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A Textbook of AUT@MOBILE wlio ~—~ cad Sah Lo R. K. Rajput Sat ee JP as a Published by : LAXMI PUBLICATIONS (P) LTD 118, Golden House, Daryaganj, New Dethi-110002 Phone : 011-48 53 25 00 Fax : 011-43 53 25 28 www.laxmipublications.com info@laxmipublications.com Compiled by : Smt. Ramesh Rajput © All rights reserved with the Author and Publishers. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise without the prior written permission of the publisher. Price’: Rs. 350.00 Only. First Edition ; 2007 Offices : India USA Bangalore (Phone : 080-26 61 15 61) © Boston © Chennai (Phone : 044-24 34 47 26) 11, Leavitt Street, Hingham, © Cochin (Phone : 0484-239 70 04) MA 02043, USA © Guwahati (Phones : 0361-254 36 69, 251 38 81) Phone : 781-740-4487 © Hyderabad (Phone : 040-24 75 02 47) e Jalandhar City (Phone : 0181-222 12 72) © Kolkata (Phones : 033-22 27 37 73, 22 27 52 47) ‘» Lucknow (Phone : 0522-220 95 78) © Mumbai (Phones : 022-24 91 54 15, 24 92 78 69) ‘@ Ranchi (Phone : 0651-230 77 64) EAE-0697-350-AUTOMOBILE ENGINEERING ‘C—13047/06/08 ‘Typeset at : Goswami Printers, Delhi. Printed at : Mebra Offset Press, Delhi. EE EEREESEERERERER 218. g Heat Engines Devel of LC. Engines ‘Classification of LC. Engines Application of LC. Engines ‘Engine Cycle-Energy Balance Basic Idea of LC. Engines Different Parts of ILC. Engines ‘Terms Connected with I.C. Engines Working Cycles Indicator Diagram Four Stroke Cycle Engines Intake for Compression Ignition Engines Comparison of Four Stroke and Two Stroke Cycle Engines Comparison of Spark Ignition (S.) and Compression Ignition (C.I.) Engines Comparison between a Petrol and a Diesel Engi How to Tell a Two Stroke Cycle Engine from a Four Stroke Cycle Engine ? 1. Combustion in S.. Engines Introduction to Combustion in S.J. Engines Combustion Phenomenon Copyrighted U Sf 8 82 BERERPBEBBESREE f diivB cana F I (vii) 2.21, Spark Advance and Factors Affecting J; 2.23, Detonation 2.24, eetegtis: Neier a | 2.25. Useful Com; UCR), [roa e | 2.20, Effect of Engine Variables on Ignition | | | 227. Some Types of Combustion Chambers - IIL Combustion in C.I Engines 2.28, Introduction to Combustion in C.I. Engines oe 2.29, Combustion Phenomenon in C.1. Engines ae 2.30. Fundamentals of the Combustion Process in Diesel Engines me 2.81. Delay Period ition Lag) in C.1. Engi 2.32. Diesel Knock 2.38. 234, -EBR EREREERR a C1 Engine Combustion Chambers “ | 284. Cold Starting of C.l. Engines oe | IV. Two Stroke Engines General_As Intake for Two stroke Cycle Engines Scavenging P: Scavenging Parameters Scavenging Systems Cranixease Scavenging Scavenging Pumps and Blowers Y. Fuels for ILC Engines Conventic Fuels (for 1.C. ) Alternative Fuels for 1.C. Engines V1. Superet of LO. Purpose of Supercharging ‘Supercharging of S.J. Engines Supercharging of C.l. Engines - ‘Modification of an Engine for Supercharging ments BE RREEE BEEREEE EE are | BEE BERR BEBEBEE RE EEERERBE Es Copyrighted material aL (viii) VIL Miscellaneous Engines Dual-fuel and Multi-fuel Engines Stratified Charge Engine The Wankel Rotary Combustion (RC) Engine Veriable Compression Ratio (VOR) Engines Free-Piston Engine Plant IX. Air Pollution from IC. Engines and ita Control }. Introduction to Air Pollution from I.C. Engines . Pollutants ‘Spark Ignition (S.1.) Engine Emissions 1. Engine Emission Control Diesel Smoke and Control Comparison of Gasoline and Diesel Emissions Zero Emission Air Pollution from Gas Turbines and its Control Effects of Engine Emissions on Human Health Comparative Data of Constructional Features of Engines of Some India Vehicles Air, Fuel and Exhaust Gases Circuits of Petrol and Diesel Engines L SL Engines Introduction to Carburetion and Carburettors: Induction Transient Mixture Requirements A Simple or Elementary Carburettor ‘Complete Carburettor Carburetiors . Petrol Injection Theory of Simple Carburettor IL CL. Engines |. Introduction to Fuel Injection Systems for C.I. Engines . Functions! Requirements of an Injection System ;. Functions of a Fuel Injection System BEBRRBBSEES 8 i BEEBE 315 316 316 Chapter 3.16. 3.18. 3.21. 3.22. (x) Fuel Injection Systems Fuel Pump and Fuel Injector (Atomiser) ‘Types of Nozzles and Fuel Spray Patterns Engine Starting Systems Fuel Injection Com} in OL. Engi ‘Troubleshooting of a Fuel System Troubleshooting of Carburetior Comparative Diesel Engine Fuel System Data of aia r Short Answer Questions Highlights Objective Type Questions Theoretical Questions Unsolved Examples Effect of Engine Parameters on Engine Friction Determination of Engine Friction Lubrication Lubrication Systems Crankease Ventilation Lubrication System of Some Indian Vehicles Short Answer Questions Highli ee ioe Type Quest Theoretical Questions a FERE | EEEESEE Necessity of © Areas of Heat Flow in Engines Gas Temperature Variation Heat Transfer, Temperature Distribution and Temperature Profiles Effects of Operating Variables on Engine Heat Transfer Cooling Air and Water Requirements Cooling Systems Components of Water Cooling System Specifications for the Cooling System of an Engine Troubleshooting of Cooling System Cooling System Data of Some Indian Vehicles Short Answer Questions Highlights jective tions Theoretical Questions SBBE i BEREREE BESEBBEREEE 3 cent BRABEBREREEE GREER & i EREEREEE BEERE 7, ‘TRANSMISSION SYSTEM Tals 12 13. ‘LA 15. 16. LL it 516 Highlights 521 Objective Type Questions 522 Theoretical Questions 525 8 STEERING AND FRONT AXLE 528-558 ___ A: Steering System ; 8.1. Purpose of a Steering System — 528 82, Functions of a Steering System 528 83, Requirements of a Good Steering System ‘629 84, General arrangement of a Steering System 529 85, Steering Gears ! aL 86, Steering Ratio 534 Copyrighted material iQ BEE BEEEREEEREE ‘ ar 28 (ai) Power-Steering Adjustment of Steering Geometry Steering Troubleshooting Comparative ing Data of Some Indian Automobiles B. Front Azle Introduction to Front Axle Construction of Front Axle ‘Types of Front Axles Stub Axles Short Answer tions Highlights Objective Type Questions Theoretical Questions 9, __BRAKING SYSTEM EBREBBE 9.8. 9.9. 9.10. BEEEEEREEE Introduction to Braki m Necessity of a Braking Sj Functions of Brakes ments of a Good Br 7m Classification of Brak Mechanical Brakes Hydraulic Brakes Power Brakes Brake Effectiveness Factors Controlling the Stop of an Automobile Arrangement of Brakes in Different Vehicles Brake Shoes and Linings Brake Drum Brake Shoe Holding Down Arrangements Brake Testers Brake Service Troubleshooting Chart of Hydraulic Brakes System Troubleshooting Chart of Air Brakes Troubleshooting Chart of Brake Shoes and Drums Comparative Brake Data of Some Indian Vehicles Short Answer Questions Highlights Objective Type Questions Theoretical Questions es SSEES2BE BEREREEEEEE F g a 576 (aii) Chapter Pages 10._AUTOMOTIVE ELECTRICAL SYSTEM 580690 10.1. Introduction to Electrical System “ 589 1. Starting System Introduction to starting System “ 591 The Battery 591 Starting Motor (or Self-starter) is 608 IL. Charging system 10.5. Introduction to Charging System “ 615 10.6, Generator (Dynamo) 615 10.7, Alternator (A.C. generator) 621 Til, Ignition System 10.8. Introduction to Ignition System we 626 10.9. Purpose of Ignition System 627 10.10. Requirements of an Ignition System ' 627 10.11. Basic Ignition Systems as 627 10.12. Battery (or coil) Ignition System ss 628 10.12. Magneto Ignition System - 635 10.14. Firing Order i 637 10.15. Ignition Timing : 638 10.16. Spark Plugs o 641 10.17. Limitations of Conventional Ignition ie 643 10.18. Electronic Ignition Systems oa 644 10.19. Troubleshooting of Ignition System . 647 IV. Lighting and Accessory System 10.20, Introduction to Lighting and Accessory System 649 10.21, Main Cireuits of the Automobile Electrical 649 10.22. Lighting System 653 10.23. Accessories i 661 Short Answer Questions . 676 Highlights 681 Objective Type Questions 688 Theoretical Questions i 688 691—744 i a1 112. Troubleshooting ‘i 125 Short Answer Questions “ ‘741 Highlights 142 Objective Type Questions ". 143 Theoretical Questions $8 143 12, MISCELLANY 745—863 12.1. Gas Power Cycles zs 45 Chapter 12.3. 12.4, 12.5. 12.6. (iii) Automotive Gas Turhines Automobile Body and Safety Considerations Car Driving Fuel Saving Garage Tools and Equipment Technical Specifications of Automotive Vehicles Short Answer Questions Highlights Objective Type Questions Theoretical Questions ADDITIONAL OBJECTIVE TYPE QUESTIONS’ BANK APPENDICES INDEX 790 1 Introduction 1.1. Introduction to an automobile. 1.2. Brief history of automobile. 1.3. Classification of automobiles. 1.4. Parts of an automobile—mechanical portion—chassis and transmission—the engine—electrical system—body or carriage portion. 1.5. Description of an automobile. 1.6. Performance of an automobile—Short Answer Questions—Highlights—Objective Type Questions—Theoretical Questions. 1.1. INTRODUCTION TO AN AUTOMOBILE Automobile. An “automobile” is a self-propelled vehicle driven by an internal combustion engine and is used for transportation of passengers and goods on ground. Examples : Bus, car, jeep, truck, tractor, scooter, motor cycle, ‘The modern automobile, in general, is essentially a transportation equipment unit. It con- sists of a “frame” supporting the “body” and certain “power developing and transmitting units” which are further supported by “tyres and wheels” through “springs and axles”. ‘An “engine” supplies the power, which is delivered by the “transmission system” to the wheels through the clutch or fluid coupling. Automobile engineering. Automobile (or automotive) engineering is a branch of engineer- ing in which we study all about the automobiles and have practice to propel them. — Mobile or motive means one which can move. Automobile or automotive means one which itself can move. The different names for the automobile are : @ Auto @ Automobile Autocar @ Autobuggy @ Car @ Motor @ Motor car @ Motor vehicle @ Motor coach @ Motor wagon © Horseless coach. 1,2, BRIEF HISTORY OF AUTOMOBILE ‘The famous years in early automobile history are as follows » Year Event @ 1769 French engineer Captain Nicholas Cugnot of France built the first road vehicle propelled by its own power (Attained a speed of about 2.5. m.p.h. in 15 minutes), © 1801 First steam carriage built by Richard Trevithick in England. 7 @ 1804 Oliver Evans built the finest American self-propelled steam vehicle. © 1827 Onesiphare Pacqueur of France invented first differential. e 1832 First 3-speed Transmission patented by W.H. James in England. © 1880 German and French efforts developed an internal combustion engine vehicle (which was used to carry fruits). The present day automobile i= the develop- ment of this vehicle. 2 AUTOMOBILE ENGINEERING © 1885 Benz in Germany developed tricycle propelled by an internal combustion engine. © 1886 One of the first gasoline engine powered automobiles by Gottlieb Daimler of Germany. © 1894 Panhard and Levassor in France developed a car which incorporated the chief features of the modern automobile. © 1895 First motor car race held. © 1897 First car arrived in India. © 1900 ‘The design of the automobile was so improved that it awakened the public to. the fact that this new form of transportation was really practical for use. © 1902 First volume of production car “The Curved Dash Oldsmobile” in America. © 1906 ‘The production and sale of these vehicles became a business. e@ 1908 Ford ‘T’ model car produced in America by Ford Motor Company (Ford started his model with an initial run of 20000 vehicles, an output unheard at that time). © 1911 First electric self-starter installed in the automobile © 1920 ‘There was a gradual change and refinement in automobile design ‘The design development of recent years has provided the owners with cars that are : — Safer; — Easier to drive ; — Comfortable ; — More reliable. “Germany is the birth place of the automobile. It was invented there, it went through its first paces there and it was developed there to @ high level of technical maturity. The list of German ‘automobile pioneers is a long one. Starting with Nicholas Cugnot, August Otto, Carl Benz, Gottlieb Daimler, Wilhelm Maybach and Rudolf Diesel and going all the way upto Ferdinand Posche and Felin Wankel.” .. From SCALA INTERNATIONAL Automobile in India : — In India the first motor car appeared in 1897. For about 50 years from 1897, India was an importer of automobiles. — The late Bharat Ratna Sir M. Vivesvaraya made an automobile industry in India, but the government did not approve the plan. — In 1943 and 1944 two automobile factories namely, Hindustan Motors Limited, Caleutta and premier Automobiles Limited, Bombay were set up in India. At present, several automobile companies are manufacturing automobiles. Use of Diesel engines in cars : Following are the advantages of using Diesel engines in cars : 1, Diesel fuel is much cheaper than petrol. 2. The diesel engine uses 50 per cent less fuel in heavy traffic than does the available spark- ignition engine. — One reason for extra economy is that diesel’s good low-speed torque makes it possible to drive at low speeds in a higher gear. 3. The high thermal efficiency of the diesel engine, reflected in low specific fuel consumption gives its high advantages in the matter of range. 4. The crankshaft speed of about 5000 r.p.m. enables the diesel engine to propel the cars at high speeds, with acceleration comparable to that of S.I. engine. INTRODUCTION 3 5. The use of diesel engine eliminates the complication of spark-ignition with its spark plugs, breaker points, condenser, ignition cables, distributor rotor and other components that may have to be replaced several times during the life of engine. 6, Operating tests are further reduced by having no carburettor to service periodically. 7. Owing to the absence of electrical ignition equipment, non-volatile fuel end lower exhaust, temperature, the diesel engine is a much smaller fire risk than the petrol engine when working in losed places and in the neighbourhood of inflammable material. 8, The special foature of diesel engines called “torque back up” (an inbuilt performance fea- ture) makes it convenient for the vehicle to climb a steep incline (such as ghats) with low consump- tion at high load. Under these conditions diesel engines run comparatively cold than an equivalent petrol engine under the similar load conditions. Inspite of all the above mentioned advantages uptill now, diesel engines for cars were re- jected from majority of customers, due to their heavy weight and size, high noise, vibration and smoke levels. These problems finally led to the development of compact, light weight and fuel effi- cient passenger car diesel engines. In this connection, the reference needs to be mentioned to : — Over-square bore-stroke ratio ; — Fast responding value gear trains ; — Cold starting equipments ; — Combustion chamber design ; — Fuel injection equipment ; — Solution of metallurgical problems to ensure satisfactory working life of aluminium alloy components, crankshaft journals, bearings, cylinder bores and other highly stressed components. © The sacrifice of German engineer Rudolf Diesel is memorable in Automobile and I.C. engine history. He got very seriously injured when he successfully exploded coal dust as fuel. And in 1913 although he invented Diesel engine using liquid fuel ‘Diesel’ but he committed suicide as he could not get financial co-operation from his friend for his research and development. 1.3. CLASSIFICATION OF AUTOMOBILES Automobiles can be classified with different regards which are as under : 1, Purpose : (i) Passenger carriers — Car, Jeep, Bus ete. Gi) Goods carriers — Truck ete. 2, Fuel used : (i) Petrol vehicle — Motor eycles, Scooters, Cara, Station wagons (ii) Diesel vehicle — Trucks, Buses ete. (iii) Gas vehicle — Coal gas turbine (iv) Electric — Using storage batteries (v) Steam — Using steam engine (obsolete). 3, Capacity : (i) HTV (Heavy Transport Vehicles) — Trucks, Buses, Dumpers ete. or HMV (Heavy Motor Vehicles) (i) LTV (Light Transport Vehicles) — Pick up, Station wagon (iii) LMV (Light Motor Vehicles) — deep, Cars (iv) Medium vehicle — Station wagon, Tempo, Minibus and small trucks.

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