basic automotive technology an introduction to basic automotive technology for non technical staff....

Basic Automotive technology

An introduction to basic automotive technology for non technical staff.

Presented by Selamat Basir


By the end of this presentation

1. You should understand the basic principals of automotive technology

2. You should understand the terminology associated with modern vehicles

3. You should know where to find additional information

Objective


Objective

This should allow you to….

1. Use your enhanced technical understanding to help you

make better use out of future product training

2. Improve you understanding of customers’ needs and

concerns

3. Better understand the impact a vehicle’s performance has

on customer satisfaction

4. More effectively identify customers’ requirements and

discuss technical topics more confidently


Engine

Transmission

Running gear

Electrics

Safety

Lets break things down into manageable groups


Engine

In line 4 cylinder, single over head camshaft, 8 valve engine

Camshaft

Valves

Pistons

Timing belt

Distributor

Flywheel

Crankshaft


Engine

Intake valve

Valve cover

Intake port

Cylinder head

Coolant

Engine block

Oil sumpOil

Crankshaft

Camshaft

Spark plug

Exhaust valve

Exhaust port

Piston

Con-rod

Big-end

The same engine from a different view


Engine

The four stroke cycle of a petrol engine or Spark Ignition (SI) engine

Intake Compression Combustion Exhaust


Engine

The four stroke cycle in three dimensions

Induction Compression Power Exhaust


Engine

The four stroke cycle


Engine

The four stroke cycle of a diesel or Compression Ignition (CI) engine

Compression Combustion ExhaustIntake


Engine

SI engine: spark ignition, air and fuel drawn in to the engine & ignited by spark plug. (Petrol)

CI engine: compression ignition, only air drawn into the engine. The fuel is injected at TDC & self ignites. (Diesel)

SI is quieter, smoother, lighter and more responsive

CI is more efficient more economical and more reliable.


Engine

60 - 120°

1

2

3

4 8

7

6

5

60 - 120°

1

2

3

4 8

7

6

5

In line six cylinder engine

Eight cylinder “V” engine (known as a V8)


Engine

72°

15° 15°

72°

15° 15°

15°15°

Six cylinder narrow “V” engine (known as a VR6)

12 cylinder “W” engine (known as a W12)


Engine

In line four cylinder

“V” six cylinder

Flat four cylinder (boxer)


W 12 engine found in the Bentley Continental GT.

Engine


The cooling system

Head cooling

Block cooling

Thermostat

Radiator cap

Water pump Cooling fan

Expansion bottle

RadiatorHeater matrix

Heater fan

Engine


Engine

The cooling system


Fuel tank

Fuel pump

Fuel filter

Distributor

Ignition coil

Oxygen sensor

Knock sensor

ECU

Throttle position sensor

Injector

Air mass meter

Cold start injector

Manifold pressure sensor

Fuel rail Fuel pressure regulator Non return valve

Crank position sensor Temp sensor Battery

Engine


Turbocharger:Gives almost limitless improvements in engine performance.

Efficiency is high as the charger is driven by waste exhaust gas.

Engine


Closed loop three way catalytic converter.

Reduces the emission of the three main pollutants produced by combustion Nox, CO & HC.

A - Reduction Catalyst B - Oxidation Catalyst C - Honeycomb

Engine


Transmission

Front Wheel Drive

Rear Wheel Drive

All Wheel Drive

Three basic options


Transmission

Manual transmission is controlled by the driver using the gear stick, can be 4, 5 or 6 speed. Needs a clutch to allow for smooth gear changes and for pulling away from rest.Advantages: More efficient, More reliable.

Semi Automatic transmissions are becoming more common these days. The most basic types are really just an Automatic transmission but with some driver input possible. Some of the most advanced systems are derived from F1 and give the driver full control plus better acceleration and quicker gear changes.


Transmission


Transmission

Automatic or manual

Automatic transmission is controlled by hydraulic pressure or by electronics or by a mixture or the two, can be 3, 4, 5 or 6 speed. Does not need a clutch as the take up of the drive is done automatically as are the gear changes.

Advantages: Smooth, Easy to drive.


Running gear

Brakes Steering Suspension


Running gear

Disc brakes

Brake calliper

Wheel hub

Brake pad grips disc

Brake cylinder Disc joined to wheel

Hydraulic cylinder

Callipers force pad onto disc

Fluid enters brake cylinder

Fluid goes down pipe

Disc

Brake lever pressed


Running gear

Drum brakes Brake shoe

Hydraulic cylinder pushed brake shoe

onto drum

Springs pull shoes away from drum when brake is

released


Running gear

Brake system layout


Running gear

ABS brakes, Anti-lock Brake System

Wheels speed sensors send signals to the ECU for comparison. If the signals show a wheel to be rotating at a different speed the ECU can adjust the brake pressure to unlock the wheel.


Running gear

Steering

Can be assisted by a hydraulic pump

Pinion joined to steering column

Steering wheel

Steering column

Rack

Pinion

Steering shaft turns, pinion rotates, driving the rack along

Rack is joined to rods that push the wheels left or right

Rack is pushed along

Pinion turns


Running gear

Steering


Running gear

Suspension

Front Suspension

Rear Suspension


Running gear

Air suspension

The conventional springs are replaced with air suspension units. The units are controlled by an ECU to give optimum performance and comfort. The driver can also select the suspension characteristics, firmer for high performance and softer for greater comfort. The ride height can also be controlled. In some cases where there is a total failure of the electrical system the vehicle will be at its lowest setting and may require to be jacked up so that blocks can be inserted to give sufficient clearance.


Running gear

Special note for Bentley Continental GT

Prior to raising the motor car, it is necessary to de-activateThe ride height control function, and place in ‘Jack Mode’• Switch on the engine

• Simultaneously press and hold these two buttons located on the lower centre console for 5 seconds• JACK MODE will appear on the drivers information panel • The car can now be lifted, without damage to the air suspension


Running gear

Tyres

If a tyre needs to be replaced it is important that the replacement is of the same size and specification. It is also preferable for the tyre to be the same make.

If a wheel has to be changed the wheel nuts must be tightened with a torque wrench.


Electrics

Battery

Performance can be affected by low temperatures so failure in winter is more common. Hot conditions can also affect battery life. In hot climates battery life can be 18-24 months, in more temperate climates 36-50 months.

If the battery is in good condition but the vehicle is unused for a period of time the battery can become discharged. In most cases trying to start the engine with a discharged battery will cause the battery to fail.


Electrics

BatteryPrecautions:Jump starting the vehicle can damage the control units, to prevent damage jump cables must be surge protected. Alternatively a purpose built booster pack can be used. Connect positive cable first followed by the negative cable, when disconnecting remove the negative first then the positive.

Safety:The acid contained in the battery can cause skin and eye irritation, gloves and goggles should be worn when handling battery's. If a person does come into contact with acid the area should be flushed with water until irritations stops

Battery's produce hydrogen gas which is highly flammable, only work in well ventilated areas and avoid sparks or naked flames. Always disconnect the negative battery terminal first to avoid sparks and when connecting attach the positive terminal first.


Electrics

Starter motor

Uses stored energy from the battery to start the engine. Requires a large amount of current during starting, the larger the engine the more current is needed. This sudden large current draw can cause a weak battery to short circuit and become faulty.


Electrics

AlternatorGenerates electrical power for the vehicle when the engine is running. Is able to produce enough power to run all of the vehicle electrical systems and charge the battery. Alternators are rated in amps.

When an alternator fails there will normally be a warning lamp showing on the dash board. The vehicle can still run for a short time before the battery will become discharged. Normally when the charging system warning lamp is showing the vehicle will need to be recovered to the dealer. Possible causes of failure can be an internal fault requiring a new alternator but loose connections are possible.


Electrics

General

Modern vehicle electrical systems drain current from the battery when the vehicle is switched off. All of the control units (ECU) require current to retain their memory, radios, clocks, alarm systems also require current. In some cases vehicles will have two battery's, one for starting and one for delivering power to consumers.

If the battery becomes discharged and is either changed or jump started it is possible for an ECU to record a fault in its memory due to low current. This fault may cause a warning light or multiple warning lights to be displayed on the dashboard. In cases like this the vehicle should be recovered to the dealer for investigation. Starting the vehicle may not be possible after the battery has been discharged and or changed due to loss if signal to the immobilizer system. To resolve this the dealer will need to re-set the immobilizer so recovery will be necessary.


Electrics

Immobilisers

To prevent theft many modern vehicles employ an immobiliser system. The system prevents the engine from being started by an unauthorised person. The system can be activated by a transponder or by an infrared remote control.


Electrics

CAN data bus = Controller Area Network

Modern vehicles can have up to 20 Electronic Control Units and the speed of data transfer is vital for effective operation. Many new cars now employ this CAN data bus system to speed up communications.


Safety

Passive safety

Passive safety systems are designed to reduce injury and increase survivability in the event of an accident.

Passive safety systems include, Air bags, Seat belts, crumple zones and safety cells.


Safety

Active safety

Active safety systems are designed to help the driver avoid accidents.

Active safety systems include, ABS, ESP, TCS, EBD, EBC and HBA.

ABS=Anti-lock Brake System (prevents wheels locking up when braking)

ESP=Electronic Stability Programme (prevents vehicle skidding when cornering)

TSC=Traction Control System (prevents wheels from spinning under acceleration)

EBD=Electronic Brake Distribution (ensures correct distribution of braking force)

EBC=Engine Brake Control (assists foot brake to slow the vehicle)

HBA=Hydraulic Brake Assistance (increases the power of the brakes)


End

Questions ?

basic automotive technology an introduction to basic automotive technology for non technical staff....

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