An introduction to basic automotive technology for non

An introduction to basic automotive technology for non technical staff. Presented by Selamat Basir Basic Automotive technology

Objective 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 Basic Automotive technology

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 Basic Automotive technology

Lets break things down into manageable groups Engine Transmission Running gear Electrics Safety Basic Automotive technology

Engine Camshaft Distributor Valves Flywheel Pistons Crankshaft Timing belt In line 4 cylinder, single over head camshaft, 8 valve engine Basic Automotive technology

Engine The same engine from a different view Camshaft Intake valve Exhaust valve Valve cover Spark plug Exhaust port Intake port Cylinder head Piston Con-rod Coolant Big-end Engine block Crankshaft Oil sump Oil Basic Automotive technology

Engine The four stroke cycle of a petrol engine or Spark Ignition (SI) engine Intake Compression Basic Automotive technology Combustion Exhaust

Engine The four stroke cycle in three dimensions Induction Compression Basic Automotive technology Power Exhaust

Engine The four stroke cycle Basic Automotive technology

Engine The four stroke cycle Basic Automotive technology

Engine The four stroke cycle of a diesel or Compression Ignition (CI) engine Intake Compression Basic Automotive technology Combustion Exhaust

Engine SI engine: spark ignition, air and fuel drawn in to the engine & ignited by spark plug. (Petrol) SI is quieter, smoother, lighter and more responsive CI engine: compression ignition, only air drawn into the engine. The fuel is injected at TDC & self ignites. (Diesel) CI is more efficient more economical and more reliable. Basic Automotive technology

Engine In line six cylinder engine Eight cylinder “V” engine (known as a V 8) Basic Automotive technology

Engine Six cylinder narrow “V” engine (known as a VR 6) 12 cylinder “W” engine (known as a W 12) Basic Automotive technology

Engine In line four cylinder “V” six cylinder Flat four cylinder (boxer) Basic Automotive technology

Engine W 12 engine found in the Bentley Continental GT. Basic Automotive technology

Engine The cooling system Head cooling Thermostat Radiator cap Heater fan Expansion bottle Heater matrix Radiator Block cooling Basic Automotive technology Water pump Cooling fan

Engine The cooling system Basic Automotive technology

Engine Fuel tank Fuel rail Fuel pressure regulator Non return valve ECU Throttle position sensor Fuel pump Fuel filter Injector Distributor Air mass meter Ignition coil Cold start injector Oxygen sensor Manifold pressure sensor Knock sensor Crank position sensor Basic Automotive technology Temp sensor Battery

Engine Turbocharger: Gives almost limitless improvements in engine performance. Efficiency is high as the charger is driven by waste exhaust gas. Basic Automotive technology

Engine Closed loop three way catalytic converter. A - Reduction Catalyst B - Oxidation Catalyst C - Honeycomb Basic Automotive technology Reduces the emission of the three main pollutants produced by combustion Nox, CO & HC.

Transmission Three basic options Front Wheel Drive Rear Wheel Drive All Wheel Drive Basic Automotive technology

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 F 1 and give the driver full control plus better acceleration and quicker gear changes. Basic Automotive technology

Transmission Basic Automotive technology

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. Basic Automotive technology

Running gear Brakes Basic Automotive technology Steering Suspension

Running gear Disc brakes Hydraulic cylinder Brake lever pressed Brake pad grips disc Disc Fluid goes down pipe Brake calliper Fluid enters brake cylinder Callipers force pad onto disc Wheel hub Brake cylinder Basic Automotive technology Disc joined to wheel

Running gear Drum brakes Springs pull shoes away from drum when brake is released Basic Automotive technology Brake shoe Hydraulic cylinder pushed brake shoe onto drum

Running gear Brake system layout Basic Automotive technology

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. Basic Automotive technology

Running gear Steering Can be assisted by a hydraulic pump Steering wheel Pinion joined to steering column Steering column Pinion Rack is joined to rods that push the wheels left or right Steering shaft turns, pinion rotates, driving the rack along Rack Pinion turns Basic Automotive technology Rack is pushed along

Running gear Steering Basic Automotive technology

Running gear Suspension Rear Suspension Front Suspension Basic Automotive technology

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. Basic Automotive technology

Running gear Special note for Bentley Continental GT Prior to raising the motor car, it is necessary to de-activate The 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 Basic Automotive technology

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. Basic Automotive technology

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. Basic Automotive technology 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 Battery Precautions: 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. Basic Automotive technology

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. Basic Automotive technology

Electrics Alternator Generates 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. Basic Automotive technology 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. Basic Automotive technology

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. Basic Automotive technology

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. Basic Automotive technology

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. Basic Automotive technology

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) Basic Automotive technology

End Questions ? Basic Automotive technology