SCHEME OF EXAMINATION
The examination shall consist of three papers, Papers 1, 2 and 3; all of which must be taken. Papers 1 and 2 will be composite and will be taken at one sitting.
PAPER 1: Will comprise forty multiple choice objective questions, all of which must be answered within 1 hour for 40 marks.
PAPER 2: There will be five essay questions out of which candidates will be required to answer four in 1½ hours for 60 marks.
PAPER 3: This will be a practical test comprising two compulsory questions to be attempted by candidates in 2 hours for 100 marks.
Schools will be required to supply materials needed for the practical test by their candidates.
EXAMINATION SYLLABUS
S/NO. TOPIC THEORY PRACTICAL 1 WORKSHOP 1.1 Instructions in basic safety 1.1.1 Identification and use REGULATION rules relating to personnel, of various safety S AND tools, equipment and devices e.g. aprons, SAFETY environment. goggles, shield, etc. 1.2 Types of fire extinguishers. 1.2.1 Demonstration/use Foam, dry powder, sand, of fire extinguishers. water and wet-blanket types 2 BASIC TOOLS, 2.1 Use of basic tools e.g. 2.1.1. Identification and INSTRTUMENTS AND hand tools and power use of basic tools. EQUIPMENT tools. 2.2 Use of measuring 2.2.1 Identification and instruments use of measuring instruments. 2.3 Use of basic equipment 2.3.1 Identification and use e.g. jacks, hoist, air- of basic equipment. compressors, etc.
3 LAYOUT OF A 3.1 Layout of a conventional MOTOR VEHICLE motor vehicle. 3.2. Functions of the main components.
3.1.1 Inspection of the layout of a motor vehicle.
3.2.1 Identification of the main components.
3.3 Drive arrangements: 3.3.1 Inspection of the drive Front engine rear wheel arrangements. drive, rear engine rear wheel drive, front engine front wheel drive, four- wheel drive. 4 ENGINE 4.1 Classification of engine 4.2.1 Identification of main (a) Main Components (petrol and diesel components. engine) and their main parts. 4.2 Arrangement and 4.2.2 Decarbonization of functions of the main cylinder head. components: Cylinder head and cover; cylinder block, crankshaft, flywheel, connecting rod, piston and rings, spark plug (petrol) fuel injection pump and injector (diesel), valve, valve springs, oil seal, cam- shaft, push rod, rocker shaft/arms. (b) Principles of 4.3 Two stroke and four stroke 4.3.1 Identification of two operation. cycle petrol and diesel and four stroke engines. engine. (c) Types of engine 4.4 Advantages and disadvantages of petrol and diesel engines. 4.5 Single and 4.5.1 Inspection and multi-cylinder engines. classification of engines (d) Crank according to cylinders. arrangement 4.5.2 Compression test. and firing order. 4.5.3 Measurement of the bore and crank- journals for wear. 4.6 Crank arrangement and 4.6.1 Determination of (e) Valve- firing orders: 2, 4 and 6 firing order through operating cylinder in-line engines. valve opening. mechanis V-4,V-6 and 4-cylinder 4.6.2 Fault diagnosis. horizontally- opposed engines. 4.7 Functions and operation 4.7.1 Identification of main of valve operating components. mechanisms. Drives 4.7.2 Valve adjustments. layout, main 4.7.3 Fault diagnosis. components, 4-cylinder 12 – and 16 - valve engine. Valve timing including calculation of valve opening and closing periods. 5 FUEL SUPPLY SYSTEMS 5.1 Fuels and combustion: 5.1.1 Checking fuel elements of combustion; system troubles. air-fuel ratios; types and 5.1.2 Inspection of exhaust properties of fuel-petrol gases for normal air-fuel and diesel. ratios and excessively worn engine. 5.2 Petrol: Layout and 5.2.1 Inspection layout of operation of petrol supply petrol supply system: system-gravity and force- dismantling, feed systems: examination and simple carburetor, reassembling of a multi-jet carburetor. mechanical fuel pump. Air filters/cleaners. Mechanical and electrical 5.2.2 Fault diagnosis. fuel pumps. Advantages and disadvantages. 5.3 Petrol-injection system: 5.2.3 Dismantling, inspection Merits and demerits. and reassembling of a Electronic Fuel (Petrol) carburetors. injection (EFI). 5:3:1 Identify the main components
5.4 Diesel: Layout of a diesel 5.4.1 Inspection of various supply system: types of injection elementary treatment of pumps, servicing of injection pumps and injectors and bleeding. injectors. Cold starting devices. 6 EXHAUST SYSTEM 61 Purpose and layout of 6.1.1 Inspection of exhaust the system. Types of system and silencers and manifolds. identification of the exhaust and inlet manifolds. 6.1.2 Checking the system for leakage. 7 LUBRICATION 7.1 Engine Lubrication: 7.1.1 Identification of main Reasons for lubrication components. and types: boundary layer and film lubrication. 7..2.1 Changing of oil and oil Lubricated parts and filters. components. 7.2 Types of feed-splash, 7.2.2. Servicing and testing of forced and petroil. (Wet pumps and dry). Principle of operation of gear and rotor oil pumps. Oil filters. 7.2.3 Fault diagnosis 7.3 Lubricants: Applications 7.3.1. Identification of different in engines, transmission, types of lubricants. steering, suspension Comparing fresh and system and doors: used oil. Use of grease Viscosity rating, SAE gun and oil can. numbers. 8 COOLING SYSTEM 8.1 Process of heat transfer. 8.2 Water Cooling System: 8.2.1 Identification of main Purpose and layout of components, inspection the system: functions of of radiator and its main components. construction, replacement Thermo-syphon and of fan belt and hoses. pump assisted systems. Elementary treatment of 8.2.2 Flushing. pressurized cooling system. 8.2.3 Fault diagnosis. Thermostats: Purpose and types. (bellows and wax pellet). 8.3.1 Fault diagnosis. 8.3 Air Cooling System: Layout and functions of the system: main components. Comparison of the air and water cooled systems. 10 TRANSMISSION 9.1 Function and layout of 9.1.1 Identification of SYSTEM the transmission different types of (a) Layout system. layout. Types-manual and automatic (excluding twin axles and double reduction axles) merits and demerits. (b) Clutch 9.2 Functions of a clutch. 9.2.1 Dismantling, Assembly Types and operating identifying parts and principles of single plate re-assembling a clutch and multiplate. unit (single plate). Methods of actuation- Adjusting clutch pedal hydraulic and clearance and mechanical. Simple bleeding clutch unit. calculations. 9.2.2 Fault diagnosis. 9.3 Introduction to automatic transmission. Functions of torque converter and fluid flywheel. (c) Gearbox 9.4 Types, layout and 9.4.1 Identification of operating principles of components of a sliding-mesh, constant gearbox. mesh and synchromesh gearboxes; main 9.4.2 Inspection of gear teeth components and their for wear. functions. Gear selector mechanism; simple 9.4.3 Fault diagnosis. calculations of gear ratios. (d) Propeller shaft 9.5 Functions and types of 9.5.1 Examination of the and universal joint. the propeller shaft, propeller shaft and universal joint and universal joint bearings sliding joint. for bow and wear respectively. (e) Rear Axle 9.6 Purpose of rear axle. 9.6.1 Identification of main Arrangement and components. functions of main components: final drive, 9.6.2 Fault diagnosis. differential unit, half - shaft, oil seal and hub 9.7.1 Identifying main bearings. components. 9.7 Methods of supporting axle shafts. Advantages and disadvantages 10 WHEELS AND TYRES 10.1 Types of wheel rims: 10.1.1 Checking and pressed steel, disc and adjustment of wheel wire spoke wheels. bearing clearance, Hub attachments. removal and changing Wheel balancing. of road wheels. Tyre sizes and markings. 10.2 Tyres: tubed and 10.2.1 Tyre fitting and checking tubeless types: tyre pressure. Advantages and 10.2.2 Tube and tyre patching. disadvantages. 10.3 Wheel balancing, tyre 10.3.1 Wheel balancing. sizes, markings. 11 BRAKING SYSTEM 11.1 Layout, functions and 11.1.1 Inspection of different operation of braking types of brakes. system, drum and disc, Replacement of pads and mechanical and shoes, bleeding and hydraulic. Brake lining adjustment. “Spottesting” materials and methods of brakes. of attachment. 11.2.1 Fault diagnosis. Importance of servo- assisted brake. Advantages and disadvantage of disc and drum brakes. 11.2 Brake fault. 12 STEERING SYSTEM 12.1 General layout and 12.1.1 Identification of main functions of the front components of different axle and steering layout. systems. 12.2 Steering geometry. 12.2.1 Front wheel alignment, Ackerman linkage, inspection of tyre wear castor, camber, king pin patterns. inclination, toe-in and toe-out. Types of steering gearboxes-rack and pinion, recalculating balls only. 12.3 Steering faults 12.3.1 Fault diagnosis. 13 SUSPENSION SYSTEM 13.1 Purpose of the 13.1.1 Identification of suspension system, differences between layout and types, rigid the rigid beam and beam and independent. independent Suspension (semi- suspension. elliptic and coil springs); advantages and 13.1.2 Fault diagnosis. disadvantages, dampers (shock absorbers.) 14 ELECTRICAL SYSTEMS 14.1 Basic electrical terms 14.1.1 Setting up simple (a) Fundamentals and symbols. A.C and electrical circuits, use of D.C sources, simple simple electrical circuits, Ohm’s law and measuring instruments. calculations involving series and parallel circuits. Basic components and their functions-relays, resistors, lamps, fuses and switches. 14.2 Wire gauges, colour 14.2.1 Inspection and (b) Auto Wiring system coding – reasons for identification of various their use. Wiring components. Simple system – earth and soldering and joining of insulated returns: ways of cables. joining cables- jointing, terminals, connectors and soldering. 14.3 Purpose, construction (c) Battery and testing of lead-acid 14.3.1 Examination and battery. Electrolyte testing of lead-acid composition. Battery battery. Preparation of care and maintenance. electrolyte.
14.4 Layout of the coil
ignition system. Function 14.4.1 Identification of main (d) Ignition System and operation of the main components; ignition components. timing, setting of Introduction to contact breaker points computerized ignition and spark plug gaps. system. 14.5 Layout and functions of the main components. Types of starter motor. 14.5.1 Inspection and (e) Starting System identification of main 14.6 Purpose and layout components. (dynamo and alternator). 14.6.1 identification of the (f) Charging System Main components and component parts. their operation. Comparison of d.c and a.c generators. 14.7 Layout of the system main components and their functions. Fuses 14.7.1 Identification of main (g) Lighting System and bulbs-types and components, ratings. inspection and replacement of bulbs 14.8 Layout and operations of and fuses. the auxiliary units. 14.7.2 Head lamp focusing. Instrument panel, horn, 14.8.1 Inspection and testing (h) Auxiliary Unit windscreen wiper. of main components. 14.9 Electrical faults. 14.9.1. Fault diagnosis. 15 ELECTRONICS 15.1 Explanation of the tem (a) Fundamentals of Auto Electronics. 15.1 Identification of Electronics. Identification of components. electronic components: diodes, transistors, resistors, capacitors, LED, transducers, coil and motors. Functions of components. Symbols in a circuit. (b) Electronic Ignition 15.2 Operation of transistorized ignition system. Types of transistorized and electronic ignition system: Inductive and hall effect. Merits and demerits. (c) Electronic Fuel 15.3 Purpose and type of 15.3.1 Identification of Injection systems (single-point components in systems and multi-point (single-point and multi- injections). point). 16 AUTO AIR- 16.1 Purpose, layout and 16.1.1 Inspection and CONDITIONIN identification of major identification of air- G components conditioning system (compressor, and the components. condenser, evaporator and dryer). Principles of operation. . 17 SAFE MOTORING 17.1 Main causes of 17.1.1 Identification of faults accident, essentials of and defective safe driving and components that could application of highway cause accidents. code and safety Identification and devices. interpretation of road signs. RECOMMENDED READING LIST 1. Technology for Motor Mechanics Volumes 1 – 4 by S. C. Mudd (Edward Arnold Publishers). 2. Vehicle and Engine Technology by Heinz Heister 3. Motor Vehicle Technology and Practical Work by J. A. Dolan 4. Fundamentals of Motor Vehicle Technology by Hillier and Pittuck (4th Edition) 5. Automobile Engine and Vehicle Technologyby Ian Chisholm 6. Motor Vehicle Technology (Books I and II) by R. W. Bent 7. Motor Vehicle Mechanic’s Textbook by E. K. Sulley (New Edition) 8. Highway Code
9. Motor Vehicle Technology for Mechanics by P. P. J Read and V. C. Reid.