29 th June 2011 13 th May 2012
Teaching/ Learning  Deliver the theoretical content through lectures and group discussions.
Activities  Use brainstorming to identify factors that need to be taken in to
consideration is assigning job activities to workers.
 Conduct practical exercises mentioned under practical.
 Simulate planning and assigning of jobs using dummy activities.
 Arrange industrial training in such away that students could gain the
practical experience related to this module.

Weighting
Continuous assessment Role plays 50%
Case study to plan and
assign jobs
Duration 50 hrs
29 th June 2011 13 th May 2012
MODULE DESCRIPTOR
Module Title Supervise Work in- Progress
Pre-Requisites -

 Monitor and supervise work in progress in automobile service / repair
workshops

 Check preparation of vehicle before attending to repairs
 Check use of appropriate tools and equipment for repairs
 Inspect dismantled parts
 Check progress of work against planned work schedules
 Minimize delays
 Ensure quality of work
 Identify components to be replaced or repaired
 Authorize requisition to obtain materials/ components
 Obtain customer approval for additional replacements / repairs
Learning Content /  Activities & Safety precautions to be taken during preparation of vehicle
Topics for repairs / replacements.
 Knowledge of use in service manuals, repair manuals, wiring diagrams.
 Obtain in required parts and materials in time.
 Different types of cleaning agents and their applications and restrictions.
 Methods and techniques used to identify wear and tear, cracks and other
abnormal conditions of different vehicle components.
 Factors that help to determine wear and tear, damages and defects of
vehicle components / parts.
 Application of specifications and tolerances to identify defects.
 Identification of “part numbers/codes” and different patterns or standard
patterns used by the different manufacturers.
 Preparation of time schedule for a job and measurement of progress as
against time schedules.
 Method of maintain quality of vehicle components and workmanship.
 Method of maintain environmental standards
 Method for the use of different measuring & diagnostic tools, equipment
and methods of checking their accuracy.
 Evaluate against original estimate and additional cost and communicate same
to customer
Practical  Check preparation of vehicle before attending to repairs as mention in the

job cards
 Check use of appropriate tools and equipment for repairs
 Inspect dismantled parts
 Check progress of work against planned work schedules
 Identify components to be replaced or repaired
 Authorize requisition to obtain materials/ components
 Check material /spare parts to be replace for conforming requirements
29 th June 2011 13 th May 2012
Resources  Stationary items
 Calculator
 Computer
 Printer
 Different formats of job cards
 Different formats of inventory used in Automobile industry
 Competency Assessment forms
 Resource planning formats
 Measuring tapes, Pressure gauge, Multi meter, Filler Gauges, Measuring
tools such as calipers, micro meters, multi meters etc.
 Covering or protection materials used to cover fenders, seat covers,
steering, and other interior and exterior components liable to damaged or
soiled.
Prescribed Texts &  Auto data sheets/CD

/ or References
Activities  Provide handouts to supplement lectures covering the important points
and aspects.

Weighting
Continuous assessment Role plays 50%
Activities to plan and
assign jobs
Duration 100 hrs
29 th June 2011 13 th May 2012
MODULE DESCRIPTOR
Module Title Perform General Administrative Functions of the Workshop

 Manage automobile repair/ service workshop effectively and efficiently while
adhering to relevant laws & regulation of the land

 Basic management theories
 Maintain attendance and leave records of workers
 Identify training requirements of workers
 Maintain workshop discipline
 Identify & proposed about recruitment requirements
 Monitor & maintain the renewal of relevant insurance policies, maintenance
agreements, safety equipments, plant & machinery
 Arrange /conduct training programs for staff
 Demonstrate the use of equipments to staff effectively.
Learning Content /  Basic administrative functions at workshop

Topics  Relevant Labour rules and regulations.
 Labour management practices in industry
 Standard rules and regulations applicable in maintaining discipline at
workshop
 W ork ethics
 Organizing workshop layout according to the facilities available
 Different types of renewals, rules and regulations applicable to insurance,
different types of insurance policies.
 Their renewals related to the automotive industry such as workshop
license, business registration, and environmental license etc
 Workshop proper facility an incentives
 Performance appraisals
Practical  Maintaining attendance and leave records of workers

 Demonstration of use of new equipment
 Arrange & conduct training programs
 Identification of training needs of staff
Resources  Computer & accessories

 General office equipment
 Stationary
 Leave registers
 Relevant forms & formats
 Relevant reference material
 Administrative regulations
Prescribed Texts & -

/ or References
29 th June 2011 13 th May 2012
and aspects.

Weighting
Continuous assessment Case studies 50%
Role plays and
simulations
Duration 100 hrs
29 th June 2011 13 th May 2012
MODULE DESCRIPTOR
Module Title Problem solving and decision making
Module Code EMPM04
Pre-Requisites None

 Understand the importance of following a systematic approach to identifying
and analyzing problem situation/s
 Acquire the skills required to compare different solutions to decide the most
suitable.
 Apply standard techniques of problem solving and decision making to solve
problems and make decisions at workplace.

 Analyse a situation and accurately identify a problem
 Assess the impact of a problem
 Apply systematic procedure and process of solving a problem
 Follow a standard approach to foresee likely problems
 Follow an acceptable decision making process
Learning Content /  Problem solving models

Topics  Problem solving techniques
 Decision making models
 Decision making process - (Reference to two commonly used decision models)
 Decision making styles - (Participatory approaches may be given priority)
 Creative decision making - (Particular reference to six stages in Creative
decision making process)
 Six stages in Creative decision making process
 Recognition
 Fact finding
 Problem finding
 Idea finding
 Solution finding
 Acceptance finding
 Vroom and Yetter’s tool for decision making - “Decision tree”
 Brainstorming technique
 Nominal group technique
 Front end analysis

ment, Tools & Mate-  Documents on Company policies and procedures
rials  Documents on Industry/Workplace codes of Practice/Codes of ethics
 Documents on Manufacturer’ s specifications and product specifications
 Model of Vroom and Yetter’s tool for decision making - “Decision tree”
 Calculator

 Screen
 Computer
 Flash cards
29 th June 2011 13 th May 2012
 Flip charts
 Transparencies
 Illustrations of “Problem solving models”
 Illustrations of “Problem solving techniques”
 Illustrations of “Decision making models”

or References
Teaching/Learning  (Small group activity -1) - Provide relevant case studies to trainees and make
Activities them work in small groups to identify problems and the impact of the problems
on one’s immediate area of responsibilities
 (Small group activity -2) - Get trainees work in small groups to generate ideas
using divergent and convergent approaches to create solutions to problems
identified in activity -1
 (Small group activity -3) Get trainees work in small groups to select and
communicate the most appropriate solution from among those generated in
activity -2
 Explain
- Problem solving models
- Problem solving techniques
- Decision making models
- Decision making process - (Reference to two commonly used decision
models)
- Decision making styles – (Participatory approaches may be given
priority)
- Creative decision making
 Provide a real problem situation (case study) to follow the Six stages in
“Creative decision making” process to make appropriate decisions to problems
identified in the above case study
 Describe Vroom and Yetter’s tool for decision making - “Decision tree”
- Brainstorming technique
- Nominal group technique
- Front end analysis
 Provide examples from real workplace situations to make trainees apply
principles learnt in each of the above techniques

Weighting
Matching and Completion topics on problem solving /
test items and structured decision making
oral questioning technique Knowledge of various 10%

during class room topics on problem solving /
presentations decision making
Viva voce knowledge in applications 10%

of problem solving /
decision making
continuous assessment Skills in problem solving / 50%

through assignments decision making
Duration 75 Hours
29 th June 2011 13 th May 2012
MODULE DESCRIPTOR
Module Title Teamwork and leadership
Module Code EMPM05
Pre-Requisites None

 Acquire the skills of working with others as a team
 Understand the need of maintaining positive relationships with others under
varying work conditions.
 Lead and facilitate work teams to achieve planned outcome while enhancing
organisational productivity

 Define objectives and functions of teams to develop team plans towards
achieving corporate goals of the organisation
 Identify the important aspects of motivating individuals/teams and enhancing
co-operation and commitment
 Demonstrate an understanding of analyzing ideas and information through
discussion and making informed decisions.
 Manage and develop team performance by applying appropriate techniques
and methods
 Apply understanding of roles of team leadership and membership to build
trust and confidence
 Encourage members in the team to take initiative and make innovations

Topics - Functions and roles of leadership, teams in an organization
 Leadership styles and Leadership roles
 Team processes, Identifying your role within a team, How a team develops,
Team planning- defining objectives, purpose functions and accountabilities
 Discussion techniques
 Communication in a team environment
 Decision making techniques
 Leadership and personality development
 Social analysis - culture and values, psychological and social aspects of
individuals
Resources: Occupational Tools, Instruments, Equipment, material

Equipment, Tools &  Documents on Company policies and procedures
Materials  Calculator
 Computer
 Documents on Industry / Workplace Codes of Practice / Codes
 of ethics
 Documents on Manufacturer’ s specifications and product
 specifications
 Safety signs
 Variety of forms, formats used within the organization
29 th June 2011 13 th May 2012
 Screen
 Flash cards
 Flip charts
 Transparencies
 Safety manuals

or References
Teaching/Learning  Lectures for imparting the fundamental aspects teamwork and leadership
Activities  Brainstorm appropriate interpersonal skills for working with and for others
 Conduct exercises in team planning
 List out in small groups attitudes of workers that create a positive working
atmosphere
 Brainstorm how to develop commitment and cooperation within a team
 How to manage and develop team performance
 Prepare a check list that would outline the main steps in developing team
performance

Weighting
Multiple Choice Test Items/ knowledge on Leading and 30%
Matching and Completion facilitating work teams
test items and structured
Oral questioning technique knowledge on Leading and

during class room presen- facilitating work teams 10%
tations
Viva voce knowledge in application of

Leading and facilitating
work teams 10%
Continuous assessment Skills in application of

through assignments Leading and facilitating
work teams 50%
Duration 75 Hours
29 th June 2011 13 th May 2012
MODULE DESCRIPTOR
Module Title Automobile Advance Electrical & Electronic Equipment and Systems
Pre-Requisites -

 Diagnose and rectify faults of automobile electrical and electronic components
and systems

 Identify faults and deficiencies of the electrical & electronic systems and
components in automobile & suggest remedial measure to rectify same
Learning Content /  Vehicle safety

Topics  Driver convenience
 Passenger comfort systems
 Air bags
 Security systems
 Speed control
 Heat up display
 Networks & Multiplexing
 Sun roof
 Mirror positioning
 Seat belt positioning
 CD players
 Radio
 Balancers
 Remote keyless entry
 Passive entry systems
 GPS navigation systems
 Seat positioning
 Steering wheel positioning
 Audio and visual units
 Analogue tape drives
 Speaker systems
 Antenna
 Immobilizer systems
 Transmitter and receiver operation
 Climate control systems
Practical  Visual /aural tests, scanning test, test using on board diagnostic
equipment, road test
Resources  Owner’s hand book, workshop manual, technical data book, service
manual, internet, general hand tools, analogue /digital multimeter, data
scanner, test light, oscilloscope, onboard diagnostic equipment, workshop
based diagnostic equipment
Prescribed Texts &

/ or References
29 th June 2011 13 th May 2012
Teaching/ Learning 
Activities

Weighting
Continuous assessment Individual assignments 50%
Practical viva
Duration 100 hrs
29 th June 2011 13 th May 2012
MODULE DESCRIPTOR
Module Title Manage vehicle handing-over activities
Pre-Requisites -

 Hand over vehicles after repair services, following standard practice.

 Demonstrate the understanding of the procedures to be followed and aspects
that need to be taken into consideration when handing over vehicles after
repairs /services.
 Hand over the vehicles to customer and help customers to settle the bills
by making necessary arrangements.
Learning Content /  Guidelines to carry out visual checkups,

Topics  Knowledge about driving cycle, Guidelines and factors to be considered during
the test runs in relation to vehicle models and use of appropriate trade
plates as per traffic regulations.
 Types and formats used for job cards, Knowledge about repair
 Description used for jobs/repairs and method of entering job description and
other details.
 General norms rules and regulations pertaining to settlement of final bill.
 General procedures, rules and regulations; documents to be exchanged
when handing over the vehicle
Practical  Carryout visual Check-up

 Perform test run
 Prepare condition reports
 Close the job card
 Check the inventory and cleanliness of the vehicle
 Arrange removed unserviceable parts for customer’s inspection
 Make arrangements for customer to settle the final bill
 Hand over the vehicle to the customer
Resources  Automobile repair workshop or a simulated environment with facilities such

as, Ramp/hoist, hand light, calculator, computer, Job cards, Road test
plates.
 Computer, printer, job cards and inventories
Prescribed Texts &

/ or References
Teaching/ Learning  Deliver the theoretical content through lectures and group discussions.
Activities  Let students to perform the practical mentioned in the module.
 Simulate the vehicle handing over activity.
 Use role play to simulate the customer handing part.
29 th June 2011 13 th May 2012
Weighting
Role plays and simulations
Duration 50 Hours
29 th June 2011 13 th May 2012
MODULE DESCRIPTOR
Module Title Provide Technical Workshop Information / Specifications to Staff and other
Departments
Pre-Requisites -

 Communicate information to other staff in the workshop using appropriate
communication techniques.

 Advice staff on technical specifications and procedures for repairs
 Provide technical specifications for purchasing vehicle components/ spares
 Advise stores personnel on the movement pattern of spares
 Advice other staff members on Management of diagnostic software and
hardware
 Advise other staff on energy and cost reduction procedures
Learning Content /  Technical specifications of relevant vehicle model.

Topics  Fast moving / slow moving / non moving spares/ materials
procedures to be followed in order to advise stores personnel
 Different practices used for storing inventerising and maintaining of tools,
equipment , machines and materials
 Factors to be considered in replacing worn out tools and equipment
 Tools sharpening, storing, adjusting, calibrating & ordering procedures and
techniques.
 Preparation and maintaining of maintenance records for tools and
equipment
 Identification of required diagnostic software, hardware and their upgrades.
 Relationship between exhaust emissions and environment
 Energy Vs cost and issues on cost reduction
 Different techniques and procedures used for reduction of energy consumption
and cost
Practical  Advice staff on technical specifications and procedures for repairs

 Provide technical specification for purchasing vehicle components/spares
 Advise stores personnel on the movement pattern of spares
 Manage tools and equipment
 Manage diagnostic software and hardware
 Illustrate energy and cost reduction procedures
Resources  Computer & accessories

 Calculator
 Work shop manual. Spares catalogue
 Presentation equipment, equipment used manual
 Vehicle tech. sp. manual
Prescribed Texts &

/ or References
29 th June 2011 13 th May 2012
Teaching/ Learning  Lectures, group discussions are suitable for the delivery of the theoretical
Activities content.
 Role plays and simulations could be used to developed skills and related
attitudes.

Weighting
Role plays and
simulations
Duration 75 hrs.
29 th June 2011 13 th May 2012
MODULE DESCRIPTOR
Module Title Modify / Alter Vehicle / Vehicle Components
Pre-Requisites -

 Modify/ alter vehicles to meet the user requirements while conforming to
safety regulations introduced by local authorities.

 Modify/ Alter body of the vehicle
 Modify/Alter mechanical components
 Modify/Alter Electrical/ Electronic circuits and components
Learning Content /  Rules and regulations pertaining to vehicle modifications/alterations

Topics stipulated by government authorities / vehicle manufacture.
 Basic chassis and body designs and modification limitations
 Compression, tension, shear and torsion members of vehicle body,
properties of materials and sections used for vehicle, second moment of
Inertia, welding designing, fixing methods and design aspects of joints.
 Different materials used as surface protective coating and Painting, including
factors affecting quality of painting
And finishing of the body.
 Properties of welding materials, painting materials, surface protecting materials
and finishing materials.
Practical  Design to Modify/ Alter body of the vehicle to suit the given requirements
 Design to Modify/Alter mechanical components to improve performance
 Design to Modify/Alter Electrical/Electronic circuits and components to
improve performance and/or to meet the customer requirements
Resources  Multi meter, Hydrometer, Battery load tester, Battery charger/ booster,
 Alternator / starter motor tester, Head lamp aligner, Stroboscope, Lux meter
 General hand tools, Oscilloscope
 Compression tester, Compression leak tester, Spark plug tester, Radiator/
cap pressure tester, Thermometer, Stethoscope, Pressure gauges (fuel,
oil, pneumatic),Vacuum pump, Vacuum meter, Tachometer, Dwell angle
tester, Suspension system tester, Tapley meter, Brake dynamo meter,
Wheel balancer, Wheel alignment gauge
 Chassis and body aligning jigs, DC tester/ test lamp, Brake fluid quality
tester,
 Tyre inflator, Refrigerant gas pressure/ recovery machine, AC vacuum pump,
 AC manifold gauge, On board diagnosis equipment, Computer, Printer
 General Automobile workshop tools, equipment, machinery
Prescribed Texts &

/ or References
29 th June 2011 13 th May 2012
Teaching/ Learning  Deliver the theoretical content through lectures, group discussions,
Activities brainstorming activities and assignments.
 Involve Industry practitioners who are engaged in vehicle modification activities
as guest lectures and resource persons in conducting practical sessions.
 Develop practical exercises to cover the practical mentioned and assign
to students as group projects, for them to do the required modifications.
 Involve officers from the department of motor traffic or from the traffic police
to discuss with students the legal aspects related to vehicle alterations
and modifications

Weighting
Continuous assessment  Case studies 50%
 Role plays and
simulations
 Project work
Duration 175 hrs
29 th June 2011 13 th May 2012
MODULE DESCRIPTOR
Module Title Manage Assembly lines/Production line
Pre-Requisites -

 Manage functions of an automobile assembly line/ Production line

 Provide guidance and technical details to workers in assembly lines/
Production line
 Manage assembly lines/ Production line
Learning Content /  Knowledge of assembly procedures / Production procedures

Topics  Methods of manage assembly line
 Technical data from manufacturers’ specifications/designer’s specification/
plans for production line
 Assembly line control systems/production line control systems
 Hints and tips to solve/manage assembly line problems/production line
problems
 Time management in assembly lines/production lines
 Methods of drawing /preparing simple production drawings
 Use of different tools, special tools and testing equipment as per instruction
given by manufactures / design engineer
Practical  Practical aspects related to this module should be covered during the
industrial training of students
Resources  Computer
 Calculator
 Drawing instruments
 Workshop manuals
 Machine user manuals and maintenance manuals
 Maintenance charts Production chart and manufacturing drawings
Prescribed Texts &

/ or References
and aspects.
 Conduct group discussion
 Organize field visits to automobile or automobile parts assembly/production
workshops / factories.
 Arrange guest lectures.
 Arrange industrial training in such a way that students could gain the
practical experience related to this module
29 th June 2011 13 th May 2012
Weighting
Continuous assessment  Case studies 50%
 Role plays and
simulations
Duration 175 hrs
29 th June 2011 13 th May 2012
MODULE DESCRIPTOR
Module Title Collect, process data and analyze information
Related Unit/s EMPUO1
Pre-Requisites -

 Make use of information and information systems to carry out organizational
functions and enhance workplace performance

 Collect relevant data from a range of sources using standard techniques /
methods.
 Process data using standard techniques / methods and practices as relevant
to the organization concerned
 Analyze and use information to carry out organizational functions and to
enhance workplace performance
Learning Content /  Identify Data sources and Information.

Topics  Data sources
 (enterprise records, business directories, telephone directories, and sales
records, records of details obtained from customers (users of services).
 Organizing of data collection activities - Guidelines.
 Designing of Survey questions to elicit required data.
 Designing of formats to record details provided by customers.
 Carrying out data collection process.
 Processing of collected data.
 Determining resource requirements and selecting appropriate methodology
for processing data and analyzing information.
 Preparing a simple data base.
 Condensing and describing information in appropriate form to facilitate
interpretation.
 Interpretation of information.
 Making of recommendations through interpretations.
 Relevant legislations, codes, regulations and standards specific to
organization.
 Interpretation of all applicable laws, policies and procedures.
 Presenting of results through records.
 Maintenance of records of data / information.
 Preparing a standard documentation system.
 Prepare progress report to represent management.
 Identify confidential data and others.
Practical
Resources  Occupational Tools, Instruments, Equipment, material;

 Documents on Company policies and procedures
 MIS resources
 Software used for information purposes
 Equipment/system manuals and specifications
29 th June 2011 13 th May 2012
 Variety of forms, formats used in the organization
 Guidelines - Organizing of data collection
 Guidelines - Processing of data
 Calculator
 Computer
Instructional Tools, Instruments, Equipment, material;

 Screen
 Flash cards
 Flip charts
 Permanent and white board
 Markers
 Over head projector
 Printer
 Transparencies
 Safety manuals
Prescribed Texts &

/ or References
Teaching/ Learning Explain each of the following with examples;

Activities Comparative analysis
Biographical analysis
Link analysis
Demographics or geographic analysis
Scenario generation
Discuss how each of the following could be achieved
Meeting of agreed data collection targets.
Accurate recording of data.
Reflecting a professional image in representing the company
Small groups activity
Design Survey questions to elicit data/information
Design formats for recording data/information provided by customers
Individual activity -Computer application skills
Conduct individual practice sessions to develop Computer application skills

Weighting
Continuous assessment - presentations 50%
- viva on collecting and
processing of data and
analyzing information
Duration 100 hrs
29 th June 2011 13 th May 2012
MODULE DESCRIPTOR
Module Title Creating & maintaining a learning culture at workplace
Module Code EMPM06
Pre-Requisites None

 Create awareness and understanding of the concept of learning culture.
 Develop competencies required to create and maintain a learning culture at
the workplace.

 Inform management about training requirements of workers
 Arrange /Conduct training programmes
 Demonstrate the use of new equipment and methods
Learning Content /  Definition of training, definition of performance, performance appraisal, methods

Topics of identifying performance gaps of workers, how to design training programs
 Setting of learning outcomes, Motivating workers for participation at training
programmes, Hints and tips on conducting demonstrations
 Practice - Arrange /Conduct training programmes
 Demonstrate the use of new equipment and methods
Resources:  Hand outs

Equipment, Tools &  Computer
Materials  Printer
 Photocopier
 Models
 Transparencies
 Manuals
Prescribed Texts &

References
Teaching/Learning  Use lectures to impart theoretical knowledge on various aspects of learning

Activities culture.
 Use group discussions, case studies, Role plays, to develop required skills
and attitudinal aspects.
 Create and maintain a positive learning culture at the training centre.
 Arrange guest lectures on learning culture.

Weighting
Multiple Choice Test Items, Knowledge of various 60%
structured essay type aspects of learning culture
questions, case studies at work place
Role plays and simulations skills and attitudes related to 40%

various aspects of learning
culture at work place
Duration 75 Hours
29 th June 2011 13 th May 2012

Automobile CBT

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CBT CURRICULUM

NVQ LEVELS 5 & 6

Technical Education Development Project

University of Vocational Technology

Copyrights © 2010, TVEC

Tertiary & Vocational Education Commission

Technical Education Development Project

MINISTRY OF YOUTH AFFAIRS & SKILLS DEVELOPMENT

Hector Hemachandra Dr. Tissa Jinasena Dr.T.A.Piyasiri

NATIONAL DIPLOMA IN AUTOMOBILE TECHNOLOGY AT NVQ LEVEL 5 & 6

Curriculum code: G50C001

4. Development Group Developed by - Mr. ......................................, Consultant, Technical

 Dr. Victor Mendis, Consultant

List of Modules Code No. Page

1. Occupational Health and workshop safetyProcedures G50C001M01 1

1. Manage Workplace Information EMPM 01 17

1. Plan work to be performed at workplace EMPM03 38

List of Modules Code No. Page

1. Estimate preparation for repairs/services G50C001M17 44

1. Problem Solving and decision making EMPM 04 54

1. Automobile Advance Electrical and Electronic Equipment G50C001M23 58

1. Creation and maintenance of a Learning Culture. EMPM06 70

G50C001M01 Occupational Health and Workshop C 50 30 10 10

G50C001M02 Automobile Repair/ Service Workshop C 150 75 50 25

G50C001M03 Engineering Drawing C 75 30 40 05

G50C001M04 Applied Electricity C 75 50 15 10

G50C001M05 Applied Electronics C 75 50 15 10

G50C001M06 Engineering Materials C 75 50 15 10

G50C001M08 Theory of machines C 100 75 15 10

EMPM01 Manage Workplace Information C 75 60 - 15

EMPM02 Manage Workplace Communication C 75 60 15

Total 825 530 175 120

G50C001M10 Automobile Engines E 100 75 20 05

G50C001M11 Automobile Engine Systems C 150 120 25 05

G50C001M12 Automobile Electrical and Electronic C 100 75 25 -

G50C001M13 Automobile Drive Chains C 100 75 25 -

G50C001M14 Emission Control, Engine Performance C 75 50 15 10

G50C001M15 Automobile Chassis and Allied C 100 75 20 05

G50C001M16* Automobile Heating Ventilation and

G50C001M22* Identify and assess defects and E 100 75 20 05

EMPM03 Plan work to be performed at C 75 60 - 15

Total 775 580 145 50

* 1. Only one of these elective modules will be offered

2. Institutional training component of these electives are 100 hours.

G50C001M17 Estimate preparation for repair/services C 50 20 20 10

G50C001M18 Vehicle body and body finishes C 75 60 10 05

G500001M19 Plan and assign Jobs C 50 30 15 05

G500001M20 Supervise work in- progress C 100 75 15 10

G500001M21 Perform General Administrative C 100 75 15 10

EMPM04 Problem Solving and decision making C 75 60 - 15

EMPM05 Team work and Leadership C 75 60 - 15

Total 525 380 75 70

G500001M23 Automobile Advance Electrical and C 100 75 20 05

G500001M24 Manage Vehicle Handover Activities C 50 30 15 05

G500001M25 Provide Technical Workshop C 75 50 20 05

G50C001M26* Modify/Alter vehicle/vehicle components E 175 125 40 05

G50C001M27* Manage Assembly Lines/Production line E 175 125 40 10

G50C001M28 Collect, process data and analyze C 100 50 40 10

EMPM06 Creation and maintenance of a learning C 75 50 15 10

Total 575 380 150 45

* 1. Only one of these elective modules will be offered

Module Code Module Competency Unit/s related

M01 Occupational Health and workshop G50T001U10

M02 Automobile repair /serviceworkshop G50T001U02