Tamil Nadu HSE First Year Basic Automobile Engineering study plan

State five safety rules each for hand-tool use, jacking and lifting, fuel handling, and battery charging, and identify the personal protective equipment needed for each.

Select and describe the correct use of at least 15 workshop tools (ring and open-end spanner, socket set, torque wrench, screwdriver, plier, hammer, chisel, file, hacksaw, puller, feeler gauge, micrometer, vernier caliper, jack, axle stand) and match each to the fastener or job it serves.

Draw the layout of a front-engine rear-wheel-drive chassis from memory, labelling engine, clutch, gearbox, propeller shaft, universal joints, differential, rear axle, suspension, steering and brakes, within 10 minutes.

Compare front-engine rear-wheel drive, front-engine front-wheel drive and rear-engine layouts on traction under load, passenger space, driveline part count and handling, and state one vehicle class where each is used.

List the main components of the chassis and state the function of the frame, suspension and steering in carrying and controlling the vehicle.

Explain the four-stroke cycle for both spark-ignition and compression-ignition engines stroke by stroke, stating piston direction, valve position, and what happens to pressure and temperature at each stroke, without referring to notes.

Sketch and label the cylinder block, cylinder head, piston, piston rings, gudgeon pin, connecting rod, crankshaft, camshaft, flywheel, valves and combustion chamber, and state one function of each part.

Calculate swept volume, clearance volume, compression ratio and total engine capacity for four-cylinder examples given bore and stroke, and complete eight numerical problems showing formula, substitution and unit at every step.

Describe valve timing and port timing with a simple valve-timing diagram, and state the valve overlap period and its effect on breathing.

State the firing orders 1-3-4-2 and 1-2-4-3 for four-cylinder engines and explain why firing order affects crankshaft balance and vibration.

Trace the fuel path from tank to cylinder for a carburetted petrol engine and for a diesel engine, naming every component (tank, filter, fuel pump, carburettor or injection pump and injector, air cleaner, manifold) and its function.

Explain carburetion using the venturi and pressure-difference principle, and describe the purpose of the idle circuit, main metering circuit, accelerator pump and choke.

Distinguish petrol and diesel on calorific value, volatility, octane number versus cetane number, and auto-ignition temperature, and state why each fuel suits its engine.

Explain the three stages of combustion in a spark-ignition engine (ignition lag, flame propagation, afterburning), describe normal combustion against detonation, and list four causes of detonation with three remedies.

State the air-fuel ratio required at idling, cruising, acceleration and full load, and describe four common carburettor faults with the symptom each produces.

Explain why a clutch is needed, describe the construction and operation of a single-plate dry friction clutch with a sketch, and list four clutch faults with their symptoms.

Explain why a gearbox is required and why engine torque must be multiplied, and describe sliding-mesh and constant-mesh synchromesh gearboxes with a labelled sketch of each.

Explain the propeller shaft, universal joint and slip joint, stating why each is necessary in a rear-wheel-drive vehicle.

Explain the differential: why it is needed, how the crown wheel and sun and planet gears allow different wheel speeds in a turn, and what the final drive does.

Compute the overall gear ratio and vehicle speed from engine speed, tyre circumference and gear ratios in three worked problems.

Explain why an engine must be cooled, compare air cooling and water cooling on four points, and describe the components and coolant flow path of a forced-circulation system including radiator, water pump, thermostat, fan and hoses.

State the functions of a lubricant, explain viscosity and viscosity index and how SAE grades are read, and describe splash, pressure-feed and dry-sump lubrication with a sketch.

Diagnose overheating, oil dilution and low oil pressure by stating likely cause and remedy for each.

Define camber, caster, king-pin inclination and toe-in, and state the effect of each on tyre wear and steering effort when it is set incorrectly.

Compare leaf spring, coil spring, torsion bar and independent suspension, and state the function of the shock absorber and the steering gearbox.

Explain the construction and working of a lead-acid battery, describe the chemical reactions during charging and discharging, and define ampere-hour capacity, cold cranking amps and specific gravity.

Describe the charging system (alternator and regulator) and the starting system (starter motor, solenoid and drive engagement) component by component, stating the job of each part.

Trace the lighting and ignition circuits and state the role of fuses, relays and the earth return path.

Describe the layout and operation of drum and disc brakes, the hydraulic system from master cylinder through wheel cylinder to brake fluid, and the procedure and purpose of bleeding.

Explain spongy pedal, pulling to one side and brake fade by stating cause and remedy for each, and state the purpose of the parking brake.

Read and record measurements with a vernier caliper, micrometer, feeler gauge and dial gauge, stating the least count and correct unit for each instrument.

Describe the daily, weekly and 5,000 km preventive maintenance checks and state what each check protects against.

Re-solve ten mixed numericals on compression ratio, engine capacity, valve timing, gear ratio and vehicle speed without using notes.

Diagnose eight given symptom statements spanning engine, fuel, cooling and transmission systems and name the most likely fault for each.

List the steps of a routine engine tune-up including tappet adjustment, spark plug gap setting and ignition timing check.

Complete two full-length timed mock papers of 90 minutes covering all ten domains and mark each to a corrected score.

Reproduce from memory the ten highest-yield diagrams: chassis layout, engine parts, four-stroke cycle, carburettor, cooling circuit, clutch, gearbox, differential, steering geometry and brake layout.

Rewrite in your own words the correct reasoning for every question missed in weeks 1 to 7 and group the mistakes by domain.

Revisit the two heaviest domains, engine construction and fuel supply, and answer five long-form questions on them under exam timing.