INTRODUCTION TO VECHILE MAINTENANCE LAB

CYLINDER RE-BORING

The cylinder wall wear occurs due to piston and ring movement, the high temperature and
pressure of combustion, and the washing action of fuel entering the cylinder. At the beginning of
power stroke when pressure is the greatest, the compression rings are forced with the greatest
pressure against the cylinder wall. Also at the same time, the temperature is also greatest due to
the oil film is least effective in protecting the cylinder wall. Thus it is clear that most wear will
take at the top of cylinder. As the piston moves down on the power stroke, the combustion
pressure decreases so that less wear takes place. The cylinder thus wears irregularly. The cylinder
also tends to wear somewhat oval-shaped due to the side thrust of the pistons as it moves down
in the cylinder on the power stroke. Honing thee cylinder usually requires removal of less
material than boring. If wear is not too great, only honing can be done. If the wear is too great,
the cylinder must be bored first and then honed. The size to which the cylinder must be re-bored
is determined by the amount of material that needs to be removed from the walls. The bore must
have to be finished to the proper size to take the correct oversize piston.

VALVE

Valve is a device to close and open a passage. In motor vehicle engine, two valves are used for
each cylinder- an inlet (or intake) valve and an exhaust valve. Fuel is admitted to the cylinder by
the inlet valve, and the burned gases escape by the exhaust valve. When closed, the valve must
seal the combustion space tightly. The valves are usually made up of austenitic stainless steel,
which is corrosion and heat resistant material. Exhaust valve is usually made of chrome steel,
which is an alloy of silicon and chromium with unusual resistance to heat. Inlet valve being
subjected to less heat is usually made of nickel chromium alloy steel.

The valves used in modern passenger car engines are termed as poppet or mushroom valves. The
head of the valve has an accurately ground face with enough margin left to avoid a thin edge.
The angular face is ground on the valve head to make and angle of 45 or 30 to match the angle
of valve seat in the cylinder head. Spring retainer lock grooves are provided at the end of the
valve stem.

VALVE MECHANISM

Cams mounted on a camshaft operate the valves; the camshaft gets motion from crankshaft. As
the camshaft turns, the cam operates the valve, according to the location of the valves the valve
mechanisms are of two types.

1. Valve mechanism for operating the valve in engine block.

2. Valve mechanism for operating the valve in engine head.

FUEL INJECTION SYSTEM

To run an engine the fuel from the tank must reach by some means to the engine cylinder. In
diesel engine, the fuel is injected into the engine cylinder by an injector. The fuel burns in the
cylinder and during the exhaust stroke, the burned gases leave the cylinder passing through the
exhaust pipe and silencer.

FUNCTIONS AND QUALITY OF FUEL INJECTION PUMP

It should pump the metered quantity of fuel.

It should pump equal quantity of fuel to all cylinders.
It should commence supplying the metered quantity of fuel at same degrees before TDC,
to all cylinders.
It should build up enough pressure so that diesel when injected is in the form of atomized
spray.
The injection of diesel should be such that combustion process is kept under control.
The beginning and end of injection should be sharp.
Provision should be there to change injection timing to suit load and speed condition.
The complete system to be light in weight so that dead weight of vehicle is reduced.
It should have a long life.
It should be easy to repair.
It should have provision to vary the fuel quantity to suit speed and load conditions.

INJECTOR

While studying the working of compression ignition engine, it was that the injector has spray
diesel oil in a fine atomized form just before the piston reaches TDC in compression stroke. The
main functions of injector are as follows.

FUNCTION OF INJECTOR

It should inject the fuel in fine atomized form.

The atomized fuel should mix up with hot air to form a homogenous mixture for proper
combustion.
Fuel commencement and cut off of fuel should be repaid.
It should not dribble.
WORKING OF INJECTOR

When the diesel oil reaches with pressure from the injection pump in the pressure chamber of
nozzle, it acts on its seat and lifts the needle of its seat against the pressure of spring. When the
needle is lifted off its seat, the fuel gets sprayed through the nozzle hole in atomized form. As
soon as the pressure of fuel oil reduces, the spring pushes back the needle valve on its seat thus
closing the passage of diesel to the nozzle body holes.

WHEEL ALLIGNMENT

The wheel alignment refers to the positioning of the front wheels and steering mechanism that
gives the vehicle directional stability promotes case of steering and reduces tire wear to a
minimum. A vehicle is said to have directional stability or control if it can run straight down a
road, enter and leave a turn easily and resist road shock. The front wheel alignment depends
upon the following terms camber, caster, king pin inclination, toe-in and toe-out on turns. The
front wheel geometry or steering geometry refers to the angular relationship between the front
wheels, the front wheel attaching parts and the car frame all the above terms are included in the
front wheel geometry.
 1. STUDY OF TOOLS & EQUIPMENTS

AIM

To study the list of tools and equipments.

EQUIPMENT REQUIRED

The only really essential fixture in any workshop is a suitable bench and although an old table
(or) box sometime serves well enough, it is always better to have a purpose made workbench.
The bench must be strong and rigid.

The next essential is a good mechanic vice 4 Inch jaws. The vice should be mounted close to one
of the bench top. The accommodation for tool is important and much damage then can result
from keeping them into the box, with trays and compartment (or) in cupboards fitted with
suitable racks, shelves and hooks.

TOOLS

The tools listed below on the basis of a good mechanics kit which may repair any given job.

SPANNERS

Various types are available and in each case it is essential to select spanners to suit the threads in
use. The professional mechanics first choice is usually a ring spanner.

WRENCHES

A 14Stillson wrench and a pair of 9footprint grip are useful heavier tools for mechanic.

HAMMER

A ball-peen hammer of about 1lb weight is essential, and a heavier size also desirable. A hide or
plastic faced hammer is most useful for soft metals knocking out dent and freeing a tyre from
rim.

FILES

Many types of files are made with different types of teeth. To start with one should have a 10flat
file, a smaller size 2nd cut file, 8flat smooth file.

PLIERS

Several types are available but for best application, use 8side cut or combination pliers and a
smaller pair of long-nosed pliers those with insulated handles being handy for electrical work.

DRILL
Drilling equipment is among the basic tools for a mechanic and it is wise to obtain best quality
one can afford.

BENCH GRINDER

A hand operated emery wheel, bench mounted, with metal cutting tools sharp, whereas wood
cutting tools are sharpened on an oilstone.

GARAGE SERVICING EQUIPMENTS

Auto service unit.

Car washing machine.
Hydraulic lift.
Greasing equipment.
Lubricating equipment.
Tyre inflator.
Air compressor.
Hydraulic platform.
Spray painting machine.
Cranel.
Lifting jack.
Ramp.
Chain pulley block.

RECONDITIONING MACHINE TOOLS

Crankshaft Grinder
Brake Drum lathe
Cylinder boring machine.
Cylinder boring bar.
Connecting rod boring machine.
Nozzle grinding lapping machine.
Valve refacing machine
Centre less grinder.
Spark plug testing machine.
Connecting rod aligner
Chassis Alignment Equipment
Wheel balancing machine.
Battery charger.
Wheel geometry aligner.
Disc brake lathe.

ULTRAMODERN MACHINE
 Car disc brake lathe.
Ultrasonic cleaning and degreasing machine.
Ultrasonic plastic welding machine.
Ultrasonic and degreasing machine.
Ultrasonic metal inserting machine.
Ultrasonic spot welder.

TESTING EQUIPMENTS

Remote controlled brake, suspension, side-slip and weight testing.

Diesel fed pump testing machine.
Engine analyzer.
Spring testing machine.

MEASURING INSTRUMENTS AND GAUGES

Vernier caliper.
Micrometer.
Dial bore gauge.
Vernier height gauge.
Vernier depth gauge.
Feeler and wire gauge.

REPAIRIND ACCESSORIES AND EQUIPMENTS

Engine repairing stand.

Multi jet part cleaner.
Mechanical press.
Hydraulic press.
Hydraulic ram.
Hydraulic pump.
Bench vice.
Creeper.
Welding plant.

CONCLUSION

Thus the requirement of various tools was studied.

2. STUDY AND LAYOUT OF AUTOMOBILE REPAIR SHOP

Aim:
To study the layout of the automobile repair shop and to study different areas in the repair shop.

Requirements:

All types of spanners like double ended, rings, box and special tools.
Enough spaces and spares parts.
First aid box.
Fire extinguisher, etc.

Work shop arrangement:

First main thing that the work shop should have is enough manpower, spaces, tools and special
equipment. The workshop should have good security system and safety devices and good
appearance, good customer care and service.

Car parking:

It should have more area for vehicle parking. In this area, Job card making and Inventory check-
up are carried out.

Front office:

It should have good appearance and customer care executives for receiving the customers. The
front office should have the photos of all models of the vehicles. Then, the executive will make a
Job card and inform the details like estimated delivery time etc, to the customer.

Water washing section:

The vehicle must be washed before starting the repair work. The water washing station should
have modern equipment like hydraulic ram and special water injecting pressure nozzles and good
lighting arrangement. On the other hand, the service station should have the greasing facility.

Problem analyzing and work allotment:

First analysis the problems and see how it is to be rectified and then allot to suitable mechanics,
helpers and supply equipment like special tools and correct location place etc.

Engine work section:

This section should have a separate room for nozzle testing and pump testing, tappet and tappet
setting. The problems in the engine are identified and rectified.

Transmission work section:

This section should have some equipment like small trolley and ropes for dismantling the
gearbox from the vehicle.

Chassis maintenance section:

This section should have hydraulic jacks; hammer spanner set, etc for checking the chassis. This
section should have all the facilities for checking and rectifying the problems in the chassis.

Machining work section:

The workshop should have small separate areas where machining, welding and some pressing
works are done.

Wheel alignment and tire checking section:

This section should have the general check-up tools like battery charging unit A/C repairing
equipment. In this section, all the mounting bolts and nuts, radiator water levels and all other oil
levels are checked. Here the tire balancing and wheel alignment is done.

Checking by mechanics and supervisor:

In this section, the vehicle is operated by the mechanic with supervision and he also checks the
conditions of the vehicle and repairs the faults.

Checking by supervisor along with customer:

In this section, the supervisor will explain the problem and maintenance done on the vehicle to
the customer.

Stores:

The stores should have the spare parts and first aid kit. The store keeper should maintain the
spare parts and proper details of the tools for work and also send a copy to the accounts dept. for
billing.

Accounts and billing section:

This section collects the bills for the spare parts, labor and servicing charges and collects the
amount and issues the gate pass with the customer satisfaction.

Conclusion:

Thus, the study on the layout of automobile repair shop was performed.

3. STUDY & PREPARATION OF WORKSHOP STATEMENTS

AIM

To study various statements and various sheets like trip, maintenance, log, inspection, etc in a
workshop.

WORKSHOP STATEMENTS

This is the statement which is given by workshop organization. These statements mainly consists
of warranty, stores, customer care, accounts PDI, gate pass. They are used while servicing all the
vehicles in the station. They help in easy process of the vehicle in the workshop.

DAILY TRIP SHEET

When the vehicle is taken for trip each time sheet is filled. Trip sheet consists of time of
departure and return.

RUNNING LOG SHEET

It contains information about the travel distance its mileage and details related to that and also
contains times of departure and return.

MAINTAINANCE LOG SHEET

It contains information about the maintenance of vehicle. It has detail about repairs, replaced
spare, damaged spares. It also contains the condition of vehicle before and after repair.

VEHICLE INSPECTION FORM

This is a basic form which remains details of the inspection of the vehicle on a periodic basis the
various components to be checked are noted and checked periodically and its details are noted in
this sheet.

PRE TRIP & POST TRIP REPORT

This statement contains details of the pre and post trip condition of various parts. The condition
break system, fuel, lubrication, clutch, electrical system and tire are checked and recorded.

CONCLUSION

Thus workshop statement and trip sheet, log sheet, etc., were studied.

4. STUDY OF AIR BLEEDING IN A HYDRAULIC BRAKE SYSTEM

AIM :

To study the procedure of air bleeding in a hydraulic brake system

MATERIALS REQUIRED

Brake fluid collecting jar, flexible hose

TOOLS REQUIRED

1. Spanner Set

2. Hammer

BRAKE BLEEDING OPERATION

It is an important maintenance procedure carried out on the brake system of a vehicle. Brake
bleeding removes the air bubbles present in the master and wheel cylinder. This optimizes the
brake performance of the vehicle.

PROCEDURE

Remove the top of the master cylinder reservoir. It is usually a light colored reservoir
with a black cap. Remove the old brake fluid from the system.
Fill half of the transparent jar with the brake fluid
Connect the rubber hose in the brake drum nipple and dip the other end in the transparent
jar.
Compress the brake pedal to build up pressure and keep the pedal in the pressed position.
Now open the nipple to let the air trapped in get out.
Continue the process till all the air in the system is removed. Refill the master cylinder
whenever required.
This process should be in the sequence
Rear wheel Far brake
Rear wheel Near brake
Front wheel Far break
Front Wheel Near break

Finally all the air trapped in the system is removed.

RESULT

Thus the brake system bleeding was performed and all air trapped has been removed.

5. STUDY OF AIR BLEEDING IN DIESEL FUEL INJECTION SYSTEM

AIM

To study the procedure of air bleeding operation in a diesel fuel injection system

PROCEDURE

In case of a new engine or an engine which has been standing idle for a long time it is
important that the fuel system be bled before commencing operation. Turn the engine to
the position of 30-60 (approximately) after TDC for land six cylinders by turning the
crank pulley.

Slacken the air vent screw provided on the primary side of the air filter and operate the
hand primary of the fuel feed pump till there is free flow of air-free fuel. Tighten the air
vent screw on the primary filter. Slacken the air vent screw on the secondary filter and
operate the hand primary till there is air-free fuel flow. Tighten the vent screw.

Slacken the air vent screw on the final fuel filter (if provided) and operate the hand
primer till there is air free fuel flow. Tighten the vent screw

Slacken the center bleeding screw provided on the head of the distributor pump. Prime
the system by operating the hand primer on the feed pump. Normally it would be
necessary to bleed the system at the inlet connection of the injector. Slacken the High
pressure connection at the injector and turn/crank the engine till you get air-free fuel and
then tighten.

Now the engine is ready for starting.

RESULT

Thus the bleeding of the diesel fuel injector system is studied and performed successfully.

6. ADJUSTMENT OF WHEEL BEARING

AIM

To study the procedure for the adjustment of wheel bearing

TOOLS REQUIRED

1. Spanners

2. Screw drivers

3. Hammer

PROCEDURE

1. Loosen the wheel nits.

2. Lift the vehicle with the help of a jack

3. Remove the tyre

4. Loosen the axle nut and the drum

5. Take out the outer bearing, washers , spacers and inner bearing

6. Clean them neatly with the using diesel.

7. Assemble the components without grease. First the inner bearing with the hub.

8. Tighten the axle nut and the horizontal axis of the bearing.

9. If there is any shake in the bearing take out the shims one by one or put in one by one
properly.

10. If the shake is arrested , remove the fitted parts. Grease the bearing and hub properly and the
assemble in the same procedure as described above.

11. Refit the tyre. Lift down the jack and tighten the wheel nuts.

RESULT

The adjustment of wheel bearing was performed successfully.

7. REMOVAL AND FITTING OF TYRE AND TUBE\

AIM

To perform the removal and fitting of the tyre and tube of a given vehicle.

TOOLS REQUIRED

1. Hammer

2. Tyre lever

3. Spanners

PROCEDURE

Remove the valve stem cap and press the valve stem down to deflate the tyre. Push both edges
into the base of the rim at a point diametrically opposite to the valve. Using two levers at
intervals of 6in (approx. 15cm) , remove the tube carefully. Don not pull on the valve and keep
the tyre and wheel upright. Keep the bead on the base of the rim. Lever the bead at an angle and
at the same time push the wheel away from the cover with the other hand.

FITTING OF TYRES AND TUBES

1. Inspect the inside of the cover carefully and remove all dirt. The wheel rim must be clean, rust
free and undamaged

2. Dust the inside of the cover with French chalk

3. Fill air into the flat tube until it begins to round and then insert it in the cover.

4. Apply a frothy solution of soap and water generously around the center base of the tube
extending upwards =between the tyre beads and the tube itself for at least 2in (approx. 50.8mm)
on both sides

5. Also apply the solution on the tyre beads, but do not allow the solution to run on the crown of
the tyre.

6. The solution must be strong enough to feel slippery when fingers are wetted in the solution
and rubbed together.

7. Mount the tyre on the rim immediately, whilst the soap solution is still wet. Push one edge of
the cover over the edge of the rim. It will go in quite easily if the first part is fitted on the
opposite side to the valve and pushed right down to the rim base.

8. Move it around so that the balance sides coincide with those of the inner tube when it is
inserted with the valve passing through the hole in the rim
9. Take care that the valve fitted is on the correct side of the rim

10. Before inflating ensure that the tyre beads are clear of the wall of the rim all the way around
and push the valve into the tyre as far as possible to ensure the tyre is not trapped in between its
correct position

11. Inflate slowly till the beads are fully seated

12. Remove the valve core to deflate the tube completely.

13. Re-inflate to the correct working pressure . This procedure must be followed whenever a tube
is fitted.

RESULT

Thus the removal and fitting of tyre and tube was performed successfully.

8. ADJUSTMENT OF HEADLIGHTS
AIM

To adjust and alight the headlights of a given vehicle

INTRODUCTION

The headlight alignment gauge is an instrument which is used to align the headlight beam. It can
be used to align both the low and high beam. This is important for safety as it affects night
visibility and improper adjustment can lead to poor visibility for the driver and cause dazzling
for oncoming traffic.

ACCESSORIES

1. Head lamp focusing gauge

2. L stand

3. Wheel stand

4. Rail Track

5. Foundation belts

6. Operating Manual

PROCEDURE

1. Park the car in front of the headlight alignment gauge.

2. Keep a three feet gap between the instrument and the car. Use the measuring tape provided in
the gauge.

3. Now adjust the headlamp focusing gauge in such a way that the center of the car headlamp
and the headlamp gauge matches.

4. Measure the height of the center using the scale provided at the back of the L stand. Check
whether the height is more or less than 830mm.

5. Now switch on the headlight.

6. Using the manufacturers specifications check whether the curve of the headlamp is correct.

7. If not adjust the spring loaded screws in the headlamp to get it aligned.

INSTALLATION
1. Fix the variable L stand on the wheel stand and tighten the nut provided at the bottom of the
wheel stand. Fix the lamp focusing gauge on the variable L stand.

2. Drill the holes to fix the foundation belt to fix the rails. Now keep the wheel stand over the top
of the rails. The installation procedure is completed.

RESULT

Thus the headlight of the car was adjusted and aligned successfully.

9. STUDY OF DOOR LOCK AND WINDOW RISING MECHANISM

AIM

To study the door lock and window rising mechanism in an automobile.

DESCRIPTION

TO OPEN FROM OUTSIDE

As soon as the push button is pressed the catch is raised upward and the slotted disc rotates and
is freed form the V fitting. When the catch is raised upwards the locking bar is also raised up
with it. When the V fitting is freed form the slotted disc the door opens.

TO OPEN FROM INSIDE

To unlock the door from inside the locking bar is raised and then the inside opening bar is pulled.
This pulls up the clutch, rotating the slotted disc thereby freeing the V fitting.

DOOR IS IN CLOSED POSITION

When the door is closed the slotted disc rotates and fastens into the V fitting. During this
operation the clutch with lock bar also slots into position. Once the slotted disc fastens into the
V fitting the door is locked.

WINDOW RISING MECHANISM

Windows are provided in the upper part of doors to improve the visibility. They also admit
natural light and allow inflow of air when open. To provide additional space to the passenger ,
without increasing overall vehicle weight the window glasses are curved at the shoulder level.
They are made of one piece. Safety glasses are 5mm thick , like windshield glass they are also
made of toughened glass. The window can be raised or lowered by means of a lever through a
rack and pinion mechanism employed for this purpose.

RESULT

Thus the study of door lock and window rising mechanism was done successfully
 10. PERFORMANCE OF ENGINE TUNING OPERATION USING ENGINE
ANALYSER

AIM

To check the engine fault by using engine analyzer

EQUIPMENT REQUIRED

Engine Analyzer
Probe
Clips

SPECIFICATION

Red Clip : Positive for battery

Blue Clip : Negative for battery

Yellow Clip : Positive for ignition coil

Green Clip : Negative for ignition coil

Red Probe : First spark plug lead

Grey Probe : Secondary winding (between coil to distribution)

Amps Probe : Connect to negative terminal so that the arrow mark is facing

towards positive terminal.

UTILITIES

Install Software (Floppy) : F1

Remove Software (Floppy) : F2

Install Software (CD-ROM) : F3

Remove Software (CD-ROM) : F4

Exit to DOS : F5

Window : F6

PROGRAM
Engine Test : F1

MAIN MENU

For engine test press F1 key after the 3 mode was displayed.

1. Automatic test 2. Manual test 3. Utilities

1. AUTOMATIC TEST

New vehicle : F1

Diagnostic : F2

Tune-up : F3

Symptom Analysis : F4

Component : F5

NEW VEHICLE

Procedure to be followed for checking any new vehicles, select the new vehicle option and
display the sub option.

Manual data entry : F1

Manual data armed : F2

Change customer details : F3

Vehicle data on Disk A : F4

Vehicle data on hard disk : F5

DIAGNOSIS

Select the diagnostic option sequence order to check the engine component after the complete
order.

TUNE-UP

Select the tune-up option sequence order to check the engine component at the same time live
reading will be displayed.

SYMPTON ANALYSIS

In this analysis the defect in an engine can be identified with the help of functional keys, such as
F2, F3etc.
Poor cold start : F2

Poor hot start : F3

Engine misfires : F4

Engine lacks power : F5

COMPONENTS

To check components given below

Battery : F1

Alternator : F2

Distributor : F3

Coil : F4

Plug leads : F5

2. MANUAL TEST

WAVE FORM

Particular components wave form to be checked as given below

Alternator : F1

Primary superimposed : F2

Secondary superimposed : F3

Secondary parade : F4

Injector : F5

ADJUSTMENTS

After the defect in any component has been identified the component is to be adjusted with
respect to the user normal.

Battery : F1

Alternator : F2

Distributor : F3
Coil : F4

Plug leads : F5

MULTIMETER

This option is used for checking the voltage and amperage.

VISUAL INSPECTION

This option is normal checking with our naked eyes.

Cooling System : F2

Oil level : F3

Drive belts : F4

Wiring/connections : F5

Battery lever & cables : F6

Exhaust systems : F7

Head and side lights : F2

Indicators/Hazard lights : F3

Brake/Reverse lights : F4

EXIT

To exit the menu, press the ESC button, the following option will be displayed.

YES: EXIT JETD3

NO: Return to main menu

RESULT

Thus the analyzing of the given vehicle was checked by engine analyzer and tuned-up
successfully

11. FAULT DIAGNOSIS OF IGNITION CHARGING AND STARTING SYSTEM

AIM

To find out the trouble in an ignition system.

APPARATUS REQUIRED

Mechanical tool kit, ignition timing light and feeler gauge.

CAUSES OF IGNITION FAILURE

Ignition system failure contact point system can be grouped into 3 categories.

Loss of energy in the primary circuit:

1. Resisting the primary circuit due to defective leads, bad connection, burned distributor contact
point or switch or open coil primary winding.

2. Points not properly set.

3. Discharged battery or defective alternator.

4. Defective condenser.

5. Grounded primary circuit in coil, wiring or distributor.

Loss of energy in the secondary circuit:

1. Spark plug fouled, broken or gapped.

2. Defective high voltage wiring.

3. High voltage leakage across coil head, distributor cap or rotor.

4. Defective ignition coil.

Out of time:

1. Timing is not set properly.

2. Distributor bearing or shaft worn or shaft bends.

3. The ignition due to plugs of worn heat range.

Engine does not run:

1. Defective coil secondary winding or coil head.

2. The CB points are out of adjustment.

3. The condenser is shorted.

4. The coil primary circuit is grounded.

5. Loose connection.

Engine miss firing:

1. Poor connections.

2. Defective spark plug.

3. Defective secondary winding.

Over heating:

This condition may be caused by improper ignition timing. Retained or late, ignition timing
sends more heat through the cylinder wall into the coolant. This occurs because with late timing
the air fuel mixture is burning later in the power stroke.

RESULT

The fault of ignition system of the vehicles engine was traced out and system was restored to the
working condition.

12. BRAKE ADJUSTMENT

AIM

To adjust brake show on ambassador car

TOOLS REQUIRED

Spanner set, screw driver, hammer, screw jack.

MATERIAL REQUIRED

Cotton waste

PROCEDURE

1. Set the chuck at the rear wheel of the vehicle for safety precaution.

2. Jack the front wheel up off the floor.

3. Two wheel cylinders are seen horizontally opposite.

4. Identify the rotating cam screw on the wheel cylinder.

5. Rotating cam screw is to be screwed using a screwdriver to adjust the brake.

6. Jack the wheel down to the floor.

RESULT

The brake adjustment is successfully carried out.

13. CALIBRATION OF FUEL INJECTION PUMP

AIM
To perform calibration operation of fuel injection pump.

APPARATUS REQUIRED

Fuel injection pump calibration machine

TOOLS REQUIRED

Spanner, screwdriver set

MATERIAL REQUIRED

Diesel cotton waste

PROCEDURE

1. The FIP, which is to be tested, is mounted on the calibration testing machine.

2. Check the fuel level in the fuel tank that is placed on the machine.
3. Switch on the fuel feed supply pump, supplying the fuel from the tank to the main gallery of
the fuel injection pump.
4. Main drive switch is turned on towards forward direction and at the same time control level
should be at fuel load condition.
5. Then set the rpm at our requirement with the help of the digital rpm indicator and set the
number of strokes. (Plunger movement)
6. Push the start button switch for operation. (Red button)
7. Once the operation is over check the quantity of fuel collected in the jar.
8. If any of the injectors will give variation of the quantity of the fuel the particular plunger
position has to be changed.
9. First loosen the clamp screw and the plunger (control sleeve) is rotated towards governed side,
more quantity of fuel will be delivered and vice versa.
10. After adjusting the plunger movement, clamping screw must be tightened and ensure that all
the injectors are giving equal quantity of fuel.
RESULT

The given fuel injection pump is calibrated.

14. TESTING OF INJECTORS

AIM
Testing of injectors in a test rig

TOOLS & AIDS

Injector testing machine, spanner set and nozzle

MATERIAL REQUIRED

Cotton waste, diesel

PROCEDURE

Three tests are carried out on injector testing machine to test the performance of the injector.

Pressure test
Leak off test
Spray test

1. PRESSURE TEST

Clamp the injector in the test rig and operate the hand pump. Note the reading of the dial
indicator at which the injector nozzle starts injecting. It gives pressure reading. It should be the
same as recommended by the company. If it is less, then tighten the adjusting screw of the
injector. If it is more, then loosen the adjusting screw. Repeat the process until the correct
pressure reading is obtained. Finally tighten the lock nut.

2. LEAK OFF TEST

Clamp the injector on the test rig and build up the pressure to about 150kg/cm2 by operating the
test pump. Keep this pressure for about 10 seconds. If the pressure drops it shows that there is a
leakage in the injector. Check the body seats and needle valve. Correct the seat and needle valve
grinding and lapping and after that again do the leak off test.

3. SPRAY TEST

Spray test is also done on the same injector testing machine. While operating the tester pumps
observe the spray pattern carefully. It should not be like a blob of oil or with drop splitting away
but it should be fully atomized.

RESULT

The given injector is tested and found they are in fully serviceable condition

15. VALVE GRINDING

AIM:
To perform valve grinding using valve and adjusting the angle.

TOOLS REQUIRED:

Spanner set, Helen key.

MATERIALS REQUIRED:

Coolant oil, waste.

PROCEDURE:

INTRODUCTION:

The component that is used to admit the air fuel mixture into the engine cylinder and force the
exhaust gas out at correct timings, with some control is called as valves.

NEED OF VALVE LAPPING AND GRINDING:

Due to frequent application in the engine the valves may be subjected to ware and tare. Due to
this, the valve angle may vary resulting in leakage of inlet and exhaust products from the
combustion chamber. This leads to the reduction in engine efficiency and poor performance. To
avoid this defect we have to set the valve seat angle and valve angle in the correct position. In
order to achieve this, valve lapping and grinding must be done on the valve seat.

VALVE RE-FACING:

It is an alternative method to valve grinding. We need a valve re-facing machine for this. This
machine consists of a grinding wheel operated by an electric motor. The valve is held in by a
chuck, which is rotated by the electric motor. A provision is used to set the valve chuck at a
desired angle, generally the valve facing at 30 or 45.

After starting the machine, a light cut is made first, the machine is stopped and the valve face is
inspected. If the cut is only taken on one side of the valve face, it means the valve is bent and
should be discarded. If the valve is not bent, restart the machine and reface the valve taking light
cuts until there are no more pits or scratches in the face of the valve.

RESULT:

Valve re-facing or valve grinding operation was performed.

16. VALVE LAPPING

AIM:
To perform valve lapping operation on the given valve.

TOOLS REQUIRED:

Coarse and fine abrasive paste, Lapping stick.

DESCRIPTION:

The component which is used to admit the air fuel mixture into the engine cylinder and send out
exhaust gases is called a valve.
The engine valves may be classified into three main categories:

Popped valves
Sleeve valves
Rotary valves

Generally the inlet valves are larger than exhaust valves, and the materials used are:

Silicon chrome steel

Molybdenum
Austenitic steel.

NEED FOR LAPPING OPERATION:

Due to extensive wear the valves may lose their valve seating, hence lapping is one of the
operations used to restore the valves back to perfect working condition.
PROCEDURE:

1. The valve is thoroughly cleaned.

2. A small quantity of coarse abrasive paste is applied on the valve face and the valve is slipped
into the guide hole.
3. The lapping stick, which has a hollow rubber, is lightly pressed onto the valve; the stick is
fixed to the valve face by means of vacuum.
4. Now the stick is given a reciprocating rotary motion by the palm of the hand.
5. While doing so, the valve is lifted off the valve seat with every operation to obtain a smooth
finish and proper seating.
RESULT:

Thus the lapping operation is performed successfully.

17. WHEEL ALIGNMENT

AIM:
To check caster, camber, kingpin inclination, toe-in and toe-out for a given vehicle.

EQUIPMENTS:

Computerized wheel aligner.

CAMBER:

The angle between the centerline of the tire and the vertical line when viewed from the front of
the vehicle is known as camber. When the angle is outward (i.e.) the wheels are further apart at
the top than at the bottom, the camber is positive. When the angle is inward, (i.e.) the wheels are
closer together at the top than at the bottom, then the camber is negative. Any amount of camber,
positive or negative, tends to cause uneven or more tire wear on one side than the other side and
unequal camber may result in steering wandering, road shocks and unequal tire wear.

CASTER:

In addition to being tilted inwards the center of the vehicle, the kingpin axis may also be tilted
forward or backward from the vertical line. This tilt is known as caster. Thus the angle between
the vertical line and the kingpin centerline in the plane of the wheel (when viewed from the side)
is called the caster angle. When the top of the kingpin is backward, the caster angle is positive,
and when it is forward the caster angle is negative. The purpose of the caster is to provide
steering stability which will keep the wheel in a straight position (i.e) a truck with no caster or
negative caster will tend to wander and be difficult to straighten out at the end of curves.

KINGPIN AND INCLINATION:

The angle between the vertical line and center of the kingpin axis when viewed from the front of
the vehicle is known as kingpin inclination. The kingpin inclination in combination with caster is
used to provide directional stability in modern cars, by tending to return the wheels to the
straight-ahead position after any turn. It also reduces steering effort particularly when the vehicle
is stationary. It also reduces tire wear. The kingpin inclination in modern vehicles ranges between
4 to 8 degrees. It must be equal on both sides. If it is greater on one side than on the other, the
vehicle will tend to pull to the side having the greater angle. Also, if the angle is too large, the
steering will become exceedingly difficult. The kingpin inclination is made adjustable only by
bending.

TOE-IN:

Toe-in is the distance between the front wheels less at the front (A) than at the rear (B) when
viewed from the top, when stationary. The amount of toe-in is usually 3 to 5mm.

TOE-OUT:
It is the distance between the front wheels more at the front (A) than at the rear (B) when viewed
from the top.

PROCEDURE:

1. Before starting the test of wheel alignment, check the following conditions:

Check wheel bearing for looseness and adjust/replace if necessary.

Set all tire pressure to specified values.
Check for even springing of suspension (unusual loads cause uneven springing effects).
Apply the handbrakes and check the rear wheels for safety.

2. From the main menu select new job.

3. Select the model from the list presented.

4. Enter the car registration number and odometer reading.

5. Select run out from the main menu.

6. Follow strictly the procedure outlined in the run out procedure, which is available in the
computer.

7. According to the computer data make the adjustments.

8. A printout is taken after the adjustments are done.

RESULT:

Thus the wheel alignments, caster, camber, kingpin inclination, toe-in, toe-out were studied
successfully.

18. RE-BORING
AIM:

To study the cylinder re-boring operation.

TOOLS REQUIRED:

Bore gauge, micrometer, venire caliber, tools set (cutting tools, master block).

CYLINDER RE-BORING:

The cylinder bore gets worn out with time and tends to become oval shaped further, the wear in
not uniform even on the same side from top to bottom. The maximum wear occurs at the upper
limit of ring travel. The cylinder bore should be measured to determine ovality and taper. This
can be done using either an micrometer or a bore dial gauge. The diameter is measured at the top.
Middle and perpendicular directions of the cylinder block the difference in readings from top to
bottom gives the ovality and taper.

STEPS TO BE FOLLOWED FOR RE-BORING:

The cylinder surface is thoroughly cleaned and the boring bar is set on the cylinder bore.
The bar is centered and clamped.
The cutter is then set to a desired depth of cut and the machine started. The cutter will
bore progressively to the other end.
Cylinder bore is bored 0.0125mm to 0.05mm less than required size.

PRECAUTIONS:

After the job is complete, the cylinder must be washed thoroughly to remove the entire
abrasive particular.
When re-boring has been done a couple of times, and can be done no more, a wet liner is
fitted.

RESULT:

Thus re-boring is done on the cylinder bore.

19. STUDY OF ELECTRICAL SYSTEM OF A LCV

AIM
To study electrical system such as headlight, traffic indicator lights, horn, wiper and charging
system.
DESCRIPTION
HEADLIGHTS
More recently sealed beam head units are used. It consists of a aluminized glass reflector and the
glass lens are fused from a single unit inside which is filled some inert gas, the advantage of this
type of construction is that it can be manufactured to comparatively higher accuracy because the
unit is not to be adjusted in a future. The glass lens is not blackened which further increases the
life of unit. If any filament is blown, entire unit is to be changed.
TRAFFICATOR LIGHT
It is one type of direction indicator; a solenoid contains a plunger which is further connected with
the pivoted indicator arm. When vehicle has to take a turn, the driver operates trafficator switch.
This energies the indicating arm in the direction in which vehicle is to be turned. The main
disadvantage of this type of direction indicator is the troubled caused, when the indicator arm is
lifted up at high vehicle speed.
ELECTRIC HORN SYSTEM
It consists of a diaphragm and an armature inside a filed coil. When switch is actuated by driver,
the circuit completes and horn energies. In this process, diaphragm vibrates which agitates the air
column, thus producing sound.
WIND SCREEN WIPER SYSTEM
This is operated by the help of a small motor though some manufacturers use compressed air. It
consists of a mechanism which converts rotatory motion of motor to reciprocating motion which
is linked to viper arms. Wiper arms are pivoted against the windscreen under spring pressure to
provide adequate pressure against glass.
CHARGING SYSTEM
The function of charging system is to generate, regulate and supply electrical energy for charging
the battery. It consists of a generator which draws mechanical energy from engine. A relay is
used to regulate the flow of charging current to battery.
RESULT

Thus the study of electrical system such as head light, horn, wiper, starting system and charging
system was done successfully.

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