training report maintenance and overhauling of petrol engine
TRANSCRIPT
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