Automotive Industry: Technical and Contextual Explorations Part 2

Course Contents, Concepts and Issues

Engine Building

• Concept of Engine
• Internal Combustion Engine
• Building an Engine on Paper
• Fuel Uses
• Basic Force of an Engine
• Trapping the Explosion
• Simple Engine
• Parts of Engine
• Fastening the Parts
• Lengthen the Piston
• Getting Fuel into the Engine
• Removable Cylinder Head
• Fuel Intake and Exhaust Passages
• Valves
• Four-Stroke Cycle
• Vacuum
• Vacuum Pump
• Then Intake Stroke
• The Compression Stroke
• Power Stroke
• Exhaust Stroke
• Completed Cycle
• Cycle Repeated
• Opening and Closing Valves
• Camshaft
• Valve Lifter
• Camshaft Speed
• Turning the Camshaft
• Timing the Valves
• The Flywheel
• Basic Engine Completed

Design, Construction, Application of Engine Components

• The Engine Block
• Cylinders
• Pistons
• Piston Materials
• Piston Expansion Problems
• Partial Skirt Piston
• Piston Temperature
• Piston Construction
• Piston Head Shape
• Piston Rings
• Types of Rings
• Piston Pins
• Connecting Rods
• Rod Construction
• Rod Bearing
• Crankshaft
• Main Bearings
• Crankshaft Throws
• Crank Vibration
• Vibration Damper
• Balance Shafts
• Drilled, Ground and Polished
• Timing Gears
• Sprocket
• Flywheel
• Camshaft
• Valves
• Valve Seats
• Valve Guides
• Valve Springs
• Mechanical Valve Litters
• Hydraulic Valve Litters
• Reducing Valve Wear
• Valve Timing
• Cylinder Head
• Oil Pan
• Timing Gear Cover
• Gaskets
• Sealants
• Seals
• Other Parts

Classifying Engine and Identifying the Parts

• Cycle Classification
• Valve Location Classifications
• L-Head, T-Head and F-Head Designs
• I-Head
• Overhead Valve Adjustment
• Valve-To-Piston Clearance
• Detonation and Preignition
• Combustion Chamber Design
• Ricardo Combustion Chamber
• Hemispherical Combustion Chamber
• Wedge Shape Combustion Chamber
• Cylinder Classification
• Inline Engine
• V-Type Engine
• Horizontal-Opposed Engines
• Firing Order
• Cooling Classification
• Fuel Classification
• Two-Stroke and Four-Stroke Cycle Diesel Engines
• Rotary Engines
• Miller-Cycle Engines
• Natural Gas Engines
• Experimental Engines
• Engine Mounting
• Identification and Classification

Safety Lab Procedures: Avoiding Accidents

• Kinds of Accidents
• How Accidents Happen
• Effects of Accidents
• Reducing the Possibility of Accidents
• Dressing Safely for Work
• Keeping a Neat Shop
• Identifying Unsafe Conditions
• Waste Chemical Disposal
• Proper Work Procedure

Doing the Job Right Automotive Tools

• Tool Material
• Tool Construction
• Tool Handling And Storage
• Types of Tools
• Measuring Tools

Engine Tests and Measurements

• Horsepower
• Horsepower Formula
• Potential Horsepower
• Thermal Efficiency
• Mechanical Efficiency
• Practical Efficiency
• Indicated Horsepower
• Brake Horsepower
• Gross and Net Horsepower Ratings
• Frictional Horsepower
• Torque
• Torque and Brake Horsepower, Distinctions
• Volumetric Efficiency
• Engine Size, Displacement
• Cylinder Bore
• Piston Stroke
• Compression Ratio

Electrical System Fundamentals

• Basic Electricity
• The Electron Theory
• Conventional Theory
• Matter
• Atoms
• Electrical Current
• Current Flow
• Voltage
• Electrical Resistance
• Test Meters
• Conductors (Materials)
• Insulators
• Electrical Circuits
• Series-Parallel Circuit
• Vehicle Chassis
• Ohm’s Law
• Magnetism
• Magnet
• Basic Automotive Electronics
• Diodes
• Transistors

Ignition System

• Necessity of High Voltage
• Primary Circuit
• Battery
• Ignition Switch
• Resistors
• Ignition Coil
• Methods of Current Interruption
• Distributorless Ignition System
• Primary Circuit Complete
• Secondary Circuit
• Spark Plug Construction
• Spark Plug Heat Range
• Resistor Spark Plugs
• Distributor Cap
• Rotor
• Spark Plug Wires
• Ignition Timing and Advance
• Setting Basic Timing
• Timing Advance Mechanism

Fuel Injection Systems

• Providing the Correct Air-Fuel Mixture
• Fuel Injection
• Direct and Indirect Injection
• Mechanical and Electronic Injection
• Computer-Controlled Electronic Fuel Injection System
• Pulse Fuel Injection
• Types of Pulse Fuel Injection Systems
• Throttle Body Injection
• Multiport Fuel Injection
• Pulse Fuel Injection System Components
• Air Induction System
• Fuel Delivery System
• Engine Control Computer
• Electronic Sensors
• Continuous Pulse Fuel Injection Systems
• Fuel Flow Control
• Complete Air-Fuel Control Unit
• Diesel Fuel Injection
• Diesel Fuel
• Overall Diesel Fuel System
• Injector Pump Types
• Distributor Type Injection Pump
• Other Pump Features
• Diesel Injector Types
• Glow Plugs and Intake Air Heaters
• Superchargers and Turbochargers

Fuel Supply and Carburetors

• Fuel Supply System
• Fuel Tank
• Gasoline Pickup Tube
• How Gasoline Leaves the Tank
• Electric Fuel Pump
• Fuel Filter
• Fuel Lines
• Vapour Lock Eliminations
• Carburetors
• Building a Carburetor
• Basic Carburetor is Complete
• Correcting the Remaining Faults
• Carburetor Circuits
• Intake Manifold Design
• Air Cleaners
• Carburetor Classification

Cooling System

• The Need for a Cooling System
• Methods of Cooling
• Liquid-Cooled Engines
• First Job Complete

Lubrication Systems

• The Need for Lubrication Systems
• Friction
• Fraction Reduction
• Bearing Construction and Friction
• Engine Oil
• Engine Oil Jobs
• Refining Engine Oil
• Oil Viscosity
• Engine Oil Service Classification
• Oil Change Intervals
• Engine Lubrication Systems
• How Oil Works
• Types of Lubrication Systems
• Components of the Pressure-Splash System
• Pressure Relief Valve
• Oil Galleries and Lines
• Oil Enters Bearing
• Hydraulic Valve Lifters
• Oil Filtration
• Crankcase Ventilation
• Oil Seals
• Oil Pressure Indicators
• Dipstick
• Cooling the Oil

Exhaust Systems

• Purpose of the Exhaust System
• Exhaust System Design
• Exhaust System Components
• Exhaust Manifolds
• Exhaust Pipes
• Catalytic Converters
• Mufflers
• Resonators
• Tailpipes
• Hangers
• Heat Shields
• Exhaust System Materials
• Sealing the Exhaust System
• Exhaust Pipe-To-Manifold Connections
• Pipe-To-Pipe Connections
• Other Connections

Emissions Systems

• The Need for Emission Control
• Emission Control Systems
• Engine Modifications And Controls
• Engine Modifications
• Fuel System Controls
• Spark Timing Controls
• Exhaust Gas Recirculation (EGR)
• External Cleaning Systems
• Air Injection System
• Pulse Air Injection
• Catalytic Converter
• Multiple Converters
• Diesel Catalytic Converters
• Fuel Vapour Controls
• Positive Crankcase Ventilation
• Evaporation Control Systems (ECSs)
• Computer Control Emission Systems
• Emission Systems Caution