AUTO SERVICE TECHNICIAN LEVEL 4 CURRICULUM/SYLLABUS

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1 AUTO SERVICE TECHNICIAN LEVEL 4 CURRICULUM/SYLLABUS This program is aimed at training candidates for the job of a Auto Service Technician Level 4, in the Automobile Sector/Industry and aims at building the following key competencies amongst the learner 1. Assist in performing diagnosis of vehicle for repair requirements 2. Carry out routine service and minor repairs of mechanical and electrical aggregates 4. Work effectively in a team 5. Maintain a healthy, safe and secure working environment 3. Plan and organise work to meet expected outcomes This course encompasses 5 out of 5 National Occupational Standards (NOS) of Auto Service Technician Level 4 ASC/ Q 1402 Qualification Pack issued by Automotive SSC. S.No Topic/Module Key Learning Outcomes Corresponding 1 Introduction to the Industry Understand the purpose of Automobiles Understand the Types of Automobiles Understand the History of Automobiles Understand the Major Developments in the Indian Automobile Industry 2 Role of an Auto service Technician Understand the need for Auto Service Technician Understand the Roles and Responsibilities of an Auto Service Technician Level 4 3 Maintain a healthy, safe and secure working environment comply with organisation s current health, safety and security policies and procedures report any identified breaches in health, safety, and security policies and procedures to the designated person ASC/ N 0003 Page 1

2 Coordinate with other resources at the workplace to achieve the healthy, safe and secure environment for all incorporating all government norms esp. for emergency situations like fires, earthquakes etc. identify and correct any hazards like illness, accidents, fires or any other natural calamity safely and within the limits of individual s authority report any hazards outside the individual s authority to the relevant person in line with organisational procedures and warn other people who may be affected follow organisation s emergency procedures for accidents, fires or any other natural calamity identify and recommend opportunities for improving health, safety, and security to the designated person complete all health and safety records are updates and procedures well defined 4 functioning of various components and aggregates of the vehicle understand the auto component manufacturer specifications related to the various components/ aggregates in the vehicle o engines and fuel system (diesel, petrol, electrical, gas, hybrid etc.) o cooling system o air supply systems o emission and exhaust system o ignition systems o clutch assembly o clutch operating system o gearbox (manual and automatic) o drivelines and hubs o drive-train assembly and transmission systems (manual, automatic etc.) o steering system o suspension system o brake system (including regenerative braking systems) o tyres and wheels (including wheel alignment) o radiator o batteries and power storage system ASC/ N 1402 Page 2

3 o power-generating systems (including charging systems especially for electrical and hybrid vehicles) o electrical wire harness, lighting, ignition, electronic and air-conditioning systems etc. o energy recuperation systems, if applicable (e.g. in electric, gas and hybrid vehicles) o electronic systems including active and passive safety, media and other systems o electronic control unit o hydraulic and pneumatic system o various lubrication systems understand the functioning of each system, component and aggregate (including both mechanical and electrical aggregates) of a vehicle understand the tools used to assess and confirm technical faults that cannot be determined through a visual inspection, including use of: o pressure indicators: fuel pressure testers, manifold gauge sets, oil pressure gauges, tire pressure gauges o measuring equipment: vernier callipers, micrometer, feeler gauges, multi- metre, flow metre, temp gauge, dial gauge etc. o electrical and electronic testing equipment: volt meters, ammeters, ohmmeters, battery testing equipment, dedicated and computer based diagnostic equipment, oscilloscopes etc. dismantle and assemble aggregates ensure any malfunctions observed in tools and equipment are reported to the concerned persons understand the various values and tolerance limits of various components across the mechanical/ electrical aggregates (e.g. within the engine assembly the following sub-aggregates : bore diameter, Liner fitment, piston height and butt clearance of piston rings, permissible imbalance in crankshaft (main and BE journal), axial and radial play in the camshaft etc.) 5 Assessing service and repair requirements understand he various sources of information ASC/ N 1402 Page 3

4 available for assessing service and repair requirements of the vehicle including: o diagnostic displays o visual inspections o test drives o vehicle/equipment manufacturer specifications o standard operating procedures for diagnosis understand typical symptoms of common technical faults in a vehicle 6 Assist in the diagnosis of the root cause of the vehicle trouble follow standard operating procedures for using workshop tools and equipment for fault diagnosis or troubleshoot problem in a vehicle conduct test drives to assist the Senior Technician in finding the fault basis the performance of the vehicle during the test drive review the job card and understand customer complaints follow standard operating procedure set out for diagnosing faults under the supervision of a Senior Technician follow instructions of seniors for specific tasks related to diagnosing faults in the various sub-assemblies and aggregates in a vehicle use checklists and standard OEM operating procedures to understand if the fault is because of improper servicing, or low levels of oils, coolants, grease etc. or poor quality oil/ air filters etc. ensure any malfunctions or repair requirements observed in vehicles (and beyond own scope of work) are reported to the concerned person understand the various precautions to be taken to avoid damage to the vehicle and its components while working on diagnosis or troubleshooting the vehicle for any faults ensure safe movement and parking of the vehicle in the workshop especially in case some aggregate to ASC/ N 1402 Page 4

5 be diagnosed had been disassembled ensure that trainings organized by the OEM from time-to-time are attended and knowledge levels are upgraded (esp. in case of newly launched products, product refreshes) drive a relevant 2/3/4 wheeler vehicle which is an important part of the diagnosis of the type of vehicle that is dealt by the relevant OEM 7 Functioning of various components and component systems understand the basic technology used in and functioning of various components and component systems of the vehicle including: o engines and fuel system (diesel, petrol, electrical, gas etc.) o other engine allied aggregates (e.g. radiator, turbocharger etc.) o emission and exhaust system o clutch assembly o gear box assembly and aggregates (manual, automatic etc.) o propeller shaft and other allied transmission systems o hydraulic and pneumatic system o brake system o drive-train assembly o steering system o suspension system o tyres and wheel alignment o cooling system o electrical, ignition, electronic and airconditioning system etc. understand the tools used to assess deviations from specifications during routine servicing, including use of: o pressure indicators: fuel pressure testers, manifold gauge sets, oil pressure gauges, tire pressure gauges etc. o pullers: ball joint separators, bearing pullers, gear puller tools, slide hammers etc. o specialty wrenches: alignment wrenches, chain ASC/ N 1403 Page 5

6 wrenches, locking wrenches, lug wrenches etc. o trim or moulding tools: carbon scrapers, gasket scrapers, scrapers, spoons etc. o measuring equipment: vernier callipers, micrometre, feeler gauges, multi- metre, flow metre, temp gauge, dial gauge etc. o other tools: hand tools, power tools, lifting and jacking equipment, tensioning equipment, brake roller tester, chassis dynamometer, suspension activation, security activator etc. o tools for other tasks such as cleaning of vehicles, tools, equipment and workshop follow standard operating procedures for using workshop tools and equipment for service and minor aggregate repairs in the vehicle 8 Carry out routine service and minor repairs of mechanical & electrical aggregates follow standard operating procedures for using workshop tools and equipment for service and minor aggregate repairs in the vehicle conduct test drives to assess need for repairs, calibration or any other adjustments in the electrical/ mechanical aggregates in the vehicle review the job card and understand work to be carried out ensure OEM recommended procedure and checklist is followed for routine servicing in case of nonroutine service or repair, confirm tasks to be carried out with superior calibrate, align and adjust settings, alignment and other routine service and maintenance of various parts and aggregates including: o engine and aggregates o other engine sub-assemblies like turbocharger, radiator etc. o gear box and it aggregates o propeller shafts and other transmission systems o clutch and brake systems and sub-assemblies o chassis o electrical and electronic components ASC/ N 1403 Page 6

7 o steering systems o suspension system o other components (including to valves, ignition, fuel and emissions, transmission, lights, tyres, steering and body fittings) ensure that for routine maintenance and service, the correct spare parts and appropriate grade of lubricants, coolant, oils and grease required have been obtained ensure all dismantled components (including mechanical and electrical aggregates) are cleaned and conditioned prior to reassembly identify and change components requiring change due to continuous wear and tear including: o oil and air filters o belts o wiper blades o ensure disposal of materials (including waste oil, scrap of failed parts/ aggregates) in accordance with the organisation s policies understand the various precautions to be taken to avoid damage to the vehicle and its components while working on other aggregates record all service and repairs carried out and ensure completeness of tasks assigned before releasing vehicle for the next procedure ensure all workshop tools, equipment and workstations are adequately maintained by carrying out scheduled checks, calibration and timely repairs where necessary ensure any malfunctions observed in tools and equipment are reported to the concerned persons ensure any other repair requirements observed in the other components/ aggregates systems (like engine, gear box etc.) while repairing/ overhauling of braking systems are reported to supervisor/ service advisor for further inspection by other specialists measure/ inspect the machining or any other repair done from an outside source/ local machining garages Page 7

8 ensure that trainings organized by the OEM from time-to-time are attended and knowledge levels are upgraded (esp. in case of newly launched products, product refreshes) 9 Work requirements including various activities within the given time and set quality standards 10 Appropriate use of resources keep immediate work area clean and tidy treat confidential information as per the organisation s guidelines work in line with organisation s policies and procedures work within the limits of job role obtain guidance from appropriate people, where necessary ensure work meets the agreed requirements ASC/ N 0001 ASC/ N 0001 establish and agree on work requirements with appropriate people manage time, materials and cost effectively use resources in a responsible manner 11 Interact & communicate effectively with colleagues including member in the own group as well as other groups maintain clear communication with colleagues (by all means including face-to-face, telephonic as well as written) work with colleagues to integrate work pass on information to colleagues in line with organizational requirements both through verbal as well as non-verbal means work in ways that show respect for colleagues carry out commitments made to colleagues let colleagues know in good time if cannot carry out commitments, explaining the reasons identify problems in working with colleagues and take the initiative to solve these problems follow the organisation s policies and procedures ASC/ N 0002 Page 8

9 for working with colleagues 12 Writing skills The user/individual on the job needs to know and create documentation required on the job (including job cards, work sheets, etc.) regarding the basic details of repair, maintenance and service performed write any additional requirement of work on the vehicle reported for service, maintenance or repair found during the work done as specified in the job card (for e.g. while working on the engine and transmission system, if low level of engine oil/ greasing, then convey to the superiors) write in at least one language 13 Reading skills The user/individual on the job needs to know and read job cards and instructions from supervisors and the service advisor read various sources of information available for assessing service and repair requirements of the vehicle including service manual and diagnostic and visual displays put up in the workshop read policies and regulations pertinent to the job, including OEM guidelines, health and safety instructions etc. 14 Oral Communication (Listening and Speaking skills) The user/individual on the job needs to know and clearly communicate workplace information and ideas with colleagues (verbal & non-verbal) use terms, names, grades and other nomenclature pertaining to the automotive trade, tools, specific workshop equipment etc. communicate with colleagues to handle verbal enquiries, such as clarifying instructions and responding to requests for information interact with the customer through Service Advisor/ Supervisor in case any additional work needs to be done on the vehicle which may not Page 9

10 have been indicated in the job card and found during the work being carried out as per the job card 15 Decision making The user/individual on the job needs to know and analyse information and evaluate results to choose the best solution and solve problems decide on the repair/ replacement of any aggregate (including those in the electrical and mechanical sub- assemblies) post the diagnosis (with help from a superior in case required) judge when to ask for help from a superior 16 Plan and Organise The user/individual on the job needs to know and plan work according to the required schedule and location organise the schedule to complete work on the vehicle timely in case other aggregate repairs/ maintenance work is also required to be done 17 Customer centricity The user/individual on the job needs to know and interpret the needs of customers by evaluating job cards and talking to Service Advisor and Superiors ensure that the service provided is of the highest order to ensure higher levels of customer satisfaction ensure timely communication of the additional requirements in a vehicle to the Service Advisor who in turn communicates it to the customer follow up with the Service Advisor on any unfavourable feedback received from customer 18 Problem solving The user/individual on the job needs to know and recognise a workplace problem or a potential problem and take action (e.g. leaks or oil spills in the workshop) Page 10

11 determine problems needing priority action (e.g. while working on the engine, crank / pistons require machining as they have been worn out, inform the service advisor or supervisor for urgent action) refer problems outside area of responsibility to appropriate person (e.g. unavailability of required spare parts or materials in the workshop) gather information while working on an aggregate/ components and take appropriate action, by consulting superiors 19 Analytical thinking The user/individual on the job needs to know and assess repairs required based on technical faults identified as specified in the job card/ supervisor notes refer complex problems (outside the current scope of work) to a superior in case any additional work requirement comes up 20 Critical thinking The user/individual on the job needs to know and Analyse, evaluate and apply the information gathered from observation, experience, reasoning, or communication to act efficiently use the diagnosis results to take an appropriate decision on repair/ replacement of an aggregates (including mechanical and electrical subassemblies) in consultation with the Supervisor/ Aggregate Specialist/ Service Advisor Page 11

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