AUTOTECH Kerala

AIM: OVERHAULING OF LEAF SPRING ASSEMBLY  TOOLS REQUIRED 1. BOX SPANNER SET 2. RING SPANNER SET 3. DOUBLE END OPEN SPANNER SET 4. HYDRAULIC JACK 5. LONG SCREW DRIVER (-) 6. TORQUE WRENCH 7. MALLET MATERIALS REQUIRED 1. KEROSENE OIL 2. COTTON WASTE 3. EMERY PAPER 4. GREASE 5. RUBBER BRUSHES 6. LUBRICANT 7. GRAPHITED OIL PROCEDURE 1. Chock the wheels. 2. Jack up the frame and lift the vehicle just enough for the wheels to clear the ground. 3. Place a horse to support the frame and take out the jack. 4. Disconnect the shock absorber, if provided. 5. Remove the clamp bolt from the shackle. 6. Remove the spring fixing bolts and nuts all pads. 7. Put the jack to support the axles. And Remove the grease nipples. 8. Remove the shackle pins with the help of special tools. 9. Remove the leaf spring assembly from the axle. 10. Put up the spring in a press, measure the pre - camber. 11. Apply full load and observe the camber. This will be the negative camber. 12. Set the spring eye...

AIM:      OVERHAULING OF SINGLE PLATE CLUTCH TOOLS REQUIRED 1. DOUBLE END OPEN SPANNER SET 2. DOUBLE END RING SPANNER SET 3. TRY SQUARE 4. SPRING COMPRESSOR 5. SCREW DRIVER (-) 6. CLUTCH JIG MATERIALS REQUIRED 1. KEROSENE OIL 2. COTTON WASTE 3. EMERY PAPER PROCEDURE Task 1: DISMANTLE THE CLUTCH 1. Mark with some paint the position of the clutch cover and flywheel. 2. While resetting, this mark will be aligned to ensure the original position of the clutch cover and the flywheel so that the balancing of the flywheel and clutch cover does not get disturbed. 3. Remove the locking wire of the clutch cover mounting set screws. 4. Unscrew the diagonally opposite mounting set screws  of the clutch cover. Each screw should be loosened by two turns at a time, If these screws are loosened and removed all at once, then the spring pressure will act on the remaining screws and the screw thread in the flywheel may shear. 5. Remove the clutch cover assembly a...

AIM:   OVERHAULING CYLINDER HEAD ASSEMBLY TOOLS REQUIRED: 1. 12-13mm RING SPANNER 2. BOX SPANNER SET 3. VALVE GRINDING STICK 4. FEELER GAUGE 5. SCREW DRIVER (-, +) 6. VALVE LIFTER, TORQUE WRENCH 7.CAM GEAR PULLER MATERIALS REQUIRED 1. KEROSENE OIL 2. COTTON WASTE 3. GRINDING PASTE 4. EMERY PAPER PROCEDURE DISMANTLING   1. Ensure that the cylinder head does not tilt while removing, so as to avoid damage to the cylinder head studs. 2. Place the cylinder head on a workbench over two wooden block stands. 3. Remove rocker arm assembly the cylinder head. 4. Remove the cylinder head gasket and keep it in a safe place. 5. Press the valve spring with the help of the special tool. 6. Take out the cotters locks/collets using the special tool. Release the valve spring and take out the special tool. Remove the spring, and the valve and retainer. 7. Keep the valves in order. Number the valves.   Cleaning and inspection 1. Clean exhaust manifold with solvent (cau...

AIM: OVERHAULING OF WORM & ROLLER TYPE STEERING GEAR BOX. TOOLS REQUIRED 1. BOX SPANNER SET 2. DOUBLE END OPEN SPANNER SET 3. DOUBLE END RING SPANNER SET 4. SCREWDRIVER (-) 5. PLASTIC HAMMER 6. TORQUE WRENCH MATERIALS REQUIRED 1. KEROSENE OIL 2. COTTON WASTE 3. EMERY PAPER 4. TRAY 5. LUBRICATING OIL PROCEDURE DISMANTLING   1. Disconnect the battery. 2. Chock the wheels. 3. Remove the bottom shield of the steering assembly. 4. Disconnect the horn button and horn wire at the bottom of steering assembly. 5. Remove the horn button. 6. Release the steering wheel nut lock. 7. Remove the steering nut. 8. Remove the steering wheel by using the puller 9. Remove the instrument panel bracket. 10. Remove the exhaust pipe from the manifold. 11. Remove the steering column cover plate on the floor board. 12. Note the position of the steering gearbox and make a mark on the frame and steering gearbox. 13. Remove the steering gearbox mounting bolts and bracket. 14. Remove...

AIM: CHECKING CHASSIS FRAME BY USING A PLUMB BOB TOOLS REQUIRED 1. PLUMB BOB 2. MEASURING TAPE 3. MALLET 4. BALL PEEN HAMMER 5. RIVETS & GUN MATERIALS REQUIRED 1. MANUFACTURER'S DIAGRAM 2. CHALK PIECE 3. COTTON WASTE  PROCEDURE 1. Check the chassis frame visually for cracks and major damage. If any major damage is found send the chasis frame for repair. 2. Mark a diagram on the floor according to the manufacturer's specification (in-line and diagonal). 3. Place the frame on the floor of the diagram. 4. Check the diagonal and in-line measurement of the frame on the floor. 5. If the frame is bent or twisted its side members (1) and cross-member's (2) points will not align with the floor diagram. If the deviation found is more than the specified limits of the manufacturer, send the frame for repair. 6. Place the frame on the horse support and coincide the same with the floor diagram. 7. Make a number of plumb bob point (3) marks, where the plumb bob point touch...