Safeer Ahmad New Report 22 (1) 1111111

INDUSTRIAL TRAINING REPORT 20-MCT-28
Industrial Training Report

B.Sc. Mechanical Engineering Technology
Submitted by Registration #
Safeer Ahmad
2020-UET-NFC-MECH-TECH-26
Place of Training
Toyota Layallpur Motors Sargodha Road Faisalabad
Year
2024
DEPARTMENT OF MECHANICAL ENGINEERING
NFC INSTITUTE OF ENGINEERING AND FERTILIZER

REASERCH FAISALABAD
NFC IFER MECHANICAL ENGINEERING DEPARTMENT 1

B.Sc. Mechanical Engineering Technology
2024
INDUSTRIAL TRAINING REPORT

Industrial Training Report

(Session 2020-2024)
This report is submitted to the faculty of the Department of

Mechanical Engineering, NFC Institute of Engineering and
Fertilizer Research, Faisalabad in partial fulfilment of the
requirements for the degree of Bachelor of Science in Mechanical
Engineering Technology
DEPARTMENT OF MECHANICAL ENGINEERING

Declaration
It is declared that this is original piece of our own work, except where otherwise
acknowledge in text and references. This work has not been submitted in any form
for another degree at any university or other institution for tertiary education and shall
not be submitted by me in future for obtaining any degree from this or any other
university or institution.
Signature of Student
Safeer Ahmad
(Reg # 2020-UET-NFC-MECH-TECH-26)

Acknowledgements
First of all, praises to ALLAH Almighty the source of all knowledge, wisdom within
and beyond my comprehension, and I cannot repay even a single blessing conferred
upon me by ALLAH.
For the achievement of this goal many personalities have helped me out. First I am
highly thankful to Mr. Malik Zhoor-ul-Din Shahrooz (CEO Toyota Layallpur
Motors)who allowed me for internship.
I am also very grateful to Dr. Aqeel Abbas (Research Supervisor). Their valuable
constructive suggestions helped me a lot in learning and understanding the
different things.
Special Thankful of Head of Department (H.O.D) Dr. Syed Murawat Abbas Naqvi
I have no opposite words to manifest my feelings of respect, gratefulness, and

obligations.
Finally, I’m thankful to my respected Faculty & Parents for their inspiration,
collaboration and love for completing my industrial Report.

Abstract
In my internship at Toyota Lyallpur Motors, I was able to investigate my interests
in scanner tools, wheel alignment, wheel balancing, and car tuning, under the
supervision of Mr. Malik Zahoor-ul-Din Shahroze.
I became proficient in using a variety of automotive tools and acquired knowledge
of their different kinds and parts, under the guidance of Dr. Aqeel Abbas. This
hands-on experience strengthened my comprehension of a variety of automotive
tools and functions, complementing my academic knowledge.
This Report concludes my educational experience by going into detail about wheel
alignment and balancing, Car Tuning, Break Repairing and their operational
procedures, types, and components, as well as advantages and significance. I also
learned how to operate and handle various kinds of scanner Tools. It will surely be
helpful for my upcoming projects.
In addition to improving my technical abilities, the experience has given me insig
htful knowledge
about the real-world applications of automotive tools in the automotive sector.
My professional journey has been greatly aided by this internship and I will surely
find use for the information and abilities, I have gained in the future.

Table of Content
Industrial Training Report ..................................................................................................................... 3
Acknowledgements .................................................................................................................................. 6
Abstract........ ............................................................................................................................................. 7
Chapter 1: Introduction ....................................................................................................................... 11
1. Place of Internship: ............................................................................................. 12
2. Motivation: .......................................................................................................... 12
3. Importance of the Internship: .............................................................................. 12
4. Value of Automobile Industry: ........................................................................... 12
5. Significance: ....................................................................................................... 12
6. Working Experience in the Organization: ........................................................... 13
7. Policy of the organization: ................................................................................. 13
Chapter 2: Company Information .................................................................................. 14
Chapter 3: Training Work ................................................................................................ 17
3.1. Car Tuning Techniques .................................................................................................................. 18
3.1.1. ECU Remapping/Chip Tuning ................................................................................... 18
3.1.2. Installation of an aftermarket air intake ...................................................................... 18
3.1.3. Upgrading to an aftermarket exhaust system ............................................................. 20
3.1.4. Turbocharging/Supercharging .................................................................................... 20
3.1.5. Upgrading the Suspension .......................................................................................... 21
3.1.6. Upgrading the Breaks ................................................................................................. 22
3.1.7. Lightweight wheel and tire upgrades ......................................................................... 23
3.1.8. Installing limited slip differentials .............................................................................. 25
3.1.9. Upgrading to a high-performance clutch and flywheel .............................................. 26
3.2. Car Tuning Tools ............................................................................................................................ 27
3.2.1. Performance Guage .................................................................................................... 28

3.2.2. Tuning Software and Hardware.................................................................................. 28
3.2.3. Diagnostic Scanner ..................................................................................................... 30
3.2.4. Dynamometers ............................................................................................................ 30
3.2.5. Torque Wrenches........................................................................................................ 30
3.2.6. Socket Set and Pliers .................................................................................................. 31
3.2.7. Screwdrivers and Spanners......................................................................................... 31
3.2.8. Pulley Removal Tool .................................................................................................. 32
3.2.9. Oil Filter Wrenches .................................................................................................... 32
3.3 Wheel Alignment...............................................................................................................................34
3.3.1 Stability and Handling...................................................................................................34
3.3.2 Tire Wear.......................................................................................................................35
3.3.3 Main aspects of Wheel Alignment................................................................................36
3.3.4 Benefits of Wheel Alignment........................................................................................38
3.3.5 Tools used in Wheel Alinment......................................................................................39
3.3.6 Importance of Wheel Alignment...................................................................................41
3.4 Wheel Balancing................................................................................................................................42
3.4.1 Wheel Maintenance......................................................................................................42
3.4.2 Signs of Ubalanced Wheel...........................................................................................43
3.4.3 How to balance the Wheels..........................................................................................44
3.4.4 Difference between Wheel Alignment and Wheel Balancing......................................44
3.5 Brake Repair.....................................................................................................................................46
3.5.1 Braking System............................................................................................................47
3.5.2 Hydraulic Brake Circuit...............................................................................................48
3.5.3 Signs of Worn Out Brake.............................................................................................49
3.5.4 Anti-Lock Braking System (ABS)................................................................................50
3.6 Scanner Tool......................................................................................................................................51
3.6.1 On-Board Diagnostic (OBD-I) Scanner.......................................................................51

3.6.2 On-Board Diagnostic (OBD-II) Scanner......................................................................52
3.6.3 BlueDriver Bluetooth....................................................................................................53
3.6.4 Autel Maxicom MK808................................................................................................54
3.6.5 Kasmotion Scanner.......................................................................................................55
3.6.6 Actron CP9690..............................................................................................................56
3.6.7 MotoPower MP69033...................................................................................................57
Conclusion................................................................................................................................................58

Chapter 1: Introduction

Chapter 1: Introduction
1. Place of Internship:
Opposite METRO Cash and Carry, Main Sargodha Road, Faisalabad.
2. Motivation:
As a Mechanical Technologist, I absolutely need practical experience to

succeed in my job. I gained invaluable skills in my field through exposure to
auto mechanics. It is a privilege to have the opportunity to intern at Toyota
Lyallpur Motors.
3. Importance of Intern ship:
An important link between academic understanding and real-world

application was made possible by this internship. I was able to put theory
into practice in a practical context by working directly in the automotive
sector, which improved my technical knowledge and comprehension. With
the knowledge and skills I gained from this practical exposure, I will be
able to succeed in the field of an automotive industrial engineering in the
future.
4. Value of Automobile Industry:
The automobile industry is an important sector of the country's economy,

contributing significantly to its overall GDP. The value of the industry is
estimated to be around $6-7 billion. The sector has witnessed steady growth in
recent years, with an increasing demand for vehicles in the country and also
provide jobs in different auto mobile departments. Some of the key players in
the Pakistani automobile industry include Toyota, Honda, Suzuki, and Hyundai.
Being employed in this field, it gave me the exceptional chance to support a vital
industry and get insight into its complex dynamics and difficulties.
5. Significance for Pakistan’s Future:
The auto-mobile industry plays a significant role in Pakistan's future

for several reasons. Firstly, it contributes to the country's economic
growth by generating revenue, creating jobs, and attracting foreign
investment. This industry also has a positive impact on other sectors
such as the manufacturing and services industries, contributing to
overall economic development.
Moreover, the auto-mobile industry helps in the development of

infrastructure and technology in Pakistan. As the industry advances, it
pushes for better roads, fuel efficiency, and safety standards, which
ultimately benefits the country as a whole. This technological
advancement also helps in reducing carbon emissions and improving
air quality, leading to a healthier environment for the populati on.
Additionally, the auto-mobile industry plays a crucial role in

transportation and mobility in Pakistan. With a growing population and
urbanization, the demand for vehicles is increasing, and the industry
helps in meeting this demand by providing a variety of vehicles for
different purposes. Overall, the auto-mobile industry is an essential part
of Pakistan's future as it contributes to economic growth, technological
advancement, and transportation needs.
6. Working Experience in the Organization:
Toyota Lyallpur Motors has given me a 4-month training session. While I was
there, I carried out my responsibilities and picked up knowledge about tyre
and wheel services such as wheel alignment, brake service, oil change and
auto electric. My four months at this organisation taught me a lot. My
objectives and ambitions for my intern ship were greatly aided by the
workplace atmosphere.
7. Policy of the organization:
Toyota is regarded as the premium brand in the automotive business by

people worldwide. In addition to providing the quality that customers have
come to expect from Toyota, the company is unquestionably seen as leading
the way globally in fostering a more thoughtful interaction between the
environment and the vehicle.

Chapter 2: Company Information

CEO MESSAGE
Toyota Lyallpur Motors was incorporated in year 2010 on 07th day of May and
commenced its operations in the same year. Toyota Lyallpur Motors is a well-
known car dealership in the community that places a high value on reliability and
client happiness. The company's departments include a used car department, a spare
parts department, a CR department, a sales showroom, and a service department
with highly skilled technicians, supervisors, and state-of-the-art workshop
equipment. The management of the organisation is transparent and goal-oriented,
and they support a methodical approach to organisational and personnel
development as well as drive to fulfil corporate values and objectives. All our
efforts lead towards customer satisfaction through entering into transactions of
Brand New & Used Vehicles, Quality Services and a strong backup of Genuine
Spare Parts. We focus on Customer Relations through a regular backup to our
valued customers by handling their complaints and suggestions for continuous
improvement.
Malik Zahoor ul Din
Chief Executive

Corporate Profile
The company comprises of:
⚫ Sales Showroom
⚫ Spare Parts Department
⚫ CR Department
⚫ Used Car Department
⚫ A Service Department having qualified technicians & supervisors and equipped with high-tech
workshop equipment.
Despite the fact Toyota Lyallpur Motors is quite young in the corporate world but
the journey covered is more than the time consumed. The achievement during this
short span on existence as as following:
⚫ Toyota Lyallpur Motors achieved Best in Service Nationwide award for the year
2012-13
⚫ Central Star in CR for year 2012-13
⚫ Best in Service Regional Award for the year 2013-14
⚫ The certifications achieved are MRS (Maintenance Reminder System), EM

(Express Maintenance), Green Dealer, TSM Kodawari, DERAP, TSM B&P, FIR
(Fix-it-Right, 1st time), and TWSM (Toyota Way in Sales & Marketing) Awards.
The company has an open and outward looking management, which believes in a
systematic approach in Organization & Personnel Development and motivation to
achieve Corporate Principles and Goals.

Chapter 3: Training Work

Chapter 3: Training Work
3.1 Car Tuning Techniques
Car tuning involves modifying a vehicle beyond its original factory standards to
enhance its appearance, performance, and functionality. Enthusiasts customize
their cars to unlock their full potential and achieve a desired driving experience.
This practice has become increasingly popular among automotive enthusiasts in
recent years as more people seek to personalize their cars and make them stand out
on the road.
There are many different ways to tune a car, ranging from simple upgrades like new
air filters or exhaust systems to complex installations such as turbochargers or
suspension modifications. These changes can improve a car's power, handling, and
overall performance while also enhancing its aesthetic appeal.
Professional workshops offer a wide range of tuning services for those who wish to
take their modification efforts to the next level. Dyno tuning is one example of this
kind of service which optimizes engine performance by fine-tuning critical
components such as fuel delivery and ignition timing.
Bodywork services like painting and vinyl wrapping are other common options that
allow owners to customize their vehicles with eye-catching colors and designs.
Some extreme modifiers will go so far as completely overhauling an entire vehicle,
stripping it down then rebuilding it piece-by-piece with custom parts tailor-made
for superior function or style. Here are some Car tuning techniques:
3.1.1 ECU Remapping/Chip Tuning
ECU remapping or chip tuning is a popular way to improve the performance of a

car's engine and can also enhance its fuel efficiency. The term ECU stands for
"engine control unit" which serves as the brain of the modern automobile,
controlling various functions such as throttle response, ignition timing, and fuel
delivery.
Chip tuning involves modifying the programming code on a vehicle's ECU to

optimize engine performance by altering certain parameters within it. This can be

done either by physically replacing an existing chip in older vehicles or changing
software values in newer cars using specialized equipment connected directly to the
OBD-II port.
There are many benefits associated with ECU remapping. First and foremost, it can
improve overall power output leading to faster acceleration times and increased top
speed capability; secondly improved torque figures might lead owners towards new
horizons like towing or longer drives without worrying about efficiency; thirdly
more efficient fuel consumption due more precise calibration between air-fuel
ratio,target Air/Fuel Ratio (AFR),improvements in Ignition Timing chain/advance
thus yielding better mpg/economy than stock configuration - providing significant
savings over time.
However, there are potential risks involved too. Incorrect modification could cause
damage to other engine components resulting in costly repair bills down later –
sometimes many months & years from initial installation. It is important that only
qualified professionals who specialize in this type of work carry out these kinds of
modifications ensuring everything remains safe for road use while improving your
own experience behind wheel.
Fig: 3.1 EUC Remapping Chip

3.1.2 Installation of an aftermarket air intake
Installing an aftermarket air intake is a common and relatively simple modification

that can improve the performance of a car's engine. An air intake system works by
bringing more cold, dense air into the engine, leading to better combustion
efficiency and increased power output.
Aftermarket air intakes typically replace the restrictive factory airbox with a high-
performance cone-style filter placed directly outside or inside the engine bay. This
allows for smoother airflow and reduces restriction in comparison to stock systems.
There are several benefits associated with installing an aftermarket air intake,
including improved throttle response, faster acceleration times due to reduced lag
between pedal input & delivery of power; enhanced sound like opening throatier
exhaust note as part-air-intake muffles down sound from motor thus freeing up
more acoustics behind firewall/chassis mounts etc.,and even possible fuel economy
depending upon driving habits & tune applied post- installation.
However, there are some potential risks involved too. A poorly installed or low-
quality aftermarket intake may lead you towards your vehicle making unusual
sounds, stalling and cause other problems that could impact reliability over-time.
Fig: 3.2 Aftermarket Air Intake System
Therefore it is important to consult professionals who specialize in this type of

work before making any significant modifications ensuring proper function while
achieving desired results safely over-road-use duration.
NFC IEFR MECHANICAL ENGINEERING DEPARTMENT 18

3.1.3 Upgrading to an aftermarket exhaust system
Upgrading to an aftermarket exhaust system is another popular modification that

can increase the performance of a car's engine and enhance its sound. An
aftermarket exhaust system typically replaces the OEM exhaust components, such
as the muffler and pipes, with higher-performance versions.
These upgraded parts allow for better airflow and less restriction in comparison to
stock systems, improving engine power output while producing a louder and more
aggressive exhaust note. Moreover, some high-end systems even incorporate
special materials like titanium or inconel to save weight from standard steel/cast
iron counterparts while enduring temperatures that would cause such metal types
issues when under extreme duress.
Besides enhanced performance & sound experience,you may also find certain
manufacturers promoting fuel economy gains although uncertified due different
driving habits/test scenarios often yielding mixed results.
However, there are several potential risks associated with an aftermarket exhaust
installation. Some poorly designed or constructed systems may result in excessive
drone making it unbearable over long drives (often termed resonant frequency
inside cabin), lettering stench emanating sometimes lasting longer than anticipated
& failure chance at moose-test level leading you towards momentary panic on road
which may impact reliability later!
Fig: 3.3 Aftermarket Exhaust System
For these reasons, it is important for car owners to consult professionals

specialized in this type of work before modifying their vehicles. They will ensure
your new custom solution fulfills your expectations correctly intended per
application judged by trials/error/testing/research ensuring necessary safety
checks alongside legal/vehicle code guidelines put forward appreciated by writer
avoiding any surprises down-the-line.
3.1.4 Turbocharging/Supercharging
Turbocharging and supercharging are two popular methods to increase a car's

engine performance by boosting the amount of air going into it, thereby increasing
fuel combustion efficiency.
Turbochargers use exhaust gas to power a turbine that forces more air into the
engine through compressed volumetric ratio ensuring optimal AFR/Timing settings
leading towards greatest output. Superchargers, on the other hand, use a belt-driven
compressor to push additional air into the intake system after first passing through
an intercooler or heat exchanger depending upon configuration allowing cooler
denser inducted volume via displacement/rotational force.
Both turbocharger/supercharger systems enable engines to produce higher

horsepower & torque outputs than their atmospheric counterparts either across an
extended RPM band-of-use (e.g.: in-line 4 cylinder/twin-scroll) or instantaneously
(e.g: V8/v12) yielding improved acceleration times than possible otherwise without
these forced induction aids.
However, there are some risks involved too. For example insufficient oiling/cooling
& inconsistent knock/fuel patterns may lead towards catastrophic damage
ultimately rendering such installs impossible for long-term road-use if not
supervised properly! It is important that experienced professionals carry out such
work only while fulfilling safety/legal guidelines made mandatory at certain
geographical locations worldwide.
Overall both turbocharging and supercharging offer significant improvements in

terms of performance enhancement but require expert tuning with proper
components only utilizing quality-assured products under appropriate conditions
eventually yielding desired outcome wrt/exceeding customer requirements within
proposed application domain over time.

Fig: 3.4 (a) Turbocharging (b) Supercharging
3.1.5 Upgrading the Suspension
Upgrading the suspension in car tuning refers to modifying the shock absorbers,
springs and other components of a vehicle's suspension system. By doing so, one
can improve handling, performance and overall ride comfort.
Some popular upgrades include stiffer yet adjustable spring/shock setups for
improved cornering ability - feel that often brings more stable road-attachment
characteristics than factory OEM approved choices with appropriate visual or
aerodynamic mod focused towards completion of desired look/functionality while
achieving necessary compliance checks alongside safety requirements put forward
around world.
Also of note are sway bars/links that help reduce body roll during hard turns along
with wider tires offering more surface area-to-road contact improving grip/traction
for better steering response at higher speeds or quick transitions (avoidance
maneuvers) when dealing with unanticipated environmental situations occurring on
roads/surface areas like moose test oriented environments.etc depending upon
driving conditions/course specifications /intended use-case scenario judged by
competent authorities must be undertaken for optimal balancing & fine-tuning
needs over time.
However, just like any modification or upgrade made outside notification from
supplier/dealer network may void warranty programs leading owner to undertake
full responsibility hence it advisable that experienced professionals carry out such
work only while fulfilling safety/legal guidelines made mandatory at certain

geographical locations worldwide.
Overall upgrading your vehicles suspension is an excellent way to customize your

vehicle according to personal preferences whilst improving its
responsiveness,coupled with a proper tune(street/race) ensuring optimum reliability
furthermore durability meeting intended application purposes keeping these
essential aspects in mind ensures achievement goals quickly but safely.
Fig: 3.5 Suspension Upgrade
3.1.6 Upgrading the Breaks
Upgrading the brakes in car tuning involves replacing or modifying various

components of a vehicle's braking system to improve its stopping power and overall
performance.
Common upgrades include larger, more durable brake rotors, higher-quality brake
pads and calipers, as well as upgraded brake lines and fluid. These changes can help
increase braking force and reduce stopping distance during high-speed driving
conditions or emergency stops.
It is important to consider the intended usage of the vehicle when upgrading brakes
- for example, a track-focused car will have different needs than a daily driver.
Additionally, proper installation by experienced professionals is crucial to ensuring
safety and avoiding potential issues such as reduced reliability or compromised
handling characteristics.
As with any modification made outside of manufacturer recommendations, it is also

important to be aware that warranty coverage may be affected. Being aware of legal
requirements specific to one's location is essential too before implementing them.
Overall, upgrading vehicle's brakes can significantly improve its performance on

both the street & track alongside great aesthetics but must be done correctly while
keeping all necessary considerations (usage,durability,maintenance) in mind.
Fig: 3.6 Break Repair
3.1.7 Lightweight wheel and tire upgrades
Lightweight wheel and tire upgrades in car tuning refers to replacing the factory
wheels or tires on a vehicle with lighter, high-performance models to improve
handling, acceleration and fuel efficiency.
These types of upgrades can significantly reduce unsprung weight (the weight not
supported by the suspension) which results in better acceleration, sharper braking
under harder driving scenarios coupled with optimum road holding capabilities
while increasing overall agility during cornering maneuvers making it more
responsive/agile.

Fig: 3.7 Boost Hub vs Standard Hub
Some benefits include reduced inertia, decrease in rotational mass and lower center-
of-gravity all yielding improved feedback characteristics when undergoing hard
lateral loads. However, be sure to choose products that maintain proper fitment
specifications as some modifications may cause damaging vibrations especially
after installation is completed without professional help adding risks towards
warranty coverage following accident occurrences if applicable.
It is important that users identify their intended purpose for lightweight wheel/tire
upgrades before deciding on specific components "e.g: either just for
looks(limitations still apply)/performance/track-days etc.". Additionally, ensuring
correct installation from experienced professionals whilst fulfilling safety/legal
guidelines made mandatory at certain geographical locations worldwide must be
Fig: 3.8 Wheel Dimensions
undertaken thereby leading optimal performance goals eventually over time.
Overall upgrading your vehicles wheels/tires represents significant potential

towards personalizing aspects based upon preferences personifying greater control
& stability across varying environments depending upon application parameters

defined ahead of expected use.
3.1.8 Installing limited slip differentials
Limited slip differentials are an important component of car tuning that help to
enhance a vehicle's performance on the road. By improving traction, handling and
power delivery, limited slip differentials can make for a more responsive and
enjoyable driving experience. When installing these components, it is important to
consider the specific needs and requirements of your vehicle as well as your driving
style and preferences. Professional installation by a qualified mechanic or tuner is
also recommended in order to ensure optimal performance and safety.Installing
limited slip differentials involves replacing the stock differential with a unit that
has been specifically designed to improve a vehicle's traction and handling. The
installation process typically involves removing the old differential, installing the
new one, and making sure all parts are properly aligned and secured. Some
modifications may also need to be made to other components of the vehicle in order
for everything to work together smoothly.
It is important to note that there are different types of limited slip differentials
available on the market, each with their own unique benefits and drawbacks. Some
popular options include helical gear LSDs, clutch-type LSDs, and viscous LSDs.
When deciding whether or not to install a limited slip differential, it is important to

take into account your specific driving needs and preferences. If you frequently
drive on slippery or uneven surfaces (such as dirt roads or snow), an LSD can
greatly improve your vehicle's performance and safety. Similarly, if you enjoy
taking corners at high speeds or participating in racing events, an LSD can provide
better acceleration out of turns and overall stability on the road.
Overall, installing limited slip differentials is considered an advanced modification

that should only be attempted by experienced mechanics or tuners who have
knowledge of automotive engineering principles. It requires attention-to-detail
during installation in order for it work correctly once installed - but when done right
it could considerably enhance any car enthusiast’s driving experience

Fig: 3.9 Limited Slip Differentials
3.1.9 Upgrading to a high-performance clutch and flywheel
Upgrading to a high-performance clutch and flywheel is another common

modification that car enthusiasts make in order to improve their vehicle's
performance. The clutch and flywheel work together to transfer power from the
engine to the wheels, so upgrading these components can result in faster
acceleration, smoother gear changes, and improved overall driving experience.
A high-performance clutch typically has stronger friction materials that can better
handle increased power output, while a lightweight flywheel reduces rotational
mass which results in faster revving of the engine. Both modifications require
professional installation by qualified mechanics or tuners who are experienced with
high-performance vehicles.
Fig: 3.10 Flywheel and Clutch Disc

When deciding whether or not to upgrade your clutch and flywheel, it is important
to consider your specific driving needs and preferences. If you frequently engage
in spirited driving or participate in racing events where quick shifts are required, a
high-performance setup may benefit you greatly. However, if you mostly use your
vehicle for commuting or daily driving purposes, an upgraded clutch may be more
than enough for your needs.
Overall, upgrading the clutch and flywheel should only be done after careful
consideration of one's own needs as well as consulting with knowledgeable
automotive professionals before making any final decisions.
Fig: 3.10 Parts of Flywheel
3.2 Car Tuning Tools
Some of the most common tools used in car tuning include:
➢ Performance Gauges
➢ Tuning Software and Hardware
➢ Diagnostic Scanners
➢ Dynamometers (dynos)

➢ Torque Wrenches
➢ Socket Sets and Pliers
➢ Screwdrivers and Spanners
➢ Pulley Removal Tools
➢ Oil Filter Wrenches
3.2.1 Performance Guage
Performance gauges are instruments that measure various aspects of a car's

performance, such as speed, RPMs, boost pressure and fuel pressure. These gauges
allow tuners to monitor their vehicle in real-time and make adjustments to improve
performance. They can help identify issues with the engine or other components
before they become serious problems. Performance gauges may be analog or digital
and can be mounted on the dashboard or elsewhere in the cabin for easy viewing
while driving.
3.2.2 Tuning Software and Hardware
Tuning software and hardware are used by car tuners to modify the engine and other
components of the vehicle. Tuning software can be installed on a computer or laptop,
which is connected to the car's electronic control unit (ECU) through a diagnostic
port. The software allows tuners to adjust various parameters such as fuel injection
timing, air/fuel ratios, ignition timing, and boost pressure. Tuning hardware includes
performance chips or modules that plug into the ECU directly, along with
specialized sensors like wideband oxygen sensors for more accurate tuning. These
tools allow for precise adjustments that can significantly improve a car's
horsepower, torque, and overall performance. However, it's important to note that
improper use of tuning software/hardware could lead to damage or even system
failure in extreme cases if not done correctly by a trained professional tuner.

Fig: 3.11 Automotive Ethernet
3.2.3 Diagnostic Scanner
Diagnostic scanners are tools used in car tuning to identify potential problems with
the engine or other components of a vehicle. These scanners are connected to the
car's electronic control unit (ECU) through a diagnostic port and provide real-time
feedback on various aspects of performance, such as fuel efficiency, emissions
levels, and error codes for malfunctions. This information helps tuners to diagnose
issues before they become major problems and make necessary modifications or
changes for better performance. Some diagnostic scanners also offer additional
features like live data streaming, automated code reading/clearing functions, and
advanced diagnostics capabilities beyond what basic scan tools can offer.
Fig: 3.12 OBD Scanner
3.2.4 Dynamometers

Dynamometers are instruments used in car tuning to measure the power output of
an engine. They work by applying a load or resistance to the vehicle's drivetrain
and measuring how much torque and horsepower it can produce at different
Fig: 3.13 Dynamometer Wiring and Setup
speeds. Dynamometers are essential for tuners as they provide accurate data about
a car's performance before and after modifications, allowing them to fine-tune
settings for optimal results. Some types of dynamometers also have features like
emissions testing capabilities that help meet specific regulatory standards set by
local governments. Overall, using dynamometers in car tuning helps achieve better
overall performance, reliability, and fuel efficiency while ensuring legal
compliance with emissions regulations.
3.2.5 Torque Wrenches
A torque wrench is a tool that's commonly used in car tuning to measure and set the
amount of force or tightening torque applied to bolts. This can be important for
ensuring that various components are properly secured and functioning as intended.
Torque wrenches come in different types, such as click-type and beam-type, but
they all generally work by indicating when a certain level of torque has been
reached through clicks, vibrations, or other mechanisms. Some common uses for
torque wrenches in car tuning might include adjusting wheel lug nuts, tightening
engine cylinder head bolts, or setting suspension component torques.

Fig: 3.14 Torque Wrench
3.2.6 Socket Set and Pliers
Socket sets and pliers are both important tools for working on cars. Socket sets
typically include a range of sockets in different sizes, which can be used to loosen
or tighten nuts and bolts. Pliers come in many varieties as well, such as slip joint
Fig: 3.15 Pliers

pliers, needle nose pliers, and locking pliers. They can be used for tasks like
gripping onto small objects or bending wire. Overall, having a good set of socket
wrenches and various types of pliers is essential for any car mechanic or DIY
enthusiast looking to work on their vehicle's maintenance or repairs.
3.2.7 Screwdrivers and Spanners
Screwdrivers and spanners are important tools for car tuning. Screwdrivers come
in many types, such as flathead and Phillips head, and can be used to remove or
tighten screws that hold various components together. Spanners, also known as
wrenches, come in different shapes and sizes and are used to loosen or tighten bolts
of specific sizes. Some common uses for screwdrivers and spanners in car tuning
might include adjusting the air-fuel mixture on a carburetor or tightening engine
mounting bolts. Having a good set of screwdrivers and spanners is essential for any
mechanic or DIY enthusiast looking to make adjustments under the hood.
Fig: 3.16 Screwdriver and Spanner
3.2.8 Pulley Removal Tool
A pulley removal tool is a specialized tool used in car tuning to remove pulleys
from the engine. Pulleys are often used in engines for timing belts and other belt-
driven components, and they can be difficult to remove without damaging
surrounding parts. A pulley removal tool typically consists of a bracket that attaches
to the pulley and a mechanism that allows the user to apply force to break the pulley
loose from its mounting. This type of tool is essential for mechanics or DIY
enthusiasts looking to make repairs or upgrades on their vehicle's engine.
Fig: 3.17 Pulley Removal Tool
3.2.9 Oil Filter Wrenches

Oil filter wrenches are special tools used for removing oil filters during car tuning.
Oil filters can become stuck over time, making them difficult to remove without
the proper tool. An oil filter wrench usually has a set of adjustable metal jaws that
can be tightened around the filter for easy removal. This tool is essential for
mechanics or DIY enthusiasts who regularly change their vehicle's oil to ensure
they can remove and replace the old filter with ease and efficiency.
Fig: 3.18 Oil Filter Wrench
3.3 Wheel Alignment
Wheel alignment is an important aspect of car maintenance that involves adjusting

the angles of the wheels to ensure they are parallel to each other and perpendicular
to the ground. Proper wheel alignment helps ensure even tire wear, improves
handling and steering, and extends the life of your tires. It is recommended to have
your wheel alignment checked regularly, especially after hitting a pothole or curb,
to ensure optimal performance and safety. In addition to ensuring even tire wear
and improving handling, proper wheel alignment also helps to maintain fuel
efficiency and reduce the strain on suspension components. When your wheels are
not properly aligned, it can lead to problems such as steering wheel vibration,
uneven tire wear, and a vehicle that pulls to one side. Regular wheel alignment
checks and adjustments can help prevent these issues and keep your car running
smoothly.
3.3.1 Stability and Handling
Proper wheel alignment plays a crucial role in the stability and handling of a car.
When the wheels are correctly aligned, the vehicle will drive straight and true, with
minimal vibration or pulling to one side. This improves overall handling and makes
the car safer to drive, especially at high speeds or in poor road conditions.
Maintaining proper wheel alignment also helps prevent premature tire wear,
ensuring that the tires grip the road evenly for better stability and control. Overall,
wheel alignment is essential for maintaining optimal stability and handling of a car.
Fig: 3.19 Stability and Handling of Car Wheel
3.3.2 Tire Wear
When a vehicle's wheel alignment is off, it can cause uneven tire wear. This will
manifest as one side of the tire showing more wear than the other, or a pattern of
wear across the tire that is not consistent. It is important to have proper wheel
alignment to prevent premature tire wear and ensure safe driving conditions. Patchy
wear occurs when specific areas of the tire tread wear away unevenly. These
patches can create a bumpy ride and affect traction. To address this issue, consider
the following steps:
⚫ Balancing: Regularly balance your tires to distribute the wear evenly.
⚫ Suspension Inspection: Check your vehicle’s suspension components for any

worn parts that might contribute to uneven wear.

⚫ One-Sided Wear (Inner or Outer Edge): When one side of the tire wears faster
than the other, it’s often due to misalignment.
⚫ Alignment: Schedule regular tire alignments (approximately once a year or when

changing tires) to prevent one-sided wear.
⚫ Tire Rotation: Rotate your tires regularly to ensure even wear across all sides.
⚫ Center Wear: Excessive wear in the center of the tire tread indicates that the tire
pressure is too high.
⚫ Proper Inflation: Maintain the recommended tire pressure (usually listed in your
owner’s manual or on the driver’s side door jamb).
⚫ Edge Wear: Edge wear occurs when the tire shoulders make more contact with the
road due to under inflation.
⚫ Inflating Properly: Inflate your tires to the recommended pressure level
Fig: 3.20 Tire Wear Patterns
3.3.3 Main aspects of Wheel Alignment
Wheel alignment is crucial for maintaining proper vehicle handling, tire wear, and
overall safety. Let’s delve into the three main aspects of wheel alignment:
1. Camber Angle:

Imagine looking at a car head-on. The camber angle refers to the tilt of the wheels
in relation to the vertical axis. If the top of the wheel leans inward toward the car,
it’s called negative camber. Conversely, if the top of the wheel leans outward away
from the car, it’s positive camber. Most cars have optimized settings with 0 to -1
degrees of negative camber. This ensures maximum tire contact with the road
during cornering. Some vehicles may have different specs for the left and right
wheels due to the road’s crown. Proper camber alignment contributes to stable
handling during turns.
2. Caster Angle: Fig: 3.21 Camber Angle
When viewing the car from the side, the caster angle relates to the angle between
the center of the wheel and the upper mounting point of the steering knuckle or
spindle. Zero caster occurs when the top mount and the wheel’s center are perfectly
aligned vertically. Positive caster means the axis leans back, while negative
caster means it leans forward. All cars require positive caster (negative caster
makes a car undriveable), but the exact amount varies by vehicle. More positive
caster results in heavier steering feel but better self-centering when moving
forward.

Fig: 3.22 Caster Angle
3. Toe Angle:
The toe angle refers to the direction the wheels point relative to the vehicle’s
longitudinal axis. Toe-in occurs when the front edges of the wheels are closer
together than the rear edges. Toe-out is the opposite, with the front edges farther
apart. Proper toe alignment ensures even tire wear and stable straight-line tracking.
Fig: 3.23 Toe Angle
3.3.4 Benefits of wheel Alignment
1. Fuel Efficiency:
Misaligned wheels can decrease gas mileage by up to 10%1. When tires are
misaligned, they drag instead of rolling freely, resulting in increased fuel
consumption. Proper alignment ensures smoother movement and better fuel
efficiency.
2. Smoother Ride:

Correct wheel alignment leads to a smoother driving experience. When your car’s
wheels are properly aligned, it handles bumps and road imperfections more
effectively, providing a comfortable ride.
3. Improved Steering:
Misaligned wheels make steering harder. If your car pulls to one side or the steering
feels off-center, it’s likely due to poor alignment. Proper alignment ensures precise
steering control, making your driving experience safer and more enjoyable.
4. Fewer Auto Repairs:
Misalignment can cause uneven tire wear and stress on other components like
suspension and steering parts. By maintaining proper alignment, you reduce the
risk of premature wear and tear, leading to fewer repairs and expenses.
5. Longer-Lasting Tires:
Misaligned wheels may lead to uneven tire wear. When tires wear unevenly, their
lifespan decreases. Proper alignment ensures that tires wear evenly, extending their
longevity and saving you money on replacements
3.3.5 Tools used in Alignment of wheel
1. Wheel Aligner Machines:
Wheel aligner machines are the most common and advanced tools used for wheel
alignment. These machines utilize sensors and cameras to measure the angles of
your car’s wheels and provide precise readings. They help determine parameters
such as caster, camber, and toe angles, allowing technicians to make accurate
adjustments.

Fig: 3.24 Wheel Aligner Machine
2. Alignment Lifts:
Alignment lifts are essential tools used during wheel alignment. These lifts allow
mechanics to raise the car off the ground, making it easier to access the wheels
and perform adjustments.
Fig: 3.25 Wheel Alignment Lifts
3. Alignment Tools and Gauges:
Various handheld tools and gauges are available for DIY enthusiasts and
professionals.
These include:
⚫ Camber Gauges: Used to measure the inward or outward tilt of the steering
knuckle at the upper control arm from the front or rear of the vehicle.

⚫ Toe Plates: Used to measure the difference in fractions of an inch between the front
tires, compensating for slack in the steering system.
⚫ Caster/Camber Wrenches: Used to adjust caster and camber settings.
⚫ Alignment Rods: Used for precise measurements during alignment procedures.
⚫ Steering Wheel Holders: Keep the steering wheel centred during adjustments.
⚫ Cam Knockout Punches: Used to remove cam bolts.
⚫ Sleeve Wrenches: For adjusting suspension components.
⚫ Cam Adjusting Wrenches: Used to fine-tune camber settings.
Fig: 3.26 Alignment Tools and Gauges
3.3.6 Importance of Wheel Alignment
⚫ Enhanced Handling and Safety: When your car’s wheels are correctly aligned,
it ensures predictable handling and stability on the road. You’ll feel more
confident when accelerating, braking, and cornering.
⚫ Reduced Tire Wear: Incorrect alignment leads to uneven tire wear. Misaligned
wheels can cause specific areas of the tire to wear down faster than
others. Regular alignment helps extend the life of your tires.
⚫ Improved Fuel Efficiency: Misaligned wheels create unnecessary drag, which
forces your car’s engine to work harder. As a result, you consume more
fuel. Proper alignment minimizes this drag, leading to better fuel efficiency.
⚫ Prolonged Tire Life: By preventing uneven wear, wheel alignment helps your
tires last longer. This not only saves you money but also ensures better overall
performance.
⚫ Optimized Driving Stability: Accurate wheel alignment maximizes driving

stability, making your vehicle handle better and improving overall safety.
3.4 Wheel Balancing
Wheel balancing is the process of equalizing the weight distribution around a car's
tires and wheels to ensure they rotate smoothly. This is typically done by placing
small weights on the rim of the wheel to counteract any imbalances. Proper wheel
balancing can help prevent uneven tire wear, vibrations while driving, and improve
overall vehicle performance and handling.
In addition to improving vehicle performance and handling, proper wheel balancing

also helps to increase the lifespan of your tires and reduce fuel consumption. It is
recommended to have your car's wheels balanced regularly, especially after any
changes to the tires or wheels, to maintain a smooth and safe driving experience.
Wheel balancing is typically done using a specialized machine that quickly
identifies any imbalances and allows for precise adjustments to be made.
3.4.1 Wheels Maintenance
First, the vehicle’s tire and wheel assembly are removed from the car. The removed
wheels are then mounted on a specialized balancing machine. This machine spins
the assembly at high speed to identify any imbalances. Based on the data obtained
during the spinning process, the technician determines the imbalance in the wheel.
This could be due to uneven weight distribution caused by factors like
manufacturing variations or damage.
To achieve the desired balance, the technician places appropriate wheel weights on
the wheel’s inner and outer surfaces. These weights help counteract the imbalances.
After adding the weights, the assembly is retested to ensure proper balance.
Fig:3.27 Wheel Balancer
3.4.2 Signs of Unbalanced Wheel
Unbalanced wheels can lead to various issues, affecting both driving comfort and
safety. Here are some common signs that the wheels may be unbalanced:
1. Vibration: If you feel excessive vibration in the steering wheel, floorboard, or seats
while driving, it could be due to unbalanced wheels. The vibration typically occurs
at specific speeds (e.g., between 50 and 70 mph).
2. Uneven Tire Wear: Unbalanced wheels can cause uneven wear on your tires.
Inspect your tires for irregular wear patterns, such as one side wearing faster than
the other. This can reduce tire lifespan and compromise traction.
3. Steering Pull: When your wheels are unbalanced, your vehicle may pull to one
side even when you’re driving on a straight road. This can be subtle or pronounced.
4. Noisy Ride: Unbalanced wheels can create noise, especially at higher speeds.
Listen for unusual sounds coming from your tires or wheels.
5. Reduced Fuel Efficiency: Imbalanced wheels can increase rolling resistance,

leading to decreased fuel efficiency. If you notice a sudden drop in gas mileage,
consider checking your wheel balance.

6. Suspension Issues: Over time, unbalanced wheels can strain your vehicle’s
suspension components. This can result in premature wear and potentially costly
repairs.
3.4.3 How to balance the Wheels
⚫ Regular Maintenance: Technicians recommend getting your tires balanced

every 5,000 to 6,000 miles, or as recommended by your vehicle manufacturer1.
This routine maintenance helps extend tire lifespan and improves overall
performance.
⚫ Free Lifetime Rotation and Balancing: Many tire dealers include free lifetime
rotation and balancing when you purchase new tires. Rotation ensures even wear,
while balancing eliminates vibrations. If your tires came with this service, make
sure to remind the shop to check the balance during rotations.
⚫ Even if balancing costs extra, it’s a good idea to have it checked at least every two
years. This helps maintain optimal performance and safety.
⚫ Road Conditions: In areas with poorly maintained roads, consider balancing more
frequently.
⚫ After Flat Repair: After getting a flat tire repaired, it’s advisable to balance the
wheel.
⚫ New Tires: Whenever you buy new tires, ensure they are balanced before
installation
3.4.4 Difference between Wheel Balancing and Wheel Alignment
Wheel Balancing Wheel Alignment
Purpose Tire balancing, also Wheel alignment

known as wheel refers to adjusting a
balancing, corrects car’s suspension
the uneven system to keep the
distribution of wheels properly
weight in the
wheels. aligned.
Issue Addressed Imbalanced wheels Proper alignment

can lead to prevents the car from
vibration, excessive veering to one side,
tire wear, improves handling,
suspension damage, and reduces on-the-
and other problems. road vibrations.
Procedure During a tire Alignment

balance service, adjustments focus on
your tires and specific suspension
wheels are mounted parts, not the tires or
onto a tire balancing wheels themselves.
machine. The
machine spins the
tire and wheel
assembly to
measure the
imbalance. A
technician then
precisely installs the
correct tire weights
to achieve a
properly balanced
wheel and tire
assembly.
Signs  Uneven tire wear.  Car pulling to one

side.
 Vibration in the
steering wheel,  Premature or uneven
floorboard, or seat. tire tread wear.

 After a flat tire  Squealing tires.
repair or during
 Off-center steering
scheduled
wheel while driving.
maintenance.
 Vibrating steering
 Trembling in
wheel during
specific parts of the
acceleration.
car (steering wheel
for front tires, seats
for back tires).
 Tires can become

unbalanced due to
uneven wear or loss
of a wheel weight
(e.g., hitting a curb
or pothole).
3.5 Brake Repair
Brake repair is a crucial aspect of car maintenance that should not be overlooked.
When your brakes start to show signs of wear and tear, such as squeaking or
grinding noises, it is essential to address the issue promptly to ensure your safety
on the road. The brake system of a car consists of various components, including
brake pads, rotors, callipers, and brake fluid.
During a brake repair, the technician will inspect the condition of these components
and determine if any replacements or repairs are necessary. Brake pads are often
the first to wear out and will need to be replaced periodically. The rotors, which the
brake pads press against to slow down the vehicle, may also need to be resurfaced
or replaced if they become warped or heavily worn. Callipers, which hold the brake
pads in place, can also experience issues such as leaking brake fluid or sticking
pistons. Brake fluid is essential for transferring the force from the brake pedal to
the brake pads, so it is crucial to ensure it is at the proper level and free of
contaminants.
Overall, regular brake inspections and maintenance are essential for safe driving
and the longevity of your car's braking system. It is recommended to have your
brakes checked at least once a year or as soon as you notice any unusual noises or
sensations while braking.
3.5.1 Braking System
Modern cars typically have brakes on all four wheels, operated by a hydraulic
system. The braking system can be either disc type or drum type. Front brakes play
a greater role in stopping the car because braking shifts the car’s weight forward
onto the front wheels. Many cars have disc brakes at the front and drum brakes at
the rear. Some high-performance cars use all-disc braking systems, while older or
smaller cars may have all-drum systems.
The braking system of a vehicle is crucial for ensuring safe and effective stopping
power. It consists of various components, including brake pads, rotors, callipers,
and brake fluid. When the driver presses the brake pedal, brake fluid is applied to
the callipers, which then squeeze the brake pads against the rotors, creating
Fig:3.28 Auto mobile Braking System
friction and slowing down the vehicle. This process converts kinetic energy into

heat energy, dissipating it through the brake system. Proper maintenance of the
braking system is essential to ensure optimal performance and safety. Regular
inspections, brake pad replacements, and brake fluid flushes are necessary to
prevent brake failure and accidents. Additionally, advancements in technology,
such as anti-lock braking systems (ABS) and electronic stability control (ESC),
have further improved the efficiency and safety of braking systems in modern
vehicles.
3.5.2 Hydraulic Brake Circuit
A hydraulic brake circuit consists of fluid-filled master and slave

cylinders connected by pipes. When you press the brake pedal, it depresses a piston
in the master cylinder, forcing fluid along the pipe. The fluid travels to slave
cylinders at each wheel, pushing out pistons to apply the brakes. The combined
surface area of all slave pistons is greater than that of the master cylinder piston,
allowing for powerful braking. Most modern cars have twin hydraulic circuits with
two master cylinders in tandem, in case one fails. Rear brakes are intentionally
made less powerful than front brakes to prevent dangerous skids during heavy
braking.
The hydraulic brake circuit of a car plays a crucial role in transmitting force from
the brake pedal to the brake pads. It consists of a master cylinder, brake lines, brake
hoses, and wheel cylinders or brake callipers. When the driver presses the brake
pedal, brake fluid is forced from the master cylinder through the brake lines to the
brake callipers or wheel cylinders. This creates hydraulic pressure, which then
applies the brake pads against the rotors, resulting in the vehicle slowing down or
stopping. The hydraulic system operates on the principle that an incompressible
fluid can transmit force through a closed system. Proper maintenance of the
hydraulic brake circuit is essential to ensure efficient braking performance. Any
leaks in the system or air bubbles can compromise the braking function and safety
of the vehicle. Regular checks and fluid changes are necessary to keep the hydraulic
brake circuit functioning properly.

Fig:3.29 Hydraulic Brake System
3.5.3 Signs of Worn-out Brakes
1. Squeaking or Grinding Noises:
If you hear high-pitched squeaking or grinding sounds when you apply the brakes,
it’s likely due to worn brake pads. Brake pads have a metal indicator that makes
noise when it contacts the rotor. This noise serves as a warning that the pads need
replacement.
2. Reduced Braking Performance:
If your car takes longer to stop or the pedal feels spongy, it could indicate worn-out
brake pads or a loss of brake fluid. Reduced braking performance is a safety concern
and should be addressed promptly.
3. Vibration or Pulsation:
A pulsating sensation in the brake pedal or steering wheel during braking suggests
unevenly worn brake rotors.
4. Warning Lights:
Modern cars have dashboard warning lights for various systems, including the
brakes. If the brake warning light illuminates, it’s essential to have your brakes
inspected.
5. Pulling to One Side:
If your car pulls to one side when braking, it could be due to uneven brake pad wear
or a sticking brake caliper. An alignment issue can also cause pulling, so it’s
essential to diagnose the problem accurately.
6. Visible Wear on Brake Pads:
Inspect your brake pads through the wheel spokes. If the pads appear thin (less than
3 mm), they need replacement.
3.5.4 Anti-Lock Braking System (ABS)
Anti-lock braking system (ABS) is a safety feature in vehicles that prevents the
wheels from locking up during sudden braking, allowing the driver to maintain
steering control. ABS works by modulating the brake pressure on individual wheels
to prevent skidding and improve stopping distance. The system works by using
sensors to monitor the speed of each wheel. If the system detects that a wheel is
about to lock up, it will reduce the brake pressure to that wheel until it regains
traction. This rapid cycling of brake pressure helps the driver to maintain control of
the vehicle, even in emergency braking situations.
ABS is particularly useful on wet or slippery roads where the risk of skidding is
higher. It can also help prevent accidents by allowing the driver to steer around
obstacles while braking. Overall, ABS is a crucial safety feature in modern vehicles
that has contributed to reducing accidents and improving road safety. Its
effectiveness has been proven through numerous studies and real-world crash data,
making it a standard feature in most new cars today.

Fig: 3.30 Anti-Lock Braking System
3.6 Scanner Tool
A car scanner tool, also known as an OBD-II scanner, is a diagnostic tool used to
communicate with a vehicle's on board computer system. It is typically plugged
into a port located under the dashboard of the car and can read and interpret the data
stored by the computer. Car scanner tools are essential for diagnosing and
troubleshooting issues with a vehicle, as they can identify problems such as engine
misfires, air-bag malfunctions, and faulty sensors. These tools can also read and
clear diagnostic trouble codes (DTCs), which are generated when a component of
the vehicle is not functioning properly. In addition, car scanner tools can provide
real-time data on a vehicle's performance, such as fuel efficiency and engine
temperature. Car scanner tools come in various shapes and sizes, with some
connecting to a smart phone or tablet for easy access to data. They are a must-have
for mechanics and car enthusiasts alike, as they can save time and money by
pinpointing issues quickly and accurately.
Fig: 3.31 Scanner Tool
3.6.1 On-Board Diagnostic (OBD-I) Scanner Tool
An OBD-I scanner tool, also known as an On-Board Diagnostic System I scanner

tool, is a diagnostic tool used to troubleshoot and identify issues with a car's engine
and other systems. OBD-I scanner tools were primarily used in vehicles
manufactured in the early 1980s to mid-1990s. These tools are equipped with a
connector that plugs into the vehicle's OBD-I port, typically located under the
dashboard or in the engine compartment. Once connected, the scanner tool
communicates with the car's onboard computer to retrieve diagnostic trouble codes
(DTCs) that indicate specific problems within the vehicle.
OBD-I scanner tools are capable of reading a wide range of DTCs, including issues
with the engine, transmission, emissions system, and other critical components.
This information is displayed on the scanner tool's screen, allowing the user to
quickly identify and address any problems present in the vehicle. While newer
vehicles now use OBD-II scanner tools, OBD-I scanner tools are still useful for
diagnosing issues in older cars that are equipped with OBD-I systems. These tools
can be a valuable asset for mechanics, car enthusiasts, and DIYers looking to
troubleshoot and maintain their vehicles.
Fig: 3.32 OBD-I Code Reader
3.6.2 On-Board Diagnostic (OBD-II) Scanner Tool
OBD-II, or On-Board Diagnostics II, is a standardized system implemented in all

cars and light trucks produced in the United States since 1996. Its main purpose is
to monitor the performance of the vehicle's engine and various other components,
including the emissions system. This system is vital for detecting and diagnosing
problems that may arise, helping mechanics and technicians quickly identify issues
and perform necessary repairs.

OBD-II systems use a series of sensors located throughout the vehicle to gather
data on various aspects of its operation. This data is then fed into the onboard
computer, which analyzes it and alerts the driver to any potential problems via a
dashboard warning light. The system also stores trouble codes that can be read by
a diagnostic tool, making it easier for technicians to pinpoint the source of the issue.
One of the key benefits of OBD-II is that it can help improve the overall efficiency
and performance of a vehicle by ensuring that its systems are functioning optimally.
It also plays a crucial role in reducing harmful emissions by monitoring the vehicle's
emissions control system. In addition, OBD-II compliance is a requirement for
passing emissions inspections in many states. Overall, OBD-II is an important tool
for both vehicle diagnostics and environmental protection, helping to ensure that
cars are running smoothly and cleanly for the benefit of both drivers and the
environment.
Fig: 3.33 OBD-II Scanner Tool
3.6.3 BlueDriver Bluetooth
Bluedriver Bluetooth OBD devices are a popular choice for car diagnostics and
maintenance. These devices use Bluetooth technology to connect to a mobile app
on your smartphone, allowing you to easily access and interpret diagnostic trouble
codes from your vehicle's onboard computer. One key feature of Bluedriver
devices is their compatibility with both Android and iOS operating systems, making
them versatile and convenient for a wide range of users. The device is also known

for its user-friendly interface and quick connection process, making it easy for even
beginners to use.
Bluedriver devices offer a wide range of capabilities, including reading and clearing
trouble codes, monitoring real-time engine data, and performing mode 6 and smog
check functions. This allows users to efficiently identify and address any issues
with their vehicle, potentially saving time and money on unnecessary repairs.
Overall, Bluedriver Bluetooth OBD devices are a reliable and efficient tool for car
owners and enthusiasts alike, providing valuable insights and data to help maintain
and improve the performance of their vehicles.
Fig: 3.34 Blue Driver
3.6.4 Autel Maxicom MK808
The Autel Maxicom MK808 is a diagnostic tool designed for automotive

professionals and enthusiasts. It is a versatile tool that can perform a wide range of
functions, including reading and clearing diagnostic trouble codes, performing
active tests, and providing live data streams. The MK808 is equipped with a 7-inch
touch screen display, making it easy to navigate through menus and select the
desired functions. It also has built-in Wi-Fi connectivity, allowing users to easily
download software updates and access online resources. One of the key features of
the Autel Maxicom MK808 is its extensive vehicle coverage, with the ability to
diagnose over 80 vehicle brands from Asia, Europe, and the United States. This
makes it a valuable tool for professionals working on a wide variety of vehicles.
Additionally, the MK808 is backed by Autel's excellent technical support and
software updates, ensuring that users have access to the latest features and functions.
Overall, the Autel Maxicom MK808 is a powerful and user-friendly diagnostic tool
that is suitable for both professionals and enthusiasts working on a wide range of
vehicles. Its extensive vehicle coverage, intuitive interface, and reliable support
make it a valuable addition to any workshop or garage.
Fig: 3.35 Autel Maxicom MK808
3.6.5 Kasmotion Scanner
The kasmotion scanner is a cutting-edge technology that offers advanced scanning

capabilities for various applications. It uses a combination of advanced sensors and
software to accurately capture detailed images and measurements of objects or
environments. This versatile scanner can be used in industries such as architecture,
construction, engineering, and more. The kasmotion scanner has the ability to
create highly detailed 3D models and maps, allowing for precise measurements and
analysis. It can capture both still images and videos, providing a comprehensive
view of the scanned area. The scanner is lightweight and portable, making it easy
to transport and use in different locations. Overall, the kasmotion scanner is a
powerful tool that can revolutionize the way we capture and analyze information in
various fields. Its advanced features and capabilities make it a valuable asset for
professionals seeking accurate and detailed scans for their projects.

Fig: 3.36 Kasmotion Scanner
3.6.6 Actron CP9690
The Actron CP9690 is a state-of-the-art automotive diagnostic scanner that

provides advanced features and functionalities for professionals and DIY
enthusiasts. This versatile tool offers a wide range of capabilities, including reading
and clearing trouble codes, live data monitoring, and vehicle health status checks.
One of the key features of the Actron CP9690 is its compatibility with a wide range
of vehicle makes and models, allowing users to diagnose and fix issues with various
vehicles. The scanner also comes with a large, easy-to-read display screen that
provides clear and detailed information about the vehicle's health and performance.
Moreover, the Actron CP9690 offers advanced functionalities such as battery
voltage monitoring, ABS and airbag system diagnostics, and OBD-II readiness
testing. These features make it a comprehensive diagnostic tool that can help users
identify and address a wide range of vehicle issues.
Additionally, the Actron CP9690 is equipped with a user-friendly interface that

makes navigation and operation easy for users of all skill levels. The scanner also
comes with a built-in code library that provides definitions for diagnostic trouble
codes, helping users quickly identify the root cause of any issues. In conclusion,
the Actron CP9690 is a powerful and reliable diagnostic scanner that offers
advanced features and functionalities for diagnosing and fixing vehicle issues. Its
compatibility, user-friendly interface, and comprehensive diagnostic capabilities
make it a valuable tool for automotive professionals and enthusiasts alike.
Fig: 3.37 Actron CP9690
3.6.7 Motopower MP69033
The Motopower MP69033 is a versatile and reliable battery charger and maintainer
designed for various types of lead-acid batteries, including AGM, Gel, and flooded
batteries. It offers multiple charging modes to accommodate different battery sizes
and conditions, making it a great choice for automotive, marine, motorcycle, and
power sport applications. One of the key features of the Motopower MP69033 is
its microprocessor-controlled technology, which ensures precise charging and
maintenance of the battery without overcharging or damaging it. The charger also
comes with built-in safety features such as reverse polarity protection, spark-proof
technology, and overcharge protection to ensure safe and efficient charging.
Moreover, the Motopower MP69033 features a compact and portable design,
making it easy to use and transport. The charger also comes with a digital display
that provides real-time information on the charging status, battery voltage, and
charging current, allowing users to monitor the charging process easily.
Overall, the Motopower MP69033 is a high-quality and user-friendly battery

charger and maintainer that offers reliable performance and safety features for

various battery types and applications. Its versatility, compact design, and advanced
technology make it a great choice for maintaining the health and longevity of your
batteries.
Fig: 3.38 Motopower MP69033

Conclusion
In the final year of industrial training, I had the chance to learn more about the
captivating world of automotive tools, their different kinds, parts and working.
I have gained academic information and practical skills from this experience that will
surely be extremely useful in my future profession. It has been both educational and
transforming. Car tools and operations, which are essential to many car sectors, were
the main emphasis of my training.
I obtained knowledge about a variety of automotive equipment and procedures, such

as wheel alignment and balancing, break repair systems, and car tuning, each with
distinctive merits and uses.
Additionally, I learned about the several kinds of scanner tools, such as OBD-I and
OBD-II, and their subtypes that are most frequently employed in the automotive
industry.
One of the most beneficial aspects of my training was learning how to use advanced
automotive tools like On-Board Diagnostics (OBD) devices. These devices have
come a long way in the last few years, and they can now track driving habits and
vehicle maintenance schedules in a addition to providing real time vehicle data,
diagnostic trouble codes and fuel efficiency information. OBD devices are becoming
indispensable tools for car owners and mechanics to monitor and maintain vehicle
health.
Wheel alignment and wheel balancing are crucial components of car tuning that
guarantee a vehicle operates at its best and is safe. Wheel alignment is the process of
changing the wheel angles so that they are parallel to one another and perpendicular
to the ground. This keeps the tires from wearing unevenly and guarantees straight
driving. Wheel balancing is a technique used to guarantee a smooth ride by balancing
the weight of the tires and wheels. Both procedures can enhance gas efficiency and
the overall driving experience. They are necessary for regular car maintenance. My
comprehension of these procedures has provided me with a thorough grasp of the
upkeep and functioning of automobiles. The significance of safety precautions when
operating a vehicle was also stressed throughout my training.

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INDUSTRIAL TRAINING REPORT 20-MCT-28

Industrial Training Report

DEPARTMENT OF MECHANICAL ENGINEERING

NFC INSTITUTE OF ENGINEERING AND FERTILIZER

NFC IFER MECHANICAL ENGINEERING DEPARTMENT 1

B.Sc. Mechanical Engineering Technology

INDUSTRIAL TRAINING REPORT

NFC IFER MECHANICAL ENGINEERING DEPARTMENT 2

Industrial Training Report

NFC IFER MECHANICAL ENGINEERING DEPARTMENT 3

This report is submitted to the faculty of the Department of

DEPARTMENT OF MECHANICAL ENGINEERING

NFC IFER MECHANICAL ENGINEERING DEPARTMENT 4

NFC IFER MECHANICAL ENGINEERING DEPARTMENT 5

I have no opposite words to manifest my feelings of respect, gratefulness, and

NFC IFER MECHANICAL ENGINEERING DEPARTMENT 6

NFC IFER MECHANICAL ENGINEERING DEPARTMENT 7

Industrial Training Report ..................................................................................................................... 3

Chapter 1: Introduction ....................................................................................................................... 11

1. Place of Internship: ............................................................................................. 12

3. Importance of the Internship: .............................................................................. 12

4. Value of Automobile Industry: ........................................................................... 12

6. Working Experience in the Organization: ........................................................... 13

7. Policy of the organization: ................................................................................. 13

Chapter 2: Company Information .................................................................................. 14

Chapter 3: Training Work ................................................................................................ 17

3.1. Car Tuning Techniques .................................................................................................................. 18

3.1.1. ECU Remapping/Chip Tuning ................................................................................... 18

3.1.2. Installation of an aftermarket air intake ...................................................................... 18

3.1.3. Upgrading to an aftermarket exhaust system ............................................................. 20

3.1.4. Turbocharging/Supercharging .................................................................................... 20

3.1.5. Upgrading the Suspension .......................................................................................... 21

3.1.6. Upgrading the Breaks ................................................................................................. 22

3.1.7. Lightweight wheel and tire upgrades ......................................................................... 23

3.1.8. Installing limited slip differentials .............................................................................. 25

3.1.9. Upgrading to a high-performance clutch and flywheel .............................................. 26

3.2. Car Tuning Tools ............................................................................................................................ 27

3.2.1. Performance Guage .................................................................................................... 28

NFC IFER MECHANICAL ENGINEERING DEPARTMENT 8

3.2.3. Diagnostic Scanner ..................................................................................................... 30

3.2.4. Dynamometers ............................................................................................................ 30

3.2.5. Torque Wrenches........................................................................................................ 30

3.2.6. Socket Set and Pliers .................................................................................................. 31

3.2.7. Screwdrivers and Spanners......................................................................................... 31

3.2.8. Pulley Removal Tool .................................................................................................. 32

3.2.9. Oil Filter Wrenches .................................................................................................... 32

3.3 Wheel Alignment...............................................................................................................................34

3.3.1 Stability and Handling...................................................................................................34

3.3.2 Tire Wear.......................................................................................................................35

3.3.3 Main aspects of Wheel Alignment................................................................................36

3.3.4 Benefits of Wheel Alignment........................................................................................38

3.3.5 Tools used in Wheel Alinment......................................................................................39

3.3.6 Importance of Wheel Alignment...................................................................................41

3.4 Wheel Balancing................................................................................................................................42

3.4.1 Wheel Maintenance......................................................................................................42

3.4.2 Signs of Ubalanced Wheel...........................................................................................43

3.4.3 How to balance the Wheels..........................................................................................44