Summer Training Course

Mechanical Basic
FTR131
Ghabbour Academy
Submitted by: Ali Esam Ali Mohamed
ID No: 20200190
Mechatronics Eng. Dept.
Higher technological institute
Submitted to:
DR. Hany A Mohamed
Dr. Said Zoalfakar
ENG. Mostafa Abdel Jalil
 Abstract
This report consists of five chapters with the aim of
identifying the components of the car, the components
of the engine, and the tools used in the maintenance of
the car, The transmission system, the knowledge of the
brake cycle, as well as the explanation of the tires.

In the first chapter there is a definition of all the

tools and tools used in diagnosing faults and repairing
the car. In the second chapter, there is a definition of the
car engine and all its parts and knowledge of the cooling
cycle and the lubrication cycle.

In the third chapter, the definition of the manual

transmission system and its parts .In the fourth chapter,
the definition of the hydraulic brake system and the
components of the brake circuit and how each part
works. In the last chapter, there is an explanation of car
tires.

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 Acknowledgment
At first, Thanks to ALLAH the most merciful the most
gracious, for this moment has come and this work has
been accomplished. Thanks to the Higher Technological
Institute of 10th Ramadan for preparing me to be a
successful Engineer and lifting me up to achieve this
training in an environment that’s full of encouragement
and motivation.
Deepest gratitude is to be delivered to Dr. Said
Zoalfakar, DR. Hany A Mohamed role model in
engineering. He understood the nature of my thoughts
and guided me step by step till this work brought to light.
Endless trust in my potentials guided me till the end.
Thank you.
Special thanks to [instructor] for his help and
knowledge in the field of training. There
professional touches are sensed within every phase of
this summer training.
I’d like to thank my father, who is my motivators,
visionaries, and great supporter ever since my
graduation. He always pushes me up and drives me to
the success.
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 List of Contents

Chapter (1): Tools and Equipment Pages

1.1 Vernier caliper…………………………………………………………………………………. 9

1.2 Micrometer ……………………………………………………………………………………. 10

1.3 Feeler Gauge …………………………………………………………………………………… 11

1.4 Compression Gauge ………………………………………………………………………… 12

1.5 Dial Gauge ………………………………………………………………………………………. 13

1.6 Torque Wrench ………………………………………………………………………………. 14

1.7 Angle Gauge …………………………………………………………………………………. 15

1.8 Refractometer …………………………………………………………………………………. 15

1.9 Bore Gauge ……………………………………………………………………………………. 16

Chapter (2): Car Engine Parts and Functions

2.1 The Main Car Engine Parts................................................................................................ 20
2.1.1 Cylinder Block .................................................................................................... 21
2.1.2 Cylinder Head ..................................................................................................... 22
2.1.3 Crankshafts ........................................................................................................... 25
2.2 Cooling System ................................................................................................................ 27
2.2.1 Radiator ...................................................................................................................... 29
2.2.2 Thermostat ................................................................................................................ 30
2.2.3 Coolant pump............................................................................... 31

2.2.4 Expansion tank.......................................................................... …… 32

2.2.5 Engine fan............................................................................... …… 33

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 2.3 lubrication system....................................................................................... 34
2.3.1 Engine oil viscosity........................................................................... …. 36
2.3.2 The American Petroleum Institute (API).......................................... …. 37
2.3.3 Oil filter........................................................................................... …. 38
2.3.4 Oil pan............................................................................................ …. 38

2.4 fuel system................................................................................................. 39

2.4.1 Air filters............................................................................................... 41
2.4.2 Intake manifold................................................................................ …. 42
2.4.3 Throttle body...................................................................................... 43
2.4.4 Exhaust manifold................................................................................. 44
2.4.4 Catalytic converter............................................................................. 45

Chapter (3): Transmission system

3.1 Transmission system ………………………………………………………………………………….46 7
3.2 Types of Transmission …………………………………………………………………………………. 47
3.3 Manual Transmission ………………………………………………………………………………. 48

3.3.1 clutch …………………………………………………………………………………………………. 48

3.3.2 Synchronizer gearbox: …………………………………………………………………… 49

3.4 Drivetrain layout ………………………………………………………………………………………. 50

3.4.1 front mounted rear wheel drive ………………………………………………. 51

3.4.2 front mounted front wheel drive… ………………………………………. 51

3.4.3 Rear mounted rear wheel drive………………………………………………………. 52
3.5 propeller shaft ……………………………………………………………………………………. 53

3.6 Differential ……………………………………………………………………………………. 54

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 Chapter (4): Brake system

4.1 Functions of the Brakes ..................................................................................................... 55

4.2 Operating principle ............................................................................................................. 55
4.3 layout of hydraulic brakes………………………………………………………………...………. 56
4.4 brake pedal ……………………………………………………………………………………………... 56
4.5 brake booster……………………………………………………………………………………………. 57
4.6 Master cylinder ................................................................................................................... 58

4.7 Anti-lock braking system (APS): ...................................................................................... 59

4.8 Brake Pressure Proportioner Valve......................................................... 60
4.9 Brake Calipers..........................................................................………………… 60
4.10 Disc and Drum Brake Mechanism............................................................ 61
4.11 Brake fluid properties...........................................................................………….62
4.12 Braking circuit layout (Hydraulic split) ................................................... 63

Chapter (5): Tire service

5.1 Tire size …………………………………………………………………………………. 65

5.2 Tire speed rating ………………………………………………………………………………. 66

5.3 Tire weight index chart ……………………………………………………………………. 67

5.4 tire pressure plat: …………………………………………………………………… 68

5.5 wheel torquing ………………………………………………………………………………………. 69

Conclusion…………………………………………………………………………………………… 70

Reference………………………………………………. ……………………………………………. 71

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 LIST OF Figures

pages

Chapter (1): Tools and Equipment

Figure (1.1): Vernier caliper 9
Figure (1.2): Micrometer 10
Figure (1.3): Feeler Gauge 11
Figure (1.4): Compression Gauge 12
Figure (1.5): Dial Gauge. 13
Figure (1.6): Torque Wrench 14
Figure (1.7): Angle Gauge 15
Figure (1.8): Refractometer 16

Figure (1.9): Bore Gauge 17

Chapter (2): Car Engine Parts and Functions

Figure (2.1): Cylinder Block 21

Figure (2.2): Cylinder Head 23
Figure (2.3): Crankshafts 25
Figure (2.4): Cooling System 27
Figure (2.5): Radiator 29

Figure (2.6): Thermostat 30

Figure (2.7): Coolant pump. 31

Figure (2.8): Expansion tank 32

Figure (2.9): Engine fan 33

Figure (2.10): Engine Oil Functions 35

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 Figure (2.11): Engine oil viscosity 36

Figure (2.12): The American Petroleum Institute (API) 37

Figure (2.13): Oil pan 38

Figure (2.14): Full system 39

Figure (2.15): Air filters 41

Figure (2.16): Intake manifold 42

Figure (2.17): Throttle body 43
Figure (2.18): Exhaust manifold. 44

Figure (2.19): Catalytic converter 45

Chapter (3): Transmission system

Figure (3.1): Types of Transmission 47

Figure (3.2): Manual Transmission 48
Figure (3.3): clutch 49
Figure (3.4): Synchronizer gearbox 50
Figure (3.5): front mounted rear wheel drive 51
Figure (3.6): front mounted front wheel drive 51

Figure (3.7): Rear mounted rear wheel drive 52

Figure (3.8): propeller shaft 53
Figure (3.9): Differential 54

Chapter (4): Brake system

Figure (4.1): layout of hydraulic brakes 56

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 Figure (4.2): brake booster 57
Figure (4.3): Master cylinder 58

Figure (4.4): Anti-lock braking system (APS) 59

Figure (4.5): Brake Calipers 61

Figure (4.6): Disc and Drum Brake Mechanism 62

Figure (4.7): Braking circuit layout (Hydraulic split) 63

Chapter (5): Tire service

Figure (5.1): tire information 64

Figure (5.2): Tire size 65
Figure (5.3): Tire speed rating 66
Figure (5.4): Tire weight index chart 67
Figure (5.5): tire pressure plat 68
Figure (5.6): wheel torquing 69

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 Chapter (1)
Tools and Equipment
1.1 Vernier caliper:

A measuring device that is used for the measurement of

linear dimensions. It is also used for the measurement of
diameters of round objects with the help of the
measuring jaws.

Figure (1.1)

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1.2 Micrometer:

A micrometer, sometimes known as a micrometer screw

gauge, is a device incorporating a calibrated screw widely
used for accurate measurement of components in
mechanical engineering and machining as well as most
mechanical trades

Figure (1.2)

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1.3 Feeler Gauge:

a gauge consisting of several thin blades for measuring

narrow gaps or clearances

Figure (1.3)

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1.4 Compression Gauge:

A compression gauge or compression tester is a tool

inserted into the spark plug hole on an engine while the
flywheel is rotated. This will result in a pressure reading
that can be used to judge the condition of a cylinder,
piston, and rings

Figure (1.4)

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1.5 Dial Gauge:

a gauge consisting of a circular graduated dial and a

pointer actuated by a member that contacts with the
part being calibrated

Figure (1.5)

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1.6 Torque Wrench:

a wrench that measures and indicates the amount of

turning and twisting force applied in tightening a nut or
bolt.

Figure (1.6)

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1.7 Angle Gauge:

An angle gauge is a tool used by foresters to determine

which trees to measure when using a variable radius plot
design in forest inventory

Figure (1.7)

1.8 Refractometer:

A refractometer is an optical device used for measuring

the extent to which light is bent or refracted when it

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moves through a substance. It works because light travels
at different velocities in different mediums.

Figure (1.8)

1.9 Bore Gauge:

A bore gauge is a tool used to measure the inside of a
bore, or hole. Once a bore gauge is inserted into the hole
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that needs measuring, small parts called anvils expand
outward to determine the diameter. Bore gauges are also
known as cylinder tests, hole tests, bore mics, internal
micrometers, hold bore gauges, or telescoping gauges.

Figure (1.9)

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 Chapter (2)

Car Engine Parts and Functions

Engine Functions:

The engine is the vehicle’s main source of power. The

engine uses fuel and burns it to produce mechanical
power Chemical Energy converted into Mechanical
Energy.

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2.1 The Main Car Engine Parts Are as Follows:

1. Cylinder Block.
2. Cylinder Head.

3. Crank Shaft.

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 2.1.1 Cylinder Block:

Figure (2.1)

• The cylinder block is usually made of grey cast iron or

aluminum and its alloys.
• While the crankcase is fixed to its bottom. Apart from
these other parts like timing gear
water pump, ignition distributor, flywheel, fuel pump etc.,

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are also attached to it.
• Passages are provided in the cylinder walls for the
circulation of cooling water.
• Mating surfaces of the block are carefully machined to
provide a perfect sealing surface.
• Cylinder block also carries lubrication oil to various
components through drilled passages
called oil galleries.

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 2.1.2 Cylinder Head:

Figure (2.2)

• It is usually made up of cast iron and aluminum

alloy.
• The top of the cylinder is covered by a separate
cast piece known as the cylinder head.
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 • The cylinder head is attached to the cylinder block
by means of studs fixed to the block gaskets are used
to provide a tight, leak-proof joint between the head
and block.
• Cylinder head contains a combustion chamber
above each cylinder.
• It also contains valve guides, valve seats, ports,
coolant jackets and threaded holes for spark
plugs. It incorporates passages for the flow of
cooling water

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 2.1.3 Crankshafts:

Figure (2.3)

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 The crankshaft is the engine component from which
the power is taken. It is one of the main powers
transmission sources in all engine parts The
Crankshaft is the first part of the power transmission
system in which the reciprocating motion of the
piston is converted into the rotating motion with the
help of connecting rod.

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 2.2 Cooling System:

Figure (2.4)

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 All engine cooling systems are based on
the following components:
• radiator.
• Thermostat.
• Coolant pump
• Expansion tank.
• tubes.
• Engine fan

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 2.2.1 Radiator:

Figure (2.5)

A radiator helps to remove excess heat from the

engine. It is part of the engine ‘s cooling system,
which also includes a liquid coolant, hoses to
circulate the coolant, a fan, and a thermostat that
monitors the coolant temperature. The coolant flows
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 through the hoses from the radiator, through the
engine to absorb excess engine heat, and back to the
radiator

2.2.2 Thermostat:

Figure (2.6)

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 The thermostat is one of the important components
in the car cooling system, its main function is to
regulate the circulation of engine cooling from the
radiator to prevent overheating of the engine. While
the engine cooling system functions so that the
temperature inside the engine remains at an ideal
condition

2.2.3 Coolant pump:

Figure (2.7)

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 Car water pump is an assembly allowing the flow of
coolant across it to keep the engine cool

2.2.4 Expansion tank:

Figure (2.8)

The expansion tank absorbs excess coolant and

minimizes excess pressure in the engine cooling system.
An expansion tank helps maintain a minimal pressure
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 increase during heated water expansion, helps reduce
coolant hammer, and helps protect the engine cooling
system from stress.

2.2.5 Engine fan:

Figure (2.9)

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 The fan system works by forcing air flow through the
radiator. Its function is to facilitate and support the
engine's temperature management

Engine complement system:

2.3 lubrication system:

Lubrication is the action of applying a substance such as

oil or grease to an engine or component to minimize
friction and allow smooth movement. Lubricating
system is a mechanical system of lubricating internal
combustion engines in which a pump forces oil into the
engine bearings.

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 Engine Oil Functions:

Figure (2.10)

1-Lubrication of moving parts.

2- Engine cooling.

3- Prevent rust and sediment.

4- Helps tighten the piston pins.

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 2.3.1 Engine oil viscosity:

Figure (2.11)

Engine oil viscosity refers to how easily oil pours at a

specified temperature. Thin oils have lower viscosity
and pour more easily at low temperatures than thicker
oils that have a higher viscosity. Thin oils reduce friction
in engines and help engines start quickly during cold
weather

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 2.3.2 The American Petroleum Institute (API( :

Figure (2.12)

The service rating of passenger car and commercial

automotive motor oil is classified.
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2.3.3 Oil filter:
The oil filter helps remove contaminants from
your car engine's oil that can accumulate over time as the
oil keeps your engine clean.

2.3.4 Oil pan:

Figure (2.13)

The oil pan is attached to the bottom of the engine with

bolts and is the reservoir for oil that gets pumped

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throughout the engine to lubricate, clean and cool
moving parts. A pump forces the oil from the pan through
a filter to remove dirt and other debris before it circulates
through the engine.

2.4 fuel system:

Figure (2.14)

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The fuel system is made up of the fuel tank, pump, filter
and injectors or carburetor, and is responsible for
delivering fuel to the engine as needed. Each component
must perform flawlessly to achieve expected vehicle
performance and reliability.

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 2.4.1 Air filters:

Figure (2.15)

Air filters help the system by filtering dirt and other

particles from the air. In doing so, the filters prevent

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contaminants from clogging up the air intake system and
potentially damaging your car's engine.

2.4.2 Intake manifold:

Figure (2.16)

Most cars operate with a multi-point injection

(MPI)system so that the sprinklers are placed on the
intake manifold close to the valves.
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 2.4.3 Throttle body:

Figure (2.17)

A throttle body is a tube-shaped housing that contains a

flat valve (butterfly) that rotates to vary
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the amount of air entering an engine.

2.4.4 Exhaust manifold:

Figure (2.18)

Bolted directly to the engine block, the exhaust manifold

is the first section of a vehicle's exhaust system. It
funnels exhaust gases from all the cylinders and routes
them to the car's catalytic converter.

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 2.4.4 Catalytic converter

Figure (2.19)

A catalytic converter turns harmful emissions from the

car's exhaust into less harmful gases before they are
pumped out into the atmosphere.

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 Chapter (3)
Transmission system

3.1 Transmission system:

The transmission system is one of the most basic and
important parts of a vehicle. You can define it like this, it
transfers power from the engine to the wheels.
Transmission simply refers to the gearbox, which uses
gears and gear trains to provide speed and torque.

It is one of the most complex components of your vehicle

consisting of a series of gears (gearbox). It is primarily
responsible for making sure the wheels get the right
amount of power so that they can operate at a certain
speed.

There are many types of car transmissions. The most

common are automatic, while manual transmissions in
stick-shift cars require the driver to complete additional
steps to effectively operate the vehicle.

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3.2 Types of Transmission:

Figure (3.1)

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3.3 Manual Transmission:

Figure (3.2)

3.3.1clutch:
In a motor vehicle, the clutch acts as a mechanical
linkage between the engine and transmission, and briefly
disconnects, or separates the engine from the
transmission system. This disconnects the drive wheels
whenever the clutch pedal is depressed, allowing the
driver to smoothly change gears.

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 Figure (3.3)

3.3.2 Synchronizer gearbox:

Featured snippet from the web
Synchronizers are conical mechanical clutches used to
synchronize the speed of the rotating parts.
Synchronizers are used in manual transmission,
automated manual transmission, and dual clutch

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transmissions for passenger and commercial vehicles.
The most used material for synchronizer is brass.

Figure (3.4)

3.4 Drivetrain layout:

The final touch of how a vehicle puts the power on the
ground includes various layouts. The car may accelerate
using only the front tires, only the rear tires, both
simultaneously, and both under various conditions

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3.4.1 front mounted rear wheel drive:

Figure (3.5)

3.4.2 front mounted front wheel drive:

Figure (3.6)

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3.4.3 Rear mounted rear wheel drive:

Figure (3.7)

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3.5 propeller shaft:
The propeller shaft is a component used for transmitting
mechanical power, torque, and rotation. These shafts as
also known as driveshaft, driving shaft, tail shaft, or
Cardan shaft.

The driveshaft is used to transfer torque between

components that cannot be connected directly because
of distance or the need to allow relative motion between
them.

Figure (3.8)

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3.6 Differential:
The differential is a system of gears that allows different
drive wheels (the wheels to which power is delivered
from the engine) on the same axle to rotate at different
speeds, such as when the car is turning.

Figure (3.9)

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 Chapter (4)
Brake system

4.1 Functions of the Brakes:

1. Stopping a moving vehicle.
2. Slowing vehicle on downhill roads.

4.2 Operating principle:

Hydraulic brakes work on the principle of Pascal’s law.
According to this law whenever pressure is applied on
fluid it travels uniformly in all the directions. Therefore,
when we apply force on a small piston, the pressure gets
created which is transmitted through the fluid to a larger
piston.

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4.3 layout of hydraulic brakes:

Figure (4.1)

4.4 Brake pedal:

The brake pedal acts as the input of the master cylinder,
or we can say that the entire assembly will start working
when the brake pedal is pressed. It is manually pressed
when we must stop or slow down the running body.

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4.5 Brake booster:
A brake booster, also known as a 'brake servo' or
'vacuum booster', does exactly as the name suggests,
it helps to 'boost' the performance of the brakes. A brake
booster makes it easier for the driver to brake by
increasing the force exerted without the need for
additional force applied on the foot pedal

Figure (4.2)

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4.6 Master cylinder:
The master cylinder, also known as the master brake
cylinder, converts the pressure on the brake pedal to
hydraulic pressure by feeding brake fluid into the brake
circuit and controlling this according to the mechanical
force

Figure (4.3)

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4.7 Anti-lock braking system (APS):
An anti-lock braking system is a system which is used to
avoid skidding of the wheel by rapid braking action.

Generally, in vehicles without ABS, when a driver presses

the brake pedal, due to braking, the wheel immediately
gets locked. Hence wheel skids on the road. So, in such
case, if suddenly a big rock comes in front of the vehicle,
the driver presses the brake pedal & then due to skidding
of a wheel, the driver loses control over the vehicle.

Therefore, by ABS, if suddenly a big rock comes in front

of the vehicle, then with ABS, the driver can easily reduce
the vehicle speed and change the direction of the
vehicle. In easy language, ABS helps to stop the constant
locking of a vehicle wheel, hence resulting in vehicle
stops without the skidding of a wheel. Figure (4.4)

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4.8 Brake Pressure Proportioner Valve:
The brake limiter is used in old type vehicles without ABS
braking system. Braking pressure generally needs to be
sent 70% to the front wheels and 30% to the rear wheels;
Because the engine is in front and the weight of the
vehicle is on the front wheels during braking, the front
wheels of the vehicle need more brake pressure and the
rear wheels need less brake pressure. This hydraulic
valve, which reduces the pressure of the brake fluid to
the rear wheels when the brake is applied, is called the
brake limiter.
4.9 Brake Calipers:
In the case of brake brakes, brake calipers are parts of
the braking system that performs the brakes. Inside the
brake calipers, pistons are placed, which are responsible
for braking. Brake pads are also attached to pistons.
Calipers are placed on the circumference of the disc. The
disc brake is an externally applied braking system. A disc
is placed between the calipers.

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 Figure (4.5)

4.10 Disc and Drum Brake Mechanism:

This is the part where braking occurs. Pressurized brake
fluid coming from the brake main center acts on the
piston in the caliper, the piston moves forward with
pressure and presses the brake pad in front of the brake
disc, and the disc-wheel slows down or stops because of
friction. In new generation passenger cars, disc brakes
are used on both the front and rear wheels, however,
disc brakes at the front and drum brakes at the rear are
very common in passenger cars and light commercial
vehicles
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 Figure (4.6)

4.11 Brake fluid properties:

1- High boiling point.
2- Low viscosity.
3- Anti-corrosive properties on all metals.
4- High lubricant power.

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4.12 Braking circuit layout (Hydraulic split):

Figure (4.7)

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 Chapter (5)
Tire service

Figure (5.1)

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5.1 Tire size:

Figure (5.2)

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5.2 Tire speed rating:

Figure (5.3)

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5.3 Tire weight index chart:

Figure (5.4)

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5.4 Tire pressure plat:

Figure (5.5)

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 5.5 wheel torquing:

Figure (5.6)

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 Conclusion
In this report, we have studied all the different parts
of a car in every detail. And there are some more parts.

The above components are the main components of

a car. The car also contains many other parts, hoses,
wires, and fasteners to hold everything together.
Bearings and oil throughout the car prevent premature
wear, and a timing belt or chain ensures all components
function together at the correct time.

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 Reference
[1] Automotive Fuel, Lubricating & Cooling Systems:
Construction, Operation and Maintenance William Harry
Crouse & Donald L. Anglin.

[2] AUTOMOTIVE INDUSTRY TRAINING RETAIL, SERVICE

AND REPAIR AUR05.

[3] https://www.idolz.com/en/2021/08/12/discover-the-
main-parts-of-a-car-engine-and-its-functions/.

[4] https://themechanicalengineering.com/engine-parts-
and-their-function/.

[5] https://www.britannica.com/science/micrometre

[6] https://www.starrett.com/category/1106

[7] https://www.physics.hmc.edu/~physics50/wp/index
.php/calipers/

[8] https://www.sunautoservice.com/car-engine-parts/

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[9] https://studentlesson.com/everything-you-need-to-
know-about-transmission-system/.

[10] https://www.cartrade.com/blog/2011/auto-
guides/brake-systems-in-cars-17.html

[11] https://help.summitracing.com/app/answers/detail/a_id/
5292/~/what-is-a-brake-master-cylinder%3F

[12] https://www.researchgate.net/figure/Diagram-of-vacuum-
booster-system_fig3_326618599

[13] https://what-when-how.com/automobile/brake-operating-
systems-automobile/

[14] https://www.treadwright.com/blogs/treadwright-
blog/understanding-tires-load-index-vs-load-range

[15] https://www.uniroyal-tyres.com/car/tyre-guide/tyre-
knowledge/tyre-speed-ratings

[16] https://cheap- sale.outletsale2022.ru/category?name=

car%20tire%20construction

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