Auto fundamentals pdf free download

Connecting rod bearing inserts must be able to fit precisely while being rigid enough to withstand the tremen- dous forces in an engine. The crankshaft uses bearings sim- ilar to the connecting rod bearings. The camshaft is connected to the crank shat through the use of timing gears or sprockets and a chain crbelt.

Mechanical and hydraulic liters transfer the force from the camshatt to the valves. Valves are designed to tum in order to reduce heat and carbon buildup. Cutaway of an 8. Study al the parts. The valves in most engines are housed in the cylinder Seutfing Mechanical valve ters head.

The oil pan and timing cover house the crankcase and timing gears respectively Gaskets, sealants, and seals are Saat ieee hee used to seal the engine and other vehicle components.

Do not write in this book. Write your answers on a sepa: fale sheet of paper. Technician A says that a dry sleeve can be thin because the block metal supports it, Technician B says that coolant in the engine directly contacts the wet sleeve. Who is ight? Technician A says that a cylinder that is round to within " 2.

Technician B says that a cylinder that is round to within. Who is right? Whois right? The head of the piston will generally be. What are some of the reasons for these shapes? What does a piston heat dam protect? A Piston. A Outside.

Internal combustion engines can te classified in many ways. The most common methods used fo classify engines are by cycle, valve location, cylinder rangement, type of fuel used, cooling, and number of cylin- ets. This chapter will discuss each classification Cycle Classification Engines are often classified according to cycle. The basic engine which was discussed in the first two chapters is a four-stroke cycle engine. Figure illustrates, that it takes two complete crankshaft revolutions to complete the cycle.

As a result, each cylinder receives only one power stroke per cycle. All modern automobile engines use the four stroke cycle engine. This is accomplished by eliminating the valves used in the four-stroke cycle engine.

In place of the valves, two ports enter the cylinder wall. One is used for the intake of fuel and the other for exhaust.

The airfuel mixture is drawn into the crankcase through a reed valve or a rotary valve. Oi is usually mixed with the gasoline to provide lubrication. Some two-stroke cycle engines use an ol injection system. Upon entry into the crankcase, the oll provides ample lubrication forthe bearings.

Four-stroke cycle principle. Valves are in the block, both on the same side, Note letter L. TRW, Inc Figure This configuration is nat used anymore, but may be found on some older engines.

Head In the head engine, both valves are located in the cyiin- er head. They may be arranged in a straight line, Figure or Staggered, Figure This is sometimes referred to as a vave-ivhead engine, Since the valves are placed in the I-head, a valve train must be used to operate them.

F-head engine. Note that there is one valve in the block and one in the head. TRW, Inc. Figure Lead engine. Both valves are located in the head, TW Inc of a rocker arm and push rod setup to actuate the valves. Note how push rad force is transferred in the opposite direction by the rocker arm, Figure ilustrates the use of a rocker arm-push rod valve train on an actual engine.

Figure shows a different rocker arm design. Instead of oscillating on a rocker arm shat, this type uses a Ball pivot arrangement on which the rocker arm pivots. Note the hydraulic lash adjuster. Ford Figure Cross-sectional view of an engine wihich incorpo- fas a single overhead camshaft SOHC to operate tho vahes. Chrysler Iter scussed earlier in Chaptor 2. Cutaway view of a 3. Note the camshaft lobes act directly on the ends of the valves.

No rocker arms are used. The only adjustment necessary isthe ini- tial setting to place the liter plunger at the halfway point in its travel. Figure shows such a setup. Push rods of slightly different lengths are available to make minor changes. This non-adjustable rocker arm depends upon pre- cise paris so that the hydraulic ifter plunger willbe at midpoint of travel upon assembly.

These indenta- tions, or grooves, keep the piston head from striking the valves at the top of the exhaust stroke when both valves may bbe partially open. If the piston and valve s are allowed to make contact, extensive engine damage would result Detonation and Preignition When highly compressed air-fuel charge is fired, the flame travels from the plug in an outward direction.

Piston indentations used for valve clearance. Each piston has two small indentations to allow the valves to clear. Chevrole charge continues to bur, chamber pressure greatly increases. If the combustion chamber pressure increases, faster in another part of the cylinder before the flame reaches, it, this area wil become hot enough to fire itself. This will pro duce two flame fronts, which increases the fuel charge bum, rate. Instead of fring smoothly, there isa violent explosion that literally slams the piston down.

This is called detonation, Which is very damaging to an engine. Detonation can be caused by an excessively high com: pression ratio or by a low grade of gasoline. An overheated valve or piece of carbon can ignite the remaining air-fuel mix ture and cause the formation of the second flame front, Figure, When preignition occurs, the premature explosion attempts to drive the piston down against the direc: tion of rotation.

A—Proper lame travel. B—Two fla fronts increase burning rate and cause detonation. Many arrangements have been used, but only those in popular use today wil be covered inthis tex. Figure shows one other type. In this racial engine, all the connecting rods are fastened to the master rod. This design has been used for many years in aircraft Inline Engine The inline engine has its eyinders arranged one after the othor ina straight lino, They are in a vertical, or near ver- tical position, Figure Most modem inline engines are four cylinders.

Inline sicoylinder engines were used in older vehicles and can stil be found in a few modem ight trucks. Until the adoption of the V8, eight cylinder inne engines were common. A few three- and five-cylinder inline engines are now produced. A variation of the inline engine isthe slant oF inclined engine, Figure An incined engine is an inline engine withthe cyinder block slanted to one side. This is done to fit the engine into a smaller engine compartment, allowing for a lower hood line.

The V-type engine has several advantages: short length, extra block rigidity, a shor, heavy crankshaft, and low profile that is con- ducive to low hood lines. The shorter block permits a reduc tion in vehicle length with no sacrifice in passenger room, Higher compression ratios can be used in the V-type engine without block distortion under load. The short, heavy crankshaft is mote resistant to torsional vibration.

Cutaway view of an inline, four-cylinder, overhead valve, electronic fuel injected engine. Note the ribbed drive and timing belts. Ford Motor Co. V, and V engines were widely used. The advan- tage here is an extremely low overall height, which makes ths engine ideally suited to installations where space is limited Figure shows a horizontal-opposed engine. It is an ai cooled, six-cylinder engine.

Firing Order Firing order rofers to the sequence in which the ey ders fire. Firing orders are given in order from the front of the engine tothe rear. The order in which the engine must fies determined by the number of cyinders and the arrangement of the crankshaft throws.

Fring order can be found in the sex vice manual forthe vehicle being serviced. Most vehicles use liquid-cooled engines. Both types have advantages and disadvantages.

Ar cooling is simple and has no coolant to leak or freeze in cold weather. Cross-sectional view of an inclined four-cylinder engine. By setting the engine at an angle, overall height is reduced. Tis alows fora lower vehicle hood. Gasoline powers the majority of vehicles, butdiest fue is used in some vehicles. Disel engines do not use a carburetor or an ignition system. Dis fo the pressures and stresses involved, diesel engines ie constructed very rigily. The theory of diesel engines is tareed in the diesel injection section in Chapter 9.

Diesel lmgies are ether two- or four-stroke cycle types. The two:stroke cycle diesel engine utiizes an exhaust valve. No fuel mixture enters the crankcase. Due to the pressures involved, a supercharger is used to force air into the cylinder intake ports. Figure shows the two-stroke cycle operation in a diesel engine, Notice that air rushing in through the cylinder liner ports helps scavenge the cylinder by flowing out the exhaust passage for a portion ofthe piston travel.

Since only air enters the oylinder, there is no loss of fuel, Figure shows a typical four-stroke cycle, four-cylinder automotive diesel engine. Inne five, six, and V-8 diesels are also used, Figure Diesel fuel injection system operation is discussed in Chapter 9.

Detroit Diesel Engine Div. The rotary tngie Is very powerul for its size. This engine is often ted to as a Wankel engine, Figure , The rotary engine has fewer moving pars than a piston engine. Since it has no reciprocating motion, the rotary engine fooduces less vibration and offers more horsepower. Two-stroke cycle diesel engine operation.

Note the use of a supercharger to force the ali-luel mixture nto the combus- Rotary Engine Construction Rotary engines are classified according to the number of rotors used in the engine. The remainder of the engine con: sists of one or more rotor housings, end housings, fixed gears, and a center housing all held rigidly together with a series of bott. There are just two or three moving parts in the rotary engine depending upon the number of rotors the engine has —the eccentric shaft also called the mainshaft and the cast iron rotor assemblies.

Four-cyinder diesel engine. Note the use of a tim ing bet instead of gears or chains. Cross-section of a 6. Note how similar this engine is to some gasoline engines. General Motors and the housing surface while providing a barrier against com- Pression loss and oll consumption.

Rotary Engine Operation The rotary engine performs the four distinct strokes—intake, compression, power, and exhaust, Figure Each face of the triangular rotor acts like a conventional Piston. Cutaway view of a turbocharged rotary engine, This particular engine has a compression ratio of 8. Study the rotor movement in Figure A through Figure E. We will follow one rotor face through the com: plete cycle.

Note that this face lies between rotor tips A and B. As tip B passed the intake por, the chamber vol ume increased. In Figure 3 , the rotor has tumed further to the right and in so doing, chamber size has started to reduce, compressing the fuel When rotor face A-B has turned to the position shown in C,, maximum compression is applied.

When compression is at its maximum, the spark plug ignites the fuel charge, Figure C. When the charge. Follow rotor love AB from Figure A to Figure E and note that as the ports are uncovered and the chamber volume changes, ach phase of a four-stroke cycle is performed. To prevent the air-fuel mixture from exit ing through the intake valve, a supercharger raises the intake nanfld pressure.

Ths forces more ofthe air-fuel mixture into tte ofinder. The Miller-cycle design is said to produce more fower and economy over a wider RPM range. Figure shows a cutaway of a Miller-cycle engine. Natural Gas Engines Natural gas is piped to millions of homes, where itis tuned in water heaters, furnaces, and stoves.

In addition, same vehicles operate on natural gas. The gas must be main tse ina liquid state, as the vehicle could not carry enough togo very far i the gas were in its vapor state. In fact, most natural gas engines tre production gasoline engines with a modified fuel system, The uel system is modified to alow the natural gas to vapor: lee and mix with the incoming alr.

A simple mixing valve farangement replaces the carburetor or fuel injectors. The nat- ural gas system can even be adapted to work with the exist- ing computer control system. The E equust 0 within the rotor housing. The rotor internal gear and housing gear are not shown. NSU Figure This Miler-cycle engine design allows the intake valve to open sooner. A supercharger is used to force the alr fuel micure into the cylinders.

Also, since most vehicles are gasoline powered, refueling stations are hard to find Refueling time is slightly longer than for gasoline. Experimental Engines "The search for better engines is nover ending. Manufacturers are also developing vehicles driven by electricity. Engine Mounting Tis common practice to mount the engine on filed or rubber pads, usualy called engine mounts.

This heps I also eases torque twisting strain loatng ofthe drive ine. This method uses one mount on ether side of the engine near the font and one at tho back, usally under the transmission, However ofr setups use two, tree, four oF five engine mount arrange ments This varie rom each model and manufacturer Figure shows a five pont mounting pater.

Study all the engine figures in this chapter very carefully, especially Figure through Figure , Make certain you know the names and uses of all parts.

It is most important that you build a complete and accurate mental image of the various types of engines, and the relationship of one part to the other. In addition to knowing the names and uses of all parts, be certain to test your knowledge of the various systems by identitying the cooling, lubrication, ignition, and fuel systems, Summary Engines canbe clase in many ways.

The most com monly Used eassfleatons are by cyl, vave locaton, ey der arrangement, uel used, cooing and number of eyinders The vast major of auto engines ae ofthe four-stoke eye type The two-stroke cyt Ie generally usedin small engines Both have advantages and disadvantages. The nea over head valve or vavern-head engines in elmosl niersl uso inc The most commonly used combustion chamber shapes are the wedge and the hemispherical Detonation Guin he compression sre can be stopped by proper lel and com.

One type of front-uheel crive engine mount. Toyota bustion chamber design. Ricardo, in early experiments, set forth some basic principles of combustion chamber design that are stil incorporated in modem engines. He found that by. The V-8, V-6, and inline four-cylinder engines dominate the field of engine design and use. The diesel two-stroke cyole tengine differs from the small gasoline engine of the same, type.

The Wankel rotary piston engine uses a triangular shaped rotor that revolves inside a housing. An exploded view of an inline six-cylinder engine.

Study the constuction. The engine has a compres- Se alo of 9. Toyota Motor Corp. Experiments with new and different types of engines are fray in progress. Further development of existing engines [sao taking place. Considerable research is being done on faual gas and electric dive autos. Write your answers on a sepa: rate sheet of paper. List the strokes in a four-cycle engine in their proper order. What type of valves does the two-cycle gasoline engine have?

Ina two-cycle engine, what opens and closes the reed valve s? A Air pressure and vacuum. Explain where the valves are located in the following engines. Using cylinder arrangement, list the three most popular engines in use today. Where are the valves located in an overhead camshaft I-head engine?

This chapter covers the importance of safety. The safety precautions given here are intended to help Jouavoid accidents as you perform laboratory jobs under your insructors supervision. Learning good safety practices fw wil give you the safety habit at all jobs in the future. This chapter examines various types of unsafe shop conditions and work practioes, and discusses ways to correct or avoid them Preventing Accidents ale working condone and safely procedures protect te automate technician, the vehicle, and the shop, Jecilents are unplanned events that can occur without any- toe ntendng for them to happen.

Other accidents are caused when Shop personnel fall 10 correct dangerous conditions in the work area. Accidents are often caused by a series of unsafe acts or unsafe conditions, which lead to other actions. An example of an unsafe act is leaving spiled gasoline on the shop floor in some shops, his spill would remain unattended indet- intely because everybody is too busy to clean it up.

Another uneafe act is using a standard light bulb in a drop ight, which many technicians do because it is too much trouble to obtain 2 rough service bub Neither ofthese unsafe acts becomes fan accident until someone drops the light to the shop flor. It breaks, and the spark ignites the gasoline. This causes a large fre, which could result in severe damage to the shop and any vehices in the shop. It may also severely burn, or ven kil someone in the shop.

In tis example, no one delib- frately set out to cause an accident. Instead, it was just a Sores of things that were too much trouble todo correcty. Figure shows a spedal brake washer tool, which should be used to clean brakes belore service work begins. Folow all safety ues when working with parts containing asbestos. Do not hale the dust. If you spill oi, gasoline, cleaning solvents, or any her substance on your skin, clean it off immediately Prolonged exposure to even mild solvents or petroleum prod lets oan cause severe skin rashes or chemical burns.

Whenever you are assigned projects in the school shop or th clean and return all tools and equipment to their proper places wien the job is completed. Do not alow cit, ol, old fats, boxes, or other refuse to pile up. Keep al workbenches clean. A clean workbench 0 edes the possiblity that crical parts wl be lstin the liter.

Return all tools and equipment to thei proper storage flces, Tis saves time in the long run, as well as reducing the chance of accidents and theft. If tools are itor ly, clean thom before you put them away. This wil not tay extend the lie ofthe tool, but is also a courtesy to ot as who use them. Figure , Use an approved brake washing tool in a well vr lated area ofthe shop.

Clayton Mig. Hybrid drives and the operation of hybrid vehicles are characteristic of contemporary automotive technology. This technical reference book provides the reader with a firsthand comprehensive description of significant components of automotive technology. All texts are complemented by numerous detailed illustrations. Innovations by Bosch have shaped the development of the automobile.

Uh-oh, it looks like your Internet Explorer is out of date. For a better shopping experience, please upgrade now. Javascript is not enabled in your browser. Enabling JavaScript in your browser will allow you to experience all the features of our site. With eager eyes, I proceeded to peruse through the whole book, scanning for the pages that described the typical additions to your car that would make your car insurance cringe.

Blow-off valves, turbochargers, superchargers, coilovers, air-bag suspension systems, cold-air intakes, limited slip differentials, roll cages—none were apparent in this book. My heart broke a little bit. I was hoping to refer to this book, rather than cramming episodes of Mighty Car Mods on youtube into my brain.

Then, after giving this book a chance by working through the problems, along with the critical thinking scenarios presented in this book, it redeemed itself to me. I may have learned my share in working and fixing cars with my dad, but it delved in depth on the thermodynamics that occur in things such as the four stroke cycle of an engine, and what the process occurs in catalytic converters. In case the links are not working, use the comment section to inform us. We will update the links as soon as possible.

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