AT2405 VEHICLE MAINTENANCE AND RECONDITIONING LAB

0 0 3 2
LIST OF EXPERIMENTS
1. Study and layout of an automobile repair, service and maintenance shop.
2. Study !d "#$"#t%&! &' d%''$#$!t (tt$)$!t(*#$+&#d( #$,u%#$d '&# t-$ #$"%# !d )%!t$!!+$
.&#/(.
3. Cy0%!d$# #$1&#%!2 3 +-$+/%!2 t-$ +y0%!d$# 1&#$4 S$tt%!2 t-$ t&&0 !d #$1&#%!2.
4. V05$ 2#%!d%!24 505$ 0""%!2 6 S$tt%!2 t-$ 505$ !20$4 2#%!d%!2 !d 0""%!2 !d +-$+/%!2 '&#
505$ 0$/2$
5. C0%1#t%&! &' 'u$0 %!7$+t%&! "u)"
8. M%!&# !d )7&# tu!$ u" &' 2(&0%!$ !d d%$($0 $!2%!$(.
9. Study !d +-$+/%!2 &' .-$$0 0%2!)$!t 6 t$(t%!2 &' +)1$#4 +(t$#.
:. T$(t%!2 /%!2"%! %!+0%!t%&!4 t&$6%! !d t&$6&ut
;. B#/$ d7u(t)$!t !d B#/$ 10$$d%!2.
10. S%)"0$ t%!/$#%!24 (&0d$#%!2 .&#/( &' 1&dy "!$0(4 (tudy &' d&&# 0&+/ !d .%!d&. 20(( #%(%!2
)$+-!%()(.
11. Btt$#y t$(t%!2 !d )%!t$!!+$.
12. Practice the following:
I. Ad7u(t)$!t &' "$d0 "0y %! +0ut+-4 1#/$4 -!d 1#/$ 0$5$# !d (t$$#%!2 .-$$0 "0y
II. A%# 10$$d%!2 '#&) -yd#u0%+ 1#/$(4 %# 10$$d%!2 &' d%$($0 'u$0 (y(t$)
III. <-$$0 1$#%!2( t%2-t$!%!2 !d d7u(t)$!t
IV. Ad7u(t)$!t &' -$d 0%2-t( 1$)
V. R$)&50 !d '%tt%!2 &' ty#$ !d tu1$


Wheels
and Tyres
Repairs
Transmission
Repairs
Body
Repairs
Main
Replacements
Supervisor Cabin Waiting Room


Air
Supply
Lubrication Petrol
Supply
Diesel
Supply

Painting
Section
Tinering
Section
!nspection
Section
"lectrical #ehicle Testing Stores
Repair
#ehicles
$or display
#ehicles
a%aiting
services
Security
&ate
Way 'or
vehicles
"ngine Repair
Section
Washing
Ramp
Time
(''ice
Security
&ate
Way 'or
vehicles
")TR* "+!T
Fig 1.1 Layout of Automobile Service Station
Manager Spares Sho% Room and
Cabin Shop #ehicle Sales
Cabin
STUDY AND LAYOUT OF AN AUTOMOBL! "!#A"$ S!"%&!
AND MANT!NAN&! S'O#.
!( No )1
Date )

AM )
To dra% the layout o' an automobile repair, service and maintenance shop and study the
di''erent sections o' the layout-
D!S&"#TON )
S!"%&! STATON )
A service is a place %here in addition to care o' the motor vehicle lie mechanical
service and minor repairs, petrol is supplied, cars are lubricated, cleaned, %ashed and other types p'
simpler services that are re.uired daily are per'ormed- !n general it includes a number o' sections
lie garage general services, mechanical service, ma/or repair shop, tyre shop, paint shop, body shop
etc-
A service station is addition to the e.uipment available is garage is usually run in con/uction %ith a
sales agency 'or a particular type o' motor vehicle to provide comprehensive repair service 'or that
particular vehicle-
The e.uipment available, in general garage %ill be added %ith speciali0ed e.uipment lie
li'ting tacle, and di''erent types o' /igs, 'i1tures and tools specially designed 'or checing, ad/usting
and repair o' particular type and mae o' vehicle- A service station may consist o' a machine shop
having a lathe, drilling machine etc-
!n case o' big service station special types o' machines lie cransha't grinding machine,
valve re'acer, sur'ace grinder, reboring and boring machine, brae drum lathe also %ill be used- !n
service station 'uel 'illing and %ater servicing 'acilities are available- !t has a small %orshop to
provide repair 'or particular mae o' vehicle- !t may have sales agency 'or a particular type o'
vehicle- All the e.uipment in the garage plus small %orshop tools2 vi0, lathe, drilling machine, /igs,
'i1tures are available-
LAYOUT OF *A"A*!S AND S!"%&! STATON )
The internal layout o' a garage should be such as to mae it %ater proo', clean and spacious
to provide su''icient space 'or small %orbenches to storage and repair benches- $ollo%ing
considerations should be made in the layout o' garage and service stations2
To provide light to the %orbenches, openings the %indo%s should be provided at the proper
place-
To eep the 'loor cleanable, it should be a smooth concrete 'loor %ith a sur'ace3scaling
compound-
The doors are provided as many members as re.uired 'or easy 'lo% o' men and materials-
The electrical control should be accessible to the operators-
To 'orm a neat storage 'or hanging tools, hoos or scre% eyes should be provided on the
pegboards-
To provide a deposit o' %aste material-
&ON&LUSON )
Thus, the general layout o' an automobile repair, service and maintenance shop %as
dra%n and the 'unctions o' the di''erent sections o' the layout %ere studied-
Table No. +.1 #erio,ic Maintenance &-ec. S-eet
Dealer2
Place2
Date o' Sale2
S"R#!C" T*P"
Ro )o2
Mileage2 4ms2
Ro Date2
"ngine )o-
$raame )o2
Mileage54ms6 78888 98888 :8888 ;8888 <8888 778888 798888 7:8888
Service type
Mileage54ms6 7;8888 7<8888 =78888 =98888 =:8888 =;8888 =<8888 978888
Service type
Mileage54ms6 998888 9:8888 9;8888 9<8888 >78888 >98888 >:8888 >;8888
Service type
Mileage54ms6 ><8888 :78888 :98888 ::8888 :;8888 :<8888 ?78888 ?98888
Service type
S- )o C@"C4 !T"M C@"C4 STATAS R"MAR4S
7 BAS!C ")&!)" C(MP()")"TS
"ngine (il
"ngine oil 'ilter
R
R
= !&)!T!() S*ST"M
Battery T
9 $A"L A)D "M!SS!() C()TR(L
Pre3'ilter
Water sediment 'ilter
Air cleaner 'ilter
R
CA
C
> C@ASS!S A)D B(D*
Brae pedal, Paring brae
Brae pads and discs
Brae linings and Brae drums
Brae line pipes and hoses
Brae 'luid
Clutch
Po%er steering 'luid
Ball Boints and dust covers
Tyres and in'lation pressures
Lights, horns, %ipers
Steering %heel linage and gear bo1 oil
$ront and rear suspension
Tightening o' bolts and nuts
CA
CA
CA
CR
R
CA
CR
CR
CA
CA
CA
CA
T
: AC C Cooler Re'rigerant )A
C CleanD R ReplaceD CA ChecE Ad/ustD CR Chec E ReplaceD T Tighten
ADD!T!()AL B(B2
M!L"A&" 7-:8,888 >,:8,888
T!M!)& B"LT Replace Replace
)ame o' the !nspector Signature
STUDY AND #"!#A"ATON OF DFF!"!NT STAT!M!NTS
AND "!&O"DS "!/U"!D FO" T'! "!#A" AND
MANT!NAN&! S'O#.
!( No ) +
Date )
AM )
To prepare and study the di''erent statements and records re.uired 'or the repair and
maintenance shop-
TY#!S OF "!&O"DS )
76 Periodic maintenance chec sheet-
=6 Maintenance schedule sheet-
96 Trip sheet
>6 Log boo etc-
D!S&"#TON )
#erio,ic maintenance c-ec. 0-eet
The periodic maintenance chec sheet is used to record the inspection status made
during the maintenance chec operation- !t contains various details such as the dealer name, place,
date o' sale, manu'acturers name, mileage, 'rame number, chassis number etc- the mileage and
service type are indicated in the various cells o' the chec sheet- The chec sheet also contains the
chec item name, status and remars-
The chec items include the 'ollo%ing2
Basic engine components-
"ngine oil
"ngine oil 'ilter
!gnition system
Battery
$uel and "mission Control
Pre3 $ilter
Water sediment 'ilter
Air cleaner 'ilter
Chassis and Body
Brae pedal, paring brae
Brae pads and discs
Brae linings E brae drums
Clutch
Po%er steering 'luid
Ball /oints and dust covers
Tyres and in'lation pressures
Lights, horns, %ipers
Steering %heel linage E gear bo1 oil etc-
The status and remars 'or all the items mentioned above are indicated on the chec sheet
during the maintenance operation-
#ehicle Reg )o2 Bob )o 2
Chassis )o 2 Date 2
Table +.+ "oa, Te0t "e1ort
S-)o Parameter to chec Be'ore %or A'ter %or
7 $ront side abnormal noise
= Rear side abnormal noise
9 $rontCrear suspension noise
> Steering noise
: Brae caliper noise
? Mis'iring C starting
; @unting problems C Stopping problems
F Anderbody noise
< Abnormal noise 'rom doors C glasses and body
78 (verheating o' engine on AC and )on AC
operation
77 Braes poor C Wea line e''ective C noisy
7= Wheel bearings noisy
79 Drive sha't noise C vibration
7> #ehicle pulling to one side
7: Poor pic up o' vehicle 5%ith AAAC and
%ithout AC6
Table +.2 T"# S'!!T
)ame and Address o' the Agency R"P(RT T(
Mr- C Mrs-
333333333333333333333333333333333333333333333333333333333333333
333333333333333333333333333333333333333333333333333333333333333
33333333333333333
"ngaged by Arranged by 333333333333333333333 )o- 333333333333333 Date2 333333333333333333
#ehicle )umber 3333333333333333333333333333333 Driver )ame 333333333333333333333333333333333333
Closing Time 33333333333333333
Starting Time 33333333333333333
T(TAL Time 33333333333333333
Signature o' the Customer
@ire Charges
Charge Per m
Driver Batta
"1cess @ours
"1cess 4ms
Service Ta1
Permit Charges
Rupees Paise
Advance Rs- 333333333333333 T(TAL
DriverGs Signature $or Agency
"OAD T!ST "!#O"T)
7- The road test inspector or the machine maes the road test report a'ter the completion o'
the maintenance operation-
=- This report contains the vehicle reg number, chassis number, /ob no, date o' test etc-
9- The parameters to be checed include the 'ollo%ing2
$ront side and rear side abnormal noise-
Steering and brae caliper noise-
!lunting, mis'iring, sudden stoppage o' vehicle-
Brae condition-
Wheel and bearing chec-
Pic up o' the vehicle-
Mileage o' the vehicle etc-
The road test report gives a 'are idea o' the condition o' the vehicle be'ore and a'ter the
maintenance operation-
T"# S'!!T )
The trip sheet gives the entire details o' the vehicle be'ore and a'ter a trip- The starting
m and ending m, time o' start and closing o' the /ourney time and the charges per m and
also the overall cost o' trip is described in the trip sheet-
LO*BOO3 )
The logboo o' a vehicle gives the details o' the vehicle, %hich %ill be use'ul not only 'or
the o%ner o' the vehicle but also to the mechanic %ho might tae the /ob o' vehicle
maintenance latter-
The logboo contains the 'ollo%ing details2
Distance covered
$uel consumption
Average 'uel consumption
Best and %orst mileage
Total maintenance cost
Running costs
$aults in the vehicle
Lies and dislies
Date o' the previous maintenance report
&ON&LUSON )
The di''erent statements and records re.uired 'or the repair and maintenance %ors %ere
prepared and the uses o' records %ere studied-
&YLND!" "!BO"N*4&'!&3N* T'! &YLND!" BO"!$ S!TTN* T'! TOOLS
AND "!BO"N*
"1-)o29
Date2
A!M2
Checing the cylinder bore, measurement setting and rebore the %orn out cylinder
bore o' an !C engine and set the tools and rebore the given cylinder
T((LS R"HA!R"D2
Telescopic bore gauge, #ernier gauge,Micrometer,Test lamp ,Machine clamping tool, bore clamp,
telescopic gauge, vernier calipers, 'erler gauge, u3 clamp and Allen ey setting micrometer-
C*L!)D"R SAR$AC"2
)ormally in the !C engine cylinder %ear at the top is ma1imum and impact scoring mar either
thrust a1is or cran pin a1is to eliminate the scoring re.uired by boring- The measurement o' the
cylinder %ears, taper and ovality by using telescopic gauge- These gauge and vernier callipers can be
used to measure the %orn out bore-The cylinder ovality and taper should not e1ceed 8-8:8mm
other%ise u-s-p and blo% by %ill occur Bore dial gauge %ith setting ring is also used to measure the
cylinder taper is high di''cult 'or the rings to control by blo% gases- The recondining that have
e1cessive tapper or out o' cylindricity is done by boring or reboring-&enerally a cylinder greater than
8-88?inches must be rebored and boring is done-
R"B(R!)&2
A cylinder that can not be cleaned by boring and it must be done by reboring process boring %hich
rotates a cutting tool in the cylinder to remove the metals-These operation increase the cylinders bore
diameter-
PR(C"DAR"2
!nitially measure the cylinder bore si0e at 9 points lie top, middle and
bottom using telescopic bore gauge or vernier caliper-
Set the cylinder bore centre and the 'ont mounted spindle centre by
using spring loaded pin arrangement-
A'ter ensuring the boring part is rotated at the e1act centre o' bore ,
tight the clamp giving more to.ue-
Sides should be bored-
Set the depth o' stopper upto b-d-c-
Rebore , then clean the ovality, taper , scoring mars e-t-c
The vertical boring machine is placed on the engine, a'ter it is 'i1ed to
the stand-
Boring machine is 'i1ed to the engine clamp and machine clamp-
The spindle is li'ted and to centered to the cylinder %hich is to be
measured and machines using the pin and spring-
The centering pins are introduced into their respective holes and the
spring is introduced over them-
The spindle is lo%ered into the bore and the centering pins are
e1tended by turning the e1pander nob-
Machine position is ad/usted and the centre pins are e1tended and
brought in such that the gap bet%een the pins and the cylinders %alls
are same-
A'ter 'i1ing the spindle is li'ted and the centre pin spring are removed-
The boring tool is no% placed in the holder and the nut above the
holder is ad/usted using Allen ey to move the boring tool- !ts distance
'rom the centre is measured by tool setting micrometer-
Tool is set the re.uired length according to the ne1t speci'ied bore
diameter and tool ad/usting nut-
The tool position is 'i1ed using the locer nut on one side, no% the
motor is started and the gear is engaged 'or automatic movement o'
spindle-
"e0ult2
The !C engine cylinder reboring machine setting and machined to e1act si0e o' cylinder
bore and tolls are set and cylinder o' the given engine is rebored to the ne1t standard si0e-
%AL%! *"NDN* AND %AL%! LA##N*$ S!TTN* T'! %AL%! AN*L! AND
&'!&3N* FO" %AL%! L!A3A*!
!(.No)5
Date)
AM)
To per'orm the grinding , lapping , valve setting and valve leaage in the given valve
TOOLS "!/U"!D)
#alve grinding machine,Spanner,Lapping paste
Lapping stic, Cutter seat, compressed air,%ater and Lathe machine
#"O!&DU"!)
At 'irst the valve is taen out the valve assembly- Chec the valve head
'or craning, valve seat 'or radial run out in the given valve-
!' there is a good margin still le't over it can re'aced and reused thus
the correct o' proper valve seat cutter assembly %ith point-
This assembly is placed on the valve seat %hich is rotated in the
cloa%ise> direction- The carbon o' dust and radial run out on the
valve head is grinded and cleaned by using the valve grinding
machine-
Then the lapping paste is applied over the valve 'ace-
To rotate valve and li't it during the lapping, suction cup is attached to
the stic is used-
When the lapping seat is important to give a valve reciprocating under
a racing motion not continuously rotary movement- Then the valve is
removed in the head and paste is applied, thus the process is done-
To chec up the valve seat and its setting 'ollo%ing methods can be
employed
Checing %ith petrol
Selection on cup method
Compressed test
By blo%ing compressed air

Compressed test2 compression test method is used %here the air is pumped %ith help o' rubber and
the %hole unit is ept light over cylinder head- A'ter building o' pressure at57: lbs s.uare inch6
%ait 'or a 'e% minutes, there should be no drop in pressure-
Blo%ing %ater and compressed air2 in this method compressed air is blo%n through suitable adapted
'iltered on mani'old-
Chamber is 'itted %ith %ater
(n blo%ing the air- )o air bubble should be sealing the %ater
"!SULT)

Thus grinding, lapping , setting the valve angle and checing the valve leaage is done
&ALB"ATON OF FU!L N6!&TON #UM#
!(.No)7
Date)
AM)
To study the calibration o' 'uel in/ection pump 'or a ulticylinder diesel engine-
TOOLS "!/U"!D) 'uel in/ection test bench, micro pump-
#"O!&DU"!)
The calibration test is usually carried to chec connect .uality o' 'uel is
in/ected 'or various load and speed condition- the rac o' the 'uel ump under
test should be in no load position %hen the test bench is started speed is
controlled by hand %heel-
$it the correct rac setting device> to the in/ection pump, remove the tapped
inspection cover gauge restriction %heel coc is ept closed to avoid the
damage to pressure gauge set the rac setting device to 0ero then connect the
'le1ible supply line to the supply connection build up the re.uired pressure-
By closing the valves, inspect 'or leaage the pump housing around discharge
union, air vents and locing scre%- When the counter nob is engaged and
start button one electronic tachometer is pressed 'uel %ill cut o'' the 'uel to
the test tub- Then the speed o' the varied 'or varying load condition and the
corresponding 'uel .uantity in/ected is noted and the readings are tabulated-

R"SALT2 Thus the calibration o' 'uel in/ection pump 'or a multicylinder diesel engine is carried out
and tabulated-
MNO" AND MA6O" TUN!4U# OF *ASOLN! AND D!S!L !N*N!S.
!( No) 8
Date )
AM )
To per'orm the ma/or and minor tune3up o' gasoline and diesel enginesI
TOOLS AND NST"UM!NTS "!/U"!D )
Cell tester, Double end spanner, Scre% driver, Battery charger, $eeler guage, Pliers, Ball3
peen hammers, socet spanner, Wrenches, Dial indicators, @ydrometer, $iles, Piston ring e1pander,
Piston ring compressor, #alve spring compressor, Spar plug spanner, &rinding machine etc-
#"O&!DU"! )
#!T"OL !N*N! TUN!4U# )
"i,ge in cylin,er liner)
The %ear starts in the linear 'rom the height o' ring travel i-e-, on top o' linerD there is
practically no %ear- Since this portion does not come in contact %ith the rings- !n %orn out engine
you can 'eel this area by your 'inger running up and do%n in the liner- !n case %ith %orn out liner
%hen rings have to be changed to chec up this ridge, in case it is prominent it should be cut %ith
ridge cutter- Then only ne% set o' rings can be placed, other%ise there are chances o' ne% rings
being thicer in %idth then the used %orn out rings may strie the ridge and brea- Secondly, the
piston assembly can easily slide in Boring and honing o' cylinder liners-
The cylinder bores do %ear out a'ter some use- The amount o' %ear can be controlled to
some e1tent by cleaning the air cleaner, eeping %atch on proper %oring o' cooling system and
lubrication system, in spite o' all this care a'ter >8 to :8 thousand ms in diesel engine and in petrol
engine ?8 to ;8 thousand ms %ear is predominant in the liner %hich you can see %hen you
dismantle the engine 'or overhauling- $rom the %orn out cylinder bores 'e% more li'e can be taen
by boring the same %ith boring machine- When using the boring machine, the boring tool %ill leave
very 'ine line on the bore, %hich cannot be seen by naed eyes- Presence o' these lines o' honing is
not desirable- To rub these lines, bores are honed, i-e-, polished %ith the help o' honing stone 'i1ed in
the cylinder hone head- These hones are driven %ith portable electric hand drill and %hile %oring
.uicly up and do%n motion are given-
Maintenance of fly9-eel )
$ly%heel does not re.uire much maintenance e1cept that is mounting bolts %ith
cransha't should be tightened %ith proper tor.ue, the 'ace %here the clutch plate is 'i1ed sometimes
gets scored because o' loose rivals or rivets touching the 'ace %hen lining is %orn out- Ander such
circumstances the 'ace o' 'ly%heel should be got simmed- The 'ace o' 'ly%heel should be e1amined
at each overhaul and %hile changing clutch plates this 'ace should be rubbed %ith emery paper to
remove the gla0e- The 'ly%heel a'ter 'itting should be checed that it is running true- $or checing
run out, place the cransha't %ith the 'ly%heel mounted on #3bloc to avoid scoring o' cransha't
main /ournal place paper in the # o' # bloc- $i1 up dial guage- With its point resting on clutch plate
mating sur'ace, remove the cransha't and note the run out- !t should not be more than 8-= mm-
%AL%! S!"%&N* )
The valve is sub/ected to very high temperature, runs at high speed and is one o' the critical
part %hich re.uires care'ul e1amination at the time o' overhaul %hile inspecting the valve, tae care
o' the 'ollo%ing points2
'ea, )
Chec the head 'or crac, burning, valve seat and radial run out- !t should not have ni'e
edge %arped and should have good margin- $or checing radial runs out place the valve in # bloc,
'i1 up the pointer o' dial guage on edge o' valve head- Revolve the valve and note the reading i' run
out is more than 8-99 mm- Discord the valve-
%alve 0y0tem )
#alve system should be straight %ithout scoring- !' it is slightly bent it can be straightened,
but in case it is bent too much, valve should be replaced-
"efacing of valve )
#alve a'ter dismantling 'rom the head should be e1amined, i' there is a good margin still le't
over, it can be re'aced and reused- !t is desirable to mar each valve as it is removed 'rom the guide
so that it may be put bac to its original position- This may save .uite a lot o' time in ad/usting
tappet clearance %hen the engine is reassembled- Moreover, 'itting valve bac to its o%n3guide %ill
ensure proper %oring clearance- $or re'acing valve, re'acing machine is used- !t has a grinding
%heel and a revolving chuc to hold the valve- The post on %hich revolving chuc is 'i1ed is
movable, angle o' %hich can be set and loced in any speci'ic angle-
Be'ore starting grinding, chec up that valve head is running true and valve head is not
protruding out much 'rom the chuc- (ther%ise it %ill not give desired 'inish, then start the coolant
supply directing it /et on grinding stone, bring the valve closer to the regular hammering action, the
tip o' the valve also gets damaged, provision is also made in the valve3re'acing machine to re'ace-
*ASOLN! !N*N! TUN! U# )
BATT!"Y
Clean the battery terminals
Chec the loose connections-
Chec the battery 'or 'i1ing in bo1 or cradle-
Chec up electrolyte level in the battery-
Chec up the capacity o' battery-
&'A"*N* SYST!M
#isually inspect the dynamo 'or any %ear
Chec up 'or any loose connections
Chec the belt 'rom %hich dynamo gets po%er
Chec the charging rate-
STA"TN* SYST!M
#isually inspect the sel'3starter, cable and s%itch
Chec the %oring s%itch 'or any loose connections
Chec the consumption o' current by starter motor-
*NTON SYST!M
Chec the cable connections 'rom distributor to spar plugs
Chec the distributor sha't bushes 'or any looseness
Chec the contact breaer point
Chec the %ear on distributor cam-
Chec the %ear in distributor cap
Chec the ignition system %ith oscilloscope
FU!L SYST!M
#isually inspect 'or any lea
Clean the air cleaner
Chec the 'unctioning o' choe
Chec the 'uel pump pressure
Chec the plunger assembly
&A"BU"!TTO"
Chec the 'uel line 'rom 'uel pump to 'loat chamber
Chec the butter'ly o' the carburetor
Ad/ust the height o' the 'loat
Ad/ust the /et needle and needle /et
A'ter assembling, ad/ust the idle and high3speed ad/ustments
LUB"&ATON SYST!M
Chec the level o' lubrication oil in the crancase
Chec the lubrication oil 'ilter, i' clogged replace it %ith ne% one
!' the oil is bad, remove the oil and introduce ne% oil o' the correct grade
&OOLN* SYST!M
Chec the radiator 'or any damage and blocs
Chec the hoses that connect radiator and engine
Chec 'or any leaage
Chec the 'an belt
Ase clean %ater in the radiation
T"ANSMSSON LN!
#isually inspect the transmission line 'or damages, cracs etc-
Chec the propeller sha't
Chec the di''erential assembly
Chec the state o' lubrication oil in the di''erential assembly
D!S!L !N*N! TUN! U# )
FU!L N6!&TON #UM#
#isually inspect the 'lo% lines 'rom tan to pump and to in/ector
Chec the in/ection pressure
Chec 'or any %ear and tear in the 'uel in/ection pump
Chec the entire components o' the 'uel pump
FU!L N6!&TO"
Chec the in/ector no00le 'or any bloc and clean it thoroughly
Chec the pressure at %hich the no00le sprays the 'uel droplets
Ad/ust the scre% 'or correct pressure
'!AT!" #LU*
Chec the heater plug by connecting it %ith battery terminal
Chec the heater plug 'or any dirt deposition
Replace it a'ter cleaning ii thoroughly
Also chec the air induction system, 'uel 'eed system and other important
components have to be checed 'or per'orming the tune up operations-
&ON&LUSON )
Thus the minor and ma/or tune up o' gasoline and diesel engines %ere per'ormed-
STUDY AND &'!&3N* OF :'!!L AL*NM!NT
T!STN* OF &'AMB!"$ &ASTO"
!(.No);
Date)
AM)
To contact the %heel alignment test on the given vehicles and to 'ind the castor angle and
camber 'or a given vehicles-
TOOLS "!/U"!D)
Wheel alignment gauge, spanner,
5i6 Wheel alignment gauge
5ii6 Toe3in and Toe3out bar
5iii6 Turning table
D!S&"#TON )
The %heel alignment re'ers to the positioning o' the 'ront %heels and steering mechanism
that gives the vehicle directional stability, promotes case o' steering and reduces tyre %ear to a
minimum- A vehicle is said to have directional stability or control i' it can run straight do%n a road,
enter and leave a turn easily and resist road shocs- The 'ront %heel alignment depends upon the
'ollo%ing terms J Camber, Caster, 4ingpin inclination, toe3in and toe3out on turns- The 'ront %heel
geometry or steering geometry re'ers to the angular relationship bet%een the 'ront %heels, the 'ront
%heel attaching parts and the vehicle 'rame- All the above terms are included in the 'ront %heel
geometry- The various 'actors that a''ect the %heel alignment o' the vehicles are given belo%
7- $actors pertaining to %heel
a- Balance o' %heels
b- !n'lation o' tyres
c- Brae ad/ustment
=- Steering &eometry
a- Camber
b- Caster
c- 4ingpin inclination
d- Toe3in and Toe3out
9- Steering linages
>- Suspension System
&amber
The angle bet%een the centerline o' the tyre and the vertical line %hen vie%ed 'rom the 'ront
o' the vehicle is no%n as camber- When the angle is turned out%ard, so that the %heels are 'arther
apart at the top than at the bottom, the camber is positive- When the angle is in%ard, so that the
%heels are closer together at the top than at the bottom, the camber is negative- Any amount o'
camber, positive or negative, tends to cause uneven or more tyre %ear on one side that on the other
side- Camber should not
"1ceed =
8-
$ig ;-7
$ig ;-=
#roce,ure
5i6 Turn the %heel to 98
8
L@S
5ii6 Ad/ust the sprit level such that the bubble occupies the center position-
5iii6 )ote the reading o' the ?8
8
scale-
5iv6 Turn the %heel to 98
8
R@S and the above procedure is repeated and the value
is noted-
5v6 The di''erence bet%een the t%o readings gives the camber angle-
&a0ter
The angle bet%een the vertical line and the ingpin centerline in the plane o' the %heel
5%hen vie%ed 'rom the side6 is called the Caster angle- When the top o' the ing pin is bac%ard, the
caster angle is positive and %hen it is 'or%ard the caster angle is negative- The caster angle in
modern vehicles range 'rom = to F degrees-
Procedure
5i6 Par the car on the turning table
5ii6 Turn the %heel alignment gauge to <8
8
-
5iii6 $i1 the %heel alignment gauge on the %heel-
5iv6 Turn the %heel to =:
8
in R@S-
5v6 Ad/ust the bubble to its original position
5vi6 )ote the reading on the :8
3degree
scale and the noted value %ill give the caster
angle-
"!SULT)
Thus the 'ront %heel geometry o' the given car %as studied
T!STN* 3N* #N N&LNATON$ TO!4N AND TO!4OUT
!(.No)<
Date)
AM)
To conduct the %heel alignment test on the given vehicles and to 'ind the angle and ing3pin,
inclination- Toe3in and toe3out 'or the given angle-
TOOLS "!/U"!D)
Wheel alignment gauge-
Toe3in and toe3out bar-
Turning table-
3N*4#N N&LNATON)
The angle bet%een the vehicle line and the centre o' ing pin 5or6
steering a1le, %hen vie%ed 'rom the 'ront o' no%n as ing Jpin inclination in combination %ith
castor is used to provide directional stability in modern cars, by tending to return the %heels to
straight e''ort particularly %hen the vehicle is stationary- it reduces tyre %ear also the ing3pin
inclination in modern range 'rom > toF
8
-
#"O!&DU"!)
Par the car on the turning table-
$i1 the %heel alignment gauge in the %heel-
Turn the %heel to 98
8
R@S and ad/ust the sprit level such that the bubble
occupies centre position-
TO!4N AND TO!4 OUT)
The 'ront %heels are usually turned in slightly in 'ront so that the
distance bet%een the 'ront ends5A6 is slightly less than the di''erence bet%een the bac ends 5B6 ,
%hen vie%ed 'rom the top the di''erence bet%een these distance is called toe in- the amount o' toe3in
is usually 9 to : mm-The toe in is provided to ensure parallel rolling at the 'ront %heels to stabili0e
steering and prevent side slipping and e1cessive tyre %ear-
Toe out is the di''erence in angle bet%een the t%o 'ront %heels and the caar 'rame during
turns steering system is designed to turn the inside %heel through a larger angle- Then the outside
%heel %hen braing in a turn, the condition causes the %heels to toe3out on turn due to di''erent in
their turning angle, the toe3out is scre%ed by nucle, nobs and 'itness arms-
#"O&!DU"!)
The toe3out bar is positioned 'ront the 'ront o' the vehicle such that the pointer
to %here the %heel and the distance bet%een the %heel is 'ound the scale on
the bar is ept as5A6
Similarly the distance bet%een the 'ront %heels on the rear side is oted-eep it
as 5B6-
$rom the reading, %e can 'ind toe3in and toe3out- !' A,B then it is toe3out, i'
BIA ,then it is toe3in-
TO!4N ON T!"MS)
7- Par the car in the turning table-
=- Turn the %heels to e1treme le't-
9- The readings in both the turn tables are noted- The di''erence in reading %ill
give the toe3out and le't turn-
>- Similarly the values are calculated 'or the right turn-
"!SULT)
Thus the 'ront %heel geometry, ing Jpin inclination- Toe3in, toe3out o' the given car
is studied o' the given car is studied-
B"A3! AD6USTM!NT AND B"A3! BL!!DN*
!(.No)=
Date)
AM)
To study and practice the brae ad/ustment and brae bleeding in a vehicle-
TOOLS "!/U"!D2
Spanner set, scre% driver, hammer ,brae oil-
B"A3! AD6USTM!NT) There are 'our type o' brae ad/ustment are in use-
7-:e,ge ty1e) This type is used in Leyland vachiles a bolt called %edge has a tapper head and can
be scre%ed in or out opera table 'orm the bac o' brae bac palte %hile scre%ing in the %edge
pushes apart the bac o' t%o lin %hich in turn bushing the brae shoe apart- An ad/usting scre%
head 'i1ed %ith serrated %heel
5toothed disc6is scre%ed in or out by moving the serrated %heel %ith scre% driver through an
operating at the bac o' end play-
=-Snail an, can ty1e a,>u0ter) Lever is connected to cam spindle by turning the lever the cam can
be turn the cam is located bet%een the brae shoe and brae lining is 'i1ed over the brae shoe-
When the brae pedal is depressed the cam are turning because o' linage and lever on them contact
the inner sur'ace o' the brae drum-
9-&ran. ty1e a,>u0ter) This is used in Tata vehicle the cran positioning o' an ad/usting bolt
remain in contact %ith the bac o' the shoe, on turning bolt, the cran end %ill push the shoe to
drum-
#"O&!DU"!)
Raise the vehicle until the %heels are o'' the 'loor-
With a %rench loosen the locnut 'or the 'or%ard brae shoe and hold it-
With another an other %rench turns the eccentric to%ards the 'ront o' the vehicle until the
%heel turn 'reely-
While turning the %heel one hand, release the eccentric until the %heel turn 'reely-
@old the eccentric in position and 'asten the locnut-
Repeat this operation to ad/ust the reverse shoe but only turn the eccentric to%ards the bac
o' the vehicles-
-
B"A3! BL!!DN*) The hydraulic brae system %or e''iciently %hen there is no trapped air in
the system- %hen open a pipe or any other component o' a system has run o' brae oil, air is liely to
get into the system and must be removed at once, removing the air 'rom the system is called
bleeding o' brae-
#"O!&DU"!)
To bleed the braes manually chec the 'luid level in reservoir or i' necessary add approved
'luid-
Clean all dirtGs 'orm around the master cylinder plug and clean the bleeding connection-
Attach a bleeder tube to the bleeder valve o' the %heel cylinder-
4eep the other end o' the pipe in a glass bottle-
$or bleeding press the brae pedal > to: times and eep it pressed times- )o% unscre% the
bleed scre% o' %heel cylinder you %ill see brae oil, air bubbles coming out in bottle-
When the pedal goes do%n close the vent scre% again, press the brae pedal > to : times to
build up pressure and eep it last time-
Again loosen the bleed till such time %hen the rae oil start coming 'rom the bleeding tube
'reely o' air bubbles-
At that time tighten the vent scre% and remove the bottle o' bleed pipe-
Similarly the bleeding operation in the rest o' %heel cylinder-
"!SULT) Thus the brae ad/ustment and brae bleeding is studied-
SM#L! TN3!"N* AND SOLD!"N* :O"3S OF BODY
#AN!LS$ STUDY OF DOO"4LO&3 AND :NDO: "SN*
M!&'ANSM
!(.No ) 1?
Date )
AM )
To study the Simple Tinering and Soldering %ors o' body panels, study o' door3loc and
%indo% rising mechanism
TOOLS "!/U"!D )
Spanners, hammers, soldering tools, dolly blocs, dinging hammers, metal shear etc-
D!S&"#TON )
Sol,ering
Soldering is the process o' /oining t%o or more pieces o' metal by means o' 'usible alloy or
metal called solder, applied in the molten state-
Soldering is basically o' t%o types-
7- So't soldering
=- @ard soldering
Soft 0ol,ering
!t is used e1tensively in sheet metal %or 'or /oining parts that are not e1posed to the action
o' high temperatures and are not sub/ected to e1clusive loads and 'orced-
'ar, 0ol,ering
!t employs solders %hich melt at high temperatures and are stronger than those used in so't
soldering- Silver soldering is hard soldering method and silver alloyed either tin uses a solder- The
temperature o' various hard solders varies 'rom ?88 to <88 degrees- The 'lu1es are mostly in the
'orm o' paste and are applied to /oint %ith a brush be'ore heating-
Denting
The process o' body repairing and re'inishing is called denting- !t mainly involves sheet
metal %ors in %hich the damaged body panels and 'enders are straightened or given pro'iles to
mae them loo lie the original item-
The need 'or denting o' a vehicle arises %hen,
The 'enders, doors or panels are /uned-
Panels are t%isted a'ter collision-
A series o' ridges are seen on certain area-
A damaged %rinled panel is to be straightened-
A protruding sheet metal is to be pressed bac into position-
The patches or scratches have come up and the original colour has 'aded-
The denting is also called as dinging process %hich involves number o' processes such as
bending, 'lattening, shearing, 'illing, painting, colour matching etc- These processes are
per'ormed %ith the help o' modern tools are e.uipments most o' %hich are described- Some
tools are very common and essential 'or the denting and are generally re'erred as denting tools-
These are 'ender3straightening hand tools, center punches, metal shears, pull rods, dolly blocs,
dinging hammers et-
:in,o9 ri0ing mec-ani0m
Windo%s are provided in the upper part o' the doors- They are used to admit natural light
%hen closed and allo% in'lo% o' air %hen open- To provide additional passenger space %ithout
increasing the overall vehicle %idth, the %indo% glasses are curved at passenger shoulder level-
They are made o' one3piece sa'ety glass o' bout : J ? mm thicness- Lie %indshield glass they are
also made o' toughened 5tempered6 or laminated glass- The %indo% can be raised or lo%ered by
means o' a %indo% lever through mechanism- A rac and pinion mechanism is employed 'or this
purpose-
DOO" LO&3N* M!&'ANSM )
To o1en form out0i,e
As soon as the push button is pressed, the catch is raised up%ards and the slotted disc rotates
and 'ree 'rom the A3'itting- When the catch is raised up, locing bar is also raised up %ith the catch-
When the A3'itting is 'ree 'rom slotted disc, the door is opened-
To o1en from in0i,e
To unloc the door 'rom inside, the locing bar is raised initially and then inside opening
lever is pulled up- !' this inside opening lever is pulled up the catch is raised and the slotted disc
rotated and 'ee 'rom the A3'itting-
Door in clo0e, 1o0ition
When the door is closed the slotted disc rotates and 'astens into the #3'itting- During this
operation the catch %ith locing bar is also selected into the slot- (nce the slotted side 'astens the #3
'itting, the door is loced-
&ON&LUSON )
Thus, the study o' simple Tinering and Soldering %ors o' body panels, door3loc and
%indo% rising mechanism has been made-
BATTER= AND MAITENANCE
!(. No. )11
Date )
AM )
To study the battery testing , maintenance and 'aults in "lectrical system such a @ead lights,
side or paring lights, tra''icator lights, electrical horn system, %indscreen %iper system, starter
system and charging system-
#"O&!DU"! )
'y,rometer$Battery$'ea,lig-t0$ Trafficator lig-t0 an, #ar.ing lig-t0
The re.uirements o' headlights 'or automobile are that this should illuminate the road ahead
at the reasonable distance %ith su''icient intensity-
The tra''icator are sho%n in the diagram- A solenoid contains a plunger, %hich is 'urther
connected %ith the pivoted indicator arm- When the vehicle has to tae a turn, the driver operates the
tra''icator s%itch- This energies the solenoid %hich pulls the plunger do%n so that the indicating arm
is li'ted up to the hori0ontal position- The direction o' the vehicle about to turn is indicated by it-
:in,0creen 9i1er
Windscreen %iper is operated by means o' a small motor- The motor drives the %orm KAG
%hich rotates the %heel KBG, the sector K"G reciprocates about the 'ulcrumG&G-
This motion is then imparted to a similar sector K$G on the spindle on %hich it is mounted the %iper
arm- Wiper blade is attached to the %iper arm by means o' a spring loc- A rubber3%iping element is
held in place in the %iper blade- When the motor rotates the %iper blade %ipes o'' the glass-
'orn 0y0tem
The electrically operated horn system consists o' a diaphragm and an armature inside a 'ield
coil- The contacts are sho%n closed, %hich is the position %hen the horn s%itch is in the o'' position-
When the driver pushes the horn s%itch the circuit is completed and the 'ield coil produces an em',
%hich causes the armature along %ith it the diaphragm too move do%n, the contacts separate
opening the electrical circuit- The 'ield coil is then de energi0ed and again the armature moves up on
account o' the 'orce o' a mechanical spring, %hich eeps it into the upper most position- This motion
causes the diaphragm to vibrate in up and do%n motion causing the vibrations o' air column belo%
it- These vibrations o' air column subse.uently produce the horn sound, %hich depends upon the
're.uency o' diaphragm- The horn system is used to alert the pass>ngers on the road or the other
vehicles to move a%ay-
$ig ?-7
$ig ?-=
$ig ?-9

$ig ?->
&-arging 0y0tem
The 'unction o' the charging system in an automobile is to generate, regulate and supply the
electrical energy 'or charging the battery- The charging system consists o' a generator 'or converting
mechanical energy 'rom the engine to electrical energy, a regulator to control the amount o'
electrical energy so produced, a relay to regulate the 'lo% o' the charging current 'rom the generator
to the battery relevant to the state o' the charge o' the battery and an ammeter or indicating lamp to
indicate %hether the system is operating or not-
STA"TN* SYST!M )
Te0ting of 0tarter motor
There are t%o methods o' testing a starter motor-
No loa, te0t
Mount the starter motor in a 'i1ture or vice-
The battery, ammeter, carbon pile rheostat, starter motor are connected in series-
The voltmeter is connected in parallel and ground-
Ad/ust the carbon pile rheostat to obtain the speci'ied voltage as recommended by the
manu'acturer-
)ote the ammeter reading
Place the tachometer against the drive end o' the armature sha't to no% the running speed at
no load conditions-
Stall tor@ue te0t
The ob/ective o' this test to no% the overall electrical conditions o' the motor-
A tor.ue bar is used to loc the pinion gear and spring scale connected to the bar-
Ad/ust the carbon pile rheostat to obtain the speci'ied voltage-
)ote the correct value and the spring scale reading-
Stall tor.ue J spring reading 1 length o' the tor.ue arm-
&ON&LUSON )
Thus the battery te0ting $ maintenance an,'aults in electrical system such as head lights, side
or paring lights, tra''icator lightsD electrical horn system, %indscreen, %iper system, starter system
and charging system are studied-

PRACTC! T"! #$%%$&'(:
1.Ad7u(t)$!t &' "$d0 "0y %! +0ut+-4 1#/$4 -!d 1#/$ 0$5$# !d (t$$#%!2 .-$$0 "0y
2.A%# 10$$d%!2 '#&) -yd#u0%+ 1#/$(4 %# 10$$d%!2 &' d%$($0 'u$0 (y(t$)
3.<-$$0 1$#%!2( t%2-t$!%!2 !d d7u(t)$!t
4.Ad7u(t)$!t &' -$d 0%2-t( 1$)
5.R$)&50 !d '%tt%!2 &' ty#$ !d tu1$
!(.No) 1+
Date )
Aim )
To practice the 'ollo%ing
i- Ad/ustment o' pedal plays in clutch, brae, hand brae lever and steering %heel-
ii- Air bleeding 'rom hydraulic braes, air bleeding o' diesel 'uel system
iii Wheel bearings tightening and ad/ustment-
5iv6 Ad/ustment o' head lights beam
5v6 Removal and 'itting o' tyre and tube
TOOLS "!/U"!D )
Spanners, Scre%drivers, @ammers, Scre%drivers, Tyre removing etc-
#"O&!DU"! )
AiB A,>u0tment of 1e,al 1lay
&lutc- 1e,al 1lay a,>u0tment
Clutch pedal 'ree play 5= to > mm6 is ad/usted 'rom clutch release arm %ith clutch operating
'le1ible cable coming 'rom clutch pedal-
While 'itting clutch release arm on the clutch release sha't, 'i1 up the arm such that the
punched mar on the clutch release is shi'ted to%ards the 'ront side but one notch 'rom the punched
mar on the clutch release sha't, a'ter tightening the arm 'i1 up the cable and ad/ust clutch pedal 'ree
play through ad/uster nut 7- !t is not possible to get the desired play then ad/ust %ith ad/uster nut =-
Clutch Repairs and !nspection
7- Clutch 'acing and service limit
=- Loose holding do%n rivets
9- Chec up the tor.ue spring
>- Chec 'or distortion or crac on clutch
:- Chec 'or 'lat run out 5L8-> mm6
?- Chec 'or lateral run out 5L8-; mm6
Bra.e 1e,al 1lay a,>u0tment
The 'ree pedal play should be atleast 7=-; mm or as recommended by the company- The
procedure 'or brae pedal play ad/ustment is as 'ollo%s
Raise the vehicle until the %heels are o'' the road-
With a %rench loosen the locnut 'or the 'or%ard brae shoe and hold it-
With another %rench turn the eccentric to%ards the 'ront o' the vehicle until brae shoe strie
the drum-
While turning the %heel %ith one hand, release the eccentric until the %heel turn 'reely-
$ig <-7 Clutch Linage
$ig <-= Clutch Pedal Play Ad/ustment
$ig <-9
$ig <->
@old the eccentric in position and 'asten the locnut-
Repeat this procedure to ad/ust the reverse shoe- But, turn the eccentric to%ards the bac o'
the vehicle-
Repeat this on all the 'our braes-
Chec the 'luid level in the master cylinder-
A,>u0tment of 'an, bra.e lever 1lay
7- Pull up the paring lever all the %ay %ith one hand to apply brae 'ully and see ho%
many notches o' ratchet the lever has traversed-
=- !' the number o' traversed notches is more than eight, then the paring brae cable has
to be ad/usted-
9- Also, chec the tooth tip o' each notch 'or damage or %ear- !' any damage or %ear is 'ound
replace the paring lever-
Steering 1lay a,>u0tment
To chec the amount o' play in the steering system on vehicles %ith po%er steering, chec
the condition and tension o' the drive belt 'rom the po%er steering pump- Then chec the 'luid level
in the pump reservoir- Start the engine- )e1t, %ith the 'ront %heels in the straight3ahead position,
turn the steering %heel %ith a mar on a ruler or scale- )o% slo%ly turn the steering %heel in the
opposite direction until the 'ront %heels start to move again- The distance that the steering %heel
re'erence mar ahs moved along the ruler is the amount o' 'ree play in the steering system- !' the
steering %heel rim moves too much be'ore the 'ront %heels begin to move, there is e1cessive play-
Air Blee,ing
The purpose o' air bleeding is to remove the air bubbles-
The air bleeding is done by the 'ollo%ing the procedure given belo%2
Be'ore brae bleeding, ensure su''icient oil is present in master cylinder-
Start the process %ith the Wheel cylinder, %hich is 'ar o'' 'rom the master cylinder-
$irst, 'i1 up bleeder pipe in vent scre% provided in the %heel cylinder-
4eep the other end o' pipe in glass bottle-
Press the brae pedal > or : times and eep it pressed the last time-
)o% unscre% the vent scre% o' %heel cylinder-
Brae oil and air bubbles come out in the glass bottle-
When the pedal goes do%n, close the vent scre%-
Again repeat the procedure until all the bubbles are removed-
:-eel Bearing Tig-tening an, A,>u0tment
@oist the vehicle and remove the rear %heel-
Remove spindle cap by hammering at 9 or > locations-
Remove the split pin, castle nut and %asher-
Chec to ensure that the paring brae lever is not pulled up-
Remove the bac plate plug attached to the bacside o' brae plate, so as to increase
clearance bet%een brae shoe and brae drum-
Remove the %heel bearings-
!nsert the ne% stud in drum hole a'ter rotating the stud slo%ly to assure the serrations are
aligned %ith these made by original bolt-
"nsure that all the nuts are tightened properly-
&ON&LUSON )
Thus the 'ollo%ing basic maintenance techni.ues %ere carried out-
5i6 Ad/ustment o' pedal play in clutch, brae, hand brae lever
and steering %heel play-
5ii6 Air bleeding 'rom hydraulic braes, air bleeding o' diesel 'uel
system-
5iii6 Wheel bearing tightening and ad/ustment-
AD6USTM!NT OF '!AD L*'T B!AM )
The headlights o' a vehicle have to be 'ocused to ensure that light 'alls at proper angle on the road-
To ad/ust these proceed as 'ollo%s
Par the vehicle on level ground =: 'eet a%ay 'rom a %hite %all- Dra% three lines A, B and C-
Distance AB should be center distance o' headlights and distance C should be headlight center
height 'rom the ground- )o% s%itch on the light- The ma/ority o' light rays should 'all on circular
area as sho%n- !' one light ray goes up, do%n or side%ise, it should be ad/usted through ad/usting
scre%s 'i1ed in the headlamp body as sho%n
"!MO%AL AND FTTN* OF TY"! AND TUB! )
The procedure 'or the removal and 'itting o' tyre and tube is as belo%2
76 Loosen the %heel nuts o' tyre to be removed-
=6 Place the %edge be'ore and a'ter resting the three %heels to prevent vehicle 'rom rolling-
96 $i1 up /ac and li't the vehicle to the e1tent that %heel is 'ree 'rom ground-
>6 Remove the %heel a'ter removing the %heel nuts-
:6 4eep the %heel 'lat on ground and de'late it a'ter removing valve %ith valve die-
?6 @ammer the tyre at shoulder so that its bead is 'ree 'rom rim on both sides-
;6 Press tyre lever bet%een bead o' tyre and rim 'lange-
F6 Tae another tyre leverD press it in the same %ay a little apart 'rom the 'irst lever-
<6 )o% press both levers do%n- By doing so some portion o' tyre bead %ill come out o' rim-
786 Pull out 'irst lever and insert it again at some distance a%ay 'rom the second lever- Press
it do%n-
776 )o% go on changing the lever till tyre is out o' the rim completely-
7=6 When one bead o' tyre is out tae out the tube a'ter unscre%ing valve body securing nut-
796 !' tyre is to be completely replaced, proceed in the same %ay to remove the second bead-
7>6 !n case, only tube is to be replaced, 'i1 up the ne% tube-
7:6 $inally replace the tyre %ith caution using the levers and in'late it to correct pressure-
&ON&LUSON)
Thus the 'ollo%ing basic maintenance techni.ues %ere carried out-
5i6 Ad/ustment o' pedal play in clutch, brae, hand brae lever
and steering %heel play-
5ii6 Air bleeding 'rom hydraulic braes, air bleeding o' diesel 'uel
system-
5iii6 Wheel bearing tightening and ad/ustment-
5iv6 Ad/ustment o' head light beam
5v6 Removal and 'itting o' tyre and tube-