Scan to download

free android App

AUTOMOTIVE BASICS

Engineering| www.CarEager.com

Victorious Managers Group (Private)

Sun-Roof

C Pillar

B Pillar

1. Car body construction

2. Engines

3. Fuel Supply in Petrol & Diesel Engines

4. Engine related systems

5. Drive Train

6. Suspension & steering

7. For safety

8. Emissions

9. Electrical & HVAC systems

Windshield

Bonnet

A Pillar

Door glass

Grille
Side view
Front door mirror
Bumper
Fender

WHATS IN PRESENTATION

1. CAR BODY CONSTRUCTION

Two main ways of automobile construction

1. Chassis and Body method (or Body-on-frame)
2. Monocoque method.
1. In the Chassis method the body is made as a separate unit and then joined with ladder type structure known as the
chassis. All other parts like steering, suspension etc. are attached to the chassis.
The benefit of chassis construction is higher load capacity and strength. But the body tends to vibrate easily & overall
vehicle handling and refinement is lower. Thus this application is used mostly for SUVs and bigger vehicles today.
2. Here, the ladder frame is absent and the components like the suspension, steering etc. are all bolted directly to the
body, the body is thus made sturdier. The advantages here are that the full car is now more solid and rattles and
squeaks are not easily developed. Handling is also better due to the higher body rigidity.
Only major drawback is the load carrying capacity is lower. For passenger cars this is not a major concern, and with
modern process Monocoque bodies are able to handle more loads.

1. CAR BODY CONSTRUCTION

2. ENGINES

Inline
All the cylinders of the engine are arranged in a straight line.

V-Engine
The cylinders are arranged in two blocks,
connected to the same crankshaft.

Flat / Horizontally Opposed

The cylinders are arranged in two blocks
connected to the same crankshaft and which
are horizontally opposed (flat).

2. ENGINES - CLASSIFICATION

Those Engines which gives the power at every second stroke of the piston
Spark plug
1 Stroke BDC to TDC Suction & Compression
st

As the piston moves upwards , air/fuel mixture enters the

crankcase through the inlet port.

Transfer port

At the same time air/fuel mixture is compressed in the

combustion chamber and ignited by spark plug.
2nd Stroke TDC to BDC Power & exhaust
As the air/fuel mixture gets ignited, combustion takes place
which gives power and as a result the piston moves
downwards and is called power stroke.
At the same time , Inlet port gets closed and the air/fuel
mixture in the crankcase is compressed and is forced in
to the combustion chamber through transfer port. which
in turn put the exhaust gases out of combustion chamber
and fills the chamber with a new charge.

TWO STROKE ENGINES

Crankcase

SPARK PLUG
EXHAUST
PORT

FRESH
AIR

EXHAUST

INLET
PORT

INTAKE &
COMPRESSION

COMBUSTION

TWO STROKE ENGINE CYCLES

SCAVENGING
SCAVENGING &
&
EXHAUST
EXHAUST

hese Engines gives one power stroke in every two revolutions of crankshaft. Four strokes of the engine are:
1 - Intake
The Piston moves
downwards from TDC to BDC taking the air fuel mixture inside the cylinder through inlet valve.
In this condition inlet valve remains open and exhaust
Valve remains closed

2 - Compression
The Piston moves upwards from BDC to TDC compressing the air fuel mixture. In this condition both inlet and
exhaust valves remains closed
As and when the piston
near the TDC, spark plug ignites. As a result combustion takes place
3 - Power
In this stroke , due to combustion the Piston
Moves downwards from TDC to BDC giving the power to the crankshaft

In this condition
both inlet and exhaustENGINES
valves remains closed.
FOUR
STROKE

Two Stroke Engines

Four Stroke Engines

It gives power in every revolution of

crankshaft

It gives power in every two revolution of

crankshaft

Valve less construction , due to which it is

lighter and cheaper

It is having valves in he construction so heavier

compared to 2 stroke engines

Less volumetric efficiency

More Volumetric efficiency

Cooling is difficult so it may result in

overheating

Cooling of the engine is easier

Lubrication system is simpler

Lubrication system is complex

Two Stroke Engines Vs. Four Stroke Engines

ROCKER ARMS
CAM SHAFT

INLET VALVE
SPARK PLUG

EXHAUST VALVE
PISTON RINGS
PISTON

CYLINDER BLOCK
CONNECTING ROD

CRANK SHAFT
SUMP

ENGINE BASIC TERMINOLOGY

1. Torque
Is the turning force/effort required to turn or twist any object
Torque = Force x Radial Distance
2. Engine Torque
Is the turning or twisting force developed by
engine at the crankshaft
As the engine runs it develops some amount of torque
(turning force), which varies with the rpm.
A high torque at low rpm will give the vehicle good pulling
power, and easy drivability.

Brake Horse Power (BHP) is the British unit of

measuring power, developed by an engine.
Power (BHP) of the engine depends on its torque and
engine speed (RPM)
BHP = IHP FHP
(IHP Indicated H.P & FHP Frictional H.P)
PS is a German term for Metric Horse Power a
different unit of measurement of power developed by
the engine.
1 Metric hp = 1 PS = 0.986 bhp

3. Engine Power
Power is a measure of how quickly work can be done (moving the car)
Power of the engine depends on its torque and engine speed (RPM). More the torque and
more the rpm, greater is the power

TERMS RELATED TO AN ENGINE

3. FUEL INTAKE

There are two types of fuel intake systems:

1. Carburetor
2. Fuel Injection
Carburetor functioning Air/fuel mixture is controlled by the combined working of
1. Carburetor
a) Venturi system
Petrol and air is mixed in the Carburetor b) Main jet, slow jet & starter jet
and then sent to combustion chamber.
c) The butterfly valve ( Accelerator pedal)
Main functions are :
1) To vaporize the fuel to get a
homogeneous air fuel mixture

Venturi system As the air flows through this venturi. A negative pressure
(vaccum) develops in the passage due to which fuel rises from the Jet and
mix up with the moving air forming a homogeneous air/fuel mixture.

2) To supply correct amount of air

The supply of fuel is
fuel mixture at different conditions At Idle condition
Fuel comes from the Slow jet .
At Running condition Fuel comes from the main jet
3) To keep small reserve of fuel at
At Starting condition Fuel comes from Starter jet.
constant level in the float level
Butterfly valve It controls the quantity of air going in to the combustion chamber and
Disadvantage It becomes difficult to ensure
accordingly fuel supply also varies in quantity. This valve is actuated
uniformity of Mixture quantity in multi cylinders.
through accelerator pedal.

FUEL INTAKE PETROL ENGINE

Sensors
TPS
CKP/CMP

IAT

ECT
MAP

VSS
O2

Air from air filter

ECM

Throttle body
Fuel

Fuel rail

1)
2)
3)
4)
5)
6)
7)
8)

Combustion
chamber

Injection Actuators
At intake manifolds

VSS
It gives the information about the vehicle speed
CKP/CMP It gives the information about the piston of the piston and the stroke
MAF
It gives the information about mass air flow entering the throttle body
MAP
- It gives the information about intake Manifold air pressure
O2 sensor It senses the oxygen level in the exhaust manifold, accordingly ECM decides monitors
the proportion of air-fuel going to the combustion chamber.
IAT It sends the Intake air temperature info and accordingly ECM monitors the A/F ratio
TPS Throttle position sensor gives information about the position of throttle (acceleration)
ECT it gives the information about the engine coolant temperature (engine temperature)

2) Fuel Injection system In these engines, Petrol in atomized form is sprayed

Separately in to the intake air, giving a homogenous
Air fuel mixture which burns more efficiently in
Combustion chamber.

Simultaneous injection

Fuel injection is of two types

1) Direct injection: In this fuel is sprayed directly into
the combustion chamber
2) Multi point fuel injection: In this fuel is injected in to
each intake port of the manifold

Injectors inject fuel for a group of

2 cylinders at a time in a sequential manner.

In this system all the injectors inject fuel

simultaneously into the intake Manifold.

Group sequential Injection

Sequential MPFI
one injector injects fuel for one cylinder at a time and the
injectors are timed to release fuel exactly the moment
it is needed

Multi point fuel injection

In this system there is separate injector for each cylinder mounted in the inlet port.
Injectors directs the fuel in to the intake manifold giving improved mixture preparation
and distribution.
Based on the timing of fuel injection MPFI is classified in following three types

MPFI system is controlled by a device called ECM Engine control module

Sensors

Actuators

Injectors

IAT

Igniter

MAP

EVAP

Knock

TPS

ENGINE CONTROL MODULE

(ECM/ECU)

ECT

EGR

MAF

CMP

Fuel pump

CKP

IAC
O2s

Total - 10 Sensors

VSS

Radiator fan

CONTROL SYSTEM OF MPFI

Current
Distributor Assembly

The function of the ignition coil is to boost the

battery voltage to a very high level needed for the
spark to ignite the fuel.
On most cars one coil is used to build current for
all the spark plugs.
Ignition Coil

Spark Plug

All Petrol cars require an ignition system to supply current to the spark plug.
Two main components of the system are the ignition coil and the distributor.

DDLI- Dual distributor less ignition system (Advanced Version)

IGNITION SYSTEM

The function of the distributor is to distribute

current from the ignition coil to the spark plugs at
the correct time.
Mostly the distributor is a mechanical device that
has an arm that rotates and distributes the current.

Diesel/Compression ignition Engines are of two types Indirect Injection

In this system , fuel is injected in Pre combustion chamber where the fuel and air
mixes completely and then the mixture goes to main combustion chamber
where actual combustion takes place.

Direct Injection
In this system , the fuel is injected directly in to
the combustion chamber.

FUEL INTAKE DIESEL ENGINE

High pressure pump

Common Fuel rail
fuel temp sensor
Fuel Pressure
Regulator

Fuel
filter
Water in fuel
sensor

Electric feed
pump

FUEL SUPPLY COMPONENTS

Rail
pressure
sensor
Electrically
operated
Solenoid

S.No

Petrol Engine (S.I)

Diesel Engine (C.I)

Mixture of Air & Petrol is drawn into the Cylinder and

compressed

Only air is compressed

Compression ratio
9:1 to 11:1 (min. to max.)

Compression ratio 15:1 to 24:1 resulting in

higher thermal efficiency & low fuel consumption

Less noisy and runs smoothly

Most of the engines are noisy compared to petrol

Low Volumetric efficiency

High Volumetric efficiency resulting in fuel

economy

Petrol is costly and more volatile

Diesel is cheaper and less volatile

Initial cost of engine is low

Initial cost of Engine is high due to more robust

construction

Lower combustion efficiency

Higher combustion efficiency

No heater plugs required for cold starting

Heater plugs required for colds starting

Petrol Engine (SI) Vs. Diesel Engine (CI)

4. ENGINE RELATED SYSTEMS

Lubrication System

Cooling System

ain functions of Lubricating oil is

o reduce wear and tear of the Engine parts.

ther functions
Cleaning - During its circulation , it dissolves
many impurities like carbon particles.
Cooling - During circulation , it takes heat from
the hot engine parts and delivers it to the
surrounding through crankcase .
Cushioning Oil layer can also serve as a cushion
against the shocks &vibrations produced by the
Engine parts.
Sealing - Lubricating oil also helps the piston ring
to maintain an effective seal against the high pressure
gases in the combustion chamber.

The Purpose of cooling system is to keep the

Engine at its most efficient operating temperature
At all speeds and under all operating conditions.
Some of the heat is absorbed by the cylinder
Walls, head and pistons. They in turn must
Be provided by some means of cooling so
That they will not get too hot.
Types of cooling systems
1) Air cooled
2) Water cooled
In Most of the Automobile cars, water cooling
System is used.

4. ENGINE RELATED SYSTEMS

Turbo-charger

Compressor

It is a device used to increase the Volumetric efficiency &

therefore Engine power by delivering pressurized air to the
Intake
Intake.

Exhaust
Waste
Gate

Exhaust gases move the turbine which is fitted in the

turbocharger.
Turbine in turn rotates the compressor rotor , which is
connected to the turbine by a shaft.
Compressor sucks the Fresh air coming from the air filter.
This pressurized air is sent to Intake manifold.
Waste Gate Valve prevents the turbocharger from
overcharging the
engine. as and when the air pressure in
the intake becomes too high, the waste gate valve opens and
as a result some percentage of exhaust
gases are sent
to exhaust line by passing the Turbocharger.

Turb
ine

valve

5. DRIVE TRAIN

Clutch -

Transmission system -

Clutch is placed between Engine & Gear box.

Transmission system is an assembly of gears &

shafts that varies the torque and speed coming
from the engine as per requirement & transmits
it to the drive axle through clutch.
Helical gear
Types of Gears used

Clutch Transmits Power from Engine to Gear Box.

It disconnects the power from engine to gear box

for smooth gear shifting operation & to stop the vehicle.

n all the MSIL products Diaphragm type of clutch

s used.

5. DRIVE TRAIN

Spur gear

Spur Gear
Helical gear
Planetary Gear

Planetary gear used in automatic transmission

Transmission system Type of transmissions

1) Manual Transmission
2) Automatic transmission
Manual transmission arrangement
3) Sliding mesh gears box
4) Constant mesh gears box
5) Synchromesh gear box
Types of transmission on basis of speed
6) 3 speed gear box
2) 4 speed gear box
3) 5 speed gear box

Transfer gear box

It is a secondary gear box
attached to the main gear box . It
takes the power from the main
gear box and delivers it to the
rear wheel or to all the four
wheels according to the driving
requirement and the selection.
Propeller shaft
It is used to transmit the power
from gear box to the differential
(Rear wheel)

r bo
e
f
s
n
Tra

x
pe
Pro

t
haf
s
r
lle

Automatic Transmission system -

Differential

There are three basic systems in

A/Transmission

- To differentiate the Torque evenly in both

left & right wheels

Torque converter
- It is a kind of device used to
transmit the power from Engine
to the Gear box

- To compensate the difference in distance

that the drive wheel travel when the car
rounds a turn

Hydraulic system
- Hydraulic pressure is used to
shift the gear system
Gear system
- Gears are shifted by
hydraulic pressure in response
to the car speed and throttle
opening.

Types of gears used in differential

1) Spur bevel Gears
2) Spiral bevel Gears

Bevel gear

Spiral bevel

Spur bevel

6. SUSPENSION & STEERING

Suspension System
System to absorb the road shocks to provide a
comfort feel to the passengers.
Control Arm

Types of suspension system

1. Rigid suspension
- In rigid suspension ,
both the wheels are connected through a
rigid beam. The shocks due to irregularities
are observed by one wheel is partially
Transferred to the second wheel.
IRREGULAR
SURFACE

TYRES

SPRINGS

SUSPENSION

AXLE

2. Independent Suspension
- In this system , each wheel is mounted
separately. The road irregularities observed by one
wheel do not affects the other wheel.

Strut assy.

TYPES OF INDEPENDENT SUSPENSION SYSTEMS

StrutIt is a support having one end connected to the
lower control arm and the
other to body ground.

1. McPherson Strut

This system uses a combination of

coil spring and shock absorber joined
together in the shape of tower as
shown in the figure.
The wheel is held at the bottom by a
control arm, thus in this system there
is no upper control arm.
This system is an independent
suspension system.

Extra Purpose To avoid the forward/reverse

movement of the control arm/wheel
McPherson while moving on bumps or at the time of braking.
Strut

3. Torsion Bar type

In this system , two long steel bars serves as a
Spring, One end attached to the frame and
other to the control arm. The spring action is
obtained due to the twisting movement of
Torsion Bar

2. Control Arm type Control arm is connected to the vehicle body at one end and holds the wheel at the
Other end. Generally two arms are used to hold the wheel, upper and lower control arms. The
spring and the shock absorber are placed between either upper or lower control arm.

Suspension System Components 1) Spring Function of spring is to absorb the shocks

due to road irregularities.
Commonly used springs
- Leaf Spring
- Coil Spring
2) Shock absorber It absorbs/damp the vibration of
spring. Commonly used Shock absorbers
-

Hydraulic Shock absorber

Gas filled shock absorber

3) Torsion bar Function of torsion bar is same as that

of spring. They are rigid at one end
and they twist around the center as the suspension
arm deflects.

SUSPENSION

Upper Mount

Piston
Fluid
Lower Mount

Reserve
Cylinder

Steering System
The purpose of steering system is to change the direction of the
vehicle movement as desired by the driver
Steering can be
1) Manually operated In this system , Drivers muscular
energy is directly used in steering the wheels of the vehicle
2) Power assisted In this Driver is aided by an external power
assistance so as to lower down the steering effort.
Mode of operation
Hydraulic - Pressure generated by a power steering pump.

Components of steering system

1) Steering gear box - Steering gear box converts

rotary motion of the steering wheels in to the linear
motion of the tie rod which is connected to both
left and right wheels.
Types of Steering boxes

2) Worm and Worm gear

3) Re-circulating ball & Nut type
4) Rack and Pinion type
(Steering can be either be manual or power assisted)

Electric aka Electric Power Steering (EPS)

- An electric motor driven by the vehicle electrical system and
controlled by ECU. Also known as
Hydraulic Power
Steering

STEERING

Electric Power
Steering

7. FOR SAFETY

BRAKES
Components of Hydraulic assisted brakes
The Purpose of brake is to slow down or stop the
vehicle when ever required.
Brakes can be of three types
1) Drum Brakes Where a set of brake liners expand
against a brake drum leading to braking of he vehicle.
This is operated manually or hydraulically.
2) Disc Brakes Where a set of Brake liners expand
against a Brake disc leading to braking of the vehicle.

Primary piston

Secondary
piston

Booster

Reservoir

Master cylinder

Brake Pedal

5 way
union

Disc Brake
Drum Brake
Vacuum assisted Hydraulically operated Brakes
Cylinder
In this type of brakes , Drum/Disc brakes are actuated Master
It Converts Driver foot effort in to hydraulic pressure and transmits it to the
by the force of hydraulic pressure.
wheel cylinders.

Brake Booster Bake booster is fitted in between the Master

Cylinder and brake pedal. It supplies the additional force to the master
cylinder as the driver presses the pedal.

SAFETY

Vacuum pump It generates vacuum for the Brake booster.

Anti Lock Brake System (ABS)

The function of the ABS unit is to prevent wheel

lock up (skidding of wheel) under braking.

Wheel lock up (stopping of wheel) is not desired

for the following reasons:-

Without ABS

With ABS

1) With the wheel lock up the weight of the moving car

slides the car further, thus increasing the braking
distance.
VSS Sensors are mounted on all four wheels.
It senses when lock up is about to happen,
and the ABS unit regulates (decreases)
pressure to that wheel accordingly.
Thus under braking, ABS prevents wheel lock
& maintains steering control, on all surfaces.

2) As the wheel is stopped, steering the car is no longer

possible and driver can loose the direction control.
Tyres wear out faster.

SAFETY

CRUMPLE ZONES DEFORMATION SAFETY

Crumple Zones are deformable

structures, provided in the car.
Advantage: These are
intentionally designed to deform
during an accident and absorb
the impact of the collision.

SIDE IMPACT BARS DEFORMATION SAFETY

SAFETY

The side impact bars are provided inside the doors to

reduce injuries during collisions into the side of the car.

Supplementary Restraint System (SRS) (Air Bags)

Airbags are for protecting head and

chest region of passengers
Present in the Steering wheel for the
driver, dashboard area for the Co Driver
and in doors/roof for rear passengers.

In an accident, the air bag system ignites certain elements, which

burn rapidly to create a large volume of gas (Ammonium Nitrate) to inflate the bag.
The bag then bursts at up to 200 mph, faster than the blink of an eye! Thus
cushioning the occupants. A second or so later, the gas dissipates.
A Word Of Caution: Children generally below the age of 12 should not travel in the
front when cars are equipped with the airbag.

SAFETY

Additional Safety Features

Pre-tensioner (in seat belts):

Load Limiter:
They are devices which incase of a severe impact, tighten the The load limiters are used to minimize severe injuries
seat belt and prevent the slight forward motion that normal
that may be caused by the pre-tensioner. Thus in a
ELR seat belts have.
severe impact, the pre-tensioner pulls the occupant in,
while the airbag fully inflates and then the load limiter
They do so by either pulling the belt downwards near the reel
releases some of the belt from the reel, so that the
or pulling the belt buckle. They are mostly used in
conjunction with airbags and load limiters and hold a person
occupant is cushioned by the inflated airbag.
in for just a short while, enough for the airbag to fully inflate.
Like airbags if once used, new ones have to be installed.
Head Restraints
Head restraints installed on top of the seat reduce the risk of
neck injuries (whiplash injuries) in the case of a rear collision.

Proper Restraint

Without Proper
Restraint

SAFETY

8. EMISSIONS CONTROL

1.Exhaust gas recirculation

A part of Exhaust gases are reused for combustion so as to
bring down the NOx level in emission (lowering down the
Engine temperature).
2. Reduction catalyst

2. Positive Crankcase ventilation

- Air/fuel vapors are segregated from Blow by gas
It uses Platinum and rhodium to help in reducing NOx emission
(constituting Engine oil vapors & air/fuel vapors) and sentWhen
backan NO or NO2 molecule contacts the catalyst, the catalyst rips the
nitrogen atom out of the molecule and holds on to it, freeing the oxygen in the
to the intake manifold.
form of O2. The nitrogen atoms bond with other nitrogen atoms that are also
stuck to the catalyst, forming N2. For example:

3. Evaporative emission control System

In this system , fuel vapors from the fuel tank are send2NO
to => N2 + O2 or 2NO2 => N2 + 2O2
Intake manifold.
4. Catalytic converter
It consists mainly of three elements

1) Honeycomb
2) Reduction catalyst
3) Oxidation Catalyst

EMISSIONS

3. Oxidation Catalyst
The oxidation catalyst is the second stage of the catalytic converter. It reduces
the unburned hydrocarbons and carbon monoxide by burning (oxidizing) them
over a platinum and palladium catalyst. This catalyst aids the reaction of the CO and
hydrocarbons with the remaining oxygen in the exhaust gas.
For example:
2CO + O2 => 2CO2

9. ELECTRICAL & HVAC

Charging System
The function of charging system in Automobile is to
generate, regulate and supply the electrical energy
for charging the battery.
-

To supply the current demands of all the loads.

To supply constant voltage at all the conditions.

Alternator It converts the mechanical energy coming

from the engine in to the Electrical energy.
Current produced by Alternator is
A.C Alternating current
Due to the movement of rotor inside the stator, magnetic
field develops and as a result Alternating current is
produced.

ELECTRICAL

Regulator The function of regulator is to control/regulate the

voltage coming from the alternator.
Rectifier The function of rectifier is to change the AC current
in to DC current.
Starting circuit To start the engine battery voltage is supplied
to the starter motor as the
driver switches on the ignition.

HVAC allows the passengers to control the climate

conditions inside the vehicle to their comfort and
convenience. The Basic functions of HVAC:
Cooling + Heating + Ventilation
1) Compressor Compressor sucks the refrigerant from the
evaporator and delivers at high pressure to the condenser.
2) Condenser Condenser is just like radiator in which Hot
refrigent is cooled.
3) Receiver/Drier bottle Receives the compressed and cooled
refrigerant and removes the moisture from that and also acts
as a reservior.
4) Expansion Valve Receives cooled and compressed
refrigerant, expands it and passes it to the evaporator.
Expanded refrigerant gases are very cold.
5) Evaporator it is similar to radiator. The expanded cold
refrigerant is passed over warm air from inside the vehicle.
6) Blower Blower fan sucks warm air from inside the
vehicle and passes it over the evaporator so as to cool the
interior.

HVAC

THANK YOU!
AUTOMOTIVE BASICS PRESENTATION BY -

CarEager.com

fa c e b o o k .co m / C a rE a ge rW o rld
tw i e r.c o m / C a rE a ge rW o rld
in sta gra m . co m / C a rE a ge rW o rld
p lu s.go o gle . co m / +C a rE a ge rW o rld

Automotive Enthusiasts Network