CONTENTSCHAPTER

1. INTRODUCTIONComponents of an automobile. the basic structure,

power plant, transmission system, auxiliaries, controls,superstructure. classification of automobiles, car bodystyles, transport vehicles, theory questions. questions for

viva, multiple choice questions. .2. THE CHASSIS CO STRUCTION

Classification, con ventional construction, subframes,defects, in frames. trameless construction, vehicledimensions. theory questions., questions forviva, multiplechoice questions.

3.CLUTCHES 38-96Requirements or clutch, types of clutches, principle of

friction clutches. dry friction clutches, clutch operation, wetclutch, clutch components. clutch plate, clutch facing. otherclutch components, preliminary inspection of clutch. clutchadjustment, clutch overhaul. dutch refacing, clutch troubleshoottag, fluid flywbeel, fluid flywheel trouble shooting,comparative clutch data, references, theory .questions,questions for viva, multiple choice questions.

4.TRANSMISSIQN-I 97 -130

Page3-28

29-37

Jntroducticn, funeuons of transmission. necessity' oftransmission. typeS of transmission: manual transmission,sliding mesh gear box. constant mesh gear box.synchromesh gear box, selector mechanism. lubrication ofgear box, transfer box, gear box trouble shooting.comparatl ve transmission data, theory questions.numerical problems. questions for viva, multiple choice .questions.

5. TRANSMISSION-D 131 -156

Automatic transmission, epicyclic gear box.freewheel unit, torque converter, principle of automatictransmission, theory questions. questions for viva, multiplechoice questions ..

6. THE DRIVE LINE 157 - 201Propeller shaft, universal joints, analysis of Hooke's

joint, propeller shaft overhaul, propeller. shaft troubleshooting. final drive, differential," rear axle; rear axJedrives, rear axle shaft supporting. rear axle casing. rear axletrouble shooting, improvements in four wheel drive.

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Chapter Page

comparative rear axle data. references. Cheory questions.numerical problems. questions for viva, mUhipte choicequestions.

7.SUSPENSION SYSTEM 202 _

248

Introduction, objects. of suspension. basicrequirements, function of suspension springs. types orsuspension springs, lear springs. coil springs, torsion bats.rubber springs. plastic suspension. shock absorbers.independent suspension. stabilizer or anti-soll device,interconnected suspension systems, air suspension.hydrotasuc suspension, Daimler Benz vehicle suspension,Hydragas interconnected suspension system. suspensionsystem trosble shooting, comparative suspension data,theory questions, questions for viva, multiple choicequestions.

8. FRONT AXLE AND STEERING 249 -313

Introduction. front axle, wheel alignment. factors ofwheel alignment, factors penaining to wheels. steeringgeometry. correct steering angle; sleering mechanisms.cornering force. self-righting torque, understeer andoversteer, steering linkages, steering gears, steering ratio.reversibility; special steering columns. power sreertag,advanced steering systems, steering adjustments, checkingof wheel alignment and steerilng geometry. steering troubleshooting, comparan ve steering data. references, theoryquesrlons, numerical problems, questions for viva, multiplechoice questions.

9. WHEELS AND Ty'RES 3]4 _ 373

Types of wheels, wheel dimensions. tyre, desirabletyre properties. types of lyres, carcass types. comparison ofradiaJ-and bias-ply Ilyres, lyre materials, considerations: intread design. tyre section, lyre designalions. factorsaffecling lyre life, tyre manufacture. DunJop 'Denovo' lyre;precautions regarding the lyres.. wheel and lyre (rouble.shooting, comparative wheel and lyre data, references. theoryQuestions, questions for viva. multiple choice quesnons,

10. BRAKES-I 374- 427

Principle. braking reguirements; brake efficiency andstopping distances. fading of brakes. weighltransfer, wheelskidding.lypes of brakes. drum brakes. disc brakes.mechanical brakes, Girling mechanical brake. hydralllicbrakes; bleeding of brakes. brake nuid. brake system (orMaruli (Suzuki) 800 car, references. Cheory queslions,numerical problems, questions (or viva, mulliple choicequestions,

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Chapter Page

11. BRAKES-II 428 - 487Electric brakes, servo brake systems, vacuum servo

brakes. Bendix Hydromax brakes, engine exhaust brakes, airbrakes. band brake, hill holding device, brake drums, brakeshoes. brake linings. disc brake pads. inspection of brakesystem, adjustment of brakes, replacing brake lining,servicing disc brakes. brake maintenance, braking systemtrouble-shooting. references, comparative brake data,referesces, theory questions, questions for viva, multiplechoice questions.

12. LIGHTING SYSTEM 488 - 508

Lighting system, wiring circuit, wires, headlights.aiming of headlights. lighting switches, indicating lights.lighting system trOuble shooting, theory questions. questions forviva. multiple cho.ice quesli.ons.

13. A.CCESSORIES ·509 - 534

Accessories, direcrion indicators. windscreen wiper.windscreen washer, horn, speedometer, ventilatingsystem, heating system. air conditioning, mirrors, sun visors,sliding roof, central locking facility, power windows,lockable tank cap. :roof carrier, winch, theory questions,questions for viva, multiple choice questions.

14. BODY AND SAFETY CONSIDERATIONS 535 - 565

Requirements of automobile body, constructionalderails, materials for body work, rust protection, safetyconsiderations, state of the art safety systems, latestapproach to automotive safety, theory questions, questionsfor vi va.

15. VEHICLE CHASSIS SPECIFICATIONS 566 - 653

Introduction, Maroti Udyog Ltd. India, HindestanMotors Ltd. India, The Premier Automobiles Ltd. India.Daewoo Motors India Ltd .• Standard Motor Products ofIndia Ltd., Hyundai Motor India Ltd., Ford India. Ltd., FiatIndia Automobiles Ud., Skoda India Ltd., Toyota KirloskarMotor Lid .• Honda Siel Cars India Ltd., General MotorsIndia, Mahindra & Mahindra Ltd. India, Tata Engineeringand Locomotive Co. Ltd. India, Ashok Leyland Ltd. India,Swaraj Mazda Ltd. India, Eicher Motors Ltd. India, BajajTempo Ud. India, -Volvo India Pvt. Ltd .• Chrysler UnitedKin.gdom Ltd., Rolls Royce Motors (car division) U.K.,Morgan Motor Co. Ltd. U.K., Vauxhall Motors Ltd. U.K"A.e.. Cars us, U.K., Jaguar Rover Triumph Ltd., U.K.,Austin Rover Group Ltd U.K.,. Land Rover, U.K., CitroenCars Ltd. U.K.-, Automobiles Peugeot. France. Daimler-BenzAG

Chapter

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Pag«

Germany, Volkswagenwerk Germany. Dr. mg .. H.C.Porsche AG. Germany, Alta Romeo Italy. Ferrari S.p.A. Italy,Volvo In.tematibmd Development Corporation Sweden,Steyr.Daimler-Puch AG Austria. Ford. Motor Co. (U.S.A.),Genera) Motors Corporation (U.S.A.). General Motors ofCanada Ltd .• Leyland Motor Corporation of Australia Ud.,-Nissan Diesel Motor Co. Ltd. Japan, Toyoto- MotorCorporation. Japan. Hyundai Motor Co. Japan, questions forviva, multiple choice questions.

16. AUTOMOBILE SHOP EQUIPMENT 654 - 702Introduction, screw drivers, spanners, pliers, hammers,chisels, flies, hacksaws, cleaning tools. tools for tubes. tapesand dies, drilling machines and twi.st drills. reamers,soldering tools, grinder, bench vice, measuring tools, chainpulley block, liftingjacks and axle stands. creeper, lubricatingequipment, battery testing and charging equipmenl. electricequipment, hydraulic lift, tools for tyres, tyre remover,wheel balancing equipment, brake testing equipment,high pressure washing equipment, engi1ne analyzer.hydraulic press and arbor press. spark plug testing andcleaning machine, chassis dynamometer. equipment forrepainting. pl"ecautions to be observed in the auto shop.theory questions. questions for viva. multiple choicequestions.

17. AUTOMOTIVE MATERIALS 703 - 710Introduction, steel, aluminium, magnesium, copper,

plastics, theory questions. questions for viva.18. MISCELLANEOUS TOPICS 711-741

Automobile law, automobile industry in India,emission norms, auto components industry in India, drivinghints; milestones in the development of automobile,Volkswagen's 1 IitrellOO km 2002 modelcar, car inspection. theory questions. questions for viva.

APPENDIX-AAPPENDIX ...• BAPPENDIX-CAPPENDIX.;..DAPPENDIX-E

INDEX

742-747748-752

753-754755-759760-765

'''-774

Introduction

. COMPONENTS OF AN AUTOMOBILE The

main units of an automobile are :

1. The basic structure.

2. The power plant.

3. The transmission system.

4. The auxiliaries.

5. The controls.

6. The superstructure.

U nits I to 5 above constitute automobile chassis. 2.

THE BASIC STRUCTURE

This is the unit on which are to be built the 'remainder of the units required toturn it into a power-operated vehicle. It consists of the frame~ the suspensionsystem~ axles, wheels and tyres, -

fl. Frame

There are two distinct forms of construction in common use:..J..:-Tl1e conventional pressed steel frame to which all the mechanical units are

attached and on which the body is superimpos~~:L

,.z...Tbe integral or frarneless construction. in which the body structure is sodesigllled as to combine the functions of body and frame, the units normallyattached to (he frame then being attached directly to the body,

The frameless construction. is, however, possible only in the case of a closedcar, since the roof, screen pillars, door pillars and rear panel are essenrial load-taklngparts. of the structure ..

The frarneless construction- has the following advantages over the conventionalframed construction:

W Reduced weight and consequent saving in fuel consumption. (jj)Lower manufacturing cost.

4.4

wZ«.;>ZW

INTRODUccrION 5

(iiI) Otlnng collision the body. crumbles, thereby absorbiug the shock due toi.mpact and thus providing saf~ty to the passengers,

- . , _.. . : '

(ill) Compared to framed ceastmction lower lJody position may beobtained, thus resulting in incJ,ased stltbillty of the' automobile.

However these advantages are accompanied by the followingdisadvantages also:

'(0 Reduction of strength and durabilitY

(is) Ecoliomi,ca16nly- if frameless construction is. adopted ·in~s prOduct!QJl.. '- -!It' _

(iii) Increased cost of repairs in case of'damage to body dunng'accidents. .'.

(i)l):to~'less cars are difficult .to design with tb~ frameless construction.

Apart from above two.types of-construction, a compromise has also beenadopted in many cases (e.g; Volkswagen, Germany), which incorporates featuresof both of these types. In this' a pressed steel floor, suitably strengthen~. by somelongitudinal and cross members, lRCluding the central longnucmel sieei mne,caned backbone 1S used.

2.2. SUspension System

Theobjects of SUSpension are .

Fig. 1.2 (a) Suspension system of Nissan CM80 truck (front)(Court.esy-Nissan Diesel Motor Co. Ltd., Japan)

1. 1;0 prevent the road shocks from being transmitted to the vehiclecomponents. - ...•. ~. I. , -

2. "'::0 s~AyygJbs....o~~oa~ shoeD .

. 3. ,!:o £re~!,Y~be .§~~!mX.~J~s.bi.fk.i~~lJj~bjle in !!!,ot!Qj)...

~ere are two distinct types of suspension systems:

\.,/ 1..: The c9nventional system, inwhic~oad • .mriqgs are",,!ttached to,arigid'beam axle, • .

oi

,,/ 2. nw..in.E~1?scl.eDt system, in \¥hi.cbJb.el'e is no ~g.kbe@m aDd ea£b:.wheeIi'sfree to move verticany without any Tl;~.li.an..on.the. other.wheel.

I!I'! .....-.au _ - , _

6 AUTOMOBILE ENGINEERING

Fi~. 1.2 (b) Suspension system of Nissen CMSO truck {.(Coul1esy-Nissan Diesel Motor Co. [.t(l.,}apan,

2.3. AxlesThe weight-carrving portions ofthe axles. whether itmaybe frontnerear •. may

be considered as beams supported at the ends. Ioadedar two intermediate poirus "mespring centres) ana sumected to t!he fonowmz.ioads :

L The vertical load at the spring centres ldue to the weight of th.e vehicle.

2. A fore and-aft load at die wheel centre, due to driving or braking effort

3. The torque reactions due to drive or brakes.

4.A side thrust at the radius of the tyJ'el due to centrifugal force whenrounding a curve .

. There are three distinct types oflive rear axles, ""

(a) 'fully floating type.

.(b1)three-qu~er" floating type.

G"~mi-flOa~ing type. ".A conventional front axle still.usedin heavy vehicles, being a dead axle, is

almost invariably a simple section forging connected with stub axles, at its outerends by means of king pins or ball joints.

J 2.4.Wbeels

Wire-spoked wheels have been used mainly on sports cars, primarily on accountof their ligbt weight and quickness in changing the wheel. However, the pressedsteel wheel has displaced these for all ordinary purposes. Such a wheel consists of acentral flanged disc pressed into a rolled section rim and retained in position bywelding. Light alloy wheels are currently used in case of luxuary and sports cars andare called 'formula wheels'.

'"V 3. THE POWER PLANTThe power plant (engine) provides the motive power for all the various functions

which the vehicle or any part of it, may be called upon to perform.'-~ .

~e power plant generally consists of an internal combustion engine. which may be either of spark-ignition. or of compression-i.gnition type.

However, the gas-turbines have also been used successfully in certain cars,though the cost has been a disadvantage in spite of their better performance comparedto I.e. engines.

lNTR,ODUCl'ION

Fig. l.3. Engine for 1981 model Escort car(Courtesy-Ford Motor co, U.S.A.)

4. THE TRANSMISSION SYSTEM

1l!e tran§IDissiQD s)!:!tem cOD~jsts gfA elW. il.2eit hOY (also calledtransmission) ~jving t!!r~foUr or evenJiye ~s..o.~pu·£ WJ.Qrque -inp~ apropel!e~ s~aft to_1!ans~J~tqe~ 19If.l-q~-9'y':~pt fr.2-rnJh.~.g~lYbox to the rearaxle and a differential gear to distribute the final torque equally b~tw';;~the·dri'Ving wheels. Fig. 1 4 shows a layout of the. transmission system of anautomobile.

The functions of a transmission system are :

1. To disconnect the engine from the road wheels when desired.

2. To connect the engine to the driving wheels without shock.

3. To vary the leverage between the engine and the driving wheels.

4. To reduce the.engine speed perman.ently in a fixed ratio.

5. To tum the drive through a right angle.

5.

6.

,·,Yot~1

'.

PREFACE NINTH EDITION

It was 33 years ago that the first edition of this book was puJ?lished. Athorough revision of the book has been done now for the ninth edition. Care has beentaken of even the minor details. A few topics have been added in 'a number ofchapters, while some of the articles have been rewritten. The chapter on'Transmission' has been subdivided for simplification and rationalisation, while thelast chapter on 'Miscellaneous Topics' has been enlarged to include other topics, viz.,'Milestones in the development of Automobile'. 'Volkswagen.'s 1 litreJlOO km car'and 'Car Inspection', Data has also been included about many latest Indian andforei.gn cars, such as, Sonata, Ikon, Mondeo, Opel Corsa, Opal Swing, Accord;Palio, Baleno, Wagen-R, Versa" Alto, Octavia. Tala Sedan, etc.

Many new diagrams as well as photographs have been added to make thematter more understandable. Exclusive use of S.1. system of units has been madefor all the numerical problems in the book.

It is hoped that the revised book will be more useful to not only the students ofthe engineering colleges and polytechnics for whom it is primarily meant, but also tothe serving engineers in the automobile field. The book is also expected to servethe students aspiring for the membership of profession.al bodies.

However. as the man is never perfect. some errors and omissions may have beenleft still. The author wilt be highly indebted for any suggestions to improve the bookfurther.

In the end, the author thanks various manufacturers 'Who have providedillustrations of their products for the book. The Individual acknowledgements aremade alongwith such illustrations in the book.

Chandigarh, February 2003 Dr. KIRPAL SINGH

PREFACE TO THE FIRST EDITION

This book is an endeavour to help the students of Automobile Engineering logain a thorough understanding of the complete chassis. Part II is under preparationwhich deals. exclusively. with the engine portion.

Many books are already available in the market, but (hey contain sketcheswhich are either too complicated to understand or they arc oversimplified. In thisbook, special effort has been made to keep the sketches simple 10 understa d andthen to reproduce. yet not so simplified as to be erroneous.

Selected questions on theory have been givel3.at the end of each chapter.To further help the students. typical questions for viva voce examination are alsogiven.

Data regarding premier Indian automobiles have' been given in each chapterto enable the reader to understand (he applicability of the things he has studied intheory.

The author feels highly indebted to Dr. S.K. Sachdev, Principal. PunjabEngineering College. Chandigarh. with whose inspiration the book has beenwritten.

Any suggestion for the improvement of the book will be welcome.

Chandigarh, Feb. 1969. Dr. KJRPAL SINGH