MECHANICAL DEPARTMENT

AUTOMOTIVE REPORT
NAME : MUHAMMAD NAZIRUL HAKIM BIN
YUSOF..
CLASS : DAD1A..
GROUP : GROUP 3..
REG. NO. : 02DAD11F1017..
LECTURE : ENCIK KAMARUZAMAN BIN
KAMARUDDIN..

CONTENT
INTRODUCTION

...

TIRE
TIRE WORKSHEET

...

ENGINE OIL
CHECKING ENGINE OIL

...

DRAINING ENGINE OIL

...

OIL FILTER WORKSHEET

...

REFILLING OIL ENGINE

...

TOP OVERHAUL

SUSPENSION

 IDENTIFICATION

...

FRONT & REAR SHOCK

ABSORBER REPLACEMENT
MACPHERSON STRUT
REPLACEMENT

...

...

INTRODUCTION

ASSALAMUALAIKUM BISMILLAHIRROHMANIRRAHIM..

I MUHAMMAD NAZIRUL HAKIM BIN YUSOF from class

DAD1A. Firstly, want to thankful to Hadrat Ilahi. With the
permission of the work I managed to finish the
report successfully. Secondly, I want to special thanks to my
lecture EN. KAMARUZAMAN & EN. RAMZAM for guide me how
finish this report with the correct ways. Next, thanks also to my
fellow friend because help me in giving some points and
information. I would like to thanks once again on all the people
involved and hopefully God will repay you..

TIRE WORKSHEET
OBJECTIVE :
Removing and fitting the tires..
Balance the wheels of the vehicle..
Know the characteristic of tires..

 Know the checking & adjusting the tires pressure and

dynamically..

INTRODUCTION OF TIRE :

How

to know tire characteristic

Tire characteristics

How to change the tire

SAFETY :
Make sure the car is stand correctly with the car jack because
if the car not stand correctly the car will fall back..
When jack the car make sure no one near the side car because
if the car fall back it will harm the near person..

DESCRIPTION :

 Tires provide a cushion between the road and the vehicle to

vehicle to reduce road shocks..
They also provide friction with the road surface. During
acceleration, friction is in the form of traction to propel the
vehicle along the road..
Friction also provides adhesion, which opposes the tendency
to skid on turns and allows quick stops to be made during
braking..
Tires should be inflated to the pressure recommended by the
vehicle manufacturer or as shown on the placard attached to
the vehicle..
Incorrect pressures can cause tire wear as well as steering and
braking problem..
Under inflation will cause heavy steering and tire squeal on
turns..
It will also allow the tire to flex excessively..
This builds up excessive heat and imposes a greater load on
the tire cords..
Over inflation gives a hard ride and subjects the tire to road
shock because the tire does not flex normally..

TOOLS NEED :

Hand Tool..
Box Set..
Jack..
Safety Stand..

STEP :
Firstly, take the box set and hand tools at the bonet..
Then use the equipment in the box like spanar to loosen the
wheel nuts first..

 Second, jack the car with correct ways because if the car not
jack correctly the car will not stable then the car will fall back..
Third, if you have safety stand use it to stand the car. This give
your procedure more safety..
Fourth, take the spanar again to remove the nuts and remove
the tire..
Then, take the spare tire to replace it..
Fifth, put the nuts back and tight it but dont to tight..
Sixth, down the car and tight the nuts tightly again..
Lastly, the car is ready to move..

CONCLUSION :
From this lesson, I learned how to know the characteristic of
tire..
I also have been taught how to use jack car, how to loosen and
tight the nuts..
How to remove and install back the tire with the correct ways..

CHECKING ENGINE OIL

OBJECTIVE :
Adjust and check engine oil level and condition whenever it
can use again or must to change..

SAFETY :
Make sure that you understand and observe all personal
safety procedures when carrying out the following tasks like
clothing wear policies..

DESCRIPTION :
Make sure first, the vehicle is on a level surface and
the engine is off before taking a reading. If you don't, you'll get
inaccurate readings..
Oil Level should be checked regularly. Using too little or too
much oil can damage the engine.
It is normal to add some oil between maintenance intervals
depending on the severity of the operating conditions..
The oil engine should be change at list every 5,000km to
6,000km..

TOOLS NEED :
Jack and safety stand..
Cotton napkin..

STEP :

Oil level at the dipstick

how to check engine oil

Park the vehicle on level ground and apply the handbrake..

Run the engine until it reaches operating temperature..
Turn off the engine. Wait a few minutes for the oil to drain back
into the oil pan..
Remove the dipstick and wipe it clean with a dry cloth. Reinsert it fully..

 Remove the dipstick again and check the oil level. It should be
between the "H" and "L" marks. If the oil is below the "L"
mark, remove the oil filler cap and pour recommended oil
through the opening..

CONCLUSION :
From this lessons, I have been teach how to measure the oil
engine level with the dipstick with the correct ways..
Also know when to change the oil engine with look at the oil
condition..

DRAINING OIL ENGINE

OBJECTIVE :

 Remove the old oil engine..

To empty the oil engine for replacement with new oil engine..

SAFETY :
Hot oil can burn so carefully when handle it..
Wear a glove for safety..

TOOLS NEED :
Oil pan..
Glove..
Hand tools..

STEP :

The oil move out from the hole remove nut under engine block
Place the drain pan underneath the sump..
Ready to catch the flow..
Once all the oil has completely drained, refit the sump plug
(preferably with a new gasket) and tighten firmly but not too
tight..

CONCLUSION :
At the end of this lesson I have learned how to manage the
nuts above the engine oil that control the flow oil engine..
I also know how to drain the oil engine correctly..

OIL FILTER WORKSHEET

OBJECTIVE :
Remove the oil filter..
Install new oil filter..

SAFETY :
Make sure that you understand and observe all personal
safety procedures when carrying out the following tasks like
clothing wear policies..

DESCRIPTION :
To help judge the correct degree of the turn, make a mark on
the outside of the filter with a pencil or even a dab of oil, but
remember to wipe of the oil again when you have finished. Do
not over tighten the oil filter. Typically three quarters of a full
turn is adequate torque for a seal that will not leak..

TOOLS NEED :
Oil filter removal..
Glove..
New oil filter..

STEP :

remove the oil filter

Install new oil filter

Using an oil filter removal tool, remove the oil filter..

The new oil filter is now ready to be installed..
Rub some fresh engine oil over the oil filter gasket and then
screw it into location..
Hand tight is usually adequate though a slight tighten up with
the filter wrench may be necessary when hands are a little
oily..

CONCLUSION :
At the end of lessons, I have learned how to use removal oil
filter. I also learned how to remove and change new oil filter
with correct ways..

REFILLING OIL ENGINE

OBJECTIVE :
Refill oil engine..

SAFETY :
Dont over limit when fill the oil engine..
Make sure the oil that you fill is match with the car..

DESCRIPTION :
Ensure that you know the quantity of oil your car takes before
you add any oil to the engine. Never fill exactly the specified
quantity of oil immediately as it is good practice to initially fill
80% of the specified capacity. If your car takes 5 litres put 4
litres in to begin with..
The dipstick will often indicate an overfill when the correct
quantitiy of oil is added. The level will drop once the oil has
circulated to the new filter. Start the engine and make sure the
dashboard OIL light goes out or the gauge indicates pressure.
If not, stop the engine immediately..

TOOLS NEED :
Hand tools..
Box set..
Cotton napkin..
New bottle of engine oil..

STEP :

How to install new oil engine

Remove the oil filler cap on the top of the engine..

Place a medium sized funnel in the aperture and surround the
base with a rag or two to catch any spills..
Carefully pour in the new oil SLOWLY. Some engines have a
habit of developing airlocks which result in the oil spilling
back out the filler hole..
Periodically, stop pouring and allow the oil to settle down into
the engine sump..
Check the dipstick until you have the correct level..

CONCLUSION :
From the lessons I have learned how to refill engine oil with
the correct ways..
I also know how to compare the good quality oil engine..

TOP OVERHAUL
OBJECTIVE :
Open the head of block..

 Service the component in the head block..

Check the leaking of valve..
Grain the valve..
Remark the timing belt..

SAFETY :
Make sure that you understand and observe all personal safety
procedures when carrying out the following tasks like clothing
wear policies..
Remove the battery to stop the current..
Handle the equipment in head cylinder carefully..
Dont loss the nuts and bold..

DESCRIPTION :
Some engine parts are very heavy get assistance to lift heavy or
awkward parts like intake and exhaust manifolds..

TOOL NEED :
Hand tools..
Chop stick..
Grease..
Ratchet..
Socket..

STEP :

Remove the rocker arms

component of cylinder head

Install back the bold

Firstly, prepare the tool box..
Second, take the spanar and open the timing belts from
cylinder head..
Remove the nuts that covering the head cylinder cap..
Third, separate the head cylinder from cylinder block..
Next, remove the part from cylinder head like camshaft, rocker
arm, valve spring, valve..
Check the condition of block..

 Clean the cylinder head..

Grained the valve..
Then, we install the components back to cylinder head..
When finished, put the cylinder head back to the cylinder
block..
Install the timing belts and remark the timing belts..

CONCLUSION :
At the end of the lessons, I have learned how to check the
condition of cylinder head..
I also learned how to service the cylinder head like grain valve,
check the component condition, mark the timing belts..

SUSPENSION
OBJECTIVE :
Identify the type of suspension that car used..
Know the position of ball joint, strut rods, stabilizer,
Bushing, shock absorber, rear suspension..

Macpherson strut

SAFETY :
Sometimes these bolts are splined and need to be hammered
out of the knuckle. To avoid damaging the threads on the bolt,
turn the nut until it's flush with the end of the bolt. This way
you can hammer on the nut without damaging the bolt
threads..

DESCRIPTION :
Adaptive air suspension advantages :
Vehicle's suspension height remaining constant irrespective of
the load it is carrying..
Adjustable dampening characteristics and ride height using a
single process, via the manufacturers installed Car
Performance..
Generally, an ability for the driver to influence
the suspension characteristics, and thus the operating
dynamics, as individually preferred..

Independent air suspension advantages :

It helps keep unsprung mass low..
It allows wheel camber to be adjusted individually, when
provided for by the manufacturer..
When wheel hits an irregularity, it won't upset the opposite
wheel on the same axle..

CONCLUSION :
At the end of lesson I have learn how to know the type of the
suspension that car used whether adaptive air suspension and
independent suspension..

FRONT AND REAR SHOCK ABSORBER

REPLACEMENT

OBJECTIVE
Remove suspension..
To check if there are damage occur in suspension and make
sure the suspension is in good condition..

SAFETY :
Do not remove the center strut shaft nut; you'll be in for a
disaster..
Springs are under extreme pressure. They must be
compressed properly to avoid injury. If you're not comfortable
doing it yourself take the strut assembly to a reputable garage..
Be ready to catch the shock absorber because it will likely fall
after moving the last retaining bolts (FRONT)..
All shock absorber should be replaced in pairs only. Do not
replace just one shock absorber..

DESCRIPTION :
Once the strut knuckle bolts are removed, the lower
suspension is free to move or fall. If it moves enough it can
over extend the CV driveshaft, messing up your the CV joints.
Make sure the lower suspension has some sort of support once
the strut bolts are removed to prevent damage to the
driveshafts..

TOOLS NEED :
Floor jack and safety stand..

 Spring compressor..
Hand tools..
Socket..
Ratched..

STEPS FOR FRONT AND REAR :

Remove the nuts

Open the damper shaft cover

FRONT ABSORBER:
Check bent or damage shock or mounting hardware..
Check whether the shock absorber is leaking hydraulic fluid..
Then, compare the replacement shocks to the original shocks
to be sure they are correct..
Raise the hood and remove the upper retaining nuts (both left
and right side)..
Safely jack the vehicle..
Remove the lower shock absorber retaining bolts (nuts)..
Extend the rod on the replacement shock and install the lower
retaining bolts (nuts)..

 Install the upper retaining fasterner, the wheel and lower the
vehicle..
Bounce the vehicle to check that the replacement shock does
not interfere with any part of the suspension or frame..
Test drive the vehicle..

REAR ABSORBER:
Verify that the front shock absorber requires replacement..
Check bent or damage shock or mounting hardware..
Check whether the shock absorber is leaking hydraulic fluid..
Then, compare the replacement shocks to the original shocks
to be sure they are correct..
Locate and remove upper shock absorber mount retainer bolts
(nuts)..
Safely jack the car..
Remove the lower shock absorber retainer bolts (nuts)..
Extend the rod on the replacement shock and install the lower
retaining bolts (nuts)..
Install the upper retaining fasterner, the wheel and lower
vehicle..

 Bounce the vehicle to check that the replacement shock does

not interfere with any part of the suspension or frame..
Test drive the vehicle..

CONCLUSION :
The lesson that I have learned is how to check the suspension
with spring compressor..
I also know how to remove front and rear suspension from the
car..

MACPHERSON STRUT REPLACEMENT

WORKSHEET
OBJECTIVE :
How to install back the suspension..
Check damaged shock or mountings hardware..
Check whether shock absorber is leaking hydraulic fluid..
Check excessively worn that causing tire wear or riding comfort
problems..

SAFETY :

 Suspension components support the weight of the vehicle.

Make sure the vehicle is supported by something other than
the vehicle's suspension system, such as a hoist or jack stands,
before removing any suspension components..
Some vehicles use the shock absorbers to limit the amount of
suspension travel. In removing the shock absorber an
unsupported part of the suspension may fall from the vehicle.
If you are to remove the shock absorbers make sure the
vehicle suspension is supported by suitable means..

Strut assemblies contain a coil spring that is held under

compression. Always use a spring compressor to release the
spring pressure before disassembly..
Always wear protective clothing and the appropriate safety
equipment..

DESCRIPTION :
Shock absorbers are also known as dampers. Their task is to
reduce suspension oscillations. The two most common types
are strut cartridges and telescopic shock absorbers. Each type
has a different shock absorberreplacement procedure. The
objective of this procedure is to show you how to safely
replace shock absorbers..

STEP :

Install the suspension back

Tight the nuts

Verify that the front shock absorber requires replacement..

Check bent or damage shock or mounting hardware..

 Check whether the shock absorber is leaking hydraulic fluid..

Then, compare the replacement shocks to the original shocks
to be sure they are correct..
Safely jack the car..
Remove upper and lower attaching bolts and nuts..
Carefully remove the MacPherson strut assembly from the
vehicle..
Compress the coil spring with proper equipment and replace
the strut assembly..
Reinstall the complete assembly..

CONCLUSION :
At the end of lesson, I know how to identify the problem and
install back the suspension to the car with correct ways..