1.

Engine Maintenance and Diagnosis Tune-up

1.1 Objective of the training:
The main objective is to address quality training mainly on SI and CI engine maintenance
and diagnosis tune-up which full fill skill gap of our trainees and to improve their
performance on maintain of engine to be competent enough in fundamental knowledge
and technical skill.
1.2 Description of the training:
Diagnosis tune-up (test required evaluating engine performance: compression test,
vacuum test, leakage test, power balance test) and maintenance of major engine
components (removing engine from vehicle, disassembly, inspection, measuring,
repaired/rebuilding, assembly of engine components and endurance engine testing) of SI
and CI engines.
Table 1.0 List of training topics
S.N List of training topics Duration (Hrs.)
1.3 Demonstrations and safety: display all about 4
 Automotive shop safety rules
 Personal safety
 Working area safety
 Auto shop hand tools and precision measuring tools
 Introduction to engines
 Engine construction
 Engine classification
1.4 Diagnosis tune-up for CI and SI Engine: 16
 Compression Test
 Cylinder Leakage Test
 Cylinder Power Balance test
 Testing Engine oil pressure
 Engine Vacuum Test
 Engine Noise Diagnosis
1.5 Disassemble and Cleaning of Engine components 12

1.6 Inspection and Measurement: 24

 Inspection
 For flatness
 Crack
 Measuring
 Bore diameter
 Free length of valve spring
 Straightening,
 Taperness and out of roundness

1.7 Repairing/Reconditioning of engine components 8

1.8 Assembling: 8

1.9 Endurance and bench test: 8

 Engine's fuel consumption
 Engine's noise and air pollutant emissions
 Characteristics of IC Engines
 Volumetric Efficiency
 Air Fuel Ratio
 Torque and Power under variable speed

2.0 Laboratory Information

Table 2.0 Laboratory Information

Name of Laboratory Automotive Engineering work shop

Location Block No Room No Room No Phone extension
AWS Ground floor Ground floor 228
Capacity 10 trainees at a 10 trainees at
20 trainees time a time
  vehicles prepared for training
 full set hand tools
 Valve reface grinding machine
 Connecting road alignment
 Valve spring free length measuring machine
 Surface plate
 Testers (Compression, Cylinder Leakage, Oil Pressure,
Listof lab equipment
Engine Vacuum, Cylinder Power Balance)
 Stethoscope
 Tachometer digital engine analyzer
 Air Compressor
 Emission analyzer

Reference materials
1. Engine diagnosis and tue-up hand out
2. Toyota manual
2.1 list of photo labs

Fig.Valve refacing grinding machine Fig. Connecting road alignment

Fig. Valve spring free length measuring Fig. Surface plate

 Fig. Compression Testers

Fig. Cylinder Leakage Tester

Fig. Oil Pressure tester Gauge Fig. Stethoscope

Fig.Engine Vacuum Test Fig. Tacho meter digital engine analyzer

Fig. Air Compressor Fig. Emission analyzer