AEL-I Manual 2016 PDF

CONTROL SYSTEMS LABORATORY MANUAL
V Semester (10AUL57)
Name of the Student :

Semester /Section
USN
Batch
DAYANANDA SAGAR COLLEGE OF ENGINEERING

Accredited by National Assessment & Accreditation Council (NAAC) with A Grade
(An Autonomous Institution affiliated to Visvesvaraya Technological University, Belagavi
&
ISO 9001:2008 Certified)
AUTOMOBILE ENGINEERING DEPARTMENT
SHAVIGE MALLESWARA HILLS, KUMARASWAMY LAYOUT
BENGALURU-560078
Automobile Engg. Lab-I: [2016]

(Backside of cover page)
Vision of the Institute

To impart quality technical education with a focus on
Research
and
Innovation
emphasising
on
Development of Sustainable and Inclusive Technology
for the benefit of society.
Mission of the Institute
To provide an environment that enhances

creativity and Innovation in pursuit of Excellence.
To nurture teamwork in order to transform
individuals
as
responsible
leaders
and
entrepreneurs.
To train the students to the changing technical
scenario and make them to understand the
importance of Sustainable and Inclusive
technologies.
Automobile Engg. Dept., Dayananda Sagar College of Engineering, Bengaluru
Page 2
AUTOMOBILE ENGG. LAB-I MANUAL

V Semester (10AUL55)
Name of the Student :

Semester /Section
USN
Batch

(An Autonomous Institution affiliated to Visvesvaraya Technological University, Belagavi)
AUTOMOBILE ENGINEERING DEPARTMENT

SHAVIGE MALLESWARA HILLS
KUMARASWAMY LAYOUT
BENGALURU-560078

DEPARTMENT OF AUTOMOBILE ENGINEERING, BENGALURU-560078
VISION OF THE DEPARTMENT

To impart appropriate, latest, sustainable, quality Automobile Engineering Education with
continuous assessment for fostering Research, Innovation beneficial to the Society at large.
MISSION OF THE DEPARTMENT
To provide world class Education to students for learning and applying their acquired
Knowledge of sciences to Automobile Engineering.
To inculcate a passion for Automobile Engineering amongst students by providing
hands on training on Automobiles using latest Diagnostic Tools and Techniques.
To Encourage Learning through Interdisciplinary interaction by conducting
workshops, expert lectures, certification programs, quizzes and competitions for
efficient design.
To create awareness and develop sensitivity towards Society and Environment, by
adopting necessary cutting edge Research and Innovation through collaborations.
PROGRAMME EDUCATIONAL OBJECTIVES [PEOs]
PEO-1: An ability to apply knowledge of mathematics, science, and engineering to identify,
formulate and solve problems in technologically challenging Automotive field which has
evolved highly interdisciplinary with..
PEO-2: An experience of working on live projects in design, modeling and analysis of
Automotive systems and its components using Engineering application software and to
service the recent models of Automobiles using the latest Diagnostic tools.
PEO-3: An Awareness on contemporary areas of socio-technological issues like energy
crisis, automotive safety, pollution, hybrid automobiles, formal practices of human
resources and industrial relations in order to achieve professional development.
PEO-4: Proficiency in spoken English to actively participate in team meetings to plan,
organize, propose ideas in a multicultural environment and also be able to communicate
effectively through proficient writing skills.
PEO-5: Solid knowledge foundation and will be able to upgrade, refine his knowledge
through professional experience, higher studies or research.
PROGRAMME SPECIFIC OUTCOMES [PSOs]
PSO-1: The students will be able to apply the engineering fundamentals in using
application software to design and Analyse Automotive Engine components, Vehicle
chassis, Suspension and Drive train.
PSO-2: The students will be able to work in interdisciplinary environment to design
systems in line with the present emission norms, Safety standards and emerging fields like
alternate fuels, fuel cells, electric and hybrid vehicles.
Page 4


AUTOMOBILE ENGG. LAB-I (SYLLABUS)
V SEMESTER B. E (AU)
Sub. Code: 10AUL57
Hrs/Week : 03
Total Hrs: 42
IA Marks
: 25
Exam Hrs
: 03
Exam Marks : 50
Course Objectives:
Students will learn about the basic hand tools used in the automobile engine
assembly and disassembly
Assembly and disassembly of numerous engines will be known
Various engine parts will be identifiable by the students
The defects in major components and remedies can be well interpreted by the
students with ease.
Syllabus:
1. Study of hand tools- sketching, materials used and their applications.

2. Writing technical specifications and description of all types of automobile engines.
3. Study of traffic rules as per M.V. Act 1988 and driving practice of four wheel vehicle.
4. Trouble shooting charts for all engine components.
5. Note the specifications of given engines and component standard dimensions. Dismantle
& assemble of engine components of SI and CI engines (Two stroke and four stroke
engines) of any commercial vehicles, using special tools needed. Note procedure of
dismantling & assembly; identify the major components, noting their functions & materials
used. Measurement & comparison of major components dimension with standard
specifications. Inspection for wear and tear, crack, breakdown. Identify the service
requirements of engine, such as decarburizing, degreasing, sparkplug cleaning, fuel injector
cleaning, etc.
6. Compression test, vacuum test on diesel and petrol engines.
7. Study (Dismantling & assembly): Different carburetors, fuel injection pumps, injectors,
fuel tanks, fuel filters, fuel pumps, turbo-chargers, cooling systems and lubricating systems.
Identify location of above components in a vehicle and note their functions along with the
brand names.
Course Outcomes:
Automotive engine lab-I aims to improve understanding of the automobile engines

and their operation and to use them to experience how materials on fluid
mechanics, thermodynamics, and heat transfer studied in previous years integrates
into a total engineering concept.
It also aims to advance students problem solving skills such that the basics learned
from the course can be used to deal with the real research and engineering
challenges
Page 5

DEPARTMENT OF AUTOMOBILE ENGINEERING

CONTROL SYSTEMS LABORATORY (10EEL68)
I - CYCLE
1. To study and prepare report on the application details, materials used and sketching of the hand and
special tools used in order to dismantling and assembling of automotive engines.
2. To study and prepare report on the construction details, materials used and sketching of the engine
components.
3. To write technical specifications and description of all types of automobile engines (Two wheelers, four
wheelers and heavy duty vehicles at least 10# each)
4. To study and prepare report on traffic rules as per M.V. Act 1988
II - CYCLE
5. To write trouble shooting charts for all engine components.
6. Dismantle & assemble of engine components of SI and CI engines (Two stroke and four stroke
engines) of any commercial vehicles. Note procedure of dismantling & assembly; identify the major
components, noting their functions & materials used. Measurement & comparison of major
components dimension with standard specifications. Inspection for wear and tear, crack, breakdown.
Identify the service requirements of engine, such as decarburizing, degreasing, sparkplug cleaning,
fuel injector cleaning, etc.
III CYCLE
7. To find compression pressure and suction pressure of given diesel and petrol engines.
8. Dismantling & assembly of different carburetors, fuel injection pumps, injectors, fuel tanks, turbochargers, cooling systems and lubricating systems. Identify location of above components in a vehicle
and note their functions
Page 6

DEPARTMENT OF AUTOMOBILE ENGINEERING
BENGALURU 560078
DOs
Adhere and follow timings, proper dress code with appropriate foot wear.
Bags, and other personal items must be stored in designated place.
Come prepare with the viva, procedure, and other details of the experiment.
Secure long hair, loose clothing & know safety and emergency procedures.
Do check for the correct ranges/rating and carry one meter/instrument at a time
Inspect all equipment/meters for damage prior to use
Conduct the experiments accurately as directed by the teacher.
Immediately report any sparks/ accidents/ injuries/ any other untoward incident to the
faculty /instructor.
Handle the apparatus/meters/computers gently and with care
In case of an emergency or accident, follow the safety procedure.
Switch OFF the power supply after completion of experiment
DONTs
The use of mobile/ any other personal electronic gadgets is prohibited in the laboratory.
Do not make noise in the Laboratory & do not sit on experiment table.
Do not crowd around equipment & machines.
Dont touch equipments without prior permission from the concerned staff.
Do not carry out experiments without guidance from the concerned staff.
Never leave the experiments while in progress.
Experiment No:________
Date:____________
Do not leave the Laboratory without the signature of the concerned staff in observation book
Title of the
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Experiment
Experiment No: 01
Date: ____________
Study of Hand Tools
Aim: To study and prepare report on the application details, materials used and sketching
of the hand and special tools used in order to dismantling and assembling of automotive
engines
Theory:
A hand tool is a device for performing work on a material or a physical system using
only hands. The hand tools can be manually used employing force, or electrically powered,
using electrical current. Virtually every type of tool can be a hand tool and many have also
been adapted as power tools, which get their motive power from motors or engines rather
than from human mechanical action. Some examples of a hand tools
are hammers, spanners, pliers, screwdrivers and chisels.
Screw driver:
A screwdriver is a tool for driving screws or bolts with
special slots, and sometimes for rotating other machine
elements with the mating drive system. The screwdriver is
made up of a head or tip, which engages with a screw,
a mechanism to apply torque by rotating the tip, and some
way to position and support the screwdriver.
Phillips screw driver:

Created by Henry F. Phillips, the Phillips
to cam out
in building torque limiting into the early drivers.
Offset screw driver:
A screwdriver with the blade at right angles to the shaft for use where a straight
screwdriver cannot reach the screw head.
Page 8

Spanner
A spanner or wrench is a tool used to provide grip and mechanical advantage in
applying torque to turn objectsusually rotary fasteners, such as nuts and boltsor keep
them from turning.
In British English, spanner is the standard term. The most common shapes are called openended spanner and ring spanner. The term wrench refers to a type of adjustable spanner.
Open spanner
A one-piece wrench with a U-shaped opening that grips
two opposite faces of the bolt or nut. This wrench is
often double-ended, with a different-sized opening at
each end. The ends are generally oriented at an angle of
around 15 degrees to the longitudinal axis of the
handle. This allows a greater range of movement in
enclosed spaces by flipping the wrench over.
Ring spanner
Widely regarded as "the king of
wrenches, this is a one-piece
wrench with an enclosed opening
that grips the faces of the bolt or nut.
The recess is generally a six-point or
twelve-point opening for use with nuts or bolt heads with a hexagonal shape.
Open Ring spanner

A double-ended tool with one end
being like an open-end wrench or
open-ended spanner, and the other
end being like a box-end wrench or
ring spanner. Both ends generally fit the same size of bolt.
Adjustable wrench
An adjustable spanner or adjustable wrench is
a spanner with a "jaw" of adjustable width,
allowing it to be used with different sizes
of fastener head (nut, bolt, etc.) rather than just
one fastener, as with a conventional fixed
spanner.
Page 9

Tubular spanner
A tube with six-sided sockets on both ends. It is turned with a short length of rod (tommy
bar or T bar) inserted through two holes in the middle of the tube.
Double-ended tubular spanner
Single-ended tubular spanner
Spark Plug Wrench
Page 10

Hammer
A hammer is a tool meant to deliver
an impact to an object. The most
common uses are for fitting parts,
forging metal and breaking up
objects.
Mallet
A mallet is a kind of hammer,
usually
of rubber,
or
sometimes wood and usually with a
relatively large head. Mallets are
used when a softer blow is called for
than that delivered by a metal
hammer and they don't leave marks.
Files
A file is a metalworking, woodworking and plastic
working tool used to cut fine amounts of material from
a work piece. It most commonly refers to the hand
tool style, which takes the form of a steel bar with
a case hardened surface and a series of sharp, parallel
teeth. Most files have a narrow, pointed tang at one end
to which a handle can be fitted.
Cutting Pliers
It is used to hold objects firmly,
for bending, cutting or physical
compression.
Generally,
pliers
consist of a pair of metal first-class
levers joined at a fulcrum positioned
closer to one end of the levers,
creating short jaws on one side of the fulcrum, and longer handles on the other side. This
arrangement creates a mechanical advantage, allowing of the hand's grip to be amplified
and focused on an object with precision. The jaws can also be used to manipulate objects
too small or unwieldy to be manipulated with the fingers.
Page 11

Needle nose pliers
Needle-nose pliers are both cutting and gripping pliers used to
bend, re-position and cut wire.
Tin cutter
Tin cutter, also known as shears, are hand
tools used to cut sheet metal and other
tough webs.
There
are
two
broad
categories: tinner's snips, which are similar to
common scissors, and compound-action snips,
which use a compound leverage handle system
to increase the mechanical advantage.
Allen Key
A wrench used to turn screw or bolt heads designed with a
hexagonal socket (recess) to receive the wrench. The wrenches
come in two common forms: L-shaped and T-handles.
Speed wrench
Useful for quickly tightening and
loosening a nut or bolt particularly
where other types of wrenches will not
reach.
Page 12

Ratchet wrench
It contains a one-way mechanism which allows the socket to be turned without removing it
from the nut or bolt simply by cycling the handle backward and forward
Torque wrench
A torque wrench is a tool used to precisely apply a specific torque to a fastener such as
a nut or bolt. It is usually in the form of a socket wrench with special internal mechanisms.
A torque wrench is used where the tightness of screws and bolts is crucial. It allows the
operator to measure the torque applied to the fastener so it can be matched to the
specifications for a particular application. It was designed to prevent over tightening bolts.
Piston ring removal
Heres a universal tool that handles piston rings of all sizes. Rings can be removed or
installed on the piston without fear of breakage from the unnatural twisting that occurs
when using just your hands.
Page 13

Piston ring compressor
It is a spring metal sleeve that goes over a piston to
compress the rings so that the piston can be install in the
motor. It tightens down on the piston, forcing the rings
into the grooves in the piston then you tap it into the
cylinder.
Piston ring groove cleaner
A piston ring groove cleaner is a tool

specifically designed to quickly remove
carbon and other accumulated materials
from piston ring grooves to allow new rings
to make a better seal against the piston.
Piston ring groove cleaners typically come
with a set of two or three cutters which
allow the tool to be adapted to a range of
piston groove sizes. A heavy coil spring
holds the cutter in place in the groove.
Valve lifter tool

A device for opening the valve of a cylinder as
in an internal combustion engine.
And designed to compress and release valve
spring after removing the collets.
Page 14

Stud removal
Stud Removal and Installer Tool makes the job of removing those
hard to turn studs a simple task. It assures a positive engagement
on installation.
Oil-filter wrench:
An oil-filter wrench is a tool for removing
spin-on type oil filters. These filters are
smooth, cylindrical canisters with knurling
on the bottom that are difficult to grip,
especially when they are oily.
The loop of strap is placed around the filter,
and the bar is turned anticlockwise by hand
until the band wraps itself tightly around
the filter which helps prevent slippage.
Measuring instruments
Vernier caliper:
The vernier caliper give a direct reading of the distance measured to high accuracy (error is
0.05 mm). An ordinary vernier caliper has jaws you can place around an object, and on the
other side jaws made to fit inside an object. These secondary jaws are for measuring the
inside diameter of an object. Also, a stiff bar extends from the caliper as you open it that can
be used to measure depth.
Page 15

Micrometer
A micrometer sometimes known
as a micrometer screw gauge, is
a
device
incorporating
a
calibrated screw used widely for
precise measurement of small
distances
in mechanical
engineering and machining as
well as most mechanical trades,
Dial gauge
Dial indicators, also known as dial gauges and probe indicators, are
instruments used to accurately measure small linear distances, and are
frequently used in industrial and mechanical processes. They are named
so because the measurement results are displayed in a magnified way by
means of a dial.
Outside and inside calipers

A caliper is a device used to measure the distance between two
opposing sides of an object. A caliper can be as simple as
a compass with inward or outward-facing points. The tips of the
caliper are adjusted to fit across the points to be measured, the
caliper is then removed and the distance read by measuring
between the tips with a measuring tool, such as a ruler.
The inside calipers are used to measure the internal size of an
object.
Outside calipers are used to measure the external size of an
object.
Page 16

Feeler gauge
A feeler gauge is a tool used to measure gap widths. Feeler gauges are mostly used in
engineering to measure the clearance between two parts. They consist of a number of small
lengths of steel of different thicknesses with measurements marked on each piece. They are
flexible enough that, even if they are all on the same hinge, several can be stacked together
to gauge intermediate values.
Dial bore gauge:
A dial or vernier bore gauge measures a bore directly. The gauge has three symmetrical
anvils that protrude from the gauge body that are connected to the dial or micrometer
mechanism. As the knob is rotated it moves the anvils in or out with respect to the
measurements. The knob usually has a slipping mechanism to take the feel out of the
device and increase reliability between measurements. The measurement given is the
mean diameter of the three anvils, and is usually good to 0.001 mm
Signature of Staff Incharge with date:

Page 17

Experiment
Experiment No: 02
Date: ____________
Study of Engine Components
Aim: To study and prepare report on the construction details, materials used and
sketching of the engine components.
Theory:
Cylinder block:
The cylinders and the upper part of the crankcase
are usually made together in one block of metal
called the cylinder block. In L- and F-head
engines, the block has valve seats and ports
beside the cylinders. It also serves as a mounting
foundation for the crankshaft and other engine
parts.
The cylinders of the liquid-cooled engine have
jackets all around them to hold the cooling liquid.
These jackets are made with, and are a part of,
the cylinder block. Passages in the top of the
block allow the coolant to pass between the block
and the cylinder head.
Material: grey cast iron, aluminium alloy
Cylinder head:
The cylinder head contains the upper half of the
combustion chambers and is bolted to the top of
the cylinder block. It contains coolant passages
that align with the coolant passage in the cylinder
block. The head also has a threaded hole in each
combustion chamber for spark plugs to be
screwed into.
A metal or a metal-asbestos gasket is used
between the head and the block to prevent the
leakage of coolant and cylinder pressure. Holes
are cut in the gasket that align with the cylinders,
bolt holes, and coolant passages.
I- and F-head engine cylinder heads have valves
and valve operating mechanisms mounted on
them. These heads also have passages so lubricating oil can flow between the crankcase
and the valve mechanism. A rocker armor valve cover is bolted to the top of the cylinder
head. This prevents the leakage of oil and keeps dirt out of the valve mechanism.
Material: cast iron, aluminium alloy
Page 18

Crankcase:
The crankcase is the part of the engine that supports
and encloses the crankshaft and holds the lubricating
oil. As you know, the upper part of the crankcase is a
part of the cylinder block. It supports the crankshaft in
bearings that are called the main bearings.
Oil pan:
The lower part of the crankcase holds the oil and is called the oil pan. It is usually made of
sheet metal and is bolted to the bottom of the cylinder block. A gasket is used between the
block and pan to prevent oil leaks. A threaded plug in the bottom of the oil pan allows the
lubricating oil to be drained without removing the pan.
Material for oil pan: pressed steel, aluminium alloy casting
Piston:
The pistons in use today are made of metal that is lightweight but very strong. The pistons
must come to a complete stop, and then start again in the opposite direction at the end of
each stroke. Therefore, lightweight pistons are desired because they take less power away
from the engine. The pistons must be strong to withstand the force created by the
combustion of the fuel-air mixture.
Page 19
Since the piston must be free to slide up and down inside the cylinder, there must be
clearance between the piston and cylinder wall. There must not be too much clearance
though or the piston skirt will slap against the wall. This would put excessive strain on the
piston and prevent the piston rings from doing their job properly.
The main parts of a piston are:
1 - The top, which may also called the Head or Crown.
2 - The Ring belt.
3 - The Pin bosses.
4 - The Skirt.
So we can say that The piston performs the following functions :
(1) Forms a movable gas-tight plug to confine the charge in the cylinder.
(2) Transmits to the connecting rod the forces generated by combustion of the charge.
(3) Forms a guide and a bearing for the small end of the connecting rod, and takes the
lateral thrust due to the obliquity of that rod.
Material: cast iron, aluminium alloy
Page 20

Piston rings:
The rings on pistons do more than prevent gases from leaking between the piston and
cylinder wall. They also assist in cooling the piston and keep lubricant from entering the
combustion chamber. They cool the piston by transmitting heat from the piston to the
cylinder block. Two types of rings, compression and oil-regulating, are used.
Material: fine-grained alloy cast iron containing silicon and manganese, chromium
plated rings
Page 21

Piston pin:
To reduce the weight of the pistons, the
piston pins are made hollow. They are
made of hard steel; therefore, their ends
must not be allowed to touch the cylinders
as this will score their walls. Also, the pins
must fit in the pistons and connecting rods
with the proper amount of operating
clearance. Too little clearance will not
allow the connecting rod to swing freely
from the piston; too much clearance will
cause a knocking noise when the piston
changes its direction of travel.
Several different methods of securing a
piston pin in the piston are used. Each
method can be placed in one of three
different
classifications.
These
are
anchored or fixed, semifloating, and full-floating pins.
Fixed pin: The fixed pin is attached firmly to the piston, and the connecting rod is free to
swing on the pin.
Semi floating pin: The semi floating pin is anchored to the connecting rod and is free to
turn in the piston.
Full-floating pin: The full-floating pin is free to turn in both the piston and connecting rod.
It is prevented from working out against the cylinder wall by plugs or snap rings.
Fixed pin
Semi floating pin
Full floating pin
Material: low carbon case hardened steel

Page 22

Cylinder Liner
Cylinder liners are inserted steel tubes, placed in the cylinder block of an internal
combustion piston engine. They form the wall of the cylinder and the surface upon which
the piston and the piston rings run directly.
Dry liners are liners that do not form part of the water jacket. Their main advantage over
an un linered block is that they allow better metals to be used for the wearing surface of the
cylinder. They are inserted into iron or aluminium blocks that already have cast-in water
jackets.
Because of the need to cool the cylinder, most liners have been wet liners. These form the
inner wall of the engine's water jacket. The thinness of the liner provides good cooling, with
little thermal resistance between the cylinder and the coolant. As the water jacket can be
cast open on the cylinder side, they also simplify the casting process.
Material: special alloy iron containing silicon, manganese, nickel and chromium.
Connecting rod:
Page 23

In a reciprocating piston engine, the connecting rod connects the piston to the crank or
crankshaft. Together with the crank, they form a simple mechanism that converts linear
motion into rotating motion.
Connecting rods that are used with fixed or full-floating pins generally have a bushing-type
bearing pressed into the pin hole. The lower end is fitted with two-piece bearings that
encircle machined bearing surfaces of the crankshaft throws. Connecting rod bearings with
too much running clearance will cause a knocking noise and can result in a broken rod or a
scarred crankshaft throw.
Material: grey cast iron, aluminium alloy
Crankshaft:
The crankshaft may well be called the backbone of the engine. It ties together the action of
all the pistons--changing their back and forth motion into rotary motion and carrying the
power to the flywheel.
In addition to having many throws, the crankshaft has several machined bearing surfaces
for mounting it in the crankcase. Each mounting point in the crankcase is called a main
bearing. The main bearings are made much like the connecting rod bearings with
removable caps and two-piece bearing inserts. One of the main bearings has a lip or thrust
surface on the sides of the bearing inserts. This is to control the end thrust or endwise
movement of the crankshaft. Oil seals are used at each end of the shaft, where it sticks out
of the crankcase, to prevent the leakage of lubricating oil.
Material: spheroidal ghaphite iron (SG iron), cast steel.
Page 24

Crank shaft throw arrangements.
Flywheel:
As more cylinders are added to an engine, the size and weight of the flywheel is reduced.
This is because the power strokes are closer together and in some cases overlapping.
Therefore, the weight of the flywheel is not needed as much to smooth out the crankshaft
rotations.
Page 25

However, the flywheels of engines serve other purposes in addition to causing the engine to
run smoother. A ring gear is usually installed around its outer edge to mesh with a starter
motor gear for cranking. The rear side of the flywheel is machined so the clutch or other
parts may be fastened to it for driving the vehicle.
Material: cast iron
Valves and operating mechanism:
Every cylinder of a four-stroke-cycle engine has intake and exhaust valves. The intake ports
from the intake valves are usually connected to one common pipe called a manifold. The
manifold then leads to a mixing point that supplies the fuel-air mixture. Likewise, the ports
leading away from the exhaust valves are connected to a common manifold for carrying
exhaust gases away from the engine. V-type engines generally have two exhaust manifolds,
one for each row of cylinders.
The camshaft extends the full length of the engine and has a cam for each valve, except in a
few cases where one cam is used to operate more than one valve. The location of the
camshaft, tappets, and other valve operating parts depends on the design of the engine they
are used in.
In the in-line, L-head engine, the valve mechanism is located in the cylinder block. An
adjusting screw is threaded into the top of the tappet to allow an adjustment of the
operating clearance between the tappet and the valve stem. One or two covers with gaskets
are bolted to the side of the cylinder block to cover the mechanism, protecting it from dirt
and preventing oil leakage.
Overhead valves: The valves of the in-line, overhead valve (I-head) engine may be
operated by either one of two different methods. In one method the camshaft and tappets
are located in the cylinder block. Rocker arms that pivot on a shaft are located on the head.
The valves are forced open when the rocker arms pivot. Tappet movements are transferred
to the rocker arms through a pushrod which rests on top of the tappet and extends up to
one end of the rocker arm. Notice that in this system the valve clearance adjusting screw is
Page 26

located at the pushrod end of the rocker arm. A cover, bolted to the top of the cylinder
head, covers the rocker arms.
Overhead cam: In the other method of operating the valves of the overhead valve engine,
the camshaft is located on the cylinder head. This engine may be called an overhead cam
engine. In technical manuals, it may even be shortened to read OHC engine. Rocker arms
that pivot on studs are the only link between the valves and cams. Valve clearance is
adjusted by inserting shims between the cam lobe and the lifter.
The F-head engine has its camshaft in the cylinder block. For the valves located in the block,
it uses a mechanism like the L-head engine. Rocker arms and pushrods are used on the
valves in the head as with the overhead valve engine.
On V-type and horizontal-opposed engines, one camshaft is generally located in the center
of the engine and operates the valves on both rows of cylinders. Of course, if the overhead
cam method is used, a camshaft is needed on each row of cylinders.
Page 27

Hydraulic valve tappet
Hydraulic valve tappets are used on many engines.
These tappets make minor valve clearance
adjustments automatically each time a valve closes.
This way, all the tappet noise is stopped because the
engine is operated without any valve stem to tappet
clearance.
Basically, a hydraulic valve tappet is made up of a
cylinder fitted with a plunger or piston and a ballcheck valve. Oil under pressure is forced through the
ball-check valve into the cylinder below the plunger
when the tappet is on the base circle of the cam. This
raises the plunger which, in effect, increases the
tappet's length and removes all clearance in the
valve linkage. When the lobe lifts the tappet, oil tries
to flow out of the chamber from under the plunger.
This closes the ball check valve, and the trapped oil
lifts the plunger opening the engine valve. When the lobe moves out from under the tappet,
any slight loss of oil from under the plunger is replaced by oil pressure from the lubricating
system.
Material: silicon-chrome steel, nimonic alloys.
Camshaft drives:
There are two common methods of turning the camshafts of multi-cylinder engines in
wheeled vehicles. One is with gears as you studied on the basic one-cylinder engine. In the
other method, two sprockets and a timing chain or belt, something like a bicycle drive, are
used. A timing chain or belt is most likely to be used when the crankshaft and camshaft are
not very close together.
Page 28

Gaskets:
Gaskets or static seals are used between attaching engine parts to seal the joints for
preventing either internal or external leakage. A gasket must withstand the high pressure
and temperature of the engine. Therefore the gasket
(i) Must be impermeable to the fluids in contact
(ii) Must conform to any existing surface imperfections
(iii) Must be resilient to maintain sealing pressure even
when the joints are slightly loosened as a result of
temperature changes or vibration
(iv) Must be resistant to all expected changes in its
environment due to temperature pressure variations
and age and
(v) Must be stable under compression conditions
avoiding excessive setting.
Material: cork, asbestos, rubber, embossed steel,
Multiple Layers Steel coated with a rubber, copper
Inlet manifold:
In automotive
engineering,
an inlet
manifold or intake manifold is the part
of
an engine that
supplies
the fuel/air mixture to the cylinders.
The primary function of the intake
manifold is to evenly distribute the
combustion mixture (or just air in a
direct injection engine) to each intake
port in the cylinder head(s). Even
distribution is important to optimize the
efficiency and performance of the
engine. It may also serve as a mount for
the carburetor, throttle body, fuel
injectors and other components of the
engine.
Material: light alloy metal castings, glass fiber, polyamide nylon based materials
Exhaust manifold:
In automotive engineering, an exhaust manifold collects the exhaust gases from
multiple cylinders into one pipe.
Exhaust manifolds are generally simple cast iron or stainless steel units which collect
engine exhaust from multiple cylinders and deliver it to the exhaust pipe.
Page 29
Material: cast iron, S.G iron
Mufflers:
A muffler (or silencer in British English) is a device for reducing the amount of noise
emitted by the exhaust of an internal combustion engine.
Mufflers are installed within the exhaust system of most internal combustion engines,
although the muffler is not designed to serve any primary exhaust function. The muffler is
engineered as an acoustic soundproofing device designed to reduce the loudness of the
sound pressure created by the engine by way of Acoustic quieting. The majority of the
sound pressure produced by the engine is emanated out of the vehicle using the same
piping used by the silent exhaust gases absorbed by a series of passages and chambers
lined with roving fiberglass insulation and/or resonating chambers harmonically tuned to
cause destructive interference wherein opposite sound waves cancel each other out. An
unavoidable side effect of muffler use is an increase of back pressure which
decreases engine efficiency. This is because the engine exhaust must share the same
complex exit pathway built inside the muffler as the sound pressure that the muffler is
designed to mitigate.
Page 30

Spark plug:
A spark plug is a device for delivering electric current from an ignition system to
the combustion chamber of a spark-ignition engine to ignite the compressed fuel/air
mixture by an electric spark, while containing combustion pressure within the engine. A
spark plug has a metal threaded shell, electrically isolated from a central electrode by
a porcelain insulator. The central electrode, which may contain a resistor, is connected by a
heavily insulated wire to the output terminal of an ignition coil or magneto. The spark
plug's metal shell is screwed into the engine's cylinder head and thus electrically grounded.
The central electrode protrudes through the porcelain insulator into the combustion
chamber, forming one or more spark gaps between the inner end of the central electrode
and usually one or more protuberances or structures attached to the inner end of the
threaded shell and designated the "side", "earth", or "ground" electrode(s).
Page 31

Experiment
Experiment No: 03
Date: ____________
Technical Specifications
Aim: To write technical specifications and description of all types of automobile engines
(Two wheelers, Four wheelers and Heavy duty vehicles at least 10# each)
Picture:
Tabular Column:
Engine
Displacement
Bore and Stroke
Compression Ratio
Max. Power
Max. Torque
Transmission
Clutch
Ignition
Fuel Supply
4 Stroke, Single Cylinder, Air Cooled

223 cc
65.5 X 66.2
9:1
17.2 PS (12.68 KW)@ 7000rpm
18.35 Nm @ 6000rpm
5 Speed Constant Mesh
Multiplate Wet
CDI
VE fuel pump, Constant Vaccum Carburettor

Page 32

Experiment
Experiment No: 04
Date: ____________
Study of Traffic Rules
Aim: To study and prepare report on traffic rules as per M.V. Act 1988.
Theory:
The Motor Vehicle Act 1988 suggests various rules and regulation for the public and it has a
huge importance in the traffic regulation, so that the system goes systematically and in a
proper way. If any of the rules are violated there are serious punishments. This Act ensures
everyone gets treated in a fair manner and to avoid disaster accidents.
The act as amendment up to 1988 has 14 chapters, are as follows:
CHAPTER I: PRELIMINARY
Short title, extent and commencement
Definitions
CHAPTER II: LICENSING OF DRIVER OF MOTOR VEHICLES
Necessity for driving license

Age Limit in connection with driving of
motor vehicles
Responsibility of owners of motor vehicles
for contravention of sections 3 and 4
Restrictions on the holding of driving
licenses
Restrictions on the granting of learners
licenses for certain vehicles
Grant of learner's license
Grant of driving license
Form and contents of licenses to drive
Additions to driving license
Licensing and regulation of schools or
establishments for imparting instruction in
driving of motor vehicles
Extent of effectiveness of license, to drive
motor vehicles
Currency of licenses to drive motor vehicles
Renewal of driving licenses
Revocation of driving license on grounds of

disease or disability
Orders refusing or revoking driving licenses
and appeals there from
Driving licenses to motor vehicles, belonging
to the Central Government
Power of licensing authority to disqualify
from holding a driving license or revoke such
license
Power of Court to disqualify
Suspension of driving license in certain cases
Suspension or cancellation of driving license
on conviction
Effect of disqualification order
Endorsement
Transfer of endorsement and issue of driving
license free from endorsement
Maintenance of State Registers of Driving
Licenses
Power of Central Government to make rules
Power of State Government to make rules
CHAPTER III: LICENSING OF CONDUCTORS OF STAGE CARRIAGES
Necessity for conductor's license

Grant of conductor's license
Disqualifications for the grant of conductor's
license
Revocation of a conductor's license on
grounds of disease or disability
Orders refusing etc., conductor's licenses and
appeals there from
Power of licensing authority to disqualify

Power of Court to disqualify
Certain provisions of Chapter II to apply to
conductor's license
Savings
CHAPTER IV: REGISTRATION OF MOTOR VEHICLES

Page 33
Necessity for registration

Registration, where to be made
Registration, how to be made
Special provision for registration of motor
vehicles of diplomatic officers, etc
Temporary ,registration
Production of vehicle at the time of
registration
Refusal of registration or renewal of the
certificate of registration
Effectiveness in India of registration
Assignment of new registration mark on
removal to another State
No objection certificate
Change of residence or place of business
Transfer of ownership
Special provisions regarding motor vehicle
subject to hire purchase agreement, etc.
Alteration in motor vehicle
Suspension of registration
Cancellation of registration suspended under

section 53
Cancellation of registration
Certificate of fitness of transport vehicles
Appeals
Special provisions in regard to transport
vehicles
Power to fix the age limit of motor vehicle
Registration of vehicles belonging to the
Central Government
Application of Chapter to trailers
Information regarding stolen and recovered
motor vehicles to be furnished by the police
to the State Transport Authority
Maintenance of State Registers of Motor
vehicles
Power of the Central Government to make
rules
CHAPTER V: CONTROL OF TRANSPORT VEHICLES
Necessity for permits

Power to State Government to control road
transport
Transport authorities
General provision as to applications for
permits
Application for stage carriage permit
Procedure of Regional Transport Authority
in considering application for stage carriage
permit
Grant of stage carriage permit
Application for contract carriage permit
Grant of contract carriage permit
Scheme for renting of motor cabs
Application for private service vehicle permit
Application for goods carriage permit
Consideration of application for goods
carriage permit
Grant of goods carriage permit
Procedure in applying for and granting
permits
Duration and renewal of permits

Transfer of permit
Replacement of vehicles
General conditions attaching to all permits
General form of permits
Cancellation and suspension of permits
Temporary permits
Validation of permits for use outside region
in which granted
Appeals
Revision
Restriction of hours of work of drivers
Voidance of contracts restrictive of liability
Agent or canvasser to obtain license
Bar or jurisdiction of Civil courts
Power of State Government to make rules as
to stage carriages and contract carriage
Power of state Government to make rules for
the
purposes
of
this
Chapter
CHAPTER VI: SPECIAL PROVISIONS RELATING TO STATE TRANSPORT
Definition
Chapter to override Chapter V and other
laws
Preparation and publication of proposal
regarding road transport service of a State
transport undertaking
Objection to the proposal
UNDERTAKINGS
Operation of additional services by a State

transport
undertaking
in
certain
circumstances
Cancellation or modification of scheme
Issue of permits to State transport
undertakings
Restriction of grant of permits in respect of a

notified area or notified route
Principles and method of determining
compensation and payment thereof
Disposal of articles found in vehicles

Certain powers of State Government
exercisable by the Central Government
CHAPTER VII: CONSTRUCTION, EQUIPMENT AND MAINTENANCE OF MOTOR VEHICLES

General provision regarding construction
and maintenance of vehicles

CHAPTER VIII: CONTROL OF TRAFFIC
Limits of speed
Limits of weight and limitation on use
Power to have vehicles weighed
Power to restrict the use of vehicles
Power to erect traffic signs
Parking places and halting stations
Driving regulations
Duty to obey traffic signs
Vehicles with left hand control
Signals and signaling devices
Leaving vehicles in dangerous position
Riding on running board, etc.
Prohibition against traveling without pass or
ticket
Obstruction of driver
Stationary vehicles
Removal of motor vehicles abandoned or left
unattended on a public place
Safety measures for drivers and pillion riders

Wearing of protective headgear
Duty to produce license and certificate of
registration
Duty to the driver to take certain precautions
at unguarded railway level crossings
Duty of driver to stop in certain cases
Duty of owner of motor vehicle to give
information
Duty of driver in case of accident and injury t
a person
Schemes to be framed for the investigation of
accident cases and wayside amenities, etc.
Inspection of vehicle involved in accident
CHAPTER IX: MOTOR VEHICLES TEMPORARILY LEAVING OR VISITING INDIA
CHAPTER X: LIABILITY WITHOUT FAULT IN CERTAIN CASES
Liability to pay compensation in certain

cases on the principle of no fault
Provisions as to other right to claim
compensation for death or permanent
disablement
Permanent disablement
Applicability of Chapter to certain claims
under Act 8 of 1923
Overriding effect
CHAPTER XI: INSURANCE OF MOTOR VEHICLES AGAINST THIRD PARTY RISKS
Definitions
Necessity for insurance against third party
risk
Requirements of policies and limits of
liability
Validity of Policies of insurance issued in
reciprocating Countries
Duty of insurers to satisfy judgments and

awards against persons insured in respect of
third party risks
Rights of third parties against insurers on
insolvency of the insured
Duty to give information as to insurance
Settlement between insures and insured
persons
Page 35
Saving in respect of sections 150, 151 and

152
Insolvency of insured persons not to affect
liability of insured or claims by third parties
Effect of death on certain causes of action
Effect of certificate of insurance
Transfer of certificate of Insurance
Production of certain certificates, license and
permit in certain cases
Production of certificate of insurance on

application for authority to use vehicle
Duty to furnish particulars of vehicle
involved in accident
Special provisions as to compensation in case
of hit and run motor accident
Refund in certain cases of compensation paid
under section 161
Scheme for payment of compensation in case
of hit and run motor accidents
CHAPTER XII: CLAIMS TRIBUNALS
Claims Tribunals
Application for compensation
Option regarding claims for compensation in
certain cases
Award of the Claims Tribunal
Procedure and Powers of Claims Tribunals
Impleading insurer in certain cases
Award of interest where any claim is allowed
Award of compensatory costs in certain

cases
Appeals
Recovery of money from insurer as arrears
of land revenue
Bar on jurisdiction of Civil Courts
CHAPTER XIII: OFFENCES, PENALTIES AND PROCEDURE
General provision for punishment of offences

Penalty for traveling without pass or ticket
and for dereliction of duty on the part of
conductor and refusal to ply contract
carriage, etc
Disobedience of orders, obstruction and
refusal of information
Allowing unauthorised persons to drive
vehicles
Driving vehicles in contravention of section 3
or section 4
Offences relating to licenses
Driving at excessive speed etc.
Driving dangerously
Driving by a drunken person or by a person
under the influence of drugs
Driving when mentally or physically unfit to
drive
Punishment for offences relating to accident
Punishment for abetment of certain offences
Racing and trials of speed
Using vehicle in unsafe condition
Sale of vehicle in or alteration of vehicle to
condition contravening this Act
Using vehicles without registration
Using vehicle without permit

Punishment of agents and canvassers
without proper authority
Driving vehicle exceeding permissible weight
Imposition of minimum fine under certain
circumstances
Driving uninsured vehicle
Taking vehicle without authority
Unauthorised interference with vehicle
Offences by companies
Composition of certain offences
Penalty for causing obstruction to free flow
of traffic
Power to arrest without warrant
Breath tests
Laboratory test
Presumption of unfitness to drive
Power of police officer to impound to drive
Power to detain vehicles used without
certificate of registration permit, etc.
Summary disposal of cases
Restriction on conviction
Courts to send intimation about conviction
CHAPTER XIV: MISCELLANEOUS
Power of levy fee
Publication commencement and laying of

rules and notifications
Page 36
Appointment of motor vehicles officers

Effect of appeal and revision on orders
passed by original authority
Road Safety Councils and Committees
Power to remove difficulties

Repeal and savings
Full text of "Motor vehicle Act 1988" available on www.tn.gov.in/sta/Mvact1988.pdf

Traffic Signs: (The ninth schedule, Section 75, 77 & 78)

Page 37

Experiment
Experiment No: 05
Date: ____________
Trouble Shooting Charts
Aim: To write trouble shooting charts for all engine components.

Tabular Column:
For Example: Carburetor
Defects
OVERFLOW
POOR IDLING
POOR FUEL ECONOMY
POOR ACCELERATION
Causes
1. Restricted fuel tank vent
system.
2. Loose float bowl screws.
4. Damaged or leaking float
assembly.
1. Idle speed improperly
adjusted.
2. Inlet system air leak
(faster idling).
3. Loose low speed jet.
Remedies
1. Correct restricted hose.
Replace vapor vent valve.
2. Tighten screws.
4. Replace float assembly.
1. Excessive use of
enrichener system.
2.Dirty air cleaner filter
element.
system.
6. Idle speed improperly
adjusted.
7. Loose jets.
8. Fuel level too high.
10. Worn or damaged needle
or needle jet.
1. Throttle cables
misaligned.
2. Inlet system air leak.
system.
4. Restricted fuel supply
passages.
5. Plugged bowl vent or
overflow.
1. Limit system use.

2. Clean or replace as
required.
6. Adjust operating idle
speed.
7. Tighten jets.
8. Adjust float tab for correct
fuel level.
10. Replace needle or needle
jet.
1. Adjust throttle cables.
2. Correct as required.
4. Correct and clear
restriction.
5. Clean and clear passages.
1. Adjust operating idle

speed.
2. Correct as required.
3. Tighten jet

Page 38

Experiment
Experiment No: 06
Date: ____________
Dismantle & Assemble of SI and CI engines
Aim: Dismantle & assemble of engine components of SI and CI engines (Two stroke and
four stroke engines) of any commercial vehicles. Note procedure of dismantling &
assembly; identify the major components, noting their functions & materials used.
Measurement & comparison of major components dimension with standard specifications.
Inspection for wear and tear, crack, breakdown. Identify the service requirements of
engine, such as decarburizing, degreasing, sparkplug cleaning, fuel injector cleaning, etc.
Apparatus/Components required: Screw driver, Spanner, Spark Plug Wrench,

Hammer, Mallet, Needle nose pliers, Allen Key, Speed wrench, Torque wrench, Piston ring
removal, Piston ring compressor, Piston ring groove cleaner, Valve lifter tool, Stud removal,
Vernier caliper, Micrometer, Feeler gauge, Dial bore gauge
Page 39

Specification of engine:
Procedure: General dismantling steps
1. Preparatory measures.
Drain off the engine oil.
Remove the oil dipstick tube.
2. Detach the engine mounting bracket with the engine mounting.
3. Attach the engine to the assembly stand.
4. Detach the bracket.
5. Detach the EGR system.
6. Detach the inlet manifold bracket from the engine.
7. Detach the alternator and bracket.
8. Detach the engine mounting bracket with the engine mounting.
9. Detach the crankshaft position sensor (CKP sensor).
10. Detach the oil filter.
11. Detach the clutch.
12. Detach the crankshaft belt pulley/vibration damper.
13. Detach the flywheel.
14. Detach the crankcase breather (PCV) tube
15. Remove the spark plugs
Detach the ignition coil cover.
Disconnect the spark plug connectors.
Remove the ignition coils (two bolts each).
Remove the spark plugs
16. Detach the engine lifting eyes.
17. Detach the cylinder head cover (eleven bolts and four nuts).
18. Detach the upper timing chain cover.
19. Detach the lower timing chain cover.
20. Detach the oil pump sprocket and chain.
Remove the chain tensioner for the oil pump chain.
Remove the oil pump sprocket with the chain.
21. Set the camshaft sprockets to the marks.
Tabular Column: Observation table

SI. No.
Component
name
Tool used
No. of
fasteners
Dimension
Defects/Remarks

Page 40

Experiment
Experiment No: 07
Date: ____________
Compression and Vacuum Test
Aim: To find compression pressure and suction pressure of given diesel and petrol
engines.
Apparatus/Components required: Spark plug wrench, Spanner, Compression and
Vacuum testing kit (Indicator dial gauge, Testing tube, Spark plug hole adapters).
a. Compression test:
Theory:
This test can tell you a lot about the overall health of the engine. If your car is blowing blue
smoke out of the tailpipe, or if your car is losing lots of oil, you could have a bad piston ring.
This will also cause low compression in that cylinder, and a compression test will tell you.
The same goes for a bad valve. Even if you are just noticing a general lack of power, a
compression test can help you rule out some of the more serious possible causes.
Procedure:
Before you begin the compression test, the engine needs to be warm. Get the engine up to
operating temperature by running it for a while, or you can do your compression test after
a drive.
You'll also need to disable your ignition system. We are going to need to crank the starter
to turn the engine over but we don't want it to actually start.
Remove one spark plug and insert the appropriate testing adapter. A spark plug socket will
insert it easily. Tighten it snugly as you would a spark plug, but don't over tighten it, this
can damage your engine.
With the correct adapter snugly in place, screw the long black testing tube onto the silver
adapter. It's a pain in the neck to screw in, but just keep turning the whole thing like a giant
straw until its snug. Do not tighten the tube with a tool! Hand tight is enough.
With the testing tube firmly seated on the silver
adapter, you're ready to attach the test gauge.
The gauge displays engine compression. To
install it, pull back the collar at the end of the
gauge and slide it over the metal end of the tube.
Give it a tug to be sure that it's on.
You're all set up now and ready to actually do
the compression test. Double check that you
disconnected the appropriate stuff so the engine
doesn't actually start.
Page 41

Now turn the key and crank the engine over for about 10 seconds.
The needle on the compression gauge will stay at the highest indicated compression
reading. This number indicates the compression for that cylinder only. Record it so that you
can compare it to the other readings you're about to take.
Don't remove the gauge just yet!
Don't just remove the gauge, there's a lot of
pressure in the line and you want to release it
first. Thankfully they thought of this, and there's
a little button on the side. Depress the button
and you'll hear the pressure hiss out. Now it's
safe to remove the gauge, unscrew the testing
tube, and take out the adapter.
Replace the spark plug and repeat the whole
process on the next cylinder until you have
readings for all of them. Check your repair
manual to see if the readings you got are
healthy.
Results:
Remarks :
Page 42

b. Vacuum test:
Theory:
Engine vacuum tests are another great method of
pinpointing engine problems as well as determining
the overall health of your vehicles power plant.
Manifold vacuum is tested with a vacuum gauge.
The downward movement of the piston forms
vacuum during the intake stroke. If the cylinder is
properly sealed a maximum amount of vacuum will
be formed.
This will also improve the volumetric efficiency and
the power created by the engine. Why not make
sure you are getting the most out of the intake
cycle. You can interpret or identify many engine
conditions by monitoring a vacuum gauge.
You can test for proper valve timing that works together with ignition timing to insure
proper combustion. If the base timing setting is retarded a low steady reading can be
observed on the test gauge.
You can also verify a free-flowing exhaust system with no clogs or restrictions. This is a
great way to pinpoint the problem without having to drop the exhaust.
A clogged exhaust will show on the vacuum gauge as a low and steady reading that
decreases, with increasing engine rpm. A common restricted exhaust problem would be a
collapsed catalytic converter.
Ideally, each cylinder of an internal combustion engine will produce the same amount of
vacuum. This is why the vacuum gauge readings should be steady and give a reading of at
least 18 to 20 inches of mercury at closed throttle.
Engine vacuum tests results
If one or more cylinders produce less vacuum than the others the needle of the vacuum
tester will fluctuate. When performing the engine vacuum tests, the intensity of the
fluctuation of the needle on the vacuum gauge indicates the severity of the engine problem.
For example, if the reading on the vacuum gauge fluctuates between 9 and 19.
You should then look at the rhythm of the needle. If the needle stays at 19 inches of
mercury, but drops to 9 and then quickly rises we know that reading is probably caused by
a malfunction in one cylinder.
If the vacuum testers gauge reads low all the time let's say a reading of 10 inches and has
no fluctuation. This would be a good or strong indication of a clogged exhaust system.
This could be a clogged converter, restricted muffler or even a smashed or damaged pipe. If
you disconnect the exhaust system in front of the catalytic converter and the vacuum
returns to full strength, this would verify a clogged catalytic converter or other parts
behind it.
Page 43

What causes low engine vacuum tests results?
Stuck or burned valves and weak valve springs can cause in proper sealing of the
combustion chamber. Therefore providing low test results. If you think this applies to your
vehicle I put a page together about the old fashioned valve job.
Uneven compression caused by worn piston rings or damage cylinder walls can also cause
a fluctuating vacuum reading. Leaking cylinder head gaskets can also lower the ability of
your engine to create vacuum. And of course a manifold vacuum leak will also affect the
readings.
Performing engine vacuum testing is a cheap and easy diagnostic step in the right direction.
The tester itself can be found for less than $15. The tests procedure is basically just
connecting the gauge to a strong manifold vacuum source.
Most engines will have a few places where you can pull a vacuum line off the manifold and
insert the vacuum tester. I have also used the hose that goes to the power brake booster for
a quick test. Just make sure that you reconnect the hose before driving the vehicle.
Procedure:
Connect the vacuum gauge hose as close to the intake manifold as possible and start engine.
Run engine until normal operating temperature has been reached and then allow to idle.
On V type engines having two manifolds, make separate tests on each manifold. If required,
set the idle adjustment on the carburetor so that the engine idles smoothly.
NOTE: Vacuum readings will vary according to the altitude in different localities. From sea
level to 2,000 feet elevation all normal engines should show a vacuum reading between
17 to 21 inches. Above 2,000 feet elevation the vacuum reading will be about one (1) inch
lower per each 1,000 feet rise in elevation.
Results:
Remarks :
Page 44

Experiment
Experiment No: 08
Date: ____________
Study of Auxiliary Components
Aim: Dismantling & assembly of different carburetors, fuel injection pumps, injectors, fuel
tanks, turbo-chargers, cooling systems and lubricating systems. Identify location of above
components in a vehicle and note their functions.
Apparatus/Components required: Screw driver, Spanner, Hammer, Mallet, Needle
nose pliers, Allen Key, Vernier caliper, Micrometer.
a. Carburetor
Theory:
A carburetor is a mechanical device on an internal combustion engine, for the purpose of

mixing air and gasoline into a combustible fine vapor, in automatically changing
proportions, depending on the operating conditions of the engine. As an example, an engine
that runs continually at one speed, day in and day out has need only for a carburetor of the
simplest construction. One that has only to mix air and gasoline in one fixed ratio. However,
when the demands of the engine are changed and it is desirable to run it at variable speeds,
the carburetor must mix air and gasoline in different proportions and therefore, its
construction must be more complex.
Tabular Column:
SI. No.
Component
name
Tool used
No. of
fasteners
Dimension
Defects/Remarks
Page 45

b. Fuel injector pump
Theory:
Jerk type fuel injector pump

Distributor type fuel injector pump
An Injection Pump is the device that pumps fuel into the cylinders of a diesel engine.
Traditionally, the pump is driven indirectly from the crankshaft by gears, chains or a
toothed belt (often the timing belt) that also drives the camshaft. It rotates at half
crankshaft speed in a conventional four-stroke engine. Its timing is such that the fuel is
injected only very slightly before top dead centre of that cylinder's compression stroke. It is
also common for the pump belt on gasoline engines to be driven directly from the camshaft.
In some systems injection pressures can be as high as 200 MPa.
Tabular Column:
SI. No.
Component
name
Tool used
No. of
fasteners
Dimension
Defects/Remarks
Page 46

c. Fuel injector
Theory:
Fuel injection is a system for admitting fuel into
an internal combustion engine. It has become
the primary fuel delivery system used
in automotive
engines,
having
replaced carburetors during the 1980s and
1990s. A variety of injection systems have
existed since the earliest usage of the internal
combustion engine.
The primary difference between carburetors
and
fuel
injection
is
that
fuel
injection atomizes the fuel by forcibly pumping
it through a small nozzle under high pressure,
while a carburetor relies on suction created by
intake air rushing through a venturi to draw the
fuel into the air stream.

Modern fuel injection systems are designed specifically for the type of fuel being used.
Some systems are designed for multiple grades of fuel (using sensors to adapt the tuning
for the fuel currently used). Most fuel injection systems are for gasoline
or diesel applications.
Tabular Column:
SI. No.
Component
name
Tool used
No. of
fasteners
Dimension
Defects/Remarks
d. Diesel Fuel Injector Balance Pressure Tester
Page 47

Procedure:
Bolt the tester to your work bench

Fill the tester reservoir with diesel fuel
Use face respirator - test outside or below exhaust fan at window to vent fumes
Attach a fuel injector to the hard line fitting included
Bleed the air out at the injector fitting
Pump the handle a few times up to the point the injector fires (pops)
Note the consistency of the spray pattern
Read the release pressure
Hold pressure with handle just before release point and check for injector leaks
Disassemble the injector to inspect / clean
Select thicker or thinner shim washer to change pressure
Measure shims with dial caliper to confirm correct size
Clean, oil, and reassemble injector to proper torque
Repeat test and re-adjust pressure if needed
Replace with new nozzles if yours fail the test
Install back into your engine using new crush washers and injector return hose
Results:
e. Fuel Tank
Theory:
A fuel tank is a safe container for flammable fluids.
Though any storage tank for fuel may be so called,
the term is typically applied to part of an engine
system in which the fuel is stored and propelled
(fuel pump) or released (pressurized gas) into an
engine. Fuel tanks range in size and complexity from
the small plastic tank of a butane lighter to the
multi-chambered cryogenic Space Shuttle external
tank.
Tabular Column:
SI. No.
Component
name
Tool used
No. of
fasteners
Dimension
Defects/Remarks
Page 48

f. Turbo-Chargers
Theory:
A turbocharger is a turbine-driven forced induction device that increases an internal
combustion engine's efficiency and power output by forcing extra air into the combustion
chamber. This improvement over a naturally aspirated engine's power output is because
the compressor can force more air and proportionately more fuel into the combustion
chamber than atmospheric pressure alone.
Tabular Column:
SI. No.
Component
name
Tool used
No. of
fasteners
Dimension
Defects/Remarks
g. Cooling System
Theory:
Various methods used for cooling of automobile engines are
1 Direct cooling or cooling by air
2 Indirect cooling or liquid cooling
Air cooling:
The basic principle involved in this method is to have current
of air flowing continuously over the heated metal surface
from where the heat is to be removed. The heat dissipated
depends upon following factors;
a) Surface area of metal into contact with air
b) Mass flow rate of air
c) Temperature difference between the heated surface and air
d) Conductivity of metal
Page 49

Water cooling:
In water cooling system, the cooling medium used is water. In this, the engine cylinders are
surrounded by water jackets through which the cooling water flows. Heat flows from the
cylinder walls into water which goes to the radiator where it loses its heat to the air. Usually
some antifreeze is added to the cooling water, due to which it is often referred to as coolant.
Water cooling systems are of two types;
1 Thermosyphon system
2 Pump circulation system
Tabular Column:
SI. No.
Component
name
Tool used
No. of
fasteners
Dimension
Defects/Remarks
g. lubricating system
Theory:
The various systems adopted for the lubrication of automobile engine are
1 Petroil system
Splash system
2 Pressure system
3 Dry sump system
Petroil system
This is used generally for small two stroke engines, e.g. in majority of scooter and motor
cycle engines. It is the simplest of all types of engine lubrication systems. Certain amount of
the lubricating oil is mixed with the petrol itself, the usual ratio being 2% to 3% of oil. If it
is less, there is danger of oil starvation or insufficient lubrication causing damage to the
Page 50

engine; if however, it is more, there will be excessive carbon deposits in the cylinder head
and the engine will also give dark smoke.
When the petrol mixture enters the crankcase, due to high temperatures there, the petrol
component vaporizes leaving a thin film of lubricating oil on the crankcase, cylinder walls,
crankshaft and bearings.
The main requirements of lubricating oil for two stroke engine are that it should readily
mix with petrol and burn without leaving much residue.
Splash system:
This was employed for the engines of early
motor cycles. It is one of the cheapest methods
of engine lubrication. A scoop is made in the
lowest part of the connecting rod and the oil is
stored in the oil trough it being pumped there
from the crankcase oil sump. When the engine
runs the scoop causes the oil to splash on the
cylinder walls each time it passes through its
BDC position. This affects the lubrication of engine walls, gudgeon pin, main crankshaft
bearings, big end bearings etc.
Pressure system:
This system is used
almost universally
in
modern
car
engines. The splash
system
though
cheaper,
is
not
suitable
for
automobile engines
because
of
the
absence of positive
lubrication. In the
pressure system an
oil pump takes the
oil from the wet
sump through a
strainer
and
delivers it through a
filter to the main oil
gallery at a pressure
of 200 to 400kPa.
The oil pressure is controlled by means of a pressure relief valve, situated in the filter unit
or the pump housing.
Page 51

Dry sump system:
This system is employed in some

racing car engines for situations
where the vehicle has to be
operated at very steep angles, for
example, sports cars, jeeps etc. if
ordinary pressure system of
lubrication is used in such cases, the
situations may arise when there is
no oil at the place where oil pump is
installed. To avoid such instances,
dry sump system is used wherein
two pumps, instead of one, are
used. The scavenge pump A is
installed in the crankcase portion
which is the lowest. It pumps oil to
a separate reservoir B, from where
the pressure pump C pumps the oil
through filter D, due to the cylinder bearings; a full pressure system of lubrication is
employed. The oil pressure is maintained at 400-50 kPa for the main and big end bearings
while about 5-100kpa pressure is used for timing gears and cam shaft bearings etc.
Tabular Column:
SI. No.
Component
name
Tool used
No. of
fasteners
Dimension
Defects/Remarks

Page 52

Probable viva questions:
1. The constant volume process in I.C. engines is characteristic of the _________.
2. Compression-ignition engines use liquid fuels of _______ volatility.
3. Compression ratio maybe of the order of 11.5 : 1 to 22 : 1 in case of _______.
4. Low CO and hydrocarbon emission occurs at low and moderate loads in case of_______.
5. A triangular rotor rotates on an eccentric shaft inside an epitrochoidal housing, the rotor tips
being in constant contact with the housing and form three working chambers.
6. In case of aircraft engines, the power at 6100 m altitude is about_______% of the sea level
wide-open throttle output for any given speed.
7. The stroke-bore ratio in case of aircraft engines in normally _________.
8. The spontaneous combustion or autoignition of an appreciable portion of the charge
9. A divided chamber construction, a combination of the precombustion chamber and the
turbulence chamber design.
10. Early or late injection of fuel in the diesel engine results in _________.
11. Injection system which forces fuel through spray nozzle by hydraulic pressure.
12. It times, meters and forces the fuel at high pressure through the spray nozzle.
13. A restriction in the outer end of the carburettor to provide an extra rich air-fuel mixture for
starting.
14. Used to produce gas-tight seal between the piston and the cylinder liners.
15. It takes care of the fluctuations or the cyclic variations in speed.
16. Closes one end of the cylinder and contains the inlet and exhaust valves.
17. A _______is a device used to diminish noise of the intake or exhaust.
18. The finished part of a shaft which rotates in or against a bearing is called_______.
19. An item made of thin layers.
20. The most effective knock suppressor.
21. Optimum spark advance is the timing which develops maximum
22. Higher concentrations of NOx, are found in I.C. engines with_______compression ratio.
23. The principal source of exhaust carbon monoxide is_______.
24. Masses used for balancing purposes.
25. A device for atomising and vaporising the fuel and mixing it with air in varying proportions.
26. Used to step up 6 or 12 volts to high tension voltage of about 20 Kvolts.
27. The closed area formed by suction and exhaust operation in I.C. engines.
28. Ratio of brake power to indicated power.
29. The ratio of brake power output to the fuel energy input per unit time _________.
30. The ratio of the mass of the charge admitted during the suction stroke of the engine to the
mass at normal pressure and temperature of the volume of the charge equal to piston
displacement.
31. Ratio of the indicated thermal efficiency to the corresponding ideal air standard efficiency
32. The ratio of actual fuel air ratio and chemicall correct fuel air ratio.
33. Specific fuel consumption is minimum for fuel air ratio _________.
34. Mean effective pressure is maximum for fuel air ratio _________.
35. The mechanical efficiency of a multicylinder engine is determined by _______test.
36. The four stroke cycle is complete in _______revolutions of crankshaft.
37. For completion of four strokes, the cam shaft makes _______revolution.
38. In _______ engine only air is sucked in during suction stroke.
Page 53

39 operation in 4 stroke cycle petrol engine continues from 50 before bottom dead centre to 10
after top dead centre.
40. The thermal efficiency of diesel engine in comparison to petrol engine is ________.
41 _______ is used for obtaining required firing order in spark ignition engines.
42. Petrol engines employ governing.
43. Standard firing order for 4 cylinder petrol engine is _______.
44. Standard firing order for 6 cylinder petrol engine is _______.
45. Morse test is used for multicylinder spark ignition engines to determine
46. Auto-ignition reaction time for petrol-air mixture is minimum for relative fuel air ratio of
_______.
47. The tendency to knock in C.I. engines increases with_______the cooling water temperature.
48. Iso-octane in a fuel for spark ignition engines auto ignition.
49. Normal heptane in fuel for spark ignition engines _______auto ignition.
50. The knocking in S.I. engines increases with _______in compression ratio.
51. Advancing the spark timing in S.I. engines _______the tendency for knocking.
52. Tendency to knock in S.I. engines and the cooling water temperature are related.
53. Ignition quality of fuel for S.I. engines is determined by_______number rating.
54. The petrol available commercially in the country has octane number of_______.
55. The diesel available commercially in the country has cetane number of_______.
56. The knocking tendency in C.I. engines increases with ______ of compression ratio.
57. Name of the various fuel supply system?
58. Which one is most accurate fuel supply system for petrol cars?
59. Where the fuel pump is usually located in the car?
60. Why the carburetor float is made hollow?
61. What is the function of check valve is the carburetor?
62. What is the function of venturi in the carburetor?
63. Name any Indian vehicle using solex carburetor?
64. What is the purpose of petrol injection?
65. What is the common rail fuel injection system?
66. What are the various types of petrol injection system?
67. What is the function of a fuel feed pump/
68. What is the function of fuel injector?
69. What is the necessity for cooling an engine?
70. Name various method of engine cooling?
71. Name the main components of water cooling system?
72. What is the function of radiator in cooling system?
73. What is the necessity of engine cooling?
74. State different S.A.E. viscosity rating of oil?
75. What is the multi grade oil?
76. Which solid lubricant is most commonly used in automobiles?
77. What is viscidity?
78. Give an example of synthetic lubricant?
79. Multi-hole type diesel injectors are generally employed in _______.
80. Which one of the following carburetors does not contain separate accelerating pump circuit?
(a) Solex Carburetor (b) Zenith Carburetor
(c) Carter Carburetor (d) SU Carburetor
Page 54

References:
1) Automobile Engineering Volume I & II Dr Kirpal Singh, Standard Publishers Distributors
Delhi, 2011.
2) Internal Combustion Engines - Mathur and Sharma, Dhanpat Rai Publications, 2010.
3) Automobile Mechanics N.K. Giri, Khanna publications, 2011.
Page 55

Dayananda Sagar College of Engineering
Automobile Engineering Department
Bengaluru-560078
AUTOMOBILE ENGG. LAB -I (10AUL57)
PROBABLE/SUGGESTED QUESTION BANK
(Please include Question Bank of respective Lab here)
Appendix (If any)
Page 56

CONTINUAL EVALUATION FORMAT
(Academic Year)
S
No
.
USN
Semester /Section :
student Name
Expt. No: 1
Date:
Viva
(05)
Faculty Signature With

Date
Name of the Faculty Incharge
Record
(10)
Total
(15)
Expt. No:2
Date:
Expt. No:3
Date:
viva
(05)
Viva
(05)
Record
(10)
Total
(15)
Record
(10)
Batch :
Expt. No:4
Date:
Total
(15)
Viva
(05)
Record
(10)
(1)
(2)
(3)
Note:
(1) Viva questions to be asked w.r.t the current experiment of the particular week.
(2) The above same page format is used for next set of experiments i.e. 5, 6,.expts.
(3) Separate sheets must be used for different batches.
Page 57
Total
(15)

FINAL IA MARKS FORMAT
Year:
Semester /Section :
SN
USN
Batch :
Name Of The Student
Continual
IA Test
Evaluation
Marks
Marks
(10)
(15)
Final
Marks
(25)
Signature of
Student
Page 58

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CONTROL SYSTEMS LABORATORY MANUAL

Name of the Student :

DAYANANDA SAGAR COLLEGE OF ENGINEERING

Automobile Engg. Lab-I: [2016]

Vision of the Institute

Mission of the Institute

To provide an environment that enhances

Automobile Engg. Dept., Dayananda Sagar College of Engineering, Bengaluru

Automobile Engg. Lab-I: [2016]

AUTOMOBILE ENGG. LAB-I MANUAL

Name of the Student :

DAYANANDA SAGAR COLLEGE OF ENGINEERING

AUTOMOBILE ENGINEERING DEPARTMENT

Automobile Engg. Lab-I: [2016]

DEPARTMENT OF AUTOMOBILE ENGINEERING, BENGALURU-560078

VISION OF THE DEPARTMENT

Automobile Engg. Dept., Dayananda Sagar College of Engineering, Bengaluru

Automobile Engg. Lab-I: [2016]

DEPARTMENT OF AUTOMOBILE ENGINEERING, BENGALURU-560078

1. Study of hand tools- sketching, materials used and their applications.

Automotive engine lab-I aims to improve understanding of the automobile engines

Automobile Engg. Dept., Dayananda Sagar College of Engineering, Bengaluru

Automobile Engg. Lab-I: [2016]

DEPARTMENT OF AUTOMOBILE ENGINEERING

Automobile Engg. Dept., Dayananda Sagar College of Engineering, Bengaluru

Automobile Engg. Lab-I: [2016]

Automobile Engg. Lab-I: [2016]

Study of Hand Tools

Phillips screw driver:

Offset screw driver:

Automobile Engg. Lab-I: [2016]

Open Ring spanner

Automobile Engg. Dept., Dayananda Sagar College of Engineering, Bengaluru

Automobile Engg. Lab-I: [2016]

Double-ended tubular spanner

Single-ended tubular spanner

Spark Plug Wrench

Automobile Engg. Dept., Dayananda Sagar College of Engineering, Bengaluru

Automobile Engg. Lab-I: [2016]

Automobile Engg. Lab-I: [2016]

Automobile Engg. Dept., Dayananda Sagar College of Engineering, Bengaluru

Automobile Engg. Lab-I: [2016]

Piston ring removal

Automobile Engg. Lab-I: [2016]

Piston ring groove cleaner

A piston ring groove cleaner is a tool

Valve lifter tool

Automobile Engg. Dept., Dayananda Sagar College of Engineering, Bengaluru

Automobile Engg. Lab-I: [2016]

Automobile Engg. Lab-I: [2016]

Outside and inside calipers

Automobile Engg. Dept., Dayananda Sagar College of Engineering, Bengaluru

Automobile Engg. Lab-I: [2016]

Dial bore gauge:

Signature of Staff Incharge with date:

Automobile Engg. Lab-I: [2016]

Study of Engine Components

Automobile Engg. Lab-I: [2016]

Material for oil pan: pressed steel, aluminium alloy casting

Automobile Engg. Dept., Dayananda Sagar College of Engineering, Bengaluru

Automobile Engg. Lab-I: [2016]

Automobile Engg. Dept., Dayananda Sagar College of Engineering, Bengaluru

Automobile Engg. Lab-I: [2016]