MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
WINTER – 2024 EXAMINATION
Model Answer – Only for the Use of RAC Assessors
Subject Name: AUTOMOBILE ENGINEERING Subject Code: 22656
Important Instructions to examiners:
1) The answers should be examined by key words and not as word-to-word as given in the model answer
scheme.
2) The model answer and the answer written by candidate may vary but the examiner may try to assess the
understanding level of the candidate.
3) The language errors such as grammatical, spelling errors should not be given more Importance (Not applicable
for subject English and Communication Skills.
4) While assessing figures, examiner may give credit for principal components indicated in the figure. The figures
drawn by candidate and model answer may vary. The examiner may give credit for any equivalent figure
drawn.
5) Credits may be given step wise for numerical problems. In some cases, the assumed constant values may vary
and there may be some difference in the candidate’s answers and model answer.
6) In case of some questions credit may be given by judgement on part of examiner of relevant answer based on
candidate’s understanding.
7) For programming language papers, credit may be given to any other program based on equivalent concept.
8) As per the policy decision of Maharashtra State Government, teaching in English/Marathi and Bilingual (English
+ Marathi) medium is introduced at first year of AICTE diploma Programme from academic year 2021-2022.
Hence if the students write answers in Marathi or bilingual language (English +Marathi), the Examiner shall
consider the same and assess the answer based on matching of concepts with model answer.

WINTER– 2024 EXAMINATION

Model Answer – Only for the Use of RAC Assessors
Subject Name: AUTOMOBILE ENGINEERING Subject Code: 22656
Q. Sub Answer Markin
No Q. g
N. Scheme

1 Attempt any FIVE of the following(2X5=10) 10M

a) Compare front engine front wheel drive (FEFWD) with front engine rear wheel drive 2M
(FERWD) (Any Four Points).

Answer:(Any Four Points)

S.N. Front Engine Front Wheel Drive Front Engine Rear Wheel Drive
1 Engine is mounted in front of Engine is mounted at the front and the power Any
the front axle, and the drive is is transmitted from the engine to the four
also given to the front axle for Differential, rear axle via the propeller shaft. Points,
driving the front wheels.
1/2
2 More weight distribution at Balanced (Even) weight distribution
forward. Marks
3 No need for a Propeller shaft Need of Propeller shaft for power flow. for

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
for power flow. each)
4 No speed limitations due to the Speed limitations due to whirling of the
absence propeller
of a propeller shaft. shaft.
5 Increased interior space. Decreased interior space.
6 Lower center of gravity. Higher center of gravity.
7 Ground clearance is less. Ground clearance is more.
8 Improved fuel efficiency due Less fuel efficient compared to Front Engine
to less weight. Front Wheel Drive.
9 Lower initial cost. Higher initial cost.
b) State the function of Gearbox in Automobile 2M

Answer:
Function of Gear Box-
1. Torque produced by the engine varies with speed only within narrow limits. But under Any two
practical condition automobile demands a large variation of torque available at the wheels. Functio
2. Transmission provides a means to vary the torque ratio between engine and road wheels as ns,
required.
3. For Neutral position. 1 Marks
4. Reversing the direction of rotation of the drive for
each)

c) Enlist requirement of brake 2M

Answer: Any two

1. To stop or slow down the vehicle in the shortest possible distance in emergencies. require
2. It is used to control the vehicle while descending along the hill. ments,
3. Easy to operate
4. Good directional stability during braking.
1 Marks
for
5. The brakes must have good Anti fade characteristics
each)

d) State the different types of Rims 2M

Answer: Any
Types of Rims: - four
1. Drop Centre rim types ,
2. Flat Based rim
3. Wide Base Rim 1/2
4. Semi-drop center rim Marks
5. Divided Wheel for
6. One piece rim each)
7. Two piece rim
8. Cast Rims
9. Forged Rims
10. Aluminum Alloy Rims
11. Steel Rims

e) State the function of Sensor in Automobile 2M

Answer: Function of Sensor

1. Automotive sensors are essential to the smooth operation of modern automobiles.
2. These sensors provide information about numerous vehicle parameters to the Any
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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
Electronic Control Unit (ECU) so that safety, efficiency, and performance are two,
maximized.
3. They do this by translating physical quantities into electrical impulses. 1 Marks
for each

f) Define i) Public Service Vehicle ii) Transport Vehicle 2M

Answer:
i) Public Service Vehicle: - A Public Service Vehicle (PSV) is a vehicle that is used to
transport passengers for hire or reward, typically as part of a public transportation system.
ii) Transport Vehicle:- A Transport Vehicle is any type of vehicle used for the movement or
transportation of goods, passengers, or both from one location to another. Transport (1
vehicles can vary widely depending on their purpose, size, design, and the type of cargo or Marks
passengers they are intended to carry. for
(1 Marks for each) each)

g) State working principle of Clutch 2M

Answer: Working principle of automobile clutch It works on the principle of friction. It connects the
engine shaft and gear box shaft. The transmission of power can be affected by friction between two or
more, rotating concentric surfaces, called as friction plate. The friction plates can be pressed firmly (2M for
against one another by means of axial force provided by spring and pressure plate. When it engaged, appropri
ate
the clutch tends to rotate as a single unit. The rotating speed of the concentric surface or other shaft is
principle
depends upon the friction force which is proportional to axial force applied by spring.
statemen
t)

2 Attempt any THREE of the following(4X3=12) 12

a) Differentiate between Frame and Frameless vehicle 4M

Answer:(Any Four Points).

Sr. Feature Frame Vehicle Frame less Construction
Separate body and frame Body and frame are integrated
1 Structure
(chassis). into one piece. Any
Lighter since it uses a single unit four
2 Weight Heavier due to separate frame.
construction. Points,
Stronger and more durable, Less durable in extreme
3 Durability especially for off-road and conditions, more suited for on- (1 M
heavy-duty use. road use.
Smoother ride due to integrated for
Rougher ride, as the frame point
4 Ride Comfort structure and better shock
doesn’t absorb shock as well. each)
absorption.
Repairs can be more complex
Easier to repair individual
5 Reparability since body and frame are
components (body or frame).
combined.
Generally more expensive to Generally less expensive to
6 Cost
build. manufacture.
Towing/Hauli Higher towing and hauling Lower towing and hauling
7
ng Capacity capacity. capacity.
8 Safety Typically equipped with fewer Modern unibody vehicles are
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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
safety features due to older often equipped with advanced
design. crumple zones and safety
systems.
Trucks, SUVs (older models), Most modern cars, crossovers,
9 Examples
commercial vehicles and sports cars.

b) List various parts of the synchromesh gear box with the role of each component. 4M
Answer:(Any Four Points).
Sr.No Name of Component Role/Function of Component
. Any 4
1 Clutch (Engine Shaft) Connected to the flywheel as the input Point
shaft. s
2 Gears on Main (Splined) Shaft Gears on the main shafts are free and
always in mesh with corresponding gears ( 1/2
on the countershaft. Mark
3 Free Members Free members are free to slide on s for
Name
splines on the main shaft.
of
4 Ring Shaped Member Ring-shaped members having internal teeth
comp
fit onto the external teeth members. onent
5 Dog Teeth on Gear B & Gear D Dog teeth fit onto the teeth of ring-shaped s&
members. 1/2
6 Forks Used to select appropriate gear as per Mark
requirement. s for
7 Spring Loaded Balls Tend to prevent the sliding of ring-shaped Role
members on free members. /Func
8 Frictional Surfaces Frictional surfaces are slightly attached and tions)
meshed with the respective conical faces of
gears after synchronizing the speed as per
gear requirement.
9 Gears on Counter Shaft Always fixed on the countershaft and
meshed with the gears on the main shaft.
10 Reverse Gear on Reverse Shaft To make reverse position arrangement.

c) Explain working of Pneumatic Braking system with neat sketch 4M

Answer:(Description -2 M, Neat Sketch-2 M)

Compressor takes air from the atmosphere to the filter and the compressed air is sent to the reservoir
through the unloaded valve, which gets lifted at a predetermined reservoir pressure Descript
(900KPa) & relieves the compressor of load. From the reservoir, the air goes to various ion
accessories & also to the brake chambers located at each wheel. The control of brake valve is 2
with a driver who can control the intensity of braking according to the requirements. When Marks,
pressure drops to 700 KPa, the governor again cuts in the compressor to raise system pressure.
When air system pressure falls to 400 KPa, a warning in the form of a buzzer is sounded.

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________

Sketch-2
Marks

d) Describe wishbones type suspension system with neat sketch. 4M

Answer:(Description -2 M, Neat Sketch-2 M)

1) A wishbone suspension system, also known as a double-wishbone suspension Descript
2) It a type of independent suspension system commonly used in modern vehicles. ion
3) It consists of two parallel wishbone-shaped arms, one upper and one lower, that are 2 Marks
mounted to the chassis of the vehicle.
4) These arms are connected to the wheel hub assembly and allow for independent movement
of each wheel.
5) Wishbone suspension systems are known for providing excellent handling, stability, and
ride comfort, making them popular in high-performance and luxury vehicles.

Sketch-2
Marks

3 Attempt any THREE of the following(4X3=12) 12M

a) State any four advantages and disadvantages of electric vehicle. 4M

Answer:- (Any other appropriate Explanation Equivalent credit shall be given.)
Advantages of Electric Vehicles (EVs):
A) Environmental Benefits:
1.Lower Emissions: EVs produce zero tailpipe emissions, reducing air pollution and

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
greenhouse gas emissions compared to conventional internal combustion engine (ICE)
vehicles.
Advanta
2.Cleaner Energy: When charged using renewable energy sources (like solar or wind), EVs ges-2
can significantly reduce the carbon footprint of transportation. Mark
B) Reduced Operating Costs:
1.Lower Fuel Costs: Charging an EV is typically much cheaper than refueling a gasoline or (any 4
advanta
diesel vehicle. Electricity costs are generally lower, and some home charging options are even
ges )
cheaper.
2.Less Maintenance: EVs have fewer moving parts than traditional vehicles, leading to lower
maintenance costs. There's no need for oil changes, and brake systems often last longer due to
regenerative braking.
C) Quiet Operation:
Reduced Noise Pollution: EVs operate more quietly than their ICE counterparts, contributing
to lower noise pollution in urban areas and providing a more pleasant driving experience.
D)Government Incentives:
Tax Credits and Subsidies: Many governments offer incentives, such as tax credits, rebates,
or reduced registration fees, to encourage the adoption of electric vehicles, making them more
affordable.

Disadvantages of Electric Vehicles (EVs):

A) Limited Driving Range:

Range Anxiety: Although EVs' ranges have been increasing, they are still typically lower than
those of gasoline-powered cars. Long-distance travel can be a challenge, especially in areas
with limited charging infrastructure.
Disadva
B) Charging Infrastructure:
ntages -
Limited Charging Stations: While charging networks are growing, they are not as 2 Marks
widespread or as accessible as gas stations. Long charging times also make EVs less
convenient for long trips or in areas with sparse charging options. (any 4
C) Higher Upfront Cost: disadva
Initial Purchase Price: EVs are often more expensive to purchase than traditional vehicles, ntages )
mainly due to the high cost of the battery. While this cost is decreasing, it can still be a barrier
for some consumers.
D) Battery Life and Disposal:
1.Battery Degradation: Over time, EV batteries can degrade, leading to reduced driving
range and performance. Replacing an EV battery can be costly.
2.Environmental Impact of Battery Disposal: Disposal and recycling of EV batteries pose
environmental challenges due to the materials used in them, such as lithium and cobalt, which
need proper handling to avoid contamination.

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
b) Explain working of rack & pinion type gearbox with neat sketch. 4M

Answer:(Explanation 2 marks, Sketch-2 marks)

Sketch-2
Marks

Fig:- Rack and Pinion type gearbox

Rack and Pinion type of steering gear box: The rotary motion of the steering wheel is Explanat
transmitted to the pinion of the steering gear through the universal joints. The pinion is in ion -
mesh with rack. The circular motion of the pinion is transferred to the rack and rack moves
linearly and this linear movement of rack is transmitted to the stub axle and wheel gets 2 Marks
steered. The rack has ball joints at each end to allow for rise and fall of the wheels.

c) Sketch telescopic shock absorber and label main parts. 4M

Answer:

Sketch 03
Marks
and
proper
labeling
01 Mark

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
d) Explain working of starting system of a vehicle with neat sketch 4M

Answer:

Neat
Sketch-2
Marks
Figure Starting System

Working of Vehicle Starting System:

The starting or cranking system consists of a starting motor, battery, control switch,
and interconnecting wiring. The starting system is the heart of the electrical system in
automobiles. The key is inserted into the ignition switch and turned to the start position a
small number of current passes through the neutral safety switch to the starter relay or starter Working
solenoid. The Starter solenoid allows a high current to flow - 2Marks
Through the battery cable to the starter motor. The starter motor cranks the engine so
that the piston moving downward, can create suction that draws the air-fuel mixture into the
cylinder.

4 Attempt any THREE of the following(4X3=12)s 12M

a) Explain importance of aerodynamic shape of car body. 4M

Answer: (Any 4 Points – 1 Marks each)

1. Fuel Efficiency and Reduced Energy Consumption
Reduced Drag Force: An aerodynamic shape minimizes air resistance (drag) as the
vehicle moves, allowing it to travel more smoothly through the air. This reduction in drag
Any
helps the car conserve fuel, as the engine doesn't need to work as hard to overcome the
four
resistance, especially at higher speeds.
Points,
Fuel Economy: A well-designed aerodynamic body contributes to better fuel
efficiency, reducing the car’s overall energy consumption and lowering emissions. (1
2. Improved Stability and Handling Marks
Downforce: An aerodynamically shaped car can generate downforce, which is the for
force that pushes the car downward, increasing tire grip on the road. This helps improve each)
traction, especially at high speeds or during cornering, making the car more stable and
responsive.
Better Control: The reduction of turbulent air around the car also reduces the
likelihood of instability, especially during crosswinds, helping the driver maintain better
control of the vehicle.

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
3. Higher Speed and Performance
Reduced Drag and Increased Speed: Cars designed with aerodynamics in mind can
reach higher speeds more efficiently. The smoother airflow minimizes drag, allowing the car
to accelerate and travel faster with less effort.
Sporty and Racing Cars: In high-performance or racing cars, aerodynamics is crucial
for maximum performance. These vehicles use specific aerodynamic shapes, such as spoilers
and diffusers, to enhance their speed and handling at extreme velocities.
4. Noise Reduction
A more aerodynamic design can reduce the amount of wind noise generated at higher
speeds. This results in a quieter, more comfortable driving experience, particularly on
highways.
5. Temperature Control and Cooling
Engine Cooling: A well-designed body shape allows for proper airflow to cool the
engine, brakes, and other components, preventing overheating during operation.
Reduced Drag from Cooling Openings: Aerodynamic cars often have strategically
placed air vents and intakes that help cool the vehicle without creating excessive drag.
6. Safety in High-Speed Conditions
Reduced Risk of Lift: At high speeds, cars with poor aerodynamics may experience
unwanted lift or reduced contact with the road. Aerodynamic designs help reduce this risk,
making the car more stable at high speeds and improving overall safety.
7. Environmental Impact
As aerodynamic vehicles consume less fuel, they contribute to lower carbon emissions
and less pollution. This is increasingly important in the context of global efforts to reduce the
environmental impact of transportation.
8. Aesthetic Appeal
Modern Design: Aerodynamics often intersects with aesthetic considerations. Sleek,
flowing lines that reduce drag can also make the car look more modern, sporty, and attractive
to consumers.

b) Explain construction and working of Bendix drive 4M

Answer:
Construction: - Main Components of Bendix drive are
1) Drive shaft
2) Spring
3) Pinion gear
4) Threaded sleeve
5) Coller
Working of Bendix Drive: - Construct
Bendix drive is an inertia based drive in which the pinion on the starter motor armature ion and
engages and disengages with the flywheel depending on the inertia of motor and flywheel. Working
– 2 Marks
When the ignition switch is turned „ON‟, the starter motor armature starts spinning. This
causes the sleeve to rotate while the pinion is stationary due to the unbalanced weight. The
pinion hence moves axially towards the collar until it engages with the flywheel ring gear.
Since the pinion cannot move further axially, it starts to rotate along with the sleeve thereby
also rotating the flywheel. When the flywheel starts rotating at above 100 rpm the engine gets
starts. After the engine has started the pinion gear is turned by the engine much faster than
rotated by starting motor. This causes, the pinion gear to turn back on the threaded sleeve,
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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
making it disengage with the flywheel.

Diagram-
2 Marks

(Note: Equivalent credit shall be given to any other suitable sketch if drawn)

c) Describe role and responsibility of service supervisor in service station 4M

Answer:-
A Service Supervisor in a service station plays a vital role in overseeing the daily operations,
ensuring customer satisfaction, and maintaining high standards of service. Here are the
primary roles and responsibilities of a Service Supervisor:
Any
1. Managing Day-to-Day Operations
four
a) Overseeing Service Activities: The service supervisor ensures that all service activities,
Points,
such as vehicle repairs, maintenance, and inspections, are carried out efficiently and meet
quality standards. (1
b) Work Scheduling: They create and manage daily work schedules for technicians, service Marks
staff, and other team members to ensure that service demands are met in a timely manner. for
each)
c) Resource Allocation: The supervisor ensures the proper allocation of tools, equipment, and
materials required for various services. They also ensure the maintenance and upkeep of all
equipment.
2. Team Supervision and Training
a) Staff Supervision: They are responsible for managing a team of technicians, mechanics,
service advisors, and other support staff, providing guidance, direction and ensuring smooth
workflow.
b) Training and Development: The service supervisor is responsible for providing on-the-job
training for new employees, as well as conducting regular skill development sessions for the
team to enhance their technical knowledge and service quality.
c) Performance Monitoring: They monitor the performance of service staff, ensuring that
standards are met in terms of productivity, efficiency, and customer service. They provide
feedback and corrective actions when necessary.
3. Customer Service and Satisfaction
a) Customer Interaction: The supervisor often acts as the point of contact for customers in
the service station, addressing any concerns or complaints promptly and professionally to
maintain high customer satisfaction.
b) Quality Control: They ensure that all services provided meet or exceed customer
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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
expectations in terms of quality and timeliness. This involves checking the work done by
technicians and ensuring that it complies with company standards.
c) Handling Difficult Situations: When issues arise, such as delays or customer
dissatisfaction, the service supervisor steps in to resolve the situation by communicating with
the customer and providing solutions.
4. Inventory Management
a) Parts and Supplies Management: The supervisor is responsible for maintaining an
inventory of parts and tools required for the service operations. They track usage and order
new parts when necessary, ensuring the service station is well-stocked to avoid delays.
b) Inventory Control: They also ensure that parts and equipment are properly stored and
organized, minimizing the risk of damage, loss, or theft.
5. Ensuring Health and Safety Standards
a) Safety Compliance: The supervisor ensures that the service station adheres to all safety
regulations and guidelines. They are responsible for maintaining a safe working environment
for both employees and customers by enforcing safety protocols, such as the proper use of
tools, handling hazardous materials, and maintaining a clean work area.
b) Training in Safety: They regularly conduct safety training sessions to ensure staff are
aware of safety procedures and accident prevention techniques.
6. Budgeting and Cost Control
a) Budget Management: The service supervisor may be involved in managing the service
department's budget, ensuring that costs are controlled and resources are used efficiently.
b) Cost Tracking and Reporting: They are responsible for tracking the cost of services,
parts, and labor, ensuring that service operations remain within the budgetary limits set by the
station or company.
7. Quality Assurance and Performance Tracking
a) Monitoring Service Quality: The supervisor conducts regular checks on the quality of
services being provided to ensure that repairs and maintenance are performed to the highest
standards.
b) Feedback Collection: They may also collect feedback from customers regarding their
experiences, using this information to improve service processes and employee performance.
c) Reports and Documentation: The supervisor is responsible for maintaining detailed
records of services performed, parts used, and any other relevant documentation for both
customers and management.
8. Handling Administrative Tasks
a) Reporting to Management: The supervisor reports to higher management regarding daily
operations, challenges, and customer satisfaction levels. They may also present performance
metrics and suggest improvements.
b) Documentation and Record Keeping: Ensuring that all work orders, invoices, and
customer records are accurately maintained is also a key responsibility. This includes ensuring
compliance with any legal or industry regulations.
9. Conflict Resolution
a) Employee Conflict Resolution: The service supervisor handles conflict within the service
team, ensuring that staff can work harmoniously to deliver quality service.
b) Customer Complaints: They also address customer complaints, resolving any issues

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
related to service delays, quality of work, or other concerns, ensuring customer retention and
satisfaction.
10. Marketing and Promotions
a) Promoting Services: The supervisor may assist in promoting the service station’s
offerings, such as special discounts, seasonal offers, or new services, to attract more
customers.
b) Ensuring Brand Consistency: They ensure that all employees are upholding the service
station’s brand image and values while interacting with customers.
(Enlisting at list 8 points or in details 4 Points)
Or other suitable points related to this may considered
d) Enlist any four gauges and sensors with their function
Answer:-Gauges with their Functions:
[1] Fuel Gauge: To indicate the level of fuel in the fuel tank. Any four
gauges
[2] Water temperature Gauge: To indicate the temperature of engine cooling water. with their
function,
[3] Oil Pressure Gauge: To indicate the oil pressure in the engine. 1/2
Marks
[4] Speedometer: Use to measure the speed of the automobile vehicle. each,
[5] Tachometer: Use to Measure the RPM of the Engine.
Sensors with their Functions:
[1] Mass airflow Sensor: Use to calculate the air density in the engine. Any four
Sensors
[2] Engine Speed Sensor: Use to monitor the crankshaft rotation speed. with their
function,
[3] Oxygen Sensor: Use to monitor the content of exhaust gases. 1/2Marks
each
[4] Coolant Sensor: Use to check temp. of coolant.
[5] Voltage Sensor: Use to manage the car idling speed.
Note: Equivalent credit shall be given to any other appropriate Gauges & Sensors
enlisted.
e) State the factors considered for site selection to set up your own garage. 4M

When setting up a garage, selecting the right site is crucial to ensuring its success. Several
factors should be considered to maximize efficiency, attract customers, and meet operational
needs. Here are the key factors for site selection:
When selecting a site for a four-wheeler garage or service center, you can consider
Any four
factors such as:
points
( 1
Accessibility:The site should be easily accessible for vehicles of all sizes. Consider factors Marks
such as entry and exit points, road quality, and traffic flow. Proximity to major roads or each )

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
intersections can increase customer convenience.

Parking:Ample parking space is necessary for both customer vehicles and employees. The
garage should have a large enough area for customers to park while waiting for service, as
well as space for storing vehicles under repair.

Competitors: Research the number and type of competing garages or service stations in the
area. Too many competitors in a single location may reduce business, while a location with
few service providers can offer a competitive advantage.

Costs: Lease or Purchase Costs: Evaluate the cost of leasing or purchasing the property.
Ensure that the costs are manageable and fit within the business's financial plan. Consider
other hidden costs such as property taxes and insurance.
Infrastructure and equipment: Whether the site has a well-equipped workshop, site should
have access to essential utilities such as electricity, water, sewage, and natural gas. These are
critical for operating the equipment, performing repairs, and maintaining a clean facility.

Other things to consider when opening a car service center include:

Business planning

Legal requirements and certifications

Staffing and training

Building customer trust

Marketing and promotion

Customer service

(Note- Any suitable 4 points from this or related to this)

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________

Q.5 Attempt any TWO of the following(6X2=12) Marks 12

a) Explain construction and working of differential with neat sketch. 6

Construction:-
The differential unit comprises several components.
Constructi
A pinion gear is mounted on the propeller shaft, rotating the large ring gear. The ring gear supports a
on -
Carrier unit consisting of two bevel pinions (planet pinions) and two bevel gears (sun gears). The sun 2 Marks
bevel gears are connected to the half shaft of the rear axle. A differential housing covers the entire
assembly, while the axle housing protects the half shaft.
Working
The working principle of a Differential Gearbox can be bifurcated into subheadings:
When Running Straight
In a straight-line movement, power is transmitted from the propeller shaft to the bevel
pinion, which drives the crown wheel. This power then flows into the differential cage,
housing planet pinions and sun gears. As the vehicle moves forward, the crown wheel,
differential cage, planet pinions, and sun gears rotate together as a single unit, resulting in no
relative motion between the sun gear and planet pinions. Since the planet pinions do not rotate
about their axis, and the resistance offered by the road wheels, half shafts, and sun gears is
uniform, the differential gearing does not engage, causing both road wheels to turn at the same
speed. Working-
When Taking a Turn 2 Marks
During a turn, the inner wheel faces resistance, prompting it to rotate in the opposite
direction. Consequently, the planet pinions start rotating about their own axis while revolving
around the sun gear. This leads to increased rotary motion being transmitted to the outer-side
sun gear, causing it to rotate faster than the inner sun gear. As a result, the outer road wheel
runs at a higher speed than the inner road wheel, allowing it to cover a greater distance while
turning. This differential action ensures smooth cornering and stability while navigating bends
or curves.

Neat
Sketch
-
2 Marks

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
b) Explain master cylinder with neat sketch 6

Neat
Sketch –
2M

Construction:-Master cylinder can be rightly named as heart of the hydraulic braking system.
There are two main chambers viz. the fluid reservoir & compression chamber in which the piston
operates. The fluid in the reservoir compensates for any change In the fluid volume in the pipelines
due to temperature variations & to some extent due to leakage. To prevent leakage there are rubber
seals on both ends of the piston in the compression chamber. The reduced diameter region of the Constructi
piston is always surrounded by the fluid. A rubber boot covers the push rod end of the master cylinder on – 2M
to prevent the dirt from entering inside towards the brake lines side of the compression chamber, there
is a fluid check value with a rubber cup inside. It serves to retain the residual pressure in the brake
lines even when the brakes are released.

Working: When the brake pedal pressed the push rod moves toward left by moving the piston
against the spring force as it covers bypass port, a pressure built up in the compression chamber when Working -
sufficient pressure built up, the fluid check valve deflected & the fluid under pressure flows in the 2M
pipeline. When the brake pedal release, the spring force in the master cylinder moves the piston
towards right. This same force of spring keep the check valve pressed on its seat for sometime, there
by delay the return of fluid into compression chamber. This delay causes vacuum in compression
chamber & there may be chance of air leakage into the system. This vacuum is destroyed by entering
the fluid from reservoir through intake port & holes in the piston which deflect rubber cup & enter in
compression chamber.

c) Explain procedure of wheel balancing and alignment 6

Wheel balancing Procedure

Step 1 All four tyres are taken off the vehicle and placed on a computerized wheel balancer.
Wheel
Step 2 All four wheels are tested individually for weight imbalance and the computer simulates all the Balancing
specific irregularities. Procedure
- 3M
Step 3 The weight imbalance is corrected by placing counterweights on the rim at the exact spot
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where the computer instructs.
Step 4 The wheels are checked again if the imbalance persists.
Note:- if you are required to use counterweights of more than 100 gms for a single wheel, then you
might want to consider changing your rim or tyre.
Wheel Alignment Procedure:-

Wheel alignment, also known as tire alignment, is the process of adjusting the angles of the wheels to the
manufacturer’s specifications. This ensures that the vehicle drives straight and that the tires wear evenly. A
proper wheel alignment helps improve the safety, fuel efficiency, and longevity of tires. Below is a step-by-
step procedure for performing wheel alignment: Wheel
1. Preparation Alignment
a) Inspect the Vehicle: Ensure the vehicle is in good condition before starting the alignment process. Procedure
Check for any worn-out suspension parts, tires, or steering components that could affect alignment. - 3M
b) Check Tire Pressure: All tires should be inflated to the correct pressure as per the manufacturer’s
recommendation.
c) Drive the Vehicle: Drive the vehicle for a short distance to ensure the suspension is settled and the
tires are warm. This can help in achieving more accurate alignment.
2. Lift the Vehicle
a) Lift the Vehicle Off the Ground: Use a hydraulic lift or jack to raise the vehicle so that the wheels
are free to rotate.
b) Ensure Safety: Use jack stands or other safety measures to secure the vehicle. This is important for
stability and to avoid accidents.
3. Mount Alignment Equipment
a) Attach Wheel Alignment Sensors: Alignment equipment typically uses sensors or cameras to
measure the angles of each wheel. Attach the sensors to each wheel according to the alignment system’s
guidelines.
b) Set the Alignment System: Use an alignment machine to calibrate and set the system before taking
measurements.
4. Take Measurements
a) Measure the Angles: The alignment system will measure key parameters including:
b) Camber: The angle of the wheel relative to the vertical axis when viewed from the front of the
vehicle.
c) Toe: The angle of the wheels relative to the centerline of the vehicle when viewed from above. This
can be "toe-in" or "toe-out."
d) Caster: The angle of the steering axis when viewed from the side of the vehicle.
e) Thrust: The alignment of the rear axle and the centerline of the vehicle. This ensures the vehicle
drives straight.
f) Compare with Manufacturer Specifications: These angles are compared to the manufacturer’s
recommended specifications to determine if adjustments are needed.
5. Adjustments
a) Adjust Toe Angles: This is the most common adjustment. The toe angle is altered by adjusting the
steering rack or tie rods to ensure the wheels point in the correct direction.
b) Adjust Camber: Camber can usually be adjusted by modifying the position of the strut or
suspension arms.
c) Adjust Caster: Caster is often adjusted by changing the upper or lower control arm positions or the
steering knuckle.
d) Adjust Thrust Angle: If necessary, adjust the rear axle alignment to ensure the vehicle tracks
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straight.
6. Recheck Measurements
After making the adjustments, recheck all the angles to ensure they are within the correct
specifications. Ensure that the vehicle is aligned correctly with no angles out of spec.
7. Test Drive
a) Drive the Vehicle: Take the vehicle for a short test drive to ensure it drives straight and doesn’t pull
to one side.
b) Check Handling: Pay attention to how the steering feels. It should return to center naturally, and
the vehicle should not wander or pull.
8. Final Inspection and Documentation
a) Inspect the Alignment Results: Double-check the final measurements and ensure that the
alignment is accurate.
b) Document the Results: Keep a record of the alignment measurements and adjustments for future
reference. Some shops provide a printout showing the before-and-after measurements.
9. Lower the Vehicle
Once all the measurements and adjustments are complete, lower the vehicle back to the ground.
a) Tighten All Components: Make sure that any components that were adjusted are properly tightened
according to the manufacturer’s specifications.
10. Post-Alignment Check
Check tire pressure again to ensure they are correctly inflated after the alignment.
Monitor the vehicle over the next few weeks for any signs of misalignment or unusual tire wear.

Q.6 Attempt any TWO of the following(6X2=12) Marks 12

a. Write the difference between live and dead axle describe semifloating axle with neat sketch 6

Sr Dead Axle Live Axle

No
Any three
Dead axles are those axles, which do Live axles are used to transmit power from
1 points-3
not rotate. gear box to front or rear or both wheels. Marks

These axles have sufficient rigidity Along with strength and rigidity this axle
2
and strength to take the weight. need to transmit power also

The ends of front axle are suitably Axle designed to carry power from
3 designed to accommodate stub differential to wheel hub or rotor
axles.

In which there is no connection with To differentiate speed while taking turn

4 the engine and having no differential differential is must in this type
mechanism.

It take weight of vehicle, Steering It along with weight of vehicle along with
5
steering system driving thrust

Generally front axle remains dead In car, four wheel drive vehicle front axle
6
axle in heavy vehicle remain live axle

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Semi Floating axle:

The arrangement of the semi-floating axle is shown in Fig. It is also called as the half floating
rear axle. The driving wheel is directly bolted to the axle shaft at its outer end. The inner end of the 1M
Explainati
axle shaft is splined and is supported by the differential unit. It has a single ball bearing which is on
mounted on the axle shaft and inside the axle casing.

Neat
Sketch-
2M

Figure: Semi Floating Rear Axle

b. Explain wire harness and describe colour coding used in automobile wiring system 6

In order to quickly identify and also to simplify the wiring system, the cables are colored. For
quick identification, insulations of various wires in a circuit are assigned different colors. The seven-
color code system is the general one and involves brown, yellow, red, white, green, blue, and black
colors. In motor vehicle wiring systems there are a number of wires for different systems such as a 3M
headlamp, fog, side indicator, horn, etc. As the wires are more for each circuit, we have limited space Descripti
for making a suitable arrangement of wiring. Thus, the following seven color code systems mentioned on
below, used in an automobile:

Colour Code:-

Sr Colour Colour Code Function

No

01 Brown BR Battery Circuit

02 Yellow Y Generator Circuit

03 White W Ignition Circuit

Colour
04 Green G Auxiliary Circuit Code -
3M
05 Blue BL Head Lamp Circuit

06 Red R Headlamp Circuit

07 Black B For Grounding

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c) Draw labelled layout of modern service station used in automobile workshop 6

(Suitable
layout 3
Marks
and
labelling
3 Marks)

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