A Laboratory Manual for

VEHICLE MAINTENANCE AND

GARAGE PRACTICE

(3160210)

B.E. Semester 7 (Automobile)

Directorate of Technical Education, Gandhinagar,

Gujarat
 L. D. College of Engineering, Ahmedabad
Certificate

This is to certify that Mr./Ms.

Enrollment No. Of B.E. Semester

Automobile Engineering of this Institute (GTU Code: 028) has

satisfactorily completed the Practical / Tutorial work for the subject

VEHICLE MAINTENANCE AND GARAGE PRACTICE (3160210) for the

academic year ____________

Place:

Date:

Name and Sign of Faculty member Head of the Department

VEHICLE MAINTENANCE AND GARAGE PRACTICE (3160210)

Preface

The main motto of any laboratory/practical/field work is for enhancing required skills as well as
creating the ability amongst students to solve real-time problems by developing relevant
competencies in the psychomotor domain. By keeping this in view, GTU has designed a
competency-focused outcome-based curriculum for engineering degree programs where
sufficient weightage is given to practical work. It shows the importance of enhancement of
skills amongst the students and it pays attention to utilize every second of time allotted for
practical amongst students, instructors and faculty members to achieve relevant outcomes by
performing the experiments rather than having merely study type experiments. It is must for
effective implementation of competency focused outcome-based curriculum that every practical
is keenly designed to serve as a tool to develop and enhance relevant competency required by
the various industry among every student. These psychomotor skills are very difficult to
develop through traditional chalk-and-board content delivery methods in the classroom.
Accordingly, this lab manual is designed to focus on the industry-defined relevant outcomes,
rather than the old practice of conducting practical to prove concepts and theory.

By using this lab manual students can go through the relevant theory and procedure in advance
before the actual performance which creates an interest and students can have basic idea prior to
performance. This in turn enhances pre-determined outcomes amongst students. Each
experiment in this manual begins with competency, industry relevant skills, course outcomes as
well as practical outcomes (objectives). The students will also achieve safety and necessary
precautions to be taken while performing practical.

This manual also provides guidelines to faculty members to facilitate student centric lab
activities through each experiment by arranging and managing necessary resources in order that
the students follow the procedures with required safety and necessary precautions to achieve the
outcomes. It also gives an idea that how students will be assessed by providing rubrics.

Utmost care has been taken while preparing this lab manual however always there is chances of
improvement. Therefore, we welcome constructive suggestions for improvement and removal
of errors if any.
VEHICLE MAINTENANCE AND GARAGE PRACTICE (3160210)

Practical – Course Outcome matrix

Course Outcomes (COs):

CO1: Understand the importance of vehicle inspection, Maintenance and application of tools.
CO2: Diagnose the causes of Engine problem and provide the remedial action.
CO3: Identify the causes and service and maintain the clutch, gear box, universal joints, propeller
shaft, differential and braking system.
CO4: Possess the knowledge about the inspection and maintenance of suspension, steering system and
wheels and tyre.
CO5: Apply the basic knowledge and rectify the electrical systems and cooling system problems and
maintain vehicle body.

Sr. CO CO CO CO CO
Objective(s) of Experiment
No. 1 2 3 4 5

Study workshop management, Prepare Garage layout, Job

1. card and Automotive service &diagnosis tools and √
equipments.

2. Perform Underhood, Undercar and body Inspection of a

vehicle and prepare and fill visual inspection worksheet. √

Study working principle and perform operation of Garage

3. service and repair equipments like (a) Two post hoist (b)
Electronic air inflator (c) Battery Charger (d) Car Washer.
√
(e) Tyre changer

4. Perform Overhauling and service of automobile

transmission system. √

5. Perform service of hydraulic braking system and study of

air brake circuit. √

6. Alignment measurement and checking on Wheel Aligner. √

7. Perform service and testing of wheel and tyre. √

8. Inspection and service of an Air conditioning system of a

car using an AC recovery unit. √
VEHICLE MAINTENANCE AND GARAGE PRACTICE (3160210)

Industry Relevant Skills

The following industry relevant competency is expected to be developed in the student by

undertaking the practical work of this laboratory.
1. Students are able to diagnose the various problems of the vehicle.
2. Students are able to solve the various problems of the vehicle.

Guidelines for Faculty members

1. Teacher should provide the guideline with demonstration of practical to the students
with all features.
2. Teacher shall explain basic concepts/theory related to the experiment to the students
before starting of each practical
3. Involve all the students in performance of each experiment.
4. Teacher is expected to share the skills and competencies to be developed in the
students and ensure that the respective skills and competencies are developed in the
students after the completion of the experimentation.
5. Teachers should give opportunity to students for hands-on experience after the
demonstration.
6. Teacher may provide additional knowledge and skills to the students even though not
covered in the manual but are expected from the students by concerned industry.
7. Give practical assignment and assess the performance of students based on task
assigned to check whether it is as per the instructions or not.
8. Teacher is expected to refer complete curriculum of the course and follow the
guidelines for implementation.

Instructions for Students

1. Students are expected to carefully listen to all the theory classes delivered by the faculty
members and understand the COs, content of the course, teaching and examination
scheme, skill set to be developed etc.
2. Students shall organize the work in the group and make record of all observations.
3. Students shall develop maintenance skill as expected by industries.
4. Student shall attempt to develop related hand-on skills and build confidence.
5. Student shall develop the habits of evolving more ideas, innovations, skills etc. apart from
those included in scope of manual.
6. Student shall refer technical magazines and data books.
7. Student should develop a habit of submitting the experimentation work as per the schedule
and s/he should be well prepared for the same.

Common Safety Instructions

1. Students are expected to carefully
 VEHICLE MAINTENANCE AND GARAGE PRACTICE (3160210)

Index
(Progressive Assessment Sheet)

Sr. Objective(s) of Experiment Pag Date of Date of Assessme Sign. of

No. e performan submission nt Teacher
No. ce Marks with date
Study workshop management, Prepare Garage
1 layout, Job card and Automotive service
&diagnosis tools and equipments.
Perform Underhood, Undercar and body
2 Inspection of a vehicle and prepare and fill
visual inspection worksheet.
Study working principle and perform operation
3 of Garage service and repair equipments like (a)
Two post hoist (b) Electronic air inflator (c)
Battery Charger (d) Car Washer. (e) Tyre changer
4 Perform Overhauling and service of automobile
transmission system.

5 Perform service of hydraulic braking system and

study of air brake circuit.

6 Alignment measurement and checking on Wheel

Aligner.

7 Perform service and testing of wheel and tyre.

Inspection and service of an Air conditioning

8 system of a car using an AC recovery unit.

Total
 VEHICLE MAINTENANCE AND GARAGE PRACTICE (3160210)
Experiment No: 1 Date:

Study workshop management, Prepare Garage layout, Job card and

automotive service &diagnosis tools and equipments.

Competency and Practical Skills:

Relevant CO: CO1: Understand the importance of vehicle inspection, Maintenance and application of
tools.

Objectives: (a) To study about inspection and maintenance of vehicle.

(b) To study about application of various tools.

Theory:
Breakdown of vehicles can occur due to accidents, loss of strength in components
material, and several other unforeseen reasons. Such vehicles require servicing ad repairing, for that
automotive workshop should require the vehicle to perform trouble free operation without any
breakdown.
Modern auto garages are capable of undertaking all sorts of repairs. For that they
need to equipped with trained technicians, varieties of tools and equipments.

PROCEDURE:

• Differentiates Garage, Service station and Industrial workshop.

• Study of different types of Garages layouts
• Study of different activities in Service stations.
• Make Service report / Job card.
• Study about different automobile equipments and tools for service of an auto vehicle.

Conclusion: (Students have to write their own experiential learning outcome in own words)

Quiz: (Sufficient space to be provided for the answers)

1. Prepare a Layout of modern service station of your vehicle. Mention activity of each work
base.
2. Prepare a Job Card of your vehicle. Define the importance of a Job Card.
3. Enlist automobile service equipments and tools and write down function of each of them.

Suggested Reference: (I) Vehicle Service book (II) Vehicle Workshop Manual (III) Job cards of
modern service station

References used by the students: (Sufficient space to be provided)

1.
2.

Marks (out of ) Sign

 VEHICLE MAINTENANCE AND GARAGE PRACTICE (3160210)
Experiment No: 2 Date:

Perform Underhood, Undercar and body Inspection of a vehicle and prepare

visual inspection worksheet.

Competency and Practical Skills:

Relevant CO: CO1: Understand the importance of vehicle inspection, Maintenance and application of
tools.

Objectives: (a) To be knowledgeable about vehicle inspection and checks.

(b) Safely and competently perform a complete vehicle checks.

PROCEDURE:
● Perform on ground brake systems checks.
● Perform on ground steering and suspension checks.
● Perform an exhaust system inspection.
● Perform fuel system checks.
● Perform cooling system checks.
● Perform electrical system checks.
● Inspect tires.
● Perform driveline checks.
● Prepare and fill up visual inspection worksheet for different checks performed for above
mentioned systems.
● Pinpoint and prepare safety notes in need of attention while inspecting vehicle.

INSPECTION WORKSHEET FOR VEHICLE

Your Vehicle:_____________________ Your vehicle Registration number:_________________

Date of Inspection:_____________________________

Model:______________________ Odometer Reading:________________

Chassis NO:___________________________________________________
======================================================

1. BRAKE INSPECTION:

✔ Pedal Travel & Feel______________________________________

✔ Parking brake___________________________________________
✔ Brake hoses and Lines____________________________________
✔ Master Brake cylinder fluid level____________________________
✔ Brake fluid condition_____________________________________

2. ON-GROUND STEERING, SUSPENSION, DRIVE LINE CHECKS:

✔ Steering wheel freeplay____________________________________

✔ Power steering fluid level___________________________________________
✔ Shock absorber bounce test( Good/Unsafe)
Front____________________________________
Rear_____________________________________
✔ No Squeaks___________________________________
✔ Ride Height check_______________________________
✔ Check ATF level_______________________________
 VEHICLE MAINTENANCE AND GARAGE PRACTICE (3160210)

3. UNDER CAR SUSPENSION AND STEERING CHECKS:

✔ Steering Linkages____________________________________________
✔ Shock absorber___________________________________________
✔ Suspension bushings____________________________________
✔ Ball joints_______________________________________________

4. EXHAUST SYSTEM CHECKS:

✔ Muffler and pipes____________________________________________

✔ Pipe Hangers___________________________________________
✔ Exhaust Leak____________________________________

5. COOLING SYSTEM CHECKS:

✔ Coolant Level____________________________________________
✔ Strength of Coolant brake__________________________________
✔ Leakage____________________________________
✔ Condition of Hoses
Radiator_____________________________________
Heater_______________________________________
Thermostate bypass hose________________________
✔ Pressure Test
Coolant pump Belt__________________

6. ENGINE OIL CHEKS:

✔ Oil Level check____________________________________________

✔ Oil condition______________________________________________
✔ Oil Filter check for leak______________________________________

7. FUEL SYSTEM CHEKS:

✔ Condition of Hoses____________________________________________
✔ Gas cap condition____________________________________________
✔ Air cleaner__________________________________________________
✔ Fuel filter(Kms until change suggested)____________________________
✔ Condition of fuel tank_____________________________________

8. INFLATE AND CHECK TIRES:

✔ Inflated to____________________(psi)
✔ Tire condition( Good / Fair /Unsafe)
RF__________________LF_________________
RR__________________LR_________________
Spare Wheel______________________________

9. ELECTRICAL SYSTEM CHECKS:

✔ Wiring visual inspection______________________________________

✔ Battery:
Top off water level_________________________________________________
Posts and cables (Clean/Corroded/Damaged)______________________________
Charging Condition__________________________________________________
✔ Lights
Park________Brake_______Signal_______________Emergency_____________Dash lights
back up______________________________________________
✔ Headlight Operation
 VEHICLE MAINTENANCE AND GARAGE PRACTICE (3160210)
Left__________________High Right_____________Low Right______
Horn Operation_____________________________________________________
10. VISIBILITY CHEKS:

✔ Mirrors___________________________________________________
✔ Wiper Blades_______________________________________________
✔ Wiper Operation____________________________________________
✔ Washer fluid and pump_______________________________________
✔ Glasses cleanliness___________________________________________

Conclusion: (Students have to write their own experiential learning outcome in own words)

Quiz: (Sufficient space to be provided for the answers)

1. Prepare safety notes in need of attention while inspecting vehicle.

2. Prepare safety check list.
3. Define the minimum standard brake fluid that can be used in automobile.
4. Explain the checks are done to a gas cap.
5. Define the radiator hose most likely to suffer heat damage, the top of bottom.
6. Explain tire tread wear which is more typical: outside edges or center.
7. Classify the flexible brake hoses do most car have.

Suggested Reference: (I) Vehicle Service book (II) Vehicle Workshop Manual

References used by the students: (Sufficient space to be provided)

1.
2.

Marks (out of ) Sign

 VEHICLE MAINTENANCE AND GARAGE PRACTICE (3160210)
Experiment No: 3 Date

Study working principle and perform operation of Garage service and repair

equipments like (a) Two post hoist (b) Electronic air inflator (c) Battery Charger

(d) Car Washer. (e) Tyre changer

Competency and Practical Skills:

Relevant CO: CO2: Diagnose the causes of Engine problem and provide the remedial action.

Objectives: (a) To be knowledgeable about various equipment and their application.

(A) TWO POST HOIST:

TECHNICAL SPECIFICATION:

Lifting Capacity 3.5 T

Lift Time 60 Sec.
Lowering Time 55 Sec.
Overall Weight 1000 kg.
Working Temp. Range -10°C / +50°C
Motor 2.2 KW / 400V (3 Phase) / 1400 RPM

MAJOR PARTS OF FOUR POST HOIST:

● Pressure Regulator : Regulator has the pressure range of 0psi to 150psi.

● Condensate Filter : Moisture content in the inlet air is removed.
● Auto drain Valve : Drains out condensate automatically.
● Solenoid Valve : Directing the air to the desired direction.
● Pressure sensor : sense Inlet air pre. And pr. In the tube base on solenoid valve open.
● SMPS Board : Input supply board for the controller and solenoid valves.

(B) ELECTRONIC TYRE INFLATOR:

APPLICATION:
● Inflate or deflate Compressed air as per specific data for each auto vehicle.

(C) TYRE CHANGER:

APPLICATION:
● To mount and De-mount the tyres.

NEED:
● To avoid damages to rim , tyre and tube.
● To reduce operator’s fatigue.
VEHICLE MAINTENANCE AND GARAGE PRACTICE (3160210)
● To improve productivity.
● To ensure customer satisfaction.

TECHNICAL SPECIFICATION:

● Power : 1HP
● Voltage : 230 VAC
● Air Pressure : 8-10kgf
● Rim Size
● ( Internal Clamping) : 12 -20 Inches
● ( External Clamping) : 10-18 Inches
● Max. Tyre Dia. : 35 Inches
● Bead Breaking power :2000kg at 10 bar
●
STEPS IN DE-MOUNTING THE TYRE:
● Deflate the tyre.
● Locate the tyre in Bead Breaking area and Bead the wheel on the both sides.
● Locate and clamp the rim on the turn table.
● Locate mounting and de-mounting tool on the rim properly.
● Lock the tool.
● Release the top bead from the rim using tyre lever.
● Rotate the turn table by operating the respective foot pedal.
● Release the bottom bead from the rim using tyre lever.
● Rotate the turn table by operating the respective foot pedal.
● Release the mounting and de-mounting tool from its location , remove the tyre from
rim
------------------------------------------------------------------------------------------------------------
(D) VEHICLE WASHER:

APPLICATION:
● Vehicle Washing
● Radiator Servicing
● Automobile components cleaning
● Floor and wall cleaning.
FUNCTION:
● Removes particle dust accumulated on the surfaces by pressure of Applying force.
● Water is used as intermediate agent.
● Oil can be removed by using chemicals or detergents.

TECHNICAL SPECIFICATION:

● Power : 2HP
● Version : Tank or base mounted.
● No. of Guns : one
● Delivery : 22.6 LPM
● Delivery at jet : 12.5 LPM
● No.of plungers : one
● Dia. And Strokes : 40 x 60 mm
● Speed : 3000rpm
● Working pr. : 22kg/cm2
● Gun : Spray and Jet

Conclusion: (Students have to write their own experiential learning outcome in own words)
 VEHICLE MAINTENANCE AND GARAGE PRACTICE (3160210)

Quiz: (Sufficient space to be provided for the answers)

1. Define the base on which we can classify Lifting equipments.

2. Explain the function of Hydraulic and Pneumatic Circuit in case of Four post lift.
3. Explain the main accessories/parts of the Four post lift. Explain function of each.
4. Define the function of pressure sensor in case of an Electronic tyre inflator.
5. Explain functions of an operating key in Electronic tyre inflator.
6. Explain principle operation of ETI with neat sketch.
7. Justify the Bead breaking for changing the tyres.
8. Explain the major parts of tyre changer. Explain function of each.
9. If 16 inch tyre mounts on a 16.5 inch rim, then explain the type of problems occurs and
provide solution for it.
10. If 17 inch tyre mounts on a 16.5 inch rim, then explain the type of problems occurs and
provide solution for it.
11. Explain the cleaning factors which have a significance role in washing to achieve optimum
results.
12. Define the meaning of one and two step cleaning methods. Explain with sketch.
13. Explain Construction details & working of Vehicle washer with schematic diagram.

Suggested Reference: (I) Vehicle Service book (II) Vehicle Workshop Manual

References used by the students: (Sufficient space to be provided)

1.
2.

Marks (out of ) Sign

 VEHICLE MAINTENANCE AND GARAGE PRACTICE (3160210)
Experiment No: 4 Date

Perform Overhauling and service of automobile transmission system.

Competency and Practical Skills:

Relevant CO: CO3: : Identify the causes and service and maintain the clutch, gear box, universal joints,
propeller shaft, differential and braking system.

Objectives:
● Evaluate Overhauling of transmission is required or not by road test.
● Removal of the transmission lines another system.
● Procedure for Disassembling the clutch, gearbox and differential.
● Identify the service, repair & replace solutions.
● Prepare worksheet.

Conclusion: (Students have to write their own experiential learning outcome in own words)

Quiz: (Sufficient space to be provided for the answers)

1. Explain Overhauling of 4 speed manual constant mesh Gearbox.

2. Explain how to clean and inspect manual transmission parts.
3. Explain the cause of a CV joint boot to crack and tear and the reason of outer boot fail more
often than the inner boot.
4. Explain servicing of drive line.

Suggested Reference: (I) Automotive Mechanics by William H. Crouse & Donald L. Anglin; Tata
McGrawHill Publishing Company Ltd.

References used by the students: (Sufficient space to be provided)

1.
2.

Marks (out of ) Sign

 VEHICLE MAINTENANCE AND GARAGE PRACTICE (3160210)
Experiment No: 5 Date

Perform service of hydraulic braking system and study of air brake circuit.
Competency and Practical Skills:

Relevant CO: CO3: : Identify the causes and service and maintain the clutch, gear box, universal joints,
propeller shaft, differential and braking system.

Objectives:
• Perform manual bleeding in hydraulic brake system,
• Inspection & Overhauling of Master cylinder and wheel cylinder.
• Study air brake circuit.

THEORY:

Brake Bleeding:

Brake bleeding is the process in which brake fluid is forced through the hydraulic system until all air
is purged from the system. The brakes must be bled when the hydraulic system is first filled, every time the
system is opened for service, and any time air has entered the system creating a spongy brake pedal.There are
three ways to bleed a hydraulic system:
1) Manual bleeding
2) Pressure bleeding
3)Vacuum bleeding
Here, we perform bleeding operation manually.

PROCEDURE FOR BLEEDING:

• The master cylinder is topped up completely with the brake fluid and pipe is connected to the
bleeding valve( provided on the shoe expander or the disc caliper) nipple.
• The other end of this pipe is dipped in the brake fluid contained in some jar.
• One person sits on the driver’s seat and presses the brake pedal, after which the bleeder valve is
opened by the second person with a spanner, when some air bubbles will come out of the pipe and
escape through the brake fluid into the atmosphere.
• The bleeder valve is now closed and the brake pedal released and pressed once more after which the
bleeder valve is opened again when some more air bubbles will come out.
• This procedure is repeated till on pressing the brake pedal, no more air bubbles are noted when with
the pedal in the pressed position the bleeder valve is closed.
• The reservoir is then topped up with the fresh fluid. This procedure is then repeated for all wheels.
Overhauling and Inspection of Master Cylinder & Wheel Cylinder
Master Cylinder:
The master cylinder converts the mechanical force provided by leg power, leverage, and in
some cases a power booster, into hydraulic pressure. This pressure is then distributed to the wheel
friction assemblies where its is converted back into mechanical force that applies the brakes.

Wheel Cylinder:
Wheel cylinders actuate drum brake friction assemblies by converting hydraulic pressure
from the master cylinder into mechanical force that moves the brake shoe linings into contact with
the brake drums. Although there are minor differences in wheel cylinder designs, all cylinders operate
in essentially the same way.

Conclusion: (Students have to write their own experiential learning outcome in own words)
 VEHICLE MAINTENANCE AND GARAGE PRACTICE (3160210)

Quiz: (Sufficient space to be provided for the answers)

1. Justify the need of bleeding the brake.

2. Explain the function of the main parts of the master cylinder & Wheel cylinder With
the sketch or a diagram.
3. State the main requirements of brake fluid.
4. Justify the need of overhauling for Hydraulic Braking system.
5. Explain the maintenance of Hydraulic Braking system.

Suggested Reference: (I) Automotive Mechanics by William H. Crouse & Donald L. Anglin; Tata
McGrawHill Publishing Company Ltd.

References used by the students: (Sufficient space to be provided)

1.
2.

Marks (out of ) Sign

 VEHICLE MAINTENANCE AND GARAGE PRACTICE (3160210)
Experiment No: 6 Date

Alignment measurement and checking on Wheel Aligner.

Competency and Practical Skills:

Relevant CO: CO4: Possess the knowledge about the inspection and maintenance of suspension, steering
system and wheels and tyre.

OBJECTIVE:
• Checking for requirement of wheel alignment.
• Pre alignment inspection
• Checking front wheel alignment angles
• Caster, camber and Toe adjustment.
• Rear wheel alignment

THEORY:

Basics of wheel alignment:

The basic purpose of a wheel alignment is to restore the vehicle suspension to the original or
manufacturer’s specification. It is the proper adjustment of al the interrelated suspension angles affecting the
running and steering of the vehicle.
A computerized four wheel aligner simultaneously displays the alignment measurements for all four wheels.
It has rim mounted heads or sensors on each wheel that feed information to a computer in the console. The
specifications, readings, and corrections needed are displayed on meters, screens, or paper printouts.

PROCEDURE FOR FOUR WHEEL ALIGNMENT:

Pre-Alignment Inspection:

● Checking for unusual loads in the vehicle or trunk.

● Checking tire pressure and condition.
● Checking wheel bearings for condition and adjustment.
● Checking wheel and tire balance and run out
● Checking ball joints and steering for looseness.
● Checking rear suspension condition.
● Checking front suspension condition.

Checking and adjusting of front & rear wheel alignment angles:

The six basic wheel alignment factors are suspension height, caster, comber, toe, steering axis
inclination, and turning radius.
● Measuring Camber, Caster, Steering axis inclination, turning radius, toe.
● First adjust Caster then camber and in last toe.
● For adjusting caster and camber installing or removing shims, adjusting the cam bolts in the control
arms, shifting the control arm inner shaft and changing the length of the strut rod.
● After making caster and camber adjustments, check and adjust toe. First measure toe using toe gauge.
To adjust toe, loosen the tie rod locknuts. Rotate the tie rods until the toe measurement is set to
specification.
● When all four wheels are properly aligned, the steering wheel will be centered while the vehicle is
moving straight ahead. If not, the steering wheel can be centered by adjusting the tie rods.
● After that adjusting rear wheel camber and rear wheel toe.

Conclusion: (Students have to write their own experiential learning outcome in own words)
 VEHICLE MAINTENANCE AND GARAGE PRACTICE (3160210)

Quiz: (Sufficient space to be provided for the answers)

1. State the advantages of a wheel alignment.

2. Explain briefly computerized wheel aligner with specification.
3. Define the six basic factors in wheel alignment and describe how each affects steering.

Suggested Reference: (I) Automotive Mechanics by William H. Crouse & Donald L. Anglin; Tata
McGrawHill Publishing Company Ltd.

References used by the students: (Sufficient space to be provided)

1.
2.

Marks (out of ) Sign

 VEHICLE MAINTENANCE AND GARAGE PRACTICE (3160210)

Experiment No: 7 Date

Perform service and testing of wheel and tyre.

Competency and Practical Skills:

Relevant CO: CO4: Possess the knowledge about the inspection and maintenance of suspension,
steering system and wheels and tyre.

OBJECTIVE:
● Perform Wheel Balancing using wheel balncer.
● Perform wheel and tire service procedure.
● Tire rotation procedure.

WHEEL BALANCING:

Balance is the stability resulting from the equalization of opposing forces. -Imbalance
is caused by the mass (weight) of a tyre not being properly distributed around axis. This is caused by
one side of the tire/wheel being heavier than other.
-The mass of a tire and wheel can be unequally distributed in two ways (i) The tyre wheel may have
heavy spots internally. (ii) The wheel may not properly centered on its axis.
-Imbalance will increase vibrations with speed n wheel assembly and it is transferred to other parts.
-The four most common problems that create vibrations related to tire and wheel assemblies are,
● Static Imbalance
● Dynamic Imbalance
● Mounting errors
● Excessive run-out (lateral or radial)

Static Imbalance:
Static imbalance or force imbalance is the condition for which the principle axis is displaced
only parallel to the shaft axis. Static balance is when the weight of the wheel and tire
assembly is distributed equally around the axis of the wheel rotation. If static balance exists
the wheel will have no tendency to rotate. Static unbalance is corrected by mass correction in
one plane only.

Dynamic Imbalance:
Correcting static balance should improve riding comfort but not eliminate all vibration
problems. So that dynamic balancing is required. Dynamic unbalance is the condition in which the
forces acts across both principle and shaft axis. Dynamic unbalance is corrected by mass correction
in at least two planes perpendicular to the shaft axis.

WHEEL BALANCER:
Function: Static and dynamic balancing of wheel (Steel and alloy)

PROCEDURE TO DO BALANCING:
• Switch ON the machine.
• Check the tyre pressure and inflate or deflate based on the need.
• Select the correct sizes of cone, based on the rim internal ID.
• Insert the cone on the shaft.
• Insert the wheel on the shaft
• Tighten the wheel with the lock nut (do not over tight or loose)
 VEHICLE MAINTENANCE AND GARAGE PRACTICE (3160210)
• Remove the stones and pieces from the tyre grooves.
• Remove old weights
• Enter the dimensions ( a-Distance of plane from reference plane b-Rim width,d-Dia of
wheel)
• Press ‘Start’ Button.
• Wait till the wheel stops on its own.
• Rotate the wheel till the weight placement location is displaced by the machine(all LEDs will
glow either on left side or right side)
• Add the displayed amount of weight on the wheel at 12O’clock position.
• Repeat last two steps.
• Press ‘Start’Button.
• Wait till the wheel stops on its own.
• Now, the machine has to show ‘0’ on both sides.
• Press ‘Fine button to ensure the amount of unbalance on the wheel. It should be less than 2
grams.
• For alloy wheels generally we are doing Static balancing. But base on the profile of the rim
you may also choose the Dynamic Balancing based upon that the dimensions fed in to the
machine will vary.

OBSERVATION TABLE:

Wheel Observation Wheel Wheel Initial Weight Final Remark

specification Made. Diameter rim Reading added Reading
width

Conclusion: (Students have to write their own experiential learning outcome in own words)

Quiz: (Sufficient space to be provided for the answers)

1) Explain the problems caused by imbalance?

2) Differentiate between static and dynamic balancing?
3) With neat sketch explain working principle and construction details of wheel balancer.
4) Define the reasons for weight chasing on wheel balancer?
5) Define the initial check for balancing the wheel.
6) Explain the procedure for tire rotation.

Suggested Reference: (I) Automotive Mechanics by William H. Crouse & Donald L. Anglin; Tata
McGrawHill Publishing Company Ltd.

References used by the students: (Sufficient space to be provided)

1.
 VEHICLE MAINTENANCE AND GARAGE PRACTICE (3160210)
2.

Marks (out of ) Sign

Experiment No: 8 Date

Inspection and service of an Air conditioning system of a car using AC recovery

unit.

Competency and Practical Skills:

Relevant CO: CO5: Apply the basic knowledge and rectify the electrical systems and cooling
system problems and maintain vehicle body.

OBJECTIVE:
- Study function of A/C system and refrigerant.
- Component Malfunction.
- Common tests conducted for checking component malfunction.
- Study and Demonstration of Refrigerant Management System.
- Refrigerant management system circuits ( Recovery, Vacuum, Charging )

Conclusion: (Students have to write their own experiential learning outcome in own words)

Quiz: (Sufficient space to be provided for the answers)

1. Enlist components of A/C system of a car and explain service required in each components.
2. Define AC recovery unit.Explain working of AC recovery unit with neat sketch.

Suggested Reference: (I) Automotive Mechanics by William H. Crouse & Donald L. Anglin; Tata
McGrawHill Publishing Company Ltd.

References used by the students: (Sufficient space to be provided)

1.
2.

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VEHICLE MAINTENANCE AND GARAGE PRACTICE (3160210)

Vehicle Maintenance and Garage Practice

(3160210)

Lab Manual is Prepared by

Prof. K. D. Chaudhari
Asst. Professor, Automobile Engineering
L.D. College of Engineering,
Ahmedabad

Prof. P. D. Patel
Asst. Professor, Automobile Engineering
L.D. College of Engineering,
Ahmedabad

Branch Coordinator
Prof. Vimal R. Patel
Asst. Professor, Automobile Engineering
L.D. College of Engineering,
Ahmedabad

Committee Chairman
Dr N M Bhatt
Professor of Mechanical Engineering
L. E. College, Morbi