Automotive Components Lab Manual - New

BHARATHIDASAN INSTITUTE OF TECHNOLOGY (BIT) CAMPUS
ANNA UNIVERSITY
TIRUCHIRAPPALLI-620024
DEPARTMENT OF AUTOMOBILE ENGINEERING
LABORATORY MANUAL
AT 6311 AUTOMOTIVE COMPONENTS LABORATORY
NAME OF THE STUDENT:
REGISTER NUMBER:
YEAR /SEMESTER/SECTION:
BHARATHIDASAN INSTITUTE OF TECHNOLOGY (BIT) CAMPUS, TIRUCHIRAPPALLI - 24 Page 1

VISION
Committed to serve the society by state of art engineering education to develop attitudes,
skills, and values while establishing development in pioneer areas of automobile engineering
MISSION
• To provide a scholarly and vibrant learning environment for achieving professional
competency
• To create successful professionals who contribute their knowledge, skill and attitudes
to design, re-design, research & development in the automotive industry
• To make their noteworthy contributions in developing the society through continuous

learning – teaching methodology
Programme Educational Objectives

The Graduates will
• Be successful in their professional careers in automobile industries that meet the
needs of Indian and Multinational companies
• Develop the ability to synthesize data for application in automotive design
• Build up the attitude of self-reliance, creativity, professional ethics and the capacity
for continuing professional and intellectual growth.
• Demonstrate leadership qualities in activities related to sustainable development of
society

Programme Outcomes
The programme is preparing the graduates
(a) To apply knowledge of mathematics, science and engineering in the field of
automobile engineering
(b) To design and conduct experiments, as well as to analyze and interpret data related to
automobile engineering
(c) To design a system, component, or process to meet desired the automotive needs
within realistic constraints such as economic, environmental, social, political, ethical,
health and safety, manufacturability & sustainability,
(d) To identify, formulate, and solve complex automobile engineering problems.
(e) To use the techniques, skills, and modern engineering tools necessary for automobile
engineering practice.
(f) To apply knowledge to assess societal, health, safety, legal, and cultural issues and the
consequent responsibilities relevant to the professional engineering practice
(g) To understand the impact of engineering solutions in a global, economic,
environmental, and societal context,.
(h) To demonstrate professional and ethical responsibility
(i) To work in teams and apply interpersonal skills in engineering contexts
(j) To communicate effectively with a wide range of both engineering and non-
engineering personnel
(k) To follow management and financial principles and apply them in execution of
projects
(l) To lay a foundation for continued learning beyond graduation

AT 6311 – AUTOMOTIVE COMPONENTS LABORATORY
Course Objective
• To train the Students to know the details of different components, dismantling and
assembling them.
Course outcome
• Identify & locate various elements of automobile for dismantling and assembling of
different elements.
• Understand the construction, principle & working of automobile.

A LIST OF BASIC SAFETY RULES
1. When you handle chemicals wear eye protection (chemical splash goggles or full face
shield).
2. When you work with furnaces for heat treatment procedures or other thermally activated
equipment you should use special gloves to protect your hands.
3. Students should wear durable clothing that covers the arms, legs, torso and feet. (Note:
sandals, shorts, tank tops etc. have no place in the lab. Students inappropriately dressed for
lab, at the instructors discretion, be denied access)
4. To protect clothing from chemical damage or other dirt, wear a lab apron or lab coat. Long
hair should be tied back to keep it from coming into contact with lab chemicals or flames.
5. In case of injury (cut, burn, fire etc.) notify the instructor immediately.
6. In case of a fire or imminently dangerous situation, notify everyone who may be affected
immediately; be sure the lab instructor is also notified.
7. If chemicals splash into someone's eyes act quickly and get them into the eye wash station,
do not wait for the instructor.
8. In case of a serious cut, stop blood flow using direct pressure using a clean towel, notify
the lab instructor immediately.
9. Eating, drinking and sleeping are prohibited in the laboratory at all times.
10. Never work in the laboratory without proper supervision by an instructor.
11. Never carry out unauthorized experiments. Come to the laboratory prepared. If you are
unsure about what to do, please ask the instructor.
12. Always remember that HOT metal or ceramic pieces look exactly the same as COLD
pieces are careful what you touch.
13. Know the location and operation of :Fire Alarm Boxes, Exit Doors and Telephones.

LABORATORY CLASSES - INSTRUCTIONS TO STUDENTS
1. Students must attend the lab classes with ID cards and in the prescribed uniform.
2. Boys-shirts tucked in and wearing closed leather shoes. Girls‟ students with cut shoes,
overcoat, and plait incite the coat. Girls’ students should not wear loose garments.
3. Students must check if the components, instruments and machinery are in working
condition before setting up the experiment.
4. Power supply to the experimental set up/ equipment/ machine must be switched on only
after the faculty checks and gives approval for doing the experiment. Students must start to
the experiment. Students must start doing the experiments only after getting permissions from
the faculty.
5. Any damage to any of the equipment/instrument/machine caused due to carelessness, the
cost will be fully recovered from the individual (or) group of students.
6. Students may contact the lab in charge immediately for any unexpected incidents and
emergency.
7. The apparatus used for the experiments must be cleaned and returned to the technicians,
safely without any damage.
8. Make sure, while leaving the lab after the stipulated time, that all the power connections
are switched off.
EVALUATIONS:
1. All students should go through the lab manual for the experiment to be carried out for that
day and come fully prepared to complete the experiment within the prescribed periods.
2. Student should complete the lab record work within the prescribed periods.
3. Students must be fully aware of the core competencies to be gained by doing
experiment/exercise/programs.
4. Students should complete the lab record work within the prescribed periods.
5. The following aspects will be assessed during every exercise, in every lab class and
marks will be awarded accordingly:
Preparedness, conducting experiment, observation, calculation, results, record
presentation, basic understanding and answering for viva questions.
In case of repetition/redo, 25% of marks to be reduced for the respective component.
NOTE 1
Preparation means coming to the lab classes with neatly drawn circuit diagram
/experimental setup /written programs /flowchart, tabular columns, formula, model graphs etc

in the observation notebook and must know the step by step procedure to conduct the
experiment.
Conducting experiment means making connection, preparing the experimental setup
without any mistakes at the time of reporting to the faculty.
Observation means taking correct readings in the proper order and tabulating the readings in
the tabular columns.
Calculation means calculating the required parameters using the appropriate formula and
readings.
Result means correct value of the required parameters and getting the correct shape of the
characteristics at the time of reporting of the faculty.
Viva voice means answering all the questions given in the manual pertaining to the
experiments.
Full marks will be awarded if the students performs well in each case of the above
component
NOTE 2
Incompletion or repeat of experiments means not getting the correct value of the
required parameters and not getting the correct shape of the characteristics of the first
attempt. In such cases, it will be marked as “ IC” in the red ink in the status column of the
mark allocation table given at the end of every experiment. The students are expected to
repeat the incomplete the experiment before coming to the next lab. Otherwise the marks for
IC component will be reduced to zero.
NOTE 3
Absenteeism due to genuine reasons will be considered for doing the missed
experiments. In case of power failure, extra classes will be arranged for doing those
experiments only and assessment of all other components preparedness; viva voice etc. will
be completed in the regular class itself.
NOTE 4
The end semester practical internal assessment marks will be based on the average of
all the experiments.

LIST OF EXPERIMENTS
Sl.No. Name of the Experiments
1 Dismantling and study of Multi-cylinder Petrol Engine
2 Assembling of Multi-cylinder Petrol Engine
3 Dismantling and study of Multi-cylinder Diesel Engine
4 Assembling of Multi-cylinder Diesel Engine
5 Study of petrol engine fuel system
6 Study of diesel engine fuel system
7 Study and measurement of light and heavy commercial Vehicle Frame
8 Study, dismantling and assembling of front and rear Axles
9 Study, dismantling and assembling of differential
10 Study, dismantling and assembling of Clutch
11 Study, dismantling and assembling of Gear Box
12 Study of steering system
Experiments beyond the syllabus
13 Wheel alignment: measuring and adjustment of castor, camber, king-
14 pin inclination,
Study, toe-in
dismantling andand toe- out of braking system
assembling

Cycle – I
Experiment Observation Record Remarks

Sl.No Name of the Experiment
Date Date Date
1 Dismantling and study of Multi-cylinder

Petrol Engine
2 Assembling of Multi-cylinder Petrol

Engine
Dismantling and study of Multi-cylinder

3
Diesel Engine
Assembling of Multi-cylinder Diesel

4
Engine
5 Study of petrol engine fuel system
6 Study of diesel engine fuel system
Study and measurement of light and

7
heavy commercial Vehicle Frame

Cycle – II
Experiment Observation Record Remarks

Sl.No Name of the Experiment
Date Date Date
Study, dismantling and assembling of front

1
and rear Axles
Study, dismantling and assembling of

2
differential

3
Clutch
Study, dismantling and assembling of Gear

4
Box
5 Study of steering system
Experiment - Beyond the syllabus
Wheel alignment: measuring and adjustment
6 of castor, camber, king-pin inclination, toe-in
and toe- out

7
braking system

DEVELOPMENT OF SKILLS:
Intellectual Skill
I1: Identify & locate various elements of automobile for dismantling and assembling of
different elements.
I2: Select proper tools and their range
I3: Understand the construction, principle & working of automobile
I4: Take the reading from the instrument
Motor Skill
M1: Draw a neat sketch of an auto engine component
M2: Use of various tools
M3: Disassembling and assembling
M4: To operate the automobile

FIG I: LAYOUT OF MAJOR COMPONENTS IN AN AUTOMOBILE
FIG II: CHASIS AND FRAME

STUDY ON MAJOR COMPONENTS OF AN AUTOMOBILE
Ex. No:
Date :
Aim:
To study about the various functions of major components of an automobile.
Introduction:
1. Chasis and Frame:
The chasis is formed by the frame with the frame side members and cross members.
The frame is usually made of box, tubular and channel members that are welded or riveted
together. In addition to this, it comprises of the springs with the axles and wheels, the steering
system and the brakes, the fuel tank, the exhaust system, the radiator, the battery and other
accessories. Along with this the frame supports the body.
2. Engine or Power Plant
The engine is the power plant of the vehicle. In general, internal combustion engine
with petrol or diesel fuel is used to run a vehicle. An engine may be either a two-stroke
engine or a four-stroke engine.
An engine consists of a cylinder, piston, valves, valve operating mechanism, carburetor (or
MPFI in modern cars), fan, fuel feed pump and oil pump, etc.
Besides this, an engine requires ignition system for burning fuel in the engine cylinder.
3. Transmission System (Clutch and Gear Box)
The power developed by the engine is transferred to the wheels by transmission
system. Transmission system must do three jobs:
(a) It must provide varying gear ratios. Numbers of gear ratios are equal to number of gears in
a vehicle.

FIG III CLUTCH
FIG IV GEAR BOX

(b) It must provide a reverse gear for moving vehicle in reverse direction.
(c) It must provide a neutral or disconnecting arrangement so that the engine can be
uncoupled from the wheels of the vehicle. In a conventional transmission system, there is a
clutch, a manually operated transmission (gear box), a propeller shaft and a differential or
final drive.
4. Clutch
The purpose of the clutch is to allow the driver to couple or decouple the engine and
transmission. When clutch is in engaged position, the engine power flows to the transmission
through it (clutch). When gears are to be changed while vehicle is running, the clutch permits
temporary decoupling of engine and wheels so that gears can be shifted. In a scooter, the
clutch is operated by hand where as in a car the clutch is operated by foot. It is necessary to
interrupt the flow of power before gears are changed. Without a clutch, it will be very
difficult.
5. Final Drive
Final drive is the last stage in transferring power from engine to wheels. It reduces the
speed of the propeller shaft (drive shaft) to that of wheels. It also turns the drive of the
propeller shaft by an angle of 90o to drive the wheels.
The propeller shaft has a small bevel pinion which meshes with crown wheel. The crown
wheel gives rotary motion to rear axles. The size of crown wheel is bigger than that of bevel
pinion, therefore, the speed of rear axles (or crown wheel) in lower than the speed of pinion.
Final drive is of two types, i.e. chain type and gear type.

6. Braking System
Brakes are used to slow down or stop the vehicle. Hydraulic brakes are generally used
in automobiles, where brakes are applied by pressure on a fluid. Mechanical brakes are also
used in some vehicles. These brakes are operated by means of leavers, linkages, pedals, cams,
etc. Hand brake or parking brake is usually a mechanical brake. These are used for parking
the vehicles on sloppy surfaces and also in case of emergency.
7. Gear Box
Gear box contain gearing arrangement to get different speeds. Gears are used to get
more than one speed ratios. When both mating gears have same number of teeth, both will
rotate at same number speed. But when one gear has fewer teeth than other, the gear with less
number of teeth will rotate faster than larger gear. In a typical car, there may be six gears
including one reverse gear. First gear gives low speed but high torque. Higher gears give
progressively increasing speeds. Gears are engaged and disengaged by a shift lever.
8. Steering System
In front wheels can be turned to left and right by steering system so that the vehicle
can be steered. The steering wheel is placed in front of driver. It is mechanically linked to the
wheels to provide the steering control. The primary function of the steering system is to
provide angular motion to front wheels so that vehicle can negotiate a turn. It also provides
directional stability to vehicle when the vehicle moves ahead in straight line.
Now-a-days, many vehicles are equipped with power steering which uses pressure of a fluid
to reduce steering effort. When driver turns the steering wheel, a hydraulic mechanism comes
into play to provide most of the effort needed to turn the wheel.
9. Front Axle
Front axles are mounted at the end of front axle. A part of the weight of vehicle is
transmitted to the wheels through this axle. The front axle performs several functions.

It carries the weight of the front of the vehicle and also takes horizontal and vertical loads
when vehicle moves on bumpy roads. When brakes are provided on front wheels, it endures
bending stresses and torsional stresses. It is generally made from steel drop forging. It is
robust in construction.
10. Suspension System
Suspension system of an automobile separates the wheel and axle assembly of the
automobile from its body. Main function of the suspension system is to isolate the body of
the vehicle from shocks and vibrations generated due to irregularities on the surface of roads.
Shock absorbers are provided in the vehicles for this purpose.
It is in the form of spring and damper. The suspension system is provided both on front end
and rear end of the vehicle.
A suspension system also maintains the stability of the vehicle in pitching or rolling when
vehicle is in motion.
RESULT:
Thus the major components of an automobile and its functions were studied.

IDENTIFICATION AND APPLICATION OF MECHANIC’ S TOOLS
Ex. No:
Date :
Aim:
To identify the various mechanic’ s tools and to study the applications of each tool.
Introduction:
A good automobile shop must have equipment to undertake all types of fault finding
and servicing jobs. The following is a list of tools and equipments, which are a must in the
auto shop.
1. Screw driver:
These are used to tighten or loose the screw in the machine element. The main parts
of screwdrivers are,
i. Handle which is a smooth and shaped properly for good grip. It is usually made of wood on
moulded plastics.
ii. Blade made of hardened and tempered carbon steel or alloy steel for strength. Blades are
usually rounded, though occasionally square or rectangular sections are also used. The length
sizes various from 40 mm to 250 mm or even more. The ends of the blades are formed in to
flared tips for turning screw by fitting in to their head slots.
iii. Screwdrivers are specified according to the length of the blade and width of the tip.
Normally blade length of 45mm and 300mm and tips 3mm to10mm wide are available.
2. Spanners:
These are also called wrenches. These are used for tightening or loosening the nuts.
These are made of high tensile or alloy steel and are drop forged & heat-treated. Their size in
determined by the nuts or blots is fits. In the unified system used commonly, the spanners are
marked with sign A/F followed by a number representing decimal equivalent of the nominal

size across the flats of the hexagonal nuts or bolts. The following types of spanner are
commonly used.
3. Ring Spanners:
The ring spanners also called box spanners. The end openings completely enclosed by
the nuts and the bolt heads, for which they cannot slip and cause damage. Further the end
holes in some ring spanners are twelve sides, because of which they can be used in restricted
spaces.
4. Open-Ended Spanners:
These are the most commonly used type of the spanners in the garage, although they
may not be the best means of tightening or loosening the nuts. Therefore these are employed
where ring spanners or socket wrenches cannot work.
It is observed that spanner opening is kept at an angle with the body axis. This is done to
facilitate the turning of the nut in restricted space.
5. Combination Spanners:
These are on one end and have hole on the other end. Thus they are combination of
open-ended and the ring spanners. Initially for loosening jammed nuts more torque is
required and we use ring end, which will not slip. However after the nut is already loose, it is
more convenient to further continue with the open end.
6. Socket Spanner:
These types of spanners are useful in restricted spaces where common types of
spanners cannot be used. Both 6&12-point socket should be included in the well-equipped
tool kit. This consists of different sizes, which can be used with various types of handles. A
part from handles, both electric and air operated impact wrenches are used to drive socket for
speeding up the work.

FIG III MECHANIC TOOLS

7. Torque Wrench:
Important nuts and bolts in automobile work have to be tightened with the specified
amount of torque because excessive torque may result in there breakage while with lesser
torque they will come out loose during use. This is made possible by a torque wrench. It is a
specialized form of a socket spanner.
8. Wheel Nut Spanner:
A number of different types of spanners are used for tightening or loosening wheel
nuts.
9. Allen Wrenches:
Allen keys are used on Allen screws, which have hexagonal shaped grooves in their
heads.
10. Pliers:
Different types of pliers have been shown in figure. A plier a device mainly used
gripping only and should never be used as substitute for spanners that will damage the nut by
rounding off its corner.
11. Hammers:
A hammer is a tool used for striking operations such as denting, bending, punching,
straightening, riveting, etc. the head and the handle form the two parts of hammers. The head
is made of drop forged carbon steel and has a hole for fitting the handle there in. A medium
weight ball peen hammer is the one commonly used in automobile work.
12. Chisels:
A common application is the tearing open of corroded nuts and bolts with a flat
chisels. The main parts of a chisels are the head the body and the cutting edge or point. These
are made of high carbon steel or chrome vanadium steel. Chisels should be kept sharp. These
should be sharpened approximately 60 degree included angle.

13. Files:
Files are used for smoothing rough surface and for removing small amount of metal.
The cut in file may be classified either as single cut or double cut, depending up on whether
they have cuts in one direction or in both directions. Files may be also be classified according
to the shape of cross section.
14. Hacksaws:
Hacksaws are meant for cutting metals by sawing. A hacksaw consists of an
adjustable frame with a handle and replaceable hacksaw blade. The construction of the
hacksaw is such that different blade length can be accommodated within limits. The hacksaw
blade has a thin harrow strips with teeth on one or both sides and two pin holes at the ends.
15. Drilling Machine:
Drilling machine may be hand operated or electrical ones. The tool used for drilling is
called a twist drill. It is main parts are shank, body and the point; shank is fitted in to the drill
chuck of the machine, while the points is the conical end, which does the cutting. The cutting
edges of the point are called tips.
16. Twist Drill:
The position of the drill between the shank and the point is termed body, which
consist mainly of the spiral grooves called flutes. These form the cutting edges and provided
passage for the chips to come out and the coolant to flow down to the point. A set of twist
drills, generally from 0.5mm to 6mm is sufficient for automobile work.
17. Reamers:
After drilling the hole, the same can be finished by a reamer. It may be a straight
fluted type and spiral fluted type. The initial hole is drilled by a drill 0.3mm smaller then the
final finished size required, after which the reamer is turned only in the forward direction till
the desired size is obtained.

18. Bench Vice:
Bench vice is used to hold the component while it is worked on. This is permanently
fixed on the workbench. While holding the component some soft material is placed in the
vice, it is better to place some other wooden or plastic flats between the vice jaws and the
components to avoid damage to the later.
19. Steel Rule:
Most simple tool for measurements length is the ordinary steel rule, which is 300 mm
long. It is quite satisfactory for measurement with accuracy up to 0.5mm. Besides straight
edges of the steel rule or even otherwise unmarked straight edge may be used to measure
surface irregularities.
20. Outside Micrometer:
In case of measurements where still greater accuracy is required in that place
micrometer is used. External dimension of parts such as thickness, diameter are measured
with the help of outside micrometer, whereas internal dimensions are measured with inside
micrometer.
21. Lifting Jacks:
To work under the car or to change wheels, it is necessary to lift the car. For, doing
this, lifting jack is use which may be mechanically or hydraulically operated. Such a jack is a
standard accessory with many cars. It consists of a diamond shaped frame having a nut on
one side and a sleeve on the other side.
22. Axle Stand:
It is always necessary to make sure that before start working the car with axle stand.
The axle is not suppurated by the jack or any other support and also it is not safe to use
bricks, for supporting purpose. So axle stand is the batter way to support the weight of the
vehicle.

23. Vernier Caliper:
Most simple tool for measurements length is the ordinary steel rule, which is 300 mm
long. It is quite satisfactory for measurement with accuracy up to 0.5mm.besides straight
edges of the steel rule or even otherwise unmarked straight edge may be used to measure
surface irregularities. Used in hole diameter, depth of hole, outerdiameter and inner
diameters.
RESULT:
Thus the various mechanic tools are identified and the applications were studied.

FIG 1.1 CYLINDER BLOCK
FIG 1.2 CRANKCASE

FIG 1.3 CYLINDER HEAD

FIG 1.4 SUMP OR OIL PAN
FIG 1.5 GASKETS

FIG 1.6 INLET AND EXHAUST MANIFOLD

DISMANTLING OF MULTICYLINDER PETROL ENGINE
Ex. No : 1
Date :
AIM:
To dismantle the given 4-cylinder petrol engine
TOOLS REQUIRED:
Double ended spanner, ring spanner, tubular spanner, socket wrenches, nose pliers, circlip
plier, ball peen hammer, ratchet spanner etc.
PROCEDURE:
The given engine with its accessories and with the oil drained should be removed from
the vehicle and dismantled. Engine dismantling should be carried out in a sequence as
explained below
As the components are removed they should be grouped properly and placed
conveniently on a bench or table, prior to cleaning. Before taking of any components from
the engine unit make sure that it is marked identically with mating part.
1. Get the tool set.
2. Remove the water pump.
3. Remove the exhaust manifold.
4. Remove the water outlet.
5. Remove the thermostat.
6. Remove all external accessories like motor, dynamo, ignition unit, and spark plug.
7. Remove engine sump. Disconnect oil pump drive and oil pump at the most convenient
stage in the preceding operation. The oil filter and cleaner are removed. Dipstick or
level gauge is taken out.
8. Remove timing gear cover, after removing pulley etc.
9. Remove clutch unit.
10. Take off all valves with their tappets, rocker arms, push rods etc.
11. Remove the cylinder head.
12. Remove connecting rod big end caps, pistons and connecting rods.
13. Take off timing chain and remove sprockets.
14. Remove crankshaft with flywheel by taking off main bearing caps.
15. Remove camshaft.
16. If necessary, drive out valve guides.
Clean the engine components.

All components are to be immersed in a bath on a deep tray containing oil scrub with bristle
brush to remove all dirt.

After cleaning the parts are to be placed on a metal plate or slab and dry them in a warm
place
RESULT:
Thus the given 4-cylinder petrol engine is dismantled and studied.

RUBRICS
Grade
S.No Description Excellent Good Satisfactory
Obtained
Aim and Tools

1. 3 2 1
Required
Theory and
2. 3 2 1
Components sketch
Formula, calculation
3. 3 2 1
and units
4. Procedure 3 2 1
5. Results and Discussion 3 2 1
Significance and
6. Application of the 3 2 1
experiments
Total

FIG 2.1 FOUR STROKE PETROL ENGINE WORKING CYCLE
FIG 2.2 EXPLODED VIEW OF AN ENGINE

ASSEMBLING OF MULTICYLINDER PETROL ENGINE
Ex. No : 2
Date :
AIM :
To assemble the given dismantled 4-cylinder petrol engine
TOOLS REQUIRED :
Double ended spanner, ratchet spanner, ring spanner, ball peen hammer, nylon hammer,
circlip plier etc.
PROCEDURE :
After dismantling all the parts they are inspected carefully and the defective parts arte
replaced and the reassembling of the engine is done in following sequence.
2. Place the oil gallery plugs in their places.
3. Place the valve tappets and push rods in their places
4. Assemble the camshaft
5. Assemble the inlet valves; exhaust valves and rocker arm assembly with cylinder
head.
6. Assemble the crankshaft and tighten the main bearings to the required torque level
using torque wrench.
7. Assemble the piston and connecting rod assembly
8. Assemble the piston rings back on piston with the help of piston ring compressor
9. Assemble the clutch
10. Screw back in position the flywheel housing
11. Assemble the oil pan
12. Assemble the cylinder head
13. Assemble all external accessories like motor, dynamo, ignition unit and spark plug
14. Assemble the sprockets and timing chain
15. Assemble the thermostat
16. Assemble the water inlet, outlet hoses, water pump and radiator.
17. Assemble the Inlet and exhaust manifolds.
In all cases the torque wrench is used to tighten the nuts to the required torque level.
RESULT:
The given dismantled 4-cylinder petrol engine is assembled

RUBRICS
Grade
Obtained
Aim and Tools

1. 3 2 1
Required
Theory and
2. 3 2 1
Components sketch
3. 3 2 1
and units
4. Procedure 3 2 1
Significance and
experiments
Total

FIG 3.1 CYLINDER LINERS
FIG 3.2 PISTON RINGS:

FIG 3.3 CONNECTING ROD
FIG 3.4 CRANKSHAFT

FIG 3.5 VALVES:

DISMANTLING OF MULTICYLINDER DIESEL ENGINE
Ex. No: 3
Date :
AIM:
To dismantle the given 4-cylinder petrol engine
TOOLS REQUIRED:
Double ended spanner, ring spanner, tubular spanner, socket wrenches, nose pliers,
circlip plier, ball peen hammer, ratchet spanner etc.
PROCEDURE:
The given engine with its accessories and with the oil drained should be removed from
the vehicle and dismantled. Engine dismantling should be carried out in a sequence as
explained below
As the components are removed they should be grouped properly and placed
conveniently on a bench or table, prior to cleaning. Before taking of any components from
the engine unit make sure that it is marked identically with mating part.
2. Remove the water pump.
3. Remove the exhaust manifold.
4. Remove the water outlet.
5. Remove the thermostat.
6. Remove all external accessories like motor, dynamo, injection pump and injector.
7. Remove engine sump. Disconnect oil pump drive and oil pump at the most convenient
stage in the preceding operation. The oil filter and cleaner are removed. Dipstick or
level gauge is taken out.
8. Remove timing gear cover, after removing pulley etc.
9. Remove clutch unit.
10. Take off all valves with their tappets, rocker arms, push rods etc.
11. Remove the cylinder head.
12. Remove connecting rod big end caps, pistons and connecting rods.
13. Take off timing chain and remove sprockets.
14. Remove crankshaft with flywheel by taking off main bearing caps.
15. Remove camshaft.
16. If necessary, drive out valve guides.
Clean the engine components.
All components are to be immersed in a bath on a deep tray containing oil scrub with bristle
brush to remove all dirt.
After cleaning the parts are to be placed on a metal plate or slab and dry them in a warm
place

RESULT:
Thus the given 4-cylinder diesel engine is dismantled

RUBRICS
Grade
Obtained
Aim and Tools

1. 3 2 1
Required
Theory and
2. 3 2 1
Components sketch
3. 3 2 1
and units
4. Procedure 3 2 1
Significance and
experiments
Total

FIG 4.1 FOUR STROKE DIESEL ENGINE WORKING CYCLE
FIG 4.2 LUBRICATION SYSTEM

ASSEMBLING OF MULTICYLINDER DIESEL ENGINE
Ex. No: 4
Date :
AIM:
To assemble the given dismantled 4-cylinder diesel engine.
TOOLS REQUIRED:
Double ended spanner, ratchet spanner, ring spanner, ball peen hammer, nylon hammer,
circlip plier
PROCEDURE:
After dismantling all the parts they are inspected carefully and the defective parts arte
replaced and the reassembling of the engine is done in following sequence.

2. Place the oil gallery plugs in their places.
3. Place the valve tappets and push rods in their places
4. Assemble the camshaft
5. Assemble the inlet valves; exhaust valves and rocker arm assembly with cylinder
head.
6. Assemble the crankshaft and tighten the main bearings to the required torque level
using torque wrench.
7. Assemble the piston and connecting rod assembly
8. Assemble the piston rings back on piston with the help of piston ring compressor
9. Assemble the clutch
10. Screw back in position the flywheel housing
11. Assemble the oil pan
12. Assemble the cylinder head
13. Assemble all external accessories like motor, dynamo, injection pump and injector
14. Assemble the sprockets and timing chain
15. Assemble the thermostat
16. Assemble the water inlet, outlet hoses, water pump and radiator.
17. Assemble the Inlet and exhaust manifolds.
In all cases the torque wrench is used to tighten the nuts to the required torque level.
RESULT:
The given dismantled 4-cylinder diesel engine is assembled

RUBRICS
Grade
Obtained
Aim and Tools

1. 3 2 1
Required
Theory and
2. 3 2 1
Components sketch
3. 3 2 1
and units
4. Procedure 3 2 1
Significance and
experiments
Total

FIG 5.1 SCHEMATIC DIAGRAM OF FUEL SUPPLY SYSTEM IN PETROL
ENGINE
FIG 5.2 SIMPLE CARBURETOR

FIG 5.3 SOLEX CARBURATOR
FIG 5.4 FLOAT CIRCUIT

FIG 5.5 IDLING CIRCUIT & ACCELERATION CIRCUIT:
FIG 5.6 AC MECHANICAL FUEL PUMP

STUDY OF PETROL ENGINE FUEL SYSTEM
Ex no: 5
Date :
AIM:
To dismantle, study and assemble the given petrol engine fuel system.
TOOLS REQUIRED:
Screw driver, Double ended spanner, combination player, nylon hammer.
PROCEDURE:
Rotor type Oil Pump

The dismantling of the oil pump is done in the following sequence. The screw’ s which holds
the engine is removed first. Now the gear meshes are separated and then the pump driver
which is connected with the cam shaft is removed. The pump driver is nothing but a gear
connected with the camshaft
WORKING:
A is the external rotor having the number of lobes one more then on the internal rotor
B. The axes of rotation of the two rotor are different which cause the size of the spaces
between them to vary. Rotor B gets its drive from the engine camshaft and cause rotor A to
rotate along with it. The oil centers the pump through inlet port, as the rotor lobes are moving
out of mesh, as the lobes of the rotors move into mesh at the outlet port. This type of pump is
25% more efficient and compact then the pump. This is also quieter running since there are
comparatively lesser teeth in mesh for each revolution. Because of these advantages, its use is
on increase in the engine.
The assembling of the pump is carried in the reverse manner opposite to that of the
dismantling
A.C. Mechanical Fuel Pump

This dismantling of the A.C.Mechanical fuel pump is done in the following sequence.
The upper and the lower body are separated. The end cap and valve assembly ios the
dismantled. The rocker arm is now dismantled. The diaphragm assembly is separated from
lower body. Now the one way valve assembly is dismantled which completes the total
dismantling of the A.C.Mechanical fuel pump.
WORKING
The rocker arm, is operated by the eccentric of the cam shaft. By the up and down
motion of the rocker arm the diaphragm is operated, which sucks the fuel in through the in let
valve opening. Now the alternate motion of the diaphragm, this strained fuel is pushed out
through the pressure valve into the outlet valve opening to the carburetor.
The assembly of the A.C.Mechanical fuel pump is done exactly opposite to that of the
dismantling procedure

Solex Carburetor:
Solex carburetor is a down drought type of carburetor with special provision for a progressive
starter, which supplies richer mixture for starting and then gradually weakens if till the engine
has richen its normal operating temperature.
STARTING CIRCUIT
The starting valve is in the form of a flat disc with holes of different sizes. These holes
cannot allow the petrol jet and start the jet sides to the passage, which opens into the air horn
just below the throttle valve. Initially for starting purpose, a rich mixture is required and after
the engine starts the richness decreases.
IDLING CIRCUIT
In the idle port, it controls the idle adjusting screw is provided in the engine side of
throttle valves. As the throttle is almost closed, the engine suction is applied at the pilot petrol
jet, which supplies petrol. The jet itself drops the petrol from the main jet circuit. The air
drops in the form of pilot air jet. The petrol and air mix is the idle passage and the mixture
comes out of the idle port below the throttle valve slow speed openings are provided on
venturi side of the throttle valve to ensure smooth transfer form the idling circuit to main jet
circuit without “ flow spet”
NORMAL RUNNING CIRCUIT

Now the throttle valve is open and the main jet sucks which supplies the fuel. The air
moves through venturi and mixes with fuel. The air is governed by throttle valve.
ACCELERATION CIRCUIT
It requires more fuel which fuel which is applied by membrane pump. The pump level
is attached to accelerator when the pedal is depressed the pump level pressures forces the fuel
into the jet, when the pedal is returned to membrane moves back.

RESULT:
Thus the fuel supply system for petrol engine was studied.

RUBRICS
Grade
Obtained
Aim and Tools

1. 3 2 1
Required
Theory and
2. 3 2 1
Components sketch
3. 3 2 1
and units
4. Procedure 3 2 1
Significance and
experiments
Total

FIG 6.1 DIESEL FUEL FEED SYSTEM
FIG 6.2 FUEL FEED PUMP

FIG 6.3 FUEL INJECTOR

STUDY OF DIESEL ENGINE FUEL SYSTEM
Ex no: 6
Date :
AIM:
To dismantle, study and assemble the given diesel engine fuel system.
TOOLS REQUIRED:
Screw driver, Double ended spanner, combination player, nylon hammer.
PROCEDURE:
FUEL SUPPLY SYSTEM OF DIESEL ENGINE:
During engine operation, the fuel is supplied by gravity from fuel tank to the primary filter
where coarse impurities are removed. From the primary filter, the fuel is drawn by fuel
transfer pump and is delivered to fuel injection pump through second fuel filter. The fuel
injection pump supplies fuel under high pressure to the injectors through high pressure pipes.
The injectors atomise the fuel and inject it into the combustion chamber of the engine. The
fuel injection pump is fed with fuel in abundance. The excess fuel is by-passed to the intake
side of the fuel transfer pump through a relief valve.
Fuel supply system of diesel engine consists of the following components.
1. Fuel tank
2. Fuel lift pump or fuel feed pump
3. Fuel filter
4. Fuel injection pump
5. High pressure pipe
6. Overflow valve
7. Fuel injector
FUEL TANK
It is a storage tank for diesel. A wire gauge strainer is provided under the cap to prevent
foreign particles entering the tank
FUEL LIFT PUMP (FEED PUMP OR TRANSFER PUMP)
It is a pump, which transfers fuel from the fuel line to the fuel injection pump. It is mounted
on the body of fuel injection pump. It delivers adequate amount of fuel to the injection pump.
The pump consists of: (I) body (2) piston (3) inlet valve and (4) pressure valve. The valves
are tightly pressed against their seats by springs. The piston is free to slide in the bore. The
fuel contained in the space below the piston is forced to flow through secondary fuel filter to
the injection pump. At the same time downward movement of the piston creates a depression
in the space above the piston which causes the fuel to be drawn in the transfer pump from the
fuel tank through the inlet valve and the primary filter.

FUEL INJECTING PUMP
It is a pump, which delivers metered quantity of fuel to each cylinder at appropriate time
under high pressure. Tractor engines may use two types of fuel injection pump:
(i) Multi-element pump and (ii) Distributor (Rotary) type pump.
FUEL INJECTOR:
It is the component, which delivers finely atomised fuel under high pressure to the
combustion chamber of the engine. Modern tractor engines use fuel injectors, which have
multiple holes. Main parts of injector are: nozzle body and needle valve. The nozzle body and
needle valve are fabricated from alloy steel. The needle valve is pressed against a conical seat
in the nozzle body by a spring. The injection pressure is adjusted by adjusting the screw.
FUEL INJECTION SYSTEM
Diesel fuel is injected in diesel engine through injectors with the help of fuel injection pump.
The system using injectors, fuel injection pump, fuel filter, and fuel lines is called fuel
injection system.
The main functions of fuel injection system are:
(i) To measure the correct amount of fuel required by engine speed and load,
(ii) To maintain correct timing for beginning and end of injection,
(iii) To inject the fuel into the combustion space against high compression pressure.
(iv) To atomise the fuel for quick ignition.
Process of fuel injection in diesel engine is of two types: (i) Air injection (ii) Solid injection.
Air injection: In this process, the engine uses compressed air to force the fuel into the
cylinder. It is a bulky system and hence it is not considered very suitable for vehicles and
tractors. It is mostly used on heavy-duty stationary engines.
Solid injection: A high-pressure pump is used for forcing the fuel into the combustion
chamber.
FUEL FILTER
It is a device to remove dirt from fuel oil. Solid particles and dust in diesel fuel are very
harmful for giving a fine degree of filtration. Fuel injection equipment in diesel engines is
extremely sensitive to dirt and solid particles present in fuel. A filter is used to remove the
dirt and solid particles from the fuel to ensure trouble free fuel supply. It consists of a hollow
cylindrical element contained in a shell, an annular space being left between the shell and the
element. The filtering element consists of metal gauge in conjunction with various media
such as packed fibres, woven cloth, felt, paper etc. These filters are replaced at certain
intervals, specified by the manufacturer.
Usually there are two filters in diesel engine: (1) Primary filter and (2) Secondary filter.

The primary filter removes water and coarse particle of dirt from the fuel. The secondary
filter removes fine sediments from the fuel.

RESULT:
Thus the fuel supply system for diesel engine was studied.

RUBRICS
Grade
Obtained
Aim and Tools

1. 3 2 1
Required
Theory and
2. 3 2 1
Components sketch
3. 3 2 1
and units
4. Procedure 3 2 1
Significance and
experiments
Total

FIG 7.1 CHASSIS FRAME

STUDY AND MEASUREMENT OF LIGHT AND HEAVY VEHICLE CHASSIS
FRAME
Ex. No: 7
Date :
AIM:
To study about the various features and measure the various dimensions of the given
chassis.
TOOLS REQUIRED:
Measuring tape.
PROCEDURE:
1. Study the layout of the chassis and identify the type of drive employed in the vehicle (e.g.)
front engine rear wheel drive, front engine front wheel drive, four wheel drive, rear engine
rear wheel drive etc., Then suitably draw the transmission layout. If the front axle is a dead
axle, examine the type of the axle.
2. Check whether it is of conventional frame construction or integral type. Draw the frame
construction including the details where the side members have been joined with cross
members, the position of the axles and the location of the suspension attachments. Draw the
cross-section of the members of the frame and measure the dimensions of it.
3. Identify the type of clutch and gearbox used in the vehicle.
4. Identify the suspension type whether it is of rigid axle suspension or independent
suspension. Find out the type of suspension system fitted in the front and rear of the vehicle.
5. Identify the type of rear axle drive whether it is made up of one or two universal joints, one
or two-piece propeller shaft with or without slip joint etc., the type of rear axle housing and
the type of rear axle employed.
6. Identify the details of steering system including the type of steering box used, its linkage
details etc.,
7. Identify the braking system and the type of brake used in the vehicle.
8. Identify the type of wheels and tyres fitted.
9. The steering geometry can be obtained by the procedure as described below. Before
measuring, it is advisable to see that:
10. Front wheels are true running and wheel bearings are properly adjusted.
11. Tyres are inflated as specified.
12. Front suspension springs are properly seated and ball joints are not excessively loose.
13. The vehicle is in the laden or unladen condition as recommended by the manufacturer.
14. As far as possible, the surface over which the vehicle being checked should be perfectly
level.

15. Measure the wheelbase, wheel track, overall length, maximum width, overall height,
ground clearance, front overhang, rear overhang etc., using measuring tape.
RESULT:
The various features of the chassis are studied and its dimensions have been
measured.
S.No Description For Light Vehicle For Heavy Vehicle
a) Chassis details
(i) Frame
(ii) Front axle
(iii) Steering
(iv) Brakes
b) Suspension
(i) Front
(ii) Rear
c) Chassis dimensions
(i) Wheelbase
(ii) Wheel track
(iii) Max. Width
(iv) Overall length
(v) Overall height
(vi) Ground clearance
(vii) Front overhang
(viii) Rear overhang

RUBRICS
Grade
Obtained
Aim and Tools

1. 3 2 1
Required
Theory and
2. 3 2 1
Components sketch
3. 3 2 1
and units
4. Procedure 3 2 1
Significance and
experiments
Total

FIG 8.1 FRONT AXLE

FIG 8.3 REAR AXLE
FIG 8.4 TORQUE DRIVE
FIG 8.5 SEMI-FLOATING AXLE

FIG 8.6 THREE QUARTER FLOATING AXLE
FIG 8.7 FULL FLOATING AXLE

STUDY, DISMANTLING AND ASSEMBLING OF FRONT AND REAR AXLE
Ex. No: 8
Date :
AIM:
To dismantle and study about the various types of front and rear axles and their
components and assemble them.
TOOLS REQUIRED:
Spanner set, cutting plier, screw driver, hammer, punch
FRONT AXLE- INTRODUCTION:

Front axles are used in nearly all trucks and in many automobiles for suspending the
front-end load. The majority of front axles have steel, I-beam for the main member. Tubular
members also have been widely used. Some front axles are driving members of the power
train. Generally, however, the characteristics and mountings of the front drive axle housing
are similar to those of the solid type. A front axle consists of a beam, which extends across
the underside of the vehicle for almost the entire width of the tread. Swiveling device is
attached to both the ends of this beam. The beam is attached to the vehicle frame by means of
springs, usually of the leaf type. The swiveling device is called the steering knuckle. The
steering knuckle is attached to the beam by means of substantial pins known as kingpins or
steering knuckle pivot pins. The steering knuckle is a heavy forging on which the road wheel
revolves.
Types of Axle construction and Component parts:
Front axles are built according to either of two basis designs for attaching the steering
knuckle to the beam. These are known as the Elliot type and the Reverse Elliot type axle.
The Elliot axle:
In the Elliot axle, each end of the main beam is open to form a C shaped yoke. The
steering knuckle fits between the upper arms of this yoke. The kingpin extends through the
upper arm of this yoke, through the knuckle and into the lower arm of the yoke. Usually, the
kingpin is secured in the steering knuckle so that when the knuckle swivels, the kingpin turns
in the yoke. The holes in the yoke, which receive the ends of the kingpin, are fitted with
bushings called kingpin bushings, so that the kingpin can enter easier. In some vehicles, roller
bearings are used instead of bushings. A thrust bearing is installed on the kingpin between the
steering knuckle and the upper arm of the Elliot type. In most cases, this is a sealed ball
bearing or roller bearing. This steering knuckle thrust bearing actually supports the weight of
the vehicle.

Reverse Elliot Axle:
As the name suggests, the construction is reversed in the reverse Elliot axle. The yoke
is a part of the steering knuckle and fits over the end of the axle. The kingpin is secured in a
vertical hole through the end of the axle beam and the knuckle swivels on it. The kingpin
bushings or bearings are mounted in the steering knuckle. The steering knuckle thrust bearing
is located between the axle and the lower ear of the knuckle. There are no appreciable
differences I merit of performance between the two types of axle construction.
Steering Knuckles:
The steering knuckle consists of a spindle for the wheel, devices for attaching the unit
to the main beam or axle, and an arm for holding the knuckle in any desired position in its
swing or travel. In some designs, the knuckle, spindle and steering knuckle are are forged in
one piece, while in other designs, the steering knuckle arm is a separate forging attached to
bolts or by securing a tapered end into a corresponding hole in the knuckle by means of a nut
and cotter pin.
Steering knuckles are Elliot or reverse Elliot, depending of course, on the style of axle
to which they are attached.
Steering knuckle Arm:
The steering knuckle arm is a lever for swiveling the knuckle. One end of the arm is
secured to the knuckle. The free end of the arm is made with either a ball or a hole for
attaching the tie rod, which connects the right and left steering knuckle arms. One of the
steering knuckles must also be connected to the linkage from the steering gear. Therefore,
one steering knuckle arm must be so constructed as to provide either an additional hole on the
ball for attachment of the linkage from the steering gear or one of the steering knuckles must
be made to provide for attachment of a second arm which is connected to the steering gear
linkage. On a left-hand drive vehicle, the left knuckle or arm would have to be so arranged.
On a right-handed drive vehicle, the right knuckle or arm would follow the chosen
arrangement.
Tie Rods:
In Solid axle types of suspensions, the spindles are held in proper alignment by means
of a connection or linkage between the two steering knuckle arms. This connecting
mechanism is known as the steering tie rod or simply as the tie rod.
REAR AXLE- INTRODUCTION:

Semi-floating axle:
The wheel hub is directly connected to the axle shaft or is an extension of the same.
The inner end of the axle shaft is splined and is supported by the final drive unit, whereas a
single bearing inside the axle casing supports the outer end. In this the axle shaft takes all the
loads. The vehicle load is transmitted to each of the half shafts through the casing and the
bearing. This causes a bending load and a tendency to shear at the point marked ‘ A’ .

Besides, the side forces also cause end thrust and bending moment in the axle shafts, which
have to take driving torque also. The semi-floating axle is the simplest and the cheapest of all
types, because of which it is widely used on cars. However, since the axle shafts have to
support all loads, they have to be of larger diameter for the same torque transmitted compared
to the other types of axle supporting.
Full floating axle:
This type is very robust one and is used for heavy vehicles. As is seen in the fig. the
axle shafts have flanges at the outer ends, which are connected to the flanged sleeve by
means of bolts. There are two taper roller bearings supporting the axle casing in the hub,
which take up any side load. Thus in this the axle shafts carry only the driving torque. They
do not carry the weight of the vehicle and the end thrust, the weight being completely
supported by the wheels and the axle casing. As the axle shafts carry only the driving torque,
their failure or removal does not affect the wheels.
Thus the axle shafts can be taken out or replaced without jacking up the vehicle. For
the same reason the vehicle can be towed even with a broken half-shaft. However, it is the
costliest type.
Procedure:
Dismantling:
2. Remove wheels and brake drum. The half shaft is removed by removing flange bolt.
3. Now it can be seen that the hub revolves on the axle casing completely independent of
the half shaft. At the end of the axle there are two nuts for tightening the axle hub in a
position the lock washer is opened and first outer nut is removed and then inner nut.
4. Using bearing puller, the hub is removed. The oil seal inside the hub is removed.
Spray kerosene and brush it thoroughly high pressure water cleaning is done.
5. Any trace of dust found hard to remove by water jet must be cleaned by hacksaw
blade.
6. Any scratch or crack or wear on roller bearings must be inspected and if any such
defects found, the bearings must be replaced.
Assembling:
1. Assemble larger bearing at the rear side of the axle and smaller size bearing at the
front.
2. The back nut is tightened and end shake is tested. To minimize end shake and also
maintain bearing freeness, spacer tube and spacing washers of less thickness are
placed between the inner cone and outer bearing cone adjacent hub shoulder. Inner
lock nut is tightened and axle hub is pre-loaded using a spring balance.

3. The load required to move the hub is noted and compared with manufactures
instruction. Add or remove the lock nut and outer bearing cone and spacers. Pull out
the wheel hub radial lip oil fitted and then refit wheel hub.
4. After bearing seating, outer lock nut is tightened without disturbing the inner lock nut.
5. The axles are inserted and their flanges are tightened with their hubs.
6. Brake assembly and brake drum are refitted. Wheels are fitted in their hubs. After
assembly, oil leakage is checked. Brake shoe adjustments are done as over the
manufactures specification.
RESULT:
Thus the give front and rear axle is dismantled, assembled and studied.

RUBRICS
Grade
Obtained
Aim and Tools

1. 3 2 1
Required
Theory and
2. 3 2 1
Components sketch
3. 3 2 1
and units
4. Procedure 3 2 1
Significance and
experiments
Total

FIG 9.1 FINAL DRIVE
FIG 9.2 DIFFERENTIAL DRIVE

STUDY, DISMANTLING AND ASSEMBLING OF DIFFERENTIAL
Ex.No:9
Date :
AIM:
To dismantle, assemble and inspect of final drive and differential unit.
NECESSITY:
Differential gears permit the driving wheels to rotate at different speeds while the
vehicle is taking a turn. The differential is also be used to reduce the power from propeller
shaft and get changed it carefully to both the wheels when the vehicle is running in a plain
roads.
OPERATION OF DIFFERENTIAL:
When the car is on straight road, the ring gear, differential case, differential pinion
gears and two differential side gears all turn as a unit. The two differential pinion gears do not
rotate on the pinion shaft. This is because they exert equal force on the two differential side
gears. As a result, the side gears turn at the same speed as the ring gear, which causes both
drive wheels to turn at the same speed also.
However, the car begins to round a curve, the differential pinion gears rotate on the
pinion shaft. This permits the outer wheel to run faster than the inner wheel.
Suppose one wheel turns slower than the other does as the car rounds a curve. As the
differential case rotates, the pinion gear rotates on their shaft. This occurs because the pinion
gear must walk around the slower-turning differential side gear. Therefore, the pinion gears
carry additional rotary motion to the faster turning outer wheel on the turn. The differential
case speed is considered to be 100 percent.
The rotating action of the pinion gears carries 90 percent of this speed to the slower
rotating inner wheel. It sends 110 percent of the speed to the faster rotation outer wheel.
Procedure:
1. Drain the oil in the differential by removing the drain plug and remove the half axle
shaft.
2. Disconnect the propeller shaft. Remove the differential bearing.
3. Remove the ring gear, pinion shaft and the gears. Check the differential case for wear
and the ring gear for run out.
4. Remove the front and rear bearing cups from the carrier and check the bores.
5. Check and adjust the pinion depth and check pinion preload.

6. Install differential case in the carrier. Fill up the recommended oil in housing.
Inspection:
Before connecting the unit with axle shaft and propeller shaft, check the following.
a. Sufficient lubrication in the casing.
b. Differential case bearing and pinion shaft bearing for wear.
c. Sufficient backlash and Pinion gear and play.
Backlash adjustment of differential gears:

The assembly of the differential spider bevel gears and axle gears should rotate freely without
binding and back lash between them should be in specification. To adjust the back lash select
correct thrust washer thickness.
Tail pinion preload:
Taper roller bearings of the tail pinion assembly have to be assembled with preload to give a
friction moment. The spacer rings are available in different thickness. Found the friction
moment of bearings, compare with the specification and select correct spacer thickness.
Backlash adjustment:
Using dial gauge found the backlash between crown wheel and tail pinion. If backlash less
than the specification loosen left adjusting ring and equally tighten the right one.
RESULT:
Thus the given differential was dismantled and reassembled.

RUBRICS
Grade
Obtained
Aim and Tools

1. 3 2 1
Required
Theory and
2. 3 2 1
Components sketch
3. 3 2 1
and units
4. Procedure 3 2 1
Significance and
experiments
Total

FIG 10.1 CLUTCH
FIG 10.1 SINGLE PLATE CLUTCH

STUDY, DISMANTLING AND ASSEMBLING OF CLUTCH
Ex.No:10
Date :
AIM:
To dismantle and study the various features and assemble the given clutch.
TOOLS REQUIRED:
Double head spanner, box type spanner, arbor press, cutting plier.
INTRODUCTION:
The power developed in the engine is transmitted to the gear box through the clutch
only. When the clutch is disengaged, the power is not transmitted. Clutch will always be in
engaged position unless the clutch pedal is depressed. The clutch permits the gradual taking
up of the load. When the pressure on the friction plate is decreased it automatically decreases
the load on the engine. Clutch is a frictional plat, by the frictional contact between the
flywheel and pressure plate it transmits the torque from the engine to gear box.
PROCEDURE:
The clutch is dismantled by placing in the Arbor press, by removing the nuts of the
clutch assembly. It is inspected for worn out parts and again assembled.
WORKING:
The single plate clutch works as follows. Clutch plate is placed between flywheel and
pressure plate. Pressure plate rigidly forces the clutch plate towards the flywheel by the
spring force. When the clutch pedal is in ordinary position it fully engages with the flywheel.
Therefore, the power is transmitted from the flywheel to gearbox. When the pedal is pressed,
pressure plate is forced against the spring force, a gap is created between the pressure plate
and flywheel, and therefore no power is transmitted. When the clutch is half pressed due to
slight friction contact only part load is supplied to the engine. Thus the clutch is functioning.
Dismantling procedure of clutch:

1. Mount clutch assembly on clutch fixture.
2. Mark driving and pressure plate, so that they may be replaced in the same relative
position on reassembly.
3. Remove set screw holding the spring plate to withdrawal plate and remove the
withdrawal plate and compress the clutch assembly using fixture.

4. Loosen the bolts on the adjuster pads and remove the trust pads.
5. Slowly relieve the pressure on the springs by unscrewing the clutch fixture.
6. Separate the pressure plates, springs and drive plate.
7. Remove bolts holding the lever brackets on the driving plate, and dismantle the
withdrawal lever.
Inspection:
The pressure plate friction area, clutch finger, finger bracket, thrust pad, withdrawal plate,
release bearing, clutch operating linkages, springs, clutch shafts splines are thoroughly
checked.
Assembling procedure of clutch:
1. Place the pressure plate under the clutch fixture and place the spring on the pressure
plate.
2. Assemble the lever brackets along with the lever pivot pin, bush etc., on the driving
plate apply grease on the pivot pin and bush while fitting.
3. Lay the driving plate completely with spring cups and lever bracket assemblies on the
top springs; make sure the identification marks line up.
4. Compress the assembly slowly, making sure the springs are seated properly then fit
the trust pads with stepped portions upwards and tighter the bolts.
5. Release the pressure on the clutch and remove the clutch assembly.
6. Locate the clutch withdrawal plate on the levers and tighten the bolts securing the
spring plate.
RESULT:
Thus the given single plate clutch is dismantled, overhauled, reassembled and
adjusted.

RUBRICS
Grade
Obtained
Aim and Tools

1. 3 2 1
Required
Theory and
2. 3 2 1
Components sketch
3. 3 2 1
and units
4. Procedure 3 2 1
Significance and
experiments
Total

FIG 11.1 GEAR BOX ARRANGEMENT

FIG 11.2 FIRST GEAR
I gear: Power is transmitted through the gears, 1-2-3-7.
FIG 11.3 SECOND GEAR
II gear: Power is transmitted through 1-2-3-8

FIG 11.4 THIRD GEAR
FIG 11.5 REVERSE GEAR

STUDY, DISMANTLING AND ASSEMBLING OF GEAR BOX
Ex.No : 11
Date :
AIM:
To dismantle the gearbox, inspect and find the gear ratio and to reassemble the
gearbox.
INTRODUCTION :
Gearbox is a main part of the transmission system. The torque produced by the engine
vary only by narrow limits. Therefore, there is necessary to change the torque produced by
the engine. The change of torque in the gearboxes is helpful in take off the vehcle from the
rest or when full loaded during normal speed. During high speed there is no need of high
torques therefore you can change the torque to the lowest or directly couple the engine to
differential.
Types of Gear Box:

Different types of gearbox used in practice are
1. Constant mesh gearbox
2. Sliding mesh gearbox
3. Synchromesh gearbox
Out of these we dismantled the constant mesh gear box.
WORKING:
The working of constant mesh gearbox is, all the gears are in constant mesh with the
corresponding gears on the lay shaft. The gears on the main shaft, which is splined, are fixed.
When the left dog clutch slides to the left by means of selector mechanism its teeth are
engaged with those on the clutch gear and we get direct gear. The same dog clutch however
when slide to right make contact with second gear. Similarly the movement of right dog
clutch to left results in low gear and towards right in reverse gear.
I-Gear:
While shifting the selector mechanism to gearbox first gear is engaged. The gear ratio
of the first gear is around 6.9
II-Gear:
While shifting the gear to second gear the second gear is selected. The gear ratio for
the second gear will be around 4.5.

III-Gear:
While the third gear is engaged the torque is less than the second gear and more than
the fourth gear. Normally third gear will be 3.0.
IV Gear
While the fourth gear is engaged the torque is less than the third gear and more than the
fourth gear. Normally third gear will be 1.7.
V-Gear:
While the fourth gear is engaged the torque is very less, actually the engine is directly
coupled to the rear wheel without any reduction. Normally gear ratio is 1.
Reverse Gear:
When the reverse is engaged, the propeller shaft will rotate in the opposite direction
and the vehicle will move in the reverse direction. Normally gear ratio for reverse gear is
around 6.5.
Procedure:
1. Disconnect battery terminals.

2. Remove front and rear propeller shaft bolts and removed propeller shaft to the chassis
frame.
3. Disconnect clutch assembly.
4. Disconnect speed o meter cable reverse indicator switch wiring connections.
5. Drain gear box trolley oil in a clean container.
6. Locate the gear box trolley under the gear box and unscrew clutch housing unit.
7. Check for natural position of selectors spindles, after remove selector casing unit.
8. Remove rear flange from main shaft.
9. Remove clutch shaft, ball bearing, main shaft, counter shaft, pinion wheel, dog clutch and
roller bearings from casing.
10. Clean all parts in kerosene.
11. To assemble counter shaft assembly.
12. To assemble main shaft, assembly.
13. Fit the 1st gear, sliding dog clutch, reverse gear, pinion wheel, and thrust washer.
14. Fit 2nd gear and 3rd gear fixed dog clutch, and sliding dog clutch.
15. Fit 4th and 5th fixed dog clutch and sliding dog clutch.
16. To check the individual gears end play measure the height difference between the bush
and the gear.
17. Check for free engagement of sliding dog clutches.

18. Check for free rotation of I, Reverse, II, III and IV gear wheel.
19. Fit the clutch shaft and ball bearing.
20. Fit the flange, and selector mechanism to clutch assembly, gear box casing.
21. Fill lubricating oil. Check for filly of lubricating oil up to required level.
22. Check for any oil leakage, noise and smooth running.
23. Fit the vehicle, Connect to Battery terminals.
24. Check for proper gear engagement for different in running condition.
RESULT:
Thus the given gearbox is dismantled, the gear ratios are calculated and the gearbox is
assembled.
S.No Gear Engaged Gear Ratio

1 First gear
2 Second gear
3 Third gear
4 Fourth gear
5 Fifth gear

RUBRICS
Grade
Obtained
Aim and Tools

1. 3 2 1
Required
Theory and
2. 3 2 1
Components sketch
3. 3 2 1
and units
4. Procedure 3 2 1
Significance and
experiments
Total

FIG 12.1 LAYOUT OF STEERING SYSTEM
FIG 12.2 RACK AND PINION TYPE STEERING GEAR

FIG 12.3 STEERING LINKAGE FOR RIGID AXLE SUSPENSION
FIG 12.4 STEERING LINKAGE FOR INDEPENDENT SUSPENSION

STUDY OF STEERING SYSTEM
Ex.No :12
Date :
AIM:
To dismantle, study about the various features and assemble the parts of the steering
system.
INTRODUCTION:
Steering linkage depends upon the type of the vehicle, whether it is a car which has
independent front suspension or a commercial vehicle having generally a rigid axle type front
suspension, two types of steering linkages are used. They are:
i. Steering linkage for vehicle with rigid axle front suspension

ii. Steering linkage for vehicle with independent front suspension
i. Steering linkage for vehicle with rigid axle front suspension:

The drop arm is rigidly connected to the cross-shaft of steering gear at its upper end,
while its lower end is connected to link rod through a ball joint. To the other end of link rod
is connected to link rod arm thorugh ball joint. Attached rigidly to other end of the link rod
arm is the stub axle on which road wheel is mounted. Each stub axle has a forged track rod
arm rigidly bolted to the wheel axle. The other end of the track rod is connected by means of
ball joints. An adjuster is provided in the track rod to change its length for adjusting wheel
alignment.
The steering gear provides mechanical advantage so that only a small effort is
required. It provides velocity ratio so that larger movement of steering wheel obtains smaller
movement of stub axle. When the steering wheel is turned, drop arm gives a linear motion to
the link rod. This movement is transmitted through link rod arm to stub axle so as to turn the
later. Thus only one wheel is positively turned.
ii. Steering linkage for vehicle with independent front suspension:

In the case of conventional rigid axle suspension, the main axle beam ensures the
movement of stub axle in the horizontal plane only. In this therefore, there is no vertical
deflection of the suspension and hence there is no change in effective track-rod length.
However, in the case of independent suspension, the two stub axles can move up or down
independent of each other due to which distance between ball-joint ends of the two track rod
arms is continuously varying. On account of this a single track rod as in conventional system
described above, cannot be used.
Fig. depicts one linkage for independent suspension where the above difficulty is avoided.
Here three-piece track rod is used, the center portion being called the relay rod, which is

connected at one end to an idler arm supported on body structure and to drop arm of the
steering gear at the other end through ball joints. The relay rod is restricted to move in
horizontal plane only. Movement in vertical plane is provided by the outer portions, viz., the
tie rods about the end ball joints.
Dismantling procedure:
1. Using hydraulic jack, the vehicle is lifted and the front wheels are removed. The
pressure hose and return hose coming from the steering pump are removed. The oil
coming out the system is collected.
2. The tie rods are removed. The universal joints connecting the inner shaft of steering
wheel and pinion of the steering box is removed.
3. The mounting bracket bolt connecting steering box is loosened and the steering box is
removed. The pressure hoses connecting the pinion housing and steering box housing
are removed. The lock nuts of the tie rod, dust boots and adjustable clips are removed.
4. The ball joints connected to the both sides of the rack shaft are removed.
5. The circlip on the pinion is rotated and removed along with the pinion itself and both
bearings. All the components are thoroughly cleaned with kerosene. If required,
replace the defective components.
Assembling procedure:
1. The power steering assembly is carried out in the following order: power steering
housing, rack shaft, rack shaft side lock, pinion with bearing, circlip. Ball joint, dust
boot and tie rod. Also check for free rotation of pinion.
2. The mounting bolt, tie rod of the stub axle, universal joint, power steering hose are
assembled in order. The power steering oil is filled to the required level in the
reservoir. The steering pump is removed after removing fan belt, mounting bolt and
reservoir hose.
3. The side covers and spring, drive shaft, vanes and O rings are inspected then
assembled.
4. The vehicle is started and steering is turned on either side to check the proper working
of the steering wheel.

RESULT:
Thus the steering system along with the linkages is dismantled, assembled and
studied.

RUBRICS
Grade
Obtained
Aim and Tools

1. 3 2 1
Required
Theory and
2. 3 2 1
Components sketch
3. 3 2 1
and units
4. Procedure 3 2 1
Significance and
experiments
Total

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Automotive Components Lab Manual - New

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BHARATHIDASAN INSTITUTE OF TECHNOLOGY (BIT) CAMPUS

DEPARTMENT OF AUTOMOBILE ENGINEERING

AT 6311 AUTOMOTIVE COMPONENTS LABORATORY

NAME OF THE STUDENT:

BHARATHIDASAN INSTITUTE OF TECHNOLOGY (BIT) CAMPUS, TIRUCHIRAPPALLI - 24 Page 1

• To make their noteworthy contributions in developing the society through continuous

Programme Educational Objectives

BHARATHIDASAN INSTITUTE OF TECHNOLOGY (BIT) CAMPUS, TIRUCHIRAPPALLI - 24 Page 2

BHARATHIDASAN INSTITUTE OF TECHNOLOGY (BIT) CAMPUS, TIRUCHIRAPPALLI - 24 Page 3

• Understand the construction, principle & working of automobile.

BHARATHIDASAN INSTITUTE OF TECHNOLOGY (BIT) CAMPUS, TIRUCHIRAPPALLI - 24 Page 4

10. Never work in the laboratory without proper supervision by an instructor.

BHARATHIDASAN INSTITUTE OF TECHNOLOGY (BIT) CAMPUS, TIRUCHIRAPPALLI - 24 Page 5

BHARATHIDASAN INSTITUTE OF TECHNOLOGY (BIT) CAMPUS, TIRUCHIRAPPALLI - 24 Page 6

BHARATHIDASAN INSTITUTE OF TECHNOLOGY (BIT) CAMPUS, TIRUCHIRAPPALLI - 24 Page 7

Sl.No. Name of the Experiments

1 Dismantling and study of Multi-cylinder Petrol Engine

2 Assembling of Multi-cylinder Petrol Engine

3 Dismantling and study of Multi-cylinder Diesel Engine

4 Assembling of Multi-cylinder Diesel Engine

5 Study of petrol engine fuel system

6 Study of diesel engine fuel system

7 Study and measurement of light and heavy commercial Vehicle Frame

8 Study, dismantling and assembling of front and rear Axles

9 Study, dismantling and assembling of differential

10 Study, dismantling and assembling of Clutch

11 Study, dismantling and assembling of Gear Box

12 Study of steering system

Experiments beyond the syllabus

13 Wheel alignment: measuring and adjustment of castor, camber, king-

BHARATHIDASAN INSTITUTE OF TECHNOLOGY (BIT) CAMPUS, TIRUCHIRAPPALLI - 24 Page 8

Experiment Observation Record Remarks

1 Dismantling and study of Multi-cylinder

2 Assembling of Multi-cylinder Petrol

Dismantling and study of Multi-cylinder

Assembling of Multi-cylinder Diesel

5 Study of petrol engine fuel system

6 Study of diesel engine fuel system

Study and measurement of light and

BHARATHIDASAN INSTITUTE OF TECHNOLOGY (BIT) CAMPUS, TIRUCHIRAPPALLI - 24 Page 9

Experiment Observation Record Remarks

Study, dismantling and assembling of front

Study, dismantling and assembling of

Study, dismantling and assembling of

Study, dismantling and assembling of Gear

5 Study of steering system

Experiment - Beyond the syllabus

Wheel alignment: measuring and adjustment

6 of castor, camber, king-pin inclination, toe-in

and toe- out

Study, dismantling and assembling of

BHARATHIDASAN INSTITUTE OF TECHNOLOGY (BIT) CAMPUS, TIRUCHIRAPPALLI - 24 Page 10

I2: Select proper tools and their range

I3: Understand the construction, principle & working of automobile

I4: Take the reading from the instrument

M1: Draw a neat sketch of an auto engine component

M2: Use of various tools

M3: Disassembling and assembling

M4: To operate the automobile

BHARATHIDASAN INSTITUTE OF TECHNOLOGY (BIT) CAMPUS, TIRUCHIRAPPALLI - 24 Page 11

FIG II: CHASIS AND FRAME

BHARATHIDASAN INSTITUTE OF TECHNOLOGY (BIT) CAMPUS, TIRUCHIRAPPALLI - 24 Page 12

To study about the various functions of major components of an automobile.

1. Chasis and Frame:

accessories. Along with this the frame supports the body.