INDUSTRIAL TRAINING

An Industrial Training report submitted for partial fulfillment of

requirements for the award of

DIPLOMA
IN
MECHANICAL ENGINEERING

SUBMITTED BY

PATNALA ESWAR 20375-M-036

DEPARTMENT OF MECHANICAL ENGINEERING

KAKINADA INSTITUTE OF TECHNOLOGY AND SCIENCE

(II Shift Polytechnic)
(Approved by AICTE, Affiliated to SBTET)
TIRUPATHI(V),DIVILI,PEDDAPURAM(M)-533433
www.kitsdivili.ac.in

(2020-2023)

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KAKINADA INSTITUTE OF TECHNOLOGY AND SCIENCE
(II Shift Polytechnic)
(Approved by AICTE, Affiliated to SBTET

DEPARTMENT
OF
MECHANICAL ENGINEERING

CERTIFICATE

This is to certify that the industrial training report being

submitted by PATNALA ESWAR bearing roll no.20375-M-036 in
partial fulfillment for the award of the Diploma in Mechanical
Engineering. It is record of bonafied work carried out by me under
the esteemed guidance and supervision of Sri.

B.BALA RAJU A.V.S.RAJU

TRANING GUIDE HEAD OF THE DEPT
LECTURER MECHANICAL ENGINEERING

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 ACKNOWLEDGEMENT

I would like to take this opportunity to express my profound sense of gratitude to

Principal M.ANAND KUMAR M.Tech, Kakinada Institute Of Technology And Science
college for his refining comments and critical judgments of the industrial training.

I have great pleasure in expressing my deep sense of gratitude to our Head of the
Department Mr. A.V.S.RAJU B.Tech, Department of Mechanical Engineering, Kakinada
Institute Of Technology And Science (II shift polytechnic) for providing all necessary
support for successful completion of our training.

I would like to express my special thanks of gratitude to my trainer. B. BALARAJU,

who gave me the golden opportunity to do this Industrial Training in LAKSHMI HYUNDAI
which helped me in learn so many new things, Knowledge and Hands- on experience.

I wish to convey my sincere gratitude to my guide Mr.S.M.V.Ram B.Tech,

Department of Mechanical Engineering, Kakinada Institute Of Technology And Science (II
shift polytechnic), DIVILI. We are highly Indebted to him for his guidance, timely
suggestions at every stage and encouragement to complete this training successfully.

I thank all the staff members of our department & the college administration
and all my friends who helped me directly and indirectly in carrying out this training
successfully.

Sincerely,
PATNALA ESWAR

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 INDEX
S.NO TOPIC NAME Page no.

1. Working In Workshop. 1-4

2. Service Shop. 5-10

3. Working during in workshop. 11-16

4. Wheel Alignment and Balancing. 17-18

5. Suspension & Transmission. 19-23

6. Functions of Steering System. 24-25

7. Types of Breaking System. 26-28

8. Electric Power System. 28-29

9. Automotive Power Generation. 29-30

10. Engine. 31-32

11. Partys of Engine. 32-34

12. Wheel Alignment. 35-37

13. Advantages & Oil changing Process. 38-40

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 Working in workshop

While working in the workshop I have seen and learnt about how a workshop
running at full speed and achieve target as much faster as they can, so they
meet the customer requirement and satisfaction.

There are four departments in workshop as follows:

1. Body shop
2. Painting shop
3. Service shop
4. Washing

When a car enters the workshop, firstly they made a repair order for the
customer in which the customer tells the problem what he is facing with the
car, or it may be its general repairs. Then the service adviser inspect the car and
he told the technician what he find at first stage then the technician fully
examine the whole car & each n every parts of the car and then he noted down
in the job card. Generally the company provide 4 free general services, in
which the mechanic or technician checks the engine oil, lubricating oil, water,
air filter, A/C filter and other electronic controls. And if he detects any problem
which might reduce the car efficiency he will notify to the service advisor and
then service advisor calls to the customer and tell him about the defects and
then if the customer is ready to repair it then the service adviser tell to the
mechanic and then mechanic repair the problem so the car run effortlessly.

Defected cars are selected on the basis of their faults and then send to it their
specified category of shop such as if any car having damage related to tits body

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 Fig. 1 Service adviser room

1.1Body shop

In the body shop of Sikka Hyundai those cars having some damage on its body
are repaired. Dents, breaking of body parts, etc. are some common problems
which comes to the body shop.

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 Fig. 2 Damage car body
1.2 Denting

Denting is a process in which the body of the car is not repair or replaced in
these a selected portion or we can say it a defected part of body of the car on
which dents, marks, scratches, stains, are to be repaired by some devices and
equipments.

Fig. 3 Denting shop

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1.3Paint shop.
Paint shop is the kind of parlor for cars, the aesthetic look of the cars are
prepared here in this paint shop. Priming, painting, etc. are some processes
perform in this shop.
Fig. 4 Painted parts

Fig. 5 Paint shop

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 Service shop

In service shop, as name shows in this shop the general service or repairing is
done like regular service or any problem related to internal mechanisms,
engines, etc. changing of engine oil, brake oil, clutch oil , gear oil, changing of
air filter, etc. comes under this shop.

In this shop four types of services are to be done they are as follows:

1. Free services
2. Paid services
3. Running repair services
4. Quick Services

Fig. 6 Opening of engine

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Fig. 7 Separating gear box from engine

Fig.8

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 Fig. 9 Repairing A/C system

Regular servicing on your car in general is the key to keeping it in the best-possible
condition. It’s for this reason that OEMs issue their individual maintenance
schedules that use various odometer milestones as reminders for when you should
get certain maintenance done on the car. As it happens, a lot of damage done to
cars is a result of people thinking that they’ll save some money in the short term by
skipping steps on that schedule. The real result is that they end up with more costly
repairs being needed further down the road.

If you drive a car with an automatic transmission, then that component is also in
need of proper maintenance and servicing, but when? You might rotate your tyres
and change your oil once every 5,000 miles, but is the transmission in such regular
need of attention? This is a point that we will try to clarify in today’s blog.
A/C is still blowing but is blowing hot or a little warmer than usual (and is not cooling, no
matter the setting), your likely culprit is a leak in the freon system. A slow leak can usually
be limped along by recharging the car’s A/C system once a year during the warmer months,
but a more significant leak in the A/C system will prevent it from being able to hold freon
at all.

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While a car’s air conditioning system is designed to be a closed vacuum system, age can
eventually affect the rubber, plastic, and metal components of a car’s air conditioning.

*Free services

Under this type of service category only those types of customer’s cars are to
be repaired which are within period of company’s warranty. When any
customer buys a new car the company provided them first 3 to 4 services are
free that means customer did not need to be pay for his first four services. Only
those parts to be repaired which are in fall under warranty period otherwise it
will be go in paid service.

*Paid services.

In these type of service customer have to pay for his cars services whenever he
visit for getting service. In this category warranty period cover cars are not to
be included for repairing, but in some rushes cases it can be repaired if some
might faults are to be solve.

*Running repair

In these the running cars to be repaired that means they come & order for
repair and then go in a same day after the service done which are to be listed
in job card.

*Quick services

In Quick Service Station, the car comes for general repair like to check engine
oil, lubricating oil, water level in battery and wind shied cleaning reservoir, air
filter, A/C filter and other electronic controls and if require top-up it.
According to the repair oder the store keeper gives the parts, which are to be
used to repair the car and placed in it carefully. It is a quick and short period of
time service.

*Washing

In washing the final cleaning is done with water and car washing shampoo. An
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automatic machine first washes the car then the whole washes are done by
washers (manpower). Sometimes it is done first then after service accordingly
customer’s requirement.

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 Fig. 10 Washing shop

Fig. 11 Automatic washing machine

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 Working in during in workshop
Replacement of the oil filter cartridge

The oil filter cartridge is present at the bottom of the car which can be open
with the rachet. After opening it the used engine oil is taken out and after that
the new cartridge is put in with a new washer. New washer is used to get
proper fitting so that the oil should not leak.

Air filter

A particulate air filter is a device composed of fibrous materials which

removes solid particulates such as dust, pollen, mold, and bacteria from the air.
A chemical air filter consists of an absorbent or catalyst for the removal of
airborne molecular contaminants such as volatile organic compounds or ozone.
Air filters are used in applications where air quality is important, notably in
building ventilation systems and in engines.

Fig. 12 Inserting new air filter

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A/C filter

A particulate a/c filter is a device composed of fibrous materials which

removes solid particulates such as dust, pollen, mold, and bacteria from the a/c
of car to release filtered cooled air inside the car. A chemical air filter consists
of an absorbent or catalyst for the removal of airborne molecular contaminants
such as volatile organic compounds or ozone. A/c filters are used in
applications where air quality is important, notably in building ventilation
systems and in vehicle cabinet.

Fig. 13 Left side new a/c filter other side

polluted a/c filter

Engine oil

Motor oil, engine oil, or engine lubricant is any of various well-developed

lubricants (comprising oil enhanced with additives, for example, in many
cases, extreme pressure additives) that are used for lubrication of internal
combustion engines. The main function of these lubricants is to reduce wear on
moving parts; they also clean, inhibit corrosion, improve sealing, and cool the
engine by carrying heat away from moving parts.

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Clutch plate

A clutch is a mechanical device that engages and disengages the power

transmission, especially from driving shaft to driven shaft. Clutches are used
whenever the transmission of power or motion must be controlled either in
amount or over time. The vast majority of clutches ultimately rely on frictional
forces for their operation. The purpose of friction clutches is to connect a
moving member to another that is moving at a different speed or stationary,
often to synchronize the speeds, and/or to transmit power. Usually, as little
slippage (difference in speeds) as possible between the two members is
desired.

Fig 14 Filling engine oil in engine

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 Fig. 15 Clutch plate

Brake

A brake is a mechanical device which inhibits motion, slowing or stopping a

moving object or preventing its motion. Most brakes commonly use friction
between two surfaces pressed together to convert the kinetic energy of the
moving object into heat, though other methods of energy conversion may be
employed. The brake disc (or rotor in American English) is usually made of
cast iron, but may in some cases be made of composites such as reinforced
carbon–carbon or ceramic matrix composites. This is connected to the wheel
and/or the axle. To retard the wheel, friction material in the form of brake pads,
mounted on a device called a brake caliper, is forced mechanically,
hydraulically, pneumatically, or electromagnetically against both sides of the
disc. Friction causes the disc and attached wheel to slow or stop.

Fig. 16 Brake wheel

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 Fig. 17 Disc brake assembly

Brake pad

Brake pads are a component of disc brakes used in automotive and other
applications. Brake pads are steel backing plates with friction material bound
to the surface that faces the disk brake rotor.

Brake pads are designed for high friction with brake pad material embedded in
the disc in the process of bedding while wearing evenly. Friction can be
divided into two parts. They are: adhesive and abrasive.

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Depending on the properties of the material of both the pad and the disc and
the configuration and the usage, pad and disc wear rates will vary
considerably. The properties that determine material wear involve trade-offs
between performance and longevity.

The brake pads must usually be replaced regularly (depending on pad material,
and drive style), and some are equipped with a mechanism that alerts drivers
that replacement is needed, such as a thin piece of soft metal that rubs against
the disc when the pads are too thin causing the brakes to squeal, a soft metal
tab embedded in the pad material that closes an electric circuit and lights a
warning light when the brake pad gets thin, or an electronic sensor.
Generally road-going vehicles have two brake pads per caliper, while up to six
are installed on each racing caliper, with varying frictional properties in a
staggered pattern for optimum performance.
Early brake pads (and linings) contained asbestos, producing dust which
should not be inhaled. Although newer pads can be made of ceramics, Kevlar,
and other plastics, but again inhalation of brake dust should still be avoided
regardless of material.

Fig. 18 Disc brake pad

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 Wheel alignment & balancing

Wheel alignment and Wheel Balancing are totally two different things. Wheel
alignment consists of adjusting the angles of the wheels so that they are
perpendicular to the ground and parallel to each other. The purpose of these
adjustments is maximum tire life and a vehicle that tracks straight and true
when driving along a straight and level road. Wheel Balancing, on the other
hand allows the tires and wheels to spin without causing any vibrations. This is
accomplished by checking for any heavy spots on the wheel-tire combination
and compensating for it by placing a measured lead weight on the opposite site
of the wheel from where the heavy spot is.

Fig. 19 Wheel alignment

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Fig. 20 Wheel balancing

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Final Inspection

In final inspection, the last inspection is done so, that there should not be any
single problem left in the car before handle to the customer.

This work station is just for the zero error service. This increases the customer
satisfaction and hence increases the standard of the workshop as well as the
service which is providing.

Fig. 21 I am doing final inspection

Fig. 22 Checking all spare parts are tight or not

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 SUPENSION SYSTEM

To fully understand what you’re suspension does, you have to grasp what would
happen if your car didn’t have one.

When you drive on the road, your car’s tires naturally roll over various
imperfections and bumps. Those bumps interact with your car’s wheels,
applying force each time. The laws of physics dictate that every force exerted
on an object has magnitude and direction.

When you encounter a bump on the road, it forces your wheel to move up and
down at a perpendicular angle (vertically relative to the road’s surface). Of
course, small bumps won’t transmit a lot of vertical kinetic energy to your car.
But larger road bumps or surface imperfections can transfer quite a bit of
energy.

It’s common sense; when your car’s wheels hit a bump, your car receives
energy and jolts upward or downward.

Fig.23 Suspension.

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 If you didn’t have a suspension, all that energy would transmit into your car’s
frame. That kind of energy transfer can make riding in a car uncomfortable at

TYPES OF SUPENSIONS :
 Macpherson Suspension. Macpherson is a suspension whose name is taken from
its inventor, Earle Macpherson
 Double Wishbone Suspension.
 Independent Suspension. .
 Rigid suspension - Leaf Spring.
 Trailing Arm Suspension.
 Air Suspension.

Fig.24 Different Suspension System

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 In a nutshell, your car's suspension system is a protective lattice of shock-
absorbing components such as springs and dampers. Your car's suspension
helps ensure that your drive is safe and smooth by absorbing the energy
from various road bumps and other kinetic impacts. Suspension systems
maximize the friction between your car's tires and the road. By
maximizing friction, you can steer your vehicle with more stability and
experience more comfortable handling. The more contact your tires have
with the road, the safer and more securely you'll be able to drive.

TRANSMISSION

 Provide means of connection and disconnection of engine with

rest of power train without shock and smoothly
 Provide a varied leverage between the engine and the drive wheels
 Provide means to transfer power in opposite direction.
 Enable power transmission at varied angles and varied lengths
 Enable speed reduction between engine and the drive wheels in
the ratio
 Enable diversion of power flow at right angles.
 Provide means to drive the driving wheels at different speeds
when required.
 Bear the effect of torque reaction , driving thrust and braking
effort effectively

Fig.25 Wheel Drive

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 There is no mechanical interconnection between the impeller and
the rotor and the power is transmitted by virtue of the fluid filled
in the coupling. The impeller when rotated by the prime mover
imparts velocity and energy to the fluid, which is converted into
mechanical energy in the rotor thus rotating it. The fluid follows a
closed circuit of flow from impeller to rotor through the air gap at
the outer periphery and from rotor to impeller again through the air
gap at the inner periphery. To enable the fluid to flow from
impeller to rotor it is essential that there is difference in the "heat"
between the two and thus it is essential that there is difference in
R.P.M., known as slip between the two

Fig.26 Engine.

*In telecommunications, a transmission system is a system that

transmits a signal from one place to another. The signal can be
an electrical, optical or radio signal.

*Manual is the simplest and oldest type of transmission still in use. The
gearbox uses a mechanical clutch and gear selector to switch between
speeds.

*It had various names throughout the years, referred to as a manual, stick
shift, standard, three, four, five, or six-speed. But whatever you call it, in

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 the US, fewer and fewer car models are manufactured with this
transmission type. In fact, many drivers are not even sure how to use it.

*It was featured in a vast selection of vehicles for decades, but now it’s
gradually fading in favor of automatic transmissions. However, drivers
*who enjoy manually shifting gears also enjoy better fuel economy and
enhanced vehicle control.

*While driving up an incline with traffic can be hellish on manual,

nothing beats that feeling of being fully in control of your car.

STEERING :

Cars respond so well to the driver? Great handling makes you feel safe and in
control – and makes panic swerves and steering corrections as effective as
possible. The lightest touch of the wheel should direct the steering system
effortlessly and precisely. As well as a well-designed suspension, it takes a good
quality steering system and steering parts to achieve excellent handling. If you’d
like to know the anatomy of a steering system and how it supports handling,
road holding and driver ability, here is an easy overview

Fig.27.Steering.
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THE FUNCTION OF A STEERING SYSTEM The steering
wheel, the car responds. But how does this steering system in cars give you a smooth
route forward? A group of parts called the steering system transmits the movement of
the steering wheel down the steering shaft to move the wheels left and right – although
car wheels don’t turn at the same angle.

Fig.27.Function of Steering.

1. Whatever a car’s make and model, quality auto steering parts support a
flawless drive. Premium rack and pinion parts manufactured by
MOOG include axial rods, tie rod ends, drag links, centre arms,
steering rack gaiter kits, tie rod assemblies and wheel end bearings.

2. These steering parts are robust and hard wearing enough to provide
both strength and durability. Choosing parts which meet OE
manufacturer specifications means the whole assembly will be
responsive and long- lasting.

3. Beyond the swivel of the front wheels, some cars have a steering
system which affects all four. This has traditionally been exclusive to
sporty or

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 luxury models, but there’s a growing trend towards the feature in more
affordable cars.

4. A four-wheel steering control unit sits behind the rear axle of the car and
affects the rear wheels as needed. Car wheels turn in opposite directions
at low speeds, but at high speeds, turning all four wheels in concert
helps to maintain stability and prevent fishtailing.

BREAKE

Originally, most systems for stopping vehicles were mechanically actuated

drum brakes with internally expanding shoes; i.e., foot pressure exerted on the
brake pedal was carried directly to semicircular brake shoes by a system of
flexible cables. Mechanical brakes, however, were difficult to keep adjusted so
that equal braking force was applied at each wheel; and, as vehicle weights and
speeds increased, more and more effort on the brake pedal was demanded of the
driver.

. Fig 28 Breaking System.

Mechanical brakes were replaced by hydraulic systems, in which the

brake pedal is connected to pistons in master cylinders and thence by
steel tubing with flexible sections to individual cylinders at the wheels.
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Front and rear hydraulic circuits are separated. The wheel cylinders are
located between

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 TYPES OF BREAKS
 Disc Brakes. Disc brakes consist of a brake rotor which is attached directly
to the wheel
 Drum Brakes. Drum brakes consist of a brake drum attached to the inside of
the wheel
 Emergency Brakes
 Anti-Lock Brakes

Fig.29 Types of Breakes

Disc brakes consist of a brake rotor which is attached directly to the

wheel. Hydraulic pressure from the master cylinder causes a caliper
(which holds the brake pads just outside the rotor) to squeeze the brake
pads on either side of the rotor. The friction between the pads and the
rotor causes the vehicle to slow and stop. Emergency brakes, also known
as parking brakes, are a secondary braking system that work independent
of the service brakes While there are many different kinds of emergency
brakes (a stick lever between the driver and passenger, a third pedal, a
push button or handle near the steering column, etc.),

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Disc Brakes:
Disc brakes consist of a brake rotor which is attached directly to the wheel.
Hydraulic pressure from the master cylinder causes a caliper (which holds the
brake pads just outside the rotor) to squeeze the brake pads on either side of the
rotor. The friction between the pads and the rotor causes the vehicle to slow and
stop. The disc brake is a mechanism for slowing or stopping the rotation of a
wheel from its motion. A disc brake is normally made of cast iron, but in some
cases, it is also made of composites such as carbon-carbon or ceramic -matrix
composites. This is linked to the wheel and/or the axle. To stop the wheel,
friction material in the form of brake pads is forced against both sides of the
disc. Friction caused, on the disc wheel will slow or stop. The mechanical
braking system powers the hand brake or emergency brake. It is the type of
braking system in which the brake force applied on the brake pedal is carried to
the final brake drum or disc rotor by the various mechanical linkages like
cylindrical rods, fulcrums, springs etc. In order to stop the vehicle. Mechanical
brakes were used in several old automobile vehicles but they are archaic
nowadays due to their less effectiveness.

Drum Brakes:
Drum brakes consist of a brake drum attached to the inside of the wheel. When
the brake pedal contracts, hydraulic pressure presses two brake shoes against the
brake drum. This creates friction and causes the vehicle to slow and stop. A
drum brake is a traditional break in which the friction is caused by a set of shoes
or pads that press against a rotating drum-shaped part called a brake drum.

The term \"drum brake\" usually means a brake in which shoes press on the
inner surface of the drum. Where the drum is pinched between two shoes,
similar to a standard disk brake , it is sometimes called a \"pinch drum brake\",
although such brakes are relatively rare.

Emergency Brakes:

Emergency brakes, also known as parking brakes, are a secondary braking

system that work independent of the service brakes. While there are many
different kinds of emergency brakes (a stick lever between the driver and
passenger, a third pedal, a push button or handle near the steering column, etc.),
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almost all emergency brakes powered by cables which mechanically apply
pressure to the wheels. They are generally used to keep a vehicle
stationary while parked, but can also be used in emergency situations if the
stationary brakes fail.

Anti-Lock Brakes

Anti-lock braking systems (ABS) are found on most newer vehicles. If the
stationary brakes are applied suddenly, ABS prevent the wheels from locking up
in order to keep the tires from skidding. This feature is especially useful when
driving on wet and slippery roads. Electromagnetic braking is fast and cheap.
• In electromagnetic braking, there is no maintenance cost like replacing brake
shoes periodically.
• By using electromagnetic braking, the capacity of the system( like higher
speeds, heavy loads) can be improved.
• A part of the energy is delivered to the supply consequently the running cost is
reduced.
• In electromagnetic braking, a negligible amount of heat is generated whereas
in mechanical braking enormous heat is produced at brake shoes which leads to
a brake failure.

Fig.30

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 ELECTRIC POWER SYSTEM

Fig.31.Electric Power System

The electrical system comprises a storage battery, generator, starting (cranking)

motor, lighting system, ignition system, and Various s accessories and controls.
Originally, the electrical system of the automobile was limited to the ignition
equipment. With the advent of the electric starter on a 1912 What type of
electrical systems are used in automotive applicationsThe alternator provides
the electrical power that charges the battery, however, the current produced is
alternating current (AC). Because vehicles use a 12-volt DC electrical system,
this alternating current (AC) power is quickly converted to direct current (DC).
The conversion of fuel energy into power in an engine starts when petrol is
mixed with air in a device called a to form a highly combustible mixture. On the
induction stroke the piston is descending, the inlet valve is fully open and the
exhaust valve closed. The strength of the current is measured in amperes
(amps); the pressure that drives it round the circuit is called voltage ( volts ).
Modern cars have a 12 volt battery. Its capacity is measured in amp/hours. A 56
amp/hour battery should be able to deliver a current of 1 amp for 56 hours, or 2
amps for 28 hours The extent to which a wire resists the flow of current is
called resistance , and is measured in ohms The energy needed to push current
through a resistance is transformed into heat. This can be useful, for example in
the very thin filament of a light bulb, which glows white hot.

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 AUTOMOTIVE POWER GENERATION

The ‘current’ demands made by modern vehicles are considerable. The

electricity generation system must be able to meet these demands under all
operating conditions and charge the battery.

*The main component of the electricity generation system is the alternator

*The alternator generates AC but must produce DC at its output terminal as

only DC can be used to charge the battery and run electronic circuits.

*The output of the alternator must be a constant voltage regardless of engine

speed and current load.

Fig32.Automotive Electricity Generation

There are only two main types of electric systems used around the world,
with varying physical connections: 100–127 volts, at 60 Hz frequency (in
general: North America including Central America, Japan) 220–240
volts, at 50 Hz frequency (in general: the rest of the world, with some
exceptions) n auto electrician, also known as a car electrician, knows how
to install and maintain wiring and electrical systems in a variety .

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 ENGINE
It is a complex machine built to convert heat from burning gas into the force that
turns the road wheels. The chain of reactions which achieve that objective is set in
motion by a spark , which ignites a mixture of petrol vapour and compressed air
inside a momentarily sealed cylinder and causes it to burn rapidly. Diesel, petrol,
electric, hybrid or gas: each has its own advantages. It's up to you to find the one
that best suits your needs. The chain of reactions which achieve that objective is set
in motion by a spark , which ignites a mixture of petrol vapour and compressed air
inside a momentarily sealed cylinder and causes it to burn rapidly. That is why the
machine is called an internal combustion engine . As the mixture burns it expands,
providing power to drive the car.

Fig.33. Engine

It is a complex machine built to convert heat from burning gas into the
force that turns the road wheels. The chain of reactions which achieve
that objective is set in motion by a spark , which ignites a mixture of
petrol vapour and compressed air inside a momentarily sealed cylinder
and causes it to burn rapidly.
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35
Internal Combustion:
The principle behind any reciprocating internal combustion engine: If you
put a tiny amount of high-energy-density fuel (like gasoline) in a small,
enclosed space and ignite it, an incredible amount of energy is released in
the form of expanding gas

You can use that energy for interesting purposes. For example, if you can
create a cycle that allows you to set off explosions like this hundreds of
times per minute, and if you can harness that energy in a useful way, what
you have is the core of a car engine.

Fig.34

*The piston starts at the top, the intake valve opens, and the piston moves
down to let the engine take in a cylinder full of air and gasoline. This is
the intake stroke. Only the tiniest drop of gasoline needs to be mixed into
the air for this to work. Then the piston moves back up to When the
piston reaches the top of its stroke, the emits a spark to ignite
the gasoline. The gasoline charge in the explode , driving the
cylinder s
36
piston down Once the piston hits the bottom of its stroke, the exhaust
valve opens and the exhau

37
 parts of a engine
Engine Block (Cylinder Block):
The engine block is the core of your engine. It is usually made of aluminum
alloy, and on rare occasion iron. It is also called a cylinder block because of
the cylinder tubes that help make it up. The cylinder block is the home for the
pistons (where they move up and down). Often cars have more than one
cylinder (usually four, six, or eight). The more cylinders that the engine has
the more powerful it is.

The combustion chamber :

The combustion chamber is where the energy is transformed in the combustion
process. This is the area of the engine in which the fuel, air, electricity, and
pressure have an explosive reaction that causes the pistons to move up and
down. The movement of the pistons gives the car the power to move.

The Cylinder Head

The cylinder head sits above the engine’s cylinders creating a space at the top
of the chamber for combustion. It is also the home for various other parts such
as intake and outtake valves, the spark plugs, and the fuel injectors.

The Pistons
As explained before, when the energy is created the pistons then move up in
down to give the vehicle power to move. They look similar to cans and are
connected to the crankshaft. Pistons also consist of compression rings and oil
rings which help to seal the combustion chamber and prevent oil from leaking
into that area.

The crankshaft
The crankshaft is the part of the engine that rounds out the up and down
motion of the pistons. It is connected to rubber belts which are connected to the
camshaft allowing for power to be delivered to various parts of the car.
The camshaft is connected to the drive train which is the part that transfers
power to the wheels.

The Camshaft

The camshaft works with the crankshaft, connected by a timing chain, allowing
the intake and outtake valves to open and close according to a specific timeline.

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The Timing Chain

The camshaft and crankshaft, as mentioned above, are connected by a timing

chain. These parts work together to make sure certain actions take place at
certain times, which is vital for the functioning of the engine.

The valvetrain

The valvetrain is the part of the engine that controls the movement of the valves.
It is made up of the valves, as well as the pushrods and lifters, and rocker arms.
It is connected to the cylinder head.

The Valves

The valves in an engine are the intake valves and the outtake valves. Intake
valves work to transfer the air and fuel levels into the combustion chamber.
The outtake valves work to move the exhaust that is created from the
combustion out of the chamber.

The Rocker Arms

The rocker arms work with the cams (from the camshaft) to press down on the
valve system and let the needed air into the chamber or the exhaust out.

The pushrods/lifters
In engines (overhead valve engines) in which the camshaft lobes don’t touch the
rocker arms, the pushrods/lifters are used in place in the valve system.

The spark plugs

There is a spark plugs that resides above each of the cylinders. During the
combustion process, the spark plugs spark which ignites the compressed fuel
and air and therefore causing the “explosive” process that pushes the piston
down. Having a bit of knowledge of the different parts of your car and how
they work is highly beneficial for you as the driver. This especially comes in
handy when taking your car into the shop. Having a McKinney car shop that
you can trust makes all the difference. Here at Nortex Lube & Tune, you can
rely on us. We will happily help explain any services your car needs and why,
as we pride ourselves in being a trustworthy business. If you have any questions
or would like to schedule an appointment with our expert mechanics, contact us
today.

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 WHEEL ALIGIMENT
Wheel alignment refers to the angle of your wheels in comparison to each other
and the body of your vehicle. Wheel alignment is adjusted by altering the
vehicle’s suspension. Using state of the art technology, Tyre Specialists at Tyres
and More are able to accurately determine exactly how much adjustment is
required and apply accordingly. We recommend that you get your wheel
alignment checked at least every 10000km as well as any time you experience a
change in the driving or handling of your vehicle.

Fig 36

Fig.37

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Alignment refers to an adjustment of a vehicle's suspension – the system that
connects a vehicle to its wheels. It is not an adjustment of the tires or wheels
themselves. The key to proper alignment is adjusting the angles of the tires
which affects how they make contact with the roadEach car's manufacturer
designates standard angles for the alignment, specified in degrees. If you're a
driver of a high-performance car or sports car, your mechanic may be able to
align your suspension to improve handling and tire performance, but such an
alignment still may lead to uneven tire wear. One of the most important
benefits of wheel alignment is improved handling. Properly aligned wheels will
make your car handle better on the road, especially when you're driving at high
speeds. If your car's wheels are out of alignment, you'll notice that it drifts to
one side of the road or the other. What is the important of wheel alignment?
Having your wheels aligned not only offers a much smoother drive, it
ensures you are driving within road safety standards. Frequent wheel
alignments also: Improves Fuel Efficiency – When your vehicle's wheels are
misaligned, the driving pressure pushed onto the tyres is not equally balanced

Fig

TYPES OF WHEEL ALIGIMENT

 Front-end alignment
 Thrust alignment.
 Four-wheel alignment.

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FRONT END ALIGIMENT :

A front-end
THRUST alignment only measures and adjusts the front axle. It is
ALIGIMENT
sometimes done on vehicles with a solid rear axle and is the most basic
Aalignment
thrust angle
as italignment
covers theensures that all four
bare minimum. wheels are
Sometimes it is“squared” with each
called a “toe-in”
otherIt is recommended for all vehicles with a solid rear suspension, as it
alignment or a “toe and go”. Toe-in means that the tyres are pointing toward
provides a better result on the road in terms of tyre wear, fuel economy and
each other.The
safety.This correct toe
is especially positioniffor
important youyour
are vehicle
having an willalignment
vary slightly
completed
after an accident
depending on itsor a hard knock
suspension and to
onyour suspension,
whether such as running
it is front-wheel, up a or
rear-wheel
gutter.
all-wheel driveMany tyre fitters consider a front-end-only alignment unsuited
to modern cars due to its incomplete nature and may refuse to offer it.
FOUR WHEEL ALIGIMENT
Tyreright recommends that you

The four-wheel alignment is for cars or 4WDs with four-wheel independent

suspensions. It’s also for front-wheel drive vehicles with adjustable rear
suspensions.This type of alignment combines the elements of a front and thrust
alignment but goes another step further by measuring and positioning the rear
axle anglesThe four-wheel alignment will restore all four corners of your
vehicle to the manufacturer’s specifications.This type of alignment requires
specialist equipment and is the most comprehensive alignment. It also results in
the best overall handling for your vehicle and performance for your tyres in
terms of durability, fuel economy and safety.

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 Oil changing process & advantages
 The advantages of changing your car’s engine oil:
1. Gets rid of dirt and debris– Modern engine oils clean carbon deposits in the engine
which helps reduce friction and emissions
2. Improves engine performance– The reduced friction, clean emissions, and improved
car functioning also mean better engine performance
3. Ensures better fuel efficiency- When the engine is operating optimally, it also offers
the best fuel efficiency possible
4. Keeps emissions in check- With Pollution Under Control (PUC) checks now
centralised, it is important to ensure your car meets the emission regulations. Modern
cars have to work extra hard to keep emissions low, and you can help your vehicle
with a timely engine oil change
5. A healthy engine equals a longer lifespan– An internal combustion engine has over
2,000 moving parts, most of which run at really high speeds and temperatures.
Something as little as a worn bearing can lead to complicated, expensive repairs at
some point down the line, not to mention increased fuel consumption. Hence, it is best
to keep your engine healthy with a timely car oil change

Fig.38

43
 Oil Changing process.

1. To start with, you’ll need a ramp. If you don’t have a ramp, then you’ll need a flat
area, at least one jack and four jack stands, your owner’s manual, a torque wrench or
spanner for the drain bolt, the drain bolt gasket, replacement engine oil, a new oil
filter, a pan to collect the new engine oil in, empty cans for the used engine oil, a
funnel, cotton waste or disposable cloths to wipe your oily hands on, and finally a
bunch of newspaper to lay on the ground so that you don’t lay in the dirt.

2. Go through your owner’s manual to find out the type and quantity of engine oil your
car requires. If it requires synthetic oil, don’t use mineral oil – but the converse is
acceptable. Also, check if your oil filter requires replacement. If it does, purchase one.
Get a new drain bolt gasket as well while you’re at the parts store. You’ll need an oil
collection pan that will hold significantly more than the amount of oil your engine
holds.

3. Put the car on the ramp. If you don’t have access to a ramp, put the car on the jack
stands. Make sure that each jack stand is stable; you don’t want the car falling off and
crushing you. It will help if you have a bottle jack to jack up the car, else you will
spend a LOT of time and effort inserting and removing the standard jack at each
jacking point – you’ll have to do this a total of eight times, remember.

4. Place the collection pan under the drain bolt. Loosen the bolt, and let the oil drain into
the pan.

5. Once it has drained fully, replace the oil filter if necessary. Your owner’s manual will
tell you where it is. If it doesn’t, you’ll require a service manual or a Haynes manual if
your car is an international model.

6. Replace the drain bolt with the new gasket. Use the torque wrench and make sure it
isn’t cross-threaded. If using a standard spanner, do not over-tighten it.

7. Fill the new oil in the engine. Use the amount specified in the manual.

8. Get the car off the stands.

9. Use the funnel to fill the old engine oil in the empty cans.

10.By this time, the oil in the engine has settled; use the dipstick to check the level. If
required, top it up.

11.Move the car a short distance to a clean patch of road and wait for a while. If you see
oil dropped under the car, you’ve probably got a leak and will have to inspect the car

44
 for the source.

12.Don’t forget to carry the used newspaper along and throw it in the trash; for the oil,
you’ll have to dispose it of by giving it to a mechanic. Do not throw it into the trash or
down the drain, it is an environmental hazard.

Fig.40. Oil Changing Process.

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