Technical English For Automotive Engineering - Chapter 1 - Automotive Introduction-Đã G P

AUTOMOTIVE INTRODUCTION.
Chapter 1: Automotive Introduction.

I. PRE-READING QUESTION:
1. What are the main functions of automobile nowadays?

2. How automobile can be classified?
3. How many major systems in automobile?
II. READING
Part a: Automobile Introduction
Automobile, self-propelled vehicle used primarily on public roads but adaptable to other
surfaces. Automobiles changed the world during the 20th century. From the growth of
suburbs to the development of elaborate road and highway systems, the so-called horseless
carriage has forever altered the modern landscape. The manufacture, sale, and servicing of
automobiles have become key elements of industrial economies. But along with greater
mobility and job creation, the automobile has brought noise and air pollution, and automobile
accidents rank among the leading causes of death and injury throughout the world. But for
better or worse, the 1900s can be called the Age of the Automobile, and cars will no doubt
continue to shape our culture and economy well into the 21st century.
Automobiles are classified by size, style, number of doors, and intended use. The typical
automobile, also called a car, auto, motorcar, and passenger car, has four wheels and can carry
up to six people, including a driver. Larger vehicles designed to carry more passengers are
called vans, minivans, omnibuses, or buses. Those used to carry cargo are called pickups or
trucks, depending on their size and design. Minivans are van-style vehicles built on a
passenger car frame that can usually carry up to eight passengers. Sport-utility vehicles, also
known as SUVs, are more rugged than passenger cars and are designed for driving in mud or
snow.
The automobile is built

around an engine. Various
systems supply the engine
with fuel, cool it during
operation, lubricate its
moving parts, and remove
exhaust gases it creates. The
engine produces mechanical
power that is transmitted to
the automobile’s wheels
through a drivetrain, which
includes a transmission, one
or more driveshafts, a
differential gear, and axles.
Fig1.1: The drive-train. Suspension systems,

which include springs and
shock absorbers, cushion the ride and help protect the vehicle from being damaged by bumps,
heavy loads, and other stresses.
Technical English for AUTOMOTIVE ENGINEERING. 1

AUTOMOTIVE INTRODUCTION. 1
Fig 1.2: A multi-link rear axle,

– a type of suspension system
which is progressively
replacing the semi-trailing arm
axle, and consists of at least one
trailing arm on each side.
Fig 1.3: Four-bar twist beam

axle by Renault, with 2
torsion bar springs both for
the left and right axle sides.
Wheels and tires support the vehicle on the roadway and, when rotated by powered
axles, propel the vehicle forward or backward. Steering and braking systems provide control
over direction and speed.
Fig 1.4: Steering and

suspension system.
An electrical system starts and operates the engine, monitors and controls many aspects
of the vehicle’s operation, and powers such components as headlights and radios. Safety
features such as bumpers, air bags, and seat belts help protect occupants in an accident.

Part b: Automobile Physical Configuration
Fig 1.5: Automobile systems
The automobile configuration is depicted in Figure 1.5, in which many of the important
automotive systems are illustrated. These systems include the following:
1. Engine 6. Instrumentation
2. Drivetrain (transmission, differential, 7. Electrical/electronic
axle) 8. Motion control
3. Suspension 9. Comfort/convenience
4. Steering 10.Entertainment/communication/navigati
5. Brakes on.
III. NEW WORDS
Look up for the new words
Automobile (n) Rank (n) Truck (n) Driveshafts (n)

Self-propelled vehicle (n) Doubt (n, v) Carriage (n) Differential (n)
Suspension systems (n) Shape (v, n) Rugged (a) Gear (n)
Steering system (n) Classify (v) Mud (n) Axles (n)
Sport-utility vehicles (n) Van (n) Snow (n) So-called (a)
braking system (n) Omnibuses (n) Wheel (n) Springs (n)
For better or worse (exp) Pickup (n) Drive-train (n) shock absorbers (n)
Element (n) Landscape (n) Transmission (n) cushion (n)
Elaborate (a) bumps (n) electrical system (n) headlight (n)
Suburbs (n) bumper (n) occupant (n)
adaptable to (a) Highway (n) Primary (a)
IV. COMPREHENSION QUESTION
Answer these questions:
1. Why do we call automobiles as self-propelled vehicles?

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2. What are the key elements of industrial economies?
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3. What are advantages of automobile in our life?
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4. What are disadvantages of automobile in our life?
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5. What are the main functions of the engine?
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6. What are the main functions of Suspension systems?
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7. What are the main functions of wheels and tires?
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8. What are the main functions steering and braking systems?
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9. What are the main functions of electrical system?
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10. What component(s) makes automobiles safer?
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V. TRUE/FALSE
Decide if these statements are True or False:
1. Automobiles can be use primarily on public roads. ( True False)

2. Servicing of automobiles has become key elements of industrial economies.( True
False)
3. Automobile industries create only mobilities and jobs. ( True False)
4. The 21st century can be called the Age of the Automobile. ( True False)
5. Vans are designed to carry people. ( True False)
6. Minivans can carry more than 9 people. ( True False)
7. Sport-utility vehicles are more rugged than passenger cars. ( True False)
8. Sport-utility vehicle can be drived in mud or snow. ( True False)

9. The engine produces mechanical power. ( True False)

10. Drivetrain consist of a transmission, one or more driveshafts, a differential gear, and axles.
( True False)
11. Suspension systems includes springs and shock absorbers and cushion. ( True False)
12. Wheels and tires are rotated by powered axles. ( True False)
13. Steering and braking systems provide control over direction and speed. ( True False)
14. Electrical system only starts and operates the engine. ( True False)
15. Bumpers, air bags, and seat belts are safety features of automobile. ( True False)
VI. WORD(S) SELECTIONS
Select ONE word(s) in the below box and fill in the gap in column B with its meaning word in
column A
a. The system c. Cars designed e. Self- g. The system i. Vehicles

protects vehicles for driving in propelled locates car’s used to carry
from bumps, loads, mud or snow. vehicle. position. cargo
and stresses
b. Capable of d. The system f. The system h. Double- j. The system
transmit engine’s controls car’s deck bus cools the
power to the direction. engine during
wheels its operation.
No Column A Column B No Column A Column B

1 Automobile 6 Sport-utility vehicles
2 Pickups 7 Omnibus
3 Adaptable to 8 Drivetrain system
4 Steering system 9 Navigation system
5 Suspension system 10 Coolant system

THE ENGINE 2
Chapter 2: The Engine

I. PRE-READING QUESTION
1. Name some kinds of engines you know.

2. Do you have a four-stroke engine in your house? How powerful is it?
3. What type of fuel does a four-stroke engine run on?
II. READING
1. The reciprocating engine
The engine is the heart of a car although it is normally hidden under the bonnet. The
engine is exposed in a motorcycle but the detailed mechanisms are not visible.
Fig 2.1:
Cutaway of four-
stroke cycle
petrol engine
(courtesy of
Volvo Car
Corporation).
There are two main types of reciprocating engine, the four-stroke and the two-stroke
engine:
1.1. The petrol engine
1.1.1. Four-stroke engine
Fig2.2: Basic operations of four-stroke cycle engine.

THE ENGINE 2
The four-stroke engine is also referred to as the Otto cycle engine after its inventor N.A.
Otto. Most cars use the four-stroke engine. An individual cycle comprises four strokes: 1,
intake stroke; 2, compression stroke; 3, power stroke and 4, exhaust stroke. These four strokes
repeat to generate the crankshaft revolution.
+ Intake stroke: the intake stroke draws air and fuel into the combustion chamber. The piston
descends in the cylinder bore to evacuate the combustion chamber. When the inlet valve
opens, atmospheric pressure forces the air-fuel charge into the evacuated chamber. As a
result, the combustible mixture of fuel and air fills the chamber.
+ Compression stroke: at the end of the intake stroke, both inlet and exhaust valves are
closed. The inertial action of the crankshaft in turn lifts the piston which compresses the
mixture. The ratio of the combustion chamber volume before and after compression is called
the compression ratio.
+ Power stroke: when the piston ascends and reaches top dead center, an electric current
ignites the spark plug and as the mixed gas burns, it expands and builds pressure in the
combustion chamber. The resulting pressure pushes the piston down with several tons of
force.
+ Exhaust stroke: during the exhaust stroke, the inlet valve remains closed whilst the exhaust
valve opens. The moving piston pushes the burned fumes through the now open exhaust port
and another intake stroke starts again.
During one cycle, the piston makes two round trips and the crankshaft revolves twice. The
inlet and exhaust valves open and close only once. The ignition plug also sparks only once. A
petrol engine, whether four- or two-stroke, is called a Spark Ignition (SI) engine because it
fires with an ignition plug. The four-stroke-cycle engine contains the lubricating oil in the
crankcase. The oil both lubricates the crankshaft bearings and cools the hot piston.
1.1.2. The two-stroke engine
The two-stroke engine is similar to that of the four-stroke-cycle engine in its reciprocating
mechanism. It uses the piston-crankshaft mechanism, but requires only one revolution of the
crankshaft for a complete power-producing cycle. The two-stroke engine does not use inlet
and exhaust valves. The gas exchange is implemented by scavenging and exhaust port-hole
openings in the bore wall. The upward and downward motion of the piston simultaneously
opens and closes these port-holes. The air-fuel mixture then goes in or out of the combustion
chamber through the port-holes. Combustion takes place at every rotation of the crankshaft.
In the two-stroke engine, the space in the

crankcase works as a pre-compression chamber
for each successive fuel charge. The fuel and
lubricating oil are premixed and introduced
into the crankcase, so that the crankcase cannot
be used for storing the lubricating oil. When
combustion occurs in the cylinder, the
combustion pressure compresses the new gas
in the crankcase for the next combustion. The
burnt gas then exhausts while drawing in new
gas. The lubricating oil mixed into the air-fuel
mixture also burns.
Since the two-stroke engine does not use a
valve system, its mechanism is very simple.
The power output is fairly high because it
achieves one power stroke per two revolutions
of the crankshaft. However, although the
power output is high, it is used only for small
motorcycle engines and some large diesel
Fig2.3: Two-stroke engine

THE ENGINE 2
applications. Since the new gas pushes out the burnt gas, the intake and exhaust gases are not
clearly separated. As a result, fuel consumption is relatively high and cleaning of the exhaust
gas by a catalytic converter is difficult.
1.2. The diesel engine
The name diesel comes from the inventor of the diesel engine, R. Diesel. There are both
four- and two-stroke-cycle diesel engines. Most automotive diesels are four-stroke engines.
The intake stroke on the diesel engine draws only air into the cylinder. The air is then
compressed during the compression stroke. At near maximum compression, finely atomized
diesel fuel (a gas oil having a high flashpoint) is sprayed into the hot air, initiating auto
ignition of the mixture. During the subsequent power stroke, the expanding hot mixture works
on the piston, then burnt gases are purged during the exhaust stroke.
Since diesel engines do not use a spark plug, they are also referred to as compression
ignition (CI) engines. In the case of petrol engines, too high a temperature in the combustion
chamber ignites the petrol spontaneously. When this occurs, the plug cannot control the
moment of ignition. This unwanted phenomenon is often referred to as ‘knocking’.
The diesel is an injection engine. A

petrol engine normally needs a throttle
valve to control airflow into the cylinder,
but a diesel engine does not. Instead, the
diesel uses a fuel injection pump and an
injector nozzle sprays fuel right into the
combustion chamber at high pressure.
The amount of fuel injected into the
cylinder controls the engine power and
speed. There are two methods by which
fuel is injected into a combustion
chamber, direct or indirect injection.
With direct injection engines (DI)
the fuel is injected directly into the
cylinder and initial combustion takes
place within the bowl that is machined
into the piston head itself. With indirect
injection engines (IDI) the fuel is
injected and initial combustion takes
place in a small pre combustion chamber
Fig 2.4: Basic parts of a diesel engine formed in the cylinder head. The burning
gases then expand into the cylinder where
combustion continues.
2. Advantages and disadvantages of reciprocating engines
-> An engine with a piston-cylinder mechanism has the following advantages:
a. It is possible to seal the gap between the piston and the cylinder, resulting in high
compression ratio, high heat efficiency and low fuel consumption.
b. The piston ring faces the cylinder bore wall, separated by an oil film. The resulting
hydrodynamic lubrication generates low friction and high durability.
c. The piston loses speed at the dead-center points where the travelling direction
reverses, which gives enough time for combustion and intake as well as for exhaust.
-> However, the reciprocating engine also has disadvantages:
a. The unbalanced inertial force and resulting piston ‘slap’ can cause noise and vibration.
b. It is difficult to reuse the exhaust heat.

THE ENGINE 2
3. The rotary engine (Wankel engine)

The rotary-piston engine (or Wankel engine, named by its inventor) generates power by
the compression, ignition, and expansion of gasoline/air mixture in a 4-stroke cycle in the
same way as conventional internal combustion engines. The completely different mechanical
design allows all moving parts to have a continuous rotary motion instead of a reciprocating
movement. The rotor (or piston) is roughly triangular shaped and rotates on an eccentric on
the output shaft within a housing of epitrochoid shape. The term is given to the path described
by a point within a circle rolling around another circle.
Fig 2.5: The Wankel rotary engine cycle
III. NEW WORDS
Look up for the new words
Bonnet (n) Crankshaft Cylinder head Exhaust valve

Valve lifter Lambda sensor Valve spring Inlet valve
Spark ignition (SI)
Camshaft Catalytic converter Fuel injector
engine
Valve seat Exhaust manifold Intake manifold Ignition plug
Combustion
Camshaft drive chain Piston Scavenge (v)
chamber
Cylinder Connecting rod Crank case Air-fuel mixture
Compression ignition
Spontaneously Phenomenon Referred to
(CI) engines
Direct injection Indirect injection
Knocking Injector nozzle
engines (DI) engines (IDI)

1. What is the role of engine in cars?
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2. How many types of reciprocating engine?
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3. Name 4 strokes of the 4-stroke engine?
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4. How are the air and fuel mixture drawn into combustion chamber in intake stroke?

THE ENGINE 2
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5. In compression stroke, how the mixture is compressed?
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6. Why is the piston pushed down in power stroke?
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7. Why can we call a petrol engine as a Spark Ignition (SI) engine?
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8. What is the same feature of the two-stroke engine and the four-stroke-cycle engine?
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9. Does two-stroke engine use inlet and exhaust valves?
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10. In the two-stroke engine, what is the function of the space in the crankcase?
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11. Why is a two-stroke engine mechanism very simple?
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12. How about a two-stroke engine power? Is it more than or less than the same capacity of
four-stroke engine? Why?
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13. Why isn’t a two-stroke engine as popular as four-stroke one?
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14. What kind of mixture is intaken in intake-stroke of a diesel engine?
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15. Why doesn’t a diesel engine have a spark plug?
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16. How many methods for injecting fuel into a combustion chamber in diesel engine?
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17. Advantages and disadvantages of reciprocating engines?

THE ENGINE 2
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V. QUIZ
1. Most automobile engines are

a. large and heavy
b. gasoline-fueled, spark-ignited, liquid-cooled internal combustion type
c. unable to run at elevations that are below sea level
d. able to operate with any fuel other than gasoline.
2. An exhaust valve is
a. a hole in the cylinder head
b. a mechanism for releasing the combustion products from the cylinder
c. the pipe connecting the engine to the muffler
d. a small opening at the bottom of a piston.
3. Power is produced during
a. intake stroke
b. compression stroke
c. power stroke
d. exhaust stroke.
4. The air–fuel ratio is
a. the rate at which combustible products enter the engine
b. the ratio of the mass of air to the mass of fuel in a cylinder before ignition
c. the ratio of gasoline to air in the exhaust pipe
d. intake air and fuel velocity ratio.
5. An SI engine is
a. a type of internal combustion engine
b. a Stirling engine
c. always fuel injected
d. none of the above.
VI. TRUE/FALSE
Decide if these statements are True or False:
1. We can see the detailed mechanisms of a engine in a car ( True False)

2. The four-stroke engine is also referred to as the Otto cycle engine when petrol is used as
fuel ( True False)
3. In four-stroke petrol engine, only air is intaken in induction stroke ( True False)
4. Two-stroke engine uses inlet and exhaust valves ( True False)
5. The name diesel comes from the inventor of the diesel engine, R. Diesel ( True False)
6. The intake stroke on the diesel engine draws air/diesel mixture into the cylinder ( True
False)
7. A diesel engine uses a spark plug for ignition. ( True False)
8. A petrol engine normally needs a throttle valve to control airflow into the cylinder and a
diesel engine does ( True False)
9. In DI engine, the fuel is injected directly into the cylinder ( True False)
10. In IDI engine, the fuel is injected and initial combustion takes place in a small pre-
ombustion chamber formed in the cylinder head ( True False).

THE ENGINE 2
VII. SUBSTITUTION
1. “The engine is the heart of a car although it is normally hidden under the bonnet”
(paragraph 1). It refers to:
a. the man’s heart.
b. The engine’s heart.
c. The car’s heart.
d. All correct.
2. “Power stroke: when the piston ascends and reaches top dead center, an electric current
ignites the spark plug and as the mixed gas burns, it expands and builds pressure in the
combustion chamber” (paragraph 2, part 1.1.1). It refers to:
a. spark plug
b. air.
c. Fuel.
d. Air/fuel mixture.
3. “Compression stroke: at the end of the intake stroke, both inlet and exhaust valves are
closed. The inertial action of the crankshaft in turn lifts the piston which compresses the
mixture” (paragraph 2, part 1.1.1). Which refers to:
a. The inertial action.
b. the crankshaft.
c. the piston.
d. the mixture
4. “There are two methods by which fuel is injected into a combustion chamber, direct or
indirect injection” (paragraph 4, part 1.2). Which refers to:
a. the way to control engine power
b. the way to inject fuel into cylinder.
c. the way to control engine speed.
d. All correct.
5. “The piston loses speed at the dead-center points where the travelling direction reverses,
which gives enough time for combustion and intake as well as for exhaust” (paragraph 3,
part 2). Which refers to:
a. the travelling direction reverses.
b. the dead-center points
c. the loosen speed of the piston.
d. all correct.

DRIVETRAIN 3
Chapter 3: The Drivetrain.

1. How to transmit motive power from the engine to the wheels?
2. How to adjust the ratio of engine speed to wheel speed?
3. In the front-engine car, how to transmit the power from the engine to the rear wheels?
4. When the vehicle turn a corner, what component allows each driven wheel to turn at a
different speed?
II. READING
The engine drivetrain system of the automobile consists of the engine, clutch,
transmission, drive shaft, differential and driven wheels. We have already discussed the SI
engine and we know that it provides the motive power for the automobile. Now let’s examine
the clutch, transmission, drive shaft and differential in order to understand the roles of these
devices.
1. CLUTCH
A clutch is a releasable coupling connecting the adjacent ends of two coaxial shafts.
Mechanical clutches fall into two main categories: positive engagement and progressive
engagement.
The former is either positively disengaged, so that no torque can be transmitted from the
driving to the driven shaft, or positively engaged, in which case the shafts rotate together,
connected by some mechanical devices such as splines, keys. In contrast, the progressive type
is gradually engaged, so that the speed of the driving shaft falls while, simultaneously, that of
the driven shaft rises from its initial stationary state until both are rotating at equal speeds.
Positive engagement clutches are unsuitable for connecting the engine to the gearbox.
For road vehicles, a progressive engagement clutch of the friction type is interposed
between the engine and the gearbox. To illustrate the basic principles applicable to all
progressive engagement clutches, a simple clutch stripped of all complications such as friction
linings and actuation mechanism is shown in Fig. 3.1. The two plates E and F are keyed on
the ends of shafts A and B, which are carried in bearings C and D. All rotate about a common
axis XY.
Fig 3.1: Basic principle of the

friction-type clutch
Fig 3.2: Clutch position in car.

DRIVETRAIN 3
Fig 3.3: Clutch components
Fig 3.4: Single-plate Fig 3.5: Multi-spring single-plate Fig 3.6: Triple-plate clutch
clutch clutch
At high rotational speeds, problems can arise with multi-spring clutches owing to the
effects of centrifugal force on both the springs themselves and the levers of the release
mechanism. These problems are obviated when diaphragm-type springs are used, and a
number of other advantages are experienced.

DRIVETRAIN 3
Fig 3.7: The diaphragm-spring clutch.
2. TRANSMISSION
The transmission is a gear system that adjusts the ratio of engine speed to wheel speed.
Essentially, the transmission enables the engine to operate within its optimal performance range
regardless of the vehicle load or speed. It provides a gear ratio between the engine speed and vehicle
speed such that the engine provides adequate power to drive the vehicle at any speed.
Fig 3.8: Transmission position in car
Fig 3.9: Mercedes-Benz C-class sport coupe, Fig 3.10: Mercedes-Benz Actros, manual
six-speed manual transmission transmission
To understand the basic idea behind a standard transmission, the Fig 3.11 shows a very simple
two-speed transmission in neutral:

DRIVETRAIN 3
Fig 3.11: Two-speed transmission

The shaft 1 comes from the engine through the clutch. The shaft 1 and gear 1 are connected as a
single unit.
The shaft 2 and gears in this shaft are called the layshaft. These are also connected as a single
piece, so all of the gears on the layshaft and the layshaft itself spin as one unit. The shaft 1 and the
shaft 2 are directly connected through their meshed gears so that if the shaft 1 is spinning, so is the
shaft 2. In this way, the layshaft receives its power directly from the engine whenever the clutch is
engaged.
The shaft 3 is a splined shaft that connects directly to the drive shaft through the differential to the
drive wheels of the car. If the wheels are spinning, the shaft 3 is spinning.
The gears 3 ride on bearings, so they spin on the shaft 3. If the engine is off but the car is coasting,
the shaft 3 can turn inside the gears 3 while the gears 3 and the layshaft are motionless.
The purpose of the collar is to connect one of the two gears 3 to the drive shaft 3. The collar is
connected, through the splines, directly to the shaft 3 and spins with the shaft 3. However, the collar
can slide left or right along the shaft 3 to engage either of the gears 3. Teeth on the collar, called dog
teeth, fit into holes on the sides of the gears 3 to engage them.
The five-speed manual transmission is fairly standard on cars today. Internally, it looks something
like Fig 3.12
Fig 3.12: Five-speed manual transmission

DRIVETRAIN 3
Manual transmissions in modern

passenger cars use synchronizers to
eliminate the need for double-
clutching. A synchro's purpose is to
allow the collar and the gear to make
frictional contact before the dog teeth
make contact. This lets the collar and
the gear synchronize their speeds
before the teeth need to engage, like
Fig 3.13
The cone on the gear fits into
the cone-shaped area in the collar,
Fig 3.13: Synchronizers and friction between the cone and
the collar synchronize the collar and
the gear. The outer portion of the collar then slides so that the dog teeth can engage the gear.
Every manufacturer implements transmissions and synchros in different ways, but this is
the general idea.
3. DRIVE SHAFT
The drive shaft is used on front-engine, rear wheel drive vehicles to couple the
transmission output shaft to the differential input shaft (fig 3.8). Flexible couplings, called
universal joints, allow the rear axle housing and wheels to move up and down while the
transmission remains stationary. In front wheel drive automobiles, a pair of drive shafts
couples the transmission to the drive wheels through flexible joints known as constant
velocity (CV) joints.
Fig. 3.14 The drive shaft and universal joints

4. DIFFERENTIAL
The differential serves three purposes (see Figure 1.13).
• The most obvious is the right angle transfer of the rotary motion of the drive shaft
to the wheels.
• The second purpose is to allow each driven wheel to turn at a different speed. This
is necessary because the “outside” wheel must turn faster than the “inside’’ wheel
when the vehicle is turning a corner.
• The third purpose is the torque increase provided by the gear ratio.
This gear ratio can be changed in a repair shop to allow different torque to be delivered to
the wheels while using the same engine and transmission. The gear ratio also affects fuel
economy.

DRIVETRAIN 3
Fig 3.15: Differential
III. NEW WORDS
clutch stationary disc Release bearing

coaxial shafts state flywheel Release fork
positive engagement unsuitable crankshaft spring
progressive Pilot
gearbox centrifugal force
engagement bearing/bushing
diaphragm-type
splines friction type Front/rear
springs
keys interposed seal transmission
Transmission input
gradually principles gear ratio
shaft
simultaneously stripped Bearing retainer regardless
adequate meshed cone front-engine
neutral collar implements couple
layshaft dog teeth synchros differential
spin synchronizers Drive Shaft universal joints
constant velocity
obvious right angle torque
joints

1. What is a clutch?
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2. How many types of clutch?
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3. How many types of positive engagement clutch?
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DRIVETRAIN 3
4. Are ositive engagement clutches suitable for connecting the engine to the gearbox?
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5. What is the typical type of progressive engagement clutch?
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6. What is/are the main problem(s) for the multi-spring clutches at high rotational speeds?
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7. And how can we solve that (those) problem(s)?
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8. What is the main function of transmission?
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9. What is the layshaft?
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10. What is the main purpose of the collar?
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11. What is the name of the teeth on the collar?
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12. What is the main function of synchronizer?
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13. How does the synchronizer operate?
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14. What is the drive shaft function?
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15. What is the Universal joint?
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16. What are the purposes of differential?
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DRIVETRAIN 3
V. TRUE/FALSE
1. Engine, clutch, transmission, drive shaft, differential and driven wheels are elements of
drivetrain system. ( True False)
2. A clutch is a releasable coupling. ( True False)
3. There are two main categories of mechanical clutches. ( True False)
4. Progressive engagement clutch is friction type. ( True False)
5. Centrifugal force is the main problem which arises with multi-spring clutches. ( True
False)
6. Diaphragm-type springs obviate the problems in the multi-spring clutches at high
rotational speeds. ( True False)
7. The transmission enables the engine to operate within its optimal performance range. (
True False)
8. By providing a gear ratio between the engine speed and vehicle speed of the clutch,
engine provides adequate power to drive the vehicle at any speed. ( True False)
9. Layshaft is a intermidiate shaft in gear box. ( True False)
10. Synchronizers add the need for double-clutching in cars. ( True False)
11. Transmissions and synchros are implemented in the same way by all auto manufacturer.
( True False)
12. The drive shaft is used to couple the transmission output shaft to the differential input
shaft. ( True False)
13. Universal joints a rigid couplings. ( True False)
14. Differential allows each driven wheel to turn at a different speed. ( True False)
15. Differential is the torque decrease provided by the gear ratio. ( True False)

SUSPENSION SYSTEM 4
Chapter 4: Suspension System.

1. How to maximize the friction between the tires of a car and the road surface?
2. How to provide steering stability with good handling and to ensure the comfort of the
passengers?
3. How to absorb the vibration in moving of the cars?
II. READING
Another major automotive sub-system is the suspension system, which is the mechanical
assembly that connects each wheel to the car body. The primary purpose of the suspension
system is to isolate the car body from the vertical motion of the wheels as they travel over the rough
road surface. The suspension system can be understood with reference to Figure 4.1, which illustrates
the major components.
Fig 4.1: Major components of suspension system.

1. SPRINGS
Notice that the wheel assembly is connected through a movable assembly to the body. The weight
of the car is supported by SPRINGS. Today's springing systems are based on one of four basic
designs:
1.1. Coil springs: this is the most common type of spring and is, in essence, a heavy-duty torsion
bar coiled around an axis. Coil springs compress and expand to absorb the motion of the wheels (Fig
4.1).
1.2. Leaf springs: this
type of spring consists of
several layers of metal
(called "leaves") bound
together to act as a single
unit. Leaf springs were
first used on horse-drawn
carriages and were found
on most American
automobiles until 1985.
They are still used today
on most trucks and heavy-
duty vehicles (Fig 4.2) Fig 4.2: Leaf spring.

SUSPENSION SYSTEM 4
Fig 4.3: Leaf spring assembly

1.3 Torsion bars: torsion bars
use the twisting properties of a steel
bar to provide coil-spring-like
performance. The short torsion bar
springs grip into the guide tubes 2 and
3 in the centre of the vehicle (Fig 4.4).
Parts 2, 3 and 4 are jointly subjected
to torsional stresses and so the
torsional stiffness of the transverse
tubes contributes to the spring rate. On
the outside, the cast trailing arms 1
are welded to the transverse tubes,
which (pushed into each other) support
each other on the torsionally elastic
bearings 5 and 6. This creates a
sufficiently long bearing basis, which
largely prevents camber and toe-in
changes when forces are generated.
Fig 4.4: Torsion bars in suspension system The entire assembly is fixed by the
brackets 7 which permits better force
transfer on the body side sill. Guide tubes 2 and 3 are mounted in the brackets and can rotate, as well
as the outer sides of the two torsion bars 4. The two arms thus transfer all vertical forces plus the
entire springing moment to the body. The anti-roll bar 8 is connected to the two trailing arms via two
U-shaped tabs. The two rubber bearings 5 and 6 located between the tubes 2 and 3 also contribute
to the stabilizing effect. The bump and rebound travel stops are fitted into the shock absorber 9.
1.4 Air springs: The air-spring bellows

are supplied by an electrically powered
compressor. The individual wheel
adjustment permits the lowering or lifting of
the vehicle as well as a constant vehicle
height, regardless of – even onesided –
loading. It is also possible to counteract
body tilt during cornering. The damping
properties of the shock absorbers are
affected by spring bellow pressure
depending on the load (Fig 4.5)
Fig 4.5: Air springs in suspension system

SUSPENSION SYSTEM 4
2. SHOCK ABSORBER (sometimes a strut)

(Fig 4.6), which is in effect a viscous damping
device. There is a similar assembly at each wheel,
although normally there are differences in the
detailed configuration between front and rear
wheels.
Enter the shock absorber, or snubber, a
device that controls unwanted spring motion
through a process known as dampening. Shock
absorbers slow down and reduce the magnitude
of vibratory motions by turning the kinetic
energy of suspension movement into heat
energy that can be dissipated through hydraulic
fluid.
A shock absorber is basically an oil pump
placed between the frame of the car and the
Fig 4.6: Shock Absorber. wheels. The upper mount of the shock connects
to the frame (i.e., the sprung weight), while the
lower mount connects to the axle, near the wheel (i.e., the unsprung weight). In a twin-tube
design, one of the most common types of shock absorbers, the upper mount is connected to a
piston rod, which in turn is connected to a piston, which in turn sits in a tube filled with
hydraulic fluid. The inner tube is known as the pressure tube, and the outer tube is known as
the reserve tube. The reserve tube stores excess hydraulic fluid.
When the car wheel encounters a bump in the road and causes the spring to coil and
uncoil, the energy of the spring is transferred to the shock absorber through the upper mount,
down through the piston rod and into the piston. Orifices perforate the piston and allow fluid
to leak through as the piston moves up and down in the pressure tube. Because the orifices are
relatively tiny, only a small amount of fluid, under great pressure, passes through. This slows
down the piston, which in turn slows down the spring.
Shock absorbers work in two cycles -- the compression cycle and the extension cycle.
The compression cycle occurs as the piston moves downward, compressing the hydraulic
fluid in the chamber below the piston. The extension cycle occurs as the piston moves toward
the top of the pressure tube, compressing the fluid in the chamber above the piston. A typical
car or light truck will have more resistance during its extension cycle than its compression
cycle. With that in mind, the compression cycle controls the motion of the vehicle's unsprung
weight, while extension controls the heavier, sprung weight.
SUSPENSION TYPES
3.1 Dependent Suspensions
3.1.1 Dependent front suspensions: have a
rigid front axle that connects the front
wheels. Basically, this looks like a solid bar
under the front of the car, kept in place by leaf
springs and shock absorbers. Common on
trucks, dependent front suspensions haven't
been used in mainstream cars for years.
Fig 4.7: Dependent front

suspensions

SUSPENSION SYSTEM 4
3.1.2 Dependent rear suspensions
Fig 4.8: Solid-axle, leaf-spring Fig 4.9: Solid-axle, coil-spring
Contrary to the front version of

this system, many cars are still
designed and built with
dependant (linked) rear
suspension systems.
Fig 4.10: Beam Axle
3.2 Independent Suspensions

3.2.1 Independent front Suspensions
Fig 4.12: Coil Spring type 1
Fig 4.11: Macpherson strut

So-named because the front wheel's
suspension systems are independant of
each other (except where joined by an
anti-roll bar). These came into existance
around 1930 and have been in use in one
Fig 4.13: Coil Spring type 2

SUSPENSION SYSTEM 4
form or another pretty much ever since then.
Fig 4.14: Double Wishbone Fig 4.15: Multi-link suspension

3.2.2 Independent rear Suspensions
Fig 4.16: The rear axle on Mitsubishi Pajero
III. NEW WORDS
isolate rough suspension system shock absorber

spring car frame lower control arm coil spring
in essence heavy-duty torsion absorb
leaf spring bound horse-drawn carriages torsion bars
twist grip guide tubes torsional stress
stiffness transverse tube trailing arms air springs
counteract tilt strut snubber
magnitude vibratory kinetic energy dissipate
sprung weight axle unsprung weight twin-tube
hydraulic fluid reserve tube excess encounters
orifice perforate dependent suspensions rigid front axle
mainstream contrary independent suspensions so-named
existance wishbone multi-link suspension antiroll bar

SUSPENSION SYSTEM 4

1. What system connects each wheel to the car body?
-----------------------------------------------------------------------------------------------------------------
2. What is/are the primary purpose(s) of the suspension system?
-----------------------------------------------------------------------------------------------------------------
3. How to support the weight of the car?
-----------------------------------------------------------------------------------------------------------------
4. What are the four basic designs of the springing systems?
-----------------------------------------------------------------------------------------------------------------
5. How do coil springs absorb the motion of the wheels?
-----------------------------------------------------------------------------------------------------------------
6. How to constitute the leaf springs?
-----------------------------------------------------------------------------------------------------------------
7. What is/are the property(ies) of the Torsion bars for supplying coil-spring-like
performance?
-----------------------------------------------------------------------------------------------------------------
8. Are the air springs possible to counteract body tilt during cornering?
-----------------------------------------------------------------------------------------------------------------
9. Is it the same kind of shock absorber assembly at each wheel in a car?
-----------------------------------------------------------------------------------------------------------------
10. How do the shock absorbers slow down and reduce the magnitude of vibratory motions?
-----------------------------------------------------------------------------------------------------------------
V. TRUE/FALSE
1. Suspension system connects each wheel to the car body. ( True False)
2. The primary purpose of the suspension system is to isolate the car body from the
horizontal motion of the wheels as they travel over the rough road surface. ( True
False)
3. The springs in suspension system support the weight of the car. ( True False)
4. Coil springs compress and expand to absorb the motion of the wheels. ( True False)
5. Leaf springs consist of several layers of metal bound together to act as a single unit. (
True False)

SUSPENSION SYSTEM 4
6. Leaf springs were first used on bicycle. ( True False)

7. Leaf springs are used today on all trucks and heavy-duty vehicles. ( True False)
8. Torsion bars use the compressing properties of a steel bar to provide coil-spring-like
performance. ( True False)
9. The air-spring suspension system are supplied by an electrically powered compressor. (
True False)
10. Shock absorbers effect as a viscous damping device. ( True False)
11. Shock absorbers control wanted spring motion through a process known as dampening. (
True False)
12. Shock absorbers slow down and reduce the magnitude of vibratory motions by turning the
kinetic energy of suspension movement into chemical energy. ( True False)
13. A shock absorber is basically an oil source placed between the frame of the car and the
wheels. ( True False)
14. The sprung weight is the upper mount of the shock connects to the frame. ( True
False)
15. The unsprung weight is the lower mount connects to the axle, near the wheel. ( True
False)
16. Shock absorbers work in the compression cycle and the extension cycle. ( True False)
17. Dependent Suspensions have a rigid axle that connects the front wheels. ( True False)
18. Independent suspensions is named because the wheel's suspension systems are
independant of each other. ( True False)
19. Engine, clutch, transmission, drive shaft, differential and driven wheels are elements of
drivetrain system. ( True False).
VI. WORD(S) SELECTIONS.
column A
a. One type of c. One type of

i. The lower
spring is spring consists of e. The upper
mount
supplied by an several layers of mount of the
g. link connects to
electrically metal bound shock connects
the axle, near
powered together to act as to the frame.
the wheel
compressor a single unit
b. A device
h. One type of
controls
f. System spring uses twisting
wanted spring j. frustrate
d. High connects each properties of a steel
motion through
performance wheel to the car bar to provide coil-
a process
body spring-like
known as
performance
dampening.

1 Suspension system 6 air-spring suspension
2 Leaf spring 7 Shock absorbers
3 Torsion bars 8 The sprung weight
4 The unsprung weight 9 counteract
5 heavy-duty 10 bound

STEERING SYSTEM 5
Chapter 5: STEERING SYSTEM.

1. How to turn direction of a moving car?
2. What component(s) helps the car change its direction?
3. How about the speed of the front wheels in the car when they turn?
II. READING
1. TURNING THE CAR

You might be surprised to learn that when you turn your car, your front wheels are not
pointing in the same direction. For a car to turn smoothly, each wheel must follow a different
circle. Since the inside wheel is following a circle with a smaller radius, it is actually making
a tighter turn than the outside wheel. If you draw a line perpendicular to each wheel, the lines
will intersect at the center point of the turn. The geometry of the steering linkage makes the
inside wheel turn more than the outside wheel.
Fig 5.1: Turning car with their steering system

2. STEERING TYPES
2.1 Rack-and-pinion Steering
a. System introduction
Rack-and-pinion steering is
quickly becoming the most
common type of steering on cars,
small trucks and SUVs. It is
actually a pretty simple mechanism.
A rack-and-pinion gearset is
enclosed in a metal tube, with each
end of the rack protruding from the
tube. A rod, called a tie rod,
connects to each end of the rack.
The pinion gear is attached to
the steering shaft. When you turn
the steering wheel, the gear spins,
moving the rack. The tie rod at each
Fig 5.2: Rack-and-pinion steering

STEERING SYSTEM 5
end of the rack connects to the steering arm on the spindle.

b. Advantages and disadvantages:
+ The advantages:
• simple construction
• economical and uncomplicated to
manufacture;
• easy to operate due to good degree
of efficiency;
• contact between steering rack and
pinion is free of play and even
internal damping is maintained
• tie rods can be joined directly to
the steering rack;
• minimal steering elasticity
compliance.
• compact (the reason why this type
Fig 5.3: Top view of the rack and pinion steering of of steering is fitted in all European
the front-wheel drive Opel (Vauxhall) Astra (up to and Japanese front-wheel drive
1997) and Vectra (up to 1996) vehicles);
• the idler arm (including bearing)
and the intermediate rod are no longer needed;
• easy to limit steering rack travel and therefore the steering angle.
+ The main disadvantages:
• greater sensitivity to impacts;
• greater stress in the case of tie rod angular forces;
• disturbance of the steering wheel is easier to feel (particularly in front-wheel
drivers);
• tie rod length sometimes too short where it is connected at the ends of the rack
• size of the steering angle dependent on steering rack travel;
• decrease in steering ratio over the steer angle associated with heavy steering during parking
if the vehicle does not have power-assisted steering;
• cannot be used on rigid axles.
2.2 Power Rack-and-pinion steering
When the rack-and-pinion is in

a power-steering system, the rack
has a slightly different design. Part
of the rack contains a cylinder with
a piston in the middle. The piston
is connected to the rack. There are
two fluid ports, one on either side
of the piston. Supplying higher-
pressure fluid to one side of the
piston forces the piston to move,
which in turn moves the rack,
providing the power assist.
Fig 5.4: Power Rack-and-pinion

STEERING SYSTEM 5
5.3 Recirculating-ball Steering

Recirculating-ball steering is used
on many trucks and SUVs today. The
linkage that turns the wheels is slightly
different than on a rack-and-pinion
system.
The recirculating-ball steering gear
contains a worm gear. You can image the
gear in two parts. The first part is a block
of metal with a threaded hole in it. This
block has gear teeth cut into the outside of
it, which engage a gear that moves the
pitman arm (Fig 5.5). The steering wheel
connects to a threaded rod, similar to a
bolt, that sticks into the hole in the block.
Fig 5.5: Recirculating-ball steering When the steering wheel turns, it turns the
bolt. Instead of twisting further into the
block the way a regular bolt would, this bolt is held fixed so that when it spins, it moves the
block, which moves the gear that turns the
wheels.
Instead of the bolt directly engaging
the threads in the block, all of the threads
are filled with ball bearings that recirculate
through the gear as it turns. The balls
actually serve two purposes:
• reduce friction and wear in the gear.
• reduce slop in the gear.
Slop would be felt when you change the
direction of the steering wheel without the
balls in the steering gear, the teeth would
come out of contact with each other for a
moment, making the steering wheel feel Fig 5.6: Recirculating ball gearbox
loose.
Power steering in a recirculating-ball system works similarly to a rack-and-pinion system.
Assist is provided by supplying higher-pressure fluid to one side of the block.
Fig 5.7: The steering damper is supported on the one side at the
intermediate rod and on the other side on the suspension subframe.

STEERING SYSTEM 5
5.4 Power Steering

There are a couple of key components in power steering (Fig 5.8) in addition to the rack-and-
pinion or recirculating-ball mechanism.
Fig 5.8: Power Steering

a. Pump
The hydraulic power for the

steering is provided by a rotary-
vane pump (Fig 5.9). This pump is
driven by the car's engine via a belt
and pulley. It contains a set of
retractable vanes that spin inside an
oval chamber.
As the vanes spin, they pull

hydraulic fluid from the return line
at low pressure and force it into the
outlet at high pressure. The amount
of flow provided by the pump
depends on the car's engine speed.
The pump must be designed to
provide adequate flow when the
Fig 5.9: Rotary-vane pump
engine is idling. As a result, the
pump moves much more fluid than necessary when the engine is running at faster speeds.
The pump contains a pressure-relief valve to make sure that the pressure does not get too
high, especially at high engine speeds when so much fluid is being pumped.
b. Rotary Valve
A power-steering system should assist the driver only when he is exerting force on the
steering wheel (such as when starting a turn). When the driver is not exerting force (such as
when driving in a straight line), the system shouldn't provide any assist. The device that
senses the force on the steering wheel is called the rotary valve. (Fig 5.10)

STEERING SYSTEM 5
The key to the rotary valve is a

torsion bar. The torsion bar is a thin rod
of metal that twists when torque is
applied to it. The top of the bar is
connected to the steering wheel, and the
bottom of the bar is connected to the
pinion or worm gear (which turns the
wheels), so the amount of torque in the
torsion bar is equal to the amount of
torque the driver is using to turn the
wheels. The more torque the driver uses
to turn the wheels, the more the bar
twists.
The input from the steering shaft
Fig 5.10: The rotary valve forms the inner part of a spool-valve
assembly. It also connects to the top end
of the torsion bar. The bottom of the torsion bar connects to the outer part of the spool valve.
The torsion bar also turns the output of the steering gear, connecting to either the pinion gear
or the worm gear depending on which type of steering the car has.
As the bar twists, it rotates the inside of the spool valve relative to the outside. Since the
inner part of the spool valve is also connected to the steering shaft (and therefore to the
steering wheel), the amount of rotation between the inner and outer parts of the spool valve
depends on how much torque the driver applies to the steering wheel.
III. NEW WORDS
direction smoothly wheel perpendicular

Rack-and-pinion
intersect geometry linkage
steering
rack-and-pinion
tie rod pinion gear steering shaft
gearset
steering wheel steering arm spindle steering rack
Power Rack-and- Recirculating-ball
angular forces worm gear
pinion steering
threaded hole pitman arm spin slop
Power Steering hydraulic rotary-vane pump belt
pressure-relief
pulley Retractable vane adequate
valve
Rotary Valve assist exerting force sense
torsion bar twist torque pinion
spool-valve
inner part connect rotate
assembly

1. When you turn your car, are your front wheels pointing in the same direction?
-----------------------------------------------------------------------------------------------------------------
2. How to turn your car smoothly?

STEERING SYSTEM 5
-----------------------------------------------------------------------------------------------------------------
3. Why does Rack-and-pinion steering become the most common type of steering on cars?
-----------------------------------------------------------------------------------------------------------------
4. In Rack-and-pinion steering, what is attached to the steering shaft?
-----------------------------------------------------------------------------------------------------------------
5. What is/are the main advantages of Rack-and-pinion steering?
-----------------------------------------------------------------------------------------------------------------
6. What is/are the main disadvantages of Rack-and-pinion steering?
-----------------------------------------------------------------------------------------------------------------
7. What is/are the difference(s) between Power Rack-and-pinion steering and Rack-and-
pinion Steering?
-----------------------------------------------------------------------------------------------------------------
8. Where are the Recirculating-ball steerings applied?
-----------------------------------------------------------------------------------------------------------------
9. What is/are the difference(s) between Recirculating-ball steering and Rack-and-pinion

Steering?
-----------------------------------------------------------------------------------------------------------------
10. What is/are components in power steering?
-----------------------------------------------------------------------------------------------------------------
V. TRUE/FALSE
1. The front wheels in a car are pointing in the same direction. ( True False)
2. For turning smoothly, each wheel must follow a same circle. ( True False)
3. Rack-and-pinion steering is a sophisticated system. ( True False)
4. Rack-and-pinion steering is always applied on trucks. ( True False)
5. Power Rack-and-pinion steering is a power assisted steering system. ( True False)
6. Recirculating-ball steering is used on many trucks and SUVs today. ( True False)
7. The recirculating-ball steering gear contains a worm gear. ( True False)
8. Power steering in a recirculating-ball system works similarly to a rack-and-pinion system.
( True False)
9. Pump and Rotary Valve are key components in power steering. ( True False)
10. The hydraulic power for the steering is provided by a rotary-vane pump. ( True False)

STEERING SYSTEM 5
VI. WORD(S) SELECTIONS.
column A
a. A type of
d. A rack-and-
steering system e. A type of
pinion steering
uses Pump and steering system is
b. To cut into c. Right angle system assisted by
Rotary Valve used on many
hydraulic cylinder
to turn the trucks and SUVs.
with a piston.
front wheels
f. A type of
h. A pump
steering system j. The device that
uses vane & i. A type of oil
uses rack & g. A device to senses the force
rotor to using in steering
pinion to turn turn the car on the steering
control oil system
the front wheel
flow
wheels

1 perpendicular 6 intersect
Rack-and-pinion
2 Steering wheel 7
steering
Power Rack-and-
3 8 Power Steering
pinion steering
Recirculating-ball Rotary Valve
4 9
steering
5 rotary-vane pump 10 slop

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AUTOMOTIVE INTRODUCTION.

Chapter 1: Automotive Introduction.

1. What are the main functions of automobile nowadays?

Part a: Automobile Introduction

The automobile is built

Fig1.1: The drive-train. Suspension systems,

Technical English for AUTOMOTIVE ENGINEERING. 1

Fig 1.2: A multi-link rear axle,

Fig 1.3: Four-bar twist beam

Fig 1.4: Steering and

Technical English for AUTOMOTIVE ENGINEERING. 2

Part b: Automobile Physical Configuration

Fig 1.5: Automobile systems

Look up for the new words

Automobile (n) Rank (n) Truck (n) Driveshafts (n)

Answer these questions:

1. Why do we call automobiles as self-propelled vehicles?

Technical English for AUTOMOTIVE ENGINEERING. 3

2. What are the key elements of industrial economies?

3. What are advantages of automobile in our life?

4. What are disadvantages of automobile in our life?

5. What are the main functions of the engine?

6. What are the main functions of Suspension systems?

7. What are the main functions of wheels and tires?

8. What are the main functions steering and braking systems?

9. What are the main functions of electrical system?

10. What component(s) makes automobiles safer?

Decide if these statements are True or False:

1. Automobiles can be use primarily on public roads. ( True False)

Technical English for AUTOMOTIVE ENGINEERING. 4

9. The engine produces mechanical power. ( True False)

VI. WORD(S) SELECTIONS

a. The system c. Cars designed e. Self- g. The system i. Vehicles

No Column A Column B No Column A Column B

Technical English for AUTOMOTIVE ENGINEERING. 5

Chapter 2: The Engine

1. Name some kinds of engines you know.

1. The reciprocating engine

Fig2.2: Basic operations of four-stroke cycle engine.

Technical English for AUTOMOTIVE ENGINEERING. 6

In the two-stroke engine, the space in the

Technical English for AUTOMOTIVE ENGINEERING. 7

The diesel is an injection engine. A

Technical English for AUTOMOTIVE ENGINEERING. 8

3. The rotary engine (Wankel engine)

Fig 2.5: The Wankel rotary engine cycle

III. NEW WORDS

Look up for the new words

Bonnet (n) Crankshaft Cylinder head Exhaust valve

IV. COMPREHENSION QUESTION

2. How many types of reciprocating engine?

3. Name 4 strokes of the 4-stroke engine?

Technical English for AUTOMOTIVE ENGINEERING. 9

5. In compression stroke, how the mixture is compressed?

6. Why is the piston pushed down in power stroke?

7. Why can we call a petrol engine as a Spark Ignition (SI) engine?

9. Does two-stroke engine use inlet and exhaust valves?

11. Why is a two-stroke engine mechanism very simple?

13. Why isn’t a two-stroke engine as popular as four-stroke one?

14. What kind of mixture is intaken in intake-stroke of a diesel engine?

15. Why doesn’t a diesel engine have a spark plug?

17. Advantages and disadvantages of reciprocating engines?

Technical English for AUTOMOTIVE ENGINEERING. 10