TAMILNADU COLLEGE OF ENGINEERING

Department of Automobile Engineering

AU3711-VEHICLE MAINTENANCE AND TESTING LABORATORY

(R -2021)
VII semester
Academic Year: ________________________________________________

Name

Reg. No

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Year

Branch

Certified That This Is Bonafide Record Of Work Done By The Above Student In The
Laboratory During The Year / Semester_____________

SIGNATURE OF LAB-IN-CHARGE SIGNATURE OF HEAD OF DEPARTMENT

SUBMITTED FOR THE PRACTICAL EXAMINATION HELD ON

____________________

Internal Examiner External

Examiner

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Ex Page
Date Name of the Experiment Staff sign
No. No.

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Staff In-Charge

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Ex No: 1

STUDY AND LAYOUT OF AN AUTOMOBILE REPAIR, SERVICE AND

MAINTENANCE SHOP.

AIM :
To draw the layout of an automobile repair, service and maintenance shop and study
the different sections of the layout.

DESCRIPTION:

SERVICE STATION:
A service is a place where in addition to care of the motor vehicle like mechanical
service and minor repairs, petrol is supplied, cars are lubricated, and cleaned, washed and
other types pf simpler services that are required daily are performed. In general it includes a
number of sections like garage general services, mechanical service, major repair shop, tyre
shop, paint shop, body shop etc.
A service station is addition to the equipment available is garage is usually run in
conjunction with a sales agency for a particular type of motor vehicle to provide
comprehensive repair service for that particular vehicle.
The equipment available, in general garage will be added with specialized equipment
like lifting tackle, and different types of jigs, fixtures and tools specially designed for
checking, adjusting and repair of particular type and make of vehicle. A service station may
consist of a machine shop having a lathe, drilling machine etc.
In case of big service station special types of machines like crankshaft grinding
machine, valve refacer, surface grinder, reboring and boring machine, brake drum lathe also
will be used. In service station fuel filling and water servicing facilities are available. It has a
small workshop to provide repair for particular make of vehicle. It may have sales agency for
a particular type of vehicle. All the equipment in the garage plus small workshop tools: viz,
lathe, drilling machine, jigs, fixtures are available.

LAYOUT OF GARAGES AND SERVICE STATION :

The internal layout of a garage should be such as to make it water proof, clean and
spacious to provide sufficient space for small workbenches to storage and repair benches.
Following considerations should be made in the layout of garage and service stations:
 To provide light to the workbenches, openings the windows should be provided at the
proper place.
 To keep the floor cleanable, it should be a smooth concrete floor with a surface-
scaling compound.
 The doors are provided as many members as required for easy flow of men and
materials.
 The electrical control should be accessible to the operators.
 To form a neat storage for hanging tools, hooks or screw eyes should be provided on
the pegboards.
 To provide a deposit of waste material.

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 Figure: Layout of Automobile Service Station

RESULT:
Thus, the general layout of an automobile repair, service and maintenance
shop was drawn and the functions of the different sections of the layout were studied.

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Ex No: 2

MINOR AND MAJOR TUNE-UP OF GASOLINE AND DIESEL ENGINES.

AIM:
To perform the major and minor tune-up of gasoline and diesel engines.

TOOLS AND INSTRUMENTS REQUIRED:

Cell tester, Double end spanner, Screw driver, Battery charger, Feeler guage, Pliers,
Ball-peen hammers, socket spanner, Wrenches, Dial indicators, Hydrometer, Files, Piston
ring expander, Piston ring compressor, Valve spring compressor, Spark plug spanner,
Grinding machine etc.

PROCEDURE:

PETROL ENGINE TUNE-UP:

Ridge in cylinder liner:

The wear starts in the linear from the height of ring travel i.e., on top of liner; there is
practically no wear. Since this portion does not come in contact with the rings. In worn out
engine you can feel this area by your finger running up and down in the liner. In case with
worn out liner when rings have to be changed to check up this ridge, in case it is prominent it
should be cut with ridge cutter. Then only new set of rings can be placed, otherwise there are
chances of new rings being thicker in width then the used worn out rings may strike the ridge
and break. Secondly, the piston assembly can easily slide in Boring and honing of cylinder
liners.

The cylinder bores do wear out after some use. The amount of wear can be controlled
to some extent by cleaning the air cleaner, keeping watch on proper working of cooling
system and lubrication system, in spite of all this care after 40 to 50 thousand kms in diesel
engine and in petrol engine 60 to 70 thousand kms wear is predominant in the liner which
you can see when you dismantle the engine for overhauling. From the worn out cylinder
bores few more life can be taken by boring the same with boring machine. When using the
boring machine, the boring tool will leave very fine line on the bore, which cannot be seen by
naked eyes. Presence of these lines of honing is not desirable. To rub these lines, bores are
honed, i.e., polished with the help of honing stone fixed in the cylinder hone head. These
hones are driven with portable electric hand drill and while working quickly up and down
motion are given.

Maintenance of flywheel:

Flywheel does not require much maintenance except that is mounting bolts with
crankshaft should be tightened with proper torque, the face where the clutch plate is fixed
sometimes gets scored because of loose rivals or rivets touching the face when lining is worn
out. Under such circumstances the face of flywheel should be got skimmed. The face of
flywheel should be examined at each overhaul and while changing clutch plates this face

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should be rubbed with emery paper to remove the glaze. The flywheel after fitting should be
checked that it is running true. For checking run out, place the crankshaft with the flywheel
mounted on V-block to avoid scoring of crankshaft main journal place paper in the V of V
block. Fix up dial gauge. With
its point resting on clutch plate mating surface, remove the crankshaft and note the run out. It
should not be more than 0.2 mm.

VALVE SERVICING:

The valve is subjected to very high temperature, runs at high speed and is one
of the critical part which requires careful examination at the time of overhaul while
inspecting the valve, take care of the following points:

Head:

Check the head for crack, burning, valve seat and radial run out. It should not have
knife edge warped and should have good margin. For checking radial runs out place the
valve in V block, fix up the pointer of dial guage on edge of valve head. Revolve the valve
and note the reading if run out is more than 0.33 mm. Discord the valve.

Valve system:

Valve system should be straight without scoring. If it is slightly bent it

can be straightened, but in case it is bent too much, valve should be replaced.

Refacing of valve :

Valve after dismantling from the head should be examined, if there is a good margin
still left over, it can be refaced and reused. It is desirable to mark each valve as it is removed
from the guide so that it may be put back to its original position. This may save quite a lot of
time in adjusting tappet clearance when the engine is reassembled. Moreover, fitting valve
back to its own-guide will ensure proper working clearance. For refacing valve, refacing
machine is used. It has a grinding wheel and a revolving chuck to hold the valve. The post on
which revolving chuck is fixed is movable, angle of which can be set and locked in any
specific angle.

Before starting grinding, check up that valve head is running true and valve head is
not protruding out much from the chuck. Otherwise it will not give desired finish, then start
the coolant supply directing it jet on grinding stone, bring the valve closer to the regular
hammering action, the tip of the valve also gets damaged, provision is also made in the
valve-refacing machine to reface.

GASOLINE ENGINE TUNE UP :

BATTERY
 Clean the battery terminals

 Check the loose connections.

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  Check the battery for fixing in box or cradle.

 Check up electrolyte level in the battery.

 Check up the capacity of battery.

CHARGING SYSTEM
 Visually inspect the dynamo for any wear

 Check up for any loose connections

 Check the belt from which dynamo gets power

 Check the charging rate.

STARTING SYSTEM
 Visually inspect the self-starter, cable and switch

 Check the working switch for any loose connections

 Check the consumption of current by starter motor.

IGNITION SYSTEM
 Check the cable connections from distributor to spark plugs

 Check the distributor shaft bushes for any looseness

 Check the contact breaker point

 Check the wear on distributor cam.

 Check the wear in distributor cap

 Check the ignition system with oscilloscope

FUEL SYSTEM
 Visually inspect for any leak

 Clean the air cleaner

 Check the functioning of choke

 Check the fuel pump pressure

 Check the plunger assembly

CARBURETTOR
 Check the fuel line from fuel pump to float chamber

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  Check the butterfly of the carburetor

 Adjust the height of the float

 Adjust the jet needle and needle jet

 After assembling, adjust the idle and high-speed adjustments

LUBRICATION SYSTEM
 Check the level of lubrication oil in the crankcase

 Check the lubrication oil filter, if clogged replace it with new one

 If the oil is bad, remove the oil and introduce new oil of the correct grade

COOLING SYSTEM
 Check the radiator for any damage and blocks

 Check the hoses that connect radiator and engine

 Check for any leakage

 Check the fan belt

 Use clean water in the radiation

TRANSMISSION LINE
 Visually inspect the transmission line for damages, cracks etc.

 Check the propeller shaft

 Check the differential assembly

 Check the state of lubrication oil in the differential assembly

DIESEL ENGINE TUNE UP :

FUEL INJECTION PUMP

 Visually inspect the flow lines from tank to pump and to injector

 Check the injection pressure

 Check for any wear and tear in the fuel injection pump

 Check the entire components of the fuel pump

FUEL INJECTOR
 Check the injector nozzle for any block and clean it thoroughly

 Check the pressure at which the nozzle sprays the fuel droplets

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  Adjust the screw for correct pressure

HEATER PLUG
 Check the heater plug by connecting it with battery terminal

 Check the heater plug for any dirt deposition

 Replace it after cleaning ii thoroughly

Also check the air induction system, fuel feed system and other
important components have to be checked for performing the tune up operations.

RESULT :

Thus the minor and major tune up of gasoline and diesel engines were performed.

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Ex No: 3
CALIBRATION OF FUEL INJECTION PUMP

AIM:
To study the calibration of fuel injection pump for a Multicylinder diesel engine.

TOOLS REQUIRED: fuel injection test bench, micro pump.

PROECDURE:
 The calibration test is usually carried to check connect quality of fuel is injected for
various load and speed condition. the rack of the fuel ump under test should be in no
load position when the test bench is started speed is controlled by hand wheel.

 Fit the correct rack setting device4 to the injection pump, remove the tapped
inspection cover gauge restriction wheel cock is kept closed to avoid the damage to
pressure gauge set the rack setting device to zero then connect the flexible supply line
to the supply connection build up the required pressure.

 By closing the valves, inspect for leakage the pump housing around discharge union,
air vents and locking screw. When the counter knob is engaged and start button one
electronic tachometer is pressed fuel will cut off the fuel to the test tub. Then the
speed of the varied for varying load condition and the corresponding fuel quantity
injected is noted and the readings are tabulated.

RESULT:
Thus the calibration of fuel injection pump for a multicylinder diesel engine is carried
Out.

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Ex No: 4

ADJUSTMENT OF PEDAL PLAY IN CLUTCH, BRAKE, HAND BRAKE LEVER

AND STEERING WHEEL PLAY

Aim:
Adjustment of pedal play in clutch, brake, hand brake lever and steering wheel play
1. Air bleeding from hydraulic brakes, air bleeding of diesel fuel system
2. Removal and fitting of tyre and tube

TOOLS REQUIRED:
Spanners, Screwdrivers, Hammers, Screwdrivers, Tyre removing etc.,

PROCEDURE:

(i) Adjustment of pedal play

Clutch pedal play adjustment

Clutch pedal free play (2 to 4 mm) is adjusted from clutch release arm with clutch
operating flexible cable coming from clutch pedal.
While fitting clutch release arm on the clutch release shaft, fix up the arm such that
the punched mark on the clutch release is shifted towards the front side but one notch from
the punched mark on the clutch release shaft, after tightening the arm fix up the cable and
adjust clutch pedal free play through adjuster nut 1. It is not possible to get the desired play
then adjust with adjuster nut 2.
Clutch Repairs and Inspection
1. Clutch facing and service limit
2. Loose holding down rivets
3. Check up the torque spring
4. Check for distortion or crack on clutch
5. Check for flat run out (<0.4 mm)
6. Check for lateral run out (<0.7 mm)

Brake pedal play adjustment

The free pedal play should be at least 12.7 mm or as recommended by the company.
The procedure for brake pedal play adjustment is as follows
 Raise the vehicle until the wheels are off the road.
 With a wrench loosen the locknut for the forward brake shoe and hold it.
 With another wrench turn the eccentric towards the front of the vehicle until brake
shoe strike the drum.
 While turning the wheel with one hand, release the eccentric until the wheel turn
freely.

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 Fig 9.1 Clutch Linkage

Fig 9.2 Clutch Pedal Play Adjustment

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 Fig 9.3

Fig 9.4

 Hold the eccentric in position and fasten the locknut.

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  Repeat this procedure to adjust the reverse shoe. But, turn the eccentric towards the
back of the vehicle.
 Repeat this on all the four brakes.
 Check the fluid level in the master cylinder.

Adjustment of Hand brake lever play

1. Pull up the parking lever all the way with one hand to apply brake fully and see
how many notches of ratchet the lever has traversed.
2. If the number of traversed notches is more than eight, then the parking brake
cable has to be adjusted.
3. Also, check the tooth tip of each notch for damage or wear. If any damage or wear
is found replace the parking lever.

Steering play adjustment

To check the amount of play in the steering system on vehicles with power steering,
check the condition and tension of the drive belt from the power steering pump. Then check
the fluid level in the pump reservoir. Start the engine. Next, with the front wheels in the
straight-ahead position, turn the steering wheel with a mark on a ruler or scale. Now slowly
turn the steering wheel in the opposite direction until the front wheels start to move again.
The distance that the steering wheel reference markahs moved along the ruler is theamount of
free play in the steering system. If the steering wheel rim moves too much before the front
wheels begin to move, there is excessive play.

Air Bleeding

The purpose of air bleeding is to remove the air bubbles.

The air bleeding is done by the following the procedure given below:
 Before brake bleeding, ensure sufficient oil is present in master cylinder.
 Start the process with the Wheel cylinder, which is far off from the master cylinder.
 First, fix up bleeder pipe in vent screw provided in the wheel cylinder.
 Keep the other end of pipe in glass bottle.
 Press the brake pedal 4 or 5 times and keep it pressed the last time.
 Now unscrew the vent screw of wheel cylinder.
 Brake oil and air bubbles come out in the glass bottle.
 When the pedal goes down, close the vent screw.
 Again repeat the procedure until all the bubbles are removed.

CONCLUSION:

Thus the following basic maintenance techniques were carried out.

Adjustment of pedal play in clutch, brake, hand brake lever and steering wheel play.

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Ex No: 5
WHEEL BEARING TIGHTENING AND ADJUSTMENT

AIM:
To adjust the wheel bearings and tightening

TOOLS REQUIRED:
Spanners, Screwdrivers, Hammers, Screwdrivers, etc.,

PROCEDURE:

 Hoist the vehicle and remove the rear wheel.

 Remove spindle cap by hammering at 3 or 4 locations.
 Remove the split pin, castle nut and washer.
 Check to ensure that the parking brake lever is not pulled up.
 Remove the back plate plug attached to the backside of brake plate, so as to increase
clearance between brake shoe and brake drum.
 Remove the wheel bearings.
 Insert the new stud in drum hole after rotating the stud slowly to assure the serrations
are aligned with these made by original bolt.
 Ensure that all the nuts are tightened properly.

CONCLUSION:

Thus the Wheel bearing tightening and adjustment were carried out.

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Ex No: 6

REMOVAL AND FITTING OF TYRE

AIM:
To Removal and fitting of tyre in a given tyre vehicle

TOOLS REQUIRED:
Spanners, Screwdrivers, Hammers, Screwdrivers, Tyre Remover etc.,

PROCEDURE:

The procedure for the removal and fitting of tyre and tube is as below:
1) Loosen the wheel nuts of tyre to be removed.
2) Place the wedge before and after resting the three wheels to prevent vehicle from
rolling.
3) Fix up jack and lift the vehicle to the extent that wheel is free from ground.
4) Remove the wheel after removing the wheel nuts.
5) Keep the wheel flat on ground and deflate it after removing valve with valve die.
6) Hammer the tyre at shoulder so that its bead is free from rim on both sides.
7) Press tyre lever between bead of tyre and rim flange.
8) Take another tyre lever; press it in the same way a little apart from the first lever.
9) Now press both levers down. By doing so some portion of tyre bead will come out
of rim.
10) Pull out first lever and insert it again at some distance away from the second lever.
Press it down.
11) Now go on changing the lever till tyre is out of the rim completely.
12) When one bead of tyre is out take out the tube after unscrewing valve body
securing nut.
13) If tyre is to be completely replaced, proceed in the same way to remove the second
bead.
14) In case, only tube is to be replaced, fix up the new tube.
15) Finally replace the tyre with caution using the levers and inflate it to correct
pressure.

CONCLUSION:

Thus the Tyre Removal and fitting of Tyre in given vehicle were carried out.

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Ex No: 7

WHEEL ALIGNMENT IN FOUR WHEELERS

AIM:
To contact the wheel alignment test on the given vehicles and to find the castor angle
and camber for a given vehicles.

TOOLS REQUIRED:
Wheel alignment gauge, spanner,

(i) Wheel alignment gauge

(ii) Toe-in and Toe-out bar
(iii) Turning table

DESCRIPTION:

The wheel alignment refers to the positioning of the front wheels and steering
mechanism that gives the vehicle directional stability, promotes case of steering and reduces
tyre wear to a minimum. A vehicle is said to have directional stability or control if it can run
straight down a road, enter and leave a turn easily and resist road shocks. The front wheel
alignment depends upon the following terms – Camber, Caster, Kingpin inclination, toe-in
and toe-out on turns. The front wheel geometry or steering geometry refers to the angular
relationship between the front wheels, the front wheel attaching parts and the vehicle frame.
All the above terms are included in the front wheel geometry. The various factors that affect
the wheel alignment of the vehicles are given below
1. Factors pertaining to wheel
a. Balance of wheels
b. Inflation of tyres
c. Brake adjustment
2. Steering Geometry
a. Camber
b. Caster
c. Kingpin inclination
d. Toe-in and Toe-out
3. Steering linkages
4. Suspension System

Camber

The angle between the centerline of the tyre and the vertical line when viewed from
the front of the vehicle is known as camber. When the angle is turned outward, so that the
wheels are farther apart at the top than at the bottom, the camber is positive. When the angle
is inward, so that the wheels are closer together at the top than at the bottom, the camber is
negative. Any amount of camber, positive or negative, tends to cause uneven or more tyre
wear on one side that on the other side. Camber should not
Exceed 20.

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 Fig 7.1

Procedure Fig 7.2

(i) Turn the wheel to 300 LHS
(ii) Adjust the sprit level such that the bubble occupies the center position.
(iii) Note the reading of the 600 scale.

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 (iv) Turn the wheel to 300 RHS and the above procedure is repeated and the
value is noted.
(v) The difference between the two readings gives the camber angle.

Caster

The angle between the vertical line and the kingpin centerline in the plane of the
wheel (when viewed from the side) is called the Caster angle. When the top of the king pin is
backward, the caster angle is positive and when it is forward the caster angle is negative. The
caster angle in modern vehicles range from 2 to 8 degrees.

Procedure
(i) Park the car on the turning table
(ii) Turn the wheel alignment gauge to 900.
(iii) Fix the wheel alignment gauge on the wheel.
(iv) Turn the wheel to 250 in RHS.
(v) Adjust the bubble to its original position
(vi) Note the reading on the 50-degree scale and the noted value will give the
caster angle.

RESULT:
Thus the front wheel geometry of the given car was studied.

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Ex No: 8

FAULT DIAGNOSIS AND SERVICE OF ELECTRICAL SYSTEM LIKE BATTERY,

STARTING SYSTEM, CHARGING SYSTEM

AIM:

To diagnose the fault and service of electrical system like battery, starting system

TOOLS REQUIRED:

Battery tester,Hydrometer,Multimeter,Voltmeter

PROCEDURE:

Charging system

The function of the charging system in an automobile is to generate,regulate and supply

the charging system. It consist of a generator, a regulator, realy and an ammeter or indicating
ramp to indicate whether the system is working or not.

STARTING SYSTEM:

TESTING OF STARTER MOTOR:

There are two ways of testing a starter motor

1 no load test:

Mount the starter motor in a fixture or vice

Adjust the carbon piece to obtain the specified voltage as recommended.
Start torque = spring reading *length of torque arm.

2 lightning system:

Illumination of the road

Indication of intended movement
Warning other road users
Indicated operating rates

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RESULT:

Thus the battery testing, maintenance and faults in the electrical system such as lights ride
or parking lights, wind screen, wiper system and charging system was studied.

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Ex No: 9

FAULT DIAGNOSIS OF BRAKE SYSTEM - AIR BLEEDING FROM HYDRAULIC

BRAKES

AIM:
To diagnose the fault and service of braking system.
Tools required:
 Caliper rocket set
 Brake shoe hold down spring tool
 Bleeder wrenches.
Procedure:
 Check for proper pedal operations
 The pedal should feed not spongy.
 Low pedal indicate a leak.
 Excessive wear
 Swing
 Out of sound.

Result:
Thus the system Fault diagnosis and service of braking system.

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Ex No: 10

PERFORMANCE TEST OF A TWO WHEELER USING CHASSIS

DYNAMOMETER

APPARATUS REQUIRED:

o Chassis dynamometer.
o Engine RPM pickup probe [Red probe].

PRE-TEST INSPECTION:

Check the tyre pressure.

PROCEDURE:

 Load the vehicle on test rig

 Lock the font wheel so that the center of the rear wheel would test on the
roller found.
 Secure the chain on the seat and lock it properly for safety concern.
 Fix the RPM probe [red probe] on the high tension lead from spark plug.
 Run the Chassis Dynamometer software by the shortcut on desktop on PC.
now the main will open
 Click the triangle one the menu or press.
 Now a message will pop up, informing to start and warm up the engine.
 Start the two wheeler and keep it in neutral gear and warm up for two minutes.
 Enter the title name.
 Now press the start icon.
 Run the vehicle and gradually shift the gear to top gear.
 Accelerate the engine to maximum speed.
 Now press the clutch and release the acceleration level.
 Wait till roller stops.
 Close the popup menu.
 The test result will be stored.
 Press the printer icon to take the print out.

Result:
Thus the performance test of two wheeler was done and the results are,
Maximum power: 6.4kw
Minimum power: 16.51 N.M

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