Higher Technological Institute

Mechanical Engineering Department

A Technical Report About

Automotive Maintenance

Course Code: ENG112

Group: 1

Submitted to:

Assistant Professor Mahmoud Osama

Prepared By:

Abdelrahman Magdy Attia

20150495

13 April 2024
 Abstract

Why Vehicle Maintenance is Important

You have invested thousands of dollars in your vehicle, so you need to be sure to maintain your
vehicle properly. This is not the only reason to take regular vehicle maintenance seriously.
There are several other factors that need to be considered.
Extend the Life of Your Vehicle: Just by following the regular maintenance schedule, you
can keep several vehicle problems at bay. When you are traveling in your vehicle, the last thing
you want is a car breakdown. Keeping up with the regular maintenance schedule can help by
preventing costly repairs of the cooling system, transmission system, drivetrain and other
components. Preventive car care reduces wear and tear of the engine and other components
that extend the life of your vehicle.
Increased Safety: A car breakdown at night on a quiet road can be a dangerous situation. You
can never predict what may happen when you are stranded on a quiet road. Regular
maintenance reduces the probability of a car breakdown, and your car will be in great condition
to support your journey. Checking treads of tires and air pressure is important for your vehicle
for a strong grip on the road. It also plays an important role in the comfort of the journey.
Reduced Repair Costs: Regular maintenance doesn’t cost much but unexpected repairs and
replacements can be expensive. Engine and other components don’t fail without a reason.
When you neglect maintenance, it gives way to minor problems developing that can become
major with continued neglect of vehicle maintenance. Regular maintenance of your vehicle
gives you an opportunity to check whether there are any signs of minor problems like cracks,
leaks, as well as excessive wear and tear due to friction. If you pay attention to these things and
perform repairs, the specific part can be saved and you will not need a replacement for a long
time. In a way, vehicle maintenance extends the longevity of the engine and other components
and reduces the need for an early replacement. Thus, it helps in reducing repair costs as well.
Here are some of the routine inspections that are part of vehicle maintenance:
Fluids: Systems in your vehicle use fluids for functioning. Since they are enclosed in tight
chambers, there is no risk of evaporation. However, over time, their levels deplete and the level
of protection they offer against friction decreases. If you neglect vehicle maintenance, there
will more wear and tear of the engine and other components, and ultimately you will be
required to replace them.
Tires: The right air pressure and proper rotation ensures equal wearing of your tires.
Maintaining the correct air pressure is the easiest thing to do and you can get it done at gas
station when refueling. It doesn’t take much time but it goes long way in increasing gas mileage
and reducing wear and tear.
Oil Change: It is one of the most important aspects of vehicle maintenance that you should
keep your eye on. Auto experts suggest vehicle owners change their oil after every 3,000 to
5,000 miles. It is essential to maintain your engine in good condition.

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Always remember, vehicle maintenance might cost you a few hundred dollars while
replacements and emergency repairs can cost thousands or more. This one factor is enough for
everyone to understand the importance of vehicle maintenance.

II
 Acknowledgements
I would like to express my gratitude to my primary supervisor Dr. Eman Ibrahim , who guided
me throughout this course . I would also like to thank my colleague who supported me and
offered deep insight into the study
I wish to acknowledge the help provided by the technical and support staff in the mechanical
department of the tenth of Ramadan institute . I would also like to show my deep appreciation
for Engineer. Kamel sultan , all technicians specially Muhammed batea, Abdullah Bakkar,
Yasser, Islam.

III
Contents
Abstract ...................................................................................................................................... I
Acknowledgements .................................................................................................................. III
Abbreviations ........................................................................................................................ VIII
Chapter (1) ................................................................................................................................. 1
Introduction ................................................................................................................................ 1
Jeep Maintenance ................................................................................................................... 1
Regular Maintenance ............................................................................................................. 1
Jeep-Specific Maintenance .................................................................................................... 1
Routine Vehicle Maintenance .................................................................................................... 2
1. Acquaint Yourself with Your Owner’s Manual................................................................. 3
2. Check Your Tires Monthly ................................................................................................ 3
3. Change Your Oil and Oil Filter on Schedule ..................................................................... 4
4. Replace the Air Filter With Oil Changes ........................................................................... 4
5. Inspect All Other Fluids ..................................................................................................... 4
6. Examine Belts and Hoses................................................................................................... 4
7. Always Listen and Feel for Brake Issues ........................................................................... 5
8. Replace Wiper Blades as Needed ...................................................................................... 5
9. Remove Battery Corrosion ................................................................................................ 5
Maintenance cycle ..................................................................................................................... 7
Documentation ....................................................................................................................... 7
Chapter (2) ................................................................................................................................. 9
Engine ........................................................................................................................................ 9
What Is A Car Engine? .......................................................................................................... 9
How Does an Engine Work?................................................................................................ 10
The Four Strokes Of A Four-Stroke Engine ............................................................................ 10
What do V mean in cars? ................................................................................................. 11
V6:........................................................................................................................................ 12
V8:........................................................................................................................................ 13
Chapter (3) ............................................................................................................................... 14
Gearbox .................................................................................................................................... 14
Jeeps: The basics of transmissions, transfer cases and gear positions ................................. 14
Off-road system basics ......................................................................................................... 14
Full-time 4x4 (4WD) ....................................................................................................... 14
All-wheel drive (AWD) ................................................................................................... 14

IV
 Part-time 4WD ................................................................................................................. 14
On-demand 4WD ............................................................................................................. 15
Chapter (4) ............................................................................................................................... 16
Breaking system ....................................................................................................................... 16
Braking – fundamentals: friction and how it applies to automobiles .................................. 16
Chapter (5) ............................................................................................................................... 19
Engine cooling system: ............................................................................................................ 19
how it works and main components..................................................................................... 19
Components of a cooling system ............................................................................................. 19
Radiator ................................................................................................................................ 19
Water pump .......................................................................................................................... 19
Thermostat ........................................................................................................................... 19
Other components ................................................................................................................ 19
Freeze Plugs ..................................................................................................................... 19
Timing head/cover gasket ................................................................................................ 19
Radiator overflow tank .................................................................................................... 20
Hoses ................................................................................................................................ 20
How an engine cooling system works ................................................................................. 20
Car air Conditioning system ................................................................................................... 21
Why do We Need an Automobile or Car Air Conditioning System? ...................................... 21
Components of Car Air Conditioning System. ........................................................................ 21
1. Compressor – ................................................................................................................... 22
2. Condenser – ..................................................................................................................... 22
3. Expansion valve- .............................................................................................................. 22
4. Evaporator – ..................................................................................................................... 22
5. Receiver-Dryer- ............................................................................................................... 23
6. Refrigerant – .................................................................................................................... 23
Working of an Automobile or Car AC .................................................................................... 23
Chapter (6) ............................................................................................................................... 25
EXHAUST SYSTEM .............................................................................................................. 25
Chapter (7) ............................................................................................................................... 27
SENSORS ................................................................................................................................ 27
OXYGEN SENSOR ............................................................................................................ 27
SPEED TIMING SENSOR.................................................................................................. 27
MASS AIR FLOW SENSOR .............................................................................................. 28

V
 SPEED SENSOR ................................................................................................................. 29
OIL PRESSURE SENSOR .................................................................................................. 30
TOP DEAD CENTER SENSOR ......................................................................................... 31
Tire pressure sensor ............................................................................................................. 31
SPARK PLUG ......................................................................................................................... 32
Chapter (8) ............................................................................................................................... 34
ON-BOARD DIAGNOSTICS (OBD) SYSTEM .................................................................... 34
What the OBD system does ..................................................................................................... 34
How to tell if the OBD is working ? ........................................................................................ 35
OBD-Codes Explained............................................................................................................. 35
Second Digit - Code Type........................................................................................................ 36
Third Digit - Sub-System ......................................................................................................... 36
Fourth and Fifth Digits............................................................................................................. 36
Observation on the workshop .................................................................................................. 36
Chapter (9) ............................................................................................................................... 37
Tools in the workshop .............................................................................................................. 37
Chapter (10) ............................................................................................................................. 38
Safety ....................................................................................................................................... 38
Safety Rules for Automotive Repair Shops ............................................................................. 39
Safety Gear You Should Wear in an Auto Shop.................................................................. 39
Auto Shop Organization Tips for Safety ............................................................................. 39
Auto Shop Flooring Care ..................................................................................................... 40
Chemical Caution in the Auto Shop .................................................................................... 40
Vehicle Safety in the Auto Shop .......................................................................................... 40
CONCLUSION ........................................................................................................................ 40
REFERENCES ........................................................................................................................ 42

VI
FIGURE 1BATTERY CORROSION ................................................................................................... 6
FIGURE 2 JOB-ORDER .................................................................................................................. 7
FIGURE 3 JOB ORDER ................................................................................................................... 8
FIGURE 4 WORKFLOW IN THE SERVICE SECTION ............................................................ 8
FIGURE 5 ENGINE ........................................................................................................................ 9
FIGURE 6 FOUR STROKE ENGINE CYCLE .................................................................................... 10
FIGURE 7 FOUR STROKE ENGINE ............................................................................................... 11
FIGURE 8 V ENGINE .................................................................................................................. 12
FIGURE 9 V6 ENGINE ................................................................................................................ 12
FIGURE 10 V8 ENGINE .............................................................................................................. 13
FIGURE 11 GEARBOX ................................................................................................................. 16
FIGURE 12 TYPICAL AUTOMOTIVE BRAKING SYSTEM ............................................................... 17
FIGURE 13 TYPICAL DISC BRAKE ............................................................................................... 18
FIGURE 14 COOLING SYSTEM .................................................................................................... 20
FIGURE 15AIR CONDITIONING SYSTEM ..................................................................................... 22
FIGURE 16 AC FOR CARS .......................................................................................................... 23
FIGURE 17 EXHAUST SYSTEM ............................................................................................. 25
FIGURE 18 EXHAUST SYSTEM ............................................................................................. 25
FIGURE 19 OXYGEN SENSOR ...................................................................................................... 27
FIGURE 20 SPEED TIMING SENSOR ............................................................................................. 27
FIGURE21 MASS AIR FLOW SENSOR ........................................................................................ 28
FIGURE22 SPEED SENSOR ......................................................................................................... 29
FIGURE23 OIL PRESSURE SENSOR............................................................................................. 30
FIGURE24 TDC SENSOR ........................................................................................................... 31
FIGURE25 INDIRECT TPMS ...................................................................................................... 32
FIGURE26 DIRECT TPMS ......................................................................................................... 32
FIGURE27 SPARK PLUG ............................................................................................................. 33
FIGURE28 OBD DEVICE .......................................................................................................... 34
FIGURE 29 OBD DEVICE ........................................................................................................... 34
FIGURE30 MISFIRE .................................................................................................................. 36
FIGURE31 REPORT AFTER OBDT ............................................................................................. 36
FIGURE 33 TOOLS IN WORKSHOP .............................................................................................. 37
FIGURE 34 SAFETY EQUIPMENT’S ............................................................................................. 38
FIGURE 35 SAFETY ON WORKSHOP ............................................................................................ 39
FIGURE 36 SAFETY ON WORKSHOP ............................................................................................ 40

VII
 Abbreviations
OBD On board diagnostic
AWD All-wheel drive
TPMS Tire pressure Measure sensor
TDC Top Dead Center
VSS Vehicle Speed Sensor

VIII
 Chapter (1)
Introduction

Jeep Maintenance
You don’t buy your Jeep to blend in with the crowd. Since their introduction Jeeps have
stood out from the crowd, both in terms of looks as well as performance. That being said, a
unique vehicle requires a unique level of care. With the right repairs and maintenance, a Jeep
can serve you for decades – just look around, and you’ll see plenty of Cherokees, Grand
Cherokees, and Wranglers with years of service, still in great condition.

Regular Maintenance
Some types of maintenance are the same for any vehicle, whether it’s a Jeep Grand Cherokee
or a subcompact hatchback. This includes maintenance such as:

• Checking your front and rear lights and tire pressure monthly.
• Change your Jeep’s oil and filter every 4,000 miles or so, and while you’re at it, see
about lubricating the chassis.
• Inspect belts and hoses underneath the hood at each oil change.
• Rotate the tires and balance the wheels every 6,000-8,000 miles.
• Replace the air filter every 20,000 miles.
• Check your wheel alignment every 20,000 miles, or when you put on new wheels.
• Cooling system flush and refill every 50,000 miles.
• Drive belt, hose, and engine timing belt checks every 20,000 miles, with replacement
every 50,000-80,000 miles.

Jeep-Specific Maintenance
Of course, if you’re planning on using your Jeep for the heavy-duty, off-road traveling it is
capable of, there are higher levels of maintenance you’ll need to perform.

• In addition to the monthly checks, make sure you check your tire pressure before and
after any off-road activities.
• Any time you cross water that is deep enough to rise over the hubs of your wheels,
you’ll want to replace the fluids in your differentials as a precaution.
• In addition to the regular tire rotation and wheel balancing, check your wheel weights
after any off-road driving.
• If you have a Jeep with drum brakes, make sure they have been cleaned out properly
after any off-road drives – mud and snow can work its way into the brakes and reduce
your stopping power.
• Check your air filter on a regular basis and clean it when necessary if you plan on
hitting the dusty trail often. The more dust and dirt the filter has to keep out, the

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 shorter its life span will be. Heavy off-roading can lower the replacement period down
to every 12,000 miles.
• Off-roading can knock wheels out of alignment easily, so if you take your Jeep off
road often, have your wheels aligned every 3 months.

Repairing Your Jeep

Even with regular maintenance, you’ll need repairs every so often, even more if you plan on
working your Jeep hard on the off-road trails. There is no such thing as a “common” repair,
as every repair will have its own oddities. We recommend you leave the repairs to
professional mechanics, particularly when it comes to the drivetrain, brakes, and handling
components.

Routine Vehicle Maintenance

Vehicles are machines, and like any machine they need maintenance. For most vehicles,
regular maintenance begins at 5,000 miles and continues from there every 5,000-10,000
miles. Of course, checking your car on a more regular basis is even better.

Maintenance keeps your vehicle running smoothly and safely down the road for a much
longer distance compared to never doing upkeep. Your owner’s manual will outline all of the
maintenance that needs to be done and when it needs to be done so that you’re prepared.

But do you need to pay for a mechanic to handle the vehicle maintenance? You can handle a
lot of basic vehicle maintenance yourself by following the advice below.

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Vehicle Maintenance Measures You Can DIY
You need a mechanic for most repairs, but there’s a lot of vehicle maintenance you can do on
your own. Here’s a rundown that will get you started.

1. Acquaint Yourself with Your Owner’s Manual

Every vehicle has an owner’s manual. It’s a thick book typically squirreled away in the glove
box. If you can’t find your copy, an electronic version could be online. Otherwise, contact
your dealer for a copy.

With manual in hand, head to the maintenance schedule section. Take note of the intervals for
maintenance items like the engine oil, oil filter, tire rotation, belts, hoses and so on. It’s
important to follow these manufacturer recommendations to keep the engine running as
smoothly as possible.

2. Check Your Tires Monthly

A lot is riding on your tires - like the entire vehicle. The thing that keeps your car driving
down the road is the tires. They need to be properly inflated to do their job as well as lessen
the chance of a blowout.

You probably know how to add air to your tires already. What you may not know is the
correct tire pressure, which is extremely important. You’ll find the ideal tire pressure on a
placard located on the driver’s door jamb or in the owner’s manual.

3
Tires should be inflated when they are cold (driven less than one mile) to get an accurate
reading. If that isn’t possible, add 4 PSI to the recommended amount, explains Bridgestone
Tire. Check your spare tire while you’re at it and confirm all pressures with a tire gauge once
the tires have rested.

3. Change Your Oil and Oil Filter on Schedule

Oil is your engine’s life blood. It serves as a lubricant, keeping important engine parts from
grinding against each other and destroying the engine. Motor oil that’s not changed regularly
can damage your engine as accumulated contaminants cause friction when they rub against
parts.

What type of oil should you use — petroleum-based or synthetic? Is one better than the
other? According to Edmunds.com Engineering Editor Jason Kavanagh, the type of oil is not
important. He noted, “As long as the oil meets the service and viscosity requirements set out
in your owner's manual, you can switch back and forth as much as you want.”

4. Replace the Air Filter with Oil Changes

When it comes to the air filter, you may need to replace it once or twice each year. It largely
depends on how much you drive. It’s best practice to check the air filter when you change
your oil.

5. Inspect All Other Fluids

Motor oil isn’t the only fluid that needs to be checked. Experts recommend checking your car
brake fluid, transmission fluids, coolant and windshield washer fluid.

Like motor oil, you’ll check transmission fluid with a dipstick. Determine brake fluid, coolant
and washer fluid levels by removing related covers and visually inspecting each. They should
reach a designated fill line.

NEVER remove the radiator cap to check coolant levels. You risk getting scalded if the cap is
removed. Instead, check the coolant level in the nearby transparent refill container, says Car
Talk.

6. Examine Belts and Hoses

If you want to go one step beyond basic routine vehicle maintenance, then inspect the hoses
and belts in the engine bay. These hoses direct coolant flow to ensure the engine doesn’t
overheat. If a hose has separated, shows cracks or bulges, then have it replaced.

Similarly, check the belts too. The timing belt, as found in most cars and small SUVs, is
critical to the operation of your engine, notes Your Mechanic. If this belt shows signs of
wear, including cracking, glazing and material loss (chunks missing from the belt itself), then
replace it ASAP. If the timing belt goes while driving it can cause serious engine damage.

4
7. Always Listen and Feel for Brake Issues

Brakes are a critical component on every vehicle. You should always be aware of how your
brakes feel and what they sound like every time you drive. If the brakes, feel spongy or it
takes more pressure to apply the brakes than normal they need to get inspected by a
professional.

Brake sounds can indicate when maintenance or repair is needed. Here’s a quick rundown of
common brake sounds:

Squealing - It’s time for new brake pads when you hear squealing because the ones you have
now are worn out and rubbing against the rotor.

Grinding - This isn’t a normal sound, but it may not be a major issue if brake grinding is
happening only the first time you drive the vehicle in a day. When the humidity levels are
high outside, rust can form on the brake rotors in a matter of a day if the vehicle isn’t driven.
The grinding sound is the rust getting knocked off. The simple fix is to park the vehicle in a
garage when it’s snowing, raining or humid.

Rattling - A rattling or vibration sound suggests one of the rotors is warped or worn out and
needs to be replaced.

Intermittent Sounds - If brake sounds come and go it could be an indicator of brake fade from
overheating. When the brake pads, rotors or brake fluid overheat you may hear brake sounds
and the brakes won’t feel as responsive. This problem should be looked at by a professional
who can pinpoint the cause and fix it.

8. Replace Wiper Blades as Needed

If the windows streak or the blades screech when the system is operating it’s time for a
replacement set. This is actually a very important vehicle maintenance measure. If you find
yourself in a rainstorm the windshield wipers are what give you visibility. You never know
when you may need them so check the wiper blades often.

9. Remove Battery Corrosion

As for the car battery, the main requirement here is to ensure that the battery terminals remain
free from corrosion. Just like the brakes, environmental factors can cause buildup that hinders
operation. A wire brush along with a solution of water and baking soda will knock the
corrosion right off.

Now that you know vehicle maintenance, you’re on your way to ensuring your car keeps
safely cruising down the road for miles

5
Figure 1battery corrosion

6
 Maintenance cycle
Documentation

Figure 2 job-order

7
In this document we record all data related to the automobile , owner .
As Engineer you should write down all his info
1. Client name
2. owner phone number so You can be in Touch with them.
3. chassis number its located in the driver side dash viewable through the Windshield –
driver’s side door frame
4. Engine number
5. Odometer
6. Licenses number
7. Plate number

Figure 3 job order

8
 Chapter (2)

Engine
From Fuel to Function: Working of the Car Engine Explained
What Is A Car Engine?

The engine is the heart of your car. It’s a complex machine built to convert the heat from
burning gas into the power that turns the road wheels.

The chain of reactions that achieves this goal is set in motion by a spark that ignites a mixture
of gasoline vapor and compressed air in a momentarily closed cylinder and burns rapidly.
That is why the machine is called an internal combustion engine. When the mixture burns, it
expands and provides energy to power the car.

What is Internal Combustion Engine?

To withstand its heavy workload, the engine must have a sturdy structure. It consists of two
main parts: the lower, heavier part is the engine block, a housing for the main moving parts of
the engine; The removable top cover is the cylinder head.

The cylinder head contains valve-controlled channels through which the air-fuel mixture
enters the cylinders, and others through which the gases produced during their combustion
are expelled.

The block houses the crankshaft, which converts the reciprocating motion of the pistons into
rotary motion on the crankshaft. Often the block also houses the camshaft, which operates
mechanisms that open and close the valves in the cylinder head. Sometimes the camshaft is
mounted in the head or above.

Figure 5 Engine

9
How Does an Engine Work?

Specifically, an internal combustion engine is a heat engine in that it converts energy from the
heat of combustion of gasoline into mechanical work or torque. This torque is applied to the
wheels to get the car moving.

Engines have pistons that move up and down in metal tubes called cylinders. Imagine you are
riding a bicycle: your legs move up and down to press the pedals. Pistons are connected to a
crankshaft by rods (they’re like your shins) and move up and down to turn the engine’s
crankshaft, just as your legs turn those of the bicycle – which in turn turns the bicycle’s drive
wheel or car’s drive wheels drives.

Depending on the vehicle, there are typically between two and 12 cylinders in its engine, in
each of which a piston moves up and down.

What drives these pistons up and down are the thousands of tiny, controlled explosions that
occur every minute and are created by mixing fuel with oxygen and igniting the mixture. Each
time the fuel ignites is called the combustion or power stroke. The heat and expanding gases
from this mini explosion push the piston down the cylinder.

Almost all of today’s internal combustion engines (for the sake of simplicity we will focus on
gasoline engines here) are four-stroke engines. In addition to the combustion stroke, which
pushes the piston down from the top of the cylinder, there are three other strokes: intake,
compression, and exhaust.

Engines need air (namely oxygen) to burn fuel. During the intake stroke, valves open to allow
the piston to act like a syringe as it moves down, drawing ambient air through the engine’s
intake system.

When the piston reaches the bottom of its stroke, the intake valves close, effectively sealing
the cylinder for the compression stroke, which is in the opposite direction of the intake stroke.
The upward movement of the piston compresses the intake charge.

The Four Strokes Of A Four-Stroke Engine

Most internal combustion engines work in a four-stage cycle process. These steps are formally
known as strokes, referring to the four movements a piston makes to complete each cycle. The
strokes take place in this order: intake, compression, combustion, exhaust.

With each stroke, the piston moves either up or down in the cylinder and moves in conjunction
with the intake of air and fuel or the exhaust of exhaust gases. Here is an overview of how the
process works

Figure 6 Four stroke Engine cycle

10
 Figure 7 four stroke Engine

• Intake: The piston is pulled down inside the cylinder by the momentum of the
crankshaft. Most of the time the car is moving along, so the crankshaft is always
turning. The inlet valve opens, letting a mixture of fuel and air into the cylinder through
the purple pipe.
• Compression: The inlet valve closes. The piston moves back up the cylinder and
compresses (squeezes) the fuel-air mixture, which makes it much more flammable.
When the piston reaches the top of the cylinder, the sparking plug fires.
• Power: The spark ignites the fuel-air mixture causing a mini explosion. The fuel burns
immediately, giving off hot gas that pushes the piston back down. The energy released
by the fuel is now powering the crankshaft.
• Exhaust: The outlet valve opens. As the crankshaft continues to turn, the piston is
forced back up the cylinder for a second time. It forces the exhaust gases (produced
when the fuel burned) out through the exhaust outlet.

What do V mean in cars?

The ‘V’ represents the way cylinders are arranged in your engine. V-type engines have
cylinders placed in a V-like shape, or to put it the other way, in two equal rows. This design is
commonly used since it requires less space and can fit in most cars.

11
 Figure 8 V Engine

Now let us talk about a few famous V engines. The most widely used V engines are V6, V8,
and V12 engines. These engines are discussed as follows:
V6:

A V engine having six cylinders mounted on the crankshaft in two banks of three cylinders set
at 60o or 90o angle to each other is a V6 engine. It is one of the most compact engine
configurations shorter than an inline 4-cylinder engine. Its short length enables it to be used
widely in transverse engine front-wheel-drive layout. A V6 engine is successful in mid-sized
cars because it is less expensive to manufacture and smoother in a large size than an inline 4-
cylinder engine. The 90o V6 configuration will fit in an engine compartment designed for a V8
hence providing a cost-effective alternative to V8. It usually ranges from 2.0L to 4.3L
displacement.

Figure 9 V6 Engine

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V8:

A V8 engine has eight cylinders mounted on the same crankshaft in two sets of four. All the
eight pistons drive a common crankshaft. Most banks are set at an angle of 90o to each other,
but more configurations are 45o, 60o, and 72o. The V8 is two parallel inline-four engines sharing
a common crankshaft. In 90o V8 engines, balance shafts are incorporated to reduce vibrations,
thus resulting in a complex crankshaft. 72o V8 engines are used in modern racing cars. 45o
engines were used in diesel locomotive but are being used in modern 4-wheel drive racing cars.
60o engines were designed for transverse front-wheel-drive configuration and are narrower for
efficient use of space. V8 engines usually vary from 3.0L to 8.0L in displacement.

10 V8 Engine Figure

13
 Chapter (3)

Gearbox
Jeeps: The basics of transmissions, transfer cases and gear positions

One of the best things about a Jeep is its ability to go nearly anywhere the driver can imagine.
We push it through sand or mud, up steep hills, over logs and rocks, all in the name of adventure
and thrills.

There are many reasons why Jeeps don’t fail in those conditions – small wheelbase, lighter
weight, solid frame, ultra-flexible suspension, quality knobby tires, etc. But one of the main
reasons for successful outings is one you can’t see with a glance at the rig. But it really is the
vehicle’s performance backbone – an extremely well-engineered transmission system.

Regardless of manual or automatic set up, the gears are designed for maximum execution in
the most challenging on- or off-road conditions.

But how does it all work? What’s the point of each setting? How does one make the best use
of the gears?

Off-road system basics

Generally speaking, Jeeps are equipped with a dual transfer case, meaning a second case is
located behind the transmission case and acts to transfer torque to only the rear differential or
to the front and rear at the same time.

Full-time 4x4 (4WD)

A setting in which four-wheel drive is engaged at all times and the driver can travel safely and
securely on all surfaces. Regardless of whether the road is dry, wet, or covered in snow, the
driver can maneuver with confidence. The system uses either a clutch or a center differential
to allow the front and rear drive shafts to turn at varying speeds.

All-wheel drive (AWD)

A setting that is similar to full-time 4-wheel drive (4WD). While the system powers all four
wheels at all times and can be used full-time on all surfaces like full-time 4WD, the difference
is that a “4-low” setting isn’t available on AWD vehicles. Due to the lack of “low range,” AWD
vehicles are much less capable off-road than full-time 4WD but work perfectly well on well-
maintained or paved surfaces.

Part-time 4WD

This setting operates naturally like a two-wheel drive vehicle. The key here is that unlike the
full-time system, part-time 4WD doesn’t use a center differential. Instead, the system locks the
front and rear drive shafts. It’s used exclusively during off-road travel or challenging road
conditions. However, if a driver uses part-time 4WD excessively, they may experience
driveline noise or binding that can lead to overheating or early part failure. Therefore, when
driving under normal conditions, a driver should switch to the vehicle’s two-wheel-drive mode.

14
On-demand 4WD

This setting operates primarily in two-wheel drive during normal driving conditions. When a
slick or slippery surface such as snow or mud is encountered, 4WD is automatically engaged
and power is transferred to the secondary axle.

15
 Chapter (4)

Breaking system

Brakes are one the key parts of any vehicle, without which it is virtually not possible to use the
vehicle for travel. Clearly, a brake, which serves to slow down the vehicle, should not be too
weak. But interestingly, when designing a brake system, it should also be taken care that it’s
not too efficient. A too strong a brake would expose us continuously to the ill effects of a
sudden brake application in bus or car. If a vehicle is stopped abruptly or strongly, the passenger
may hit the front seat or whatever is there. Hence, too efficient a brake system is not required!

The braking system is strongly relation to Newton’s laws of motion. Indeed, the above
phenomenon is linked to Newton’s second law of motion, which states “A body continues to
be in its state of rest or of motion unless external force acts on the same”.

On the other hand, if a brake system is too weak, the stopping distance would increase and
hence may lead to accidents. Thus, a brake system should be perfect enough to stop the vehicle
at minimum safe distance, without affecting the comfort of the passenger to achieve this there
have been a lot of developments in the brake system technology, right from Mechanical brakes
to Air brakes in automobiles. In this article we would like to provide the relevant information
regarding the same

Figure 11 gearbox

Braking – fundamentals: friction and how it applies to automobiles

A brake system is designed to slow and halt the motion of vehicle. To do this, various
components within the brake system must convert vehicle’s moving energy into heat. This is
done by using friction.

Friction is the resistance to movement exerted by two objects on each other. Two forms of
friction play a part in controlling a vehicle: Kinetic or moving, and static or stationary. The

16
amount of friction or resistance to movement depends upon the type of material in contact, the
smoothness of their rubbing surfaces and the pressure holding them together.
Thus, in a nutshell a car brake works by applying a static surface to a moving surface of a
vehicle, thus causing friction and converting kinetic energy into heat energy. The high-level
mechanics are as follows.

As the brakes on a moving automobile are put into motion, rough-textures brake pads or brake
shoes are pressed against the rotating parts of vehicle, be it disc or drum. The kinetic energy or
momentum of the vehicle is then converted into heat energy by kinetic friction of the rubbing
surfaces and the car or truck slows down.

When vehicle comes to stop, it is held in place by static friction. The friction between surfaces
of brakes as well as the friction between tires and roads resist any movement. To overcome the
static friction that holds the car motionless, brakes are released. The heat energy of combustion
of in engine is converted into kinetic energy by transmission and drive train, and the vehicle
moves.

Figure 12 typical automotive braking system

The hydraulic brake system uses brake fluid to transfer pressure from the brake pedal to the
pads or shoe. By exercising the pedal, brake fluid transfers this pressure to the brake pads. This
transfer of pressure is reliable and consistent because liquids are not compressible, i.e. pressure
applied to liquid in a closed system is transmitted by the liquid equally to every other part of
system.

A hydraulic brake system apart from liquid pipes mainly consists of Brake pedal, Master
cylinder, wheel cylinder and brake pads/shoe connected at the wheel. The function of the
Master cylinder is to distribute pressure to lines leading to front or rear wheels as required. At

17
the wheel cylinder, a small piston is provided which is operated due to pressure application
through brake fluid. The operation of the piston is converted to movement of brake liners.

In brief, when a driver applies pressure at the brake pedal, the mechanical force (stepping of
driver on pedal) is changed to hydraulic pressure which is transmitted through liquid to
respective wheel cylinder and changed back to mechanical force (operation of brake pads,
shoe)

Figure 13 typical disc brake

18
 Chapter (5)

Engine cooling system:

how it works and main components

The engine in your car works best at a high temperature. When the engine is cold, components
wear out easily, emits more pollutants, and the engine becomes less efficient. Thus, another
important task of the cooling system is to allow the engine to warm up as quickly as possible,
and then to maintain a constant engine temperature. The main function of a cooling system is
to ensure that the engine runs at its optimum operating temperature. If the cooling system or
any part of it fails, it will overheat the engine, which can lead to many serious issues.

Have you ever imagined what would happen if your engine cooling system did not work
properly? Overheating can cause cylinder head gaskets to explode and even crack engine
blocks if the problem is serious enough. And all this heat must be fought. If the heat cannot be
removed from the engine, the pistons are literally welded to the inside of the cylinders. Then
you just must throw the engine away and buy a new one. So, you should take care of your
engine cooling system and learn how it works.

Components of a cooling system

Radiator

The radiator acts as a heat exchanger for the engine. It is usually made of aluminum and has
many small diameter pipes with fins attached to them. It exchanges the heat of the hot water
coming from the engine with the ambient air. It also has a drainage plug, an inlet port, a sealed
cover, and an outlet port.

Water pump
When the coolant cools after being in the radiator, the water pump sends the fluid back to
the cylinder block, heater core, and cylinder head. Eventually, the liquid enters the radiator
again, where it cools down again.

Thermostat
It is a thermostat that acts as a valve for the coolant and only allows it to pass through the
radiator when a certain temperature has been exceeded. The thermostat contains paraffin wax,
which expands at a certain temperature and opens at that temperature. The cooling system
uses a thermostat to regulate the normal operating temperature of the internal
combustion engine. When the engine reaches standard operating temperature, the thermostat
is triggered. Then the coolant can enter the radiator.

Other components
Freeze Plugs: This is actually a steel plug designed to seal openings in the cylinder block and
cylinder heads created during the casting process. In frosty weather, they can pop out if there
is no frost protection.
Timing head/cover gasket: Seals major engine parts. Prevents mixing of oil, antifreeze, and
cylinder pressure.
19
Radiator overflow tank: This is a plastic tank that is usually installed next to the radiator and
has an inlet connected to the radiator and one overflow hole. This is the same tank that you
pour water into before driving.
Hoses: A series of rubber hoses connect the radiator to the engine through which the coolant
flows. These hoses can also start leaking after years of use.

Figure 14 cooling system

How an engine cooling system works

the cooling system works by constantly passing coolant through channels in the engine block.
Coolant, driven by a water pump, is pushed through the cylinder block. As the solution
passes through these channels, it absorbs heat from the engine.

Leaving the engine, this heated fluid enters the radiator, where it is cooled by the air flow
entering through the car’s radiator grill. The fluid will cool as it passes through the radiator,
returning to the engine again to pick up more engine heat and carry it away.

There is a thermostat between the radiator and engine. Depending on the temperature, the
thermostat regulates what happens to the liquid. If the fluid temperature drops below a
certain level, the solution bypasses the radiator and is instead directed back to the engine block.
The coolant will continue to circulate until it reaches a certain temperature and opens the valve
on the thermostat, allowing it to pass through the radiator again for cooling.

It seems that due to the very high engine temperature, the coolant can easily reach its boiling
point. However, the system is under pressure to prevent this from happening. When the system
is under pressure, it is much more difficult for the coolant to reach its boiling point.
Occasionally, however, pressure builds up and must be relieved before it can deflate the
hose or gasket. The radiator cap relieves excess pressure and fluid by accumulating in the

20
reserve tank. After the liquid in the storage tank has cooled to an acceptable temperature, it is
returned to the cooling system for re-circulation.

Car air Conditioning system

A car air conditioning system consists of a compact version of the components of the normal
air conditioner that has an evaporator, compressor, condenser, expansion device, and a fan
which are fitted in a car to provide air condition inside the passenger’s compartment.

This air conditioning system takes power from the engine’s crankshaft and is operated by the
passengers from the cockpit by pressing the button assigned to this system.

Why do We Need an Automobile or Car Air Conditioning System?

As we have already mentioned that air conditioning system inside a cabin is required to provide
a relaxed and fatigue free atmosphere to the humans which in turn provides comfort which is
essential for the health of a human being. But in a car, it is required due to the following reasons.

• When a vehicle is running through cities like Cairo passengers have to face lots of
traffic that causes slow motion of vehicle due to which it is essential for a vehicle to be
equipped with a system that can provide a comfort zone for the passengers.
• In Egypt during summers there is lots of hot and humid air in the atmosphere which
causes difficulty for a driver to drive and also for the passengers to travel, so during
summer, an effective air conditioning system is required in a car which can provide a
cool and humid free environment inside a passenger’s compartment.
• Air conditioning does not only condition the environment inside a passenger’s cabin
but also provides filtered air which is very essential in cities like Cairo due to the very
hazardous air pollution condition that can cause health issues to the passengers.
• In winters a vehicle faces a problem of fog or vapor formation over a front mirror which
causes visibility problems and makes it difficult for a driver to drive a car, so it is
essential for a vehicle to be equipped with a system that can fight with this problem.
• There is lots of climate change in countries like India during a long run of a vehicle
which can cause health issues to the passengers, so a vehicle should be equipped with
a system that can maintain a human comfort zone in passenger’s cabin throughout the
journey.

Due to these problems, almost all the vehicle on the road today is equipped with an air
conditioning system which nowadays becomes the basic need for human being.

Components of Car Air Conditioning System.

The components of a car’s AC system is almost same as a room’s AC but there are lots of
modification made in an automobile AC to make it compact and to fit it with engine’s
component. The components used in automobile AC are-

21
 Figure 15air Conditioning system

1. Compressor –

It is also known as the heart of the AC system, A compressor provide pressure rise to the
refrigerant to convert the vapor refrigerant into liquid refrigerant which in turn enables the
further flow of the refrigerant through condenser.

The compressor of the car air conditioning system is driven by the crankshaft of the
engine through the belt drive.

2. Condenser –

It is the device looks like a small radiator and is used after the compressor as it provides
condensing i.e. lowers the temperature, of the high pressure and high temperature liquid
refrigerant sent by compressor through forced convection provided either by radiator fan or
by separated fan used with condenser.

3. Expansion valve-

It is a device used in car air conditioning system to expand the high pressure, low temperature
liquid refrigerant sent by the condenser in order to release pressure of the refrigerant before
sending it to evaporator for the further process.

4. Evaporator –

It is a device that looks like another heat exchanger and is place just behind the AC vent over
a dashboard of a car, an evaporator takes heat from the passenger’s compartment and convert
the liquid refrigerant sent by the expansion valve into vapor, which in turn provides cooling
through the fan inside a passenger’s cabin

22
Note – Thermal expansion valve is used in vehicles that enable the passenger to change the
temperature according to the requirement, by just adjusting the knob provided over a
dashboard in passenger’s cabin.

5. Receiver-Dryer-

It is a safety catch used in an automobile or car air conditioning system as there is a chance
that instead of vapors some liquid also flows towards the compressor which can damage the
compressor, so the receiver dryer is used in between evaporator and compressor to convert
that remaining liquid into vapors before sending it to compressor for compression.

6. Refrigerant –

It is the heat sensitive fluid with very low boiling point that is used in AC as a medium of
heat exchanging.

Working of an Automobile or Car AC

The working of an automobile AC system is also almost same as the normal AC but little
difference is there-

1. The evaporator which is the another heat exchanger used in AC takes heat from the
passenger’s cabin which in turn converts the liquid refrigerant flowing through the evaporator
into vapors which in turn provide cooling with the help of the blower fan.

2. This vapor having high temperature low pressure is then sent to compressor which in turn
increases the pressure over the vapors and converts the vapor refrigerant into liquid
refrigerant.

• Now the refrigerant is in high pressure and high temperature liquid state.

3. This high pressure high temperature liquid refrigerant is then sent to the condenser which
lowers the temperature of this refrigerant by forced convection provided by the radiator fan or
by separated fan used.

• Now the refrigerant is having low temperature, but the pressure of the liquid is almost
the same.

4. This high pressure and the low-temperature refrigerant is then sent to the expansion valve
which in turn releases the pressure from the refrigerant and converts it into its original state.

5. This refrigerant is then again sent to the evaporator for the further cycle.

23
Note – Between evaporator and compressor a receiver dryer is used that convert the
remaining liquid refrigerant from the evaporator into the vapors before sending it to the
compressor.

• Receiver dryer also provide filtering of the system by absorbing the contaminated
foreign materials inside the AC system.

So, this is how an automobile or car air conditioning system is used in a vehicle which makes
the drive comforting and provides health safety to the passengers.

24
 Chapter (6)

EXHAUST SYSTEM

Figure 17 EXHAUST SYSTEM

Figure 18 EXHAUST SYSTEM

25
Exhaust system has come a long way from the old days of exhaust pipes and
mufflers. Today, the exhaust system is safety and emissions control rolled into
one. Have your car’s exhaust system inspected regularly and check it
immediately if you suspect any problems.
The exhaust fumes travel through an exhaust pipe/tube, which carries them
through the catalytic converter, right through the muffler, and out the exhaust
tip. Along the exhaust pipe are oxygen sensors so that they can keep track of
the emission levels
The Exhaust Gas Recirculation (EGR) Valve is responsible for single-handily
bringing down the amount of exhaust emissions your car expels from the
tailpipe into the atmosphere. The valve makes it possible to recirculate the
engine gasses by putting them back into the intake manifold. At this point the
engine burns them again, so there are no emissions to worry about
The catalytic converter converts pollutants in the exhaust system into less toxic
pollutants by using a redox reduction method.
The exhaust system routes dangerous exhaust gas from the engine out and away
from the car to keep from affecting the occupants. Next, the exhaust system
reduces exhaust noise from the engine. The catalytic converter reduces the level
of harmful pollutants in the exhaust. The oxygen sensors mounted in the
exhaust system monitor the level of oxygen in the exhaust gases to maintain
efficient engine operation and to monitor the converter’s operation
Symptoms: Loud noise, rattling noise when starting, accelerating, or braking,
Drowsiness while driving, Rotten eggs smell, a sudden loss of power, Poor fuel
economy, Vehicle is performing poorly, such as stalling while driving or a
jerking feeling, Misfiring engine, Check Engine Light

26
 Chapter (7)

SENSORS
OXYGEN SENSOR
The oxygen sensor in your vehicle measures the exhaust gases exiting the engine
and this information is used by the ECU to determine the air to fuel ratio in your
engine in real time. The oxygen sensor transmits the data to the vehicle’s
computer to keep the optimal air to fuel to air ratio in your engine. A bad or failing
oxygen sensor will have a bad impact on the environment and poor engine
performance, so there are a few things to watch out for before your oxygen sensor
completely fails.
1- Check engine lights comes on
2- Bad gas milage
3- Rough Engine idle and misfire

Figure 19 oxygen sensor

SPEED TIMING SENSOR

Figure 20 speed Timing sensor

27
Engines needs a speed timing sensor (note that some engines have more than one speed
timing sensor). You might be more familiar with this as the crankshaft sensor. The speed
timing sensor is responsible for monitoring the teeth on the crankshaft as it spins.
The spin of the crankshaft actually creates a magnetic field around the sensor (which is a
magnetic coil).
As the teeth pass, they create minute fluctuations in the field, which the sensor detects. This
information is transmitted to the car’s computer, which uses that data to adjust things like
variable valve timing, the amount of fuel to be injected into each cylinder and more Your
car’s speed timing sensor is in use at any point that the engine is running. Because of that, it
is subjected to a lot of wear and tear. There are also other issues that could affect its
longevity, including contaminants, debris, and the like. Additionally, the wiring harness could
be damaged, which would prevent the sensor from transmitting information to the car’s
computer It’s important to know some of the more common symptoms of speed timing sensor
failure so you can be prepared for it. These include: The Check Engine light is on in the dash,
the engine runs rough (misfire), Loss of power from the engine, The engine may not crank

MASS AIR FLOW SENSOR

Figure21 Mass Air Flow Sensor

The right amount of air and fuel in your engine is a vital component in keeping
the engine running as it should. Making sure that all of the vital components of
the air and fuel system are running at peak condition is the best way to keep a car
running at peak condition. The mass airflow sensor records the amount of air that
is coming into the engine and will then calculate how much fuel is needed to
offset it.

28
Without a properly working mass airflow sensor, it will be nearly impossible to
keep your car running as intended. Addressing the issues with the mass air flow
sensor in a hurry will reduce the amount of
trouble that you have and can also reduce the damage that is done to the vehicle.

When your mass air flow sensor is going bad, here are some of the things that
you may notice: The car does not have the power that it once did, there is an
excessive amount of fuel being used, the car will not start due to carbon clogging
the sensor, the Check Engine Light is on Taking these signs seriously and getting
the right repairs performed will help to restore the performance that your car has
lost. Having professionals perform this type of repair is the best way to get the
right results
SPEED SENSOR

Figure22 speed sensor

The vehicle speed sensor (VSS) is usually located on the transmission’s output
shaft (although it can be located in other areas). It’s responsible for sending a
signal to the car’s computer that tells it how fast the vehicle is traveling

29
The speed sensor is also tied into the car’s anti-lock braking system and helps provide
information that is used in determining when ABS should be activated and when it
should not be.

The speed sensor is in use any time your car is in motion. Thus, it’s exposed to a lot of
heat, wear and tear.

If your car’s speed sensor begins to fail, you’ll notice a very wide range of possible
these symptoms
include:
Inconsistent speedometer readings (the needle does not maintain a reading even though
you’re driving at a steady speed), Check Engine light is on, the transmission sounds like
it is revving very high before shifting, the speedometer doesn’t work, the overdrive light
flashes, the transmission struggles to shift into the highest gear, the ABS light is on in
the dash

OIL PRESSURE SENSOR

Figure23 oil pressure sensor

The lubrication that the oil in your engine offers is important in maintaining the car’s
functionality. A variety of parts go into ensuring that the oil supply in a car stays at peak levels.
Making sure that the
pressure level of the oil is right is the job of the oil pressure sensor. The oil pressure sensor
helps to send the information regarding the oil pressure to the gauge that is located on the
instrument cluster. In order
to keep a car running smoothly, you will have to be alerted when there is a problem with the
oil pressure. By having a fully functional pressure sensor, you will be able to get this

30
information easily.For the most part, you will not give your oil pressure sensor any thought
until there are repair issues. The location and important role that this part plays in your engine
is a big reason why allowing a professional to replace the oil pressure sensor would be a good
idea
Here are some of the things that you will notice when your oil pressure sensor is going out:
• The Oil Pressure light is on
• The oil pressure gauge is erratic
• The Check Engine light is on
As soon as you begin to notice that these symptoms are showing up, you will have to take the
time to get the appropriate repairs

TOP DEAD CENTER SENSOR

The top dead center (TDC) sensor is the point from which the firing order is determined, and
the ignition system measurements are taken. The measurements are normally defined as before
top dead center and after top dead center. The TDC is meant to be a reference point that tells
the spark plugs when it should fire and ignite the fuel in the combustion chamber
Over time, the sensor can go bad due to becoming old, wearing out, cracking, or starting to
corrode because of the harsh operating environment. If the sensor goes bad, the engine
control module will not receive the correct signal and the spark may be sent to the wrong
cylinder at the wrong time. This can cause your vehicle to have issues running, or it may
cause the engine to not run at all. Two of the biggest signs your TDC sensor is bad is the
Check Engine Light will come on and your vehicle will not start. Since the TDC sensor can
go bad over time, it is important that you can recognize the symptoms that indicate it needs to
be replaced

Tire pressure sensor

24 TDC Sensor Figure

The purpose of the tire pressure monitoring system (TPMS) in your vehicle is to warn you that
at least one or more tires are significantly under-inflated, possibly creating unsafe driving
conditions. The TPMS low tire pressure indicator is a yellow symbol that illuminates on the

31
dashboard instrument panel in the shape of a tire cross-section (that resembles a horseshoe)
with an exclamation point.

Figure 25 Indirect TPMS

Figure 26 Direct TPMS

SPARK PLUG
Spark plugs are an integral part of your vehicles motor as they provide the
much-needed spark that ignites the air and fuel mixture within the cylinders.
This continuous ignition is what keeps your car moving on the road.

32
If spark plugs are not checked with regular services, cleaned or changed,
when necessary, they can cause problems to occur with the vehicle’s engine.
Below are six signs for when to change your spark plugs:
When to change spark plugs
1. Engine has a rough idle
2. Having trouble starting your car?
3. Your engine misfires
4. Engine surging
5. High fuel consumption
6. Lack of acceleration

spark plug27 Figure

33
 Chapter (8)

ON-BOARD DIAGNOSTICS (OBD) SYSTEM

What Is the On-Board Diagnostics (OBD) System?

29 OBD device Figure OBD device28 Figure

Your car contains a vast number of different systems, all of which must work in harmony to
ensure proper operation. There must be a way to monitor your ignition and emissions systems
and the On- Board Diagnostics (OBD) is a computer that keeps tabs on what’s going on with
your vehicle.

What the OBD system does

Simply stated, the OBD system is an on-board computer that communicates with other systems,
including the ECU, TCU and more. It monitors the performance of your ignition system, engine
performance, transmission operation, emissions system operation and more. Based on feedback
from sensors around the vehicle, the OBD system determines if everything is working properly,
or if something is beginning to go wrong. It’s advanced enough to warn drivers before a serious
problem occurs, often at the first symptom of a failing component.
When the OBD system identifies an issue, it turns on a warning light in the dash (generally,
the Check Engine Light), and then stores a trouble code (called a DTC, or diagnostic trouble
code). A mechanic can connect a scan tool to the OBD II connector under the dash and read
this code. This provides the information needed to begin the diagnostic process. Note that

34
reading a code does not necessarily mean that the mechanic knows immediately what has gone
wrong, but that the mechanic has a place to begin looking.

As a note, the OBD system also determines whether your car will pass emissions testing. If the
Check Engine Light is on, your car won’t pass the test. There’s also a chance that it won’t pass
even if the Check Engine Light is not on.

How to tell if the OBD is working ?

Determining if your OBD system is working is actually very simple.
Start with the engine off. Turn the key to "on," and then run so that the engine cranks. Watch
the dash during this time. The Check Engine Light should flash on and stay on for a brief
period. It should then turn off. The brief flash on is the signal that the system is up and running,
and ready to monitor your vehicle during operation
if the Check Engine Light comes on and stays on, then there’s a trouble code (DTC) stored in
the computer that indicates a fault somewhere in the engine, the transmission or the emissions
system. This code should be checked by a mechanic so that an accurate repair can be made.
If the Check Engine Light does not flash and turn off (or if it never comes on at all), it’s a sign
that there is something wrong with the system, and it must be checked by a professional
mechanic.
Your vehicle will not pass annual testing without an operable OBD system, and you will also
have no way of knowing if something is wrong with the vehicle.

OBD-Codes Explained
OBD-II codes consist of a number of parts. Here is a sample OBD2 code: P0171
Here is a breakdown of what each digit of the code mean :
First Character - System
The first character identifies the system related to the trouble code.
P = Powertrain
B = Body
C = Chassis
U = Undefined

35
Second Digit - Code Type
The second digit identifies whether the code is a generic code or a manufacturer specific
code:

0 = Generic (this is the digit zero -- not the letter "O")

1 = Enhanced (manufacturer specific)

Third Digit - Sub-System

The third digit denotes the type of sub-system that pertains to the code
1 = Emission Management (Fuel or Air)
2 = Injector Circuit (Fuel or Air)
3 = Ignition or Misfire
4 = Emission Control
5 = Vehicle Speed & Idle Control
6 = Computer & Output Circuit
7 = Transmission
8 = Transmission

Fourth and Fifth Digits

These digits, along with the others, are variable, and relate to a particular problem.

Observation on the workshop

Figure30 Misfire
Figure31 report after OBDT

36
 Chapter (9)

Tools in the workshop

Figure 32 Tools in Workshop

37
 Chapter (10)

Safety

Most accidents in servicing/mechanical repair involve slips, trips and falls or poor manual
handling. Other causes of incidents sometimes resulting in serious injury or death include
working under inadequately supported vehicles, bridging the car battery with a spanner,
incidents involving petrol and vehicle movement. Keeping work areas free of clutter is an
important, but often overlooked, step in running a safe and productive workshop. Requiring
appropriate protective gear minimizes eye and finger lacerations, which are common auto body
shop injuries. Shops should purchase appropriate overall, safety boot, eyewear, and make
protective gloves available to prevent cuts from glass, sheet metal or other jagged objects.

Figure 33 safety Equipment’s

38
Safety Rules for Automotive Repair Shops
Working on vehicles can be a fun, exciting, and rewarding career. However, repair shop owners
and their staff need to ensure the proper safety precautions and rules are implemented and
followed at all times. Safety measures help protect employees from accidental injuries to
themselves, their co-workers, customers, and the vehicles they are repairing. The following is
a list of general safety tips every repair shop should use to keep everyone safe.

Figure 34 safety on workshop

Safety Gear You Should Wear in an Auto Shop

• Gloves to avoid burns when engines and other auto parts get extremely hot
• Safety goggles to prevent eye injury while working with chemicals, welding, or
grinding
• Work overalls or a protective uniform to protect your whole body from extreme
temperatures and dangerous chemicals
• Steel toe work boots with non-slip soles to protect your feet and reduce the risk of
slipping or falling
• Ear protection when using loud equipment: Common power tools used in auto repair
shops, such as disk sanders, impact wrenches, shop vacs, and electric drills, can create
enough noise to cause hearing damage over time
• A back brace when lifting heavy parts: Use proper lifting techniques and ask a
coworker for help or use hoists if needed

Auto Shop Organization Tips for Safety

• Organize your shop so your equipment and tools are safe and accessible. Securely
store tools and auto parts in cabinets to keep the shop free from clutter.
• Auto repair work can be full of fire hazards. Make sure your shop has easily
accessible and appropriate fire extinguishers for each type of fire: gas, oil, electrical.
Test fire alarms regularly.

39
 • Keep your work area clean and organized, so emergency exits are always clear and
easy to evacuate in case of a fire.

Auto Shop Flooring Care

• Spilled oil, transmission fluid, or other liquids can put you at risk for falls. Make sure
you clean up spills immediately.
• Floors should be swept and cleaned daily to avoid inhaling residue from dust particles
or chemical waste.

Chemical Caution in the Auto Shop

• Never eat or drink on the shop floor to avoid contamination from hazardous
chemicals.
• Follow proper state guidelines for disposing of chemical waste, especially flammables
such as gasoline or oil.
• Vent your shop adequately to reduce the risk of inhaling harmful fumes.
• Never ever smoke in or near the garage. The shop is full of flammable and
combustible fluids that can easily ignite if they come into contact with hot ash or a
cigarette butt.

Vehicle Safety in the Auto Shop

• Be sure that the vehicle is stopped, and the brakes are engaged before you start
working on it. Never work underneath a car unless it is adequately supported and
stable to avoid the risk of falling and causing injury.
• Remove keys from the ignition switch and cut the power supply to all electrical parts
before working on them to avoid electrocution. Besides an electrical shock to
yourself, electrical spikes may damage electronic components and wiring. Even when
the vehicle is off, there is still the potential for current to pass through electrical
wiring.
• Never place hands, tools, or other objects near the engine while it is running. The
moving parts could cause injury to you or damage to the vehicle.

CONCLUSION

Figure 35 safety on workshop

40
During my internship, I have learned a lot from working for this company. Internship is a
really good program in order to enhance the hands-on skills, abilities and knowledge more
about their course. It was a good experience and memories as not only I gained experience,
but also a new connections and knowledge. The internship was also good to find out what my
strengths and weaknesses are. This helped me to define what skills and knowledge I have to
improve in the coming time AL SELMY JEEP is a good place for internship. The work
environment is not that stressful. All the technician and staffs very friendly to me and
colleague. A very big thank you to my service manager DR Eman and the master technician
Engineer Kamel for the opportunity. Also for the other technician they also helped me a lot
to gain more
knowledge and helped me to polish my skill.
I think those few months of internship is not enough for me to learn more in detail the job. I
encourage for the student of Autotropic & Hybrid system to grab opportunity to do industrial
training because it will help a lot to identify your strength and weaknesses.

41
 REFERENCES
1. Taylor, C. F.: The Internal Combustion Engine in Theory and Practice, vol. I, p. 506, MIT Press.
2. Society of Automotive Engineers (1998). Automotive Engineering Handbook. Warren dale, PA:
Society of Automotive Engineers, Inc.
3. SIWES. (2008). Retrieved January 2015, from ITF: http://odich.com/itfnig/siwes.p
4. Paul Dempsey. (November 5, 2007). 4th Edition: Troubleshooting and Repair of Diesel Engine
5. wikipedia.com/automobile/dictionary
6. 1998 NAPA Institute of Automotive Technology. Introduction to OBD
7. Charles Fayette Taylor, 1995, The Internal Combustion Engine in Theory and Practice: Volume 1
8. Willard W. Pulkrabek : Engineering Fundamentals of the Internal Combustion E

42