Table Of ContentAutomobile Engineering
About TTTI, Bhopal
TTTI Bhopal was established in 1965 with the primary goal of preparing professionally competent teachers for Technician
Education Systems of the Western Regional states of India—Goa, Gujarat, Madhya Pradesh and Maharashtra and the
newly created state of Chhattisgarh. It is an autonomous institution of the Government of India.
Over the years, the nature of activities and role of TTTI Bhopal has expanded far beyond teacher development
concept. These enhancements occurred in a series of stages from the early seventies. As a consequence of the
transformation, TTTI Bhopal has now become a national resource institution of excellence for the technician and technical
eduction systems in the country. It has also demonstrated its potential for catering to the needs of allied education systems
like technical and, vocational education, even industries as well as to the needs of developing countries.
Many international organisations like The World Bank, ILO, UNESCO, Commonwealth Secretariat and the British
Council seek its assistance on various projects. TTTI Bhopal has developed excellent relationship and working
partnership with industry and community. Mutual support between TTTI and its clientele occurs in various fields, e.g.
curriculum development, teacher training, training of trainers, management development programmes, learning resource
development, examination reforms, continuing education, on-line learing and resource and experience sharing. The
institute has a number of departments/centres and three extension centres which are located at Ahmedabad, Gujarat;
Panaji, Goa; and Pune, Maharashtra for accomplishing its aims and objectives. For the state Madhya Pradesh, and the
newly formed state of Chhattisgarh, the institue operates from its headquarters at Bhopal.
In its endeavour to support technical education system in the country, the institute in addition to short term training
programmes also offers long term staff development programmes—Master of Technical Education (M.Tech.Ed.) and
Doctor of Philosophy (PhD) under the Faculty of Technical Education, Barkatullah University, Bhopal.
About the Authors
Prof. K K Jain is the Head of the Mechanical Engineering Department of the Technical Teachers’ Training Institute (TTTI)
Bhopal, India. He holds a Bachelor of Engineering Degree and a Master’s Degree in Technical Education from the
University of Bhopal. He was awarded a British Council Fellowship in 1991 for an Advanced Course in Educational
Project Planning and Management at Leeds University in UK. He was also awarded World Bank Fellowship in 1999
for Advanced Training in Economics of Technical Education at Huddersfield University UK. He has written self-learning
modules in technical areas like NC/CNC machines, laboratory manuals, textbook for technicians and professionals in
industry and also published papers in several national and international journals.
He is currently engaged in organising training programmes for technical teachers and supervisory skills development
training programmes for industry. He is also involved in developing curricula for high technology courses at diploma and
post diploma levels.
Prof. Jain is an active member of different professional bodies related to Mechanical and Automobile Engineering,
including the Boards of Studies in Mechanical Engineering of different technical examination boards.
R B Asthana is Consultant Bhilai Management Service Pvt. Ltd., Bhilai. Before that he was working as Superintendent
of Engineering Shops at Bhilai Steel Plant. He has 35 years of industrial experience in engineering manufacturing and
textile mills. He has obtained his Bachelor’s Degree in Mechanical Engineering form BITS, Pilani.
Mr. Asthana has been to the erstwhile USSR, where he underwent in-plant industrial training related to process control
and manufacturing of steel. He has served as a high level professional in the field of management specially in shopfloor
management for many organisations. He has published technical books for diploma and undergraduate students of
engineering.
He has also published articles in national and international journals. He is an active member of Institution of Engineers
(India).
Presently he is actively engaged in writing books.
Automobile Engineering
Developed at
Technical Teachers’ Training Institute
Bhopal
K.K. Jain
Assistant Professor and Head
Mechanical Engineering Department
Technical Teachers’ Training Institute, Bhopal
R.B. Asthana
Consultant
Bhilai Management Service Pvt. Ltd.
Bhilai
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Foreword
The last one decade has witnessed a phenomenal growth in the population of automobiles in India.
It is said that the civilisation of a country can be measured in terms of the number of automobile
vehicles. It has been timely for the authors to come up with a book on Indian automobiles. The
book has touched upon various issues like the adequacy of technology, the various constraints
which were coming earlier in the way of growth and also the future trends of the industry. The
book will be beneficial to all those who would like to delve deeper into the subject. In the current
context, Prof. K.K. Jain’s and Mr. R.B. Asthana’s work is just in time, especially when the Indian
automobiles are poised for a great leap into the international market.
The salient features of the book are:
• In-depth treatment of engine with maintenance aspects and troubleshooting.
• Fuel systems for various models and supercharges of I.C. engine have been specially given
for beginners in automobile study.
• Transmission of power from engine to wheel has an objective role to play in modern-age
cars. Distinct characters, which are based on design of transmission, of many vehicles have
been dealt with.
• Modern automobile’s special features are for passenger comfort, and its suspension system
takes the lead over old generation cars, the reasoning for which could be very well under-
stood.
• In this computer age, automobile’s electrical systems are more sophisticated and use com-
puter technology for different electrical components. This has been kept in mind.
• Service aspect of any automobile is important in making it a success. How to maintain a
vehicle at its optimum performance level has been covered adequately.
A very good attempt has been made to put down all the parameters of automobile engineering
in this text.
I am sure that this book will prove useful for students as well as practising engineers.
I wish all the best to the authors.
Dr K Kumar
Director (Engineering)
Maruti Udyog Ltd.
Preface
Automobile Industry has witnessed a phenomenal growth in India in the post independence period.
Rapid industrialisation of the country has resulted in an unprecedented advancement in the techno-
logical processes and improvement in the efficiency of structures, machines and transport vehicles
under various operating conditions. To cope with the advances in the automobile engineering field,
the engineers and technicians engaged in the field must understand the various constructional and
working details of the components used in different vehicles. They are also expected to understand
repair, and maintenance of automobiles in the country.
A large number of automobiles consisting of four-wheelers and two-wheelers are manufactured
by various companies in India and abroad. Different manufacturing companies provide detailed
information in their catalogues and service manuals. However, there are very few books on auto-
mobile engineering which deal with the components, designs and processes adopted by the auto-
mobile manufacturers in India. The present textbook endeavours to provide relevant information on
various types of components used in the Indian automobile industry and thus fulfils a long felt need
of students, teachers and professional in the field.
One of the salient features of the book is its practical approach in dealing with the subject. It
deals with in detail, aspects like fault diagnosis and maintenance of various assemblies of vehicles,
troubleshooting and remedial measures among others. The authors have pooled in their technical
knowledge and experience in the industry and educational sector in developing this book.
The book deals with the latest technology used in different models and presents comparative data
on Indian vehicles with suitable illustrations.
It is our hope that this book, will be of immense value to the technical teachers, students as well
as professional in the field. We look forward to receiving invaluable suggestions from the users and
experts in the field. This textbook could be improved further on the basis of these erudite sugges-
tions.
TTTI, Bhopal
Acknowledgements
Many books on Automobile Engineering are available in the country, but most of them do not
specifically deal with the Indian automobiles. Looking at the advancements in the Automobile
Industry in India, Shri B R Jain, Ex-Chairman, Board of Governors, TTTI, Bhopal motivated the
authors to write a book on Automobile Engineering based on Indian vehicles for students, teachers
and professionals working in the industry. The authors wish to express their sincere gratitude to him.
While preparing this book the material made available by various organisations and individuals in
the form of manuals, catalogues and brochures on current practices has been extensively referred
to. The permission for the same was given by M/s Maruti Udyog Ltd, M/s Hindustan Motors Ltd.,
M/s The Premier Automobiles Ltd., M/s Mahindra & Mahindra Ltd, M/s Tata Engineering and
Locomotive Company Ltd., M/s Hyundai Motors India Ltd., M/s Daewoo Motors India Ltd., etc.
The authors wish to express their thanks for the help and guidance in this endeavour, to all the
organisations which permitted them to use their technical material.
The authors wish to thank Shri D Guha, formerly Superintendent, Bhilai Technical Institute,
Bhilai Steel Plant, for inspiring them to write this book. In completing this book the contributions
made by the following experts, Late (Prof.) N L Jain, Formerly Director of Technical Education,
Madhya Pradesh, Prof S M Pandey, Formerly Head of the Mechanical Engineering, Department,
Government Engineering College, Jabalpur and Dr A D Telang, Professor, Mechanical Engineering,
Department, MACT, Bhopal had been of immense value.
Special thanks are also due to Mr S Majumdar, Manager (Service Deptt.), Maruti Udyog Ltd.,
Prof. P P Prabhu, Principal, Father Agnel Technical College, Bandra, Mumbai and Dr N K Banthiya,
Formerly Head of the Mechanical Engineering & Continuing Education Department, TTTI Bhopal
for having taken pains to edit the text materials.
The authors are grateful to Late (Prof.) S A Balu and Prof. R K Mani both Ex-Principals of
TTTI, Bhopal for providing invaluable support while collecting the data for the book. They are
extremely grateful to Prof. P C Jain, Principal, TTTI, Bhopal for his continued inspiration in
completing the book as well as providing valuable guidance and support during the project.
The authors thank all the colleagues and supporting staff of TTTI Bhopal who have helped them
in the completion of this book. Special thanks are due to the faculty and supporting staff of
Mechanical Engineering Department of TTTI, Bhopal for their cooperation and assistance at various
stages of this project.
K K Jain
R B Asthana
Contents
Foreword v
Preface vii
Acknowledgements ix
1. Introduction 1
1.1 Introduction to an Automobile 1
1.2 History of the Automobile 1
1.3 Indian Automobiles 2
1.4 Types of Automobiles 3
1.5 Layout of an Automobile 4
1.6 Major Components of the Automobile 4
1.7 Functions of the Automobile Components 6
1.8 Manufacturers of Motor Vehicles in India 11
Review Questions 15
2. Automobile Engines 16
2.1 Introduction 16
2.2 Classification of Automobile Engines 16
2.3 Use of Engines 20
2.4 Merits and Demerits of Vertical and Horizontal Engines 21
2.5 Reasons for Using Single-cylinder Two-stroke
Air-cooled Petrol Engine on Two-wheelers 22
2.6 Reasons for Using Multi-cylinder Diesel Engine for Commercial Vehicles 22
2.7 Merits and Demerits of Two-stroke and Four-stroke Cycle Engines 22
2.8 Advantages of a Multi-cylinder Engine for the Same Power 23
Review Questions 24
3. Engine Construction 25
3.1 Introduction 25
3.2 Cylinder Blocks 25
3.3 Cylinder Liner 27
3.4 Crankcase 28
xii Contents
3.5 Cylinder Head 30
3.6 Gaskets 30
3.7 Piston 31
3.8 Piston Rings 32
3.9 Piston Pin 34
3.10 Connecting Rod 35
3.11 Crankshaft 36
3.12 Balance Weight 38
3.13 Vibration Damper 40
3.14 Camshaft 40
3.15 Valves 41
3.16 Port-timing Diagram 45
3.17 Fly Wheel 46
3.18 Manifolds 47
Review Questions 52
4. Engine Maintenance and Troubleshooting 53
4.1 Introduction 53
4.2 Preventive Maintenance 53
4.3 Engine Maintenance 54
4.4 Dismounting the Engine 59
4.5 Engine Disassembly 60
4.6 Inspection of Engine Components 62
4.7 Engine Reassembly 76
Review Questions 90
5. Combustion Process in Petrol Engines 92
5.1 Introduction 92
5.2 Properties of Petrol (gasoline) 92
5.3 Octane Number 93
5.4 Octane Ratings 94
5.5 Combustion Process in Petrol Engine 96
5.6 Types of Combustion Chambers 97
Review Questions 101
6. Combustion Process in Diesel Engines 102
6.1 Introduction 102
6.2 Properties of Diesel Fuel 102
6.3 Combustion Process in CI Engine 103
6.4 Diesel Knock 105
6.5 Types of CI Combustion Chambers 106
6.6 Open Combustion Chamber 106
6.7 Pre-Combustion Chamber 108
6.8 Turbulence Combustion Chamber 110
6.9 Air Cell Combustion Chamber 110
Contents xiii
6.10 Energy Cell Combustion Chamber 110
Review Questions 112
7. Fuel System for Petrol Engine 113
7.1 Introduction 113
7.2 Fuel System for Petrol Engine 114
7.3 Gravity Feed System 114
7.4 Fuel Pumps 116
7.5 Properties of Air–fuel Mixture 118
7.6 Engine Requirements 120
7.7 Simple Carburettor 121
7.8 Throttle Valve 122
7.9 Mixture Control Devices 123
7.10 Types of Inlet Manifolds 125
7.11 Air Cleaner 125
7.12 Working of Popular Makes of Carburettors Used in Indian Vehicles 127
Review Questions 138
8. Fuel Injection Equipment for Diesel Engine 140
8.1 Introduction 140
8.2 Fuel Injection System 140
8.3 Fuel Injection Pump for Diesel Engine 141
8.4 Diesel Injector 144
8.5 Governor 147
Review Questions 149
9. Cooling System of Engines 150
9.1 Introduction 150
9.2 Cooling System 150
9.3 Parts of Cooling System 152
9.4 Water Jacket 153
9.4 Cooling Water Additives 157
Review Questions 161
10. Lubrication System of Engines 162
10.1 Introduction 162
10.2 Friction 162
10.3 Mechanism of Lubrication 163
10.4 Functions of Lubricating Oil 163
10.5 Viscosity 164
10.6 Properties of Lubricating Oil 164
10.7 Additives for Lubricants 166
10.8 Importance of Low Viscosity Oil 167
10.9 Lubrication in Automobile Engines 168
10.10 Classification of Lubricating Oils 168
10.11 Lubrication System 169
10.12 Crankcase Ventilation 175
