Free Engine Repair Technician Level 4 (6Months)

Engine Repair Technician Level 4:

Brief Job Description

An Auto Engine Repair Technician is responsible for the repair of vehicle engines and aggregates

Personal Attributes

An individual on this job must have good communication and interpersonal skills in addition to being a team player, as the job requires coordination with other Technicians as well. The individual must have a technical bend of mind to understand the technical aspects related to engine and allied aggregates (like turbocharger), which would also help in understanding the fault diagnosis in the engine. Keeping oneself abreast of the latest developments and newer technologies used in the mechanical systems of engine aggregates is highly desirable.

Plan and organise work to meet expected outcomes:

Elements and Performance Criteria

Work requirements including various activities within the given time and set quality standards

To be competent, the user/individual on the job must be able to:

PC1.                 keep immediate work area clean and tidy

PC2.                 treat confidential information as per the organisations guidelines

PC3.                 work in line with organisations policies and procedures

PC4.                 work within the limits of job role

PC5.                 obtain guidance from appropriate people, where necessary

PC6.                 ensure work meets the agreed requirements

Appropriate use of resources

To be competent, the user/individual on the job must be able to:

PC7.                 establish and agree on work requirements with appropriate people

PC8.                 manage time, materials and cost effectively

PC9.                 use resources in a responsible manner

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1.     the organisations policies, procedures and priorities for area of work, role and responsibilities in carrying out that work

KU2.     the limits of responsibilities and when to involve others

KU3.     specific work requirements and who these must be agreed with

KU4.     the importance of having a tidy work area and how to do this

KU5.     how to prioritize workload according to urgency and importance and the benefits of this

KU6.     the organisations policies and procedures for dealing with confidential information and the importance of complying with these

KU7.     the purpose of keeping others updated with the progress of work

KU8.     who to obtain guidance from and the typical circumstances when this may be required

KU9.     the purpose and value of being flexible and adapting work plans

KU10. how to complete tasks accurately by following standard procedures

KU11. technical resources needed for work and how to obtain and use these

Generic Skills (GS)

User/individual on the job needs to know how to:

GS1.     write in at least one language

GS2.     read instructions, guidelines/procedures

GS3.     ask for clarification and advice from appropriate persons

GS4.     communicate orally with colleagues

GS5.     make a decision on a suitable course of action appropriate for accurately completing the task within resources

GS6.     agree objectives and work requirements

GS7.     plan and organise work to achieve targets and deadlines

GS8.     deliver consistent and reliable service to customers

GS9.     check own work and ensure it meets customer requirements

GS10. anomalies to the concerned persons

GS11. analyse problems and identify work-arounds taking help from

GS12. apply own judgement to identify solutions in different situations

Engine Repair Technician Level 4

Work effectively in a team:

Elements and Performance Criteria

Effective communication

To be competent, the user/individual on the job must be able to:

PC1.    maintain clear communication with colleagues

PC2.    work with colleagues

PC3.    pass on information to colleagues in line with organisational requirements

PC4.. work in ways that show respect for colleagues

PC5.    carry out commitments made to colleagues

PC6.    let colleagues know in good time if cannot carry out commitments, explaining the reasons

PC7.            identify problems in working with colleagues and take the initiative to solve these problems

PC8.    follow the organisations policies and procedures for working with colleagues

PC9.    ability to share resources with other members as per priority of tasks

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1. the organisations policies and procedures for working withcolleagues, role and responsibilities in relation to this

KU2. the importance of effective communication and establishing goodworking relationships with colleagues

KU3. different methods of communication and the circumstances inwhich it is appropriate to use these

KU4. benefits of developing productive working relationships withcolleagues

KU5. the importance of creating an environment of trust and mutualrespect

KU6. whether not meeting commitments, will have implications onindividuals and the organisation

KU7. different types of information that colleagues might need and theimportance of providing this information when it is required

KU8. the importance of problems, from colleagues perspective andhow to provide support, where necessary, to resolve these

Generic Skills (GS)

User/individual on the job needs to know how to:

GS1.     complete well written work with attention to detail

GS2.     read instructions, guidelines/procedures

GS3.     listen effectively and orally communicate information

GS4.             make decisions on a suitable course of action or response

GS5.             plan and organise work to achieve targets and deadlines

GS6.             check that the work meets customer requirements

GS7.     deliver consistent and reliable service to customers

GS8.             apply problem solving approaches in different situations

GS9.             apply balanced judgements to different situations

GS10. apply good attention to detail

GS11. check that the work is complete and free from errors

GS12. get work checked by peers

GS13. work effectively in a team environment

Engine Repair Technician Level 4

Maintain a healthy,safe and secure working environment:

Elements and Performance Criteria

Resources needed to maintain a safe, secure working environment

To be competent, the user/individual on the job must be able to:

PC1.    comply with organisations current health,safety and security policies and procedures

PC2. report any identified breaches in health,safety, and security policies and procedures to the designated person

PC3.. Coordinate with other resources at the workplace to achieve the healthy, safe and secure environment for all incorporating all government norms esp. for emergency situations like fires,earthquakes etc.

PC4.    identify and correct any hazards like illness, accidents, fires or any other natural calamity safely and within the limits of individuals authority

PC5.    report any hazards outside the individuals authority to the relevant person in line with organisational procedures and warn other people who may be affected

PC6.    follow organisations emergency procedures for accidents, fires or any other natural calamity

PC7.    identify and recommend opportunities for improving health,safety, and security to the designated person

PC8.    complete all health and safety records are updates and procedures well defined

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1.     legislative requirements and organisations procedures for health, safety and security and individuals role and responsibilities in relation to this

KU2.     what is meant by a hazard, including the different types of health and safety hazards that can be found in the workplace

KU3.     how and when to report hazards

KU4.     the limits of responsibility for dealing with hazards

KU5.     the organisations emergency procedures for different emergency situations and the importance of following these

KU6.     the importance of maintaining high standards of health, safety and security

KU7.     implications that any non-compliance with health, safety and security may have on individuals and the organisation

KU8.     different types of breaches in health, safety and security and how and when to report these

KU9.     evacuation procedures for workers and visitors

KU10. how to summon medical assistance and the emergency services,where necessary

KU11. how to use the health, safety and accident reporting procedures and the importance of these

Generic Skills (GS)

User/individual on the job needs to know how to:

GS1.     complete accurate, well written work with attention to detail

GS2.     read instructions, guidelines/procedures/rules

GS3.     listen and orally communicate information

GS4.     make decisions on a suitable course of action or response

GS5.     plan and organise work to achieve targets and deadlines

GS6.     build and maintain positive and effective relationships withcolleagues and customers

GS7.     apply problem solving approaches in different situations

GS8.     analyse data and activities

GS9.     apply balanced judgements to different situations

GS10. apply good attention to detail

GS11. check that the work is complete and free from errors

GS12. get work checked by peers

GS13. work effectively in a team environment

Automotive Engine Repair Tech Level 4 @ Scope - Satyam Centre of  Professional Excellence | (A unit of Satyam & Sparsh Autotech Pvt Ltd)

Carry out repairs of engine and other related mechanical aggregates:

Elements and Performance Criteria

Carry out the repair and assemble / disassemble of the engine & related aggregates

To be competent, the user/individual on the job must be able to:

PC1. .     understand the auto component manufacturer specifications related to the various engine components/ aggregates in the vehicle (including turbocharger)

PC2. .     follow standard operating procedures for using workshop tools and equipment for service and repairs of engine and its aggregates

PC3. .     conduct test drives to assess need for repairs, calibration or any other adjustments in the engine and its related mechanical aggregates

PC4. .     review the job card and understand work to be carried out in the engine and related aggregates

PC5. .     in case of non-routine service or repair, confirm tasks to be carried out with superior

PC6. .     ensure that the correct spare parts, lubricants, tools and other materials required have been obtained

PC7. .     calibrate, align and adjust settings, alignment and other tolerance levels relevant to the following engine and allied aggregates: engine and aggregates (including flywheel) allied engine aggregates (like radiator etc.) air intake and exhaust systems like (like turbocharger, intercooler etc.) cooling & lubrication system fuel ignition system (like injectors, fuel injection high pressure lines etc.) transmission system (including gearbox, differential, propeller shaft and axles) steering system clutch and brake assembly electrical and electronic components (related to engine including alternator, wire harness etc.)

PC8. .     repair and replace: cylinder block cylinder head piston liner piston (including piston rings) crankshaft (including main and BE journal) camshaft connecting rod air compressor flywheel (including ring gear and damper) fuel systems (diesel, petrol, electrical, gas etc.) radiator emission and exhaust system steering system various lubrication systems connected to the engine

PC9. .     carry out repair activities on the engine aggregates safely to ensure: no damage to the vehicle or other vehicles no damage to vehicle components and systems no contact with hazardous materials

PC10. . dismantle, assess, repair, clean, replace, adjust and reassemble vehicle mechanical engine aggregates

PC11..    identify and change engine components requiring change due to continuous wear and tear(including oil and air filters)

PC12..    ensure all dismantled engine components are cleaned and conditioned prior to reassembly

PC13. . ensure disposal of materials (including waste oil, scrap of failed parts/ aggregates) in accordance with the organisations policies

PC14. . refill correct grade of coolants, lubricants, engine oil and other fluids in the engine aggregates as per OEM guidelines

PC15..    understand the various precautions to be taken to avoid damage to the vehicle and its components while working on the engine aggregates and sub-assemblies

PC16. . record all service and repairs carried out on the engine and allied aggregates and ensure completeness of tasks assigned before releasing vehicle for the next repair or maintenance procedure

PC17..    ensure all workshop tools, equipment and workstations are adequately maintained by carrying out scheduled checks, calibration and timely repairs where necessary

PC18..    ensure any malfunctions observed in tools and equipment are reported to the concerned persons

PC19..    ensure any other repair requirements observed in the other components/ aggregates systems (like engine, gear box etc.) while repairing/ overhauling of braking systems are reported to Supervisor/ Service Advisor for further inspection by other specialists

PC20. . use resources responsibly (e.g. use of grease and other consumables)

PC21..    measure/ inspect the machining or any other repair done from an outside source/ local machining garages

PC22..    recognise when to seek assistance from a senior technician in case of diagnosis of the engine related aggregates

PC23. . ensure that trainings organized by the OEM from time-to-time are attended and knowledge levels are upgraded (esp. in case of newly launched products, product refreshes

PC24..    drive a relevant 2/3/4 wheeler vehicle which is an important part of the diagnosis of the type of vehicle that is dealt by the relevant OEM

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1.     standard operating procedures for servicing and repair of the engine components and aggregates in the vehicle

KU2.     standard schedules and checklists recommended by the OEM for servicing and repair of the engine components and aggregates in the vehicle

KU3.     identification codes, nomenclature of various engine components and aggregates in a vehicle

KU4.     correct and appropriate grade of engine oil, coolant or lubricant to be used for the corresponding engine variants as specified by the OEM/ Engine Manufacturer

KU5.     standard operating procedures recommended by the Dealership/ Suppliers/OEM for using tools and equipment to be followed related to various engine aggregates and components in a vehicle as per the Tool Manufacturer instructions

KU6.     standard operating procedures for rectification of errors in information (e.g. rectification of job card, reissue of correct tools and equipment etc.)

KU7.     safety requirements for equipment and components prescribed by the OEM (e.g. preventing/ dealing with oil spillage and inflammable materials)

KU8.     documentation requirements for each procedure carried out as part of roles and responsibilities as specified by OEM/ auto component manufacturer

KU9.     organisational and professional code of ethics and standards of practice

KU10. safety, health and environmental policies and regulations for the workplace as well as for automotive trade in general(e.g. safe working practices inside pits/ under vehicles)

KU11. the basic technology used for various types of engine and allied aggregates: working cycle (2 stroke and 4 stroke) fuel (petrol, diesel, CNG, LPG, electric/ hybrid types) cylinder type – single cylinder – multi cylinder (including inline, straight, horizontal, inline V shape) cooling system (air or water cooled)

KU12. the functioning of of various components and component systems in the engine and its aggregates(including the various repair requirements) including: air intake and exhaust systems – air filter – turbocharger – intercooler – exhaust and intake manifold – intake and exhaust valve cooling system – water pump fuel system – fuel tank – fuel injectors – FIP (fuel injection pump) lubrication system – oil pump (including pressure relieve valve) – oil filter & heat exchanger

KU13. the functioning of other aggregates (other than engine and allied aggregates) including : clutch assembly transmission systems (manual, automatic etc.) hydraulic and pneumatic system brake system drive-train assembly steering system suspension system electrical, ignition, electronic and air-conditioning system etc.

KU14. typical causes and symptoms of operational faults and failures of a vehicle which are related to engine and it aggregates : poor pickup HEOC (high engine oil consumption) low power generation low oil pressure blow-by excessive black smoke noisy turbocharger oil leakage unusual noise from the engine or allied aggregates any other complaint/ fault related to mainly the engine and its aggregates

KU15. the tools used to assess deviations from specifications during routine servicing, including use of: pressure indicators: fuel pressure testers, manifold gauge sets, oil pressuregauges, tire pressure gauges etc. pullers: ball joint separators, bearing pullers, gear puller tools, slidehammers etc. specialty wrenches: alignment wrenches, chain wrenches, locking wrenches,lug wrenches etc. trim or moulding tools: carbon scrapers, gasket scrapers, scrapers, spoonsetc. measuring equipment: vernier calipers, micrometre, feeler gauges, multimetre,flow metre, temp gauge, dial gauge etc. other tools: hand tools, power tools, lifting and jacking equipment,tensioning equipment, brake roller tester, chassis dynamometer, suspensionactivation, security activator etc. tools for other tasks such as cleaning of vehicles, tools, equipment andworkshop

KU16. how to repair, routine service and maintenance of the major aggregates within the engine including: cylinder block cylinder head piston liner piston (including piston rings) crankshaft (including main and BE journal) camshaft connecting rod air compressor flywheel (including ring gear and damper) fuel systems (diesel, petrol, electrical, gas etc.) radiator emission and exhaust system

KU17. how to select the right materials for the job such as seals, sealants, fittings, gaskets, joints, fasteners etc.

KU18. how to carry out routine maintenance including: checking engine condition in the vehicle against OEM specifications to identify damage, corrosion, wear and tear, fluid levels, leaks and other problems in serviceability make adjustments to settings, alignment and tolerance levels relevant to: – engine and aggregates (including flywheel) – allied engine aggregates (like radiator etc.) – air intake & exhaust system like (like turbocharger, intercooler etc.) – cooling & lubrication system – fuel ignition system (like injectors, fuel injection high pressure lines etc.)- transmission system (including gearbox, differential, propeller shaft and axles)- steering system- clutch and brake assembly- electrical and electronic components (related to engine including alternator, wire harness etc.)

KU19. how to measure/ inspect the machining or any other repair done from an outside source/ local machining garages on the various engine aggregates (like machining of the piston, cylinder head, cylinder block)

KU20. how to carry out the full overhaul of the engines (with support from the other technicians and machine shops from local garages)

KU21. the various sources of information available for assessing service and repair requirements of the engine and allied aggregates in a vehicle including: diagnostic displays visual inspections test drives various manuals from OEM and engine manufacturer vehicle/equipment manufacturer specifications standard operating procedures

KU22. procedures recommended by the OEM and Dealership to be used during routine servicing of the various engine and its aggregates

KU23. the type and quality of components specified by the OEM for use as replacement parts

KU24. The correct and appropriate grade of engine oil, coolant or lubricants for the corresponding engine variants as specified by the OEM/ engine manufacturer for use

KU25. corrective action to be taken for common engine and aggregate system faults and failures

KU26. faults and failures in the engine and allied aggregates that necessitate replacement of components and other units

KU27. how to dispose -off replaced failed components and changed oil, lubricant, grease etc. in accordance with safety, health and environmental policies and regulations

KU28. precautions to be taken to ensure the following while working on the engine aggregates and components (including specific precautions to be taken when working with alternative fuel/ hybrid vehicles): no damage to the electrical / other advanced systems (in case of hybrid/ electrical vehicles) no damage to the vehicle on which work is being done along with other vehicles parked besides no damage to vehicle components sub-assemblies and other systems (other than the engine aggregates on which the repair is being done) no contact with hazardous materials

KU29. when to ask for assistance from a superior

Generic Skills (GS)

User/individual on the job needs to know how to:

GS1. create documentation required on the job (including job cards, work sheets, etc.) regarding the basic details of repair , maintenance and service performed on the engine and its allied aggregates

GS2.     write any additional requirement of work on the vehicle reported for engine service, maintenance or repair found during the work done as specified in the job card (for e.g. while working on the engine and transmission system, if low level of engine oil/ greasing or coolant, then convey to the superiors)

GS3.     write in at least one language

GS4.     read job cards and instructions from Supervisors and the Service Advisor regarding the repair and service of engine aggregates

GS5.     read various sources of information available for assessing service and repair requirements of the engine aggregates in a vehicle including service manual and diagnostic and visual displays put up in the workshop

GS6.     read policies and regulations pertinent to the job, including OEM guidelines, Health and Safety instructions etc. while working on the engine and its aggregates

GS7.     clearly communicate workplace information and ideas with workplace colleagues (verbal & non-verbal)

GS8.     use terms, names, grades and other nomenclature pertaining to the Automotive trade, tools, specific workshop equipment etc

GS9.     communicate with colleagues to handle verbal enquiries, such as clarifying instructions and responding to requests for information

GS10. interact with the customer through Service Advisor/ Supervisor in case any additional work needs to be done on the engine aggregates as a result of diagnosis of some complaint leading to additional repair in the vehicle in the engine aggregate

GS11. analyse information and evaluate results to choose the best solution and solve problems

GS12. decide on the repair/ replacement of any engine aggregate post the diagnosis (with help from a superior in case required)

GS13. judge when to ask for help from a Superior or senior diagnosis technician

GS14. plan work according to the required schedule and location

GS15. plan the assigned engine repair work (including the specific engines that needs to be overhauled)and provide estimates of time required for each engine overhaul repair

GS16. organise the schedule to complete work on the engine aggregate timely in case other aggregate repairs/ maintenance work is also required to be done

GS17. interpret the customer needs basis the complaint which may be as a result of some fault in the engine aggregates (like high engine oil consumption, noisy engine, engine oil leakage)are assessed and every effort is made to resolve the complaints

GS18. ensure that the service provided is of the highest order to ensure higher levels of customer satisfaction

GS19. ensure timely communication of the additional work on the engine aggregates while carrying out other repairs in the engine aggregates to the Service Advisor/ Supervisor who in turn communicates it to the customer

GS20. follow up with the Service Advisor on any unfavourable feedback received from customer on the service and repair on the engine aggregates

GS21. recognise a workplace problem or a potential problem and take action (e.g. leaks or oil spills in the workshop

GS22. determine problems needing priority action (e.g. while working on the engine, crank / pistons require machining as they have been worn out, inform the service advisor or supervisor for urgent action)

GS23. refer problems outside area of responsibility to appropriate person (e.g. unavailability of required spare parts or materials in the workshop)

GS24. gather information while working on engine aggregate/ components and take appropriate action, by consulting superiors

GS25. assess repairs required based on technical faults identifiedas specified in the job card/ supervisor notes

GS26. refer complex problems(outside the current scope of work) to a superior in case any additional work requirement comes up

GS27. analyse, evaluate and apply the information gathered from observation, experience, reasoning, or communication to act efficiently

GS28. use the diagnosis results to take an appropriate decision on repair/ replacement of engine aggregates in consultation with the supervisor/ aggregate specialist/ service advisor

Assessment Guidelines:

  1. Criteria for assessment for each Qualification Pack will be created by the Sector Skill Council. Each Element/ Performance Criteria (PC) will be assigned marks proportional to its importance in NOS. SSC will also lay down proportion of marks for Theory and Skills Practical for each Element/ PC.
  • The assessment for the theory part will be based on knowledge bank of questions created by the SSC.
  • Assessment will be conducted for all compulsory NOS, and where applicable, on the selected elective/option NOS/set of NOS.
  • Individual assessment agencies will create unique question papers for theory part for each candidate at each examination/training center (as per assessment criteria below).
  • Individual assessment agencies will create unique evaluations for skill practical for every student at each examination/ training center based on these criteria.
  • To pass the Qualification Pack assessment, every trainee should score the Recommended Pass % aggregate for the QP.
  • In case of unsuccessful completion, the trainee may seek reassessment on the Qualification Pack.