1. Modern Automotive Technology PowerPoint for by Russell Krick
Publisher The Goodheart-Willcox Co., Inc. Tinley Park, Illinois

2. Chapter 1
The Automobile

3. Contents Parts, assemblies, and systems Frame, body, and chassis
(11 Topics)
Parts, assemblies, and systems
Frame, body, and chassis
Engine
Computer system
Fuel system
Electrical system

4. Contents Cooling and lubrication systems
Exhaust and emission control systems
Drive train systems
Suspension, steering, and brake systems
Accessory and safety systems

5. Auto mobile Derived from the Greek word autos, which means self.
Derived from the French word mobile, which means moving.

6. Parts, Assemblies,
and Systems

7. Part The smallest removable item on a vehicle
Not normally disassembled
Electrical or electronic parts are often called components

8. Assembly Set of fitted parts designed to complete a function
the engine is an assembly that converts fuel into usable power to move the vehicle
Technicians take assemblies apart and put them back together during maintenance, service, and repair operations

9. System
Group of related parts and assemblies that performs a specific job
the steering system is comprised of the steering wheel, gears, swivel joints, and other parts
allows the driver to turn the wheels when maneuvering the vehicle

10. Major Vehicle Systems

11. Frame, Body, and Chassis

12. Body Forms the outside of the vehicle
Serves as an attractive covering for the chassis
Made of steel, aluminum, fiberglass, plastic, or composite materials

13. Chassis
Consists of the vehicle’s frame and everything attached to it except the body
Includes the tires, wheels, engine, transmission, drive axle assembly, and frame

14. Frame
Strong metal structure that provides a mounting place for other parts of the vehicle
Body-over-frame construction
chassis parts and body bolt to the frame
Unibody (unitized) construction
sheet metal body panels are welded together to form the body and frame

15. The frame is an integral part of the body
Unibody Construction
The frame is an integral part of the body

16. Body-over-Frame Construction
The body bolts to a thick steel frame

17. Body Types Automobiles are available in several body types, including:
sedan
hardtop
convertible
hatchback
station wagon
minivan
sport-utility vehicle

18. Sedan
Uses center body pillars, or “B” pillars, between the front and rear doors. A hardtop does not use “B” pillars.

19. Uses a vinyl or cloth top that can be raised and lowered
Convertible
Uses a vinyl or cloth top that can be raised and lowered

20. The large rear door allows easy access when hauling items
Hatchback
The large rear door allows easy access when hauling items

21. Provides a large rear interior compartment
Station Wagon
Provides a large rear interior compartment

22. Has a higher roofline for more headroom and cargo space
Minivan
Has a higher roofline for more headroom and cargo space

23. Sport-Utility Vehicle
Provides the comfort of a passenger car, the interior space of a station wagon, and the durability of a truck

24. Automobile Body Parts

25. Engine

26. Engine 1) Provides the energy to propel the vehicle.
2) Operate other systems
Most engines burn gasoline or diesel fuel
The fuel burns to produce heat, the heat causes gas expansion which creates pressure
The pressure moves the internal engine parts to produce power

27. Automotive Engine

28. Engine Locations

29. Engine Placement Transverse (Side to side)
Longitudinal (Length of the vehicle)
Crankshaft is Perpendicular to the F.E.A.D. belt.
Identify by looking for the:
F.E.A.D (Front End Accessory Drive) Belt
- “V” Belts
- Serpentine Belts
Worn out by:
Glazing, Cracking, or measurement tool.
May cause “Squealing” on cold starts or by revving

30. Crankshaft is “Perpendicular” to the FEAD BELT

31. Drivetrain Types Front Wheel Drive Rear Wheel Drive All Wheel Drive
Four Wheel Drive
What do you look for first?
The REAR PUMPKIN (Differential)

32. Rear Differentials

33. Cylinder Arrangement 3 Main Designs: (Angle of Valve Covers) In-Line
V-Block
Opposing Cylinder

34. Number of Cylinders
What can we look for to identify how many cylinders it has?
- Spark Plugs
- Spark Plug wires
- Ignition Source (Distributor, Coil Pack, Direct Ignition)
- Fuel Injectors
- Intake manifold
- Exhaust manifold

35. Vehicle Identification
V.I.N. (Vehicle Identification Number)
17 Digit Code
Located: - Driver’s side dash – seen through windshield.
- Driver’s side door or pillar label.

37. Basic Engine Parts

38. Crankshaft
Purpose:
To convert the up and down motion of the piston into the rotary motion we use at the wheels
Stroke: Twice rod journal offset – totaling the distance the piston moves up and down in the cylinder
Throw: ½ of Stroke, or rod journal offset

39. Stroke and Throw

40. Four-Stroke Cycle
Four separate piston strokes are needed to produce one cycle:
intake stroke
compression stroke
power stroke
exhaust stroke
The piston must slide down, up, down, and up again to complete one cycle
Crankshaft turns 2 times per cycle
Camshaft turns 1 time per cycle

41. Draws the air-fuel mixture into the cylinder
Intake Stroke
Draws the air-fuel mixture into the cylinder

42. Compresses the air-fuel mixture
Compression Stroke
Compresses the air-fuel mixture

43. Produces the energy to operate the engine
Power Stroke
Produces the energy to operate the engine

44. Removes the burned gases from the combustion chamber
Exhaust Stroke
Removes the burned gases from the combustion chamber

45. Automotive Engines Multi-cylinder engines are used
4,5,6,8, or 10 cylinders may be used
Additional cylinders smooth engine operation and increase power output because there is less time between power strokes

46. Engine Components

47. Computer System

48. Computer System
Uses electronic and electrical devices to monitor and control various systems
The systems controlled include the:
fuel system
ignition system
drive train
safety and security systems

49. 3 Main Computer System Components
Sensors (Input)
input devices that can produce or modify electrical signals with changes in a condition, such as motion, temperature, or pressure
Control module
computer that uses signals from input devices (sensors) to control various output devices

50. Computer System Components
Actuators (Output)
output devices that can move parts when energized by the control module
output devices include electric motors and solenoids

51. Computerized Door Locks
The doors are locked as soon as the vehicle starts moving in drive or reverse

52. Fuel System

53. Fuel System 2 Purposes for the fuel system: 14.7:1 (Air:Fuel)
1) Provides the correct mixture of air and fuel for efficient combustion
2) Alters the air-fuel ratio with changes in operating conditions such as engine temperature, speed, and load.
14.7:1 (Air:Fuel)
Fuel system types:
gasoline injection system
diesel injection system
carburetor system

54. Maintenance Items -Fuel Filters
Most are a maintenance item.
- In line or in tank (50,000 miles)

55. Air Filter All Systems require clean air – usually a maintenance item.
Usually square or round. (15-30,000 miles)

56. Gasoline Injection System
Uses a control module, sensors, and electrically operated fuel injectors to meter fuel into the engine
An electric fuel pump pressurizes the fuel
Uses a Spark Plug to ignite the air/fuel mixture.
The control module monitors sensor values and opens the injectors for the correct amount of time to deliver the desired quantity of fuel

57. Injection System Monitor Air Flow and Mixture (Inputs)
Throttle Valve – Controls Air Flow (2 Types):
- Manual
- Electronic Throttle By Wire
Monitor Air Flow and Mixture (Inputs)
- Mass Air Flow Sensor
- Manifold Absolute Pressure Sensor
- Air Temp Sensor
- Oxygen Sensor – end of line sensor

58. Gasoline Injection System

59. Diesel Injection System
Forces fuel directly into the combustion chambers
High Pressure Mechanical Fuel pump
High pressure produced during compression heats the air enough to ignite the fuel
When fuel is injected into the cylinder, the heated air causes the fuel to ignite and burn
Compressed Air Ignites the Fuel Mixture – no spark plug!
NO THROTTLE VALVE

60. Diesel Injection System

61. Carburetor Fuel System
Uses vacuum to draw fuel into the engine
A mechanical or low pressure electric fuel pump delivers fuel to the carburetor
A throttle valve controls airflow and engine power output
Spark Plug ignites air fuel mixture

62. Carburetor Fuel System

63. Electrical System

64. Electrical System Consists of several subsystems:
ignition system
starting system
charging system
lighting system
Each subsystem is designed to perform a specific function

65. Ignition System
Needed on gasoline engines to ignite the air-fuel mixture
2 Things needed to Ignite:
Produces an extremely high voltage surge, which operates the spark plugs
An electric arc jumps across the tip of each spark plug at the correct time, causing the air-fuel mixture to burn

66. Ignition Coil

67. Ohms Law Things to Identify: Ignition Sources: - Ignition Source
- Spark Plug Wires
- Spark Plugs
Ignition Sources:
Distributor (Single Coil)
Coil Pack
Direct Ignition

68. Ignition System

69. Starting System
An electric starting motor rotates the engine until it “fires” and runs on its own power – TURNS THE CRANKSHAFT AROUND!
When the key is turned to the start position, current flows from the battery through the starting system circuit
The starting motor turns, and the starting motor pinion gear engages a gear on the flywheel, turning the crankshaft

70. Starting System 2 major components of the system: Starter Motor
Battery

71. Starting System

72. Charging System
Replaces electrical energy drawn from the battery by forcing electric current back into it (Re-charge the Battery)
When the engine is running, the alternator produces electricity to recharge the battery and operate other electrical devices
The voltage regulator controls system voltage ( volts)

73. Charging System Location: Identify by looking for: Fins (Vents) Fans
FEAD Belt (Usually)
Identify by looking for:
Fins (Vents)
Fans

74. Charging System

75. Lighting System
Consists of the components that operate a vehicle’s interior and exterior lights
Components may include:
Fuses – (Provides circuit protection)
wires
switches
Relays – (Small amp circuit controls a large amp circuit)
control modules

76. Fuses and Relays
Battery Junction Box (late 1990’s and up on most vehicles)
Anywhere under the hood on early 1990’s and previous vehicles.

77. Cooling and Lubrication
Systems

78. Cooling System
1. Maintains a constant engine operating temperature ( )
2. Minimizes engine warm-up time
Removes excess combustion heat to prevent engine damage
Coolant is pumped through the engine, where it absorbs heat
Coolant then flows to the radiator, where heat is released to the outside air

79. Cooling System

80. Things to identify Radiator – Radiator Cap – Pressure (15-21psi)
Usually drops degrees – located in front of engine compartment by radiator fan. Do not point through the front of the grill to find.
Radiator Cap – Pressure (15-21psi)
Upper Radiator Hose – Large Hose
Lower Radiator Hose – Large Hose
Overflow Bottle – Do not overfill
Fan – mechanical or electrical

81. Things to identify Water Pump – Circulates Coolant
Smooth Pulley – usually 4 bolts
Follow LOWER radiator hose
Thermostat – Controls Flow
Follow UPPER radiator hose
Antifreeze Mixture = 50/50 water/coolant = -34’F
Ethylene Glycol and Propylene Glycol
DO NOT MIX COOLANTS
Electrolysis in cooling system: Greater than 0.30 volts excessive

82. Lubrication System
Reduces friction and wear between internal engine parts by circulating filtered oil to high-friction points in the engine
Helps cool the engine by carrying heat away from internal engine parts

83. API = American Petroleum Institute
Ratings:
API = American Petroleum Institute
SAE = Society of Automotive Engineers
API ratings of oil – can use newer rating in older vehicle but not older ratings in newer vehicle!
- API Ratings since before 1930 with oil grade “SA” good until then…
- “SN” current since October 2010

84. Viscosity
A quantity expressing the magnitude of internal friction, as measured by the force per unit area resisting a flow in which parallel layers unit distance apart have unit speed relative to one another.
The ability of a fluid to flow
The weight of the oil (ex: 5W-20)

85. Lubrication System

86. Things to Identify Oil Filter – caution: “double gasket”
Oil Pan – behind crankshaft pulley
Drain Plug – Do not over tighten
Oil Fill Spout – in valve cover usually
Dipstick – Pull, wipe, recheck

87. Exhaust and Emission
Control Systems

88. Exhaust System Quiets the noise produced by engine operation
Routes engine exhaust gases to the rear of the vehicle body

89. Things to Identify
Exhaust Manifold – Where multiple cylinders converge into a single pipe.
Catalytic Converter – may have a single converter or multiple converters
Resonance Tube, or chamber
Flex Coupler (Chinese finger trap) or Flex Joint (Bolt and Spring)
Muffler
Tailpipe

90. Exhaust System

91. Emission Control Systems
1. remove unburned (CO) and partially burned (HC) fuel from the engine exhaust – Catalytic Converter (Reduce harmful tailpipe emissions)
2. prevent raw fuel vapors from entering the atmosphere – Vapor Storage Canister
Nox gasses – contribute to Acid Rain – EGR reduces these.

92. Things to Identify EGR – Exhaust Gas Recirculation Valve
Evap Canister – stores raw fuel vapors until the engine can burn them off.

93. Drive Train Systems

94. Purpose To transfer the energy produced by the engine to the wheels!
Includes everything from behind the engine to the wheels.
“Powertrain” includes the engine.

95. Rear-wheel-drive Front-wheel-drive
Drive Train Systems
Rear-wheel-drive Front-wheel-drive

96. Clutch
Allows the driver to engage or disengage the engine and manual transmission or transaxle
Clutch pedal released
clutch locks the flywheel and the transmission together
power flows to the transmission
Clutch pedal depressed
clutch disengages power flow

97. Transmission
Uses various gear combinations (ratios), to multiply engine speed and torque to accommodate driving conditions
Low gear ratios allow the vehicle to accelerate quickly
High gear ratios permit lower engine speed, providing good fuel economy

98. Manual Transmission
Uses gears and shafts to achieve various gear ratios. Engaged/Disengaged with Clutch

99. Automatic Transmission Engaged/Disengaged with Torque Converter
Does not have to be shifted by the driver
Uses an internal hydraulic system and, in most cases, electronic controls to shift gears
Internal clutches or bands control gearsets to provide various gear ratios
Input shaft is connected to the engine crankshaft through a torque converter

100. Automatic Transmission
- Has a pan – hydraulics need a reservoir
- 1 input 1 output – straight line

101. Drive Shaft
Transfers power from the transmission to the rear axle assembly
Universal joints allow the rear suspension to move up and down without damaging the drive shaft

102. Drive Shaft

103. Rear Axle Assembly Contains a differential and two axles Differential
set of gears and shafts that transmits power from the drive shaft to the axles
Axles
steel shafts that connect the differential and drive wheels

104. Consists of a transmission and a differential in a single housing
Transaxle
Consists of a transmission and a differential in a single housing
1 input – 2 outputs

105. Transaxle Used with front-wheel-drive vehicles
Both manual and automatic transaxles are available

106. Front Drive Axles
Connect the transaxle differential to the hubs and wheels of the vehicle
Equipped with constant-velocity joints
constant-velocity joints allow the front wheels to be turned to the left or right and to move up and down

107. Suspension, Steering, and
Brake Systems

108. Suspension System
Allows the vehicle’s wheels and tires to move up and down with little effect on body movement
Prevents excessive body lean when cornering quickly
Component that prevent body lean: Sway Bar
Various springs, bars, swivel joints, and arms make up the system

109. Types of Springs A. Coil spring B. Leaf spring C. Air spring
D. Torsion bar
Springs control Ride Height

110. Shocks and Struts Shocks control Jounce and Rebound
Jounce is the Compression of the shock
Rebound is the Extension of the shock
Struts - Combine the shock and spring into a single unit.
Struts - Provide STRUCTURE in the suspension.

111. Spring and Shock
Short arm long arm suspension

112. Struts

113. Suspensions
Independent – Little to No direct effect on opposite wheel when hitting bumps.
Nonindependent - Direct effect on opposite wheel when hitting bumps.

114. Steering System
Allows the driver to control vehicle direction by turning the wheels right or left
Uses a series of gears, swivel joints, and rods
Most are Hydraulic System – Check Fluid with engine NOT running

115. Steering
Basic linkage steering
Basic rack-and-pinion steering

116. Suspension and Steering Systems

117. Brake System
The Braking system converts Kinetic energy into Thermal energy through Friction.
When the driver presses the brake pedal, fluid (Hydraulic) pressure actuates a brake mechanism at each wheel
Master Cylinder – produces Hydraulic pressure used at the brakes
Mechanisms force friction material against metal discs or drums to slow wheel rotation

118. Complete Brake System

119. Wheel Brake Assembly

120. Hydraulic Brake Action

123. Accessory and Safety
Systems

124. Accessory Systems Common accessory systems include: air conditioner
sound system
power seats
power windows
rear window defogger

125. Safety Systems Common safety systems include: seat belts air bags
security systems

126. This vehicle is equipped with front and side-impact air bags
Safety Systems
This vehicle is equipped with front and side-impact air bags