BTEB Automotive Mechanics study plan

Label the major components and sub-assemblies of a four-stroke SI engine on a hand-drawn diagram, explaining the function of each in one sentence.

Sequence the correct steps for removing, inspecting and refitting a cylinder head, and state the torque-and-angle tightening procedure for a typical head gasket.

Select the correct precision measuring instrument (vernier caliper, micrometer, dial bore gauge, feeler gauge, plastigauge) for six given measurement tasks and state its least count.

Demonstrate and explain five workshop safety practices covering lifting equipment, jack stands, fire extinguisher selection, PPE and safe handling of solvents.

Measure cylinder bore taper and out-of-round with a dial bore gauge and decide whether a rebore or hone is required from given wear limits.

Inspect and assess a crankshaft for journal wear, taper and runout, and select correct undersize bearing shells from a clearance table.

Explain valve timing, valve clearance adjustment and the effect of incorrect clearance on engine performance.

Describe the purpose and operation of the cooling and lubrication circuits inside the engine block, linking oil galleries and coolant passages to the components they serve.

Trace power flow through clutch, gearbox, propeller shaft, final drive and differential, naming each component and its gear ratio role.

Diagnose three clutch faults (slipping, dragging, judder) by listing the probable causes and the inspection sequence for each.

Explain the construction and operation of a synchromesh manual gearbox and identify the function of the layshaft, mainshaft and selector mechanism.

Describe differential action during a turn and calculate the final drive ratio from given gear tooth counts.

Identify the parts of a propeller shaft assembly and explain the causes and symptoms of unbalanced or worn universal joints.

Explain the construction, rating and testing procedure of a lead-acid battery, including specific gravity and open-circuit voltage checks.

Trace the starting circuit and the charging circuit component by component, stating the function of the starter solenoid, alternator rectifier and regulator.

Interpret a simple automotive wiring diagram, identifying series and parallel circuits and calculating total resistance in each.

Test an ignition coil, spark plug and alternator output using a multimeter and state the acceptable readings for each.

Explain the function of sensors and actuators in a basic engine management system, including coolant temperature, oxygen and crankshaft position sensors.

Describe the construction and operation of a hydraulic braking system and perform a brake bleeding sequence in the correct order.

Explain steering geometry terms (camber, caster, toe, kingpin inclination) and their effect on tyre wear and steering feel.

Inspect and assess suspension components including shock absorbers, coil springs, leaf springs and ball joints, stating rejection criteria.

Diagnose three steering faults (wandering, hard steering, vibration) by listing causes and the check sequence.

Explain the operation of the fuel supply system from tank to injector and describe the function of the fuel filter and fuel pump.

Describe lubrication system components and select the correct oil grade for given operating conditions using the viscosity classification.

Explain the cooling system components and diagnose overheating and overcooling using a systematic checklist.

Build a periodic maintenance schedule covering daily, weekly, monthly and annual service items for a light vehicle.

Apply a systematic troubleshooting method (symptom, probable cause, test, conclusion) to three given vehicle complaints.

Explain safe handling, storage and disposal of used oil, coolant and batteries, and state the environmental regulations that apply.

Describe professional practice expectations including documentation, customer communication and workplace housekeeping.

Perform trade calculations for fuel consumption, engine displacement and gear ratio, showing each step.

Solve ten mixed trade mathematics problems covering area, volume, percentage, ratio and unit conversion without reference notes.

Produce a freehand sketch of a simple machine part with correct dimensioning, line types and a title block.

Explain the scientific principles behind levers, friction, pressure and heat transfer as applied to vehicle systems.

Review all nine domains using a personal error log and re-attempt the weakest items under timed conditions.

Confirm workshop safety and measuring instrument knowledge by explaining the least count and use of five instruments from memory.