Global automobile manufacturers see India as a

Unit

manufacturing hub for auto components due to the

3 Major Systems and following reasons:
(i) Low-cost labour force and availability of raw
material which makes India cost competitive
Components of an (ii) An established manufacturing base in India
(iii) Setting up of the operations of major international
auto components including Delphi, Visteon, Bosch
Automobile and Meritor in India
(iv) 6HWWLQJ XS RI ,QWHUQDWLRQDO 3XUFKDVLQJ 2I
(IPOs) of automobile manufacturers and auto
2IÀFHV
component manufacturers in India
(v) Fine-quality components manufactured in Ind India
dia
(vi) India being a global hub for research and
development (R&D), General Motors, Dia amler
Diamler
Chrysler, Bosch, Suzuki, Johnson Controls, etc.,
have their research centres in India
In this Unit, you will learn about the var various
rious
components and systems that make a com mplete
complete
automobile — the engine and its parts, the body
INT
NTRODUCTION
TRODUCTION
and chassis, drive transmission and steering p parts,
In the previous Units, we learnt about the different suspension and brake parts, electrical parts and o other
typ
pes of automobile. In this Unit, we will discuss the
types systems that make running an automobile possiblpossible.
le.
maajor systems and components of an automobile. An
major
auttomobile is made of several components, assemblies
automobile SESS
SION 1: CH
ESSION HASSIS
ASSIS AND
AND AUTO BODY
andd systems. The growing automotive industry has
giv
ven rise to a growing auto component industry also.
given Chassis
Ind
dia has emerged as a global outsourcing hub for
India Chassis is a French term and was initially use used
ed to
maanufacturing of various automobile components. All
manufacturing denote the frame or main structure of a vehicle
vehicle.. The
major
maajor companies like Toyota, Hyundai, Ford, Volvo, necessary
chassis (Fig. 3.1) contains all the major units neces
ssary
Renault
Rennault and others are now sourcing their automotive to propel the vehicle, guide its motion, stop itt and
com
mponents from Indian manufacturers.
components allow it to run smoothly over uneven surfaces. It is
The auto components industry is predominantly the main mounting for all the components inclu including
uding
GLY
YLGHGLQWRÀYHVHJPHQWV
GLYLGHGLQWRÀYHVHJPHQWV the body. It is also known as the carrying unit.
The chassis includes the following m major
((i)
i) Engine parts Fig.
Fi
ig. 3.1: Chassis with suspension components.
(ii)
(i i) Drive transmission and steering parts and exhaust system
(i) A steel frame, which is a major part.
(iii)
(ii i) Suspension and brake parts (ii) In case of a passenger car, the whole bod body
dy is
(iv) Electrical parts also
l an integral
i l part off the
h chassis.
h i HHowever, in
(v) Body and chassis commercial vehicles like trucks and buses, the
body is not a part of the chassis. Therefore, a
chassis is almost a complete vehicle except the
AUTOMOTIVE SERVICE TECHNICIAN – CLASS
L IX
40
 body and other accessories, which are not involved the journey comfortable, cushioned seats are provided.
in the movement of the vehicle. 7KHERG\LVSURYLGHGRQDOOVLGHVZLWKJODVVSDQHVÀ[HG
(iii) Other major components include engine, to protect the passengers from dust and rain.
transmission system, front and rear axle, steering The body of a bus is made of metal, like
system, suspension system, wheels, tyres (a) steel section pillars with steel sheet panelling,
and brakes. (b) steel section pillars with aluminium panelling and
Functions of the chassis (c) all aluminium bodies, i.e., pillars, framework
and panelling made of aluminium sections and
The functions of the chassis includes
sheets. This is because aluminium is very light in
(i)
i) carrying the weight of the vehicle and its passengers,
i h compared
weight d to steel.
l
(ii)
(i i) withstanding the engine and transmission torque The body of a truck has the driver’s compartm ment
compartment
and thrust stresses, as well as accelerating and covered and the rest is kept open. Such bodies s are
braking torque, usually called load bodies. In most of the cases, it is an
(iii)
(ii i) withstanding the centrifugal force while taking a open body, whereas for liquid material like water, milk
turn and and fuel products, a tank is mounted on the cha assis.
chassis.
(iv)
(iv
v) withstanding the bending load and twisting due to 7KH ERG\ LV À[HG WR WKH FKDVVLV ZLWK WKH KHOS RI , RU
the rise and fall of the front and rear axles. 8EROWVZLWKUXEEHUSDFNLQJSODFHGEHWZHHQWKHFK
8EROWVZLWKUXEEHUSDFNLQJSODFHGEHWZHHQWKHFKDVVLV DVVLV
and body cross members.
Automobile
Au
utomobile Body or Superstructure
In case
c of integral or frameless construction, the body is an Requirements of automobile body
int egral part of the chassis. But, in case of the conventional
integral 7KH ERG\ RI D PRWRU YHKLFOH VKRXOG IXOÀOO FH
FHUWDLQ
HUWDLQ
chaassis, the body or superstructure is made after receiving
chassis, requirements. It should
thee chassis from the manufacturer. The shape of the body (i) be light weight.
deppends upon the ultimate use for which the vehicle
depends (ii) have minimum number of components.
is meant.
m
(iii) have long fatigue life.
The body of a car (Fig. 3.2) is made of a sheet of metal
RU ÀEUHJODVVVRWKDWSDVVHQJHUVFDQVLWLQLW7RPDNH
RUÀEUHJODVVVRWKDWSDVVHQJHUVFDQVLWLQLW7RPDNH (iv) have uniformly distributed load.
 Y
Y KDYHVXIÀFLHQWVSDFHIRUSDVVHQJHUVDQGOXJJ
KDYHVXIÀFLHQWVSDFHIRUSDVVHQJHUVDQGOXJJDJH
JDJH
(vi) have good access to the engine and suspension sy
system.
ystem.
running.
(vii) have minimum vibrations when the vehicle is runnning.
(viii) have minimum resistance to air.
(ix) be cheap and easy in manufacturing.
 [
[ KDYHFOHDUDOOURXQGYLVLRQWKURXJKJODVVDUHD
KDYHFOHDUDOOURXQGYLVLRQWKURXJKJODVVDUHDV
DV
(xi) have an attractive shape and colour.
Check Your Progress
A. Fill in the blanks
1. A chassis is almost a complete _________ mounting body.
2. The shape of the chassis depends ______ upon the ultimate
Fig. 3.2: Body of a car use of the __________________.
MAJOR SYSTEMS AND COMPONENTS OF AN AUTOMOBILE AUTOMOTIVE SERVICE TECHNICIAN – CLASS
L IX
41 42
 3. Major part of a chassis is the __________frame. SESSION 2: ENGINE AND ITS COMPONENTS
4. In commercial vehicles like trucks and buses the body is An engine (Fig. 3.3) is complex unit in which different
not a _________ of the chassis. components are assembled together, and fuel is burned
5. In most of the cases, it is an open body, whereas for liquid to produce power or energy. The engine
material like water, milk and fuel a __________ is mounted converts chemical energy (heat energy)
on the chassis.
into mechanical energy, which is
B. Multiple choice questions then utilised for vehicular movement.
There are different processes of fuel
1. Chassis is a French term and was initially used to denote combustion. When the fuel is burned
_____________________.
within the engine, it is called an Inte
Internal
ernal
(a) main structure of a vehicle
Combustion (IC) engine, and when n it is
EÀ[LQJWKHDXWRPRELOHERG\
burned externally and the prod duced
produced
(c) transmission system, front and rear axle
steam is used for the mecha mechanical
anical
(d) carrying the bolt
movement, it is called an Exte External
ernal
2. What are the functions of the chassis frame? Combustion (EC) engine. Nowadays,
Nowad days,
(a) To carry the weight of the vehicle and its passengers. automobile engines are quite econom
economical
mical
(b) To withstand the engine and transmission to orque.
torque. due to the developments taking pla place
ace in
(c) To withstand the centrifugal force while c ornering.
cornering. WKHÀHOGRILQWHUQDOFRPEXVWLRQHQJLQH
WKHÀHOGRILQWHUQDOFRPEXVWLRQHQ QJLQH
Fig. 3.3: Engine
(d) All of the above On the basis of the process of igni
ignition,
ition,
________________.
3. Automobile body is made of _________ _______
__. WKHDXWRPRELOHHQJLQHVDUHFODVVLÀHGLQWRVSDUNLJQLWLRQ
WKHDXWRPRELOHHQJLQHVDUHFODVVLÀHGLQWRVSDUNLJQ QLWLRQ
DVKHHWPHWDORUÀEUHJODVV engine (petrol or gas) and compression ignition en engine
ngine
(b) iron (diesel). In an IC engine, the reciprocating motion o of the
(c) copper crankshaft
piston is converted into rotary motion of the crank shaft
(d) gun metal and the produced power is then transmitted to m move
 7KHERG\LVÀ[HGWRWKH
HF
FKDVVLV
VZ
ZLWKWKH
HK
KHOOSR
RIBBBBBBBB
7KHERG\LVÀ[HGWRWKHFKDVVLVZLWKWKHKHOSRIBBBBBBBB the vehicle. In case of a rotary engine or Wa Wankel
ankel
________________. engine, the rotor rotates and completes the proce process
ess of
(a) I or U bolts combustion and produces the power, which helps s the
(b) rivet vehicular movement.
(c) welding The spark ignition engine can be differentiated fromm the
(d) threaded bolt compression ignition engine as per the following factfactors.
tors.
$XWRPRELOH
 $XWRPRELOH ERG\ VK VKRXOG
KRXOGG IIXOÀOO
XOÀOO ZKLFK RI WKH IROORZLQJ (i) The type of fuel used.
requirements? (ii) The way the fuel enters in the combustion cham
chamber.
mber.
(a) The body sho should
ould be light.
(iii) The way in which fuel is ignited.
(b) It should h have
ave a llong
ong fatigue life.
(a)
(c) Both (aa) aand
nd ((b)
b)
Spark Ignition Engine (Petrol or Gas Eng
Engine)
gine)
(d) None o off th
the
he above
The spark ignition engine uses a highly volatile fuel,
C.. Short answer questions such as gasoline, which turns into vapour easily.. The
1. Differentiate between chassis frame and automobile body. fuel is mixed with air before it enters in the combustion
2. Explain the use of the chassis frame. chamber, and forms a combustible air-fuel mixture.
3. How does auto body help in transport? This mixture then enters the cylinder and gets
MAJOR SYSTEMS AND COMPONENTS OF AN AUTOMOBILE AUTOMOTIVE SERVICE TECHNICIAN – CLASS
L IX
43 44
compressed with the help of a piston. An electric spark
is produced by the ignition system which ignites the
combustible air-fuel mixture. The combustible gases
burn and expand, which forces the piston downwards for
generating power.
Compression Ignition Engine (Diesel Engine)
In the compression ignition engine or diesel engine,
only fresh air enters the cylinder, which is compressed
to a very high pressure and temperature, which could
go up to 1000°F (538°C). The diesel is then injected or
spr
rayed into the engine combustion chamber. This
sprayed
VSU
UD\FRQWDLQVYHU\ÀQHDQGWLQ\SDUWLFOHVRIGLHVHOLQ
VSUD\FRQWDLQVYHU\ÀQHDQGWLQ\SDUWLFOHVRIGLHVHOLQ
an atomised form. The hot air or heat of compression
ignites
ign
nites the fuel and generates the power stroke.
Components
Co
omponents of an IC Engine
1. Cylinder: The cylinder or cylinder liner of an IC
HQJLQH LV ÀWWHG LQ WKH F\OLQGHU EORFN ZKLFK LV D
single casted unit and is considered to be the main
body of an engine. The block has cylinder liners.
The piston reciprocates up and down from Top
Dead Centre (TDC) to Bottom Dead Centre (BDC)
to generate power.
The cylinder liner and the cylinder block have
to withstand very high pressure (about 70 bar)
and temperature (about 700°C) during power
stroke. The material used for the cylinder block
must withstand such heat and also disperse it
effectively. The cylinder block is well-designed
with water passages to remove the excess heat
and separate oil passages are provided for the
circulation of lubricating oil. The top portion of the
cylinder block is covered by the cylinder head. The
crankcase is an integral part of the cylinder block
which houses the crankshaft and the lower portion
is dipped in an oil pan.
Nowadays, cylinder liners are made of special
alloy and internal portion is coated with material
OLNHWLWDQLXPZKLFKSURYLGHVPLUURUÀQLVKDQGFDQ
withstand the wear resistance. The upper end of
MAJOR SYSTEMS AND COMPONENTS OF AN AUTOMOBILE
45
WKHF\OLQGHUOLQHUKDVDÁDQJHZKLFKÀWVZHOOLQWKH
cylinder block. The exterior portion of the cylinder
liner is exposed to water jacket for easy dispersion
of heat.
2. Cylinder Head: The cylinder head is also single-
casted unit and bolted to the top portion of the cylinder
block. The combustion chamber is a part of the
cylinder head, where the combustion of gases takes
place. The water passages are provided to remove
the heat from the cylinder head. In latest eng engines,
the cylinder head also houses the camshaft w which
has the inlet and exhaust valves with suppo supportive
ortive
YDOYHPHFKDQLVP7KLVSURYLVLRQLVPDGHWRÀ[VSDUN
KLVSURYLVLRQLVPDGHWRÀ[V VSDUN
plug in SI engines and nozzle in CI engines.. The
lower portion of the cylinder head is well-mach
well-machined
hined
to ensure there is no leakage of gases. Cylinder head
gasket is usually cast as one piece and bolte bolteded to
the top of the cylinder (engine block). Copperr and
asbestos gaskets are provided between the cyl cylinder
inder
and cylinder-head to obtain a gas-tight joint.. The
charge enters the combustion chamber through h the
inlet valve connected to the inlet manifold, and d the
exhaust gases are removed through the exh exhaust
haust
valves connected to the exhaust manifold.
3. Piston and Piston Rings: Piston is a cylindrical unit,
used to compress the charge during compre compression
ssion
stroke and to transmit the gas force to o the
connecting rod and then to the crankshaft du during
uring
power stroke. The pistons of IC engines are us usually
sually
made of aluminium alloy, which has high the thermal
ermal
conductivity and is light in weight. The matermaterial
rial of
piston must have the ability for higher heat tran
transfer.
nsfer.
The piston moves up and down (from TDC to B BDC)
and assists in completing the engine cycle.
The piston rings are placed in the ring gr groove
roove
and provide sealing between the piston and d the
cylinder liner, thereby preventing the leakage off high
pressure gases. These are made of special g grade
cast iiron, which
hi h retains
i iits elastic
l i property even at
very high temperature. The upper piston rings are
called the compression rings and the lower piston
rings are called the oiling or oil control rings.
AUTOMOTIVE SERVICE TECHNICIAN – CLASS
L IX
46
 4. Connecting Rod: It is usually manufactured by friction and shell bearings are used
Pin Con Rod
using drop-forged steel. It is made in the shape for smooth rotation of crankshaft.
of ‘I’’ so as to reduce its weight and to withstand Front end of the crankshaft will
strength. Its small end is connected to the piston transmit drive to the camshaft and
with the help of gudgeon pin and the big end is also to the timing gear, whereas
connected to the crankpin with shell bearings. It WKHÁ\ZKHHOLVEROWHGWRWKHÁDQJH
has a passage for the transfer of lubricating oil at rear end of the crankshaft.
from the big end bearing to the small end bearing Snap ring Main journal of the crankshaft
(gudgeon pin). The major function of the connecting carries the oil passages to lubricate
rod is to convert the reciprocating motion of piston shell bearings.
bearings
to the rotary motion of the crankshaft. In case of a single cyli inder
cylinder
5. Crank and Crankshaft: The crankshaft (Fig. 3.4) Snap ring engine crank assembly (Fig. 3.5) 3.5) is
is called the backbone of an engine because it used, two crank webs are conne
connected
ected
converts the reciprocating motion of piston into the with the crank pin, and crank w webs
rotary motion of the crankshaft. The crankshaft is a VKDIWV DUH SUHVV ÀWWHG LQ ERWK
ERWK $W
K $W
single casted unit and is made of drop-forged steel one side of the shaft magnemagneto
eto is
main journals which are placed and supported in fastened whereas clutch asse assembly
embly
Fig. 3.5: Crank assembly of single cylinder engine
the crank case. The main journal and connecting is mounted to the other. The c crank
MRXUQDOVDUHPDFKLQHGWRDVPRRWKÀQLVKWRUHGXFH dynamically
assembly is balanced dynami ically
as well as statically for the smooth transmistransmission
ssion
of power.
Cylinder
Cylinder
6. Piston Pin or Gudgeon Pin. This unit conn connects
nects
Piston the piston and small end of the connecting g rod
and passes through the piston (Fig. 3.6). Circlips
Cirrclips
UP
UP
Intake camshaft
Exhaust cam
camshaft
mshaft
Piston Pin Spark
Bolt
Down plug Exhaust Valve
Cylinder
Cylinder
head
head
Connecting
Rod Exhaustt Intake
Exhau
ust v
Exhaust alve
valve Intake v
Intake alve
valve
Piston
Piston
head
head
Around in Piston
Piston
nppin
in
a cricle Inlet Valve
Va
alve
Crank Pin
Piin Connecting
Con
nnecting
g
rod
rod
Engine b
block
lock Cylinder
Cylinder
Crank
shaft Lower Rod
g Cap
Bearing p Crankshaft
Crank
nksh
haaft
Waster
Waster
Nut
Fig. 3
Fig 3.4:
4: Crankshaft of multicylinder engine
Fig. 3.6: Important components of piston
MAJOR SYSTEMS AND COMPONENTS OF AN AUTOMOBILE AUTOMOTIVE SERVICE TECHNICIAN – CLASS
L IX
47 48
 DUH ÀWWHG LQWR UHFHVVHV LQ WKH SLVWRQ WR SUHYHQW
the gudgeon from touching the cylinder wall. The Air Cleaner
QHHGOH EHDULQJ RU EURQ]H EXVKLQJ LV SUHVV ÀWWHG
into the connecting rod, due to this the gudgeon
pin provides bearing for the oscillating small end
of the connecting rod.
7. Inlet Valve: The major role of the inlet valve is to
submit fresh charge in to the cylinder during the Carburettor
Carburettor
suction stroke. Opening and closing of the valve
will control the admission of the charge into the Intake Manifold
Intake
petrol engine or air into diesel engine during
suction stroke of an engine. The valve operations
will be as per the valve timings. The inlet valve has
a wider face or in latest engines two inlet valves are
Manifo
old
Exhaust Manifold
XVHGWRPDLQWDLQYROXPHWULFHIÀFLHQF\RIDQHQJLQH
8. Exhaust Valve: The exhaust valve removes out
the burnt gases from the combustion chamber Heat Control
Valve Spring
after power stroke. The exhaust valve has to bare
more heat resistance.
9 Valve Spring: The valve spring (Fig.
9.
3.7)plays an important role to close
the valve and also provides air tight Fig. 3.8: Exhaust Manifold
compartment to seal the combustible 12. Camshaft: The major function of the camsha
camshaftaft is
gases during power stroke and to operate the intake and exhaust valves thr ough
through
also maintain the self-centering the cam lobe, the gear drive transmits the p power
movement of the valve. Both ends for the rotation of oil pump, therefore th he oil
the
of the vale spring are machined for pump sucks the oil from the oil sump and tra
transits
ansits
smooth function and up and down the same to the oil gallery. The camshaft (Fig
(Fig.. 3.9)
movements of the valves. Fig 3.7: Valve Spring is driven by crankshaft at half the spee speeded of
10.
10. Inlet Manifold: The fuel air mixture the crankshaft.
is carried from the carburettor to the cylinder 13. Cam Lobe and Tappet: The cam lobe
through a separate pipe through inlet manifold in a (see Fig. 3.10) of the camshaft is placed dir
directly
rectly
carbureted engine. Whereas in compression ignition above the bucket tappet, such that the lobe co omes
comes
engines (diesel), the air is sucked through the around it and pushes down the bucket tappett and
induction manifold. In M.P.F.I the engine holds the the valve, thus opening the valve. In an over
overhead
rhead
throttle body on top of the manifold and the supply camshaft with rocker arm, the cam lobe co comes
omes
of air is monitored by the throttle body sensor. under the valve lifter, and causes the rockerr arm
11.
1 1. Exhaust Manifold: ,WLVDVHWRISLSHVDQGPXIÁHU to rock or turn the lobe and pushes downd
which
hi h iis usedd to remove theh exhaust
h gases ffrom the valve steam and it moves down to open.
the exhaust ports. Engines oxygen sensors and When the cam lobe passes the valve lifter
catalic convertors are used to reduce sound and Fig. 3.9: Camshaft
the valve spring retains back to the original
air pollution, respectively (see Fig. 3.8).
MAJOR SYSTEMS AND COMPONENTS OF AN AUTOMOBILE AUTOMOTIVE SERVICE TECHNICIAN – CLASS
L IX
49 50
 length. To close the valve the rocker Variab
ble cam timing acuator
Variable 15. Crank Case: The crank case is an integrated
arm turns back and the valve lifter is Oil pressure
ep orts
ports part of the cylinder block. The casing is provided
pushed down on the cam. In case of to hold the crankshaft. The crankshaft is allowed
double overhead camshaft engine, the to rotate freely and transmit the power to the
double row valves are usually operated Á\ZKHHO)LJ
by the separate overhead camshaft. 16. Water Pump and Water Jacket: The function of
14. Push Rod and Rocker Arm: The Cam
m follower/
/lifterr
follower/lifter water pump is to draw water from the radiator
Fig. 3.12: Crank Case
motion of the cam lobe pushes the and supply it to the water passages provided in
valve lifter upwards. This movement Cam return spring
Cam
pushes the push rod (Fig
(Fig. 3
3.11)
11) and the
rocker turns the upward motion of the Valve
push rod to the downward movement of
the valve stem resulting in opening of Fig. 3.10: Cam Lobe and Tappet
the valve.
Rocker Arm
Valve Spring Retainer
Push Rod
Spring Collet Fig. 3.13: Water Pump and Jacket
Valve Spring the cylinder block and cyl cylinder
inder
head with certain pressure.. The
Cam Follower
circulation of coolant removees the
removes
excessive heat from an en engine.
ngine.
Cam
This helps in maintaining g the
Valve Guide
Valve engine temperature and als alsoo the
life of an engine (Fig. 3.13)..
17. Radiator: The major func function
ction
of the radiator is to rad radiate
diate
Camshaft
Valve Stem coolants.
the heat from the coolant ts. It
Valve Head
has two tanks located att the
top and bottom. The upper u
tank is connected to the llower
Valve Seat Insert
tank with the core through h the
passages for easy radiation
of the heat. The radiator also
Fig. 3.11: Push Rod and Rocker Arm
Fig 3.14: Radiator
stores the coolant (Fig. 3.14).
MAJOR SYSTEMS AND COMPONENTS OF AN AUTOMOBILE AUTOMOTIVE SERVICE TECHNICIAN – CLASS
L IX
51 52
18. Flywheel: It is a wheel mounted on the crankshaft amount of fuel in case of diesel engine to maintain
which stores the energy during the power stroke the speed of the engine constant, when the load
and transmits the energy to the transmission requirement varies.
system, the clutch and then to the gear The components described above are commonly used
box (Fig. 3.15). for all types of IC engine. Here we are describing only
a few components which are used in particular types
of engines.
20. Carburettor: The major function of the carburetor
(Fig. 3.17) is to supply carburised fuel as per
speed and the engine load. In petrol engines the
carburettor is mounted on the induction pip pe or
pipe
on the induction manifold. The quantity of fuel
fuel air
mixture in appropriate ratio is controlled by y the
throttle valve and the movements of the thr throttle
rottle
valve are connected to the accelerator.
Fi
Fig. 3.15:
3 15 Fl
Fly wheel
h l Idle speed screw Idle mixture screw
19.
19
9. Governor: It is run by drive from the crankshaft.
Throttle plate Choke plate
The function of the governor (Fig. 3.16) is to
regulate the charge in case of petrol engine and
Clean air
enters
throat
Fuel line
)XHOÀOWHU
Float
Float bowl
Jet
Pedestal
Fig 3.17: Carburettor
21. Spark Plug: The function of the spark plug is to
Fig. 3.16: Governor ignite the fuel air mixture after completion of the
compression stroke in an engine. It is generally
MAJOR SYSTEMS AND COMPONENTS OF AN AUTOMOBILE AUTOMOTIVE SERVICE TECHNICIAN – CLASS
L IX
53 54
 placed in the combustion chamber of the cylinder The high pressure of fuel is then sent to the distributor
head. This is only used in petrol engine (Fig. 3.18). rotor through the metering valve and from rotor the
fuel is sent to the injector (Fig. 3.19). In case of
Ground Electrode Metal Shell
Terminal nut a multi point fuel injection system, the electric fuel
pump is used and placed in the fuel tank. The pump
Hexa
agon
Hexagon
Gasket
Corrug
gations
Corrugations
generates the injection pressure and sends it to
WKHIXHOÀOWHUDQGWKHQWRWKHFRPPRQUDLODWD
Thread
pressure of 3 to 4 bar. The common rail or fuel rail
is connected to the fuel injector.
23. Fuel Injector: The function of fuel inje injector
)LJ  LV WR EUHDN WKH IXHO LQWR ÀQH VVSUD\
(atomised condition) as it enters the combuscombustion
stion
chamber of diesel engine.In case of an MPFI en engine
ngine
Centre Electrode
petrol is injected at the end of compression strokesttroke
(with copper core) Insulator Top Insulator DVWKHÀQHVSUD\RIWKHIXHOEXUQVPRUHHIÀFLHQWO\
DVWKHÀQHVSUD\RIWKHIXHOEXUQVPRUHHIÀFLH HQWO\
in the combustion chamber giving better fuel
Insulator Nose HIÀFLHQF\ZLWKOHVVDLUSROOXWLRQ
Nipple
Fig. 3.18: Spark Plug
Oil outlet valve Spring
22.
22
2. Fuel Injection Pump: In case of diesel engine the
Oil outlet valve seat
diesel oil from the fuel tank is sucked by the fuel
IHHGSXPS7KHSXPSÀUVWVHQGVWKHGLHVHORLOWR Pump body
WKHIXHOÀOWHUDQGWKHQto the transfer pump. The
transfer pump increase the pressure of the fuel.
Tooth ring
Barrel
Rack
Plunger
Rotating
sleeve
Retainer
Spring
Ratainer
Roller body Adjusting
VFUHZ
Roller
Camshaft body
Fig. 3.20: Fuel Injector
Fig. 3.19: Fuel Injection Pump
MAJOR SYSTEMS AND COMPONENTS OF AN AUTOMOBILE AUTOMOTIVE SERVICE TECHNICIAN – CLASS
L IX
55 56
 Practical
Prac
ctiicall EExercises
xerccises 2. The cylinder of an IC engine is generally made of
__________________.
Activity 1 (a) cast iron
1DPHDQ\ÀYHFRPSRQHQWVRIDQDXWRPRELOHV\VWHPXVHGLQ (b) copper
a vehicle.
(c) iron
S. No. Name of the system GÀEUH
G ÀEUH
1. 3. The charge (fuel and air mixture for SI engine and only
air for CI engine) enters through the ___________________.
2.
(a) inlet valve
3. (b) spark plug
4. (c) outlet valve
5. (d) piston
4. The heart of the engine is the _______________
_______________.
_.
6.
(a) piston
7. (b) cylinder head
(c) connecting rrod
od
(d) All of the
eaabove
bov
ve
Check
Che
eck Your Progress C. Short answer
answ
wer q uestions
questions
1. Explai
Explain
in tthe
he ro
role
ole of engi
engine
ine a
and
nd its components.
A Fill in the blanks
A. 2. Ex
Explain
xplain tthe difference
he differennce b between ignition
etween compression ign
nition
1. Engine is the _____________ off a
ann automobile. IIts
automobile. ts rrole
ole is engine and
engine a k iignition
nd spark gn
nition engine?
very important.
2. Engine converts the e C hemicall Energy ((heat
Chemical hea
at energy) to
energy)
________________ Ene
ergy.
Energy.
SE SSION 3
ESSION 3:: LUBRICATION SYSTEM
3. Major parts of engine e are ___
are _____
______, _____________,
____________,
________________ and _________
________.
_______________. $V \RX NQRZ RXU ERG\ UHTXLUHV ÁXLGV OLNH ZDWHU
ZDWHU
U DQG
also oil in the form of fats like ghee, butter, cookin ng oil
cooking
4. The function of the car rburettorr is to supply uniform
carburettor
for maintenance of our system. Similarly, lubricalubrication
ation
______________ to the
ec yliinde
cylinderer of a __________ through the
intake manifold.
is required for maintenance of engine. Lubrica Lubrication
ation
system is one of the most important parts of an en engine.
ngine.
5. Sparkplug is use
ed to ____________
used The engine cannot run smoothly for more than a few
B Multiple choice
B. eqquestions
uestions minutes without the lubricating oil.
Whenever two metallic surfaces move over each o other
1. The compression-ignition
comp
presssion-ignition engine air is compressed so that
temperatture goes up to ____________________.
its temperature
produced.
under direct contact, dry or solid friction is produ uced.
This is due to the irregularities on the two sur surfaces
faces
( )
(a) 538 °C (1000
( °F)) or higher
g
interlocking each other
other. The dry friction thus crecreated
(b) 348 °C
(c) 2480 °C
produces a lot of heat and results in wear and tear of
(d) None of the above the metal surface.
MAJOR SYSTEMS AND COMPONENTS OF AN AUTOMOBILE AUTOMOTIVE SERVICE TECHNICIAN – CLASS
L IX
57 58
Objectives of Lubrication Check Your Progress
The main objectives of lubrication are A. Fill in the blanks
(i) to reduce friction between moving parts to its 1. Dry or solid friction is produced in _____________.
minimum value so that power loss is minimised, and 2. Dry friction creates lot of ________________.
(ii) to reduce wear and tear of the moving parts as 3. The objective of lubrication is to reduce __________.
much as possible. 4. Lubrication provides ________ and ______ effect.
Apart from these objectives, lubrication also serves other B. Multiple choice questions
important purposes, which may be called secondary. 1. Viscosity is measured using a ______________________.
These
ese are as follows. (a) barometer
(a)
a) To provide cooling effect: The lubricating oil
(a (b) thermometer
takes heat from the hot moving parts during its (c) viscometer
(d) fathometer
circulation and delivers it to the surrounding air
2. Lubricating oil is used for ___________________..
through the crank case. (a) minimising wear in moving parts
(b)
b) To provide cushioning effect: The lubricating oil
(b (b) help in keeping parts cool
(c) Both (a) and (b)
also serves as a good cushion against the shocks
(d) None of the above
experienced by the engine. For example, instant
3. Which type of lu ubrication system iis
lubrication su sed
d iin
used n a two-sttroke
two-stroke
combustion of the fuel in the combustion chamber engine?
produces a sudden rise of pressure in the cylinder (a) petrol sy ystem
system
and the shock goes to the bearings through the (b) wet s ump s
sump ystem
system
piston, gudgeon pin and the connecting rod. This (c) dry ys sump
um mp ssystem
ystem
shock is then absorbed by the layer of oil present (d) A ll o
All off tthe
he above
above
in the main bearings. 4. Viscosity
Vis scosity y iindex
ndex is a m easure for the change of visc
measure cosity
viscosity
with c
with hange in _______________.
change ______________.
(c)
c) To provide cleaning action: The lubricating oil serves
(c ((a)
a) ppressure
ressure
another useful purpose of providing a cleaning ((b)
b) ttemperature
empera ature
((c) volume
c) volum me
action. During its circulation, it carries away many
(d) mass
impurities, such as carbon particles, etc.
(d)
d) To provide a sealing action: The lubricating oil also
(d C.. Short
C Sh
horrt aanswer
nswer questions
helps the piston rings in maintaining an effective 1. E
Explain
xpllain the importance of lubrication in engine.
seal against the high pressure gases in the cylinder 2. Lis
st the properties of lubricant.
List
thus preventing leakage towards the crank case.
SE SSION 4: COOLING SYSTEM
ESSION
Pr
ractical
ticcal Exercis
Practical Exercises
ses
Like our body requires air and water for cooling our sys
system,
stem,
Activity 1 cooling.
similarly the engine of a vehicle also requires cooling
g.
List a few impo
L important
ortan
nt functions of lubrication. The cooling system (Fig. 3.21(a-d)) has three prim primary
mary
S. No. Functions of lubrication functions, which are as follows.
1. ((i)) Remove excess heat from the engine
g
2. (ii) Maintain a constant engine operating temperature
3.
(iii) Increase the temperature of a cold engine as quickly
4.
as possible by maintaining the thermostat valve
MAJOR SYSTEMS AND COMPONENTS OF AN AUTOMOBILE AUTOMOTIVE SERVICE TECHNICIAN – CLASS
L IX
59 60
 LQ D FORVHG SRVLWLRQ ZKLFK LVÀWWHG
LV ÀWWHG LQ WKH SDWK RI
coolant circulation Practical
Pra
acticcal Exe
Exercises
ercise
rccisses
Activity 1
List a few important functions of the cooling system.
S. No. Functions of cooling system
1.
2.
3.
4.
5.
(a) (b)
Check Your Progress
A. Fill in the blanks
1. The cooling sy
system
ystem removes exce
excess________________
ess____
_____________ from
the engine.
2. Cooling _____________________ constant
_______________________ a con operating
nstant engine opera
ating
temperature.
temperraturre.
3. The
eoobjective
bje
ectiv cooling
ing iis
ve of cooli s tto
o reduce_____________.
4. Liquid
Liq cooling
quid co employed
ooling is e engines.
mployed in most ______________ eng
gines.
B. M
Multiple
ultiple choice q question
uestion
1. W
Which
hiich of th
the
he ffollowing
ollowin
ng type of cooling system is used
d in a
motorcycle?
motorcyclle?
(c) (d)
(a) A ir c
Air ooling system
cooling
Fig. 3.21 (a–d): Cooling system of an engine (b)
(b Water
b) W ater cooling system
Necessity
Ne
ecessity of Cooling (c)
(c Both
c) B oth (a) and (b)
(d
d) N
(d) one of the above
None
The
Th e cylinders of internal combustion engines require 2
2.. The cooling fan is _________________________________.
coo
oling because the engine cannot convert all the heat
cooling
(a) driven by belt and pulleys
energy
eneergy released by combustion into useful work. Liquid
EÀWWHGEHWZHHQWKHHQJLQHDQGWKHUDGLDWRU
cooling
coo
oling is employed in most of the IC engines, whether
(c) driven from the camshaft
they
ey are used in automobiles or elsewhere. The water
the
(d) All of the above
(co
oolant) is circulated around the cylinders to pick up
(coolant)
3. In water cooling, the water in the jacket obtains heat from
heat
heaat and then dissipate it through a radiator. As the the cylinder due to _____________________.
temperature
mperature increases from 71 to 82 degrees centigrade,
tem
( ) conduction
(a)
the th
thermostat
t t valve
l opens and
d sendsd water
t tto th
the
(b) convection
radiator to radiate the heat. When the temperature rises
(c) radiation
above 82 degrees, the thermostat switch operates the
(d) All of the above
cooling fan to support the cooling process in radiator.
MAJOR SYSTEMS AND COMPONENTS OF AN AUTOMOBILE AUTOMOTIVE SERVICE TECHNICIAN – CLASS
L IX
61 62
 C. Short answer questions ignition engine the common rail direct injection system
(CRDI) is used for better engine performance.
1. How does a cooling system work?
2. What is the role of coolants? Fuel Supply Components
The fuel supply components include the following:
1. Fuel Tank: In most of the vehicles the fuel tank is
SESSION 5: FUELL SUPPLY
L SYSTEM located at the rear end of the vehicle. The fuel tank
is made of a metal sheet or plastic. It is attached to
WKHFKDVVLV7KHÀOOHURSHQLQJLVFORVHGZLWKDFDS
Fuel Supply System
The fuel line is attached to the fuel pump and also
In petrol
p engines, the fuel and air mixture is supplied to to the fuel gauge.
the
e combustion chamber of an engine. This mixture is
2. Fuel Line: The fuel line carries the fuel fromm the
ato
omised and then vapourised by the carburettor. Then
atomised fuel tank to the carburettor or to the common n rail
e mixture is ignited by the spark plug. The fuels, such
the system used in MPFI engines. The line ha has
as to
as petrol, benzoyl and alcohol are used in an SI engine withstand the pressure and provide resistresistance
tance
)LJ
J1RZDGD\VIXHOLVLQMHFWHGLQWKHÁRZRIDLU
)LJ1RZDGD\VIXHOLVLQMHFWHGLQWKHÁRZRIDLU for the corrosion. The rigid line is placed s safely
at a certain temperature and pressure and the fuel in the chassis. It is connected to the units s like
vapourises
vappourises faster and the combustion process is better, FDUEXUHWWRUWKURXJKDÁH[LEOHSLSH
ZLWKORZHPLVVLRQ,WDOVRVKRZVEHWWHUIXHOHIÀFLHQF\
ZLW
WKORZHPLVVLRQ,WDOVRVKRZVEHWWHUIXHOHIÀFLHQF\
3. Fuel Filter: 7KH PDMRU UROH RI WKH IXHO ÀOWÀOWHU
WHU LV
In case of compression ignition engine (diesel) the
to send clean fuel to the engine. This prev prevents
vents
fue
el is sent through the fuel pump to the injector and
fuel
EORFNDJHV LQ WKH IXHO V\VWHP 7KH ÀOWHU FRQ
FRQWDLQV
WDLQV
the
e injector sprays the fuel at end of compression stroke
DFDUWULGJHRIÀOWHULQJWKHHOHPHQWWKURXJKZKLFK
DFDUWULGJHRIÀOWHULQJWKHHOHPHQWWKURXJKZ ZKLFK
(Fig.
g. 3.23). The oil fuels which are used in CI engines
(Fig WKH IXHO SDVVHV WKH ÀOWHU WUDSV DQ\ SDUWLFOHV
SDUWLFOHV
V DQG
do not vapourise easily. Therefore, a separate injection prevents them from entering the fuel sys system.
stem.
system
stem is used consisting of fuel injection pump (FIP) and
sys 7KH IXHO ÀOWHU LV UHTXLUHG WR EH UHSODFH
UHSODFHG
HG DW
injectors.
inje
ectors. These injectors atomise the fuel and it is then regular intervals.
sent
nt for combustion. Nowadays, in case of compression
sen
4. Air Cleaner: It is the main unit of the fuel sys
system.
stem.
It supplies clean air to the engine. The eleme
element
ent of
the air cleaner must be cleaned and replace
replaced
ed at
regular intervals for maintaining a healthy llife
ife of
the engine.
5. Fuel Injection Pump: In case of a diesel en engine,
ngine,
the diesel oil from the fuel tank is sucked by y the
IXHOIHHGSXPS7KHSXPSÀUVWVHQGVWKHGLHVHORLO
IXHOIHHGSXPS7KHSXPSÀUVWVHQGVWKHGLHV VHORLO
WRWKHIXHOÀOWHU)URPWKHUHLWLVVHQWWRWKHWUDQVIHU
WRWKHIXHOÀOWHU)URPWKHUHLWLVVHQWWRWKHWUDQVIHU
pump. The transfer pump increases the pres pressure
ssure
of the fuel. This high pressure of the fuel is then
ICU
transferred to the distributor rotor through the
metering valve. From the rotor the fuel is sent to the
injector. In case of multi-point fuel injection system
Fig. 3.22: Fuel Supply System Fig 3.23: Fuel line the electric fuel pump is used. The pump generates
MAJOR SYSTEMS AND COMPONENTS OF AN AUTOMOBILE AUTOMOTIVE SERVICE TECHNICIAN – CLASS
L IX
63 64
 WKHLQMHFWLRQSUHVVXUHDQGVHQGVLWWRWKHIXHOÀOWHU Check Your Progress
and then to the common rail at a pressure of 3 to 4
A. Fill in the blanks
bar. The common rail or fuel rail is connected to the
fuel injector 1. Air and fuel are _______ outside the engine.
6. Fuel Injector: The solonide injector used in the 2. The fuels, such as petrol, benzol and alcohol are used in
M.P.F.I fuel system is operated electrically as per the ______________ engine.
variation in the supply of current with resistance. 3. Oil fuels which are used in CI engines do not _________
The solonide winding induces current within it and easily.
controls the movements of the needle valve to inject 4. The fuel system is controlled by the ______________.
fuel as per the variations in speed and the load
load. The
fuel system is controlled by the ECM. B. Multiple choice questions
7 Pressure Regulator: It controls the amount of
7. 1. Which of these is used as a fuel in IC engine?
pressure that enters the injector. The extra fuel is (a) methanol
sent back to the fuel tank. (b) LPG
(c) Benzoyl
Fuel Supply Components Fuel Supply Component
Components ts (d) All of the above
for SI Engine for CI Engine 2. The carburettor is used to ______________
_______.
___________________.
‡‡)XHOWDQN
)XHOWDQN ‡)XHOWDQN (a) mix petrol anand
nd air in correct p proportion
ropo
ortion
‡‡)XHOOLQHV
)XHOOLQHV ‡)XHOOLQHV (b) supply fue el a
fuel ir m
air ixture to tthe
mixture he e ngine
engine
(c) Both (a)) aand
nd (b))
‡‡ )XHO SXPS $& PHFKDQLFDO W\SH RU ‡ )XHO IHHG SXPS 0HFKDQ QLFDO
0HFKDQLFDO (d) Noneeooff tthe
he a bove
above
electrical type) type or electrical type) 3. In a multi-point
multi-p poiint fuel injection
injjection the
the injector is used forr how
‡‡)XHOÀOWHU
)XHOÀOWHU ‡)XHOÀOWHUV maany cy
many ylinder engine
cylinder es?
engines? ?
‡‡&DUEXUHWWRU
&DUEXUHWWRU ‡)XHOLQMHFWLRQSXPS),3 ((a) Five
a)) F ive
‡‡,QOHWPDQLIROG
,QOHWPDQLIROG ‡)XHOLQMHFWRUV ((b)
b) TTwo
wo
‡‡$LUFOHDQHU
$LUFOHDQHU ((c)
c) FFour
our
No ote: In case of modern MPFI engines carburettor
Note: ((d)
d) Six
is replaced by injectors and sensors. 4. Which of th the
he following is not an injector fault?
(a) B Blue
lue nozzle body
((b)
b) N ozzle wetness blue nozzle body
Nozzle
(c)
(cc) EExcessive
xcessive leak off
((d)
d) BBlow
low holes
Practical
Practi
icall EExercises
xerciises
e
C.. Sh
C Short
hort answer questions
Activity
A ctiviity 1
1. Write the importance of a fuel supply system.
List
L the important fun
functions
nctions of the fuel supply system.
2. Explain the correct method of injecting fuel in
S.No. Fun
Functions
nctiions of the fuel supply system an automobile.
1.
2. SESSION 6: TRANSMISSION SYSTEM
3
3.
Transmission
T i i system
t is
i used d in
i motor
t vehicles
hi l to
4. supply the output of the internal combustion engine to
5. the drive wheels. The transmission reduces the higher
engine speed to the slower wheel speed, increasing
MAJOR SYSTEMS AND COMPONENTS OF AN AUTOMOBILE AUTOMOTIVE SERVICE TECHNICIAN – CLASS
L IX
65 66
torque in the process. Transmissions are also used in (b) Gradual engagement, i.e., to engage gradually and
SHGDO ELF\FOHV À[HG PDFKLQHV DQG ZKHUH URWDWLRQDO avoid sudden jerks.
speed and torque need to be adapted. (c) Heat dissipation, i.e., ability to dissipate large
amount of heat generated during the clutch
Transmission System operation due to friction.
The transmission system consists of the following (d) Dynamic balancing, which means that the clutch
components. should be dynamically balanced. This is particularly
required in the case of high-speed engine clutches.
(i) Clutch assembly
(e) Vibration damping, i.e., having a suitable mechanism
(ii) Gear box assembly (Transmission case assembly)
to damp vibrations to eliminate noise prod produced
(ii i) Propeller shaft
(iii) during the power transmission.
Pilot bush
hing
bushing (f) Size of the clutch should be as small as possib ble so
possible
Clu
utch assembly
Clutch Clutch components
that it occupies minimum space.
Clutch
Cluutch (Fig. 3.24) is (g) Free pedal play, which helps the clutch to re reduce
educe
a mechanism which effective load on the carbon thrust bearing g and
Throw-out
enables
enaables the rotary bearing its wear.
mo otion of one shaft
motion (h) Easy in operation and requiring as little exe exertion
ertion
to be transmitted, as possible on the part of the driver.
whhen desired. The
when (i) clutch
Light weight of the driven member of the clutc ch so
axees of driving shaft
axes that it does not continue to rotate for any leng
length
gth of
and d driven shaft are Flywheel time after the clutch has been disengaged.
coincident.
coiincident. Clutch disk
Throw-out Clutch pressure Main Parts of a Clutch
Functions
Fu
unctions of clutch fork plate assembly
The main parts of a clutch are divided into three gro groups.
oups.
(a) To disconnect (a) Driving members: The driving members co consist
onsist
Fig. 3.24: Clutch assembly
the engine power RI D Á\ZKHHO PRXQWHG RQ WKH HQJLQH FUDQNV
FUDQNVKDIW
VKDIW
from the gear box as required, under the following 7KH Á\ZKHHO LV EROWHG WR D FRYHU ZKLFK FDUU
FDUULHV
ULHV D
circumstances: pressure plate or driving disc, pressure sp springs
rings
((i)
i) to start the engine and warm it up; and releasing levers. Thus, the entire asse assembly
embly
 L L WRHQJDJHÀUVWDQGVHFRQGJHDUWRVWDUWWKHYHKLFOH
LL RI WKH Á\ZKHHO DQG WKH FRYHU URWDWH DOO WKH WLPH
from rest; The clutch housing and the cover provided with
(ii i) to facilitate changing the gear as required; and
(iii) openings, dissipate the heat generated by fri friction
iction
(ivv) disconnect from the engine to stop the vehicle after
(iv) during the clutch operation.
application of brakes. (b) Driven members: The driven members consi consist
ist of
(b) To allow the engine to take up load gradually without a disc or plate, called the clutch plate. It is s free
shock or jerk. to slide lengthwise on the splines of the cl clutch
lutch
shaft (primary shaft). It carries friction materi
material
ial on
Requirements
equirements of a Clutch
both of its surfaces. When it is gripped between
The clutch should meet the following requirements. WKHÁ\ZKHHODQGWKHSUHVVXUHSODWHLWURWDWHVWKH
(a) Torque transmission or the ability to transmit clutch shaft through the splines.
maximum torque of the engine.
MAJOR SYSTEMS AND COMPONENTS OF AN AUTOMOBILE AUTOMOTIVE SERVICE TECHNICIAN – CLASS
L IX
67 68
 (c) Operating members: The operating members Check Your Progress
consist of a foot pedal, linkage, release bearing,
release levers and the springs. A. Fill in the blanks
Gear Box (Transmission Case) Assembly 1. Transmission system consists of ___________ components.
2. The main parts of a clutch are _________ and ___________.
We need different gear ratios in the gear box or
transmission system to enable the vehicle to move at 3. Different gear ratios in the _________ makes the vehicle
move at different speeds.
different speeds. At the time of starting the vehicle, the
PD[LPXPDPRXQWRIWRUTXHLVDYDLODEOHRQWKHÁ\ZKHHO  7KH FOXWFK DVVHPEO\ FRQVLVW RI Á\ZKHHO SUHVVXUH SODWH
7KH
and ________________
________________.
forr which low gear ratio is selected for the movement of
thee vehicle. As the engine speed increases, the amount
B. Multiple choice questions
RIWWRUTXHLVUHGXFHGRQWKHÁ\ZKHHODQGLWLVUHTXLUHGWR
RIWRUTXHLVUHGXFHGRQWKHÁ\ZKHHODQGLWLVUHTXLUHGWR
select
sellect higher gear ratio. 1. Which of these systems is used in motor vehicle
vehicles
es to
supply the output of the internal combustio
combustion
on eengine
ngin
ne to
Functions
unctions of a gear box
Fu drive wheels?
(a) Transmission system
((i)
i) To provide a means to vary the leverage or torque (b) Power system
ratio between the engine and the road wheels (c) Torque system m
as required. (d) None of the ea bove
above
2. Which type e ofof transmission
transmiss sion sysystem
ystem is used fo for
or a
(ii)
(i i) The transmission also provides a neutral disengagem
disengagement ment a nd engagem
and ment b
engagement etween the engine
between e and
position so that the engine and the road wheels the remainder
rem transmission
mainder of transm mission s system?
ystem?
are disconnected even with the clutch in the (a) CClutch
lutch
engaged position. Differential
(b)) D iffereential
((c)
c) P roppeller shaf
Propeller ft
shaft
(iii)
(ii i) It provides a means to reverse the car by selecting ((d) None
d) N one of the eaabove
bove
the reverse gear. 3
3.. IIn n a ffour-wheel
our-wh heel d
drive
rivee tthere
here is _________________.
(a)
(a) one liv live axle
ve axxle
(b) no live a xle
axle
Practical
Pract
tical EExercises
xercise
es (c) ttwo
wo llive
ive axle
(d) N
(d) one o
None off the above
4.
4. ___________________
____________________ produces different gear ratios ratio
os in
Activity 1
au utomobiles.
automobiles.
clutch
Make a list of the parts of clut
M assembly
tch a ssembly used in a vehicle. (a) Transmission system
(b) Differential
S.No. P
Parts
arts o
off c
clutch
lutch assembly (c) Steering
(d) Gear box
1.
C. Short answer questions
2.
1. Discuss the role of a transmission system.
3.
2. Explain the function of a gear box.
4.
5.
MAJOR SYSTEMS AND COMPONENTS OF AN AUTOMOBILE AUTOMOTIVE SERVICE TECHNICIAN – CLASS
L IX
69 70
SESSION 7: FRONT AND REAR AXLE to the front wheels, turning right or left as required.
To prevent interference due to front engine location,
In this session, we shall discuss the axle and steering
and for providing greater stability and safety at high
system, which transmits power to the wheel. It plays a
speeds by lowering the centre of gravity of the road
crucial role in the movement of a vehicle.
vehicles, front axle includes the axle-beam, stub-
Propeller Shaft axles with brake assemblies. It is made of drop forged
alloy steel consisting of 0.4% carbon steel and 1.3%
This is a shaft which transmits power from an engine nickel steel.
to the wheels of a motor vehicle. It is a hollow tubular The axle is made of I-section at centre and of circular
shaft and consists of mainly three parts. or elliptical section in the ends since it has to bea
bear the
(ii) Shaft: It mainly bears torsional stress produced
(i) bending stress and torsional stress. In order to llower
due to twisting. It is usually made of tubular the chassis height a downward sweep is provided a at the
cross section. centre of the beam axle.
(ii)
(iii) Universal joints: One or two universal joints are The main beam axle is connected to the stub axle
used, depending on the type of rear axle drive with a king pin. The front road wheels are mounte
mounted ed on
used. The universal joints help in the up and down the stub axle.
movements of the rear axle when the vehicle is in For smooth steering effects and maintaining pr proper
roper
running condition. control, the front axle of a car is supported wit with
th an
(iiii) Slip joint: Depending on the type of drive, one slip
(iii) independent suspension system, such as Mac-pher
Mac-pherson.
rson.
joint may be there in the shaft. This serves to adjust The strut and coil spring allows the wheel to mov move
ve up
the length of the propeller shaft when demanded and down but does not allow to change the dr driving
riving
by the rear axle movements. smoothly.
angle of axle shaft to transmit the drive smooth hly. It
also allows the wheel to rotate freely. This suppor
supports
rts in
Fr
ront and Rear Axle
Front steering the vehicle.
Fro
ont axle
Front Rear Axle
Like the front axle,
Front
Froont axle carries
S pring Seats
Spring the rear axle is also
thee weight of the
made of drop fo orged
forged
fro nt portion of the
front A steel. The rear axle
auttomobile as well as
automobile B
(Fig.3.26) bears the
facilitates
cilitates steering
fac
A weight of the ve ehicle
vehicle
andd controls the
body and load with
rol ling of wheels. It
rolling B
springs. It enabl
enableses to
als
so absorbs road
also
transmit the dr driving
riving
shocks
shoocks arising due
Section AT A-A Section AT B-B torque
and breaking torqque to
to road surface
the chassis frame e and
variations.
varriations. Fig. 3.25: Front axle
body of the vehvehicle.
hicle.
In case of a
It also bears the side
commercial vehicle the front axles (Fig. 3.25) are
thrust or pull due to
generally dead axles. The front axle is designed to Fig. 3.26: Rear axle
any side load on the
transmit the weight of the automobile from the springs
MAJOR SYSTEMS AND COMPONENTS OF AN AUTOMOBILE AUTOMOTIVE SERVICE TECHNICIAN – CLASS
L IX
71 72
wheel. It supports various parts like bevel pinion, bevel 2. The end of the front axle is mounted with ____________.
gear, cage of sun gear and star pinions, axle shafts, and (a) stub axles (b) king pin
different support bearings. (c) piston ring (d) axle shaft
It is important to note that rear road wheels 3. What kind of load does the axle take due to the load of
are mounted on the axle shaft and the differential the vehicle?
mechanism enables the outer wheel to move faster than (a) Bending load (b) Frictional load
the inner wheel while taking a turn. (c) Torsional load (d) None of these
C. Short answer questions
Practical
Practi
icall EExercises
xerciisess 1. What is the role of a front axle?
2. Why are rear axles required?
Activity 1
Make a list of parts of rear axle of a vehicle.
M
SESSION 8: STEERING AND SUSPENSION
N SYST
YSTEM
TEM
S. No. List of parts of rear axle
Steering System
1.
The steering mechanism permits the driver to co control
ontrol
2. the car on a straight road and turn right or le eft as
left
desired. The steering mechanism includes a stee steering
ering
3. wheel, which the d driver
controls, a steering
steeering
4. Steering Wheel gear, which con verts
converts
steering
rotary motion of stee ering
5. wheel in to straight line
motion and steering
steeering
Steering Column linkages. In modern cars,
Che
eck Your Progress
Check the manually oper operated
rated
steering system (Fig. 33.27)
A.. Fill in the blanks
is assisted by power aand is
1. Axle and steering system transm
mit ______ to the wheel.
transmit called power steering.
steering. The
Rack and Pinion
system
2. Front and rear axle system iis
s used for __________. electric power drawn from
3. Differential mechanism enables
m enables the __________ to move the battery or hydr
hydraulic
raulic
faster than the iinner
nner wheel while taking a turn power is used.
________
4. Rear axle ___ __ tthe
_____ he weight of vehicle body.
Tie Rod Functions of a Steering
Stee
ering
B.. Multiple choice
ch
hoice q
questions
uestions System
directional
1. It provides directiional
1. The central portion of the front axle is made
of________________.
of________________. King
g Pin y to the
stability
(a) I section (b) T section vehicle when moving
(c) Q section (d) U section in a straight (ahead)
Fig. 3.27: Steering System
direction.
MAJOR SYSTEMS AND COMPONENTS OF AN AUTOMOBILE AUTOMOTIVE SERVICE TECHNICIAN – CLASS
L IX
73 74
2. It provides perfect steering condition, i.e., perfect mechanism are available, viz., the Davis and the
rolling motion of the wheels at all times. Ackermann steering mechanism. Out of these
3. It facilitates straight ahead recovery after completion Ackermann type is more popularly used because
of turn. of its simplicity. It also lessens wear of tyre and
4. It controls the wear and tear of the tyre. lowers friction.
5. It is used to turn the vehicle as per the will of the driver. Steering Linkages
6. It converts the rotary motion of the steering wheel
A steering linkage is the part of an automotive steering
into angular displacement of the front wheel.
system that connects to the front wheels. In a commercial
7. It multiplies
p the effort of the driver to ease operation.
p
vehicle a rigid axle type front suspension system is u
used.
8. It absorbs road shocks and prevents them from
reaching the driver. Steering Wheel
Requirements
Reequirements of a Good Steering System It is made of polyurethane or hard plastic. It consistss of a
1. It should be very accurate. circular rim with a hub at the centre. The rim is slislightly
ightly
elliptical in cross section to maintain strength and pr
provide
rovide
2. It should be easy to handle.
hand grip. The steering shaft is mated in the undula
undulations
ations
3. The effort required should be minimal.
cut on the inside of the steering wheel hub.
4. It should provide directional stability.
5. The front wheels should roll without lateral skid Steering Column
while negotiating curves. It is tubular in nature. It provides switches for hhorn,
6. There should be proper proportion between the light and wiper for easy and quick operation. The
angles turned by the front wheels. collapse
collapsible columns are used for safety, which colllapse
7. The tyre must have good elasticity so that on turns, upon impact and reduce the chances of injur injury
ry to
these may follow an arc of greater radius than the the driver.
stiff tyre.
Steering Shaft
8. The wheels should automatically come to the
straight ahead position after negotiating the bend. It is made from drop forged alloy steel. It connects the
connects
When going straight, the wheels must maintain the transfers
steering wheel to the steering gear box and tran nsfers
neutral position. movements of the steering wheel to the steering geaar, or
gear,
9. The angular oscillations of the wheels must to the pinion.
be minimum. Drop Arm
10.. The system must be irreversible to a certain degree
10
It is also called as pitmen arm. It is made up of drop
so that minimum front wheel shocks are transmitted
to the driver’s hands. forged steel. It connects the cross shaft with the drag
draglink.
glink.
Draglink
Steering
Ste
eering Mechanism
It connects the drop arm to the steering knuckle. It is
Forr perfect steering
steering, it must always have an
also made up of drop forged steel.
instantaneous centre about which all the wheels
must rotate. To achieve this the inner wheel has
to turn more than the outer wheel. Two types of
MAJOR SYSTEMS AND COMPONENTS OF AN AUTOMOBILE AUTOMOTIVE SERVICE TECHNICIAN – CLASS
L IX
75 76
 The tie rod ends are different parts of the steering Various Components of Suspension System
linkage will be connected to the ball joints which provide
The components of a suspension system can be
angular motion to the steering system.
categorised as follows.
Steering Gears
Mechanical Suspension
The steering gear converts the turning motion of the
(i) Leaf springs
steering wheel into the to-and-fro motion of the link rod
(ii) Coil springs
of the steering linkage. It also provides the necessary
leverage so that the driver is able to steer the vehicle (iii) Rubber springs
without
thout fatigue. ( )
(iv) Torsion bars
Suspension
Su
uspension System Hydraulic Suspension
Su spension is the term given to the system of springs,
Suspension (i) Hydraulic shock absorber
shoock absorbers and linkages that connects a vehicle
shock (ii) Telescopic fork absorber
to its wheels. The suspension system serves a dual
pu rpose, contributing to the vehicle’s road holding or
purpose,
Air Suspension
hanndling and braking for safety and driving comfort,
handling Compressed air is used in an air suspension syste
em.
system.
andd keeping the vehicle occupants comfortable and Mechanical Suspension
rea
asonably well isolated from road noise, bumps and
reasonably
1. Leaf Spring: A leaf spring (Fig. 3.28) is a compo
component
onent
vib
brations, etc.
vibrations,
of a vehiclse’ suspension system. Leaf sp rings
springs
Functions
Fu
unctions of suspension system are curved and the curvature helps the sp pring
spring
The e main functions of a suspension system are as follows: absorb impact.
((i)
i) To safeguard the occupants against road shocks
and provide riding comfort.
(ii)
(i i) To minimise the effects of stresses due to road
shocks on the mechanism of the motor vehicle and
provide a cushioning effect.
(iii)
(ii i) To keep the body perfectly in level while travelling
over rough uneven ground, i.e., the up and down
movement of the wheels should be relative to
the body.
Fig 3.28: Leaf spring
(iv)
v) To isolate the structure of the vehicle from shock
(iv
loading and vibration due to irregularities of the 2. Coil Spring: Coil springs are commonly c called
road surface without impairing its stability. compression springs, torsion springs or he elical
helical
(v)
(v
v) To provide the requisite height to the body springs. They store energy and release it to abbsorb
absorb
structure as well as to bear the torque
q and shock or maintain a force between two conta
contacting
acting
braking reactions. surfaces.
f Mostly
l coil
il springs
i or h
helical
li l springs
i are
used in engine starter and hinges (Fig. 3.29).
3. Rubber Spring: A rubber string stores more
energy per unit mass than any other type of spring
MAJOR SYSTEMS AND COMPONENTS OF AN AUTOMOBILE AUTOMOTIVE SERVICE TECHNICIAN – CLASS
L IX
77 78
 material. The rubber spring The telescopic fork uses fork tubes and sliders
(Fig. 3.30) is installed which contain springs and dampers.
between the frame and the
top link of the suspension Air Suspension
system. When the spring is In this suspension, compressed air is used as a spring.
connected to a point near This suspension system is operated with air and
WKH OLQN SLYRW GHÁHFWLRQ controlled by a microprocessor. It helps in maintaining
of the spring reduces self-driving
f driving conditions and supports the weight of
self-
to a minimum, without the vehicle.
affecting the total wheel
movement. The energy
released from the rubber Practical
Practiicall EExercises
xercise
xerci
ises
Fig. 3.29: Coil spring
VSULQJ DIWHU GHÁHFWLRQ LV Activity 1
considerably less than that List the components of a suspension system.
imparted to it.
4. Torsion Bars: Torsion S. No. componen
nt
Name of the component
bars are of two types — 1.
helical or spiral. These
2.
bars are used in
automobile vehicles for 3.
transmitting torque. 4.
Hydraulic
Hy
ydraulic Suspension 5.
Hydraulic
Hyydraulic suspension combines 6
6..
rubbber springs with a damper
rubber 7
7..
sysstem, linking the front and
system, Fig. 3.30: Rubber spring added 8.
rear
ar wheel on the same side of
rea
thee car. As the front wheel rises over a bump, some of 9.
WKHÁXLGIURPLWVVXVSHQVLRQXQLWNQRZQDVDGLVSODFHU
WKHHÁXLGIURPLWVVXVSHQVLRQXQLWNQRZQDVDGLVSODFHU 10
0.
10.
XQ LW ÁRZV WR WKH UHDUZKHHO XQLW DQG UDLVHV LW VR
XQLW
tending
nding to keep the car level. In each of the displacer
ten
XQLWVWKHÁXLGSDVVHVWKURXJKDWZRZD\YDOYHZKLFK
XQ LWVWKHÁXLGSDVVHVWKURXJKDWZRZD\YDOYHZKLFK Check
C heck Your Progress
provides
proovides the damping effect. Once the rear wheel has
SDVVVHG RYHU WKH EXPS WKH ÁXLG UHWXUQV WR WKH IURQW
SDVVHG A. Fill in the blanks
displacer
dis
splacer unit and the original level is restored. 1. Steering system is used for __________.
1.. Hydraulic Shock Absorber: It is a mechanical
1 steering
2. Main parts of steering system are __________and stee
ering
device designed to absorb shock impulses. This column.
device is also used for checking or damping out 3. A suspension system consists of springs, __________ and
the suspension spring to a comfort level. linkages that connect a vehicle to its wheels.
2. Telescopic Fork Absorber: A telescopic fork is 4. A suspension system keeps vehicle occupants
a form of motorcycle front suspension whose _____________.
use is so common that it is virtually universal.
MAJOR SYSTEMS AND COMPONENTS OF AN AUTOMOBILE AUTOMOTIVE SERVICE TECHNICIAN – CLASS
L IX
79 80
 B. Multiple choice questions
Rim (iv) To balance dynamically (i.e., when
the vehicle is in motion) and statically
1. The tilting of the front wheels away from the vertical is (i.e., when the vehicle is at rest).
called _____________.
(a) camber
(b) caster
Rim
(c) toe-in The rim (Fig. 3.32 [a-b]) is the ‘outer edge of a
(d) toe- out
wheel, holding the tyre’. It makes up the outer
2. Which of the following types of mechanism is used in a Wheel
disk circular design of the wheel on which the inside
steering system?
edge of the tyre is mounted on vehicles, such as
(a) Rack and pinion steering
(b) Rotary motion is turning automobiles For example, on a bicycle w
automobiles. wheel
(c) Reciprocating motion (a) the rim is a large hoop attached to the o outer
(d) Power steering system holds
ends of the spokes of the wheel that hold s the
3. Leaf spring absorbs shocks by __________________. tyre and the tube.
(a) tension Heavy
Heavy v
vehicle
ehic
cle w
wheel
heel rrim
im
(b) compression Different types of wheel rim
(c) twisting (i) Disc wheel rim
(d) bending
4. Compressed air is used for ___________________
______.
________________________. (ii) Wire spoke wheel rim (used d in
(a) air suspension system motorcycle, bicycle)
(b) hydraulic suspension (iii) Split wheel rim (used in scooter)
(c) mechanical suspension
(d) None of the above (iv) Heavy vehicle wheel rim (availab
(available
ble in
three piece and four piece inclu
including
uding
C.. Short answer questions locking ring)
1. How does a steering system wo
work?
ork? 1. Disc wheel Rim: A wheel is gene generally
erally
2. What is a power steering sy
ystem?
system? (b)
composed of rim and disc. Rim is an outerr part
Fig. 3.32(a–b): Rim
of the wheel and holds the tyre. Disc is a pa part
art of
wheel which connects the rim and the axle hu hub.
ub.
SESSION
E 9: WHEEL, TYYRE
RE AND BR
RAKE
AKE 2. Wire Spoke Wheel Rim (used in motorc motorcycle,
cycle,
bicycle): Wire spoke wheel rim is where the ou outside
utside
Wheel
Wh
heel part of the wheel (rim) and axle installed parpart
rt are
The
Th e wheel is an important component of a vehicle. connected by many numbers of wires called spo spokes.
okes.
Whheel of a four-wheeler vehicle is mounted on a hub
Wheel 3. Spilt Wheel Rim (used in scooter): Spilt wheel w
and
d consists of parts like rim, tyre and tube (Fig.3.31). rim is used in a multi-piece wheel. This whee
wheelel rim
The
Th e wheels not only support the weight of the vehicle, holds the tyre with a locking ring. A split whee
wheelel rim
butt also protect it from road shocks. All the four wheels
bu cannot be used normally in all types of vehicl
vehicle.
le.
muust resist the braking stresses and withstand side
must 4. Heavy Vehicle Wheel Rim (available e in
thr
rust. A wheel should be light and easily removable.
thrust. three piece and four piece including locking loccking
Functions
Fuunctions of the wheel Fig. 3.31: Wheel ring): Heavy vehicle wheel rim have a three e and
four-piece
four piece locking ring.
ring This type of wheel rim ri is
(i) To withstand the weight of the vehicle.
used in heavy vehicles wheel like truck, buses
(ii) To absorb road shocks. container, etc., because it has a longer life.
(iii) To grip the road surface.
MAJOR SYSTEMS AND COMPONENTS OF AN AUTOMOBILE AUTOMOTIVE SERVICE TECHNICIAN – CLASS
L IX
81 82
Tyre
The tyre (Fig. 3.33) is mounted on the wheel rim. It
carries the vehicle load and provides a cushioning
effect. It must produce minimum noise, while the
wheel turns on the road. It resists the tendency for
the vehicle to oversteer. It should have good grip
while accelerating and braking the vehicle on both
dry and wet roads.
Desirable
esirable Properties of a Tyre
A tyre
t must have the following properties.
((i)
i) Non-skidding: The tyre must have grip to avoid
skidding or slipping on the road surface.
(ii)
(i i) Uniform wear: The tyre must get worn uniformly
over its outer circumference.
(iii)
(ii i) Load carrying: The tyre is required to carry the
vehicle load.
(iv)
(ivv) Cushioning: The tyre needs to absorb the
vibrations due to the different road surfaces and
their impact, and thus, provide cushioning effect
to the vehicle.
(v)
(vv) Power consumption: While rolling on the road,
the tyre should consume little power created by
the engine.
(vi)
(v i) Noise: The tyre should create minimum noise
while running on the road.
(vii)
(viii) Balancing: The tyre should be balanced
dynamically as well as statically, i.e., maintain
balance at both times — when the vehicle is in
motion as well as at rest.
Functions
Fuunctions of Tyre
((i)
i) To carry the load of the vehicle.
(ii)
Types of Tyre
(i) Solid tyre: It is used in children’s cycle and is
ÀOOHGZLWKVROLGPDWHULDOOLNHUXEEHUZKLFKPDNHV
it sturdy.
(ii) Tube tyre: It consists of a tube between the rim
DQG WKH W\UH LQ ZKLFK DLU LV ÀOOHG ,W LV XVHG LQ
most of the vehicles seen on road.
(iii) Tubeless tyre: Nowadays, with the advancements
in technology, tubeless tyres are replacing the tube
tyres. Tubeless tyres are mainly used in mo modern
FDUV 7KH EHQHÀWV RI WXEHOHVV W\UHV LQFOXGH VORZ
Fig. 3.33: Tyre leakage of air during punctures, better balan balancing
ncing
of wheels, low cost and ease of puncture repai repairing.
iring.
Brake
Brakes (Fig. 3.34) are one of the most
important control components of a vehvehicle.
hicle.
They are required to stop the vehicle w
within
the smallest possible distance and th this
his is
energy
done by converting the kinetic energ gy of
the wheels into the heat energy whic ch is
which
dissipated into the atmosphere.
Requirements of A Good Braking System
System
shortest
(i) To stop the vehicle in the shoortest
possible distance and time.
(ii) To control the vehicle speed w while
Fig. 3.34: Brake
moving on plain roads and hills.
(iii) To work equally well on fair and bad roads.
(iv) To ensure that the pedal effort applied by the d
driver
inconvenience
is not much, thereby reducing the inconveni ience
for the driver.
(i i) To absorb minor road shocks.  Y
Y 7RZRUNHIÀFLHQWO\LQDOOZHDWKHUV
(iii)
(ii i) To reduce vibration to some extent. (vi) It should have very few wearing parts.
(ivv) To transmit the power from the engine through gear
(iv) (vii) It should require little maintenance.
box, propeller shaft and rear axle to the ground (viii) Brake, when applied should not disturb the
with which the vehicle moves. steering geometry.
(v) The treads made on the tyres grip the road for
(ix) There should be minimum sound when brake
better traction.
is applied.
MAJOR SYSTEMS AND COMPONENTS OF AN AUTOMOBILE AUTOMOTIVE SERVICE TECHNICIAN – CLASS
L IX
83 84
Types of Brake 4. Disc Brake or External Contracting Brakes: It
1. Foot Brake: Foot brake is one of the most common is the type of braking system in which instead
brake systems operated by the foot pedal. When of a drum assembly a disc rotor is attached to
pressure is applied to the foot pedal, the vehicle the hub of the wheel in such a fashion that it
stops. Pedal force applied by the driver is further rotates with the wheel (see Fig. 3.36). This disc
multiplied and sent to the braking drum or disc rotor is clamped in between the caliper which is
either by mechanical linkages or by hydraulic ULJLGO\ À[HG ZLWK WKH NQXFNOH RU XSULJKW RI WKH
pressure which in turn causes braking. It is also vehicle. When brakes are applied the actuation
known as a service brake. mechanism contracts the attached brake shoes
2. Hand Brake: Hand brakes are which in turn make the frictional contact with
Spring Cam
usually used for stable parking the rotating disc rotor and cause the stop stopping
pping
RI WKH YHKLFOH HLWKHU D RQ ÁDW Brake
lining
of a vehicle. An external contracting brak brakeke is
road or slope. They are also used for only parking purpose as well as us used
ed to
called parking brakes. Hand RSHUDWHLQÁRXUPLOOVYDULRXVW\SHVRIHOHFWULFDO
RSHUDWHLQÁRXUPLOOVYDULRXVW\SHVRIHOHFWWULFDO
brakes are connected to the components, etc.
brake mechanism directly and 5. Mechanical Brake: This brake system ha hass an
the other end is operated by inbuilt mechanical device for absorbing en energy
nergy
the driver. This type of brake from a moving system. Mechanical brake is a c cable
is also known as emergency pull system, which consists of rim-like brakes s just
brake as it is independent of the arranged in a different way.
main service brake. 6. Power Brake: Power brake system iis s a
3. Drum Brakes or Internal combination of the mechanical componentcomponents ts to
Expanding Brakes: Drum multiply the force applied to the brake peda pedalal by
brakes (Fig. 3.35) are usually Fig. 3.35: Drum brake
the driver to stop the vehicle. In a power b brake
used as rear brakes in most system we mainly use the vacuum boosterr and
automobiles, which utilises master cylinder, brake calipers, drum brake brake,, etc.
the friction between the drum These braking systems are designed to reduc reduce ce the
and the brake shoes to stop effort required to depress the brake pedal w when
the vehicle. This type of brake stopping a vehicle.
LV  ÀWWHG LQ  DXWRPRELOH OLJKW 7. Vacuum Brake: It is the conventional typ type
pe of
vehicle, such as car and light braking system in which vacuum inside the b brake
trucks. These brakes have a two lines causes brake pads to move, which in turn
shoe, the left hand shoe is ÀQDOO\ VWRS RU GHDFFHOHUDWH WKH YHKLFOH 7KLV W\SH
known as a primary shoe and of brake is mainly used in railways in place o of air
the right-hand shoe is known brakes. This brake can remove the kinetic en energy
nergy
as trailing shoe. Shoes are and convert it into a form of heat. The conver
conversion
rsion
ÀWWHG LQ WKH GUXP 7KH IULFWLRQ is usually done by applying a contact material
materiial to
between the shoes and the the rotating wheel attached to the axles. Vac Vacuum
cuum
drum
d produces
d th
the b
braking
ki brakes
b k are cheaper
h than
h air
i b brakes
k b
but are less
torque and reduces the safe than air brakes.
Fig. 3.36: Disc Brake
speed of the drum so that the
vehicle stops.
MAJOR SYSTEMS AND COMPONENTS OF AN AUTOMOBILE AUTOMOTIVE SERVICE TECHNICIAN – CLASS
L IX
85 86
8. Air Brake: Air brake system is a very advanced
braking system. It is generally used in very heavy Practical
Prac
ctiical EExercises
xercise
rciises
vehicles like buses and trucks. It is the type
of braking system in which the atmospheric Activity 1
air through compressors and valves is used to List the different types of brake used in an automobile.
transmit brake pedal force from brake pedal to
WKHÀQDOGUXPRUGLVFURWRU$LUEUDNHVJHQHUDWH S. No. Types of brake
higher brake force than hydraulic brake which
is the need of the heavy vehicle. High-end cars 1.
these days are using air brake systems due to its
effectiveness and fail proof ability. 2.
9. Hydraulic Brakes: A hydraulic braking system
3.
transmits brake-pedal force to the wheel brakes
WKURXJK SUHVVXULVHG ÁXLG FRQYHUWLQJ WKH ÁXLG 4.
pressure into useful work of braking at the
wheels. The brake pedal relays the driver’s 5.
foot effort to the master-cylinder piston, which
FRPSUHVVHV WKH EUDNH ÁXLG 7KLV ÁXLG SUHVVXUH 6.
LV HTXDOO\ WUDQVPLWWHG WKURXJKRXW WKH ÁXLG WR
7.
the front disc-caliper pistons and to the rear
wheel-cylinder pistons. The pressure on a liquid
8.
is called hydraulic pressure. The brakes which
are operated by means of hydraulic pressure are
called hydraulic brakes. Check
Che
eck Your
Your Progress
Progre
ess
10.. Anti-lock Braking System: Anti-lock Braking
10
System prevents the wheels from locking or A.. Fill iin
A n the bl
blanks
lanks
s
skidding. The anti-lock braking (ABS) system is 1. Whe
Wheel
eel iis
s an iimportant
mportant component of the ___________
___________.
_.
a component that ensures passenger safety by 7
7 \UH
HLLVÀ
ÀWWHGRQWKHBBBBBBBBBBBBB
7\UHLVÀWWHGRQWKHBBBBBBBBBBBBB
stopping the vehicle in adverse conditions, like 3
3.. Brake
Brak
ke should work ______________ on roads.
stopping very quickly or if the road is slippery. 4. Hand
Hand brake is also known as ____________ brake.
To simplify it, the ABS prevents the wheels of
the vehicle from locking up and causing you to B.. M
B Multiple
ultiple choice questions
skid out of control. 1. The most important component of a vehicle is _______
__________.
____.
11.
11. Electric Brake: It is the type of braking used (a) wheel
in electric vehicle. Electric brakes use electrical (b) rim
motors which are the main source of power in (c) disk
electric vehicles. Electric brakes or secondary (d) tyre
shoe are similar to the drum brakes in an 2. The tyre is mounted on the ____________.
automobile.
bil Electric
El i brakes
b k are actuated
d bby (a) vehicle
(b) disc
an electromagnet.
MAJOR SYSTEMS AND COMPONENTS OF AN AUTOMOBILE AUTOMOTIVE SERVICE TECHNICIAN – CLASS
L IX
87 88
 (c) wheel rim Main components of the electrical system
(d) None of the above
Starting Generating or
3. The main component of the generating or charging system Ignition system Lighting system Accessories
system Charging system
is (are) ______________.
(a) generator/alternator ‡%DWWHU\ ‡*HQHUDWRU ‡%DWWHU\ ‡+HDGOLJKW ‡+RUQV
(b) ammeter ‡6WDUWLQJ Alternator ‡,JQLWLRQVZLWFK ‡6LGHOLJKW ‡:LQGVFUHHQZLSHU
(c) the battery ‡0RWRU ‡$PPHWHU ‡,JQLWLRQFRLO ‡5HDUOLJKW ‡(OHFWULFIXHOSXPS
(d) All of the above ‡0RWRU ‡7KHFXWRXW ‡'LVWULEXWRU ‡)RJ/DPSV ‡)XHOJDXJHV
‡&RQWURO ‡6ZLWFK ‡6SDUNSOXJV ‡1XPEHUSODWH ‡7HPSHUDWXUHJDXJH
C. Short answer questions ‡%DWWHU\ ‡&RQWDFWEUHDNHU illumination lamp ‡5DGLRVHWV
‡9ROWDJHDQG
‡9ROWDJHDQG ‡$XWRPDWLF ‡,QWHULRUOLJKWV ‡&LJDUOLJKWHUPRELOH
1 What
1. Wh are the
h components off a wheel?
h l? l
current regulator d
advance andd , GL Á K
‡,QGLFDWRUÁDVKHUV h
phone h
charger
retard unit ‡+HDWHU
2. How does the brake system function?
‡9DFXXPFRQWURO ‡:LQGVFUHHQGHIURV VWHU
‡:LQGVFUHHQGHIURVWHU
unit ‡6LJQDOOLQJGHYLFHV
SESSION
E 10: ELECTRICAL OR ELECTRONIC AND Note: In modern vehicles, various types of electr
electronic
ronic
AIIR
R CONDITIONING SYSTEMS VHQVRUVDQGDFWXDWRUVDUHÀWWHGLQGLIIHUHQWV\VWHPPVRI
VHQVRUVDQGDFWXDWRUVDUHÀWWHGLQGLIIHUHQWV\VWHPVRI
the engines, which are also operated electrically.
Electrical
Ele
ectrical or Electronic System
Air Conditioning System
Nowadays,
No wadays, all the automobiles run with the help
During summer, an automobile requires conside
considerable
rable
of electrical and electronic system, and therefore,
amount of refrigerating capacity to maintain cooll and
it plays an important part in the functioning of
Similarly,
comfortable conditions in the sitting space. Simil larly,
an automobile.
when moving in a cold day in winter, the same ve vehicle
ehicle
The electrical and electronic systems consist of the
would require considerable heating capacity to kekeep
eep it
foll
lowing.
following.
comfortably warm for passengers.
(i) Starting system: The starting motor is driven by Modern-day automobiles have an air conditio
conditioning
oning
means of the current taken from the battery. unit (Fig. 3.37) to maintain suitably contr controlled
rolled
( Ignition system: The function of the ignition system
(ii) temperature and humidity conditions inside the veh
vehicle.
hicle.
is to produce a spark in the engine combustion In automobiles, an air conditioner is a refrigera
refrigeration
ation
chamber at the end of the compression stroke. machine which requ requires
uires
(iii)
(iiii) Generating or charging system: The function of the electrical energy dr drawn
rawn
charging system in an automobile is to generate, from the battery sys system.
stem.
regulate and supply the electrical energy for The battery is charged
charge ed by
charging the battery. energy of the engine.
For heating purp
purposes,
oses,
(iv)
(iiv) Lighting system: It consists of various types of
the warm water from m the
lighting used during the vehicle running, such as
engine cooling system m is
head light, tail light, fog light, brake light, reversing
used. The heat requ required
uired
light, left and right indicators, parking light, cabin
to warm the autom
automobile
mobile
light,
light panel board lights,
lights etc.
etc
is generally provided by
(v) Connections for other accessories. circulating warm water
Fig. 3.37: Air conditioner in a car through a heating coil.
MAJOR SYSTEMS AND COMPONENTS OF AN AUTOMOBILE AUTOMOTIVE SERVICE TECHNICIAN – CLASS
L IX
89 90
 Besides controlling the temperature levels, the air a radiator. The condenser is a cooling device in
conditioner also cleans the air. During summer, the which the vapour is condensed to a liquid because
humidity of the air inside the vehicle is reduced with of the high pressure that is driving it in, and this
air conditioner in operation, which makes the sitting generates a great deal of heat. The heat is then in
area comfortable. Car air conditioner comes inbuilt in WXUQ UHPRYHG IURP WKH FRQGHQVHU E\ DLU ÁRZLQJ
air conditioned (AC) car models. However, these can through the condenser on the outside.
DOVR EH ÀWWHG DW D ODWHU VWDJH LQ D QRQ$& PRGHO RI 4. Receiver-drier: The main function of this device is
the car. WRÀOWHUUHIULJHUDQW7KHOLTXLGUHIULJHUDQWPRYHVWR
the receiver-drier. This is a small reservoir vessel
Different Components of Automobile Air
for the liquid refrigerant, which removes any
Co
onditioning System
Conditioning
moisture that may have leaked into the refrige erant
refrigerant
((i)
i) Compressor and also stores excess quantity of refrigerant..
(ii)
(i i) Magnetic clutch 5. 7KHSUHVVXULVHGUHIULJHUDQWÁRZV
Expansion Valve: 7KHSUHVVXULVHGUHIULJHUDQW ÁRZV
(iii)
(ii i) Condenser from the receiver-drier to the expansion valve. The
(iv)
(iv
v) Receiver-drier (or dehydrator) controls
expansion valve is a controlling device which con ntrols
the varying load when there are pressure cha changes
anges
(v)
(v
v) Expansion valve
in the evaporator, as it may increase or decr decrease.
rease.
(vi)
(v i) Evaporator throughout
The valve maintains a constant pressure throug ghout
(vii)
(vi i) Throttling valve the varying load on the evaporator controlling g the
1. Compressor: A compressor is unit driven by the TXDQWLW\RIUHIULJHUDQWÁRZLQJLQWRWKHHYDSRUDWRU
TXDQWLW\RIUHIULJHUDQWÁRZLQJLQWRWKHHYDSRUDW WRU
engine. It has a low pressure side port which is 6. Evaporator: It is the main componen component nt of
connected to the evaporator and a high pressure a refrigeration system and is also called d the
side port which is connected to the condenser FRROLQJ FRLO ,W KDV WXEHV DQG ÀQV RU IUHH
IUHH]LQJ
H]LQJ
using rubber hoses. The compressor is the main coil. It is usually placed inside the passe passenger
enger
mechanical part of the system. In hybrid engines compartment above the footwell. As the cold
the compressor is electrically powered. A small low-pressure refrigerant is passed into the
HOHFWULF PRWRU LV ÀWWHG LQVLGH WKH FRPSUHVVRU evaporator, it vapourises and absorbs heat
which pressurises the refrigerant. These from the air in the passenger compartment.. The
compressors have a pair of large gauge wires blower fan inside the passenger compartmcompartment ment
which form the compressor controller. In latest pushes air over the outside of the evaporato
evaporator, or, so
cars, where the climetrons are used the electric cold air is circulated inside the car. On the ‘air-
power supply is controlled by ECU as per the side’ of the evaporator, the moisture in the a air is
temperature settings. reduced, and the ‘condensate’ is collected.
2. Clutch: 7KH FRPSUHVVRU LV DOZD\V À[HG ZLWK 7. Throttling Device: It is a part of refriger
refrigeration
ration
a clutch. The major function of the clutch is to system and air conditioning system. W When
transmit the power smoothly to the compressor refrigerant comes out from the condenser at a
when the system is operated. medium temperature and high pressure, it e enters
nters
3. Condenser: The major function of this device will the throttling valve. In the throttling valve,, the
be to change the high-pressure refrigerant vapour pressure and d temperature off theh refrigerant
f i are
to a liquid. The condenser is mounted in front decreased suddenly and the cooling effect is provided
of the engine’s radiator, and it looks similar to to the evaporator.
MAJOR SYSTEMS AND COMPONENTS OF AN AUTOMOBILE AUTOMOTIVE SERVICE TECHNICIAN – CLASS
L IX
91 92
Working of Air Conditioning System
Practical
Prac
ctiical EExercises
xercise
rciises
In a car’s air conditioning system, the refrigerant vapour
from the evaporator is compressed to high pressure by A. Fill in the blanks
1. ________ is the main component of a refrigeration system.
the compressor. The compressor is driven by the engine 2. Battery is used for _______ vehicle.
through a belt drive. In a hybrid car, the compressor 3. Starting system consist of battery and starting _________.
is driven by the motor and the power is used from 4. Warm temperature in the car is maintained by ____________.
the battery. B. Multiple choice questions
The compressor is connected by an electromagnetic 1. The starting motor is driven by means of the current taken
clutch which serves, engages and disengages the from the________________.
(a) battery
compressor
commpressor as required. A variable displacement A/C (b) stabiliser
compressor
commpressor is sometimes used to match a compressor (c) ignition coil
capacity
cappacity to varying cooling requirement. The refrigerant (d) None of the above
pressure
preessure and temperature increases in the compressor ____________________.
2. The function of the ignition system is ______________________.
(a) to produce a spark in the engine combust tion c
combustion hammber
chamber
and d converts it into the vapour form and then to the (b) to generate, regulate and supply the elect
electrical
trica energy
al eneergy
condensed
conndensed form. In the condenser the refrigerant (c) to produce a current for charging
liberates
libeerates heat and converts into the liquid form. (d) None of the above
6RPHWLPHV WKH DLU LV QRW VXIÀFLHQW DQG WKHUHIRUH 3. List the electrical accessories used iin vehicle.
n veh
hicle.
an extra engine or electric driven fan is used to S. No. List o
off ac
accessories
ccessoriies
cool
coool the refrigerant. This cooled but high pressure 1.
refrigerant
frigerant is passed through the dehydrator to extract
refr 2.
any y moisture. Dry refrigerant liquid is then made to pass 3..
3
through
thrrough expansion valve mounted at the inlet side of the 4. Airr condi
conditioner
itioner loss
losses
ses
seenergy
ne
ergy from the ______________
_______________.
__.
evaporator.
evaaporator. The expansion valve allows the refrigerant (a)
(a) bbattery system
attery syste em
liquid
liquuid to expand to low pressure in the evaporator. (b) c
(b) ondenserr
condenser
(c)
(c) engine
The
Th e process of expansion to low pressure makes the (d)
(d) None o off th
the above
he above
refrigerant
frigerant evaporate and thereby cool the evaporator.
refr
C.. Short a
C answer
nswer q questions
uestions
A sensing device, called temperature tube signals 1. Disc
Discuss
cuss tthe
he importance of electrical and electronic sy
system
stem
thee diaphragm in the expansion valve to change the in automobiles.
in automobiles.
size
siz e depending upon the refrigerant temperature at the 2. W ha
Whatat are the components of an air conditioning syst em?
system?
evaporator
evaaporator outlet, thus achieving automatic temperature
control
conntrol (Fig. 3.38). SE SION 11: ACTIVE
ESSION
SS AND PASSIVE SAFETY
There are different safety and security systems s for
automobiles available in the market and some of which
w
DUHÀWWHGE\WKHPDQXIDFWXUHU6RPHRIWKHDFWLYHDQG
DUHÀWWHGE\WKHPDQXIDFWXUHU6RPHRIWKHDFWLYHHDQG
follows..
passive security systems are mentioned as follows
Safety Glass
Safety glass is used
Safet sed in all windows
indo s and doors of a
automotives.
tomo
The safety glass used in today’s vehicles is of two
types — laminated and tempered. These are considered
Fig 3.38: Air Conditioning System in a Car as safety glass because of their varying strength.
MAJOR SYSTEMS AND COMPONENTS OF AN AUTOMOBILE AUTOMOTIVE SERVICE TECHNICIAN – CLASS
L IX
93 94
 Laminated plate glass is used to make windshields. Energy-absorber Safety Bumpers
It consists of two thin sheets of glass with a thin layer of
Modern bumpers are designed to absorb the energy of a
clear plastic between them. Some glass manufacturers
low-speed impact, minimising the shock directed to the
increase the thickness of the plastic material for better
frame and to the occupants of the vehicle. Most energy
strength. When this type of glass breaks, the plastic
absorbers are mounted between the bumper face bar or
material tends to hold the shattered glass in place and
bumper reinforcement bar and the frame.
thus, prevents it from causing injury.
Tempered glass is used for side and rear window Security Devices
glass but rarely for windshields. It is a single piece of
There are three basic types of security devices available
at treated glass and has more resistance to impact
heat-treated
— locking devices, disabling devices and alarm syst tems.
systems.
thaan the regular glass of the same thickness. Thus, it has
than
In automobile vehicle, an anti-theft system m or
greater
greeater strength compared to a laminated plate glass.
device is installed to prevent theft of a vehicle. M Many
Seat
Se
eat belts car security devices are available in the market. T These
A seat
s belt is also called a safety belt. It is a are mechanical devices and ignition cut off dev vices,
devices,
har rness designed to protect the occupant of
harness intelligent computerised anti-theft devices, sat satellite
tellite
a vehicle
v from harmful movement, during a tracking system, engine control module, etc. Vehicle Ve
ehicle
colllision or when the vehicle stops suddenly.
collision owners may select as per risk and install it in their
A seat belt (Fig. 3.39) reduces the vehicles. Prior to purchasing, the customers sh should
hould
OLNHOLKRRGDQGVHYHULW\RILQMXU\LQDWUDIÀF
OLNHHOLKRRGDQGVHYHULW\RILQMXU\LQDWUDIÀF check that these theft devices are duly approved from
colllision. It prevents the vehicle occupant
collision. the Automobile Research Association of India (A (ARAI).
ARAI).
fro
fromm hitting hard against the interior Important features of these devices are explained b below.
elow.
elements
ele ments of the vehicle or other passengers, ‡ $ODUP
‡ $ODUPIn
In the case of vehicle tampering, au audible
udible
and d keeps the occupants positioned in warning sounds emerge
SODDFHIRUPD[LPXPEHQHÀWIURPWKHDLUEDJ
SODFHIRUPD[LPXPEHQHÀWIURPWKHDLUEDJ ‡ .H\OHVV/RFN
‡ .H\OHVV/RFN'HYLFHTo
'HYLFH To use the vehicle, electr
electronic
ronic
The passenger must fasten the seat belt coding device is required
forr crash protection. However, in case of a ‡
‡ (OHFWURQLF ,PPRELOLVHUV
,PPRELOLVHUV These bu ilt-in
built-in
SDVVLYHVDIHW\V\VWHPVXFKDVWKHLQÁDWLRQ
SDV VVLYHVDIHW\V\VWHPVXFKDVWKHLQÁDWLRQ Fig. 3.39: Seat belt transponders send signals to the ignition and d fuel
of air bags at the time of an accident, is pump system. The vehicle remains in stationa ary or
stationary
automatic.
aut tomatic. No action is required of the occupant to make inoperable state if the ignition starters do no ot get
not
it functional.
fu Nowadays, seat belts are also provided for correct signals.
rear
reaar seat occupants. ‡
‡ 6WHHULQJ :KHHO /RFN /RFN7KLV ÀWWHG
7KLV GHYLFH LV ÀWWHHG LQ
the steering of the vehicle and it locks it in n one
Airbags
Air
rbags place so that no one can drive it without removing
remo oving
An airbag (Fig. 3.40) is one of the passive the lock.
saf
fety systems for the occupants of a four-
safety ‡ 9HKLFOH7UDFNLQJEven
‡ 9HKLFOH7UDFNLQJ Even if a thief steals a veh
vehicle,
hicle,
whheeler. The electrical system of airbags
wheeler. the tracking technologies can help trac trace
ce it.
includes
inc
cludes impact sensors and an electronic Tracking devices offer real-time location off the
control
ntrol module
module. In case of an accident
accident, stolen vehicle with the help of the global positio
positioning
the sensor detects the impact and the system (GPS).
airbag opens up to save the driver and Fig. 3.40: Air bags
other occupants.
MAJOR SYSTEMS AND COMPONENTS OF AN AUTOMOBILE AUTOMOTIVE SERVICE TECHNICIAN – CLASS
L IX
95 96
 Practical
Prac
ctiicall EExercises
xerccises
Activity 1
List the different active and passive safety devices.
S.No. List of devices
1.
2.
3.
4.
5.
Che
eck Your Progress
Check
A.. Fill in the blanks
1. Air bags are used for ___________.
2. Seat belt is also known as a __________ belt.
3. Passive safety system helps __________.
4. Active safety system is used for avoiding ________________.
________
_______.
B.. Multiple choice questions
1. Which types of anti-theft devices are ea
available
vailablle iin
n a vehi
vehicle?
icle?
(a) Locking devices
(b) Disabling devices
(c) Alarm systems
(d) All of the above
2. Tempered glass is use ed ffor
used or _____________________.
____________________.
(a) side and rear window
win
ndow g lass
glass
(b) auto window and d oor
door
(c) head light
(d) All of the above
systems
3. Which of these safety syste operated
ems are operated automatically?
system
(a) Passive safety sys stem
(b) Active safety syste em
system
(c) Energy-absorber
Energy-absorrber saf fety
safety
(d) None of the a above
bove
4. Impact senso
sensors
ors aare
re used in ___________________________.
(a) electri
ical s
electrical ystem
system
(b) mechanical
mecha anicall system
(c) auto-mechanical
auto-mec chanical system
(d) None of the above
C. Short answer question
1. Discuss the components of the active and passive
safety system.
MAJOR SYSTEMS AND COMPONENTS OF AN AUTOMOBILE
97