Automotive Servicing

NC1
Community Based Training
What is Automobile
a vehicle used for carrying or transporting
passengers and load on streets and road
usually four-wheeled vehicle designed for
transportation
 The word automobile comes from the
French automobile that is made of Greek
autos meaning self moving and mobilis
meaning moving.
What is Automotive
The phrase automotive industry encompasses
not just all the cars and other passenger
vehicles made all over the world by all other
ancillary industries that are connected with,
and supply parts and systems to car makers.
In a broader sense, all repair and fuel stations
also come under automotive industry. All
sellers, marketers and manufacturers are also
included in automotive industry.
What is Engine
 Engine is the heart of an automobile.
 It is a device that converts chemical energy of

fuel into mechanical energy which is used to

drive vehicle.
 It is basically a device that produces power.
Types of Engine

 External combustion (E.C.) Engine

It is an engine in which combustion of fuel take
place outside of the engine. In this type of engine
heat, which is generated by burning of fuel is use
to convert the water or other low boiling
temperature fluid into steam. This high pressure
steam used to rotate a turbine. In this engine we
can use all solid, liquid and gases fuel. These
engines are generally used in driving locomotive,
ships, generation of electric power etc.
Nicolas Joseph Cugnot

was a French inventor who built the first working self

propelled land based mechanical vehicle, the worlds
first automobile.
Was born February, 26,1725 who died october,2,
1804.
 Internal Combustion (I.C.) Engine
It is an engine in which combustion of fuel take
place inside the engine. When the fuel burns inside
the engine cylinder, it generates a high temperature
and pressure. This high pressure force is exerted on
the piston (A device which free to moves inside the
cylinder and transmit the pressure force to crank by
use of connecting rod), which used to rotate the
wheels of vehicle. In these engines we can use only
gases and high volatile fuel like petrol, diesel. These
engines are generally used in automobile industries,
generation of electric power etc.
Types of Internal Combustion Engine

 I.C. engine is widely used in automobile

industries so it is also known as automobile
engine.

 An automobile engine may be classified in

many manners.
types of engine strokes
 According to number of stroke:
 1. Two stroke engine

 2. Four stroke engine

Definition of piston stroke
A phase of the engine's cycle (e.g.
compression stroke, exhaust stroke),
during which the piston travels from
top to bottom or vice versa. The type
of power cycle used by
a piston engine (e.g. two-stroke
engine, four-stroke engine).
"Stroke length", the distance travelled
by the piston in each cycle.
Firing Order
 The firing order is the sequence of
power delivery of each cylinder in a
multi-cylinder reciprocating engine.
This is achieved by sparking of the
spark plugs in a gasoline engine in the
correct order, or by the sequence of
fuel injection in a Diesel engine.
Running Mate
 Running mate are
two pistons moving at the
same time in the same
direction but performing
different strokes.
According to design of engine:

 Reciprocating engine (piston engine)

 Rotary engine (Wankel engine)

According to fuel used:

 Diesel
 Petrolium
 Bio- Gas
 Battery
According to method of ignition:

 Compression ignition engine

 Spark ignition engine
According to number of cylinder:
 Single cylinder engine
 Multi-cylinder engine
According to arrangement of cylinder
 1. In-line engine
 2. V-type engine
 3. Opposed cylinder engine
 4. W-type engine
 5. Opposite piston engine
 6. Radial engine 
v type engine
opposed cylinder engine
W type engine
Radial engine
According to air intake process
 Naturally aspirated
 Supercharged engine
 Turbocharged engine
BASIC ENGINE SYSTEM
Basic System of an Automobile
 Lubricating System
 Cooling System
 Fuel System
 Ignition System
 Starting and Charging System
 Braking System
 Suspension System
 Electrical System
Lubricating System
 Supplies oil and protect to all moving parts of
an engine.
 Oil also acts as a coolant to the engine

There are different variety of oil used in

Automobile Engine

Engine Oil Pressure

may vary according to manufacturer
7.1-70 psi
Method of Lubrication
Splashing Method
In the splash lubricating system, oil is
splashed up from the oil pan or oil trays in
the lower part of the crankcase. The oil is
thrown upward as droplets or fine mist and
provides adequate lubrication to valve
mechanisms, piston pins, cylinder walls, and
piston rings.
 This system is too uncertain for automotive
applications. One reason is that the level of
oil in the crankcase will vary greatly the
amount of lubrication received by the engine.
A high level results in excess lubrication and
oil consumption and a slightly low level
results in inadequate lubrication and failure
of the engine.
Combination Splash and Force Feed
 The oil from the pump enters the oil galleries.
From the oil galleries, it flows to the main
bearings and camshaft bearings. The main
bearings have oil-feed holes or grooves that
feed oil into drilled passages in the
crankshaft. The oil flows through these
passages to the connecting rod bearings.
From there, on some engines, it flows
through holes drilled in the connecting rods
to the piston-pin bearings.
 Cylinder walls are lubricated by splashing oil thrown off
from the connecting-rod bearings. Some engines use
small troughs under each connecting rod that are kept
full by small nozzles which deliver oil under pressure
from the oil pump. These oil nozzles deliver an
increasingly heavy stream as speed increases. At very
high speeds these oil streams are powerful enough to
strike the dippers directly. This causes a much heavier
splash so that adequate lubrication of the pistons and the
connecting-rod bearings is provided at higher speeds.
Force Feed
 A somewhat more complete pressurization of lubrication is achieved in
the force-feed lubrication system (fig. 6-31). Oil is forced by the 
oil pump from the crankcase to the main bearings and the camshaft 
bearings. Unlike the combination system the connecting-rod bearings
are also fed oil under pressure from the pump.
 Oil passages are drilled in the crankshaft to lead oil to the connecting-
rodbearings. The passages deliver oil from the main bearing journals to
the rod bearing journals. In some engines, these opening are holes that
line up once for every crankshaft revolution. In other engines, there are
annular grooves in the main bearings through which oil can feed
constantly into the hole in the crankshaft.
 The pressurized oil that lubricates the connecting- rod bearings goes on
to lubricate the pistons and walls by squirting out through strategically
drilled holes. This lubrication system is used in virtually all engines that
are equipped with semifloating piston pins.
Part of Lubricating System
 Oil Sump
 Oil Pump
◦ Recives power from the engine through belt and pulley arrangement

 Oil Strainer
◦ Collect and filter oil from oil sump
 Oil Pressure Regulator

 Oil Filter
 Oil Galleries
 Oil Sprout/High Pressure Nozzle
 Oil Pressure Gauge
 Oil Pan
Oil
 What does the "w" in a grade of motor oil stand for?
 The "w" in motor oil stands for winter. The first
number in the oil classification refers to a cold
weather viscosity. The lower this number is, the
less viscous your oil will be at low temperatures.
For example, a 5W- motor oil will flow better at
lower temperatures than a 15W- motor oil. The
higher number, following the “w” refers to hot
weather viscosity, or how fluid your oil is at hot
temperatures. The higher the number, the thicker
the oil at a specified temperature.
 LOW TEMPERATURES
 The first number followed by the letter W describes the

viscosity of oil at low temperatures (the W stands for winter).

The lower the number the thinner the oil. A thinner oil at low
temperatures is good because it flows more easily and is
therefore able to protect the engine when it is first started
from cold. If oil is too thick when cold, it will not circulate
freely and will reduce fuel economy.
 HIGH TEMPERATURES
 The second number describes how thick the oil is at the

engine’s normal operating temperature. The higher the

second number, the thicker the oil. If it's too thin when hot, it
may not protect effectively. If it's too thick, you lose
efficiency.
 There are different variety of oil used in
Automobile in example:
 Gasoline Engine

◦ SAE 15w-30
◦ SAE 20w-30
Diesel Engine
SAE 15w-40
SAE 20w-40
Cooling System
 Heat Transfer
◦ The transfer of heat is normally from a
high temperature object to a lower temperature
object.
3 Types of Heat Transfer
 Conduction
 Occurs when an object is directly contact with the hot
object.
Example : holding a hot mug by hand
Convection

occucrs in liquid and gases, heat transfer through the

movement of particles
warm particles rises and cool particles fill spaces below
Radiation
Transfer of heat particles through waves
Cooling System
I.C.E uses either air or a liquid to remove the waste
heat from an internal combustion engine. For small
or special purpose engines, air cooling makes for a
lightweight and relatively simple system.
The more complex circulating liquid-cooled
engines also ultimately reject waste heat to the air,
but circulating liquid improves heat transfer from
internal parts of the engine. Engines for watercraft
may use open-loop cooling, but air and surface
vehicles must recirculate a fixed volume of liquid.
Antifreeze/Coolant
 basically, coolant or antifreeze, which mixes with water in an
engine’s cooling system is designed to both lower the freezing
point and raise the boiling point of the system.
 Coolant or antifreeze is an alcohol-based additive that’s usually
green in color (although it can also be red, blue, and orange)
and made up of Ethylene Glycol.
 The boiling point of water is 100-degrees C. The accepted
pressure range for a car’s radiator is between 75-100kPa (or 11-
15psi) and with a mix of 33% coolant/antifreeze to water the
boiling point is raised to 121-125-degrees C. Change the ratio to
55% and this lifts to 125-129-degrees C.
Antifreeze/Coolant
The Components of a Cooling System

 Radiator
 Radiator Cooling Fans
 Pressure Cap & Reserve Tank
 Water Pump
 Thermostat
 Bypass System
 Head Gaskets
 Heater Core
 Hoses
Radiator
 an engine-cooling device in a motor vehicle
or aircraft consisting of a bank of thin tubes
in which circulating fluid is cooled by the
surrounding air.
Radiator Fans
 These fans are there to keep the air flow going
through the radiator while the vehicle is going slow
or is stopped with the engine running.  If these
fans stopped working, every time you came to a
stop, the engine temperature would begin rising.
Radiator Cap
 The radiator pressure cap is a simple device that will
maintain pressure in the cooling system up to a certain
point. 
 If the pressure builds up higher than the set pressure
point, there is a spring loaded valve, calibrated to the
correct Pounds per Square Inch (psi), to release the
pressure.
Reservior Tank
 the word reservoir refers to a place where
large amounts of water get stored.
Thermostat
 The thermostat is simply a valve that measures
the temperature of the coolant and, if it is hot
enough, opens to allow the coolant to flow through
the radiator. If the coolant is not hot enough, the
flow to the radiator is blocked and fluid is directed
to a bypass system that allows the coolant to
return directly back to the engine
Bypass System
 This is a passage that allows the coolant to
bypass the radiator and return directly back
to the engine.  Some engines use a rubber
hose, or a fixed steel tube
Radiator Hose
 There are several rubber hoses that make up
the plumbing to connect the components of
the cooling system.
Valve Clearance
 Valve Lash or Valve Clearance is the gap
between the Rocker Arms and the valve
tappet..
 This clearance must be tightly controlled.

 If it is too little, the valves may not seat

properly.

 If it is too much, you create valve train noise,

and excess load on the valves and valve train
components
Cylinder Head Gaskets
 .  The head gasket has several things it needs to
seal against.  The main thing is the combustion
pressure on each cylinder.  Oil and coolant must
easily flow between block and head and it is the
job of the head gasket to keep these fluids from
leaking out or into the combustion chamber, or
each other for that matter
Ignition System
Firing Order

the order of sparking of spark plug in the

cyclinders of a multi-cylinder engine
it may varries according to the number of
the cyclinder of an engine
power storkes also need to be equally
place to get an Equally Balanced Movement of
the Crankshaft
Ignition System
 Function
 Ignite fuel and air mixture
 Produces 30,000 volts across to spark plug
 Distribute high voltage of spark to each spark

plug in correct squence according to firing

order
IGNITION SYSTEM TYPES
 CONTACT POINT IGNITION SYSTEM
 ELECTRONIC IGNITION SYSTEM
 DISTRIBUTORLESS IGNITION SYSTEM
BASIC IGNITION SYSTEM
COMPONENTS
 BATTERY
 IGNITION SWITCH
 IGNITION COIL
 SWITCHING DEVICE
 SPARK PLUG
 IGNITION SYSTEM WIRES

BASIC IGNITION
Battery supplies power
to entire system SYSTEM
 Ignition Switch turns

engine on or off
 Coil transforms volts
 Switching device

triggers ignition coil

 Spark Plug and wires

distribute spark
 Ignition Parts
BATTERY provides power for system.

IGNITION SWITCH allows driver to turn ignition on and off.

IGNITION COIL changes battery voltage to 30,000V during

normal operation and has a potential to produce up to
60,000V.

SWITCHING DEVICE mechanical or electronic switch that

operates
Ignition coil(Pick-up coil, Crank sensor, Cam sensor).

SPARK PLUG uses high voltage from ignition coil to

produce an arc
in the combustion chamber.
PRIMARY CIRCUIT
 Consists of low
voltage wiring and
components
 Uses conventional

type automotive
primary wires
 Controls when

ignition will take

place. (When coil
Pg 115C
fires)
SECONDARY CIRCUIT
 Distributes current
to individual
cylinders to jump
spark plug gap
 Must have thicker,

heavier insulation
on wires
 Typical voltage to

jump gap - 10K

Volts
IGNITION COIL
 TRANSFORMER
 2 SETS OF

WINDINGS
◦ Primary windings
◦ Secondary windings
 IRON CORE
 PRODUCES

MAGNETIC FIELD
 Ignition Coil
Primary Windings are made up of several
hundred turns of heavy wire wrapped around
or near the secondary windings.

Secondary Windings consist of several

thousand
turns of very fine wire, located inside or
near
the secondary windings.
 Distributor

•Actuates the on/off cycle of current flow through the ignition coil
primary windings.

•It distributes the coils high voltage to the plugs wires.

Point Ignition System

PARTS Distributor Cam, Breaker Points, and Condenser.

 Point Ignition System

Points are wired in Primary Circuit – When the points are closed,
a magnetic field builds in the coil. When the points open, the field
collapses and voltage is sent to one of the spark plug.
DWELL (CAM ANGLE)
 Amount of time in
distributor degrees
that points remain
closed between
each opening
 Coil saturation time

is controlled by
amount of dwell
ELECTRONIC IGNITION SYSTEM
 Uses electronic
control circuit to
operate the
ignition coil
 More dependable

than contact
system
 Higher secondary

Ignition voltages
 Electronic Ignition System

•Trigger wheel passes by the pick-up coil.

•# of cylinders = # of teeth.
MAGNETIC PICK UP COIL
 Produces tiny
voltage pulses to
create magnetic
field changes
 Trigger Wheel

interrupts magnetic
field
 Tell control unit

(amplifier) when to
fire ignition coil
 Hall Effect element is HALL EFFECT
a solid state device
 Contains a DEVICE
permanent magnet
next to element
 A Tab shunts

magnetic field to
send signal to
control unit
 Signal is On or Off
SPARK PLUGS
 1 2 3 4 5
1.Normal
2.Overheated
3.Pre-ignition
4.Cracked
insulator 6 7 8 9 10
5.Bridged gap
6.Deposit
fouled
7.Carbon
glazed
8.Splashed
9.Glazed
10. Oil fouled
DISTRIBUTORLESS IGNITION
 Timing is very precise
 No mechanical parts to wear out
 Requires less maintenance
 Ignition timing is USUALLY not adjustable
 Computer relies on ignition sensors
 On-board computer controls ignition timing

usually through a ignition module

Distributor Cap

•Insulated plastic cap

•Transfers voltage from coil (wire) to Rotor.

 Distributor Rotor

•Transfers voltage from the distributor cap

center terminal(coil) to distributor cap
outer terminals(spark plugs).

•Provides spark in the correct Firing Order.

•Sometimes the firing order can be found

on the intake manifold.
The Distributorless Ignition System (DIS)

• Newer automobiles (1980 onwards) have

evolved from a mechanical system
(distributor) to a completely solid state
electronic system with no moving parts (Direct
Ignition type - SAAB).
• These systems are completely controlled by
the on-board computer ( ECU).
• In place of the distributor, there are multiple
coils that each serve one or two spark
plugs
What is horse power

 Is a unit of measurement of power or the rate

at which work is done
Engine Displacement
 Is the swept volume of all the pistons inside
the cylinder of a reciprocating Engine in the
in the movement from TDC and BDC And it
also represents the total volume of all the
cylinders in a cars engine.
Engine timing
 A timing belt ,timing Chain and timing gear is
a part of an internal combustion engine that
synchronized the rotation of the crank shaft
so that the engine valves open and close at
the proper times during each cylinders intake
and exhaust
What is timing mark
 A timing mark is an indicator used for setting
the timing of the ignition system of an engine
typically found on crankshaft pulley or the
flywheel, being the largest radius rotating at
crankshaft speed and therefore the place
where marks at one degree intervals will be
farthest apart.
Timing gears
 Timing gears are
markers that
found on a gear of
a timing geared
engine some times
marks are X,Y, And
Z but others are
numbers like 1,0
and 2
Timing gears
 Timing belt marks
 Timing belts are
commonly used on
small engines and also
use by a tensioners
and adjusters
Timing chain
 Timing chains
are also used
on automotive
engines due to
its simplicity
on design and
quietness.
Timing belt mark
Compression Test
Compression tests are usually done to test the engine in
racing cars and other vehicles with high-performance
engines.
The test can be used to diagnose problems in the engine or
to measure and improve engine performance.
Some basic knowledge about automobile parts and
maintenance is helpful if you want to learn how to do a
compression test.

 Wet Compression Test

 Dry Compression Test

Procedure in Compression Test
 Bring the engine to its normal running temperature.
 Switch off the engine completely before beginning the test.
 Remove the fuel pump relay. This will disable the fuel system since
the fuel will not be injected into the cylinders.
 Disconnect the electrical connection from the ignition coil pack. This
will disable the ignition system since the ignition coil pack will be
unable to create and distribute the spark from the spark plug.
 Take out the spark plugs and disconnect the wires for each spark
plug. Handle the spark plugs cautiously since the ceramic insulator
of a spark plug can break or malfunction if not handled delicately.
 Put the engine compression gauge into the first cylinder's spark plug
hole (this is the hole that is nearest to the drive belt). Don't use any
additional tools to tighten the compression gauge, you should only
use hand force.
 Ask a helper to start the engine. The needle on the
pressure gauge will rise and once the needle has risen to
its maximum reading your helper should stop the engine.
This maximum reading is the maximum compression
value for the first cylinder that you have just tested.
 Repeat the engine compression test for the other cylinders
until you have tested all of the cylinders on your engine.
 Readings for compression tests usually vary between 175
to 250 PSI (Pounds per Square Inch). A higher reading
generally indicates better engine performance; however
you should check your vehicle manual to find out what the
ideal reading should be for your vehicle.
What is the purpose of Turbo
Charger and Super Charger

This devices forces air into the cylinder

and maintain the normal air intake of the
engine especially in high altitude places.
Fuel System
Function of the fuel system is to store and
supply fuel to the cylinder chamber where it
can be mixed with air, vaporized, and burned
to produce energy.
Gasoline Engine Fuel System
Purpose of a fuel system of the internal
combustion engine is to provide a
combustible mixture of fuel and air into the
engine.
Gasoline
is a highly volatile flamamable liquid
hydrocarbon mixture used as a fuel for
internal combustion engine.
Properties of a good gasoline

 Proper voatility
 Resistance to detonation
 Oxidation inhibitors(prevent formation of

gum in the fuel system)

 Anti-rust agents
 Anti-icers
 Detergents to help keep the fuel system clean
 Dye for identification
Air – Fuel Mixture Ratio
 For proper combustion engine performance,
the right amount of air and fuel must be
mixed together. If too fuel or too little fuel is
used, engine power, fuel economy and
efficiency are reduced
 The theorethical air and fuel mixture in a 4

cylinder engine is14.7:1(14.7 parts air to 1

part fuel by weight)
Lean Air- Fuel Mixture
 It contains a large amount of air. For example
20:1 would be a verry lean mixture.
 Extra air in the cylinder ensures that all fuel

wi bell burned;however, too lean of a mixture

can cause por engine performance
 Lack of power, missing and even engine

damage
Rich Air-Fuel Mixture
 Contains a little more fuel mixed with air. For
gasoline,8:1 (8parts of air to 1 part of fuel) is
a very rich mixture.
 A slightly increase in fuel tends to increase

power, however, it also increase fuel

consumption and exhaust emission.
 A overly rich mixture will reduce engine

power, foul spark plugs, and cause

incomplete burning.(black smoke at engine
exhaust)
Diesel Fuel System
 Diesel
◦ Diesel fuel is heavier than gasoline beacause it
obtained from the residue of the crude oil after the
more volatile fuel have been removed.
◦ The efficiency of diesel fuel varies within the type of
engine in which is used.
◦ The compression ratio ranges between 14.1 :1 and
19:1. This ratio cause high engine compression
pressure of 400 – 600 psi and cylinder temp reach
800F to 1200F.
Diesel Fuel System(cont)
 It produces more power per pound of fuel,is
more reliable, has lower fuel consumption per
horsepower per hour and presents less of fire
hazzard.
Fuel System Parts
 GOVERNORS
◦ A governor is required on a diesel engine to control the
idling and maximum speeds of the engine, with some
governors being designed to control the speed within the
overall operating range of the engine. It is possible for the
operator to control the engine speed between idle and
maximum through the operation of the throttle. Idle and
maximum speeds must be controlled to prevent the engine
from stalling during low-speed idle and to keep the speed
from exceeding the maximum desired limits desired by the
manufacturer.
◦ The main reason that a diesel requires a governor is that a
diesel engine operates with excess air under all loads and
speeds.
Gauges
 The electric gauges used in the diesel fuel
system are the same types as used in the 
gasoline fuel system. Some manufacturers
use a bayonet type gauge permanently
attached to the filler cap of the fuel tank or
installed under the fuel cap. These are
graduated and the fuel level is checked by the
same method as oil in an engine.
Fuel Filters
 The purpose of any diesel 
fuel filter is mainly to remove
foreign particles as well as water.
The use of a suitable filtration
system on diesel engines is a must
to avoid damage to closely fitted
injection pump and injector
components. The components are
manufactured to tolerances as
little as 0.0025 mm; therefore,
insufficient fuel filtration can
cause serious problems.
 Six principal filter elements have been used
for many years
 :Pleated paper
 2. Packed cotton thread
 3. Wood fibers
 4. Mixtures of packed cotton and wood fibers
 5. Wound cotton or synthetic yarn
 6. Fiber glass
Water Separators
 Generally, when a fuel
filter/water separator is
used on a diesel engine, it
also serves as the primary
filter. There are a number
of manufacturers who
produce fuel filter/water
separators with their
concept of operation being
common and only design
variations being the major
difference. Basic operation
is as follows:
Water Separators(cont)
 The first stage of the fuel
filter/water separator uses a
pleated paper element to
change water particles into
large enough droplets that will
fall by gravity to a water sump
at the bottom of the filter.
 The second stage is made of
silicone-treated nylon that
acts as a safety device to
prevent small particles of
water that avoid the first stage
from passing into the engine.
 Fuel Feed Pump
 Fuel injection pumps must be
supplied with fuel under pressure
because they have insufficient
suction ability.
 All diesel injection
systems require a supply pump
to transfer fuel from the supply
tank through the filters and lines
to the injection pump. Supply
pumps can be either external or
internal to the injection pump.
 The two types of supply pumps
used on diesel engines today are
the gear type and the vane type.
Fuel Injector Nozzles
 Fuel injection nozzles (hereafter called "nozzles") are
enclosed in nozzle holders and mounted onto the engine
cylinder head. The fuel, that is pressurized to a high
pressure by the fuel injection pump, flows through the
injection steel pipe to the nozzle.
 The fuel is then injected from the nozzle into the

combustion chamber.
The injected fuel spreads in the cylinder, and after it
reaches a high temperature and comes in contact with
air, the fuel self-ignites and combusts. Therefore, the
quality of injected fuel from the nozzles is an important
factor in achieving a favorable combustion. Thus, the use
of good nozzles that are appropriate for the engine
greatly affects the performance of the engine.
Glow Plug
 The purpose of a glow plug is to beat up the
air that is drawn into the precombustion
chamber to assist starting, especially in cold
weather.
Types of Diesel Fuel Injection
Pump – Diesel Fuel Injection
Types of Diesel Fuel Injection
 Common Rail Injection
 Fuel tank- The storage compartment, under the trunk in most
cars, that holds the fuel for the vehicle. Also called the gas tank.

 Fuel pump- A vacuum device, operated either mechanically or

electrically, that is used to draw gasoline from the tank and sends
it into the carburetor or fuel injector nozzles. Mechanical pumps
have a Rocker arm that is activated by a cam on the camshaft; the
arm causes a diaphragm to move up and down, thus pulling the
gas through the pump. Some electrical pumps have a rocker arm
which is activated electrically and does the same thing as the
mechanical pump. Other electrical pumps are located at the
bottom of the fuel tank and push the fuel through the fuel lines.
 Fuel injection pump- A pump which receives
fuel from the fuel tank (often through the
fuel-feed pump in the case of diesel engines)
and delivers it under pressure to the
injectors.
  
 Fuel injector- A special nozzle which sprays

the proper amount of gasoline or diesel fuel

into the inlet ports, either directly into the
combustion chamber.
 Fuel line- The metal, plastic, or rubber hose
or pipe through which the fuel passes from
the fuel tank to the fuel pump to the
carburetor or fuel injector nozzle.
BRAKES
BRAKES
Friction is the resistance to motion between two objects in contact
with each other.
•Dry friction (Brakes)

•Greasy Friction (Wheel bearings)

•Viscous (Crank main bearings)

Friction varies with the roughness of the surfaces.

Kinetic (Motion) Friction

Static (Rest) Friction

BRAKES
Friction between Drums & Shoes or Pads & Rotors slows the car.

Friction between TIRES and ROAD stops the car.

BRAKES
•Air Brakes. (Pneumatic)

•Hydraulic Brakes use hydraulic fluid pressure to transmit power.

(Incompressible)

•Two pistons of same size will travel the same distance, with the
same force.

•If the small piston acts on a large piston,

the large piston will travel with more
force, but a shorter distance.

•If the larger piston acts on a small piston, the small piston will
travel a longer distance, but with less force.
 BRAKES
Brake Action

•Brake Pedal is connected to the Master Cylinder.

•Each wheel has a Wheel cylinder Or Caliper

(Rear) (Front)

•Each wheel has a brake Drum Or Disk

(Rear) (Front)

•Each wheel has Shoes Or Pads

(Rear) (Front)
BRAKES
When the vehicle comes to a stop, most of the weight is shifted
to the front

70% - 80% of the work is done by the front brakes

BRAKES
Brake Lining

Brake lining is made of various materials (Asbestos)

Some are bonded or glued to a metal plate.

Some are riveted to a metal plate.

Brake lining must be strong enough to absorb the heat and last
a long time, yet save the drums and rotors from wearing too quickly.
 BRAKES
Disk brakes found on front of most vehicles as well as at rear
of four wheel Disk brakes vehicles.

•Has a rotor/disk between two pads

•Caliper squeezes the pads against

the disk when the brakes are applied

•Disk brakes work much better then

the drum brakes, as they cool better
and apply more pressure.

CHOICES
•Metallic(last longer, but bad for rotor)
•Semi-metallic
•Ceramic
Steering system
Steering is the collection of components,
linkages, etc. which allow a vessels like ships
and boat or vehicle like
car motorcycle, bicycle to follow the desired
course.
Steering System
Provides the control of the travel of
direction of the vehicle it may be
Maneuverability, smooth recovery from
turn to turn
It also absorb the minimum road shock
of the road condition
Converts Circular Motion of the Steering
wheel in Linear Motion according to
road condition
Function OF steering system
 Control of the front wheel sometimes rear
wheel direction
 Transmit road feel to the drivers hand
 Maintain correct amount of effort needed to

turn the wheels

 Absorb most of the shock going to the

steering wheel as the tire hits holes and

bumps in the road
 Allow for suspension action
 Components of steering system
STEERING WHEEL :- A wheel turned by the driver of
a motor vehicle, ship, etc, when he or she wants to
change
the direction of the vehicle or ship.

STEERING COLUMN :- A shaft connecting the

steering wheel to the steering gear assembly. It is also
called steering shaft
STEERING GEAR :- The gear mounted on the
lower end of the steering column, that are used
to multiply the driver turning force. It converts
the rotary motion of the steering wheel into the
straight line motion.
STEERING LINKAGE :- The system that
connects the steering wheel to the front
wheel and allows the wheel to change
direction in response to command from
driver.
 Steering system types

Mechanical Power
Steering Steering

Rack & Hydrauli

Pinion c

Worm &
Roller Electric
 Mechanical steering

 Mechanical steering is a system in which

Mechanical force is used for steering.
Rack and Pinion
Rack-and-pinion steering-
 A rack-and-pinion gear set is enclosed in a

metal tube, with each end of the rack

protruding from the tube. A rod, called a tie
rod, connects to each end of the rack.
 BASIC RACK & PINION STEERING

PINION GEAR :- Rotated by the steering wheel

and steering shaft, it’s teeth mesh with the teeth on
the rack.
RACK :- Long steel bar with the teeth along one
section, slides sideways as the pinion gear turns.
 The pinion gear is attached to the steering shaft.
When you turn the steering wheel, the gear spins,
moving the rack. The tie rod at each end of the
rack connects to the steering arm on the spindle
(see diagram above).
 The rack-and-pinion gearset does two things:
 It converts the rotational motion of the steering

wheel into the linear motion needed to turn the

wheels.
 It provides a gear reduction, making it easier to

turn the wheels.

BASIC RACK & PINION
STEERING

GEAR HOUSING :-It Holds the pinion

gear and rack.

TIE RODS :- Connects the rack with the

steering
Knuckle.
 STEERING
LINKAGE

PITMAN ARM :- Transfers gearbox

motion to the
steering linkage.
Pitman arm is splinted to the gearbox
 STEERING LINKAGE
CENTER LINK ROD(RELAY ROD) :
Steel bar connects right and left side of
steering linkage. Connects to pitman
arm, tie rod and idler arm.

IDLER ARM :- Supports the end of the

Centre link on the
passenger side of the Vehicle.
Bolts to the vehicle frame.

TIE ROD ASSEMBLIES :- Two tie rods

assemblies are used
to fasten the centre link to steering
knuckles. Assembly is consist of inner
tie-rod end, Outer tie-rod end, and a
toe adjustment Sleeve.
Recirculating-ball steering
 - is used on many trucks and SUVs today.
The linkage that turns the wheels is slightly
different than on a rack-and-pinion system.
 The recirculating-ball steering gear contains a
worm gear. You can image the gear in two parts. The
first part is a block of metal with a threaded hole in
it. This block has gear teeth cut into the outside of it,
which engage a gear that moves the pitman arm (see
diagram above). The steering wheel connects to a
threaded rod, similar to a bolt, that sticks into the
hole in the block. When the steering wheel turns, it
turns the bolt. Instead of twisting further into the
block the way a regular bolt would, this bolt is held
fixed so that when it spins, it moves the block, which
moves the gear that turns the wheels.
 Instead of the bolt directly engaging the threads
in the block, all of the threads are filled with
ball bearings that recirculate through the gear as
it turns. The balls actually serve two purposes:
First, they reduce friction and wear in the gear;
second, they reduce slop in the gear. Slop would
be felt when you change the direction of the
steering wheel -- without the balls in the
steering gear, the teeth would come out of
contact with each other for a moment, making
the steering wheel feel loose.
 POWER STEERING
 An automobile steering system in which
the
engine’s power is used to supplement the
driver’s
effort in turning the steering wheel.

 There are two types of power steering

1 Electric power steering

2 Hydraulic power steering
 ELECTRIC POWER STEERING

Electric power steering uses the electric motor to

assist the driver of a vehicle. Sensors detect the
position and torque of the steering column and
computer module applies assistive torque via the
motor, which connects to either the steering gear or
steering column.
 Hydraulic power steering

 Most power steering systems work by using a

hydraulic system to steer the vehicle’s wheels.
The hydraulic pressure
typically comes from a
rotary vane pump driven
by the vehicle’s engine.
A double acting
hydraulic cylinder
applies a force to steering
gear which in turn
steer the road wheel. The steering wheel
operates valve to control flow to the cylinder.
Power Rack and Pinion
 When the rack-and-pinion is in a power-
steering system, the rack has a slightly
different design.
 Part of the rack contains a cylinder with a
piston in the middle. The piston is connected
to the rack. There are two fluid ports, one on
either side of the piston. Supplying higher-
pressure fluid to one side of the piston forces
the piston to move, which in turn moves the
rack, providing the power assist.
Suspension System