CURRICULUM AND SCHEME OF EXAMINATION DIPLOMA IN AUTOMOBILE ENGINEERING V TERM Code No 8301 8302 8401 8303 8304 8402

Course Name Automobile Engines Automobile Chassis and Transmission Diversified Course - I Automobile Engines Lab Workshop - III (Special Machines) Diversified Course Lab - I Total
DIVERSIFIED COURSE - I 8401 - Diversified Course - I 8401 A- Automobile Electrical Equipments 8401 B - Two Wheeler Technology
Hrs / Credit Scheme of Examination Duration of Internal External Total

6 6 5 6 6 6 35

6 6 5 3 3 3 26

25 25 25 25 25 25 150

75 75 75 75 75 75 450

100 100 100 100 100 100 600

3 3 3 3 3 3 18

DIVERSIFIED COURSE LABORATORY-I 8402 - Diversified Course - I 8402 A - Automobile Chassis and Transmission and Electrical Equipments Lab 8402 B - Two Wheeler Technology Lab

VI TERM Code No 8305 8306 8403 8307 8404 8308 Course Name Industrial Management and Road Transport Organization Body Building Technology Diversified Course - II Automobile Workshop Diversified Course Lab - II Project Work, Enterproneurship & Personal Skills
Scheme of Examination Duration Allocation marks Hrs / Credit of Week Internal External Total exam

7 7 6 6 6 3

7 7 6 3 3 1.5

25 25 25 25 25 25

75 75 75 75 75 75

100 100 100 100 100 100

3 3 3 3 3 3

Total
DIVERSIFIED COURSE 8403 - Diversified Course Lab - II 8403 - A - CAD / CAM* 8403 - B - Tractor and Farm Equipments

35

27.5 150

450

600

18

DIVERSIFIED COURSE LABORATORY 8404 - Diversified Course - II 8404 - A - CAD / CAM Lab* 8404 - B - Tractor and Farm Equipments Lab

* Common with Diploma in Mechanical Engineering 1

8301 AUTOMOBILE ENGINES V TERM ( Applied Course ) 6 Hours / Week UNIT I Petrol Engines UNIT II Petrol Fuel feed system and carburetors UNIT III Cooling System and Lubrication System UNIT IV Diesel Engines and Emission control UNIT V Diesel fuel feed system, Governors & Super Chargers UNIT I : PETROL ENGINES (14 hours) Total Hours : 72 Hrs

Petrol Engines Working principle of two stroke and four stroke engines comparisonconstructional details: main bearings, connecting rod bearings - major parts of an engine engine block, Cylinder head, Liner, piston, crank shaft, cam shaft babbits - Precision inserts Shell bearings Materials of construction Types of engines, Straight, V, Square engine combustion chamber design L,I,F,T types Valve gear arrangement, types of valves Mushroom valve inlet and exhaust manifolds - mufflers and silencers- Static balance and dynamic balance torsional vibration Vibration dampers analysis of performance of single and multi cylinder engines Firing order 4,6 & 8 Cylinders-Detonation / Petrol knock - Octane number. UNIT II : PETROL FUEL FEED SYSTEMS & CARBURETORS (15 hours)

Fuel feed systems layout construction and working of mechanical and Electrical fuel feed pumps . Fuel filters Air filter, types - dry type, wet type and oil bath type carburation principles simple carburetors - drawbacks of simple carburetors compensating systems carburetor circuits -float circuit , starting circuit , idle and low speed circuit , high speed circuit and acceleration circuit Solex carburetor - S.U Carburetor, Mikuni carburetor - Carburetor troubles Fuel injection: Introduction advantages working principle of throttle body injection, MPFI and Gasoline Direct injection (qualitative treatment only) UNIT III : COOLING & LUBRICATION SYSTEM (14 hours)

Cooling system Air cooling system, water cooling system Comparison pump circulation in water cooling system thermostat construction wax pellet and Bellows type water pump Radiators Cellular and tubular constructional details. Lubrication systems splash, full pressure system Characteristics of lubricating oils classification and identification of SAE oils Filtering systems Full flow and by pass systems oil strainer oil pumps Gear and Rotor type construction and operation Pressure Relief valve oil pressure gauge Bourdon type crank case ventilation system construction and

working of draft tube and positive crankcase ventilation systems. UNIT IV : DIESEL ENGINES & EMISSION CONTROLS

(14 hours)

High speed Diesel Engines two stroke and four stroke - combustion of Diesel fuel, stages of combustion in diesel engines diesel knock , Cetane number fuel dopes Types of Diesel engine combustion chamber. open , pre combustion, turbulent, air cell and energy cell combustion chambers types of open combustion chambers. Emission : sources of emission in petrol and diesel engines types of pollutants emission control evaporative emissions and tail pipe emissions: catalytic converter EGR working principle of gas analyzer emission standards. UNIT V : DIESEL FUEL FEED SYSTEM, GOVERNORS AND SUPER CHARGERS. (14 hours) Diesel fuel system - Layout - Feed pump single and double acting Fuel injection pump, jerk type and distributor type introduction to CRDI system (description only)- Construction and operation Diesel filters Pre filter and Micro filter Water separator Injectors Open type and Closed type, single hole , multi hole, pintle and pintaux type nozzles. Governors Mechanical and pneumatic type super charging Its effect Types of Super chargers Roots type, sliding vane and centralized types Turbo chargers advantages and limitation necessity of inter coolers. REFERENCE BOOKS: 1. 2. 3. 4. 5. 6. 7. 8. A.W.Judge, Automobile Engine Volume I, BI Publication, 1983. William H.Grouse, Automobile Engines, MCGraw Hill Book Comany,1959. William H.Grouse, Automobile Fuel, Lubricating and Cooling System, MCGraw Hill Book Comany,1959. E.Venk & W.Billiet, Automotive Engine, Taraporevala Sons & Co Ltd, 1969. K.Newton & Steeds, The Motor Vehicle, London Iliffe Books Ltd, 1962. S.Abbey, Practical Automobile Engineering, Asia Publishing House,1962. A.W.Judge, Maintenance of High Speed Diesel Engine, Chapman & Hall Ltd, 1956. P.M.Heldt, High Speed Coimbustion Engine, Oxford & IBH Publishing Co, 1969.

8301 AUTOMOBILE ENGINES Model Question Paper 3 hrs Note : 1. Answer all questions selecting any one from Section A (5 marks) and one from Section B (10 marks) 2. All questions carry equal marks. i) ii) List out the major parts of an IC engine Write short notes on firing order of an engine. Max. Marks : 75

I A

B.i) Explain the working principle of four stroke S.I. Engine. ii) Explain the vibration damper with help of neat sketch. II A i) ii) i) ii) i) ii) i) ii) Briefly explain different types of air filter. What are the advantages of MPFI system? Explain the construction and working of mechanical fuel feed pumps. Explain the construction and working of Solex carburetor with help of neat sketch. What is the difference between air cooled and water cooled engines? Explain the classification of SAE oils. Explain the pumped circulation water cooling system which help of neat sketch. Write short notes on following: a) Pressure relief valve b) Positive crankcase ventilation system Write short notes on Diesel knock. Explain briefly air cell combustion chamber Explain the various phases of combustion in diesel engine. Explain the construction and working principle of catalytic converters Write short notes on Diesel fuel filters. State briefly the advantages and limitations of turbocharger Explain the construction and operation of distributor type fuel pump. Explain the construction and working of Pneumatic governor with help of neat

III A

IV A

i) ii) i) ii) i) ii) i) ii)

B.

V A

sketch. 8302 AUTOMOBILE CHASSIS AND TRANSMISSION V TERM ( Applied Course ) 6 Hours/ Week MAJOR DIVISIONS: UNIT UNIT UNIT UNIT UNIT I II III IV V Clutch, Gear Box, Gear Shifting Mechanism Universal Joint, Propeller Shaft, Axles, Differential Suspension System, Steering System Brakes, Tyres Garage Equipment, Servicing, Maintenance (14 hours) Total Hours: 72 Hrs

UNIT I : CLUTCH, GEAR BOX, GEAR SHIFTING MECHANISM

Clutch function clutch actuating mechanism Mechanical and hydraulic types clutch material single plate dry clutch dual plate clutch multi plate wet clutch semi centrifugal and centrifugal clutch motor cycle clutch fluid coupling Gear Box purpose resistance offered to the motion of the vehicle air resistance rolling resistance offered to the motion of the vehicle gradient resistance tractive effort effect of gear ratio on fuel consumption types of gear boxes sliding mesh constant mesh synchromesh device epicyclic torque converter automatic transmission advantages (description only ) overdrive four wheel drive transfer cases - gear shifting mechanism floor shifting and steering column shifting mechanical and hydraulic control systems variomatic transmission Trouble shooting of clutch and gear box. UNIT II : UNIVERSAL JOINT, PROPELLER SHAFT, AXLES, DIFFERENTIAL (15 hours) Universal Joints cross type constant velocity joints Rzeppa joints centre support joint construction for heavy vehicles propeller shaft two piece and three piece construction rear axle construction Hotchkiss, torque tube drive - floating axles semi-floating three quarter floating and full floating final drive-function types Spiral bevel, Hypoid worm and worm wheel Differential function differential action non slip differential differential lock Front axle construction live and dead axle beam and tubular construction stub axle types Elliot and reverse Elliot Lemoine and Lemoine inverted Trouble shooting of final drive, differential and rear axle. UNIT III : SUSPENSION SYSTEM, STEERING SYSTEM (14 hours)

Suspension system rigid axle and independent suspension function of spring and shock absorber coil, leaf spring, torsion bar front independent suspension types wishbone and Macpherson strut - rear independent suspension - antiroll bar steering system Ackerman principle of steering front end geometry caster, camber, king pin inclination, toe-in, toe-out on turns steering gear box types cam and roller cam and peg recirculating ball rack and pinion power steering, linkage booster type, integral type- power steering pumps shock absorbers Telescopic type Air suspension systems Trouble shooting in suspension & 5

steering systems. UNIT IV : BRAKES, TYRES

(15 hours)

Brakes function stopping distance Braking system types: mechanical, hydraulic and air brake systems brake shoes, primary and secondary shoes servo action of brake shoes drum and disc brakes construction and operation master cylinder single and Tandem master cylinder wheel cylinders power assisted brakes : vacuum and air assisted types bleeding of brakes brake shoe adjustment mechanism Micram adjusters Snailcam, screw adjuster Air brake system - Tyres and tubes cross ply and radial ply tubeless tyres wheels types disc, split type, spoked and alloy purpose of tandem rear axle trouble shooting of braking system and tyres. UNIT V : GARAGE EQUIPMENT, SERVICING, MAINTENANCE (14 hours)

Garage and service station specialist repairs brake drum servicing lubricating service battery service power and machine tools extractors and presses compressed air supply air operated gauges preventive maintenance and service schedule of maintenance preventive maintenance of Fiat, Ambassador, Maruti, Leyland, TATA (From Manuals) brake adjustment - wheel bearing adjustments steering adjustment clutch pedal play adjustment servicing of brake system servicing of master cylinder and wheel cylinder wheel balancing tyres maintenance . REFERENCE BOOKS: 1. 2. 3. 4. 5. 6. W.H.Grouse, Automotive Chassis and Body, Mc Graw Hill, 1971. W.H.Grouse & D.L.Anglin, Automotive Mechanics, TMH Publishing, 2007. K.Newton & Steeds, The Motor Vehicle, Iliffe Books Ltd, 1962. W.H.Grouse, Automotive Transmission & Power Train, Mc Graw Hill, 1959. A.W.Judge, Car Maintenance and Reairs, Chapman & Hall Ltd, 1967. P.M.Heldt, Torque Convertors or Transmission, Chilton Company, 1955.

8302 AUTOMOBILE CHASSIS AND TRANSMISSION Model Question Paper Time : 3 hrs Note : 1. 2. I A B i) ii) i) ii) Max. Marks : 75 Answer all questions selecting any one from Section A (5 marks) and one from Section B (10 marks) All questions carry equal marks. What are the resistances offered to the motion of the vehicle ? Write short notes on automatic transmission With neat sketch explain the construction and working of single plate dry clutch.. Explain the construction and working of five speed synchromesh gearbox with the help of neat sketch. Write short notes on constant velocity joint. What are the different types of stub axle Explain the three quarter and full floating axles with neat sketch. Explain the function of differential and also explain differential action Explain the functions of shock absorber. What is Ackermans steering principle? Explain the following front wheel geometry: a) Camber b) Caster c) King pin inclination d) Toe-in Explain with help of neat sketch the working of integral type of power steering system. Compare drum and disc brakes. Write short notes on alloy wheel. Explain the construction and operation of a tandem master cylinder with sketch. Explain the air brake system with help of neat sketch. List out the power and machine tools used in garage and service stations. Write short notes on tyre maintenance. Explain the preventive maintenance and schedule maintenance Explain the servicing of master cylinder and wheel cylinder

II A B

i) ii) i) ii) i) ii) i)

III A

ii) IV A i) ii) B. i) ii) V A i) ii) B i) ii)

8401A AUTOMOBILE ELECTRICAL EQUIPMENTS V TERM (Diversified Course - I) 5 Hours/ Week MAJOR UNITS UNIT UNIT UNIT UNIT UNIT I II III IV V Electrical Systems in Automobiles, Lead Acid Battery Generator and Regulator Starting Motor and Drive Mechanisms Ignition System Lighting System and Accessories Total Hours: 60 Hrs

UNIT I : ELECTRICAL SYSTEMS IN AUTOMOBILES LEAD ACID BATTERY (12 hours) Brief introduction to the basic electrical system in the automobile Ignition system Starting system Charging system Lighting system and Auxiliary system Their needs. Lead acid battery purpose construction chemical reaction during charging and discharging capacity ratings testing hydrometer test open voltmeter test high rate discharge test charging methods trouble shooting in batteries (run down over charging sulphation bulging) UNIT II : GENERATOR AND REGULATOR (12 hours)

Generator Purpose construction field winding armature winding commutator brushes brush gears testing field winding armature- growler testing brush spring tension under cutting skimming commutator brush bedding. Alternator Purpose construction body stator winding rotor winding slip rings brush diode advantages of alternator. Regulator: Need for the regulators cut out or reverse cut out relay constant current and voltage regulator compensated voltage regulator trouble shootings in dynamo, alternator & regulator. UNIT III : STARTING MOTOR AND DRIVE MECHANISMS (12 hours)

Starting motor need working principle - construction -body - field coil - armature windings poles commutator and brush gears solenoid switch. Starting motor drive mechanism - Bendix - folo through - over running clutch type drive axial drive and co axial drive mechanism in the heavy vehicles complete electrical circuits of heavy duty starting motor -first contact and second contact closing troubles causes & remedies- electric starting circuits in two wheelers. UNIT IV : IGNITION SYSTEM (12 hours)

Battery coil ignition purpose components & its functions battery coil distributor spark plug (types) -condenser breaker point mechanism importance of ignition timing setting of ignition timing needs and types of advance mechanism centrifugal vacuum 8

advance mechanism. Magneto ignition advantages over battery / coil ignition to magnetic coil ignition (in two wheelers ) - transistorized ignition system electronic ignition system capacitor discharge ignition system distributor less ignition system Heater Plugs cold starting devices in diesel engines. UNIT V : LIGHTING AND ACCESSORIES (12 hours)

Lighting purpose & construction of lamps holder bulbs Head lamps -Head Lamp Beam setting and adjustments -Halogen lamps Sealed beam, dip switch beam indicator fog lamp park lamp rear number plate lamp door lamp pillar lamp roof light fluorescent lamp in transport vehicles brake light brake light switch traffic indicators (resistance & transistor type) panel lamps. Horn construction working horn relay - horn circuit, horn tuning - wind screen wiper construction working Trouble shooting of horn and wind screen. Gauges fuel gauge oil pressure gauge cooling water temperature gauge ammeter charging indicator. Radio interference suppressors audio system wiring single pole double pole cable size colour code wiring harness cable connection fuses circuit breakers window glass panel operating system. Earth return and insulated return systems positive and negative earth system advantages of 12 V system - colour coding. REFRENCE BOOKS: 1. 2. 3. 4. 5. 6. 7. 8. W.H.Grouse, Automotive Electrical Equipment, Mc Graw Hill, 1959. A.P.Young & Griffith, Automotive Electrical Equipment, Elbs & New Press, 1999. Barry Holleam Beak, Automotive Electricity, Electronics & Computer Controls, Delmar Publishers, 1998. Tom Denton, Automotive Electrical & Electronic Systems, Edward Arnold, 1995. V.A.W.Hillier, Fundamentals of Automotive Electronics, Hutchinson, 1987. P.L.Kohli, Automotive Electrical Equipment,TMH, 2004. A.W.Judge, Modern Electrical Equipment for Automotive, Chapman and Hall, 1973. W.H.Grouse, Automotive Electronics and Electrical Equipment, Mc Graw Hill, 1981.

8401A AUTOMOBILE ELECTRICAL EQUIPMENTS Model Question Paper Time : 3 hrs Note : Max. Marks : 75

1. Answer all questions selecting any one from Section - A (5 marks) and one from Section B (10 marks) 2. All questions carry equal marks. i) ii) Draw the circuit of a charging system and explain the function of the components. Explain the causes and remedy for the sulphation and bulging of the battery. With neat sketches, explain the construction and function of each component of a lead acid battery. What are the methods of charging a battery? Explain any two of them in detail. What are the advantages of alternator over D.C. generator? Explain briefly the purpose of a cut-out. Explain with neat sketch the construction and working of a two pole shunt wound D.C. generator. Explain construction and working of a constant current and voltage regulator with a neat circuit diagram. Give any two troubles, causes and remedies of the starting systems. Explain the working principle of a starting motor. Explain the construction and working of a Bendix drive starter mechanism with neat sketch. Explain the construction and working of over running clutch starter driver mechanism with neat sketch. What are the types of spark plugs? Explain briefly. What are the advantages of the battery coil ignition system over magneto ignition system? With a neat sketch explain the principle, construction and working of an electronic ignition system? What are the needs and types of ignition advance mechanism? Explain the construction and working of a vacuum advance mechanism. What is radio interference? Explain how it can be avoided? Compare earth return and insulated return systems. What are the types of traffic indicators? Explain the construction and working of any one type with neat circuit diagram. Explain briefly the working of following components with neat sketch: a) Horn 10

I A

i) ii)

II A B

i) ii) i) ii)

III A B

i) ii) i) ii)

IV A

i) ii) i) ii)

V A

i) ii) i) ii)

b) Windscreen wiper. 8401B TWO WHEELER TECHNOLOGY V TERM (Diversified Course - I ) 5 hours/ week MAJOR DIVISIONS UNIT UNIT UNIT UNIT UNIT I II III IV V Introduction Vehicle Components Electrical System Wheel, Brake, Suspension and Tyre Trouble Shooting (10 hrs) Total hours: 60 hrs

UNIT I : INTRODUCTION

Four stroke engine intake system of two stroke cycle engine - special features of engines-reed valve intake system- electronic ignition etc., lubrication of engine in two wheelerengine specification- periodic maintenance of vehicle(engine and transmission)- tracing the power flow from engine- lubrication points in the vehicle. UNIT II : VEHICLE COMPONENTS (12 hrs)

Engine components removal without dismounting the engine as whole - engine disassembly - engine components inspection and servicing bearing oil seal crankshaft gears and shifting fork clutch plates springs cylinder head cylinder pistong ringsreassembly - gear shift mechanism. UNIT III : ELECTRICAL SYSTEM (13 hrs)

Ignition system- charging and lighting system- instrument panelbattery- lamps- turn signal light- brake light. UNIT IV : WHEEL, BRAKE, SUSPENSION AND TYRE (13 hrs)

Front wheel and front brake. Inspection of wheel bearing- axle shaft- wheel drumtyre pressure- brake shoe- brake drum- front fork- disassembly and assembly- steering stemrear wheel and rear brake- rear suspension. UNIT V : TROUBLE SHOOTING Trouble shooting in two wheeler- cause and remedies for: 1. 2. 3. 4. 5. 6. Engine difficult to start Engine over heats Engine fail to start Engine stop immediately after starting Engine stops while running Engine misfiring 11 (12 hrs)

7. 8. 9. 10. 11.

Engine lacking power Engine popping and spiting Excessive fuel consumption Gear shift problems Poor stability and steering

REFERENCE BOOKS 1. 2. 3 4. 5. 6. 7. 8. 9. 10. Motor Cycle, Two Stroke Motor Cycle, Iliffe & Sons Ltd, 1958. D.W.Munro, BSA Motor Cycle, C.Arthur Person Ltd, 1955. Paul Richards, Vincent Motor Cycles, C.Arthur Person Ltd, 1955. Torrens, The Motor Cyclists Workshop Iliffe & Sons Ltd,1954. A.ST.Masters, Motor Cycle Repair, C.Arthur Person Ltd, 1953. E.M.Franks, Norton Motor Cycles, C.Arthur PersonLtd, 1956. R.B.Rainson, Rudge Motor Cycle, C.Arthur PersonLtd, 1953. F.W.Neill, Matchiless Twin Motor Cycle, C.Arthur PersonLtd, 1957. P.E.Irving, Two Stroke Power Units, Temple Press Booksw, 1967. Grahamgap Sdyke, Motor Cycle Maintenance Illustrated, C.Arthur PersonLtd, 1967.

12

8401-B TWO WHEELER TECHNOLOGY Model Question Paper Time : 3 hrs Note : Marks : 75

1. Answer all questions selecting any one from Section A (5 marks) and one from Section B (10 marks) 2. All questions carry equal marks. i) ii) i) ii) i) ii) i) ii) Write short notes on reed valve intake system Explain the lubrication method adopted in two stroke engines Explain the working principle of two stroke cycle engine Explain the periodic maintenance of engine and transmission with a schedule Write short notes on cylinder head servicing in a two wheeler What are the common troubles in two wheeler gear shift mechanism ? Explain the servicing procedure of cylinder, piston, rings, connecting rod and crankshaft assembly of a engine Explain the overhauling procedure for two wheeler clutch and transmission system Explain the working of headlight in a two wheeler Explain about the functioning of brake light in a two wheeler Describe the working of ignition system in a two wheeler with circuit Describe the working of charging system in a two wheeler with circuit Write short notes on tyre pressure of two wheeler Explain the working rear suspension in two wheeler. Explain the construction and working of front fork assembly. Explain the servicing procedure of rear wheel and rear brake assembly. List out the reasons for engine overheating. List out the reasons and remedy for poor stability and steering of two wheeler. Explain the trouble shooting of two wheeler engine. List out the gear shift problems and remedial method for it.

I A

II A

III A

i) ii) i) ii) i) ii) i) ii) i) ii) i) ii)

IV A

V A

13

8303 AUTOMOBILE ENGINES LAB V TERM ( Applied Course ) 6 hrs/Week 1. 2. 3. 4. 5. 6. 7. 8. 9. Dismantling of Four stroke engines and identification of components Valve timing and port timing diagrams Dismantling and assembling of two stroke engines and identification of parts Cylinder bore measurement Servicing of cylinder head and adjustment of valve clearance Servicing of camshaft and connecting rod piston assembly Determination of flash and fire point of fuel Determination of viscosity of oil using redwood and Saybolt viscometer Water pump and oil pump service Total Hrs : 72 Hrs

10. Petrol fuel feed system servicing AC pump Carburettor 11. Engine Tune-up 12. Performance test on IC engine 13. Morse Test on multi-cylinder engine 14. Dismantling and assembling of inline and distributor type of F.I.P. 15. Setting up Fuel injection pump timing. 16. Fuel injector testing and servicing. 17. Servicing of diesel fuel feed system. 18. Study of Euro I, Euro II, Euro III, Emission Standards and Green tax (not for examination) SCHEME OF EXAMINATION
S.No 1 2 Topics Exercise Viva Voice Total Marks 70 5 75

14

8304 WORK SHOP III (SPECIAL MACHINES) V TERM (Applied Course) 6 Hours/Week Syllabus: 1. Introduction to shaping machine and its parts. 2. 3. 4. 5. 6. 7. 8. 9. Introduction to planning machine and its parts. Introduction to slotting machine and its parts. Introduction to milling machine and its parts. Introduction to grinding machine and its parts. Introduction to turret and capstan lathe. Introduction to work holding devices. Types of tools used in shaping, planning and slotting machines. Types of cutter used in milling machine. Total Hours : 72 Hrs

10. Types of grinding wheels used in grinding machines. 11. Types of tools used in turret and capstan lathes. 12. Setting of work, tools and cutters in shaping, planing, slotting and grinding machines. 13. Operation performed in shaping, planing, slotting, milling and grinding machines. 14. Operation of shaping, planing, slotting, milling and grinding machines.

15