Automotive test 1

Duryea Brothers (FRANK CHARLES)

First to make and sell gas powered cars in US

Forced Induction Methords

Forced Ram Supercharging Turbocharging

Longitudinal torsion

Front left and back left on bump. Chassis twists in opposite direction Side and cross members are affected

POWER vs TORQUE

POWER= rate of doing work (depends on torque and rpm) Torque and rpm (measured) HP (calculated)

Four Stroke Engine

1 power stroke every 2 revolutions Valve and fuel injection run half engine speed energy from power stroke is stored in flywheel to proved energy for other stokes

Un-sprung mass

Part not support by springs Rotor, caliper, wheel tire, frame, brake Keep low as possible for better ride and handling

Asymmetrical tread

Pattern changes across tire large tread blocks for increased stability during cornering small inner blocks to disperse water and heat unidirectional

Tread Patterns

Symmetrical Asymmetrical Unidirectional

Compression Ratio

TDC to BDC

DOT age code

4007 40th week of 2007 Change if older than 6 years old

MEP Definition

Theoretical pressure on top of piston during power stroke. Used as a comparison of performance between diff engines. Above 200 only if forced induction Higher the better.

TPS

Throttle Position Sensor Around throttle body Uses potentiometer

3 Bearing on Crankshaft

Thrust Main Rod

TDC

Top dead center

Types of Chassis

Unibody Frame

Engine Management System

Uses voltage inputs from sensors and decides what actuators to use

Variable fan drive

Vary fans speed less power and reduces noise torque or temp driven

Fuel System Components

Vented fuel tank, pressure regulated circuit level indicator fuel pump fuel filter fuel lines

Chassis Stresses

Vertical Bending Longitudinal torsion Lateral Bending Horizontal Lozenging

Horsepower derivation

Watt say that hours could turn mill 2.4 times a min that was 12 in. formula 180lb*2.4*2pi*12/min=33000ftlbf/min

Frame Chassis

Weld body on the frame More comfortable and quieter ride. Put different bodies on different frames (cheaper) Heavy Durability Can be straightened if in collision Holds heavier loads

Axel Components

Wheel carrier Wheel bearings Links Springs Damper

Horizontal Lozenging

Wheel impact from road obstacles Distorts in parallelogram shape

Independent Suspension Rear

Wheels move individually Reduces body movement since wheels both wheels wont be subject to the same forces

Preignition

When heat source other than spark plug ignites air fuel mixture

Hot Wire Method

Wire with current going through is in air stream. Resistance increases when temp increases. Air cools it and rate tells flow.

External Wastegate

Added on exhaust manifold or header Advantage is that exhaust can be dumped downstream of tubine

Rotating Lobe Supercharger

Air drawn between blades and forces out the other side (top down) Air not compressed. Proportional to engien speed More throttle response at lower speeds compared to turbo

Suspension bushings

Bearnign of suspension to allow for movement of component while maintaining alignment Rubber

BOV

Blow-Off valve Prevents turbo surging On intake Between compressor discharge and throttle body Happens when throttle closed rapidly.

BDC

Bottom Dead center

aTDC

after TDC Retarded advance or retarded spark

CMP

Camshaft Position Sensor Around valve cover Tells what part of stroke cylinder is on

Vertical Bending

Cargo Weight concentrated across the middle. the side members will sag from vertical force(look at pic)

Vc

Clearence value Remaining volume above the piston when it reaches TDC to prevent piston from interacting with the valves.

2 forms engine block construction

Closed deck (top is closed) and Open deck (top free standing)

Cylinder Head and Gasket

Closes cylinders Gas porting system Hold spark plug Allows coolant flow

McPherson Suspension

Common because compact and low cost Shock absorber serves as link to control wheel position (eliminates upper control arm) Front or back

2 stoke

Compression Power

Interior cooling flow

Compressor Condnenser Receiver Drier evaporator and blower expansion valve

Exhaust Manifolds

Connect exhaust port to down pipe large port sizes and large radius bends

Solid (Beam) Axles Rear

Connect rear wheel on each side. If one wheel moves the other does too Leaf and coil springs Live if axle is powered

Connecting rod and bearings

Constraining link btwn piston and rotating crankshaft Connects to crankpin (large) and wrist pin (small) Divided in two halves so it can connect to crankpin

Ignition Systems

Contact breaker points and condenser Electronic Ignition

Crankshaft Assembly Function

Converts reciprocating motion at the piston to flywheel One piece contruction Timinnig belt on front and drives pullys and belt drives Flywheel attatched to rear of crank supported by regular and thrust bearings

ECT

Coolant Temperature Sensor outside of block

Charge Cooling (intercooler)

Cools air for more power. Air to air and air to water. Plastic and aluminum

CKP

Crankshaft Position Sensor Bottom of block Reads magnetic pulses Controls ignition timing coil on-time start of injection vtec

Fuel tank criteria

Crash resistance to environmental impremeability resisting to agin good workability manufactrability recyling

Sliding Vane

Cylindrical rotor with slits.

Toothed Timing Belt

No lube Light Easy to replace

Gear Train Drives

Not used Expensive Loud

Ball joints

allow for swiveling and suspension movement Locate wheel assemblies on lateral wishbones or control arms

Internal Wastegate

build in turbine housing and consists of flapper valve, crank arm, rod end and pneumatic actuator

OBD

On board Diagnostics

Intake Manifold V-Engine

One or two tier constructions runners to each cylinder

Dead Axle

Only supports vehicle and rotates

2 types of control system in ECU

Open Loop (set parameters. Cold start that uses more fuel. or open throttle) Closed Loop- normal fuel consumption. works to keep 14.7:1 ratio

Pressure Regulating devices

Orfice Tube Expansion valve

Mr. Olds created what kind of part system?

Other companies build car subassemblys

O2

Oxygen sensor Before and after Cat

Receiver Dryer

Ensures that expansion valve gets liquid refrigerant seperates gas and liquid removes moisture and dirt on high pressure side with expansion valve

EPA

Environmental protection agency

Engine block materials

cast iron and aluminum

3 reasons for open loop

cold start WOT acceleration MIL is on

Fixed fan drive

commercial vehicles rotated by crankshaft

Octane Ratins

compares gas mixture of heptane and iso-octane Measured and researched(motor) /2 if 87 then 13 heptane and 87 iso-octane

Turbocharging

compresses air to increase density, temp and pressure.

Symmetrical Tread Pattern

conssitant accross face same on both halves

Wastegate

control boost pressure of engine Bypass exhaust flow from turbine wheel

New Fuel System

cut our regulater, filter and return line tank-injectors

Progressive rate coil spring

deflects readily under light load and increase its resistance as load increases (soft ride)

Wheel offset

distance in mm betwen center line of wheel rim and line through face positive { I )} center { I) } negative { )I }

EVAP

Evaporative emission control system store and dispose of evaportated fuel vapors delivers fumes to intake manifold to be burnt with fuel uses charcoal that removed at night

Sprung Mass

Everything supported by the spring

Components of ICE

engine block and crankcase piston and rings connection rod and bearings crankshaft assembly and bearings cylinder head and gasket valve train and timing drive engine support mountings

What controls EVAP?

engine speed, intake air volume, coolant temperature and o2 sensor.

Coil springs

formed from single steel rod Absorb force by twisting Front suspension of most modern light vehicles Load depends on diameter of wire and spring, shape and spacing of coils

Tire sizes 31x10.5x15

height by width by rim

Primary Ingredient of gas

hydrocarbon Octane

Inline engines

in a line good balance for reciprocating parts

Orifice tube

inlet of evaporator or btwn outlet of condenser and inlet of evaporator controls flow into evaporator

Cylinder Bore

inside diameter

Pitch circle diameter

invisible circle through the center of lug 5x114.42 5 bolt pattern with 114.42mm diameter

Thermostatic contol

keeps engine from overheating by regulating flow of coolant rhough radiator

Cyclone filter

long service life disel trucks swirls air which seperates dust

Torsion Bars

long solid bar of allow steel. Chassis at one and and free to move at another at suspension control arm Bar twist around center to displace vertically Trailing arm can connect between axles as well Used as anti roll bar

Cooling fan

maintain air flow throuhg radiator Irregularly space blades to reduce noise level normally pull air through

Double Wishbone drawback

more costly MOre components and suspension pick up points

All season tires

most production cars Comprimise grip, performance, longevity, noise and wet weather saftey

Piston function

moving pressure transmitter and connecting rod guide Need to be light to reduce inertia forces Withstand high heat need to seal

Expansion valve

older vehicles and after market senses temp and pressure efficent at regulating refrigerant flow creates pressure differential atomizes regfrigerant as it enters evaporator

Leaf springs

oldest type ) All heavy vehicles solid axle rear has swinging shackle to change under loads

Valve Timing Drives

operates half speed of engine Driven from front of crank shaft Gear Train Chain and Sprockets Toothed Belt

Turbo Cycle

outside-filter-compressor-inter cooler-intake-exhaust-turbine

Vane meter sensor

paddle project intake from spring arm. Vane moves to airflow and voltage is generate in proporiton to the distance. Measure volume not mass

Single Bore Displacement Equation

pi/4 *B^2*stroke*#cylinders

Swing axle rear

poor handling camber changed by road lots of body roll

V

reduces length compared to inline More difficult balancing More elaborate intake manifold More costly than inline

Bump Stops

rubber that stop extreme suspension movement Rubber because doesn't need lube, easy to make and silent

Wet Weather tires

soft compound Most grip possible to heat up faster More sipping to disperse water

McPherson components

spring and short absorber called a strut Lower end fitted into knuckle of control arm Most FWD cars

Old fuel system

tank, pump, filter feed, injector, regulator, return/manifold

Bore/Stoke Ratio

tax to make it change increases size of valve ports lowers piston speed more rigid crankshaft due to smaller crank-throw reduces engine height

HP calcuation

torque * rpm / 5252

two-stroke vs 4

twice as many power stoke (not twice power) smoother flow at high speed mechanically simpler (light and less valves) Less fuel economy Higher chance of overheating Mixes fuel and oil for lube (bad for mother earth)

Trailing arm suspension

two trailing arms pivoted to car body Arms are large rigidly fixed to wheel at other end Only allows vertical movements When body moves wheels more to adjust camber (causes understeer)

Accumulator

used with orifice tubes meters refrigerants connected to low pressure side conneected to evaporator outle and stores excess refridgerant. stops liquid and debris from going into compressor

Oil bath and mesh air cleaning

uses oil bath and cotton or foam media to stop dirt Lower efficenty but higher performance

Spark advance

usually 10 degress of crank angle before piston reaches TDC

Piston displacement

volume of displacement swept by a single stroke.

Names for anti roll

Sway bar Roll bar Stabilizer bar

Stoichiometeric AF

14.7:1

Ethanol in today's fuel

15 but some can run on 85

Tire Size Notation 185 65 G R 13

185 is width in mm 65 (Aspect ratio) is the height of tire sidewell in mm percent .65*185 H is speed rating R radial constrction 13 diameter of rim in inches

Henry Fords contribution?

Designing for and using mass production

Wheel track

Distnace between tire to tire on same axel (measure from center)

Types of independent front suspension

Double A-arm (double wish bone) Macpherson strut

Radiator construction

Down flow Cross flow

Electric Fan drive

Driven by motor controlled and controlled by ecu mounted right on radiator

EDS

Electronic distribution system

Air suspension

Electronically controlled at all 4 hweels with adaptive damping system Best handling and comfort Change ride hight

William Durant was in charge of what company in 1916?

GM: Chevy Olds Buick Cadilac

Boxer

Good balance Lowe center of gravity Easy to cool with air Long manifolds more coolant lines harder to access cylinders

Cylinder Bore function

Guide and sealing surface Controlled surface Most important of black

Torsion Beam

Half-independent Connects both wheels together which allows limited degree of freedom. Poor handling and ride

Resin-Impregnated paper

Has resin, replaceable filter, high efficenty, long life, mounted in any position

Evvaporator

Heat absorption component Remove heat from inside of vehicle Dehumidifiys Mosisture and dust gets stuck and falls off Temp is 32f or 0C Enters bottom as low pressure liquid Absorbs heat and leaves as a gas

HO2

Heated Oxygen Sensors

HVAC

Heating Ventilation AC

Cowl

High pressure zone under windsheil

Rotating Impeller/Centrifual

Impeller turns fixed guide vanes (5 times engine speed)

Electronic Ignition Systems (HEI-high engine ignition)

Increaed energy during spark more consistent sparking (good for cold) Less restricted rate of sparking (mechanical is 400 per second) Stable ignition timing Reduced maintenance

Why independent suspension for front?

Lighter unsprung mass Both tires are not subject to same road impacts Allows camber to be adjusted individually

Wheelbase

Longitudinal distance between front and wheel axle centers

Types of engine blocks

Inline V Boxer VR W

4 stroke cycle

Intake Compression Power Exhaust

IAT

Intake Air Temperature Reads intake air charge to find temperature. built into MAF

What happens for each cycle?

Intake-A/F enters Compression- compresses power-ignition and expansion exhaust- leaves cylinders

2 types of wastegates

Internal External

ICE

Internal Combustion engine

Plenum chamber

Internal air pressure higher than atmosphere Located at cowl

KS

Knock Sensor Uses an accelerator to determine vibrations.

ATV tires

Large and medium rubber compound noisy on road and less contackt

Suspension springs

Leaf Coil Torsion bars

Axle Wrap

Leaf sprung vehicles axle hops up and down tracion bars help

William Deming famous for?

Lean manufacturing. Japan with toyota where it started

Typical front wheel drive rear suspenstion

Macpherson or double a frame No steering so no need for bearing in upper mounting on macpherson

Piston ring function

Maintain gas compression and seals all leaks. Scrapes oil so just enough for lubrication Transfer heat from piston to cylinder walls Prevent knocking

MAP

Manifold Absolute Pressure senor silicone tranducer. Voltage proportional to pressure in the manifold uses engines speed, air temp and pressure to determine flow rate By tps or on plenum

MAF

Mass Air Flow Sensor mass of air going into engine types vane and hot wire By air intake

MEP (Equation)

Mean Effective Pressure (con*torque)/displacement in^3 con=150.8 4 stroke =75.4 for 2 stroke

What controls ignition timing

Modified by knock, coolant and air temperatures. Uses look up tables in PCM

Unibody Chassis

Most common Sheet metal. Body and Chassis are one piece. Rigid (resists flexing better) Better handling Lighter weight Cheaper (less material) Crumple zones

Double Wishbone

Most ideal front and rear independent perfect camber control Old- parallel equal length wishbone arms (causes excessive tire scrubbing) New-unequal length, non parallel A-arm

Cradle

Mounts suspension onto a subframe Subframe absorb NVH (noise, vibration and harshenss) Subrame mounted by bushings

Fuel tank

Plastic, steel or aluminum designed to protect against damage Baffles to prevent surging during movement.

What causes detonation

Poor octane loss of egr raised CR due to carbon build up too much air/fuel bad spark plug

PFI

Port Fuel Injection

PCM

Powertrain control Module or ECM or ECU (electronic control module) Controls engine and vehicle Controls ignition and air fuel (most important)

What if use wrong heat range spark plug?

Preignition Could burn up ground electrode

Radiator cap

Pressurized cooling cap is combination of filler cap and prssure control valve spring loaded plate to maintain pressure Standard pressure is 15 psi

Dampening

Prevents spring from returning to original shape too quickly Done by shock absorber Piston filled with oil

Spark Plugs

Provides a gap for the current to jump which causes a spark Specified in size and heat ranges Hot plugs in cooler engines and cold in hot ones

Chassis

Provides strength to support vehicular component and payloads

Axel

Provides wheel location, motion and reaction to external forces

Valve Systems

Push Rod Overhead Cam

Intake Manifold

Receive mixture and distribute air fuel mix to cylinder head Circular cross sections for least resistance.

Methods of air Cleaning

Resin-impregnated paper Oil bath and mesh cyclone filter with paper

Two type of Axels

Rigid Independent

Chassis Joining Methods

Rivets Bolts Welds

2 types of lobe superchargers

Roots-normal Screw-weird lobes, compress air, cost more

Types of Superchargers

Rotating Lobe Sliding Vane Rotating Impeller

Unidirectional tires

Rote in one direction enhance acceleration better stopping

Fan cowl

Sheet metal or plastic casing prevented heated air from recirculating through radiator

Lateral bending

Side members subject to a frowny face ( From road camber, side wind, turning or collision Tires oppose lateral force which causes the bending

Why did toyota "Crown" fail in US?

Slow Couldnt hand US heat

Detonation

Spontaneous combustion of gases after natural spark. Called knock and ping

Basic Suspension Components

Springs Axles Shocks arms rods Ball joints

Solid axle coil springs

Springs vertical support and lateral support comes from control arms. attached to chassis and axle

Red Flag Act

Stop steam powered cars because they were a threat to the train

Fuel System Function

Store, transfer and filter gas required by carburetor or fuel injection system

Chain and Sprocket Drives

Subject to slight wear Needs to be changed often

Engine Diplacement

Total volume of all cylinders

Semi trailing arm

Trailing arm but pivoted half trailing(understeer) and have transverse (oversteer) which cancel out