DEPARTMENT OF AUTOMOBILE ENGINEERING

MGM
POLYTECHNIC COLLEGE
MGM TECHNOLOGICAL CAMPUS , PAMPAKUDA

DEPARTMENT OF AUTOMOBILE ENGINEERING

LAB MANUAL

2059 - AUTOMOBILE SERVICING LAB - I

SEMESTER - II

1
 DEPARTMENT OF AUTOMOBILE ENGINEERING

SAFETY PRECAUTIONS

Safety means protecting yourself and others from possible danger and injury. Don’t want to get hurt
and you don’t want to hurt others.

1. Work quality and give your full attention, for the job you are doing.
2. Keep your tools and equipment under control.
3. Keep jack handles out of the way stand creeper against the wall when it is not in use.
4. Never indulge in horse play or other foolish activities. You would cause some to get seriously
hurt.
5. Don’t put sharp objects, such as screw driver in your pocket. It may damage upholstery in the
car.
6. Make sure you clothes are right for the job dangling sleeves or ties can get caught in machinery
and cause serious injuries. Don’t wear sandals or open toe shoes. Wear full leathers shoes with
non skid rubber heal and soles. Keep long hair out of machinery by wearing a cap.
7. Don’t wear rings, bracelets or watches when working around moving machinery or electrical
equipment. Jewelry can catch in moving machinery with very serious results. Also if a ring or a
bracelet should accidently create a short circuit of the car battery; the metal of the ring or
bracelet may become white hot in an instant. This would produce serious burns.
8. Wipe excess oil and grease off your hands and tools so that you can get a good grip on tools or
parts. If you spill oil, grease or any liquid on the floor, clean it up so that no one will slip and fall.
9. Always wear safety glasses or goggles or a face shield.
10. When using a car jack, make sure it is centered so that it won’t slip. Never Jack up a car when
someone is working under it. People have been killed when the jack slipped and the car fell on
them. Always use safety stands before going under a car.
11. Keep your hands from the engine fan and belt when the engine is running. You would be badly
cut or even loose fingers, if your hand gets caught in the fan or fan belt.
12. If in the workshop fire is caused due to oil or petrol or electricity; it may not be extinguished by
water. For this sand and fire extinguishing gas may be used.
13. Before starting any work; full planning of the work may be sketched. Machines may be properly
cleaned and lubricated before starting any operation on them.
14. Properly clean and put the tools and machines at proper places after using them.

2
 DEPARTMENT OF AUTOMOBILE ENGINEERING

STUDY: 01
STUDY OF TOOLS

AIM
To study about the various hand tools and measuring tools used in Automobile Servicing
lab.

INTRODUCTION
You will use two main types of tools in the shop type is known as hand tools because the
hand supplies the energy to operate them. Other type is called machine or power tools.

HAND TOOLS

1. Screw driver:-
Which is used to drive or turn the screws. Most common type is a single flat blade for driving
screws with slotted heads and cross slot or Philips type.

2. Ball peen hammer:-

The ball peen hammer is the commonly used hammer in the workshop. It should be gripped
on the end of the handle. Rubber hammers are used to strike easily marked surface. When
you swing the hammer. The face should strike the object squarely and not at an angle.

3. Open wrench (open end spanner):-

The wrenches are the simplest to use the opening should be the right size of fit the out or belt
if the wrench opening is two layer it could round off the corners of the box. The makes the
use of the proper wrenches more difficult open end wrenches usually have a different size on
each end.

4. Box wrench (ring spanner):-

The box wrench does the same job as the open end spanners.Wrench is a tool that fits around
a nut. Another property of the wrench is that is uses leverage.

5. Combination wrench:-
The combination wrench has a box on one end and an open on other end. Both ends are the
same size. The box wrench is more convenient for final tightness or breaking loose of a nut
or bolt because it will not slip off the box must be lifted. Completely free after each swing.

6. Socket Wrenches (box spanner):-

A socket wrench is a type of wrench or spanner that has a socket attached at one end, usually
used to turn a fastener. The most prevalent form is the ratcheting socket wrench, often
informally called a ratchet.

3
 DEPARTMENT OF AUTOMOBILE ENGINEERING

7. Ratchet:-
A ratchet is a mechanical device that allows continuous linear or rotary motion in only one
direction while preventing motion in the opposite direction.

8. Adjustable wrench:-
The wrenches has just that can be adjusted to light nuts and bolt heads of a various sizes.

9. Torque wrench:-
It is a tool used to apply a specific torque to a fastener such as a nut or bolt. It allows the
operator to set the torque applied to the fastener so it can be matched to the specifications for
a particular application.

10. Piston Ring Compressor :-

The piston ring compressor is a special tool that is specifically designed for compressing the
piston rings when a piston is re-installed.

11. Piston ring expander:-

A unique tool that will speed the removal and installation of piston rings with minimum ring
distortion.

12. Circlip pliers:-

It is used to remove and refitting the circlips. There are two types of circlip pliers , Internal
and External circlip pliers.

13. Oil can:-

Oil can is a device used for lubricating purpose. A vacuum pump is provided inside the oil
can and when the handle is operated the oil is lubricated on.

14. Pullers:-
Pullers are used for to remove gear , bearings and pulley from shafts bearing from blind
holes. A puller set has many pieces that can be fitted together to from the proper combination
for any pulling job.

15. Nose plier:-

Nose plier is used for both cutting and holding pliers . Because of their long shape they are
useful for reaching into small areas where cables or other materials have become stuck or
unreachable with fingers or other means.

4
 DEPARTMENT OF AUTOMOBILE ENGINEERING

16. .Allen key:-

Allen key or Allen wrench is a tool used to drive bolts and screws with hexagonal sockets in
their heads .Mostly after screws are in hexagonal shapes at the head so it is made in
hexagonal shape on and in bent at an angle 90͑

17. Feeler gauge:-

It is a gauge which is used for checking the clearance between the mating surfaces. They are
made in the form of a set of steel precision machine blade .03 to 1mm thick and 10 mm long.
The blades are pivoted balder each blade have a indication of its thickness.

18. Combination plier:-

This is another type of plier which is used for cutting wires holding puts etc.

19. Valve lifter or valve spring compressor:-

The valve may be removed from the cylinder head. The functions of valve lifter is to
compress the spring and remove the spring loaded valve .

5
 DEPARTMENT OF AUTOMOBILE ENGINEERING

cross slot \ Philips type

flat type

Open wrench (open end spanner)

Box wrench (ring spanner)

6
 DEPARTMENT OF AUTOMOBILE ENGINEERING

Socket wrenches(box spanner)

Adjustable wrench

Torque wrench

7
 DEPARTMENT OF AUTOMOBILE ENGINEERING

Oil can puller

8
 DEPARTMENT OF AUTOMOBILE ENGINEERING

MEASURING TOOLS:

1. Vernier calipers:-
These are used for measuring outside as well as inside dimensions accurately. It may also be
used as a depth gauge. It has two jaws. One jaw is formed at one end of its main scale and the
other jaw is made part of a vernier scale
2. Steel rule:-

9
 DEPARTMENT OF AUTOMOBILE ENGINEERING

Steel rule is a simple measuring instrument consisting of a long, thin metal strip with a marked
scale of unit divisions. It is an important tool for linear measurement.
3. Dial Gauge:-
A gauge that a dial dose and a needle to register used to measure variations in dimensions and
distance too small to be measured accuracy by the means it is used to measure and play so shaft
or fears also.
4. Screw gauge(micrometer):-
It is an instrument used for measuring accurately the diameter of a thin wire or the thickness of a
sheet of metal. It consists of a U-shaped frame fitted with a screwed spindle which is attached to
a thimble.

10
 DEPARTMENT OF AUTOMOBILE ENGINEERING

Vernier caliper

Screw gauge(micrometer) dial gauge

Steel rule

STUDY NO : 1

CONSTRUCTIONAL DETAILS AND WORKING PRINCIPLE OF

2 – STROKE PETROL ENGINE
AIM

To study the construction details and working principal of two stroke petrol engine

11
 DEPARTMENT OF AUTOMOBILE ENGINEERING

APPARATUS REQUIRED

Model of 2 – stroke petrol engine

THEORY

The working principle of engine:-

In 2 stroke petrol engine one power is obtained by one complete revolution of the
crankshaft. The valves are replaced by ports in case of two stroke petrol engine.

As the piston moves upwards , it uncovers the inlet port and the air – fuel mixture enters the
crank case. At the same time the air – fuel mixture present inside the cylinder I compressed. At the end
of compression, spark plug is activated and spark is produced in the cylinder. The air-fuel mixture is
ignited and combustion takes place. The burnt gas start expanding and pushes the piston downwards.
Thus power stroke takes place. During this expansion process , the piston covers the inlet port and
uncovers the exhaust port. The burnt gas escapes through the exhaust port. Then the transfer port is
uncovered and the compressed air-fuel mixture from the crank case flows into the cylinder.

The fresh air-fuel mixture entering the cylinder helps to remove the burnt gases present in the
upper part of the cylinder. This phenomenon is known as Scavenging.

Constructional details :-

1. Cylinder :- Its main function is to provide enough space for the movement of the piston .The
combustion is take place inside the cylinder
2. Piston :- It is the reciprocating part of an IC engine inside the cylinder. It convert the heat energy
produced by the combustion of fuel inside the cylinder into mechanical energy.
3. Connecting rod :- It connects the piston and the crankshaft
4. Crank shaft :- It converts reciprocating motion of the piston into rotational motion.
5. Spark plug :- It is used to ignite the air-fuel mixture in combustion chamber.

RESULT

The construction details and working principal of two stroke petrol engine is studied.

12
 DEPARTMENT OF AUTOMOBILE ENGINEERING

Working of 2-stroke petrol engine

STUDY NO : 2

CONSTRUCTIONAL DETAILS AND WORKING PRINCIPLE OF

4 – STROKE DIESEL ENGINE
AIM

13
 DEPARTMENT OF AUTOMOBILE ENGINEERING

To study the construction details and working principal of 4- stroke diesel engine

APPARATUS REQUIRED

Model of 4 – stroke diesel engine

THEORY

The working principle of engine:-

In 4-stroke diesel engine one power stroke is obtained by two complete revolution of the crank
shaft. The entire process is completed by 4 strokes , they are : Suction , Compression , Power and
Exhaust .

Suction stroke :-

 Piston moves downwards (TDC to BDC)

 Inlet valve is open , Exhaust valve is closed.
 The air sucked into the cylinder through the inlet valve.

Compression stroke:-

 Piston moves upwards (BDC to TDC)

 The air inside the cylinder is compressed.
 The temperature and pressure of the air increases.
 Both valves remains closed.
 At the end of the compression stroke the fuel is sprayed into the cylinder by the fuel injector and
fuel starts burning.

Power stroke:-

 When combustion take place the pressure of the gas increases instantaneously and gas start
expanding and piston moves downwards (TDC to BDC)
 Hence work is done on the piston.
 Both valves are remain closed.

Exhaust stroke:-

 Piston moves upwards (BDC to TDC)

 Exhaust valve opens and inlet valve remains closed.
 The gas escape from the cylinder through the exhaust valve.
 By completing this stroke , one cycle has finished and the process is continues.

14
 DEPARTMENT OF AUTOMOBILE ENGINEERING

Constructional details :-

1. Cylinder : Its main function is to provide enough space for the movement of the piston. The
combustion is take place inside the cylinder
2. Piston :- It is the reciprocating part of an IC engine inside the cylinder. It convert the heat energy
produced by the combustion of fuel inside the cylinder into mechanical energy.
3. Connecting rod :- It connects the piston and the crankshaft
4. Crank shaft :- It converts reciprocating motion of the piston into rotational motion.
5. Fuel injector:- it is used to inject the fuel into the cylinder.
6. Valves:- Valves controls the intake of air and exhaust of the combustion gases in the cylinder.
7. Cam shaft:- The valves are operated by the cam shaft.

RESULT

The construction details and working principal of 4-stroke diesel engine is studied.

15
 DEPARTMENT OF AUTOMOBILE ENGINEERING

4-stroke diesel engine

16
 DEPARTMENT OF AUTOMOBILE ENGINEERING

EXP. NO: 01

REMOVING AND REFITTING OF SPARK PLUG

AIM

To remove and refit the spark plug from the engine cylinder head.

TOOLS REQUIRED

Open end spanner, screw driver, spark plug spanner, T-rod , ratchet handle.

MATERIALS REQUIRED

Petrol engine, Cotton waste, kerosene.

DESCRIPTION

Spark plug is device used in ignition system of an SI engine ,it is fitted on the cylinder head or
cylinder block .The spark plug is a device for delivering electric current from an ignition system to
the combustion chamber.It consist of central electrode fitted in the porcelain insulator and sealed within
a steel shell, which also holds the side electrode. The electrode is set with the lower end of the central
electrode to form the spark gap .The steel shell has external threads which fit into the cylinder head to
make an earthing contact. Spark plug gap mainly 0.5 to 1.2 mm

PROCEDURE

1. Park the vehicle on a level surface.

2. Remove key from the vehicle
3. Remove the battery negative terminal
4. Remove the high tension coil from spark plug.
5. Remove the spark plug using spark plug socket
6. Check the spark plug gap using feeler gauge
7. Check any defective or any short circuit in spark plug.
8. Clean the plug with sand paper
9. Refit the spark plug if it is found faulty, change with new spark plug
10. Refit the high tension coil in spark plug
11. Refit the battery terminal
RESULT

Thus the given spark plug is dismantled and assembled from a given cylinder head.

17
 DEPARTMENT OF AUTOMOBILE ENGINEERING

EXP NO:02

CALCULATION OF CC ( CUBIC CAPACITY ) OF AN ENGINE

AIM

To measure the cc (cubic capacity) of a given engine.

TOOLS REQUIRED

Cylinder bore dial gauge, Vernier caliper.

MATERIALS REQUIRED

Engine cylinder, cotton waste.

DESCRIPTION

The bore and stroke on a cylinder determines the displacement of an engine(cubic capacity-cc or
swept volume). It determines the engine power. If the bore and stroke is large, we get more powerful
engine. The engine cc is determined by two measurements, these are Bore and stroke. The bore is
determined by the diameter of a cylinder and the stroke is determined by the distance a piston travels up
and down inside that cylinder.

BASIC ENGINE TERMINOLOGY

1. Bore:
It is the diameter of the engine cylinder.
2. Stroke:
It is the linear distance traveled by the piston from Top dead centre (TDC) to Bottom dead
centre (BDC).
3. Stroke-bore ratio:
The ratio of length of stroke (L) and diameter of bore (D) of the cylinder is called stroke- bore
ratio (L/D). In general, this ratio varies between 1 to 1.45
4. Swept volume or piston displacement:
It is the volume (A x L) displaced by one stroke of the piston where A is the cross sectional area
π 2
of piston and L is the stroke length. Vs= D xL
4
5. Compression ratio:
It is the ratio of the volume of the cylinder at the beginning of the compression stroke to that at
the end of compression stroke, i.e. ratio of total cylinder volume to clearance volume. The
Compression ratio of diesel engine varies from 14:1 to 22:1 and that of carburetor type engine
(spark ignition engine) varies from 6:1 to 8:1.

18
 DEPARTMENT OF AUTOMOBILE ENGINEERING

PROCEDURE

1. Ensure the piston is at the bottom of the cylinder.

2. Clean the given engine cylinder by using cotton waste.

3. Measure the cylinder bore by using cylinder bore dial gauge. Take 4 bore readings by placing the dial
gauge at different positions of the cylinder.

4. Now measure the stroke length of the cylinder by using a vernier caliper. Take 4 stroke length
readings by placing the vernier caliper at different positions of the cylinder.

5. Now tabulate the readings and find out the total cc.

RESULT

Thus the Cubic Capacity (CC) of the given engine is calculated

19
 DEPARTMENT OF AUTOMOBILE ENGINEERING

OBSERVATIONS

Total Number of given engine cylinder (n) =………

TABULAR COLOUMN

Trial Bore Stroke Length Swept Volume

No. D in mm L in mm π 2
Vs= D x L
4
1
2
3
4
Average Vs

Total swept volume of the given engine (Vd) = Average Vs ×number of cylinders

Total cc of the given engine = Vd/1000 cm3

= ………cc

SAMPLE CALCULATIONS

Set no:

Diameter of the cylinder(bore dia) D =………..mm

Stroke length L =………..mm

Total number of cylinder n =………

Swept volume of one cylinder Vs = D2 x L

=…………..mm3

Total swept volume of the given engine Vd = Vs × n

= ………..mm3
Vd/1000=……….cm3
=……….cc

20
 DEPARTMENT OF AUTOMOBILE ENGINEERING

EXP NO: 03

JACKING UP THE VEHICLE AND REMOVING THE WHEEL

AIM

To lift the vehicle up using a hydraulic or mechanical jack and remove one wheel.

TOOLS AND EQUIPMENTS REQUIRED

Wheel spanner, hydraulic jack, wooden block

PROCEDURE

1. Place the vehicle on a level surface, wooden blocks were placed in to and fro position of the right side
tyre. This helps avoiding the vehicles slips in any of the direction due to gravity or if standing on a little
inclined.

2. Place the side jack between the doors, under the running board.

3. The nuts of the needed wheel were made loosened

4. The jack was lifted slowly up and the under inspection was made.

5. After that wheel was taken out by removing the nuts.

6. The wheels where put on to the drum and nuts were tightened slightly with wheel brace.

7. The vehicle was lowered to the ground, removed the jack and the nut were tightened completely.

PRECAUTION

1. Wheel nut must be loosened before jacking up the vehicle.

2. Jack must be at proper place and solid surface

3. A jack handle is easily tripped over if felt in the low position, and it should, therefore always be raised
to its highest point.

4. A screw jacks with worn out threads should not be used.

5. After completion of works, wooden blocks and jacks, must kept at proper places.

RESULT

Thus the jacking up and changing of tyre from the given vehicle is completed.

21
 DEPARTMENT OF AUTOMOBILE ENGINEERING

EXP NO:04

MAINTENANCE SCHEDULE OF A VEHICLE

AIM

study about vehicle maintenance.

DESCRIPTION

Vehicle maintenance can be defined as the repairing, reconditioning or replacement work done
on any unit or machine parts of a motor vehicle to retain its original condition or performance. There are
two types of maintenance

1: Predictable/Planned Maintenance:

a) Monthly Maintenance b) Preventive Maintenance c) Periodic Maintenance

2: Unpredictable/Unplanned Maintenance:

a) Break Down/Emergency Maintenance

PREVENTIVE MAINTENANCE

1. ENGINE OIL LEVEL

 Park the vehicle on the ground
 Warm up the engine and turn it off.
 Wait for a minute, then remove dipstick.
 Wipe oil from the dipstick with a clean cloth.
 Re-insert the dipstick fully.
 Remove the dipstick again to check oil level.
 Oil level should be between “F” and “L” mark.
 If oil level is found below or at “L” (low) mark, open Oil Filter cap and add oil till it reaches “F”
mark.
 Reconfirm the oil level once again
2. ENGINE COOLANT LEVEL
 Park the car on a level ground.
 Check for coolant level in the reservoir bottle
 The level should be between “F” and “L” mark.  If found below or at “L” (low) mark, open
the Reservoir cap and add plain water.
3. RADIATOR
 Let the engine cool down if it is hot.
 Remove the Radiator cap by pressing it and turning clockwise.
 Check the level in the Radiator.
 The level should be up to the brim.
22
 DEPARTMENT OF AUTOMOBILE ENGINEERING

 If less, add water to bring it up to the brim level.

 Replace the Radiator cap. (Radiator Coolant concentration: Water 65% & Anti- freeze 35%)
CAUTION
 Never open the radiator cap when engine is hot. If level drops frequently, contact Hyundai
Service Centre.
4. BRAKE OIL LEVEL
 Park the vehicle on the level ground.
 Check the Brake Fluid Level in the Reservoir Bottle.
 Level should be between Min and Max mark.
 If found low, top up to the Max-mark.
 Use genuine Brake Oil.

Caution !

Mixing of any oil other than DOT-3, can seriously effect Brake performance

5. WINDSHIELD WASHER FLUID LEVEL

 Check the Windshield Washer Fluid level in the Reservoir.
 The level of the fluid should be up to the brim.
 If level found low, top up with clean Tap Water.
6. TYRE CARE
 Check Tyre pressure at least once a week.
 Always maintain a tyre pressure of 30 PSI in all tyre.
 High tyre pressure adversely affects tyre life, suspension, comfort and safety of the vehicle.
 Low tyre pressure adversely affects tyre life, fuel efficiency, steering effort and steering stability.
 Check tyre periodically for abnormal wear, damage and cuts.
 CARE Make sure that Tyre Pressure gauge used to measure pressure is in good condition.

7. CHECKING OF BELT TENSIONS

 Keep the Engine in the switched off condition.

 To check the belt tension press the respective belt with Thumb pressure in the middle.
 The deflection for the respective belt should be as under:
 Deflection Value Alternator/ water Pump Drive belt 9 -10 mm
 Deflection Value Air Con Drive Belt 8 – 9 mm
 Deflection Value Power Steering Pump Drive Belt 7 – 10 mm

RESULT

Thus the maintenance schedule of a vehicle was completed.

23