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MAITAIN VEHICLE PETROL ENGINE

MAINTENANCE NOTES: VEHICLE PETROL ENGINE

1. INTRODUCTION

A petrol engine (spark-ignition engine) uses petrol fuel and an ignition spark to create combustion. Regular maintenance improves:

  • Engine performance

  • Fuel economy

  • Emission control

  • Engine lifespan

  • Safety and reliability

2. MAIN PETROL ENGINE COMPONENTS

1. Air Intake System

  • Air filter

  • Throttle body

  • Intake manifold

2. Fuel System

  • Fuel tank

  • Fuel pump

  • Fuel filter

  • Fuel injectors/carburetor

3. Ignition System

  • Spark plugs

  • Ignition coil

  • Distributor (older models)

  • ECU (modern engines)

4. Lubrication System

  • Engine oil

  • Oil pump

  • Oil filter

  • Sump

5. Cooling System

  • Radiator

  • Coolant

  • Water pump

  • Thermostat

  • Cooling fan

6. Exhaust System

  • Exhaust manifold

  • Catalytic converter

  • Muffler

3. ROUTINE PETROL ENGINE MAINTENANCE

3.1 Air Intake System Maintenance

  • Inspect and replace air filter every 10,000–15,000 km

  • Clean throttle body

  • Inspect intake hoses for cracks or leaks

Effects of poor maintenance:

  • Reduced power

  • High fuel consumption

  • Poor acceleration

3.2 Fuel System Maintenance

  • Replace fuel filter as recommended

  • Use clean petrol to prevent injector blockage

  • Clean injectors if engine misfires or idles roughly

  • Check fuel lines for leaks

Effects of poor maintenance:

  • Hard starting

  • Engine hesitation

  • Poor fuel economy

3.3 Ignition System Maintenance

  • Inspect and replace spark plugs (usually 20,000–60,000 km)

  • Check ignition wires/coils for damage

  • Set spark plug gap correctly

  • Scan ECU for ignition-related error codes

Effects of poor maintenance:

  • Misfiring

  • Loss of power

  • Increased emissions

3.4 Lubrication System Maintenance

  • Change engine oil regularly (5,000–10,000 km or per manufacturer)

  • Replace oil filter with every oil change

  • Check oil level and quality using dipstick

  • Inspect for oil leaks

Effects of poor maintenance:

  • Engine wear and overheating

  • Low oil pressure

  • Engine seizure

3.5 Cooling System Maintenance

  • Maintain correct coolant level

  • Inspect radiator and hoses for leaks

  • Flush and replace coolant periodically

  • Ensure fans and thermostat function properly

Effects of poor cooling maintenance:

  • Engine overheating

  • Head gasket failure

  • Reduced engine life

3.6 Exhaust System Maintenance

  • Check for exhaust leaks

  • Inspect catalytic converter condition

  • Ensure emission sensors are functioning

  • Tighten or replace loose clamps

Effects of poor maintenance:

  • Increased emissions

  • Reduced fuel economy

  • Excessive engine noise

4. GENERAL ENGINE MAINTENANCE TASKS

1. Check Drive Belts

  • Inspect serpentine belt for cracks

  • Replace if loose or noisy

2. Check Hoses

  • Replace swollen or cracked hoses

3. Inspect Battery

  • Clean terminals

  • Test voltage and charging system

4. Check Engine Mounts

  • Look for cracks and excessive movement

5. Check for Abnormal Noises

  • Knocking, ticking, or squealing sounds indicate problems

6. Scan ECU for Error Codes

  • Use OBD-II scanner to detect and diagnose faults

5. PETROL ENGINE TUNE-UP PROCEDURES

A tune-up includes:

  • Replace spark plugs

  • Adjust/clean throttle body

  • Clean or replace air filter

  • Replace fuel filter

  • Check ignition timing (older engines)

  • Adjust idle speed (carbureted engines)

  • Test battery and charging system

  • Inspect vacuum hoses

6. SAFETY PRECAUTIONS

  • Work on a cool engine to avoid burns

  • Disconnect battery before electrical work

  • Use correct tools for spark plugs and filters

  • Keep flammable liquids away from sparks

  • Wear gloves and eye protection

  • Always support vehicle with jack stands

7. BENEFITS OF REGULAR PETROL ENGINE MAINTENANCE

  • Improved power and acceleration

  • Better fuel efficiency

  • Lower emissions

  • Longer engine life

  • Reduced risk of breakdowns

  • Smoother and quieter operation

SERVICE STEERING AND SUSPENSION SYSTEM

SERVICE NOTES: STEERING AND SUSPENSION SYSTEM

1. Introduction

The steering and suspension system ensures vehicle stability, handling, comfort, and safety. Both systems work together to maintain tire-to-road contact, absorb shocks, and allow the driver to control the vehicle’s direction.

2. STEERING SYSTEM

2.1 Types of Steering Systems

a) Manual Steering

  • Requires more physical effort.

  • Uses a mechanical linkage to turn wheels.

b) Power Steering

  • Uses hydraulic pressure or electric motor to assist steering.

  • Types:

    • Hydraulic Power Steering (HPS)

    • Electric Power Steering (EPS)

    • Electro-Hydraulic Power Steering (EHPS)

2.2 Major Components

1. Steering Wheel

  • Driver input device.

2. Steering Column

  • Connects wheel to steering gearbox.

  • Includes:

    • Column shaft

    • Universal joints

    • Collapsible section (for safety)

3. Steering Gearbox

Converts rotary motion to linear motion.

  • Types:

    • Rack-and-Pinion (most common)

    • Recirculating Ball

4. Tie Rods

  • Transmit motion from rack to steering knuckles.

  • Include inner and outer tie rods.

5. Steering Knuckles

  • Hold wheel hub and allow pivoting.

6. Power Steering Pump (Hydraulic)

  • Supplies hydraulic pressure for steering assist.

7. ECU + Electric Motor (EPS)

  • Provides variable assist depending on speed.

2.3 Common Steering Problems

  • Hard steering

  • Excessive play

  • Steering pull

  • Vibrations

  • Leaking power steering fluid

  • Noise during turning

2.4 Steering System Service Procedures

Inspection

  • Check fluid level & condition (HPS)

  • Check belt tension (if pump-driven)

  • Inspect tie rods and ball joints for play

  • Inspect rack boots for tears

  • Check steering wheel free play

  • Inspect power steering hoses for leaks

Service Tasks

  • Replace power steering fluid

  • Tighten or replace drive belt

  • Replace worn tie rod ends

  • Replace leaking rack-and-pinion unit

  • Wheel alignment after steering repairs

3. SUSPENSION SYSTEM

3.1 Functions

  • Support vehicle weight

  • Absorb shocks and vibrations

  • Maintain tire contact with road

  • Control body movement during acceleration, braking, and cornering

3.2 Types of Suspension

Front Suspension

  • MacPherson Strut

  • Double Wishbone

  • Multi-link

Rear Suspension

  • Torsion Beam

  • Leaf Spring

  • Multi-link

  • Rigid Axle

3.3 Components

1. Springs

Absorb road impacts.

  • Coil springs

  • Leaf springs

  • Torsion bars

  • Air springs

2. Shock Absorbers (Dampers)

  • Control spring oscillations.

  • Types:

    • Hydraulic shock absorber

    • Gas-charged shock absorber

    • Struts (combine shock + structural support)

3. Control Arms

  • Connect wheels to frame.

  • Contain bushings and sometimes ball joints.

4. Ball Joints

  • Allow free pivoting movement.

5. Stabilizer (Anti-roll) Bar

  • Reduces body roll during cornering.

  • Includes bushings and end links.

6. Wheel Hub & Bearings

  • Allow wheel rotation.

3.4 Common Suspension Problems

  • Uneven tire wear

  • Clunking noises

  • Excessive bouncing

  • Poor handling

  • Vehicle pulling or drifting

  • Sagging ride height

3.5 Suspension System Service Procedures

Inspection

  • Inspect shocks/struts for oil leaks

  • Bounce test for worn dampers

  • Check bushings for cracks

  • Inspect ball joints & tie rod ends

  • Check springs for cracks or sagging

  • Inspect stabilizer bar links and bushings

Service Tasks

  • Replace shocks and struts in pairs

  • Replace worn ball joints

  • Replace worn control arm bushings

  • Replace broken springs

  • Wheel alignment after suspension work

4. WHEEL ALIGNMENT

Three Primary Angles

  1. Camber – inward/outward tilt of wheel

  2. Caster – steering axis tilt

  3. Toe – direction wheels point inward or outward

Symptoms of Poor Alignment

  • Uneven tire wear

  • Vehicle drifts left/right

  • Crooked steering wheel

5. SAFETY PRECAUTIONS

  • Always use jack stands when working under vehicle

  • Wear eye and hand protection

  • Relieve system pressure (hydraulic systems)

  • Torque suspension components to specification

  • Perform road test after service