Automobile Chassis Allied Systemms – 2022

01.

(1). Automobile Engineering Terms

(a). Helper Spring

A helper spring is an additional spring used in conjunction with the main suspension spring to provide
extra support when the vehicle is heavily loaded. It is typically softer and engages only when the primary
spring is compressed beyond a certain point, helping to maintain ride height and improve load-carrying
capacity.

(b). Sprung Weight

Sprung weight refers to the portion of a vehicle's total mass that is supported by the suspension system.
This includes the body, engine, transmission, passengers, and cargo. Proper management of sprung
weight is crucial for vehicle stability and ride comfort.

(c). Unsprung Weight

Unsprung weight is the mass of the components that are not supported by the suspension system, such
as wheels, tires, brake assemblies, and parts of the suspension system itself (e.g., control arms, springs).
Lower unsprung weight contributes to better handling and ride quality because it allows the suspension
to respond more quickly to road surface changes.

(d). Independent Suspension

Independent suspension refers to a system in which each wheel on the same axle can move vertically
independently of the others. This allows for better handling and ride comfort, as the movement of one
wheel does not directly affect the opposite wheel. Common types of independent suspension include
MacPherson struts, double wishbones, and multi-link systems.

(11). Why are Leaf Springs Made of a Series of Steel Strips?

Leaf springs are made of a series of steel strips, or leaves, to distribute the load more evenly across the
spring. This design allows for a progressive spring rate, where the spring becomes stiffer as it
compresses, providing a combination of comfort and load-carrying capacity. The multiple leaves also
provide durability and reduce the risk of spring failure by spreading the stress across several strips.
(III). Purpose of a Leaf Spring in Rear Suspension

The primary purpose of a leaf spring in rear suspension is to support the weight of the vehicle, absorb
shocks from the road, and maintain the proper alignment of the rear axle. Leaf springs provide a simple
and robust solution for rear suspension, especially in heavy-duty vehicles like trucks and SUVs, where
load-carrying capacity is critical.

(IV). Causes and Remedies of Suspension System Symptoms

(a). Noise in the Suspension System

Causes:

Worn or damaged bushings

Loose or damaged components (e.g., shock absorbers, springs)

Lack of lubrication in moving parts

Damaged or worn-out ball joints or control arms

Remedies:

Inspect and replace worn or damaged bushings

Tighten or replace loose or damaged components

Lubricate moving parts regularly

Replace damaged or worn-out ball joints or control arms

(b). Rough Ride

Causes:

Worn-out or damaged shock absorbers or struts

Inadequate or uneven tire pressure

Damaged or worn springs

Misaligned wheels or suspension components

Remedies:

Replace worn-out or damaged shock absorbers or struts

Check and adjust tire pressure to the manufacturer's specifications

Replace damaged or worn springs

Perform wheel alignment and inspect suspension components for proper alignment and condition

03.

1. What is a Steering Ratio?

The steering ratio is a measure of how much the steering wheel needs to be turned to turn the vehicle's
wheels by a certain angle. It is the ratio of the angle turned by the steering wheel to the angle turned by
the wheels. For example, if turning the steering wheel by 360 degrees results in the wheels turning by 30
degrees, the steering ratio is 12:1. A higher steering ratio means more turns of the steering wheel are
required for the same turn of the wheels, resulting in a lighter but less responsive steering feel.
Conversely, a lower steering ratio means fewer turns of the steering wheel are needed, resulting in a
more responsive but heavier steering feel.

11. Types of Steering Systems Used in Motor Vehicles

Rack and Pinion Steering System

Commonly used in passenger cars.

Provides a direct and precise steering feel.

Recirculating Ball Steering System

Often used in trucks and larger vehicles.

Known for durability and the ability to handle heavier loads.

Electric Power Steering (EPS) System

Uses an electric motor to assist the driver.

Improves fuel efficiency and allows for advanced features like lane keeping assistance.

III. Causes and Repair Solutions for Steering Symptoms

(a). Hard Steering

Causes:

Low power steering fluid level.

Faulty power steering pump.

Clogged power steering hose or filter.

Worn or damaged steering rack.

Belt issues (e.g., loose or worn-out belt driving the power steering pump).

Misaligned or damaged front-end components.

Repair Solutions:

Check and refill the power steering fluid.

Inspect and, if necessary, replace the power steering pump.

Clean or replace clogged hoses and filters.

Repair or replace the steering rack.

Inspect and replace the drive belt if needed.

Perform a front-end alignment and inspect for damaged components.

(b). Excessive Play or Looseness in the Steering System

Causes:

Worn tie rod ends.

Worn or damaged steering gear or rack.

Loose steering column or intermediate shaft.

Worn ball joints.

Worn idler or pitman arms (in recirculating ball systems).

Loose or worn wheel bearings.

Repair Solutions:

Inspect and replace worn tie rod ends.

Repair or replace the steering gear or rack.

Tighten or replace the steering column or intermediate shaft.

Inspect and replace worn ball joints.

Replace worn idler or pitman arms.

Inspect and tighten or replace wheel bearings.

Proper diagnosis is essential before attempting any repairs to ensure the correct cause of the issue is
addressed.

04.

Part 1: Five Important Angles in Steering Geometry

Camber Angle

Caster Angle

Toe Angle

Kingpin Inclination (Steering Axis Inclination)

Ackermann Angle

Part 2: Explanation of Two Angles

1. Camber Angle

The camber angle is the angle between the vertical axis of the wheels and the vertical axis of the vehicle
when viewed from the front or rear. This angle can be either positive (top of the wheel tilts outward) or
negative (top of the wheel tilts inward).
Importance:

Improves Cornering: A negative camber can improve grip during cornering by placing the tire tread flat
on the road when the vehicle is turning.

Reduces Tire Wear: Proper camber angle helps in distributing the load evenly across the tire, reducing
uneven tire wear.

Stability and Control: The right camber angle enhances vehicle stability and control, particularly in high-
speed turns.

2. Caster Angle

The caster angle is the angle formed by the steering axis and the vertical axis when viewed from the side
of the vehicle. This angle can be positive (top of the steering axis tilts toward the rear) or negative (top of
the steering axis tilts toward the front).

Importance:

Improves Straight-Line Stability: A positive caster angle helps in maintaining straight-line stability by
providing a self-centering action to the steering.

Enhances Cornering: Positive caster also aids in better cornering by increasing the dynamic camber of the
outer wheel in a turn, which improves grip.

Steering Feel: It provides a better steering feel and feedback to the driver, contributing to overall driving
confidence and comfort.

(III). Live Pre-Visit Factors to Consider Before Wheel Alignment

Tire Condition:

Inspect the tires for wear and tear, bulges, or uneven wear patterns. Uneven tire wear can indicate
alignment issues, and damaged tires should be replaced before alignment.

Vehicle Load:

Ensure the vehicle is at its normal operating weight, including regular cargo and passengers. This ensures
the alignment settings are accurate for typical driving conditions.

Suspension and Steering Components:

Check for any worn or damaged suspension and steering components, such as ball joints, tie rods, and
bushings. Any issues in these parts should be repaired before alignment.

Tire Pressure:

Verify that all tires are inflated to the manufacturer's recommended pressure. Incorrect tire pressure can
affect alignment measurements and results.

Wheel and Rim Condition:

Ensure the wheels and rims are not damaged or bent. Damaged wheels can affect alignment accuracy
and may need to be repaired or replaced.

Vehicle History:

Review the vehicle's maintenance history for any past alignment issues or repairs that could influence
the current alignment process.

Road Test:

Conduct a brief road test to identify any noticeable issues with steering, handling, or unusual noises that
might indicate underlying problems affecting alignment.

(IV). Four Defects as Causes of Incorrect Wheel Alignment

Worn or Damaged Suspension Components:

Worn out or damaged suspension components, such as ball joints, control arms, and bushings, can lead
to misalignment. These components are crucial for maintaining proper wheel angles and ensuring the
wheels are correctly aligned with the vehicle's frame.

Bent or Damaged Wheels and Rims:

Hitting a curb, pothole, or other obstacles can bend or damage the wheels and rims. A bent wheel can
cause the tire to sit at an incorrect angle, leading to alignment issues.

Misaligned Steering Components:

Misaligned or damaged steering components, such as tie rods and steering racks, can cause the wheels
to point in different directions. This misalignment can result in uneven tire wear and poor handling.

Improper Installation of Suspension or Steering Parts:

If suspension or steering parts are not installed correctly after a repair or modification, it can lead to
incorrect alignment. Proper installation and alignment procedures must be followed to ensure the
vehicle's wheels are correctly positioned.

05.

(1) Features of an Efficient Braking System

An efficient braking system should have the following features:

Reliability: Consistently performs under various conditions without failure.

Stopping Power: Provides sufficient force to stop the vehicle quickly.

Heat Dissipation: Effectively dissipates heat to prevent brake fade.

Responsiveness: Offers quick and precise control over braking force.

Durability: Resistant to wear and tear, ensuring a long service life.

Fade Resistance: Maintains braking performance even under heavy use.

Low Maintenance: Requires minimal maintenance and is easy to service.

Safety Features: Includes features like anti-lock braking systems (ABS) to prevent skidding.

Comfort: Provides smooth and gradual deceleration without causing discomfort.

Compatibility: Works well with other vehicle systems, such as suspension and tires.

(11) Major Advantages of Disk Brakes

Better Heat Dissipation: Disk brakes have a better cooling mechanism compared to drum brakes,
reducing the risk of brake fade.

Consistent Performance: They provide more consistent braking performance in various conditions (e.g.,
wet, dry, and dusty environments).

Improved Stopping Power: Disk brakes generally offer superior stopping power.

Less Prone to Deformation: They are less likely to deform under high-stress conditions.

Self-Cleaning: The open design helps in ejecting debris and water, maintaining performance.

Easier Maintenance: Disk brakes are easier to inspect and replace compared to drum brakes.

Weight Distribution: They can be lighter, contributing to better overall vehicle weight distribution and
handling.
(III) Causes and Repair Solutions for Braking System Faults

(a) Excessive Pedal Travel

Causes:

Air in the Brake Lines: Air bubbles in the hydraulic system can cause the brake pedal to travel further
than usual.

Worn Brake Pads/Shoes: Excessive wear can result in more pedal travel.

Low Brake Fluid Level: Insufficient brake fluid can lead to increased pedal travel.

Faulty Master Cylinder: A failing master cylinder can cause excessive pedal travel.

Flexible Brake Hoses: Worn or damaged brake hoses can expand under pressure, causing excessive
travel.

Repair Solutions:

Bleed the Brake System: Remove air from the brake lines.

Replace Worn Components: Install new brake pads, shoes, or other worn parts.

Check and Refill Brake Fluid: Ensure the brake fluid is at the proper level.

Inspect and Replace Master Cylinder: If faulty, replace the master cylinder.

Replace Brake Hoses: Install new, non-expanding brake hoses.

(b) Spongy Pedal Feel

Causes:

Air in the Brake Lines: Air bubbles in the hydraulic system can create a spongy pedal feel.

Moisture in Brake Fluid: Contaminated brake fluid can cause a soft pedal.

Worn Brake Pads/Shoes: Worn components can contribute to a spongy feel.

Damaged Brake Lines: Flexible brake lines can swell, causing a spongy pedal.

Repair Solutions:
Bleed the Brakes: Remove air from the brake lines.

Replace Brake Fluid: Flush and refill with clean brake fluid.

Replace Worn Components: Install new brake pads or shoes.

Inspect and Replace Brake Lines: If damaged, replace the brake lines.

(c) Inefficient Braking

Causes:

Worn Brake Pads/Shoes: Excessive wear can reduce braking efficiency.

Contaminated Brake Fluid: Dirty or old brake fluid can impair braking performance.

Glazed Brake Pads/Rotors: Glazing can reduce friction and braking power.

Faulty Brake Calipers: Sticking or failing calipers can lead to inefficient braking.

Malfunctioning ABS: Problems with the anti-lock braking system can affect overall braking efficiency.

Repair Solutions:

Replace Worn Components: Install new brake pads, shoes, or rotors.

Flush and Replace Brake Fluid: Use fresh, uncontaminated brake fluid.

De-glaze Brake Pads/Rotors: Resurface or replace glazed pads and rotors.

Inspect and Repair Calipers: Fix or replace faulty brake calipers.

Check and Repair ABS: Diagnose and fix issues with the ABS system.

06.

(i) Purpose of Anti-lock Braking System (ABS)

The purpose of the Anti-lock Braking System (ABS) is to prevent the wheels of a vehicle from locking up
during braking. This ensures that the driver maintains steering control and the vehicle remains stable and
maneuverable during emergency stops or on slippery surfaces. ABS improves overall vehicle safety by
reducing the risk of skidding and maintaining better traction.

(ii) Actuators and Sensors Used in ABS Braking System

Sensors:

Wheel Speed Sensors: Measure the speed of each wheel to detect when a wheel is about to lock up.

Brake Pressure Sensors: Monitor the hydraulic pressure in the braking system.

Yaw Rate Sensors: Measure the vehicle's rotational speed to help in stability control.

Actuators:

Hydraulic Valves: Control the brake fluid pressure to each wheel based on signals from the ABS control
module.

Pump Motor: Reapplies pressure to the brakes after it has been reduced by the hydraulic valves to
prevent wheel lock-up.

(iii) Purpose of Traction Control System (TCS)

The purpose of the Traction Control System (TCS) is to prevent wheel slip during acceleration. TCS
enhances vehicle stability and control by automatically adjusting the power delivered to the wheels,
reducing engine power, or applying brake force to individual wheels when it detects loss of traction. This
is especially useful in conditions where road grip is low, such as on wet or icy roads.

(iv) Four Causes for "Pulling the Vehicle to One Side Braking"

Uneven Brake Pad Wear: If the brake pads on one side of the vehicle are more worn than those on the
other side, it can cause the vehicle to pull to one side when braking.

Malfunctioning Brake Caliper: A sticking or seized brake caliper can apply uneven braking force, leading
to pulling.

Brake Fluid Leak: A leak in the brake fluid line can cause reduced braking efficiency on one side, resulting
in the vehicle pulling to the opposite side.

Misaligned Wheels: Poor wheel alignment can cause uneven tire wear and lead to the vehicle pulling to
one side during braking.