PROJECT REPORT

On

BS 4 Diesel Engine
Submitted by :- Pankaj Kalal
PH No. = 7727077665

DAKSH AUTO INDIA PVT.LTD.

UDAIPUR (RAJ.)
Under the Supervision Of :- Mr. Jogendra Singh
(Technical Coordinator)
 DECLARATION

I am student of Geetanjali institute of technical studies,

Department of Automobile Engineering, State that we
have completed the summer training from 10th May
2018 To 15th June 2018 at Daksh Auto India Private
Limited.

Pankaj kalal ( 15EGIAE015 ) …………………………

 CERTIFICATE
This is to certify that the report of summer training is
being submitted by Pankaj kalal in fulfilment of the
requirement for the award of degree of bachelor of
technology in the discipline of Automobile Engineering
and has been carried out under my supervision and
guidance. The matter embodied in this report has not
been submitted, in part or in full, to any other university
or institute for the award of any degree ,diploma or
certificate.

Mr. JOGENDRA SINGH

(Technical coordinator)

DAKSH AUTO INDIA PVT.LTD.

Debari

Udaipur – 313601
 Acknowledgement
The internship opportunity I had with DAKSH AUTO INDIA PVT. LIMITED
was a great chance for learning and professional development. Therefore, I
consider myself as a very lucky individual as I was provided with an
opportunity to be a part of it. I am also grateful for having a chance to meet
so many wonderful people and professionals who led me though this
internship period.

I express my deepest thanks to Mr. JOGENDRA SINGH (Technical

coordinator ) for taking part in useful decision & giving necessary advices
and guidance and arranged all facilities to make life easier. I choose this
moment to acknowledge his/her contribution gratefully.

We would like to thank Mr. Rakesh Lohar (Asst. Tech.

coordinator ) for his support and cooperation in preparing the
topic of training and guiding us. I also thanks Mr. Piyush
Shrimali for the valuable inputs and providing us his valuable
time from starting of work.

I perceive as this opportunity as a big milestone in my career

development. I will strive to use gained skills and knowledge in
the best possible way, and I will continue to work on their
improvement, in order to attain desired career objectives. Hope to
continue cooperation with all of you in the future.
BLAZO Series:-
1.Blazo 25

2.Blazo 25 Tipper

3.Blazo 25 Tipper and Transmit Mixer

4.Blazo 25 Rig cowl

5.Blazo 31

6.Blazo 31 8*4 Tipper r

7.Blazo 31 8*2 Tipper

8.Blazo 37

9.Blazo 37 Pusher Axle

10.Blazo 35 SWB

11.Blazo 40

12.Blazo 40 Tip Tipper

13.Blazo 49

14.Blazo 49 Tip Tipper

Chapter 2.

HCV Engine

1.Introduction to the engine

Mahindra's FuelSmart engine with 7.2 L displacement has a large

heart with immense reserve capacity and a backing of 10 years of
CRDe expertise. This engine, in combination with the multi-mode
switches, delivers uncompromising performance. Giving mileage
without short changing you when you need power, pickup or
pulling ability. At the same time, this engine cuts down on
emissions to give you cleaner, greener running for years to come.
2. Engine specification in BSIV engine
In Mahindra the BSIV engines are fitted with electric
engines and additional system at the exhaust known as
SCR. And a urea tank.

2.1 Performance parameter

PERFORMANCE

Engine Mpower Fuelsmart 7.2 lit.

Emission Norms BS-IV

Engine Cylinders 6

Displacement (cc) 7200

Max. Power 274bhp@2,200rpm

Max Torque 950Nm@ 1200-1600 rpm

Transmission Manual
Diaphragm Type Single Plate
Clutch Dry Type , 395 mm
 Gearbox 9 and 6 speed

Fuel Tank ( Liters ) 350

Gradeability (%) 20.7

Turning Radius

Max Speed (km/h) 80 Km/hr ( with speed limiter)

AD Blue Tank Capacity 35 lit.

2.2 ENGINE COMPONENTS

 High Pressure Pump:- The high-pressure pump delivers
the fuel into the connected rail under high pressure. The HPP
consists of one or two high-pressure elements, each integrated in a
housing with its own camshaft. The pump camshaft is driven by
belts, chains, or cogwheels and moves the pump pistons to generate
the required high pressure. High pressure Pump handles pressure
levels from 1,800 to 2,700 bar and is used for both on- and off-
highway applications from passenger cars, light and medium duty
vehicles up to small heavy duty vehicles
  Common Rail Injection System:-
The Common Rail System is modular in design. The right combination of
high-pressure pump, injectors, rail and electronic control unit results in
systems for all types of engine. Conventional injection systems can be
replaced with the Common Rail System with relatively few changes. The
injectors can be fitted in the cylinder head like a nozzle-holder combination,
and the high-pressure pump replaces the one previously used.

Features
 Designed for injection pressures of up to 1350 bar

Benefits
 Clean and highly efficient fuel injection thanks to extremely short injection
gaps and multiple injections
 High engine performance and quiet running with low fuel consumption and
fewer emissions

Suitable for installation in passenger car and commercial vehicles

 Exhaust Unit :- Exhaust unit of BSIV system is fitted with SCR

which mix the exhaust gases with the AD Blue additive or urea .
which Undergoes certain reaction and are than sent to atmosphere .
hence certain norms of emission are achieved.
CHAPTER -3

Disassembly Of Engine

1 . Engine removal from vehicle

 Tilt the cabin with Tilt pump Too

l
 Disconnect the battery cable and remove the battery

 Loosen the radiator drain plug and drain the coolant

 Loosen the oil sump drain plug and drain the engine oil
 Remove the oil filter
 Remove electrical connection of all the sensors, starter
motor, alternator and tank
 Remove the hose connection
 Remove the air intake hose
 Loosen the nut and disconnect air compressor air supply
hose pipe
 Remove the exhaust pipe at turbo charger outlet
 Remove the fuel line from filter to HP pump and return to
fuel tank
 Loosen the radiator mounting bolt

 Disconnect drive line secured at transmission end

 Disconnect the steering vane pump from engine
 Disconnect the selector and shifter cable linkage secured to
gear box assembly
 Loosen the gear box cross member mounting bolts
 Using engine lifting rope or hydraulic jack lift the engine
from vehicle
 Fix the engine on its stand
2. Dismantling of Engine

 Remove starter motor

 Remove idler pulley and alternator bracket

 Remove viscous fan

 Remove turbocharger oil return line

 Remove hose water pump to block
 Remove hose (compressor to water pump housing)
 Remove water inlet (thermostat housing to compressor )
 Remove HP fuel lines and remove of manifold air intake with
common rail
 Remove turbo charger along with exhaust manifold
 Remove fuel back flow pipe
 Remove alternator assembly
 Remove clamp nozzle injector
 Remove air compressor
 Removal of injector
a. Loosen the HP pipes from the common rail
end and injector

b. Note down the IQA no.(7 digit ) of each

nozzle

 Remove oil separator drain line

 Remove rocker arm assembly

 Remove intake manifold and gasket

 Remove gasket with manifold
 Remove all cylinder head assembly and all head gasket
 Remove flywheel assembly

 Remove oil sump gasket and oil sump

 Remove mass balancer
 Remove oil strainer
 Remove oil pump
 Remove rear oil seal retainer cover
 Remove pipe oil cooler inlet
 Remove damper gear
 Remove timing pin
 Remove oil coolant outlet hose
 Remove water pump assembly

 Remove cam sprocket oil jet

 Remove camshaft along with sprocket

 Remove pump gear

 Remove oil cooler

 Remove all main bearing caps

 Remove thrust washer
 Remove crankshaft

 Remove all tappet and tappet plug

 Remove oil jet
 Remove high pressure pump

 Dismantling the piston and connecting rod assembly

FINISH ……………………………………………………………
 TABLE OF CONTENTS
 Declaration

 Certificate

 Acknowledgement

 Abstract

 Chapter 1
i) Introduction to the firm and
workshop
ii) Vehicle categories
iii) Blazo Series
iv) HCV series manual

 Chapter 2
i) Introduction to engine
ii) Engine specification and
performance parameters
iii) Engine components

 Chapter 3
i) Removal of engine from
vehicle
ii) Dismantling of engine