Comprehensive Automotive Electrical, Electronic and Mechanical Diagnostic, Maintenance and Repair - Intensive Full-time (Durban)

Modules Title:

Module 1: Automotive Industry: Technical and Contextual Explorations Part 1
Module 2: Automotive Industry: Technical and Contextual Explorations Part 2
Module 3: Advanced Mechanical Engineering: Automotive Fault Diagnosis and Repair
Module 4: Automotive Electrical Wiring
Module 5: Automotive Repair and Maintenance

Module Contents, Concepts and Issues

Module 1: Automotive Industry: Technical and Conceptual Explorations Part 1

Engine Building

• Concept of Engine
• Four-Stroke Cycle
• Opening and Closing Valves
• The Flywheel
• Basic Engine Completed

Design, Construction, Application of Engine Components

• The Engine Block
• Cylinders
• Pistons
• Connecting Rods
• Crankshaft
• Vibration Damper
• Timing Gears
• Sprocket
• Flywheel
• Camshaft
• Valves
• Mechanical Valve Litters
• Hydraulic Valve Litters
• Cylinder Head
• Oil Pan
• Timing Gear Cover
• Gaskets
• Sealants
• Seals
• Other Parts

Classifying Engine and Identifying the Parts

• Cycle Classification
• Valve Location Classifications
• Combustion Chamber Design
• Cylinder Classification
• Firing Order
• Cooling Classification
• Fuel Classification
• Experimental Engines
• Engine Mounting
• Identification and Classification

Safety Lab Procedures: Avoiding Accidents

• Kinds of Accidents
• How Accidents Happen
• Effects of Accidents
• Reducing the Possibility of Accidents
• Dressing Safely for Work
• Keeping a Neat Shop
• Identifying Unsafe Conditions
• Waste Chemical Disposal
• Proper Work Procedure
• Doing the Job Right

Automotive Tools

• Tool Material
• Tool Construction
• Tool Handling and Storage
• Types of Tools
• Measuring Tools

Engine Tests and Measurements

• Horsepower
• Volumetric Efficiency
• Engine Size, Displacement
• Compression Ratio

Electrical System Fundamentals

• Basic Electricity
• Basic Automotive Electronics

Ignition System

• Necessity of High Voltage
• Primary Circuit
• Secondary Circuit
• Ignition Timing and Advance

Fuel Injection Systems

• Providing the Correct Air-Fuel Mixture
• Fuel Injection
• Pulse Fuel Injection
• Types of Pulse Fuel Injection Systems
• Pulse Fuel Injection System Components
• Continuous Pulse Fuel Injection Systems
• Diesel Fuel Injection
• Superchargers and Turbochargers

Fuel Supply System

• Carburetors
• Air Cleaners
• Carburetor Classification

Cooling System

• The Need for a Cooling System
• Methods of Cooling

Lubrication Systems

• The Need for Lubrication Systems
• Engine Oil
• Engine Lubrication Systems
• Oil Filtration
• Crankcase Ventilation
• Oil Seals
• Oil Pressure Indicators
• Dipstick
• Cooling the Oil

Exhaust Systems

• Purpose of the Exhaust System
• Exhaust System Design
• Exhaust System Components
• Exhaust System Materials
• Sealing the Exhaust System

Emissions Systems

• The Need for Emission Control
• Emission Control Systems
• Engine Modifications and Controls
• External Cleaning Systems
• Fuel Vapor Controls
• Computer Control Emission Systems
• Emission Systems Caution

Module 2: Automotive Industry: Technical and Contextual Explorations Part 2

Computer Systems

• Computers on Modern Vehicles
• Static Electricity

Charging and Starting Systems

• Battery
• Charging System
• Starter System

Chassis Electrical

• Chassis Wiring
• Circuit Protection Devices
• Vehicle Lights and Light Switches
• Chassis Mounted Solenoids and Relays
• Horns and Horn Relays
• Rear Window and Mirror Defroster
• Electric Gauges
• Cruise Control
• Air Bag Systems
• Holding Members
• Hydraulic Control System
• Transmission Lubrication
• Fluid Cooling

Axles and Drives

• Rear Wheel Drive Shafts
• Constant Velocity (CV) Axles
• Rear-Wheel Drive Axle Assemblies
• Rear-Wheel Drive Axle Components
• Four-Wheel Drive Front Drive Axles

Brakes

• Hydraulic Basics
• Master Cylinder
• Brake System Hydraulic Control Valves
• Disc Brake Calipers
• Wheel Cylinders
• Brake Friction Members
• Disc Brake Assembly
• Drum Brake Assembly
• Power Brake Systems
• Vacuum-Assisted Power Booster
• Hydraulic Pressure-Operated Power Booster
• Anti-Lock Brake Systems (ABS)
• Traction Control Systems
• Brake Lights

Suspension Systems

• The Need for A Suspension System
• Suspension System Components
• Springs
• Shock Absorbers
• Air Shock Absorbers
• Front Suspension Systems
• Conventional Independent Front Suspension
• Rear Suspension Systems
• Suspension Lubrication
• Automatic Level Control
• Computerized Ride Control Systems

Steering Systems

• Steering Systems
• Steering Linkage
• Steering Wheel, Steering Shaft and Steering Gear
• Power Steering

Wheels and Tires

• Wheels
• Wheel Hubs and Bearings
• Tires

Wheel Alignment

• Purpose of Wheel Alignment
• Wheel Alignment Angles
• Steering Geometry
• Tire Wear Patterns and Alignment
• Alignment Equipment
• Other Factors That Can Affect Alignment

Air Conditioning and Heating

• Purposes of Automotive Air Conditioning
• Principles of Refrigeration
• How the Refrigeration System Works
• Major Components of the Air Conditioning System
• Service Valves
• Refrigerant Oil
• Refrigerant Handling Precautions
• Retrofitting
• Heater Systems
• Air Distribution and Control
• Heater-Air Conditioning Control Systems

Module 3: Advanced Mechanical Engineering: Automotive Fault Diagnosis and Repair

Overview

• Understanding Diagnosis
• Work Safety Practices
• Diagnostic Terminology
• Report Writing

Techniques in Diagnosing

• Overview
• Diagnostic Process
• Making Diagnosis on Paper
• Mechanical Diagnostic Techniques
• Electrical Diagnostic Techniques
• Fault Codes
• Systems
• Sources of Data

Automotive Tools and Equipment

• Basic Equipment
• Oscilloscopes
• Scanners
• Emission Testing
• Pressure Testing

Using Diagnosing Sensors, Actuators and Oscilloscope

• Sensors
• Actuators
• Engine Waveforms
• Communication Networks

Managing On-board Diagnostics (OBD)

• Evolution
• Understanding On-board Diagnostics
• Gasoline On-Board Diagnostic Monitors
• Mist Redetection
• OBD Summary
• Driving Cycles
• Future Developments in Diagnostic Systems

Engine System

• Overview
• Engine Operation
• Diagnosing Engine
• Fuel System
• Diagnosing Fuel System
• Engine Management
• Ignition
• Diagnosing Ignition System
• Emissions
• Diagnosing Emission
• Fuel Injection
• Diagnosing Fuel Injection Systems
• Diesel Injection
• Diagnosing Diesel Injection Systems
• Engine Management
• Diagnosing Combined Ignition and Fuel Systems
• Engine Management and Fault Finding Information
• Air Supply and Exhaust Systems
• Diagnosing Exhaust and Air Supply
• Cooling
• Diagnosing Cooling
• Lubrication
• Diagnosing Lubrication
• Batteries
• Diagnosing Batteries
• Starting
• Starting Diagnostics
• Charging
• Charging Diagnostics

Automotive Chassis Systems

• Brakes
• Diagnosing Brakes Problems
• Antilock Brakes
• Diagnosing Antilock Brakes Problems
• Traction Control
• Traction control
• Steering and Tyres
• Steering and Tyres Diagnostics
• Suspension
• Diagnosing Suspension
• Active Suspension
• Active Suspension Diagnostic

Working with Electrical Systems

• Electronic Components and Circuits
• Multiplexing
• Multiflexing Diagnostics
• Lightning
• Lighting Diagnostics
• Auxiliaries
• Diagnosing Auxiliary
• Diagnosing ICE, Security and Communication
• Body Electrical Systems
• Diagnosing Body Electrical
• Instrumentation
• Instruments Diagnostics
• Heating, Ventilation and Air Conditioning (HVAC)
• Diagnosing HVAC
• Cruise Control
• Diagnosing Cruise Control
• Airbags and Belt Tensioners
• Diagnosing Airbags and Belt Tensioners

Automatic and Manual Gear Transmission Systems

• Manual Transmission
• Diagnosing Manual Transmission
• Automatic Transmission
• Automatic Transmission Diagnostic

Module 4: Automotive Electrical Wiring

Automotive Electrical Principles and Circuits

• Electrical Principles
• High Current or Low Voltage
• Ohm’s Law
• The Power of Formula
• Combinations
• Kirchhoff’s Law
• Forming and Tracing a Circuit
• Wire Resistance Chart
• Installing an Electric Fuel Pump
• On-Board Computer Risks
• Battery Disconnecting

Tools for Automotive Wiring

• Essential Tools for Auto Electrical Wiring
• Using Test Lights
• Using Analogue Multi-Meters
• Using Digital Multi-Meters
• Functions Multi-Meter

Essentials of Automotive Wiring

• Essential Connections
• Crimp-Style Connections
• Using Crimping Tools
• Soldering Iron and Guns
• Insulating Connections
• Temporary Mechanical Connectors
• Distribution-Type Connectors
• Connectors and Plugs
• Basics for AWG Wire 8 and Larger
• Ignition Switches, Wiring Harness and Controllers
• Ignition Switch
• Wiring Harness
• Essentials of Controllers

Power Accessories and the Charging System

• Electronic Door Lock Circuits
• Electronic Window Circuits
• The Charging System

Equipment Wiring and Component Upgrade

• Observing Safety
• Metal Barrier
• Tachometer Installation
• The Charging System
• Work Protection

Troubleshooting

• Flowcharts
• Typical Problems
• Circuit Inoperable
• Blown Circuits
• Blown Fuses
• Working to Burned Up Wiring
• Detecting Faulty Battery: Battery Testing Methods
• Checking Intermittent Circuit Operation

Installation and Interface

• Power Door Lock and Power Window Circuit Interfacing
• Factory Wiring Diagrams
• Power Sunroof and Convertible Top Circuit Interfacing
• Upgrading Headlights to Higher Power Units
• Auxiliary Battery
• Accessory Fuse Panel

Developing Wiring Harness

• Essentials of Harness
• Building a Harness from the Start
• Harness Construction Project

Module 5: Automotive Repair and Maintenance

Motor Vehicles and Their Function

• Motor Vehicle and Its General Operation
• The Internal Combustion Engine
• General Vehicle Electronics
• Vehicular Electrical Circuits

Tyre Management and Wheel Balancing

• Tyre Examination
• Determining Legal Tread Limit
• Wheel Inspection
• Tyre and Wheel Maintenance
• Removing the Tyre-Wheel Assembly
• Wheel Balancing
• Replacing the Tyre-Wheel Assembly

Equipment in Lifting Vehicle

• Using Trolley Jack
• Using Hydraulic Lifts
• Understanding the Two-Post Lift
• Regulating the Four-Post Lift

Servicing a Vehicle

• Importance of Regular Servicing
• Servicing Checklist
• 10,000 Miles Servicing
• 30,000 Miles Servicing
• 50,000 Miles Servicing
• Free Window Servicing
• Preparing For a Minor Service
• Carrying Out a Minor Service
• Pre-Acceptance Inspection
• The Pre-Delivery Inspection

Batteries and Alternators

• Tracing Electrical Circuits
• Testing Alternators
• Matching Battery Type with Alternator Output
• Battery Polarity
• The Differing Batteries
• Battery Efficiency Testing
• Battery Chargers

Lubrication Service

• Importance of Lubricating
• Oil Properties
• Servicing the Engine Oil and Filter
• Checking the Manual Transmission Oil
• Servicing the Automatic Transmission Oil and Filter
• Checking the Differential Oil on a Rear Axle Assembly
• Checking Brake Fluid
• Checking Engine Coolant
• Checking Steering Fluids
• Greasing
• Inspecting For Leaks
• Disposal of Used Lubricants

Vehicular Lightning System

• The Headlights
• Park Lights
• Hazard Warning Lights
• Traffic Indicator System
• Headlight Adjustment System
• Bulb Replacement
• Rear and Front Fog Lamps
• Dashboard Lights
• Interior Lights
• Daylight Running Lights
• Interior Pilot Lights
• Statutory Vehicular Lighting Regulation

Dismantle Vehicle Components

• Safety and Good Housekeeping
• Planning and Preparing
• Service Procedure

Removing and Fitting Mechanical and Electrical Components

• Electric Circuit Parts
• Replacing the Solenoid on a Starter Motor
• Removing and Replacing an Alternator
• Removing and Replacing the Radiator
• Removing and Fitting:
• Fitting Door Speakers
• Fitting an Interior Fan