1.

INTRODUCTION

Cars need maintenance from time to time. Cars need to be kept clean. Automobiles have to
run on dirty roads and in a polluted environment. They run on uneven roads with potholes
and other obstructions and are therefore subjected to loads that damage them. Therefore,
there is a need for regular maintenance and servicing of Cars, which is usually done in
service stations. In this, we will understand the concept of vehicle maintenance and servicing.
The International Energy Agency finds suggests that passenger car ownership in India will
grow by 775% over the next two decades with 175 cars per 1000 people in 2040. Nowadays
India has less population and car ratio as compared to other countries. A motor vehicle
service or tune-up is a series of maintenance procedures carried out at a set time interval or
after the vehicle has travelled a certain distance. The service intervals are specified by the
vehicle manufacturer in a service schedule and some modern cars displays the due date for
the next service electronically on the instrument panel. A tune-up should not be confused
with engine tuning, which is the modifying of an engine to perform better than the original
specification, rather than using maintenance to keep the engine running as it should.
To keep our vehicle in good condition we should do the following things regularly,
Inspection - vehicle components are visually inspected for wear or any leaks. A diagnostic is
performed to identify any electrical components reporting a failure or a part operating outside
of normal conditions. Examples: Wheel air, Brake oil, etc.
Replacement - Given certain lubricants break down over time due to heat and wear,
manufacturers recommend replacement. Any parts that are close to their expected failure are
replaced too to avoid a failure while operating the vehicle. Examples: Engine oil, Air filter,
Oil filter, etc.
Adjustments - as vehicle components wear, they may need adjustment over time. Example:
parking brake cable, Wheel alignment, Wheel balancing, etc.
 2. Importance of Vehicle Maintenance and Servicing

As you may be aware, there is an increase in the number of vehicles, such as motorcycles,
scooters, buses, cars, jeeps, tempo, trucks, tankers, etc., running in the cities. Every new
vehicle comes with a vehicle maintenance manual. The owner of the vehicle is expected to
read and use this manual, as it mentions vehicle maintenance. Introduction to Vehicle
Maintenance and Servicing 157 tips during driving. It has been noticed that after getting a car
or vehicle, the owners do not care much about regular car or vehicle maintenance. Even if the
owners regularly service their vehicle, the vehicle maintenance tips given in the vehicle
maintenance manual increase the longevity or life of the vehicle to a great extent. Vehicle
maintenance and servicing are carried out when the vehicle completes certain kilometres on
its normal running or when the vehicle does not give a proper performance. It is suggested
that the vehicle owners carry out regular and periodical checks on their vehicles, some of
which are mentioned below.

2.1. Daily Inspection (DI):

It is the responsibility of a driver or owner of a vehicle to carry out the following inspection
and checks daily, before starting the engine, to avoid any type of breakdown on the road.
(i)Check the tire pressure in all the tyres visually or by hitting the tyre wall with the help of a
stone and judging the sound
(ii) Check the radiator’s coolant level
(iii) Check the fan belts for looseness
(iv) Check the level of engine oil
(v) Check the windscreen, rear-view mirror, and rear-window glass for their cleanliness
 3.Scheduling

The actual schedule of car maintenance varies depending on the year, make, and model of a
car, its driving conditions, and driver behaviour. Carmakers recommend the so called extreme
or the ideal service schedule based on impact parameters such as the number of trips and
distance travelled per trip per day extremely hot or cold climate conditions mountainous,
dusty, or De-iced roads heavy stop-and-go vs. long-distance cruising towing a trailer or other
heavy load Service advisers in dealerships and independent shops recommend schedule
intervals, which are often in between the ideal or extreme service schedule.
3.1. Common maintenance:
Maintenance tasks commonly carried out during a motor vehicle service include:
 Change the engine oil
 Replace the oil filter
 Replace the air filter
 Replace the fuel filter
 Replace the cabin or a/c filter
 Replace the spark plugs
 Check level and refill brake fluid/clutch fluid
 Check Brake pads/Liners, Brake discs/Drums, and replace if worn out
 Check Coolant Hoses
 Check the charging systems
 Check the battery
 Check level and refill power steering fluid
 Check level and refill Automatic/Manual Transmission Fluid
 Grease and lubricate components
 Inspect and replace the timing belt or timing chain if needed
 Check condition of the tires
 Rotate Tires Check for proper operation of all lights, wipers, etc. Mechanical parts that
may cause the car to cease transmission or prove unsafe for the road are also noted and
advised upon.
 4.Service tools

The necessary tools and materials are shown in fig. The tools required for a service operation
include sets of sockets, spanners, screwdrivers, ratchets, extension bars, and the T-bar.
Necessary materials for a service operation include engine oil, motor flush, oil filter, and oil
supplement.
4.1. Service tools:
Some of the tools used for a typical service exercise are highlighted below:  Mechanical jack
(hydraulic or electric),  Axle stand,  Funnel,  Set of sockets,  Set of spanners,  Ratchet
and extensions, etc.
4.1.1. Hydraulic jack:
A mechanical jack is a device that lifts heavy equipment. It works on the principle of
pressure transmission. Mechanical jacks are usually rated for a maximum lifting capacity. A
hydraulic jack uses a fluid, which is incompressible, that is forced into a cylinder by a pump
plunger. Oil is used since it is self-lubricating and stable. In the case of electric lifts, electrical
power is required. The electric lift used at Genesis Auto Company has a maximum lifting
capacity of 4100kg. The jack is used in lifting the vehicle to create enough clearance for work
to be done underneath it.

4.1.2. Axle stand:

Axle stands are tripod-shaped bodies used in keeping a suspended vehicle parked while work
is being done underneath it. After lifting the vehicle to the desired height using a mechanical
jack, it is used to keep the vehicle at that height. It is much safer as the risk of failure of a
hydraulic jack is greatly reduced
4.1.3. Set of spanners:
The set of spanners contains spanners of various sizes. The spanners are used to loosen the
guiding nuts of the protector covering the underside of the vehicle, especially when the
protector is hindering access to the engine sump. Other nuts and/or bolts that need to be
removed to access the oil sump can also be removed with the spanners.
4.1.4. Ratchet:
A ratchet is a mechanical device that allows continuous linear or rotary motion in only one
direction while preventing motion in the opposite direction. A ratchet makes it easy to loosen
nuts since it eliminates the stress caused by using a spanner.
5. SERVICING & REPLECEMENT OF PART
5.1. OIL & FILTER:
The motor oil in your vehicle’s engine serves a whole slew of functions: it lubricates the
moving parts, helps act as a sealant against debris, cools the engine, reduces wear and tear,
and helps prevent engine corrosion. Keeping it clean is vital for good engine health.
Depending on your car and what kind of oil you’re using, you may need to change both the
oil & oil filter as much as every 6 months or 10,000 kilometres. Many newer vehicles’
owners’ manuals will recommend changing your oil less frequently – often in between 8,000
and 16,000 kilometres. Check your vehicle owner’s manual and consult with a professional to
be certain what is appropriate for your vehicle.
5.1.1 Replacement of the oil filter cartridge:
The oil filter cartridge is present at the bottom of the car which can be open with the rachet.
After opening it the used engine oil is taken out and after that, the new cartridge is put in with
a new washer. A new washer is used to get proper fitting so that the oil should not leak.
5.2. Air filter:
A particulate air filter is a device composed of fibrous materials which remove solid
particulates such as dust, pollen, mold, and bacteria from the air. A chemical air filter consists
of an absorbent or catalyst for the removal of airborne molecular contaminants such as
volatile organic compounds or ozone. Air filters are used in applications where air quality is
important, notably in building ventilation systems and in engines.

5.3 A/C filter:

A particulate a/c filter is a device composed of fibrous materials which remove solid
particulates such as dust, pollen, mold, and bacteria from the a/c of the car to release filtered
cooled air inside the car. A chemical air filter consists of an absorbent or catalyst for the
removal of airborne molecular contaminants such as volatile organic compounds or ozone.
A/c filters are used in applications where air quality is important, notably in building
ventilation systems and in-vehicle cabinets.

5.4 Engine oil:

Motor oil, engine oil, or engine lubricant is any of various well-developed lubricants
(comprising oil enhanced with additives, for example, in many cases, extreme pressure
additives) that are used for lubrication of internal combustion engines. The main function of
these lubricants is to reduce wear on moving parts; they also clean, inhibit corrosion, improve
sealing, and cool the engine by carrying heat away from moving parts Img. Engine oil

5.5. WHAT IS ENGINE COOLANT?

Engine coolant, also known as antifreeze, is mixed with water to keep the radiator from
freezing in extreme cold and overheating in extreme heat. There are many different types of
coolant, so it’s important to know what variety is right for your car or truck.
 6. REPLACEABLE PARTS

6.1. Clutch plate:

A clutch is a mechanical device that engages and disengages the power transmission,
especially from the driving shaft to the driven shaft. Clutches are used whenever the
transmission of power or motion must be controlled either in amount or over time. The vast
majority of clutches ultimately rely on frictional forces for their operation. The purpose of
friction clutches is to connect a `speed or stationery, often to synchronize the speeds, and/or
to transmit power. Usually, as little slippage (difference in speeds) as possible between the
two members is desired.

6.2. Shock absorber replacement:

The automobile frame and body are mounted on the front and rear axle not directly but
through the springs and shock absorbers. Without shock absorbers and springs, the vehicle
would not be able to dampen the vibrations resulting from its motion. Suspension is the term
given to the system of springs, shock absorbers, and linkages that connects a vehicle to its
wheels and allow relative motion between the two. Suspension systems serve a dual purpose
– contributing to the vehicle’s handling and braking for good active safety and driving
pleasure, and for keeping the vehicle occupants comfortable and reasonably well isolated
from road noise, bumps and vibrations. These goals are generally at odds, so the tuning of
suspensions involves finding the right compromise. Required tools: Hydraulic jack, Wheel
spanner, Sets of spanners and sockets, Ratchet
6.2.1 Procedure:
1. Using tire chocks, keep the vehicle stationary.
2. Slack the wheel nuts or bolts keeping the tire of the respective shock absorber to be
replaced in place.
3. Elevate the vehicle to a convenient height using the hydraulic jack, to allow enough space
for the removal of the tires.
4. Loosen the tire nuts completely and remove the tyres.
5. If it’s located in the front part of the vehicle, open the hood to get access to where the top
of the shock absorber is screwed and/or bolted to.
6. With the aid of the necessary tools – Ratchet, Spanner, or T-bar, loosen the guiding nuts of
the shock absorbers.
7. Repeat step 6 for the bottom mounting hook of the shock absorber.
8. Remove the old shock absorber and replace it with the new one.
9. Fix it properly according to the guiding marks on it. These marks are guides to the proper
orientation of the shock absorbers.
10. Fix the bolts and/or nuts and tighten them to keep the shock absorber in place.
11. Fix the tyre, bolt them in place and reduce the vehicle’s elevation to ground level.
12. Tighten the tyre again to ensure they are not loose. The process is complete.

6.3. Brake pad:

The brake system is a very important subsection of the suspensions system of an automobile.
Without the brakes in the vehicle, it automatically becomes a weapon of destruction because
it won’t be able to stop when it is needed to do so. To achieve this mission, the brake system
comes with a wide range of components like the brake drum, brake piston, brake callipers,
and most
important of all, the brake pads. Oftentimes, brake pads get used up and need to be replaced.
The procedure for a brake pad removal exercise at the company is described below.
6.3.1 Procedure:
 Using tire chocks, keep the vehicle stationary.
 With the aid of the wheel spanner, slack the wheel nuts keeping the tire in place.
 Elevate the vehicle to a convenient height using the hydraulic jack, to allow enough space
for the removal of the tires.
 Loosen the tire nuts completely and remove the tires.
 The wheel is now exposed. With the aid of ratchets and necessary sockets, remove the bolts
and screws guiding the brake calliper.
 Lift the calliper and carefully remove one of the brake pads to be replaced.
 With one of the pair left, carefully pull the calliper to press the brake piston against the
brake drum. This enables it to return to its original position before the brake pads were
reduced.
 With the piston in its position, remove the remaining brake pad.
 Fit the new pair of brake pads to the brake calliper.
 Ensure the brake pads are properly fitted.
 Return the brake calliper to its position and tighten the guiding bolts and nuts.
 Replace the wheel in position and tighten the wheel nuts to keep it in place.
 With the aid of the hydraulic jack, bring the vehicle down to ground level.
 Tighten the wheel nuts again to ensure they are secured in place.

6.4 Link rods:

Link rods are subjected to massive shock loading – more so on increasingly pot-holed roads.
The safety of the vehicle depends on the smallest and most vulnerable part of the whole
steering and suspension system.
6.4.1 The purpose of link rods:
Link rods (or stabilizer links or anti-roll bar links or drop links) connect the left and right-
hand suspension components to either end of a common anti-roll bar made of spring steel
which is like a torsion bar running across the car. The anti-roll bar only comes into play if the
suspension on one side of the car moves but the other side does not. For example, a car drives
over a speed hump that goes the full width of the road. The suspension is compressed equally
on each side, the anti-roll bar simply pivots – it is not twisted and there is no strain on the link
rods. But if one wheel hits a speed hump and the other does not, one end of the anti-roll bar is
raised – twisting the bar. The force needed to twist the bar is all transmitted through the link
rods which are normally quite light metal or plastic rods with a ball joint on either or both
ends.
6.4.2. Why do they fail?
Deteriorating road quality and speed humps are a big factor. If one-wheel drops into a pothole
the link rod is subjected to a massive shock loading. If this occurs in cold and wet conditions
when materials used in the ball joint part of the rod are in a more brittle condition, then the
ball joint may become vulnerable to water and grit ingress with the inevitable result – total
failure. The thicker the anti-roll bar the greater the impact. Sportier cars have thicker anti-roll
bars to make them handle better, but this places increased stress on the link rods. Another
vulnerable group is the current generation of SUVs which often have longer suspension travel
than conventional cars, but the link rods are often no more heavily engineered.

6.5 Condenser:
The condenser works to reduce the temperature of the refrigerant at the time of the
condensation process. When the warm temperature is successfully lowered, a cool liquid will
be formed which will be released through the car air conditioner holes. This condenser is
commonly located at the front of the car radiator. Given this position, it is inevitable that a lot
of dirt might get into the car and make the condenser dirty. Dirt that lands in the car air
conditioner condenser can hinder the process of condensation. Taking into account its
important role, the car condenser does need some extra attention. The aim is to avoid the
possibility of the condenser leaking which will impact the heat of the cabin when driving at
low speeds or stopping. A condenser leak can be caused by something trivial and rarely
realized by drivers, namely the presence of dust and gravel. Bouncing pebbles can hit the air
conditioner condenser, causing it to leak. The condenser is indeed a component of a car air
conditioner system that is quite prone to break. Apart from car air conditioning, problems
with the condenser can also occur with an overheated car engine when the air conditioner is
on. Conversely, when the air conditioner is turned off, the engine heat will return to normal.

6.6. Lower control arm:

Control arm bushings usually consist of an outer metal sleeve, a durable rubber or
polyurethane bushing, and an inner metal sleeve. Control arm bushings are important for
driving comfort and handling. They cushion the suspension system which in turn controls
noise and vibrations, and also provide a softer ride over bumps. Bushings can flex and move
while retaining stiffness and the ability to return to their original shape and position. Many
suspensions and steering joints utilize bushings when components need to be mounted
together where vibration is a concern. Bushings are used in control arms, shock absorber
mounts, stabilizer bars, stabilizer links, engine and transmission mounts, and other
suspension and steering components. Bushings have a function similar to cartilage in joints of
the body. Worn or damaged cartilage results in bone-on-bone contact and discomfort. Worn
or damaged bushings can allow metal on metal contact, tire wear, discomfort, noises, and
vibrations. Bushings deteriorate due to heat, age, exposure, heavy loads, salt, oils, and the
stress of frequent movement.
 7.CONCLUSION

Though the industrial training lasted just for some months, I learned quite a lot. I had
the privilege to participate as an assistant in a sizeable number of repairs and services.
The automotive maintenance industry is a rapidly evolving industry with a lot of
potentials. Some repair and prevention tasks are well within the skill of anyone who
can drive the vehicle and can save the owner the hassle and expense of going to the
shop. Changing fluids and filters and paying attention to the sounds, smells, and
sensations felt through the vehicle goes a long way toward increasing vehicle
longevity and directing informed maintenance choices. Likewise, knowing a little
more about the issues that create safety hazards and how to respond to them by
seeking appropriate professional repairs allows the owner to maximize safety for both
drivers and passengers alike. Equipping a vehicle for use, adjusting for seasonal
changes, pursuing modern safety systems and handling the occasional bump in the
car-ownership road are all topics that this guide illuminates for the reader. By staying
current on preventative tasks, the owner is able to minimize costly repairs and
breakdowns and maximize fulfilment and enjoyment as a safe operator on the busy
roads ahead.