U18PCAU4L3 - Automotive Engines

and Chassis Lab

LAB MANUAL

B.Tech II Year

DEPARTMENT OF AUTOMOBILE ENGINEERING

BHARATH INSTITUTE OF HIGHER EDUCATION AND RESEARCH
173, AGARAM MAIN ROAD, SELAIYUR, CHENNAI - 600073
AUTOMOTIVE ENGINE AND CHASSIS
COMPONENTS LABORATORY MANUAL

DEPARTMENT OF AUTOMOBILE ENGINEERING

FACULTY OF ENGINEERING AND TECHNOLOGY

BHARATH INSTITUTE OF SCIENCE AND TECHNOLOGY

173, Agaram Main Road, Selaiyur,

Chennai-600073, Tamilnadu.
DEPARTMENT VISION AND MISSION

Vision

To evolve as world renowned institution for graduates studies and research in the field of
Automobile Engineering and to build a society of Automobile Engineering with
professionalism and social ethics.

Mission

M1: To provide a teaching learning environment through innovative teaching methods,

modern teaching aids and planning and to create a platform for advanced studies.
M2: To promote research by state of art facilities and through partnership with industries,
academia and research organisations through due emphasize in the curriculum.
M3: To impart soft skills, multi lingual capabilities, social skills such as team building,
leadership qualities with professional ethics and values.

PROGRAMME EDUCATIONAL OBJECTIVES

PEO1: PREPARATION:
Automobile Engineering graduates are to process in mathematical, scientific and engineering
fundamentals necessary to analyze, formulate and solve engineering problems in the field of
Automobile Engineering.

PEO2: CORE COMPETENCE:

Automobile Engineering graduates have competence to enhance the skills and experience in
defining problems in the field of Automobile Engineering and Technology design and
implement, analyzing the experimental evaluations, and finally making appropriate decisions.

PEO3: PROFESSIONALISM:
Automobile Engineering graduates made competence to enhance their skills and embrace
new thrust areas through self-directed professional development and post-graduate training or
education.
PEO4: PROFICIENCY:

Automobile Engineering graduates became skilled to afford training for developing soft skills
such as proficiency in many languages, technical communication, verbal, logical, analytical,
comprehension, team building, inter personal relationship, group discussion and leadership
skill to become a better professional.

PEO5: ETHICS:

Automobile Engineering graduates are morally merged to apply the ethical and social aspects
of modern Engineering and Technology innovations to the design, development, and usage of
new product, in line with the societal needs.

PEOs with Mission of the Department:

PEO Statements M1 M2 M3
PEO1: PREPARATION 3 - -
PEO2: CORE COMPETENCE 3 2 -
PEO3: PROFESSIONALISM 1 3 3
PEO4: SKILL 2 - 3
PEO5: ETHICS - 1 3

Correlation levels 1, 2 or 3 as defined as follows:

1. Slight (Low)
2. Moderate (Medium)
3. Substantial (High).
AUTOMOTIVE ENGINE COMPONENTS

LIST OF EXPERIMENTS

1. Study, Dismantling and Assembling of Multi Cylinder SI Engine

2. Study, Dismantling and Assembling of Multi Cylinder CI Engine
3. Study of Oil Filter, Fuel Filter, Fuel Injection System and Carburetor
4. Study of Ignition Systems
5. Study of Engine Cooling System Components
6. Study of Engine Lubrication System Components

LIST OF EQUIPMENTS

1. Multi cylinder SI engine (dead)

2. Multi cylinder CI engine (dead)
3. Fuel injection system cut section
4. CRDI and MPFI
5. Engine cooling system
6. Engine lubrication system
 Exp.No : 1 DISMANTLING, STUDY AND ASSEMBLING OF MULTI –
CYLINDER SI ENGINE

Aim :

To dismantle, Study and assemble the given four stroke, Multi – Cylinder petrol engine.

Tools Required

i) Double end spanner.

ii) Socket Spanner.
iii) Screw Driver
iv) Extension rod.
v) Vernier Calliper.
vi) Telescopic Gauge.

Dismantling Procedure

i) Remove the crank shaft pulley and the timing gear set up. Notice that you
have marked the reference point.
ii) Remove the rocker cover
iii) Remove the inlet manifold from the cylinder head. The carburetor along
with the air filter should also be removed.
iv) Remove the exhaust manifold from the cylinder head.
v) Remove the rocker arm assembly and the push rods.
vi) Dismount the cylinder head after removing the lock nuts.
vii) Tilt the engine and then remove the crank case and the oil pump. Make sure
you have drained the oil completely before removing the crank case.
viii) Remove the connecting rod big end cap and its bearing.
ix) Remove the piston along with the connecting rod.
x) Remove the oil and compression rings from the piston.
xi) Remove the crankshaft main bearing and pull out the crankshaft.
xii) Remove the camshaft finally.
Study

i) The engine is a 4 – Cylinder, in – line type engine.

ii) The arrangement of valves is over head valve type.
iii) The type of cooling is water cooled.
iv) The type of lubrication in pressure lubrication.
v) The crankshaft has got three main bearings.

Assembling Procedure.

i) Fit the crankshaft and cam shaft along with its bearings.
ii) Neatly clean the rings and lubricate them with grease before placing them in
the groove of the piston.
iii) Fit the piston along with the connecting rod within the cylinder block.
iv) Fit the big end of the connecting rod and tighten the lock nuts appropriately.
v) Fit in the crank case and fill them with the oil.
vi) Mount the cylinder head suitably and tighten the lock nuts.
vii) Appropriately fit in the push rod and the rocker arm assembly.
viii) Fit the exhaust and the intake manifold along with the accessory components.
ix) Mount the rocker cover and tighten the lock nuts.
x) Finally position the timing gear according to the reference point and fit it.
xi) Fit the pulley and tighten them correspondingly.

Result :

Thus the given 4-stroke, 4-Cylinder Petrol engine was dismantled, studied
and assembled.
Exp.No : 2 DISMANTLING, STUDY AND ASSEMBLING
OF MULTICYLINDER CI ENGINE

Aim :
To dismantle, study and assemble the given multi-cylinder diesel engine.

Tools Required
i) Double end spanner.
ii) Ring spanner.
iii) Screw Driver & Hammer.
iv) Telescopic gauge.
v) Vernier Calliper.

Dismantling Procedure
i) Remove the crank shaft pulley along with the timing gear. Make sure you
have marked the reference point.
ii) Remove the rocker cover
iii) Dismount the intake manifold and its accessories. Remove the fuel
injector along with the pump.
iv) Remove the exhaust manifold.
v) Remove the cylinder head by unlocking the lock nuts. Before doing so,
ensure that you have removed the valves along with the rocker arm
assembly and the pushrods.
vi) Remove the crankcase and drain the oil.
vii) Remove the connecting rod big end cap
viii) Remove the piston along with the connecting rod.
ix) Remove the piston rings along with the circlips.
x) Remove the crankshaft bearings and pull out the crank shaft.
xi) Remove the camshaft as well.
 Study :
i) The given engine is a 4-cylinder, 4-stroke In-Line vertical type engine.
ii) The engine is water-cooled and is pressure lubricated.
iii) The fuel is directly injected (DI injection). Naturally aspirated.
iv) Valve arrangement is over head valve type.

Assembling Procedure
i) Fit the crank shaft and the cam shaft assembly in the corresponding space
provided in the block.
ii) Carefully insert the piston along with the connecting rod. Note that you have
properly cleaned and lubricated the rings before assembling.
iii) Fit the connecting rod big end cap and tighten the lock nut.
iv) Fit in the crankcase along with the lubricating oil.
v) Mount the cylinder head and tighten the lock nuts.
vi) Place the push rods, rocker arm assembly and the valves correspondingly.
vii) Mount the intake and exhaust manifold respectively.
viii) Fit the fuel injection system along with the injector.
ix) Fit the rocker cover and tighten the lock nut.
x) Fit the crankshaft pulley along with the timing gear set up based on the reference
point.

Result :
` Thus the given multi – cylinder diesel engine is dismantled, studied and assembled.
 Exp.No. 3 DISMANTLING, STUDY AND ASSEMBLING OF OIL FILTER,
FUEL FILTER, FUEL INJECTION SYSTEM and
CARBURETTOR

AIM:
To dismantle, study and assemble the given oil filter, fuel filter, fuel injection system
and carburetor.

Functions of fuel Supply Systems

Certain functions of fuel supply systems are,

i) Storing of fuel.
ii) Filtering of fuel.
iii) Delivery of fuel to injection pump.
iv) Injecting the fuel into engine cylinders.
v) Controlling the engine speed.

Fuel Injection System

The function of a fuel injection system is to inject proper quantity of fuel in to the
engine cylinders at the correct time and at a pre-determined rate.

Types of Injection System

i) Common rail fuel injection system
In this type of injection system, a single injection pump with injector called
as unit injector is employed on each cylinder. The unit injectors are operated by
rocker arms and spring similar to the engine valves. A linkage connects the
control racks of all the unit injectors so that fuel injection in all the cylinders
may be equal and simultaneously controlled.

ii) Individual pump fuel injection system

Here, fuel is drawn from the fuel tank by means of a fuel feed pump which
is operated from the injection pump cam-shaft. The fuel injection pump then
injects definite quantity of fuel in to the individual cylinders in turn according to
the firing order, through injectors fitted on them.
The injection pump is gear driven from the engine crankshaft so that it is driven
at half the engine speed. There is a governor which provides automatic speed
control, relative to any set position of the accelerator pedal.
Fuel Filter :
The most commonly used primary filter is the wire gauze installed on the suction side
of the feed pump. A better alternative is to use a sedimentation type primary filter. The
fuel from the tank enters the filter and flows around the conical diffuser funnel to accelerate
downwards to the sediments chamber. The secondary filter is installed after the feed pump
and it separates out abrasive particles and any water in the fuel. The fine pores of the filter
element retain the abrasive particles and other solid impurities.

Carburettors

Functions of a carburettor
i) To keep a small reserve of fuel at a constant head,
ii) To vaporise the fuel to prepare a homogenous air-fuel mixture.
iii) To supply correct amount of air-fuel mixture at the correct strength under all
conditions of load and speed of the engine.

Types of carburettors
i) Simple Carburettor
ii) Carter Carburettor
iii) Zenith Carburettor
iv) S.U. Carburettor
v) Solex Carburettor
vi) Solex Mikuni double venturi carburettor.

Simple Carburettor
The main parts are a float chamber, fuel jet, venturi, nozzle and a throttle valve. The
needle valve attached to the float lever serves to close or open the fuel inlet to the float
chamber depending upon the requirements. When the fuel level falls below a definite
predetermined value, the float also falls along with the fuel level, thus opening the
passage for the fuel supply. The fuel starts flowing in and the float rises gradually till
the fuel level reaches the desired value. At this time, the float needle closes the fuel
inlet passage. Thus a constant head of fuel is maintained in the float chamber. This
constant level of fuel is slightly below the nozzle outlet, so that the fuel may not drop
all the time from the nozzle, even when the engine is not working. A small vent in the
float chamber keeps the pressure inside is atmospheric. The fuel supply from the float
 chamber at any time is metered by means of a fuel jet from where the fuel flows to the
venturi through the discharge nozzle. The venturi is simply a restriction in the air
passage. Thus due to less area, the air velocity increases and because of this increase in
velocity, decrease in pressure is caused at the nozzle which is located in the venturi
itself. Due to depression being applied at the nozzle, the fuel comes out and is
vaporized by the coming air stream. The mixture then goes to the inlet manifold, to the
engine cylinders. The amount of fuel delivered depends upon the jet size, float level
and venturi vacuum. The purpose of a throttle valve is to control the quantity of air fuel
mixture. It is attached to the accelerator pedal by means of suitable linkage so that when
the pedal is depressed the valve opens out.

Result:

Thus the given oil filter, fuel filter, fuel injection system and carburetor is dismantled,
studied and assembled.

\
 Exp.No:4 STUDY OF IGNITION SYSTEM

Aim:
To study the functions of various ignition systems and its components used in automotive.

Function
The function of the Ignition system is to produce a spark in the engine cylinder
towards the end of the compression stroke.

Types of Ignition System

i) Battery Coil Ignition System.

There are two basic circuits in the system, the primary and the secondary circuit.
The battery, primary winding of the Ignition coil, condenser and the contact breaker
form the primary circuit, whereas the secondary winding of the Ignition coil, the
distributor and the spark plugs constitute the secondary circuit.

When the Ignition switch is in the ‘ON’ position, the current flowing in the primary
circuit will grow exponentially during the make period of the contact breaker. The
electromagnetic energy on account of this build-up of current in the primary circuit is
stored in the laminated iron core of the Ignition coil. As the contact breaker points
open, the magnetic field built up by the growth of the current collapses and the energy
stored during the make period is projected into the secondary circuit. It is this energy
which is suddenly passed on to the secondary, inducing an e.m.f there. As the break is
made very sharp, the induced e.m.f. is very large being proportional to the rate of
change of flux in the winding. This self-induction effect is combined with the
transformer step-up action of the Ignition coil. As a result a sudden voltage surge of
very high amplitude is produced in the secondary causing a spark to occur at the spark
plug electrodes.

ii) Magneto Ignition System

In the magneto ignition system, it is the magnet which produces and
supplies the current in the primary winding. The other parameters are same as
that of battery coil ignition system.

The magneto ignition system is of two types.

 a) Rotating Armature type.
b) Rotating Magnet type.

Advantages over rotating armature type

a) Larger armature may be provided, which means more space for insulation.
b) No centrifugal stresses occur in the windings, because these remain stationary.
c) Contact breaker and condenser are also stationary.
iii) Electronic Ignition System.
In the electronic ignition system a timer is employed in the distributor instead of
a contact breaker. This timer may be a pulse generator or a Hall Effect switch
which triggers the electronic ignition control unit. This control unit primarily
contains transistor circuit whose base current is triggered off and on by the timer
which results in the starting and stopping of the primary current. Other than this,
the electronic ignition system works similar to the conventional system.

Result:
Thus the functions of various ignition systems and its components used in automotive were
studied.
Exp.No. 5 STUDY OF COOLING SYSTEM COMPONENTS

Aim:
To study the functions of various cooling systems and its components used in automotive.

Introduction
All the heat produced by the combustion of fuel in the engine cylinder is not converted
into useful power at the crank shaft. It is seen that the quantity of heat given to the cylinder
wall is considerable and if this heat is not removed from the cylinders it would result in
pre-ignition of the charge. In addition, the lubricant would also burn away, thereby causing
the seizing of the piston. Excess heating will also damage the cylinder material. Keeping
the above factors in view, it is observed that suitable means must be provided to dissipate
the excess heat from the cylinder walls, so as to maintain the temperature below certain
limits. However, cooling beyond optimum limits is not desirable because it decreases the
overall efficiency of the engine.

Methods of Cooling
i) Air Cooling
ii) Water Cooling
a) Thermosyphon System of cooling
b) Pump circulation system.

Components of water cooling system

i) Radiator.
The function of the radiator is to ensure close contact of the hot coolant
coming out of the engine with outside air, so as to ensure high rates of heat
transfer from the coolant to air. A radiator consists of an upper tank, core and
the lower tank. Besides, an overflow pipe in the upper tank and drain pipe in the
lower tank are provided. Hot coolant from the engine enters the radiator at the
top and is cooled by the cross flow of air, while flowing down the radiator. The
coolant collects in the collector tank from where it is pumped to the engine for
cooling.
ii) Pressure Cap and expansion reservoir
A pressure cap contains a pressure valve and a vacuum valve. When due to
severe working conditions, the coolant starts boiling and vaporises, the pressure
in the system exceeds a certain predetermined value, the pressure blow-off
 valve open releasing the excess pressure to the atmosphere through the overflow
pipe. On the other hand if due to any reason a vacuum is created inside, the
vacuum valve operates to avoid collapse of the radiator.
iii) Thermostat
To keep a rigid control over the cooling, a thermostat is used, which
automatically keeps the cooling water temperature at a pre-determined value.
Moreover, it also helps the engine to reach the operating temperature as soon as
possible after starting.
Two types of thermo stats are used in automobiles
a) Bellows or aneroid type.
b) Wax or hydrostatic type.
iv) Coolant Pump:
A coolant pump is a necessity for the forced circulation type of engine
cooling system. The pump is mounted at the front end of the engine and is driven from the
crank shaft by means of a v-belt. Centrifugal type pump is the one which is used for this
purpose. The coolant from the radiator enters the pump at the centre where inlet is located.
The flow of the coolant depends upon the pump speed which is proportional to engine
speed. The main parts of the pump are casing and a shaft – mounted impeller having
number of vanes. The impeller shaft is mounted on bearing while the seal serves to prevent
the leakage of coolant around the shaft.

v) Fan
When the vehicle is going at high speed with light load, the natural draft of air
passing through the radiator may be sufficient for cooling of the engine, but when the
vehicle is moving under heavy load and at a slow speed, the natural draft is certainly
insufficient to produce the desired cooling. That is why fan is a necessary part of the
cooling system. It is mounted behind the radiator on the same shaft on which the water
pump is mounted. It is driven by a v-belt from the crankshaft pulley. It may have four
to seven blades, sometimes spaced unevenly to reduce noise. It is generally made of
sheet metal, but these days moulded plastic materials are being used for making fans.

Result:
Thus the functions of various cooling systems and its components used in automotive were
studied.
Exp.No. 6 STUDY OF LUBRICATION SYSTEM COMPONENTS

Aim:
To study the functions of various lubrication systems and its components used in automotive

Introduction
Lubrication circuit is one of the most important ones in the engine. The engine cannot
run smoothly for more than a few minutes without lubricating oil.

Functions of Lubrication
i) It reduces the friction between moving parts & so that power loss in minimum.
ii) It reduces wear of the moving parts.
iii) It provides cooling effect.
iv) It provides cushioning effect.
v) It provides cleaning action.
vi) It provides sealing action.

Systems of Engine Lubrication

The various systems adopted for the lubrication of automobile engines are
i) Petroil System.
ii) Splash System.
iii) Pressure System.
iv) Dry-Sump System.
The main parts of an automotive engine which require lubrication are
i) Main crankshaft bearings.
ii) Big end bearings.
iii) Gudgeon pin bearings.
iv) Piston rings & Cylinder walls.
v) Timing Gears.
vi) Camshaft and camshaft bearings.
vii) Valve Mechanisms.
viii) Electrical Equipments.
Components of Lubrication System
i) Oil Strainers.
Oil strainer is attached at the inlet of the oil pump to guard it against the entry of grit etc. The
strainer is made of ordinary wire mesh screen. A good practice is to install a floating strainer,
which is hinged to the oil pump inlet. The floating strainer remains at the surface of the oil,
whereas the grit, dust etc., remains at the bottom of the crankcase. The result is that very small
amount of impurities goes to the strainer screen and hence the chances of it being blocked up are
minimised.

ii) Oil Pumps

Next to oil strainer in the lubrication system sequence, comes the pump. Its function
is to supply oil under pressure to the various engine parts. The oil pump is generally
located inside the crankcase below the oil level.

The pump is usually driven from the end of the distributor shaft, which gets its drive
from the camshaft through a skew gear if a low-mounted camshaft is employed. In some
automobile engines mounted transversely, the oil pump is driven directly from the
camshaft end through a coupling, since no separate shaft is required, this is a compact
arrangement. The oil pressure in the engine increases with the increase in engine speed
which would increase the pump speed.
The size of the pump should be sufficient to maintain the desired pressure with
reasonable amount of wear. The different types of pumps used are.
a) Gear Pump.
b) Vane Pump.
c) Rotor Pump.
d) Plunger Pump.
iii) Oil Filters
The lubricating oil with use is deteriorated resulting in the formation of sludge, lacquer
and carbon. Further it is contaminated by various by-products of combustion of fuel. In
addition to these the fine particles of metal due to wear are the other impurities present in
the oil. It is therefore necessary to remove these impurities to avoid permanent damage to
any running parts of the engine. Commonly used materials for filtering are wire gauze,
cotton, plastic – impregnated paper etc. The filtering element must let the oil pass through
without much resistance, but should prevent the undesirable particles from entering the oil
galleries.

Oil filters are basically of two types, the primary and the secondary, the primary filter is
 also called as surface filter or strainer since the impurities are retained on the outer surface
of the filter. The secondary filters used in the automobile engines are of various kinds.
a) Cartridge Type.
b) Edge Type.
c) Centrifugal Type.
iv) Oil Coolers.
In all heavy duty engines, the temperature of oil becomes quite high because of high
engine temperature. As the viscosity of the lubricating oil decreases with temperature
rise, the oil film in the bearings might break and the conditions of boundary lubrication
may be created instead of fluid lubrication which is desired. To avoid such thing oil
coolers are provided. Oil coolers are simple heat exchangers.
v) Oil Pressure Gauges
If any leakage occurs at any part of the lubrication system, the pressure in the entire
system would fall, reducing consequently the oil supply to various bearings as a result of
which they are bound to starve and be damaged. Thus is very important for the driver to
keep a watch on the oil pressure in the gauge. The gauges generally are bourdon type or
electrical type.

Result:
Thus the functions of lubrication systems and its components used in automotive were studied.
AUTOMOTIVE CHASSIS COMPONENTS

LIST OF EXPERIMENTS

1. Study and measurement of the chassis frames: Heavy duty vehicle & Light duty vehicle
2. Dismantle, study and assemble of Front Axle, Rear Axle and Differential
3. Dismantle study and assemble of various Steering systems.
4. Dismantle, study and assemble of various Braking systems
5. Dismantle, study and assembling of various clutch assemblies
6. Dismantle, study and assembling of various gear boxes and transfer case

LIST OF EQUIPMENTS

1. Heavy duty chassis and Light duty (monocoque) chassis

2. front axle assembly and rear axle assembly

3. full floating and semi floating assembly

4. steering system with steering gearboxes

a. rack and pinion steering gear box
b. recirculating ball type steering gear box
c. power steering system

5. Single plate clutch and Diaphram type (cut section)

6. gearbox assembly

7. fluid flywheel and torque converter (working model)

8. Transfer case with stand for dismantling and assembly
9. Vacuum assisted drum brake assembly
Ex. No. 1 STUDY AND MEASUREMENT OF HEAVY DUTY AND LIGHT DUTY

Date : CHASSIS FRAME

1. Aim: To take measurements of the Ashok Leyland Chassis.

2. Tools required: 1. Scales 2. Measuring tape 3. Plumb knob .

3. Function:

1. To carry load of the passengers or goods carried in the body.

2. To support the load of the body, engine, gear box etc.,
3. To withstand the forces caused due to the sudden braking or
acceleration
4. To withstand the stresses caused due to the bad road condition.
5. To withstand centrifugal force while cornering
6. For a good chassis design and for its good performance it must have fast pick
up, strength, safety, durability, dependability, ease of control, quietness, speed,
economy of operation, low centre of gravity, stability, loadclearance, braking
ability, simplicity of lubrication, etc. the chassis frame and front and rear
suspension systems without abnormally raising the frameor transmitting shock
to the frame due to road irregularities.

4. Study:

 A vehicle without body is called a chassis.

 It is the backbone of the vehicle.
 All moving parts of the vehicle are fitted to it.
 It is made of steel.
 To give it extra strength, it is provided with bolted, riveted or welded
crosspieces.
 The chassis in general is equipped with I – beam construction front
axles.
Main components of the Chassis

1. Frame: it is made up of long two members called side members

riveted together with the help of number of cross members.
2. Engine or Power plant: It provides the source of power
3. Clutch: It connects and disconnects the power from the engine fly
wheel to the transmission system.
4. Gear Box
5. U Joint
6. Propeller Shaft
7. Differential
Types of chassis
Classification of Chassis with respect to its controls
1. Conventional control chassis
2. Semi-forward control chassis
3. Full forward control chassis
Classification of Chassis with respect to engine fitting
1. Engine at front
2. Bus chassis
3. Engine fitted at back
4. Engine fitted in front but cross wise
5. Semi-forward chassis
6. Engine fitted at the centre of the chassis

Types of chassis frames:

There are three types of frames
1. Conventional frame
2. Integral frame
3. Semi-integral frame

1. Conventional frame: It has two long side members and 5 to 6 cross

members joined together with the help of rivets and bolts. The frame
sections are used generally.

a. Channel Section - Good resistance to bending

b. Tabular Section - Good resistance to Torsion
c. Box Section-Good resistance to both bending and torsion

2. Integral Frame: This frame is used now a days in most of the cars. There
is no frame and all the assembly units are attached to the body.All the
functions of the frame carried out by the body itself.
Due to elimination of long frame it is cheaper and due to less weight most
economical also.
Only disadvantage is repairing is difficult.

3. Semi - Integral Frame: In some vehicles half frame is fixed in the front endon
which engine gear box and front suspension is mounted.
It has the advantage when the vehicle is met with accident the front framecan
be taken easily to replace the damaged chassis frame.
This type of frame is used in FIAT cars and some of the European andAmerican
cars.

Various loads acting on the frame:

1. Short duration Load - While crossing a broken patch.
2. Momentary duration Load - While taking a curve.
3. Impact Loads - Due to the collision of the vehicle.
4. Inertia Load - While applying brakes.
 5. Static Loads -Loads due to chassis parts.
6. Over Loads - Beyond Design capacity.

1. Wheel base : mm
2. Front overhang : mm
3. Rear overhang : mm
4. Overall length : mm
5. Maximum width : mm
6. Length of rear leaf spring : mm
7. Length of front leaf spring : mm

8. Thickness : mm
9. Web : mm
10. Legs (Flange width) : mm
11. No. of leaf spring in the front axle : 19
12. No. of leaf spring in the rear axle : 32

6. Result: Thus the study of vehicle chassis was done and main dimensions
werenoted.
Ex. No. 2A STUDY, DISMANTLING AND ASSEMBLING

Date : OF FRONT AXLE

Aim :

To dismantle, study and assemble the given front axle.

Tools Required.

i) Double end Spanner.

ii) Ring Spanner.
iii) Socket with extension.
iv) Hammer.
v) Screw driver.

Dismantling Procedure

i) Remove the steering knuckle arm joint.

ii) Remove the wheel bearing.
iii) Remove the brake shoe assembly.
iv) With the use of king pin remover, remove the king pin.
v) Finally remove the steering knuckle.

Study :

Conventionally the front axle is a dead axle. However for four wheel drive vehicles
and most of the cars, it is a live axle. The majority of front axles have steel I – beam for
the main member. Front axle consists of a beam, which extends across the underside of
the vehicle for almost the entire width of the tread.

Swivelling device is attached to both ends of this beam. The beam is attached to
the vehicle frame by means of springs. The swivelling device is called steering
knuckle. The steering knuckle is attached to the beam by means of kingpins.
Components of front Axle Type of stub Axles

i) Elliot Axle.

In the Elliot axle, each end of the main beam is open to form a C-Shaped
yoke. The steering knuckle fits between the upper arms of this yoke. The king pin
extends through the upper arm of this yoke through the knuckle and in to the lower
arm of the yoke. Usually the king pin is secured in the steering knuckle so that when
the knuckle swivels, the king pin turns in the yoke.

Reverse Elliot Axle :

In reverse Elliot axle, the yoke is a part of the steering knuckle and fits over
the end of the axle. The king pin is secured in a vertical hole through the end of the
axle beam and the knuckle swivels on it.

Steering knuckles :

The steering knuckle consists of a spindle for the wheel, devices for attaching
the unit to the main beam or axle and an arm for holding the knuckle in any desired
position in its swing or travel.

Steering knuckle arm

The steering knuckle arm is a lever for swivelling the knuckle. One end of
the arm is secured to the knuckle. The free end of the arm is made with either a ball
or a hole for attaching the rod.

Assembling Procedure

i) Carefully position the steering knuckle.

ii) Fit the king pin appropriately in the steering knuckle.
iii) Mount the brake shoe assembly in the position appropriately.
iv) Fit the wheel bearings.
v) Connect the steering knuckle arm to the tie rod assembly.

Result : Thus the given front axle is dismantled, studied and assembled.
Ex. No. 2B STUDY, DISMANTLING AND ASSEMBLING

Date : OF REAR AXLE

Aim:

To dismantle, Study and assemble the given rear axle.

Tools Required

i) Double end spanner.

ii) Socket with extension
iii) Ring spanner.
iv) Hammer.
v) Screw driver.

Dismantling Procedure

i) Remove the wheel bearing.

ii) Remove the brake drum from the brake assembly unit.
iii) Remove the brake shoe assembly.
iv) Remove the taper bearings of the half axle Shafts.
v) Pull the half axle shafts that are splined to the sun gear of the final drive unit.

Study :

The rear wheels are mounted on bearings on the ends of the axle shaft. There are two
half shafts.
Various forces and torques experienced by the rear axle are.

i) Weight of the body.

ii) Driving thrust.
iii) Torque reaction.
iv) Side thrust.

There are two rear axle drives. In all the drives employed for near axle, the springs take
the weight of the body. The drives are
i) Hotchkiss Drive.
ii) Torque Tube drive.

Types of Rear Axle Shaft support i) Semi – Floating axle.

The wheel hub is directly connected to the axle shaft or is an extension of the
same. The inner end of the axle is splined and is supported by the final drive unit,
whereas the outer end is supported by a single bearing inside the axle casing. In this
all the loads listed above are taken by the axle shaft, the vehicle load is transmitted to
each of the half shafts through the casing and the bearing. This causes a bending load
and a tendency to shear.

ii) Fully – Floating axle.

The axle shafts have flanges at the outer ends, which are connected to the flanged
sleeve by means of bolts. There are two taper roller bearings supporting the axle casing
in the hub, which take up any side load. Thus is this case the axle carries only the
driving torque.

Assembling Procedure

i) Insert the half axle shafts such that the inner end is keyed to the sun gear of the
final drive unit.
ii) Fit the taper roller bearing in the appropriate position within the housing of the
axle casing.
iii) Fit in the brake shoe assembly.
iv) Fit in the wheel bearing and complete the assembly process.

Result :

Thus the given rear axle is dismantled, studied and assembled.

Ex. No. 2C STUDY, DISMANTLING ANDASSEMBLING OF

Date : DIFFERENTIAL UNIT

Aim :

To dismantle, Study and assemble the given differential unit.

Tools Required.

i) Double end spanner

ii) Socket with extension
iii) Ring spanner.
iv) Hammer.
v) Screw driver.

Dismantling Procedure

i) Remove the two half axle shafts of the rear axle.

ii) Remove the crown wheel with the differential assembly.
iii) Disconnect the differential assembly from the crown wheel by removing the
mounting bolts.
iv) Finally remove the sun gear, planet pinion and cross pin or spider
from the differential assembly.

Study

To the crown wheel of the final drive is attached a cage, which carries a cross pin
or a spider. Two sun gears mesh with the two or four planet pinions. Axle half shafts
are splined to each of these gears. The crown wheel is free to rotate on the half shaft.

When the vehicle is going straight, the cage and the inner gears rotate as a single
unit and the two half shafts revolve at the same speed. In this situation there is no
relative movement among the various differential gears.

When the vehicle is taking a turn, assume that the cage is stationary. Then turning
one sun gear will cause the other to rotate in the opposite direction. That means that if
left sun gear rotates ‘n’ times in a
 particular time, the right sun gear will also rotate ‘n’ times in the same period but in the
opposite direction. This rotation is super – imposed on the normal wheel speed when the
vehicle is taking a turn.

Assembling Procedure

i) Assemble the differential unit by keeping all the planet pinions in the
cross pin and by positioning the sun gears in the cage.
ii) Fit the differential unit with the crown wheel by tightening the mounting
bolts.
iii) Assemble the crown wheel with the differential unit in the rear axle
and ensure that the crown wheel tooth meshes with the pinion teeth.
iv) Finally the two half shafts of the rear axles are positioned and checked for
proper working conditions.

Result :

Thus the given differential unit is dismantled, studied and assembled,

Ex. No. 3A STUDY, DISMANTLING AND ASSEMBLING

Date: OF STEERING SYSTEM WITH RACK AND PINION

STEERING GEAR BOX

Aim :

To dismantle, study and assembly the given steering system.

Tools Required

i) Double end spanner.

ii) Socket with extension.
iii) Ring Spanner.
iv) Hammer.
v) Screw Driver.

Dismantling Procedure

i) Remove the joint that connect the steering gear box and the steering column.
ii) Remove the drop arm from the cross shaft of the steering gear box unit.
iii) Remove the other linkages such as link rod, track rod, track arm.
iv) Finally the steering gear box is dismantled.

Study :

Functions of steering system

i) To achieve angular motion of the front wheels to negotiate a turn.

ii) To provide directional stability.
iii) To provide perfect steering condition.
iv) To facilitate straight ahead recovery.
v) To minimise tyre wear.

Construction of a Steering System

The drop arm is rigidly connected to the cross-shaft of the steering gear at its
upper end, while its lower end is connected to the link rod through a ball joint. To the
other end of the link rod arm is the stub axle on which the road wheel is mounted. Each
stub axle has a forged track rod arm rigidly bolted to the wheel axis.
 The other ends of the track rod arms are connected to the track rod by means of ball
joints – an adjuster is also provided in the track rod to change its length for adjusting wheel
alignment. The steering gear provides mechanical advantage so that only a small effort is
required at the steering wheel to apply a much larger force to the steering linkage.

When the steering wheel is turned, the swinging action of the drop arm imparts a linear
motion to the link rod. This movement is transmitted through the link rod arm to the stub
axle.

Types of steering gears used

i) Worm and wheel steering gear

ii) Worm and nut steering gear.
iii) Re-circulating ball type steering gear
iv) Rack & pinion steering gear.

Assembling Procedure

i) Fit the components of the steering gear box.

ii) Assemble the track arm, tie rod, link rod with the corresponding linkages.
iii) Fit the cross shaft to the drop arm.
iv) Fit the steering column to the steering gear boy.
v) Check the assembly for proper working of the steering system.

Result :

Thus the given steering system was dismantled, studied & assembled.
Ex. No. 3B STUDY, DISMANTLING AND ASSEMBLING

Date: OF STEERING SYSTEM WITH RECIRCULATING BALL

TYPE STEERING GEAR BOX

Aim :

To dismantle, study and assembly the given steering system.

Tools Required

vi) Double end spanner.

vii) Socket with extension.
viii) Ring Spanner.
ix) Hammer.
x) Screw Driver.

Dismantling Procedure

v) Remove the joint that connect the steering gear box and the steering column.
vi) Remove the drop arm from the cross shaft of the steering gear box unit.
vii) Remove the other linkages such as link rod, track rod, track arm.
viii) Finally the steering gear box is dismantled.

Study :

Functions of steering system

vi) To achieve angular motion of the front wheels to negotiate a turn.

vii) To provide directional stability.
viii) To provide perfect steering condition.
ix) To facilitate straight ahead recovery.
x) To minimise tyre wear.

Construction of a Steering System

The drop arm is rigidly connected to the cross-shaft of the steering gear at its
upper end, while its lower end is connected to the link rod through a ball joint. To the
other end of the link rod arm is the stub axle on which the road wheel is mounted. Each
stub axle has a forged track rod arm rigidly bolted to the wheel axis.
 The other ends of the track rod arms are connected to the track rod by means of ball
joints – an adjuster is also provided in the track rod to change its length for adjusting wheel
alignment. The steering gear provides mechanical advantage so that only a small effort is
required at the steering wheel to apply a much larger force to the steering linkage.

When the steering wheel is turned, the swinging action of the drop arm imparts a linear
motion to the link rod. This movement is transmitted through the link rod arm to the stub
axle.

Types of steering gears used

v) Worm and wheel steering gear

vi) Worm and nut steering gear.
vii) Re-circulating ball type steering gear
viii) Rack & pinion steering gear.

Assembling Procedure

vi) Fit the components of the steering gear box.

vii) Assemble the track arm, tie rod, link rod with the corresponding linkages.
viii) Fit the cross shaft to the drop arm.
ix) Fit the steering column to the steering gear boy.
x) Check the assembly for proper working of the steering system.

Result :

Thus the given steering system was dismantled, studied & assembled.
Ex. No. 4 STUDY, DISMANTLING AND ASSEMBLING

Date : OF DRUM BRAKING SYSTEM

Aim :

To dismantle, study and assemble the given braking system.

Tools Required

i) Double end spanner.

ii) Socket with extension.
iii) Ring Spanner.
iv) Hammer.
v) Screw driver.

Dismantling Procedure

i) Drain the hydraulic fluid from the master cylinder first.

ii) Remove the linkages connected to the braking assembly from brake pedal
till the brake shoe assembly.
iii) Remove the brake drum.
iv) Remove the wheel cylinder within the brake shoe assembly.
v) Remove the retainer spring which is fired to the shoes.

Study ;

Principle

The requirement of a braking system is to stop the vehicle within the smallest
possible distance and this is done by converting the kinetic energy of the vehicle into
the heat energy which is dissipated into the atmosphere.
 Methods of Braking

i) Mechanical Braking.
ii) Hydraulic Braking.
iii) Electric Braking.
iv) Vacuum Braking.
v) Air Braking.

Components of Hydraulic Braking

The two main components of the hydraulic braking system are master & wheel cylinder

i) Master Cylinder

In can be rightly named as the heart of the hydraulic braking system. It contains the
reservoir for the brake fluid. It is operated by the brake pedal and is further connected to
the wheel cylinders in each wheel through steel pipe lines, unions and flexible hoses.

There are two main chambers. One is the fluid reservoir and the other is the
compression chamber in which the piston operates. The fluid in the reservoir
compensates for any change in the fluid volume in the pipelines.

These are a number of holes in the piston head on the high pressure side. Two holes
connect the fluid reservoir to the compression chamber. The push rod is operated with
the foot brake pedal through linkage. As the pedal is pressed, push rod moves the
piston to the left against the force of the spring, till it covers the by-pass port. Further
movement of the push rod causes building up of pressure in the compression chamber.
Finally when sufficient pressure has built-up, the inner rubber cup of the fluid check
valve is deflected, forcing the fluid under pressure in the lines. This fluid enters the
wheel cylinder and moves the pistons there by applying the brakes.
 Wheel cylinders.

They are meant to force the brake shoes against the drum. Each wheel cylinder is
provided with pistons, rubber seal, springs and dust covers. The brake line from the
master cylinder is attached to the inlet port and a bleeder screw with a cover is
provided to bleed air from the system. Wheel cylinders are mounted on the back plate.

When brakes are applied the fluid under pressure from the master cylinder enters the
inlet port and forces the piston to move outwards to push the shoes against the drum.
Similarly when the brakes are released, the brake shoe retractor springs force the brake
fluid out of the wheel cylinder by pushing the piston inwards.

Assembling Procedure

i) Fit the retractor spring and the wheel cylinders appropriately.

ii) Mount the brake drum over the brake shoe assembly and tighten the lock
nuts.
iii) Fit the linkages from the master cylinder to the wheel cylinders including the
rubber hoses.
iv) Fill the reservoir of the master cylinder with the brake fluid and
remove any air present inside the cylinder.
v) Fit the master cylinder and connect the push rod of the cylinder to the
corresponding link of the brake pedal.
vi) Finally ensure proper working of the brake system.

Result :

Thus the given brake system was dismantled, Studied and assembled.
Ex. No. 5 STUDY, DISMANTLING AND ASSEMBLING OF
Date CLUTCH SYSTEM

Aim :

To dismantle, study and assemble the given clutch system.

Tools Required

i) Double end spanner

ii) Ring Spanner
iii) Socket with extension
iv) Screw Driver
v) Hammer.

Dismantling Procedure

i) Hold the clutch cover assembly in the vice.

ii) Remove the lock nuts of the clutch cover by compressing the cover spring
with the help of a special tool.
iii) Remove the clutch spring, release lever, adjusting screw and cotter pin from their
locations.
iv) Finally take out the clutch plate and the pressure plate separately.

Study :

The power developed in the engine is transmitted to the gear box through the clutch.
When the clutch is disengaged, the power is not transmitted. Clutch will always be in
engaged position unless the clutch pedal is depressed. The clutch permits the gradual taking
up of the load. When the pressure on the friction plate is decreased it automatically
decreases the load on the engine. By the frictional contact between the flywheel and the
pressure plate it transmits the torque from the engine to the gear box.
Working

The clutch plate is placed between the flywheel and pressure plate. Pressure plate
rigidly forces the clutch plate towards the flywheel by the spring force. When the clutch
pedal is in ordinary position, it fully engages with the flywheel. Therefore the power is
transmitted from the engine to the gear box. When the pedal is pressed, pressure plate is
forced against the spring force and a gap is created between the pressure plate and the
flywheel and hence no power is transmitted.

Assembling Procedure

i) Place the cultch springs, adjusting screw, Cotter pin, Release lever, lock plate
in the appropriate locations.
ii) Place the clutch cover over the springs and then the cover is held by means of
the special tool to compress the springs
iii) Assemble the cover by tightening the lock nuts.

Result :

Thus the given single plate clutch was dismantled, studied and assembled.
 Ex. No. 6A STUDY , DISMANTLING AND ASSEMBLING

Date : OF SLIDING MESHGEAR BOX

Aim:

To dismantle, study and assemble the given sliding mesh gear box.

Tools Required

i) Double end spanner.

ii) Ring Spanner.
iii) Socket with extension
iv) Hammer.
v) Screw Driver.

Dismantling Procedure

i) Remove the clutch shaft from the gear box.

ii) Remove the main shaft with the gears
iii) Remove the idler (or) reverse gear from its shaft in the gear box.
iv) Remove the lay shaft from the gear box.

Study.

Gear box is a main part of the transmission system. The torque produced by the
engine varies only by narrow limits. Therefore there is a necessity to change the torque
produced by the engine. The change of torque in the gear boxes is helpful in take-off of
the vehicle from rest or when full loaded during normal speed. During high speed there
is no need of high torques and hence you can change the torque to the lowest gear.

Assembling Procedure.

i) Assemble the lay shaft in the gear box housing.

ii) Position the reverse (or) idler gear in its location.
iii) Assemble the main shaft with gears in the appropriate place.
iv) Put back the clutch shaft in the other end of the gear box.
v) After fitment of all the shaft and gears, the gear box is checked for
proper working in all gears.

Result :

Thus the given sliding mesh gear box is dismantled,

studied & assembled.
Ex. No.6B STUDY, DISMANTLING AND ASSEMBLING OF
Date : SYNCHROMESH GEAR BOX

Aim :

To dismantle, study and assemble the given synchromesh gear box.

Tools Required

i) Double end spanner.

ii) Socket with extension.
iii) Hammer.
iv) Screw Driver.
v) Ring Spanner.

Dismantling Procedure

i) Remove the clutch shaft from the gear box.

ii) Remove the gears from the main shaft and then remove the main shaft.
iii) Remove the synchronizer ring from the main shaft.
iv) Remove the idler gear from its shaft.
v) Remove the lay shaft.

Assembling Procedure

ii) Fit the lay shaft.

iii) Assemble the idler gear shaft and the idler gear.
iv) Place the gears in the main shaft appropriately.
v) Fit the synchronizer ring in its position.
vi) Fit the clutch shaft into the gear box assembly.
vii) Finally check proper working of the system.

Result :

Thus the given gear box was dismantled, studied and assembled.