Presented by:
P.UDAY KIRAN
P.MAHESH BABU
K.CHALAMAIAH
S.V.SRINIVASA REDDY
B.MADHU BABU

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ABSTRACT
Engine is one of the most important and costliest part/system of a vehicle, which acts like a heart of the human being, so, we have to keep it in always good condition.
It consumes around 55% of operating cost of the vehicle, due to which we have to concentrate more on it to reduce the operating cost and to improve the efficiency.
The following main systems of the engine are to be taken care of for optimum performance and long life of the engine.
1. Air intake system.
2. Cooling system.
3. Lubrication system.
4. Fuel injection system.
In order to observe the above systems, we have done a mini project on
“Assembly and disassembly of TATA 497d 6-cylinder engine and it’s systems” at ‘TATA MOTORS’ in Ongole.
This includes:
 Procedure for checking & replacement of air filters, proper maintenance of the turbo charger, proper care of inter cooler etc., of the air intake system.
 Do’s and don’ts and precautions of cooling system.
 Procedures for the change of oils and oil filters along with do’s and don’ts of engine lubrication system.
 Fuel injection system with the replacing procedure of fuel filters and do’s and don’ts of fuel system.
 Important assembly procedure like cylinder head tightening process, taper adjustment, fuel injection pump installation procedure and timing etc.,
 Trouble shooting of various parts of engine along with “Check lists” which are to be carried out for best performance of engine.
AIR INTAKE SYSTEM
The system consists of Air filter, turbocharger, intercooler and connecting
pipe lines.
AIRFILTER  TURBOCHARGER INTERCOOLERINTAKE MANIFOLD
Dry type air filter :
Requirement of dry type air filter in the system:
As the turbocharger shaft is rotating at a speed more than 1 lakh
rpm, he air entering the air compressor of turbocharger should
be very clean, lest the compressor blades will get damaged.
Dry type air filter efficiency is upto 99.99%
For checking the the condition of air filter cartridge Service
indicator is provided.
Effect of air filter cartridge chocking :
• Poor pick up.
• Higher fuel consumption.
• Higher engine oil consumption due to engine oil is getting sucked from the turbocharger oil chamber by turbocharger compressor and thrown into air intake of the engine.
PURPOSE OF SERVICE INDICATOR :
Service indicator is provided on air filter to indicate the blockage in the air filter. There is a red band can be seen from the transparent side of the indicator when blockage takes place.
When th red band is seen in service indicator, reset the service indicator by pressing down the black cap. Start the engine and if the red band is seen again then replace the primary cartridge.
Procedure foe checking & replacement air filter cartridge:
 Primary cartridge should be removed for replacing only red band appears on the vaccum indicator. There is no schedule for replacing the filter cartridge. If red band appears on service indicator, replace the primary cartridge. THE SECONDARY CARTRIDGE SHOULD NEBER BE CLEANED BUT ONLY REPLACED AT RECOMMENDED INTERVALS (After every 3 replacements of the primary cartridge ).
PRECAUTIONS :
Never remove the secondary cartridge , as it is the last barrier for the dust. It is to be removed only at the time of replacement.
TURBOCHARGER
A turbocharger is a gas compressor that is used for forced-induction of an internal combustion engine. The purpose of the turbocharger is to increase the density of air entering the engine to create more power