Automobile Enginees - 2

ARYABHARATHI POLYTECHNIC, TUMKUR.
AUTOMOBILE ENGINES – II LAB
Workshop Safety Rules
Before you can use equipment and machines or attempt practical work in a workshop you
must understand basic safety rules. These rules will help keep you and others safe in the workshop.
1) Always listen carefully to the teacher and follow instructions.

2) Do not run in the workshop, you could ‘bump’ into another pupil and cause an accident.
3) Know where the emergency stop buttons are positioned in the workshop. If you see an accident
at the other side of the workshop you can use the emergency stop button to turn off all
electrical power to machines.
4) Always wear an apron as it will protect your clothes and hold loose clothing such as ties in
place.
5) Wear good strong shoes. Training shoes are not suitable.
6) When attempting practical work all stools should be put away.
7) Bags should not be brought into a workshop as people can trip over them.
8) When learning how to use a machine, listen very carefully to all the instructions given by the
teacher. Ask questions, especially if you do not fully understand.
9) Do not use a machine if you have not been shown how to operate it safely by the teacher.
10) Always be patient, never rush in the workshop.
11) Always use a guard when working on a machine.
12) Keep hands away from moving/rotating machinery.
13) Use hand tools carefully, keeping both hands behind the cutting edge.
14) Report any damage to machines/equipment as this could cause an accident.
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DEPARTMENT OF AUTOMOBILE ENGINEERING
ARYABHARATHI POLYTECHNIC, TUMKUR. AUTOMOBILE ENGINES – II LAB
Page2
Experiment No. : 1
AIM: Identification of different components in Fuel supply system of Petrol engines
Components of fuel supply system
a) Fuel tank
b) Fuel filter
c) Intake manifold
d) Fuel pump
e) Carburettor
f) Fuel pipe lines
g) Fuel gauge to include to the drive the fuel level in the fuel tank
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Experiment No. : 2
AIM: Identification and cleaning of fuel tank and fuel lines.
Tools required: D, E, spanner, ring spanner, screw driver.
Materials required: cotton waste, kerosene etc;
Procedure:
1. Remove the fuel tank from the chassis.

2. Remove the fuel lines from the fuel tank
3. Clean the fuel tank with soap water
4. Clean the fuel line with compressed air
5. Refit the fuel lines of fuel tank, add washer if needed
6. Replace if it is badly brokered or bended
7. Refit the fuel tank to chassis.
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Experiment No. : 3
AIM: Servicing and Testing of AC mechanical fuel pump
Tools required: D, E, spanner, screw driver, multipurpose piler.
Materials required: petrol, cotton waste.
Procedure:
1. Remove the pump assembly from the block
2. Clean all parts with kerosene / petrol
3. Check the pump out put by disconnected the carburetor pipe
4. Check the input to pump the removing the pipe from the tank
5. Check the diaphragm, if it is weared, replace with new one
6. Check the valve assembly, if it is weared, replace with new one
7. Check the tension of the spring if it is week replace with new one
8. Check the rocker arm &linkages if they are worn out replace with new one
9. In Maruthi vehicle-discharge pressure is 0.20-.030kg/cm
10. Pump capacity -0.2lt/min at 2000rpm
11. While assembly takes care that mark IN should be connected to inlet hose from tank &
opposite side to carburetor.
12. Volume test: it is performed by disconnecting the pump from the carburetor and measuring
the discharging separately by means of a graduated container and stop watch, while the
engine is running at idle speed it is to be noted here that the engine in this case will be run
only by the petrol in the carburetor float chamber. If the observed rate of flow is less than the
specified the pump needs replacement or replacement.
13. Vacuum test: each fuel pump create some vacuum inlet side which is specified by the
manufacturer, to test it connect a vacuum gauge in between the tank or the pump and the
engine at idle speed the reading of the vacuum gauge must confirm to the specifications, the
vacuum has to be taken out for at least 10sec, after closing the engine otherwise, pump has to
be taken out for repairs or replacements.
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Experiment No. : 4
AIM: Servicing and testing of electrical fuel pump.
Tools required: screw driver, M.P. plier, star screwdriver, spanner (12-13)
Materials required: petrol, waste.
Procedure:
Before servicing the electrical fuel pump, it should be tested for proper working of its winding &
inside wires by means of voltmeter or lamp and a battery.
1. Place one lead of voltmeter or battery to main electrical terminal other to magnet housing.
2. If the lamp or voltmeter does not show a voltage then windings are burnt or if the Lamp
flickers or dim or needle in voltmeter moves slightly the rewinding may be done.
3. Correct the sticking movable contacts, distorted diaphragm of upset adjustment of the rod.
4. Check the movable contact arm diaphragm, if needed replaced with new one.
5. Clean all the parts before assembly.
6. The screws and spring washes passing through holes in the diaphragm should not crush or cut
the material when fitting them finger tight.
7. Adjust the gap between the contact points to 0.75mm by moving the flexible contact point
arm.
8. Volume test: it is performed by disconnecting the pump from the carburetor and measuring
the discharging separately by means of a graduated container and stop watch, while the
engine is running at idle speed it is to be noted here that the engine in this case will be run
only by the petrol in the carburetor float chamber. If the observed rate of flow is less than the
specified the pump needs replacement or replacement.
9. Vacuum test: each fuel pump create some vacuum inlet side which is specified by the
manufacturer, to test it connect a vacuum gauge in between the tank or the pump and the
engine at idle speed the reading of the vacuum gauge must confirm to the specifications, the
vacuum has to be taken out for at least 10sec, after closing the engine otherwise, pump has to
be taken out for repairs or replacements.
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Experiment No. : 5
AIM: servicing of two-wheeler carburetor and identify its different circuits.
Tools required: DE spanner (10-11), screw driver, multipurpose plier.
Procedure:
1. Chose linkages
2. Loose the flange nuts and remove carburetor gently
3. Clean all the parts in petrol
4. Inspect each and every parts and faulty ones are replaced
5. Reassemble the parts.
6. Tight the flange belts.
7. Adjust idle screw till the engine runs smoothly at required speed or using vacuum gauge
adjust the idle screw unit max vacuum is optioned.
8. On releasing the acceleration pedal throttle valve should be completely closed connect the
throttle and choke linkage.
9. Connect the air cleaner.
Precautions: while on pressuring pedal fully nit should be in full open position. This must be
checked and if not found correct, the linkage may be adjust as per manufacturer.
1. Never clean the jet with wires; it should be cleaned with compressed air & petrol
2. Always work with clean hands and places
3. Always adjust according to manufacturer’s manual to get more performance and mileage.
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Experiment No. : 6
AIM: Servicing of S U carburetor and identify its different circuits.
Tools required: D E spanner, 10, 11, 12, 13, 14, 15, screw driver, multipurpose piler.
Procedure:
1. Dismantle the carburetor completely, wash it which clean petrol

2. Check each circuit by blowing compressed air in each to ensure these are absolutely clean
3. Check all the jet by blowing air by mouth to see they are not blocked.
4. While fitting if fiber washers are placed under the jet seat, always use a new fiber washer
5. Always use a new gasket while assembling carburetor.
6. While over handling engine use major overhead kit.
7. Never clean the jet or petrol passage in carburetor body with steel wire it may injure the
passage only use compressed air for cleaning
8. Check float ball for any leakage for checking this hold the float ball in hot water for some
time see if bubbles are coming if it leaking never try to repair it change it which new one.
9. Adjust float ball lift as per manufacturer’s recommendations.
10. Check the throttle valve, its shaft and bushes fore wear, out get them repaired.
11. If a new throttle valve disc has been replaced, punch the holding screw so that it is located
and there is no change of its getting loose.
12. After assembling the carburetor, never test it with compressed air it offset float ball setting or
may puncture it.
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Experiment No. : 7
AIM: Identification of different components in Fuel supply system of Diesel engines.
Components of fuel supply system

a) Fuel tank
b) Fuel filter ( primary & secondary Filters)
c) Air filter
d) Intake manifold
e) Fuel pump
f) Injection pump
g) Injectors
h) Fuel gauge
i) Fuel pipe lines
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Experiment No. : 8
AIM: servicing of air cleaner.
Tools required: DE spanner, screw driver, multipurpose plier.
Materials required: compressed air diesel oil, cotton waste.
Procedure:
1. Remove the filter

2. Wash the filter element with kerosene.
3. Wash the filter element with water.
4. Wash the filter element with compressed air.
5. Insert the filter element into the filter holder.
6. Tight the drain plug nut.
7. Fill the oil up to correct level
8. Tight the nut of the casing bolt.
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Experiment No. : 9
AIM: Replacement of diesel and petrol fuel filter.
Tools required: DE spanner, 10-11-12-13, 18-19 screw driver,
Materials required: kerosene or diesel, filter element.
Procedure:
1. Before removing filter housing clean the filter assembly from outside.
2. Unscrew the center belt of filter while keeping hand under bowl
3. Take out the filter element from the filter bowl
4. Take the cleaning plugs the these are readily available from micro distributors
5. Fix up the plug in the element plugging this way will not allow the cleaning solvent to find
this way in the body of element through central hole
6. Place the filter along with plug in the cleaning tray
7. Clean the filter element with a bristle brush
8. After clean take the filter element out blow air through the plug pipe
9. Keep the filter element on clean place
10. Clean the bowl with diesel and wipeout with filter free cloth
11. Assemble the filter element in bowl and fix the bowl with top cover
12. Always use clean diesel & petrol filter
13. Always wash your hand before cleaning filters.
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Experiment No. : 10
AIM: Servicing of plunger type fuel feed pump
Tools required: DE spanner, 10-11-12-13, 18-19 screw driver, multipurpose piler.
Materials required: kerosene or diesel, cotton waste etc.
Procedure:
1. Place the feed pump on test bench and down the angle of delivery on fly wheel.(fuel feed
pump plungers must supply equal quantity of fuel to all the cylinders and supply should
commence at certain crank angle for each cylinder ,these are adjusted by means of injection
pump test bench.)
2. Crank the engine till position no.1 is at TDC in compression stroke, at this stage both the
valve are closed.
3. Remove the injection plate and turn the injection pump till the plunger lifts up
4. Engage the pump coupling with driving member and lock Fix
5. Up the spill cut of pipe to plunger no.1
6. Connected the fuel inlet to pump and hand prime till all the air is to removed
7. Move the pump coupling till fuel spills out from pipe will stop ensuring that pump plunger
should be in lifted stage.
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Experiment No. : 11
AIM: Servicing of plunger type fuel injection pump
Tools required: spanner, 11-12-16, 18-19 screw driver, multipurpose piler.
Procedure:
1. Fix up the injection pump on its foundation and tighten its mounting bolts by hand
2. Loose the bolt of pump coupling.
3. Crank the engine by hand un piston 1 is TDC in compression stroke at this stage both the
valves are in closed position
4. Crank back the engine slightly fill the injection timing mark coincides with the pointer over
the fly wheel
5. Remove the inspection plate of injection pump and the injection pump in the drive direction
till plunger starts lifting.
6. At this stage engage the pump with the driving member and lock the same.
7. Remove the holder of plunger of pump and face out delivery valve, washer from its seat, fix
back holder.
8. Fix up the spill cut of pipe plunger
9. Connect the fuel fixed line of injection pump prime the hand pump and bleed the injection
pump to ensure that there is no trapped air in the system.
10. Shift the control rack to full fuel position.
11. Loosen the bolts of the fine adjustments on pump coupling.
12. More the pump coupling by hand till such time the fuel from spill cut off pipe stops coming
ensuring that at this stage pump plunger should be oil lifting stage.
13. At this stage tighten the five adjusting ball of coupling.
14. Remove the spill cut off pipe and fix back delivery valve holder, gasket delivery valve spring
and holder.
15. Connect injector pipe, before connection ensure that they are perfectly clean
16. Tight the pump foundation bolt
17. Fix up the inspection cover
18. Fill lubricating oil to cam & governor box up to correct level
19. Adjust the idling screw unit the engine runs without hunting
20. Crank the engine till fuel starts to come from all pipes and unions
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Experiment No. : 12
AIM: Servicing and testing of fuel injectors
Tools required: DE spanner, 10-11-12-13, 18-19 screw driver,
Procedure:
1. Remove the nozzle clean it thoroughly

2. Remove carbon from nozzle hole with special tool as per the manufacturer’s specification
3. Test the injector pressure using injector test as below
Pressure test: place the injector on injector tester & opening pressure is noted from gauge it
should be 1 atmospheric pressure, in case if pressure is less than 1atm then it is increased by
loosening the check nut and tightening the adjusting screw and if it is more than specified the
adjusting screw is loosened, after adjustment-lock the cap. In some injectors instead of
adjusting screw shims are added or removed over the under cap to get desires pressure.
4. Test injector for leak of pressure from injector
Leak test: fix up injector on tester builder up to 150atm and keep the pressure about 10sec,
after 10sec check up the these is no drop in pressure and wetness is felt or droplet is seen
dismantle the injection get the seat of nozzle valve grounded and nozzle body seat lapped if
the nozzle valve seat is fitted it should be replaced.
5. Test the injector for spray test using injector tester
Spare test: fix up the injector and work the handle of tester for 4 to 5 times and note the
spray pattern if it is in fine automated from it is ok if it is in stream from the nozzle seat and
valve seats are grounded and tested once again the good injector fines peculiar whistling
sound the spray angle also tested during this test.
Caution: never bring hand, finger or any part of the body under the spray while injector was
being tested.
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Experiment No. : 13
AIM: Bleeding of diesel fuel feed system
Tools required: DE spanner, screw driver, multipurpose piler.
Procedure:
1. Connect all fuel lines connection properly.

2. Kick the prime pump for 10-15min full the tank as to fill to all fuel lines
3. Open the bleeding nipple.
4. Remove the air
5. Tight the bleeding nipple.
6. Once again repeat the same procedure
7. Unit all the air cones out from the fuel lines
8. Tight all connections with full tight.
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Experiment No. : 14
AIM: Servicing of radiator
Tools required: DE spanner, 12-13-14-15, screw driver, cutting plier
Materials required: Patti, solder flux solder rod etc.
Procedure:
1. Drain the coolant from radiator by loosening the drawn plug

2. Disconnected the air cleaner and head lights horn wires and remove then from sheet metal
3. Disconnect the radiator hose connection at the radiator and side the clamps towards the
middle of the hose
4. Remove the radiator shall attaching bolts and remove the shell
5. Remove the fan shroud
6. Check the upper tank for leaks
7. Check the fit for being bent or closed
8. Check the lower tank for leaks
9. To install the radiator reverse the procedure as mentioned above
10. Fill the cooling system with cooled and the proper amount of anti freeze depending upon
weather conditions.
11. Run the engine for several minutes and check for radiator leaks.
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Experiment No. : 15
AIM: Cleaning of water jackets by measuring flushing method
Tools required: DE spanner, screw driver
Materials required: water, acid, kerosene,
Procedure: normally rust, sludge and other foreign material can be readily be removed from the
cooling system using cooling system cleaning solvent however in severe cases reverse flush method
is to be adopted. A pulsating & reversed flow flushing will loosen sediments more quickly &
efficiently.
It this method is using, always remove the thermostat and make sure the cylinder head bolts are
tightened properly before flushing after the cooling system has been cleaned a filled a good
commercial rust inhibitor should be added. However the rust inhibitor is not necessary if not
necessary if the cooling system is to be conditioned with permanent anti freeze containing rust
inhibitor
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Experiment No. : 16
AIM: Servicing of water pump
Tools required: DE spanner, 12-13, screw driver, cutting plier
Materials required: water body kit, bearing hose pipe clamp etc.
Procedure:
1. Remove the four attaching bolts and remove the fan from the pump gasket.
2. Using puller band sleeve, remove the pulling from the shaft.
3. Remove the four bolts the Retain the front and rear cover of the pump housing, separate the
pump cover and discard the gasket.
4. Using arbor press and sleeve remove the bearing assembly, shaft impeller out of the pup
housing
5. Support the flat side of the impeller between two blocks & press to shaft assembly using
small sleeve.
6. Remove the seal
7. Check impeller, seal seat, bearing shaft, slinger assembly, bearing pump housing, it needed
replace with new one
8. With sleeve press a new slinger on to shaft and press anew seal to pump housing
9. Press bearing shaft and slinger into housing using a sleek.
10. Support the shaft on a block of wood so as not to damaged its ends using arbor press
11. Support the shaft on a block of wood and press pulley on the shaft, after installation be shore
that the pulley must be on the shaft.
12. Assemble the front and rear of the pump together using anew gasket, tight the bolts to
specified torque.
13. Install the fan on the pulley tight the bolts to specified torque.
14. Place the new water pump gasket and place the water pump on to cylinder block & attach the
bolts. Place the drive belt and adjust tension the adjusting arm bolt and generator bolts,
15. Install the radiator.
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Experiment No. : 17
AIM: Replacing of engine oil and oil filters
Tools required: DE spanner, Flat screw driver, cutting plier.
Materials required: Oil filtering Element, Rubber “o” rings, petrol & Cotton waste.
Procedure:
1. Place cleaning tray below oil filter housing or crank case.

2. Open drain nut & drain the oil.
3. Unthread center bolt of oil filter & take out bolt from the body.
4. Dismount filter cover & take all parts of filter.
5. Remove clogged & shrinked filter element & broken oil seal.
6. Clean all the compounds in petrol & check bypass hole of oil filter cap found ok.
7. Mount oil filter cap & replace new filter element “o” ring & rubber seal.
8. Fill engine oil in oil filter & crank case. Mount filter cap properly.
9. Start engine & check filter body for leakage.
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Experiment No. : 18
AIM: Servicing of gear type oil pump
Tools required: DE spanner, 10-11, 12-13, screw driver,
Materials required: kerosene etc.
Procedure:
1. Remove the gear type oil pump from crank shaft.

2. Check the clearance between gear teeth, stub shaft wear bush and oil relief valve
3. Measure the clearance with feeder gauge.
4. If the clearance between gear teeth’s than 0.5mm the gear wheels are to be replaced.
5. Stub shaft is replaced if the wear is more than 0.5mm
6. The brush in the drive gear or the drive shaft has to be discarded if the clearance has
exceeded0.1mm
7. In the relief valve, the spring is to be tested for stiffness, if needed replace with new one.
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Experiment No. : 19
AIM: Servicing of vane type oil pump
Materials required: kerosene etc.
Procedure:
1. Remove the Vane type oil pump from crank shaft.

2. Check the clearance between vanes, stub shaft wear bush and oil relief valve
3. Measure the clearance with feeder gauge.
4. If the clearance between vanes than 0.15mm.
5. Stub shaft is replaced if the wear is more than 0.5mm
6. The bush in the drive gear or the drive shaft has to be discarded if the clearance has not to
exceeded 0.15mm
7. In the relief valve, the spring is to be tested for stiffness, if needed replace with new one.
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Experiment No. : 20
AIM: Servicing of rotor type oil pump
Materials required: kerosene cotton waste etc.
Procedure: at the time of overhead, pump should be thoroughly examined, as the oil pump is the
heart of the engine there are few clearances which must be kept within tolerance limits.
1. Clearance between outer rotor and body is tested by feeler gauge, it should be not more than
0.25mm
2. Clearance between rotor with tap face i.e., axial clearance should not be me than 0.0102mm.
3. Clearance between main body and outer rotor, is to be tested, thus clearance should not be
exceed 0.25mm.
4. The brush of rotor shaft, should not have any play, it should be free to move.
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MODEL QUESTIONS
1. Service the given fuel tank with fuel lines.
2. Service the given AC mechanical fuel pump and test the same.
3. Service the given Electrical fuels pump and test the same.
4. Service the given two wheeler carburettor and identify its circuits.
5. Service the given S U carburettor and identify its circuits.
6. Remove the air filter element from the vehicle and service the same.
7. Remove the petrol filter from the vehicle and service the same.
8. Remove the Diesel filter from the vehicle and service the same.
9. Remove the fuel feed pump from the engine and service the same.
10. Remove the inline fuel injection pump from the engine and service the same.
11. Remove the diesel injectors from the engine and service the same.
12. Conduct the experiment to test the given diesel injectors.
13. Conduct the experiment to bleed the diesel fuel feed system.
14. Remove the radiator from the vehicle and service the same.
15. Conduct the experiment to reverse flush the cooling system.
16. Remove the water pump from the engine and service the same.
17. Remove the gear type oil pump from the engine and service the same.
18. Remove the rotor type oil pump from the engine and service the same.
19. Remove the vane type oil pump from the engine and service the same.
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ARYABHARATHI POLYTECHNIC, TUMKUR.

AUTOMOBILE ENGINES – II LAB

Workshop Safety Rules

1) Always listen carefully to the teacher and follow instructions.

Tools required: D, E, spanner, ring spanner, screw driver.

Materials required: cotton waste, kerosene etc;

1. Remove the fuel tank from the chassis.

Tools required: D, E, spanner, screw driver, multipurpose piler.

Materials required: petrol, cotton waste.

Materials required: petrol, waste.

Tools required: DE spanner (10-11), screw driver, multipurpose plier.

Materials required: petrol, cotton waste.

Materials required: petrol, cotton waste.

1. Dismantle the carburetor completely, wash it which clean petrol

Components of fuel supply system

Tools required: DE spanner, screw driver, multipurpose plier.

Materials required: compressed air diesel oil, cotton waste.

1. Remove the filter

Tools required: DE spanner, 10-11-12-13, 18-19 screw driver,

Materials required: kerosene or diesel, filter element.

Tools required: DE spanner, 10-11-12-13, 18-19 screw driver, multipurpose piler.

Materials required: kerosene or diesel, cotton waste etc.

Tools required: spanner, 11-12-16, 18-19 screw driver, multipurpose piler.

Materials required: kerosene or diesel, cotton waste etc.

Tools required: DE spanner, 10-11-12-13, 18-19 screw driver,

Materials required: kerosene or diesel, cotton waste etc.

1. Remove the nozzle clean it thoroughly

Tools required: DE spanner, screw driver, multipurpose piler.

Materials required: kerosene or diesel, cotton waste etc.

1. Connect all fuel lines connection properly.

Tools required: DE spanner, 12-13-14-15, screw driver, cutting plier

Materials required: Patti, solder flux solder rod etc.

1. Drain the coolant from radiator by loosening the drawn plug

Tools required: DE spanner, screw driver

Materials required: water, acid, kerosene,

Tools required: DE spanner, 12-13, screw driver, cutting plier

Tools required: DE spanner, Flat screw driver, cutting plier.

1. Place cleaning tray below oil filter housing or crank case.

Tools required: DE spanner, 10-11, 12-13, screw driver,

Materials required: kerosene etc.

1. Remove the gear type oil pump from crank shaft.

Tools required: DE spanner, 10-11, 12-13, screw driver,

Materials required: kerosene etc.

1. Remove the Vane type oil pump from crank shaft.

Tools required: DE spanner, 10-11, 12-13, screw driver,

Materials required: kerosene cotton waste etc.

1. Service the given fuel tank with fuel lines.

5. Service the given S U carburettor and identify its circuits.

12. Conduct the experiment to test the given diesel injectors.

15. Conduct the experiment to reverse flush the cooling system.

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