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

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

2. Objective • By the end of this presentation • You should understand the basic principals of automotive technology • You should understand the terminology associated with modern vehicles • You should know where to find additional information

3. Objective This should allow you to…. • Use your enhanced technical understanding to help you make better use out of future product training • Improve you understanding of customers’ needs and concerns • Better understand the impact a vehicle’s performance has on customer satisfaction • More effectively identify customers’ requirements and discuss technical topics more confidently

4. Lets break things down into manageable groups Engine Transmission Running gear Electrics Safety

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

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

7. Engine The four stroke cycle of a petrol engine or Spark Ignition (SI) engine Intake Compression Combustion Exhaust

8. Engine The four stroke cycle in three dimensions Induction Compression Power Exhaust

9. Engine The four stroke cycle

10. Engine The four stroke cycle

11. Engine The four stroke cycle of a diesel or Compression Ignition (CI) engine Intake Compression Combustion Exhaust

12. 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.

13. Engine In line six cylinder engine Eight cylinder “V” engine (known as a V8)

14. Engine Six cylinder narrow “V” engine (known as a VR6) 12 cylinder “W” engine (known as a W12)

15. Engine In line four cylinder “V” six cylinder Flat four cylinder (boxer)

16. Engine W 12 engine found in the Bentley Continental GT.

17. Engine The cooling system Head cooling Thermostat Radiator cap Heater fan Expansion bottle Heater matrix Radiator Block cooling Water pump Cooling fan

18. Engine The cooling system

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

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

21. 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

22. Transmission Three basic options Front Wheel Drive Rear Wheel Drive All Wheel Drive

23. 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.

24. Transmission

25. 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.

26. Running gear Brakes Steering Suspension

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

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

29. Running gear Brake system layout

30. 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.

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

32. Running gear Steering

33. Running gear Suspension Rear Suspension Front Suspension

34. 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.

35. 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

36. 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.

37. 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.

38. 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.

39. 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.

40. Electrics 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. 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.

41. 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.

42. 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.

43. 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.

44. 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.

45. 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)

46. End Questions ?