CODE : 686550

AUTOMOTIVE ENGINE COMPONENTS &

AUTOMOTIVE CHASSIS COMPONENTS LAB

AUTOMOTIVE ENGINE COMPONENTS

LIST OF STUDY TOPICS
1. Introduction to I.C Engines.
2. Study of fuel filter, fuel injection system, carburettor and MPFI system.
3. Study of Ignition system.
4. Study of cooling system.
5. Study of lubrication system.

LIST OF EXPERIMENTS
1. Dismantling, study and Assembling of four stroke, multi-cylinder petrol engine.
2. Dismantling, study and Assembling of four stroke, multi-cylinder diesel engine.

AUTOMOTIVE CHASSIS COMPONENTS

LIST OF EXPERIMENTS
1. Dismantling, study and assembling of single plate clutch system.
2. Dismantling, study and Assembling of sliding mesh gear box.
3. Dismantling, study and assembling of synchromesh gear box.
4. Dismantling, study and assembling of front Axle.
5. Dismantling, study and assembling of Rear Axle.
6. Dismantling, study and assembling of differential unit.
7. Dismantling, study and assembling of steering system.
8. Dismantling, study and assembling of braking system.

AUTOMOTIVE ENGINE COMPONENTS

INTRODUCTION TO I.C. ENGINES

S.Nl:
Date:
Introduction

Internal combustion engine is a heat engine that converts chemical energy of a fuel into mechanical
energy which is made available on a rotating output shaft.
The chemical energy of the fuel is first converted into thermal energy by means of combustion
inside the engine. This thermal energy raises the temperature and pressure of the gases within the
combustion chamber and the high pressure gases then expand against the mechanical components of the
engine. This expansion is converted by the mechanical linkages of the engine to a rotating crankshaft,
which is the output of the engine.
I.C Engine Classification
(i) Based on type of Ignition
a) Spark Ignition Engine (S.I)
b) Compression Ignition engine (C.I)
ii) Based on No-of. Strokes
a) Four Stroke engine
b) Two stroke engine.

iii) Based on the shape of cylinder head

a) I Head.
b) L Head.
c) F Head.
d) T Head.

iv) Based on cylinder arrangement : a) In-line engine

b) Horizontally Opposed engines.
c) V-type engine.
d) Radial engine.
Constructional Details of an I.C Engine
In order to understand the operation, function of the engine, it is very essential that the
constructional features of the I.C engines are known.
The I.C engine produces power with the help of stationary parts such as cylinder block, crankcase,
cylinder head and cylinder liner coupled with moving parts such as crankshaft, connecting rod, piston,
piston rings.
The piston housed by the cylinder is linked to the crankshaft through the connecting rod. The piston
rotates the crank shaft through the connecting rod. The crank shaft revolves due to the reciprocatory motion
of the piston. The crankshaft drives the cam shaft. The camshaft operates the valves by means of cam,
tappet, push rods and rocker arm. The flywheel stores up the energy produced during the power stroke and
releases the energy during the other strokes.
The components are briefly explained as follows.
i) Cylinder Block
The cylinder block is usually cast in a single block of one piece. It has cylinders for piston, ports for
valves and passages for cooling water to flow. Oil passages are provided for lubrication. There are tunnels
in the cylinder block for push rods. These tunnels carry the crank shaft and the cam shaft as well.
ii) Crank Case :
The crankcase is the base of the engine. It supports the crank shaft in bearings. The cam shaft is
also held by the crank case in bearings. This crankcase is fitted with brackets that support the engine on the
frame.

iii) Cylinder Head :The cylinder head has passages for circulation of coolant. It supports the valve, spring and rocker
arm. The head also possesses the inlet & exhaust ports.
iv) Cylinder liners :
The cylinder undergoes wear due to the movement of piston against the cylinder walls. To prevent
the cylinder from wearing, a cylinder liner is used which can be replaced when it is worn out. Cylinder
liners are cast centrifugally in the shape of a barrel using a special iron alloy. They can be classified into
dry and wed type of liners.
v) Piston
The piston reciprocates within the cylinder. Nowadays pistons are manufactured from aluminium
alloys and are made in one piece. The top portion of the piston gets the maximum heat during the
combustion process.
There are piston rings in the piston to prevent any leakage. Suitable grooves are provided on the
piston to fit in the rings. There are holes provided in the piston to house the gudgeon pin and is seated to
accommodate the connecting rod.
vi) Piston rings
a) Compression rings
It is made of cast iron. The rings are installed in the grooves of the piston. The rings press tightly
against the cylinder wall and therefore the fresh mixture and exhaust gas cannot pass through the
piston clearance.
b) Oil rings
As the piston reciprocates, it rubs against cylinder wall and causes scratches on the piston
and cylinder wall. To prevent the rubbing, oil is splashed to the cylinder wall through the oil rings.
No of oil rings depends upon the design of the piston.

vii) Poppet Valve.

The poppet valve has its head in the shape of a mushroom and so it is also called mushroom valve. It
has a head, stem and a spring retainer lock groove.
viii) Connecting Rod
It is generally manufactured using steel or duraluminum. The top of the connecting rod called the small
end in connected to the piston pin and the bottom end called the big end is fitted to the crank shaft.
ix) Crankshaft.
The crank shaft is made of forged steel. The main parts of the shaft are journals, crankpins, crank
webs. The journals rotate the main bearings. The crank pin rotates the big end bearing of the connecting
rod. The webs join the journal to the crank pin and serve as balance weights.
The flywheel is fitted to the rear end of the crank shaft. A fan pulley is fitted in the front end of the
crank shaft. Holes are provided in the crankshaft from the main bearing journals to the crank pins for
the lubricating oil to pass through.
x) Cam shaft.
It is made of forged steel or of cast iron. It has cams for operating the inlet and exhaust valves
against the pressure of the valve springs. A gear is fitted to one end of the camshaft to get the drive
from crank shaft.

S.N. 2.

STUDY OF FUEL FILTER, FUEL INJECTION SYSTEM,

CARBURETTOR & MPFI

Date :

Functions of fuel Supply Systems

Certain functions of fuel supply systems are,
i)

Storing of fuel.

ii)

Filtering of fuel.

iii)

Delivery of fuel to injection pump.

iv)

Injecting the fuel into engine cylinders.

v)

Controlling the engine speed.

Fuel Injection System

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

Common rail fuel injection system

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

ii)

Individual pump fuel injection system

Here, fuel is drawn from the fuel tank by means of a fuel feed pump which is operated from
the injection pump cam-shaft. The fuel injection pump then injects definite quantity of fuel in to
the individual cylinders in turn according to the firing order, through injectors fitted on them.
The injection pump is gear driven from the engine crankshaft so that it is driven at half the
engine speed. There is a governor which provides automatic speed control, relative to any set
position of the accelerator pedal.

Fuel Filter :
The most commonly used primary filter is the wire gauze installed on the suction side of the feed
pump. A better alternative is to use a sedimentation type primary filter. The fuel from the tank enters the
filter and flows around the conical diffuser funnel to accelerate downwards to the sediments chamber. The
secondary filter is installed after the feed pump and it separates out abrasive particles and any water in the
fuel. The fine pores of the filter element retain the abrasive particles and other solid impurities.
Carburettors
Functions of a carburettor
i)

To keep a small reserve of fuel at a constant head,

ii)

To vaporise the fuel to prepare a homogenous air-fuel mixture.

iii)

To supply correct amount of air-fuel mixture at the correct strength under all conditions of load
and speed of the engine.

Types of carburettors
i)

Simple Carburettor

ii)

Carter Carburettor

iii)

Zenith Carburettor

iv)

S.U. Carburettor

v)

Solex Carburettor

vi)

Solex Mikuni double venturi carburettor.

Simple Carburettor
The main parts are a float chamber, fuel jet, venturi, nozzle and a throttle valve. The needle valve
attached to the float lever serves to close or open the fuel inlet to the float chamber depending upon the
requirements. When the fuel level falls below a definite predetermined value, the float also falls along
with the fuel level, thus opening the passage for the fuel supply. The fuel starts flowing in and the float
rises gradually till the fuel level reaches the desired value. At this time, the float needle closes the fuel
inlet passage. Thus a constant head of fuel is maintained in the float chamber. This constant level of
fuel is slightly below the nozzle outlet, so that the fuel may not drop all the time from the nozzle, even

when the engine is not working. A small vent in the float chamber keeps the pressure inside is
atmospheric. The fuel supply from the float chamber at any time is metered by means of a fuel jet from
where the fuel flows to the venturi through the discharge nozzle. The venturi is simply a restriction in
the air passage. Thus due to less area, the air velocity increases and because of this increase in velocity,
decrease in pressure is caused at the nozzle which is located in the venturi itself. Due to depression
being applied at the nozzle, the fuel comes out and is vaporized by the coming air stream. The mixture
then goes to the inlet manifold, to the engine cylinders. The amount of fuel delivered depends upon the
jet size, float level and venturi vacuum. The purpose of a throttle valve is to control the quantity of air
fuel mixture. It is attached to the accelerator pedal by means of suitable linkage so that when the pedal
is depressed the valve opens out.
MPFI. (Multi Point Fuel Injection)
In this system, there is a separate injector for each cylinder mounted in the inlet port. The injectors
direct fuel onto the back of the valve giving improved mixture preparation and distribution compared to
the conventional single point and carburettor systems. Air metering is controlled by a throttle body and
butterfly valve fitted in the intake manifold.

STUDY OF IGNITION SYSTEM

S.No: 3
Date:
Function

The function of the Ignition system is to produce a spark in the engine cylinder towards the end of
the compression stroke.
Types of Ignition System
i)

Battery Coil Ignition System.

There are two basic circuits in the system, the primary and the secondary circuit. The battery,

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

Magneto Ignition System

In the magneto ignition system, it is the magnet which produces and supplies the current in
the primary winding. The other parameters are same as that of battery coil ignition system.
The magneto ignition system is of two types.
a) Rotating Armature type.
b) Rotating Magnet type.

Advantages over rotating armature type

a) Larger armature may be provided, which means more space for insulation.
b) No centrifugal stresses occur in the windings, because these remain stationary.
c) Contact breaker and condenser are also stationary.
iii)

Electronic Ignition System.

In the electronic ignition system a timer is employed in the distributor instead of a contact
breaker. This timer may be a pulse generator or a Hall Effect switch which triggers the
electronic ignition control unit. This control unit primarily contains transistor circuit whose base
current is triggered off and on by the timer which results in the starting and stopping of the
primary current. Other than this, the electronic ignition system works similar to the
conventional system.

STUDY OF COOLING SYSTEM COMPONENTS

S.No. 4
Date:
Introduction

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

Air Cooling

ii)

Water Cooling
a) Thermosyphon System of cooling
b) Pump circulation system.

Components of water cooling system

i)

Radiator.
The function of the radiator is to ensure close contact of the hot coolant coming out of the
engine with outside air, so as to ensure high rates of heat transfer from the coolant to air. A
radiator consists of an upper tank, core and the lower tank. Besides, an overflow pipe in the
upper tank and drain pipe in the lower tank are provided. Hot coolant from the engine enters the
radiator at the top and is cooled by the cross flow of air, while flowing down the radiator. The
coolant collects in the collector tank from where it is pumped to the engine for cooling.

ii)

Pressure Cap and expansion reservoir

A pressure cap contains a pressure valve and a vacuum valve. When due to severe working
conditions, the coolant starts boiling and vaporises, the pressure in the system exceeds a certain
predetermined value, the pressure blow-off valve open releasing the excess pressure to the

atmosphere through the overflow pipe. On the other hand if due to any reason a vacuum is
created inside, the vacuum valve operates to avoid collapse of the radiator.
iii)

Thermostat
To keep a rigid control over the cooling, a thermostat is used, which automatically keeps the
cooling water temperature at a pre-determined value. Moreover, it also helps the engine to reach
the operating temperature as soon as possible after starting.
Two types of thermo stats are used in automobiles
a) Bellows or aneroid type.
b) Wax or hydrostatic type.

iv)

Coolant Pump:
A coolant pump is a necessity for the forced circulation type of engine cooling system. The

pump is mounted at the front end of the engine and is driven from the crank shaft by means of a v-belt.
Centrifugal type pump is the one which is used for this purpose. The coolant from the radiator enters the
pump at the centre where inlet is located. The flow of the coolant depends upon the pump speed which is
proportional to engine speed. The main parts of the pump are casing and a shaft mounted impeller having
number of vanes. The impeller shaft is mounted on bearing while the seal serves to prevent the leakage of
coolant around the shaft.
v)

Fan
When the vehicle is going at high speed with light load, the natural draft of air passing through the

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

STUDY OF LUBRICATION SYSTEM COMPONENTS

S.No. 5
Date :
Introduction

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

It reduces the friction between moving parts & so that power loss in minimum.

ii)

It reduces wear of the moving parts.

iii)

It provides cooling effect.

iv)

It provides cushioning effect.

v)

It provides cleaning action.

vi)

It provides sealing action.

Systems of Engine Lubrication

The various systems adopted for the lubrication of automobile engines are
i)

Petroil System.

ii)

Splash System.

iii)

Pressure System.

iv)

Dry-Sump System.
The main parts of an automotive engine which require lubrication are

i)

Main crankshaft bearings.

ii)

Big end bearings.

iii)

Gudgeon pin bearings.

iv)

Piston rings & Cylinder walls.

v)

Timing Gears.

vi)

Camshaft and camshaft bearings.

vii)

Valve Mechanisms.

viii)

Electrical Equipments.

Components of Lubrication System

i)

Oil Strainers.
Oil strainer is attached at the inlet of the oil pump to guard it against the entry of grit etc. The

strainer is made of ordinary wire mesh screen. A good practice is to install a floating strainer, which is
hinged to the oil pump inlet. The floating strainer remains at the surface of the oil, whereas the grit,
dust etc., remains at the bottom of the crankcase. The result is that very small amount of impurities
goes to the strainer screen and hence the chances of it being blocked up are minimised.
ii)

Oil Pumps
Next to oil strainer in the lubrication system sequence, comes the pump. Its function is to
supply oil under pressure to the various engine parts. The oil pump is generally located inside
the crankcase below the oil level.
The pump is usually driven from the end of the distributor shaft, which gets its drive from
the camshaft through a skew gear if a low-mounted camshaft is employed. In some automobile
engines mounted transversely, the oil pump is driven directly from the camshaft end through a
coupling, since no separate shaft is required, this is a compact arrangement. The oil pressure in
the engine increases with the increase in engine speed which would increase the pump speed.
The size of the pump should be sufficient to maintain the desired pressure with reasonable
amount of wear. The different types of pumps used are.
a) Gear Pump.
b) Vane Pump.
c) Rotor Pump.
d) Plunger Pump.

iii)

Oil Filters
The lubricating oil with use is deteriorated resulting in the formation of sludge, lacquer and
carbon. Further it is contaminated by various by-products of combustion of fuel. In addition to
these the fine particles of metal due to wear are the other impurities present in the oil. It is
therefore necessary to remove these impurities to avoid permanent damage to any running parts
of the engine. Commonly used materials for filtering are wire gauze, cotton, plastic
impregnated paper etc. The filtering element must let the oil pass through without much
resistance, but should prevent the undesirable particles from entering the oil galleries.

Oil filters are basically of two types, the primary and the secondary, the primary filter is also
called as surface filter or strainer since the impurities are retained on the outer surface of the
filter. The secondary filters used in the automobile engines are of various kinds.
a) Cartridge Type.
b) Edge Type.
c) Centrifugal Type.
iv)

Oil Coolers.
In all heavy duty engines, the temperature of oil becomes quite high because of high engine
temperature. As the viscosity of the lubricating oil decreases with temperature rise, the oil film
in the bearings might break and the conditions of boundary lubrication may be created instead
of fluid lubrication which is desired. To avoid such thing oil coolers are provided. Oil coolers
are simple heat exchangers.

v)

Oil Pressure Gauges

If any leakage occurs at any part of the lubrication system, the pressure in the entire system
would fall, reducing consequently the oil supply to various bearings as a result of which they
are bound to starve and be damaged. Thus is very important for the driver to keep a watch on
the oil pressure in the gauge. The gauges generally are bourdon type or electrical type.

Exp : 1

DISMANTLING, STUDY AND ASSEMBLING

Date :

OF 4S, MULTI CYLINDER

PETROL ENGINE

Aim :
To dismantle, Study and assemble the given four stroke, Multi Cylinder petrol engine.
Tools Required
i)

Double end spanner.

ii)

Socket Spanner.

iii)

Screw Driver

iv)

Extension rod.

v)

Vernier Calliper.

vi)

Telescopic Gauge.

Dismantling Procedure
i)

Remove the crank shaft pulley and the timing gear set up. Notice that you have marked the
reference point.

ii)

Remove the rocker cover

iii)

Remove the inlet manifold from the cylinder head. The carburettor along with the air filter
should also be removed.

iv)

Remove the exhaust manifold from the cylinder head.

v)

Remove the rocker arm assembly and the push rods.

vi)

Dismount the cylinder head after removing the lock nuts.

vii)

Tilt the engine and then remove the crank case and the oil pump. Make sure you have
drained the oil completely before removing the crank case.

viii)

Remove the connecting rod big end cap and its bearing.

ix)

Remove the piston along with the connecting rod.

x)

Remove the oil and compression rings from the piston.

xi)

Remove the crankshaft main bearing and pull out the crankshaft.

xii)

Remove the camshaft finally.

Study
i)

The engine is a 4 Cylinder, in line type engine.

ii)

The arrangement of valves is over head valve type.

iii)

The type of cooling is water cooled.

iv)

The type of lubrication in pressure lubrication.

v)

The crankshaft has got three main bearings.

Assembling Procedure.
i)

Fit the crankshaft and cam shaft along with its bearings.

ii)

Neatly clean the rings and lubricate them with grease before placing them in the groove of
the piston.

iii)

Fit the piston along with the connecting rod within the cylinder block.

iv)

Fit the big end of the connecting rod and tighten the lock nuts appropriately.

v)

Fit in the crank case and fill them with the oil.

vi)

Mount the cylinder head suitably and tighten the lock nuts.

vii)

Appropriately fit in the push rod and the rocker arm assembly.

viii)

Fit the exhaust and the intake manifold along with the accessory components.

ix)

Mount the rocker cover and tighten the lock nuts.

x)

Finally position the timing gear according to the reference point and fit it.

xi)

Fit the pulley and tighten them correspondingly.

Result :
Thus the given 4-stroke, 4-Cylinder Petrol engine was dismantled, studied and assembled.

Ex : No : 2

DISMANTLING, STUDY AND ASSEMBLING

Date :

OF 4-STROKE MULTICYLINDER DIESEL ENGINE

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

Double end spanner.

ii)

Ring spanner.

iii)

Screw Driver & Hammer.

iv)

Telescopic gauge.

v)

Vernier Calliper.

Dismantling Procedure
i)

Remove the crank shaft pulley along with the timing gear. Make sure you have marked the
reference point.

ii)

Remove the rocker cover

iii)

Dismount the intake manifold and its accessories. Remove the fuel injector along with the
pump.

iv)

Remove the exhaust manifold.

v)

Remove the cylinder head by unlocking the lock nuts. Before doing so, ensure that you have
removed the valves along with the rocker arm assembly and the pushrods.

vi)

Remove the crankcase and drain the oil.

vii)

Remove the connecting rod big end cap

viii)

Remove the piston along with the connecting rod.

ix)

Remove the piston rings along with the circlips.

x)

Remove the crankshaft bearings and pull out the crank shaft.

xi)

Remove the camshaft as well.

Study :
i)

The given engine is a 4-cylinder, 4-stroke In-Line vertical type engine.

ii)

The engine is water-cooled and is pressure lubricated.

iii)

The fuel is directly injected (DI injection). Naturally aspirated.

iv)

Valve arrangement is over head valve type.

Assembling Procedure
i)

Fit the crank shaft and the cam shaft assembly in the corresponding space provided in the block.

ii)

Carefully insert the piston along with the connecting rod. Note that you have properly cleaned
and lubricated the rings before assembling.

iii)

Fit the connecting rod big end cap and tighten the lock nut.

iv)

Fit in the crankcase along with the lubricating oil.

v)

Mount the cylinder head and tighten the lock nuts.

vi)

Place the push rods, rocker arm assembly and the valves correspondingly.

vii)

Mount the intake and exhaust manifold respectively.

viii)

Fit the fuel injection system along with the injector.

ix)

Fit the rocker cover and tighten the lock nut.

x)

Fit the crankshaft pulley along with the timing gear set up based on the reference point.

Result :
Thus the given multi cylinder diesel engine is dismantled, studied and assembled.

AUTOMOTIVE CHASIS COMPONENTS

DISMANTLING, STUDY AND ASSEMBLING OF

Ex.No. 3

CLUTCH SYSTEM

Date
Aim :

To dismantle, study and assemble the given clutch system.

Tools Required
i)

Double end spanner

ii)

Ring Spanner

iii)

Socket with extension

iv)

Screw Driver

v)

Hammer.

Dismantling Procedure
i)

Hold the clutch cover assembly in the vice.

ii)

Remove the lock nuts of the clutch cover by compressing the cover spring with the help of a
special tool.

iii)

Remove the clutch spring, release lever, adjusting screw and cotter pin from their locations.

iv)

Finally take out the clutch plate and the pressure plate separately.

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

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

Place the cultch springs, adjusting screw, Cotter pin, Release lever, lock plate in the appropriate
locations.

ii)

Place the clutch cover over the springs and then the cover is held by means of the special tool to
compress the springs

iii)

Assemble the cover by tightening the lock nuts.

Result :
Thus the given single plate clutch was dismantled, studied and assembled.

Ex. No. 4

DISMANTLING, STUDY AND ASSEMBLING

Date :

OF SLIDING MESHGEAR BOX

Aim:
To dismantle, study and assemble the given sliding mesh gear box.
Tools Required
i)

Double end spanner.

ii)

Ring Spanner.

iii)

Socket with extension

iv)

Hammer.

v)

Screw Driver.

Dismantling Procedure
i)

Remove the clutch shaft from the gear box.

ii)

Remove the main shaft with the gears

iii)

Remove the idler (or) reverse gear from its shaft in the gear box.

iv)

Remove the lay shaft from the gear box.

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

Assemble the lay shaft in the gear box housing.

ii)

Position the reverse (or) idler gear in its location.

iii)

Assemble the main shaft with gears in the appropriate place.

iv)

Put back the clutch shaft in the other end of the gear box.

v)

After fitment of all the shaft and gears, the gear box is checked for proper working in all
gears.

Result :
Thus the given sliding mesh gear box is dismantled, studied & assembled.

DISMANTLING, STUDY AND ASSEMBLING OF

Ex. No.5

SYNCHROMESH GEAR BOX

Date :
Aim :

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

Tools Required
i)

Double end spanner.

ii)

Socket with extension.

iii)

Hammer.

iv)

Screw Driver.

v)

Ring Spanner.

Dismantling Procedure
i)

Remove the clutch shaft from the gear box.

ii)

Remove the gears from the main shaft and then remove the main shaft.

iii)

Remove the synchronizer ring from the main shaft.

iv)

Remove the idler gear from its shaft.

v)

Remove the lay shaft.

Assembling Procedure
i)

Fit the lay shaft.

ii)

Assemble the idler gear shaft and the idler gear.

iii)

Place the gears in the main shaft appropriately.

iv)

Fit the synchronizer ring in its position.

v)

Fit the clutch shaft into the gear box assembly.

vi)

Finally check proper working of the system.

Result :
Thus the given gear box was dismantled, studied and assembled

Ex. No. 6

DISMANTLING, STUDY AND ASSEMBLING

Date :

OF FRONT AXLE

Aim :
To dismantle, study and assemble the given front axle.
Tools Required.
i)

Double end Spanner.

ii)

Ring Spanner.

iii)

Socket with extension.

iv)

Hammer.

v)

Screw driver.

Dismantling Procedure
i)

Remove the steering knuckle arm joint.

ii)

Remove the wheel bearing.

iii)

Remove the brake shoe assembly.

iv)

With the use of king pin remover, remove the king pin.

v)

Finally remove the steering knuckle.

Study :
Conventionally the front axle is a dead axle. However for four wheel drive vehicles and most of the
cars, it is a live axle. The majority of front axles have steel I beam for the main member. Front axle
consists of a beam, which extends across the underside of the vehicle for almost the entire width of the
tread.
Swivelling device is attached to both ends of this beam. The beam is attached to the vehicle frame
by means of springs. The swivelling device is called steering knuckle. The steering knuckle is attached
to the beam by means of kingpins.

Components of front Axle

Type of stub Axles
i)

Elliot Axle.
In the Elliot axle, each end of the main beam is open to form a C-Shaped yoke. The steering
knuckle fits between the upper arms of this yoke. The king pin extends through the upper arm of
this yoke through the knuckle and in to the lower arm of the yoke. Usually the king pin is secured in
the steering knuckle so that when the knuckle swivels, the king pin turns in the yoke.
Reverse Elliot Axle :
In reverse Elliot axle, the yoke is a part of the steering knuckle and fits over the end of the
axle. The king pin is secured in a vertical hole through the end of the axle beam and the knuckle
swivels on it.
Steering knuckles :
The steering knuckle consists of a spindle for the wheel, devices for attaching the unit to the
main beam or axle and an arm for holding the knuckle in any desired position in its swing or travel.
Steering knuckle arm
The steering knuckle arm is a lever for swivelling the knuckle. One end of the arm is
secured to the knuckle. The free end of the arm is made with either a ball or a hole for attaching the
rod.
Assembling Procedure
i)

Carefully position the steering knuckle.

ii)

Fit the king pin appropriately in the steering knuckle.

iii)

Mount the brake shoe assembly in the position appropriately.

iv)

Fit the wheel bearings.

v)

Connect the steering knuckle arm to the tie rod assembly.

Result :

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

Ex. No. 7

DISMANTLING, STUDY AND ASSEMBLING

Date :

OF REAR AXLE

Aim:
To dismantle, Study and assemble the given rear axle.
Tools Required
i)

Double end spanner.

ii)

Socket with extension

iii)

Ring spanner.

iv)

Hammer.

v)

Screw driver.

Dismantling Procedure
i)

Remove the wheel bearing.

ii)

Remove the brake drum from the brake assembly unit.

iii)

Remove the brake shoe assembly.

iv)

Remove the taper bearings of the half axle Shafts.

v)

Pull the half axle shafts that are splined to the sun gear of the final drive unit.

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

Weight of the body.

ii)

Driving thrust.

iii)

Torque reaction.

iv)

Side thrust.

There are two rear axle drives. In all the drives employed for near axle, the springs take the weight of
the body. The drives are

i)

Hotchkiss Drive.

ii)

Torque Tube drive.

Types of Rear Axle Shaft support

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

Fully Floating axle.

The axle shafts have flanges at the outer ends, which are connected to the flanged sleeve by means

of bolts. There are two taper roller bearings supporting the axle casing in the hub, which take up any
side load. Thus is this case the axle carries only the driving torque.
Assembling Procedure
i)

Insert the half axle shafts such that the inner end is keyed to the sun gear of the final drive unit.

ii)

Fit the taper roller bearing in the appropriate position within the housing of the axle casing.

iii)

Fit in the brake shoe assembly.

iv)

Fit in the wheel bearing and complete the assembly process.

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

Ex. No. 8

DISMANTLING, STUDY & ASSEMBLING OF

Date :

DIFFERENTIAL UNIT

Aim :
To dismantle, Study and assemble the given differential unit.
Tools Required.
i)

Double end spanner

ii)

Socket with extension

iii)

Ring spanner.

iv)

Hammer.

v)

Screw driver.

Dismantling Procedure
i)

Remove the two half axle shafts of the rear axle.

ii)

Remove the crown wheel with the differential assembly.

iii)

Disconnect the differential assembly from the crown wheel by removing the mounting bolts.

iv)

Finally remove the sun gear, planet pinion and cross pin or spider from the differential
assembly.

Study
To the crown wheel of the final drive is attached a cage, which carries a cross pin or a spider. Two
sun gears mesh with the two or four planet pinions. Axle half shafts are splined to each of these gears.
The crown wheel is free to rotate on the half shaft.
When the vehicle is going straight, the cage and the inner gears rotate as a single unit and the two
half shafts revolve at the same speed. In this situation there is no relative movement among the various
differential gears.
When the vehicle is taking a turn, assume that the cage is stationary. Then turning one sun gear will
cause the other to rotate in the opposite direction. That means that if left sun gear rotates n times in a

particular time, the right sun gear will also rotate n times in the same period but in the opposite
direction. This rotation is super imposed on the normal wheel speed when the vehicle is taking a turn.
Assembling Procedure
i)

Assemble the differential unit by keeping all the planet pinions in the cross pin and by
positioning the sun gears in the cage.

ii)

Fit the differential unit with the crown wheel by tightening the mounting bolts.

iii)

Assemble the crown wheel with the differential unit in the rear axle and ensure that the
crown wheel tooth meshes with the pinion teeth.

iv)

Finally the two half shafts of the rear axles are positioned and checked for proper working
conditions.

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

Ex. No. 9

DISMANTLING, STUDY AND ASSEMBLING

Date:

OF STEERING SYSTEM

Aim :
To dismantle, study and assembly the given steering system.
Tools Required
i)

Double end spanner.

ii)

Socket with extension.

iii)

Ring Spanner.

iv)

Hammer.

v)

Screw Driver.

Dismantling Procedure
i)

Remove the joint that connect the steering gear box and the steering column.

ii)

Remove the drop arm from the cross shaft of the steering gear box unit.

iii)

Remove the other linkages such as link rod, track rod, track arm.

iv)

Finally the steering gear box is dismantled.

Study :
Functions of steering system
i)

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

ii)

To provide directional stability.

iii)

To provide perfect steering condition.

iv)

To facilitate straight ahead recovery.

v)

To minimise tyre wear.

Construction of a Steering System

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

Worm and wheel steering gear

ii)

Worm and nut steering gear.

iii)

Re-circulating ball type steering gear

iv)

Rack & pinion steering gear.

Assembling Procedure
i)

Fit the components of the steering gear box.

ii)

Assemble the track arm, tie rod, link rod with the corresponding linkages.

iii)

Fit the cross shaft to the drop arm.

iv)

Fit the steering column to the steering gear boy.

v)

Check the assembly for proper working of the steering system.

Result :
Thus the given steering system was dismantled, studied & assembled.

Ex.No. 10

DISMANTLING, STUDY AND ASSEMBLING

Date :

OF BRAKING SYSTEM

Aim :
To dismantle, study and assemble the given braking system.
Tools Required
i)

Double end spanner.

ii)

Socket with extension.

iii)

Ring Spanner.

iv)

Hammer.

v)

Screw driver.

Dismantling Procedure
i)

Drain the hydraulic fluid from the master cylinder first.

ii)

Remove the linkages connected to the braking assembly from brake pedal till the brake shoe
assembly.

iii)

Remove the brake drum.

iv)

Remove the wheel cylinder within the brake shoe assembly.

v)

Remove the retainer spring which is fired to the shoes.

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

Methods of Braking
i)

Mechanical Braking.

ii)

Hydraulic Braking.

iii)

Electric Braking.

iv)

Vacuum Braking.

v)

Air Braking.

Components of Hydraulic Braking

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

Master Cylinder
In can be rightly named as the heart of the hydraulic braking system. It contains the reservoir for the

brake fluid. It is operated by the brake pedal and is further connected to the wheel cylinders in each
wheel through steel pipe lines, unions and flexible hoses.
There are two main chambers. One is the fluid reservoir and the other is the compression chamber
in which the piston operates. The fluid in the reservoir compensates for any change in the fluid volume
in the pipelines.
These are a number of holes in the piston head on the high pressure side. Two holes connect the
fluid reservoir to the compression chamber. The push rod is operated with the foot brake pedal through
linkage. As the pedal is pressed, push rod moves the piston to the left against the force of the spring, till
it covers the by-pass port. Further movement of the push rod causes building up of pressure in the
compression chamber. Finally when sufficient pressure has built-up, the inner rubber cup of the fluid
check valve is deflected, forcing the fluid under pressure in the lines. This fluid enters the wheel
cylinder and moves the pistons there by applying the brakes.

Wheel cylinders.
They are meant to force the brake shoes against the drum. Each wheel cylinder is provided with
pistons, rubber seal, springs and dust covers. The brake line from the master cylinder is attached to the
inlet port and a bleeder screw with a cover is provided to bleed air from the system. Wheel cylinders
are mounted on the back plate.
When brakes are applied the fluid under pressure from the master cylinder enters the inlet port and
forces the piston to move outwards to push the shoes against the drum. Similarly when the brakes are
released, the brake shoe retractor springs force the brake fluid out of the wheel cylinder by pushing the
piston inwards.
Assembling Procedure
i)

Fit the retractor spring and the wheel cylinders appropriately.

ii)

Mount the brake drum over the brake shoe assembly and tighten the lock nuts.

iii)

Fit the linkages from the master cylinder to the wheel cylinders including the rubber hoses.

iv)

Fill the reservoir of the master cylinder with the brake fluid and remove any air present
inside the cylinder.

v)

Fit the master cylinder and connect the push rod of the cylinder to the corresponding link of
the brake pedal.

vi)

Finally ensure proper working of the brake system.

Result :
Thus the given brake system was dismantled, Studied and assembled.