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Study plan distributed over all semesters
Number of units No Course
code Course name Pre-requisite C.U L W T C.H
1 ENG 101 General English Language - - - 3 2 2 4 2 ISL 101 Islamic Culture - - - 2 2 - 2 3 MAT 161 Specialized Mathematics - - - 3 3 1 4 4 CMP 101 Introduction to Computer - - - 2 - 4 4 5 MEV 111 Preparatory Workshop - - - 2 - 4 4 6 MEV 112 Industrial Safety - - - 1 - 2 2
Firs
t Sem
este
r
7 MEV113 Introduction to Automotive Electric System - - - 2 1 2 3 Total 15 8 14 1 23
Number of units No Course code Course name Pre-requisite C.U L W T C.H
1 ENG 192 Technical English ENG 101 3 2 2 4 2 ARB 101 Arabic Language - - - 2 2 - 2 3 PHY 101 Specialized Physics - - - 3 2 2 4 4 MEV 121 Technical Drawing - - - 2 - 4 4 5 MEV 122 Fuel System (Gasoline) MEV 111 4 2 4 6 Se
cond
Sem
este
r
6 MEV 123 Engines (1) MEV 111 4 2 4 6 Total 18 10 16 26
Number of units No Course code Course name Pre-
requisite C.U L W T C.H1 ENG 293 Technical English II ENG 192 3 2 2 4 2 MEV 211 Power Trains (I) MEV 111 4 2 4 6 3 MEV 212 Brake System MEV 111 4 2 4 6 4 MEV 213 Engines (2) MEV 123 4 2 4 8
Thi
rd S
emes
ter
5 MEV 214 Fuel System (Diesel) MEV 123 3 2 2 4 Total 18 10 16 26
Number of units No Course code Course name Pre-requisite C.U L W T C.H
1 ISL 102 Islamic Culture ISL 101 2 2 - 2 2 MGT 101 Professional Ethics - - - 2 2 - 2 3 MEV 221 Engineering Drawing MEV 121 2 - 4 4 4 MEV 222 Power Trains (2) MEV 211 4 2 4 6 5 MEV 223 Suspension & Steering System MEV 111 4 2 4 6 Fo
urth
Sem
este
r
6 MEV 224 Fault Diagnosis MEV 213 4 2 4 6 Total 18 10 16 26
Number of units No Course code Course name Pre-requisite C.U L W T C.H
Sum
mer
1 MEV 230 Cooperative Training - - - 4 According to working hours
Number of units C.U L W T C.H Program total number of units 73 38 62 - 101
C.U.: Credit Hours L: Lecture W: Workshop T: Practice C.H.: Contact Hours
Department Mechanical Technology Major Engines and Vehicles
Course name Preparatory Workshop Code MEV 111
Prerequisite None
Course description: In this course the student is introduced to the fundamentals of preparatory workshops and engineering measuring, as well as the basis of safety procedures. The student is also introduced to the tools and equipment used in the workshop. Car parts which include the engine, power train systems, friction clutch and its types, different gearboxes, driving shafts, differential, suspension, different brake systems and their types and parts are also covered.
Semester 1 2 3 4
Credit hours 2
L
W 4 Contact hours
(hour/week) T
General course objectives: This course aims to introduce the student to the fundamentals of preparatory workshops and engineering measuring as well as the basics of safety procedures. The student is also introduced to the tools and equipment used in the workshop, and all car parts.
Skill Objectives: The student should be able to: • Know the fundamentals of preparatory workshops and engineering measuring. • Know the basics of safety procedures. • Know the tools and equipment used in the workshop. • Know car parts which include; the engine, different power train systems, suspension, different
brake systems and their types and parts.
Subjects (theoretical and practical): • The fundamentals of preparatory workshops and engineering measuring • Safety procedures • Tools and equipment used in the workshop • Car parts which include; the engine, different power train systems, suspension, different brake
systems and their types and parts
Detailed Practical Course
Hours Content Skill Objectives Related tasks
8
Basic skills which include: - safety rules - measuring methods - manual cutting methods using
different tools
The student should be able to: - Apply safety rules. - Carry out measuring methods. - Carry out manual cutting
methods using different tools.
A1, A2
8
Metal forming which includes: - filing - bending - cutting - forming
- Carry out metal forming by filing, bending, cutting and forming. A4
4
Metal joining methods which includes:
- joints classifications - joints riveting - joints welding
- Carry out methods of metal joining which include
- joints classifications - joints riveting - joints welding
A3
8
Machine and tool operation basics which include:
- types of tools and equipment - operating equipment
- Have basic knowledge of operating machines and tools which include:
- types of tools and equipment - operating equipment
A3
2
Workshop industrial safety procedures:
- precaution methods - methods of storing flammable
materials - methods of arranging
equipment for emergencies
- Have knowledge of workshop industrial safety procedures which include:
- precaution methods - methods of storing flammable
materials - methods of arranging
equipment for emergencies
A1, A2
2
Tools, machines and equipment used in the workshop
- all types of filing tools with different smoothing levels
- all forging tools in all shapes and sizes
- wrenches and pullers in all shapes and sizes
- heavy machinery (turning machines for valves, discs, drums, ... etc)
- Have knowledge of correctly
using tools, machines and equipment in the workshop.
- Know how to protect one's self from injuries when using workshop tools, machines and equipment.
- Protect tools, machines and equipment from any harm.
A3
8
The engine, its components and parts which include:
- cooling system (radiator – connections – water pump – water jackets)
- lubricating system (oil pan – oil pump – oil galleries - oil filter)
- fuel system (conventional system which includes: fuel tank – fuel pump – fuel filter – connections – carburetor)
- fuel injection (includes: fuel tank – fuel pump – connections – fuel filter – control unit – injectors)
- ignition system (battery – ignition coil – distributor – spark plugs)
- electric circuits (front and rear light circuits – wipers – signal lights … etc)
- Identify the cooling system
and its main parts. - Identify the lubricating
system in the engine and its main parts.
- Identify the fuel system and its main parts.
- Identify the ignition system and its main parts.
- Identify external and internal engine parts and the four strokes.
- Identify the electric circuits in the car.
D4, D7, D10, D8
6
Power train parts- their types and components which include:
- friction clutch and its different types
- sliding and constant mesh gearboxes
- different types of propeller shafts, connections and bearings
- back axel unit, its components and importance
- axels and rods
- Identify power train parts, their types and components which include:
- friction clutch and its different types
- sliding and constant mesh gearboxes
- different types of propeller shafts, connections and bearings
- back axel unit, its components and importance
- axels and rods
E1,E7
6
Steering and suspension- their types and components which include:
- springs, shock absorbers …etc - control arms, rods, dust boots,
rubber bushings, ball bearing … etc
- wheel alignment angles, their types and importance
- Identify Steering and
suspension, their types and components which include:
- springs, shock absorbers … etc
- control arms, rods, dust boots, rubber bushings, ball bearing … etc
- wheel alignment angles, its types and importance
G1, G6
4
Brakes, their types and components which include:
- hydraulic brakes (drum and disc brakes)
- air brakes (air reservoir, valves, … etc)
- booster, levers, linkages, parking brakes and engine brakes
- Identify the brakes, their
types and components which include:
- hydraulic brakes (drum and disc brakes)
- air brakes (air reservoir, valves … etc)
- booster, levers, linkages, parking brakes and engine brakes
F1, F2, F3, F4, F5, F6, F7, F8, F9,
F10
Department Mechanical Technology Major Engines and Vehicles
Course name Industrial safety Code MEV 112
Prerequisite None
Course description: industrial safety is part of the job principles the student should know. This course covers the way of how to wear work clothes, safety helmet …etc. As well as to choose and prepare the appropriate workplace, methods of using tools and equipment and their safety and methods of using lifts. The workshop safety part covers the proper methods of getting rid of exhaust gases, proper storing of flammable materials and using fire extinguishers.
Semester 1 2 3 4
Credit hours 1
L -
W 2 Contact hours
(hour/week) T -
General course objectives: The course aims to introduce the student to industrial safety which is part of the job principles. The student learns how to wear work clothes, safety gear, choosing the proper location for work- and to provide the workplace with suitable equipment, as well as to know the methods of using tools, equipment and their safety and methods of using lifts. The student also learns the workshop safety procedures, proper storing of flammable materials and using fire extinguishers. Skill Objectives: The student should be able to: • know how to wear work clothes and safety gear • know how to choose a suitable location for work and prepare it • know how to correctly use tools and operate equipment and their safety, and methods of using
lifts • follow safety procedures inside the workshop (properly get rid of exhaust gases) • properly store flammable materials and use fire extinguishers
Subjects (theoretical and practical): • method of wearing work clothes and safety gear • method of choosing a suitable location for work and prepare it • method of using and operating tools and equipment and their safety, and methods of using lifts • following safety procedures in the workshop (properly get rid of exhaust gases) • method of storing flammable materials and using fire extinguishers
Detailed Practical Course
Hours Content Skill Objectives Related tasks
2
1 – Clothes - wearing work clothes - be sure that the clothes are
free from any metal parts - wear safety goggles - wear gloves
The student should be able to: - Know how to wear work
clothes and safety gear for his safety, the safety of the car and for the general appearance of the mechanic.
A1
2
2 – The place - choosing a proper location for
the job - placing the car in the right
location for the job - be sure that the floor is free of
any liquid spills - be sure of the presence of
safety equipment
- Prepare a suitable place for
working on the car - Be sure that the floor is free
from any liquid spills - Be sure of the presence of
safety equipment A2
4
3 – Using tools - Knowing the tools and using
the suitable ones for the job - Taking care of the tools - being sure of the safety of the
vehicle
- Use tools properly to avoid
injuries and for protecting the tools from any harm A3
4
4 – Equipment - Proper usage of equipment - Using the right device - Taking care of the equipment
- Use equipment properly to avoid injuries and for protecting the equipment from any harm
A4
4
5 – Lifts - Learn about lifts and methods
of using them. - Proper placement of vehicle
on the lift - Be sure of the stability of the
vehicle.
- Secure car lifts to ensure the
safety of the car, the worker and the workshop. A5
2
6 – Exhaust gases - Be sure of the suction of
exhaust gases. - Use exhaust gas suction hoses.
- Use exhaust gas suction hoses with special equipment to prevent air pollution inside the workshop.
A6
2
7 – Flammable materials - Store flammable materials in
their designated places. - Caution when carrying
flammable materials - Ventilation of their storing area - Locking the place
- Store flammable materials in their designated places for the safety of the workshop, the car, the worker and for general safety.
A7
4
8 – Fire extinguishers - Learn how to use fire
extinguishers and their types. - Know the location of the fire
extinguishers.
- Use fire extinguishers to
combat flames in case of a fire. A8
4
9 – Manufacturing company’s recommendations
- Placing shields on cars while working
- Protect car when working on it
- Adhere to manufacturing
company’s recommendations to protect the car body and the workshop facilities.
A9
Department Mechanical Technology Major Engines and Vehicles
Course name Introduction to Automotive Electric System Code MEV 113
Prerequisite None
Course description: This course covers minor vehicle electric faults. It includes electricity fundamentals, the battery, lighting circuit, signal lights circuit, wipers circuit, horn circuit, generator, starter, as well as checking, repairing or replacing minor electric parts in the vehicle.
Semester 1 2 3 4
Credit hours 2
L 1
W 2 Contact hours
(hour/week) T -
General course objectives: this course aims to introduce the student to the minor vehicle electric faults which include electricity fundamentals, the battery, lighting circuit, signal lights circuit, wipers circuit, horn circuit, generator, starter, as well as being able to check, repair or replace minor electric parts in the vehicle.
Skill Objectives: The student should be able to: • Identify minor vehicle electric faults. • Basic knowledge of electricity fundamentals, the battery, lighting circuit, signal lights circuit,
wipers circuit, horn circuit, generator, starter. • Check, repair or replace minor electric parts in the vehicle
Subjects (theoretical and practical): • Minor vehicle electric faults. • Electricity fundamentals, the battery, lighting circuit, signal lights circuit, wipers circuit, horn
circuit, generator, starter. • Check, repair or replace minor electric parts in the vehicle.
References:
- James E. Duffy, "Auto Electricity, Electronics, Computers", The Goodheart-Willcox Company Inc., ISBN - Stockel, and Johanson, "Auto Service and Repair", The Goodheart- Willcox Company Inc., ISBN 1 -56637-144-9 - John Deere, "Electrical Systems, Fundamentals of Service&', ISBN 0- 8669 1-0476 - William Toboldt, Larry Johnson and W. Scott Gauthier, "Automotive Encyclopedia", 1995, The Goodheart-Willcox Company Inc., ISBN - Ilarcourt Brace Jovanivicb, "Automotive computer control systems", Fundamentals and services, Publishers, ISBN 0-15-504355-2 - Stockel and Johanson, "Auto Service and Repair", The Goodheart- Willcox Company, ISBN 1-5663 7-144-9 - Robert Bosch GmbH, "Automotive Handbook", ISBN 0-89 283-518-6 - Harper and Row, "Automotive Electrical Systems", Classroom Manual, Check-Chart Automotive Series - Harper and Row, "Automotive Electrical Systems", Workshop Manual, Check-Chart Automotive Series - Martin W. Stockel and Martin T. Stockel, "Auto Mechanic Fundamentals", The Goodheart-Wilcox Company Inc. -Robert Bosch Coop, "Bosch Technical Instruction Series", 1. Engine Electronics 2. Alternators 3. Starting Systems - Robert Bosch Coop, "Automotive Handbook", Bosch, VDI-Verlag, ISBN - Robert Bosch Coop, "Fault Detection with Oscilloscope", ISBN 1-689- 9804)86
Detailed Theoretical Course
Hours Content Skill Objectives Related tasks
1
Electricity basics - Electricity fundamentals - Semiconductors
The student should be able to: Understand the fundamentals of electricity which include: - Electricity fundamentals - Semiconductors
L2
1
The battery - Battery function - Battery parts
- Identify the vehicle battery, its function and components.
- Understand the symbols and numbers on the battery.
L1
1
Lighting circuit - Lighting circuit function - Lighting circuit components - Method of operation
- Identify lighting circuit, its function and components.
- Know how the lighting circuit works.
L2
1
Signal light circuit - Signal light circuit function - Signal light circuit
components - Method of operation
- Identify the signal light circuit, its function and components.
- Know how the signal light circuit works.
L2
1
Wiper circuit - Wiper circuit function - Wiper circuit components - Method of operation
- Identify the wiper circuit, its function and components.
- Know how the wiper circuit works.
L2
1
Horn circuit - Horn circuit function - Horn circuit components - Method of operation
- Identify the horn circuit, its function and components.
- Know how the horn circuit works.
L2
4
Generator - Generator function - Generator parts - Method of operation - Types of generators
- Identify the charging circuit, its function and operation.
- Know how the charging circuit works.
L2
4
Starter - Starter function - Starter parts - Method of operation
- Identify starter circuit, its function and components.
- Know how the starter circuit works.
L2
Detailed Practical Course
Hours Content Skill Objectives Related tasks
2
Electricity basics - Electricity fundamentals - Semiconductors
The student should be able to: - Test minor electric units using
special tools and equipment to ensure their serviceability.
L3, L4
2
The battery - Battery function - Battery parts - Checking the battery - Testing battery voltage
- Testing the battery voltage with a special device to know its ability to operate the starter and other electric circuits in the vehicle.
L1, L4
2
Lighting circuit - Lighting circuit function - Lighting circuit parts - Checking the lighting circuit - Diagnosing faults - Replacing all parts of the lighting
circuit
- Identify the lighting circuit, and its parts.
- Know how to check lighting circuit.
- Diagnose faults. - Repair or replace the lighting
circuit completely.
L3, L4, L5
2
Signal light circuit - Signal light circuit function - Signal light circuit parts - Checking signal light circuit - Learn to diagnose faults - Replacing parts of the signal light
circuit
- Identify signal light circuit, and its parts.
- Know how to check signal light circuit.
- Diagnose faults. - Repair or replace signal light
circuit completely.
L3, L4, L5
2
Wiper circuit - Wiper circuit function - Wiper circuit parts - Checking wiper circuits - Learn to diagnose faults - Replacing wiper circuit
completely
- Identify the wiper circuit, and its components.
- Know how to check the wiper circuit.
- Diagnose faults. - Repair or replace wiper circuit
completely.
L3, L4, L5
2
Horn circuit - Horn circuit function - Horn circuit components - Checking horn circuit and
diagnose fault - Replacing horn circuit completely
- Identify the horn circuit, and its components.
- Know how to check the horn circuit.
- Diagnose faults. - Repair or replace horn circuit
completely.
L3, L4, L5
8
Generator - Generator function - Generator parts - Method of checking generator and
judging its condition while installed
- Method of removing the generator from the car
- Checking the generator uninstalled - Disassembling the generator - Checking and testing the parts - Replacing faulty parts - Reassembling the generator - Reinstalling the generator in the
car
- Identify charging circuit, and its components.
- Know how to check the charging circuit.
- Diagnose faults. - Repair or replace the circuit
completely. L3, L4,
L5
4
Starter - Starter function - Starter parts - Method of checking the started
while installed - Method of removing the starter
from the car - Checking the starter uninstalled - Disassembling the starter - Checking and testing the starter
parts - Replacing faulty parts - Reassembling the starter - Reinstalling the starter in the car
- Identify starter circuit, and its components.
- Know how to check the starter - Diagnose faults. - Repair or replace the starter
parts completely. L3, L4,
L5
Department Mechanical Technology Major Engines and Vehicles
Course name Technical Drawing Code MEV 121
Prerequisite None
Course description: This course includes technical drawing basics, orthographic projection, conversions, symbols, sections and hatching.
Semester 1 2 3 4
Credit hours 2
L
W 4 Contact hours
T
General course objectives: This course aims to give the student the ability to use technical drawing as a language to be able to read symbols and drawings. It also makes the student correctly employ the basics of technical drawing and symbols.
Skill Objectives: The student should be able to: • Explain different lines used in technical drawing. • Identify different symbols used to pass information. • Read, understand technical drawings and printed drawings. • Analyze the drawing and write a technical report.
Subjects (theoretical and practical): • The fundamentals of technical drawing • Orthographic projection • Conversions and symbols • Sections and hatching
References:
- James H; "Drafting, technology,, Earle Addison-Wesley Publications co. - M.A. Parker & L.J. Dennis, "Engineering drawing Fundamentals', Stanley Theories. - Warren .I. Luzadder, ,, Fundamentals of Engineering Drawing', Prentice-Hall, 1986, Ninth Edition.
Detailed Practical Course
Hours Content Skill Objectives Related tasks
12
Introduction - Technical drawing as a
technician language - Projection methods - Tools and equipment used - Line types - Drawing sheet distribution - Freehand drawing
The student should be able to: - Explain ways of projection - Identify different types of
lines - Preparing the drawing sheet - Improve freehand drawing of
simple shapes
12
Dimensions - Introduction - Dimensions technology - Reference and dimension lines - Arrow lines - Dimensions placement - Methods of writing dimensions - Advantages of writing
dimensions in general (circles, diameters … etc)
- Use basic standards to
produce drawing dimensions
12
Orthographic projection - Orthographic projection of
points, lines and areas - Orthographic projection of the
first angle - Orthographic projection of the
third angle - Projection symbols - Final view projection - Measurements - Hidden details
- With the help of drawings explain the meaning of orthographic projection using the fundamentals of views, dotted lines, areas and body
- Produce drawings using hidden lines by utilizing projection of the first and third angles
12
Sections and sectioned figures: - The need for sections - Sections levels - Full sections - Half sections - Broken out, revolved, removed,
and partial section.
- Use basic standards to
produce drawing sections
B6, E1, E8, E10, E11, E12, G13, H1, H2, I1,
I10, I14, I17, K7,
K10 A3
Department Mechanical Technology Major Engines and Vehicles
Course name Fuel system (gasoline) Code MEV 122
Prerequisite MEV 111
Course description: This course covers the principals of combustion in gasoline engines and the requirements of air fuel mixture. Fuel delivery systems; conventional and electronically controlled, their components and function. Fault diagnosis, repair, servicing, maintenance and replacing faulty parts.
Semester 1 2 3 4
Credit hours 4
L 2
W 4 Contact hours
T
General course objectives: This course aims to introduce the student to the fundamentals of combustion in the gasoline engine and the requirements of air fuel mixture, fuel delivery systems; conventional and electronically controlled, their components and function. The student is also introduced to fuel injection systems, their types, advantages, parts and their functions. The course introduces the student to fault diagnosis, repair, servicing, maintenance and replacing faulty parts.
Skill Objectives: The student should be able to: • Determine fuel air mixture requirements suitable for the different engine operating conditions. • Explain different carburetor designs; simple, integrated conventional and electronically
controlled. • Explain, analyze different constructions and the principals of operation of fuel injection
systems in the gasoline engines. • Explain, practically, the functions of different fuel injection systems, carry out measurements,
diagnose and repair faults, and evaluate their expected causes by using practice engine. • Diagnose and locate faults; visually and by using equipment, repair and calibrate:
- Electronically controlled carburetors - Fuel injection systems in the gasoline engines
Subjects (theoretical and practical): • The fundamentals of combustion in the gasoline engine and the requirements of air fuel
mixture. • Fuel delivery systems; conventional and electronically controlled, their parts and function. • Fuel injection systems, their types, advantages, parts and their functions. • Fault diagnosis and repairs. • Servicing and maintenance of fuel systems. • Replacing faulty parts of the fuel systems.
References:
- Duffy, James E., and Smith, Howard B.," Auto Fuel and Emission Control Systems Technology", The Goodheart-Willcox company, INC, ISBN 0- 87006 932 2 - Robert Bosch GmbH "Automotive Electric I Electronic Systems", 2nd edition 1995, 1 SBN 1-56091-596-X - Heinze Heisler, Advanced Engine Technology, Edward Amold, ISBN 0340568224 - William H. Crouse and Donald L. Anglin, "Automotive Mechanics The McGraw Hill Book Company, ISBN 04)2-800943-6 - Martin, W. Stokel and Martin, "Auto Mechanics Fundamentals", The Goodheart Willcox company, -C, ISBN 1-56637-138-4, 1996 - Martin W. Stokel, Martin T. Stokel Chris Johanson "Auto Fundamentals The Goodheart – Willcox company, INC, ISBN 1-56637-1384, 1996 - William, K. Toboldi, Larry Johnson, and W. Scon Oavthier, "Automotive Encyclopedia " Fundamental, Principles, Operation, Construction, Service, and Repair, The Goodheart –Willcox company, INC, ISBN 1-56637-150-3, 1995 - Duffy, James E., "Auto Engines" The Goodheart Willcox company, INC, ISBI;J 0-87006477-3 - Jack Enjavec and Robert Scharif "Automotive Technology" Delmar Publishers, An International Thomson Publishing Company.
Detailed Theoretical Course
Hours Content Skill Objectives Related tasks
2
1 - Gasoline engine fuel system - The fundamentals of combustion
and the requirements of air fuel mixture
- Gasoline properties - Combustion theory - Fuel / air ratio and its variations - Combustion in the gasoline engine - Air fuel mixture requirements
under different operating conditions
- Gasoline engine fuel systems; conventional and electronic injection
The student should be able to: - Explain the advantages of
gasoline fuel. - Calculate fuel / air ratio and
differentiate between rich and poor fuel mixtures.
- Differentiate between normal and abnormal combustion.
- Explain and show the effects of different operating conditions on engine performance.
- Describe the mixture requirements for different operating conditions.
D8, H5
8
2 – Conventional fuel system (carburetor)
- Different carburetor constructions and types
- Simple carburetor systems, operation, circuits and their designs
- Construction and function of the conventional two stage carburetor
- Simple operation and parts of the electronically controlled carburetor
- Explain carburetor systems, operation- differentiate between its types.
- Describe the functions of carburetor systems to cope with the mixture requirements for different operating conditions.
D8, H5
4
3 - Fuel injection systems in gasoline engines
- Different types of fuel injection systems in gasoline engines
- Advantages and general specifications
3 – 1 – Continuous fuel injection systems (K & KE-Jetronic)
- Introduction about the system, its specifications, parts and their functions
- Common problems, faults and their possible causes
- Describe different types of fuel injection systems and show the advantages of each one.
- Describe the combined mechanical - electronic fuel injection systems.
- Show the circuit diagrams for these systems; name their parts, functions and method of operation.
- Determine types of faults and their causes and improve them.
D8, H5
4
3 – 2 – Intermittent fuel injection systems
- General information about intermittent fuel injection systems which include:
- Electronic fuel injection systems (L-jetronic, LE-jetronic, LH-jetronic, EFI, SEFI, MPFI, mono-jetronic, TBI system)
- Electronic combined fuel injection systems (Motronic and Mono-Motronic)
- Explain electronic intermittent
fuel injection and describe its different systems.
D8, H5
4
3 - 2 – 1 – electronic fuel injection systems
- Introduction about the electronic fuel injection systems:
- System specifications, circuit diagrams, parts, mode of operation
- Control unit circuit diagram, input sensors, output operators
- Output pulse timing diagram - The system includes different
operating conditions
- Explain the advantages of different electronic fuel injection systems.
- Summarize the system diagram. - Describe the mode of operation
of different parts. - Describe how the system adopts
different engine operating conditions.
- Summarize diagram for the control unit, sensors, and operators.
- Explain the system pulse timing diagram.
- Describe closed control circuit.
D8, H5
6
3 – 2 – 2 – Combined electronic fuel injection –ignition systems:
- Introduction about combined electronic fuel injection – ignition systems; their advantages, specifications, diagrams, parts, mode of operation
- Explanation of electronic ignition part
- Explanation of electronic injection part
- The diagram for measuring amount of fuel
- Time span of injection and pulse timing
- The system includes different operating conditions
- Common problems, faults and possible causes of system problems
- Explain the advantages of combined mechanical - electronic fuel injection systems (Motronic).
- Explain both systems; combustion and injection.
- Summarize system diagram. - Describe how the system adopts
different engine operating conditions.
- Summarize diagram for control unit, sensors, and operators.
- Explain the system pulse timing diagram.
- Describe closed control circuit.
D8, H5
Detailed Practical Course
Hours Content Skill Objectives Related tasks
4
1 - Checking and repairing fuel system in gasoline engines:
- Introduction to fuel systems workshop, its contents and equipment
- Doing different tests on car engine to find out mixture ratio and how it affects the engine and environment.
The student should be able to: - Know the fuel systems workshop,
its contents and equipment - Do different tests on a car engine
to know mixture ratio and how it affects the engine and environment.
D8, H5
16
2 - Checking and repairing conventional fuel system (carburetor):
- Removing and reinstalling the carburetor, fuel pump, filter and checking fuel circuit
- Checking and repairing carburetor, fuel pump, filter, connections and gas pedal
- Replacing faulty parts - Testing the system after replacing
and repairing
- Check and repair conventional fuel system (carburetor)
- Remove and reinstall the carburetor, fuel pump, filter and checking the fuel circuit
- Check and repair the carburetor, fuel pump, filter, connections and gas pedal
- Replace faulty parts in the system - Test the system after replacing
and repairing
D8, H5
8
3 - Checking and repairing fuel injection systems in gasoline engines:
- Introduction to fuel injection systems
3 – 1 – Checking and repairing continuous fuel injection systems (K & KE-Jetronic)
- Checking and repairing sensors - Checking and repairing injectors,
fuel regulator - Checking and repairing fuel pump,
engine heat regulator - Replacing faulty parts and testing
the system
- Check and repair fuel injection system in gasoline engines
- Identify fuel injection systems - check and repair continuous fuel
injection systems (K & KE-Jetronic)
- Check and repair sensors - Check and repair injectors, fuel
regulator - Check and repair fuel pump,
engine heat regulator - Replace faulty parts and test the
system
D8, H5
8
3 – 2 - Checking and repairing intermittent fuel injection systems:
- Electronic fuel injection systems (L-jetronic, LE-jetronic, LH-jetronic, EFI, SEFI, MPFI, mono-jetronic, TBI system)
- Electronic combined ignition and fuel injection systems (Motronic and Mono-Motronic)
Check and repair intermittent fuel injection systems: - Electronic injection systems (L-
jetronic, LE-jetronic, LH-jetronic, EFI, SEFI, MPFI, mono-jetronic, TBI system)
- Electronic combined fuel injection and ignition systems (Motronic and Mono-Motronic)
D8, H5
8
3 – 2 – 1 – Checking and repairing electronic injection systems:
- Checking and repairing injectors and sensors
- Checking and repairing fuel pump and filters
- Checking and repairing regulators and electric connections
- Checking and repairing electronic control unit
- Replacing faulty parts and testing the system
Check and repair electronic injection systems: - Check and repair injectors and
sensors. - Check and repair fuel pump and
filters. - Check and repair regulators and
electric connections. - Check and repair electronic
control unit. - Replace faulty parts and test the
system.
D8, H5
12
3 – 2 – 2 - Electronic combined ignition and fuel injection systems: Checking and repairing the electronic injection part: - Sensors, injectors, fuel pump,
regulators - Replacing faulty parts and testing
the system Checking and repairing the ignition part: - Checking distributor, ignition coil,
spark plugs, connections, electronic parts, high tension cables, ignition system sensors
Checking the combined system control unit - Replacing faulty parts and testing
the system
Check and repair electronic injection part: - Sensors, injectors, fuel pump,
regulators. - Replace faulty parts and test the
system. Check and repair ignition part: - Check distributor, ignition coil,
spark plugs, connections, electronic parts, high tension cables, ignition system sensors.
Check the combined system control unit - Replace faulty parts and test the
system.
D8, H5
Department Mechanical Technology Major Engines and Vehicles
Course name Engines I Code MEV 123
Prerequisite MEV 111
Course description: In this course the student is introduced to the fundamentals of internal combustion engines operation, their kinds, types, main parts, mode of operation. Mechanical engine systems; lubricating system, cooling system and ignition system. Checking and repairing mechanical systems.
Semester 1 2 3 4
Credit hours 2
L
W 4 Contact hours
T
General course objectives: This course aims to introduce the student to the fundamentals of the operation of the internal combustion engines, their kinds, types, main parts, and mode of operation, as well as to the mechanical engine systems; lubricating system, cooling system and ignition system. After that, the student will check and repair mechanical systems.
Skill objectives: The student should be able to: • Know the fundamentals of internal combustion engines, their types, main parts, mode of
operation. • Know the mechanical engine systems such as the lubricating system, cooling system and
ignition system. • Check and repair mechanical systems.
Subjects (theoretical and practical): • The fundamentals of internal combustion engines, their types, main parts, mode of operation. • Mechanical engine systems; lubricating system, cooling system and ignition system. • Checking and repairing mechanical systems.
References:
- Heinze Heisler, Advanced Engine Technology, Edward Amold, ISBN 0340568224 - William H. Crouse and Donald L. Anglin, "Automotive Mechanics" The McCrawHill Book Company, ISBN 0-02-800943-6 - Manufacturer's data and repair manuals - Martin, W. Stokel and Martin "Auto Mechanics fundamentals", The Goodheart Willcox company, INC, ISBN 1-56637-138-4, 1996 - Stockel, Stockel, and Johanson, "Auto Service and Repair", The Goodheart Willcox company, INC, - Martin W. Stokel, Martin T. Stokel Cluis Johanson "Auto Fundamentals" The Goodheart Willcox company, INC, ISBN 1-56637-1384, 1996 - William, K. Toboldt, Larry Johnson, and W. Scott Gavthier, "Automotive Encyclopedia " Fundamental, Principles, Operation, Construction, Service, and Repair- The Goodheart -Willcox company, INC, ISBN 1- 56637-150-3, 1995 - Jack Enjavec and Robert Schaiff "Automotive Technology" Delmar Publishers, An International Thomson Publishing Company, - Robert Bosch GmbH "Automotive Handbook" Published by VDI-Verlag, 1996 - Duffy, James E., "Auto Engines" The Goodheart Willcox company, INC, ISBN 0-87006A77-3
Detailed Theoretical Course
Hours Content Skill Objectives Related tasks
6
Fundamentals of internal combustion engines: - Mode of operation of four stroke
engines - Kinds of engines - Engine parts, their functions and
mode of operation
The student should be able to: - Understand mode of operation of
the four stroke engines. - Identify kinds of engines. - Identify engine parts, their
functions and mode of operation.
2
Engine lubricating system: - The reasons for lubricating engine
parts, types of engine oils - Different types of lubricating
circuits - Lubricating system parts, their
functions and mode of operation
- Identify engine lubricating system.
- Identify the reasons for lubricating engine parts, types of engine oils.
- Identify the different types of lubricating circuits.
- Identify lubricating system parts, their functions and mode of operation.
D7, H3
6
Engine cooling system: - Cooling system function – water
cooling and air cooling - Cooling system parts, their
functions and mode of operation - The reason for using thermostat in
the cooling circuit - Cooling system faults - Ways of checking cooling system
by using equipment and tools
- Identify engine cooling system. - Identify cooling system function –
water cooling and air cooling. - Understand mode of operation of
cooling system circuit, its parts, their functions and mode of operation.
- Understand the reason for using the thermostat in the cooling circuit.
- Know cooling system faults - Understand ways of improving
cooling system performance. - Understand methods of checking
cooling system by using equipment and tools.
D4, H4
4
Ignition systems: - 1 – Introduction to the principals of
ignition - Ignition system function - Principals of ignition coil function - Effects of ignition timing on:
- Engine power, fuel consumption, engine torque, exhaust emission
- Primary current buildup - Conditions affecting spark energy
and volt - Ignition coil types; primary and
secondary circuit forms - 2 – Conventional ignition system - System specifications and
components - Ignition coil, distributor - Contact points, condenser - Spark plugs, and their different
designs - Ballast resistor, advance
mechanisms - System limitations - Primary and secondary circuit
forms
- Identify ignition systems. - Identify the principals of ignition. - Understand ignition system
function. - Know the principals of ignition
coil function. - Understand the effects of ignition
timing on: - Engine power, fuel
consumption, engine torque, exhaust emission
- Primary current buildup - Conditions affecting spark
energy and volt - Ignition coil types; primary and
secondary circuit forms - Identify conventional ignition
system. - Understand system
specifications and components. - Understand mode of operation of
ignition coil, distributor. - Understand mode of operation of
contact points, condenser. - Identify spark plugs, and their
different designs. - Identify ballast resistor, advance
mechanisms. - Understand system limitations. - Understand mode of operation of
primary and secondary circuit forms.
D10, H6
6
3 – Transistorized ignition systems (semi-electronic ignition)
- Contact points problems - The necessity for using advanced
ignition systems in cars - Connection and disconnection in
primary circuit - The transistor, connecting and
disconnecting specifications, gain factor and protection circuit
3 -1 - Transistorized ignition system with contact points:
- System specifications and parts, circuit diagram
- Transistor and contact points functions
- Primary current and control, Darlington magnifier
3 - 2 – transistorized ignition with Hall generator TCI-H:
- Pulse generator function - Coil ignition systems with pulse
generator - Hall Effect and Hall pulse
generator - Hall pulse generator signal shaper - 3 – 3 – Transistorized ignition
with induction type pulse generator TCI-I:
- Induction type pulse generator parts and mode of operation
- Induction type pulse generator signal shaper
- Open and closed loop dwell-angle control system
- Identify transistorized ignition systems (semi-electronic ignition).
- Understand contact points problems.
- Understand the necessity for using advanced ignition systems in cars.
- Understand connection and disconnection in the primary circuit.
- Understand the transistor, connecting and disconnecting specifications, gain factor and protection circuit.
- Identify transistorized ignition system with contact points:
- Understand system specifications and parts, circuit diagram.
- Understand transistor and contact points.
- Understand primary current and control, Darlington Magnifier.
- Identify transistorized ignition with Hall generator TCI-H:
- Understand pulse generator function.
- Understand coil ignition systems with pulse generator.
- Understand Hall Effect and Hall pulse generator.
- Understand Hall pulse generator signal shaper.
- Identify transistorized ignition with induction type pulse generator TCI-I:
- Identify induction type pulse generator parts and mode of operation.
- Identify induction type pulse generator signal shaper.
- Draw ignition signal. - Understand open and closed
loop dwell-angle control system.
D10, H6
4
4 – Electronic ignition systems
- Principals of electronic ignition systems
- Crankshaft speed sensor (engine speed)
- Camshaft position sensor - MAP-TPS sensor - Electronically controlled ignition
timing - Types and design of electronically
controlled ignition - Ignition systems without
distributor - High tension distribution method - Ignition coils
5- Principals of capacitor discharge ignition system (CDI):
- Its mode of operation principals and advantages
- Circuit diagram and system parts - Condenser charging circuit - Ignition coil
Thyristor and on/off control
- Identify electronic ignition systems.
- Understand principals of electronic ignition systems.
- Identify crankshaft speed sensor (engine speed).
- Identify camshaft position sensor.
- Identify MAP-TPS sensor. - Understand electronically
controlled ignition timing. - Identify types and design of
electronically controlled ignition.
- Identify non-distributor ignition - Understand high tension
distribution method. - Identify ignition coils and their
mode of operation. - Understand principals of
capacitor discharge ignition system (CDI):
- Understand its mode of operation principals and advantages.
- Analyze circuit diagram and system parts.
- Understand condenser charging circuit mode of operation.
- Understand ignition coil mode of operation.
- Identify the thyristor and on/off control and its mode of operation.
D10, H6
Detailed Practical Course
Hours Content Skill Objectives Related
tasks
12
Disassembling and assembling practice engine:
- Disassemble four stroke gasoline engines.
- Identify the upper and lower parts of the engine.
- Disassemble the internal parts of the engine and identify them.
- Assemble the internal parts of the engine by following instructions.
- Assemble the upper and lower engine parts.
The student should be able to: - Disassemble and assemble
practice engine. - Disassemble four stroke gasoline
engines. - Identify the upper and lower
parts of the engine. - Disassemble the internal parts of
the engine and identify them. - Assemble the internal parts of
the engine by following instructions.
- Assemble the upper and lower engine parts.
4
Disassembling practice engine: - Disassemble engine external parts. - Check and replace oil pump. - Check oil galleries and passages in
the engine. - Replace oil filter, and engine oil
(following instructions). - Measure oil pressure. - Replace faulty parts in lubricating
system.
- Disassemble practice engine. - Disassemble engine external
parts. - Check and replace oil pump. - Check oil galleries and passages
in the engine. - Replace oil filter, and engine oil
(following instructions). - Measure oil pressure. - Replace faulty parts in
lubricating system.
D7, H3
12
Checking cooling system: - Notice leakage and noise. - Check cooling system parts
operation. - Determine faults in cooling
system. Repairing cooling system:
- Repair faulty parts in cooling system.
- Replace faulty parts if needed. - Change coolant. - Use cooling system testing device. - Check car performance after doing
the maintenance jobs on the cooling system.
Check cooling system. - Notice leakage and noise. - Check cooling system parts. - Determine faults in cooling
system. - Repair cooling system. - Repair faulty parts in cooling
system. - Replace faulty parts if needed. - Change coolant. - Use cooling system testing
device. - Check car performance after
doing the maintenance jobs on the cooling system.
D4, H4
8
Checking and repairing ignition systems:
- Identify main components of the ignition system and their mode of operation by performing tests on a practice engine, simulating some faults (disconnect some parts from the circuit one at a time).
- Check and repair conventional ignition systems:
- Distributor, ignition coil, spark plugs cables, spark plugs, connecting points, ignition switch, electric connections, condenser
- Replace faulty parts in the system. - Test the system.
- Check and repair ignition systems.
- Identify main components of the ignition system and their mode of operation by performing tests on a practice engine, simulating some faults (disconnect some parts from the circuit one at a time).
- Check and repair conventional ignition systems:
- Distributor, ignition coil, spark plugs cables, spark plugs, connecting points, ignition switch, electric connections, condenser
- Replace faulty parts in the system.
- Test the system.
D10, H6
8
3 - Checking and repairing semi-electronic ignition system:
- Identify system parts. - Test system parts using special test
device. - Determine faults in the system. - Repair or replace faulty parts. - Check system after the repair job is
done. 4 - Checking and repairing electronic ignition system:
- Identify system parts. - Test system parts using special test
device. - Determine faults in the system. - Repair or replace faulty parts. - Check system after the repair job is
done.
- Check and repair semi-electronic ignition system:
- Identify system parts. - Test system parts using special
test device. - Determine faults in the system. - Repair or replace faulty parts. - Check system after the repair job
is done. - Check and repair electronic
ignition system: - Identify system parts. - Test system parts using special
test device. - Determine faults in the system. - Repair or replace faulty parts. - Check system after the repair job
is done.
D10, H6
12
5 - Checking and repairing capacitor discharge ignition system (CDI):
- Identify system parts. - Test system parts using special test
device. - Determine faults in the system. - Repair or replace faulty parts. - Check system after the job is done.
- Check and repair capacitor discharge ignition system (CDI):
- Identify system parts. - Test system parts using special
test device. - Determine faults in the system. - Repair or replace faulty parts. - Check system after the job is
done.
Department Mechanical Technology Major Engines and Vehicles
Course name Power Train (1) Code MEV 211
Prerequisite MEV 111
Course description: This course covers how to carry out repair and maintenance jobs on different power train components which include friction clutch and its types, different gearboxes, propeller shafts and differential. This is done after diagnosing and determining faults by using tools and advanced equipment in this field.
Semester 1 2 3 4
Credit hours 4
L 2
W 4 Contact hours
T
General course objectives: This course aims to introduce the student to the methods of performing repair and maintenance jobs on different power train components which include friction clutch and its types, different gearboxes, propeller shafts and differential. As well as to diagnose and determine faults by using tools and advanced equipment in this field.
Skill Objectives: The student should be able to: • Know how to carry out repair and maintenance jobs on different power train components. • Identify friction clutch and its types. • Identify different gearboxes, propeller shafts and differential. • Diagnose and determine faults and repair or replace faulty parts in the power train system. • Test the system using tools and advanced equipment in this field.
Subjects (theoretical and practical): • The methods of performing repair and maintenance jobs on different power train components. • Friction clutch and its types. • Different gearboxes, propeller shafts and differential. • Diagnosing and determining faults, then performing repair and maintenance jobs on different
power train components. • Testing the system using tools and advanced equipment in this field.
References:
- Stockel, M.W., Stockel, M.T, and Johanson C.: "Auto Fundamentals", Goodheart Willcox Company, Inc., 1996, ]SBN 1-56637-138-4 Stockel, Stockel, and Johanson, "Auto Service & Repair", Goodheart- Willcox Company, Inc., 1996 ISBN 1-56637-144-9 - William K Toboldt, Larry Jolmson, and W. Scott Gauthier, "Automotive Encyclopedia", The Goodheart-Willcox Company, Inc., 1995 ISBN I- 56637-150-3. Enjavec, Jack and Schai~, Robert, "Automotive Technology", 2nd Edition Delmar Publishers, An international Thomson Publishing Company, 19%, ISBN. - William Crouse, "All Automobile" (12 parts), Mars Publishing House, ISBN William Il. Crouse and Donald I,. Anglin, "Automotive Technician's t-landbook", The McGraw-Hill Book Company, ISBN Robert Bosch GmbH, "Automotive Handbook", 4th Edition, 1996, Published by VD1-Verlag, ISBN - William H. Crouse and Donald L. Anglin, "Automotive Mechanics" The McGrawHill Book Company, IOth Edition, ISBN 04)2-800943A - Stokel, Martin W., Stokel, Martin T., and Johanson, Chris, "Auto Fundamentals" The Goodheart Willcox company, fl'rC, ISBN 1-56637- 1384, 1996 - William, K. Toboldt, Larry Johnson, and W. Scott Gavthier, "Automotive Encyclopedia" Fundamental, Principles, Operation, Construction, Service, and Repair, The Goodheart -Willcox company, INC, ISBN 1-56637-150-3, 1995 - Duffy, James E., "Auto Engines" The Goodheart Willcox company, INC, ISBN 0-87006A77-3 - Jack Enjavec and Robert Scharif "Automotive Technology" Delmar Publishers, An International Thomson Publishing Company.
Detailed Theoretical Course
Hours Content Skill Objectives Related tasks
2
Introduction to different power train units (clutch, gearbox, rear axel):
- Friction clutch and its different types
- Sliding mesh and constant mesh gearboxes
- Different types of propeller shafts and universal joints
- Differential, its parts and importance
- Drive axels
The student should be able to: - Identify different power train
units (clutch, gearbox, rear axel): - Identify friction clutch and its
different types. - Identify sliding mesh and constant
mesh gearboxes. - Identify different types of
propeller shafts and universal joints.
- Identify differential, its parts and importance.
- Identify drive axels.
E1
2
Studying the importance of using oils and sealants in different power train units (clutch, gearbox, rear axel)
- Understand the importance of using oils.
- Know about sealants in different power train units (clutch, gearbox, rear axel).
E2, E3, E4
6
Studying the importance and types of power train units (clutches, gearboxes) and the causes of noise in power train components, as well as determining faults in: 1 – clutch: - friction plate, pressure plate, flywheel - sliding parts and splines - sealants - mechanical and hydraulic connections - springs and release levers 2 – sliding mesh and constant mesh gearboxes: - ball bearing - oil seals and gaskets - end play of the main shaft - splines - mechanical parts (gears, phalanges, sleeves) - synchronizer (synchronizer sleeve, blocking ring … etc) - cone clutch, blocking ring - shift lever - shift fork
- Understand the importance and types of power train units (clutches, gearboxes) and the causes of noise in the power train components, as well as determining faults in the system.
- Identify clutch. - Identify friction plate, pressure
plate, and flywheel. - Identify sliding parts and splines. - Identify sealants. - Differentiate between mechanical
and hydraulic connections. - Identify springs and release
levers. - Identify sliding mesh and constant
mesh gearboxes. - Identify ball bearing. - Identify oil seals and gaskets. - Understand the reason for end
play of the main shaft. - Identify splines. - Understand mechanical parts
(gears, phalanges, sleeves). - Identify synchronizer
(synchronizer sleeve, blocking ring … etc).
- Identify cone clutch, blocking ring.
- Identify shift lever. - Understand mode of operation of
shift fork.
E5, E6, E7, I1, 18, 19
4
Studying shapes and types of gears, joints and roller bearings used in clutches and constant mesh gearboxes. Also to know the methods of determining gear reduction ratios.
Study shapes and types of gears, joints and roller bearings used in clutches and constant mesh gearboxes. Know methods of determining gear reduction ratios.
E7, E9
2
Introduction to the importance of shift lever and levers used in different types of clutches and gearboxes, and methods of motion transfer.
Introduction to the importance of shift lever and levers used in different types of clutches and gearboxes, and methods of motion transfer.
E7, I10
4
Studying of the different types of propeller shafts in the power train system and their performance.
- Hollow shafts - Covered shafts - Uncovered shafts
Identify different types of propeller shafts in power train system and their performance.
- Identify hollow shafts. - Identify covered shafts. - Identify uncovered shafts.
E7, E9, E10, E12, I17
4
Studying types and shapes of gear in the differential: Worm gear, straight toothed bevel gear, spiral bevel gear, hypoid gear and the methods of determining possible faults and their types:
Pinion gear Crown gear Differential case
Identify types and shapes of gear in the differential: Identify worm gear, straight toothed bevel gear, spiral bevel gear, hypoid gear. Know the methods of determining possible faults and their types:
Pinion gear Crown gear
Differential case
E7, E8, E9, I12,
I16
2
Studying the importance of axels and shafts in the final drive, as well as to study the importance of rear axel sensors Types of differential
- Conventional - Limited slip differential
- Understand the importance of axels and shafts in the final drive to the power train.
- Understand the importance of rear axel sensors.
- Identify types of differential. - Identify conventional. - Identify limited slip differential.
E7, E8, E11, I14,
I15, I18
2
Preparing a conclusive report on the maintenance operations of all types of clutches and different gearboxes (sliding and constant mesh) and the power train
Prepare a conclusive report on the work done on the mechanical faults in the power train. I19
Detailed Practical Course
Hours Content Skill Objectives Related tasks
4
Introduction to different power train units (clutch, gearbox, rear axel):
- Friction clutch and its different types
- Sliding mesh and constant mesh gearboxes
- Different types of propeller shafts and universal joints
- Differential, its parts and importance
- Drive axels
The student should be able to: Identify type of transmission to be able to diagnose possible faults (manual, hydraulic, automatic).
E1
4
Checking the condition of grease, oils and sealants of different types Oil leakage in one of the power train units (clutch, gearbox or rear axel) Incorrect amount of transmission fluid in different power train units (clutch, gearbox, rear axel).
- Check the proper oil level. - Observe the color and smell of the
fluid. - Ensure that the fluid meets the
manufacturing company’s specifications.
- Determine the type of fluid that meets manufacturing company’s specifications.
E2, E3, E4
6
- Finding noise source in the clutch and gearbox, diagnosing their faults and determining their type; mechanical or hydraulic. Also methods of measuring using tools and equipment in the workshop and on the road.
- Clutch - Disassembling clutch - Clutch disassembling steps - Checking clutch and replacing
faulty parts - Checking flywheel and replacing it
if needed - Clutch faults - Wear of the friction plate, pressure
plate or flywheel - Glazed surface of the friction plate,
pressure plate or flywheel - Presence of oil on the friction plate,
pressure plate or flywheel - Distortion of the friction plate,
pressure plate or flywheel - Weakness of springs or release lever- Clutch faults during release and
engage - Shaking that happens during engage - Vibration or hardness of clutch
pedal - Assembling the clutch and testing it
- Find noise source using special tools and equipment.
- Determine fault location. - Determine fault type (electric,
mechanical, hydraulic). - Check flywheel. - Replace clutch. - Replace oil seals and gaskets using
special tools to prevent oil leakage. - Use testing equipment for accurate
diagnosis of faults as per manufacturing company’s recommendations.
E5, E6, E7, I1,
I9
6
- Constant and sliding mesh gearbox - Disassemble the constant or sliding
mesh gearbox - Constant and sliding mesh gearbox
disassembling steps - Check the gearboxes and replace
faulty parts - Faults of the sliding and constant
mesh gearboxes: - Wear of the ball bearing - Damage and distortion of the
splines - Wrong installation of parts
(phalanges, gears, bushings … etc) - Wear in the cone clutch of
synchronizer block - Oil leakage in the gearbox - Presence of noise at any shift - Hard gear shifting or a metallic
squeaking sound - Complete breaking of the clutch
fork (release fork) - Reassembling the constant or
sliding mesh gearbox and testing it
- Locate noise source using special tools and determining fault location.
- Determine fault type (electric, mechanical, hydraulic).
- Replace gears and ball bearings of the manual gearbox using special tools for better performance under different driving conditions.
- Replace oil seals and gaskets to prevent oil leakage for proper performance of the gearbox.
- Use testing equipment for accurate diagnosis as per manufacturing company’s recommendations.
E5, E6, E7, I8,
I98
8
- Methods of checking the condition and performance of gears and connections in the clutch, the constant and sliding mesh gearboxes and ball bearing using the special testing equipment, as well as replacing faulty parts with ones that meet the recommended specifications
- Use testing equipment as recommended for accurate diagnosis.
- Check sealants correctly.
E7, E9
4
- Methods of checking and testing control levers in different types of clutches and gearboxes (constant and sliding mesh) using tools and equipment needed. Also the method of motion transfer, and replacing faulty parts with ones that meet the recommended specifications
- Adjust the control levers for the gearbox for easy shifting.
- Use testing equipment as recommended for accurate diagnosis.
E7, I10
8
- Introduce the student to the different types of propeller shafts and their parts, the universal joints, the methods of diagnosing faults and their types using the special tools and equipment for that. The faults include:
- Bending of the propeller shaft - Excessive clearance in the universal
joints - Noise in the center bearing - Faulty ball bearing - Determine joints faults during
rotation - Replace universal joints … etc - Install propeller shaft - Check propeller shaft balancing and
inclination angle - Adjust and repair or replace faulty
parts with ones that meet the recommended specifications
- Correctly check universal joints and ensure their stability and proper performance
- Check propeller shaft with the special tools
- Replace the universal joints cross using tools
- Properly check sealants - Use testing equipment as
recommended for accurate diagnosis
E7, E9, E10,
E12, I17
8
- Method of checking and adjusting differential as per specifications, also checking faults and determining their types using the special tools for that. The faults could be:
- Pinion gear - Crown gear - Differential case - Loud noise at the start of motion or
while shifting - Knocking sound - Shaking and noise at the start of
motion - Noise while accelerating or turning - Uneven tire wear - Road traction problems - Low traction effort - Adjusting, repairing or replacing
faulty parts with ones that meet the recommended specifications
- Check axel gears using the special tools
- Replace axel gears using the special tools
- Adjust axel gears using the special tools
- Use testing equipment as recommended for accurate diagnosis
- Properly check sealants E7, E8, E9, I12,
I16
4
- Method of checking and testing the condition and serviceability of axels, shafts and the rear axel sensors using the special tools for that.
- Types of construction of rear axels - Conventional differential - Limited slip differential - Adjusting, repairing or replacing
faulty parts with ones that meet the recommended specifications
- Check axel gears using the special tools
- Properly check axel bearings - Replace axel bearings - Replace axels and shafts - Replace axel sensors - Properly check sealants - Use testing equipment for accurate
diagnosis
E7, E8, E11, I14, I15, I18
4
- Choosing spare parts as per standard specifications
- Preparing a conclusive report on the maintenance operations of all types of clutches, different gearboxes (sliding and constant mesh), the power train and recording the service labor time
- Prepare a conclusive report on the work done on the mechanical faults in the power train
I19
Department Mechanical Technology Major Engines and Vehicles
Course name Brake system Code MEV 212
Prerequisite MEV 111
Course description: this course covers the principles of vehicle brake systems, their different types, antilock brake system (ABS). Master and wheel cylinders, hydraulic valves, boosters and their mode of operation. Brake performance calculations (brake pressure, stopping distance and time) checking, repairing or replacing brakes and its parts. Adjusting brakes and using the brake test stand.
Semester 1 2 3 4
Credit hours 4
L 2
W 4 Contact hours
T
General course objectives: this course aims to introduce the student to the principals of vehicle brake systems, their different types, antilock brake system (ABS). Master and wheel cylinders, hydraulic valves, boosters and their mode of operation. Brake performance calculations (brake pressure, stopping distance and time). As well as teaching the student how to check, repair or replace brakes and its parts, adjust brakes and use the brake test stand.
Skill Objectives: The student should be able to: • Know the principals of vehicle brake systems and their different types. • Know antilock brake system (ABS). • Identify master and wheel cylinders, hydraulic valves, boosters and their mode of operation. • Calculate brake performance (brake pressure, stopping distance and time). • Check, repair, replace and adjust brakes and its parts. • Use the brake test stand.
Subjects (theoretical and practical): • The principals of vehicle brake systems and their different types. • Antilock brake system (ABS). • Master and wheel cylinders. • Hydraulic valves, boosters and their mode of operation. • Brake performance calculations (brake pressure, stopping distance and time). • Checking, repairing, replacing brakes and its parts, and adjusting brakes. • Using the brake test stand.
References:
- Jack Enjavec and Robert Scharff: "Automotive Technology", 2nd Edition 1996, Delmar Publishers, An international Thomson Publishing Company, ISBN. - Stockel, Stockel, and Johanson, "Auto Service & - 1996, The Goodheart Willcox Company, Inc., Tinley Park, Illinois, ISBN, 1-56637-144-9 - William K. Toboldt, Larry Johnson, and W. Scott Gauthier, "Automotive Encyclopedia', The Goodheart-Willcox Company, Inc., Tinley Park, Illinois, ISRN 1-56637-150-3, 1995 - Stockel, M.W, Stockel, M. 7`., and Johanson, C., "Auto Fundamentals", 1996, The Goodheart-Willcox Company, Inc., Tinley Park, Illinois, I SBN 1-5 663 7-138-4 - Crouse-Anglin, "Auto Fundamentals", I0th Edition, The McGraw-Hill Rook Company - William Crouse, "All Automobile", (12 parts), Mars Publishing House. - William H. Crouse and Donald L. Anglin, "The Auto Book", 3rd Edition, The McGraw-Hill Book Company - Robert Bosch GmbH, "Automotive Handbook", 4th Edition- 1996, Published by VDI-Verlag, ISBN - Martin W. Stockel and Martin, "Auto Mechanics Fundamentals", The Goodheart Willcox Company, Inc., Tinley Park, Illinois, ISBN 156637-1384, 1996 - Crouse, William H. and Donald L. Anglin, "Automotive Technician's Handbook", The McGraw-Hill Book Company, ISBN 0-070-14751-5 - Robert Schar- "Complete Brake Systems", Delmar Publisher, Inc., ISBN 0-8273-3539-3 - Robert Bosch Cooperation, "Bosch Technkal Instruction Series", - Compressed air brake Systems, Symbols- - Compressed air brake Systems, Equipment- - Compressed air brake Systems, Schematic Diagrams
Detailed Theoretical Course
Hours Content Skill Objectives Related tasks
4
Vehicle brake system: - Its function, types and main parts - Vehicle brake system mode of
operation
The student should be able to: - Identify brake system, its function,
types and main parts - Understand vehicle brake system and
mode of operation
F1
6
Linings, drums … etc - Linings, their types, checking and
replacing them - Drums, discs and wheel bearing:
their types, checking and replacing them
- Ways of checking linings and drums in the lab, taking measurements, fault causes
- Identify linings, their types, check and replace them
- Identify drums, discs and wheel bearing: their types, check and replace them
- Understand ways of checking linings and drums in the lab, take measurements, fault causes
J1, J2, J3, J11, F2, F4,
F5
4
The booster: - Its function, mode of operation,
related parts - Booster faults, their causes and how
to repair them
- Identify the booster - Understand its function, mode of
operation, related parts - Know booster faults, their causes and
how to repair them
J9, J10, F6
6
Master and wheel cylinders: - Their function, mode of operation,
related parts - Master and wheel cylinder faults - Brake pipes - Their function, types and faults - Master and wheel cylinder and brake
pipes maintenance
Identify master and wheel cylinders: - Their function, mode of operation,
related parts - Master and wheel cylinder faults Identify brake pipes: - Their function, types and faults Understand master and wheel cylinder and brake pipes maintenance
J4, J5, J7, J8, F3, F9
6
Antilock brake system (ABS): - Its function, mode of operation, parts
and their mode of operation - Types and designs of antilock brake
systems - Construction and function of the
system - Checking and maintenance of the
system - Using the ABS testing device
Identify antilock brake system (ABS) - Its function, mode of operation, parts
and their mode of operation - Types and designs of antilock brake
systems - Construction and function of the
system - Understand methods of checking and
maintenance of the system Know how to use the ABS testing device
J6, J13, J14, F7
2
Parking brakes - Brake pedal: - Parking brake function, mode of
operation, types and parts - Brake pedal - Checking brake pedal and its faults
- Identify parking brakes and brake pedal
- Understand parking brake function, mode of operation, types and parts
- Identify brake pedal - Understand how to check brake
pedal and its faults
J12, J15, F8,
F10
Detailed Practical Course
Hours Content Skill Objectives Related tasks
4
Identify vehicle brake system: - Check oil level - Locate oil leakage sources in the
brake system
The student should be able to: - Identify brake system - Check oil level - Locate oil leakage sources in the
brake system
F1
16
Locate noise source in the brake system: - Method of locating noise source - Method of checking brake system
parts and determining fault - Writing a report about the faulty
parts Linings, drums … etc - Checking, repairing and replacing
linings - Checking, repairing (turning,
grinding) replacing - Checking wheel bearing and
replacing it - Methods of removing, installing and
replacing faulty parts
Locate noise source in the brake system: - Know method of locating noise
source - Know method of checking brake
system parts and determining fault - Write a report about the faulty parts - Identify linings, drums … etc - Check, repair and replace linings - Check, repair (turn, grind) replace - Check wheel bearing and replace it - Know methods of removing,
installing and replacing faulty parts
J1, J2, J3, J11, F2, F4,
F5
8
The booster: - Method of checking and repairing - Method of replacing and periodic
maintenance
- Identify the booster - Know method of checking and
repairing - Know method of replacing and
periodic maintenance
J9, J10, F6
12
Master and wheel cylinders: - Methods of checking, repairing and
replacing master and wheel cylinders
- Checking, repairing and replacing brake pipes
- Method of changing brake fluid and bleeding air from the circuit as per maintenance manual
- Identify master and wheel cylinders - Know methods of checking,
repairing and replacing master and wheel cylinders
- Check, repair and replace brake pipes
- Change brake fluid and bleed air from the circuit as per maintenance manual
J4, J5, J7, J8, F3, F9
12
Checking and repairing antilock brake system (ABS): - Identify system parts - Using the ABS testing device and
the method of testing - Running needed tests on the system
as per manufacturing company’s instructions
- Repairing and replacing faulty parts and sensors in the system
Check and repair antilock brake system (ABS) - Identify system parts - Use the ABS testing device and
know the method of testing - Run needed tests on the system as
per manufacturing company’s instructions
Repair and replace faulty parts and sensors in the system
J6, J13, J14, F7
4
Checking parking brakes: - Method of checking, repairing and
replacing faulty parts Brake pedal: - Method of checking and repairing
brake pedal Adjusting parking and rear brake: - Method of adjusting brakes and
testing them
- Check and adjust rear and parking brakes using special tools for proper performance for the safety of the car and passengers
- Properly check brake pedal - Prepare a conclusive report on the
work done on the mechanical faults in the brake system
J12, J15, F8,
F10
Department Mechanical Technology Major Engines and Vehicles
Course name Engines (2) Code MEV 213
Prerequisite MEV 123
Course description: checking internal combustion engines, engine oil evaporation, determining type and source of noise, measuring engine compression pressure and analyzing exhaust gases. Removing faulty engine from vehicle, disassembling engine (cylinder head, cylinder block … etc), doing the needed repairs to the cylinder head and cylinder block and replacing faulty part are all covered in this course. Reassembling and reinstalling engine, as well as operating the engine after the repairs and testing it is included.
Semester 1 2 3 4
Credit hours 4
L 2
W 4 Contact hours
T
General course objectives: this course aims to introduce the student to inspecting internal combustion engines, engine oil evaporation, determining type and source of noise, measuring engine compression pressure and analyzing exhaust gases. As well as removing faulty engine from vehicle. The student will be able to disassemble engine (cylinder head, cylinder block … etc), as well as to know the method of doing the needed repairs to the cylinder head and cylinder block and to replace faulty parts. The student will be able to reassemble, reinstall engine and operat the engine after the repairs and test it. Skill Objectives: The student should be able to: • Check internal combustion engines, engine oil evaporation. • Determine type and source of noise. • Measure engine compression pressure. • Analyze exhaust gases. • Remove faulty engine from vehicle, and disassemble engine (cylinder head, cylinder block …
etc). • Do the needed repairs to the cylinder head and cylinder block and replace faulty parts. • Reassemble and reinstall engine. • Operate the engine after the repairs and test it.
Subjects (theoretical and practical): • Checking internal combustion engines. • Observing engine oil evaporation. • Determining type and source of noise. • Measuring engine compression pressure. • Analyzing exhaust gases. • Removing faulty engine from vehicle. • Disassembling engine (cylinder head, cylinder block … etc). • Doing the needed repairs to the cylinder head and cylinder block and replacing faulty parts. • Reassembling and reinstalling engine. • Operating the engine after the repairs and testing it.
References:
Heinze Heisler, Advanced Engine Technology, Edward Arnold, ISBN 0340568224 - William H. Crouse and Donald L. Anglin, "Automotive Mechanics" The McGraw Hill Book Company, ISBN 0-02-800943-6 - Manufacturer's data and repair manuals - Martin, W. Stokel and Martin "Auto Mechanics fundamentals", The Goodheart Willcox company, INC, ISBN 1-56637-138-4, 1996 - Stockel, Stockel, and Johanson, "Auto Service and Repair", The Goodheart Willcox company, INC, - Martin W. Stokel, Martin T. Stokel Cluis Johanson "Auto Fundamentals" The Goodheart Willcox company, INC, ISBN 1-56637-]384, 1996 William, K. Toboldt, Larry Johnson, and W. Scott Gavthier, "Automotive Encyclopedia " Fundamental, Principles, Operation, Construction, Service, and Repair- The Goodheart -Willcox company, INC, ISBN I- 56637-150-3, 1995 - Jack Enjavec and Robert Schaiff "Automotive Technology" Delmar Publishers, An International Thomson Publishing Company, - Robert Bosch GmbH "Automotive Handbook" Published by VDI-Verlag, 1996 - Duffy, James E., "Auto Engines" The Goodheart Willcox company, INC, ISBN 0-87006A77-3
Detailed Theoretical Course
Hours Content Skill Objectives Related tasks
2
Engine oil evaporation: Amount of engine oil, amount of evaporation, causes, measuring oil level and viscosity, causes of excessive evaporation, causes of low oil level
The student should be able to: - Notice oil evaporation: Amount of engine oil, amount of evaporation, causes - Understand the method of measuring
oil level and viscosity - Know the causes of excessive
evaporation, causes of low oil level
D2, D3
2
Car engine noise: - Types of abnormal engine noise
using the stethoscope - Locations of noise causing parts in
the engine
Identify car engine noise: - Identify types of abnormal engine
noise - Understand how to use the
stethoscope - Identify the locations of noise
causing parts in the engine
D5
2
Measuring engine compression pressure: - Engine compression pressure,
engine compression pressure value - Causes for low compression
pressure, its effects and how to solve them
- Method of checking engine compression pressure
Know the method for measuring engine compression pressure: - Engine compression pressure, engine
compression pressure value Know the causes for low compression pressure, its effects and how to solve them Know the method of checking engine compression pressure
D6
2
Analyzing exhaust gases: - Exhaust gases, their kinds, causes
and methods of controlling them - Methods for checking exhaust gases
- Know how to analyze exhaust gases - Exhaust gases, their kinds, causes
and methods of controlling them - Know the methods for checking
exhaust gases
D9
9
Repairing cylinder head: - Cylinder head, its types and parts - Camshaft, its types, methods of
inspection and replacing it - Engine valves, their types and
methods of inspecting them - Parts related to engine valves,
methods of inspecting, repairing and replacing them
- Methods of grinding valves and their effect on engine power
- Methods of repairing and replacing valves
- Checking cylinder head flatness, its effect on the engine, methods of repairing it
- Reassembling engine after the maintenance job is done
Know the method for repairing cylinder head: - Cylinder head, its types and parts - Camshaft, its types, methods of
inspecting and replacing it - Engine valves, their types and
methods of inspecting them - Parts related to engine valves,
methods of inspecting, repairing and replacing them
- Methods of grinding valves and their effect on engine power
- Methods of repairing and replacing valves
- Checking cylinder head, its effect on the engine, methods of repairing it
Know the method for reassembling engine after the maintenance job is done
H1
9
Repairing cylinder block faults: - Cylinder block, its types and related
parts - Crankshaft, checking and measuring
it - Piston assembly, its types and faults - Connecting rod, piston rings, piston
pin - Complete and half circle bearing,
their types and faults - Cylinder measuring and boring - Timing chain, its types, method of
timing - Camshaft assembly and its mode of
operation - Reassembling engine (cylinder block
with cylinder head) - Reinstalling the engine after the
maintenance job is done - Testing the engine
Know the method for repairing cylinder block: - Cylinder block its types and related
parts - Crankshaft, checking and measuring
it - Piston assembly, its types and faults - Connecting rod, piston rings, piston
pin - Complete and half circle bearing,
their types and faults - Measuring cylinder bore and boring
it - Timing chain, its types, method of
timing - Camshaft assembly and its mode of
operation Know how to reassemble engine (cylinder block with cylinder head) - Reinstalling the engine after the
maintenance job is done - Testing the engine
H2
D4, H4, D7, D10,
D8, H5, H3, H6
Detailed Theoretical Course
Hours Content Skill Objectives Related tasks
6
Engine oil evaporation: - Method of checking oil evaporation
and the necessary measurements - Measuring oil level and viscosity,
method of changing oil - Preparing a concise work report with
observations
The student should be able to: Observe engine oil evaporation: - Check evaporation and take the
necessary measurements - Measure oil level and viscosity - Know the method of changing oil - Prepare a brief work report with
observations
D2, D3
6
Engine noise: - Locating them, using lifts for lower
parts - Using the stethoscope to locate
source of noise - Determining fault in engine
- Locate engine noise - Know the methods for locating them,
use lifts for lower parts - Use the stethoscope to locate source
of noise - Determine fault in engine
D5
6
Measuring engine compression pressure: - Measuring engine compression
pressure of the practice engine - Test procedures and connecting the
device - Running the engine and take
readings - Finishing the test and preparing a
report
Measure engine compression pressure: - Measure engine compression
pressure of the practice engine - Know test procedures and
connecting the device - Run the engine and take readings - Prepare a report
D6
6
Checking and analyzing exhaust gases: - Exhaust gases; their kinds and their
causes - Methods of inspection and
equipment needed
Check and analyze exhaust gases: - Exhaust gases; their kinds and their
causes - Knowing methods of inspection and
equipment needed
D9
24
Checking and repairing cylinder head: - Removing cylinder head, method of
cleaning it, disassembling it - Checking faulty parts - Removing, checking, lapping,
replacing valves - Valve assembly, methods of
checking, repairing, replacing it - Checking cylinder head flatness,
repairing, replacing it - Checking camshaft, measuring,
replacing it - Checking timing chain or belt,
replacing it - Method of reassembling engine after
maintenance
Check and repair cylinder head: - Removing cylinder head, method of
cleaning it, disassembling it - Checking faulty parts - Removing, checking, lapping,
replacing valves - Valve assembly, methods of
checking, repairing, replacing it - Checking cylinder head flatness,
repairing, replacing it - Checking camshaft, measuring,
replacing it - Checking timing chain or belt,
replacing it Know the method of reassembling engine after maintenance
H1
24
Checking and repairing cylinder block faults: - Disassembling cylinder block,
method of cleaning it - Checking crankshaft, measuring its
diameters - Checking pistons and connecting
rod, repairing, cleaning them, replacing faulty parts
- Checking piston rings and replacing them
- Checking complete and half circle bearings, cleaning them, replacing them
- Checking the size of cylinder bore and boring it
- Checking and replacing timing chain, method to insure correct timing after installing cylinder head
- Disassembling camshaft in the cylinder block, checking camshaft assembly and their mode of operation
- Reassembling cylinder block to cylinder head
Check and repair cylinder block faults: - Disassembling cylinder block,
method of cleaning it - Checking crankshaft, measuring its
diameters - Checking pistons and connecting
rod, repairing, cleaning them, replacing faulty parts
- Checking piston rings and replacing them
- Checking complete and half circle bearings, cleaning them, replacing them
- Checking the size of cylinder bore and boring it
- Checking and replacing timing chain, method to insure correct timing after installing cylinder head
- Disassembling camshaft inside the cylinder block, checking camshaft assembly and their mode of operation
Reassemble cylinder block to cylinder head
H2
3
reinstalling the engine Use tools correctly for safety and protection of the tools and equipment from any harm Use devices correctly for their safety and protection Secure car lift for the safety of car, technician and workshop
A3, A4, A5
6
Method of testing the engine using tools and equipment after the maintenance job is done
Check, repair or replace - Check and repair lubricating system
faults and replace faulty parts - Check and repair cooling system
faults and replace faulty parts - Check and repair fuel system faults
and replace faulty parts - Check and repair ignition system
faults and replace faulty parts using special tools and equipment
D4, H4, D7, D10,
D8, H5, H3, H6
Department Mechanical Technology Major Engines and Vehicles
Course name Fuel system (Diesel) Code MEV 214
Prerequisite MEV 123
Course description: this course discusses how to repair and maintain diesel injection system.
Semester 1 2 3 4
Credit hours 3
L 2
W 2 Contact hours
T General course objectives: this course aims to introduce the student to the methods of repairing and maintaining diesel injection system. It includes; fuel tank, fuel supply pump, injection pump, their calibration, the regulation of the injection, pressure and amounts of diesel according to the different operating conditions, methods of controlling fuel injection and glow plugs and their connections. As well as introducing the student to the methods of determining and diagnosing faults and inspecting using advanced tools and equipment in that field.
Skill Objectives: The student should be able to: • Know how to maintain diesel injection systems. • Identify diesel circuit components. • Know methods of adjusting the engine through the system without removing any parts. • Know methods of adjusting and calibrating amounts of pumped fuel by the injection pump
using the diesel injection pump test stand. • Know methods of adjusting and calibrating amounts injected by the injectors according to
engine operating conditions and by using the diesel injection pump tester. • Determine and diagnose faults and repair or replace faulty parts of the diesel injection system. • Check the system using advanced tools and equipment in that field.
Subjects (theoretical and practical): • Method of repairing and maintaining diesel injection system • Fuel supply pump, connections, injectors • Fuel injection pump • Determining and diagnosing faults and repairing or replacing faulty parts of the diesel injection
system • Checking the system using advanced tools and equipment in that field
References:
- Schulz: Erick J., and Evridge, Ben L., "Diesel Mechanics", Glencoel McGraw-Hill, ISBN 0-074)55836-1. - Duffy, James E., and Smith, Howard B., " Auto Fuel and Emission Control Systems Technology", The Goodheart-Willcox company, INC, ISBN O- 87006-932-2 - Heinze Heisler, "Advanced Engine Technology", Edward Arnold, ISBN 0340568224 - William H. Crouse and Donald L. Anglin, "Automotive Mechanics" The McGraw Hill Book Company, ISBN 04)2-800943-6 - Stokel, Martin W., Stokel, Martin T., and Johanson, Chris, "Auto Fundamentals" The Goodheart Willcox company, INC, ISBN 1-5663 7-1384, 1996 - William, K. Toboldt, Larry Johnson, and W. Scott Gavthier, "Automotive Encyclopedia " Fundamental, Principles, Operation, Construction, Service, and Repair, The Goodheart -Willcox company; INC, ISBN 1-56637-150-3, 1995 - Duffy, James E., "Auto Engines" The Goodheart Willcox company, INC, ISBN 0-87006477-3 - Jack Enjavec and Robert SclmIff "Automotive Technology " Delmar Publishers, An International Thomson Publishing Company.
Detailed Theoretical Course
Hours Content Skill Objectives
The student should be able to:
Related tasks
2
Diesel fuel characteristics • Study fuel characteristics
(evaporation, density, effects of fuel characteristics on fuel injection system)
• Fuel injection systems (direct and indirect)
• Types of combustion chambers • Effects of different injection systems
on diesel engine performance
ID
4
Fuel injection systems Fuel injection system components: • Fuel tank • Fuel supply pump • Fuel filters • Fuel injection pump • Fuel lines and pipes • Injectors
Identify fuel injection system components: - Fuel tank, its contents and connections - Fuel hoses and pipes - Diesel float Effect of the presence of air in the diesel circuit
ID4, ID10, ID11, ID15, ID16
4
Fuel supply pumps • Construction and mode of operation
of the different types of pumps (mechanical and electric)
• Comparison between the different pumps from the point of view of their effect on the performance of the fuel injection system
• Advantages and disadvantages of each type of pumps
• Causes of faults and their effect on the fuel injection system
Identify the components of the fuel supply pump and its types
ID1, ID9
4
Fuel filters • Construction and mode of operation
of different filter types • Comparison between different
systems • Advantages and disadvantages of
each type • Fuel passage through different filters • Fault causes and their effects on the
fuel system • Method of separating fuel from
water
Identify the components of the diesel filters, types, mode of operation and the advantages and disadvantages of each system
ID3
6
Fuel injection pump • Construction and mode of operation
of the in-line pump • Construction and mode of operation
of distributor pump • Different fuel injection control
methods • Comparison between different types • Fault causes in the different pumps
and their effects on the fuel system
Identify: - Electric diesel pump - Pump valve - In-line diesel pump - Distributor diesel pump their types, mode of operation and the advantages and disadvantages of each system
ID2, ID5, ID12, ID13
4
Fuel injectors • different types of injectors • Construction and mode of operation
of injectors • Comparison between different types • Advantages and disadvantages of
each type • Fault causes in the injectors and
their effects on the fuel system
Identify the components of injectors, their types, mode of operation and the advantages and disadvantages of each type
ID7, ID14
4
Fuel injection control • Method of controlling fuel injection
timing • Method of controlling amount of
injection • Construction and mode of operation
of fuel injection regulators • Comparison between different types
Identify: • Diesel pump timing • Injection amount (manually) • Electronic injection system • Electronic injection components
ID6, ID8, ID17, ID18
Detailed Theoretical Course
Hours Content Skill Objectives Related tasks
2
Safety procedures for the diesel workshop Checking the components of the fuel system and the characteristics of diesel fuel Types of fuel injection systems Types of combustion chambers The effects of different injection system types on the diesel engine
The student should be able to: - Visually inspect diesel components
and identify the different diesel fuel injection systems
ID
2
Methods of locating faults and adjusting fuel injection systems without removing parts. The faults include: • Hard engine starting • Loss in engine power • Irregular engine rotation • Diesel engine knock • Back fire in the induction manifold • Presence of black smoke in the
exhaust fumes • Engine vibration • Excessive fuel consumption
Identify fuel system faults
ID4, ID10, ID11, ID15, ID16
2
Methods of checking for faults and adjusting fuel injection systems: • Fuel tank (electric connections,
leakages, removing the float and repairing it, … etc)
• Clean suitable fuel • Fuel filters • Fuel injection pump • Fuel lines and pipes (injection and
return lines) • Diesel hoses and pipes • Injectors
• Check fuel tank • Replace fuel tank • Replace fuel hoses and pipes • Replace diesel float • Bleed air from the diesel circuit
ID4, ID10, ID11, ID15, ID16
2
Adjusting, repairing and replacing what is needed in: - Mechanical fuel supply pumps - Electric fuel supply pumps - Check amounts of fuel intake - Check electric connections - Bleed air
- Check fuel supply pump - Replace fuel supply pump
ID1, ID9
2
Adjusting, repairing and replacing what is needed in: - Different types of fuel filters - Visually inspect filter or by a magnifying glass - Cleaning filter
- Check diesel filters
ID3
6
Method of adjusting the fuel injection pump using the diesel injection pumps test stand. This includes: - Equal amount of injection from every injector - Injector stroke length (injection time) - Full load amounts - Engine starting amounts - Injection timing - Controlling engine rotation speed
- Check electric diesel pump - Check pump valve - Replace diesel pump - Replace electric diesel pump ID2,
ID5, ID6, ID12, ID13
4
Method of repairing fuel injection pumps (in-line and distributor). This includes: - Injection plunger - Cams - Injection control springs - Bearings - Pump components - Supply valves
- Check electric diesel pump - Check pump valve - Replace diesel pump - Replace electric diesel pump
ID2, ID5, ID6, ID12, ID13
4
Adjusting, repairing and maintaining what is needed in: - Different types of injectors - Amount and pressure of injection - Observe spray pattern - Fuel injection lines - Glow plugs
- Check injectors - Replace injectors
ID7, ID8, ID14
4
Checking and repairing fuel injection control - Control system for the glow plugs - Injection amounts control spring - Injection amounts control resistance
- Check diesel fuel pump timing - Check injection amount manually - Check electronic injection system - Replace electronic injection parts
ID6, ID8, ID17, ID18
Department Mechanical Technology Major Engines and Vehicles
Course name Engineering Drawing Code MEV 221
Prerequisite MEV 121
Course description: this course covers the principles of assembly drawing by using fits and tolerance. Also construction methods of coupling, keys, splines, threads and nuts, and determining surface quality.
Semester 1 2 3 4
Credit hours 2
L
W 4 Contact hours
T
General course objectives: this course aims to introduce the student to the principals of assembly drawing by using fits and tolerance. Also construction methods of coupling, keys, splines, threads and nuts, and determine surface quality of machined surfaces.
Skill Objectives: The student should be able to: • Know the principals of assembly drawing by using fits and tolerance. • Know the construction methods of coupling, keys, splines, threads and nuts. • Determine surface quality of machined surfaces. • Analyze the drawing and write a technical report.
Subjects (theoretical and practical): • The principals of assembly drawing by using fits and tolerance • Construction methods of coupling • Construction of keys, splines, threads and nuts • Determining surface quality of machined surfaces
References:
- James H, "Drafting, technology,, Earle Addison-Wesley Publications co. - M.A. Parker & L.J. Dennis, "Engineering drawing Fundamentals', Stanley Theoris. - Warren J. Luzadder, ,, Fundamentals of Engineering Drawing', Prentice- Hall, 1986, Ninth Edition.
Detailed Practical Course
Hours Content Skill Objectives Related tasks
8
Assembling parts - Importance of assembling in
engineering drawing - Methods of determining surface
quality of machined surfaces - Determining roughness of machined
surfaces - Applications of assembling
engineering drawing
The student should be able to: - Know the importance of assembling
in engineering drawing - Know methods of determining
surface quality of machined surfaces - Determine roughness of machined
surfaces - Apply assembling engineering
drawing
12
Fits and tolerance - Factors affecting fits and tolerance - Parts standard dimensions - Obtaining fits and tolerance values - Inserting fits and tolerance into the
assembly drawing
- Understand factors affecting fits and tolerance
- Read parts standard dimensions - Obtain fits and tolerance values - Insert fits and tolerance into the
assembly drawing
12
Threads, bolts and springs - Types of springs and threads - Finding the specifications of springs,
threads and bolts - Methods of choosing and using
design tables
- Draw types of springs and threads - Find the properties of springs,
threads and bolts - Know methods of choosing and
using design tables
12
Bearings, gears and cams - Bearing types - Gears types - Cam types - Methods of selecting bearing
- Draw types of bearings - Draw types of gears - Draw types cams - Know methods of selecting bearing
12
Connections, bolts and keys - Types of sealants - Types of keys and splines - Choosing locking devices - Methods of locking coupling
- Know types of sealants - Differentiate between types of keys
and splines - Choose locking devices - Know methods of locking coupling
Department Mechanical Technology Major Engines and Vehicles
Course name Power Trains (2) Code MEV 222
Prerequisite MEV 211
Course description: this course covers the automatic transmission. It includes a study of automatic transmission, clutch, torque converter, planetary gear system and hydraulic control methods. It also covers checking, repairing or replacing faulty parts in the automatic transmission.
Semester 1 2 3 4
Credit hours 4
L 2
W 4 Contact hours
T -
General course objectives: this course aims to introduce the student to the automatic transmission. It includes a study of automatic transmission, clutch, torque converter, planetary gear system and hydraulic control methods. It also covers checking, repairing or replacing faulty parts in the automatic transmission.
Skill Objectives: The student should be able to: • Know the automatic transmission and its importance. • Know automatic transmission, clutch, torque converter, planetary gear system and hydraulic
control methods. • Check automatic transmission. • Repair or replace faulty parts in the automatic transmission.
Subjects (theoretical and practical): • Automatic transmission and its importance • Construction of automatic transmission • Clutch, torque converter, planetary gear system • Hydraulic control methods • Checking automatic transmission • Repairing or replacing faulty parts in the automatic transmission
References:
- Stockel, M.W.: Stockel, M.T, and Johanson C., "Auto Fundamentals", Goodheart Willcox Company, Inc., 1996, ISBN 1-56637-138-4 - Stockel, Stockel, and Johanson, "Auto Service & Repair", Goodheart- Willcox Company, Inc., 1996 ISBN 1-56637-144-9 - William K Toboldt, Larry Johnson, and W. Scott Gauthier, "Automotive Encyclopedia", The Goodheart-Willcox Company, Inc., 1 995 ISBN i-5663 7-150-3. - Enjavec,.lack and Schai-, Robert, "Automotive Technology", 2nd Edition Delmar Publishers, An international Thomson Publishing Company, 19%. ISBN. - William Crouse: "All Automobile" (12 parts), Mars Publishing House, ISBN - William H. Crouse and Donald L. Anglin, "Automotive Technician’s Handbook", The McGraw-Hill Book Company, ISBN - Robert Bosch GmbH, "Automotive Handbook", 4th Edition, 1996, Published by VDI-Verlag, ISBN - William H. Crouse and Donald L. Anglin, "Automotive Mechanics" The McGraw Hill Book Company, I0th Edition, ISBN 04)2-800943A - Stokel, Martin W., Stokel, Martin T., and Johanson, Chris, "Auto Fundamentals" The Goodheart Willcox company, fl'rC, ISBN 1-56637- 1384, 1996 - William, K. Toboldt, Larry Johnson, and W. Scott Gavthier, "Automotive Encyclopedia" Fundamental, Principles, Operation, Construction, Service, and Repair, The Goodheart -Willcox company, IXIC, ISBN 1 -5663 7- 1 50-3, 1 995 - Duffy, James E., "Auto Engines" The Goodheart Willcox company, INC, ISBN 0-87006A77-3 - Jack Enjavec and Robert Scharif "Automotive Technology" Delmar Publishers, An International Thomson Publishing Company.
Detailed Theoretical Course
Hours Content Skill Objectives Related tasks
2
Automatic transmission - Introduction to automatic
transmission - Define automatic transmission - Advantages of automatic
transmission - Types of automatic transmission
The student should be able to: - Identify automatic transmission - Define automatic transmission - Know advantages of automatic
transmission - Know types of automatic
transmission
I3
2
Clutch and torque converter - Hydraulic coupling, its parts and
mode of operation - Torque converter, its parts and
mode of operation
Identify clutch and converter - Identify hydraulic coupling and its
parts - Understand its mode of operation - Identify torque converter and its
parts - Understand its mode of operation
I2, I7, I9, I13
8
Planetary gears unit - Identify planetary gears - Three speed planetary gear unit - Hydraulic control system - Oil pump and types of oil used in
automatic transmission - Identify all parts of automatic
transmission - Hydraulic shift control circuit
Identify planetary gears unit - Identify three speed planetary gear
unit - Understand hydraulic control system - Understand oil pump mode of
operation - Know types of oil used in automatic
transmission - Identify all parts of automatic
transmission - Understand mode of operation of the
hydraulic shift control circuit
I4, I5
16
Hydraulic control methods - Regulator - Pressure regulator vacuum valve - Mode of operation of the hydraulic
shift control circuit - Transmission throttle valve - Manual kick down valve - Automatic transmission auxiliary
cooler/ heat exchanger - Different pressures in parts of the
hydraulic circuit and their relation to valve operation
- Reverse shift valve - 1 and 2 shift valve and its piston - 2 and 3 shift valve and its piston Transmission - Observe power transmission in the
(D) position and first shift - Observe power transmission in the
(D) position and second shift - Observe power transmission in the
(D) position and third shift - Observe power transmission in the
reverse shift - Identify clutches - Identify sensors - Identify faults of automatic
transmission
Identify hydraulic control methods - Regulator - Pressure regulator vacuum valve - Mode of operation of the hydraulic
shift control circuit - Transmission throttle valve - Manual kick down valve - Identify automatic transmission
auxiliary cooler/ heat exchanger - Identify the different pressures in
parts of the hydraulic circuit and their relation to valve operation
- Reverse shift valve - 1 and 2 shift valve and its piston - 2 and 3 shift valve and its piston Identify transmission - Observe power transmission in the
(D) position and first shift - Observe power transmission in the
(D) position and second shift - Observe power transmission in the
(D) position and third shift - Observe power transmission in the
reverse shift - Identify clutches - Identify sensors Identify faults of automatic transmission
I6, I11
Detailed Theoretical Course
Hours Content Skill Objectives Related tasks
2
Automatic transmission - Introduction to automatic
transmission - Define automatic transmission - Advantages of automatic
transmission - Types of automatic transmission
The student should be able to: - Identify automatic transmission - Define automatic transmission - Know advantages of automatic
transmission - Know types of automatic
transmission
I3
2
Clutch and torque converter - Hydraulic clutch, its parts and mode
of operation - Torque converter, its parts and
mode of operation
Identify clutch and converter - Identify hydraulic clutch and its parts - Understand its mode of operation - Identify torque converter and its
parts - Understand its mode of operation
I2, I7, I9, I13
8
Planetary gears unit - Identify planetary gears - Three speed planetary gear unit - Hydraulic control system - Oil pump and types of oil used in
automatic transmission - Identify all parts of automatic
transmission - Gear ratio electronic control circuit
Identify planetary gears unit - Identify three speed planetary gear
unit - Understand hydraulic control system - Understand oil pump mode of
operation - Know types of oil used in automatic
transmission - Identify all parts of automatic
transmission - Understand mode of operation of the
gear ratio electronic control circuit
I4, I5
16
Hydraulic control methods - Regulator - Pressure regulator vacuum valve - Mode of operation of the gear ratio
hydraulic control circuit - Gearbox throttle valve - Manual valve - Automatic transmission radiator - Different pressures in parts of the
hydraulic circuit and their relation to valve operation
- Reverse shift valve - 1 and 2 shift valve and its piston - 2 and 3 shift valve and its piston Transmission - Observe power transmission in the
(D) position and first shift - Observe power transmission in the
(D) position and second shift - Observe power transmission in the
(D) position and third shift - Observe power transmission in the
reverse shift - Identify clutches - Identify sensors - Identify faults of automatic
transmission
Identify hydraulic control methods - Regulator - Pressure regulator vacuum valve - Mode of operation of the gear ratio
hydraulic control circuit - Gearbox throttle valve - Manual valve - Identify automatic transmission
radiator - Identify the different pressures in
parts of the hydraulic circuit and their relation to valve operation
- Reverse shift valve - 1 and 2 shift valve and its piston - 2 and 3 shift valve and its piston Identify transmission - Observe power transmission in the
(D) position and first shift - Observe power transmission in the
(D) position and second shift - Observe power transmission in the
(D) position and third shift - Observe power transmission in the
reverse shift - Identify clutches - Identify sensors Identify faults of automatic transmission
I6, I11
Detailed Practical Course
Hours Content Skill Objectives Related tasks
4
Automatic transmission - Introduction to automatic
transmission - Define automatic transmission - Advantages of automatic
transmission - Types of automatic transmission
The student should be able to: - Identify automatic transmission - Define automatic transmission - Know advantages of automatic
transmission - Know types of automatic
transmission
I3
4
Checking and repairing clutch and torque converter - Hydraulic coupling, its parts and
mode of operation - Torque converter, its parts, mode of
operation and method of checking torque converter
Identify clutch and converter - Identify hydraulic coupling and its
parts - Understand its mode of operation - Identify torque converter and its
parts - Understand its mode of operation
and method of checking torque converter
I2, I7, I9, I13
16
Checking and repairing planetary gears unit - Steps for removing automating
transmission - Steps for disassembling automatic
transmission with special tools - Identify parts and mode of operation
of each part - Checking oil pump - Checking lubricating circuit - Replacing oil filter - Replacing sealants and gaskets
Check and repair planetary gears unit - Follow steps for removing automatic
transmission - Follow steps for disassembling
automatic transmission with special tools
- Identify parts and mode of operation of each part
- Check oil pump - Check lubricating circuit - Replace oil filter - Replace sealants and gaskets
I4, I5
32
Checking and repairing hydraulic control system - Replacing torque converter - Checking clutches - Installing clutches with special tools - Checking pistons - Check control unit - Check sensors Transmission - Method of reassembling
transmission using special tools - Reinstalling automatic transmission - Test transmission after reinstallation
Check and repair hydraulic control system - Replace torque converter - Check clutches - Install clutches with special tools - Check and replace pistons - Check and replace control unit - Check and replace sensors Install transmission - Know method of reassembling
transmission using special tools - Reinstall automatic transmission - Test transmission after reinstallation - Reprogram automatic transmission
for proper performance
I6, I11
Department Mechanical Technology Major Engines and Vehicles
Course name Steering and Suspension System Code MEV 223
Prerequisite MEV 111
Course description: this course covers the different steering systems, different types of steering gearboxes, methods and equipment for measuring, as well as checking and adjusting them. This course also covers different suspension systems, whether for the front or rear axels, and the importance of springs and shock absorbers for the comfort and safety of the passengers and car. Also the different wheel alignment angles, their importance and the methods, tools and equipment for measuring them - comparing them to the standard specifications and adjusting them. The effect of wheel alignment on the stability and safety of the car are included.
Semester 1 2 3 4
Credit hours 4
L 2
W 4 Contact hours
T -
General course objectives: this course aims to introduce the student to the different steering systems, and different types of steering gearboxes and the methods and equipment for measuring, checking and adjusting them. This course also aims to introduce the student to the different suspension systems, whether for the front or rear axels, and the importance of springs and shock absorbers for the comfort and safety of the passengers and car. Also the different wheel alignment angles, their importance and the methods, tools and equipment for measuring them - comparing them to the standard specifications and adjusting them. The effect of wheel angles on the stability and safety of the car. Skill Objectives: The student should be able to: • Know the different steering systems. • Know the different types of steering gearboxes in relation to their direction of motion. • Know the methods and equipment for measuring, checking and adjusting them. • Know different suspension systems for the front and rear axels, and the importance of springs
and shock absorbers for the comfort and safety of the passengers and car. • Know the different wheel alignment angles, their importance and the methods, tools and
equipment for measuring them, comparing them to the standard specifications and adjusting them and their effect on the stability and safety of the car.
Subjects (theoretical and practical): • The different steering systems • The different types of steering gearboxes in relation to their direction of motion • Methods and equipment for measuring, checking and adjusting them • Different suspension systems for the front and rear axels • The importance of springs and shock absorbers for the comfort and safety of car and
passengers • Different wheel alignment angles and the methods and equipment for measuring, checking and
adjusting them according to the standard specifications • Their importance and effect on the stability and safety of the car
References:
-'Thomas W. Birch "Automotive Suspension & Steering Systems", Harcourt Brace Jovanovich College Publishing, 1993, ISBN 04)3- 09682-4, 1993 - Martin W. Stokel, Martin T. Stokel Chris Johanson "Auto Fundamentals" The (Goodheart-Willcox company, INC - ISBN 1-56637- 138-4, 1996 - Robert Scharif "Complete under~ar systems" Suspension and Steering Delmar Publisher Inc - 1989. ISBN 0-8273-3571-7 - Martin W. Stokel and Martin "Auto Mechanics Fundamentals" The Goodheart -Willcox company, INC:, ISBN 1-56637-1384, 1996 - Stockel, Stockel, and Johanson "Auto Service and Repair" The Goodheart -Willcox company, INC, ISBN 1-56637-144-9 - William H. Crouse and Donald L. Anglin "Automotive technician's Handbook" The McGraw - Hill Book Company, ISBN 0-07014751-5 - William K. Toboldt, Larry Johnson and W. Scott Gavthier "Automotive Encyclopedia "Fundamental, Principles, Operation, Construction, Service, and Repair- The Goodheart - Willcox company, INC- ISBN 1-56637-150-3 , 1995 - Allan W. M. Bonnick, "Vehicle Electronic systems Fault Diagnosis" ARNOLD, ISBN 0-340-70630-9, 1998 - Jack Enjavec and Robert Scharif "Automotive Technology " Delmar Publishers, An International Thomson Publishing Company - Crouse Anglin "Auto Mechanics" The McGraw - Hill Book Company - William H. Crouse and Donald L. Anglin" The Auto Book" The McGraw - Hill Book Company - Robert Bosch GmbH "Automotive Handbook" Published by VDI- Verlag, 1996
Detailed Theoretical Course
Hours Content Skill Objectives Related tasks
2
Study the different types of steering systems - Ackermann steering theory and
connections - Importance of front wheel
inclination - The effect of front axel on the
steering systems - Different types of steering
gearboxes - Rack and pinion steering linkage
system - Ball joints - Shock absorbers - Steering column lock - Direction of motion and its effect on
car motion and safety
The student should be able to: Identify the different types of steering systems: - Ackermann steering theory and
connections - Importance of front wheel inclination - The effect of front axel on the
steering systems - Different types of steering gearboxes - Rack and pinion steering linkage
system - Ball joints - Shock absorbers - Steering column lock - Direction of motion and its effect on
car motion and safety
G1, G2, G3
4
Study the causes of noise and vibrations in the steering gearbox. Also the importance of sealants and gasket in the connections and steering gearbox.
- Identify the causes of noise and vibrations in the steering gearbox
- Understand the importance of sealants and gasket in the connections and steering gearbox
G4, G5, K3, K4,
K5
4
Study the effect of the steering gearbox motion with and without power steering on the stability and safety of the car. This includes: - Steering gearbox performance - Steering system boosters - Steering wheel - Steering shaft - Gearbox with steering linkages and
control valve - Van pump, oil cooler and reservoir
Know the effect of the steering gearbox motion with and without power steering on the stability and safety of the car. This includes: - Steering gearbox performance - Steering system boosters - Steering wheel - Steering shaft - Gearbox with steering linkages and
control valve - Van pump, oil cooler and reservoir
G6, G7, K1, K2, K8, K9,
K13, K17
4
Study the types and importance of tires and wheel alignment angles, arms, joints and ball bearing, and their effect on the motion and safety of the car: - Installation, dimensions and
maintenance of tires - Joints and linkages - Wheel alignment angle types ( toe
in, camber,… etc)
Know the types and importance of tires and wheel alignment angles, arms, joints and ball bearing, and their effect on the motion and safety of the car: - Understand the installation,
dimensions and maintenance of tires - Identify joints and linkages - Identify wheel alignment angle types
( toe in, camber, … etc)
G8, G12, G14, K14, K15, K16
4
The effect of the motion, types and condition of springs and their compliance with the specifications on the motion, stability and safety of the car: - Leaf and coil springs - Air suspension and torsion bars - Independent axel suspension - Importance and limits of the
independent front axel suspension - Construction and performance of
the independent front axel suspension
- Rear axel suspension - Independent rear axel suspension - The effect of stabilizer bar
Know the effect of the motion, types and condition of springs and their compliance with the specifications on the motion, stability and safety of the car: - Leaf and coil springs - Air suspension and torsion bars - Independent axel suspension - Importance and limits of the
independent front axel suspension - Construction and performance of the
independent front axel suspension - Rear axel suspension - Independent rear axel suspension - The effect of stabilizer bar
G13, G15, K10
2
The effect of the motion, types and condition of shock absorbers on the motion, stability and safety of the car: - Telescopic shock absorbers - Types of shock absorbers - Leakage in shock absorbers
Know the effect of the motion, types and condition of shock absorbers on the motion, stability and safety of the car: - Telescopic shock absorbers - Types of shock absorbers - Leakage in shock absorbers
G11
6
- Study the condition of tires - Study the condition of arms and
joints - The pump and hydraulic suspension
system - Study the importance of rubber
bushings for the performance of the suspension system
- Ball bearing The effect of all these factors on the values and limits of wheel angles and their effect on the safety of the car motion
Identify each of : - The condition of tires - The condition of arms and joints - The pump and hydraulic suspension
system - The importance of rubber bushings
for the performance of the suspension system
- Ball bearing Know the effect of all these factors on the values and limits of wheel angles and their effect on the safety of the car motion
G9, G10, G16,
K6, K7, K11, K12, K18, K19
2
Identify the ideal methods for the periodic maintenance and how to prepare a technical report on the performance of the steering and suspension system
Identify the ideal methods for the periodic maintenance and how to prepare a technical report on the performance of the steering and suspension system
K20
Detailed Practical Course
Hours Content Skill Objectives Related tasks
4
Introduce the student to the different steering systems, their parts and the differences between the parts of each system: - The effect of the front axel
suspension on the steering systems - Different types of steering gearboxes - The importance of front wheel
inclination - Rack and pinion, linkages and joints - Inspecting the steering gearbox for
the movement in two directions - Check oil level and its condition - Using special tools and equipment
The student should be able to: Identify the different steering systems, their parts and the differences between the parts of each system - The effect of the front axel
suspension on the steering systems - Different types of steering
gearboxes - The importance of front wheel
inclination - Rack and pinion, linkages and joints - Inspecting the steering gearbox for
the movement in two direction - Check oil level and its condition - Use special tools and equipment
G1, G2, G3
8
Locate the sources of noise and vibrations in the steering gearbox while the car is in the workshop and on the road. The faults include: - Rack and pinion wear - Tie-rod end wear - Excessive clearance in the joints and
linkages - Plastic bushings wear - Power steering lines - Distortion or breakage of one of the
arms and bars - Bearing wear … etc • Checking the sources of leakage
in the links to and from the steering gearbox
• Methods of repairing leakage in the joints
• Methods of dealing with faults in pipes, repairing or replacing faulty parts
• Use special tools and equipment
Locate the sources of noise and vibrations in the steering gearbox while the car is in the workshop and on the road. The faults include: - Rack and pinion wear - Tie-rod end wear - Excessive clearance in the joints
and linkages - Plastic bushing wear - Power steering lines - Distortion or breakage of one of the
arms and bars - Bearing wear … etc • Checking the sources of leakage
in the links to and from the steering gearbox
• Methods of repairing leakage in the joints
• Methods of dealing with faults in pipes, repairing or replacing faulty parts
• The usage of special tools and equipment
G4, G5, K3, K4,
K5
8
- Measuring, checking and testing the steering gearbox
- Method of removing and installing steering wheel and aligning it
- Removing flex coupling - Removing the main shaft of steering
column - Gearbox with linkages and control
valve - Van pump, oil cooler, and reservoir - Measuring, checking and testing the
steering gearbox with the hydraulic system
- Replace faulty parts using special tools and equipment
- Measure, check and test the steering gearbox
- Know the method of removing and installing steering wheel and aligning it
- Remove flex coupling - Check the main shaft of steering
column - Check gearbox with linkages and
control valve - Check Van pump, oil cooler, and
reservoir - Measure, check and test the steering
gearbox with the hydraulic system - Replace faulty parts using special
tools and equipment
G6, G7, K1, K2, K8, K9,
K13, K17
8
Check tires and the shape of their wear. The methods of checking for faults include: - Measure and check all types of
wheel angles - Centering and alignment of steering
wheel - Motion of arms joints and the effect
of their looseness on the system - Joints and linkages of arms and their
effectiveness for the steering system - Check ball bearing - Determine the serviceability of arms
and joints Replace faulty parts using special tools and equipment
Check tires and the shape of their wear, and the methods of checking for faults include: - Measure and check all types of
wheel angles - Centering and alignment of steering
wheel - Motion of arms joints and the effect
of their looseness on the system - Joints and linkages of arms and
their effectiveness for the steering system
- Check ball bearing - Determine the serviceability of arms
and joints Replace faulty parts using special tools and equipment
G8, G12, G14, K14, K15, K16
8
Check and determine the serviceability of: - Leaf and coil springs - Air springs and torsion bars - Independent axel suspension - Independent front axel suspension
limit - Construction and performance of the
independent front axel suspension - Rear axel suspension - Independent rear axel suspension - Stabilizer bar - Replace faulty parts using special
tools and equipment
- Check and replace springs and their serviceability and compliance to the standard specifications
- Check stabilizer bar and its compliance to the recommended specifications for the car
G13, G15, K10
4
- Check the performance of shock absorbers and determine their serviceability
- Telescopic shock absorbers - Leakage in shock absorbers - Using special tools and equipment
- Check shock absorbers and determine their serviceability using special tools
G11
12
- Adjust tire inflation pressure and replace worn-out ones
- Align all wheel angles - Align steering wheel - Adjust arms, rods and joints - Check rubber bushings - Adjust shock absorbers - Replace bearings - Check pump and hydraulic
suspension system Determine serviceability of rods and joints after doing the repair jobs and replace faulty ones using special tools and equipment, and compare the results of the adjustments done to the standard specifications and their effect on the motion, stability and safety of the car
- Adjust tire inflation pressure using special equipment for the safety of the passengers
- Check and align wheel angles using special equipment and check wheel balance
- Check, repair and replace pump and hydraulic suspension system using special tools
- Replace arms using special tools for proper performance
- Replace rods and joints using special tools
- Replace shock absorbers using special tools for proper performance as per recommended specifications
G9, G10, G16,
K6, K7, K11, K12, K18, K19
4
Method of performing periodic maintenance for the steering, suspension and calculating the costs of the repairs done including (spare parts – time spent) -in case of repairing, replacing or periodic maintenance. As well as the method of preparing a worksheet
- Prepare a detailed report about the work done on the mechanical faults in the steering and suspension system K20
Department Mechanical Technology Major Engines and Vehicles
Course name Fault Diagnosis Code MEV 224
Prerequisite MEV 213
Course description: this course covers the principals of mechanical fault diagnosis of the automobile and methods of repairing them, Testing and inspection equipment. Also methods of checking the vehicle according to its manual. Different applications for car problems which include the different systems and the causes for their faults are included. Practical methods of checking for faults and the equipment used for that are covered too.
Semester 1 2 3 4
Credit hours 4
L 2
W 4 Contact hours
T -
General course objectives: this course aims to introduce the student to the principals of mechanical fault diagnosis of the automobile and methods of repairing them, testing and inspection equipment. As well as introducing the student to the methods of checking the vehicle according to its manual. Plus different applications for car problems which include the different systems and the causes for their faults. Practical methods of checking for faults and the equipment used for that will be taught.
Skill Objectives: The student should be able to: • Know the principals of mechanical fault diagnosis of the automobile and methods of repairing
them. • Know the methods using testing and inspection equipment. Methods of checking the vehicle
according to its manual. • Know the different problems in different car systems and the causes for their occurrence. • Know the practical methods of checking for faults and the equipment used for that.
Subjects (theoretical and practical): • The principals of mechanical fault diagnosis of the automobile and methods of repairing them • Methods of using testing and inspection equipment • Methods of checking the vehicle according to its manual • Predicting causes of different problems in different car systems • Practical methods of checking for faults and the equipment used for that
References:
Allan W. M. Bonnick, "Vehkle Electronic systems, Fault Diagnosis AKNOLD:ISBN 0-340-70630-9, 1998 - Stockel, Stockel, and Johanson "Auto Service and Repair" The Goodheart -Willcox company, INC, ISBN 1-56637-144-9 I - Technical manuals and manufacturer data books - William H. Crouse, and Donald I,. Anglin, "Automotive technician's Handbook", 7`he McGraw-Hill Book Company, ISBN 04)7014751-5 W. Stokel, Martin T. Stokel and Chris Johanson, "Auto Fundamentals" The Goodheart-Willcox company, INC, ISBN i-56637-1384, 1996 - "Automotive Engine Management, and Fuel Injection Systems, Manual" ISBN 1-85960 344 0, 1997 - "Automotive Diesel Engine, Service Guide", ISBN 1-85960-286>( William K. Toboldt, Larry Johnson and W. Scott Gavilfier, "Automotive Encyclopedia" Fundamental, Principles, Operation, Construction, Service, and Repair- The Goodheart Willcox company, INC, ISBN 1-56637-150-3, 1995 - Jack Enjavec and Robert Scharfr "Automotive Technology" Delmar Publishers, An International Thomson Publishing Company - Crouse Anglin "Auto Mechanics" The McGraw- Hill Book Company - William H. Crouse and Donald L. Anglin" The Auto Book" The McGraw - Hill Book Company - Robert Bosch Gmbh "Automotive Handbook" Published by VDI- Verlag, 1996
Detailed Theoretical Course
Hours Content Skill Objectives Related tasks
2
Query car user about car problems The student should be able to: - Know how to ask the car user about
the symptoms of the fault to be repaired, about noise, smells and the different operating conditions
B1
2
Inspect the car by sight, listening and smelling
Understand the methods of inspecting the car by sight, listening and smelling; to locate and determine the mechanical fault
B2
2 Check car while driven and stopped Understand the method of checking
the car while driven and stopped for an accurate fault diagnosis
B3
2
Place car on lift - Ensure that the engine reaches
working temperature
- Know how to secure car lifts for the safety of the car, technician and workshop
- Know how to place the car on the lift to inspect the lower parts which are not visible while the car is on the ground
- Know how to ensure that the engine reaches working temperature suitable for proper fault diagnosis
A5, B4, D1
2
Locate noise sources: - Investigate and locate noise sources
in: - The engine - Transmission (clutches and
gearboxes) - Propeller shaft, rear axel and tires - Different parts of steering and
suspension
Understand methods of locating noise sources: Know how to locate noise sources in - The engine - Transmission (clutches and
gearboxes) - Propeller shaft, rear axel and tires - Different parts of steering and
suspension
D5, E5, F2
4
Using testing tools equipment for determining faults: Methods of using devices for calibration and measuring temperature and pressure in: - Engine - Transmission (clutches and
gearboxes) - Propeller shaft, rear axel and tires - Different parts of steering and
suspension
- Understand the methods of using testing tools and devices to determine different mechanical faults
- Understand the methods of using testing devices for accurate fault diagnosis as recommended by the manufacturing company
- Understand the methods of measuring engine pressure with the special device to ensure proper engine performance
B5, D6, E7
12
Know how to: - Remove some parts if needed - Determine mechanical faults - Follow manufacturing company’s
instructions for doing the periodic maintenance
- Clean the part to be repaired with the suitable cleaner
- Determine the spare parts needed
Know the method to do the following: - Remove some parts if needed - Determine mechanical faults - Follow manufacturing company’s
instructions for doing the periodic maintenance
- Clean the part to be repaired with the suitable cleaner
- Determine the spare parts needed
B6, B7, B8, C3, C4, C5,
E6
2
Comprehensive report about the mechanical repairs done, and this includes: - The engine - Transmission - Brake system - Steering and suspension system
Prepare a comprehensive report about the mechanical repairs done. This includes: - The engine - Transmission - Brake system - Steering and suspension system
H7, I19, J15, K20
Detailed Practical Course
Hours Content Skill Objectives Related tasks
4
Query car user about car problems The student should be able to: - Know how to ask the car user about
the symptoms of the fault to be repaired, about noise, smells and the different operating conditions
B1
4 Inspect the car by sight, listening and smelling
Inspecting the car by sight, listening and smelling; to locate and determine the mechanical fault
B2
4 Check car while driven and stopped Check the car while driven and
stopped for an accurate fault diagnosis
B3
4
Place car on lift - Ensure that the engine reaches
working temperature
- Know how to secure car lifts for the safety of the car, technician and workshop
- Know how to place the car on the lift to inspect the lower parts which are not visible while the car is on the ground
- Know how to ensure that the engine reaches working temperature suitable for proper fault diagnosis
A5, B4, D1
4
Locate noise sources: - Investigate and locate noise sources
in: - The engine - Transmission (clutches and
gearboxes) - Propeller shaft, rear axel and tires - Different parts of steering and
suspension
- Determine type and source of noise by hearing and by using the stethoscope to identify faulty parts
- Determine type and source of noise, locate fault and verify normal sound characteristics in the transmission when shifting gears while the car is stopped or driven
- Locate source of noise to locate fault and preventing it from affecting other parts in the brake system
D5, E5, F2
8
Using testing tools equipment for determining faults: Methods of using devices for calibration, measuring temperature and pressure in: - Engine - Transmission (clutches and
gearboxes) - Propeller shaft, rear axel and tires - Different parts of steering and
suspension
• Be capable of using testing tools and devices to determine faults
• Be capable of using testing devices for accurate fault diagnosis of the following:
- Engine - Transmission (clutches and
gearboxes) - Propeller shaft, rear axel and tires - Different parts of steering and
suspension
B5, D6, E7
24
- Remove some parts if needed - Determine mechanical faults - Follow manufacturing company’s
instructions for doing the periodic maintenance
- Clean the part to be repaired with the suitable cleaner
- Determine the spare parts needed
Know how to do the following: - Remove some parts if needed - Determine mechanical faults to
carry out the needed repairs - Follow manufacturing company’s
instructions for doing the periodic maintenance for correct repair jobs
- Choose the suitable cleaner to clean the part to be repaired - to avoid its wear during cleaning
- Determine the spare parts needed
B6, B7, B8, C3, C4, C5,
E6
4
Comprehensive report about the mechanical repairs done, and this includes: - The engine - Transmission - Brake system - Steering and suspension system
Prepare a comprehensive report about the mechanical repairs done. This includes: - The engine - Transmission - Brake system - Steering and suspension system
H7, I19, J15, K20
Study plan distributed over all semesters
Number of units No Course code Course name Pre-
requisite C.U L W T C.H1 ENG 101 General English Language - - - 3 2 2 4 2 ISL 101 Islamic Culture - - - 2 2 - 2 3 MAT 161 Specialized Mathematics - - - 3 3 1 4 4 CMP 101 Introduction to Computer - - - 2 - 4 4 5 MEV 111 Preparatory Workshop - - - 2 - 4 4 6 MEV 112 Industrial Safety - - - 1 - 2 2
Firs
t Sem
este
r
7 MEV113 Introduction to Automotive Electric System - - - 2 1 2 3 Total 15 8 14 1 23
Number of units No Course code Course name Pre-requisite C.U L W T C.H
1 ENG 192 Technical English ENG 101 3 2 2 4 2 ARB 101 Arabic Language - - - 2 2 - 2 3 PHY 101 Specialized Physics - - - 3 2 2 4 4 MEV 121 Technical Drawing - - - 2 - 4 4 5 MEV 122 Fuel System (Gasoline) MEV 111 4 2 4 6 Se
cond
Sem
este
r
6 MEV 123 Engines (1) MEV 111 4 2 4 6 Total 18 10 16 26
Number of units No Course code Course name Pre-
requisite C.U L W T C.H1 ENG 293 Technical English II ENG 192 3 2 2 4 2 MEV 211 Power Trains (I) MEV 111 4 2 4 6 3 MEV 212 Brake System MEV 111 4 2 4 6 4 MEV 213 Engines (2) MEV 123 4 2 4 8
Thi
rd S
emes
ter
5 MEV 214 Fuel System (Diesel) MEV 123 3 2 2 4 Total 18 10 16 26
Number of units No Course code Course name Pre-requisite C.U L W T C.H
1 ISL 102 Islamic Culture ISL 101 2 2 - 2 2 MGT 101 Professional Ethics - - - 2 2 - 2 3 MEV 221 Engineering Drawing MEV 121 2 - 4 4 4 MEV 222 Power Trains (2) MEV 211 4 2 4 6 5 MEV 223 Suspension & Steering System MEV 111 4 2 4 6 Fo
urth
Sem
este
r
6 MEV 224 Fault Diagnosis MEV 213 4 2 4 6 Total 18 10 16 26
Number of units No Course code Course name Pre-requisite C.U L W T C.H
Sum
mer
1 MEV 230 Cooperative Training - - - 4 According to working hours
Number of units C.U L W T C.H Program total number of units 73 38 62 - 101
C.U.: Credit Hours L: Lecture W: Workshop T: Practice C.H.: Contact Hours
A Follows safety procedures
A1) Wears appropriate
work clothes
A2)
Prepare workplace
A3)
Use tools properly
A4)
Use equipment properly
A5)
Follow car lift safety procedures
Diagnose car mechanical
faults
B1) ask car user about
car problems
B2)
Visually inspect the car
B3) Check the car driven and stopped
B4)
Place car on lift
B5) Use test
equipment to determine car
faults
C Carry out periodic
maintenance
C1) Choose proper location in the
workshop
C2) Place suitable shields on the
car
C3) Choose suitable
cleaning materials
C4) Clean parts to be
repaired with proper cleaning
materials
C5) Follow the
manufacturer’s instructions for
the periodic maintenance
D Determine faults in engine
D1) ensure that the
engine reaches its working
temperature
D2) Observe engine
oil vapor
D3)
Check engine oil level and
quality
D4)
Inspect cooling system
D5)
Determine type and source of
noise
E Determine
faults in power train system
E1) Determine type of
transmission
E2) Check
transmission fluid level
E3) Observe
transmission fluid quality by color and smell
E4) Determine type of transmission fluid
E5) Determine type and source of
noise
F Determine the
faults in the brake system
F1) Check brake fluid level and quality
F2) Determine type and source of
noise
F3) Locate source of
brake fluid leakage
F4) Check brake
friction material (pads and linings)
F5) Check discs and
drums of the brakes
G1) Identify the type of suspension system
(hydraulic, mechanical, air)
G2) Check oil level
G3) Check steering
gearbox
G4)
Determine type and source of
noise
G5) Locate source of
oil leakage
G
Determine the faults in
steering and suspension
systems and wheel
alignment
G13) Check leaf and coil
springs
G14) Check ball and roller bearings
G15) Check stabilizer
bar
G16) Check pump and
the hydraulic suspension system
H Repair engine
mechanical faults
H1)
Repair faults in cylinder head
H2) Repair faults in cylinder block
H3) Repair faults in
lubricating system
H4)
Repair faults in cooling system
H5)
Repair faults in fuel system
A6) Use exhaust
gases ventilation
system
A7) Safely store flammable materials
A8) Learn how to
use fire extinguishers
A9) Follow car
manufacturers’ safety
procedures
B6) Disassemble
parts if needed
B7) Determine mechanical
faults
B8)
Determine the required spare parts
D6)
Measure engine
compression pressure
D7)
Check lubricating
system
D8)
Check fuel system
D9)
Analyze exhaust gases
D10)
Check ignition system
E6) Determine
type of faults (electric,
mechanical, hydraulic)
E7) Use testing equipment
E8)
Check differential
gears
E9)
Check seals, oil rings and
gaskets
E10)
Check drive axles
E11)
Check propeller
shaft support bearings
E12)
Check universal
joints
F6) Check brake
booster
F7) Check anti-lock brake
system (ABS)
F8)
Check parking brakes
F9) Check master
and wheel cylinders
F10)
Check brake pedal
G6)
Check steering wheel
G7) Check power
steering pump and drive belt
G8)
Check steering linkages
G9)
Check tires inflation
pressure and condition
G10)
Check wheel
alignment
G11) Check shock
absorbers
G12)
Check suspension arms and
joints H6) Repair faults
in ignition system
H7)
Fill in the final job
sheet
I1) Inspect the fly
wheel and replace clutch
I2) Replace the automatic
transmission clutches
I3) Replace filter and check oil
pan
I4) Repair
transmission oil pump
I5) Replace
transmission oil pump
I Repair
mechanical faults in power
train system I13)
Repair oil leakage sources
I14) Replace drive
axles
I15) Replace drive axles bearings
I16) Adjust
differential gears
I17) Replace
the universal joints of the
propeller shaft
J1) Replace brake
friction material (pads and linings)
J2)
Repair drums and discs
J3) Replace drums
and discs
J4) Repair master
and wheel cylinders
J5) Replace master
and wheel cylinders
J
Repair mechanical
faults in brake system
J13) Replace ABS
pump
J14) Replace ABS
sensors
J15) Fill in the final
job sheet
K1)
Repair power steering pump
K2) Replace power steering pump
K3)
Repair oil leakage
K4) Repair oil
passages and pipes
K5) Replace oil
pipes
K
Repair mechanical
faults in steering and suspension
systems K13)
Replace power steering pump
belt
K14)
Replace tires
K15)
Replace dust boots and
rubber bushings
K16) Replace wheel
bearings
K17) Align steering
wheel
L
Repair minor electrical faults
L1)
Check battery voltage
L2)
Test basic car electrical circuits
L3) Test basic car
electrical components
L4) Replace faulty
electrical components
L5)
Repair faulty electrical
components
I6)
Replace transmission
sensors
I7) Replace
hydraulic coupling or
torque converter
I8) Replace gears and bearings
of transmission
I9) Replace
transmission oil seals and
gaskets
I10)
Adjust the gearshift lever
I11)
Reprogram automatic
transmission
I12)
Replace differential
gears
I18) Replace axel
sensors
I19)
Fill in the final job sheet
J6) Replace brake
fluid and bleed the
brakes
J7) Repair brake
pipes
J8) Replace brake
pipes
J9)
Repair vacuum booster
J10)
Replace vacuum booster
J11) Replace wheel
bearings
J12)
Adjust rear and parking
brakes
K6)
Replace steering linkages
K7) Replace
suspension arms and ball
joints
K8)
Repair steering gearbox
K9)
Replace steering gearbox
K10)
Replace springs
K11) Adjust wheel
alignment angles
K12) Replace shock
absorbers
K18) Repair the pump of hydraulic
suspension system
K19) Replace the
pump of hydraulic
suspension system
K20)
Fill in the final job sheet
General Knowledge and Skills Professional Ethics
1. English language knowledge 2. Computer literacy 3. Ability to use maintenance manuals 4. Basic Knowledge of technical calculations 5. Ability to work in a group 6. Knowledge of technical terms 7. Knowledge of trade terminology 8. Keeping up to date with the trade developments
1. Adherence to safety rules 2. Self confidence 3. Cooperation with others 4. Honesty in doing the job 5. Sense of responsibility 6. Precision in doing the job 7. Taking care of equipment / tools, work place 8. Decision making ability
Future Interests and Directions Equipment, Tools and Materials
1. Mechanical advancement of testing and measuring equipment
2. More usage of modern vehicle technology 3. Usage of alternative fuel 4. The need for broader knowledge of vehicle
electric / electronic systems
1. General and special hand tools 2. Petroleum products (gasoline, oil, diesel, grease
…etc) 3. Cleaning materials 4. Sealing materials (special enforced papers, paste,
glue …etc) 5. Pressure measuring apparatus (fuel, oil, engine,
air … etc