Maharashtra HSC NSQF Automotive Service Technician (G3) study plan

Sketch and label the four-stroke cycle (intake, compression, power, exhaust) for both petrol and diesel engines, stating valve positions and piston direction at each stroke

Identify on a labelled diagram the major engine components: cylinder block, head, piston, rings, gudgeon pin, connecting rod, crankshaft, camshaft, flywheel, and state the function of each in one sentence

Explain the firing order of 4-cylinder inline engines and relate it to crankshaft and camshaft rotation ratio (2:1)

Select and correctly use a vernier caliper and micrometer to measure cylinder bore and piston diameter, and record readings to 0.01 mm

Describe the purpose of cylinder head gasket, valve clearance, and cooling passages in the engine assembly

Compare petrol (SI) and diesel (CI) combustion in terms of fuel-air mixing, ignition source, and compression ratio ranges

Trace the path of lubricating oil and coolant through the engine, naming pump, filter, galleries, radiator, and thermostat

Demonstrate correct workshop safety behaviour: PPE selection, safe jacking and axle-stand placement, wheel chocking, and fire extinguisher class selection for fuel and electrical fires

Apply the 5S principles (sort, set in order, shine, standardise, sustain) to a simulated workbench and tool board layout

Explain safe handling and disposal of used engine oil, coolant, and batteries under common environmental rules

Describe the construction and power flow of a manual gearbox: input shaft, countershaft, main shaft, synchronisers, and select the gear ratios for a given speed

Explain the function of clutch components (pressure plate, friction disc, release bearing) and describe clutch slip and judder symptoms

Differentiate between propeller shaft, universal joints, differential, and final drive in a rear-wheel-drive layout, and identify the equivalent components in a front-wheel-drive transaxle

Describe steering system types (rack and pinion, recirculating ball) and identify steering geometry terms: camber, caster, toe-in, toe-out, kingpin inclination

Identify suspension types (MacPherson strut, double wishbone, leaf spring, torsion bar) and state one advantage and one limitation of each

Explain lead-acid battery construction, state of charge measurement by hydrometer and open-circuit voltage, and safe jump-starting procedure

Describe the working of the starter motor circuit and alternator charging circuit, including regulator function and warning lamp behaviour

Trace a basic lighting and horn circuit from battery through fuse, switch, and earth, and identify common earth-fault symptoms

Diagnose a simulated steering pull or uneven tyre wear case by linking wear pattern to camber, toe, or inflation causes

Calculate simple series and parallel resistance and Ohm's law values for automotive bulb and relay circuits

List the periodic maintenance schedule items for a typical passenger car at 5,000, 10,000, and 20,000 km service intervals

Perform and record checks on engine oil level and condition, coolant, brake fluid, battery electrolyte, tyre pressure and tread depth, and belt condition

Explain the procedure for engine oil and filter change, including torque values, drain plug washer, and disposal of waste oil

Describe brake inspection: pad thickness measurement, disc run-out check, and bleeding sequence for a hydraulic brake system

Interpret a multimeter reading to test battery voltage, charging voltage, and parasitic drain on a simulated vehicle

Apply a structured diagnostic sequence (verify complaint, gather information, form hypothesis, test, repair, verify) to three written case studies

Diagnose engine no-start by distinguishing fuel, spark or compression causes using a compression test and spark test procedure

Diagnose overheating and abnormal noise complaints by ranking likely causes and stating the confirming test for each

Describe reading and clearing diagnostic trouble codes on a generic scan tool and explain the meaning of a stored versus pending code

Explain the correct procedure for road testing a vehicle after repair and documenting the result

Write a job card for a given repair scenario including customer complaint, vehicle details, work authorised, parts used, and labour time

Prepare an estimate and invoice for a service job, calculating parts cost, labour charge, and applicable taxes

Draft a customer explanation of a technical fault in non-technical language, including cost and time expectations

Describe professional ethics in the trade: honesty in parts replacement, avoiding unnecessary repairs, confidentiality of customer data, and warranty honesty

Explain the importance of maintaining service records and vehicle history for both the workshop and the customer

Identify self-employment options in the automotive service sector: independent garage, mobile service, parts retail, and specialised diagnostic service, with basic startup cost categories

Explain the role of customer relationship, repeat business, and reputation in a small automotive enterprise

Demonstrate interview readiness by preparing answers to five common trade interview questions and listing relevant certifications

Revise all safety and 5S points and all measuring instrument procedures, then self-test with a 40-question mixed quiz covering all nine domains

Build a personal revision sheet of the ten facts most often recalled incorrectly during the practice quiz