DETAILED SYLLABUS ONE YEAR DIPLOMA IN AUTOMOBILE TECHNICIAN

1st Year IA Max. Marks 25 25 25 25 25 25 25 University Examinations Max. Min. Marks Pass 75 35 75 75 75 75 75 75 35 35 35 35 35 35 Total Marks 100 100 100 100 100 100 100 Min. Pass 35 35 35 35 35 35 35 Total Credits

Subject Code DC101 DAT102 DAT103 DAT104 DAT105 DAT106 DAT107

Subject Title LIFE SKILLS AUTOMOBILE CHASSIS AND BODY AUTOMOBILE TRANSMISSION SYSTEM AUTOMOBILE POWER PLANT AUTOELECTRICAL AND ELECTRONICS AUTOMOTIVE ENGINES (Practical) BASIC FOUR WHEELER SERVICING (Practical)

Credits 4 6 6 6 6 6 6 40

TEXT BOOK
AUTOMOBILE ENGINEERING VOL1 & VOL 2 DR KIRPAL SINGH PUBLISHED BY STANDARD PUBLICATIONS NEWDELHI.

REFERENCE BOOKS
AUTOMOTIVE MECHANICS BY S.SRINIVASAN PUBLISHED BY TATA MCGRAW-HILL AUTOMOBILE ENGINEERING BY R.B GUPTA PUBLISHED BY SATYAPRAKASHAN

THEORY PAPER -1-AUTOMOBILE CHASSIS AND BODY

1. Introduction to Automobile Automobile Component of Automobile 2. Chassis Chassis Construction Details Frame Different types and constructional details 3. Body Requirements Materials And Constructional details Protection Of Body 4. Suspension system Suspension in Automobile and considerations Suspension springs Shock Absorber suspension systems- Rigid axle and independent Independent -Different types Interconnected suspension systems Air suspension Hydrolastic suspension Hydra gas interconnected suspension 5. Wheels and Tires Wheel-Different types and Constructional details Tire- Requirements and properties Types of Tires Tube tire ,Tubeless tire and special types of tires Types of carcass Different constructions and designations of tires Factors affecting tire life 6. Brakes Requirements, Principle. Fading and skidding Types of brake Drum brake- Types of brake lining arrangement

Disc brake Types and Construction Comparison of disc and drum brakes Mechanical brakes Hydraulic brakes-principle and working Brake adjuster and bleeding Brake fluid

7. Steering System And Front Axles Front Axle Stub axle Different Types Steering geometry and steering angle Ackermann Mechanism Steering linkages for rigid axle and independent suspension Steering gear Different types Steering columns Power steering Adjustments and Alignment in steering THEORY PAPER -2- AUTOMOBILE TRANSMISSION SYSTEM 1. Clutch Principle and requirements Types of clutches friction and fluid fly wheel Friction clutches- Dry and Wet clutches Dry friction clutches working and types Wet clutch Clutch operating mechanisms Components of clutches and construction details Fluid flywheel 2. Transmission System Requirements and functions Types of transmission manual and Automatic Manual Sliding mesh gear box Constant mesh Synchromesh Selector mechanism Transfer box Automatic Epicyclical gearbox Torque converter Freewheel unit and over drives Automatic transmission system

Continuously variable transmission

3. Driveline Propeller shaft-constructional details Universal joints-different types ,Functions Construction and working Differential unit or final drive 4. Rear axle Forces And torques on rear axle Rear axle drives-Hotchkiss and torque tube drive Rear axle supports semi floating, full floating and three-quarter floating Rear axle cases THEORY PAPER 3-AUTOMOBILE POWER PLANT

1. Engines Basic engine terminology Engine Cycles-auto and diesel Working of I.C engines [S.I and C.I] S.I engines Two stroke and four stroke C.I engines Four stroke engines Comparison of petrol and diesel engines Firing order, Square engine Different types of engine Wankel engine HCCI engines Electric vehicle Hybrid vehicle Wheel motors , fuel cell vehicle and air car 2. Constructional details of automobile power plant Cylinder block and crank case Cylinder head Oil pan Manifolds Gaskets Cylinder liner Piston Piston rings-Compression and oil control rings Connecting rod Piston pin Crank shaft

Fly wheel and vibration damper Bearings Valves and valve timing Mufflers

3. Engine cooling and lubrication system Purpose of cooling Types of cooling system air and liquid Liquid Thermosyphon system and pump circulation system Components radiator, pressure cap with expansion reservoir Thermostat, water pump and cooling fan Temperature Gauges Objects of lubrication Lubrication system petrol splash, pressure, dry sum and Pre-lubrication system Components-Oil strainers ,oil filters, oil coolers, oil pumps Types of oil pumps Oil pressure gauge, oil level indicator Gearbox lubrication, steering box, rear axle, wheel hub and chassis lubrication Lubricants-Types Requirements Oil additives Crank case Ventilation 4. Engine tests Types of engine tests Fault finding testes-vacuum and cylinder compression tests Measurements of brake power and dynamo meters Morse test and mechanical efficiency Fuel consumption measurements, air consumption measurements Oil consumption and heat balance sheet 5. Fuel Properties of engine fuel Types of fuel Properties of conventional fuels Alternative fuels

6. Petrol engine fuel supply system Types of fuel supply system Components of fuel supply system

Different carburetors and working Petrol injection- type Super charger and turbo charger

7 Diesel engine fuel supply system Different types Components Filter , air cleaner , feed pump , fuel injection pump , injection pump , governors Individual pump and common rail fuel injection system Turbo and supercharging in diesel engine Glow plug 8 Combustion and details Combustion in SI engines Destination in S.I engines Pre ignition Combustion chambers for S.I engines Combustion in C.I engines Diesel knock Compression between detonation and diesel knock Combustion chambers for C.I engines 9 Performance and emission control Losses in engine Fuel consumption and efficiency Performance and atmospheric conditions on engines Improvements of engine performance

THEORY PAPER 4 -AUTOELECTRICAL AND ELECTRONICS

Ignition system Requirements of ignition system Battery ignition system Sparkplug-different types Magneto ignition system Comparison between Battery and magneto ignition system Electronic ignition System 2. Storage batteries

 Lead acid battery constructional details Tastings in a lead acid battery Battery troubles and maintenance Precautions during handling of battery Chemical reaction in lead acid battery Alkaline, zinc- air and lithium ion battery 3 Charging System Charging circuit and requirements Generator Cut out relay and regulator Alternator Comparison between alternator and generator 4 Starting system Starting motors-Constructional details Types of starting drives Starting motor switches

5 Lighting system and accessories Head lights Aiming of head lights The horn Speedometer, odometer, tachometer Heating and air conducting Power window

PRACTICAL-1-AUTOMOTIVE ENGINES

EXPERIMENT INDEX
1. SAFETY RULES 2. AUTOMOBILE TOOLS 3. AIR FILTER 4. INJECTOR 5. FUEL FEED PUMP 6. WATER PUMP 7. FUEL FILTER 8. FUEL INJECTION PUMP 9. SU CARBURRETTOR 10. SOLEX CARBURRETTOR 11. VALVE TAPPET CLEARANCE 12. REMOVE AND REFIT OF VALVES 13. VALVE LAPPING 14. ENGINE OIL AND FILTER CHANGE 15. PISTON AND CONNECTING ROD ASSEMBLY 16. REPAIR AND OVERHAULING OF ENGINE SYSTEM (PETROL & DIESEL) 17. GEAR TYPE OIL PUMP 18. ROTOR TYPE OIL PUMP 19. VALVE TIMING 20. AC FUEL PUMP 21. RADIATOR AND THERMOSTAT VALVE

EXPERIMENT 1 -SAFETY RULES Aim:-To avoid accident follow the safety rules 1.Work quietly and give attention to the job you are doing 2.Keep your tools and equipments under control 3.Keep jack handles out of the way stand creeper against the wall when not in use. 4. Never indulge in casual or foolish action. 5. Never put screw drives on other sharp object in your pocket. you could cut your self or damage the car 6.Make sure your cloths are right for the job 7.Do not wear any rings, Watches or bracelets when working around moving machinery or electrical equipments 8. Wipe oil and grease of your hands and tools you need a good grip on tools and parts. 9. If you spill oil, grease, any other liquids on the floor, clean it up . Help prevent in jury from slips and falls. 10. Never use compressed air to blow dirt from your cloths. 11.Always wear eye protection when liquid spry or particles flying about 12.When out for spark flying from a grinding wheel or a welding job 13.When using chemicals wear glues and goggles 14.When used a floor jack position it property . it must not slip out. 15. Always use the right tool for the job the wrong tools could damage the part 16.Keep you hands away from the engine fan and drive belt

EXPERIMENT- 2- AUTOMOBILE TOOLS

1. 2. 3. 4. 5. 6. 7. 8. 9.

Screw Drivers Spanners, wrenches etc Pliers Hammers Chisels Files Hacksaw Cleaning tools Taps and Dies

10. 11. 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Tools for tubes. Drilling Machine Reamers Soldering Tools Grinder Bench Vice Measuring Tools Chain Pulley Block Lifting jacks and axle stands Lubricating equipment Battery testing and charging equipment Hydraulic lift or service ramp Tools for tyres Wheeler balancing equipment Brake testing equipment Ring remover Electric welding set Fire extinguisher Piston grove cleaner Air compressor and pressure gauge Spark plug testing and cleaning equipments

EXPERIMENT -3- REPAIR AND OVERHAULING OF ENGINE SYSTEM (PETROL/DIESEL)

Aim: - Dismantle and assemble an unserviceable engine Tools required :Spanner set , hammer , pliers , feeler gauge , filter wrench ,pulley puller , torque wrench , piston ring compressor , piston ring expander , screw driver , spark plug spanner Materials required: Kerosene oil, engine oil, Emery paper &Cotton waste Procedure Dismantling 1.Drain the engine oil 2.Drain the radiator 3.Remove the radiator 4.Disconnect all electrical connections 5.Disconect fuel lines 6.Remove air cleaner

7.Disconnect the accelerator linkages 8.Loosen the engine mounting bolts. 9.Place and fix the crane chain in the proper place of the engine 10.remove the engine from the vehicle 11.Place the engine at a work bench 12.Remove the fan belt & fan 13.Remove the carburetor & spare plug 14.Remove the fly wheel 15.Remove the dynamo/alternator 16.Remove the self starter 17.Remove the water pump assembling 18.Remove the inlet & exhaust manifold 19.Remove the valve covers 20.Remove the rocker assembly from the cylinder head 21.Remove the push rods 22.Remove the valve tappet 23.Remove the cylinder head mounting bolt & remove the cylinder head 24.Remove the cylinder head gasket 25.Remove crank shaft pulley using the special puller 26.Remove the timing cover 27.Remove the timing gear & chain. (Note down the timing marks) 28.Remove the cam shaft 29.Remove the oil sump 30.Remove the oil pump & strainer 31.Remove the oil filter 32.Remove the connecting rod caps 33.Remove the piston & connecting rod from engine 34.Remove the main bearing caps 35.Remove the flywheel housing 36.Remove the crank shaft. Assembling 1.Clean all the parts 2.Clean the engine block and keep the block up side down 3.Place the upper main bearings shell on the engine block & upper thrust washer 4.Place the crank shaft on the engine block 5.Fix the main bearing cap with lower bearing shell & thrust washers. 6. Tighten the main bearing cap bolt at specified torque 7.Check the free rotation at the crank shaft after tightening 8.Fix the timing plate 9.Fix the flywheel housing 10.Fix the flywheel and tighten

EXPERIMENT -4- PISTON AND CONNECTING ROD ASSEMBLY

Aim: - Dismantle, assemble and checking the piston & connecting rod assembly Tools required: - Spanner set, Screw driver, plier, piston ring remover and piston ring compressor Materials required: - Cotton waste, kerosene & Piston ring.

Procedure:Dismantling 1. Remove the oil sump and oil pump 2. Remove the cylinder head from cylinder block 3. Clean and check for ridge formation of all cylinders. 4. Turn the crankshaft till the piston comes at B.D.C 5. Remove the bolts/ nuts of the connecting rod 6. Tap the connecting rods cap with a mallet and remove the cap along with the bearing shell from the connecting rod 7. Tap the connecting rod with a wooden block and remove connecting rod piston assembly from cylinder block 8. Place the upper & lower bearing shell in the respective position in the connecting rod & cap. 9. Repeat the relevant steps to remove all the piston 10. Clean all the cylinders. 11. Hold the connecting rod on the vice. Insert the ring expanders opening in the ring grove & open the by pressing the expanders handle and remove the ring from the piston. 12. Repeat the above steps and remove the entire ring. 13. Remove the Circlip of piston pin using a Circlip plier 14. Remove the piston pin with the help of a draft and hammer. Repeat the steps to all the pistons Cleaning & Inspection 1. Remove the carbon deposits from the piston ring grooves. 2. Clean the piston using kerosene oil. 3. Check visually the piston skirt and crown for scuffing, crack, scoring etc. 4. Check the bearings, piston ring for wearing. Assembling:1. Fit one Circlip in the groove of the piston 2. Align the connecting rod small and bore and the gudgeon pin bore of the piston 3. Tap the gudgeon pin in the piston with the help of a mallet .Fit another Circlip on the groove 4. Repeat the above steps to all the pistons and rods. 5. Hold the piston ring in the ring expander and fit it in the piston groove. 6. Fit the entire ring to all the pistons. 7. Place the upper and lower bearing shells in all the connecting rods and caps and keep them in proper order.

EXPERIMENT 5- VALVE TIMING Aim: - Set the valve timing in the given Maruti engine Tools required: - Spanner set, screw driver, hammer, Plier and feeling gauge

Procedure:1. Rotate the flywheel, Bring piston number one on TDC 2. Rotate the cam shaft 3. Bring the key way to the top of the camshaft 4. Fire up the cam shaft drive too that pulley with its punch make to more the index mark in the uppermost position 5. Lock the camshaft drive toothed pulley at this position 6. Fix up the belt by hand so that the tensioner in the timing housing 7. Tighten the bolt by hand so that the tensioner can be moved by head 8. Rotate the camshaft toothed pulley. 9. Align the cam shaft key mark, punch mark, on the cam shaft sprocket and the arrow mark on the timing housing fall on one line. 10. Rotate the crank shaft in the clock wise direction, so that its key way and mark the crank shaft toothed pulley are in line with arrow mark on the housing. 11. Put the belt tensioner with push gauge to the pressure of 3 kg 12. After setting the belt tensioner, rotate the crank shaft in clock wise direction 13. Check the marks and crank shaft key way locate them selves on the same straight line 14. If they do not line up straight, repeat the procedure to satisfy the requirement 15. Tighten the bolt and not of the tensioner with a torque of 2 kg 16.Fix up the timing cover with a new gasket and oil seal and adjust the tappet.

EXPERIMENT 6- AC FUEL PUMP

Aim: - Dismantle and assemble a Ac fuel pump Tools required: - Spanner set, screw driver & Plier Material required: - Kerosene oil & cotton waste Procedure Dismantling 1.Disconect the inlet fuel line from the tank to the fuel pump 2.Remove the out let pipe connection which connects the fuel pump 3.Remove the fuel pump mounting bolts

4.Remove the fuel pump with the gasket 5.Make an inline on the valve housing cover , pump chamber and bottom cover, to ensure the same position of the above parts when assembling back 6.Remove the screws and washer of the pump body 7.Separate the pump chamber and bottom cover 8.Remove the housing cover screw , then remove the housing cover 9.Remove the valve housing gasket 10. Remove the strainer 11.Remove the inlet valve set 12. Remove the lever pin plug 13.Remove the com lever return spring & cam lever 14.Remove diaphragm assembly 15.Remove diaphragm return spring lock & diaphragm return spring 16.Clean all metal parts by kerosene oil. Assembling:1. Fix the diaphragm return on the diaphragm and lock the spring with diaphragm lock 2.Align the fuel pump lever centre hole and bottom chamber cam lever pin boss 3. Insert the cam lever pin. 4. Lock the com lever pin by retainer pin lock 5. Fix the lever pin plug 6.Fix the fuel pump lever with the diaphragm spindle 7. Install the out let valve set 8. Install the inlet valve set 9. Place the strainer 10.Place the valve housing gaskets 11.Fix the housing covers 12.Align the mark lines of the valve housing cover , pump champers and bottom cover to position these part 13. Fix the pump body screws, while fixing them , first tighten up low threads by hand , them by spanner 14 Test the pump for suction & delivery . 15. Fix the new gasket on the mounting flange 16.Position the fuel pump on the cylinder block. 17. Fix the fuel pump mounting bolts and tighten. 18 Connect the out let pipe connection 19.Connect the inlet pipe connection which connects the fuel pump & fuel tank 20.Start the engine & check for fuel leakage.

EXPERIMENT -7- AIR FILTER

Aim:-Service air cleaner

Tools required:-Spanner, plier and screwdriver Materials required: - Kerosene oil and cotton waste, light duty type air cleaner Procedure:1. Unscrew the bolt or wing nut of the oil cleaner cover with the help of a plier 2.Remove the top cover with the fitter elements and gaskets 3.Loosen the nut fixing the air cleaner on the inlet manifold 4. Remove the bottom case of the air cleaner 5.Clean the air cleaner housing and cover with cloth 6.Inspect the filter element .If it is clogged , replace the same 7.Blow off the dust from the inside element by compressed air 8.Check the plastic or rubber gasket ring for smoothness which act as a gasket Installation 1.Place the New / old element in the lower housing 2.Put the plastic gasket ring on the element 3.Put the top cover on the element 4.Tighten the wing nut with the help of a plier 5.Test the air cleaner by starting the engine for smooth running 2. Oil bath type 1. Open the bonnet of the vehicle 2.Unscrew the bolt on the top cover by plier 3.Remove the top cover with the element and gaskets 4. Loosen the nut fixing clip of the lower portion of the air cleaner 5.remove the bowl from inlet manifold 6.Drain the oil from the bowl and clean the sludge 7.Clean the air cleaner element using kerosene oil until all the dust in removed from the wire mesh 8.Blow the compressed air under reduced pressure over the wire mesh from the opposition side and dry the elements 9.Clean the bottom case of the air cleaner 10.Check the gasket ring and clean it 11. Mount the bowl on the engine manifold 12. Refill the air cleaner bowl up to the oil level mark with clean, recommended grade of oil 13.Place the gasket & install the element in the housing bowl. 14. Place the gasket ring & fit the cover by tightening the wing not 15.Start the engine and check the performance of the engine for smooth running

EXPERIMENT -8- INJECTOR

Aim: - Dismantle, assemble, and testing a fuel injector. Tools required: - Spanner set, screw driver, plier, injector cleaning tools, and injector testing equipment. Materials required:-Diesel oil, emery paper and cotton waste

Procedure:Dismantling 1.Remove overflow line of injector 2.Remove the high pressure line 3. Remove the injector clamp & take out injector 4. Clean the nozzle tip and tip and wipe off the dirt from the injectors 5.Hold the injector in injector position 6.Unscrew nozzle cap nut & remove the cap nuts 7.Remove nozzle, intermediate washer, pressure bolt, spring & shims 8.Clean all components Assembling 1. Hold nozzle body in inverted position on vice place shim, spring , pressure bolt , intermediate washer and nozzle with needle in nozzle body. 2. Tighten the nozzle cap nut by hand and centralize the nozzle. Then tight the nozzle cap nut Testing 1.Fit injector on injector tester. 2. Filter oil in container 3.Close shut valve knob 4.Operate hand lever as fast as possible and observe that test oil is sprayed through nozzle 5.Open the shut off valve knob 6.Operate hand laver & Observe the maximum pressure from gauge at which test oil sprays out of nozzle 7.If the pressure does not match with manufactures then adjust it with a shin 8.Observe that the test oil is sprayed from the holes of nozzle. 9. Remove injector from injector tester 10.Fit injector on engine with new seating washer 11.Connect high pressure pipe 12.Connect over flow pipe

EXPERIMENT 9- ENGINE OIL AND FILTER CHANGE

Aim: - Change the engine oil and oil filters Tools required: - Oil filter wrench Materials required: - Engine oil, oil filter and cotton waste Procedure:1.Drain engine oil by removing drain plug 2.After draining oil, wipe draining plug clean. Reinstall draining plug, and tighten it

securely. 3. Loosen oil filter by using oil filter wrench 4.Screw new filter on oil filter stand by hand until filter o ring contacts mounting surface 5.Tighten filter 3/2 torn from the point of contact with mounting surface using an oil filter wrench 6.Refill oil until oil level is brought to full level mark on dipstick 7.Start the engine and run it for three minutes. Stop it and wait another 5 minutes before checking oil level. Add oil, as necessary, to bring oil level to full level mark on dipstick. 8. Check oil filter and drain plug for oil for leakage.

EXPERIMENT -10- FUEL INJECTION PUMP

Aim: - To dismantle and assemble the fuel injection pump Tools Required -Spanner, Screw driver, etc Procedure 1. Firstly disconnect the connection of fuel filter, fuel injector to the FI pump. 2. Then remove the FIP from the engine by using spanner 3.Remove the hand primer and side cover and pulley cover. 4. Remove the governor unit and bearing seat of cam 5.Remove the spring lock and take out spring plunger and toothed sleeve. 6. Loose the barrel locking screw and take out the barrel 7.Take out the rack from seat 8.Take out the cam shaft and tappet 9. Check the parts to damage and repair the damage parts 10.Placed the tooth rack on the seat 11. Place the barrel in the seat and lock in with seat 12.Place the toothed sector with sleeve and plunger 13. Place the retaining spring seat and spring 14.place the tappet and cam shaft 15. Lock the spring with plunger 16. Assemble the governor unit and refit on the fuel injection pump 17. Place the bearing seat of cam shaft of both sides. 18. Refit the hand primer and side cover of fuel injection pump 19. Fill the oil at specified level 20. Refit the fuel injection pump on the engine 21. The work is completed

EXPERIMENT -11- FUEL FEED PUMP

Aim: - Dismantle and assemble the fuel feed pump Tools required: - Spanner set, screw driver, plier & mallet Materials required: - Kerosene oil, cotton waste Procedure:Dismantling 1.Disconect the fuel lines of the feed pump 2.Remove feed pump assembly from fuel injection pump 3. Remove filter housing by loosening the clamping nut screw & clip along with spring, filter and washer 4.Remove snap ring and take out roller tappet assembly of the feed pump 5. Remove screw plug and washer and take out plunger spindle with return spring 6.Remove hand priming pump and washer 7.Remove screw plug, washer and remove valves, along with springs 8.Remove roller pin & roller 9.Remove slider, tappet and spring. Cleaning & Inspection 1.Clean all parts of fuel feed pump with kerosene or diesel 2. Check all parts for wear & replace it required 3.Check tension of all the springs and replace if necessary 4.check valve seats 5.Check washer & replace if necessary Assembling 1.Assemble roller tappet assembly in housing and secure it by snap ring 2.Assmble spindle plunger assembly & tighten screw plug 3.Place valves on its seat along with spring 4.Tishten hand priming pump & screw plug 5.Fit the filter assembly by locking clamp nut 6.Fitthe feed pump on F.I.P 7.Tighten feed pump mounting screw uniformly 8.Connect all the fuel lines 9.Check for operation of pump by hand priming pump

EXPERIMENT 12- WATER PUMP

Aim: - Dismantle and assemble the given water pump Tools required: - Double end spanner set, Ring spanner set, screw driver, hammer and puller Material required:-Kerosene oil, cotton waste and gaskets. Procedure:Dismantling:1.Remove the fan belt and fan from the water pump 2.Remove the water pump pulley hub nut

3.Remove the water pump pulley hub use a puller 4. Remove the water pump rear cover. 5. Unscrew the oil seal holder and remove the oil seal slims and gasket 6. Place the water pump housing on support and press out the water pump shaft with the bearings assembly from the impeller 7.Remove the inner oil seal from the housing. 8. Remove the outer race of the bearing from the housing with the help of a drift and hammer 9.Remove the water seal, from the water pump housing Cleaning& inspections 1. Clean all parts 2. Inspect the following parts visually for any crack or damage, Water pump shaft, bearing, water seal, impeller, Water pump housing. Assembly 1. Press the bearings on the water pump shaft. 2. Press the water pump pulley hub on the shaft 3.Fit the oil seal in the water pump housing, use a drift 4.Fit the water seal in the water pump housing, use drift 5.Press the shaft assembly in the pump housing 6.Press the impeller on the water pump shaft 7.Checkthe free rotation of impeller & Water pump shaft 8.Fit the rear cover with a new gasket 9.Fix the water pump on the engine 10.Fit the fan on the water pump pulley hub 11. Refit the belt and check the correct tension. 12. Start the engine and check the water pump working

EXPERIMENT -13- GEAR TYPE OIL PUMP

Aim: - Dismantle and assemble a gear type oil pump Tools required: - Ring Spanner, double end spanner, screw driver , feeler gauge , hammer and gear puller Material required: - Kerosene oil, cotton waste and gaskets Procedure:Dismantling:1. Drain out the oil from the sump. 2. Remove the oil sump 3.Remove the oil pump mounting bolts and nuts 4.Take out the oil pump along with strainer 5.Remove the strainer assembly from the pump 6.Remove the oil pump end cover 7.Remove the pump cover packing 8.Remove the idler gear from the oil pump housing

9.Remove the driving gear with shaft 10.Remove the driving gear by using the puller Cleaning and inspection 1. Clean all the parts by kerosene oil 2.Clean the strainer and suction pipe by compressed air 3.Inspect visually the gears and shaft for pitting and damage 4.Check visually the contact surface of the oil pump housing and gear teeth with a feeler gauge. 5. Check the radial clearance between the oil pump housing and gear teeth with a feeler gauge. 6. Check the back lash between the oil pump gears with a feeler gauge. 7. Check the depth of the gears from the oil pump housing surface by using a steel rule and feeler gauge 8. Check the condition of the strainer and suction pipe four damage & blocks. Assembling 1. Fix the driving gear on the driving shaft with a new woodruff key 2.Place the driving gear with the shaft in the pump housing 3.Place the driven gear on spindle in the pump housing. 4. Place the pump housing packing and align the holes 5.Place the pump cover, and tighten the pump cover bolts. 6. Check for the free rotation of gear 7.Fit the suction strainer 8.Insert the oil pump in to the crank case 9.Tighten the mounting bolt to the specified torque. 10. Install the oil sump with a new gasket 11.Fill the recommended oil in the sump up to the correct level 12.Start the engine 13.Check the oil pressure at the various R.P.M and compare them with the manufactures specification EXPERIMENT -14- VALVE TAPPET CLEARANCE

Aim: - Adjust the valve tappet clearance of a four cylinder engine. Tools required: - Spanner screw driver, feeler gauge Procedure:1. Remove the valve cover 2.Turn crankshaft in clock wise direction and coincide flywheels TDC 1/6 or 1/4 make with flywheel housings pointer. Confirm that 1st cylinder is in compression stroke 3.Place the ring spanner on the lock nut 4.Place the specified thickness feeler gauge between the valve stem and the rocker tip 5.Tighen the adjusting screw by screw driver and at the same time move feeler gauge to and fro. 6. Stop tightening of the adjusting screw when it moves with the load, but it should not

be jammed. 7. Hold the adjusting screw with the screw driver firmly and tighten lock nut by a ring spanner. 8. Ensure that the adjusting screw does not rotate while tightening the locking nut. 9. Check again the movement of the feeler gauge leaf and push rod. 10. Repeat the above steps to adjust the tappet clearance for remaining cylinder according to firing order

EXPERIMENT 15-REMOVAL AND REFIT OF VALVES

Aim: - To study about removing and refitting of valves from cylinder head Tools required:-Spanner, torque wrench, valve spring compressor, screw driver etc. Procedure:1. Firstly remove the cylinder head from cylinder block and put on the work bench. 2. Then remove the valves by the help of valve spring compressor (Press the valve spring by the help of spring compressor and take the lock and remove the valve 3.Then check the valves for any demand and clean it 4.Refit the valves on the cylinder head as per the reverse order of dismantling 5.The work is completed

EXPERIMENT -16-VALVE LAPPING

Aim: - To study about the working of valve lapping work. Tools required:-Spanner, Torque wrench, Valve spring compressor, valve lapping stick. Material required:-Rough and smooth graining paste Procedure:1.First remove the cylinder head from cylinder block and put on the bench 2.Then remove the valve by the help of valve spring by compressor 3.Clean the valve seat and face 4.Smeared on the valve seat and face with the special graining paste (rough paste) 5.Then put the valve in to the valve guide hole 6.Then take lapping stick and press its hollow rubber hollow head with the valve 7.Then rotate the valve by rotating the stick by head , while doing so the valve is lifted of its seat for spreading the graining paste properly 8.When the pitting on the valves face and valve seat are disappearance 9.Remove the rough paste on its by clean 10.Then smeared smooth past on that surfaces

11.Then repeat the procedure as above for smoothness of that surfaces 12.After lapping the valve face are smeared the oil 13.Then repeat the same procedure on all valves of engine 14.Then refit the valve on cylinder head 15.The work is completed.

EXPERIMENT - 17 -ROTOR TYPE OIL PUMP Aim: - To dismantle and assemble the rotor type oil pump. Tools required:-Spanner, Screw drivers etc. Procedure for dismantling 1. Firstly remove the oil pump from the engine 2.Remove the strainer and top cover 3.Remove the inner rotor with shaft 4.Remove the outer rotor 5.Clean the parts and check the following a. Clearance between inner rotor and outer rotor b. Clearance between outer rotor and pump housing c. Clearance between pump rotor and housing top cover d. Play of pump shaft c. Replace the damaged shaft 6.Replace the damaged parts Procedure four Assembling 1. Firstly refit the outer rotor assembly 2.Then insert the inner rotor with shaft 3.Refit the top cover and strainer 4.Refit the oil pump in to the engine

EXPERIMENT -18- SU CARBURATER

Aim: - To dismantle, assemble and study about the SU carburetor Tools required: - Spanner, Screw driver etc. Procedure:1.Firstly remove the air cleaner from the carburetor 2.Disconnect the connection of throttle valve , chock system, fuel line from fuel pump 3.Then remove the carburetor from the engine 4.Dismantle the carburetor 5.clean the parts by petrol

6.Feul jet is cleaned by petrol and air 7.Then check all the parts for any damage and studied about it 8.It contain , oil cap nut ,dumber , plunger ,pin suction chamber , piston, tapper jet (needle valve) 9.Fuel line from the float chamber throttle valve adjusting nut , needle valve , throttle pivot and float chamber 10.Then assemble the carburetor and relief it on inlet manifold 11.Air cleaner is fitted on the carburetor and Finish the work

EXPERIMENT 19-SOLEX CARBURATOR

Aim: - To dismantle, assemble and study about the Solex carburetor Tools required:-Screw driver, Spanner etc. Procedure:1.Remove the carburetor from the engine 2.Dismantle float system and study about it 3.Check the parts of float and also the parts in the chamber 4. Dismantle the accelerator system operating lever, retaining spring diaphragm and study about the parts and circuit 5.Dismantle the cad staring system and check lever retaining disc, spring, etc and study about circuit 6.Dismantle the power circuit and main metering circuit check the parts and study about the circuit and emulsion tube 7.Remove the various adjustments and study about its working 8.Assemble the Solex carburetor in the reverse order of dismantling.

EXPERIMENT -20 FUEL FILTER Aim:-study of fuel filter Tools required: - Spanner, Screw driver, etc. Procedure:1. Firstly remove the filter assembly (primary filter and secondary filter) After disconnecting the fuel fed pump connecting from it 2.Then dismantle the filter assembly 3.Then check and study about all the parts 4.It contain mounting bolt, paper filter and cloth filter Rubber washer, bleeding hole, inlet and out let connection 5.If necessary replace the filter with new one 6.Then assemble the filter assembly has the reverse order of dismantling 7.The work is completed

EXPERIMENT -21-RADIATOR AND THERMOSTAT VALVE

Aim: - Servicing the radiator and study of thermostat valve. Tools required: - Spanner set, Screw driver, Plier, Hammer, Thermometer, Beaker Materials required: - Coolant, Cotton waste. Radiator:Dismantling radiator:1.Remove the radiator cap 2.unscrew the drain plug and drain the water from the radiator 3.Open the drain plug at the cylinder block and drain the water from the cylinder block 4. Disconnect the top and bottom water hoses 5. Remove the nuts securing the radiator to mounting bracket on the frame 6. Remove the stay bolt the radiator end. 7. Remove the radiator; place it vertically with proper support. Cleaning and inspection of radiator 1. Check the radiator filler cap 2. Check the radiator core for damage, clogging & leakage 3. Check the Soldered joints of the top & bottom tank 4. Clean the radiator core by reverse flushing method. Assembling the radiator 1. Place the radiator on the mounting bracket 2.Place the stay bolt and tighten 3. Connect the radiator top and bottom water hoses 4. Fill the coolant in radiator at maximum level. 5. Place and tighten the radiator cap Thermostat valve 1. Remove the thermostat cover from the thermostat case 2.Remove the thermostat valve 3.Clean the thermostat Valve cap, and valve seat 4. Immerse the thermostat valve in water 5.Heat up the water 6.Nate down the temperature of the water in the thermometer at which the thermostat start to open

7.Note down the temperature at which the thermostat opens fully. 8. Remove the thermostat valve from water, and compare the temperature at which the thermostat starts to open & thermostat opens completely, with the specification give by the manufacture. 9. If any of this observation does not match with manufactures specifications, replace the thermostat 10. Fit the thermostat in the thermostat case 11. Fit the thermostat cover in the thermostat case.

LAB 2 - BASIC FOUR WHEELER SERVICING EXPERIMENT INDEX

1) 2) 3) 4) 5)

REMOVE & REFIT OF MC-PHERSON STRUT TYPE SUSPENSION REMOVE AND REFIT OF REAR SUSPENSION (CAR) DISMANTLING AND ASSEMBLING OF STEERING LINKAGE DISMANTLING AND ASSEMBLING OF FRONT WHEEL ASSEMBLY DISMANTLING AND ASSEMBLING OF RECIRCULATING BALL TYPE STEERING GEAR BOX 6) DISMANTLING AND ASSEMBLING OF RACK AND PINION STEERING GEAR BOX 7) REMOVE AND REFIT OF DISC BRAKE 8) DISMANTLE AND ASSEMBLING OF REAR DRUM BRAKE 9) DISMANTLING AND ASSEMBLING OF MASTER CYLINDER 10) DISMANTLE AND ASSEMBLING OF TANDEM MASTER CYLINDER 11) BRAKE ADJUSTMENT 12) DISMANTLING AND ASSEMBLING OF SINGLE PLATE COIL SPRING CLUTCH 13) DISMANTLE AND ASSEMBLING OF DIAPHRAM CLUTCH

14) DISMANTLING AND ASSEMBLING OF SLIDING MESH GEAR BOX 15) REMOVE AND REFIT OF CLUTCH
16) DISMANTLING AND ASSEMBLING OF CONSTENT MESH GEAR BOX 17) DISMANTLING AND ASSEMBLING OF SYNCHRO MESH GEAR BOX 18) PROPELLER SHAFT AND UNIVERSAL JOINT 19) DISMANTLING AND ASSEMBLING OF SELECTOR MACHANISM 20) BRAKE BLEEDING 21) DIFFERENTIAL AND DRIVE OF A CAR 22) BATTERY 23) STARTING MOTOR 24) DISTRIBUTOR 25) DYNAMO 26) WIRING OF IGNITION CIRCUIT 27) ALTERNATOR 28) HEAD LAMP CIRCUIT 29) FLASHER CIRCUIT 30) HORN CIRCUIT 31) ELECTRIC HORN 32) WIPER MECHANISM 33) SPRAY TEST AND INJECTION PRESSURE TEST

EXPERIMENT -1-REMOVE & REFIT OF MC-PHERSON STRUT TYPE SUSPENSION

Aim: - To remove and refit Mc-pherson strut type suspension system Tools required:-Spanner, Jack, coil spring compression. Procedure for removal 1. Firstly park the vehicle on a level surface and movement of the vehicle is stopped, then using jack & Spanners remove the front wheel 2.Disconnect the connection with the tie rod and steering arm 3.Remove the steering knuckle by removing the nut and bolt of lower arm 4.Compress the coil spring by using coil spring compressor 5.Loose the lower mounting nut of shock adsorb and take it out side. 6. Remove the lower arm and upper arm from the body 7.Study about the suspension system 8.Lastly clean the spring and shock absorber Procedure for refitting 1. Firstly refit the lower arm 2.Refit the lower end of shock absorber on the lover arm. 3. Place the coil spring over shock absorber 4.Jack up the lower arm and insert the shock absorber piston rod in to the frame set tightly. 5. Connect the steering knuckle on lower arm 6.Assemble the tie rod and refit the wheel 7.Lastly remove the jack under the vehicle and finish the work.

EXPERIMENT -2-REMOVE & REFIT OF REAR SUSPENSION (CAR)

Aim: - To Remove and refit the rear suspension Maruti 800car Tools required:-Spanner, jack, etc.

Materials required: - Wooden block, waste Procedure for removing 1. Firstly park the vehicle on the leveler ground 2.Then prevent the moment of vehicle by using wooden block. 3. Then jack up the vehicle and remove the wheel 4.Then support the body by using a jack 5. Then remove the shackle pin nut and bracket pin nut 6.Then remove the shock absorber lower mounting nut with the set 7. Then remove the u bolt ant and U mounting plate 8.Then lower the axle and free the leaf 9.Then take out the shackle pin and bracket pin 10.Then take out the leaf spring set 11. Then clean the blades Procedure for Refitting 1. Then place the leaf spring on the axel seat and cover it 2.Then lowered the body and fit shackle and bracket pin 3.Then fit shackle pin and bracket pin nut 4.Then place the U bolt mounting plate over the leaf spring 5.Then fit the U bolt 6.Then fit the lower mounting of nut of shock absorber. 7. Then fit the wheel 8.The work is completed

EXPERIMENT -3-DISMANTLING AND ASSEMBLING OF STEERING LINKAGE

Aim: - To dismantle and assemble steering linkages of a heavy duty truck Tools required:-Spanner, Wooden block, Hammer Procedure for removing 1. Firstly park the vehicle on a level ground and stop the vehicle movement by using wooden block 2Loose the steering wheel nut and remove steering wheel 3.Remove the drop arm and cross shaft 4. Separate the drop arm and cross shaft 5.Disconnect the drop arm and drag link 6. Separate the drag link from right and left steering arm 7.Remove the tie rod from right and left steering arm 8. Remove the mounting bolt of steering gear box and frame 9.Take the steering shaft with steering gear assembly on side 10.Lastly dismantle steering gear box and study about the part

Procedure for assembling 1. Firstly assemblies the steering gear box 2.Place the steering shaft with steering gear box on the frame and light the mounting bolt, tight the steering column clamp. 3. Fit the drop arm one end is connected to the cross shaft and other end is connected to drag ling 4.Fit other end of drag link in to steering arm 5.Fit the tie rod in the right and left steering arm 6.Lastly fit the steering wheel on the steering shaft place key and lock is by lock nut 7.Clean the work place and tools finish the work

EXPERIMENT -4-DISMANTING AND ASSEMBLING OF FRONT WHEEL ASSEMBLY

Aim: - To dismantle and assembly the front wheel assembly Tools required: - Jack, Hammer, wheel spanner, Wooden block, Spanner, Lever Procedure for dismantling 1. Firstly park the vehicle on a level surface. 2.Stop the rotation of wheel by using wooden block 3.Jack up the front wheel and remove the wheel by using wheel spanner 4.Remove the axle nut cover and remove the split pin 5.Loose the axle nut and remove the nut and brake drum assembly by pulling 6.Disconnect the connection between steering arm and tie-rod 7.Remove the brake pipe connection , remove the clamp bolt of back plate and remove it 8.Loose the screw of king pin top cover and remove it 9.Remove the cotter pin by using a lever and hammer 10.Remove the king pin by hammering on the top by using lever 11.Remove the thrust washer and also remove stub axel 12.Sapperate the hub and brake drum and take the bearing in the hub 13.clean the bearing and check it

Procedure for Assembling 1.Place the stub axle on eye of axle 2.Place the thrust washer under the eye 3.Insert the king pin , thrust washer on the stub axle eye 4.Lock the king pin by insert in cotter pin and tight the top of cover 5.Place the back plate and tight it

6.Connet the brake pipe 7.Assembly the brake drum hub and bearing and place on the stub axle 8.Tight the castle nut and lock it with split pin 9.Refit the axle nut cover and connect the tie-rod and steering arm 10.Refit the wheel and remove the jack and wooden block under the wheel 11.Then clean the work place and finish the work

EXPERIMENT -5-DISMANTLING AND ASSEMBLING OF RECIRCULATING BALL TYPE STEERING GEAR BOX Aim: - To dismantle and assemble the recirculating ball type steering gear box of heavy duty vehicles Tools required:-Spanner, screw driver, hammer etc. Procedure 1.Firstly take the recirculating ball type steering gear box from the vehicle 2.Loose the mounting bolts , disconnect the bottom cover 3.Then remove the sector cover and side cover by loosing its mountain bolt 4.Take the gear sector with cross shaft assembly out said and take shaft with worn nut 5.Take the upper bearing and lower bearing 6.Take the recirculating ball by removing the ball guard 7.Clean the recirculating ball in to worn nut assemble and lock the ball guide 8.Assemble the recirculating ball in to worn nut , assemble and lock the guide 9.Insert the worn and nut assemble in the gear box housing 10.Fit the cross shaft and bottom cover 11.Put inside cover and bottom cover 12.Check the gear box gear and refit the assembly in to the vehicle 13.Check the working and finish the work

EXPERIMENT -6-DISMANTING AND ASSEMBLING OF RACK AND PINION STEERING GEAR BOX

Aim: - To dismantle and assemble rack and pinion steering gear box Tools required:-Spanner, Hammer, pipe wrench, Circlip plier Procedure 1.Firstly remove the tie rod end from steering knuckle 2.Remove the steering shaft from the coupling of the pinion shaft 3.Loose the chassis mounting U bolts from the frame 4.Clean the outer linkage and unlock the lock plate and take the steering gear box out

side 5.Clean the pipe wrench loose the tie rod ends and remain adjusting nut 6.Using cir clip plier take the Circlip from the pinion out side 7.Take out the pinion assemble and racks 8.Clean the assemble and check for worn out of the pinion and rack , replace the damaged parts if necessary 9.Check the ball and socket joint of tie rod ends , replace it if necessary 10.Fit the grease in side the rack housing and place the rack 11.Place the pinion with bushes and cir clip 12.Fit the adjusting nut and the tie rod end 13.Add the approximate shims for correcting the tight of ball and socket joint and lock the tie rod 14.Fit the rubber boot with grease and assemble it 15.Fit the steering gear box in the chassis frame 16.Check the back lash and working it the finish the work

EXPERIMENT -7-REMOVE AND REFIT OF DISC BRAKE Aim: - To Remove and refit the front disc brake of Maruti 800 car Tools required:-Ring spanner, Double end spanner, screw driver, Hammer, Box spanner Materials required:-Cotton waste, Brake oil Procedure:1. Park the car on a level ground. And prevent the movement by using wooden block 2.Then lift the front portion and remove the tyre 3.Then remove flexible brake pipe from the caliper and plus it 4.Then take out the caliper from the stub axle by removing the mounting plate 5.Then take out the brake pads from wear the caliper and check it 6.Then remove the dust boot and piston from the caliper 7.Then remove the rubber seal from the caliper cylinder 8.Then clean the caliper, cylinder , piston, brake pad , etc. and inspect for wear , or score also check that the rubber seal and dust cover for damage 9.Replace the damage or worn out parts 10.Then fit the assembly the reverse order of dismantling 11.Then connect the brake pipe to the caliper 12.Then bleed out the air , then check the performance, then finish the work

EXPERIMENT -8-DISMANTLE AND ASSEMBLING OF REAR DRUM BRAKE Aim: - To dismantle and assemble the rear brake system of Maruti 800 car

Tools required:-Ring spanners, double end spanner, screw driver, drum puller, hammer Material required: - Brake oil, waste, glass jar, rubber tube Procedure:1.Firstly park the car on level ground ,and prevent the movement of wheels by using wooden block 2.The lift the rear portion and remove the rear wheels 3.Then remove the axle nut and take out the brake by using drum puller 4.Then remove parking brake connection from the left shoe 5.Then remove the study post of the brake shoe by using plier 6.Then remove the brake shoe with automatic brake adjustment unit 7.Then disconnect the rubber hose from the cylinder and take out by removing the mounting bolts 8.Then take the piston and rubber seal from the wheel cylinder 9.Then the all parts and inspects for wear and damage ,replace the damage parts if necessary 10.Then assemble the unit in the reveres order of dismantling .Then make the connecting 11.Then bleed out the system up check the performance .Then clean the tools 12.Then finish the work

EXPERIMENT -9-DISMANTLING AND ASSEMBLING OF MASTER CYLINDER

Aim: - To dismantle and assemble the master cylinder. Tools required: - Spanner, Circlip, plier etc. Procedure 1. Disconnect the master cylinder pipe connection 2.Remove the master cylinder assembly from the vehicle. 3.Remove the piston rod with rubber boot 4.Drain out the brake oil 5.Remove the cir clip and take out side the piston stop washer 6.Take out the piston with secondary cup 7.Take out the primary cup and retaining spring 8.Take out the fluid check valve and study about 9.Clean the parts check the following parts a. Piston for worn out b. Primary and secondary cup for damaged c. Retaining spring tension d By pass and inlet port for any block e. Check valve for worn out 10.Insert the fluid check valve 11.Insert the retaining spring and primary cup

13.Insert the piston with secondary cup 14.Insert the piston rod and rubber boot 15.Refit the master cylinder of the vehicle , refit the out pipe connection 16.Fill the brake oil at specified level 17.Blead out the air check the brake ,the work is completed

EXPERIMENT -10-DISMANTLE AND ASSEMBLING OF TANDEM MASTER CYLINDER Aim: - To dismantle and assemble of tandem master cylinder Tools required: - Spanner set, Screw driver, wooden block. Procedure 1.Park the vehicle on a level ground 2.Prevent the movement of the vehicle by using wooden block 3.Disconnect the tandem master cylinder and take out the tandem master cylinder 4.Take out the cir clip by using cir clip plier 5.Remove the stopper and take out the piston with retaining spring 6.Take out the check valve 7.Check the tandem master cylinder parts 8.Refit the piston and fit the stop 9.Then fit the cir clip with help of cir clip plier 10.Refit the tandem master cylinder to the vehicle 11.Finally clean the tools, Then finish the work

EXPERIMENT -11-BRAKE ADJUSTMENT Aim: - To done the brake adjusting work Tools required:-Jack, Spanner Procedure 1. First park the vehicle on a level ground 2.Jack up the vehicle and give proper support 3.Tight the adjuster by using screw driver and lock the wheel 4.Loos the adjuster unit the wheel become free 5.Rotate the wheel and apply the brake 6.If the wheel is stop suddenly with out any slip, the adjustment is satisfactory

7.The same procedure is done on the other brake shoe and on the remaining 3 wheeler 8.Remove the jack, then work is completed.

EXPERIMENT -12-DISMANTLING AND ASSEMBLING OF SINGLE PLATE COIL SPRING CLUTCH Aim: - To dismantle and assemble the single plate coil spring cutch Tools required:-Spanner, Arber press, Try square, vernier caliper, Steel rule Procedure 1. First park the vehicle on level ground then stop the movement of the vehicle 2.Remove the gear box from the vehicle 3.Remove the clutch assembly from the vehicle engine fly wheel 4.Mark the position of pressure plate with lower by using a punch and also mark the release figure position 5. Put the assembly in a Arber press with pressure plate respecting on a wooden block and put a wooden block on the cover 6.Press the arbor press and loose the release finger adjusting nut 7.Remove the assembly from the press and separate the cover and pressure plate 8.Separate the release finger from the pressure plate by lifting the end of the finger and eye bolt (so that end of the finger and the eye bolt are close together as possible , then lift strut up cover the rigid on the end of the finger an bolt) 9.Remove the retaining spring from the cover 10.Clean the parts by using diesel check the parts like spring for tension a) Coil spring:By using spring tension , free length of coil spring by using steel rule squareness of the spring by using a try square b) Clutch plate 1.Worn out of friction liners 2.Loos of damper spring 3.Loose of splined hub 4.Run out of clutch plate by using dial gauge C) Pressure plate 1.Run out of pressure plate by using a dial gauge 2.Worn out and check squareness of pressure plate D)Fly wheel 1 Worn out and check squareness of fly wheel Procedure for Assembling 1.First fit the release finger on the pressure plate 2.Fit the retaining spring on lever 3.Then position or coil spring on the pressure plate and plate cover 4.Press the cover and pressure plate in a Arber press and tight the release finger adjusting nut

5.Check and adjust the pressure plate and release finger tight by a vernier caliper 6.Mesure the sap between release finger and cover by a vernier caliper and steel role Fit the clutch assembly on the fly wheel 1.Take the dummy clutch shaft and plate the clutch plate , pressure plate and cover assembly on the fly wheel noted that the clutch shaft 2.Tight the cover bolt as per the torque 3.Remove the dummy clutch shaft 4.Mesure the gap between figure and cover . Then correct it by tight the adjusting nut 5.Fit the gear box in the vehicle 6.Adjusting the free pedal play 7.Start the engine and shift the gear box .Then work is completed

EXPERIMENT -13-DISMANTLE AND ASSEMBLING OF DIAPHRAM CLUTCH

Aim: - To dismantle and assemble the diaphragm clutch Tools required:-Spanner, screw driver, Arbor press Procedure 1. Park the vehicle on level ground then stop the moving of the vehicle 2.Remove the gear box from the vehicle. 3. Remove the clutch disc and pressure plate assembly 4.Check the following parts and replace the damaged parts a. crank of pressure plate b. Run out pressure plate by using a dial gauge c. crank of fly wheel d. Run out fly wheel by using a dial gauge e. worn out of friction lining d. Run out of clutch disc by using a dial gauge g. Loose the splined hub 5.Take a dummy clutch shaft and place the clutch disc and pressure plate assembly 6. Tight the mounting bolt on the fly wheel 7.Take out the dummy clutch shaft 8.Refit the gear box on the vehicle and adjust the free pedal play 9. Start the engine and shift the gear box .Then finish the work

EXPERIMENT -14-REMOVE AND REFIT OF CLUTCH

Aim: - To remove and refit of clutch assembly from vehicle Tools required: - Spanner, Screw driver, Chisel, Hammer

Procedure 1. First park the vehicle on a level ground 2.Then prevent the movement of the vehicle by placing wooden block 3.Then mark on the gear box finger and propeller shaft flange 4. Then remove the flange bolt and remove the propeller shaft 5.Then disconnect the speed meter connection 6.Then remove the gear box from the engine 7. Then mark on the clutch assembly and fly wheel 8.Then remove the clutch assembly from the vehicle 9.Then clean the parts and check the following parts for damage of worn out Procedure for Refit 1. First fit the clutch with dummy clutch shaft assembly on the fly wheel 2. Then fit the gear box on frame 3.Then fit the clutch cover on the engine 4.Then connect the speedometer connection on the gear box 5.Then fit the propeller shaft flange and gear box flange of correct position 6.Then adjust the free pedal play 7.Then clean the tools, Then work is completed

EXPERIMENT -15-DISMANTLING AND ASSEMBLING OF SLIDING MESH GEAR BOX

Aim: - To dismantle and assemble and study about sliding mesh gear box Tools required:-Spanner Procedure 1. First park the vehicle on leveled ground and stop the movement of the vehicle by placing wooden block 2.Drain out the oil from gear box 3.Remove the sliding mesh gear box from vehicle 4. Remove the top of cover; clutch cover and main shaft cover 5.Remove the counter shaft 6.Take out the main shaft gears 7.Take out the main shaft gears one by one 8.Take out the reverse gear by removing the shaft 9. Dismantle the selector mechanism 10.Study about the working of gear box and clean the gears bleeding and main shaft with diesel 11.Check the following parts a. Gear for play worn out of teeth

b. Bearing for play and worn out c. Main shaft spleens for worn out or damaged d. Selector for worm out e. Selector lever for worn out Procedure for Fitting 1. First assemble the selector Mechanism 2.Place counter shaft gear in the gear box fit the shaft and reverse gear 3.Insert main shaft units the gear box and place main shaft gears after the spleens of main shaft as per order 4.Place clutch shaft 5. Place counter shaft 6.Re fit the clutch shaft cover, main shaft cover and top cover 7.Shift gears for checking 8. Refit gear box on vehicle 9. Fill the oil in the gear box at specified level 10.The work is completed

EXPERIMENT -16-DISMANTLING AND ASSEMBLING OF CONSTANT MESH GEAR BOX Aim: - To dismantle and assemble and study about constant mesh gear box Procedure 1. First park the vehicle on a level ground and stop the movement of vehicle 2.Drain the oil from gear box 3.Removing the constant mesh gear box from vehicle 4.Remove the top cover and main shaft cover 5.Remove the selector mechanism fork 6.Remove the clutch shaft with gear 7.Remove the spring and ball lock from main shaft 8. Remove the main shaft gear and riding sleeves and dog clutch 9. Take out the main shaft 10.Take out the reverse gear shaft and reveres gear 11. Take out the counter shaft with counter gear and its bearing 12.Dismantle selector mechanism 13.Clean the parts on diesel and study about working and check the following parts a. Mesh out of gears b. Worn out of bearing c. Play of gears d. Crankiness of gears e. worn out of teeth 14.Replace the damage parts

Procedure for Assembling 1. Firstly assemble selector mechanism 2. Insert the counter shaft on the counter gear 3.Place the reverse gears and reveres shaft 4.Isert the main shaft 5.Place the 1st gear 6.Place the 2nd gear its bearing 7. Place the dog teeth for second gear and third gear and its sliding mesh sleeve 8.Place the 3rdgear with dog teeth and its bearing 9. Place the 4th gear with dog teeth and its bearing 10.Place the dog clutch for fourth gear and top gear its riding sleeve 11. Lock the main shaft gears by using ball and spring 12. Fit the clutch shaft and bring the gear in natural position 13.Place the selector fork 14.Fit the side cover clutch shaft cover and main shaft cover 15.Bring the selector lever in neutral position and fit the top cover 16.Shift the gears 17.Refit the gear box on vehicle 18. Fill the gear oil 19. Start the engine and check the gear box 20. The work is completed EXPERIMENT -17-DISMANTLING AND ASSEMBLING OF SYNCHRO MESH GEAR BOX

Aim: - To dismantle and assemble and study about Synchro mesh gear box Tools required:-Spanner, screw driver, wooden block Procedure 1. Firstly park the vehicle on a level and stop the movement of vehicle by using wooden block 2. Drain out gear oil from gear box 3. Remove the synchromesh gear box from the vehicle 4. Remove the clutch shaft cover, main shaft cover and top cover 5. Remove the lock nut of counter shaft remove it 6. Take out the clutch shaft with gear 7. Take out the synchronizing unit of 2nd and 1st gear 8. Take out the lock nut 9. Take out the 3rd synchronizing unit of 2ndand 1st gear 10. Remove the main shaft, reverse gear take out the counter shaft gear 11. Dismantle the selector mechanism 12. Remove the synchronizing sleeves and separate the synchronizing hub by removing lock ring 13. Clean the parts and study about working of gear box 14. Checking the following parts

a. gear box play worn out or break b. Bearing for worn out and play c. Synchronizing ring for worn out and play d. Synchronizing sleeve and hub for worn out e. Ball and spring for worn out and low tension f. Bushes for worn out and main shaft . 15. Assemble the selector mechanism and Synchronizing unit 16.Place the counter shaft gear and reverse in the gear box 17. Insert the main shaft and refit the first gear Synchronizing unit of second to third gear 18. Lock the unit with lock ring and place the Synchronizing unit to third and fourth gear 19. Refit the clutch shaft with gear 20. Refit the counter shaft and lock it with lock unit 21. Refit the main shaft cover clutch shaft cover and selector mechanism 22. Shift the gear for checking 23. Refit the Synchro mesh gear box on vehicle and fill gear oil at specified level 24. Then work is completed

EXPERIMENT -18-PROPELLER SHAFT AND UNIVERSAL JOINT

Aim: - To remove and refit propeller shaft and universal joint Tools required: - Spanner, Hammer Procedure for removing 1. Firstly park the vehicle on a level ground and stop movement of the vehicle by using wooden block 2. Mark the main shaft flange and propeller shaft flange position by using chisel 3. Mark the level pinion flange and propeller shaft flange position 4. Loose the flange and bolts of front side and remove the propeller shaft from the vehicle 5. Loose the nuts of connecting bolts and nuts of gear side Procedure for dismantling 1.Mark the slip joint and propeller shaft pinion 2. Remove the slip joint and universal joint assembly 3.Mark the yoke position of universal joint 4. Remove the opposite side cir clip and hammer on the bearing cup 5. Hammer the spider with wooden block and remove the other side bearing cup 6. Remove the other side bearing cup as the above procedure 7. Clean the parts with diesel and check the following parts a. Needle bearing for worn out b. Cup worn put

c. Slip joint for worn out d. Spider for worn out Procedure for Assembling 1. Insert the spider in to the yoke on the mark and relit the needle bearing cup 2. Lock the cups with cir clip 3. Insert the propeller shaft spline in to the slip joint as the mark. Procedure for Refitting 1. Align the propeller shaft flange with main shaft flange on the mark 2. Refit the propeller shaft flange with bevel pinion flange on the mark 3. Then finish the work

EXPERIMENT -19-DISMANTLING AND ASSEMBLING OF SELECTOR MECHANISM

Aim: - To study dismantle and assemble a selector mechanism of gear box Tools required: - Double end spanner, screw driver, Hammer Procedure 1. Firstly park the vehicle on a level ground and stop the movement of the vehicle 2. Remove the gear box from the vehicle and remove the top gear 3. Remove the locking pin and take out the gear lever 4. Loose the locking bolt of a sector fork 5. Using suitable lever hammer gently take the selector rod out 6. Same procedure is done for other selector fork 7. Clean the parts with diesel 8. Check the shaft for worn out the fork for breakage check the other selector mechanism 9. Place the selector shaft and cover fork to the cover to the cover 10. Tight locking ball, and then bring the fork in neutral 11. Fit the gear lever and fit the top cover on the gear box 12. Fit the gear box it the vehicle 13. The work is completed

EXPERIMENT -20-BRAKE BLEEDING

Aim: - To do brake bleeding in the given vehicle. Tools required: - Spanner and screw driver Material required: -Cotton waste, brake fluid, jar and pipe Procedure 1. Park the vehicle on a level ground. 2. A bleeder pipe is connected with bleeder valve in the wheel cylinder, farthest from the master cylinder 3.The end of this bleeding pipe is kept dipped in a bottle. 4. One person sits on the drivers seat and press the brake pedal 5. Then, the bleeder valve in the wheel cylinder is opened by the second person with a spanner. 6. When some air bubbles will come out of the pipe and escape though the brake fluid 7.The bleeder value is closed again. 8. This procedure is repeated till no more air is come out of the pipe 9. The bleeder valve closed when the brake pedal is pressed. 10. This procedure is then repeated for all wields.

EXPERIMENT -21-DIFFERENTIAL AND DRIVE OF A CAR Aim: - To dismantle and assemble a differential and final drive assembly of a car Tools required: - Hammer, screw driver, Spanner Procedure for dismantling 1. Firstly park the vehicle on a level round and stop the movement of the vehicle 2.Remove the differential and final drive assembly from the vehicle 3.Remove the bearing flange of the differential cage and remove the crown wheel from the differential cage. 4. Remove the crown wheels from the differential cage 5.Remove the lock of cross pin and remove the cross pin. 6. Remove the sun gear and star pinion 7.Remove the bevel pinion flange. 8. Take out the bevel pinion from the casing 9.Check the following parts and clean the parts by diesel. a. Crown wheel for damage. b. Bevel pinion for damage. c. Bearing for worn out d. Star pinion teeth for damage e. Sun gear teeth for damage f. Crown wheel or bevel pinion bent 10. Replace the damage parts. Procedure for assembling.

1. First place the bevel pinion assembly in to the differential assembly. 2. Place the flange and tight the flange at correct torque 3. Place the star pinion and insert the cross pin and lock it 4.Place the sun gear to its position 5.Assemble the crown wheel with differential cage 6.Place the crown wheel with differential cage on the cover 7.Then finish the work

EXPERIMENT -22-BATTERY Aim: - Study about the battery & battery testing. Tools required: - Spanner, Screw driver, hydrometer, voltmeter, & high rate discharge tester Material required: - Battery water, Emery paper, Cotton waste Procedure 1.Disconnect the cables from the battery terminals 2.Remove the mounting clamp nut 3.Lift the battery from the vehicle 4.Clean the top of the battery with water & cotton waste 5.Clean the battery terminals by non metallic wire brush & emery paper 6.Check & top up the electrolyte level with distilled water . Battery testing Specific gravity test 1. Keep the battery on a leveled wooden work bench 2.Remove all the vent plug 3.Hold the hydrometer vertically. 4. Place the nose of the hydrometer in the cell. 5. Press the rubber bulb of the hydrometer 6.Release it to draw the electrolyte up wards 7.Note the float level which is flouting in the electrolyte up wards. Open circuit voltage test 1.Connect the leads of the D.C voltmeter to the respective terminal (+ve & -ve ) 2.Take the reading from the voltmeter & record 3.Repeat the procedure for all the cells and record the readings. High rate discharge test 1.Hold the handle of the high rate discharge tester 2.Keep the prods of the high discharge tester to individual Cell connectors (+ve & -ve ), Press it by hand 3.Read the volt meter reading & record in table 4.Repeat the procedure for all the cell & record the readings

EXPERIMENT -23-STARTING MOTOR

Aim:-Dismantle and assemble and testing a starting motor. Tools required: - Spanner set, Screw driver, plier & hammer Material required: - Cotton waste, grease, emery paper Procedure Dismantling: 1.Disconnect the negative lead battery 2.Disconnect the magnetic switch lead wires and the battery cable from the starting motor terminals. 3. Remove the two mounting bolt. 4. Remove the starter motor 5.Remove the cable terminal nut and disconnect the lead wires from the magnetic switch 6.Remove the two mounting nuts and then take out the magnetic switch by slight titling . 7. Remove the through bolts 8. Take off the commutator end housing. 9. Remove the brush holder cover from the brush holder 10.Take out the brush spring and brush 11. Remove the yoke assembly. 12. Remove the armature along with the pinion driver lever 13.Insert the screw driver tip in the gap between the pin two stop collars 14. Push the front collar out ward 15.Remove the armature snap ring by using a snap ring plier and with the help of a screw driver 16.Pull out the rear pinion stop color and over running clutch Assembling 1.Apply grease and install the over running clutch to the armature shaft 2.Insert the gear stop collar in the armature shaft 3.Insert a snap ring in the armature shaft 4.Insert the front stop collar in the armature shaft 5.Apply grease the drive lever 6.Cobine it with the armature 7.Assemble them with the drive housing 8.Install the yoke 9.Install the brush holder 10.Instal 4 sets of brush with the springs 11.Install the brush holder cover. 12. Apply grease and install the commutator end housing 13.Replace the magnetic switch and its boot with a new one if required 14.Place the starting motor in the engine frame

15.Tishten the mounting bolts 16.Connect the wires the same in the same order as noted earlier.

EXPERIMENT -24-DISTRIBUTOR

Aim: - Dismantle and assemble a distributer Tools required: - Spanner set, screw driver, plier & feeler gauge Material required: - Cotton waste, kerosene oil & grease Procedure:Dismantling 1. Remove the high tension wires from the distributor cap 2.Remove the primary lead 3.Remove the distributor cap 4.Remove the screw and lift the distributor assembly from the engine 5.Remove the rotor 6.Disconect the Vacuum unit linkages 7.Remove the screw and little the C.B point assembly 8.Remove the centrifugal timing control assembly 9.Remove the condenser 10.Remove the bush by press Inspection 1. Check visually the C.B point for pitting 2.Check the centrifugal weight springs for tension 3.Check the vacuum unit diaphragm for damage 4.Check the bearing bush & thrust for wear 5. Replace the parts which are damage. Assembling 1. Assemble the bearing bush by push fit 2.Refit the vacuum unit 3.Reassemble the centrifugal timings control unit 4.Refit the condenser 5.Refit the C.B point assembly 6.Fit rotor on the shaft 7.Refit the distributor or assembly to the engine 8.Abjust C.B point gap

EXPERIMENT -25-DYNAMO

Aim:- Dismantle and assemble and testing a dynamo Tools required :- Spanner set , screw driver , testing lamp , Material required :- Kerosene oil , grease , cotton waste , emery paper Procedure Dismantling 1. Disconnect the wires from the dynamo. 2. Loosen the mounting bolts of the dynamo 3.Remove the fan belt 4.Remove the mounting bolt and lift the dynamo from the engine 5.Dismantle the dynamo 6.Remove the frame screws 7.Remove the end place along with the brushes 8.Pull the drive and head along with armature from the body 9.Remove the field coil and magnet from the body. 10. Remove the nut & washer from the armature shaft and remove the pulley. 11. Place the puller on the drive end head 12.Place the puller leg below the drive head 13.Tigten the centre bolt by hand. Ensure that the centre bolt site securely on the armature shaft 14.Tighton the centre bolt till the drive end head comes out of the armature shaft take out the pulley key 15.Remove the three screws and the look washer in the grease retainer 16.Remove the retainer and felts washer 17.Remove the bearing using a copper drift and hammer Test armature for ground 1.Connect one prod of a test lamp to the core or shaft 2.Touch each commutator segment with the other prod 3.If the lamp lights the segment is grounded to the armature . Replace the armature Test for armature open circuit 1.Connect one prod of the test lamp to the commutator segment 2.Connect the other prod to fourth segment from the first proud 3.If the lamp fails to light there is discontinuity. Replace the armature. 4. Test the entire segment in the same way. Test for field coils open circuit 1.Connect the prod and of the test lamp to the two leads from each coil 2.If the lamp to light the coil is open. Then replace it Test four ground brush holder 1.Touch the brush holder with the proud 2.Touch the other prod to the frame 3.If the lamp lights a grounded brush holder is indicated. Then place the insulator between the brush hold and end plate

Assembling 1.Fit the washer to the drive end heat 2.Fit the retainer to the drive end head 3.Fit the bearing in the drive end head 4.Fit the lock washer to the drive end head 5.Fit the field coil grid magnet to the body 6.Press the drive end head assembly to armature shaft 7.Fit the pulley to the armature shaft 8.Put the washer and tighten the nut 9.Fit the armature and drive end assembly to the body 10.Fit the end plate with brusher 11.Place the dynamo in the engine frame 12.Fit the fan belt & adjust the tension 13.Fit the mounting bold 14.Tighten the mounting bolt 15.Connect the wires in the same order as noted earliest

EXPERIMENT -26-WIRING OF IGNITION CIRCUIT Aim: -To study about the wiring of ignition circuit Tools required:- Spanner, Screw driver Procedure 1. First connect the battery +ve terminal to the solenoid. Switch of the battery +ve terminal and take connection from this point to ignition switch. 2. Connect the solenoid switch winding wire to the starting point on the ignition switch. 3.Connect the ignition timing point of ignition switch to +ve point of ignition switch to +ve point of ignition coil primary terminal 4.Connect the ve point to ignition coil primary with contact barker point (B point) +ve connection. 5. Connect the secondary terminal of ignition coil to the distributor cup and connect the high tension lead which is inline with the rotor blade to the spark plug 6.Connect the cable according to the firing order. 7. Connect the +ve point of starter motor with solenoid switch 8.Connect the ve of battery to the body of engine 9.The work is completely

EXPERIMENT -27-ALTERNATOR

Aim: - To dismantle and assemble the alternator Tools required:-Screw driver, Spanner, Multimeter etc. Procedure 1.Firstly remove the alternator from the vehicle after removing the v-Belt and mounting bolt 2.Then dismantle the alternator 3.Then clean all parts and study about its working .The parts are rotor,stator,carbon brush, slip ring, rotor shaft bearing , rectifiers, casing. 4.Check the parts and replace the damaged parts with new one 5.Then assemble the alternator and refit on the engine 6.Then check its working , it finish ok. 7. Then work is completed

EXPERIMENT -28-HEAD LAMP CIRCUIT

Aim: - To wire the head lamp circuit. Tools required:-Screw driver, Spanners Material required: - Main light Switch, dipper switch, head light bulb, wire. Procedure 1. First connect a connection from the battery main lighting switch through Switch. 2. Then connection from main lighting switch to dipper switch 3.Then connect the connection from dipper switch to head lamp. Then other connection from dipper switch to head lamp (high beam and low beam) 4.Then connect the earth connection to body from head light assembly 5.Then the work is completed

EXPERIMENT -29-FLASHER CIRCUIT

Aim: - To wire the flasher circuit Tools required:-Spanner, Screw driver. Procedure 1. Firstly connect the wire from +ve terminal to flasher unit. 2. Then connect a wire from flasher to indicating switch. 3.Then connect the wire from c-point to flasher unit to body of earth 4.Then connect a wire from indicating switch assembly to front and rear indicate lamp through fuse

5.Then connect a wire from indicating light assembly to body of earth (Front and rear). Then earth ve terminal of batter. 6. Then the work is completed

EXPERIMENT -30-HORN CIRCUIT

Aim: - To wire the horn circuit Tools required:-Spanner, Screw driver. Procedure 1. Firstly connect a wire connection from battery to b-point of horn relay. 2. Then wire from S-point of relay to horn push bottom and earth. 3. Then wire from the point of relay and to earth. 4. Then earth ve terminal of battery. 5. Then push the push button then the horn is worked. 6. Then the work is completed

EXPERIMENT -31-ELECTRIC HORN

Aim: - To dismantle and assemble the electric hone. Tools required: - Spanner, Screw driver Procedure 1. Firstly dismantle the electric horn by the help of screw driver, and spanner. 2. Then study about their parts. It contain diaphragm , tune disc , armature , plunger, contact point, etc 3.Then study about the working of horn 4.Then check the parts and replace the damaged parts with new one 5.Then assemble the horn and the working of electric hone , and it is ok. 6. The work is completed.

EXPERIMENT -32-WIPER MECHANISM

Aim: - To study about wiper mechanism Tools required:-Spanner, Screw driver

Procedure 1. Firstly dismantle the wiper mechanism and study about all the parts. It contain wiper motor , terminals , worn gear ,connecting head ,Flexible cable 2.Then study about its working and then assemble the wiper mechanism 3.Then check its working and if it is ok 4.Then the work is completed

EXPERIMENT -33-SPRAY TEST AND INJECTION PRESSURE TEST

Aim: -To test pressure, Leak, Spray pattern by the help of fuel injection pressure tester Tools required:-Spanner Fuel injection pressure tester Material required: - Diesel, Cotton Waste Procedure for Pressure test 1. First fix the injector to the testing machine. Then open the coke and operate the handle lever up and down until the fuel injects through injector. The same time note the pressure gauge reading .It shows the injection pressure .Then compare this reading with original injection pressure .It there is any variation the adjusting nut on the injector should be adjusted for set the correct spring tension Procedure for Leak Test Fix the injector on the tester and build up a pressure gust bellow the injection pressure and locked for 10 seconds and check up the tip of the nozzle body for any leakage or wetness. If it presented, dismantle the injector and correct it. Procedure for Spray Test First fix the injector on the tester. Then operate the handle of tester and note the spray pattern. If it is fine atomized from it is ok.