ASSIGNMENT 3.

3. ANALYSES AND RECTIFICATION OF LEAKAGES IN

THE VEHICLE

3.1 AIM:

To analyse the LEAKAGES in vehicle ARIA and their RECTIFICATION

3.2 OBJECTIVE:

1. To collect data of shower leakages

2. Rectification of leakage problems

3. Finding the permanent solution

3.3 IMPORTANCE OF PROJECT:

Various problems due to shower leakages:

• Water affects the electronic parts and may cause permanent damage.

• Leakages inside the vehicle are due to improper joints which symbolises the quality of
vehicle.

• Water leakage inside the vehicle causes discomfort to the consumer.

3.4 INTRODUCTION TO SHOWER TESTING:

1. What is a shower test?

Checking the leakage inside the cabinet

2. Why shower test is needed?

To check and ensure that there is no water leakage inside the cabinet

3. How is the shower test performed?

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 Vehicle is kept under the shower for 3 minutes and VISUALLY CHECKED from
INSIDE for a LEAKAGE from windshields, glass door pads, windows, firewall, tailgates
etc.

3.5 EQUIPMENT: 1. Shower area

2. Supply pipe

3. Motor

4. Nozzles

5. Blower

3.6 SPECIFICATIONS

3.6.1 SHOWER TEST AREA SPECIFICATION:

Shower Test Indicruz TCF

Technical Parameters I.S-11865 revision 2006 Equipment Specification

Riser Pitch 400 mm 400 mm
Nozzle Pitch 400 mm 400 mm
Nozzle Spray angle 60 deg 60 deg
Flow rate per nozzle 15 lpm +/- 15% 15lpm +/- 10%
Water pressure at Nozzle 2 bar +/- 15% 2 bar +/- 10%
Length of booth NA 5.4 m
Test time NA 3 min
Additional Fitures

( Rain And Light Sensor Testing)

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3.6.2 MOTOR SPECIFICATION:-

Manufactured by- Kirloskar Brothers Ltd.

Type- SP- IHM

S no.- A0DAJF0366

Size mm- 40x40 mm

IP kw- 1.75

Head m- 13.5

IMP.DIA.mm-134.0

HEAD RANGE m-9.0-18.0

Lps-4.5

RPM-2800 CAPACITY RANGE lps- 6.2-1.5

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kW/HP -1.5/2.0

OVERALL EFF. %-34.0

INS B 50Hz 3 Ph

CONN S 415V

A 3.9 DUTY S1 INDUCTION MOTOR

3.7 TEST PROCEDURE:

1. Close all the doors, windows and fold carpet in the cabinet.

2. Pull the shower test ON cord and start the shower.

3. Start wipers

4. Enter the vehicle in the shower testing booth.

5. Stop vehicle in the shower for 3 minutes.

6. Visually check for leakages closely.

7. Check whether the wiper blades are over shouting on the wind shield.

8. If a leakage is found mark on the history card for rework.

9. If no leakage is found allow vehicle to dry on platform.

3.8 PREPARATION OF VEHICLE FOR SHOWER TEST:

1. Ensure Door beading is fitted properly and no sealing gap in BIW.

2. Ensure doors and windows are fitted properly.

3. Ensure Sealant application as per specification.

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 4. Check tailgate bidding.

5. Ensure that AC air is not sucked from outside.

6. Ensure that parking lighjt switch is ON when vehicle is inside the shower area.

3.8.1 ACCEPTED NORMS/ STANDARD:

No water leakage inside the CAB.

3.9 SHOWER LEAKAGE DATA COLLECTED

Vehicle
No Leakage place Cause
CH 468 D Pillar leakage sealant not properly filled
CH 449 T/G seal leakage seal loose
CH 460 f-lhs door sash sash immature
CH 464 Both f -door sash sash immature
CH 439 T/G panel joint sealant not properly filled
CH 440 f-lhs door sash sash immature
CH 471 r-lhs door quarter glass sealant not properly filled
CH 488 T/G panel joint sealant not properly filled

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CH 501 r-lhs door sash sash immature
CH 511 f-rhs door sash sash immature
CH 500 f-lhs door sash sash immature
CH 511 A pillar (windshield glass) sealant not properly filled
CH 508 f&r-rhs door sash sash immature
CH 519 A pillar (windshield glass) sealant not properly filled
CH 522 f-rhs door sash sash immature
CH 368 D Pillar leakage sealant not properly filled
CH 544 D Pillar leakage sealant not properly filled
CH 539 A pillar (windshield glass) sealant not properly filled
CH 379 T/G seal leakage seal loose

3.10 PROBLEMS

3.10.1 THE COMMON PROBLEMS:

1. Water leakage through TAILGATE OR SEATBELTS due to improper fitting of

the TAILGATE BEADING.

2. Water leakage through inner BEADING of the DOORS due to DOOR SASH
PROBLEM.

3. Water leakage through the INNER BEADING of the FRONT DOORS due to
improper use of SEALANT for the ROOF.

4. Water leakage through D-pillar due to improper sealant filling.

3.10.2 SEVERE UNCOMMON PROBLEMS:

1. Leakage due to blow holes.

2. Leakage due to dents on tail gate.

3.10.3 ANALYSES OF PROBLEMS :

PROBLEM REASON CAUSE

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Leakage through the Improper fitting of the Tailgate and roof joint left
TAILGATE or SEATBELTS tailgate BEADING open hence loose tailgate
beading

Leakage through Inner BELT Improper sealant filling Sealant not continuously
of the doors applied on the roof
No checking in the BIW shop
for Sealant application
Roof of the cab too high for
the operators to apply sealant
in a proper manner
Water leakage through door Door sash is immature
sash
Water leakage through Improper SEALENT filling Change in operators
TAILGATE glass by the OPERATOR Improper Inspection
Water leakage through Improper SEALENT filling Change in operators
WINDSHIELD GLASS by the OPERATOR
Leakage through QUARTER Improper SEALENT filling Change in operators
GLASS by the OPERATOR
Front and Rear BIW joints mismatch

3.11 SOLUTIONS:

PROBLEM SOLUTION
Leakage through the TAILGATE or PS-Beating of joints suggested to be done
SEATBELTS regularly

TS-Proper pressing of TAILGATE beading

before fixing

Leakage through Inner BELT of the doors
PS- Change in sealant filling procedure
• Proper Instructions given to the
operator
• Strict follow up in BIW shop advised
TS- White sealant filled

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Water leakage through door sash No permanent solution

TS- pulling the door inside

PS- Instructions given to the operator
Water leakage through TAILGATE glass Follow up taken by supervisors

TS- black sealant filled

Water leakage through WINDSHIELD PS-Instructions given to the operator
GLASS Follow up taken by supervisors

TS- black sealant filled

Leakage through QUARTER GLASS PS-Instructions given to the operator
Front and Rear Follow up taken by supervisors

TS- black sealant filled

Abbreviations used:-

TS- Temporary solution PS- permanent solution

3.12 CONCLUSION:

After analysing the leakages in the cars during shower testing and after giving appropriate
suggestions, it was observed that

• Testing Procedure Time on the whole was reduced considerably

• As the leakages reduced , the damage of the interior parts was reduced, hence
reduction in losses

• The quality of the vehicle to the accepted standard, was obtained.

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