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Automobile 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 Tata McGraw-Hill Publishing Company Limited NEW DELHI McGraw-Hill Offices New Delhi New York St Louis San Francisco Auckland Bogotá Caracas Kuala Lumpur Lisbon London Madrid Mexico City Milan Montreal San Juan Santiago Singapore Sydney Tokyo Toronto Tata McGraw-Hill A Division of The McGraw◊◊◊◊◊Hill Companies Information contained in this work has been obtained by Tata McGraw-Hill Publishing Company Limited, from sources believed to be reliable. However, neither Tata McGraw-Hill nor its authors guarantee the accuracy or completeness of any information published herein, and neither Tata McGraw-Hill nor its authors shall be responsible for any errors, omissions, or damages arising out of use of this information. This work is published with the understanding that Tata McGraw-Hill and its authors are supplying information but are not attempting to render engineering or other professional services. If such services are required, the assistance of an appropriate professional should be sought. © 2002, Tata McGraw-Hill Publishing Company Limited No part of this publication can be reproduced in any form or by any means without the prior written permission of the publishers This edition can be exported from India only by the publishers, Tata McGraw-Hill Publishing Company Limited ISBN 0-07-044529-X Published by Tata McGraw-Hill Publishing Company Limited, 7 West Patel Nagar, New Delhi 110008, typeset in Times New Roman at Tej Composers, WZ 391, Madipur, New Delhi 110063, and printed at Pashupati Printers, 1/429/16 Gali No. 1, Friends Colony Industrial Area, GT Road, Shahdara, Delhi 110 095 Cover Design: B&M Design RADQCRCARAQAC 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 computer 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 automobile engineering which deal with the components, designs and processes adopted by the automobile 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 suggestions. 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