S.NO TITLE………(WORK LEARNT)

1 Tools , guages ,and different devices and equipments used in automobile workshop

2 Identification of basic components of engine

3 Clutch4 Gearbox

5 Fuel system

6 Inlet and exhaust systems

7 Cooling system

8 Trouble shootings

9 Electrical connections

10 a/c working

11 Special systems in vehicle

We were trained at lakshmi hyundai (malakpet) 21-05-13 to 19-11-13 Done by the students trained at malakpet

INTRODUCTION

• It has been emphasized that the goal of Hyundai is to achieve 1st position in customer satisfaction and even staff satisfaction

• Generally service station of any automobile company involves the following requirements

1.tools 2.measuring devices 3.lifting devices 4.special tools 5.firstaid box

DESCRIPITION• TOOL: a tool is a device that provides a mechanical (or) mental advantage in

accomplishing a simple machine or a combination of them• the tools generally used in workshop are:• double ended spanner • Ring spanner • Socket spanner• ratchet spanner• Bits• Pliers• Screw drivers• hammers (plastic and iron)• Punches • Allen keys• Files etc…..

TOOLS

Special tools

Description

• A part from the already shown tools on the slide there are also special service tools (SST)

• available, these are required to perform a repair job and shorten work time

• For example special bit to remove an oil filter • The company even offers different scan tools which are required to

communicate with various systems of the vehicle such as …. Engine control module …..transmission control module …… body control module not only these tools some tools such as torque wrench, hydraulic

presses ,feeler gauge, valve spring compressor, piston ring compressor, oil can, steel rule, and many other

•

SPECIAL TOOLS

• Torque wrench: it is a retched handle with a device built into it for a precisely measuring the amount of torque you are applying to a nut or a bolt.

• example … torque for a flywheel bolt is 70nm.

• Hydraulic press: it is used for mounting a bearing..

Measuring devices

• Vernier calipers • Micro meter • Cylinder gauge• Digital multimeter.• a/c cooling meter etc vernier caliper is a device used to measure the external and the

internal diameters of the objects such as brake pads micro meter is widely used for measuring the thickness of the

blocks….. cylinder gauge is used to measure the bore and the stroke of the

cylinder multimeter is used to measure the resistance values of a copper

wire a/c meter is used to measure the cooling of a/c inside the vehicle

Special scan tools

• Apart from these scan tools such as …g scan …hi pro -scan etc ..are even used these tools are used to measure the

engine mechanism ..through electrical connections..(e.c.m)

Even some tools such as feeler gauge [a gauge used to measure the clearance between to parts(valve clearance)] ,etc are used

Vehicles in Hyundai1 Santro Petrol:- 3.1l2 I 10 Kappa:-3.6l

IRDE :--3.3l3 I 20 Petrol:-3.5l

Diesel:-5.3l4 Verna Petrol:-3..5l

Diesel:-5.3l5 Verna fluidic Diesel:-5.3l6 Ascent Petrol:3.5l

Diesel:4.75l7 Eon Petrol:2.5l8 Getz Petrol:-3.5l

Diesel:-5.3l9 Elantra Diesel:-5.9l10 Santefe Diesel:5.9l11 Grand I 10 Fuel:4.1l

Periodic check upsFor every vehicle in general:

60,000 Engine oil ,oil filterGear oil coolantFuel filterWiper rubbers

80,000 Engine oil Oil filterGear oilCoolant Belts ,transmutation oil

1,00,000 Engine overhaulEngine oil oil filterGear oil Coolant

distance replacement10,000 Engine oil , oil filter

30,000 Engine oil , oil filterGear oil coolant

Service learnt about the process of general service 1. lift the vehicle up so that the four wheels are free to move 2.remove the tyres and clean the brake pads and the brake liners in front and rear

respectively 3.Replace engine oil 4.Replace oil filter5.Cleaned air filter6.Check wiper rubbers if necessary replace the wiper rubbers7.Check all lights 8.Check working of engine 9.Check wind shield water spraying nozzle10.Do general check up11.Fill nitrogen air into tyres and fix all the tyres to the vehicle12.Tighet all the bolts and nuts13.Lubricate all the doors and bonet,dicky with grease14.Check the engine performance15 check the noise in the vehicle16.Check the under body at last inspect the whole vehicle and then delivery the vehicle

service

First service:(this is carried out for 1000km after the vehicle is purchased) Check the engine oil , gear oil level Check the coolant , brake oil levels All lights check up Vehicle interior check up Under body check up Lubricate doors Check horn , air pressure in tyres wiper working Final inspection to be doneSecond service :(this is carried out for 10000km after the vehicle is purchased In this engine oil and oil filter are replaced And even the brakes are cleaned with rough paper And all the general service things are done as in first service third service:( this is carried for 30000kms after the vehicle is purchased) In this engine oil ,oil filter ,gear oil ,coolant , air filter are changed need to replace the wiper rubbers Need to replace the brake pads Adjust the clutch play Check under body And all the service things are done as in all services

General check up• Check all doors working• Check the working the windows• Check all lights• Check handbrake • Check a/c cooling• Check the level of engine oil• Check coolant level in radiator • Check water in washer of wind shield• Check battery acid level• Check belts , check the performance of engine• Check noises if occurring vehicle starting under body check up: check all the bolts of axles , shock absorbers , lower arm , sump bolts Silencer, wheel nuts check leakages of oils from the vehicle Check tyres Check the dryshaft Check the suspension Check the steering rack and Check the entire unit if there are any faults repair itIntertior check up Check seat adjustments Check dickey absorbers Check power windows Check the sound system Check the seat folding Check the dash board glow box locks Check the lights in cluster Check the gear boots

Identification of parts of enginePetrol engine Diesel engine

General components.cylinder head.cylinder block.piston.piston rings.spark plugs.connecting rod.crank shaft.cam shaft along with pulley.valve and valve springs (mechanism).timing pulley.water pump.crankcase along with strainer

General components. Cylinder head .cylinder block.piston. Piston rings.heater plugs.connecting rods.crank shaft.cam shaft. valve mechanical parts.timing gear along with chain.water pump. Crank case along with strainer and turbine

2.Compression ratio varies from 6:1 to 9:1 compression ratio varies 12:1 to 22:1

3.It works on Otto cycle(constant volume cycle

It works on diesel cycle

4.Spark plugs is used to ignite the charge due to very high compression of air fuel gets automatically

Engine• The engine consists of several parts, • To understand the construction of the

engine we have to know the function and constructional details of at least the main parts.

• The main parts of an engine are – Cylinder or Cylinder block – Cylinder liner– Piston– Connecting rod– Crank shaft– Piston pin– Main bearings– Valves …etc.,

Working principle

Some terms• TDC – Top Dead Centre

• BDC – Bottom Dead Centre

• Stroke – Movement of Piston between Dead Centers

• IV – Inlet Valve

• EV – Exhaust Valve

Working principle

Four Stroke cycle Comprises:

• Suction or Intake Stroke

• Compression Stroke

• Power Stroke

• Exhaust Stroke

Working principle

Suction or Intake Stroke:• Piston Moves from TDC to BDC

• Exhaust Valve remain closed

• Inlet Valve opens

• Air-Petrol mixture enters the cylinder

• Crank rotates by ½ revolution

Working principle

Compression Stroke:

• Piston Moves from BDC to TDC

• Both Valves remain closed

• Air-Petrol mixture is compressed

• Spark is released just before the piston reaches TDC

• Ignition of charge takes place

• By now crank rotates by 1 revolution

Working principle

Power Stroke:

• Piston Moves from TDC to BDC• Both Valves remain closed• Burning of Air-Fuel mixture

• Pressure and Temperature rise to approx. 35 bar and 2200 °C

• Heat generated causes gases to expand on piston crown & forcing it to BDC

• By now, the crank has completed 1½ revolution

Working principle

Exhaust Stroke:• Piston Moves from BDC to TDC

• Suction Valve remain closed

• Exhaust Valve opens

• Gases inside the cylinder are no more

capable of doing work

• These gases are expelled out of cylinder making room for fresh charge

• By now crank has completed 2 revolutions

• Thus 4 strokes are completed in 2 revolutions of crank shaft

Dismantling the engine from the vehicle• Procedure:• remove the connections batteryterminals,battery, batter

plate.• Remove bumper, head lights ,head light panel,• Remove the a/c gas from the vehicle by recovering it through

robiner• Remove the connections of the suction pipes and remove the

entire assembly of the radiator• Removed all the connections of sensors (electrical

connections)• Remove the air filter assembly• Remove the alternator , drive belts, elbows, hose pipes• Remove engine oil,gearoil,coolant , transmutation oil

Dismantling the engine from the vehicle• All the bolts of the engine mountings(4)along with some nuts• Remove the dry shaft connections with gear box and silencer

connections with exhaust manifold • Care should be taken that the engine supported by the crane

before removing the mountings• Now remove the engine assembly out ..inspect if any of the

connections are striking it• After removing engine assembly out , remove the self starter

and even the bolts including self starter and clutch plate, pressure plate .with gearbox

• Remove the timing belt, tappet cover, cylinder head , cylinder block, valve mechanism,pistons,cam shaft assembly ,crank shaft assembly

• Clean the dismantled parts .along with bolts(en head and block

Dismantling the engine • The whole block and head are given to lathe machine for re boring• After that re assemble all the parts• Set the valve springs and valve clearance(inlet vav-0.18mm,,exhaust-0.10mm)• set the piston rings and piston into the piston and block respectively• Fix flywheel, clutch plate, pressure plate,allign them and fix the gearbox .• Fix the self starter, tappet cover, sensors ,water pump and the parts removed• Take the engine assembly fixed near to the vehicle refax the engine mountings,

electrical connections and dry shaft connections to the gear box and the connections removed

• Refax the head light panel, head lights, battery plate battery and all other terminal connections

• Recharge the gas which is recovered and start the vehicle• Keep it running for 6hrs to check its performance• Take the vehicle for a long drive to check its performance• After that check the leakage under the vehicle care should be taken that all gaskets are kept

clutch• In general clutch is used to engage and disengage the transmission of power

from the engine to the gearbox• It is located b\w the engine and the gearbox• It works on the principle of the fricition i.e..• Constructional details

Similar to single plate

Diaphragm spring is used

instead of coil spring

Diaphragm spring is a large

disc of conical form It contains number of radial

fingers in its centre portion

It takes on a flat shape in

engaged position

Flywheel fixed on engine shaft (crank shaft)

Clutch plate is freely mounted on the splines of the clutch shaft

Pressure plate assembly

fixed to the flywheel

lay out of clutch

Working of clutch

Clutch engage• Diaphragm spring takes on flat position and exerts a load upon the pressure

plate

• Pressure plate exerts pressure on clutch plate, to keep in contact with flywheel• Clutch plate rotates with fly wheel

• Clutch shaft also rotates and power is transmitted• When driver presses the clutch pedal• Diaphragm spring takes on its original shape of conical form

• There is no pressure exertion by pressure plate on clutch plate• Clutch plate moves axially outwards and stops rotating• Power is not transmitted from engine shaft to clutch shaft

Dismantling the clutch

• Clutch is removed out by removing the gearbox out..• Procedure: lift the vehicle on the hoist and remove tyres in front drain out the engine oil, gear oil. remove the battery and plate connections remove the gear lever and

remove the rounding bolts on the top remove the mountings and the rounding bolts in the bottom remove the dry shaft in contact with the gear box and remove the gear box

out remove the clutch plate, pressure plate and release bearing check the parts and replace them if necessary re fix all the connections which are removed check the clutch pedal if necessary replace the clutch cable

Gear box• At low speed engine speed a reciprocating piston engine does not develop suficent

torque to move the vehicle forward• Therefore gear box is necessary to move the vehicle by providing different torque ratios• dismantiling the gear box1) place the vehicle on the lift and drain the oil from gear box2) disconnect thte speedometer cable and dryshaft connections3) Remove the gear box with the help of special jacks4) take the dust covers out of box and remove the gears of layshaft and main shaft

remove the reverse gear and bearings, syncronizer,and all locks5) clean the pars with petrol 6) Examine the teeth all other parts if necessary replace them7) Ref ix all the parts removed in the reverse order of the removed8) Check the working of the gear box 9) Care should be taken that the parts remove are prefixed and the connections

removed are connected10) At last fill the gear box with the lubricating oil of 75-85grade

Fuel system

• Petrol system the fuel system involves1. Fuel tank2. Fuel pump3. Fuel filter 4. Fuel pipe lines5. Throttle body6. Air filter 7. Engine valves the cylinder block

Diesel fuel system

• Fuel tank

• Fuel feed pump

• Fuel filters

• Fuel injection pump

• Hand Primer

• Injectors

• Common rail

• Fuel lines

Inlet and exhaust systems• Inlet system involves fuel system intake manifold in general the intake manifold is a series of tubes that carry air

or fuel mixture into the engine cylinder in diesel engines intake manifold carry only the air into the

engine In petrol engine manifold carries the whole air fuel mixture

through throttle body exhaust manifold The both manifolds are connected on the opposite sides of the

engine its purpose is send out the exhaust gas into the atmosphere it is next connected to the silencer Exhaust gases before they are led out are passed through mufflers

and catalytic converter so as to reduce noise and pollution

cooling systems• Cooling system• Learnt only about water cooling system this system involves 1. Radiator2. Water pump3. Water jackets4. Thermostat they are of two types…thermosyphon system….forced circulation system when the circulation is done the water pump it is called as the

forced circulation system . In general we learnt only about this type of circulation

when the circulation of water is achieved by the virtue of its density then it is known as thermosyphon type

Maintenance

There are three types of maintenancePreventivePeriodic Break down preventive is the maintenance done to prevent break down like

replacing the brake pads

periodic is the maintenance done periodically for all the vehicles at different intervals

break down is the maintenance done after the vehicle is stopped while running automobile work shops provide this as e.r.s (emergency road service)

Trouble shootingsFault and cause remedy Engine doesn’t start1. Less amount of fuel in fuel tank2. Weak sparking at spark plugs3. Belt tension improper4. Electrical connection of sensors

are cut off5. Poor compression6. Clutch stopper breakage 7. Self motor not working8. Battery discharged\9. Ignition coil damage or cut off

Incorrect running10. Silencer outlet pipe chocked with

carbon11. Spark plug not well screwed with

cylinder head12. Air filter may be clogged13. Poor compression

refill the tankCheck the spark plugs if short replace themAdjust the belt tensionCheck the wiring and connectionsEngine overhaul to be doneReplace the clutch stopper near the pedalSelf overhaul to be doneReplace the battery or keep it for chargingReplace the ignition coil

Clean the carbon

Remove the spark plug out and re screw it

Replace air filterEngine over haul to be done

Trouble shootingsFault and cause Remedy

Engine noise1. cut off any sensors connections 2. Piston rings to be replaced3. Bolts of the parts are loose4. Clutch problem

High fuel consumption5. Air cleaner is chocked with dirt or any

other 6. Faulty throttle body7. Worn out engine parts inside

Poor braking8. Stroke of pedal or level too long9. Brake linings worn out10. Brake pads worn out

Check the connectionsReplace the piston ringsTighten the boltsCheck the clutch and do clutch overhaul

Clean or replace itClean the bodyService the engine parts

AdjustReplaceReplace

Trouble shootingsFault and cause remedy

Engine getting over heated1. Excessive carbon deposition in silencer and the

ports2. Coolant leakage3. Hose pipes breakage4. Radiator breakage

Less pick up5. Too tight brake6. Less tyre pressure7. Belt tension improper8. Clutch plate worn out 9. Turbocharger defect

De carbonizeCheck the leakage and replace the partsReplace the hose pipesReplace the radiator

Adjust themInflateAdjust the tensionReplace the clutch plateReplace the turbocharger

Trouble shootingsFault and cause remedy

Clutch draggingRelease bearing defect Pressure plate defectClutch plate defectClutch turns hardWeak or broken pressure plateWorn out facing of clutchRusty or jammed clutch facingClutch chatter or grabs when engagingGrease or oil liningWorn out splines of clutch plate facingBroken or loose release bearingClutch cable defect

ReplaceReplaceReplace

ReplaceReplaceReplace

ReplaceReplaceReplacereplace

Trouble shootingsFault and cause remedyNoisy gear box1. Bearing worn out2. Gears worn or teeth broken3. Gears loose on main shaft4. check the release bearingHard shifting of gears5. The main shaft gears are tight on

splines6. Selector fork may be jammed7. Synchromesh unit may be jammedBrake pedal goes to gloom board

with out applying the brake8. Air in system9. worn master cylinder10. Leakage of fluid11. Wheelcylinder leakage

ReplaceReplace the gearTightened it or fix it againReplace the release bearing

Adjust

Clean it or replace itReplace the unit

Add fluid and bleed the systemReplace the masterCheck the leakage and prevent itReplace

Electrical systems• There are many electrical connections in an automobile in general the connections we have learnt areOnly about the sensors1. oxygen sensor- 2. Map sensor-mass air pressure sensor3. Maf sensor-mass air flow sensor4. Ckp sensor- crank shaft sensor5. Cmp sensor-cam shaft sensor6. Aps sensor-accelerator pressure sensor7. Ect sensor-engine coolant sensor8. Tps sensor-throttle poistion sensor9. Vss sensor-vehicle speed sensor10. Bps sensor-boost pressure sensor11. Ots sensor –oil temperature sensor12. Fts sensor-fuel temperature sensor these connections will send feed back to engine control

module( E.C.M) IF there is cutoff in any wiring there will some defect in engine performance

A/CProblems which occur in a/c system are1. a/c gas leakage2. a/c not effective3. a/c not cooling4. a/c not working in these cases the very first step to be done is to

Fault and cause remedy

a/c gas leakage1. Suction pipes2. Evaporator3. Expansion valve4. Gas filling nozzlea/c not effective or not working5. check the fuse in fuse box6. Check the working of compressor 7. Check the leakagea/c less cooling8. evaporator 9. Insufficient gas

ReplaceReplaceRemove and replaceAdjust the valve

Replace the fuseReplace the compressorIf there is any replace the part

Clean the evaporatorFull the gas

a/c over haulingProcess• Remove the wiper blade and the whole assembly• Recover the gas from the vehicle through the robiner• Remove the cluster , dash board by removing all the screws ,bolts, nuts • Remove the connections of steering column in contact with dash board

remove all the electrical connections• remove the wiper motor and remove the bolts connected• Remove the coolant pipes ,expansion valve• Remove the evaporator and replace it• Refix the dash board• Reconnect all the connections• Refix all the parts removed refix steering column , coolant pipes, expansion

valve , cluster etc..• Refix all the electrical connections and the wiper assembly• Recharge the gas again• Check the cooling of a/c it will ranging from5°c to 8˚c • Inspect the lights in cluster and all the pars removed are working

Special systems

There are some special systems in automobile to be in favour of an customer

1.Turbo charger2.Sound deck connection 3. Stereo and many other to be in an

automobile to satisfy the customer

Turbocharger

• In Turbocharger is an exhaust gas driven turbo compressor used to supply

air under pressure to cylinders.

• The turbocharger consists of a,

• Centrifugal compressor with impeller

• Gas turbine with wheel

• Common shaft

Brief description

• The power output of a diesel engine can be increased by supplying

compressed air to the engine cylinders.

• If more air is delivered to cylinders, the fuel charge can also be

increased.

• Due to this more energy can be released

• It is driven by the exhaust gases

the end

t