Second Semester Syllabus of Mechanic Diesel

	Syllabus for the trade of		Mechanic Diesel
	SecondSemester	(Semester code No.			)
	Duration: Six Months.
	Syllabus for Trade practical and Trade Theory
Week	Trade Practical (27 Hrs/week)		Trade Theory (5 Hrs/week)
No.
1 & 2	Identification of parts in a diesel engine of		Introduction to Engine:
	LMV/ HMV		Description    of    internal    &    external
	Practice on starting and stopping of diesel		combustion	engines,		Classification  of  IC
			engines, Principle & working of 2&4-stroke
	engines.
			diesel engine (Compression ignition Engine
	Observe   and   report   the   reading   of		(C.I)),   Principle    of    Spark    Ignition
	Tachometer,  Odometer,  temp  and  Fuel		Engine(SI),  differentiate  between  2-stroke
	gauge under ideal and on load condition.		and  4  stroke,  C.I  engine  and  S.I  Engine,
	Practice  on  dismantling  Diesel  engine  of		Direct  injection  and  Indirect  injection,
			Technical  terms		used	in	engine,	Engine
	LMV/HMV as per procedure.		specification.		Study		of	various
			gauges/instrument  on  a  dash  board  of  a
			vehicle-	Speedometer,			Tachometer,
			Odometer  and  Fuel  gauge,  and  Indicators
			such as gearshift position, Seat belt warning
			light,  Parking-brake-engagement  warning
			light and an Engine-malfunction light.
			Different  type  of  starting  and  stopping
			method of Diesel Engine
			Procedure for dismantling of diesel engine
			from a vehicle..
3 & 4	Overhauling  of  cylinder  head  assembly,		Diesel Engine Components: Description
	Use of service manual for clearance and		and  Constructional  feature  of  Cylinder
	other  parameters,  Practice  on  removing		head, Importance of Cylinder head design,
	rocker arm assembly manifolds.		Type  of  Diesel  combustion  chambers,
	Practice on removing the valves and  its		Effect  on  size  of  Intake  &  exhaust
	parts  from  the  cylinder  head,  cleaning.		passages,  Head  gaskets.  Importance  of
	Inspection of cylinder head and manifold		Turbulence
	surfaces for warping, cracks and flatness.		Valves & Valve Trains- Description and
	Checking  valve  seats  &  valve  guide  –		Function of Engine Valves, different types,
	Replacing the valve if necessary. Testing		materials,   Type   of   valve   operating
	leaks  of  valve  seats  for   leakage   –		mechanism,  Importance  of  Valve  seats,
	Dismantle rocker shaft assembly -clean &		Valve  seats  inserts  in  cylinder  heads,
	check  rocker  shaft-and  levers,  for  wear		importance of Valve rotation,  Valve stem
	and cracks and reassemble. Check valve		oil  seals,  size  of   Intake  valves,  Valve
	springs, tappets, push rods, tappet screws		trains, Valve- timing diagram, concept of
	and valve stem cap. Reassembling valve		Variable  valve  timing.  Description  of
	parts in sequence, refit cylinder head and		Camshafts  &  drives  ,  Description  of
	manifold   &   rocker   arm   assembly,		Overhead  camshaft,  importance  of  Cam
	adjustable   valve   clearances,	starting	lobes, Timing belts & chains, Timing belts
	engine after adjustments.		& tensioners.

5

Overhauling piston and connecting rod

Description & functions of different types

Assembly.  Use  of  service  manual  for

of pistons, piston rings and piston pins and

clearance and other parameters:-

materials.  Used

recommended

clearances

Practice  on  removing  oil  sump  and  oil

for the rings and its necessity precautions

pump  –  clean  the  sump.  Practice  on

while  fitting  rings,  common  troubles  and

removing the big end bearing, connecting

remedy. Compression ratio.

rod with the piston. Practice on removing

Description  &  function

of

connecting

the  piston

rings;  Dismantle the

piston

rod,

importance   of

big-

end

split

and

connecting

rod.  Check  the

side

obliquely, Materials used for connecting

clearance of piston

rings

in the piston

rods

big  end  &

main

bearings.  Shells

groove & lands for wear. Check piston

piston pins and locking methods of piston

skirt

and

crown

for

damage

and

pins.

scuffing, clean oil holes.

Measure -the piston ring close gap in the

cylinder, clearance between the piston and

the liner, clearance between crank pin and

the connecting rod big end bearing.

Check connecting rod for bend and twist.

Assemble the piston and connecting rod

assembly.

6

Overhauling of crankshaft, Use of service

Description and function of Crank shaft,

manual for clearance and other parameters:-

camshaft,  Engine  bearings-  classification

Practice  on  removing  damper  pulley,

and   location   –    materials   used   &

timing gear/timing chain, flywheel, main

composition  of  bearing  materials-  Shell

bearing caps, bearing shells and crankshaft

bearing   and   their   advantages-   special

from

engine  checking  oil  retainer  and

bearings   material   for   diesel   engine

thrust  surfaces

for

wear,

Measure

crank

application bearing failure & its causes-care

&   maintenance.

Crank-shaft

balancing,

shaft

journal for wear, taper and

ovality,

Firing order of the engine.

Checking crankshaft for fillet radii, bend

& twist.

7

Checking

of

flywheel

and

mounting

Description and function of the fly wheel

flanges,  spigot,  bearing.  Check  vibration

and

vibration  damper.

Crank

case

&  oil

damper for defects, Practice on removing

pump, gears timing mark, Chain sprockets,

cam  shaft  from  engine  block,  Check  for

chain tensioner etc. Function of clutch &

bend  &  twist  of  camshaft.  Inspection  of

coupling units attached to flywheel.

cam lobe,  camshaft  journals and  bearings

and measure cam lobe lift. Fixing bearing

inserts in cylinder block & cap check nip

and spread clearance & oil holes & locating

lugs fix crank shaft on block-torque bolts -

check  end  play  remove  shaft  -  check

seating, repeat similarly for connecting rod

and Check seating and refit.

8

Cleaning and Checking of

cylinder blocks

Description  of  Cylinder  block,  Cylinder

Surface  for  any crack,  flatness,  Measure

block construction, and  Different  type of

cylinder bore for taper & ovality, clean oil

Cylinder sleeves (liner).

gallery passage and oil pipe line, Bore -

descale   water   passages   and   examine

Removing   cylinder   liners   from   scrap

cylinder block, practice in measuring and

refitting   new   liners   as   per   maker’s

recommendations precautions while fitting

new liners.

9

Reassemble all parts of engine in correct

Engine  assembly  procedure  with  aid  of

Sequence and torque all bolts and nuts

special tools  and  gauges  used  for  engine

as per workshop manual of the engine.

assembling.  Introduction  to  Gas  Turbine,

Engine component procedures- Testing

Comparison of single and two stage turbine

cylinder  compression,  Checking  idle

engine, Different between gas turbine and

speed,  Removing  &  replacing  a  cam

Diesel Engine.

belt, Inspecting & adjusting an engine

drive  belt,  Replacing  an  engine  drive

belt.

10-12

Practice on Checking &Top up coolant,

Need for Cooling systems, Heat  transfer

Draining & refilling coolant, Checking /

method,   Boiling   point   &   pressure,

replacing   a   coolant   hose,   Testing

Centrifugal

force,

Vehicle

coolant

cooling  system  pressure,  Practice  on

properties  and  recommended  change  of

Removing

&

replacing

radiator/

interval, Different type of cooling systems,

thermostat. Inspect the radiator pressure

Basic   cooling   system   components-

cap, Testing of thermostat. Cleaning &

Radiator,

Coolant

hoses,

Water

pump,

Cooling

system

thermostat,

Cooling  fans,

reverse

flushing.

Overhauling

water

Temperature

indicators,

Radiator

pressure

pump and refitting.

cap, Recovery system, Thermo-switch.

Practice on Checking engine oil, Draining

engine

oil,

Replacing  oil  filter,

Refilling

Need for lubrication system, Functions of

engine

oil.

Overhauling  of

oil

pump,

oil

oil,  Viscosity and its grade as per SAE ,  Oil

coolers,

air

cleaners  and

air

filters

and

additives,  Synthetic

oils,

The  lubrication

adjust oil pressure

relief valves,

repairs to

system,  Splash

system,

Pressure

system,

oil flow pipe lines and unions if necessary.

Corrosion/noise reduction in the lubrication

system.  Lubrication system  components -

Description  and  function  of   Sump,  Oil

collection  pan,   Oil  tank,  Pickup  tube,

different type of Oil pump & Oil filters  Oil

pressure   relief   valve,   Spurt   holes   &

galleries, Oil indicators, Oil cooler.

13.

Practice on Dismantling air compressor and

Intake & exhaust systems – Description

exhauster and cleaning all parts - measuring

of  Diesel  induction  &  Exhaust  systems.

wear in the cylinder, reassembling all parts

Description & function of air compressor,

exhauster,

Super   charger,

Intercoolers,

and fitting them in the engine.

turbo   charger,   variable   turbo   charger

Dismantling & assembling of turbocharger,

mechanism.

check  for  axial  clearance  as  per  service

Intake system components- Description

manual.

and  function  of  Air  cleaners,  Different

Check Exhaust system for rubber mounting

type  air  cleaner,  Description  of  Intake

for damage, deterioration and out of position;

manifolds and material,

for leakage, loose connection, dent and

damage;

Exhaust system components- Description

Practice on Exhaust manifold removal and

and   function

of

Exhaust

manifold,

installation.

Exhaust

pipe,

Extractors,

Mufflers-

Practice on Catalytic converter removal and

Reactive,

absorptive,

Combination.,

installation.

Catalytic converters, Flexible connections,

Ceramic

coatings,

Back-pressure,

Electronic mufflers.

14 -

Practice  on  removing  &  Cleaning  fuel

Diesel  Fuel  Systems-  Description  and

16

tanks, checking leaks in the fuel lines,

function  of  Diesel  fuel  injection,  fuel

soldering  &  repairing  pipe  lines  and

characteristics,  concept  of  Quiet  diesel

Unions, brazing nipples to high pressure

technology & Clean diesel technology.

line  studying  the  fuel  feed  system  in

Diesel   fuel   system   components   –

diesel   engines,   draining   of   water

Description and function of Diesel tanks &

separators.

lines, Diesel fuel filters, water separator,

Bleeding  of

air  from  the

fuel

lines,

Lift pump, Plunger pump, Priming pump,

Inline

injection

pump,

Distributor-type

Servicing primary & secondary filters.

injection  pump,  Diesel  injectors,  Glow

Removing a fuel injection pump from

plugs, Cummins & Detroit Diesel injection.

Electronic

Diesel

control-

Electronic

an engine-refit the pump to the engine

Diesel

control

systems,

Common

Rail

re- set timing - fill lubricating-oil start

Diesel

Injection

(CRDI)

system,

and adjust slow speed of the engine.

Hydraulically

actuated

electronically

Practice on

overhauling of

injectors and

controlled

unit

injector

(HEUI)

diesel

testing of injector.

injection  system.

Sensors,  actuators

and

General  maintenance  of  Fuel

Injection

ECU

(Electronic

Control

Unit)  used

in

Pumps (FIP).

Diesel Engines.

17

Practice on Start engine adjust idling

Marine & Stationary Engine:- Types,

speed  and  damping  device  in  pneumatic

double  acting  engines,  opposed  piston

governor and venture control unit checking

engines, starting systems, cooling systems,

Performance  of  engine  with  off  load

lubricating  systems,  supplying  fuel  oil,

adjusting timings. Start engine- adjusting

hydraulic  coupling,  reduction  gear  drive,

idle  speed  of  the  engine  fitted  with

electromagnetic  coupling,

electrical

drive,

mechanical  governor  checking-   high

generators and motors, supercharging.

speed operation of the engine.

Checking

performance

for

missing

cylinder  by  isolating  defective  injectors

and test- dismantle and replace defective

parts and reassemble and refit back to the

engine

18

Monitoring emissions procedures by use of

Emission Control:- Vehicle emissions

Engine gas analyser or Diesel smoke meter.

Standards- Euro and Bhart II, III, IV, V Sources

Checking & cleaning a Positive crank case

of   emission,   Combustion,   Combustion

ventilation  (PCV)  valve.  Obtaining  &

chamber   design.   Types  of  emissions:

interpreting  scan  tool  data.  Inspection  of

Characteristics and Effect of Hydrocarbons,

EVAP canister purge system by use of scan

Hydrocarbons in exhaust gases, Oxides of

Tool.

nitrogen,  Particulates,  Carbon  monoxide,

EGR /SCR Valve Remove and installation

Carbon  dioxide,  Sulfur  content  in  fuels

for inspection.

Description

of

Evaporation

emission

control, Catalytic conversion, Closed loop,

Crankcase  emission  control,  Exhaust  gas

recirculation (EGR) valve, , Controlling air-

fuel ratios, Charcoal storage devices, Diesel

particulate filter (DPF). Selective Catalytic

Reduction (SCR), EGR VS SCR

19

Practice

on

removing

alternator

from

Description .of charging circuit operation

vehicle dismantling, cleaning checking for

of  alternators,  regulator

unit,

ignition

defects,

assembling

and

testing

for

warning  lamp-  troubles  and  remedy  in

motoring

action of  alternator

& fitting to

charging system.

vehicles.

Practice on removing starter motor Vehicle

Description of starter motor circuit,

Constructional  details

of

starter

motor

and overhauling the starter motor, testing of

solenoid

switches,  common

troubles  and

starter motor

remedy in starter circuit.

20 &

Practice

on

troubleshooting

in

Troubleshooting : Causes and remedy for

21

LMV/HMV

for  Engine

Not

starting  –

Engine Not starting – Mechanical &

Mechanical

&

Electrical

causes,  High

Electrical causes, High fuel consumption,

Engine

overheating,

Low

Power

fuel

consumption,  Engine  overheating,

Generation,

Excessive

oil

consumption,

Low

Power

Generation,

Excessive

oil

Low/High

Engine  Oil

Pressure,

Engine

consumption,

Low/High

Engine

Oil

Noise.

Pressure, Engine Noise.

22-23

In-plant Training

24-25

Revision and Test

26

NCVT Exam

Automobile Group – 1 year Trade 2^nd Semster

			Workshop Calculation and Science
			Syllabus for the trade of
			1.	Mechanic Diesel
Week				Workshop calculation and
No.				Science (3 Hrs/week)
	Factorisation and quadratics: multiply expressions in brackets by a number, symbol or
1 & 2	by another expression in a bracket; by extraction of a common factor eg ax + ay, a(x + 2)
	+ b(x + 2) ; by grouping eg ax − ay + bx − by ; quadratic expressions eg a2 + 2ab + b2 ;
	roots of an equation eg quadratic equations with  real roots by factorisation, and by the use
	of formula
3	Geometry– Use of scientific calculator,/logarithmic table  Angles -Angular measurement,
	Angles and		rotation, Examples of angles in automotive work, Adding and subtracting
	angles.  Types of angle- Adjacent angles, Opposite angles, Corresponding angles, Alternate
	angle
4-6	Trigonometry- Types of triangle - Acute angled triangle, Obtuse angled triangle,
	Equilateral triangle, Isosceles triangle, Scalene triangle, Right angled triangle,
	Labelling sides and angles of a triangle, Sum of the three angles of a triangle.
	Pythagoras’ theorem, Circles, Ratio of diameter and circumference, Length of arc,
	Timing marks, Wheel revolutions and distance travelled, Valve opening area.
	Trigonometry-  Using sines, cosines and tangents to solve vehicle problems.
7 -10	Formulae for		Perimeter and Area of Plane figure - Rectangle, Square, Parallelogram,
	Triangle,  Hexagon,  any  regular  polygon,  Trapezium,  Circle,  sector,  Fillet,  Ellipse,
	segment of a circle;
	Formulae for		Volume and surface area of solids- Rectangular solid, Prism, cylinder,
	pyramids and cones, Frustum of pyramid and cones, sphere, Hollow sphere, segment of
	sphere, circular ring, spherical sector,
	Calculation of volume and weight of simple solid bodies such as cubes, square and
	hexagonal prism-shop problem.
11-13	Statistics – Collecting and sorting raw data, Definition of Discrete variable, continuous
	variable	with	Shop examples. Constructing pictographs-pie chart, Bar chart. Frequency
	and tally	Charts.  Importance of the shape of a frequency distribution- histogram,
	frequency polygon,   Cumulative frequency plot. Interpreting statistics- sampling,
	arithmetic mean, median,
14 &	Heat and temperature –Temperature-Thermodynamic temperature scale (Kelvin),
15	Cooling system temperature;			Standard temperature and pressure (STP); Thermal expansion
	with calculation; Heat- Sensible heat, Latent heat, Specific latent heat, Specific heat
	capacity, Quantity of heat with calculation; Heat transfer – Conduction, Convection,
	Radiation ;
16 &	Heating, expansion and compression of gases - Absolute pressure, Absolute temperature;
17	Laws relating to the compression and expansion of gases -Heating a gas at constant volume,
	Heating a gas at constant pressure, Charles’ law. Expansion or compression at constant
	temperature – isothermal

18-20 Internal combustion engines- Engine power-Brake power, Horsepower, PS – the DIN, Indicated power, Mean effective pressure, Calculation of indicated power, Cylinder pressure vs. crank angle, Mechanical efficiency of an engine, Volumetric efficiency, Torque vs. engine speed, Specific fuel consumption vs. engine speed, Brake power, torque and sfc( Specific fuel consumption) compared, Brake mean effective pressure, Thermal efficiency, Indicated thermal efficiency, Brake thermal efficiency petrol vs. Diesel.

21                    Fuels and combustion- Calorific value, Combustion-Products of combustion, Relevant combustion equations. Air–fuel ratio-Petrol engine combustion, Detonation, Pre-ignition, Octane rating, Diesel fuel, Flash point , Pour point, Cloud point, Biofuels, Liquefied petroleum gas (LPG) ,Hydrogen, Zero emissions vehicles (ZEVs)

	2nd  Semester
	Engineering Drawing
	Syllabus for the trade of Mechanic Diesel
Week	Engineering Drawing (3 Hrs/week)
Nos.	2nd  Semester
1-4	Read and interpret drawings- Determine information from the title block, Read and
	interpret industrial prints, Read and interpret detailed and assembly drawings,
	Identify casting drawings and machining drawings, Read and interpret diagrams,
	Distinguish between a monodetail and a multidetail drawing.
5-8	Identify different drawing projections - Interpret pictorial and multi-view drawings.
	Interpret auxiliary and section views, Determine views in a drawing and the
	significance of the view being shown.  Identify missing lines and missing views.
9-12	Free hand sketching of key and screw threads. Read and interpret three Types of
	screw thread representation: pictorial, schematic and simplified presentation. Terms
	used in describing a threaded Part , Designation of Thread Specifications, Left-Hand
	Thread Notations, read and interpret the different type of Finish Symbols, Fillets and
	Rounds and Machine Slots.
13	Drawing of I .C engine – Diesel and their parts.
14	Sketching of otto cycle, Diesel cycle, valves and valve timing diagram.
15	Free hand sketch of piston assembly, Free hand sketching of piston gudgeon pins
	rings and connecting rod .
16	Free hand sketching of crank shaft and cam shaft showing all parts.
17	Free hand sketching of cylinder block and cylinder head, cylinder liners .
18	Free hand sketching of different cooling system -showing all necessary parts such as
	water pump, thermostatic valve, Radiator etc.
19	Free hand sketching of lubrication system, showing all necessary parts such as filters ,
	oil pump, pressure release valve etc.
20	Freehand sketching of staring system.
21	Freehand sketching of charging system and solenoid switch circuit.