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PREFACE

I have great satisfaction in learning about the technology of the worlds leading motor vehicle company NISSAN and getting in depth knowledge of their new product NISSAN EVALIA. The evaluation study was initiated by the training which a student has to for the fulfilment of the curriculum. The study, which has been conducted and completed within a record time of two months, is an excellent example of cooperative endeavour among the colleagues and the organisation. The training taken at NISSAN gave me practical insight into the working of the company, especially in the field of technology of motor vehicles which until now limited to book only. But these 60 days have been special and proved to be a value addition and how actually functions are performed in the a massive vehicle as well as in the organization. The initial part of project report gives details of the company, like its departments, functions, and the structure etc and the next part is related to NISSAN EVALIA and its working.

ACKNOWLEGEMENT

No man is an island itself rightly proclaim John Donne, the metaphysical poet to let the world know the reality of human existence and human life. First and foremost would like to thank the Director and teachers of PACIFIC POLYTECHNIC COLLEGE for giving me an opportunity to develop understanding and skills to attain quality knowledge. I express my deep and sincere gratitude to the NISSAN for allowing me to have my training in this organization and my Trainer Mr. Hemendra whose valued guidance, dexterous knowledge and unabated zeal paved my way for the completion of the work smoothly. Finally and without being specific, I would like to thank my parents and my friends who helped and encourage me directly or indirectly in the project and whose enthusiasm and cheerfulness made my work on this project an enjoyable experience with a perfect balance between pleasure and work.

DIPAL JAIN

INDEX
S. No. 1 2 Particulars INTRODUCTION TO THE COMPANY NISSAN EVALIA Photo Gallery FRONT SIDEWAYS VEHICLE SUMMARY OVERVIEW OF NISSAN EVALIA NISSAN EVALIA AT A GLANCE SUSPENSION ASSEMBLY BRAKING ASSEMBLY EXPLODED VIEW OF THE FRONT DISC BRAKE ASSEMBLY OTHER COMPONENTS IN THE HYDRAULIC SYSTEM FRONT DISC BRAKE REAR DISC BRAKE POWER BRAKE BOOSTER FINDINGS CONCLUSION FINDINGS Page No. 4 6

3 4 5 6 7

7 10 15 17 19 19 22 24 26 29 31 33 34

8 9 10

INTRODUCTION TO THE COMPANY

Nissan Motor Company Ltd usually shortened to Nissan, is a Japanese multinational automaker headquartered in Japan. It was a core member of the Nissan Group, but has become more independent after its restructuring under Carlos Ghosn (CEO). Nissan was the sixth largest automaker in the world behind General Motors, Volkswagen AG, Toyota, Hyundai Motor Group, and Ford in 2011.[2] It formerly marketed vehicles under the "Datsun" brand name. As of 2011, the company's global headquarters is located in Nishiku, Yokohama. In 1999, Nissan entered a two way alliance with Renault S.A. of France, which owns 43.4% of Nissan while Nissan holds 15% of Renault shares, as of 2008. Along with its normal range of models, Nissan also produces a range of luxury models branded as Infiniti.

Nissan's footprint in India has been growing steadily since its inception in 2005. Marked by an impressive rise in sales, award-winning quality from locally-built products, an expanding range of innovative cars and a rapidly evolving dealer network the growth underlines the strategic importance of India to Nissan. Together with its global Alliance partner Renault, Nissan has made a long-term and largescale 45 Mn INR investment commitment in a manufacturing plant at Oragadam, Chennai. The Alliance has also invested in a state-of the-art global R&D center with more than 2000 engineers to support product innovation and customization. NMIPL has appointed Hover Automotive India (HAI) as their sole distributor for India to handle sales and marketing, dealer development, customer relationship management and after sales in India. Guided by its global Brand commitment "Innovation and Excitement for Everyone" Nissan delivers cutting-edge technology, Innovative design and a rewarding experience to all its customers. In India, Nissan has been constantly expanding innovative and exciting product offerings across hatchback, sports car, SUV and sedan segments. Today, Nissan has strongly positioned three locally produced models premium hatchback Micra, entry level sedan Sunny and Urban Class Utility Vehicle Evalia. Other existing range of products include the X-Trail (SUV model), the Teana (luxury Sedan) and 370Z (iconic sports car) all three imported from Japan as CBU (completely built units). NMIPL also commenced exports in September 2010 to more than 100 countries including Europe, Middle East and Africa.

In line with its global philosophy of corporate sustainability, Nissan India is demonstrating its corporate commitment through various sustainable programs including safety campaigns and rehabilitation projects. Nissan has constructed residential homes for relocated families from the construction site, local Police Station and a fire service station in the Oragadam village. Nissan has also partnered with Habitat for Humanity for providing shelter to various families by constructing homes for the socially and economically less fortunate section of the society. India is a key growth market for Nissan. The company continues its quest to optimize product development and deliver highly innovative technology to the India market and its growing customer base.

NISSAN Model 70 Phaeton, 1938

NISSAN EVALIA
The following project consist of study of NISSANs new vehicle EVALIA

FRONT

SIDEWAYS

VEHICLE SUMMARY
Name: Model: Car Body Type: Segment: Fuel Consumption: Highway Fuel Consumption: City Evalia XE MUV C+ Segment 19.30 kmpl.

14.00 kmpl.

ENGINE SPECIFICATIONS
Displacement: Engine Type: 1461cc, Nissan K9K, BS4 Diesel

Maximum Power: 85 Bhp @ 3750 rpm Maximum Torque: 200 Nm @ 2000 rpm

DIMENSIONS
Length: Width: Height: 4400 mm 1700 mm 1860 mm

OTHER SPECIFICATIONS
Seating Capacity: Tyre Size: 7 165 R14

Suspension: Turning Circle: Steering: Brakes: Gears:

McPherson Struts, Multi-Leaf Rigid 5.20 mtrs. Tilt Front Disk, Rear Drum 5 Manual

Ground Clearance: 180.00 mm Kerb Weight: Fuel Tank: Body Color Bumpers: Tachometer: Alloys: ORVM Indicator: 1446.00 kgs. 55.00 YES YES NO NO

Xenon Headlamps: NO Trip Meter: 2

Headlamp Washer: NO

ACTIVE AND PASSIVE SAFETY


Airbag: 1 NO NO NO YES YES NO

Parking Sensors: Fog Lamp: Traction Control: EBD: ABS: ESP:

COMFORT AND CONVENIENCE


AC: Power Windows: Central Locking: Remote Boot: AC without Climate Control NO None YES

Remote Fuel Filler: YES Rear Wiper: Rear Defogger: Rear Armrest: Steering Adjustment (Rake/Reach): Driver Seat Adjustment: Music System: Leather Seats: Door Mirror: Tinted Glass: Rear AC Vent: YES YES With Cup Holder

YES/NO

Manual 1 DIN AM/FM/CD NO Both Side Electric YES NO

Folding Rear Seats: YES Sun Roof: Buttons/Controls on Steering: Auto Viper: Auto Headlamp: NO NO NO NO

OVERVIEW OF NISSAN EVALIA


Multi-purpose vehicle is a segment of cars in India which is totally dominated by Innova from Toyota. Ever since its launch its the undisputed champion of its segment. Initially this was not a popular segment of cars in India but now consumers and manufacturers both are rushing towards it. Recently we have seen new competitors of Innova including Ertiga from Maruti Suzuki, face-lifted Xylo from Mahindra and nowNissan Evalia. Yes, Nissan has entered this segment of market with their MPV known as Evalia. Till now Nissan is widely known for its cars like Micra and Sunny in India. With Evalia, Nissan targets those looking for an alternative of Innova for both family and commercial use. Majority of cars in this segment faces the problem of identity crisis. Either they are given the identity of a car which is just suitable for family or they are known as taxi which is more appropriate for commercial usage. No owner would like his personal car to be taunted as a taxi. Innova has managed it brilliantly. It has won hearts of many families despite being a successful commercial vehicle. Its space, comfort with premium quality made it a huge hit in the market. Nissan knows it perfectly as they have seen Xylo being tagged as a taxi while only families are opting for Ertiga. It will be a tough task for Evalia to carry two successful images with two colored number plates. Nissan India unveiled the 'Evalia' in India at the 2012 Auto Expo in New Delhi. The Indian version of NV200 would be more luxurious and feature-rich in comparison to the Evalias (NV200) sold all over the world. Nissan Evalia is a proper seven-seater multi-utility vehicle and will compete against the likes of Toyota Innova, Tata Aria, Chevrolet Tavera and to some extent with ICML Rhino. On 8th August Nissan India unveiled all the technical specifications and features of Evalia to the online media persons. It is available in four variants: XE, XE+, XL and top-of-the-line XV. All the variants are powered by Nissan K9K diesel engine which is mated to five-speed manual gearbox. It generates maximum power of 85 bhp at 3750 rpm with maximum torque of 200 nm at 2000 rpm. In terms of looks, Nissan Evalia has commercial van-type designing with sliding doors to access the rear seats. It has to be seen that if private owners will prefer Evalia over Innova for routine day-to-day use. Nissan has kept the design very neat and simple. The interiors of Nissan Evalia are very spacious with sufficient head-room and leg-room for all seven passengers. The top-of-the-line XV variant will come fully loaded with features like body coloured bumpers, body coloured outside rear-view mirrors, Electrically adjustable outside rear-view mirrors, front fog lamps, alloy wheels, tachometer, trip meter, 12V power outlet, multi-information display, 2DIN music system with 4 speakers, key-less entry, central locking system, tilt-adjustable power steering, power windows, seat back table, rear-monitor camera with display, air conditioner with rear AC vents, reclining seats, passenger plus driver airbag, ABS+EBD with brake assist, immobilizer and door ajar warning.

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The Nissan Evalia is designed for perfection. Ample amount of cargo space, first-class functionality and the latest automotive technology make it stand apart from the crowd. Nissan exhibits a high performance on the road with its excellent diesel engine option. The interior is a showcase of comfort and the true sporty nature of the car. They are provided with lumber support, folding options in the passenger seats and Thermoplastic Polyolefin front row covering. The remote keyless entry system, central console with controls, front map lights, Rear Glass defogger, bottle holders and passenger side rear cargo door all enhance the comfort of the car. The Nissan Evalia is facilitated with 2-Din AM/FM/CD with four speakers. Nissan India has launched the Evalia today (25th September, 2012) in Indian market. The base variant of Evalia is priced at Rs. 8.49 lakhs and Rs. 9.99 lakhs for the top model.

Nissan Evalia Exterior


One thing is for sure; Evalia looks distinct from its competitors. We are not sure if its going to work in its favour or not. The car looks tall; thats it. Evalia neither looks smart or beautiful nor its curvy or macho, its just tall. The front of the car is much more appealing than its whole body. It has a big, broad bumper which has nice flowing lines over it along with fog lights and air dam fitted very low. There is huge gap between headlights and fog lights which grabs your attention instantly. It has nice angular headlights which are well mated with an innovative front grille. There is big Nissan logo in center with a nice finish of chrome on the last layer of grille. The bonnet sits high above on this front grille which is not that big in size. Overall its face looks very aerodynamic. Its side view makes it look like any other, cargo van. It has long vertical front doors with sliding doors at the back. Yes, it has sliding doors which wont take you long to compare it with much cheaper Marutis van like Omni or Eeco. It has body colored front door handles and big side mirrors. It has nice wheel arches but its 14 inch alloys spoils the party. Its side profile with small size of tyres looks very boxy and bland. Rear of the car makes it worse. Its rear gate makes it a typical van. Its rear bumper is the most irritating thing that you can notice. It has a tall rear gate which has extremely low fitted tail lamps. When companies are trying to make their MPVs as stylish as possible, we wonder why Nissan has chosen this typical van design for its car. Looking at its competitors design and style, Evalia looks like a thing of the past.

Nissan Evalia Interior


Things get better inside Evalia. It uses beige and grey colors inside. Seats and door panels are of beige colour which makes it look up market. The car features clear and easily readable instrument dials. It has familiar three spoke steering wheel with a big Nissan logo over it. The upward placement of gear knob may remind you of i10s AC vents, gear knob and center console are surrounded with metallic colour finish. The quality of plastic material and buttons used inside are just fine as they are not that soft to touch. If we compare it with its rivals like Xylo than it surely has an upper hand as the total arrangement inside with fit and finish is far better. It also has a Multi information display which provides important information to driver.

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Comfort and Convenience


Evalia is available as a seven-seater multi-purpose vehicle. Basic function of MPVs is to provide extra space and thats the USP of this car. Nissan has made it very spacious and even with full seating; luggage of a full size family can fit into its boot. Front seats are very comfy and there is enough legroom and headroom available in the front. People who are six feet plus may find a bit cramped knee room in the front, otherwise headroom is no issue. There are front power windows and rear wiper and defogger. Its power steering is available with tilt option. Driver seat is manually adjustable. Driving position will again realize you that it is more like a van as you lack that confidence in driving position. Seating in second row is also very comfortable. There is ample amount of headroom and legroom. Under thigh support is just enough. It has non sliding seats in its 2nd row. Sliding doors and almost flat floor makes it convenient to use these rows. The tall structure of Evalia allows the passengers in third room to get fair amount of headroom. The under thigh support could have been better. There is rear AC vent for 3rd row, we are not sure about 2nd row if it will have AC ducting or not. It also features electrically adjustable but not retractable outside mirrors and rear parking camera with display. The car has a smart key with function of auto lock/unlock with the help of sensors.

Dashboard and Storage


Its long dashboard uses dual tone colors. It has in-built glove box with bottle holders on either side. Thats the only storage space this dashboard offers. The center console is fitted with Multi information display which fits in well with the dashboard and looks sophisticated. It has round and rectangular shaped AC vents. Overall appearance and quality of dashboard is satisfactory. The car has no lockable storage space to keep essential or private documents. It also has cup holder in rear center armrest. The car has first in its class tray table on the back of front seats just like a plane. To get more storage, the rear seats folds down and allow you to carry enormous amount of luggage.

Music system of Nissan Evalia


Nissan Evalia is equipped with double din music system fitted in center console. It has radio and CD player coupled with four speakers. There is no audio control switches mounted on its steering wheel. The car also lacks Bluetooth connectivity. It features a 12v power outlet at front.

Nissan Evalia Engine and Gearbox


The familiar Renaults 1.5 K9K common rail diesel engine powers this car. The maximum power produced by this engine is of 85 bhp which comes at 3750 rpm. It churns out a maximum torque output 200 Nm available at 2000 rpm. Nissan is already using this engine in its Micra and Sunny. This diesel unit is specially tuned for Indian Evalia. Its mated with 5speed manual gearbox. This engine is less powerful than most of its competitors.

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Acceleration and Performance


Those numbers seem to be very less on papers for a vehicle of this segment but drive it on road and you will find it completely different. As per Nissan, Evalia reaches 100km/hr mark faster than any of its competitors. Its hard to believe but yes it does. The car feels very light and fast. Once you pass 2000 rpm mark it is fun to drive this vehicle. It suffers a major turbo lag, especially with full seating you will continuously have to work on its gear shifting. It also gets noisy if rev hard otherwise its a nice performer. It cant match the performance and drivability of Innova but it is better than what we get in Xylo. Its lightweight helps it to manage the power to weight ratio better than others. Its tall gear ratios can be irritating in city traffic as you can avail torque only after 2000 rpm. It has smooth gear transition which is very handy in city traffic and its gear ratios are well proportioned.

Mileage of Nissan Evalia


Nissan claims Evalia to be the most fuel efficient car in its segment. As per ARAI certification, it manages to return 19km/ltr. When tested the car returns a mileage of around 13-15km/ltr in city conditions while on highways you can expect anything around 1517km/ltr. These numbers are surely better than its competitors like Innova and Xylo. There are two reasons which undoubtedly make it the most fuel efficient car in its segment. First its lightweight due to its monocoque design which is very lighter in comparison to its competitors as it weighs around 1.4 tonnes and secondly its relatively taller gear ratios.

Nissan Evalia Ride and Handling


The car handles really well in traffic conditions. Its reduced turning radius along with large door glasses on either side makes it easy while parking this car. Given its weight and usage, its suspension has been given special treatment. It is capable of bearing heavy loads with optimum comfort. Its strong suspension allows it to stay grounded at high speeds. Shifting lanes quickly at high speeds is not an issue. It also digests big bumps and potholes easily and with its high ground clearance. Its long wheelbase along with well mated suspension confirms you a comfortable ride. It doesnt give you enough confidence to drive it fast at corners because its suspension takes time to settle down and its small tyres are not capable to hold it firmly on road.

Braking and Safety Features


Nissan Evalia has ventilated disk brake at its front while drum brakes are used at its back. Brakes respond very accurately and sometime they stop this car way before than what you expect. Top model of this car will also carry features like ABS with EBD and brake assist which will make its braking more precise. Though it lacks ESP but you will hardly miss it. Nissan has tried to make it a safe vehicle thats why ABS and driver side air bag is a standard feature while the top model will also feature airbag for front passenger.

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Verdict
MPVs are known for their space and Evalia is surely a winner in this department. Its very spacious and offers enough comfort what you expect from a vehicle of this segment. It handles nicely in city traffic and on highways also it wont disappoint you. Evalia is very economical in terms of fuel efficiency and for that you dont even have to compromise on power either. These are some of its qualities which will surely appeal to many buyers. We wish if it was enough for this car to succeed as it has some major drawbacks. Nissan Evalia looks much like a van with sliding doors which makes it look like a typical MPV. Its competitors like Marutis Ertiga and Toyota Innova on the other hand are trying to get rid of this image and they more look like any other city car which is more acceptable by family buyers. It can appeal to those who are looking for a commercial MPV but again its warranty period is an issue. Innova comes with longer warranty period which makes it worth in comparison to Evalia. There are relatively less features in Evalia when compared to its competitors. It will be hard for Evalia to get the trusted buyers of Innova which is better than it in almost every department.

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Nissan EVALIA at a glance

Manufacturer Nissan Also called


Nissan Evalia Nissan NV200 Vanette Mitsubishi Delica D:3 2009present 2010-present Aguascalientes, Mexico Shnan, Kanagawa, Japan Nissan Motor Ibrica S.A., Spain(November 2009) Zhengzhou Nissan, China (2010) Chennai, India (2012-) Purwakarta, Indonesia (2012-present) Nissan Vanette Van (Japan) Nissan Kubistar (Europe) Light commercial vehicle 4-door van Front engine, front-wheel drive Nissan B platform 1.6 L HR16DE I4 2.0 L MR20DE I4 (starting in 2013) 1.5 L K9K Diesel I4 (Europe)

Production Model years Assembly

Predecessor

Class Body style Layout Platform

Engine

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1.5 L HR15DE (Indonesia)

Transmission Wheelbase Length Width Height

CVT 2010-12: 2,860 mm (112.6 in) 2013-: 115.2 in (2,926 mm) 2010-12: 4,400 mm (173.2 in) 2013-: 186.2 in (4,729 mm) 2010-12: 1,695 mm (66.7 in) 2013-: 68.1 in (1,730 mm) 2010-12: 1,8501,855 mm (7373.0 in) 2013-: 73.5 in (1,867 mm)

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SUSPENSION ASSEMBLY

Front-wheel-drive car with MacPherson-strut front suspension and struttype independent rear suspension

Automotive suspension
The springs and related parts intermediate between the wheels and the frame, subframe, or side rails of a unitized body. The suspension supports the weight of the upper part of a vehicle on its axles and wheels, allows the vehicle to travel over irregular surfaces with a minimum of up-and-down body movement, and allows the vehicle to corner with minimum roll or loss of traction between the tires and the road. See also Automobile; Spring (machines). In a typical suspension system for a vehicle with front-engine and front-wheel drive (see illustration), the weight of the vehicle applies an initial compression to the coil springs. When the tires and wheels encounter irregularities in the road, the springs further compress or expand to absorb most of the shock. The suspension at the rear wheels is usually simpler than for the front wheels, which require multiple-point attachments so the wheels can move up and down while swinging from side to side for steering. A telescoping hydraulic damper, known as a shock absorber, is mounted separately or in the strut at each wheel to restrain spring movement and prevent prolonged spring oscillations.

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The shock absorber contains a piston that moves in a cylinder as the wheel moves up and down with respect to the vehicle body or frame. As the piston moves, it forces a fluid through an orifice, imposing a restraint on the spring. Spring-loaded valves open to permit quicker flow of the fluid if fluid pressure rises high enough, as it may when rapid wheel movements take place. Most automotive vehicles use gas-filled shock absorbers in which the air space above the fluid is filled with a pressurized gas such as nitrogen. The gas pressure on the fluid reduces the creation of air bubbles and foaming. See also Shock absorber. Most automotive vehicles have independent front suspension, usually using coil springs as part of either a short-arm long-arm or a MacPherson-strut suspension system. A MacPhersonstrut suspension (see illustration) combines a coil spring and shock absorber into a strut assembly that requires only a beam-type lower control arm. Some vehicles with short-arm long-arm front suspension use either longitudinal or transverse torsion bars for the front springs. One end of the torsion bar is attached to the lower control arm, and the other end is anchored to the vehicle body or frame. As the tire and wheel move up and down, the torsion bar provides springing action by twisting about its long axis. Turning an adjustment bolt at one end of the torsion bar raises or lowers the vehicle RIDe height. See also Torsion bar. Most automobiles and many light trucks have coil springs at the rear. These may mount on the rear drive axle, on struts, or on various types of control or suspension arms in an independent suspension system. Some rear-drive vehicles have leaf springs at the rear. Others use transverse torsion bars.

What is Suspension?
Suspension is the term given to the system of springs, shock absorbers and linkages that connects a vehicle to its wheels and allows relative motion between the two.[1] Suspension systems serve a dual purpose contributing to the vehicle's roadholding/handling and braking for good active safety and driving pleasure, and keeping vehicle occupants comfortable and reasonably well isolated from road noise, bumps, and vibrations,etc. These goals are generally at odds, so the tuning of suspensions involves finding the right compromise. It is important for the suspension to keep the road wheel in contact with the road surface as much as possible, because all the forces acting on the vehicle do so through the contact patches of the tires. The suspension also protects the vehicle itself and any cargo or luggage from damage and wear. The design of front and rear suspension of a car may be different.

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BRAKING ASSEMBLY

Exploded view of the front disc brake assembly

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DETAILED BRAKING ASSEMBLY DESCRIPTION

The modern automotive brake system has been refined for over 100 years and has become extremely dependable and efficient. The typical brake system consists of disk brakes in front and either disk or drum brakes in the rear connected by a system of tubes and hoses that link the brake at each wheel to the master cylinder. Other systems that are connected with the brake system include the parking brakes, power brakebooster and the anti-lock system. When you step on the brake pedal, you are actually pushing against a plunger in the master cylinder, which forces hydraulic oil (brake fluid) through a series of tubes and hoses to the braking unit at each wheel. Since hydraulic fluid (or any fluid for that matter) cannot be compressed, pushing fluid through a pipe is just like pushing a steel bar through a pipe. Unlike a steel bar, however, fluid can be directed through many twists and turns on its way to its destination, arriving with the exact same motion and pressure that it started with. It is very important that the fluid is pure liquid and that there are no air bubbles in it. Air can compress, which causes a sponginess to the pedal and severely reduced braking efficiency. If air is suspected, then the system must be bled to remove the air. There are "bleeder screws" at each wheel cylinder and caliper for this purpose.

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On a disk brake, the fluid from the master cylinder is forced into a caliper where it presses against a piston. The piston, inturn, squeezes two brake pads against the disk (rotor), which is attached to the wheel, forcing it to slow down or stop. This process is similar to a bicycle brake where two rubber pads rub against the wheel rim creating friction.

With drum brakes, fluid is forced into the wheel cylinder, which pushes the brake shoes out so that the friction linings are pressed against the drum, which is attached to the wheel, causing the wheel to stop. In either case, the friction surfaces of the pads on a disk brake system, or the shoes on a drum brake convert the forward motion of the vehicle into heat. Heat is what causes the friction surfaces (linings) of the pads and shoes to eventually wear out and require replacement.

Let's take a closer look at each of the components in a brake system and see where other problems can occur...

Master Cylinder
The master cylinder is located in the engine compartment on the firewall, directly in front of the driver's seat. A typical master cylinder is actually two completely separate master cylinders in one housing, each handling two wheels. This way if one side fails, you will still be able to stop the car. The brake warning light on the dash will light if either side fails, alerting you to the problem. Master cylinders have become very reliable and rarely malfunction; however, the most common problem that they experience is an internal leak. This will cause the brake pedal to slowly sink to the floor when your foot applies steady pressure. Letting go of the pedal and immediately stepping on it again brings the pedal back to normal height.

Brake Fluid
Brake fluid is a special oil that has specific properties. It is designed to withstand cold temperatures without thickening as well as very high temperatures without boiling. (If the

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brake fluid should boil, it will cause you to have a spongy pedal and the car will be hard to stop.) Brake fluid must meet standards that are set by the Department of Transportation (DOT). The current standard is DOT-3, which has a boiling point of 460 F. But check your owners manual to see what your vehicle manufacturer recommends. The brake fluid reservoir is on top of the master cylinder. Most cars today have a transparent reservoir so that you can see the level without opening the cover. The brake fluid level will drop slightly as the brake pads wear. This is a normal condition and no cause for concern. If the level drops noticeably over a short period of time or goes down to about two thirds full, have your brakes checked as soon as possible. Keep the reservoir covered except for the amount of time you need to fill it and never leave a can of brake fluid uncovered. Brake fluid must maintain a high boiling point. Exposure to air will cause the fluid to absorb moisture, which will lower that boiling point. NEVER PUT ANYTHING BUT APPROVED BRAKE FLUID IN YOUR BRAKES. ANYTHING ELSE CAN CAUSE SUDDEN BRAKE FAILURE! Any other type of oil or other fluid will react with the brake fluid and very quickly destroy the rubber seals in the brake system causing brake failure.

Brake Lines
The brake fluid travels from the master cylinder to the wheels through a series of steel tubes and reinforced rubber hoses. Rubber hoses are used only in places that require flexibility, such as at the front wheels, which move up and down as well as steer. The rest of the system uses non-corrosive seamless steel tubing with special fittings at all attachment points. If a steel line requires a repair, the best procedure is to replace the complete line. If this is not practical, a line can be repaired using special splice fittings that are made for brake system repair. You must never use brass "compression" fittings or copper tubing to repair a brake system. They are dangerous and illegal.

OTHER COMPONENTS IN THE HYDRAULIC SYSTEM

Proportioning valve or Equalizer Valve


These valves are mounted between the master cylinder and the rear wheels. They are designed to adjust the pressure between the front and rear brakes depending on how hard you are stopping. The shorter you stop, the more of the vehicle's weight is transferred to the front wheels, in some cases, causing the rear to lift and the front to dive. These valves are designed to direct more pressure to the front and less pressure to the rear the harder you stop. This minimizes the chance of premature lockup at the rear wheels.

Pressure Differential Valve


This valve is usually mounted just below the master cylinder and is responsible for turning the brake warning light on when it detects a malfunction. It measures the pressure from the two sections of the master cylinder and compares them. Since it is mounted ahead of the proportioning or equalizer valve, the two pressures it detects

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should be equal. If it detects a difference, it means that there is probably a brake fluid leak somewhere in the system.

Combination Valve
The Combination valve is simply a proportioning valve and a pressure differential valve that is combined into one unit.

Electronic Brake Force Distribution


Newer cars use the antilock brake hardware and the onboard computer to replace these proportioning valve systems with a system called Electronic Brake force Distribution (EBD) in order to distribute the exact amount of pressure at each wheel to insure a balanced brake system.

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DISK BRAKES

The disk brake is the best brake we have found so far. Disk brakes are used to stop everything from cars to locomotives and jumbo jets. Disk brakes wear longer, are less affected by water, are self adjusting, self cleaning, less prone to grabbing or pulling and stop better than any other system around. The main components of a disk brake are the Brake Pads, Rotor, Caliper and Caliper Support.

Brake Pads
There are two brake pads on each caliper. They are constructed of a metal "shoe" with the lining riveted or bonded to it. The pads are mounted in the caliper, one on each side of the rotor. Brake linings used to be made primarily of asbestos because of its heat absorbing properties and quiet operation; however, due to health risks, asbestos has been outlawed, so new materials are now being used. Brake pads wear out with use and must be replaced periodically. There are many types and qualities of pads available. The differences have to do with brake life (how long the new pads will last) and noise (how quiet they are when you step on the brake). Harder linings tend to last longer and stop better under heavy use but they may produce an irritating squeal when they are applied. Technicians that work on brakes usually have a favorite pad that gives a good compromise that their customers can live with. Brake pads should be checked for wear periodically. If the lining wears down to the metal brake shoe, then you will have a "Metal-to-Metal" condition where the shoe rubs directly against the rotor causing severe damage and loss of braking efficiency. Some brake pads come with a "brake warning sensor" that will emit a squealing noise when the pads are worn to a point where they should be changed. This noise will usually be heard when your foot is off the brake and disappear when you step on the brake. If you hear this noise, have your brakes checked as soon as possible.

Rotor
The disk rotor is made of iron with highly machined surfaces where the brake pads contact it. Just as the brake pads wear out over time, the rotor also undergoes some wear, usually in the form of ridges and groves where the brake pad rubs against it. This wear pattern exactly matches the wear pattern of the pads as they seat themselves to the rotor. When the pads are replaced, the rotor must be machined smooth to allow the new pads to have an even contact surface to work with. Only a small amount of material can be machined off of a rotor before it becomes unusable and must be replaced. A minimum thickness measurement is stamped on every rotor and the technician doing the brake job will measure the rotor before and after machining it to make sure it doesn't go below the legal minimum. If a rotor is cut

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below the minimum, it will not be able to handle the high heat that brakes normally generate. This will cause the brakes to "fade," greatly reducing their effectiveness to a point where you may not be able to stop!

Caliper & Support


There are two main types of calipers: Floating calipers and fixed calipers. There are other configurations but these are the most popular. Calipers must be rebuilt or replaced if they show signs of leaking brake fluid. Single Piston Floating Calipers are the most popular and also least costly to manufacture and service. A floating caliper "floats" or moves in a track in its support so that it can center itself over the rotor. As you apply brake pressure, the hydraulic fluid pushes in two directions. It forces the piston against the inner pad, which in turn pushes against the rotor. It also pushes the caliper in the opposite direction against the outer pad, pressing it against the other side of the rotor. Floating calipers are also available on some vehicles with two pistons mounted on the same side. Two piston floating calipers are found on more expensive cars and can provide an improved braking "feel". Four Piston Fixed Calipers are mounted rigidly to the support and are not allowed to move. Instead, there are two pistons on each side that press the pads against the rotor. Four piston calipers have a better feel and are more efficient, but are more expensive to produce and cost more to service. This type of caliper is usually found on more expensive luxury and high performance cars.

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DRUM BRAKES

So if disk brakes are so great, how come we still have cars with drum brakes? The reason is cost. While all vehicles produced for many years have disk brakes on the front, drum brakes are cheaper to produce for the rear wheels. The main reason is the parking brake system. On drum brakes, adding a parking brake is the simple addition of a lever, while on disk brakes, we need a complete mechanism, in some cases, a complete mechanical drum brake assembly inside the disk brake rotor! Parking brakes must be a separate system that does not use hydraulics. It must be totally mechanical, but more on parking brakes later. Drum brakes consist of a backing plate, brake shoes, brake drum, wheel cylinder, return springsand an automatic or self-adjusting system. When you apply the brakes, brake fluid is forced under pressure into the wheel cylinder, which in turn pushes the brake shoes into contact with the machined surface on the inside of the drum. When the pressure is released, return springs pull the shoes back to their rest position. As the brake linings wear, the shoes must travel a greater distance to reach the drum. When the distance reaches a certain point, a self-adjusting mechanism automatically reacts by adjusting the rest position of the shoes so that they are closer to the drum.

Brake Shoes
Like the disk pads, brake shoes consist of a steel shoe with the friction material or lining riveted or bonded to it. Also like disk pads, the linings eventually wear out and must be replaced. If the linings are allowed to wear through to the bare metal shoe, they will cause severe damage to the brake drum.

Backing Plate
The backing plate is what holds everything together. It attaches to the axle and forms a solid surface for the wheel cylinder, brake shoes and assorted hardware. It rarely causes any problems.

Brake Drum
Brake drums are made of iron and have a machined surface on the inside where the

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shoes make contact. Just as with disk rotors, brake drums will show signs of wear as the brake linings seat themselves against the machined surface of the drum. When new shoes are installed, the brake drum should be machined smooth. Brake drums have a maximum diameter specification that is stamped on the outside of the drum. When a drum is machined, it must never exceed that measurement. If the surface cannot be machined within that limit, the drum must be replaced.

Wheel Cylinder
The wheel cylinder consists of a cylinder that has two pistons, one on each side. Each piston has a rubber seal and a shaft that connects the piston with a brake shoe. When brake pressure is applied, the pistons are forced out pushing the shoes into contact with the drum. Wheel cylinders must be rebuilt or replaced if they show signs of leaking.

Return Springs
Return springs pull the brake shoes back to their rest position after the pressure is released from the wheel cylinder. If the springs are weak and do not return the shoes all the way, it will cause premature lining wear because the linings will remain in contact with the drum. A good technician will examine the springs during a brake job and recommend their replacement if they show signs of fatigue. On certain vehicles, the technician may recommend replacing them even if they look good as inexpensive insurance.

Self-AdjustingSystem
The parts of a self adjusting system should be clean and move freely to insure that the brakes maintain their adjustment over the life of the linings. If the self adjusters stop working, you will notice that you will have to step down further and further on the brake pedal before you feel the brakes begin to engage. Disk brakes are self adjusting by nature and do not require any type of mechanism. When a technician performs a brake job, aside from checking the return springs, he will also clean and lubricate the self adjusting parts where necessary.

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PARKING BRAKES

The parking brake (a.k.a. emergency brake) system controls the rear brakes through a series of steel cables that are connected to either a hand lever or a foot pedal. The idea is that the system is fully mechanical and completely bypasses the hydraulic system so that the vehicle can be brought to a stop even if there is a total brake failure. On drum brakes, the cable pulls on a lever mounted in the rear brake and is directly connected to the brake shoes. this has the effect of bypassing the wheel cylinder and controlling the brakes directly. Disk brakes on the rear wheels add additional complication for parking brake systems. There are two main designs for adding a mechanical parking brake to rear disk brakes. The first type uses the existing rear wheel caliper and adds a lever attached to a mechanical corkscrew device inside the caliper piston. When the parking brake cable pulls on the lever, this corkscrew device pushes the piston against the pads, thereby bypassing the hydraulic system, to stop the vehicle. This type of system is primarily used with single piston floating calipers, if the caliper is of the four piston fixed type, then that type of system can't be used. The other system uses a complete mechanical drum brake unit mounted inside the rear rotor. The brake shoes on this system are connected to a lever that is pulled by the parking brake cable to activate the brakes. The brake "drum" is actually the inside part of the rear brake rotor. On cars with automatic transmissions, the parking brake is rarely used. This can cause a couple of problems. The biggest problem is that the brake cables tend to get corroded and eventually seize up causing the parking brake to become inoperative. By using the parking brake from time to time, the cables stay clean and functional. Another problem comes from the fact that the self adjusting mechanism on certain brake systems uses the parking brake actuation to adjust the brakes. If the parking brake is never used, then the brakes never get adjusted.

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POWER BRAKE BOOSTER

The power brake booster is mounted on the firewall directly behind the master cylinder and, along with the master cylinder, is directly connected with the brake pedal. Its purpose is to amplify the available foot pressure applied to the brake pedal so that the amount of foot pressure required to stop even the largest vehicle is minimal. Power for the booster comes from engine vacuum. The automobile engine produces vacuum as a by-product of normal operation and is freely available for use in powering accessories such as the power brake booster. Vacuum enters the booster through a check valve on the booster. The check valve is connected to the engine with a rubber hose and acts as a one-way valve that allows vacuum to enter the booster but does not let it escape. The booster is an empty shell that is divided into two chambers by a rubber diaphragm. There is a valve in the diaphragm that remains open while your foot is off the brake pedal so that vacuum is allowed to fill both chambers. When you step on the brake pedal, the valve in the diaphragm closes, separating the two chambers and another valve opens to allow air in the chamber on the brake pedal side. This is what provides the power assist. Power boosters are very reliable and cause few problems of their own, however, other things can contribute to a loss of power assist. In order to have power assist, the engine must be running. If the engine stalls or shuts off while you are driving, you will have a small reserve of power assist for two or three pedal applications but, after that, the brakes will be extremely hard to apply and you must put as much pressure as you can to bring the vehicle to a stop.

Anti-Lock Brakes (ABS)


The most efficient braking pressure takes place just before each wheel locks up. When you slam on the brakes in a panic stop and the wheels lock up, causing a screeching sound and leaving strips of rubber on the pavement, you do not stop the vehicle nearly as short as it is capable of stopping. Also, while the wheels are locked up, you loose all steering control so that, if you have an opportunity to steer around the obstacle, you will not be able to do so. Another problem occurs during an extended skid is that you will burn a patch of rubber off the tire, which causes a "flat spot" on the tread that will produce an annoying thumping sound as you drive. Anti-lock brake systems solve this lockup problem by rapidly pumping the brakes whenever

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the system detects a wheel that is locked up. In most cases, only the wheel that is locked will be pumped, while full braking pressure stays available to the other wheels. This effect allows you to stop in the shortest amount of time while maintaining full steering control even if one or more wheels are on ice. The system uses a computer to monitor the speed of each wheel. When it detects that one or more wheels have stopped or are turning much slower than the remaining wheels, the computer sends a signal to momentarily remove and reapply or pulse the pressure to the affected wheels to allow them to continue turning. This "pumping" of the brakes occurs at ten or more times a second, far faster then a human can pump the brakes manually. If you step on the brakes hard enough to engage the anti-lock system, you may feel a strong vibration in the brake pedal. This is a normal condition and indicates that the system is working, however, it can be disconcerting to some people who don't expect it. If your vehicle has anti-lock brakes, read your owner's manual to find out more about it. The system consists of an electronic control unit, a hydraulic actuator, and wheel speed sensors at each wheel. If the control unit detects a malfunction in the system, it will illuminate an ABS warning light on the dash to let you know that there is a problem. If there is a problem, the anti-lock system will not function but the brakes will otherwise function normally.

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FINDINGS

On the completion of the training, the technical aspects that were are listed below 1. Lifting Point 1.1. Safety stand point and lift up point(Front) 1.2. Safety stand point and lift up point(Rear) 2. Garage Jack Point 2.1. Garage Jack point(Front) 2.2. Garage Jack point(Front) 3. Turbochargers 3.1. Fuel 3.2. Consult checking system 3.3. Body control system components parts location 4. Components parts location 4.1. Arrangement of combination meter 5. FRONT hydraulic piping 5.1. Brake Boosters 5.2. Front Disc Brake 5.3. ABS actuator and electric unit 5.4. Connectors 5.5. Rear Drum Brakes 6. Brake piping 6.1. Brake booster 6.2. Master cylinder 6.3. Brake tube 6.4. Connector 6.5. ABS(actuator and electronic unit) 6.6. Lock plate 6.7. Brake hose 6.8. Union Bolt 6.9. Copper washer 6.10. 2 Front brake hose 6.11. 2 Rear brake tube 7. Brake booster : The brake booster equipped with brake assist is adapted for all vehicles 7.1. Master cylinder assembly 7.2. Brake booster 7.3. Lock Nut 7.4. Clevis 7.5. Gasket 8. Brake master cylinder 8.1. Sub Tank Cap

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8.2. Brake Fluid level switch 8.3. Sub Tank 8.4. Clamp 8.5. Hose 8.6. Reservoir Tank 8.7. Cylinder Body 8.8. Pin 8.9. Secondary Piston Assembly 8.10. Drain Plug washer 8.11. Stopper Cap 8.12. Seal 8.13. Primary Piston Assembly 9. Front Disc Brake 10. Rear Drum Brake 11. Front Suspension Member 12. Stabilizer 13. Shock Absorber 14. Rebound Spring 15. High Caster Geometry

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CONCLUSION

The training was of great value which provided in depth knowledge of the subject Mechanical Engineering. Learning the concepts with an organization like NISSAN was very beneficial and the innovative technology used by NISSAN in Evalia was very amazing. The topics were understood very well with their practical application and working on them was a good job. The training was completed successfully with grasping the concepts of Mechanical Engineering with new technologies and practically working on them.

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REFERENCES

1. The books which were followed are M. L. Mathur and F. S. Mehta Thermal Engineering R. K. Purohit 2. Websites which were followed are www.google.com www.nissanevalia.co.in autos.maxabout.com

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