mechanical technology department engines and vehicles section

Mechanical Technology Department

Engines and vehicles section

Study plan distributed over all semesters

Number of units No Course

code Course name Pre-requisite C.U L W T C.H

1 ENG 101 General English Language - - - 3 2 2 4 2 ISL 101 Islamic Culture - - - 2 2 - 2 3 MAT 161 Specialized Mathematics - - - 3 3 1 4 4 CMP 101 Introduction to Computer - - - 2 - 4 4 5 MEV 111 Preparatory Workshop - - - 2 - 4 4 6 MEV 112 Industrial Safety - - - 1 - 2 2

Firs

t Sem

este

r

7 MEV113 Introduction to Automotive Electric System - - - 2 1 2 3 Total 15 8 14 1 23

Number of units No Course code Course name Pre-requisite C.U L W T C.H

1 ENG 192 Technical English ENG 101 3 2 2 4 2 ARB 101 Arabic Language - - - 2 2 - 2 3 PHY 101 Specialized Physics - - - 3 2 2 4 4 MEV 121 Technical Drawing - - - 2 - 4 4 5 MEV 122 Fuel System (Gasoline) MEV 111 4 2 4 6 Se

cond

Sem

este

r

6 MEV 123 Engines (1) MEV 111 4 2 4 6 Total 18 10 16 26

Number of units No Course code Course name Pre-

requisite C.U L W T C.H1 ENG 293 Technical English II ENG 192 3 2 2 4 2 MEV 211 Power Trains (I) MEV 111 4 2 4 6 3 MEV 212 Brake System MEV 111 4 2 4 6 4 MEV 213 Engines (2) MEV 123 4 2 4 8

Thi

rd S

emes

ter

5 MEV 214 Fuel System (Diesel) MEV 123 3 2 2 4 Total 18 10 16 26


1 ISL 102 Islamic Culture ISL 101 2 2 - 2 2 MGT 101 Professional Ethics - - - 2 2 - 2 3 MEV 221 Engineering Drawing MEV 121 2 - 4 4 4 MEV 222 Power Trains (2) MEV 211 4 2 4 6 5 MEV 223 Suspension & Steering System MEV 111 4 2 4 6 Fo

urth

Sem

este

r

6 MEV 224 Fault Diagnosis MEV 213 4 2 4 6 Total 18 10 16 26


Sum

mer

1 MEV 230 Cooperative Training - - - 4 According to working hours

Number of units C.U L W T C.H Program total number of units 73 38 62 - 101

C.U.: Credit Hours L: Lecture W: Workshop T: Practice C.H.: Contact Hours

Department Mechanical Technology Major Engines and Vehicles

Course name Preparatory Workshop Code MEV 111

Prerequisite None

Course description: In this course the student is introduced to the fundamentals of preparatory workshops and engineering measuring, as well as the basis of safety procedures. The student is also introduced to the tools and equipment used in the workshop. Car parts which include the engine, power train systems, friction clutch and its types, different gearboxes, driving shafts, differential, suspension, different brake systems and their types and parts are also covered.

Semester 1 2 3 4

Credit hours 2

L

W 4 Contact hours

(hour/week) T

General course objectives: This course aims to introduce the student to the fundamentals of preparatory workshops and engineering measuring as well as the basics of safety procedures. The student is also introduced to the tools and equipment used in the workshop, and all car parts.

Skill Objectives: The student should be able to: • Know the fundamentals of preparatory workshops and engineering measuring. • Know the basics of safety procedures. • Know the tools and equipment used in the workshop. • Know car parts which include; the engine, different power train systems, suspension, different

brake systems and their types and parts.

Subjects (theoretical and practical): • The fundamentals of preparatory workshops and engineering measuring • Safety procedures • Tools and equipment used in the workshop • Car parts which include; the engine, different power train systems, suspension, different brake

systems and their types and parts

Detailed Practical Course

Hours Content Skill Objectives Related tasks

8

Basic skills which include: - safety rules - measuring methods - manual cutting methods using

different tools

The student should be able to: - Apply safety rules. - Carry out measuring methods. - Carry out manual cutting

methods using different tools.

A1, A2

8

Metal forming which includes: - filing - bending - cutting - forming

- Carry out metal forming by filing, bending, cutting and forming. A4

4

Metal joining methods which includes:

- joints classifications - joints riveting - joints welding

- Carry out methods of metal joining which include

- joints classifications - joints riveting - joints welding

A3

8

Machine and tool operation basics which include:

- types of tools and equipment - operating equipment

- Have basic knowledge of operating machines and tools which include:

- types of tools and equipment - operating equipment

A3

2

Workshop industrial safety procedures:

- precaution methods - methods of storing flammable

materials - methods of arranging

equipment for emergencies

- Have knowledge of workshop industrial safety procedures which include:

- precaution methods - methods of storing flammable

materials - methods of arranging

equipment for emergencies

A1, A2

2

Tools, machines and equipment used in the workshop

- all types of filing tools with different smoothing levels

- all forging tools in all shapes and sizes

- wrenches and pullers in all shapes and sizes

- heavy machinery (turning machines for valves, discs, drums, ... etc)

- Have knowledge of correctly

using tools, machines and equipment in the workshop.

- Know how to protect one's self from injuries when using workshop tools, machines and equipment.

- Protect tools, machines and equipment from any harm.

A3

8

The engine, its components and parts which include:

- cooling system (radiator – connections – water pump – water jackets)

- lubricating system (oil pan – oil pump – oil galleries - oil filter)

- fuel system (conventional system which includes: fuel tank – fuel pump – fuel filter – connections – carburetor)

- fuel injection (includes: fuel tank – fuel pump – connections – fuel filter – control unit – injectors)

- ignition system (battery – ignition coil – distributor – spark plugs)

- electric circuits (front and rear light circuits – wipers – signal lights … etc)

- Identify the cooling system

and its main parts. - Identify the lubricating

system in the engine and its main parts.

- Identify the fuel system and its main parts.

- Identify the ignition system and its main parts.

- Identify external and internal engine parts and the four strokes.

- Identify the electric circuits in the car.

D4, D7, D10, D8

6

Power train parts- their types and components which include:

- friction clutch and its different types

- sliding and constant mesh gearboxes

- different types of propeller shafts, connections and bearings

- back axel unit, its components and importance

- axels and rods

- Identify power train parts, their types and components which include:

- friction clutch and its different types

- sliding and constant mesh gearboxes

- different types of propeller shafts, connections and bearings

- back axel unit, its components and importance

- axels and rods

E1,E7

6

Steering and suspension- their types and components which include:

- springs, shock absorbers …etc - control arms, rods, dust boots,

rubber bushings, ball bearing … etc

- wheel alignment angles, their types and importance

- Identify Steering and

suspension, their types and components which include:

- springs, shock absorbers … etc

- control arms, rods, dust boots, rubber bushings, ball bearing … etc

- wheel alignment angles, its types and importance

G1, G6

4

Brakes, their types and components which include:

- hydraulic brakes (drum and disc brakes)

- air brakes (air reservoir, valves, … etc)

- booster, levers, linkages, parking brakes and engine brakes

- Identify the brakes, their

types and components which include:

- hydraulic brakes (drum and disc brakes)

- air brakes (air reservoir, valves … etc)

- booster, levers, linkages, parking brakes and engine brakes

F1, F2, F3, F4, F5, F6, F7, F8, F9,

F10


Course name Industrial safety Code MEV 112

Prerequisite None

Course description: industrial safety is part of the job principles the student should know. This course covers the way of how to wear work clothes, safety helmet …etc. As well as to choose and prepare the appropriate workplace, methods of using tools and equipment and their safety and methods of using lifts. The workshop safety part covers the proper methods of getting rid of exhaust gases, proper storing of flammable materials and using fire extinguishers.

Semester 1 2 3 4

Credit hours 1

L -

W 2 Contact hours

(hour/week) T -

General course objectives: The course aims to introduce the student to industrial safety which is part of the job principles. The student learns how to wear work clothes, safety gear, choosing the proper location for work- and to provide the workplace with suitable equipment, as well as to know the methods of using tools, equipment and their safety and methods of using lifts. The student also learns the workshop safety procedures, proper storing of flammable materials and using fire extinguishers. Skill Objectives: The student should be able to: • know how to wear work clothes and safety gear • know how to choose a suitable location for work and prepare it • know how to correctly use tools and operate equipment and their safety, and methods of using

lifts • follow safety procedures inside the workshop (properly get rid of exhaust gases) • properly store flammable materials and use fire extinguishers

Subjects (theoretical and practical): • method of wearing work clothes and safety gear • method of choosing a suitable location for work and prepare it • method of using and operating tools and equipment and their safety, and methods of using lifts • following safety procedures in the workshop (properly get rid of exhaust gases) • method of storing flammable materials and using fire extinguishers



2

1 – Clothes - wearing work clothes - be sure that the clothes are

free from any metal parts - wear safety goggles - wear gloves

The student should be able to: - Know how to wear work

clothes and safety gear for his safety, the safety of the car and for the general appearance of the mechanic.

A1

2

2 – The place - choosing a proper location for

the job - placing the car in the right

location for the job - be sure that the floor is free of

any liquid spills - be sure of the presence of

safety equipment

- Prepare a suitable place for

working on the car - Be sure that the floor is free

from any liquid spills - Be sure of the presence of

safety equipment A2

4

3 – Using tools - Knowing the tools and using

the suitable ones for the job - Taking care of the tools - being sure of the safety of the

vehicle

- Use tools properly to avoid

injuries and for protecting the tools from any harm A3

4

4 – Equipment - Proper usage of equipment - Using the right device - Taking care of the equipment

- Use equipment properly to avoid injuries and for protecting the equipment from any harm

A4

4

5 – Lifts - Learn about lifts and methods

of using them. - Proper placement of vehicle

on the lift - Be sure of the stability of the

vehicle.

- Secure car lifts to ensure the

safety of the car, the worker and the workshop. A5

2

6 – Exhaust gases - Be sure of the suction of

exhaust gases. - Use exhaust gas suction hoses.

- Use exhaust gas suction hoses with special equipment to prevent air pollution inside the workshop.

A6

2

7 – Flammable materials - Store flammable materials in

their designated places. - Caution when carrying

flammable materials - Ventilation of their storing area - Locking the place

- Store flammable materials in their designated places for the safety of the workshop, the car, the worker and for general safety.

A7

4

8 – Fire extinguishers - Learn how to use fire

extinguishers and their types. - Know the location of the fire

extinguishers.

- Use fire extinguishers to

combat flames in case of a fire. A8

4

9 – Manufacturing company’s recommendations

- Placing shields on cars while working

- Protect car when working on it

- Adhere to manufacturing

company’s recommendations to protect the car body and the workshop facilities.

A9


Course name Introduction to Automotive Electric System Code MEV 113

Prerequisite None

Course description: This course covers minor vehicle electric faults. It includes electricity fundamentals, the battery, lighting circuit, signal lights circuit, wipers circuit, horn circuit, generator, starter, as well as checking, repairing or replacing minor electric parts in the vehicle.

Semester 1 2 3 4

Credit hours 2

L 1

W 2 Contact hours

(hour/week) T -

General course objectives: this course aims to introduce the student to the minor vehicle electric faults which include electricity fundamentals, the battery, lighting circuit, signal lights circuit, wipers circuit, horn circuit, generator, starter, as well as being able to check, repair or replace minor electric parts in the vehicle.

Skill Objectives: The student should be able to: • Identify minor vehicle electric faults. • Basic knowledge of electricity fundamentals, the battery, lighting circuit, signal lights circuit,

wipers circuit, horn circuit, generator, starter. • Check, repair or replace minor electric parts in the vehicle

Subjects (theoretical and practical): • Minor vehicle electric faults. • Electricity fundamentals, the battery, lighting circuit, signal lights circuit, wipers circuit, horn

circuit, generator, starter. • Check, repair or replace minor electric parts in the vehicle.

References:

- James E. Duffy, "Auto Electricity, Electronics, Computers", The Goodheart-Willcox Company Inc., ISBN - Stockel, and Johanson, "Auto Service and Repair", The Goodheart- Willcox Company Inc., ISBN 1 -56637-144-9 - John Deere, "Electrical Systems, Fundamentals of Service&', ISBN 0- 8669 1-0476 - William Toboldt, Larry Johnson and W. Scott Gauthier, "Automotive Encyclopedia", 1995, The Goodheart-Willcox Company Inc., ISBN - Ilarcourt Brace Jovanivicb, "Automotive computer control systems", Fundamentals and services, Publishers, ISBN 0-15-504355-2 - Stockel and Johanson, "Auto Service and Repair", The Goodheart- Willcox Company, ISBN 1-5663 7-144-9 - Robert Bosch GmbH, "Automotive Handbook", ISBN 0-89 283-518-6 - Harper and Row, "Automotive Electrical Systems", Classroom Manual, Check-Chart Automotive Series - Harper and Row, "Automotive Electrical Systems", Workshop Manual, Check-Chart Automotive Series - Martin W. Stockel and Martin T. Stockel, "Auto Mechanic Fundamentals", The Goodheart-Wilcox Company Inc. -Robert Bosch Coop, "Bosch Technical Instruction Series", 1. Engine Electronics 2. Alternators 3. Starting Systems - Robert Bosch Coop, "Automotive Handbook", Bosch, VDI-Verlag, ISBN - Robert Bosch Coop, "Fault Detection with Oscilloscope", ISBN 1-689- 9804)86

Detailed Theoretical Course


1

Electricity basics - Electricity fundamentals - Semiconductors

The student should be able to: Understand the fundamentals of electricity which include: - Electricity fundamentals - Semiconductors

L2

1

The battery - Battery function - Battery parts

- Identify the vehicle battery, its function and components.

- Understand the symbols and numbers on the battery.

L1

1

Lighting circuit - Lighting circuit function - Lighting circuit components - Method of operation

- Identify lighting circuit, its function and components.

- Know how the lighting circuit works.

L2

1

Signal light circuit - Signal light circuit function - Signal light circuit

components - Method of operation

- Identify the signal light circuit, its function and components.

- Know how the signal light circuit works.

L2

1

Wiper circuit - Wiper circuit function - Wiper circuit components - Method of operation

- Identify the wiper circuit, its function and components.

- Know how the wiper circuit works.

L2

1

Horn circuit - Horn circuit function - Horn circuit components - Method of operation

- Identify the horn circuit, its function and components.

- Know how the horn circuit works.

L2

4

Generator - Generator function - Generator parts - Method of operation - Types of generators

- Identify the charging circuit, its function and operation.

- Know how the charging circuit works.

L2

4

Starter - Starter function - Starter parts - Method of operation

- Identify starter circuit, its function and components.

- Know how the starter circuit works.

L2



2

Electricity basics - Electricity fundamentals - Semiconductors

The student should be able to: - Test minor electric units using

special tools and equipment to ensure their serviceability.

L3, L4

2

The battery - Battery function - Battery parts - Checking the battery - Testing battery voltage

- Testing the battery voltage with a special device to know its ability to operate the starter and other electric circuits in the vehicle.

L1, L4

2

Lighting circuit - Lighting circuit function - Lighting circuit parts - Checking the lighting circuit - Diagnosing faults - Replacing all parts of the lighting

circuit

- Identify the lighting circuit, and its parts.

- Know how to check lighting circuit.

- Diagnose faults. - Repair or replace the lighting

circuit completely.

L3, L4, L5

2

Signal light circuit - Signal light circuit function - Signal light circuit parts - Checking signal light circuit - Learn to diagnose faults - Replacing parts of the signal light

circuit

- Identify signal light circuit, and its parts.

- Know how to check signal light circuit.

- Diagnose faults. - Repair or replace signal light

circuit completely.

L3, L4, L5

2

Wiper circuit - Wiper circuit function - Wiper circuit parts - Checking wiper circuits - Learn to diagnose faults - Replacing wiper circuit

completely

- Identify the wiper circuit, and its components.

- Know how to check the wiper circuit.

- Diagnose faults. - Repair or replace wiper circuit

completely.

L3, L4, L5

2

Horn circuit - Horn circuit function - Horn circuit components - Checking horn circuit and

diagnose fault - Replacing horn circuit completely

- Identify the horn circuit, and its components.

- Know how to check the horn circuit.

- Diagnose faults. - Repair or replace horn circuit

completely.

L3, L4, L5

8

Generator - Generator function - Generator parts - Method of checking generator and

judging its condition while installed

- Method of removing the generator from the car

- Checking the generator uninstalled - Disassembling the generator - Checking and testing the parts - Replacing faulty parts - Reassembling the generator - Reinstalling the generator in the

car

- Identify charging circuit, and its components.

- Know how to check the charging circuit.

- Diagnose faults. - Repair or replace the circuit

completely. L3, L4,

L5

4

Starter - Starter function - Starter parts - Method of checking the started

while installed - Method of removing the starter

from the car - Checking the starter uninstalled - Disassembling the starter - Checking and testing the starter

parts - Replacing faulty parts - Reassembling the starter - Reinstalling the starter in the car

- Identify starter circuit, and its components.

- Know how to check the starter - Diagnose faults. - Repair or replace the starter

parts completely. L3, L4,

L5


Course name Technical Drawing Code MEV 121

Prerequisite None

Course description: This course includes technical drawing basics, orthographic projection, conversions, symbols, sections and hatching.

Semester 1 2 3 4

Credit hours 2

L

W 4 Contact hours

T

General course objectives: This course aims to give the student the ability to use technical drawing as a language to be able to read symbols and drawings. It also makes the student correctly employ the basics of technical drawing and symbols.

Skill Objectives: The student should be able to: • Explain different lines used in technical drawing. • Identify different symbols used to pass information. • Read, understand technical drawings and printed drawings. • Analyze the drawing and write a technical report.

Subjects (theoretical and practical): • The fundamentals of technical drawing • Orthographic projection • Conversions and symbols • Sections and hatching

References:

- James H; "Drafting, technology,, Earle Addison-Wesley Publications co. - M.A. Parker & L.J. Dennis, "Engineering drawing Fundamentals', Stanley Theories. - Warren .I. Luzadder, ,, Fundamentals of Engineering Drawing', Prentice-Hall, 1986, Ninth Edition.



12

Introduction - Technical drawing as a

technician language - Projection methods - Tools and equipment used - Line types - Drawing sheet distribution - Freehand drawing

The student should be able to: - Explain ways of projection - Identify different types of

lines - Preparing the drawing sheet - Improve freehand drawing of

simple shapes

12

Dimensions - Introduction - Dimensions technology - Reference and dimension lines - Arrow lines - Dimensions placement - Methods of writing dimensions - Advantages of writing

dimensions in general (circles, diameters … etc)

- Use basic standards to

produce drawing dimensions

12

Orthographic projection - Orthographic projection of

points, lines and areas - Orthographic projection of the

first angle - Orthographic projection of the

third angle - Projection symbols - Final view projection - Measurements - Hidden details

- With the help of drawings explain the meaning of orthographic projection using the fundamentals of views, dotted lines, areas and body

- Produce drawings using hidden lines by utilizing projection of the first and third angles

12

Sections and sectioned figures: - The need for sections - Sections levels - Full sections - Half sections - Broken out, revolved, removed,

and partial section.

- Use basic standards to

produce drawing sections

B6, E1, E8, E10, E11, E12, G13, H1, H2, I1,

I10, I14, I17, K7,

K10 A3


Course name Fuel system (gasoline) Code MEV 122

Prerequisite MEV 111

Course description: This course covers the principals of combustion in gasoline engines and the requirements of air fuel mixture. Fuel delivery systems; conventional and electronically controlled, their components and function. Fault diagnosis, repair, servicing, maintenance and replacing faulty parts.

Semester 1 2 3 4

Credit hours 4

L 2

W 4 Contact hours

T

General course objectives: This course aims to introduce the student to the fundamentals of combustion in the gasoline engine and the requirements of air fuel mixture, fuel delivery systems; conventional and electronically controlled, their components and function. The student is also introduced to fuel injection systems, their types, advantages, parts and their functions. The course introduces the student to fault diagnosis, repair, servicing, maintenance and replacing faulty parts.

Skill Objectives: The student should be able to: • Determine fuel air mixture requirements suitable for the different engine operating conditions. • Explain different carburetor designs; simple, integrated conventional and electronically

controlled. • Explain, analyze different constructions and the principals of operation of fuel injection

systems in the gasoline engines. • Explain, practically, the functions of different fuel injection systems, carry out measurements,

diagnose and repair faults, and evaluate their expected causes by using practice engine. • Diagnose and locate faults; visually and by using equipment, repair and calibrate:

- Electronically controlled carburetors - Fuel injection systems in the gasoline engines

Subjects (theoretical and practical): • The fundamentals of combustion in the gasoline engine and the requirements of air fuel

mixture. • Fuel delivery systems; conventional and electronically controlled, their parts and function. • Fuel injection systems, their types, advantages, parts and their functions. • Fault diagnosis and repairs. • Servicing and maintenance of fuel systems. • Replacing faulty parts of the fuel systems.

References:

- Duffy, James E., and Smith, Howard B.," Auto Fuel and Emission Control Systems Technology", The Goodheart-Willcox company, INC, ISBN 0- 87006 932 2 - Robert Bosch GmbH "Automotive Electric I Electronic Systems", 2nd edition 1995, 1 SBN 1-56091-596-X - Heinze Heisler, Advanced Engine Technology, Edward Amold, ISBN 0340568224 - William H. Crouse and Donald L. Anglin, "Automotive Mechanics The McGraw Hill Book Company, ISBN 04)2-800943-6 - Martin, W. Stokel and Martin, "Auto Mechanics Fundamentals", The Goodheart Willcox company, -C, ISBN 1-56637-138-4, 1996 - Martin W. Stokel, Martin T. Stokel Chris Johanson "Auto Fundamentals The Goodheart – Willcox company, INC, ISBN 1-56637-1384, 1996 - William, K. Toboldi, Larry Johnson, and W. Scon Oavthier, "Automotive Encyclopedia " Fundamental, Principles, Operation, Construction, Service, and Repair, The Goodheart –Willcox company, INC, ISBN 1-56637-150-3, 1995 - Duffy, James E., "Auto Engines" The Goodheart Willcox company, INC, ISBI;J 0-87006477-3 - Jack Enjavec and Robert Scharif "Automotive Technology" Delmar Publishers, An International Thomson Publishing Company.



2

1 - Gasoline engine fuel system - The fundamentals of combustion

and the requirements of air fuel mixture

- Gasoline properties - Combustion theory - Fuel / air ratio and its variations - Combustion in the gasoline engine - Air fuel mixture requirements

under different operating conditions

- Gasoline engine fuel systems; conventional and electronic injection

The student should be able to: - Explain the advantages of

gasoline fuel. - Calculate fuel / air ratio and

differentiate between rich and poor fuel mixtures.

- Differentiate between normal and abnormal combustion.

- Explain and show the effects of different operating conditions on engine performance.

- Describe the mixture requirements for different operating conditions.

D8, H5

8

2 – Conventional fuel system (carburetor)

- Different carburetor constructions and types

- Simple carburetor systems, operation, circuits and their designs

- Construction and function of the conventional two stage carburetor

- Simple operation and parts of the electronically controlled carburetor

- Explain carburetor systems, operation- differentiate between its types.

- Describe the functions of carburetor systems to cope with the mixture requirements for different operating conditions.

D8, H5

4

3 - Fuel injection systems in gasoline engines

- Different types of fuel injection systems in gasoline engines

- Advantages and general specifications

3 – 1 – Continuous fuel injection systems (K & KE-Jetronic)

- Introduction about the system, its specifications, parts and their functions

- Common problems, faults and their possible causes

- Describe different types of fuel injection systems and show the advantages of each one.

- Describe the combined mechanical - electronic fuel injection systems.

- Show the circuit diagrams for these systems; name their parts, functions and method of operation.

- Determine types of faults and their causes and improve them.

D8, H5

4

3 – 2 – Intermittent fuel injection systems

- General information about intermittent fuel injection systems which include:

- Electronic fuel injection systems (L-jetronic, LE-jetronic, LH-jetronic, EFI, SEFI, MPFI, mono-jetronic, TBI system)

- Electronic combined fuel injection systems (Motronic and Mono-Motronic)

- Explain electronic intermittent

fuel injection and describe its different systems.

D8, H5

4

3 - 2 – 1 – electronic fuel injection systems

- Introduction about the electronic fuel injection systems:

- System specifications, circuit diagrams, parts, mode of operation

- Control unit circuit diagram, input sensors, output operators

- Output pulse timing diagram - The system includes different

operating conditions

- Explain the advantages of different electronic fuel injection systems.

- Summarize the system diagram. - Describe the mode of operation

of different parts. - Describe how the system adopts

different engine operating conditions.

- Summarize diagram for the control unit, sensors, and operators.

- Explain the system pulse timing diagram.

- Describe closed control circuit.

D8, H5

6

3 – 2 – 2 – Combined electronic fuel injection –ignition systems:

- Introduction about combined electronic fuel injection – ignition systems; their advantages, specifications, diagrams, parts, mode of operation

- Explanation of electronic ignition part

- Explanation of electronic injection part

- The diagram for measuring amount of fuel

- Time span of injection and pulse timing

- The system includes different operating conditions

- Common problems, faults and possible causes of system problems

- Explain the advantages of combined mechanical - electronic fuel injection systems (Motronic).

- Explain both systems; combustion and injection.

- Summarize system diagram. - Describe how the system adopts

different engine operating conditions.

- Summarize diagram for control unit, sensors, and operators.

- Explain the system pulse timing diagram.

- Describe closed control circuit.

D8, H5



4

1 - Checking and repairing fuel system in gasoline engines:

- Introduction to fuel systems workshop, its contents and equipment

- Doing different tests on car engine to find out mixture ratio and how it affects the engine and environment.

The student should be able to: - Know the fuel systems workshop,

its contents and equipment - Do different tests on a car engine

to know mixture ratio and how it affects the engine and environment.

D8, H5

16

2 - Checking and repairing conventional fuel system (carburetor):

- Removing and reinstalling the carburetor, fuel pump, filter and checking fuel circuit

- Checking and repairing carburetor, fuel pump, filter, connections and gas pedal

- Replacing faulty parts - Testing the system after replacing

and repairing

- Check and repair conventional fuel system (carburetor)

- Remove and reinstall the carburetor, fuel pump, filter and checking the fuel circuit

- Check and repair the carburetor, fuel pump, filter, connections and gas pedal

- Replace faulty parts in the system - Test the system after replacing

and repairing

D8, H5

8

3 - Checking and repairing fuel injection systems in gasoline engines:

- Introduction to fuel injection systems

3 – 1 – Checking and repairing continuous fuel injection systems (K & KE-Jetronic)

- Checking and repairing sensors - Checking and repairing injectors,

fuel regulator - Checking and repairing fuel pump,

engine heat regulator - Replacing faulty parts and testing

the system

- Check and repair fuel injection system in gasoline engines

- Identify fuel injection systems - check and repair continuous fuel

injection systems (K & KE-Jetronic)

- Check and repair sensors - Check and repair injectors, fuel

regulator - Check and repair fuel pump,

engine heat regulator - Replace faulty parts and test the

system

D8, H5

8

3 – 2 - Checking and repairing intermittent fuel injection systems:

- Electronic fuel injection systems (L-jetronic, LE-jetronic, LH-jetronic, EFI, SEFI, MPFI, mono-jetronic, TBI system)

- Electronic combined ignition and fuel injection systems (Motronic and Mono-Motronic)

Check and repair intermittent fuel injection systems: - Electronic injection systems (L-

jetronic, LE-jetronic, LH-jetronic, EFI, SEFI, MPFI, mono-jetronic, TBI system)

- Electronic combined fuel injection and ignition systems (Motronic and Mono-Motronic)

D8, H5

8

3 – 2 – 1 – Checking and repairing electronic injection systems:

- Checking and repairing injectors and sensors

- Checking and repairing fuel pump and filters

- Checking and repairing regulators and electric connections

- Checking and repairing electronic control unit

- Replacing faulty parts and testing the system

Check and repair electronic injection systems: - Check and repair injectors and

sensors. - Check and repair fuel pump and

filters. - Check and repair regulators and

electric connections. - Check and repair electronic

control unit. - Replace faulty parts and test the

system.

D8, H5

12

3 – 2 – 2 - Electronic combined ignition and fuel injection systems: Checking and repairing the electronic injection part: - Sensors, injectors, fuel pump,

regulators - Replacing faulty parts and testing

the system Checking and repairing the ignition part: - Checking distributor, ignition coil,

spark plugs, connections, electronic parts, high tension cables, ignition system sensors

Checking the combined system control unit - Replacing faulty parts and testing

the system

Check and repair electronic injection part: - Sensors, injectors, fuel pump,

regulators. - Replace faulty parts and test the

system. Check and repair ignition part: - Check distributor, ignition coil,

spark plugs, connections, electronic parts, high tension cables, ignition system sensors.

Check the combined system control unit - Replace faulty parts and test the

system.

D8, H5


Course name Engines I Code MEV 123


Course description: In this course the student is introduced to the fundamentals of internal combustion engines operation, their kinds, types, main parts, mode of operation. Mechanical engine systems; lubricating system, cooling system and ignition system. Checking and repairing mechanical systems.

Semester 1 2 3 4

Credit hours 2

L

W 4 Contact hours

T

General course objectives: This course aims to introduce the student to the fundamentals of the operation of the internal combustion engines, their kinds, types, main parts, and mode of operation, as well as to the mechanical engine systems; lubricating system, cooling system and ignition system. After that, the student will check and repair mechanical systems.

Skill objectives: The student should be able to: • Know the fundamentals of internal combustion engines, their types, main parts, mode of

operation. • Know the mechanical engine systems such as the lubricating system, cooling system and

ignition system. • Check and repair mechanical systems.

Subjects (theoretical and practical): • The fundamentals of internal combustion engines, their types, main parts, mode of operation. • Mechanical engine systems; lubricating system, cooling system and ignition system. • Checking and repairing mechanical systems.

References:

- Heinze Heisler, Advanced Engine Technology, Edward Amold, ISBN 0340568224 - William H. Crouse and Donald L. Anglin, "Automotive Mechanics" The McCrawHill Book Company, ISBN 0-02-800943-6 - Manufacturer's data and repair manuals - Martin, W. Stokel and Martin "Auto Mechanics fundamentals", The Goodheart Willcox company, INC, ISBN 1-56637-138-4, 1996 - Stockel, Stockel, and Johanson, "Auto Service and Repair", The Goodheart Willcox company, INC, - Martin W. Stokel, Martin T. Stokel Cluis Johanson "Auto Fundamentals" The Goodheart Willcox company, INC, ISBN 1-56637-1384, 1996 - William, K. Toboldt, Larry Johnson, and W. Scott Gavthier, "Automotive Encyclopedia " Fundamental, Principles, Operation, Construction, Service, and Repair- The Goodheart -Willcox company, INC, ISBN 1- 56637-150-3, 1995 - Jack Enjavec and Robert Schaiff "Automotive Technology" Delmar Publishers, An International Thomson Publishing Company, - Robert Bosch GmbH "Automotive Handbook" Published by VDI-Verlag, 1996 - Duffy, James E., "Auto Engines" The Goodheart Willcox company, INC, ISBN 0-87006A77-3



6

Fundamentals of internal combustion engines: - Mode of operation of four stroke

engines - Kinds of engines - Engine parts, their functions and

mode of operation

The student should be able to: - Understand mode of operation of

the four stroke engines. - Identify kinds of engines. - Identify engine parts, their

functions and mode of operation.

2

Engine lubricating system: - The reasons for lubricating engine

parts, types of engine oils - Different types of lubricating

circuits - Lubricating system parts, their

functions and mode of operation

- Identify engine lubricating system.

- Identify the reasons for lubricating engine parts, types of engine oils.

- Identify the different types of lubricating circuits.

- Identify lubricating system parts, their functions and mode of operation.

D7, H3

6

Engine cooling system: - Cooling system function – water

cooling and air cooling - Cooling system parts, their

functions and mode of operation - The reason for using thermostat in

the cooling circuit - Cooling system faults - Ways of checking cooling system

by using equipment and tools

- Identify engine cooling system. - Identify cooling system function –

water cooling and air cooling. - Understand mode of operation of

cooling system circuit, its parts, their functions and mode of operation.

- Understand the reason for using the thermostat in the cooling circuit.

- Know cooling system faults - Understand ways of improving

cooling system performance. - Understand methods of checking

cooling system by using equipment and tools.

D4, H4

4

Ignition systems: - 1 – Introduction to the principals of

ignition - Ignition system function - Principals of ignition coil function - Effects of ignition timing on:

- Engine power, fuel consumption, engine torque, exhaust emission

- Primary current buildup - Conditions affecting spark energy

and volt - Ignition coil types; primary and

secondary circuit forms - 2 – Conventional ignition system - System specifications and

components - Ignition coil, distributor - Contact points, condenser - Spark plugs, and their different

designs - Ballast resistor, advance

mechanisms - System limitations - Primary and secondary circuit

forms

- Identify ignition systems. - Identify the principals of ignition. - Understand ignition system

function. - Know the principals of ignition

coil function. - Understand the effects of ignition

timing on: - Engine power, fuel

consumption, engine torque, exhaust emission

- Primary current buildup - Conditions affecting spark

energy and volt - Ignition coil types; primary and

secondary circuit forms - Identify conventional ignition

system. - Understand system

specifications and components. - Understand mode of operation of

ignition coil, distributor. - Understand mode of operation of

contact points, condenser. - Identify spark plugs, and their

different designs. - Identify ballast resistor, advance

mechanisms. - Understand system limitations. - Understand mode of operation of

primary and secondary circuit forms.

D10, H6

6

3 – Transistorized ignition systems (semi-electronic ignition)

- Contact points problems - The necessity for using advanced

ignition systems in cars - Connection and disconnection in

primary circuit - The transistor, connecting and

disconnecting specifications, gain factor and protection circuit

3 -1 - Transistorized ignition system with contact points:

- System specifications and parts, circuit diagram

- Transistor and contact points functions

- Primary current and control, Darlington magnifier

3 - 2 – transistorized ignition with Hall generator TCI-H:

- Pulse generator function - Coil ignition systems with pulse

generator - Hall Effect and Hall pulse

generator - Hall pulse generator signal shaper - 3 – 3 – Transistorized ignition

with induction type pulse generator TCI-I:

- Induction type pulse generator parts and mode of operation

- Induction type pulse generator signal shaper

- Open and closed loop dwell-angle control system

- Identify transistorized ignition systems (semi-electronic ignition).

- Understand contact points problems.

- Understand the necessity for using advanced ignition systems in cars.

- Understand connection and disconnection in the primary circuit.

- Understand the transistor, connecting and disconnecting specifications, gain factor and protection circuit.

- Identify transistorized ignition system with contact points:

- Understand system specifications and parts, circuit diagram.

- Understand transistor and contact points.

- Understand primary current and control, Darlington Magnifier.

- Identify transistorized ignition with Hall generator TCI-H:

- Understand pulse generator function.

- Understand coil ignition systems with pulse generator.

- Understand Hall Effect and Hall pulse generator.

- Understand Hall pulse generator signal shaper.

- Identify transistorized ignition with induction type pulse generator TCI-I:

- Identify induction type pulse generator parts and mode of operation.

- Identify induction type pulse generator signal shaper.

- Draw ignition signal. - Understand open and closed

loop dwell-angle control system.

D10, H6

4

4 – Electronic ignition systems

- Principals of electronic ignition systems

- Crankshaft speed sensor (engine speed)

- Camshaft position sensor - MAP-TPS sensor - Electronically controlled ignition

timing - Types and design of electronically

controlled ignition - Ignition systems without

distributor - High tension distribution method - Ignition coils

5- Principals of capacitor discharge ignition system (CDI):

- Its mode of operation principals and advantages

- Circuit diagram and system parts - Condenser charging circuit - Ignition coil

Thyristor and on/off control

- Identify electronic ignition systems.

- Understand principals of electronic ignition systems.

- Identify crankshaft speed sensor (engine speed).

- Identify camshaft position sensor.

- Identify MAP-TPS sensor. - Understand electronically

controlled ignition timing. - Identify types and design of

electronically controlled ignition.

- Identify non-distributor ignition - Understand high tension

distribution method. - Identify ignition coils and their

mode of operation. - Understand principals of

capacitor discharge ignition system (CDI):

- Understand its mode of operation principals and advantages.

- Analyze circuit diagram and system parts.

- Understand condenser charging circuit mode of operation.

- Understand ignition coil mode of operation.

- Identify the thyristor and on/off control and its mode of operation.

D10, H6


Hours Content Skill Objectives Related

tasks

12

Disassembling and assembling practice engine:

- Disassemble four stroke gasoline engines.

- Identify the upper and lower parts of the engine.

- Disassemble the internal parts of the engine and identify them.

- Assemble the internal parts of the engine by following instructions.

- Assemble the upper and lower engine parts.

The student should be able to: - Disassemble and assemble

practice engine. - Disassemble four stroke gasoline

engines. - Identify the upper and lower

parts of the engine. - Disassemble the internal parts of

the engine and identify them. - Assemble the internal parts of

the engine by following instructions.

- Assemble the upper and lower engine parts.

4

Disassembling practice engine: - Disassemble engine external parts. - Check and replace oil pump. - Check oil galleries and passages in

the engine. - Replace oil filter, and engine oil

(following instructions). - Measure oil pressure. - Replace faulty parts in lubricating

system.

- Disassemble practice engine. - Disassemble engine external

parts. - Check and replace oil pump. - Check oil galleries and passages

in the engine. - Replace oil filter, and engine oil

(following instructions). - Measure oil pressure. - Replace faulty parts in

lubricating system.

D7, H3

12

Checking cooling system: - Notice leakage and noise. - Check cooling system parts

operation. - Determine faults in cooling

system. Repairing cooling system:

- Repair faulty parts in cooling system.

- Replace faulty parts if needed. - Change coolant. - Use cooling system testing device. - Check car performance after doing

the maintenance jobs on the cooling system.

Check cooling system. - Notice leakage and noise. - Check cooling system parts. - Determine faults in cooling

system. - Repair cooling system. - Repair faulty parts in cooling

system. - Replace faulty parts if needed. - Change coolant. - Use cooling system testing

device. - Check car performance after

doing the maintenance jobs on the cooling system.

D4, H4

8

Checking and repairing ignition systems:

- Identify main components of the ignition system and their mode of operation by performing tests on a practice engine, simulating some faults (disconnect some parts from the circuit one at a time).

- Check and repair conventional ignition systems:

- Distributor, ignition coil, spark plugs cables, spark plugs, connecting points, ignition switch, electric connections, condenser

- Replace faulty parts in the system. - Test the system.

- Check and repair ignition systems.

- Identify main components of the ignition system and their mode of operation by performing tests on a practice engine, simulating some faults (disconnect some parts from the circuit one at a time).

- Check and repair conventional ignition systems:

- Distributor, ignition coil, spark plugs cables, spark plugs, connecting points, ignition switch, electric connections, condenser

- Replace faulty parts in the system.

- Test the system.

D10, H6

8

3 - Checking and repairing semi-electronic ignition system:

- Identify system parts. - Test system parts using special test

device. - Determine faults in the system. - Repair or replace faulty parts. - Check system after the repair job is

done. 4 - Checking and repairing electronic ignition system:


device. - Determine faults in the system. - Repair or replace faulty parts. - Check system after the repair job is

done.

- Check and repair semi-electronic ignition system:

- Identify system parts. - Test system parts using special

test device. - Determine faults in the system. - Repair or replace faulty parts. - Check system after the repair job

is done. - Check and repair electronic

ignition system: - Identify system parts. - Test system parts using special

test device. - Determine faults in the system. - Repair or replace faulty parts. - Check system after the repair job

is done.

D10, H6

12

5 - Checking and repairing capacitor discharge ignition system (CDI):


device. - Determine faults in the system. - Repair or replace faulty parts. - Check system after the job is done.

- Check and repair capacitor discharge ignition system (CDI):

- Identify system parts. - Test system parts using special

test device. - Determine faults in the system. - Repair or replace faulty parts. - Check system after the job is

done.


Course name Power Train (1) Code MEV 211


Course description: This course covers how to carry out repair and maintenance jobs on different power train components which include friction clutch and its types, different gearboxes, propeller shafts and differential. This is done after diagnosing and determining faults by using tools and advanced equipment in this field.

Semester 1 2 3 4

Credit hours 4

L 2

W 4 Contact hours

T

General course objectives: This course aims to introduce the student to the methods of performing repair and maintenance jobs on different power train components which include friction clutch and its types, different gearboxes, propeller shafts and differential. As well as to diagnose and determine faults by using tools and advanced equipment in this field.

Skill Objectives: The student should be able to: • Know how to carry out repair and maintenance jobs on different power train components. • Identify friction clutch and its types. • Identify different gearboxes, propeller shafts and differential. • Diagnose and determine faults and repair or replace faulty parts in the power train system. • Test the system using tools and advanced equipment in this field.

Subjects (theoretical and practical): • The methods of performing repair and maintenance jobs on different power train components. • Friction clutch and its types. • Different gearboxes, propeller shafts and differential. • Diagnosing and determining faults, then performing repair and maintenance jobs on different

power train components. • Testing the system using tools and advanced equipment in this field.

References:

- Stockel, M.W., Stockel, M.T, and Johanson C.: "Auto Fundamentals", Goodheart Willcox Company, Inc., 1996, ]SBN 1-56637-138-4 Stockel, Stockel, and Johanson, "Auto Service & Repair", Goodheart- Willcox Company, Inc., 1996 ISBN 1-56637-144-9 - William K Toboldt, Larry Jolmson, and W. Scott Gauthier, "Automotive Encyclopedia", The Goodheart-Willcox Company, Inc., 1995 ISBN I- 56637-150-3. Enjavec, Jack and Schai~, Robert, "Automotive Technology", 2nd Edition Delmar Publishers, An international Thomson Publishing Company, 19%, ISBN. - William Crouse, "All Automobile" (12 parts), Mars Publishing House, ISBN William Il. Crouse and Donald I,. Anglin, "Automotive Technician's t-landbook", The McGraw-Hill Book Company, ISBN Robert Bosch GmbH, "Automotive Handbook", 4th Edition, 1996, Published by VD1-Verlag, ISBN - William H. Crouse and Donald L. Anglin, "Automotive Mechanics" The McGrawHill Book Company, IOth Edition, ISBN 04)2-800943A - Stokel, Martin W., Stokel, Martin T., and Johanson, Chris, "Auto Fundamentals" The Goodheart Willcox company, fl'rC, ISBN 1-56637- 1384, 1996 - William, K. Toboldt, Larry Johnson, and W. Scott Gavthier, "Automotive Encyclopedia" Fundamental, Principles, Operation, Construction, Service, and Repair, The Goodheart -Willcox company, INC, ISBN 1-56637-150-3, 1995 - Duffy, James E., "Auto Engines" The Goodheart Willcox company, INC, ISBN 0-87006A77-3 - Jack Enjavec and Robert Scharif "Automotive Technology" Delmar Publishers, An International Thomson Publishing Company.



2

Introduction to different power train units (clutch, gearbox, rear axel):

- Friction clutch and its different types

- Sliding mesh and constant mesh gearboxes

- Different types of propeller shafts and universal joints

- Differential, its parts and importance

- Drive axels

The student should be able to: - Identify different power train

units (clutch, gearbox, rear axel): - Identify friction clutch and its

different types. - Identify sliding mesh and constant

mesh gearboxes. - Identify different types of

propeller shafts and universal joints.

- Identify differential, its parts and importance.

- Identify drive axels.

E1

2

Studying the importance of using oils and sealants in different power train units (clutch, gearbox, rear axel)

- Understand the importance of using oils.

- Know about sealants in different power train units (clutch, gearbox, rear axel).

E2, E3, E4

6

Studying the importance and types of power train units (clutches, gearboxes) and the causes of noise in power train components, as well as determining faults in: 1 – clutch: - friction plate, pressure plate, flywheel - sliding parts and splines - sealants - mechanical and hydraulic connections - springs and release levers 2 – sliding mesh and constant mesh gearboxes: - ball bearing - oil seals and gaskets - end play of the main shaft - splines - mechanical parts (gears, phalanges, sleeves) - synchronizer (synchronizer sleeve, blocking ring … etc) - cone clutch, blocking ring - shift lever - shift fork

- Understand the importance and types of power train units (clutches, gearboxes) and the causes of noise in the power train components, as well as determining faults in the system.

- Identify clutch. - Identify friction plate, pressure

plate, and flywheel. - Identify sliding parts and splines. - Identify sealants. - Differentiate between mechanical

and hydraulic connections. - Identify springs and release

levers. - Identify sliding mesh and constant

mesh gearboxes. - Identify ball bearing. - Identify oil seals and gaskets. - Understand the reason for end

play of the main shaft. - Identify splines. - Understand mechanical parts

(gears, phalanges, sleeves). - Identify synchronizer

(synchronizer sleeve, blocking ring … etc).

- Identify cone clutch, blocking ring.

- Identify shift lever. - Understand mode of operation of

shift fork.

E5, E6, E7, I1, 18, 19

4

Studying shapes and types of gears, joints and roller bearings used in clutches and constant mesh gearboxes. Also to know the methods of determining gear reduction ratios.

Study shapes and types of gears, joints and roller bearings used in clutches and constant mesh gearboxes. Know methods of determining gear reduction ratios.

E7, E9

2

Introduction to the importance of shift lever and levers used in different types of clutches and gearboxes, and methods of motion transfer.

Introduction to the importance of shift lever and levers used in different types of clutches and gearboxes, and methods of motion transfer.

E7, I10

4

Studying of the different types of propeller shafts in the power train system and their performance.

- Hollow shafts - Covered shafts - Uncovered shafts

Identify different types of propeller shafts in power train system and their performance.

- Identify hollow shafts. - Identify covered shafts. - Identify uncovered shafts.

E7, E9, E10, E12, I17

4

Studying types and shapes of gear in the differential: Worm gear, straight toothed bevel gear, spiral bevel gear, hypoid gear and the methods of determining possible faults and their types:

Pinion gear Crown gear Differential case

Identify types and shapes of gear in the differential: Identify worm gear, straight toothed bevel gear, spiral bevel gear, hypoid gear. Know the methods of determining possible faults and their types:

Pinion gear Crown gear

Differential case

E7, E8, E9, I12,

I16

2

Studying the importance of axels and shafts in the final drive, as well as to study the importance of rear axel sensors Types of differential

- Conventional - Limited slip differential

- Understand the importance of axels and shafts in the final drive to the power train.

- Understand the importance of rear axel sensors.

- Identify types of differential. - Identify conventional. - Identify limited slip differential.

E7, E8, E11, I14,

I15, I18

2

Preparing a conclusive report on the maintenance operations of all types of clutches and different gearboxes (sliding and constant mesh) and the power train

Prepare a conclusive report on the work done on the mechanical faults in the power train. I19



4

Introduction to different power train units (clutch, gearbox, rear axel):

- Friction clutch and its different types

- Sliding mesh and constant mesh gearboxes

- Different types of propeller shafts and universal joints

- Differential, its parts and importance

- Drive axels

The student should be able to: Identify type of transmission to be able to diagnose possible faults (manual, hydraulic, automatic).

E1

4

Checking the condition of grease, oils and sealants of different types Oil leakage in one of the power train units (clutch, gearbox or rear axel) Incorrect amount of transmission fluid in different power train units (clutch, gearbox, rear axel).

- Check the proper oil level. - Observe the color and smell of the

fluid. - Ensure that the fluid meets the

manufacturing company’s specifications.

- Determine the type of fluid that meets manufacturing company’s specifications.

E2, E3, E4

6

- Finding noise source in the clutch and gearbox, diagnosing their faults and determining their type; mechanical or hydraulic. Also methods of measuring using tools and equipment in the workshop and on the road.

- Clutch - Disassembling clutch - Clutch disassembling steps - Checking clutch and replacing

faulty parts - Checking flywheel and replacing it

if needed - Clutch faults - Wear of the friction plate, pressure

plate or flywheel - Glazed surface of the friction plate,

pressure plate or flywheel - Presence of oil on the friction plate,

pressure plate or flywheel - Distortion of the friction plate,

pressure plate or flywheel - Weakness of springs or release lever- Clutch faults during release and

engage - Shaking that happens during engage - Vibration or hardness of clutch

pedal - Assembling the clutch and testing it

- Find noise source using special tools and equipment.

- Determine fault location. - Determine fault type (electric,

mechanical, hydraulic). - Check flywheel. - Replace clutch. - Replace oil seals and gaskets using

special tools to prevent oil leakage. - Use testing equipment for accurate

diagnosis of faults as per manufacturing company’s recommendations.

E5, E6, E7, I1,

I9

6

- Constant and sliding mesh gearbox - Disassemble the constant or sliding

mesh gearbox - Constant and sliding mesh gearbox

disassembling steps - Check the gearboxes and replace

faulty parts - Faults of the sliding and constant

mesh gearboxes: - Wear of the ball bearing - Damage and distortion of the

splines - Wrong installation of parts

(phalanges, gears, bushings … etc) - Wear in the cone clutch of

synchronizer block - Oil leakage in the gearbox - Presence of noise at any shift - Hard gear shifting or a metallic

squeaking sound - Complete breaking of the clutch

fork (release fork) - Reassembling the constant or

sliding mesh gearbox and testing it

- Locate noise source using special tools and determining fault location.

- Determine fault type (electric, mechanical, hydraulic).

- Replace gears and ball bearings of the manual gearbox using special tools for better performance under different driving conditions.

- Replace oil seals and gaskets to prevent oil leakage for proper performance of the gearbox.

- Use testing equipment for accurate diagnosis as per manufacturing company’s recommendations.

E5, E6, E7, I8,

I98

8

- Methods of checking the condition and performance of gears and connections in the clutch, the constant and sliding mesh gearboxes and ball bearing using the special testing equipment, as well as replacing faulty parts with ones that meet the recommended specifications

- Use testing equipment as recommended for accurate diagnosis.

- Check sealants correctly.

E7, E9

4

- Methods of checking and testing control levers in different types of clutches and gearboxes (constant and sliding mesh) using tools and equipment needed. Also the method of motion transfer, and replacing faulty parts with ones that meet the recommended specifications

- Adjust the control levers for the gearbox for easy shifting.

- Use testing equipment as recommended for accurate diagnosis.

E7, I10

8

- Introduce the student to the different types of propeller shafts and their parts, the universal joints, the methods of diagnosing faults and their types using the special tools and equipment for that. The faults include:

- Bending of the propeller shaft - Excessive clearance in the universal

joints - Noise in the center bearing - Faulty ball bearing - Determine joints faults during

rotation - Replace universal joints … etc - Install propeller shaft - Check propeller shaft balancing and

inclination angle - Adjust and repair or replace faulty

parts with ones that meet the recommended specifications

- Correctly check universal joints and ensure their stability and proper performance

- Check propeller shaft with the special tools

- Replace the universal joints cross using tools

- Properly check sealants - Use testing equipment as

recommended for accurate diagnosis

E7, E9, E10,

E12, I17

8

- Method of checking and adjusting differential as per specifications, also checking faults and determining their types using the special tools for that. The faults could be:

- Pinion gear - Crown gear - Differential case - Loud noise at the start of motion or

while shifting - Knocking sound - Shaking and noise at the start of

motion - Noise while accelerating or turning - Uneven tire wear - Road traction problems - Low traction effort - Adjusting, repairing or replacing

faulty parts with ones that meet the recommended specifications

- Check axel gears using the special tools

- Replace axel gears using the special tools

- Adjust axel gears using the special tools

- Use testing equipment as recommended for accurate diagnosis

- Properly check sealants E7, E8, E9, I12,

I16

4

- Method of checking and testing the condition and serviceability of axels, shafts and the rear axel sensors using the special tools for that.

- Types of construction of rear axels - Conventional differential - Limited slip differential - Adjusting, repairing or replacing

faulty parts with ones that meet the recommended specifications

- Check axel gears using the special tools

- Properly check axel bearings - Replace axel bearings - Replace axels and shafts - Replace axel sensors - Properly check sealants - Use testing equipment for accurate

diagnosis

E7, E8, E11, I14, I15, I18

4

- Choosing spare parts as per standard specifications

- Preparing a conclusive report on the maintenance operations of all types of clutches, different gearboxes (sliding and constant mesh), the power train and recording the service labor time

- Prepare a conclusive report on the work done on the mechanical faults in the power train

I19


Course name Brake system Code MEV 212


Course description: this course covers the principles of vehicle brake systems, their different types, antilock brake system (ABS). Master and wheel cylinders, hydraulic valves, boosters and their mode of operation. Brake performance calculations (brake pressure, stopping distance and time) checking, repairing or replacing brakes and its parts. Adjusting brakes and using the brake test stand.

Semester 1 2 3 4

Credit hours 4

L 2

W 4 Contact hours

T

General course objectives: this course aims to introduce the student to the principals of vehicle brake systems, their different types, antilock brake system (ABS). Master and wheel cylinders, hydraulic valves, boosters and their mode of operation. Brake performance calculations (brake pressure, stopping distance and time). As well as teaching the student how to check, repair or replace brakes and its parts, adjust brakes and use the brake test stand.

Skill Objectives: The student should be able to: • Know the principals of vehicle brake systems and their different types. • Know antilock brake system (ABS). • Identify master and wheel cylinders, hydraulic valves, boosters and their mode of operation. • Calculate brake performance (brake pressure, stopping distance and time). • Check, repair, replace and adjust brakes and its parts. • Use the brake test stand.

Subjects (theoretical and practical): • The principals of vehicle brake systems and their different types. • Antilock brake system (ABS). • Master and wheel cylinders. • Hydraulic valves, boosters and their mode of operation. • Brake performance calculations (brake pressure, stopping distance and time). • Checking, repairing, replacing brakes and its parts, and adjusting brakes. • Using the brake test stand.

References:

- Jack Enjavec and Robert Scharff: "Automotive Technology", 2nd Edition 1996, Delmar Publishers, An international Thomson Publishing Company, ISBN. - Stockel, Stockel, and Johanson, "Auto Service & - 1996, The Goodheart Willcox Company, Inc., Tinley Park, Illinois, ISBN, 1-56637-144-9 - William K. Toboldt, Larry Johnson, and W. Scott Gauthier, "Automotive Encyclopedia', The Goodheart-Willcox Company, Inc., Tinley Park, Illinois, ISRN 1-56637-150-3, 1995 - Stockel, M.W, Stockel, M. 7`., and Johanson, C., "Auto Fundamentals", 1996, The Goodheart-Willcox Company, Inc., Tinley Park, Illinois, I SBN 1-5 663 7-138-4 - Crouse-Anglin, "Auto Fundamentals", I0th Edition, The McGraw-Hill Rook Company - William Crouse, "All Automobile", (12 parts), Mars Publishing House. - William H. Crouse and Donald L. Anglin, "The Auto Book", 3rd Edition, The McGraw-Hill Book Company - Robert Bosch GmbH, "Automotive Handbook", 4th Edition- 1996, Published by VDI-Verlag, ISBN - Martin W. Stockel and Martin, "Auto Mechanics Fundamentals", The Goodheart Willcox Company, Inc., Tinley Park, Illinois, ISBN 156637-1384, 1996 - Crouse, William H. and Donald L. Anglin, "Automotive Technician's Handbook", The McGraw-Hill Book Company, ISBN 0-070-14751-5 - Robert Schar- "Complete Brake Systems", Delmar Publisher, Inc., ISBN 0-8273-3539-3 - Robert Bosch Cooperation, "Bosch Technkal Instruction Series", - Compressed air brake Systems, Symbols- - Compressed air brake Systems, Equipment- - Compressed air brake Systems, Schematic Diagrams



4

Vehicle brake system: - Its function, types and main parts - Vehicle brake system mode of

operation

The student should be able to: - Identify brake system, its function,

types and main parts - Understand vehicle brake system and

mode of operation

F1

6

Linings, drums … etc - Linings, their types, checking and

replacing them - Drums, discs and wheel bearing:

their types, checking and replacing them

- Ways of checking linings and drums in the lab, taking measurements, fault causes

- Identify linings, their types, check and replace them

- Identify drums, discs and wheel bearing: their types, check and replace them

- Understand ways of checking linings and drums in the lab, take measurements, fault causes

J1, J2, J3, J11, F2, F4,

F5

4

The booster: - Its function, mode of operation,

related parts - Booster faults, their causes and how

to repair them

- Identify the booster - Understand its function, mode of

operation, related parts - Know booster faults, their causes and

how to repair them

J9, J10, F6

6

Master and wheel cylinders: - Their function, mode of operation,

related parts - Master and wheel cylinder faults - Brake pipes - Their function, types and faults - Master and wheel cylinder and brake

pipes maintenance

Identify master and wheel cylinders: - Their function, mode of operation,

related parts - Master and wheel cylinder faults Identify brake pipes: - Their function, types and faults Understand master and wheel cylinder and brake pipes maintenance

J4, J5, J7, J8, F3, F9

6

Antilock brake system (ABS): - Its function, mode of operation, parts

and their mode of operation - Types and designs of antilock brake

systems - Construction and function of the

system - Checking and maintenance of the

system - Using the ABS testing device

Identify antilock brake system (ABS) - Its function, mode of operation, parts

and their mode of operation - Types and designs of antilock brake

systems - Construction and function of the

system - Understand methods of checking and

maintenance of the system Know how to use the ABS testing device

J6, J13, J14, F7

2

Parking brakes - Brake pedal: - Parking brake function, mode of

operation, types and parts - Brake pedal - Checking brake pedal and its faults

- Identify parking brakes and brake pedal

- Understand parking brake function, mode of operation, types and parts

- Identify brake pedal - Understand how to check brake

pedal and its faults

J12, J15, F8,

F10



4

Identify vehicle brake system: - Check oil level - Locate oil leakage sources in the

brake system

The student should be able to: - Identify brake system - Check oil level - Locate oil leakage sources in the

brake system

F1

16

Locate noise source in the brake system: - Method of locating noise source - Method of checking brake system

parts and determining fault - Writing a report about the faulty

parts Linings, drums … etc - Checking, repairing and replacing

linings - Checking, repairing (turning,

grinding) replacing - Checking wheel bearing and

replacing it - Methods of removing, installing and

replacing faulty parts

Locate noise source in the brake system: - Know method of locating noise

source - Know method of checking brake

system parts and determining fault - Write a report about the faulty parts - Identify linings, drums … etc - Check, repair and replace linings - Check, repair (turn, grind) replace - Check wheel bearing and replace it - Know methods of removing,

installing and replacing faulty parts

J1, J2, J3, J11, F2, F4,

F5

8

The booster: - Method of checking and repairing - Method of replacing and periodic

maintenance

- Identify the booster - Know method of checking and

repairing - Know method of replacing and

periodic maintenance

J9, J10, F6

12

Master and wheel cylinders: - Methods of checking, repairing and

replacing master and wheel cylinders

- Checking, repairing and replacing brake pipes

- Method of changing brake fluid and bleeding air from the circuit as per maintenance manual

- Identify master and wheel cylinders - Know methods of checking,

repairing and replacing master and wheel cylinders

- Check, repair and replace brake pipes

- Change brake fluid and bleed air from the circuit as per maintenance manual

J4, J5, J7, J8, F3, F9

12

Checking and repairing antilock brake system (ABS): - Identify system parts - Using the ABS testing device and

the method of testing - Running needed tests on the system

as per manufacturing company’s instructions

- Repairing and replacing faulty parts and sensors in the system

Check and repair antilock brake system (ABS) - Identify system parts - Use the ABS testing device and

know the method of testing - Run needed tests on the system as

per manufacturing company’s instructions

Repair and replace faulty parts and sensors in the system

J6, J13, J14, F7

4

Checking parking brakes: - Method of checking, repairing and

replacing faulty parts Brake pedal: - Method of checking and repairing

brake pedal Adjusting parking and rear brake: - Method of adjusting brakes and

testing them

- Check and adjust rear and parking brakes using special tools for proper performance for the safety of the car and passengers

- Properly check brake pedal - Prepare a conclusive report on the

work done on the mechanical faults in the brake system

J12, J15, F8,

F10


Course name Engines (2) Code MEV 213


Course description: checking internal combustion engines, engine oil evaporation, determining type and source of noise, measuring engine compression pressure and analyzing exhaust gases. Removing faulty engine from vehicle, disassembling engine (cylinder head, cylinder block … etc), doing the needed repairs to the cylinder head and cylinder block and replacing faulty part are all covered in this course. Reassembling and reinstalling engine, as well as operating the engine after the repairs and testing it is included.

Semester 1 2 3 4

Credit hours 4

L 2

W 4 Contact hours

T

General course objectives: this course aims to introduce the student to inspecting internal combustion engines, engine oil evaporation, determining type and source of noise, measuring engine compression pressure and analyzing exhaust gases. As well as removing faulty engine from vehicle. The student will be able to disassemble engine (cylinder head, cylinder block … etc), as well as to know the method of doing the needed repairs to the cylinder head and cylinder block and to replace faulty parts. The student will be able to reassemble, reinstall engine and operat the engine after the repairs and test it. Skill Objectives: The student should be able to: • Check internal combustion engines, engine oil evaporation. • Determine type and source of noise. • Measure engine compression pressure. • Analyze exhaust gases. • Remove faulty engine from vehicle, and disassemble engine (cylinder head, cylinder block …

etc). • Do the needed repairs to the cylinder head and cylinder block and replace faulty parts. • Reassemble and reinstall engine. • Operate the engine after the repairs and test it.

Subjects (theoretical and practical): • Checking internal combustion engines. • Observing engine oil evaporation. • Determining type and source of noise. • Measuring engine compression pressure. • Analyzing exhaust gases. • Removing faulty engine from vehicle. • Disassembling engine (cylinder head, cylinder block … etc). • Doing the needed repairs to the cylinder head and cylinder block and replacing faulty parts. • Reassembling and reinstalling engine. • Operating the engine after the repairs and testing it.

References:

Heinze Heisler, Advanced Engine Technology, Edward Arnold, ISBN 0340568224 - William H. Crouse and Donald L. Anglin, "Automotive Mechanics" The McGraw Hill Book Company, ISBN 0-02-800943-6 - Manufacturer's data and repair manuals - Martin, W. Stokel and Martin "Auto Mechanics fundamentals", The Goodheart Willcox company, INC, ISBN 1-56637-138-4, 1996 - Stockel, Stockel, and Johanson, "Auto Service and Repair", The Goodheart Willcox company, INC, - Martin W. Stokel, Martin T. Stokel Cluis Johanson "Auto Fundamentals" The Goodheart Willcox company, INC, ISBN 1-56637-]384, 1996 William, K. Toboldt, Larry Johnson, and W. Scott Gavthier, "Automotive Encyclopedia " Fundamental, Principles, Operation, Construction, Service, and Repair- The Goodheart -Willcox company, INC, ISBN I- 56637-150-3, 1995 - Jack Enjavec and Robert Schaiff "Automotive Technology" Delmar Publishers, An International Thomson Publishing Company, - Robert Bosch GmbH "Automotive Handbook" Published by VDI-Verlag, 1996 - Duffy, James E., "Auto Engines" The Goodheart Willcox company, INC, ISBN 0-87006A77-3



2

Engine oil evaporation: Amount of engine oil, amount of evaporation, causes, measuring oil level and viscosity, causes of excessive evaporation, causes of low oil level

The student should be able to: - Notice oil evaporation: Amount of engine oil, amount of evaporation, causes - Understand the method of measuring

oil level and viscosity - Know the causes of excessive

evaporation, causes of low oil level

D2, D3

2

Car engine noise: - Types of abnormal engine noise

using the stethoscope - Locations of noise causing parts in

the engine

Identify car engine noise: - Identify types of abnormal engine

noise - Understand how to use the

stethoscope - Identify the locations of noise

causing parts in the engine

D5

2

Measuring engine compression pressure: - Engine compression pressure,

engine compression pressure value - Causes for low compression

pressure, its effects and how to solve them

- Method of checking engine compression pressure

Know the method for measuring engine compression pressure: - Engine compression pressure, engine

compression pressure value Know the causes for low compression pressure, its effects and how to solve them Know the method of checking engine compression pressure

D6

2

Analyzing exhaust gases: - Exhaust gases, their kinds, causes

and methods of controlling them - Methods for checking exhaust gases

- Know how to analyze exhaust gases - Exhaust gases, their kinds, causes

and methods of controlling them - Know the methods for checking

exhaust gases

D9

9

Repairing cylinder head: - Cylinder head, its types and parts - Camshaft, its types, methods of

inspection and replacing it - Engine valves, their types and

methods of inspecting them - Parts related to engine valves,

methods of inspecting, repairing and replacing them

- Methods of grinding valves and their effect on engine power

- Methods of repairing and replacing valves

- Checking cylinder head flatness, its effect on the engine, methods of repairing it

- Reassembling engine after the maintenance job is done

Know the method for repairing cylinder head: - Cylinder head, its types and parts - Camshaft, its types, methods of

inspecting and replacing it - Engine valves, their types and

methods of inspecting them - Parts related to engine valves,

methods of inspecting, repairing and replacing them

- Methods of grinding valves and their effect on engine power

- Methods of repairing and replacing valves

- Checking cylinder head, its effect on the engine, methods of repairing it

Know the method for reassembling engine after the maintenance job is done

H1

9

Repairing cylinder block faults: - Cylinder block, its types and related

parts - Crankshaft, checking and measuring

it - Piston assembly, its types and faults - Connecting rod, piston rings, piston

pin - Complete and half circle bearing,

their types and faults - Cylinder measuring and boring - Timing chain, its types, method of

timing - Camshaft assembly and its mode of

operation - Reassembling engine (cylinder block

with cylinder head) - Reinstalling the engine after the

maintenance job is done - Testing the engine

Know the method for repairing cylinder block: - Cylinder block its types and related

parts - Crankshaft, checking and measuring

it - Piston assembly, its types and faults - Connecting rod, piston rings, piston

pin - Complete and half circle bearing,

their types and faults - Measuring cylinder bore and boring

it - Timing chain, its types, method of

timing - Camshaft assembly and its mode of

operation Know how to reassemble engine (cylinder block with cylinder head) - Reinstalling the engine after the

maintenance job is done - Testing the engine

H2

D4, H4, D7, D10,

D8, H5, H3, H6



6

Engine oil evaporation: - Method of checking oil evaporation

and the necessary measurements - Measuring oil level and viscosity,

method of changing oil - Preparing a concise work report with

observations

The student should be able to: Observe engine oil evaporation: - Check evaporation and take the

necessary measurements - Measure oil level and viscosity - Know the method of changing oil - Prepare a brief work report with

observations

D2, D3

6

Engine noise: - Locating them, using lifts for lower

parts - Using the stethoscope to locate

source of noise - Determining fault in engine

- Locate engine noise - Know the methods for locating them,

use lifts for lower parts - Use the stethoscope to locate source

of noise - Determine fault in engine

D5

6

Measuring engine compression pressure: - Measuring engine compression

pressure of the practice engine - Test procedures and connecting the

device - Running the engine and take

readings - Finishing the test and preparing a

report

Measure engine compression pressure: - Measure engine compression

pressure of the practice engine - Know test procedures and

connecting the device - Run the engine and take readings - Prepare a report

D6

6

Checking and analyzing exhaust gases: - Exhaust gases; their kinds and their

causes - Methods of inspection and

equipment needed

Check and analyze exhaust gases: - Exhaust gases; their kinds and their

causes - Knowing methods of inspection and

equipment needed

D9

24

Checking and repairing cylinder head: - Removing cylinder head, method of

cleaning it, disassembling it - Checking faulty parts - Removing, checking, lapping,

replacing valves - Valve assembly, methods of

checking, repairing, replacing it - Checking cylinder head flatness,

repairing, replacing it - Checking camshaft, measuring,

replacing it - Checking timing chain or belt,

replacing it - Method of reassembling engine after

maintenance

Check and repair cylinder head: - Removing cylinder head, method of

cleaning it, disassembling it - Checking faulty parts - Removing, checking, lapping,

replacing valves - Valve assembly, methods of

checking, repairing, replacing it - Checking cylinder head flatness,

repairing, replacing it - Checking camshaft, measuring,

replacing it - Checking timing chain or belt,

replacing it Know the method of reassembling engine after maintenance

H1

24

Checking and repairing cylinder block faults: - Disassembling cylinder block,

method of cleaning it - Checking crankshaft, measuring its

diameters - Checking pistons and connecting

rod, repairing, cleaning them, replacing faulty parts

- Checking piston rings and replacing them

- Checking complete and half circle bearings, cleaning them, replacing them

- Checking the size of cylinder bore and boring it

- Checking and replacing timing chain, method to insure correct timing after installing cylinder head

- Disassembling camshaft in the cylinder block, checking camshaft assembly and their mode of operation

- Reassembling cylinder block to cylinder head

Check and repair cylinder block faults: - Disassembling cylinder block,

method of cleaning it - Checking crankshaft, measuring its

diameters - Checking pistons and connecting

rod, repairing, cleaning them, replacing faulty parts

- Checking piston rings and replacing them

- Checking complete and half circle bearings, cleaning them, replacing them

- Checking the size of cylinder bore and boring it

- Checking and replacing timing chain, method to insure correct timing after installing cylinder head

- Disassembling camshaft inside the cylinder block, checking camshaft assembly and their mode of operation

Reassemble cylinder block to cylinder head

H2

3

reinstalling the engine Use tools correctly for safety and protection of the tools and equipment from any harm Use devices correctly for their safety and protection Secure car lift for the safety of car, technician and workshop

A3, A4, A5

6

Method of testing the engine using tools and equipment after the maintenance job is done

Check, repair or replace - Check and repair lubricating system

faults and replace faulty parts - Check and repair cooling system

faults and replace faulty parts - Check and repair fuel system faults

and replace faulty parts - Check and repair ignition system

faults and replace faulty parts using special tools and equipment

D4, H4, D7, D10,

D8, H5, H3, H6


Course name Fuel system (Diesel) Code MEV 214


Course description: this course discusses how to repair and maintain diesel injection system.

Semester 1 2 3 4

Credit hours 3

L 2

W 2 Contact hours

T General course objectives: this course aims to introduce the student to the methods of repairing and maintaining diesel injection system. It includes; fuel tank, fuel supply pump, injection pump, their calibration, the regulation of the injection, pressure and amounts of diesel according to the different operating conditions, methods of controlling fuel injection and glow plugs and their connections. As well as introducing the student to the methods of determining and diagnosing faults and inspecting using advanced tools and equipment in that field.

Skill Objectives: The student should be able to: • Know how to maintain diesel injection systems. • Identify diesel circuit components. • Know methods of adjusting the engine through the system without removing any parts. • Know methods of adjusting and calibrating amounts of pumped fuel by the injection pump

using the diesel injection pump test stand. • Know methods of adjusting and calibrating amounts injected by the injectors according to

engine operating conditions and by using the diesel injection pump tester. • Determine and diagnose faults and repair or replace faulty parts of the diesel injection system. • Check the system using advanced tools and equipment in that field.

Subjects (theoretical and practical): • Method of repairing and maintaining diesel injection system • Fuel supply pump, connections, injectors • Fuel injection pump • Determining and diagnosing faults and repairing or replacing faulty parts of the diesel injection

system • Checking the system using advanced tools and equipment in that field

References:

- Schulz: Erick J., and Evridge, Ben L., "Diesel Mechanics", Glencoel McGraw-Hill, ISBN 0-074)55836-1. - Duffy, James E., and Smith, Howard B., " Auto Fuel and Emission Control Systems Technology", The Goodheart-Willcox company, INC, ISBN O- 87006-932-2 - Heinze Heisler, "Advanced Engine Technology", Edward Arnold, ISBN 0340568224 - William H. Crouse and Donald L. Anglin, "Automotive Mechanics" The McGraw Hill Book Company, ISBN 04)2-800943-6 - Stokel, Martin W., Stokel, Martin T., and Johanson, Chris, "Auto Fundamentals" The Goodheart Willcox company, INC, ISBN 1-5663 7-1384, 1996 - William, K. Toboldt, Larry Johnson, and W. Scott Gavthier, "Automotive Encyclopedia " Fundamental, Principles, Operation, Construction, Service, and Repair, The Goodheart -Willcox company; INC, ISBN 1-56637-150-3, 1995 - Duffy, James E., "Auto Engines" The Goodheart Willcox company, INC, ISBN 0-87006477-3 - Jack Enjavec and Robert SclmIff "Automotive Technology " Delmar Publishers, An International Thomson Publishing Company.


Hours Content Skill Objectives

The student should be able to:

Related tasks

2

Diesel fuel characteristics • Study fuel characteristics

(evaporation, density, effects of fuel characteristics on fuel injection system)

• Fuel injection systems (direct and indirect)

• Types of combustion chambers • Effects of different injection systems

on diesel engine performance

ID

4

Fuel injection systems Fuel injection system components: • Fuel tank • Fuel supply pump • Fuel filters • Fuel injection pump • Fuel lines and pipes • Injectors

Identify fuel injection system components: - Fuel tank, its contents and connections - Fuel hoses and pipes - Diesel float Effect of the presence of air in the diesel circuit

ID4, ID10, ID11, ID15, ID16

4

Fuel supply pumps • Construction and mode of operation

of the different types of pumps (mechanical and electric)

• Comparison between the different pumps from the point of view of their effect on the performance of the fuel injection system

• Advantages and disadvantages of each type of pumps

• Causes of faults and their effect on the fuel injection system

Identify the components of the fuel supply pump and its types

ID1, ID9

4

Fuel filters • Construction and mode of operation

of different filter types • Comparison between different

systems • Advantages and disadvantages of

each type • Fuel passage through different filters • Fault causes and their effects on the

fuel system • Method of separating fuel from

water

Identify the components of the diesel filters, types, mode of operation and the advantages and disadvantages of each system

ID3

6

Fuel injection pump • Construction and mode of operation

of the in-line pump • Construction and mode of operation

of distributor pump • Different fuel injection control

methods • Comparison between different types • Fault causes in the different pumps

and their effects on the fuel system

Identify: - Electric diesel pump - Pump valve - In-line diesel pump - Distributor diesel pump their types, mode of operation and the advantages and disadvantages of each system

ID2, ID5, ID12, ID13

4

Fuel injectors • different types of injectors • Construction and mode of operation

of injectors • Comparison between different types • Advantages and disadvantages of

each type • Fault causes in the injectors and

their effects on the fuel system

Identify the components of injectors, their types, mode of operation and the advantages and disadvantages of each type

ID7, ID14

4

Fuel injection control • Method of controlling fuel injection

timing • Method of controlling amount of

injection • Construction and mode of operation

of fuel injection regulators • Comparison between different types

Identify: • Diesel pump timing • Injection amount (manually) • Electronic injection system • Electronic injection components




2

Safety procedures for the diesel workshop Checking the components of the fuel system and the characteristics of diesel fuel Types of fuel injection systems Types of combustion chambers The effects of different injection system types on the diesel engine

The student should be able to: - Visually inspect diesel components

and identify the different diesel fuel injection systems

ID

2

Methods of locating faults and adjusting fuel injection systems without removing parts. The faults include: • Hard engine starting • Loss in engine power • Irregular engine rotation • Diesel engine knock • Back fire in the induction manifold • Presence of black smoke in the

exhaust fumes • Engine vibration • Excessive fuel consumption

Identify fuel system faults

ID4, ID10, ID11, ID15, ID16

2

Methods of checking for faults and adjusting fuel injection systems: • Fuel tank (electric connections,

leakages, removing the float and repairing it, … etc)

• Clean suitable fuel • Fuel filters • Fuel injection pump • Fuel lines and pipes (injection and

return lines) • Diesel hoses and pipes • Injectors

• Check fuel tank • Replace fuel tank • Replace fuel hoses and pipes • Replace diesel float • Bleed air from the diesel circuit

ID4, ID10, ID11, ID15, ID16

2

Adjusting, repairing and replacing what is needed in: - Mechanical fuel supply pumps - Electric fuel supply pumps - Check amounts of fuel intake - Check electric connections - Bleed air

- Check fuel supply pump - Replace fuel supply pump

ID1, ID9

2

Adjusting, repairing and replacing what is needed in: - Different types of fuel filters - Visually inspect filter or by a magnifying glass - Cleaning filter

- Check diesel filters

ID3

6

Method of adjusting the fuel injection pump using the diesel injection pumps test stand. This includes: - Equal amount of injection from every injector - Injector stroke length (injection time) - Full load amounts - Engine starting amounts - Injection timing - Controlling engine rotation speed

- Check electric diesel pump - Check pump valve - Replace diesel pump - Replace electric diesel pump ID2,


4

Method of repairing fuel injection pumps (in-line and distributor). This includes: - Injection plunger - Cams - Injection control springs - Bearings - Pump components - Supply valves

- Check electric diesel pump - Check pump valve - Replace diesel pump - Replace electric diesel pump

ID2, ID5, ID6, ID12, ID13

4

Adjusting, repairing and maintaining what is needed in: - Different types of injectors - Amount and pressure of injection - Observe spray pattern - Fuel injection lines - Glow plugs

- Check injectors - Replace injectors

ID7, ID8, ID14

4

Checking and repairing fuel injection control - Control system for the glow plugs - Injection amounts control spring - Injection amounts control resistance

- Check diesel fuel pump timing - Check injection amount manually - Check electronic injection system - Replace electronic injection parts



Course name Engineering Drawing Code MEV 221


Course description: this course covers the principles of assembly drawing by using fits and tolerance. Also construction methods of coupling, keys, splines, threads and nuts, and determining surface quality.

Semester 1 2 3 4

Credit hours 2

L

W 4 Contact hours

T

General course objectives: this course aims to introduce the student to the principals of assembly drawing by using fits and tolerance. Also construction methods of coupling, keys, splines, threads and nuts, and determine surface quality of machined surfaces.

Skill Objectives: The student should be able to: • Know the principals of assembly drawing by using fits and tolerance. • Know the construction methods of coupling, keys, splines, threads and nuts. • Determine surface quality of machined surfaces. • Analyze the drawing and write a technical report.

Subjects (theoretical and practical): • The principals of assembly drawing by using fits and tolerance • Construction methods of coupling • Construction of keys, splines, threads and nuts • Determining surface quality of machined surfaces

References:

- James H, "Drafting, technology,, Earle Addison-Wesley Publications co. - M.A. Parker & L.J. Dennis, "Engineering drawing Fundamentals', Stanley Theoris. - Warren J. Luzadder, ,, Fundamentals of Engineering Drawing', Prentice- Hall, 1986, Ninth Edition.



8

Assembling parts - Importance of assembling in

engineering drawing - Methods of determining surface

quality of machined surfaces - Determining roughness of machined

surfaces - Applications of assembling

engineering drawing

The student should be able to: - Know the importance of assembling

in engineering drawing - Know methods of determining

surface quality of machined surfaces - Determine roughness of machined

surfaces - Apply assembling engineering

drawing

12

Fits and tolerance - Factors affecting fits and tolerance - Parts standard dimensions - Obtaining fits and tolerance values - Inserting fits and tolerance into the

assembly drawing

- Understand factors affecting fits and tolerance

- Read parts standard dimensions - Obtain fits and tolerance values - Insert fits and tolerance into the

assembly drawing

12

Threads, bolts and springs - Types of springs and threads - Finding the specifications of springs,

threads and bolts - Methods of choosing and using

design tables

- Draw types of springs and threads - Find the properties of springs,

threads and bolts - Know methods of choosing and

using design tables

12

Bearings, gears and cams - Bearing types - Gears types - Cam types - Methods of selecting bearing

- Draw types of bearings - Draw types of gears - Draw types cams - Know methods of selecting bearing

12

Connections, bolts and keys - Types of sealants - Types of keys and splines - Choosing locking devices - Methods of locking coupling

- Know types of sealants - Differentiate between types of keys

and splines - Choose locking devices - Know methods of locking coupling


Course name Power Trains (2) Code MEV 222


Course description: this course covers the automatic transmission. It includes a study of automatic transmission, clutch, torque converter, planetary gear system and hydraulic control methods. It also covers checking, repairing or replacing faulty parts in the automatic transmission.

Semester 1 2 3 4

Credit hours 4

L 2

W 4 Contact hours

T -

General course objectives: this course aims to introduce the student to the automatic transmission. It includes a study of automatic transmission, clutch, torque converter, planetary gear system and hydraulic control methods. It also covers checking, repairing or replacing faulty parts in the automatic transmission.

Skill Objectives: The student should be able to: • Know the automatic transmission and its importance. • Know automatic transmission, clutch, torque converter, planetary gear system and hydraulic

control methods. • Check automatic transmission. • Repair or replace faulty parts in the automatic transmission.

Subjects (theoretical and practical): • Automatic transmission and its importance • Construction of automatic transmission • Clutch, torque converter, planetary gear system • Hydraulic control methods • Checking automatic transmission • Repairing or replacing faulty parts in the automatic transmission

References:

- Stockel, M.W.: Stockel, M.T, and Johanson C., "Auto Fundamentals", Goodheart Willcox Company, Inc., 1996, ISBN 1-56637-138-4 - Stockel, Stockel, and Johanson, "Auto Service & Repair", Goodheart- Willcox Company, Inc., 1996 ISBN 1-56637-144-9 - William K Toboldt, Larry Johnson, and W. Scott Gauthier, "Automotive Encyclopedia", The Goodheart-Willcox Company, Inc., 1 995 ISBN i-5663 7-150-3. - Enjavec,.lack and Schai-, Robert, "Automotive Technology", 2nd Edition Delmar Publishers, An international Thomson Publishing Company, 19%. ISBN. - William Crouse: "All Automobile" (12 parts), Mars Publishing House, ISBN - William H. Crouse and Donald L. Anglin, "Automotive Technician’s Handbook", The McGraw-Hill Book Company, ISBN - Robert Bosch GmbH, "Automotive Handbook", 4th Edition, 1996, Published by VDI-Verlag, ISBN - William H. Crouse and Donald L. Anglin, "Automotive Mechanics" The McGraw Hill Book Company, I0th Edition, ISBN 04)2-800943A - Stokel, Martin W., Stokel, Martin T., and Johanson, Chris, "Auto Fundamentals" The Goodheart Willcox company, fl'rC, ISBN 1-56637- 1384, 1996 - William, K. Toboldt, Larry Johnson, and W. Scott Gavthier, "Automotive Encyclopedia" Fundamental, Principles, Operation, Construction, Service, and Repair, The Goodheart -Willcox company, IXIC, ISBN 1 -5663 7- 1 50-3, 1 995 - Duffy, James E., "Auto Engines" The Goodheart Willcox company, INC, ISBN 0-87006A77-3 - Jack Enjavec and Robert Scharif "Automotive Technology" Delmar Publishers, An International Thomson Publishing Company.



2

Automatic transmission - Introduction to automatic

transmission - Define automatic transmission - Advantages of automatic

transmission - Types of automatic transmission

The student should be able to: - Identify automatic transmission - Define automatic transmission - Know advantages of automatic

transmission - Know types of automatic

transmission

I3

2

Clutch and torque converter - Hydraulic coupling, its parts and

mode of operation - Torque converter, its parts and

mode of operation

Identify clutch and converter - Identify hydraulic coupling and its

parts - Understand its mode of operation - Identify torque converter and its

parts - Understand its mode of operation

I2, I7, I9, I13

8

Planetary gears unit - Identify planetary gears - Three speed planetary gear unit - Hydraulic control system - Oil pump and types of oil used in

automatic transmission - Identify all parts of automatic

transmission - Hydraulic shift control circuit

Identify planetary gears unit - Identify three speed planetary gear

unit - Understand hydraulic control system - Understand oil pump mode of

operation - Know types of oil used in automatic

transmission - Identify all parts of automatic

transmission - Understand mode of operation of the

hydraulic shift control circuit

I4, I5

16

Hydraulic control methods - Regulator - Pressure regulator vacuum valve - Mode of operation of the hydraulic

shift control circuit - Transmission throttle valve - Manual kick down valve - Automatic transmission auxiliary

cooler/ heat exchanger - Different pressures in parts of the

hydraulic circuit and their relation to valve operation

- Reverse shift valve - 1 and 2 shift valve and its piston - 2 and 3 shift valve and its piston Transmission - Observe power transmission in the

(D) position and first shift - Observe power transmission in the

(D) position and second shift - Observe power transmission in the

(D) position and third shift - Observe power transmission in the

reverse shift - Identify clutches - Identify sensors - Identify faults of automatic

transmission

Identify hydraulic control methods - Regulator - Pressure regulator vacuum valve - Mode of operation of the hydraulic

shift control circuit - Transmission throttle valve - Manual kick down valve - Identify automatic transmission

auxiliary cooler/ heat exchanger - Identify the different pressures in

parts of the hydraulic circuit and their relation to valve operation

- Reverse shift valve - 1 and 2 shift valve and its piston - 2 and 3 shift valve and its piston Identify transmission - Observe power transmission in the




reverse shift - Identify clutches - Identify sensors Identify faults of automatic transmission

I6, I11



2






transmission

I3

2

Clutch and torque converter - Hydraulic clutch, its parts and mode

of operation - Torque converter, its parts and

mode of operation

Identify clutch and converter - Identify hydraulic clutch and its parts - Understand its mode of operation - Identify torque converter and its


I2, I7, I9, I13

8

Planetary gears unit - Identify planetary gears - Three speed planetary gear unit - Hydraulic control system - Oil pump and types of oil used in

automatic transmission - Identify all parts of automatic

transmission - Gear ratio electronic control circuit

Identify planetary gears unit - Identify three speed planetary gear

unit - Understand hydraulic control system - Understand oil pump mode of

operation - Know types of oil used in automatic

transmission - Identify all parts of automatic

transmission - Understand mode of operation of the

gear ratio electronic control circuit

I4, I5

16

Hydraulic control methods - Regulator - Pressure regulator vacuum valve - Mode of operation of the gear ratio

hydraulic control circuit - Gearbox throttle valve - Manual valve - Automatic transmission radiator - Different pressures in parts of the

hydraulic circuit and their relation to valve operation

- Reverse shift valve - 1 and 2 shift valve and its piston - 2 and 3 shift valve and its piston Transmission - Observe power transmission in the




reverse shift - Identify clutches - Identify sensors - Identify faults of automatic

transmission

Identify hydraulic control methods - Regulator - Pressure regulator vacuum valve - Mode of operation of the gear ratio

hydraulic control circuit - Gearbox throttle valve - Manual valve - Identify automatic transmission

radiator - Identify the different pressures in

parts of the hydraulic circuit and their relation to valve operation

- Reverse shift valve - 1 and 2 shift valve and its piston - 2 and 3 shift valve and its piston Identify transmission - Observe power transmission in the




reverse shift - Identify clutches - Identify sensors Identify faults of automatic transmission

I6, I11



4






transmission

I3

4

Checking and repairing clutch and torque converter - Hydraulic coupling, its parts and

mode of operation - Torque converter, its parts, mode of

operation and method of checking torque converter

Identify clutch and converter - Identify hydraulic coupling and its

parts - Understand its mode of operation - Identify torque converter and its


and method of checking torque converter

I2, I7, I9, I13

16

Checking and repairing planetary gears unit - Steps for removing automating

transmission - Steps for disassembling automatic

transmission with special tools - Identify parts and mode of operation

of each part - Checking oil pump - Checking lubricating circuit - Replacing oil filter - Replacing sealants and gaskets

Check and repair planetary gears unit - Follow steps for removing automatic

transmission - Follow steps for disassembling

automatic transmission with special tools

- Identify parts and mode of operation of each part

- Check oil pump - Check lubricating circuit - Replace oil filter - Replace sealants and gaskets

I4, I5

32

Checking and repairing hydraulic control system - Replacing torque converter - Checking clutches - Installing clutches with special tools - Checking pistons - Check control unit - Check sensors Transmission - Method of reassembling

transmission using special tools - Reinstalling automatic transmission - Test transmission after reinstallation

Check and repair hydraulic control system - Replace torque converter - Check clutches - Install clutches with special tools - Check and replace pistons - Check and replace control unit - Check and replace sensors Install transmission - Know method of reassembling

transmission using special tools - Reinstall automatic transmission - Test transmission after reinstallation - Reprogram automatic transmission

for proper performance

I6, I11


Course name Steering and Suspension System Code MEV 223


Course description: this course covers the different steering systems, different types of steering gearboxes, methods and equipment for measuring, as well as checking and adjusting them. This course also covers different suspension systems, whether for the front or rear axels, and the importance of springs and shock absorbers for the comfort and safety of the passengers and car. Also the different wheel alignment angles, their importance and the methods, tools and equipment for measuring them - comparing them to the standard specifications and adjusting them. The effect of wheel alignment on the stability and safety of the car are included.

Semester 1 2 3 4

Credit hours 4

L 2

W 4 Contact hours

T -

General course objectives: this course aims to introduce the student to the different steering systems, and different types of steering gearboxes and the methods and equipment for measuring, checking and adjusting them. This course also aims to introduce the student to the different suspension systems, whether for the front or rear axels, and the importance of springs and shock absorbers for the comfort and safety of the passengers and car. Also the different wheel alignment angles, their importance and the methods, tools and equipment for measuring them - comparing them to the standard specifications and adjusting them. The effect of wheel angles on the stability and safety of the car. Skill Objectives: The student should be able to: • Know the different steering systems. • Know the different types of steering gearboxes in relation to their direction of motion. • Know the methods and equipment for measuring, checking and adjusting them. • Know different suspension systems for the front and rear axels, and the importance of springs

and shock absorbers for the comfort and safety of the passengers and car. • Know the different wheel alignment angles, their importance and the methods, tools and

equipment for measuring them, comparing them to the standard specifications and adjusting them and their effect on the stability and safety of the car.

Subjects (theoretical and practical): • The different steering systems • The different types of steering gearboxes in relation to their direction of motion • Methods and equipment for measuring, checking and adjusting them • Different suspension systems for the front and rear axels • The importance of springs and shock absorbers for the comfort and safety of car and

passengers • Different wheel alignment angles and the methods and equipment for measuring, checking and

adjusting them according to the standard specifications • Their importance and effect on the stability and safety of the car

References:

-'Thomas W. Birch "Automotive Suspension & Steering Systems", Harcourt Brace Jovanovich College Publishing, 1993, ISBN 04)3- 09682-4, 1993 - Martin W. Stokel, Martin T. Stokel Chris Johanson "Auto Fundamentals" The (Goodheart-Willcox company, INC - ISBN 1-56637- 138-4, 1996 - Robert Scharif "Complete under~ar systems" Suspension and Steering Delmar Publisher Inc - 1989. ISBN 0-8273-3571-7 - Martin W. Stokel and Martin "Auto Mechanics Fundamentals" The Goodheart -Willcox company, INC:, ISBN 1-56637-1384, 1996 - Stockel, Stockel, and Johanson "Auto Service and Repair" The Goodheart -Willcox company, INC, ISBN 1-56637-144-9 - William H. Crouse and Donald L. Anglin "Automotive technician's Handbook" The McGraw - Hill Book Company, ISBN 0-07014751-5 - William K. Toboldt, Larry Johnson and W. Scott Gavthier "Automotive Encyclopedia "Fundamental, Principles, Operation, Construction, Service, and Repair- The Goodheart - Willcox company, INC- ISBN 1-56637-150-3 , 1995 - Allan W. M. Bonnick, "Vehicle Electronic systems Fault Diagnosis" ARNOLD, ISBN 0-340-70630-9, 1998 - Jack Enjavec and Robert Scharif "Automotive Technology " Delmar Publishers, An International Thomson Publishing Company - Crouse Anglin "Auto Mechanics" The McGraw - Hill Book Company - William H. Crouse and Donald L. Anglin" The Auto Book" The McGraw - Hill Book Company - Robert Bosch GmbH "Automotive Handbook" Published by VDI- Verlag, 1996



2

Study the different types of steering systems - Ackermann steering theory and

connections - Importance of front wheel

inclination - The effect of front axel on the

steering systems - Different types of steering

gearboxes - Rack and pinion steering linkage

system - Ball joints - Shock absorbers - Steering column lock - Direction of motion and its effect on

car motion and safety

The student should be able to: Identify the different types of steering systems: - Ackermann steering theory and

connections - Importance of front wheel inclination - The effect of front axel on the

steering systems - Different types of steering gearboxes - Rack and pinion steering linkage

system - Ball joints - Shock absorbers - Steering column lock - Direction of motion and its effect on

car motion and safety

G1, G2, G3

4

Study the causes of noise and vibrations in the steering gearbox. Also the importance of sealants and gasket in the connections and steering gearbox.

- Identify the causes of noise and vibrations in the steering gearbox

- Understand the importance of sealants and gasket in the connections and steering gearbox

G4, G5, K3, K4,

K5

4

Study the effect of the steering gearbox motion with and without power steering on the stability and safety of the car. This includes: - Steering gearbox performance - Steering system boosters - Steering wheel - Steering shaft - Gearbox with steering linkages and

control valve - Van pump, oil cooler and reservoir

Know the effect of the steering gearbox motion with and without power steering on the stability and safety of the car. This includes: - Steering gearbox performance - Steering system boosters - Steering wheel - Steering shaft - Gearbox with steering linkages and

control valve - Van pump, oil cooler and reservoir

G6, G7, K1, K2, K8, K9,

K13, K17

4

Study the types and importance of tires and wheel alignment angles, arms, joints and ball bearing, and their effect on the motion and safety of the car: - Installation, dimensions and

maintenance of tires - Joints and linkages - Wheel alignment angle types ( toe

in, camber,… etc)

Know the types and importance of tires and wheel alignment angles, arms, joints and ball bearing, and their effect on the motion and safety of the car: - Understand the installation,

dimensions and maintenance of tires - Identify joints and linkages - Identify wheel alignment angle types

( toe in, camber, … etc)

G8, G12, G14, K14, K15, K16

4

The effect of the motion, types and condition of springs and their compliance with the specifications on the motion, stability and safety of the car: - Leaf and coil springs - Air suspension and torsion bars - Independent axel suspension - Importance and limits of the

independent front axel suspension - Construction and performance of

the independent front axel suspension

- Rear axel suspension - Independent rear axel suspension - The effect of stabilizer bar

Know the effect of the motion, types and condition of springs and their compliance with the specifications on the motion, stability and safety of the car: - Leaf and coil springs - Air suspension and torsion bars - Independent axel suspension - Importance and limits of the

independent front axel suspension - Construction and performance of the

independent front axel suspension - Rear axel suspension - Independent rear axel suspension - The effect of stabilizer bar

G13, G15, K10

2

The effect of the motion, types and condition of shock absorbers on the motion, stability and safety of the car: - Telescopic shock absorbers - Types of shock absorbers - Leakage in shock absorbers

Know the effect of the motion, types and condition of shock absorbers on the motion, stability and safety of the car: - Telescopic shock absorbers - Types of shock absorbers - Leakage in shock absorbers

G11

6

- Study the condition of tires - Study the condition of arms and

joints - The pump and hydraulic suspension

system - Study the importance of rubber

bushings for the performance of the suspension system

- Ball bearing The effect of all these factors on the values and limits of wheel angles and their effect on the safety of the car motion

Identify each of : - The condition of tires - The condition of arms and joints - The pump and hydraulic suspension

system - The importance of rubber bushings

for the performance of the suspension system

- Ball bearing Know the effect of all these factors on the values and limits of wheel angles and their effect on the safety of the car motion

G9, G10, G16,

K6, K7, K11, K12, K18, K19

2

Identify the ideal methods for the periodic maintenance and how to prepare a technical report on the performance of the steering and suspension system

Identify the ideal methods for the periodic maintenance and how to prepare a technical report on the performance of the steering and suspension system

K20



4

Introduce the student to the different steering systems, their parts and the differences between the parts of each system: - The effect of the front axel

suspension on the steering systems - Different types of steering gearboxes - The importance of front wheel

inclination - Rack and pinion, linkages and joints - Inspecting the steering gearbox for

the movement in two directions - Check oil level and its condition - Using special tools and equipment

The student should be able to: Identify the different steering systems, their parts and the differences between the parts of each system - The effect of the front axel

suspension on the steering systems - Different types of steering

gearboxes - The importance of front wheel

inclination - Rack and pinion, linkages and joints - Inspecting the steering gearbox for

the movement in two direction - Check oil level and its condition - Use special tools and equipment

G1, G2, G3

8

Locate the sources of noise and vibrations in the steering gearbox while the car is in the workshop and on the road. The faults include: - Rack and pinion wear - Tie-rod end wear - Excessive clearance in the joints and

linkages - Plastic bushings wear - Power steering lines - Distortion or breakage of one of the

arms and bars - Bearing wear … etc • Checking the sources of leakage

in the links to and from the steering gearbox

• Methods of repairing leakage in the joints

• Methods of dealing with faults in pipes, repairing or replacing faulty parts

• Use special tools and equipment

Locate the sources of noise and vibrations in the steering gearbox while the car is in the workshop and on the road. The faults include: - Rack and pinion wear - Tie-rod end wear - Excessive clearance in the joints

and linkages - Plastic bushing wear - Power steering lines - Distortion or breakage of one of the

arms and bars - Bearing wear … etc • Checking the sources of leakage

in the links to and from the steering gearbox

• Methods of repairing leakage in the joints

• Methods of dealing with faults in pipes, repairing or replacing faulty parts

• The usage of special tools and equipment

G4, G5, K3, K4,

K5

8

- Measuring, checking and testing the steering gearbox

- Method of removing and installing steering wheel and aligning it

- Removing flex coupling - Removing the main shaft of steering

column - Gearbox with linkages and control

valve - Van pump, oil cooler, and reservoir - Measuring, checking and testing the

steering gearbox with the hydraulic system

- Replace faulty parts using special tools and equipment

- Measure, check and test the steering gearbox

- Know the method of removing and installing steering wheel and aligning it

- Remove flex coupling - Check the main shaft of steering

column - Check gearbox with linkages and

control valve - Check Van pump, oil cooler, and

reservoir - Measure, check and test the steering

gearbox with the hydraulic system - Replace faulty parts using special

tools and equipment

G6, G7, K1, K2, K8, K9,

K13, K17

8

Check tires and the shape of their wear. The methods of checking for faults include: - Measure and check all types of

wheel angles - Centering and alignment of steering

wheel - Motion of arms joints and the effect

of their looseness on the system - Joints and linkages of arms and their

effectiveness for the steering system - Check ball bearing - Determine the serviceability of arms

and joints Replace faulty parts using special tools and equipment

Check tires and the shape of their wear, and the methods of checking for faults include: - Measure and check all types of

wheel angles - Centering and alignment of steering

wheel - Motion of arms joints and the effect

of their looseness on the system - Joints and linkages of arms and

their effectiveness for the steering system

- Check ball bearing - Determine the serviceability of arms

and joints Replace faulty parts using special tools and equipment

G8, G12, G14, K14, K15, K16

8

Check and determine the serviceability of: - Leaf and coil springs - Air springs and torsion bars - Independent axel suspension - Independent front axel suspension

limit - Construction and performance of the

independent front axel suspension - Rear axel suspension - Independent rear axel suspension - Stabilizer bar - Replace faulty parts using special

tools and equipment

- Check and replace springs and their serviceability and compliance to the standard specifications

- Check stabilizer bar and its compliance to the recommended specifications for the car

G13, G15, K10

4

- Check the performance of shock absorbers and determine their serviceability

- Telescopic shock absorbers - Leakage in shock absorbers - Using special tools and equipment

- Check shock absorbers and determine their serviceability using special tools

G11

12

- Adjust tire inflation pressure and replace worn-out ones

- Align all wheel angles - Align steering wheel - Adjust arms, rods and joints - Check rubber bushings - Adjust shock absorbers - Replace bearings - Check pump and hydraulic

suspension system Determine serviceability of rods and joints after doing the repair jobs and replace faulty ones using special tools and equipment, and compare the results of the adjustments done to the standard specifications and their effect on the motion, stability and safety of the car

- Adjust tire inflation pressure using special equipment for the safety of the passengers

- Check and align wheel angles using special equipment and check wheel balance

- Check, repair and replace pump and hydraulic suspension system using special tools

- Replace arms using special tools for proper performance

- Replace rods and joints using special tools

- Replace shock absorbers using special tools for proper performance as per recommended specifications

G9, G10, G16,

K6, K7, K11, K12, K18, K19

4

Method of performing periodic maintenance for the steering, suspension and calculating the costs of the repairs done including (spare parts – time spent) -in case of repairing, replacing or periodic maintenance. As well as the method of preparing a worksheet

- Prepare a detailed report about the work done on the mechanical faults in the steering and suspension system K20


Course name Fault Diagnosis Code MEV 224


Course description: this course covers the principals of mechanical fault diagnosis of the automobile and methods of repairing them, Testing and inspection equipment. Also methods of checking the vehicle according to its manual. Different applications for car problems which include the different systems and the causes for their faults are included. Practical methods of checking for faults and the equipment used for that are covered too.

Semester 1 2 3 4

Credit hours 4

L 2

W 4 Contact hours

T -

General course objectives: this course aims to introduce the student to the principals of mechanical fault diagnosis of the automobile and methods of repairing them, testing and inspection equipment. As well as introducing the student to the methods of checking the vehicle according to its manual. Plus different applications for car problems which include the different systems and the causes for their faults. Practical methods of checking for faults and the equipment used for that will be taught.

Skill Objectives: The student should be able to: • Know the principals of mechanical fault diagnosis of the automobile and methods of repairing

them. • Know the methods using testing and inspection equipment. Methods of checking the vehicle

according to its manual. • Know the different problems in different car systems and the causes for their occurrence. • Know the practical methods of checking for faults and the equipment used for that.

Subjects (theoretical and practical): • The principals of mechanical fault diagnosis of the automobile and methods of repairing them • Methods of using testing and inspection equipment • Methods of checking the vehicle according to its manual • Predicting causes of different problems in different car systems • Practical methods of checking for faults and the equipment used for that

References:

Allan W. M. Bonnick, "Vehkle Electronic systems, Fault Diagnosis AKNOLD:ISBN 0-340-70630-9, 1998 - Stockel, Stockel, and Johanson "Auto Service and Repair" The Goodheart -Willcox company, INC, ISBN 1-56637-144-9 I - Technical manuals and manufacturer data books - William H. Crouse, and Donald I,. Anglin, "Automotive technician's Handbook", 7`he McGraw-Hill Book Company, ISBN 04)7014751-5 W. Stokel, Martin T. Stokel and Chris Johanson, "Auto Fundamentals" The Goodheart-Willcox company, INC, ISBN i-56637-1384, 1996 - "Automotive Engine Management, and Fuel Injection Systems, Manual" ISBN 1-85960 344 0, 1997 - "Automotive Diesel Engine, Service Guide", ISBN 1-85960-286>( William K. Toboldt, Larry Johnson and W. Scott Gavilfier, "Automotive Encyclopedia" Fundamental, Principles, Operation, Construction, Service, and Repair- The Goodheart Willcox company, INC, ISBN 1-56637-150-3, 1995 - Jack Enjavec and Robert Scharfr "Automotive Technology" Delmar Publishers, An International Thomson Publishing Company - Crouse Anglin "Auto Mechanics" The McGraw- Hill Book Company - William H. Crouse and Donald L. Anglin" The Auto Book" The McGraw - Hill Book Company - Robert Bosch Gmbh "Automotive Handbook" Published by VDI- Verlag, 1996



2

Query car user about car problems The student should be able to: - Know how to ask the car user about

the symptoms of the fault to be repaired, about noise, smells and the different operating conditions

B1

2

Inspect the car by sight, listening and smelling

Understand the methods of inspecting the car by sight, listening and smelling; to locate and determine the mechanical fault

B2

2 Check car while driven and stopped Understand the method of checking

the car while driven and stopped for an accurate fault diagnosis

B3

2

Place car on lift - Ensure that the engine reaches

working temperature

- Know how to secure car lifts for the safety of the car, technician and workshop

- Know how to place the car on the lift to inspect the lower parts which are not visible while the car is on the ground

- Know how to ensure that the engine reaches working temperature suitable for proper fault diagnosis

A5, B4, D1

2

Locate noise sources: - Investigate and locate noise sources

in: - The engine - Transmission (clutches and

gearboxes) - Propeller shaft, rear axel and tires - Different parts of steering and

suspension

Understand methods of locating noise sources: Know how to locate noise sources in - The engine - Transmission (clutches and


suspension

D5, E5, F2

4

Using testing tools equipment for determining faults: Methods of using devices for calibration and measuring temperature and pressure in: - Engine - Transmission (clutches and


suspension

- Understand the methods of using testing tools and devices to determine different mechanical faults

- Understand the methods of using testing devices for accurate fault diagnosis as recommended by the manufacturing company

- Understand the methods of measuring engine pressure with the special device to ensure proper engine performance

B5, D6, E7

12

Know how to: - Remove some parts if needed - Determine mechanical faults - Follow manufacturing company’s

instructions for doing the periodic maintenance

- Clean the part to be repaired with the suitable cleaner

- Determine the spare parts needed

Know the method to do the following: - Remove some parts if needed - Determine mechanical faults - Follow manufacturing company’s




B6, B7, B8, C3, C4, C5,

E6

2

Comprehensive report about the mechanical repairs done, and this includes: - The engine - Transmission - Brake system - Steering and suspension system

Prepare a comprehensive report about the mechanical repairs done. This includes: - The engine - Transmission - Brake system - Steering and suspension system

H7, I19, J15, K20



4

Query car user about car problems The student should be able to: - Know how to ask the car user about

the symptoms of the fault to be repaired, about noise, smells and the different operating conditions

B1

4 Inspect the car by sight, listening and smelling

Inspecting the car by sight, listening and smelling; to locate and determine the mechanical fault

B2

4 Check car while driven and stopped Check the car while driven and

stopped for an accurate fault diagnosis

B3

4

Place car on lift - Ensure that the engine reaches

working temperature

- Know how to secure car lifts for the safety of the car, technician and workshop

- Know how to place the car on the lift to inspect the lower parts which are not visible while the car is on the ground

- Know how to ensure that the engine reaches working temperature suitable for proper fault diagnosis

A5, B4, D1

4

Locate noise sources: - Investigate and locate noise sources

in: - The engine - Transmission (clutches and


suspension

- Determine type and source of noise by hearing and by using the stethoscope to identify faulty parts

- Determine type and source of noise, locate fault and verify normal sound characteristics in the transmission when shifting gears while the car is stopped or driven

- Locate source of noise to locate fault and preventing it from affecting other parts in the brake system

D5, E5, F2

8

Using testing tools equipment for determining faults: Methods of using devices for calibration, measuring temperature and pressure in: - Engine - Transmission (clutches and


suspension

• Be capable of using testing tools and devices to determine faults

• Be capable of using testing devices for accurate fault diagnosis of the following:

- Engine - Transmission (clutches and


suspension

B5, D6, E7

24

- Remove some parts if needed - Determine mechanical faults - Follow manufacturing company’s




Know how to do the following: - Remove some parts if needed - Determine mechanical faults to

carry out the needed repairs - Follow manufacturing company’s

instructions for doing the periodic maintenance for correct repair jobs

- Choose the suitable cleaner to clean the part to be repaired - to avoid its wear during cleaning


B6, B7, B8, C3, C4, C5,

E6

4

Comprehensive report about the mechanical repairs done, and this includes: - The engine - Transmission - Brake system - Steering and suspension system

Prepare a comprehensive report about the mechanical repairs done. This includes: - The engine - Transmission - Brake system - Steering and suspension system

H7, I19, J15, K20

Department of Mechanical Technology

Engines and Vehicles Major

Study plan distributed over all semesters


requisite C.U L W T C.H1 ENG 101 General English Language - - - 3 2 2 4 2 ISL 101 Islamic Culture - - - 2 2 - 2 3 MAT 161 Specialized Mathematics - - - 3 3 1 4 4 CMP 101 Introduction to Computer - - - 2 - 4 4 5 MEV 111 Preparatory Workshop - - - 2 - 4 4 6 MEV 112 Industrial Safety - - - 1 - 2 2

Firs

t Sem

este

r

7 MEV113 Introduction to Automotive Electric System - - - 2 1 2 3 Total 15 8 14 1 23


1 ENG 192 Technical English ENG 101 3 2 2 4 2 ARB 101 Arabic Language - - - 2 2 - 2 3 PHY 101 Specialized Physics - - - 3 2 2 4 4 MEV 121 Technical Drawing - - - 2 - 4 4 5 MEV 122 Fuel System (Gasoline) MEV 111 4 2 4 6 Se

cond

Sem

este

r

6 MEV 123 Engines (1) MEV 111 4 2 4 6 Total 18 10 16 26


requisite C.U L W T C.H1 ENG 293 Technical English II ENG 192 3 2 2 4 2 MEV 211 Power Trains (I) MEV 111 4 2 4 6 3 MEV 212 Brake System MEV 111 4 2 4 6 4 MEV 213 Engines (2) MEV 123 4 2 4 8

Thi

rd S

emes

ter

5 MEV 214 Fuel System (Diesel) MEV 123 3 2 2 4 Total 18 10 16 26


1 ISL 102 Islamic Culture ISL 101 2 2 - 2 2 MGT 101 Professional Ethics - - - 2 2 - 2 3 MEV 221 Engineering Drawing MEV 121 2 - 4 4 4 MEV 222 Power Trains (2) MEV 211 4 2 4 6 5 MEV 223 Suspension & Steering System MEV 111 4 2 4 6 Fo

urth

Sem

este

r

6 MEV 224 Fault Diagnosis MEV 213 4 2 4 6 Total 18 10 16 26


Sum

mer

1 MEV 230 Cooperative Training - - - 4 According to working hours

Number of units C.U L W T C.H Program total number of units 73 38 62 - 101

C.U.: Credit Hours L: Lecture W: Workshop T: Practice C.H.: Contact Hours

Occupational Analysis Workshop

A Follows safety procedures

A1) Wears appropriate

work clothes

A2)

Prepare workplace

A3)

Use tools properly

A4)

Use equipment properly

A5)

Follow car lift safety procedures

Diagnose car mechanical

faults

B1) ask car user about

car problems

B2)

Visually inspect the car

B3) Check the car driven and stopped

B4)

Place car on lift

B5) Use test

equipment to determine car

faults

C Carry out periodic

maintenance

C1) Choose proper location in the

workshop

C2) Place suitable shields on the

car

C3) Choose suitable

cleaning materials

C4) Clean parts to be

repaired with proper cleaning

materials

C5) Follow the

manufacturer’s instructions for

the periodic maintenance

D Determine faults in engine

D1) ensure that the

engine reaches its working

temperature

D2) Observe engine

oil vapor

D3)

Check engine oil level and

quality

D4)

Inspect cooling system

D5)

Determine type and source of

noise

E Determine

faults in power train system

E1) Determine type of

transmission

E2) Check

transmission fluid level

E3) Observe

transmission fluid quality by color and smell

E4) Determine type of transmission fluid

E5) Determine type and source of

noise

F Determine the

faults in the brake system

F1) Check brake fluid level and quality

F2) Determine type and source of

noise

F3) Locate source of

brake fluid leakage

F4) Check brake

friction material (pads and linings)

F5) Check discs and

drums of the brakes

G1) Identify the type of suspension system

(hydraulic, mechanical, air)

G2) Check oil level

G3) Check steering

gearbox

G4)

Determine type and source of

noise

G5) Locate source of

oil leakage

G

Determine the faults in

steering and suspension

systems and wheel

alignment

G13) Check leaf and coil

springs

G14) Check ball and roller bearings

G15) Check stabilizer

bar

G16) Check pump and

the hydraulic suspension system

H Repair engine

mechanical faults

H1)

Repair faults in cylinder head

H2) Repair faults in cylinder block

H3) Repair faults in

lubricating system

H4)

Repair faults in cooling system

H5)

Repair faults in fuel system

A6) Use exhaust

gases ventilation

system

A7) Safely store flammable materials

A8) Learn how to

use fire extinguishers

A9) Follow car

manufacturers’ safety

procedures

B6) Disassemble

parts if needed

B7) Determine mechanical

faults

B8)

Determine the required spare parts

D6)

Measure engine

compression pressure

D7)

Check lubricating

system

D8)

Check fuel system

D9)

Analyze exhaust gases

D10)

Check ignition system

E6) Determine

type of faults (electric,

mechanical, hydraulic)

E7) Use testing equipment

E8)

Check differential

gears

E9)

Check seals, oil rings and

gaskets

E10)

Check drive axles

E11)

Check propeller

shaft support bearings

E12)

Check universal

joints

F6) Check brake

booster

F7) Check anti-lock brake

system (ABS)

F8)

Check parking brakes

F9) Check master

and wheel cylinders

F10)

Check brake pedal

G6)

Check steering wheel

G7) Check power

steering pump and drive belt

G8)

Check steering linkages

G9)

Check tires inflation

pressure and condition

G10)

Check wheel

alignment

G11) Check shock

absorbers

G12)

Check suspension arms and

joints H6) Repair faults

in ignition system

H7)

Fill in the final job

sheet

I1) Inspect the fly

wheel and replace clutch

I2) Replace the automatic

transmission clutches

I3) Replace filter and check oil

pan

I4) Repair

transmission oil pump

I5) Replace

transmission oil pump

I Repair

mechanical faults in power

train system I13)

Repair oil leakage sources

I14) Replace drive

axles

I15) Replace drive axles bearings

I16) Adjust

differential gears

I17) Replace

the universal joints of the

propeller shaft

J1) Replace brake

friction material (pads and linings)

J2)

Repair drums and discs

J3) Replace drums

and discs

J4) Repair master

and wheel cylinders

J5) Replace master

and wheel cylinders

J

Repair mechanical

faults in brake system

J13) Replace ABS

pump

J14) Replace ABS

sensors

J15) Fill in the final

job sheet

K1)

Repair power steering pump

K2) Replace power steering pump

K3)

Repair oil leakage

K4) Repair oil

passages and pipes

K5) Replace oil

pipes

K

Repair mechanical

faults in steering and suspension

systems K13)

Replace power steering pump

belt

K14)

Replace tires

K15)

Replace dust boots and

rubber bushings

K16) Replace wheel

bearings

K17) Align steering

wheel

L

Repair minor electrical faults

L1)

Check battery voltage

L2)

Test basic car electrical circuits

L3) Test basic car

electrical components

L4) Replace faulty

electrical components

L5)

Repair faulty electrical

components

I6)

Replace transmission

sensors

I7) Replace

hydraulic coupling or

torque converter

I8) Replace gears and bearings

of transmission

I9) Replace

transmission oil seals and

gaskets

I10)

Adjust the gearshift lever

I11)

Reprogram automatic

transmission

I12)

Replace differential

gears

I18) Replace axel

sensors

I19)

Fill in the final job sheet

J6) Replace brake

fluid and bleed the

brakes

J7) Repair brake

pipes

J8) Replace brake

pipes

J9)

Repair vacuum booster

J10)

Replace vacuum booster

J11) Replace wheel

bearings

J12)

Adjust rear and parking

brakes

K6)

Replace steering linkages

K7) Replace

suspension arms and ball

joints

K8)

Repair steering gearbox

K9)

Replace steering gearbox

K10)

Replace springs

K11) Adjust wheel

alignment angles

K12) Replace shock

absorbers

K18) Repair the pump of hydraulic

suspension system

K19) Replace the

pump of hydraulic

suspension system

K20)

Fill in the final job sheet

General Knowledge and Skills Professional Ethics

1. English language knowledge 2. Computer literacy 3. Ability to use maintenance manuals 4. Basic Knowledge of technical calculations 5. Ability to work in a group 6. Knowledge of technical terms 7. Knowledge of trade terminology 8. Keeping up to date with the trade developments

1. Adherence to safety rules 2. Self confidence 3. Cooperation with others 4. Honesty in doing the job 5. Sense of responsibility 6. Precision in doing the job 7. Taking care of equipment / tools, work place 8. Decision making ability

Future Interests and Directions Equipment, Tools and Materials

1. Mechanical advancement of testing and measuring equipment

2. More usage of modern vehicle technology 3. Usage of alternative fuel 4. The need for broader knowledge of vehicle

electric / electronic systems

1. General and special hand tools 2. Petroleum products (gasoline, oil, diesel, grease

…etc) 3. Cleaning materials 4. Sealing materials (special enforced papers, paste,

glue …etc) 5. Pressure measuring apparatus (fuel, oil, engine,

air … etc

6. Stethoscope 7. Wheel alignment angles measuring equipment 8. Clearance measuring equipment 9. Dynamic wheel balancer 10. Wheel replacement equipment 11. Bore scope 12. Hydraulic press 13. Electric lifts

mechanical technology department engines and vehicles section

Documents