DEPARTMEN OF AUTOMOBILE ENGINEERING AUTOMOBILE SERVICING LAB …madinpoly.com/pdf/labmanual/4/AU -AS LAB MANUAL.pdf · mptc page 1 departmen of automobile engineering automobile servicing

AUTO MOBILE SERVICING LAB

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DEPARTMEN OF AUTOMOBILE

ENGINEERING

AUTOMOBILE SERVICING LAB MANUAL

COURCE CODE:2059

SEMESTER-2


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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 quietly 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 include horse play or other foolish activities. It cause some to get

seriously hurt.

5. Don‟t put sharp objects, screw driver in your pocket. You could cut yourself

or you could damage upholstery in the car.

6. Make sure you clothes are right for the job loose 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 in your hands and tools so that you can get a good

grip on tools and parts.

9. If you spill oil, grease or any liquid on the floor, clean it up so that no one

will slip and fall.

10. Never use compressed air to remove dirt from your cloths. Never point a

compressed air blow gun at another person.

11. Always wear safety glasses or goggles or a face shield.

12. Watch out for sparks flying from a grinding wheel or welding equipment.

The sparks can get your cloths on fire.


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13. To protect your eyes wear goggles when using chemical such as solvents. If

you get chemical in your eyes, flush them with pure water at once and then see

the doctor as soon as possible.

14. 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.

15. Always use the right tool for the job. The wrong tool could damage the part

being worked on and would get hurt you.

16. 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.

17. Do not stand directly in line with the engine fan when it is turning or the

engine is running. Some fans, especially fans with the flexible blade can throw

off a blade while spinning. A flying fan blade can injure or kill anyone if

strikes.

18. Oiling or greasing may not be done while the machine is being operated.

19. If the workshop is fired due to oil, petrol or electricity; it may not be

extinguished by water, must use sand and fire extinguishing gas.

20. Before starting any work; full planning of the work must be sketched.

21. Machines may be properly cleaned and lubricated before starting any

operation on them.

22. Clean the tools and machines at proper places after using them.

23. be careful while removing radiator cap of a hot engine cooling system.

Sudden removal of cap may cause burning of face and hands.

24. If cutting a pipe or metal piece by hacksaw do not over tight the hacksaw

blade.


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AUTO SERVICING

MAJOR STEPS INVOLOVED IN AUTOMOBILE SERVICING ARE ;

1. Trouble Shooting

2. Locating the root cause and dismantling.

3. Inspection of parts.

4. Reconditioning or replacement of parts.

5. Reassembling.

6. Adjusting.

1. Trouble shooting:-

Finding the problem of the vehicle is called trouble shooting.

2. Locating the root cause and dismantling.

After the trouble shooting dismantle the required parts as per the

procedure.

3. Inspection of parts.

After dismantling check the given part for wear and tear.

4. Reconditioning or replacement of parts.

After inspection replaced the worn out parts and installed new parts.

5. Reassembling.

After the repairing the parts reassemble as per the procedure.

6. Adjusting.

After reassembling adjust the give part as required.

STUDY OF 2 & 4 STROKE ENGINE

FOUR STROKE CYCLE ENGINE ( DIESEL/ PETROL ENGINE)

In four stroke cycle engines the four events namely suction, compression,

power and exhaust take place inside the engine cylinder. The four events are

completed in four strokes of the piston (two revolutions of the crank shaft). This

engine has got valves for controlling the inlet of charge and outlet of exhaust

gases. The opening and closing of the valve is controlled by cams, fitted on

camshaft. The camshaft is driven by crankshaft with the help of suitable gears

or chains. The camshaft runs at half the speed of the crankshaft. The events

taking place in I.C. engine are as follows:


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1. Suction stroke 2. Compression stroke

3. Power stroke 4. Exhaust stroke

Suction stroke

During suction stroke inlet valve opens and the piston moves downward. Only

air or a mixture of air and fuel are drawn inside the cylinder. The exhaust valve

remains in closed position during this stroke. The pressure in the engine

cylinder is less than atmospheric pressure during this stroke (Fig. 1a).

Compression stroke

During this stroke the piston moves upward. Both valves are in closed position.

The charge taken in the cylinder is compressed by the upward movement of

piston. If only air is compressed, as in case of diesel engine, diesel is injected at

the end of the compression stroke and ignition of fuel takes place due to high

pressure and temperature of the compressed air. If a mixture of air and fuel is

compressed in the cylinder, as in case of petrol engine, the mixture is ignited by

a spark plug.


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Power stroke

After ignition of fuel, tremendous amount of heat is generated, causing very

high pressure in the cylinder which pushes the piston downward (Fig.1b). The

downward movement of the piston at this instant is called power stroke. The

connecting rod transmits the power from piston to the crank shaft and crank

shaft rotates. Mechanical work can be taped at the rotating crank shaft. Both

valves remain closed during power stroke.


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Exhaust stroke

During this stroke piston moves upward. Exhaust valve opens and exhaust

gases go out through exhaust valves opening. All the burnt gases go out of the

engine and the cylinder becomes ready to receive the fresh charge. During this

stroke inlet valve remains closed (Fig.1d).

TWO STROKE CYCLE ENGINE (PETROL ENGINE)

In two stroke cycle engines, the whole sequence of events i.e., suction,

compression, power and exhaust are completed in two strokes of the piston i.e.

one revolution of the crankshaft. There is no valve in this type of engine. Gas

movement takes place through holes called ports in the cylinder. The crankcase

of the engine is air tight in which the crankshaft rotates.

Upward stroke of the piston (Suction + Compression)

When the piston moves upward it covers two of the ports, the exhaust port and

Transfer port, which are normally almost opposite to each other. This traps the

charge of air- fuel mixture drawn already in to the cylinder. Further upward

movement of the piston compresses the charge and also uncovers the suction

port. Now fresh mixture is drawn through this port into the crankcase. Just

before the end of this stroke, the mixture in the cylinder is ignited by a spark

plug (Fig 2 c &d). Thus, during this stroke both suction and compression events

are completed.


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Downward stroke (Power + Exhaust)

Burning of the fuel rises the temperature and pressure of the gases which forces

the piston to move down the cylinder. When the piston moves down, it closes

the suction port, trapping the fresh charge drawn into the crankcase during the

previous upward stroke. Further downward movement of the piston uncovers

first the exhaust port and then the transfer port. Now fresh charge in the


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crankcase moves in to the cylinder through the transfer port driving out the

burnt gases through the exhaust port. Special shaped piston crown deflect the

incoming mixture up around the cylinder so that it can help in driving out the

exhaust gases. During the downward stroke of the piston power and exhaust

events are completed.

EXP NO:

DATE:

IDENTIFICATION AND USES OF VARIOUS SPECIAL

TOOLS

AIM

To study about the uses of various special tools used in workshop.

TOOLS REQUIRED

Torque wrench, ratchet handle, piston ring groove cleaner, piston ring

compressor, piston ring expander.

MATERIALS REQUIRED

Petrol engine, cotton waste, diesel oil

DESCRIPTION

Torque wrench

A torque wrench is necessary to tighten bolts, nuts etc. to exact the torque as

specified by the manufacturers. Excessive tightening may lead to breakage of

the fastener and loose tightening will lead to leakage or breaking during

operation. Torque wrenches are available in special shapes and sizes. Newton

meter (N-m) is the preferred metric unit.

Piston Ring Compressor

Piston rings keep oil from entering the combustion chamber of a combustion

engine. Piston rings wear over time and will begin to allow oil to burn along

with fuel. Blue smoke emitting from the tailpipe of your vehicle signifies

burning oil and worn piston rings. New piston rings fit snugly against an


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engine's cylinder walls. Installing tight fitting rings requires a piston ring

compressor to keep the rings from catching on the upper lip of the cylinder wall

and breaking during installation.

Piston ring groove cleaner

It is used for cleaning the carbon deposits in the piston ring gaps.

Oil Filter Wrench

An oil filter casing hand-tightened during installation will tighten when the

engine heats up and cools down. During the 3,000 to 5,000 miles between oil

changes, the filter casing can tighten enough that a filter wrench is needed to

remove it. Oil filter wrenches are available in many variations but two common

styles are affordable and easy to find. Strap-style filter wrenches fit different-

size filters and adjust to tighten on a casing. Socket-style wrenches fit a

specified type and size of filter casing but require less room to operate than a

strap-style wrench.

Ratchet handle

The mechanism permits one of required direction only whereas the reverse

turning of handle is free. So that nuts, bolts can be easily removed.

RESULT

To study about special tools and its operations.


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EXP NO:

DATE:

IDENTIFICATION OF ENGINE COMPONENTS

AIM

To identify the various engine components and its function in a SI and CI

engine.

DESCRIPTION


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An engine is a device used to convert heat energy into mechanical energy. It

consists of many interlocking parts that work together to produce the energy

that keeps a car, truck or other vehicle running smoothly. Knowing how to

identify the parts of an engine and understanding how they work together to

create energy will help drivers keep their vehicle in good shape longer. It will

also help them at the repair shop and enable them to ask the mechanic informed

questions about work that may need to be done.

Recognizing of engine components.

1. Piston, connecting rod and crankshaft.

The pistons are cylindrical pieces of metal that pump gasoline or another energy

source into the engine. A piston is attached to a connecting rod and placed

inside cylindrical holes within the engine. They move up and down and turn a

corkscrew-shaped device called a crankshaft, which is located beneath the

cylinders on an in-line engine.

Piston-Aluminium alloy

Connecting rod-forged steel or duralumin

Crankshaft-cast steel

2. Cylnder block

Recognize the cylinder block, the engine‟s largest component. It‟s usually made

of aluminum or iron and has core plugs that seal holes left after the

manufacturing process. It‟s located at the bottom of the engine and serves as a

“shell” to hold and connect the other parts of the engine. The cylinder block‟s

shape varies according to the car company, model, and how many cylinders, or

piston holes, the block contains. The more cylinders, the more powerful the

engine.

3. Spark plug

Identify the spark plug as a small electrical device that screws into the cylinder

head. Spark plugs consist of an electrode which is connected to an ignition coil

by a wire. In an internal combustion engine, this plug ignites gasoline or


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another fuel with an electric shock to turn on the engine when the driver starts

the ignition switch. It is used in spark ignition engine (petrol engine).

4. Fuel injector

This is also known as nozzle or atomizer. Its function is to inject fuel into the

cylinder in properly atomized form and in proper quantity. It can be seen in

diesel engines. The injector is operated by using a fuel injection pump.

5. Inlet manifold

The inlet manifold carries the air fuel mixture from the carburettor to the

cylinders in case of petrol engine, whereas in diesel engine only air from the

atmosphere is taken into the cylinder.

6. Exhaust manifold

Notice the exhaust manifold. It is made of stainless steel or cast iron, and

gathers gases that escape the cylinder head. An exhaust valve helps release the

gases from the manifold. These gases, in turn, leave the car through the exhaust

pipe at the back of the vehicle.

7. Oil sump

Notice the oil sump, sometimes called an oil pan. This collects oil that

lubricates the engine and stores it in a pan at the very bottom of an engine.

Made of steel or aluminum, it may resemble a sturdier version of a kitchen

roasting pan.

RESULT

Identified various engine components of SI and CI engine.


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EXP NO:

DATE:

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

studied about how to jack up a vehicle and changing of tyre from a vehicle.

EXP.NO:


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DATE:

LOOSENING AND TIGHTENING PRACTICES OF

NUTS AND BOLTS AIM

To practice loosening and tightening of different sizes of nuts and bolts by

using various tools.

TOOLS REQUIRED

Open end spanner, ring spanner, combination spanner, torque wrench, ratchet

handle.

MATERIALS REQUIRED

A set of different sizes of nuts and bolts fitted to a table, cotton waste, kerosene.

DESCRIPTION

A screw thread is a helical groove on a shaft. When used for delivering power,

it is called a drive screw. Drive screws aren't really all that efficient, as they

loose a significant amount of power to friction. However, this friction can be

put to use in the case of threaded fasteners.

As nuts and bolts are not perfectly rigid, but stretch slightly under load, the

distribution of stress on the threads is not uniform. In fact, on a theoretically

infinitely long bolt, the first thread takes a third of the load, the first three


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threads take three-quarters of the load, and the first six threads take essentially

the whole load. Beyond the first six threads, the remaining threads are under

essentially no load at all. Therefore, a nut or bolt with six threads acts very

much like an infinitely long nut or bolt.

Loosening a bolt can be either relatively easy or difficult, depending on how

tightly the bolt is attached. Over time a bolt can become stuck because rust

forms on its threads or it undergoes some other form of damage. Consider

several ways to loosen a bolt, starting with good old-fashioned elbow grease

and ending with drilling it out after all else fails.

PROCEDURE

1. Clean around the bolt with a wire brush, removing as much external

buildup as possible.

2. Try loosening the bolt with a wrench, open end spanner, ring spanner,

combination spanner, ratchet handle, torque wrench.

3. If the bolt won't turn, try tightening it and then loosening it. The back-

and-forth action will make it loose.

4. Spray penetrating oil around the bolt.

5. Now tight the bolts with these same tools again.

6. For stubborn nuts and bolts, Try loosening the bolt with a wrench

7. Gently tap the wrench with a tool such as a small hammer or chisel, and

try loosening it with a wrench again.

RESULT

Practiced the loosening and tightening of different sizes of nuts and bolts and

studied about the use of various tools.


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EXP NO:

Date:

MAINTANANCE PROGRAM OF A VEHICLE

AIM

To 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: Un Predictable/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


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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 upto the brim.

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

Replace the Radiator cap. (Radiator Coolant concentration: Water

65% & Antifreeze 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.


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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

Studied about the maintenance schedule of a vehicle


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EXP.NO:

DATE:

CALCULATION OF CC ( CUBIC CAPACITY ) OF AN

ENGINE

AIM

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

TOOLS REQUIRED

Cylinder bore dial guage,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

Bore 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).


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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

and for tractor engines, this ratio is about 1.25.

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 of piston and L is the stroke length.

𝑉 =𝜋

4 D

2×L

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.

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.


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

RESULT

Calculated the CC of the given engine.

OBSERVATIONS

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

TABULAR COLOUMN

Trial

No.

Bore

Stroke length

Swept volume

D

L

VS =𝜋

4 D

2×L

Mm mm mm3

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 cm

3

= ………cc


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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 = VS =𝜋

4 D

2×L

=…………..mm3

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

= ………..mm3

= Vd

1000 =……….cm

3

=……….cc


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Vernier caliper


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EXP NO:

DATE:

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 purpose of spark plug is to provide a gap

across which a high voltage of the ignition system can jump .It consist of

central electrode fitted in the porcelain insulator and sealed within asteel 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 mm

PROCEDURE FOR REMOVING SPARK PLUG

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

Dismantled and assembled the given spark plug from a given cylinder head


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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 quietly 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 include horse play or other foolish activities. It cause some to get

seriously hurt.

5. Don‟t put sharp objects, screw driver in your pocket. You could cut yourself

or you could damage upholstery in the car.

6. Make sure you clothes are right for the job loose 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 in your hands and tools so that you can get a good

grip on tools and parts.

9. If you spill oil, grease or any liquid on the floor, clean it up so that no one

will slip and fall.

10. Never use compressed air to remove dirt from your cloths. Never point a

compressed air blow gun at another person.

11. Always wear safety glasses or goggles or a face shield.

12. Watch out for sparks flying from a grinding wheel or welding equipment.

The sparks can get your cloths on fire.


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13. To protect your eyes wear goggles when using chemical such as solvents. If

you get chemical in your eyes, flush them with pure water at once and then see

the doctor as soon as possible.

14. 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.

15. Always use the right tool for the job. The wrong tool could damage the part

being worked on and would get hurt you.

16. 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.

17. Do not stand directly in line with the engine fan when it is turning or the

engine is running. Some fans, especially fans with the flexible blade can throw

off a blade while spinning. A flying fan blade can injure or kill anyone if

strikes.

18. Oiling or greasing may not be done while the machine is being operated.

19. If the workshop is fired due to oil, petrol or electricity; it may not be

extinguished by water, must use sand and fire extinguishing gas.

20. Before starting any work; full planning of the work must be sketched.

21. Machines may be properly cleaned and lubricated before starting any

operation on them.

22. Clean the tools and machines at proper places after using them.

23. be careful while removing radiator cap of a hot engine cooling system.

Sudden removal of cap may cause burning of face and hands.

24. If cutting a pipe or metal piece by hacksaw do not over tight the hacksaw

blade.


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STUDY OF TOOLS

1.OPEN END SPANNER

Open end spanner is used to tight and loosen majority nut and bolt in an

automobile work shop. it has two legs one is larger than the other. they are

available in various size.

2.RING SPANNER

It is stronger and tighter than open end spanner. it can turn a nut or a bolt

is a restricted space. they will not slip while using since one bolt are 12 sides

and they surrounded the nut completely.

3.SCREW DRIVER(FLAT)

It is a hand tool used for screwing and unscrewing the flat headed screws.

4.SCREW DRIVER(STAR)

It is a hand tool used for screwing and unscrewing the star headed screws.

5.BALL PEEN HAMMER

They are commonly used for hammering work like bending bars,rods,etc.the

ball peen is used for riveting. They are usually made of high carbon steel with

wood handle.

6. PLASTIC HAMMER

They are commonly used for light hammering works without deformation on

the working parts. It is usually made of plastic materials.

7. STEEL RULE

It is a measuring instrument. It is used for linear measurements.

8. WHEEL SPANNER

It used for removing and tightening the wheel nut of a vehicle.

9.COMBINATION PLIER

It is normally used to cut wire, springs etc. and hold a object with grip. It has

a plastic covering in the handle to prevent electric shocks.

10.NOSE PLIER

It is a plier used for holding small things in a cavity where combination

plier is not used.

11.SPEED HANDLE

It is used for screwing and unscrewing the nuts and bolt with in more speed

than spanner

12.PLUG SPANNER


MPTC Page 38

It is a hand operated tool used to loosen and tighten spark plug.

Documents

DEPARTMEN OF AUTOMOBILE ENGINEERING AUTOMOBILE SERVICING LAB …madinpoly.com/pdf/labmanual/4/AU -AS LAB MANUAL.pdf · mptc page 1 departmen of automobile engineering automobile servicing