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INTRODUCTION
NOTE: interested candidates can download the automobile engineering file for free: DOWNLOAD
An automobile (automotive) may be a vehicle that's capable of propellant itself. Since the seventeenth century, many tries are created to style and construct a much operative automobile.
Today, vehicles play an inconceivable role at intervals in the social, economic, and industrial growth of any country.
Innovation and invention
Steam power to a burning engine
Steam engine used until late 1940 s fossil oil "spirit" used by Dr. OTTO within the 1870 s was a useless by-product of solvent used for lamps. Dr. engineer improved the OTTO engine victimization fossil oil vapor and in parallel, Karl Benz conjointly created tri-wheel carriage in 1885.
Mass production
Cars were developed from horse carriages. Henry Ford "mass production" of an automobile,1909. The construct from rifle manufacture of warfare. automobile initial automotive with a style for manufacture Engine 2898 metal was designed by ford and numerous freelance bodybuilders from buses to elegant family cars. Hand-built cars to interchangeable components.
In the 1970 s, Volkswagen "Beetle" was oversubscribed in giant
numbers tho' the design was archaic because it was
Non-rusting automotive
Mechanically reliable
Toyota's contribution:
Production was versatile
Quality dominant, obtaining right initial time LEAN
Shorter production runs, wide variants
Development of World Motor trade
1920 s-1930 s tiny coachbuilders co-exist with giant firms. By the highest of the second war solely some of the specialized makers stay Rolls Royce giant conglomerates like British Motor Corporation (BMC), British Leyland (BL) moon-faced a problem of enormous stock Americans and Japanese touched components of operations around the world thanks to export restrictions and to use facilities everywhere the globe.
Construction development:
Till the 1930 s wood frames with material or wood skin wont to build coaches, Late 1930 s onward, ironed steel plates for skin Multiple curvatures additional strength, and body panels shared the load Recent cars have shell structures with mechanics structures. Wooden/Steel chassis frame was done away and replaced by stiff floor "pan" by spot attachment By 1950 s, "unitary" construction was universally followed for factory-made cars Composite body for low weight and corrosion free body started when WWII (Lotus) Wheels progressed from wood spoke to a metal spoke to metal hub construction to metal spokes Alloy).
Styling Development:
Powered versions of horse carriages Engine was placed below vehicle by industrialist laborious maintenance 1890 s, Pan laborious-Levassor created the construct of getting the engine before with a clutch and shell system Pan hard windshield was fictitious in 1920 s with the increasing speed of the vehicle. By the 1930 s, to a fault elongated engine covers had become American state rigueur' for powerful cars with sporting aspirations. bags were strapped within the rear of the vehicle and it became integral in European cars. It grew in fifty s,60 s, and seventy s to larger volume until fifty s "open top" was most popular as galvanized from horse carriages.
Now, these area units changed and convert into a cushty manner.
INDEX
TABLE OF CONTENTS
CHAPTER 8 CONSISTS OF TABLES
Table 1- models of cars with codes
Table 2- versions in MARUTI SUZUKI
CHAPTER-1
AUTO PARTS
THE LIST OF FIGURES AND CONTENTS
- battery
- Brake system
- Axle
- Fuel injector
- Piston
- AC compressor
- Radiator
- Condenser
- Clutch set
- Flywheel
- Struts
- Transmission
- Shock absorbers
- Air filter
- Spark plug
- Catalytic converter
- Alternator
- Power steering motor
- Fuel filter
- Oil filter
- Oil separator
- Water pump
- Timing chain
- Common rail
- Nozzle pipes
- Nozzle jets
- Bearings
- Intercooler
- Turbocharger
- Inlet manifold
- Cooling coil
- Thermostat
- Starter motor
- Heater coil
- Tensioner
- Differential
- Dog clutch
LIST OF FIGURES
CHAPTER 1
Figure a1- car parts
CHAPTER 2
Figure b1- battery
Figure b2- brake system
Figure b3- axle
Figure b4- fuel injector
Figure b5- piston
Figure b6- AC compressor
Figure b7- radiator
Figure b8- condenser
Figure b9- clutch set
Figure b10- flywheel
Figure b11- front suspension
Figure b12- transmission
Figure b13- shock absorbers
Figure b14- air filter
Figure b15- spark plug
Figure b16- catalytic converter
Figure b17- alternator
Figure b18- power steering motor
Figure b19- fuel filter
Figure b20- oil filter
Figure b21- oil separator
Figure b22- water pump
Figure b23- timing chain
Figure b24- common rail
Figure b25- nozzle pipes
Figure b26- nozzle jets
Figure b27- bearings
Figure b28- inter Cooler
Figure b29- turbocharger
Figure b30- inlet manifold
Figure b31- cooling coil
Figure b32- thermostat
Figure b33- starter motor
Figure b34- heater coil
Figure b35- tensioner
Figure b36- differential
Figure b37- dog clutch
CHAPTER 3
Figure c1- power steering column assembly
Figure c2- power steering motor
Figure c3- abs line diagram
Figure c4- abs sensors
Figure c5- abs valve assembly
Figure c6- engine control module
CHAPTER 4
Figure d1- manual transmission gearbox inner side
Figure d2- planetary gearset
Figure d3- CVT drive Pulley and driven pulley
Figure d4- CVT gearbox
CHAPTER 5
Figure e1- camshaft
Figure e2- valve cover
Figure e3- engine head
Figure e4- crankcase
Figure e5- fuel injector
Figure e6- pistons with connecting
CHAPTER 6
Figure f1- mass airflow sensor
Figure f2- throttle position sensor
Figure f3- manifold absolute pressure sensor
Figure f4- engine speed sensor
Figure f5- heated oxygen sensor
Figure f6- coolant sensor
Figure f7- Spark knock sensor
Figure f8- fuel temperature sensor
Figure f9- cam position sensor
Figure f10- crank position sensor
Figure f11- vehicle speed sensor
Figure f12- voltage sensor
Figure f13- engine control module
Figure f14- body control module
Figure f15- transmission control module
CHAPTER 7
Figure g1- gear oil 75w 90
Figure g2- gear oil 80w 90
Figure g3- gear oil another type 75w 90
CHAPTER 2
FUNCTION OF EACH PART AND ITS USE
1. BATTERY
(Fig-e1)
Battery, which supplies the power for lighting and starting, ignition. It consists of cells and stores the power and supplies to the car. The Battery utilizes de-ionized water. And also it is a rechargeable battery.
2. BRAKES
(Fig-e2)
In cars, hydraulic brakes are used. These brakes utilize the brake fluid dot 3. The function of brakes is stopping rotating wheels. In cars these brakes are activated by pressing the brake pedal which increases the pressure in the master cylinder and transfers to slave cylinders, pistons through brake pipes and these are connected to the brake shoes and brake pads which are pressing against the brake and brake drum which causes the braking of wheels. The use of brakes in cars are stops vehicles in motion.
3. AXLE
(Fig-e3)
An axle is a central shaft that supports the vehicle. Axles are used for the transmission of rotary energy to the wheels. These consist of bearings. NKG814 grease is used to drive shaft bearings. In the former case, bearings or bushings are provided at the mounting points where the axle is supported.
4. FUEL INJECTER
(Fig-e4)
Fuel injectors are the fuel suppliers to engine cylinders from the common rail. Which supplies the fuel with high pressure. These fuel injectors are used in diesel engines.
5. PISTON
(Fig-e5)
The piston is made up of aluminum. The piston is connected to the connecting rod. In the IC engines, the piston moves from TDC to BDC in the combustion chamber and transfers the movement to the crankshaft through the connecting rod.
6. A/C COMPRESSOR
(Fig-e6)
Ac compressor is used to compress ac gas(134A) and transfers to the condenser on to the cooling coil. Where the ac gas is chilled in the tubes of the cooling coil. The blower flows the air to the cooling coil and gets cooled spread into the car. The ac compressor consists of an electrical clutch which starts running while the ac switch is in on. This clutch starts operating pistons in the compressor where the pistons compress the ac gas. This compressor pulley is connected to the crankshaft pulley by a belt. This compressor uses the compressor oil for the free piston movement.
7. RADIATOR
(Fig-e7)
The radiator is a device that is used to cool the coolant when the coolant temperature increases. The hot coolant is passed through radiator parallel tubes and then the radiator fan motor rotates and cools. The radiator pipe is connected to the outside thermostat for inlet of coolant to the radiator.
8. CONDENSER
(Fig-e8)
A condenser is a device that is used to condense the compressed ac gas and transfer it to the cooling coil. The condenser is similar to a radiator. The condenser is a device used to convert gaseous state to liquid state
9. CLUTCH
(Fig-e9)
The clutch is a set of the pressure plate and clutch disc. The function of the clutch is smoothly engaged and disengage the gearbox from the engine. The clutch can operate this process at any speed without noise. When clutch pedal pressed then the release bearing pushes the pressure plate wings then the clutch disc is free from motion. When you release the clutch pedal then the pressure plate highly mesh the clutch disc with the flywheel. Then the power transmission transfer to the gearbox. The clutch disc is made up of high friction material.
10. FLYWHEEL
A flywheel is may be a robot specifically designed to efficiently store rotational energy (kinetic energy).
(Fig-e10)
Flywheel resist changes in rotational speed by their moment of inertia.The amount of energy stored in a flywheel is proportional to the square of its rotational speed and its mass. The way to change a flywheel's stored energy without changing its mass is by increasing or decreasing its rotational speed. Since flywheel act as mechanical energy storage devices.
11. STRUTS
(Fig-e11)
Struts are considerably different. Struts are a structural a part of the suspension and are mounted to the chassis of the vehicle on the highest, and that they come down through. They give us an area to mount the volute spring, and therefore the spring is what maintains the peak of the vehicle, so we have a plate in here for the spring. It also replaces the upper control arm and it connects on to the knuckle on the car, which in many cases gives us a minor ability to regulate alignment.
12. TRANSMISSION
(Fig-e12)
Transmission is used to transfer the rotational energy to the wheels from the engine by varying speeds. Transmission consists of different types of gears for different speed variations. The picture shows the constant mesh type gearbox. This gearbox consists of a dog clutch for smooth engagement of gears.
13. SHOCK ABSORBERS
(Fig-e13)
shock absorbers are hydraulic (oil) pump like devices that help to regulate the impact and rebound movement of your vehicle's springs and suspension. Along with smoothening out bumps and vibrations, the key role of the shock is to make sure that the vehicle’s tires remain in touch with the paved surface at all times, which ensures the safest control and braking response from your car.
14. AIR FILTER(ENGINE)
The air filter is used to prevent the dust to enter the engine. Without an engine air filter, the engine can be damaged within a short time.
(Fig-e14)
Due to dust is entered and rugged the engine cylinder and the engine comes to rebore.
15. SPARK PLUG
(Fig-e15)
The spark plug is used to generate the spark on time. It generates the spark at the compression stage of a piston. It is only used in petrol engines.
16. CATALYTIC CONVERTER
(Fig-e16)
The catalytic converter is a device, which is connected to the exhaust stream. It is used to filter the exhaust gas produced from engine. It consists of two heated oxygen sensors one is on top and the other is on bottom of the catalytic converter. A turbocharger is connected to top of the catalytic converter.
17. ALTERNATOR
(Fig-e17)
Alternator is a device used to produce the electrical energy from mechanical energy. The pulley of alternator is connected to main pulley of engine. Alternator consists of an armature winding, which produces the electromotive force(EMF) while it is rotating. Then the alternator charges the battery and used for lighting when the vehicle is in motion.
18. POWER STEERING MOTOR
(Fig-e18)
Power steering motor is connected to a steering rod through planetary gear set. The power steering motor is used to gives supportive motion while driving. It helps easy steer while driver driving a car.
19. FUEL FILTER
(Fig-e19)
The fuel filter is only used in diesel vehicles. The fuel filter is used to filter the diesel and catch the dust particles in the diesel. Send the filtered diesel to engine.
20. OIL FILTER
(Fig-e20)
Oil filter is used to filter the engine oil. It prevent dust enter into the engine. These oil filters are used in both petrol and diesel vehicles.
21. OIL SEPARATOR
(Fig-e21)
The oil separator is used to catch the vapourous engine oil and transfers to the turbo and engine oil sump. It is located on the manifold.
22. WATER PUMP
(Fig-e22)
The water pump is used in all engines. The pulley of a water pump is connected to the crankshaft pulley through a chain or belt and supplies the coolant to the overall engine by rotating self.
23. TIMING CHAIN
(Fig-e23)
The timing chain connects the crankshaft to the head of an engine by sprockets. The engine head consists of valves and camshafts. This chain depends on timing. While replacing the timing chain, first of all, lock the camshaft and flywheel at providing slots then fix the new timing chain.
24. COMMON RAIL
(Fig-e24)
Commonrail is connected to fuel injectors and through a nozzle pipes. The common rail supplies the fuel from the high-pressure pump to fuel injectors. It supplies only amount of fuel required to injectors.
25. NOZZLE PIPES
(Fig-e25)
Nozzle pipes connected between commonrail to fuel injectors. Which transfers fuel from commonrail to fuel injectors. The ends of a pipe consists of nozzles.
26. NOZZLE JETS
(Fig-e26)
Nozzle jets are located on the downside of block. The nozzle jets are used for supplies the engine oil to connecting when the engine is running.
27. BEARINGS
(Fig-e27)
Bearings are the friction reducers and depend on the inertia of motion. These bearings are used in cars at flywheel, wheels. Bearings are different types like a ball bearing, roller bearing, bush bearing. Mainly ball and roller bearings are used in cars.
28. INTERCOOLER
(Fig-e28)
Intercooler is used to cool the air from air filter for the engine. The intercooler is connected between the turbocharger and manifold. Turbo supplies the air from the atmosphere to the engine intake manifold.
29. TURBOCHARGER
The Turbo charger is located on the catalytic converter. It is based on a two-way principal. It means the turbocharger rotates by using exhaust gas and creates suction for air
(Fig-e29)
inside entering the engine. A turbocharger consists of vanes in it. These vanes are rotated by using exhaust gas and create suction another side to transfer the atmospheric air to the manifold.
30. INLET MANIFOLD
(Fig-e30)
The Inlet manifold is a part used to transfer the air to the engine. It consists of a MAP sensor and it calculates the pressure and air ratio. The Inlet manifold consists of a packing to avoid leakage of air.
31. COOLING COIL
(Fig-31)
The cooling coil is located inside the center of the dashboard of a vehicle. It gives the cooling to passengers. The chilling of ac gas (134a) in the cooling coil cause the cooling inside the car. While it's chilling the air passes to the cooling coil gets cooled. The air is transferred by the blower.
32. THERMOSTAT
(Fig-e32)
The thermostat is a device that connected to the engine head. It consists of a coolant temperature sensor. The main function of the thermostat valve is to allow hot coolant to the radiator for cooling the heated coolant.
33. STARTER MOTOR
(Fig-e33)
Starter motor also called a self motor. The self motor is fixed to touch the flywheel. Self motor is used for starting of the vehicle by rotating the flywheel. It runs by the battery.
34. HEATER COIL
(Fig-e34)
Heater coil is present besides of the cooling coil. It is similar to radiator. The hot coolant is directed into the heater coil. This is located by the firewall that separates the engine compartment to the passengers compartment. It consists of fins and tubes. These are intended to cool before it returns to the engine. However, as it passes through the heater coil it's still amply warm enough to give heat.
35. TENSIONER
(Fig-e35)
Tensioners are two types one is a belt tensioner and the other is a chain tensioner. The belt tensioner is mainly used in old petrol vehicles. The chain tensioner is mainly used in both petrol and diesel vehicles. Which reduce the tension to chains or belts. Avoid the looseness of chains.
36. DIFFERENTIAL
(Fig-e36)
Differential is used to avoid skidding of a vehicle when negotiating a curve. And also used to transfer the power to right angles. It consists of sun gears and pinion gears. Gives different rotational speeds to the road wheels while negotiating curve through driveshafts. Differential is present in the gearbox.
37. DOG CLUTCH
(Fig-e37)
Dog clutch function is similar to the clutch. Dog clutch present inside the gearbox, between gears. The dog clutch operates the gears smoothly while changing the gears. It operates freely without noise by a gear oil.
CHAPTER 3
POWER STEERING AND ANTI LOCK BRAKING SYSTEM
1. POWER STEERING
Electric power-assisted steering (EPS/EPAS) or motor-driven power steering (MDPS) uses an electrical motor to help the driving force of a vehicle. Sensors detect the position and torque of the steering column, and a computer module applies assistive torque via the motor, which connects to either the gear or steering column. This allows varying amounts of assistance to be applied counting on driving conditions. Engineers can, therefore, tailor the steering-gear response to variable-rate and variable-damping suspension systems, optimizing ride, handling, and steering for every vehicle. On Fiat group cars the quantity of assistance is often regulated employing a button named "CITY" that switches between two different assist curves, while most other EPS systems have variable assist. These give more assistance because the vehicle slows down, and fewer at faster speeds.
A mechanical linkage between the wheel and therefore the gear is retained in EPAS. In the event of component failure or a power outage that causes a failure to supply assistance, the mechanical linkage is a back-up. If EPAS fails, the driver encounters a situation where heavy effort is required to steer. This heavy effort is analogous thereto to an inoperative hydraulic steering assist system[citation needed]. Depending on the driving situation, driving skill, and strength of the driving force, steering assist loss may or might not cause a crash. The difficulty of steering with inoperative power-assisted steering is compounded by the selection of steering ratios in assisted steering gears vs. fully manual. The NHTSA has assisted car manufacturers with recalling EPAS systems susceptible to failure.
Electric systems have a plus in fuel efficiency because there's no belt-driven hydraulic ram constantly running, whether assistance is required or not, and this is often a serious reason for his or her introduction. Another major advantage is that the elimination of a belt-driven engine accessory, and a number of other high-pressure hydraulic hoses between the hydraulic ram, mounted on the engine, and therefore the gear, mounted on the chassis. This greatly simplifies manufacturing and maintenance. By incorporating electronic stability control electrical power steering systems can instantly vary torque assist levels to assist the driving force in corrective maneuvers.
2. ANTI LOCK BRAKING SYSTEM (ABS)
The anti-lock brake controller is additionally referred to as the CAB (Controller Anti-lock Brake).
Typically ABS includes a central electronic control unit (ECU), four-wheel speed sensors, and a minimum of two hydraulic valves within the brake hydraulics. The ECU constantly monitors the rotational speed of every wheel; if it detects the wheel rotating significantly slower than the speed of the vehicle, a condition indicative of impending wheel lock, it actuates the valves to scale back hydraulic pressure to the brake at the affected wheel, thus reducing the braking force thereon wheel; the wheel then turns faster. Conversely, if the ECU detects a wheel turning significantly faster than the others, brake hydraulic pressure to the wheel is increased therefore the braking force is reapplied, slowing down the wheel. This process is repeated continuously and may be detected by the driving force via pedal pulsation. Some anti-lock systems can apply or release braking pressure 15 times per second. Because of this, the wheels of cars equipped with ABS are practically impossible to lock even during panic braking in extreme conditions.
The ECU is programmed to disregard differences in wheel rotative speed below a critical threshold because when the car is popping, the 2 wheels towards the middle of the curve turn slower than the outer two. For this same reason, a differential is employed in virtually all roadgoing vehicles.
If a fault develops in any a part of the ABS, a red light will usually be illuminated on the vehicle control panel, and therefore the ABS is going to be disabled until the fault is rectified.
Modern ABS applies individual brake pressure to all or any four wheels through an impact system of hub-mounted sensors and a fanatical micro-controller. ABS is obtainable or comes standard on most road vehicles produced today and is that the foundation for electronic stability control systems, which are rapidly increasing in popularity thanks to the vast reduction in the price of vehicle electronics over the years.
Modern electronic stability control systems are an evolution of the ABS concept. Here, a minimum of two additional sensors are added to assist the system work: these are a wheel angle sensor and a gyroscopic sensor. The theory of operation is simple: when the gyroscopic sensor detects that the direction taken by the car doesn't coincide with what the wheel sensor reports, the ESC software will brake the required individual wheel(s) (up to 3 with the foremost sophisticated systems), in order that the vehicle goes the way the driving force intends. The wheel sensor also helps within the operation of Cornering Brake Control (CBC), since this may tell the ABS that wheels on the within of the curve should brake quite wheels on the surface, and by what proportion.
ABS equipment may also be used to implement a traction control system (TCS) on the acceleration of the vehicle. If, when accelerating, the tire loses traction, the ABS controller can detect things and take suitable action in order that traction is regained. More sophisticated versions of this will also control throttle levels and brakes simultaneously. The speed sensors of ABS are sometimes used in an indirect tire pressure monitoring system (TPMS), which can detect under-inflation of the tire(s) by the difference in the rotational speed of wheels. A speed sensor is employed to work out the acceleration or deceleration of the wheel. These sensors use a magnet and a Hall effect sensor, or roulette and an electromagnetic coil to get a sign. The rotation of the wheel or differential induces a magnetic flux around the sensor. The fluctuations of this magnetic flux generate a voltage within the sensor. Since the voltage induced within the sensor may be a result of the rotating wheel, this sensor can become inaccurate at slow speeds. The slower rotation of the wheel can cause inaccurate fluctuations within the magnetic flux and thus cause inaccurate readings to the controller.
There is a valve within the brake line of every brake controlled by the ABS. On some systems, the valve has three positions: In position one, the valve is open; pressure from the master cylinder is passed right through to the brake. In position two, the valve blocks the road, isolating that brake from the brake cylinder. This prevents the pressure from rising further should the driving force push the pedal harder. In position three, the valve releases a number of pressures from the brake. The majority of problems with the valve system occur thanks to clogged valves. When a valve is clogged it is unable to open, close, or change position. An inoperable valve will prevent the system from modulating the valves and controlling pressure supplied to the brakes.
The pump within the ABS is employed to revive the pressure to the hydraulic brakes after the valves have released it. A signal from the controller will release the valve at the detection of wheel slip. After a valve releases the pressure supplied from the user, the pump is employed to revive the desired amount of pressure to the braking system. The controller will modulate the pump's status so as to supply the specified amount of pressure and reduce slipping.
Controller;
The controller is a European type unit within the car that receives information from each individual wheel speed sensor. If a wheel loses traction, the signal is shipped to the controller. The controller will then limit the brake force (EBD) and activate the ABS modulator which actuates the braking valves on and off.
CHAPTER 4
TRANSMISSION
Transmission may be a machine during a power transmission, which provides controlled application of the facility. Often the term transmission refers simply to the gearbox that uses gears and kit trains to supply speed and torque conversions from a rotating power source to a different device. The term transmission refers to the whole drive train, including clutch, gearbox, differential, driveshafts.
The most common use is in automobiles, where the transmission adapts the output of the interior combustion engine to the drive wheels. Such engines got to operate at a comparatively high rotational speed, which is inappropriate for starting, stopping, and slower travel. The transmission reduces the upper engine speed to the slower wheel speed, increasing torque within the process.
Transmissions also are used on pedal bicycles, fixed machines, and where different rotational speeds and torques are adapted. Often, a transmission has multiple gear ratios (or simply "gears") with the power to modify between them as speed varies. This switching could also be done manually (by the operator) or automatically.
In automobiles, the transmission generally is connected to the engine crankshaft via a flywheel or clutch partly because combustion engines cannot run below a specific speed. Types of transmissions: 1. Manual transmission(MT)
Automatic transmission(AT)
Continuously variable transmission(CVT)
MANUAL TRANSMISSION (MT)
Manual transmissions come in two basic types:
A simple but rugged sliding-mesh or unsynchronized/non-synchronous system, where straight-cut spur gear wheelsets spin freely and must be synchronized by the operator matching engine revs to road speed, to avoid noisy and damaging clashing of the gears The now ubiquitous constant-mesh gearboxes, which may include non-synchronized, or synchronized / synchromesh systems, where typically diagonal cut helical (or sometimes either straight-cut, or double-helical) gear sets are constantly "meshed" together, and a dog clutch is used for changing gears.
2. AUTOMATIC TRANSMISSION (AT)
Automatic transmission that selects an appropriate gear ratio without any operator intervention. They primarily use hydraulics to pick gears, counting on the pressure exerted by fluid within the transmission assembly. Rather than employing a clutch to interact with the transmission, a fluid flywheel or converter is placed in between the engine and transmission. It is possible for the driving force to regulate the number of gears in use or select reverse, though precise control of which gear is in use may or may not be possible.
3. CONTINUOUSLY VARIABLE TRANSMISSION (CVT)
The continuously variable transmission (CVT) may be a transmission during which the ratio of the rotational speeds of two shafts, because the input shaft and output shaft of a vehicle or other machine, are often varied continuously within a given range, providing an infinite number of possible ratios. The CVT allows the driving force or a computer to pick the connection between the speed of the engine and therefore the speed of the wheels within endless range. This can provide even better fuel economy if the engine constantly runs at one speed. The transmission is, in theory, capable of higher user experience, without the increase and fall in the speed of an engine, and therefore the jerk felt when changing gears poorly.
CHAPTER 5
ENGINES AND IT'S PARTS WITH FUNCTIONS
SERIES OF ENGINES:
There are five series of engines in Maruti Suzuki. They are:
1. F-series(Maruti 800,wagon r,Zen Estilo)
2. G-series(two variants like swift, dzire)
3. M-series(sx4)
4. K-series(latest all petrol vehicles)
5. E-series(latest ARL)
BASIC ENGINE INTERNAL COMBUSTION ENGINE:
It consists of the valve cover, camshafts, head, valves, block, pistons with connecting, crank, crankcase, sump.
VALVE COVER:
The valve cover may be a casing found on the highest of the engine. It covers the valves of the engine, protects the machinery from the weather, and prevents oil leaks. Cracks, corrosion, and misalignment of the valve cover can cause an engine oil leak. Diesel engine valve cover consists of camshafts.
ENGINE HEAD:
The engine head consists of inlet valves, exhaust valves, valve springs, valve locks, stem oil seals, and also engine head is the way to coolant and engine oil for the engine block. The engine head allows the fuel and air to the engine chamber also transfers the exhaust gases to the catalytic converter. Stem oil seals are fixed to the valves and head. These are used to prevent the oil leak to the engine chamber while valves are in operation. Each valve consists of one stem oil seal. Upon a valve spring is placed and locked the valve with two locks for every valve. The engine head fixed to the block by a head bolt. In between the head and engine block consists of a head gasket which prevents the leaks. Mostly engine hands are made up of aluminum and cast iron. The valves are present on the head operated by Rocker arms these Rocker arms operated by a camshaft. one side of the engine head connected to the intake manifold and the other side is connected to the catalytic converter means exhaust manifold. The engine head is covered by the valve cover. The right side of the engine head connects to the thermostat valve. Which is used to collect the hot coolant from the heat and transfer to the radiator the engine head possesses the main roll in power production.
BLOCK:
Block consists of cylinder chambers, coolant, engine oil ways. In which the pistons are fixed to the crankshaft through connecting rods and rotated by on connecting bearings. the bottom of the block is connected to the crankcase in between crankcases and the bottom of the block the crank is mounted and rotated by crank bearings and thrust bearings.
A crankshaft is a shaft driven by a crank mechanism, consisting of a series of cranks and crank pins to which the connecting rods of an engine are attached. It is a mechanical part ready to perform a conversion between reciprocating motion and rotational motion. According to the crank rotation, the RPM is described. And now the piston consists of 3 piston rings in 2 are compression rings and another one is an oil ring. The compression rings do not allow to leak of the burning gases while in the compression stage of a piston. The oil ring prevents oil leaks from the cylinder chamber. A four-cylinder engine consists of a burning order that is 1342.
Four-stroke engine
In the four-stroke diesel engine is that the ignition occurs spontaneously due to the high temperature of the compressed air. The diesel engine operates in a very similar way as that of a petrol engine. and the spark plug of a petrol engine is replaced with the fuel injector. The sequence of operation in four-stroke diesel and petrol engines as the same. Sequence of operation
Suction stroke: during the suction stroke only air is admitted into the cylinder. in this stroke, the inlet valve is open exhaust valve is closed and the piston moves downwards.
Compression stroke: both valves remain closed the piston moving upward compresses the air to high pressure and temperature. fuel is injected into the cylinder at the end of the compression stroke and ignition occurs spontaneously due to the high temperature of the compressed air. But in petrol engines, the ignition occurred by the spark plugs.
Expansion stroke: the burnt gases expand doing work on the piston. both valves closed, the piston moves downwards. This is the power stroke of the engine.
Exhaust stroke: expanded gases are driven out of the cylinder. Inlet valve closed, exhaust valve open. The piston moves upwards from BDC to TDC. At the end of the exhaust stroke exhaust valve is closed, the inlet valve opens to admit the air the above events are repeated from the next engine cycle operation.
All the internal combustion engines have four strokes.
The engine cycle is completed in two revolutions of the crankshaft.
The valves are operated on timing by a timing chain that is connected to camshafts and crankshaft through sprockets. The timing chain is covered by a timing chain cover in between a gasket is fixed. Which prevents the oil leak from the timing chain.
And also the main pulley is connected to the crank by a pulley bolt. All the pulleys are like water pump pulley, alternator pulley,main pulley,ac compressor pulley connected through a belt for power production.
The engine oil is supplied to all the bearings and connecting through an oil pump which is connected to the crankshaft. And also the oil pump is fixed to the strainer. Which prevents the entering of resins.
All the engine oil is present in the sump, which is connected to the bottom of the crankcase. The oil pump strainer is dipped into the oil and starts pumping by an oil pump.
These oil sumps are varied according to the series of engines.
When the engine temperature raised more than 80 degrees Celsius then the radiator fan is on and cools the hot coolant.
In exhaust gases, three main components are presented as nitrogen oxide, carbon monoxide, hydrocarbons. These gases are harmful to the environment which are filtered and converted into H2O and nitrogen and carbon dioxide by the catalytic converter.
The power is transmitted from pistons to crank in order to the flywheel, clutch disk, pressure plate, gearbox, differential, driveshafts, and wheels.
The engine oil is applied to bearings and connecting through oil ways. Especially the engine oil is supplied continuously. But the engine oil is supply to connecting by a nozzle jets. It forcibly strikes the connecting for free and smooth operation.
CHAPTER 6
TYPES OF SENSORS, MODULES USED IN CARS
1.MAF (mass airflow sensor)
(Fig-f1)
Mass airflow sensors used to calculate the air density in the engine. If the working of
the mass airflow sensor halts, then the running of the vehicle will be stopped. In addition,
the usage of petroleum will be high.
2. THROTTLE POSITION SENSOR
(Fig-f2)
The throttle position sensor mainly used for carburetion and electronic fuel injection. It
informs the computer regarding the throttle opening rate as well as the position of the
relative throttle.
This sensor is a variable resistor, which is used to change the resistance as the throttle open.
3. MAP (manifold absolute pressure sensor)
(Fig-f3)
The main function of the MAP sensor is used to monitor the load of the engine.
Mostly it measures the dissimilarity of manifold pressure.
This can be received from the outside pressure by the car to make sure that the car
engine is capable to receive petroleum depending on the changes in the pressure.
4. ENGINE SPEED SENSOR
(Fig-f4)
Engine speed sensor connected to crankshaft. The main purpose of
this sensor is to monitor the crankshaft's rotating speed.
So that the fuel injection & the engine timing can be controlled.
5. OXYGEN SENSOR
(Fig-f5)
Oxygen sensor located within the exhaust stream, usually near the exhaust manifold and after
the catalytic converter, the O2 sensor monitors the oxygen in the exhaust gas.
The information is compared to the oxygen content of ambient air and is used to detect
whether the engine is running an upscale fuel ratio or a lean one. The ECM uses this
information to workout fuel metering strategy and emission controls.
6.COOLANT SENSOR
(Fig-f6)
The coolant sensor is the most significant sensor. The ECM depends on the sensor inputs
to control all the functions. For instance, turn on/off the EFE system
(early fuel evaporation system), retard, spark advance, the flow of EGR, and canister
purge. General this sensor connected on the board. If the sensor is failed, then there
will be some indication stalling, poor fuel mileage, etc. So the status of the sensor should
be checked whether it is defective or not. If it is damaged, then it will be a problem.
7.SPARK KNOCK SENSOR
(Fig-f7)
The spark knock sensor is used to ensure whether the fuel is burning smoothly,
otherwise, it will cause an unexpected ignition. This ignition is very dangerous which
will cause damage in the engine of the car damage like piston rings,
head gasket, and rod bearings. Fitting these parts can be costly. So this sensor is used to
save all the troubles that occurred in the engine of the car.
8. FUEL TEMPERATURE SENSOR
(Fig-f8)
The fuel temperature sensor is used to check the temperature of fuel continuously whether
the fuel utilization is optimum or not. When the fuel of the engine is cold,
then it will take much time to burn due to its high density. Similarly, if the fuel is warm
then it will take less time to burn. Here, the main problem is the inflow varying levels.
So this can injure other parts. This sensor will monitor the petroleum is injected at the
right speed and temperature. So that engine works properly.
9.CAM POSITION SENSOR
(Fig-f9)
The Cam position sensor is used to monitor the position of the camshaft and reports that
data to ECM. Data from the CPS, the fuel injectors know when to fire. When the sensor
malfunction, the ECM does not know when to fire the injectors and may not fire them
at all. The faulty readouts may also throw off spark timing, which will cause an effect
of a car's fuel economy. This sensor is used to conjunction in a crankshaft position sensor
to control ignition timing. It is common for warmth and oil leaks to cause this sensor to fail.
10. CRANKSHAFT POSITION SENSOR
(Fig-f10)
The crankshaft position sensor is used to monitor the crank position and rotational
speed. This data used by the engine control module to control the fuel injection and
ignition system timing and other engine parameters.
11.VEHICLE SPEED SENSOR
The vehicle speed sensor is used to monitor the wheels of a car. It is a type of tachometer.
This sensor is arranged within the ABS(Anti look braking system).
(Fig-f11)
Additionally, the output of the sensor is utilized for the odometer to read the speed
of the vehicle to control the gears.
12. VOLTAGE SENSOR
(Fig-f12)
The main function of the voltage sensor is used to manage the car speed and make
sure that speed increased or decreased as required.
13. ENGINE CONTROL MODULE (ECM)
(Fig-f13)
A car's engine control module (ECM) may be a computing system that acts because of
the "brain" of a car.
This little computer analyzes much information so as to regulate the car's performance. When the ECM fails, it'll greatly hurt the engine's performance.
14. BODY CONTROL MODULE (BCM)
(Fig-f14)
In automotive electronics, body control module or 'body computer' may be a generic term for an electronic control unit liable for monitoring and controlling various electronic accessories in a vehicle's body. Typically during a car, the BCM controls the
facility windows, power mirrors, air-con, immobilizer system, central locking, etc. The BCM communicates with other onboard computers via the car's vehicle bus, and its main application is controlling load drivers – actuating relays that successively perform actions within the vehicle like locking the doors or dimming the salon overhead lamp.
15. TRANSMISSION CONTROL MODULE (TCM)
(Fig-f15)
The transmission control module does what its name implies: it's an electronic module that controls the operation of your transmission. In some vehicles, the TCM is a separate component, while in others the TCM is a sub-module inside the power train control module. The TCM takes input file from various switches and sensors in your car, such as those monitoring the positions of the gas and brake pedals, the transmission input and output speeds, gear selection, engine torque and speed, oil temperature, and wheel speed. The module then uses those inputs to implement an operating strategy. The TCM determines when and the way hard the transmission shifts and when the converter clutch engages or releases.
CHAPTER 7
TYPES OF ENGINE OILS, GEAR OILS OR
DIFFERENTIAL OILS USED IN CARS
TYPES OF ENGINE OILS:
MGO-0W-20
MGO- 5W-30
MGO-5W-30 (magnetic professional oil) or (fully synthetic oil)
MGDO-5W-30
MGDO-10W-30(synthetic oil)
These are the engine oils used in Maruti Suzuki cars. 0w-20,5w-30 used in only petrol vehicles like RD, A1K. Etc. 5w-30(ACEA),10w-30 engine oils used in diesel vehicles like ALK,AKN,AVB di.
TYPES OF GEAR OILS:
MGGO-75W-90
MGGO-80W-90
MGGO-75W-80
CHAPTER 8
MODELS OF CARS AND ITS CODES, VERSIONS IN MARUTI SUZUKI, ABBREVIATIONS
MODELS OF CARS AND WITH CODES:
VERSIONS IN MARUTI SUZUKI:
The Maruti Suzuki company broadly divided into two types, the first one is an arena and other is nexa. 4 types of versions present in both arena and nexa.
Xi symbol for petrol vehicles, Di symbol for diesel vehicles. The following symbols are described with versions only for the arena.
ABBREVIATIONS:
APP - accelerator pedal position
A/F - air fuel ratio
A/C - air condition
AC - alternate current
ABDC - after bottom dead centre
ABS - anti lock braking system
AB - air bag
AT - automatic transmission
ATDC - after top dead centre
BARO - barometric pressure
B+ - battery positive terminal
BB+ - battery positive voltage for backup
BTDC - before top dead centre
BBDC - before bottom dead centre
BCM - body control module
CMP - cam position
CKP - crank position
CVT - continuously variable transmission
CAN - controller area network
CPP - clutch pedal position
CO - carbon monoxide
CO2 - carbon dioxide
CPU - central processing unit
DC - direct current
DOHC - double over head camshaft
DTC - diagnostic trouble code
DLC - data link connector
DRL - daytime running light
DOT - department of transportation
EBD - electronic braking force distribution
ECM - engine control module
ECU - electronic control unit
EEPROM - electrical erasable programmable read only memory
ECT - engine coolant temperature
EGR - exhaust gas re circulation
EPS - electrical power steering
ESP - electronic stability program
GND - ground
GPS - global positioning system
HFC - hydro fluro carbon
HC - hydro carbon
HAVAC - heating, ventilation and air conditioning HO2S - heated oxygen sensor
IAT - intake air temperature
IMT - intake manifold tuning
ISO - international standardization for organization
ISC - idle speed control
JIS - Japanese industrial standards
J/B - junction block
J/C - junction connector
LIN - Local interconnect network
LCD - liquid crystal display
LED - light-emitting diode
LSPV - load-sensing proportioning valve
MAF - mass airflow
MAP - manifold absolute pressure
MFI - multi-port fuel injection
MIL - malfunction indicator lamp
M/T - manual transmission
NOX - nitrogen oxide
O2S - oxigen sensor
OBD - onboard diagnostic system
OCM - occupant classification module
OCV - oil control valve
PCM - power train control module
PCV - positive crankcase ventilation
PM - particulate matter
PS - power steering
RAM - randomly access memory
ROM - read-only memory
RPM - revolution per minute
SDM - sensing and diagnostic module
SAE - society of automotive engineers
SDT - a smart diagnostic test
SRS - supplemental restraint system
SI - system international
SOHC - single overhead camshaft
TCC - torque converter clutch
TCM - transmission control module
TP - throatle position
TDC - top dead centre
TPMS - tire pressure monitoring system
TWC - 3-way catalytic converter
USB - universal serial bus
VIN - vehicle identification number
VSS - vehicle speed sensor
VVT - variable valve timing
2WD - two-wheel drive
4WD - four-wheel drive
CONCLUSION
There have been many advancements in technology over the last 50 years, but arguably
none as drastic as the advancements made in the auto industry. An unthinkable amount
of improvements to automotive technology have been made, making cars easier to drive
and operate, safer, and perform better. The result being cars have become a very valuable
part of world lives, and cars will continue to get better with technology. they offer a lot
more with growing technology, they are fun to drive, they offer music, field phone calls,
are our navigators, and keep us safe. Cars have changed lives in the United States, they
are the most common and efficient method of travel for short distances in the United
States, and it is important that people utilize the technology cars can offer.