DJJ 20032

AUTOMOTIVE WORKSHOP PRACTICE 1

CHASIS
TITLE:SUSPENSION
LECTURER:TS.MUHD HASNUL ISYRAF BIN MAT
JUHOH
EN MOHD FAIS BIN ISMAIL

DAD3S4

NAME NO.MATRIX
MUHAMMAD HAIKAL 13DAD20F1024
IKHWAN BIN NAHARUDDIN
MUHAMMAD AIMAN BIN 13DAD20F1012
MOHD AZIZOL
13DAD20F
13DAD20F
OBJECTIVE
Demonstrate suspension system service. Upon the completion of this workshop
activity the student will able to;
a) Suspension system check
b) Dismantle front suspension system
c) Radiator fan functional test

THEORY
The modern automobile has come along way since the days when “just being
self propelled” was enough to satisfy the car owner. Improvement in
suspension, increased strength & durability of components, and advances in
tire design and construction has made large contributions to tiding comfort and
driving safety.
Basically, suspension refers to the use of front and rear springs to suspend a
vehicles frame, body, engine and power train above the wheels. These relatively
heavy assemblies constitute what is known as Sprung weight. Unsprung weight,
on the other hand, includes wheels and tire, break assemblies and other
structural members not supported by the springs.
The springs used in today’s cars and trucks are engineered in a wide variety of
types, shapes, sizes, rates and capacities. Types include leaf springs, coil
springs, air springs and torsion bars.
Independent Suspension System
These are used in sets of four per vehicle, or they are paired off in various
combinations and are attached to the vehicle by a number of different mounting
techniques.
The automobile frame and body are mounted on the front and rear axle not
directly but through the springs and shock absorbent. The assembly of parts,
which perform the isolation of parts from the road shocks, may be in the forms
of bounce, pitch and roll is called suspension system.
Suspension system of an automobile separates the wheel and axle assembly of
the automobile from its body. Main function of the suspension system is to
isolate the body of the vehicle from shocks and vibrations generated due to
irregularities on the surface of roads. Shock absorbers are provided in the
vehicles for this purpose. It is in the form of spring and damper. The suspension
system is provided both on front end and rear end of the vehicle.
Functions of suspension system:
• It prevents the vehicle body and frame from road shocks.
• It gives stability of the vehicle.
• It safeguards the passengers and goods from road shocks.
• It gives the good road holding while driving, cornering and braking.
• It gives cushioning effect.
• It provides comfort
Components of Suspension system:
Coil springs, Leaf springs, shock absorbers, Spring shackles, stabilizer

EQUIPMENTS & MATERIAL

TOOLS AND EQUIPMENT FUNCTION/USAGE

 To loosen and tighten the bolt or nut

Combination spanner set

 To loosen and tighten the screw

Screw driver set

  Protection against cuts by sharp
materials.

 Protection against cold or heat.

Glove

 The reservoir for oil that gets

pumped throughout the engine to
lubricate, clean and cool moving
parts.

Waste container/drainage pan

 Storing energy in order to release it,

absorb shock or maintain force
between two surfaces.

Coil spring compressor

 Used for cleaning up spills, hands

and surfaces in the workshop
environment

Rag or cloth
PROCEDURES
Suspension system check
Introduction To Front Suspension Diagnosis

If the front suspension is faulty, the vehicle will not run straight forward or
noise will occur. Incorrect wheel alignment, malfunction of strut assembly,
stabilizer bar, coil spring, or worn or out-of-balance tires can cause these
problems.

Lifting and supporting vehicle.

Step 1:CHOCK THE WHEEL.Place wheel chocks and blocks in front of and
behind at least one tire at the opposite end of the vehicle from where you are
working.
Step 2:RAISE THE VEHICLE.Jack the vehicle up from the appropriate jacking
points or astrong frame location
Step 3:PLACE THE JACK STAND.Just like jacking the vehicle up,place the
jacks stands at a strong chasis location to support the vehicle.Once
placed,slowly lower the vehicle onto the stands.Move the floor jack to support
the suspension under each corner as you are replacing the shocks because the
suspension will droop down a bit when you remove the shock
REMOVE AND INSTALL SHOCK
Step 1:REMOVE THE UPPER SHOCK BOLT.Removing the upper shock bolt
first makes it easier to slide the shock out from the bottom.
Step 2:REMOVE THE LOWER SHOCK BOLT.By having removed the upper
shock bolt first,you can now lower the shock out of the bottom of the
vehicle.Otherwise,it would drop out if you remove the bottom bolt before the
top.
Step 3:INSTALL THE NEW SHOCK.From under the vehicle,push the upper
part of the shock into its upper mount.have a friend help you secure the shock
bolt into the upper mount as you are pushing it up.
Step 4:INSTALL THE LOWER SHOCK BOLT.Once you have aligned the
shock to the suspension mounting secure the lower shock bolt.
 RESULT/OBSERVATION

NO. Task/Inspection/Checking/ Result/Observation/ Others Specificatio

Condition information n
(If
Relevant)
1. Absorber condition fully functional
(Compress and extend the shock
absorber rod and check that there
is no abnormal resistance)
2. Leaking inspection Transmission fluid, reddish
and thin
3. Mounting condition In good condition
4. Spring height In good condition

DISCUSSION
1. how do you know the condition of the absorber is still good or
unsatisfactory?
- Vibrations while driving
If the valving or piston seal inside the shock is wearing out then it may not sit properly,
allowing fluid to flow uncontrolled past the valve or piston seal and thereby allowing every
tiny bump in the road to cause an overreaction that you will actually feel with your hands on
the steering wheel.
- Swerving or nose diving while braking
If the valving or piston seal inside the shock is wearing out then the fluid flows uncontrolled
and even the slightest steering wheel movement or the slightest brake application by the
driver allows extreme movement of the piston within the cylinder. This means that if you take
a right turn for instance then the weight of the vehicle will shift harder to the left during the
turn and the driver will have to correct it, causing a swerve. When braking, the weight will
shift farther forward than anticipated causing a nose dive.
- Brakes take more time to stop the car
In addition to nose diving when applying the brakes, it takes extra time for the vehicle to take
up all the piston rod length if uncontrolled and this adds time and extends the stopping
distance required to come to a complete stop.
2. What happens when shock absorbers go bad?
A broken shock absorber will result in your car bouncing around, as well as excessive rolling,
squatting and diving. In other words, it won't be comfortable. Plus, your car will be harder to
control, especially at high speeds.

3. what happen if the mount on the absorber is damaged

- A Noisy Strut Mount
Do you hear a clunking sound like metal on metal? It is likely because the rubber in the
mount has disintegrated to the point of it being no longer able to provide a barrier between
the mount and the strut itself.

- Not So Good Vibrations

If you fee like you’re teeth are chattering when driving your car, your suspension needs work.
Check the upper strut mount first and asses its condition. Generally, the vibrations will be a
lot more intense than normal.

-Steering Issues
By steering issues, we mean that it is too stiff, too loose, or making a noise. None of these are
healthy. The steering may seem completely unrelated, but it’s interlinked with the suspension
system.
Conclusion
At the end of this lesson we can conclude that the suspension on the car is
very important because the suspension is one of the important suspension
system for a vehicle because this system acts as a safety member who acts
as a comfort function on a vehicle. Car if it hits a bump or puddle on the
road surface.The suspension system absorbs energy generated due to road
deviation or bumps, potholes and energy is transferred from the vehicle to
the ground or road.

REFERENCES
-https://oards.com/bad-strut-mount-symptoms/
-https://www.yourmechanic.com/article/how-to-replace-a-shock-absorber-
by-ronny-brown
-https://aftermarket.zf.com/go/en/sachs/technology-in-practice/workshop-
tips/shock-absorbers-and-dampers/impact-damage/
-https://motor.onehowto.com/article/how-to-replace-a-shock-absorber-
12597.html
EQUIPMENTS & MATERIAL