Automotive Book 2

Automotive
Technology
Theory and Workbook
Table of Contents
# Topic Page
1.0 Introduction to Automotive 1
1.1 Different Parts of Automotive 3
1.2 Engine 4
1.3 Four Stroke Engine 5
1.4 Two Stroke Engine 6
1.5 Differences in Two and Four Stroke Engine 8
2.0 Tools and their Identification 11
2.1 Types of Tools 12
Practical Activity 1 22
3.0 Engine Components 25
3.1 Engine Block 26
3.2 Cylinder 26
3.3 Piston 27
3.4 Connecting Rod 27
3.5 Crankshaft 28
3.6 Flywheel 28
3.7 Valves 29
3.8 Timing Gear and Chain 30
3.9 Spark Plug 30
4.0 Car Parts 38
4.1 Power Transmission 39
4.2 Suspension System 40
4.3 Shock Absorber 41
4.4 Steering Systems 42
4.5 Wheels 43
4.6 Braking System 44
Answer Key 47
Automotive Technology Page 1

Foreword
This textbook is a product of the vision of this Institute to become a respected
training and development arm of the Almarai.
A training institute that has created its own textbooks speaks highly of the
level of competence of such an organization. In creating textbook, we have
tapped on the varied expertise, experiences and talents of the institute’s
Trainers and industry expert advisers.
This textbook is tailor-made for the learning capabilities of typical DFP trainees.
It presents topics with a reasonable technical depth and breadth, and it has
written in the most simple and direct language possible. This textbook would
be a valuable introductory material for professional who are new to the field of
electronics.
Some may still find areas for improvement in the first edition of the textbook,
but this is just beginning. It can only get better in the future. We would like to
commend the whole textbook creation for a job well-done! All these have
been made possible by the outstanding leadership of MR department HOD,
Mr. Babur Ali.
The whole DFP management team is very proud of this milestone and fully
endorses the use of this textbook for teaching at Diary & Food Polytechnic.
The DFP management
Mr. Ibrahim Alegaily

Director, DFP
Mr. Mohammed Bham

Designation
Mr. Alexander Imperial

Technical Training Manage
Preface
Automotive Technology covered in the third trimester of an eight trimester

course.
Dairy and Food Polytechnic was created in line with the Saudization efforts of
the Kingdom of Saudi Arabia. It aims to give vocation to Saudi youth and make
them contributing part of the society.
This textbook was written with Saudi trainee in mind. The authors who are also
the Instructors of this course, tried their utmost to present all the principles
and information in the most simple and direct language. Whenever possible,
extensive use of illustrations and pictures were used. The content of the
textbooks exactly reflect the curriculum design of the training.
The Automotive subject prepares the trainee for the transportation

department in Almarai so that they can capably work with all the required
knowledge of both the theory and the practical.
Acknowledgements
Although many of the drawing in this book are based on commercial
components, they are mainly intended to illustrate about Automotive
Technology.
Every effort has been made to trace the copyright holders but if any have been
inadvertently overlooked the publishers will be pleased to make the necessary
arrangements at the first opportunity.
The author and publisher would like to thank the following the use of copyright
material:
Thomas Floyd
FAIRCHILD
Microchip
Fluke Corporation
The publishers are grateful to the following people for their assistance with the
review process.
Abdul Bari
MR - Senior Trainer, Dairy & Food Polytechnic
Babur Ali
MR - HOD, Dairy & Food Polytechnic
HOW TO USE THIS BOOK
Welcome to the Automotive Technology, Theory and Workbook which has
been specially designed to encourage you to work independently and help you
through your course with ease. You can complete the questions, exercises and
activities directly into the workbook and refer back to your answers when it’s
time to revise!
You will find some text within each chapter that discuss the basic principles;
This will help you to recap and ensure that you have a full understanding of
these.
Here are the features you will notice as you work through the book:
E E–These boxes contain a variety of exercises for you to

complete including multiple choice questions, labelling,
sketching and missing words.
Q Q – These boxes contain straight forward questions for you

to answer or to draw block diagram/Circuit Diagram.
Practical Activity
Practical activities – these activities, at the end of chapters,
will help you to put the theory you have learnt to practice.
Answers Key – Answers for multiple choice questions are

Answers Key
provided at end of this book.
Chapter 1
Introduction to Automotive
1.0 Introduction:
Automotive Technology is the practical application of knowledge about
vehicles or machines. Students studying Automotive Technology learn about
engine construction, fuel and ignition systems, power trains, brakes,
transmissions, diagnostic equipment and much more.
Figure 1.1: Automotive Technology
The average car has 30,000 different parts

and all parts have to function properly for a
car to move

Automotive Technology students become skilled in operating a variety of hand
and machine tools and are in charge of repairing and maintaining Automobiles.
People who study Automotive Technology have a strong desire to understand
how things work. The Automotive field requires good problem solvers who are
able to work in a team setting.
Figure 1.2: Students in Workshop

1.1 Different Parts of Automotive
a
b
c d
Figure1.4: Parts of Automotive (a) Engine (b) Power Transmission (c) Shock Absorber (d)
Brake (e) Aerodynamic Body
The Bugatti Veyron takes ten seconds to

stop from its top speed of 253 mph

1.2 Engine
An engine is a machine designed to convert one form of energy into
mechanical energy. Heat engines burn a fuel to create heat which then creates
a force. Mechanically driven engines are usually run by liquid fuels but solid
and gas fuels have also been made available.
There are two types of Engine which we will concentrate our course on:
1-Four Stroke Engine
2-Two Stroke Engine
Stroke
Stroke is defined as the movement the piston carries out from the Top Dead
Centre to the Bottom Dead Centre.
Figure 1.5: Piston Stroke

1.3 Four Stroke Engine
A four stroke Engine is an internal combustion engine in which the piston
completes four separate strokes. The four separate strokes are termed:
1- Intake
2- Compression
3- Ignition
4- Exhaust
Figure 1.6: Engine Four Strokes
The Ford GT is so strong that during the

“Roof Crush” test, it broke the crushing
machine

Basic Parts of Four Stroke Engine:
There are some basic parts of Four Stroke which we find commonly in all four
stroke engines. Some of the basic parts of the engine with their images are
shown below
a b
c d
Figure 1.6: Four Stroke Engine Parts (a) Camshaft (b) Valves (c) Connecting Rod (d)
Connecting Rod (e) Crankshaft

1.4 Two Stroke Engine
A two stroke engine is an internal combustion engine which completes a cycle
with two strokes of the piston during only one crankshaft revolution.
The two separate stokes are termed
1- Intake and Compression

2- Ignition and Exhaust
Figure 1.7: Two Stroke Engine
The Ford GT is so strong that during the

“Roof Crush” test, it broke the crushing
machine

Parts of Two Stroke Engine
a b
c d
Figure 1.8: Two Stroke Engine Parts (a) Reed Valve (b) Exhaust Port (c) Crankcase (d)
Transfer Port
The most powerful engine is also a two

stroke engine

1.5 Differences in Two and Four Stroke Engine
Two Stroke Engine
 In a two stroke engine there is a power stroke in every rotation of the

crankshaft since the thermodynamic cycle is completed in two strokes of
the piston. Lighter flywheel is used in the case of a two stroke engine
 Because of the ability to obtain a power stroke in each rotation of the
crankshaft, the power produced is twice compared to four stroke engine
if the size is same
 There is no valve system provided for two stroke engine which makes
the working and design simpler.
 Due to absence of valve system and light weight, the initial production
cost of two stroke engine is low.
 Thermal efficiency is lower and part load efficiency is poorer.
 There is chance for incomplete burning due to short circuiting and so is a
cause of environmental pollution.
Four Stroke Engine
 In a four stroke engine there is only a power stroke in every two

rotations of the crankshaft since the thermodynamic cycle is completed
in four strokes of the piston. Heavier flywheel is used in the case of a
four stroke engine
 Because of the production of only a power stroke in each two rotations
of the crankshaft, the power produced is half compared to two stroke
engine if the size is same
 There is a valve system provided for four stroke engine. This made the
working and design of this engine complex
 Due to presence of valve system and increased weight, the initial
production cost of four stroke engines is high.
 Thermal efficiency is higher and part load efficiency is better
 There is less chance for incomplete burning and so less chances for
environmental pollution

E
1. _________ is the main stroke in a four stroke engine
a. Intake
b. Compression
c. Ignition
d. Exhaust
E
2. _________ is shown in picture
a. Crankshaft
b. Piston
c. Connecting Rod
d. Camshaft
E
3. Reed Valve is present in _____________
a. Two Stroke Engine
b. Four Stroke Engine
c. All of the above
d. None of the above
E
a. Reed Valve
b. Transfer Port
c. Exhaust Port
d. Crankcase
E
5. _________ is second stroke in a two stroke engine
a. Intake and Compression
b. Intake and Exhaust
c. Ignition and Compression
d. Ignition and Exhaust

E
6. _________ is the number of crank rotation in four stroke engine.
a. 1
b. 2
c. 3
d. 4
E
7. _________ Part of Automotive is shown in picture.
a. Transmission
b. Shock Absorber
c. Disk Brake
d. Engine
E
8. _______ has high Mechanical Efficiency
a. Four Stroke Engine
b. Two Stroke Engine
c. None of the above
d. Both have same
E
9. The picture shows _________
a. Piston
b. Connecting Rod
c. Crankshaft
e. Nucleus
E
10. We have ports in _________
a. Four Stroke Engine
b. Two Stroke Engine
c. Both have ports
Automotive Technology
e. Nucleus Page 11
Chapter 2
Tools and their Identification
Figure 2.1: Tools used in Automotive
Today’s technician must be familiar with a large number of tools. Proper tool
selection and use will improve both the quality and speed of any repair
operation. Many repair jobs are extremely difficult to perform without the
right tools. Good technicians own a wide selection of quality tools.

What to Look for in a Tool
Some people prefer one certain band of tools while others prefer more than
one brand. You will find that technicians agree on several important features
that are found in quality tools.
 Tool Material
 Tool Construction
2.1 Types of Tools
The basic tools common to Automotive Industry and owned by every

technician will be discussed in this chapter.
1-Hammers
Technicians frequently use ball peen, brass tipped and plastic tipped hammers.
The ball peen hammer is used for general striking work and is available in
several different weights. Brass and Plastic tipped hammers are used when
there is danger of steel ball peen marring the work surface. Some plastic
tipped hammers have their heads filled with lead shot. This prevents hammer
from rebounding when striking a hard object.
Figure 2.2: Types of Hammers (a) Ball Peen (b) Sledge Hammer (c) Brass
Hammer (d) Plastic Hammer
2-Chisels
Several types and sizes of chisels are important for cutting bolts or rivets. The
flat cold chisel is used for general cutting. Special chisels such as cape and half
round chisels are used when their shapes fit a definite need.
Figure 2.3: Chisel
3-Impact Wrench
A power impact wrench is a must for fast work. Most impact wrenches are air
operated, though electric impart tools are available. Parts can be replaced and
removed in a fraction of the times required with hand wrenches.
Figure 2.4: Impact Wrench

4-Screw Drivers
Screw Drivers of various lengths and types are required. Screw Drivers cover
the various types of jobs ordinarily encountered by the Automotive Technician.
The various types of screw head shapes used in most vehicles are shown in
Figure 2.5
Figure 2.5: Screw Drivers
5-Wrenches
All automotive technicians must have a wide variety of both standard and
metric wrenches at their disposal. A few of the wide variety of wrenches
will be discussed here.
5.1- Box-End Wrenches
The box-end wrench is an excellent tool since it grips the nut or bolt head on
all sides. This reduces the chance of slippage which would reduce the resultant
damage to the fastener and possibly the hand.
Figure 2.6: Box End Wrench

5.2- Open-End Wrenches
Open End Wrenches are handy, but they are not as dependable as box-end
wrenches. They grasp the nut or bolt head on only two of its flats and are
subject to slipping under a heavy pull. There are tight places, however, where
they must be used.
Figure 2.7: Open End Wrench
5.3- Combination Wrench
The combination wrench has a box-end head on one end and an open end on
the other. Both ends are both the same size. The combination wrench is a very
convenient tool since the box end can be used for both breaking loose and
final tightening. The open end is for faster removal or installation.
Figure 2.8: Combination Wrench

5.4- Adjustable Wrenches
The adjustable wrench is handy in that it can be adjusted for size. However it
tends to slip, so it is a poor wrench to use when other tools are available for a
given job. When an adjustable wrench is used, adjust the laws firmly. Also,
make certain the wrench is placed so the pull on the handle is towards the
bottom side.
Figure 2.9 Adjustable Wrenches
5.5- Torque Wrenches
The torque wrenches allow technicians to tighten fasteners to exact torque

(tightness) specifications supplied by the manufacturer. It is of utmost
importance that bolts be tightened to specifications. Torque wrenches are
available in special shapes and sizes.
Figure 2.10 Torque Wrenches

6-Sockets and Ratchets
Sockets and Ratchets are very convenient and in instances faster than normal
wrenches. Both sockets are ratchets are available in a variety of sizes and
types.
6.1 Sockets
Most sockets are available with 6-point, 12-point and a variety of other
openings and driver shapes. The driver size refers to the size of the square hole
into which the socket handle fits. The larger the drive, the heavier and bulkier
the socket.
Figure 2.11 Sockets
6.2 Socket Handles and Ratchets
Various handles are available for sockets. The speed handle is used for fast
operation because it can be turned quickly. Extension bars of different lengths
allow the technician to lengthen the socket setup to reach difficult areas. The
sliding T-handle varies the handle length.

The ratchet is versatile. It allows the user to either tighten or remove a nut or
bolt without removing the socket from the fastener. On the backstroke the
handle ratchets.
Figure 2.12 Ratchets

E
1. _________ hammer is shown in the figure
a. Ball Peen
b. Sledge
c. Brass
d. Plastic
E
2. _________ hammer is shown in the figure
a. Ball Peen
b. Sledge
c. Brass
d. Plastic
E
3. _________ hammers are filled with lead shot
a. Ball Peen
b. Sledge
c. Brass
d. Plastic
E
4. _________ is used for cutting bolts or rivets
 a. Hammer
 The b.fundamental
Chisel property of a diode is its tendency to conduct
electric current in only one direction
c. Ratchet
 Mostd.diodes are made
Adjustable with semiconductor materials such as silicon,
Wrenches
germanium, or selenium
E
5. _________ is used to reduce slippage
a. Box End Wrench
Figure 2.3:
b. Combination Diode and Diode Circuit Symbol
Wrench
c. Adjustable Wrench
d. Open End Wrench

E
6. _________ wrench is used for fast opening and closing
a. Box End Wrench
b. Combination Wrench
d. Open End Wrench
E
7. _________ is available with 6 point and 12 point driver shapes
a. Ratchet
b. Socket
c. Torque Wrench
E
8. _________ is shown in the picture
a. Ratchet
b. Socket
c. Torque Wrench
E
9. _________ is more versatile in use
a. Ratchet
b. Socket
d. Torque Wrench
E
10. _________ is shown in the figure
a. Ratchet
b. Socket
d. Torque Wrench

Q
Name the tools shown in the picture
A D
B
E
C
F
A____________ D____________
B____________ E_____________
C____________ F_____________

Practical Activity 1
Disassemble and Re assemble Rocker Arm in a Four Cylinder Engine
Tools and Equipment Required:

1. Philips and Flat Screw Driver
2. Socket Handle
3. Combination Wrench
4. Torque Wrench
5. Ratchet
6. Allen Key Set
Figure 3.1 Rocker Arm used for practical
Procedure:
1. Remove the tappet cover from the cylinder head by using Socket Handle
2. Loose the bolts in the Rocker Arm by first using Socket Handle and then Ratchet
3. Remove from number one cylinder to the last cylinder in the correct sequence
4. For reassembling put the Rocker Arm in the same sequence as used for removing
5. Rest the bolt in a cross manner
6. Tighten the bolt with Torque Wrench

Observation and Discussion:
Disassemble and Re assemble Camshaft in a Four Cylinder Engine

2. Socket Handle
3. Box-End Wrench
4. Torque Wrench
5. Ratchet
6. Allen Key Set
Figure 3.2 Engine used for practical

Procedure:
1. Turn the engine clockwise and align the mark on the timing gear from camshaft
towards crankshaft
2. Remove the Rocker Arm assembly as done in the previous practical
3. The cylinder number one piston be positioned at the Top Dead Centre (TDC) after
compression stroke and can be checked manually by checking the position of the
valves.
4. After alignment loose the tension belt between the camshaft and crankshaft so that
the timing belt can be moved.
5. Remove timing belt form the camshaft timing gear.
6. Remove camshaft by first using Socket Handle and then Ratchet
7. Place camshaft and fix the timing gear
8. Align mark from camshaft to crankshaft
9. Fix timing belt
10. Tight tension belt as required for timing belt
11. Fix Rocker Arm Assembly
12. Tight the bolts in the correct sequence

Chapter 3
Engine Components
Engine has many important components and all of these components have
their own design, construction and application. The list of all the important
engine components to be covered in this chapter are as follows
1- Engine Block
2- Cylinder
3- Piston
4- Connecting Rod
5- Crankshaft
6- Camshaft
7- Spark Plug
8- Rocker Arm
9- Valves
10- Timing Gear
11- Chain
12- Flywheel
13- Cylinder Head
14- Gas Kits
15- Piston Ring
16- Sleeves
Figure 3.1 Engine Picture with some labelled parts

3.1 Engine Block:
The Engine block serves as a rigid metal foundation for all parts of an engine. It
contains the cylinders and supports the camshaft and crankshaft. Blocks are
made of either cast iron or aluminium. The lighter the block providing it has
sufficient strength the better.
Figure 3.2 Engine Block
3.2 Cylinder:
Cylinder is the central working part of an engine and is the space in which
piston travels. Cylinder maybe sleeved or be sleeveless. Multiple cylinders are
commonly arranged side by side in a bank. Cylinders are bores in which fuel is
burn and a lot of heat energy converted to mechanical energy.
Figure 3.3 Four-Cylinder Engines

3.3 Piston:
Piston is one of the most parts in an engine which helps converting the
chemical energy of air and petrol into useful mechanical power. Piston is a
cylindrical plug that moves up and down inside the cylinder. Piston is made
gas-tight by piston rings.
Piston Rings are used to provide a good seal between the cylinder wall and
piston. The efficiency and economy of the engine primarily depends on the
working of piston. It must operate in the cylinder with minimum friction and
should be able to withstand a high explosive force in the cylinder and also the
very high temperature ranging from 2000°C to 2800°C during operation
Figure 3.4 Piston and Piston Rings
3.4 Connecting Rod:
Connecting Rod is a rod which

connects the piston to the
crankshaft. Together with crank they
convert reciprocating motion to
rotating motion.
Figure 3.5 Connecting Rod

3.5 Crankshaft:
The engine crankshaft provides a constant turning force to the wheels. It has
throws to which connecting rods are attached and its function to change the
reciprocating motion of the piston to a rotary motion to drive the wheels.
Crankshafts are made up of cast iron or alloy steel.
Figure 3.6 Crank Shaft
3.6 Flywheel:
A flywheel is a rotating mechanical device that is used to store rotational
energy. Flywheel delivers energy at rates beyond the ability of a continuous
energy source. This is achieved by collecting energy in the flywheel over time
and then releasing the energy quickly
at rates that exceed the abilities of the
energy source.
Flywheels are also used for controlling

the orientation of a mechanical
system.
Flywheel are typically made of steel Figure 3.7 Flywheel
and rotate on conventional bearings;
these are generally limited to a few thousand RPM.
3.7 Valves:
Each cylinder engine ordinarily has two valves. However, modern engines
often use four valves per cylinder (two intake and two exhaust). Valves
function is to allow at exactly the right time intake and exhaust of air and fuel
from the cylinder. Hence the timing of opening and closing of valves is an
essential part of the working of an engine.
The valve is usually a flat disk of metal with a long rod known as the valve stem
attached to one side. The stem is used to push down on the valve and open it,
with a spring generally used it to return it to the closed position.
Figure 3.8 Valves

3.8 Timing Gear and Chain:
Timing Gear and Chain are used to rotate
camshaft to open valves as per proper timing to
make ignition and exhaust strokes. In some
engine we use timing belt on timing gears
instead of chains.
Figure 3.8 Timing Gear and Chain
3.9 Spark Plug:

A spark plug is a device for delivering electric current from an ignition system
to the combustion chamber of a spark ignition engine to ignite the compressed
air/fuel mixture by an electric spark while containing combustion pressure
within the engine. The plug is connected to the high voltage generated by an
ignition coil or magneto. As current flows from the coil a voltage develops
between the central and side electrodes.
Figure 3.9 Spark Plug

Summary:
All parts studied above in the engine are shown in the following image in a one
page view to understand the position of these parts with respect to its
function.
Figure 3.10 Engine with all parts labelled

E
1. _________ is used for opening and closing of valves
a. Crankshaft
b. Camshaft
c. Spark Plug
d. Connecting Rod
E
2. _________ connects piston with crankshaft
a. Valves
b. Timing Gear and Chain
c. Connecting Rod
d. Camshaft
E
3. _________ is the name of the third piston ring
a. Compression Ring
b. Top Ring
c. Second Ring
d. Oil Ring
E
4. _________ is controlled by rocker arm
a. Connecting Rod
b. Crankshaft
c. Piston
d. Camshaft
E
5. Picture shows ___________
a. Rocker Arm
b. Piston
c. Connecting Rod
d. Spark Plug

E
6. Flywheel is used to _______________
a. Make Power
b. Move Power
c. Store Energy
d. None of the Above
E
7. Picture shows ___________
a. Crankshaft
b. Camshaft
c. Spark Plug
d. Valves
E
8. Four Cylinder Engine has _______ spark plugs
a. One
b. Two
c. Three
d. Four
E
9. Valve movement is controlled by __________
a. Rocker Arm
b. Springs
c. Camshaft
E
a. Crankshaft
b. Camshaft
c. Spark Plug
d. Engine Block

Disassemble and Re-assemble Cylinder Head in a Four Cylinder Engine

2. Socket Handle
4. Torque Wrench
5. Ratchet
6. Allen Key Set
Figure 3.1 Engine of which Cylinder Head is disassembled

Procedure:

Disassemble and Re-assemble Two Pistons in a Four Cylinder

Engine

2. Socket Handle
4. Torque Wrench
5. Ratchet
6. Allen Key Set
Figure 3.2 Cylinder of which piston to be removed

Procedure:

Chapter 4
Car Parts
Car Parts
There are many basic car parts which you must have a basic understanding of
both in terms of its types and applications. To cover all the car parts involved is
very difficult and cumbersome so we will limit ourselves to the basic parts of
which understanding is an absolute must.
The basic car parts are:
1- Power Transmission
2- Suspension System
3- Steering Systems
4- Wheels and Tires
5- Braking Systems
Figure 4.1 Basic Car Parts

4.1 Power Transmission:
Power Transmission is the transmission of power from engine to the tire. This
transmission process has several parts in between in order to control the
transmission. This power transmission is an integral part of the automobile and
the performance of an automobile depends largely on the effectiveness of the
transmission system.
Figure 4.2 Main Parts in Power Transmission
The main parts involved in power transmission are:
1- Clutch
2- Gear
3- Drive Shaft
4- Differential
5- Axles
The types and importance of these parts involved will be explained in detail in
the upcoming course in next trimester termed as “Mechanical Power
Transmission”.

4.2 Suspension System
If the vehicle’s axles were bolted directly to its frame or body every rough spot
in the road would transmit a force throughout the vehicle. Riding would be
uncomfortable and handling at freeway would be impossible. The fact that
modern vehicles ride and handles well is a direct result of a suspension system.
The purpose of any suspension system is to allow the body of vehicle to travel
forward with the minimum amount of up and down movement. The
suspension should also allow the vehicle to turn without excessive body roll or
tire skidding.
Figure 4.3 Suspension

4.3 Shock Absorber
When the vehicle is travelling forward on a level

surface and wheel strikes a bump, the spring is
rapidly compressed or twisted. The spring will return
to its normal loaded length. In doing so, it will
rebound causing the body of the vehicle to be lifted.
Figure 4.4 Shock Absorber
The weight of the vehicle then pushes the spring
down after the spring rebounds. Shock Absorber is constructed by having an
inner cylinder, an outer cylinder, a piston and a piston rod and in some cases
an outer dusk and rock shield. A series of valves in the piston and at the
bottom of the inner cylinder control the movement of the hydraulic fluid
within the shock.
Figure 4.5 Types of Shock Absorber

4.4 Steering Systems
The steering system is designed to allow the driver to move the front wheels to
the right or left with a minimum of effort and without excessive movement of
the steering wheel. Although the driver can move the wheels easily, road
shocks are not transmitted to the driver. This absence of road shock transfer is
referred to as the non-reversible feature of steering systems.
Many types of steering systems have been used:
 Spindle and Steering Arm Assembly

 Parallelogram Linkage
 Rack and Pinion Linkage
Figure 4.6 Rack and Pinion Power Steering

4.5 Wheels
Wheel consists of two parts:
1- Rubber Tire
2- Rim
Rim is the outer edge of a wheel holding the tire. In past

almost all factories supplied rims were made up of
stamped steel. Today custom wheels are made up of
Aluminium, Magnesium and Graphite.
Wheel Rim Size is determined by three measurements:

 Rim Width Figure 4.7 Rim
 Rim Diameter
 Flange Height
Tires serve two main functions:

 Provide a cushioning action
 Provide traction
Figure 4.8 Tire
Figure 4.9 Tire Information

4.6 Braking Systems
Braking Systems can be divided into two main categories:
1- Disk Brake Systems

2- Drum Brake Systems
Disk Brake System
A disk brake is a type of brake that uses

callipers to squeeze pair of pads against
a disk in order to create friction that
retards the rotation of shaft. Hydraulic
Disk Brakes are the most commonly
used form of brake for motor vehicles.
Figure 4.10 Disk Brake
Drum Brake Systems
A drum brake is a brake that uses friction caused by a set of shoes or pads that
press outward against a rotating cylinder shaped part called a drum brake. The
term brake usually means a brake in which shoes press on the internal surface
of the drum.
Figure 4.11 Drum Brake

E
1. _________ is shown in figure
a. Disk Brake
b. Drum Brake
c. Tire
d. Rim
E
2. The P in tire shows _________
a. Tire Type
b. Tire Width
c. Aspect Ratio
d. Diameter
E
3. _________ is purpose of clutch
a. Make Power
b. Move Power
c. Control Power
E
4. Wheel rim size is determined by ________
a. Rim Width
b. Rim Diameter
c. Flange Height
d. All of the above
E
a. Suspension System
b. Shock Absorber
c. Braking System

Mark the following parts in the workshop with a trainer for evaluation

Answer Key
Chapter 1: Chapter 4:
1. c 1. d
2. d 2. a
3. b 3. c
4. d 4. d
5. d 5. a
6. b
7. c
8. b Questions:
9. a A- Ball Peen Hammer
10. b B- Socket Wrench
C- Ratchet
D- Open End Wrench
Chapter 2: E- Impact Wrench
F- Plastic Hammer
1. a
2. d
3. d
4. b
5. a
6. b
7. b
8. b
9. a
10. d
Chapter 3:
1. b
2. c
3. d
4. d
5. d
6. c
7. d
8. d
9. c
10. d

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Automotive

Automotive Technology Page 1

The DFP management

Mr. Ibrahim Alegaily

Mr. Mohammed Bham

Mr. Alexander Imperial

Automotive Technology covered in the third trimester of an eight trimester

The Automotive subject prepares the trainee for the transportation

E E–These boxes contain a variety of exercises for you to

Q Q – These boxes contain straight forward questions for you

Answers Key – Answers for multiple choice questions are

Figure 1.1: Automotive Technology

The average car has 30,000 different parts

Automotive Technology Page 1

Figure 1.2: Students in Workshop

Automotive Technology Page 2

The Bugatti Veyron takes ten seconds to

Automotive Technology Page 3

Figure 1.5: Piston Stroke

Automotive Technology Page 4

Figure 1.6: Engine Four Strokes

The Ford GT is so strong that during the

Automotive Technology Page 5

Automotive Technology Page 6

The two separate stokes are termed

1- Intake and Compression

Figure 1.7: Two Stroke Engine

The Ford GT is so strong that during the

Automotive Technology Page 7

The most powerful engine is also a two

Automotive Technology Page 8

Two Stroke Engine

 In a two stroke engine there is a power stroke in every rotation of the

Four Stroke Engine

 In a four stroke engine there is only a power stroke in every two

Automotive Technology Page 9

Automotive Technology Page 10

Figure 2.1: Tools used in Automotive

Automotive Technology Page 12

2.1 Types of Tools

The basic tools common to Automotive Industry and owned by every

Figure 2.3: Chisel

Figure 2.4: Impact Wrench

Automotive Technology Page 14

Figure 2.5: Screw Drivers

5.1- Box-End Wrenches

Figure 2.6: Box End Wrench

Automotive Technology Page 15

Figure 2.7: Open End Wrench

5.3- Combination Wrench

Figure 2.8: Combination Wrench

Automotive Technology Page 16

Figure 2.9 Adjustable Wrenches

5.5- Torque Wrenches

The torque wrenches allow technicians to tighten fasteners to exact torque

Figure 2.10 Torque Wrenches

Automotive Technology Page 17

Figure 2.11 Sockets

6.2 Socket Handles and Ratchets

Automotive Technology Page 18

Figure 2.12 Ratchets

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