A TRAINING REPORT

Maintenance & Overhauling of Petrol engine

HASSAN MOTORS (MARUTI AUTH. WORKSHOP)

DOWNTOWN SOPORE, KASHMIR

MOHAMMAD IRFAN HAJAM

College Roll No: 1203034

Submitted to Savera Group of Institutions,

Department of Mechanical Engineering,

in Partial Fulfilment of Requirement for the Degree of

Bachelor of Technology in Mechanical Engineering

Faculty of Engineering,

Maharishi Dayanand University

Rohatk, Haryana, India.

November, 2015.

CERTIFICATE OF EXAMINATION

This is to certify that we have examined the training report on Overhauling

and maintenance of Petrol engine submitted by Mohammad Irfan Hajam

student of final year B. Tech (Mechanical Engineering). We hereby accord

our approval of it as an Industrial Training carried out and presented in a

manner required for partial fulfillment for the Bachelor of Technology

(Mechanical Engineering) degree of Maharishi Dayanand University (Rohtak).

This approval does not necessarily endorse or accept every statement made,

opinion expressed or conclusion drawn as recorded in the Training report; it

only signifies the acceptance of the Training report for the purpose for which

it is submitted.

Mr. Kuldeep Malik

(HOD M.E)

DECLARATION

I Mohammad Irfan Hajam hereby declare that this submission is my own

work and that, to the best of my knowledge and belief, it contains no

material previously published or written by another person nor material

which to a substantial extent has been accepted for the award of any other

degree of the university or other institute of higher learning, except where

due acknowledgment has been made in the text.

Mohammad Irfan Hajam

ACKNOWLEDGEMENT

I express to my sincere to all officers at “HASSAN MOTORS” who has assisted

me during my training period. I should be particularly thanks to “MR ALTAF

AHMAD” who helped in joining and completing the training.

I extended my special thanks to him for their guidance & co-operation throughout

my training for completion of this project report. Their guidance has helped me a

lot understanding other process of service in workshop.

I also thank to all instructors for their kind that they have paid to me. That project

is result of co-operation of all the members and staff of “HASSAN MOTORS”.

PREFACE

I worked with “HASSAN MOTORS” as trainee in “Automobile Engineering” I

complete six-week training under supervision. During my training period I have

learn many things such as, what happen in different types of services.

In my training period I come to know that the specification of any vehicle can be

done by the following things Dimension, Weight, Engine, Capacity, Specification,

Servicing and Maintenance etc.

During my training, it has been put my knowledge that which part are covered

under warranty. I also to know the important of servicing and maintenance.

I am including all those things, which I have learnt during period in this project

report.

CONTENTS

1) HISTORY OF MARUTI SUZUKI

2) CAR NAMES & SPECIFICATIONS OF MARUTI SUZUKI

3) TOOLS, GAUGES & EQUIPMENT USED IN WORKSHOP

4) DESCRIPTION OF FOUR STROKE IN PETROL AND DIESEL ENGINE

5) ENGINE

DIESEL ENGINE AND PETROL ENGINE

MAIN PARTS OF ENGINE

6) TRANSMISSION SYSTEM

CLUTCH

GEAR BOX

PROPELLER SHAFT

DIFFERENTIAL

7) COOLING SYSTEM

RADIATOR

THERMOSTAT

WATER PUMP

FAN

8) FUEL SYSTEM IN DIESEL ENGINE

FUEL TANK

FUEL FEED PUMP

FUEL INJECTION PUMP

INJECTOR

9) FUEL SYSTEM IN PETROL ENGINE

FUEL TANK

FUEL FILTER

FUEL PUMP

CARBURETTOR

SPARK PLUG

10) STEERING SYSTEM

11) BRAKE SYSTEM

12) CHASSIS

13) PARTS NAME AND ITS FUNCTION

HISTORY OF MARUTI SUZUKI

Maruti Suzuki India Limited (MSIL, formerly known as Maruti Udyog Limited) is a

subsidiary of Suzuki Motor Corporation, Japan. Maruti Suzuki has been the leader of

the Indian car market for over two and a half decades. The company has two

manufacturing facilities located at Gurgaon and Manesar, south of New Delhi, India.

Both the facilities have a combined capability to produce over a 1.5 million (1,500,000)

vehicles annually. The company plans to expand its manufacturing capacity to 1.75

million by 2013.

The Company offers 15 brands and over 150 variants ranging from people's car Maruti

800 to the latest Life Utility Vehicle, Ertiga. The portfolio includes Maruti 800, Alto, Alto

K10, A-star, Estilo, WagonR, Ritz, Swift, Swift DZire, SX4, Omni, Eeco, Kizashi, Grand

Vitara, Gypsy and Ertiga. In an environment friendly initiative, in August 2010 Maruti

Suzuki introduced factory fitted CNG option on 5 models across vehicle segments.

These include Eeco, Alto, Estilo, Wagon R and Sx4. With this Maruti Suzuki became the

first company in India to introduce factory fitted CNG vehicles.

In terms of number of cars produced and sold, the Company is the largest subsidiary of

Suzuki Motor Corporation. Cumulatively, the Company has produced over 10 million

vehicles since the roll out of its first vehicle on 14th December, 1983.

Maruti Suzuki is the only Indian Company to have crossed the 10 million sales mark

since its inception. In 2011-12, the company sold over 1.13 million vehicles including

1,27,379 units of exports.

The Company employs over 9000 people (as on 31st March, 2012). Maruti Suzuki's

sales and service network is the largest among car manufacturers in India. The

Company has been rated first in customer satisfaction in the JD Power survey for 12

consecutive years. Besides serving the Indian market, Maruti Suzuki also exports cars

to several countries in Europe, Asia, Latin America, Africa and Oceania

DESCRIPTION OF FOUR STROKE IN PETROL ENGINE

1. In starting the piston position at top, when the piston moves downward the inlet

valve is open, then the air/fuel is intake the cylinder. This is known as SUCTION

STROKE.

2. Then the piston moves upwards and compresses the air/fuel mixture. There is a

spark plug is provided which produce spark to brunt the fair/fuel mixture. This stroke

known as COMPRESSION STROKE.

3. When the spark plug produce spark there is blast in the cylinder and the piston

moves down wards strictly and power is produce. By this power, the vehicle is move

forward /backward as per desire. This stroke is known as POWER STROKE.

4. Now the piston is moves upwards, there are gasses are produce by the burning of

the air/fuel mixture are exit from the outlet valve. This stroke is known as EXHAUST.

DESCRIPTIONOF FOUR STROKE IN DIESEL ENGINE

1. In starting the piston position at top, when the piston moves downward the inlet

valve is open, then the air is intake the cylinder. This is known as SUCTION STROKE.

2. Then the piston moves upwards and compresses the air. There is a injector is

inject the fuel in spray formation to brunt the air and fuel. This stroke known as

COMPRESSION STROKE.

3. When the injector inject the fuel there is blast in the cylinder and the piston moves

down wards strickly and power is produce. By this power, the vehicle is move forward

/backward as per desire. This stroke is known as POWER STROKE.

4. Now the piston is moves upwards, there are gasses are produce by the burning of

the air/fuel mixture are exit from the outlet valve. This stroke is known as EXHAUST.

MAIN PARTS

1. CYLINDER BLOCK

Fig CYLINDER BLOCK

a) Carbon 2.2%

b) Silicon 1.2%

c) Manganese 0.63%

d) Sulphur 0.12%

e) Phosphorus 0.85%

Top of the cylinder is covered by separate cast iron piece known as cylinder head. It is

bolted on the top of the block. It contains nozzles, valves, rocker arms, tappets etc. The

bottom of cylinder head and top of the cylinder block is machined very accurately. so

that there are very less changes of gas leakage for sound gas tight joint the holding

studs must be distributed as possible around the circumference of each cylinder the

combustion chamber is made of cast iron.

1. CRANK CASE

Crankcase is attached to the bottom face of the cylinder. It acts as the base of the

engines. It supports the cranks shaft and camshaft in suitable bearings lower part of the

cylinder block together is called the crankcase.

2. CONNECTING ROD

The connecting rod is the connection between piston and crankshaft. Small end of the

connecting rod is connected to the piston pin and big end is connected to the crank pin.

The function main function of connecting rod is to convert the liner motion of the piston

to rotary motion of crankshaft.

Aluminum alloy is also used for connecting rod. The connecting rod carries the power

thrust from piston to crank pin and hence it must be very rigid and as light as possible.

Crankshaft is the first in power transmission. System the reciprocating motion of piston

is converting into rotary motion with the help of connecting rod. Crankshaft consists of

crank pins, webs balancing weights and main journals. Big end of connecting rod is

connecting to crank pins of crankshaft.

The part of crankshaft inside the main bearing is called the main journals. Balancing

weights are provide on the opposite side of crank arms for balancing crankshaft is made

of casting of forging of heat created.

3. FLYWHEEL

Fig : Flywheel

A flywheel is a heavy steel wheel attached to the near end of the crankshaft. The size

of flywheel is depends upon the number of cylinder and general construction of the

engine. The flow of power from the engine cylinder is not smooth although the power

impulses in a multi cylinder overlap or follow each other to provide a fair fly even flow of

power, however additional leveling off power impulses is required.

It also has teeth on its periphery to mesh with electric cranking motor drive pinion when

engine is being cranked to start it.

4. VALVES

Valve is a device to close and open a passage. In motor vehicle, engines valves used

for each cylinder and an exhaust valve. Exhaust valve is usually of austenitic stainless

steel, which is highly heat &corrosion resistant. Inlet valve is being subject to less heat

usually of nickel chromium alloy.

5. CAMSHAFT

Fig : camshaft

A camshaft is simply a shaft on which cams are mounted. The camshaft is mounted on

lower part of the camshaft into linear motion of the follower or lifter. A camshaft is

responding for opening.

A camshaft has a numbers of cams along the length, two cams for elfish cylinder one to

operate inlet valve and other to exhaust valve. In addition, camshaft has an eccentric to

operate the fuel pump and gear to drive the ignition distributers and oil pump.

The camshaft is drive by crankshaft by machine gears. The crankshaft gear have twice

the as many as on crankshaft gear.

6. OIL PAN OR SUMP

The bottom half of the crankshaft is called oil pan or sump. It is bolted or screwed to

lower flange of the main casting and usually made of pressed steel or aluminum. It

serves as a reservoir for the storage, cooling and ventilation of engine oil. The oil sump

draws oil from the pan and sends it in the engine. The oil drains off run down into pan.

There is a constant circulation of oil between pan and the working parts of the engine.

7. OIL PUMP

It is generally located inside the crankcase below the oil level. The function of oil pump

is to supply oil under pressure to the various engine parts are lubricated. We generally

use gear type oil pump. It consists two gear of equal size. One is called driven gear and

other is called driving gear.

The driving gear should be 0.5 mm and clearance between the bodies to gear should be

0.5mm-1mm. The oil enters the pump from the inlet port. The wear and tear of teeth,

which occurs slowly, produces an adverse effect on the delivery

8. GASKETS

A gasket is placed between the cylinder head and to ensure metallic tight fit joint. The

gasket should able to withstand not only high pressure but also extreme temperature.

Following important gaskets are used in automobile engine:

1. Copper—Asbestos Gasket

2. Steel-- Asbestos Gasket

3. Steel-- Asbestos –Copper Gasket

4. Single Steel rigid or Corrugate Gasket

Fig :Gasket

9. PISTON

Piston is considered one of the most important parts in a reciprocating engine that is

used to convert the chemical energy obtained by the combustion of fuel into useful

mechanical power.

The piston must possess the following qualities: -

1. Rigid to withstand high pressure.

2. Lightness to reduce the weight of reciprocating masses and so enable to get

higher engines speeds.

3. Good heat conductivity.

4. Material should have low co-efficient of expansion.

Common Problems in piston

11. PISTON RING

Piston rings are fitted into the grooves to maintain good seal between the piston and the

cylinder wall.

Fig : Piston rings

TRANSMISSION SYSTEM

12. CLUTCH

It consists of only one clutch plate, mounted on the spines of the clutch shaft, the

flywheel is mounted on engine crankshaft and rotates with it the pressure plates bolted

to the flywheel through clutch springs and free to slide on clutch shift when the clutch

pedal is operated. When the clutch is engaged plates is gripped between the flywheel

and pressure plate.The friction linings are on both the sides of the clutch plate due to

friction between the flywheel. Clutch plate and pressure plate, the clutch plate revolves

with the flywheel. As clutch shaft is also connected to the transmission thus engine

power is transmitted to the crankshaft to the clutch shaft.

When the clutch pedal is pressed, the pressure plate move back against the force of the

strings and the clutch plate become free between the flywheel and the pressure plate

thus the flywheel remain rotating as long as the engine running and the clutch shaft

speed reduce slowly and finally it stop rotating as soon the clutch pedal is pressed, the

clutch is said to be disengaged, otherwise it remains engaged due to the spring faces.

Problems in Clutch

13. GEAR BOX

Its function is to provide the high torque at the starting, hill climbing, accelerating and

pulling a load. When a vehicle is starting from rest, hill climbing, accelerating and

meeting other resistance, high torque is required, at the drive wheels. Hence, a device

must be providing to prevent the engine crankshaft to revolve a relatively high speed,

while the wheels turn at slower speed.

This obtained by set of gear called a transmission or gear set of enclose in metal box

called a gearbox. The vehicle speed is also change with the help of the transmission

box keeping the engine speed it with certain limit

.

Common Problems in Gear box

14. PROPELLER SHAFT

This shaft is used to transmit power from universal joint to differential in case of rear

wheel drive vehicles. This shaft doesn’t remain at fixed position. There are two reasons

for this. One, the rear axle moves up and down because of unevenness of the road.

Secondly, while braking and starting, it tends to move axially forward and backward.

One is internally splined and one externally.

15. DIFFERENTIAL

When the automobile round a corner or travel over uneven ground, its right and left

wheel covered differential distance. If the wheels are rotates at equal speeds. One of

them would be forced skid. To prevent skidding, there must be a mechanism is called

differential.

the car use a differential pinions is free mounted on the journal of the slider. The slider

with pinions is secured in the differential case to rotate with the letter. The pinion is

inconstant mesh with the left and right side gear.

When an automobile moves straight on the even road, the right and left driving wheels

meet the same rolling resistance and the ring gear of the final drive rotate the differential

case with the sliders and pinions. Meshed with the right and left side gears the pinion

rotates them at equal speed but do not revolve themselves around their axes.

16. COOLING SYSTEM

1. Radiator: - A radiator very efficiently cools the circulating water passing through it.

It hard water jackets and tubes, which acts as insulator and make the in efficient.

Common Problems in radiator

2. Thermostat: - Thermostat is a valve type components used in the cooling system,

which regulates the engine temp. by automatically controlling the quantity of cooling

water flowing from the water jackets to the radiator core.

3. Water pump: - The power is transmitted to the pump spindle for a pulley mounted

on the end of the camshaft or crankshaft. The water pump used in cooling system is

either centrifugal pump is the one which is used for this purpose.

4. Fan: - Fan is mounted behind the radiator on the same shaft on which the water

pump is mounted. It is driven by a v-belt from the crankshaft pulley.

FUEL SUPPLY SYSTEM IN PETROL ENGINE

1. Fuel tank:- The fuel tank acts as a reservoir in which fuel is stored. The fuel tank is

provided with air-want so that the pressure in the fuel tank always remain equal to the

atmospheric pressure.

2. Fuel filter: - To prevent possible blockage by dust particles, the fuel is filtered by

installing a fuel filter or strainer at the inlet to the float chamber. In a fuel supply system,

there are three fuel filters. One fuel filter is mounted at the inlet of the fuel storage tank.

The second fuel filter is fitted in the fuel pump and the third is placed in between the fuel

pump and carburetor. The fuel entering the glass bowl passes through a ceramic filter

which separates the foreign particles and the filtered fuel come out from it. The water

and sediments are collected in the bowl which can be removed for cleaning.

Fig : Oil Filter

3. Fuel pump :- The function of the fuel pump is to deliver fuel from the fuel tank to

the carburetor. Many types of fuel pumps are used, out of which two are as follows:

A. Mechanical fuel pump

B. Electrical fuel pump

Mechanical fuel pump: This type of pump is used in petrol engine for supply of fuel to

the carburetor. Due to rotation of the crankshaft the cam rotates, it operates the rocker

arm which in turn pushes the diaphragm up and down. The downward moment of the

diaphragm against the compression of spring produces a vacuum in the pump chamber.

The causes the suction of fuel though the strainer from the fuel tank. The upward

moment of diaphragm pushes the fuel up causes the inlet valve to close the outlet valve

to open. The fuel goes to the mpfi system through the outlet valve.

MPFI System: -

M.P.F.I. means Multi Point Fuel Injection system. In this system each cylinder has

number of injectors to supply/spray fuel in the cylinders as compared to one injector

located centrally to supply/spray fuel in case of single point injection system.

Advantage of M. P. F. I.

(1) More uniform A/F mixture will be supplied to each cylinder, hence the difference in

power developed in each cylinder is minimum. Vibration from the engine equipped with

this system is less, due to this the life of engine components is improved.

(2) No need to crank the engine twice or thrice in case of cold starting as happens in the

carburetor system.

(3) Immediate response, in case of sudden acceleration / deceleration.

(4) Since the engine is controlled by ECM* (Engine Control Module), more accurate

amount of A/F mixture will be supplied and as a result complete combustion will take

place. This leads to effective utilization of fuel supplied and hence low emission level.

(5) The mileage of the vehicle will be improved.

FUEL SUPPLY SYSTEM IN DIESEL ENGINE

The fuel is stored in the fuel tank from where it is lifted by means of a fuel feed pump if

the fuel tank is place at a lower level. The fed pump supplies the fuel to the injection

pump through a filler. The fuel injection pump forces the fuel under a very high pressure

to the fuel injector. The fuel under a very high pressure is injected into the engine

cylinder in the form of a fine spray by means of the fuel injector at proper instant. The

fuel injection system consists of the following components.

4. Fuel tank: - the fuel tank acts as a reservoir in which fuel is stored. The fuel tank is

provided with air-want so that the pressure in the fuel tank always remain equal to the

atmospheric pressure.

5. Fuel feed pump: - the pump which supplies fuel from the tank to the injection

pump, is known is fuel feed pump. The pressure developed by pump is 1 bar to 2 bar.

6. Fuel injection pump: - The pump which supplies a metered quantity of fuel to the

injector under a very high pressure at correct moment is known as fuel injection pump.

7. Fuel injector: - A nozzle mounted on the combustion chamber, which supplies the

fuel to the engine cylinder in the form of a fine spray, is known as fuel injector. It is also

sometime called fuel atomizer fuel valve, nozzle Or spray.

17. STEERING

This system is consisting generally of many linkages. It is mostly attached to the front

wheels. It’s main components are steering wheel, steering column, steering box, pitman

arm, pull & push rod, tie rod, tie rod arm and king pin.

The main function of steering system:-

1. It allowed gear wheel to turn to the right or left.

2. The steering gear swing on piston arm to the right or left when the wheel is turned

.

18. BRAKING SYSTEM

Stopping of the vehicle is as necessary as its starting. Once the vehicle is started, it

must be stopped somewhere. Brakes are applied on the wheels to stop the vehicle.

Before applying the brakes, the acceleration is released to stop the fuel supply thus the

engine develops no more power to run the vehicle, and then the brakes are applied

which stop the rolling of the wheels on the road and hence the vehicle is stopped.

Fig : Braking system