CHAPTER FIVE

MAINTENANCE PLAN OF VEHICLE SHEET

Study and preparation of different statements and records required for the repair and
maintenance shop
Types of records:
1) Periodic maintenance check sheet.
2) Trip sheet
3) Log book etc.

DESCRIPTION:
1. Periodic maintenance check sheet
The periodic maintenance check sheet is used to record the inspection status made during the
maintenance check operation. It contains various details such as the dealer name, place, date of
sale, manufacturers name, mileage, frame number, chassis number etc. the mileage and service
type are indicated in the various cells of the check sheet. The check sheet also contains the check
item name, status and remarks.
The check items include the following:
 Basic engine components.
 Engine oil
 Engine oil filter
 Ignition system
 Battery
 Fuel and Emission Control
 Water sediment filter
 Air cleaner filter
 Chassis and Body
 Brake pedal, parking brake
 Brake pads and discs
 Brake linings & brake drums
 Clutch

2. Trip sheet:

The trip sheet gives the entire details of the vehicle before and after a trip. The
starting km and ending km, time of start and closing of the journey time and the charges
per km and also the overall cost of trip is described in the trip sheet.

3. Logbook:

The logbook of a vehicle gives the details of the vehicle, which will be useful not only
for the owner of the vehicle but also to the mechanic who might take the job of vehicle
maintenance latter.
The logbook contains the following details:
 Distance covered
 Fuel consumption
 Average fuel consumption

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  Best and worst mileage
 Total maintenance cost
 Running costs
 Faults in the vehicle
 Likes and dislikes
 Date of the previous maintenance report

Conclusion:

The different statements and records required for the repair and maintenance works
were prepared and the uses of records were studied.

BASIC VEHICLE MAINTENANCE TIPS BEFORE TRAVELLING

Introduction: As summer and spring break fast approaches in a couple of weeks, many families
are planning to travel for a vacation. Before thinking anything about travelling, consider first
taking care of your car. The following car preservation tips are very helpful to keep you on the
road of safety.

Battery

Make sure batteries are fully charged and ready to use. Because they store power for later use,
it’s important to keep track of its safeguarding so as not to cause any delays during travelling.
It’s better to bring extra batteries too.

Fluid level: Guarantee good fluid reading results. It doesn’t matter if it’s due or not, it’s better to
change the oil before every long trip. Automatic transmissions have a dip stick in the engine
compartment and the manual transmission can be test out if you are changing the oil.

Check the windshield wiper fluid if it’s sufficient for your journey. Verify the brake fluid
making sure it’s topped off. While the rest are all right, don’t forget to look out your anti-freeze
bottle if it was filled on the proper level. Bear in mind that too much of it can cause overflow and
too little can result to your engine to overheat.

Cracks & Leaks: Most often cracks and leaks are threats of danger. Check all over the hoses
for any evidence of cracking and if it’s too loose or tight. Test the tension by twisting the belt. If
you can twist it more than a quarter turn, it means too loose. If it twists less than a quarter, that
means too tight. Try squealing and twisting to make certain it works properly and burn up the
bearings if it’s too tense.

Tire spare part: Check tire pressure. Find the recommended level seen in driver’s side door
jamb and don’t forget the spare. It should be replaced with a new one if it shows it’s already
worn out. Have the alignment checked by a nearby tire shop if the car pulls to either side when
driving or if you notice uneven tire wear. This is usually caused by long intervals of car trips or if
you haven’t use the car for a longer period of time. Maintaining his car is every owner’s

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responsibility. In caring for its smallest damage, one can prevent costly budget allocation on
repairs. It will also avoid delays on your trips because the vehicle that you are using is well-
maintained. Drive safely and have a safe journey!

DASHBOARD WARNING LIGHTS

What does that light mean and what should you do?

As cars have become more complex, the number of different dashboard warning lights has
grown significantly. Modern electronic systems like airbags or stability control are constantly
self-testing and it's important for you to know whether a warning light requires immediate
attention or whether you can continue your journey and get a garage to investigate later. If a
warning light comes on (or fails to extinguish after you've started the engine) you should stop as
soon as possible in a safe place. Many warning lights are specific to the car make or even the
model the vehicle handbook should give you a detailed explanation of their meaning and the
action to take. These will include checks for the correct function of the following warning lights,
where fitted:

Engine Oil pressure warning light: This light should illuminate when the ignition is
switched on and should extinguish as soon as the engine starts. If the light stays on after
starting or illuminates during a journey, stop immediately, switch off the engine and check
the engine oil level.

Top up straight away if the level is low. If the warning lamp illuminates, even though the oil
level is correct, do not start the engine and seek assistance.

Battery charge warning light: This light should illuminate when the ignition is switched on and
should extinguish as soon as the engine starts. If it does not illuminate at all, or if it illuminates

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while driving, your battery is not being charged as there is a fault with your charging system.
This may be due to one of the following;

 slack battery or starter terminal

 a broken or loose alternator drive belt
 an alternator failure

If the drive belt is broken, it must be replaced before you restart the engine. The coolant system
may rely on this belt and its failure could cause the engine to overheat, in turn causing engine
damage.

Immediately move the vehicle to a safe location and switch off the engine. Do not restart the
engine and seek assistance.

Charging

Brake system warning light: This light will remain illuminated when the handbrake is engaged.
Illumination after releasing the handbrake may indicate low brake fluid level.

Refer the handbook and add the correct brake fluid at once to bring the level up to the MAX
mark. As the brakes wear the fluid level will slowly drop. Check your brake fluid level
frequently to ensure there is no further rapid loss of fluid. If the brake fluid is too low and brake
pedal travel is distinctly longer than usual, one of the two hydraulic brake circuits may have
failed. Do not continue your journey and seek assistance.

If the light remains illuminated, even though the brake fluid level is correct, this may indicate a
sensor fault. Take your vehicle to a dealer or garage as soon as possible.

Brakes

ABS warning light

 When the ignition is switched on, the light illuminates briefly to confirm that the system
is operational.

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  If it illuminates when driving, it indicates a malfunction. Have this checked as soon as
possible.
 Normal braking (without ABS) will be generally be maintained and many cars will be
safe to drive on, but some will not - check the handbook for advice.

Have the vehicle checked by a dealer or garage as soon as possible.

Brakes & ABS

Brake system and ABS warning lights: If both warning lights illuminate at the same time when
driving, stop the vehicle as soon as it is safe to do so.

Reduce vehicle speed gradually and immediately move the vehicle to a safe location. Use the
brakes with great care. Do not step on the brake pedal abruptly. Seek assistance.

Fuel filter water trap (diesel engines): This light illuminates when the ignition is switched on
and should extinguish after a few seconds. If it illuminates while driving, it indicates that water
has been detected in the fuel filter. This light warns you that the amount of accumulated water in
the fuel filter has reached the specified level. Normally the vehicle is quite safe to drive, but have
the accumulated water in the fuel filter drained off as soon as possible.

If the vehicle has just been re-fuelled, immediately move the vehicle to a safe location and
switch off the engine. The fuel may have been contaminated and could cause damage to the
injection system.

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 CHAPTER SIX
SOLDERING WORKS OF BODY PANELS, STUDY OF DOOR-LOCK AND WINDOW
RISING MECHANISM

Soldering

Soldering is the process of joining two or more pieces of metal by means of fusible alloy or
metal called solder, applied in the molten state.

Soldering is basically of two types;

1. Soft soldering
2. Hard soldering
Soft soldering

It is used extensively in sheet metal work for joining parts that are not exposed to the action of
high temperatures and are not subjected to exclusive loads and forced.

Hard soldering

It employs solders which melt at high temperatures and are stronger than those used in soft
soldering.

Denting

The process of body repairing and refinishing is called denting. It mainly involves sheet metal
works in which the damaged body panels and fenders are straightened or given profiles to make
them look like the original item.

Window rising mechanism

Windows are provided in the upper part of the door. They are used to admit natural light when
closed and allow inflow of air when open. To provide additional passengers space without
increasing the overall vehicle width, the window glasses are curved at passengers shoulder level.
They are made of one-piece safety glass of about 5-6 mm thickness.

Door locking mechanism

To open from outside

As soon as the push button is pressed the catch is raised upward and the slotted disc rotates and
free from the U-lifting .When the catch is raised up, locking bar is also raised up with the clutch.
When the U-fitting is free from slotted disk, the door is open.

To open from inside

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 To unlock the door from inside, the locking bar is raised initially and then inside opening lever
is pulled up. If this inside opening lever is pulled up the catch is raised and the slotted disc
rotated and fee from the U-fitting.

Door in closed position

When the door is closed the slotted disc rotates and fastens into the V-fitting. During this
operation the catch with locking bar is also selected into the slot. Once the slotted side fastens the
V-fitting, the door is locked.

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