Auto. Maintenance Eng.

AT2422
 Types of Maintenance

Maintenance

Preventive Breakdown Corrective

Maintenance Maintenance Maintenance
It designed to retain the healthy It means that wait until system fails It improves equipment and
condition of the equipment and and then repair it. this done for its components so that the
prevent failure through the systems whose failure does not preventive maintenance can
prevention deterioration and is significantly affect the equipment be carried out reliably, it is
also called Routine maintenance operation or generate Significantly improving the equipment
because it is usually performed on loss more than repair cost durability and maintainability
a set scheduled routine.
Types of Maintenance

Preventative Maintenance

Periodic Maintenance Predictive Maintenance

Time or mileage based maintenance This is a method in which the service life
consists of periodically inspecting, of important part is predicted based on
servicing and cleaning equipment and inspection or diagnosis, in order to use
replacing parts to prevent sudden failure the parts to limit of their service life.

Compared to periodic maintenance , predictive maintenance is condition-based maintenance,

it manages trend values, by measuring and analyzing data about deterioration.
Why is Periodic Maintenance Necessary?

Vehicle is the one of mechanical products, so it has thousands of

moving, sliding and rotating parts. These parts are worn or
deteriorated little by little. After some time period, they may not work
properly and may finally break down.
So it is required to perform Periodic Maintenance in order to extend
those parts or the vehicle performance.

The main goals of periodic maintenance are:

➢ Extended equipment lifespan.
➢ Enhanced reliability.
➢ Reduced unplanned downtime.
The Importance of Periodic Maintenance
Periodic Maintenance Workflow
Determine Best Time
Analyze Historical
Select Part Interval to Perform
Maintenance Data
Mantance

Yes Is the part

Perform Periodic due for
Run Vehicle Under Normal
Maintenance maintenance? Operating Conditions

NO

The identification of the interval and frequency of service tasks are evaluated depending on
parameters specific to the part. Manufacturer company might suggest calendar-based
schedules to perform checks on part.
ITEMS REQUIRING MAINTENANCE:
1- Engine Lubrication system (Oil, Oil filter and check leakage)
2- Engine air filter and cabin filter
3. Engine Sparkplugs , Acc. Belt
4. Engine cooling system (Coolant tank , Pipes and fan)
5. Under-hood inspection and fluid checks (brake, steering , Windshield washer and gearbox)
3. Tire inflation pressure check, inspection, and rotation
4. Brake and suspension system inspection
6. Under-vehicle inspection and fluid checks
7. Air-conditioning system inspection and service
8. Safety inspection, such as all lights and windshield wiper blades
9. Routine cleaning of vehicle both inside and out
BASIC SERVICES
ENGINE OIL AND
OIL FILTER
Engine oil provides the following functions:
1. Protect the engine part against wear and corrosion
( Increase engine life time )
2. Cooling the engine parts
( Prevent energy loss and improve engine efficiency )
3. Reduces friction between moving parts and seal space between pistons and cylinders
( Increase engine performance and reduce fuel consumption )
4. Prevent rust and corrosion and remove impurities
( Prevent engine from mechanical damage )

The most important thing to ensure that oil plays its role
is its thickness or viscosity.
Engine Oil Viscosity

Dynamic Viscosity

Is a measurement of a fluid’s internal friction or its resistance to

gradual deformation by shear stress or tensile stress. Its units
called centipoise (cP),

Kinematic Viscosity

Is the amount of time that it takes for a specified volume of fluid to flow,
under the force of gravity, through a fixed diameter orifice at a given
temperature. It is usually reported in centistokes (cSt) or mm2/s.
Viscosity Index (VI)
How the viscosity of oil varies with
changes in temperature. The higher the
viscosity index, the less the oil’s
viscosity changes with changes in
temperature.
Composition Of Engine Oil:
 Types of Base Oil:

Mineral Oil:
is a byproduct from petroleum distillation. can be
produced to a range of qualities associated with
the oil's refining process and It is a colorless

Semi Synthetic Oil:

Is mineral oil with some proportion and benefits of
Synthetic oil. It provide more effective than mineral
oils but available at low prices than synthetic oils.

Synthetic Oil:
Is contains chemical compounds that are artificially made by adding synthetic molecules, which are not present
in natural crude oils. Scientists designed these synthetic molecules with uniform size and chemistry to reduce
the friction, thus to give the optimum lubricant effect.
Synthetic Engine Oil:
➢ Better protection from mechanical wear.
➢ Faster lubrication even in low temperature
➢ Low oil consumption
➢ Resistance to thermal break-down
➢ Better engine cleanliness
➢ Improved efficiency & fuel economy
➢ High cost
➢ Oil film is thinner than conventional oil
➢ Decrease oil sealing effect
Engine Oil Additives:
Impart new characteristics to the base oil, or improve existing characteristics, enabling it to function in a
desired manner when used to lubricate an engine.
Oil Ratings :
Engine Oil Rating :
Engine Oil Viscosity Classification
 Engine Oil Rating :

The API performance or service classification. Oil can be classified as energy-

conserving oils . These are designed to reduce friction, which in turn reduces fuel
consumption.

GASOLINE ENGINE RATINGS:

In gasoline engine ratings, the letter S indicate spark ignition engines. The rating system is open ended so
that newer, improved ratings can be readily added as necessary
DIESEL ENGINE RATINGS:

Diesel classifications begin with the letter C, which stands for

commercial, but can also indicate compression ignition or diesel

engines.
 The (ACEA) rates the oil according to the following:

The European Automobile Manufacturers' Association is an organization that represents the 15 most

important European motor vehicle manufacturers. According to their statement, ACEA is an advocate for

the automobile industry in Europe, representing manufacturers of passenger cars, vans, trucks and buses

with production sites in the EU.

Among many other activities ACEA defines specifications for engine oils so called ACEA Oil Sequences.

The sequences are usually updated every few years to include the latest developments in engine and

lubricant technology. ACEA itself does not approve the oils, they set the standards and oil

manufacturer's may make performance claims for their products if those satisfy the relevant requirements.
The (ACEA) rates the oil according to the following:

low levels of sulfated ash, phosphorous, and sulfur,

ACEA Technical Performance level:

Low SAPS : Low levels of sulfated ash, phosphorous, and sulfur

HTHS: High temperature/high shear rate viscosity.

C ratings are catalytic converter compatible oils and include:

C1: basically A5/B5 oil with low SAPS, low HTHS
C2: A5/B5 with low HTHS and mid-level SAPS
C3: A5/B5 with high HTHS and mid-level SAPS
C4: low SAPS; high HTHS
ACEA Technical Performance level:
BASIC SERVICES
COOLING SYSTEM
Engine coolant:
Engine coolant is a mixture of water and antifreeze.
Water alone has a boiling point of 212°F (100°C )
and a freezing point of 32°F (0°C ) at sea level.
A mixture of 70 percent antifreeze and 30 percent water wi
ll raise the boiling point of the mixture to 276 ° F ( 136 ° C
) under 15 psi of pressure and lower the freezing point to
− 84 ° F ( − 64 ° C ).

Normally, the recommended mixture is:

50% Pure Water
44% to 47% Antifreeze
6% to 3% Additives (anti – rust and cleaners)
Engine coolant Types:
Inorganic Acid Technology (IAT)
This was once the most commonly used antifreeze. It uses Ethylene glycol is green in color, and provides
good protection regardless of climate but it is poisonous. IAT coolant is not compatible with newer long-life
coolants.

Organic acid technology (OAT)

This coolant is also environmentally friendly and contains zero phosphates or silicones. This orange
coolant is often referred to by a brand name “DEX-COOL” and is used in most late model.

Hybrid organic acid technology (HOAT)

This is similar to OAT coolant but has additives that make the coolant less abrasive to water pumps. This
type of coolant is used by some modern vehicles and is not compatible with IAT or OAT coolants.
Engine coolant Colors:
BASIC SERVICES
BELTS AND TENSION
WHEELS
Engine Belts:
Belts are used to transmit rotary movement from one component to another.
There are two main types of belt:

1. Toothed Belts: synchronize engine timing

2. Ribbed Belts: are reserved for transmitting movement to accessories.

Belt tensioning methods:

Axial must be Rotary must be Axial adjusted Rotary adjusted

adjusted manually adjusted manually automatically automatically
Engine Belt Tension Check:
There are four ways to check belt tension
1. Belt tension gauge.
2. Marks on a tensioner
3. Torque wrench reading
4. Deflection.

Belt Visible Wear Check:

If any of this signs present we must repla
ce the belt.
BASIC SERVICES
BRAKE FLUID
Brake Fluid:

Brake fluid is made from a combination of various types of glycol, a non-

petroleum-based fluid.
Brake fluid is a polyalkylene-glycol-ether mixture, called polyglycol for short.
All polyglycol brake fluid is clear to amber in color.
All automotive brake fluid must meet Federal Motor Vehicle Safety Standard.
The Society of Automotive Engineers (SAE) and the Department of
Transportation (DOT) have established brake fluid specification standards.
DOT 3:
- The color of DOT 3 ranges from clear to light amber.
- It absorbs moisture and it can absorb 2% of its volume in water per year.
- DOT 3 must be used from a sealed container.
- Very strong solvent and can remove paint

DOT 4:
- The color of DOT 4 ranges from clear to light amber.
- The brake fluid is formulated for use by all vehicles.
- It is commonly called low moisture absorption (LMA) because it does not absorb water as fast as DOT 3
- The cost of DOT 4 is approximately double the cost of DOT 3.
DOT 5:
- The color of DOT 5 is purple .
- This type is commonly called silicone brake fluid.
- It does not absorb water, it is called non hygroscopic.

DOT 5.1:
- The fluid is a non-silicone-based polyglycol fluid that is clear to amber in color.
- This severe duty fluid has boiling point over 500°F,(260°C) equal to boiling point of silicone-based fluid.
 Moisture is absorbed by the brake fluid
through microscopic seams in the brake
system and around seals.

Moisture can cause a spongy brake pedal because the increased

concentration of water within the fluid boils at lower temperatures
and can result in vapor lock.

DOT 5 fluid does not mix with and should not be used with DOT 3 or DOT 4 brake fluid.

If any mineral oil such as engine oil, (ATF), or power steering

fluid gets into the brake fluid, the rubber seals will swell and
cause damage to the entire braking system.

Brake Fluid compatibility chart

LHM (Liquide Hydraulic Mineral) Brake Fluid

LHM Fluid is a specially formulated mineral based hydraulic and brake fluid, it has been especially
developed for application in brake systems, levelling and hydraulic controlled clutches
LHM Fluid is manufactured from a specialized mineral oil and selected additives to produce a
hydraulic and brake fluid with a very high viscosity index.

Benefits:
• Suitable for use in systems with pressure up to and in excess of 150bar
• No water absorbing
• Excellent lubricating properties.
• Very good protection against corrosion.
• High compatibility with all types of seals and gaskets.
• High chemical stability even in the most severe conditions of thermal stress.
BASIC SERVICES
SPARK PLUGS
 Air gap:
The quenching effect between the electrodes is the work of the electrodes absorbing the heat and
extinguishing the flame, if it greater than the flame core heat generation action, the flame core is
extinguished and the combustion stops. If the plug gap is wide, the flame core is larger and the
quenching effect is smaller, so reliable ignition can be expected, but if the gap is too wide, a large
discharge voltage becomes necessary, the limits of the coil performance are exceeded, and discharge
becomes impossible.
 Air gap:
Both new and used spark plugs should have their air gaps set to
manufacturer’s specifications. Always use round wire gauges when
checking and setting the gap.

The model names tell you the installation thread diameter,

heat range, reach, and shape. Car manufacturers select
appropriate spark plugs for the engine and vehicle type,
so use the specified spark plugs.
 Heat Range

The heat that the electrode section of the spark plug

receives due to combustion is dispersed through the path in
the figure. The degree to which a spark plug disperses the
heat it receives is called its "heat range".
Spark plugs with a high degree of heat dispersion are called
high heat range (cold type) and those with a low degree of
heat dispersion are called low heat range (hot type).
This is largely determined by the temperature of the gas
inside the combustion chamber and the spark plug design.
 Heat Range
Low heat range plugs have long insulator leg sections and the surface area affected by the flame and the gas
pocket capacity are large. Also, since the heat release path from the insulator nose to the housing is long, heat
dispersion is low and the temperature of the center electrode rises easily.
On the other hand, high heat range plugs have short insulator nose and the surface area affected by the flame
and the gas pocket capacity are small.

Pre- ignition Self cleaning

Temperature Temperature
 Electrode Wear:

The electrode wears from the locations that discharge

easily with spark discharge, since the center electrode
reaches high temperatures, it oxidizes and wears.
The amount of electrode wear varies with electrode
material, strength, hardness.

In order to reduce the amount of this wear, nickel alloys, platinum, iridium, and other such materials are
used for the electrodes and service lives are also extended with fine electrodes. Also, the wear varies
with the engine type and usage conditions, but for normal nickel alloy plug, it is approximately in the
range of 0.10-0.15 mm for each 10,000 km driven.
 Effect of Electrode Wear:

Rise in required voltage

The required voltage rises in proportion to the
distance driven. This rise in the required voltage
is large until the sharp section at the end of the
center electrode is worn round to some degree
(about 4,000 km). After that, the main factor is
the enlargement of the gap due to electrode wear
and the rise in the required voltage is smaller.

Misfiring
Failure due to sparks not discharging between the electrodes of the sparkplug this occurs when the volage
generated by the ignition coil is lower than the voltage required by the spark plug.
 Sparkplug Materials:

Copper/Nickel Spark Plugs:

Sometimes referred to as "standard" or "normal", copper spark plugs actually

➢ Copper/nickel spark plugs are lower in cost

➢ Generally, have a shorter lifetime (30,000 – 60,000 km)
➢ Performs well under high-compression or turbocharged conditions
➢ Requires high voltage
 Sparkplug Materials:

Platinum Spark Plugs:

A single platinum spark plug is similar to a copper/nickel spark plug, except that its ground electrode has a
platinum disc welded to the tip instead of only nickel alloy.

➢ Expensive spark plugs.

➢ Generally, have a long lifetime up to 150000 km
➢ Easley overheat in some conditions.
➢ Reduces carbon buildup
➢ Hard material with low electrode wear rate
 Sparkplug Materials:

Double Platinum Spark Plugs:

Double platinum spark plugs have platinum coating both the center and ground electrodes. This is more
efficient and longer-lasting which makes these plugs a great choice for a wasted spark ignition system,
which exerts more wear on both electrodes than do other ignition systems.

➢ Expensive spark plugs.

➢ Generally, have a long lifetime up to 150000 km
➢ Improve engine power
➢ Reduces carbon buildup
 Sparkplug Materials:

Iridium Spark Plugs:

Iridium is said to be six times harder and eight times stronger than platinum with a 700° higher melting
point. Iridium spark plugs have extremely fine electrodes while retaining excellent wear characteristics.

➢ The most expensive type of spark plugs.

➢ Have a long lifetime
➢ Improve engine power
➢ Improve fuel efficiency
➢ Requires less voltage
➢ high corrosion resistance
 Sparkplug Diagnosing:

Carbon Fouling:
The insulator foot section and electrode section are
covered with dried, soft black carbon.

This is due to repeat short-distance driving (driving with the

engine cool), incorrect choking (overly rich air-fuel mixture),
injection timing delay, plug heat range too high.
Oil Fouling:
The insulator section and electrode section is black and lustrous with
wet oily deposits.

This is due to Oil leaking due to piston ring, cylinder, or valve guide
wear (occurs easily to new engines and engines that have just been
overhauled), high oil content in air-fuel mixture (2-stroke engines).

Lead Fouling:
The insulator leg section has yellow or yellowish-brown burnt on
deposits or is covered with a glossy surface.
This is due to use of bad fuel or fuel with much lead.
 Corona Stain:
Brown deposits on the insulator directly above the housing This
occurs due to electrical stress in the air near the insulator. (This is
not a spark plug gas leak, for which it is sometimes mistaken.)

Insulator breakage:
The Insulator cracked which happened due to spark plug
removed/installed incorrectly (spark plug turned too far with spark
plug wrench, excess tightening torque, or other inappropriate work).
Recommended Tightening Torque:
1) Use the correct wrench for the hex on the plug, and be careful not to damage the insulator.
2) When changing, make sure that the oil, on the outside of the plug does not enter the engine interior.
3) When putting plugs in, clean engine side of the flange
4) Make sure the plugs are vertical, and tighten them by hand until they cannot be tightened any further.
5) Then, use a plug wrench to tighten them accurately to the torque.
BASIC SERVICES
BATTERS
Battery:
The role of the battery is to store energy in chemical form and to release it in electrical form.
Battery Construction:
Battery types

- Lead Acid (Wet cell battery)

- Maintainable battery
- Maintenance Free battery
- GM (Gel Mat battery)
- EFB (Enhanced Flooded Battery)
- AGM (Absorbent Glass Mat battery )
Lead Acid (Wet cell battery)
A conventional starter battery consists of six battery cells. A battery cell, consists of positive and negative
set of plates, immersed in an electrolyte, a mixture of acid (H2So4) and distilled water.

Advantages

•Higher cold cranking amps (CCA)

•Longer useful life
•Can be 100% maintenance free
•Will accept higher charge rates.

Disadvantages

•Takes longer recharge after being run flat

•Requires a calcium specific charger to restore to 100% state of charge
Maintainable batteries have removable caps which In comparison, Maintenance Free batteries come sealed
enable you to visually check the electrolyte level in for life from the factory, and do not require maintenance
each cell. The lifespan of the battery can be of the electrolyte levels. The most significant benefit of
extended by periodically checking the electrolyte the sealed design is that no service attention is required,
level and top up with demineralized water if other than ensuring the battery is kept clean and fully
required. charged.
This loss of electrolyte can be caused by Maintenance Free batteries tend to lose electrolyte at a
overcharging, heat exposure, and most importantly much slower rate than Maintainable models, so
evaporation, which occurs at a faster rate when extended battery life can be expected as a result.
compared to sealed maintenance free batteries.
GM (Gel Mat battery)
Gelled batteries, or "gel cells" contain acid that has been "gelled" by the addition of silica gel, turning the
acid into a solid mass that looks like hard jelly.
Advantages

• Longer useful life

• Can be 100% maintenance free
• Impossible to spill acid even if they are broken
• Vibration resistant

Disadvantages

• Takes longer recharge after being run flat

• must be charged at a slower charge rate to prevent overheating
•Requires a calcium specific charger to restore to 100% state of charge
 EFB (Enhanced Flooded Battery)
EFB batteries are an optimized, higher performance version of the wet battery. Use thicker plates are
insulated from each other with a microporous separator. Between the plate and the separator there is
also a polyester scrim filled with liquid sulfuric acid electrolyte, This material helps to stabilize the active
material of the plates and extend the life of the battery.
EFB batteries are often installed in vehicles with simple automatic start-stop systems.

Advantages
• Wide operates temperature range from -50 to +60 ° C.
• The electrolyte practically does not evaporate.
• Charge-discharge - a cycle that can be carried out more times than with ordinary batteries.
• Takes short recharge after being run flat

Disadvantages
• High cost
• Big size
• high charge voltage
AGM (Absorbent Glass Mat battery )
Have high performance and are designed for high demands. the
structure of an AGM battery is the same as that of a wet cell
battery. However, in an AGM the electrolyte is no longer free-
floating, but rather is bound in a special glass fiber separator. The
large contact area contributes to the power output and also
makes the battery leak-proof. This feature enables internal
recombination of oxygen and hydrogen, so that there is no water
loss. To protect against excess pressure, the individual battery
cells are equipped with a safety valve, so that they remain safe,
even in case of a fault.
AGM batteries are often installed in vehicles with simple
automatic start-stop systems.
AGM (Absorbent Glass Mat battery )

Advantages

• Wide operates temperature range from -50 to +60 ° C.

• The electrolyte practically does not evaporate.
• Have three times more cycle life than a conventional starter battery
• No acid leak
• High specific power, low internal resistance
• Up to 5 times faster charge than flooded technology
• Water retention (oxygen and hydrogen combine to produce water)

Disadvantages

• High cost
• Big size
• Can only be discharged to 50%
• overcharge can kill the battery
Battery Label:
- Battery Volt
- Battery Standard Code
- Battery part number
- Battery capacity

Amper Hour Rating (AH)

Cold Cranking Amper (CCA)
Cranking Amper (CA)
Ampere-Hour Rating
The ampere-hour rating is the amount of steady current that a fully charged battery can supply for 20 hours
at 80°F (26.7°C) without the terminal voltage falling below 10.5 volts.

Cold Cranking Rating ( also called cold cranking amps (CCA))

It is determined by the load, in amperes, that a battery is able to deliver for 30 seconds at 0°F (−17.7°C)
without terminal voltage falling below 7.2 volts (1.2 volts per cell) for a 12-volt battery. The cold cranking
rating is given in total amperage and is identified as 300 CCA, 400 CCA, 500 CCA, and so on.

Cranking Amps (CA)

Is an indication of the battery’s ability to provide a cranking amperage at 32°F (0°C). This rating uses the same
test procedure as the cold cranking rating or CCA discussed earlier, except it uses a higher temperature. To
convert CA to CCA, divide the CA by 1.25.
 Factors That Affect Battery Life:

Extreme Temperatures
Excessive heat can cause sulfating and corrosion inside your battery. You usually notice the problem (trouble
with cold starts and poor charge acceptance) during cold weather.

Irregular Use
A parked car uses up to 1% of the battery´s charge for
standby functionality. In addition, depending on the
ambient temperature and the age of the battery, self-
discharge can drain the battery within a few weeks.

Short Trips
Driving only short distances does not give your
battery enough time to recharge. In winter, high-
consumption accessories such as defrosters and
heated seats make matters worse.
Battery Check:
Battery Visual check:

• Check the age of the battery.

• Check the condition of the battery case.
• In not sealed battery, check electrolyte levels in all cells
• Check the condition of the battery terminals and cables.
• Clean any corrosion from the cable ends and terminals.
• Make sure the cable ends are tightly fastened to the
terminals.
• Make sure the battery hold downs are holding the battery
securely in place.
Battery Check:
Battery Indicator Eye:
Some batteries are equipped with a built-in state of charge
indicator, commonly called green eyes.
This Typical battery charge indicator. If the specific gravity
is low (battery discharged), the ball drops away from the
reflective prism. When the battery is charged enough, the
ball floats and reflects the color of the ball (usually green)
back up through the sight glass and the sight glass is dark.
State Of Charge:
Open circuit voltage of about 12.8 V is measured with a Multimeter. If the voltage falls below 12.4 V, the
battery should be recharged as soon as possible. A continuous low charge damages the battery due to
sulfating. The voltage of a battery does not necessarily indicate whether the battery can perform satisfactorily,
but it does indicate to the technician more about the battery’s condition than a simple visual inspection.
Battery Load Test:

The load test determines how well a battery will perform under a load. A
battery load tester is used for this test. These testers have a voltmeter, an
ammeter, and variable carbon resistor. When the tester is attached to the
battery and operated, the variable carbon resistor draws current from the
battery. The ammeter reads the amount of current draw. The maximum
current draw from the battery, with acceptable voltage, is compared to the
rating of the battery.
During a load test, a load that simulates the current draw of a starting motor
is put on the battery. The amount of current draw is determined by the rating
of the battery and the battery’s voltage is observed for 15 seconds.
Battery Current Drain :

Leakage currents are considered normal if they do not exceed

a few mA. It is therefore necessary to wait a few moments after
switching off the ignition and closing the doors and switch off all
acc. Loads ,before measuring the leakage currents.
BASIC SERVICES
TIRES
Tire Dimensions :
Tire Quality Grading System:
TREAD WEAR
The tread wear grade is a comparison rating based on
the wear rate of a standardized tire, tested under
carefully controlled conditions, which is assigned a
value of 100. A tire rated 200 should have a useful life
twice as long as the standard tires.
TRACTION:
Traction performance is rated by the letters AA, A, B,
and C, with AA being the highest. The traction rating is
for wet braking distance only!
It does not include cornering traction or dry braking
performance.

TEMPERATURE RESISTANCE:
Temperature resistance is rated by the letters A, B, and C,
with A being the highest rating. Grade C is the minimum
level that all tires must be able to pass under the current
Federal Motor Vehicle Safety Standard No. 109
 DOT TIRE CODE:
All tires sold must be approved by the U.S.
Federal Department of Transportation (DOT).
The DOT tire code requirements include resistance to tire
damage that could be caused by curbs, chuckholes, and
other common occurrences for a tire used on public roads.

• The DOT code includes letters and numbers.

• The first two letters identify the manufacturer and location.
• The last four numbers are the build date code.
• The number between this two groups mean the tire approval
code.
Tire Check :
Tire Inflation Pressure Check:
Tires should always be inflated to the pressure indicated on the driver’s door or pillar sticker.
Tires should be checked when cold, before the vehicle has been driven, because driving on tires increases
the temperature and therefore the pressure of the tires.

Tire incorrect inflation affects on :

• Tire Life
• Fuel Economy
• Handling Performance
 Tread Wear Check:

Most tires used today have built-in tread wear indicators to show
when they need replacement. These indicators appear as 0.5 inch
wide bands when the tire tread depth wears to 1.6 mm.
When the indicators appear in two or more adjacent grooves at
three locations around the tire or when cord or fabric is exposed,
tire replacement is recommended.
If the tires do not have tread wear indicators, a tread depth
indicator quickly shows how much tire tread is left. When only 1.6
mm is left, it is time to replace a tire.
 Tire Rotation:
To ensure long life and even tire wear, tire rotation is essential.
It is important to rotate each tire to another location. The wear usually starts on the outer tread row.
This wear usually appears as a front-to-back (high and low) wear pattern on individual tread blocks.
Tire Wear:
New Tire Data:
Clutches
Clutch Components:
The clutch system includes the following components:

• Flywheel
• Clutch disc
• Pressure plate
• Clutch Control mechanism
• Clutch housing
Clutch Operation:
The pressure plate and flywheel are the drive
or input members of the assembly. The clutch
disc (plate), also called the friction disc , is the
driven or output member and is connected to
the transmission’s input shaft. As long as the
clutch is disengaged (clutch pedal depressed),
the drive members turn independently of the
driven member, and the engine is
disconnected from the transmission.

However, when the clutch is engaged (clutch pedal released), the pressure plate moves toward the
flywheel and the clutch disc is squeezed between the two revolving drive members and forced to turn at
the same speed.
Clutch Release Mechanisms:
Clutch release mechanism allows the driver to release the clutch. Generally, it consists of clutch pedal assembly ,
mechanical linkage , cable or hydraulic circuit and the clutch fork or bearing.

Clutch Release Mechanism

Mechanical Hydraulic Electric Hydraulic

Cables Linkage Semi Hydraulic Central Slave Cylinder

Linkage :
A clutch linkage mechanism uses levers and rods to transfe
r motion from the clutch pedal to the clutch fork. It also prov
ides a method of adjustment for the clutch traveling distanc
e.
Cable :
The clutch cable mechanism uses a steel cable inside a flexible housing to transfer pedal moveme
nt to the clutch fork. The cable housing is mounted in a stationary position. One end of the clutch c
able housing has a threaded sleeve for clutch adjustment.
Semi-Hydraulic :
Hydraulic clutch release mechanism uses a simple hydraulic circuit to transfer clutch pedal action to the clu
tch fork. It has three basic parts (master cylinder, hydraulic lines ,slave cylinder). Movement of the clutch p
edal creates hydraulic pressure in the master cylinder, which actuates the slave cylinder. The slave cylinde
r then moves the clutch fork.
Hydraulic with Central Slave Cylinder :
Fully hydraulic systems are equipped with a central slave cylinder. This consists of a ring-shaped hy
draulic cylinder with a built-in release bearing located in the bell housing between the transmission a
nd the clutch, centrally to the transmission input shaft. Additionally, this system has a high degree of
design flexibility in terms of the placement of the hydraulic line in the engine compartment.
Clutch Mechanism Service and Check

`Mechanism Semi Central Slave

Types Linkage Cables
Hydraulic Cylinder

• Check Fluid Level

• External Clutch
• Check Cable • Check Fluid Level
Linkage Check and • Check Fluid
External Condition
Lubrication leakage
• Check Fluid
• Check and Adjust leakage
Service and • Check and Adjust • Check Sleeve
Clutch pedal Free
Clutch pedal Free Cylinder push rod
Travel • Check Clutch
Check Travel
Travel
• Check Clutch
• Check mechanism
• Check mechanism Pedal Travel
noise • Check Clutch
noise
Pedal behavior
• Check Clutch
Pedal behavior
Clutch Slip
Clutch Noise
Hard Declutching
Dual Mass Flywheel:

This type of flywheel is made up of two separate pieces

that transfer torque to each other through one or
several springs. This absorbs the firing pulses of the
engine and reduces shock from sudden engine
acceleration. These flywheels are much heavier than a
single-mass flywheel but can save the transmission
from damage.
The damper assembly is completely sealed, because it also contains a fluid or
lubricant, typically silicone-based, which also helps absorb vibration and transmit
torque. Typically, the two flywheels twist out of phase with each other by up to
about 60 degrees to absorb torsional oscillations, The starter ring gear mounts on
the primary flywheel. Power from the starter motor does not have to flow through
the damper assembly to reach the engine crankshaft. The ring gear and pilot
bearing are usually attached to the primary flywheel, and the clutch friction surface
is usually the secondary flywheel
Dual Dry Clutch:
Dual Wet Clutch:
Manual Transmission
 Manual Transmission

Automatic Shifting Manual Shifting

4 – Shafts 2 – Shafts
2 Input shafts Dual Clutch 1 Input shaft Single Clutch

2 Output shaft 1 Output shafts

3 – Shafts 3 – Shafts
1 Input Shafts Single Clutch 1 Input Shafts
Single Clutch
1 Counter Shaft 1 Counter Shaft
1 Output Shafts 1 Output Shafts
 Manual Transmission

Sliding Mesh Synchromesh

2 – Shafts 3 – Shafts
1 Input shafts 1 Input shaft
1 Output shaft 2 Output shafts

3 – Shafts
1 Input Shafts
1 Counter Shaft
1 Output Shafts
Synchromesh 3-shafts transmission
Synchronizer:
Idle Position:
• The fork is moving the sleeve in axial direction
until the detents have contact with the blocker
ring.
• The detent force creates a friction torque in
the synchronizer, This friction torque positions
the blocker ring radially.
• The indexing lugs at the blocker ring bend to
the pockets in the hub. This positions the
blocking teeth at the blocker ring against the
teeth of the sleeve.
• With higher shift force the sleeve moves towards
the blocking teeth of the blocker ring
• The teeth of the sleeve push against the blocking
teeth of the blocker ring
• Speed difference is reduced until n1 = n2
• At speed difference n1=n2 the blocking condition is no longer valid.
• The sleeve can turn back the blocker ring and move forward
through the spline of the blocker ring.
• The sleeve moves forward towards the spline of the engagement ring.
• In this phase a new speed difference between n1 and n2 can occurs.
• When the sleeve has completely moved into the engagement
ring the gear is shifted.
• Back tapers at the teeth of the sleeve and the engagement ring
avoid decoupling under load.
 Types of Synchronizer:

1. Single-cone Synchronizer

Types of Synchronizer:
2. Dual-cone Synchronizer
3. Triple-Cone Synchronizer
 Gear Box Oil

API SAE
Service Classification Viscosity Grade

GL-4
(After 2004 for zero or low offset hypoid gear)
(Synchro-mesh)
GL-5
(After 2011 for high offset gears)
(Synchro-mesh)
MT-1
(For buses and Trucks)
(Sliding-mesh)
 Noise
Knocking Growling
During depress clutch pedal and stop
Gear Wear During specific shift Clutch Bearing
when pedal released

Input Shaft During clutch engaged and GB in

Syn. Cone Ring During shifting
Bearing neutral position

Broken Part in
During applied or released clutch Gear Bearing During specific shift
Clutch Release
pedal
Mechanism

Low oil level

During all shift
Shaft Bearings

Output
During all gears and direct drive
Shaft Bearings
 • Incorrect clutch adjustment
Gear Clash • Defective synchronizer blocking rings
• Incorrect oil level

• Defect Synchronizer
Hard Shifting • Control rods, shift rails, shift forks
• High viscosity oil

• Defect shift lever

Jumping Out of
• Defect internal gearshift linkage
Gear
• Synchronizer detents or spring.

• Gearshift lever linkage miss adjustment

Locked in Gear • Defective synchronizer
• Incorrect oil level
Torque Converter
 Torque Converter:

Like the clutch on a manual gearbox, the torque converter provides a hydraulic coupling between the engine
and the automatic transmission.
 Torque Converter Operation:

When the engine is running, the converter

is full of oil. This oil circulates continually at
a pressure of approximately 5 bar. The
rotation of the impeller throws oil against
the turbine thus driving it.
 Torque Converter Operation Phases:
1- Multiplication Phase : Multiplication of the engine torque by 2 to 2.5
times, During this phase, the role of the stator is to change the direction of
the oil flow in to negate the effects of braking and add a multiplier effect by
orienting the oil flow in the direction in which the impeller is rotating. In this
phase the stator is fixed in relation to the gearbox casing.
2- Coupling Phase: At high engine speed, the centrifugal force is such that the flow of oil strikes the
stator blades on the edge, then the back of the stator blades. The action of the stator begins to work
against the rotation of the turbine. Therefore, the stator is mounted on a freewheel which allows it to turn
during this phase and there is no torque multiplication. The turbine speed is then almost the same as the
impeller speed.
 Stator’s One Way Clutch:

This consists of inclined lobes and springs in contact with the stator
hub connected to the gearbox casing.

During the converter phase, the lobes straighten up and the one-way
clutch is Locked

During the coupling phase, the lobes are inclined and become free,
and the stator can turn.

1 Hub.
2 Lobe.
3 Spring.
4 Stator body.
 Lock-up Clutch :
During the converter’s coupling phase the engine
speed is not the same as the turbine speed. Loss of
driving power is due to the slippage that occurs in a
hydraulic coupling between turbine and impeller.
This slippage increases fuel consumption and
reduces engine braking. Slippage is eliminated and
the performance of the automatic transmission
improved by the lockup clutch.

Lockup involves changing the hydraulic coupling to a mechanical connection by means of a moving plate.
The hydraulic distributor cuts off the oil circulation behind the lockup clutch plate.
The pressure difference between the front and back of the plate is high enough to prevent slippage.
The turbine becomes integrated into the converter. To prevent snatching when locking up, the hydraulic
control system adjusts the pressure on each side of the plate during the progressive engagement phase.
Torque Converter Performance Curve :
THANK YOU