This document discusses vehicle testing, maintenance, and repair. It covers various types of vehicle and component testing including lighting, tires, materials, environmental effects, batteries, electrical systems, drive systems, interiors, and more. It also discusses engine overhauling which involves disassembling, cleaning, inspecting, and repairing engines. Common overhaul steps and tools used are outlined. Additionally, it covers engine tune-ups, tuning, pollution from vehicle emissions, emission control systems, and emission regulations in India.

1. Vehicle Testing & Maintenance
Prof. S.S. Petkar M.E. (Mech-Prod)

2. • Lighting technology testing
• Wheel and tire testing
• Strength/material tests at vehicle and component levels
• Simulation of environmental effects
• Battery testing
• Testing of electrical/electronic components
• Testing of drive and vehicle components
• Testing of interior and exterior equipment components
• Testing of glazing materials
• Testing of exhaust systems
• Testing of seats and belt anchorages
• Testing of fuel tanks
• Testing of burning behavior of interior materials
Prof. S.S. Petkar M.E. (Mech-Prod)
Vehicle Test

3. Overhauling
• When an engine is overhauled, it
is disassembled, cleaned, inspected, and
repaired as necessary.
• Depending on what the issue is with engine,
sometimes an overhaul is better than fully
replace it.
Prof. S.S. Petkar M.E. (Mech-Prod)

4. Prof. S.S. Petkar M.E. (Mech-Prod)
Overhauling of engine

5. Steps
• Remove the Engine. Step 1: Position the
vehicle near your hoist
• Disassemble the Engine Block. Step 1: Get the
manual for your particular vehicle.
• Disassemble the Cylinder Head.
• Reassemble the Engine Block.
• Reinstalling the engine
Prof. S.S. Petkar M.E. (Mech-Prod)

6. Engine Tune up
• engine tune-ups include checking, diagnosing,
and replacing bad spark plugs, spark plug wires,
distributor caps, fuel filters, air filters, and oil
filters.
• Tune-ups can also include checking emission
levels, fuel lines, wiring, coolant hoses, and
serpentine belts.
Prof. S.S. Petkar M.E. (Mech-Prod)

7. Engine Tuning????
• Tuning an engine primarily consists of
changing ignition timing and fuel curves, which is
generally handled by computer programmers or
performance chips on modern vehicles.
• While the process of doing so is always warranted
when aftermarket parts are installed, even the
slightest changes can dramatically impact an
engine’s performance characteristics.
• That’s why it’s commonly done on any kind of
performance application regardless of the exact
specifications.
Prof. S.S. Petkar M.E. (Mech-Prod)

8. Tools & Equipment for repair & Overhauling
Prof. S.S. Petkar M.E. (Mech-Prod)

9. • Hammer.
• Screwdrivers.
• A good set of screwdrivers is mandatory to any
basic tool kit.
• Pry Bar.
• Wrenches
• Pliers.
• Ratchet and Socket Sets.
• Allen Wrenches.
• Heavy Duty Scissors.
Prof. S.S. Petkar M.E. (Mech-Prod)
PRY BAR Wrenches

10. Overhauling tools
• CYLINDER BORING MACHINE. Easy & quick
bore centering and machining positioning is
possible with in built dial indicator.
• TOOL GRINDER. Tool Grinders is used for
grinding and shaping of tools, tips, sheets
• LINE BORING MACHINE.
• SURFACE GRINDING MACHINE.
• HEAVY DUTY LATHE MACHINE
Prof. S.S. Petkar M.E. (Mech-Prod)

11. Pollution due to vehicle Emission
• Pollutants produced by vehicle exhausts
include carbon monoxide, hydrocarbons, nitrogen
oxides, particles, volatile organic compounds and
sulphur dioxide.
• Hydrocarbons and nitrogen oxides react with
sunlight and warm temperatures to form ground-
level ozone
• Vehicle pollutants harm our health and
contain greenhouse gases that cause climate
change
Prof. S.S. Petkar M.E. (Mech-Prod)

12. Emission control system & Regulation
Prof. S.S. Petkar M.E. (Mech-Prod)

13. Vehicle emission Norms
Vehicle Type CO% HC (ppm)
2 & 3 wheelers (2/4 strokes)- vehicle manufactured before
31-3-2000
4.5 9000
2 & 3 wheelers (2 strokes)- vehicle manufactured after
31-3-2000
3.5 6000
2 & 3 wheelers (4 strokes)- vehicle manufactured after
31-3-2000
3.5 4500
Bharat stage –II compliant 4 wheelers 0.5 750
4 wheelers other than Bharat Stage-II compliant. 3.0 1500
BS-IV
Prof. S.S. Petkar M.E. (Mech-Prod)

14. Prof. S.S. Petkar M.E. (Mech-Prod)

15. Prof. S.S. Petkar M.E. (Mech-Prod)