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PREFACE
I have great satisfaction in learning about the technology of the worlds leading motor
vehicle company NISSAN and getting in depth knowledge of their new product NISSAN
EVALIA. The evaluation study was initiated by the training which a student has to for the
fulfilment of the curriculum.
The study, which has been conducted and completed within a record time of two
months, is an excellent example of cooperative endeavour among the colleagues and the
organisation.
The training taken at NISSAN gave me practical insight into the working of the
company, especially in the field of technology of motor vehicles which until now limited to
book only. But these 60 days have been special and proved to be a value addition and how
actually functions are performed in the a massive vehicle as well as in the organization.
The initial part of project report gives details of the company, like its departments,
functions, and the structure etc and the next part is related to NISSAN EVALIA and its
working.
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ACKNOWLEGEMENT
No man is an island itself rightly proclaim John Donne, the metaphysical poet to let the
world know the reality of human existence and human life.
First and foremost would like to thank the Director and teachers of PACIFIC
POLYTECHNIC COLLEGE for giving me an opportunity to develop understanding and
skills to attain quality knowledge.
I express my deep and sincere gratitude to the NISSAN for allowing me tohave my training
in this organization and my Trainer Mr. Hemendra whose valued guidance, dexterous
knowledge and unabated zeal paved my way for the completion of the work smoothly.
Finally and without being specific, I would like to thank my parents and my friends who
helped and encourage me directly or indirectly in the project and whose enthusiasm and
cheerfulness made my work on this project an enjoyable experience with a perfect balance
between pleasure and work.
DIPAL JAIN
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INTRODUCTION TO THE COMPANY
Nissan Motor Company Ltd usually shortened to Nissan, is a
Japanesemultinationalautomakerheadquartered in Japan. It was a core member of theNissan
Group, but has become more independent after its restructuring underCarlos Ghosn(CEO).
Nissan was the sixth largest automaker in the world behindGeneral Motors,Volkswagen
AG,Toyota,Hyundai Motor Group, andFordin 2011.[2]It formerly marketed vehicles under
the "Datsun" brand name. As of 2011, the company's global headquarters is located in Nishi-
ku, Yokohama. In 1999, Nissan entered a two way alliance withRenault S.A.of France,
which owns 43.4% of Nissan while Nissan holds 15% of Renault shares, as of 2008. Along
with its normal range of models, Nissan also produces a range of luxury models branded
asInfiniti.
Nissan's footprint in India has been growing steadily since its inception in
2005. Marked by an impressive rise in sales, award-winning quality from locally-built
products, an expanding range of innovative cars and a rapidly evolving dealer network the
growth underlines the strategic importance of India to Nissan.
Together with its global Alliance partnerRenault, Nissan has made a long-term and large-
scale 45 Mn INR investment commitment in a manufacturing plant at Oragadam, Chennai.
The Alliance has also invested in a state-ofthe-art global R&D center with more than 2000
engineers to support product innovation and customization. NMIPL has appointed Hover
Automotive India (HAI) as their sole distributor for India to handle sales and marketing,
dealer development, customer relationship management and after sales in India.
Guided by its global Brand commitment "Innovation and Excitement for Everyone" Nissan
delivers cutting-edge technology, Innovative design and a rewarding experience to all its
customers. In India, Nissan has been constantly expanding innovative and exciting product
offerings across hatchback, sports car, SUV and sedan segments. Today, Nissan has strongly
positioned three locally produced models premium hatchback Micra, entry level sedan
Sunny and Urban Class Utility Vehicle Evalia. Other existing range of products include the
X-Trail (SUV model), the Teana (luxury Sedan) and 370Z (iconic sports car) all three
imported from Japan as CBU (completely built units). NMIPL also commenced exports in
September 2010 to more than 100 countries including Europe, Middle East and Africa.
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In line with its global philosophy of corporate sustainability, Nissan India is demonstrating its
corporate commitment through various sustainable programs including safety campaigns and
rehabilitation projects. Nissan has constructed residential homes for relocated families from
the construction site, local Police Station and a fire service station in the Oragadam village.
Nissan has also partnered with Habitat for Humanity for providing shelter to variousfamilies by constructing homes for the socially and economically less fortunate section of the
society.
India is a key growth market for Nissan. The company continues its quest to optimize product
development and deliver highly innovative technology to the India market and its growing
customer base.
NISSAN Model 70 Phaeton, 1938
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NISSAN EVALIA
The following project consist of study of NISSANs new vehicle EVALIA
FRONT
SIDEWAYS
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VEHICLE SUMMARY
Name: Evalia
Model: XE
Car Body Type: MUV
Segment: C+ Segment
Fuel Consumption:
Highway19.30 kmpl.
Fuel Consumption:
City14.00 kmpl.
ENGINE SPECIFICATIONS
Displacement: 1461cc, Nissan K9K, BS4
Engine Type: Diesel
Maximum Power: 85 Bhp @ 3750 rpm
Maximum Torque: 200 Nm @ 2000 rpm
DIMENSIONS
Length: 4400 mm
Width: 1700 mm
Height: 1860 mm
OTHER SPECIFICATIONS
Seating Capacity: 7
Tyre Size: 165 R14
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Suspension: McPherson Struts, Multi-Leaf Rigid
Turning Circle: 5.20 mtrs.
Steering: Tilt
Brakes: Front Disk, Rear Drum
Gears: 5 Manual
Ground Clearance: 180.00 mm
Kerb Weight: 1446.00 kgs.
Fuel Tank: 55.00
Body Color
Bumpers:YES
Tachometer: YES
Alloys: NO
ORVM Indicator: NO
Xenon Headlamps: NO
Trip Meter: 2
Headlamp Washer: NO
ACTIVE AND PASSIVE SAFETY
Airbag: 1
Parking Sensors: NO
Fog Lamp: NO
Traction Control: NO
EBD: YES
ABS: YES
ESP: NO
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COMFORT AND CONVENIENCE
AC:AC
without Climate Control
Power Windows: NO
Central Locking: None
Remote Boot: YES
Remote Fuel Filler: YES
Rear Wiper: YES
Rear Defogger: YES
Rear Armrest: With Cup Holder
Steering
Adjustment
(Rake/Reach):
YES/NO
Driver Seat
Adjustment:Manual
Music System: 1 DIN AM/FM/CD
Leather Seats: NO
Door Mirror: Both Side Electric
Tinted Glass: YES
Rear AC Vent: NO
Folding Rear Seats: YES
Sun Roof: NO
Buttons/Controls
on Steering:NO
Auto Viper: NO
Auto Headlamp: NO
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OVERVIEW OF NISSAN EVALIA
Multi-purpose vehicle is a segment of cars in India which is totally dominated by Innova from
Toyota. Ever since its launch its the undisputed champion of its segment. Initially this was
not a popular segment of cars in India but now consumers and manufacturers both are rushing
towards it. Recently we have seen new competitors of Innova including Ertiga from Maruti
Suzuki, face-lifted Xylo from Mahindra and nowNissan Evalia. Yes, Nissan has entered this
segment of market with their MPV known as Evalia. Till now Nissan is widely known for its
cars like Micra and Sunny in India. With Evalia, Nissan targets those looking for an
alternative of Innova for both family and commercial use.
Majority of cars in this segment faces the problem of identity crisis. Either they are given the
identity of a car which is just suitable for family or they are known as taxi which is moreappropriate for commercial usage. No owner would like his personal car to be taunted as a
taxi. Innova has managed it brilliantly. It has won hearts of many families despite being a
successful commercial vehicle. Its space, comfort with premium quality made it a huge hit in
the market. Nissan knows it perfectly as they have seen Xylo being tagged as a taxi while
only families are opting for Ertiga. It will be a tough task for Evalia to carry two successful
images with two colored number plates.
Nissan India unveiled the 'Evalia' in India at the 2012 Auto Expo in New Delhi. The Indian
version of NV200 would be more luxurious and feature-rich in comparison to the Evalias
(NV200) sold all over the world. Nissan Evalia is a proper seven-seater multi-utility vehicleand will compete against the likes of Toyota Innova, Tata Aria, Chevrolet Tavera and to some
extent with ICML Rhino. On 8th August Nissan India unveiled all the technical specifications
and features of Evalia to the online media persons. It is available in four variants: XE, XE+,
XL and top-of-the-line XV. All the variants are powered by Nissan K9K diesel engine which
is mated to five-speed manual gearbox. It generates maximum power of 85 bhp at 3750 rpm
with maximum torque of 200 nm at 2000 rpm. In terms of looks, Nissan Evalia has
commercial van-type designing with sliding doors to access the rear seats. It has to be seen
that if private owners will prefer Evalia over Innova for routine day-to-day use. Nissan has
kept the design very neat and simple.
The interiors of Nissan Evalia are very spacious with sufficient head-room and leg-room for
all seven passengers. The top-of-the-line XV variant will come fully loaded with features like
body coloured bumpers, body coloured outside rear-view mirrors, Electrically adjustable
outside rear-view mirrors, front fog lamps, alloy wheels, tachometer, trip meter, 12V power
outlet, multi-information display, 2DIN music system with 4 speakers, key-less entry, central
locking system, tilt-adjustable power steering, power windows, seat back table, rear-monitor
camera with display, air conditioner with rear AC vents, reclining seats, passenger plus driver
airbag, ABS+EBD with brake assist, immobilizer and door ajar warning.
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The Nissan Evalia is designed for perfection. Ample amount of cargo space, first-class
functionality and the latest automotive technology make it stand apart from the crowd. Nissan
exhibits a high performance on the road with its excellent diesel engine option. The interior is
a showcase of comfort and the true sporty nature of the car. They are provided with lumber
support, folding options in the passenger seats and Thermoplastic Polyolefin front rowcovering. The remote keyless entry system, central console with controls, front map lights,
Rear Glass defogger, bottle holders and passenger side rear cargo door all enhance the
comfort of the car. The Nissan Evalia is facilitated with 2-Din AM/FM/CD with four
speakers. Nissan India has launched the Evalia today (25th September, 2012) in Indian
market. The base variant of Evalia is priced at Rs. 8.49 lakhs and Rs. 9.99 lakhs for the top
model.
Nissan Evalia Exterior
One thing is for sure; Evalia looks distinctfrom its competitors. We are not sure if its goingto work in its favour or not. The car looks tall; thats it. Evalia neither looks smart or beautiful
nor its curvy or macho, its just tall. The front of the car is much more appealing than its
whole body. It has a big, broad bumper which has nice flowing lines over it along with fog
lights and air dam fitted very low. There is huge gap between headlights and fog lights which
grabs your attention instantly. It has nice angular headlights which are well mated with an
innovative front grille.
There is big Nissan logo in center with a nice finish of chrome on the last layer of grille. The
bonnet sits high above on this front grille which is not that big in size. Overall its face looks
very aerodynamic. Its side view makes it look like any other, cargo van. It has long verticalfront doors with sliding doors at the back. Yes, it has sliding doors which wont take you long
to compare it with much cheaper Marutis van like Omni or Eeco. It has body colored front
door handles and big side mirrors. It has nice wheel arches but its 14 inch alloys spoils the
party. Its side profile with small size of tyres looks very boxy and bland. Rear of the car
makes it worse. Its rear gate makes it a typical van. Its rear bumper is the most irritating thing
that you can notice. It has a tall rear gate which has extremely low fitted tail lamps. When
companies are trying to make their MPVs as stylish as possible, we wonder why Nissan has
chosen this typical van design for its car. Looking at its competitors design and style, Evalia
looks like a thing of the past.
Nissan Evalia Interior
Things get better inside Evalia. It uses beige and grey colors inside. Seats and door panels
are of beige colour which makes it look up market. The car features clear and easily readable
instrument dials. It has familiar three spoke steering wheel with a big Nissan logo over it. The
upward placement of gear knob may remind you of i10s AC vents, gear knob and center
console are surrounded with metallic colour finish. The quality of plastic material and buttons
used inside are just fine as they are not that soft to touch. If we compare it with its rivals like
Xylo than it surely has an upper hand as the total arrangement inside with fit and finish is farbetter. It also has a Multi information display which provides important information to driver.
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Comfort and Convenience
Evalia is available as a seven-seater multi-purpose vehicle. Basic function of MPVs is to
provide extra space and thats the USP of this car. Nissan has made itvery spacious and
even with full seating; luggage of a full size family can fit into its boot. Front seats are very
comfy and there is enough legroom and headroom available in the front. People who are six
feet plus may find a bit cramped knee room in the front, otherwise headroom is no issue.
There are front power windows and rear wiper and defogger. Its power steering is available
with tilt option. Driver seat is manually adjustable. Driving position will again realize you that
it is more like a van as you lack that confidence in driving position. Seating in second row is
also very comfortable.
There is ample amount of headroom and legroom. Under thigh support is just enough. It has
non sliding seats in its 2nd row. Sliding doors and almost flat floor makes it convenient to use
these rows. The tall structure of Evalia allows the passengers in third room to get fair amountof headroom. The under thigh support could have been better. There is rear AC vent for 3rd
row, we are not sure about 2nd row if it will have AC ducting or not. It also features
electrically adjustable but not retractable outside mirrors and rear parking camera with
display. The car has a smart key with function of auto lock/unlock with the help of sensors.
Dashboard and Storage
Its long dashboard uses dual tone colors. It has in-built glove box with bottle holders on either
side. Thats the only storage space this dashboard offers. The center console is fitted with
Multi information display which fits in well with the dashboard and looks sophisticated. It hasround and rectangular shaped AC vents. Overall appearance and quality of dashboard is
satisfactory. The car has no lockable storage space to keep essential or private documents. It
also has cup holder in rear center armrest. The car has first in its class tray table on the back of
front seats just like a plane. To get more storage, the rear seats folds down and allow you to
carry enormous amount of luggage.
Music system of Nissan Evalia
Nissan Evalia is equipped with double din music system fitted in center console. It has radio
andCD player coupled with four speakers. There is no audio control switches mounted on itssteering wheel. The car also lacks Bluetooth connectivity. It features a 12v power outlet at
front.
Nissan Evalia Engine and Gearbox
The familiar Renaults1.5 K9K common rail diesel engine powers this car. The maximum
power produced by this engine is of85 bhp which comes at 3750 rpm. It churns out a
maximum torque output 200 Nm available at 2000 rpm. Nissan is already using this engine in
its Micra and Sunny. This diesel unit is specially tuned for Indian Evalia. Its mated with 5-
speed manual gearbox. This engine is less powerful than most of its competitors.
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Acceleration and Performance
Those numbers seem to be very less on papers for a vehicle of this segment but drive it on
road and you will find it completely different. As per Nissan, Evalia reaches 100km/hr mark
faster than any of its competitors. Its hard to believe but yes it does. The car feels very light
and fast. Once you pass 2000 rpm mark it is fun to drive this vehicle. It suffers a major turbo
lag, especially with full seating you will continuously have to work on its gear shifting. It also
gets noisy if rev hard otherwise its a nice performer. It cant match the performance and
drivability of Innova but it is better than what we get in Xylo. Its lightweight helps it to
manage the power to weight ratio better than others. Its tall gear ratios can be irritating in city
traffic as you can avail torque only after 2000 rpm. It has smooth gear transition which is very
handy in city traffic and its gear ratios are well proportioned.
Mileage of Nissan Evalia
Nissan claims Evalia to be the most fuel efficient car in its segment. As per ARAI
certification, it manages to return 19km/ltr. When tested the car returns a mileage of around
13-15km/ltr in city conditions while on highways you can expect anything around 15-
17km/ltr. These numbers are surely better than its competitors like Innova and Xylo. There
are two reasons which undoubtedly make it the most fuel efficient car in its segment. First its
lightweight due to its monocoque design which is very lighter in comparison to its
competitors as it weighs around 1.4 tonnes and secondly its relatively taller gear ratios.
Nissan Evalia Ride and Handling
The car handles really well in traffic conditions. Its reduced turning radius along with large
door glasses on either side makes it easy while parking this car. Given its weight and usage,
its suspension has been given special treatment. It is capable of bearing heavy loads with
optimum comfort. Its strong suspension allows it to stay grounded at high speeds. Shifting
lanes quickly at high speeds is not an issue. It also digests big bumps and potholes easily and
with its high ground clearance. Its long wheelbase along with well mated suspension confirms
you a comfortable ride. It doesnt give you enough confidence to drive it fast at corners
because its suspension takes time to settle down and its small tyres are not capable to hold it
firmly on road.
Braking and Safety Features
Nissan Evalia has ventilated disk brake at its front while drum brakes are used at its back.
Brakes respond very accurately and sometime they stop this car way before than what you
expect. Top model of this car will also carry features like ABS with EBD and brake assist
which will make its braking more precise. Though it lacks ESP but you will hardly miss it.
Nissan has tried to make it a safe vehicle thats why ABS and driver side air bag is a standard
feature while the top model will also feature airbag for front passenger.
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Verdict
MPVs are known fortheir space and Evalia is surely a winner in this department. Its very
spacious and offers enough comfort what you expect from a vehicle of this segment. It
handles nicely in city traffic and on highways also it wont disappoint you.Evalia is very
economicalin terms of fuel efficiency and for that you dont even have to compromise on
power either. These are some of its qualities which will surely appeal to many buyers. We
wish if it was enough for this car to succeed as it has some major drawbacks.
Nissan Evalia looks much like a van with sliding doors which makes it look like a typical
MPV. Its competitors like Marutis Ertiga and Toyota Innova on the other hand are trying to
get rid of this image and they more look like any other city car which is more acceptable by
family buyers. It can appeal to those who are looking for a commercial MPV but again its
warranty period is an issue. Innova comes with longer warranty period which makes it worth
in comparison to Evalia. There are relatively less features in Evalia when compared to itscompetitors. It will be hard for Evalia to get the trusted buyers of Innova which is better than
it in almost every department.
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Nissan EVALIA at a glance
Manufacturer Nissan
Also called Nissan Evalia
Nissan NV200 Vanette
Mitsubishi Delica D:3
Production 2009present
Model years 2010-present
Assembly Aguascalientes,Mexico
Shnan,Kanagawa,Japan
Nissan Motor Ibrica S.A.,Spain(November 2009)Zhengzhou Nissan,China(2010)
Chennai,India(2012-)
Purwakarta,Indonesia(2012-present)
Predecessor Nissan VanetteVan (Japan)
Nissan Kubistar(Europe)
Class Light commercial vehicle
Body style 4-doorvan
Layout Front engine,front-wheel drive
Platform Nissan B platform
Engine 1.6 LHR16DEI42.0 LMR20DEI4(starting in 2013)
1.5 L K9KDieselI4(Europe)
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1.5 LHR15DE(Indonesia)
Transmission CVT
Wheelbase 2010-12: 2,860 mm (112.6 in)2013-: 115.2 in (2,926 mm)
Length 2010-12: 4,400 mm (173.2 in)2013-: 186.2 in (4,729 mm)
Width 2010-12: 1,695 mm (66.7 in)2013-: 68.1 in (1,730 mm)
Height 2010-12: 1,8501,855 mm (7373.0 in)2013-: 73.5 in (1,867 mm)
http://en.wikipedia.org/wiki/Nissan_HR_enginehttp://en.wikipedia.org/wiki/Nissan_HR_enginehttp://en.wikipedia.org/wiki/Nissan_HR_enginehttp://en.wikipedia.org/wiki/Transmission_(mechanics)http://en.wikipedia.org/wiki/Transmission_(mechanics)http://en.wikipedia.org/wiki/Continuously_variable_transmissionhttp://en.wikipedia.org/wiki/Continuously_variable_transmissionhttp://en.wikipedia.org/wiki/Wheelbasehttp://en.wikipedia.org/wiki/Wheelbasehttp://en.wikipedia.org/wiki/Wheelbasehttp://en.wikipedia.org/wiki/Continuously_variable_transmissionhttp://en.wikipedia.org/wiki/Transmission_(mechanics)http://en.wikipedia.org/wiki/Nissan_HR_engine7/28/2019 Braking Mechanism
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SUSPENSION ASSEMBLY
Front-wheel-drive car with MacPherson-strut front suspension and strut-type independent rear suspension
Automotive suspension
The springs and related parts intermediate between the wheels and the frame, subframe, or
side rails of a unitized body. The suspension supports the weight of the upper part of a vehicle
on its axles and wheels, allows the vehicle to travel over irregular surfaces with a minimum of
up-and-down body movement, and allows the vehicle to corner with minimum roll or loss oftraction between the tires and the road. See also Automobile; Spring (machines).
In a typical suspension system for a vehicle with front-engine and front-wheel drive (see
illustration), the weight of the vehicle applies an initial compression to the coil springs. When
the tires and wheels encounter irregularities in the road, the springs further compress or
expand to absorb most of the shock. The suspension at the rear wheels is usually simpler than
for the front wheels, which require multiple-point attachments so the wheels can move up and
down while swinging from side to side for steering.
A telescoping hydraulic damper, known as a shock absorber, is mounted separately or in thestrut at each wheel to restrain spring movement and prevent prolonged spring oscillations.
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The shock absorber contains a piston that moves in a cylinder as the wheel moves up and
down with respect to the vehicle body or frame. As the piston moves, it forces a fluid through
an orifice, imposing a restraint on the spring. Spring-loaded valves open to permit quicker
flow of the fluid if fluid pressure rises high enough, as it may when rapid wheel movements
take place. Most automotive vehicles use gas-filled shock absorbers in which the air spaceabove the fluid is filled with a pressurized gas such as nitrogen. The gas pressure on the fluid
reduces the creation of air bubbles and foaming. See also Shock absorber.
Most automotive vehicles have independent front suspension, usually using coil springs as
part of either a short-arm long-arm or a MacPherson-strut suspension system. A MacPherson-
strut suspension (see illustration) combines a coil spring and shock absorber into a strut
assembly that requires only a beam-type lower control arm.
Some vehicles with short-arm long-arm front suspension use either longitudinal or transverse
torsion bars for the front springs. One end of the torsion bar is attached to the lower control
arm, and the other end is anchored to the vehicle body or frame. As the tire and wheel move
up and down, the torsion bar provides springing action by twisting about its long axis.
Turning an adjustment bolt at one end of the torsion bar raises or lowers the vehicle RIDe
height. See also Torsion bar.
Most automobiles and many light trucks have coil springs at the rear. These may mount on the
rear drive axle, on struts, or on various types of control or suspension arms in an independent
suspension system. Some rear-drive vehicles have leaf springs at the rear. Others use
transverse torsion bars.
What is Suspension?
Suspension is the term given to the system of springs, shock absorbers and linkages that
connects a vehicle to its wheels and allows relative motion between the two.[1] Suspension
systems serve a dual purpose contributing to the vehicle's roadholding/handling and
braking for good active safety and driving pleasure, and keeping vehicle occupants
comfortable and reasonably well isolated from road noise, bumps, and vibrations,etc. These
goals are generally at odds, so the tuning of suspensions involves finding the right
compromise. It is important for the suspension to keep the road wheel in contact with the road
surface as much as possible, because all the forces acting on the vehicle do so through the
contact patches of the tires. The suspension also protects the vehicle itself and any cargo or
luggage from damage and wear. The design of front and rear suspension of a car may be
different.
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BRAKING ASSEMBLY
Exploded view of the front disc brake assembly
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DETAILED BRAKING ASSEMBLY DESCRIPTION
The modern automotive brake system has been refined for over 100 years and has become
extremely dependable and efficient.
The typical brake system consists ofdisk brakesin front and eitherdiskordrum brakesin
the rear connected by a system oftubes and hosesthat link the brake at each wheel to
themaster cylinder.Other systems that are connected with the brake system includetheparking brakes,power brakeboosterand theanti-locksystem.
When you step on the brake pedal, you are
actually pushing against a plunger in the
master cylinder, which forces hydraulic oil
(brake fluid) through a series of tubes and
hoses to the braking unit at each wheel. Since
hydraulic fluid (or any fluid for that matter)
cannot be compressed, pushing fluid through a
pipe is just like pushing a steel bar through a
pipe. Unlike a steel bar, however, fluid can be
directed through many twists and turns on its
way to its destination, arriving with the exact
same motion and pressure that it started
with. It is very important that the fluid is pure liquid and that there are no air bubbles in
it. Air can compress, which causes a sponginess to the pedal and severely reduced braking
efficiency. If air is suspected, then the system must be bled to remove the air. There are
"bleeder screws" at each wheel cylinder and caliper for this purpose.
http://www.carparts.com/brakes.htm#Disc%20Brakehttp://www.carparts.com/brakes.htm#Disc%20Brakehttp://www.carparts.com/brakes.htm#Disc%20Brakehttp://www.carparts.com/brakes.htm#Drum%20Brakehttp://www.carparts.com/brakes.htm#Drum%20Brakehttp://www.carparts.com/brakes.htm#Drum%20Brakehttp://www.carparts.com/brakes.htm#Brake%20Lineshttp://www.carparts.com/brakes.htm#Brake%20Lineshttp://www.carparts.com/brakes.htm#Brake%20Lineshttp://www.carparts.com/brakes.htm#Master%20Cylinderhttp://www.carparts.com/brakes.htm#Master%20Cylinderhttp://www.carparts.com/brakes.htm#Master%20Cylinderhttp://www.carparts.com/brakes.htm#Parking%20Brakeshttp://www.carparts.com/brakes.htm#Parking%20Brakeshttp://www.carparts.com/brakes.htm#Parking%20Brakeshttp://www.carparts.com/brakes.htm#Power%20Brakeshttp://www.carparts.com/brakes.htm#Power%20Brakeshttp://www.carparts.com/brakes.htm#Power%20Brakeshttp://www.carparts.com/brakes.htm#Anti-Lock%20Brakeshttp://www.carparts.com/brakes.htm#Anti-Lock%20Brakeshttp://www.carparts.com/brakes.htm#Anti-Lock%20Brakeshttp://www.carparts.com/brakes.htm#Brake%20Fluidhttp://www.carparts.com/brakes.htm#Brake%20Fluidhttp://www.carparts.com/brakes.htm#Brake%20Fluidhttp://www.carparts.com/brakes.htm#Brake%20Fluidhttp://www.carparts.com/brakes.htm#Anti-Lock%20Brakeshttp://www.carparts.com/brakes.htm#Power%20Brakeshttp://www.carparts.com/brakes.htm#Power%20Brakeshttp://www.carparts.com/brakes.htm#Parking%20Brakeshttp://www.carparts.com/brakes.htm#Master%20Cylinderhttp://www.carparts.com/brakes.htm#Brake%20Lineshttp://www.carparts.com/brakes.htm#Drum%20Brakehttp://www.carparts.com/brakes.htm#Disc%20Brake7/28/2019 Braking Mechanism
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On adisk brake, the fluid from the master cylinder is forced
into a caliper where it presses against a piston. The piston, in-
turn, squeezes two brake pads against the disk(rotor), which
is attached to the wheel, forcing it to slow down or stop.
This process is similar to a bicycle brake where two rubber
pads rub against the wheel rim creating friction.
Withdrum brakes, fluid is forced into the wheel cylinder,
which pushes the brake shoes out so that the friction linings
are pressed against the drum, which is attached to the wheel,causing the wheel to stop.
In either case, the friction surfaces of thepadson a disk brake
system, or theshoeson a drum brake convert the forward
motion of the vehicle into heat. Heat is what causes the
friction surfaces (linings) of the pads and shoes to eventually
wear out and require replacement.
Let's take a closer look at each of the components in a brake system and see where other
problems can occur...
Master Cylinder
The master cylinder is located in the engine compartment on
the firewall, directly in front of the driver's seat. A typical
master cylinder is actually two completely separate master
cylinders in one housing, each handling two wheels. This way
if one side fails, you will still be able to stop the car. The
brake warning light on the dash will light if either side fails,
alerting you to the problem. Master cylinders have become
very reliable and rarely malfunction; however, the most
common problem that they experience is an internal leak. This will cause the brake pedal to
slowly sink to the floor when your foot applies steady pressure. Letting go of the pedal and
immediately stepping on it again brings the pedal back to normal height.
Brake Fluid
Brake fluid is a special oil that has specific properties. It is designed to withstand cold
temperatures without thickening as well as very high temperatures without boiling. (If the
http://www.carparts.com/brakes.htm#Disc%20Brakehttp://www.carparts.com/brakes.htm#Disc%20Brakehttp://www.carparts.com/brakes.htm#Disc%20Brakehttp://www.carparts.com/brakes.htm#Rotorhttp://www.carparts.com/brakes.htm#Rotorhttp://www.carparts.com/brakes.htm#Rotorhttp://www.carparts.com/brakes.htm#Drum%20Brakehttp://www.carparts.com/brakes.htm#Drum%20Brakehttp://www.carparts.com/brakes.htm#Drum%20Brakehttp://www.carparts.com/brakes.htm#Brake%20Padshttp://www.carparts.com/brakes.htm#Brake%20Padshttp://www.carparts.com/brakes.htm#Brake%20Padshttp://www.carparts.com/brakes.htm#Brake%20Shoeshttp://www.carparts.com/brakes.htm#Brake%20Shoeshttp://www.carparts.com/brakes.htm#Brake%20Shoeshttp://www.carparts.com/brakes.htm#Brake%20Shoeshttp://www.carparts.com/brakes.htm#Brake%20Padshttp://www.carparts.com/brakes.htm#Drum%20Brakehttp://www.carparts.com/brakes.htm#Rotorhttp://www.carparts.com/brakes.htm#Disc%20Brake7/28/2019 Braking Mechanism
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brake fluid should boil, it will cause you to have a spongy pedal and the car will be hard to
stop.) Brake fluid must meet standards that are set by the Department of Transportation
(DOT). The current standard is DOT-3, which has a boiling point of 460 F. But check your
owners manual to see what your vehicle manufacturer recommends.
The brake fluid reservoir is on top of the master cylinder. Most cars today have a transparent
reservoir so that you can see the level without opening the cover. The brake fluid level will
drop slightly as the brake pads wear. This is a normal condition and no cause for concern. If
the level drops noticeably over a short period of time or goes down to about two thirds full,
have your brakes checked as soon as possible. Keep the reservoir covered except for the
amount of time you need to fill it and never leave a can of brake fluid uncovered. Brake fluid
must maintain a high boiling point. Exposure to air will cause the fluid to absorb moisture,
which will lower that boiling point.
NEVER PUT ANYTHING BUT APPROVED BRAKE FLUID IN YOUR BRAKES.
ANYTHING ELSE CAN CAUSE SUDDEN BRAKE FAILURE!Any other type of oilor other fluid will react with the brake fluid and very quickly destroy the rubber seals in
the brake system causing brake failure.
Brake Lines
The brake fluid travels from the master cylinder to the wheels through a series of steel tubes
and reinforced rubber hoses. Rubber hoses are used only in places that require flexibility,
such as at the front wheels, which move up and down as well as steer. The rest of the system
uses non-corrosive seamless steel tubing with special fittings at all attachment points. If a
steel line requires a repair, the best procedure is to replace the complete line. If this is notpractical, a line can be repaired using special splice fittings that are made for brake system
repair. You must never use brass "compression" fittings or copper tubing to repair a brake
system. They are dangerous and illegal.
OTHER COMPONENTS IN THE HYDRAULIC SYSTEM
Proportioning valve or Equalizer ValveThese valves are mounted between the master cylinder and the rear wheels. They are
designed to adjust the pressure between the front and rear brakes depending on how
hard you are stopping. The shorter you stop, the more of the vehicle's weight is
transferred to the front wheels, in some cases, causing the rear to lift and the front to
dive. These valves are designed to direct more pressure to the front and less pressure
to the rear the harder you stop. This minimizes the chance of premature lockup at the
rear wheels.
Pressure Differential ValveThis valve is usually mounted just below the master cylinder and is responsible for
turning the brake warning light on when it detects a malfunction. It measures the
pressure from the two sections of the master cylinder and compares them. Since it ismounted ahead of the proportioning or equalizer valve, the two pressures it detects
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should be equal. If it detects a difference, it means that there is probably a brake fluid
leak somewhere in the system.
Combination ValveThe Combination valve is simply a
proportioning valve and a pressure
differential valve that is combined into
one unit.
Electronic Brake ForceDistribution
Newer cars use the antilock brake
hardware and the onboard computer to replace these proportioning valve systems with
a system called Electronic Brake force Distribution (EBD) in order to distribute theexact amount of pressure at each wheel to insure a balanced brake system.
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DISK BRAKES
The disk brake is the best brake we have found so far. Disk brakes are used to stop everything
from cars to locomotives and jumbo jets. Disk brakes wear longer, are less affected by water,
are self adjusting, self cleaning, less prone to grabbing or pulling and stop better than any
other system around. The main components of a disk brake are the Brake
Pads, Rotor, Caliper and Caliper Support.
Brake PadsThere are two brake pads on each caliper. They are constructed of
a metal "shoe" with the lining riveted or bonded to it. The pads
are mounted in the caliper, one on each side of the rotor. Brake
linings used to be made primarily of asbestos because of its heatabsorbing properties and quiet operation; however, due to health
risks, asbestos has been outlawed, so new materials are now being
used. Brake pads wear out with use and must be replaced
periodically. There are many types and qualities of pads available.
The differences have to do with brake life (how long the new pads
will last) and noise (how quiet they are when you step on the brake). Harder linings
tend to last longer and stop better under heavy use but they may produce an irritating
squeal when they are applied. Technicians that work on brakes usually have a favorite
pad that gives a good compromise that their customers can live with.
Brake pads should be checked for wear periodically. If the lining wears down to the
metal brake shoe, then you will have a "Metal-to-Metal" condition where the shoe
rubs directly against the rotor causing severe damage and loss of braking efficiency.
Some brake pads come with a "brake warning sensor" that will emit a squealing noise
when the pads are worn to a point where they should be changed. This noise will
usually be heard when your foot is offthe brake and disappear when you step on the
brake. If you hear this noise, have your brakes checked as soon as possible.
RotorThe disk rotor is made of iron with highly machined surfaces where the brake pads
contact it. Just as the brake pads wear out over time, the rotor also undergoes some
wear, usually in the form of ridges and groves where the brake pad rubs against
it. This wear pattern exactly matches the wear pattern of the pads as they seat
themselves to the rotor. When the pads are replaced, the rotor must be machined
smooth to allow the new pads to have an even contact surface to work with. Only a
small amount of material can be machined off of a rotor before it becomes unusable
and must be replaced. A minimum thickness measurement is stamped on every rotor
and the technician doing the brake job will measure the rotor before and aftermachining it to make sure it doesn't go below the legal minimum. If a rotor is cut
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below the minimum, it will not be able to handle the high heat that brakes normally
generate. This will cause the brakes to "fade," greatly reducing their effectiveness to a
point where you may not be able to stop!
Caliper & SupportThere are two main types of calipers: Floating calipers and fixed calipers. There are
other configurations but these are the most popular. Calipers must be rebuilt or
replaced if they show signs of leaking brake fluid.
Single Piston Floating Calipers are the most
popular and also least costly to manufacture and
service. A floating caliper "floats" or moves in a
track in its support so that it can center itself over
the rotor. As you apply brake pressure, the
hydraulic fluid pushes in two directions. It forcesthe piston against the inner pad, which in turn
pushes against the rotor. It also pushes the caliper
in the opposite direction against the outer pad,
pressing it against the other side of the rotor. Floating calipers are also available on
some vehicles with two pistons mounted on the same side. Two piston floating
calipers are found on more expensive cars and can provide an improved braking
"feel".
Four Piston Fixed Calipers are mounted rigidly to the support and are not allowed tomove. Instead, there are two pistons on each side that press the pads against the
rotor. Four piston calipers have a better feel and are more efficient, but are more
expensive to produce and cost more to service. This type of caliper is usually found
on more expensive luxury and high performance cars.
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DRUM BRAKES
So if disk brakes are so great, how come we still have cars with drum brakes? The reason is
cost. While all vehicles produced for many years have disk brakes on the front, drum brakes
are cheaper to produce for the rear wheels. The main reason is the parking brake system. On
drum brakes, adding a parking brake is the simple addition of a lever, while on disk
brakes, we need a complete mechanism, in some cases, a complete mechanical drum brake
assembly inside the disk brake rotor! Parking brakes must be a separate system that does not
use hydraulics. It must be totally mechanical, but more on parking brakes later.
Drum brakes consist of a backing plate, brake shoes, brake drum, wheel cylinder, return
springsand an automatic or self-adjusting system. When you apply the brakes, brake fluid
is forced under pressure into the wheel cylinder, which in turn pushes the brake shoes into
contact with the machined surface on the inside of the drum. When the pressure is released,
return springs pull the shoes back to their rest position. As the brake linings wear, the shoes
must travel a greater distance to reach the drum. When the distance reaches a certain point, a
self-adjusting mechanism automatically reacts by adjusting the rest position of the shoes so
that they are closer to the
drum.
Brake ShoesLike the disk pads,
brake shoes consist of a
steel shoe with the
friction material or
lining riveted or
bonded to it. Also like
disk pads, the linings
eventually wear out and
must be replaced. If
the linings are allowed
to wear through to the
bare metal shoe, they will cause severe damage to the brake drum.
Backing PlateThe backing plate is what holds everything together. It attaches to the axle and forms
a solid surface for the wheel cylinder, brake shoes and assorted hardware. It rarely
causes any problems.
Brake DrumBrake drums are made of iron and have a machined surface on the inside where the
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shoes make contact. Just as with disk rotors, brake drums will show signs of wear as
the brake linings seat themselves against the machined surface of the drum. When
new shoes are installed, the brake drum should be machined smooth. Brake drums
have a maximum diameter specification that is stamped on the outside of the drum.
When a drum is machined, it must never exceed that measurement. If the surfacecannot be machined within that limit, the drum must be replaced.
Wheel CylinderThe wheel cylinder consists of a cylinder that has two pistons, one on each side. Each
piston has a rubber seal and a shaft that connects the piston with a brake shoe. When
brake pressure is applied, the pistons are forced out pushing the shoes into contact
with the drum. Wheel cylinders must be rebuilt or replaced if they show signs of
leaking.
Return Springs Return springs pull the brake shoes back to their rest position after the pressure is
released from the wheel cylinder. If the springs are weak and do not return the shoes
all the way, it will cause premature lining wear because the linings will remain in
contact with the drum. A good technician will examine the springs during a brake job
and recommend their replacement if they show signs of fatigue. On certain vehicles,
the technician may recommend replacing them even if they look good as inexpensiveinsurance.
Self-AdjustingSystemThe parts of a self adjusting system should be clean and move freely to insure that the
brakes maintain their adjustment over the life of the linings. If the self adjusters stop
working, you will notice that you will have to step down further and further on the
brake pedal before you feel the brakes begin to engage. Disk brakes are self adjusting
by nature and do not require any type of mechanism. When a technician performs a
brake job, aside from checking the return springs, he will also clean and lubricate the
self adjusting parts where necessary.
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PARKING BRAKES
The parking brake (a.k.a. emergency brake) system controls the rear brakes through a series
of steel cables that are connected to either a hand lever or a foot pedal. The idea is that the
system is fully mechanical and completely bypasses the hydraulic system so that the vehicle
can be brought to a stop even if there is a total brake failure.
On drum brakes, the cable pulls on a lever mounted in the rear brake and is directly
connected to the brake shoes. this has the effect of bypassing the wheel cylinder and
controlling the brakes directly.
Disk brakes on the rear wheels add additional complication for parking brake systems. There
are two main designs for adding a mechanical parking brake to rear disk brakes. The first typeuses the existing rear wheel caliper and adds a lever attached to a mechanical corkscrew
device inside the caliper piston. When the parking brake cable pulls on the lever, this
corkscrew device pushes the piston against the pads, thereby bypassing the hydraulic system,
to stop the vehicle. This type of system is primarily used with single piston floating calipers,
if the caliper is of the four piston fixed type, then that type of system can't be used. The other
system uses a complete mechanical drum brake unit mounted inside the rear rotor. The brake
shoes on this system are connected to a lever that is pulled by the parking brake cable to
activate the brakes. The brake "drum" is actually the inside part of the rear brake rotor.
On cars with automatic transmissions, the parking brake is rarely used. This can cause a
couple of problems. The biggest problem is that the brake cables tend to get corroded and
eventually seize up causing the parking brake to become inoperative. By using the parking
brake from time to time, the cables stay clean and functional. Another problem comes from
the fact that the self adjusting mechanism on certain brake systems uses the parking brake
actuation to adjust the brakes. If the parking brake is never used, then the brakes never get
adjusted.
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POWER BRAKE BOOSTER
The power brake booster is mounted on the firewall directly
behind the master cylinder and, along with the master
cylinder, is directly connected with the brake pedal. Its
purpose is to amplify the available foot pressure applied to
the brake pedal so that the amount of foot pressure required
to stop even the largest vehicle is minimal. Power for the
booster comes from engine vacuum. The automobile engineproduces vacuum as a by-product of normal operation and is
freely available for use in powering accessories such as the
power brake booster. Vacuum enters the booster through a
check valve on the booster. The check valve is connected to
the engine with a rubber hose and acts as a one-way valve
that allows vacuum to enter the booster but does not let it
escape. The booster is an empty shell that is divided into two
chambers by a rubber diaphragm. There is a valve in the
diaphragm that remains open while your foot is off the brake pedal so that vacuum is allowed
to fill both chambers. When you step on the brake pedal, the valve in the diaphragm closes,
separating the two chambers and another valve opens to allow air in the chamber on the brake
pedal side. This is what provides the power assist. Power boosters are very reliable and
cause few problems of their own, however, other things can contribute to a loss of power
assist. In order to have power assist, the engine must be running. If the engine stalls or shuts
off while you are driving, you will have a small reserve of power assist for two or three pedal
applications but, after that, the brakes will be extremely hard to apply and you must put as
much pressure as you can to bring the vehicle to a stop.
Anti-Lock Brakes (ABS)
The most efficient braking pressure takes place just before each wheel locks up. When you
slam on the brakes in a panic stop and the wheels lock up, causing a screeching sound and
leaving strips of rubber on the pavement, you do not stop the vehicle nearly as short as it is
capable of stopping. Also, while the wheels are locked up, you loose all steering control so
that, if you have an opportunity to steer around the obstacle, you will not be able to do
so. Another problem occurs during an extended skid is that you will burn a patch of rubber
off the tire, which causes a "flat spot" on the tread that will produce an annoying thumping
sound as you drive.
Anti-lock brake systems solve this lockup problem by rapidly pumping the brakes whenever
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the system detects a wheel that is locked up. In most cases, only the wheel that is locked will
be pumped, while full braking pressure stays available to the other wheels. This effect allows
you to stop in the shortest amount of time while maintaining full steering control even if one
or more wheels are on ice. The system uses a computer to monitor the speed of each wheel.
When it detects that one or more wheels have stopped or are turning much slower than theremaining wheels, the computer sends a signal to momentarily remove and reapply or pulse
the pressure to the affected wheels to allow them to continue turning. This "pumping" of the
brakes occurs at ten or more times a second, far faster then a human can pump the brakes
manually. If you step on the brakes hard enough to engage the anti-lock system, you may feel
a strong vibration in the brake pedal. This is a normal condition and indicates that the system
is working, however, it can be disconcerting to some people who don't expect it. If your
vehicle has anti-lock brakes, read your owner's manual to find out more about it.
The system consists of an electronic control unit, a hydraulic actuator, and wheel speed
sensors at each wheel. If the control unit detects a malfunction in the system, it willilluminate an ABS warning light on the dash to let you know that there is a problem. If there
is a problem, the anti-lock system will not function but the brakes will otherwise function
normally.
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FINDINGS
On the completion of the training, the technical aspects that were are listed below
1. Lifting Point1.1.Safety stand point and lift up point(Front)1.2.Safety stand point and lift up point(Rear)
2. Garage Jack Point2.1.Garage Jack point(Front)2.2.Garage Jack point(Front)
3. Turbochargers3.1.Fuel3.2.Consult checking system3.3.Body control system components parts location
4. Components parts location4.1.Arrangement of combination meter
5. FRONT hydraulic piping5.1.Brake Boosters5.2.Front Disc Brake5.3.ABS actuator and electric unit5.4.Connectors5.5.Rear Drum Brakes
6. Brake piping6.1.Brake booster6.2.Master cylinder6.3.Brake tube6.4.Connector6.5.ABS(actuator and electronic unit)6.6.Lock plate6.7.Brake hose6.8.Union Bolt6.9.Copper washer6.10. 2 Front brake hose6.11. 2 Rear brake tube
7. Brake booster : The brake booster equipped with brake assist is adapted for all vehicles7.1.Master cylinder assembly7.2.Brake booster7.3.Lock Nut7.4.Clevis7.5.Gasket
8.
Brake master cylinder8.1.Sub Tank Cap
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8.2.Brake Fluid level switch8.3.Sub Tank8.4.Clamp8.5.Hose8.6.
Reservoir Tank8.7.Cylinder Body
8.8.Pin8.9.Secondary Piston Assembly8.10. Drain Plug washer8.11. Stopper Cap8.12. Seal8.13. Primary Piston Assembly
9. Front Disc Brake10.Rear Drum Brake11.Front Suspension Member12.Stabilizer13.Shock Absorber14.Rebound Spring15.High Caster Geometry
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CONCLUSION
The training was of great value which provided in depth knowledge of the subject
Mechanical Engineering. Learning the concepts with an organization like NISSAN was very
beneficial and the innovative technology used by NISSAN in Evalia was very amazing.
The topics were understood very well with their practical application and working on
them was a good job. The training was completed successfully with grasping the concepts of
Mechanical Engineering with new technologies and practically working on them.
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REFERENCES
1. The books which were followed are M. L. Mathur and F. S. Mehta Thermal Engineering R. K. Purohit
2. Websites which were followed are www.google.com www.nissanevalia.co.in autos.maxabout.com
http://www.google.com/http://www.google.com/http://www.nissanevalia.co.in/http://www.nissanevalia.co.in/http://autos.maxabout.com/http://autos.maxabout.com/http://autos.maxabout.com/http://www.nissanevalia.co.in/http://www.google.com/