Maintenance & Service -I Course Code: 4360201

GUJARAT TECHNOLOGICAL UNIVERSITY (GTU)

Competency-focused Outcome-based Green Curriculum-2021 (COGC-2021)

Semester -VI
Course Title: Maintenance & Service -I
(Course Code: 4360201)

Diploma programme in which this course is offered Semester in which

offered
Automobile Engineering 6th

1. RATIONALE

The automotive industry heavily relies on skilled professionals who can effectively maintain
and service automobile engines. There is a high demand for technicians who possess the
necessary knowledge and practical skills to diagnose, troubleshoot, and repair engine-related
issues. Engine malfunctions or failures can lead to hazardous situations, accidents, or
breakdowns on the road. By emphasizing maintenance and service, students learn how to
identify and rectify problems in automobile engines components, fuel supply system & cooling
and lubricating system.

2. COMPETENCY
The course content should be taught and curriculum should be implemented with the aim to
develop different types of skills leading to the achievement of the following competency.

 Apply principles, techniques, and practices involved in maintaining and servicing

automobile engines.

3. COURSE OUTCOMES (COs)

The underpinning knowledge and the relevant skills associated with this competency are to be
developed in the student to display the following COs:

a) Identify diagnostic tools and techniques used in engine condition diagnosis.

b) Inspect and service/repair of engine components for signs of wear, damage, or
malfunction.
c) Identify the root cause of fuel supply system issues accurately.
d) Inspect and service/repair of engine cooling system and lubricating system effectively.
e) Rebuild and overhaul engines for optimal performance and reliability.

4. TEACHING AND EXAMINATION SCHEME

Teaching Scheme Total Credits Examination Scheme
(In Hours) (L+T+P/2) Theory Marks Practical Marks Total
L T P C CA ESE CA ESE Marks
2 0 2 3 30* 70 25 25 150

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(*): Out of 30 marks under the theory CA, 10 marks are for assessment of the micro-project to
facilitate integration of COs and the remaining 20 marks is the average of 2 tests to be taken
during the semester for the assessing the attainment of the cognitive domain UOs required for
the attainment of the COs.
Legends: L-Lecture; T – Tutorial/Teacher Guided Theory Practice; P - Practical; C – Credit,
CA - Continuous Assessment; ESE - End Semester Examination.

5. SUGGESTED PRACTICAL EXERCISES

The following practical outcomes (PrOs) that are the sub-components of the COs. These PrOs
need to be attained to achieve the COs.
Sr. Practical Outcomes (PrOs) Unit Approx.
No No. Hrs.
required
Conduct engine smoke analysis, visual inspections, and Any 1 4
1
noise diagnostics to ascertain the condition of the engine. one
2 Conduct engine compression and vacuum testing. 1 4
Perform replacement procedure of engine piston, connecting Any 2 4
3
rod, crankshaft and main journal bearings. one
Conduct an inspection and reconditioning of valves and 2 4
4
valve seats.
5 Perform service and testing of fuel injector. Any 3 2
Trouble shooting and service procedure of fuel supply one 3 4
6
system of Petrol engine/Diesel engine.
Describe replacement procedure of components of cooling Any 4 4
7
system. Three
8 Trouble shooting and service procedure of cooling system.
9 Perform oil changing procedure in a given vehicle. 4 4
Describe replacement procedure of components of 4 4
10
lubricating system.
Trouble shooting and service procedure of lubricating 4 4
11
system.
12 Perform engine tune up. Any 5 4
13 Perform diagnosis of engine by scan tool. one 5 4
Total Hrs. 28
Note
i. More Practical Exercises can be designed and offered by the respective course teacher to
develop the industry relevant skills/outcomes to match the COs. The above table is only a
suggestive list.
ii. Care must be taken in assigning and assessing study report as it is a study report. Study
report, data collection and analysis report must be assigned in a group. Teacher has to
discuss about type of data (which and why) before group start their market survey.
iii. The following are some sample ‘Process’ and ‘Product’ related skills (more may be
added/deleted depending on the course) that occur in the above listed Practical Exercises
of this course required which are embedded in the COs and ultimately the competency.
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S. No. Sample Performance Indicators for the Practical’s Weightage in %

1 Basic knowledge and understanding of experiments 40%
2 Identification of components of experiments 20%
3 Answer to questions 20%
4 Timely submission 20%
Total 100%

6. MAJOR EQUIPMENT/ INSTRUMENTS REQUIRED

These major equipment with broad specifications for the PrOs is a guide to procure them by the
administrators to usher in uniformity of practical in all institutions across the state.
Sr. Equipment Name with Broad Specifications PrO. No.
No.
1 Light motor vehicle: A modern car or jeep of any make and All
model along with all relevant accessories and systems
2 Digital Compression Test Kit. 2
 Max. pressure: 300 psi (20.5 bar) (2,070 kPa)
 Digital compression tester comprising of test gauge with
rubber boot, 10 in. (250 mm) high-pressure hose and
female quick-change coupler
 14 mm standard reach thread x 6.5 in. (165 mm) hose
adapter.
 14 mm standard reach thread x 12 in. (305 mm) hose
adapter
 14 mm reach thread x 12 in. (305 mm) hose adapter
 18 mm standard reach thread x 12 in. (305 mm) hose
adapter
 18 mm reach male thread x 14 mm standard reach female
thread plug adapter
 16 mm male thread x 14 mm standard reach female thread
plug adapter
 10 mm male thread x 14 mm standard reach female thread
plug adapter
 12 mm male thread x 14 mm standard reach female thread
plug adapter
 Air hold adapter

3 Digital Diesel Compression Test Kit 2

 Max. pressure: 1000 psi (6890 kPa) (68.9 bar)
 Digital compression tester comprising of test gauge with
rubber boot, 15 in. (380 mm) long, high-pressure hose,
quick-change coupler
 Injector adapter
 Glow plug adapter
 Right-angle adapter
 Field service kit
 Displays values in psi, bar and kPa

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4 Air Compressor: All

 Horse Power : 7.5 HP
 Compressor Technology : Reciprocating Compressor
 Model Name/Number : TS07
 Discharge Pressure : 30 BAR
 Maximum Flow Rate : 11.51 CFM
 Weight : 248 Kg
 Product Dimension : 1490 x 600 x 695 mm
5 Fuel Injector Tester 5
 Voltage 220 V
 Frequency 50 Hz
 Phase Phase Single Phase
 Rotation Speed 10000 RPM
 Tube Volume 120ml
 Tank Volume 4 Liter
 Fuel Flow 4.5L/min
 Automation Type Automatic
 Display Digital
 Injection Time 0-600 sec
 Oil Pump Pressure 0-6.5kg/cmA
6 Ultrasonic Cleaner: 5
 Capacity (L): 2 LtrUltrasonic
 Frequency: 40 Khz
 Digital Timer: 5-60 minutes
 Heating: 0-80°C
 Power: 50 W
 BasketDimension (mm): 175x165x250 mm
7 Scan Tool: 5, 12, 13
 Screen 8" diagonal, daylight readable color LCD screen;
1280*800 pixel
 Touch with Gloves Supported
 Operating System Android system
 CPU Quad-Core, 1. 3GHz
 Memory 2GB DDR3L
 SSD Hard drive 32GB
 Communication Interface Built-in WIFI 802.11 b/g Wireless
LAN micro USB 2.0 OTG, USB 2.0 HOST standard
Bluetooth 4.0 (10-20 m)
 HDMI Yes
 Camera 5 megapixels rear-facing
 Battery 8000mAh, lithium-polymer battery. Chargeable via
5V AC/DC power supply
 Protocols ISO 9141-2, ISO 14230-2(KWP2000), SAE J1850-
PWM, SAE J1850-VPW, SAE J2740(GM UART), UART
Echo Byte Protocol(SAE J2809、SAE J2818), Honda Diag-H
Protocol, SAE J2610(SCI), ISO 11898, ISO 15765-4, KW81,
KW82, GWM 3089 (Single Wire CAN), SAE J2819(TP2.0),

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SAE J3054(TP1.6), ISO 11898-3(Low Speed Fault-Tolerant

CAN), SAE J2284 (High Speed CAN)
 OBD2 Compatible with Indian cars
8 Digital Multimeter 6
 -DC 48 V Capacity
 With Continuity and Resistance measurement functions
9 Radiator pressure tester kit 8
 Allows Radiator Cap Relief Pressure and Seal Condition to
Be Tested
 Shaft Diameter: 0.47 inch
 Maximum Pressure: 30 PSI
 Used For: Most Vehicle Radiators
 Vehicle Make: Universal

7. AFFECTIVE DOMAIN OUTCOMES

The following sample Affective Domain Outcomes (ADOs) are embedded in many of the
above-mentioned COs. More could be added to fulfil the development of this course
competency.
a) Work as a leader/a team member.
b) Follow ethical practices.
c) Practice environmentally friendly methods and processes. (Environment related)
The ADOs are best developed through the field based exercises/project work. Moreover, the
level of achievement of the ADOs according to Krathwohl’s ‘Affective Domain Taxonomy’
should gradually increase as planned below:
i. ‘Valuing Level’ in 1st year
ii. ‘Organization Level’ in 2nd year.
iii. ‘Characterization Level’ in 3rd year.

8. UNDERPINNING THEORY
The major underpinning theory is given below based on the higher level UOs of Revised
Bloom’s taxonomy that are formulated for development of the COs and competency. If required,
more such higher level UOs could be included by the course teacher to focus on attainment of
COs and competency.
Unit Unit Outcomes (UOs) Topics and Sub-topics
(4 to 6 UOs at different levels)
Unit I 1.a Students will acquire the 1.1 Primary assessment of engine
Engine ability to evaluate engine condition involves employing the
condition smoke, conduct visual following techniques:
diagnosis inspections, and analyze  Evaluating engine smoke to
determine potential issues.
engine noise to pinpoint
 Conducting a visual inspection to
potential issues and assess identify potential sources of engine
the overall condition of oil and coolant leakage.
the engine.  Analyzing engine noise to diagnose
1.b Students will be able to possible problems.
describe and conduct 1.2 Various engine test methods
mentioned below:
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engine test methods,  Engine compression test

comprehend the objectives  Cylinder leakage test
of each test, and recognize  Vacuum test
their importance in  Oil pressure testing
diagnosing specific engine  Cylinder Power Balance Test
issues.
Unit II 2.a Students will have the 2.1 Service procedure, inspection, causes
Engine ability to conduct in-depth and remedies of following engine
components inspections of the engine components:
maintenance components, pinpointing  Piston and piston ring
common problems and  Connecting rod, piston pin and half
understanding their -split bearings
fundamental causes.  Crankshaft and main bearing
2.b Students will be able to journal
clarify the core principles  Flywheel
and procedures related to  Inlet and exhaust valve
these engine  Inlet- exhaust valve and spring
reconditioning techniques, assembly
with an emphasis on
 Camshafts, Lifters, Timing Belts,
highlighting safety and Chains
measures and precise
 Combustion chamber
implementation.
 Engine head
 Engine cylinder liners
 Engine cylinder block

2.2 Describe engine repowering and

reconditioning method as mentioned in
the following.
 Engine cylinder boring & honing.
 Engine cylinder head resurfacing.
 Engine valve face and seat
grinding.
Unit III 3.a Students will be able to 3.1 Common problems related to fuel
Maintenance accurately identify and supply system and its remedies
and servicing classify various (Petrol/diesel/CNG/LPG/PFI/GDI).
of Fuel supply automotive fuel systems, 3.2 Inspection, problems, causes and its
system including Petrol, Diesel, remedies & repair/replacement of
CNG, LPG, PFI, and GDI. following components of fuel supply
3.b Students will be able to system.
identify problems, causes,  Fuel tank
and implement proper  Fuel line and fittings
servicing and replacement  Fuel filters
techniques.  Fuel pumps

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 Fuel Injectors
 Intake manifold
3.3 Servicing and replacement procedure
of air filter.
3.4 Testing methods and techniques of
fuel injectors. (Petrol & Diesel fuel)
3.5 Calibration and phasing of fuel
injection pump
Unit IV 4.a Students will be able to 4.1 Low temperature & high temperature
Maintenance diagnose common cooling engine problems and its remedies
and servicing system problems and 4.2 Inspection and testing of coolant.
identify their causes. 4.3 Inspection/service/Testing and
of engine
4.b Students will be able to repair/replacement of following
Cooling & diagnose common components of engine cooling
Lubricating lubricating system system.
system problems, such as low oil  Water pump
pressure, oil leaks, and oil  Thermostat valve
contamination,
 Hoses and gasket
Recommend appropriate
remedies for common  Radiator & pressure cap
lubricating system  Cooling fan
problems. 4.4 Engine radiator flushing and cleaning
technique.
4.5 Common problems related to engine
lubrication system and its remedies.
4.6 Inspection, problems, causes and
remedies of lubricating system and its
components.
4.7 Factors affecting the oil pressure
4.8 Service and repair/replacement of
Engine Oil Pump.
4.9 Procedure for changing engine oil.
Unit V 5.a Students will be able to 5.1 Reason for engine failure and need for
Engine formulate informed rebuilding.
rebuilding decisions on the need for 5.2 Dismantling of engine components and
engine rebuilding based on cleaning, visual and dimensional
and
inspection findings, inspection.
Overhauling considering factors such as 5.3 Engine removal procedure.
component condition, 5.4 Overhauling of engine with safety
wear patterns, and overall precautions.
engine health. 5.5 Procedure of Engine decarbonizing.
5.b Students will be able to 5.6 Procedure of Engine major and minor
conduct engine tune-ups, tune up.
including adjustments to 5.7 Diagnostic equipment scans tools.
ignition timing, fuel
delivery, and other
parameters, to optimize
engine efficiency and
performance.
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Note: The UOs need to be formulated at the ‘Application Level’ and above of Revised Bloom’s
Taxonomy’ to accelerate the attainment of the COs and the competency.
9. SUGGESTED SPECIFICATION TABLE FOR QUESTION PAPER DESIGN
Unit Unit Title Teaching Distribution of Theory Marks
No. Hours R U A Total
Level Level Level Marks
I Engine condition diagnosis 04 3 3 6 12
II Engine components
maintenance 06 3 3 6 14

III Maintenance and servicing of

06 4 4 8 14
Fuel supply system
IV Maintenance and servicing of
engine Cooling & Lubricating 08 4 6 8 18
system

V Engine rebuilding and

Overhauling 04 3 3 6 12

Total 28 17 19 34 70
Legends: R=Remember, U=Understand, A=Apply and above (Revised Bloom’s taxonomy)
Note: This specification table provides general guidelines to assist student for their learning
and to teachers to teach and question paper designers/setters to formulate test
items/questions to assess the attainment of the UOs. The actual distribution of marks at
different taxonomy levels (of R, U and A) in the question paper may slightly vary from above
table.
10. SUGGESTED STUDENT ACTIVITIES
Other than the classroom and laboratory learning, following are the suggested student-related
co-curricular activities which can be undertaken to accelerate the attainment of the various
outcomes in this course: Students should conduct following activities in group and prepare
reports of each activity. They should also collect/record physical evidences for their (student’s)
portfolio which will be useful for their placement interviews:
a) Charts can be prepared.
b) Small report on any topic given by concern faculty.
c) Small groups of students can be formed for assigned work. Assigned work should be
such that it covers market survey, team work, presentation, time management, quality
development.

11. SUGGESTED SPECIAL INSTRUCTIONAL STRATEGIES (if any)

These are sample strategies, which the teacher can use to accelerate the attainment of the various
outcomes in this course:
a) Massive open online courses (MOOCs) may be used to teach various topics/sub topics.
b) Guide student(s) in undertaking micro-projects.

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c) ‘L’ in section No. 4 means different types of teaching methods that are to be employed
by teachers to develop the outcomes.
d) About 20% of the topics/sub-topics which are relatively simpler or descriptive in nature
is to be given to the students for self-learning, but to be assessed using different
assessment methods.
e) With respect to section No.10, teachers need to ensure to create opportunities and
provisions for co-curricular activities.
f) Guide students on how to address issues on environment and sustainability

12. SUGGESTED MICRO-PROJECTS

Only one micro-project is planned to be undertaken by a student that needs to be assigned to
him/her in the beginning of the semester. In the first four semesters, the micro-project are group-
based. However, in the fifth and sixth semesters, it should be preferably being individually
undertaken to build up the skill and confidence in every student to become problem solver so
that she/he contributes to the projects of the industry. In special situations where groups have
to be formed for micro-projects, the number of students in the group should not exceed three.
The micro-project could be industry application based, internet-based, workshop-based,
laboratory-based or field-based. Each micro-project should encompass two or more COs which
are in fact, an integration of PrOs, UOs and ADOs. Each student will have to maintain dated
work diary consisting of individual contribution in the project work and give a seminar
presentation of it before submission. The total duration of the micro-project should be about
14 - 16 (fourteen to sixteen) student engagement hours during the course. The student
ought to submit micro-project by the end of the semester to develop the industry-oriented COs.
A suggestive list of micro-projects is given here. This has to match the competency and
the COs. Similar micro-projects could be added by the concerned course teacher:

1) Prepare a checklist for primary assessment of engine condition.

2) Develop a training module on how to identify and diagnose engine problems based
on smoke color and opacity.
3) Conduct a study on the effectiveness of different engine oil and coolant leak
detection methods.
4) Develop a training module on how to perform an engine compression test, cylinder
leakage test, vacuum test, oil pressure test.
5) Conduct a study on the common causes of piston and piston ring failure.
6) Develop a training module on how to service and inspect connecting rods, piston
pins, and half-split bearings.
7) Conduct a study on the common causes of crankshaft and main bearing journal
failure.
8) Develop a training module on how to service and inspect inlet and exhaust valve
spring assemblies.

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9) Conduct a study on the common causes of camshaft, lifter, timing belt, and chain
failure.
10) Conduct a study on the common causes of engine head gasket failure and cracking.
11) Conduct a study on the common causes of combustion chamber carbon buildup and
detonation.

13. SUGGESTED LEARNING RESOURCES

Sr. Title of Book Author Publication with place, year

No. and ISBN
1 Automobile Mechanics William Crouse Tata Mc-Graw Hill Publication
ISBN-13:978-0-07-063435-0

2 Automotive Technology James Halderman Pearson Publication

ISBN-10: 0-13-254261-7
ISBN-13: 978-0-13-254261-6
3 Advanced Automotive Tom Denton Elsevier publication
fault diagnosis ISBN 13:978-0-75-066991-7
4 Automotive Service: Tim Gills ● Cengage Learning, 2015.
Inspection, ● ISBN 13: 9781305445932
Maintenance, Repair.
5 Vehicle Maintenance Jigar A. Doshi ● Prentice Hall India Learning
and Garage practice Dhruv U. Panchal Private Limited
Jayesh P. Maniar ISBN-10 : 8120349822
ISBN-13 : 978-8120349827
6 Automotive maintenance Ernest A. Venk, ● American Technical Society
and trouble shooting. Edward Dale ASIN : B000U7AB7A
Spicer & Irving
●
Augustus Frazee

14. SOFTWARE/LEARNING WEBSITES

a) https://www.howacarworks.com
b) https://swayam.gov.in
c) https://auto.howstuffworks.com
d) https://nptel.ac.in
e) https://tinyurl.com/yc88v5jf for video link
f) https://tinyurl.com/5d3cjzy7 for web link

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15. PO-COMPETENCY-CO MAPPING

Semester VI Maintenance & Service -I (4360201)
POs
Competency PO 1 PO 2 PO 3 PO 4 PO 5 PO 6 PO 7
& Course Outcomes Basic & Proble Design/ Engineering Engineering Project Life-long
Disciplin m develop Tools, practices for Manage learning
e specific Analysi ment of Experiment society, ment
knowled s solutions ation sustainability &
ge &Testing environment
 Apply principles,
techniques, and
practices involved
3 2 2 3 2 2 3
in maintaining and
servicing
automobile engines
a) Identify diagnostic tools
and techniques used in 3 2 3 3 2 3
engine condition diagnosis.

b) Inspect and service/repair

of engine components for
signs of wear, damage, or 3 2 2 2 2 3
malfunction.

c) Identify the root cause of

fuel supply system issues 3 2 2 2 2
accurately.

d) Inspect and service/repair

of engine cooling system
and lubricating system 3 2 2 2 2
effectively.

e) Rebuild and overhaul

engines for optimal 3 2 2 2 2 2
performance and reliability.

Legend: ‘3’ for high, ‘2’ for medium, ‘1’ for low and ‘-’ for no correlation of each CO with PO.

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16. COURSE CURRICULUM DEVELOPMENT COMMITTEE

GTU Resource Persons

S. Name and Institute Contact No. Email

No Designation
Mr. D. A. Dave (Retd. Sir B.P.T.I, Bhavnagar
1 9427182407 [email protected]
HOD Automobile)
Mr. D. J. Gohel C. U. Shah Polytechnic [email protected]
2 9879428562
Lect. Automobile Surendranagar
Mr. H. V. Patel Sir B.P.T.I, Bhavnagar [email protected]
3 99788 72090
Lect. Automobile
Mr. N. R. Dave C. U. Shah Polytechnic [email protected]
4 7984370804
Lect. Automobile Surendranagar
Mr. V. H. Nandoliya Govt. Polytechnic, vhnandoliya@gpahmedabad
5 9727833530 .ac.in
Lect. Automobile Ahmedabad

GTU BOS and Branch Co-ordinator Persons

Sr. Name and Institute Contact Email

No Designation No.
Mr. Shyam Varghese Sir B.P.T.I, Bhavnagar
1 HOD Automobile 9426396640 [email protected]
Branch Co-ordinator
Mr. A. K. Nanavati, Govt. Polytechnic, [email protected]
2 9426674409
HOD Automobile Ahmedabad

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