VEHICLE DIAGNOSIS AND SOLUTIONS

A Summer Training Presentation

By

Sandesh Giri

110106240

B.Tech ME

4th Year

OBJECTIVE OF THE TRAINING

• To exercise my knowledge acquired from textbooks

• To learn the practical aspects which were constricted to visualization only

• To learn time management

• To learn management and leadership skills by learning and understanding the techniques followed and the ways they are implemented

• To know how to manage a good workshop facility.

• To be familiar with the working environment of workshop and behaviour of workers.

• To know about team work in organization.

• To know about the technical information of an automobile, their service schedule, parts, basic construction of automobile, break down maintenance etc.

• To be familiar with new technologies in automobile field.

• To experience the practical and professional life as an Engineer.

• To know how to deal and assess problems to customers and help understand the problem for swift assessment.

PROFILE OF SIPRADI TRADING PVT. LTD.

• Sipradi is a major company in Automotive and Allied business and is one ofthe largest and most prestigious brands in Nepal. 30 years down the line,Sipradi has exceeded USD 150 million annual revenue and is growingrapidly in automotive, energy, lubricant, financial services, and equipmentbusinesses.

• Sipradi Trading Private Ltd (STPL) has been the exclusive distributor of TataMotors Ltd in Nepal since 1982.

• STPL sells and services the full range of Tata Motors’ commercial andpassenger vehicles. The company has the largest sales and servicedistribution network throughout Nepal

• Sipradi Trading Pvt. Ltd. Soltimod Branch concerns with Service andDiagnosis of Commercial Vehicles.

SAFETY PROCEDURES

• Always wear the safety equipment at the Workspace

• Always check for lifter pad’s positioning before lifting the Vehicle

• Avoid spillage of oil and fluid and clean immediately if there is spillage

• Never use heavy equipment without guidance from a workshop employee

GENERAL VEHICLE DIAGNOSIS

• Changing Engine Oil1. Open Drain Plug2. Collect the to be replaced oil in the oil-pan or tray3. Close the drain plug4. Open the oil-cap on the cylinder head and pour in the engine oil and

replace the cap

• Changing Oil Filter1. Locate the oil-filter and remove the old oil filter by using filter

wrench2. Dispose the filter and on the new filter pour some engine oil and

smear the gasket ring with engine oil as well3. Re-install the oil filter by using filter wrench

• Changing Fuel Filter• Locate the fuel filter and remove the fuel filter and the fuel pipes

connected to it from the fuel tank• Replace the new fuel filter and connect the fuel pipes and pump the

filter to release air

GENERAL VEHICLE DIAGNOSIS

• Changing Air Filter1. Unscrew the air filter plastic cover and remove the air filter

2. Air blow the plastic housing to remove dust

3. Replace the new air-filter and screw the plastic cover

• Checking and changing brake pads and brake liners1. Open the tyres and remove the brake calipers or the brake drums

2. Check for wear on the brake pads and liners

3. Replace the pads and liners and re-install the calipers and the drum along with the tyres

GENERAL VEHICLE DIAGNOSIS

• Undercarriage NoiseUnder carriage noise is the noise or disturbance heard from underneath the floor board of a vehicle. The noise persists because of multiple reasons.Worn Ball Joints 1. Jack the control arms to check or play2. If there is play then remove the control arms and remove the ball

joint from the knuckle3. Replace the ball joint and re-position it on the knuckle and re-install

the control armsWorn Suspension and Control arm Bushes 1. Remove the control arms from the mounting point and check the

bushes for wear2. If there is wear then replace the bushesSway Bars Bushes1. The sway bars are removed and the bushes are checked2. If the bushes are worn out then they are replaced

GENERAL VEHICLE DIAGNOSIS

• Checking and Changing Timing Belt1. Open the bonnet and open the timing belt cover

2. Check for wear and tear in the timing belt

3. Is there is any wear then replace then remove the timing belt and replace it

Software Diagnosis

• A software scan tool provides access to the vehicle’s onboard diagnostics and states the problem related with the vehicle.

• The modern tools allow multiple operations such as airflow, coolant temperature, oxygen sensor outputs, throttle position and other sensor readings. agnostics and states the problem related with the vehicle.

• The limitation of diagnostic tool is that it can only be used in the vehicle which has an Electronic Control Unit or the ECU.

Wheel alignment

• Procedure of aligning the various wheel and suspension geometries

• The process requires slight adjustment of front or rear suspension components.

• Caster, camber and toe- in/ toe-out are the primary considerations

• Performed in a wheel alignment post by the use of sensors controlled though a computer

Camber

• Its the angle of lean of the wheel away from the vertical when viewed from the front of the vehicle. If the wheel leans too far then uneven wear will occur.

Toe

• Wheel toe is an angle formed by the center line of the wheel looking at the vehicle from above.

Caster

• Caster is the angle of steering pivot which is measured in degrees.

• Viewed from the side, the caster is the tilt of the steering axis.

TATA NANO BREAKING SYSTEM ASSEMBLY

Tata Nano has drum brakes in all the 4-wheels and is assisted by the brake booster technology.

Brake Assembly Without Brake Boosters Brake Assembly With Brake Boosters

Brake Master Cylinder• The master cylinder converts the motion of the brake pedal into hydraulic

pressure.

• It consists of the reservoir tank, which contains the brake fluid and the piston and cylinder which generate the hydraulic pressure.

Brake Master Cylinder Construction

Brake boosters• The brake booster is designed to create a greater braking force from a minimum

pedal effort.

• It increases the pedal force 2 to 4 times depending on the size of the diaphragm.

• The brake booster is located between the brake pedal and the master cylinder.

• When pressure is applied to the brake pedal, pressure is exerted on the booster air valve.

• With pressure created by the booster the master cylinder is applied.

Brake Booster when Brake AppliedBrake Booster when Partial Brake

Applied

General Engine Problems

• Engine starts but runs evenly and misfires

• Lack of power

• Excessive oil consumption

• Excessive mechanical noise from engine

• Unusual vibration

• Engine Heating Problem

CYLINDER HEAD ASSEMBLY AND DIS-ASSEMBLY

• Cylinder head dis-assembly relates to dismantling the cylinder head to check for problems and assess with the possible diagnostic method

Procedure for Disassembly• Remove the head cover

• Head cover provides housing and protection to the head. Head cover consists of the oil filler cap and oil filler gasket.

• Remove the cam shaft

• Remove the tappet or the hydraulic lash adjuster (HLA)

• HLA a device for maintaining zero valve clearance in an engine which eliminates the need for periodical valve adjustment as they set automatically and also reduces engine noise and increase engine durability.

• Remove spring retainer, valve spring and washer

• Shim is a seal for the valve seal guide. Value seal guide is a cover which locks the valve half lock into position. The value half lock locks valve spring retainer to the spring. The valve spring is removed by the use of a special valve spring compressor tool.

• Remove intake and exhaust valves from the cylinder

• Remove valve stem seals

• Remove all the bolts on the head

• Remove the head

Procedure for Assembly• Install cylinder head gasket

• Install the cylinder head

• Install the value seal on value guides

• Place the valves in their location

• Install the washer, valve spring and spring retainer

• Using vale spring compressor tool, compress the valve spring

• Install valve lock on the values

• Install the HLA or the tappet

• Replace the cam shaft

• Tighten the bolts to specified torque.

• Install the head cover

धन्यवाद!