Vehicles

Department: Mechanical Technology
Major: Vehicles
Kingdom of Saudi Arabia

General Organization for Technical Education and Vocational Training Colleges of Technologe Directorate

Deanship of Academic Affairs
DEPARTMENT OF CONSTRUCTION TECHNOLOGY
CURRICULUM FOR
CONSTRUCTION
BY PREPARED Prof. Dr. Lotfy H. Rabie Saker Dr. Mossad M. Kandil Dr. Kamel A. Ahmed Dr. Magdy B. Abdel Hady Mr. Ahmed Al Fadl
FIRST EDITION
G H
Major: Vehicles
Department Mechanical Technology Course Title Internal Combustion Engines Prerequisite
Major Code
Vehicles MEV 221

1 2 3 4 2 4 30 60 4 5 6
Semester Course Description : The principles of operation of Internal Combustion engines, classifications, various types, main components, and functions. Engine performance, calculations, and the influence of different parameters on engine performance. Combustion and knock in I.C.E. Engine mechanical systems. Fault diagnosis, adjustment, repair, and maintenance of engine mechanical systems. Credit hr/w L Contact hr/w W T L Contact hr/sem. W T
General Goal : The course provides the basic knowledge about internal combustion engines, principle of operation, working cycle, the constructional design and functions of the different components. It gives the practical experience and skills to diagnose, repair, adjust and maintain engine mechanical components and systems.
Behavioral Objectives : By the end of this course, the student will be able to: Explain engine operation, working cycle, components and function, Distinguish between different engine types, Carry out engine calculations, e.g. Swept volume, compression ratio, engine power and efficiency, MEP, piston pressure and speed, gas velocity and charge volume Explain combustion process in I.C.E, engine knock, diesel knock and factors affecting their occurrence Adapt the innovations in the field of advanced engine technologies Describe engine performance and its relation with different operating conditions. Carry out fault diagnosis regarding all mechanical parts of engines and locate defects using different inspection techniques and equipment. Carry out repair and adjustment work with suitable test equipment including final inspection of the engine, valves, cooling and lubricating systems.
L = Lecture Hours, W = Workshop/Laboratory Hours, T = Tutorial Hours
Department: Mechanical Technology Topics: Theory: 1. Fundamentals of Internal combustion engines: Principle of operation and Working Cycle ( Four Stroke, Two Stroke ) Engine classification and types Engine components and their Function. Engine characteristics 2. Performance of internal combustion engines: Performance factors, and parameters influencing performance, Engine performance calculations, engine power, torque, efficiency, MEP, Combustion in SIE and CIE, and Knock effects in internal combustion engines 3. Engine Mechanical Systems: Intake and exhaust systems. Engine-Timing system. Lubricating system, Cooling system. Practice:
Major: Vehicles
Laboratory: Engine performance tests Influence of different factors upon engine performance Workshop: Engine testing and diagnosing equipment. Fault diagnosing, repair and adjustment of: - Mechanical system (cylinder, crank drive, valve system). - Cooling system. - Lubricating system
Textbook:
Heinze Heisler, Advanced Engine Technology, Edward Arnold, ISBN 0340568224 William H. Crouse and Donald L. Anglin, Automotive Mechanics The McGrawHill Book Company, ISBN 0-02-800943-6 Manufacturers data and repair manuals Automotive journals and magazines Martin, W. Stokel and Martin, Auto Mechanics Fundamentals, The Goodheart-Willcox company, INC, ISBN 1-56637-138-4 , 1996 Stoekel, Stockel, and Johanson, Auto Service and Repair, The GoodheartWillcox company, INC, Martin W. Stokel, Martin T. Stokel Chris Johanson Auto Fundamentals The GoodheartWillcox company, INC, ISBN 1-56637-138-4 , 1996 William, K. Toboldt, Larry Johnson, and W. Scott Gavthier, Automotive Encyclopaedia Fundamental, Principles, Operation, Construction, Service, and Repair- The Goodheart -Willcox company, INC , ISBN 1-56637-150-3 , 1995 Jack Enjavec and Robert Scharff 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 GoodheartWillcox company, INC, ISBN 0-87006-677-3
Additional Reading:
References:
Major: Vehicles
Detailed Curriculum (Theory)

Hrs Contents Behavioral Objectives
10
1. Fundamentals of Internal combustion engines: 1.1 Principle of operation and Working Cycle Operation of Four stroke and Two stroke engines Actual working Cycle of S.I.E and C.I.E, and their P-V diagrams Thermodynamic cycles 1.2 Engine classification and types Engine classification and types regarding: Mixture formation and firing, Mode of operation, Piston motion, Engine cooling, Cylinder arrangement and numbering. 1.3 Parts of the Engine and their Function. I.C engine parts and their functions, as: Cylinder head, crank case, crankshaft, piston, piston bolt, piston rings and connecting rod, Different combustion chambers Different cylinder layout as: Inline-engine, V-engine, - Boxerengine (horizontally-opposed engine), and Under floor-engine Cylinder numbering, Advantages and disadvantages of different engine - constructions 1.4 Engine characteristics and dimensions: Technical engine terms: Stroke and bore, Displacement, and Compression ratio. Engine displacement, and Compression ratio calculations.
The Student should be able to: - Describe the principle of operation of internal combustion engines, and their thermodynamic cycles,
- Explain engine types and classifications,
- Describe engine parts, construction and their function, - Distinguish different combustion chambers, and cylinder layouts.
- Explain and calculate engine technical terms
10 2. Performance of internal combustion engines: 2.1 Performance factors, Performance factors such as: Engine torque and engine speed, Engine power; brake indicated power, brake horse-power, power per unit of displacement, and specific fuel consumption, Engine efficiency; indicated, and brake - Explain and interpret performance factors
Department: Mechanical Technology efficiencies
Major: Vehicles - Explain and interpret different parameters which influence the performance of internal combustion engines (Otto and diesel engines)
2.2 Parameters influencing performance, Different parameters which influence the performance of internal combustion engines (Otto and diesel engines) such as: Fuel types and mixture preparation, and Airfuel ratio, Intake requirements (pressure, temperature, air - density), and Charge cycle (valve timing), Compression ratio, Ignition timing, and Fuel injection point, Engine temperature, Combustion chamber shape, Engine speed (piston speed), and Engine load. 2.3 Engine performance calculations, Calculations of engine performance technical parameters as: Engine power, Mean effective pressure, Specific fuel consumption, Engine efficiency, Piston force and average piston speed, Alteration of compression ratio, Valve opening angle and valve opening time, and Volumetric efficiency. 2.4 Combustion in spark and compression ignition engines (SIE and CIE) Petrol and diesel fuels characteristics; Octane and - Cetane numbers. Simplified combustion equations. Fuel / air ratio and mixture quality. Normal combustion in petrol and diesel engines. Abnormal combustion and knock in petrol engines 2.5 Knock effects in internal combustion engines.
- Calculate different engine performance parameters as: - Engine power, - Mean effective pressure, - Specific fuel consumption, - Engine efficiency, - Volumetric efficiency
- Explain the general characteristics of SIE and CIE fuels, and define the meaning of Octane and Cetane numbers,
- Explain the technical term "knocking" and describe the origin of engine knocking in Otto and diesel engines. - Describe the negative consequences of a knocking combustion, - Analyze causes of engine knocking in Otto engines - Analyze causes of Diesel knock,
Engine knocking in Otto and diesel - engines, Negative consequences of knocking combustion, Causes of engine knocking in Otto engines which are dependent on: Compression ratio, Ignition timing, Throttle of the air mass current, Mixture formation, Engine speed, Temperature and pressure of intake air, Engine temperature, Octane number, Combustion chamber shape, Intake gas whirl, Causes of "Diesel knock" which are dependent
Department: Mechanical Technology on the following: Cetane number, Fuel injection quantity, Compression ratio, Temperature and pressure of intake air, Combustion chamber shape
Major: Vehicles
10
- Explain and interpret the recent developments of engine intake and exhaust systems,
- Compare multi-valve engines with conventional engines and state the essential differences. - Explain the influence of supercharging in Otto and diesel engines on engine power, emissions and fuel consumption,
3. Engine Mechanical Systems: 3.1 Intake- and exhaust-systems: New developments of intake and exhaust systems which minimise the fuel consumption and exhaust emissions without power loss of the engine such as: Multi-valve engines, Variable valve timings, and Resonance charging. Multi-valve engines compared with conventional engines, and the essential differences regarding: Cylinder volumetric efficiency, Charge cycle with a minimum of loss, Complete combustion. Engine supercharging, influence of supercharging in Otto and Diesel engines concerning: Engine power and torque, Emissions, Fuel consumption 3.2 Engine Timing System. Engine timing system components and function, Valve guide, valve camshaft, gear drives, push rods, rocker arms Engine timing system with variable valve timing Reasons for the dependency on engine speed and effects in the engines characteristics regarding: Engine torque and engine power, Specific fuel consumption, Exhaust emissions 3.3 Lubricating System.
- Explain engine timing system components and function - Distinguish different designs of timing systems gears.
- Explain the necessity for engine lubrication, and different lubricating systems and circuits. - Describe lubricating system components and their function.
- Name the advantage and disadvantage of engine cooling, and distinguish between water-cooling and air-cooling. - Describe different cooling circuits, components and their functions, - Explain the necessity of the thermostat.
Department: Mechanical Technology Necessity for lubricating engine components, and engine oils Different lubricating circuits, Component of a lubricating system and function,
Major: Vehicles
3.4 Cooling System. Function engine cooling, Water cooling and air cooling, Cooling circuits, components and their function, The necessity for the thermostat in the circuit
Major: Vehicles
Detailed Curriculum (Practice)

Laboratory
1. Engine performance tests. Using engine test bench, carry out different engine tests to determine engine performance parameters as: Engine torque, Engine power, Specific fuel consumption, Composition of exhaust emissions.
- Carry out different engine tests on the engine test bench to determine engine performance parameters.
10 2. Influence of different factors on engine performance. Carry out engine performance tests at different engine speeds, different engine loads, and different ignition timings, and measure: Engine speed, Rotary force, Fuel flow rate time. Calculate engine torque, engine power and the specific fuel consumption in accordance with air pressure and air humidity. Draw up in diagrams engine torque curves, engine power curves and specific fuel consumption curves with the aid of the previous calculation results. Interpret and value these characteristics. Deduce the influence of different operating conditions upon engine performance parameters, - Deduce the influence of different operating conditions upon engine performance parameters. - Explain the performance parameters of an engine, and show the influence of different factors.
Major: Vehicles

Workshop
2 1. Introduction: Engine workshop Safety regulation instructions, Engine components, systems and functions, 8 - Distinguish engine mechanical components and systems, and define their functions.
2. Engine test equipment. Engine test equipment, diagnostic equipment, measuring instruments and their special area of application, e.g.: Stethoscope (localise non typical engine noises), Endoscope type tool (detecting of engine wear in case of high engine oil consumption for example), Compression gauge tester (determination of power loss e.g. piston ring wear, valve seat wear), Vacuum gauge tester (detecting of combustion chamber pressure loss), Exhaust emission tester (drawing own conclusion of faulty mixture preparation), Fuel flow meter (sufficient fuel supply), Tachometer (determination of idle speed and ignition setting), Engine power test bench (determination of engine power factors), Application of engine test equipment on a running engine to check for faults and troubles.
- Distinguish different engine test equipment, diagnostic equipment and measuring instruments, and define their special area of application,
- Demonstrate the proper use of engine test equipment
20
- Explain the possible troubles of engine mechanical systems.
3. Engine mechanical system (cylinder crankcase, valve - Design a diagnosis and trouble actuating mechanism). shooting strategy for engine Development of a fault diagnosing strategy for engine mechanical parts, mechanical systems troubles; Using a running engine: a. Study one of the following problems in details: Loss of power, Non typical engine noises, Excessive engine oil consumption, Loss of coolant, Excessive gas exhaust emission, etc.
- Identify the possible causes related to engine trouble.
Department: Mechanical Technology b.
Major: Vehicles
Assuming that the causes are well-founded in the engine mechanical systems, relate the problem to one of the possible causes as: Cylinder head or cylinder head gasket leakage, damaged or worn components, e.g. Cylinder, piston, piston rings, piston pins, valves, valve seats, guides, and actuating mechanism, - Carry out inspection and testing of camshaft, crankshaft-, camshaft- or connecting rod engine systems and components to bearings, locate faults using different inspection Valve clearance adjustment incorrect, techniques and equipment Valve timing gear incorrect or cogged belt / chain drive loose, etc. Carry out following tasks to locate the cause of trouble: Visibility test of: Damages, leakage, and loose components, Localise causes of wear on a running Otto engine using a stethoscope, Localise causes of faults in the combustion - Carry out repair and adjustment work chamber area with the aid of: of the faulty component. Compression test, loss of pressure test, and test of - Carry out final inspection of the valve actuating mechanism especially valve clearance complete engine, adjustment, Diagnose and evaluate damages of the cylinder chambers and combustion chambers with the aid of an endoscope Measure and evaluate wear and carry out required repair work of engine components, e.g.: Piston, piston rings, bore, cylinder, connecting rod shells, crankshaft bearing shells, crankshaft bearing pins, sprocket (chain) wheels, cogged (toothed) wheels, camshafts, valves, valve guides, cylinder head, and seals, Work on required joint faces, Assemble engine components with the help of manufacturer's data especially specific data of screw torque, clearances and tolerances, Carry out test run and examines leakage and - Explain possible troubles of engine functions. cooling system. - Design a trouble shooting strategy for engine cooling system.
c.
4. Engine cooling system:
Development of a fault diagnosing strategy for engine cooling - Identify the possible causes related to system troubles; Using a running engine, the symptoms of the trouble. a. Study one of the following problems in details: Engine temperature too high, Low operating temperature, Loss of coolant, Non typical engine noises, etc. b. Assuming that these causes are well-founded in the engine cooling system, relate the problem to one of the possible causes as: Low coolant level or incorrect coolant condition,
Department: Mechanical Technology Leakage in the cooling system; radiator, hoses, water pump, and engine, Defective thermostat, or water pump, Faulty radiator cap (high pressure valve), Incorrect cooling fan system, Radiator badly soiled or clogged, Incorrect operation of cooling temperature gauge, Broken, loose or slipping fan belt, etc. c. Carry out following tasks to locate the cause of trouble: Visibility tests of cooling system components to check condition, leakage and functioning, e.g.: coolant level, and condition, water pump circulation, water pump drive bearing, opening temperature of thermostat, radiator and radiator-cap conditions, hoses, fan drive clutch, electrical fan, and thermo-switch working temperature, warning system (temperature gauge), air guiding fins, Localise leakage in the cooling liquid system with the aid of a pressure test in: Radiator, hoses, Water pump, and Cylinder head, Erase faults in the cooling liquid system, Test water system for leakage and functioning in different operational modes, Determine mixture ratio of corrosion inhibitors, corrects and fills the cooling system if necessary, Carry out final check.
Major: Vehicles
- Carry out inspection and testing of engine cooling system to locate faults using different inspection techniques and equipment - Carry out repair and adjustment work of the faulty component of the system. - Carry out final inspection of the system.
- Explain possible troubles of engine lubricating system. - Design a diagnosis and trouble shooting strategy for engine lubricating system.
5. Engine lubrication system. Development of a fault diagnosing strategy for engine lubrication system troubles; Using a running engine, a. Study one of the following problems in details: non typical engine noises, engine oil pressure too high, or too low, engine oil pressure warning light on, excessive smoke in exhaust gas emission, etc. b. Assuming that these causes are well-founded in the engine lubrication system, relate the problem to one or more of the possible causes as: oil level or oil condition incorrect, oil filter soiled or clogged, oil pump does not generate necessary oil pressure, leakage in lubrication circuit, oil pressure warning light defect or defective electrical connection, - Identify the possible causes related to the symptoms of the trouble.
- Carry out inspection and testing of engine lubricating system to locate faults using different inspection techniques and equipment
Department: Mechanical Technology faulty operating of pressure regulating , nonreturn or overflow valve, damaged oil pan, etc. c. Carry out following tasks to locate the cause of trouble: Carry out visibility and pressure tests of engine oil lubrication circuit if necessary: measure oil level, and analyse its condition, testing of full-flow filter, testing of regulating valves, testing of oil pan for possible damage, testing of oil pressure sender unit and oil pressure gauge, Measure and evaluate wear of removed and dismantled components in lubrication system: oil pumps, regulating valves, bearings and seals, Erase faults in the engine lubrication- and lubrication controlled system: Replacement of oil pumps, cleaning or replacement of regulator valves, cleaning or replacement of induction filters, cleaning of oil galleries and injector tubes, sealing of bearings, replacement of controlling sender- and / or controlling gauge units, Test oil pressure by measurement in different operational modes, Determine type and quality of lubricating oil necessary for usage and fills up level as required, Carry out final inspection.
Major: Vehicles
- Carry out repair and adjustment work of the faulty component of the system.
- Carry out final inspection of the system
Major: Vehicles
Department Mechanical Technology Course Title Automotive Brakes Prerequisite
Major Code
Vehicles MEV 222

1 2 3 3 2 3 30 45 4 5 6
Semester Course Description : Principles of automotive brake systems, different types (hydraulic, anti-lock (ABS), and air brake systems), main components (drum brakes, disc brakes, tandem master cylinder, power assisted brakes, brake power controller, etc), and their functions. Brake system performance calculations (brake pressure, stopping distance, stopping time, .etc). Fault diagnosis, repairs, adjustment, and maintenance of brake systems. Credit hr/w L Contact hr/w W T L Contact hr/sem. W T
General Goal : This course provides the students with the knowledge about automotive brake systems. It also, gives the practical experience and skills necessary to diagnose system faults and troubles, and to carry out maintenance, adjustment, and repair work. Behavioral Objectives : By the end of this course, the student will be able to: Describe automotive brake systems construction, components, and functions. Differentiate and compare between the different types of brake systems. Explain the function and the operation of ABS brake systems. Calculate brake system performance parameters. Carry out fault diagnosing and locate system troubles, using various equipment, techniques, and manufacturer manuals and data. Dismantle and assemble system components in a proper manner. Carry out repairs, adjustment, and maintenance work for brake system components.
Topics: Theory: Hydraulic Brake Systems Anti-Lock Brake Systems (ABS) Introduction to Air Brake Systems Practice: Laboratory: Hydraulic Brake Systems Anti-Lock Brake Systems Air Brake Systems Workshop: Fault diagnosis, maintenance, repair, and adjustment of : Hydraulic Brake Systems Anti-Lock Brake Systems
Major: Vehicles
Jack Enjavec and Robert Scharff, Automotive Technology", 2nd Edition 1996, Delmar Publishers, An international Thomson Publishing Company, ISBN . Textbook: Stockel, Stockel, and Johanson, "Auto Service & Repair", 1996, The GoodheartWillcox Company, Inc., Tinley Park, Illinois, ISBN, 1-56637-144-9
Additional Reading:
William K. Toboldt, Larry Johnson, and W. Scott Gauthier, Automotive Encyclopedia", The Goodheart-Willcox Company, Inc., Tinley Park, Illinois, ISBN 1-56637-150-3, 1995
Stockel, M.W, Stockel, M. T., and Johanson, C., "Auto Fundamentals", 1996, The Goodheart-Willcox Company, Inc., Tinley Park, Illinois, ISBN1-56637-138-4 Crouse-Anglin, "Auto Fundamentals", 10th Edition, The McGraw-Hill Book 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 References: Martin W. Stockel and Martin, Auto Mechanics Fundamentals, The Goodheart-Willcox Company, Inc., Tinley Park, Illinois, ISBN 156637-138-4, 1996 Crouse, William H. and Donald L. Anglin, Automotive Technicians Handbook, The McGraw-Hill Book Company, ISBN 0-070-14751-5 Robert Scharff, Complete Brake Systems", Delmar Publisher, Inc., ISBN 08273-3539-3 Robert Bosch Cooperation, "Bosch Technical Instruction Series", - Compressed air brake Systems, Symbols- Compressed air brake Systems, Equipment- Compressed air brake Systems, Schematic Diagrams
Major: Vehicles

Hrs Contents Behavioral Objectives The student should be able to: 4 1. Basics of Automotive Brakes: Hydraulic basics: - Hydrostatic pressure and force transmission, - Brake fluids - Hydraulic principles in vehicle brake systems Friction and motion resistance Forces acting on vehicle body and axles during braking action, and braking efficiency. Brake pressures and brake forces for drum and disc brakes. Brake action stopping distance and time. 14 - Describe hydrostatic pressure, Pascal law, force transmission and force multiplication. - Explain braking action and friction. - Calculate forces acting on vehicle during braking action, stopping distance and time.
2. Hydraulic Brake Systems: Hydraulic brake system components : - Master cylinder, construction and operation - Wheel cylinder, construction and operation - Safety switches and valves - Brake lines, hoses, and fittings Brake friction members : - Coefficient of friction - Friction linings - Brake fade Drum brakes : - Drum brake operation, components, and designs - Brake shoes and linings - Drum parking brakes - Integral parking brakes Disc brakes : - Disc brake components and their functions - Rear disc/drum (auxiliary drum) parking brake - Rear disc parking brake Power brake systems : - Vacuum-assisted power booster: - Booster operation, types, and failure Calculation of brake pressures and brake forces for drum and disc brakes 3. Anti-Lock Brake Systems (ABS): Pressure modulation. Pedal feel. Types and designs of anti-lock brake systems. Construction and function of the most common system. Integrated and nonintegrated anti-lock brake systems. Automatic stability (traction) control. Vehicle dynamics control. Lateral dynamics of a vehicle. - Describe the construction, components, types, and functions of the hydraulic brake systems. - Explain the essential differences between hydraulic brake systems with drum and disc brakes. - Explain principles of the power brake systems and their types. - Calculate the brake pressures, and forces of drum and disc brakes.
- Describe the construction, components, and functions of the most common anti-lock brake systems
Major: Vehicles
4 4. Introduction to Air Brake Systems : Principles of air brake systems. Symbols of compressed air brake systems. Circuit diagrams for compressed air brake systems. Components for compressed-air brake systems - Describe the symbols, components, and schematic diagrams of the compressed-air brake systems
Major: Vehicles

Laboratory
The student will be able to ...
1. Hydraulic Brake Systems: Using the hydraulic brake system test panels the following experiments are to be carried out: - Installation of a hydraulic brake system in working order - Measurements of brake forces by different friction resistance - Measurements of brake pedal forces, brake line pressures, and wheel brake forces - Testing of brake performance of drum brakes especially of primary and secondary brake shoes during forward or backward motion - Investigation of brake drum or brake disc behavior when continuous braking (fading) - Checking of brake fluid behavior when heated - Install and operate hydraulic brake systems. - Measure the brake forces and pressures. - Measure brake performance of drum brakes. - Explain the behavior of disc or drum brakes when fading. - Explain the effect of heat on the fluid brake behavior.
4 2- Anti-Lock Brake Systems (ABS): Using the ABS brake system test panel the following experiments are to be carried out: - Demonstration of the principles of operation of ABS hydraulic brake system. - Sensors and pressure modulator testing. - Demonstration of an emergency stop with ABS - Faults simulation and investigation of the consequences Compare the performance of brake systems with and without ABS Simulate the anti-lock brake system faults
3- Air Brake Systems : Using the air brake system test panels the following experiments are to be carried out - Installation of different air brake systems with the aid of a circuit diagrams for a tractor and trailer - Investigation of functioning of single components as well as complete system and measuring of the corresponding pressure - Fault simulation in the system and evaluation consequences
Install a complete air brake system for a tractor and trailer - Explain the function of the components of air brake systems Measure the corresponding pressure in an air brake system Simulate the air brake system faults
Major: Vehicles
Major: Vehicles

Workshop
2 1- Introduction - Safety precautions and regulations - Automotive brake system components and functions - Use of the manufacturer's service manual
The student will be able to ... - Identify system components and functions - Use the manufacturers service manuals, and special tools
16
2- Fault Diagnosis and repair of Hydraulic Brake Systems: a- Describe the following problems in detail : - poor brake performance when driving and stopping (emergency brake) - brakes pull to one side when braking - braking pedal respectively vehicle vibrates when braking - brakes blocked - excessive brake noises (e.g. squeaking) - poor pedal effort - .etc b- Relate these problems to one of the following causes assuming that these causes are well-founded in the hydraulic brake system : condition and level of brake fluid improper - leakage, wear or damages of : power brake unit (booster), brake pipes, and hoses, brake pressure regulator, brake cylinders, brake calipers, brake lining, brake drums, brake pads, and, brake discs. - incorrect adjustment of : brake shoes of drum brakes, emergency brake, brake pedal clearance, ..etc c- Carrying out the following tasks : - checking of hydraulic brake system as well as emergency break with the aid of a break test bench for functioning and comparison of measured values with manufacturers vehicle data and demanded data - Carrying out visibility checks regarding leakage, damages, condition, wear, and functioning of brake system components - Measuring and comparison of wear (tolerances) with the aid of manufacturers data considering :
- Diagnose faults, troubles, and malfunctions of the hydraulic brake systems - Dismantle and assemble the components of hydraulic brake systems in a proper manner. - Carry out repair, adjustment, and maintenance work for the hydraulic brake systems - Perform final checks after repairing
Department: Mechanical Technology Brake drums, Brake discs, Brake lining, and Brake pads Making out a resultant diagnosis which includes all checks and determining the required repair work such as : Master cylinder overhaul, Brake cylinder overhaul, Brake caliper overhaul, Replacement of brake lining, Changing of brake fluid, and Turning or grinding of brake drums and discs Final checks
Major: Vehicles
12
3- Fault Diagnosis and repair of Anti-Lock Brake Systems (ABS) a- Looking at the following problems in detail, when ABSwarning light is: - Off when switching on ignition switch - On or temporarily on when the car is in driving mode b- Relate the behavior of ABS-warning light to the following causes of anti-lock brake system : - Warning light defective - Poor power supply of electrical loads - Plug-and-socket connection faulty - Switch defective - Hydraulic pump motor not operational - Motor-or solenoid valve relay not functional - Electrical control unit defective - Hydraulic unit defective or incorrectly connected - Hydraulic system leakage - Wheel speed-or acceleration sensor defective or incorrectly or faulty connection - Incorrect gap clearance between speed sensor and impulse device (toothed wheel) - Impulse device defective or loose, - ..etc c- Carrying out the following tasks : - Check the functions of ABS-devices with the aid of a test plan when vehicle stops - Determining actual values and comparison these with manufacturers data (specified values) - Making out a resultant diagnosis and determining the required repair work - Carrying out repair work with the help of manufacturers data such as e.g. replacement of : Electrical control unit, Hydraulic unit, and Speed sensor - Final checks
- Use the manufacturers established strategy, workshop service manuals, and special tools - Diagnose faults, troubles, and malfunctions of the ABS brake systems - Dismantle and assemble the components of ABS brake systems in a proper manner. - Carry out repair, adjustment, and maintenance work for the ABS brake systems - Perform final checks after repairing
Major: Vehicles
Major: Vehicles
Department Mechanical Technology Course Title Automotive Transmission and Power Trains Prerequisite
Major
Vehicles Code MEV 223

1 2 3 3 2 2 30 30 4 5 6
Semester Course Description : The principles of transmission and power train systems, types, components and functions. Construction and operation of clutch, gear box, driving shaft and joints, final drive with differentials, and power-wheel drive. Power transmission calculations, acting forces, transmitted torque, and speed ratios. Fault diagnosis, repair, adjustment, and maintenance operations of power transmission systems. Credit hr/w L Contact hr/w W T L Contact hr/sem. W T
General Goal : This course provides students with the full knowledge about transmission and power train systems. It also, provides them with the practical experience and skills required to diagnose faults and malfunctions, adjust, repair and maintain these systems. Behavioral Objectives : By the end of this course, the student will be able to: Describe the transmission and power train systems, aggregates, components, and functions. Differentiate and compare between the different transmission and power train systems. Calculate some important transmission and power train parameters such as, acting forces, transmitted torque, speed ratios, and transmission efficiency. Carry out fault diagnosis for the transmission and power train systems using different equipment and techniques. Decide whether to repair or replace any of the aggregates or components of the transmission and power train systems. Carry out repairs, adjustment, and maintenance work for transmission and power train system aggregates and components.
Department: Mechanical Technology Topics: Theory: Elements and Characteristics of Automotive Transmissions and Power Trains. Engine Clutches Manual Transmissions and Trans-axles Automatic Transmissions and Trans-axles Four-Wheel Drive Axles and Drive-Lines
Major: Vehicles
Practice: Workshop: Fault diagnosis, service, repair and adjustment of : Clutch and Flywheel Manual Transmission and Trans-axle Automatic Transmission and Trans-axle Axles and Drive-Lines
Textbook:
Stockel, M.W., Stockel, M.T, and Johanson C., Auto Fundamentals, GoodheartWillcox 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
Additional Reading:
Technical and repair manuals Automotive magazines and periodicals
References:
William K. Toboldt, Larry Johnson, and W. Scott Gauthier, Automotive Encyclopedia, The Goodheart-Willcox Company, Inc., 1995 ISBN 1-56637-1503. Enjavec, Jack and Scharff, Robert, Automotive Technology, 2nd Edition Delmar Publishers, An international Thomson Publishing Company, 1996, ISBN . William Crouse, All Automobile (12 parts), Mars Publishing House, ISBN William H. Crouse and Donald L. Anglin, Automotive Technicians 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 McGrawHill Book Company, 10th Edition, ISBN 0-02-800943-6 Stokel, Martin W., Stokel, Martin T., and Johanson, Chris, Auto Fundamentals The GoodheartWillcox company, INC, ISBN 1-56637-138-4 , 1996 William, K. Toboldt, Larry Johnson, and W. Scott Gavthier, Automotive Encyclopaedia Fundamental, Principles, Operation, Construction, Service, and Repair, The Goodheart -Willcox company, INC , ISBN 1-56637-150-3 , 1995 Duffy, James E., Auto Engines The GoodheartWillcox company, INC, ISBN 0-87006-677-3 Jack Enjavec and Robert Scharff Automotive Technology Delmar Publishers, An International Thomson Publishing Company.
Major: Vehicles

The student should be able to: 1. Elements and Characteristics of Automotive Transmissions and power trains: Constructions, and functions of transmissions and - Describe the possibilities of the power trains: power transmissions and the rear-wheel drive, location of aggregates, front-wheel drive, components, and functions. and four-wheel drive - Explain the characteristics of Power transmission characteristics: power transmission. Gear ratio, Speed changing, and Torque characteristics - Describe the components of the engine clutch and their 2. Engine Clutches : functions. Clutch purpose and construction : - Calculate the clutch surface Flywheel pressure and the transfer Clutch disc torque. Pressure plate assembly Clutch release lever operating mechanism Clutch housing and input shaft (clutch shaft) Clutch pedal linkage : Mechanical linkage Hydraulic linkage Self-adjusting clutch Clutch calculations : Surface pressure on lining Transfer clutch torque - Describe the components of the manual transmissions and 3. Manual Transmissions and Trans-axles: trans-axles and their functions. Torque multiplication - Calculate the driving speed Torque multiplication through gears - Explain the traction Transmission construction characteristics and curves. Synchronizing mechanism Transmission operation Four-speed, five-speed and over-drive transmissions Calculation of driving speed in the single gears with the help of real transmission gear ratios, speeds and torque Traction characteristics and curves - Describe components of the automatic transmissions and trans-axles and their functions 4. Automatic Transmissions and Trans-axles: (torque converter, planetary Automatic transmission and trans-axle components gear-sets, holding members, Torque converter : hydraulic control system, and Construction of a torque converter ECU. Stator Torque converter operation Torque multiplication curve Lockup torque converter Planetary gear-sets : Torque increase Planetary gear-sets in automatic
Department: Mechanical Technology transmissions Holding members : bands multiple disc clutch overrunning clutches Hydraulic control system : Fluid pump Control valve Simple hydraulic system Transmission and trans-axle shifting Complete control circuit Transmission case Electronic control unit (ECU) 5. Four-Wheel Drive : Purpose of the four-wheel drive Four-wheel drive components and design Transfer case : Operation of full-time and part-time transfer cases Selection control and lubrication of transfer case Locking Hubs 6. Axles and Drives : Rear-wheel drive shafts : Drive shafts Universal joint Slip yoke How the wheels drive the vehicle Hotch-kiss drive Universal joint can cause fluctuating shaft speed Rear-wheel drive axle components and assemblies : Axle housing Solid axles Independent axles Types of axles Differential construction Ring and pinion Differential operation Differential carrier and bearings Limited-slip differential Ring and pinion adjustments Gear ratio Axle lubrication Trans-axle differential assembly Four-wheel drive front drive axle : Front axle steering provision
Major: Vehicles
- Describe the purpose of use, components, and - Designs of the four-wheel drive, transfer cases, and locking hubs.
- Describe the types, components, assemblies, and the functions of the different axles and drive-lines.
Major: Vehicles

Workshop
1- Introduction: - Workshop safety regulations - Automotive transmissions and power trains, types, components, and functions. - Manufacturers service manual.
The student will be able to: - Identify the components of the system and functions - Use of manufacturer's service manual. - Explain the use of special tools.
2- Fault diagnosis and repair of Clutch and Flywheel: a- Study the following troubles in detail: - Clutch slips while engaged - Clutch chatters or grabs when engaging - Clutch spins or drags when disengaged - Clutch is noisy when engaged or disengaged - Clutch pedal pulsates - Friction-disk facings wear rapidly - Clutch pedal is stiff, etc b- Relate these troubles to one or more of the following causes : - Wrong clutch installed - Pedal free play adjustment - Warped or distorted disc - Mechanical linkage components damaged or hydraulic system has a leakage - Clutch disc surface worn, overheated or greasy - Weak or broken diaphragm in clutch cover - Smooth running and damages of throw-out bearing, etc c- Carry out the following tasks (remove, check, replace, and install) - Clutch removal - Mark the pressure plate and flywheel - Remove the pressure plate - Sand clutch friction surface - Flywheel-to-clutch friction surface - Checking flywheel run-out - Flywheel mounting - Flywheel ring gear removal and installation - Pressure plate assembly and its rebuilding - Replace the clutch pilot bushing or bearing - Checking clutch housing face and bore run-out - Installation the clutch disc and pressure plate assembly - Final checks
- Use the manufacturers established strategy, workshop service manuals, and special tools - Diagnose faults, troubles, and malfunctions of the clutches and flywheels - Dismantle and assemble the components of different types of clutches - Carry out repair, adjustment, and maintenance work for clutch components and parts - Decide whether to repair or replace components or parts of the clutch - Perform final checks after repairing
Major: Vehicles
3- Fault diagnosis and repair of Manual Transmission and Transaxle: a- Study the following troubles in detail: - Transmission slips out, will not shift, or is difficult to shift in one gear - Gears clash in shifting - Transmission sticks in gear - Transmission is noisy in neutral or in gear - Poor tractive power of the vehicle - Oil leaks . Etc. b- Relate these troubles to one or more of the following causes: - Improper transmission oil quantity and/or condition - Misalignment of shift linkages - Worn or damaged parts of shifting mechanism, synchronization system, bearings and seats, gear wheels and shafts, and shaft and housing seals .etc. c- Carry out the following tasks : - Test transmission oil level and condition - Evaluate damages and measure wear of seats, gear wheels and shafts, shifting shafts and forks, and shaft and housing seals - Check clutch and shift linkage - Road test when possible - Transmission and trans-axle removal - Clean exterior and flush interior - Inspect : input shaft, output shaft and gears, countershaft and gears, synchronizers, reverse idle gear, extension housing, trans-axle chain and sprockets or gears, and trans-axle differential unit - Check case and other housings for cracks and burrs - Use new snap rings, thrust washers, and gaskets - General internal part installation procedures and lubrication - Installation shift cover - Adjust shift linkage - Final checks
- Use the manufacturers established strategy, workshop service manuals, and special tools - Diagnose faults, troubles, and malfunctions of the manual transmissions - Dismantle and assemble the components of different types of manual transmissions. - Carry out adjustment, repair, and maintenance work for manual transmission components. - Perform final checks after repairing
- Use the manufacturers established strategy, workshop service manuals, and special tools - Diagnose faults, troubles, and malfunctions of automatic transmissions - Dismantle and assemble the components of at least one type of automatic transmissions - Carry out repair, adjustment, and maintenance work for
4- Fault diagnosis and repair of Automatic Transmission and Trans-axle: a- Study the following troubles in detail: - Vehicles jerks in starting behavior - Slippage of power transmission while shifting - Harsh shifts - Incorrect shifting points - Poor acceleration while passing
Major: Vehicles automatic transmissions components and parts - Perform final checks after repairing
No downshift occurs when pushing accelerator pedal
b- Relate these troubles to one or more of the following causes: - Improper transmission oil quantity and/or condition - Leakage in hydraulic oil circuit - Worn bands or clutches - Incorrect adjustment of gear shift lever position - Shift valves jam or shift springs broken - Governor jams - Throttle valve jams - Kick-down switch jams or damaged - Bowden cable of kick-down switch defected or incorrectly adjusted - Electronic control unit (ECU) is defected etc. c- Carry out the following tasks : - Check functions of automatic transmission while in driving operation : shift points in all driving ranges, shifting gears difficult or smooth, kick-down, starting behavior, pressure pipes, function of ECU, and functions of gearshift selector. - Test: the lock-up speed of torque converter, pressure of hydraulic oil pump, and the main line oil pressure - Adjust bands - Drain old oil - Clean screens and filters - Transmission fluid and filter change cycle - Band adjustments - Manual shift linkage adjustment - Throttle linkage (TV) adjustment - Leak detection - Transmission or trans-axel removal - Torque converter cleaning - Transmission installation - Installation shift cover - Final checks 5- Fault diagnoses and repair of Drive-Lines and Axles: a- Study the following troubles in detail: - Harsh klick when starting or while shifting - Vehicle vibrations, vehicle driving noises - Humming - Noise on acceleration, on curves, and tires show unevenly worn tread when cornering - Tractive problems when road surface slipping . Etc. b- relate these troubles to one or more of the following causes: - Improper installation of drive shaft - Drive shaft out of balance - Worn or damaged universal joints or bearings - Loose drive shaft mountings
- Use the manufacturers established strategy, workshop service manuals, and special tools - Diagnose faults, troubles, and malfunctions of the axles and drive-lines - Dismantle and assemble the components of at least one type of differentials, driving axles, driving shaft joints, transfer cases and hubs, and vacuum motor - Carry out repair, adjustment, and maintenance work for axle and drive-line components and parts - Perform final checks after
Major: Vehicles repairing
Improper differential oil quantity and condition
Incorrect adjustment in differential between drive pinion gear and ring gear - Worn or damaged of differential components : bearings, teeth of drive pinion or ring gear, teeth of side gears, seals, .etc c- Carry out the following tasks : - Visibility checks for universal joint and bearing defects, smooth running, leakage of differential oil, differential oil level, and metal abrasion in differential oil - Localize faults of driving joints while driving and of dismantled differentials - Repairing cross-and-roller universal joints - Drive shaft installation - Check drive shaft balance and angle - Flanged end side axle removal - C-lock axle removal - Axle shaft inspection - Axle oil seal replacement - Rear wheel bearing replacement - Check axle end play - Ring and pinion, differential removal - Limited slip differential service - Drive axle lubrication - Service and overhaul transfer case - Service locking hubs and vacuum motor - Final checks
Major: Vehicles
Department Mechanical Technology Course Title Automotive Suspension and Steering Systems Prerequisite
Major Code
Semester
Vehicles MEV 224

1 2 3 3 2 2 30 30 4 5 6
Course Description : Various types of vehicles frames and bodies, wheels and tyres, The principles of operation of suspension systems. Different types of springs and shock absorbers. Air and hydraulic suspension systems. Steering systems, wheel alignment, manual and power steering systems. Fault diagnosis, adjustment, maintenance and repair of suspension and steering systems
Credit hr/w L Contact hr/w W T L Contact hr/sem. W T
General Goal : The course provides the knowledge about different vehicles frames, wheels, tyres, suspension and steering systems. It develops the practical experience and skills required to carry out tests, adjustment and necessary repair work for these systems. Behavioral Objectives : By the end of this course, the student will be able to: Describe different types of vehicles frames and bodies, wheels and tyres Describe the vibrations modes of vehicles body, and identify the needs for using a suspension system Identify various types of suspension systems, explain various constructions and functions Explain principles of operation of various types of springs and shock absorbers. Describe the wheel alignment geometry. Explain the various types of manual and power steering systems. Explain the vehicle handling characteristics Carry out fault diagnosis, repair and adjustment work with suitable test equipment of different suspension and steering systems
Major: Vehicles
Topics: Theory: The frames and vehicle bodies Wheels and Tyres Suspension systems Steering systems Practice (Workshop): Safety procedure, identification of the system components Fault diagnosis, repair and adjustment of : - Wheels and Tyres - Suspension systems - Steering systems
Thomas W. Birch Automotive Suspension & Steering Systems, Harcourt Brace Jovanovich College Publishing, 1993, ISBN 0-03-09682-4, 1993 Textbook: Martin W. Stokel, Martin T. Stokel Chris Johanson Auto Fundamentals The GoodheartWillcox company, INC ISBN 1-56637-138-4 , 1996
Additional Reading:
References:
Robert Scharff Complete under-car 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 1-56637-138-4 , 1996 Stoekel, 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 technicians 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 systemsFault Diagnosis ARNOLD , ISBN 0-340-70630-9, 1998 Jack Enjavec and Robert Scharff 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
Major: Vehicles

The student should be able to: 4 1- Vehicles frames and bodies: General description of frames Types of frames X- type frames Ladder frames Perimeter frames Stub frames Unitized body Body material (Steel sheet, Aluminum and Plastics) Effect of vehicle body shapes on aerodynamic resistance - Describe different types of vehicle frames and bodies. - Explain the effect of vehicle body shapes on aerodynamic resistance
2- Wheels and Tyres: Introduction Wheel Construction Wheel nave Wheel disc (wheel body) Wheel rim Wheel rim sizes Tyre construction Tyre leads Cord body (bias- ply tyre, bias belted tyre, and radial tyre) Tyre treads Tyre sizes Tyre characteristics (load, pressure, speed, and life span) - Describe various types and constructions of wheels and tyres.
12 3- Suspension systems: Types of movements and vibrations affecting vehicle Vibration of suspended body Suspension types and characteristics a. Front suspension systems Solid axle Independent front suspension Double wishbone McPherson struts Swing axle b. Rear suspension systems Solid axle Independent rear suspension Air suspension Hydraulic suspension Hydro-pneumatic suspension
- Describe various modes of vehicles vibrations and identify the need for using a suspension system.
- Explain the construction of various suspension systems including different types of
Department: Mechanical Technology Vehicle suspension elements Leaf springs Coil springs Torsion bars Rubber springs Shock absorbers operating principles Single tube shock absorbers Double tube shock absorbers Calculations of stiffness and damping coefficients. Introduction to the electronic suspension
Major: Vehicles springs and chock absorbers.
10
4- Steering systems Wheel alignment geometry Camber, Toe - in and Toe out Caster and King pin inclination Steering geometry mechanism Manual steering systems Rack and pinion steering gear. Worm and nut steering gear. Recirculating ball steering gear. Worm and sector steering gear. Power steering systems. Power steering components. Principles of operations. Vehicle handling characteristics Neutral steer, under-steer and over-steer Calculations of steering gear ratio, turn radius and lateral forces affecting vehicle while turning.
- Explain wheel alignment geometry. - Explain the principles of operations of various types of manual and power steering systems. - Determine the important aspects affecting the vehicle handling characteristics.
Major: Vehicles

Workshop
1. Introduction: 2
The student should be able to: - Identify the components of suspension and steering system
Safety Procedures Suspension and steering system components
2. Fault diagnosis, adjustment and repair of Wheels ( tyres and Rims) a- Study one the following problems in detail: - Vehicle pulls / drifts to one side of the road, - Unstable vehicle, - Vehicle swims, - Steering wobbles, - Vehicle vibrates, - Etc. b- Assuming that these causes are well-founded in the wheel system of the vehicle, relate the problem to one or more of the following causes: - Loose wheel nuts, - Unbalanced wheels, - Rim or tyre damaged, - Incorrect tyre mounting: direction of rotation incorrect, vehicle overload or unevenly loaded maximum permissible speed exceeded, - Different type tyre in the car, - Incorrect tyre pressure, - Excessive tyre tread wear, - Tyres too old ..etc. c- Carries out following tasks: - Make a decision regarding necessary tests and the sequences. - Test vehicle tyres and rims considering: permissible size and construction, correct mounting, tyre pressure, tyre condition, and wear damage, permissible speed limit, and load range, radial, lateral tyre run-out, Unbalance tyre. - Carry out required repair work such as: tyres and rims mounting, repair of tyres and tubes if necessary, wheels balancing (directly on the vehicle and electronically).
- Carry out fault diagnosis regarding all mechanical parts of wheels and tyres - Carry out adjustment and repair work using suitable test equipment including final inspection for wheels and tyres
Major: Vehicles
12
3. Fault diagnosis, adjustment and repair of the Suspension System. a- Study the following problems in detail: - Unstable vehicle, - Vehicle pulls to one side of the road, - Uneven tyre tread wear, - Heavy tyre noises when driving straight or cornering, - Vehicle vibrations, - Non typical noises when driving on bumpy road, ..etc. b- Assuming that the causes are well-founded in the suspension system of the vehicle, relate the problem to one or more of the following causes: - Axle mounting or wheel suspension loose, - Suspension arms or stabilizer bent, - Worn suspension arms or stabilizer bearings, - Broken spring, - Shock absorber leakage, - Loose spring or shock absorber mountings , - Worn rubber suspension and / or stops, - Etc. c- Carries out following tasks: - Develop a trouble shooting strategy, - Carry out visibility checks for the condition, wear, functioning, mounting, and positioning of suspensions system springs, dampers, stabilizers, of axles and wheel suspensions - Carry out instrumental testing for functioning of suspension system components. - Carry out with the help of manufacturers instructions the required repair, adjustment, maintenance or replacement of e.g:. suspension arms, dampers, stabilizers, suspension struts, radios arms, bushes, bearings. Carry out final checks. 4. Fault diagnosis, adjustment and repair of the steering system: a- Study the following problems in detail: - Unstable vehicle, - Vehicle vibrations, - Steering wobbles,
- Diagnosis regarding all mechanical parts of suspension systems. - Carry out repair and adjustment work with suitable test equipment including final inspection for suspension systems.
10
- Carry out fault diagnosis regarding all mechanical parts of steering systems.
Department: Mechanical Technology - Non typical noises in the steering system, - Heavy steering, - Steering jams, - Wheel angle different when cornering, - Self-aligning forces too low, - Excessive tread wear, ..etc. - Relate these problems to one or more of the following causes, assuming that the causes are well-founded in the steering system or in the wheel alignment (steering geometry): - Damaged or worn steering components: Steering gearbox, Steering shaft, Steering box lever, Tie rods, Idler arm, Rubber articulation (joint), Steering knuckle or ball-and-socket joint, High pressure oil pump or hydraulic control unit of power steering, - Leakage or improper oil in steering box respectively in hydraulic system or power steering, - Incorrect adjustment of steering gear box respectively steering system: longitudinal clearance of steering pinion or shaft, flank clearance between steering shaft and sector gear respectively ball unit, steering angle (wheel angle), - Incorrect adjustment of the front wheels or maladjustment of steering geometry: toe, camber, steering axis inclination, caster, difference in wheel angles while turning, etc c- Carries out following tasks: - Develop a trouble shooting strategy in steering systems and geometry. 1. Steering system - Carry out visibility checks for condition, functioning, mounting, positioning, and clearance of steering wheel, steering shaft, (outer tube or universal joint), steering gear box, steering linkage and joints. - Carries out with the aid of manufacturers manuals and data the following: pressure test, checking for leakage, checking for function, - Erases faults with aid of manufacturers instructions by adjustment, repair or replacement of components, e.g:.
Major: Vehicles - Carry out repair and adjustment work with suitable test equipment including final inspection for steering systems
Department: Mechanical Technology steering wheel, steering shaft, steering gear box, hydraulic pump, steering linkage, idler arm, steering joint, replacement of transmission or hydraulic oil with the help of manufactures instruction. 2. Steering geometry - Measures with the aid of suitable test equipment front wheel alignment (steering geometry): toe, camber, steering axis inclination, caster, difference in wheel angles while turning, - Makes a decision with the aid of test report whether required wheel alignment should be adjusted or repaired, - Carries out corresponding adjustment respectively repair work, - Carries out final checks.
Major: Vehicles
Major: Vehicles
Department Mechanical Technology Course Title Ignition Systems Prerequisite Physics II
Major Code
Vehicles MEV 225

1 2 3 4 4 2 4 30 60 5 6
Semester Course Description : The principles of coil ignition systems, spark generation and energy storage. Functions and components of conventional ignition system, transistorized ignition systems, capacitor discharge ignition system and fully electronic ignition system. Fault diagnosis, repairs and adjustment on these systems. Credit hr/w L Contact hr/w W T L Contact hr/sem. W T
General Goal : The curse gives knowledge about coil ignition system, spark generation and energy storage, functions and components of different ignition systems. It also gives the practical experience and skills required to diagnose faults, and carry out repairs, adjustments with modern test equipment in these systems Behavioral Objectives : By the end of this course, the student will be able to: Explain spark generation and energy storage in a coil ignition system Explain the components and function of conventional, transistorized, capacitor discharge and fully electronic ignition system. Assemble and run different kinds of ignition system circuits, demonstrate their functions and carry out measurements in the laboratory Carry out fault diagnosis, repair and adjustments on various ignitions systems with the aid of modern test equipment
Topics: Theory: Introduction to the ignition principles Conventional Ignition Systems Transistorized coil ignition systems Electronic ignition systems Capacitor discharge ignition system Practice: Laboratory: Assemble and run various ignition systems to discover simulated faults. Carry out performance tests. Workshop: Fault diagnosis, testing procedures, repair and adjustments of: Transistorized coil ignition systems Electronic ignitions systems
Major: Vehicles
Textbook:
James E. Duffy, Auto Electricity, Electronics, Computers, The GoodheartWillcox Company Inc., ISBN Harcourt Brace Jovanivich, Automotive computer control systems; Fundamentals and services, Publishers, ISBN 0-15-504355-2 Stockel, and Johanson, Auto Service and Repair, The Goodheart-Wilcox Company Inc., ISBN 1-56637-144-9 German Advisory Team and GOTEVT publications: - Fault Detection with Oscilloscope - Testing a Conventional Coil Ignition (CI) - Testing a Transistorized Ignition (TI-I) - Testing a Transistorized Ignition (TI-H) - Testing a Transistorized Coil Ignition (TCI-I) - Testing a Transistorized Coil Ignition (TCI-H - Testing a Semiconductor Ignition (SI) - Analysis with Motor-testers
Additional Reading:
Derato, Frank C., Automotive Ignition Systems, Gregg Division, McGraw- Hill Book Company, ISBN 0-07-016501-7 William Toboldt, Larry Johnson and W. Scott Gauthier, Automotive Encyclopedia, 1995, The Goodheart-Wilcox Company Inc., ISBN Harcourt Brace Jovanivich, Publishers, Automotive computer control systems Fundamentals and services, ISBN 0-15-504355-2 Stockel, and Johanson, Auto Service and Repair, The Goodheart-Willcox Company, ISBN 1-56637-144-9 Robert Bosch Coop, Automotive Handbook, 6th edition, ISBN 0-89 283-518-6 Harper and Row, Automotive Electrical Systems, Classroom Manual, CheckChart Automotive Series References: Harper and Row, Automotive Electrical Systems, Shop Manual, Check-Chart Automotive Series Martin W. Stockel and Martin T. Stockel, Auto Mechanic Fundamentals, The Goodheart-Wilcox Company Inc., ISBN Robert Bosch GmbH, Bosch Technical Instruction Series, 1. Engine Electronics 2. Spark Plugs 3. Battery Ignition System Robert Bosch GmbH, Automotive electric/electronic systems, ISBN 1-56091596-X Robert Bosch GmbH, Fault detection with the Oscilloscope, ISBN 1-698-980086 Allan, W. M. Bonnick, Vehicle Electronic Systems Fault diagnosis, ARNOLD, ISBN 0-340-70630-9, 1998
Major: Vehicles

Hrs Contents Behavioral Objectives The student should be able to: 6 1. Introduction to ignition principles Operational function of ignition system The operation principles of coil ignition Basic components and circuit diagram. Primary and secondary circuits Energy storage mechanism Production of high voltage Energy distribution Influence of ignition timing on: Engine power Fuel consumption Engine knock Exhaust emission performance Development of primary current. Factors affecting spark energy and voltage Sparking rate, spark time, dwell time and angle calculations, Effect of engine speed and number of cylinders. Coil ignition patterns; primary and secondary patterns 4 2. Conventional coil ignition (CI) system Characteristics and system components: Ignition coil Distributor Contact breaker and Condenser Spark plugs and their different classifications Ballast resistor Timing advance mechanisms Limitations of the system. Primary and secondary ignition patterns 8 3. Transistorized coil ignition systems Contact breaker troubles. Necessity for new ignition in modern cars. Electronic switching of primary current. Transistors, switching characteristics, gain factor and protection circuit. 1. Transistorized coil ignition system with contact breaker: System characteristics, components, circuit diagram and advantages. Function of the transistor and the contact breaker. Primary and control current relation and Darlington - Describe the operation principles of the coil ignition systems
- Explain the components and the functions of conventional coil ignitions systems and describes the interaction of the components and ignition timing - Explain the significance of ignition timing
- Explain the components and the functions of transistorized coil ignitions systems and describes the interaction of the components
Department: Mechanical Technology amplifier System disadvantages. 2. Transistorized coil ignition systems with hall pulse generator (TCI-H) Function of pulse generator. Advantages of pulse generator coil ignition systems. Hall effect and Hall pulse generator. Hall pulse generator signal processing . 3. Transistorized coil ignition systems with induction pulse generator (TCI-I) Induction pulse generator components and principle of operation. Induction pulse generator signal processing Open loop and closed loop Dwell control
Major: Vehicles
10
4. Electronic ignition systems Principles of computer controlled ignition systems, components Ignition charts and tables. Electronic Control unit Crankshaft-sensor (engine speed) Camshaft-position sensor Load sensor (MAP or TPS sensors) Computer controlled ignition timing Different types and designs of computer ignition controls. Distributerless ignition systems: Methods of high voltage distribution. Ignition coils
- Explain the components and the functions of fully electronic ignitions systems and describes the interaction of the components.
- Explain the components and the functions of CDI-systems
5. Principles of Capacitor-Discharge Ignition system (CDI): Principles of operation and advantages, Circuit diagram and system components. Capacitor charging circuit Ignition transformer Thyristor and switching control
Major: Vehicles

Laboratory
4 The principles of the ignition fault detection with the oscilloscope
The student should be able to: - Describe ignition patterns, and demonstrate the use of the oscilloscope to detect ignition faults. - Assemble and connect different ignition systems correctly, and run the systems
Conventional coil ignition systems tests: Using Ignition system training panels, the following experimental tests are carried out Dwell angle Ignition timing Current consumption Ignition patterns
10
Transistorized ignition systems Tests with Hall-impulse generator (TCI-H): Function of Hall-impulse generator Dwell angle control Closed-circuit connection Current consumption, current limiting and driver stage Protective function of output stage Tests with Induction-type generator (TCI-I): Function of Induction-type generator Dwell angle control Closed circuit cut-off Current consumption, current limiting and driver stage
- Carry out various tests with an engine testers, oscilloscope and timing light in order to: Measure the performance and characteristic of the system Simulate faults and check the difference in system characteristics and performance Evaluate proper operation of the systems Topics (3 and 4)
10
Fully electronic ignition systems Tests of functions of the whole system and the components with oscilloscope and multi-meter: Throttle-valve switch Engine-temperature sensor Engine-speed and reference-mark sensor Tests on the effect of engine operating conditions upon Ignition timing Dwell angle
Major: Vehicles

30
Workshop
Introduction General Instructions, Safety Measures Conventional, Transistorized and Electronic Ignition Systems Components and main functions Maintenance Work
The student should be able to: - Identify different components of coil ignition systems - Explain the necessary maintenance work on these systems.
Trouble shooting, system tune up and repairs: 2.1 Fault simulation Use of an operating engine to simulate consequently one of the following faults in the electronic ignition systems (TCI, SI, DSI): Engine cannot be started Engine misfires, Excessive vibrations when engine runs, Loss of engine power, Non typical engine noises by acceleration, Etc. 2 Relate the problem to one or more of the following possible causes Electrical plug-and-socket connections faulty, loose or incorrectly joined: Battery connections, high tension wiring, pulse generator wiring, Components worn or damaged: Ignition switch, pre-resistor with relay, contact breaker points, pulse generator, computer, speed sensors ignition coil, ignition distributor with ignition timing, spark plugs,
- Explain the working conditions of an operating engine under a simulated fault.
- Identify possible causes related to this fault.
Major: Vehicles
Incorrect adjustment of: Firing point, timing angle, spark plug gap, dwell angle at contact breaker, etc. 2.3 Testing procedures: Carrying out visibility test of electronic ignitions system for defects and condition of wiring connections, Localizing causes of fault with the aid of an engine tester, system tester and multi-meter and assigning them to special component groups: Ignition starting device Ignitions coil Ignition distributor Computer Contact breaker, pulse generator or crankshaft-speed sensor Spark plugs Testing these components with the aid of technical data and detail test equipment, comparing of the determined results and their evaluation Decision whether components should be replaced or repaired 2.4 Repair work and adjustment Carrying out essential adjustment work, e.g.: Dwell angle, Ignition timing point, Characteristics of ignition timing (code plug contact), Spark plug gap, Carrying out required repair work with the aid of repair manuals, Carrying out final checks. - Carry out necessary tests with the aid of different inspection techniques and equipment, such as: - visibility test Reading trouble codes System checking, comparison of nominal and actual values Engine-test with oscilloscope to localize sources of the fault.
- Perform the necessary repair work and final adjustment
Major: Vehicles
Department Mechanical Technology Course Title Petrol Engines Fuel Systems Prerequisite Internal Combustion Engines
Major Code
Semester 1
Vehicles MEV 226

2 3 4 4 3 3 45 45 5 6
Course Description : Principles of combustion in petrol engine and air-fuel mixture requirements. Carburation systems; conventional and electronically controlled, components and function. Fuel injection systems, types, characteristics, components and functions. Fault diagnosis, repair, adjustment and maintenance of petrol fuel systems.
Credit hr/w L Contact hr/w W T L Contact hr/sem. W T
General Goal : The course provides the basic knowledge about petrol engines fuel systems. It covers carburation and fuel injection systems. It also provides the practical experience and skills required to carry out diagnosis, adjustment, repair and maintenance operations of petrol fuel systems. Behavioral Objectives : By the end of this course, the student will be able to: Define the requirement of air-fuel mixture suitable for different engine operating conditions. Explain different carburettor designs, basics and supplementary systems of conventional and electronically controlled carburettors.
Explain and analyse different constructions and operating principles of different fuel injection systems in petrol engines. Demonstrate functions of the fuel injection, carry out measurements, find and erase faults and evaluate their possible consequences, using simulation models. Carry out fault diagnosis, trouble shooting, visual and instrumental inspection, repair and adjustment of: Conventionaland electronically controlled carburettors. Fuel injection systems in petrol engines
Major: Vehicles
Topics: Theory: 1. Principles of Combustion and mixture requirement: Petrol fuel characteristics, combustion equations, products, and fuel/air ratio Combustion process in Otto engine Influence of operating conditions on engine power, pollutants and fuel consumption. Mixture requirement for different engine operating conditions. Fuel system in petrol engines, function, components and types Practice: Laboratory: Using the Training Panels of different electronic injections systems carry out measurement to define system performance and component characteristics.
Workshop: Fault diagnosis, troubleshooting, repair and adjustment of: 2. Conventional Fuel system (Carburettors): Conventional carburettors, and Electronically controlled Carburettor basic operation, carburettor system Design and function of different carburettors Fuel injection systems in - Conventional carburettor and Electronically controlled carburettor petrol engines: 3. .Fuel injection systems in petrol engines: Electro-mechanical fuel Different classifications of fuel injection systems in petrol injection, engines, types advantages, and general characteristics Electronic fuel injection, Continuous fuel injection systems, Combined fuel injection and Electronic fuel injection systems, ignition systems. Combined electronic ignition and fuel injection systems.
Textbook:
Duffy, James E., and Smith, Howard B., Auto Fuel and Emission Control Systems Technology, The Goodheart-Willcox company, INC, ISBN 0-87006932-2 Robert Bosch GmbH Automotive Electric / Electronic Systems, 2nd edition, 1995, ISBN 1-56091-596-X Manufacturers data and repair manuals Automotive journals and magazines Heinze Heisler, Advanced Engine Technology, Edward Arnold, ISBN 0340568224 William H. Crouse and Donald L. Anglin, Automotive Mechanics The McGrawHill Book Company, ISBN 0-02-800943-6 Martin, W. Stokel and Martin, Auto Mechanics Fundamentals, The Goodheart-Willcox company, INC, ISBN 1-56637-138-4 , 1996 Martin W. Stokel, Martin T. Stokel Chris Johanson Auto Fundamentals The Goodheart Willcox company, INC, ISBN 1-56637-138-4 , 1996 William, K. Toboldt, Larry Johnson, and W. Scott Gavthier, Automotive Encyclopaedia Fundamental, Principles, Operation, Construction, Service, and Repair, The Goodheart -Willcox company, INC , ISBN 1-56637-150-3 , 1995 Duffy, James E., Auto Engines The GoodheartWillcox company, INC, ISBN 0-87006-677-3 Jack Enjavec and Robert Scharff Automotive Technology Delmar Publishers, An International Thomson Publishing Company.
Additional Reading:
References:
Major: Vehicles

1. Principles of Combustion and mixture requirements: Characteristics of petrol fuels Combustion equation of petrol fuel, and products of combustion Fuel / air ratio, excess air factor, correct, lean and rich mixtures The combustion process in petrol engine, normal and detonating combustion, and the influence of mixture strength on flame speed and combustion efficiency, Influence of operating conditions such as; Engine speed, Engine load, Engine temperature Outside air temperature and density on engine power, efficiency, pollutants, and fuel consumption, Mixture requirement for different engine operating conditions as: Cold start, post-start phase, and warmup Acceleration, Idling, part load, and full load overrun engine-speed limiting Adaptation of the air-fuel mixture at high altitude Petrol engines fuel systems, function, components and classifications as: Conventional fuel systems Fuel injection systems
The student should be able to: - Describe characteristics of petrol fuel - Calculate fuel / air ratio and distinguish between correct, lean and rich mixtures. - Distinguish normal and detonating combustion. - Explain and interpret the influence of different operating conditions on engine performance. - Describe the mixture requirements for different operating conditions
2. Conventional Fuel system (Carburettors): Different carburettor constructions, and their classification Operation principle of basic carburettor systems as well as the additional circuits, and the basic design of a carburettor as: Float assembly Cold-starting device Idling and bypass system Main jet system Acceleration system Mixture enrichment system Additional devices The construction and function of a two-stage conventional carburettor, Trouble shooting strategies on two-stage carburettors
- Explain the principle of carburettors operation, and distinguish between different types. - Describe the operational functions of components to meet mixture requirements for different engine operating conditions
Major: Vehicles
Major: Vehicles

Hrs Contents Basic operation and components of electronically controlled carburettor, considering: Idle stabilisation, Mixture control Overrun and speed limit control Controlling of second phase, Enrichment devices for cold start, idling, full load, and acceleration 3 3. Fuel injection systems in petrol engines. Different classifications of fuel injection systems in petrol engines as: Mechanical, electronic, and ignition integrated fuel injection systems, Continuous and intermittent fuel injection systems Single and multi injector systems, Advantages, and general characteristics, 4 3.1 Continuous fuel injection systems: An overview of continuous fuel injection systems, characteristics of mechanical electronically controlled (KE-jetronic) fuel injection systems, block diagrams, components, and their functions related to: Idle speed with idle stabilisation, Partial load, full load, Cold start device, Acceleration enrichment, Overrun conditions, Exhaust emission control Typical defects, faults and the possible causes of troubles in the system, 3.2 Intermittent fuel injection systems: General knowledge about intermittent fuel injection systems which includes: electronically controlled fuel injection systems such as L-jetronic , LE-jetronic, LH-jetronic, EFI, SEFI, MPFI, mono-jetronic, TBI systems, combined electronic ignition and fuel injection systems as Motronic and mono-Motronic, - Distinguish different types of fuel injection systems, and outline the characteristics of each system. Behavioral Objectives - Explain the control of an electronic carburettor concerning the: - Idle stabilisation - Mixture control - Enrichment devices for cold start, idling, full load, and acceleration
- Describe the mechanical electronically controlled fuel injection systems, (KEjetronic). - Outline the block diagram of these systems, name their components, functions, and their mode of operation
- Assign typical faults and causes of troubles in the system and develops a corresponding trouble shooting strategy. - Explain characteristics of intermittent electronic fuel injection and describe different systems,
Major: Vehicles
Major: Vehicles

Hrs 18 Contents 3.2.1 Electronically controlled fuel injection systems: An overview of electronic fuel injection systems, system characteristics, block diagrams, system components, and their mode of operation, Block diagrams of the control unit, input sensors, and output actuators, Pulse timing output diagram of the system, System adaptation to different operating conditions as: cold starting, post-start adaptation warm-up enrichment acceleration adaptation full load adaptation idle adaptation overrun air temperature adaptation mixture adaptation at high altitudes Lambda closed-loop control, typical defects, faults, and causes of system troubles 3.2.2 Combined electronic ignition and fuel injection systems: an overview of combined electronic ignition and fuel injection system, advantages, characteristics, block diagrams, system components, and their mode of operation, the electronic ignition sub-system including: ignition timing control dwell-angle control engine speed detection measuring of the crankshaft angle engine-speed and reference mark sensor. High-tension circuit The electronic ignition sub-system including: Fuel supply Air flow measurement Control and fuel metering Block diagram concerning the fuel metering system (measured variables, sensors, actuators, fuel supply system, signal processing ), Injection duration time and pulse timing, Adaptation of the system to different operating conditions, Typical defects, faults, and possible causes of system troubles Behavioral Objectives
- Explain characteristics of different electronic fuel injection systems. - Outline block-diagram of the system. - Describe the mode of operation of different components. - Describe the adaptation of the system to different engine operating conditions. - Outline block diagrams of the control unit, sensors, and actuators. - Explain the pulse timing diagram of the system. - Describe the Lambda closed-loop control.
6 - Explain characteristics and the advantages of combined electronic fuel injection and ignition (e.g. Motronic) systems, - Explain both the ignition and the injection subsystems. - Outline block-diagram of the system. - Describe the operation mode of different components, and the adaptation to different operating conditions, - Outline block diagrams of the control unit, sensors, and actuators. - Describe the pulse timing diagram of the system. - Describe the Lambda closed-loop control.
Major: Vehicles

Laboratory
15 Electronic Fuel injection systems performance and characteristics: Using the Training Panels of different electronic injections systems as L-, LE-, LU- ,LH- jetronic, Mono-jetronic, or Motronic, the following experiments are carried out: Demonstration of system operation, Display of the injection signal on an oscilloscope, The relation between voltage signal of the air flow sensor (or throttle valve potentiometer in case of mono-jetronic and TBI systems) and the air flow rate, Dependency of injection pressure on the manifold air pressure, Dependence of the Base Injection Time on engine load and speed, Influence of system voltage on the injection (pulse) time system (voltage corrections) Influence of the different operating conditions (cold start, post-start, warm up, idling, overrun cut off, air temperature, etc.) on the Injection Time Correction Factor, Relation between ignition and injection pulses Demonstrate Lambda sensor signal as function of mixture strength,
- Demonstrate the operation of each system. - Carry out experiments to define the performance and characteristics of the system. - Explain the relation between injection time and engine operating parameters.
Major: Vehicles

Workshop
2 1. Introduction: Workshop safety regulation instructions, Petrol engine fuel system components, and functions, 2. Conventional and electronically controlled carburettors. Development of a fault diagnosing strategy for carburettor system troubles; Using a running engine: a. Study one of the following problems in details: Engine will not start in cold condition, Engine stalls after starting in cold condition, Engine stalls during warm-up phase, Hard starting in hot engine condition, Engine stalls when idling in warm condition, Engine jerks in constant speed in partial load range, Hesitates by acceleration, Excessive fuel consumption, Maximum power not attainable, "running-on" of the engine, etc.
The student should be able to: - Distinguish components of petrol engine fuel system and define their functions. - Construct a trouble shooting strategy for conventional and electronic carburettors. - Explain common faults of conventional and electronic carburettors,
- Relate the fault to the possible causes. b. Assuming that these causes are well-founded in the conventional or electronic controlled carburettors, relate the problem the possible causes as: Leakage in mixture preparation, Damaged, worn or loose components Incorrect adjustment in one or more systems of conventional carburettor, Electric plug- and socket connections defective especially in electronically controlled carburettors, Faulty sensors or control unit of electronic carburettors defective. c. Carry out following tasks to locate the cause of trouble: Visibility check for leakage, and damage of components of conventional carburettor throttle valve position, and choke position, electrical components and connections, Visibility check for the connections of electronically controlled carburettor, Carry out instrumental tests with the aid of suitable test equipment considering: Check in addition to the mechanical system of the electronic carburettor the electronic components with the aid of suitable test equipment: Determine the causes of faults and troubles in - Carry out the diagnosing strategy to locate defects using different inspection techniques and equipment. - Carry out repair and adjustment work with suitable test equipment including final inspection of the complete engine.
Department: Mechanical Technology electronic carburettor systems for the following functions, e.g.:
Major: Vehicles
Major: Vehicles

Hrs Contents Cold start and warm-up phase, Correction of engine characteristics map, Acceleration, Fuel- and engine shut-off, Idle speed control, Carry out the required cleaning, repair, and adjustment work with the aid of manufacturer's data. Carry out final check. 20 3. Petrol fuel injection systems. Development of a fault diagnosing strategy for fuel injection system troubles; Using a running engine: a. Study one of the following problems in details: Engine will not start, Idle speed uneven, Poor change-over, and Poor engine power, Hard starting in cold engine condition, Hard starting in hot engine condition, etc. Assuming that the causes are well-founded in the fuel injection system, relate the problem to the possible causes as: Fuel tank empty, Air filter or fuel filter clogged, Leakage in fuel supply system or in mixture preparation, Damaged, worn, loose or incorrect operating components: Electric fuel pump, Fuel accumulator, Line pressure or fuel pressure regulator, Mixture control unit, air flow sensor, Warm-up- or electro-hydraulic pressure regulator, Injectors and cold start injector, Auxiliary air valve or idle actuator, Throttle valve switch, Electronic control unit (ECU), Water temperature sensor and start injector time switch, Circuit opening and fuel pump control relay, etc., Incorrect adjustment of: Idle speed, - Establish a diagnosis and trouble shooting strategy for different fuel injection systems - Explain common faults and troubles of petrol injection systems Behavioral Objectives
- Relate the problem to the most probable causes.
b.
Department: Mechanical Technology Idle-mixture setting, Electric plug- and socket connections defective, Etc.
Major: Vehicles
Major: Vehicles

Hrs c. Contents Carry out following tasks to locate the cause of trouble: Visibility test of components regarding leakage, damages and condition in the following systems: Fuel supply system, Air filter system, Mixture preparation system, Electrical system, Testing the operation of system components for proper functioning, e.g.: throttle valve switch, air flow sensor, air mass sensor, electronic control unit (ECU), line pressure regulator, fuel pump, injectors, and relays, Single components checking using suitable test and diagnosing equipment, and compares test results with vehicle technical data Repair of electronic fuel injection systems by the replacement of faulty components, Checking complete fuel injection systems with the help of test programs and adjusts idle speed and exhaust gas limits, Applying previously learned test and measurement methods in combined fuel injections, e.g. Bosch Motronic, Checking integrated systems if necessary such as Knock control, fuel shut-off, oxygen sensor control (Lambda probe), transmission control, Repairing combined fuel injection systems by replacement of faulty components, Checking combined fuel injection systems with the help of test programs and adjusts idle speed and exhaust gas limits, and carry out final checks Checking CO / HC values with the help of an exhaust gas emission tester, Faults erase with the help of manufacturer's data, and carry out adjustment, repair or replacement of defective part Adjustment of idle speed and exhaust gas limits with the aid of manufacturer's. Behavioral Objectives - Carry out the diagnosing strategy to locate defects using different inspection techniques and equipment.
d.
- Carry out repair and adjustment work with suitable test equipment including final inspection of the complete engine
Major: Vehicles
Department Mechanical Technology Course Title Automotive Electric Systems and Circuits Prerequisite Physics II
Major Code
Vehicles MEV 227

1 2 3 4 4 2 4 30 60 5 6
Semester Course Description : The principles of current generation, rectification and electric motors. Components and functions of different kinds of starting, charging, and electrical circuit systems. Fault diagnosis and repair on these systems. Credit hr/w L Contact hr/w W T L Contact hr/sem. W T
General Goal : The course provides knowledge about starting and charging systems, and electrical circuits and gives practical experience and skills required to diagnose, repair, adjust, and maintain these systems with modern test equipment. Behavioral Objectives : By the end of this course, the student will be able to: Explain the principles of current generation, rectification and electric motors Explain the components and functioning of starting, charging systems and basic automotive electric circuits Assemble and run starting, charging and different kinds of automotive electrical circuits systems and evaluate their performance parameters Carry out fault diagnosis, repair and adjustment work with suitable test equipment of different starting, charging- and electrical systems.
Topics: Theory: Starting system Charging system Electrical automotive circuits Practice: Laboratory: Assemble and run various electric systems and carry out performance tests. Workshop: Fault diagnosis and repair of: 1- Starting System 2- Charging System 3- Electrical automotive circuits L = Lecture Hours, W = Workshop/Laboratory Hours, T = Tutorial Hours
Major: Vehicles
Textbook:
James E. Duffy, Auto Electricity, Electronics, Computers, The GoodheartWillcox Company Inc., ISBN Stockel, and Johanson, Auto Service and Repair, The Goodheart-Wilcox Company Inc., ISBN 1-56637-144-9 John Deere, Electrical Systems, Fundamentals of Service, ISBN 0-86691-047-6
Additional Reading:
William Toboldt, Larry Johnson and W. Scott Gauthier, Automotive Encyclopedia, 1995, The Goodheart-Wilcox Company Inc., ISBN
References:
Harcourt Brace Jovanivich, 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 1-56637-144-9 Robert Bosch GmbH, Automotive Handbook, ISBN 0-89 283-518-6 Harper and Row, Automotive Electrical Systems, Classroom Manual, CheckChart Automotive Series Harper and Row, Automotive Electrical Systems, Workshop Manual, CheckChart 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 1-689-980-086
Major: Vehicles

Hrs Contents Behavioral Objectives The student : 6 1. Starting system. Principle of electric motors Principles and operation of starter systems. Construction and function of a screw shift pinion starter: Starter solenoid. Engaging of pinion and free-wheeling system - Describes the operation principal of the starting system - Explain the components and function of a screw shift pinion starter
8 2. Charging System. Current rectification in an alternator. Diode circuits, Excitation circuit (external excitation), Field excitation circuit (self-excitation), Alternator circuit (primary circuit). Characteristics of the alternator circuit curve. Calculations: Current intensity, Voltage, Electrical work and power, Efficiency. Factors affecting charging voltage of alternators as: Electrical load through connecting loads, Alternator revolutions, Field current. Construction and function of voltage regulators: Electro-mechanic voltage regulator, Transistorized voltage regulator Field current and voltage curves. Necessity of over-voltage protection and its function. Calculations to determine a necessary alternator type with the aid of vehicle load factors. - Describes current rectification in an alternator - Explains the different circuits in an alternator - Interprets the characteristics of the alternator curves. - Calculates alternator performance parameters.
- Describes factors affecting charging voltage of an alternator - Describes construction and function of voltage regulator. - Interprets field current curves. - Explains necessity of over-voltage protection and its function. - Carries out calculations to determine a necessary alternator type with the aid of vehicle load factors.
16
- Explains the construction and function of different headlight systems. - Calculates electrical power and power consumption of electrical loads
3. Electrical Automotive Circuits Construction and functioning of following light systems:
Department: Mechanical Technology Advantages and disadvantages of parabolic, ellipsoid and DE headlights Sealed beams Classification of light bulbs Litronic light systems Necessity for headlight leveling. Calculations of electrical power and power consumption of electrical loads. The constructions and functions of : Optical signal devices. Acoustic signal devices Windshield wiper systems. Drawing of electrical wiring diagrams of: Lighting systems, Acoustic signal devices. Construction and basic functioning of driver information and electrical comfort systems such as: Failure and wear indicators, Supply and operation indicators Central locking system, Power windows,
Major: Vehicles - Describes the constructions and functions of the different electrical systems with the aid of electrical wiring diagrams - Draws different electrical wiring diagrams. - Describes the construction and basic functioning of driver information systems and electrical comfort systems.
Major: Vehicles

Laboratory
The student:
Using a training panel to assemble various different electric systems: 6 1. Starting system with screw shift pinion starter for the demonstration of specialties of series-wound motors as automotive starters and their advantage. Function of pull-in- and hold-in coil. Torque characteristics Revolution Effective power Efficiency - Assembles the starting system. - Demonstate and Explain various performance parameters of the starting system.
10
2. Charging system circuit with alternator, electronic or electro-mechanic voltage regulator, battery, excitation and charging current circuit for the demonstration of: Mark-space ratio dependent on load current with the help of an oscilloscope. The correlation between maximum field current, mark-space ratio and field current and comes up with the maximum field current. Direction of rotation performance. Influence of high number of pole pairs of the claw-pole rotor on the maximum current. Frequency response characteristic of the stator winding. 2/3 current to test specified value. Voltage performance dependent on revolutions. Operating frequency of voltage regulators. Essential differences between two-level- and three-level control. Indicates variety of operational performance of electronic- and electro-mechanic voltage regulators.
- Assembles charging systems with different voltage regulators. - Demonstrate and Explain various performance parameters of the charging systems and shows the influence of different factors.
12 3. Electric Circuits: Headlights systems with headlight flasher, two relays and headlights with stepping relay, fog light system and parking light system: Function of relays - Assembles the various light systems system. - Demonstrate and Explain various performance parameters of these light systems
Department: Mechanical Technology Function of high / low-beam switch, Requirement of fuses, Principle of voltage divider
Major: Vehicles
Acoustical signal equipment. Standard horn construction with coil, diaphragm, plunger, etc. Function of relays Optical signal equipment. Single and dual-circuit indicator systems Brake warning- and turn signal lamps. Hazard warning system Function of flasher units Function of relays
- Assembles standard acoustic signal equipment of the system. - Demonstrate and Explain various performance parameters. - Assembles different optical signal systems system. - Demonstrate and Explain various performance parameters of these signal systems.
- Assembles different wiper and washer systems. - Demonstrate and Explain various performance parameters of these wiper and washer systems.
4. Windshield wiper with two speeds and limited position switch and wiper-washer pulse circuit. Speed changing to power consumption, Torque and power consumption, Current lines in different operational modes. Mono-stable- and stable output Washer pulse system is additionally
Major: Vehicles

Workshop
The student should be able to: 2 1. Introduction 8 Workshop safety regulations Components of the automotive electrical systems, their function and location Introduction to testing equipment e.g.: Engine Tester Battery tester Starter tester Multi-meter - Explain workshop safety regulations. - Distinguish various electrical systems and their functions.
2. Fault diagnosis and repairs of Starting system Using simulated Faults on a car: 2.1. Study the following problems in detail e.g.: Starter will not crank, Starter has slow-cranking problems, Starter clicks only, Starter will not shut off, Non typical noises by starting, etc. Assuming that these problems are one of the following causes in the starting system e.g.: Battery discharged, partly discharged or dead Ignition switch defective, Electrical cable or cable connections interrupted, corroded or incorrectly joined, Series resistor or starter relay defective, Bearing- and / or pinion damage, Defective free-wheeling mechanism, Solenoid switch corroded or defective, Worn brushes, commutator wear, winding damages Etc. Fault identification on the car with engine tester, battery tester, starter tester, voltmeter, ammeter and ohmmeter in comparison with vehicle technical data. Resistance Voltage drop Current consumption of the starter Engine revolutions Fault identification on the starter test bench in comparison with vehicle technical data. Revolutions
- Explain possible troubles of the starting system, and constructs a diagnosis and trouble shooting strategy to locate the causes of the trouble.
- Identify the possible causes of the trouble
- Carry out a diagnosis strategy to locate faults using different inspection techniques and equipment.
- Carry out the repair and adjustment work with suitable tools and test equipment including final inspection.
Department: Mechanical Technology Torque Current consumption Relay operation Function of overrunning clutch Insulation Efficiency, Etc
Major: Vehicles
Visual inspection of mechanical components for damages of: Flywheel ring gear, Starter mounting, Starter bushes Repair of faulty starters, replacement or repair of components with the aid of technical manuals 8
- Explain possible troubles of the charging system, and constructs a diagnosis and trouble shooting strategy to locate the causes of the trouble. - Identify the possible causes of the trouble - Carry out the diagnosis strategy using suitable inspection techniques and equipment to locate faults - Carry out the repair and adjustment work with suitable tools and test equipment including final inspection.
3. Fault diagnosis and repair of Charging system: Using simulated Faults on a car: Study the following charging system problems in detail: Charging indicator lamp does not glow when engine stops and ignition switch is in operational mode, Charging indicator lamp glows all the time when engine runs, Charging indicator lamp glows only when connecting electrical load, Charging indicator (voltmeter) shows indications too high or too low, Battery overheats, Etc. Assuming that these problems are one of the following causes in the charging system: Battery uncharged, insufficient charged or faulty, Slipping, loose or broken drive belt, Electrical cables or plug-and-socket connections interrupted, faulty, corroded or incorrectly joined, Contact resistance in the charging circuit, Charging indicator lamp burned out, Voltage regulator faulty, Alternator defective, e.g.: Short circuit of a diode, Brushes worn, Corroded slip rings, Interruption or short circuit in stator- or rotor winding, Rectifier defective, Bearing defective, Etc. Visual inspection of battery condition, belt drives, connections of alternator and voltage regulator for damages, e.g.: Battery check for electrolyte level, Drive belt tension, Properly seated pulley, Broken mounting, Bad ground connection, Electric cables have worn through, Corroded plug-and-socket connections,
Department: Mechanical Technology Fault identification in the charging current circuit on the car with engine tester, voltmeter, ammeter, oscilloscope in comparison with vehicle technical data e.g.: Battery voltage, Charging voltage with or without electrical load, Charging current with or without electrical load, Function of diodes with the aid of an oscilloscope, Excitation current, Fault identification on the alternator and voltage regulator on test bench in comparison with vehicle technical data e.g. Field excitation, Regulating voltage, Idle voltage, Charging voltage under load, Charging current under load, Power Repair of faulty starters, replacement or repair of components with the aid of technical manuals 4. Automotive Electrical circuits Using simulated Faults on a car: . Study the following automotive electrical circuits problems in detail e.g.: One or more lamps inoperable, Improper functioning of one or more lamps, Poor road illumination of headlights, Horn inoperable or insufficient, Windshield wiper inoperable, wiper speed too low or wiper / washer system inoperable All door locks or one door lock on central locking system can not be locked or unlocked All or one electrical power window can not be opened Meters and gauges are not working Indicator and warning lamps are not working, Etc. Assuming that these problems are caused by one of the or more of the following causes in the in the lighting, signal or windshield wiper system: Blown fuses, Switch defective, Bulbs burned out, Plug-and-socket connections faulty, Incorrect connections, corrosion defects, switch defective, Improper headlight adjustment, Turn signal flasher unit defective, Defective horn, relay, and electric motors Windshield wiper linkage damaged, Heavy or worn bearing bushes, Wiper motor and / or hoses leaks or porous, Etc. Visual inspection for damages in the complete lighting system including optical signal system e.g.: Fuses, Bulbs, and Electrical connections, Fault identification in the electrical circuits of lighting and optical signal system with the aid of test lamp, voltmeter and wiring diagrams
Major: Vehicles
12
- Explain possible troubles of the automotive electrical systems, and constructs a diagnosis and trouble shooting strategy to locate the causes of the trouble. - Relate the problem to its possible causes - Carry out a diagnosis strategy to locate faults using different inspection techniques and equipment. - Carry out repair and adjustment work with suitable tools and test equipment including final inspection.
Department: Mechanical Technology Aiming of low- or high-beam of headlight,
Major: Vehicles
Major: Vehicles
Department Mechanical Technology Course Title Automotive Workshop Management Prerequisite
Major Code
Vehicles MEV 301

1 2 3 4 5 6 2 2
Semester Course Description : Principles of automotive workshop operation management, including; work organization, cost estimates, spare parts stocking, maintenance scheduling of various vehicles groups and proper selection of tools and equipment. Types of maintenance and its scheduling methods. An introduction to workshop Planing. Credit hr/w L Contact hr/w W T L Contact hr/sem. W T
30
General Goal : This course provides the principles of automotive workshop operation management and planning.
Behavioral Objectives : By the end of this course, the student will be able to: Organize and manage the maintenance operations in vehicles workshops.
Conduct needed calculations to choose the necessary labor and put their working plan. Conduct cost estimation steps for any certain types of maintenance Demonstrate awareness in stocking control management. Explain maintenance types.
Determine basis and rules of maintenance scheduling and estimate its cost.
Put maintenance schedules for many maintenance operations for a certain group of vehicles. Layout vehicles workshop plans and their equipment.
Topics (Theory): Automotive workshops management Maintenance scheduling Spare parts stocking Introduction to workshop planing L = Lecture Hours, W = Workshop/Laboratory Hours, T = Tutorial Hours
Major: Vehicles
Textbook:
Frank J. Thiessen, Automotive Service Management, Technology publications, 1989, ISBN 0-15-504375-7
Additional Reading:
References:
. .
Major: Vehicles

10
1. Workshops Management: Organization of maintenance operations, Importance of maintenance operation management Basis of maintenance Safety procedures Workshop manuals and catalogs Maintenance cost estimation Fixed costs Running costs Equipment and vehicles depreciation One hour maintenance cost in workshops Equipment replacement methods Workshop performance rates evaluation Follow-up technical reports Preparation Maintenance forms
The student should be able to: - Organize and manage the maintenance operations in vehicles workshops. - Carry out the necessary calculations to choose the necessary labor and put their working plan. - Conduct cost estimation steps for any certain types of maintenance. - Explain maintenance forms.
2. Spare Parts Stocking and its Management: Objectives of stocking management Internal layout of stocking management Incentive systems in maintenance management - Demonstrate awareness in stocking control management.
10
3. Maintenance Scheduling: Maintenance definitions Types of vehicles maintenance Maintenance operations and scheduling Vehicles over-all major repairs - Explain maintenance types - Determine basis and rules of maintenance scheduling and estimate its cost. - Put maintenance schedules for many maintenance operations for a 4. Introduction to Workshops Planning certain group of vehicles. - Layout vehicles workshop plans and their equipment.
Workshops building requirements Basis for workshop internal divisions and department organizations determining the departmental areas Equipment selection and layout of workshops and its departments.
Major: Vehicles
Department Mechanical Technology Course Title Automotive Fault Diagnosis Prerequisite
Major Code
Vehicles MEV 321

1 2 3 4 5 6 3 2 2 30 30
Semester Course Description : Principles of fault diagnosis and trouble shooting strategies. Testing and diagnosing equipment. Manufacturers special fault diagnosis routines. Various applications to vehicle problems, which have multi-system inter-related causes. Practical fault diagnosis applications using different diagnosing techniques and equipment. Credit hr/w L Contact hr/w W T L Contact hr/sem. W T
General Goal : This course provides a comprehensive overview to fault diagnosis and trouble-shooting techniques used for various vehicle problems. It gives the practical skills and experience to develop and perform the suitable strategy using the suitable test equipment.
Behavioral Objectives : By the end of this course, the student will be able to: Explain principles of diagnosis and trouble shooting techniques as a basis for performing maintenance and repair in a right scientific manner. Construct a trouble shooting strategy to identify the cause of trouble by relating the symptoms of the problem with the possible causes Carry out visual and instrumental testing using various techniques and equipment to localize the cause of complicated vehicle troubles Determine the suitable diagnosing and test equipment. Demonstrate the use of different diagnosing equipment.
Use of manufacturers diagnosing routines, and manuals of repair and maintenance.
Topics: Theory: Diagnosis and trouble shooting strategies. Diagnosing and testing equipment. Manufacturers fault diagnosis and trouble shooting routines. Applications to various vehicle problems. Practice: Workshop: Diagnosing and testing equipment Manufacturers fault diagnosis and trouble shooting routines Applications to various vehicle problems.
Major: Vehicles
Allan W. M. Bonnick, Vehicle Electronic systems, Fault Diagnosis ARNOLD , ISBN 0-340-70630-9, 1998 Textbook: Stoekel, Stockel, and Johanson Auto Service and Repair The Goodheart Willcox company, INC, ISBN 1-56637-144-9
Additional Reading:
Technical manuals and manufacturer data books
William H. Crouse, and Donald L. Anglin, Automotive technicians Handbook, The McGraw-Hill Book Company, ISBN 0-07014751-5 Martin W. Stokel, Martin T. Stokel and Chris Johanson, Auto Fundamentals The GoodheartWillcox company, INC, ISBN 1-56637-138-4 , 1996 Automotive Engine Management, and Fuel Injection Systems, Manual ISBN 1-85960 344 O, 1997 Automotive Diesel Engine, Service Guide, ISBN 1-85960-286X References: William K. Toboldt, Larry Johnson and W. Scott Gavthier, Automotive Encyclopedia Fundamental, Principles, Operation, Construction, Service, and Repair- The GoodheartWillcox company, INC, ISBN 1-56637-150-3 , 1995 Jack Enjavec and Robert Scharff 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
Major: Vehicles

1. Diagnosis and trouble shooting strategies Diagnosing methods: Conventional method Hierarchical methods Diagnosing principles: Study of problem symptoms Possible causes related to the problem Visual and instrumental inspection Functional and performance testing of the system Identifying the cause of trouble Fault repair
The student should be able to: - Explain different diagnosing methods - Explain different stages of the diagnosing strategy - Construct the suitable diagnosing strategy to identify the cause of a vehicle trouble of multi-system nature
2. Diagnosing and testing Equipment - Distinguish different types of testing and diagnosing equipment Multi-system diagnosing equipment: and explain their suitable Motor testers applications Multi-meters Electronic Scan Tools - Choose the suitable test equipment Single system diagnosing equipment to carry out the designed Auto-electrical systems test benches and instrumental investigation testers, Wheel alignment testers, Noise detection electronic stethoscope, Engine Gas analyzers, Ignition system testers Brake testers Transmission testing equipment Fuel injection diagnosing equipment, Diesel system diagnostic equipment as: - Diesel smoke and motor testers - Diesel injection pumps and injectors test benches. Determination of the suitable test equipment
4 3. Manufacturers fault diagnosis and trouble shooting routines. System diagnosis flow charts Special diagnosing and testing equipment Functional and performance tests - Carry out the special routines designed by the manufacturers to diagnose their own vehicle troubles
Major: Vehicles
14 4. Applications to various vehicle problems Analysis of a number of vehicle problems which are of multisystem nature in order to develop a fault diagnosis strategy. Some of these problems are: Vehicle lakes power during acceleration, high speed performance, Poor tractive power of the vehicle or vehicle lakes power when ascending hills, Engine cannot start at all conditions, Engine will not start in cold condition, Engine stalls after starting in cold condition, Engine hard starting at hot conditions, Engine stalls when idling in warm condition, Engine misfires or backfires, Excessive black or white smokey exhaust, Excessive vibrations when engine runs, Non typical engine noises, Non typical vehicle noises, Excessive engine oil consumption, Excessive fuel consumption, Irregular running of the engine, Engine knocks evenly. Excessive gas exhaust emission, Engine jerks in constant speed, Vehicle hesitates by acceleration, Uneven idle speed, Transmission is noisy in neutral or in gear, Harsh klick when starting or while shifting Vehicle vibrations, vehicle driving noises Noise on acceleration, on curves, and tires show unevenly worn tread when cornering Vehicle pulls to one side while driving and or braking, Etc. - Construct and execute a trouble shooting strategy to identify causes of various vehicle problems, which are related to more than one of the vehicle systems.
Major: Vehicles

Workshop
6 1. Diagnosing and testing Equipment Multi-system diagnosing equipment: Motor testers Multi-meters Electronic Scan Tools Single system diagnosing equipment: Auto-electrical systems test benches and testers, Wheel alignment testers, Noise detection electronic stethoscope, Engine Gas analyzers, Ignition system testers Brake testers Transmission testing equipment Fuel injection diagnosing equipment, Diesel system diagnostic equipment as: Diesel smoke and motor testers Diesel injection pumps and injectors test benches.
The student should be able to: - Experience the use of different types of testing and diagnosing equipment and explain their suitable applications - Choose the suitable test equipment to carry out the designed instrumental investigation
4 2. Manufacturers fault diagnosis and trouble shooting routines: System diagnosis flow charts Special diagnosing and testing equipment Functional and performance tests
- Use the manufacturer data, repair and maintenance manuals, - Carry out manufacturers special routines designed to diagnose their own vehicle troubles
20 3. Applications to various vehicle problems: Practical applications to develop fault diagnosis strategies to a number of vehicle problems which are multi-system nature as: Using an actual running engine, simulate any of the following problems and study in details: Vehicle lakes power during acceleration, high speed performance, Poor tractive power of the vehicle or vehicle lakes power when ascending hills, Engine cannot start at all conditions, Engine will not start in cold condition, Engine stalls after starting in cold condition, Engine hard starting at hot conditions,
- Construct and execute a troubleshooting strategy to identify the fault causes for vehicle problems of multi-system nature. - Analyse the symptoms of the problem to define the most possible causes of the problem in all vehicle systems, - Carry out both visual and instrumental investigation using various testing and diagnosing techniques, and the suitable equipment to define the cause or causes of the trouble.
Major: Vehicles
Engine stalls when idling in warm condition, Engine misfires or backfires, Excessive black or white smokey exhaust, Excessive vibrations when engine runs, Non typical vehicle or engine noises, Excessive engine oil consumption, Excessive fuel consumption, Irregular running of the engine, Engine knocking, Excessive gas exhaust emission, Engine jerks in constant speed, Vehicle hesitates by acceleration, Uneven idle speed, Transmission is noisy in neutral or in gear Harsh klick when starting or while shifting Vehicle vibrations, vehicle driving noises Noise on acceleration, on curves, and tires show unevenly worn tread when cornering Vehicle pulls to one side while driving and or braking, .. etc. Assuming that the problem is caused by any of the systems of the vehicle, analyse the problem to relate it the most possible causes in different vehicle systems as: Engine mechanical components and systems, Computer engine management system, Ignition system Fuel management system Starting and charging system, Power transmission system, Vehicle suspension system, Vehicle steering system, Vehicle braking system, Vehicle electric circuits, Different control circuits. Carry out following tasks to locate the cause of trouble: Visibility check to the components of the system for leakage, damage, worn, and bad connection. An instrumental investigation to vehicle systems, components for proper functioning, operation and optimum performance using different testing and diagnosing techniques, and the suitable equipment.
Major: Vehicles
Department Mechanical Technology Course Title Diesel Engine Fuel Systems Prerequisite Internal Combustion Engines
Major Code
Vehicles MEV 322

1 2 3 4 5 6 2 1 3 15 45
Semester Course Description : The principles of operation of diesel engine fuel injection systems, components and functions. Various types of lift pumps, fuel filters, injection pumps, governors and injection nozzles. Methods of regulating injection quantity and timing. Fault sources, diagnosis, repair and adjustment of diesel injection fuel systems. Credit hr/w L Contact hr/w W T L Contact hr/sem. W T
General Goal : The course provides knowledge about various diesel fuel injection systems and develops the skills required to carry out tests, adjustment and necessary repair work for these systems with the help of manuals, manufacturers data, diesel engine testers and test-benches. Behavioral Objectives : By the end of this course, the student will be able to: Explain different constructions and operation of diesel fuel injection systems. Distinguish between different diesel fuel injection methods. Measure and evaluate the performance parameters of injection pumps and nozzles. Develop trouble shooting strategies, localise faults systematically, carry- out repair and adjustment work with the aid of various diesel engine testers.
Topics: Theory: Diesel fuel characteristics Direct and in-direct injection systems Diesel engine fuel circuit and equipment Fuel injection pumps, injection nozzles and governors Practice: Laboratory: Evaluation of diesel fuel characteristics Evaluation of the performance parameters of : lift pumps, diesel injection, pumps, and diesel injection nozzles. Workshop: Fault diagnosis, repair and adjustment of : Fuel supply systems, fuel return systems and injection systems Mechanical and electrical systems of diesel engines (combustion chamber, and pre-heating equipment)
Major: Vehicles
Schulz, Erick J., and Evridge, Ben L., Diesel Mechanics, Glencoe/McGraw Hill, ISBN 0-07-055836-1. Textbook: Duffy, James E., and Smith, Howard B., Auto Fuel and Emission Control Systems Technology, The Goodheart-Willcox company, INC, ISBN 0-87006932-2
Manufacturers data and repair manuals Additional Reading: Automotive journals and magazines
Heinze Heisler, Advanced Engine Technology, Edward Arnold, ISBN 0340568224 William H. Crouse and Donald L. Anglin, Automotive Mechanics The McGrawHill Book Company, ISBN 0-02-800943-6 Stokel, Martin W., Stokel, Martin T., and Johanson, Chris, Auto Fundamentals The GoodheartWillcox company, INC, ISBN 1-56637-138-4 , 1996 William, K. Toboldt, Larry Johnson, and W. Scott Gavthier, Automotive Encyclopaedia Fundamental, Principles, Operation, Construction, Service, and Repair, The Goodheart -Willcox company, INC , ISBN 1-56637-150-3 , 1995 Duffy, James E., Auto Engines The GoodheartWillcox company, INC, ISBN 0-87006-677-3 Jack Enjavec and Robert Scharff Automotive Technology Delmar Publishers, An International Thomson Publishing Company.
References:
Major: Vehicles

Hrs Contents Behavioral Objectives The student should be able: - Explain the characteristics of the diesel fuel and its effect on the combustion process. - Distinguish between direct and indirect injection systems and explain advantages and disadvantages of each system. - Explain different designs of fuel circuits and name the various components and their functions..
1- Diesel fuel characteristics Volatility, viscosity, Cetane number, effect of fuel quality on the combustion process in diesel engines. 2- Direct and indirect injection systems Direct injection systems. Indirect injection systems (pre-combustion chambers). Types of air swirl generation methods. Effect of direct injection and in-direct injection on the diesel engines performance parameters. 3- Diesel engine fuel circuits and equipment Fuel tank, lift pump, fuel filter, injection pump, transfer pump, injection lines, injection nozzles, fuel return systems 4- Lift pumps Construction and operation of mechanical and electrical types. Comparison between performance parameters, Advantages and disadvantages of each type. Wiring diagrams of the electrical type. Related fault sources and various causes. 5- Fuel filters Construction and operation of various diesel fuel filters. Fuel flow through filters. Water separation process. 6- Fuel injection pumps In-line plunger injection pumps. Rotary distributor injection pumps. Distributor pump control. Related fault sources and various causes. 7- Injection Nozzles Nozzles mechanism parts and operation. Related defects and various causes. Related fault sources and various causes. 8- Control of Injection timing and quantity Necessity for control. Diesel injection pump governor types. Diesel fuel injection point.
- Evaluate the performance parameters, explain the constructions and the operation of various components of diesel injection systems (topics 4 to 7). - Identifies fault sources and related causes.
- Explain the control of injection quantity and injection timing, governors mechanism parts and operation
Major: Vehicles

Laboratory
The student: 3 1- Diesel Fuel Characteristics and Quality Fuel specific gravity for: Pure diesel fuel mixture of diesel and petrol fuels mixture of diesel fuel and water Estimation of fuel quality (general indication) and approximate Cetane rating. Testers : hydrometer fuel quality testers 2- Diesel injection pumps use the diesel pump bench to: Evaluate the performance parameters of distributor and in-line injection pumps: outlet fuel pressure (at various speeds) outlet fuel flow rate (at various speeds) the relationship between fuel injection quantity and pressure - effect of injection timing variation on outlet volume and pressure compare between various output readings with the manufactures data use running diesel engines to Measure injection pump housing pressure. Measure the transfer pump pressure. Measure the return pressure from the injection pump. Compare between various output readings with the manufactures data and find reasons behind any difference if exists. 3- Lift pump use running diesel engines to measure: The output volume of the lift pump with the fuel tank cab fitted and removed. The output pressure of the lift pump at engines idle speed (measure fuel pressure with the filter fitted and removed). Evaluate the variation of the output pressure as the engine speed is changed. Compare the results obtained previously with the manufactures data and find reasons behind any difference if exists. 2 4- Injection nozzle testing Use the nozzle testers to : Measure injector-opening pressure. Evaluate spray patterns. - Measures the fuel characterises and quality. - Identifies the presence of water and/or gasoline in diesel fuel. - Explains how this could cause injection pump and nozzle damage.
- Measures and evaluates the performance parameters of the diesel injection pumps, transfer pump, lift pump and injection nozzles on testbenches and on running engines. - Compares the output results with the manufactures data and identifies the reasons behind any difference. (Topics 2 and 3)
- Measures the injector opening pressure, evaluates and compares spray patterns for various injectors
Department: Mechanical Technology Compare various spray patterns for different injectors.
Major: Vehicles
Major: Vehicles

Workshop
The student should: 2 1- 1. Introduction Workshop safety regulations Diesel fuel systems: Components and functions - Identify different components of diesel fuel injection systems and explain their functions
28
2- Diesel fuel injection systems: Trouble-shooting strategies, repair and adjustment work. aa. Fault simulation: - Explain the working conditions of a diesel running engine under a simulated fault.
Use running diesel engines to simulate Consequently one of the following faults : Engine will not start or hard to start (cold and hot conditions) or engines starts then stalls. Low power or loss of power. Irregular engine running. Engines knock evenly. Engine misfires or backfires. Engine black smoke. Excessive white smoke. Excessive engine vibrations. Excessive fuel consumption. Etc. b- b. Possible causes: Relate the fault to one or more from the following possible causes: Fuel tank empty. Incorrect fuel quality. Incorrect fuel viscosity. Air leakage or restriction in air inlet duct or intake manifold. Restricted exhaust system. Air in the fuel system. Supply lines, injection lines, fuel tank vaporisation, Overflow valve, fuel filter. Tubing and / or delivery valves have a leakage. Faulty components in the injection system: Lift pump Tubes, hoses Injection nozzles Overflow valve Injection timer Fuel pump governor Diesel injection pump
- Identify possible causes related to this fault.
Major: Vehicles
Faulty components in the pre-heating system: Glow plugs tips or glow plugs, Heater plug starting switch Glow plug system control module, Glow plug relay, Pre-resistor, Damages, defects or leakage in the mechanical part of diesel engine. Irregular adjustments of diesel injection pump: Injection timing Idle speed (idle injection quantity), Maximum injection quantity, Governor, Etc. Faulty adjustment of opening pressure of injection nozzles c. Testing procedures: Visibility tests of tubes, hoses and wiring connections for leakage, defects, condition and fastenings, Tests of start ability of diesel engines Leakage of fuel supply system/ filter system Injection timing, Minimum starting speed, Maximum speed Diesel exhaust smoke test, Pressure tests of lift pump, injection pump and transfer pump Pre-heating system. Valves, cylinders, combustion chamber and if necessary pre-combustion chamber Tests of injection nozzles for proper operation Etc Testers: (Diesel engine testers, Voltmeter, Ammeter, Injector pop tester, End-scopes, Stroboscopic, Timing light, Smoke meters and Pressure gauges)
- Carry out necessary tests with the aid of diesel engine testers to localise sources of fault.
- Perform the repair work and final adjustment. r work and adjustment: Bleeding of the injection system. Repair work / replacement of: Supply lines Injection lines Return lines Fuel filter Hoses Injection nozzles Overflow valves Adjusts injection pumps installed on the diesel injection pump bench with the aid of technical data specially: Equal fuel supply, Supply fuel stroke, Full load quantity, Start quantity,
Department: Mechanical Technology Injection timing, Engine speed control Repair work of distributor and in-line injection pumps with the aid of special tools through replacement of the following components e.g. Injection elements, Came plate, Control spring, Injection timer spring, Bearing, Injection pump elements, Delivery valves Repair work/ replacement of glow plugs Glow plug system control module Glow plug relay Pre-resistor Final adjustment of: Minimum starting speed Maximum speed Injection timing.
Major: Vehicles
Major: Vehicles
Minor Field Courses

There are four groups each representing a Minor Field in the Major of Automotive Technology. The student may chose only one of them, and if necessary, the Department Committee may introduce additional groups following the same manner. The First Group is Computer Engine Management , and includes two courses as follows: Course Computer Engine Management Electronic Diagnosis Equipment L 2 2 W 2 2 Credit hrs 3 3
The Second Group is Diesel Engines , and includes two courses as follows: Course Electronic Diesel Fuel Systems Diesel Engines L 2 2 W 2 2 Credit hrs 3 3
The Third Group is Automotive Intelligent Systems , and includes two courses as follows: Course Auxiliary Comfort and Safety Systems Electronic Transmission and Suspension L 2 2 W 2 2 Credit hrs 3 3
The Fourth Group is Heavy Duty Vehicles , and includes two courses as follows: Course Heavy Duty Vehicles air Brake Systems Hydraulic and Pneumatic Control Systems L 2 2 W 2 2 Credit hrs 3 3
Major: Vehicles
Department Mechanical Technology Course Title Computer Engine Management (Elective 1 - Course I) Prerequisite Petrol Engine Fuel Systems, & Ignition Systems
Semester Course Description : The principles of combined Computer Engine Management. Components and functions of various types of combined fuel and ignition computer controlled systems. Fault diagnosis and repairs on these systems. Credit hr/w
Major Code
1 2
Vehicles MEV 331

3 4 5 6 3 2 2 30 30
L Contact hr/w W T L Contact hr/sem. W T
General Goal : This course provides the knowledge about Computer Engine Management systems, and gives practical experience and skills required for carrying out diagnosing and repair work of these systems with suitable test equipment. Behavioral Objectives : By the end of this course, the student will be able to: Explain main advantages of combined fuel- and ignitions computer controlled systems Explain formation of pollutants
Classify different emission control systems
Identify all components of various Engine Management Systems and explain their functions Carry out fault diagnosis, testing- and repair work with the aid of modern test equipment
Topics: Theory: Principles of fuel injection and ignition management Principles of automotive micro computers Principles of emission control Computer Engine Management systems, components and their functions Practice: Workshop: Fault diagnosis, testing procedures and repair of engines with Computer Engine Management (combined fuel- and ignition computer controlled systems): 1- Various procedures of computer trouble code retrieval 2- System and component inspection with engine tester and multi-meter 3- Inspection of exhaust gases
Major: Vehicles
Textbook:
William L. Husselbee, Automotive Computer Control Systems, Fundamentals and Services, Harcourt Brace Jovanovich Publishers, ISBN 0 15 504355 2
Additional Reading:
Manufacturers data and repair manuals Automotive journals and magazines
References:
Haynes Techbooks: Automotive Computer Codes / electronic Engine Management Systems, ISBN 1 56392 232 Fuel Injection, 1986 thru 1996, ISBN 1 56392 233 Automotive Emissions Control, ISBN 1 85010 667 Bosch Technical Instructions: Motronic Engine Electronics Emission control for Spark-Ignition Engines 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 / Electronic Systems, 2nd edition, 1995, ISBN 1-56091-596-X William H. Crouse and Donald L. Anglin, Automotive Mechanics The McGrawHill Book Company, ISBN 0-02-800943-6 Martin, W. Stokel and Martin, Auto Mechanics Fundamentals, The GoodheartWillcox company, INC, ISBN 1-56637-138-4 , 1996 Martin W. Stokel, Martin T. Stokel Chris Johanson Auto Fundamentals The Goodheart Willcox company, INC, ISBN 1-56637-138-4 , 1996 William, K. Toboldt, Larry Johnson, and W. Scott Gavthier, Automotive Encyclopaedia Fundamental, Principles, Operation, Construction, Service, and Repair, The Goodheart -Willcox company, INC , ISBN 1-56637-150-3 , 1995 Duffy, James E., Auto Engines The GoodheartWillcox company, INC, ISBN 087006-677-3 Jack Enjavec and Robert Scharff Automotive Technology Delmar Publishers, An International Thomson Publishing Company.
Major: Vehicles

The student should be able to: 2 Principles of Fuel injection and ignition management: Excess Air factor Ignition timing and its influence to power, consumption and exhaust emissions - Describe operation principles of fuel injection and ignition management, the importance of exact air ratio and optimized ignition timing - Explain operation principles of automotive micro computers
Principles of Automotive micro computers Input signal and input signal sources Processing information Output devices Open- and closed-loop control
Principles of Emission Control Formation of pollutants Characteristics of pollutant components The relations of excess air factor and ignition point on pollutant emissions and fuel consumption Lambda closed-loop control Catalytic exhaust treatment Exhaust gas recirculation, Etc.
- Explain the formation and characteristics of pollutants. - Explain the relations between Lambda, ignition point and formation of pollutants and fuel consumption. - Draw the lambda closed-loop control system. - Explain the influence of gas recirculation and catalytic converter on exhaust gas reduction.
Computer Control Sensors and Actuators. 4.1- Engine Sensors : Construction and function of different sensors used in Computer Engine Management systems Manifold absolute pressure (MAP) sensor, Vane air-flow sensor, Mass-air-flow sensor (hot-wire, hot-film,), Air- and engine temperature sensors, Throttle position sensor and throttle valve switch, Oxygen sensor, Crankshaft- and camshaft-position sensor (engine speed sensor), Knock sensor, Etc.
- Explain construction and function of various different sensors used in Computer Engine Management Systems.
Major: Vehicles
4.2- Engine Control Actuators : Construction and function of different actuators used in Computer Engine Management systems. Fuel injectors Idle speed control Canister purge valve Exhaust gas recirculation valve Fuel pump control Ignition control Boost-pressure control for turbo-charged engines
- Explain construction and function of various different actuators used in Computer Engine Management Systems.
12
Computer Engine Management Systems: Function of different computerized engine control sub-systems of various Computer Engine Management Systems e.g.: Motronic, and Mono-Motronic (Bosch) PFI, (GM motors) EEC, (Ford motors) TCCS, ECCS Etc Operation of the system for: Cold starting Post-start phase, Warm-up Idle-speed control Idle-mixture control Full-load enrichment Overrun fuel cut-off Acceleration enrichment Engine-speed limiting Electronic accelerator Cylinder cut-out Fuel induction and emission control Evaporative emission control, fuel vapour canister Overheating and ping-protection Ignition control depending on engine temperature Electronic dwell-angle control Electronic spark advance Electronic closed-loop dwell-angle control, primary-current limiting and stationaryengine cut-off Electronic knock control and emission Lambda closed-loop control
- Explain the functions of different computerized engine control subsystems of various Computer Engine Management Systems.
- Explain the operation of the different engine control subsystems of each Computer Engine Management System to control : fuel injection pulse time spark ignition timing and dwell time, according to different engine operating conditions.
Major: Vehicles

Workshop
4 Electronic engine management system components and functions
The student should be able to: - Distinguishes various types of electronic engine management systems, - Explain system components and their functions. - Explain possible faults of the computer engine management systems - Develops a fault diagnosing strategy to identify the fault causes.
26
Development of fault diagnosis strategy for various electronic engine management system failures on an engine. Using a running engine diagnose one of the following Problems in detail e.g.: Engine will not start, Idle speed uneven, Engine misfires Poor acceleration, Poor engine power Excessive exhaust smoke Hard starting in cold engine condition, Hard starting in hot engine condition, etc. Assuming that these problems are due to one or more of the following causes in the electronic engine management system: Damaged, worn, loose or incorrect operation of compo-nents: Electric fuel pump, line pressure or fuel pressure regulator, air flow sensor, or air mass sensor, MAP sensor, Fuel injectors Cold start injector, Auxiliary air valve or idle actuator, Throttle valve switch, Throttle valve position sensor Electronic control unit (ECU), Water temperature sensor Engine temperature sensor Start injector time switch, Circuit opening and fuel pump control relay, Ignition coil, Ignition distributor with ignition timing Crankshaft and camshaft position sensor Knock sensor
- Identify the possible causes related to the trouble.
Department: Mechanical Technology High tension wiring, Electrical plug-and-socket Connections faulty, loose or incorrectly joined etc. Carrying out following tasks to locate the cause of trouble: Fault code reading with diagnostic tester and blink codes. Fault identification, of faults not represented by trouble codes in the memory of ECU, with engine tester and multi-meter to identify e.g.: Faulty sensors Faulty actuators Broken connections and cables Connector loose Connector corroded High resistance in connectors and cables Faulty relays No supply voltage Faulty ECU Etc Replacement or repair of faulty components with the aid of technical manuals
Major: Vehicles - Carry out inspection and testing of the electronic engine management systems to locate faults using different inspection techniques and equipment
- Carry out repair and adjustment work with suitable tools and test equipment including final inspection
Major: Vehicles
Department Mechanical Technology Course Title Electronic Diagnosis Equipment (Elective 1 - II) Prerequisite
Semester Course Description : The principles of different types of electronic testing and diagnosis equipment; operation procedures, suitable applications limitations, and maintenance operations. Practical applications on their proper use for trouble shooting. Credit hr/w
Major Code
1 2
Vehicles MEV 332

3 4 5 6 3 2 2 30 30
General Goal : This course gives the knowledge about various types of electronic diagnosis equipment. It provides the practical experience and skills required for their proper use on engines with Computer Management systems. Behavioral Objectives : By the end of this course, the student will be able to: Explain the necessity for different electronic diagnosis equipment. Explain the functions of different test equipment and their limitations. Use the required test equipment in the proper way Describe and perform the necessary maintenance work of the equipment Choose the proper equipment for a certain type of job operation Carry out fault diagnosis, testing and repair work with the aid of modern electronic equipment.
Topics: Theory: Principles of different types of test and diagnosis equipment including functions, operation, suitable applications, limitations, and maintenance operations of: 1- Multi-meters, 2- Electronic Engine Analysers and testers, 3- Electronic Scan Tools, 4- Break-out box (BOB), 5- Exhaust gas analysers. Practice: Workshop: The proper use of electronic fault diagnosis equipment, testing procedures through practical applications on real engine problems, and equipment maintenance operations of: 1- Multi-meters, 2- Electronic Engine Analysers, testers and tuneup equipment 3- Electronic Scan Tools, 4- Break-out boxes (BOB) 5- Exhaust gases analysers,
Major: Vehicles
Textbook:
Engine management and fuel injection systems manual, Haynes Publishing, ISBN 1 85960 344 0 Equipment technical manuals
Additional Reading:
References:
Haynes Technical books: 1- Automotive Computer Codes / electronic Engine Management Systems, ISBN 1 56392 232 2- Fuel Injection, 1986 thru 1996, ISBN 1 56392 233 3- Automotive Emissions Control, ISBN 1 85010 667 Bosch Technical Instructions: 1- Motronic 2- Engine Electronics 3- Emission control for Spark-Ignition Engines Duffy, James E., and Smith, Howard B., Auto Fuel and Emission Control Systems Technology, The Goodheart-Willcox company, INC, ISBN 0-87006932-2 Robert Bosch GmbH Automotive Electric / Electronic Systems, 2nd edition, 1995, ISBN 1-56091-596-X William H. Crouse and Donald L. Anglin, Automotive Mechanics The McGrawHill Book Company, ISBN 0-02-800943-6 Martin, W. Stokel and Martin, Auto Mechanics Fundamentals, The Goodheart-Willcox company, INC, ISBN 1-56637-138-4 , 1996 Martin W. Stokel, Martin T. Stokel Chris Johanson Auto Fundamentals The Goodheart Willcox company, INC, ISBN 1-56637-138-4 , 1996 William, K. Toboldt, Larry Johnson, and W. Scott Gavthier, Automotive Encyclopaedia Fundamental, Principles, Operation, Construction, Service, and Repair, The Goodheart -Willcox company, INC , ISBN 1-56637-150-3 , 1995 Duffy, James E., Auto Engines The GoodheartWillcox company, INC, ISBN 0-87006-677-3 Jack Enjavec and Robert Scharff Automotive Technology Delmar Publishers, An International Thomson Publishing Company.
Major: Vehicles

Hrs Contents Behavioral Objectives The student should be able to: 4 Electronic Multimeters: Principles of operation Types; analog and digital multimeters Functions, Ranges and accuracy Electronic Engine Testers and Analysers Different types; Engine testers, Engine analysers, Oscilloscopes, Lab-top Engine analysers Principles of operation Various functions, Attachments, Test procedures. Electronic Scan Tools and Fault Code readers Various types, Functions, Connections, and attachments, Reading and abbreviations, Tests and test procedures Break-out boxes (BOB) Different types, Attachments Exhaust gas analysers Types Functions, Ranges and accuracy Handling, maintenance and calibration - Describe the necessity, functions, different types, ranges, accuracy and suitable applications of different types of electronic diagnosing equipment - Explain operation principles of different electronic diagnosing equipment
12
Major: Vehicles

Workshop
4 Electronic Multi-meters: The proper use of different multimeters Applications on various vehicle systems to practice the measurements of various system components characteristics 12 Electronic Engine Testers and Analysers Applications on various vehicle systems to practice the proper use of different equipment types; Engine testers, Engine analysers, Oscilloscopes, Engine tests, e.g.; Complete test Cranking test High and low cruise test Power balance test Ignition and injection timing tests Primary and secondary ignition circuit tests Functional tests on different sensors, actuators and control units etc Engine analysis and diagnosis with testers-installed software Various attachments, 8 Electronic Scan Tools and Fault Code readers Functions, Connections, handling and attachments, Tests and test procedures Reading (Fault codes, engine management data stream),
The student should be able to: - Select the appropriate range, connect, measure values of system component characteristics and compare these values with the manufacturers specifications - Select the correct vehicle identification set-up and prepare the analyzer for testing - Connect the analyzer to the engine with the appropriate attachment cable set. - Carry out complete, individual and pin point tests with engine analyzers, oscilloscopes and multimeters - Print outs diagnosing and test results. - Carry out maintenance on test equipment
- Select the correct vehicle identification set-up and prepare the Scan tool for testing - Connect the Scan Tool to the engine with the appropriate attachment cable set. - Read out the stored fault codes - Read out data stream values of the engine management system and compare with normal values. - Connect the break-out box to the engine with the appropriate interface attachment multi-plug harness - Connect multi-meter and oscilloscope to the break-out box to measure input and output signals
2 Break-out boxes (BOB) Different types, Attachments
Department: Mechanical Technology 4 Exhaust gas analysers Proper use and connections Handling, maintenance and calibration
Major: Vehicles - Prepare the engine and the analyser for testing - Connect to the engine exhaust system - Carry out measurements and compare with the manufacture specifications - Print out the results - Carry out maintenance and calibration operations
Major: Vehicles
Department Mechanical Technology Course Title Electronic Diesel Fuel Systems (Elective 2 - Course I) Prerequisite
Semester Course Description : Electronically controlled diesel injection systems, advantages. Principles of operation, system components and their functions. Computer controlled injection pump types, construction and operation. Diesel injection sensors, solenoids and electronic governors. Electronic control of injection quantity and timing. Diesel engine electronic controls. Fault diagnosis, repair and adjustment of electronic diesel injection system. Credit hr/w
Major Code
1 2
Vehicles MEV 333

3 4 5 6 3 2 2 30 30
General Goal : To provide students with the necessary skills and knowledge to deal with electronic diesel fuel injection systems and to carry out diagnosis, testing, adjustment and repair work of these systems. The course completes and deepens the basic knowledge and skills on diesel injection systems. Behavioral Objectives : By the end of this course, the student will be able to: Explain the operation of electronically controlled diesel injection systems,
Describe the construction and operation of computer controlled injection pump, and electronic governors, Describe the operation of fuel shut-off solenoid, cold start solenoid, fast idle solenoid, and altitude advance solenoid Describe the function and operation of diesel engine sensors, Perform injection pump timing and TDC offset according to Service Manual procedures. Perform system diagnosis using electronic scan tools, and on-board diagnostic systems Carry out adjustment, repair and maintenance operations.
Topics: Theory: Electronic diesel fuel injection systems. Computer controlled diesel injection pumps. Diesel engine sensors. Diesel injection pump actuators and electronic governors. Electronic control of injection quantity and timing. Diesel engine electronic controls Practice: Workshop: System components and functions. Diesel diagnostic and scan tools Diagnosis, adjustment and repair of Diesel EFI systems.
Major: Vehicles
Textbook:
Heinz, Heisler, Advanced Engine Technology, Edward Arnold, ISBN 0 340 568224 Schulz, Erich j., and Evridge, Ben J., Diesel Mechanics, 3rd edition, Macmillan/McGraw-Hill, ISBN 0-07- 055836-1
Manufacturers data and repair manuals Additional Reading: Automotive journals and magazines
References:
Automotive Diesel Engine, Service Guide ISBN 1-85960-286X Martin W. Stokel and Martin Auto Mechanics Fundamentals The Goodheart Willcox company, INC ISBN 1-56637-138-4 , 1996 Stoekel, Stockel, and Johanson Auto Service and Repair The Goodheart Willcox company, INC William H. Crouse and Donald L. Anglin Automotive technicians Handbook The McGraw Hill Book Company Martin W. Stokel, Martin T. Stokel Chris Johanson Auto Fundamentals The Goodheart Willcox company, INC ISBN 1-56637-138-4 , 1996 Bosch Technical Instruction Series Delta Press Ltd 1981, English translation 1985 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 Scharff 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
Major: Vehicles

The student should be able to: 4 Electronic diesel fuel injection systems (EFI): Functional operation and advantages, System components and their functions, Supply pump Diesel filters Injection pump Injection nozzles Computer (electronic control module) Diesel engine sensors Injection pump actuators Glow plugs - Explain the operation of electronically controlled diesel injection systems, and the advantages of the system - Distinguish components of the system and explain their functions advantages
Computer controlled diesel injection pumps: Critical functions. Types and construction of: In line plunger injection pumps. Rotary-distributor injection pumps Time controlled single injector pumps Etc. Components and their functions Pumping plunger Metering sleeve Delivery valves Transfer pump Governor Injection timing advance mechanism Cam and drive shaft Engine power and speed control mechanism Operation and performance characteristics. Pressurisation Metering and distribution - Explain the computer controlled injection pump functions and types
- Describe the construction and function of computer controlled injection pump components
4 Diesel engine sensors Function and operation of engine sensors Crankshaft position (engine speed and TDC) sensor, Acceleration pedal position (APP) sensor, Engine coolant temperature (ETC) sensor, Metering valve sensor, Vehicle speed sensor, Injection nozzle sensor (optical sensor), Intake air temperature (IAT) sensor,
- Describe the operation and performance characteristics of the computer controlled injection pump - Explain the function and operation of different diesel engine sensors
Department: Mechanical Technology Fuel temperature sensor, Water in fuel (WIF) sensor Absolute pressure sensor (EGR control pressure BARO sensor) Cruise control signal Diesel engine sensors circuit diagrams.
Major: Vehicles
Diesel injection pump actuators and electronic governors Function and operation of injection pump solenoids ; Fuel shut-off solenoid, Cold start solenoid, Fast idle solenoid, Altitude advance solenoid Function and operation of injection pump servomotors; Fuel control motor Injection advance control motor Electronic governor function and operation Fuel metering control, Idle speed control, Engine speed limiting, - Explain the function and operation of injection pump solenoids, servomotors, and electronic governor .
Electronic control of injection quantity and timing. Diesel injection system computer (electronic control module ECM) Fuel control inputs and outputs, Injection timing control inputs and outputs
Diesel engine operation controls Engine power and speed control. Glow plug control inputs and outputs. EGR control inputs and outputs. Cruise control inputs and outputs. Booster control inputs and outputs. Transmission control inputs and outputs.
- Explain the function of the electronic control module (ECM) and how it controls the quantity of injected fuel, injection timing, engine speed and power according to various engine-operating conditions .
- Explain the role of the electronic control module (ECM) in the control of engine preheating, cruise, supercharging, and transmission operations.
Major: Vehicles

Workshop
2 Diesel electronic injection system components and their function
The student should be able to:
- Distinguish the diesel fuel electronic injection system components and define their operational functions. - Explain the function and demonstrate the use of diesel diagnostic and scan tools testing equipment.
Diesel diagnostic and scan tools
Diesel Electronic injection systems: 26 Trouble-shooting strategies, repair and adjustment work. a. Possible system faults: Use running diesel engines to simulate one of the following faults : Engine will not start or hard to start (cold and hot conditions) or engines starts then stalls. Low power or loss of power. Irregular engine running. Engine knocks evenly. Engine misfires or backfires. Engine black smoke. Excessive white smoke. Excessive engine vibrations. Excessive fuel consumption. Fail safe system signal. Etc. b- Possible causes: Assuming that these causes are well-founded in the electronic fuel injection system, relate the problem the possible causes as (one or more from the following) Incorrect fuel quality Incorrect fuel viscosity Faulty component in the electronic injection system: electric lift pump fuel filter injection nozzles Overflow valve Injection timer Fuel pump governor Diesel injection pump - Explain possible faults of diesel electronic injection systems and construct a fault diagnosis strategy to identify the fault causes.
- Identify the possible causes related to symptoms of the fault.
Department: Mechanical Technology Faulty engine sensor Crankshaft position (engine speed and TDC) sensor, Acceleration pedal position (APP) sensor, Engine coolant temperature (ETC) sensor, Metering valve sensor, Vehicle speed sensor, Injection nozzle sensor (optical sensor), Intake air temperature (IAT) sensor, Fuel temperature sensor, Water in fuel (WIF) sensor Absolute pressure sensor (EGR control pressure / BARO sensor) Cruise control signal Faulty injection pump solenoid ; Fuel shut-off solenoid, Cold start solenoid, Fast idle solenoid, Altitude advance solenoid Faulty injection pump servomotors; Fuel control motor Injection advance control motor Faulty electronic governor Fuel metering control, Idle speed control, Engine speed limiting, Faulty electronic control module (computer) Faulty components in the pre-heating system Glow plugs tips or glow plugs, Heater plug starting switch Glow plug system control module, Glow plug relay, Pre-resistor, Irregular adjustments of diesel injection pump Injection timing Idle speed (idle injection quantity), Maximum speed limit (maximum injection quantity), c. Fault detection tests: To locate the cause of trouble, the following inspection tests are carried out: 1. Visibility tests regarding leakage, damages and condition of components of the system 2. Carry out instrumental tests with the aid of suitable test equipment to check the operational function of system components: Check for diesel EFI computer fault codes Injection system and engine sensors tests EFI injection system actuators (solenoids and servomotors) tests Engine cylinder balance test Injection timing, Minimum starting speed,
Major: Vehicles
- Locate the cause of trouble, by carrying out: 1. visibility tests regarding leakage, damages and condition of components of the system. 2. instrumental tests using the suitable test equipment to check the operational function of diesel electronic injection system
Department: Mechanical Technology Maximum speed Diesel exhaust smoke test, Injection pressure tests Pre-heating system test Tests of injection nozzles for proper operation Etc. Testers: (diesel engine testers, voltmeter, ammeter Injector pop tester, stroboscopic, timing light, Smoke meters and pressure gauges and diesel Engine computer scan tools.) d- Repair work and adjustment: To erase the trouble of the system and restore its optimum performance, the following repair and adjustment are carried out 1. Repair of the diesel fuel electronic injection system by the replacement of faulty components, 2. Checking complete fuel injection systems with the help of test programs and carry out the final adjustment of: Pump injection timing Diesel engine idle speed Curb idle speed Cold idle speed Engine maximum speed Vacuum valve
Major: Vehicles
- Carry out repair of the diesel fuel electronic injection system by the replacement of the .Perform adjustment operations of the system by the replacement of the faulty components.
Major: Vehicles
Department Mechanical Technology Course Title Diesel Engines (Elective 2 - II) Prerequisite
Major Code
Vehicles MEV 334

1 2 3 4 5 6 3 2 2 30 30
Semester Course Description : Diesel engines principles, main components, characteristics, and various types. Diesel engines combustion characteristic, knocking, combustion chamber designs, supercharging and performance. Routine maintenance, fault diagnosis, adjustment and repair of diesel engines. Credit hr/w L Contact hr/w W T L Contact hr/sem. W T
General Goal : This course gives knowledge about diesel engines special features, performance, and applications. It provides practical experience and skills required for fault diagnosis, adjustment and repair with the use of suitable equipment. Behavioral Objectives : By the end of this course, the student will be able to: Describe the different types of diesel engines and their functions Identify special construction of diesel engine components Identify the characteristic of diesel fuel, Explain combustion stages of diesel fuel, diesel knocking, and different combustion chamber designs, Explain supercharging of diesel engines; types, advantages, system components, Describe the operation of two stroke engines, advantages, special construction, power calculations, performance, applications, Carry out fault diagnosis, adjustment, repair, maintenance and servicing operations
Topics: Theory: Diesel engines special characteristics Diesel engine combustion and knock Diesel Engines Combustion Chambers Diesel engine components and systems Supercharging systems in diesel engines Practice (Workshop): Introduction to diesel engine workshop Diesel engine routine maintenance and servicing Diesel engines fault diagnosis, adjustment and repair of: Engine mechanical components (engine block, cylinder, crank drive, valve system) Intake and exhaust systems and Supercharging system Lubricating, Cooling and Starting systems Diesel engine brakes and hydraulic retarders
Major: Vehicles
Heinz, Heisler, Advanced Engine Technology, Edward Arnold, ISBN 0 340 568224 Textbook: Schulz, Erich j., and Evridge, Ben J., Diesel Mechanics, 3rd edition, Macmillan/McGraw-Hill, ISBN 0-07- 055836-1
Additional Reading:
"Automotive Diesel Engine, Service Guide" ISBN 1-85960-286X Martin W. Stokel and Martin "Auto Mechanics Fundamentals" The Goodheart Willcox company, INC ISBN 1-56637-138-4 , 1996 Stoekel, Stockel, and Johanson Auto Service and Repair The Goodheart Willcox company, INC William H. Crouse and Donald L. Anglin Automotive technicians Handbook The McGraw Hill Book Company Martin W. Stokel, Martin T. Stokel Chris Johanson Auto Fundamentals The Goodheart Willcox company, INC ISBN 1-56637-138-4 , 1996 References: " Bosch Technical Instruction Series Delta Press Ltd 1981, English translation 1985 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 Scharff 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
Major: Vehicles

The student should be able to: 6 Diesel engines special characteristics: Principle of operation, thermodynamic cycles and pdiagram Construction and main components Control of diesel engine output power Various applications Calculation of diesel engine performance parameters: Air consumption and volumetric efficiency Engine torque and power Engine thermal efficiency Engine specific fuel consumption Diesel engines performance curves. - Explain the principles of operation of diesel engines and Describe their special features. - Calculate diesel engines performance parameters - Explain and interpret diesel engine performance curves
Diesel engine combustion and knock Diesel fuel characteristics: Fuel properties and classification Cetane number Fuel air ratio Smoke limit Low power limit Pressure-crank angle diagram Normal diesel combustion phases, Delay period and the influence of different factors Effect of injection rate diagrams on combustion Diesel knock and factors affecting diesel knock
- Describe diesel fuel characteristics - Explain the pressure crank angle p- diagram - Explain phases of normal combustion - Explain diesel knock and factors affecting its occurrence
Diesel Engines Combustion Chambers Combustion chamber design Open combustion chamber (Direct injection); Swirling action within open chambers, advantages and disadvantages Divided or pre- combustion chambers (indirect injection) Effect of turbulence on combustion efficiency and engine performance Pre-combustion chambers Swirl or turbulent chambers
- Describe the different types of diesel engine combustion chambers, design characteristics, advantages and disadvantages. - Influence of combustion chamber design on combustion efficiency and diesel engine performance
Major: Vehicles
Diesel engine components and systems: Diesel engine components; Cylinder block Crank shaft, camshaft and bearings Connecting rod, piston and rings Diesel engine brakes and hydraulic retarders Intake and exhaust systems Lubricating system Cooling system Starting system Electric starting Air and hydraulic starting Cold weather starting aids
- Describe the special features of diesel engine components and systems
Supercharging systems in diesel engines Principles of supercharging, different types, Effect of supercharging on engine performance Turbocharging, Computer controlled turbocharging
- Explain the principles of supercharging, types, and its influence upon diesel engine performance - Describe turbocharging and computer controlled turbocharging
Major: Vehicles

Hrs Contents Behavioral Objectives The student should be able to:
Workshop
2 Introduction to diesel engine workshop Workshop safety procedures Diesel engines components and systems Diesel engines diagnosing and testing equipment
- Describe safety procedures applied in testing and repairs diesel engine - Identify diesel engine systems and components
Diesel engine routine maintenance & servicing Important of routine maintenance Scheduling of diesel engine maintenance Lubrication system Fuel system Mechanical system esel engines fault diagnosis, adjustment and repair of : Engine mechanical components (engine block, cylinder, crank drive, valve system ) Supercharging system Diesel engine brakes and hydraulic retarders Intake and exhaust systems Lubricating, Cooling and Starting systems a. On an actual running diesel engine, the following problems are studied in detail: Engine turns but will not start Low cranking speed Difficult starting Misfiring / rough idle Lack of power Excessive fuel consumption Excessive oil consumption Engine knock Black smoke in exhaust Over heating Low or high pressure, etc. b. Apply these problems to one of the following causes assuming that these causes are well-founded in diesel engine: Poor compression Cylinder head or head gasket leakage, Damaged or worn components, e.g.
- Carry out diesel engines routine maintenance and servicing work
24
- Carry out fault diagnosis and develop trouble shooting flowchart - Carry out the necessary repair work
Department: Mechanical Technology Cylinder Piston, piston rings, piston pins, valves, valves seats, valve guides, valve actuating mechanism, camshaft crankshaft-, camshaft- or connecting rod bearings, Faulty pre-heating system Defective cold start advance mechanism, Valve clearance adjustment incorrect, Valve timing gear incorrect, Leakage in injection nozzles, Injection timing incorrect, Disconnection of glow plugs, Incorrect engine oil grade Turbocharger jammed, Etc. c. Carry out following tasks: Develop a trouble shooting flowcharts Choose the suitable test equipment Identify the damaged or wear engine parts Carries out required repair work as described in the maintenance and repair Manuals Carries out final check.
Major: Vehicles
Major: Vehicles
Department Mechanical Technology Course Title Auxiliary Comfort and Safety Systems (Elective 3 - I) Prerequisite Automotive Electric Systems and Circuits Semester Course Description :
The principles of operation of air conditioning systems; components, and various control systems. Different electrical operated comfort systems and wiring diagrams. Electrical operated safety systems including air bags and warning systems. Aspects of fault sources, and plans of trouble shooting. Diagnosis, repair and adjustment of comfort, safety and air conditioning systems. Credit hr/w L Contact hr/w
Major Code
1 2
Vehicles MEV 335

3 4 5 6 3 2 2 30 30
W T L
Contact hr/sem.
W T
General Goal :
This course provides the knowledge about air conditioning systems, various electrical operated comfort and safety systems. It develops the skills required to carry out tests, adjustment and necessary repair work for these systems with the help of wiring diagrams and modern testers..
Behavioral Objectives :
By the end of this course, the student will be able to: Explain the construction and operation of air conditioning systems. Explain different types of air conditioning control systems. Draw and read electrical wiring diagrams of these systems.
Distinguish between different types of compressors, condensers, protection and control switches. Explain the construction and operation of different electrical operated comfort and safety systems. Develop trouble - shooting strategies, localise faults systematically, carry out repair and testers.
adjustment work for comfort, safety and air conditioning systems with the aid of wiring diagram and
Topics: Theory:
Air conditioning systems Electrical operated comfort systems Electrical operated safety systems
Practice (Workshop):
Fault diagnosis, repair and adjustment of : Air conditioning systems Electrical operated comfort systems Electrical operated safety systems
Major: Vehicles
James E. Duffy, Auto Electricity, Electronics, Computers, The GoodheartWillcox Company Inc., ISBN Textbook: John Deere, Electrical Systems, Fundamentals of Service, ISBN 0-86691047-6
Additional Reading:
Harcourt Brace Jovanivich, 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 1-56637-144-9 Robert Bosch GmbH, Automotive Handbook, ISBN 0-89 283-518-6 Harper and Row, Automotive Electrical Systems, Classroom Manual, Check-Chart Automotive Series Martin W. Stokel and Martin "Auto Mechanics Fundamentals" The Goodheart Willcox company, INC ISBN 1-56637-138-4 , 1996 William H. Crouse and Donald L. Anglin Automotive technicians Handbook The McGraw Hill Book Company " Robert Bosch Gmbh Automotive Handbook Published by VDI- Verlag, 1996
References:
Major: Vehicles

The student should be able to: 10 Air conditioning system Operation Cooling capacity Magnetic clutch Protection and control switches Compressor types Condensers Accumulator and receiver Suction pressure control valve Electric circuits and various control systems related fault sources and various causes Explain the construction and operation of the air conditioning systems, Distinguish between different types of compressors, condensers, clutches, protection and control switches. Draw and read wiring diagrams and explain different types of control systems.
Electrical Operated Comfort Systems 10 Central locking Power windows Power seats Cruise control systems related fault sources and various causes
Explain the construction and operation of electrical operated comfort systems, Draw and read electrical wiring diagrams of these systems, identify fault sources and related causes.
10
Electrical Operated Safety Systems Low tyre pressure warning system Low oil level warning system Brakes lining wear warning system Air-bag systems control module, impact sensor, coil assembly and inflator module air bag operation and electrical circuit related fault sources and various causes
Explain the construction and operation of electrical operated safety systems, draw and read electrical wiring diagrams of these systems, Identify fault sources and related
Major: Vehicles

Hrs Contents Behavioral Objectives The student should be able to:
Workshop
10 Air Conditioning system: 1.1 System components
Identify components and electrical circuits of air conditioning systems.
1.2 Trouble-shooting strategies, adjustment and repair work. a. Fault simulation: Use actual cars and running models to simulate Consequently one of the following faults : Inoperative air conditioning system Poor cooling effect Fixed cooling range Etc b- Possible causes: (one or more from the following) Switch defective Broken or loose drive belt Coolant circuit leakage Relay defective Components defective damaged or worn : Compressor, Condenser, Evaporator, high pressure switch, expansion valve, etc.. Electrical / electronic system : Blown fuses, plug and socket connections faulty, relay defective, electronic control unit faulty, faulty blower or supplemental blower motor non operable magnetic valve or clutch temperature sensor defective etc.. c- Testing procedures: Tests of electrical parts and wiring connections Checking of drive belt tension Checking of compressor, mountings, filter, condenser and evaporator for damages and looseness. Test of leakage on cooling circuit Measurement of pressure at suction hose (low pressure) and at liquid hose (high pressure) Etc. d- repair work and adjustment Explain the working conditions of an air conditioning system under a simulated fault. Identify possible causes related to this fault. Carry out the necessary tests with the aid of testers and circuit diagrams. Locate sources of faults, and perform the repair work and final adjustment
Department: Mechanical Technology Repair work / replacement of: Fuses and electrical wiring connections Electrical circuits components Operating system System discharging Filter Expansion valve Compressor Vacuum hoses Non return valve High pressure switch System charging , etc.
Major: Vehicles
20
2. Comfort and safety electrical equipment : Central locking Power windows Power seats Cruise control systems Low tyre pressure warning system Low oil level warning system Brakes lining wear warning system Air bag systems 2.1 Trouble-shooting strategies, adjustment and repair work. a. Fault simulation: Use actual cars and running models to simulate consequently one of the following faults : No door lock of central locking system can be unlocked and / or locked Only one door lock can be unlocked or locked All electrically driven power windows can be opened and / or closed One windows can be opened and / or closed Power seat partly inoperable or only on side operable. Electrical sliding sun-roof cannot be opened and / or closed Cruise control will not store the actual driving speed Cruise control will not hold driving speed or indicates incorrectly Cruise control will not turn off when braking No signals, false / true signals from : Tyre pressure display lamp, oil level display lamp, brake lining condition display lamp Air bag cannot be opened and / or closed, etc. b- Possible causes: (one or more from the following) Blown fuses Switch defective Plug-and-socket connections faulty Electrical motors inoperable Relay defective
Identify different components and electrical circuits of comfort and safety equipment. Explain the working conditions of comfort and safety electrical equipment under a simulated fault.
Identify possible causes related to these faults. Carry out necessary tests with the aid of circuit diagrams and testers. Locate sources of faults, and perform the repair work and final adjustment
Department: Mechanical Technology Door operating (locking) mechanism damaged or worn Seat adjustment mechanism or guide rails damaged or worn. Sliding sun-roof guides damaged or worn Speed sensor or control unit of cruise control defective. Tyre pressure sensor defective Air bag impact sensor defective Etc
Major: Vehicles
c- Testing procedures: Tests of fuses and electrical wiring connections Measurements of power supply, power consumption and resistance of electrical loads and circuits with the help of test lamp, voltmeter and ohmmeter. Electrical circuits components including plugs, sockets, relays, switches, motors, sensors, actuators and control units, System operating mechanism, etc.... d- repair work and adjustment Repair work / replacement of: Fuses and electrical wiring connections Electrical circuits components Operating mechanisms
Major: Vehicles
Department Mechanical Technology Course Title Electronic Transmission and Suspension (Elective 3 - II)
Semester Course Description : The principles of operation of different controllable suspension and electronic transmission systems. Functions and components of electronic transmission systems including hydraulic and electronic circuits. Automatic level control, electronic damping control and active suspension systems. Fault diagnosis, repair and adjustment of various parts of controlled suspension and transmission systems. Credit hr/w L Contact hr/w
Major
Code
Vehicles MEV 336
Prerequisite Automotive Transmission , Automotive Suspension and Steering Systems

1 2 3 4 5 6 3 2 2 30 30
W T L
Contact hr/sem.
W T
General Goal : This course provides the recent knowledge about various controlled suspension and transmission systems and develops the skills required to carry out tests, adjustment and necessary repair work for these systems with the help of modern testers and scan-tools.
Behavioral Objectives :
By the end of this course, the student will be able to:

Differentiate and compare between different types of electronic transmission systems and describe their advantages to conventional systems Explain the functions and characteristics of electronic transmission systems Explain the advantages of modern controllable suspension systems. Distinguish between different methods of controlling a suspension system. Explain different constructions and operation of various controlled suspension systems. evelop trouble shooting strategies, localise faults systematically, carry- out repair and adjustment work with the aid of modern testers and scan-tools.
Major: Vehicles
Topics Theory: 1. Electronic Transmission Systems 2. Electronic Suspension Systems . Practice (Workshop): Fault diagnosis, repair, adjustment and maintenance of: Different Electronic Transmission Systems Different Electronic Suspension Systems Self-levelling systems Electronically operated shock absorbers
James E. Duffy, Auto Electricity, Electronics, Computers, The Goodheart-Willcox Company Inc., ISBN Textbook: John Deere, Electrical Systems, Fundamentals of Service, ISBN 0-86691-047-6
Additional Reading:
Harcourt Brace Jovanivich, 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 1-56637-144-9 Robert Bosch GmbH, Automotive Handbook, ISBN 0-89 283-518-6 References: Martin W. Stokel and Martin "Auto Mechanics Fundamentals" The Goodheart Willcox company, INC ISBN 1-56637-138-4 , 1996 William H. Crouse and Donald L. Anglin Automotive technicians Handbook The McGraw Hill Book Company " Robert Bosch Gmbh Automotive Handbook Published by VDI- Verlag, 1996
Major: Vehicles

Hrs Contents Behavioral Objectives The student should be able to: Summarize the functions of automatic transmission systems with different planetary gear sets. Explain main differences between various electronic transmission systems and underline the advantages to conventional systems. Explain the construction and function of a slip-controlled torque converter. Explain the system and function of the hydraulic control unit with the brakes and clutches. Sensors List and classify different sensors used in electronic transmission systems. Explain the various types of shifting-programs and their functioning.
16
1. Electronic Transmission Systems Recapitulation and consolidation of Automatic Transmission Systems and different planetary gear sets Overview, comparison and advantages of different electronic transmission systems
Slip-controlled torque converters
Hydraulic control unit, brakes and clutches
Electronic Control Unit (ECU) with adaptive transmission control systems
2. Controlled Suspension Systems: 14 2.1 Advantages of controlled suspension systems Vehicle support, stability and direction control during handling manoeuvres effective isolation from road disturbance and ride comfort. 2.2. Methods of suspension movement control. automatic level control electronic damping control active suspension control Explain how it is impossible for a passive suspension system to cover all conflicting requirements and identify the need for using controllable suspension systems. Distinguish between different methods of suspension control, and explain the advantages and disadvantages of each method.
Major: Vehicles
2.3. Automatic level control systems. automatic level control operation height control sensor vacuum operated air compressor pressure regulator valve over-travel valve level control system dryer unit. related fault sources and various causes 2.4. Electronic damping control (EDC) system Adjustable shock absorbers soft and firm modes of operation various sensors (steering sensors, brake sensor, acceleration signal sensor, etc) control module air controlled shock absorbers hydraulic controlled shock absorbers including the solenoid valve Continuously variable e shock absorbers Related fault sources and various causes 2.5. Active suspension systems damping control procedures stiffness control procedures various sensors including on-board gyroscope yaw sensor. The control unit Hydraulic pumps and accumulators Hydraulic actuators (single acting, double acting types)
Explain the construction and operation of various components of controlled suspension systems, and identify fault sources and related causes. (topics 2.3 to 2.5)
Major: Vehicles
Department Mechanical Technology Course Title Heavy-Duty Vehicle Air Brake Systems (Elective 4 - I) Prerequisite Automotive Brakes Semester
Course Description : Principles of operation of heavy-duty vehicle air brake systems, characteristics, various types, components and functions. System performance, and calculations. Air brake circuits. ABS for air brake systems, components and operating principles. Fault diagnosis, repair, adjustment and maintenance. Credit hr/w L Contact hr/w W T L Contact hr/sem. W T
Major Vehicles
Code MEV 337
6 3 2 2 30 30
General Goal : This course gives knowledge of air brake system technology applied to heavy-duty vehicles. It also provides the practical experience and skills necessary to perform fault diagnosis, repair, adjustment, and maintenance operations. Behavioral Objectives : By the end of this course, the student will be able to: Distinguish different types of air brake systems, their advantages and disadvantages. Explain and interpret air brake systems, types, components and their functions. Calculate braking force, pressure and stopping distance. Explain air brake circuits, and service, parking and emergency brakes. Demonstrate the use of safety procedures applied in testing and repairing air brake systems. Show how to use technical manuals to find proper data required for adjustment & repairing procedures. Carry out fault diagnosis, maintenance and repair Prepare evaluation report for compressed air brake system performance.
Topics: Theory: Principle of heavy-duty vehicle air brake systems. - Air brake system characteristics, components and functions. Air brake systems performance and calculations. Air brake circuits. Wheel brake components ABS for air brake system. Practice (Workshop): Air brake systems circuits and components Diagnosis, faults trouble shooting, visual and instrumental inspection, repair and adjustment of heavy-duty air brake systems.
Major: Vehicles
Textbook:
Thomas W. Birch Automotive Braking Systems Harcourt Brace Jovanovich College Publishing, 1988, ISBN 0-15-5043643 Robert ScharffComplete Brake systems Delmar Publisher, Inc, 1989
Additional Reading:
Martin W. Stokel and Martin Auto Mechanics Fundamentals The Goodheart Willcox company, INC, ISBN 1-56637-138-4 , 1996 Stoekel, 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 technicians Handbook The McGraw Hill Book Company, ISBN 0-07014751-5 Martin W. Stokel, Martin T. Stokel Chris Johanson Auto Fundamentals The Goodheart Willcox company, INC ISBN 1-56637-138-4 , 1996 References: Bosch Technical Instruction Series Delta Press Ltd 1981, English translation 1985 Compressed Air Brake Systems, Symbols Compressed Air Brake Systems, Equipment Compressed Air Brake Systems, Schematic Diagrams 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
Major: Vehicles

The student should be able to: 4 1. Principles of heavy-duty vehicle air brake systems Pneumatic in automotive Graphic symbols of single components Circuit diagram of an air brake systems Explain functions and the operation of heavy-duty vehicles air brake systems.
8 Compressed air brake system components 2.1 Compressed air supply components Air compressor Pressure regulator Antifreeze pump Four-circuit safety valve Air reservoir Drain valve Monitoring switch ervice brake system components Service-brake valve Load-sensing valve Brake cylinder Combination brake cylinder Parking brake system components Non-return valve Parking-brake valve Relay valve Monitoring switch Height-control Trailer control system components Trailer control valve Coupling head supply Coupling head brake
Describe air brake system components and their functions.
Braking performance and calculations. 4 Braking deceleration Retardation Total braking time and distance Braking characteristic Braking efficiency
Calculate braking force, pressure, time, distance and efficiency.
Major: Vehicles
Compressed air brake system circuits: 8 Single-circuit, power assisted air brake system, Dual-circuit, air power brake system (low pressure) with mechanical parking brake: construction and operating principle. Dual-circuit, compressed-air power-brake system (low pressure) with no-linkage parking brake Dual-circuit, compressed air power brake system (high pressure) with no-linkage parking brake Dual-circuit, dual line compressed air power brake system (low pressure) for trailer operation with no linkage parking brake. Single-circuit, dual line compressed air trailer power brake system (low pressure) with mechanical parking brake.
Explain different types of air brake circuits.
Wheel Brake components Drums and disks Shoes and brake plate and lining /pad 2 ABS for heavy duty vehicles air brake system Why the ABS? Control principles ABS components: Wheel-speed sensor, Electronic controller, Pressure-control valve Operating principle
Describe different types of wheel brakes
Explain the operation and components of air brake systems provided with ABS system.
Major: Vehicles

Workshop
4 1. Introduction Safety measures Air brake system circuits and components
The student should be able to: Identify components of air brake system
18
2. Fault diagnosis, adjustment, repair and maintenance of : Energy supply components Operation components Transmission components Brake components. ABS for air brake system a- Study the following problems in detail Compressed air pressure reads Low High compressor oil consumption High compressor temperature with noise Pressure regulator does not cut-off when the engine is idle Relative short time between cut-on and cut-off Air leaks through the atmospheric air vent Air leaks through the over flow air port when the engine is not running The pressure regulator does not supply the compressed air to the reservoirs or a little amount of air is reached. Four-Circuit Protection Valve - Unequal and irregular circuits filling - Unsafe supply operation of compressed air Air leaks through the atmospheric air vent One or more circuits do not open Build up braking pressure is not smooth In braking position the air leaks through the ventilation port Very high initiation pressure The arm does not self-return from braking position to idle position Inlet valve is not properly closed, or piston sealing ring worn off
Explain the working conditions of an air brake system with and without ABS under a simulated fault.
Identify possible causes related to this fault. Carry out the necessary tests with the aid of testers and circuit diagrams. Locate sources of faults, and perform the repair work and final adjustment
Major: Vehicles
Valve does not pass the air easily, or grease is glued, or piston is sealed. Pressure calibration board values could not be reached In braking position air leaks through the pressure equalizing vent air leaks through the brake cylinder Very high pressure is needed to release the hand brake Air leaks through the ventilation port of the cylinder diaphragm The brake cylinder warning lamp goes off very late or earlier that it should do The brake cylinder warning lamp does not work when the brake cylinder is empty from compressed air c. b- Possible causes: Compressor: The belt is worn off or broken, or one of the valves is not shut properly, or head gasket is worn off, or piston pressure rings is worn off, or pressure hose connections are blocked. The filter is dirty, or the pressure in the entrance port is very low, or pressure rings are worn off. Lubricating oil is not in a good condition, or hoses to pressure regulator are blocked, or pressure regulator does not cut-off. Pressure regulator: the air chamber is blocked or the diaphragm gasket of the outlet valves is worn off, or control piston is sealed or frozen. Pressure regulator is not properly sealed, or hoses connected to pressure regulator are not fitted properly. Cup seal of the control valve is not properly sealed Non return valve in the pressure regulator is not properly closed Pressure regulator filter is dirty, or control piston is sealed, or pressure regulator is frozen. Four-Circuit Protection Valve and its springs become difficult to pass air to circuits. Valve does not close. Diaphragm or piston sealing rings is worn. Opening pressure is not set properly, or valve supplies air with difficulty Etc.
c- Repair work and adjustment Carrying out required repair work by repair or replacement of necessary components.
Major: Vehicles
3. Wheel brakes: Poor brake performance Brakes pull to one side when braking Excessive brake noise Relate these problems to the possible causes and carry the necessary repair work
4. ABS for air brake system: ABS-warning light is off when switching on ignition switch ABS-warning light is on or temporarily on when driving, etc. Relate these problems to one or more of the following causes: Warning light defective Poor power supply of electrical loads Plug-and-socket connection faulty Switch defective Motor- or solenoid valve relay not functional Electrical control unit defective Wheel speed or acceleration sensor defective Incorrect clearance of the wheel sensor Impulse device defective or loose Etc. Carry out following tasks: Develop a trouble shooting flowcharts Choose the suitable test equipment Identify the damaged or wear circuits parts Carry out required repair work such as in the maintenance Manuals Carry out final check.
Major: Vehicles
Department Mechanical Technology Course Title Hydraulic and Pneumatic Control Systems (Elective 4 - II) Prerequisite Semester
Course Description : The principles of control systems. Basics of fluid mechanics. Hydraulic and pneumatic control systems, components and performance. Hydraulic and pneumatics control applications in heavy duty vehicles and equipment. Credit hr/w L Contact hr/w W T L Contact hr/sem. W T
Major Vehicles
Code MEV 338
6 3 2 2 30 30
General Goal : This course provides the students with the knowledge about hydraulic and pneumatic control systems, and their applications in heavy-duty vehicles and equipment.. Behavioral Objectives : By the end of this course, the student will be able to: Explain and Interpret the basics of fluid mechanics. Explain the principles of automatic control concepts. Describe the importance of various control systems and difference between these systems Describe the hydraulic and pneumatic control systems. Explain system components operation, performance, and fields of application. Describe symbols, and block diagrams of hydraulic and pneumatic control systems Explain the applications of hydraulic and pneumatic controls in the heavy duty vehicles Describe their system components, construction, operation and performance. Explain the block diagrams of these applications Carry out experiments to determine performance characteristicses of hydraulic and pneumatic systems.
Topics: Theory: Basics of Hydraulics and Pneumatics. Principles of Automatic Control and Control Systems Basics of Hydraulic and Pneumatic Control Systems Heavy Duty Vehicles and Equipment Applications Practice (Laboratory): 1. Hydraulic and pneumatic control system components, Basic hydraulic and pneumatic control systems Heavy duty vehicles and equipment applications 2. Evaluation of various performance parameters.
Major: Vehicles
Textbook:
James A. Sullivan, Fluid Power - Theory and Applications", Prentice-Hall International, Inc. 1998 Deppert Werner, Pneumatic Control - An Introduction to The Principles
Additional Reading:
Robert Bosch GmbH, Automotive Handbook", 4th Edition 1996, Published by VDIVerlag
References:
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
Major: Vehicles

Hrs 6 Contents 1. Basics of Hydraulics and Pneumatics Pneumatic in automotive Physical properties of fluids, incompressible (liquids) and compressible (gases), density, specific gravity, viscosity, temperature, pressure, etc. Units, and dimensions, Hydrostatic pressures, Pascal law, transmission of forces, and force multiplication. Continuity and Energy equations for fluid flows and applications. Ideal gases and the general equation Standard conditions of atmospheric air. Introduction to fluids power. 2. Principles of Automatic Control and Control Systems: Basic elements of control systems Analysis of engineering systems as control systems Open-loop and closed-loop control systems Amplifiers (specifications and functions) Various types of control systems 3. Basics of Hydraulic and Pneumatic Control Systems: Systems component and functions. Construction and operation of: - Pumps - Compressors - Various fluid control valves - Fluid sensors and actuators - Matching components. Hydraulic and pneumatic control systems, circuits, and fields of application. Constant flow and constant pressure systems. Load-sensing systems. Open and closed-center circuits. Single-acting and double-acting circuits Sequence circuits Interlock circuits Heavy Duty Vehicle and Equipment Applications: Systems, component construction and operational functions, and block diagrams of different hydraulic and pneumatic control systems in heavy-duty vehicles and equipment such as: Truck controls Bus controls Fork lift controls Tractor Controls Construction Equipment controls etc Behavioral Objectives The student should be able to: - Define and describe the properties of fluids - Distinguish incompressible and compressible fluids - Explain the concepts of hydrostatic pressure, pressure force relation, and Pascal law - Explain continuity and energy equations. - Interpret the general equation of gases
- Explain the principles of automatic control concepts. - Describe the importance of various control systems and difference between these systems. - Describe the hydraulic and pneumatic control systems. - Explain system components operation, performance, and fields of application. - Describe symbols, and block diagrams of hydraulic and pneumatic control systems.
10
- State the main applications of hydraulic and pneumatic control in the heavy duty vehicles, - Describe system components, construction, operation and performance. - Explain the block diagrams of these applications.
Major: Vehicles

Laboratory
10 1. Carry out experimental tests to determine the performance characteristics of Hydraulic and Pneumatic Control System components: Pumps Compressors Various fluid control valves Fluid sensors and actuators Matching components. 2. Carry out experimental tests to determine the performance characteristics of basic Hydraulic and Pneumatic Control Systems: Constant flow and constant pressure systems Load-sensing systems. Open and closed-center circuits. Single-acting and double-acting circuits Interlock circuits Simplified logic pneumatic circuits Sequential control circuits Combined logical circuit of an electro-pneumatic system having not more than 4 inputs direct and indirect controlled circuits 3. Carry out experimental tests to determine the performance characteristics of Some of hydraulic and pneumatic Control System in applications in Heavy Duty Vehicle and Equipment as: Applications: Air brake systems Truck controls Bus controls Fork lift controls Tractor Controls Construction Equipment controls etc.
The student should be able to: - Carry out experiments to determine and explain the performance characteristics of - Hydraulic and pneumatic control system components - Basic hydraulic and pneumatic control systems - Some of hydraulic and pneumatic control system applications in Heavy Duty Vehicle and Equipment
10
10
Major: Vehicles
Department Mechanical Technology Course Title Selective Topics Prerequisite
Major
Code
Vehicles MEV 328
Semester Course Description : The course covers the recent and new developments in Automotive theory, technology, and application, which are not included in any of the compulsory or elective courses. The course topics may be related to the elective courses group, the project and the field training to give the student some depth of specialisation in one area of automotive technology. Credit hr/w Contact hr/w Contact hr/sem. L W T L W T
6 3 2 2 30
General Goal : The course provides the latest development in technology, theory and applications of Automotive field. Behavioral Objectives : By the end of this course, the student will be able to: Explain the latest development in the technology, theory, and applications of Automotive field
Topics (Theory): At the beginning of each semester, the department council approves the topics of the course given to a group of students. The course topics: Should include recent and new developments in Automotive theory, technology, and applications, which are not covered in the compulsory or elective courses. May be related to the elective courses group, the project and the field training to give the student some depth of specialisation in one area of automotive technology
Auxiliary Comfort and Safety Systems
Page

Vehicles

Загружено:

Сведения о документе

Исходное описание:

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Vehicles

Загружено:

Авторское право:

Доступные форматы

Department: Mechanical Technology

Kingdom of Saudi Arabia

DEPARTMENT OF CONSTRUCTION TECHNOLOGY

Department: Mechanical Technology

Department Mechanical Technology Course Title Internal Combustion Engines Prerequisite

Vehicles MEV 221

L = Lecture Hours, W = Workshop/Laboratory Hours, T = Tutorial Hours

Department: Mechanical Technology

Detailed Curriculum (Theory)

- Explain engine types and classifications,

- Explain and calculate engine technical terms

Department: Mechanical Technology efficiencies

Department: Mechanical Technology

Detailed Curriculum (Practice)

Department: Mechanical Technology

Detailed Curriculum (Practice)

- Demonstrate the proper use of engine test equipment

- Explain the possible troubles of engine mechanical systems.

- Identify the possible causes related to engine trouble.

Department: Mechanical Technology b.

4. Engine cooling system:

- Carry out final inspection of the system

Department: Mechanical Technology

Department Mechanical Technology Course Title Automotive Brakes Prerequisite

Vehicles MEV 222

L = Lecture Hours, W = Workshop/Laboratory Hours, T = Tutorial Hours

Department: Mechanical Technology

Department: Mechanical Technology

Detailed Curriculum (Theory)

Department: Mechanical Technology

Department: Mechanical Technology

Detailed Curriculum (Practice)

Department: Mechanical Technology

Department: Mechanical Technology

Detailed Curriculum (Practice)

Department: Mechanical Technology

Department: Mechanical Technology

Vehicles Code MEV 223

L = Lecture Hours, W = Workshop/Laboratory Hours, T = Tutorial Hours

Technical and repair manuals Automotive magazines and periodicals

Department: Mechanical Technology

Detailed Curriculum (Theory)

Department: Mechanical Technology

Detailed Curriculum (Practice)

Department: Mechanical Technology

Department: Mechanical Technology

No downshift occurs when pushing accelerator pedal

Department: Mechanical Technology

Major: Vehicles repairing

Improper differential oil quantity and condition

Department: Mechanical Technology

Vehicles MEV 224

Credit hr/w L Contact hr/w W T L Contact hr/sem. W T

L = Lecture Hours, W = Workshop/Laboratory Hours, T = Tutorial Hours

Department: Mechanical Technology

Department: Mechanical Technology

Detailed Curriculum (Theory)

- Explain the construction of various suspension systems including different types of

Major: Vehicles springs and chock absorbers.

Department: Mechanical Technology

Detailed Curriculum (Practice)

Safety Procedures Suspension and steering system components

Department: Mechanical Technology