iti 15 April 2025
Mechanic Motor Vehicle

ITI Mechanic Motor Vehicle Trade Syllabus

The ITI Mechanic Motor Vehicle trade is a two-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 diagnosing, servicing, repairing, and maintaining motor vehicles, including petrol and diesel engines, transmission systems, braking systems, suspension, steering, and electrical/electronic components. The syllabus integrates theoretical knowledge, practical skills in vehicle repair, and employability skills to prepare students for roles such as automotive mechanics, service technicians, or spare parts specialists in garages, service centers, or automobile dealerships, or as self-employed garage owners.

Course Overview

  • Duration: 2 years (4 semesters, each 6 months)
  • NSQF Level: Level 5
  • Eligibility: Minimum 10th grade pass with Science and Mathematics (or equivalent)
  • Objective: To train individuals in ensuring the optimal performance, safety, and reliability of motor vehicles through maintenance, repair, and diagnostics.

Detailed Syllabus Breakdown

1. Trade Theory (Theoretical Knowledge)

Covers principles of vehicle systems, repair techniques, and automotive technology.

  • Semester 1
    • Introduction to Motor Vehicles
      • Overview: types of vehicles (cars, jeeps, LCVs), their applications.
      • Industry scope: roles in service centers, dealerships, garages, OEMs.
      • Safety: PPE (gloves, goggles, boots), lifting jacks, workshop hazards.
    • Basic Mechanics
      • Concepts: force, torque, friction, levers, gears in vehicle systems.
      • Components: nuts, bolts, bearings, gaskets, seals, springs.
      • Materials: steel, aluminum, composites in automotive parts.
    • Petrol and Diesel Engines
      • Principles: combustion cycles (Otto, Diesel), valve timing, compression ratios.
      • Components: piston, crankshaft, camshaft, fuel pump, injectors, turbochargers.
      • Operation: differences between petrol and diesel engines, efficiency factors.
    • Fuel Systems
      • Types: carburetors, fuel injection (MPFI, CRDI), fuel pumps, air filters.
      • Operation: fuel-air mixture, throttle bodies, emission control systems.
      • Maintenance: cleaning injectors, replacing filters, checking fuel pressure.
    • Cooling and Lubrication Systems
      • Components: radiators, water pumps, oil pumps, filters, coolants.
      • Operation: heat dissipation, oil viscosity, engine lubrication.
      • Maintenance: flushing radiators, changing oil, inspecting hoses.
    • Electrical Systems (Basic)
      • Components: battery, alternator, starter motor, ignition coil, wiring harness.
      • Principles: DC circuits, charging systems, grounding, fuses.
      • Safety: handling high-voltage batteries, avoiding short circuits.
    • Tools and Measuring Instruments
      • Hand tools: spanners, torque wrenches, screwdrivers, pliers.
      • Diagnostic: multimeters, OBD scanners, compression testers, feeler gauges.
      • Precision: measuring clearances (±0.01 mm), torque settings (±1 Nm).
    • Workshop Practices
      • Operations: filing, drilling, tapping, welding, tightening fasteners.
      • Techniques: dismantling engines, assembling chassis components.
      • Documentation: service manuals, job cards, spare parts inventories.
  • Semester 2
    • Transmission Systems
      • Types: manual, automatic, CVT, clutch systems, differentials.
      • Components: gears, shafts, torque converters, propeller shafts, axles.
      • Maintenance: adjusting clutches, changing gear oil, inspecting CV joints.
    • Braking Systems
      • Types: drum brakes, disc brakes, hydraulic, ABS, vacuum boosters.
      • Components: brake pads, rotors, master cylinders, brake fluid.
      • Maintenance: bleeding brakes, replacing pads, checking ABS sensors.
    • Suspension Systems
      • Types: leaf spring, coil spring, MacPherson strut, independent suspension.
      • Components: shock absorbers, control arms, bushings, stabilizers.
      • Maintenance: greasing joints, replacing shocks, checking alignment.
    • Steering Systems
      • Types: rack and pinion, recirculating ball, power steering (hydraulic, electric).
      • Components: tie rods, steering gear, pumps, fluid reservoirs.
      • Maintenance: adjusting steering play, topping fluid, inspecting belts.
    • Wheels and Tyres
      • Types: radial, bias-ply, tubeless tyres, alloy and steel wheels.
      • Operation: tyre pressure, tread depth, wheel balancing, alignment.
      • Maintenance: rotating tyres, patching punctures, aligning wheels.
    • Troubleshooting Basics
      • Methods: fault diagnosis (noise, vibration, power loss), symptom analysis.
      • Tools: diagnostic charts, OBD-II scanners, pressure gauges.
      • Solutions: tuning engines, recalibrating fuel systems, fixing leaks.
    • Preventive Maintenance
      • Schedules: daily, monthly checks for engines, brakes, fluids.
      • Techniques: oil changes, filter replacements, belt inspections.
      • Records: logging service intervals, predicting component wear.
  • Semester 3
    • Advanced Electrical Systems
      • Components: ECU, sensors (O2, MAF, crankshaft), actuators, wiring looms.
      • Systems: electronic ignition, fuel injection, CAN bus, immobilizers.
      • Maintenance: scanning codes, replacing sensors, updating firmware.
    • Emission Control Systems
      • Components: catalytic converters, EGR valves, DPF, PCV systems.
      • Operation: reducing NOx, CO, particulate matter, Euro/BS norms.
      • Maintenance: cleaning EGR, replacing catalysts, checking lambda sensors.
    • Air Conditioning Systems
      • Components: compressors, condensers, evaporators, refrigerants (R134a).
      • Operation: cooling cycles, pressure regulation, leak detection.
      • Maintenance: recharging gas, replacing filters, inspecting hoses.
    • Powertrain Systems
      • Components: flywheels, drive shafts, universal joints, transfer cases (4WD).
      • Operation: torque transfer, gear ratios, driveline efficiency.
      • Maintenance: balancing shafts, greasing joints, inspecting mounts.
    • Vehicle Electronics
      • Systems: infotainment, GPS, reverse cameras, parking sensors.
      • Components: displays, relays, microcontrollers, wiring diagnostics.
      • Maintenance: updating software, replacing modules, testing circuits.
    • Welding and Body Repair
      • Techniques: arc welding, MIG welding, dent removal, panel beating.
      • Applications: repairing chassis, frames, body panels.
      • Safety: shielding gases, fume extraction, weld inspections.
    • Road Testing and Diagnostics
      • Methods: test drives, analyzing performance (acceleration, braking).
      • Tools: dynamometers, alignment racks, emission testers.
      • Solutions: fine-tuning systems, documenting test results.
  • Semester 4
    • Hybrid and Electric Vehicles (Intro)
      • Components: batteries (Li-ion), electric motors, inverters, chargers.
      • Operation: regenerative braking, power management, charging systems.
      • Maintenance: inspecting HV cables, testing battery health, safety protocols.
    • Advanced Diagnostics
      • Techniques: CAN bus analysis, oscilloscope use, ECU reprogramming.
      • Tools: advanced scanners, thermal imagers, vibration analyzers.
      • Solutions: resolving complex faults, optimizing vehicle performance.
    • Automotive Safety Systems
      • Systems: airbags, seat belts, traction control, ESC, ADAS basics.
      • Components: sensors, actuators, control modules, warning systems.
      • Maintenance: testing airbags, calibrating sensors, updating software.
    • Workshop Management
      • Practices: inventory control, customer service, billing, scheduling.
      • Compliance: pollution norms (PUC), RTO regulations, safety audits.
      • Documentation: warranty claims, service reports, compliance records.
    • Entrepreneurship and Industry Trends
      • Business: starting a garage, sourcing spares, managing contracts.
      • Trends: electric vehicles, autonomous driving, connected cars.
      • Marketing: promoting services, building client networks.
    • Professional Ethics
      • Practices: transparency in repairs, quality assurance.
      • Responsibilities: ensuring road safety, customer satisfaction.
      • Compliance: adhering to environmental, automotive regulations.

2. Trade Practical (Hands-On Skills)

Focuses on practical tasks in automotive workshops and simulated service environments.

  • Semester 1
    • Safety Practices
      • Using PPE: wearing gloves, goggles, boots in workshops.
      • Procedures: operating jacks, handling fuel, fire safety drills.
      • Checks: ensuring vehicle stability, spill cleanup, tool safety.
    • Engine Work
      • Dismantling: removing pistons, valves from mock petrol/diesel engines.
      • Assembling: fitting gaskets, tightening bolts to torque specs.
      • Testing: checking compression, valve timing in labs.
    • Fuel System Maintenance
      • Servicing: cleaning carburetors, injectors in mock setups.
      • Adjusting: tuning fuel pressure, throttle valves in labs.
      • Testing: verifying fuel delivery, emission levels in mock engines.
    • Cooling and Lubrication Practice
      • Servicing: flushing radiators, changing oil in mock systems.
      • Inspecting: checking hoses, oil filters for leaks in labs.
      • Testing: ensuring temperature regulation, oil flow in mock setups.
    • Electrical System Basics
      • Wiring: connecting batteries, lights in mock circuits.
      • Testing: checking alternator output, battery voltage with multimeters.
      • Repairing: replacing fuses, soldering wires in labs.
    • Workshop Operations
      • Performing: filing, welding, assembling mock chassis parts.
      • Measuring: checking piston clearance, bolt torque in labs.
      • Documenting: preparing job cards, service logs for repairs.
    • Project Work
      • Servicing an engine: dismantling, cleaning, reassembling, testing.
      • Report: documenting faults fixed, tools used, performance data.
  • Semester 2
    • Transmission System Repair
      • Servicing: adjusting clutches, inspecting gears in mock gearboxes.
      • Repairing: replacing synchros, changing gear oil in labs.
      • Testing: ensuring smooth shifts, torque transfer in mock setups.
    • Braking System Maintenance
      • Servicing: inspecting brake pads, rotors in mock vehicles.
      • Repairing: bleeding hydraulic brakes, replacing ABS sensors in labs.
      • Testing: verifying stopping power, ABS functionality in mock setups.
    • Suspension System Practice
      • Servicing: greasing bushings, inspecting shocks in mock suspensions.
      • Repairing: replacing struts, aligning components in labs.
      • Testing: ensuring ride comfort, stability in mock vehicles.
    • Steering System Maintenance
      • Servicing: inspecting tie rods, topping power steering fluid in mock setups.
      • Adjusting: aligning steering racks, checking play in labs.
      • Testing: verifying steering response, precision in mock vehicles.
    • Wheel and Tyre Maintenance
      • Performing: rotating tyres, patching tubes in mock wheels.
      • Balancing: aligning wheels, checking tyre pressure in labs.
      • Testing: ensuring grip, alignment in mock setups.
    • Troubleshooting Practice
      • Diagnosing: identifying misfires, brake fade in mock vehicles.
      • Repairing: tuning fuel systems, fixing wiring faults in labs.
      • Testing: verifying performance post-repair in mock setups.
    • Project Work
      • Restoring a transmission: repair, reassembly, testing in labs.
      • Portfolio: presenting logs, photos, system performance data.
  • Semester 3
    • Advanced Electrical Repair
      • Diagnosing: scanning ECU codes, testing sensors in mock vehicles.
      • Repairing: replacing MAF sensors, rewiring looms in labs.
      • Testing: ensuring ignition, fuel systems functionality in mock setups.
    • Emission System Maintenance
      • Servicing: cleaning EGR valves, inspecting DPF in mock engines.
      • Repairing: replacing catalytic converters, O2 sensors in labs.
      • Testing: verifying emission compliance in mock setups.
    • Air Conditioning Repair
      • Servicing: recharging refrigerants, inspecting compressors in mock AC units.
      • Repairing: replacing condensers, fixing leaks in labs.
      • Testing: ensuring cooling efficiency in mock vehicles.
    • Powertrain Maintenance
      • Servicing: inspecting drive shafts, greasing joints in mock drivelines.
      • Repairing: replacing universal joints, balancing shafts in labs.
      • Testing: verifying torque delivery in mock setups.
    • Vehicle Electronics Practice
      • Installing: fitting infotainment, sensors in mock dashboards.
      • Repairing: updating software, replacing relays in labs.
      • Testing: ensuring GPS, camera functionality in mock vehicles.
    • Welding and Body Repair
      • Performing: welding frames, removing dents in mock panels.
      • Repairing: aligning chassis, patching rust in labs.
      • Testing: inspecting weld strength, panel fitment in mock setups.
    • Project Work
      • Servicing a vehicle’s electrical system: repair, testing in labs.
      • Portfolio: presenting logs, photos, diagnostic results.
  • Semester 4
    • Hybrid/Electric Vehicle Practice
      • Inspecting: testing batteries, motors in mock EV setups.
      • Repairing: replacing HV cables, recalibrating inverters in labs.
      • Testing: verifying range, charging in mock vehicles.
    • Advanced Diagnostics Practice
      • Diagnosing: analyzing CAN bus, using oscilloscopes in mock vehicles.
      • Repairing: reprogramming ECUs, fixing complex faults in labs.
      • Testing: optimizing performance in mock setups.
    • Safety System Maintenance
      • Servicing: inspecting airbags, testing ESC in mock vehicles.
      • Repairing: replacing sensors, calibrating ADAS in labs.
      • Testing: ensuring system activation in mock scenarios.
    • Road Testing Practice
      • Performing: test drives, analyzing braking, acceleration in mock vehicles.
      • Testing: using dynamometers, emission testers in labs.
      • Documenting: preparing test reports, performance logs.
    • Workshop Management Practice
      • Simulating: managing mock garage, handling customer queries.
      • Planning: scheduling services, ordering spares in labs.
      • Documenting: preparing bills, warranty claims in mock setups.
    • Project Work
      • Restoring a vehicle: full service, repair, road testing in labs.
      • Portfolio: presenting logs, photos, vehicle performance data.

3. Workshop Calculation and Science

Supports vehicle repair with relevant concepts.

  • Semester 1: Arithmetic (ratios, tolerances), physics (force, torque).
  • Semester 2: Algebra (gear ratios, efficiency), thermodynamics (engines).
  • Semester 3: Geometry (wheel alignment), fluid mechanics (hydraulics).
  • Semester 4: Statistics (failure rates), applied physics (electronics, EVs).

4. Engineering Drawing

Focuses on technical drafting for vehicle systems.

  • Semester 1: Sketching engine parts, fuel systems, orthographic views.
  • Semester 2: Drawing transmission, brake systems, suspension layouts.
  • Semester 3: Designing wiring diagrams, AC systems, powertrains.
  • Semester 4: Creating blueprints for EVs, safety systems, chassis.

5. Employability Skills

Enhances job readiness and soft skills.

  • Semester 1: Communication (customer queries), time management, basic IT (diagnostics).
  • Semester 2: Teamwork (with technicians), problem-solving (fault diagnosis).
  • Semester 3: Leadership (supervising repairs), negotiation (vendor deals), advanced IT (scanners).
  • Semester 4: Entrepreneurship (garage business), client management, trends (EVs, ADAS).

Assessment and Certification

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

Career Opportunities

  • Employment: Automotive mechanic, service technician, spare parts specialist in garages, dealerships, or service centers.
  • Self-Employment: Starting a garage or mobile repair service.
  • Further Studies: Diploma in Automobile Engineering, certifications in EV repair, or ADAS calibration.

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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