1.

List the major parts and sub parts of an automobile and describe the function
of each one of them briefly?

A. POWER TRAIN SYSTEM

• POWER PLANT (POWER GENERATION - ENGINE)

• ENGINE
• FUEL SYSTEM
• INTAKE SYSTEM
• EXHAUST SYSTEM
• COOLING SYSTEM

• DRIVE LINE (POWER TRANSMISSION)

• CLUTCH
• GEAR BOX/TRANSMISSION
• TRANSFER CASE
• DIFFERENTIAL
• WHEELS/TYRES

B. RUNNING SYSTEM

• SUSPENSION
• STEERING
• BRAKING

C. COMFORT SYSTEM

• HVAC/AC/HEATER SYSTEM
• SEATING/UPHOLSTRY/FACIA/

1. ENGINE

ENGINE IS THE HEART OF THE AUTOMOBILE

• IT GENERATES MOTIVE POWER FOR LOCOMOTION

• IT CONVERTS CHEMICAL ENERGY OF THE FUEL TO MECHANICAL ENERGY
• ENGINE DEVELOPS POWER & TORQUE

2. FUEL SYSTEM

• FUEL SYSTEM IS THE HEART OF THE ENGINE

• IT TRANSPORTS FUEL FROM THE FUEL TANK AND INJECTS IT UNDER
HIGH PRESSURE IN TO THE ENGINE
• FUEL INJECTION SYSTEM IS A HIGH PRECISION, HIGH TECHNOLOGY
PRODUCT

3. INTAKE SYSTEM

INTAKE SYSTEM CLEANS & TRANSPORTS ATMOSPHERIC AIR

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TO THE ENGINE CYLINDERS
NA ENGINE - NATURALLY ASPIRATED ENGINE - The air is transported to the engine
cylinder, at atmospheric pressure
TURBO ENGINE - TURBO CHARGED ENGINE - The air is compressed and transported to
engine cylinder, at higher than atmospheric pressure.

4. EXHAUST SYSTEM

EXHAUST SYSTEM TRANSPORTS THE BURNED EXHAUST GASES FROM ENGINE

CYLINDER TO THE ATMOSPHERE, TOWARDS THE REAR OR TO THE RIGHT SIDE
OF THE VEHICLE.
Since the exhaust gases are at higher pressure than atmospheric pressure, the exhaust system
has to reduce the pressure of exhaust gases so that there is no noise on discharge to
atmosphere.

5. COOLING SYSTEM

Cooling system circulates coolant (Combination of water and a chemical) through the engine
components which absorbs the heat and transfers the heat to the atmospheric air through a
heat exchanger.

DRIVE LINE

POWER IS GENERATED BY THE POWER PLANT (ENGINE) THE GENERATED

POWER NEEDS TO BE MODIFIED & TRANSMITTED TO THE WHEELS FOR
VEHICLE LOCOMOTION.
DRIVELINE MODIFIES & TRANSMITS THE POWER/TORQUE TO THE WHEELS OF
THE AUTOMOBILE.

1. CLUTCH SYSTEM

CLUTCH IS THE CRUCIAL LINK BETWEEN THE POWER PLANT (ENGINE) AND
THE DRIVELINE THE PURPOSE OF THE CLUTCH IS TO LINK OR DELINK
(ENGAGE OR DIS-ENGAGE) THE ENGINE FROM THE DRIVELINE, AS DESIRED BY
THE DRIVER

2. GEAR BOX (TRANSMISSION)

GEAR BOX MODIFIES & TRANSMITS THE TORQUE OF THE ENGINE TO THE
DRIVE LINE.
THE AMOUNT OF MODIFICATION OF TORQUE REQUIRED IS DECIDED BY THE
DRIVER AND IS ACTUATED BY A GEAR LEVER WHICH SELECTS A REQUIRED
GEAR RATIO

3. TRANSFER CASE

TRANSFER CASES ARE FITTED ONLY IN 4WD VEHICLES. TRANSFER CASE

MODIFIES & RE-DIRECTS THE TORQUE OF THE ENGINE TO BOTH FRONT AND
REAR AXLES, AS DESIRED.

4. DIFFERENTIAL

DIFFERENTIAL RECEIVES TORQUE FROM THE GEAR BOX, MODIFIES AND

TRANSMITS IT TO THE WHEELS, IN A PERPENDICULAR DIRECTION.

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DIFFERENTIAL ALSO ALLOWS EACH WHEEL TO ROTATE AT DIFFERENT
SPEEDS, ESPECIALLY WHEN THE VEHICLE TAKES A TURN

5. WHEELS

WHEELS CARRY THE LOAD OF THE VEHICLE & TRANSMIT THE

TORQUE TO THE TYRES
WHEELS ARE SUPPORTED IN WHEEL BEARINGS. BASED ON WAY IN WHICH
THE LOAD IS CARRIED AND THE TORQUE IS TRANSMITTED

RUNNING SYSTEM

THE RUNNING SYSTEM CONTROLS THE VEHICLE RUNNING SYSTEM CONSISTS

OF

SUSPENSION - Provides a comfortable ride

BRAKES - Allows slowing down the vehicle
STEERING - Allows changing direction of the vehicle

1. SUSPENSION

SUSPENSION ABSORBS ROAD SHOCKS AND PROVIDES COMFORTABLE RIDE

FOR THE PASSENGERS

2. STEERING SYSTEM

THE PURPOSE OF THE STEERING IS TO CHANGE THE DIRECTION OF VEHICLE

MOVEMENT, AS DESIRED BY THE DRIVER.

3. BRAKES

THE PURPOSE OF THE BRAKES IS TO SLOW DOWN OR STOP THE VEHICLE AS

DESIRED BY THE DRIVER

COMFORT/CONVIENIENCE SYSTEMS

COMFORT/CONVIENIENCE SYSTEM CONSISTS OF

HVAC/AC - Provides a comfortable climate inside the vehicle
ELECTRICALS - Operates a host of electrical aggregates
INSTRUMENTS - Provides information about vehicle systems
AUDIO/VIDEO - Provides in-car entertainment
SEAT/UPHOLSTRY

1. HEATING, VENTILATION & COOLING

HVAC SYSTEM ALLOWS THE PASSENGERS TO CONTROL THE CLIMATIC

CONDITIONS INSIDE THE VEHICLE TO THEIR COMFORT

2. ELECTRICAL SYSTEM

POWER GENERATION - Generation of electrical power when the engine is running -

Alternator
STORAGE - Storage of electrical energy for use in the vehicle when the engine is not running
- Battery

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TRANSMISSION & CONTROLS - Transmits & controls the power flow to the consumers -
Wiring harness, Fuses, Relays.
CONSUMERS - Electrical aggregates which consume electricity for functioning.

2. What is the difference between power and torque?

TORQUE: - Is the capacity to do work Measured in Kg-m, N-m, and Lb-ft

POWER: - How fast the work can be done measured in - Horse Power, Kilo watt

3. What are two stroke and four stroke cycle engines?

If the engine is going to operate, the fuel and air mixture must be fed into the combustion
chamber. The burnt gases also must be exhausted. To accomplish this, there is a passage to
the combustion chamber called the intake port, and a passage from the combustion chamber
to the exhaust system called the exhaust port.

A diesel engine uses the internal combustion process to convert the energy stored in the
chemical bonds of the fuel into useful mechanical energy. This occurs in two steps. First, the
fuel reacts chemically (burns) and releases energy in the form of heat.
Second the heat causes the gasses trapped in the cylinder to expand, and the expanding gases,
being confined by the cylinder, must move the piston to expand. The reciprocating motion of
the piston is then converted into rotational motion by the crankshaft.
To convert the chemical energy of the fuel into useful mechanical energy all internal
combustion engines must go through four events: intake, compression, power, and exhaust.
How these events are timed and how they occur differentiates the various types of engines.
All diesel engines fall into one of two categories, two-stroke or four-stroke cycle engines. The
word cycle refers to any operation or series of events that repeats itself. In the case of a four
stroke cycle engine, the engine requires four strokes of the piston (intake, compression,
power, and exhaust) to complete one full cycle. Therefore, it requires two rotations of the
crankshaft, or 720° of crankshaft rotation (360° x 2) to complete one cycle. In a two-stroke
cycle engine the events (intake, compression, power, and exhaust) occur in only one rotation
of the crankshaft, or 360°.

4. Explain the working of four stroke engine cycle?

If the engine is going to operate, the fuel and air mixture must be fed into the combustion
chamber. The burnt gases also must be exhausted. To accomplish this, there is a passage to
the combustion chamber called the intake port, and a passage from the combustion chamber
to the exhaust system called the exhaust port.

By putting openings in the combustion chamber, a problem is created; the force of the
burning fuel and air mixture will be lost through the exhaust and intake ports rather than used
to push down the piston. To solve this problem, there must be something that opens and
closes the intake and exhaust ports to the combustion chambers. To accomplish this, a valve is

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added to each of these ports; these valves are called the intake and exhaust valves. A
simplified arrangement is shown in following figure

Each time the piston moves from top dead centre to bottom dead centre, or vice versa, it
completes a movement called a stroke. Therefore, the piston completes two strokes for every
full crankshaft revolution. There are four definite phases of operation that an engine goes
through in one complete operating cycle. Each one of these operating phases is completed in
one piston stroke. Because of this, each operating phase is also referred to as a stroke and,
because there are four strokes of operation, the engine is referred to as a four stroke cycle
engine.

5. Explain the working of two stroke engine cycle?

Like the four-stroke engine, the two-stroke engine must go through the same four events:
intake, compression, power, and exhaust. But a two-stroke engine requires only two strokes of
the piston to complete one full cycle. Therefore, it requires only one rotation of the crankshaft
to complete a cycle. This means several events must occur during each stroke for all four
events to be completed in two strokes, In a two-stroke engine the camshaft is geared so that it
rotates at the same speed as the crankshaft

The power of a two-stroke engine is usually double that of a four-stroke engine of comparable
size.
• First Stroke (Suction And Compression Stroke)
• Second Stroke (Power and Exhaust Stroke)

First Stroke
During the first stroke, as the piston moves up from the BDC (Bottom dead centre), it closes
all the three ports, namely the inlet, transfer and exhaust ports. The piston compresses the
mixture of petrol and air inside the cylinder.

Second stroke
During the second stroke, the piston moves down from the TDC (top dead centre)
And the inlet port is closed. The fuel mixture is compressed by the bottom of the piston and
the crank. It then gets pushed into the cylinder through the transfer port.

6. What is the difference between C.I and S.I engine?

Compression Ignition/Spark Ignition are a classification of engine by the type of ignition.

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COMPRESSION IGNITION ENGINES
• Basically Diesel engines
• Use diesel fuel
• Combustion is initiated by heat, on its own

DIESEL ENGIENS ARE COMPRESSION IGNITION ENGINES & USE DIESEL FUEL
and ARE BROADLY CLASSIFIED AS DIRECT INJECTION (DI) AND INDIRECT
INJECTION (IDI)

DIRECT INJECTION ENGINE (DI)

ON DIRECT INJECTION DIESEL ENGINES, FUEL IS SPRAYED DIRECTLY ON TOP
OF THE PISTON.
• Highly fuel efficient
• Noisy
• Easy cold starting ability

INDIRECT INJECTION ENGINE (IDI)

ON INDIRECT INJECTION DIESEL ENGINES, FUEL IS SPRAYED ON TO A
SEPARATE PRE-CHAMBER.
• Less fuel efficient
• Less Noisy/smoother
• Requires pre-heating for starting

SPARK IGNITION ENGINES

• Basically Petrol engines, LPG engines, CNG engines
• Use leaded or unleaded petrol, Alcohol, LPG or CNG
• Combustion is initiated by a spark from a spark plug

PETROL ENGINES ARE SPARK IGNITION ENGINES & USE GASOLINE/CNG/LPG

FUEL AND ARE BROADLY CLASSIFIED AS CARBURATED AND FUEL INJECTED
ENGINE

CARBURETED ENGINE
ON CARBURETED ENGINE, THE PETROL & AIR ARE MIXED IN THE
CARBURETER BEFORE BEING SENT IN TO THE ENGINE

FUEL INJECTED ENGINE

ON FUEL INJECTED ENGINES, THE PETROL IS INJECTED SEPERATELY AND THE
PETROL AND AIR ARE MIXED INSIDE THE CYLINDER.
FUEL INJECTED ENGINES CAN BE FURTHER CLASSIFIED AS:
SINGLE/MULTI POINT FUEL INJECTION, Where the fuel is injected outside the cylinder

GASOLINE DIRECT INJECTION (GDI), where the fuel is injected directly in to the engine
cylinder

7. List and name four strokes of four stroke engine cycle?

In a four-stroke engine the camshaft is geared so that it rotates at half the speed of the
crankshaft. This means that the crankshaft must make two complete revolutions before the
camshaft will complete one revolution.

Intake Stroke

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 During the suction stroke, the inlet valve is opened and the exhaust valve is closed.

Compression stroke

During the compression stroke both the inlet and exhaust valves are closed.

Power Stroke

Both the inlet and exhaust valves remain closed during the power stroke.

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Exhaust Stroke

During the exhaust stroke, the inlet valve is closed and the exhaust valve is opened. When
the burnt gas is pushed out of the cylinder, the exhaust valve closes.

8. List two applications of four stroke and two stroke engines?

These engines are widely used in vehicles, portable power plants it supply the power to run
pumps and other machinery on farms. Many small boats, aero planes, trucks and buses also
use it

The four-stroke cycle of an internal combustion engine is the cycle most commonly used for
automotive and industrial purposes today (cars and trucks, electrical generators, etc).

9. What is meant by engine performance parameters, list them?

ENGINE CAPACITY
cc = CYL. CAPACITY X No OF CYL
UNITS - cc - Cubic centimetre
- Lit - Lifters = cc/1000

BORE, mm: The diameter of the cylinder

STROKE, mm: The distance between top most points of piston travel to the Bottommost
point of piston movement

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CAPACITY, cc: Also called displacement. The volume displaced by all pistons while moving
from top to bottom. Also indicate in Litres.

CLEARANCE VOLUME: The volume available above piston, with the piston in top most
point.

COMPRESSION RATIO: The ratio between the total volume to the clearance volume.

VALVE MECHANISM: The mechanism by which the valves are operated. It could be push
rod type or overhead camshaft type

TIMING SYSTEM: The mechanism by which the camshaft & fuel injection pump are
operated . It could be gear driven, chain driven or belt driven.

10. What is meant by firing order of an engine?

The cycle of operations of four-stroke engines is completed in two turns of the crankshaft.
With such an operating cycle, the crankshaft receives energy from the piston only during
one half its turn when the piston moves on the power stroke. During the remaining three
half turns, the crankshaft continues to revolve by inertia and, aided by the flywheel, it
moves the piston on all its supplementary strokes – exhaust, intake, and compression.

The order in which like piston strokes occur in the engine cylinders is known as the firing
order.

For a multi-cylinder engine to run uniformly, the spaced rotationally at one and the same
crank angle (i.e., they must occur at regular intervals, called the firing intervals). To find this
angle, the duration of the engine cycle, expressed in degrees of crankshaft rotation, is divided
by the number of the engine cylinders. For example, in a four cylinder four-stroke engine, the
power stroke occurs every 180° (720°/ 4), i.e., every half turn of the crankshaft. The other
strokes in this engine occur also every 180°. Therefore, the crankshaft throws (or crank
throws) of four-cylinder four-stroke engines are spaced at 180°, i.e. they lie in a single plane.
The crank throws of the first and fourth cylinders are arranged on one side of the crankshaft,
and those of the second and third cylinders, on the opposite side. Such a shape of the
crankshaft provides for even firing intervals and a good engine balance, since all the pistons
simultaneously reach their extreme positions (two pistons reach their TDC at the same time as
the other two reach BDC).power strokes of its pistons must be

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Firing-order of a four-cylinder four-stroke engine

The firing order of the four-cylinder engines is usually 1-3-4-2. This means that after the
piston in the first cylinder has completed its power stroke, the next power stroke occurs in the
third cylinder, then in the fourth cylinder, and finally, in the second cylinder

When selecting a firing order for a particular engine, designers try to distribute the load on the
crankshaft as uniformly as possible.

The firing order of eight-cylinder four-stroke engines is 1-5-4-2-6-3-7- 8 and that of six-
cylinder ones, 1-4-2-5-3-6.

Knowing the firing order of an engine, one can correctly connect the ignition wires to the
spark plugs and adjust the valves.

11. How is IC engines classified?

An internal combustion engine is any engine in which the fuel is burned from within. A four
stroke cycle engine is an internal combustion engine because the combustion chamber is
located within the engine.

IC ENGINES CAN BE CLASSIFIED IN MANY WAYS:

1. By Mechanical construction - 4 Stroke/2-Stroke
2. By type of Ignition - Compression Ignition/Spark Ignition

COMPRESSION IGNITION ENGINES

• Basically Diesel engines

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• Use diesel fuel
• Combustion is initiated by heat, on its own

SPARK IGNITION ENGINES

• Basically Petrol engines, LPG engines, CNG engines
• Use leaded or unleaded petrol, Alcohol, LPG or CNG
• Combustion is initiated by a spark from a spark plug

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