Odisha CHSE VOC-ITV Four Wheeler Service Technician study plan

Identify workshop hand tools, torque wrench, micrometer, vernier caliper and bore gauge, state the resolution of each, and demonstrate correct use on a scrap engine.

List the PPE and safety precautions required for fuel, coolant, battery acid, compressed air, lifting and jack stands, then apply them while removing an engine from a vehicle.

Draw and label the four-stroke SI engine cycle, naming piston, rings, valves, camshaft, crankshaft and the purpose of each stroke.

Explain valve timing events and the firing order of a four-cylinder in-line engine using a timing diagram.

Sequence the removal, dismantling and reassembly of a four-cylinder engine, naming the fasteners released at each stage and the parts that must be renewed.

Measure cylinder bore taper and out-of-round, crankpin ovality, piston ring end gap and valve stem clearance, then compare each reading with the manufacturer's wear limit.

Explain torque-to-yield head bolt tightening, correct tightening sequences, gasket selection and sealant application points.

Describe valve seat lapping, seat width checking and camshaft-to-crankshaft timing alignment using belt or chain marks.

Explain single-plate dry clutch operation and release mechanism, and diagnose slip, drag and judder from described road-test symptoms.

Measure and adjust clutch pedal free play, and describe the hydraulic clutch bleeding procedure in correct order.

Describe constant-mesh gearbox power flow in each gear, the role of synchronisers, and calculate individual and overall gear ratios.

Explain propeller shaft universal joint phasing, centre bearing and slip joint function, and state how final drive ratio affects speed versus torque.

Interpret crown wheel and pinion backlash and differential noise patterns such as whine on drive, whine on overrun and knock on turns, and state the likely cause of each.

Apply Ohm's law and series/parallel rules to calculate current, voltage drop and resistance in simple vehicle circuits.

Test a lead-acid battery by open-circuit voltage, hydrometer specific gravity and load test, and state pass or fail with justification.

Trace starting and charging circuits on a wiring diagram, naming battery, ignition switch, solenoid, starter, alternator, charge warning lamp and fuse links.

Describe alternator construction and testing, including rectifier, regulator, no-load output and voltage-drop checks, and explain starter motor no-load and stall testing.

Explain the operation and signal type of MAP, MAF, throttle position, coolant temperature, intake air temperature, oxygen, knock and wheel speed sensors.

Identify ECU inputs and outputs and describe CAN bus twisted-pair signalling, including checks for open circuit, short to ground and termination faults.

Diagnose lighting, horn, wiper and power-window faults using a multimeter and the relevant wiring diagram.

Explain the layout of petrol MPFI and common-rail diesel fuel systems, naming tank, pump, filter, rail, injectors, pressure regulator and return lines.

Test fuel pump pressure and flow and interpret injector balance or diesel leak-off results against specification.

Explain three-way catalytic converter, EGR, PCV, EVAP and DPF operation, and identify likely causes of high CO, HC or NOx on a gas analyser reading.

Describe coolant flow, thermostat, water pump, radiator cap pressure test and fan control, and diagnose the main causes of overheating.

Explain the lubrication circuit, oil pump types, oil grade and specification, oil pressure testing, and causes of low oil pressure.

Describe manual rack-and-pinion and electric power steering layouts, then check steering free play and explain how camber, caster and toe affect tyre wear.

Inspect MacPherson strut, coil spring, shock absorber, ball joint and bushes, and test shock absorbers for leakage and bounce.

Explain wheel balancing, radial and lateral run-out, tyre size markings, tread depth and the wear pattern caused by incorrect inflation.

Explain hydraulic braking with tandem master cylinder, disc and drum brakes, proportioning valve, correct bleeding sequence and brake fluid specification.

Diagnose spongy pedal, brake pull, drag and ABS warning lamp faults, and describe ABS components and wheel speed sensor testing.

Apply a structured diagnostic routine of verifying the complaint, gathering data, isolating the system, testing the component and confirming the repair to three written case studies.

Interpret OBD-II diagnostic trouble codes and live data for at least three codes and state the most probable root cause for each.

Build a periodic service schedule covering daily and weekly checks, 5,000, 10,000 and 20,000 km services and fluid or filter intervals for a typical Indian petrol and diesel vehicle.

Describe job card handling, workshop layout, 5S practice, hazardous fluid and waste disposal, and how a service estimate is costed.