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S.NOTITLE………(WORK LEARNT) 1Tools, guages,and different devices and equipments used in automobile workshop 2Identification of basic components of engine.

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Presentation on theme: "S.NOTITLE………(WORK LEARNT) 1Tools, guages,and different devices and equipments used in automobile workshop 2Identification of basic components of engine."— Presentation transcript:

1 S.NOTITLE………(WORK LEARNT) 1Tools, guages,and different devices and equipments used in automobile workshop 2Identification of basic components of engine 3Clutch 4Gearbox 5Fuel system 6Inlet and exhaust systems 7Cooling system 8Trouble shootings 9Electrical connections 10a/c working 11Special systems in vehicle We were trained at lakshmi hyundai (malakpet) 21-05-13 to 19-11-13 Done by the students trained at malakpet

2 INTRODUCTION It has been emphasized that the goal of Hyundai is to achieve 1 st position in customer satisfaction and even staff satisfaction Generally service station of any automobile company involves the following requirements 2.measuring devices 3.lifting devices 4.special tools 5.firstaid box

3 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…..


5 Special tools

6 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

7 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..

8 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

9 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

10 Vehicles in Hyundai 1SantroPetrol:- 3.1l 2I 10Kappa:-3.6l IRDE :--3.3l 3I 20Petrol:-3.5l Diesel:-5.3l 4VernaPetrol:-3..5l Diesel:-5.3l 5Verna fluidicDiesel:-5.3l 6AscentPetrol:3.5l Diesel:4.75l 7EonPetrol:2.5l 8GetzPetrol:-3.5l Diesel:-5.3l 9ElantraDiesel:-5.9l 10SantefeDiesel:5.9l 11Grand I 10Fuel:4.1l

11 Periodic check ups For every vehicle in general: 60,000Engine oil,oil filter Gear oil coolant Fuel filter Wiper rubbers 80,000Engine oil Oil filter Gear oil Coolant Belts,transmutation oil 1,00,000Engine overhaul Engine oil oil filter Gear oil Coolant distancereplacement 10,000Engine oil, oil filter 30,000Engine oil, oil filter Gear oil coolant

12 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 filter 5.Cleaned air filter 6.Check wiper rubbers if necessary replace the wiper rubbers 7.Check all lights 8.Check working of engine 9.Check wind shield water spraying nozzle 10.Do general check up 11.Fill nitrogen air into tyres and fix all the tyres to the vehicle 12.Tighet all the bolts and nuts 13.Lubricate all the doors and bonet,dicky with grease 14.Check the engine performance 15 check the noise in the vehicle 16.Check the under body at last inspect the whole vehicle and then delivery the vehicle

13 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 done Second 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

14 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 it Intertior 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

15 Identification of parts of engine Petrol engineDiesel engine General components.cylinder head.cylinder block.piston.piston rings.spark plugs.connecting rod.crank 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. 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

16 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.,

17 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

18 Working principle Four Stroke cycle Comprises: Suction or Intake Stroke Compression Stroke Power Stroke Exhaust Stroke

19 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

20 Working principle Compression Stroke: Piston Moves from BDC to TDC Both Valves remain closed Air-Petrol mixture is compressed just Spark is released just before the piston reaches TDC Ignition of charge takes place By now crank rotates by 1 revolution

21 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

22 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

23 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

24 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

25 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

26 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

27 lay out of clutch

28 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

29 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

30 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 box 1) place the vehicle on the lift and drain the oil from gear box 2) disconnect thte speedometer cable and dryshaft connections 3)Remove the gear box with the help of special jacks 4) 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 locks 5) clean the pars with petrol 6)Examine the teeth all other parts if necessary replace them 7)Ref ix all the parts removed in the reverse order of the removed 8)Check the working of the gear box 9)Care should be taken that the parts remove are prefixed and the connections removed are connected 10)At last fill the gear box with the lubricating oil of 75-85grade

31 Fuel system Petrol system the fuel system involves 1.Fuel tank 2.Fuel pump 3.Fuel filter 4.Fuel pipe lines 5.Throttle body 6.Air filter 7.Engine valves the cylinder block

32 Diesel fuel system Fuel tank Fuel feed pump Fuel filters Fuel injection pump Hand Primer Injectors Common rail Fuel lines

33 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

34 cooling systems Cooling system Learnt only about water cooling system this system involves 1.Radiator 2.Water pump 3.Water jackets 4.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

35 Maintenance There are three types of maintenance Preventive Periodic 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)

36 Trouble shootings Fault and cause remedy Engine doesn’t start 1.Less amount of fuel in fuel tank 2.Weak sparking at spark plugs 3.Belt tension improper 4.Electrical connection of sensors are cut off 5.Poor compression 6.Clutch stopper breakage 7.Self motor not working 8.Battery discharged\ 9.Ignition coil damage or cut off Incorrect running 1.Silencer outlet pipe chocked with carbon 2.Spark plug not well screwed with cylinder head 3.Air filter may be clogged 4.Poor compression refill the tank Check the spark plugs if short replace them Adjust the belt tension Check the wiring and connections Engine overhaul to be done Replace the clutch stopper near the pedal Self overhaul to be done Replace the battery or keep it for charging Replace the ignition coil Clean the carbon Remove the spark plug out and re screw it Replace air filter Engine over haul to be done

37 Trouble shootings Fault and causeRemedy Engine noise 1. cut off any sensors connections 2.Piston rings to be replaced 3.Bolts of the parts are loose 4.Clutch problem High fuel consumption 1.Air cleaner is chocked with dirt or any other 2.Faulty throttle body 3.Worn out engine parts inside Poor braking 1.Stroke of pedal or level too long 2.Brake linings worn out 3.Brake pads worn out Check the connections Replace the piston rings Tighten the bolts Check the clutch and do clutch overhaul Clean or replace it Clean the body Service the engine parts Adjust Replace

38 Trouble shootings Fault and causeremedy Engine getting over heated 1.Excessive carbon deposition in silencer and the ports 2.Coolant leakage 3.Hose pipes breakage 4.Radiator breakage Less pick up 1.Too tight brake 2.Less tyre pressure 3.Belt tension improper 4.Clutch plate worn out 5.Turbocharger defect De carbonize Check the leakage and replace the parts Replace the hose pipes Replace the radiator Adjust them Inflate Adjust the tension Replace the clutch plate Replace the turbocharger

39 Trouble shootings Fault and causeremedy Clutch dragging Release bearing defect Pressure plate defect Clutch plate defect Clutch turns hard Weak or broken pressure plate Worn out facing of clutch Rusty or jammed clutch facing Clutch chatter or grabs when engaging Grease or oil lining Worn out splines of clutch plate facing Broken or loose release bearing Clutch cable defect Replace replace

40 Trouble shootings Fault and causeremedy Noisy gear box 1.Bearing worn out 2.Gears worn or teeth broken 3.Gears loose on main shaft 4. check the release bearing Hard shifting of gears 1.The main shaft gears are tight on splines 2.Selector fork may be jammed 3.Synchromesh unit may be jammed Brake pedal goes to gloom board with out applying the brake 1.Air in system 2. worn master cylinder 3.Leakage of fluid 4.Wheelcylinder leakage Replace Replace the gear Tightened it or fix it again Replace the release bearing Adjust Clean it or replace it Replace the unit Add fluid and bleed the system Replace the master Check the leakage and prevent it Replace

41 Electrical systems There are many electrical connections in an automobile in general the connections we have learnt are Only about the sensors 1. oxygen sensor- 2.Map sensor-mass air pressure sensor 3.Maf sensor-mass air flow sensor 4.Ckp sensor- crank shaft sensor 5.Cmp sensor-cam shaft sensor 6.Aps sensor-accelerator pressure sensor 7.Ect sensor-engine coolant sensor 8.Tps sensor-throttle poistion sensor 9.Vss sensor-vehicle speed sensor 10.Bps sensor-boost pressure sensor 11.Ots sensor –oil temperature sensor 12.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

42 A/C Problems which occur in a/c system are 1.a/c gas leakage 2.a/c not effective 3.a/c not cooling 4.a/c not working in these cases the very first step to be done is to Fault and causeremedy a/c gas leakage 1.Suction pipes 2.Evaporator 3.Expansion valve 4.Gas filling nozzle a/c not effective or not working 1. check the fuse in fuse box 2.Check the working of compressor 3.Check the leakage a/c less cooling 1. evaporator 2.Insufficient gas Replace Remove and replace Adjust the valve Replace the fuse Replace the compressor If there is any replace the part Clean the evaporator Full the gas

43 a/c over hauling Process 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

44 Special systems There are some special systems in automobile to be in favour of an customer 1.Turbo charger 2.Sound deck connection 3. Stereo and many other to be in an automobile to satisfy the customer

45 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

46 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

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