Akhil Bharatiya Maratha Shikshan Parishad's

Anantrao Pawar College of Engineering & Research

B.Voc Automobile Servicing

Second year
Question Bank for Automobile Electrical System

Que1. a) What is a spark plug? Draw the diagram and list down its parts (8)
Answer: The spark plug is a device that produces an electric spark to ignite the compressed air-
fuel mixture inside the engine cylinder. The spark plug is screwed into the top of the
cylinder so that its electrodes project into the combustion chamber.

Following are the main parts of a spark plug:

1. Centre electrode or insulated electrode.

2. Earth electrode.
3. Insulation separates the two electrodes.
4. Terminal
5. Shell
6. Stud
7. Contact spring
8. Core nose
9. Silment seal
10. Rust-resistant shell
11. Ceramic insulator

Description of Parts:
1. The upper end of the center electrode is connected to the spark plug terminal, where the
H.T. cable from the ignition coil is connected and surrounded by a porcelain insulator.
2. The below half portion of the insulator is fastened with a metal shell. The lower portion of
the shell has a short electrode attached to one side and bent in towards the center electrode
so that there is a gap between the two electrodes.
3. The two electrodes are thus separated by the insulator. The sealing gaskets are provided
between the insulator and the shell to prevent the escape of gases under various temperature
and pressure conditions.

Que1. b) What are types of spark plug? (8)

Following are the main types of spark plugs:

1. Copper spark plugs

2. Platinum spark plugs
3. Iridium spark plugs
4. Double platinum spark plugs
5. Plustar spark plugs
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6. Silver spark plugs

1. Copper Spark Plugs:

 These types of spark plugs are very popular nowadays. As the name suggests, these
spark plugs have a copper core and use a nickel alloy at the working end of the
electrode that generates the spark.
 Since both nickel and copper have relatively low melting points, the edge of these
electrodes wears out quickly, resulting in a gap as small as 10,000 miles. This leads
to misfires, reduced gas mileage, and damage to coils and ignition wires. Most
high-performance vehicles are built with this spark plug because of its efficiency.
2. Platinum Spark Plugs:
 Platinum spark plugs typically have a platinum disc at the end of the electrode tip,
which protects the electrode edge with its high melting point. Platinum is a precious
metal which makes these spark plugs very expensive.
 These spark plugs feature long life, typically 30-40 thousand miles, and are hotter
than copper type. Platinum metal is quite hard, resulting in increased durability of
spark plugs. Platinum spark plugs are more resistant to carbon buildup.
3. Iridium Spark Plugs
 Iridium is a more rigid metal than platinum and has an even higher melting point,
allowing these spark plugs to last about 25% longer than platinum-type spark plugs.
When high power output from the engine is required, iridium spark plugs are used.
 Since they have a smaller electrode tip diameter, which increases spark efficiency
and improves engine function. They provide a very efficient spark, thus ensuring
complete combustion and running the engine smoothly. Due to their high cost, they
are less likely to be used.
4. Double Platinum Spark Plugs
 They are similar to platinum spark plugs, but the only difference is that both their
electrodes are made of platinum, i.e. the ground electrode as well as the center
electrode, both are made of platinum.

5. Plustar Spark Plugs

 Plustar plugs create a high-intensity electrical pulse by adding an internal capacitor
TP stores energy and releases, it beyond the benefits of conventional plugs.
 It uses pulsed electricity technology to convert a small portion of the gaseous air-
fuel mixture into a highly excited plasma that ignites instantly and burns quickly.
This offers a more powerful and consistent engine that starts quickly, idles
smoothly, generates more torque, uses less fuel, and emits less.
6. Silver Spark Plugs
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 As the name suggests, spark plugs are made using silver metal. They are known for
high performance and excellent thermal conductivity. This type of spark plug is
commonly used in European high-performance vintage cars and motorcycle
engines.
 Despite their advantages, they have a short lifespan and low durability. These spark
plugs are further classified into two types based on the amount of heat dissipation
and operating temperature. They are described below.
I. Hot spark plug:
 Heat range is a means of designating how hot a plug will run in operation.
It refers to the ability of the spark plug to heat transfer from the firing tip of
the insulator to the cooling system of the engine.
 The temperature that a spark plug will attain depends upon the distance
through which the heat is transferred. If the oath of heat travel is long, the
plug will run hotter than if the path is short.
 This types of spark plug have a longer path of heat travel and run hotter
than the cold spark plug which has a shorter path of heat travel and runs
cooler.

II. Cold spark plug:

 These types of spark plugs are used in the heavy-duty continuous running
high-speed engine to avoid overheating. When a plug runs tool cold, the
carbon deposits on the insulator around the center electrode.
 A hotter running plug will burn this carbon away and prevent its formation.
A plug that runs hot will wear more rapidly since the high temperature
causes the electrode to burn away more quickly.

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Que1. c) Explain working of Spark Plug? (8)

 The use of the spark plug is to produce an electric spark to ignite the compressed air-
fuel mixture inside the engine cylinder. It must produce the spark at the correct
movement at the end of the compression stroke.
 A proper gap is to be maintained between the two electrodes of the spark plug so that
the sparking may take place. When the spark plug is screwed into the cylinder head,
the ground electrode is said to be connected with the ground.
 The terminal of the center electrode is directly connected with the H.T. lead of the
ignition coil in the case of a single-cylinder engine, or through the distributor in the
case of a multi-cylinder engine.
 The secondary circuit of the electrical system is to be completed through the gap
between the electrodes. When the H.T. current passes through the circuit, it jumps the
gap producing a spark, which ignites the compressed air-fuel mixture in the cylinder.

Que2. a) Explain Capacitor Discharge Ignition (CDI). What are advantages & Disadvantages
(8)
 Capacitor discharge ignition (CDI) or thyristor ignition is a type of automotive
electronic ignition system which is widely used in outboard motors, motorcycles,
lawn mowers, chainsaws, small engines, turbine-powered aircraft, and some cars.
 It was originally developed to overcome the long charging times associated with
high inductance coils used in inductive discharge ignition (IDI) systems, making

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the ignition system more suitable for high engine speeds (for small engines, racing
engines and rotary engines).
 The capacitive-discharge ignition uses capacitor discharge current to the coil to
fire the spark plugs.
The advantages of CDI include the following.
 The major advantage of CDI is that the capacitor can be fully charged in a
very short time (typically 1ms). So the CDI is suited to an application
where insufficient dwell time is available.
 The capacitor discharge ignition system has a short transient response, a
fast voltage rise (between 3 to 10 kV/ µs) compared to inductive systems
(300 to 500 V/ µs), and a shorter spark duration (about 50-80 µs).
 The fast voltage rising makes CDI systems unaffected to shunt resistance.
The disadvantages of CDI include the following.
 The capacitor discharge ignition system generates huge electromagnetic
noise and this is the main reason why CDIs are rarely used by automobile
manufacturers.
 The short spark duration is not good for lighting relatively lean mixtures
as used at low power levels. To solve this problem many CDI ignitions
release multiple sparks at low engine speeds.

Que2. b) What is Magneto Ignition System? (8)

 A combustion engine that has some flaming features, such as high speed and high
internal compressions, requires a system that produces very high ignitions from
spark plugs that are used as a source.
 The ignitions system is the system that uses spark plugs as their source where
electrical energy input is given to the spark plug.
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 Magneto is a major part of this type of ignition system as it is a source of energy.

A magneto is a small electrical generator that is rotated by the engine and is
capable of producing very high voltages, and does not require a battery as a source
of external power.
 The magneto has both primary and secondary windings and thus does not require
a separate coil to boost the voltage required to operate the spark plug.
 There are two types of the magneto. The first one is known as the rotating
armature type, and the other is known as the rotating magnet type.
 In the first type, the armatures rotate between stationary magnets. On the other
hand, the second type of armature is stationary, and the magnets are moving
around the armature.

Que.3 a) What are requirements of automobile lighting and explain its types. (5)

1. level of minimum illumination (normal visibility)

2. maximum light intensity (but not blinding drivers of cars moving to the meeting)
3. Conventional headlights should provide high-quality lighting, and such a paradox –
the larger the size of the reflector, the better the light quality of the dipped
headlights.
4. On the geometric component of the range, the effect of the headlight increases with
the height of the headlight.
A. Front exterior lighting includes the:
1. Low beam headlamp (passing beam)
2. High beam headlamp (driving beam)
3. Front fog headlamp
4. Daytime running light (DRL)
5. Turn indicator
6. Front position lamp
B. In the rear, the lighting includes the:

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1. Taillight position lamp (tail lamp)

2. Taillight stop-lamp
3. Turn indicator
4. Reversing light
5. Rear fog lamp
6. Center high-mounted stop light (CHMSL)
7. Along the sides of a vehicle, there may be:
8. A side turn indicator (fender or side mirror)
9. Side marker lights

Que.3 a) Explain Tungsten Halogen Lamps. (5)

 Tungsten Halogen Lamps are similar in construction to conventional gas filled
tungsten filament lamps except for a small trace of halogen (normally bromine)
in the fill gas.
 The halogen gas reacts with the tungsten that has evaporated, migrated outward,
and been deposited on the lamp wall. As the quartz envelope wall reaches a
temperature of approximately 250C, the halogen reacts with the tungsten to form
tungsten halide, which is freed from the wall of the lamp and migrates back to the
filament.
 The filament of a Tungsten Halogen Lamp has two purposes. One is to generate
light, and the second is to generate the heat necessary to obtain a wall temperature
exceeding 250C.
 Tungsten Halogen Lamps are ideal light sources for spectrophotometers as they
provide broad band spectral radiation ranging from the ultraviolet, through the
visible and into the infrared out to five microns. Some radiation output can be
obtained at 320 and 340 nanometers.

b) Explain the auxiliary front Fog light, Brake Light, Flasher Unit? (5)
Fog Light:
 Front fog lights provide a wide, bar-shaped beam of light with a sharp cutoff at
the top, and are generally aimed and mounted low.
 They may produce white or selective yellow light, and were designed for use at
low speed to increase the illumination directed towards the road surface and
verges in conditions of poor visibility due to rain, fog, dust or snow.
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 They are sometimes used in place of dipped-beam headlights, reducing glare from
fog or falling snow.
Brake Light:
 The brake light switch on your vehicle serves an important safety function. When
you press the brake pedal, it supplies power to the signal lights at the back of your
vehicle to warn other drivers you have slowed.
 Current designs employ a relay, allowing a lower-voltage control circuit to operate
the main power supply switch for the brake lights. This configuration creates a
reliable switching mechanism with a long lifespan.
Flasher Unit:
 The flasher unit, often called “flasher relay”, controls the flashing impulse of the
vehicle’s flasher. A defect of the flashing light is signalized by a change of the
flashing frequency of the indicator lamps.
 When towing a trailer, the original flashing unit normally is replaced by a flashing
unit with C2 function, and an additional indicator lamp is installed in the
combination instrument. When exchanging the flasher unit, the connecting panel
of the original flasher unit has to be considered.

c) Explain the warning lights?

1. Oil Pressure Warning: Oil Pressure

Warning: If this light stays lit it indicates loss
of oil pressure. Immediately check oil level
and pressure.

2. Battery/Charging Alert: Indicates voltage

level is below normal level and the vehicle’s
charging system is not functioning properly.
Check battery terminals, alternator belt, and
battery condition.

3. Check Engine or Malfunction Indicator Light

(MIL): Indicates the engine computer has set a
Diagnostic Trouble Code (DTC). Usually
requires diagnosis with a professional scan tool.

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4. ABS Light: Indicates that the Anti-lock Brake

computer has set a code and needs professional
diagnosis.

5. Lamp Out: Indicates that there is an exterior

light on the vehicle that is not functioning
properly.

6. Door Ajar: Indicates that a door (including

hood and trunk) is not closed. Open and close all
doors, including hood and trunk. If vehicle is left
in this condition overnight it can drain the
battery

7. Brake System: Indicates one of three possible

conditions: parking brake is on; problem with
the braking system/brake fluid is low, or ABS
problem. Check brake fluid and make sure the
parking brake is fully released. If the problem is
in
8. the
TPMSABS(Tire
system, it may
Pressure need a professional
Monitoring System): Indicates the
diagnosis.battery
tire pressure monitoring system has found a tire with low air
pressure or there may be a sensor malfunction. Check tire
pressure. Some vehicles will allow manual reset of TPMS
warning light and others will require professional diagnosis.

9. Airbag Fault: If this light stays illuminated after starting it

indicates that the vehicle has found a fault in the airbag
system and the computer has set a code. Professional repair
of the supplemental restraint system is highly recommended.

10. Cruise Control: Indicates that cruise control is

set during driving.

c) Explain Adaptive Front-lighting System and its Functions?

 The Adaptive Front-lighting System (AFS) is one part of the active safety system
of a middle-high end passenger car, providing an optimized vision to the driver
during night time and other poor-sight conditions of the road by adapting the
headlight angle and intensity, and judging the speed of the car, the steering wheel
angle, the weather condition, and yaw and tilt rate of the car.

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 Functions:
1. Town passing beam (Class V): At speeds below 50 km/h, town light provides
a wider light distribution at reduced range, helping drivers to more clearly see
pedestrians on the edge of the road.
2. Basic/Country passing beam (Class C): The basic light illuminates the left-
and right-hand edges of the road more brightly and widely than the
conventional low beam. It is usually activated at speeds between 50 and 100
km/h.
3. Motorway passing beam (Class E): Motorway light improves vision on
highways and expressways. From 100 km/h, this beam illuminates the
roadway significantly further ahead and focuses more on the left-hand edge of
the road. The motorway light switches on automatically at speeds greater than
100 km/h.
4. Wet-road passing beam (Class W): This beam is activated when the rain
sensor detects precipitation or the windshield wipers are on for 2 minutes or
more. The edges of the road are more strongly illuminated for better
orientation to the guiding lines.
5. Static cornering light: Static cornering light helps during maneuvers in dark
access roads. At speeds of up to 40 km/h, one additional cornering light comes
on when the indicator is actuated or the steering wheel turned through about
90 degrees to the right or left.
6. Dynamic swiveling and leveling:
• Leveling: The AFS adjusts the direction of the headlight (projector)
vertically according to the front and rear chassis height sensors. Adjusting the
pitch angle of the headlight according to static vehicle load transfer (occupant
numbers, luggage) is called static leveling, while adjusting headlight pitch
angle according to dynamic vehicle load transfer (acceleration, deceleration)
is known as dynamic leveling.
• Swiveling: The AFS swivels the headlights horizontally by judging the input
from the steering angle sensor and the speed of the car. The system provides
a curve rate at up to 15 degrees; obstacles become more easily visible.

Que.5 a) Explain Oil Pressure gauge and its working. (5)

 An oil pressure gauge is an essential part of the car and acts as an indicator of your
car's engine's health. This instrument tells you about the well-being of your engine
and acts as an early warning system
 The oil pressure gauge works as a monitor, and its job is to see the oil pressure in
the main oilways near the filter and the pump. The engine block has a tapping and

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either an oil pipe or a sensor screwed into it.

 The oil warning light has a sensor and is screwed into the T-piece or the union. It
doesn't matter if the car has a fitted oil pressure gauge or not.
 The mechanical gauges work because the engine's pressure forces the needle into
the dial. On the other hand, electrical gauges work with a sensor that produces
variable resistance and is screwed into the engine block. This affects the circuit
that has the sensor and the gauge through the current that passes through it.

Que.5 b) Explain cooling water temperature gauge and its working. (5)
 For safety, comfort, performance, and reliability reasons, modern vehicles keep
track of a variety of variables and quantities using sensors and integrated systems.
Among those quantities, the temperature is the most frequently measured variable
for all of the above reasons.
 Any change in external or internal temperature triggers the relevant system to act
accordingly. In fossil fuel vehicles, the engine temperature is continuously
monitored and kept at a certain level to make the engine perform optimally. The
primary sensor involved to monitor the engine temperature is known as the Engine
Coolant Temperature Sensor, and the temperature is regulated via a liquid
substance called engine coolant.
 Engine Coolant Temperature (ECT) sensor measures the engine temperature and
indicates how much heat the engine is giving off. The sensor works with the
Engine Control Module (ECM). ECT sensor monitors the engine coolant
temperature continuously and makes sure the engine is running at the optimum
temperature. The resistance of the temperature sensor (Thermistor) varies with
temperature when ECM sends voltage to the ECT sensor.

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Que.5 b) Explain rear defogger? (5)

 A rear defogger is a system that removes fog and melts frost from a car's rear
windshield. Invented by Heinz Kunert, a German engineer.
 In the case of a rear defogger, we have heating elements made from very fine
wires running across the rear windshield.
 These wires heat up to evaporate the mist or condensation off the glass. These
lines heat up when the rear defogger is activated and thus, reduce fog or mist on
the rear windshield.
The pros or advantages of a rear dogger are:
 Helps keep the rear windshield free of fog
 Improves rear visibility, especially during the rains and winters
The disadvantages:
 Higher cost of repair if rear windshield cracks.
 The heating elements may cause minor rear visibility issues for some people.

Que.5 c) How Does a Car’s Heater Work? (5)

 Heater is part of a system that accomplishes two things. In addition to heating vehicle, it also helps
to keep the car’s engine cool.
There are a few key components like
 Heater Core
 Blower Motor
 Heater Hoses
 Heater Control Valve
 HVAC Control Panel
 Heater interacts with the coolant, thermostat, radiator, and water pump in vehicle’s cooling system.
The heat generated by the engine needs somewhere to go so that the engine doesn’t get too hot,
while you want to be warmer. This makes car’s heating system active.
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 Majority of the heat generated from your engine goes out of through the exhaust system. However,
the rest of it is transferred into the coolant inside your HVAC system.
 This coolant is transferred much in the same way refrigerant moves to create cool air when the air
conditioner is on.

Que.5 c) How Does a Car’s AC Work? (5)

Common parts of air conditioning system are.

 HVAC Control Panel

 Compressor
 Condenser
 Accumulator
 Expansion Valve
 Evaporator
 Blower Motor
 These parts will be in action when you turn on your car’s AC unit through the HVAC control panel.
The compressor constricts the refrigerant, and it begins to lose heat as it passes through the
condenser. The receiver and dryer remove contaminants and moisture, then the refrigerant enters the
expansion valve or accumulator.
 The refrigerant is becoming depressurized and getting cooler. Finally, refrigerant makes its way to
your evaporator, which removes any remaining moisture and cools the temperature even further.
 From there, the ventilation system’s motor blows air over the evaporator, making it cold before
pushing it out of your car’s vents.

Que.5 d) What is significance of Glow Plugs Work? (5)

 A glow plug is a component within your vehicle that is used to aid the starting of your diesel-powered
engine. They are crucial for colder environments, as cold weather can prevent diesel engines from
starting completely.
 Diesel engines rely on the heat created by compression in the chamber in order to properly start.
When a diesel engine is lacking an outside source of heat while also being exposed to extremely
cold weather, the diesel engine will not be able to start. The solutions to this issue are diesel glow
plugs.

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Que.5 e) What is Power door locks and power windows? (6)

 Power door locks (also known as electric door locks or central locking) allow the driver or front
passenger to simultaneously lock or unlock all the doors of an automobile or truck, by pressing a
button or flipping a switch.
 Power windows or electric windows are automobile windows which can be raised and lowered by
pressing a button or switch, as opposed to using a crank handle.

Que.5 e) What is windscreen wiper? (6)

 A windscreen wiper, windshield wiper, wiper blade or simply wiper, is a device used to remove rain,
snow, ice, washer fluid, water, or debris from a vehicle's front window. Almost all motor vehicles,
including cars, trucks, buses, train locomotives, and watercraft with a cabin—and some aircraft—
are equipped with one or more such wipers, which are usually a legal requirement.

Que.5 f) Explain the working of Automotive Horn Principle?

 Horns are the metal diaphragms that vibrate when a vehicle is in motion. It produces sound
electrically using a thin metal disc and an electromagnet or solenoid. As the solenoid gets energized
or triggered by the button, it exerts a force on the metal disc. The byproduct of this process is a loud
vehicle sound known as horns.
 When testing the functionality of a horn, connect it from the battery to the jumper wire and then to
the hot terminal to ensure that it works properly. When the horn does not function properly, it should
be grounded. Once it is working, you will be able to determine what is wrong with the ground
connection. Screws with cadmium plating are frequently used to prevent these types of failures.

Que.5 f) Explain the working of blower in cars?

 The blower assists in moving the air to allow ventilation. The movement of air either flows from
inside to outside or vice versa. This movement effectively transfers any heat present inside the car
to the outside or the opposite side.
 A blower motor resistor controls the speed of a blower. This instrument is present near the blower,
right in the airflow path.

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