IM
THIS REPORT IS SUBMITTED TO THE FACULTY OF MECHANICAL ENGINEERING IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE AWARD OF DIPLOMA IN MECHANICAL ENGINEERING ( AUTOMOTIVE ) FROM MARA UNIVERSITY OF TECHNOLOGY, SHAH ALAM.
Students :
AZLAN BIN ABD GHANI ( UiTM NO. 98079846 )
Signature • J »v<«•••••••*••••••*»««••»
n . ^ l 5 t o J i V
Date :... .. 2001.
ZUREAN AZUAN BIN ZULKIFLI ( UiTM NO. 98080708 )
S t a t u r e ...
Date ... , 2001.
ISMANIZIKRI BIN ISMAIL ( UiTM NO. 98157468 )
Signature:.
i w 15 1nni
Date :... .. 2001.
Approved by :... Date :... .. 2001.
EN. ZAINAL ABIDIN B. KAMARUL BAHARIN (Project Advisor)
Lecturer,
Diploma In Mechanical Engineering ( Automotive) MARA UNIVERSITY OF TECHNOLOGY
Content
CONTENT ___________________________________PAGE
BIODATA iv
APPRECIATION vii
TOPIC
1.0: INTRODUCTION
1.1 : Objective And Aim Of Project 1
1.2 : Introduction To AUDI - 100 2
1.3 : Case Study 5
1.4 : What Is An Engine Overhauling 8
1.5 : Executive Summary 11
2.0 : WORKSHOP SAFETY AND TOOLS
2.1 : Safety While Working 12
2.2 : Hand Tools And Power Tools 13
2.3 : Battery Boosting 14
2.4 : Mechanical Measuring Tools 18
3 .0: STARTER MOTOR
3.1 : Specification 19
3.2 : Starter Motor Trouble Diagnose 20
3.3 : Removal And Refitting Procedures 21
3.4 : Starter Motor Test 23
3.5 : Faulty Diagnosis 26
4 .0: COMPRESSION TEST
4.1 : Theory O f The Compression Test 27
4.2 : Compression Test On AUDI - 100 Engine 32
4.2.1 : Compression Test Result Versus Specification 37
4.2.2 : Logical Explanation 39
4.3 : Compression Test On PROTON Engine 41 4.3.1 : Compression Test Result Versus Specification 42
4.3.2 : Logical Explanation 44
5.0 : MEASUREMENT
5.1 : Theory O f Measurement 45
5.2 : Measuring Cylinder Bore And Stroke 48
5.3 . Result Versus Specification 50
5.4 : Logical Explanation 52
6.0 : ENGINE OVERHAULING
6.1 : Removal Work 54
6.2 : Cleaning Work 78
6.3 : Reassemble Work 86
6.4 : Result Of Engine Overhauling 103
7.0 : RECOMMENDATION
7.1: Comment 105
7.2 : Suggestion 107
8.0: CONCLUSION 109
APPENDIX REFERENCE
Introduction
1.2 INTRODUCTION TO AUDI - 100
The Audi - 100 was announced in October 1982 with the Audi - 200 versions becoming available in early 1984. All models features startling new advances in automotive design and technology in its era, foremost among these being the excessive attention to aerodynamics shape with a drag coefficient (Cd) of 0.30 for the Audi - 100, these cars are of a design, which is amongst the most aerodynamically efficient in their class ( See Figure 1 . 2 ( a ) )
In addition to aerodynamic excellence, all model offer a comprehensive package of standard and optional equipment features. Full instrumentation is provided, together with electric windows, central locking, on - board computer, extensive audio system and power steering. United Kingdom ( UK ) models are available with carburetor fuel injection or fuel injection with turbocharger engine. North America models are available with fuel injection or fuel injection with turbocharger engine. ( Also see Figure 1.2 ( b ) and 1.2 ( c ) )
Figure 1 . 2 ( a ) : AUDI - 100 CD : United Kingdom ( UK )
2
