iti 14 April 2025
Mechanic Diesel Engine

ITI Mechanic Diesel Trade Syllabus

The ITI Mechanic Diesel trade is a one-year vocational training program under the Craftsman Training Scheme (CTS), governed by the National Council for Vocational Training (NCVT). This course equips trainees with skills in servicing, troubleshooting, repairing, and overhauling diesel engines used in automobiles, generators, pumps, and industrial machinery. The syllabus integrates theoretical knowledge, practical mechanical skills, and employability skills to prepare students for roles such as diesel mechanics, service technicians, or engine specialists in workshops, service centers, or industries, or as self-employed repair service providers.

Course Overview

  • Duration: 1 year (2 semesters, each 6 months)
  • NSQF Level: Level 4
  • Eligibility: Minimum 10th grade pass with Science and Mathematics (or equivalent)
  • Objective: To train individuals in maintaining and repairing diesel engines to ensure performance, fuel efficiency, and durability.

Detailed Syllabus Breakdown 

1. Trade Theory (Theoretical Knowledge)

Covers principles of diesel engines, systems, and repair techniques.

  • Semester 1
    • Introduction to Diesel Engines
      • Overview: diesel engine types (2-stroke, 4-stroke), applications (vehicles, generators).
      • Industry scope: career opportunities, workshop safety, environmental regulations.
      • Safety: PPE (gloves, goggles, boots), handling fuel, avoiding burns.
    • Diesel Engine Fundamentals
      • Principles: compression ignition, air-fuel ratio, combustion process.
      • Components: cylinder block, piston, crankshaft, camshaft, valves.
      • Cycles: suction, compression, power, exhaust in 4-stroke engines.
    • Fuel Supply System
      • Components: fuel tank, filters, pumps, injectors, governors.
      • Types: inline pumps, distributor pumps, common rail systems.
      • Operation: fuel delivery, injection timing, atomization.
    • Cooling System
      • Types: air-cooled, water-cooled systems in diesel engines.
      • Components: radiator, water pump, thermostat, coolant.
      • Maintenance: checking leaks, flushing systems, topping coolant.
    • Lubrication System
      • Purpose: reducing friction, cooling engine parts, sealing gaps.
      • Components: oil pump, filters, sump, oil cooler.
      • Oils: viscosity grades, synthetic vs. mineral oils for diesel engines.
    • Tools and Equipment
      • Hand tools: spanners, torque wrenches, pliers, screwdrivers.
      • Special tools: compression testers, injector pullers, dial gauges.
      • Measuring tools: vernier calipers, micrometers, feeler gauges.
    • Engine Assembly
      • Parts: bearings, gaskets, seals, timing gears, flywheel.
      • Procedures: assembling block, head, valve train, crankcase.
      • Checks: tolerances, clearances, torque specifications.
  • Semester 2
    • Air Intake and Exhaust Systems
      • Components: air filters, turbochargers, intercoolers, exhaust manifolds.
      • Operation: air supply, boosting power, emission control.
      • Maintenance: cleaning filters, inspecting turbo, EGR systems.
    • Troubleshooting Diesel Engines
      • Faults: starting issues, smoke, power loss, knocking, overheating.
      • Diagnosis: compression tests, fuel pressure checks, visual inspections.
      • Solutions: adjusting injectors, replacing filters, tuning governors.
    • Fuel Injection Systems
      • Types: mechanical, electronic, high-pressure common rail (HPCR).
      • Components: nozzles, pressure regulators, electronic control modules (ECM).
      • Calibration: injection timing, fuel quantity, spray pattern.
    • Emission Control
      • Standards: Bharat Stage (BS) norms, Euro standards for diesel engines.
      • Systems: diesel particulate filters (DPF), selective catalytic reduction (SCR).
      • Maintenance: regenerating DPF, refilling urea (AdBlue) for SCR.
    • Engine Overhauling
      • Procedures: dismantling, inspecting, reconditioning, reassembling engines.
      • Checks: cylinder wear, piston ring gaps, valve seating, bearing clearance.
      • Tools: honing machines, valve grinders, torque wrenches.
    • Maintenance Practices
      • Schedules: oil changes, filter replacements, belt inspections.
      • Records: service logs, warranty tracking, failure analysis.
      • Preventive care: checking leaks, tightening bolts, monitoring gauges.
    • Professional Skills
      • Customer service: explaining repairs, estimating costs, timelines.
      • Entrepreneurship: starting a diesel repair shop, sourcing spares.
      • Trends: hybrid diesel systems, low-emission engines, diagnostic tools.

2. Trade Practical (Hands-On Skills)

Focuses on practical tasks in workshops and simulated diesel engine setups.

  • Semester 1
    • Safety Practices
      • Using PPE: wearing gloves, safety glasses, steel-toe boots in workshops.
      • Safe handling: managing diesel fuel, avoiding hot surfaces, lifting engines.
      • Emergency drills: fire safety, fuel spill response, first aid.
    • Tool Handling
      • Using tools: tightening bolts, adjusting valves with spanners, torque wrenches.
      • Measuring: checking clearances with feeler gauges, micrometers in labs.
      • Maintaining: cleaning, organizing toolkits, calibrating instruments.
    • Engine Dismantling
      • Dismantling: removing cylinder head, pistons, crankshaft in mock engines.
      • Inspecting: checking wear, cracks, alignment of parts.
      • Cleaning: degreasing components, preparing for reassembly.
    • Fuel System Maintenance
      • Servicing: dismantling fuel pumps, injectors in mock setups.
      • Testing: checking fuel pressure, spray patterns with testers.
      • Repairing: replacing filters, seals, cleaning nozzles.
    • Cooling System Work
      • Servicing: flushing radiators, replacing coolant in mock engines.
      • Inspecting: checking pumps, hoses, thermostat function.
      • Testing: verifying temperature regulation, leak-free operation.
    • Lubrication System Work
      • Servicing: changing oil, replacing filters in mock engines.
      • Inspecting: checking oil pump, cooler, sump condition.
      • Testing: ensuring proper oil pressure, flow in labs.
    • Project Work
      • Servicing a fuel system: dismantling, repairing, testing performance.
      • Report: documenting faults fixed, tools used, outcomes.
  • Semester 2
    • Air and Exhaust System Maintenance
      • Servicing: cleaning air filters, inspecting turbochargers in mock setups.
      • Repairing: replacing EGR valves, exhaust pipes in labs.
      • Testing: verifying boost pressure, emission levels with testers.
    • Engine Overhauling
      • Overhauling: dismantling, reconditioning, reassembling a mock engine.
      • Inspecting: measuring cylinder bore, piston rings, valve seats.
      • Testing: checking compression, alignment post-overhaul.
    • Fuel Injection Repair
      • Servicing: calibrating injectors, pumps in mock common rail systems.
      • Repairing: replacing nozzles, sensors, ECM in labs.
      • Testing: verifying injection timing, fuel delivery accuracy.
    • Emission Control Maintenance
      • Servicing: regenerating DPF, refilling SCR urea in mock setups.
      • Inspecting: checking catalysts, sensors for emission systems.
      • Testing: ensuring compliance with BS norms using analyzers.
    • Troubleshooting Practice
      • Diagnosing: tracing faults (smoke, no-start) in mock engines.
      • Repairing: adjusting governors, replacing faulty parts in labs.
      • Testing: verifying engine performance, fuel efficiency post-repair.
    • Customer Interaction
      • Explaining: discussing faults, solutions with mock clients.
      • Documenting: preparing service reports, cost estimates.
      • Resolving: handling mock complaints, ensuring satisfaction.
    • Project Work
      • Overhauling a diesel engine: full repair, testing all systems.
      • Portfolio: presenting repair logs, photos, performance data.

3. Workshop Calculation and Science

Supports diesel engine repair with relevant concepts.

  • Semester 1
    • Arithmetic: calculating fuel consumption, torque values, oil volumes.
    • Physics: thermodynamics, pressure, heat transfer in engines.
    • Materials: properties of steel, alloys in engine components.
  • Semester 2
    • Geometry: piston displacement, valve angles, crankshaft balance.
    • Mechanics: force, friction, power output in diesel engines.
    • Chemistry: fuel combustion, additives, emission reactions.

4. Engineering Drawing

Focuses on technical drafting for diesel engines.

  • Semester 1: Sketching engine components, orthographic views, fuel pump diagrams.
  • Semester 2: Drawing engine assemblies, injector layouts, turbocharger schematics.

5. Employability Skills

Enhances job readiness and soft skills.

  • Semester 1
    • Communication: reporting engine faults, interacting with clients.
    • Time management: prioritizing repairs, meeting service deadlines.
    • Basic IT: using apps for inventory, service tracking.
  • Semester 2
    • Entrepreneurship: planning a diesel repair shop, sourcing parts.
    • Teamwork: coordinating with fuel system specialists, welders.
    • Problem-solving: addressing complex engine faults, customer complaints.

Assessment and Certification

  • Examinations: Semester-wise (theory + practical).
  • Certification: National Trade Certificate (NTC) from NCVT, recognized nationally.
  • Evaluation: Based on repair accuracy, diagnostic proficiency, engine performance, and project work.

Career Opportunities

  • Employment: Diesel mechanic, service technician, engine specialist in workshops, service centers, or industries (automotive, marine, agriculture).
  • Self-Employment: Starting a diesel engine repair or service business.
  • Further Studies: Diploma in Mechanical Engineering, certifications in advanced diesel technology, or heavy equipment repair.

Note

  • This syllabus aligns with NCVT guidelines and may vary slightly by institution or state.
  • For the latest version, refer to the Directorate General of Training (DGT) or local ITI.

Trade Type

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