8 - Psscive
Contents
1. Performance standards Yes No Able to tighten the cylinder head induction and exhaust manifold Able to identify general tools used to handle the fasteners o AutoL3U1 NQ2012 Session 8 Engine Timing Tuning Relevant Knowledge To run the engine smoothly it is necessary to supply fuel by opening and closing the inlet valve similarly it is also needed to remove the exhaust gases at right time from the cylinder The movements of the valves are related to the crankshaft revolution and engine otto cycle It is necessary to check and set valve timing For the process of combustion it is necessary to ignite the charge by using sparkplug at the right time Plug should ignite the charge at end of compression stroke There is a need to set the ignition system in relation to rotation of crankshaft Thus check and set ignition timing Stroboscope Lamp Gun Stroboscope is an instrument used to make a cyclically moving object our flywheel appears to be slow moving or stationary otroboscopes are used in timing lights to dynamically set the ignition timing of an Otto cycle combustion engine The timing light is connected to the ignition circuit mostly inductively and used to illuminate the timing marks with the engine running The apparent position of the marks frozen by the stroboscopic effect indicates the current timing of the spark in relation to piston position Those tools come in various shapes most in gun or torc2. compare with the service manual Session 5 Tuning of Engine Lubrication System Exercise Assignment 1 Listthe steps used in tuning of engine lubrication system SNo Steps used n n AutoL3U1 NQ2012 2 Prepare a line diagram of engine lubrication system of a vehicle Session 5 Tuning of Engine Lubrication System Answer the following questions Use additional sheets of paper if necessary Fill in the blanks 1 is used for lubrication the engine of vehicle 2 The lack of lubrication will to engine sound and also the tune of engine will because of increase In 3 Change the oil if oil looses viscosity or after recommended distance of Session 5 Tuning of Engine Lubrication System Checklist for Assessment Activity Use the following checklist to see if you ve met all the requirements for tuning of engine lubrication system Part A Share importance of engine lubrication in a vehicle Part B Discussed in class the following e Why is engine lubrication necessary AutoL3U1 NQ2012 e What are the steps to be followed while checking the lubrication system e Leakages in lubrication systems Performance standards criteria covered by this assessment Performance standards Yes No Able to explain importance of engine lubrication pp Able to list general steps during checking engine lubrication system AutoL3U1 NQ2012 Session 6 Tuning of engine cooling system Relevant Knowledge You must hav
3. ignition system of Able to trace the primary and an engine secondary circuit s Check the terminals for loose connection Able to clean spark plug and distributor AutoL3U1 NQ2012 Tuning engine lubrication system Able to check the level and quality of lubricating oil Able to replace the oil and change the oil filter Able to check the oil pressure Tuning of engine cooling system Able to read the temperature gauge Able to check circulation of water in cooling system Able to trace for coolant leakage Tightening of fastener Able to tight fasteners with specified Nuts Bolts Screws torque and with sequence in the following components cylinder head induction manifold Exhaust manifold and engine foundation nuts and bolt Engine Timing Able to understand importance of engine timing Able to feel the sound change after tuning process AutoL3U1 NQ2012 Relevant Knowledge and Skills 1 Relevant Knowledge Inspection of an engine Washing of an engine Tuning fuel system of an engine Tuning of the an ignition system of an engine Tuning of the engine lubrication system Tuning of the engine cooling system Tightening of fastener Nuts Bolts Screws Engine Timing Skills Able to do the following tasks in a vehicle Able to trace different leakages like oil coolant and combustion gases Able to wash an engine externally Able to handle the washing equipment Able to follow appropriate precautions Able to tra
4. lubricating oil can be traced by simple method Place a news paper below the engine Now run the engine for 5 min do not move the vehicle The leakages will be traced on the news paper as spots will be observed Exactly perpendicular to the spot noticed will be the area of leakage stop leakage by changing the gasket oil seal etc Note down the area of leakage in the table given below Name of area of leakage AutoL3U1 NQ2012 Session 1 Inspection of an engine Exercise Assignment 1 List the types of leakages found in an engine SNo Types of leakage kn en n n 2 Prepare a diagram of an engine of a vehicle Session 1 Inspection of an engine Answer the following questions Use additional sheets of paper if necessary Fill in the blanks 1 For fuel leakage following areas l l must be checked in the engine 2 Check hose pipe for deterioration 3 Inspect radiator cap neck and radiator core for leakage 4 Inspect radiator hose clips for If noticed leakage the clips Session 1 Inspection of an engine Checklist for Assessment Activity Use the following checklist to see if youve met all the requirements for maintenance of engine Part A Share importance of leakages in an engine AutoL3U1 NQ2012 Part B Discussed in class the following e Why leakages must be controlled e What are the steps to be followed while checking the leakages in engine Performance standards criteria covered
5. water pressure clean the engine externally Also clean the bonnet area and engine room Now start the compressor and give air pressure to remove the water from the electrical and electronic gadgets Allow the engine to dry Connect the battery terminal and start the engine and check for smoother working Precautions Do not use high pressure to clean engine Safeguard sensors spark plugs nozzle and electronic gadgets from water Do not give water pressure when engine is in running condition Do not clean the engine when engine is hot Do not blow air at high pressure Session 2 Washing of an engine Exercise Assignment 1 List the elements of safeguard during engine washing AutoL3U1 NQ2012 2 Prepare a diagram of car washer Session 2 Washing of an engine Answer the following questions Use additional sheets of paper if necessary Fill in the blanks 1 Latest engines are compact and fitted in the small area 2 IS used for washing the engine 3 Spray and remove the oily layers and muck water from an 4 Liquid soap should be applied slowly in the where the hand can reach 5 Do not clean the when engine is hot Session 2 Washing of an engine Checklist for Assessment Activity Use the following checklist to see if you ve met all the requirements for washing of an engine Part A Share importance of washing of an engine Part B Discussed in class the following e Why washing is necessary e What are the step
6. 012 Session 1 Inspection of an engine Relevant Knowledge When it comes to a car the most important component is its engine The engine can well be regarded as the soul of a car In fact you might have the most well maintained and sparkling set of wheels in your neighborhood but if its engine is not working it is as good as waste In order to make sure that your car has a long life you need to undertake regular maintenance of the engine As we know engine is a power producing unit of an automobile where fuel is burned to create EN mi W heat energy and that heat energy is me YE converted into kinetic energy Engine is a complex unit of different parts which work together and produces power for the movement of a vehicle Various types of leakages take place in an engine and it is a very important element of regular vehicle checkup e The leakage of combustible gases will reduce millage and pickup e The leakage of coolants leads to increased engine temperature and may causes engine overheating due to which the components will deteriorate faster e The leakage of the lubricating oil will increase the friction and engine will reduce power output So it is necessary to regularly inspect for the leakage and if traced then the leakage must be repaired to avoid failure of an engine Procedure to check the leakage in the vehicle e Keep the vehicle on hard surface e Open the engine bonnet and support with lever e Adopt the fo
7. 1 NQ2012 Unit Information Unit name Regular maintenance of an engine Unit code Auto L3U1 NQ2012 Unit descriptor This unit provides introductory knowledge amp skills covering vehicle servicing specially for engine of a four wheeler Students will be given a broad view of these important issues Resources required e Notebooks Pen Pencil Eraser e Computer Open Source Software for making digital presentation e LCD projector e Sketches pictures animation and videos of engine of automobiles and its components e Posters for building awareness about these topics Nominal hours 80 Periods AutoL3U1 NQ2012 Elements and Performance Criteria e Elements define the critical learning outcomes of a unit of competency e Performance criteria specify the level of performance required to demonstrate the achievement of the Competency Element Element of knowledge Performance Criteria Inspection of an engine Able to trace different leakages like those of oil coolant and combustion gases Washing of a engine Able to wash an engine externally Able to handle the washing equipment Able to follow appropriate precautions Tuning fuel system of an engine Able to trace the fuel system in a given vehicle engine Able to check the fuel line for leakage Able to conduct fuel pump test and compare its reading with the service manual Able to set carburetor for ideal speed Able to test nozzle for pressure Tuning of an
8. Nan aa n S ii Curriculum AUTO SRV L3 NQ 7 Unit AUTO SRV L3U1 Regular maintenance of an engine AutoL3U1 NQ2012 PREFACE Improving the parity of esteem between the general academic education and vocational education is the policy priority of the Government of India The National Vocational Education Qualification Framework NVEQF developed by the Ministry of Human Resource Development MHRD Government of India is a descriptive framework that provides a common reference for linking various qualifications It will be used for setting common principles and guidelines for a nationally recognized qualification system covering Schools Vocational Education and Training Institutions Technical Education Institutions Colleges and Universities The NVEQF will act as a translation device to make qualifications more understandable to employers students and institutions It will promote transparency of qualifications and facilitate learners mobility between different qualifications thus encouraging lifelong learning PSSCIVE has taken lead in development of learning material for the Automobile Sector for all level in collaboration with the Automobile Skill Development Corporation ASDC The present material contains activity related to Level L 3 for the Automobile service sector This will fulfill the needs of the students willing to learn activities relating to the Automobile Service Sector Any student entre
9. Tighten belt adjusting bolt and alternator pivot bolt Session 6 Tuning of engine cooling system Exercise Assignment 1 List the steps used in tuning of cooling system SN6 Stepsused n en n n 2 Prepare a line diagram of cooling system of a vehicle Session 6 Tuning of engine cooling system Answer the following questions Use additional sheets of paper if necessary Fill in the blanks 1 IS used for cooling the vehicle 2 Normal temperature of engine is in the range of and 3 Percentage of heat removed by cooling system is Yo AutoL3U1 NQ2012 Session 6 Tuning of engine cooling system Checklist for Assessment Activity Use the following checklist to see if you ve met all the requirements for tuning of engine cooling system Part A Share importance of cooling of a vehicle Part B Discussed in class the following e Why is cooling necessary e What are the steps to be followed while checking the functioning of the cooling system e Leakages in cooling systems Performance standards criteria covered by this assessment Performance standards Yes No Able to explain importance of cooling a n Able to list general steps during checking cooling system AutoL3U1 NQ2012 Session 7 Tightening of Fastener Nuts Bolts Screw Relevant Knowledge As you know that the engine is a complex piece of machinery in which different components are assembled by using different types of fasteners Due to power pr
10. by this assessment Performance standards Yes No Able to explain importance of inspection of engine Able to list general steps during inspection of engine AutoL3U1 NQ2012 Session 2 Washing of an engine Relevant Knowledge The modern automobile is equipped with latest technology So while providing services like engine washing proper care must be taken to avoid the damages to the components as they are very expensive The latest engines are compact and fitted in the small area It is necessary to clean the engine at regular intervals to remove oily layers depositions of muck mud and water which may causes engine heating and changes in engine performance Material and equipment required to clean engine e Car washer e Compressor e Diesel sprayer gun etc Steps to clean wash the engine e Keep the vehicle on hard surface e Open the engine bonnet cover and support it properly e Inspect for external leakage of oil coolant gases locate the area e Allow the engine to reach atmospheric temperature e Disconnect negative terminal of battery for safety e Now use diesel sprayer and spray the diesel only on oily layer of an engine e Now operate the car washer and set the water spraying nozzle at low pressure AutoL3U1 NQ2012 Spray water and remove the oily layers and muck water from an engine Now take some liquid soap and apply the soap slowly in the area where the hand can reach Again with low
11. ce fuel system in a given vehicle engine Able to check the fuel line for leakages Able to conduct fuel pump test and compare its reading with service manual Able to set carburetor for ideal speed Able to test nozzle for pressure Able to trace the primary and secondary circuit S Check the terminals for loose connection Able to clean the spark plug and distributor Able to check the level and quality of lubricating oil Able to replace the oil and change the oil filter AutoL3U1 NQ2012 e Able to check the oil pressure e Able to read temperature gauge e Able to check circulation of water in cooling system e Able to trace for coolant leakage e Able to tight fasteners with specified torque and with sequence in the following components cylinder head induction manifold Exhaust manifold and engine foundation nuts and bolt e Able to understand importance of engine timing e Able to feel the change in sound after tuning Assessment Plan Assessment method Completion Date Filin the Blanks Fill in the Blanks n n Filin the Blanks n n AutoL3U1 NQ2012 Introduction Driving a car can be fun but its maintenance can be a pain No one really enjoys the task of automobile maintenance As long as the automobile works fine we are happy and don t always remember to get its maintenance of done Even if your vehicle works fine getting its servicing and maintenance of regularly is necessary General vehicle maintenance helps t
12. cece cece cece eee r eee nr rara 38 Session 8 Engine Timing TUNING cc cece eee cece cease rr 40 Relevant Knowledge cccceeceeeeeeeeeeeeeeeeeeeeeeeeeeaeeeesaeeeeas 40 EWO NO SO tt aa a pon e a ia l a ok ank n p av a e a e fk ae l te e ane RR RR RR RR RR KRA 42 Assessment CLENVIlCS ssososssrsrsrsrererrrrrrrrrrrrr rr rr rr rr KKR KR KRK RR KRK RKA ns 42 Checklist for Assessment ACtVIllCS sssssosssssessessrsrrerrrr ee ee eee rr reda 42 Suggested REACINGS ccccc cece ttet aaa teeaetesoeeeooeeeseoeeooeoeoees 44 Contributors to the Workbook Development ceeeeeeee 45 AutoL3U1 NQ2012 About this Workbook This workbook is to assist students with completing the Auto Sector L3U1 NQ2012 unit of competency Reqular maintenance of an engine Students should peruse the workbook in class or in their own time This workbook contains sessions for imparting knowledge amp skills on various basic aspects of the unit of competency The workbook also includes information exercises and assessment activities to complete The assessment plan has been included in the workbook to assist you in scheduling your time for completing the assignments Each assessment activity is followed by a checklist for meeting the assessment criteria The criteria will help you to ensure that you have fulfilled all of the assessment requirements to receive a competency grading Certification by ASDC AutoL3U
13. cludes the engine s water jacket thermostat water pump radiator and radiator cap cooling fan electric or belt driven hoses heater core and overflow tank Checking Circulation of water in cooling system Switch off the ignition switch of vehicle Remove the negative terminal from the battery Turn the upper radiator cap slowly and allow the stem water vapors to Ly release from the radiator A MA AOO Turn the radiator cap and remove the cap from the neck of the radiator Connect the battery terminal and switch on the ignition Run the engine at idle soeed Inspect the circulation of water in the radiator Circulation of water should be observed as rate of inlet must be equal to rate of outlet of coolant This shows healthy running of coolant system Checking of Coolant Leakage Inspect coolant tank and its connections Inspect radiator hose clips for looseness and if notice leakage tighten the clips Check hose pipe for distortion deterioration and replace Inspect radiator cap neck and radiator core for coolant leakage Inspect for torn thermostat housing gasket for leakage Inspect for water pumps seal and gasket for leakage of coolant AutoL3U1 NQ2012 Setting of cooling fan belt tension Inspect belt for cracks cut deformation wear and cleanliness If necessary change the belt Check belt tension as 6 7 mm as deflection To adjust the belt to tight or loose change the position of the alternator e
14. e observed in your room home that whenever there is rise in ambient temperature we switch on the fan AC to reduce the temperature It becomes comfortable to do our routine work Similarly our vehicle also works on the principle of cooling during running Cooling system in a Pressure car protects the engine Heater Hoses Cap Upper Hose from overheating Cooling ee es I system removes 30 of the heat of the engine An Heater Core efficient cooling system keeps the engine protected Rise in engine 1 Radiator temperature may causes gt over heating of engine Fan x Reserve Tank D which changes its XY performance Components Illustration provided by the National la 7 Water Pump O f the engine will get Automotive Radiator Service Association A A ANN distorted and reduce its Lower Hose VY Cooler lite Hence it is necessary to check the functioning of the cooling system at specified intervals One must always use good quality coolant for car engine The coolant level must be checked at least once a fortnight During summers it must be checked more frequently Steps involved in checking the cooling system Reading of temperature Gauge Temperature gauge is fixed on dash board which regularly monitors the variation in engine temperature Moderate temperature of engine is 75 80 degree centigrade which needs to be constantly maintained AutoL3U1 NQ2012 Parts of Cooling System The cooling system in
15. f Ignition system of engine Checklist for Assessment activity Use the following checklist to see if you ve met all the requirements for tuning of ignition system of engine Part A ohare importance of tuning of ignition system of engine Part B Discussed in class the following e Why tuning of ignition system of engine is necessary e What are the steps to be followed while tuning of ignition system of engine Performance standards criteria covered by this assessment Performance standards Yes No Able to explain importance of tuning of ignition system of engine Able to list general steps during tuning of ignition system of engine AutoL3U1 NQ2012 Session 5 Tuning of Engine Lubrication System Relevant Knowledge We know that the lubrication fulfills the following purposes e It reduces wear friction o It reduces heat e It provides cleaning of an engine parts e It helps in giving cushioning effect It fill the gap The engine lubrication system working on pressurized lubrication system In which the oil sump stores and collects the circulated lubricating oll Oil pump will circulate lubricating oil to lubricate engine components at recommended pressure and control by salty valve The role of oil filter and oil strainer is to filter the circulated lubricating oil and re circulate the same The lack of lubrication will lead to engine sound and also the tune of engine will changes because of increase in friction t
16. h shape All need a power supply 230V or 12V and they have a pickup unit mostly an induction clamp to be put around the HT cable for impulse pickup AutoL3U1 NQ2012 In new modern vehicles we use multipoint fuel injection system In the process of combustion of fuel injection system it is I necessary to inject the fuel by using fuel injector The fuel injector will inject the fuel at right time at appropriate pressure at end of compression stroke There is a need felt to set the injection timing FIP system in relation to rotation of crankshaft Thus fe check and set fuel injection trimming E a a W 1 pen E FAM a Fig Tuning Timing will maintain total functioning of the engine and governs the fuel economy Steps for checking of valve timing e Remove the timing cover e Check the alignment of the following 6 Turn the crankshaft pulley with transmission belt and mark on the pully must align with crankcase mark e At the same time camshaft pulley mark must align with crankcase marking This indicates proper valve timing Steps for checking of ignition timing Connect the stroboscope connection as per manual e Now hold stroboscope lamp near the fly wheel and run the engine at idle speed Check timing mark on the flywheel matches with pointer of crankcase housing at a same time lamp must glow shows the alignment e This indicate proper ignition timing AutoL3U1 NQ2012 Steps for checking
17. hus it is necessary to check the lubricating oil at specified intervals Also change the lubricating oil if oil looses viscosity or after recommended interval of distance in km Tuning procedure Slowly remove the dip stick from the sump and wipe it with cotton waste Now check the level on the dip stick and if it is low check the quality of oil If it is heavy quality of oil is better viscosity then add the oil If the oil is black it lacks viscosity Then change the oil and oil filter Fig Checking of Engine Oil AutoL3U1 NQ2012 Changing of the oil Bring the vehicle on lubrication bay and place the EE container below the drain plug MA Mat Using specified spanners loosen the drain plug and Mi drain the oil in container Switch on the engine for 3 seconds so that engine becomes warm It will remove oil present in pores of engine and oil will be drained out easily Fix the plug with a new washer and tighten the same with specified torque Refill the lubricating oil from filler plug with the recommended quantity and quality Changing of oil filter Slowly remove the oil filter Use rubber gasket of appropriate size and place the gasket in the housing groove Check the gasket is not twisted or trained Now fix the new oil filter tightly at specified torque Measuring oil pressure Fig Changing of Oil Filter Start and run the engine to achieve optimum temperature Check the oil pressure on pressure gauge and
18. ize wap I Ki of socket spanner with appropriate torque wrench Use strictly the service manual as per prescribed sequence Inspect the exhaust manifold gasket Material and Tools requirement for tightening of fastener socket spanner Tommey bar Extension bar rod Torque wrench Torque wrench socket Session 7 Tightening of Fastener Nuts Bolts Screw Exercise Assignment List the torque required for tightening of fasteners using service manual 1 AutoL3U1 NQ2012 2 Prepare a poster showing tools used in tightening of fasteners Session 7 Tightening of Fastener Nuts Bolts Screw Answer the following questions Use additional sheets of paper if necessary A Fill in the blanks 1 Tightening is required to avoid 2 Inlet manifold is used for 3 Exhaust manifold is used for B Tick the correct answer 1 Mallet is made of A Iron B Wood C Steel D Aluminum Session 7 Tightening of Fastener Nuts Bolts Screw Checklist for Assessment Activity Use the following checklist to see if you ve met all the requirements for tightening of fastener nuts bolts screw Part A e Share importance of tightening the fasteners Part B Discussed in class the following Why tightening is important What are the different types of tools used in tightening of fasteners How to set the torque wrench AutoL3U1 NQ2012 Steps used in tightening Performance standards criteria covered by this assessment
19. llowing process for the checking of the leakages AutoL3U1 NQ2012 A Cooling system leakage When we notice greenish colour near below mentioned points it indicates that there are chances of coolant leakage e Inspect coolant tank and its connections e Inspect radiator hose clips for looseness and if noticed leakage tighten the clips e Check hose pipe for distortion deterioration and replace e Inspect radiator cap neck and radiator core for coolant leakage e Inspect for torn thermostat housing gasket for leakage e Inspect for water pumps seal and gasket for leakage of coolant B Fuel leakage Fuel leakage can be easily checked by smell and leakage of fuel It reduces mileage of vehicle The causes of fuel leakage can be Evaporation of fuel 0 Broken or loose fuel line connection Following areas must be inspected for fuel leakage Fuel tank out let and tank cap rubber washer Flexible fuel line for slackness Torn fuel filter gasket or loose fuel filter Fuel pump connections and connectors Loose connection at nozzle carburetor areas C Combustion gases leakage The leakage of combustion gases may be traced when black soot is noticed around following areas on an engine e Cylinder head and cylinder block AutoL3U1 NQ2012 D Torn cylinder head gasket Spark plug nozzle Engine induction and exhaust manifold Value guide improper tappet clearance Lubricating oil leakage The leakage of
20. ng To avoid this situation it is necessary to tune the fuel system of a vehicle Steps for fuel tuning Clean the air cleaner and fuel filter Remove the tank cap e Inspect the rubber washer AutoL3U1 NQ2012 e Clean the vent hole to maintain atmospheric pressure on the fuel Now inspect the fuel line for leakage and if flexible fuel line is damage replace immediately e Inspect the suction vacuum of fuel pump 0 Check the fuel pump pressure Compare reading with specification as specified in the service manual Setting idle speed of an engine Warm up the engine and turn the idle speed screw in clock wise direction so the engine rpm will increase e Now slowly turn idle speed screw in the anti clock wise direction till you get the prescribed rpm Use tachometer to read rom e Now turn the air screw in clockwise direction so that the engine will stop Slowly open the screw and start the engine till we get recommended rom of an engine Nozzle pressure test 0 Remove the injector nozzle from an engine e Hold container below the injector nozzle e Connect the fuel pipe to the nozzle and start the engine Observe the injector nozzle spray if proper fix it back to the cylinder head e Repeat for all cylinders If pressure is noticed less than it is necessary calibrate the FIP pump Precautions e Do not pull out the flexible pipe connection e Do not over tighten the fuel line connection e Do not twis
21. ng Vol II Kirpal Singh Standard Publishers Text Book of Automobile Rajput R K Laxmi Engineering Publications Automobile Engineering R K Singal S K Kataria and Sons Automobile Engineering Kapil Dev Computech Theory Publications Automobile Engineering K M Moeed S K Kataria and Sons Websites auto indiamart com auto technology www automobileindia com consumer guide automobile technology auto indiamart com auto technology books google com books about Automobile_Engineering html www bikeadvice org www wikipedia com www shell com home content ind products_services on_the_road AutoL3U1 NQ2012 List of Contributors 1 Mr Sunil K Chaturvedi CEO Automotive Skills Development Council Core 4 B 5 Floor India Habitat Centre Lodhi Road New Delhi 03 Mr A C Deb Sr Lecturer Auto HOD PUSA Polytechnic PUSA New Delhi 12 Mr Vikas Gautam S B V NO 1 Morigate Delhi 06 Ms Shubhra Mathur Free Lancer Automobile Janakpuri New Delhi Mr Dhirendra Chandra Srivastava Divisional Manager Tech Uttranchal Parivahan Nigam Kathgodam Dist Nainital Mr Nagendra D Kore l c Vice Principal Purushottom Walawakar Hr Sec School Khurlim Mapusa Goa Dr Saurabh Prakash Associate Professor E amp T Division PSSCIVE Bhopal Programme Coordinator
22. o keep it in good condition and can save your trouble of repairing or changing its major parts in the long run Regular oil check and change is required and can be considered as one of the most important steps to maintain your car Vehicle owners never keeps track of when their engine needs an oil change Old oil or insufficient oil in your engine will heat up the engine quickly and might lead to damage and other problems in your vehicle To fix these problems you will have to pay quite a lot To keep your automobile running efficiently and engine well maintained a regular oil change is essential Checking air regularly and filling air in the tyres is another important task which is often neglected by car owners The pressure in the tyres goes down over a period of time but due to some leak it might go down even sooner Air in tyres should be filled in correct proportion If tyres have insufficient air they will wear out faster In the case of less air the tyres touches the road and the rim of car which will spoil the treads of tyres Overfilling of tyres without using a gauge might cause your tyres to burst and this can be very dangerous Tuning up your motor on a regular basis will save you from a sudden shock and expense if costly parts in your car fail Regular check up of your car will keep you updated on the performance of your car and car parts In this unit we will go through all the maintenance procedure for a vehicle AutoL3U1 NQ2
23. oduction transmission of power variation in speed and load vibration leads to loosening of fasteners This may change the stability of components and lead to development of bending Further it may develop scratches cracks and may cause leakage of coolant and gases etc It will affect the engine performance A Tightening of Cylinder Head Induction manifold and Exhaust Manifold n To avoid the combustion gases it is necessary 5 4 de to tight cylinder head in following manner G e Remove the tappet cover from cylinder a head a EE e Remove the rocker arm assembly Slowly remove the pushrods overhead valve mechanism P Pa Fr f ik Me Use specific size of socket spanner with appropriate torque wrench e Use strictly the service manual as per the prescribed sequence e Tighten the cylinder with specified torque Induction Manifold Loose induction manifold may create vacuum leakage which leads to supply lean mixture which may causes hesitation in engine running Fig Induction Manifold AutoL3U1 NQ2012 Tighten the induction manifold using specific size of socket spanner with appropriate torque wrench Use strictly the service manual as per prescribed sequence Inspect the induction manifold gasket Exhaust Manifold Loose induction manifold may cause emission leakage and lead to cause blackening of bottom of body and may catch fire Tighten the exhaust manifold by using specific s
24. of injector timing Check the alignment the FIP timing with camshaft gears pulley which ensures Injection timing Session 8 Engine Timing Tuning Exercise Assignment 1 Visit the service centre and check the valve timing ignition timing and injection timing of four types of vehicle 2 Prepare a poster showing valve timing ignition timing and injection timing of a vehicle Session 8 Engine Timing Tuning Answer the following questions Use additional sheets of paper if necessary Fill in the blanks 1 Valve timing is used for 2 Ignition timing helps in an engine 3 Injection timing are used in 4 Stroboscope helps in of ignition timing Session 8 Engine Timing Tuning Checklist for Assessment Activity Use the following checklist to see if you ve met all the requirements for engine AutoL3U1 NQ2012 timing tuning Part A e Share importance of different timings related to engine performance Part B Discussed in class the following e What is meaning of timing e What are the different between ignition and injection timing e Name tool used in checking engine timing Performance standards criteria covered by this assessment Performance standards Yes No Able to explain importance of timing in engine coolant Able to check the ignition injection and valve timing AutoL3U1 NQ2012 Suggested Reading Books Title Automobile ha Vol Kirpal ge hiatal Publishers Automobile Engineeri
25. park plug slowly from each cylinder AutoL3U1 NQ2012 e Inspect the spark plug condition e Colour black soot rich mixture cold engine e Dead white soot lean mixture hot engine e Brownish colour normal Check for eroded central electrode and make it straight to maintain air gap e Check for deposition and clean the plug by sand blast machine or by emery paper e Using wire feeler gauge set the spark plug gap as per the specification Clean the spark plug threads Apply oil and check spark plug sealing gasket washer if need replace e To install plug first fix it with hand e Thread it smoothly and tighten the same with specified torque e Connect the lead wire with plug Start the engine and check the engine sound and ascertain if there is any change in engine sound Session 4 Tuning of Ignition system of engine Exercise Assignment 1 List the steps used in tuning of ignition system 2 Prepare a line diagram of ignition system of a vehicle AutoL3U1 NQ2012 Session 4 Tuning of Ignition system of engine Answer the following questions Use additional sheets of paper if necessary Fill in the blanks 1 The ignition system plays role in process of combustion and ignition system converts current from to 20 000 volt 2 Normal temperature of engine is in the range of and 3 Ignition system is classified in two ways circuit with LT leads and circuit with HT leads Session 4 Tuning o
26. preneur willing to start an Automobile service Sector can acquire the desired competencies with the help of this book The book has been written by experts but reviewed by all the members of the group am grateful to the authors for the development of this book and to the members of the Working Group for their candid suggestions during the development and review Their names are given elsewhere appreciate efforts put in the by Dr Saurabh Prakash as the Project Coordinator of the Working Group in planning and organizing Meetings which led to the final form of this title shall be grateful to receive suggestions and observations from readers which would help in bringing out a revised and improved version of this book Prof R B Shivagunde Joint Director Bhopal Pandit Sunderlal Sharma June 2012 Central Institute of Vocational Education AutoL3U1 NQ2012 AutoL3U1 NQ2012 O Ministry of Human Resource Development 2012 Copyright protects this publication Except for purposes permitted by the Copyright Act reproduction adaptation electronic storage and communication to the public are prohibited without prior written permission This student workbook was developed with active involvement of the Automobile Skill Development Council ASDC keeping in view the National Occupation Standard NOS for Service Technicians L4 developed by ASDC This project for development of the student workbook was coordinated by the PSS Cen
27. r rr rr rr rr K e a KRK RR RR RR te RRD an RR RR RR RR RR KRA Assessment CLENVIlCS ssososssrsrsrsrerrerrrrrrrrrrrrr rr rr rr rr KKR KR KRK RR RR K RKA ns Checklist for Assessment ACctivitieS cccccceee cece eee rens or rn dra Session 5 Tuning of engine lubrication system e se Relevant Knowledge ccccccceceece eee eneeeeeeeeteeenaeeeeegaeeenenas EK SO SO it at a ka rr rr veces rr rr ve l ke e e n e ae e A e ee AE aze ki Assessment CLENVIlCS ssososssrsrsrsrerrerrrrrrrrrrrrr rr rr rr Kr KKR KR KRK RR RR KRKA ns Checklist for Assessment ACLtVItCS sssossossssesresrsrrrrr sees rer ror rr dra Session 6 Tuning of engine cooling System eeeeeeeooonononeos AutoL3U1 NQ2012 Relevant Knowledge sssseseessrrrrrrrererrrrrrrrnrrrrr rr rr nr rr rer rr n rr resan 32 EXCICISO ssseesersererererrrrrrr rr rr rr rr rr rr rr a KRK RR KRK RR RR a RR RR RR RR KR An 34 Assessment ActivitieS c ccc ccccccc cece cee e essen rr rr rr rr KKR KR KRK RR RR KRKA ns 34 Checklist for Assessment ACtVIlleS sssssosssssessessrsrrrrrrr ee ee rr rr rr rara 35 Session 7 Tightening of fastener Nuts Bolts SCreWS 36 Relevant Knowledge cccccecceeeeeceeeeeeeeteeeeeeteeenaeeeeeneeeeees 36 E45 6 ols a nn rr een ere 3 Assessment ActivitieS ccc ccccccc cece cece ee eeeee rr rr rr rr KKR KR KRK RR RR KRKA ns 38 Checklist for Assessment ACTIVITICS 0 cece
28. s an important role in process of combustion The system converts current from 12volt to 20 000 volt To ignite the charge the weak or the advance spark retarded spark will change the process of combustion and will lead to imbalanced combustion which will affect engine performance Due to which engine tune will also change The thin wires and their connections will supply the current between 12 volt and are called Low Tension Leads The wires which are thick will supply the current of 20 25 000 volt and are called High Tension Leads The ignition system is classified in two ways i e primary circuit with LT leads and secondary circuit with HT leads The connection from battery to ignition switch to HT coil and to the distributor C D I comes under primary circuit Whereas from distributor till Sparkplug connections come under H T leads or secondary connection Steps for tuning of ignition system e Inspect the battery terminal for loose contact e Inspect the socket connection for slackness Check the connection to ignition switch e Inspect connection at primary circuit of LT lead e Inspect the connection with pick up coil and CDI unit e Disconnect the sparkplug connection e Now remove the distributor cap and check the HT lead for loose connections e Check distributor contact point for erosion burn Inspect working of spark advance mechanism e Clean distributor cap and fix it properly Using appropriate spanner loosen the s
29. s to be followed while washing the engine Performance standards criteria covered by this assessment Performance standards Yes No Able to explain importance of washing po Able to list general steps during washing of an engine n AutoL3U1 NQ2012 Session 3 Tuning fuel system of an engine Relevant Knowledge One of the basic components of a car comprises of its engine and talking about the car engine its fuel system needs to be properly taken care of In fact proper car maintenance is as good as incomplete without adequate maintenance of the fuel system Taking proper care of the fuel system will ensure that your car does not consume extra fuel runs smoothly and does not suffer from frequent breakdowns Tuning The final and finest adjustment at recommended interval to maintain originality in performance of an engine is called tuning Every new engine gives better mileage and good performance to achieve high and low speeds in variation with load But after certain intervals due to vibration etc normal wear of components take place So it is necessary to inspect and adjust the following systems of an engine e Fuel system 0 Ignition system e Cooling system Lubrication system e Mechanical system Tuning of fuel system of an engine As we have seen the sound of an engine it should be maintained to its original level If there is less fuel supply the engine performance will change and it will make a noise while runni
30. t the fuel line AutoL3U1 NQ2012 Do not work on fuel system with flame spark Change the gaskets to avoid evaporation of fuel after regular intervals Session 3 Tuning fuel system of an engine Exercise Assignment 1 Listthe steps used in tuning of fuel system Sr No Stepsused 2 Prepare a line diagram of fuel system of a vehicle Session 3 Tuning fuel system of an engine Answer the following questions Use additional sheets of paper if necessary Fill in the blanks 1 is used as fuel in the vehicle 2 Warm up the and turn the idle speed screw in direction so the engine rom will increase 3 Use to read rpm 4 Injector nozzle is used in an Session 3 Tuning fuel system of an engine Checklist for Assessment Activity Use the following checklist to see if you ve met all the requirements for tuning fuel system of an engine AutoL3U1 NQ2012 Part A Share importance of tuning fuel system of an engine Part B Discussed in class the following e Why tuning is necessary e What are the steps to be followed while tuning the fuel system e Advantages of tuning Performance standards criteria covered by this assessment Performance standards bonn man Able to Able to explain importance of tuning Importance of tuning l e NAN to list general steps during tuning of a o system AutoL3U1 NQ2012 Session 4 Tuning of Ignition system of engine Relevant Knowledge The ignition system play
31. tral Institute of Vocational Education a constituent unit of National Council of Educational Research and Training which is under the Ministry of Human Resource Development Government of India AutoL3U1 NQ2012 Student Details Student Name Student Roll Number Batch Start Date AutoL3U1 NQ2012 Contents About this WOL O OO Fet a oi kan t at at ea patka ed rr rr rr rr rr a be rr rer bk at IC TP F TT 2 1e a serna srt A A DE MN A S PW ME A AW Elements and performance CritEriAD eeerereeooeeooeooooooon Relevant knowledge and skillS sssssssssssssrrsrsrrrsrrrrsrrr rr rrr ren r rena Assessment PlAN cece ccc eee eee cess eee aaa tataaeestseesoeoeeeeeooseee Introduction i bani at je vii ee een aie Assessment Activities issoooossssssoserrrssserrrr rr sr aa eeeaaneeeeeeeaeseeaeeoeeonn Checklist for Assessment ACTtIVITICS cccccceecceccecccecceuccaceees Session 3 Tuning fuel system of an engine reerrrreerrreenrorennns Relevant Knowledge ssnosssrrressrrrrrersrrrrrrrrrr rar nr rr rr rr rr rr nns rr Kross PX CI 0 SO FR Assessment CLHNVIlCS ssososssrssesesrsrrrrrrrrr ers rr rr rr rr rr rn KRK KKR KRK RR RAKA Checklist for Assessment ACTIVITICS 0 0 cece cece cece e cece rr rr rn rara session 4 Tuning of an ignition system of engine evere Relevant Knowledge ssnocsssrressrrrrersrrrrrrrrrr rar nr rr rr rr rr rr nns rr Krok ss EWO NO IS O rr rr rr r
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