AUTO AND DIESEL CRAFT-NEC

NEW SYLLABUS
APPLIED SCIENCE
The Applied Science module is designed to give the trainee the capacity to understand the
operation, structure and function of the motor vehicle and its component parts from a scientific
perspective. The trainee would therefore become a well-rounded, knowledgeable technician
within the field of Auto and Diesel Craft.

The main objective of this module is to provide the trainee with basic applicable knowledge of
the scientific principles underlying the mechanical, electrical and chemical operations in the
motor vehicle.

YEAR I TOPICS

MODULAR UNIT-1: INTRODUCTION TO APPLIED SCIENCE

This is a foundational module that introduces the trainee to basic concepts and definitions of
essential topics in Applied Science. The trainee will cover introductory topics such as Matter,
Mass, Weight, Density, Relative density, Force and Pressure.

1.1 MATTER AND ITS STRUCTURE

On completion of this unit, the trainee should be able to:

 Define an atom.
 Draw the structure of an atom.
 Identify sub-atomic structures.
 State the function of sub-atomic structures.
 Define matter.
 Identify the composition of matter.
 Define molecules.
 List the states of matter.
 Define elements, mixtures and compounds.
  Identify elements, mixtures and compounds in the motor vehicle application.
 Define mass.
 Define weight.
 Differentiate between mass and weight.
 Convert mass to weight and vice versa.

1.2 DENSITY AND RELATIVE DENSITY

On completion of this unit, the trainee should be able to:

 Define density.
 State the Scientific International (S.I.) unit for density.
 List the density of common substances applicable to motor vehicles.
 Perform calculations involving density, mass and volume of a substance.
 Explain relative density/specific gravity.
 Perform calculations involving density, relative density and density of water.
 Identify the hydrometer as an instrument used to measure the specific density of the
electrolyte in a battery.

1.3 Force and Pressure

On completion of this unit, the trainee should be able to:

 Define force.
 State the ‘unit’ of a force.
 Deduce that a force is the product of the mass of a body and its acceleration.
 Define the different types of forces: tensile, compressive, shear, torsional.
 Illustrate the application of the different types of forces in the motor vehicle.
 Define pressure.
 Explain the effects of pressure by making reference to appropriate examples.
 Perform calculations involving force, pressure and cross-sectional area of an object.
MODULAR UNIT 2: MOTION, MOMENT, ENERGY AND POWER
The trainee is introduced to the definitions and SI units of Length, Mass, Time, Velocity
[Linear and Angular], Acceleration, Braking efficiency, Force, Moments, Torque, Work,
Energy and Power. Techniques including, velocity time graphs and equations of motion, will
be used to solve problems involving distance, time, acceleration and velocity. This unit would
also cover energy as it relates to the motor vehicle. The first law of thermodynamics is
introduced and the trainee would become familiar with of energy conversions within the motor
vehicle. This unit is also intended to impart knowledge of torque and moments of a force.

2.1 SI Units and Measurements

On completion of this unit, the trainee should be able to:

 identify the SI units for length, mass, time, velocity, acceleration work, energy and
power.

 convert units to S.I. units: E.g. Grams to kilograms.

2.2 Motion

On completion of this unit, the trainee should be able to:

 define scalar quantity.

 list examples of scalar quantities.
 define vector quantity.
 list examples of vector quantities.
 define the following terms.
- Distance
- Displacement
- Speed
- Velocity
- Acceleration
- Deceleration/Retardation.
 determine the above listed quantities using basic formulae. E.g. Speed = Distance /
Time
 use equations of motion to solve problems of objects moving with uniform
acceleration.
  plot velocity-time graphs.
 determine the following from velocity time graphs:
- Distance travelled
- Acceleration
- Deceleration/retardation.
 determine braking efficiency.
 calculate angular velocity.
 demonstrate that linear velocity and angular velocity are related.

2.3 Work and Power

On completion of this unit, the trainee should be able to:

 define work.
 calculate work done by a force moving through a distance.
 define Power.
 perform calculations involving work, time and power.

2.4 Energy

On completion of this unit, the trainee should be able to:

 define energy.
 define the first law of thermodynamics.
 state the types of energy.
 define the types of energy.
 identify the types of energy and energy conversion within the engine of a motor
vehicle.
 define kinetic energy.
 calculate kinetic energy.
 define potential energy.
 calculate potential energy.
 2.5 Torque

On completion of this unit, the trainee should be able to:

 define torque.
 perform calculations involving force, radius and torque.

2.6 Moment of a Force

On completion of this unit, the trainee should be able to:

 define centre of gravity.

 define lever.
 state the parts of a lever.
 define moments of a force.
 state the principle of moments.
 perform calculations involving moments of a force about a point.

MODULAR UNIT 3: HEAT, TEMPERATURE AND FUELS

This unit would give the trainee an insight into the effects of heat with reference to motor
vehicular components. Trainees would also understand the characteristics of fuels and
importance of these specific characteristics in ensuring the safe and efficient operation of the
automobile.

3.1 Heat and Temperature

On completion of this unit, the trainee should be able to:

 define heat and temperature.

 differentiate between heat and temperature.
 state the units of measure of heat and temperature.
 convert between degree Celsius and Kelvin.
 describe the effects of heat on materials.
 identify instruments used to measure temperature.
 proficiently use instruments used to measure temperature.
  define specific heat capacity.
 calculate Quantity of heat using Mass, temperature change and specific heat
capacity.
 identify the various methods of heat transfer.
 define each method of heat transfer.
 define thermal conductivity.
 list the thermal conductivity of common metals.

3.2 Latent heat

On completion of this unit, the trainee should be able to:

 explain the change of state of a material caused by a change in heat. E.g. Solid to
liquid.
 define the following terms:
- Water vapour - Humidity
- Evaporation - Condensation
- Boiling - Melting
- Freezing
 define latent heat of fusion.
 define latent heat of vaporization.

3.4 Expansion and contraction of materials

On completion of this unit, the trainee should be able to:

 explain expansion and contraction of materials
 identify areas in the motor vehicle where expansion and contraction occurs.
 explain the operation of the bimetallic strip.
 list the various applications of the bimetallic strip in motor vehicles.
 define coefficient of expansion.
 state the types of coefficients of expansion: Linear, superficial and cubical.
  define each type of expansion coefficient.
 list the values of coefficient of linear expansion of materials commonly used in
motor vehicle engineering.
 solve problems related to coefficient of expansion.

3.5 Fuels

On completion of this unit, the trainee should be able to:

 define a fuel.
 give examples of fuels used in the motor vehicle.
 explain combustion
 define the following terms
- Flash point - Calorific value
- Fire point - Cetane rating
- Boiling point - Octane number
- Volatility - Anti-Detonators

MODULAR UNIT 4: ELECTRICITY AND ELECTRONICS FOR AUTOMOTIVE

This unit as provides an understanding of electricity and electronics as it relates to motor

vehicles. The trainee at the end of this unit should be able to understand basic electronics and
perform calculations involving electrical current, voltage and resistance. Types of batteries and
their charging and discharging mechanisms are also addressed within the unit. The trainee
would gain knowledge on but not limited to conductors, insulators, diodes, transistors
magnetism and sensors.

4.1 Atomic Structure

On completion of this unit, the trainee should be able to:

 define an atom.
 identify sub-atomic structures.
 state the charge carried on each sub-atomic structure.
 define electricity.
 identify the sub-atomic structure responsible for the flow of electricity.
4.2 Conductors, Insulators and Semi-conductors

On completion of this unit, the trainee should be able to:

 define a conductor.
 give examples of conductors used in the motor vehicle.
 define an insulator.
 give examples of insulators used in the motor vehicle.
 explain the flow of electrons within:
- conductors
- insulators
 define a semi-conductor.
 give examples of semi-conductors used in the motor vehicle.
 describe N-type and P-type devices.
 state examples of impurities added to semiconductors and their effect on the charge.

4.4 Circuits

On completion of this unit, the trainee should be able to:

 describe an electrical circuit.

 identify electrical circuits in the motor vehicle.
 describe:
- open circuits
- short circuits
- partial open circuits
- partial short circuits.
 sketch common electrical signs and symbols used in simple circuit diagrams.
 draw a simple circuit within the motor vehicle.
 draw simple circuits in series and parallel.
 calculate total resistance (RT) in series circuits.
 calculate total resistance (RT) in parallel circuits.

4.5 Ohm’s Law, Resistance, Current, Voltage.

On completion of this unit, the trainee should be able to:

 define the following terms and state the units used to measure each:
- electric current
- electrical resistance
- electrical potential difference (Voltage).
 state Ohm’s law.
 show the relationship between Current (I), Voltage (E) and Resistance(R).
 perform calculations relating to Ohm’s law.
 State three effects of an electric current giving examples: (Heating, chemical and
magnetic effect)

 state the effect of temperature on the resistance of a material.

MODULAR UNIT 5: PROPERTIES OF ENGINEERING MATERIALS

This unit provides the trainee with general knowledge of the types and properties of materials
used in the motor vehicle. The trainee would comprehend how the application of stress changes
the physical characteristics of materials. Processes by which the properties of the material can
be changed in other to limit the effects of stress on the material are covered. It also contains
the method of determining the safe working stress of a material.

5.1 Properties of Materials

On completion of this unit, the trainee should be able to:

 define the following terms:

- Elasticity - Strength
- Plasticity - Hardness
- Ductility - Toughness
- Malleability - Brittleness
 identify materials that possess the above characteristics.
 differentiate between ferrous and non-ferrous metals.
 explain the process of case hardening of auto components and tools.
 describe the normalizing process.
 describe the annealing process.
5.2 Stress and Strain

On completion of this unit, the trainee should be able to:

 define stress
 define the following:
- Tensile stress - Shear stress
- Compressive stress - Torsional stress
 identify areas in the motor vehicle where the above stresses occur.
 perform calculations involving stress, load and cross-sectional area.
 define strain.
 perform calculations involving strain, extension and original length.
 define Hooke’s law.
 explain Young’s Modulus of Elasticity.
 perform calculations involving Young’s modulus of elasticity, stress and strain.
 draw a stress-strain graph of mild steel.
 identify the following areas on stress-strain graph:
- Limit of proportionality - Ultimate Tensile Strength/ Maximum load
- Elastic limit - Point of fracture
- Yield point
 explain what is meant by “factor of safety”.
 perform calculations involving working stress, tensile strength (stress) and factor of
safety.
 YEAR II TOPICS

MODULAR UNIT: ELECTRICITY AND ELECTRONICS FOR AUTOMOTIVE

4.3 Diodes and Transistors

On completion of this unit, the trainee should be able to:

 define a diode.
 explain the operation of diodes.
 state the purpose of diodes.
 explain P-N junction.
 define Light emitting diodes (LED).
 state the use of (LEDs) in the motor vehicle.
 define transistors.
 state the purpose of transistors in the electrical system of a motor vehicle.

4.6 Capacitors, Resistors and Thermistors

On completion of this unit, the trainee should be able to:

 define a capacitor.
 list the types of capacitors.
 state the purpose of a capacitor in the electrical system of automobiles.
 describe the function of a capacitor in the electrical system of an automobile.
 define a resistor.
 list the types of resistors.
 state the purpose of a resistor in the electrical system of automobiles.
 describe the function of a resistor in the electrical system of an automobile.
 define thermistor.
 define PTC thermistors.
 define NTC thermistors.
 explain the function of a thermistor.
 state the purpose of thermistors in automotive electrical circuits.
4.7 Battery

On completion of this unit, the trainee should be able to:

 state what is a battery.

 describe the functioning of a battery.
 explain capacity of a battery.
 identify types of batteries used in the motor vehicle.
 state the purpose of a battery in the motor vehicle.
 describe the use of a hydrometer for testing the condition of a battery.

4.8 Magnetism

On completion of this unit, the trainee should be able to:

 define magnetism.
 differentiate between attraction and repulsion in magnets.
 explain the magnetic effect of an electrical system.
 describe the direction of magnetic field due to an electric current in a straight
conductor and a solenoid.
 outline the factors that affect the strength of a solenoid.
 state the purpose of a generator.
 describe the basic functioning of a generator.
 state the types of generators: d.c. and a.c.

4.9 Sensors

On completion of this unit, the trainee should be able to:

 define a sensor
 explain the functioning of a sensor.
 state the purpose of sensors in the motor vehicle.
 list and briefly describe the following and give examples of sensors belonging to each
category:
- Resistive sensors
- Voltage generating sensors
  state what is a switch sensor.
 identify the functions of a switch sensor.

MODULAR UNIT 6: PROPERTIES OF GASES

Within the cylinder of an engine the burnt fuel produces gases high in pressure and
temperature. This unit would give the trainee an understanding of gas pressure and how it can
be determined. They would also be shown the relationships between pressure, volume and
temperature of gases. In addition, the trainee would be able to determine the compression
ratio of gases.

6.1 Gas Pressure and Temperature

On completion of this unit, the trainee should be able to:

Define the following terms:
- atmospheric pressure
- gauge pressure
- absolute pressure
 show the relationship among the above terms.
 describe a simple method for determining atmospheric pressure.
 explain the concept of a perfect vacuum.
 convert temperature units from o C to K.

6.2 Compression Ratio

On completion of this unit, the trainee should be able to:

 state what is mean by the term compression ratio of an engine.

 explain compression ratio making reference to a piston and cylinder diagram.
 calculate the swept volume an engine cylinder.
 calculate the total capacity of an engine cylinder.
 perform calculations involving compression ratio, clearance volume and swept
volume.

6.3 Gas Laws

On completion of this unit, the trainee should be able to:

  describe changes in the volume of a gas that occurs when:
- the pressure of the gas is changed
- the temperature of the gas is changed
- both pressure and temperature of the gas are changed.
 define:
- Boyle’s law
- Charles’ law
- Pressure Law
- the general gas equation.
 perform calculations involving the formulae of the above.

6.4 Expansion and Contraction of Gases.

 define isothermal processes.

 define adiabatic processes.

MODULAR UNIT 7: FRICTION AND LUBRICATION

Within the motor vehicle there are numerous parts that are in contact with and move over each
other. This unit would create an understanding of friction and its effects. The trainee would be
able to identify components within the motor vehicle where friction occurs and how to
determine the value of the frictional force. Trainees would be exposed to the method of
determining frictional torque in the journal bearing. Calculations involving torque and power
transmitted by a clutch and clutch plate pressure are addressed. The use of lubricants as a mean
of reducing friction and some of its properties are also explored.
7.1 Friction

On completion of this unit, the trainee should be able to:

 define friction.
 state the different types of friction.
 identify where each type of friction occurs in the motor vehicle.
 state the laws governing friction between dry surfaces.
 differentiate between static and sliding friction.
 state the advantages and disadvantages of friction.
 define the term coefficient of friction.
  perform calculations involving coefficient of friction, horizontal force and downward
Force.

7.2 Friction in bearing

On completion of this unit, the trainee should be able to:

 calculate frictional torque in the shaft.

 calculate the power absorbed by friction.
 calculate heat generated due to friction.

7.3 Clutch

On completion of this unit, the trainee should be able to:

 determine frictional torque transmitted by a clutch.

 determine power transmitted by a clutch.
 perform calculations involving clutch plate pressure.

7.4 Lubrication

On completion of this unit, the trainee should be able to:

 define a lubricant.
 state the purpose of a lubricant.
 state the forms of lubrication.
 identify where in the motor vehicle each form of lubrication is needed.
 describe the two main properties of lubricating oils:
- oiliness
- viscosity
 explain viscosity index.
 define multi-grade oils.
 define the following types of lubricating oil additives:
- viscosity index improvers
- anti-oxidants
 - corrosion and rust inhibitors
- detergents
- dispersants
- anti-foam preventers
- anti-wear additives
- extreme pressure additives

MODULAR UNIT 8: BEARINGS AND BEARING PRESSURE

This unit enables the trainee to identify the three main parts of bearing assemblies and the
different types of fits. The trainee would also be able to Calculate bearing pressure.

8.1 Bearing Characteristics

On completion of this unit, the trainee should be able to:

 state what is a ‘bearing’.

 state the main purpose of bearings in the motor vehicle.
 identify the three main parts associated with bearing assemblies.
 state the desired properties of bearing materials. E.g. resistance to wear.
 state the types of bearing fits
- free fit - tolerance
- shrink fit - clearance
- allowance - nominal dimension
- interference

8.2 Bearing Pressure

On completion of this unit, the trainee should be able to:

 perform calculations involving bearing pressure, gas pressure, bore area and projected
area.
MODULAR UNIT 9: MACHINES AND TRANSMISSION OF MOTION AND
POWER

This unit enables the trainee to state the purpose of a machine and define terms used in
simple machine theory. The trainee would also be able to identify simple machines applicable
to the motor vehicle. Calculations with respect to different machines are also covered.

9.1 Simple Machine Calculations

On completion of this unit, the trainee should be able to:

 define ‘machine’.
 state the purpose of a machine.
 distinguish between load and effort.
 define the following terms used in simple machine theory:
- mechanical advantage (Force ratio)
- velocity ratio (Movement ratio)
- efficiency
 calculate the velocity ratio, mechanical advantage and efficiency in the following
simple machines:
- screw jack
- wheel and axle
- pulley and chain blocks
 explain hydraulic systems.
 give examples of hydraulic systems.
 calculate fluid pressure in hydraulic systems.
 calculate the following values in hydraulic jack and press systems:
- mechanical advantage
- velocity ratio
- hydraulic pressure
 calculate the number of pumping strokes required to move the ram a specified
distance.

9.2 Transmission of Motion and Power

On completion of this unit, the trainee should be able to:

  describe the different types of drives between engine crankshaft and camshaft.
 define velocity ratio in relation to shafts connected by belts, chains or gears.
 perform calculations involving velocity ratio of shafts connected by belts, chains
and gears.
 describe gear systems.
 differentiate between simple and compound gear trains.
 calculate gear ratio in a motor vehicle gearbox.
 calculate rear axle ratio.
 calculate overall gear ratio.
 calculate torque and speed in final drives.
 calculate linear speeds in:
- pulleys
- axles
- road wheels
 calculate torque in engines.
 calculate power in engines

MODULAR UNIT 10: ENGINE TESTING

In this unit the trainee would be shown how to determine the general performance
characteristics of an engine including brake power, indicated power, indicated mean effective
power, and brake mean effective power.

10.1 Brake Power and Engine Torque

On completion of this unit, the trainee should be able to

 show the relationship between engine power and engine torque.

 determine torque and brake power by means of calculations.
10.2 Indicated Power, Brake Power, i.m.e.p., b.m.e.p. and Mechanical
Efficiency.

On completion of this unit, the trainee should be able to:

 define mean effective pressure.

 define indicated power.
 show the relationship between indicated power(i.p.), brake power (b.p.) and
frictional power (f.p.)
 calculate indicated power using information on indicated mean effective pressure
(i.m.e.p.), cross-sectional area of piston, length of stroke and number of working
strokes per minute.
 define mechanical efficiency in relation to brake power and indicated power.
 explain ‘brake mean effective pressure’ and show how it differs from ‘indicated
mean effective pressure’.

 determine ‘brake mean effective pressure’ by means of calculations.

10.3 Morse Test

On completion of this unit, the trainee should be able to:

 explain the Morse Test

 calculate indicated power and mechanical efficiency by using the Morse test.

10.4 Engine Characteristics

On completion of this unit, the trainee should be able to:

 define and determine by means of calculations

- fuel Consumption
- thermal efficiency
- volumetric efficiency
- air-fuel ratio
- exhaust gas analysis
MODULAR UNIT 11: FORCES ON A VEHICLE

This unit gives the trainee an understanding of how different forces acting on a motor vehicle
affects its performance in terms of its motion.

11.1 Newton’s laws of motion

On completion of this unit, the trainee should be able to:

 state Newton’s three laws of motion.

 explain momentum.
 state the law of conservation of momentum.
 perform calculations involving momentum, mass and velocity of a vehicle.

11.2 Forces opposing motion

On completion of this unit, the trainee should be able to:

 list and describe the three main forces opposing the motion of a motor vehicle
travelling in a straight line:
- rolling resistance
- gradient resistance
- air resistance.

11.3 Tractive Effort and Tractive Resistance

On completion of this unit, the trainee should be able to:

 define tractive effort and tractive resistance.

 perform calculations to determine tractive effort and tractive resistance.