Advance Automotive systems lab.

Experiment No: 1

Servicing of Turbocharger

Aim: Servicing of Turbocharger

Tools required: mechanic tool kit.

Materials required: cotton waste & kerosene.

Procedure:

1. Clean the outside of turbo charger with the cleaning solvent & blow by compressed air.
2. Clean the air passage & air filtering element.oil level in crank case.
3. Clean the duct & compressor area for carbon build up.
4. Change air filter & oil filter seal.
5. Adjust the oil levels.
6. Check the hoses from turbo charger & to it for blockage. As it may noise operation.
7. Check the spring at boost control, if worn out replace it.
8. Inspect the oil drain line a congested drain is noise. Observe oil for sludge or thick.
9. Change the oil & drain line also.
10. Finally check for blue smoke. If it is so check for engine reconditioning.

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Troubleshooting of Turbocharger

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Experiment No: 2

CONDENSER INSPECTION

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Troubleshooting of air conditioning system

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Experiment No: 3

Hydraulic Power Steering System

Aim: Servicing of hydraulic power steering system.

Tools Required: Toolkit, tube wrench, bleeding kit.

Materials Required: cotton waste, fluid.

Theory: Power steering is a hydraulic system assisting the driver in turning the front wheels. The system
usually consists of a hydraulic pump & fluid reservoir, a power actuating mechanism such as power
cylinder, control valve & a series of hydraulic hoses & couplings.

Servicing Includes:

Check power steering fluid level

Checking of belts & hoses for leak

Bleeding system

Checking power steering fluid level

To check the level of power steering fluid, you should not let the engine to run with the parking brake
set, place the transmission either in park or neutral.

Procedure:

• Unscrew & remove the cap to power steering reservoir, the cap will normally have dipstick
attached.

• Wipe off the dipstick & reinstall the cap, remove the cap and inspect the level of the fluid on the
dipstick.

• If required add enough fluid to reach the correct mark on dipstick.

Checking Belt & Hoses.

• Always inspect the condition of hoses & belt very carefully.

• The hoses are exposed to tremendous pressure if a hose ruptures. A sudden & dangerous loss of
power assist occurs. Make sure that the hose is not rubbing on hot components.

• Replace hoses if necessary.

• Loose belt can slip, causing belt squeal & erratic or high shocked belt may break during
operation which would cause a loss of power.

Basic Procedure For Installing Belt.

• Loosen the belts that hold the power steering pump to its bracket.

• Push inward on the pump to release tension on belt with tension removed slide the belt from the
pully.

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• Obtain a new belt & install in reverse order.

• Remember when adjusting belt tension to specification.

Checking System For Leak.

The fluid leakage with pressure over 1000psi, can develop leaks easily around fittings.

Procedure

• Wipe the fluid soaked area & start the engine at idle.

• While watching for leaks have steering wheel turned to right & left. This action will pressurize
all components of the system that might be indicate the leaking component to remove & replace
it.

Bleeding Of Power System

• To bleed out any air, start the engine & run the steering wheel fully.

• Checking the fluid & add as needed, this will force the air in to reservoir & out of system.

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Experiment No: 3A

Servicing of Power Rack And Pinion

Aim: Servicing of power rack and pinion

Tools required: Mechanic tool kit, vice

Materials required: cotton waste, kerosene.

Theory: This is in a power steering system, the rack has a slightly different design.

Parts of rack contains a cylinder with piston in middle. The piston is connected to rack. There are two
fluid parts. One on either side of piston supplying high pressure fluid to one side of piston forces the
piston to move, which in turn moves the rack, providing the power assistance.

Procedure:

• Clamp the assembly in the vise & remove control valves.

• Remove pressure tubes, arms & track rod, tie rods, boots claw washers etc..

• Remove rack guide springs lock nut, rack housing cap, control valve from housing, oil seal.

• Remove cylinder end stoppers

• Remove rack from rack housing & remove the bushes from rack.

• Remove cylinder housing oil seal, spacer with special tools.

Cleaning:

Clean all parts using cleaning solvent & blow by compressed air.

Inspection:

• Check the condition of boot, if cracked excessively replace it.

• Thoroughly examine rack gear, if damaged, cracked replace it.

• Thoroughly examine pinion gear, if damaged, cracked replace it.

• Inspect bearing if worn out replace it.

• Inspect tie-rod outer & inner socket.

• Inspect cylinder tubes for scratches or other damages if necessary replace it.

Assembling: Reverse the process of dismantling. After assembly test the same for proper working.

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Experiment No; 3B

Servicing of Hydraulic Power Steering Pump

Aim: Servicing of hydraulic power steering pump

Tools Required: Hammer press, ratchet, screw drivers, sockets, torque wrench & vise.

Materials Required: solvent, grease etc..

The pump is the heart of the hydraulic steering system. It converts rotational energy by engine in to
hydraulic energy, flow & pressure. For use of steering gear.

Procedure:

1. Stop the vehicle with wheels pointed straight & clean the outside parts of pump & hoses.
2. Remove the pump from vehicle & clean its outer surface before disassembly.
3. Place the pump in vise & clamp firmly. Drain the fluid.
4. Remove the valve spool assembly.
5. Separate the housing from the cover & remove spring.
6. Separate each part of pump & clean all parts.
7. Disassemble the spool & count the shims

Inspection:

1. Inspect housing for cracks, stripped threads, damaged sealing area.

2. Make sure for nicks in O-rings, seal drain, bottom plate rests are worn out or not.
3. Inspect needle & needle bearing, top plate seal area nicks & abnormal wear.
4. Inspect the rotor vanes are properly rotating or for broken vanes & input shaft for damaged
splines
5. Check relief valve seat assembly for wear & spool for nicks.

Assembly: Assemble all components which is reverse process of dismantling.

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Troubleshooting of power steering system

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Experiment No: 4

Wheel Balancing

Aim: to conduct an experiment on wheel balancing machine to balance by applying weight in suitable
points as per the result shown by balancing machine.

Tools required: mechanic tool kit, hammer.

Equipments required: wheel balancing machine.

Materials required: cotton waste & wheel weights.

Procedure:

1. Remove the wheel & tyre assembly from vehicle.

2. Mount this assembly on the balancing machine as recommended.
3. The safety hood is lowered over the tyre & activates the balancer control to spin the wheel.
4. Operate the balancer brake to slow & stop the wheel & observe the display to determine the size
& location of weight.
5. Install the weights on the wheel using hammer & pliers.
6. Spin the wheel again on the balancer, the screen should indicate a balanced wheel assembly.

Remove the wheel from balancing machine & place it on the vehicle based on wheel alignment marks.

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Experiment No: 5

Manual/Computerised Wheel Alignment

 Alignment Measurements
There measures to each alignment: caster, camber, toe and thrust angle. Because this is a Back2Basics
article, we are not going to get too deep into the explanations, driver desires or options here; more
advanced explanations are available from many resources.

• Camber: This suspension angle shows how the tire angles away from 0 degrees vertical when viewed
from either the front or rear of the vehicle. Expressed in degrees, negative camber means the top of the
tire tilts toward the center of the vehicle, while positive camber means the top of the tire tilts away from
center. A visual cue for a camber problem is excessive tire wear on the inner or outermost ribs.

• Caster: This angle shows the forward or backward slope of a line drawn through the upper and lower
steering pivot points, when viewed directly from the side of the vehicle. Also expressed in degrees, caster
is measured by “comparing a line running through the steering system’s upper and lower pivot points
(usually the upper and lower ball joints of an A-arm or wishbone suspension design, or the lower ball
joint and the strut tower mount of a McPherson strut design) to a line drawn perpendicular to the
ground,” Tire Rack experts say. “Caster is said to be positive if the line slopes toward the rear of the
vehicle at the top, and negative if the line slopes toward the front.” A visual cue for a caster problem is
serious tire scrub laterally across the tread face.

• Toe: Identifies the direction tires are pointed relative to the centerline of the vehicle, when viewed from
directly above. Toe can be expressed in either degrees or fractions of an inch. When looking down upon
a vehicle, “toe-in” is when the leading edge of the tire is pointed toward the centerline of the vehicle.

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Conversely, “toe-out” refers to a tire face which points away from the vehicle centerline. “The toe setting
is typically used to help compensate for the suspension bushings compliance to enhance tire wear. Toe
also can be used to adjust vehicle handling,” Tire Rack experts say.

• Thrust Angle: Consider an imaginary line drawn perpendicular to the rear axle’s centerline. This
measure, expressed in degrees, compares the direction that the rear axle is aimed with the centerline of
the vehicle. Thrust angle also confirms if the rear axle is parallel to its front axle and that the wheelbase
on both sides of the vehicle is the same. “If the thrust angle is not correct on a vehicle with a solid rear
axle, it often requires a trip to the frame straightening shop to correctly reposition the rear axle,” Tire
Rack says.

Note: There are a variety of reasons for any of these alignment measures to be incorrect. At the same
time, adjustment angles can be adjusted by a skilled technician to correct for inherent vehicle problems,
correct for unusual tire wear, or to improve the performance and feel of a vehicle.

Alignment Specifications
All vehicle manufacturers have set specific alignment specifications for each of their vehicles. These are
the “preferred” angles for camber, caster and toe (with preferred thrust angle always being 0 degrees).
provide the acceptable “minimum” and “maximum” angles for each specification, and are usually within
plus or minus one degree of the preferred angle.

Alignment Procedure

• Drive the vehicle onto your alignment rack. Chock wheels and raise lift to a comfortable and safe work
height, then lock the rack. Lift the vehicle by the center jacks of the alignment rack, suspending the
wheels. This will allow you to check tires for uneven, irregular wear, as well as to visually check the
front-end and rear axle for any compromised suspension or steering components. If there is a bad ball
joint, tie-rod end, broken coil spring, loose wheel bearing, or any other problem with the suspension or
steering, the component needs to be replaced before the alignment is performed.

• Next, check and adjust tire pressures to OEM specification; some systems have an automatic inflation
feature. Remove hubcaps if present.

• Mount targets to wheel ends as required by the rack manufacturer. Most alignment racks require the
alignment heads be attached to all four wheels, even if no adjustments are made to the rear wheels. With
many FWD vehicles, adjustments can be made to the rear and should be performed before the front
wheel alignment adjustments are made.

• Depending on your alignment equipment and system, there are unique procedures that will measure the
current camber, caster and toe angles of the vehicle and report that information either on a print-out or on
a diagnostic screen. Some systems even print a “symptom report” that you can show the customer, which
explains the potential damage to tire health if alignment issues are not corrected.

• As previously mentioned, if the rear alignment needs to be adjusted, this has to be performed before
working on front-end adjustments.

• With front-end alignments, correct caster and camber adjustments first. Certain FWD vehicles do not
offer caster adjustments, but correcting the camber may bring the caster within specs. Refer to the

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alignment machine instructions (or a repair manual) for the specific vehicle to perform the correct caster
and camber adjustments.

• With caster and camber adjusted, then adjust toe angles.

• Restart the car, remove the steering wheel lock, turn the steering wheel back and forth a couple times,
then re-center and replace the steering wheel lock. Recheck alignment specifications, and then readjust
angles as necessary.

• Remove the alignment heads and lower the vehicle.

• Complete the alignment by taking a test drive to ensure any previously noted symptoms are gone or can
be attributed to other vehicle issues (such as vibrations caused by worn suspension parts).

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Troubleshooting of wheel alignment

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Experiment no: 7

Servicing Of Vacuum Servo Brake Booster

Aim: Servicing of vacuum servo brake booster

Tools Required: Mechanic tool kit bench, vice.
Materials Required: cotton waste & kerosene.
Procedure:
Dismantling:
1. Chock the front & rear wheels, remove brake pedal return spring & connections.
2. Loosen the foundation nut & take out the assembly.
3. Clean the external side of booster & remove non return valve.
4. Fix the booster in bench vice & disassemble the booster.
5. Remove the diaphragm return spring & pivot assembly.
6. Remove diaphragm, segment retainer, spring guide, disc, seal ring & operating rod assembly
with filters.
7. Loosen the nuts from rear housing, remove lip seal, filter retainer, gaiter.
Cleaning & Inspection:
1. Wash & clean all the parts & dry with compressed air.
2. Inspect all the parts for wear, if necessary replace & check valve body, diaphragm, disc for
damage.
3. Use the recommended repair kit.
Assembly:
1. Lube all the moving parts & replace worn out or damaged parts.
2. Assemble the seal rings with new one.
3. Reverse the disassembling process for assembly. & fix it to the vehicle.

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Experiment No: 8A

Servicing of Air Brake Valve.

Aim: Servicing of Air Brake Valve.

Tools Required: mechanic tool kit, bench vice.

Material Required: cotton waste, kerosene etc..,

Procedure:

Removal:

1. Release the entire air pressure from the system.

2. Clean the air lines & connections.
3. Disconnect the air lines & plug the open ends.
4. Remove the brake valve assembly by unscrewing the mounting nuts.
5. Remove boots, plunger, adapter plate, spring washer.
6. Remove the piston, return spring, rubber O-rings, inlet cap nut,
7. Remove inlet & exhaust valve, valve seating, valve guides valve stem.
8. Remove plug, washer, exhaust diaphragm valve.

Inspection:

1. Clean all the parts and inspect for damage, scratches, nicks.
2. Inspect body for damage.

Assembling:

Lubricate the required parts & replace worn out parts. Assemble in reverse procedure of dismantling.

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Experiment No: 8B

Servicing of Unloader Valve.

Aim: Servicing of unloader valve.

Tools Required: mechanic tool kit, bench vice.

Materials required: cotton waste, kerosene.

Procedure:

Dismantling:

1. Park the vehicle on level ground using parking brakes.

2. Drain the air from connections & clean connections & hoses.
3. Disconnect all the connections & measure the length of adjusting screw.
4. Remove mounting top cover, spring retainer, washer & spring, spring guide etc..,
5. Remove exhaust gaiter, internal circlip, spring retainer, valve guide, plug & washers.
6. Remove unloader plunger, sealing rings, filters, retainer plate, end cover & nor return valve.

Cleaning & Inspection:

1. Clean all the parts & pipe lines. & blow by compressed air.
2. Inspect body & cover, threads for crack or damages.
3. Check valve seating, unloader valve, governing plunger bore for wear.
4. Check rings, circlips & springs.

Assembling:

1. Lubricate all the moving parts & reverse the dismantling procedure by replacing damaged or
worn out parts.
2. Mount on the vehicle & adjust as per specifications.

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Experiment No: 8C

Servicing of Brake Chamber.

Aim: Servicing of Brake Chamber.

Tools Required: mechanic tool kit, bench vice.

Material Required: cotton waste, kerosene etc..,

Procedure:

Dismantling:

1. Note down the position of brake lever & brake chamber push rod to refit them.
2. Disconnect airlines & push rod yoke.
3. Clean the brake chamber assembly externally.
4. Remove the brake chamber from the mountings.
5. Remove the lock nut from push rod.
6. Fit assembly on vice. Remove the clamp ring, pressure plate & diaphragm.
7. Remove the push rod assembly, spring, seal assembly from pressure plate.

Inspection:

Clean all the parts & inspect damaged parts & replace it.

Assembly:

Use reverse procedure of dismantling with replacing the worn out & damaged parts.

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Experiment No: 9

Servicing Of Air Brake Air Compressor.

Aim: Servicing of air brake air compressor.

Tools Required: mechanic tool kit, bench vice.

Material Required: cotton waste, kerosene etc..,

Procedure:

Dismantling:

1. Remove the drain plug & drain the air tank.

2. Disconnect air lines & plug the open ends of the air lines to avoid entry of air.
3. Remove mounting brackets & remove the tank.
4. Remove safety valve body, circlip, retaining plate, ball & spring.

Inspection:

1. Inspect visually air tank for cracks & welded ends. If cracks are found re weld it.
2. Check the ball & sealing in the valve body & spring for any damage replace it.

Assembling:

Assemble in the reverse procedure of dismantling & mount it on vehicle.

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Experiment No: 10

Brake Drum Skimming

Aim: to learn how to measure the brake drum & recondition it.

Tools Required: inside micrometer, wilding rod with feeler gauge, work bench with vice.

Equipments Required: brake drum skimming lathe or lathe to accommodate the drum.

Procedure:

1. Place the drum on work bench

2. Measure the inside dia of the drum at different places & note the reading
3. The difference should not be more than 0.005
4. Place the drum on the lathe check the centre of drum
5. Attach the left hand tool on the tool post and lock it.
6. Turn the depth to minimum depth to clear the ovality & scoring in drum.
7. Do not take more than 0.060 depth, if more the drum is to be replaced.
8. Remove the required cavity.
9. Remove the drum & clean the lathe.

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Experiment No: 11

Brake Shoe Riveting Machine

Aim: to replace the old brake shoe lining by new one using riveting & de-riveting machine.

Tools Required: Bench vice, hammer, centre punch, files.

Materials required: cotton waste & rivets.

Equipments Required: Riveting & de-riveting machine.

Procedure:

1. Fix the de-riveting tool in the tool holder & tighten.

2. If old rivet has projection file it to level it.
3. Mount the brake shoe & adjust the tool.
4. Press the pedal to remove the old rivet.
5. Similarly remove all rivets & remove lining materials.
6. Remove the tool & fix the riveting tool.
7. Clean the brake shoe & place the new lining material.
8. Rivet it using the machine.

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Troubleshooting of air brake system

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Experiment No: 12

Practice on Measuring Stopping Distance

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Stopping distance under dry conditions

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