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Due for revision............................................... AT-01-13

STUDENTS’ TEXT
AMENDMENT RECORD

Sl Date Amendment Detail Authority

No
AUTOMOBILE TECHNOLOGY

(CI ENGINE,S/MAZ & E/CANTER)

MAY 2018

AUTO TECH

IPT-TERM II

MTTI AF
_______________________________________________________
DESIGNED FOR TRAINING COURSE USE, DO NOT QUOTE AS AUTHORITY

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AT-01-13

CI ENGINE,S/MAZ & E/CANTER

CONTENTS
Chap Syllabus Index Page
COMPILED BY : JWO SK Mandal MT Fit Subject
No. No No
CI Engine
EDITED BY : JWO A Settu MT Fit
1 Compression ignition (CI) Engine ATT/AT(CI)/T2/1 1-10

2 Fuel System ATT/AT(CI)/T2/2 11-25

EDITED ON : Apr 2018
3 Intake and Exhaust System ATT/AT(CI)/T2/3 26-31

4 Faults Analysis and Rectification ATT/AT(CI)/T2/4 32-33

CHECKED BY : Wg Cdr V Bhargavi Shankar AE(M)
Swaraj Mazda and Eicher Canter
Leading Particulars and Special
5 ATT/AT(CI)/T2/5 34-39
Features of S/Mazda & E/Canter
6 Cooling System ATT/AT(CI)/T2/6 40-44

7 Engine Lubrication System ATT/AT(CI)/T2/7 45-51

8 Transmission System ATT/AT(CI)/T2/8 52-57

9 Suspension System ATT/AT(CI)/T2/9 58-61

10 Steering System ATT/AT(CI)/T2/10 62-65

11 Brake System ATT/AT(CI)/T2/11 66-71

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CHAPTER- 1
4. Advantages & Disadvantages of CI Engine. Advantages & COMPRESSION IGNITION (CI) ENGINE
disadvantages of CI engine are given below:-

(a) Advantages. Following are the advantages of 1. Introduction and Principle of CI Engine. Compression
compression ignition engine over spark ignition engine. ignition engines are also known as diesel engine. In this engine, only air
is compressed in place of fuel and air mixture (as in SI engine). Due to
(i) It utilizes less expensive fuel and gives better fuel compression, enormous heat is produced inside the combustion
economy compared to petrol engine. chamber, which ignites the fuel sprayed. Thus in diesel engine, fuel is
ignited by compressed air; hence diesel engines are known as CI
(ii) Reduced fire hazard due to high flash point of engine. Brief description of CI & SI are as follows:-
diesel.
(a) Compression ignition engines are similar to spark ignition
(iii) More reliable due to absence of carburettor and engine since same basic components are used in the mechanical
ignition system. FIP and Injectors are less prone to layout e.g. cylinder, crankshaft, connecting rod etc. But some
faults. parts are made more robust and heavier to withstand great stress
involved in compression ignition engines.
(iv) Better suited for supercharging because of less
fouling and dilution of the lubricating oil. (b) The main difference between two types is that carburetion
and ignition equipments fitted in spark ignition engines are
(v) Because of low exhaust temperature, exhaust valve replaced by fuel injection and injectors on compression ignition
does not burn out as quickly as those of petrol engine. engines

(vi) Less heat is lost to the cooling system, thus a 2. Difference between S I and C I Engine. The difference
smaller radiator is used. between SI and CI engine are given below:-

(vii) Under correct operating condition, the exhaust SI Engine CI Engine

gases are comparatively purer with very low carbon
monoxide content. Uses petrol as fuel Uses diesel as fuel
Air and fuel mixture is drawn inside Pure air is drawn inside during
(viii) Higher thermal efficiency because the CI engine cylinder during induction stroke induction stroke
operates at much higher compression ratio than petrol Air fuel mixture is compressed to Air is compressed to 1/20th of
engine. 1/6th of the total volume of the the total volume of the cylinder.
cylinder.
(ix) It has longer operating life.

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and raises the pressure and temperature of gas to 45-55 Kg/ cm²
Pressure generated due to Pressure generated due to
and 2200°C respectively.
compression of air fuel mixture is compression of air is 400-500 PSI
90-100 PSI.
(c) Power Stroke. The hot products of combustion expand
Temperature of compressed air Temperature of compressed air is
and force the piston downwards. The burning is spread over the
fuel mixture is 60 ºC - 80ºC. around 500 ºC - 700 ºC.
period of injection of the fuel. This prolonged burning imparts a
Spark is given by spark plug to Fuel is injected on hot air.
more sustained pressure on piston during power stroke as
ignite the air fuel mixture
compared to more rapid rise of pressure obtained in the spark
Carburettor is used to supply Fuel injection pump and injectors ignition engine. At the end of this stroke, the pressure and
correct air fuel mixture as per are used to supply fuel to each temperature of the gases come down to 5 Kg/ cm² and 600°C
engine speed. cylinder as per firing order. respectively.
Less reliable More reliable

3. Construction and Operation of Four Stroke Engine. A

German engineer, Dr. Rudolf Diesel designed an engine in 1897 which
worked on a much higher compression ratio than the petrol engine. The
compression ratio of CI engine is usually 12:1 to 20:1 as compared 6:1
to 10:1 in Spark Ignition engine. In this engine, four strokes are also
completed in two revolution of crankshaft and very similar to spark
ignition engine. They are as follows (Refer Figure No.1.1).

(a) Induction Stroke. During this stroke, the piston moves

downwards from TDC to BDC creating a partial vacuum inside
the cylinder. The inlet valve remains opened and atmospheric air
enters inside the cylinder due to the pressure difference.

(b) Compression Stroke. During this stroke, piston moves

upwards from BDC to TDC. Both valves remain closed; the air is
compressed to high pressure of 25-45 Kg/cm² and temperature
rises to 500°C - 700°C. This temperature is higher than the Fig. No. 1.1 : Four Stroke Cycle
required self -ignition temperature of fuel (100°C -300°C). At the
end of this stroke, fuel is spread into the combustion chamber by (d) Exhaust Stroke. The ascending piston forces out the
means of an injector under a pressure of about 150Kg/cm², which exhaust gases to the atmosphere. The exhaust valve remains
is higher than that existing pressure in the cylinder. The fuel opened throughout the stroke.
having a self - ignition temperature of about 400°C, self ignites

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8. Easy Starting Aids. In cold weather, difficulty is experienced (b) Disadvantages of CI Engine. Following are the
while starting the engine; especially, engines employed with pre- disadvantages of CI engine over SI engine are as follows:-
combustion chamber and indirect injection. This is due to the greater
heat loss and consequent lower final temperature of the compressed air (i) The initial cost is higher.
in the cylinder. To overcome these disadvantages, various forms of
starting aids are used on different engines. Basically three types of (ii) The power/weight ratio is lower because CI engine
starting aids are used on modern high speed diesel engines. They are requires stronger engine parts which become heavier.
as follows:
(iii) More efficient filtering of fuel is required.
(a) Manifold Heaters. Manifold heaters fed with fuel are
widely used for easy starting during extreme cold weather (iv) High speed CI engine delivers roughly 20 horse
condition. It consists of a small electrical heater rated at about power per litre of piston displacement compared to 40
150 watt and installed in the manifold. A small amount of fuel is horse power for SI engines. Thus CI engine require more
fed on to it. The ongoing air passing through the heater picks up space for same power output.
heat as well as partially burnt products which aids in combustion
process. Manifold heaters are commonly used for direct injection (v) The CI engine is difficult to start than the SI engine
engines where the heater plugs cannot be fitted in the because it requires greater cranking effort to overcome
combustion chamber. In its crude form, holding a burning pad higher compression pressure.
soaked in fuel at intake manifold can be used with any engine in
case difficulty is experienced in starting during extreme cold 5. Diesel Knock. The most noticeable characteristics of CI engine
weather condition. is the feature, which is commonly called ‘Diesel Knock’. It gives rough
and noisy running. When fuel is sprayed into cylinder, initially small
(b) Electric Glow Plug/Heater Plug. These are very amount of fuel particles come in contact with air particles. Burning and
commonly used with pre-combustion chambers. Electric glow rise in pressure takes place and this burning process keeps occurring
plug initiates combustion by acting as localized igniters (some of throughout the injection period which creates high pressure waves
fuel spray reaching the plug). The advantage of electric glow plug inside the cylinder. This high pressure waves created during power
is its simplicity and reliable operation. However presence of the stroke cause diesel knock. The piston head receives unevenly heavy
plug and its recess reduces the engine performance slightly load which sounds like hammer blow, known as knocking.
Heater plug is generally screwed into the pre-combustion
chamber of each cylinder in the manner of spark plug. A wire 6. Steps to Avoid Diesel knock. Steps to avoid diesel knock are
element glows when current from the battery is passed through listed below:-
by closing a switch. The switch is closed for 30 seconds during
this period; the combustion chamber walls are heated up and (a) Diesel knock can be reduced by increasing the turbulence
then the starter is operated. A warning light indicates when the of compressed air which promotes homogeneous mixture by
heater plugs are switched on. stripping the fuel from the spray.

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(b) By increasing the pressure of the injected fuel which minimum clearance is left between the cylinder head and piston
encourages atomization of fuel and prevents diesel knock. when piston is at TDC. On some engines, each cylinder has
second combustion chamber which communicates with the first
7. Type of Combustion Chamber and its Description. The most chamber. The fuel is injected into the Pre-combustion chamber
important function of the CI Engine combustion chamber is to mix fuel and combustion is initiated. The resulting pressure rise forces the
and air within a short time. Describtion of two types of combustion flaming droplets together with some air and combustion products
chambers are given below:- rush out at high velocity through the small hole into main
combustion chamber, where bulk of combustion takes place.
(a) Open Type (Direction Injection) Combustion Chamber. Asthe piston starts to descend, the high-pressure in the chamber
An open type combustion chamber is defined as one in which the forces the product of partial combustion and the remaining fuel
combustion space is essentially a single cavity with little through communicating passage. Thus high turbulence is
restriction. There are no large differences in pressure at different created which assists the final combustion in the cylinder and the
parts of the combustion chamber during the combustion process. piston is protected from the high initial pressure arising from too
Induction swirl method is used in open combustion chamber in rapid combustion.
which flow of the air is directed during its entry into the cylinder.

Injector

Pre
Combustion
Chamber

Combustion
Chamber

Fig. No. 1.2 : Open Type Combustion Chamber

(b) Pre-Combustion (Indirect Injection) Type Chamber. It

Fig. No. 1.3 : Pre-Combustion Chamber (Indirect Injection)
consists of pre-combustion chamber or anti-chamber connected
to the main chamber through a narrow throat or holes. Only the

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(c) Injection of Ether. This method is based on the unique

3. Main Components of Fuel System. Main components are:- properties of ether. Ether has a very low self-ignition temperature
and has wide range of mixing strength. Therefore, injection of a
(a) Fuel Tank small amount of externally carburetted mixture (with limited air to
avoid high pressure rise) would fire a diesel engine even at every
(b) Fuel Feed Pump (Transfer Pump) low ambient temperature or at low cranking speed. In this system,
a capsule of ether is placed in a separate container having a
(c) Fuel Injection Pump sharp edge rod with pumping system. This container is connected
to induction manifold by means of a metal pipeline. Before
(d) Fuel Filters
starting the engine, one capsule is placed in the container and by
(e) Injectors pressing the handle; capsule is punctured by sharp edge rod and
then pumped to the induction manifold. The ether having lower
(f) Governor flash point than the fuel, is easily ignited, thus engine is started.
Ether capsule is replaced for every start of engine during cold
4. Purpose and Description of Main Components in Fuel weather condition.
System. Purpose & description of main components are:-

(a) Fuel Tank. Fuel tank is provided to store the fuel and
can be located at any suitable place in a vehicle.

(b) Fuel Feed Pump. This pump is fitted to those engines in

which the tank is positioned below the level of the injection pump.
It lifts the fuel from a low level tank and supply at a higher level
fuel injection pump. It is mounted on Fuel Injection Pump body
and gets drive from FIP camshaft. A gauge filter is provided in the
banjo bolt at the inlet side.

(c) Fuel Injection Pump. The pump supplies measured

quantity of fuel to the injectors at correct intervals. Normally, inline
fuel injection pumps and rotary pumps are used in the
automobiles. Latest fuel systems like CRDI (Common Rail Direct
Injection) are equipped with PT Pumps (Pressure Time Pump).
Fig. No. 1.4 : Injection of Ether
(d) Fuel Filters. Very efficient filters are employed in CI
engine because of the small working clearance between the
plunger and barrel in fuel injection pump.

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SUMMARY CHAPTER- 2
FUEL SYSTEM
1. During the induction stroke, only pure air is drawn in a CI Engine.

2. During the compression stroke, the air is compressed to 400-500 1. Introduction to Fuel System. In general, the fuel system for
PSI and heated to the temperature of 500°C to 700°C which is sufficient compression ignition engine is broadly similar to those used for spark
to ignite the fuel when sprayed. ignition engine. The requirement is to supply liquid fuel to the carburettor
in SI engine and to the fuel injection pump in CI engine. The type of fuel
3. The compression ratio of CI engine is between12 – 20: 1 as feed system employed will depend mainly on the positioning of fuel tank.
compared to spark ignition engine (6 - 10: 1). Either the tank is mounted high enough to be able to feed the injection
pump by gravity or a feed pump is used to supply the fuel to the injection
4. The longer the delay period, the quicker will be the pressure rise pump. Each injector is supplied fuel by its own individual pump, but it is
during second phase of combustion. more usual to incorporate all the pumps in one component i.e. inline fuel
injection pump. The differences between the two systems are explained
QUESTIONS below:-
1. Why diesel engine is known as compression ignition engine? (a) Different fuels are used.
2. What are the advantages and disadvantages of CI engine over SI (b) The carburettor supplies fuel directly into the engine
engine? whereas the fuel injection pump supplies fuel to individual
cylinders by means of pipes and injectors.
3. What are direct and indirect type combustion chambers?
(c) A much finer degree of filtration of fuel is required before it
4. Write short notes on: reaches to injection pump on compression ignition engines.
(a) Pre-combustion chamber. 2. Objective of Fuel System. Any combustible substance, which
liberates (releases) heat energy on combustion, is called fuel. Fuel is in
(b) Injection of Ether. the form of liquid gas energy which is converted into heat energy by the
process of combustion and ignition in automotive engines. The power
and performance of an automotive engine depends upon the type of fuel
used. The fuel supply system takes liquid fuel from the fuel tank and
delivers it to various cylinders to form the combustible mixture.

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8. Introduction to Feed Pump. Fuel has to be fed to diesel

engine under pressure of about 1 atmospheric pressure as the quantity
of fuel delivered would otherwise be inadequate. Only in stationary
engines and in some tractors, a gravity feed tank can be placed at high
level so as to provide sufficient pressure. Hence in diesel vehicles, fuel
has to be pumped to fuel injection pump. Fuel feed pump has been
designed to meet this demand. Feed pump is of two types, i.e. single
acting and double acting.

9. Construction of Single Acting Feed Pump. A Fuel feed

pump consists of Roller, Tappet, Pressure spindle, Plunger, Suction and
pressure valves and Plunger spring. The roller is mounted on tappet by
means of pin and is free to rotate on it. At the same time, roller tappet
assembly is free to move in the channel formed in pump body on guide Fig. No. 2.1 : Pump Feed System
pin. Pressure spindle is just like small rod placed between tappet roller
and plunger. Barrel is formed in the pump body. Suction and pressure (e) Injector. Injectors are directly or indirectly mounted in
chambers are formed below and above the plunger. combustion chamber. They spray fuel in a fine atomised form into
the combustion chamber. Injector consists of injector body,
nozzle, spring and needle valve. Electromagnetic injectors are
used in modern automobile.
(f) Governor. The Governor controls the maximum and
minimum speed of the engine and can be operated either
mechanically or pneumatically.

5. Fuel Filter and its Type. The fuel system of an automobile

engine has filters and screens to prevent dirt in the fuel. It consists of
three main parts i.e. housing, filtering element and cover. The housing is
made of pressed steel and contains the filtering element. The cover
holds the filtering element inside the housing and provides connection
for in and out flow of the fuel. The fuel has to pass through filtering
element before it goes out. Thus all the dirt is accumulated in the
housing and the filtered fuel is delivered out. A drain plug is provided at
the bottom of the housing to drain out any contamination. There are two
Fig. No. 2.4 : Single Acting Feed Pump types of filters:-

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(a) Cloth or Felt Type (Pre Filter). (b) Remove the drain plug and drain the fuel.

(b) Paper Filter (Micro Filter). (c) Remove centre bolt from top cover and pull the element
and lower supporting plate.
High Pressure Pipe Lines
(d) Flush the lower supporting plate with fuel.

(e) Fit the drain plug.

(f) Replace the filtering element with new one.

(g) Before fitting the filter, check the condition of ‘O’ ring
provided with element.

(h) Fit the filter in reverse order and bleed the system.

FIP
Fuel
Feed Pump Filter Outlet
Governor Fuel Line from Tank
Fig. No. 2.2 : Fuel System Components Inlet
6. Introduction to Fuel Filters in Swaraj Mazda. Earlier,
Cover t
S/Mazda vehicle was provided with dual type filtering element but
nowadays it is equipped with single element replaceable type filter. The
Centre Bolt
impurities are collected in the filter element; larger dirt particles and
waste settle in the lower supporting plate in the form of sludge. It has a
drain plug. In order to drain this sludge, the drain plug should be
removed. Supporting
Plate
7. Removal, Cleaning and Ffitment of Fuel Filters in S/Mazda.
Removal, cleaning & fitment of fuel filters in S/Mazda are as follows :-
Fig. No. 2.3 : Fuel Filter S/Mazda
(a) Loose the air vent screw in top cover.

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15. Lay Out of Fuel System of S/Mazda. The layout of fuel system 10. Operation of Single Acting Feed Pump. The operation of
in S/Mazda vehicle is given below.-:- the single acting feed pump is completed in two strokes are:-

(a) Fuel tank. Fuel tank is made up of mild steel sheet and (a) Intermediate Stroke (Downward). During this stroke, the
it is galvanized to have anti corrosive qualities. Baffles are revolving eccentric of FIP camshaft presses the plunger through
provided inside the tank to avoid shaking up of fuel due to road tappet roller and pressure spindle against spring tension. Suction
irregularities. The vent pipe is provided on the fuel tank so that is created on top of plunger and pressure is created below
atmospheric pressure can act inside the fuel tank. It is fitted at the plunger. Due to pressure in suction chamber, suction valve
right side of chassis side member with the help of fixing band. closes and pressure valve opens and the fuel present in suction
Fuel gauge float unit is fitted in the tank to show the quantity of chamber equal to the swept volume is delivered through pressure
fuel in tank. valve to the pressure chamber. This stroke is known as
intermediate stroke as fuel is being transferred from suction
(b) Water Separator. The sedimenter type water separator chamber to pressure chamber.
separates diesel and water centrifugally by taking advantage of
their difference in specific gravity. The water separator sediments
not only water but also dust particles from fuel. A red float, going
up and down. with the water level in semi-transparent case,
makes it possible to visually check the water quantity. The fuel Hand Primer
flown in from the inlet connector is squeezed by the fuel path in
sedimenter head to increase velocity and spin. Inlet

Pump Body
Baby filter

Mounting Flange
Roller Tappet

Fig. No. 2.5 : Parts of Single Acting Feed Pump

Fig. No. 2.7 : Water Separator

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(b) Feed and Suction Stroke (Upward). As soon as the (a) Hand priming knob
eccentric passes away its maximum stroke, plunger along with
pressure spindle and roller tappet moves upward due to spring (b) Hand primer
tension. Due to upward movement of the plunger, pressure is
created in the pressure chamber and the portion of fuel present in (c) Pump body
pressure chamber is thereby delivered to the injection pump
through filter. Simultaneously, suction is created below plunger. (d) Suction Valve & spring
Due to suction, suction valve opens and pressure valve closes
and fuel is drawn from the fuel tank to suction chamber through (e) Plunger & spring
preliminary filter. This stroke is known as suction and feed stroke
because suction and feed both takes place simultaneously. (f) Operating Spindle

11. Elastic Operation. The volume of pressure chamber is

comparatively less than suction chamber by the volume of pressure
spindle. Therefore, during the intermediate stroke, a quantity of fuel
equal to the volume of the spindle is fed to the injection pump. When the
pressure in the feed pipe exceeds a specified value, the plunger spring
lifts the plunger by only part of a stroke. The fuel quantity delivered per
stroke is thus correspondingly smaller. Hence, the higher is the
pressure in the feed pipe, the smaller is the quantity of fuel delivered.
Thus fuel feed is made “elastic”. For instance, if the overflow valve is
clogged, pressure in the feed pipe would quickly rise to such an extent
that the feed pump would stop functioning. The feed pump is thus safe
against excessive pressure. Fuel leaking through the pressure spindle is
returned to the suction chamber through the leakage channel. Fig. No. 2.6 : Hand Priming Device
12. Construction of Hand Priming Device and its Components.
14. Operation. With the aid of hand priming device, fuel can be
The hand-priming device consists of a barrel, a plunger and a spindle. A
pumped from the tank to the fuel injection pump through fuel filter with
knurled knob is fitted at the top of the spindle. It is screwed into the feed
the engine at rest. In order to operate the priming device, the knurled
pump above the suction valve. It can be operated for bleeding purpose
knob is screwed out until the plunger can be pulled upwards, causing
of the fuel system. The quantity delivered per stroke is about 6 cc.
the suction valve to open and fuel to flow into the suction chamber.
13. Main Components. Hand priming device consists of following When the plunger is pressed down, the suction valve closes and the
components:- pressure valve opens resulting in fuel flow from the feed pump to the
njection pump through fuel filter. After use, it is essential to tighten the
knob.

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(iv) Repeatedly depress and release the head of The separated water is sedimented in the bottom of the case
priming pump until air free fuel flows out from fuel return whereas water free fuel is drawn through sedimenter unit by the
hose. feed pump.

(v) Connect the fuel return hose to fuel tank. (c) Fuel Feed Pump. Fuel feed pump is mounted on the fuel
injection pump. It takes drive from the camshaft of the injection
(vi) Depress the head of hand priming pump and turn pump. Feed pump is fitted with hand priming device for bleeding.
clockwise. A gauge filter is provided in the banjo bolt. It is a single acting fuel
feed pump. The fuel pressure of the feed pump is 1.8-2.2Kg/cm2
18. Bleeding of Fuel System (E/Canter). Bleeding procedure of at 600 RPM. The gauge filter should be cleaned every after
fuel system in E/Canter is explained below:- 25,000 km. If fuel pressure is above 1.6kg/cm2 at FIP, the fuel
pressure relief valve opens and part of fuel returns to the fuel
(a) Ensure sufficient quantity of fuel in tank. tank. The fuel stop system operated electrically allows or stops
the fuel from the injection pump when the engine switch is turned
(b) Ensure all pipe lines and connections are intact. ON and OFF respectively.

(c) Loosen the bleeding screw of fuel filter, unscrew knurled (d) Fuel Filter. The fuel filter is of element-replace type
knob and operate the hand priming device. (centre bolt type) that can have its element replaced individually.
The filter element should be replaced after 25, 000 km.
(d) First fuel along with air will come out from the screw then
only fuel will come.

(e) Tighten the bleeding screw.

(f) Bleed the Fuel injection Pump from its bleeding screw in
same manner.

(g) Tighten the knurled knob of hand priming device and

check the engine performance after starting.

Fig. No. 2.8 : Lay Out of Fuel System S/Mazda

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(e) Injection Pump. The injection pump is of Mico Bosch The separated water is sedimented in the case whereas water
in-line type. It generates a high injection pressure of 170kg/cm 2. A free fuel is drawn through sedimenter unit by the feed pump.
ball seat type over flow valve is fitted on the top of FIP stabilizes
fuel pressure in FIP to make sure that the amount of fuel injected 17. Bleeding of Fuel System (S/Mazda). Bleeding procedure are:-
into each cylinder is maintained constant.
(a) Bleeding of Air from Fuel Tank to Fuel Filter. Bleeding
(f) Injection Nozzle. Fuel is injected from the injection procedure of air from fuel tank to fuel filter is given below:-
nozzle as a fine spray and at a wide range into combustion
chamber which improves combustion and increases power. The (i) Confirm that plugs on sedimenter are closed and
injection nozzle is multi holes type having five holes with a spray fuel hoses are connected.
angle of 160°. The opening pressure is 220 – 230 Kg/cm2 for new
and 200 Kg/cm2 for old nozzles. The pressure can be adjusted by (ii) Turn the head of the hand priming device in counter
adding or removing number of shims on the spring. clockwise to release priming pump head.

(g) Governor. The governor is a variable speed governor. It (iii) Loosen air bleeding plug on fuel filter.
is capable of holding any speed steadily between idling and
maximum. (iv) Repeatedly depress and release head of priming
pump until air free fuel flows out from bleeding screw.
16. Fuel System of Eicher Canter. In E/Canter, the fuel filter
installed between fuel tank and injection pump is of paper element type. (v) Retighten air bleeding screw.
The priming pump is fitted to bleed air from the fuel system. The
sedimenter chamber is provided under the filter element. The injection (vi) Depress the head of priming pump and turn
pump generates a high injection pressure of 170kg/cm 2. The fuel is clockwise.
injected from the injection nozzle as a fine spray and at a wide range
into combustion chamber which improves combustion and increases (b) Bleeding of Air from Fuel Filter to Injection Pump in
power. The describtion of water separator are given below:- S/Mazda. Bleeding procedure of air from fuel filter to injection
(a) The sedimenter type water separator separates diesel and pump is given below:-
water centrifugally by taking advantage of their difference in
specific gravity. The water separator sediments not only water but (i) Confirm that plugs on sedimenter are closed and
also dust particles from fuel. A red float going up and down with fuel hoses are connected.
water level in the semi-transparent case makes it possible to
visually check the water quantity. (ii) Turn the head of the hand priming device in counter
clockwise to release priming pump head.
(b) The fuel flown in from the inlet connector is squeezed by
the fuel path in sedimenter head to increase velocity and spin. (iii) Disconnect the fuel return hose to fuel tank.

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3. Pre-Air Cleaner. Pre-cleaner is used for all such vehicles SUMMARY

which operate in very dusty condition as tractor, heavy earth moving
vehicle etc. This is a small air cleaner fitted before the intake of main air 1. Venting (bleeding) to be carried out if any fuel pipe connection
cleaner. At the bottom, it is fitted with deflector plates. The air is made to loose or filters are renewed.
pass through deflector plates. These deflector plates deflect the
incoming air at certain angle and give a cyclonic motion resulting in 2. Micro fuel filters are not to be cleaned and used again. They are
settling of heavier dust particles in pan provided in it. In some of the pre- to be renewed only.
cleaner, glass bowl is clamped and used as dust collector in which the
dust can easily be seen and cleaned immediately when it is full. 3. Feed pump is consists of pump body, roller, spindle, plunger,
Hand priming knob, suction valve and pressure valve.

4. The fuel filter of S/Mazda is of element-replace type (centre bolt

type) that can have its element replaced individually. The filter element
should be replaced after 25, 000 km.

5. The priming pump is fitted to bleed air from the fuel system.

QUESTIONS

1 Explain the layout diagram of fuel system.

2. Explain construction and operation of single acting fuel feed

Fig. No. 3.2 : Pre-Air Cleaner pump.
4. Exhaust System and its Components. The basic requirement
of exhaust system is to expel the burnt gases to the atmosphere freely 3. Explain bleeding procedure of E/Canter fuel system.
and without any abnormal noise. The exhaust system of CI engine
consists of following components:- 4. Which type of governor is fitted in S/Mazda vehicle?

(a) Exhaust manifold. 5. What are the main components of fuel feed pump?

(b) Exhaust pipe. 6. Explain the procedure of removal, cleaning and fitment of fuel
(c) Exhaust muffler. filters in S/Mazda.

(d) Tail pipe.

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CHAPTER – 3 (c) Inlet Manifold. It is a series of passage leading from

INTAKE AND EXHAUST SYSTEM the air cleaner to intake ports of the engine. It is designed for
even and equal distribution of air to all cylinders. These are
usually made of aluminium alloy and have smooth finish in its air
1. Intake System & Its Purpose. Intake system & its purpose are passage, so there is no restriction of flow due to rough surface. It
given below:- is fixed to cylinder head with studs or bolts with packing or gasket
placed at each opening to ensure airtight joint. The bore of
(a) In an automobile engine, intake system consists of manifold should be the same as the inlet valve port. When a
following components:- curved shape is employed, the mean radius of the curves should
be as greater as possible so that there should not be any
(i) Air cleaner. restriction for incoming air.

(ii) Inlet manifold. 2. Purpose & Types of Air Cleaners. Purpose & types of air
cleaners are explained below:-
(iii) Inlet Valves.
(a) Purpose. As the name implies, it cleans the air
(b) Purpose. The purpose of intake system is to carry the entering the cylinder. It is fitted before induction manifold. The
clean air to the cylinders. main reasons for fitting air cleaner are that-

(i) It traps the dust from incoming air and does not
allow it to go inside cylinder.

(ii) It also reduces the hissing sound produced by fast

moving of air to intake pipe.

(iii) In petrol vehicles, it does not allow the flame

(caused due to back firing) to come out to intake system.

(b) Types of Air Cleaner. Types of air cleaner are:-

(i) Wet type.

Inlet Manifold (ii) Dry type.

Fig. No. 3.1 : Inlet Manifold (iii) Pre cleaner.

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CHAPTER – 4 5. Silencer (Muffler) Assembly. The function of silencer (muffler)

FAULTS ANALYSIS AND RECTIFICATION is:-
(a) The function of muffler or silencer assembly in a vehicle is
1. Engine Does Not Crank. Faults & rectification for engine does to cool the exhaust gases by expansion and to reduce the noise
not crank are given below:- of the outgoing gases.
(b) There are different types of mufflers used in different type
(a) Fully discharged battery : Recharge the battery. of vehicles. The exhaust gases must be discharged into the
atmosphere with minimum restriction. The restriction of flow
(b) Battery terminal loose : Tighten the connection causes back pressure on the piston head during exhaust stroke
Or disconnected which may be generally 0.7- 0.9 kg/cm² at maximum RPM. The
back pressure must be maintained at low value by proper design
(c) Faulty ignition switch : Repair or replace. of exhaust system. The noise reduction takes place because of
long travel of exhaust gases.
(d) Loose solenoid connection : Tighten the connection
6. Purpose of Fitting Exhaust Muffler. The purpose of exhaust
(e) Faulty solenoid : Repair or replace. muffler are as follows:-

(f) Faulty starter motor : Repair or replace. (a) To reduce the temperature of exhaust gases.

(b) To clamp down (minimise) the sound of exhaust gases.

(g) Starter motor pinion : Replace the pinion.
worn out (c) To trap the flame of hot gases or un-burnt gases.

(h) Fly wheel ring worn out : Replace the ring. (d) To reduce the speed of outgoing gases.

7. Description of Exhaust Manifold. The exhaust manifold

(j) Hydraulic lock : Clear the fault. connects the exhaust port of an engine and leads the exhaust gases to
the muffler. It is made of cast iron. It is designed and fixed to the exhaust
(k) Engine seize : Complete port in such a way that no adjacent cylinders will exhaust into one
Overhauling required. branch. The flow of gases must be such that no restriction is placed in
their path. Big bends are provided for a stream line flow. Such a design
2. Engine Does Not Start. Faults & rectification for engine does reduces the back pressure. In some engines, the fresh charge is heated
not start are given below- by exhaust gases flowing through the manifold to improve vaporisation
and atomization. When the intake manifold is cool during idling, hot
(a) Lack of fuel in system : Refuel.

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exhaust gases are allowed to flow across intake manifold. The QUESTIONS
flow is shut off automatically when the intake manifold is hot.
1. What are the purposes for fitting air cleaner?

2. Explain Pre cleaner.

3. What are the purposes of fitting a silencer?

Exhaust Manifold

Exhaust Manifold: Fig. No. 3.3

SUMMARY

1. Pre cleaners are used in earth mover vehicle which operates in

dusty condition.

2. Exhaust muffler is used to reduce the temperature of exhaust

gases.

3. The purpose of intake system is to supply clean air to the

cylinders.

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(d) It is equipped with exhaust brake system apart from (b) Fuel cock turned : Turn fuel cock to ‘ON’
service brakes. to ‘off’ position position and bleed

(e) A bypass oil filter is fitted for better filtration of lubricating (c) Choked fuel filter : Remove, clean and
oil, longer oil change periods and lower oil temperature. refit.
(f) Loose cylinder liners are incorporated for easy servicing. (d) Air in fuel pump : Bleed the pump.
(g) Exhaust controlled heating system has been used to (e) Fuel feed pump defective : Check, repair or
improve heating performance, reduce warming up time of engine replace.
and minimize the emission of white smoke.

(h) Oil jets are fitted in the oil pan upper block for cooling of (f) Drive to FIP disconnected : Inspect and rectify.
pistons.
(g) Incorrect pump timing : Set the timing correctly.
(j) An air heater is used instead of glow plug for DI engine.
(h) Cams worn out : Renew the camshaft.
3. Leading Particulars of E/Canter. Leading particulars are
given below by system wise:- (j) Weak Battery : Charge the battery.

(a) Engine Specifications. Engine specifications are:- 3. Engine Knocks Regularly. Faults & rectification for engine
knocks regularly are given below:-
Model and type 4 Cylinder in-line, direct
injection, diesel Engine (a) Pump injects too early : Adjust pump coupling
Compression Ratio 17.5: 1 to retard the injection.
Max Power ps/rpm 92.5Kgm/3500 rpm
Max torque 22.5Kgm/ 2200rpm (b) Opening pressure of : Test injector nozzles and
Firing Order 1-3-4-2 nozzle too high adjust pressure with
Valve System Overhead valve nozzle testing outfit.
Valve Clearance inlet 0.4 mm
Valve clearance Exhaust 0.4mm (c) Some of the holes are : Clean holes with
blocked in nozzle cleaning needle
Cylinder liner Dry Type
Piston Rings Two compression and one oil (d) Worn small or big end : Renew.
Scraper ring bearings
Piston Pin Fully Floating

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CHAPTER – 5 (c) Cooling system. Cooling system specifications are as

LEADING PARTICULARS AND SPECIAL FEATURES follows:-
OF S/MAZDA & E/CANTER
Cooling system Water Cooling
“V” belt tension New – 9-10mm, Used – 10-11mm
1. Leading Particulars of S/Mazda. Leading particulars are given Thermostat Wax Type (stainless steel)
below by system wise:- Starts opening at 82°C
Fully open at 95°C
(a) Engine Specifications. Engine specifications are listed Driving Method “V” belt type
below:- Radiator Corrugated fin (Pressure type)

Model and Type 4 Cylinder in-line, direct injection, (d) Fuel System. Fuel system specifications are given
diesel Engine below:-
Displacement 3455 cc
Compression Ratio 18:1 Fuel Tank position Right external side of frame
Max Power (DIN) ps/rpm 86.5 DIN/3000rpm Fuel Filter Paper element type
Max torque (DIN) 22.9 DIN/2000rpm Fuel Injection Pump Bosch Inline type
Firing Order 1-3-4-2 Idling Speed 620-700rpm
Valve System Overhead poppet valve Injection timing 12° BTDC
Valve Clearance Inlet 0.3mm (0.012 inch) Injection nozzle Multi hole type (5 hole)
Valve Clearance Exhaust 0.35mm (0.014 inch) Air cleaner Oil bath type
Cylinder liner Dry loose
Piston Rings two Compression& one 2. Special Features of S/Mazda. The Swaraj Mazda engine is
oil Scraperring water cooled, 4 cylinders, 4 stroke cycle and direct Injection type diesel
Piston Pin Fully Floating engine. The engine has following special features:

(a) The combustion chamber is of the swirl flow chamber type

(b) Lubrication System. Lubrication system specifications
which consists of a main combustion chamber and swirl chamber.
are appended below:-
(b) An oil pan upper block is provided between the cylinder
Lubrication System Fully force feed system
block and oil pan.
Oil Pump Double rotor type
Oil Filter Bypass depth filter and main oil
(c) Fuel system is fitted with sedimenter unit to separate water
filter
from fuel system.
Oil Cooler Water cooled type

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CHAPTER – 6 (b) Lubrication System. Lubrication system leading

COOLING SYSTEM particulars are given below:-

Lubrication Fully force feed system

System
1. Cooling System of S/Mazda & E/Canter. The engine is
cooled by forced circulation of coolant by water pump. The water pump Oil Pump Double rotor type
is of centrifugal type and it is driven by a V-belt from crankshaft pulley. Oil Filter Bypass depth filter
The radiator, with a tube and corrugated-fin type core and equipped with Oil Cooler Water cooled type
a pressure cap, not only cools the engine but also separates vapour
(c) Cooling system. Cooling system leading particulars are
from water and regulates pressure in the system. The thermostat is of
listed below:-
wax type enclosed in a pellet. The wax changes its state from solid to
liquid as it is heated, involving volumetric change for regulating the flow Cooling system Water Cooling force feed
of coolant. The reservoir tank is open to atmosphere. Coolant level “V” belt tension 10-15 mm
warning and sensor units are fitted to warn and check the coolant level.
Thermostat Wax Type
Starts opening at 82°C
Radiator Water pump & Fan Fully open at 95°c
Driving Method “V” belt type
Radiator Corrugated fin type

(d) Fuel System. Fuel system leading particulars are

appended below:-

Fuel Tank position Right External side of frame

Fuel Filter Paper element type
Fuel Injection Pump Bosch Inline type
Idling Speed 600-650 rpm
Injection timing 12°BTDC
Injection nozzle Multi hole type (5 hole)
Lower hose Upper hose Water jacket Air cleaner Oil bath type

3. Special Feature of E/Canter. Special feature of E/Canter are

given by system wise:-

Fig. No. 6.1 : Coolant Circulation in Cooling System of S/Mazda

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(a) Combustion chamber consists of cylinder head and SUMMARY

toroidal piston with multi hole type injection nozzle installed in the
cylinder head. 1. An oil pan upper block is provided between the cylinder block and
oil pan in S/Mazda engine.
(b) The valve mechanism is an overhead valve type.
2. Oil jets are fitted in oil pan upper block for piston cooling in
(c) Camshaft is provided with an integral oil pump drive gear. S/Mazda.

(d) Three camshaft bushings are installed in the crankcase. 3. Piston is made of aluminium alloy casting. Weight mark plus front
To facilitate fitment and removal of the camshaft from the front of mark stamped on the top surface of the piston.
the crankcase, the bushing internal diameter is made smaller
towards the rear. 4. Five main bearings of crank shaft are split style plain bearing
made of special alloy (KELMET) plated with steel back.
(e) The special cast iron cylinder sleeve, highly resistant to
wear, is press fitted into the crankcase. 5. To install and remove camshaft from front, bushings are made
smaller in diameter towards rear in E/Canter engine.
(f) Piston is made of aluminium alloy casting. Weight mark
plus front mark stamped on the top surface of the piston. QUESTIONS

(g) Two compression rings and one oil scrapper ring is fitted. 1. Enumerate the special features of Swaraj Mazda engine.
The sliding surface of each ring is hard chrome plated.
2. Where the oil jets are fitted on Swaraj Mazda engine and why?
(h) The connecting rod is with an ‘I’ cross section ensuring
high rigidity. A lead bronze bush is press fitted to its small end 3. What type of combustion chamber is provided in S/Mazda
while a split-style plain bearing is used in big end. engine?

(j) Five main bearings of crank shaft are split style plain 4. Why the exhaust controlled heating system is used in S/Mazda?
bearing made of special alloy (KELMET) plated with steel back.
5. Write the special feature of Eicher Canter.
(k) Split style thrust plates are mounted with the rear main
bearing of crank shaft. 6. Which type of marking is provided on piston in E/Canter?

(l) Timing marks are stamped on each gear such as 1, 2, 3 on 7. What type of liner is fitted in E/Canter?
crankshaft gear, camshaft gear and FIP gear respectively. The
idler gear has all three markings. 8. Where the timing marks are stamped in E/Canter vehicle?

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QUESTIONS 2. Adjusting of Fan Belt in S/Mazda & E/Canter. Procedure of

adjustment of fan belt in S/Mazda & E/Canter are as follows:-

1. Explain the procedure of adjusting fan belt tension in S/ Mazda. (a) Park the vehicle in hard level ground, Chock the wheels
and disconnect the battery.
2. Explain the procedure of removal and fitment of radiator in
S/Mazda and E/Canter vehicle. (b) Tilt the cabin. The E/Canter is provided with locking
mechanism whereas S/Mazda is needed to put a wooden block
3. Write the procedure of Flushing Radiator in SITU. between chassis front cross member and cabin.

(c) Loosen the alternator mounting and adjusting bolts.

4. Explain cooling system of S/Mazda and E/Canter.
(d) Pull the alternator (with tyre lever) away from the engine to
give tension to “V” belt. Push the alternator towards engine to
loosen the “V” belt.

(e) When the tension is correct, hold the alternator in this

position and tighten the adjusting and mounting bolts & nuts.

Adjusting Bolt

Alternator
Mounting Bolt Fan Belt

Fig. No. 6.2 : Fan Belt Adjustment

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(f) Check the fan belt tension on longest run. (d) Drain coolant from radiator and engine block in a suitable
container by loosening the drain cock.
(g) Press the belt with thumb pressure of 10 kg force
(moderate). The belt should deflect 9-10mm (new belt) and 10-11 (e) Loosen the jubilee clips of radiator upper and lower hoses
mm (used belt) for S/Mazda and 10-15 mm for E/Canter. and disconnect the hoses from the radiator.

Note: While fitting a new fan belt, first put it over the crankshaft pulley (f) Remove upper and lower half of radiator guard by
then water pump pulley and alternator pulley. removing mounting bolts.

3. Flushing of Radiator in SITU. Flush the radiator in situ with (g) Remove two side supporting bolts and two lower mounting
clean water as follows. bolts of radiator and remove the radiator. Care should be taken of
radiator fins while removing.
(a) Completely drain the coolant system of the vehicle; if anti-
freeze solution is in use, drain it into clean container for further (h) Fit the radiator in reverse order and check for any leakage.
use. Leave the drain cock open.

(b) Insert a hose in the radiator filler neck and adjust the flow SUMMARY
of water to keep the radiator full without overflowing.

(c) Allow the water to flow through the system (for 1. Centrifugal type water pump driven by the V-belt from the
approximately 15 minutes) until the water runs out clean. crankshaft pulley is used in both the vehicles.

4. Removal and Refitting of Radiator Assembly in S/M & E/C. 2. The radiator, with a tube and corrugated-fin type core, not only
Removal & refitting of radiator assembly in S/M & E/C are as follows:- cools the engine but also separates vapour from liquid water and
regulates pressure in the system.
(a) Park the vehicle on a hard level ground.
3. The E/Canter is provided with locking mechanism for the tilted
(b) Chock the wheels and disconnect the battery. cabin where as S/Mazda is needed to put a wooden block between
chassis front cross member and cabin for safety purpose.
(c) Lift up the cabin and put the wooden blocks in between
chassis cross member and cabin to support the cabin at a 4. Check the fan belt deflection with thumb pressure of 10 kg force
suitable position in S/Mazda. E/Canter is provided with locking (moderate); the belt should deflect 9-10 mm (new belt) and 10-11 mm
mechanism. (used belt) for S/Mazda and 10-15 mm for E/Canter.

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(g) From No.1 camshaft bushing, oil passage is taken to front CHAPTER – 7
end of rocker shaft bracket to lubricate the rocker shaft bushing. ENGINE LUBRICATION SYSTEM

Shel 1. Lubrication System of S/Mazda. The lubrication system

used in S/Mazda is a wet sump, pressure lubrication system. The engine
is lubricated by a double rotor type oil pump that forces engine oil
Front cover
through the oil cooler and oil filter into the engine for lubrication of
Clogged oil hole various engine parts in S/Mazda.
By pass valve
Rear cover 2. Special Feature of Lubrication System of S/Mazda. Special
feature of lubrication of S/Mazda are listed below:-

Fig. No. 7.2 : Oil Cooler of E/Canter (a) Oil jets are incorporated to cool the piston.

(b) The FIP is lubricated by engine oil instead of fuel.

Cam Shaft Gear Oil Cooler
(c) High capacity double rotor type oil pump is used.

(d) To improve cooling of engine, oil cooler of higher capacity

is used.

(e) Oil pan upper block, the oil pan and the packing are
modified for reduction in vibration and noise.

(f) Oil lines and oil bypass are incorporated in the system.

Oil Pump 3. Lubrication System of E/Canter. Lubrication system of

E/Canter are described as follows:-

(a) The wet sump pressure lubrication system is used in

E/Canter. It consists of Gear type oil pump, oil filter and oil cooler.
Oil pump is driven by the skew gear mounted on the camshaft.
Filter Element Oil Filter Oil cooler is shell and tube type to maintain the lubricating oil
temperature. Oil filter is paper, full flow type with built in bypass
Fig. No. 7.3 : Components Lubrication System of E/Canter valve and bypass alarm.

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(b) Oil pump sucks oil from the oil sump through oil strainer (d) Camshaft bushings are lubricated from MOG through
and sends it to oil filter. After getting filtered, it flows to oil cooler individual drilled passages. From No. 1 camshaft bushing, oil
under pressure. The oil pump cover has a relief valve that re- passage is given to lubricate the rocker shaft assembly. From
routes oil to the oil pan when pressure exceeds 3.7 to 4.3 there, it falls on the valve stems then push rods and it falls back in
Kg/cm2.. In case of choking of oil filter, the lubrication-warning the sump through tappets.
lamp will glow and serve as an alert to the operator. If the
temperature of the engine is below normal working temperature, (e) Timing gears and their bushings are lubricated through the
oil is sent directly to the main oil gallery bypassing the oil cooler. drilled passage from MOG. The idler shaft is provided with an oil
If the temperature of engine is at normal working temperature, oil jet for the forced lubrication of the auto timer. Oil pressure switch
is allowed to pass through oil cooler for cooling and further to the is incorporated in the system to indicate the oil pressure. Injection
main oil gallery. pump is lubricated through a separate pipe which is taken from
the oil filter cover on the way to the MOG. The camshaft skew
gear and oil pump gear are lubricated by oil sprayed from the oil
hole drilled in the oil pump case.

4. Special feature of Lubrication System of E/C. Special

features of lubrication system of E/C are briefed below:-

(a) The oil pump is of gear type and driven by the skew gear
mounted on the camshaft.

(b) The oil bypass alarm in the cover is interconnected with oil
pressure switch.

(c) The oil pump cover has a relief valve that re-routes the
engine oil to oil pan when oil pressure exceeds a pre-determined
level.
Fig.No. 7.1 : Structural View and Lubrication Circuit of S/Mazda
(d) The oil pump cover also serves as the oil filter head.
(c) From MOG (Main Oil Gallery), oil flows to each main
bearing of crankshaft through drilled passages in cylinder block (e) The oil cooler has a bypass valve which opens when the
and further to crank pin through drilled passage in crankshaft. oil passage of oil cooler is clogged.
Vertical drilled passage is provided in connecting rod to lubricate
small end bushing. The oil is sprayed through oil jets to cool down (f) The idler shaft is provided with an oil jet for the forced
the pistons. lubrication of the auto timer.

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CHAPTER – 8
TRANSMISSION SYSTEM

1. Transmission System of S/Mazda and E/Canter.

Transmission system of S/Mazda & E/Canter are explained below:-

(a) Clutch. The clutch of S/Mazda and E/Canter vehicles is

single dry plate, hydraulically operated and diaphragm spring
type. Clutch master cylinder and release cylinder are used to
exert and release pressure. The clutch pedal is hanging type.
The clutch master cylinder has a one way valve to improve
feeling when clutch is suddenly engaged. Since the clutch is
operated hydraulically, its effectiveness depends on air free
operation. To expel air from the system, a bleeding screw is fitted
in clutch release cylinder. For removal of clutch, remove the
gearbox and take out the clutch assembly.
Fig. No. 7.4 : Oil Filter Element of E/Canter

5. Removal & Fitment of Oil Filter in S/Mazda. Procedure of

removal & fitment of oil filter in S/Mazda are as follows:-

(a) Park the vehicle in hard level ground and chock the
wheels.

(b) Unscrew the filter by using suitable spanner.

(c) Apply a thin layer of oil on filter ‘O’ ring and screw in the
filter.

Fig. No. 8.1 : Clutch Master and Release Cylinder (d) Tighten the filter by hand only.

(b) Gearbox. Gear box of both the vehicles has five (e) Start the engine and check for any leakage.
forward and one reverse speed gear. It has floor mounted gear
shift mechanism. The gear box is provided with synchroniser for

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6. The lubrication system is a wet and pressure type in S/Mazda &

E/Canter.

7. The oil filter is full flow bypass type in S/Mazda & E/Canter.

8. The idler shaft is provided with an oil jet for the forced lubrication
of the auto timer E/Canter.

QUESTIONS

1. What are the special features of lubrication system in S/Mazda?

2. How much is the opening pressure of oil pump regulating valve of

Fig. No. 7.5 : Oil Filter Element of S/Mazda E/Canter?

3. What is the various warning systems used for S/Mazda Engine?

SUMMARY
4. How many type of oil filters are used in S/Mazda Engine?
1. Lubrication system incorporates a double rotor pump providing
full force lubrication in S/Mazda. 5. How the timing gears and camshaft bearings are lubricated in
E/Canter?
2. There are two oil filters, main and bypass, provided for efficient
filtering of oil in S/Mazda. 6. Which type of oil pump is fitted in S/Mazda?

3. Oil pressure switch, oil level sensor and oil bypass alarm switch 7. How piston and cylinder walls are lubricated in E/Canter?
are provided for warning in both the vehicles.
8. How rocker shaft assembly is lubricated in E/Canter?
4. Oil jets are provided in oil pan upper block to cool pistons in
S/Mazda. 9. How oil pump gets drive in E/Canter?

5. The oil pump is of gear type and driven by the skew gear
mounted on the camshaft.

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(e) When fluid pressure in the clutch pipe is reduced to zero, first gear to enable the operator to engage first gear in moving
clutch pedal will reach to floor. Now tighten the bleeder screw. condition without noise.
Repeat procedures (c) and (d).
(c) Propeller Shaft. The propeller shafts are two in number
(f) When clutch fluid no longer contains air, firmly tighten the with sliding joint at the front side of the rear propeller shaft and
bleeder screw. both the propeller shafts are supported at the centre by a centre
support bearing. There are 3 universal joints in both vehicles.
(g) Add appropriate quantity of clutch fluid to the fluid
reservoir. (d) Differential Assembly. Both vehicles are fitted with
differential assembly to transmit the drive to road wheels.
(h) Start the engine, depress clutch pedal and engage
different gears. Make sure that the clutch functions properly. (e) Front Axle. The front axle is Reverse Elliot type dead
stub axle.

SUMMARY (f) Rear Axle. Rear axle is fully floating. Banjo casing
differential gears are mounted on a spider in the vehicle.

1. The clutch is a single dry plate, hydraulically operated and Clutch Assembly Propeller Shaft Differential
diaphragm spring type in both vehicles.

2. Gear box of both vehicles has five forward and one reverse
speed gear.

3. Centre brake is installed at the rear of transmission and acts as a

parking brake in S/Mazda and E/Canter.

4. Before removing propeller shafts, make a matching mark on each

yoke, parking brake drum and each companion flange.

5. For checking pedal height, measure distance from centre of pedal

pad upper surface to floor. It should be 192mm-200mm for S/Mazda.

Gear Box Universal Joint Rear Axle

Fig. No. 8.2 : Transmission System

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2. Pedal Height Checking and Adjustment of S/Mazda. (d) Before removing propeller shafts, make a matching mark
Procedure of checking and adjustment of pedal height is as follows:- on each yoke, parking brake drum and each companion flange.

(a) Measure distance from centre of upper surface of the (e) Remove the nuts and bolts from the flange which connect
pedal pad to floor. It should be 192mm-200mm. If not, adjust as rear propeller shaft and pinion. Separate the yoke from the
described below. companion flange.

(b) Loosen lock nut and adjust the pedal height by turning (f) Remove the nuts and bolts from the flange which connect
stopper bolt. rear of front propeller shaft and front of rear propeller shaft.

(g) Never detach rear propeller shaft from sliding joint.

(h) Remove the centre support bearing by removing two

mounting bolts.

(j) Remove nuts which connect the propeller shaft and

parking brake drum.

(k) Install the propeller shaft in reverse order.

4. Bleeding of Clutch System of S/Mazda & E/Canter. Bleeding

procedure of clutch system is explained below:-

(a) Before bleeding the clutch system, fill the fluid reservoir
with clutch fluid more than half of its capacity. Fluid level must be
Fig. No. 8.3 : Clutch Pedal Height and Play Checking of S/Mazda maintained throughout the bleeding procedure.
3. Removal & Refitting Of Propeller Shaft In S/M & E/C. (b) Connect one end of vinyl tube to the bleeder screw of
Procedure for removal & refitting of propeller shaft is as follows:- clutch release cylinder and place the other end into a container.
(a) Park the vehicle in hard level ground.
(c) Depress the clutch pedal several times. Hold the pedal in
(b) Chock the wheels and disconnect the battery. depressed position and loosen the bleeder screw.

(c) Pull the parking brake to immobilize the propeller shaft and (d) Air bubbles along with the clutch fluid will be coming out
shift the transmission to fifth gear. through the vinyl tube.

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3. Removal and Refitting of Shock Absorber. Procedure of QUESTIONS

removal and refitting of shock absorber is explained below:-
1. Write a short note on clutch fitted on S/Mazda and E/Canter.
(a) Tilt the cabin and support it with the help of wooden block
in the case of S/Mazda and locking mechanism In case of 2. Write the procedure of bleeding of clutch system in S/Mazda and
E/Canter. E/Canter.

(b) Remove the upper mounting bolt of the shock absorber. 3. Write down the procedure of removal and installation of the
propeller shaft.
(c) Hold the shock absorber and remove the bottom mounting
bolt. 4. Write the procedure of pedal height checking and adjustment in
S/Mazda.
(d) Remove the shock absorber and keep it in upright position.

(e) Install the shock absorber in reverse order.

SUMMARY

1. Chassis frame is conventional type and suspension is semi

elliptic leaf spring type assisted by cylindrical double acting shock
absorber in both vehicles.

2. The rear leaf spring has main and auxiliary leaf springs and
mounted with shackle and pivoting pin in both vehicles.

3. The front leaf springs consist of main leaf, supporting leaf and ten
other leaves in S/Mazda and seven leaves in E/Canter.

4. The cylindrical double acting shock absorbers are used in both

vehicles.

5. The rear suspension consists of leaf spring, axle housing and

shock absorbers in both vehicles.

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CHAPTER – 9 2. Checking of Front & Rear Road Spring on vehicle.

SUSPENSION SYSTEM Checking of front & rear road spring on vehicle are explained below:-

(a) Front Leaf Spring Checking on Vehicle. Checking of front

1. Suspension System of S/Mazda & E/Canter. The chassis leaf spring on vehicle are explained below:-
frame of the S/Mazda and E/Canter is a conventional type with side
(channel section) and cross members (five). The suspension system (i) Check for any fatigue and damage on leaf spring.
consists of leaf spring (semi elliptic) with clampers. At the front, a
stabilizer bar is used. The rear leaf suspension is fitted with rubber (ii) Check for the damage on U- bolts.
bushing which ensures noiseless operation and does not need
lubrication. The front end of the front spring is pivoted and rear end is (iii) Check for attaching nuts of U-bolts, spring pins and
shackled. The rear leaf spring has main and auxiliary leaf springs shackle for looseness.
mounted with shackled and pivoting pin. The cylindrical double acting
shock absorbers are used in both vehicles. (iv) Check for damage and deterioration of the stopper
rubber.

Shock Absorber Shackle (v) Check for damage and deterioration of the rubber
bushing.

(b) Rear Leaf Spring Checking on Vehicle. Checking of rear

leaf spring on vehicle are explained below:-

(i) Check for fatigue and damage on the leaf spring.

(ii) Check for any damage on spring clamp and

U- bolts.

Lower Mounting (iii) Check for attaching nuts used for the U-bolts, spring
Shock Absorber Road Spring pins and shackles for looseness.

(iv) Check for damage and deterioration of the stopper

rubber and rubber bushing.
Fig. No. 9.1 : Front Road Spring and Shock Absorber Mounting

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3. Toe-In Adjustment. Procedure of Toe-in adjustment are QUESTIONS

explained below:-

(a) Place the vehicle on hard level ground and set the tyres in 1. Which type of leaf spring is fitted in the front suspension system
straight ahead position. of S/Mazda?

(b) Adjust tyre pressure up to the specification. 2. What is the purpose of suspension bushing?

(c) Check the front suspension for bent axle, wear on king pin 3. What are the points to be checked on front and rear leaf springs
bushing and wear on front hub bearings. fitted on vehicle?

(d) Put marks on RH and LH in front of front wheels on their 4. Write down the procedure of removal and installation of shock
centre line with chalk. absorber in S/Mazda and E/Canter.

(e) Set toe in gauge needle tip at the height of marks on the
RH and LH wheels and measure the distance between the marks
at this position. Jack up again and turn wheels through 180° and
jack down the wheels. Set the measuring points at the rear side
of the front wheels.

(f) Measure the distance between the new measuring points

which are 180° away from the first measuring points.

(g) The difference between above two values is toe-in.

(h) The toe- in is 0 – 6 mm in S/Mazda and 3 mm in E/Canter.

(j) To adjust toe-in, loosen the right and left clamp bolts of the
tie rod and turn the tie rod with a pipe wrench. After adjustment,
tighten the clamp bolts.

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CHAPTER – 10 2. Special Features of Steering System (S/Mazda & E/Canter).

STEERING SYSTEM OF S/M & E/C The constructional features of the steering system are as follows.

(a) Steering wheel has three spokes design in S/Mazda and

two spokes in E/Canter.
1. Steering System of S/Mazda & E/Canter. The steering
system used in S/Mazda and E/Canter is a re-circulating ball and nut (b) The joint between the steering shaft and the steering
type. Steering wheel has three spokes in S/Mazda and two spokes in wheel is a taper type joint in both vehicles.
E/Canter. The joint between steering shaft and steering wheel is a taper
type joint. The toe- in can be adjusted by increasing or decreasing the (c) Increased steering column shaft length in both vehicles.
length of tie rod. To be able to adjust the position of the steering wheel
according to the driver’s size or driving condition, the telescopic option (d) The fitting of steering lock, ball bearing and the steering
has been added. It allows the steering wheel to adjust up and down in shaft is tight fit in both vehicles.
the range of 35 mm in addition to tilt feature.
(e) The telescopic tilt steering shaft is provided with two
universal joints and a sliding joint which allows the driver to select
an optimum driving position in both the vehicles.

Fig. No. 10.1 : Ball and Re-Circulating Type Fig. No. 10.2 : Structural View of Steering System

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SUMMARY
3. Brake System of Eicher Canter. Brake system of E/Canter
are explained as follows:-
1. The telescopic tilt steering shaft is provided with two universal
(a) The service brake of E/Canter is hydraulically operated on joints and a sliding joint which allows the driver to select an optimum
all wheels. The brakes are two leading shoes type for front driving position in both the vehicles.
wheels and dual two leading shoes type for rear wheels.
2. The steering is re-circulating ball and nut type in both vehicles.
(b) The brake booster is a Master VAC that builds-up faster
hydraulic pressure. The Master VAC Vacuum line is equipped 3. The toe in is 0 – 6 mm in S/Mazda and 3 mm in E/Canter.
with a Vacuum tank which minimizes negative pressure change
even in the case of repeated and frequent braking operation.
QUESTION
(c) Tandem type brake master cylinder also contributes to
safety.

(d) The brake pedal, which is hanging type, is easy to operate 1. How do you adjust toe in on S/Mazda / E/Canter?
and transmits pedal force via operating rod to the Master VAC
which boosts force and operates the master cylinder. 2. Write the special features of Steering system of E/Canter.

(e) A brake fluid level sensor is installed in the brake fluid 3. What type of steering is used in E/Canter?
reservoir which senses the brake fluid level.
4. How many steering spokes are provided in E/Canter?
4. Free Play Checking and Adjustment of Brake Pedal in E/C.
Procedure for checking & adjustment of brake pedal free play are as 5. Explain briefly about the steering system of S/Mazda.
follows:-

(a) Park the vehicle in hard level ground, chock the wheels
and disconnect the battery.

(b) Ensure that the pedal height is adjusted.

(c) Eliminate the negative pressure from the VAC by

depressing the pedal few times for correct free play reading.

(d) Press the pedal lightly by hand and measure the free travel
which should be 10 - 15 mm.

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CHAPTER – 11 (b) S/Mazda is equipped with vacuum assisted hydraulic

BRAKE SYSTEM OF S/MAZDA & E/CANTER brake. Operate the pedal until vacuum is eliminated from vacuum
booster chamber to get the correct free play reading.

1. Brake System of S/Mazda. Brake system of S/Mazda are (c) Lightly depress the pedal by hand and measure the free
explained below:- play (until the power piston starts to operate).

(a) The Swaraj Mazda is employed with efficient braking (d) The pedal free play should be 9-11 mm.
system, operated hydraulically and assisted by vacuum booster.
Brake pedal is hanging type. Master cylinder is tandem type, (e) Adjust the pedal free play by turning the operating rod and
working independently at front and rear wheels. It acts as a tightened the locking nut.
brake fail safe device. For better braking effects, the front wheel
cylinder and shoes dimensions are larger than rear wheels. Rear Vacuum Chamber (VAC) Fluid Reservoir
brake consists of dual two leading shoes and twin wheel cylinders
with notch disc for adjusting shoe clearance manually; the shoes
Vacuum
are internal expanding type.
Pump
(b) Parking brake is mechanical stick operated in driver’s
cabin and acts through cables on the rear of transmission.
Maximum numbers of notches on the stick are 22.

(c) Exhaust brake is an auxiliary brake, working on the engine

Brake Pedal Master Cylinder
by blocking the exhaust gases. It exerts back pressure on the
piston, thus reduces the engine speed. It assists the service
brake. Exhaust brake unit is operated by a switch at a dash Fig. No. 11.1 : Vacuum Assisted Master Cylinder
board, working with the help of a power chamber. Exhaust brake
valve on the exhaust system near silencer is operated.

2. Brake Pedal Free - Play Checking and Adjustment inS/Mazda.

Checking & adjustment of brake pedal free play are given below:-

(a) Park the vehicle in hard level ground, chock the wheels
and disconnect the battery.

Fig. No. 2 : Brake Free Play Adjustment

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BIBLIOGRAPHY (e) To adjust the free play, loosen the lock nut of the master
VAC operating rod.

1. IAP: 3159 (f) Turn the knuckled portion of the master VAC operating rod
to adjust the free play.
2. MT Tech training notes on Compression Ignition Engine.
(g) Tighten the lock nut and recheck the play.
3. Auto Mechanics Fundamentals by Martin W Stockel and Martin T
Stockel. Note: The operating rod must serve as a pedal stopper and while
checking brake pedal free play, the master VAC negative pressure must
4. IC Engine by ML Mathur and Sharma. be zero.

5. Automotive Technology by HM Sethi. 5. Brake Shoe Clearance Adjustment of Parking Brake (S/M &
E/C). Procedure for brake shoe clearance adjustment of parking
6. Fuel Injection Systems by Robert N Brady brake are explained below:-

7. Standard Technical Training Notes. (a) Park the vehicle in hard level ground, chock the wheels
and disconnect the battery.
8. Workshop Manual of Maruti Gypsy.
(b) Remove the plug from the centre brake drum.
9. Workshop Manual of Amb Car.
(c) Lock the drum by turning the adjuster in direction shown by
10. Standard MT Tech training notes. arrow mark. Make this adjustment through the adjusting hole on
back plate.
11. Workshop manual Swaraj Mazda T3500.
(d) Turn the adjuster 6 - 7 notches back from the locked
12 Service Manual E/Canter. position in S/Mazda & 8 - 10 notches back in E/Canter.

(e) Pull the parking brake lever with a force of 30 kg and

ensure that the pulled clearance is 7-13 notches.

(f) Check the effectiveness of the centre brake and make sure
that the brake is not dragging.

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6. Air Bleeding of Brake System of S/Mazda & E/Canter. 4. The parking brake is stick operated mechanical type on
Procedure of air bleeding of brake system is as follows:- transmission in both vehicles.

(a) Fully fill the brake fluid reservoir with brake fluid. During 5. Front brakes are two leading shoes whereas rear brakes are dual
bleeding, ensure that the tank is more than half filled at all times. two leading shoes type in E/Canter.

(b) Remove the bleeder screw cap from the Master cylinder, if 6. Tandem Master cylinder acts as a failsafe in S/Mazda & E/
provided. Connect one end of vinyl (transparent) pipe to the Canter.
bleeder screw and place the other end of the pipe in a container.
7. Service brake is vacuum boosting type in S/Mazda.
(c) Depress the brake pedal several times (until pressure is
build-up) and hold it in depressed condition. 8. The brake fluid level sensor is installed in brake fluid reservoir to
sense the brake fluid level in the reservoir in S/Mazda & E/ Canter.
(d) Loosen the bleeder screw to bleed air.
9. Adjustment of hand brake lever should be made after the
(e) Air bubbles along with the brake fluid will be coming out. clearance between the parking brake drum and shoe lining has been
adjusted.
(f) Re-tighten the bleeder screw (when pressure is released).

(g) Repeat this procedure 3 or 4 times until the air disappears QUESTIONS
from the brake fluid.
1. How do you adjust and check the brake pedal height and play in
(h) Repeat the above procedures for rest of the wheels S/Mazda?
starting from farthest wheel cylinder (rear left wheel) as per their
distance from the master cylinder in reducing order. 2. How the parking brake is adjusted in S/Mazda?

SUMMARY 3. Where and how the centre brake is fitted in E/Canter?

1. S/Mazda and E/Canter brakes are hydraulic, internal expanding 4. Write the procedure of carrying out the air bleeding process in the
assisted by vacuum booster. brake system in E/Canter.

2. Brake pedal is hanging type in E/Canter and S Mazda.

3 The foot brake is hydraulically operated and hand brake is

operated by a lever in the cabin which acts on transmission brake drum
for braking mechanically in both vehicles.

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73

Appendix ‘A’
(Refer to para 6 (l) of
TCASI Part II/T (CA)/01/15
dated 02 Jun 15)

TEXT EDITING CERTIFICATE

(To be personally signed by the Commanding Officer/Chief

Instructor/Senior instructor)

It is certified that CD, diagrams and script of the student

text/training notes, title Automobile Technology (CI Engine, S/Maz and
E/Canter) reference number AT- 01- 13 required to be printed has been
thoroughly edited, checked for spelling and grammatical mistakes and
brought up to date in all respects. The requirement of number of copies
has been worked out on the basis of the training Flow Chart.

(G K Nair)
Gp Capt
Date: 13 Jun 18 Chief Instructor

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