B.E./B.Tech. DEGREE EXAMINATION, APRIL/MAY 2013 .

Automobile Engineering

708AMT03 - VEHICLE MAINTENANCE.

Time: Three hours Maximum : 100 marks

Answer ALL questions.

PART A (10 x 2 = 20 marks)

1. What are the advantages of scheduled maintenance?

2. List out importance of maintenance.
3. Write short notes on logbook.
4. List out the special tools to be used in the maintenance of an engine.
5. Define clutch drag and clutch slip.
6. What do you mean by toe-in and toe-out?
7. What is tyre rotation?
8. What are the causes for radiator boiling?
9. What is meant by Brake pedal play adjustment
10. Mention the types of tyre wear.

Part -B
11. (a) Discuss in detailed way about the various forms used in vehicle maintenance (16)
(Or)
(b) (i) Discuss about the preparation of maintenance check list (8)
(ii) Explain the periodic maintenance of a diesel vehicle. (8)

12. (a) Explain the step-by-step procedure of dismantling of multi cylinder diesel engine. (16)
(Or)

(b) Explain engine tune-up? What are all special tools used for maintenance and overhauling draw
them. (16)

13. (a) Discuss the various troubles experienced in steering system and explain their causes and
remedies. (16)

(Or)

(b) Explain in detail:

 (i) Clutch pedal play
(8)
(ii) Brake pedal play
(8)
14. (a) Explain the maintenance procedure and the various tests to be conducted on a lead acid battery

(16)
(Or)
(b) (i) Explain briefly about the maintenance of D.C Generator and alternator (8)
(ii) Describe in detail about the adjustment and testing of headlight aiming (8)

15. (a) Write notes on the following:

(i) Window rising mechanism (8)
(ii) Door locks mechanism. (8)
(Or)
(b) Explain the procedure for removal and fitting of tyre and tube:
(16)
 Answer Key
Part –a
1. Advantages of scheduled maintenance
* It reduces cost of operation, it renders work scheduling easy, it reduces starting problem, Control of store inventory
easy.

2. Importance of Maintenance
* To keep the vehicle available for protective work for maximum period, to extract optimum life for the vehicle, to
get maximum utilization of vehicle at minimum cost.

3. The log book contains the following details:

*Distance covered, Fuel consumption, Average fuel consumption, best and worst mileage

4. Special Tools
*Double spanner, Ball-peen hammer, Pliers, Feeler gauge, Socket Spanner, Wrenches, Screwdriver

5. Clutch drag:
*A dragging clutch or clutch drag will make the transaxle or transmission grind when trying to engage or shift gears. This
state results when the clutch disc does not completely disengage from the pressure plate or flywheel when the clutch
pedal is depressed.
Clutch slip:
*A clutch slip occurs when the driver of a vehicle alternately applies and releases the clutch to achieve some movement
of the vehicle. It's called a 'slip' because the clutch plate will slip against the flywheel surface when such an action is
performed

6. Toe-in:
*The front wheels are usually turned in slightly in front so that the distance between the front ends is slightly less
than the difference between the back ends, when viewed from the top. The difference between these distances is
called toe-in
Toe-out:
*Toe-out is the difference in angle between the two front wheels and the car frame during turns. The steering system
is designed to turn the inside wheel through a larger angle than the outside wheel when making a turn.

7. Tyre Rotation:
*Tyre rotation or rotating tires is the practice of moving automobile wheels and tires from one position on the car, to
another,to ensure even tire wear.

8. Causes for Radiator Boiling:

Poor ventilation, failure of radiator fan, leakage in hoses

9. The Brake pedal play

The Brake pedal play should be at least 12.7 mm with wrench turn the eccentric towards the front of the vehicle until
brake shoe strike the drum. While turning the wheel with one hand, release the eccentric until the wheel turn freely.

10. Type’s tyre wears:

Toe-in or toe-out wear,Camber wear, Cornering wear, uneven tire wear, High-speed wear
 Answer Key
Part –b

11.(a) Various Forms:

(i) Road Test Report (6)
*The road test report gives a fare idea of the condition of the vehicle before and after the
maintenance operation.
*The road test inspector or the machine makes the road test report after the completion of the
maintenance operation.
*This report contains the vehicle reg number, chassis number, job no, date of test etc.
*The parameters to be checked include the following:
*Front side and rear side abnormal noise.
*Steering and brake caliper noise.
*Ilunting, misfiring, sudden stoppage of vehicle.
*Brake condition.
*Wheel and bearing check.
*Pick up of the vehicle.
*Mileage of the vehicle etc.

(ii) Trip Sheet: (5)

*The trip sheet gives the entire details of the vehicle before and after a trip. The starting km and ending km, time of start and
closing of the journey time and the charges per km and also the overall cost of trip is described in the trip sheet.

(iii) Logbook : (5)

The logbook of a vehicle gives the details of the vehicle, which will be useful not only for the
owner of the vehicle but also to the mechanic who might take the job of vehicle maintenance latter.

The logbook contains the following details:

Distance covered
Fuel consumption
Average fuel consumption
Best and worst mileage
Total maintenance cost
Running costs
Faults in the vehicle
Likes and dislikes
Date of the previous maintenance report

(b) (i) Preparation Of Maintenance Check List (8)

Maintenance Checklist:-

1. Check the oil level in the sump

2. Check the replacement of engine oil period
3. Check the oil level in the fuel injection pump
4. Check the steering gear box.
5. Check the condition of the rubber sleeve on cylinder head cover.
6. Check the belt tension of the cooling fan.
 7. Check and adjust clutch free pedal play.
8. Check the wheel alignment parameters.
9. Check the level of battery electrolyte level.
10. Check all the lighting system.
11. Check the sock observers.
12. Check the brake shoe pins and holes.
13. Check the tyre inflation pressure.
14. Check the level of fluid in fluid coupling.
15. Check all the instruments working in dashboard.

(b) (ii) periodic maintenance of a diesel vehicle. (8)

The periodic maintenance check sheet is used to record the inspection status made during the maintenance
check operation. It contains various details such as the dealer name, place, date of sale, manufacturers name, mileage,
frame number, chassis number etc. the mileage and service type are indicated in the various cells of the check sheet. The
check sheet also contains the check item name, status and remarks.

The check items include the following:

 Basic engine components.

 Engine oil
 Engine oil filter
 Ignition system
 Battery
 Fuel and Emission Control
 Pre- Filter
 Water sediment filter
 Air cleaner filter
 Chassis and Body
 Brake pedal, parking brake
 Brake pads and discs
 Brake linings & brake drums
 Clutch
 Power steering fluid
 Ball joints and dust covers
 Tyres and inflation pressures
12. (a) Dismantling Of Multi Cylinder Diesel Engine: (16)

1. Drain oil sump

2. Remove subassemblies like generator, starter motor, oil filter and engine flywheel.
Note: Put mark on flywheel and crank shaft flange as they are dynamically balanced in
assembled condition.
3. Remove cylinder head cover, rocker-shaft assembly and push rods.
4. Remove manifolds.
5. Remove high pressure fuel lines
6. Remove all studs at the cylinder block cylinder head
7. Keep the engine in upside down position
8. Remove oil sump
9. Remove oil strainer and oil pump
10. Remove connecting rod caps
11. Remove pistons and connecting rods from topside of cylinder bore (engine in normal
position).
12. Remove the water pump and crank shaft vibration damper
13. Remove timing gear cover and pull out timing gears
14. Remove valve lifters and slide out the cam shaft
 15. Remove the assembly of fuel injection pump and fuel feed pump
16. With inverted position of engine remove the main bearing caps, separate crankshaft
from crankcase.
16. Refit the main bearing caps to avoid damage to shell-bearings.

(b) Engine Tune-Up: (6)

A tuneup means different things to different people, it means using test instruments to do a complete analysis of the
engine and its systems.
Engine TuneUp Procedure:
(i) Test and servicing the battery and starting motor
(ii) Inspect the drive belts
(iii) Warm up
(iv) Check the abnormal ignition systems
(v) Inspect PCV systems

Special Tools:
DRAWINGS MUST (10)
Double end spanner
Hammers
Pliers
Feeler gauge
Hydrometer
Socket spanners
Wrenches
Torque wrench
Piston ring expander
Piston ring compressor
Dial indicator
Valve spring compressor

13. (a) Various Troubles In Steering System. (16)

COMPLAINTS POSSIBLE CAUSES CHECK(OR) CORRECTION

1. Excessive play in  Looseness in steering gear  Readjust, replace worn parts
steering system  Looseness in linkage  Readjust, replace worn parts
 Loose wheel bearing  Readjust
2. Hard steering  Low tyre pressure  Inflate to correct tyre
 Friction in steering gear pressure
 Lubricate, readjust, replace
 Friction in linkage worn parts
 Lubricate, readjust, replace
worn parts
3. Car wander  Low or uneven tyre pressure  Inflate to correct tyre
 Steering gear binding pressure
 Readjust, lubricate, replace
 Linkage binding worn parts
 Readjust, lubricate, replace
 Incorrect wheel alignment worn parts
 Check alignment and
readjust
4. Car pulls to one side  Uneven tyre pressure  Inflate to correct tyre
during normal driving  Uneven castor or camber pressure
 Wheel not tracking  Check alignment, adjust
 Check tracking, replace
defective parts
 5. Car pulls to one side  Brakes grab  Readjust, replace brake
while braking  Uneven tyre pressure lining
 Uneven castor or camber  Inflate to correct tyre
pressure
 Check alignment, adjust
6. Front wheel shimmy at  Uneven tyre pressure  Inflate to correct tyre
low pressure  Loose linkage pressure
 Loose ball joints  Readjust, replace worn parts
 Dynamic imbalance  Replace worn parts
 Balance the wheels
7. Steering shakes  Uneven tyre pressure  Inflate to correct tyre
 Looseness in linkage pressure
 Looseness in steering gear  Readjust, replace worn parts
 Shock absorber defective  Readjust, replace worn parts
 Repair or replace
8. Tyres squeal on  Excessive speed on curves  Take curves at slow speed
turns(skids)  Uneven tyre pressure  Inflate to correct tyre
 Front alignment incorrect pressure
 Worn tyres  Check and adjust
 Replace tyres

(b) (i) Clutch pedal play: (8)

Clutch pedal play adjustment Clutch pedal free play (2 to 4 mm) is adjusted from clutch release arm with clutch operating
flexible cable coming from clutch pedal. While fitting clutch release arm on the clutch release shaft, fix up the arm such that the
punched mark on the clutch release is shifted towards the front side but one notch from the punched mark on the clutch
release shaft, after tightening the arm fix up the cable and adjust clutch pedal free play through adjuster nut 1. It is not possible
to get the desired play then adjust with adjuster nut
Clutch Repairs and Inspection
1. Clutch facing and service limit
2. Loose holding down rivets
3. Check up the torque spring
4. Check for distortion or crack on clutch
5. Check for flat run out (<0.4 mm)
6. Check for lateral run out (<0.7 mm)

Clutch Pedal Play Adjustment

(ii) Brake pedal play: (8)

The free pedal play should be atleast 12.7 mm or as recommended by the company. The procedure for brake pedal play
adjustment is as follows:
 Raise the vehicle until the wheels are off the road.
 With a wrench loosen the locknut for the forward brake shoe and hold it.
* With another wrench turn the eccentric towards the front of the vehicle until brake shoe strike the drum. While turning the
wheel with one hand, release the eccentric until the wheel turn freely

14.(a) Maintenance Procedure: (16)

It includes:
` 1. Visual inspection
2. cleaning the battery
3. Testing the battery
4. Charging the battery

Various Tests: (Drawings must)

1. Specific Gravity Test (Hydrometer Test)

2. Cadmium test
3. High rate discharge test
4. Open volt test:
5. Vibration test
6. Life cycle test

(b) (i) Maintenance Of D.C Generator And Alternator. (8)

MAINTENANCE OF GENERATORS:

 The maintenance of generator infact includes mainly its lubrication, brush wear inspection and adjustment of belt.
 Certain generators do not need lubrication as their bearings are pre-packed with grease whereas other models should
be lubricated at the appropriate holes provided for this purpose after intervals of 10,000 Km.
 The brushes should be inspected after every 30,000km and should be replaced if their wear is found to be more than
specified value.
 This inspection should be done on and off to see that there is enough tension.
 The sagging when present at the middle of the belt should be about 12mm.
 If the belt is too tight, it is liable to damage the water pump gland and generator bearings.
 On the other hand a very loose belt will not drive the generator efficiently and also ensure that generator pulley does
not become oily as this will cause the belt to slip.
 ALTERNATOR MAINTENANCE:

 An alternator in an AC generator producing alternating current instead of direct current.

- At regular intervals , inspect the terminals for corrosion and loose connection.
- Check for mounting bolts, nuts and belts.
- Adjust the belt tension according to the recommendation of manufacturer of engine.
- Check for noisy operation that may be due to worn out bearings.

. (ii) Testing Of Headlight Aiming. (8)

Adjusting Head light:

 It is necessary to focus the bulb before aiming.

 Adjustment of the bulb can be made by moving the bulb back and forth with respect to reflector.
 Aim the head lights such that it points correctly both horizontally as well as vertically.

Head light Aiming:

There are two aiming devices in use:

1. Screen.
2. Prism and reflector.

1. Screen test:

 A screen on which the head light pattern can be studied with the vehicle located 25 feet infront of the
screen.
 Draw 3 lines A, B, C. Distance AB should be centre distance of headlights and distance C should be headlight
centre height from the ground. Now switch on the light. The majority of light should fall on the lower portion of
screen and if the light rays are not focused properly, then it has to be adjusted.

2. Prism and reflectors:

 This does not require so much room. This method consists of series of prisms and reflectors that show an
accurate miniature pattern of the head light beam and miniature screen.
 Adjusting screw and mounting bracket nuts must be turned or loosened to permit swinging of light up or
down or from one side to others.

15. (a) (i) Window rising mechanism. (8)

Windows are provided in the upper part of the doors. They are used to admit natural light when closed and
allow inflow of air when open. To provide additional passenger space without increasing the overall vehicle width, the
window glasses are curved at passenger shoulder level. They are made of one-piece safety glass of bout 5 – 6 mm
thickness. Like windshield glass they are also made of toughened (tempered) or laminated glass. The window can be
raised or lowered by means of a window lever through mechanism. A rack and pinion mechanism is employed for this
purpose.

(ii) Door Lock Mechanism. (8)

To open form outside

 As soon as the push button is pressed, the catch is raised upwards and the slotted disc rotates and
free from the U-fitting. When the catch is raised up, locking bar is also raised up with the catch. When the U-fitting is
free from slotted disc, the door is opened.

To open from inside

To unlock the door from inside, the locking bar is raised initially and then inside opening lever is pulled up. If this inside opening
lever is pulled up the catch is raised and the slotted disc rotated and fee from the U-fitting.

Door in closed position

When the door is closed the slotted disc rotates and fastens into the V-fitting. During this operation the catch with
locking bar is also selected into the slot. Once the slotted side fastens the V-fitting, the door is locked.

(b). Procedure For Removal And Fitting Of Tyre And Tube : (16)

The procedure for the removal and fitting of tyre and tube is as below:
1) Loosen the wheel nuts of tyre to be removed.
2) Place the wedge before and after resting the three wheels to prevent vehicle from rolling.
3) Fix up jack and lift the vehicle to the extent that wheel is free from ground.
4) Remove the wheel after removing the wheel nuts.
5) Keep the wheel flat on ground and deflate it after removing valve with valve die.
6) Hammer the tyre at shoulder so that its bead is free from rim on both sides.
7) Press tyre lever between bead of tyre and rim flange.
8) Take another tyre lever; press it in the same way a little apart from the first lever.
9) Now press both levers down. By doing so some portion of tyre bead will come out of rim.
10) Pull out first lever and insert it again at some distance away from the second lever. Press it
down.
11) Now go on changing the lever till tyre is out of the rim completely.
12) When one bead of tyre is out take out the tube after unscrewing valve body securing nut.
13) If tyre is to be completely replaced, proceed in the same way to remove the second bead